EPA 10 - US, Canada, Mexico

2010 MaxxForce® DT, 9 and 10 Engine Diagnostic Manual

DIAGNOSTIC MANUAL
DIAGNOSTIC MANUAL

2010 MaxxForce® DT, 9 and 10 Engine Diagnostic Manual

0000001624

Navistar, Inc.
January 2021
Revision 33

2701 Navistar Drive, Lisle, IL 60532 USA

© 2021 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
 DIAGNOSTIC MANUAL I

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

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

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

Diagnostic Troubleshooting Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Engine System Tests and Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1301

Engine Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1675

Diagnostic Tools and Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1709

Component Locator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1755

Engine Systems Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1763

Engine and Vehicle Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1831

Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1839

Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1851
II DIAGNOSTIC MANUAL
 DIAGNOSTIC MANUAL 1

Foreword
Navistar®, Inc. is committed to continuous research and development to improve products and introduce
technological advances. Procedures, specifications, and parts defined in published technical service literature
may be altered.
NOTE: Photo illustrations identify specific parts or assemblies that support text and procedures; other areas in
a photo illustration may not be exact.
This manual includes necessary information and specifications for technicians to maintain MaxxForce® diesel
engines. See vehicle manuals and Technical Service Information (TSI) bulletins for additional information.

Technical Service Literature

1172040 MaxxForce® DT, 9, and 10 Engine Operation and Maintenance Manual
0000001835 2010 MaxxForce® DT, 9, and 10 Engine Service Manual
0000001624 2010 MaxxForce® DT, 9, and 10 Engine Diagnostic Manual
0000003221 MaxxForce® DT, 9, and 10 Electronic Control Systems Form

Technical Service Literature is revised periodically. If a technical publication is ordered, the latest revision will
be supplied.
NOTE: To order technical service literature, contact your International® dealer.
2 DIAGNOSTIC MANUAL

Service Diagnosis
Service diagnosis is an investigative procedure that must be followed to find and correct an engine application
problem or an engine problem.
If the problem is engine application, see specific vehicle manuals for further diagnostic information.
If the problem is the engine, see specific Engine Diagnostic Manual for further diagnostic information.
Prerequisites for Effective Diagnosis
• Availability of gauges and diagnostic test equipment
• Availability of current information for engine application and engine systems
• Knowledge of the principles of operation for engine application and engine systems
• Knowledge to understand and do procedures in diagnostic and service publications
Technical Service Literature required for Effective Diagnosis
• Engine Service Manual
• Engine Diagnostic Manual
• Electronic Control Systems Diagnostics Forms
• Service Bulletins
 DIAGNOSTIC MANUAL 3

Safety Information
This manual provides general and specific maintenance procedures essential for reliable engine operation and
your safety. Since many variations in procedures, tools, and service parts are involved, advice for all possible
safety conditions and hazards cannot be stated.
Read safety instructions before doing any service and test procedures for the engine or vehicle. See related
application manuals for more information.
Disregard for Safety Instructions, Warnings, Cautions, and Notes in this manual can lead to injury, death or
damage to the engine or vehicle.

Safety Terminology
Three terms are used to stress your safety and safe operation of the engine: Warning, Caution, and Note.
Warning: A warning describes actions necessary to prevent or eliminate conditions, hazards, and unsafe
practices that can cause personal injury or death.
Caution: A caution describes actions necessary to prevent or eliminate conditions that can cause damage to
the engine or vehicle.
Note: A note describes actions necessary for correct, efficient engine operation.

Safety Instructions
Work Area
• Keep work area clean, dry, and organized.
• Keep tools and parts off the floor.
• Make sure the work area is ventilated and well lit.
• Make sure a First Aid Kit is available.
Safety Equipment
• Use correct lifting devices.
• Use safety blocks and stands.
Protective Measures
• Wear protective safety glasses and shoes.
• Wear correct hearing protection.
• Wear cotton work clothing.
• Wear sleeved heat protective gloves.
• Do not wear rings, watches or other jewelry.
• Restrain long hair.
Vehicle
• Make sure the vehicle is in neutral, the parking brake is set, and the wheels are blocked before servicing
engine.
4 DIAGNOSTIC MANUAL

• Clear the area before starting the engine.

Engine
• The engine should be operated or serviced only by qualified individuals.
• Provide necessary ventilation when operating engine in a closed area.
• Keep combustible material away from engine exhaust system and exhaust manifolds.
• Install all shields, guards, and access covers before operating engine.
• Do not run engine with unprotected air inlets or exhaust openings. If unavoidable for service reasons, put
protective screens over all openings before servicing engine.
• Shut engine off and relieve all pressure in the system before removing panels, housing covers, and caps.
• If an engine is not safe to operate, tag the engine and ignition key.
Fire Prevention
• Make sure charged fire extinguishers are in the work area.
NOTE: Check the classification of each fire extinguisher to ensure that the following fire types can be
extinguished.
1. Type A – Wood, paper, textiles, and rubbish
2. Type B – Flammable liquids
3. Type C – Electrical equipment
Batteries
• Always disconnect the main negative battery cable first.
• Always connect the main negative battery cable last.
• Avoid leaning over batteries.
• Protect your eyes.
• Do not expose batteries to open flames or sparks.
• Do not smoke in workplace.
Compressed Air
• Use an OSHA approved blow gun rated at 30 psi (207 kPa).
• Limit shop air pressure to 30 psi (207 kPa).
• Wear safety glasses or goggles.
• Wear hearing protection.
• Use shielding to protect others in the work area.
• Do not direct compressed air at body or clothing.
Tools
• Make sure all tools are in good condition.
• Make sure all standard electrical tools are grounded.
 DIAGNOSTIC MANUAL 5

• Check for frayed power cords before using power tools.

Fluids Under Pressure
• Use extreme caution when working on systems under pressure.
• Follow approved procedures only.
Fuel
• Do not over fill the fuel tank. Over fill creates a fire hazard.
• Do not smoke in the work area.
• Do not refuel the tank when the engine is running.
Removal of Tools, Parts, and Equipment
• Reinstall all safety guards, shields, and covers after servicing the engine.
• Make sure all tools, parts, and service equipment are removed from the engine and vehicle after all work is
done.
6 DIAGNOSTIC MANUAL
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 7

Table of Contents

Diagnostic Trouble Code (DTCs) List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

How To Use Symptom Based Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Operational Checkout Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

1.0 - Preliminary Vehicle Operational Checkout Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
2.0 - Engine Does Not Start Operational Checkout Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
3.0 - Engine Hard to Start Operational Checkout Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
4.0 - Engine Running, Engine Not Under Load Operational Checkout Procedure. . . . . . . . . . . . . . . . .29
5.0 - Engine Running, Engine Under Load Operational Checkout Procedure. . . . . . . . . . . . . . . . . . . . . .31
6.0 - Cooling System Operational Checkout Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
7.0 - Engine Oil System Operational Checkout Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
8.0 - Fuel System Operational Checkout Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
9.0 - Engine Compression Brake Operational Checkout Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
10.0 - ECM Loss of Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
11.0 Soot Buildup at Exhaust Manifold / Gasket Out of Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Engine Does Not Start Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

2.1 - Engine Cranks Slow or Does Not Crank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
2.2 - Engine No Start, Cold Ambient Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
2.3 - Engine at Operating Temperature, No Re-Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
2.4 - Engine Never Starts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Engine Hard to Start Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

3.1 - Engine Hard to Start, Cold Ambient Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
3.2 - Engine at Operating Temperature, Hard to Re-Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
3.3 - Engine Starts, Then Stalls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Engine Running, Engine Not Under Load Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

4.1 - Rough Idle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
4.2 - Engine Unable To Reach Rated Speed (No Load). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
4.3 - Popping Noise from Intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

Engine Running, Engine Under Load Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

5.1 - Low Power (Slow Acceleration). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
5.2 - Misfire (Stumble / Surge / Runs Rough). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
5.3 - Engine Unable to Reach Desired Speed During PTO Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

Engine Coolant Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

6.1 - Coolant Overflow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
6.2 - Coolant Over Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
6.3 - Engine Unable to Reach Operating Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
6.4 - Coolant Leak to Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
6.5 - Coolant Leak to Intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
6.6 - Coolant Leak to Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
8 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Engine Lubrication Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

7.1 - Engine Oil Contamination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
7.2 - Engine Oil Leak to Intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
7.3 - Engine Oil Leak to Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107
7.4 - Low Engine Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
7.5 - High Engine Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
7.6 - Engine Oil Aeration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
7.7 - Engine Oil in Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117

Fuel System Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119

8.1 - Fuel Delivery Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
8.2 - Fuel in Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123

Engine Brake Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

9.1 - Engine Compression Brake Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
9.2 - Engine Compression Brake Engaged When Not Commanded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127

Fault Code Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129

Diagnostic Trouble Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 9

Diagnostic Trouble Code (DTCs) List

SPN FMI Condition Description
27 0 EGRP fault: over temperature (page 131)
27 3 EGRP signal Out of Range HIGH (page 132)
27 4 EGRP signal Out of Range LOW (page 135)
27 7 EGRP does not agree with commanded position (page 138)
27 14 EGR internal circuit failure (page 140)
51 0 ETP fault: over temperature (page 142)
51 2 ETP does not agree with commanded position (page 145)
51 3 ETP signal Out of Range HIGH (page 148)
51 4 ETP signal Out of Range LOW (page 150)
51 5 ETP open load/circuit (page 157)
51 7 ETP does not agree with commanded position (page 159)
51 11 ETP operation fault - underVolt, overAmp, overTemp/ETP H-bridge Electrical Check (page 16
91 2 APP1 and APP2 signal conflict (page 168)
91 3 APP1 signal Out of Range HIGH (page 177)
91 4 APP1 signal Out of Range LOW (page 182)
94 0 Fuel Delivery Pressure Above Critical (page 188)
94 1 Fuel Delivery Pressure below Critical (page 190)
94 2 FDP Signal Erratic, Intermittent, or Incorrect (page 192)
94 3 FDP signal Out of Range HIGH (page 194)
94 4 FDP signal Out of Range LOW (page 197)
94 17 Fuel Delivery Pressure below minimum (page 203)
94 18 Fuel Delivery Pressure below min during cranking (page 205)
100 1 Engine Oil System below Critical Pressure (page 207)
100 3 EOP signal Out of Range HIGH (page 208)
100 4 EOP signal Out of Range LOW (page 212)
100 18 Engine Oil System below Warning Pressure (page 217)
102 2 IMP signal erratic, intermittent, or incorrect (page 219)
102 3 IMP signal Out of Range HIGH (page 220)
102 4 IMP signal Out of Range LOW (page 223)
102 7 IMP signal not responding as expected (page 228)
102 10 Boost slow response fault (page 230)
102 16 Over boost (page 235)
102 18 Under boost (page 238)
105 2 IMT Signal Erratic, Intermittent, or Incorrect (page 242)
10 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN FMI Condition Description

105 3 IMT signal Out of Range HIGH (page 247)
105 4 IMT signal Out of Range LOW (page 252)
108 2 BARO signal erratic, intermittent or incorrect (page 254)
108 3 BARO signal Out of Range HIGH (page 256)
108 4 BARO signal Out of Range LOW (page 258)
110 0 Engine Cooling System above Critical Temperature (page 260)
110 2 ECT1 signal erratic, intermittent, or incorrect (page 261)
110 3 ECT1 signal Out of Range HIGH (page 267)
110 4 ECT1 signal Out of Range LOW (page 273)
110 7 ECT1 and EOT temperature conflict (page 275)
110 15 Engine Coolant System above Warning Temperature (page 279)
110 16 Engine Coolant System Above OBD Maximum Temperature (page 281)
110 17 Engine Coolant Temperature stuck in range low (page 282)
110 18 Engine Coolant System below closed loop minimum Temperature (page 284)
111 1 ECL below Warning/Critical Level (page 286)
111 2 ECL signal erratic, intermittent, or incorrect (page 298)
132 0 Engine Inlet Air Mass Flow Rate High (page 309)
132 1 Engine Inlet Air Mass Flow Rate Low (page 311)
132 3 MAF signal Out of Range HIGH (page 314)
132 4 MAF Frequency out of range (page 319)
132 11 MAF Sensor Calibration - Insufficient number of data points (page 325)
132 13 MAF Sensor Calibration Needed (page 333)
132 14 MAF Sensor Calibration Failed (page 335)
132 31 MAF Frequency not detected (page 337)
158 15 ECM Switched voltage too HIGH (page 349)
158 17 ECM Switched voltage too LOW (page 351)
164 0 ICP above KOEO Spec (page 360)
164 1 ICP Unable to Build During Engine Cranking (page 362)
164 2 ICP signal erratic, intermittent, or incorrect (page 364)
164 3 ICP signal Out of Range HIGH (page 365)
164 4 ICP signal Out of Range LOW (page 375)
164 10 ICP signal abnormal rate of change (page 378)
164 13 ICP adaptation In-Range fault (page 379)
164 15 ICP too high during test (page 380)
164 16 ICP above desired level (page 382)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 11

SPN FMI Condition Description

164 17 ICP unable to build during test (page 384)
164 18 ICP below desired level (page 386)
164 20 ICP Above desired level (page 389)
172 2 IAT Signal Erratic, Intermittent, or Incorrect (page 391)
172 3 IAT Signal Out of Range HIGH (page 395)
172 4 IAT Signal Out of Range LOW (page 401)
173 2 EGT signal erratic, intermittent, or incorrect (page 403)
173 3 EGT Signal Out of Range HIGH (page 409)
173 4 EGT Signal Out of Range LOW (page 415)
175 2 EOT signal erratic, intermittent, or incorrect (page 417)
175 3 EOT signal Out of Range HIGH (page 422)
175 4 EOT signal Out of Range LOW (page 428)
175 7 EOT not warming along with engine (page 431)
175 15 Engine Oil System above Warning Temperature (page 438)
188 0 Engine unable to achieve desired idle speed (too high) (page 445)
188 1 Engine unable to achieve desired idle speed (too low) (page 447)
190 0 Engine Over Speed - Most Severe Level (page 450)
191 3 TOSS/VSS Signal Out of Range HIGH (page 453)
191 4 TOSS/VSS Signal Out of Range LOW (page 455)
191 5 TOSS/VSS Open Circuit Fault (page 457)
191 14 TOSS/VSS Error invalid signal (page 459)
518 2 Torque Limitation - Too High ECT (page 461)
521 2 Brake applied while APP applied (page 464)
521 19 Brake Switch circuit fault (page 467)
593 31 Engine Stopped by IST (page 470)
596 19 Cruise Control Enable Switch not detected on J1939 (page 473)
597 2 Brake switch or circuit fault (page 475)
597 19 Brake Switch not detected on J1939 (page 477)
609 3 DCU Switched voltage too HIGH (page 479)
609 4 DCU Switched voltage too LOW (page 480)
609 12 DCU Internal chip Error (page 484)
609 19 DCU not detected on J1939 (page 486)
628 12 ECM Memory Error (page 491)
629 0 ECM Error - CPU Load Excessively HIGH (page 493)
629 8 ECM Error - Engine Off Timer fault (page 494)
12 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN FMI Condition Description

629 12 ECM Internal Chip Error (page 496)
636 2 CMP and CKP Synchronization Error (page 498)
636 7 CMP to CKP incorrect reference (page 506)
637 8 CKP signal noise (page 508)
637 10 CKP signal inactive (page 513)
639 14 J1939 Data Link Error (ECM unable to transmit) (page 518)
651 4 Injector 1 open coil - short circuit (page 523)
651 5 Injector 1 open coil - open circuit (page 529)
651 7 Injector 1 (through 6) Spool Motion Compensation Max Authority Reached (page 534)
651 14 Injector 1 Fuel quantity/timing error (page 536)
652 4 Injector 2 open coil - short circuit (page 540)
652 5 Injector 2 open coil - open circuit (page 546)
652 7 Injector 1 (through 6) Spool Motion Compensation Max Authority Reached (page 551)
652 14 Injector 2 Fuel quantity/timing error (page 553)
653 4 Injector 3 open coil - short circuit (page 557)
653 5 Injector 3 open coil - open circuit (page 563)
653 7 Injector 1 (through 6) Spool Motion Compensation Max Authority Reached (page 568)
653 14 Injector 3 Fuel quantity/timing error (page 570)
654 4 Injector 4 open coil - short circuit (page 574)
654 5 Injector 4 open coil - open circuit (page 580)
654 7 Injector 1 (through 6) Spool Motion Compensation Max Authority Reached (page 585)
654 14 Injector 4 Fuel quantity/timing error (page 587)
655 4 Injector 5 open coil - short circuit (page 591)
655 5 Injector 5 open coil - open circuit (page 597)
655 7 Injector 1 (through 6) Spool Motion Compensation Max Authority Reached (page 602)
655 14 Injector 5 Fuel quantity/timing error (page 604)
656 4 Injector 6 open coil - short circuit (page 608)
656 5 Injector 6 open coil - open circuit (page 614)
656 7 Injector 1 (through 6) Spool Motion Compensation Max Authority Reached (page 619)
656 14 Injector 6 Fuel quantity/timing error (page 621)
679 3 IPR short to PWR (page 625)
679 4 IPR Open or short to GND (page 629)
679 5 IPR open load / circuit (page 634)
729 3 IAHC short to PWR (page 644)
729 4 IAHC short to GND (page 647)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 13

SPN FMI Condition Description

729 5 IAHC open load / circuit (page 651)
729 18 IAH Monitor fault: Lack of Heat in the Intake Manifold (page 658)
931 3 EFP short to PWR (page 660)
931 4 EFP open load/circuit or short to GND (page 664)
931 11 EFP operation fault (page 672)
931 19 EFP not detected on J1939 (page 673)
974 3 Remote APP signal Out of Range HIGH (page 674)
974 4 Remote APP signal Out of Range LOW (page 677)
1136 0 ECM Error - over temperature (page 679)
1173 2 TC2CIT signal erratic, intermittent, or incorrect (page 681)
1173 3 TC2CIT signal Out of Range HIGH (page 684)
1173 4 TC2CIT signal Out of Range LOW (page 690)
1173 16 TC2CIT signal above desired (Interstage CAC under cooling) (page 692)
1189 3 TC2WC short to PWR (page 695)
1189 4 TC2WC Open or short to GND (page 698)
1209 0 EBP above desired level (page 702)
1209 1 EBP below desired level (page 707)
1209 2 EBP Signal Erratic, Intermittent, or Incorrect (page 711)
1209 3 EBP signal Out of Range HIGH (page 712)
1209 4 EBP signal Out of Range LOW (page 715)
1209 7 EBP signal not responding as expected (page 721)
1231 19 DCU Error - J1939 communication fault (page 722)
1322 31 Misfire - Multiple Cylinders (page 728)
1323 31 Misfire - Cylinder 1 (page 731)
1324 31 Misfire - Cylinder 2 (page 735)
1325 31 Misfire - Cylinder 3 (page 739)
1326 31 Misfire - Cylinder 4 (page 743)
1327 31 Misfire - Cylinder 5 (page 747)
1328 31 Misfire - Cylinder 6 (page 751)
1378 31 Change Engine Oil Service Interval (page 755)
1387 31 Altitude Reference Adder Fault (page 756)
1659 20 ECT1 below expected: Check Thermostat (page 759)
2623 3 APP2 signal Out of Range HIGH (page 763)
2623 4 APP2 signal Out of Range LOW (page 768)
2630 2 CACOT signal erratic, intermittent, or incorrect (page 774)
14 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN FMI Condition Description

2630 3 CACOT signal Out of Range HIGH (page 776)
2630 4 CACOT signal Out of Range LOW (page 781)
2630 16 CACOT Undercooling (page 783)
2659 10 EGR Slow Response Fault (page 789)
2659 14 EGR System flow rate error during Air Management Test (page 792)
2659 20 EGR High Flow Rate detected (page 794)
2659 21 EGR Low Flow Rate detected (page 796)
2791 2 EGR valve communication fault (page 800)
2791 3 EGRV supply voltage is too HIGH (page 809)
2791 4 EGRV supply voltage is too LOW (page 811)
2791 7 EGR Valve unable to achieve commanded position (page 817)
2791 8 EGR valve not receiving ECM PWM signal (page 819)
2791 12 EGR Valve Internal self test fault (page 828)
2791 14 EGR valve Initialization Fault (page 830)
2796 2 Transfer Case Switch or Circuit Fault (page 832)
2797 3 Injector Control Group 1 open coil short (page 836)
2797 4 Injector Control Group 1 close coil short (page 843)
2797 6 Injector Control Group 1 - short circuit (INJ 1, 2, 3) (page 849)
2798 3 Injector Control Group 2 open coil short (page 861)
2798 4 Injector Control Group 2 close coil short (page 868)
2798 6 Injector Control Group 2 - short circuit (INJ 4, 5, 6) (page 874)
3055 2 ICP/IPR Adaptation In-Range Fault (page 886)
3242 2 DPFIT signal erratic, intermittent, or incorrect (page 890)
3242 3 DPFIT signal Out of Range HIGH (page 892)
3242 4 DPFIT signal Out of Range LOW (page 894)
3242 7 DPFIT sensor or circuit fault (page 897)
3242 10 DPFIT signal abnormal rate of change (page 900)
3242 20 DPFIT signal drifted HIGH (page 903)
3242 21 DPFIT signal drifted LOW (page 907)
3246 2 DPFOT signal erratic, intermittent, or incorrect (page 909)
3246 3 DPFOT signal Out of Range HIGH (page 912)
3246 4 DPFOT signal Out of Range LOW (page 915)
3246 7 DPFOT not warming along with engine (page 918)
3246 20 DPFOT signal drifted HIGH (page 923)
3246 21 DPFOT Signal Drifted LOW (page 926)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 15

SPN FMI Condition Description

3251 0 DPFDP excessively HIGH (Plugged filter) (page 929)
3251 2 DPFDP signal erratic, intermittent, or incorrect (page 935)
3251 3 DPFDP signal Out of Range HIGH (page 938)
3251 4 DPFDP signal Out of Range LOW (page 941)
3251 10 DPFDP signal abnormal rate of change (page 946)
3251 14 DPFDP sensor pressure hoses reversed (page 949)
3251 21 DPFDP excessively LOW (Sensor/circuit fault or missing DPF) (page 954)
3387 20 Cylinder 1 Balance maximum limit exceeded (page 959)
3387 21 Cylinder 1 Balance below minimum limit (page 960)
3388 20 Cylinder 2 Balance maximum limit exceeded (page 961)
3388 21 Cylinder 2 Balance below minimum limit (page 962)
3389 20 Cylinder 3 Balance maximum limit exceeded (page 963)
3389 21 Cylinder 3 Balance below minimum limit (page 964)
3390 20 Cylinder 4 Balance maximum limit exceeded (page 965)
3390 21 Cylinder 4 Balance below minimum limit (page 966)
3391 20 Cylinder 5 Balance maximum limit exceeded (page 967)
3391 21 Cylinder 5 Balance below minimum limit (page 968)
3392 20 Cylinder 6 Balance maximum limit exceeded (page 969)
3392 21 Cylinder 6 Balance below minimum limit (page 970)
3464 3 ETC short to PWR (page 971)
3464 4 ETC short to GND (page 976)
3464 11 ETC operation Fault (page 981)
3464 31 Intake Throttle Valve short circuit fault (page 984)
3471 1 AFT Fuel Pressure 1 below desired (Low System Pressure) (page 990)
3471 7 AFT Fuel Doser Valve not responding as expected (page 995)
3471 10 AFT Fuel Pressure incorrect dosing pressure multiple events (page 1000)
3479 3 AFT Fuel Doser Valve Short to PWR (page 1006)
3479 4 AFT Fuel Doser Valve Open or Short to GND (page 1012)
3479 5 AFT Fuel Pressure Control Valve Open or short to GND on low side (page 1018)
3479 6 AFT Fuel Pressure Control Valve Open or short to PWR on high side (page 1024)
3480 3 AFTFP1 signal Out of Range HIGH (page 1030)
3480 4 AFTFP1 signal Out of Range LOW (page 1035)
3482 3 AFT Fuel Shutoff Valve short to PWR (page 1038)
3482 4 AFT Fuel Shutoff Valve open or short to GND (page 1049)
3509 3 VREF 1 voltage above maximum (page 1060)
16 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN FMI Condition Description

3509 4 VREF 1 voltage below minimum (page 1068)
3510 3 VREF 2 voltage above maximum (page 1084)
3510 4 VREF 2 voltage below minimum (page 1086)
3511 3 VREF 3 voltage above maximum (page 1089)
3511 4 VREF 3 voltage below minimum (page 1093)
3512 14 DCU Vref 1 or 2 voltage above or below normal (page 1101)
3556 0 AFT Fuel Pressure 2 excessively high (page 1108) (Restricted injection)
3556 1 AFT Fuel Pressure 2 below desired (page 1111) (Possible system leak)
3556 7 AFT Fuel Injector not responding as expected (page 1113)
3659 4 Injector 1 close coil - short circuit (page 1115)
3659 5 Injector 1 close coil - open circuit (page 1120)
3660 4 Injector 2 close coil - short circuit (page 1125)
3660 5 Injector 2 close coil - open circuit (page 1130)
3661 4 Injector 3 close coil - short circuit (page 1135)
3661 5 Injector 3 close coil - open circuit (page 1140)
3662 4 Injector 4 close coil - short circuit (page 1145)
3662 5 Injector 4 close coil - open circuit (page 1150)
3663 4 Injector 5 close coil - short circuit (page 1155)
3663 5 Injector 5 close coil - open circuit (page 1160)
3664 4 Injector 6 close coil - short circuit (page 1165)
3664 5 Injector 6 close coil - open circuit (page 1170)
3719 0 DPF soot load - highest (level 3/3) (page 1175)
3719 15 DPF Soot Load - Lowest (level 1/3) (page 1176)
3719 16 DPF Soot Load - Moderate (level 2/3) (page 1177)
3936 0 DPF Soot Load - Severe De-Rate (page 1178)
3936 2 DPF System Feedback Control Fault (page 1179)
3936 8 DPF regenerations are occurring too frequently (page 1180)
3936 14 DPF, Regen duration above limit (page 1181)
3936 20 DPF Feedback Adaptive Limits Reached (page 1183)
4077 3 AFTFP2 signal Out of Range HIGH (page 1187)
4077 4 AFTFP2 Signal Out of Range LOW (page 1194)
4192 3 WIF signal Out of Range HIGH (page 1196)
4192 4 WIF signal Out of Range LOW (page 1198)
4192 5 WIF Signal Open or Short to PWR (page 1201)
4192 31 Water in Fuel Detected (page 1203)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 17

SPN FMI Condition Description

4227 7 CC Oil Separator: Not spinning (page 1205)
4257 7 Injector Coking Compensation Factor Reached Maximum Authority (page 1210)
4257 16 Multiple Injector High Flow fault (page 1212)
4257 18 Multiple Injector Low Flow fault (page 1215)
4287 0 ECBP above desired level (page 1218)
4287 1 ECBP below desired level (page 1220)
4287 3 ECBP signal Out of Range HIGH (page 1223)
4287 4 ECBP signal Out of Range LOW (page 1233)
4752 4 EGR Cooler Efficiency: EGR Outlet Temperature above expected (page 1235)
4765 2 DOCIT signal erratic, intermittent, or incorrect (page 1238)
4765 3 DOCIT signal Out of Range HIGH (page 1243)
4765 4 DOCIT signal Out of Range LOW (page 1246)
4765 7 DOCIT not increasing with engine temperature (page 1249)
4765 20 DOCIT Signal Drifted HIGH (page 1253)
4765 21 DOCIT signal drifted LOW (page 1256)
4766 10 Catalyst System Efficiency Below Threshold (page 1258)
5319 31 DPF incomplete Regeneration (page 1261)
5395 0 Engine unable to achieve desired idle torque (too high) (page 1264)
5395 1 Engine unable to achieve desired idle torque (too low) (page 1267)
5456 2 AFTFT signal erratic, intermittent, or incorrect (page 1270)
5456 3 AFTFT signal Out of Range HIGH (page 1274)
5456 4 AFTFT Signal Out of Range LOW (page 1279)
5541 1 TC1TOP pressure below minimum (page 1281)
5541 2 TC1TOP signal erratic, intermittent, or incorrect (page 1283)
5541 3 TC1TOP signal Out of Range HIGH (page 1284)
5541 4 TC1TOP signal Out of Range LOW (page 1286)
5543 3 EBPC short to PWR (page 1291)
5543 4 EBPC short to GND (page 1293)
5543 5 EBPC open load/circuit (page 1295)
18 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 1 Warning Lamps

 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 19

How To Use Symptom Based Diagnostics

Begin symptom based diagnostic troubleshooting by performing 1.0 Preliminary Vehicle Operational Checkout
Procedure, unless the customer’s concern aligns with one of the other Operational Checkout Procedures.
For example, if the vehicle is experiencing coolant loss, start with 5.0 Cooling System Operational Checkout
Procedure. The 1.0 Preliminary Vehicle Operational Checkout Procedure inspects fundamental engine
systems needed for proper operation: fuel, batteries, air intake, exhaust, engine oil, coolant, and control system
communication. The final step points to more specific operational checkout procedures for your symptom.
Never use Symptom based diagnostics when fault codes are present, unless specifically directed from the fault
code diagnostic.
20 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Operational Checkout Procedures

1.0 - Preliminary Vehicle Operational Checkout Procedure

Step 1 Inspect fuel level, quality, and fuel system. Decision

Perform Fuel Level Inspection (page 1634) and Fuel System Inspection (page 1631) and Yes: Go to Step 2.
the Fuel Quality Inspection (page 1632).
No: Correct low fuel
Are fuel level to specification, and is fuel system not damaged or leaking? level. Repair fuel system
leaks or damage. If fuel
contamination is found drain
fuel and replace with known
good fuel. If engine was
run with fuel contamination
replace injectors and fuel
filters. Perform Injector
Coil End of Motion (CEOM)
Reset Procedure (page
1334) and Injector Coking
Accumulation Reset
Procedure (page 1338).
After repairs are complete,
retest for original problem.

Step 2 Inspect batteries, electrical system, and connections. Decision

Perform Batteries and Electrical System Inspection (page 1666). Yes: Go to Step 3.
Are batteries, electrical system, and connections in good condition, tight, not corroded, No: Repair broken, loose, or
and is battery voltage in specification? corroded electrical system
connections or components.
Charge batteries to 12.6
volts. After repairs are
complete, retest for original
problem.

Step 3 Inspect air intake system for damage or restrictions. Decision

Perform Intake Air Inspection (page 1648). Yes: Repair air intake
system damage or
Are air intake system components damaged or restricted?
restrictions. After repairs are
complete, retest for original
problem.
No: Go to Step 4.

Step 4 Inspect exhaust system for damage or restrictions. Decision

Inspect Diesel Oxidation Catalyst (DOC), Diesel Particulate Filter (DPF), and exhaust Yes: Repair exhaust system
piping for damage or restrictions. damage or restrictions. After
repairs are complete, retest
Are exhaust system components damaged or restricted?
for original problem.
No: Go to Step 5.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 21

Step 5 Inspect engine oil level. Decision

Perform Engine Oil Level and Quality Inspection (page 1635). Yes: Go to Step 6.
Is engine oil level and quality to specification? No: Correct engine oil level
or quality problem. If oil is
aerated, run engine for 10
minutes to attempt to clear
oil aeration. Go to Step 6.

Step 6 Inspect engine coolant level and quality. Decision

Perform Coolant Level Inspection (page 1637) and Coolant Quality Inspection (page Yes: Go to Step 7.
1638).
No, Adjust coolant level to
Are coolant level and quality to specification? specification. Go to Step 7.

No, Oil present, perform 7.7

Engine Oil in Coolant (page
117).
No, DEF or other
contaminants present,
perform Coolant Flush
Procedure (see iKNow
article IK1201248).

Step 7 Verify Engine Control Module (ECM) communicates with Electronic Service Decision
Tool (EST), obtain vehicle health report, and check for current ECM calibration.
A. Connect EST with Navistar® Engine Diagnostics and log-in. Yes: Go to Step 8.
B. Perform Obtain Vehicle Health Report (page 1324). No, ECM calibration not
current: Ensure vehicle has
Is EST communicating with the ECM, and is ECM calibration current?
latest ECM calibration. After
repairs are complete, retest
for original problem.
No, EST not communicating
with ECM: Go to 11.0 ECM
Loss of Communication
(page 40).
22 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 8 Review results from previous steps, Repair Order (RO), vehicle history, and operator complaint.
Go to operational checkout procedure for specific symptom:
• 2.0 Engine Does Not Start Operational Checkout Procedure (page 23)
• 3.0 Engine Hard to Start Operational Checkout Procedure (page 26)
• 4.0 Engine Running, Engine Not Under Load Operational Checkout Procedure (page 29)

• 5.0 Engine Running, Engine Under Load Operational Checkout Procedure (page 31)

• 6.0 Cooling System Operational Checkout Procedure (page 33)

• 7.0 Engine Oil System Operational Checkout Procedure (page 36)
• 8.0 Fuel System Operational Checkout Procedure (page 38)
• 9.0 Engine Compression Brake Operational Checkout Procedure (page 39)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 23

2.0 - Engine Does Not Start Operational Checkout Procedure

Overview
The following steps direct technicians to systematically troubleshoot engine no start conditions and avoid
unnecessary repairs.

Step 1 Perform preliminary operational checkout procedure. Decision

Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers Yes: Go to Step 2.
complaint align with this operational checkout procedure?
No: Go to 1.0 Preliminary
Vehicle Operational
Checkout Procedure
(page 20).

Step 2 Determine if injector buzz test will identify a failed fuel injector. Decision
Perform Injector Test (page 1365). Yes: Go to Step 3.
Is an audible buzz sound heard from each injector? No: Do injector circuit
diagnostics (SPN
651-656 FMI 4, 5;
SPN 2797; 2798 FMI
3, 4; SPN 3659-3664
FMI 4, 5) for specific
failed injector(s). If circuit
diagnostics passes,
replace failed injector(s).

Step 3 Check for no start related Diagnostic Trouble Codes (DTC). Decision
®
Using Electronic Service Tool (EST) with Navistar Engine Diagnostics, check DTC list for: Yes: Go to Fault Code
Diagnostics for no start
• SPN 94 Fuel Delivery Pressure (FDP)
related SPN.
• SPN 931 Electric Fuel Pump (EFP)
No: Go to Step 4.
• SPN 164, 3055 Injection Control Pressure (ICP)
• SPN 679 Injection Pressure Regulator (IPR)
• SPN 636 Camshaft Position (CMP)
• SPN 637 Crankshaft Position (CKP)
• SPN 108, 158, 628, 629, 1136, 1387 Engine Control Module (ECM)

• SPN 27, 2791 Exhaust Gas Recirculation (EGR)

• SPN 110, 1659 Engine Coolant Temperature 1 (ECT1)
• SPN 175 Engine Oil Temperature (EOT)

• SPN 51, 3464, Engine Throttle Valve (ETV)

• SPN 651-656, 2797, 2798, 3055, 3659-3664, 4257 Injector (INJ) faults
• SPN 4287 Engine Compression Brake Pressure (ECBP)
Does EST DTC list have any active fault codes listed above?
24 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 4 Record snapshot of no start related Key-On Engine-Off (KOEO) data. Decision
A. Perform Record Snapshot of KOEO Data (page 1330). Yes: Go to Step 5.
B. Wiggle the ICP harness, IPR harness, UVC connector (for ICP); 24-pin, 42-pin (IP), No: Battery voltage
and 36-pin ECM connectors. out of specification:
Repair battery, starting
system, charging system,
or ECM PWR circuit
problem. After repairs
are complete, retest for
original problem.
No, FDP out of
specification: Go to 8.1
Fuel Delivery Pressure
(page 119).
No, ICP out of
specification: Go to
SPN 164 FMI 0 Fault
Code Diagnostics (page
360).
Are battery voltage, FDP, ICP, and engine temperature sensor values within KOEO No, One or more engine
specifications? temperature sensors
not within 20°F (11°C)
of others after cold
soak: Go to (Fault
Code Diagnostics, page
129) for sensor out of
specification.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 25

Step 5 Record snapshot of engine cranking data. Decision

A. Perform Engine Cranking Test (page 1374). Yes: Go to Step 6.
B. Wiggle the ICP harness, IPR harness, UVC connector (for ICP); 24-pin, 42-pin (IP), No, SWBAT or Engine
and 36-pin ECM connectors. Speed (rpm) out of
specification: Go to 2.1
Engine Cranks Slow or
Does Not Crank (page
49).
No, ICP or IPR out of
specification: Go to
CPA High-Pressure Oil
Pump (HPOP) Test (page
1440).
No, FDP out of
specification: Go to 8.1
Fuel Delivery Pressure
(page 119).
Are Switch Battery (SWBAT), Engine Speed (rpm), ICP, IPR Ctrl, FDP, and EGR Position No, EGR out of
within engine cranking specification (page 1679)? specification: Go to
SPN 2791 FMI 7 Fault
Code Diagnostics (page
817).

Step 6 Engine no start, cold ambient temperature. Decision

Attempt to start engine. Yes: Go to 2.2 Engine
No Start, Cold Ambient
Does engine fail to start, specifically during cold ambient temperatures?
Temperature (page 52).
No: Go to Step 7.

Step 7 Engine at operating temperature, no re-start. Decision

A. Run engine to operating temperature. Yes: Go to 2.3 Engine at
Operating Temperature,
B. Attempt to start engine at operating temperature.
No Re-Start (page 54).
Does engine fail to start, specifically after being run to operating temperature?
No: Go to 2.4 Engine
Never Starts (page 56).
26 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

3.0 - Engine Hard to Start Operational Checkout Procedure

Overview
The following steps direct technicians to systematically troubleshoot engine hard to start conditions and avoid
unnecessary repairs.

Step 1 Perform preliminary operational checkout procedure. Decision

Yes: Go to Step 2.
Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers No: Go to 1.0 Preliminary
complaint align with this operational checkout procedure? Vehicle Operational
Checkout Procedure
(page 20).

Step 2 Check for hard to start related Diagnostic Trouble Codes (DTC). Decision
Using Electronic Service Tool (EST) with Navistar® Engine Diagnostics, check DTC list for: Yes: Go to Fault Code
Diagnostics for hard to
• SPN 94 Fuel Delivery Pressure (FDP)
start related SPN.
• SPN 931 Electric Fuel Pump (EFP)
• SPN 164 Injection Control Pressure (ICP)
• SPN 679 Injection Pressure Regulator (IPR)
• SPN 636 Camshaft Position (CMP)
• SPN 637 Crankshaft Position (CKP)
• SPN 108, 158, 628, 629, 1136, 1387 Engine Control Module (ECM)
• SPN 27, 2791 Exhaust Gas Recirculation (EGR)
• SPN 110, 1659 Engine Coolant Temperature 1 (ECT1)
• SPN 175 Engine Oil Temperature (EOT)
• SPN 1209 Exhaust Back Pressure (EBP)
• SPN 3251 Diesel Particulate Filter Differential Pressure (DPFDP)
• SPN 5541, 5543 Exhaust Back Pressure Valve (EBPV)
• SPN 51, 3464 Engine Throttle Valve (ETV)
• SPN 102 Intake Manifold Pressure (IMP)

• SPN 132 Mass Air Flow (MAF)

• SPN 651-656, 2797, 2798, 3055, 3659-3664, 4257 Injector (INJ) faults
• SPN 4287 Engine Compression Brake Pressure (ECBP)
Does EST DTC list have any of the fault codes listed above?
No: Go to Step 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 27

Step 3 Record snapshot of hard to start related Key-On Engine-Off (KOEO) data. Decision
A. Perform Record Snapshot of KOEO Data (page 1330). Yes: Go to Step 4.
B. Wiggle the ICP harness, IPR harness, UVC connector (for ICP); 24-pin, 42-pin (IP), No, battery voltage
and 36-pin ECM connectors. out of specification:
Repair battery, starting
Are battery voltage, Fuel Delivery Pressure (FDP), Injection Control Pressure (ICP), and
system, charging system,
engine temperature sensor values within Key-On Engine-Off specifications?
or ECM PWR circuit
problem. After repairs
are complete, retest for
original problem.
No, FDP out of
specification: Go to 8.1
-Fuel Delivery Pressure
(page 119).
No, ICP out of
specification: Go to
SPN 164 FMI 0 Fault
Code Diagnostics (page
360).
No, one or more engine
temperature sensors
Not within 20°F (11°C)
of others after cold
soak: Go to Fault Code
Diagnostics for sensor
out of specification.

Step 4 Record snapshot of engine cranking data. Decision

A. Perform Engine Cranking Test (page 1374). Yes: Go to Step 5.
B. Wiggle the ICP harness, IPR harness, UVC connector (for ICP); 24-pin, 42-pin (IP), No, SWBAT or Engine
and 36-pin ECM connectors. Speed (rpm) out of
specification: Go to 2.1
Are Switch Battery (SWBAT), Engine Speed (rpm), ICP, IPR, FDP, EGR, Turbocharger 1
Engine Cranks Slow or
Turbine Outlet Pressure (TC1TOP), EBP, and DPFDP within Engine cranking specification?
Does Not Crank (page
49).
No, ICP or IPR out of
specification: Go to CPA
High-Pressure Oil Pump
(HPOP) Test (page 1440).
No, FDP out of
specification: Go to 8.1
Fuel Delivery Pressure
(page 119).
No, EGR out of
specification: Go to
SPN 2791 FMI 7 Fault
28 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Code Diagnostics (page

817).
No, TC1TOP, EBP,
or DPFDP out of
specification: Look for
exhaust restrictions.

Step 5 Determine if engine will not start specifically during cold ambient Decision
temperatures.
Attempt to start engine. Yes: Go to 3.1 Engine
Hard to Start, Cold
Is engine hard to start, specifically during cold ambient temperatures?
Ambient Temperature
(page 58).
No: Go to Step 6.

Step 6 Determine if engine is hard to re-start after being run to operating Decision
temperature.
A. Run engine to operating temperature. Yes: Go to 3.2 Engine at
Operating Temperature,
B. Attempt to re-start engine at operating temperature.
Hard to Re-Start (page
Is engine hard to re-start specifically after being run to operating temperature? 60).
No: Go to Step 7.

Step 7 Determine if engine starts, and then stalls. Decision

Attempt to start engine. Yes: Go to 3.3 Engine
Starts, Then Stalls (page
Does engine start and then stall?
62).
No: Go to 2.4 Engine
Never Starts (page 56).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 29

4.0 - Engine Running, Engine Not Under Load Operational Checkout Procedure

Overview
The following steps direct technicians to systematically troubleshoot engine running problems while engine is
not under a load.

Step 1 Perform preliminary operational checkout procedure. Decision

Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers Yes: Go to Step 2.
complaint align with this operational checkout procedure?
No: Go to 1.0 Preliminary
Vehicle Operational
Checkout Procedure
(page 20).

Step 2 Check for related Diagnostic Trouble Codes (DTCs). Decision

Using Electronic Service Tool (EST) with Navistar® Engine Diagnostics, check DTC list for: Yes: Go to Fault
Code Diagnostics for
• SPN 91, 2623 Accelerator Pedal Position (APP)
appropriate SPN.
• SPN 94 Fuel Delivery Pressure (FDP)
No: Go to Step 3.
• SPN 931 Electronic Fuel Pump (EFP)
• SPN 164, 3055 Injection Control Pressure (ICP)
• SPN 679 Injection Pressure Regulator (IPR)
• SPN 636 Camshaft Position (CMP)
• SPN 637 Crankshaft Position (CKP)
• SPN 27, 2791 Exhaust Gas Recirculation (EGR)
• SPN 110, 1659 Engine Coolant Temperature 1 (ECT1)
• SPN 175 Engine Oil Temperature (EOT)
• SPN 1209 Exhaust Back Pressure (EBP)
• SPN 5541, 5543 Exhaust Back Pressure Valve (EBPV)
• SPN 3251 Diesel Particulate Filter Differential Pressure (DPFDP)
• SPN 51, 3464 Engine Throttle Valve (ETV)
• SPN 102 Intake Manifold Pressure (IMP)

• SPN 132 Mass Air Flow (MAF)

• SPN 651-656, 2797, 2798, 3055, 3659-3664, 4257 Injector (INJ)
• SPN 105 Intake Manifold Temperature (IMT)
Does EST DTC list have any of the above listed SPN?
30 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Record snapshot of engine running data and determine if engine idles properly. Decision
A. Perform Record Snapshot of Engine Running Data (page 1464) while symptom Yes: Go to 4.1 Rough Idle
is occurring. (page 64).
B. Wiggle the ICP harness, IPR harness, UVC connector (for ICP); 24-pin, 42-pin (IP), No: Go to Step 4.
and 36-pin ECM connectors.

C. Run engine at idle.

D. Full throttle for 15 seconds.

E. Idle for 30 seconds.
F. Full throttle for 15 seconds.
G. Idle for 30 seconds.
H. Stop recording.
Does engine idle rough or surge at idle?

Step 4 Determine if engine is able to reach rated speed. Decision

A. Start engine. Yes: Go to Step 5.
B. Increase engine rpm to rated speed, and return to idle. No: Go to 4.2 Engine
Unable to Reach Rated
Is engine able to reach rated speed?
Speed (No Load) (page
67).

Step 5 Determine if a popping noise is coming from engine air intake. Decision
A. Start engine. Yes: Go to 4.3 Popping
Noise from Intake (page
B. Listen for popping noise from engine air intake.
69).
C. Increase engine rpm to rated speed and return to idle.
No: Review operator
Is popping noise heard from engine air intake? complaint.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 31

5.0 - Engine Running, Engine Under Load Operational Checkout Procedure

Overview
The following steps direct technicians to systematically troubleshoot engine running problems while under a
load.

Step 1 Perform preliminary operational checkout procedure.

Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers Yes: Go to Step 2.
complaint align with this operational checkout procedure?
No: Go to 1.0 Preliminary
Vehicle Operational
Checkout Procedure (page
20).

Step 2 Check for Diagnostic Trouble Codes (DTCs). Decision

Using Electronic Service Tool (EST) with Navistar® Engine Diagnostics, check DTC list for: Yes: Go to Fault Code
Diagnostics for appropriate
• SPN 91, 2623 Accelerator Pedal Position (APP)
SPN (page 130).
• SPN 94 Fuel Delivery Pressure (FDP)
No: Go to Step 3.
• SPN 931 Electronic Fuel Pump (EFP)
• SPN 164, 3055 Injection Control Pressure (ICP)
• SPN 679 Injection Pressure Regulator (IPR)
• SPN 636 Camshaft Position (CMP)
• SPN 637 Crankshaft Position (CKP)
• SPN 27, 2791 Exhaust Gas Recirculation (EGR)
• SPN 110, 1659 Engine Coolant Temperature 1 (ECT1)
• SPN 175 Engine Oil Temperature (EOT)
• SPN 1209 Exhaust Back Pressure (EBP)
• SPN 5541, 5543 Exhaust Back Pressure Valve (EBPV)
• SPN 3251 Diesel Particulate Filter Differential Pressure (DPFDP)
• SPN 51, 3464 Engine Throttle Valve (ETV)
• SPN 102 Intake Manifold Pressure (IMP)

• SPN 132 Mass Air Flow (MAF)

• SPN 651-656, 2797, 2798, 3055, 3659-3664, 4257 Injector (INJ)
• SPN 105 Intake Manifold Temperature (IMT)
Does EST DTC list have any of the above listed SPN?
32 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Record snapshot of engine running data and determine if engine has a misfire.
Perform 0 to 60 MPH Test (page 1514). Yes: Go to 5.2 Misfire
(Stumble/Surge/Runs
Does engine speed vary by 50 rpm or more while symptom is occurring?
Rough) (page 81).
No: Go to Step 4.

Step 4 Determine if engine has low power or slow acceleration.

Review 0 to 60 MPH Test results. Yes: Go to 5.1 Low Power
(Slow Acceleration) (page
Does vehicle have low power or slow acceleration?
71).
No, if equipped with Power
Takeoff (PTO): Go to Step 5.
No, if not equipped with
PTO: review operator
complaint.

Step 5 Determine if engine is able to reach desired speed during PTO operation.
A. Start engine. Yes: Review operator
complaint.
B. Operate PTO.
No: Go to 5.3 Engine Unable
C. If vehicle is equipped with a manual PTO, increase engine rpm to desired
to Reach Desired Speed
operating speed.
During PTO Operation (page
Does engine reach desired speed during PTO operation? 84).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 33

6.0 - Cooling System Operational Checkout Procedure

Overview
The following steps direct technicians to systematically troubleshoot engine cooling system problems and avoid
unnecessary work and repairs.

Step 1 Perform preliminary operational checkout procedure. Decision

Yes: Go to Step 2.
Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers No: Go to 1.0 Preliminary
complaint align with this operational checkout procedure? Vehicle Operational
Checkout Procedure (page
20).

WARNING:

To prevent personal injury or death, wear safety glasses with side shields.

Step 2 Determine if air flow thru cooling package is restricted or cooling system Decision
components are damaged.
A. Inspect for restrictions and debris in front of and between radiators and other Yes: Clear restrictions and
cooling package components. clean debris from cooling
package. Repair damaged
B. Inspect cooling fan blades, fan shroud, accessory drive belt(s), drive belt
cooling system components.
tensioner(s), cooling package, and other cooling system components for
After repairs are complete,
damage.
retest for original problem.
Were restrictions or debris found, or are cooling system components damaged?
No: Go to Step 3.

Step 3 Determine if deaeration tank cap holds to rated pressure. Decision

Perform Deaeration Tank Cap Test (page 1600). Yes: Go to Step 4.
Does deaeration cap hold to rated pressure?
No: Replace deaeration
tank cap. After repairs are
complete, retest for original
problem.
34 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 4 Determine if engine or cooling system components are leaking externally Decision
or internally.
Perform Coolant Leak Visual Inspection (page 1643). Yes: Go to Step 5.
Does cooling system holding pressure for 15 minutes?
No, external leaks: Repair
external cooling system
leaks. After repairs are
complete, retest for original
problem.
No, internal leaks: Go to
Step 8.

Step 5 Determine if cooling system will not get up to proper operating temperature. Decision
®
A. Connect Electronic Service Tool (EST) with Navistar Engine Diagnostics and Yes: Go to Step 6.
log in.
No: Go to 6.3 Engine
B. Run engine to operating temperature while monitoring Engine Coolant Unable to Reach Operating
Temperature (ECT). Temperature (page 93).

Does ECT reach 180°F (82°C) or higher?

Step 6 Determine if cooling system overflows. Decision

Perform Coolant Over-Flow / Over-Temperature Test (page 1607). Yes: Go to 6.1 Coolant
Overflow (page 87).
Does coolant overflow out of the deaeration tank, before over temperature?
No: Go to Step 7.

Step 7 Determine if vehicle cooling system goes over temperature or overheats. Decision
NOTE: Do not run vehicle on a dynamometer to duplicate over temperature or over-heat Yes: Go to 6.2 Coolant Over
concern. False results will occur due to lack of proper air flow across the cooling package. Temperature (page 90).
Does vehicle cooling system go over temperature 220°F (104°C) or overheat?
No: Go to Step 8.

Step 8 Determine if coolant is in the engine oil. Decision

Perform Coolant to Engine Oil Inspection (page 1658). Yes: Go to 6.6 Coolant Leak
to Engine Oil (page 98).
Is engine oil contaminated with coolant?
No: Go to Step 9.

Step 9 Determine if coolant is in the engine air intake. Decision

Remove the CAC hose at Engine Throttle Valve and inspect for signs of coolant. If Yes: Go to 6.5 Coolant Leak
equipped with Interstage Cooler (ISC), Perform Coolant to Intake Inspection (page 1644). to Intake (page 97).

NOTE: Some moisture and streaking inside the intake system is normal.
Is coolant present in the engine intake?
No: Go to Step 10.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 35

WARNING:

To prevent personal injury or death, allow engine to cool before working with
components.

Step 10 Determine if coolant is in the exhaust. Decision

Perform Coolant in Exhaust Inspection (page 1639). Yes: Go to 6.4 Coolant Leak
to Exhaust (page 95).
Is coolant or white residue visible in the exhaust system?
No: Review operator
complaint.
36 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

7.0 - Engine Oil System Operational Checkout Procedure

Overview
The following steps direct technicians to systematically troubleshoot engine oil system problems and avoid
unnecessary work and repairs.

Step 1 Perform preliminary operational checkout procedure. Decision

Yes: Go to Step 2.
Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers No: Go to 1.0 Preliminary
complaint align with this operational checkout procedure? Vehicle Operational
Checkout Procedure (page
20).

Step 2 Check for engine oil related Diagnostic Trouble Codes (DTC). Decision
Using Electronic Service Tool (EST) with Navistar® Engine Diagnostics, check DTC list for: Yes: Go to Fault Code
Diagnostics for engine oil
• SPN 100 Engine Oil Pressure (EOP)
related SPN.
• SPN 110 Engine Coolant Temperature 1 (ECT1)
• SPN 111 Engine Coolant Level (ECL)
• SPN 175 Engine Oil Temperature (EOT)
Does EST DTC list have any of the fault codes listed above?
No: Go to Step 3.

Step 3 Determine if engine has external oil leaks. Decision

Inspect for engine oil leaks (turbocharger oil drain line, crankcase breather, front main Yes: Repair engine oil leaks
seal, etc.). as needed. After repairs are
complete, retest for original
Is engine oil visibly leaking from the engine, or does vehicle leave oil stains on the
problem.
ground where parked?
No: Go to Step 4.

NOTE: Some condensation on the dipstick and dipstick tube is normal.

Step 4 Verify engine oil quality, and determine if oil is aerated. Decision
Review results from Engine Oil Level and Quality Inspection (page 1635). Yes, fuel is in engine oil:
Go to 8.2 Fuel in Engine Oil
(page 123).
Yes, engine oil
contaminated: Go to 7.1
Engine Oil Contamination
(page 100).
Yes, engine oil aerated: Go
to 7.6 Engine Oil Aeration
(page 115).
Is engine oil contaminated or aerated? No: Go to Step 5.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 37

Step 5 Determine if engine oil is leaking into the cooling system. Decision
A. Allow engine to cool for 15 minutes or more. Yes: Go to 7.7 - Engine Oil
in Coolant (page 117).
B. Remove deaeration tank cap.
C. Inspect deaeration tank for engine oil.
Is engine oil in the deaeration tank? No: Go to Step 6.

Step 6 Determine if engine oil pressure is low or high. Decision

A. Start engine. Yes, oil pressure low: Go to
7.4 Low Engine Oil Pressure
B. Read engine oil pressure gauge.
(page 109).
Is engine oil pressure lower or higher then specification (page 1680).
Yes, oil pressure high: Go to
7.5 High Engine Oil Pressure
(page 113).
No: Go to Step 7.

Step 7 Determine if engine oil is leaking into air intake. Decision

Remove Charge Air Cooler (CAC) piping from the Engine Throttle Valve (ETV). Yes: Go to 7.2 Engine Oil
Leak to Intake (page 103).
Is excessive oil present in air intake?
No: Go to Step 8.

Step 8 Determine if engine oil is leaking into exhaust. Decision

Disconnect turbocharger down pipe at Exhaust Back Pressure Valve (EBPV) outlet. Yes: Go to 7.3 Engine Oil
Leak to Exhaust (page 107).
Is excessive oil present in exhaust?
No: Review complaint.
38 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

8.0 - Fuel System Operational Checkout Procedure

Step 1 Perform preliminary operational checkout procedure. Decision

Yes: Go to Step 2.
Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers No: Go to 1.0 Preliminary
complaint align with this operational checkout procedure? Vehicle Operational
Checkout Procedure (page
20).

Step 2 Determine if fuel is contaminated. Decision

Perform Fuel Quality Inspection (page 1632). Yes: Flush fuel system.
Replace fuel filters. After
Is fuel contaminated?
repairs are complete, retest
for original problem.
No: Go to Step 3.

Step 3 Determine if engine has a fuel delivery problem. Decision

Perform Fuel Delivery Pressure (FDP) Test (page 1554). Yes: Go to Step 4.
Is fuel pressure between 80 and 100 psi?
No: Go to 8.1 Fuel Delivery
Pressure (page 119).

Step 4 Determine if engine has fuel in the engine oil. Decision

Perform Engine Oil Level and Quality Inspection (page 1635). Yes: Go to 8.2 Fuel in
Engine Oil (page 123).
Is fuel in the engine oil?
No: Review operator
complaint.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 39

9.0 - Engine Compression Brake Operational Checkout Procedure

Step
Perform preliminary operational checkout procedure. Decision
1
Yes: Go to Step 2
Did a symptom Fault Code Action Plan (FCAP) bring you here or does the No: Go to 1.0 Preliminary Vehicle
customers complaint align with this operational checkout procedure? Operational Checkout Procedure
(page 20).

Step
Check for related Diagnostic Trouble Codes (DTC). Decision
2
Using Electronic Service Tool (EST) with Navistar® Engine Diagnostics, check Yes: Go to Fault Code Diagnostics
DTC list for: for appropriate SPN.
• SPN 191 Transmission Output Shaft Speed (TOSS) / Vehicle Speed Sensor
(VSS)
• SPN 597 Engine compression brake switch
• SPN 4287 Engine Compression Brake Pressure (ECBP)
Does EST DTC list have any of the above listed SPN?
No: Go to Step 3.

Step Determine if engine compression brake is operating, or is engaged when

Decision
3 not commanded On.
A. Perform 0 to 60 MPH Test (page 1514) while symptom is occurring, No, engine brake does not activate:
activate and deactivate engine brake. Go to 9.1 Engine Compression
Brake Inoperative (page 125).
B. Review 0 to 60 snapshot.
Does engine brake activate and deactivate properly when commanded?
No, engine brake does not
disengage when commanded Off:
Go to 9.2 Engine Compression
Brake Engaged When Not
Commanded (page 127).
Yes: Review operator complaint.
40 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

10.0 - ECM Loss of Communication

Overview
Diagnose Engine Control Module (ECM) not communicating with the Electronic Service Tool (EST).
Possible Causes
• Theft deterrent system
• Public Controller Area Network (CAN) circuit (terminating resistor, etc.)
• Any failed module on Public CAN
• Power and / or ground circuits to Diagnostic Connector
• Engine Control Module (ECM) power circuit (ECM fuse, ECM PWR Relay, etc.)
• ECM ground circuit
• Low battery voltage
• Faulty ECM

Test Procedure

Step
Perform preliminary operational checkout procedure. Decision
1
Yes: Go to Step 2.
Did a symptom Fault Code Action Plan (FCAP) bring you here or does the No: Go to 1.0 Preliminary Vehicle
customers complaint align with this operational checkout procedure? Operational Checkout Procedure
(page 20).

Step
Determine if Electronic Service Tool (EST) is working properly. Decision
2
A. Key-On Engine-Off (KOEO) Yes: Go to Step 3.
B. Connect EST with Navistar® Engine Diagnostics to a second vehicle
and log in.
Does EST communicate properly with second vehicle? No: Repair EST. After repairs
are complete, retest for original
problem.

Step
Determine if EST communicates with other modules. Decision
3
A. Key-On Engine-Off (KOEO). Yes: Go to Step 4.
®
B. Connect EST with Navistar Engine Diagnostics to initial vehicle and
log in.
C. Under the Connection (Sniffer) tab verify equipped modules are listed
under Module Name and Count is actively changing.
Does EST communicate with modules other than the Engine Control Module No: Go to Step 15.
(ECM)?
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 41

NOTE: See latest version of Engine and Aftertreatment Wiring Schematic Form for additional circuit
information.

Step
Determine if ECM ground circuits are working properly. Decision
4
A. Key Off. Yes: Go to Step 5.
B. Connect Breakout Harness 00-00959-01 to ECM 76-pin gray chassis
connector and leave ECM disconnected.
C. Connect Breakout Harness 00-00959-01 to 180-pin Breakout Box
00-00956-08.
D. Key-On Engine-Off (KOEO).
E. Measure voltage between battery positive and pins C-2, 4, and 6.
Are ECM ground circuits between pins C-2, 4, 6 and battery positive within 0.5V No: Repair ground circuits. After
of battery voltage? repairs are complete, retest for
original problem.

Step
Determine if ECM is receiving ignition switch power. Decision
5
A. KOEO. Yes: Go to Step 8.
B. Measure SWBAT circuit voltage between battery ground and pin C-31.
Is voltage between pin C-31 and battery negative within 0.5V of battery voltage? No: Go to Step 6.

Step
Determine if vehicle has an anti-theft system installed. Decision
6
Look for anti-theft password switch panel on vehicle center panel. Yes: See Electrical System
troubleshooting Guide for anti-theft
system checks. After repairs
are complete, retest for original
problem.
If anti-theft system is operating
correctly, and problem remains, go
to Step 7.
Does vehicle have an anti-theft system installed? No: Go to Step 7.

Step
Determine if IPR PWR circuit has proper voltage. Decision
7
A. Inspect F1-A ( 5A or 10A) fuse for loose terminals or corrosion (see Yes: Repair Open or high resistance
appropriate Truck Circuit Diagram). between F1-A fuse and ECM pin
C-31. After repairs are complete,
B. Key-On Engine-Off (KOEO).
retest for original problem.
C. Measure voltage between ground and each side of the F1-A fuse.
No, voltage is within 0.5V of battery
voltage only on one side of F1-A
fuse: Replace blown fuse and / or
repair loose terminals or corrosion.
42 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Diagnosis short or other reason fuse

blew. After repairs are complete,
retest for original problem.
Is voltage within 0.5V of battery voltage on both sides of the F1-A fuse? No, voltage not within 0.5V of
battery voltage on either side:
Diagnosis and repair power circuit
to F1-A fuse (see Electrical System
Troubleshooting Guide). After
system repairs are complete, retest
for original problem.

Step
Determine if ECM MPR ground circuit is operating properly. Decision
8
A. KOEO. Yes: Go to Step 10.
B. Remove ECM PWR Relay.
C. Measure voltage between battery positive and ECM PWR relay pin-85.
Is voltage between pin–85 and battery positive within 0.5V of battery voltage? No: Go to Step 9.

Step
Determine if ECM MPR ground circuit is Open. Decision
9
A. KOEO. Yes: Go to Step 10.
B. Measure voltage between battery positive and pin C-70.
Is voltage between pin C-70 and battery positive within 0.5V of battery voltage? No: Replace Engine Control Module
(ECM). After repairs are complete,
retest for original problem.

Step
Determine if power circuits to the ECM are working properly. Decision
10
A. Key-On Engine-Off (KOEO). Yes: Go to Step 11.

B. Measure voltage between battery ground and pins C-1, 3 and 5.

Are power circuits between pins C-1, 3, and 5 and battery ground within 0.5V of No: Diagnose and repair ECM
battery voltage? power circuit (40A fuse, ECM
PWR relay, etc.). After repairs
are complete, retest for original
problem.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 43

Step Determine if Public CAN circuits between ECM and Diagnostic Connector
Decision
11 are Open or have high resistance.
A. Key Off. Yes: Go to Step 12.
B. Disconnect batteries.

C. Measure resistance between 9-pin Diagnostic Connector pin-D and

ECM pin C-62 (CAN-L).
D. Measure resistance between Diagnostic Connector pin-C and ECM pin
C-61 (CAN-H).
Are measured resistances 5 ohms or less? No: Repair Open or high resistance
in Public CAN circuit(s). After
repairs are complete, retest for
original problem.

Step
Measure resistance between Public CAN circuits. Decision
12
Measure resistance between Diagnostic Connector pin-C and pin-D. Yes: Go to Step 14.
Is resistance between Diagnostic Connector pin-C and pin-D approximately 60 No: Go to Step 13.
ohms?

Step
Measure terminating resistors. Decision
13
A. Remove both 120 ohm Public CAN terminating resistors. Yes: Repair Public CAN circuit
wiring. After repairs are complete,
B. Measure resistance of each terminating resistor.
retest for original problem.
Is resistance of each terminating resistor approximately 120 ohms? No: Replace defective terminating
resistor(s). After repairs are
complete, retest for original
problem.

Step
Determine if Public CAN J1939 data link is operating properly. Decision
14
A. Connect vehicle batteries. Yes: Replace Engine Control
Module (ECM). After repairs
B. Key-On Engine-Off (KOEO).
are complete, retest for original
C. Measure voltage between 9-pin Diagnostic Connector pin-C (CAN-H) problem.
and ground. Record measurement.
D. Measure voltage between Diagnostic Connector pin-D (CAN-L) and
ground. Record measurement.
NOTE: The sum of CAN-H and CAN-L voltage measurements should add up to
approximately 5V, and CAN-H voltage should be greater than CAN-L.
Is the sum of CAN-H and CAN-L voltage measurements approximately 5V, and No: Repair Public CAN circuit
is CAN-H 2.7V (+-0.5V) and CAN-L 2.3V (+-0.5V)? wiring. After repairs are complete,
retest for original problem.
44 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step
Determine if Diagnostic Connector has proper voltage and ground. Decision
15
A. Measure voltage between 9-pin Diagnostic Connector pin-B and battery Yes: Go to Step 16.
negative.
B. Measure voltage between Diagnostic Connector pin-A and battery
positive.
Is power circuit between pin-B and battery ground within 0.5V of battery voltage; No: Repair power and/or ground
and is voltage between ground circuit pin-A and battery positive within 0.5V of circuit(s) to the Diagnostic
battery voltage? Connector. After repairs are
complete, retest for original
problem.

Step
Determine if Public CAN J1939 data link is operating properly. Decision
16
A. KOEO. Yes: Go to Step 17.
B. Measure voltage between 9-pin Diagnostic Connector pin-C (CAN-H)
and ground. Record measurement.
C. Measure voltage between Diagnostic Connector pin-D (CAN-L) and
ground. Record measurement.
NOTE: The sum of CAN-H and CAN-L voltage measurements should add up to
approximately 5V, and CAN-H should be greater than CAN-L.
Is the sum of CAN-H and CAN-L voltage measurements approximately 5V, and No: repair Public CAN circuit wiring.
is CAN-H 2.7V (+-0.5V) and CAN-L 2.3V (+-0.5V)? After repairs are complete, retest
for original problem.

Step
Determine what module is causing communication failure. Decision
17
Unplug one Public CAN module at a time, and check when EST CAN Yes: Replace faulty module with a
communication returns. Verify only one module is unplugged at any time. known good module. After repairs
are complete, retest for original
problem.
Does EST CAN communication return when a specific module is unplugged? No: End Diagnostic Steps.

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify each step was completed correctly and the proper decision
was made. Notify Supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 45

11.0 Soot Buildup at Exhaust Manifold / Gasket Out of Position

Overview
Diagnose reason for soot buildup at exhaust manifold. Exhaust manifold gasket damage and position are key
to determine required steps.
Some cold start exhaust leaks / soot accumulation at exhaust joints is normal, and does Not require exhaust
manifold and gasket replacement. Examples:
• Exhaust manifold slip joint between ports 2 and 3
• EGR cooler to exhaust manifold slip joint (goose neck)
Exhaust manifold gasket condition and position must be checked.
NOTE: Do not remove exhaust manifold to measure warpage.
NOTE: Minor exhaust leaks will not cause engine performance or frequent exhaust regeneration problems.
Possible Causes
• Exhaust manifold gasket out of position / failed
• Exhaust manifold slip joint leaking (blow by)
• Cracked exhaust manifold (likely near cylinder 4)
• Leaking exhaust downpipe gasket(s), loose V-band clamps, etc.

Test Procedure
NOTE: Do not remove exhaust manifold for cuff seal installation.

Step
Determine if soot is accumulating near the exhaust manifold. Decision
1
Inspect entire exhaust manifold / gasket area for soot accumulation. Yes: Go to Step 2.
Is soot accumulation present? No: Do not remove exhaust
manifold. Inspect cuff seal slip joint
between ports 2 and 3. Repair if
needed. After repairs are complete,
retest for original problem.

Step Determine if soot is accumulating between exhaust manifold ports 2 and

Decision
2 3, or cylinder 6 port?
Yes: Go to Step 3.
Is soot accumulating between exhaust manifold ports 2 and 3, or cylinder 6 port? No: Go to Step 4.
46 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 2
A. Acceptable Gasket Position Between Cylinders 2 and 3

Figure 3
A. Unacceptable Gasket Position Between Cylinders 2 and 3
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 47

Figure 4
A. Acceptable Gasket Protrusion at Cylinder 6

Figure 5
A. Unacceptable Gasket Protrusion at Cylinder 6
48 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step
Determine if exhaust manifold gasket is out of position. Decision
3
A. Inspect top and bottom of exhaust manifold gasket. Yes: Install new exhaust manifold
and gasket kit. Inspect cuff seal on
B. Determine if exhaust manifold gasket holes are aligned halfway or
exhaust manifold slip joint between
better with respect to bolt hole in the cylinder head. See (Figure 2) and
ports 2 and 3. Repair if needed.
(Figure 3).
After repairs are complete, retest
C. Determine if exhaust manifold gasket protrudes from manifold flange for original problem.
more then 3/8 inch (0.95 cm) at cylinder 6 exhaust port. See (Figure 4)
and (Figure 5) .
Is exhaust manifold gasket out of proper position? No: Go to Step 4.

Step Determine if soot has accumulated in other areas near the exhaust
Decision
4 manifold.
Inspect for soot accumulation at the following areas: Yes: Inspect exhaust downpipe
gasket(s) for leaks or loose v-band
• Turbocharger housings
clamps. Repair as necessary.
• Top of EGR cooler housing Inspect cuff seal on exhaust
manifold slip joint between ports
• EGR crossover pipe
2 and 3. Repair if needed. After
• Exhaust downpipe connections repairs are complete, retest for
original problem.
Is soot buildup present in these locations? No: Go to Step 5.

Step
Determine if exhaust manifold is cracked. Decision
5
Inspect exhaust manifold for cracks, especially near cylinder 4. Yes: Install new exhaust manifold
and gasket kit. Inspect cuff seal on
exhaust manifold slip joint between
ports 2 and 3. Repair if needed.
After repairs are complete, retest
for original problem.
Is exhaust manifold cracked? No: End Diagnostic Steps.

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify each step was completed correctly and the proper decision
was made. Notify Supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 49

Engine Does Not Start Symptoms

2.1 - Engine Cranks Slow or Does Not Crank

Overview
Determine reason engine will not crank or will not crank fast enough to start the engine.

Possible Causes
• Failed batteries or low charge
• Corroded or loose battery cables
• Master battery switch turned Off, or Open battery cable circuit
• Starting system faults
• Crank inhibit fault
• Charging system faults
• Internal engine damage (hydro lock due to Exhaust Gas Recirculation (EGR) cooler or fuel injector tip failure,
etc.)
• Starter or flywheel gear binding or not engaging properly
• Power Take Off (PTO) or engine drive engaged
NOTE: See appropriate Truck Electrical System Troubleshooting Guide for additional starting and charging
system information.

Test Procedure

Step 1 Perform operational checkout procedure. Decision

Yes: Go to Step 2.
Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers No: Go to 2.0 Engine
complaint align with this specific symptom procedure? Does Not Start Operational
Checkout Procedure (page
23).

WARNING:

To prevent personal injury or death when working with batteries, always wear face or eye
protection, have water supply available, ensure good ventilation, and be sure no flames
or sparks are present.

Step 2 Determine if each vehicle battery is fully charged. Decision

Measure batteries voltage with a Digital Multimeter (DMM). Yes: Go to Step 3.
Is voltage of each battery 12.5 volts or more? No: Charge batteries. Test
charging system. After
repairs are complete, retest
for original problem.
50 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Determine if master battery switch is Off or battery cable circuit has high Decision
resistance.
Turn ignition key to the Run position and observe instrument panel lights and listen for Yes: Go to Step 4.
injector pre-cycle.
No: Turn master battery
Do instrument panel lights come On and did injectors pre-cycle? switch On or fix battery
cable circuit. After repairs
are complete, retest for
original problem.

CAUTION:

Follow instructions and safety procedures suggested by test equipment manufacturers.

NOTE: Cold batteries deliver less current.

Step 4 Determine if batteries are able to deliver appropriate current to start engine. Decision
Perform Electrical System Test (page 1577). Yes: Go to Step 5.
Do batteries pass test? No: Slow charge or replace
each battery that fails test.
After repairs are complete,
retest for original problem.

Step 5 Determine if PTO or engine drive is engaged. Decision

Are PTO or engine drive engaged? Yes: Disengage PTO
accessories and engine
drives. After repairs are
complete, retest for original
problem.
No: Go to Step 6.

Step 6 Determine if engine has internal damage or starter / flywheel gears are binding. Decision
Using Engine Rotation Tool ZTSE6072, rotate crankshaft by hand to determine if Yes: Go to Step 7.
starter/flywheel gears are binding or engine has internal damage.
Does crankshaft rotate appropriately? No: Go to Step 8.

Step 7 Determine if starting system is operating properly. Decision

Perform Starting System Test Procedure (page 1584). Yes: End diagnostics.
Does starting system pass the test? No: Repair starting system.
After repairs are complete,
retest for original problem.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 51

Step 8 Determine if engine is hydro locked. Decision

A. Remove fuel injectors. See Engine Service Manual. Yes: Clean out fluid and
debris. Perform Piston
B. Inspect each cylinder for hydro lock. Excess liquid (fuel / coolant / oil) in a
Height Measurement Test
cylinder can cause extremely high cylinder pressure (hydro lock) and a bent
(page 1595). If a bent
connecting rod.
connecting rod is found
remove cylinder head &
replace that connecting
rod and install cylinder
kit (piston, rings, liner,
bearings). After repairs are
complete, retest for original
problem.
Are cylinder(s) hydro locked? No: Repair starter/flywheel
binding or internal engine
damage. If starter/flywheel
is not binding, remove oil
pan and inspect lower end.
After repairs are complete,
retest for original problem.

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify if each step was completed correctly and the proper decision
was made. Notify supervisor for further action.
52 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

2.2 - Engine No Start, Cold Ambient Temperature

Overview
Diagnose engine no start in cold ambient conditions (40°F {4°C} or colder).

Possible Causes
• Engine Coolant Temperature 1 (ECT1) sensor or circuit fault
• Engine Oil Temperature (EOT) sensor or circuit fault
• Low cylinder compression
• Failed intake air grid heater
• Open or shorted IAH grid heater wiring (high current)
• Failed Intake Air Heater Relay
• Intake Air Heater Control (IAHC) circuit fault (relay control)
• Open or shorted IAH relay wiring (high current)
• Failed engine coolant heater
• Failed oil pan heater

Test Procedure

Step 1 Perform operational checkout procedure Decision

Yes: Go to Step 2.
Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers No: Go to 2.0 Engine
complaint align with this specific symptom procedure? Does Not Start Operational
Checkout Procedure (page
23).

Step 2 Check for Intake Air Heater Control (IAHC) Diagnostic Trouble Codes (DTC). Decision
Using Electronic Service Tool (EST), check DTC list for SPN 729 Intake Air Heater Yes: Go to Fault Code
Control (IAHC) fault codes. Diagnostics for SPN 729
fault codes.
Are any SPN 729 fault codes active? No: Go to Step 3.

Step 3 Test Intake Air Heater (IAH) system. Decision

Perform Intake Air Heater (IAH) System Test (page 1590). Yes: Go to Step 4.
Is IAH system operating properly? No: Repair IAH faults. After
repairs are complete, retest
for original problem.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 53

Step 4 Test coolant heater assembly. Decision

Perform Coolant Heater Assembly Test (page 1575). Yes: Go to Step 5.
Is engine coolant heater operating properly and did all tests pass? No: Repair engine coolant
heater assembly faults.
After repairs are complete,
retest for original problem.

Step 5 Test oil pan heater assembly. Decision

Perform Oil Pan Heater Test (page 1593). Yes: Perform Relative
Compression Test Plus
(RCT+) (page 1465). If
one or more cylinders
have significant speed
difference(s) than others,
repair engine mechanical
problem. After repairs are
complete, retest for original
problem.
Is oil pan heater operating properly and did all tests pass? No: Repair oil pan heater
assembly faults. After
repairs are complete, retest
for original problem.

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify if each step was completed correctly and the proper decision
was made. Notify supervisor for further action.
54 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

2.3 - Engine at Operating Temperature, No Re-Start

Overview
Engine will not re-start, after being run to operating temperature.

Possible Causes
• Injection Control Pressure (ICP) leak
• ICP circuit fault
• Combustion leak to low-pressure fuel system (injector)

Test Procedure

Step 1 Perform operational Checkout procedure. Decision

Yes: Go to Step 2.
Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers No: Go to 2.0 Engine
complaint align with this specific symptom procedure? Does Not Start Operational
Checkout Procedure (page
23).

Step 2 Start and run engine to operating temperature. Decision

Is Engine Coolant Temperature 1 (ECT1) 158°F (70°C) or more? Yes: Go to Step 3.
No: Run engine to operating
temperature.

Step 3 With engine at operating temperature, check Injection– Control Pressure (ICP) Decision
at Key-On Engine-Off (KOEO).
A. Do not crank or run engine for 3 minutes or more, to allow ICP to bleed off. Yes: Go to SPN 164 FMI
0 (page 360) Fault Code
B. Using Electronic Service Tool (EST) with Navistar® Engine Diagnostics, check
Diagnostics.
ICP at KOEO.

Is ICP above KOEO specification?

No: Go to Step 4.

Step 4 With engine at operating temperature, record snapshot of engine cranking Decision
data.
Perform Engine Cranking Test (page 1374). Yes: Go to Step 5.

Are ICP and Injection Pressure Regulator (IPR) within cranking specification?
No: Go to CPA
High-Pressure Oil Pump
(HPOP) Test (page 1440).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 55

Step 5 Determine if cylinder relative compression is within specification. Decision

Perform Relative Compression Test Plus (RCT+) (page 1465). Yes: Repair mechanical
problem with cylinder(s)
Does CPA Tool indicate a problem or generate a warranty authorization code (WAC)?
indicating low performance.
After repairs are complete,
retest for original problem.
No: Go to Step 6.

Step 6 Measure fuel pressure to determine if combustion pressure is leaking into Decision
the fuel system.
Perform Fuel Delivery Pressure (FDP) Test (page 1554). Yes: Remove each fuel
injector and inspect injector
Is fuel pressure greater than specification and/or erratic?
seals and bottom of injector
for burning. After repairs are
complete, retest for original
problem.
No: End Diagnostic Steps.

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify if each step was completed correctly and the proper decision
was made. Notify supervisor for further action.
56 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

2.4 - Engine Never Starts

Overview
Determine reason engine cranks but will not start.

Possible Causes
• Engine Control Module (ECM) fault
• No Start related Diagnostic Trouble Codes (DTC)
• Air intake restriction
• Exhaust restriction
• Low Injection Control Pressure (ICP) or ICP leaks
• Injection Pressure Regulator (IPR) fault
• Low Fuel Delivery Pressure (FDP)
• Engine compression loss or mechanical problems
• Exhaust Gas Recirculation (EGR) system fault
• Combustion into fuel system

Test Procedure

Step 1 Perform operational checkout procedure Decision

Yes: Go to Step 2.
Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers No: Go to 2.0 Engine
complaint align with this specific symptom procedure? Does Not Start Operational
Checkout Procedure (page
23).

Step 2 Determine if engine air intake is restricted. Decision

A. Key-On Engine-Off (KOEO). Yes: Repair intake
restriction. After repairs
B. Connect Electronic Service Tool (EST) to vehicle diagnostic connector.
are complete, retest for
C. Select > Sessions > Default > Pressure tab. original problem.
D. Observe Key-On Engine-Off (KOEO) Intake Manifold Absolute Pressure (IMAP). No: Go to Step 3.

E. Observe IMAP while cranking the engine.

F. Calculate intake restriction: KOEO IMAP – Cranking IMAP = intake restriction

while cranking.
Is intake restriction 0.9 psi (6.2 kPa) or greater?
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 57

Step 3 Determine if exhaust is restricted. Decision

Review Engine Cranking Test (page 1374) data. Yes: Go to Step 4.
Are Turbocharger 1 Turbine Outlet Pressure (TC1TOP), Exhaust Back Pressure (EBP),
and Diesel Particulate Filter Differential Pressure (DPFDP) within cranking specification?
No: Repair exhaust
restriction. After repairs
are complete, retest for
original problem.

Step 4 Determine if engine is able to build Injection Control Pressure (ICP). Decision
Review Engine Cranking Test (page 1374) data. Yes: Go to Step 5.
Are ICP and Injection Pressure Regulator (IPR) both in specification?
No: Go to CPA
High-Pressure Oil Pump
(HPOP) Test (page 1440).

Step 5 Determine if engine is able to build Fuel Delivery Pressure (FDP). Decision
Record Snapshot of KOEO Data (page 1330) and review Engine Cranking Test (page Yes: Go to Step 6.
1374).
Is FDP in specification during KOEO and cranking tests?
No: Go to 8.1 Fuel Delivery
Pressure (page 119).

Step 6 Determine if cylinder relative compression is within specification. Decision

Perform Relative Compression Test Plus (RCT+) (page 1465). Yes: Repair mechanical
problem with cylinder(s)
Does CPA Tool indicate a problem or generate a warranty authorization code (WAC)?
indicating low performance.
After repairs are complete,
retest for original problem.
No: Go to Step 7.

Step 7 Measure fuel pressure to determine if combustion pressure is leaking into Decision
the fuel system.
Perform Fuel Delivery Pressure (FDP) Test (page 1554). Yes: Inspect fuel injector
seals and bottom of each
Is fuel pressure greater then specification and/or erratic?
injector for burning. After
repairs are complete, retest
for original problem.
No: End Diagnostic Steps.

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify if each step was completed correctly and the proper decision
was made. Notify supervisor for further action.
58 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Engine Hard to Start Symptoms

3.1 - Engine Hard to Start, Cold Ambient Temperature

Overview
Diagnose engine hard to start in cold ambient conditions (40°F {4°C} or colder).

Possible Causes
• Engine Coolant Temperature 1 (ECT1) sensor or circuit fault
• Engine Oil Temperature (EOT) sensor or circuit fault
• Low cylinder compression
• Failed intake air grid heater
• Open or shorted Intake Air Heater (IAH) grid heater wiring (high current)
• Failed intake air heater relay
• Intake Air Heater Control (IAHC) circuit fault (relay control)
• Open or shorted IAH relay wiring (high current)
• Failed engine coolant heater
• Failed oil pan heater

Test Procedure

Step 1 Perform operational checkout procedure Decision

Yes: Go to Step 2.
Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers No: Go to 3.0 Engine Hard to
complaint align with this specific symptom procedure? Start Operational Checkout
Procedure (page 26).

Step 2 Check for Intake Air Heater Control (IAHC) Diagnostic Trouble Codes (DTC). Decision
Using Electronic Service Tool (EST), check DTC list for SPN 729 IAHC fault codes. Yes: Go to Fault Code
Diagnostics for SPN 729
fault code.
Are any SPN 729 fault codes pending or active? No: Go to Step 3.

Step 3 Test Intake Air Heater (IAH) system. Decision

Perform Intake Air Heater (IAH) System Test (page 1590). Yes: Go to Step 4.
Is IAH system operating properly? No: Repair IAH faults. After
repairs are complete, retest
for original problem.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 59

Step 4 Test engine coolant heater assembly. Decision

Perform Coolant Heater Assembly Test (page 1575). Yes: Go to Step 5.
Is engine coolant heater operating properly and did all tests pass? No: Repair engine coolant
heater assembly faults.
After repairs are complete,
retest for original problem.

Step 5 Test oil pan heater assembly. Decision

Perform Oil Pan Heater Test (page 1593). Yes: Perform Relative
Compression Test Plus
(RCT+) (page 1465). If
one or more cylinders
have significant speed
difference(s) than others,
repair engine mechanical
problem. After repairs are
complete, retest for original
problem.
Is oil pan heater operating properly? No: Repair oil pan heater
faults. After repairs are
complete, retest for original
problem.

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify if each step was completed correctly and the proper decision
was made.
60 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

3.2 - Engine at Operating Temperature, Hard to Re-Start

Overview
Diagnose engine hard to re-start after being run up to operating temperature.
NOTE: Do not replace Injection Control Pressure (ICP) sensor unless directed by diagnostic procedure.

Possible Causes
• Injection Control Pressure (ICP) leak
• ICP circuit fault
• Combustion leak to low-pressure fuel system (injector)

Test Procedure

Step 1 Perform operational checkout procedure Decision

Yes: Go to Step 2.
Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers No: Go to 3.0 Engine Hard to
complaint align with this specific symptom procedure? Start Operational Checkout
Procedure (page 26).

Step 2 Start and run engine to operating temperature. Decision

Is Engine Coolant Temperature 1 (ECT1) 158°F (70°C) or more? Yes: Go to Step 3.
No: Run engine to operating
temperature, then go to Step
3.

Step 3 With engine at operating temperature, check Key-On Engine-Off (KOEO) Decision
Injection Control Pressure (ICP).
A. Do not crank or run engine for 3 minutes or more, to allow Injection Control Yes: Go to SPN 164 FMI
Pressure (ICP) to bleed off. 0 (page 360) Fault Code
Diagnostics.
B. Using Electronic Service Tool (EST), check ICP at KOEO.
Is ICP above KOEO specification?
No: Go to Step 4.

Step 4 Determine if ICP and Injection Pressure Regulator (IPR) are within cranking Decision
specification.
With engine at operating temperature, perform Engine Cranking Test (page 1374). Yes: Go to Step 5.
Are ICP and Injection Pressure Regulator (IPR) within cranking specification?
No: Go to CPA
High-Pressure Oil Pump
(HPOP) Test (page 1440).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 61

Step 5 Determine if cylinder relative compression is within specification. Decision

Perform Relative Compression Test Plus (RCT+) (page 1465). Yes: Repair mechanical
problem with cylinder(s)
Does CPA Tool indicate a problem or generate a warranty authorization code (WAC)?
indicating low performance.
After repairs are complete,
retest for original problem.
No: Go to Step 6.

Step 6 Measure fuel pressure to determine if combustion pressure is leaking into Decision
fuel system.
Perform Fuel Delivery Pressure (FDP) Test (page 1554). Yes: Remove each fuel
injector and inspect injector
Is fuel pressure greater than specification and/or erratic?
seals and bottom of injector
for burning. After repairs are
complete, retest for original
problem.
No: End Diagnostic Steps.

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify if each step was completed correctly and the proper decision
was made. Notify supervisor for further action.
62 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

3.3 - Engine Starts, Then Stalls

Overview
Engine is able to start (possibly briefly), but is not able to continue to run.

Possible Causes
• Damaged or restricted intake: Change Air Cooler (CAC), Engine Throttle Valve (ETV), Mass Air Flow (MAF),
air filter, intake piping, clamps, connections, etc.
• Damaged or restricted exhaust: Diesel Oxidation Catalyst (DOC), Diesel Particulate Filter (DPF), Exhaust
Back Pressure Valve (EBPV), exhaust piping, etc.
• Exhaust Gas Recirculation (EGR) valve (stuck or sticking open)
• Combustion gasses in fuel (injector)

Test Procedure

Step 1 Perform operational checkout procedure Decision

Yes: Go to Step 2.
Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers No: Go to 3.0 Engine Hard to
complaint align with this specific symptom procedure? Start Operational Checkout
Procedure (page 26).

Step 2 Determine if engine air intake is restricted. Decision

A. Key On Engine Off (KOEO). Yes: Repair intake
restriction. After repairs
B. Connect Electronic Service Tool (EST).
are complete, retest for
C. Select > Sessions > Default > Pressure tab. original problem.
D. Observe KOEO Intake Manifold Absolute Pressure (IMAP).
E. Observe IMAP, while cranking engine.
F. Calculate intake restriction: KOEO IMAP – Cranking IMAP = intake restriction
while cranking.
G.
Is intake restriction 0.9 psi (6.2 kPa) or greater?
No: Go to Step 3.

Step 3 Check for seized Exhaust Back Pressure Valve. Decision

Key ON, Engine OFF (KOEO). Inspect if Exhaust Back pressure Valve (EBPV) in exhaust Yes: Go to Step 4.
is against its rest in the Open position.
Is EBPV against its rest in the open position at KOEO?
No: Repair seized EBPV.
After repairs are complete,
retest for original problem.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 63

Step 4 Determine if Exhaust Gas Recirculation (EGR) valve is stuck or sticking open. Decision
Perform EGRV Operational Test (page 1543). Yes: Go to Step 5.
Does EGR system pass EGRV Operational Test?
No: Repair EGR system
problem. After repairs are
complete, retest for original
problem.

Step 5 Determine if cylinder relative compression is within specifications. Decision

Perform Relative Compression Test Plus (RCT+) (page 1465). Yes: Repair mechanical
problem with cylinder(s)
Does CPA Tool indicate a problem or generate a warranty authorization code (WAC)?
indicating low performance.
After repairs are complete,
retest for original problem.
No: Go to Step 6.

Step 6 Measure fuel pressure to determine if combustion pressure is leaking into Decision
the fuel system.
Perform Fuel Delivery Pressure (FDP) Test (page 1554). Yes: Inspect fuel injector
seals and bottom of each
Is fuel pressure greater then specification and / or erratic?
injector for burning. After
repairs are complete, retest
for original problem.
No: End Diagnostic Steps.

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify if each step was completed correctly and the proper decision
was made. Notify supervisor for further action.
64 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Engine Running, Engine Not Under Load Symptoms

4.1 - Rough Idle

Overview
Diagnose cause of engine running rough or surging at idle. It is normal for engine to idle rough until engine
coolant temperature reaches approximately 141°F (61°C) or more.
NOTE: Do not replace Injection Control Pressure (ICP) sensor unless directed by diagnostic procedure.

Possible Causes
• Injection Control Pressure (ICP)
• Injection Pressure Regulator (IPR)
• Fuel Delivery Pressure (FDP) (low pressure, aerated fuel, etc.)
• Injector circuit or mechanical failure
• Engine compression loss in one or more cylinders
• Engine air intake leaks (unmetered air entering engine air intake)
• Engine accessory dragging or locking up (A/C compressor, belt tensioner, fan drive, etc.)

Test Procedure

Step 1 Perform operational checkout procedure. Decision

Yes: Go to Step 2.
Did a symptom Fault Code Action Plan (FCAP) bring you here or does the No: Go to 4.0 Engine Running,
customers complaint align with this specific symptom procedure? Engine Not Under Load
Operational Checkout Procedure
(page 29).

Step 2 Determine if Injection Pressure Regulator (IPR) system is operating Decision

properly.
Review engine running snapshot: verify IPR Ctrl is less than 35% at idle. Yes: Go to CPA High-Pressure Oil
Pump (HPOP) Test (page 1440).
Is IPR Ctrl 35% or greater at idle? No: Go to Step 3.

Step 3 Determine if ICP system is operating properly. Decision

Review engine running snapshot: verify Injection Control Pressure (ICP) is Yes: Go to Step 4.
approximately the same as ICP Desired.
Is Injection Control Pressure approximately the same as ICP Desired? No: Go to CPA High-Pressure Oil
Pump (HPOP) Test (page 1440).

Step 4 Determine if IPR system is operating properly. Decision

Review engine running snapshot: Verify IPR Ctrl is less than 80%. Yes: Go to CPA High-Pressure Oil
Pump (HPOP) Test (page 1440).
Is IPR Ctrl 80% or greater? No: Go to Step 5.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 65

Step 5 Determine if injectors and injector circuits are operating properly. Decision
Perform CPA Cold Idle Test (page 1407) and CPA Hot Idle Test (page 1421). Yes, injector fault: Check
resistance of suspect injector
Does CPA Cold Idle Test and / or CPA Hot Idle Test determine a fault?
circuit. Repair circuit problem(s).
If circuit checks are good, replace
injector. Perform Injector Coil
End of Motion (CEOM) Reset
Procedure (page 1334) and
Injector Coking Accumulation
Reset Procedure (page 1338).
After repairs are complete, retest
for original problem.
Yes, high-speed fluctuation: Check
resistance in injector circuits
through the UVC gasket. Repair
circuit problem(s). If UVC checks
are good, go to CPA High-Pressure
Oil Pump (HPOP) Test (page
1440).
No: Go to Step 6.

Step 6 Determine if fuel delivery pressure is within specification. Decision

Perform Fuel Delivery Pressure (FDP) Test (page 1554). Yes: Go to Step 7.
Is fuel delivery pressure (gauge) within Low Idle, No Load, Stabilized Engine
Operating Temperature (page 1680) specification?
No: Go to 8.1 Fuel Delivery
Pressure (page 119).

CAUTION:

To prevent engine damage, do not run engine more than 2 minutes with accessory drive
belts disconnected.

Step 7 Determine if engine accessories are dragging or locking up. Decision

A. Remove accessory drive belt(s). Yes: Go to Step 8.

B. Start engine and check for accessories dragging or locking up.

Is rough engine idle still present?
No: Find and repair accessory
dragging or locking up. After
repairs are complete, retest for
original problem.
66 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 8 Determine if cylinder relative compression is within specification. Decision

Perform Relative Compression Test Plus (RCT+) (page 1465). Yes: Repair mechanical problem
with cylinder(s) indicating low
Does CPA Tool indicate a problem or generate a warranty authorization code
performance. After repairs are
(WAC)?
complete, retest for original
problem.
No: Go to Step 9.

Step 9 Determine if engine has air intake leaks. Decision

Perform Intake Air Inspection (page 1648). Yes: Repair engine air intake as
needed. After repairs are complete,
Is engine air intake leaking, damaged, or restricted?
retest for original problem.
No: Connect Cylinder Performance
Analyzer (CPA) Tool (page 1402)
and test injectors for leaks and
misfires. Perform CPA Signal
Check (page 1413), CPA Hot Idle
Test (page 1421), and CPA Road
Test (page 1427).

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify if each step was completed correctly and the proper decision
was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 67

4.2 - Engine Unable To Reach Rated Speed (No Load)

Overview
Engine without a load, is not able to increase rpm up to rated speed.
NOTE: Do not replace Injection Control Pressure (ICP) sensor unless directed by diagnostic procedure.

Possible Causes
• Accelerator Pedal Position (APP)
• Injection Control Pressure (ICP)
• Injection Pressure Regulator (IPR)
• Exhaust Gas Recirculation (EGR)
• Exhaust restriction
• Engine air restriction
• Fuel Delivery Pressure (FDP)

Test Procedure

Step 1 Perform operational checkout procedure. Decision

Yes: Go to Step 2.
Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers No: Go to 4.0 Engine
complaint align with this specific symptom procedure? Running, Engine Not
Under Load Operational
Checkout Procedure
(page 29).

Step 2 Determine if Accelerator Pedal Position (APP) meets full range %. Decision
Review engine running snapshot: Verify APP % at idle and at full throttle. Yes: Go to Step 3.
Is Accelerator Pedal Position: 0% at idle, and 99% or greater at full throttle?
No: Repair APP sensor
or circuit problem. After
repairs are complete,
retest for original problem.

Step 3 Determine if Injection Control Pressure (ICP) system is operating properly. Decision
Review engine running snapshot: Verify Injection Control Pressure is approximately the Yes: Go to Step 4.
same as ICP Desired.

Is Injection Control Pressure approximately the same as ICP Desired?

No: Go to CPA
High-Pressure Oil Pump
(HPOP) Test (page 1440).
68 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 4 Determine if Exhaust Gas Recirculation (EGR) system is operating properly. Decision
Review engine running snapshot: Verify EGR valve remains closed (35%). Yes: Go to Step 5.
Is EGR Position 35%?
No: Go to SPN 2791 FMI
7 (page 817) Fault Code
Diagnostics. After repairs
are complete, retest for
original problem.

Step 5 Determine if exhaust system is restricted. Decision

Review engine running snapshot: Verify TC1 Turbine Outlet Pressure is less than 10 psi. Yes: Repair exhaust
system restriction. After
Is TC1 Turbine Outlet Pressure 10 psi or greater?
repairs are complete,
retest for original problem.
No: Go to Step 6.

Step 6 Determine if air intake is restricted. Decision

Review engine running snapshot. Verify Intake Manifold Absolute Pressure is above BARO Yes: Go to Step 7.
(not creating a vacuum).
Is Intake Manifold Absolute Pressure above BARO?
No: Repair intake
restriction. After repairs
are complete, retest for
original problem.

Step 7 Determine if fuel delivery pressure is within specification. Decision

Perform Fuel Delivery Pressure (FDP) Test (page 1554). Yes: Perform CPA Signal
Check (page 1413), CPA
Does fuel delivery pressure (gauge) meet specification?
Hot Idle Test (page 1421),
and CPA Road Test (page
1427).
No: Go to 8.1 Fuel
Delivery Pressure (page
119).

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify if each step was completed correctly and the proper decision
was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 69

4.3 - Popping Noise from Intake

Overview
Engine cylinder compression popping back through the intake.

Possible Causes
• Sticking, damaged, or leaking intake or exhaust valve(s)
• Damaged pushrod(s)
• Damaged rocker arm or shaft
• Failed roller tappet assembly
• Failed camshaft

Test Procedure

Step 1 Perform operational checkout procedure. Decision

Yes: Go to Step 2.
Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers No: Go to 4.0 Engine
complaint align with this specific symptom procedure? Running, Engine Not Under
Load Operational Checkout
Procedure (page 29).

Step 2 Determine if cylinder relative compression is within specification. Decision

Perform Relative Compression Test (page 1371). Yes: Focus on cylinder(s) with
low compression, and go to
Does one or more cylinders have significant speed difference(s) than others?
Step 3.
No: Go to Step 3.

Step 3 Inspect valve train for loose or damaged rocker arm assembly, or valve Decision
lash out of adjustment.
A. Remove valve cover. See Engine Service Manual . Yes, damaged rocker arm
assembly: Replace damaged
B. Inspect valve train for loose or damaged rocker arms, or valve lash out of
valve train components. After
adjustment (focusing on any cylinders with low compression from Step 1).
repairs are complete, retest for
C. Measure valve lash. original problem.
Is valve train for any cylinders loose, damaged, or valve lash out of adjustment?
Yes, valve lash out of
adjustment: Perform Cleaning
and Inspection of Push rods,
and Measure Camshaft Lobe
Lift in the Engine Service
Manual. If camshaft lobe lift
is out of specification, replace
camshaft.
No: End Diagnostic Steps.
70 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify if each step was completed correctly and the proper decision
was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 71

Engine Running, Engine Under Load Symptoms

5.1 - Low Power (Slow Acceleration)

Overview
Vehicle or engine is not able to accelerate properly while under a load.
NOTE: Perform a MAF Sensor Calibration after doing repairs that change engine air intake, exhaust, or Exhaust
Gas Recirculation (EGR) flow characteristics.
NOTE: Do not replace Injection Control Pressure (ICP) sensor unless directed by diagnostic procedure.

Possible Causes
• Vehicle overloaded (load higher then engine designed for)
• Road speed governor programmable parameter set too low
• Injection Control Pressure (ICP)
• Injection Pressure Regulator (IPR)
• Engine Control Module (ECM) barometric pressure error
• Exhaust restriction
• Boost control system fault
• Fuel Delivery Pressure (FDP)
• Exhaust Gas Recirculation (EGR) valve stuck or sticking Open
• Intake restriction
• Turbocharger coking or damage
• Failed high-pressure turbocharger
• Failed low-pressure turbocharger
• Low compression
• Engine compression brake engaged when not commanded.

Test Procedure

Step 1 Perform operational checkout procedure. Decision

Yes: Go to Step 2.
Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers No: Go to 5.0 Engine
complaint align with this specific symptom procedure? Running, Engine Under
Load Operational Checkout
Procedure (page 31).
72 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 2 Determine if vehicle is overloaded. Decision

Review vehicle and engine load hauling capacity and compare to TCAPE summary Yes: Reduce load. After
(available from International® dealer). repairs are complete, retest
for original problem.
Is vehicle overloaded? No: Go to Step 3.

Step 3 Verify Road Speed Governor programmable parameter is set above desired Decision
vehicle speed.
A. Key-On Engine-Off (KOEO). Yes: Go to Step 4.
B. Connect Electronic Service Tool (EST) and log-in.
C. Select: Sessions > Parameters > Max Vehicle Speed with Road Speed Limiting
On, OR Road Speed Limiting Secondary Vehicle Speed Limit.
Are Road Speed Limiting programmable parameters set above desired vehicle speed? No: Set Road Speed
Limiting programmable
parameters to maximum
desired vehicle speed. After
repairs are complete, retest
for original problem.

Step 4 Determine if engine compression brake is operating properly (if equipped). Decision
Review 0 to 60 snapshot: verify BCP actual is approximately the same as BCP desired. Yes: Go to Step 5.
Is BCP actual approximately the same as BCP desired; and when desired is 0, actual No: Go to 9.2 Engine
is below 100 psi? Compression Brake
Engaged when Not
Commanded (page 127).

Step 5 Determine if Injection Control Pressure (ICP) system is operating properly. Decision
Review 0 to 60 snapshot: verify Injection Control Pressure is approximately the same as Yes: Go to Step 6.
ICP Desired.
Is Injection Control Pressure approximately the same as ICP Desired? No: Go to CPA
High-Pressure Oil Pump
(HPOP) Test (page 1440).

Step 6 Determine if Injection Pressure Regulator (IPR) system is operating properly. Decision
Review 0 to 60 snapshot: verify IPR Ctrl is less than 80%. Yes: Go to CPA
High-Pressure Oil Pump
(HPOP) Test (page 1440).
Is IPR Ctrl 80% or greater? No: Go to Step 7.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 73

Step 7 Verify Engine Control Module (ECM) is reading proper Barometric Absolute Decision
Pressure for local elevation and barometric pressure.
A. Review 0 to 60 snapshot: determine recorded Barometric Absolute Pressure. Yes: Go to Step 8.
B. Determine local elevation and barometric pressure. (Examples: 14.7 psia at sea
level, 13.2 psia at 3000 ft., 11.8 psia at 6000 ft., 10.1 psia at 10,000 ft.)

C. If Barometric Absolute Pressure is not reasonable relative to local barometric

pressure, verify local barometric pressure on a second vehicle.
Is Barometric Absolute Pressure reasonable relative to local barometric pressure? No: Install a new ECM. After
repairs are complete, retest
for original problem.

Step 8 Determine if exhaust is restricted. Decision

A. Determine TC1 Turbine Outlet Pressure at KOEO. Pressure may be in absolute Yes: Go to Step 9.
or gauge pressure depending on ECM calibration.
B. Review 0 to 60 snapshot TC1 Turbine Outlet Pressure.
C. Subtract KOEO TC1 Turbine Outlet Pressure from 0 to 60 TC1 Turbine Outlet
Pressure, and determine if pressure is within specification:
• MaxxForce DT: 6 psi or less
• MaxxForce 9 and 10: 12 psi or less
Is 0 to 60 TC1 Turbine Outlet Pressure within specification? No: Repair exhaust system
restriction. After repairs are
complete, retest for original
problem.

Step 9 Determine if boost control system is operating properly. Decision

Review 0 to 60 snapshot: verify Exhaust Back Pressure (EBP) is less than 70 psi. Yes: Go to Step 10.
Is EBP less than 70 psi? No: Perform Boost Control
System Test (page 1533).
Repair or replace faulty
component(s). After repairs
are complete, retest for
original problem.

Step 10 Determine is Fuel Delivery Pressure (FDP) meets specification. Decision

Review 0 to 60 snapshot: verify FDP is within Full Load specification. Yes: Go to Step 11.
Is FDP within Full Load specification? No: Go to 8.1 Fuel Delivery
Pressure (page 119).
74 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 11 Determine if Exhaust Gas Recirculation (EGR) valve is operating properly. Decision
Review 0 to 60 snapshot: verify EGR Position is approximately the same as EGR Valve Yes: Go to Step 12.
CTL.
Is EGR Position approximately the same as EGR Valve CTL? No: Go to SPN 2791 FMI
7 (page 817) Fault Code
Diagnostics. After repairs
are complete, retest for
original problem.

Step 12 Determine if air management system is operating properly. Decision

Perform Air Management Test (page 1376). Yes: Go to Step 13.
Is Intake Manifold Pressure (IMP), and MAF Mean Value Difference within specification? No, IMP not in specification:
Perform Boost Control
System Test (page 1533).
Repair or replace failed
component(s). After repairs
are complete, go to Step 26.
No, only MAF Mean
Value Difference not in
specification: Go to Step 24.

Step 13 Determine if Intake Manifold Pressure (IMP) during acceleration is reasonable. Decision
Review 0 to 60 snapshot: verify IMP is at Full Load specification or higher for specific Yes: Go to Step 23.
rating of engine. IMP can vary based on ECM calibration (engine rating) and vehicle
weight.
Is IMP at Full Load specification or higher, for specific rating? No: Go to Step 14.

Step 14 Inspect for engine air intake (boost) leaks or restrictions. Decision
A. Perform Intake Air Inspection (page 1648). Yes: Go to Step 15.
B. Perform High-Pressure Charge Air Cooler (HPCAC) Pressure Test (page 1545).

C. Perform Interstage Cooler (ISC) Pressure Test (page 1551).

Is air intake system and CAC system free of restrictions, leaks, or physical damage? No, Repair air intake system
leaks or damage. After
repairs are complete, go to
Step 26.
No, Restrictions found,
clean or replace restricted
component(s). After repairs
are complete go to Step 20.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 75

Step 15 Determine if turbocharger has coking or soot build-up. Decision

A. Remove turbocharger intake tube. Yes, go to Step 20.
B. Inspect turbocharger for soot build-up or coking.
Does turbocharger have coking or soot build-up? No: Go to Step 16.

Step 16 Determine if high-pressure turbocharger is causing oil leak. Decision

Remove high-pressure turbocharger center section (see Engine Service Manual). Yes: Go to Step 17.
Is oil pooling in high-pressure turbocharger turbine housing? No: Go to Step 18.

Step 17 Determine if high-pressure turbocharger turbine housing is damaged. Decision

With high-pressure turbocharger center section removed, inspect inside of turbine Yes: Replace entire
housing (exhaust side) for evidence of contact with turbine wheel. high-pressure turbocharger
assembly with turbine
• Indications of contact can include bright spots of bare metal, nicks, or gouges on
housing. After repairs are
turbine housing inner surface.
complete, retest for original
• Turbocharger end play does not indicate a failure. problem.
Is turbine housing damaged or are there signs that turbine wheel has contacted turbine No: Replace only
housing? high-pressure turbocharger
center section. After repairs
are complete, retest for
original problem.

Step 18 Determine if low-pressure turbocharger is causing oil leak. Decision

Remove low-pressure turbocharger center section (see Engine Service Manual). Yes: Go to Step 19.
Is oil pooling in low-pressure turbocharger turbine housing? No: Go to Step 23.

Step 19 Determine if low-pressure turbocharger turbine housing is damaged. Decision

With low-pressure turbocharger center section removed, inspect inside of turbine housing Yes: Replace entire
(exhaust side) for evidence of contact with turbine wheel. low-pressure turbocharger
assembly with turbine
• Indications of contact can include bright spots of bare metal, nicks, or gouges on
housing. After repairs are
turbine housing inner surface.
complete, retest for original
• Turbocharger end play does not indicate a failure. problem.
Is turbine housing damaged or are there signs that turbine wheel has contacted turbine No: Replace only
housing? low-pressure turbocharger
center section. After repairs
are complete, retest for
original problem.
76 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 6 Open Crankcase Breather (Typical)

1. Crankcase breather assembly outlet tube (open)
2. Crankcase breather assembly part number

Step 20 Determine if engine has an open crankcase breather. Decision

A. Inspect crankcase breather assembly outlet tube (Figure 6) (1). Yes: Inspect air filter and
housing for restrictions
B. Determine if outlet tube is open to atmosphere, or is connected to the
and repair as needed.
turbocharger air inlet duct (closed).
Perform Dual Turbocharger
Compressor Cleaning and
Inspection, (see Engine
Service Manual). After
repairs are complete, go to
Step 26.
Is crankcase breather assembly outlet tube open? No: Go to Step 21.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 77

Figure 7 Valve Cover

1. Breather inlet pipe
78 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 8 Valve Cover Breather Inlet Port

1. Cast aluminum baffle (early production)
2. Deep stamped steel baffle (updated version)

Step 21 Determine Open Breather Kit needed. Decision

Go to iKNow article IK1201117, open service kit selection form. Enter last 7 digits of Yes: Go to Step 27.
Engine Serial Number, follow form instructions.
Does selection form provide a kit part number? No: Go to Step 22.

Step 22 Determine if crankcase breather / oil separator is operating properly. Decision

Perform Crankcase Oil Separator (CCOS) Speed Test (page 1572). Yes: Go to Step 23.
Is crankcase breather / oil separator operating properly? No: Install new closed
crankcase breather
assembly kit. Perform Dual
Turbocharger Compressor
Cleaning and Inspection,
(see Engine Service
Manual). After repairs
are complete, go to Step 26.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 79

Step 23 Determine if cylinder relative compression is within specification. Decision

Perform Cylinder Performance Analyzer (CPA) RCT+ Test (page 1465). Yes: Make repair indicated
by CPA tool. After repairs
are complete, retest for
original problem.
Does CPA Tool indicate a problem or generate a warranty authorization code (WAC)? No: Go to Step 24.

Step 24 Determine if air and EGR mixer duct is restricted. Decision

A. Remove Engine Throttle Value (ETV) assembly, see Engine Service Manual. Yes: Remove and clean
air and EGR mixer duct.
B. Inspect air and EGR mixer duct assembly for restrictions and carbon build up.
Do not replace EGR Valve.
Replace O-rings if needed.
After repairs are complete,
Go to Step 26.
Is a severe amount of carbon restricting the air and EGR mixer duct? No: Go to Step 25.

Step 25 Determine if EGR cooler is restricted. Decision

Remove EGR crossover pipe from rear of engine and inspect EGR cooler for restrictions. Yes: Replace EGR cooler.
After repairs are complete,
go to Step 26.
Is EGR cooler restricted? No: Go to Step 26.

Step 26 Check MAF sensor calibration. Decision

Perform a MAF Sensor Calibration (page 1539). Yes: End Diagnostics.
Retest for original problem.
Did MAF sensor calibration run successfully without setting codes? No: Repair MAF fault codes.
After repairs are complete,
retest for original problem.
80 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 27 Determine if crankcase breather / oil separator is operating properly. Decision

Perform Crankcase Oil Separator (CCOS) Speed Test (page 1572). Yes: Install breather kit
indicated in Step 21.
Perform Dual Turbocharger
Compressor Cleaning and
Inspection, (see Engine
Service Manual). After
repairs are complete, retest
for original problem.
Is crankcase breather / oil separator operating properly? No: Install new breather
assembly and breather
kit indicated in Step 21.
Perform Dual Turbocharger
Compressor Cleaning and
Inspection, (see Engine
Service Manual). After
repairs are complete, retest
for original problem.

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify if each step was completed correctly and the proper decision
was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 81

5.2 - Misfire (Stumble / Surge / Runs Rough)

Overview
Engine power or speed (rpm) varies unexpectedly by more than 50 rpm under a load.
NOTE: Perform a MAF Sensor Calibration after doing repairs that change engine air intake, exhaust, or Exhaust
Gas Recirculation (EGR) flow characteristics.
NOTE: Do not replace Injection Control Pressure (ICP) sensor unless directed by diagnostic procedure.
Possible Causes
• Accelerator Pedal Position (APP) sensor or circuit
• Exhaust Back Pressure Valve (EBPV)
• Engine Throttle Valve (ETV)
• Exhaust Gas Recirculation (EGR) valve stuck or sticking
• Injection Control Pressure (ICP) system
• Injection Pressure Regulator (IPR)
• Fuel Delivery Pressure (FDP)
• Air intake (boost) leaks
• Engine compression loss of one or more cylinders
• Injector circuit or mechanical problem

Test Procedure

Step 1 Perform operational checkout procedure. Decision

Yes: Go to Step 2.
Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers No: Go to 5.0 Engine
complaint align with this specific symptom procedure? Running, Engine Under
Load Operational Checkout
Procedure (page 31).

Step 2 Determine if Accelerator Pedal Position (APP) signal is correct and stable. Decision
Review 0 to 60 Test data: Verify APP signal moves smoothly as the throttle is depressed Yes: Go to Step 3.
and does not jump unexpectedly.
Is APP signal stable and not jumping unexpectedly, 0% at idle, and 99% or greater at full No: Repair APP sensor or
throttle? circuit problem. After repairs
are complete, retest for
original problem.
82 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Determine if Exhaust Back Pressure Valve (EBPV) is operating properly. Decision
A. Start engine. Yes: Go to Step 4.
B. Visually verify if EBPV is fully open and not moving (unless in regen mode).
Look at valve and verify rod is fully retracted and not moving.

C. Verify if EBPV cycles opened and closed three times after engine shutdown.
Some engines will only cycle the EBPV if Engine Coolant Temperature (ECT)
is 140°F (60° C).
Is EBPV fully open and not moving (unless in regen mode), and does EBPV cycle after No: Diagnose and repair
shutdown? EBPV system. After repairs
are complete, retest for
original problem.

Step 4 Determine if Engine Throttle Valve (ETV) is operating properly. Decision

Review 0 to 60 Test data: compare Engine Throttle Position (actual) to Engine Throttle Yes: Go to Step 5.
CTL.
Is Engine Throttle Position approximately the same as Engine Throttle CTL? No: Repair ETV or circuit
problem. After repairs are
complete, retest for original
problem.

Step 5 Determine if Exhaust Gas Recirculation (EGR) system is operating properly. Decision
Review 0 to 60 Test data: verify if EGR Position is approximately the same as EGR Yes: Go to Step 6.
Valve CTL.
Is EGR Position approximately the same as EGR Valve CTL? No: Go to SPN 2791 FMI
7 (page 817) Fault Code
Diagnostics. After repairs
are complete, retest for
original problem.

Step 6 Determine if Injection Control Pressure (ICP) system is operating properly. Decision
Review 0 to 60 Test data: verify Injection Control Pressure is approximately the same as Yes: Go to Step 7.
ICP Desired.
Is Injection Control Pressure approximately the same as ICP Desired? No: Go to CPA
High-Pressure Oil Pump
(HPOP) Test (page 1440).

Step 7 Determine if Injection Pressure Regulator (IPR) system is operating properly. Decision
Review 0 to 60 Test data: verify if IPR Ctrl is less than 80% while under load or less Yes: Go to CPA
than 35% when stationary. High-Pressure Oil Pump
(HPOP) Test (page 1440).
Is IPR Ctrl 80% or greater under load, or greater than 35% when stationary? No: Go to Step 8.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 83

Step 8 Determine if fuel delivery pressure is proper. Decision

Perform Fuel Delivery Pressure (FDP) Test (page 1554). Yes: Go to Step 9.
Is fuel delivery pressure (gauge) within specification (page 1677)? No: Go to 8.1 Fuel Delivery
Pressure (page 119).

Step 9 Inspect for air intake (boost) leaks or restrictions. Decision

A. Perform Intake Air Inspection (page 1648). Yes: Go to Step 10.
B. Pressurize Charge Are Cooler (CAC) system to 30 psi using Charge Air Cooler
(CAC) Tester ZTSE4341 and Interstage Cooler Test Kit ZTSE4937.
Is air intake system and CAC system free of restrictions, leaks, or physical damage? No: Repair air intake
system leaks, damage, or
restrictions. After repairs are
complete, retest for original
problem.

Step 10 Determine if cylinder relative compression is within specification. Decision

Perform Relative Compression Test Plus (RCT+) (page 1465) and Blow By Test (page Yes: Repair mechanical
1486). problem with cylinder(s)
indicating low performance.
After repairs are complete,
retest for original problem.
Does CPA Tool indicate a problem or generate a warranty authorization code (WAC)? No: Go to Step 11.

Step 11 Perform CPA misfire diagnostics. Decision

• Perform CPA Signal Check (page 1413). Yes: Make repair indicated
by CPA Tool.
• Perform CPA Cold Idle Test (page 1407).
• Perform CPA Hot Idle Test (page 1421).
Does CPA Tool indicate a problem or generate a warranty authorization code (WAC)? No: End diagnostics and
retest for original complaint.

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify if each step was completed correctly and the proper decision
was made. Notify supervisor for further action.
84 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

5.3 - Engine Unable to Reach Desired Speed During PTO Operation

Overview
Engine is not able to increase rpm up to desired speed during Power Take Off (PTO) operation.
NOTE: Perform a MAF Sensor Calibration after doing repairs that change engine air intake, exhaust, or Exhaust
Gas Recirculation (EGR) flow characteristics.
NOTE: Do not replace Injection Control Pressure (ICP) sensor unless directed by diagnostic procedure.
Possible Causes
• PTO circuit or system fault
• Auxiliary Engine Speed Control (AESC) set speed (not set high enough or not set correctly)
• Accelerator Pedal Position (APP)
• Injection Control Pressure (ICP)
• Injection Pressure Regulator (IPR)
• Exhaust Gas Recirculation (EGR)
• Exhaust restriction
• Intake restriction
• Fuel Delivery Pressure (FDP)

Test Procedure
NOTE: See CT-471 Body Builder books for additional PTO and AESC information.

Step 1 Perform operational checkout procedure. Decision

Yes: Go to Step 2.
Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers No: Go to 5.0 Engine
complaint align with this specific symptom procedure? Running, Engine Under
Load Operational
Checkout Procedure
(page 31).

Step 2 Determine if Power Take Off (PTO) engages. Decision

Engage PTO. Yes: Go to Step 3.
Did PTO engage properly? No: Diagnose and repair
PTO problem. After
repairs are complete,
retest for original
problem.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 85

Step 3 Verify if Auxiliary Engine Speed Control (AESC) / remote engine throttle Decision
programmable parameters are set above desired speed.
A. Key-On Engine-Off (KOEO). Yes: Go to Step 4.
B. Connect Electronic Service Tool (EST) (page 1345) with Navistar® Engine
Diagnostics and log in.

C. Select: Sessions > Parameters.

Are AESC parameters set above desired engine speed? No: Set AESC
programmable
parameters to maximum
desired engine speed.
After repairs are
complete, retest for
original problem.

Step 4 Determine if Accelerator Pedal Position (APP) meets full range percent. Decision
Review 0 to 60 Test data: Verify APP % at idle and full throttle. Yes: Go to Step 5.
Is Accelerator Peddle Position: 0% at idle, and 99% or greater at full throttle?
No: Repair APP sensor
or circuit problem. After
repairs are complete,
retest for original
problem.

Step 5 Determine if Injection Control Pressure (ICP) system is operating properly. Decision
Review 0 to 60 Test data: Verify if Injection Control Pressure is approximately the same Yes: Go to Step 6.
as ICP Desired.
Is Injection Control Pressure approximately the same as ICP Desired?
No: Go to CPA
High-Pressure Oil Pump
(HPOP) Test (page
1440).

Step 6 Determine if Exhaust Gas Recirculation (EGR) system is operating properly. Decision
Review 0 to 60 Test data: Verify if EGR Position is approximately the same as EGR Valve Yes: Go to Step 7.
CTL.
Is EGR Position approximately the same as EGR Valve CTL?
No: Go to SPN 2791 FMI
7 Fault Code Diagnostics
(page 817). After repairs
are complete, retest for
original problem.
86 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 7 Determine if exhaust system is restricted. Decision

Review 0 to 60 Test data: Verify if TC1 Turbine Outlet Pressure is less than 20 psi. Yes: Repair exhaust
system restriction. After
Is TC1 Turbine Outlet Pressure 20 psi or greater?
repairs are complete,
retest for original
problem.
No: Go to Step 8.

Step 8 Determine if air intake is restricted. Decision

Review 0 to 60 Test data: Verify if Intake Manifold Absolute Pressure is above BARO (not Yes: Go to Step 9.
creating a vacuum).
Is Intake Manifold Absolute Pressure above BARO?
No: Repair intake
restriction. After repairs
are complete, retest for
original problem.

Step 9 Determine is fuel delivery pressure meets specification. Decision

Perform Fuel Delivery Pressure (FDP) Test (page 1554). Yes: Perform CPA Signal
Check (page 1413),
Does fuel delivery pressure (gauge) meet specification?
CPA Hot Idle Test (page
1421), and CPA Road
Test (page 1427).
No: Go to 8.1 Fuel
Delivery Pressure (page
119).

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify if each step was completed correctly and the proper decision
was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 87

Engine Coolant Symptoms

6.1 - Coolant Overflow

Overview
Determine reason coolant overflows out of deaeration tank with the deaeration tank cap installed.
Possible Causes
• Air compressor
• Exhaust Gas Recirculation (EGR) cooler
• Cracked cylinder sleeve
• Cylinder head gasket
• Incorrect cylinder sleeve protrusion

Test Procedure

Step 1 Perform operational checkout procedure. Decision

Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers Yes: Go to Step 2.
complaint align with this specific symptom procedure?
No: Go to 6.0 Cooling
System Operational
Checkout Procedure (page
33).

WARNING:

To prevent personal injury or death, wear safety glasses with side shields.

Step 2 Verify coolant overflow occurs before coolant over temperature. Decision
Does coolant overflow occur before cooling system goes over temperature? Yes: Go to Step 3.
No: Go to 6.2 Coolant Over
Temperature (page 90).

Step 3 Determine if combustion pressure is in the cooling system. Decision

Perform Combustion in Cooling System Test (page 1614). Yes: Retain test setup. Go
to Step 4.
Are bubbles present in test beaker? No: Verify coolant is not
overfilled. After repairs are
complete, retest for original
problem.
88 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 4 Determine if air compressor is causing coolant overflow. Decision

A. Fill deaeration tank with coolant to proper level. Yes: Go to Step 5.

B. Pinch closed air compressor coolant supply and return hoses.

C. Run engine for no more than 2 minutes.

CAUTION:

Do not run engine for more than 2 minutes with air compressor
coolant hoses pinched off.
Are air bubbles present in test beaker with air compressor coolant hoses pinched off? No: Replace air compressor.
After repairs are complete,
retest for original problem.

Step 5 Determine if Exhaust Gas Recirculation (EGR) cooler is leaking. Decision

Perform On-Engine EGR Cooler Leak Test (page 1616). Yes: Repair EGR cooler
(See Engine Service
Manual). After repairs
are complete, retest for
original problem.
Is EGR cooler leaking coolant? No: Go to Step 6.

CAUTION:

To prevent engine damage, when replacing cylinder sleeves inspect piston cooling tubes
for damage or obstructions.

Step 6 Inspect underside of crankcase and cylinder sleeves seals for cooling system Decision
leaks.
A. Remove Oil Pan (see Engine Service Manual). Yes: Repair crankcase or
cylinder liner crevice seal.
B. Perform Cooling System Pressure Test (page 1603) while inspecting inside of
After repairs are complete,
crankcase for cooling system leaks.
retest for original problem.
Were any cylinder liner crevice seals or cooling system leaks found? No: Go to Step 7.

Step 7 Inspect cylinder sleeves for leaks, staining, pinholes, and cracks. Decision
NOTE: Cylinder head will need to be removed to perform this test. Yes: Go to Step 8.

Perform Cylinder Sleeve Cavitation and Crack Inspection (page 1661).

Are all cylinder sleeves free of coolant leaks, pinholes, and cracks? No: Replace leaking or
cracked cylinder sleeves.
After repairs are complete,
retest for original problem.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 89

Step 8 Determine if cylinder sleeve protrusion is in specification for each cylinder. Decision
Measure cylinder sleeve protrusion using Sleeve Protrusion Hold Down Clamps Yes: Go to Step 9.
ZTSE4825 and a dial indicator with magnetic base. See Engine Service Manual.
Is Sleeve protrusion in specification for all 6 cylinders? No: Go to Engine
Service Manual for
counterbore and cylinder
sleeve measurement and
resurfacing.

Step 9 Determine if cylinder head is leaking. Decision

See Engine Service Manual and Perform Cylinder Head Pressure Test. Yes: Replace cylinder head.
After repairs are complete,
retest for original problem.
Was cylinder head leakage observed? No: End diagnostics, retest
for original problem.

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify if each step was completed correctly and the proper decision
was made. Notify supervisor for further action.
90 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

6.2 - Coolant Over Temperature

Overview
Determine reason engine cooling system goes over temperature or over heats.

Possible Causes
• Cooling package debris clogging
• Accessory belt / tensioner failure
• Inoperative / slipping fan clutch
• Inoperative / damaged cooling fan or shroud
• Damaged water pump impeller
• Stuck closed thermostat

Test Procedure

Step 1 Perform operational checkout procedure. Decision

Yes: Go to Step 2.
Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers No: Go to 6.0 Cooling
complaint align with this specific symptom procedure? System Operational
Checkout Procedure (page
33).

Step 2 Determine if air flow thru cooling package is restricted. Decision

Inspect for restrictions and debris in front and between radiators and other cooling Yes: Clear restrictions and
package components. clean debris from cooling
package. After repairs are
complete, retest for original
problem.
Were restrictions or debris found? No: Go to Step 3.

Step 3 Determine if cooling system components are damaged. Decision

Inspect cooling fan blades, fan shroud, accessory drive belt(s), drive belt tensioner(s), Yes: Repair damaged
cooling package, and other cooling system components for damage. cooling system components.
After repairs are complete,
Are cooling system components damaged?
retest for original problem.
No: Go to Step 4.

WARNING:

To prevent personal injury or death, wear safety glasses with side shields.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 91

Step 4 Determine if coolant is flowing properly in the deaeration tank and coolant lines. Decision
A. Fill deaeration tank with coolant to proper level. Yes: Go to Step 5.
B. Run engine.
C. Observe deaeration tank and coolant lines for coolant flow.
Is coolant circulating in the deaeration tank?
No: Go to Step 8.

Step 5 Determine if fan clutch is operating properly. Decision

Determine if fan turns On and operates properly for your application. Yes: Go to Step 6.
Does fan clutch operate properly?
No: Repair fan clutch. After
repairs are complete, retest
for original problem.

Step 6 Determine if thermostat is stuck closed. Decision

Perform Thermostat Operational Test (page 1608). Yes: Go to Step 7.
At engine operating temperature, is upper radiator hose temperature approximately equal
to ECT1?
No: Replace thermostat.
After repairs are complete,
retest for original problem.

Step 7 Determine if radiator will not dissipate heat properly. Decision

A. Run engine to operating temperature at high idle. Yes: End Diagnostic Steps.

B. Turn air conditioning Off.

C. Using an Infrared Thermometer target upper radiator hose, and record reading.
D. Using an Infrared Thermometer target lower radiator hose, and record reading.
E. Calculate temperature difference (upper radiator hose temp – lower radiator
hose temp)
Is there an appropriate temperature drop between the lower radiator hose and upper
radiator hose?
NOTE: Greater temperature drop should occur in colder weather.
No: Clean or replace
radiator. After repairs are
complete, retest for original
problem.
92 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 8 Remove water pump and inspect water pump and front cover for damage Decision
or cavitation.
Does water pump and/or front cover have damage or cavitation? Yes: Replace damaged
components. After repairs
are complete, retest for
original problem.
No: End Diagnostic Steps.

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify if each step was completed correctly and the proper decision
was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 93

6.3 - Engine Unable to Reach Operating Temperature

Overview
Diagnosis reason engine will not get up to operating temperature.
Possible Causes
• Thermostat stuck Open
• Winterfront not installed during cold ambient temperatures
• Cooling fan stuck On

WARNING:

To prevent personal injury or death, wear safety glasses with side shields.
NOTE: In cold ambient temperatures, and low engine loads, engine will take longer to heat up.
NOTE: Minimum engine operating temperature is approximately 180°F (82°C).

Test Procedure

Step 1 Perform operational checkout procedure. Decision

Yes: Go to Step 2.
Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers No: Go to 6.0 Cooling
complaint align with this specific symptom procedure? System Operational
Checkout Procedure (page
33).

Step 2 Determine if engine cooling fan stays On while engine temperature is below Decision
fan engagement temperature.
A. Run engine at high idle for 10 minutes. Yes: Repair cooling fan or
fan controls. After repairs
B. Attempt to run engine up to operating temperature.
are complete, retest for
NOTE: Viscous fan may be engaged while engine is cold. original problem.
Does engine cooling fan stay engaged before operating temperature is reached?
No: Go to Step 3

Step 3 Determine if proper winter front is installed during cold ambient temperature. Decision
Is proper winterfront installed during cold ambient temperatures? Yes: Replace thermostat.
After repairs are complete,
retest for original problem.
No: Install proper winter
front on vehicle during cold
ambient temperatures. After
repairs are complete, retest
for original problem.
94 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify if each step was completed correctly and the proper decision
was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 95

6.4 - Coolant Leak to Exhaust

Overview
Determine reason engine coolant is leaking into exhaust system.
Possible Causes
• Failed Exhaust Gas Recirculation (EGR) cooler
• Interstage Cooler (ISC) leaking
• Aftertreatment Fuel Injector (AFTFI) cracked
• Head gasket leaking

Test Procedure

Step 1 Perform operational checkout procedure. Decision

Yes: Go to Step 2.
Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers No: Go to 6.0 Cooling
complaint align with this specific symptom procedure? System Operational
Checkout Procedure (page
33).

Step 2 Determine if Exhaust Gas Recirculation (EGR) cooler is leaking. Decision

Perform On-Engine EGR Cooler Leak Test (page 1616). Yes: Replace EGR cooler
(see Engine Service
Is EGR Cooler leaking?
Manual). After repairs
are complete, retest for
original problem.
No: Go to Step 3.

Step 3 Determine if Interstage Cooler (ISC) is leaking. Decision

Perform Interstage Cooler (ISC) Pressure Test (page 1551). Yes: Replace ISC. After
repairs are complete, retest
Is the ISC leaking?
for original problem.
No: Go to Step 4.

Step 4 Determine if combustion gas is in cooling system. Decision

Perform Combustion in Cooling System Test (page 1614). Yes: Remove cylinder head.
Inspect for failed head
Is combustion gas getting in cooling system?
gasket, warped or damaged
cylinder head, or incorrect
cylinder sleeve protrusion.
See Engine Service Manual.
No: End Diagnostic Steps.
96 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify if each step was completed correctly and the proper decision
was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 97

6.5 - Coolant Leak to Intake

Overview
Determine what component is causing engine coolant to leak into the engine air intake.

Possible Causes
• Failed Exhaust Gas Recirculation (EGR) cooler
• Failed Interstage Cooler (ISC)

Test Procedure

Step 1 Perform operational checkout procedure. Decision

Yes: Go to Step 2.
Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers No: Go to 6.0 Cooling
complaint align with this specific symptom procedure? System Operational
Checkout Procedure (page
33).

Step 2 Determine if EGR cooler is leaking. Decision

Perform On-Engine EGR Cooler Leak Test (page 1616). Yes: Replace EGR cooler
(See Engine Service
Is EGR cooler leaking?
Manual). After repairs
are complete, retest for
original problem.
No: Go to Step 3.

Step 3 Determine if Interstage Cooler (ISC) is leaking. Decision

Perform Interstage Cooler (ISC) Pressure Test (page 1551). Yes: Replace ISC. After
repairs are complete, retest
Is the ISC Leaking?
for original problem.
No: End Diagnostic Steps

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify if each step was completed correctly and the proper decision
was made. Notify supervisor for further action.
98 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

6.6 - Coolant Leak to Engine Oil

Overview
Determine component causing coolant to leak into the engine oil.
Possible Causes
• Cracked cylinder liner
• Leaking cylinder liner o-ring(s)
• Failed air compressor
NOTE: White condensation under the oil filler cap and on dipstick is normal.

Test Procedure

Step 1 Perform operational checkout procedure. Decision

Yes: Go to Step 2.
Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers No: Go to 6.0 Cooling
complaint align with this specific symptom procedure? System Operational
Checkout Procedure
(page 33).

Step 2 Determine if coolant is leaking into air compressor oil return. Decision
Perform Air Compressor Coolant Leak Test (page 1611). Yes: Repair or replace air
compressor. After repairs
Does coolant come out of air compressor oil return line?
are complete, retest for
original problem. Change
engine oil and filter.
No: Go to Step 3.

Step 3 Determine if EGR cooler is leaking. Decision

Perform On-Engine EGR Cooler Leak Test (page 1616). Yes: Replace EGR cooler
(See Engine Service
Is EGR cooler leaking?
Manual). After repairs
are complete, retest for
original problem.
No: Go to Step 4.

Step 4 Determine if Interstage Cooler (ISC) is leaking. Decision

Perform Interstage Cooler (ISC) Pressure Test (page 1551). Yes: Replace ISC. After
repairs are complete, retest
Is the ISC Leaking?
for original problem.
No: Go to Step 5.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 99

Step 5 Determine if coolant is leaking from cylinder liners. Decision

A. Remove engine oil pan. See Engine Service Manual. Yes: Replace failed
cylinder liner(s) (See
B. Perform Cooling System Pressure Test (page 1603).
Engine Service Manual).
C. Inspect for coolant leaking between each cylinder liner and piston. After repairs are
complete, retest for
D. Inspect for coolant leakage between cylinder liner and crankcase.
original problem. Change
Is coolant leaking between piston and liner, or between cylinder liner and crankcase? engine oil and filter.
No: Go to Step 6.

Step 6 Determine if oil cooler assembly is leaking. Decision

Perform Oil Cooler Pressure Test (page 1621). Yes: Repair oil cooler.
After repairs are
Are bubbles present in oil ports or on outside of cooler assembly?
complete, retest for
original problem. Change
engine oil and filter.
No: End diagnostic
steps.

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify if each step was completed correctly and the proper decision
was made. Notify supervisor for further action.
100 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Engine Lubrication Symptoms

7.1 - Engine Oil Contamination

Overview
Determine reason fluid or solid debris are in engine oil. Some fine metal residue is normal in engine oil.

Possible Causes
• Leaking cylinder liners
• External debris
• Valve train failure / internal engine damage
• Wrong fluid added during servicing

Test Procedure

Step 1 Perform operational checkout procedure. Decision

Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers Yes: Go to Step 2.
complaint align with this specific symptom procedure?
No: Go to 7.0 Engine
Oil System Operational
Checkout Procedure (page
36).

Step 2 Determine what contamination is in engine oil. Decision

A. Drain engine oil into a clean oil container. Yes, Liquid(s): Go to Step 3.
B. Evaluate oil for contaminants and debris. Yes, Magnetic / ferrous
metals 1/16 inch (1.6 mm)
Is engine oil contaminated with: liquid(s), metallic debris 1/16 inch (1.6 mm) or larger,
or larger: Go to Step 4.
other solid debris?
Yes, Non-ferrous metals
1/16 inch (1.6 mm) or larger:
Go to Step 5.
Yes, Other solid debris:
change engine oil and
filter. Monitor engine oil for
continued contamination.
No: Review complaint.

Step 3 Determine if engine oil is contaminated with coolant. Decision

Is engine oil contaminated with coolant? Yes: Go to 6.4 Coolant leak
to Engine Oil. (page 98).
No: Change engine oil
and filter. After repairs are
complete, retest for original
problem.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 101

Step 4 Determine if valve train damage is causing ferrous metal contamination in Decision
engine oil.
A. Remove valve cover (see Engine Service Manual). Yes: Repair loose or
damaged valve train
B. Inspect push tubes, rocker arms, valve bridges for damage and loose
components. Change
components.
engine oil and filter. After
C. Verify valve lash is set correctly. repairs are complete, retest
for original problem.
Is valve train loose or damaged?
No: Remove oil pan.
Inspect rotating assembly
and crankcase for damage.
Repair damage. Change
engine oil and filter. After
repairs are complete, retest
for original problem.

Step 5 Determine if air compressor is causing non-ferrous metal contamination in Decision

engine oil.
A. Remove air compressor oil return line. Yes: Repair or replace air
compressor. Change engine
B. Inspect oil return line for debris.
oil and filter. After repairs
Is metal in air compressor return line? are complete, retest for
original problem.
No: Go to Step 6.

Step 6 Determine if camshaft bearings are causing non-ferrous metal contamination Decision
in engine oil.
A. Remove oil pan (see Engine Service Manual). Yes: Replace camshaft
bearings. Change engine oil
B. Inspect camshaft bearings for damage.
and filter. After repairs are
Are camshaft bearings damaged? complete, retest for original
problem.
No: Go to Step 7.
102 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 7 Determine if connecting rod or main bearings are causing non-ferrous metal Decision
contamination in engine oil.
A. Remove three connecting rod caps and three main bearing caps (see Engine Yes, bearing damage only:
Service Manual). Replace worn bearings.
Repair root cause of failure.
B. Inspect bearings for excessive wear.
Change engine oil and filter.
Do connecting rod and / or main bearings have excessive wear? After repairs are complete,
retest for original problem.
Yes, crankshaft damage:
Replace engine. After
repairs are complete, retest
for original problem.
No: Review complaint.

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify if each step was completed correctly and the proper decision
was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 103

7.2 - Engine Oil Leak to Intake

Overview
Determine reason engine oil is leaking into air intake. Some oil film or residue in air intake system is normal.
If required, IK1201117 may provide additional details about selecting correct crankcase breather kit for specific
engines.

Possible Causes
• Restricted air intake / air filter
• Crankcase breather failed
• Failed high-pressure turbocharger
• Failed low-pressure turbocharger

Test Procedure

Step 1 Perform operational checkout procedure. Decision

Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers Yes: Go to Step 2.
complaint align with this specific symptom procedure?
No: Go to 7.0 Engine
Oil System Operational
Checkout Procedure (page
36).

NOTE: If air inlet is restricted, oil can be drawn from air compressor clean air supply.

Step 2 Determine if air intake / air filter is restricted. Decision

A. Disconnect air supply hose between air compressor and engine air intake. Yes: Repair restricted air
intake / air filter. After
B. Inspect inside air supply hose for excess oil.
repairs are complete, retest
Is excessive oil in air supply hose? for original problem.
No: Go to Step 3.
104 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 9 Open Crankcase Breather (Typical)

1. Crankcase breather assembly outlet tube (open)
2. Crankcase breather assembly part number

Step 3 Determine if engine has an open crankcase breather. Decision

A. Inspect crankcase breather assembly outlet tube (Figure 9) (1). Yes: Go to Step 6.
B. Determine if outlet tube is open (Figure 9) (1) to atmosphere or is connected
to turbocharger air inlet duct (closed).
Is crankcase breather assembly outlet tube open? No: Go to Step 4.

Step 4 Determine Open Breather Kit needed. Decision

Go to iKNow article IK1201117, open service kit selection form. Enter last 7 digits of Yes: Go to Step 9.
Engine Serial Number, follow form instructions
Does selection form provide a kit part number? No: Go to Step 5.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 105

Step 5 Determine if crankcase breather / oil separator is operating properly. Decision

Perform Crankcase Oil Separator (CCOS) Speed Test (page 1572). Yes: Go to Step 6.
Is crankcase breather / oil separator operating properly? No: Replace closed
crankcase breather (See
Engine Service Manual),
do not convert to open
breather. After repairs are
complete, retest for original
problem.

Step 6 Determine if turbocharger has coking or soot build-up. Decision

A. Remove turbocharger intake tube. Yes: Perform Dual
Turbocharger Compressor
B. Inspect turbocharger for soot build-up or coking.
Cleaning and Inspection,
(see Engine Service
Manual). After repairs
are complete, retest for
original problem.
Does turbocharger have coking or soot build-up? No: Go to Step 7.

Step 7 Determine if high-pressure turbocharger is causing oil leak. Decision

Remove high-pressure turbocharger center section (see Engine Service Manual). Yes: Go to Step 8.
Is oil pooling in high-pressure turbocharger turbine housing? No: Go to Step 9.

Step 8 Determine if high-pressure turbocharger turbine housing is damaged. Decision

With high-pressure turbocharger center section removed, inspect inside of turbine Yes: Replace entire
housing (exhaust side) for evidence of contact with turbine wheel. high-pressure turbocharger
assembly with turbine
• Indications of contact can include bright spots of bare metal, nicks, or gouges on
housing. After repairs are
turbine housing inner surface.
complete, retest for original
• Turbocharger end play does not indicate a failure. problem.
Is turbine housing damaged or are there signs that turbine wheel has contacted turbine No: Replace only
housing? high-pressure turbocharger
center section. After repairs
are complete, retest for
original problem.

Step 9 Determine if low-pressure turbocharger is causing oil leak. Decision

Remove low-pressure turbocharger center section (see Engine Service Manual). Yes: Go to Step 10.
Is oil pooling in low-pressure turbocharger turbine housing? No: Go to Step 11.
106 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 10 Determine if low-pressure turbocharger turbine housing is damaged. Decision

With low-pressure turbocharger center section removed, inspect inside of turbine housing Yes: Replace entire
(exhaust side) for evidence of contact with turbine wheel. low-pressure turbocharger
assembly with turbine
• Indications of contact can include bright spots of bare metal, nicks, or gouges on
housing. After repairs are
turbine housing inner surface.
complete, retest for original
• Turbocharger end play does not indicate a failure. problem.
Is turbine housing damaged or are there signs that turbine wheel has contacted turbine No: Replace only
housing? low-pressure turbocharger
center section. After repairs
are complete, retest for
original problem.

Step 11 Determine if crankcase breather / oil separator is operating properly. Decision

Perform Crankcase Oil Separator (CCOS) Speed Test (page 1572). Yes: Install breather kit
indicated in step 4. After
repairs are complete, retest
for original problem.
Is crankcase breather / oil separator operating properly? No: Install new breather
assembly and breather kit
indicated in step 4. After
repairs are complete, retest
for original problem.

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify if each step was completed correctly and proper decision
was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 107

7.3 - Engine Oil Leak to Exhaust

Overview
Determine reason engine oil is leaking into exhaust.

Possible Causes
• High-pressure turbocharger
• Low-pressure turbocharger
• Internal engine damage

Test Procedure

Step 1 Perform operational checkout procedure. Decision

Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers Yes: Go to Step 2.
complaint align with this specific symptom procedure?
No: Go to 7.0 Engine
Oil System Operational
Checkout Procedure
(page 36).

Step 2 Determine if engine has internal engine damage. Decision

Perform Crankcase Pressure Test (page 1567). Yes: Go to Step 3.
Is crankcase pressure within specification (page 1683)? No: Repair cause of
excessive crankcase
pressure. After repairs
are complete, retest for
original problem.

Step 3 Determine if high-pressure turbocharger is causing oil leak to exhaust. Decision

Remove high-pressure turbocharger center section (see Engine Service Manual). Yes: Go to Step 4.
Is oil pooling in high-pressure turbocharger turbine housing? No: Go to Step 5.

Step 4 Determine if high-pressure turbocharger turbine housing is damaged. Decision

With high-pressure turbocharger center section removed, Inspect inside of turbine housing Yes: Replace
(exhaust side) for evidence of contact with turbine wheel. entire high-pressure
turbocharger assembly
• Indications of contact can include bright spots of bare metal, nicks, or gouges on
with turbine housing.
turbine housing inner surface.
After repairs are
• Turbocharger end play does not indicate a failure. complete, retest for
original problem.
Is turbine housing damaged or are there signs that turbine wheel has contacted turbine No: Replace
housing? only high-pressure
turbocharger center
section. After repairs
are complete, retest for
original problem.
108 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 5 Determine if low-pressure turbocharger is causing oil leak to exhaust. Decision

Remove low-pressure turbocharger center section (see Engine Service Manual). Yes: Go to Step 6.
Is oil pooling in low-pressure turbocharger turbine housing? No: End diagnostics.
Retest for original
problem.

Step 6 Determine if low-pressure turbocharger turbine housing is damaged. Decision

With low-pressure turbocharger center section removed, Inspect inside of turbine housing Yes: Replace
(exhaust side) for evidence of contact with turbine wheel. entire low-pressure
turbocharger assembly
• Indications of contact can include bright spots of bare metal, nicks, or gouges on
with turbine housing.
turbine housing inner surface.
After repairs are
• Turbocharger end play does not indicate a failure. complete, retest for
original problem.
Is turbine housing damaged or are there signs that turbine wheel has contacted turbine No: Replace
housing? only low-pressure
turbocharger center
section. After repairs
are complete, retest for
original problem.

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify if each step was completed correctly and proper decision
was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 109

7.4 - Low Engine Oil Pressure

Overview
Determine reason engine oil pressure is low and / or oil pressure gauge reads low.

Possible Causes
• Engine oil pressure gauge or circuit
• Engine Oil Pressure (EOP) sensor
• Incorrect oil viscosity
• Oil suction tube or gasket
• Piston cooling tubes
• Connecting rod and / or main bearings
• Oil pressure regulator
• Loose rocker arm bolts / worn rocker arms or rocker arm shaft
• Oil pump

Test Procedure

Step 1 Perform operational checkout procedure. Decision

Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers Yes: Go to Step 2.
complaint align with this specific symptom procedure?
No: Go to 7.0 Engine
Oil System Operational
Checkout Procedure
(page 36).

Step 2 Determine if instrument panel oil pressure gauge is working properly. Decision
®
A. Connect Electronic Service Tool (EST) with Navistar Engine Diagnostics and log-in. Yes: Go to Step 3.
B. Select: Pressure tab. No: Repair instrument
panel oil pressure gauge
C. Monitor Engine Oil Pressure.
or circuit. After repairs
Does Engine Oil Pressure match oil pressure shown on instrument panel oil pressure gauge? are complete, retest for
original problem.

Step 3 Determine if Engine Oil Pressure (EOP) sensor is operating properly. Decision
Perform Oil Pressure Verification Test (page 1625). Yes: Replace EOP
sensor. After repairs
Does pressure gauge read engine oil pressure in specification?
are complete, retest for
original problem.
No: Go to Step 4.
110 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

CAUTION:

Low viscosity engine oil will cause lower engine oil pressure in hot ambient temperatures
and high engine loads.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 111

Step 4 Determine if engine has correct oil viscosity for current ambient temperatures Decision
and operating conditions.
A. Review oil change records. Yes: Go to Step 5.
B. See Engine Operation and Maintenance Manual “SAE Oil Viscosity Grades and No: Change engine oil.
Temperature Ranges” for correct oil viscosity for ambient temperatures and Add correct viscosity
operating conditions. oil for conditions. After
repairs are complete,
Does engine have the correct oil viscosity for current ambient temperatures and operating
retest for original
conditions?
problem.

Step 5 Determine if oil pressure regulator is operating properly. Decision

Perform Oil Pressure Regulator Inspection (page 1659). Yes: Go to Step 6.
Is oil pressure regulator spring, piston, and bore in good condition and not damaged, worn, No: Install new oil
or binding? pressure regulator
assembly. If bore
is worn or damaged
install a new oil cooler
module. After repairs
are complete, retest for
original problem.

Step 6 Determine if oil suction tube, piston cooling tubes, main or connecting rod Decision
bearings are causing low oil pressure.
A. Perform Oil and Crankcase Inspection (page 1662). Yes, oil suction tube
or gasket damaged or
B. Remove three connecting rod caps, and three main bearing caps.
restricted: Install new
C. Measure connecting rod, and main bearing clearances (see Engine Service oil suction tube and
Manual). gasket. After repairs
are complete, retest for
Is oil suction tube or piston cooling tubes cracked, damaged, or restricted; or are connecting
original problem.
rod or main bearings out of specification?
Yes, piston cooling
tube(s) damaged or
restricted: Install new
piston cooling tubes
(see Engine Service
Manual). After repairs
are complete, retest for
original problem.
Yes, connecting rod or
main bearings out of
specification: Install new
connecting rod and/or
main bearings. After
repairs are complete,
retest for original
problem.
No: Go to Step 7.
112 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 7 Determine if loose or worn valve train components are causing low oil pressure. Decision
A. Remove valve cover (see Engine Service Manual). Yes: Repair loose
or worn valve train
B. Inspect for loose rocker arm bolts, worn rocker arms, or worn rocker arm shaft.
components. After
Are rocker arm bolts loose, or are rocker arms or rocker shaft worn excessively? repairs are complete,
retest for original
problem.
No: Go to Step 8.

Step 8 Determine if oil pump, oil pump housing, or front cover are causing low oil Decision
pressure.
A. Remove drive belts (see Engine Service Manual). Yes: Replace damaged
or excessively worn
B. Remove vibration damper.
components. After
C. Remove damper hub. repairs are complete,
retest for original
D. Remove oil pump housing.
problem.
E. Inspect oil pump housing, front cover, inner and outer rotor for damage and
No: End Diagnostic
excessive wear.
Steps.
F. Perform Oil Pump Side Clearance, and Oil Pump End Clearance measurements
(see Engine Service Manual).
Does oil pump, oil pump housing, or front cover have excessive wear, or are oil pump
clearances out of specification?

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify if each step was completed correctly and the proper decision
was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 113

7.5 - High Engine Oil Pressure

Overview
Determine reason engine oil pressure is high and / or oil pressure gauge reads high.

Possible Causes
• Engine oil pressure gauge or circuit
• Engine Oil Pressure (EOP) sensor
• Incorrect oil viscosity
• Oil pressure regulator

Test Procedure

Step 1 Perform operational checkout procedure. Decision

Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers Yes: Go to Step 2.
complaint align with this specific symptom procedure?
No: Go to 7.0 Engine
Oil System Operational
Checkout Procedure
(page 36).

Step 2 Determine if instrument panel oil pressure gauge is working properly. Decision
A. Connect Electronic Service Tool (EST) with Navistar® Engine Diagnostics and log-in. Yes: Go to Step 3.
B. Select: Pressure tab. No: Repair instrument
panel oil pressure gauge
C. Monitor Engine Oil Pressure.
or circuit. After repairs
Does Engine Oil Pressure match oil pressure shown on instrument panel oil pressure gauge? are complete, retest for
original problem.

Step 3 Determine if Engine Oil Pressure (EOP) sensor is operating properly. Decision
Perform Oil Pressure Verification Test (page 1625). Yes: Replace EOP
sensor. After repairs
Does pressure gauge read engine oil pressure in specification?
are complete, retest for
original problem.
No: Go to Step 4.

CAUTION:

High viscosity engine oil will cause higher engine oil pressure in cold ambient
temperatures.
114 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 4 Determine if engine has correct oil viscosity for current ambient temperatures Decision
and operating conditions.
A. Review oil change records. Yes: Go to Step 5.
B. See Engine Operation and Maintenance Manual “SAE Oil Viscosity Grades and No: Change engine oil.
Temperature Ranges” for correct oil viscosity for ambient temperatures and Add correct viscosity
operating conditions. oil for conditions. After
repairs are complete,
Does engine have the correct oil viscosity for current ambient temperatures and operating
retest for original
conditions?
problem.

Step 5 Determine if oil pressure regulator is operating properly. Decision

Perform Oil Pressure Regulator Inspection (page 1659). Yes: End Diagnostic
Steps.
Is oil pressure regulator spring, piston, and bore in good condition and not damaged, worn,
or binding? No: Install new oil
pressure regulator
assembly. If bore
is worn or damaged
install a new oil cooler
module. After repairs
are complete, retest for
original problem.

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify if each step was completed correctly and the proper decision
was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 115

7.6 - Engine Oil Aeration

Overview
Determine reason engine oil is aerated (air bubbles in oil).

Possible Causes
• Overfilled engine oil
• Oil suction tube or gasket
• Cracked or leaking front cover
• Damaged oil pump gasket or housing

Test Procedure

Step 1 Perform operational checkout procedure. Decision

Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers Yes: Go to Step 2.
complaint align with this specific symptom procedure?
No: Go to 7.0 Engine
Oil System Operational
Checkout Procedure
(page 36).

Step 2 Determine if oil suction tube or gasket is causing oil aeration. Decision
A. Adjust engine oil level to proper level, if not already done. Yes: Go to Step 3.
B. Add two gallons of extra engine oil. No: Replace oil suction
tube and gasket. After
C. Start engine and run for 10 minutes.
repairs are complete,
D. Turn Off engine. retest for original
problem.
E. Check dipstick for oil aeration.
Is engine oil aerated?

Step 3 Determine if oil pump, oil pump housing, or front cover is leaking, cracked Decision
or damaged.
A. Remove drive belts (see Engine Service Manual). Yes: Replace leaking,
cracked or damaged
B. Remove vibration damper.
components. After
C. Remove damper hub. repairs are complete,
retest for original
D. Remove oil pump housing.
problem.
E. Inspect oil pump housing, front cover, inner and outer rotor for leaks, cracks, or
No: Go to Step 4.
damage.
Does oil pump, oil pump housing, or front cover have leaks, cracks, or damage?
116 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 4 Determine if front cover and / or oil suction tube is cracked or damaged. Decision
A. Remove oil pan (see Engine Service Manual). Yes: Replace cracked or
damaged components.
B. Inspect front cover and oil suction tube for cracks and damage.
After repairs are
Is front cover or oil suction tube cracked or damaged? complete, retest for
original problem.
No: End Diagnostic
Steps.

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify if each step was completed correctly and the proper decision
was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 117

7.7 - Engine Oil in Coolant

Overview
Determine reason Coolant contaminated with lube oil will have oil in the deaeration tank.

Possible Causes
• Failed oil cooler

Required Tools
• Oil Cooler Pressure Test Plate ZTSE4939
• Pressure Test Kit ZTSE4409
• Regulated compressed air

WARNING:

To prevent personal injury or death, do not smoke and keep fuel away from flames and
sparks.

WARNING:

To prevent personal injury or death, wear safety glasses with side shields.

WARNING:

To prevent personal injury or death, do the following when removing the radiator cap or
deaeration cap:
• Allow engine to cool for 15 minutes or more.
• Wrap a thick cloth around the radiator cap or deaeration cap.
• Loosen cap slowly a quarter to half turn to vent pressure.
• Pause for a moment to avoid being scalded by steam.
• Continue to turn cap counterclockwise to remove.
118 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Test Procedure

Step 1 Perform operational checkout procedure. Decision

Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers Yes: Go to Step 2.
complaint align with this specific symptom procedure?
No: Go to 7.0 Engine
Oil System Operational
Checkout Procedure
(page 36).

Step 2 Check for coolant contamination by inspecting deaeration tank for presence Decision
of oil.
A. Place a coolant drain pan under the oil cooler module. Yes: Replace Oil Cooler.
After repairs are made,
B. Remove the coolant drain plug installed in the bottom of the oil cooler module.
perform Cooling Flush
Drain coolant. This procedure will drain the entire cooling system.
Procedure (see iKNow
C. Remove the oil cooler following the procedure in Engine Service Manual. article IK1201248).
D. Perform Oil Cooler Pressure Test (page 1621). No: End diagnostic
steps.
Is there a noticeable leak?

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify if each step was completed correctly and the proper decision
was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 119

Fuel System Symptoms

8.1 - Fuel Delivery Pressure

Overview
Diagnosis fuel delivery pressure low or high problem.
Possible Causes
• Low / no fuel in fuel tank(s)
• Restricted fuel strainer
• Fuel filter restriction
• Fuel gelling in cold weather
• Fuel inlet restriction or leak (supply line, tank, pickup, optional primary fuel filter)
• Restricted fuel return line
• Electric fuel pump power, ground, or relay circuits
• Failed fuel pressure regulator
• Leaking or damaged fuel supply or return fittings
• Incorrect fuel pump O-rings
• Failed fuel pump

WARNING:

To prevent personal injury or death, keep fuel away from flame and sparks.

Test Procedure

Step 1 Perform operational checkout procedure. Decision

Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers Yes: Go to Step 2.
complaint align with this specific symptom procedure?
No: Go to 8.0 Fuel System
Operational Checkout
Procedure (page 38).

Step 2 Measure fuel delivery pressure Decision

Review results from Fuel Delivery Pressure (FDP) Test (page 1554). No, Less than specification:
Go to Step 3.
Did fuel delivery pressure meet specification?
No, Greater than
specification: Go to Step 8.
Yes: End Diagnostic Steps.
120 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 10 Fuel Pump and O-rings

1. Electric Fuel Pump 2. Brown fuel pump O-rings 3. Fuel strainer

Step 3 Inspect fuel filter, fuel strainer, and fuel pump O-rings. Decision
A. Disconnect fuel inlet from engine mounted fuel filter module. Yes: Go to Step 4.
B. Inspect and clean fuel inlet fitting of debris. No: Install International®
approved fuel filter.
C. Turn Key On for 20 seconds (to reduce fuel in filter module).
Clean or replace fuel
D. Turn Key OFF.
strainer.
E. Remove and inspect engine mounted fuel filter.
Install proper brown O-rings
F. Remove and inspect fuel pump, strainer, and O-rings. on fuel pump.

NOTE: Low fuel delivery pressure, hard to start, or no start can be caused by non-Original After repairs are complete,
Equipment Manufacturer (OEM) fuel filters and/or wrong O-rings installed on the fuel pump. retest for original problem.

Is fuel filter made by an International® approved manufacturer? Is fuel filter and strainer
clean, and are fuel pump O-rings brown?
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 121

Figure 11 Electronic Fuel Pump PWR and GND

Step 4 Determine if fuel pump will run when provided power and ground. Decision
Yes: Reinstall fuel pump. Go
CAUTION:
to Step 5.
No: Replace electric fuel
Use a 10 amp fuse in the circuit, in case pump is shorted.
pump. After repairs are
With fuel pump removed from engine, provide power and ground to the pump: complete, retest for original
problem.
A. Install Fuel Pump Breakout Harness ZTSE6023 on fuel pump connector, leave
engine harness disconnected.
B. Install power circuit with 10 amp fuse to Pins-4 and 6.
C. Ground Pin-1.
D. Listen for pump running. Let pump run for 30 seconds.
Does pump run?

Step 5 Determine if electric fuel pump power and ground circuits are operating Decision
properly.
Perform Fuel Pump Voltage Test (page 1557). Key must be Off for 10 seconds, or Yes: Go to Step 7.
more, and then cycled On for the Electronic Control Module (ECM) to command the
fuel pump On.
Is voltage reading between Pin-6 and Pin-1, and between Pin-4 and Pin-1 within 0.5 volt No: Leave Breakout
of battery voltage when the fuel pump is energized? Harness connected. Go
to Step 6.
122 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 6 Determine if electric fuel pump power circuit is operating properly. Decision
Using a Digital Multimeter (DMM) measure voltage between Pin-4 and ground, and Yes: Repair electric fuel
between Pin-6 and ground, when fuel pump is commanded On. pump ground circuit. After
repairs are complete, retest
for original problem.
Is voltage at pins 4 and 6 within 0.5 volts of battery voltage? No: Repair electric fuel
pump power circuit. After
repairs are complete, retest
for original problem.

Step 7 Determine if fuel inlet problem is present. Decision

Perform the Clean Fuel Source Test (page 1559). Inspect for debris at fuel inlet, clean as Yes: Repair restriction in fuel
needed. supply line, pickup, fuel tank,
or optional chassis mounted
Is fuel pressure 80 to 100 psi?
fuel filter. After repairs are
complete, retest for original
problem.
No: Replace Fuel Pressure
Regulator (see Engine
Service Manual). After
repairs are complete, retest
for original problem.

Step 8 Determine if fuel return line is restricted. Decision

A. Check vehicle fuel return line from the fuel filter module fitting to the fuel tank for Yes: Repair fuel return
restrictions. restriction. After repairs are
complete, retest for original
B. Connect Clean Fuel Source Tool Return Line 15-637-01-3 to the fuel filter
problem.
module fuel return port.
No: Inspect that fuel filter
C. Start engine.
module dry break fitting
Is fuel pressure now within specification? opens when return line fitting
is attached. After repairs are
complete, if fuel pressure
is still high, replace fuel
pressure regulator. After
repairs are complete, retest
for original problem.

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify if each step was completed correctly and the proper decision
was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 123

8.2 - Fuel in Engine Oil

Overview
Determine cause of fuel getting into the engine oil.
NOTE: Some fuel in engine oil is normal. Depending on engine drive cycles.

Possible Causes
• Worn piston rings
• Broken fuel injector tip
• Loose fuel injector hold downs
• Leaking fuel injector O-rings
• Extended engine oil service intervals
• Engine misfire

Test Procedure

Step 1 Perform operational checkout procedure. Decision

Did a symptom Fault Code Action Plan (FCAP) bring you here or does the customers Yes: Go to Step 2.
complaint align with this specific symptom procedure?
No: Go to 8.0 Fuel
System Operational
Checkout Procedure
(page 38).

Step 2 Check for Diagnostics Trouble Codes (DTC) related to excessive fueling. Decision
®
Using Electronic Service Tool (EST) with Navistar Engine Diagnostics, check DTC list for: Yes: Go to Fault
Code Diagnostics for
• SPN 1322 -1328, 4257 Injector (INJ)
appropriate SPN/FMI.
Does EST DTC list have any of the above SPN?
No: Go to Step 3.

Step 3 Determine if engine has a misfire. Decision

Does engine misfire of run rough? Yes: Go to 5.2 Misfire
(Stumble / Surge / Runs
Rough) (page 81). After
repairs are complete,
retest for original problem.
Change engine oil and
filter.
No: Go to Step 4.
124 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 4 Determine if cylinder relative compression is within specification. Decision

Perform Relative Compression Test Plus (RCT+) (page 1465). Yes: Repair mechanical
problem with cylinder(s)
Does CPA Tool indicate a problem or generate a warranty authorization code (WAC)?
indicating low
performance. After
repairs are complete,
retest for original problem.
Change engine oil and
filter.
No: Go to Step 5.

Step 5 Determine if engine oil has been changed according to maintenance schedule. Decision
A. Examine last three oil service interval records. Yes: Go to Step 6.
B. Compare oil change records to Operators Operation and Maintenance Manual No: Change engine oil
schedule. and filter. Recommend
customer change
Has oil been changed according to Maintenance Schedule?
engine oil according to
Maintenance Schedule.

Step 6 Determine if fuel injectors are loose or injector seals are leaking. Decision
A. Remove valve cover (see Engine Service Manual). Yes: Remove injectors
and inspect injector
B. Remove high-pressure oil manifold.
O-rings and combustion
C. Re-torque injector hold down clamp bolts. seals. Look for doubled
combustion seals, burned
Is one or more injector hold down loose?
injectors, or burned
O-rings. Repair as
needed. After repairs
are complete, retest for
original problem. Change
engine oil and filter.
No: Change engine oil
and filter. Monitor for fuel
in engine oil: Operate
vehicle for 1/3 of normal
oil change interval and
inspect for fuel in engine
oil.

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify if each step was completed correctly and the proper decision
was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 125

Engine Brake Symptoms

9.1 - Engine Compression Brake Inoperative

Overview
Engine compression brake will not activate when commanded On.
Possible Causes
• Incorrect brake lash adjustment
• Brake (oil) pressure relief valve stuck Open
• Brake Control Pressure (BCP) leak (worn brake piston seals, etc.)
• Failed Engine Compression Brake 1 (ECB1) valve
• Engine compression brake switch or circuit inoperative (switch, circuit, or body controller could not enable
brake due to not receiving required signals)
• Engine compression brake control system entry conditions not met

Test Procedure

Step
Perform operational checkout procedure. Decision
1
Did a symptom Fault Code Action Plan (FCAP) bring you here or does the Yes: Go to Step 2.
customers complaint align with this specific symptom procedure?
No: Go to 9.0 Engine Compression
Brake Operational Checkout
Procedure (page 39).

Step Determine if Brake Ctrl Pressure Desired goes above 0 when

Decision
2 commanded.
Review 0 to 60 snapshot. Yes: Go to Step 6.
Did Brake Ctrl Pressure Desired go above 0? No: Go to Step 3.

Step Check for Accelerator Pedal Position (APP) or Transmission Output Shaft
Decision
3 Speed (TOSS) Diagnostic Trouble Codes (DTC).
Using Electronic Service Tool (EST) with Navistar® Engine Diagnostics, check Yes: Got to Fault Code Diagnostics
DTC list for: for SPN 91,191 or 2623.

• SPN 91 and 2623 APP No: Go to Step 4.

• SPN 191 TOSS

Is SPN 91, 191, or 2623 active?
126 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step
Verify operator controls are set properly to allow engine brake operation. Decision
4
Verify the following are true: Yes: Go to Step 5.
• Traction Control is not active No: Bring operator controls to
proper condition to allow engine
• Clutch pedal is released
compression brake operation. After
• Cab mounted engine brake ON/OFF switch is set to ON repairs are complete, retest for
original problem.
• Accelerator pedal is not depressed
• Vehicle transmission is in gear (driveline engaged)
• Torque convertor lockup engaged
• Engine Oil temperature is greater than 25°C (77°F)
• Anti-lock Brake System (ABS) not active
• Engine speed is greater than 1000 rpm
Are all the above conditions true?

Step Determine if programmable parameter is enabled to allow engine

Decision
5 compression brake operation.
A. Connect EST with Navistar® Engine Diagnostics and log-in. Yes: Go to Step 6.
B. Select Sessions > Programming. No: Enable Vehicle Retarder
Control Mode programmable
C. Select the Engine Brake tab.
parameter. After repairs are
Is Vehicle Retarder Control Mode programmable parameter enabled? complete, retest for original
problem.

Step
Determine if Injection Control Pressure (ICP) system is operating properly. Decision
6
Review 0 to 60 snapshot: verify Injection Control Pressure is approximately the Yes: Go to Step 7.
same as ICP Desired.
No: Go to CPA High-Pressure Oil
Is Injection Control Pressure approximately the same as ICP Desired? Pump (HPOP) Test (page 1440).

Step
Determine if ICP system is operating properly. Decision
7
Review 0 to 60 snapshot: Verify ICP Ctrl is less than 80% Yes: Go to CPA High-Pressure Oil
Pump (HPOP) Test (page 1440).
Is ICP Ctrl 80% or greater?
No: Check and adjust brake lash
(see Engine Service Manual). After
repairs are complete, retest for
original problem.

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify each step was completed correctly and the proper decision
was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 127

9.2 - Engine Compression Brake Engaged When Not Commanded

Overview
Engine compression brake activate when Not commanded On.
Possible Causes
• Failed high-pressure oil manifold
• Brake pressure relief valve stuck closed
• Engine Compression Brake 1 (ECB1) solenoid stuck Open or leaking
• ECB1 circuit fault
• Incorrect brake lash adjustment
• Brake Control Pressure (BCP) sensor or circuit fault

Test Procedure

Step
Perform operational checkout procedure. Decision
1
Did a symptom Fault Code Action Plan (FCAP) bring you here or does the Yes: Go to Step 2.
customers complaint align with this specific symptom procedure?
No: Go to 9.0 Engine Compression
Brake Operational Checkout
Procedure (page 39).

Step Determine if Brake Ctrl Pressure is approximately the same as Brake

Decision
2 Ctrl Pressure Desired.
Review 0 to 60 snapshot. Yes: adjust engine brake lash (see
Engine Service Manual). After
Is Brake Ctrl Pressure below 100 psi, when Brake Ctrl Pressure Desired is 0?
repairs are complete, retest for
original problem.
No: Do BCP sensor and circuit
checks (SPN 4287 Pin-Point Tests).
If checks are good, Go to Step 3.

NOTE: See latest version of Engine and Aftertreatment Wiring Schematic Form for additional circuit
information.

Step
Determine if ECB1 actuator or O-rings are leaking or damaged. Decision
3
A. Remove ECB1 actuator. See Engine Service Manual. Yes: Replace O-rings and reinstall
original ECB1 (if undamaged). After
B. Check ECB1 actuator and O-rings for leaks or damage.
repairs are complete, retest for
Is ECB1 actuator or O-rings leaking or damaged? original problem.
No: Go to Step 4.
128 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step
Determine if ECB1 actuator, or high-pressure oil manifold have failed. Decision
4
A. Install new ECB1 actuator. Yes: End Diagnostic Steps.
B. After repairs are complete, retest for original problem. No: Install a new high-pressure
oil manifold. Adjust engine brake
Is engine compression brake engaged when not commanded problem repaired?
lash (see Engine Service Manual).
After repairs are complete, retest
for original problem.

End Diagnostic Steps

After performing all diagnostic steps, if fault remains, verify each step was completed correctly and the proper decision
was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 129

Fault Code Diagnostics

130 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Diagnostic Trouble Codes

Diagnostic Trouble Code Overview
All electrical faults in the engine control system can be diagnosed in this section. All components are divided
into separate test procedures and contain the following information:
• SPN / FMI with possible cause
• Circuit diagram
• Component function
• Circuit operation
• Component location
• Diagnostic tool list
• Sensor End Diagnostics (with EST)
• Pin-point Diagnostics (without EST)
• Step Based Diagnostics
• Harness resistance check
• Operational voltage check (most components)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 131

SPN 27 FMI 0 - EGRP fault: over temperature

Fault Overview
Fault sets when the Engine Control Module (ECM) senses Exhaust Gas Recirculation Valve Position (EGRP)
temperature is too high.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• Failed EGR valve

Step 1 Check for active fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON Yes: Replace EGR Valve. After
Engine OFF (KOEO), check Diagnostic Trouble Codes (DTC) list for SPN 27 FMI 0. repairs are complete, retest for
SPN 27 FMI 0.
Is SPN 27 FMI 0 active? No: Repair active faults. After
repairs are complete, retest for
SPN 27 FMI 0.

End Diagnostic Tests

After performing all diagnostic steps, if SPN 27 FMI 0 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
132 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 27 FMI 3 - EGRP Signal Out of Range HIGH

Fault Overview
This fault sets when Exhaust Gas Recirculation (EGR) valve receives a voltage supply of greater than 18 volts
for 5 seconds.

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

Associated Faults
None

Fault Facts
This is not an EGR valve problem; it is a voltage supply problem.
This fault may set if vehicle has been jump-started or charged using a 24V power supply.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Charging system over voltage
• Incorrect battery pack wiring (series instead of parallel)
• Use of battery charger on boost mode
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 133

Step 1 Check for active or pending fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON, Yes: Go to Step 2.
Engine OFF (KOEO), check Diagnostic Trouble Codes (DTC) list for SPN 27 FMI 3.
Is SPN 27 FMI 3 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Figure 12 Check Battery Pack Wiring

Step 2 Check for correct parallel battery pack wiring. Decision

Check positive battery cable(s) connected from positive battery terminal to positive Yes: Go to Step 3.
battery terminal. Check negative battery cable(s) connected from negative battery
terminal to negative battery terminal.
Is battery pack correctly assembled (wired in parallel and not in series)? No: Reassemble battery pack.
After repairs are complete, retest
for SPN 27 FMI 3.

Step 3 Check EGRV PWR circuit for high voltage. Decision

Perform Test 1 (page 134). Use Digital Multimeter (DMM), measure voltage Yes: Perform Electrical System
between Breakout Harness ZTSE4948 pin-4 and known good GND. Test (page 1577). If charging
system fails, replace alternator.
After repairs are complete, retest
for SPN 27 FMI 3.
Is voltage greater than 18 volts? No: End diagnostics, retest for
SPN 27 FMI 3.

End Diagnostic Tests

After performing diagnostic steps, if SPN 27 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
134 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 27 FMI 3)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4948
• DMM
• EST with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Figure 13 ACT PWR Circuit Check

Test 1
A. Key OFF.
B. Disconnect EGRV connector.
C. Connect Breakout Harness ZTSE4948 to vehicle harness and leave EGRV disconnected.

D. Start engine and allow it to idle.

 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 135

SPN 27 FMI 4 - EGRP Signal Out of Range LOW

Fault Overview
This fault sets when Exhaust Gas Recirculation (EGR) valve receives a voltage supply of less than 8 volts for
13 seconds.

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

Associated Faults
None

Fault Facts
This is not an EGR valve problem; it is a voltage supply problem.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Battery, starting or charging system failure
• ACT PWR Open or short to GND
• ACT GND Open or high resistance

Step 1 Check for active or pending fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON, Yes: Go to Step 2.
Engine OFF (KOEO), check Diagnostic Trouble Codes (DTC) list for SPN 27 FMI 4.
Is SPN 27 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Inspect connections at Engine Gas Recirculation Valve (EGRV) Decision

connector.
A. Key OFF. Yes: Go to Step 3.
B. Disconnect EGRV connector.

C. Check EGRV and connector terminals for: damaged or pinched wires;

moist or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are EGRV connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for
SPN 27 FMI 4.
136 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Check for excessively drained batteries. Decision

Interview operator or customer and (or) review the initial write up. View the freeze Yes: Perform Batteries and
frame data for SPN 27 FMI 4 in EST. Electrical System Inspection
(page 1666) and Electrical
System Test (page 1577). Repair
or replace failed components
as needed. After repairs are
complete, retest for
SPN 27 FMI 4.
Is SWBAT voltage greater than 16 volts or less than 8 volts in freeze frame data, or No: Go to Step 4.
is it possible the engine was cranked when battery voltage dropped below 8 volts?

Step 4 Check EGRV PWR circuit voltage. Decision

Perform Test 1 (page 137). Use DMM, measure voltage between Breakout Harness Yes: Repair Open or high
ZTSE4948 pin-4 and known good GND. resistance between EGRV pin-3
and GND. After repairs are
complete, retest for
SPN 27 FMI 4.
Is voltage B+ ± 0.5 volts? No: Repair Open or short to GND
between EGRV pin-4 and ACT
PWR relay pin-87. After repairs
are complete, retest for SPN 27
FMI 4.

End Diagnostic Tests

After performing diagnostic steps, if SPN 27 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 137

Pin-Point Tests (SPN 27 FMI 4)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4948
• Digital Multimeter (DMM)
• EST with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Figure 14 ACT PWR Circuit Check

Test 1
A. Key OFF.
B. Disconnect EGRV connector.
C. Connect Breakout Harness ZTSE4948 to vehicle harness, leave EGRV disconnected.

D. Key ON.
138 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 27 FMI 7 - EGRP does not agree with commanded position

Fault Overview
Fault code sets when Engine Control Module (ECM) determines Exhaust Gas Recirculation (EGR) valve is Not
functioning properly when commanded.

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

Associated Faults
• SPN 27 FMI 0, 3, and 4 • SPN 2791 FMI 2, 3, and 4
(EGR) (EGR)

Fault Facts
This fault is also used to detect EGR valve positive and negative deviation faults.

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• Exhaust Gas Recirculation (EGR) valve motor internal duty cycle greater than 95%
• EGR valve motor stuck
• Deposits on EGR valve
• Stuck or sticking EGR valve
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 139

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 138).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 27 FMI 7.

Step 2 Inspect connections at Exhaust Gas Recirculation Valve (EGRV). Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect EGRV connector.
C. Check EGRV and connector for: damaged or pinched wires; wet or
corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are EGRV connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 27
FMI 7.

Step 3 Test for proper Exhaust Gas Recirculation Valve (EGRV) operation. Decision
Perform Exhaust Gas Recirculation Valve (EGRV) Operational Test (page 1543). Yes: Replace EGR valve. After
repairs are complete, retest for
SPN 27 FMI 7.
Is SPN 2791 FMI 7 or SPN 27 FMI 7 Pending or Active in DTC list after running test? No: Fault no longer present at this
time. After repairs are complete,
retest for SPN 27 FMI 7.

End Diagnostic Test

After performing diagnostic steps, if SPN 27 FMI 7 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
140 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 27 FMI 14 - EGR internal circuit failure

Fault Overview
Fault sets when Engine Control Module (ECM) determines Exhaust Gas Recirculation (EGR) valve is not
functioning properly when initialized.

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

Associated Faults
• SPN 27 FMI 3, 4, and 7 • SPN 2791 FMI 2, 3, 4 and
(EGR) 7 (EGR)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• EGR valve unable to seat closed
• Stuck or sticking EGR valve
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 141

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 140).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 27 FMI 14.

Step 2 Check for active or pending fault codes. Decision

Use EST with Navistar® Engine Diagnostics. Key ON Engine OFF (KOEO), check Yes: Go to Step 3.
DTC list for SPN 27 FMI 14.
Is SPN 27 FMI 14 active or pending? No: Repair active fault codes.
After repairs are complete, retest
for SPN 27 FMI 14.

Step 3 Inspect connections at Exhaust Gas Recirculation Valve (EGRV). Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect EGRV connector.
C. Check EGRV and connector for: damaged or pinched wires; wet or
corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are EGRV connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 27
FMI 14.

Step 3 Exhaust Gas Recirculation Valve (EGRV) Operational Test. Decision

Perform Exhaust Gas Recirculation Valve (EGRV) Operational Test (page 1543). Yes: Replace EGRV. After repairs
are complete, retest for SPN 27
FMI 14.
Are there any active SPN 2791 or SPN 27 fault codes active? No: System OK.

End Diagnostic Tests

After performing all diagnostic steps, if SPN 27 FMI 14 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
142 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 51 FMI 0 - ETP fault: over temperature

Fault Overview
Fault sets when Engine Control Module (ECM) determines Engine Throttle Position (ETP) signal is erratic.

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

Associated Faults
SPN 2630 FMI 16

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Charge Air Cooler (CAC) under cooling
• Sensor or valve failure
• Interstage cooler under cooling
• Engine overheat
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 143

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 142).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 51 FMI 0.

Step 2 Check for active or pending fault codes. Decision

Use EST with Navistar® Engine Diagnostics. Key ON Engine OFF (KOEO), check Yes: Go to Step 3.
DTC list for SPN 51 FMI 0.
Is SPN 51 FMI 0 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 51 FMI 0.

Step 3 Inspect Engine Throttle Valve (ETV) sensor and connector. Decision
A. Key OFF. Yes: Go to Step 4.
B. Disconnect ETV sensor.
C. Check ETV sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are ETV sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 51
FMI 0.

Step 4 Determine if ETP circuit is out of specification. Decision

A. Key OFF. Yes: Go to Step 5.
B. Connect EST to vehicle Diagnostic Connector. (page 1345).
C. Key On Engine Off (KOEO), log in to Navistar® Engine Diagnostics.

D. Perform Output State High or Low(page 1359) test.

E. Monitor Engine Throttle Position (ETP) and Engine Throttle Valve Control
(ETV CTL) in Actuator Window.
Does ETP closely match ETV CTL? No: Replace ETV. After repairs
are complete, retest for SPN 51
FMI 0.
144 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 5 Check coolant level. Decision

Park vehicle on level ground. Check coolant level as indicated on deaeration tank Yes: Fill deaeration tank. Perform
level window. Coolant Leak Visual Inspection
(page 1643). After repairs are
complete, retest for SPN 51 FMI
0.
Is level below deaeration tank fill level? No: Go to Step 6.

Step 6 Check vehicle grille for obstructions. Decision

Inspect grille for obstructions that may reduce air flow to Charge Air Cooler (CAC). Yes: Go to Step 7.
Is grille clear of obstructions? No: Repair or remove obstruction
from grille. After repairs are
complete, retest for SPN 51 FMI
0.

Step 7 Decision
Check engine fan, fan shroud, and air dams for damage and proper operation. Yes: Go to Step 8.
Are engine fan, fan shroud, and air dams intact and operating properly? No: Repair or replace engine fan,
fan shroud, and/or air dams. After
repairs are complete, retest for
SPN 51 FMI 0.

Step 8 Check CAC for oil, dirt, or other debris. Decision

Do CAC checks (page 1646). Yes: After doing all diagnostic
Steps, if SPN 51 FMI 0 remains
active, verify each step was
completed correctly and proper
decision was made. Notify
supervisor for further action.
CAC system free of dirt, debris, or oil? No: Clean CAC. After repairs are
complete, retest for SPN 51 FMI
0.

End Diagnostic Test

After performing diagnostic Steps, if SPN 51 FMI 0 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 145

SPN 51 FMI 2 - ETP does not agree with commanded position

Fault Overview
Fault sets when Engine Control Module (ECM) determines Engine Throttle Position (ETP) signal does not agree
with Engine Throttle Valve Control (ETV CTL).

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

Associated Faults
• SPN 51 FMI 3 and 4 (ETV) • SPN 3464 FMI 3 and 4
(ETV)

Fault Facts

Drive Cycles
Continuous
Possible Causes
• Open ETP Signal Return
• Frozen gears (water ingestion that turned to ice)
• Failed ETV
146 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 145).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 51 FMI 2.

Step Inspect Engine Throttle Valve (ETV). Decision

Inspect ETV for signs moisture, condensation, or freezing. Yes: Go to Step 3.
Is ETV dry and not frozen? No: Warm and dry ETV. Use
winter front in cold weather to
eliminate fault. After repairs are
complete, retest for SPN 51 FMI
2.

Step Decision
A. Perform Test 1 (page 147). Yes: Replace ETV. After repairs
are complete, retest for SPN 51
B. Use DMM, measure voltage between Breakout Harness ZTSE4735A
FMI 2.
pin-3 and PWR.
Is voltage B+ ± 0.5 volts? No: Repair Open between ETV
pin-3 and ECM pin E-28. After
repairs are complete, retest for
SPN 51 FMI 2.

End Diagnostic Test

After performing diagnostic steps, if SPN 51 FMI 2 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 147

Pinpoint Diagnostics (SPN 51 FMI 2)

Figure 15 ETV Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools
• Breakout Harness ZTSE4735A (ETV)
• Digital Multimeter (DMM)

Figure 16 ETV Circuit Check

Test 1
A. Key OFF.

B. Disconnect Engine Throttle Valve (ETV) connector.

C. Connect Breakout Harness ZTSE4735A to engine harness connector and leave ETV disconnected.

D. Key ON Engine OFF (KOEO).

148 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 51 FMI 3 - ETP signal Out of Range HIGH

Fault Overview
Fault code sets when Electronic Control Module (ECM) detects Engine Throttle Position (ETP) signal is greater
than 4.902 volts.

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

Associated Faults
SPN 3509 FMI 3 and 4
(VREF 1)

Fault Facts
None

Drive Cycles
Key ON
Possible Causes
• ETP circuit short to PWR
• Failed ETV sensor
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 149

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 148).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 51 FMI 3.

Step 2 Check for active or pending fault codes. Decision

Use EST with Navistar® Engine Diagnostics. Key ON Engine OFF (KOEO), check Yes: Go to Step 3.
DTC list for SPN 51 FMI 3.
Is SPN 51 FMI 3 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 3 Inspect connections at Engine Throttle Valve (ETV) sensor. Decision

A. Key OFF. Yes: Go to Step 4.
B. Disconnect ETV connector.
C. Check ETV connector and terminals for damaged or pinched wires; wet or
corroded terminals; or loose, bent, or broken connector housing.
Are ETV connector, harness, and terminals clean and undamaged? No: Repair connector, harness, or
terminal damage. After repairs are
complete, retest for SPN 51 FMI 3.

Step 4 Inspect connections at Engine Throttle Valve (ETV) sensor. Decision

A. Key-Off. Yes: Repair short to PWR
between ETV pin-5 and ECM pin
B. Disconnect ETV connector.
E-68. After repairs are completed,
C. Connect EST to vehicle Diagnostic Connector. (page 1345). retest for SPN 51 FMI 3.

D. Key-On Engine-Off (KOEO), log in to Navistar® Engine Diagnostics.

E. Use EST, clear DTC list.
Does SPN 51 FMI 3 set after DTC list is cleared? No: Replace ETV. After repairs
are completed, retest for SPN 51
FMI 3.

End Diagnostic Steps

After performing all diagnostic steps, if SPN 51 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
150 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 51 FMI 4 - ETP signal Out of Range LOW

Fault Overview
Fault code sets when Electronic Control Module (ECM) detects that Engine Throttle Position (ETP) circuit reading
is less than 0.352 volts.

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

Associated Faults
SPN 3509 FMI 3 and 4
(VREF 1)

Fault Facts
None

Drive Cycle to Determine Fault Status

Key ON.
Possible Causes
• ETP Signal short to GND
• VREF 1 circuit Open
• ETP signal Open
• Failed ETV sensor
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 151

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 150).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 51 FMI 4.

Step 2 Check for active or pending fault codes. Decision

Use EST with Navistar® Engine Diagnostics. Key ON Engine OFF (KOEO), check Yes: Go to Step 3.
DTC list for SPN 51 FMI 4.
Is SPN 51 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 3 Inspect connections at Engine Throttle Valve (ETV) connector. Decision

A. Key OFF. Yes: Go to Step 4.
B. Disconnect ETV connector.
C. Check ETV and connector terminals for: damaged or pinched wires; wet
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are ETV connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 51
FMI 4.

Step 4 Check ETP circuits for Opens. Decision

A. Perform Test 1 (page 153). Yes: Go to Step 5.
B. Use DMM, measure voltage between Breakout Harness ZTSE4735A pin-1
and known good GND.
Is voltage 5 ± 0.5 volts? No: Repair Open between ETV
pin-1 and ECM pin E-35. After
repairs are complete, retest for
SPN 51 FMI 4.

Step 5 Check ETV circuits. Decision

A. Perform Test 2 (page 154). Yes: Replace ETV. After repairs
®
are complete, retest for SPN 51
B. Use EST with Navistar Engine Diagnostics, clear DTC list.
FMI 4.
Does SPN 51 FMI 3 set after DTC is cleared? No: Go to Step 6.
152 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 6 Check ETV circuits. Decision

A. Perform Test 3 (page 155). Yes: Repair short to GND
between ETV pin-5 and ECM pin
B. Use EST with Navistar® Engine Diagnostics, clear DTC list.
E-68. After repairs are complete,
retest for SPN 51 FMI 4.
Does SPN 3509 FMI 4 set after DTC is cleared? No: Repair Open between ETV
pin-5 and ECM pin E-68. After
repairs are complete, retest for
SPN 51 FMI 4.

End Diagnostic Tests

After performing diagnostic steps, if SPN 51 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 153

Pin-Point Tests (SPN 51 FMI 4)

Figure 17 ETP circuit diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4735A
• Breakout Harness ZTSE4498
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP-1210B-compliant supporting J1939 and J1708)
154 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 18 VREF 1 Circuit Check

Test 1
A. Key OFF.
B. Disconnect Engine Throttle Valve (ETV)
C. Connect Breakout Harness ZTSE4735A to vehicle harness connector and leave ETV disconnected.
D. Key ON Engine OFF (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 155

Figure 19 ETV Sensor Circuit Check

Test 2
A. Key OFF.
B. Disconnect Engine Throttle Valve (ETV)
C. Connect Breakout Harness ZTSE4735A to vehicle harness connector and leave ETV disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4735A pin-1 and pin-5 together.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
156 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 20 ETV Sensor Circuit Check

Test 3
A. Key OFF.
B. Connect Breakout Harness ZTSE4735A to Engine Throttle Valve Position (ETP) vehicle harness connector
and leave ETP disconnected.
C. Use Breakout Harness ZTSE4498, short pin-1 and pin-5 of Breakout Harness ZTSE4735A together.
D. Connect EST to vehicle Diagnostic Connector (page 1345).
E. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 157

SPN 51 FMI 5 - ETP open load/circuit

Fault Overview

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Open circuit for intake throttle position power
• Open circuit for intake throttle position ground
• Open intake throttle circuit
158 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON Yes: Go to Step 2.
Engine OFF (KOEO), check Diagnostic Trouble Codes (DTC) list for SPN 51 FMI 5.
Is SPN 51 FMI 5 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 51 FMI 5.

Step 2 Inspect connections at Engine Throttle Valve (ETV). Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect ETV connector.
C. Check ETV and connector for: damaged or pinched wires; wet or corroded
terminals; loose, bent, or broken pins; or broken connector housing.
Are ETV connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 51
FMI 5.

Step 3 Determine if Engine Throttle Position (ETP) sensor is operating within Decision
specification.
A. Key OFF. Yes: After doing all diagnostic
Steps, if SPN 51 FMI 5 remains,
B. Connect breakout harness ZTSE4735A between ETV and ETV connector.
verify each step was completed
C. Connect EST to vehicle Diagnostic Connector. (page 1345). correctly and proper decision
was made. Notify supervisor for
D. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
further action.
E. Do Key On Engine Off (KOEO) Output State High or Low Test (page 1359).
Is voltage within specification (page 1677)? No: Replace ETV. After repairs
are complete, retest for SPN 51
FMI 5.

End Diagnostic Test

After performing diagnostic steps, if SPN 51 FMI 5 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 159

SPN 51 FMI 7 - ETP does not agree with commanded position

Fault Overview
The Engine Control Module (ECM) senses a positive or negative error in Engine Throttle Position (ETP) sensor
based on actual throttle position minus throttle position set point after 25 seconds. ETP must be in closed loop
control.

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

Associated Faults
SPN 51 FMI 3 and 4 (ETV) SPN 3464 FMI 3 and 4
(ETV)

Fault Facts
Vehicles that chronically experience this fault condition in cold weather may require use of winter fronts to help
with issue. Note that an open ETP Signal Return (SRTN) does NOT set a circuit fault (Type 2 error) and does
set a mechanically sticking fault (Type 1 error). voltage is approximately constant 4 volts with an open SRTN.

Drive Cycle to Determine Fault Status

Key ON
Possible Causes
• Open ETP Signal Return
• Frozen gears (water ingestion that turned to ice)
• Failed Engine Throttle Valve (ETV)
160 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 159).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 51 FMI 7.

Step 2 Inspect Engine Throttle Valve (ETV). Decision

A. Key OFF. Yes: Go to Step 3.
B. Remove ETV, see Engine Service Manual.
C. Inspect ETV valve for signs moisture, condensation, or freezing.
Is ETV valve dry and not frozen. No: Warm and dry ETV. Use
winter front in cold weather to
eliminate fault. After repairs are
complete, retest for SPN 51 FMI
7.

Step 3 Determine if SIG GND circuit is operating properly. Decision

A. Perform Test 1 (page 161). Yes: Replace ETV. After repairs
are complete, retest for SPN 51
B. Use DMM, measure voltage between Breakout Harness ZTSE4735 pin-3
FMI 7.
and PWR.
Is voltage B+ ± 0.5 volts? No: Repair Open / high resistance
between ETV pin-3 and ECM pin
E-28. After repairs are complete,
retest for SPN 51 FMI 7.

End Diagnostic Tests

After performing diagnostic steps, if SPN 51 FMI 7 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 161

Pin-Point Tests (SPN 51 FMI 7)

Figure 21 ETV Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4735A
• Digital Multimeter (DMM)

Figure 22 ETV Circuit Check

Test 1
A. Key-Off.

B. Disconnect Engine Throttle Valve (ETV)

C. Connect Breakout Harness ZTSE4735A to vehicle connector and leave ETV disconnected.

D. Key-On Engine-Off (KOEO).

162 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 51 FMI 11 - ETP operation fault - underVolt, overAmp, overTemp/ETP H-bridge Electrical Check

Fault Overview
Fault sets when Engine Control Module (ECM) detects short circuit on Engine Throttle Valve (ETV)

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• ETV-CL Short to GND
• ETV-CH Short to GND
• ETV-CL Short to PWR
• ETV-CH Short to PWR
• ETV-CL shorted to ETV-CH
• Failed Engine Throttle Valve (ETV)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 163

Step 1 Check for active or pending fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON Yes: Go to Step 2.
Engine OFF (KOEO), check Diagnostic Trouble Code (DTC) list for SPN 51 FMI 11.
Is EST DTC list SPN 51 FMI 11 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 51 FMI 11.

Step 2 Inspect connections at Engine Throttle Valve (ETV) connector. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect ETV.
C. Check ETV and connector terminals for: damaged or pinched wires;
moisture in terminals; corroded terminals; loose, bent, or broken pins; or
broken connector housing.
Are ETV connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 51
FMI 11.

Step 3 Check for short to GND. Decision

A. Perform Test 1 (page 165). Yes: Go to Step 4.
B. Use DMM, measure resistance between Breakout Harness ZTSE4735A
pin-2 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ETV pin-2 and ECM pin E-57
and pin E-75. After repairs are
complete, retest for SPN 51 FMI
11.

Step 4 Check for Short to GND. Decision

A. Perform Test 2 (page 165). Yes: Go to Step 5.
B. Use DMM, measure resistance between Breakout Harness ZTSE4735A
pin-6 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ETV pin-6 and ECM pin E-58
and pin E-76. After repairs are
complete, retest for SPN 51 FMI
11.
164 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 5 Check for short to PWR. Decision

A. Perform Test 3 (page 166). Yes: Go to Step 6.
B. Use DMM, measure resistance between Breakout Harness ZTSE4735A
pin-2 and PWR.
Is resistance greater than 1000 ohms? No: Repair short to PWR between
ETV pin-2 and ECM pin E-57
and pin E-75. After repairs are
complete, retest for SPN 51 FMI
11.

Step 6 Check for short to PWR. Decision

A. Perform Test 4 (page 166). Yes: Go to Step 7
B. Use DMM, measure resistance between Breakout Harness ZTSE4735A
pin-6 and PWR.
Is resistance greater than 1000 ohms? No: Repair short to PWR between
ETV pin-6 and ECM pin E-58
and pin E-76. After repairs are
complete, retest for SPN 51 FMI
11.

Step 7 Check for ETV-CL shorted to ETV-CH. Decision

A. Perform Test 5 (page 167). Yes: Replace ETV. After repairs
are complete, retest for SPN 51
B. Use DMM, measure resistance between Breakout Harness ZTSE4735A
FMI 11.
pin-2 and pin-6.
Is resistance greater than 1000 ohms? No: Repair short between ETV-CL
and ETV-CH circuits. After repairs
are complete, retest for SPN 51
FMI 11

End Diagnostic Test

After performing diagnostic steps, if SPN 51 FMI 11 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 165

Pin-Point Tests (SPN 51 FMI 11)

Figure 23 ETV Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4735A
• Digital Multimeter (DMM)

Figure 24 ETV Connector Circuit Check

Test 1
A. Key OFF.
B. Disconnect Engine Throttle Valve (ETV) connector.
C. Connect Breakout Harness ZTSE4735A to vehicle harness and leave ETV connector disconnected.
166 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 25 ETV Connector Circuit Check

Test 2
A. Key OFF.
B. Disconnect Engine Throttle Valve (ETV) connector.
C. Connect Breakout Harness ZTSE4735A to vehicle harness and leave ETV connector disconnected.

Figure 26 ETV Connector Circuit Check

Test 3
A. Key OFF.

B. Disconnect Engine Throttle Valve (ETV) connector.

C. Connect Breakout Harness ZTSE4735A to vehicle harness and leave ETV connector disconnected.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 167

Figure 27 ETV Connector Circuit Check

Test 4
A. Key OFF.
B. Disconnect Engine Throttle Valve (ETV) connector.
C. Connect Breakout Harness ZTSE4735A to vehicle harness and leave ETV connector disconnected.

Figure 28 ETV Connector Circuit Check

Test 5
A. Key OFF.

B. Disconnect Engine Throttle Valve (ETV) connector.

C. Connect Breakout Harness ZTSE4735A to vehicle harness and leave ETV connector disconnected.
168 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 91 FMI 2 - APP1 and APP2 signal conflict

Fault Overview
Fault code sets when Engine Control Module (ECM) detects difference between Accelerator Pedal Position 1
(APP1) signal and Accelerator Pedal Position 2 (APP2) signal is greater than 0.14 volts at 1.1 volts and greater
than 0.52 volts at 4.1 volts.

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

Associated Faults
• SPN 91 FMI 3 and 4 • SPN 2623 FMI 3 and 4 • SPN 3510 FMI 3 and 4 • SPN 3511 FMI 3 and 4
(APP1) (APP2) (VREF 2) (VREF 3)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• APP1 circuit Open or high resistance
• APP2 circuit Open or high resistance
• SIG GND (APP1) circuit Open or high resistance
• SIG GND (APP2) circuit Open or high resistance
• VREF 2 circuit Open or high resistance
• VREF 3 circuit Open or high resistance
• Failed APP

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 168).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 91 FMI 2.

Step 2 Check for active or pending fault codes. Decision

Use EST with Navistar® Engine Diagnostics. Key ON Engine OFF (KOEO), check Yes: Go to Step 3
DTC list for SPN 91 FMI 2.
Is SPN 91 FMI 2 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 91 FMI 2.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 169

Step 3 Inspect Accelerator Pedal Position 1 (APP1) sensor and connector. Decision
A. Key OFF. Yes: Go to Step 4
B. Disconnect APP sensor.
C. Check APP sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are APP sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 91
FMI 2.

Step 4 Check for high resistance in Accelerator Pedal Position 1 (APP1). Decision
A. Perform Test 1 (page 171). Yes: Go to Step 6.
B. Use DMM, measure voltage between Breakout Harness ZTSE4485A
pin-A and pin-B.
Is voltage 1.15 ± 0.25 volts? No: Go to Step 5.

Step 5 Check for high resistance in Accelerator Pedal Position 1 (APP1). Decision
A. Perform Test 2 (page 171). Yes: Repair Open or high
resistance in SIG GND circuit
B. Use DMM, measure voltage between Breakout Harness ZTSE4485A pin-A
between APP connector pin-B
and known good GND.
and ECM pin C-34. After repairs
are complete, retest for SPN 91
FMI 2.
Is voltage 1.15 ± 0.25 volts? No: Repair Open or high
resistance in SIG circuit between
APP connector pin-A and ECM
pin C-33. After repairs are
complete, retest for SPN 91 FMI
2.

Step 6 Check VREF 2 circuit. Decision

A. Perform Test 3 (page 172). Yes: Go to Step 7.
B. Use DMM, measure voltage between Breakout Harness ZTSE4485A pin-C
and known good GND.
Is voltage 5.0 ± 0.25 volts? No: Repair Open or short to GND
in VREF 2 circuit between APP
pin-C and ECM pin C-63. After
repairs are complete, retest for
SPN 91 FMI 2.
170 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 7 Check for high resistance in Accelerator Pedal Position 2 (APP2). Decision
A. Perform Test 4 (page 173). Yes: Go to Step 9.
B. Use DMM, measure voltage between Breakout Harness ZTSE4485A
pin-E and pin-F.
Is voltage 0.60 ± 0.25 volts? No: Go to Step 8.

Step 8 Check for high resistance in Accelerator Pedal Position 2 (APP2). Decision
A. Perform Test 5 (page 174). Yes: Repair Open or high
resistance in SIG GND circuit
B. Use DMM, measure voltage between Breakout Harness ZTSE4485A pin-F
between APP connector pin-E
and known good GND.
and ECM pin C-36. After repairs
are complete, retest for SPN 91
FMI 2.
Is voltage 0.60 ± 0.25 volts? No: Repair Open or high
resistance in SIG circuit between
APP connector pin-F and ECM pin
C-48. After repairs are complete,
retest for SPN 91 FMI 2.

Step 9 Check VREF 3 circuit. Decision

A. Perform Test 6 (page 175). Yes: Replace APP. After repairs
are complete, retest for SPN 91
B. Use DMM, measure voltage between Breakout Harness ZTSE4485A pin-D
FMI 2.
and known good GND.
Is voltage 5.0 ± 0.25 volts? No: Repair Open or short to GND
in VREF 3 circuit between APP
pin-D and ECM pin C-9. After
repairs are complete, retest for
SPN 91 FMI 2.

End Diagnostic Test

After performing diagnostic steps, if SPN 91 FMI 2 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 171

Pin-Point Tests (SPN 91 FMI 2)

Figure 29 APP Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4485A
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Figure 30 APP Circuit Check

Test 1
A. Key OFF.

B. Disconnect Accelerator Pedal Position (APP) sensor.

C. Connect Breakout Harness ZTSE4485A between vehicle harness connector and APP sensor.

D. Key ON Engine OFF (KOEO).

172 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 31 APP Circuit Check

Test 2
A. Key OFF.
B. Disconnect Accelerator Pedal Position (APP) sensor.
C. Connect Breakout Harness ZTSE4485A between vehicle harness connector and APP sensor.
D. Key ON Engine OFF (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 173

Figure 32 APP Circuit Check

Test 3
A. Key OFF.
B. Disconnect Accelerator Pedal Position (APP) sensor.
C. Connect Breakout Harness ZTSE4485A to vehicle harness connector and leave APP sensor disconnected.
D. Key ON Engine OFF (KOEO).
174 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 33 APP Circuit Check

Test 4
A. Key OFF.
B. Disconnect Accelerator Pedal Position (APP) sensor.
C. Connect Breakout Harness ZTSE4485A between vehicle harness connector and APP sensor.
D. Key ON Engine OFF (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 175

Figure 34 APP Circuit Check

Test 5
A. Key OFF.
B. Disconnect Accelerator Pedal Position (APP) sensor.
C. Connect Breakout Harness ZTSE4485A between vehicle harness connector and APP sensor.
D. Key ON Engine OFF (KOEO).
176 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 35 APP Circuit Check

Test 6
A. Key-Off.
B. Disconnect Accelerator Pedal Position (APP) sensor.
C. Connect Breakout Harness ZTSE4485A to vehicle harness connector and leave APP sensor disconnected.
D. Key ON Engine OFF (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 177

SPN 91 FMI 3 - APP1 signal Out of Range HIGH

Fault Overview
Fault code sets when Engine Control Module (ECM) detects Accelerator Pedal Position 1 (APP1) signal is
greater than 4.575 volts.

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

Associated Faults
SPN 3510 FMI 3 and 4
(VREF 2)

Fault Facts
None

Drive Cycle to Determine Fault Status

Key ON
Possible Causes
• APP1 signal circuit short to PWR
• SIG GND circuit Open
• Failed APP sensor
178 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults(page 177).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 91 FMI 3.

Step 2 Check for active or pending fault code. Decision

Use EST with Navistar® Engine Diagnostics. Key ON Engine OFF (KOEO), check Yes: Go to Step 3.
DTC list for SPN 91 FMI 3.
Is EST DTC list SPN 91 FMI 3 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 3 Inspect connections at Accelerator Pedal Position (APP) sensor. Decision

A. Key OFF. Yes: Go to Step 4.
B. Disconnect APP sensor and connector.
C. Check APP sensor and connector terminals for damaged or pinched
wires; corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are APP sensor connector, harness, and terminal clean and undamaged? No: Repair connector, harness, or
terminal damage. After repairs are
complete, retest for SPN 91 FMI 3.

Step 4 Decision
A. Key OFF. Yes: Repair short to PWR
between APP sensor connector
B. Disconnect Accelerator Pedal Position (APP) sensor.
pin-A and ECM pin C-33.
C. Connect EST to vehicle Diagnostic Connector. (page 1345).
D. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
E. Use EST with Navistar® Engine Diagnostics, clear DTC list.
Does SPN 91 FMI 3 set after DTC list is cleared? No: Go to Step 5.

Step 4 Decision
A. Perform Test 1(page 180). Yes: Replace APP sensor. After
repairs are complete, retest for
B. Use Digital Multimeter (DMM), measure voltage between Breakout
SPN 91 FMI 3.
Harness ZTSE4485A pin-B and PWR.
Is voltage B+ ± 0.5 volt? No: Repair Open between APP
pin-B and ECM pin C-34. After
repairs are complete, retest for
SPN 91 FMI 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 179

End Diagnostic Tests

After performing diagnostic steps, if SPN 91 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
180 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 91 FMI 3)

Figure 36 Pin-Point Test APP Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4485A
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 181

Figure 37 APP1 Circuit Check

Test 1
A. Key OFF.
B. Disconnect Accelerator Pedal Position (APP) sensor.
C. Connect Breakout Harness ZTSE4485A to vehicle harness and leave APP sensor disconnected.
D. Key ON Engine OFF (KOEO).
182 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 91 FMI 4 - APP1 signal Out of Range LOW

Fault Overview
Fault code sets when Engine Control Module (ECM) detects Accelerator Pedal Position 1 (APP1) signal is less
than 0.825 volts.

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

Associated Faults
SPN 3510 FMI 3 and 4
(VREF 2)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• APP1 signal circuit Open
• APP1 VREF circuit Open
• APP1 signal circuit short to GND
• Failed APP sensor
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 183

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults(page 182).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 91 FMI 4.

Step 2 Check for active or pending fault codes. Decision

Use EST with Navistar® Engine Diagnostics. Key ON Engine OFF (KOEO), check Yes: Go to Step 3.
DTC list for SPN 91 FMI 4.
Is SPN 91 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 3 Inspect connections at Accelerator Pedal Position (APP) sensor. Decision

A. Key OFF. Yes: Go to Step 4.
B. Disconnect APP sensor connector.
C. Check APP1 sensor and connector terminals for damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are APP sensor connector, harness, and terminal clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 91
FMI 4.

Step 4 Check VREF circuit in APP sensor. Decision

A. Perform Test 1(page 184). Yes: Go to Step 5.
B. Use DMM, measure voltage between Breakout Harness ZTSE4485A pin-C
and known good GND.
Is voltage 5.0 ± 1.0 volts? No: Repair Open between APP
sensor connector pin-C and ECM
76-pin connector pin C-63. After
repairs are complete, retest for
SPN 91 FMI 4.

Step 5 Check APP sensor. Decision

A. Perform Test 2(page 185). Yes: Replace APP sensor. After
®
repairs are complete, retest for
B. Use EST with Navistar Engine Diagnostics, clear DTC list.
SPN 91 FMI 4.
Does SPN 91 FMI 3 set after DTC list is cleared? No: Go to Step 6.
184 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 6 Check signal circuit in APP sensor. Decision

A. Perform Test 3(page 186). Yes: Repair short to GND
between APP sensor pin-A and
B. Use EST with Navistar® Engine Diagnostics, clear DTC list.
ECM pin C-33. After repairs are
complete, retest for SPN 91 FMI
4.
Does VREF fault code set after DTC list is cleared? No: Repair Open between APP
sensor pin-A and ECM pin C-33.
After repairs are complete, retest
for SPN 91 FMI 4.

End Diagnostic Tests

After performing diagnostic steps, if SPN 91 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.

Pin-Point Tests (SPN 91 FMI 4)

Figure 38 APP1 Sensor Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4485A
• Breakout Harness ZTSE4498
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 185

Figure 39 APP1 Circuit Check

Test 1
A. Key OFF.
B. Disconnect Accelerator Pedal Position (APP) sensor.
C. Connect Breakout Harness ZTSE4485A to APP and leave sensor disconnected.
D. Key ON Engine OFF (KOEO).
186 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 40 APP1 Circuit Check

Test 2
A. Key OFF.
B. Disconnect Accelerator Pedal Position (APP) sensor.
C. Connect Breakout Harness ZTSE4485A to APP and leave sensor disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4485A pin-A to pin-C together.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 187

Figure 41 APP1 Circuit Check

Test 3
A. Key OFF.
B. Disconnect Accelerator Pedal Position (APP) sensor.
C. Connect Breakout Harness ZTSE4485A to APP and leave sensor disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4485A pin-A to pin-C together.
E. Connect EST to vehicle Diagnostic Connector (page 1345).
F. Key ON Engine OFF (KOEO) Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
188 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 94 FMI 0 - Fuel Delivery Pressure Above Critical

Fault Overview
Fault code sets when Fuel Delivery Pressure (FDP) is greater than 134 psi (924 kPa).

Lamp Reaction
No Lamp

Associated Faults
SPN 94 FMI 3 and 4 (FDP)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed FDP sensor
• Fuel delivery pressure system failure
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 189

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 188).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 94 FMI 0.

Step 2 Inspect Fuel Delivery Pressure (FDP) sensor and connector. Decision
A. Key OFF. Yes: Go to Step 3.
B. Disconnect FDP sensor.
C. Check FDP sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are FDP sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 94
FMI 0.

Step 3 Check fuel pressure with Navistar® Engine Diagnostics. Decision

A. Key OFF. Yes: End diagnostics. Retest for
SPN 94 FMI 0.
B. Disconnect electric fuel pump connector and leave disconnected during
test.
C. Connect EST to vehicle Diagnostic Connector. (page 1345).
D. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
E. Use EST with Navistar® Engine Diagnostics, monitor FDP when fuel pump
is not powered.
Is fuel pressure 0 psi? No: go to Step 4.

Step 4 Determine if engine has a fuel delivery problem. Decision

Perform Fuel Delivery Pressure (FDP) Test (page 1554). Yes: Replace FDP sensor. After
repairs are complete, retest for
SPN 94 FMI 0.
Is fuel pressure between 80 and 100 psi? No: Go to 8.1 Fuel Delivery
Pressure(page 119) Step 2.

End Diagnostic Steps

After performing all diagnostic steps, if SPN 94 FMI 0 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
190 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 94 FMI 1 - Fuel Delivery Pressure below Critical

Fault Overview
Fault code sets when Electronic Control Module (ECM) detects that Fuel Delivery Pressure (FDP) is below 30
psi (207 kPa).

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected during one drive cycle.

Associated Faults
• SPN 931 FMI 4 (EFP) • SPN 94 FMI 18 (FDP)

Fault Facts
None.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Recent fuel system service requiring priming
• Vehicle unused for long period of time requiring priming
• Diesel fuel
• Failed Fuel Pressure Regulator (FPR)
• Low fuel level in either tank (defective fuel level gauge or transfer pump)
• Restricted fuel supply line
• Restricted pickup tube in fuel tank
• Failed or incorrectly installed secondary fuel filter
• Failed Engine Fuel Pump (EFP)
• EFP circuit Open or high resistance
• EFP GND circuit Open

Step 1 Check for associated fault codes Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 190).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 94 FMI 1.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 191

Step 2 Check Fault Code Status Decision

®
Use EST with Navistar Engine Diagnostics, check DTC list for SPN 94 FMI 1 (EFP). Yes: Go to Fuel Delivery Pressure
symptom (page 119).
Is SPN 94 FMI 1 pending or active? No: Repair Active faults. After
repairs are complete, retest for
SPN 94 FMI 1.

End Diagnostic Steps

After performing all diagnostic steps, if SPN 94 FMI 1 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
192 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 94 FMI 2 - FDP Signal Erratic, Intermittent, or Incorrect

Fault Overview
Fault sets when Engine Control Module (ECM) determines Fuel Delivery Pressure (FDP) signal value is incorrect
when compared to other sensor values.

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

Associated Faults
SPN 94 FMI 3 and 4

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• FDP sensor drift

Step 1 Action Decision

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 192).
Is EST DTC list clear of Associated Faults? No: Repair associated faults.
After repairs are complete, retest
for SPN 94 FMI 2.

Step 2 Inspect Fuel Delivery Pressure (FDP) sensor and connector. Decision
A. Key OFF. Yes: Go to Step 3.
B. Disconnect FDP sensor.
C. Check FDP sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are FDP sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness, or
terminal damage. After repairs are
complete, retest for SPN 94 FMI 2.

Step 3 Test for intermittent circuit operation. Decision

A. Use Navistar® Engine Diagnostics, perform Continuous Monitor Test Yes: Go to Step 4.
(page 1361).
B. Compare FDP sensor to the Key On, Engine Off specification (page 1677).
Are FDP sensor circuits within specifications? No: Locate specific circuit
component causing erratic or
intermittent operation. Perform
voltage and resistance checks
in this section. Repair circuits
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 193

as required. After repairs are

complete, retest for SPN 94 FMI 2.

Step 4 Action Decision

With KOEO, wait 30 seconds for fuel pressure to stabilize, turn key off, and observe Yes: After doing all diagnostic
FDP voltage use EST with Navistar® Engine Diagnostics. steps, if SPN 94 FMI 2 remains,
verify each step was completed
correctly and proper decision
was made. Notify supervisor for
further action.
Is FDP less than 1.104 volts? No: Replace FDP sensor. After
repairs are complete, retest for
Signal name in Navistar® Engine Diagnostics is S_FDP Volts
SPN 94 FMI 2.

End Diagnostic Test

After performing diagnostic steps, if SPN 94 FMI 2 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
194 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 94 FMI 3 - FDP signal Out of Range HIGH

Fault Overview
Fault sets when Fuel Delivery Pressure (FDP) sensor signal voltage is greater than 4.912 volts (152 psi {1049
kPa}) for 5 seconds.

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

Associated Faults
SPN 3509 FMI 3 and 4
(VREF 1)

Fault Facts
None

Drive Cycle
Key ON
Possible Causes
• FDP signal circuit short to PWR
• SIG GND circuit Open
• Failed FDP sensor

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 194).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 94 FMI 3.

Step 2 Check for active or pending fault codes. Decision

Use EST with Navistar® Engine Diagnostics. Key ON Engine OFF (KOEO), check Yes: Go to Step 3.
DTC list for SPN 94 FMI 3.
Is SPN 94 FMI 3 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 195

Step 3 Inspect connections at Fuel Delivery Pressure (FDP) sensor. Decision

A. Key OFF. Yes: Go to Step 4.
B. Disconnect FDP sensor connector.
C. Check FDP sensor and connector terminals for damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are FDP sensor connector, harness, and terminal clean and undamaged? No: Repair connector, harness, or
terminal damage. After repairs are
complete, retest for SPN 94 FMI 3.

Step 4 Decision
A. Key OFF. Yes: Repair short to PWR between
FDP pin-3 and ECM pin E-32.
B. Disconnect Fuel Delivery Pressure (FDP) sensor vehicle harness
After repairs are complete, retest
connector.
for SPN 94 FMI 3.
C. Connect EST to vehicle Diagnostic Connector (page 1345).
D. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
E. Use EST with Navistar® Engine Diagnostics, clear DTC list.
Does SPN 94 FMI 3 set after DTC list is cleared? No: Go to Step 5.

Step Decision
A. Perform Test 1 (page 196). Yes: Replace FDP sensor. After
repairs are complete, retest for
B. Use DMM, measure voltage between Breakout Harness ZTSE4850 pin-1
SPN 94 FMI 3.
and PWR
Is voltage 12 ± 0.5 volts? No: Repair Open between FDP
pin-1 and ECM pin E-28. After
repairs are complete, retest for
SPN 94 FMI 3.

End Diagnostic Tests

After performing diagnostic steps, if SPN 94 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
196 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 94 FMI 3)

Figure 42 FDP Sensor Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4850
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Figure 43 SIG GND Circuit Check

Test 2
A. Key OFF.

B. Disconnect Fuel Delivery Pressure (FDP) sensor vehicle harness connector.

C. Connect Breakout Harness ZTSE4850 to vehicle harness connector and leave FDP sensor disconnected.

D. Key ON Engine OFF (KOEO).

 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 197

SPN 94 FMI 4 - FDP signal Out of Range LOW

Fault Overview
Fault sets when Fuel Delivery Pressure (FDP) sensor signal voltage is less than 0.093 volts for five seconds.

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

Associated Faults
SPN 3509 FMI 3 and 4
(VREF 1)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• FDP circuit Open
• FDP circuit short to GND
• VREF 1 circuit Open
• Failed FDP sensor
198 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 197).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 94 FMI 4.

Step 2 Check for active fault codes. Decision

Use EST with Navistar® Engine Diagnostics, Key On Engine Off (KOEO), check Yes: Go to Step 3.
DTC list for SPN 94 FMI 4.
Does EST DTC list show SPN 94 FMI 4 as Active or Pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 3 Inspect connections at Fuel Delivery Pressure (FDP) sensor. Decision

A. Key OFF. Yes: Go to Step 4.
B. Disconnect FDP sensor connector.
C. Check FDP sensor and connector terminals for damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are FDP sensor connector, harness, and terminal clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 94
FMI 4.

Step 4 Check for Open. Decision

A. Perform Test 1 (page 200). Yes: Go to Step 5.
B. Use DMM, measure voltage between Breakout Harness ZTSE4850 pin-2
and known good GND.
Is voltage 5 ± 0.5 volts? No: Repair Open between FDP
pin-2 and ECM pin E-35. After
repairs are complete, retest for
SPN 94 FMI 4

Step 5 Determine if FDP sensor has failed. Decision

A. Perform Test 2 (page 200). Yes: Replace FDP sensor. After
®
repairs are complete, retest for
B. Use EST with Navistar Engine Diagnostics, clear DTC list.
SPN 94 FMI 4.
Does SPN 94 FMI 3 set after DTC list is cleared? No: Go to Step 6.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 199

Step 6 Determine if signal circuit is shorted to ground. Decision

A. Perform Test 3 (page 201). Yes: Repair short to GND between
FDP pin-3 and ECM pin E-32.
B. Use EST with Navistar® Engine Diagnostics, clear DTC list.
After repairs are complete, retest
for SPN 94 FMI 4.
Does SPN 3509 FMI 4 set in DTC list? No: Repair Open between FDP
pin-3 and ECM pin E-32. After
repairs are complete, retest for
SPN 94 FMI 4.

End Diagnostic Tests

After performing diagnostic steps, if SPN 94 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
200 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 94 FMI 4)

Figure 44 FDP Sensor Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4850
• Breakout Harness ZTSE4498
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Figure 45 VREF 1 Circuit Check

Test 1
A. Key OFF.

B. Disconnect Fuel Delivery Pressure (FDP) sensor.

C. Connect Breakout Harness ZTSE4850 to vehicle harness connector and leave FDP sensor disconnected.

D. Key ON Engine OFF (KOEO).

 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 201

Figure 46 FDP Sensor Circuit Check

Test 2
A. Key OFF.
B. Disconnect Fuel Delivery Pressure (FDP) sensor.
C. Connect Breakout Harness ZTSE4850 to vehicle harness connector and leave FDP sensor disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4850 pin-2 and pin-3 together.
E. Connect EST to vehicle Diagnostic Connector. (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
202 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 47 FDP Sensor Circuit Check

Test 3
A. Key OFF.
B. Disconnect Fuel Delivery Pressure (FDP) sensor.
C. Connect Breakout Harness ZTSE4850 to vehicle harness connector and leave FDP sensor disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4850 pin-2 and pin-3 together.
E. Connect EST to vehicle Diagnostic Connector. (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 203

SPN 94 FMI 17 - Fuel Delivery Pressure below minimum

Fault Overview
Fault code sets when Fuel Delivery Pressure (FDP) is below 60 psi (414 kPa) for 45 seconds.

Lamp Reaction
Wrench lamp will illuminate when this fault is active.

Associated Faults
• SPN 94 FMI 1 (EFP) • SPN 94 FMI 18 (FDP) • SPN 931 FMI 4 (EFP)

Fault Facts
Fault is normally caused by fuel filter needing to be changed.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Recent fuel system service requiring priming
• Vehicle unused for long period of time requiring priming
• Low fuel level
• Diesel fuel contamination
• Failed secondary (engine mounted) fuel filter
• Failed primary (chassis mounted) fuel filter
• Restricted strainer
• Restricted/leaking fuel supply
• Failed fuel pressure regulator
204 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for associated fault codes. Decision

®
Use EST with Navistar Engine Diagnostics, check DTC list for Associated Faults Yes: Go to Step 2.
(page 203).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 94 FMI 17.

Step 2 Check Fault Code Status Decision

Use EST with Navistar® Engine Diagnostics, check DTC list for SPN 94 FMI 17 Yes: Go to Fuel Delivery Pressure
(FDP). symptom (page 119).
Is SPN 94 FMI 17 pending or active? No: Repair Active faults. After
repairs are complete, retest SPN
94 FMI 17.

End Diagnostic Steps

After performing all diagnostic steps, if SPN 94 FMI 17 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 205

SPN 94 FMI 18 - Fuel Delivery Pressure below min during cranking

Fault Overview
Fault code sets when Fuel Delivery Pressure (FDP) is below 45 psi for 8 seconds while engine is cranking.

Lamp Reaction
No Lamp

Associated Faults
SPN 931 FMI 4 (EFP)

Fault Facts
This fault may set due to fuel gelling, low fuel level, or recent engine service.

Drive Cycles
Engine Cranking
Possible Causes
• Recent fuel system service that required priming
• Diesel fuel waxing or icing in cold temperatures
• Low fuel level in either fuel tank
• Vehicle unused for long period of time
• Unseated fuel filter that causes fuel to drain back to tank
• High resistance in fuel pump circuits
• High resistance in FP GND circuit
• Stuck Open fuel pressure regulator
• Damaged fuel filter
• Completely plugged strainer
• Failed fuel pump
206 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 205).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 94 FMI 17.

Step 2 Check Fault Code Status Decision

Use EST with Navistar® Engine Diagnostics, Key On Engine Off (KOEO), check Yes: Go to 8.1 Fuel Delivery
DTC list for SPN 94 FMI 18 (FDP). Pressure (Step 2) (page 119).
Is SPN 94 FMI 18 pending or active? No: End Diagnostics. Retest for
SPN 94 FMI 18.

End Diagnostic Steps

After performing all diagnostic steps, if SPN 94 FMI 18 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 207

SPN 100 FMI 1 - Engine Oil System below Critical Pressure

Fault Overview
Fault sets when Engine Control Module (ECM) senses Engine Oil Pressure (EOP) is below Critical Pressure.

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

Associated Faults
SPN 100 FMI 3 and 4
(EOP)

Fault Facts
This fault sets when Engine Warning Protection System (EWPS) detects Engine Oil Pressure (EOP) has fallen
below a critical set point. This fault may be caused by actual low oil pressure or by a fault in EOP sensor circuit.
Insure engine oil level and quality are appropriate.

Drive Cycle to Determine Fault Status

Continuous (Engine Running)
Possible Causes
• Low oil level: oil leak, oil consumption, or incorrect servicing
• High oil level: incorrect servicing, fuel in oil, or coolant in oil
• Incorrect or biased EOP sensor or circuit
• Oil pressure regulator stuck open
• Broken, missing, or loose piston cooling jets
• Missing, damaged, or worn bearing inserts or camshaft bushings
• Scored/damaged oil pump
• Aeration
• Loose rocker arm bolt or worn rocker shaft

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics, check Yes: Do Diagnostic
Diagnostic Trouble Code (DTC) list for Associated Faults(page 207). Troubleshooting Procedures:
7.6 - Low Oil Pressure(page 109).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 100 FMI 1.

End Diagnostic Tests

After performing all tests, if no problem is found, verify each step was completed correctly and proper decision was
made. Return to SPN 100 FMI 1 fault code diagnostics.
208 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 100 FMI 3 - EOP signal Out of Range HIGH

Fault Overview
None

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected during one drive cycle.

Associated Faults
SPN 3509 FMI 3 and 4
(VREF 1)

Fault Facts
None

Drive Cycle to Determine Fault Status

Key ON
Possible Causes
• EOP circuit short to PWR
• SIG GND circuit Open
• Failed EOP sensor
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 209

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 208).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 100 FMI 3.

Step 2 Check for active or pending fault codes. Decision

Use EST with Navistar® Engine Diagnostics. Key-On Engine-Off (KOEO), check Yes: Go to Step 3.
DTC list for SPN 100 FMI 3.
Is SPN 100 FMI 3 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 3 Inspect connections at Engine Oil Pressure (EOP) sensor. Decision

A. Key OFF. Yes: Go to Step 4.
B. Disconnect EOP sensor connector.
C. Check EOP sensor and connector terminals for damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are EOP sensor connector, harness, and terminal clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 100
FMI 3.

Step 4 Inspect connections at Engine Oil Pressure (EOP) sensor. Decision

A. Key OFF. Yes: Repair short to PWR
between EOP sensor pin-3 and
B. Connect EST to vehicle Diagnostic Connector. (page 1345).
ECM pin E-13. After repairs are
C. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics. complete, retest for SPN 100 FMI
3.
D. Use EST with Navistar® Engine Diagnostics, clear DTC list.
Does SPN 100 FMI 3 set after DTC list is cleared? No: Go to Step 5.

Step Decision
A. Perform Test 1 (page 211). Yes: Replace EOP sensor. After
repairs are complete, retest for
B. Use DMM, measure voltage between Breakout Harness ZTSE4850 pin-1
SPN 100 FMI 3.
and PWR.
Is voltage B+ ± 0.5 volts. No: Repair Open between EOP
sensor pin-1 and ECM pin E-28.
After repairs are complete, retest
for SPN 100 FMI 3
210 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

End Diagnostic Tests

After performing diagnostic steps, if SPN 100 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 211

Pin-Point Tests (SPN 100 FMI 3)

Figure 48 EOP Sensor Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4850
• Digital Multimeter (DMM)

Figure 49 EOP Circuit Check

Test 1
A. Key OFF.
B. Disconnect Engine Oil Pressure (EOP) sensor.
C. Connect Breakout Harness ZTSE4850 to vehicle harness connector and leave EOP sensor disconnected.

D. Key ON Engine OFF (KOEO).

212 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 100 FMI 4 - EOP Signal Out of Range LOW

Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Oil Pressure (EOP) signal is out of range
low.

Lamp Reaction
No Lamp

Associated Faults
SPN 3509 FMI 3 and 4
(VREF 1)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• EOP circuit Open
• EOP circuit short to GND
• VREF 1 circuit Open
• Failed EOP sensor

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 212).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 100 FMI 4.

Step 2 Check for active or pending fault codes. Decision

®
Use EST with Navistar Engine Diagnostics, Key On Engine Off (KOEO), check Yes: Go to Step 3.
DTC list for SPN 100 FMI 4.
Is EST DTC list SPN 100 FMI 4 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 213

Step 3 Inspect connections at Engine Oil Pressure (EOP) sensor. Decision

A. Key OFF. Yes: Go to Step 4.
B. Disconnect EOP sensor connector.
C. Check EOP sensor and connector terminals for damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are EOP sensor connector, harness, and terminal clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 100
FMI 4.

Step 4 Check EOP circuits for Open. Decision

A. Perform Test 1 (page 214). Yes: Go to Step 5.
B. Use DMM, measure voltage between Breakout Harness ZTSE4850 pin-2
and known good GND.
Is voltage 5 ± 0.5 volt? No: Repair Open between EOP
pin-2 and ECM pin E-35. After
repairs are complete, retest for
SPN 100 FMI 4.

Step 5 Check EOP circuits. Decision

A. Perform Test 2 (page 214). Yes: Replace EOP sensor. After
®
repairs are complete, retest for
B. Use EST with Navistar Engine Diagnostics, clear DTC list.
SPN 100 FMI 4.
Does SPN 100 FMI 3 set after DTC list is cleared? No: Go to Step 6

Step 6 Check EOP circuits. Decision

A. Perform Test 3 (page 215). Yes: Repair short to GND between
EOP pin-3 and ECM pin E-13.
B. Use EST with Navistar® Engine Diagnostics, clear DTC list.
After repairs are complete, retest
for SPN 100 FMI 4.
Does SPN 3509 FMI 4 set after DTC list is cleared? No: Repair Open between EOP
pin-3 and ECM pin E-13. After
repairs are complete, retest for
SPN 100 FMI 4.

End Diagnostic Tests

After performing diagnostic steps, if SPN 100 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
214 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 100 FMI 4)

Figure 50 EOP Sensor Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4850
• 3-Banana Plug Harness ZTSE4498
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Figure 51 VREF 1 Circuit Check

Test 1
A. Key OFF.

B. Disconnect Engine Oil Pressure (EOP) sensor.

C. Connect Breakout Harness ZTSE4850 to vehicle harness and leave EOP sensor disconnected.

D. Key ON Engine OFF (KOEO).

 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 215

Figure 52 EOP Circuit Check

Test 2
A. Key OFF.
B. Disconnect Engine Oil Pressure (EOP) sensor.
C. Connect Breakout Harness ZTSE4850 to vehicle harness and leave EOP sensor disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4850 pin-2 and pin-3 together.
E. Connect EST to vehicle Diagnostic Connector. (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
216 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 53 EOP Circuit Check

Test 3
A. Key OFF.
B. Disconnect Engine Oil Pressure (EOP) sensor.
C. Connect Breakout Harness ZTSE4850 to vehicle harness and leave EOP sensor disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4850 pin-2 and pin-3 together.
E. Connect EST to vehicle Diagnostic Connector. (page 1345).
F. Key-On Engine-Off (KOEO). Log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 217

SPN 100 FMI 18 - Engine Oil System below Warning Pressure

Fault Overview
Fault sets when Engine Control Module (ECM) senses Engine Oil Pressure (EOP) is below Warning Pressure.

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

Associated Faults
• SPN 100 FMI 1 (EWPS) • SPN 100 FMI 3 and 4
(EOP)

Fault Facts
RPM values can be found in PP 77031, 77041, and 77051.
Insure engine oil level and quality are appropriate.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Low oil level
• High oil level
• Failed EOP sensor
• Oil pressure regulator stuck open
• Broken, missing, or loose piston cooling tubes
• Missing, damaged, or worn bearing inserts/camshaft bushings
• Failed oil pump
• Oil aeration
• Loose rocker arm bolt or worn rocker shaft

Step 1 Troubleshoot Low Oil Pressure issues. Decision

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics, check Yes: Check engine oil level
Diagnostic Trouble Code (DTC) list for Associated Faults (page 217). and go to Engine Oil System
Operational Checkout Procedure
(Step 3) (page 36). After repairs
are complete, retest for SPN 100
FMI 18.
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 100 FMI 18.
218 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

End Diagnostic Tests

After performing diagnostic steps, if SPN 100 FMI 18 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 219

SPN 102 FMI 2 - IMP signal erratic, intermittent, or incorrect

Fault Overview
Fault code sets when the Key-On Engine-Off (KOEO) absolute pressure difference between Intake Manifold
Pressure (IMP) and Barometric Absolute Pressure (BARO), IMP and Exhaust Back Pressure (EBP), and EBP
and BARO is greater than 4.4 psi (30 kPa) for two seconds with the Wastegate Actuator Position Command less
than 100%.

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

Associated Faults
• SPN 102 FMI 3 and 4 (IMP) • SPN 108 FMI 3 and 4 • SPN 1209 FMI 3 and 4 • SPN 3509 FMI 3 and 4
(BARO) (EBP) (VREF 1)

Fault Facts
Intake Manifold Pressure (IMP) sensor cannot be compared to other similar sensors in Navistar® Engine
Diagnostics, because IMP values cannot be negative, and IMP value is in gauge units.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed IMP sensor

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 219).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 102 FMI 2.

Step 2 Check for active or pending fault code. Decision

Use EST with Navistar® Engine Diagnostics. Key On Engine Off (KOEO), check Yes: Replace IMP sensor. After
DTC list for SPN 102 FMI 2. repairs are complete, retest for
SPN 102 FMI 2.
Is EST DTC list SPN 102 FMI 2 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

End Diagnostic Tests

After performing all diagnostic steps, if SPN 102 FMI 2 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
220 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 102 FMI 3 - IMP signal Out of Range HIGH

Fault Overview
Fault code sets when Intake Manifold Pressure (IMP) is greater than 4.8 volts (89 psi {613.3 kPa}) for 2.55
seconds.

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

Associated Faults
SPN 3509 FMI 3 and 4
(VREF 1)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• IMP sensor signal circuit short to power
• Signal GND circuit Open or high resistance.
• Failed IMP sensor
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 221

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 220).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 102 FMI 3.

Step 2 Inspect connections at Intake Manifold Pressure (IMP) sensor. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect IMP sensor connector.
C. Check IMP sensor and connector terminals for damaged or pinched
wires; moist or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are IMP sensor connector, harness, and terminal clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 102
FMI 3.

Step 3 Check IMP sensor signal circuit for short to PWR. Decision
A. Key OFF. Yes: Repair short to PWR
between IMP pin-3 and ECM pin
B. Disconnect Intake Manifold Pressure (IMP) vehicle harness connector.
E-48. After repairs are complete,
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector retest for SPN 102 FMI 3.
(page 1345).
D. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
E. Use EST with Navistar® Engine Diagnostics, clear DTC list.
Does SPN 102 FMI 3 set after DTC list is cleared? No: Go to Step 4.

Step 4 Check SIG GND circuit Open or high resistance. Decision

A. Perform Test 1 (page 222). Yes: Replace IMP sensor. After
repairs are complete, retest for
B. Use DMM, measure voltage between Breakout Harness ZTSE4850 pin-1
SPN 102 FMI 3.
and B+.
Is voltage within B+ ± 0.5 volts? No: Repair Open or high
resistance between IMP sensor
pin-1 and ECM pin E-28. After
repairs are complete, retest for
SPN 102 FMI 3.

End Diagnostic Tests

After performing diagnostic steps, if SPN 102 FMI 3 remains, verify step was completed correctly and proper decision
was made. Notify supervisor for further action.
222 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 102 FMI 3)

Figure 54 IMP Sensor Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4850
• Breakout Harness ZTSE4498
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Test 1
A. Key OFF.

B. Disconnect Intake Manifold Pressure (IMP) vehicle harness connector.

C. Connect Breakout Harness ZTSE4850 to IMP vehicle harness connector, leave IMP sensor disconnected.
D. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 223

SPN 102 FMI 4 - IMP signal Out of Range LOW

Fault Overview
Fault sets when Intake Manifold Pressure (IMP) voltage is less than 0.1899 volts (4 psi {31 kPa}) for 2.55
seconds.

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

Associated Faults
SPN 3509 FMI 3 and 4
(VREF 1)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Intake Manifold Pressure (IMP) signal circuit Open or high resistance
• IMP signal circuit short to GND
• VREF 1 circuit Open
• Failed IMP sensor

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 223).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 102 FMI 4.

Step 2 Inspect connections at Intake Manifold Pressure (IMP) sensor. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect IMP sensor connector.

C. Check IMP sensor and connector terminals for damaged or pinched

wires; moist or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are IMP sensor connector, harness, and terminal clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 102
FMI 4.
224 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Check IMP signal circuit for Open or high resistance. Decision
A. Perform Test 1 (page 225). Yes: Go to Step 4
B. Use DMM, measure voltage between Breakout Harness ZTSE4850 pin-2
and known good GND.
Is voltage 5.0 ± 1.0 volts? No: Repair Open or high
resistance between IMP pin-2 and
ECM pin E-35. After repairs are
complete, retest for SPN 102 FMI
4.

Step 4 Check for failed IMP sensor. Decision

A. Perform Test 2 (page 225). Yes: Replace IMP sensor. After
repairs are complete, retest for
B. Use EST with Navistar® Engine Diagnostics, clear DTC list.
SPN 102 FMI 4.
Does SPN 102 FMI 3 set after DTC list is cleared? No: Go to Step 5.

Step 5 Check IMP circuit for electrical faults. Decision

A. Perform Test 3 (page 226). Yes: Repair Short to GND
®
between IMP pin-3 and ECM pin
B. Use EST with Navistar Engine Diagnostics, clear DTC list.
E-48. After repairs are complete,
retest for SPN 102 FMI 4.
Does SPN 3509 FMI 4 set after DTC list is cleared? No: Repair Open or high
resistance between IMP pin-3 and
ECM pin E-48. After repairs are
complete, retest for SPN 102 FMI
4.

End Diagnostic Tests

After performing diagnostic steps, if SPN 102 FMI 4 remains, verify step was completed correctly and proper decision
was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 225

Pin-Point Tests (SPN 102 FMI 4)

Figure 56 IMP Sensor Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4850
• Breakout Harness ZTSE4498
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Figure 57 IMP Sensor Circuit Check

Test 1
A. Key OFF.
B. Disconnect Intake Manifold Pressure (IMP) sensor.
C. Connect Breakout Harness ZTSE4850 to IMP vehicle harness connector, leave IMP sensor disconnected.

D. Key-On Engine-Off (KOEO).

226 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 58 IMP Sensor Circuit Check

Test 2
A. Key OFF.
B. Disconnect Intake Manifold Pressure (IMP) sensor.
C. Connect Breakout Harness ZTSE4850 to IMP vehicle harness connector, leave IMP sensor disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4850 pin-2 and pin-3 together.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
F. Key-On Engine-Off (KOEO). Log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 227

Figure 59 IMP Sensor Circuit Check

Test 3
A. Key OFF.
B. Disconnect Intake Manifold Pressure (IMP) sensor.
C. Connect Breakout Harness ZTSE4850 to IMP vehicle harness connector, leave IMP sensor disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4850 pin-2 and pin-3 together.
E. Connect EST to vehicle Diagnostic Connector (page 1345).
F. Key-On Engine-Off (KOEO). Log in to Navistar® Engine Diagnostics.
228 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 102 FMI 7 - IMP signal not responding as expected

Fault Overview
Fault sets when the Engine Control Module (ECM) detects Intake Manifold Pressure (IMP) is stuck in range.

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

Associated Faults
• SPN 102 FMI 3 and 4 • SPN 108 FMI 3 and 4
(IMP) (BARO)

Fault Facts
None

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• Induction system damage
• Restricted IMP sensor port
• Defective IMP sensor
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 229

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 228).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 102 FMI 7.

Step 2 Check for active or pending fault code. Decision

Use EST with Navistar® Engine Diagnostics. Key ON Engine OFF (KOEO), check Yes: Go to Step 3.
DTC list for SPN 102 FMI 7.
Is EST DTC list SPN 102 FMI 7 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 102 FMI 7.

Step 3 Inspect induction system for damage. Decision

Inspect induction system for damage; disconnected CAC hoses or pipes, check for Yes: Repair induction system
broken turbochargers. damage. After repairs are
complete, retest for SPN 102 FMI
7.
Was damage found? No: Go to Step 4.

Step 4 Inspect IMP sensor port on intake manifold. Decision

Inspect IMP sensor port on intake manifold for plugging. Yes: Repair plugged IMP sensor
port. After repairs are complete,
retest for SPN 102 FMI 7.
Is IMP sensor port on intake manifold plugged? No: Replace IMP sensor. After
repairs are complete, retest for
SPN 102 FMI 7.

End Diagnostic Tests

After performing all diagnostic steps, if SPN 102 FMI 7 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
230 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 102 FMI 10 - Boost slow response fault

Fault Overview
Fault sets when Engine Control Module (ECM) determines Intake Manifold Pressure (IMP) does not maintain
pressure.

Malfunction Indicator Lamp (MIL) Reaction

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

Associated Faults
• SPN 94 (FDP) • SPN 1209 (EBP) • SPN 164 (ICP)

Fault Facts
Perform MAF Sensor Calibration after doing repairs that change engine air intake, exhaust, or Exhaust Gas
Recirculation (EGR) flow characteristics.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Engine Control Module (ECM) calibration out of date
• Restricted exhaust
• Intake or exhaust system leak or damage
• Damaged, failed, or clogged Intake Manifold Pressure (IMP) or Intake Manifold Temperature (IMT) sensor
• Coked or damaged turbochargers
• Wastegate failure
• Cylinder mechanical problem
• Exhaust Back Pressure valve (EBPV) failure
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 231

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 230).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 102 FMI 10.

Step 2 Check for active or pending fault codes. Decision

Use EST with Navistar® Engine Diagnostics. Key On Engine Off (KOEO), check Yes: Go to Step 3
DTC list for SPN 102 FMI 10.
Is SPN 102 FMI 10 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 102 FMI 10.

Step 3 Determine if Engine Control Module (ECM) calibration is current. Decision

Verify ECM calibration is up to date. Yes: Go to Step 4.
Is ECM calibration up to date? No: Program ECM with latest
calibration. After repair are
complete, retest for SPN 102 FMI
10.

Step 4 Check intake and exhaust systems for leaks and / or damage. Decisions
• Perform Intake Air Inspection (page 1648), Yes: Go to Step 5.
• Charge Air Cooler Inspection (page 1646),
• and Exhaust and Aftertreatment System Inspection (page 1651).
Are all inspections checked in good condition and clear of leaks and damage? No: Repair leaks or damage to
intake and exhaust. After repairs
are complete, Perform MAF
Sensor Calibration (page 1539)
and retest for SPN 102 FMI 10.

Step 5 Test for engine air intake (boost) leaks. Decision

Perform Smoke Test (Air Intake System) (page 1598). Yes: Go to Step 6.
Are air intake system clamps, hoses, components, and piping free of major leaks? No: Repair air intake system
leaks. After repairs are complete,
perform MAF Sensor Calibration
(page 1539) and retest for SPN
102 FMI 10.
232 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 6 Determine if leaks are present in Charge Air Cooler (CAC) system. Decision
Perform High-Pressure Charge Air Cooler (HPCAC) Pressure Test. (page 1545) Yes: Go to Step 7.
Does CAC system pass test? No: Repair CAC leaks. After
repairs are complete, Perform
MAF Sensor Calibration (page
1539) and retest for SPN 102 FMI
10.

Step 7 Inspect Intake Manifold Pressure (IMP), Intake Manifold Temperature Decision
(IMT) and Exhaust Back Pressure (EBP) sensors and bores.
A. Remove IMP, IMT, and EBP sensors. See Engine Service Manual. Yes: Clean sensors and sensor
bores. Replace damaged
B. Inspect IMP, IMT, and EBP sensors and bores for carbon build up, coking,
sensors. After repairs are
restrictions, and damage.
complete, Perform MAF Sensor
Calibration (page 1539) and retest
for SPN 102 FMI 10.
Do sensors or sensor bores have carbon build up, coking, restrictions, or damage? No: Go to Step 8.

Step 8 Determine if Exhaust Gas Recirculation Valve (EGRV) is operating Decision

properly.
Perform Exhaust Gas Recirculation Valve (EGRV) Operational Test (page 1543). Yes: Replace EGRV. After repairs
are complete, Perform MAF
Sensor Calibration (page 1539)
and retest for SPN 102 FMI 10.
Did SPN 27 or SPN 2791 fault code set during test? No: Go to Step 9.

Step 9 Determine if air management system is operating properly. Decision

Perform Air Management Test (page 1376). Yes: Go to Step 11.
Are MAF Mean Value Difference within specification? No: Go to Step 10.

Step 10 Determine if air and EGR mixer duct is restricted. Decision

A. Remove Engine Throttle Value (ETV) assembly. See Engine Service Yes: Remove and clean air and
Manual. EGR mixer duct. Do not replace
EGR Valve. Replace O-rings
B. Inspect air and EGR mixer duct assembly for restrictions and carbon
if needed. After repairs are
build up.
complete, Perform MAF Sensor
Calibration (page 1539) and retest
for SPN 102 FMI 10.
Is a severe amount of carbon restricting air and EGR mixer duct? No: Install new EGR cooler. After
repairs are complete, Perform
MAF Sensor Calibration (page
1539) and retest for SPN 102 FMI
10.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 233

Step 11 Determine if KOEO IMP is within specification. Decision

®
A. Key-On Engine-Off (KOEO), log in to Navistar Engine Diagnostics. Yes: Go to Step 12.
B. Use EST with Navistar® Engine Diagnostics, select: Pressure tab.
C. Compare Navistar® Engine Diagnostics Intake Manifold Pressure value to
KOEO specification.
Is IMP within KOEO specification? No: Replace IMP sensor. After
repairs are complete, Perform
MAF Sensor Calibration (page
1539) and retest for SPN 102 FMI
10.

Step 12 Check Boost Control System. Decision

Perform Boost Control System Test (page 1533). Yes: Repair as directed by
test. After repairs are complete,
Perform MAF Sensor Calibration
(page 1539) and retest for SPN
102 FMI 10.
Did the test identify any failed components? No: Go to Step 13.

Step 13 Determine if Exhaust Back Pressure Valve (EBPV) is operating Decision

properly.
Perform Exhaust Back Pressure Valve (EBPV) Test (page 1531). Yes: Go to Step 14.
Did EBPV cycle three times when engine was shut down? No: Replace EBPV if valve is
seized in exhaust or Air Control
Valve (ACV) if air cannot be
heard. After repairs are complete,
Perform MAF Sensor Calibration
(page 1539) and retest for SPN
102 FMI 10.

Step 14 Determine if turbocharger has coking or soot build-up. Decision

A. Remove turbocharger intake tube. Yes: Go to Step 2 of 7.2 - Engine
Oil Leak to Intake (page 103)
B. Inspect turbocharger for soot build-up or coking.
to diagnose cause of oil in the
intake. After repairs are complete,
Perform MAF Sensor Calibration
(page 1539) and retest for SPN
102 FMI 10.
Does turbocharger have signs of oil, coking, or soot build-up? No: Go to Step 15.
234 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 15 Determine if exhaust aftertreatment system is restricted. Decision

A. Perform Record Snapshot of Engine Running Data (page 1464). If Engine Yes: Go to Step 17.
does not start, Perform Engine Cranking Test (page 1374).
B. After Test is complete, use Snapshot Viewer to open and review recorded
snapshot data.
Is TC1 Turbine Outlet Pressure less than 5.0 psi (69 kPa) and DPF Differential No: Go to Step 16.
Pressure less than 1.0 psi (3.4 kPa)?

Step 16 Determine if DPF, DOC, and PDOC are reusable. Decision

A. Remove DPF, DOC, and PDOC. Yes: Clean components as
necessary and reinstall on
B. Compare DPF, DOC, and PDOC to Reuse Guidelines. (See Aftertreatment
vehicle. If DPF was cleaned,
Symptom-Based Diagnostic and Service Manual 0000003081.)
use Navistar EST to reset DPF
Soot Load. Perform MAF Sensor
Calibration, and retest for SPN
102 FMI 10.
Are DPF, DOC, and PDOC reusable? No: Repair source of
contamination (fuel, oil, or
coolant leak to exhaust). Replace
damaged DPF, DOC, and / or
PDOC. If DPF was replaced,
use Navistar EST to reset DPF
Soot Load. Perform MAF Sensor
Calibration, and retest for SPN
102 FMI 10.

Step 17 Identify cylinders that may have valve train issues or other mechanical Decision
problems.
Perform Relative Compression Test Plus (RCT+) (page 1465). Yes: Repair as directed by
test results. After repairs are
complete, Perform MAF Sensor
Calibration (page 1539) and retest
for SPN 102 FMI 10.
Does CPA Tool indicate a problem or generate a warranty authorization code No: End diagnostics. Perform
(WAC)? MAF Sensor Calibration (page
1539) and retest for SPN 102 FMI
10.

End Diagnostic Test

After performing diagnostic steps, if SPN 102 FMI 10 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 235

SPN 102 FMI 16 - Over boost

Fault Overview
Fault sets when Engine Control Module (ECM) determines Intake Manifold Pressure (IMP) is too high.

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

Associated Faults
• SPN 94 • SPN 1209 • SPN 164 • 1322 - 1328 FMI 31
• SPN 651-656 • SPN 2797-2728 • SPN 3659 – 3664 • SPN 4257

Fault Facts
Perform MAF Sensor Calibration after doing repairs that change engine air intake, exhaust, or Exhaust Gas
Recirculation (EGR) flow characteristics.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Engine Control Module (ECM) calibration out of date
• Intake or exhaust system leak or damage
• Damaged turbochargers
• Wastegate failure

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 235).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 102 FMI 16.

Step 2 Check for active or pending fault codes. Decision

®
Use EST with Navistar Engine Diagnostics. Key On Engine Off (KOEO), check Yes: Go to Step 3
DTC list for SPN 102 FMI 16.
Is SPN 102 FMI 16 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 102 FMI 16.
236 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Determine if Engine Control Module (ECM) calibration is current. Decision

Verify ECM calibration is up to date. Yes: Go to Step 4.
Is ECM calibration up to date? No: Program ECM with latest
calibration. After repair are
complete, retest for SPN 102 FMI
16.

Step 4 Check intake and exhaust systems for leaks and / or damage. Decisions
• Perform Intake Air Inspection (page 1648), Yes: Go to Step 5.
• Charge Air Cooler Inspection (page 1646),
• and Exhaust and Aftertreatment System Inspection (page 1651).
Are all items checked in good condition and clear of leaks and damage? No: Repair leaks or damage
to intake and exhaust. After
repair are complete, perform MAF
Sensor Calibration (page 1539)
and retest for SPN 102 FMI 16.

Step 5 Determine if Wastegate is operating properly. Decision

Perform Boost Control System Test (page 1533). Yes: Repair failed component.
After repair are complete, perform
MAF Sensor Calibration (page
1539) and retest for SPN 102 FMI
16.
Was a failed component identified during the test? No: Go to Step 6.

Step 6 Inspect Intake Manifold Pressure (IMP), Intake Manifold Temperature Decision
(IMT) and Exhaust Back Pressure (EBP) sensors and bores.
A. Remove IMP, IMT, and EBP sensors. See Engine Service Manual. Yes: Clean sensors and sensor
bores. Replace damaged
B. Inspect IMP, IMT, and EBP sensors and bores for carbon build up, coking,
sensors. After repair are
restrictions, and damage.
complete, perform MAF Sensor
Calibration (page 1539) and retest
for SPN 102 FMI 16.
Do sensors or sensor bores have carbon build up, coking, restrictions, or damage? No: Go to Step 7.

Step 7 Determine if Exhaust Gas Recirculation Valve (EGRV) is operating Decision

properly.
Perform Exhaust Gas Recirculation Valve (EGRV) Operational Test (page 1543). Yes: Replace EGRV. After repair
are complete, perform MAF
Sensor Calibration (page 1539)
and retest for SPN 102 FMI 16.
Did SPN 27 or SPN 2791 fault code set during test? No: Go to Step 8.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 237

Step 8 Determine if turbocharger has coking or soot build-up. Decision

A. Remove turbocharger intake tube. Yes: Go to Step 2 of 7.2 - Engine
Oil Leak to Intake (page 103)
B. Inspect turbocharger for soot build-up or coking.
to diagnose cause of oil in the
intake. After repairs are complete,
Perform MAF Sensor Calibration
(page 1539) and retest for SPN
102 FMI 16.
Does turbocharger have signs of oil, coking, or soot build-up? No: End diagnostics. Perform
MAF Sensor Calibration (page
1539) and retest for SPN 102 FMI
16.

End Diagnostic Test

After performing diagnostic steps, if SPN 102 FMI 16 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
238 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 102 FMI 18 - Under boost

Fault Overview
Fault sets when Engine Control Module (ECM) determines engine intake manifold pressure is too Low.

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

Associated Faults
• SPN 94 (FDP) • SPN 1209 (EBP) • SPN 164 (ICP)

Fault Facts
Perform MAF Sensor Calibration after doing repairs that change engine air intake, exhaust, or Exhaust Gas
Recirculation (EGR) flow characteristics.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Engine Control Module (ECM) calibration out of date
• Intake or exhaust system leak or damage
• Damaged, failed, or clogged Intake Manifold Pressure (IMP) or Intake Manifold Temperature (IMT) sensor
• Coked or damaged turbochargers
• Wastegate failure
• Cylinder mechanical problem
• Exhaust Back Pressure valve (EBPV) failure

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 238).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 102 FMI 18.

Step 2 Check for active or pending fault codes. Decision

Use EST with Navistar® Engine Diagnostics. Key On Engine Off (KOEO), check Yes: Go to Step 3.
DTC list for SPN 102 FMI 18.
Is SPN 102 FMI 18 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 102 FMI 18.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 239

Step 3 Determine if Engine Control Module (ECM) calibration is current. Decision

Verify ECM calibration is up to date. Yes: Go to Step 4.
Is ECM calibration up to date? No: Program ECM with latest
calibration. After repair are
complete, retest for SPN 102 FMI
18.

Step 4 Check intake and exhaust systems for leaks and / or damage. Decisions
• Perform Intake Air Inspection (page 1648), Yes: Go to Step 5.
• Charge Air Cooler Inspection (page 1646),
• and Exhaust and Aftertreatment System Inspection (page 1651).
Are all items checked in good condition and clear of leaks and damage? No: Repair leaks or damage
to intake and exhaust. After
repairs are complete, perform
MAF Sensor Calibration (page
1539)and retest for SPN 102 FMI
18.

Step 5 Test for engine air intake (boost) leaks. Decision

Perform Smoke Test (Air Intake System) (page 1598). Yes: Go to Step 6.
Are air intake system clamps, hoses, components, and piping free of major leaks? No: Repair air intake system
leaks. After repairs are complete,
perform MAF Sensor Calibration
(page 1539) and retest for SPN
102 FMI 18.

Step 6 Determine if leaks are present in Charge Air Cooler (CAC) system. Decision
Perform High-Pressure Charge Air Cooler (HPCAC) Pressure Test. (page 1545) Yes: Go to Step 7.
Does CAC system pass test? No: Repair CAC leaks. After
repairs are complete, perform
MAF Sensor Calibration (page
1539)and retest for SPN 102 FMI
18.

Step 7 Inspect Intake Manifold Temperature (IMT) and Exhaust Back Pressure Decision
(EBP) sensors and bores.
A. Remove IMP and EBP sensors. See Engine Service Manual. Yes: Clean sensors and sensor
bores. Replace damaged
B. Inspect IMP and EBP sensors and bores for carbon build up, coking,
sensors. After repairs are
restrictions, and damage.
complete, perform MAF Sensor
Calibration (page 1539)and retest
for SPN 102 FMI 18.
Do sensors or sensor bores have carbon build up, coking, restrictions, or damage? No: Go to Step 8.
240 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 8 Determine if Exhaust Gas Recirculation Valve (EGRV) is operating Decision

properly.
Perform Exhaust Gas Recirculation Valve (EGRV) Operational Test (page 1543). Yes: Replace EGRV. After
repairs are complete, perform
MAF Sensor Calibration (page
1539)and retest for SPN 102 FMI
18.
Did SPN 27 or SPN 2791 fault code set during test? No: Go to Step 9.

Step 9 Determine if air management system is operating properly. Decision

Perform Air Management Test (page 1376). Yes: Go to Step 11.
Are MAF Mean Value Difference within specification? No: Go to Step 10.

Step 10 Determine if air and EGR mixer duct is restricted. Decision

A. Remove Engine Throttle Value (ETV) assembly. See Engine Service Yes: Remove and clean air and
Manual. EGR mixer duct. Do not replace
EGR Valve. Replace O-rings
B. Inspect air and EGR mixer duct assembly for restrictions and carbon
if needed. After repairs are
build up.
complete, perform MAF Sensor
Calibration (page 1539)and retest
for SPN 102 FMI 18.
Is a severe amount of carbon restricting air and EGR mixer duct? No: Install new EGR cooler. After
repairs are complete, perform
MAF Sensor Calibration (page
1539)and retest for SPN 102 FMI
18.

Step 11 Determine if KOEO IMP is within specification, and IMP sensor bore Decision
is not restricted.
A. Key-On Engine-Off (KOEO), log in to Navistar® Engine Diagnostics. Yes: Go to Step 12.
®
B. Use EST with Navistar Engine Diagnostics, select: Pressure tab.
C. Compare Navistar® Engine Diagnostics Intake Manifold Pressure value to
KOEO specification.
Is IMP within KOEO specification? No: Replace IMP sensor. After
repairs are complete, perform
MAF Sensor Calibration (page
1539)and retest for SPN 102 FMI
18.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 241

Step 12 Check Boost Control System. Decision

Perform Boost Control System Test (page 1533). Yes: Repair as directed by
test. After repairs are complete,
perform MAF Sensor Calibration
(page 1539)and retest for SPN
102 FMI 18.
Did the test identify any failed components? No: Go to Step 13.

Step 13 Determine if Exhaust Back Pressure Valve (EBPV) is operating Decision

properly.
Perform Exhaust Back Pressure Valve (EBPV) Test (page 1531). Yes: Go to Step 14.
Did EBPV cycle three times when engine was shut down? No: Replace EBPV if valve is
seized in exhaust or Air Control
Valve (ACV) if air cannot be
heard. After repairs are complete,
perform MAF Sensor Calibration
(page 1539)and retest for SPN
102 FMI 18.

Step 14 Determine if turbocharger has coking or soot build-up. Decision

A. Remove turbocharger intake tube. Yes: Go to Step 2 of 7.2 - Engine
Oil Leak to Intake (page 103)
B. Inspect turbocharger for soot build-up or coking.
to diagnose cause of oil in the
intake. After repairs are complete,
Perform MAF Sensor Calibration
(page 1539) and retest for SPN
102 FMI 18.
Does turbocharger have signs of oil, coking, or soot build-up? No: Go to Step 15.

Step 15 Identify cylinders that may have valve train issues or other mechanical Decision
problems.
Perform Relative Compression Test Plus (RCT+) (page 1465). Yes: Repair as directed by test
results. After repairs are complete,
Perform MAF Sensor Calibration
(page 1539) and retest for SPN
102 FMI 18.
Does CPA Tool indicate a problem or generate a warranty authorization code No: End diagnostics. Perform
(WAC)? MAF Sensor Calibration (page
1539) and retest for SPN 102 FMI
18.

End Diagnostic Test

After performing diagnostic steps, if SPN 102 FMI 18 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
242 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 105 FMI 2 - IMT Signal Erratic, Intermittent, or Incorrect

Fault Overview
Engine Control Module (ECM) Compares Intake Manifold Temperature (IMT) sensor to Intake Air Temperature
(IAT), Turbocharger 2 Compressor Intake Temperature (TC2CIT), Charge Air Cooler Outlet Temperature
(CACOT), Engine Coolant Temperature 1 (ECT1), and Engine Oil Temperature (EOT) sensors at initial Key
ON after an 8-hour cold soak.

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

Associated Faults
SPN 105 FMI 3 and 4 (IMT)

Fault Facts
None

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• High resistance in IMT circuit
• High resistance in SIG GND circuit
• Failed IMT sensor

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 242).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 105 FMI 2.

Step 2 Check for active or pending fault codes. Decision

Use EST with Navistar® Engine Diagnostics. Key On Engine Off (KOEO), check Yes: Go to Step 3.
DTC list for SPN 105 FMI 2.
Is EST DTC list SPN 105 FMI 2 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 243

Step 3 Inspect connections at Intake Manifold Temperature (IMT) connector. Decision

A. Key OFF. Yes: Go to Step 4.
B. Disconnect IMT connector.
C. Check IMT and connector terminals for: damaged or pinched wires; moist
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are IMT connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 105
FMI 2.

Step 4 Check for high resistance in IMT circuit. Decision

A. Perform Test 1 (page 244). Yes: Replace IMT sensor. After
®
repairs are complete, retest for
B. Use EST with Navistar Engine Diagnostics, monitor IMT.
SPN 105 FMI 2.
Is temperature 302 ± 10°F (150 ± 6°C)? No: Go to Step 5.

Step 5 Check for high resistance in SIG GND circuit Decision

A. Perform Test 2 (page 246). Yes: Repair SIG GND circuit
between IMT pin-1 and ECM pin
B. Use EST with Navistar® Engine Diagnostics, monitor IMT.
E-28. After repairs are complete,
retest for SPN 105 FMI 2.
Is temperature 302 ± 10°F (150 ± 6°C)? No: Repair SIG circuit between
IMT pin-2 and ECM pin E-15.
After repairs are complete, retest
for SPN 105 FMI 2.

End Diagnostic Tests

After performing diagnostic steps, if SPN 105 FMI 2 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
244 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 105 FMI 2)

Figure 60 IMT Sensor Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4993
• 500-ohm Resistor Harness ZTSE4497
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 245

Figure 61 IMT Signal Circuit Check

Test 1
A. Key OFF.
B. Disconnect Intake Manifold Temperature (IMT) sensor.
C. Connect Breakout Harness ZTSE4993 to vehicle harness connector and leave IMT sensor disconnected.
D. Connect Resistor Harness ZTSE4497 between Breakout Harness ZTSE4993 pin-1 and pin-2.
E. Connect EST to vehicle Diagnostic Connector. (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
246 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 62 IMT Signal Circuit Check

Test 2
A. Key OFF.
B. Disconnect Intake Manifold Temperature (IMT) sensor.
C. Connect Breakout Harness ZTSE4993 to vehicle harness connector and leave IMT sensor disconnected.
D. Connect Resistor Harness ZTSE4497 between Breakout Harness ZTSE4993 pin-2 and known good GND.
E. Connect EST to vehicle Diagnostic Connector. (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 247

SPN 105 FMI 3 - IMT signal Out of Range HIGH

Fault Overview
Fault Code sets when Engine Control Module (ECM) detects that Intake Manifold Temperature (IMT) signal is
greater than 4.80 volts.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• IMT circuit Open
• IMT circuit short to PWR
• SIG GND circuit Open
• Failed IMT sensor

Step 1 Check for active or pending fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for SPN 105 FMI 3.
Does EST DTC list show SPN 105 FMI 3 as active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 2 Inspect connections at Intake Manifold Temperature (IMT) sensor. Decision

A. Key OFF. Yes: Go to Step 3.

B. Disconnect IMT sensor connector.

C. Check IMT sensor and connector terminals for damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are IMT sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
and terminal damage. After
repairs are complete, retest for
SPN 105 FMI 3.
248 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Check IMT circuit for short to PWR. Decision

A. Perform Test 1 (page 249). Yes: Repair short to PWR
between IMT pin-2 and ECM pin
B. Use DMM, measure voltage between Breakout Harness ZTSE4993 pin-2
E-15. After repairs are complete,
and known good GND.
retest for SPN 105 FMI 3.
Is voltage greater than 6 volts? No: Go to Step 4.

Step 4 Check for failed IMT sensor. Decision

A. Perform Test 2 (page 249). Yes: Replace IMT sensor. After
®
repairs are complete, retest for
B. Use EST with Navistar Engine Diagnostics, clear DTC list.
SPN 105 FMI 3.
Does SPN 105 FMI 4 set after DTC list is cleared? No: Go to Step 5.

Step 5 Check IMT circuit for Open. Decision

A. Perform Test 3 (page 250). Yes: Repair Open between IMT
pin-1 and ECM pin E-28. After
B. Use EST with Navistar® Engine Diagnostics, clear DTC list.
repairs are complete, retest for
SPN 105 FMI 3.
Does SPN 105 FMI 4 set after DTC list is cleared? No: Repair Open between IMT
pin-2 and ECM pin E-15. After
repairs are complete, retest for
SPN 105 FMI 3.

End Diagnostic Tests

After performing diagnostic steps, if SPN 105 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 249

Pin-Point Tests (SPN 105 FMI 3)

Figure 63 Intake Manifold Temperature (IMT) Sensor Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4993
• Breakout Harness 3-Banana Plug ZTSE4498
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Figure 64 IMT Signal Circuit Check

Test 1
A. Key OFF.
B. Disconnect Intake Manifold Temperature (IMT) sensor.

C. Connect Breakout Harness ZTSE4993 to vehicle harness connector and leave IMT sensor disconnected.

D. Key ON Engine OFF (KOEO).

250 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 65 IMT Signal Circuit Check

Test 2
A. Key OFF.
B. Disconnect Intake Manifold Temperature (IMT) sensor.
C. Connect Breakout Harness ZTSE4993 to vehicle harness and leave IMT sensor disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4993 pin-1 and pin-2 together.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 251

Figure 66 IMT Circuit Check

Test 3
A. Key OFF.
B. Disconnect Intake Manifold Temperature (IMT) sensor.
C. Connect Breakout Harness ZTSE4993 to vehicle harness and leave IMT sensor disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4993 pin-2 circuit to known good GND.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
252 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 105 FMI 4 - IMT signal Out of Range LOW

Fault Overview
Fault Code sets when Engine Control Module (ECM) detects Intake Manifold Temperature (IMT) signal is less
than 0.16 volts.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• IMT signal circuit short to GND
• Failed IMT
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 253

Step 1 Check for active or pending fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON Yes: Go to Step 2.
Engine OFF (KOEO), check Diagnostic Trouble Code (DTC) list for SPN 105 FMI 4.
Is EST DTC list SPN 105 FMI 4 active or pending? No. Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 2 Inspect connections at Intake Manifold Temperature (IMT) sensor. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect IMT sensor connector.
C. Check IMT sensor and connector terminals for damaged or pinched wires;
wet or corroded terminals; loose, bent, broken pins; or broken connector
housing.
Are IMT sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
and terminal damage. After
repairs are complete, retest for
SPN 105 FMI 4.

Step 3 Check IMT signal circuit for short to GND. Decision

A. Key OFF. Yes: Replace IMT sensor. After
repairs are complete, retest for
B. Disconnect Intake Manifold Temperature (IMT) sensor.
SPN 105 FMI 4.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).
D. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
E. Use EST with Navistar® Engine Diagnostics, clear DTC list.
Does SPN 105 FMI 3 set after DTC list is cleared? No: Repair short to GND between
IMT connector pin-2 and ECM pin
E1-15. After repairs are complete,
retest for SPN 105 FMI 4.

End Diagnostic Tests

After performing diagnostic steps, if SPN 105 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
254 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 108 FMI 2 - BARO signal erratic, intermittent or incorrect

Fault Overview
Fault code sets when Electronic Control Module (ECM) detects that Barometric Absolute Pressure (BARO)
sensor signal is erratic intermittent or incorrect

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

Associated Faults
None

Fault Facts
BARO sensor is located inside Engine Control Module (ECM). If there is a confirmed BARO failure, ECM must
be replaced.

Drive Cycles
Initial Key ON
Possible Cause
• Failed ECM
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 255

Step 1 Obtain vehicle health report and check for current Engine Control Decision
Module (ECM) calibration.
Perform Obtain Vehicle Health Report(page 1324). Yes: Go to Step 2.
Is ECM calibration current? No: Ensure vehicle has latest
ECM calibration. After repairs are
complete, retest for SPN 108 FMI
2.

Step 2 Check for active or pending fault code. Decision

Using Electronic Service Tool (EST) with Navistar® Engine Diagnostics. Key On Yes: Replace ECM, following
Engine Off (KOEO), check Diagnostic Trouble Code (DTC) list for SPN 108 FMI 2. approved warranty procedures.
After repairs are complete, retest
for SPN 108 FMI 2.
Is EST DTC list SPN 108 FMI 2 active or pending? No: Diagnostics complete. After
repairs are complete, retest for
SPN 108 FMI 2.

End Diagnostic Steps

After performing all diagnostic steps, if SPN 108 FMI 2 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
256 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 108 FMI 3 - BARO signal Out of Range HIGH

Fault Overview
Fault Code sets when Barometric Pressure (BARO) sensor is above maximum threshold.

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

Associated Faults
None

Fault Facts
BARO sensor is installed inside Engine Control Module (ECM).

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed ECM
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 257

Step 1 Obtain vehicle health report and check for current Engine Control Decision
Module (ECM) calibration.
Perform Obtain Vehicle Health Report(page 1324). Yes: Go to Step 2.
Is ECM calibration current? No: Ensure vehicle has latest
ECM calibration. After repairs are
complete, retest for SPN 108 FMI
3.

Step 2 Check for active or pending fault codes. Decision

Using Electronic Service Tool (EST) with Navistar® Engine Diagnostics. Key On Yes: Replace ECM, following
Engine Off (KOEO), check Diagnostic Trouble Code (DTC) list for SPN 108 FMI 3. approved warranty procedures.
After repairs are complete, retest
for SPN 108 FMI 3.
Is EST DTC list SPN 108 FMI 3 active or pending? No. Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

End Diagnostic Steps

After performing all diagnostic steps, if SPN 108 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
258 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 108 FMI 4 - BARO signal Out of Range LOW

Fault Overview
Determines if Barometric Pressure (BARO) sensor is below minimum threshold.

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

Associated Faults
None

Fault Facts
BARO sensor is installed inside Engine Control Module (ECM).

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Internal ECM failure
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 259

Step 1 Obtain vehicle health report and check for current Engine Control Decision
Module (ECM) calibration.
Perform Obtain Vehicle Health Report(page 1324). Yes: Go to Step 2.
Is ECM calibration current? No: Ensure vehicle has latest
ECM calibration. After repairs are
complete, retest for SPN 108 FMI
4.

Step 2 Check for active or pending fault codes. Decision

Using Electronic Service Tool (EST) with Navistar® Engine Diagnostics. Key On Yes: Replace ECM, following
Engine Off (KOEO), check Diagnostic Trouble Code (DTC) list for SPN 108 FMI 4. approved warranty procedures.
After repairs are complete, retest
for SPN 108 FMI 4.
Is EST DTC list SPN 108 FMI 4 active or pending? No. Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

End Diagnostic Steps

After performing all diagnostic steps, if SPN 108 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
260 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 110 FMI 0 - Engine Cooling System above Critical Temperature

Fault Overview
Fault is set by Engine Control Module (ECM) when Engine Coolant Temperature 1 (ECT1) exceeds value of
Programmable Parameter (PP) 77021.

Lamp Reaction
Engine shutdown is commanded and Red Stop Lamp (RSL) active if feature is enabled.

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• Incorrect value in PP 77021
• Blockage between radiator and Charge Air Cooler (CAC)
• Cooling system overheating
• Degraded coolant

Step 1 Check for active or pending fault code. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON Yes: Go to 6.0 Cooling System
Engine OFF (KOEO), check Diagnostic Trouble Codes (DTC) list for SPN 110 FMI 0. Operational Checkout Procedure
(Step 2) (page 33).
Is EST DTC list SPN 110 FMI 0 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

End Diagnostic Tests

After performing diagnostic steps, if SPN 110 FMI 0 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 261

SPN 110 FMI 2 - ECT1 Signal Erratic, Intermittent, or Incorrect

Fault Overview
Engine Control Module (ECM) compares Engine Coolant Temperature 1 (ECT1) sensor to Intake Air
Temperature (IAT), Turbocharger 2 Compressor Intake Temperature (TC2CIT), Charge Air Cooler Outlet
Temperature (CACOT), Intake Manifold Temperature (IMT), and Engine Oil Temperature (EOT) sensors at Key
ON, Engine OFF (KOEO) with engine cold.

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

Associated Faults
SPN 110 FMI 3 and 4
(ECT1)

Fault Facts
ECT1 sensor shares a common ground circuit with multiple sensors and actuators. If multiple sensor and
actuator fault codes are present, suspect a ground circuit failure.

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• Open or high resistance in ECT1 SIG circuit
• Open or high resistance in ECT SIG GND circuit
• Failed ECT1 sensor
• Short to GND in ECT1 SIG circuit
262 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 261).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 110 FMI 2.

Step 2 Check for active or pending fault codes. Decision

Use EST with Navistar® Engine Diagnostics. Key ON, Engine OFF (KOEO), check Yes: Go to Step 3.
DTC list for SPN 110 FMI 2.
Is SPN 110 FMI 2 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 3 Inspect connections at ECT1 connector. Decision

A. Key OFF. Yes: Go to Step 4.
B. Disconnect ECT1 connector.
C. Check ECT1 and connector terminals for: damaged or pinched wires;
moist or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are ECT1 connector, harness, and terminals clean and undamaged? No: Repair connector, harness, or
terminal damage. After repairs are
complete, retest for
SPN 110 FMI 2.

Step 4 Check for short to ground in ECT1 SIG Circuit. Decision

A. Perform Test 1 (page 264). Yes: Go to Step 5.
®
B. Use EST with Navistar Engine Diagnostics, perform Continuous Monitor
Test (page 1361).
C. With test in progress, monitor ECT1 voltage.
Is voltage 5.0 ± 0.25 volts? No: Repair short to ground in SIG
circuit between EGT1 pin-2 and
ECM pin E-33. After repairs are
complete, retest for SPN 110 FMI
2.

Step 5 Check for failed ECT1 sensor. Decision

A. Perform Test 2 (page 265). Yes: Replace ECT1 sensor. After
repairs are complete, retest for
B. Use EST with Navistar® Engine Diagnostics, perform Continuous Monitor
SPN 110 FMI 2.
Test (page 1361).
C. With test in progress, monitor ECT1 voltage.
Is voltage 0.0 ± 0.25 volts? No: Go to Step 6.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 263

Step 6 Check ECT1 circuit for High resistance. Decision

A. Perform Test 3 (page 266). Yes: Repair Open or high
resistance in SIG GND circuit
B. Use EST with Navistar® Engine Diagnostics, perform Continuous Monitor
between ECT1 sensor pin-1 and
Test (page 1361).
ECM pin E-28. After repairs are
C. With test in progress, monitor ECT1 voltage. complete, retest for SPN 110 FMI
2.
Is voltage 0.0 ± 0.25 volts? No: Repair Open or high
resistance in SIG circuit between
ECT1 pin-2 and ECM pin E-33.
After repairs are complete, retest
for SPN 110 FMI 2.

End Diagnostic Tests

After performing diagnostic steps, if SPN 110 FMI 2 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
264 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 110 FMI 2)

Figure 67 ECT1 Sensor Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4602
• 3-Banana Plug Harness ZTSE4498
• EST with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Test 1
A. Key OFF.
B. Disconnect ECT1 sensor.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
D. Key ON, Engine OFF (KOEO). Log into Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 265

Figure 68 ECT1 Circuit Check

Test 2
A. Key OFF.
B. Disconnect ECT1 sensor.
C. Connect Breakout Harness ZTSE4602 to vehicle harness connector and leave ECT1 sensor disconnected.
D. Connect Resistor Harness ZTSE4498 between Breakout Harness ZTSE4602 pin-1 and pin-2.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
F. Key ON, Engine OFF (KOEO). Log into Navistar® Engine Diagnostics.
266 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 69 ECT1 Circuit Check

Test 3
A. Key OFF.
B. Disconnect ECT1 sensor.
C. Connect Breakout Harness ZTSE4602 to vehicle harness connector and leave ECT1 sensor disconnected.
D. Connect Resistor Harness ZTSE4498 between Breakout Harness ZTSE4602 pin-2 and known good GND.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
F. Key ON, Engine OFF (KOEO). Log into Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 267

SPN 110 FMI 3 - ECT1 signal Out of Range HIGH

Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Coolant Temperature (ECT1) signal is
greater than 4.80 volts.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• ECT1 signal circuit Open
• ECT1 signal circuit short to PWR
• SIG GND circuit Open
• Failed ECT1 sensor
268 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault code. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for SPN 110 FMI 3.
Is SPN 110 FMI 3 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 2 Inspect connections at Engine Coolant Temperature 1 (ECT1) sensor. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect ECT1 sensor connector.
C. Check ECT1 sensor and connector terminals for damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are ECT1 sensor, connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 110
FMI 3.

Step 3 Check ECT1 signal circuit for short to PWR. Decision

A. Perform Test 1(page 270). Yes: Repair short to power
between ECT1 pin-2 and ECM pin
B. Use Digital Multimeter (DMM), measure voltage between Breakout
E-33. After repairs are complete,
Harness ZTSE4602 pin-2 and known good GND.
retest for SPN 110 FMI 3.
Is voltage greater than 6 volts? No: Go to Step 4.

Step 4 Check for failed ECT1 sensor. Decision

A. Perform Test 2(page 270). Yes: Replace ECT1 sensor. After
®
repairs are complete, retest for
B. Use EST with Navistar Engine Diagnostics, clear DTC list.
SPN 110 FMI 3.
Does SPN 110 FMI 4 set after DTC list is cleared? No: Go to Step 5.

Step 5 Check ECT1 signal and SIG GND circuits for Opens. Decision
A. Perform Test 3(page 271). Yes: Repair Open between ECT1
pin-1 and ECM pin E-28. After
B. Use EST with Navistar® Engine Diagnostics, clear DTC list.
repairs are complete, retest for
SPN 110 FMI 3.
Does SPN 110 FMI 4 set after DTC list is cleared? No: Repair Open between ECT1
pin-2 and ECM pin E-33. After
repairs are complete, retest for
SPN 110 FMI 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 269

End Diagnostic Tests

After performing diagnostic steps, if SPN 110 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
270 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 110 FMI 3)

Figure 70 ECT1 Sensor Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4602
• Breakout Harness ZTSE4498
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Figure 71 ECT1 Sensor Circuit Check

Test 1
A. Key OFF.

B. Disconnect Engine Coolant Temperature 1 (ECT1) sensor.

C. Connect Breakout Harness ZTSE4602 to vehicle harness and leave ECT1 sensor disconnected.

D. Key ON Engine OFF (KOEO).

 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 271

Figure 72 ECT1 Sensor Circuit Check

Test 2
A. Key OFF.
B. Disconnect Engine Coolant Temperature 1 (ECT1) sensor.
C. Connect Breakout Harness ZTSE4602 to vehicle harness and leave ECT1 sensor disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4602 pin-1 and pin-2 together.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
272 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 73 ECT1 Sensor Circuit Check

Test 3
A. Key OFF.
B. Disconnect Engine Coolant Temperature 1 (ECT1) sensor.
C. Connect Breakout Harness ZTSE4602 to vehicle harness and leave ECT1 sensor disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4602 pin-2 to known good GND.
E. Connect EST to vehicle Diagnostic Connector (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 273

SPN 110 FMI 4 - ECT1 signal Out of Range LOW

Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Engine Coolant Temperature 1 (ECT1) sensor
signal voltage is less than 0.17 volts.

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

Associated Faults
SPN 3509 FMI 3 and 4
(VREF 1)

Fault Facts
None

Drive Cycle to Determine Fault Status

Key ON.
Possible Causes
• ECT1 signal circuit short to GND
• Failed ECT1 sensor
274 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults(page 273).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 110 FMI 4.

Step 2 Inspect connections at Engine Coolant Temperature 1 (ECT1) sensor. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect ECT1 sensor connector.
C. Check ECT1 sensor and connector terminals for damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are ECT1 sensor, connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 110
FMI 4.

Step 3 Check ECT1 sensor Decision

A. Key OFF. Yes: Replace ECT1 sensor. After
repairs are complete, retest for
B. Disconnect Engine Coolant Temperature 1 (ECT1) connector.
SPN 110 FMI 4.
C. Connect EST to vehicle Diagnostic Connector (page 1345).
D. Key ON Engine OFF (KOEO). Log into Navistar® Engine Diagnostics.
E. Use EST with Navistar® Engine Diagnostics, clear DTC list.
Does SPN 110 FMI 3 set after DTC list is cleared? No: Repair short to GND between
ECT1 connector pin-2 and ECM
pin E-33. After repairs are
complete, retest for SPN 110 FMI
4.

End Diagnostic Tests

After performing diagnostic steps, if SPN 110 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 275

SPN 110 FMI 7 - ECT1 and EOT temperature conflict

Fault Overview

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

Associated Faults
• SPN 110 FMI 2, 3 and 4 • SPN 175 FMI 2, 3 and 4
(ECT1) (EOT)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed ECT1 sensor
• Failed EOT Sensor
• Low Coolant or coolant loss symptom
• Cooling package damage or air flow restriction
• Failed engine fan, shroud or air dams
• Failed engine thermostat
276 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults(page 275).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 110 FMI 7.

Step 2 Check for active or pending fault codes. Decision

Use EST with Navistar® Engine Diagnostics. Key ON Engine OFF (KOEO), check Yes: Go to Step 3.
DTC list for SPN 110 FMI 7.
Is SPN 110 FMI 7 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 110 FMI 7.

Step 3 Inspect connections at Engine Coolant Temperature (ECT1) sensor. Decision

A. Key OFF. Yes: Go to Step 4.
B. Disconnect ECT1 sensor connector.
C. Check ECT1 sensor and connector terminals for damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are ECT1 sensor, connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 110
FMI 7.

Step 4 Inspect connections at Engine Oil Temperature (EOT) sensor. Decision

A. Key OFF. Yes: Go to Step 5.
B. Disconnect EOT sensor connector.
C. Check EOT sensor and connector terminals for damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are EOT sensor, connector, harness, and terminals clean and undamaged? No: Repair connector, harness, or
terminal damage. After repairs are
complete, retest for SPN 110 FMI
7.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 277

Step 5 Sensor Compare Check. Decision

Compare ECT1, EOT, Charge Air Cooler Outlet Temperature (CACOT), Yes: Go to Step 6.
Turbocharger 2 Compressor Intake Temperature (TC2CIT) and Exhaust Gas
Temperature (EGT) sensors with engine cold.
Are ECT1 and EOT within 30°F (16°C) of other sensors? No: Replace ECT1 and/or
EOT sensors. After repairs are
complete, retest for SPN 110 FMI
7.

Step 6 Check coolant level. Decision

Perform Coolant Level Inspection(page 1637). Yes: Go to Step 7.
Is coolant level within specifications? No: Fill deaeration tank. Go
to Step 2 of 6.0 - Cooling
System Operational Checkout
Procedure(page 33). After repairs
are complete, retest for SPN 110
FMI 7.

Step 7 Inspect Cooling Package and front of truck. Decision

Inspect vehicle grille, radiators, and HPCAC for obstructions or damage that may Yes: Go to Step 8.
reduce air flow through Cooling Package.
Is Cooling Package free of air flow obstructions and/or damage? No: Repair or remove obstruction
or damage. After repairs are
complete, retest for SPN 110 FMI
7.

Step 8 Check engine fan, fan shroud, and air dams. Decision
Check engine fan, fan shroud, and air dams for damage and proper operation. Yes: Go to Step 9.
Are engine fan, fan shroud, and air dams intact and operating properly? No: Repair or replace engine fan,
fan shroud, and/or air dams. After
repairs are complete, retest for
SPN 110 FMI 7.

Step 9 Check thermostat operation. Decision

Perform Thermostat Operational Test (page 1608). Yes: Go to Step 2 of 6.0 - Cooling
System Operational Checkout
Procedure(page 33). After repairs
are complete, retest for SPN 110
FMI 7.
Is thermostat working properly? No: Replace thermostat. After
repairs are complete, retest for
SPN 110 FMI 7.
278 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

End Diagnostic Test

After performing diagnostic steps, if SPN 110 FMI 7 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 279

SPN 110 FMI 15 - Engine Coolant System above Warning Temperature

Fault Overview
Fault code sets when Electronic Control Module (ECM) detects Engine Coolant Temperature 1 (ECT1) is above
Programmable Parameter (PP) 77011.

Lamp Reaction
Red Stop Lamp and Warning buzzer turned ON.

Associated Faults
SPN 110 FMI 2, 3, and 4
(ECT1)

Fault Facts
Fault may set by incorrect value in programmable parameters in Navistar® Engine Diagnostics.

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• Incorrect value in PP 77011
• Engine Overheating

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 279).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
SPN 110 FMI 15.

Step 2 Check Programmable Parameter (PP) 77011. Decision

A. Key OFF. Yes: Go to 6.0 Cooling System
Operational Checkout Procedure
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(Step 2) (page 33).
(page 1345).
C. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.

D. Use EST with Navistar® Engine Diagnostics, go to Sessions >

Programming > Engine Warn Protection System.
E. Check value, verify with customer desired temperature limit and compare
to normal operating temperature.
Is PP 77011 programmed correctly? No: Program PP 77011 to correct
value. After repairs are complete,
retest for SPN 110 FMI 15.
280 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

End Diagnostic Tests

After performing diagnostic steps, if SPN 110 FMI 15 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 281

SPN 110 FMI 16 - Engine Coolant System Above OBD Maximum Temperature

Fault Overview
Fault sets when ECT1 signal is stuck in range high.

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

Associated Faults
SPN 110 FMI 2, 3, and 4

Fault Facts
This fault sets when the Engine Warning Protection System (EWPS) detects Engine Coolant Temperature 1
(ECT1) has risen above a critical set point. Fault may be caused by actual high coolant temperature or by a
fault in ECT1 sensor circuit.

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• Low coolant level
• Check for leaks or boiling out

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 281).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 110 FMI 16.

Step 2 Check for active or pending fault code. Decision

®
Use EST with Navistar Engine Diagnostics. Key ON Engine OFF (KOEO), check Yes: Do Diagnostic
DTC list for SPN 110 FMI 16. Troubleshooting Procedures:
Coolant Over-Temp (page 90).
Is EST DTC list SPN 110 FMI 16 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 110 FMI 16.

End Diagnostic Tests

After performing diagnostic steps, if SPN 110 FMI 16 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
282 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 110 FMI 17 - Engine Coolant Temperature stuck in range low

Fault Overview
Fault sets when Engine Control Module (ECM) determines Engine Coolant Temperature 1 (ECT1) signal is in
range, but lower then expected.

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

Associated Faults
SPN 110 FMI 2, 3, and 4
(ECT1)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Thermostat stuck open
• Engine fan stuck On
• Low coolant level
• Engine Fan Control (EFC) short to GND
• Failed ECT1

Step 1 Check for associated fault codes Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 282).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 110 FMI 17.

Step 2 Check coolant level Decision

Perform visual inspection of deaeration tank level. Yes: Go to Step 3.
Is deaeration tank filled to operating level? No: Fill or drain deaeration tank
to operating level. After repairs
are complete, retest for SPN 110
FMI 17.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 283

Step 3 Check for failed Engine Coolant Temperature 1 (ECT1) Decision

A. Key-Off. Yes: Go to Step 4.
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).

C. Key On Engine Off (KOEO), log in to Navistar® Engine Diagnostics.

D. Key-On Engine-Running (KOER).
E. Run engine at high idle.
F. Use Digital IR Thermometer ZTSE4799, measure temperature at ECT1
temperature sensor.
G. Compare temperature reading to ECT1 temperature in shown in Navistar®
Engine Diagnostics.
Is thermometer reading within 10°F (6°C) of ECT1 reading Navistar® Engine No: Replace ECT1 sensor. After
Diagnostics? repairs are complete, retest for
SPN 110 FMI 17.

Step 4 Check for proper fan clutch operation Decision

Perform Engine Cooling Fan Test (page 1609). Yes: Replace thermostat. After
repairs are complete, retest for
SPN 110 FMI 17.
Is engine cooling fan circuits and fan clutch operating correctly? No: Repair engine cooling fan
circuits or fan clutch as indicated
by Engine Cooling Fan Test. After
repairs are complete, retest for
SPN 110 FMI 17.

End Diagnostic Tests

After performing diagnostic steps, if SPN 110 FMI 17 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
284 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 110 FMI 18 - Engine Coolant System below closed loop minimum Temperature

Fault Overview
Fault sets when minimum closed-loop coolant temperature of < 68°F (20°C) is not reached.

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

Associated Faults
SPN 110 FMI 2, 3, and 4
(ECT1)

Fault Facts
None

Drive Cycle to Determine Fault Status

Key ON
Possible Causes
• Thermostat stuck open
• Engine fan stuck on
• Low coolant level
• Engine Fan Control (EFC) Short to GND
• Failed ECT1

Step 1 Check for associated fault codes Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Fault (page 284).
Is EST DTC list free of Associated Fault? No: Repair Associated Fault.
After repairs are complete, retest
for SPN 110 FMI 18.

Step 2 Check coolant level Decision

Perform visual inspection of deaeration tank level. Yes: Go to Step 3.
Is deaeration tank filled to operating level? No: Fill or drain deaeration tank to
operating level. After repairs are
complete, retest for SPN 110 FMI
18.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 285

Step 3 Check for failed Engine Coolant Temperature 1 (ECT1) Decision

A. Key-Off. Yes: Go to Step 4.
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).

C. Key-On Engine-Off (KOEO), log in to Navistar® Engine Diagnostics.

D. Key-On Engine-Running (KOER).
E. Run engine at high idle.
F. Use Digital IR Thermometer ZTSE4799, measure temperature at ECT1
temperature sensor.
G. Compare temperature reading to ECT1 temperature in shown in Navistar®
Engine Diagnostics.
Is thermometer reading within 10°F (6°C) of ECT1 reading Navistar® Engine No: Replace ECT1 sensor. After
Diagnostics? repairs are complete, retest for
SPN 110 FMI 18.

Step 4 Check for proper fan clutch operation Decision

Perform Engine Cooling Fan Test (page 1609). Yes: Replace thermostat. After
repairs are complete, retest for
SPN 110 FMI 18.
Is engine cooling fan circuits and fan clutch operating correctly? No: Repair engine cooling fan
circuits or fan clutch as indicated
by Engine Cooling Fan Test. After
repairs are complete, retest for
SPN 110 FMI 18.

End Diagnostic Tests

After performing diagnostic steps, if SPN 110 FMI 18 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
286 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 111 FMI 1 - ECL below Warning/Critical Level

Fault Overview
Fault code sets when Engine Control Module (ECM) detects coolant level is below minimum level.

Lamp Reaction
Red Stop Lamp will illuminate when this fault is detected during two consecutive drive cycles.

Associated Faults
None

Fault Facts
This fault sets when Engine Warning Protection System (EWPS) detects Engine Coolant Level (ECL) has fallen
below a minimum level. Fault may be caused by actual low coolant level or by a fault in Engine Coolant Level
(ECL) sensor circuit. SPN 111 FMI 1 fault also sets RSL.

Drive Cycle to Determine Fault Status

Continuous (engine running)
Possible Causes
• Low coolant level - see Cooling System Diagnosis/Repair
• Incorrect level sensor programmable parameter
• Open or high resistance in VREF circuit
• Open or high resistance in ground circuit
• Short or high resistance ECL signal circuit
• Failed ECL sensor
• Failed Coolant Level Module (CLM)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 287

Step 1 Check coolant level. Decision

Perform Coolant Level Inspection (page 1637). Yes: Go to Step 2 in
Cooling System Operational
Checkout Procedure (page
33).
Is Coolant level low, is there evidence of coolant loss, or does operator complain of No: Go to Step 2.
coolant leaks or consumption?

Step 2 Identify what ECL sensor is installed. Decision

Determine weather ECL sensor is threaded into deaeration tank or clipped into tank. Yes: Go to Step 6.
Is ECL sensor threaded into deaeration tank? No: Go to Step 3.

Step 3 Inspect connections at ECL (6401) sensor. Decision

A. Key OFF. Disconnect ECL sensor connector. Yes: Go to step 4
B. Check ECL sensor and connector terminals for damaged or pinched wires;
corroded terminals; loose, bent, or broken pins; or broken connector housing.
Are ECL sensor, connector, harness, and terminals clean and undamaged? No: Repair connector,
harness, or terminal
damage. After repairs
are complete, retest for fault.

Step 4 Check for active or pending fault code. Decision

®
Using Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON, check Yes: Go to Step 5.
Diagnostic Trouble Codes (DTC) list for SPN 111 FMI 1.
Is EST DTC list SPN 111 FMI 1 active or pending? No: Go to Intermittent or
Not Active Fault Diagnostic
Procedure (page 1344).

Step 5 Check if SPN 111 FMI 1 is active with ECL disconnected. Decision
A. Key OFF. Disconnect ECL sensor. Yes: Repair short between
ECL sensor pin-A and ECM
B. Key ON, clear codes.
pin C-42. After repairs are
C. Key OFF. complete, retest for fault.
D. Key ON, check Diagnostic Trouble Codes (DTC) list for SPN 111 FMI 1.
Is EST DTC list SPN 111 FMI 1 still active? No: Replace ECL sensor.
After repairs are complete,
retest for fault.
288 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 6 Check Engine Coolant Level Programmable Parameter. Decision

®
Using Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON, select Yes: Go to Step 7.
the Parameters tab. Locate Parameter number 92001 - Coolant Tank Selection.
Is 92001 - Coolant Tank Selection set to "Conductive Probe (Metallic or Plastic Tank) (1)"? No: Set parameter to
"Conductive Probe (Metallic
or Plastic Tank) (1)" and
retest for fault.

Step 7 Inspect connections at CLM (6410). Decision

A. Key OFF. Disconnect CLM. CLM is located on Powertrain Harness towards Yes: Go to Step 8.
left front of engine.
B. Check connector terminals for: damaged or pinched wires; moisture or corroded
terminals; loose, bent, or broken pins; or broken connector housing.
Is CLM connector, harness, and terminals clean and undamaged? No: Repair / replace
connector, harness, or
terminal. After repairs are
complete, retest for fault.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 289

A
A

D
E

0000433250

Step 8 Check for Open or high resistance in VREF circuit. Decision

A. Key OFF. Connector CLM disconnected. Yes: Go to step 10.
B. Use Terminal Test Kit ZTSE4435C, insert proper terminal into vehicle harness
pin-A and pin-D.
C. Key ON. Using Digital Multimeter (DMM), measure voltage between pin-A and
pin-D.
Is voltage B+ ± 0.5 volts? No: Go to Step 9.
290 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 9 Check for Open \ high resistance in VREF circuit. Decision

A. Key OFF. Connector CLM disconnected. Yes: Repair Open or high
resistance between CLM
B. Insert proper terminal into vehicle harness pin-A.
pin-D and ground circuit.
C. Key ON. Measure voltage between pin-A and ground. After repairs are complete,
retest for fault.
Is voltage B+ ± 0.5 volts? No: Repair Open or short
between CLM pin-A and
ECM pin C-45. After repairs
are complete, retest for fault.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 291

Step 10 Inspect connections at ECL sensor. Decision

A. Key OFF. Disconnect ECL sensor. Yes: Go to Step 11.
B. Check connector terminals for: damaged or pinched wires; moisture or corroded
terminals; loose, bent, or broken pins; or broken connector housing.
Is ECL sensor connector, harness, and terminals clean and undamaged? No: Repair / replace
connector, harness, or
terminal. After repairs are
complete, retest for fault.
292 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

0000431421

Step 11 Check for Open in ECL ground circuit. Decision

A. Key OFF. CLM and ECL disconnected. Yes: Go to Step 12.

B. Insert proper terminal into vehicle harness ECL pin-B.

C. Measure resistance between pin-B and ground.
Is resistance less than 5 ohms? No: Repair Open or high
resistance between ECL
pin-B and CLM pin-D. After
repairs are complete, retest
for fault.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 293

0000431420

Step 12 Check for short in ECL signal circuit. Decision

A. Key OFF. CLM and ECL disconnect. Yes: Go to Step 13.

B. Insert proper terminal into vehicle harness ECL pin-A.

C. Measure resistance between pin-A and ground.
Is resistance greater than 1,000 ohms? No: Repair short to ground
between CLM pin-B and
ECL sensor pin-A. After
repairs are complete, retest
for fault.
294 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

A
B

E
B A

0000433249

Step 13 Check for Open in ECL signal circuit. Decision

A. Key OFF. ECL and CLM disconnected. Yes: Go to Step 14.
B. Insert proper terminal into vehicle harness ECL pin-A and CLM pin-B.
C. Measure resistance between ECL pin-A and CLM pin-B.
Is resistance less than 5 ohms? No: Repair Open between
CLM pin-B and ECL sensor
pin-A. After repairs are
complete, retest for fault.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 295

0000433248

Step 14 Check for an Open or short in ECL signal circuit. Decision

A. Key OFF. Disconnect CLM. Yes: Go to Step 15.
B. Use Engine Terminal Test Kit ZTSE4435C, insert proper terminal into harness
connector pin-C.
C. Measure resistance between pin-C and ground.
Is resistance greater than 1,000 ohms? No: Repair Open \ high
resistance between CLM
pin-C and ECM pin C-42.
After repairs are complete,
retest for fault.
296 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 15 Check for failed ECL. Decision

A. Key OFF. Disconnect ECL sensor. Yes: Go to Step 16.

B. Drain coolant below ECL sensor and remove sensor from tank.

C. Insert proper terminal into sensor pin-A and pin-B.

D. Measure resistance between pin-A and pin-B.
Is resistance within 199.5K - 220.5K ohms? No: Replace ECL sensor. After
repairs are complete, retest for
fault.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 297

Step 16 Check for failed CLM. Decision

A. Key OFF. Disconnect ECL sensor. Yes: Replace CLM. After repairs
are complete, retest for fault.
B. Insert proper terminal into sensor pin-A.
C. Measure resistance between pin-A and sensor tip.
Is resistance within 64.6K - 71.4K ohms? No: Replace ECL sensor. After
repairs are complete, retest for
fault.

End Diagnostic Tests

After performing all tests, if no problem is found, verify if each step was completed correctly and the proper decision
was made. Return to fault code diagnostics.
298 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 111 FMI 2 - ECL signal erratic, intermittent, or incorrect

Fault Overview
The Engine control Module (ECM) will set this fault when Engine Coolant Level (ECL) signal is greater than 3.5
volts or less than 4.4 volts.

Lamp Reaction
Amber Warning Lamp (AWL) will illuminate when this fault is detected.

Associated Faults
None

Fault Facts
This fault code can only set on vehicles equipped with the Coolant Level Module (CLM) and probe level sensors.
The float style sensors will not set this fault code.

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• Low coolant level - see Cooling System Diagnosis/Repair
• Incorrect Level sensor programmable parameter
• Open or high resistance in VREF circuit
• Open or high resistance in ground circuit
• Short or high resistance ECL signal circuit
• Failed ECL sensor
• Failed (CLM)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 299

Step 1 Check for active or pending fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON Yes: Go to Step 2.
Engine OFF (KOEO), check Diagnostic Trouble Codes (DTC) list for SPN 111 FMI 2.
Is SPN 111 FMI 2 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 2 Check Engine Coolant Level Programmable Parameter. Decision

Using (EST) with Navistar® Engine Diagnostics. Key ON, select the Parameters tab. Yes: Go to Step 3.
Locate Parameter number 92001 - Coolant Tank Selection.
Is 92001 - Coolant Tank Selection set to "Conductive Probe (Metallic or Plastic No: Set parameter to "Conductive
Tank) (1)"? Probe (Metallic or Plastic Tank)
(1)" and retest for fault.

Step 3 Check coolant level. Decision

Perform Coolant Level Inspection(page 1637). Yes: Go to Step 2 in Cooling
System Operational Checkout
Procedure (page 33).
Is Coolant level low, is there evidence of coolant loss, or does operator complain of No: Go to Step 4.
coolant leaks or consumption?

Step 4 Inspect connections at CLM (6410). Decision

A. Key OFF. Disconnect CLM. CLM is located on Powertrain Harness towards Yes: Go to Step 5.
left front of engine.
B. Check connector terminals for: damaged or pinched wires; moisture or
corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Is CLM connector, harness, and terminals clean and undamaged? No: Repair / replace connector,
harness, or terminal. After repairs
are complete, retest for fault.
300 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

A
A

D
E

0000433250

Step 5 Check for Open or high resistance in VREF circuit. Decision

A. Key OFF. Connector CLM disconnected. Yes: Go to step 7.
B. Use Terminal Test Kit ZTSE4435C, insert proper terminal into vehicle
harness pin-A and pin-D.
C. Key ON. Using Digital Multimeter (DMM), measure voltage between pin-A
and pin-D.
Is voltage B+ ± 0.5 volts? No: Go to Step 6.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 301

Step 6 Check for Open \ high resistance in VREF circuit. Decision

A. Key OFF. Connector CLM disconnected. Yes: Repair Open or high
resistance between CLM pin-D
B. Insert proper terminal into vehicle harness pin-A.
and ground circuit. After repairs
C. Key ON. Measure voltage between pin-A and ground. are complete, retest for fault.
Is voltage B+ ± 0.5 volts? No: Repair Open or short
between CLM pin-A and ECM pin
C-45. After repairs are complete,
retest for fault.
302 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 7 Inspect connections at ECL sensor. Decision

A. Key OFF. Disconnect ECL sensor. Yes: Go to Step 8.
B. Check connector terminals for: damaged or pinched wires; moisture or
corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Is ECL sensor connector, harness, and terminals clean and undamaged? No: Repair / replace connector,
harness, or terminal. After
repairs are complete, retest for
fault.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 303

0000431421

Step 8 Check for Open in ECL ground circuit. Decision

A. Key OFF. CLM and ECL disconnected. Yes: Go to Step 9.

B. Insert proper terminal into vehicle harness ECL pin-B.

C. Measure resistance between pin-B and ground.
Is resistance less than 5 ohms? No: Repair Open or high
resistance between ECL pin-B
and CLM pin-D. After repairs are
complete, retest for fault.
304 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

0000431420

Step 9 Check for short in ECL signal circuit. Decision

A. Key OFF. ECL and CLM disconnected. Yes: Go to Step 10.

B. Insert proper terminal into vehicle harness ECL pin-A.

C. Measure resistance between pin-A and ground.
Is resistance greater than 1,000 ohms? No: Repair short to ground
between CLM pin-B and ECL
sensor pin-A. After repairs are
complete, retest for fault.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 305

A
B

E
B A

0000433249

Step 10 Check for Open in ECL signal circuit. Decision

A. Key OFF. ECL and CLM disconnected. Yes: Go to Step 11.
B. Insert proper terminal into vehicle harness ECL pin-A and CLM pin-B.
C. Measure resistance between ECL pin-A and CLM pin-B.
Is resistance less than 5 ohms? No: Repair Open between CLM
pin-B and ECL sensor pin-A.
After repairs are complete, retest
for fault.
306 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

0000433248

Step 11 Check for an Open or short in ECL signal circuit. Decision

A. Key OFF. Disconnect CLM. Yes: Go to Step 12.
B. Insert proper terminal into harness connector pin-C.
C. Measure resistance between pin-C and ground.
Is resistance greater than 1,000 ohms? No: Repair Open \ high
resistance between CLM pin-C
and ECM pin C-42. After repairs
are complete, retest for fault.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 307

Step 12 Check for failed ECL. Decision

A. Key OFF. Disconnect ECL sensor. Yes: Go to Step 13.

B. Drain coolant below ECL sensor and remove sensor from tank.

C. Insert proper terminal into sensor pin-A and pin-B.

D. Measure resistance between pin-A and pin-B.
Is resistance within 199.5K - 220.5K ohms? No: Replace ECL sensor. After
repairs are complete, retest for
fault.
308 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 13 Check for failed CLM. Decision

A. Key OFF. Disconnect ECL sensor. Yes: Replace CLM. After repairs
are complete, retest for fault.
B. Insert proper terminal into sensor pin-A.
C. Measure resistance between pin-A and sensor tip.
Is resistance within 64.6K - 71.4K ohms? No: Replace ECL sensor. After
repairs are complete, retest for
fault.

End Diagnostic Tests

After performing all tests, if no problem is found, verify if each step was completed correctly and the proper decision
was made. Return to fault code diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 309

SPN 132 FMI 0 - Engine Inlet Air Mass Flow Rate High

Fault Overview
Fault sets when Engine Control Module (ECM) determines difference between desired Mass Air Flow (MAF)
rate and measured MAF rate is incorrect and/or erratic.

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

Associated Faults
SPN 27 FMI 0 and 14 SPN 132 FMI 3 and 4 SPN 2791 FMI 2, 7, 8, and
14

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Disconnected Charge Air Cooler (CAC) hoses or tubes after turbochargers
• MAF auto-calibration
• Water ingestion in air cleaner
• MAF configuration Programmable Parameters (PP)

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 309).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 132 FMI 0.

Step 2 Check for active or pending fault codes. Decision

®
Use EST with Navistar Engine Diagnostics. Key ON Engine OFF (KOEO), check Yes: Go to Step 3.
DTC list for SPN 132 FMI 0.
Is SPN 132 FMI 0 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 132 FMI 0.
310 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Inspect air intake system and air filter for restrictions, air leaks, or Decision
physical damage.
Perform Intake Air Inspection (page 1648) and Charge Air Cooler Inspection (page Yes: Go to Step 4.
1646).
Is air intake system and air filter free of restrictions, leaks, and physical damage? No: Repair intake air system or
replace air filter. After repairs are
complete, retest for SPN 132 FMI
0.

Step 4 Inspect connections at Mass Air Flow/Inlet Air Temperature (MAF/IAT) Decision
sensor.
A. Key OFF. Yes: Go to Step 5.
B. Disconnect MAF/IAT connector.
C. Inspect MAF/IAT and connector for: damaged or pinched wires; wet or
corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are MAF/IAT connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 132
FMI 0

Step 5 Determine if Exhaust Gas Recirculation (EGR) valve is operating Decision

properly.
Perform Exhaust Gas Recirculation Valve (EGRV) Operational Test. Yes: Replace EGR valve. After
repairs are complete, retest for
SPN 132 FMI 0.
Did SPN 2791 FMI 7 or SPN 2791 FMI 14 fault set? No: Go to Step 6.

Step 6 Determine if EGR cooler is restriced. Decision

A. Remove EGR crossover pipe (see Engine Service Manual). Yes: Replace EGR Cooler. After
repairs are complete, retest for
B. Inspect EGR cooler outlet for restriction. Some soot build up is normal.
SPN 132 FMI 0.
Inspect for heavy soot build up that would restrict air movement.
Is EGR cooler restricted with heavy build-up? No: End diagnostics. Retest for
fault.

End Diagnostic Step

After performing all diagnostic steps, if SPN 132 FMI 0 remains, verify each step was completed correctly and proper
decision was made.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 311

SPN 132 FMI 1 - Engine Inlet Air Mass Flow Rate Low

Fault Overview
Fault sets when Engine Control Module (ECM) determines deviation between Mass Air Flow (MAF) rate and
measured MAF rate is below threshold.

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

Associated Faults
• SPN 27 (EGR) • SPN 132 FMI 3, 4, and 13 • SPN 164 (ICP) • SPN 651 - 656 (INJ)
(MAF)
• SPN 2791 (EGR) • SPN 2797 (INJ) • SPN 2798 (INJ) • SPN 3659 - 3664 (INJ)
• SPN 4257 (INJ Perf.)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Disconnected hose to air filter
• MAF auto-calibration
• Defective MAF sensor
• MAF configuration Programmable Parameters (PP)
• Restricted air filter
• Restricted CAC or pipes
• Failed Turbocharger(s)

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 311).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 132 FMI 1.
312 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 2 Check for active or pending fault codes. Decision

®
Use EST with Navistar Engine Diagnostics. Key ON Engine OFF (KOEO), check Yes: Go to Step 3.
DTC list for SPN 132 FMI 1.
Is SPN 132 FMI 1 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 132 FMI 1.

Step 3 Inspect air intake system and air filter for restrictions, air leaks, and Decision
physical damage.
Perform Intake Air Inspection (page 1648) and Charge Air Cooler Inspection (page Yes: Go to Step 4.
1646).
Is air intake system and air filter free of restrictions, leaks, and physical damage? No: Repair intake air system or
replace air filter. After repairs are
complete, retest for SPN 132 FMI
1.

Step 4 Inspect connections at Mass Air Flow (MAF)/Inlet Air Temperature Decision
(IAT) sensor.
A. Key OFF. Yes: Go to Step 5.
B. Disconnect MAF/IAT sensor.
C. Check MAF/IAT sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are MAF/IAT sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 132
FMI 1

Step 5 Test for intermittent circuit operation. Decision

Use EST with Navistar® Engine Diagnostics. Do Key On, Engine Off (KOEO) Yes: Go to Step 6.
Continuous Monitor Test (page 1361).
Does circuit operate properly? No: Locate specific circuit
component causing erratic or
intermittent operation. Perform
voltage and resistance checks
in this section. Repair circuit as
required, and retest for SPN 132
FMI 1.

Step 6 Determine if MAF Sensor Calibration will pass. Decision

Perform MAF Sensor Calibration (page 1539) . Yes: Go to Step 7.
Did MAF Sensor Calibration pass? No: Go to MAF fault code
diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 313

Step 7 Determine if boost control system is operating properly. Decision

Perform Boost Control System Test (page 1533). Yes: After doing all diagnostic
steps, if SPN 132 FMI 1 remains
active, verify each step was
completed correctly and proper
decision was made.
Does turbocharger wastegate operate correctly? No: Repair or replace failed
component(s). After repairs are
complete, retest for SPN 132 FMI
1.

End Diagnostic Step

After performing all diagnostic steps, if SPN 132 FMI 1 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
314 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 132 FMI 3 - MAF Signal Out of Range HIGH

Fault Overview
Fault sets when Mass Air Flow (MAF) frequency is out of range.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• MAF signal circuit OPEN or short to PWR
• Failed MAF sensor
• Open in SIG GND

Step 1 Check for active or pending fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON, Yes: Go to Step 2.
Engine OFF (KOEO), check Diagnostic Trouble Codes (DTC) list for SPN 132
FMI 3.
Is EST DTC list SPN 132 FMI 3 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 2 Determine if MAF Sensor Calibration will pass. Decision

Perform MAF Sensor Calibration (page 1539). Yes: Clear previously active MAF
fault. After repairs are complete,
retest for SPN 132 FMI 3.
Did MAF Sensor Calibration pass? No: Go to Step 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 315

Step 3 Inspect sensor and connector. Decision

A. Key OFF. Yes: Go to Step 4.
B. Disconnect MAF sensor.
C. Check MAF sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are MAF sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 132
FMI 3.

Step 4 Check for power to MAF. Decision

Perform Test 1 (page 317). Use Digital Multimeter (DMM), measure voltage Yes: Go to Step 6.
between Breakout Harness ZTSE4960 pin-D and pin-E.
Is voltage B+ ± 0.5 volts? No: Go to Step 5.

Step 5 Check for open in ACT PWR circuit. Decision

Perform Test 2 (page 318). Use DMM, measure voltage between Breakout Harness Yes: Repair Open or High
ZTSE4960 pin-D and known good GND. resistance between Pin-E and
76-pin ECM connector Pin E-12.
After repairs are complete, retest
for SPN 132 FMI 3.
Is voltage B+ ± 0.5 volts? No: Repair ACT PWR circuit.
After repairs are complete, retest
for SPN 132 FMI 3.

Step 6 Check for expected reference voltage in MAF circuit. Decision

Perform Test 3 (page 318). Use DMM, measure voltage between Breakout Harness Yes: Replace MAF. Go to Step 7.
ZTSE4960 pin-C and known good GND.
Is voltage 5 ± 0.25 volts? No: Repair open or short to power
between Pin-C and 76-pin ECM
connector Pin E-67. After repairs
are complete, Go to Step 7.

Step 7 Check MAF sensor calibration. Decision

Perform MAF Sensor Calibration (page 1539). Yes: End diagnostics. Retest for
SPN 132 FMI 3.
Did MAF sensor calibration run successfully without setting codes? No: Repair fault codes set during
MAF calibration. After repairs are
complete, retest for SPN 132 FMI
3.
316 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

End Diagnostic Step

After performing diagnostic steps, if SPN 132 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 317

Pin-Point Tests (SPN 132 FMI 3)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4960
• DMM

Figure 88 MAF Circuit Check

Test 1
A. Key OFF.
B. Disconnect MAF sensor.
C. Connect Breakout Harness ZTSE4960 to vehicle harness and leave MAF sensor disconnected.

D. Key ON, Engine OFF (KOEO).

318 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 89 MAF Circuit Check

Test 2
A. Key OFF.
B. Disconnect MAF sensor.
C. Connect Breakout Harness ZTSE4960 to vehicle harness and leave MAF sensor disconnected.
D. Key ON, Engine OFF (KOEO).

Figure 90 MAF Circuit Check

Test 3
A. Key OFF.

B. Disconnect MAF sensor.

C. Connect Breakout Harness ZTSE4960 to vehicle harness and leave MAF sensor disconnected.
D. Key ON, Engine OFF (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 319

SPN 132 FMI 4 - MAF Frequency out of range

Fault Overview
Fault sets when Mass Air Flow (MAF) frequency is out of range.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• MAF Circuit Open or Short to GND
• ACT PWR Open or high resistance
• MAF GND open or high resistance
• Failed MAF sensor
320 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON Yes: Go to Step 2.
Engine OFF (KOEO), check Diagnostic Trouble Codes (DTC) list for SPN 132
FMI 4.
Is SPN 132 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect sensor and connector. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect MAF sensor.
C. Check MAF sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are MAF sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 132
FMI 4.

Step 3 Inspect air intake system, CAC, and MAF sensor for air leaks or Decision
physical damage.
Perform Intake Air Inspection (page 1648) and Charge Air Cooler (page 1646) Yes: Go to Step 4.
Inspection. Also check MAF sensor for damage, oil contamination, or debris.
Is air intake system and CAC free of leaks and physical damage? No: Repair intake air system or
CAC system as required. Replace
MAF if damage or contamination
is present. After repairs are
complete, retest for SPN 132 FMI
4.

Step 4 Test MAF circuit for Open or short to GND. Decision

A. Perform Test 1 (page 322). Yes: Go to Step 5.
B. Use DMM, measure voltage between Breakout Harness ZTSE4960 pin-C
and known good GND.
Is voltage between 4.6 and 5 volts? No: Repair Open or Short to GND
between MAF pin-C and ECM pin
E-67. After repairs are complete,
retest for SPN 132 FMI 4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 321

Step 5 Test ACT PWR for Open or high resistance. Decision

A. Perform Test 2 (page 322). Yes: Go to Step 6.
B. Use DMM, measure voltage between Breakout Harness ZTSE4960 pin-D
and known good GND.
Is voltage B+ ± 0.5 volts? No: Repair Open or High
resistance between MAF
connector pin-D and ACT PWR
relay. After repairs are complete,
retest for SPN 132 FMI 4.

Step 6 Test MAF GND for Open or high resistance. Decision

A. Perform Test 3 (page 323). Yes: Go to Step 7.
B. Use DMM, measure voltage between Breakout Harness ZTSE4960 pin-E
and B+.
Is voltage B+ ± 0.5 volts? No: Repair Open or high
resistance between MAF pin-E
and ECM pin E-12. After repairs
are complete, retest for SPN 132
FMI 4.

Step 7 Check MAF Hz in Navistar® Engine Diagnostics. Decision

A. Key OFF. Yes: Replace MAF sensor. After
repairs are complete, retest for
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
SPN 132 FMI 4.
(page 1345).
C. Key ON Engine OFF (KOEO).
D. Use EST with Navistar® Engine Diagnostics. Check all signals for MAF Hz.
Is MAF Hz greater than 16,667 Hz? No: End diagnostics. Retest for
SPN 132 FMI 4.

End Diagnostic Test

After performing diagnostic steps, if SPN 132 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
322 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 132 FMI 4)

Figure 91 MAF/IAT Sensor Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Required Tools
• Breakout Harness ZTSE4960
• Digital Multimeter (DMM)

Figure 92 MAF Circuit Test

Test 1
A. Key-Off.

B. Disconnect Mass Air Flow (MAF) sensor.

C. Connect Breakout Harness ZTSE4960 to vehicle harness and leave MAF sensor disconnected.

D. Key-On Engine-Off (KOEO).

 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 323

Figure 93 MAF ACT PWR Circuit Test

Test 2
A. Key-Off.
B. Disconnect Mass Air Flow (MAF) sensor.
C. Connect Breakout Harness ZTSE4960 to vehicle harness and leave MAF sensor disconnected.
D. Key-On Engine-Off (KOEO).
324 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 94 MAF GND Circuit Test

Test 3
A. Key-Off.
B. Disconnect Mass Air Flow (MAF) sensor.
C. Connect Breakout Harness ZTSE4960 to vehicle harness and leave MAF sensor disconnected.
D. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 325

SPN 132 FMI 11 - MAF Sensor Calibration - Insufficient number of data points

Fault Overview
Fault code sets when Mass Air Flow (MAF) sensor calibration fails due to entry criteria not being met.

Lamp Reaction
Amber Warning Lamp (AWL) illuminates when fault is active.

Associated Faults
None

Fault Facts
Engine Coolant Temperature (EOT) and Engine Oil Temperature (EOT) must be at or above 176°F (80°C) during
entire MAF calibration procedure.

Drive Cycle to Determine Fault Status

MAF Sensor Calibration.
Possible Causes
• Incorrect MAF programming
• Intake air system (boost) leaks or restrictions
• Restricted or non-Origional Equipment Manufacture (OEM) air filter
• Exhaust manifold leaks
• Intake Manifold Pressure (IMP) sensor or bore restricted, or circuit problem
• Intake Manifold Temperature (IMT) sensor or bore restricted, or circuit problem
• Exhaust Back Pressure (EBP) sensor or bore restricted, or circuit problem
• MAF sensor or circuit damage
• Turbocharger coking
• EGR mixer housing restriction
• EGR valve sticking
• EGR cooler restriction
• Turbocharger 2 Wastegate Control (TC2WC) valve or boost lines damaged or leaking

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for Yes: Go to Step 2.
SPN 132 FMI 11.
Is EST DTC list SPN 132 FMI 11 active or pending? No: Repair active faults. After
repairs are complete, retest for
SPN 132 FMI 11.
326 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 2 Determine if MAF Sensor Calibration will pass. Decision

Perform MAF Sensor Calibration (page 1539). Yes: Clear previously active MAF
fault. After repairs are complete,
retest for SPN 132 FMI 11.
Did MAF Sensor Calibration pass? No: Go to Step 3.

Figure 95 MAF Configuration Example in Navistar® Service Portal

1. Components tab
2. “VEPS PROG” under
Description column
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 327

Figure 96 MAF Configuration Example in Navistar® Engine Diagnostics

1. Parameters tab 2. MAF Configuration Selection 3. ID 99131
Value

Step 3 Determine if MAF configuration in Navistar® Service Portal, and Decision

Navistar® Engine Diagnostics match.
A. Open web browser and go to Navistar® Service Portal. Yes: Go to Step 4.

B. Enter last 8 digits of Vehicle Identification Number (VIN) in Chassis/VIN

Number field (upper right).
C. Select Components tab (1), navigate to “VEPS PROG” under Description
(2) (Figure 95), and determine AIR FLOW SENSOR Programmable
Parameter number.
D. Use EST with Navistar® Engine Diagnostics, select: View > Parameters.
E. Select Parameters tab (1), navigate to ID 99131 (3), and determine MAF
Configuration Selection Value (Figure 96).
Monaco RV 405 hp, Monaco RV 350 hp, and KME Fire truck 405 hp MAF
configurations should be 5.
Does AIR FLOW SENSOR Programmable Parameter number from Navistar® No: Open a Tech Services
Service Portal, and MAF Configuration Selection Value in Navistar® Engine Case File and request MAF
Diagnostics match? configuration programming. After
repairs are complete, retest for
SPN 132 FMI 11.
328 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 4 Determine if MAFT Co-efficients are set to 0.00. Decision

®
A. Use EST with Navistar Engine Diagnostics, select: View > Parameters. Yes: Open a Tech Services Case
File. After repairs are complete,
B. Select: Parameters tab, navigate to ID 99393 MAFT Co-efficient A1, and
retest for SPN 132 FMI 11.
99403 MAFT Co-efficient B1.

C. Determine MAFT Co-efficient A1, and B1 Value.

Are MAFT Co-efficients A1 and B1 both set to 0.00? No: Go to Step 5.

Step 5 Determine if air filter and intake air system are leaking, damage or Decision
restricted.
Perform Intake Air Inspection (page 1648) and Charge Air Cooler Inspection (page Yes, minor leak: Repair air
1646). intake system leaks, damage or
restrictions. Go to Step 6.
Are intake air system components leaking, damaged or restricted? Yes, major leak: Repair air
intake system leaks, damage
or restrictions. Rerun MAF
calibration.
No: Go to Step 6.

Step 6 Determine if exhaust manifold has excessive leaks. Decision

Inspect exhaust manifold for excessive leaks, soot accumulation, and cracks; Yes: Install new exhaust manifold
especially near cylinder 6 exhaust port. Go to 11.0 Soot Buildup at Exhaust Manifold kit. After repairs are complete,
/ Gasket Out of Position (page 45). retest for SPN 132 FMI 11.
Does exhaust manifold have excessive leaks or cracks? No: Go to Step 7.

Step 7 Determine if MAF sensor, connector, wiring, and/or terminals are Decision
damaged or corroded.
A. Turn ignition Key-Off. Yes: Repair connector, wiring,
terminal, pin damage or corrosion.
B. Disconnect MAF sensor connector.
After repairs are complete. Retest
C. Inspect MAF sensor, connector, wiring and terminals for: for SPN 132 FMI 11.

• Damaged or pinched wires

• Corroded terminals

• Loose, bent or broken pins

• Damaged connector housing
Are MAF sensor, connector, wiring, and terminals damaged, loose or corroded? No: Go to Step 8.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 329

Step 8 Determine if KOEO Intake Manifold Pressure (IMP), Intake Manifold Decision
Temperature (IMT), and Exhaust Back Pressure (EBP) are within
specification.
A. Turn ignition Key-On, Engine-Off (KOEO). Yes: Go to Step 9.
B. Use EST with Navistar® Engine Diagnostics Select: Pressure tab.
C. Determine Intake Manifold Pressure, and Exhaust Back Pressure Value.

D. Select: Temperature tab, and determine Intake Manifold Temperature

Value.
E. Compare Navistar® Engine Diagnostics values to specifications.
EBP, IMP, KOEO Specification is greater than 0 psi (atmospheric pressure)
Are Intake Manifold Pressure, Intake Manifold Temperature, and Exhaust Back No: Diagnosis IMP, IMT, and/or
Pressure within specifications? EBP circuit problem(s). Then go
to Step 9.

Step 9 Determine if IMP and IMT sensors or bores are coked, restricted, or Decision
damaged.
A. Remove IMP and IMT sensors. See Engine Service Manual. Yes: Clean sensors and sensor
bores. Replace damaged
B. Inspect IMP and IMT sensors and bores for carbon build up, coking,
sensors. After repairs are
restrictions and damage.
complete, retest for SPN 132 FMI
11.
Do sensors or sensor bores have carbon build up, coking, restrictions, or damage? No: Go to Step 10.

Step 10 Determine if vehicle is a Monaco RV with Rated Power of 350 hp. Decision
Use EST with Navistar® Engine Diagnostics, determine vehicles Rated Power listed Yes: Go to Step 11.
in Vehicle Information tab on default page.
Is this a Monaco RV with Rated Power of 350 hp? No: Go to Step 12.

Step 11 Determine if Monaco RV 350 hp has low power. Decision

Determine if Monaco RV 350 hp has low power. Yes: Go to 5.0 - Engine Running,
Engine Under Load Operational
Checkout Procedure(page 31)
Step 3. After repairs are complete,
retest for SPN 132 FMI 11.
Does vehicle have a low power problem? No: Open a Tech Services Case
File and request programming of
MAF Co-efficients A1 and B1.
330 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 97 MAF Sensor Calibration Recording (Typical)

1. Engine Speed 2. MAF Mean Value maximum 3. Graph boxes

Step 12 Determine if MAF Mean Value maximum was greater than 1500 mg Decision
during MAF Sensor Calibration.
A. Use EST with Navistar® Engine Diagnostics select: File > Open Snapshot Yes: Go to Step 14.
Recording File.
B. Select and Open MAF Sensor Calibration previously recorded.
C. Select Graph box (3) for: Engine Speed (1) and MAF Mean Value (Figure
97).
Is MAF Mean Value maximum (2) greater than 1500 mg? No: Go to Step 13.

Step 13 Determine if turbocharger has coking. Decision

A. Remove turbocharger air inlet duct. See Engine Service Manual. Yes: Perform 7.2 Engine Oil
Leak to Intake (page 103).
B. Inspect turbocharger for coking / soot build up on impeller. Medium to light
Perform Dual Turbocharger
coking does not affect engine performance.
Compressor Cleaning and
Inspection procedure in Engine
Service Manual. After repairs are
complete, retest for SPN 132 FMI
11.
Does turbocharger have coking? No: Go to Step 14.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 331

Step 14 Determine if Charge Air Cooler (CAC) or hoses are restricted. Decision
A. Remove CAC hoses. Yes: Clean or replace restricted
component(s). After repairs are
B. Inspect CAC hoses for internal damage.
complete, retest for SPN 132 FMI
C. Inspect CAC for carbon buildup and restrictions. 11.
Is CAC and/or CAC hoses restricted? No: Go to Step 15.

Step 15 Determine if air management system is operating properly. Decision

Perform Air Management Test (page 1376). Yes: Go to Step 19.
Is Intake Manifold Pressure (IMP), and MAF Mean Value Difference within No, only IMP out of specification:
specification? Replace IMP sensor. After repairs
are complete, retest for SPN 132
FMI 11.
No, MAF Mean Value Difference
not within specification: Go to
Step 16.

Step 16 Determine if air and EGR mixer duct is restricted. Decision

A. Remove Engine Throttle Valve (ETV) assembly. See Engine Service Yes: Remove and clean air and
Manual. EGR mixer duct. Do not replace
EGR valve. Replace O-rings
B. Inspect air and EGR mixer duct assembly for restrictions and carbon
if needed. After repairs are
build up.
complete, retest for SPN 132 FMI
11.
Is a severe amount of carbon restricting air and EGR mixer duct? No: Go to Step 17.

Step 17 Determine if EGR valve is sticking. Decision

Perform Exhaust Gas Recirculation Valve (EGRV) Operational Test (page 1543) Yes: Install new EGR valve. After
5 time or more to determine if EGR valve is sticking. Do not remove EGR valve repairs are complete, retest for
unless it is stuck open more than 1/8 inch (3 mm). SPN 132 FMI 11.
Is EGR valve sticking? No: Go to Step 18.

Step 18 Determine if EGR cooler is restricted. Decision

Remove EGR cooler crossover duct. See Engine Service Manual. Yes: Replace EGR cooler. After
repairs are complete, retest for
SPN 132 FMI 11.
Is rear of EGR cooler restricted? No: Go to Step 19.

Step 19 Determine if boost control system is operating properly. Decision

Perform Boost Control System Test (page 1533). Yes: Go to Step 20.
Is boost control system operating properly? No: Repair or replace failed
component(s). After repairs are
complete, retest for SPN 132 FMI
11.
332 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 20 Determine if leaks are present in Charge Air Cooler (CAC) system. Decision
Perform High-Pressure Charge Air Cooler (HPCAC) Pressure Test. (page 1545) Yes: Go to Step 21.
Does CAC system pass test? No: Repair CAC leaks. After
repairs are complete, retest for
SPN 132 FMI 11.

Step 21 Determine if turbocharger has coking. Decision

A. Remove turbocharger air inlet duct. See Engine Service Manual. Yes: Perform 7.2 Engine Oil
Leak to Intake (page 103).
B. Inspect turbocharger for coking/soot build up on impeller. Medium to light
Perform Dual Turbocharger
coking does not affect engine performance.
Compressor Cleaning and
Inspection procedure in Engine
Service Manual. After repairs are
complete, retest for SPN 132 FMI
11.
Does turbocharger have coking? No: Verify each step was
completed correctly and proper
decision was made. If SPN 132
FMI 11 remains contact Tech
Services.

End Diagnostic Step

After performing all diagnostic steps, if SPN 132 FMI 11 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 333

SPN 132 FMI 13 - MAF Sensor Calibration Needed

Fault Overview
Fault code sets when Engine Control Module (ECM) has been programmed and Mass Air Flow (MAF) sensor
needs to be calibrated.

Lamp Reaction
Amber Warning Lamp (AWL) illuminates when this fault is active.

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Key-On
Possible Causes
• Improperly calibrated MAF
334 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Determine if SPN 132 FMI 13 is active. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON Yes: Go to Step 2.
Engine OFF (KOEO), check Diagnostic Trouble Codes (DTC) list for SPN 132
FMI 13.
Is SPN 132 FMI 13 active? No: Clear fault codes. After
repairs are complete, retest for
SPN 132 FMI 13.

Step 2 Determine if MAF Sensor Calibration will pass. Decision

Perform MAF Sensor Calibration (page 1539). Yes: Clear previously active MAF
fault. After repairs are complete,
retest for SPN 132 FMI 13.
Did MAF Sensor Calibration pass? No: Go to SPN 132 FMI 11 fault
code diagnostics.

End Diagnostic Step

After performing diagnostic steps, if SPN 132 FMI 13 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 335

SPN 132 FMI 14 - MAF Sensor Calibration Failed

Fault Overview
Fault code sets when Mass Air Flow (MAF) sensor calibration fails.

Lamp Reaction
Amber Warning Lamp (AWL) illuminates when fault is active.

Associated Faults
None

Fault Facts
Engine Coolant Temperature (EOT) and Engine Oil Temperature (EOT) must be at or above 176°F (80°C) during
entire MAF calibration procedure.

Drive Cycle to Determine Fault Status

MAF Sensor Calibration.
Possible Causes
• Incorrect MAF programming
• Intake air system (boost) leaks or restrictions
• Restricted or non-Origional Equipment Manufacture (OEM) air filter
• Exhaust manifold leaks
• Intake Manifold Pressure (IMP) sensor or bore restricted, or circuit problem
• Intake Manifold Temperature (IMT) sensor or bore restricted, or circuit problem
• Exhaust Back Pressure (EBP) sensor or bore restricted, or circuit problem
• MAF sensor or circuit damage
• Turbocharger coking
• EGR mixer housing restriction
• EGR valve sticking
• EGR cooler restriction
• Turbocharger 2 Wastegate Control (TC2WC) valve or boost lines damaged or leaking

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for Yes: Go to Step 2.
SPN 132 FMI 14.
Is SPN 132 FMI 14 Active or pending? No: Repair Active Faults. After
repairs are complete, retest for
SPN 132 FMI 14.
336 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 2 Determine if MAF Sensor Calibration will pass. Decision

Perform MAF Sensor Calibration (page 1539). Yes: Clear previously active MAF
fault. After repairs are complete,
retest for SPN 132 FMI 14.
Did MAF Sensor Calibration pass? No: Go to SPN 132 FMI 11 (Step
3) fault code diagnostics. (page
327)

End Diagnostic Step

After performing all diagnostic steps, if SPN 132 FMI 14 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 337

SPN 132 FMI 31 - MAF Frequency not detected

Fault Overview
Fault sets when Engine Control Module (ECM) detects a short to PWR, short to GND, or an Open circuit in Mass
Air Flow (MAF) sensor circuits.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Open or high resistance in ACT PWR circuit
• Open or high resistance in MAF GND circuit
• Open or high resistance in MAF circuit
• Short to GND in MAF circuit
• Short to PWR in MAF circuit
• Failed MAF
338 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON Yes: Go to Step 2.
Engine OFF (KOEO), check Diagnostic Trouble Codes (DTC) list for SPN 132
FMI 31.
Is EST DTC list SPN 132 FMI 31 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 2 Inspect connections at Mass Air Flow (MAF) connector. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect MAF connector.
C. Check MAF and connector terminals for: damaged or pinched wires;
moisture or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are MAF connector, harness, and terminals clean and undamaged? No: Repair connector, harness, or
terminal damage. After repairs are
complete, retest for SPN 132 FMI
31.

Step 3 Inspect connections at 24-pin Engine to Chassis connector. Decision

A. Key OFF. Yes: Go to Step 4.
B. Disconnect 24-pin Engine to Chassis connector.
C. Check 24-pin Engine to Chassis and connector terminals for: damaged
or pinched wires; moisture or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are 24-pin Engine to Chassis connector, harness, and terminals clean and No: Repair connector, harness, or
undamaged? terminal damage. After repairs are
complete, retest for SPN 132 FMI
31.

Step 4 Check for power to MAF. Decision

A. Perform Test 1 (page 341). Yes: Go to Step 7.
B. Use DMM, measure voltage between Breakout Harness ZTSE4960 pin-D
and pin-E.
Is voltage B+ ± 0.5 volts? No: Go to Step 5.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 339

Step 5 Check for open in ACT PWR circuit. Decision

A. Perform Test 2 (page 342). Yes: Go to Step 6.
B. Use DMM, measure voltage between Breakout Harness ZTSE4960 pin-D
and known good GND.
Is voltage B+ ± 0.5 volts? No: Repair ACT PWR circuit.
After repairs are complete, retest
for SPN 132 FMI 31.

Step 6 Check for open in MAF GND circuit. Decision

A. Perform Test 3 (page 343). Yes: Repair open in MAF GND
circuit between 24-pin Engine to
B. Use DMM, measure voltage between Breakout Harness ZTSE6020 pin-3
Chassis connector pin-3 and MAF
and B+.
pin-E. After repairs are complete,
retest for SPN 132 FMI 31.
Is voltage B+ ± 0.5 volts? No: Repair open in MAF GND
circuit between ECM pin E-12
and 24-pin Engine to Chassis
connector pin-3. After repairs are
complete, retest for SPN 132 FMI
31.

Step 7 Check for expected reference voltage in MAF circuit. Decision

A. Perform Test 4 (page 343). Yes: Replace MAF. After repairs
are complete, retest for SPN 132
B. Use DMM, measure voltage between Breakout Harness ZTSE4960 pin-C
FMI 31.
and known good GND.
Is voltage 5 ± 0.5 volts? No: Go to Step 8.

Step 8 Check for short to GND in MAF circuit. Decision

A. Perform Test 5 (page 344). Yes: Go to Step 9.
B. Use DMM, measure voltage between Breakout Harness ZTSE4960 pin-D
and pin-C.
Is voltage B+ ± 0.5 volts? No: Go to Step 10.

Step 9 Check for short to GND in MAF circuit. Decision

A. Perform Test 6 (page 345). Yes: Repair short to GND in MAF
circuit between ECM pin E-67
B. Use DMM, measure voltage between Breakout Harness ZTSE6020 pin-1
and 24-pin Engine to Chassis
and pin-4.
connector pin-4. After repairs are
complete, retest for SPN 132 FMI
31.
Is voltage B+ ± 0.5 volts? No: Repair short to GND in MAF
circuit between 24-pin Engine to
Chassis connector pin-4 and MAF
340 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

pin-C. After repairs are complete,

retest for SPN 132 FMI 31.

Step 10 Check for open in MAF circuit. Decision

A. Perform Test 7 (page 346). Yes: Go to Step 12.
B. Use DMM, measure voltage between Breakout Harness ZTSE4960 pin-C
and known good GND.
Is voltage greater than 5.5 volts? No: Go to Step 11.

Step 11 Check for expected reference voltage in MAF circuit. Decision

A. Perform Test 8 (page 347). Yes: Repair open in MAF circuit
between 24-pin Engine to Chassis
B. Use DMM, measure voltage between Breakout Harness ZTSE6020 pin-4
connector pin-4 and MAF pin-C.
and known good GND.
After repairs are complete, retest
for SPN 132 FMI 31.
Is voltage 5 ± 0.5 volts? No: Repair open in MAF circuit
between ECM pin E-67 and 24-pin
Engine to Chassis connector
pin-4. After repairs are complete,
retest for SPN 132 FMI 31.

Step 12 Check for short to PWR in MAF circuit. Decision

A. Perform Test 9 (page 347). Yes: Repair short to PWR in MAF
circuit between ECM pin E-67
B. Use DMM, measure voltage between Breakout Harness ZTSE6020 pin-4
and 24-pin Engine to Chassis
and known good GND.
connector pin-4. After repairs are
complete, retest for SPN 132 FMI
31.
Is voltage B+ ± 0.5 volts? No: Repair short to PWR in MAF
circuit between 24-pin Engine to
Chassis connector pin-4 and MAF
pin-C. After repairs are complete,
retest for SPN 132 FMI 31.

End Diagnostic Step

After performing diagnostic step, if SPN 132 FMI 31 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 341

Pin-Point Tests (SPN 132 FMI 31)

Figure 98 Mass Air Flow (MAF) Sensor Circuit Diagram

See latest version of Navistar® N9 and N10 Engine and Aftertreatment Wiring Schematic Form 0000003481 for
additional circuit information.
Tools Required
• Breakout Harness ZTSE4960
• Breakout Harness ZTSE6020
• Digital Multimeter (DMM)
342 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 99 MAF Circuit Check

Test 1
A. Key-Off.
B. Disconnect Mass Air Flow (MAF) sensor.
C. Connect Breakout Harness ZTSE4960 to vehicle harness and leave MAF sensor disconnected.
D. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 343

Figure 100 MAF Circuit Check

Test 2
A. Key-Off.
B. Disconnect Mass Air Flow (MAF) sensor.
C. Connect Breakout Harness ZTSE4960 to vehicle harness and leave MAF sensor disconnected.
D. Key-On Engine-Off (KOEO).

Figure 101 MAF Circuit Check

Test 3
A. Key-Off.

B. Disconnect 24-pin Engine to Chassis connector.

C. Connect Breakout Harness ZTSE6020 to engine harness and leave chassis harness disconnected.
D. Key-On Engine-Off (KOEO).
344 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 102 MAF Circuit Check

Test 4
A. Key-Off.
B. Disconnect Mass Air Flow (MAF) sensor.
C. Connect Breakout Harness ZTSE4960 to vehicle harness and leave MAF sensor disconnected.
D. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 345

Figure 103 MAF Circuit Check

Test 5
A. Key-Off.
B. Disconnect Mass Air Flow (MAF) sensor.
C. Connect Breakout Harness ZTSE4960 to vehicle harness and leave MAF sensor disconnected.
D. Key-On Engine-Off (KOEO).
346 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 104 MAF Circuit Check

Test 6
A. Key-Off.
B. Disconnect 24-pin Engine to Chassis connector.
C. Connect Breakout Harness ZTSE6020 to engine harness and leave chassis harness disconnected.
D. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 347

Figure 105 MAF Circuit Check

Test 7
A. Key-Off.
B. Disconnect Mass Air Flow (MAF) sensor.
C. Connect Breakout Harness ZTSE4960 to vehicle harness and leave MAF sensor disconnected.
D. Key-On Engine-Off (KOEO).

Figure 106 MAF Circuit Check

Test 8
A. Key-Off.

B. Disconnect 24-pin Engine to Chassis connector.

C. Connect Breakout Harness ZTSE6020 to engine harness and leave chassis harness disconnected.
D. Key-On Engine-Off (KOEO).
348 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 107 MAF Circuit Check

Test 9
A. Key-Off.
B. Disconnect 24-pin Engine to Chassis connector.
C. Connect Breakout Harness ZTSE6020 to engine harness and leave chassis harness disconnected.
D. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 349

SPN 158 FMI 15 - ECM Switched Voltage Too HIGH

Fault Overview
Fault sets when Engine Control Module (ECM) switched voltage is too high.

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

Associated Faults
None

Fault Facts
This fault may set if vehicle has been jump-started or charged using a 24V power supply.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Charging voltage excessive
• Incorrect battery pack wiring (series instead of parallel)
350 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON Yes: Go to Step 2.
Engine OFF (KOEO), check Diagnostic Trouble Codes (DTC) list for SPN 158
FMI 15.
Is SPN 158 FMI 15 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Figure 108 Check Battery Pack Wiring

Step 2 Check for correct parallel battery pack wiring. Decision

Check positive battery cable(s) connected from positive battery terminal to positive Yes: Perform Electrical System
battery terminal. Check negative battery cable(s) connected from negative battery Test (page 1577). If charging
terminal to negative battery terminal. system fails, replace alternator
and retest for SPN 158 FMI 15.
Is battery pack correctly assembled (wired in parallel and not in series)? No: Reassemble battery pack.
After repairs are complete, retest
for SPN 158 FMI 15.

End Diagnostic Tests

After performing diagnostic steps, if SPN 158 FMI 15 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 351

SPN 158 FMI 17 - ECM Switched voltage too LOW

Fault Overview
Fault sets when Engine Control Module (ECM) switched voltage is too low with battery voltage within normal
operating range.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Low battery or charging system voltage
• Failed ECM PWR Relay
• ECM PWR circuit Open or short to GND
• GND circuit Open or high resistance

WARNING:

To prevent property damage, personal injury, or death, keep flames or sparks away from
vehicle and do not smoke while servicing vehicle’s batteries.

To prevent property damage, personal injury, or death, disconnect ground battery

terminal first. When reconnecting battery cables, connect positive cables first, and then
reconnect negative cables.

To prevent property damage, personal injury, or death, wear eye protection when working
near batteries.
352 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON Yes: Go to Step 2.
Engine OFF (KOEO), check Diagnostic Trouble Codes (DTC) list for SPN 158
FMI 17.
Is SPN 158 FMI 17 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Inspect battery connections and terminals. Decision

Perform Batteries and Electrical System Inspection (page 1666). Yes: Go to Step 3.
Are batteries, electrical system, and connections in good condition, tight, not No: Repair broken, loose,
corroded, and is battery voltage in specification? or corroded electrical system
connections or components.
Charge batteries. After repairs are
complete, go to Step 3.

Step 3 ECM PWR relay connector inspection. Decision

A. Key OFF. Yes: Go to Step 4.
B. Disconnect ECM PWR relay.
C. Check ECM PWR relay and relay terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are ECM PWR relay connectors, harness, and terminals clean and undamaged? No: Repair connector, harness, or
terminal damage. After repairs are
complete, retest for SPN 158 FMI
17.

Step 4 Check ECM PWR relay circuit voltage. Decision

A. Perform Test 1 (page 354). Yes: Go to Step 8.
B. Use DMM, measure voltage between Breakout Harness ZTSE4674 pin-87
and known good GND.
Is voltage B+ ± 0.5 volts? No: Go to Step 5.

Step 5 Check for failed ECM PWR relay. Decision

A. Perform Test 2 (page 354). Yes: Go to Step 6.

B. Use DMM, measure voltage between Breakout Harness ZTSE4674 pin-30

and known good GND.
Is voltage B+ ± 0.5 volts? No: Repair Open or high
resistance between ECM PWR
relay pin-30 and B+. After repairs
are complete, retest for SPN 158
FMI 17.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 353

Step 6 Check for failed ECM PWR Relay. Decision

A. Perform Test 3 (page 355). Yes: Go to Step 7.
B. Use DMM, measure voltage between Breakout Harness ZTSE4674 pin-86
and known good GND.
Is voltage B+ ± 0.5 volts? No: Repair Open or high
resistance between ECM PWR
relay pin-86 and B+. After repairs
are complete, retest for SPN 158
FMI 17.

Step 7 Check for failed ECM PWR relay. Decision

A. Perform Test 4 (page 356). Yes: Replace ECM PWR Relay.
After repairs are complete, retest
B. Use DMM, measure voltage between Breakout Harness ZTSE4674 pin-85
for SPN 158 FMI 17.
and B+.
Is voltage B+ ± 0.5 volts? No: Repair Open or high
resistance between ECM PWR
relay pin-85 and ECM pin C-70.
After repairs are complete, retest
for SPN 158 FMI 17.

Step 8 Check for Open or high resistance to connector 9260. Decision

A. Perform Test 5 (page 357). Yes: Go to Step 9.
B. Use DMM, measure voltage between connector 9260 pin-C and B+.
Is voltage B+ ± 0.5 volts? No: Repair high resistance
between pin-C and GND. After
repairs are complete, retest for
SPN 158 FMI 17.

Step 9 Check for Open or high resistance to connector 9260. Decision

A. Perform Test 6 (page 358). Yes: Repair Open or high
resistance either between
B. Use DMM, measure voltage between connector 9260 pin-A and B+.
connector 9260 and ECM pin C-2,
4, and 6, or between ECM PWR
Relay pin-87 and ECM pin C-1, 3,
and 5. After repairs are complete,
retest for SPN 158 FMI 17.
Is voltage B+ ± 0.5 volts? No: Repair high resistance
between pin-A and GND. After
repairs are complete, retest for
SPN 158 FMI 17.

End Diagnostic Steps

After performing diagnostic steps, if SPN 158 FMI 17 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
354 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 158 FMI 17)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4674
• International® Electronic Engine Terminal Test Kit ZTSE4435C
• Digital Multimeter (DMM)

Figure 109 ECM PWR Relay Circuit Check

Test 1
A. Key-Off.
B. Disconnect Engine Control Module (ECM) PWR relay connector.
C. Connect Breakout Harness ZTSE4674 between vehicle harness and ECM PWR relay.
D. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 355

Figure 110 ECM PWR Relay Circuit Check

Test 2
A. Key-Off.
B. Disconnect ECM PWR relay connector.
C. Connect Breakout Harness ZTSE4674 between vehicle harness and ECM PWR relay, leave ECM PWR
relay connector disconnected.
D. Key-On Engine-Off (KOEO).
356 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 111 ECM PWR Circuit Check

Test 3
A. Key-Off.
B. Disconnect ECM PWR relay connector.
C. Connect Breakout Harness ZTSE4674 between vehicle harness and ECM PWR relay, leave ECM PWR
relay connector disconnected.
D. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 357

Figure 112 ECM PWR Circuit Check

Test 4
A. Key-Off.
B. Disconnect ECM PWR relay connector.
C. Connect Breakout Harness ZTSE4674 between vehicle harness and ECM PWR relay, leave ECM PWR
relay connector disconnected.
D. Key-On Engine-Off (KOEO).
358 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 113 ECM PWR Circuit Check

Test 5
A. Key-Off.
B. Disconnect 9260 connector.
C. Use Terminal Test Kit ZTSE4435C, insert correct terminal into connector 9260 pin-C battery side and leave
connector 9260 ECM side disconnected.
D. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 359

Figure 114 ECM PWR Circuit Check

Test 6
A. Key-Off.
B. Disconnect 9260 connector.
C. Use Terminal Test Kit ZTSE4435C, insert correct terminal into connector 9260 pin-A battery side and leave
connector 9260 ECM side disconnected.
D. Key-On Engine-Off (KOEO).
360 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 164 FMI 0 - ICP above KOEO Spec

Fault Overview
Fault sets when Engine Control Module (ECM) detects Injection Control Pressure (ICP) sensor voltage is offset
during check at Key OFF.

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

Associated Faults
None

Fault Facts
Do not replace Injection Control Pressure (ICP) sensor unless directed by diagnostic procedure.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• ECM calibration out of date
• ICP sensor
• ICP circuit shorted or high resistance

Step 1 Check ECM calibration. Decision

Using calibration scorecard or NavKal, check ECM calibration. Yes: Go to Step 2.
Is ECM calibration current? No: Update ECM calibration,
clear codes, cycle Key OFF for 30
seconds. After calibration update,
retest for SPN 164 FMI 0.

Step 2 Determine if ICP voltage is out of range high during Continuous Decision
Monitor Test.
Perform Continuous Monitor Test (page 1361)while monitoring ICP voltage. Yes: Replace ICP sensor. After
repairs are complete, retest for
SPN 164 FMI 0.
Is ICP Voltage greater than 0.55 volts? No, voltage displays “ERROR”:
Go to Step 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 361

Step 3 Determine if ICP circuit between UVC #1 connector and 36-Pin ECM Decision
Driver connector is shorted or has high resistance.
A. Key OFF. Disconnect UVC #1 connector at the valve cover front left. Yes: Go to Step 4.
B. Key ON. Using EST, clear codes by clicking the Clear DTCs button.

C. Check Diagnostic Trouble Code (DTC) list.

Is SPN 164 FMI 3 Pending or Active? No: Repair ICP circuit between
the UVC #1 connector pin-6 and
36-pin ECM Driver connector pin
D-15. After repairs are complete,
retest for SPN 164 FMI 0.

Step 4 Determine if ICP circuit between UVC harness ICP connector and Decision
UVC #1 connector is shorted or has high resistance.
A. Key OFF. Reconnect engine harness to UVC #1 connector. Yes: Replace ICP sensor. After
repairs are complete, retest for
B. Remove valve cover. See Engine Service Manual for additional information.
SPN 164 FMI 0.
C. Disconnect ICP sensor connector.
D. Key ON. Using EST, clear codes by clicking the Clear DTCs button.
E. Check Diagnostic Trouble Code (DTC) list.
Is SPN 164 FMI 3 Pending or Active? No: Repair ICP circuit between
UVC ICP harness connector pin-3
and UVC #1 connector pin-6.
After repairs are complete, retest
for SPN 164 FMI 0.

End Diagnostic Steps

After performing all diagnostic steps, if SPN 164 FMI 0 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
362 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 164 FMI 1 - ICP Unable to Build During Engine Cranking

Fault Overview
Fault code sets when Injection Control Pressure (ICP) is lower than 3.5 MPa while engine is cranking for 2.5
seconds.

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

Associated Faults
• SPN 164 FMI 3 and 4 • SPN 679 FMI 3 and 4
(ICP) (IPR)

Fault Facts
Do not replace Injection Control Pressure (ICP) sensor unless directed by diagnostic procedure. If High-Pressure
Oil Pump (HPOP) is replaced due to pump failure, remove and clean High-Pressure (HP) oil rail, HP oil hose
and fittings to remove contamination or debris.

Drive Cycle to Determine Fault Status

Cranking
Possible Causes
• High-Pressure Oil Pump (HPOP)
• Restricted HPOP intake screen clogged
• Failed Injection Pressure Regulator (IPR) hydraulic and mechanical issues
• High-pressure oil leaks
• Failed fuel injectors
• IPR electrical circuit failures
• HP oil leaks at fuel injectors

Step 1 Check for associated faults. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 362).
Is EST DTC free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 164 FMI 1.

Step 2 Check for active fault code. Decision

Use EST with Navistar® Engine Diagnostics, check DTC list for SPN 164 FMI 1 (ICP). No: Repair Active faults. After
repairs are complete, retest for
SPN 164 FMI 1.
Does EST DTC show fault code SPN 164 FMI 1 as Active or Pending? Yes: Go to Step 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 363

Step 3 Check engine oil level. Decision

Perform Engine Oil Level and Quality Inspection (page 1635). Yes: Go to Step 4.
Is engine oil level within specifications and not contaminated? No: Perform 7.0 Engine Oil
System Operational Checkout
Procedure (page 36). After
repairs are complete, retest for
SPN 164 FMI 1.

Step 4 Inspect High-Pressure Oil Pump (HPOP) pump reservoir. Decision

Loosen Engine Oil Temperature (EOT) sensor and verify that HPOP reservoir has Yes: Go to Step 5.
oil in it.
Does HPOP reservoir have oil in it? No: Go to 7.0 Engine Oil System
Operational Checkout Procedure
(page 36). After repairs are
complete, retest for SPN 164 FMI
1.

Step 5 Test HPOP. Decision

Perform Cylinder Performance Analyzer (CPA) High-Pressure Oil Pump (HPOP) Yes: Repair as required, then
Test (page 1440). Follow on-screen instructions for test. perform Fuel Pressure Adaptation
Reset (page 1341) procedure.
After repairs are complete, retest
for SPN 164 FMI 1.
Were failed components identified? No: Retest for SPN 164 FMI 1.

End Diagnostic Steps

After performing all diagnostic steps, if SPN 164 FMI 1 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
364 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 164 FMI 2 - ICP signal erratic, intermittent, or incorrect

Fault Overview
Update calibration to prevent this fault code from falsely setting.

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

Associated Faults
None

Fault Facts
Do not replace Injection Control Pressure (ICP) sensor unless directed by diagnostic procedure.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• None

Step 1 Update calibration. Decision

This fault has been disabled. Update calibration and recheck for other active faults.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 365

SPN 164 FMI 3 - ICP signal Out of Range HIGH

Fault Overview
Fault code sets when Engine Control Module (ECM) detects Injection Control Pressure (ICP) signal greater than
4.9 volts.

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

Associated Faults
SPN 3509 FMI 3 and 4
(VREF 1)

Fault Facts
Do not replace Injection Control Pressure (ICP) sensor unless directed by diagnostic procedure.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• ICP circuit Open or high resistance
• ICP circuit short to PWR
• VREF 1 circuit Open or high resistance
• SIG GND circuit Open or high resistance
• Damaged Under Valve Cover (UVC) harness
• Failed ICP sensor
• Broken Locking tab or damage to harness connector

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 365).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 164 FMI 3.

Step 2 Check for active or pending fault code. Decision

Use EST with Navistar® Engine Diagnostics, check DTC list for SPN 164 FMI 3. Yes: Go to Step 3.
Is EST DTC list SPN 164 FMI 3 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).
366 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Inspect Under Valve Cover (UVC 1) connector 1. Decision

A. Key OFF. Yes: Go to Step 4.
B. Disconnect UVC 1 connector.
C. Check UVC 1 connector terminals for damaged or pinched wires; wet
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are UVC 1 connector, harness, and terminal clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 164
FMI 3.

Step 4 Check ICP circuit for Short to PWR Decision

A. Perform Test 1 (page 368). Yes: Repair short to PWR
between UVC pin-6 and ECM pin
B. Use DMM, measure voltage between Breakout Harness ZTSE4952 pin-6
D-15. After repairs are complete,
and known good GND.
retest for SPN 164 FMI 3.
Is voltage greater than 5.5 volts? No: Go to Step 5.

Step 5 Check VREF 1 circuit for Open or high resistance. Decision

A. Perform Test 2 (page 368). Yes: Go to Step 6.
B. Use DMM, measure voltage between Breakout Harness ZTSE4952 pin-8
and known good GND.
Is voltage 5.0 ± 0.5 volts? No: Repair Open or high
resistance between UVC pin-8
and ECM pin D-13. After repairs
are complete, retest for SPN 164
FMI 3.

Step 6 Check VREF 1 circuit for Open or high resistance. Decision

A. Perform Test 3 (page 369). Yes: Go to Step 8.
B. Use EST with Navistar® Engine Diagnostics, clear DTC list.
Does SPN 164 FMI 4 set after DTC list is cleared No: Go to Step 7.

Step 7 Check SIG GND circuit for Open or high resistance. Decision
A. Perform Test 4 (page 370). Yes: Repair Open between UVC
pin-7 and ECM pin D-14. After
B. Use EST with Navistar® Engine Diagnostics, clear DTC list.
repairs are complete, retest for
SPN 164 FMI 3.
Does SPN 164 FMI 4 set after DTC list is cleared? No: Repair Open between UVC
pin-6 and ECM pin D-15. After
repairs are complete, retest for
SPN 164 FMI 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 367

Step 8 Check for broken locking tab on or damage to harness connector. Decision
A. Perform Test 5 (page 371). Yes: Go to Step 9.
B. Use DMM, measure resistance between Breakout Harness ZTSE4952
pin-6 and Breakout Harness ZTSE4686 pin-3.
Is resistance less than 5 ohms? No: Replace UVC harness. After
repairs are complete, retest for
SPN 164 FMI 3.

Step 9 Check for broken Locking tab on or damage to harness connector. Decision
A. Perform Test 6 (page 372). Yes: Go to Step 10.
B. Use DMM, measure resistance between Breakout Harness ZTSE4952
pin-8 and Breakout Harness ZTSE4686 pin-2.
Is resistance less than 5 ohms? No: Replace UVC harness. After
repairs are complete, retest for
SPN 164 FMI 3.

Step 10 Check for failed ICP sensor. Decision

A. Perform Test 7 (page 373). Yes: Replace ICP sensor. After
repairs are complete, retest for
B. Use DMM, measure resistance between Breakout harness ZTSE4952
SPN 164 FMI 3.
pin-7 and Breakout Harness ZTSE4686 pin-1.
Is resistance less than 5 ohms? No: Replace UVC harness. After
repairs are complete, retest for
SPN 164 FMI 3.

End Diagnostic Tests

After performing diagnostic steps, if SPN 164 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
368 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 164 FMI 3)

Figure 115 ICP Sensor Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4498
• Breakout Harness ZTSE4686
• Breakout Harness ZTSE4952
• Digital Multimeter (DMM)

Figure 116 ICP Sensor Circuit Check

Test 1
A. Key OFF.

B. Disconnect Under Valve Cover (UVC) harness.

C. Connect Breakout Harness ZTSE4952 to engine harness and leave UVC harness disconnected.
D. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 369

Figure 117 ICP Sensor Circuit Check

Test 2
A. Key OFF.
B. Disconnect Under Valve Cover (UVC) harness.
C. Connect Breakout Harness ZTSE4952 to engine harness and leave UVC harness disconnected.
D. Key ON Engine OFF (KOEO).
370 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 118 ICP Sensor Circuit Check

Test 3
A. Key OFF.
B. Disconnect Under Valve Cover (UVC) harness.
C. Connect Breakout Harness ZTSE4952 to engine harness and leave UVC harness disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4952 pin-6 and pin-7 together.
E. Connect EST to vehicle Diagnostic Connector (page 1345)
F. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 371

Figure 119 ICP Sensor Circuit Check

Test 4
A. Key OFF.
B. Disconnect Under Valve Cover (UVC) harness.
C. Connect Breakout Harness ZTSE4952 to engine harness and leave UVC harness disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4952 pin-6 to known good GND.
E. Connect EST to vehicle Diagnostic Connector (page 1345)
F. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
372 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 120 ICP Sensor Circuit Check

Test 5
A. Key OFF.
B. Disconnect Under Valve Cover (UVC) harness.
C. Remove valve cover (See Engine Service Manual).
D. Connect Breakout Harness ZTSE4952 to UVC harness and leave engine harness disconnected.
E. Connect Breakout Harness ZTSE4686 to UVC harness leave Injection Control Pressure (ICP) sensor
disconnected.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 373

Figure 121 ICP Sensor Circuit Check

Test 6
A. Key OFF.
B. Disconnect Under Valve Cover (UVC) harness.
C. Remove valve cover (SeeEngine Service Manual).
D. Connect Breakout Harness ZTSE4952 to UVC harness and leave engine harness disconnected.
E. Connect Breakout Harness ZTSE4686 to UVC harness and leave Injection Control Pressure (ICP) sensor
disconnected.
374 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 122 ICP Sensor Circuit Check

Test 7
A. Key OFF.
B. Disconnect Under Valve Cover (UVC) harness.
C. Remove valve cover (See Engine Service Manual).
D. Connect Breakout Harness ZTSE4952 to UVC harness and leave engine harness disconnected.
E. Connect Breakout Harness ZTSE4686 to UVC harness leave Injection Control Pressure (ICP) sensor
disconnected.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 375

SPN 164 FMI 4 - ICP signal Out of Range LOW

Fault Overview
Fault code sets when Injection Control Pressure (ICP) sensor signal is less than 0.1 volts.

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

Associated Faults
SPN 3509 FMI 3 and 4
(VREF 1)

Fault Facts
Do not replace Injection Control Pressure (ICP) sensor unless directed by diagnostic procedure.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• ICP circuit short to GND
• Failed ICP sensor

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics, check Yes: Repair Associated Faults.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 375). After repairs are complete, retest
for SPN 164 FMI 4.
Does EST DTC list show Associated Faults as active? No: Go to Step 2.

Step 2 Check for active or pending fault code. Decision

®
Use EST with Navistar Engine Diagnostics, check DTC list for SPN 164 FMI 4. Yes: Go to Step 3.
Is EST DTC list SPN 164 FMI 4 active or pending? No: Go to intermittent diagnostic
procedures (page 1344).

Step 3 Inspect connections at Under Valve Cover (UVC) harness connector Decision
for ICP sensor.
A. Key OFF. No: Go to Step 4.

B. Disconnect UVC harness connector for ICP.

C. Check UVC harness and connector terminals for: damaged or pinched

wires; corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are UVC harness connector for ICP and connector terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
376 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

are complete, retest for SPN 164

FMI 4.

Step 4 Check ICP circuit for short to GND Decision

• Key-Off. Yes: Correct short to GND
between UVC vehicle harness
• Disconnect Under Valve Cover (UVC) harness for ICP sensor connector and
for ICP pin-6 and Engine Control
leave disconnected.
Module (ECM) pin D-15.
• Connect EST to vehicle Diagnostic Connector (page 1345).
• Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
• Use EST with Navistar® Engine Diagnostics, monitor DTC list for SPN 164
FMI 4.
Is fault code SPN 164 FMI 4 active? No: Go to Step 5.

Step 5 Check for failed ICP sensor Decision

A. Perform Test 1 (page 377). Yes: Repair short to GND
between UVC vehicle harness
B. Use DMM, measure resistance of between Breakout Harness ZTSE4793
for ICP pin-6 and ECM pin D-15.
pin-6 and known good GND.
After repairs are complete, retest
for SPN 164 FMI 4.
Is resistance approximately 0 ohms? No: Replace ICP sensor. After
repairs are complete, retest for
SPN 164 FMI 4.

End Diagnostic Tests

After performing diagnostic steps, if SPN 164 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 377

Pin-Point Tests (SPN 164 FMI 4)

Figure 123 ICP Sensor Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4793 (UVC)
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Figure 124 ICP Sensor Circuit Check

Test 1
A. Key OFF.

B. Disconnect UVC engine harness connector that leads under valve cover.
C. Connect Breakout harness ZTSE4793 to UVC engine harness connector that leads under valve cover and
leave vehicle harness disconnected.
378 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 164 FMI 10 - ICP signal abnormal rate of change

Fault Overview
Update calibration to prevent this fault code from falsely setting.

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

Associated Faults
None

Fault Facts
Do not replace Injection Control Pressure (ICP) sensor unless directed by diagnostic procedure.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• None

Step 1 Update calibration. Decision

This fault has been disabled. Update calibration and recheck for other active faults.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 379

SPN 164 FMI 13 - ICP adaptation In-Range fault

Fault Overview
Update calibration to prevent this fault code from falsely setting.

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

Associated Faults
None

Fault facts
Do not replace Injection Control Pressure (ICP) sensor unless directed by diagnostic procedure.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• None

Step 1 Update calibration. Decision

This fault has been disabled. Update calibration and recheck for other active faults.
380 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 164 FMI 15 - ICP too high during test

Fault Overview
Fault sets when Engine Control Module (ECM) detects Injection Control Pressure (ICP) exceeds set point by
threshold value for current engine speed and torque.

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

Associated Faults
• SPN 164 FMI 1, 3, and • SPN 679 FMI 3 and 4 (IPR) • SPN 3055 FMI 2 (INJ)
4 (ICP)

Fault Facts
Do not replace Injection Control Pressure (ICP) sensor unless directed by diagnostic procedure.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed Injection Pressure Regulator (IPR) valve
• Contaminated Oil

Step 1 Inspect vehicle history for high-pressure oil system repairs Decision
Determine if vehicle history included high-pressure oil system repairs. Yes: Perform Fuel Pressure
Adaptation Reset (page 1341).
Retest for SPN 164 FMI 17.
Were high-pressure oil system repairs recently performed? No: Go to Step 2.

Step 2 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 3.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 380).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 164 FMI 15.

Step 3 Check for engine oil problems. Decision

Perform Engine Oil Level and Quality Inspection (page 1635). Yes: Go to Step 4.
Is engine oil at proper level and in good condition? No: Go to 7.0 Engine Oil System
Operational Checkout Procedure
(page 36). After repairs are
complete, retest for SPN 164 FMI
15.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 381

Step 4 Determine if high-pressure oil system is operating properly. Decision

Perform CPA High-Pressure Oil Pump (HPOP) Test (page 1440). Yes: Repair failed component(s).
After repairs are complete, retest
for SPN 164 FMI 15.
Was a failed component identified? No: End Diagnostics. Retest for
SPN 164 FMI 15.

End Diagnostic Steps

After performing diagnostic steps, if SPN 164 FMI 15 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
382 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 164 FMI 16 - ICP above desired level

Fault Overview
Fault sets when Engine Control Module (ECM) detects Injection Control Pressure (ICP) exceeds set point by
threshold value for current engine speed and torque.

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

Associated Faults
• SPN 164 FMI 0, 1, 3, and • SPN 679 FMI 3 and 4
4 (ICP) (IPR)

Fault Facts
Do not replace Injection Control Pressure (ICP) sensor unless directed by diagnostic procedure.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed Injection Pressure Regulator (IPR) valve
• High-Pressure Oil Pump (HPOP)

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 382).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 164 FMI 16.

Step 2 Inspect vehicle history for High-Pressure (HP) oil system repairs Decision
Determine if vehicle history included HP oil system repairs. Yes: Perform Fuel Pressure
Adaptation Reset (page 1341).
Retest for SPN 164 FMI 16.
Were HP oil system repairs recently performed? No: Go to Step 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 383

Step 3 Check for engine oil problems. Decision

Perform Engine Oil Level and Quality Inspection (page 1635). Yes: Go to Step 4.
Is engine oil at proper level and in good condition? No: Go to 7.0 Engine Oil System
Operational Checkout Procedure
(page 36). After repairs are
complete, retest for SPN 164 FMI
15.

Step 4 Test HPOP Injection Pressure Regulator (IPR) electrical circuit. Decision
Perform CPA High-Pressure Oil Pump (HPOP) Test (page 1440). Yes: Repair IPR circuit. After
repairs are complete, retest for
SPN 164 FMI 16.
Does HPOP Test detect a problem with IPR valve electrical circuit? No: Go to Step 5.

Step 5 Mechanically test IPR valve hydraulic circuit. Decision

Review results from CPA HPOP Test (page 1440). Yes: Replace IPR valve, then
perform Fuel Pressure Adaptation
Reset (page 1341). After repairs
are complete, retest for SPN 164
FMI 16.
Does HPOP Test detect a problem with IPR valve hydraulic circuit? No: Diagnostics complete.

End Diagnostic Steps

After performing diagnostic steps, if SPN 164 FMI 16 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
384 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 164 FMI 17 - ICP unable to build during test

Fault Overview
Fault sets when Engine Control Module (ECM) detects Injection Control Pressure (ICP) value remains below
set point by threshold value for current engine speed and torque.

Lamp Reaction
No Lamp

Associated Faults
• SPN 164 FMI 1, 3, and 4 • SPN 679 FMI 3 and 4 • SPN 3055 FMI 2 (INJ)
(ICP) (IPR)

Fault Facts
Do not replace Injection Control Pressure (ICP) sensor unless directed by diagnostic procedure.

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• Restricted High-Pressure Oil Pump (HPOP) intake screen
• Failed HPOP
• Injection Pressure Regulator (IPR) electrical circuit
• Failed IPR
• Leaks in High-Pressure (HP) oil system
• Failed injectors and pucks

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 384).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 164 FMI 17.

Step 2 Inspect vehicle history for HP oil system repairs Decision

Determine if vehicle history included high-pressure oil system repairs. Yes: Perform Fuel Pressure
Adaptation Reset (page 1341)
procedure. Retest for SPN 164
FMI 17.
Were HP oil system repairs recently performed? No: Go to Step 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 385

Step 3 Check for engine oil problems. Decision

Perform Engine Oil Level and Quality Inspection (page 1635). Yes: Go to Step 4.
Is engine oil at proper level and in good condition? No: Go to 7.0 Engine Oil System
Operational Checkout Procedure
(page 36). After repairs are
complete, retest for SPN 164 FMI
15.

Step 4 Inspect HPOP reservoir. Decision

Inspect HPOP reservoir for appropriate engine oil level. Remove Engine Oil Yes: Reinstall EOT sensor. Go to
Temperature (EOT) sensor. Step 5
Does engine oil drain from HPOP reservoir? No: Clean passages going to
HPOP reservoir. After repairs are
complete, retest for SPN 164 FMI
17.

Step 5 Determine if high-pressure oil system is operating properly. Decision

Perform CPA High-Pressure Oil Pump (HPOP) Test (page 1440). Yes: Follow repair direction
indicated by CPA software and
WAC. After repairs are complete,
retest for SPN 164 FMI 17.
Did CPA High-Pressure Oil Pump (HPOP) Test issue a Warranty Authorization No: Perform Fuel Pressure
Code (WAC)? Adaptation Reset (page 1341).
After repairs are complete, retest
for SPN 164 FMI 17.

End Diagnostic Steps

After performing diagnostic steps, if SPN 164 FMI 17 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
386 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 164 FMI 18 - ICP below desired level

Fault Overview
Fault sets when Engine Control Module (ECM) detects Injection Control Pressure (ICP) value remains below
set point by threshold value for current engine speed and torque.

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

Associated Faults
• SPN 164 FMI 1, 3, and 4 • SPN 679 FMI 3 and 4 • SPN 3055 FMI 2 (INJ)
(ICP) (IPR)

Fault Facts
Do not replace Injection Control Pressure (ICP) sensor unless directed by diagnostic procedure.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Restricted High-Pressure Oil Pump (HPOP) intake screen
• Failed HPOP
• Injection Pressure Regulator (IPR) electrical circuit
• Failed IPR
• Leaks in High-Pressure (HP) oil system
• Failed injectors and pucks
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 387

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 386).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 164 FMI 18.

Step 2 Inspect vehicle history for High-Pressure (HP) oil system repairs Decision
Determine if vehicle history included HP oil system repairs. Yes: Perform Fuel Pressure
Adaptation Reset (page 1341)
procedure. Retest for SPN 164
FMI 18.
Were HP oil system repairs recently performed? No: Go to Step 3.

Step 3 Check for engine oil problems. Decision

Perform Engine Oil Level and Quality Inspection (page 1635). Yes: Go to Step 4.
Is engine oil at proper level and in good condition? No: Go to 7.0 Engine Oil System
Operational Checkout Procedure
(page 36). After repairs are
complete, retest for SPN 164 FMI
15.

Step 4 Inspect High-Pressure Oil Pump (HPOP) reservoir. Decision

A. Remove Engine Oil Temperature (EOT) sensor. See Engine Service Yes: Reinstall EOT sensor. Go to
Manual. Step 5
B. Inspect HPOP reservoir for appropriate engine oil level.
Does engine oil drain from HPOP reservoir? No: Perform 7.0 Engine Oil
System Operational Checkout
Procedure (page 36). After repairs
are complete, retest for SPN 164
FMI 18.

Step 5 Test HPOP Injection Pressure Regulator (IPR) electrical circuit. Decision
Perform CPA High-Pressure Oil Pump (HPOP) Test (page 1440). Yes: Repair IPR circuit. After
repairs are complete, retest for
SPN 164 FMI 18.
Does CPA HPOP Test detect a problem with IPR valve electrical circuit? No: Go to Step 6.
388 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 6 Mechanically test IPR valve hydraulic circuit. Decision

Review results from CPA High-Pressure Oil Pump (HPOP) Test (page 1440). Yes: Replace IPR valve, then
perform Fuel Pressure Adaptation
Reset (page 1341). After repairs
are complete, retest for SPN 164
FMI 18.
Does CPA HPOP Test detect a problem with IPR valve hydraulic circuit? No: Go to Step 7.

Step 7 Perform HPOP dead head test. Decision

Review results from CPA High-Pressure Oil Pump (HPOP) (page 1440) Test. Yes: Go to Step 8.
Does CPA HPOP Test detect a problem with HPOP pump? No: Repair high-pressure oil leaks
under valve cover, then perform
Fuel Pressure Adaptation Reset
(page 1341). After repairs are
complete, retest for SPN 164 FMI
18.

Step 8 Inspect HPOP intake screen. Decision

Remove HPOP and inspect intake screen for restrictions and debris. Yes: Replace intake screen, repair
source of debris, then perform
Fuel Pressure Adaptation Reset
(page 1341). After repairs are
complete, retest for SPN 164 FMI
18.
Is debris restricting HPOP intake? No: Replace HPOP, then perform
Fuel Pressure Adaptation Reset
(page 1341). After repairs are
complete, retest for SPN 164 FMI
18.

End Diagnostic Steps

After performing diagnostic steps, if SPN 164 FMI 18 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 389

SPN 164 FMI 20 - ICP Above desired level

Fault Overview
Fault sets when the Engine Control Module (ECM) detects Injection Control Pressure (ICP) exceeds maximum
pressure for current operating conditions.

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

Associated Faults
None

Fault Facts
Do not replace Injection Control Pressure (ICP) sensor unless directed by diagnostic procedure.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Short to ground on IPR circuit
• Intermittent ICP sensor connection
• IPR valve failed or sticking
390 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key On Yes: Go to Step 2.
Engine Off (KOEO), check Diagnostic Trouble Code (DTC) list for SPN 164 FMI 20.
Is SPN 164 FMI 20 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 164 FMI 20.

Step 2 Inspect Injection Pressure Regulator (IPR) valve and connector. Decision
A. Key OFF. Yes: Go to Step 3.
B. Disconnect IPR valve.
C. Check IPR valve and connector terminals for: damaged or pinched wires;
wet or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are IPR valve connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 164
FMI 20.

Step 3 Action Decision

®
Test for intermittent circuit operation, use EST with Navistar Engine Diagnostics. Yes: Go to Step 4.
Do Key On, Engine Off Continuous Monitor Test (page 1361).
Does circuit operate properly? No: Locate specific circuit causing
erratic or intermittent operation.
Perform voltage and resistance
checks in this section. Repair
circuit as required, and retest for
SPN 164 FMI 20.

Step 4 Test high-pressure pump operation. Decision

Perform CPA High-Pressure Oil Pump (HPOP) Test(page 1440). Yes: End diagnostics, retest for
SPN 164 FMI 20.
Did HPOP Test complete satisfactory? No: Repair failed component
indicated in HPOP Test. After
repairs are complete, retest for
SPN 164 FMI 20.

End Diagnostic Test

After performing diagnostic steps, if SPN 164 FMI 20 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 391

SPN 172 FMI 2 - IAT Signal Erratic, Intermittent, or Incorrect

Fault Overview
Fault code sets when Engine Control Module (ECM) detects that difference between Intake Air Temperature
(IAT) sensor reading and other temperature sensor reading is greater than 27°F (-3°C)

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

Associated Faults
SPN 172 FMI 3 and 4 (IAT)

Fault Facts
None

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• Failed IAT sensor
• High resistance in IAT circuit
• High resistance in SIG GND circuit

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 391).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 172 FMI 2.

Step 2 Check for active or pending fault codes. Decision

Use EST with Navistar® Engine Diagnostics. Key ON Engine OFF (KOEO), check Yes: Go to Step 3.
DTC list for SPN 172 FMI 2.
Is EST DTC list SPN 172 FMI 2 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).
392 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Inspect connections at Intake Air Temperature (IAT) connector. Decision

A. Key OFF. Yes: Go to Step 4.
B. Disconnect IAT connector.
C. Check IAT and connector terminals for: damaged or pinched wires; moist
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are IAT connector, harness, and terminals clean and undamaged? No: Repair connector, harness, or
terminal damage. After repairs are
complete, retest for SPN 172 FMI
2.

Step 4 Check operation IAT sensor. Decision

A. Perform Test 1 (page 393). Yes: Replace IAT sensor. After
®
repairs are complete, retest for
B. Use EST with Navistar Engine Diagnostics, monitor intake air
SPN 172 FMI 2.
temperature.
Is temperature 154 ± 10°F (67.8 ± 6°C)? No: Go to Step 5.

Step 5 Check for high resistance in IAT circuit. Decision

A. Perform Test 2 (page 394). Yes: Repair SIG GND circuit
®
between IAT pin-B and ECM pin
B. Use EST with Navistar Engine Diagnostics, monitor intake air temperature.
C-37. After repairs are complete,
retest for SPN 172 FMI 2.
Is temperature 154 ± 10°F (67.8 ± 6°C)? No: Repair SIG circuit between
EOT pin-A and ECM pin C-29.
After repairs are complete, retest
for SPN 172 FMI 2.

End Diagnostic Step

After performing diagnostic step, if SPN 172 FMI 2 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 393

Pin-Point Tests (SPN 172 FMI 2)

Figure 125 IAT Sensor Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4960
• 500-ohm Resistor Harness ZTSE4497
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)
394 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 126 IAT Signal Circuit Check (Test 1)

Test 1
A. Key OFF.
B. Disconnect Intake Air Temperature (IAT) sensor.
C. Connect Breakout Harness ZTSE4960 to vehicle harness connector and leave IAT sensor disconnected.
D. Connect Resistor Harness ZTSE4497 between Breakout Harness ZTSE4960 pin-A and pin-B.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.

Test 2
A. Key OFF.
B. Disconnect Intake Air Temperature (IAT) sensor.

C. Connect Breakout Harness ZTSE4960 to vehicle harness connector and leave IAT sensor disconnected.
D. Connect Resistor Harness ZTSE4497 between Breakout Harness ZTSE4960 pin-A and known good GND.

E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 395

SPN 172 FMI 3 - IAT Signal Out of Range HIGH

Fault Overview
Fault code sets when Electronic Control Module (ECM) detects Intake Air Temperature (IAT) sensor voltage is
greater than 4.8 volts for 2.5 seconds.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• IAT circuit Open
• IAT circuit shorted to PWR
• SIG GND circuit Open
• Failed IAT sensor

Step 1 Check for active or pending fault code. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for SPN 172 FMI 3.
Is EST DTC list SPN 172 FMI 3 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 2 Inspect Mass Air Flow (MAF) sensor connector for damage. Decision
A. Key-On Key-Off (KOEO). Yes: Go to Step 3.

B. Disconnect MAF sensor connector.

C. Inspect MAF connector for: damage, pinched wires, corroded terminals,
loose, bent or broken pins, or broken connector housing.
Is MAF connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 172
FMI 3.
396 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Check for Short to PWR Decision

A. Perform Test 1 (page 397). Yes: Repair short to PWR between
ECM pin C-29 and MAF pin-A.
B. Use DMM, measure voltage between Breakout Harness ZTSE4960 pin-A
After repairs are complete, retest
and known good GND.
for SPN 172 FMI 3.
Is voltage greater than 6 volts? No: Go to Step 4.

Step 4 Check for Open circuit. Decision

A. Perform Test 2 (page 398). Yes: Replace MAF sensor. After
®
repairs are complete, retest for
B. Use EST with Navistar Engine Diagnostics, clear DTC list.
SPN 172 FMI 3.
Does SPN 172 FMI 4 set after DTC list is cleared? No: Go to Step 5.

Step 5 Check for Open in SIG GND circuit. Decision

A. Perform Test 3 (page 399). Yes: Repair Open between ECM
pin C-37 and MAF pin-B. After
B. Use EST with Navistar® Engine Diagnostics, clear DTC list.
repairs are complete, retest for
SPN 172 FMI 3.
Does SPN 172 FMI 4 set after DTC list is cleared? No: Repair Open between ECM
pin C-29 and MAF pin-A. After
repairs are complete, retest for
SPN 172 FMI 3.

End Diagnostic Step

After performing diagnostic step, if SPN 172 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 397

Pin-Point Tests (SPN 172 FMI 3)

Figure 127 MAF/IAT Sensor Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4498
• Breakout Harness ZTSE4960
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)
398 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 128 IAT Circuit Voltage Check

Test 1
A. Key OFF.
B. Disconnect Mass Air Flow (MAF) sensor.
C. Connect Breakout Harness ZTSE4960 to vehicle harness and leave MAF sensor disconnected.
D. Key ON Engine OFF (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 399

Figure 129 IAT Circuit Check

Test 2
A. Key OFF.
B. Disconnect Mass Air Flow (MAF) sensor.
C. Connect Breakout Harness ZTSE4960 to vehicle harness and leave MAF sensor disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4960 pin-A and pin-B together.
E. Connect Electronic Service Tool (EST) to Vehicle Diagnostic Connector (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
400 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 130 IAT Circuit Check

Test 3
A. Key OFF.
B. Disconnect Mass Air Flow (MAF) sensor.
C. Connect Breakout Harness ZTSE4960 to vehicle harness and leave MAF sensor disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4960 pin-A to known good GND.
E. Connect EST to Vehicle Diagnostic Connector (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 401

SPN 172 FMI 4 - IAT Signal Out of Range LOW

Fault Overview
Fault code sets when Electronic Control Module detects Intake Air Temperature (IAT) sensor voltage signal is
less than expected.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• IAT circuit short to ground
• Failed MAF sensor
402 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault code. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for SPN 172 FMI 4.
Is EST DTC list SPN 172 FMI 4 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 2 Inspect connections at Mass Air Flow (MAF) sensor. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect MAF sensor connector.
C. Inspect MAF connector for: damage, pinched wires, corroded terminals,
loose, bent or broken pins, or broken, connector housing.
Is MAF connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 172
FMI 4.

Step 3 Check for failed sensor. Decision

A. Key OFF. Yes: Replace MAF sensor. After
repairs are complete, retest for
B. Disconnect Mass Air Flow (MAF) sensor.
SPN 172 FMI 4.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).
D. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
E. Use EST with Navistar® Engine Diagnostics, clear DTC list.
Does SPN 172 FMI 3 set after DTC list is cleared? No: Repair short to ground
between MAF pin-A and ECM pin
C-29. After repairs are complete,
retest for SPN 172 FMI 4.

End Diagnostic Step

After performing diagnostic step, if SPN 172 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 403

SPN 173 FMI 2 - EGT signal erratic, intermittent, or incorrect

Fault Overview
Fault sets when Engine Control Module (ECM) detects difference between estimated Exhaust Gas Temperature
(EGT) and actual EGT is greater than 540°F (300°C) for 25.5 seconds.

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

Associated Faults
SPN 173 FMI 3 and 4 (EGT)

Fault Facts
ECM estimates EGT based on engine speed and torque, engine coolant temperature, and barometric pressure.

Drive Cycle to Determine Fault Status

Key-On Engine-Running (KOER)
Possible Causes
• Failed EGT sensor
• High resistance in EGT circuit
• High resistance in SIG GND circuit
404 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults(page 403).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 173 FMI 2.

Step 2 Check for active or pending fault codes. Decision

Use EST with Navistar® Engine Diagnostics. Key ON Engine OFF (KOEO), check Yes: Go to Step 3.
DTC list for SPN 173 FMI 2.
Is EST DTC list SPN 173 FMI 2 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 3 Inspect connections at Exhaust Gas Temperature (EGT) connector. Decision

A. Key OFF. Yes: Go to Step 4.
B. Disconnect EGT connector.
C. Check EGT and connector terminals for: damaged or pinched wires;
moisture or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are EGT connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 173
FMI 2.

Step 4 Check EGT circuits. Decision

A. Perform Test 1 (page 406). Yes: Replace EGT sensor. After
®
repairs are complete, retest for
B. Use EST with Navistar Engine Diagnostics, monitor exhaust gas
SPN 173 FMI 2.
temperature.
Is temperature 1020.7 ± 10°F (549.3 ± 6°C)? No: Go to Step 5.

Step 5 Check EGT circuits. Decision

A. Perform Test 2 (page 407). Yes: Repair SIG GND circuit
®
between EGT pin-1 and ECM pin
B. Use EST with Navistar Engine Diagnostics, monitor exhaust gas
E-28. After repairs are complete,
temperature.
retest for SPN 173 FMI 2.
Is temperature 1020.7 ± 10°F (549.3 ± 6°C)? No: Repair SIG circuit between
EGT pin-2 and ECM pin E-50.
After repairs are complete, retest
for SPN 173 FMI 2.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 405

End Diagnostic Tests

After performing diagnostic steps, if SPN 173 FMI 2 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
406 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 173 FMI 2)

Figure 131 EGT Sensor Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4946
• 500-ohm Resistor Harness ZTSE4497
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 407

Figure 132 Signal Circuit Check

Test 1
A. Key OFF.
B. Disconnect Exhaust Gas Temperature (EGT) sensor.
C. Connect Breakout Harness ZTSE4946 to vehicle harness connector and leave EGT sensor disconnected.
D. Connect Resistor Harness ZTSE4497 between Breakout Harness ZTSE4946 pin-1 and pin-2.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
408 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 133 EGT Signal Circuit Check

Test 2
A. Key OFF.
B. Disconnect Exhaust Gas Temperature (EGT) sensor.
C. Connect Breakout Harness ZTSE4946 to vehicle harness connector and leave EGT sensor disconnected.
D. Connect Resistor Harness ZTSE4497 between Breakout Harness ZTSE4946 pin-2 and known good GND.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 409

SPN 173 FMI 3 - EGT Signal Out of Range HIGH

Fault Overview
Fault code sets when Engine Control Module (ECM) detects Exhaust Gas Temperature (EGT) is above maximum
threshold.

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

Associated Faults
SPN 5742 FMI 19

Fault Facts
None

Drive Cycle to Determine Fault Status

Key ON
Possible Causes
• Exhaust Gas Temperature (EGT) circuit OPEN
• EGT circuit short to PWR
• SIG GND Circuit OPEN
• Failed EGT Sensor
410 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 409).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 173 FMI 3.

Step 2 Check for active or pending fault code. Decision

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics, check Yes: Go to Step 3.
Diagnostic Trouble Code (DTC) list for SPN 173 FMI 3.
Is EST DTC list SPN 173 FMI 3 Active or Pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 3 Inspect for Exhaust Gas Temperature (EGT) sensor for damage. Decision
A. Key OFF. Yes: Go to Step 4.
B. Disconnect EGT sensor connector.
C. Inspect EGT connector for: damage, pinched wires, corroded terminals,
loose, bent or broken pins, or broken connector housing.
Is EGT connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 173
FMI 3.

Step 4 Check EGT circuit for short to PWR. Decision

A. Perform Test 1(page 412). Yes: Repair short to PWR between
EGT pin-2 and ECM pin E-50.
B. Use DMM, measure voltage between Breakout Harness ZTSE4946 pin-2
After repairs are complete, retest
and known good GND.
for SPN 173 FMI 3.
Is voltage greater than 6.0 volts? No: Go to Step 5.

Step 5 Check EGT circuits. Decision

A. Perform Test 2(page 412). Yes: Replace EGT sensor. After
repairs are complete, retest for
B. Key-On Engine-Running (KOER).
SPN 173 FMI 3.
C. Run engine at high idle for 5 minutes.
D. Use EST with Navistar® Engine Diagnostics, clear DTC list.
Does SPN 173 FMI 3 set after DTC list is cleared? No: Go to Step 6.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 411

Step 6 Check EGT circuits. Decision

A. Perform Test 3(page 413). Yes: Repair Open between EGT
pin-1 and ECM pin E-28. After
B. Key-On Engine-Running (KOER).
repairs are complete, retest for
C. Run engine at high idle for 5 minutes. SPN 173 FMI 3.
D. Use EST with Navistar® Engine Diagnostics, clear DTC list.
Does SPN 173 FMI 3 set after DTC list is cleared? No: Repair Open between EGT
pin-2 and ECM pin E-50. After
repairs are complete, retest for
SPN 173 FMI 3.

End Diagnostic Tests

After performing diagnostic steps, if SPN 173 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
412 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 173 FMI 3)

Figure 134 EGT Sensor Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4498
• Breakout Harness ZTSE4946
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Figure 135 EGT Circuit Check

Test 1
A. Key-Off.
B. Disconnect Exhaust Gas Temperature (EGT) sensor.
C. Connect Breakout Harness ZTSE4946 to vehicle harness and leave EGT sensor disconnected.

D. Key-On Engine-Off (KOEO).

 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 413

Figure 136 EGT Circuit Check

Test 2
A. Key-Off.
B. Disconnect Exhaust Gas Temperature (EGT) sensor.
C. Connect Breakout Harness ZTSE4946 to EGT sensor connector and leave EGT sensor disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4946 pin-1 and pin-2 together.
E. Connect EST to vehicle Diagnostic Connector (page 1345).
F. Key-On Engine-Off (KOEO), log in to Navistar® Engine Diagnostics.
414 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 137 EGT Circuit Check

Test 3 Setup
A. Key-Off.
B. Disconnect Exhaust Gas Temperature (EGT) sensor.
C. Connect Breakout Harness ZTSE4946 to EGT sensor connector and leave EGT sensor disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4946 pin-2 to known good GND.
E. Connect EST to vehicle Diagnostic Connector (page 1345).
F. Key-On Engine-Off (KOEO), log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 415

SPN 173 FMI 4 - EGT Signal Out of Range LOW

Fault Overview
Fault sets when Engine Control Module (ECM) determines Exhaust Gas Temperature (EGT) is below minimum
allowable threshold for a predetermined amount of time.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Key-On Engine-Running (KOER)
Possible Causes
• Exhaust Gas Temperature (EGT) circuit short to PWR
• Failed EGT sensor
416 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault code. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for SPN 173 FMI 4.
Is EST DTC list SPN 173 FMI 4 Active or Pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Inspect connections at Exhaust Gas Temperature (EGT) sensor. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect EGT sensor.
C. Inspect EGT connector for: damage, pinched wires, corroded terminals,
loose, bent or broken pins, or broken connector housing.
Is EGT connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 173
FMI 4.

Step 3 Check EGT circuits for short to GND Decision

A. Key OFF. Yes: Replace EGT sensor. After
repairs are complete, retest for
B. Disconnect Exhaust Gas Temperature (EGT) sensor and leave sensor
SPN 173 FMI 4.
disconnected.
C. Connect EST to Vehicle Diagnostic Connector (page 1345).
D. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
E. Use EST with Navistar® Engine Diagnostics, clear DTC list.
Does SPN 175 FMI 3 set after DTC list is cleared? No: Repair short to GND between
EGT pin-2 and ECM pin E-50.
After repairs are complete, retest
for SPN 173 FMI 4.

End Diagnostic Tests

After performing diagnostic steps, if SPN 173 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 417

SPN 175 FMI 2 - EOT signal erratic, intermittent, or incorrect

Fault Overview
At Key-On Engine-Off (KOEO) after a cold soak, the Engine Control Module (ECM) compares the Engine Oil
Temperature (EOT) sensor to Intake Manifold Temperature (IMT), Intake Air Temperature (IAT), Turbocharger
2 Compressor Intake Temperature (TC2CIT), Charge Air Cooler Outlet Temperature (CACOT), and Engine
Coolant Temperature 1 (ECT1) sensors.

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

Associated Faults
SPN 175 FMI 3 and 4 (EOT)

Fault Facts
None

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• Failed EOT sensor
• High resistance in EOT circuit
• High resistance in SIG GND circuit

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 417).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 175 FMI 2.

Step 2 Check for active or pending fault codes. Decision

A. Key OFF. Yes: Go to Step 3.

B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector

(page 1345).

C. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.

D. Use EST with Navistar® Engine Diagnostics, clear DTC list.
Is EST DTC list SPN 175 FMI 2 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).
418 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Inspect connections at Engine Oil Temperature (EOT) connector. Decision

A. Key OFF. Yes: Go to Step 4.
B. Disconnect EOT connector.
C. Check EOT and connector terminals for: damaged or pinched wires; moist
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are EOT connector, harness, and terminals clean and undamaged? No: Repair connector, harness, or
terminal damage. After repairs are
complete, retest for SPN 175 FMI
2.

Step 4 Check EOT sensor. Decision

A. Perform Test 1 (page 419). Yes: Replace EOT sensor. After
®
repairs are complete, retest for
B. Use EST with Navistar Engine Diagnostics, monitor engine oil
SPN 175 FMI 2.
temperature.
Is temperature 194 ± 10°F (90 ± 6°C)? No: Go to Step 5.

Step 5 Check EOT circuits. Decision

A. Perform Test 2 (page 420). Yes: Repair SIG GND circuit
®
between EOT pin-1 and ECM pin
B. Use EST with Navistar Engine Diagnostics, monitor engine oil
E-28. After repairs are complete,
temperature.
retest for SPN 175 FMI 2.
Is temperature 194 ± 10°F (90 ± 6°C)? No: Repair SIG circuit between
EOT pin-2 and ECM pin E-66.
After repairs are complete, retest
for SPN 175 FMI 2.

End Diagnostic Tests

After performing diagnostic Steps, if SPN 175 FMI 2 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 419

Pin-Point Tests (SPN 175 FMI 2)

Figure 138 EOT Sensor Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4602
• 500 Ohm Resistor Harness ZTSE4497
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)
420 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 139 EOT Signal Circuit Check

Test 1
A. Key OFF.
B. Disconnect Engine Oil Temperature (EOT) sensor.
C. Connect Breakout Harness ZTSE4602 to vehicle harness connector and leave EOT sensor disconnected.
D. Connect Resistor Harness ZTSE4497 between Breakout Harness ZTSE4602 pin-1 and pin-2.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 421

Figure 140 EOT Signal Circuit Check

Test 2
A. Key OFF.
B. Disconnect Engine Oil Temperature (EOT) sensor.
C. Connect Breakout Harness ZTSE4602 to vehicle harness connector and leave EOT sensor disconnected.
D. Connect Resistor Harness ZTSE4497 between Breakout Harness ZTSE4602 pin-2 and known good GND.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
422 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 175 FMI 3 - EOT signal Out of Range HIGH

Fault Overview
None

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Engine Oil Temperature (EOT) sensor signal circuit open or short to power
• EOT sensor signal circuit open
• EOT sensor ground circuit OPEN or high resistance
• Failed EOT sensor
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 423

Step 1 Check for active or pending fault code. Decision

A. Key OFF. Yes: Go to Step 2.
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).

C. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.

D. Use EST with Navistar® Engine Diagnostics, clear DTC list.
Is EST DTC list SPN 175 FMI 3 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at Engine Oil Temperature (EOT) sensor. Decision

A. Key OFF Yes: Go to Step 3.
B. Disconnect EOT sensor connector.
C. Check EOT sensor and connector terminals for damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are EOT sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 175
FMI 3.

Step 3 Check EOT circuits for short to PWR Decision

A. Perform Test 1 (page 425). Yes: Repair EOT circuit for a
short to PWR. After repairs are
B. Use DMM, measure voltage between Breakout Harness ZTSE4602 pin-2
complete, retest for SPN 175 FMI
and known good GND.
3.
Is voltage greater than 6 volts? No: Go to Step 4.

Step 4 Check EOT circuits. Decision

A. Perform Test 2 (page 425). Yes: Replace sensor. After repairs
are complete, retest for SPN 175
B. Use EST with Navistar® Engine Diagnostics, clear DTC list.
FMI 3.
Is fault code SPN 175 FMI 4 active or pending? No: Go to Step 5.

Step 5 Check EOT circuits. Decision

A. Perform Test 3 (page 426). Yes: Repair open in signal ground
®
circuit. After repairs are complete,
B. Use EST with Navistar Engine Diagnostics, clear DTC list.
retest for SPN 175 FMI 3.
Is fault code SPN 175 FMI 4 active or pending? No: Repair open in signal circuit.
After repairs are complete, retest
for SPN 175 FMI 3.
424 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

End Diagnostic Tests

After performing diagnostic steps, if SPN 175 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 425

Pin-Point Tests (SPN 175 FMI 3)

Figure 141 EOT Sensor Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• 180-pin Breakout Box 00-00956-08
• Breakout Harness ZTSE4602
• Breakout Harness ZTSE4498
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Figure 142 EOT Circuit Check

Test 1
A. Key OFF.

B. Disconnect Engine Oil Temperature (EOT) sensor.

C. Connect Breakout Harness ZTSE4602 to vehicle harness connector and leave EOT sensor disconnected.

D. Key ON Engine OFF (KOEO).

426 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 143 EOT Sensor Circuit Check

Test 2
A. Key OFF.
B. Disconnect Engine Oil Temperature (EOT) sensor.
C. Connect Breakout Harness ZTSE4602 to vehicle harness connector and leave EOT sensor disconnected.
D. Use Breakout Harness ZTSE4498 to short Breakout Harness ZTSE4602 pin-1 to pin-2.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
F. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 427

Figure 144 EOT Sensor Circuit Check

Test 3
A. Key OFF.
B. Disconnect Engine Oil Temperature (EOT) sensor.
C. Connect Breakout Harness ZTSE4602 to vehicle harness connector and leave EOT sensor disconnected.
D. Use Breakout Harness ZTSE4498 to short Breakout Harness ZTSE4602 pin-2 to known good GND.
E. Connect EST to vehicle Diagnostic Connector (page 1345).
F. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
428 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 175 FMI 4 - EOT signal Out of Range LOW

Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Oil Temperature (EOT) signal is lower than
expected.

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

Associated Faults
SPN 3509 FMI 3 and 4
(VREF 1)

Fault Facts
None

Drive Cycles
Key ON
Possible Causes
• EOT signal circuit short to GND
• Failed EOT sensor
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 429

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults(page 428).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 175 FMI 4.

Step 2 Check for active or pending fault codes. Decision

A. Key OFF. Yes: Go to Step 3.
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).
C. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
D. Use EST with Navistar® Engine Diagnostics, clear DTC list.
Is SPN 175 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 3 Inspect connections at Engine Oil Temperature (EOT) sensor. Decision

A. Key OFF. Yes: Go to Step 4.
B. Disconnect EOT sensor.
C. Inspect EOT sensor and connector terminals for: damaged or pinched
wire; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are EOT sensor connector, harness, and terminals clean and undamaged? No: Repair or Replace connector
or pins. After repairs are
complete, retest for SPN 175 FMI
4.

Step EOT Resistance Check for short to GND. Decision

A. Key OFF. Yes: Replace EOT sensor. After
repairs are complete, retest for
B. Disconnect Engine Oil Temperature (EOT) sensor.
SPN 175 FMI 4.
C. Connect EST to vehicle Diagnostic Connector (page 1345).

D. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.

E. Use EST with Navistar® Engine Diagnostics, clear DTC list.
Does SPN 175 FMI 3 set after DTC list is cleared? No: Repair short to GND between
EOT pin-3 and ECM pin E1-63.
After repairs are complete, retest
for SPN 175 FMI 4.
430 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

End Diagnostic Tests

After performing diagnostic steps, if SPN 175 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 431

SPN 175 FMI 7 - EOT not warming along with engine

Fault Overview
Fault code sets when Engine Control Module (ECM) detects difference between Engine Oil Temperature (EOT)
and Engine Coolant Temperature 1 (ECT1) sensors is greater than 27°F (15°C) after a cold soak.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• High resistance EOT circuit
• High resistance SIG GND circuit
• Failed EOT sensor
• Failed oil system module thermal valve assembly
432 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

A. Key OFF. Yes: Go to Step 2.
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).

C. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.

D. Use EST with Navistar® Engine Diagnostics, clear DTC list.
Is EST DTC list SPN 175 FMI 7 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 2 Inspect connections at Engine Oil Temperature (EOT) connector. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect EOT connector.
C. Check EOT and connector terminals for: damaged or pinched wires; moist
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are EOT connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 175
FMI 7.

Step 3 Check EOT circuit for high resistance. Decision

A. Perform Test 1 (page 434). Yes: Go to Step 5.
®
B. Use EST with Navistar Engine Diagnostics, monitor engine oil
temperature.
Is temperature 194 ± 10°F (90 ± 6°C)? No: Go to Step 4.

Step 4 Check EOT signal circuit for high resistance. Decision

A. Perform Test 2 (page 435). Yes: Repair high resistance
®
between EOT pin-1 and ECM pin
B. Use EST with Navistar Engine Diagnostics, monitor engine oil
E-28. After repairs are complete,
temperature.
retest for SPN 175 FMI 7.
Is temperature 194F ± 10°F (90 ± 6°C)? No: Repair high resistance
between EOT pin-2 and ECM pin
E-66. After repairs are complete,
retest for SPN 175 FMI 7.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 433

Step 5 Check EOT sensor resistance. Decision

A. Perform Test 3 (page 436). Yes: Replace oil system module
thermal valve assembly. After
B. Use DMM, measure resistance between Breakout Harness ZTSE4602
repairs are complete, retest for
pin-1 and pin-2.
SPN 175 FMI 7.
Is resistance within specification? No: Replace EOT sensor. After
repairs are complete, retest for
SPN 175 FMI 7.

End Diagnostic Tests

After performing diagnostic steps, if SPN 175 FMI 7 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
434 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 175 FMI 7)

Figure 145 EOT Sensor Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4602
• 500 Ohm Resistor Harness ZTSE4497
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 435

Figure 146 EOT Signal Circuit Check

Test 1
A. Key OFF.
B. Disconnect Engine Oil Temperature (EOT) sensor.
C. Connect Breakout Harness ZTSE4602 to vehicle harness connector and leave EOT sensor disconnected.
D. Connect Resistor Harness ZTSE4497 between Breakout Harness ZTSE4602 pin-1 and pin-2.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
436 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 147 EOT Signal Circuit Check

Test 2
A. Key OFF.
B. Disconnect Engine Oil Temperature (EOT) sensor.
C. Connect Breakout Harness ZTSE4602 to vehicle harness connector and leave EOT sensor disconnected.
D. Connect Resistor Harness ZTSE4497 between Breakout Harness ZTSE4602 pin-2 and known good GND.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 437

Figure 148 EOT Signal Circuit Check

Test 3
A. Key OFF.
B. Disconnect EOT sensor.
C. Connect Breakout Harness ZTSE4602 to EOT sensor and leave vehicle harness disconnected.
438 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 175 FMI 15 - Engine Oil System above Warning Temperature

Fault Overview
This fault is set by Engine Control Module (ECM) when Engine Oil Temperature (EOT) is above 261°F (127°C).
ECM illuminates red lamp (OWL). When temperature drops below 261°F (127°C) SPN/FMI will become not
active.

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

Associated Faults
None

Fault Facts
This fault sets when Engine Warning Protection System (EWPS) detects Engine Oil Temperature (EOT) has
risen above a desired set point. Fault may be caused by actual high oil temperature or by a fault in EOT sensor
circuit.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• High resistance EOT circuit
• High resistance SIG GND circuit
• Failed EOT sensor
• Failed oil system module thermal valve assembly
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 439

Step 1 Check for active or pending fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON Yes: Go to Step 2.
Engine OFF (KOEO), check Diagnostic Trouble Codes (DTC) list for SPN 175
FMI 15.
Is EST DTC list SPN 175 FMI 15 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at Engine Oil Temperature (EOT) connector. Decision

A. Key OFF. Yes: Go to Step 3
B. Disconnect EOT connector.
C. Check EOT and connector terminals for: damaged or pinched wires; moist
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are EOT connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 175
FMI 15.

Step 3 Check EOT circuit. Decision

A. Perform Test 1 (page 441). Yes: Go to Step 5.
B. Use EST with Navistar® Engine Diagnostics, monitor engine oil
temperature.
Is temperature 194 ± 10°F (90 ± 6°C)? No: Go to Step 4.

Step 4 Check for high resistance in EOT SIG circuit Decision

A. Perform Test 2 (page 442). Yes: Repair high resistance in
SIG GND circuit between EOT
B. Use EST with Navistar® Engine Diagnostics, monitor engine oil
pin-1 and ECM pin E-28. After
temperature.
repairs are complete, retest for
SPN 175 FMI 15.
Is temperature 194 ± 10°F (90 ± 6°C)? No: Repair high resistance in
EOT circuit between EOT pin-2
and ECM pin E-66. After repairs
are complete, retest for SPN 175
FMI 15.
440 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 5 Check for failed oil system module thermal valve assembly. Decision
A. Perform Test 3 (page 443). Yes: Replace oil system module
thermal valve assembly. After
B. Use DMM, measure resistance between Breakout Harness ZTSE4602
repairs are complete, retest for
pin-1 and pin-2.
SPN 175 FMI 15.
Is resistance greater than 1000 ohms? No: Replace EOT sensor. After
repairs are complete, retest for
SPN 175 FMI 15.

End Diagnostic Tests

After performing diagnostic steps, if SPN 175 FMI 15 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 441

Pin-Point Tests (SPN 175 FMI 15)

Figure 149 EOT Sensor Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4602
• 500-ohm Resistor Harness ZTSE4497
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)
442 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 150 EOT Signal Circuit Check

Test 1
A. Key OFF.
B. Disconnect Engine Oil Temperature (EOT) sensor.
C. Connect Breakout Harness ZTSE4602 to vehicle harness connector and leave EOT sensor disconnected.
D. Connect Resistor Harness ZTSE4497 between Breakout Harness ZTSE4602 pin-1 and pin-2.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 443

Figure 151 EOT Signal Circuit Check

Test 2
A. Key OFF.
B. Disconnect Engine Oil Temperature (EOT) sensor.
C. Connect Breakout Harness ZTSE4602 to vehicle harness connector and leave EOT sensor disconnected.
D. Connect Resistor Harness ZTSE4497 between Breakout Harness ZTSE4602 pin-2 and known good GND.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
444 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 152 EOT Signal Circuit Check

Test 3
A. Key OFF.
B. Disconnect Engine Oil Temperature (EOT) sensor.
C. Connect Breakout Harness ZTSE4602 to vehicle harness connector and leave EOT sensor disconnected.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 445

SPN 188 FMI 0 - Engine unable to achieve desired idle speed (too high)

Fault Overview
Fault code sets when vehicle is stationary and engine speed is greater than what is requested by Engine Control
Module (ECM).

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

Associated Faults
• SPN 110 FMI 2 (ECT1)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• External fuel source
• Engine oil leak to intake
• Fuel leak to intake
• Contaminated fuel

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults(page 445).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 188 FMI 0.

Step 2 Inspect for airborne combustibles (such as propane saturated air or Decision
ether) near engine.
Inspect air filter and intake system for stains, concentrations of contaminants, Yes: Go to Step 3.
odors/smells from external fuel sources, and modifications.
Is engine intake system intact and free from external fuel sources? No: Repair source of airborne
combustibles. After repairs are
complete, retest for SPN 188 FMI
0.
446 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Inspect for engine oil leaking into air intake. Decision
Remove Charge Air Cooler (CAC) piping from Engine Throttle Valve (ETV), see Yes: Go to 7.2 Engine Oil Leak to
Engine Service Manual. Intake (page 103).
Is excessive engine oil leaking to intake? No: Go to Step 4.

Step 4 Inspect for contaminated fuel (alternate fuels other than diesel fuel). Decision
Perform Fuel Quality Inspection (page 1632). Yes: End Diagnostic steps. After
repairs are complete, retest for
SPN 188 FMI 0.
Is diesel fuel in good condition and not contaminated? No: Drain fuel tank, and fill with
clean and/or known good diesel
fuel. After repairs are complete,
retest for SPN 188 FMI 0.

End Diagnostic Steps

After performing diagnostic steps, if SPN 188 FMI 0 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 447

SPN 188 FMI 1 - Engine unable to achieve desired idle speed (too low)

Fault Overview
Fault sets when vehicle is stationary and engine speed is less than what is requested by Engine Control Module
(ECM).

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

Associated Faults
SPN 651 - 656 SPN 1322 - 1328 FMI 31

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Low Fuel Delivery Pressure (FDP)
• Low cylinder compression
• Clutch or Power Take Off (PTO) engagement without command

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults(page 447).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 188 FMI 1.

Step 2 Check air intake, exhaust, and fuel systems for restrictions, leaks Decision
or damage.
• Perform Intake Air Inspection(page 1648), inspect for restrictions, leaks, or Yes: Go to Step 3.
physical damage.

• Perform Exhaust and Aftertreatment System Inspection(page 1651), inspect

for restrictions, leaks, or physical damage.

• Perform Fuel System Inspection(page 1631), from fuel tank to Down Stream
Injection (DSI) assembly for leaks, physical damage, or contamination.
Are air intake system, exhaust system, fuel system, and air filter free of restrictions, No: Repair restrictions, leaks,
leaks, physical damage, and contamination? or physical damage. Replace
contaminated fluids as required.
After repairs are complete, retest
for SPN 188 FMI 1
448 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Check that Fuel Delivery Pressure (FDP) is within specification. Decision
A. Key OFF. Yes: Go to Step 4.
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).

C. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.

D. Key On Engine Running (KOER).
E. Use EST with Navistar® Engine Diagnostics, monitor FDP sensor.
Is FDP within specification? No: Perform Fuel Delivery
Pressure (FDP) Test(page 1554).
After repairs are complete, retest
for SPN 188 FMI 1.

Step 4 Determine if engine has a mechanical cylinder balance problem Decision

(compression loss).
Perform Crankcase Pressure Test.(page 1567). Yes: Repair base engine
compression imbalance. After
repairs are complete, retest for
SPN 188 FMI 1.
Does engine have excessive crankcase pressure? No: Go to Step 5.

Step 5 Check for Power Take Off (PTO) engagement without command. Decision
Key-On Engine-Running (KOER), monitor PTO output shaft rotation. Yes: Repair PTO unit. After
repairs are complete, retest for
SPN 188 FMI 1.
Is PTO output shaft rotating without throttle? No: Go to Step 6.

Step 6 Check for a misfire. Decision

Perform following checks and tests: Yes: Repair misfire on identified
cylinder. After repairs are
• CPA Signal Check(page 1413),
complete, retest for SPN 188 FMI
• CPA Cold Idle Test(page 1407), 1.
• and CPA Hot Idle Test(page 1421).
Was a misfire identified by CPA tool? No: Go to Step 7.

Step 7 Check for valve train or other mechanical failures. Decision

Perform Relative Compression Test Plus (RCT+) (page 1465). Yes: Repair mechanical problem
with cylinder(s) indicating low
performance. After repairs are
complete, retest for SPN 188 FMI
1.
Does CPA tool indicate a problem or generate a warranty authorization code (WAC)? No: Diagnostics Complete.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 449

End Diagnostic Steps

After performing diagnostic steps, if SPN 188 FMI 1 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
450 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 190 FMI 0 - Engine Over Speed - Most Severe Level

Fault Overview
Fault sets only when a vehicle is stationary and engine speed reaches 2,600 rpm with no fuel being requested
by Engine Control Module (ECM). Once conditions are met, ECM will initiate a protection strategy.

Lamp Reaction
Malfunction Indicator Lamp (MIL) and Red Stop Lamp (RSL) will illuminate when this fault is detected.

Associated Faults
None

Fault Facts
Before beginning diagnosis:
• Take pictures of all damage/failure evidence.
• Do not replace any parts until a full inspection has been completed.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed injectors
• Incorrect gear selection
• Failed low pressure turbocharger
• Failed engine
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 451

Step 1 Check for excessive oil in turbocharger outlet and Charge Air Cooler Decision
(CAC) piping.
A. Remove high-pressure turbocharger outlet pipe and CAC piping (see Yes: Go to 7.2 - Engine Oil Leak
Engine Service Manual). to Intake (page 103) step 2 to
repair oil leak to intake. After
B. Inspect outlets for excessive oil.
repairs are complete, clean CAC
using procedure in appropriate
Technician Manual and retest for
SPN 190 FMI 0.
Is there excessive oil in high-pressure turbocharger outlet pipe or CAC piping? No: Go to Step 2.

Step 2 Check for external engine block damage. Decision

Visually inspect engine block for external damage (holes or cracks in side of block). Yes: Replace engine, following
warranty policies.
Inspect Pre-Diesel Oxidation
Catalyst (DOC), DOC, and
Diesel Particulate Filter (DPF)
for oil contamination. Refer to
Aftertreatment Re-use Guidelines
in Aftertreatment Symptom
Manual 0000003081.
After repairs are complete, retest
for SPN 190 FMI 0.
Is there any external engine block damage? No: Go to Step 3.

Step 3 Check for engine block or engine sleeve damage. Decision

A. Remove engine oil pan (see Engine Service Manual). Yes: Repair or replace engine,
following warranty policies.
B. Inspect for internal engine block or engine sleeve damage.
Inspect Pre-DOC, DOC, and DPF
for oil contamination. Refer to
Aftertreatment Re-use Guidelines
in Aftertreatment Symptom
Manual 0000003081.

After repairs are complete, retest

for SPN 190 FMI 0.
Is there any internal engine block or engine sleeve damage? Go to Step 4.
452 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 4 Check for current ECM calibration. Decision

A. Key OFF. Yes: Update calibration. After
repairs are complete, retest for
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
SPN 190 FMI 0.
(page 1345).

C. Key ON, Engine OFF (KOEO), log into Navistar® Engine Diagnostics.
D. Check ECM calibration for updates.
Is there an ECM calibration update available? No: End diagnostics. Retest for
SPN 190 FMI 0.

End Diagnostic Steps

After performing all diagnostic steps, if SPN 190 FMI 0 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 453

SPN 191 FMI 3 - TOSS/VSS Signal Out of Range HIGH

Fault Overview
Fault code sets when Electronic Control Module (ECM) detects Transmission Output Shaft Speed (TOSS) sensor
signal is out of range high.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• TOSS-H Short to B+
• TOSS-L Short to B+
454 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON Yes: Go to Step 2.
Engine OFF (KOEO), check Diagnostic Trouble Codes (DTC) list for SPN 191
FMI 3.
Is SPN 191 FMI 3 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 2 Transmission Output Shaft Speed (TOSS) sensor and connector Decision
inspection
A. Key OFF. Yes: Go to Step 3.
B. Disconnect TOSS sensor.
C. Check TOSS sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are TOSS sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness, or
terminal damage. After repairs are
complete, retest for SPN 191 FMI
3.

Step 3 Check TOSS circuit for Short to B+. Decision

A. Key OFF. Yes: Repair short to B+ in TOSS-L
circuit. After repairs are complete,
B. Disconnect TOSS sensor connector.
retest for SPN 191 FMI 3.
C. Use Terminal Test Kit ZTSE4435C, insert correct terminal into TOSS
vehicle harness and leave TOSS sensor disconnected.
D. Key ON Engine OFF (KOEO).
E. Use DMM, measure voltage between TOSS vehicle harness pin-1 and
known good GND.
Is voltage less than 1.7 volts? No: Repair short to B+ in TOSS-H
circuit. After repairs are complete,
retest for SPN 191 FMI 3.

End Diagnostic Tests

After performing diagnostic steps, if SPN 191 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 455

SPN 191 FMI 4 - TOSS/VSS Signal Out of Range LOW

Fault Overview
Fault code sets when Electronic Control Module (ECM) detects Transmission Output Shaft Speed (TOSS) sensor
signal is out of range low.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• TOSS-H Short to GND
• TOSS-L Short to GND
456 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON Yes: Go to Step 2.
Engine OFF (KOEO), check Diagnostic Trouble Codes (DTC) list for SPN 191 FMI 4.
Is SPN 191 FMI 4 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 2 Transmission Output Shaft Speed (TOSS) sensor and connector Decision
inspection
A. Key OFF. Yes: Go to Step 3.
B. Disconnect TOSS sensor.
C. Check TOSS sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are TOSS sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 191
FMI 4.

Step 3 Check TOSS for Short to GND. Decision

A. Key OFF. Yes: Repair short to GND in
TOSS-L circuit. After repairs are
B. Disconnect TOSS sensor connector.
complete, retest for SPN 191 FMI
C. Use Terminal Test Kit ZTSE4435C, insert correct terminal into TOSS 4.
vehicle harness and leave TOSS sensor disconnected.
D. Key ON Engine OFF (KOEO).
E. Use DMM, measure voltage between TOSS vehicle harness pin-1 and
known good GND.
Is voltage less than 1.2 volts? No: Repair short to GND in
TOSS-H circuit. After repairs are
complete, retest for SPN 191 FMI
4.

End Diagnostic Tests

After performing diagnostic steps, if SPN 191 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 457

SPN 191 FMI 5 - TOSS/VSS Open Circuit Fault

Fault Overview
Fault code sets when the Electronic Control Module (ECM) detects the Transmission Output Shaft Speed (TOSS)
sensor has an open circuit.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• TOSS-H circuit open
• TOSS-L circuit open
• Failed TOSS sensor

Step 1 Check for active or pending fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key On Yes: Go to Step 2.
Engine Off (KOEO), check Diagnostic Trouble Codes (DTC) list for SPN 191 FMI 5.
Is SPN 191 FMI 5 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 2 Transmission Output Shaft Speed (TOSS) sensor connector Decision

inspection
A. Key OFF. Yes: Go to Step 3.
B. Disconnect TOSS sensor.

C. Check TOSS sensor and connector terminals for: damaged or pinched

wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are TOSS sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 191
FMI 5.
458 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Check TOSS-H circuit for open or high resistance. Decision

A. Key OFF. Yes: Go to Step 4.
B. Disconnect Transmission Output Shaft Speed (TOSS) sensor connector.
C. Use Terminal Test Kit ZTSE4435C, insert correct terminal into TOSS
vehicle harness and leave TOSS sensor disconnected.

D. Key ON Engine OFF (KOEO).

E. Use DMM, measure voltage between TOSS vehicle harness pin-1 and
known good GND.
Is voltage between 1.2 and 1.7 volts? No: Repair open in TOSS-H
circuit. After repairs are complete,
retest for SPN 191 FMI 4.

Step 4 Check TOSS-L circuit for open or high resistance. Decision

A. Key OFF. Yes: Replace TOSS sensor. After
repairs are complete, retest for
B. Disconnect TOSS sensor connector.
SPN 191 FMI 5.
C. Use Terminal Test Kit ZTSE4435C, insert correct terminal into TOSS
vehicle harness and leave TOSS sensor disconnected.
D. Key ON Engine OFF (KOEO).
E. Use DMM, measure voltage between TOSS vehicle harness pin-2 and
known good GND.
Is voltage between 1.2 and 1.7 volts? No: Repair open in TOSS-L
circuit. After repairs are complete,
retest for SPN 191 FMI 5.

End Diagnostic Tests

After performing diagnostic steps, if SPN 191 FMI 5 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 459

SPN 191 FMI 14 - TOSS/VSS Error invalid signal

Fault Overview
Fault code sets when the Electronic Control Module (ECM) detects an invalid vehicle speed value from the
Transmission Output Shaft Speed (TOSS) sensor.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Debris buildup on TOSS sensor
• Failed TOSS sensor
460 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault code. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON Yes: Go to Step 2.
Engine OFF (KOEO), check Diagnostic Trouble Code (DTC) list for SPN 191
FMI 14.
Is EST DTC list SPN 191 FMI 14 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 2 Inspect Transmission Output Shaft Speed (TOSS) sensor and Decision
connector.
A. Key OFF. Yes: Go to Step 3.
B. Disconnect TOSS sensor.
C. Check TOSS sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are TOSS sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness, or
terminal damage. After repairs are
complete, retest for SPN 191 FMI
14.

Step 3 Inspect TOSS sensor. Decision

Remove TOSS sensor and inspect sensor and bore. Yes: Replace VSS sensor. After
repairs are complete, retest for
SPN 191 FMI 14.
Is sensor and bore free of damage or debris? No: Clean VSS sensor with a
rag or towel and clean sensor
bore. To prevent damage, do not
use chemical cleaners to clean
TOSS/VSS sensor. After repairs
are complete, retest for SPN 191
FMI 14.

End Diagnostic Tests

After performing all diagnostic steps, if SPN 191 FMI 14 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 461

SPN 518 FMI 2 - Torque Limitation - Too High ECT

Fault Overview
Fault sets when Engine Control Module (ECM) determines engine cooling system is too hot.

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

Associated Faults
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Engine Coolant Temperature (ECT) too hot
462 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON Yes: Go to Step 2.
Engine OFF (KOEO), check Diagnostic Trouble Code (DTC) list for SPN 518 FMI 2.
Is SPN 518 FMI 2 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Decision
Inspect vehicle grille for obstructions that may reduce air flow to Charge Air Cooler Yes: Go to Step 3.
(CAC).
Is vehicle grille free of obstructions? No: Repair or remove obstruction
from grille. After repairs are
complete, retest for SPN 518 FMI
2.

Step 3 Decision
Check engine fan, fan shroud, and air dams for damage and proper operation. Yes: Go to Step 4.
Are engine fan, fan shroud, and air dams intact and operating properly? No: Repair or replace engine fan,
fan shroud, and/or air dams. After
repairs are complete, retest for
SPN 518 FMI 2.

Step 4 Decision
Check CAC for oil, dirt, or other debris. Do CAC checks (page 1646). Yes: Go to Step 5.
Is CAC system free of dirt, debris, or oil? No: Clean CAC. After repairs are
complete, retest for SPN 518 FMI
2.

Step 5 Decision
Allow engine to cool for 8 hours. Compare ECT1 to Engine Oil Temperature (EOT), Yes: Go to Step 6.
Intake Manifold Temperature (IMT), Inlet Air Temperature (IAT), Charge Air Cooler
Outlet Temperature (CACOT), and Aftertreatment Fuel Inlet Temperature (AFTFIT)
sensors. All temperature sensors should be within 59°F (33°C) of each other.
Are all temperature sensors within 59°F (33°C) other sensors? No: Replace failed temperature
sensor. After repairs are
complete, retest for SPN 518 FMI
2.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 463

Step 6 Action Decision

Determine if thermostat is stuck closed. Run engine after Step 7 has been Yes: After doing all diagnostic
completed and evaluated. Feel upper radiator hose and determine if warm coolant steps, if SPN 518 FMI 2 remains
begins to flow before thermostat opening temperature is reached. active, verify each step was
completed correctly and proper
decisions were made. Notify
supervisor for further action.
Does upper radiator hose temperature stay cool after reasonable engine warm Remove and inspect thermostats
up time? following procedure in Engine
Service Manual.
After repairs are complete, retest
for SPN 518 FMI 2.

End Diagnostic Test

After performing diagnostic steps, if SPN 518 FMI 2 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
464 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 521 FMI 2 - Brake applied while APP applied

Fault Overview

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Operator was applying Accelerator Pedal and brake pedal at same time
• APP1 sensor or circuit fault
• Brake Pedal switch or circuit fault
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 465

Step 1 Check for active or pending fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON Yes: Go to Pin-Point Tests (SPN
Engine OFF (KOEO), check Diagnostic Trouble Code (DTC) list for SPN 521 FMI 2. 521 FMI 2)(page 466).
Is SPN 521 FMI 2 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

End Diagnostic Test

After performing diagnostic steps, if SPN 521 FMI 2 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
466 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 521 FMI 2)

Harness Resistance Check

Turn ignition switch to OFF. Disconnect both battery GND cables. Connect 180-pin Breakout Box and Breakout Harness
4485A. Leave ECM and sensor disconnected. Use DMM to measure resistance.
Test Point Specification Comment: < Less than, > Greater than
A to C-33 <5Ω If > 5 Ω, check APP1 signal circuit for OPEN.
B to C-34 <5Ω If > 5 Ω, check SIG GND circuit for OPEN.
C to C-63 <5Ω If > 5 Ω, check VREF-C circuit for OPEN.
D to C-9 <5Ω If > 5 Ω, check VREF-C circuit for OPEN.
E to C-36 <5Ω If > 5 Ω, check SIG GND circuit for OPEN.
F to C-48 <5Ω If > 5 Ω, check APP2 signal circuit for OPEN.

Operational Voltage Check

Connect 180-pin Breakout Box and Breakout Harness 4485A between ECM and sensor. Turn ignition switch to ON.
Use DMM to measure voltage and EST to read signal.
Test Point Condition DMM EST Value
APP1 Foot off pedal 1.14 ± 0.25 V 0%
A to GND or
C-33 to GND Pedal to floor 4.32 ± 0.25 V 99.6 %
APP2 Foot off pedal 0.56 ± 0.25 V 0%
F to GND or
C-48 to GND Pedal to floor 2.16 ± 0.25 V 99.6 %
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 467

SPN 521 FMI 19 - Brake Switch circuit fault

Fault Overview

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Brake Pedal switch or circuit fault
468 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON Yes: Go to Pin-Point Tests (SPN
Engine OFF (KOEO), check Diagnostic Trouble Code (DTC) list for SPN 521 FMI 19. 521 FMI 19)(page 469).
Is SPN 521 FMI 19 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 521 FMI 19.

End Diagnostic Test

After performing diagnostic steps, if SPN 521 FMI 19 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 469

Pin-Point Tests (SPN 521 FMI 19)

Harness Resistance Check

Turn ignition switch to OFF. Disconnect both battery GND cables. Connect 180-pin Breakout Box and Breakout Harness
4485A. Leave ECM and sensor disconnected. Use DMM to measure resistance.
Test Point Specification Comment: < Less than, > Greater than
A to C-33 <5Ω If > 5 Ω, check APP1 signal circuit for OPEN.
B to C-34 <5Ω If > 5 Ω, check SIG GND circuit for OPEN.
C to C-63 <5Ω If > 5 Ω, check VREF-C circuit for OPEN.
D to C-9 <5Ω If > 5 Ω, check VREF-C circuit for OPEN.
E to C-36 <5Ω If > 5 Ω, check SIG GND circuit for OPEN.
F to C-48 <5Ω If > 5 Ω, check APP2 signal circuit for OPEN.

Operational Voltage Check

Connect 180-pin Breakout Box and Breakout Harness 4485A between ECM and sensor. Turn ignition switch to ON.
Use DMM to measure voltage and EST to read signal.
Test Point Condition DMM EST Value
APP1 Foot off pedal 1.14 ± 0.25 V 0%
A to GND or
C-33 to GND Pedal to floor 4.32 ± 0.25 V 99.6 %
APP2 Foot off pedal 0.56 ± 0.25 V 0%
F to GND or
C-48 to GND Pedal to floor 2.16 ± 0.25 V 99.6 %
470 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 593 FMI 31 - Engine Stopped by IST

Idle Shutdown Warning

Thirty seconds before IST-defined engine shutdown, a vehicle instrument panel indicator activates. There are
two types of indicators:
• Amber flashing idle shutdown indicator for multiplex electrical systems.
• Red flashing indicator with audible alarm for non-multiplex electrical systems.
This continues until engine shuts down or low idle shutdown timer is reset.

Engine Idle Shutdown Timer (IST) for California ESS Compliant Engines
MaxxForce® engines certified for sale in state of California (CA) conform to mandatory California Air Resources
Board (CARB) Engine Shutdown System (ESS) regulations. Prior function of IST is available on CA ESS-exempt
and federally-certified engines (school buses, emergency, and military vehicles).
Engine idle duration is limited for ESS-compliant engines as follows:
• When vehicle parking brake is set, idle shutdown time is limited to CARB requirement of 5 minutes.
• When vehicle parking brake is released, idle shutdown time is limited to CARB requirement of 15 minutes.
Duration of CARB-mandated values can be reduced by programming customer IST programmable parameter
to value lower than 15 minutes. Adjusting this parameter reduces overall system shutdown time as follows:
• Adjusting parameter value between 5 and 15 minutes reduces idle shutdown time with vehicle parking brake
released. Default value of 5 minutes for vehicle parking brake set condition remains unaffected.
• Adjusting parameter value between 2 and 5 minutes reduces idle time for both vehicle parking brake released
and set conditions.
While IST is installed, idle shutdown time is factory-defaulted to 60 minutes and cannot be adjusted. If IST is
enabled, Cold Ambient Protection (CAP) will not function.
CARB IST feature is factory-programmed. Customers cannot turn IST off for ESS-compliant engines.

CARB Idle Shutdown Timer (IST) Conditions

Following conditions must be true for idle shutdown timer to activate in all modes. Any change of true state of
one or more of these conditions will reset or disable IST.
• Manual Diesel Particulate Filter (DPF) regeneration is inactive (not enabled).
• Steady drive-line state (no transition detected). No change in state of clutch switch (manual transmission)
or transmission shifter between in-gear position and neutral or park (Automatic transmission).
• Power Takeoff (PTO) remote mode disabled.
• Engine coolant temperature greater than 60°F (16°C).
• No active coolant temperature sensor diagnostic faults.
• No active Intake Air Temperature (IAT) sensor diagnostic faults.
• Engine is operating in run mode or in active diagnostic tool mode.
• Vehicle speed is less than 1.25 mph.
• No active vehicle speed diagnostic faults.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 471

• PTO control is in OFF or Standby mode.

• Engine speed less than 700 rpm.
• Steady accelerator pedal position (no transition detected from any pre-set position).
• Steady brake pedal state (no transition detected from any pre-set state).
• Steady parking brake state (J1939) (no transition detected from any pre-set state).

Idle Shutdown Timer (IST) (Federal – Optional)

Idle time can be programmed from 5 to 120 minutes. While IST is installed, IST function will be active with
programmed shutdown time in effect. Parking brake transitions reset idler timer. If IST is enabled, Cold Ambient
Protection (CAP) will not function.

Federal IST Conditions

Following conditions must be true for IST to activate. Any change to true state of one or more of these conditions
will reset or disable IST.
Common Enable Conditions for All Federal IST Options
• Manual Diesel Particulate Filter (DPF) regeneration is inactive (not enabled).
• Steady drive-line state (no transition detected). No change in state of clutch switch (manual transmission)
or transmission shifter between in-gear position and neutral or park (Automatic transmission).
• Power Takeoff (PTO) remote mode disabled.
• Intake air temperature greater than 60°F (16°C) (Manufacturing Default, Customer adjustable parameter).
• Intake air temperature lower than 112°F (44°C) (Manufacturing Default, Customer adjustable parameter).
• Engine coolant temperature greater than 140°F (60°C).
• No active coolant temperature sensor diagnostic faults.
• No active Intake Air Temperature (IAT) sensor diagnostic faults.
• Engine is operating in run mode or in active diagnostic tool mode.
• Vehicle speed is less than 1.25 mph.
• Steady parking brake state (J1939). No transition detected from any pre-set state.
Additional operation options enable conditions depending on selected Federal IST operation mode:
Federal IST Mode 1: PTO Operation Option Enable Conditions
• Power Takeoff (PTO) control is in Off or Standby mode.
• Engine speed less than 750 rpm.
• Accelerator pedal position is less than 2%.
• No active accelerator pedal diagnostic faults.
• Steady brake pedal state (No transition detected).
• No active brake system diagnostic faults.
Federal IST Mode 2: No Load/Light Load Limit Option Enable Conditions
• Accelerator pedal position is less than 2%.
472 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

• No active accelerator pedal diagnostic faults.

• Steady brake pedal state (no transition detected).
• No active brake system diagnostic faults.
• Engine reported fuel usage (load) is less than Engine Control Module (ECM)-specified limit
(factory-calibrated, not customer adjustable).
Federal IST Mode 3: Tamper Proof Option Enable Conditions
• Engine reported fuel usage (load) is less than Engine Control Module (ECM)-specified limit
(factory-calibrated, not customer adjustable).
• Steady accelerator pedal position (no transition detected from any pre-set position).
• Steady brake pedal state (no transition detected from any pre-set state).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 473

SPN 596 FMI 19 - Cruise Control Enable Switch not detected on J1939

Fault Overview
Fault code sets when Engine Control Module (ECM) does not receive cruise control switch messages from Body
Controller.

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

Associated Faults
• SPN 597 FMI 19 (Body) • SPN 639 FMI 14 (J1939)

Fault Facts
Cruise control switches are wired to Body Controller (BC). Switch state is communicated to ECM through J1939
Data Link Network.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Cruise Control switch or circuit fault
• Incorrect Programmable Parameter (PP) setting
474 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 473).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 596 FMI 19.

Step 2 Check for active or pending fault codes. Decision

Use EST with Navistar® Engine Diagnostics. Key ON Engine OFF (KOEO), check Yes: Go to Step 3.
DTC list for SPN 596 FMI 19.
Is SPN 596 FMI 19 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 3 Verify Cruise Control Programmable Parameters (PP). Decision

A. Verify vehicle is equipped with cruise control hardware (cruise switches Yes: Go to Step 4.
on steering wheel).
B. Use EST with Navistar® Engine Diagnostics, check status of parameter
number 76001.
If vehicle is equipped with cruise switches, is PP 76001 set to ON? No: Program PP 76001 to ON, if
vehicle has cruise control. After
repairs are complete, retest for
SPN 596 FMI 19.

Step 4 Verify Cruise Control activates and controls vehicle speed. Decision
Yes: End diagnostics. Retest for
WARNING:
SPN 596 FMI 19.

To prevent personal injury or death, do not exceed local speed

limit laws or drive too fast for conditions.
A. Check PP 76031 Cruise Control Vehicle Speed Low Limit.
B. When conditions are safe, drive vehicle above PP 76031 setting and
activate cruise control.
Does cruise control activate and hold set MPH? No: Go to appropriate Electronic
Troubleshooting Guide for further
diagnosis of Cruise Control
system. After repairs are
complete, retest for SPN 596 FMI
19.

End Diagnostic Tests

After performing all diagnostic steps, if SPN 596 FMI 19 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 475

SPN 597 FMI 2 - Brake switch or circuit fault

Fault Overview
Fault code sets when Brake status is missing on J1939 CAN Bus network.

Lamp Reaction
No Lamp

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• Caused by body controller fault code
476 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active Source Address 33 Body Control Module (BCM) fault codes. Decision
Using EST with Key ON, check DTC list for SPN 597 fault codes coming from Source Yes: See appropriate
Address 33, the BCM. vehicle Technician
Manual > Electrical /
Software > Exterior
Lighting > Brake
Switch for diagnostic
overview and step based
diagnostics. After repair
are complete, retest for
SPN 597 FMI 2.
Is EST DTC list free of SPN 597 fault codes coming from the BCM? No: Diagnose and
repair BCM brake
switch fault codes.
See appropriate vehicle
Technician Manual >
Electrical / Software >
Exterior Lighting > Brake
Switch for diagnostic
overview and step based
diagnostics. After repair
are complete, retest for
SPN 597 FMI 2.

End Diagnostic Tests

After performing all diagnostic steps, if SPN 597 FMI 2 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 477

SPN 597 FMI 19 - Brake Switch not detected on J1939

Fault Overview

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Caused by body controller fault code
478 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active Source Address 33 Body Control Module (BCM) fault codes. Decision
Using EST with Key ON, check DTC list for SPN 597 fault codes coming from Source Yes: See appropriate
Address 33, the BCM. vehicle Technician
Manual > Electrical /
Software > Exterior
Lighting > Brake
Switch for diagnostic
overview and step based
diagnostics. After repair
are complete, retest for
SPN 597 FMI 19.
Is EST DTC list free of SPN 597 fault codes coming from the BCM? No: Diagnose and
repair BCM brake
switch fault codes.
See appropriate vehicle
Technician Manual >
Electrical / Software >
Exterior Lighting > Brake
Switch for diagnostic
overview and step based
diagnostics. After repair
are complete, retest for
SPN 597 FMI 19.

End Diagnostic Tests

After performing all diagnostic steps, if SPN 597 FMI 19 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 479

SPN 609 FMI 3 - DCU Switched voltage too HIGH

Fault Overview
Fault is set when voltage supply to Doser Control Unit (DCU) is higher than normal or voltage at output of DCU
voltage divider is higher than normal

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

Associated Faults
None

Fault Facts
Jump-starting from a vehicle or booster pack using greater than 16 volts can also cause this fault to set.

Drive Cycle to Determine Fault Status

None
Possible Causes
• Incorrect battery pack wiring (series instead of parallel)
• Charging voltage excessive

Step 1 Check for correct parallel battery pack wiring. Decision

A. Check for correct parallel battery pack wiring. Yes: Refer to iKNow article
IK0800403.
B. Positive battery cable(s) should be connected from positive battery
terminal to positive battery terminal.
C. Negative battery cable(s) should be connected from negative battery
terminal to negative battery terminal.
Is battery pack correctly assembled (wired in parallel and Not in series)? No: Reassemble battery pack.
After repairs are complete, retest
for SPN 609 FMI 3.

End Diagnostic Tests

After performing diagnostic steps, if SPN 609 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
480 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 609 FMI 4 - DCU Switched voltage too LOW

Fault Overview
Fault is set when voltage supply to Doser Control Unit (DCU) is lower than normal or voltage at output of DCU
voltage divider is lower than normal.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Low battery or charging system voltage
• DCU PWR circuit high resistance
• GND circuit high resistance
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 481

Step 1 Check for active or pending fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON, Yes: Go to Step 2.
Engine Off (KOEO), check Diagnostic Trouble Codes (DTC) list for SPN 609 FMI 4.
Is SPN 609 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

WARNING:

To prevent property damage, personal injury, and/or death, keep flames or sparks away
from vehicle and do not smoke while servicing vehicle’s batteries. Batteries may expel
explosive gases.

To prevent property damage, personal injury, and/or death, wear eye protection.

Step 2 Inspect battery connections and terminals. Decision

A. Key-Off. Yes: Go to Step 3.
B. Check battery connections and terminals for: damage; wet or corroded
terminals; loose, bent, or broken connections; or broken connector
housing.
Are battery connections, harnesses, and terminals clean and undamaged? No: Repair connections,
harnesses, or terminal damage.
After repairs are complete, retest
for SPN 609 FMI 4.

WARNING:

To prevent property damage, personal injury, and/or death, always disconnect ground
battery terminal first, then positive cable. When reconnecting battery cables, connect
positive cables first, and then reconnect negative cables. Failure to follow this warning
may result in a direct battery short, which is a fire or explosion hazard.

Step 3 Measure battery voltage. Decision

A. Key-Off. Yes: Go to Step 4
B. Disconnect Battery negative connection.

C. Disconnect Battery positive connection.

D. Use DMM, measure battery voltage across batteries.
Is voltage greater than 10 volts? No: Refer to iKNow article
IK0800403. After repairs are
complete, retest for SPN 609 FMI
4.
482 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 4 Inspect connections at Doser Control Unit (DCU) Module 53-pin and Decision
86-pin connectors.
A. Key OFF. Yes: Go to Step 5.
B. Disconnect DCU Module connectors.

C. Check DCU Module connectors and terminals for: damaged or pinched

wires; moist or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are DCU Module connectors, harnesses, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 609
FMI 4.

Step 5 Check for PWR and GND to DCU. Decision

A. Key OFF. Yes: End diagnostics. Retest for
SPN 609 FMI 4.
B. Disconnect DCU Module 53-pin connector.
C. Insert applicable terminal test pins from Terminal Test Kit ZTSE4435C,
into DCU 53-pin connector pin-6, pin-1, pin-7, and pin-2 and leave DCU
Module disconnected.
D. Key ON Engine OFF (KOEO)
E. Use DMM, measure voltage for following:
• Between DCU 53-pin connector pin-6 and pin-1.
• Between DCU 53-pin connector pin-7 and pin-1.
• Between DCU 53-pin connector pin-6 and pin-2.
• Between DCU 53-pin connector pin-7 and pin-2.
Is voltage B+ ± 0.5 volts? No: Go to Step 6.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 483

Step 6 Check DCU B+ circuit for Open or short to GND. Decision

A. Key OFF. Yes: Repair Open in DCU
GND circuits. After repairs are
B. Disconnect DCU Module 53-pin connector.
complete, retest for SPN 609 FMI
C. Insert applicable terminal test pins from Terminal Test Kit ZTSE4435C, 4.
into DCU 53-pin connector pin-6 and pin-7 and leave DCU Module
disconnected.

D. Key ON Engine OFF (KOEO).

E. Use DMM, measure voltage for following:
• Between DCU 53-pin connector pin-6 and known good GND.
• Between DCU 53-pin connector pin-7 and known good GND.
Is voltage B+ ± 0.5 volts? No: Repair Open or short to GND
in DCU B+ circuits. After repairs
are complete, ensure 40-amp
DCU fuse is not blown and retest
for SPN 609 FMI 4.

End Diagnostic Test

After performing diagnostic steps, if SPN 609 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
484 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 609 FMI 12 - DCU Internal chip Error

Fault Overview
The fault sets when the ECM detects that the Aftertreatment Control Module (ACM) has an internal chip error.

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

Associated Faults
SPN 609 FMI 3, 4 and 19

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• DCU calibration out of date
• Failed DCU

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 484).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 609 FMI 12.

Step 2 Check for active or pending fault codes. Decision

®
Use EST with Navistar Engine Diagnostics. Key On, Engine Off (KOEO), check Yes: Go to Step 3.
DTC list for SPN 609 FMI 12.
Is SPN 609 FMI 12 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 609 FMI 12.

Step 3 Check for Doser Control Unit (DCU) current calibration. Decision
Use NavKal or calibration scorecard, check if DCU calibration is current. Yes: Go to Step 4.
Is DCU calibration current? No: Update DCU calibration and
retest for SPN 609 FMI 12.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 485

Step 4 Check for hard fault. Decision

A. Key-Off. Yes: Replace DCU. After repairs
are complete, retest for SPN 609
B. Connect EST to vehicle Diagnostic Connector (page 1345).
FMI 12.
C. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
D. Use Navistar® Engine Diagnostics clear fault codes.

E. Key OFF for 30 seconds or until Engine Control Module (ECM) powers
down.
F. Key ON Engine OFF (KOEO).
Did SPN 609 FMI 12 set after codes were cleared? No: End diagnostics. Retest for
SPN 609 FMI 12.

End Diagnostic Test

After performing diagnostic steps, if SPN 609 FMI 12 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
486 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 609 FMI 19 - DCU not detected on J1939

Fault Overview
Fault set when CAN communication link (J1939) between Engine Control Module (ECM) and Doser Control Unit
(DCU) is not detected.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• DCU B+ circuit Open or short to GND
• DCU GND circuit Open
• SWBAT Open or short to GND
• CAN-H circuit Open or short to GND
• CAN-H circuit short to PWR
• CAN-L circuit Open or short to GND
• CAN-L circuit short to PWR
• CAN-H circuit short to CAN-L circuit
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 487

Step 1 Check for active or pending fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON Yes: Go to Step 2.
Engine OFF (KOEO), check Diagnostic Trouble Code (DTC) list for SPN 609 FMI 19.
Does EST DTC list show SPN 609 FMI 19 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Inspect connections at Doser Control Unit (DCU) Module 53-pin and Decision
86-pin connectors.
A. Key OFF. Yes: Go to Step 3.
B. Disconnect DCU Module connectors.
C. Check DCU Module connectors and terminals for: damaged or pinched
wires; moist or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are DCU Module connectors, harnesses, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 609
FMI 19.

Step 3 Check for PWR and GND to DCU. Decision

A. Key OFF. Yes: Go to Step 5.

B. Disconnect DCU Module 53-pin connector.

C. Insert applicable terminal test pins from Terminal Test Kit ZTSE4435C,
into DCU 53-pin connector pin-6, pin-1, pin-7, and pin-2 and leave DCU
Module disconnected.
D. Use DMM, measure voltage for following:
• Between DCU 53-pin connector pin-6 and pin-1.
• Between DCU 53-pin connector pin-7 and pin-1.
• Between DCU 53-pin connector pin-6 and pin-2.
• Between DCU 53-pin connector pin-7 and pin-2.
Is voltage B+ ± 0.5 volts? No: Go to Step 4.
488 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 4 Check DCU B+ circuit for Open or short to GND. Decision

A. Key OFF. Yes: Repair Open in DCU
GND circuits. After repairs are
B. Disconnect DCU Module 53-pin connector.
complete, retest for SPN 609 FMI
C. Insert applicable terminal test pins from Terminal Test Kit ZTSE4435C, 19.
into DCU 53-pin connector pin-6 and pin-7 and leave DCU Module
disconnected.

D. Use DMM, measure voltage for following:

• Between DCU 53-pin connector pin-6 and known good GND.
• Between DCU 53-pin connector pin-7 and known good GND.
Is voltage B+ ± 0.5 volts? No: Repair Open or short to GND
in DCU B+ circuits. After repairs
are complete, retest for SPN 609
FMI 19.

Step 5 Check DCU SWBAT circuit for Open or short to GND. Decision
A. Key OFF. Yes: Go to Step 6.

B. Disconnect DCU Module 53-pin connector.

C. Insert applicable terminal test pins from Terminal Test Kit ZTSE4435C,
into DCU Module 53-pin connector pin-52 and leave DCU Module
disconnected.
D. Key ON Engine OFF (KOEO).
E. Use DMM, measure voltage between DCU 53-pin connector pin-52 and
known good GND.
Is voltage B+ ± 0.5 volts? No: Repair Open or short to GND
in DCU SWBAT circuit. After
repairs are complete, retest for
SPN 609 FMI 19.

Step 6 Check for CAN-H Open or short to GND. Decision

A. Key OFF. Yes: Go to Step 7.

B. Disconnect DCU Module 53-pin connector.

C. Insert applicable terminal test pins from Terminal Test Kit ZTSE4435C,
into DCU Module 53-pin connector pin-14 and leave DCU Module
disconnected.
D. Key ON Engine OFF (KOEO).

E. Use DMM, measure voltage between DCU 53-pin connector pin-14 and
known good GND.
Is voltage greater than 1 volt? No: Repair Open or short to GND
in CAN-H circuit. After repairs are
complete, retest for SPN 609 FMI
19.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 489

Step 7 Check for CAN-H short to PWR. Decision

A. Key OFF. Yes: Go to Step 8.

B. Disconnect DCU Module 53-pin connector.

C. Insert applicable terminal test pins from Terminal Test Kit ZTSE4435C,
into DCU Module 53-pin connector pin-14 and leave DCU Module
disconnected.

D. Key ON Engine OFF (KOEO).

E. Use DMM, measure voltage between DCU 53-pin connector pin-14 and
known good GND.
Is voltage less than 4 volts? No: Repair CAN-H short to PWR.
After repairs are complete, retest
for SPN 609 FMI 19.

Step 8 Check for CAN-L Open or short to GND. Decision

A. Key OFF. Yes: Go to Step 9.

B. Disconnect DCU Module 53-pin connector.

C. Insert applicable terminal test pins from Terminal Test Kit ZTSE4435C,
into DCU Module 53-pin connector pin-15 and leave DCU Module
disconnected.
D. Key ON Engine OFF (KOEO).
E. Use DMM, measure voltage between DCU 53-pin connector pin-15 and
known good GND.
Is voltage greater than 1 volt? No: Repair Open or short to GND
in CAN-L circuit. After repairs are
complete, retest for SPN 609 FMI
19.

Step 9 Check for CAN-L short to PWR Decision

A. Key OFF. Yes: Go to Step 10.
B. Disconnect DCU Module 53-pin connector.

C. Insert applicable terminal test pins from Terminal Test Kit ZTSE4435C, into
DCU Module 53-pin connector pin-15 and leave DCU Module disconnected.
D. Key ON Engine OFF (KOEO).

E. Use DMM, measure voltage between DCU 53-pin connector pin-15 and
known good GND.
Is voltage less than 4 volts? No: Repair CAN-L short to PWR
After repairs are complete, retest
for SPN 609 FMI 19.
490 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 10 Check for short between CAN-H and CAN-L circuits. Decision
A. Key OFF. Yes: The fault code is not present
at the moment. Go to Intermittent
B. Disconnect DCU Module 53-pin connector.
or Inactive Fault Diagnostic
C. Insert applicable terminal test pins from Terminal Test Kit ZTSE4435C, into Procedure (page 1344) to isolate
DCU Module 53-pin connector pin-15 and pin-14 and leave DCU Module and repair the intermittent circuit
disconnected. failure. After repairs are complete,
retest for SPN 609 FMI 19.
D. Use DMM, measure resistance between DCU 53-pin connector pin-15
and pin-14.
Is resistance greater than 50 ohms? No: Repair Short between CAN-H
and CAN-L. After repairs are
complete, retest for SPN 609 FMI
19.

End Diagnostic Test

After performing diagnostic steps, if SPN 609 FMI 19 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 491

SPN 628 FMI 12 - ECM Memory Error

Fault Overview
Fault code sets when Engine Control Module (ECM) detects an internal memory error within ECM.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Key ON
Possible Causes
• Internal ECM failure
492 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault code. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON Yes: End diagnostics, retest for
Engine OFF (KOEO), check Diagnostic Trouble Code (DTC) list for SPN 628 SPN 628 FMI 12.
FMI 12.
Does EST DTC list show SPN 628 FMI 12 as active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344). After repairs are complete,
retest for SPN 628 FMI 12.

End Diagnostic Step

After performing diagnostic step, if SPN 628 FMI 12 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 493

SPN 629 FMI 0 - ECM Error - CPU Load Excessively HIGH

Fault Overview
Fault code sets when the Engine Control Module (ECM) detects Central Processing Unit (CPU) load is
excessively high.

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Key ON
Possible Causes
• Failed Software
• Failed ECM

Step 1 Check for active or pending fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON Yes: Reprogram ECM. After
Engine OFF (KOEO), check Diagnostic Trouble Code (DTC) list for SPN 629 FMI 0. reprogramming is complete, retest
for SPN 629 FMI 0.
Is SPN 629 FMI 0 active or pending? No: End of diagnostics. Retest for
SPN 629 FMI 0.

End Diagnostic Step

After performing diagnostic step, if SPN 629 FMI 0 remains, verify each step was completed correctly and proper
decision was made.
494 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 629 FMI 8 - ECM Error - Engine Off Timer fault

Fault Overview
Fault code sets when Engine Control Module (ECM) detects engine OFF timer is not reading as expected.
Problem with Keep Alive Power (KAPWR) circuit.

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

Associated Faults
None

Fault Facts
ECM Timer Fuse may be an in-line fuse in engine compartment, see Truck Wiring Diagram for more information.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• KAPWR high resistance, open circuit or short to GND

Step 1 Check for active or pending fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON Yes: Go to Step 2.
Engine OFF (KOEO), check Diagnostic Trouble Code (DTC) list for SPN 629 FMI 8.
Is EST DTC list show SPN 629 FMI 8 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 2 Check for active fault code after Engine Control Module (ECM) reset. Decision
A. Key OFF. Yes: Go to Step 3.

B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector

(page 1345).
C. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
D. Use EST with Navistar® Engine Diagnostics, clear codes.
E. Key OFF, wait for EST screens to clear.

F. Key ON Engine OFF (KOEO), check DTC list for SPN 629 FMI 8.
Is EST DTC list SPN 629 FMI 8 active or pending? No: Repair is complete. Retest
for SPN 629 FMI 8.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 495

Step 3 Check voltage at ECM pin C-46. Decision

Measure voltage to known good ground from ECM pin C-46 in all key states, and Yes: Go to Step 4.
with battery kill switch engaged and disengaged.
Was voltage always B+? No: Restore circuit from B+ to
ECM pin C-46. After repairs are
complete, retest for SPN 629 FMI
8.

Step 4 Inspect connections at Keep Alive Power (KAPWR) fuse holder. Decision
A. Key OFF. Yes: Go to Step 5.
B. Disconnect KAPWR fuse holder harness connector.
C. Check KAPWR fuse holder connector terminals for damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are KAPWR fuse holder connector, harness and terminals clean and undamaged? No: Repair connector, connector,
harness, or terminal damage.
After repairs are complete, retest
for SPN 629 FMI 8

Step 5 Inspect Keep Alive Power (KAPWR) 5 amp fuse. Decision

Inspect KAPWR 5 amp fuse. Yes: Replace KAPWR 5 amp fuse
and repair short to GND between
ECM pin C-46 and KAPWR 5 amp
fuse. After repairs are complete,
clear fault code and retest for
SPN 629 FMI 8.
Is KAPWR 5 amp fuse burned out? No: Go to Step 6.

Step 6 Measure voltage at KAPWR fuse. Decision

Measure voltage to known good ground on both sides of KAPWR fuse. Yes: Repair Open circuit between
KAPWR fuse and ECM terminal
C-46. After repairs are complete,
retest for SPN 629 FMI 8.
Is B+ voltage present on both sides of KAPWR fuse? No: Repair Open between
KAPWR fuse and truck wiring
harness. After repairs are
complete, retest for SPN 629 FMI
8.

End Diagnostic Steps

After performing diagnostic steps, if SPN 629 FMI 8 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
496 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 629 FMI 12 - ECM Internal Chip Error

Fault Overview
Fault code sets when Engine Control Module (ECM) detects an internal chip error within ECM.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Key ON
Possible Causes
• Failed ECM
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 497

Step 1 Check for active or pending fault codes. Decision

A. Key OFF. Yes: Replace ECM. After repairs
are complete, retest for SPN 629
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
FMI 12.
(page 1345).

C. Key ON, Engine OFF (KOEO), log into Navistar® Engine Diagnostics.
D. Use EST with Navistar® Engine Diagnostics, clear codes.
E. Key OFF, wait until ECM powers down or EST communication stops.
F. Key ON, Engine OFF (KOEO), check Diagnostic Trouble Code (DTC) list
for SPN 629 FMI 12.
Is SPN 629 FMI 12 active or pending after codes were cleared? No: End diagnostics. Retest for
SPN 629 FMI 12.

End Diagnostic Step

After performing diagnostic steps, if SPN 629 FMI 12 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
498 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 636 FMI 2 - CMP and CKP Synchronization Error

Fault Overview
Fault sets when the Engine Control Module (ECM) determines the comparison of Engine Timing Sensor signal
to modeled value is incorrect.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• CMP-H Open or shorted to GND
• CMP-H shorted to PWR
• CMP-L Open or shorted to GND
• CMP-L shorted to PWR
• CMP-H shorted CMP-L
• Failed CMP sensor
• Damaged sensor
• Incorrect sensor air gap

Step 1 Check for active or pending fault codes. Decision

®
Use EST with Navistar Engine Diagnostics. Key ON Engine OFF (KOEO), check Yes: Go to Step 2.
DTC list for SPN 636 FMI 2.
Does EST DTC list show SPN 636 FMI 2 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 499

Step 2 Inspect Camshaft Position (CMP) connections. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect CMP.
C. Check CMP connection terminals for: damaged or pinched wires; wet
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are CMP connections, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 636
FMI 2.

Step 3 Measure CMP-H circuit. Decision

A. Perform Test 1 (page 503). Yes: Go to Step 5.
B. Use DMM, measure voltage between Breakout Harness ZTSE4951 pin-1
and known good GND.
Is voltage approximately 2.5 ± 0.25 volts? No: Go to Step 4.

Step 4 Measure CMP-H circuit. Decision

A. Perform Test 1 (page 503). Yes: Repair short to PWR
between CMP pin-1 and ECM pin
B. Use DMM, measure voltage between Breakout Harness ZTSE4951 pin-1
E-42. After repairs are complete,
and known good GND.
retest for SPN 636 FMI 2.
Is voltage greater than 2.5 ± 0.25 volts? No: Voltage less than 2.5 ± 0.25
volts. Repair Open or short to
GND between CMP pin-1 and
ECM pin E-42. After repairs are
complete, retest for SPN 636 FMI
2.

Step 5 Measure CMP-L circuit. Decision

A. Perform Test 2 (page 503). Yes: Go to Step 7.
B. Use DMM, measure voltage between Breakout Harness ZTSE4951 pin-2
and known good GND.
Is voltage 2.5 ± 0.25 volts? No: Go to Step 6.
500 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 6 Measure CMP-L circuit. Decision

A. Perform Test 2 (page 503). Yes: Repair short to PWR
between CMP pin-2 and ECM pin
B. Use DMM, measure voltage between Breakout Harness ZTSE4951 pin-2
E-24. After repairs are complete,
and known good GND.
retest for SPN 636 FMI 2.
Is voltage greater than 2.5 ± 0.25 volts? No: Voltage less than 2.5 ± 0.25
volts. Repair Open or short to
GND between CMP pin-2 and
ECM pin E-24. After repairs are
complete, retest for SPN 636 FMI
2.

Step 7 Check for CMP-H shorted to CMP-L. Decision

A. Perform Test 3 (page 504). Yes: Repair short between CMP-H
and CMP-L. After repairs are
B. Use DMM, measure resistance between Breakout Harness ZTSE4951
complete, retest for SPN 636 FMI
pin-1 and pin-2.
2.
Is resistance less than 1000 ohms? No: Go to Step 8.

Step 8 Measure CMP resistance. Decision

A. Perform Test 4 (page 504). Yes: Go to Step 9.
B. Use DMM, measure resistance between Breakout Harness ZTSE4951
pin-1 and pin-2.
Is resistance between 280 and 560 ohms? No: Replace CMP sensor. After
repairs are complete, retest for
SPN 636 FMI 2.

Step 9 Inspect CMP sensor for visual mechanical damage. Decision

A. Key OFF. Yes: Correct source of contact
between camshaft peg and CMP
B. Disconnect and remove CMP sensor from engine.
sensor (walking camshaft and/or
C. Check CMP sensor for mechanical damage or a build up of metal on gear) or metal in oil. Replace CMP
sensor. sensor after source of failure has
been corrected. After repairs are
complete, retest for SPN 636 FMI
2.
Is CMP sensor mechanically damaged or is metal present on sensor tip? No: Go to Step 10.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 501

Step 10 Measure CMP Air Gap. Decision

A. Key OFF with CMP sensor still removed from Step 9. Yes: Repair incorrect gear train
timing and possible engine
B. Bar engine over until camshaft peg is visible in front cover opening.
damage. After repairs are
C. Use Vernier Caliper or equivalent, measure from front cover CMP mounting complete, retest for SPN 636 FMI
surface to camshaft gear timing peg (Measurement A (Figure 153)). 2.
D. Measure length of cam sensor from mounting flange to sensor tip
(Measurement B (Figure 155)).
E. Subtract measurement A from measurement B (B - A = Air Gap).
Is Air Gap between 0.00984 in (0.25 mm) and 0.06024 in (1.53 mm)? No: Repair worn or walking
camshaft gear spacer. After
repairs are complete, retest for
SPN 636 FMI 2.

End Diagnostic Tests

After performing all diagnostic steps, if SPN 636 FMI 2 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.

Figure 153 Measure Air Gap (Measurement A)

1. Air Gap
502 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 154 Measure Air Gap

1. Measurement A 3. Peg
2. Cam Gear 4. Front Cover

Figure 155 Measure Air Gap (Measurement B)

1. Measurement B
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 503

Pin-Point Tests (SPN 636 FMI 2)

Figure 156 CMP circuit diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4951
• 180-pin Breakout Box 00-0956-08
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Figure 157 Check CMP-H Circuits

Test 1
A. Key OFF.

B. Disconnect Camshaft Position (CMP) sensor.

C. Connect Breakout Harness ZTSE4951 to vehicle harness connector and leave CMP sensor disconnected.

D. Key ON Engine OFF (KOEO).

504 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 158 CMP-L Circuit Check

Test 2
A. Key OFF.
B. Disconnect Camshaft Position (CMP).
C. Connect Breakout Harness ZTSE4951 to vehicle harness connector and leave CMP disconnected.
D. Key ON Engine OFF (KOEO).

Figure 159 CMP Circuit Check

Test 3
A. Key OFF.
B. Disconnect Camshaft Position (CMP) sensor.
C. Connect Breakout Harness ZTSE4951 to vehicle harness connector and leave CMP sensor disconnected.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 505

Figure 160 CMP Circuit Check

Test 4
A. Key OFF.
B. Disconnect Camshaft Position (CMP) sensor.
C. Connect Breakout Harness ZTSE4951 to CMP sensor and leave engine harness disconnected.
506 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 636 FMI 7 - CMP to CKP incorrect reference

Fault Overview
Fault sets when Engine Control Module (ECM) detects comparison of Crankshaft and Camshaft signals are
incorrect.

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected during one drive cycle.

Associated Faults
SPN 636 FMI 2 (CMP)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Incorrect CMP/CKP timing
• CKP Timing Disk misaligned
• CMP and CKP timing gears out of alignment
• CMP timing gear Woodruff key damaged
• CKP timing gear Woodruff key damaged
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 507

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults(page 506).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 636 FMI 7.

Step 2 Check for active or pending fault codes. Decision

Use EST with Navistar® Engine Diagnostics. Key ON Engine OFF (KOEO), check Yes: Go to Step 3.
DTC list for SPN 636 FMI 7.
Does EST DTC list show SPN 636 FMI 7 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 3 Check for CMP and CKP incorrect timing. Decision

Inspect CMP and CKP timing gears for correct alignment, inspect CMP and CKP Yes: Repair damaged or
Woodruff keys for damage, inspect CKP timing disk for misalignment. See Engine misaligned components. After
Service Manual. repairs are complete, retest for
SPN 636 FMI 7.
Is there damaged or misaligned components? No: End of diagnostics. Retest for
SPN 636 FMI 7.

End Diagnostic Tests

After performing all tests, if no problem is found, verify each step was completed correctly and proper decision was
made. Return to SPN 636 FMI 7 fault code diagnostics.
508 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 637 FMI 8 - CKP signal noise

Fault Overview
Fault sets when Engine Control Module (ECM) detects synchronization on crankshaft signal is not achieved.

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected during one drive cycle.

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• CKP-H Open
• CKP-L Open
• CKP sensor Open
• CKP Sensor mechanically damaged
• CKP timing disk damaged
• CKP sensor incorrectly mounted
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 509

Step 1 Check for active or pending fault codes. Decision

®
Use EST with Navistar Engine Diagnostics. Key ON Engine OFF (KOEO), check Yes: Go to Step 2.
DTC list for SPN 637 FMI 8.
Does EST DTC list show SPN 637 FMI 8 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Inspect Crankshaft Position (CKP) connections. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect CKP.
C. Check CKP connection terminals for: damaged or pinched wires; wet
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are CKP connections, harness, and terminals clean and undamaged? No: Repair connector, harness, or
terminal damage. After repairs are
complete, retest for SPN 637 FMI
8.

Step 3 Measure CKP-H circuit Decision

A. Perform Test 1 (page 511). Yes: Go to Step 4.
B. Use DMM, measure voltage between Breakout Harness ZTSE4950 pin-1
and known good GND.
Is voltage approximately 2.5 volts? No: Repair open circuit between
CKP pin-1 and ECM pin E-41.
After repairs are complete, retest
for SPN 637 FMI 8.

Step 4 Measure CKP-L circuit Decision

A. Perform Test 2 (page 511). Yes: Go to Step 5.
B. Use DMM, measure voltage between Breakout Harness ZTSE4950 pin-2
and known good GND.
Is voltage approximately 2.5 volts? No: Repair open circuit between
CKP pin-2 and ECM pin E-25.
After repairs are complete, retest
for SPN 637 FMI 8.

Step 5 Measure CKP circuit Decision

A. Perform Test 3 (page 512). Yes: Go to Step 6.

B. Use DMM, measure resistance between Breakout Harness ZTSE4950

pin-1 and pin-2.
Is resistance between 616 and 1275 ohms? No: Replace CKP sensor. After
repairs are complete, retest for
SPN 637 FMI 8.
510 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 6 Inspect CKP sensor for visual mechanical damage. Decision

A. Key OFF. Yes: Replace CKP sensor. After
repairs are complete, retest for
B. Disconnect and remove CKP sensor.
SPN 636 FMI 2.
C. Check CKP sensor for mechanical damage.
Is CKP sensor mechanically damaged? No: Go to Step 7.

Step 7 Inspect CKP sensor for correct mounting Decision

A. Key OFF. Yes: Repair CKP timing disk.
After repairs are complete, retest
B. Disconnect and remove CKP sensor.
for SPN 637 FMI 8.
C. Check CKP sensor for correct mounting.
Is CKP sensor correctly mounted? No: Mount CKP sensor correctly.
After repairs are complete, retest
for SPN 637 FMI 8.

End Diagnostic Tests

After performing all diagnostic steps, if SPN 637 FMI 8 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 511

Pin-Point Tests (SPN 637 FMI 8)

Figure 161 CKP circuit diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4950
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Figure 162 CKP-H Circuit Check

Test 1
A. Key OFF.

B. Disconnect Crankshaft Position (CKP) sensor.

C. Connect Breakout Harness ZTSE4950 to vehicle harness connector and leave CKP sensor disconnected.

D. Key ON Engine OFF (KOEO).

512 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 163 CKP-L Circuit Check

Test 2
A. Key OFF.
B. Disconnect CKP sensor.
C. Connect Breakout Harness ZTSE4950 to vehicle harness connector and leave CKP sensor disconnected.
D. Key ON Engine OFF (KOEO).

Figure 164 CKP Circuit Check

Test 3
A. Key OFF.
B. Disconnect CKP sensor.

C. Connect Breakout Harness ZTSE4950 to CKP sensor and leave vehicle harness disconnected.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 513

SPN 637 FMI 10 - CKP signal inactive

Fault Overview
Fault sets when Engine Control Module detects crankshaft sensor has a short or open.

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected during one drive cycle.

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• CKP-H Open or Short to GND
• CKP-H Short to PWR
• CKP-L Open or Short to GND
• CKP-L Short to PWR
• Failed CKP sensor

Step 1 Check for active or pending fault codes. Decision

®
Use EST with Navistar Engine Diagnostics. Key ON Engine OFF (KOEO), check Yes: Go to Step 2.
DTC list for SPN 637 FMI 10.
Does EST DTC list show SPN 637 FMI 10 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Inspect Crankshaft Position (CKP) connections. Decision

A. Key OFF. Yes: Go to Step 3.

B. Disconnect CKP.
C. Check CKP connection terminals for: damaged or pinched wires; wet
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are CKP connections, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 637
FMI 10.
514 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Measure CKP-H circuit Decision

A. Perform Test 1 (page 516). Yes: Go to Step 6.
B. Use DMM, measure voltage between Breakout Harness ZTSE4950 pin-1
and known good GND.
Is voltage approximately 2.5 volts? No: Go to Step 4.

Step 4 Measure CKP-H circuit Decision

A. Perform Test 1 (page 516). Yes: Repair short to PWR
between CKP pin-1 and ECM pin
B. Use DMM, measure voltage between Breakout Harness ZTSE4950 pin-1
E-41. After repairs are complete,
and known good GND.
retest for SPN 637 FMI 10.
Is voltage greater than 2.5 Volts? No: Go to Step 5.

Step 5 Measure CKP-H circuit Decision

A. Perform Test 1 (page 516). Yes: Repair Open or short to GND
between CKP pin-1 and ECM pin
B. Use DMM, measure voltage between Breakout Harness ZTSE4950 pin-1
E-41. After repairs are complete,
and known good GND.
retest for SPN 637 FMI 10.
Is voltage less than 2.5 Volts? No: Go to Step 6.

Step 6 Measure CKP-L circuit Decision

A. Perform Test 2(page 516). Yes: Replace CKP sensor. After
repairs are complete, retest for
B. Use DMM, measure voltage between Breakout Harness ZTSE4950 pin-2
SPN 637 FMI 10.
and known good GND.
Is voltage approximately 2.5 volts? No: Go to Step 7.

Step 7 Measure CKP-L circuit Decision

A. Perform Test 2(page 516). Yes: Repair short to PWR
between CKP pin-2 and ECM pin
B. Use DMM, measure voltage between Breakout Harness ZTSE4950 pin-2
E-25. After repairs are complete,
and known good GND.
retest for SPN 637 FMI 10.
Is voltage greater than 2.5 volts? No: Go to Step 8.

Step 8 Measure CKP-L circuit Decision

A. Perform Test 2(page 516). Yes: Repair Open or short to GND
between CKP pin-2 and ECM pin
B. Use DMM, measure voltage between Breakout Harness ZTSE4950 pin-2
E-25. After repairs are complete,
and known good GND.
retest for SPN 637 FMI 10.
Is voltage less than 2.5 Volts? No: End diagnostics. Retest for
SPN 637 FMI 10.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 515

End Diagnostic Tests

After performing all diagnostic steps, if SPN 637 FMI 10 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
516 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 637 FMI 10)

Figure 165 CKP circuit diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4950
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Figure 166 Check CKP-H Circuits

Test 1
A. Key OFF.

B. Disconnect Crankshaft Position (CKP) sensor.

C. Connect Breakout Harness ZTSE4950 to vehicle harness connector and leave CKP sensor disconnected.

D. Key ON Engine OFF (KOEO).

 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 517

Figure 167 Check CKP-L Circuits

Test 2
A. Key OFF.
B. Disconnect Crankshaft Position (CKP) sensor.
C. Connect Breakout Harness ZTSE4950 to vehicle harness connector and leave CKP sensor disconnected.
D. Key ON Engine OFF (KOEO).
518 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 639 FMI 14 - J1939 Data Link Error (ECM unable to transmit)

Fault Overview
Fault sets when the Engine Control Module (ECM) is unable to transmit; J1939 data link error.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• ECM PWR circuits Open or short to GND
• ECM GND circuits Open
• SWBAT circuit Open or short to GND
• CAN-H Open or short to GND
• CAN-L Open or short to GND
• CAN-H short to PWR
• CAN-L short to PWR
• CAN-H shorted to CAN-L
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 519

Step 1 Check if Engine Control Module (ECM) will communicate with the Decision
Electronic Service Tool (EST).
A. Key-Off. Yes: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
1344).
(page 1345).

C. Key-On Engine-Off (KOEO), log in to Navistar® Engine Diagnostics.

Does Navistar® Engine Diagnostics connect to vehicle and is ECM count increasing No: Go to Step 2.
in sniffer section of default session?

Step 2 Decision
A. Key-Off. Yes: Go to Step 3.
B. Disconnect ECM 76-pin Chassis connector.
C. Connect chassis Breakout Harness 00-00959-01 between vehicle chassis
harness and ECM.
D. Connect Breakout Harness 00-00959-01 to 180-pin Breakout Box
00-00956-08.
E. Key-On Engine-Off (KOEO).
F. Use Digital Multimeter (DMM), measure voltage from ECM pins C-1, 3,
and 5 to known good GND.
Is voltage B+ ± 0.5 volts? No: Repair Open or short to GND
in ECM PWR circuit. After repairs
are complete, retest for SPN 639
FMI 14.

Step 3 Decision
A. Key-Off. Yes: Go to Step 4.
B. Disconnect ECM 76-pin Chassis connector.
C. Connect chassis Breakout Harness 00-00959-01 between vehicle chassis
harness and ECM.

D. Connect Breakout Harness 00-00959-01 to 180-pin Breakout Box

00-00956-08.
E. Key-On Engine-Off (KOEO).

F. Use DMM, measure voltage from ECM pins C-2, 4, and 6 to PWR.
Is voltage B+ ± 0.5 volts? No: Repair Open in ECM
GND circuits. After repairs are
complete, retest for SPN 639 FMI
14.
520 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 4 Decision
A. Key-Off. Yes: Go to Step 5.
B. Disconnect ECM 76-pin Chassis connector.
C. Connect chassis Breakout Harness 00-00959-01 between vehicle chassis
harness and ECM.

D. Connect Breakout Harness 00-00959-01 to 180-pin Breakout Box

00-00956-08.
E. Key-On Engine-Off (KOEO).
F. Use DMM, measure voltage from ECM pin C-31 to known good GND.
Is voltage B+ ± 0.5 volts? No: Repair Open or short to
GND between ECM pin C-31 and
Ignition switch. After repairs are
complete, retest for SPN 639 FMI
14.

Step 5 Decision
A. Key-Off. Yes: Go to Step 6.
B. Disconnect ECM 76-pin Chassis connector.
C. Connect chassis Breakout Harness 00-00959-01 between vehicle chassis
harness and ECM.
D. Connect Breakout Harness 00-00959-01 to 180-pin Breakout Box
00-00956-08.
E. Key-On Engine-Off (KOEO).
F. Use DMM, measure voltage from ECM pin C-61 to known good GND.
Is voltage greater than 1 volt? No: Repair short to GND between
ECM pin C-61 and other modules.
After repairs are complete, retest
for SPN 639 FMI 14.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 521

Step 6 Decision
A. Key-Off. Yes: Go to Step 7.
B. Disconnect ECM 76-pin Chassis connector.
C. Connect chassis Breakout Harness 00-00959-01 between vehicle chassis
harness and ECM.

D. Connect Breakout Harness 00-00959-01 to 180-pin Breakout Box

00-00956-08.
E. Key-On Engine-Off (KOEO).
F. Use DMM, measure voltage from ECM pin C-61 to known good GND.
Is voltage less than 4 volts? No: Repair short to PWR between
ECM pin C-61 and other modules.
After repairs are complete, retest
for SPN 639 FMI 14.

Step 7 Decision
A. Key-Off. Yes: Go to Step 8.
B. Disconnect ECM 76-pin Chassis connector.
C. Connect chassis Breakout Harness 00-00959-01 between vehicle chassis
harness and ECM.
D. Connect Breakout Harness 00-00959-01 to 180-pin Breakout Box
00-00956-08.
E. Key-On Engine-Off (KOEO).
F. Use DMM, measure voltage from ECM pin C-62 to known good GND.
Is voltage greater than 1 volt? No: Repair short to GND between
ECM pin C-62 and other modules.
After repairs are complete, retest
for SPN 639 FMI 14.
522 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 8 Decision
A. Key-Off. Yes: Go to Step 9.
B. Disconnect ECM 76-pin Chassis connector.
C. Connect chassis Breakout Harness 00-00959-01 between vehicle chassis
harness and ECM.

D. Connect Breakout Harness 00-00959-01 to 180-pin Breakout Box

00-00956-08.
E. Key-On Engine-Off (KOEO).
F. Use DMM, measure voltage from ECM pin C-62 to known good GND.
Is voltage less than 4 volts? No: Repair short to PWR between
ECM pin C-62 and other modules.
After repairs are complete, retest
for SPN 639 FMI 14.

Step 9 Decision
A. Key-Off. Yes: End diagnostics. Retest for
SPN 639 FMI 14.
B. Disconnect ECM 76-pin Chassis connector.
C. Connect chassis Breakout Harness 00-00959-01 to vehicle chassis
harness and leave ECM disconnected.
D. Connect Breakout Harness 00-00959-01 to 180-pin Breakout Box
00-00956-08.
E. Use DMM, measure resistance from ECM pin C-62 to ECM pin C-61.
Is resistance between 55 and 65 ohms? No: Repair short between ECM
pin C-62 and ECM pin C-61. After
repairs are complete, retest for
SPN 639 FMI 14.

End Diagnostic Tests

After performing all diagnostic steps, if SPN 639 FMI 14 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 523

SPN 651 FMI 4 - Injector 1 open coil - short circuit

Fault Overview
Fault code sets when Engine Control Module (ECM) detects a short circuit on injector 1 Open coil.

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate immediately when this fault is detected.

Associated Faults
None

Fault Facts
Final number of SPN identifies affected injector, and name in Navistar® Engine Diagnostics identifies cylinder in
which injector is installed.
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed Injector
• Open H shorted to GND
• Open L shorted to GND
• Open H shorted to Open L
• Faulty Engine Control Module (ECM)
524 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 168 Injector 1 Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

WARNING:

To prevent personal injury or death, shut engine down before doing voltage checks
for injector solenoids. When engine is running, injector circuits have high voltage and
amperage.

CAUTION:

To prevent engine damage, turn ignition switch OFF before disconnecting connectors.
Failure to turn ignition switch OFF will cause a voltage spike and damage to electrical
components.

Step 1 Check for active or pending fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON Yes: Go to Step 2.
Engine OFF (KOEO), check Diagnostic Trouble Codes (DTC) list for SPN 651
FMI 4.
Is SPN 651 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 525

Step 2 Inspect connections at Under Valve Connector (UVC) connector 2. Decision

A. Key-Off Yes: Go to Step 3.
B. Disconnect UVC 2
C. Check UVC 2 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 2 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 651
FMI 4.

Step 3 Inspect UVC harness under valve cover. Decision

A. Key-Off. Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 651 FMI 4.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 4.

Step 4 Check for Failed Injectors. Decision

A. Key-Off. Yes: Go to Step 5.

B. Remove Valve Cover (if not already done).

C. Disconnect Injector 1 through 6 connectors from UVC harness.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to each
Injector pin-2 and pin-3, leave UVC harness disconnected.
E. Use DMM, measure resistance between each individual Injector pin-2
and pin-3.
Is resistance 1.0 ± 0.5 ohms for each injector? No: Replace Failed Injector(s)
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 651 FMI
4.
526 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 5 Check Injector 1 for short to GND. Decision

A. Key-Off. Yes: Go to Step 6.
B. Disconnect Injector 1 connector from UVC harness.
C. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector 1
pin-2, leave UVC harness disconnected.

D. Use DMM, measure resistance between Injector 1 pin-2 and known good
GND.
Is resistance greater than 1000 ohms? No: Replace Injector 1 and
perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 651 FMI
4.

Step 6 Check Injector 1 Open Coil H Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 7.
B. Disconnect Injector 1 connector from UVC harness..
C. Disconnect ECM - Driver 36-pin connector.
D. Use Engine Terminal Test Kit ZTSE4435C, insert proper terminal into ECM
- Driver 36-pin connector pin D-2, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-2 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM - Driver 36-pin connector pin
D-2 and Injector 1. After repairs
are complete, retest for SPN 651
FMI 4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 527

Step 7 Check Injector 1 Open Coil L Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 8.
B. Disconnect Injector 1 connector from UVC harness.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Engine Terminal Test Kit ZTSE4435C, insert proper terminal into ECM
- Driver 36-pin connector pin D-1, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-1 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM - Driver 36-pin connector pin
D-1 and Injector 1. After repairs
are complete, retest for SPN 651
FMI 4.

Step 8 Check for short between Open H and Open L circuits in UVC harness. Decision
A. Key-Off. Yes: Go to Step 9.
B. Disconnect Injector 1 connector from UVC harness.
C. Disconnect UVC harness connector 2 from engine harness.
D. Connect Breakout Harness ZTSE4793 to UVC harness connector 2, leave
engine harness disconnected.
E. Use DMM, measure resistance between Breakout Harness ZTSE4793
pin-3 and pin-4.
Is resistance greater than 1000 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 651 FMI 4.

Step 9 Check for short between Open H and Open L circuits in Engine Decision
Harness.
A. Key-Off. Yes: Go to Step 10.

B. Disconnect UVC harness connector 2 from engine harness.

C. Disconnect ECM - Driver 36-pin connector.

D. Use Engine Terminal Test Kit ZTSE4435C, insert proper terminal into ECM
- Driver 36-pin connector pins D-1 and D-2, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-1 and pin D-2.
Is resistance greater than 1000 ohms? No: Replace Engine Harness.
After repairs are complete, retest
for SPN 651 FMI 4.
528 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 10 Check for Failed Engine Control Module. Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 651
B. Install Test ECM.
FMI 4.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).

D. Key ON Engine Running (KOER).

E. Check Diagnostic Trouble Code (DTC) list for SPN 651 FMI 4.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decision were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 651 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 529

SPN 651 FMI 5 - Injector 1 open coil - open circuit

Fault Overview
Fault code sets when Engine Control Module (ECM) detects an Open circuit on Injector 1 Open coil circuit.

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected during one drive cycle.

Associated Faults
None

Fault Facts
Final number of SPN identifies affected injector, and name in Navistar® Engine Diagnostics identifies cylinder in
which injector is installed.
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed Injector
• Open in Open H circuit
• Open in Open L circuit
• Failed Engine Control Module (ECM)
530 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 169 Injector 1 Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST). Key ON Engine OFF (KOEO), check Diagnostic Yes: Go to Step 2.
Trouble Code (DTC) list for SPN 651 FMI 5.
Is EST DTC list SPN 651 FMI 5 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at Under Valve Connector (UVC) connector 2. Decision

A. Key-Off Yes: Go to Step 3.
B. Disconnect UVC 2
C. Check UVC 2 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 2 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 651
FMI 5.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 531

Step 3 Inspect UVC harness under valve cover. Decision

A. Key-Off. Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 651 FMI 5.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 4.

Step 4 Check for failed Injectors. Decision

A. Key-Off. Yes: Go to Step 5.
B. Remove valve cover (if not already done).
C. Disconnect Injector 1 through 6 connectors from UVC harness.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to each
Injector pin-2 and pin-3, leave UVC harness disconnected.
E. Use DMM, measure resistance between each individual Injector pin-2
and pin-3.
Is resistance 1.0 ± 0.5 ohms for each injector? No: Replace Failed Injector(s)
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 651 FMI
5.

Step 5 Check for Open in Open H circuit in UVC harness. Decision

A. Key-Off. Yes: Go to Step 6.
B. Disconnect Under Valve Connector (UVC) Connector 2.
C. Disconnect Injector 1 from UVC harness.
D. Connect Breakout Harness ZTSE4793 to UVC connector 2, leave engine
harness disconnected.

E. Connect correct terminals from Terminal Test Kit ZTSE4435C to injector 1

pin-2, leave injector disconnected.
F. Use DMM, measure resistance between Breakout Harness ZTSE4793
pin-4 and injector 1 pin-2.
Is resistance less than 0.5 ohms? No: Replace UVC harness. After
repairs are complete, retest for
SPN 651 FMI 5.
532 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 6 Check for Open in Open L circuit in UVC harness. Decision

A. Key-Off. Yes: Go to Step 7.
B. Disconnect Under Valve Connector (UVC) Connector 2.
C. Disconnect Injector 1 from UVC harness.
D. Connect Breakout Harness ZTSE4793 to UVC connector 2, leave engine
harness disconnected.

E. Connect correct terminals from Terminal Test Kit ZTSE4435C to injector 1

pin-3, leave Injector disconnected.
F. Use DMM, measure resistance between Breakout Harness ZTSE4793
pin-3 and injector 1 pin-3.
Is resistance less than 0.5 ohms? No: Replace UVC harness. After
repairs are complete, retest for
SPN 651 FMI 5.

Step 7 Check for Open in Open H circuit in engine harness. Decision

A. Key-Off. Yes: Go to Step 8.

B. Disconnect Under Valve Connector (UVC) connector 2.

C. Disconnect ECM - Driver 36-pin connector.
D. Use Engine Terminal Test Kit ZTSE4435C, insert proper terminal into ECM
- Driver 36-pin connector pin D-2 and UVC Connector 2 pin-4, leave ECM
and UVC harness disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-2 and UVC connector 2 pin-4.
Is resistance less than 0.5 ohms? No: Replace engine harness.
After repairs are complete, retest
for SPN 651 FMI 5.

Step 8 Check for Open in Open L circuit in engine harness. Decision

A. Key-Off. Yes: Go to Step 9.

B. Disconnect Under Valve Connector (UVC) connector 2.

C. Disconnect ECM - Driver 36-pin connector.
D. Use Engine Terminal Test Kit ZTSE4435C, insert proper terminal into
ECM - Driver 36-pin connector pin D-1 and UVC Connector 2 pin-3, leave
ECM and UVC harness disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-1 and UVC connector 2 pin-3.
Is resistance less than 0.5 ohms? No: Replace Engine Harness.
After repairs are complete, retest
for SPN 651 FMI 5.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 533

Step 9 Check for failed Engine Control Module (ECM). Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 651
B. Install Test ECM.
FMI 5.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).

D. Key ON Engine Running (KOER).

E. Check Diagnostic Trouble Code (DTC) list for SPN 651 FMI 5.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decisions were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 651 FMI 5 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
534 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 651 FMI 7 - Injector 1 Spool Motion Compensation Max Authority Reached

Fault Overview
Fault code sets when Engine Control Module (ECM) determines injector spool motion compensation has reached
its maximum allowable time limit.

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

Associated Faults
None

Fault Facts
Final number of SPN identifies affected injector, and name in Navistar® Engine Diagnostics identifies cylinder in
which injector is installed.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Incorrect ECM programming
• Failed injector
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 535

Step 1 Check for injector replacement. Decision

Identify if affected injector was recently replaced. Yes: Perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334). After repairs are
complete, retest for
SPN 651 FMI 7.
Has affected injector been recently replaced? No: Replace affected injector
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334). After repairs are
complete, retest for
SPN 651 FMI 7.

End Diagnostic Steps

After performing all diagnostic steps, if SPN 651 FMI 7 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
536 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 651 FMI 14 - Injector 1 Fuel quantity/timing error

Fault Overview
Fault sets when Engine Control Module (ECM) determines injector timing is off when comparing cylinder balance
difference between two consecutive cylinders.

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

Associated Faults
• SPN 27 FMI 14 (EGR) • SPN 51 FMI 3, 4, and 7 • SPN 94 (FDP) • SPN 108 FMI 3 and 4
(ETV) (BARO)
• SPN 110 FMI 2, 3, and 4 • SPN 132 (MAF) • SPN 164 (ICP) • SPN 175 FMI 2, 3, and 4
(ECT1) (EOT)
• SPN 191 FMI 3 and 4 • SPN 636 FMI 2 and 7 • SPN 651 FMI 4, 5, and 7 • SPN 1322 - 1328 FMI 31
(TOSS) (CMP) (INJ) (INJ)
• SPN 1189 FMI 3 and 4 • SPN 2659 FMI 20 (AMS) • SPN 2791 FMI 2, 3, 4, 7, • SPN 3055 FMI 2 (INJ)
(TC2WC) 8, and 14 (EGR)
• SPN 3464 FMI 31 (ETV) • SPN 4257 FMI 7 (INJ) • SPN 5543 FMI 3, 4, and
5 (EBPV)

Fault Facts
None

Drive Cycle to Determine Fault Status

Road test
Possible Causes
• Injector damage
• Spool to control valve body static leakage
• Puck leakage
• Backup ring and/or O-ring leakage at injector inlet
• Biased Injection Control Pressure (ICP) sensor
• Engine oil dirty or poor quality
• Engine mechanical problem
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 537

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 536).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 651 FMI 14.

Step 2 Check for active or pending fault codes. Decision

Check DTC list for SPN 651 FMI 14. Yes: Go to Step 3.
Is EST DTC list SPN 651 FMI 14 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 651 FMI 14.

Step 3 Inspect connections at injector circuits outside valve cover connector. Decision
A. Key-Off. Yes: Go to Step 4.
B. Disconnect injector circuits outside valve cover connector.
C. Check injector circuits outside valve cover and connector terminals for:
damaged or pinched wires; moist or corroded terminals; loose, bent, or
broken pins; or broken connector housing.
Are injector circuits outside valve cover connector, harness, and terminals clean No: Repair connector, harness, or
and undamaged? terminal damage. After repairs are
complete, retest for SPN 651 FMI
14.

Step 4 Test for failed injector. Decision

Perform KOEO Injector Test(page 1365). Yes: Go to Step 7.
Did all injectors operate? No: Go to Step 5.

Step 5 Determine how many injectors operated. Decision

Determine if one injector or three injectors failed. Yes: Go to SPN 2797 FMI 6 (page
849).
Did only three injectors operate? No: Go to Step 6

Step 6 Determine if fault codes set. Decision

Determine if SPN 651 FMI 4 or 5 or SPN 3659 FMI 4 or 5 fault codes have been set Yes: Go to fault codes for
applicable injector FMI 4 or 5.
Did fault codes set? No: Replace injector 1. Perform
Injector Coil End of Motion
(CEOM) Reset Procedure (page
1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs, retest
for SPN 651 FMI 14.
538 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 7 Inspect fuel system, fuel level, and fuel quality. Decision
• Perform Fuel Level Inspection(page 1634), Yes: Go to Step 8.
• Fuel Quality Inspection(page 1632), and
• Fuel System Inspection(page 1631).
Is there sufficient supply of good quality fuel? No: Drain dirty or aerated fuel, fill
with good quality fuel. Repair any
other fuel system discrepancies.
After repairs are complete, retest
for SPN 651 FMI 14.

Step 8 Inspect air intake and exhaust systems for restrictions, leaks, or Decision
physical damage.
• Perform Intake Air Inspection(page 1648) and Yes: Go to Step 9.
• Exhaust and Aftertreatment System Inspection(page 1651).
Are air intake system and exhaust system clear of restrictions, leaks, and physical No: Repair restrictions, leaks, or
damage? physical damage. After repairs are
complete, retest for SPN 651 FMI
14.

Step 9 Check engine oil level and oil quality. Decision

Perform Engine Oil Level and Quality Inspection (page 1635). Yes: Go to Step 10.
Is there sufficient supply of clean, non-aerated oil? No: Drain dirty, aerated, or
contaminated oil, fill with clean,
non-aerated oil. After repairs are
complete, retest for SPN 651 FMI
14.

Step 10 Determine if Engine Compression Brake (ECB1), if equipped, is Decision

operating correctly.
A. Key-Off. Yes: Go to Step 11.
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).
C. Key On Engine Off (KOEO), log in to Navistar® Engine Diagnostics.
D. Use EST , do KOEO Low to High Idle Test(page 1383).

E. Monitor Brake Control Pressure (BCP).

Is BCP less than 145 psi (1 MPa)? No: Replace ECB1 valve. After
repairs are complete, retest for
SPN 651 FMI 14.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 539

Step 11 Calibrate MAF sensor. Decision

Perform KOER MAF Sensor Calibrations(page 1539). Yes: Go to Step 12.
Did MAF Sensor Calibration succeed? No: Repair fault code set during
MAF Sensor Calibration. After
repairs are complete, retest for
SPN 651 FMI 14.

Step 12 Determine cause of rough engine idle. Decision

Perform Relative Compression Test (page 1371). Yes: Go to Step 14.
Are all engine cylinder performance readings similar? No: Go to Step 13.

Step 13 Test cylinder performance further. Decision

Do Cylinder Performance Analyzer (CPA) test to evaluate cylinder performance Yes: Retest for SPN 651 FMI 14.
issues. Evaluate performance concerns during
• cold idle (page 1407)and
• hot idle (page 1421).
Due to complexity of some codes, print out CPA tool results for later use.
Did tests finish without identifying a suspect cylinder? No: Remove valve cover, check
valve lash, and crank engine to
verify cam shaft lobe operation
and lift (See Engine Service
Manual). After repairs are
complete, retest for SPN 651 FMI
14.

Step 14 Test for oil leaks under valve cover. Decision

Perform CPA High-Pressure Oil Pump (HPOP) Test(page 1440). Yes: End diagnostics, retest for
SPN 651 FMI 14.
Did HPOP Test complete satisfactory? No: Repair failed component
indicated in HPOP Test. After
repairs are complete, retest for
SPN 651 FMI 14.

End Diagnostic Tests

After performing diagnostic steps, if SPN 651 FMI 14 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
540 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 652 FMI 4 - Injector 2 open coil - short circuit

Fault Overview
Fault code sets when Engine Control Module (ECM) detects a short circuit on Injector 2 Open coil.

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate immediately when this fault is detected.

Associated Faults
None

Fault Facts
Final number of SPN identifies affected injector, and name in Navistar® Engine Diagnostics identifies cylinder in
which injector is installed.
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed Injector
• Open H shorted to GND
• Open L shorted to GND
• Open H shorted to Open L
• Faulty Engine Control Module (ECM)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 541

Figure 170 Injector 2 Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

WARNING:

To prevent personal injury or death, shut engine down before doing voltage checks
for injector solenoids. When engine is running, injector circuits have high voltage and
amperage.

CAUTION:

To prevent engine damage, turn ignition switch OFF before disconnecting connectors.
Failure to turn ignition switch OFF will cause a voltage spike and damage to electrical
components.

Step 1 Check for active or pending fault codes. Decision

Key ON Engine OFF (KOEO), check Diagnostic Trouble Codes (DTC) list for Yes: Go to Step 2.
SPN 652 FMI 4.
Is SPN 652 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).
542 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 2 Inspect connections at Under Valve Connector (UVC) connector 2. Decision

A. Key-Off Yes: Go to Step 3.
B. Disconnect UVC 2
C. Check UVC 2 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 2 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 652
FMI 4.

Step 3 Inspect UVC harness under valve cover. Decision

A. Key-Off. Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 652 FMI 4.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 4.

Step 4 Check for failed Injectors. Decision

A. Key-Off. Yes: Go to Step 5.

B. Remove Valve Cover (if not already done).

C. Disconnect Injector 1 through 6 connectors from UVC harness.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to each
Injector pin-2 and pin-3, leave UVC harness disconnected.
E. Use DMM, measure resistance between each individual Injector pin-2
and pin-3.
Is resistance 1.0 ± 0.5 ohms for each injector? No: Replace Failed Injector(s)
and Perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 652 FMI
4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 543

Step 5 Check Injector 2 for short to GND. Decision

A. Key-Off. Yes: Go to Step 6.
B. Disconnect Injector 2 connector from UVC harness.
C. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector 2
pin-2, leave UVC harness disconnected.

D. Use DMM, measure resistance between Injector 2 pin-2 and known good
GND.
Is resistance greater than 1000 ohms? No: Replace Injector 2 and
Perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 652 FMI
4.

Step 6 Check Injector 2 Open Coil H Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 7.
B. Disconnect Injector 2 connector from UVC harness.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Engine Terminal Test Kit ZTSE4435C, insert proper terminal into ECM
- Driver 36-pin connector pin D-6, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-6 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM - Driver 36-pin connector pin
D-6 and Injector 2. After repairs
are complete, retest for SPN 652
FMI 4.
544 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 7 Check Injector 2 Open Coil L Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 8.
B. Disconnect Injector 2 connector from UVC harness.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Engine Terminal Test Kit ZTSE4435C, insert proper terminal into ECM
- Driver 36-pin connector pin D-5, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-5 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM - Driver 36-pin connector pin
D-5 and Injector 2. After repairs
are complete, retest for SPN 652
FMI 4.

Step 8 Check for short between Open H and Open L circuits in UVC harness. Decision
A. Key-Off. Yes: Go to Step 9.
B. Disconnect Injector 2 connector from UVC harness.
C. Disconnect UVC harness connector 2 from engine harness.
D. Connect Breakout Harness ZTSE4793 to UVC harness connector 2, leave
engine harness disconnected.
E. Use DMM, measure resistance between Breakout Harness ZTSE4793
pin-7 and pin-8.
Is resistance greater than 1000 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 652 FMI 4.

Step 9 Check for short between Open H and Open L circuits in Engine Decision
Harness.
A. Key-Off. Yes: Go to Step 10.

B. Disconnect UVC harness connector 2 from engine harness.

C. Disconnect ECM - Driver 36-pin connector.

D. Use Engine Terminal Test Kit ZTSE4435C, insert proper terminal into ECM
- Driver 36-pin connector D-5 and D-6, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pins D-5 and D-6.
Is resistance greater than 1000 ohms? No: Replace Engine Harness.
After repairs are complete, retest
for SPN 652 FMI 4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 545

Step 10 Check for Failed Engine Control Module. Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 652
B. Install Test ECM.
FMI 4.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).

D. Key ON Engine Running (KOER).

E. Check Diagnostic Trouble Code (DTC) list for SPN 652 FMI 4.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decision were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 652 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
546 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 652 FMI 5 - Injector 2 open coil - open circuit

Fault Overview
Fault code sets when Engine Control Module (ECM) detects an Open circuit on Injector 2 Open coil circuit.

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected during one drive cycle.

Associated Faults
None

Fault Facts
Final number of SPN identifies affected injector, and name in Navistar® Engine Diagnostics identifies cylinder in
which injector is installed.
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed Injector
• Open in Open H circuit
• Open in Open L circuit
• Failed Engine Control Module (ECM)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 547

Figure 171 Injector 2 Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST). Key ON Engine OFF (KOEO), check Diagnostic Yes: Go to Step 2.
Trouble Code (DTC) list for SPN 652 FMI 5.
Is EST DTC list SPN 652 FMI 5 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at Under Valve Connector (UVC) connector 2. Decision

A. Key-Off Yes: Go to Step 3.
B. Disconnect UVC 2
C. Check UVC 2 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 2 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 652
FMI 5.
548 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Inspect UVC harness under valve cover. Decision

A. Key-Off. Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 652 FMI 5.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 4.

Step 4 Check for failed Injectors. Decision

A. Key-Off. Yes: Go to Step 5.
B. Remove valve cover (if not already done).
C. Disconnect Injector 1 through 6 connectors from UVC harness.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to each
Injector pin-2 and pin-3, leave UVC harness disconnected.
E. Use DMM, measure resistance between each individual Injector pin-2
and pin-3.
Is resistance 1.0 ± 0.5 ohms for each injector? No: Replace Failed Injector(s)
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 652 FMI
5.

Step 5 Check for Open in Open H circuit in UVC harness. Decision

A. Key-Off. Yes: Go to Step 6.
B. Disconnect Injector 2 from UVC harness.
C. Disconnect Under Valve Connector (UVC) Connector 2.
D. Connect Breakout Harness ZTSE4793 to UVC connector 2, leave engine
harness disconnected.

E. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector 2

pin-2, leave injector disconnected.
F. Use DMM, measure resistance between Breakout Harness ZTSE4793
pin-8 and injector 2 pin-2.
Is resistance less than 0.5 ohms? No: Replace UVC harness. After
repairs are complete, retest for
SPN 652 FMI 5.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 549

Step 6 Check for Open in Open L circuit in UVC harness. Decision

A. Key-Off. Yes: Go to Step 7.
B. Disconnect Under Valve Connector (UVC) connector 2.
C. Disconnect Injector 2 from UVC harness.
D. Connect Breakout Harness ZTSE4793 to UVC connector 2, leave engine
harness disconnected.

E. Connect correct terminals from Terminal Test Kit ZTSE4435C to injector 2

pin-3, leave injector disconnected.
F. Use DMM, measure resistance between Breakout Harness ZTSE4793
pin-7 and Injector 2 pin-3.
Is resistance less than 0.5 ohms? No: Replace UVC harness. After
repairs are complete, retest for
SPN 652 FMI 5.

Step 7 Check for Open in Open H circuit in Engine harness. Decision

A. Key-Off. Yes: Go to Step 8.

B. Disconnect Under Valve Connector (UVC) connector 2.

C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-6 and UVC Connector 2 pin-8, leave ECM
and UVC harness disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-6 and UVC connector 2 pin-8.
Is resistance less than 0.5 ohms? No: Replace Engine harness.
After repairs are complete, retest
for SPN 652 FMI 5.

Step 8 Check for Open in Open L circuit in Engine harness. Decision

A. Key-Off. Yes: Go to Step 9.

B. Disconnect Under Valve Connector (UVC) connector 2.

C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-5 and UVC Connector 2 pin-7, leave ECM
and UVC harness disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-5 and UVC connector 2 pin-7.
Is resistance less than 0.5 ohms? No: Replace engine harness. After
repairs are complete, retest for
SPN 652 FMI 5.
550 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 9 Check for failed Engine Control Module (ECM). Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 652
B. Install Test ECM.
FMI 5
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).

D. Key ON Engine Running (KOER).

E. Check Diagnostic Trouble Code (DTC) list for SPN 652 FMI 5.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decisions were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 652 FMI 5 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 551

SPN 652 FMI 7 - Injector 2 Spool Motion Compensation Max Authority Reached

Fault Overview
Fault code sets when Engine Control Module (ECM) determines injector spool motion compensation has reached
its maximum allowable time limit.

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

Associated Faults
None

Fault Facts
Final number of SPN identifies affected injector, and name in Navistar® Engine Diagnostics identifies cylinder in
which injector is installed.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Incorrect ECM programming
• Failed injector
552 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for injector replacement. Decision

Identify if affected injector was recently replaced. Yes: Perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334). After repairs are
complete, retest for
SPN 652 FMI 7.
Has affected injector been recently replaced? No: Replace affected injector
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334). After repairs are
complete, retest for
SPN 652 FMI 7.

End Diagnostic Steps

After performing all diagnostic steps, if SPN 652 FMI 7 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 553

SPN 652 FMI 14 - Injector 2 Fuel quantity/timing error

Fault Overview
Fault sets when Engine Control Module (ECM) determines injector timing is off when comparing cylinder balance
difference between two consecutive cylinders.

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

Associated Faults
• SPN 27 FMI 14 (EGR) • SPN 51 FMI 3, 4, and 7 • SPN 94 (FDP) • SPN 108 FMI 3 and 4
(ETV) (BARO)
• SPN 110 FMI 2, 3, and 4 • SPN 132 (MAF) • SPN 164 (ICP) • SPN 175 FMI 2, 3, and 4
(ECT1) (EOT)
• SPN 191 FMI 3 and 4 • SPN 636 FMI 2 and 7 • SPN 652 FMI 4, 5, and 7 • SPN 1322 - 1328 FMI 31
(TOSS) (CMP) (INJ) (INJ)
• SPN 1189 FMI 3 and 4 • SPN 2659 FMI 20 (AMS) • SPN 2791 FMI 2, 3, 4, 7, • SPN 3055 FMI 2 (INJ)
(TC2WC) 8, and 14 (EGR)
• SPN 3464 FMI 31 (ETV) • SPN 4257 FMI 7 (INJ) • SPN 5543 FMI 3, 4, and
5 (EBPV)

Fault Facts
None

Drive Cycle to Determine Fault Status

Road test
Possible Causes
• Injector damage
• Spool to control valve body static leakage
• Puck leakage
• Backup ring and/or O-ring leakage at injector inlet
• Biased Injection Control Pressure (ICP) sensor
• Engine oil dirty or poor quality
• Engine mechanical problem

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 553).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 652 FMI 14.
554 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 2 Check for active or pending fault codes. Decision

Check DTC list for SPN 652 FMI 14. Yes: Go to Step 3.
Is EST DTC list SPN 652 FMI 14 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 652 FMI 14.

Step 3 Inspect connections at injector circuits outside valve cover connector. Decision
A. Key-Off. Yes: Go to Step 4.
B. Disconnect injector circuits outside valve cover connector.
C. Check injector circuits outside valve cover and connector terminals for:
damaged or pinched wires; moisture or corroded terminals; loose, bent, or
broken pins; or broken connector housing.
Are injector circuits outside valve cover connector, harness, and terminals clean No: Repair connector, harness,
and undamaged? or terminal damage. After repairs
are complete, retest for SPN 652
FMI 14.

Step 4 Test for failed injector. Decision

Perform KOEO Injector Test (page 1365). Yes: Go to Step 7.
Did all injectors operate? No: Go to Step 5.

Step 5 Determine how many injectors operated. Decision

Determine if one injector or three injectors failed. Yes: Go to SPN 2797 FMI 6 (page
849).
Did only three injectors operate? No: Go to Step 6

Step 6 Determine if fault codes set. Decision

Determine if SPN 652 FMI 4 or 5 or SPN 3660 FMI 4 or 5 fault codes have been set Yes: Go to fault codes for
applicable injector FMI 4, or 5.
Did fault codes set? No: Replace injector 2. Perform
Injector Coil End of Motion
(CEOM) Reset Procedure (page
1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs, retest
for SPN 652 FMI 14.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 555

Step 7 Inspect fuel system, fuel level, and fuel quality. Decision
• Perform Fuel Level Inspection(page 1634), Yes: Go to Step 8.
• Fuel Quality Inspection(page 1632), and
• Fuel System Inspection(page 1631).
Is there sufficient supply of good quality fuel? No: Drain dirty or aerated fuel, fill
with good quality fuel. Repair any
other fuel system discrepancies.
After repairs are complete, retest
for SPN 652 FMI 14.

Step 8 Inspect air intake and exhaust systems for restrictions, leaks, or Decision
physical damage.
• Perform Intake Air Inspection(page 1648) and Yes: Go to Step 9.
• Exhaust and Aftertreatment System Inspection(page 1651).
Are air intake system and exhaust system clear of restrictions, leaks, and physical No: Repair restrictions, leaks, or
damage? physical damage. After repairs are
complete, retest for SPN 652 FMI
14.

Step 9 Check engine oil level and oil quality. Decision

Perform Engine Oil Level and Quality Inspection (page 1635). Yes: Go to Step 10.
Is there sufficient supply of clean, non-aerated oil? No: Drain dirty, aerated, or
contaminated oil, fill with clean,
non-aerated oil. After repairs are
complete, retest for SPN 652 FMI
14.

Step 10 Determine if Engine Compression Brake (ECB1), if equipped, is Decision

operating correctly.
A. Key Off. Yes: Go to Step 11.
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).
C. Key On Engine Off (KOEO), log in to Navistar® Engine Diagnostics.
D. Perform KOEO Low to High Idle Test(page 1383).

E. Monitor Brake Control Pressure (BCP).

Is BCP less than 145 psi (1 MPa)? No: Replace ECB1 valve. After
repairs are complete, retest for
SPN 652 FMI 14.
556 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 11 Calibrate MAF sensor. Decision

Perform KOER MAF Sensor Calibrations (page 1539). Yes: Go to Step 12.
Did MAF Sensor Calibration succeed? No: Repair fault code set during
MAF Sensor Calibration. After
repairs are complete, retest for
SPN 652 FMI 14.

Step 12 Determine cause of rough engine idle. Decision

Perform Relative Compression Test (page 1371). Yes: Go to Step 14.
Are all engine cylinder performance readings similar? No: Go to Step 13.

Step 13 Test cylinder performance further. Decision

Do Cylinder Performance Analyzer (CPA) test to evaluate cylinder performance Yes: Retest for SPN 652 FMI 14.
issues. Evaluate performance concerns during
• cold idle (page 1407)and
• hot idle (page 1421).
Due to complexity of some codes, print out CPA tool results for later use.
Did tests finish without identifying a suspect cylinder? No: Remove valve cover, check
valve lash, and crank engine to
verify cam shaft lobe operation
and lift (See Engine Service
Manual). After repairs are
complete, retest for SPN 652 FMI
14.

Step 14 Test for oil leaks under valve cover. Decision

Perform CPA High-Pressure Oil Pump (HPOP) Test (page 1440). Yes: End diagnostics, retest for
SPN 652 FMI 14.
Did HPOP Test complete satisfactory? No: Repair failed component
indicated in HPOP Test. After
repairs are complete, retest for
SPN 652 FMI 14.

End Diagnostic Tests

After performing diagnostic steps, if SPN 652 FMI 14 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 557

SPN 653 FMI 4 - Injector 3 open coil - short circuit

Fault Overview
Fault code sets when Engine Control Module (ECM) detects a short circuit on Injector 3 Open coil.

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate immediately when this fault is detected.

Associated Faults
None

Fault Facts
Final number of SPN identifies affected injector, and name in Navistar® Engine Diagnostics identifies cylinder in
which injector is installed.
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed Injector
• Open H shorted to GND
• Open L shorted to GND
• Open H shorted to Open L
• Faulty Engine Control Module (ECM)
558 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 172 Injector 3 Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

WARNING:

To prevent personal injury or death, shut engine down before doing voltage checks
for injector solenoids. When engine is running, injector circuits have high voltage and
amperage.

CAUTION:

To prevent engine damage, turn ignition switch OFF before disconnecting connectors.
Failure to turn ignition switch OFF will cause a voltage spike and damage to electrical
components.

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for Yes: Go to Step 2.
SPN 653 FMI 4.
Is SPN 653 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 559

Step 2 Inspect connections at Under Valve Connector (UVC) connector 3. Decision

A. Key-Off Yes: Go to Step 3.
B. Disconnect UVC 3
C. Check UVC 3 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 3 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 653
FMI 4.

Step 3 Inspect UVC harness under valve cover. Decision

A. Key-Off. Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 653 FMI 4.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 4.

Step 4 Check for failed Injectors. Decision

A. Key-Off. Yes: Go to Step 5.

B. Remove Valve Cover (if not already done).

C. Disconnect Injector 1 through 6 connectors from UVC harness.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to each
Injector pin-2 and pin-3, leave UVC harness disconnected.
E. Use DMM, measure resistance between each individual Injector pin-2
and pin-3.
Is resistance 1.0 ± 0.5 ohms for each injector? No: Replace Failed Injector(s)
and Perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 653 FMI
4.
560 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 5 Check Injector 3 for short to GND. Decision

A. Key-Off. Yes: Go to Step 6.
B. Disconnect Injector 3 connector from UVC harness.
C. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector 3
pin-2, leave UVC harness disconnected.

D. Use DMM, measure resistance between Injector 3 pin-2 and known good
GND.
Is resistance greater than 1000 ohms? No: Replace Injector 3 and
perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 653 FMI
4.

Step 6 Check Injector 3 Open Coil H Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 7.
B. Disconnect Injector 3 connector from UVC harness.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Engine Terminal Test Kit ZTSE4435C, insert proper terminal into ECM
- Driver 36-pin connector pin D-4, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-4 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM - Driver 36-pin connector pin
D-4 and Injector 3. After repairs
are complete, retest for SPN 653
FMI 4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 561

Step 7 Check Injector 3 Open Coil L Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 8.
B. Disconnect Injector 3 connector from UVC harness.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Engine Terminal Test Kit ZTSE4435C, insert proper terminal into ECM
- Driver 36-pin connector pin D-3, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-3 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM - Driver 36-pin connector pin
D-3 and Injector 3. After repairs
are complete, retest for SPN 653
FMI 4.

Step 8 Check for short between Open H and Open L circuits in UVC harness. Decision
A. Key-Off. Yes: Go to Step 9.
B. Disconnect Injector 3 connector from UVC harness.
C. Disconnect UVC harness connector 3 from engine harness.
D. Connect Breakout Harness ZTSE4793 to UVC harness connector 3, leave
engine harness disconnected.
E. Use DMM, measure resistance between Breakout Harness ZTSE4793
pin-3 and pin-4.
Is resistance greater than 1000 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 653 FMI 4.

Step 9 Check for short between Open H and Open L circuits in Engine Decision
Harness.
A. Key-Off. Yes: Go to Step 10.

B. Disconnect UVC harness connector 3 from engine harness.

C. Disconnect ECM - Driver 36-pin connector.

D. Use Engine Terminal Test Kit ZTSE4435C, insert proper terminal into ECM
- Driver 36-pin connector pins D-3 and D-4, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pins D-3 and D-4.
Is resistance greater than 1000 ohms? No: Replace Engine Harness.
After repairs are complete, retest
for SPN 653 FMI 4.
562 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 10 Check for Failed Engine Control Module. Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 653
B. Install Test ECM.
FMI 4.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).

D. Key ON Engine Running (KOER).

E. Check Diagnostic Trouble Code (DTC) list for SPN 653 FMI 4.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decision were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 653 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 563

SPN 653 FMI 5 - Injector 3 open coil - open circuit

Fault Overview
Fault code sets when Engine Control Module (ECM) detects an Open circuit on Injector 3 Open coil circuit.

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected during one drive cycle.

Associated Faults
None

Fault Facts
Final number of SPN identifies affected injector, and name in Navistar® Engine Diagnostics identifies cylinder in
which injector is installed.
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed Injector
• Open in Open H circuit
• Open in Open L circuit
• Failed Engine Control Module (ECM)
564 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 173 Injector 3 Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 653 FMI 5.
Is EST DTC list SPN 653 FMI 5 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at Under Valve Connector (UVC) connector 3. Decision

A. Key-Off Yes: Go to Step 3.
B. Disconnect UVC 3.
C. Check UVC 3 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 3 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 653
FMI 5.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 565

Step 3 Inspect UVC harness under valve cover. Decision

A. Key-Off. Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 653 FMI 5.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 4.

Step 4 Check for failed Injectors. Decision

A. Key-Off. Yes: Go to Step 5.
B. Remove valve cover (if not already done).
C. Disconnect Injector 1 through 6 connectors from UVC harness.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to each
Injector pin-2 and pin-3, leave UVC harness disconnected.
E. Use DMM, measure resistance between each individual Injector pin-2
and pin-3.
Is resistance 1.0 ± 0.5 ohms for each injector? No: Replace Failed Injector(s)
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 653 FMI
5.

Step 5 Check for Open in Open H circuit in UVC harness. Decision

A. Key-Off. Yes: Go to Step 6.
B. Disconnect Under Valve Connector (UVC) Connector 3.
C. Disconnect Injector 3 from UVC harness.
D. Connect Breakout Harness ZTSE4793 to UVC connector 3, leave engine
harness disconnected.

E. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector 3

pin-2, leave injector disconnected.
F. Use DMM, measure resistance between Breakout Harness ZTSE4793
pin-4 and Injector 3 pin-2.
Is resistance less than 0.5 ohms? No: Replace UVC harness. After
repairs are complete, retest for
SPN 653 FMI 5.
566 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 6 Check for Open in Open L circuit in UVC harness. Decision

A. Key-Off. Yes: Go to Step 7.
B. Disconnect Under Valve Connector (UVC) Connector 3.
C. Disconnect Injector 3 from UVC harness.
D. Connect Breakout Harness ZTSE4793 to UVC connector 3, leave engine
harness disconnected.

E. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector 3

pin-3, leave injector disconnected.
F. Use DMM, measure resistance between Breakout Harness ZTSE4793
pin-3 and Injector 3 pin-3.
Is resistance less than 0.5 ohms? No: Replace UVC harness. After
repairs are complete, retest for
SPN 653 FMI 5.

Step 7 Check for Open in Open H circuit in engine harness. Decision

A. Key-Off. Yes: Go to Step 8.

B. Disconnect Under Valve Connector (UVC) connector 3.

C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-4 and UVC Connector 3 pin-4, leave ECM
and UVC harness disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-4 and UVC connector 3 pin-4.
Is resistance less than 0.5 ohms? No: Replace engine harness. After
repairs are complete, retest for
SPN 653 FMI 5.

Step 8 Check for Open in Open L circuit in Engine harness. Decision

A. Key-Off. Yes: Go to Step 9.

B. Disconnect Under Valve Connector (UVC) connector 3.

C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-3 and UVC Connector 3 pin-3, leave ECM
and UVC harness disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-3 and UVC connector 3 pin-3.
Is resistance less than 0.5 ohms? No: Replace engine Harness.
After repairs are complete, retest
for SPN 653 FMI 5.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 567

Step 9 Check for failed Engine Control Module (ECM). Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 653
B. Install Test ECM.
FMI 5.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).

D. Key ON Engine Running (KOER).

E. Check Diagnostic Trouble Code (DTC) list for SPN 653 FMI 5.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decisions were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 653 FMI 5 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
568 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 653 FMI 7 - Injector 3 Spool Motion Compensation Max Authority Reached

Fault Overview
Fault code sets when Engine Control Module (ECM) determines injector spool motion compensation has reached
its maximum allowable time limit.

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

Associated Faults
None

Fault Facts
Final number of SPN identifies affected injector, and name in Navistar® Engine Diagnostics identifies cylinder in
which injector is installed.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Incorrect ECM programming
• Failed injector
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 569

Step 1 Check for injector replacement. Decision

Identify if affected injector was recently replaced. Yes: Perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334). After repairs are
complete, retest for
SPN 653 FMI 7.
Has affected injector been recently replaced? No: Replace affected injector
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334). After repairs are
complete, retest for
SPN 653 FMI 7.

End Diagnostic Steps

After performing all diagnostic steps, if SPN 653 FMI 7 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
570 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 653 FMI 14 - Injector 3 Fuel quantity/timing error

Fault Overview
Fault sets when Engine Control Module (ECM) determines injector timing is off when comparing cylinder balance
difference between two consecutive cylinders.

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

Associated Faults
• SPN 27 FMI 14 (EGR) • SPN 51 FMI 3, 4, and 7 • SPN 94 (FDP) • SPN 108 FMI 3 and 4
(ETV) (BARO)
• SPN 110 FMI 2, 3, and 4 • SPN 132 (MAF) • SPN 164 (ICP) • SPN 175 FMI 2, 3, and 4
(ECT1) (EOT)
• SPN 191 FMI 3 and 4 • SPN 636 FMI 2 and 7 • SPN 653 FMI 4, 5, and 7 • SPN 1322 - 1328 FMI 31
(TOSS) (CMP) (INJ) (INJ)
• SPN 1189 FMI 3 and 4 • SPN 2659 FMI 20 (AMS) • SPN 2791 FMI 2, 3, 4, 7, • SPN 3055 FMI 2 (INJ)
(TC2WC) 8, and 14 (EGR)
• SPN 3464 FMI 31 (ETV) • SPN 4257 FMI 7 (INJ) • SPN 5543 FMI 3, 4, and
5 (EBPV)

Fault Facts
None

Drive Cycle to Determine Fault Status

Road test
Possible Causes
• Injector damage
• Spool to control valve body static leakage
• Puck leakage
• Backup ring and/or O-ring leakage at injector inlet
• Biased Injection Control Pressure (ICP) sensor
• Engine oil dirty or poor quality
• Engine mechanical problem
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 571

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST) check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 570).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 653 FMI 14.

Step 2 Check for active or pending fault codes. Decision

Check DTC list for SPN 653 FMI 14. Yes: Go to Step 3.
Is EST DTC list SPN 653 FMI 14 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 653 FMI 14.

Step 3 Inspect connections at injector circuits outside valve cover connector. Decision
A. Key-Off. Yes: Go to Step 4.
B. Disconnect injector circuits outside valve cover connector.
C. Check injector circuits outside valve cover and connector terminals for:
damaged or pinched wires; moist or corroded terminals; loose, bent, or
broken pins; or broken connector housing.
Are injector circuits outside valve cover connector, harness, and terminals clean No: Repair connector, harness,
and undamaged? or terminal damage. After repairs
are complete, retest for SPN 653
FMI 14.

Step 4 Test for failed injector. Decision

Perform KOEO Injector Test (page 1365). Yes: Go to Step 7.
Did all injectors operate? No: Go to Step 5.

Step 5 Determine how many injectors operated. Decision

Determine if one injector or three injectors failed. Yes: Go to SPN 2797 FMI 6 (page
849).
Did only three injectors operate? No: Go to Step 6

Step 6 Determine if fault codes set. Decision

Determine if SPN 653 FMI 4 or 5 or SPN 3661 FMI 4 or 5 fault codes have been set Yes: Go to fault codes for
applicable injector FMI 4, or 5.
Did fault codes set? No: Replace injector 3. Perform
Injector Coil End of Motion
(CEOM) Reset Procedure (page
1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs, retest
for SPN 653 FMI 14.
572 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 7 Inspect fuel system, fuel level, and fuel quality. Decision
• Perform Fuel Level Inspection(page 1634), Yes: Go to Step 8.
• Fuel Quality Inspection(page 1632), and
• Fuel System Inspection(page 1631).
Is there sufficient supply of good quality fuel? No: Drain dirty or aerated fuel, fill
with good quality fuel. Repair any
other fuel system discrepancies.
After repairs are complete, retest
for SPN 653 FMI 14.

Step 8 Inspect air intake and exhaust systems for restrictions, leaks, or Decision
physical damage.
• Perform Intake Air Inspection(page 1648) and Yes: Go to Step 9.
• Exhaust and Aftertreatment System Inspection(page 1651).
Are air intake system and exhaust system clear of restrictions, leaks, and physical No: Repair restrictions, leaks, or
damage? physical damage. After repairs are
complete, retest for SPN 653 FMI
14.

Step 9 Check engine oil level and oil quality. Decision

Perform Engine Oil Level and Quality Inspection (page 1635). Yes: Go to Step 10.
Is there sufficient supply of clean, non-aerated oil? No: Drain dirty, aerated, or
contaminated oil, fill with clean,
non-aerated oil. After repairs are
complete, retest for SPN 653 FMI
14.

Step 10 Determine if Engine Compression Brake (ECB1), if equipped, is Decision

operating correctly.
A. PerformKOEO Low to High Idle Test(page 1383). Yes: Go to Step 11.
B. Monitor Brake Control Pressure (BCP).
Is BCP less than 145 psi (1 MPa)? No: Replace ECB1 valve. After
repairs are complete, retest for
SPN 653 FMI 14.

Step 11 Calibrate MAF sensor. Decision

Perform KOER MAF Sensor Calibrations (page 1539). Yes: Go to Step 12.
Did MAF Sensor Calibration succeed? No: Repair fault code set during
MAF Sensor Calibration. After
repairs are complete, retest for
SPN 653 FMI 14.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 573

Step 12 Determine cause of rough engine idle. Decision

Perform Relative Compression Test (page 1371). Yes: Go to Step 14.
Are all engine cylinder performance readings similar? No: Go to Step 13.

Step 13 Test cylinder performance further. Decision

Do Cylinder Performance Analyzer (CPA) test to evaluate cylinder performance Yes: Retest for SPN 653 FMI 14.
issues. Evaluate performance concerns during
• cold idle(page 1407) and
• hot idle (page 1421).
Due to complexity of some codes, print out CPA tool results for later use.
Did tests finish without identifying a suspect cylinder? No: Remove valve cover, check
valve lash, and crank engine to
verify cam shaft lobe operation and
lift (See Engine Service Manual).
After repairs are complete, retest
for SPN 653 FMI 14.

Step 14 Test for oil leaks under valve cover. Decision

Perform CPA High-Pressure Oil Pump (HPOP) Test (page 1440). Yes: End diagnostics, retest for
SPN 653 FMI 14.
Did HPOP Test complete satisfactory? No: Repair failed component
indicated in HPOP Test. After
repairs are complete, retest for
SPN 653 FMI 14.

End Diagnostic Tests

After performing diagnostic steps, if SPN 653 FMI 14 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
574 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 654 FMI 4 - Injector 4 open coil - short circuit

Fault Overview
Fault code sets when Engine Control Module (ECM) detects a short circuit on Injector 4 Open coil.

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate immediately when this fault is detected.

Associated Faults
None

Fault Facts
Final number of SPN identifies affected injector, and name in Navistar® Engine Diagnostics identifies cylinder in
which injector is installed.
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed Injector
• Open H shorted to GND
• Open L shorted to GND
• Open H shorted to Open L
• Faulty Engine Control Module (ECM)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 575

Figure 174 Injector 4 Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

WARNING:

To prevent personal injury or death, shut engine down before doing voltage checks
for injector solenoids. When engine is running, injector circuits have high voltage and
amperage.

CAUTION:

To prevent engine damage, turn ignition switch OFF before disconnecting connectors.
Failure to turn ignition switch OFF will cause a voltage spike and damage to electrical
components.

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for Yes: Go to Step 2.
SPN 654 FMI 4.
Is SPN 654 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).
576 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 2 Inspect connections at Under Valve Connector (UVC) connector 3. Decision

A. Key-Off Yes: Go to Step 3.
B. Disconnect UVC 3
C. Check UVC 3 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 3 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 654
FMI 4.

Step 3 Inspect UVC harness under valve cover. Decision

A. Key-Off. Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 654 FMI 4.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 4.

Step 4 Check for failed Injectors. Decision

A. Key-Off. Yes: Go to Step 5.

B. Remove Valve Cover (if not already done).

C. Disconnect Injector 1 through 6 connectors from UVC harness.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to each
Injector pin-2 and pin-3, leave UVC harness disconnected.
E. Use DMM, measure resistance between each individual Injector pin-2
and pin-3.
Is resistance 1.0 ± 0.5 ohms for each injector? No: Replace Failed Injector(s)
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 654 FMI
4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 577

Step 5 Check Injector 4 for short to GND. Decision

A. Key-Off. Yes: Go to Step 6.
B. Disconnect Injector 4 connector from UVC harness.
C. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector 4
pin-2, leave UVC harness disconnected.

D. Use DMM, measure resistance between Injector 4 pin-2 and known good
GND.
Is resistance greater than 1000 ohms? No: Replace Injector 4 and
perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 654 FMI
4.

Step 6 Check Injector 4 Open Coil H Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 7.
B. Disconnect Injector 4 connector from UVC harness.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Engine Terminal Test Kit ZTSE4435C, insert proper terminal into ECM
- Driver 36-pin connector pin D-30, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-30 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM - Driver 36-pin connector pin
D-30 and Injector 4. After repairs
are complete, retest for SPN 654
FMI 4.
578 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 7 Check Injector 4 Open Coil L Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 8.
B. Disconnect Injector 4 connector from UVC harness.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Engine Terminal Test Kit ZTSE4435C, insert proper terminal into ECM
- Driver 36-pin connector pin D-29, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-29 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM - Driver 36-pin connector pin
D-29 and Injector 4. After repairs
are complete, retest for SPN 654
FMI 4.

Step 8 Check for short between Open H and Open L circuits in UVC harness. Decision
A. Key-Off. Yes: Go to Step 9.
B. Disconnect Injector 4 connector from UVC harness.
C. Disconnect UVC harness connector 3 from engine harness.
D. Connect Breakout Harness ZTSE4793 to UVC harness connector 3, leave
engine harness disconnected.
E. Use DMM, measure resistance between Breakout Harness ZTSE4793
pin-7 and pin-8.
Is resistance greater than 1000 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 654 FMI 4.

Step 9 Check for short between Open H and Open L circuits in Engine Decision
Harness.
A. Key-Off. Yes: Go to Step 10.

B. Disconnect UVC harness connector 3 from engine harness.

C. Disconnect ECM - Driver 36-pin connector.

D. Use Engine Terminal Test Kit ZTSE4435C, insert proper terminal into ECM
- Driver 36-pin connector pins D-29 and D-30, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pins D-29 and D-30.
Is resistance greater than 1000 ohms? No: Replace Engine Harness.
After repairs are complete, retest
for SPN 654 FMI 4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 579

Step 10 Check for Failed Engine Control Module. Decision

A. Key Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 654
B. Install Test ECM.
FMI 4.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).

D. Key ON Engine Running (KOER).

E. Check Diagnostic Trouble Code (DTC) list for SPN 654 FMI 4.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decision were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 654 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
580 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 654 FMI 5 - Injector 4 open coil - open circuit

Fault Overview
Fault code sets when Engine Control Module (ECM) detects an Open circuit on Injector 4 Open coil circuit.

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected during one drive cycle.

Associated Faults
None

Fault Facts
Final number of SPN identifies affected injector, and name in Navistar® Engine Diagnostics identifies cylinder in
which injector is installed.
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed Injector
• Open in Open H circuit
• Open in Open L circuit
• Failed Engine Control Module (ECM)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 581

Figure 175 Injector 4 Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 654 FMI 5.
Is EST DTC list SPN 654 FMI 5 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at Under Valve Connector (UVC) connector 3. Decision

A. Key-Off Yes: Go to Step 3.
B. Disconnect UVC 3.
C. Check UVC 3 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 3 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 654
FMI 5.
582 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Inspect UVC harness under valve cover. Decision

A. Key-Off. Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 654 FMI 5.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 4.

Step 4 Check for failed Injectors. Decision

A. Key-Off. Yes: Go to Step 5.
B. Remove valve cover (if not already done).
C. Disconnect Injector 1 through 6 connectors from UVC harness.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to each
Injector pin-2 and pin-3, leave UVC harness disconnected.
E. Use DMM, measure resistance between each individual Injector pin-2
and pin-3.
Is resistance 1.0 ± 0.5 ohms for each injector? No: Replace Failed Injector(s)
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 654 FMI
5.

Step 5 Check for Open in Open H circuit in UVC harness. Decision

A. Key-Off. Yes: Go to Step 6.
B. Disconnect Under Valve Connector (UVC) connector 3.
C. Disconnect Injector 4 from UVC harness.
D. Connect Breakout Harness ZTSE4793 to UVC connector 3, leave engine
harness disconnected.

E. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector 4

pin-2, leave injector disconnected.
F. Use DMM, measure resistance between Breakout Harness ZTSE4793
pin-8 and Injector 4 pin-2.
Is resistance less than 0.5 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 654 FMI 5.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 583

Step 6 Check for Open in Open L circuit in UVC harness. Decision

A. Key-Off. Yes: Go to Step 7.
B. Disconnect Under Valve Connector (UVC) Connector 3.
C. Disconnect Injector 4 from UVC harness.
D. Connect Breakout Harness ZTSE4793 to UVC connector 3, leave engine
harness disconnected.

E. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector 4

pin-3, leave injector disconnected.
F. Use DMM measure resistance between Breakout Harness ZTSE4793
pin-7 and Injector 4 pin-3.
Is resistance less than 0.5 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 654 FMI 5.

Step 7 Check for Open in Open H circuit in engine harness. Decision

A. Key-Off. Yes: Go to Step 8.

B. Disconnect Under Valve Connector (UVC) connector 3.

C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-30 and UVC Connector 3 pin-8, leave ECM and
UVC harness disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
D-30 and UVC connector 3 pin-8.
Is resistance less than 0.5 ohms? No: Replace engine Harness.
After repairs are complete, retest
for SPN 654 FMI 5.

Step 8 Check for Open in Open L circuit in engine harness. Decision

A. Key-Off. Yes: Go to Step 9.

B. Disconnect Under Valve Connector (UVC) connector 3.

C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-29 and UVC Connector 3 pin-7, leave ECM
and UVC harness disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
D-29 and UVC connector 3 pin-7.
Is resistance less than 0.5 ohms? No: Replace engine harness.
After repairs are complete, retest
for SPN 654 FMI 5.
584 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 9 Check for failed Engine Control Module (ECM). Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 654
B. Install Test ECM.
FMI 5
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).

D. Key ON Engine Running (KOER).

E. Check Diagnostic Trouble Code (DTC) list for SPN 654 FMI 5.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decisions were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 654 FMI 5 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 585

SPN 654 FMI 7 - Injector 4 Spool Motion Compensation Max Authority Reached

Fault Overview
Fault code sets when Engine Control Module (ECM) determines injector spool motion compensation has reached
its maximum allowable time limit.

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

Associated Faults
None

Fault Facts
Final number of SPN identifies affected injector, and name in Navistar® Engine Diagnostics identifies cylinder in
which injector is installed.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Incorrect ECM programming
• Failed injector
586 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for injector replacement. Decision

Identify if affected injector was recently replaced. Yes: Perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334). After repairs are
complete, retest for
SPN 654 FMI 7.
Has affected injector been recently replaced? No: Replace affected injector
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334). After repairs are
complete, retest for
SPN 654 FMI 7.

End Diagnostic Steps

After performing all diagnostic steps, if SPN 654 FMI 7 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 587

SPN 654 FMI 14 - Injector 4 Fuel quantity/timing error

Fault Overview
Fault sets when Engine Control Module (ECM) determines injector timing is off when comparing cylinder balance
difference between two consecutive cylinders.

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

Associated Faults
• SPN 27 FMI 14 (EGR) • SPN 51 FMI 3, 4, and 7 • SPN 94 (FDP) • SPN 108 FMI 3 and 4
(ETV) (BARO)
• SPN 110 FMI 2, 3, and 4 • SPN 132 (MAF) • SPN 164 (ICP) • SPN 175 FMI 2, 3, and 4
(ECT1) (EOT)
• SPN 191 FMI 3 and 4 • SPN 636 FMI 2 and 7 • SPN 6546 FMI 4, 5, and 7 • SPN 1322 - 1328 FMI 31
(TOSS) (CMP) (INJ) (INJ)
• SPN 1189 FMI 3 and 4 • SPN 2659 FMI 20 (AMS) • SPN 2791 FMI 2, 3, 4, 7, • SPN 3055 FMI 2 (INJ)
(TC2WC) 8, and 14 (EGR)
• SPN 3464 FMI 31 (ETV) • SPN 4257 FMI 7 (INJ) • SPN 5543 FMI 3, 4, and 5
(EBPV)

Fault Facts
None

Drive Cycle to Determine Fault Status

Road test
Possible Causes
• Injector damage
• Spool to control valve body static leakage
• Puck leakage
• Backup ring and/or O-ring leakage at injector inlet
• Biased Injection Control Pressure (ICP) sensor
• Engine oil dirty or poor quality
• Engine mechanical problem

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 587).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 654 FMI 14.
588 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 2 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 654 FMI 14. Yes: Go to Step 3.
Is EST DTC list SPN 654 FMI 14 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 654 FMI 14.

Step 3 Inspect connections at injector circuits outside valve cover connector. Decision
A. Key-Off. Yes: Go to Step 4.
B. Disconnect injector circuits outside valve cover connector.
C. Check injector circuits outside valve cover and connector terminals for:
damaged or pinched wires; moist or corroded terminals; loose, bent, or
broken pins; or broken connector housing.
Are injector circuits outside valve cover connector, harness, and terminals clean No: Repair connector, harness,
and undamaged? or terminal damage. After repairs
are complete, retest for SPN 654
FMI 14.

Step 4 Test for failed injector. Decision

Perform KOEO Injector Test (page 1365). Yes: Go to Step 7.
Did all injectors operate? No: Go to Step 5.

Step 5 Determine how many injectors operated. Decision

Determine if one injector or three injectors failed. Yes: Go to SPN 2798 FMI 6 (page
875).
Did only three injectors operate? No: Go to Step 6.

Step 6 Determine if fault codes set. Decision

Determine if SPN 654 FMI 4 or 5 or SPN 3662 FMI 4 or 5 fault codes have been set Yes: Go to fault codes for
applicable injector FMI 4, or 5.
Did fault codes set? No: Replace injector 4. Perform
Injector Coil End of Motion
(CEOM) Reset Procedure (page
1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs, retest
for SPN 654 FMI 14.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 589

Step 7 Inspect fuel system, fuel level, and fuel quality. Decision
• Perform Fuel Level Inspection(page 1634), Yes: Go to Step 8.
• Fuel Quality Inspection(page 1632), and
• Fuel System Inspection(page 1631).
Is there sufficient supply of good quality fuel? No: Drain dirty or aerated fuel, fill
with good quality fuel. Repair any
other fuel system discrepancies.
After repairs are complete, retest
for SPN 654 FMI 14.

Step 8 Inspect air intake and exhaust systems for restrictions, leaks, or Decision
physical damage.
• Perform Intake Air Inspection(page 1648) and Yes: Go to Step 9.
• Exhaust and Aftertreatment System Inspection(page 1651).
Are air intake system and exhaust system clear of restrictions, leaks, and physical No: Repair restrictions, leaks, or
damage? physical damage. After repairs are
complete, retest for SPN 654 FMI
14.

Step 9 Check engine oil level and oil quality. Decision

Perform Engine Oil Level and Quality Inspection (page 1635). Yes: Go to Step 10.
Is there sufficient supply of clean, non-aerated oil? No: Drain dirty, aerated, or
contaminated oil, fill with clean,
non-aerated oil. After repairs are
complete, retest for SPN 654 FMI
14.

Step 10 Determine if Engine Compression Brake (ECB1), if equipped, is Decision

operating correctly.
A. PerformKOEO Low to High Idle Test(page 1383). Yes: Go to Step 11.
B. Monitor Brake Control Pressure (BCP).
Is BCP less than 145 psi (1 MPa)? No: Replace ECB1 valve. After
repairs are complete, retest for
SPN 654 FMI 14.

Step 11 Calibrate MAF sensor. Decision

Perform KOER MAF Sensor Calibrations (page 1539). Yes: Go to Step 12.
Did MAF Sensor Calibration succeed? No: Repair fault code set during
MAF Sensor Calibration. After
repairs are complete, retest for
SPN 654 FMI 14.
590 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 12 Determine cause of rough engine idle. Decision

Perform Relative Compression Test (page 1371). Yes: Go to Step 14.
Are all engine cylinder performance readings similar? No: Go to Step 13.

Step 13 Test cylinder performance further. Decision

Do Cylinder Performance Analyzer (CPA) test to evaluate cylinder performance Yes: Retest for SPN 654 FMI 14.
issues. Evaluate performance concerns during
• cold idle (page 1407)and
• hot idle (page 1421).
Due to complexity of some codes, print out CPA tool results for later use.
Did tests finish without identifying a suspect cylinder? No: Remove valve cover, check
valve lash, and crank engine to
verify cam shaft lobe operation
and lift (See Engine Service
Manual). After repairs are
complete, retest for SPN 654 FMI
14.

Step 14 Test for oil leaks under valve cover. Decision

Perform CPA High-Pressure Oil Pump (HPOP) Test (page 1440). Yes: End diagnostics, retest for
SPN 654 FMI 14.
Did HPOP Test complete satisfactory? No: Repair failed component
indicated in HPOP Test. After
repairs are complete, retest for
SPN 654 FMI 14.

End Diagnostic Tests

After performing diagnostic steps, if SPN 654 FMI 14 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 591

SPN 655 FMI 4 - Injector 5 open coil - short circuit

Fault Overview
Fault code sets when Engine Control Module (ECM) detects a short circuit on Injector 5 Open coil.

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate immediately when this fault is detected.

Associated Faults
None

Fault Facts
Final number of SPN identifies affected injector, and name in Navistar® Engine Diagnostics identifies cylinder in
which injector is installed.
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed Injector
• Open H shorted to GND
• Open L shorted to GND
• Open H shorted to Open L
• Faulty Engine Control Module (ECM)
592 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 176 Injector 5 Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

WARNING:

To prevent personal injury or death, shut engine down before doing voltage checks
for injector solenoids. When engine is running, injector circuits have high voltage and
amperage.

CAUTION:

To prevent engine damage, turn ignition switch OFF before disconnecting connectors.
Failure to turn ignition switch OFF will cause a voltage spike and damage to electrical
components.

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for Yes: Go to Step 2.
SPN 655 FMI 4.
Is SPN 655 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 593

Step 2 Inspect connections at Under Valve Connector (UVC) connector 4. Decision

A. Key-Off Yes: Go to Step 3.
B. Disconnect UVC 4
C. Check UVC 4 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 4 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 655
FMI 4.

Step 3 Inspect UVC harness under valve cover. Decision

A. Key-Off. Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 655 FMI 4.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 4.

Step 4 Check for failed Injectors. Decision

A. Key-Off. Yes: Go to Step 5.

B. Remove Valve Cover (if not already done).

C. Disconnect Injector 1 through 6 connectors from UVC harness.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to each
Injector pin-2 and pin-3, leave UVC harness disconnected.
E. Use DMM, measure resistance between each individual Injector pin-2
and pin-3.
Is resistance 1.0 ± 0.5 ohms for each injector? No: Replace Failed Injector(s)
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 655 FMI
4.
594 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 5 Check Injector 5 for short to GND. Decision

A. Key-Off. Yes: Go to Step 6.
B. Disconnect Injector 5 connector from UVC harness.
C. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector 5
pin-2, leave UVC harness disconnected.

D. Use DMM, measure resistance between Injector 5 pin-2 and known good
GND.
Is resistance greater than 1000 ohms? No: Replace Injector 5 and
perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 655 FMI
4.

Step 6 Check Injector 5 Open Coil H Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 7.
B. Disconnect Injector 5 connector from UVC harness.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Engine Terminal Test Kit ZTSE4435C, insert proper terminal into ECM
- Driver 36-pin connector pin D-26, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-26 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM - Driver 36-pin connector pin
D-26 and Injector 5. After repairs
are complete, retest for SPN 655
FMI 4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 595

Step 7 Check Injector 5 Open Coil L Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 8.
B. Disconnect Injector 5 connector from UVC harness.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Engine Terminal Test Kit ZTSE4435C, insert proper terminal into ECM
- Driver 36-pin connector pin D-25, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-25 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM - Driver 36-pin connector pin
D-25 and Injector 5. After repairs
are complete, retest for SPN 655
FMI 4.

Step 8 Check for short between Open H and Open L circuits in UVC harness. Decision
A. Key-Off. Yes: Go to Step 9.
B. Disconnect Injector 5 connector from UVC harness.
C. Disconnect UVC harness connector 4 from engine harness.
D. Connect Breakout Harness ZTSE4793 to UVC harness connector 4, leave
engine harness disconnected.
E. Use DMM, measure resistance between Breakout Harness ZTSE4793
pin-3 and pin-4.
Is resistance greater than 1000 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 655 FMI 4.

Step 9 Check for short between Open H and Open L circuits in Engine Decision
Harness.
A. Key-Off. Yes: Go to Step 10.

B. Disconnect UVC harness connector 4 from engine harness.

C. Disconnect ECM - Driver 36-pin connector.

D. Use Engine Terminal Test Kit ZTSE4435C, insert proper terminal into ECM
- Driver 36-pin connector pins D-25 and D-26, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pins D-25 and D-26.
Is resistance greater than 1000 ohms? No: Replace Engine Harness.
After repairs are complete, retest
for SPN 655 FMI 4.
596 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 10 Check for Failed Engine Control Module. Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 655
B. Install Test ECM.
FMI 4.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).

D. Key ON Engine Running (KOER).

E. Check Diagnostic Trouble Code (DTC) list for SPN 655 FMI 4.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decision were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 655 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 597

SPN 655 FMI 5 - Injector 5 open coil - open circuit

Fault Overview
Fault code sets when Engine Control Module (ECM) detects an Open circuit on Injector 5 Open coil circuit.

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected during one drive cycle.

Associated Faults
None

Fault Facts
Final number of SPN identifies affected injector, and name in Navistar® Engine Diagnostics identifies cylinder in
which injector is installed.
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed Injector
• Open in Open H circuit
• Open in Open L circuit
• Failed Engine Control Module (ECM)
598 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 177 Injector 5 Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 655 FMI 5.
Is EST DTC list SPN 655 FMI 5 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at Under Valve Connector (UVC) connector 4. Decision

A. Key-Off Yes: Go to Step 3.
B. Disconnect UVC 4.
C. Check UVC 4 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 4 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 655
FMI 5.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 599

Step 3 Inspect UVC harness under valve cover. Decision

A. Key-Off. Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 655 FMI 5.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 4.

Step 4 Check for failed Injectors. Decision

A. Key-Off. Yes: Go to Step 5.
B. Remove valve cover (if not already done).
C. Disconnect Injector 1 through 6 connectors from UVC harness.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to each
Injector pin-2 and pin-3, leave UVC harness disconnected.
E. Use DMM, measure resistance between each individual Injector pin-2
and pin-3.
Is resistance 1.0 ± 0.5 ohms for each injector? No: Replace Failed Injector(s)
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 655 FMI
5.

Step 5 Check for Open in Open H circuit in UVC harness. Decision

A. Key-Off. Yes: Go to Step 6.
B. Disconnect Under Valve Connector (UVC) connector 4.
C. Disconnect Injector 5 from UVC harness.
D. Connect Breakout Harness ZTSE4793 to UVC connector 4, leave engine
harness disconnected.

E. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector 5

pin-2, leave injector disconnected.
F. Use DMM, measure resistance between Breakout Harness ZTSE4793
pin-4 and Injector 5 pin-2.
Is resistance less than 0.5 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 655 FMI 5.
600 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 6 Check for Open in Open L circuit in UVC harness. Decision

A. Key-Off. Yes: Go to Step 7.
B. Disconnect Under Valve Connector (UVC) Connector 4.
C. Disconnect Injector 5 from UVC harness.
D. Connect Breakout Harness ZTSE4793 to UVC connector 4, leave engine
harness disconnected.

E. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector 5

pin-3, leave injector disconnected.
F. Use DMM measure resistance between Breakout Harness ZTSE4793
pin-3 and Injector 5 pin-3.
Is resistance less than 0.5 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 655 FMI 5.

Step 7 Check for Open in Open H circuit in engine harness. Decision

A. Key-Off. Yes: Go to Step 8.

B. Disconnect Under Valve Connector (UVC) connector 4.

C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-26 and UVC Connector 4 pin-4, leave ECM and
UVC harness disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
D-26 and UVC connector 4 pin-4.
Is resistance less than 0.5 ohms? No: Replace engine Harness.
After repairs are complete, retest
for SPN 655 FMI 5.

Step 8 Check for Open in Open L circuit in engine harness. Decision

A. Key-Off. Yes: Go to Step 9.

B. Disconnect Under Valve Connector (UVC) connector 4.

C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-25 and UVC Connector 4 pin-3, leave ECM
and UVC harness disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
D-25 and UVC connector 4 pin-3.
Is resistance less than 0.5 ohms? No: Replace engine harness.
After repairs are complete, retest
for SPN 655 FMI 5.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 601

Step 9 Check for failed Engine Control Module (ECM). Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 655
B. Install Test ECM.
FMI 5
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).

D. Key ON Engine Running (KOER).

E. Check Diagnostic Trouble Code (DTC) list for SPN 655 FMI 5.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decisions were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 655 FMI 5 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
602 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 655 FMI 7 - Injector 5 Spool Motion Compensation Max Authority Reached

Fault Overview
Fault code sets when Engine Control Module (ECM) determines injector spool motion compensation has reached
its maximum allowable time limit.

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

Associated Faults
None

Fault Facts
Final number of SPN identifies affected injector, and name in Navistar® Engine Diagnostics identifies cylinder in
which injector is installed.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Incorrect ECM programming
• Failed injector
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 603

Step 1 Check for injector replacement. Decision

Identify if affected injector was recently replaced. Yes: Perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334). After repairs are
complete, retest for
SPN 655 FMI 7.
Has affected injector been recently replaced? No: Replace affected injector
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334). After repairs are
complete, retest for
SPN 655 FMI 7.

End Diagnostic Steps

After performing all diagnostic steps, if SPN 655 FMI 7 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
604 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 655 FMI 14 - Injector 5 Fuel quantity/timing error

Fault Overview
Fault sets when Engine Control Module (ECM) determines injector timing is off when comparing cylinder balance
difference between two consecutive cylinders.

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

Associated Faults
• SPN 27 FMI 14 (EGR) • SPN 51 FMI 3, 4, and 7 • SPN 94 (FDP) • SPN 108 FMI 3 and 4
(ETV) (BARO)
• SPN 110 FMI 2, 3, and 4 • SPN 132 (MAF) • SPN 164 (ICP) • SPN 175 FMI 2, 3, and 4
(ECT1) (EOT)
• SPN 191 FMI 3 and 4 • SPN 636 FMI 2 and 7 • SPN 655 FMI 4, 5, and 7 • SPN 1322 - 1328 FMI 31
(TOSS) (CMP) (INJ) (INJ)
• SPN 1189 FMI 3 and 4 • SPN 2659 FMI 20 (AMS) • SPN 2791 FMI 2, 3, 4, 7, • SPN 3055 FMI 2 (INJ)
(TC2WC) 8, and 14 (EGR)
• SPN 3464 FMI 31 (ETV) • SPN 4257 FMI 7 (INJ) • SPN 5543 FMI 3, 4, and 5
(EBPV)

Fault Facts
None

Drive Cycle to Determine Fault Status

Road test
Possible Causes
• Injector damage
• Spool to control valve body static leakage
• Puck leakage
• Backup ring and/or O-ring leakage at injector inlet
• Biased Injection Control Pressure (ICP) sensor
• Engine oil dirty or poor quality
• Engine mechanical problem

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 604).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 655 FMI 14.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 605

Step 2 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 655 FMI 14. Yes: Go to Step 3.
Is EST DTC list SPN 655 FMI 14 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 655 FMI 14.

Step 3 Inspect connections at injector circuits outside valve cover connector. Decision
A. Key-Off. Yes: Go to Step 4.
B. Disconnect injector circuits outside valve cover connector.
C. Check injector circuits outside valve cover and connector terminals for:
damaged or pinched wires; moist or corroded terminals; loose, bent, or
broken pins; or broken connector housing.
Are injector circuits outside valve cover connector, harness, and terminals clean No: Repair connector, harness,
and undamaged? or terminal damage. After repairs
are complete, retest for SPN 655
FMI 14.

Step 4 Test for failed injector. Decision

Perform KOEO Injector Test (page 1365). Yes: Go to Step 7.
Did all injectors operate? No: Go to Step 5.

Step 5 Determine how many injectors operated. Decision

Determine if one injector or three injectors failed. Yes: Go to SPN 2798 FMI 6 (page
875).
Did only three injectors operate? No: Go to Step 6.

Step 6 Determine if fault codes set. Decision

Determine if SPN 655 FMI 4 or 5 or SPN 3663 FMI 4 or 5 fault codes have been set Yes: Go to fault codes for
applicable injector FMI 4, or 5.
Did fault codes set? No: Replace injector 5. Perform
Injector Coil End of Motion
(CEOM) Reset Procedure (page
1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs, retest
for SPN 655 FMI 14.
606 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 7 Inspect fuel system, fuel level, and fuel quality. Decision
• Perform Fuel Level Inspection(page 1634), Yes: Go to Step 8.
• Fuel Quality Inspection(page 1632), and
• Fuel System Inspection(page 1631).
Is there sufficient supply of good quality fuel? No: Drain dirty or aerated fuel, fill
with good quality fuel. Repair any
other fuel system discrepancies.
After repairs are complete, retest
for SPN 655 FMI 14.

Step 8 Inspect air intake and exhaust systems for restrictions, leaks, or Decision
physical damage.
• Perform Intake Air Inspection (page 1648) and Yes: Go to Step 9.
• Exhaust and Aftertreatment System Inspection (page 1651).
Are air intake system and exhaust system clear of restrictions, leaks, and physical No: Repair restrictions, leaks, or
damage? physical damage. After repairs are
complete, retest for SPN 655 FMI
14.

Step 9 Check engine oil level and oil quality. Decision

Perform Engine Oil Level and Quality Inspection (page 1635). Yes: Go to Step 10.
Is there sufficient supply of clean, non-aerated oil? No: Drain dirty, aerated, or
contaminated oil, fill with clean,
non-aerated oil. After repairs are
complete, retest for SPN 655 FMI
14.

Step 10 Determine if Engine Compression Brake (ECB1), if equipped, is Decision

operating correctly.
A. Perform KOEO Low to High Idle Test(page 1383). Yes: Go to Step 11.
B. Monitor Brake Control Pressure (BCP).
Is BCP less than 145 psi (1 MPa)? No: Replace ECB1 valve. After
repairs are complete, retest for
SPN 655 FMI 14.

Step 11 Calibrate MAF sensor. Decision

Perform KOER MAF Sensor Calibrations (page 1539). Yes: Go to Step 12.
Did MAF Sensor Calibration succeed? No: Repair fault code set during
MAF Sensor Calibration. After
repairs are complete, retest for
SPN 655 FMI 14.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 607

Step 12 Determine cause of rough engine idle. Decision

Perform Relative Compression Test (page 1371). Yes: Go to Step 14.
Are all engine cylinder performance readings similar? No: Go to Step 13.

Step 13 Test cylinder performance further. Decision

Do Cylinder Performance Analyzer (CPA) test to evaluate cylinder performance Yes: Retest for SPN 655 FMI 14.
issues. Evaluate performance concerns during
• cold idle (page 1407) and
• hot idle (page 1421).
Due to complexity of some codes, print out CPA tool results for later use.
Did tests finish without identifying a suspect cylinder? No: Remove valve cover, check
valve lash, and crank engine to
verify cam shaft lobe operation
and lift (See Engine Service
Manual). After repairs are
complete, retest for SPN 655 FMI
14.

Step 14 Test for oil leaks under valve cover. Decision

Perform CPA High-Pressure Oil Pump (HPOP) Test (page 1440). Yes: End diagnostics, retest for
SPN 655 FMI 14.
Did HPOP Test complete satisfactory? No: Repair failed component
indicated in HPOP Test. After
repairs are complete, retest for
SPN 655 FMI 14.

End Diagnostic Tests

After performing diagnostic steps, if SPN 655 FMI 14 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
608 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 656 FMI 4 - Injector 6 open coil - short circuit

Fault Overview
Fault code sets when Engine Control Module (ECM) detects a short circuit on Injector 6 Open coil.

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate immediately when this fault is detected.

Associated Faults
None

Fault Facts
Final number of SPN identifies affected injector, and name in Navistar® Engine Diagnostics identifies cylinder in
which injector is installed.
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed Injector
• Open H shorted to GND
• Open L shorted to GND
• Open H shorted to Open L
• Faulty Engine Control Module (ECM)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 609

Figure 178 Injector 6 Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

WARNING:

To prevent personal injury or death, shut engine down before doing voltage checks
for injector solenoids. When engine is running, injector circuits have high voltage and
amperage.

CAUTION:

To prevent engine damage, turn ignition switch OFF before disconnecting connectors.
Failure to turn ignition switch OFF will cause a voltage spike and damage to electrical
components.

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for Yes: Go to Step 2.
SPN 656 FMI 4.
Is SPN 656 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).
610 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 2 Inspect connections at Under Valve Connector (UVC) connector 4. Decision

A. Key-Off. Yes: Go to Step 3.
B. Disconnect UVC 4
C. Check UVC 4 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 4 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 656
FMI 4.

Step 3 Inspect UVC harness under valve cover. Decision

A. Key-Off. Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 656 FMI 4.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 4.

Step 4 Check for failed Injectors. Decision

A. Key-Off. Yes: Go to Step 5.

B. Remove Valve Cover (if not already done).

C. Disconnect Injector 1 through 6 connectors from UVC harness.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to each
Injector pin-2 and pin-3, leave UVC harness disconnected.
E. Use DMM, measure resistance between each individual Injector pin-2
and pin-3.
Is resistance 1.0 ± 0.5 ohms for each injector? No: Replace Failed Injector(s)
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 656 FMI
4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 611

Step 5 Check Injector 6 for short to GND. Decision

A. Key-Off. Yes: Go to Step 6.
B. Disconnect Injector 6 connector from UVC harness.
C. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector 6
pin-2, leave UVC harness disconnected.

D. Use DMM, measure resistance between Injector 6 pin-2 and known good
GND.
Is resistance greater than 1000 ohms? No: Replace Injector 6 and
perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 656 FMI
4.

Step 6 Check Injector 6 Open Coil H Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 7.
B. Disconnect Injector 6 connector from UVC harness.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Engine Terminal Test Kit ZTSE4435C, insert proper terminal into ECM
- Driver 36-pin connector pin D-28, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-28 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM - Driver 36-pin connector pin
D-28 and Injector 6. After repairs
are complete, retest for SPN 656
FMI 4.
612 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 7 Check Injector 6 Open Coil L Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 8.
B. Disconnect Injector 6 connector from UVC harness.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Engine Terminal Test Kit ZTSE4435C, insert proper terminal into ECM
- Driver 36-pin connector pin D-27, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-27 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM - Driver 36-pin connector pin
D-27 and Injector 6. After repairs
are complete, retest for SPN 656
FMI 4.

Step 8 Check for short between Open H and Open L circuits in UVC harness. Decision
A. Key-Off. Yes: Go to Step 9.
B. Disconnect Injector 6 connector from UVC harness.
C. Disconnect UVC harness connector 4 from engine harness.
D. Connect Breakout Harness ZTSE4793 to UVC harness connector 4, leave
engine harness disconnected.
E. Use DMM, measure resistance between Breakout Harness ZTSE4793
pin-7 and pin-8.
Is resistance greater than 1000 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 656 FMI 4.

Step 9 Check for short between Open H and Open L circuits in Engine Decision
Harness.
A. Key-Off. Yes: Go to Step 10.

B. Disconnect UVC harness connector 4 from engine harness.

C. Disconnect ECM - Driver 36-pin connector.

D. Use Engine Terminal Test Kit ZTSE4435C, insert proper terminal into ECM
- Driver 36-pin connector pins D-27 and D-28, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pins D-27 and D-28.
Is resistance greater than 1000 ohms? No: Replace Engine Harness.
After repairs are complete, retest
for SPN 656 FMI 4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 613

Step 10 Check for Failed Engine Control Module (ECM). Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 656
B. Install Test ECM.
FMI 4.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).

D. Key ON Engine Running (KOER).

E. Check Diagnostic Trouble Code (DTC) list for SPN 656 FMI 4.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decision were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 656 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
614 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 656 FMI 5 - Injector 6 open coil - open circuit

Fault Overview
Fault code sets when Engine Control Module (ECM) detects an Open circuit on Injector 6 Open coil circuit.

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected during one drive cycle.

Associated Faults
None

Fault Facts
Final number of SPN identifies affected injector, and name in Navistar® Engine Diagnostics identifies cylinder in
which injector is installed.
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed Injector
• Open in Open H circuit
• Open in Open L circuit
• Failed Engine Control Module (ECM)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 615

Figure 179 Injector 6 Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 656 FMI 5.
Is EST DTC list SPN 656 FMI 5 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at Under Valve Connector (UVC) connector 4. Decision

A. Key-Off Yes: Go to Step 3.
B. Disconnect UVC 4.
C. Check UVC 4 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 4 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 656
FMI 5.
616 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Inspect UVC harness under valve cover. Decision

A. Key-Off. Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 656 FMI 5.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 4.

Step 4 Check for failed Injector. Decision

A. Key-Off. Yes: Go to Step 5.
B. Remove valve cover (if not already done).
C. Disconnect Injector 1 through 6 connectors from UVC harness.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to each
Injector pin-2 and pin-3, leave UVC harness disconnected.
E. Use DMM, measure resistance between each individual Injector pin-2
and pin-3.
Is resistance 1.0 ± 0.5 ohms for each injector? No: Replace Failed Injector(s)
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 656 FMI
5.

Step 5 Check for Open in Open H circuit in UVC harness. Decision

A. Key-Off. Yes: Go to Step 6.
B. Disconnect Under Valve Connector (UVC) connector 4.
C. Disconnect Injector 6 from UVC harness.
D. Connect Breakout Harness ZTSE4793 to UVC connector 4, leave engine
harness disconnected.

E. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector 6

pin-2, leave injector disconnected.
F. Use DMM, measure resistance between Breakout Harness ZTSE4793
pin-8 and Injector 6 pin-2.
Is resistance less than 0.5 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 656 FMI 5.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 617

Step 6 Check for Open in Open L circuit in UVC harness. Decision

A. Key-Off. Yes: Go to Step 7.
B. Disconnect Under Valve Connector (UVC) Connector 4.
C. Disconnect Injector 6 from UVC harness.
D. Connect Breakout Harness ZTSE4793 to UVC connector 4, leave engine
harness disconnected.

E. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector 6

pin-3, leave injector disconnected.
F. Use DMM measure resistance between Breakout Harness ZTSE4793
pin-7 and Injector 6 pin-3.
Is resistance less than 0.5 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 656 FMI 5.

Step 7 Check for Open in Open H circuit in engine harness. Decision

A. Key-Off. Yes: Go to Step 8.

B. Disconnect Under Valve Connector (UVC) connector 4.

C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-28 and UVC Connector 4 pin-8, leave ECM and
UVC harness disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
D-28 and UVC connector 4 pin-8.
Is resistance less than 0.5 ohms? No: Replace engine Harness.
After repairs are complete, retest
for SPN 656 FMI 5.

Step 8 Check for Open in Open L circuit in engine harness. Decision

A. Key-Off. Yes: Go to Step 9.

B. Disconnect Under Valve Connector (UVC) connector 4.

C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-27 and UVC Connector 4 pin-7, leave ECM
and UVC harness disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
D-27 and UVC connector 4 pin-7.
Is resistance less than 0.5 ohms? No: Replace engine harness.
After repairs are complete, retest
for SPN 656 FMI 5.
618 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 9 Check for failed Engine Control Module (ECM). Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 656
B. Install Test ECM.
FMI 5
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).

D. Key ON Engine Running (KOER).

E. Check Diagnostic Trouble Code (DTC) list for SPN 656 FMI 5.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decisions were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 656 FMI 5 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 619

SPN 656 FMI 7 - Injector 6 Spool Motion Compensation Max Authority Reached

Fault Overview
Fault code sets when Engine Control Module (ECM) determines injector spool motion compensation has reached
its maximum allowable time limit.

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

Associated Faults
None

Fault Facts
Final number of SPN identifies affected injector, and name in Navistar® Engine Diagnostics identifies cylinder in
which injector is installed.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Incorrect ECM programming
• Failed injector
620 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for injector replacement. Decision

Identify if affected injector was recently replaced. Yes: Perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334). After repairs are
complete, retest for
SPN 656 FMI 7.
Has affected injector been recently replaced? No: Replace affected injector
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334). After repairs are
complete, retest for
SPN 656 FMI 7.

End Diagnostic Steps

After performing all diagnostic steps, if SPN 656 FMI 7 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 621

SPN 656 FMI 14 - Injector 6 Fuel quantity/timing error

Fault Overview
Fault sets when Engine Control Module (ECM) determines injector timing is off when comparing cylinder balance
difference between two consecutive cylinders.

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

Associated Faults
• SPN 27 FMI 14 (EGR) • SPN 51 FMI 3, 4, and 7 • SPN 94 (FDP) • SPN 108 FMI 3 and 4
(ETV) (BARO)
• SPN 110 FMI 2, 3, and 4 • SPN 132 (MAF) • SPN 164 (ICP) • SPN 175 FMI 2, 3, and 4
(ECT1) (EOT)
• SPN 191 FMI 3 and 4 • SPN 636 FMI 2 and 7 • SPN 656 FMI 4, 5, and 7 • SPN 1322 - 1328 FMI 31
(TOSS) (CMP) (INJ) (INJ)
• SPN 1189 FMI 3 and 4 • SPN 2659 FMI 20 (AMS) • SPN 2791 FMI 2, 3, 4, 7, • SPN 3055 FMI 2 (INJ)
(TC2WC) 8, and 14 (EGR)
• SPN 3464 FMI 31 (ETV) • SPN 4257 FMI 7 (INJ) • SPN 5543 FMI 3, 4, and
5 (EBPV)

Fault Facts
None

Drive Cycle to Determine Fault Status

Road test
Possible Causes
• Injector damage
• Spool to control valve body static leakage
• Puck leakage
• Backup ring and/or O-ring leakage at injector inlet
• Biased Injection Control Pressure (ICP) sensor
• Engine oil dirty or poor quality
• Engine mechanical problem

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 621).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 656 FMI 14.
622 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 2 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 656 FMI 14. Yes: Go to Step 3.
Is EST DTC list SPN 656 FMI 14 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 656 FMI 14.

Step 3 Inspect connections at injector circuits outside valve cover connector. Decision
A. Key-Off. Yes: Go to Step 4.
B. Disconnect injector circuits outside valve cover connector.
C. Check injector circuits outside valve cover and connector terminals for:
damaged or pinched wires; moist or corroded terminals; loose, bent, or
broken pins; or broken connector housing.
Are injector circuits outside valve cover connector, harness, and terminals clean No: Repair connector, harness,
and undamaged? or terminal damage. After repairs
are complete, retest for SPN 656
FMI 14.

Step 4 Test for failed injector. Decision

Perform KOEO Injector Test (page 1365). Yes: Go to Step 7.
Did all injectors operate? No: Go to Step 5.

Step 5 Determine how many injectors operated. Decision

Determine if one injector or three injectors failed. Yes: Go to SPN 2798 FMI 6(page
875).
Did only three injectors operate? No: Go to Step 6.

Step 6 Determine if fault codes set. Decision

Determine if SPN 656 FMI 4 or 5 or SPN 3664 FMI 4 or 5 fault codes have been set Yes: Go to fault codes for
applicable injector FMI 4, or 5.
Did fault codes set? No: Replace injector 6. Perform
Injector Coil End of Motion
(CEOM) Reset Procedure (page
1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs, retest
for SPN 656 FMI 14.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 623

Step 7 Inspect fuel system, fuel level, and fuel quality. Decision
• Perform Fuel Level Inspection(page 1634), Yes: Go to Step 8.
• Fuel Quality Inspection(page 1632), and
• Fuel System Inspection(page 1631).
Is there sufficient supply of good quality fuel? No: Drain dirty or aerated fuel, fill
with good quality fuel. Repair any
other fuel system discrepancies.
After repairs are complete, retest
for SPN 656 FMI 14.

Step 8 Inspect air intake and exhaust systems for restrictions, leaks, or Decision
physical damage.
• Perform Intake Air Inspection(page 1648) and Yes: Go to Step 9.
• Exhaust and Aftertreatment System Inspection(page 1651).
Are air intake system and exhaust system clear of restrictions, leaks, and physical No: Repair restrictions, leaks, or
damage? physical damage. After repairs are
complete, retest for SPN 656 FMI
14.

Step 9 Check engine oil level and oil quality. Decision

Perform Engine Oil Level and Quality Inspection (page 1635). Yes: Go to Step 10.
Is there sufficient supply of clean, non-aerated oil? No: Drain dirty, aerated, or
contaminated oil, fill with clean,
non-aerated oil. After repairs are
complete, retest for SPN 656 FMI
14.

Step 10 Determine if Engine Compression Brake (ECB1), if equipped, is Decision

operating correctly.
A. PerformKOEO Low to High Idle Test(page 1383). Yes: Go to Step 11.
B. Monitor Brake Control Pressure (BCP).
Is BCP less than 145 psi (1 MPa)? No: Replace ECB1 valve. After
repairs are complete, retest for
SPN 656 FMI 14.

Step 11 Calibrate MAF sensor. Decision

Perform KOER MAF Sensor Calibrations (page 1539). Yes: Go to Step 12.
Did MAF Sensor Calibration succeed? No: Repair fault code set during
MAF Sensor Calibration. After
repairs are complete, retest for
SPN 656 FMI 14.
624 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 12 Determine cause of rough engine idle. Decision

Perform Relative Compression Test (page 1371). Yes: Go to Step 14.
Are all engine cylinder performance readings similar? No: Go to Step 13.

Step 13 Test cylinder performance further. Decision

Do Cylinder Performance Analyzer (CPA) test to evaluate cylinder performance Yes: Retest for SPN 656 FMI 14.
issues. Evaluate performance concerns during
• cold idle(page 1407) and
• hot idle (page 1421).
Due to complexity of some codes, print out CPA tool results for later use.
Did tests finish without identifying a suspect cylinder? No: Remove valve cover, check
valve lash, and crank engine to
verify cam shaft lobe operation
and lift (See Engine Service
Manual). After repairs are
complete, retest for SPN 656 FMI
14.

Step 14 Test for oil leaks under valve cover. Decision

Perform CPA High-Pressure Oil Pump (HPOP) Test (page 1440). Yes: End diagnostics, retest for
SPN 656 FMI 14.
Did HPOP Test complete satisfactory? No: Repair failed component
indicated in HPOP Test. After
repairs are complete, retest for
SPN 656 FMI 14.

End Diagnostic Tests

After performing diagnostic steps, if SPN 656 FMI 14 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 625

SPN 679 FMI 3 - IPR short to PWR

Fault Overview
Fault code sets when Electronic Control Module (ECM) detects Injection Pressure Regulator (IPR) valve
frequency is greater than expected.

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected during one trip.

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Initial Key ON
Possible Causes
• IPR circuit short to PWR
• Failed IPR
626 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault code. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 679 FMI 3 (IPR).
Is EST DTC list SPN 679 FMI 3 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Inspect connections at Injection Pressure Regulator (IPR) valve Decision

connector.
A. Key OFF. Yes: Go to Step 3.
B. Disconnect IPR valve connector.
C. Check IPR valve and connector terminals for: damaged or pinched wires;
corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are IPR connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 679
FMI 3.

Step 3 Test IPR circuit while IPR is being actuated by ECM. Decision
A. Perform Test 1(page 627). Yes: Replace IPR valve. After
repairs are complete, retest for
B. Select KOEO Tests > Output State Test High(page 1359).
SPN 679 FMI 3.
C. While test is active, use DMM, measure voltage between Breakout
Harness 12-800-02 pin-2 and known good GND.
Is voltage less than 0.5 volts? No: Repair short to PWR between
IPR valve pin-2 and ECM pin
E-43. After repairs are complete,
retest for SPN 679 FMI 3.

End Diagnostic Test

After performing diagnostic steps, if SPN 679 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 627

Pin-Point Tests (SPN 679 FMI 3)

Figure 180 IPR Valve Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Digital Multimeter (DMM)
• Injection Pressure Regulator (IPR) Breakout Harness 12-800-02
628 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 181 IPR Valve Voltage Check

Test 1
A. Key OFF.
B. Disconnect Injection Pressure Regulator (IPR) valve connector.
C. Connect Breakout Harness 12-800-02 to vehicle harness and leave IPR valve connector disconnected.
D. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
E. Key-On Engine-Off (KOEO). Log into Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 629

SPN 679 FMI 4 - IPR Open or short to GND

Fault Overview
Fault code sets when Engine Control Module (ECM) detects Injection Pressure Regulation (IPR) valve frequency
is less than 100 Hz.

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected during one trip.

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Initial Key ON
Possible Causes
• IPR circuit Open or shorted to GND
• IPR PWR circuit Open
• Failed IPR valve
630 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 679 FMI 4 (IPR).
Is EST DTC list SPN 679 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Inspect connections at Injection Pressure Regulator (IPR) valve. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect IPR valve connector.
C. Check IPR valve and connector terminals for: damaged or pinched wires;
corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are IPR valve connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 679
FMI 4.

Step 3 Check Injection Pressure Regulator (IPR) valve circuit for Open. Decision
A. Perform Test 1(page 631). Yes: Go to Step 4.
B. Use DMM, measure voltage between Breakout Harness 12-800-02 pin-1
and known good GND.
Is voltage B+ ± 0.5 volts? No: Repair Open between IPR
valve pin-1 and ignition switch.
After repairs are complete, retest
for SPN 679 FMI 4.

Step 4 Test IPR circuit while IPR is being actuated by ECM. Decision
A. Perform Test 2(page 632). Yes: Replace IPR valve. After
repairs are complete, retest for
B. Select KOEO Tests > Output State Test High(page 1359).
SPN 679 FMI 4.
C. While test is active, use DMM, measure voltage between Breakout
Harness 12-800-02 pin-1 and pin-2.
Is voltage B+ ± 0.5 volts? No: Repair Open or short to GND
between IPR valve pin-2 and
ECM pin E-43. After repairs are
complete, retest for SPN 679 FMI
4.

End Diagnostic Test

After performing diagnostic steps, if SPN 679 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 631

Pin-Point Tests (SPN 679 FMI 4)

Figure 182 IPR Valve Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Digital Multimeter (DMM)
• Breakout Harness 12-800-02
632 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 183 IPR Valve Voltage Check

Test 1
A. Key OFF.
B. Disconnect Injection Pressure Regulator (IPR) valve connector.
C. Connect Breakout Harness 12-800-02 to vehicle harness and leave IPR valve connector disconnected.
D. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 633

12-800-02
2

0000429466

Figure 184 IPR Valve Voltage Check

Test 2
A. Key OFF.
B. Disconnect Injection Pressure Regulator (IPR) valve connector.
C. Connect Breakout Harness 12-800-02 to vehicle harness and leave IPR valve connector disconnected.
D. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
E. Key-On Engine-Off (KOEO). Log into Navistar® Engine Diagnostics.
634 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 679 FMI 5 - IPR open load / circuit

Fault Overview
Fault sets when Engine Control Module (ECM) determines Injection Pressure Regulator (IPR) has an open
circuit.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• None
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 635

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 679 FMI 5.
Is SPN 679 FMI 5 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 679 FMI 5.

Step 2 Inspect Injection Pressure Regulator (IPR) sensor and connector. Decision
A. Key OFF. Yes: Go to Step 3.
B. Disconnect IPR valve.
C. Check IPR valve and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are IPR valve connector, harness, and terminals clean and undamaged? No: Repair connector, harness, or
terminal damage. After repairs are
complete, retest for SPN 679 FMI
5.

Step 3 Test IPR valve circuit for Open or Short to GND Decision
Perform Test 1 (page 638). Use DMM, measure voltage between IPR valve Yes: Go to Step 4.
breakout harness pin-1 and known good GND.
Is voltage B+ ± 0.5 volts? No: Repair Open or Short to
GND in IPR voltage supply circuit
between IPR valve pin-1 and
switched ignition PWR. After
repairs are complete, retest for
SPN 679 FMI 5.

Step 4 Test IPR valve circuit for Short to GND Decision

Perform Test 2 (page 639). Use DMM. Measure resistance between IPR valve Yes: Go to Step 5.
breakout harness pin-2 and known good GND.
Is resistance greater than 1000 ohms? No: Repair Short to GND in IPR
low side driver control circuit
between IPR valve pin-2 and black
ECM 76-pin connector pin E-43.
After repairs are complete, retest
for SPN 679 FMI 5.
636 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 5 Test IPR valve circuit for Open or Short to PWR. Decision
A. Perform Test 3 (page 640). Yes: Clear any faults codes that
set during test, and go to Step 6.
B. Perform IPR Output State High Test (page 1359).
C. While test is running, use DMM, measure voltage between IPR valve
breakout harness pin-1 and pin-2.
Is voltage B+ ± 0.5 volts while test is running? No: Repair Open or Short to PWR
in IPR low side driver control circuit
between IPR valve pin-2 and black
ECM 76-pin connector pin E-43.
After repairs are complete, retest
for SPN 679 FMI 5.

Step 6 Test IPR valve for proper voltage drop. Decision

A. Perform Test 4 (page 641). Yes: End diagnostics. Retest for
SPN 679 FMI 5.
B. Perform Output State High Test (page 1359).
C. While test is running, use DMM, measure voltage between IPR valve
breakout harness pin-1 and pin-2.
Is voltage 5.5 ± 0.5 volts while test is running? No: Go to Step 7

Step 7 Test IPR valve for proper voltage drop. Decision

Perform Test 5 (page 642). Use DMM, measure resistance between IPR valve Yes: Repair high resistance in
breakout harness pin-1 and pin-2. either IPR low side driver control
circuit or IPR voltage supply circuit.
Is resistance 5.6 ± 1.0 ohms? No: Replace IPR valve. After
repairs are complete retest for
SPN 679 FMI 5.

End Diagnostic Test

After performing diagnostic steps, if SPN 679 FMI 5 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 637

Pin-Point Tests (SPN 679 FMI 5)

Figure 185 IPR Valve Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Digital Multimeter (DMM)
• Breakout Harness 12-800-02
• Breakout Harness ZTSE4484
638 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 186 IPR Breakout ZTSE4484

Figure 187 IPR Breakout 12-800-02

 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 639

Figure 188 IPR Valve Voltage Check

Test 1
A. Key Off.
B. Disconnect IPR valve connector.
C. Compare IPR valve connector configuration to ZTSE4484 (Figure 186) and 12-800-02 (Figure 187) connector
ends and select appropriate breakout harness.
D. Connect appropriate IPR valve breakout harness to engine harness and leave IPR valve disconnected.
E. Key-On Engine-Off (KOEO).
640 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

2
12-800-02

0000432664

Figure 189 IPR Valve Resistance Check

Test 2
A. Key Off.
B. Disconnect IPR valve connector.
C. Connect IPR valve breakout harness to engine harness and leave IPR valve disconnected.
D. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 641

12-800-02
2

0000429466

Figure 190 IPR Valve Voltage Check

Test 3
A. Key Off.
B. Disconnect IPR valve connector.
C. Connect IPR valve breakout harness to engine harness and leave IPR valve disconnected.
D. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
E. Key-On Engine-Off (KOEO). Log into Navistar® Engine Diagnostics.
642 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

12-800-02
2

0000429466

Figure 191 IPR Valve Voltage Check

Test 4
A. Key Off.
B. Disconnect IPR valve connector.
C. Install IPR valve breakout harness between IPR valve and engine harness.
D. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
E. Key-On Engine-Off (KOEO). Log into Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 643

12-800-02 2

0000432665

Figure 192 IPR Valve Resistance Check

Test 5
A. Key Off.
B. Disconnect IPR valve connector.
C. Connect IPR valve breakout harness to IPR valve and leave engine harness disconnected.
644 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 729 FMI 3 - IAHC short to PWR

Fault Overview
Fault sets when Engine Control Module (ECM) determines IAH is shorted to B+.

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

Associated Faults
SPN 158 FMI 15 and 17
(ECM)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• IAHC circuit short to PWR
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 645

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 644).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 729 FMI 3.

Step 2 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 729 FMI 3. Yes: Go to Step 3.
Is EST DTC list SPN 729 FMI 3 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 3 Intake Air Heater Control (IAHC) relay and connector inspection. Decision
A. Key OFF. Yes: Go to Step 4.
B. Disconnect IAHC relay.
C. Check IAHC relay and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are IAHC relay connector, harness, and terminals clean and undamaged? No: Repair connector, harness, or
terminal damage. After repairs are
complete, retest for SPN 729 FMI
3.

Step 4 Check IAHC circuit for short to PWR. Decision

A. Perform Test 1 (page 646). Yes: Replace IAHC Relay. After
repairs are complete, retest for
B. Use DMM, measure voltage between Breakout Harness ZTSE6025 pin-2
SPN 729 FMI 3.
and known good GND.
Is voltage less than 0.5 volts? No: Repair short to PWR between
ECM pin E-59 and IAHC Relay
pin-2. After repairs are complete,
retest for SPN 729 FMI 3.

End Diagnostic Tests

After performing diagnostic steps, if SPN 729 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
646 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 729 FMI 3)

Figure 193 IAH Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE6025
• Digital Multimeter (DMM)

Figure 194 IAHC Relay Circuit Check

Test 1
A. Key OFF.
B. Disconnect IAHC relay.
C. Connect Breakout Harness ZTSE6025 to vehicle harness and leave IAHC relay disconnected.
D. Key ON Engine OFF (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 647

SPN 729 FMI 4 - IAHC short to GND

Fault Overview
Fault sets when Engine Control Module (ECM) determines IAH is shorted to ground.

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

Associated Faults
SPN 158 FMI 15 and 17
(ECM)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• IAHC circuit short to GND
648 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 647).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 729 FMI 4.

Step 2 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 729 FMI 4. Yes: Go to Step 3.
Is EST DTC list SPN 729 FMI 4 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 3 Inspect Intake Air Heater Control (IAHC) sensor and connector. Decision
A. Key OFF. Yes: Go to Step 4.
B. Disconnect IAHC sensor.
C. Check IAHC sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are IAHC sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 729
FMI 4.

Step 4 Check Intake Air Heater Control (IAHC) circuit for short to GND. Decision
A. Perform Test 1 (page 649). Yes: Replace Intake Air Heater
Relay (IAH Relay).
B. Use DMM, measure voltage between Breakout Harness ZTSE6025 pin-2
and PWR.
Is voltage less than 0.5 volts? No: Repair short to GND between
ECM pin E-59 and IAH Relay
pin-2. After repairs are complete,
retest for SPN 729 FMI 4.

End Diagnostic Tests

After performing all diagnostic steps, if SPN 729 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 649

Pin-Point Tests (SPN 729 FMI 4)

Figure 195 IAH Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE6025
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)
650 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 196 IAHC Circuit Check

Test 1
A. Key OFF.
B. Disconnect Intake Air Heater Control (IAHC) sensor connector.
C. Connect Breakout Harness ZTSE6025 to vehicle harness and leave IAHC sensor disconnected.
D. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 651

SPN 729 FMI 5 - IAHC open load / circuit

Fault Overview
Fault code sets when Engine Control Module (ECM) detects an Open circuit in Intake Air Heater (IAH) Relay
control circuit.

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

Associated Faults
SPN 158 FMI 15 and 17
(ECM PWR)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• ACT GND circuit Open
• IAHC circuit Open
• Failed IAH Relay
652 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 651).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 729 FMI 5.

Step 2 Inspect connections Intake Air Heater (IAH) Relay. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect IAH Relay .
C. Check IAH Relay connector terminals for: damaged or pinched wires;
moist or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are IAH Relay connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 729
FMI 5.

Step 3 Check for Open in ACT GND circuit Decision

A. Perform Test 1 (page 654). Yes: Go to Step 4.
B. Use Digital Multimeter (DMM), measure resistance between Breakout
Harness ZTSE6025 pin-1 and known good GND.
Is resistance less than 5 ohms? No: Repair Open between IAHC
pin-1 and GND. After repairs are
complete, retest for SPN 729 FMI
5.

Step 4 Check for failed IAH Relay. Decision

A. Perform Test 2 (page 655). Yes: Repair Open between IAH
Relay pin-2 and ECM pin E-59.
B. Use DMM, measure resistance between Breakout Harness ZTSE6025
After repairs are complete, retest
pin-1 and pin-2.
for SPN 729 FMI 5.
Is resistance within 37 ± 5 ohms? No: Go to Step 5.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 653

Step 5 Inspect connections at Intake Manifold Temperature (IMT) connector. Decision

A. Key OFF. Yes: Go to Step 6.
B. Disconnect IMT connector..
C. Check IMT and connector terminals for: damaged or pinched wires; moist
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are IMT connector, harness, and terminals clean and undamaged? No: Repair connector, harness, or
terminal damage. After repairs are
complete, retest for SPN 729 FMI
5.

Step 6 Check for high resistance in IMT circuit. Decision

A. Perform Test 3 (page 655). Yes: Replace IMT sensor. After
repairs are complete, retest for
B. Use EST, monitor IMT.
SPN 729 FMI 5.
Is temperature 302 ± 10°F (150 ± 6°C)? No: Go to Step 7.

Step 7 Check for high resistance in SIG GND circuit. Decision

A. Perform Test 4 (page 656). Yes: Repair SIG GND circuit
between IMT pin-1 and ECM pin
B. Use EST, monitor IMT.
E-28. After repairs are complete,
retest for SPN 729 FMI 5.
Is temperature 302 ± 10°F (150 ± 6°C)? No: Repair SIG circuit between
IMT pin-2 and ECM pin E-15. After
repairs are complete, retest for
SPN 729 FMI 5.

End Diagnostic Tests

After performing diagnostic steps, if SPN 729 FMI 5 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
654 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 729 FMI 5)

Figure 197 IAH Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE6025
• Breakout Harness ZTSE4993
• Breakout Harness ZTSE4497
• Digital Multimeter (DMM)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 655

Figure 198 IAH Relay Circuit Check

Test 1
A. Key OFF.
B. Disconnect Intake Air Heater (IAH) relay
C. Connect Breakout Harness ZTSE6025 to vehicle engine and leave IAH relay disconnected

Figure 199 IAH Relay Circuit Check

Test 2
A. Key OFF.
B. Disconnect Intake Air Heater (IAH) relay
C. Connect breakout harness ZTSE6025 to IAHC and leave engine harness disconnected.
656 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 200 IMT Signal Circuit Check

Test 3
A. Key OFF.
B. Disconnect Intake Manifold Temperature (IMT) sensor
C. Connect Breakout Harness ZTSE4993 to vehicle harness connector and leave IMT sensor disconnected
D. Connect Resistor Harness ZTSE4497 between Breakout Harness ZTSE4993 pin-1 and pin-2
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 657

Figure 201 IMT Signal Circuit Check

Test 4
A. Key OFF.
B. Disconnect Intake Manifold Temperature (IMT) sensor
C. Connect Breakout Harness ZTSE4993 to vehicle harness connector and leave IMT sensor disconnected
D. Connect Resistor Harness ZTSE4497 between Breakout Harness ZTSE4993 pin-2 and known good GND
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
658 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 729 FMI 18 - IAH Monitor fault: Lack of Heat in the Intake Manifold

Fault Overview
Fault sets when Engine Control Module (ECM) detects an Intake Air Heater (IAH) monitor fault, lack of heat in
intake manifold.

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

Associated Faults
• SPN 105 FMI 3 and 4 (IMT) • SPN 729 FMI 3, 4, and 5
(IAHC)

Fault Facts
None

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• Open power supply circuit (fuse and wiring on truck side)
• Failed IAH relay
• IAH grid heater
• IAH circuit Open or short to ground.
• ACT GND circuit Open
• Intake Manifold Temperature (IMT) sensor or bore
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 659

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 658).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 729 FMI 18.

Step 2 Measure amperage draw of IAH. Decision

A. Install amp clamp on B+ feed cable to the IAH relay. Yes: Go to Step 4.
B. Activate IAH using EST. Select: Tests > KOEO Tests > Intake Air Heater
Test.
C. Measure amperage draw while IAH is active.
Is amperage draw 125 ± 30 amps, within 2 seconds of activation? No: Go to Step 3.

Step 3 Determine if IAH components and circuits are operating properly. Decision
Perform Intake Air Heater (IAH) System Test (page 1590). Yes: Repair or replace failed
components or circuits. After
repairs are complete, retest for
SPN 729 FMI 18.
Were failed IAH components or circuits identified? No: End Diagnostics. Retest for
SPN 729 FMI 18.

Step 4 Determine if Intake Manifold Temperature (IMT) sensor or bore has Decision
excessive soot or damage.
A. Key OFF. Yes: Replace IMT sensor. If
needed, clean sensor bore
B. Disconnect IMT sensor connector.
and repair source of soot
C. Remove IMT sensor from intake manifold and inspect for damage and contamination. After repairs are
excessive soot buildup. A thin layer of soot is normal. complete, retest for SPN 729 FMI
18.
Is the IMT sensor damaged or have excessive soot buildup? No: End Diagnostics. Retest for
SPN 729 FMI 18.

End Diagnostic Steps

After performing diagnostic step, if SPN 729 FMI 18 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
660 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 931 FMI 3 - EFP short to PWR

Fault Overview
Fault code sets when B+ is on EFP PWR circuit when Electric Fuel Pump (EFP) is commanded Off or when no
voltage is present when the EFP is commanded On.

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

Associated Faults
None

Fault Facts
ECM will power fuel pump for 30 seconds after key is turned on. If ECM doesn’t see engine rotation at end of
30 seconds, pump will shut off until engine rotation is detected.

Drive Cycle to Determine Fault Status

Key-On, Engine-Off (fuel pump commanded Off)
Possible Causes
• Fuel Pump PWR/FPM circuit Open or short to GND
• Fuel Pump PWR/FPM circuit short to PWR
• Failed Fuel Pump Relay

Step 1 Check for active or pending fault code. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 931 FMI 3 (EFP).
Is SPN 931 FMI 3 pending or active? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 2 Inspect connections at Electric Fuel Pump (EFP) connector. Decision

A. Key-Off. Yes: Go to Step 3.
B. Disconnect EFP relay and Fuse from instrument panel power distribution
module.

C. Check EFP relay and Fuse terminals for: damaged or pinched wires;
moist or corroded terminals; loose, bent, or broken pins; or broken
connector housing.

D. If fuse is blown replace with new. If fuse blows again, repair short to GND.
Are EFP relay and Fuse, harness, and terminals clean and undamaged? No: Repair connector, harness,
terminal damage, or short to GND.
After repairs are complete, retest
for SPN 931 FMI 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 661

Step 3 Inspect connections at Electric Fuel Pump (EFP) connector. Decision

A. Key-Off. Yes: Go to Step 3.
B. Disconnect EFP connector.
C. Check EFP and connector terminals for: damaged or pinched wires; moist
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are EFP connector, harness, and terminals clean and undamaged? No: Repair connector, harness, or
terminal damage. After repairs are
complete, retest for SPN 931 FMI
3.

Step 4 Check Fuel Pump Relay circuits. Decision

Perform this measurement with fuel pump commanded OFF. Yes: Go to Step 6.
Fuel pump will be commanded OFF 30 seconds after key is turned ON. After initial
ECM power up routine has completed.
A. Key-Off.
B. Disconnect the Fuel Pump Relay.
C. Connect breakout harness ZTSE4908 (or ZTSE4674 for Bus Application)
to relay socket and leave relay disconnected.
D. Key-On Engine-Off (KOEO) wait 30 seconds or until fuel pump is
commanded OFF.
E. Use DMM, measure voltage from ZTSE4908 (or ZTSE4674 for Bus
Application) pin-87 to known good GND when fuel pump is commanded
OFF.
Is voltage 0 Volts? No: Go to step 5.

Step 5 Check Fuel Pump Relay circuits. Decision

Perform this measurement with fuel pump commanded OFF. Yes: Repair short to GND between
fuel pump relay Pin-85 and ECM
Fuel pump will be commanded OFF 30 seconds after key is turned ON. After initial
Pin C-76.
ECM power up routine has completed.
A. Key Off.
B. Disconnect the Fuel Pump Relay.
C. Connect breakout harness ZTSE4908 (or ZTSE4674 for Bus Application)
to relay socket and leave relay disconnected.
D. Key On Engine Off (KOEO) wait 30 seconds or until fuel pump is
commanded OFF.

E. Use DMM, measure voltage from ZTSE4908 (or ZTSE4674 for Bus
Application) pin-85 to known B+ when fuel pump is commanded OFF.
Is voltage B+ ± 0.5 Volts? No: Repair short to PWR between
fuel pump relay pin-87 and ECM
pin E-69, EFP Pin-4 and EFP
662 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-6. After repairs are complete,

retest for SPN 931 FMI 3.

Step 6 Check Fuel Pump Relay circuits. Decision

Perform this measurement with fuel pump commanded ON. Yes: Go to Step 9.
Fuel pump will be commanded ON during initial ECM power up routine has
completed or when commanded by Output State High or Low (page 1359)
A. Key-Off.
B. Disconnect the Fuel Pump Relay.
C. Connect breakout harness ZTSE4908 (or ZTSE4674 for Bus Application)
between relay socket and relay.
D. Key On Engine Off (KOEO).
E. Use DMM, measure voltage from ZTSE4908 (or ZTSE4674 for Bus
Application) pin-87 to known good GND when fuel pump is commanded
ON.
Is voltage B+ ± 0.5 Volts? No: Go to Step 7.

Step 7 Check Fuel Pump Relay circuits. Decision

Perform this measurement with fuel pump commanded ON. Yes: Go to step 8.
Fuel pump will be commanded ON during initial ECM power up routine has
completed or when commanded by Output State High or Low (page 1359)
A. Key-Off.
B. Disconnect the Fuel Pump Relay.
C. Connect breakout harness ZTSE4908 (or ZTSE4674 for Bus Application)
between relay socket and relay.
D. Key On Engine Off (KOEO).
E. Use DMM, measure voltage from ZTSE4908 (or ZTSE4674 for Bus
Application) pin-86 to known good GND when fuel pump is commanded
ON.
Is voltage B+ ± 0.5 Volts? No: Repair Open between fuel
pump relay pin-86 and vehicle
PWR . After repairs are complete,
retest for SPN 931 FMI 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 663

Step 8 Check Fuel Pump Relay circuits. Decision

Perform this measurement with fuel pump commanded ON. Yes: Replace EFP relay. After
repairs are complete, retest for
Fuel pump will be commanded ON during initial ECM power up routine has
SPN 931 FMI 3.
completed or when commanded by Output State High or Low (page 1359)

A. Key-Off.
B. Disconnect the Fuel Pump Relay.
C. Connect breakout harness ZTSE4908 (or ZTSE4674 for Bus Application)
between relay socket and relay.
D. Key On Engine Off (KOEO).
E. Use DMM, measure voltage from ZTSE4908 (or ZTSE4674 for Bus
Application) pin-85 to B+ when fuel pump is commanded ON.
Is voltage B+ ± 0.5 Volts? No: Repair Open between fuel
pump relay pin-85 and ECM pin
C-76. After repairs are complete,
retest for SPN 931 FMI 3.

Step 9 Check Fuel Pump Relay circuits. Decision

Perform this measurement with fuel pump commanded ON. Yes: End diagnostics. Retest for
SPN 931 FMI 3.
Fuel pump will be commanded ON during initial ECM power up routine has
completed or when commanded by Output State High or Low (page 1359)
A. Key Off.
B. Reconnect Fuel Pump Relay. Disconnect Electric Fuel Pump connector.
C. Connect Breakout Harness ZTSE6023 between engine harness and EFP.
D. Key On Engine Off (KOEO).
E. Use DMM, measure voltage from ZTSE6023 pin-4 and 6 to known good
GND when fuel pump is commanded ON.
Is voltage B+ ± 0.5 Volts? No: Repair Open between fuel
pump relay pin-87 and ECM pin
C-76, EFP Pin-4 and EFP Pin-6.
After repairs are complete, retest
for SPN 931 FMI 3.

End Diagnostic Tests

After performing diagnostic steps, if SPN 931 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
664 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 931 FMI 4 - EFP open load/circuit or short to GND

Fault Overview
Fault code sets when Engine Control Module (ECM) detects Electronic Fuel Pump (EFP) circuit voltage is 0
volts when the the pump is commanded ON.

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

Associated Faults
None

Fault Facts
ECM will power fuel pump for 30 seconds after key is turned on. If ECM doesn’t see engine rotation at end of
30 seconds, pump will shut off until engine rotation is detected.

Drive Cycle to Determine Fault Status

Continuos
Possible Causes
• Open in B+ circuit to relay or Blown fuse
• EFP CTL circuit Open
• EFP PWR circuit Open
• EFP Monitor circuit Open
• Failed Fuel Pump Relay
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 665

Step 1 Check Fault Code Status Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 931 FMI 4.
Is SPN 931 FMI 4 pending or active? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 2 Inspect connections at Electric Fuel Pump (EFP) connector. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect EFP connector.
C. Check EFP and connector terminals for: damaged or pinched wires; moist
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are EFP connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 931
FMI 4.

Step 3 Check for Open in EFP Monitor circuit Decision

A. Perform Test 1 (page 667). Yes: Repair Open between EFP
pin-4 and ECM pin E-69. After
B. Use DMM, measure voltage between Breakout Harness ZTSE6023 pin-4
repairs are complete, retest for
and known good GND while the Output State High Test is active.
SPN 931 FMI 4.
Is voltage B+ ± 0.5 volts? No: Go to Step 4.

Step 4 Check for Open in B+ circuit to Fuel Pump Relay. Decision

A. Perform Test 2 (page 667). Yes: Go to Step 5.
B. Use DMM, measure voltage between Breakout Harness ZTSE4908 (or
ZTSE4674 for Bus Application) pin-30 and known good GND.
Is voltage B+ ± 0.5 volts? No: Repair Open or blown fuse
between B+ and Fuel Pump Relay
pin-30. See appropriate vehicle
"Electrical Circuit Diagrams".
After repairs are complete, retest
for SPN 931 FMI 4.
666 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 5 Check for Open in SWBAT circuit to Fuel Pump Relay. Decision
A. Perform Test 3 (page 668). Yes: Go to Step 6.
B. Use DMM, measure voltage between Breakout Harness ZTSE4908 (or
ZTSE4674 for Bus Application) pin-86 and known good GND.
Is voltage B+ ± 0.5 volts? No: Repair Open between ignition
switch and Fuel Pump Relay
pin-86. See appropriate vehicle
"Electrical Circuit Diagrams".
After repairs are complete, retest
for SPN 931 FMI 4.

Step 6 Check for Open in EFP PWR circuit. Decision

A. Perform Test 4 (page 669). Yes: Repair Open between
EFP pin-4 and Fuel Pump Relay
B. Use DMM, measure voltage between Breakout Harness ZTSE4908 (or
pin-87. After repairs are complete,
ZTSE4674 for Bus Application) pin-87 and known good GND while the
retest for SPN 931 FMI 4.
Output State High Test is active.
Is voltage B+ ± 0.5 volts? No: Go to Step 7.

Step 7 Check for Open in EFP CTL circuit. Decision

A. Perform Test 5 (page 670). Yes: Repair Open between ECM
pin C-76 and Fuel Pump Relay
B. Use DMM, measure voltage between Breakout Harness ZTSE4908 (or
pin-85. After repairs are complete,
ZTSE4674 for Bus Application) pin-87 and known good GND.
retest for SPN 931 FMI 4.
Is voltage B+ ± 0.5 volts? No: Replace Fuel Pump Relay.
After repairs are complete, retest
for SPN 931 FMI 4.

End Diagnostic Tests

After performing diagnostic steps, if SPN 931 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 667

Pin-Point Test (SPN 931 FMI 4)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE6023
• Breakout Harness ZTSE4908 (or ZTSE4674 for Bus Application)
• Breakout Harness ZTSE4498
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Figure 202 EFP Monitor Circuit Check

Test 1
A. Key OFF.
B. Disconnect Electric Fuel Pump (EFP).

C. Connect Breakout Harness ZTSE6023 between vehicle harness and EFP.

D. Perform Output State High Test (page 1359).
668 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 203 B+ Circuit Check

Test 2
A. Key OFF.
B. Reconnect Fuel Pump connector.
C. Disconnect Fuel Pump Relay.
D. Connect Breakout Harness ZTSE4908 (or ZTSE4674 for Bus Application) to vehicle harness and leave Fuel
Pump Relay disconnected.
E. Key ON Engine OFF (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 669

Figure 204 SWBAT Circuit Check

Test 3
A. Key OFF.
B. Disconnect Fuel Pump Relay.
C. Connect Breakout Harness ZTSE4908 (or ZTSE4674 for Bus Application) to vehicle harness and leave Fuel
Pump Relay disconnected.
D. Key ON Engine OFF (KOEO).
670 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 205 EFP PWR Circuit Check

Test 4
A. Key OFF.
B. Disconnect Fuel Pump Relay.
C. Connect Breakout Harness ZTSE4908 (or ZTSE4674 for Bus Application) between vehicle harness and
Fuel Pump Relay.
D. Perform Output State High Test (page 1359).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 671

Figure 206 EFP PWR Circuit Check

Test 5
A. Key OFF.
B. Disconnect Fuel Pump Relay.
C. Connect Breakout Harness ZTSE4908 (or ZTSE4674 for Bus Application) between vehicle harness and
Fuel Pump Relay.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4908 pin-85 to GND (manually commanding
EFP ON).
E. Key ON Engine OFF (KOEO).
672 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 931 FMI 11 - EFP operation fault

Fault Overview
Update calibration to prevent this fault code from falsely setting.

Lamp Reaction
None

Associated Faults
None

Fault Facts
Update calibration to prevent this fault code from falsely setting.

Drive Cycle to Determine Fault Status

Continuous

Possible Causes
None

Step 1 Update calibration. Decision

This fault has been disabled. Please update calibration and recheck for other active faults.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 673

SPN 931 FMI 19 - EFP not detected on J1939

Fault Overview
Update calibration to prevent this fault code from falsely setting.

Lamp Reaction
None

Associated Faults
None

Fault Facts
Update calibration to prevent this fault code from falsely setting.

Drive Cycle to Determine Fault Status

Continuous

Possible Causes
None

Step 1 Update calibration. Decision

This fault has been disabled. Please update calibration and recheck for other active faults.
674 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 974 FMI 3 - Remote APP signal Out of Range HIGH

Fault Overview
Fault code sets when Engine Control Module (ECM) detects Remote Accelerator Pedal Position (RAPP) signal
is greater than expected.

Lamp Reaction
No Lamp

Associated Faults
None

Fault Facts
Remote Accelerator Pedal Position (RAPP) signal is provided at Body Builder cut wires. Diagnosing this fault
will involve aftermarket equipment attached to these wires.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• RAPP circuit short to PWR
• Failed RAPP
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 675

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 974 FMI 3.
Is EST DTC list SPN 974 FMI 3 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 2 Inspect connections at Body Builder connector 2. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect Body Builder connector 2.
C. Check Body Builder connector 2 and connector terminals for: damaged
or pinched wires; moisture or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are Body Builder connector 2 connector, harness, and terminals clean and No: Repair connector, harness, or
undamaged? terminal damage. After repairs are
complete, retest for SPN 974 FMI
3.

Step 3 Check for short to PWR in RAPP circuit. Decision

A. Perform Test 1 (page 676). Yes: Replace RAPP. After repairs
are complete, retest for SPN 974
B. Use DMM, measure voltage from pin-A to known good GND.
FMI 3
Is voltage less than 5 volts? No: Repair short to PWR between
Engine Control Module (ECM)
pin C1-13 and Body Builder
Connector 2 pin-A. After repairs
are complete, retest for SPN 974
FMI 3.

End Diagnostic Steps

After performing all diagnostic steps, if SPN 974 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
676 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 974 FMI 3)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4435C
• Breakout Harness ZTSE4498
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Figure 207 RAPP Circuit Check

Test 1
A. Key OFF.

B. Disconnect Body Builder connector 2.

C. Insert correct pin from Terminal Test Kit ZTSE4435C into Body Builder connector 2 pin-A.

D. Key ON Engine OFF (KOEO).

 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 677

SPN 974 FMI 4 - Remote APP signal Out of Range LOW

Fault Overview

Lamp Reaction
No Lamp.

Associated Faults
None

Fault Facts
Remote Accelerator Pedal Position (RAPP) signal is provided at Body Builder cut wires. Diagnosing this fault
will involve aftermarket equipment attached to these wires.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• RAPP circuit short to PWR
• Failed RAPP
678 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 974 FMI 4.
Is EST DTC list SPN 974 FMI 4active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 2 Inspect connections at Body Builder connector 2. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect Body Builder connector 2.
C. Check Body Builder connector 2 and connector terminals for: damaged
or pinched wires; moisture or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are Body Builder connector 2 connector, harness, and terminals clean and No: Repair connector, harness, or
undamaged? terminal damage. After repairs are
complete, retest for SPN 974 FMI
4.

End Diagnostic Steps

After performing all diagnostic steps, if SPN 974 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 679

SPN 1136 FMI 0 - ECM Error - Over Temperature

Fault Overview
Fault sets when over temperature is detected in Engine Control Module (ECM).

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Cause
• ECM overheating
680 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Replace ECM, following
SPN 1136 FMI 0. approved warranty procedures.
After repairs are complete, retest
for SPN 1136 FMI 0.
Does EST DTC list show SPN 1136 FMI 0 active or pending? No: Repair active faults. After
repairs are complete, retest for
SPN 1136 FMI 0.

End Diagnostic Test

After performing diagnostic steps, if SPN 1136 FMI 0 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 681

SPN 1173 FMI 2 - TC2CIT signal erratic, intermittent, or incorrect

Fault Overview
Engine Control Module (ECM) compares Turbocharger 2 Compressor Intake Temperature (TC2CIT) sensor
to Intake Manifold Temperature (IMT), Intake Air Temperature (IAT), Charge Air Cooler Outlet Temperature
(CACOT), Engine Coolant Temperature 1 (ECT1), and Engine Oil Temperature (EOT) sensors after calibrated
adjustable cold-soak period (time).

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Initial Key-On.
Possible Causes
• Biased Turbocharger 2 Compressor Inlet Temperature (TC2CIT) sensor or circuit
• High resistance in circuit
• Shorted sensor
• Shorted wiring
682 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 1173 FMI 2.
Is EST DTC list SPN 1173 FMI 2 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Inspect connections at Turbocharger 2 Compressor Intake Decision

Temperature (TC2CIT) connector.
A. Key-Off. Yes: Go to Step 3.
B. Disconnect TC2CIT connector.
C. Check TC2CIT and connector terminals for: damaged or pinched wires;
moist or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are TC2CIT connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 1173
FMI 2.

Step 3 Inspect connections at Turbocharger 2 Compressor Intake Decision

Temperature (TC2CIT) connector.
A. Key OFF. Yes: Replace TC2CIT sensor.
After repairs are complete, retest
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
for SPN 1173 FMI 2.
(page 1345).
C. Connect Breakout Harness ZTSE4993 between pin-1 and pin-2 on
TC2CIT connector.
D. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
E. Use DMM, measure voltage between Breakout Harness ZTSE4993 pin-1
and pin-2.
Is voltage less than 0.5 volts? No: Go to Step 4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 683

Step 4 Inspect connections at Turbocharger 2 Compressor Intake Decision

Temperature (TC2CIT) connector.
A. Key OFF. Yes: Repair TC2CIT signal wire.
After repairs are complete, retest
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
for SPN 1173 FMI 2.
(page 1345).

C. Connect Breakout Harness ZTSE4993 between pin-1 and known good

GND.
D. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
E. Use DMM, measure resistance between Breakout Harness ZTSE4993
pin-1 and known good GND.
Is resistance less than 5 ohms? No: Repair TC2CIT SIG GND
wire. After repairs are complete,
retest for SPN 1173 FMI 2.

End Diagnostic Tests

After performing diagnostic steps, if SPN 1173 FMI 2 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
684 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 1173 FMI 3 - TC2CIT signal Out of Range HIGH

Fault Overview
Fault Code sets when Engine Control Module (ECM) detects that Turbocharger 2 Compressor Intake
Temperature (TC2CIT) signal is greater than 4.8 volts.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Key-On
Possible Causes
• Turbocharger 2 Compressor Intake Temperature (TC2CIT) circuit Open
• TC2CIT circuit short to PWR
• SIG GND circuit Open
• Failed TC2CIT sensor
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 685

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 1173 FMI 3.
Is EST DTC list SPN 1173 FMI 3 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Inspect connections at Turbocharger 2 Compressor Intake Decision

Temperature (TC2CIT) sensor.
A. Key-Off. Yes: Go to Step 3.
B. Disconnect TC2CIT sensor connector.
C. Check TC2CIT sensor and connector terminals for damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are TC2CIT sensor, connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 1173
FMI 3.

Step 3 Decision
A. Perform Test 1(page 687). Yes: Repair short to PWR
between TC2CIT pin-2 and
B. Use DMM, measure voltage between Breakout Harness ZTSE4993 pin-2
ECM pin E-72. After repairs are
and known good GND.
complete, retest for SPN 1173
FMI 3.
Is voltage greater than 6 volts? No: Go to Step 4.

Step 4 Decision
A. Perform Test 2(page 687). Yes: Replace TC2CIT sensor.
After repairs are complete, retest
B. Use EST, clear DTC list.
for SPN 1173 FMI 3.
Does SPN 1173 FMI 4 set after DTC list is cleared? No: Go to Step 5.

Step 5 Decision
A. Perform Test 3(page 688). Yes: Repair Open between
TC2CIT pin-1 and ECM pin E-28.
B. Use EST, clear DTC list.
After repairs are complete, retest
for SPN 1173 FMI 3.
Does SPN 1173 FMI 4 set after DTC list is cleared? No: Repair Open between
TC2CIT pin-2 and ECM pin E-72.
After repairs are complete, retest
for SPN 1173 FMI 3.
686 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

End Diagnostic Tests

After performing all diagnostic steps, if SPN 1173 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 687

Pin-Point Tests (SPN 1173 FMI 3)

Figure 208 TC2CIT Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4993
• Breakout Harness Banana Plug ZTSE4498
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Figure 209 TC2CIT Circuit Check

Test 1
A. Key OFF.

B. Disconnect Turbocharger 2 Compressor Intake Temperature (TC2CIT) sensor connector.

C. Connect Breakout Harness ZTSE4993 to vehicle harness connector and leave TC2CIT sensor connector
disconnected.

D. Key ON Engine OFF (KOEO)

688 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 210 TC2CIT Circuit Check

Test 2
A. Key-Off.
B. Disconnect Turbocharger 2 Compressor Intake Temperature (TC2CIT) sensor connector.
C. Connect Breakout Harness ZTSE4993 to vehicle harness and leave TC2CIT sensor connector disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4993 pin-1 and pin-2 together.
E. Connect EST to vehicle Diagnostic Connector (page 1345).
F. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 689

Figure 211 TC2CIT Circuit Check

Test 3
A. Key-Off.
B. Disconnect Turbocharger 2 Compressor Intake Temperature (TC2CIT) sensor connector.
C. Connect Breakout Harness ZTSE4993 to vehicle harness and leave TC2CIT sensor connector disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4993 pin-2 to ground.
E. Connect EST to vehicle Diagnostic Connector (page 1345).
F. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
690 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 1173 FMI 4 - TC2CIT signal Out of Range LOW

Fault Overview
Fault code sets when Engine Control Module (ECM) detects Turbocharger 2 Compressor Intake Temperature
(TC2CIT) signal is less than 0.195 volts.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Key-On
Possible Causes
• Turbocharger 2 Compressor Intake Temperature (TC2CIT) circuit short to GND
• Failed TC2CIT
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 691

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 1173 FMI 4.
Is EST DTC list SPN 1173 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Inspect connections at Turbocharger 2 Compressor Intake Decision

Temperature (TC2CIT) sensor.
A. Key-Off. Yes: Go to Step 3.
B. Disconnect TC2CIT sensor connector.
C. Check TC2CIT sensor and connector terminals for damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are TC2CIT sensor, connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 1173
FMI 4.

Step 3 Decision
A. Key OFF. Yes: Replace TC2CIT sensor.
After repairs are complete, retest
B. Disconnect Turbocharger 2 Compressor Intake Temperature (TC2CIT)
for SPN 1173 FMI 3.
sensor.
C. Connect EST to vehicle Diagnostic Connector (page 1345).
D. Key ON Engine OFF (KOEO), use EST clear DTC list.
Does SPN 1173 FMI 3 set in DTC list? No: Repair short to GND between
TC2CIT pin-2 and ECM pin E-72.
After repairs are complete, retest
for SPN 1173 FMI 3.

End Diagnostic Tests

After performing all diagnostic steps, if SPN 1173 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
692 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 1173 FMI 16 - TC2CIT signal above desired (Interstage CAC under cooling)

Fault Overview
Fault sets when TC2CIT signal is above desired, due to Low Pressure CAC Interstage under cooling.

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

Associated Faults
• SPN 102 FMI 3, 4, 7, and • SPN 105 FMI 2, 3, and 4 • SPN 108 FMI 3 and 4 • SPN 110 FMI 2, 3, and 4
16 (IMP) (IMT) (BARO) (ECT1)
• SPN 132 FMI 3 and 4 • SPN 172 FMI 2, 3, and 4 • SPN 191 FMI 3 and 4 • SPN 651 - 656 FMI 4 and
(MAF) (MAF) (TOSS) 5 (INJ)
• SPN 1173 FMI 2 (TC2CIT)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Low coolant
• Restricted or damaged vehicle grille and Charge Air Cooler (CAC)
• Failed turbocharger wastegate
• Leaking Interstage Cooler (ISC)
• Mass Air Flow (MAF) Calibration
• Poor coolant circulation
• Coolant bypass circuit stuck or sticking thermostat
• Biased Intake Manifold Temperature (IMT) sensor
• Biased Inlet Air Temperature (IAT) sensor
• Biased Charge Air Cooler Outlet Temperature (CACOT) sensor
• Biased Mass Air Flow (MAF) sensor
• Biased Barometric Pressure (BARO) sensor
• Biased Intake Manifold Pressure (IMP) sensor
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 693

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 692).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 1173 FMI 16.

Step 2 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 1173 FMI 16. Yes: Go to Step 3.
Is EST DTC list SPN 1173 FMI 16 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 1173 FMI 16.

Step 3 Perform coolant level inspection. Decision

Perform Coolant Level Inspection(page 1637). Yes: Go to Step 4.
Is coolant level correct? No: Add coolant. After repairs are
complete, retest for SPN 1173 FMI
16.

Step 4 Inspect vehicle grille and Charge Air Cooler (CAC) for damage or Decision
blockage.
Inspect vehicle grille and CAC for damage, blockage, or anything that could prevent Yes: Go to Step 5.
proper air flow through CAC.
Is grille and CAC undamaged, not blocked, and is air able to flow through properly? No: Repair damage or blockage.
After repairs are complete, retest
for SPN 1173 FMI 16.

Step 5 Determine if boost control system is operating properly. Decision

Perform Boost Control System Test (page 1533) Yes: Go to Step 6.
Did boost control system operate properly? No: Repair or replace failed
component(s) as needed. After
repairs are complete, retest for
SPN 1173 FMI 16.

Step 6 Inspect Interstage Cooler (ISC). Decision

Perform ISC Coolant Leak Inspection (page 1640). Yes: Go to Step 7.
Is there No evidence of coolant or coolant residue found in ISC or HP-Turbocharger No: Repair based on results. After
intake elbow? repairs are complete, retest for
SPN 1173 FMI 16.
694 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 7 Do Mass Air Flow (MAF) Calibration Procedure. Decision

A. Ensure Equipment Conditions and MAF Calibration Pre-Checks are Yes: Ensure ECM calibration is up
completed satisfactory as part of MAF sensor calibration procedure. to date, retest for SPN 1173 FMI
16.
B. Perform MAF Sensor Calibration(page 1539).
Did MAF sensor calibration run successfully? No: Repair fault code set during
MAF Calibration. After repairs are
complete, retest for SPN 1173
FMI 16.

End Diagnostic Steps

After performing diagnostic steps, if SPN 1173 FMI 16 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 695

SPN 1189 FMI 3 - TC2WC short to PWR

Fault Overview
Fault code sets when Electronic Control Module (ECM) determines that Turbocharger 2 Wastegate Control
(TC2WC) circuit is shorted to power for 25.5 seconds. TC2WC circuit current is greater than 1 amp for 20
microseconds or greater than 2 amps for 2 microseconds.

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected during one drive cycle.

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Key ON
Possible Causes
• TC2WC ground side switch circuit short to PWR
• Failed Turbocharger 2 Wastegate Control (TC2WC) solenoid

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 1189 FMI 3.
Is EST DTC list SPN 1189 FMI 3 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Inspect connections at Turbocharger 2 Wastegate (TC2WC) solenoid Decision

connector.
A. Key OFF. Yes: Go to Step 3.
B. Disconnect TC2WC connector.
C. Check TC2WC and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are TC2WC connector, harness, and terminals clean and undamaged? No: Repair connector, harness, or
terminal damage. After repairs are
complete, retest for SPN 1189 FMI
3.
696 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Check TC2WC gound side switch circuit for short to PWR. Decision
A. Perform Test 1(page 697). Yes: Repair short to PWR between
TC2WC solenoid pin-2 and
B. Use DMM, measure voltage between Breakout Harness ZTSE4831 pin-2
ECM pin E-73. After repairs are
and known good GND.
complete, retest for SPN 1189 FMI
3.
Is voltage B+ ± 0.5 volts? No: Replace TC2WC solenoid.
After repairs are complete, retest
for SPN 1189 FMI 3.

End Diagnostic Tests

After performing diagnostic steps, if SPN 1189 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 697

Pin-Point Tests (SPN 1189 FMI 3)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Digital Multimeter (DMM)
• Breakout Harness (TC2WC) ZTSE4831

Figure 212 TC2WC Solenoid Circuit Check

Test 1
A. Key OFF.
B. Disconnect Turbocharger 2 Wastegate (TC2WC) solenoid connector.
C. Connect Breakout Harness ZTSE4831 to vehicle harness and leave TC2WC solenoid connector disconnected.
D. Key ON Engine OFF (KOEO).
698 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 1189 FMI 4 - TC2WC Open or short to GND

Fault Overview
Fault code sets when Engine Control Module (ECM) determines Turbocharger 2 Wastegate (TC2WC) solenoid
circuit is shorted to ground or open.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Key ON
Possible Causes
• Turbocharger 2 Wastegate (TC2WC) solenoid ground side switch circuit open
• TC2WC ground side switch circuit shorted to GND
• ACT PWR circuit Open
• Failed TC2WC
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 699

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 1189 FMI 4.
Is EST DTC list SPN 1189 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Inspect connections at Turbocharger 2 Wastegate (TC2WC) solenoid Decision

connector.
A. Key OFF. Yes: Go to Step 3.
B. Disconnect TC2WC connector.
C. Check TC2WC and connector terminals for: damaged or pinched wires;
wet or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are TC2WC connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 1189
FMI 4.

Step 3 Check ACT PWR Circuit for open or high resistance. Decision
A. Perform Test 1 (page 700). Yes: Go to Step 4.
B. Use DMM, measure voltage between Breakout Harness ZTSE4831 pin-1
and known good GND.
Is voltage B+ ± 0.5 volt? No: Repair Open circuit between
TC2WC pin-1 and ACT PWR Relay
pin-87. After repairs are complete,
retest for SPN 1189 FMI 4.

Step 4 Check for failed TC2WC actuator valve. Decision

Perform Test 2 (page 700). Wait 10 seconds after key is turned On before taking Yes: Replace TC2WC actuator
voltage measurement. Use DMM to measure voltage between Breakout Harness valve. After repairs are complete,
ZTSE4831 pin-2 and known good GND. retest for SPN 1189 FMI 4.
Is voltage 0.5 volts ± 0.25 volt? No: Repair Open or short to
GND between TC2WC pin-2 and
ECM pin E-73. After repairs are
complete, retest for SPN 1189 FMI
4.

End Diagnostic Test

After performing diagnostic steps, if SPN 1189 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
700 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 1189 FMI 4)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Digital Multimeter (DMM)
• Breakout Harness ZTSE4831

Figure 213 TC2WC Circuit Check

Test 1
A. Key OFF.
B. Disconnect Turbocharger 2 Wastegate (TC2WC) actuator valve connector.
C. Connect Breakout Harness ZTSE4831 to vehicle harness and leave TC2WC connector disconnected.
D. Key ON Engine OFF (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 701

Figure 214 TC2WC Circuit Check

Test 2
A. Key OFF.
B. Disconnect Turbocharger 2 Wastegate (TC2WC) actuator valve connector.
C. Connect Breakout Harness ZTSE4831 to vehicle harness and leave TC2WC connector disconnected.
D. Key ON Engine OFF (KOEO). Wait 10 seconds after key is turned On before taking voltage measurement.
702 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 1209 FMI 0 - EBP above desired level

Fault Overview
Fault sets when Exhaust Back Pressure (EBP) is above desired pressure.

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

Associated Faults
• SPN 27 (EGR) • SPN 94 FMI 1 (EFP) • SPN 102 FMI 2, 3, and 4 • SPN 105 FMI 2, 3, and 4
• SPN 173 FMI 2, 3, and 4 • SPN 1189 • SPN 1209 FMI 2, 3, and 4 • SPN 2791

Fault Facts
Perform a MAF Sensor Calibration after doing repairs that change engine air intake, exhaust, or Exhaust Gas
Recirculation (EGR) flow characteristics.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Engine Control Module (ECM) calibration out of date
• Failed Intake Manifold Temperature (IMT) sensor
• Failed Exhaust Gas Temperature (EGT) sensor
• Boost control system failure
• Failed EGR valve
• Restricted air and EGR mixer duct
• EGR cooler restricted

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 702).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 1209 FMI 0.

Step 2 Check Engine Control Module (ECM) calibration. Decision

Use calibration scorecard or NavKal to check ECM calibration. Yes: Go to Step 3.
Is ECM calibration current? No: Update calibration, then go
to Step 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 703

Step 3 Check if Exhaust Back Pressure (EBP) sensor is reading correctly. Decision
A. Key-Off. Yes: Go to Step 4.
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).

C. Key-On, Engine-Off (KOEO), log in to Navistar® Engine Diagnostics.

D. Use EST, monitor EBP voltage signal.
Is EBP voltage approximately 0.75V? No: Replace EBP sensor. After
repairs are complete, retest for
SPN 1209 FMI 0.

Step 4 Check if Intake Manifold Temperature (IMT) sensor is reading correctly. Decision
A. Key-Off. Yes: Go to Step 5.
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).
C. Key-On, Engine-Off (KOEO), log in to Navistar® Engine Diagnostics.
D. Use Infrared Thermometer ZTSE4799, check intake manifold temperature
near IMT sensor.
E. Use EST, monitor IMT signal.
Is Infrared Thermometer reading and EST value within 30°F (17°C) of each other? No: Replace IMT sensor. After
repairs are complete, retest for
SPN 1209 FMI 0.

Step 5 Determine if Exhaust Gas Temperature (EGT) sensor is reading Decision

correctly.
A. Key-Off. Yes: Go to Step 7.
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).
C. Key-On Engine-Running (KOER). Run engine at High Idle for a maximum
of 5 minutes. Log in to Navistar® Engine Diagnostics.
D. Use EST, monitor EGT signal.
EGT will read 284°F (140°C) when cold and will not read exhaust
temperatures until temperature is greater than 284°F (140°C).
Does EGT value increase while running engine at high idle? No: Go to Step 6.
704 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 6 Determine if EGT sensor is stuck at 284°F (140°C). Decision

A. Key-Off. Yes: Replace EGT sensor. After
repairs are complete, retest for
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
SPN 1209 FMI 0.
(page 1345).

C. Key-On, Engine-Off (KOEO), log in to Navistar® Engine Diagnostics.

D. Use EST, monitor EGT signal.
Is EGT stuck at 284°F (140°C)? No: Go to Step 7.

Step 7 Determine if Exhaust Gas Recirculation Valve (EGRV) is operating Decision

properly.
Perform Exhaust Gas Recirculation Valve (EGRV) Operational Test (page 1543). Yes: Replace EGRV. After repairs
are complete, go to Step 12.
Did any SPN 27 or SPN 2791 fault codes set during test? No: Go to Step 8.

Step 8 Determine if air management system is operating properly. Decision

Perform Air Management Test (page 1376). Yes: Perform Boost Control
System Test (page 1533). Repair
or replace failed component(s).
After repairs are complete, go to
Step 12.
Is Intake Manifold Pressure (IMP), and MAF Mean Value Difference within No, IMP not is specification: Go
specification? to Step 9.
No, only MAF Mean Value
Difference not in specification: Go
to Step 10.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 705

Step 9 Determine if KOEO IMP is within specification, and IMP sensor bore Decision
is not restricted.
A. Key OFF. Yes: Perform Boost Control
System Test (page 1533). Repair
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
or replace failed component(s).
(page 1345).
After repairs are complete, go to
C. Key-On, Engine-Off (KOEO), log in to Navistar® Engine Diagnostics. Step 12.
D. Use EST, select: Pressure tab.
E. Compare Intake Manifold Pressure value to KOEO specification.
F. Remove IMP sensor and inspect sensor and bore for carbon buildup and
restrictions.
Is IMP within KOEO specification, and is sensor bore free of restrictions? No, KOEO IMP out of
specification: replace IMP sensor.
After repairs are complete, go to
Step 12.
No, sensor or bore restricted:
clean sensor and / or bore. After
repairs are complete, go to Step
12.

Step 10 Determine if air and EGR mixer duct are restricted. Decision
A. Remove Engine Throttle Value (ETV) assembly. See Engine Service Yes: Remove and clean air and
Manual. EGR mixer duct. Do not replace
EGR Valve. Replace O-rings
B. Inspect air and EGR mixer duct assembly for restrictions and carbon
if needed. After repairs are
build up.
complete, go to Step 12.
Is a severe amount of carbon restricting air and EGR mixer duct? No: Go to Step 11

Step 11 Determine if EGR cooler is restricted. Decision

Remove EGR crossover pipe from rear of engine (see Engine Service Manual) Yes: Replace EGR cooler. After
and inspect EGR cooler for restrictions. repairs are complete, go to Step
12.
Is EGR cooler restricted? No: Go to Step 12.

Step 12 Check MAF sensor calibration. Decision

Perform MAF Sensor Calibration (page 1539). Yes: End diagnostics. Retest for
SPN 1209 FMI 0.
Did MAF sensor calibration run successfully without setting codes? No: Repair fault codes set during
MAF calibration. After repairs are
complete, retest for SPN 1209
FMI 0.
706 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

End Diagnostic Tests

After performing all diagnostic steps, if SPN 1209 FMI 0 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 707

SPN 1209 FMI 1 - EBP below desired level

Fault Overview

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
•

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Perform Pin-Point Test(page
SPN 1209 FMI 1. 708).
Is SPN 1209 FMI 1 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 1209 FMI 1.

End Diagnostic Test

After performing diagnostic steps, if SPN 1209 FMI 1 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
708 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Test (SPN 1209 FMI 1)

Figure 215 EBP Sensor Circuit Diagram

 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 709

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4850
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)
1. Use EST with Navistar® Engine Diagnostics, open Continuous Monitor session.
2. Monitor sensor voltage. Verify an active code for sensor.
• If code is inactive, monitor signal while wiggling connector and all wires at suspected location. If circuit
is interrupted, signal will spike and code will go active.
• If code is active, proceed to next Step.
3. Disconnect engine harness from sensor.
Inspect connectors for damaged pins, corrosion, or loose pins. Repair if necessary.
4. Connect breakout harness to engine harness. Leave sensor disconnected.

Sensor Circuit Check

Test Point Specification Comment: < Less than, > Greater than
Connect Breakout Harness ZTSE4850 to engine harness. Leave sensor disconnected. Turn ignition switch to ON. Use
EST to verify correct code goes active when corresponding fault is induced. Use DMM to measure circuits.
EST - Check code SPN 1209 FMI 4 If SPN 1209 FMI 3 is active, check EBP signal for short to PWR.
DMM - Measure volts 5 ± 0.5 volts If > 5.5 volts, check VREF for short to PWR.
2 to GND If < 4.5 volts, check VREF for OPEN or short to GND. Go to
Harness Resistance Check.
EST - Check code SPN 1209 FMI 3 If SPN 1209 FMI 4 is active, check EBP signal for OPEN or
short to GND. Go to Harness Resistance Check.
Short breakout
harness across 2
and 3
DMM - Measure Volts B+ If < B+, check SIG GND for OPEN. Go to Harness Resistance
Check.
1 to B+
If checks are within specification, connect sensor and clear codes. If active code remains, replace sensor.
710 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Connector Voltage Check

Test Point Specification Comment: < Less than, > Greater than
Connect Breakout Harness ZTSE4850. Leave sensor disconnected. Turn ignition switch to ON. Use DMM to measure
voltage.
1 to B+ B+ If < B+, check for short to PWR.
2 to GND 5 ± 0.5 volts If > 5.5 volts, check VREF for short to PWR.

If < 4.5 volts, check VREF for OPEN or short to GND. Go to

Harness Resistance Check.
3 to B+ B+ If < B+, check for short to PWR.

Harness Resistance Check

Test Point Specification Comment: < Less than, > Greater than
Turn ignition switch to OFF. Disconnect ECM. Leave sensor disconnected. Connect 180-pin Breakout Box and Breakout
Harness 4850. Use DMM to measure resistance.
1 to E-28 <5Ω If > 5 Ω, check SIG GND circuit for OPEN.
2 to E-35 <5Ω If > 5 Ω, check VREF circuit for OPEN.
3 to E-20 <5Ω If > 5 Ω, check EBP signal circuit for OPEN.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 711

SPN 1209 FMI 2 - EBP Signal Erratic, Intermittent, or Incorrect

Fault Overview
Fault sets when absolute pressure difference between Barometric Absolute Pressure (BARO) and Intake
Manifold Pressure (IMP) and absolute pressure difference between Exhaust Gas Pressure (EGP) and BARO
and absolute pressure difference between EGP and IMP are greater than 4.4 psi (30 kPa) for two seconds with
Wastegate Actuator Position Command is less than 100%.

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

Associated Faults
None

Fault Facts
Exhaust Back Pressure (EBP) cannot be checked in SMX, because SMX does not display negative values for
EBP. Type 2 errors are possible due to 4.4 psi (30 kPa) value.

Drive Cycle to Determine Fault Status

Initial Key ON
Possible Causes
• Defective sensor

Step 1 Check for active or pending fault code. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 1209 FMI 2.
Is EST DTC list SPN 1209 FMI 2 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Replace Exhaust Gas
SPN 102 FMI 2. Pressure (EGP) sensor. After
repairs are complete, retest for
SPN 1209 FMI 2.
Is EST DTC list free of SPN 102 FMI 2? No: Repair SPN 102 FMI 2. After
repairs are complete, retest for
SPN 1209 FMI 2.

End Diagnostic Tests

After performing all diagnostic steps, if SPN 1209 FMI 2 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
712 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 1209 FMI 3 - EBP signal Out of Range HIGH

Fault Overview
Fault sets when Exhaust Back-Pressure (EBP) sensor signal voltage is greater than 4.8 volts for 2.5 seconds.

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

Associated Faults
SPN 3509 FMI 3 and 4
(VREF 1)

Fault Facts
A restricted exhaust system may set this fault.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• EBP signal short to battery
• Failed EBP sensor
• Open SIG GND
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 713

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 712).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 1209 FMI 3.

Step 2 Inspect connections at Exhaust Back Pressure (EBP) sensor. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect EBP sensor connector.
C. Check EBP sensor and connector terminals for damaged or pinched
wires; corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are EBP sensor, connector harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 1209
FMI 3.

Step 3 Check EBP signal for short to battery Decision

A. Key OFF. Yes: Repair short to power
between EBP pin-3 and ECM pin
B. Disconnect Exhaust Back Pressure (EBP) sensor connector.
E-20. After repairs are complete,
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector retest for SPN 1209 FMI 3.
(page 1345).
D. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
E. Use EST, clear DTC list.
Does SPN 1209 FMI 3 set after DTC list is cleared? No: Go to Step 4.

Step 4 Check for Open or high resistance in SIG GND circuit. Decision
A. Perform Test 1 (page 714). Yes: Replace EBP sensor. After
repairs are complete, retest for
B. Use DMM, measure voltage between Breakout Harness ZTSE4850 pin-1
SPN 1209 FMI 3.
and B+.
Is voltage B+ ± 0.5 volts? No: Repair Open or high
resistance between EBP pin-1
and ECM pin E-28. After repairs
are complete, retest for SPN
1209 FMI 3.

End Diagnostic Tests

After performing diagnostic steps, if SPN 1209 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
714 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 1209 FMI 3)

Figure 216 EBP Sensor Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4850
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Figure 217 EBP Sensor Circuit

Test 1
A. Key OFF.

B. Disconnect Exhaust Back Pressure (EBP) sensor connector.

C. Connect Breakout Harness ZTSE4850 to EBP vehicle harness and leave EBP sensor disconnected

D. Key ON Engine OFF (KOEO).

 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 715

SPN 1209 FMI 4 - EBP Signal Out of Range LOW

Fault Overview
Fault sets when Exhaust Back Pressure (EBP) sensor voltage less than 0.2 volts.

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

Associated Faults
SPN 3509 FMI 3 and 4
(VREF 1)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• EBP signal circuit Open or high resistance
• EBP signal circuit Short to GND
• VREF Open or high resistance
• Failed EBP sensor
716 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for associated fault codes. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 715).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 1209 FMI 4.

Step 2 Inspect connections at Exhaust Back-Pressure (EBP) sensor. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect EBP sensor connector.
C. Check EBP sensor and connector terminals for damaged or pinched
wires; corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are EBP sensor, connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 1209
FMI 4.

Step 3 Check EBP signal circuit for Open or high resistance Decision
A. Perform Test 1 (page 718). Yes: Go to Step 4.
B. Use DMM, measure voltage between Breakout Harness ZTSE4850 pin-2
and known good GND.
Is voltage 5 ± 1.0 volts? No: Repair Open between EBP
pin-2 and Engine Control Module
pin E-35. After repairs are
complete, retest for SPN 1209
FMI 4.

Step 4 Check for failed EBP sensor. Decision

A. Perform Test 2 (page 718). Yes: Replace EBP sensor. After
repairs are complete, retest for
B. Use EST to clear DTC list.
SPN 1209 FMI 4.
Does SPN 1209 FMI 3 set after DTC list is cleared? No: Go to Step 5.

Step 5 Check EBP circuit for short to GND. Decision

A. Perform Test 3 (page 719). Yes: Repair short to ground
®
between EBP pin-3 and ECM pin
B. Use EST with Navistar Engine Diagnostics to clear DTC list.
E-20. After repairs are complete,
retest for SPN 1209 FMI 4.
Does SPN 3509 FMI 4 set? No: Repair Open or high
resistance between EBP pin-3
and ECM pin E-20. After repairs
are complete, retest or SPN 1209
FMI 4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 717

End Diagnostic Tests

After performing diagnostic steps, if SPN 1209 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
718 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 1209 FMI 4)

Figure 218 EBP Sensor Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4850
• Breakout Harness ZTSE4498
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Figure 219 EBP Circuit Check

Test 1
A. Key OFF.

B. Disconnect Exhaust Back Pressure (EBP) sensor.

C. Connect Breakout Harness ZTSE4850 to vehicle harness and leave EBP sensor disconnected.

D. Key ON Engine OFF (KOEO).

 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 719

Figure 220 EBP Sensor Circuit Check

Test 2
A. Key OFF.
B. Disconnect Exhaust Back Pressure (EBP) sensor.
C. Connect Breakout Harness ZTSE4850 to vehicle harness and leave EBP sensor disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4850 pin-2 and pin-3 together.
E. Connect EST to vehicle Diagnostic Connector (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
720 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 221 EBP Sensor Circuit Check

Test 3
A. Key OFF.
B. Disconnect Exhaust Back Pressure (EBP) sensor.
C. Connect Breakout Harness ZTSE4850 to vehicle harness and leave EBP sensor disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4850 pin-2 and pin-3 together.
E. Connect EST to vehicle Diagnostic Connector (page 1345).
F. Key-On Engine-Off (KOEO). Log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 721

SPN 1209 FMI 7 - EBP signal not responding as expected

Fault Overview
Fault sets when Exhaust Back Pressure (EBP) signal does not respond as expected.

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

Associated Faults
SPN 1209 FMI 2, 3, and 4

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Restricted EBP sensor tube assembly
• Failed EBP sensor

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics, check Yes: Go to Step 2.
Diagnostic Trouble Code (DTC) list for Associated Faults (page 721).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 1209 FMI 7.

Step 2 Inspect Exhaust Back Pressure (EBP) sensor tube assembly. Decision
Inspect EBP sensor tube assembly. Yes: Replace tube assembly.
After repairs are complete, retest
or SPN 1209 FMI 7.
Is EBP sensor tube assembly plugged? No: Replace EBP sensor. After
repairs are complete, retest for
SPN 1209 FMI 7.

End Diagnostic Tests

After performing all diagnostic steps, if SPN 1209 FMI 7 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
722 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 1231 FMI 19 - DCU Error - J1939 communication fault

Fault Overview
Controller Area Network (CAN) circuit problem.

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

Associated Faults
SPN 609 FMI 3 and 4 (DCU)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• CAN-H circuit short to GND
• CAN-L circuit short to GND
• CAN-H circuit short to PWR
• CAN-L circuit short to PWR
• CAN-H circuit Open
• CAN-L circuit Open
• CAN-H circuit short to CAN-L circuit
• DCU B+ circuit Open or short to GND
• DCU GND circuit Open
• SWBAT Open or short to GND

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 722).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 1231 FMI 19.

Step 2 Check for active or pending fault codes. Decision

Use EST with , check DTC list for SPN 1231 FMI 19. Yes: Go to Step 3.
Is SPN 1231 FMI 19 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 723

Step 3 Inspect Doser Control Unit (DCU) Module 53-pin and 86-pin Decision
connectors.
A. Key-Off. Yes: Go to Step 4.
B. Disconnect DCU Module connectors.

C. Check DCU Module connections and terminals for damage; wet or

corroded terminals; loose, bent, or broken connections; or broken
connector housing.
Are DCU Module connectors, harnesses, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 1231
FMI 19.

Step 4 Check for PWR and GND to DCU. Decision

A. Key OFF. Yes: Go to Step 6.
B. Disconnect DCU Module 53-pin connector.
C. Insert applicable terminal test pins from Terminal Test Kit ZTSE4435C,
into DCU 53-pin connector pin-6, pin-1, pin-7, and pin-2 and leave DCU
disconnected.
D. Key ON Engine OFF (KOEO).
E. Use DMM, measure voltage for following:
• Between DCU Module 53-pin connector pin-6 and pin-1.
• Between DCU Module 53-pin connector pin-7 and pin-1.
• Between DCU Module 53-pin connector pin-6 and pin-2.
• Between DCU Module 53-pin connector pin-7 and pin-2.
Is voltage B+ ± 0.5 volts? No: Go to Step 5.

Step 5 Check DCU B+ circuit for Open or short to GND. Decision

A. Key OFF. Yes: Repair Open in DCU
GND circuits. After repairs are
B. Disconnect DCU Module 53-pin connector.
complete, retest for SPN 1231
C. Insert applicable terminal test pins from Terminal Test Kit ZTSE4435C, into FMI 19.
DCU 53-pin connector pin-6 and pin-7 and leave DCU disconnected.
D. Key ON Engine OFF (KOEO).

E. Use DMM, measure voltage for following:

• Between DCU Module 53-pin connector pin-6 and known good GND.

• Between DCU Module 53-pin connector pin-7 and known good GND.
Is voltage B+ ± 0.5 volts? No: Repair Open or short to GND
in DCU B+ circuits. After repairs
are complete, retest for SPN 1231
FMI 19.
724 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 6 Check DCU SWBAT circuit for Open or short to GND. Decision
A. Key OFF. Yes: Go to Step 7.
B. Disconnect DCU Module 53-pin connector.
C. Insert applicable terminal test pins from Terminal Test Kit ZTSE4435C, into
DCU 53-pin connector pin-52 and leave DCU disconnected.

D. Key ON Engine OFF (KOEO).

E. Use DMM, measure voltage between DCU Module 53-pin connector pin-52
and known good GND.
Is voltage B+ ± 0.5 volts? No: Repair Open or short to GND
in DCU SWBAT circuit. After
repairs are complete, retest for
SPN 1231 FMI 19.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 725

Step 7 Check for CAN-H short to GND. Decision

A. Key OFF. Yes: Go to Step 8
B. Disconnect DCU Module 53-pin connector.
C. Insert applicable terminal test pins from Terminal Test Kit ZTSE4435C, into
DCU 53-pin connector pin-14 and leave DCU disconnected.

D. Key ON Engine OFF (KOEO).

E. Use DMM, measure voltage between DCU Module 53-pin connector pin-14
and known good GND.
Is voltage greater than 1 volt? No: Repair CAN-H short to GND.
After repairs are complete, retest
for SPN 1231 FMI 19.

Step 8 Check for CAN-H short to PWR. Decision

A. Key OFF. Yes: Go to Step 9.
B. Disconnect DCU Module 53-pin connector.
C. Insert applicable terminal test pins from Terminal Test Kit ZTSE4435C, into
DCU 53-pin connector pin-14 and leave DCU disconnected.
D. Key ON Engine OFF (KOEO).
E. Use DMM, measure voltage between DCU Module 53-pin connector pin-14
and known good GND.
Is voltage less than 4 volts? No: Repair CAN-H short to PWR.
After repairs are complete, retest
for SPN 1231 FMI 19.

Step 9 Check for CAN-L short to GND. Decision

A. Key OFF. Yes: Go to Step 10.

B. Disconnect DCU Module 53-pin connector.

C. Insert applicable terminal test pins from Terminal Test Kit ZTSE4435C, into
DCU 53-pin connector pin-15 and leave DCU disconnected.
D. Key-On Engine-Off (KOEO).

E. Use DMM, measure voltage between DCU Module 53-pin connector pin-15
and known good GND.
Is voltage greater than 1 volt? No: Repair CAN-L short to GND.
After repairs are complete, retest
for SPN 1231 FMI 19.
726 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 10 Check for CAN-L short to PWR. Decision

A. Key OFF. Yes: Go to Step 11.
B. Disconnect DCU Module 53-pin connector.
C. Insert applicable terminal test pins from Terminal Test Kit ZTSE4435C, into
DCU 53-pin connector pin-15 and leave DCU disconnected.

D. Key-On Engine-Off (KOEO).

E. Use DMM, measure voltage between DCU Module 53-pin connector pin-15
and known good GND.
Is voltage less than 4 volts? No: Repair CAN-L short to PWR.
After repairs are complete, retest
for SPN 1231 FMI 19.

Step 11 Check for short between CAN-H and CAN-L circuits. Decision
A. Key OFF. Yes: Go to Step 12.
B. Disconnect DCU Module 53-pin connector.
C. Insert applicable terminal test pins from Terminal Test Kit ZTSE4435C, into
DCU 53-pin connector pin-14 and pin-15 and leave DCU disconnected.
D. Use DMM, measure resistance between DCU Module 53-pin connector
pin-14 and pin-15.
Is resistance greater than 50 ohms? No: Repair short between CAN-H
and CAN-L. After repairs are
complete, retest for SPN 1231
FMI 19.

Step 12 Check for Open or high resistance between DCU and ECM. Decision
A. Key OFF. Yes: Repair Open or high
resistance between DCU pin-14
B. Disconnect DCU Module 53-pin connector.
and ECM pin C-61. After repairs
C. Disconnect ECM Chassis 76-pin connector are complete, retest for SPN 1231
FMI 19.
D. Insert applicable terminal test pins from Terminal Test Kit ZTSE4435C, into
DCU 53-pin connector pin-14 and leave DCU disconnected.
E. Connect Breakout Harness 00-00959-01 between vehicle harness and
180-pin Breakout Box 00-00956-08 and leave ECM disconnected.

F. Use DMM, measure resistance between DCU Module 53-pin connector

pin-14 and 180-pin Breakout Box 00-00956-08 pin C-61.
Is resistance greater than 5 ohms? No: Go to Step 13.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 727

Step 13 Check for Open or high resistance between DCU and ECM. Decision
A. Key OFF. Yes: Repair Open or high
resistance between DCU pin-15
B. Disconnect DCU Module 53-pin connector.
and ECM pin C-62. After repairs
C. Disconnect ECM Chassis 76-pin connector are complete, retest for SPN 1231
FMI 19.
D. Insert applicable terminal test pins from Terminal Test Kit ZTSE4435C, into
DCU 53-pin connector pin-15 and leave DCU disconnected.

E. Connect Breakout Harness 00-00959-01 between vehicle harness and

180-pin Breakout Box 00-00956-08 and leave ECM disconnected.
F. Use DMM, measure resistance between DCU Module 53-pin connector
pin-15 and 180-pin Breakout Box 00-00956-08 pin C-62.
Is resistance greater than 5 ohms? No: End diagnostics. Retest for
SPN 1231 FMI 19.

End Diagnostic Test

After performing diagnostic steps, if SPN 1231 FMI 19 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
728 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 1322 FMI 31 - Misfire - Multiple Cylinders

Fault Overview
Fault sets when Engine Control Module (ECM) determines there is a balance difference between cylinders.

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

Associated Faults
SPN 27 FMI 14 (EGR) SPN 51 FMI 3, 4, 7 and 11 SPN 94 FMI 3 and 4 (FDP) SPN 102 FMI 3, 4, and 7
(ETV) (IMP)
SPN 108 FMI 3 and 4 SPN 110 FMI 2, 3, 4, 17, SPN 132 FMI 0, 1, 3, and 4 SPN 164 FMI 0, 3, 4, 15, 16,
(BARO) and 18 (ECT1) (MAF) 17, and 18 (ICP)
SPN 175 FMI 2, 3, and 4 SPN 191 FMI 3 and 4 SPN 636 FMI 2 and 7 (CMP) SPN 651 - 656 FMI 4, 5, and
(EOT) (TOSS) 7 (INJ)
SPN 1189 FMI 3 and 4 SPN 2659 FMI 20 (AMS) SPN 2791 FMI 2, 3, 4, 7, 8, SPN 2797-2798 FMI 3, 4,
(TC2WG) and 14 (EGR) and 6 (INJ)
SPN 3055 FMI 2 (INJ) SPN 3659-3664 FMI 4 and SPN 3464 FMI 31 (ETV) SPN 4257 FMI 7 (INJ)
5 (INJ)
SPN 5543 FMI 3, 4, and 5
(EBPV)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Low fuel level or contaminated fuel
• Intake system or fuel system restrictions, leaks or damage
• Low oil level or oil contamination
• Failed Engine Compression Brake (ECB) valve
• Injector circuit failure
• Engine compression loss
• Failed fuel injector
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 729

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 728).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 1322 FMI 31.

Step 2 Check fuel level and quality. Decision

Perform following: Yes: Go to Step 3.
• Fuel Level Inspection(page 1634)
• Fuel Quality Inspection(page 1632)
Is there sufficient supply of good quality fuel? No: Drain contaminated fuel if
needed and fill with clean fuel.
After repairs are complete, retest
for SPN 1322 FMI 31.

Step 3 Inspect air intake system and fuel system for leaks or physical damage. Decision
Perform following: Yes: Go to Step 4.
• Intake Air Inspection(page 1648)
• Fuel System Inspection(page 1631)
Are Intake system and fuel system free of restrictions, leaks or physical damage? No: Repair restrictions, leaks and
physical damage. After repairs
are complete, retest for SPN 1322
FMI 31.

Step 4 Check for oil level, quality, and aeration. Decision

Perform Engine Oil Level and Quality Inspection(page 1635). Yes: Go to Step 5.
Is oil level full and free of aeration and contamination? No: Remove dirty, aerated, or
contaminated oil. Fill with good
quality oil. After repairs are
complete, retest for SPN 1322
FMI 31.

Step 5 Determine cause of rough engine idle or misfire. Decision

Perform Relative Compression Test Plus (RCT+) (page 1465). Yes: Repair mechanical problem
with cylinder(s) indicating low
performance. After repairs are
complete, retest for SPN 1322
FMI 31.
Does CPA Tool indicate a problem or generate a warranty authorization code No: Go to Step 6.
(WAC)?
730 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 6 Evaluate cylinder performance issues. Decision

Perform following: Yes: Replace part indicated
by CPA Tool. After repairs are
• CPA Signal Check (page 1413)
complete, retest for SPN 1322
• CPA Cold Idle Test (page 1407) FMI 31.
• CPA Hot Idle Test (page 1421)
Does CPA Tool indicate a problem or generate a warranty authorization code No: Go to Step 7.
(WAC)?

Step 7 Check injectors for circuit issues. Decision

Perform Injector Test (page 1365). Yes: Perform appropriate SPN
651 - 656 FMI 4 or 5 and
SPN 3659 - 3664 FMI 4 or 5
diagnostics to identify failure.
Repair as needed. After repairs
are complete, retest for SPN 1322
FMI 31.
Was a failed injector or circuit identified? No: Go to Step 8.

Step 8 Determine if Engine Compression Brake (ECB) is equipped and Decision

operating correctly.
A. Key OFF. Yes: End Diagnostics. Retest for
SPN 1322 FMI 31.
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).
C. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
D. Key-On Engine-Running (KOER).
E. Operate engine at high idle.
F. Use EST, monitor Engine Compression Brake Pressure (ECBP).
Is ECBP less than 72 psi (500 kPa)? No: Replace ECB valve. After
repairs are complete, retest for
SPN 1322 FMI 31.

End Diagnostic Steps

After performing diagnostic steps, if SPN 1322 FMI 31 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 731

SPN 1323 FMI 31 - Misfire - Cylinder 1

Fault Overview
Fault sets when Engine Control Module (ECM) determines there is a balance difference between cylinders.

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

Associated Faults
SPN 27 FMI 14 (EGR) SPN 51 FMI 3, 4, 7 and 11 SPN 94 FMI 3 and 4 (FDP) SPN 102 FMI 3, 4, and 7
(ETV) (IMP)
SPN 108 FMI 3 and 4 SPN 110 FMI 2, 3, 4, 17, SPN 132 FMI 0, 1, 3, and 4 SPN 164 FMI 0, 3, 4, 15,
(BARO) and 18 (ECT1) (MAF) 16, 17, and 18 (ICP)
SPN 175 FMI 2, 3, and 4 SPN 191 FMI 3 and 4 SPN 636 FMI 2 and 7 (CMP) SPN 651 - 656 FMI 4, 5,
(EOT) (TOSS) and 7 (INJ)
SPN 1189 FMI 3 and 4 SPN 2659 FMI 20 (AMS) SPN 2791 FMI 2, 3, 4, 7, 8, SPN 2797-2798 FMI 3, 4,
(TC2WG) and 14 (EGR) and 6 (INJ)
SPN 3055 FMI 2 (INJ) SPN 3659-3664 FMI 4 and SPN 3464 FMI 31 (ETV) SPN 4257 FMI 7 (INJ)
5 (INJ)
SPN 5395 FMI 0 and 1 SPN 5543 FMI 3, 4, and 5
(Engine) (EBPV)

Fault Facts
None

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• Injector circuit failure
• Engine compression loss or mechanical damage
• Failed fuel injector

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 731).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 1323 FMI 31.
732 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 2 Check for active or pending fault codes. Decision

Use EST, Key-On Engine-Off (KOEO), check DTC list for SPN 1323 FMI 31. Yes: Go to Step 3.
Is EST DTC list SPN 1323 FMI 31 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 3 Test for failed injector. Decision

A. Key OFF. Yes: Go to Step 4.
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).
C. Key-ON Engine-OFF (KOEO), log in to Navistar® Engine Diagnostics.
D. Perform Key-On Engine-Off (KOEO) Injector Test (page 1365).
Did KOEO Injector Test pass? No: Go to Step 5.

Step 4 Inspect Under Valve Cover (UVC) connector 2. Decision

A. Key OFF. Yes: Go to Step 5.
B. Disconnect UVC connector.
C. Check UVC connector terminals for: damaged or pinched wires; wet or
corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are UVC connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 1323
FMI 31.

NOTE: Batteries must be charged (use battery charger if necessary).

Step 5 Determine cause of rough engine idle or misfire. Decision

Perform Relative Compression Test Plus (RCT+) (page 1465). Yes: Repair mechanical problem
with cylinder(s) indicating low
performance. After repairs are
complete, retest for SPN 1323
FMI 31.
Does CPA Tool indicate a problem or generate a warranty authorization code No: Go to Step 6.
(WAC)?
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 733

Step 6 Evaluate cylinder performance issues. Decision

Perform following: Yes: Replace part indicated
by CPA Tool. After repairs are
• CPA Signal Check (page 1413)
complete, retest for SPN 1323
• CPA Cold Idle Test (page 1407) FMI 31.
• CPA Hot Idle Test (page 1421)
Does CPA Tool indicate a problem or generate a warranty authorization code No: Go to Step 7.
(WAC)?

Step 7 Isolate electrical failure to injector or harness. Decision

Perform Injector 1 Open Coil - Short Circuit Fault (page 523). Yes: Go to Step 8.
Does circuit operate properly? No: Replace suspect injector or
under-valve cover wiring harness
as indicated. After repairs are
complete, retest for SPN 1323
FMI 31.

Step 8 Isolate electrical failure to injector or harness. Decision

Perform Injector 1 Open Coil - Open Circuit(page 529). Yes: Go to Step 9.
Does circuit operate properly? No: Replace suspect injector or
under-valve cover wiring harness
as indicated. After repairs are
complete, retest for SPN 1323
FMI 31.

Step 9 Isolate electrical failure to injector or harness. Decision

Perform Injector 1 Close Coil - Short Circuit(page 1115). Yes: Go to Step 10.
Does circuit operate properly? No: Replace suspect injector or
under-valve cover wiring harness
as indicated. After repairs are
complete, retest for SPN 1323
FMI 31.

Step 10 Isolate electrical failure to injector or harness. Decision

Perform Injector 1 Close Coil - Open Circuit(page 1120). Yes: End diagnostics. Retest for
SPN 1323 FMI 31.
Does circuit operate properly? No: Replace suspect injector or
under-valve cover wiring harness
as indicated. After repairs are
complete, retest for SPN 1323
FMI 31.
734 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

End Diagnostic Steps

After performing diagnostic steps, if SPN 1323 FMI 31 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 735

SPN 1324 FMI 31 - Misfire - Cylinder 2

Fault Overview
Fault sets when Engine Control Module (ECM) determines there is a balance difference between cylinders.

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

Associated Faults
SPN 27 FMI 14 (EGR) SPN 51 FMI 3, 4, 7 and 11 SPN 94 FMI 3 and 4 (FDP) SPN 102 FMI 3, 4, and 7
(ETV) (IMP)
SPN 108 FMI 3 and 4 SPN 110 FMI 2, 3, 4, 17, SPN 132 FMI 0, 1, 3, and 4 SPN 164 FMI 0, 3, 4, 15,
(BARO) and 18 (ECT1) (MAF) 16, 17, and 18 (ICP)
SPN 175 FMI 2, 3, and 4 SPN 191 FMI 3 and 4 SPN 636 FMI 2 and 7 SPN 651 - 656 FMI 4, 5,
(EOT) (TOSS) (CMP) and 7 (INJ)
SPN 1189 FMI 3 and 4 SPN 2659 FMI 20 (AMS) SPN 2791 FMI 2, 3, 4, 7, 8, SPN 2797-2798 FMI 3, 4,
(TC2WG) and 14 (EGR) and 6 (INJ)
SPN 3055 FMI 2 (INJ) SPN 3659-3664 FMI 4 and SPN 3464 FMI 31 (ETV) SPN 4257 FMI 7 (INJ)
5 (INJ)
SPN 5395 FMI 0 and 1 SPN 5543 FMI 3, 4, and 5
(Engine) (EBPV)
• SPN 3659 - 3664 FMI 4
and 5 (INJ)

Fault Facts
None

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• Injector circuit failure
• Engine compression loss or mechanical damage
• Failed fuel injector

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 735).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 1324 FMI 31.
736 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 2 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 1324 FMI 31. Yes: Go to Step 3.
Is EST DTC list SPN 1324 FMI 31 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 3 Test for failed injector. Decision

A. Key OFF. Yes: Go to Step 4.
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).
C. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
D. Perform Key On Engine Off (KOEO) Injector Test(page 1365).
Did KOEO Injector Test pass? No: Go to Step 5.

Step 4 Inspect Under Valve Cover (UVC) connector 2. Decision

A. Key OFF. Yes: Go to Step 5.
B. Disconnect UVC connector.
C. Check UVC connector terminals for: damaged or pinched wires; wet or
corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are UVC connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 1324
FMI 31.

NOTE: Batteries must be charged (use battery charger if necessary).

Step 5 Determine cause of rough engine idle or misfire. Decision

Perform Relative Compression Test Plus (RCT+) (page 1465). Yes: Repair mechanical problem
with cylinder(s) indicating low
performance. After repairs are
complete, retest for SPN 1324
FMI 31.
Does CPA Tool indicate a problem or generate a warranty authorization code No: Go to Step 6.
(WAC)?
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 737

Step 6 Evaluate cylinder performance issues. Decision

Perform following: Yes: Replace part indicated
by CPA Tool. After repairs are
• CPA Signal Check (page 1413)
complete, retest for SPN 1324
• CPA Cold Idle Test (page 1407) FMI 31.
• CPA Hot Idle Test (page 1421)
Does CPA Tool indicate a problem or generate a warranty authorization code No: Go to Step 7.
(WAC)?

Step 7 Isolate electrical failure to injector or harness. Decision

Perform Injector 2 Open Coil - Short Circuit Fault (page 523). Yes: Go to Step 8.
Does circuit operate properly? No: Replace suspect injector or
under-valve cover wiring harness
as indicated. After repairs are
complete, retest for SPN 1324
FMI 31.

Step 8 Isolate electrical failure to injector or harness. Decision

Perform Injector 2 Open Coil - Open Circuit(page 529). Yes: Go to Step 9.
Does circuit operate properly? No: Replace suspect injector or
under-valve cover wiring harness
as indicated. After repairs are
complete, retest for SPN 1324 FMI
31.

Step 9 Isolate electrical failure to injector or harness. Decision

Perform Injector 2 Close Coil - Short Circuit (page 1115). Yes: Go to Step 10.
Does circuit operate properly? No: Replace suspect injector or
under-valve cover wiring harness
as indicated. After repairs are
complete, retest for SPN 1324 FMI
31.

Step 10 Isolate electrical failure to injector or harness. Decision

Perform Injector 2 Close Coil - Open Circuit (page 1120). Yes: End Diagnostics. Retest for
SPN 1324 FMI 31.
Does circuit operate properly? No: Replace suspect injector or
under-valve cover wiring harness
as indicated. After repairs are
complete, retest for SPN 1324 FMI
31.
738 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

End Diagnostic Steps

After performing diagnostic steps, if SPN 1324 FMI 31 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 739

SPN 1325 FMI 31 - Misfire - Cylinder 3

Fault Overview
Fault sets when Engine Control Module (ECM) determines there is a balance difference between cylinders.

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

Associated Faults
SPN 27 FMI 14 (EGR) SPN 51 FMI 3, 4, 7 and 11 SPN 94 FMI 3 and 4 (FDP) SPN 102 FMI 3, 4, and 7
(ETV) (IMP)
SPN 108 FMI 3 and 4 SPN 110 FMI 2, 3, 4, 17, SPN 132 FMI 0, 1, 3, and 4 SPN 164 FMI 0, 3, 4, 15,
(BARO) and 18 (ECT1) (MAF) 16, 17, and 18 (ICP)
SPN 175 FMI 2, 3, and 4 SPN 191 FMI 3 and 4 SPN 636 FMI 2 and 7 SPN 651 - 656 FMI 4, 5,
(EOT) (TOSS) (CMP) and 7 (INJ)
SPN 1189 FMI 3 and 4 SPN 2659 FMI 20 (AMS) SPN 2791 FMI 2, 3, 4, 7, 8, SPN 2797-2798 FMI 3, 4,
(TC2WG) and 14 (EGR) and 6 (INJ)
SPN 3055 FMI 2 (INJ) SPN 3659-3664 FMI 4 and SPN 3464 FMI 31 (ETV) SPN 4257 FMI 7 (INJ)
5 (INJ)
SPN 5395 FMI 0 and 1 SPN 5543 FMI 3, 4, and 5
(Engine) (EBPV)
• SPN 3659 - 3664 FMI 4
and 5 (INJ)

Fault Facts
None

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• Injector circuit failure
• Engine compression loss or mechanical damage
• Failed fuel injector

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults(page 739).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 1325 FMI 31.
740 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 2 Check for active or pending fault codes. Decision

Use ESTe, check DTC list for SPN 1325 FMI 31. Yes: Go to Step 3.
Is EST DTC list SPN 1325 FMI 31 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 3 Test for failed injector. Decision

A. Key OFF. Yes: Go to Step 4.
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).
C. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
D. Perform Key On Engine Off (KOEO) Injector Test(page 1365).
Did KOEO Injector Test pass? No: Go to Step 5.

Step 4 Inspect Under Valve Cover (UVC) connector 3. Decision

A. Key OFF. Yes: Go to Step 5.
B. Disconnect UVC connector.
C. Check UVC connector terminals for: damaged or pinched wires; wet
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are UVC connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 1323
FMI 31.

NOTE: Batteries must be charged (use battery charger if necessary).

Step 5 Determine cause of rough engine idle or misfire. Decision

Perform Relative Compression Test Plus (RCT+) (page 1465). Yes: Repair mechanical problem
with cylinder(s) indicating low
performance. After repairs are
complete, retest for SPN 1325
FMI 31.
Does CPA Tool indicate a problem or generate a warranty authorization code No: Go to Step 6.
(WAC)?
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 741

Step 6 Evaluate cylinder performance issues. Decision

Perform following: Yes: Replace part indicated
by CPA Tool. After repairs are
• CPA Signal Check (page 1413)
complete, retest for SPN 1325
• CPA Cold Idle Test (page 1407) FMI 31.
• CPA Hot Idle Test (page 1421)
Does CPA Tool indicate a problem or generate a warranty authorization code No: Go to Step 7.
(WAC)?

Step 7 Isolate electrical failure to injector or harness. Decision

Perform Injector 3 Open Coil - Short Circuit Fault (page 523). Yes: Go to Step 8.
Does circuit operate properly? No: Replace suspect injector or
under-valve cover wiring harness
as indicated. After repairs are
complete, retest for SPN 1325
FMI 31.

Step 8 Isolate electrical failure to injector or harness. Decision

Perform Injector 3 Open Coil - Open Circuit (page 529). Yes: Go to Step 9.
Does circuit operate properly? No: Replace suspect injector or
under-valve cover wiring harness
as indicated. After repairs are
complete, retest for SPN 1325 FMI
31.

Step 9 Isolate electrical failure to injector or harness. Decision

Perform Injector 3 Close Coil - Short Circuit (page 1115). Yes: Go to Step 10.
Does circuit operate properly? No: Replace suspect injector or
under-valve cover wiring harness
as indicated. After repairs are
complete, retest for SPN 1325
FMI 31.

Step 10 Isolate electrical failure to injector or harness. Decision

Perform Injector 3 Close Coil - Open Circuit (page 1120). Yes: End diagnostics. Retest for
SPN 1325 FMI 31.
Does circuit operate properly? No: Replace suspect injector or
under-valve cover wiring harness
as indicated. After repairs are
complete, retest for SPN 1325
FMI 31.
742 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

End Diagnostic Steps

After performing diagnostic steps, if SPN 1325 FMI 31 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 743

SPN 1326 FMI 31 - Misfire - Cylinder 4

Fault Overview
Fault sets when Engine Control Module (ECM) determines there is a balance difference between cylinders.

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

Associated Faults
SPN 27 FMI 14 (EGR) SPN 51 FMI 3, 4, 7 and 11 SPN 94 FMI 3 and 4 (FDP) SPN 102 FMI 3, 4, and 7
(ETV) (IMP)
SPN 108 FMI 3 and 4 SPN 110 FMI 2, 3, 4, 17, SPN 132 FMI 0, 1, 3, and 4 SPN 164 FMI 0, 3, 4, 15,
(BARO) and 18 (ECT1) (MAF) 16, 17, and 18 (ICP)
SPN 175 FMI 2, 3, and 4 SPN 191 FMI 3 and 4 SPN 636 FMI 2 and 7 SPN 651 - 656 FMI 4, 5,
(EOT) (TOSS) (CMP) and 7 (INJ)
SPN 1189 FMI 3 and 4 SPN 2659 FMI 20 (AMS) SPN 2791 FMI 2, 3, 4, 7, 8, SPN 2797-2798 FMI 3, 4,
(TC2WG) and 14 (EGR) and 6 (INJ)
SPN 3055 FMI 2 (INJ) SPN 3659-3664 FMI 4 and SPN 3464 FMI 31 (ETV) SPN 4257 FMI 7 (INJ)
5 (INJ)
SPN 5395 FMI 0 and 1 SPN 5543 FMI 3, 4, and 5
(Engine) (EBPV)
• SPN 3659 - 3664 FMI 4
and 5 (INJ)

Fault Facts
None

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• Injector circuit failure
• Engine compression loss or mechanical damage
• Failed fuel injector

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 743).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 1326 FMI 31.
744 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 2 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 1326 FMI 31. Yes: Go to Step 3.
Is EST DTC list SPN 1326 FMI 31 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 3 Test for failed injector. Decision

A. Key OFF. Yes: Go to Step 4.
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).
C. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
D. Perform Key On Engine Off (KOEO) Injector Test(page 1365).
Did KOEO Injector Test pass? No: Go to Step 5.

Step 4 Inspect Under Valve Cover (UVC) connector 3. Decision

A. Key OFF. Yes: Go to Step 5.
B. Disconnect UVC connector.
C. Check UVC connector terminals for: damaged or pinched wires; wet
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are UVC connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 1323
FMI 31.

NOTE: Batteries must be charged (use battery charger if necessary).

Step 5 Determine cause of rough engine idle or misfire. Decision

Perform Relative Compression Test Plus (RCT+) (page 1465). Yes: Repair mechanical problem
with cylinder(s) indicating low
performance. After repairs are
complete, retest for SPN 1326
FMI 31.
Does CPA Tool indicate a problem or generate a warranty authorization code No: Go to Step 6.
(WAC)?
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 745

Step 6 Evaluate cylinder performance issues. Decision

Perform following: Yes: Replace part indicated
by CPA Tool. After repairs are
• CPA Signal Check (page 1413)
complete, retest for SPN 1326
• CPA Cold Idle Test (page 1407) FMI 31.
• CPA Hot Idle Test (page 1421)
Does CPA Tool indicate a problem or generate a warranty authorization code No: Go to Step 7.
(WAC)?

Step 7 Isolate electrical failure to injector or harness. Decision

Perform Injector 4 Open Coil - Short Circuit Fault (page 523). Yes: Go to Step 8.
Does circuit operate properly? No: Replace suspect injector or
under-valve cover wiring harness
as indicated. After repairs are
complete, retest for SPN 1326
FMI 31.

Step 8 Isolate electrical failure to injector or harness. Decision

Perform Injector 4 Open Coil - Open Circuit (page 529). Yes: Go to Step 9.
Does circuit operate properly? No: Replace suspect injector or
under-valve cover wiring harness
as indicated. After repairs are
complete, retest for SPN 1326
FMI 31.

Step 9 Isolate electrical failure to injector or harness. Decision

Perform Injector 4 Close Coil - Short Circuit(page 1115). Yes: Go to Step 10.
Does circuit operate properly? No: Replace suspect injector or
under-valve cover wiring harness
as indicated. After repairs are
complete, retest for SPN 1326
FMI 31.

Step 10 Isolate electrical failure to injector or harness. Decision

Perform Injector 4 Close Coil - Open Circuit (page 1120). Yes: End Diagnostics. Retest for
SPN 1326 FMI 31..
Does circuit operate properly? No: Replace suspect injector or
under-valve cover wiring harness
as indicated. After repairs are
complete, retest for SPN 1326
FMI 31.
746 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

End Diagnostic Steps

After performing diagnostic steps, if SPN 1326 FMI 31 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 747

SPN 1327 FMI 31 - Misfire - Cylinder 5

Fault Overview
Fault sets when Engine Control Module (ECM) determines there is a balance difference between cylinders.

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

Associated Faults
SPN 27 FMI 14 (EGR) SPN 51 FMI 3, 4, 7 and 11 SPN 94 FMI 3 and 4 (FDP) SPN 102 FMI 3, 4, and 7
(ETV) (IMP)
SPN 108 FMI 3 and 4 SPN 110 FMI 2, 3, 4, 17, SPN 132 FMI 0, 1, 3, and 4 SPN 164 FMI 0, 3, 4, 15,
(BARO) and 18 (ECT1) (MAF) 16, 17, and 18 (ICP)
SPN 175 FMI 2, 3, and 4 SPN 191 FMI 3 and 4 SPN 636 FMI 2 and 7 SPN 651 - 656 FMI 4, 5,
(EOT) (TOSS) (CMP) and 7 (INJ)
SPN 1189 FMI 3 and 4 SPN 2659 FMI 20 (AMS) SPN 2791 FMI 2, 3, 4, 7, 8, SPN 2797-2798 FMI 3, 4,
(TC2WG) and 14 (EGR) and 6 (INJ)
SPN 3055 FMI 2 (INJ) SPN 3659-3664 FMI 4 and SPN 3464 FMI 31 (ETV) SPN 4257 FMI 7 (INJ)
5 (INJ)
SPN 5395 FMI 0 and 1 SPN 5543 FMI 3, 4, and 5
(Engine) (EBPV)
• SPN 3659 - 3664 FMI 4
and 5 (INJ)

Fault Facts
None

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• Injector circuit failure
• Engine compression loss or mechanical damage
• Failed fuel injector

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 747).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 1327 FMI 31.
748 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 2 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 1327 FMI 31. Yes: Go to Step 3.
Is EST DTC list SPN 1327 FMI 31 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 3 Test for failed injector. Decision

A. Key OFF. Yes: Go to Step 4.
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).
C. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
D. Perform Key On Engine Off (KOEO) Injector Test(page 1365).
Did KOEO Injector Test pass? No: Go to Step 5.

Step 4 Inspect Under Valve Cover (UVC) connector 4. Decision

A. Key OFF. Yes: Go to Step 5.
B. Disconnect UVC connector.
C. Check UVC connector terminals for: damaged or pinched wires; wet
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are UVC connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 1327
FMI 31.

NOTE: Batteries must be charged (use battery charger if necessary).

Step 5 Determine cause of rough engine idle or misfire. Decision

Perform Relative Compression Test Plus (RCT+) (page 1465). Yes: Repair mechanical problem
with cylinder(s) indicating low
performance. After repairs are
complete, retest for SPN 1327
FMI 31.
Does CPA Tool indicate a problem or generate a warranty authorization code No: Go to Step 6.
(WAC)?
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 749

Step 6 Evaluate cylinder performance issues. Decision

Perform following: Yes: Replace part indicated
by CPA Tool. After repairs are
• CPA Signal Check (page 1413)
complete, retest for SPN 1327
• CPA Cold Idle Test (page 1407) FMI 31.
• CPA Hot Idle Test (page 1421)
Does CPA Tool indicate a problem or generate a warranty authorization code No: Go to Step 7.
(WAC)?

Step 7 Isolate electrical failure to injector or harness. Decision

Perform Injector 5 Open Coil - Short Circuit Fault (page 523). Yes: Go to Step 8.
Does circuit operate properly? No: Replace suspect injector or
under-valve cover wiring harness
as indicated. After repairs are
complete, retest for SPN 1327
FMI 31.

Step 8 Isolate electrical failure to injector or harness. Decision

Perform Injector 5 Open Coil - Open Circuit (page 529). Yes: Go to Step 9.
Does circuit operate properly? No: Replace suspect injector or
under-valve cover wiring harness
as indicated. After repairs are
complete, retest for SPN 1327
FMI 31.

Step 9 Isolate electrical failure to injector or harness. Decision

Perform Injector 5 Close Coil - Short Circuit (page 1115). Yes: Go to Step 10.
Does circuit operate properly? No: Replace suspect injector or
under-valve cover wiring harness
as indicated. After repairs are
complete, retest for SPN 1327
FMI 31.

Step 10 Isolate electrical failure to injector or harness. Decision

Perform Injector 5 Close Coil - Open Circuit (page 1120). Yes: End Diagnostics. Retest for
SPN 1327 FMI 31.
Does circuit operate properly? No: Replace suspect injector or
under-valve cover wiring harness
as indicated. After repairs are
complete, retest for SPN 1327
FMI 31.
750 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

End Diagnostic Steps

After performing diagnostic steps, if SPN 1327 FMI 31 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 751

SPN 1328 FMI 31 - Misfire - Cylinder 6

Fault Overview
Fault sets when Engine Control Module (ECM) determines there is a balance difference between cylinders.

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

Associated Faults
SPN 27 FMI 14 (EGR) SPN 51 FMI 3, 4, 7 and 11 SPN 94 FMI 3 and 4 (FDP) SPN 102 FMI 3, 4, and 7
(ETV) (IMP)
SPN 108 FMI 3 and 4 SPN 110 FMI 2, 3, 4, 17, SPN 132 FMI 0, 1, 3, and 4 SPN 164 FMI 0, 3, 4, 15,
(BARO) and 18 (ECT1) (MAF) 16, 17, and 18 (ICP)
SPN 175 FMI 2, 3, and 4 SPN 191 FMI 3 and 4 SPN 636 FMI 2 and 7 SPN 651 - 656 FMI 4, 5,
(EOT) (TOSS) (CMP) and 7 (INJ)
SPN 1189 FMI 3 and 4 SPN 2659 FMI 20 (AMS) SPN 2791 FMI 2, 3, 4, 7, 8, SPN 2797-2798 FMI 3, 4,
(TC2WG) and 14 (EGR) and 6 (INJ)
SPN 3055 FMI 2 (INJ) SPN 3659-3664 FMI 4 and SPN 3464 FMI 31 (ETV) SPN 4257 FMI 7 (INJ)
5 (INJ)
SPN 5395 FMI 0 and 1 SPN 5543 FMI 3, 4, and 5
(Engine) (EBPV)
• SPN 3659 - 3664 FMI 4
and 5 (INJ)

Fault Facts
None

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• Injector circuit failure
• Engine compression loss or mechanical damage
• Failed fuel injector

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 751).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 1328 FMI 31.
752 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 2 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 1328 FMI 31. Yes: Go to Step 3.
Is EST DTC list SPN 1328 FMI 31 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 3 Test for failed injector. Decision

A. Key OFF. Yes: Go to Step 4.
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).
C. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
D. Perform Key On Engine Off (KOEO) Injector Test (page 1365).
Did KOEO Injector Test pass? No: Go to Step 5.

Step 4 Inspect Under Valve Cover (UVC) connector 4. Decision

A. Key OFF. Yes: Go to Step 5.
B. Disconnect UVC connector.
C. Check UVC connector terminals for: damaged or pinched wires; wet or
corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are UVC connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 1328
FMI 31.

NOTE: Batteries must be charged (use battery charger if necessary).

Step 5 Determine cause of rough engine idle or misfire. Decision

Perform Relative Compression Test Plus (RCT+) (page 1465). Yes: Repair mechanical problem
with cylinder(s) indicating low
performance. After repairs are
complete, retest for SPN 1328
FMI 31.
Does CPA Tool indicate a problem or generate a warranty authorization code No: Go to Step 6.
(WAC)?
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 753

Step 6 Evaluate cylinder performance issues. Decision

Perform following: Yes: Replace part indicated
by CPA Tool. After repairs are
• CPA Signal Check (page 1413)
complete, retest for SPN 1328
• CPA Cold Idle Test (page 1407) FMI 31.
• CPA Hot Idle Test (page 1421)
Does CPA Tool indicate a problem or generate a warranty authorization code No: Go to Step 7.
(WAC)?

Step 7 Isolate electrical failure to injector or harness. Decision

Perform Injector 6 Open Coil - Short Circuit Fault (page 523). Yes: Go to Step 8.
Does circuit operate properly? No: Replace suspect injector or
under-valve cover wiring harness
as indicated. After repairs are
complete, retest for SPN 1328
FMI 31.

Step 8 Isolate electrical failure to injector or harness. Decision

Perform Injector 6 Open Coil - Open Circuit (page 529). Yes: Go to Step 9.
Does circuit operate properly? No: Replace suspect injector or
under-valve cover wiring harness
as indicated. After repairs are
complete, retest for SPN 1328
FMI 31.

Step 9 Isolate electrical failure to injector or harness. Decision

Perform Injector 6 Close Coil - Short Circuit (page 1115). Yes: Go to Step 10.
Does circuit operate properly? No: Replace suspect injector or
under-valve cover wiring harness
as indicated. After repairs are
complete, retest for SPN 1328
FMI 31.

Step 10 Isolate electrical failure to injector or harness. Decision

Perform Injector 6 Close Coil - Open Circuit (page 1120). Yes: End Diagnostics. Retest for
SPN 1328 FMI 31.
Does circuit operate properly? No: Replace suspect injector or
under-valve cover wiring harness
as indicated. After repairs are
complete, retest for SPN 1328
FMI 31.
754 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

End Diagnostic Steps

After performing diagnostic steps, if SPN 1328 FMI 31 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 755

SPN 1378 FMI 31 - Change Engine Oil Service Interval

Fault Overview
Change oil reminder can be programmed for kilometers, miles, hours, or calculated fuel consumption. These
service interval limits may be adjusted at owner's discretion. Change engine oil message below odometer
illuminates after a preselected parameter is reached.
Possible Causes
• Change oil and re-set interval counter
756 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 1387 FMI 31 - Altitude Reference Adder Fault

Fault Overview
Fault sets when Engine Control Module (ECM) determines that it has exceeded 98% CPU load.

Malfunction Indicator Lamp (MIL) Reaction

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

Associated Faults
• SPN 102 FMI 2, 7, 16, and • SPN 108 FMI 2 • SPN 628 FMI 12 • SPN 629 FMI 0 and 12
18
• SPN 1209 FMI 0, 1, 7, and
31.

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Barometric Absolute Pressure (BARO), Exhaust Back Pressure (EBP), and Intake Manifold Pressure (IMP)
do not agree
• Biased, damaged, or failed BARO (ECM), EBP, or IMP sensor
• Biased, failed, or damaged actuator PWR circuit
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 757

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 756).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 1387 FMI 31.

Step 2 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 1387 FMI 31. Yes: Go to Step 3.
Is SPN 1387 FMI 31 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 1387 FMI 31.

Step 3 Inspect Exhaust Back Pressure (EBP) and Intake Manifold Pressure Decision
(IMP) sensor and connector.
A. Key OFF. Yes: Go to Step 4.
B. Disconnect EBP and IMP sensors.
C. Check EBP and IMP sensors and connector terminals for: damaged or
pinched wires; wet or corroded terminals; loose, bent, or broken pins; or
broken connector housing.
Are EBP and IMP sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 1387
FMI 31.

Step 4 Test EBP and IMP circuits for open, short, or high resistance Decision
conditions.
• Do EBP connector voltage checks and resistance checks Yes: Go to Step 5.
• and IMP connector voltage checks and resistance checks.
Are Barometric Absolute Pressure (BARO), EBP, and IMP circuits within No: Repair circuits as required.
specifications? After repairs are complete, retest
for SPN 1387 FMI 31.
If voltage checks pass, doing resistance checks is not required.

Step 5 Test BARO, EBP, and IMP for intermittent circuit operation. Decision
A. Perform Continuous Monitor Test (page 1361). Yes: End diagnostics, retest for
SPN 1387 FMI 31.
B. Verify EBP and IMP sensor voltages are within specifications (page 1677).
Are sensor voltages within specifications (page 1677)? No: Locate specific circuit
component causing erratic or
intermittent operation. Perform
voltage and resistance checks
in this section. Repair circuits
as required. After repairs are
complete, retest for SPN 1387
FMI 31.
758 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

End Diagnostic Test

After performing diagnostic steps, if SPN 1387 FMI 31 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 759

SPN 1659 FMI 20 - ECT1 below expected: Check Thermostat

Fault Overview
Fault sets when Engine Control Module (ECM) detects Engine Coolant Temperature (ECT) is not matching the
modeled value.

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

Associated Faults
SPN 110 FMI 2, 3, and 4
(ECT1)

Fault Facts
None

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• Thermostat stuck Open
• Engine fan stuck ON
• Low coolant level
• Engine Fan Control (EFC) short to GND
• Failed ECT1
760 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 759).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 1659 FMI 20.

Step 2 Check coolant level Decision

Perform visual inspection of deaeration tank level. Yes: Go to Step 3.
Is deaeration tank level between Cold level and Hot level? No: Fill or drain deaeration tank
to operating level. After repairs
are complete, retest for SPN 1659
FMI 20.

Step 3 Check for failed Engine Coolant Temperature 1 (ECT1) Decision

A. Key-Off. Yes: Go to Step 4.

B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector

(page 1345).
C. Key-On Engine-Off (KOEO), log in to Navistar® Engine Diagnostics.
D. Key-On Engine-Running (KOER).
E. Run engine at high idle.
F. Use Digital IR Thermometer ZTSE4799, measure temperature at ECT1
temperature sensor.
G. Compare temperature reading to ECT1 temperature in shown in EST.
Is thermometer reading within 30°F (17°C) of ECT1 reading? No: Replace ECT1 sensor. After
repairs are complete, retest for
SPN 1659 FMI 20.

Step 4 Decision
Perform Thermostat Operational Test (page 1608). Yes: Go to Step 5.
Does upper radiator hose temperature increase to ECT1 ± 25°F after engine warms No: Replace thermostat. After
up past thermostat opening temperature specification? repairs are complete, retest for
SPN 1659 FMI 20.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 761

Step 5 Check EFC for short to GND. Decision

A. Perform Test 1 (page 762). Yes: Diagnose fan clutch. After
repairs are complete, retest for
B. Use DMM, measure voltage between Breakout Harness ZTSE4908 pin-85
SPN 1659 FMI 20.
and PWR.
Is voltage less than 0.5 volts? No: Repair Short to GND between
Engine Fan Relay pin-85 and
ECM pin C-58. After repairs are
complete, retest for SPN 1659
FMI 20.

End Diagnostic Tests

After performing diagnostic steps, if SPN 1659 FMI 20 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
762 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 1659 FMI 20)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4908 (EFAN)
• Digital Multimeter (DMM)

Figure 222 Engine Fan Relay Circuit Check

Test 1
A. Key OFF.
B. Disconnect Engine Fan Relay connector.
C. Connect Breakout Harness ZTSE4908 to relay vehicle harness connector and leave Engine Fan Relay
connector disconnected.
D. Key ON Engine OFF (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 763

SPN 2623 FMI 3 - APP2 signal Out of Range HIGH

Fault Overview
Fault code sets when Electronic Control Module (ECM) detects that APP2 voltage is greater than 2.476 volts.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Key ON.
Possible Causes
• APP2 signal circuit short to PWR
• SIG GND circuit Open
• Failed APP sensor
764 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault code. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 2623 FMI 3.
Does EST DTC list show SPN 2623 FMI 3 as active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure
(page 1344).

Step 2 Inspect connections at Accelerator Pedal Position (APP) sensor Decision

connector
A. Key Off. Yes: Go to Step 3.
B. Disconnect APP sensor connector.
C. Check APP sensor and connector terminals for: damaged or pinched
wires; corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are APP sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN
2623 FMI 3.

Step 3 Decision
A. Key OFF. Yes: Go to Step 4.
B. Disconnect Accelerator Pedal Position (APP) sensor
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).
D. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
E. Use EST, clear DTC list.
Does fault code SPN 2623 FMI 4 set? No: Repair short to PWR between
APP connector pin-F and ECM
connector pin C-48. After repairs
are complete, retest for SPN 2623
FMI 3.

Step 4 Decision
A. Perform Test 1(page 766). Yes: Replace APP sensor. After
repairs are complete, retest for
B. Use Digital Multimeter (DMM), measure voltage between Breakout
SPN 2623 FMI 3.
Harness ZTSE4485A pin-E and B+.
Is voltage 12.0 ± 1.0 volts? No: Repair Open between APP
sensor connector pin-E and ECM
connector pin C-36. After repairs
are complete, retest for SPN 2623
FMI 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 765

End Diagnostic Tests

After performing diagnostic steps, if SPN 2623 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
766 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 2623 FMI 3)

Figure 223 APP Sensor Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4485A
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 767

Figure 224 APP Sensor Circuit Check

Test 1
A. Key-Off.
B. Disconnect Accelerator Pedal Position (APP) sensor.
C. Connect Breakout Harness ZTSE4485A to vehicle harness connector and leave APP sensor disconnected.
D. Key-On Engine-Off (KOEO).
768 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 2623 FMI 4 - APP2 signal Out of Range LOW

Fault Overview
Fault code sets when the Electronic Control Module (ECM) detects the Accelerator Pedal Position (APP) sensor
is reading lower than 0.273 volt on APP2 signal circuit.

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

Associated Faults
SPN 3511 FMI 3 and 4
(VREF 3)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• APP2 circuit Open
• APP2 circuit short to GND
• VREF 3 circuit Open
• Failed APP sensor

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 768).
Does EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 2623 FMI 4.

Step 2 Inspect connections at Accelerator Pedal Position (APP) sensor Decision

connector
A. Key OFF. Yes: Go to Step 3.

B. Disconnect APP sensor connector.

C. Check APP sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are APP sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness, or
terminal damage. After repairs are
complete, retest for SPN 2623 FMI
4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 769

Step 3 Check VREF circuit in APP sensor. Decision

A. Perform Test 1 (page 770). Yes: Go to Step 4.
B. Use DMM, measure voltage between Breakout Harness ZTSE4485A
pin-D and known good GND.
Is voltage 5 V ± 0.25 volts? No: Repair Open between APP
sensor connector pin-D and ECM
connector pin C-9. After repairs
are complete, retest for SPN 2623
FMI 4.

Step 4 Check APP sensor. Decision

A. Perform Test 2 (page 771). Yes: Replace APP sensor. After
repairs are complete, retest for
B. Use EST, clear DTC list.
SPN 2623 FMI 3.
Does SPN 2623 FMI 3 set? No: Go to Step 5.

Step 5 Check signal circuit in APP sensor. Decision

A. Perform Test 3 (page 772). Yes: Repair short to GND between
APP pin-F and ECM pin C-48.
B. Use EST, clear DTC list.
After repairs are complete, retest
for SPN 2623 FMI 4.
Does VREF fault code set? No: Repair Open between APP
pin-F and ECM pin C-48. After
repairs are complete, retest for
SPN 2623 FMI 4.

End Diagnostic Tests

After performing diagnostic steps, if SPN 2623 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
770 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 2623 FMI 4)

Figure 225 APP Sensor Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• 180-pin Breakout Box 00-00956-08
• Breakout Harness ZTSE4485A
• 3-Banana Plug Harness ZTSE4498
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 771

Figure 226 APP Sensor Circuit Check

Test 1
A. Key OFF.
B. Disconnect Accelerator Pedal Position (APP) sensor.
C. Connect Breakout Harness ZTSE4485A to vehicle harness connector and leave APP sensor disconnected.
D. Key ON Engine OFF (KOEO).
772 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 227 APP Sensor Circuit Check

Test 2
A. Key OFF.
B. Disconnect Accelerator Pedal Position (APP) sensor.
C. Connect Breakout Harness ZTSE4485A to vehicle harness connector and leave APP sensor disconnected.
D. Use 3-Banana Plug Harness ZTSE4498 short Breakout Harness ZTSE4485A pin-D to pin-F.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 773

Figure 228 APP Sensor Circuit Check

Test 3
A. Key OFF.
B. Disconnect Accelerator Pedal Position (APP) sensor.
C. Connect Breakout Harness ZTSE4485A to vehicle harness connector and leave APP sensor disconnected.
D. Use 3-Banana Plug Harness ZTSE4498 short Breakout Harness ZTSE4485A pin-D to pin-F.
E. Connect EST to vehicle Diagnostic (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
774 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 2630 FMI 2 - CACOT signal erratic, intermittent, or incorrect

Fault Overview
ECM compares Charge Air Cooler Outlet Temperature (CACOT) sensor to Intake Manifold Temperature (IMT),
Intake Air Temperature (IAT), Turbocharger 2 Compressor Intake Temperature (TC2CIT), Engine Coolant
Temperature 1 (ECT1), and Engine Oil Temperature (EOT) sensors after calibrated adjustable cold-soak period
(time).

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Initial Key ON
Possible Causes
• Biased CACOT sensor
• High resistance connections to CACOT sensor
• Shorted connections for CACOT sensor

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 2630 FMI 2.
Is EST DTC list SPN 2630 FMI 2 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Inspect connections at Charge Air Cooler Outlet Temperature (CACOT) Decision
connector.
A. Key OFF. Disconnect CACOT connector. Yes: Go to Step 3.
B. Check CACOT and connector terminals for: damaged or pinched wires;
moist or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are CACOT connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN
2630 FMI 2.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 775

Step 3 Check for a failed CACOT sensor. Decision

A. Key OFF. Disconnect CACOT sensor. Yes: Replace CACOT sensor.
After repairs are complete, retest
B. Connect Breakout Harness ZTSE4993 to vehicle harness and leave
for SPN 2630 FMI 2.
CACOT sensor disconnected.

C. Key-ON Engine-OFF (KOEO). Use DMM, measure voltage between

Breakout Harness ZTSE4993 pin-1 and pin-2.
Is voltage 5 ± 0.25 volts? No: Go to Step 4.

Step 4 Check for Open or high resistance in GND circuit. Decision

A. Key OFF. Disconnect CACOT sensor. Yes: Repair CACOT Open or
short between ECM pin E-65 and
B. Connect Breakout Harness ZTSE4993 to vehicle harness and leave
CACOT pin-2. After repairs are
CACOT sensor disconnected.
complete, retest for SPN 2630
C. Key-ON Engine-OFF (KOEO). Use DMM, measure resistance between FMI 2.
Breakout Harness ZTSE4993 between pin-1 and known good GND.
Is resistance less than 5 ohms? No: Repair Open or high
resistance between ECM pin E-28
and CACOT pin-1. After repairs
are complete, retest for SPN 2630
FMI 2.

End Diagnostic Tests

After performing diagnostic steps, if SPN 2630 FMI 2 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
776 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 2630 FMI 3 - CACOT signal Out of Range HIGH

Fault Overview
Fault Code sets when Engine Control Module (ECM) detects Charge Air Cooler Temperature (CACOT) sensor
voltage is greater than 4.70 volts.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• CACOT circuit short to PWR
• CACOT circuit Open
• SIG GND circuit Open
• Failed component

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for Yes: Go to Step 2.
SPN 2630 FMI 3.
Is EST DTC list SPN 2630 FMI 3 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Inspect connections at CACOT Decision

A. Key OFF. Yes: Go to Step 3.

B. Disconnect Charge Air Cooler Outlet Temperature (CACOT) sensor.

C. Check CACOT sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are CACOT sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 2630
FMI 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 777

Step 3 Check for Short to Power Decision

A. Perform Test 1(page 778). Yes: Repair short to PWR
between ECM pin E-65 and
B. Use DMM, measure voltage between Breakout Harness ZTSE4993 pin-2
CACOT pin-2. After repairs are
and known good GND.
complete, retest for SPN 2630
FMI 3.
Is voltage greater than 6 volts? No: Go to Step 4.

Step 4 Check for Open circuit Decision

A. Perform Test 2(page 778). Yes: Replace CACOT sensor.
After repairs are complete, retest
B. Use EST, clear DTC list.
for SPN 2630 FMI 3.
Does SPN 2630 FMI 4 set after DTC list is cleared? No: Go to Step 5.

Step 5 Check for Open in SIG GND circuit Decision

A. Perform Test 3(page 779). Yes: Repair Open between
CACOT pin-1 and ECM pin E-28.
B. Use EST, clear DTC list.
After repairs are complete, retest
for SPN 2630 FMI 3.
Does SPN 2630 FMI 3 set after DTC list is cleared? No: Repair Open between CACOT
pin-2 and ECM pin E-65. After
repairs are complete, retest for
SPN 2630 FMI 3.

End Diagnostic Tests

After performing diagnostic steps, if SPN 2630 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
778 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 2630 FMI 3)

Figure 229 CACOT Sensor Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4498
• Breakout Harness ZTSE4993
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Figure 230 CACOT Circuit Check

Test 1
A. Key OFF.

B. Disconnect Charge Air Cooler Temperature (CACOT) sensor.

C. Connect Breakout Harness ZTSE4993 to vehicle harness connector and leave CACOT disconnected.

D. Key ON Engine OFF (KOEO).

 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 779

Figure 231 SIG GND Circuit Check

Test 2
A. Key OFF.
B. Disconnect Charge Air Cooler Temperature (CACOT) sensor
C. Connect Breakout Harness ZTSE4993 to vehicle harness connector and leave CACOT disconnected.
D. Use Breakout Harness ZTSE4498 short Breakout Harness ZTSE4993 pin-1 and pin-2 together.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
780 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 232 CACOT Circuit Check

Test 3
A. Key OFF.
B. Disconnect Charge Air Cooler Temperature (CACOT) sensor
C. Connect Breakout Harness ZTSE4993 to vehicle harness connector and leave CACOT disconnected.
D. Use Breakout Harness ZTSE4498 short Breakout Harness ZTSE4993 pin-2 of known good GND.
E. Connect EST to vehicle Diagnostic Connector (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 781

SPN 2630 FMI 4 - CACOT signal Out of Range LOW

Fault Overview
Fault Code sets when Engine Control Module (ECM) detects Charge Air Cooler Outlet Temperature (CACOT)
signal is less than 0.11 volts.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Key ON
Possible Causes
• CACOT circuit short to ground
• Failed CACOT sensor
782 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 2630 FMI 4.
Is EST DTC list SPN 2630 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Inspect connections at Charge Air Cooler Outlet Temperature Decision

(CACOT) sensor.
A. Key OFF. Yes: Go to Step 3.
B. Disconnect CACOT electrical connector.
C. Check CACOT sensor and connector terminals for: damaged or pinched
wires; corroded terminals; loose, bent or broken pins; or broken connector
housing.
Are CACOT sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 2630
FMI 4.

Step 3 Decision
A. Key OFF. Yes: Replace CACOT sensor.
After repairs are complete, retest
B. Disconnect Charge Air Cooler Outlet Temperature (CACOT) sensor.
for SPN 2630 FMI 4.
C. Connect EST to vehicle Diagnostic Connector (page 1345).
D. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
E. Use EST, clear DTC list.
Does SPN 2630 FMI 3 set after DTC list is cleared? No: Repair short to ground
between CACOT pin-1 and
ECM pin E-65. After repairs are
complete, retest for SPN 2630
FMI 4.

End Diagnostic Tests

After performing diagnostic steps, if SPN 2630 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 783

SPN 2630 FMI 16 - CACOT Undercooling

Fault Overview
Fault sets when Engine Control Module (ECM) determines Charge Air Cooler (CAC) efficiency is below
programmed threshold.

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

Associated Faults
SPN 102 SPN 105 SPN 172 SPN 1173
SPN 2630 FMI 2, 3, and 4

Fault Facts
None

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• Winter front installed during warmer ambient temperatures
• Radiator or CAC damage
• Interstage Cooler (ISC) or coolant hoses damaged or pinched
• Low or contaminated coolant
• Engine fan, air dam, or fan shroud damaged
• High resistance in CACOT signal circuit
• High resistance in CACOT GND circuit
• Failed CACOT

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 783).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 2630 FMI 16.

Step 2 Check ECM calibration. Decision

Check calibration scorecard or use NavKal to check is ECM has latest calibration. Yes: Go to Step 3.
Is calibration up to date? No: Update calibration and retest
for SPN 2630 FMI 16.
784 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Determine if winter front (grille cover) is installed during warm Decision
temperatures.
Determine if a winter front (grille cover) is installed during warm temperatures. Yes: Go to Step 4
Is winter front (grille cover) removed during warm temperatures? No: Remove winter front (grille
cover). After repairs are complete,
retest for SPN 2630 FMI 16.

Step 4 Inspect vehicle radiator and CAC for damage or blockage. Decision
Perform following: Yes: Repair damage or blockage.
After repairs are complete, retest
A. Intake Air Inspection (page 1648) to inspect vehicle radiator and radiator
for SPN 2630 FMI 16.
grille for damage, blockage, or anything that could prevent proper air flow
through CAC and radiator.
B. Charge Air Cooler Inspection (page 1646)for damage, blockage, or
anything that could prevent proper air flow through CAC.
Is radiator, radiator grille, or CAC damaged or restricted? No: Go to Step 5.

Step 5 Inspect Interstage Cooler (ISC) coolant supply and return hoses. Decision
A. Inspect Interstage Cooler (ISC) coolant supply and return hoses for Yes: Go to Step 6.
incorrect routing, damage, and pinched hoses or pipes.
B. Inspect interstage cooler for external damage.
Are ISC and coolant supply and return hoses and pipes routed correct and No: Repair ISC or coolant hoses.
undamaged? After repairs are complete, retest
for SPN 2630 FMI 16.

Step 6 Perform coolant level inspection. Decision

Park vehicle on level ground. Yes: Go to Step 7.
• Perform Coolant Level Inspection (page 1637) and
• Coolant Quality Inspection (page 1638).
Is coolant level and quality correct? No: Go to Cooling System
Operational Checkout Procedure
(Step 2) (page 33). After repairs
are complete, retest for SPN 2630
FMI 16..

Step 7 Check fan, shroud, and air dams for damage and proper operation. Decision
Check engine fan, fan shroud, and air dams for damage and proper operation. Yes: Go to Step 8.
Are engine fan, fan shroud, and air dams intact and operating properly? No: Repair or replace engine fan,
fan shroud, and/or air dams. After
repairs are complete, retest for
SPN 2630 FMI 16.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 785

Step 8 Check for failed CACOT sensor. Decision

A. Perform Test 1 (page 786). Yes: Replace CACOT sensor.
After repairs are complete, retest
B. Use EST, monitor CACOT.
for SPN 2630 FMI 16.
Is temperature 302 ± 10°F (150 ± 6°C)? No: go to Step 9.

Step 9 Check for CACOT circuit fault. Decision

A. Perform Test 2 (page 787). Yes: Repair high resistance in
SIG GND circuit. After repairs are
B. Use EST, monitor CACOT.
complete, retest for SPN 2630
FMI 16.
Is temperature 302 ± 10°F (150 ± 6°C)? No: Repair high resistance in
CACOT circuit. After repairs are
complete, retest for SPN 2630
FMI 16.

End Diagnostic Test

After performing diagnostic steps, if SPN 2630 FMI 16 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
786 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 2630 FMI 16)

Figure 233 CACOT Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4498
• Breakout Harness ZTSE4497
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 787

Figure 234 CACOT Circuit Check

Test 1
A. Key-Off.
B. Disconnect Charge Air Cooler Outlet Temperature (CACOT) sensor.
C. Connect Breakout Harness ZTSE4993 to engine harness connector and leave CACOT sensor disconnected.
D. Connect Resistor Harness ZTSE4497 between Breakout Harness ZTSE4993 pin-1 and pin-2.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
F. Key-On Engine-Off (KOEO), log in to Navistar® Engine Diagnostics.
788 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 235 CACOT Circuit Check

Test 2
A. Key-Off.
B. Disconnect Charge Air Cooler Outlet Temperature (CACOT) sensor.
C. Connect Breakout Harness ZTSE4993 to engine harness connector and leave CACOT sensor disconnected.
D. Connect Resistor Harness ZTSE4497 between Breakout Harness ZTSE4993 pin-2 and known good GND.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
F. Key On Engine Off (KOEO), log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 789

SPN 2659 FMI 10 - EGR Slow Response Fault

Fault Overview
Fault sets when Engine Control Module (ECM) determines Exhaust Gas Recirculation (EGR) mass flow rate is
low.

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

Associated Faults
• SPN 27 (EGR) • SPN 2791 (EGR)

Fault Facts
Perform a MAF Sensor Calibration after doing repairs that change engine air intake, exhaust, or Exhaust Gas
Recirculation (EGR) flow characteristics.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Intake system leak or restriction
• Restricted air and EGR mixer housing
• Restricted EGR cooler
• Boost control system failure
• IMP sensor failure
• IMP sensor bore restriction
790 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults.
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 2659 FMI 10.

Step 2 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 2659 FMI 10. Yes: Go to Step 3.
Is SPN 2659 FMI 10 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 2659 FMI 10.

Step 3 Inspect connections at Exhaust Gas Recirculation (EGR) valve. Decision

A. Key-Off. Yes: Go to Step 4.
B. Disconnect EGR valve connector.
C. Check EGR valve and connector for: damaged or pinched wires; wet
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are EGR valve connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 2659
FMI 10.

Step 4 Inspect intake air system for leaks. Decision

Perform Intake Air Inspection (page 1648). Yes: Go to Step 5.
Is intake air system clear of damage or restrictions? No: Repair intake air system.
After repairs are complete, Go to
Step 8.

Step 5 Determine if air management system is operating properly. Decision

Perform Air Management Test (page 1376). Yes: Perform Boost Control
System Test (page 1533). Repair
or replace failed component(s).
After repairs are complete, go to
Step 8.
Is Intake Manifold Pressure (IMP), and MAF Mean Value Difference within No, IMP not in specification: Go
specification? to Step 6.
No, only MAF Mean Value
Difference not in specification: Go
to Step 7.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 791

Step 6 Determine if KOEO IMP is within specification, and IMP sensor bore Decision
is not restricted.
A. Key-Off. Yes: Perform Boost Control
System Test (page 1533). Repair
B. Use EST with Navistar® Engine Diagnostics, select: Pressure tab.
or replace failed component(s).
C. Compare Intake Manifold Pressure value to KOEO specification. After repairs are complete, go to
Step 8.
D. Remove IMP sensor and inspect sensor and bore for carbon buildup and
restrictions.
Is IMP within KOEO specification, and is sensor bore free of restrictions? No, KOEO IMP out of
specification: replace IMP sensor.
After repairs are complete, go to
Step 8.
No, sensor or bore restricted:
clean sensor and/or bore. After
repairs are complete, go to Step
8.

Step 7 Determine if air and EGR mixer duct is restricted. Decision

A. Remove Engine Throttle Value (ETV) assembly. See Engine Service Yes: Remove and clean air and
Manual. EGR mixer duct. Do not replace
EGR Valve. Replace O-rings
B. Inspect air and EGR mixer duct assembly for restrictions and carbon
if needed. After repairs are
build up.
complete, go to Step 8.
Is a severe amount of carbon restricting air and EGR mixer duct? No: Install new EGR Cooler core.
After repairs are complete, go to
Step 8.

Step 8 Check MAF sensor calibration. Decision

Perform MAF Sensor Calibration (page 1539). Yes: End diagnostics. Retest for
SPN 2659 FMI 10.
Did MAF sensor calibration run successfully without setting codes? No: Repair MAF fault codes. After
repairs are complete, retest for
SPN 2659 FMI 10.

End Diagnostic Tests

After performing all diagnostic steps, if SPN 2659 FMI 10 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
792 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 2659 FMI 14 - EGR System flow rate error during Air Management Test

Fault Overview
Fault code sets when the difference between high and low Mass Air Flow (MAF) readings exceed a set threshold
during Air Management Test.

Lamp Reaction
None.

Associated Faults
• SPN 27 (EGR) • SPN 2791 (EGR)

Fault Facts
You are able to analyze the Air Management Test results even if fault became active during the test.
Perform MAF Sensor Calibration after doing repairs that change engine air intake, exhaust, or Exhaust Gas
Recirculation (EGR) flow characteristics.

Drive Cycle to Determine Fault Status

Air Management Test (page 1376)
Possible Causes
• Soot build up on EGRV
• Intake system leak or restriction
• Restricted air and EGR mixer housing
• Restricted EGR cooler

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 792).
Is EST DTC list clear of Associated Faults (page 792)? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 2659 FMI 14.

Step 2 Test for proper Exhaust gas Recirculation Valve Operation. Decision
Perform Exhaust Gas Recirculation Valve (EGRV) Operational Test (page 1543). Yes: Replace EGR valve. Perform
MAF Sensor Calibration (page
1539). After repairs are complete,
retest for SPN 2659 FMI 14.
Is SPN 2791 FMI 7 or SPN 27 FMI 7 Pending or Active in DTC list after running test? No: Go to Step 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 793

Step 3 Inspect intake air system for leaks. Decision

Perform Intake Air Inspection (page 1648). Yes: Go to Step 4.
Is intake air system clear of damage or restrictions? No: Repair intake air system.
Perform MAF Sensor Calibration
(page 1539). After repairs are
complete, retest for SPN 2659
FMI 14.

Step 4 Determine if air and EGR mixer duct is restricted. Decision

A. Remove Engine Throttle Value (ETV) assembly. See Engine Service Yes: Remove and clean air and
Manual. EGR mixer duct. Do not replace
EGR Valve. Replace O-rings if
B. Inspect air and EGR mixer duct assembly for restrictions and carbon
needed. Perform MAF Sensor
build up.
Calibration (page 1539). After
repairs are complete, retest for
SPN 2659 FMI 14.
Is a severe amount of carbon restricting air and EGR mixer duct? No: Install new EGR Cooler.
Perform MAF Sensor Calibration
(page 1539). After repairs are
complete, retest for SPN 2659
FMI 14.

End Diagnostic Tests

After performing all diagnostic steps, if SPN 2659 FMI 14 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
794 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 2659 FMI 20 - EGR High Flow Rate detected

Fault Overview
Fault code sets when Engine Control Module (ECM) detects high Exhaust Gas Recirculation (EGR) flow rate.

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

Associated Faults
• SPN 27 FMI 14 • SPN 51 FMI 3, 4, and 7 • SPN 102 FMI 2, 3, 4, 7, • SPN 105 FMI 2, 3, and 4
and 18
• SPN 172 FMI 2, 3, and 4 • SPN 2791 FMI 3, 4, 7, 8, • SPN 3464 FMI 31 • SPN 4752 FMI 4
and 14

Fault Facts
Ensure correct Programmable Parameter (PP) is programmed for air induction system.

Drive Cycle to Determine Fault Status

Key ON
Possible Causes
• EGR valve stuck open or damaged O-rings
• Induction system leaks
• Excessive exhaust back pressure
• MAF sensor calibration

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 794).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 2659 FMI 20.

Step 2 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 2659 FMI 20. Yes: Go to Step 3.
Is SPN 2659 FMI 20 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 2659 FMI 20.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 795

Step 3 Inspect Intake Air System for leaks. Decision

Perform Intake Air Inspection (page 1648). Yes: Repair air (boost) leaks.
After repairs are complete, retest
for SPN 2659 FMI 20.
Is air intake air system leaking? No: Go to Step 4.

Step 4 Exhaust Gas Recirculation (EGR) Operational Test. Decision

Perform EGR Operational Test (page 1543). Yes: Replace EGR valve. After
repairs are complete, retest for
SPN 2659 FMI 20.
Are there any active SPN 2791 or SPN 27 fault codes active? No: Go to Step 5.

Step 5 Determine if MAF Sensor Calibration will pass. Decision

Perform MAF Sensor Calibration (page 1539). Yes: Clear previously active MAF
fault. After repairs are complete,
retest for SPN 2659 FMI 20.
Did MAF Sensor Calibration pass? No: Go to MAF fault code
diagnostics.

End Diagnostic Tests

After performing all diagnostic steps, if SPN 2659 FMI 20 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
796 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 2659 FMI 21 - EGR Low Flow Rate Detected

Fault Overview
Fault sets when Engine Control Module (ECM) determines EGR mass flow rate is low.

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

Associated Faults

• SPN 27 (EGR) • SPN 2791 (EGR)

Fault Facts
Perform MAF Sensor Calibration after doing repairs that change engine air intake, exhaust, or Exhaust Gas
Recirculation (EGR) flow characteristics.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Intake system leak or restriction
• Restricted air and EGR mixer housing
• Restricted EGR cooler
• Boost control system failure
• IMP sensor failure
• IMP sensor bore restriction
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 797

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 796).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 2659 FMI 21.

Step 2 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 2659 FMI 21. Yes: Go to Step 3.
Is SPN 2659 FMI 21 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 2659 FMI 21.

Step 3 Inspect connections at Exhaust Gas Recirculation (EGR) valve. Decision

A. Key-Off. Yes: Go to Step 4.
B. Disconnect EGR valve connector.
C. Check EGR valve and connector for: damaged or pinched wires; wet
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are EGR valve connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 2659
FMI 21.

Step 4 Inspect intake air system for leaks. Decision

Perform Intake Air Inspection (page 1648). Yes: Go to Step 5.
Is intake air system clear of damage or restrictions? No: Repair intake air system.
After repairs are complete,
perform MAF Sensor Calibration
(page 1539)and retest for SPN
2659 FMI 21.
798 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 5 Determine if air management system is operating properly. Decision

Perform Air Management Test (page 1376). Yes: Perform Boost Control
System Test (page 1533). Repair
or replace failed component(s).
After repairs are complete,
perform MAF Sensor Calibration
(page 1539)and retest for SPN
2659 FMI 21.
Is Intake Manifold Pressure (IMP), and MAF Mean Value Difference within No, IMP not in specification: Go
specification? to Step 6.
No, only MAF Mean Value
Difference not within specification:
Go to Step 7.

Step 6 Determine if KOEO IMP is within specification, and IMP sensor bore Decision
is not restricted.
A. Key-Off. Yes: Perform Boost Control
®
System Test (page 1533). Repair
B. Use EST Navistar Engine Diagnostics, select: Pressure tab.
or replace failed component(s).
C. Compare Intake Manifold Pressure value to KOEO specification. After repairs are complete,
perform MAF Sensor Calibration
D. Remove IMP sensor and inspect sensor and bore for carbon buildup and
(page 1539)and retest for SPN
restrictions.
2659 FMI 21.
Is IMP within KOEO specification, and is sensor bore free of restrictions? No, KOEO IMP out of
specification: replace IMP sensor.
After repairs are complete,
perform MAF Sensor Calibration
(page 1539)and retest for SPN
2659 FMI 21.
No, sensor or bore restricted:
clean sensor and/or bore. After
repairs are complete, perform
MAF Sensor Calibration (page
1539)and retest for SPN 2659
FMI 21.

Step 7 Determine if air and EGR mixer duct is restricted. Decision

A. Remove Engine Throttle Value (ETV) assembly. See Engine Service Yes: Remove and clean air and
Manual. EGR mixer duct. Do not replace
EGR valve. Replace O-rings
B. Inspect air and EGR mixer duct assembly for restrictions and carbon
if needed. After repairs are
build up.
complete, perform MAF Sensor
Calibration (page 1539)and retest
for SPN 2659 FMI 21.
Is a severe amount of carbon restricting air and EGR mixer duct? No: Install new EGR Cooler
core. After repairs are complete,
perform MAF Sensor Calibration
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 799

(page 1539)and retest for SPN

2659 FMI 21.

End Diagnostic Test

After performing diagnostic steps, if SPN 2659 FMI 21 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
800 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 2791 FMI 2 - EGR valve communication fault

Fault Overview
Fault sets when Engine Control Module (ECM) fails to detect rising edge of a response pulse on Exhaust Gas
Recirculation (EGR) position signal line within 0.0057 seconds following commanded position change.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• EGRP circuit Open
• EGRP circuit short to PWR
• EGRP circuit short to GND
• ACT PWR circuit Open or blown fuse
• ACT PWR circuit short to GND
• Failed EGR valve

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for Yes: Go to Step 2.
SPN 2791 FMI 2.
Is SPN 2791 FMI 2 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 2 Inspect connections at Exhaust Gas Recirculation Valve (EGRV). Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect EGRV connector.

C. Check EGRV and connector for: damaged or pinched wires; wet or

corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are EGRV connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN
2791 FMI 2.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 801

Step 3 Inspect connections at Turbocharger 2 Wastegate Control (TC2WC) Decision

solenoid.
A. Key OFF. Yes: Go to Step 4.
B. Disconnect TC2WC solenoid connector.

C. Check TC2WC solenoid and connector for: damaged or pinched wires;

wet or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are TC2WC connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 2791
FMI 2.

Step 4 Check EGRP circuit for short to PWR Decision

A. Perform Test 1 (page 803). Yes: Go to Step 5.
B. Use DMM, measure voltage between Breakout Harness ZTSE4948 pin-1
and known good GND.
Is voltage less than 5.5 volts? No: Repair short to PWR between
EGRV connector pin-1 and ECM
connector pin C-26. After repairs
are complete, retest for SPN 2791
FMI 2.

Step 5 Check EGRP circuit for Open. Decision

A. Perform Test 2 (page 804). Yes: Go to Step 7.
B. Use DMM, measure voltage between Breakout Harness ZTSE4948 pin-1
and known good GND.
Is voltage greater than 4.5 volts? No: Go to Step 6.

Step 6 Check EGRP circuit for short to GND. Decision

A. Perform Test 3 (page 805). Yes: Repair Open between
EGRV connector pin-1 and ECM
B. Use DMM, measure resistance between Breakout Harness ZTSE4948
connector pin C-26. After repairs
pin-1 and known good GND.
are complete, retest for SPN 2791
FMI 2.
Is resistance greater than 1000 ohms? No: Repair short to GND between
EGRV connector pin-1 and ECM
connector pin C-26. After repairs
are complete, retest for SPN 2791
FMI 2.
802 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 7 Check ACT PWR circuit for Open or blown fuse. Decision
A. Perform Test 4 (page 805). Yes: Go to Step 10.
B. Use DMM, measure voltage between Breakout Harness ZTSE4948 pin-4
and known good GND.
Is voltage greater than 9 volts? No: Go to Step 8.

Step 8 Check ACT PWR circuit for short to GND. Decision

A. Perform Test 5 (page 806). Yes: Replace TC2WC solenoid.
After repairs are complete, retest
B. Use DMM, measure voltage between Breakout Harness ZTSE4948 pin-4
for SPN 2791 FMI 2.
and known good GND.
Is voltage greater than 9 volts? No: Go to Step 9.

Step 9 Check ACT PWR circuit for short to GND Decision

A. Perform Test 6 (page 807). Yes: Repair Open between ACT
PWR Relay pin-87 and EGRV
B. Use DMM, measure resistance between Breakout Harness ZTSE4948
connector pin-4. After repairs are
pin-4 and known good GND
complete, retest for SPN 2791
FMI 2.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ACT PWR Relay pin-87 and
EGRV connector pin-4. After
repairs are complete, retest for
SPN 2791 FMI 2.

Step 10 Check for failed Exhaust Gas Recirculation Valve (EGRV). Decision
A. Key OFF. Yes: Replace EGRV. After repairs
are complete, retest for SPN 2791
B. Connect TC2WC engine harness connector to wastegate.
FMI 2.
C. Perform Exhaust Gas Recirculation Valve (EGRV) Operational Test (page
1543).
Is SPN 2791 FMI 2 or 7 active or pending? No: End diagnostics, retest for
SPN 2791 FMI 2.

End Diagnostic Tests

After performing diagnostic steps, if SPN 2791 FMI 2 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 803

Pin-Point Tests (SPN 2791 FMI 2)

Figure 236 EGR Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4948
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant, supporting J1939 and J1708)
804 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 237 EGRV Circuit Check

Test 1
A. Key OFF.
B. Disconnect Exhaust Gas Recirculation Valve (EGRV).
C. Connect Breakout Harness ZTSE4948 to vehicle harness connector and leave EGRV disconnected.
D. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 805

Figure 238 EGRV Circuit Check

Test 2
A. Key OFF.
B. Disconnect Exhaust Gas Recirculation Valve (EGRV).
C. Connect Breakout Harness ZTSE4948 to vehicle harness connector and leave EGRV disconnected.
D. Key-On Engine-Off (KOEO).

Figure 239 EGRV Circuit Check

Test 3
A. Key OFF.
B. Disconnect Exhaust Gas Recirculation Valve (EGRV).
C. Connect Breakout Harness ZTSE4948 to vehicle harness connector and leave EGRV disconnected.
806 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 240 EGRV Circuit Check

Test 4
A. Key OFF.
B. Disconnect Exhaust Gas Recirculation Valve (EGRV).
C. Connect Breakout Harness ZTSE4948 to vehicle harness connector and leave EGRV disconnected.
D. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 807

Figure 241 EGRV Circuit Check

Test 5
A. Key-Off.
B. Disconnect Turbocharger 2 Wastegate Control (TC2WC) solenoid connector and leave solenoid disconnected.
C. Disconnect Exhaust Gas Recirculation Valve (EGRV) connector.
D. Connect Breakout Harness ZTSE4948 to engine harness connector and leave EGRV disconnected.
E. Key-On, Engine-Off (KOEO).
808 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 242 EGRV Circuit Check

Test 6
A. Key-Off.
B. Disconnect Turbocharger 2 Wastegate Control (TC2WC) solenoid connector and leave solenoid disconnected.
C. Disconnect Exhaust Gas Recirculation Valve (EGRV) connector.
D. Connect Breakout Harness ZTSE4948 to engine harness connector and leave EGRV disconnected.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 809

SPN 2791 FMI 3 - EGRV Supply Voltage is Too HIGH

Fault Overview
This fault sets when Exhaust Gas Recirculation (EGR) valve receives a voltage supply of greater than 18 volts
for 5 seconds.

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

Associated Faults
None

Fault Facts
This is not an EGR valve problem; it is a voltage supply problem.
Fault code may set if vehicle was jump started or charged using a 24-volt power supply.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Charging voltage excessive
• Incorrect battery pack wiring (series instead of parallel)
810 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for Yes: Go to Step 2.
SPN 2791 FMI 3.
Is SPN 2791 FMI 3 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Figure 243 Check Battery Pack Wiring

Step 2 Check for correct parallel battery pack wiring. Decision

Check positive battery cable(s) connected from positive battery terminal to positive Yes: Go to Step 3.
battery terminal. Check negative battery cable(s) connected from negative battery
terminal to negative battery terminal.
Is battery pack correctly assembled (wired in parallel and not in series)? No: Reassemble battery pack.
After repairs are complete, retest
for SPN 2791 FMI 3.

Step 3 Check for proper operation of battery pack and alternator. Decision
Perform Electrical System Test (page 1577). Yes: Repair or replace failed
components identified by test.
After repairs are complete, retest
for SPN 2791 FMI 3.
Did test identify an electrical system failure? No: End diagnostics. Retest for
SPN 2791 FMI 3.

End Diagnostic Tests

After performing diagnostic steps, if SPN 2791 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 811

SPN 2791 FMI 4 - EGRV supply voltage is too LOW

Fault Overview
This fault sets when Exhaust Gas Recirculation (EGR) valve receives a voltage supply of less than 8 volts for
13 seconds.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Battery, starting, or charging system failure
• ACT PWR Open or short to GND
• ACT GND Open or high resistance
• Failed EGR valve
812 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for Yes: Go to Step 2.
SPN 2791 FMI 4.
Is SPN 2791 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Check KOER battery voltage Decision

A. Key-Off. Yes: Go to Step 6.
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).
C. Key On Engine Off (KOEO), log in to Navistar® Engine Diagnostics.
D. Key-On Engine-Running (KOER).
E. Measure battery voltage.
Is KOER battery voltage less than 8 volts? No: Go to Step 3.

Step 3 Inspect connections at Engine Gas Recirculation Valve (EGRV) Decision

connector.
A. Key-Off. Yes: Go to Step 4.
B. Disconnect EGRV connector.
C. Check EGRV and connector terminals for: damaged or pinched wires;
moist or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are EGRV connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 2791
FMI 4.

Step 4 Check ACT PWR circuit for failure. Decision

A. Perform Test 1 (page 814). Yes: Go to Step 5.
B. Use DMM, measure voltage between Breakout Harness ZTSE4948 pin-4
and known good GND.
Is voltage B+ ± 0.5 volts? No: Repair Open or short to GND
between EGRV pin-4 and ACT
PWR relay pin-87. After repairs
are complete, retest for SPN 2791
FMI 4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 813

Step 5 Check ACT GND circuit for failure. Decision

A. Perform Test 2 (page 816). Yes: Replace EGRV. After repairs
are complete, retest for SPN 2791
B. Use DMM, measure voltage between Breakout Harness ZTSE4948 pin-3
FMI 4.
and PWR.
Is voltage B+ ± 0.5 volts? No: Repair Open or high
resistance between EGRV pin-3
and GND. After repairs are
complete, retest for SPN 2791
FMI 4.

Step 6 Inspect batteries, electrical system, and connections. Decision

Perform Batteries and Electrical System Inspection (page 1666). Yes: Go to Step 7.
Are batteries, electrical system, and connections in good condition, tight, and not No: Repair broken, loose,
corroded? or corroded electrical system
connections or components. After
repairs are complete, retest for
SPN 2791 FMI 4.

Step 7 Test battery pack and charging system Decision

Perform Electrical System Test (page 1577). Yes: End diagnostics, retest for
SPN 2791 FMI 4.
Did battery pack and charging system pass testing? No: Perform all necessary repairs.
After repairs are complete, retest
for SPN 2791 FMI 4.

End Diagnostic Tests

After performing diagnostic steps, if SPN 2791 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
814 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 2791 FMI 4)

Figure 244 EGR Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4948
• Digital Multimeter (DMM)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 815

Figure 245 EGR Circuit Check

Test 1
A. Key-Off.
B. Disconnect Exhaust Gas Recirculation Valve (EGRV) connector.
C. Connect Breakout Harness ZTSE4948 to vehicle harness, leave EGRV disconnected.
D. Key-On Engine-Running (KOER).
816 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 246 EGR Circuit Check

Test 2
A. Key-Off.
B. Disconnect Exhaust Gas Recirculation Valve (EGRV) connector.
C. Connect Breakout Harness ZTSE4948 to vehicle harness, leave EGRV disconnected.
D. Key-On Engine-Running (KOER).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 817

SPN 2791 FMI 7 - EGR Valve unable to achieve commanded position

Fault Overview
Fault code sets when Engine Control Module (ECM) determines Exhaust Gas Recirculation (EGR) valve is Not
functioning properly when commanded.

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

Associated Faults
SPN 2791 FMI 2, 3, 4, 8,
and 14 (EGR)

Fault Facts
This fault is also used to detect EGR valve positive and negative deviation faults.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Exhaust Gas Recirculation (EGR) valve motor internal duty cycle greater than 95%
• EGR valve motor stuck
• Deposits on EGR valve
• Stuck or sticking EGR valve
818 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 817).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 2791 FMI 7.

Step 2 Inspect connections at Exhaust Gas Recirculation Valve (EGRV). Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect EGRV connector.
C. Check EGRV connector for: damaged or pinched wires; wet or corroded
terminals; loose, bent, or broken pins; or broken connector housing.
Are EGRV connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 2791
FMI 7.

Step 3 Test for proper Exhaust Gas Recirculation Valve (EGRV) operation. Decision
Perform Exhaust Gas Recirculation Valve (EGRV) Operational Test (page 1543). Yes: Replace EGR valve. Notify
supervisor for further action.
Is SPN 2791 FMI 7 Pending or Active in DTC list? No: End Diagnostics. After
repairs are complete, retest for
SPN 2791 FMI 7.

End Diagnostic Steps

After performing diagnostic steps, if SPN 2791 FMI 7 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 819

SPN 2791 FMI 8 - EGR valve not receiving ECM PWM signal

Fault Overview
Fault code sets when the Engine Control Module (ECM) detects a failure of the Exhaust Gas Recirculation Valve
Control (EGRV CTL) circuit.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed ACT PWR relay
• EGRV CTL circuit Open
• EGRV CTL circuit short to GND
• EGRV CTL circuit short to PWR
• Failed Exhaust Gas Recirculation Valve (EGRV)
820 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 2791 FMI 8.
Is EST DTC list SPN 2791 FMI 8 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 2791 FMI 8.

Step 2 Inspect connections at Engine Gas Recirculation Valve (EGRV) Decision

connector.
A. Key-Off. Yes: Go to Step 3.
B. Disconnect EGRV connector.
C. Check EGRV and connector terminals for: damaged or pinched wires;
moist or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are EGRV connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 2791
FMI 8.

Step 3 Check ACT PWR circuit for PWR. Decision

A. Perform Test 1 (page 823). Yes: Go to Step 4.
B. Use DMM, measure voltage between Breakout Harness ZTSE4948 pin-4
and known good GND.
Is voltage B+ ± 0.5 volts? No: Go to Step 7.

Step 4 Check EGRV CTL circuit for short to GND. Decision

A. Perform Test 2 (page 824). Yes: Repair short to GND
between EGRV pin-2 and ECM
B. Use DMM, measure voltage between Breakout Harness ZTSE4948 pin-2
pin E-71. After repairs are
and PWR.
complete, retest for SPN 2791
FMI 8.
Is voltage B+ ± 0.5 volts? No: Go to Step 5.

Step 5 Check EGRV CTL circuit for short to PWR. Decision

A. Perform Test 3 (page 824). Yes: Repair short to PWR
between EGRV pin-2 and ECM
B. Use DMM, measure voltage between Breakout Harness ZTSE4948 pin-2
pin E-71. After repairs are
and known good GND.
complete, retest for SPN 2791
FMI 8.
Is voltage B+ ± 0.5 volts? No: Go to Step 6.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 821

Step 6 Check EGRV CTL circuit for an Open. Decision

A. Perform Test 4 (page 825). Yes: Replace EGRV. After repairs
are complete, retest for SPN
B. Use DMM, measure % duty cycle between Breakout Harness ZTSE4948
2791 FMI 8.
pin-2 and known good GND.
Is duty cycle between 5 and 95%? No: Repair Open circuit between
EGRV pin-2 and ECM pin E-71.
After repairs are complete, retest
for SPN 2791 FMI 8.

Step 7 Inspect connections at ACT PWR Relay connector. Decision

A. Key-Off. Yes: Go to Step 8.
B. Disconnect ACT PWR Relay connector.
C. Check ACT PWR Relay and connector terminals for: damaged or pinched
wires; moist or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are ACT PWR Relay connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 2791
FMI 8.

Step 8 Check ACT PWR circuit for short to PWR. Decision

A. Perform Test 5 (page 826). Yes: Repair Open between ACT
PWR relay pin-87 and EGRV
B. Use DMM, measure voltage between Breakout Harness ZTSE4674 pin-87
pin-4. After repairs are complete,
and known good GND.
retest for SPN 2791 FMI 8.
Is voltage B+ ± 0.5 volts? No: Go to Step 9.

Step 9 Check ACT PWR circuit for short to GND. Decision

A. Perform Test 6 (page 827). Yes: Go to Step 10.
B. Use DMM, measure voltage between Breakout Harness ZTSE4674 pin-85
and PWR.
Is voltage B+ ± 0.5 volts? No: Repair Short to GND between
ACT PWR Relay pin-85 and
ECM pin E-70. After repairs are
complete, retest for SPN 2791
FMI 8.
822 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 10 Determine if ACT PWR relay is operating properly. Decision

A. Key-Off. Yes: Replace ACT PWR relay.
After repairs are complete, retest
B. Disconnect Actuator Power (ACT PWR) relay connector.
for SPN 2791 FMI 8.
C. Connect Breakout Harness ZTSE4674 to vehicle harness and leave ACT
PWR relay disconnected.

D. Use DMM, measure voltage between Breakout Harness pin-30 and

pin-86, and GND.
Is voltage B+ ± 0.5 volts? No: Repair circuit between ACT
PWR Relay and B+. After repairs
are complete, retest for SPN 2791
FMI 8.

End Diagnostic Steps

After performing diagnostic steps, if SPN 2791 FMI 8 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 823

Pin-Point Tests (SPN 2791 FMI 8)

Figure 247 EGR Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4948
• Breakout Harness ZTSE4674
• Digital Multimeter (DMM)
824 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 248 EGR Circuit Check

Test 1
A. Key-Off.
B. Disconnect Exhaust Gas Recirculation Valve (EGRV) connector.
C. Connect Breakout Harness ZTSE4948 to vehicle harness and leave EGRV disconnected.
D. Key-ON Engine-OFF (KOEO).

Figure 249 EGR Circuit Check

Test 2
A. Key-Off.

B. Disconnect EGRV connector.

C. Connect Breakout Harness ZTSE4948 to vehicle harness and leave EGRV disconnected.
D. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 825

Figure 250 EGR Circuit Check

Test 3
A. Key-Off.
B. Disconnect EGRV connector.
C. Connect Breakout Harness ZTSE4948 to vehicle harness and leave EGRV disconnected.
D. Key-On Engine-Off (KOEO).
826 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 251 EGR % Duty Cycle

Test 4
A. Key-Off.
B. Disconnect EGRV connector.
C. Connect Breakout Harness ZTSE4948 to vehicle harness and leave EGRV disconnected.
D. Use DMM set to % duty cycle to measure duty cycle.
E. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 827

Figure 252 ACT PWR Relay Circuit Check

Test 5
A. Key-Off.
B. Disconnect ACT PWR relay connector.
C. Connect Breakout Harness ZTSE4674 between vehicle harness and ACT PWR relay.
D. Key-On Engine-Off (KOEO).

Figure 253 ACT PWR Relay Circuit Check

Test 6
A. Key-Off.

B. Disconnect ACT PWR relay connector.

C. Connect Breakout Harness ZTSE4674 to vehicle harness and leave ACT PWR relay disconnected.
D. Key-On Engine-Off (KOEO).
828 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 2791 FMI 12 - EGR Valve Internal self test fault

Fault Overview
Fault code sets when Engine Control Module (ECM) detects seated Exhaust Gas Recirculation (EGR) valve
position has increased by 2 mm during a single drive cycle.

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected during one drive cycle.

Associated Fault
None

Fault Facts
Exhaust Gas Recirculation (EGR) valve seat position is recorded during initial Key OFF.

Drive Cycle to Determine Fault Status

Key ON then Key OFF
Possible Causes
• Failed EGRV
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 829

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list Yes: Replace EGRV. After repairs
for SPN 2791 FMI 12. are complete, retest for SPN 2791
FMI 12.
Is SPN 2791 FMI 12 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 2791 FMI 12.

End Diagnostic Steps

After performing diagnostic steps, if SPN 2791 FMI 12 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
830 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 2791 FMI 14 - EGR valve Initialization Fault

Fault Overview
Fault sets when Engine Control Module (ECM) determines Exhaust Gas Recirculation (EGR) valve is not
functioning properly when initialized.

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

Associated Fault
SPN 2791 FMI 7 (EGRV)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• EGR valve unable to seat closed
• Stuck or sticking EGR valve
• Failed EGR valve
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 831

Step 1 Check for associated fault code. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 830).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 2791 FMI 14.

Step 2 Inspect connections at Exhaust Gas Recirculation Valve (EGRV). Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect EGRV connector.
C. Check EGRV and connector for: damaged or pinched wires; wet or
corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are EGRV connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 2791
FMI 14.

Step 3 Test for proper Exhaust Gas Recirculation Valve (EGRV) operation. Decision
Perform Exhaust Gas Recirculation Valve (EGRV) Operational Test (page 1543). Yes: Replace EGRV. After repairs
are complete, retest for SPN 2791
FMI 14.
Is SPN 2791 FMI 7 active or pending? No: End Diagnostics. After repairs
are complete, retest for SPN 2791
FMI 14.

End Diagnostic Steps

After performing diagnostic steps, if SPN 2791 FMI 14 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
832 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 2796 FMI 2 - Transfer Case Switch or Circuit Fault

Fault Overview

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Transfer Case Switch (XCS) not responding via CAN
• Non-Controller Area Network (CAN) XCS stuck in range
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 833

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 2796 FMI 2.
Is SPN 2796 FMI 2 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect Transfer Case Switch (XCS) and connector. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect XCS sensor.
C. Check XCS sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are XCS connectors, harnesses, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 2796
FMI 2.

Step 3 Test for intermittent circuit operation Decision

A. Key OFF Yes: Go to Step 4.
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).
C. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
D. Do Key On Engine Off Continuous Monitor Test (page 1361).
Are sensor voltages within specification (page 1677)? No: Locate specific circuit
component causing erratic or
intermittent operation. Perform
voltage and resistance checks
in this section. Repair circuits
as required. After repairs are
complete, retest for SPN 2796
FMI 2.

Step 4 Decision
Test XCS circuits for open, short, or high resistance conditions. Do connector Yes: Go to Step 5.
voltage checks and resistance checks (page 835).
Are XCS circuits within specifications? No: Replace XCS. After repairs
are complete retest for SPN 2796
If voltage checks pass, doing resistance checks is not required.
FMI 2.
834 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 5 Decision
A. Key On. Yes: After doing all diagnostic
steps, if SPN 2796 FMI 2 remains,
B. Use DMM, do KOEO voltage check of J1939 signal and ground at
verify each step was completed
Diagnostic Connector.
correctly and proper decisions
were made. Notify supervisor for
further action.
Is voltage within specification (page 1704)? No: Replace J1939 cable. After
repairs are complete retest for
SPN 2796 FMI 2.

End Diagnostic Test

After performing diagnostic steps, if SPN 2796 FMI 2 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 835

Pin-Point Tests (SPN 2796 FMI 2)

Figure 254 Transfer Case Circuit Diagram

Connector Voltage Check

Connect sensor Breakout Harness to engine harness. Leave sensor disconnected. Turn ignition switch to ON. Use
DMM to measure voltage.
Test Point Specification Comment: < Less than, > Greater than
TBD to B+ B+ If < B+, check for OPEN or short to PWR.
TBD to GND 4.6 to 5 V If < 4.5 volts, check for OPEN or short to GND. Go to Harness Resistance Check.

Harness Resistance Check

Turn ignition switch to OFF. Connect 180-pin Breakout Box and sensor Breakout Harness. Leave ECM and sensor
disconnected.
Test Point Specification Comment: < Less than, > Greater than
1 to TBD <5Ω If > 5 Ω, check for OPEN circuit.
2 to TBD <5Ω If > 5 Ω, check for OPEN circuit.
836 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 2797 FMI 3 - Injector Control Group 1 open coil short

Fault Overview
Fault code sets when short circuit is detected on Bank 0 (Injectors 1, 2, and 3) Open coil.

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

Associated Faults

• SPN 651-653 FMI 4 and 5 (INJ) • SPN 3659-3661 FMI 4 and

5 (INJ)

Fault Facts
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed Injector
• Injector 1 Open H Short to Open L
• Injector 2 Open H Short to Open L
• Injector 3 Open H Short to Open L
• Injector 1 Open Coil H Short to GND
• Injector 1 Open Coil L Short to GND
• Injector 2 Open Coil H Short to GND
• Injector 2 Open Coil L Short to GND
• Injector 3 Open Coil H Short to GND
• Injector 3 Open Coil L Short to GND
• Failed Engine Control Module (ECM)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 837

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 836).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 2797 FMI 3

Step 2 Inspect connections at Under Valve Connector (UVC) connector 2. Decision

A. Key-Off. Yes: Go to Step 3.
B. Disconnect UVC 2.
C. Check UVC 2 and connector terminals for: damage or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 2 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 2797
FMI 3 (page 1344).

Step 3 Inspect connections at Under Valve Connector (UVC) connector 3. Decision

A. Key-Off Yes: Go to Step 4.
B. Disconnect UVC 3
C. Check UVC 3 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 3 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 2797
FMI 3

Step 4 Inspect UVC harness under valve cover. Decision

A. Key-Off Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 2797 FMI 3
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 5
838 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 5 Check for failed Injector 1 Open Coil. Decision

A. Key-Off. Yes: Go to Step 6.
B. Remove valve cover.
C. Disconnect Injector 1 from Under Valve Cover (UVC) harness connector.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector
pin-2 and pin-3, leave UVC harness disconnected.

E. Use DMM, measure resistance between Injector pin-2 and pin-3.

Is resistance 1.0 ± 0.5 ohms? No: Replace Injector 1 and
perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 2797
FMI 3

Step 6 Check for failed Injector 2 Open Coil. Decision

A. Key-Off. Yes: Go to Step 7
B. Remove valve cover.
C. Disconnect Injector 2 from UVC harness connector.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Fuel
Injector pin-2 and pin-3, leave UVC harness disconnected.
E. Use DMM, measure resistance between Injector pin-2 and pin-3.
Is resistance 1.0 ± 0.5 ohms? No: Replace Fuel Injector 2 and
perform Injector Coil End of Motion
(CEOM) Reset Procedure(page
1334). After repairs are complete,
retest for SPN 2797 FMI 3

Step 7 Check for failed Injector 3 Open Coil. Decision

A. Key-Off. Yes: Go to Step 8

B. Remove valve cover.

C. Disconnect Injector 3 from UVC harness connector.

D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector

pin-2 and pin-3, leave UVC harness disconnected.
E. Use DMM, measure resistance between Injector pin-2 and pin-3.
Is resistance 1.0 ± 0.5 ohms? No: Replace Fuel Injector 3 and
perform Injector Coil End of Motion
(CEOM) Reset Procedure(page
1334). After repairs are complete,
retest for SPN 2797 FMI 3
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 839

Step 8 Check Injector 1 Open Coil H Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 9
B. Reconnect Injector 1 to UVC harness if previously left disconnected
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-2, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-2 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-2 and Injector 1. After
repairs are complete, retest for
SPN 2797 FMI 3

Step 9 Check Injector 1 Open Coil L Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 10.
B. Reconnect Injector 1 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-1, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-1 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM pin D-1 and Injector 1. After
repairs are complete, retest for
SPN 2797 FMI 3.

Step 10 Check for short between Injector 1 Open H and Open L circuits. Decision
A. Key-Off. Yes: Go to Step 11.
B. Disconnect ECM - Driver 36-pin connector.
C. Disconnect Injector 1 from UVC harness.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminals into ECM -
Driver 36-pin connector pins D-1 and D-2, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pins D-1 and D-2.
Is resistance greater than 1000 ohms? No: Repair short between INJ1
Open H and INJ1 Open L. After
repairs are complete, retest for
SPN 2797 FMI 3
840 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 11 Check Injector 2 Open Coil H Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 12.
B. Reconnect Injector 2 to UVC harness if previously left disconnected
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-6, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-6 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-6 and Injector 2. After
repairs are complete, retest for
SPN 2797 FMI 3

Step 12 Check Injector 2 Open Coil L Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 13.
B. Reconnect Injector 2 to UVC harness if previously left disconnected
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-5, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-5 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-5 and Injector 2. After
repairs are complete, retest for
SPN 2797 FMI 3

Step 13 Check for short between Injector 2 Open H and Open L circuits. Decision
A. Key-Off. Yes: Go to Step 14.
B. Disconnect ECM - Driver 36-pin connector.
C. Disconnect injector 2 from UVC harness.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminals into ECM -
Driver 36-pin connector pins D-5 and D-6, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver connector pins
D-5 and D-6.
Is resistance greater than 1000 ohms? No: Repair short between INJ2
Open H and INJ2 Open L. After
repairs are complete, retest for
SPN 2797 FMI 3
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 841

Step 14 Check Injector 3 Open Coil H Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 15
B. Reconnect Injector 3 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-4, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-4 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-4 and Injector 3. After
repairs are complete, retest for
SPN 2797 FMI 3

Step 15 Check Injector 3 Open Coil L Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 16
B. Reconnect Injector 3 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-3, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-3 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-3 and Injector 3. After
repairs are complete, retest for
SPN 2797 FMI 3

Step 16 Check for short between Injector 3 Open H and Open L circuits. Decision
A. Key-Off. Yes: Go to Step 17
B. Disconnect ECM - Driver 36-pin connector.
C. Disconnect injector 3 from UVC harness.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminals into ECM -
Driver 36-pin connector pins D-3 and D-4, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pins D-3 and D-4.
Is resistance greater than 1000 ohms? No: Repair short between INJ3
Open H and INJ3 Open L. After
repairs are complete, retest for
SPN 2797 FMI 3
842 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 17 Check for failed Engine Control Module (ECM). Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 2797
B. Install Test ECM.
FMI 3
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).

D. Key-On Engine-Off (KOEO), log in to Navistar® Engine Diagnostics.

E. Key On Engine Running (KOER).

F. Check DTC list for SPN 2797 FMI 3.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decisions were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 2797 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 843

SPN 2797 FMI 4 - Injector Control Group 1 close coil short

Fault Overview
Fault code sets when short circuit is detected on Bank 1 (Injectors 1, 2, and 3) Close coil.

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

Associated Faults

• SPN 651-653 FMI 4 and 5 • SPN 3659-3661 FMI 4 and

(INJ) 5 (INJ)

Fault Facts
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed Injector
• Injector 1 Closed H Short to Closed L
• Injector 2 Closed H Short to Closed L
• Injector 3 Closed H Short to Closed L
• Injector 3 Closed H Short to Closed L
• Injector 1 Closed Coil H Short to GND
• Injector 1 Closed Coil L Short to GND
• Injector 2 Closed Coil H Short to GND
• Injector 2 Closed Coil L Short to GND
• Injector 3 Closed Coil H Short to GND
• Injector 3 Closed Coil L Short to GND
• Failed Engine Control Module (ECM)
844 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST)e, check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 843).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 2797 FMI 4

Step 2 Inspect connections at Under Valve Connector (UVC) connector 2. Decision

A. Key-Off. Yes: Go to Step 3.
B. Disconnect UVC 2.
C. Check UVC 2 and connector terminals for: damage or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 2 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 2797
FMI 4 (page 1344).

Step 3 Inspect connections at Under Valve Connector (UVC) connector 3. Decision

A. Key-Off. Yes: Go to Step 4.
B. Disconnect UVC 3.
C. Check UVC 3 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 3 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 2797
FMI 4.

Step 4 Inspect UVC harness under valve cover. Decision

A. Key-Off. Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 2797 FMI 4.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 5.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 845

Step 5 Check for failed Injector Closed coils. Decision

A. Key-Off. Yes: Go to Step 6.
B. Remove valve cover.
C. Disconnect Injectors 1, 2 and 3 from Under Valve Connector (UVC)
harness connectors.

D. Connect correct terminals from Terminal Test Kit ZTSE4435C to each

Injector pin-1 and pin-4, leave UVC harness disconnected.
E. Use DMM, measure resistance between each Injector pin-1 and pin-4.
Is resistance 1.0 ± 0.5 ohms for each injector? No: Replace Failed Injector(s)
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 2797
FMI 4.

Step 6 Check Injector 1 Closed Coil H Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 7.

B. Reconnect Injector 1 to UVC harness if previously left disconnected.

C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-8, leave ECM disconnected.
E. Use DMM measure resistance between ECM - Driver 36-pin connector pin
D-8 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-8 and Injector 1. After
repairs are complete, retest for
SPN 2797 FMI 4

Step 7 Check Injector 1 Closed Coil L Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 8.

B. Reconnect Injector 1 to UVC harness if previously left disconnected.

C. Disconnect ECM - Driver 36-pin connector.

D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-7, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-7 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-7 and Injector 1. After
repairs are complete, retest for
SPN 2797 FMI 4
846 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 8 Check for short between Injector 1 Closed H and Closed L circuits. Decision
A. Key-Off. Yes: Go to Step 9.
B. Disconnect ECM - Driver 36-pin connector.
C. Disconnect injector 1 from UVC harness.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminals into ECM -
Driver 36-pin connector pins D-7 and D-8, leave ECM disconnected.

E. Use DMM measure resistance between ECM - Driver 36-pin connector

pins D-7 and D-8.
Is resistance greater than 1000 ohms? No: Repair short between INJ1
Close H and INJ1 Close L. After
repairs are complete, retest for
SPN 2797 FMI 4

Step 9 Check Injector 2 Closed Coil H Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 10.
B. Reconnect Injector 2 to UVC harness if previously left disconnected
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-12, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-12 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-12 and Injector 2. After
repairs are complete, retest for
SPN 2797 FMI 4

Step 10 Check Injector 2 Closed Coil L Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 11.
B. Reconnect Injector 2 to UVC harness if previously left disconnected
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-11, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-11 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-11 and Injector 2. After
repairs are complete, retest for
SPN 2797 FMI 4
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 847

Step 11 Check Injector 2 Close Coil L for short to GND Decision

A. Key-Off. Yes: Go to Step 12.
B. Disconnect ECM - Driver 36-pin connector.
C. Disconnect injector 2 from UVC harness.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminals into ECM -
Driver 36-pin connector pins D-11 and D-12, leave ECM disconnected.

E. Use DMM measure resistance between ECM - Driver connector pins

D-11 and D-12.
Is resistance greater than 1000 ohms? No: Repair short between INJ2
Close H and INJ2 Close L. After
repairs are complete, retest for
SPN 2797 FMI 4.

Step 12 Check Injector 3 Closed Coil H Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 13.
B. Reconnect Injector 3 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-10, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-10 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-10 and Injector 3. After
repairs are complete, retest for
SPN 2797 FMI 4.

Step 13 Check Injector 3 Closed Coil L Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 14.
B. Reconnect Injector 3 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-9, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-9 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-9 and Injector 3. After
repairs are complete, retest for
SPN 2797 FMI 4.
848 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 14 Check for short between Injector 3 Closed H and Closed L circuits. Decision
A. Key-Off. Yes: Go to Step 15.
B. Disconnect ECM - Driver 36-pin connector.
C. Disconnect injector 3 from UVC harness.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminals into ECM -
Driver 36-pin connector pins D-9 and D-10, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pins D-9 and D-10.
Is resistance greater than 1000 ohms? No: Repair short between INJ3
Close H and INJ3 Close L. After
repairs are complete, retest for
SPN 2797 FMI 4.

Step 15 Check for failed Engine Control Module (ECM). Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 2797
B. Install Test ECM.
FMI 4.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).
D. Key-On Engine-Off (KOEO), log in to Navistar® Engine Diagnostics.
E. Key-On Engine-Running (KOER).
F. Check DTC list for SPN 2797 FMI 4.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decisions were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 2797 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 849

SPN 2797 FMI 6 - Injector Control Group 1 - short circuit (INJ 1, 2, 3)

Fault Overview
Fault code sets when short circuit is detected on Bank 0 (Injectors 1, 2, and 3) Open or Close coil.

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

Associated Faults

• SPN 651-653 FMI 4 and 5 • SPN 3659-3661 FMI 4 and

(INJ) 5 (INJ)

Fault Facts
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.
850 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed Injector
• Injector 1 Open H Short to Open L
• Injector 1 Closed H Short to Closed L
• Injector 2 Open H Short to Open L
• Injector 2 Closed H Short to Closed L
• Injector 3 Open H Short to Open L
• Injector 3 Closed H Short to Closed L
• Injector 1 Open Coil H Short to GND
• Injector 1 Open Coil L Short to GND
• Injector 1 Closed Coil H Short to GND
• Injector 1 Closed Coil L Short to GND
• Injector 2 Open Coil H Short to GND
• Injector 2 Open Coil L Short to GND
• Injector 2 Closed Coil H Short to GND
• Injector 2 Closed Coil L Short to GND
• Injector 3 Open Coil H Short to GND
• Injector 3 Open Coil L Short to GND
• Injector 3 Closed Coil H Short to GND
• Injector 3 Closed Coil L Short to GND
• Failed Engine Control Module (ECM)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 851

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 849).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 2797 FMI 6.

Step 2 Inspect connections at Under Valve Connector (UVC) connector 2. Decision

A. Key-Off. Yes: Go to Step 3.
B. Disconnect UVC 2.
C. Check UVC 2 and connector terminals for: damage or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 2 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 2797
FMI 6. (page 1344).

Step 3 Inspect connections at Under Valve Connector (UVC) connector 3. Decision

A. Key-Off Yes: Go to Step 4.
B. Disconnect UVC 3
C. Check UVC 3 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 3 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 2797
FMI 6.

Step 4 Inspect UVC harness under valve cover. Decision

A. Key-Off Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 2797 FMI 6.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 5
852 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 5 Check for failed Injector 1 Open Coil. Decision

A. Key-Off. Yes: Go to Step 6.
B. Remove valve cover.
C. Disconnect Injector 1 from Under Valve Cover (UVC) harness connector.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector
pin-2 and pin-3, leave UVC harness disconnected.

E. Use DMM, measure resistance between Injector pin-2 and pin-3.

Is resistance 1.0 ± 0.5 ohms? No: Replace Injector 1 and
perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 2797
FMI 6.

Step 6 Check for failed Injector 1 Closed Coil. Decision

A. Key-Off. Yes: Go to Step 7.
B. Remove valve cover.
C. Disconnect Injector 1 from Under Valve Cover (UVC) harness connector.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector
pin-1 and pin-4, leave UVC harness disconnected.
E. Use DMM, measure resistance between Injector pin-1 and pin-4.
Is resistance 1.0 ± 0.5 ohms? No: Replace Fuel Injector 1 and
perform Injector Coil End of Motion
(CEOM) Reset Procedure(page
1334). After repairs are complete,
retest for SPN 2797 FMI 6.

Step 7 Check for failed Injector 2 Open Coil. Decision

A. Key-Off. Yes: Go to Step 8.

B. Remove valve cover.

C. Disconnect Injector 2 from UVC harness connector.

D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Fuel

Injector pin-2 and pin-3, leave UVC harness disconnected.
E. Use DMM, measure resistance between Injector pin-2 and pin-3.
Is resistance 1.0 ± 0.5 ohms? No: Replace Fuel Injector 2 and
perform Injector Coil End of Motion
(CEOM) Reset Procedure(page
1334). After repairs are complete,
retest for SPN 2797 FMI 6.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 853

Step 8 Check for failed Injector 2 Closed Coil. Decision

A. Key-Off. Yes: Go to Step 9.
B. Remove valve cover.
C. Disconnect Injector 2 from UVC harness connector.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Fuel
Injector pin-1 and pin-4, leave UVC harness disconnected.

E. Use DMM, measure resistance between Injector pin-1 and pin-4.

Is resistance 1.0 ± 0.5 ohms? No: Replace Fuel Injector 2 and
perform Injector Coil End of Motion
(CEOM) Reset Procedure(page
1334). After repairs are complete,
retest for SPN 2797 FMI 6.

Step 9 Check for failed Injector 3 Open Coil. Decision

A. Key-Off. Yes: Go to Step 10.
B. Remove valve cover.
C. Disconnect Injector 3 from UVC harness connector.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector
pin-2 and pin-3, leave UVC harness disconnected.
E. Use DMM, measure resistance between Injector pin-2 and pin-3.
Is resistance 1.0 ± 0.5 ohms? No: Replace Fuel Injector 3 and
perform Injector Coil End of Motion
(CEOM) Reset Procedure(page
1334). After repairs are complete,
retest for SPN 2797 FMI 6.

Step 10 Check for failed Injector 3 Closed Coil. Decision

A. Key-Off. Yes: Go to Step 11.
B. Remove valve cover.
C. Disconnect Injector 3 from UVC harness connector.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector
pin-1 and pin-4, leave UVC harness disconnected.
E. Use DMM, measure resistance between Injector pin-1 and pin-4.
Is resistance 1.0 ± 0.5 ohms? No: Replace Fuel Injector 3 and
perform Injector Coil End of Motion
(CEOM) Reset Procedure(page
1334). After repairs are complete,
retest for SPN 2797 FMI 6.
854 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 11 Check Injector 1 Open Coil H Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 12.
B. Reconnect Injector 1 to UVC harness if previously left disconnected
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-2, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-2 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-2 and Injector 1. After
repairs are complete, retest for
SPN 2797 FMI 6.

Step 12 Check Injector 1 Open Coil L Circuit for short to GND Decision
A. Key-Off. Yes: Go to Step 13.
B. Reconnect Injector 1 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-1, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-1 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-1 and Injector 1. After
repairs are complete, retest for
SPN 2797 FMI 6.

Step 13 Check Injector 1 Closed Coil H Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 14.
B. Reconnect Injector 1 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-8, leave ECM disconnected.
E. Use DMM measure resistance between ECM - Driver 36-pin connector pin
D-8 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-8 and Injector 1. After
repairs are complete, retest for
SPN 2797 FMI 6.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 855

Step 14 Check Injector 1 Closed Coil L Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 15.
B. Reconnect Injector 1 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-7, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-7 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-7 and Injector 1. After
repairs are complete, retest for
SPN 2797 FMI 6.

Step 15 Check for short between Injector 1 Open H and Open L circuits. Decision
A. Key-Off. Yes: Go to Step 16.
B. Disconnect ECM - Driver 36-pin connector.
C. Disconnect injector 1 from UVC harness.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminals into ECM -
Driver 36-pin connector pins D-1 and D-2, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pins D-1 and D-2.
Is resistance greater than 1000 ohms? No: Repair short between INJ1
Open H and INJ1 Open L. After
repairs are complete, retest for
SPN 2797 FMI 6.

Step 16 Check for short between Injector 1 Closed H and Closed L circuits. Decision
A. Key-Off. Yes: Go to Step 17.
B. Disconnect ECM - Driver 36-pin connector.
C. Disconnect injector 1 from UVC harness.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminals into ECM -
Driver 36-pin connector pins D-7 and D-8, leave ECM disconnected.
E. Use DMM measure resistance between ECM - Driver 36-pin connector
pins D-7 and D-8.
Is resistance greater than 1000 ohms? No: Repair short between INJ1
Close H and INJ1 Close L. After
repairs are complete, retest for
SPN 2797 FMI 6.
856 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 17 Check Injector 2 Open Coil H Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 18.
B. Reconnect Injector 2 to UVC harness if previously left disconnected
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-6, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-6 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-6 and Injector 2. After
repairs are complete, retest for
SPN 2797 FMI 6.

Step 18 Check Injector 2 Open Coil L Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 19.
B. Reconnect Injector 2 to UVC harness if previously left disconnected
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-5, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-5 and known good GND.
Is resistance greater than 1000 ohms? Repair short to GND between
ECM D-5 and Injector 2. After
repairs are complete, retest for
SPN 2797 FMI 6.

Step 19 Check Injector 2 Closed Coil H Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 20.
B. Reconnect Injector 2 to UVC harness if previously left disconnected
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-12, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-12 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-12 and Injector 2. After
repairs are complete, retest for
SPN 2797 FMI 6.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 857

Step 20 Check Injector 2 Closed Coil L Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 21.
B. Reconnect Injector 2 to UVC harness if previously left disconnected
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-11, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-11 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-11 and Injector 2. After
repairs are complete, retest for
SPN 2797 FMI 6.

Step 21 Check for short between Injector 2 Open H and Open L circuits. Decision
A. Key-Off. Yes: Go to Step 22.
B. Disconnect ECM - Driver 36-pin connector.
C. Disconnect injector 2 from UVC harness.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminals into ECM -
Driver 36-pin connector pins D-5 and D-6, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver connector pins
D-5 and D-6.
Is resistance greater than 1000 ohms? No: Repair short between INJ2
Open H and INJ2 Open L. After
repairs are complete, retest for
SPN 2797 FMI 6.

Step 22 Check for a short between Fuel Injector 2 Closed H and Closed L Decision
circuits.
A. Key-Off. Yes: Go to Step 23.

B. Disconnect ECM - Driver 36-pin connector.

C. Disconnect injector 2 from UVC harness.

D. Use Terminal Test Kit ZTSE4435C, insert proper terminals into ECM -
Driver 36-pin connector pins D-11 and D-12, leave ECM disconnected.
E. Use DMM measure resistance between ECM - Driver connector pins
D-11 and D-12.
Is resistance greater than 1000 ohms? No: Repair short between INJ2
Close H and INJ2 Close L. After
repairs are complete, retest for
SPN 2797 FMI 6.
858 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 23 Check Injector 3 Open Coil H Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 24.
B. Reconnect Injector 3 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-4, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-4 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-4 and Injector 3. After
repairs are complete, retest for
SPN 2797 FMI 6.

Step 24 Check Injector 3 Open Coil L Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 25.
B. Reconnect Injector 3 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-3, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-3 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-3 and Injector 3. After
repairs are complete, retest for
SPN 2797 FMI 6.

Step 25 Check Injector 3 Closed Coil H Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 26.
B. Reconnect Injector 3 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-10, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-10 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-10 and Injector 3. After
repairs are complete, retest for
SPN 2797 FMI 6.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 859

Step 26 Check Injector 3 Closed Coil L Circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 27.
B. Reconnect Injector 3 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-9, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-9 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-9 and Injector 3. After
repairs are complete, retest for
SPN 2797 FMI 6.

Step 27 Check for short between Injector 3 Open H and Open L circuits. Decision
A. Key-Off. Yes: Go to Step 28.
B. Disconnect ECM - Driver 36-pin connector.
C. Disconnect injector 3 from UVC harness.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminals into ECM -
Driver 36-pin connector pins D-3 and D-4, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pins D-3 and D-4.
Is resistance greater than 1000 ohms? No: Repair short between INJ3
Open H and INJ3 Open L. After
repairs are complete, retest for
SPN 2797 FMI 6.

Step 28 Check for short between Injector 3 Closed H and Closed L circuits. Decision
A. Key-Off. Yes: Go to Step 29.
B. Disconnect ECM - Driver 36-pin connector.
C. Disconnect injector 3 from UVC harness.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminals into ECM -
Driver 36-pin connector pins D-9 and D-10, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pins D-9 and D-10.
Is resistance greater than 1000 ohms? No: Repair short between INJ3
Close H and INJ3 Close L. After
repairs are complete, retest for
SPN 2797 FMI 6.
860 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 29 Check for failed Engine Control Module (ECM). Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 2797
B. Install Test ECM.
FMI 6.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).

D. Key-On Engine-Off (KOEO), log in to Navistar® Engine Diagnostics.

E. Key-On Engine-Running (KOER).

F. Check Diagnostic Trouble Code (DTC) list for SPN 2797 FMI 6.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decisions were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 2797 FMI 6 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 861

SPN 2798 FMI 3 - Injector Control Group 2 open coil short

Fault Overview
Fault code sets when short circuit is detected on Bank 1 (Injectors 4, 5, and 6) Open coil.

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

Associated Faults

• SPN 654-656 FMI 4 and 5 • SPN 3662-3665 FMI 4 and

(INJ) 5 (INJ)

Fault Facts
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Injector 4 Open H Short to Open L
• Injector 5 Open H Short to Open L
• Injector 6 Open H Short to Open L
• Injector 4 Open Coil H Short to GND
• Injector 4 Open Coil L Short to GND
• Injector 5 Open Coil H Short to GND
• Injector 5 Open Coil L Short to GND
• Injector 6 Open Coil H Short to GND
• Injector 6 Open Coil L Short to GND
• Failed Engine Control Module (ECM)
See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults(page 861).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 2798 FMI 3.
862 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 2 Inspect connections at Under Valve Connector (UVC) connector 3. Decision

A. Key-Off. Yes: Go to Step 3.
B. Disconnect UVC 3.
C. Check UVC 3 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 3 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 2798
FMI 3.

Step 3 Inspect connections at Under Valve Connector (UVC) connector 4. Decision

A. Key-Off. Yes: Go to Step 4.
B. Disconnect UVC 4.
C. Check UVC 4 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 4 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN
2798 FMI 3.

Step 4 Inspect UVC harness under valve cover. Decision

A. Key-Off. Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 2798 FMI 3.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 5.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 863

Step 5 Check for failed Injector 4 Open coil. Decision

A. Key-Off. Yes: Go to Step 6.
B. Remove valve cover.
C. Disconnect Injector 4 from Under Valve Connector (UVC) harness
connector.

D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector

pin-2 and pin-3, leave UVC harness disconnected.
E. Use DMM, measure resistance between Injector pin-2 and pin-3.
Is resistance 1.0 ± 0.5 ohms? No: Replace Injector 4 and
perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 2798
FMI 3.

Step 6 Check for failed Injector 5 Open coil. Decision

A. Key-Off. Yes: Go to Step 7.

B. Remove valve cover.

C. Disconnect Injector 5 from Under Valve Connector (UVC) harness
connector.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector
pin-2 and pin-3, leave UVC harness disconnected.
E. Use DMM, measure resistance between Injector pin-2 and pin-3.
Is resistance 1.0 ± 0.5 ohms? No: Replace Injector 5 and
perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 2798
FMI 3.
864 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 7 Check for failed Injector 6 Open coil. Decision

A. Key-Off. Yes: Go to Step 8.
B. Remove valve cover.
C. Disconnect Injector 6 from Under Valve Connector (UVC) harness
connector.

D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector

pin-2 and pin-3, leave UVC harness disconnected.
E. Use DMM, measure resistance between Injector pin-2 and pin-3.
Is resistance 1.0 ± 0.5 ohms? No: Replace Injector 6 and
perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 2798
FMI 3.

Step 8 Check Injector 4 Open Coil H circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 9.

B. Reconnect Injector 4 to UVC harness if previously left disconnected.

C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-30, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-30 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-30 and Injector 4. After
repairs are complete, retest for
SPN 2798 FMI 3.

Step 9 Check Injector 4 Open Coil L circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 10.

B. Reconnect Injector 4 to UVC harness if previously left disconnected.

C. Disconnect ECM - Driver 36-pin connector.

D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-29, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-29 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-29 and Injector 4. After
repairs are complete, retest for
SPN 2798 FMI 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 865

Step 10 Check for short between Injector 4 Open H and Open L circuits. Decision
A. Key-Off. Yes: Go to Step 11.
B. Disconnect ECM - Driver 36-pin connector.
C. Disconnect injector 4 from UVC harness.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pins D-29 and D-30, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pins D-29 and D-30.
Is resistance greater than 1000 ohms? No: Repair short between INJ4
Open H and INJ4 Open L. After
repairs are complete, retest for
SPN 2798 FMI 3.

Step 11 Check Injector 5 Open Coil H circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 12.
B. Reconnect Injector 5 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-26, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-26 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-26 and Injector 5. After
repairs are complete, retest for
SPN 2798 FMI 3.

Step 12 Check Injector 5 Open Coil L circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 13.
B. Reconnect Injector 5 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-25, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-25 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-25 and Injector 5. After
repairs are complete, retest for
SPN 2798 FMI 3.
866 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 13 Check for short between Injector 5 Open H and Open L circuits. Decision
A. Key-Off. Yes: Go to Step 14.
B. Disconnect ECM - Driver 36-pin connector.
C. Disconnect injector 5 from UVC harness.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pins D-25 and D-26, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pins D-25 and D-26.
Is resistance greater than 1000 ohms? No: Repair short between INJ5
Open H and INJ5 Open L. After
repairs are complete, retest for
SPN 2798 FMI 3.

Step 14 Check Injector 6 Open Coil H circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 15.
B. Reconnect Injector 6 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-28, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector pin
D-28 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-28 and Injector 6. After
repairs are complete, retest for
SPN 2798 FMI 3.

Step 15 Check Injector 6 Open Coil L circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 16.
B. Reconnect Injector 6 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-27, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-27 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-27 and Injector 6. After
repairs are complete, retest for
SPN 2798 FMI 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 867

Step 16 Check for short between Injector 6 Open H and Open L circuits. Decision
A. Key-Off. Yes: Go to Step 17.
B. Disconnect ECM - Driver 36-pin connector.
C. Disconnect injector 6 from UVC harness.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pins D-27 and D-28, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pins D-27 and D-28.
Is resistance greater than 1000 ohms? No: Repair short between INJ6
Open H and INJ6 Open L. After
repairs are complete, retest for
SPN 2798 FMI 3.

Step 17 Check for failed Engine Control Module (ECM). Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 2798
B. Install Test ECM.
FMI 3.
C. Key-On Engine-Running (KOER).
D. Check Diagnostic Trouble Code (DTC) list for SPN 2798 FMI 3.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decisions were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 2798 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
868 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 2798 FMI 4 - Injector Control Group 2 close coil short

Fault Overview
Fault code sets when short circuit is detected on Bank 2 (Injectors 4, 5, and 6) Close coil.

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

Associated Faults

• SPN 654-656 FMI 4 and 5 • SPN 3662-3665 FMI 4

(INJ) and 5 (INJ)

Fault Facts
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Injector 4 Closed H Short to Closed L
• Injector 5 Closed H Short to Closed L
• Injector 6 Closed H Short to Closed L
• Injector 4 Closed Coil H Short to GND
• Injector 4 Closed Coil L Short to GND
• Injector 5 Closed Coil H Short to GND
• Injector 5 Closed Coil L Short to GND
• Injector 6 Closed Coil H Short to GND
• Injector 6 Closed Coil L Short to GND
• Failed Engine Control Module (ECM)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 869

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults(page 868).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 2798 FMI 4.

Step 2 Inspect connections at Under Valve Connector (UVC) connector 3. Decision

A. Key-Off. Yes: Go to Step 3.
B. Disconnect UVC 3.
C. Check UVC 3 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 3 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 2798
FMI 4.

Step 3 Inspect connections at Under Valve Connector (UVC) connector 4. Decision

A. Key-Off. Yes: Go to Step 4.
B. Disconnect UVC 4.
C. Check UVC 4 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 4 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN
2798 FMI 4.

Step 4 Inspect UVC harness under valve cover. Decision

A. Key-Off. Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 2798 FMI 4.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 5.
870 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 5 Check for failed Injector Closed coils. Decision

A. Key-Off. Yes: Go to Step 6.
B. Remove valve cover.
C. Disconnect Injectors 4, 5 and 6 from Under Valve Connector (UVC)
harness connectors.

D. Connect correct terminals from Terminal Test Kit ZTSE4435C to each

Injector pin-1 and pin-4, leave UVC harness disconnected.
E. Use DMM, measure resistance between each Injector pin-1 and pin-4.
Is resistance 1.0 ± 0.5 ohms for each injector? No: Replace Failed Injector(s)
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 2798
FMI 4.

Step 6 Check Injector 4 Closed Coil H circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 7.

B. Reconnect Injector 4 to UVC harness if previously left disconnected.

C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-36, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-36 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-36 and Injector 4. After
repairs are complete, retest for
SPN 2798 FMI 4.

Step 7 Check Injector 4 Closed Coil L circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 8.

B. Reconnect Injector 4 to UVC harness if previously left disconnected.

C. Disconnect ECM - Driver 36-pin connector.

D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-35, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-35 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-35 and Injector 4. After
repairs are complete, retest for
SPN 2798 FMI 4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 871

Step 8 Check for short between Injector 4 Closed H and Closed L circuits. Decision
A. Key-Off. Yes: Go to Step 9.
B. Disconnect ECM - Driver 36-pin connector.
C. Disconnect injector 4 from UVC harness.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pins D-35 and D-36, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pins D-35 and D-36.
Is resistance greater than 1000 ohms? No: Repair short between INJ4
Close H and INJ4 Close L. After
repairs are complete, retest for
SPN 2798 FMI 4.

Step 9 Check Injector 5 Closed Coil H circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 10.
B. Reconnect Injector 5 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-32, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-32 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-32 and Injector 5. After
repairs are complete, retest for
SPN 2798 FMI 4.

Step 10 Check Injector 5 Closed Coil L circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 11.
B. Reconnect Injector 5 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-31, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-31 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-31 and Injector 5. After
repairs are complete, retest for
SPN 2798 FMI 4.
872 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 11 Check for short between Injector 5 Closed H and Closed L circuits. Decision
A. Key-Off. Yes: Go to Step 12.
B. Disconnect ECM - Driver 36-pin connector.
C. Disconnect injector 5 from UVC harness.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pins D-31 and D-32, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pins D-31 and D-32.
Is resistance greater than 1000 ohms? No: Repair short between INJ5
Close H and INJ5 Close L. After
repairs are complete, retest for
SPN 2798 FMI 4.

Step 12 Check Injector 6 Closed Coil H circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 13.
B. Reconnect Injector 6 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-34, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-34 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-34 and Injector 6. After
repairs are complete, retest for
SPN 2798 FMI 4.

Step 13 Check Injector 6 Closed Coil L circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 14.
B. Reconnect Injector 6 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-33, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-33 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-33 and Injector 6. After
repairs are complete, retest for
SPN 2798 FMI 4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 873

Step 14 Check for short between Injector 6 Closed H and Closed L circuits. Decision
A. Key-Off. Yes: Go to Step 15.
B. Disconnect ECM - Driver 36-pin connector.
C. Disconnect injector 6 from UVC harness.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pins D-33 and D-34, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pins D-33 and D-34.
Is resistance greater than 1000 ohms? No: Repair short between INJ6
Close H and INJ6 Close L. After
repairs are complete, retest for
SPN 2798 FMI 4.

Step 15 Check for failed Engine Control Module (ECM). Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 2798
B. Install Test ECM.
FMI 4.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).
D. Key ON Engine Running (KOER).
E. Check Diagnostic Trouble Code (DTC) list for SPN 2798 FMI 4.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decisions were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 2798 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
874 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 2798 FMI 6 - Injector Control Group 2 - short circuit (INJ 4, 5, 6)

Fault Overview
Fault code sets when short circuit is detected on Bank 1 (Injectors 4, 5, and 6) Open or Close coil.

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

Associated Faults

• SPN 654-656 FMI 4 and 5 • SPN 3662-3665 FMI 4 and

(INJ) 5 (INJ)

Fault Facts
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Injector 4 Open H Short to Open L
• Injector 4 Closed H Short to Closed L
• Injector 5 Open H Short to Open L
• Injector 5 Closed H Short to Closed L
• Injector 6 Open H Short to Open L
• Injector 6 Closed H Short to Closed L
• Injector 4 Open Coil H Short to GND
• Injector 4 Open Coil L Short to GND
• Injector 4 Closed Coil H Short to GND
• Injector 4 Closed Coil L Short to GND
• Injector 5 Open Coil H Short to GND
• Injector 5 Open Coil L Short to GND
• Injector 5 Closed Coil H Short to GND
• Injector 5 Closed Coil L Short to GND
• Injector 6 Open Coil H Short to GND
• Injector 6 Open Coil L Short to GND
• Injector 6 Closed Coil H Short to GND
• Injector 6 Closed Coil L Short to GND
• Failed Engine Control Module (ECM)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 875

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults(page 874).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 2798 FMI 6.

Step 2 Inspect connections at Under Valve Connector (UVC) connector 3. Decision

A. Key-Off. Yes: Go to Step 3.
B. Disconnect UVC 3.
C. Check UVC 3 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 3 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 2798
FMI 6.

Step 3 Inspect connections at Under Valve Connector (UVC) connector 4. Decision

A. Key-Off. Yes: Go to Step 4.
B. Disconnect UVC 4.
C. Check UVC 4 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 4 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN
2798 FMI 6.

Step 4 Inspect UVC harness under valve cover. Decision

A. Key-Off. Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 2798 FMI 6.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 5.
876 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 5 Check for failed Injector 4 Open coil. Decision

A. Key-Off. Yes: Go to Step 6.
B. Remove valve cover.
C. Disconnect Injector 4 from Under Valve Connector (UVC) harness
connector.

D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector

pin-2 and pin-3, leave UVC harness disconnected.
E. Use DMM, measure resistance between Injector pin-2 and pin-3.
Is resistance 1.0 ± 0.5 ohms? No: Replace Injector 4 and
perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 2798
FMI 6.

Step 6 Check for failed Injector 4 Closed coil. Decision

A. Key-Off. Yes: Go to Step 7.

B. Remove valve cover.

C. Disconnect Injector 4 from Under Valve Connector (UVC) harness
connector.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector
pin-1 and pin-4, leave UVC harness disconnected.
E. Use DMM, measure resistance between Injector pin-1 and pin-4.
Is resistance 1.0 ± 0.5 ohms? No: Replace Injector 4 and
perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 2798
FMI 6.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 877

Step 7 Check for failed Injector 5 Open coil. Decision

A. Key-Off. Yes: Go to Step 8.
B. Remove valve cover.
C. Disconnect Injector 5 from Under Valve Connector (UVC) harness
connector.

D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector

pin-2 and pin-3, leave UVC harness disconnected.
E. Use DMM, measure resistance between Injector pin-2 and pin-3.
Is resistance 1.0 ± 0.5 ohms? No: Replace Injector 5 and
perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 2798
FMI 6.

Step 8 Check for failed Injector 5 Closed coil. Decision

A. Key-Off. Yes: Go to Step 9.

B. Remove valve cover.

C. Disconnect Injector 5 from Under Valve Connector (UVC) harness
connector.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector
pin-1 and pin-4, leave UVC harness disconnected.
E. Use DMM measure resistance between Injector pin-1 and pin-4.
Is resistance 1.0 ± 0.5 ohms? No: Replace Injector 5 and
perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 2798
FMI 6.
878 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 9 Check for failed Injector 6 Open coil. Decision

A. Key-Off. Yes: Go to Step 10.
B. Remove valve cover.
C. Disconnect Injector 6 from Under Valve Connector (UVC) harness
connector.

D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector

pin-2 and pin-3, leave UVC harness disconnected.
E. Use DMM, measure resistance between Injector pin-2 and pin-3.
Is resistance 1.0 ± 0.5 ohms? No: Replace Injector 6 and
perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 2798
FMI 6.

Step 10 Check for failed Injector 6 Closed coil. Decision

A. Key-Off. Yes: Go to Step 11.

B. Remove valve cover.

C. Disconnect Injector 6 from Under Valve Connector (UVC) harness
connector.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector
pin-1 and pin-4, leave UVC harness disconnected.
E. Use DMM, measure resistance between Injector pin-1 and pin-4.
Is resistance 1.0 ± 0.5 ohms? No: Replace Injector 6 and
perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 2798
FMI 6.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 879

Step 11 Check Injector 4 Open Coil H circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 12.
B. Reconnect Injector 4 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-30, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-30 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-30 and Injector 4. After
repairs are complete, retest for
SPN 2798 FMI 6.

Step 12 Check Injector 4 Open Coil L circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 13.
B. Reconnect Injector 4 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-29, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-29 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-29 and Injector 4. After
repairs are complete, retest for
SPN 2798 FMI 6.

Step 13 Check Injector 4 Closed Coil H circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 14.
B. Reconnect Injector 4 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-36, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-36 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-36 and Injector 4. After
repairs are complete, retest for
SPN 2798 FMI 6.
880 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 14 Check Injector 4 Closed Coil L circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 15.
B. Reconnect Injector 4 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-35, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-35 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-35 and Injector 4. After
repairs are complete, retest for
SPN 2798 FMI 6.

Step 15 Check for short between Injector 4 Open H and Open L circuits. Decision
A. Key-Off. Yes: Go to Step 16.
B. Disconnect ECM - Driver 36-pin connector.
C. Disconnect Injector 4 from UVC harness.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pins D-29 and D-30, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pins D-29 and D-30.
Is resistance greater than 1000 ohms? No: Repair short between INJ4
Open H and INJ4 Open L. After
repairs are complete, retest for
SPN 2798 FMI 6.

Step 16 Check for short between Injector 4 Closed H and Closed L circuits. Decision
A. Key-Off. Yes: Go to Step 17.
B. Disconnect ECM - Driver 36-pin connector.
C. Disconnect Injector 4 from UVC harness.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pins D-35 and D-36, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pins D-35 and D-36.
Is resistance greater than 1000 ohms? No: Repair short between INJ4
Close H and INJ4 Close L. After
repairs are complete, retest for
SPN 2798 FMI 6.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 881

Step 17 Check Injector 5 Open Coil H circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 18.
B. Reconnect Injector 5 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-26, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-26 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-26 and Injector 5. After
repairs are complete, retest for
SPN 2798 FMI 6.

Step 18 Check Injector 5 Open Coil L circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 19.
B. Reconnect Injector 5 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-25, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-25 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-25 and Injector 5. After
repairs are complete, retest for
SPN 2798 FMI 6.

Step 19 Check Injector 5 Closed Coil H circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 20.
B. Reconnect Injector 5 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-32, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-32 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-32 and Injector 5. After
repairs are complete, retest for
SPN 2798 FMI 6.
882 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 20 Check Injector 5 Closed Coil L circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 21.
B. Reconnect Injector 5 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-31, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-31 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-31 and Injector 5. After
repairs are complete, retest for
SPN 2798 FMI 6.

Step 21 Check for short between Injector 5 Open H and Open L circuits. Decision
A. Key-Off. Yes: Go to Step 22.
B. Disconnect ECM - Driver 36-pin connector.
C. Disconnect Injector 5 from UVC harness.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pins D-25 and D-26, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pins D-25 and D-26.
Is resistance greater than 1000 ohms? No: Repair short between INJ5
Open H and INJ5 Open L. After
repairs are complete, retest for
SPN 2798 FMI 6.

Step 22 Check for short between Injector 5 Closed H and Closed L circuits. Decision
A. Key-Off. Yes: Go to Step 23.
B. Disconnect ECM - Driver 36-pin connector.
C. Disconnect Injector 5 from UVC harness.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pins D-31 and D-32, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pins D-31 and D-32.
Is resistance greater than 1000 ohms? No: Repair short between INJ5
Close H and INJ5 Close L. After
repairs are complete, retest for
SPN 2798 FMI 6.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 883

Step 23 Check Injector 6 Open Coil H circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 24.
B. Reconnect Injector 6 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-28, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector pin
D-28 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-28 and Injector 6. After
repairs are complete, retest for
SPN 2798 FMI 6.

Step 24 Check Injector 6 Open Coil L circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 25.
B. Reconnect Injector 6 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-27, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-27 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-27 and Injector 6. After
repairs are complete, retest for
SPN 2798 FMI 6.

Step 25 Check Injector 6 Closed Coil H circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 26.
B. Reconnect Injector 6 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-34, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-34 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-34 and Injector 6. After
repairs are complete, retest for
SPN 2798 FMI 6.
884 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 26 Check Injector 6 Closed Coil L circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 27.
B. Reconnect Injector 6 to UVC harness if previously left disconnected.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-33, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-33 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-33 and Injector 6. After
repairs are complete, retest for
SPN 2798 FMI 6.

Step 27 Check for short between Injector 6 Open H and Open L circuits. Decision
A. Key-Off. Yes: Go to Step 28.
B. Disconnect ECM - Driver 36-pin connector.
C. Disconnect Injector 6 from UVC harness.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pins D-27 and D-28, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pins D-27 and D-28.
Is resistance greater than 1000 ohms? No: Repair short between INJ6
Open H and INJ6 Open L. After
repairs are complete, retest for
SPN 2798 FMI 6.

Step 28 Check for short between Injector 6 Closed H and Closed L circuits. Decision
A. Key-Off. Yes: Go to Step 29.
B. Disconnect ECM - Driver 36-pin connector.
C. Disconnect Injector 6 from UVC harness.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pins D-33 and D-34, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pins D-33 and D-34.
Is resistance greater than 1000 ohms? No: Repair short between INJ6
Close H and INJ6 Close L. After
repairs are complete, retest for
SPN 2798 FMI 6.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 885

Step 29 Check for failed Engine Control Module (ECM). Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 2798
B. Install Test ECM.
FMI 6.
C. Key-On Engine-Running (KOER).
D. Check DTC list for SPN 2798 FMI 6.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decisions were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 2798 FMI 6 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
886 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3055 FMI 2 - ICP/IPR Adaptation In-Range Fault

Fault Overview
Fault code sets when fuel system Injection Pressure Control Valve adaptation value exceeds threshold values
immediately.

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

Associated Faults
SPN 164 FMI 3 and 4, and SPN 679 FMI 3 and 4

Fault Facts
Do not replace Injection Control Pressure (ICP) sensor unless directed by diagnostic procedure. This fault can
set if a high-pressure oil system repair was completed and "Fuel Pressure Adaptation Reset" procedure was not
performed.

Drive Cycle to Determine Fault Status

TBD

Possible Causes
• Fuel Pressure Adaptation Reset procedure not performed after high-pressure oil system repairs
• High-pressure oil system repair is necessary
• Oil level and quality
• ICP system leak
• IPR sensor or circuit fault
• IPR valve sticking or stuck
• Oil additive package worn out, foaming (overfilled)
• High pressure oil pump worn out or leaking
• High pressure oil leakage
• Injector static leakage
• Injector Oil Inlet Adapter (Puck) Assembly leakage
• Engine brake control valve leakage

Step 1 Check for active fault during engine cranking. Decision

Monitor Diagnostic Trouble Code (DTC) list while attempting to start engine. Yes: Go to Step 2.

Did SPN 164 FMI 1 fault set while cranking?

No: Go to Intermittent or
Inactive Fault Diagnostic
Procedure (page 1344).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 887

Step 2 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check DTC list for SPN 164 FMI 3 and 4, Yes: Go to Step 2.
and SPN 679 FMI 3 and 4.
Is EST DTC list free of SPN 164 FMI 3 and 4, and SPN 679 FMI 3 and 4?
No: Repair SPN 164 FMI
3 and 4, and SPN 679 FMI
3 and 4. After repairs are
complete, retest for SPN
3055 FMI 2.

Step 3 Check for engine oil issues. Decision

Check engine oil level and condition. Yes: Go to Step 4.

Is engine oil at proper level and in good condition?

No: Correct / repair engine
oil issues. After repairs are
complete, retest for SPN
3055 FMI 2.

Step 4 Inspect High-Pressure Oil Pump (HPOP) reservoir to ensure there is enough Decision
fluid.
Check that reservoir has oil in it. Remove Engine Oil Temperature (EOT) Yes: Reinstall EOT sensor
sensor for observation. and then go to Step 5.

Does reservoir have oil in it?

No: Diagnose / repair
lubrication system. After
repairs are complete, retest
for SPN 3055 FMI 2.

Step 5 Check High-Pressure Oil Pump (HPOP) Injection Pressure Regulator (IPR) Decision
electrical circuit.
Inspect IPR valve electrical circuit by connecting Cylinder Performance Analyzer Yes: Diagnose / repair
(CPA) tool(page 1402) to engine and perform CPA HPOP test(page 1440). electrical circuit for IPR
valve. After repairs are
complete, retest for SPN
Is there a detected issue with IPR valve electrical circuit?
3055 FMI 2.
No: Go to Step 6.
888 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 6 Mechanically test Injection Pressure Regulator (IPR) valve hydraulic circuit. Decision
Hydraulically block off IPR return path by connecting Cylinder Performance Yes: Replace IPR valve,
Analyzer (CPA) tool(page 1402) to engine and use IPR Plug Tester(Figure 754) then perform Fuel Pressure
to bring IPR valve hydraulic circuit under maximum pressure. Adaptation Reset(page
1341). After repairs are
complete, retest for SPN
Is there a detected issue with IPR valve hydraulic circuit?
3055 FMI 2.
No: Go to Step 7.

Step 7 Perform dead head test of High-Pressure Oil Pump (HPOP). Decision
Connect Cylinder Performance Analyzer (CPA) tool(page 1402) to engine and Yes: Go to Step 8.
use Pressure Adapter Fitting and ICP Test Kit(Figure 752) isolating hydraulic
system from HPOP to determine if it develops pressure when pump is dead
headed.

Does this test detect an issue with HPOP pump?

NOTE: CPA tool has additional capabilities to determine HPOP failure modes,
compared to a simple pressure specification.
No: Proceed to Steps 9
through 12.

Step 8 Inspect intake screen. Decision

Remove High-Pressure Oil Pump (HPOP) pump and inspect intake screen for Yes: Clean intake screen,
plugging and debris. locate and repair source of
debris, then perform Fuel
Pressure Adaptation Reset
Is debris plugging intake to HPOP?
(page 1341). After repairs
NOTE: Visual inspection determines whether or not debris on intake side of are complete, retest for
HPOP is cause of insufficient dead head pressure. SPN 3055 FMI 2.
No: Replace HPOP, then
perform Fuel Pressure
Adaptation Reset (page
1341). After repairs are
complete, retest for SPN
3055 FMI 2.

Step 9 Inspect injector spool valve. Decision

Inspect injector spool valve for debris. Yes: Clean debris and then
go to Step 10.
Is debris present?
No: Go to Step 10.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 889

Step 10 Perform Injector Test. Decision

Perform Injector Test (Buzz test) (page 1365) to ensure all injectors function properly. Yes: Go to Step 11.
Do all injectors function properly? No: Repair / replace faulty
injector(s) and then go to
Step 11.

Step 11 Remove and clean injector plumbing. Decision

Remove and clean high-pressure oil rail, high-pressure oil hose, and elbow Go to Step 12.
connections to remove contamination or debris.

Step 12 Injector replacement and reset. Decision

Replace all six injectors, pucks, and seals. Perform Fuel Pressure Adaptation Go to End Diagnostic
Reset (page 1341). Steps.

End Diagnostic Steps

After performing all tests, if no problem is found, verify each step was completed correctly and proper decision was
made. Return to SPN 3055 FMI 2 fault code diagnostics.
890 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3242 FMI 2 - DPFIT Signal Erratic, Intermittent, or Incorrect

Fault Overview
Fault code sets when Aftertreatment Control Module (ACM) detects a difference between Diesel Particulate
Filter Intake Temperature (DPFIT) sensor and Diesel Particulate Filter Outlet Temperature (DPFOT) or Diesel
Oxidation Catalyst Inlet Temperature (DOCIT) sensor readings do not match expected values for engine
operating conditions.

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

Associated Faults

• SPN 3242 FMI 3 and 4

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed DPFIT sensor
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 891

Step 1 Check for associated faults. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for Yes: Replace DPFIT sensor. After
Associated Faults (page 890). repairs are complete, retest for
SPN 3242 FMI 2.
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 3242 FMI 2.

End Diagnostic Test

After performing diagnostic steps, if SPN 3242 FMI 2 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
892 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3242 FMI 3 - DPFIT signal Out of Range HIGH

Fault Overview
Diesel Particulate Filter Inlet Temperature (DPFIT) signal is higher then the expected range.

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

Associated Faults
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• DPFIT Signal circuit OPEN or short to PWR
• SIG GND circuit OPEN
• Failed DPFIT sensor

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for Yes: Go to Step 2.
SPN 3242 FMI 3.
Is SPN 3242 FMI 3 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Inspect Diesel Particulate Filter Intake Temperature (DPFIT) sensor Decision
and connector.
A. Key OFF. Yes: Go to Step 3
B. Disconnect DPFIT sensor.

C. Check DPFIT sensor and connector terminals for: damaged or pinched

wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are DPFIT sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3242
FMI 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 893

Step 3 DPFIT connector circuit check. Decision

A. Key OFF Yes: Replace DPFIT sensor.
After repairs are complete, retest
B. Connect Breakout Harness ZTSE4760A to DPFIT chassis harness
for SPN 3242 FMI 4.
connector and leave DPFIT sensor disconnected.

C. Using ZTSE4498, short pin-1 to pin-2.

D. Key-On Engine-Off (KOEO), connect Navistar® Engine Diagnostics and
clear codes.
Did SPN 3242 FMI 4 set after the codes were cleared? No: Go to Step 4.

Step 4 Determine if signal ground is Open. Decision

A. Key OFF Yes: Replace Open or short to
power between DPFIT pin-2 and
B. Connect Breakout Harness ZTSE4760A to DPFIT chassis harness
ECM pin C-17. After repairs are
connector and leave DPFIT sensor disconnected.
complete, retest for SPN 3242
C. Using ZTSE4498, short pin-2 to ground. FMI 4.
D. Key-On Engine-Off (KOEO), connect Navistar® Engine Diagnostics and
clear codes.
Did SPN 3242 FMI 4 set after the codes were cleared? No: Repair Open between DPFIT
pin-1 and ECM pin C-37. After
repairs are complete, retest for
SPN 3242 FMI 4.

End Diagnostic Test

After performing diagnostic steps, if SPN 3242 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
894 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3242 FMI 4 - DPFIT signal Out of Range LOW

Fault Overview

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• DPFIT signal circuit short to GND
• Failed DPFIT sensor
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 895

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for Yes: Go to Step 2.
SPN 3242 FMI 4.
Is SPN 3242 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect Diesel Particulate Filter Intake Temperature (DPFIT) sensor Decision
and connector.
A. Key OFF. Yes: Go to Step 3
B. Disconnect DPFIT sensor.
C. Check DPFIT sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are DPFIT sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3242
FMI 4.

Step 3 DPFIT connector voltage check. Decision

A. Perform Test 1 (page 896). Yes: Repair short to GND
between DPFIT pin-2 and ECM
B. Use DMM, measure voltage between Breakout Harness ZTSE4760A pin-2
pin C-17. After repairs are
and known good GND.
complete, retest for SPN 3242
FMI 4.
Is voltage 5.0 ± 0.5 volts? No: Replace DPFIT sensor. After
repairs are complete, retest for
SPN 3242 FMI 4.

End Diagnostic Test

After performing diagnostic steps, if SPN 3242 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
896 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Test (SPN 3242 FMI 4)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4760A.
• Digital Multimeter (DMM)

Figure 255 DPFIT Voltage Check

Test 1
A. Key OFF.
B. Disconnect Diesel Particulate Filter Intake Temperature (DPFIT) sensor.
C. Connect Breakout Harness ZTSE4760A to DPFIT harness connector and leave DPFIT sensor disconnected.
D. Key ON Engine OFF (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 897

SPN 3242 FMI 7 - DPFIT sensor or circuit fault

Fault Overview

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Biased DPFIT sensor or circuit
898 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Pin-Point Tests(page
SPN 3242 FMI 7. 899).
Is SPN 3242 FMI 7 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

End Diagnostic Test

After performing diagnostic steps, if SPN 3242 FMI 7 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 899

Pin-Point Tests (SPN 3242 FMI 7)

Figure 256 DPFIT circuit diagram

Cold Soak High Temperature Sensor Compare Check

Temperature values need to be measured after four hours cold soak.
1. Turn switch ON, engine OFF
2. Use Navistar® Engine Diagnostics, open Continuous Monitor session.
3. Compare DPF Inlet Temp, DOC Inlet Temp and DPF Outlet Temp. All temperature sensors should be within
68°F (38°C) of each other.
• If any temperature sensor is above or below of other sensors. Check for poor circuitry going to temperature
sensor.
• If circuits are okay, then replace failed temperature sensor.

WARNING:

To prevent personal injury or death, stay clear of rotating parts (belts and fan) and hot
engine surfaces.
1. Use EST with NNavistar® Engine Diagnostics, open Continuous Monitor Session.
2. Monitor sensor voltage. Verify an active code for sensor.
• If code is inactive, monitor signal while wiggling connector and all wires at suspected locations. If circuit
is interrupted, signal will spike and code will go active.
• If code is active, proceed to next Step.
3. Disconnect chassis harness from sensor.
NOTE: Inspect connectors for damaged pins, corrosion, or loose pins. Repair if necessary.
4. Connect Breakout Harness ZTSE4760A to chassis harness. Leave sensor disconnected.
900 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3242 FMI 10 - DPFIT signal abnormal rate of change

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Biased DPFIT sensor or circuit
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 901

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Pin-Point Tests(page
SPN 3242 FMI 10. 902).
Is SPN 3242 FMI 10 active or pending? No: Repair Active faults. After
repairs are complete, retest for
3242 FMI 10.

End Diagnostic Test

After performing diagnostic steps, if SPN 3242 FMI 10 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
902 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 3242 FMI 10)

Figure 257 DPFIT circuit diagram

Cold Soak High Temperature Sensor Compare Check

Temperature values need to be measured after four hours cold soak.
1. Turn switch ON, engine OFF
2. Use Navistar® Engine Diagnostics, open Continuous Monitor session.
3. Compare DPF Inlet Temp, DOC Inlet Temp and DPF Outlet Temp. All temperature sensors should be within
68°F (38°C) of each other.
• If any temperature sensor is above or below of other sensors. Check for poor circuitry going to temperature
sensor.
• If circuits are okay, then replace failed temperature sensor.

WARNING:

To prevent personal injury or death, stay clear of rotating parts (belts and fan) and hot
engine surfaces.
1. Use EST with Navistar® Engine Diagnostics, open Continuous Monitor Session.
2. Monitor sensor voltage. Verify an active code for sensor.
• If code is inactive, monitor signal while wiggling connector and all wires at suspected locations. If circuit
is interrupted, signal will spike and code will go active.
• If code is active, proceed to next Step.
3. Disconnect chassis harness from sensor.
NOTE: Inspect connectors for damaged pins, corrosion, or loose pins. Repair if necessary.
4. Connect Breakout Harness ZTSE4760A to chassis harness. Leave sensor disconnected.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 903

SPN 3242 FMI 20 - DPFIT signal drifted HIGH

Fault Overview
Fault sets when ECM determines difference between actual Aftertreatment Fuel Temperature (AFTFT) and
measured AFTFT is incorrect and/or erratic.

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

Associated Faults
• SPN 1322 - 1328 FMI 31 • SPN 2659 FMI 20 • SPN 3471 FMI 1, 7, and • SPN 3480 FMI 3 and 4
10
• SPN 3482 FMI 7

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Biased Diesel Particulate Filter Inlet Temperature (DPFIT) sensor
• Partial short circuits in wiring
• Alternative fuel in exhaust system
• Doser leaking fuel into exhaust
• Engine misfire
• Restricted exhaust causing excessive Exhaust Gas Temperature (EGT)
904 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2
Associated Faults (page 903).
Is EST DTC list clear of Associated Faults? No: Repair associated faults.
After repairs are complete, retest
for SPN 3242 FMI 20.

Step 2 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 3242 FMI 20 Yes: Go to Step 3.
Is SPN 3242 FMI 20 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 3242 FMI 20.

Step 3 Check for biased DPFIT sensor Decision

A. Perform Hot Run Sensor Comparison Test (page 1322). Yes: Go to Step 4.
B. Compare Diesel Particulate Filter Inlet Temperature (DPFIT), Diesel
Oxidation Catalyst Inlet Temperature (DOCIT), and DPF Outlet
Temperature (DPFOT). All sensors should be within 68°F (38°C) of each
other.
Are all temperature sensors within 68°F (38°C) other sensors? No: Replace failed temperature
sensor. After repairs are complete,
retest for SPN 3242 FMI 20.

Step 4 Inspect DPFIT sensor and connector. Decision

A. Key OFF. Yes: Go to Step 5.
B. Disconnect DPFIT sensor.
C. Check DPFIT sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are DPFIT sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3242
FMI 20.

Step 5 Test DPFIT sensor. Decision

A. Connect breakout harness ZTSE4760A between DPFIT sensor and Yes: Go to Step 6.
DPFIT sensor connector.

B. Do KOEO voltage check of DPFIT sensor between DPFIT signal and

ground.
Is voltage within specification? No: Replace DPFIT sensor. After
repairs are complete, retest for
SPN 3242 FMI 20.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 905

Step 6 Inspect Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter Decision
(DPF).
A. Remove DOC and DPF. Yes: Re-install DOC. Go to Step 8.

B. Inspect DOC internal for restrictions, damage, or evidence of defects.

Look for: chips, cracks, dents, or bent rims

Dents on ends are acceptable if:

• No damage to sealing surfaces on ends of DOC canister.
• Clamps are not prevented from seating properly.
• DOC is not oil-or fuel-soaked.
DOC cannot be cleaned Use cleaning equipment. It must be cleaned Use On
Board Filter Cleaning.
Oil or fuel-soaked DOC must be replaced.
Is DOC condition satisfactory? No: Replace DOC. Go to Step 7.

Step 7 Inspect DPF. Decision

Do DPF Filter Inspection (page 1653) section. Yes: Re-install DPF. Go to Step 9.
Does DPF pass inspection? No: Clean, repair, or replace
DPF following directions in DPF
Inspection section. Reset DPF
Soot Load. In Navistar® Engine
Diagnostics, go to: Parameters
> CDPF Reset Request > Yes
> Program Engine. Locate root
cause of any contamination, and
repair. After repairs are complete,
retest for SPN 3242 FMI 20.

Step 8 Inspect Hydrocarbon Injection (HCI) assembly. Decision

A. Remove HCI assembly (see Engine Service Manual). Yes: Go to Step 9.
B. Inspect HCI assembly for AFI Plugging (see IK1200753 Hydrocarbon
Injector Housing Cleaning Procedure).
Is HCI clean? No: Replace HCI assembly. After
replacement is complete, retest
for SPN 3242 FMI 20.

WARNING:

To prevent personal injury or death, do not perform an On Board Filter Cleanliness Test
(OBFCT) or Parked Regeneration if liquid oil or fuel is present or suspected to be present
in DPF. Liquid oil or fuel will ignite during an OBFCT causing fires or damage to vehicle
or other equipment.
906 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 9 Perform On Board Filter Cleanliness Test (OBFCT). Decision

Perform OBFCT (page 1331). Yes: Go to Step 10.
Is OBFCT running without an Abort message in EST? No: Replace DPF. Reset DPF
Soot Load. In Navistar® Engine
Diagnostics, go to: Parameters
> CDPF Reset Request > Yes >
Program Engine. Redo Step 10.

Step 10 Check Diesel Particulate Filter Differential Pressure (DPFDP) signal Decision
after OBFCT complete.
A. Perform Low to High Idle Test(page 1383). Yes: After doing all diagnostic
steps, if SPN 3242 FMI 20
B. At high idle, measure DPFDP signal pressure.
remains, verify each step was
completed correctly and proper
decision was made. Notify
supervisor for further action.
Does DPFDP signal measure less than 0.5 psi (3 kPa)? No: Remove DPF for external
cleaning. After repairs are
complete, retest for SPN 3242
FMI 20.

End Diagnostic Test

After performing diagnostic steps, if SPN 3242 FMI 20 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 907

SPN 3242 FMI 21 - DPFIT Signal Drifted LOW

Fault Overview
Fault sets when Engine Control Module (ECM) determines Diesel Particulate Filter Intake Temperature (DPFIT)
is reading under 410°F (210°C).

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• DPFIT sensor not connected in exhaust system
• Exhaust system not connected to engine
908 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 3242 FMI 21.
Is SPN 3242 FMI 21 active or pending? No: Repair active faults. After
repairs are complete, retest for
SPN 3242 FMI 21.

Step 2 Inspect DPFIT sensor and connector. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect DPFIT sensor.
C. Check DPFIT sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are DPFIT sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN
3242 FMI 21.

Step 3 Check exhaust system. Decision

Perform Exhaust and Aftertreatment System Inspection (page 1651) (engine and Yes: Go to Step 4.
vehicle) for damage or leaks.
Is exhaust system undamaged? No: Repair exhaust system. After
repairs are complete, retest for
SPN 3242 FMI 21.

Step 4 Check DPFIT, against Diesel Oxidation Catalyst Inlet Temperature Decision
(DOCIT) and Diesel Particulate Filter Outlet Temperature (DPFOT).
A. Do Hot Run Sensor Compare Test (page 1322). Yes: End diagnostics. After
repairs are complete, retest for
B. Compare DPFIT against DOCIT and DPFOT.
SPN 3242 FMI 21.
Are all temperature sensors within 77°F (43°C) of other sensors? No: Replace failed temperature
sensor. After repairs are
complete, retest for SPN 3242
FMI 21.

End Diagnostic Test

After performing diagnostic steps, if SPN 3242 FMI 21 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 909

SPN 3246 FMI 2 - DPFOT signal erratic, intermittent, or incorrect

Fault Overview
This fault sets when Diesel Particulate Filter Outlet Temperature (DPFOT) sensor signal doesn't match Diesel
Oxidation Catalyst Intake Temperature (DOCIT) and Diesel Particulate Filter Intake Temperature (DPFIT) at
initial engine start up after an 8 hour cold soak.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• High resistance in the DPFOT signal circuit
• High resistance in the DPFOT GND circuit
• Failed DPFOT sensor
910 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 3246 FMI 2.
Is SPN 3246 FMI 2 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Inspect Diesel Particulate Filter Outlet Temperature (DPFOT) sensor Decision
and connector.
A. Key-Off. Yes: Go to Step 3.
B. Disconnect DPFOT sensor.
C. Check DPFOT sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are DPFOT sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3246
FMI 2.

Step 3 Check for high resistance in DPFOT signal circuit. Decision

A. Perform Test 1(page 911). Yes: Go to Step 4.
B. Use EST, clear DTC codes.
Did SPN 3246 FMI 3 set after the codes were cleared? No: Repair high resistance
between DPFOT connector pin-2
and ECM pin C-67. After repairs
are complete, retest for SPN 3246
FMI 2.

Step 4 Check for high resistance in the DPFOT GND circuit. Decision
A. Perform Test (page 911). Yes: Replace DPFOT sensor.
After repairs are complete, retest
B. Use EST, clear DTC codes.
for SPN 3246 FMI 2.
Did SPN 3246 FMI 4 set after the codes were cleared? No: Repair high resistance
between DPFOT connector pin-1
and ECM pin C-37. After repairs
are complete, retest for SPN 3246
FMI 2.

End Diagnostic Test

After performing diagnostic steps, if SPN 3246 FMI 2 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 911

Pin Point Tests (SPN 3246 FMI 2)

Figure 258 DPFOT circuit diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools
• Breakout Harness ZTSE4760A
• 3-Banana Plug Harness ZTSE4498
• Digital Multimeter (DMM)

Test 1
A. Key-Off.
B. Disconnect Diesel Particulate Filter Outlet Temperature (DPFOT) sensor.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
D. Key-On Engine-Off (KOEO), log in to Navistar® Engine Diagnostics.

Test 2
A. Key-Off.
B. Disconnect DPFOT sensor.

C. Connect breakout harness ZTSE4760A to the vehicle harness and leave the DPFOT disconnected.
D. Use 3-Banana Plug Harness ZTSE4498 to short Breakout Harness ZTSE4760A pin-1 to pin-2.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
F. Key-On Engine-Off (KOEO), log in to Navistar® Engine Diagnostics.
912 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3246 FMI 3 - DPFOT signal Out of Range HIGH

Fault Overview
Fault code sets when Aftertreatment Control Module (ACM) detects that Diesel Particulate Filter Outlet
Temperature (DPFOT) sensor signal voltage is greater than expected for 16 seconds.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• DPFOT signal circuit Open or short to PWR
• Failed DPFOT sensor
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 913

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 3246 FMI 3.
Is SPN 3246 FMI 3 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect Diesel Particulate Filter Outlet Temperature (DPFOT) sensor Decision
and connector.
A. Key-Off. Yes: Go to Step 3.
B. Disconnect DPFOT sensor.
C. Check DPFOT sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are DPFOT sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness, or
terminal damage. After repairs are
complete, retest for SPN 3246 FMI
3.

Step 3 Check for short to PWR Decision

A. Perform Test 1(page 914). Yes: Replace DPFOT sensor.
After repairs are complete, retest
B. Use EST, clear DTC codes.
for SPN 3246 FMI 3.
Did SPN 3246 FMI 4 set after codes were cleared? No: Go to Step 4..

Step 4 Determine if SIG GND is Open. Decision

A. Perform Test 2(page 914). Yes: Repair Open in SIG GND
circuit between DPFOT pin-1 and
B. Use EST, clear DTC codes.
ECM pin C-37. After repairs are
complete, retest for SPN 3246 FMI
3.
Did SPN 3246 FMI 4 set after codes were cleared? No: Repair Open or short to
PWR between DPFOT pin-2 and
ECM pin C-67. After repairs are
complete, retest for SPN 3246 FMI
3.

End Diagnostic Steps

After performing diagnostic steps, if SPN 3246 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
914 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin Point Tests (SPN 3246 FMI 3)

Figure 259 DPFOT circuit diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools
• Breakout Harness ZTSE4760A
• 3-Banana Plug Harness ZTSE4498
• Digital Multimeter (DMM)

Test 1
A. Key-Off.
B. Disconnect Diesel Particulate Filter Outlet Temperature (DPFOT) sensor.
C. Connect Breakout Harness ZTSE4760A to vehicle harness and leave DPFOT sensor disconnected.
D. Use 3-Banana Plug Harness ZTSE4498 to short Breakout Harness ZTSE4760A pin-1 to pin-2.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
F. Key-On Engine-Off (KOEO), log in to Navistar® Engine Diagnostics.

Test 2
A. Key-Off.
B. Disconnect DPFOT sensor.
C. Connect Breakout Harness ZTSE4760A to vehicle harness and leave DPFOT sensor disconnected.
D. Use 3-Banana Plug Harness ZTSE4498 to short Breakout Harness ZTSE4760A pin-2 to ground.

E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
F. Key-On Engine-Off (KOEO), log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 915

SPN 3246 FMI 4 - DPFOT signal Out of Range LOW

Fault Overview
Fault code sets when Aftertreatment Control Module (ACM) detects that DPFOT sensor signal voltage is less
than expected for 16 seconds.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• DPFOT circuit shorted to GND
• Failed DPFOT sensor
916 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for Yes: Go to Step 2.
SPN 3246 FMI 4.
Is SPN 3246 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect Diesel Particulate Filter Outlet Temperature (DPFOT) sensor Decision
and connector.
A. Key-Off. Yes: Go to Step 3.
B. Disconnect DPFOT sensor.
C. Check DPFOT sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are DPFOT sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3246
FMI 4.

Step 3 Check for short to GND. Decision

A. Perform Test 1(page 917). Yes: Replace DPFOT sensor.
After repairs are complete, retest
B. Use EST, clear DTC codes.
for SPN 3246 FMI 4.
Did SPN 3246 FMI 3 set after codes were cleared? No: Repair short to GND between
DPFOT connector pin-2 and
ECM pin C-67. After repairs are
complete, retest for SPN 3246
FMI 4.

End Diagnostic Test

After performing diagnostic steps, if SPN 3246 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 917

Pin Point Tests (SPN 3246 FMI 4)

Figure 260 DPFOT circuit diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools
• Breakout Harness ZTSE4760A
• 3-Banana Plug Harness ZTSE4498
• Digital Multimeter (DMM)

Test 1
A. Key-Off.
B. Disconnect Diesel Particulate Filter Outlet Temperature (DPFOT) sensor.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
D. Key-On Engine-Off (KOEO), log in to Navistar® Engine Diagnostics.
918 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3246 FMI 7 - DPFOT not warming along with engine

Fault Overview

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

Associated Faults
SPN 3246 FMI 3 and 4
(DPFOT)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• DPFOT signal circuit high resistance
• DPFOT Signal GND high resistance
• Failed DPFOT sensor
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 919

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 918).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 3246 FMI 7.

Step 2 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 3246 FMI 7. Yes: Go to Step 3.
Is SPN 3246 FMI 7 active or pending? No: Repair active faults. After
repairs are complete, retest for
SPN 3246 FMI 7.

Step 3 Inspect connections at Diesel Particulate Filter Outlet Temperature Decision

(DPFOT) sensor.
A. Key-Off. Yes: Go to Step 4.
B. Disconnect DPFOT sensor connector.
C. Check DPFOT sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are DPFOT sensor, connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3246
FMI 7.

Step 4 Do DPFOT Voltage Check. Decision

A. Perform Test 1 (page 921). Yes: Go to Step 5.
B. Use DMM, measure voltage from Breakout Harness ZTSE4760A pin-1 to
B+.
Is voltage B+ ± 0.5 volts? No: Repair high resistance
between DPFOT pin-1 and ECM
pin C-37. After repairs are
complete, retest for SPN 3246
FMI 7.
920 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 5 Do DPFOT Voltage Check. Decision

A. Perform Test 2 (page 921). Yes: Replace DPFOT sensor.
After repairs are complete, retest
B. Use DMM, measure voltage from Breakout Harness ZTSE4760A pin-2
for SPN 3246 FMI 7.
to known good GND.
Is voltage 5.0 ± 0.5 volts? No: Repair high resistance
between DPFOT pin-2 and ECM
pin C-67. After repairs are
complete, retest for SPN 3246
FMI 7.

End Diagnostic Test

After performing diagnostic steps, if SPN 3246 FMI 7 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 921

Pin-Point Tests (SPN 3246 FMI 7)

Figure 261 DPFOT circuit diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools
• Breakout Harness ZTSE4760A
• Digital Multimeter (DMM)

Figure 262 Voltage Check

Test 1
A. Key-Off.

B. Disconnect Diesel Particulate Filter Outlet Temperature (DPFOT) sensor.

C. Connect Breakout Harness ZTSE4760A DPFOT chassis harness and leave DPFOT sensor disconnected.

D. Key-On Engine-Off (KOEO).

922 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 263 Voltage Check

Test 2
A. Key-Off.
B. Disconnect Diesel Particulate Filter Outlet Temperature (DPFOT) sensor.
C. Connect Breakout Harness ZTSE4760A DPFOT chassis harness and leave DPFOT sensor disconnected.
D. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 923

SPN 3246 FMI 20 - DPFOT signal drifted HIGH

Fault Overview
Fault is set when Engine Control Module (ECM) detects Diesel Particulate Filter Outlet Temperature (DPFOT)
sensor reading is greater than expected for current operating conditions.

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

Associated Faults
SPN 2791 SPN 3480 SPN 4077 SPN 5456
SPN 5541

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Intake, Charge Air Cooler (CAC), or Exhaust system Damage or failure
• Mechanical Compression loss
• Cylinder misfire
• Failed Diesel Particulate Filter (DPF) or Diesel Oxidation Catalyst (DOC) (contamination or damage)

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 923).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 3246 FMI 20.

Step 2 Inspect air intake system, exhaust system, and air filter. Decision
• Perform Intake Air Inspection (page 1648) and Yes: Go to Step 3.
• Exhaust and Aftertreatment System Inspection (page 1651).
Is air intake system, exhaust system, fuel system, and air filter free of restrictions, No: Repair restrictions, air leaks,
leaks, and physical damage? fuel leaks, or physical damage.
After repairs are complete, retest
for SPN 3246 FMI 20.
924 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Inspect connections at Diesel Particulate Filter Outlet Temperature Decision

(DPFOT) sensor.
A. Key OFF. Yes: Go to Step 4.
B. Disconnect DPFOT sensor.

C. Check DPFOT sensor and connector terminals for: damaged or pinched

wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are DPFOT sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3246
FMI 20.

Step 4 Determine if engine has a mechanical cylinder balance problem Decision

(compression loss).
Perform Relative Compression Test Plus (RCT+) (page 1465). Yes: Repair mechanical problem
with cylinder(s) indicating low
performance. After repairs are
complete, retest for SPN 3246
FMI 20.
Does CPA Tool indicate a problem or generate a warranty authorization code No: Go to Step 5.
(WAC)?

Step 5 Check for a misfire. Decision

Perform following checks and tests: Yes: Repair misfire on identified
cylinder. After repairs are
• CPA Signal Check (page 1413),
complete, retest for SPN 3246
• CPA Cold Idle Test (page 1407), FMI 20.
• CPA Hot Idle Test (page 1421).
Was a misfire identified by CPA tool? No: Go to Step 6.

Step 6 Check for High DPFOT during 0-60 Road Test. Decision
Perform 0 to 60 MPH Test (page 1514). Open snapshot recording to view data. Yes: Go to Step 7.
Did DPFOT ever rise above 1022°F (550°C)? No: End Diagnostics and retest for
SPN 3246 FMI 20.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 925

Step 7 Check DPF and DOC per Reuse guidelines. Decision

Remove DPF (see Aftertreatment Symptom-Based Diagnostic and Service Yes: If needed, clean DPF,
Manual) and inspect for defects or contamination. Compare to reuse guidelines in reinstall on vehicle, and reset DPF
(Aftertreatment Symptom-Based Diagnostic and Service Manual 0000003081). Soot Load. In Navistar® Engine
Diagnostics go to: Parameters
> CDPF Reset Request > Yes >
Program Engine. After repairs are
complete, retest for SPN 3246
FMI 20.
Is DPF reusable and not contaminated? No: Repair source of
contamination (fuel, oil or coolant
leak to exhaust) see symptoms
diagnostics. Replace DOC and/or
DPF. After repairs are complete,
retest for SPN 3246 FMI 20.

End Diagnostic Test

After performing diagnostic steps, if SPN 3246 FMI 20 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
926 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3246 FMI 21 - DPFOT Signal Drifted LOW

Fault Overview
Fault sets when Engine Control Module (ECM) determines Diesel particulate Filter Outlet Temperature (DPFOT)
is less than 500°F (260°C).

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• DPFOT sensor not connected to exhaust system
• Exhaust system not attached to engine
• High resistance or open in DPFOT sensor circuit
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 927

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list Yes: Go to Step 2.
for SPN 3246 FMI 21.
Is SPN 3246 FMI 21 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 3246 FMI 21.

Step 2 Determine if exhaust system has restrictions, leaks or damage. Decision

A. Commence four hour cold soak for Step 4 below. Yes: Go to Step 3.
B. Inspect exhaust system for reversed sensor hoses, restrictions, leaks,
or physical damage.
Is exhaust system clear of restrictions, leaks, and physical damage? No: Repair restrictions, leaks, or
physical damage. After repairs
are complete, retest for SPN 3246
FMI 21.

Step 3 Inspect connections at Diesel Particulate Filter Outlet Temperature Decision

(DPFOT) sensor.
A. Key OFF. Yes: Go to Step 4.
B. Disconnect DPFOT sensor.
C. Check DPFOT sensor and connector for: damaged or pinched wires; wet
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Is DPFOT sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN
3251 FMI 21.

Step 4 Do Hot Run Sensor Compare Check. Decision

A. Do Hot Run Sensor Compare Check (page 1322). Yes: Go to Step 5.
B. Compare Diesel Particulate Filter (DPF) Inlet Temperature (DPFIT), Diesel
Oxidation Catalyst (DOC) Inlet Temperature (DOCIT), and DPF Outlet
Temperature (DPFOT).
C. All sensors should be within 68°F (38°C) of each other.
Are all temperature sensors within 68°F (38°C) other sensors? Replace failed temperature
sensor. After repairs are
complete, retest for SPN 3246
FMI 21.
928 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 5 Test DPFOT sensor. Decision

Connect breakout harness ZTSE4760A between DPFOT sensor and DPFOT Yes: After doing all diagnostic
sensor connector. Perform KOEO voltage check of DPFOT sensor between steps, if SPN 3246 FMI 21
DPFOT signal and ground. remains, verify each step was
completed correctly and proper
decision was made. Notify
supervisor for further action.
Is voltage within specification (page 1704)? No: Replace DPFOT sensor. After
repairs are complete, retest for
SPN 3246 FMI 21.

End Diagnostic Test

After performing diagnostic steps, if SPN 3246 FMI 21 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 929

SPN 3251 FMI 0 - DPFDP Excessively HIGH (Plugged filter)

Fault Overview

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

Associated Faults
SPN 3251 FMI 2 and 21 SPN 3556 FMI 0, 1, and 7

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Restricted or plugged filter
• Biased Diesel Particulate Filter Differential Pressure (DPFDP) sensor or circuit
• Reversed DPF sensor hoses
930 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 929).
Is EST DTC list clear of Associated Faults? No: No: Repair Associated Faults.
After repairs are complete, retest
for SPN 3251 FMI 0.

Step 2 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 3251 FMI 0. Yes: Go to Step 3.
Is SPN 3251 FMI 0 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 3251 FMI 0.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 931

Figure 264 DPFDP Sensor Location (Typical)

1. Diesel Particulate Filter Differential Pressure (DPFDP) sensor
2. DPFDP sensor hose
932 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Determine if exhaust system has restrictions, leaks, or damage. Decision

A. Commence four hour cold soak for Step 6 below. Yes: Go to Step 4.
B. Inspect exhaust system for reversed sensor hoses, restrictions, leaks,
or physical damage.
Is exhaust system clear of restrictions, leaks, and physical damage? No: Repair restrictions, leaks, or
physical damage. After repairs
are complete, retest for SPN 3251
FMI 0.

Step 4 Inspect connections at Diesel Particulate Filter Differential Pressure Decision

(DPFDP), Intake Air Heater (IAH), and Down Stream Injection (DSI)
sensors.
A. Key OFF. Yes: Go to Step 5.
B. Disconnect DPFDP, IAH, and DSI sensors.
C. Check DPFDP, IAH, and DSI sensors and connectors for: damaged or
pinched wires; wet or corroded terminals; loose, bent, or broken pins; or
broken connector housing.
Are DPFDP, IAH, and DSI sensor connectors, harnesses, and terminals clean No: Repair connector, harness,
and undamaged? or terminal damage. After repairs
are complete, retest for SPN 3251
FMI 0.

Step 5 Check health of regeneration system. Decision

A. Do Hot Run Sensor Compare Check (page 1322). Yes: Go to Step 6.
B. Compare Diesel Particulate Filter Inlet Temperature (DPFIT), Diesel
Oxidation Catalyst Inlet Temperature (DOCIT), and Diesel Particulate Filter
Outlet Temperature (DPFOT).
C. All sensors should be within 68°F (38°C) of each other.
Is DPFIT within 68°F (38°C) other sensors? No: Replace out of specification
sensor. After repairs are
complete, retest for SPN 3251
FMI 0.

Step 6 Test DPFDP, IAH, and DSI for intermittent circuit operation using ESTe. Decision
A. Perform Continuous Monitor Test (page 1361). Yes: Go to Step 7.
B. Verify sensor voltages are within specifications.
Are voltages within specification? No: Locate specific circuit
component causing erratic or
intermittent operation. Perform
voltage and resistance checks
in this section. Repair circuits
as required. After repairs are
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 933

complete, retest for SPN 3251

FMI 0.

Step 7 Decision
Remove DOC and DPF and inspect DPF internal areas for restrictions, damage, Yes: Clean DPF using appropriate
or evidence of defects. DPF cleaning equipment and
cleaning equipment instructions.
Look for:
Re-install DPF. Reset DPF
• Black on both ends of filter Soot Load. In Navistar® Engine
Diagnostics go to: Parameters
• Black holes on clean side (not more than 20 allowed)
> CDPF Reset Request > Yes >
• Discoloration rings Program Engine. Go to Step 8.
• Chipped, cracked, dented, or bent rims
• Packing failure
• Oil soaked
Does DPF meet all cleaning requirements? No: Replace DPF. Reinstall on
vehicle, and reset DPF Soot Load.
In Navistar® Engine Diagnostics
go to: Parameters > CDPF Reset
Request > Yes > Program Engine.
After replacement is complete,
retest for SPN 3251 FMI 0.

WARNING:

To prevent personal injury or death, do not perform an On Board Filter Cleanliness Test
(OBFCT) or Parked Regeneration if liquid oil or fuel is present or suspected in DPF.
Liquid oil or fuel will ignite during an OBFCT causing fires or damage to vehicle or other
equipment.

Step 8 Decision
Use EST, start an On Board Filter Cleanliness Test (OBFCT) (page 1331). Yes: Go to Step 9.
Is OBFCT running without an Abort Message in EST? No: Correct Parked regen
Inhibitors and redo Step 8.

Step 9 Decision
While running OBFCT, inspect exhaust system for leaks or physical damage. Yes: Go to Step 10.
Is exhaust system clear of leaks and physical damage? No: Repair leaks or physical
damage. After repairs are
complete, retest for SPN 3251
FMI 0.
934 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 10 Decision
Yes: After doing all diagnostic
steps, if SPN 3251 FMI 0 remains,
verify each step was completed
correctly and proper decisions
were made. Notify supervisor for
further action.
After OBFCT is complete, does Diesel Particulate Filter Differential Pressure No: Remove DPF and inspect for
(DPFDP) signal measure below 0.5 psi (3 kPa) at high idle? restrictions. If restricted, have DPF
cleaned using appropriate DPF
cleaning equipment. After repairs
are complete, retest for SPN 3251
FMI 0.

End Diagnostic Test

After performing diagnostic steps, if SPN 3251 FMI 0 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 935

SPN 3251 FMI 2 - DPFDP signal erratic, intermittent, or incorrect

Fault Overview
Fault code sets when Engine Control Module (ECM) detects aftertreatment Diesel Particulate Filter Differential
Pressure (DPFDP) is greater than 0.25 psi (1.5 kPa), is not changing with engine conditions, or range since last
monitor < 0.15 psi (1 kPa).

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

Associated Faults
• SPN 3251 FMI 3 and 4 • SPN 3510 (VREF)
(DPFDP)

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Missing Diesel Particulate Filter (DPF)
• DPF damaged or failed
• DPFDP sensor hoses reversed or damaged

Step 1 Check for Associated Fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 935).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 3251 FMI 2.

Step 2 Determine if a Diesel Particulate Filter (DPF) is installed. Decision

Inspect exhaust system to determine if DPF is installed. Verify DPF and is not Yes: Go to Step 3.
damaged.
Is correct DPF installed in exhaust system and is it clear of damage? No: Install correct DPF or repair
system damage as needed. After
repairs are complete, retest for
SPN 3251 FMI 2.
936 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 265 DPFDP Sensor Location (Typical)

1. Diesel Particulate Filter Differential Pressure (DPFDP) sensor
2. DPFDP sensor hose
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 937

Step 3 Inspect Diesel Particulate Filter Differential Pressure (DPFDP) sensor Decision
hoses and tubes.
Inspect DPFDP sensor hoses, and tubes for kinks, improper hose routing, reversed Yes: Go to Step 4.
hoses, or damage.
Are DPFDP hoses routed correctly and clear of damage? No: Reroute or replace DPFDP
sensor hoses and/or tubes
as needed. After repairs are
complete, retest for SPN 3251
FMI 2.

Step 4 Determine if DPF has failed. Decision

Perform Snap Acceleration Test (page 1671). Yes: Go to Symptom 5 (MEDIUM
DUTY) : BLACK SMOKE
Aftertreatment Symptom-Based
Diagnostic and Service Manual
0000003081.
Is black smoke visible at tailpipe? No: Go to Step 5.

Step 5 Determine if DPF is contaminated or not usable. Decision

A. Remove DPF see Aftertreatment Symptom-Based Diagnostic and Service Yes: If needed, clean the DPF
Manual 0000003081. and reset DPF Soot Load. In
Navistar® Engine Diagnostics, go
B. Inspect DPF for contamination and defects. Compare to reuse guidelines
to: Parameters > CDPF Reset
in Aftertreatment Symptom-Based Diagnostic and Service Manual .
Request > Yes > Program Engine.
After repairs are complete, retest
for SPN 3251 FMI 2.
Is DPF reusable and not contaminated? No: Repair source of
contamination (fuel, oil, or
coolant leak to exhaust). Install
usable DPF. After repairs are
complete, retest for SPN 3251
FMI 2.

End Diagnostic Test

After performing diagnostic steps, if SPN 3251 FMI 2 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
938 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3251 FMI 3 - DPFDP signal Out of Range HIGH

Fault Overview
Fault sets when Engine Control Module (ECM) determines DPF Differential Pressure (DPFDP) sensor voltage
is greater than 4.75 Volts.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• DPFDP signal circuit short to PWR
• DPFDP signal GND circuit Open
• Failed DPFDP/DPFOP sensor
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 939

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 3251 FMI 3.
Is SPN 3251 FMI 3 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect Diesel Particulate Filter Differential Pressure (DPFDP) sensor Decision
and connector.
A. Key-Off. Yes: Go to Step 3.
B. Disconnect DPFDP sensor.
C. Check DPFDP sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are DPFDP sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3251
FMI 3.

Step 3 Check for short to PWR. Decision

A. Perform Test 1(page 940). Yes: Go to Step 4.
B. Use DMM, measure voltage from Breakout Harness ZTSE4761A pin-2
to known good GND.
Is voltage less than 0.5 volts? No: Repair short to PWR between
DPFDP connector pin-2 and
ECM pin C-19. After repairs are
complete, retest for SPN 3251
FMI 3.

Step 4 Check for Open GND. Decision

A. Perform Test 2(page 940). Yes: Replace DPFDP sensor.
After repairs are complete, retest
B. Use DMM, measure voltage from Breakout Harness ZTSE4761A pin-1
for SPN 3251 FMI 3.
to PWR.
Is voltage B+ ± 0.5 volts? No: Repair Open ground circuit
between DPFDP connector pin-1
and ECM pin C-37. After repairs
are complete, retest for SPN 3251
FMI 3.

End Diagnostic Test

After performing diagnostic steps, if SPN 3251 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
940 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin Point Tests (SPN 3251 FMI 3)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Required Tools
• Breakout Harness ZTSE4761A
• Digital Multimeter (DMM)

Test 1
A. Key-Off.
B. Disconnect Diesel Particulate Filter Differential Pressure (DPFDP) sensor.
C. Connect Breakout Harness ZTSE4761A to chassis harness and leave DPFDP sensor disconnected.
D. Key-On Engine-Off (KOEO).

Test 2
A. Key-Off.
B. Disconnect Diesel Particulate Filter Differential Pressure (DPFDP) sensor.
C. Connect Breakout Harness ZTSE4761A to chassis harness and leave DPFDP sensor disconnected.
D. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 941

SPN 3251 FMI 4 - DPFDP signal Out of Range LOW

Fault Overview
Fault sets when Engine Control Module (ECM) determines DPF Differential Pressure (DPFDP) sensor voltage
is less than 0.425 Volts.

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

Associated Faults
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• DPFDP signal circuit short to GND
• DPFDP signal circuit Open
• VREF circuit Open
• Failed DPFDP/DPFOP sensor
942 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for Yes: Go to Step 2.
SPN 3251 FMI 4.
Is SPN 3251 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at DPFDP sensor. Decision

A. Key-Off. Yes: Go to Step 3.
B. Disconnect DPFDP sensor connector.
C. Check DPFDP sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are DPFDP sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3251
FMI 4.

Step 3 Check VREF voltage Decision

A. Perform Test 1 (page 944). Yes: Go to Step 4.
B. Use DMM, measure voltage between Breakout Harness ZTSE4761A
pin-3 and known good GND.
Is voltage 5 ± 0.5 volts? No: Repair Open in VREF between
DPFDP pin-3 and ECM pin C-51.
After repairs are complete, retest
for SPN 3251 FMI 4.

Step 4 Check DPFDP circuit faults. Decision

A. Perform Test 2 (page 944). Yes: Replace DPFDP sensor.
After repairs are complete, retest
B. Use EST, Clear DTC codes.
for SPN 3251 FMI 4.
Does SPN 3251 FMI 3 set after the codes are cleared? No: Go to Step 5.

Step 5 Check DPFDP circuit faults. Decision

A. Perform Test 2 (page 944). Yes: Repair short to GND in
DPFDP signal circuit between
B. Use EST, Clear DTC codes.
DPFDP pin-2 and ECM pin C-19.
After repairs are complete, retest
for SPN 3251 FMI 4.
Does SPN 3510 FMI 4 set after the codes are cleared? No: Repair Open in DPFDP signal
circuit between DPFDP pin-2 and
ECM pin C-19. After repairs are
complete, retest for SPN 3251 FMI
4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 943

End Diagnostic Test

After performing diagnostic steps, if SPN 3251 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
944 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests for SPN 3251 FMI 4

Figure 266 DPFDP circuit diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools
• Breakout Harness ZTSE4761A
• 3-Banana Plug Harness ZTSE4498
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B compliant supporting J1939 and J1708)

Figure 267 VREF Circuit Check

Test 1
A. Key-Off.

B. Disconnect Diesel Particulate Filter Differential Pressure (DPFDP) sensor harness.

C. Connect Breakout Harness ZTSE4761A to DPFDP chassis harness and leave DPFDP sensor disconnected.

D. Key-On Engine-Off (KOEO).

 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 945

Figure 268 DPFDP Circuit Check

Test 2
A. Key-Off.
B. Disconnect Diesel Particulate Filter Differential Pressure (DPFDP) sensor harness.
C. Connect Breakout Harness ZTSE4761A to DPFDP chassis harness and leave sensor disconnected.
D. Use 3-Banana Plug Harness ZTSE4498 short Breakout Harness ZTSE4761A pin-2 to pin-3.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
F. Key On Engine Off (KOEO), log in to Navistar® Engine Diagnostics.
946 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3251 FMI 10 - DPFDP Signal Abnormal Rate of Change

Fault Overview
Fault code sets when the Engine Control Module (ECM) detects Aftertreatment Diesel Particulate Filter
Differential Pressure (DPFDP) is not changing with engine conditions.

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

Associated Faults

• SPN 3251 FMI 3 & 4

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• DPFDP sensor tubes restricted, open, or routed incorrectly
• Failed DPFDP sensor
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 947

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST). Key ON, Engine OFF (KOEO), check Diagnostic Yes: Go to Step 2.
Trouble Codes (DTC) list for SPN 3251 FMI 10.
Is SPN 3251 FMI 10 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 3251 FMI 10.

Figure 269 DPFDP Sensor Location (Typical)

1. Diesel Particulate Filter 2. DPFDP sensor hose
Differential Pressure (DPFDP)
sensor
948 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 2 Inspect Diesel Particulate Filter Differential Pressure (DPFDP) sensor Decision
hoses and tubes.
Inspect DPFDP sensor hoses, and tubes for kinks, improper hose routing, reversed Yes: Replace DPFDP sensor.
hoses, or damage. After repairs are complete, retest
for SPN 3251 FMI 10.
Are DPFDP hoses routed correctly and clear of damage? No: Reroute or replace DPFDP
sensor hoses and/or tubes
as needed. After repairs are
complete, retest for SPN 3251
FMI 10.

End Diagnostic Tests

After performing diagnostic steps, if SPN 3251 FMI 10 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 949

SPN 3251 FMI 14 - DPFDP sensor pressure hoses reversed

Fault Overview
Fault sets when Engine Control Module (ECM) determines DPFDP is less than 0 psi (0 kPa).

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

Associated Faults
• SPN 3246 FMI 20 • SPN 3251 FMI 2 and 21 • SPN 3556 FMI 0, 1, and 7 • SPN 3719 FMI 0, 15, and
16
• SPN 3936 FMI 0, 2, and 14

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Reversed DPFDP hoses
• Restriction in prefilter hose
• Biased, damage, or faulty sensor or circuit
• Missing DPF
950 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults(page 949).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 3251 FMI 14.

Step 2 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 3.
SPN 3251 FMI 14.
Is SPN 3251 FMI 14 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 3251 FMI 14.

Step 3 Decision

Inspect exhaust system for reversed sensor hoses, restrictions, leaks, or physical Yes: Go to Step 4.
damage.
Is exhaust system clear of restrictions, leaks, and physical damage? No: Repair restrictions, leaks, or
physical damage. After repairs
are complete, retest for SPN 3251
FMI 14.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 951

Figure 270 DPFDP Sensor Location (Typical)

1. Diesel Particulate Filter Differential Pressure (DPFDP) sensor
2. DPFDP sensor hose
952 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 4 Inspect Diesel Particulate Filter Differential Pressure (DPFDP) sensor Decision
hoses and tubes.
Inspect DPFDP sensor hoses, and tubes for kinks, improper hose routing, reversed Yes: Go to Step 5.
hoses, or damage.
Are DPFDP hoses routed correctly and clear of damage? No: Reroute or replace DPFDP
sensor hoses and/or tubes
as needed. After repairs are
complete, retest for SPN 3251
FMI 2.

Step 5 Inspect Diesel Particulate Filter Differential Pressure (DPFDP) sensor Decision
and connector.
A. Key OFF. Yes: Go to Step 6.
B. Disconnect DPFDP sensor.
C. Check DPFDP sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are DPFDP sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3251
FMI 14.

Step 6 Test DPFDP circuits for open, short, or high resistance conditions. Decision

Do connector voltage checks and resistance checks (page 1677). Yes: Go to Step 7.
Are DPFDP circuits within specifications? No: Repair circuits as required.
After repairs are complete, retest
If voltage checks pass, doing resistance checks is not required.
for SPN 3251 FMI 14.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 953

Step 7 Test DPFDP for intermittent circuit operation. Decision

A. Perform Continuous Monitor Test (page 1361). Yes: After doing all diagnostic
steps, if SPN 3251 FMI 14
B. Verify sensor voltages are within specifications.
remains, verify each step was
completed correctly and proper
decision was made. Notify
supervisor for further action.
Are sensor voltages within specification? No: Locate specific circuit
component causing erratic or
intermittent operation. Perform
voltage and resistance checks
in this section. Repair circuits
as required. After repairs are
complete, retest for SPN 3251
FMI 14.

End Diagnostic Test

After performing diagnostic steps, if SPN 3251 FMI 14 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
954 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3251 FMI 21 - DPFDP excessively LOW (Sensor/circuit fault or missing DPF)

Fault Overview

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

Associated Faults
• SPN 3251 FMI 3 and 4 • SPN 3510 (VREF)
(DPFDP)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Missing Diesel Particulate Filter (DPF)
• DPF damaged or failed
• Diesel Particulate Filter Differential Pressure (DPFDP) sensor hoses reversed or damaged
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 955

Step 1 Check for Associated Fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 954).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 3251 FMI 21.

Step 2 Check exhaust system for an installed Diesel Particulate Filter (DPF). Decision
• Check exhaust system for an installed DPF. Yes: Go to Step 3.
• Check to make sure DPF is not damaged.
• Perform Exhaust and Aftertreatment System Inspection (page 1651).
Is DPF installed in exhaust system and is system free of external damage? No: Install correct DPF or repair
system damage as needed. After
repairs are complete, retest for
SPN 3251 FMI 21.
956 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 271 DPFDP Sensor Location (Typical)

1. Diesel Particulate Filter Differential Pressure (DPFDP) sensor
2. DPFDP sensor hose
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 957

Step 3 Inspect Diesel Particulate Filter Differential Pressure (DPFDP) sensor Decision
hoses and tubes.
Inspect DPFDP sensor hoses, and tubes for kinks, improper hose routing, reversed Yes: Go to Step 4.
hoses, restrictions (soot, water, icing) or damage.
Are DPFDP hoses routed correctly clear of damage and unrestricted? No: Reroute or replace DPFDP
sensor hoses and/or tubes
as needed. After repairs are
complete, retest for SPN 3251
FMI 21.

Step 4 Inspect DPFDP sensor and connector. Decision

A. Key OFF. Yes: Go to Step 5.
B. Disconnect DFDP sensor.
C. Check DPFDP sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent or broken pins; or broken
connector housing.
Are DPFDP sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN3251
FMI 21.

Step 5 Test DPFDP for intermittent circuit operation. Decision

A. Perform Intermittent or Inactive Fault Diagnostic Procedure (page 1344). Yes: Go to Step 6.
B. Verify DPFDP sensor voltages are within specifications.
Is DPFDP sensor voltage within specifications? No: Replace sensor. After repairs
are complete, retest for SPN 3251
FMI 21.

Step 6 Determine if DPF has failed. Decision

Perform Snap Acceleration Test (page 1671). Yes: Go to Symptom 5 (MEDIUM
DUTY) : BLACK SMOKE
Aftertreatment Symptom-Based
Diagnostic and Service Manual
0000003081.
Is black smoke visible at tailpipe? No: Go to Step 7.
958 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 7 Check DPF per Reuse guidelines Decision

A. Remove DPF see Aftertreatment Symptom-Based Diagnostic and Service Yes: Clean DPF if needed and
Manual 0000003081. reinstall on vehicle. Reset DPF
Soot Load. In Navistar® Engine
B. Inspect DPF for contamination and defects. Compare to reuse guidelines
Diagnostics go to: Parameters
in Aftertreatment Symptom-Based Diagnostic and Service Manual .
> CDPF Reset Request > Yes >
Program Engine. After repairs are
complete, retest for SPN 3251
FMI 21.
Is DPF reusable and not contaminated? No: Repair source of
contamination (fuel, oil, or
coolant leak to exhaust). Install
usable DPF. After repairs are
complete, retest for SPN 3251
FMI 21.

End Diagnostic Test

After performing diagnostic steps, if SPN 3251 FMI 21 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 959

SPN 3387 FMI 20 - Cyl 1 Balance Max Limit Exceeded

Fault Overview
Update calibration to prevent these codes from falsely setting.

Step 1 Obtain vehicle health report and check for current Engine Control Decision
Module (ECM) calibration.
Perform Obtain Vehicle Health Report (page 1324). Yes: Retest for active faults.
Is ECM calibration current? No: ECM calibration not current.
Ensure vehicle has latest ECM
calibration. After repairs are
complete, retest for SPN 3387
FMI 20.

End Diagnostic Test

After performing diagnostic steps, if SPN 3387 FMI 20 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
960 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3387 FMI 21 - Cyl 1 Balance Below Min Limit

Fault Overview
Update calibration to prevent these codes from falsely setting.

Step 1 Obtain vehicle health report and check for current Engine Control Decision
Module (ECM) calibration.
Perform Obtain Vehicle Health Report (page 1324). Yes: Retest for active faults.
Is ECM calibration current? No: ECM calibration not current.
Ensure vehicle has latest ECM
calibration. After repairs are
complete, retest for SPN 3387
FMI 21.

End Diagnostic Test

After performing diagnostic steps, if SPN 3387 FMI 21 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 961

SPN 3388 FMI 20 - Cyl 2 Balance Max Limit Exceeded

Fault Overview
Update calibration to prevent these codes from falsely setting.

Step 1 Obtain vehicle health report and check for current Engine Control Decision
Module (ECM) calibration.
Perform Obtain Vehicle Health Report (page 1324). Yes: Retest for active faults.
Is ECM calibration current? No: ECM calibration not current.
Ensure vehicle has latest ECM
calibration. After repairs are
complete, retest for SPN 3388
FMI 20.

End Diagnostic Test

After performing diagnostic steps, if SPN 3388 FMI 20 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
962 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3388 FMI 21 - Cyl 2 Balance Below Min Limit

Fault Overview
Update calibration to prevent these codes from falsely setting.

Step 1 Obtain vehicle health report and check for current Engine Control Decision
Module (ECM) calibration.
Perform Obtain Vehicle Health Report (page 1324). Yes: Retest for active faults.
Is ECM calibration current? No: ECM calibration not current:
Ensure vehicle has latest ECM
calibration. After repairs are
complete, retest for SPN 3388
FMI 21.

End Diagnostic Test

After performing diagnostic steps, if SPN 3388 FMI 21 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 963

SPN 3389 FMI 20 - Cyl 3 Balance Max Limit Exceeded

Fault Overview
Update calibration to prevent these codes from falsely setting.

Step 1 Obtain vehicle health report and check for current Engine Control Decision
Module (ECM) calibration.
Perform Obtain Vehicle Health Report (page 1324). Yes: Retest for active faults.
Is ECM calibration current? No: ECM calibration not current.
Ensure vehicle has latest ECM
calibration. After repairs are
complete, retest for SPN 3388
FMI 21.

End Diagnostic Test

After performing diagnostic steps, if SPN 3389 FMI 20 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
964 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3389 FMI 21 - Cyl 3 Balance Below Min Limit

Fault Overview
Update calibration to prevent these codes from falsely setting.

Step 1 Obtain vehicle health report and check for current Engine Control Decision
Module (ECM) calibration.
Perform Obtain Vehicle Health Report (page 1324). Yes: Retest for active faults.
Is ECM calibration current? No: ECM calibration not current.
Ensure vehicle has latest ECM
calibration. After repairs are
complete, retest for SPN 3389
FMI 21.

End Diagnostic Test

After performing diagnostic steps, if SPN 3389 FMI 21 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 965

SPN 3390 FMI 20 - Cyl 4 Balance Max Limit Exceeded

Fault Overview
Update calibration to prevent these codes from falsely setting.

Step 1 Obtain vehicle health report and check for current Engine Control Decision
Module (ECM) calibration.
Perform Obtain Vehicle Health Report (page 1324). Yes: Retest for active faults.
Is ECM calibration current? No: ECM calibration not current.
Ensure vehicle has latest ECM
calibration. After repairs are
complete, retest for SPN 3390
FMI 20.

End Diagnostic Test

After performing diagnostic steps, if SPN 3390 FMI 20 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
966 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3390 FMI 21 - Cyl 4 Balance Below Min Limit

Fault Overview
Update calibration to prevent these codes from falsely setting.

Step 1 Obtain vehicle health report and check for current Engine Control Decision
Module (ECM) calibration.
Perform Obtain Vehicle Health Report (page 1324). Yes: Retest for active faults.
Is ECM calibration current? No: ECM calibration not current.
Ensure vehicle has latest ECM
calibration. After repairs are
complete, retest for SPN 3390
FMI 21.

End Diagnostic Test

After performing diagnostic steps, if SPN 3390 FMI 21 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 967

SPN 3391 FMI 20 - Cyl 5 Balance Max Limit Exceeded

Fault Overview
Update calibration to prevent these codes from falsely setting.

Step 1 Obtain vehicle health report and check for current Engine Control Decision
Module (ECM) calibration.
Perform Obtain Vehicle Health Report (page 1324). Yes: Retest for active faults.
Is ECM calibration current? No: ECM calibration not current.
Ensure vehicle has latest ECM
calibration. After repairs are
complete, retest for SPN 3391
FMI 20.

End Diagnostic Test

After performing diagnostic steps, if SPN 3391 FMI 20 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
968 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3391 FMI 21 - Cyl 5 Balance Below Min Limit

Fault Overview
Update calibration to prevent these codes from falsely setting.

Step 1 Obtain vehicle health report and check for current Engine Control Decision
Module (ECM) calibration.
Perform Obtain Vehicle Health Report (page 1324). Yes: Retest for active faults.
Is ECM calibration current? No: ECM calibration not current.
Ensure vehicle has latest ECM
calibration. After repairs are
complete, retest for SPN 3391
FMI 21.

End Diagnostic Test

After performing diagnostic steps, if SPN 3391 FMI 21 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 969

SPN 3392 FMI 20 - Cyl 6 Balance Max Limit Exceeded

Fault Overview
Update calibration to prevent these codes from falsely setting.

Step 1 Obtain vehicle health report and check for current Engine Control Decision
Module (ECM) calibration.
Perform Obtain Vehicle Health Report (page 1324). Yes: Retest for active faults.
Is ECM calibration current? No: ECM calibration not current.
Ensure vehicle has latest ECM
calibration. After repairs are
complete, retest for SPN 3392
FMI 20.

End Diagnostic Test

After performing diagnostic steps, if SPN 3392 FMI 20 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
970 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3392 FMI 21 - Cyl 6 Balance Below Min Limit

Fault Overview
Update calibration to prevent these codes from falsely setting.

Step 1 Obtain vehicle health report and check for current Engine Control Decision
Module (ECM) calibration.
Perform Obtain Vehicle Health Report (page 1324). Yes: Retest for active faults.
Is ECM calibration current? No: ECM calibration not current.
Ensure vehicle has latest ECM
calibration. After repairs are
complete, retest for SPN 3392
FMI 21.

End Diagnostic Test

After performing diagnostic steps, if SPN 3392 FMI 21 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 971

SPN 3464 FMI 3 - ETC short to PWR

Fault Overview

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• ETV-CL Short to PWR
• ETV-CH Short to PWR
• ETV-CL Short to ETV-CH
• Failed Engine Throttle Valve (ETV)
972 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for Yes: Go to Step 2.
SPN 3464 FMI 3.
Is SPN 3464 FMI 3 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at Engine Throttle Valve (ETV) connector. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect ETV sensor.
C. Check ETV sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are ETV sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3464
FMI 3.

Step 3 Check for short to GND. Decision

A. Perform Test 1(page 974). Yes: Go to Step 4.
B. Use DMM, measure resistance between Breakout Harness ZTSE4735A
pin-2 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ETV pin-2 and ECM pin E-57
and pin E-75. After repairs are
complete, retest for SPN 3464
FMI 3.

Step 4 Check for short to GND. Decision

A. Perform Test 2(page 974). Yes: Go to Step 5.
B. Use DMM, measure resistance between Breakout Harness ZTSE4735A
pin-6 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ETV pin-6 and ECM pin E-58
and pin E-76. After repairs are
complete, retest for SPN 3464
FMI 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 973

Step 5 Check for ETV-CL short to ETV-CH. Decision

A. Perform Test 3(page 975). Yes: Replace ETV. After repairs
are complete, retest for SPN 3464
B. Use DMM, measure resistance between Breakout Harness ZTSE4735A
FMI 3.
pin-6 and pin-2.
Is resistance greater than 1000 ohms? No: Repair short between ETV
pin-2 and pin-6. After repairs are
complete, retest for SPN 3464
FMI 3.

End Diagnostic Test

After performing diagnostic steps, if SPN 3464 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
974 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 3464 FMI 3)

Figure 272 ETV Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
• Breakout Harness ZTSE4735A
• Digital Multimeter (DMM)

Figure 273 ETC Circuit Check

Test 1
A. Key OFF.
B. Disconnect ETV connector.
C. Connect Breakout Harness ZTSE4735A to engine harness and leave ETV disconnected.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 975

Figure 274 ETC Circuit Check

Test 2
A. Key OFF.
B. Disconnect ETV connector.
C. Connect Breakout Harness ZTSE4735A to engine harness and leave ETV disconnected.

Figure 275 ETC Circuit Check

Test 3
A. Key OFF.

B. Disconnect ETV connector.

C. Disconnect Engine Control Module (ECM) Engine 76-pin connector

D. Connect Breakout Harness ZTSE4735A to engine harness and leave ETV disconnected.
976 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3464 FMI 4 - ETC short to GND

Fault Overview
Engine Throttle Valve (ETV) control circuit is shorted to ground.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• ETV-CL Short to GND
• ETV-CH Short to GND
• ETV-CL shorted to ETV-CH
• Failed Engine Throttle Valve (ETV)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 977

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for Yes: Go to Step 2.
SPN 3464 FMI 4.
Is SPN 3464 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at Engine Throttle Valve (ETV) connector. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect ETV connector.
C. Check ETV and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are ETV connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3464
FMI 4.

Step 3 Check for short to GND. Decision

A. Perform Test 1(page 979). Yes: Go to Step 4.
B. Use DMM, measure resistance between Breakout Harness ZTSE4735A
pin-2 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ETV pin-2 and ECM pin E-57
and pin E-75. After repairs are
complete, retest for SPN 3464
FMI 4.

Step 4 Check for short to GND. Decision

A. Perform Test 2(page 979). Yes: Go to Step 5.
B. Use DMM, measure resistance between Breakout Harness ZTSE4735A
pin-6 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ETV pin-6 and ECM pin E-58
and pin E-76. After repairs are
complete, retest for SPN 3464
FMI 4.
978 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 5 Check for ETV-CL short to ETV-CH. Decision

A. Perform Test 3(page 980). Yes: Replace ETV. After repairs
are complete, retest for SPN 3464
B. Use DMM, measure resistance between Breakout Harness ZTSE4735A
FMI 4.
pin-6 and pin-2.
Is resistance greater than 1000 ohms? No: Repair short between ETV
pin-2 and pin-6. After repairs are
complete, retest for SPN 3464
FMI 4.

End Diagnostic Test

After performing diagnostic steps, if SPN 3464 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 979

Pin-Point Tests (SPN 3464 FMI 4)

Figure 276 ETV Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4735A
• Digital Multimeter (DMM)

Figure 277 ETV Circuit Check

Test 1
A. Key OFF.

B. Disconnect Engine Throttle Valve (ETV) connector.

C. Connect Breakout Harness ZTSE4735A to engine harness and leave ETV disconnected.
980 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 278 ETV Circuit Check

Test 2
A. Key OFF.
B. Disconnect Engine Throttle Valve (ETV) connector.
C. Connect Breakout Harness ZTSE4735A to engine harness and leave ETV disconnected.

Figure 279 ETV Circuit Check

Test 3
A. Key OFF.

B. Disconnect Engine Throttle Valve (ETV) connector.

C. Disconnect ECM Engine 76-pin connector.
D. Connect Breakout Harness ZTSE4735A to engine harness and leave ETV disconnected.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 981

SPN 3464 FMI 11 - ETC operation Fault

Fault Overview
Fault sets when Engine Control Module (ECM) determines ETC is receiving more than 8 amps for longer than
10 microseconds.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Jammed sector gear
• Stalled motor
• Damaged butterfly valve
• Ice water intrusion into electrical section in intake throttle
982 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list Yes: Go to Step 2.
for SPN 3464 FMI 11.
Is SPN 3464 FMI 11 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 3464 FMI 11.

Step 2 Inspect Engine Throttle Valve (ETV) sensor and connector. Decision
A. Key OFF. Yes: Go to Step 3.
B. Disconnect ETV sensor.
C. Check ETV sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are ETV sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3464
FMI 11.

Step 3 Test for intermittent circuit operation. Decision

A. Key OFF. Yes: Go to Step 4.
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).
C. Key ON Engine OFF (KOEO). Log into Navistar® Engine Diagnostics.
D. Do Continuous Monitor Test (page 1361).
Are ETV circuits within specifications? No: Locate specific circuit
component causing erratic or
intermittent operation. Perform
voltage and resistance checks
in this section. Repair circuits
as required. After repairs are
complete, retest for SPN 3464 FMI
11.

Step 4 Check for butterfly valve missing or unattached, butterfly and shaft Decision
damage, and evidence of icing.
Do visual inspection of Engine Throttle Valve (ETV) in Engine Service Manual. Yes: Go to Step 5.
Is butterfly valve condition satisfactory? No: Replace ETV. After repairs are
complete, retest for SPN 3464 FMI
11.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 983

Step 5 Determine if Engine Throttle Valve (ETV) sensor is operating within Decision
specification.
A. Key OFF. Yes: After doing all diagnostic
steps, if SPN 3464 FMI 11 remains,
B. Disconnect ETV.
verify each step was completed
C. Connect breakout harness ZTSE4735A between ETV and ETV connector. correctly and proper decision was
made. Notify supervisor for further
D. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
action.
(page 1345).
E. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
F. Do Output State High or Low(page 1359) Test.
Is voltage for Output State Test Low approximately 1.15 volts and Output State No: Replace ETV. After repairs are
Test High approximately 3.0 volts? complete, retest for SPN 3464 FMI
11.

End Diagnostic Test

After performing diagnostic steps, if SPN 3464 FMI 11 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
984 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3464 FMI 31 - Intake Throttle Valve short circuit fault

Fault Overview
Fault sets when Engine Control Module (ECM) detects short circuit on Engine Throttle Valve (ETV)

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• ETV-CL Short to GND
• ETV-CH Short to GND
• ETV-CL Short to PWR
• ETV-CH Short to PWR
• ETV-CL shorted to ETV-CH
• Failed Engine Throttle Valve (ETV)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 985

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 3464 FMI 31.
Is EST DTC list SPN 3464 FMI 31 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 3464 FMI 31.

Step 2 Inspect connections at Engine Throttle Valve (ETV) connector. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect ETV.
C. Check ETV and connector terminals for: damaged or pinched wires;
moisture in terminals; corroded terminals; loose, bent, or broken pins; or
broken connector housing.
Are ETV connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3464
FMI 31.

Step 3 Check for short to GND. Decision

A. Perform Test 1 (page 987). Yes: Go to Step 4.
B. Use DMM, measure resistance between Breakout Harness ZTSE4735A
pin-2 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ETV pin-2 and ECM pin E-57
and pin E-75. After repairs are
complete, retest for SPN 3464
FMI 31.

Step 4 Check for Short to GND. Decision

A. Perform Test 2 (page 987). Yes: Go to Step 5.
B. Use DMM, measure resistance between Breakout Harness ZTSE4735A
pin-6 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ETV pin-6 and ECM pin E-58
and pin E-76. After repairs are
complete, retest for SPN 3464
FMI 31
986 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 5 Check for short to PWR. Decision

A. Perform Test 3 (page 988). Yes: Go to Step 6.
B. Use DMM, measure resistance between Breakout Harness ZTSE4735A
pin-2 and PWR.
Is resistance greater than 1000 ohms? No: Repair short to PWR between
ETV pin-2 and ECM pin E-57
and pin E-75. After repairs are
complete, retest for SPN 3464 FMI
31.

Step 6 Check for short to PWR. Decision

A. Perform Test 4 (page 988). Yes: Go to Step 7
B. Use DMM, measure resistance between Breakout Harness ZTSE4735A
pin-6 and PWR.
Is resistance greater than 1000 ohms? No: Repair short to PWR between
ETV pin-6 and ECM pin E-58
and pin E-76. After repairs are
complete, retest for SPN 3464
FMI 31.

Step 7 Check for ETV-CL shorted to ETV-CH. Decision

A. Perform Test 5 (page 989). Yes: Replace ETV. After repairs
are complete, retest for SPN 3464
B. Use DMM, measure resistance between Breakout Harness ZTSE4735A
FMI 31.
pin-2 and pin-6.
Is resistance greater than 1000 ohms? No: Repair short between ETV-CL
and ETV-CH circuits. After repairs
are complete, retest for SPN 3464
FMI 31

End Diagnostic Test

After performing diagnostic steps, if SPN 3464 FMI 31 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 987

Pin-Point Tests (SPN 3464 FMI 31)

Figure 280 ETV Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4735A
• Digital Multimeter (DMM)

Figure 281 ETV Connector Circuit Check

Test 1
A. Key OFF.
B. Disconnect Engine Throttle Valve (ETV) connector.
C. Connect Breakout Harness ZTSE4735A to vehicle harness and leave ETV connector disconnected.
988 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 282 ETV Connector Circuit Check

Test 2
A. Key OFF.
B. Disconnect Engine Throttle Valve (ETV) connector.
C. Connect Breakout Harness ZTSE4735A to vehicle harness and leave ETV connector disconnected.

Figure 283 ETV Connector Circuit Check

Test 3
A. Key OFF.

B. Disconnect Engine Throttle Valve (ETV) connector.

C. Connect Breakout Harness ZTSE4735A to vehicle harness and leave ETV connector disconnected.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 989

Figure 284 ETV Connector Circuit Check

Test 4
A. Key OFF.
B. Disconnect Engine Throttle Valve (ETV) connector.
C. Connect Breakout Harness ZTSE4735A to vehicle harness and leave ETV connector disconnected.

Figure 285 ETV Connector Circuit Check

Test 5
A. Key OFF.

B. Disconnect Engine Throttle Valve (ETV) connector.

C. Connect Breakout Harness ZTSE4735A to vehicle harness and leave ETV connector disconnected.
990 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3471 FMI 1 - AFT Fuel Pressure 1 below desired (Low System Pressure)

Fault Overview
Fault sets when Doser Control Unit (DCU) detects Aftertreatment Fuel Pressure 1 (AFTFP1) is below desired
pressure.

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

Associated Faults
SPN 94 (FDP) SPN 3480 (AFTFP1)

Fault Facts
None

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• DCU VREF high resistance
• SIG GND high resistance
• AFTFP1 circuit high resistance
• System Leak
• Low FDP

Step 1 Check for associated fault codes Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 990).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 3471 FMI 1.

Step 2 Aftertreatment Fuel Inlet Sensor (AFTFIS) and connector inspection. Decision
A. Key OFF. Yes: Go to Step 3.
B. Disconnect AFTFIS.

C. Check AFTFIS and connector terminals for: damaged or pinched wires;

wet or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are AFTFIS connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3471
FMI 1.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 991

Step 3 Check for VREF. Decision

A. Perform Test 1 (page 993). Yes: Go to Step 5.
B. Use DMM, measure voltage between Breakout Harness ZTSE4830 pin-3
and pin-1.
Is voltage 5.0 ± 0.5 volts? No: Go to Step 4.

Step 4 Check for high resistance in SIG GND circuit. Decision

A. Perform Test 2 (page 993). Yes: Repair high resistance
in DCU VREF circuit between
B. Use DMM, measure voltage between Breakout Harness ZTSE4830 pin-1
AFTFIS pin-3 and DCU pin-23.
and PWR.
After repairs are complete, retest
for SPN 3471 FMI 1.
Is voltage B+ ± 0.5 volts? No: Repair high resistance in
SIG GND circuit between AFTFIS
pin-1 and DCU Module pin-21.
After repairs are complete, retest
for SPN 3471 FMI 1.

Step 5 Inspect for system leak between Electric Fuel Pump (EFP) and Down Decision
Stream Injection (DSI) unit.
Perform a visual inspection of DSI module and fuel supply line for damage, Yes: Go to Step 6.
restrictions, or leaks.
Is DSI module fuel supply line in good condition, not restricted, leaking, or No: Repair or replace damaged or
damaged? leaking component. After repairs
are complete, retest for SPN 3471
FMI 1.

Step 6 Check Fuel Delivery Pressure (FDP). Decision

Check for Low Fuel Delivery Pressure (page 119). Yes: Go to Step 7.
Is FDP between 80 and 100 psi? No: Perform 8.1 - Fuel Delivery
Pressure (page 119), start with
Step 2. After repairs are complete,
retest for SPN 3471 FMI 1.

Step 7 Check for Down Stream Injection (DSI) system leaks. Decision
Perform KOER DSI System Test (page 1385) to check DSI system for leaks. Yes: Repair leak. After repairs
are complete, retest for SPN 3471
FMI 1.
Does DSI system test indicate a leak? No: End diagnostics. After repairs
are complete, retest for SPN 3471
FMI 1.
992 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

End Diagnostic Steps

After performing all diagnostic steps, if SPN 3471 FMI 1 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 993

Pin-Point Tests (SPN 3471 FMI 1)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4830.
• Digital Multimeter (DMM)

Figure 286 AFTFIS Connector Circuit Check

Test 1
A. Key OFF.
B. Disconnect Aftertreatment Fuel Inlet Sensor (AFTFIS).
C. Install Breakout Harness ZTSE4830 to vehicle harness and leave AFTFIS disconnected.

D. Key ON Engine OFF (KOEO).

994 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 287 AFTFIS Connector Circuit Check

Test 2
A. Key OFF.
B. Disconnect Aftertreatment Fuel Inlet Sensor (AFTFIS).
C. Install Breakout Harness ZTSE4830 to vehicle harness and leave AFTFIS disconnected.
D. Key ON Engine OFF (KOEO).

Figure 288 AFTFIS Connector Circuit Check

Test 3
A. Key OFF.
B. Disconnect Aftertreatment Fuel Inlet Sensor (AFTFIS).

C. Install Breakout Harness ZTSE4830 to vehicle harness and leave AFTFIS disconnected.

D. Key ON Engine OFF (KOEO).

 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 995

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

Fault Overview
Fault sets when Doser Control Unit (DCU) detects Aftertreatment Fuel Doser (AFTFD) is not responding as
expected.

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

Associated Faults
• SPN 3482 (AFTFSV) • SPN 3556 (AFTFP2)

Fault Facts
None

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• DCU VREF high resistance
• SIG GND high resistance
• AFTFP2 circuit high resistance
• System Leak

Step 1 Check for associated fault codes Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 995).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 3471 FMI 7.

Step 2 Aftertreatment Fuel Pressure 2 (AFTFP2) sensor and connector Decision

inspection.
A. Key OFF. Yes: Go to Step 3.
B. Disconnect AFTFP2 sensor.

C. Check AFTFP2 sensor and connector terminals for: damaged or pinched

wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are AFTFP2 sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3471
FMI 7.
996 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Check for VREF. Decision

A. Perform Test 1 (page 997). Yes: Go to Step 5.
B. Use DMM, measure voltage between Breakout Harness ZTSE6027 pin-2
and pin-1.
Is voltage 5.0 ± 0.5 volts? No: Go to Step 4.

Step 4 Check for high resistance in SIG GND circuit. Decision

A. Perform Test 2 (page 997). Yes: Repair high resistance in
VREF circuit between DCU 53–pin
B. Use DMM, measure voltage between Breakout Harness ZTSE6027 pin-2
connector pin-43 and AFTFP2
and PWR.
pin-2. After repairs are complete,
retest for SPN 3471 FMI 7.
Is voltage B+ ± 0.5 volts? No: Repair high resistance in SIG
GND circuit between AFTFP2
pin-2 and DCU Module pin-41.
After repairs are complete, retest
for SPN 3471 FMI 7.

Step 5 Inspect for system leak between Down Stream Injection (DSI) unit and Decision
Aftertreatment Fuel Injector (AFTFI).
Check DSI module and AFTFI fuel supply line for damage, restrictions, or leaks. Yes: Go to Step 6.
Is fuel supply line and DSI module in good condition and not restricted, leaking, No: Repair or replace damaged or
or damaged? leaking component. After repairs
are complete, retest for SPN 3471
FMI 7.

Step 6 Check for Down Stream Injection (DSI) system leaks. Decision
Perform KOER DSI System Test (page 1385) to check DSI system for leaks. Yes: Repair leak. After repairs
are complete, retest for SPN 3471
FMI 7.
Does DSI system test indicate a leak? No: End diagnostics. After repairs
are complete, retest for SPN 3471
FMI 7.

End Diagnostic Steps

After performing all diagnostic steps, if SPN 3471 FMI 7 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 997

Pin-Point Tests (SPN 3471 FMI 7)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE6027.
• Digital Multimeter (DMM)

6027
2

0000413828

Figure 289 AFTFP2 Connector Circuit Check

Test 1
A. Key OFF.
B. Disconnect Aftertreatment Fuel Pressure 2 (AFTFP2).
C. Install Breakout Harness ZTSE6027 to vehicle harness and leave AFTFP2 disconnected.
D. Key ON Engine OFF (KOEO).
998 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

2
6027

0000413832

Figure 290 AFTFP2 Connector Circuit Check

Test 2
A. Key OFF.
B. Disconnect Aftertreatment Fuel Pressure 2 (AFTFP2).
C. Install Breakout Harness ZTSE6027 to vehicle harness and leave AFTFP2 disconnected.
D. Key ON Engine OFF (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 999

Figure 291 AFTFP2 Connector Circuit Check

Test 3
A. Key OFF.
B. Disconnect Aftertreatment Fuel Pressure 2 (AFTFP2).
C. Install Breakout Harness ZTSE6027 to vehicle harness and leave AFTFP2 disconnected.
D. Key ON Engine OFF (KOEO).
1000 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3471 FMI 10 - AFT Fuel Pressure incorrect dosing pressure multiple events

Fault Overview
Fault sets when Doser Control Unit (DCU) detects Aftertreatment Fuel Doser (AFTFD) valve has incorrect dosing
pressure multiple events.

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

Associated Faults
• SPN 3482 (AFTFSV) • SPN 3556 (AFTFP2)

Fault Facts
None

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• DCU VREF high resistance
• SIG GND high resistance
• Failed AFTFP2 sensor
• System Leak
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1001

Step 1 Check for associated fault codes Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 1000).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 3471 FMI 10.

Step 2 Aftertreatment Fuel Pressure 2 (AFTFP2) sensor and connector Decision

inspection.
A. Key OFF. Yes: Go to Step 3.
B. Disconnect AFTFP2 sensor.
C. Check AFTFP2 sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are AFTFP2 sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3471
FMI 10.

Step 3 Check for VREF. Decision

A. Perform Test 1 (page 1003). Yes: Go to Step 6.
B. Use DMM, measure voltage between Breakout Harness ZTSE6027 pin-2
and pin-1.
Is voltage 5.0 ± 0.5 volts? No: Go to Step 4.

Step 4 Check for high resistance in SIG GND circuit. Decision

A. Perform Test 2 (page 1003). Yes: Go to Step 5.
B. Use DMM, measure voltage between Breakout Harness ZTSE6027 pin-2
and B+.
Is voltage B+ ± 0.5 volts? No: Repair high resistance in SIG
GND circuit between AFTFP2
pin-2 and DCU Module pin-41.
After repairs are complete, retest
for SPN 3471 FMI 10.
1002 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 5 Check for high resistance in DCU VREF circuit. Decision

A. Perform Test 3 (page 1004). Yes: Replace AFTFP2. After
repairs are complete, retest for
B. Use DMM, measure voltage between Breakout Harness ZTSE6027 pin-1
SPN 3471 FMI 10.
and known good GND.
Is voltage 5.0 ± 0.5 volts? No: Repair high resistance in DCU
VREF circuit between AFTFP2
pin-1 and DCU Module pin-43.
After repairs are complete, retest
for SPN 3471 FMI 10.

Step 6 Inspect for system leak between Down Stream Injection (DSI) unit and Decision
Aftertreatment Fuel Injector (AFTFI).
Check DSI module and AFTFI fuel supply line for damage, restrictions, or leaks. Yes: Go to Step 7.
Is fuel supply line and DSI module in good condition and not restricted, leaking, No: Repair or replace damaged or
or damaged? leaking component. After repairs
are complete, retest for SPN 3471
FMI 10.

Step 7 Check for Down Stream Injection (DSI) system leaks. Decision
Perform KOER DSI System Test (page 1385) to check DSI system for leaks. Yes: Repair leak. After repairs are
complete, retest for SPN 3471 FMI
10.
Does DSI system test indicate a leak? No: End diagnostics, clear fault
and retest for SPN 3471 FMI 10.

End Diagnostic Steps

After performing all diagnostic steps, if SPN 3471 FMI 10 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1003

Pin-Point Tests (SPN 3471 FMI 10)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE6027.
• Digital Multimeter (DMM)

6027
2

0000413828

Figure 292 AFTFP2 Connector Circuit Check

Test 1
A. Key OFF.
B. Disconnect Aftertreatment Fuel Pressure 2 (AFTFP2) connector.
C. Install Breakout Harness ZTSE6027 to vehicle harness and leave AFTFP2 connector disconnected.
D. Key ON Engine OFF (KOEO).
1004 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

2
6027

0000413832

Figure 293 AFTFP2 Connector Circuit Check

Test 2
A. Key OFF.
B. Disconnect Aftertreatment Fuel Pressure 2 (AFTFP2).
C. Install Breakout Harness ZTSE6027 to vehicle harness and leave AFTFP2 disconnected.
D. Key ON Engine OFF (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1005

Figure 294 AFTFP2 Connector Circuit Check

Test 3
A. Key OFF.
B. Disconnect Aftertreatment Fuel Pressure 2 (AFTFP2).
C. Install Breakout Harness ZTSE6027 to vehicle harness and leave AFTFP2 disconnected.
D. Key ON Engine OFF (KOEO).
1006 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3479 FMI 3 - AFT Fuel Doser Valve Short to PWR

Fault Overview
Fault code sets when Doser Control Unit (DCU) detects a short to PWR on low-side driver circuit.

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

Associated Faults
None

Fault Facts
Doser Control Unit (DCU) deactivates circuits when a circuit fault is present, so NOID Lamp is needed to simulate
correct circuit. Fault is latched for a key cycle, so Engine Control Module (ECM) must be reset by a Key OFF
cycle.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Open in AFTFD CTL-L circuit
• Open in AFTFD CTL-H circuit

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 3479 FMI 3.
Is SPN 3479 FMI 3 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at Aftertreatment Fuel Doser (AFTFD). Decision

A. Key OFF. Disconnect AFTFD connector. Yes: Go to Step 3.
B. Check AFTFD connector terminals for damaged or pinched wires; wet
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are AFTFD connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3479
FMI 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1007

Step 3 Check vehicle harness / NOID Lamp illumination. Decision

A. Key OFF. Connect NOID Lamp 15-909-01 to vehicle harness and leave Yes: Replace AFTFD. After
AFTFD disconnected. repairs are complete, retest for
SPN 3479 FMI 3.
B. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
C. Perform KOEO DCU Actuator Test - Actuator Output High and Low
Diagnostics (page 1368).
Did NOID Lamp 15-909-01 illuminate? No: Go to Step 4.

Step 4 Inspect connections at 24-pin Engine to Chassis connector. Decision

A. Key OFF. Disconnect 24-pin Engine to Chassis connector. Yes: Go to Step 5.
B. Check 24-pin Engine to Chassis connector terminals for damaged or
pinched wires; wet or corroded terminals; loose, bent, or broken pins; or
broken connector housing.
Are 24-pin connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN
3479 FMI 3.

Step 5 Check for Open in AFTFD CTL-H circuit. Decision

A. Perform Test 1 (page 1010). Yes: Go to Step 6.
B. Use DMM, measure resistance between Breakout Harness ZTSE6021
pin-1 and Breakout Harness ZTSE6020 pin-9.
Is resistance less than 5 ohms? No: Repair Open in AFTFD
CTL-H circuit between AFTFD
pin-1 and 24-pin connector pin-9.
After repairs are complete, retest
for SPN 3479 FMI 3.

Step 6 Check for short to GND in AFTFD CTL-H circuit. Decision

A. Perform Test 2 (page 1010). Yes: Go to Step 7

B. Measure resistance between Breakout Harness ZTSE6021 pin-1 and

Ground.
Is resistance greater than 1000 ohms? No: Repair short to Ground
between 24-pin connector pin-9
and AFTFD pin-1. After repairs
are complete, retest for SPN 3479
FMI 3.
1008 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 7 Check for Open in AFTFD CTL-L circuit. Decision

A. Perform Test 3 (page 1010). Yes: Go to Step 8.
B. Use DMM, measure resistance between Breakout Harness ZTSE6021
pin-2 and Breakout Harness ZTSE6020 pin-10.
Is resistance less than 5 ohms? No: Repair Open in AFTFD CTL-L
circuit between AFTFD pin-2 and
24-pin connector pin-10. After
repairs are complete, retest for
SPN 3479 FMI 3.

Step 8 Check for short to GND in AFTFD CTL-L circuit. Decision

A. Perform Test 4 (page 1011). Yes: Go to Step 9
B. Use DMM, measure resistance between Breakout Harness ZTSE6021
pin-2 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
24-pin connector pin-10 and
AFTFD pin-2. After repairs are
complete, retest for SPN 3479
FMI 3.

Step 9 Inspect connections at 86-pin Doser Control Unit (DCU). Decision

A. Key OFF. Yes: Go to Step 10.
B. Disconnect DCU.
C. Check DCU and connector terminals for damaged or pinched wires,
corroded terminals; loose, bent or broken pins; or broken connector
housing.
Is 86-pin DCU module connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3479
FMI 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1009

Step 10 Check for Open in AFTFD CTL-L circuit. Decision

A. Key OFF. Yes: Go to Step 11.
B. Disconnect 24-pin connector.
C. Disconnect DCU module connector.
D. Connect Breakout Harness ZTSE6020 to chassis harness and leave
engine harness side disconnected.

E. Use Terminal Test Kit ZTSE4435C insert appropriate terminal into DCU
connector pin-10.
F. Use DMM, measure resistance between Breakout Harness ZTSE6020
pin-10 and Terminal Test Kit ZTSE4435C pin-10.
Is resistance less than 5 ohms? No: Repair Open between 24-pin
connector pin-10 and DCU
Module pin-10. After repairs are
complete, retest for SPN 3479
FMI 3.

Step 11 Check for short to GND in AFTFD CTL-L circuit. Decision

A. Perform Test 5 (page 1011). Yes: Step 12.
B. Use DMM, measure resistance between Breakout Harness ZTSE6020
pin-10 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
24-pin connector pin-10 and DCU
Module pin-10. After repairs are
complete, retest for SPN 3482
FMI 3.

Step 12 Check for Open in AFTFD CTL-H circuit. Decision

A. Key OFF. Yes: Repair short to GND
between 24-pin connector pin-9
B. Disconnect 24-pin connector.
and DCU Module pin-30. After
C. Disconnect DCU 86-pin connector. repairs are complete, retest for
SPN 3479 FMI 3.
D. Connect Breakout Harness ZTSE6020 to chassis harness and leave
engine harness side disconnected.

E. Use Terminal Test Kit ZTSE4435C insert appropriate terminal into 86-pin
connector pin-30.
F. Use DMM, measure resistance between Breakout Harness ZTSE6020
pin-9 and Terminal Test Kit ZTSE4435C pin-30.
Is resistance less than 5 ohms? No: Repair Open between 24-pin
connector pin-9 and DCU Module
pin-30. After repairs are complete,
retest for SPN 3479 FMI 3.
1010 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

End Pin-Point Tests

After performing diagnostic steps, if SPN 3479 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.

Pin-Point Tests SPN 3479 FMI 3

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE6020
• Breakout Harness ZTSE6021
• Digital Multimeter (DMM)
• Terminal Test Kit ZTSE4435C

Figure 295 AFTFD CTL-H Circuit Check

Test 1
A. Key OFF. Disconnect Aftertreatment Fuel Doser (AFTFD) connector.
B. Disconnect 24-pin Engine to Chassis connector.
C. Connect Breakout Harness ZTSE6021 to engine harness and leave AFTFD disconnected.
D. Connect Breakout Harness ZTSE6020 to 24-pin connector and leave DCU Module side disconnected.

Test 2
A. Key OFF. Disconnect AFTFD.
B. Disconnect 24-pin connector.

C. Connect Breakout Harness ZTSE6021 to engine harness and leave AFTFD disconnected.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1011

Test 3
A. Key OFF. Disconnect AFTFD connector.
B. Disconnect 24-pin connector.
C. Connect Breakout Harness ZTSE6021 to engine harness and leave AFTFD disconnected.
D. Connect Breakout Harness ZTSE6020 to 24-pin connector and leave DCU Module side disconnected.

Test 4
A. Key OFF. Disconnect AFTFD connector.
B. Disconnect 24-pin connector.
C. Connect Breakout Harness ZTSE6021 to engine harness and leave AFTFD disconnected.

Figure 296 AFTFD CTL-L Circuit Check

Test 5
A. Key OFF.
B. Disconnect 24-pin connector.

C. Disconnect DCU 86-pin connector.

D. Connect Breakout Harness ZTSE6020 to chassis harness and leave engine harness side disconnected.
1012 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3479 FMI 4 - AFT Fuel Doser Valve Open or Short to GND

Fault Overview
Fault code sets when Doser Control Unit (DCU) detects a short to ground on the high-side circuit.

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

Associated Faults
None

Fault Facts
Doser Control Unit (DCU) deactivates circuits when a circuit fault is present, so NOID lamp is needed to simulate
correct circuit. Fault is latched for a key cycle, so Engine Control Module (ECM) must be reset by a Key OFF
cycle.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• DCU circuit fault
• AFTFD circuit Open or short to GND
• Failed Aftertreatment Fuel Doser (AFTFD)

Step 1 Check for active or pending fault code. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for Yes: Go to Step 2.
SPN 3479 FMI 4.
Is EST DTC list SPN 3479 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Inspect connections at Aftertreatment Fuel Doser (AFTFD). Decision

A. Key OFF. Disconnect AFTFD connector. Yes: Go to Step 3.
B. Check AFTFD connector terminals for damaged or pinched wires; wet
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are AFTFD connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3479
FMI 4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1013

Step 3 Check vehicle harness / NOID Lamp illumination. Decision

A. Key OFF. Connect NOID Lamp 15-909-01 to vehicle harness and leave Yes: Replace AFTFD. After
AFTFD disconnected. repairs are complete, retest for
SPN 3479 FMI 4.
B. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
C. Perform KOEO DCU Actuator Test - Actuator Output High and Low
Diagnostics (page 1368).
Did NOID Lamp 15-909-01 illuminate? No: Go to Step 4.

Step 4 Inspect connections at 24-pin Engine to Chassis connector. Decision

A. Key OFF. Yes: Go to Step 5.
B. Disconnect 24-pin connector.
C. Check 24-pin connector terminals for damaged or pinched wires; wet
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are 24-pin connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN
3479 FMI 4.

Step 5 Check for Open in AFTFD CTL-H circuit . Decision

A. Key OFF. Disconnect Aftertreatment Fuel Shutoff (AFTFSO). Yes: Go to Step 6.

B. Disconnect 24-pin connector.

C. Connect Breakout Harness ZTSE6021 to engine harness and leave
AFTFD disconnected.
D. Connect Breakout Harness ZTSE6020 to 24-pin connector and leave DCU
Module side disconnected.
E. Use DMM, measure resistance between Breakout Harness ZTSE6021
pin-1 and Breakout Harness ZTSE6020 pin-9.
Is resistance less than 5 ohms? No: Repair Open in AFTFD
CTL-H circuit between AFTFD
pin-1 and 24-pin Engine to
Chassis pin-9. After repairs are
complete, retest for SPN 3479
FMI 4.
1014 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 6 Check for short to GND in AFTFD CTL-H circuit. Decision

A. Perform Test 1 (page 1017). Yes: Go to Step 7
B. Measure resistance between Breakout Harness ZTSE6021 pin-1 and GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
24-pin Engine to Chassis
connector pin-9 and AFTFD
pin-1. After repairs are complete,
retest for SPN 3479 FMI 4.

Step 7 Check for Open in AFTFD CTL-L circuit. Decision

A. Key OFF. Disconnect Aftertreatment Fuel Doser (AFTFD) connector. Yes: Go to Step 8.

B. Disconnect 24-pin Engine to Chassis connector.

C. Connect Breakout Harness ZTSE6021 to engine harness and leave
AFTFD disconnected.
D. Connect Breakout Harness ZTSE6020 to 24-pin connector and leave DCU
Module side disconnected.
E. Measure resistance between Breakout Harness ZTSE6021 pin-2 and
Breakout Harness ZTSE6020 pin-10.
Is resistance less than 5 ohms? No: Repair Open in AFTFD CTL-L
circuit between AFTFD pin-2 and
24-pin connector pin-10. After
repairs are complete, retest for
SPN 3479 FMI 4.

Step 8 Check for short to GND in AFTFD CTL-L circuit. Decision

A. Perform Test 2 (page 1017). Yes: Go to Step 9.
B. Measure resistance between Breakout Harness ZTSE6021 pin-2 and
GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
24-pin connector pin-10 and
AFTFD pin-2. After repairs are
complete, retest for SPN 3479
FMI 4.

Step 9 Inspect connections at 86-pin Doser Control Unit (DCU). Decision

A. Key OFF. Yes: Go to Step 10.
B. Disconnect DCU.

C. Check DCU and connector terminals for damaged or pinched wires,

corroded terminals; loose, bent or broken pins; or broken connector
housing.
Is 86-pin DCU module connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1015

are complete, retest for SPN 3479

FMI 4.

Step 10 Check for Open in AFTFD CTL-L circuit. Decision

A. Key OFF. Disconnect 24-pin Engine and Chassis connector. Yes: Go to Step 11.

B. Disconnect DCU 86-pin connector.

C. Connect Breakout Harness ZTSE6020 to chassis harness and leave
engine harness side disconnected.
D. Use Terminal Test Kit ZTSE4435C insert appropriate terminal into 86-pin
connector pin-10.
E. Measure resistance between Breakout Harness ZTSE6020 pin-10 and
Terminal Test Kit ZTSE4435C pin-10.
Is resistance less than 5 ohms? No: Repair Open between 24-pin
Engine to Chassis connector
pin-10 and DCU Module pin-10.
After repairs are complete, retest
for SPN 3479 FMI 4.

Step 11 Check for short to GND in AFTFD CTL-L circuit. Decision

A. Key OFF. Yes: Step 12.
B. Disconnect 24-pin Engine and Chassis connector.
C. Disconnect DCU 86-pin connector.
D. Connect Breakout Harness ZTSE6020 to chassis harness and leave
engine harness side disconnected.
E. Use DMM, measure resistance between Breakout Harness ZTSE6020
pin-10 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND
between 24-pin Engine to Chassis
connector pin-10 and DCU
Module pin-10. After repairs are
complete, retest for SPN 3482
FMI 4.

Step 12 Check for Open in AFTFD CTL-H circuit. Decision

A. Key OFF. Yes: Repair short to GND between
24-pin engine to chassis connector
B. Disconnect 24-pin Engine and Chassis connector.
pin-9 and DCU Module pin-30.
C. Disconnect DCU 86-pin connector. After repairs are complete, retest
for SPN 3479 FMI 4.
D. Connect Breakout Harness ZTSE6020 to chassis harness and leave
engine harness side disconnected.
E. Use Terminal Test Kit ZTSE4435C insert appropriate terminal into 86-pin
connector pin-30.
1016 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

F. Use DMM, measure resistance between Breakout Harness ZTSE6020

pin-9 and Terminal Test Kit ZTSE4435C pin-30.
Is resistance less than 5 ohms? No: Repair Open between 24-pin
Engine to Chassis connector pin-9
and DCU Module pin-30. After
repairs are complete, retest for
SPN 3479 FMI 4.

End Pin-Point Tests

After performing diagnostic steps, if SPN 3479 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1017

Pin-Point Tests (SPN 3479 FMI 4)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE6020
• Breakout Harness ZTSE6021
• Digital Multimeter (DMM)
• Terminal Test Kit ZTSE4435C

Test 1
A. Key OFF. Disconnect AFTFD.
B. Disconnect 24-pin Engine to Chassis connector.
C. Connect Breakout Harness ZTSE6021 to engine harness and leave AFTFD disconnected.

Test 2
A. Key OFF. Disconnect AFTFD connector.
B. Disconnect 24-pin Engine to Chassis connector.
C. Connect Breakout Harness ZTSE6021 to engine harness and leave AFTFD disconnected.
1018 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3479 FMI 5 - AFT Fuel Pressure Control Valve Open or short to GND on low side

Fault Overview
Fault code sets when Doser Control Unit (DCU) detects a short to ground on low-side circuit.

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

Associated Faults
None

Fault Facts
Doser Control Unit (DCU) deactivates circuits when a circuit fault is present, so NOID lamp is needed to simulate
correct circuit. Fault is latched for a key cycle, so Engine Control Module (ECM) must be reset by a Key OFF
cycle.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Short to GND on low side
• DCU circuit fault

Step 1 Check for active or pending fault code. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for Yes: Go to Step 2.
SPN 3479 FMI 5.
Is EST DTC list SPN 3479 FMI 5 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Inspect connections at Aftertreatment Fuel Doser (AFTFD). Decision

A. Key OFF. Disconnect AFTFD connector. Yes: Go to Step 3.
B. Check AFTFD connector terminals for damaged or pinched wires; wet
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are AFTFD connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3479
FMI 5.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1019

Step 3 Check vehicle harness/NOID Lamp illumination. Decision

A. Key OFF. Connect NOID Lamp 15-909-01 to vehicle harness and leave Yes: Replace AFTFD. After
AFTFD disconnected. repairs are complete, retest for
SPN 3479 FMI 5.
B. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
C. Perform KOEO DCU Actuator Test - Actuator Output High and Low
Diagnostics (page 1368).
Did NOID Lamp 15-909-01 illuminate? No: Go to Step 4.

Step 4 Inspect connections at 24-pin Engine to Chassis connector. Decision

A. Key OFF. Yes: Go to Step 5.
B. Disconnect 24-pin Engine to Chassis connector.
C. Check 24-pin Engine to Chassis connector terminals for damaged or
pinched wires; wet or corroded terminals; loose, bent, or broken pins; or
broken connector housing.
Are 24-pin Engine to Chassis connector, harness, and terminals clean and No: Repair connector, harness,
undamaged? or terminal damage. After repairs
are complete, retest for SPN 3479
FMI 5.

Step 5 Check for Open in AFTFD CTL-H circuit. Decision

A. Perform Test 1 (page 1022). Yes: Go to Step 6.
B. Use DMM, measure resistance between Breakout Harness ZTSE6021
pin-1 and Breakout Harness ZTSE6020 pin-9.
Is resistance less than 5 ohms? No: Repair Open in AFTFD
CTL-H circuit between AFTFD pin
1 and 24-pin Engine to Chassis
pin-9. After repairs are complete,
retest for SPN 3479 FMI 5.

Step 6 Check for short to GND in AFTFD CTL-H circuit. Decision

A. Perform Test 2 (page 1022). Yes: Go to Step 7
B. Measure resistance between Breakout Harness ZTSE6021 pin-1 and
GND.
Is resistance greater than 1000 ohms? No: Repair short to GND
between 24-pin Engine to Chassis
connector pin-9 and AFTFD pin-1.
After repairs are complete, retest
for SPN 3479 FMI 5.
1020 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 7 Check for Open in AFTFD CTL-L circuit. Decision

A. Perform Test 3 (page 1022). Yes: Go to Step 8.
B. Measure resistance between Breakout Harness ZTSE6021 pin-2 and
Breakout Harness ZTSE6020 pin-10.
Is resistance less than 5 ohms? No: Repair Open in AFTFD CTL-L
circuit between AFTFD pin-2 and
24-pin Engine to Chassis pin-10.
After repairs are complete, retest
for SPN 3479 FMI 5.

Step 8 Check for short to GND in AFTFD CTL-L circuit. Decision

A. Perform Test 4 (page 1023). Yes: Go to Step 9.
B. Measure resistance between Breakout Harness ZTSE6021 pin-2 and
GND.
Is resistance greater than 1000 ohms? No: Repair short to GND
between 24-pin Engine to Chassis
connector pin-10 and AFTFD
pin-2. After repairs are complete,
retest for SPN 3479 FMI 5.

Step 9 Inspect connections at 86-pin Doser Control Unit (DCU). Decision

A. Key OFF. Disconnect DCU. Yes: Go to Step 10.
B. Check DCU and connector terminals for damaged or pinched wires,
corroded terminals; loose, bent or broken pins; or broken connector
housing.
Is 86-pin DCU module connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3479
FMI 5.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1021

Step 10 Check for Open in AFTFD CTL-L circuit. Decision

A. Key OFF. Disconnect 24-pin Engine and Chassis connector. Yes: Go to Step 11.

B. Disconnect DCU 86-pin connector.

C. Connect Breakout Harness ZTSE6020 to chassis harness and leave
engine harness side disconnected.

D. Use Terminal Test Kit insert appropriate terminal into 86-pin connector
pin-10.
E. Measure resistance between Breakout Harness ZTSE6020 pin-10 and
ZTSE4435C pin-10.
Is resistance less than 5 ohms? No: Repair Open between 24-pin
Engine to Chassis connector
pin-10 and DCU Module pin-10.
After repairs are complete, retest
for SPN 3479 FMI 5.

Step 11 Check for short to GND in AFTFD CTL-L circuit. Decision

A. Perform Test 5 (page 1023). Yes: Step 12.
B. Measure resistance between Breakout Harness ZTSE6020 pin-10 and
GND.
Is resistance greater than 1000 ohms? No: Repair short to GND
between 24-pin Engine to Chassis
connector pin-10 and DCU
Module pin-10. After repairs are
complete, retest for SPN 3482
FMI 5.

Step 12 Check for Open in AFTFD CTL-H circuit. Decision

A. Key OFF. Disconnect 24-pin Engine and Chassis connector. Yes: Repair short to GND
between 24-pin engine to chassis
B. Disconnect DCU 86-pin connector.
connector pin-9 and DCU Module
C. Connect Breakout Harness ZTSE6020 to chassis harness and leave pin-30. After repairs are complete,
engine harness side disconnected. retest for SPN 3479 FMI 5.
D. Insert appropriate terminal into 86-pin connector pin-30.
E. Measure resistance between Breakout Harness ZTSE6020 pin-9 and
ZTSE4435C pin-30.
Is resistance less than 5 ohms? No: Repair Open between 24-pin
Engine to Chassis connector pin-9
and DCU Module pin-30. After
repairs are complete, retest for
SPN 3479 FMI 5.
1022 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

End Pin-Point Tests

After performing diagnostic steps, if SPN 3479 FMI 5 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.

Pin-Point Tests SPN 3479 FMI 5

See latest version of Engine and Aftertreatment Wiring Schematic Form for additional circuit information.
Tools Required
• Breakout Harness ZTSE6020
• Breakout Harness ZTSE6021
• Digital Multimeter (DMM)
• Terminal Test Kit ZTSE4435C

Figure 297 AFTFD CTL-H Circuit Checks

Test 1
A. Key OFF. Disconnect Aftertreatment Fuel Doser (AFTFD) connector.
B. Disconnect 24-pin Engine to Chassis connector.

C. Connect Breakout Harness ZTSE6021 to engine harness and leave AFTFD disconnected.
D. Connect Breakout Harness ZTSE6020 to 24-pin Engine to Chassis connector and leave DCU Module side
disconnected.

Test 2
A. Key OFF. Disconnect AFTFD.

B. Disconnect 24-pin Engine to Chassis connector.

C. Connect Breakout Harness ZTSE6021 to engine harness and leave AFTFD disconnected.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1023

Test 3
A. Key OFF. Disconnect Aftertreatment Fuel Doser (AFTFD) connector.
B. Disconnect 24-pin Engine to Chassis connector.
C. Connect Breakout Harness ZTSE6021 to engine harness and leave AFTFD disconnected.
D. Connect Breakout Harness ZTSE6020 to 24-pin Engine to Chassis connector and leave DCU Module side
disconnected.

Test 4
A. Key OFF. Disconnect AFTFD connector.
B. Disconnect 24-pin Engine to Chassis connector.
C. Connect Breakout Harness ZTSE6021 to engine harness and leave AFTFD disconnected.

Figure 298 AFTFD CTL-L Circuit Check

Test 5
A. Key OFF. Disconnect 24-pin Engine and Chassis connector.
B. Disconnect DCU 86-pin connector.

C. Connect Breakout Harness ZTSE6020 to chassis harness and leave engine harness side disconnected.
1024 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3479 FMI 6 - AFT Fuel Pressure Control (Doser) Valve Open or short to PWR on high side

Fault Overview
Fault code sets when Doser Control Unit (DCU) detects a short to power or Open load on high-side circuit.

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

Associated Faults
None

Fault Facts
Doser Control Unit (DCU) deactivates circuits when a circuit fault is present, so NOID Lamp is needed to simulate
correct circuit. Fault is latched for a key cycle, so Engine Control Module (ECM) must be reset by a Key OFF
cycle.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• DCU circuit fault
• AFTFD‐H circuit short to power

Step 1 Check for active or pending fault code. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for Yes: Go to Step 2.
SPN 3479 FMI 6.
Is EST DTC list SPN 3479 FMI 6 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Inspect connections at Aftertreatment Fuel Doser (AFTFD). Decision

A. Key OFF. Disconnect AFTFD connector. Yes: Go to Step 3.
B. Check AFTFD connector terminals for damaged or pinched wires; wet
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are AFTFD connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3479
FMI 6.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1025

Step 3 Check vehicle harness / NOID Lamp illumination. Decision

A. Key OFF. Connect NOID Lamp 15-909-01 to vehicle harness and leave Yes: Replace AFTFD. After
AFTFD disconnected. repairs are complete, retest for
SPN 3479 FMI 6.
B. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
C. Perform KOEO DCU Actuator Test - Actuator Output High and Low
Diagnostics (page 1368).
Did NOID Lamp 15-909-01 illuminate? No: Go to Step 4.

Step 4 Inspect connections at 24-pin Engine to Chassis connector. Decision

A. Key OFF. Disconnect 24-pin Engine to Chassis connector. Yes: Go to Step 5.
B. Check 24-pin Engine to Chassis connector terminals for damaged or
pinched wires; wet or corroded terminals; loose, bent, or broken pins; or
broken connector housing.
Are 24-pin Engine to Chassis connector, harness, and terminals clean and No: Repair connector, harness,
undamaged? or terminal damage. After repairs
are complete, retest for SPN 3479
FMI 6.

Step 5 Check for Open in AFTFD CTL-H circuit . Decision

A. Perform Test 1 (page 1028). Yes: Go to Step 6.
B. Use DMM, measure resistance between Breakout Harness ZTSE6021
pin-1 and Breakout Harness ZTSE6020 pin-9.
Is resistance less than 5 ohms? No: Repair Open in AFTFD
CTL-H circuit between AFTFD pin
1 and 24-pin Engine to Chassis
pin-9. After repairs are complete,
retest for SPN 3479 FMI 6.

Step 6 Check for short to GND in AFTFD CTL-H circuit. Decision

A. Perform Test 2 (page 1028). Yes: Go to Step 7

B. Measure resistance between Breakout Harness ZTSE6021 pin-1 and

GND.
Is resistance greater than 1000 ohms? No: Repair short to GND
between 24-pin Engine to Chassis
connector pin-9 and AFTFD pin-1.
After repairs are complete, retest
for SPN 3479 FMI 6.
1026 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 7 Check for Open in AFTFD CTL-L circuit. Decision

A. Perform Test 3 (page 1028). Yes: Go to Step 8.
B. Measure resistance between Breakout Harness ZTSE6021 pin-2 and
Breakout Harness ZTSE6020 pin-10.
Is resistance less than 5 ohms? No: Repair Open in AFTFD CTL-L
circuit between AFTFD pin-2 and
24-pin Engine to Chassis pin-10.
After repairs are complete, retest
for SPN 3479 FMI 6.

Step 8 Check for short to GND in AFTFD CTL-L circuit. Decision

A. Perform Test 4 (page 1029). Yes: Go to Step 9.
B. Measure resistance between Breakout Harness ZTSE6021 pin-2 and
GND.
Is resistance greater than 1000 ohms? No: Repair short to GND
between 24-pin Engine to Chassis
connector pin-10 and AFTFD
pin-2. After repairs are complete,
retest for SPN 3479 FMI 6.

Step 9 Inspect connections at 86-pin Doser Control Unit (DCU). Decision

A. Key OFF. Disconnect DCU. Yes: Go to Step 10.
B. Check DCU and connector terminals for damaged or pinched wires,
corroded terminals; loose, bent or broken pins; or broken connector
housing.
Is 86-pin DCU module connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3479
FMI 6.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1027

Step 10 Check for Open in AFTFD CTL-L circuit. Decision

A. Key OFF. Disconnect 24-pin Engine and Chassis connector. Disconnect Yes: Go to Step 11.
DCU 86-pin connector.
B. Connect Breakout Harness ZTSE6020 to chassis harness and leave
engine harness side disconnected.

C. Use Terminal Test Kit insert appropriate terminal into 86-pin connector
pin-10.
D. Measure resistance between Breakout Harness ZTSE6020 pin-10 and
ZTSE4435C pin-10.
Is resistance less than 5 ohms? No: Repair Open between 24-pin
Engine to Chassis connector
pin-10 and DCU Module pin-10.
After repairs are complete, retest
for SPN 3479 FMI 6.

Step 11 Check for short to GND in AFTFD CTL-L circuit. Decision

A. Perform Test 5 (page 1029). Yes: Step 12.
B. Measure resistance between Breakout Harness ZTSE6020 pin-10 and
GND.
Is resistance greater than 1000 ohms? No: Repair short to GND
between 24-pin Engine to Chassis
connector pin-10 and DCU Module
pin-10. After repairs are complete,
retest for SPN 3482 FMI 6.

Step 12 Check for Open in AFTFD CTL-H circuit. Decision

A. Key OFF. Disconnect 24-pin Engine and Chassis connector. Disconnect Yes: Repair short to GND between
DCU 86-pin connector. 24-pin engine to chassis connector
pin-9 and DCU Module pin-30.
B. Connect Breakout Harness ZTSE6020 to chassis harness and leave
After repairs are complete, retest
engine harness side disconnected.
for SPN 3479 FMI 6.
C. Insert appropriate terminal into 86-pin connector pin-30.
D. Measure resistance between Breakout Harness ZTSE6020 pin-9 and
ZTSE4435C pin-30.
Is resistance less than 5 ohms? No: Repair Open between 24-pin
Engine to Chassis connector pin-9
and DCU Module pin-30. After
repairs are complete, retest for
SPN 3479 FMI 6.

End Pin-Point Tests

After performing diagnostic steps, if SPN 3479 FMI 6 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1028 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests SPN 3479 FMI 6

See latest version of Engine and Aftertreatment Wiring Schematic Form for additional circuit information.
Tools Required
• Breakout Harness ZTSE6020
• Breakout Harness ZTSE6021
• Digital Multimeter (DMM)
• Terminal Test Kit ZTSE4435C

Figure 299 AFTFD CTL-H Circuit Checks

Test 1
A. Key OFF. Disconnect Aftertreatment Fuel Doser (AFTFD) connector.
B. Disconnect 24-pin Engine to Chassis connector.
C. Connect Breakout Harness ZTSE6021 to engine harness and leave AFTFD disconnected.
D. Connect Breakout Harness ZTSE6020 to 24-pin Engine to Chassis connector and leave DCU Module side
disconnected.

Test 2
A. Key OFF. Disconnect AFTFD.

B. Disconnect 24-pin Engine to Chassis connector.

C. Connect Breakout Harness ZTSE6021 to engine harness and leave AFTFD disconnected.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1029

Test 3
A. Key OFF. Disconnect AFTFD connector.
B. Disconnect 24-pin Engine to Chassis connector.
C. Connect Breakout Harness ZTSE6021 to engine harness and leave AFTFD disconnected.
D. Connect Breakout Harness ZTSE6020 to 24-pin Engine to Chassis connector and leave DCU Module side
disconnected.

Test 4
A. Key OFF. Disconnect AFTFD connector.
B. Disconnect 24-pin Engine to Chassis connector.
C. Connect Breakout Harness ZTSE6021 to engine harness and leave AFTFD disconnected.

Figure 300 AFTFD CTL-L Circuit Check

Test 5
A. Key OFF. Disconnect 24-pin Engine and Chassis connector.
B. Disconnect DCU 86-pin connector.

C. Connect Breakout Harness ZTSE6020 to chassis harness and leave engine harness side disconnected.
1030 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3480 FMI 3 - AFTFP1 signal Out of Range HIGH

Fault Overview
Fault code sets when the Engine Control Module (ECM) detects Aftertreatment Fuel Pressure 1 (AFTFP1) signal
voltage is greater than 4.85 volts. Engine torque may be reduced if engine is operated for an extended period
of time with this fault active. Active regeneration of the aftertreatment system may be disabled until the next key
cycle.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• AFTFP1 signal circuit Open
• AFTFP1 signal circuit short to PWR
• AFTFP1 SIG GND Open
• Failed Aftertreatment Fuel Inlet Sensor (AFTFIS)

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for Yes: Go to Step 2.
SPN 3480 FMI 3.
Is EST DTC list SPN 3480 FMI 3 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Inspect connections at Aftertreatment Fuel Inlet Sensor (AFTFIS). Decision

A. Key OFF. Yes: Go to Step 3.

B. Disconnect AFTFIS connector.

C. Check AFTFIS and connector terminals for damaged or pinched wires;

corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are AFTFIS connector, harness, and terminal clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3480
FMI 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1031

Step 3 Check voltage for VREF 5 circuit. Decision

A. Perform Test 1(page 1032). Yes: Go to Step 4.
B. Use DMM, measure voltage between Breakout Harness ZTSE4830 pin-3
and known good GND.
Is voltage 5.0 ± 1.0 volts? No: Repair short to PWR between
AFTFIS pin-3 and DCU pin-22.
After repairs are complete, retest
for SPN 3480 FMI 3.

Step 4 Check AFTFP1 circuit. Decision

A. Perform Test 2 (page 1032). Yes: Replace AFTFIS sensor.
After repairs are complete, retest
B. Use EST, clear DTC list.
for SPN 3480 FMI 3.
Does SPN 3480 FMI 4 set after DTC list is cleared? No: Go to Step 5.

Step 5 Check AFTFP1 circuit. Decision

A. Perform Test 3 (page 1033). Yes: Repair Open between
AFTFIS pin-1 and DCU pin-21.
B. Use EST, clear DTC list.
After repairs are complete, retest
for SPN 3480 FMI 3.
Does SPN 3480 FMI 4 set after DTC list is cleared? No: Go to Step 6.

Step 6 Check for plugging or carbon buildup in AFTFI. Decision

Remove AFTFI and inspect for carbon blocking on the exhaust side, or physical Yes, carbon blocking: Clean
damage. injector tip and exhaust opening.
After repairs are complete, retest
for SPN 3480 FMI 3.
Is there carbon blocking or physical damage? Yes, physical damage: Replace
AFTFI. After repairs are complete,
retest for SPN 3480 FMI 3.
No: Repair Open between AFTFIS
pin-4 and DCU pin-22. After
repairs are complete, retest for
SPN 3480 FMI 3.

End Diagnostic Tests

After performing diagnostic steps, if SPN 3480 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1032 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Test (SPN 3480 FMI 3)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4830
• Breakout Harness ZTSE4498
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Figure 301 VREF 5 Circuit Check

Test 1
A. Key OFF.

B. Disconnect Aftertreatment Fuel Inlet Sensor (AFTFIS) connector.

C. Connect Breakout Harness ZTSE4830 to vehicle harness and leave AFTFIS connector disconnected.

D. Key-On Engine-Off (KOEO).

 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1033

Figure 302 AFTFP1 Circuit Check

Test 2
A. Key OFF.
B. Disconnect Aftertreatment Fuel Inlet Sensor (AFTFIS) connector.
C. Connect Breakout Harness ZTSE4830 to vehicle harness and leave AFTFIS sensor disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4830 pin-1 and pin-4 together.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
F. Key-On Engine-Off (KOEO). Log in to Navistar® Engine Diagnostics.
1034 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 303 AFTFP1 Circuit Check

Test 3
A. Key OFF.
B. Disconnect Aftertreatment Fuel Inlet Sensor (AFTFIS) connector.
C. Connect Breakout Harness ZTSE4830 to vehicle harness and leave AFTFIS connector disconnected.
D. Use Breakout Harness ZTSE4498, short pin-4 of Breakout Harness ZTSE4830 to know good GND.
E. Connect EST to vehicle Diagnostic Connector (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1035

SPN 3480 FMI 4 - AFTFP1 signal Out of Range LOW

Fault Overview
Fault code sets when the Engine Control Module (ECM) detects the Aftertreatment Fuel Pressure 1 (AFTFP1)
signal voltage is less than 0.25 volts for 2 seconds. Active aftertreatment regeneration may be disabled until
next key cycle. Engine torque will be reduced if fault is active for an extended period of time.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• AFTFP1 signal circuit short to GND
• Open VREF
• Failed Aftertreatment Fuel Inlet Sensor (AFTFIS)

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for Yes: Go to Step 2.
SPN 3480 FMI 4.
Is EST DTC list SPN 3480 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Inspect connections at AFTFIS connector. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect AFTFIS connector.

C. Check AFTFIS and connector terminals for damaged or pinched wires;

corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are AFTFIS connector, harness, and terminal clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3480
FMI 4.
1036 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Check voltage for VREF 5 circuit. Decision

A. Perform Test 1 (page 1036). Yes: Go to Step 4.
B. Use DMM, measure voltage between Breakout Harness ZTSE4830 pin-3
and known good GND.
Is voltage 5 ± 1 volts? No: Repair Open between
AFTFIS pin-3 and DCU pin-23.
After repairs are complete, retest
for SPN 3480 FMI 4.

Step 4 Check voltage for AFTFP1 circuit for short to GND. Decision
A. Perform Test 2 (page 1037). Yes: Replace AFTFIS. After
repairs are complete, retest for
B. Use DMM, measure voltage between Breakout Harness ZTSE4830 pin-4
SPN 3480 FMI 4.
and known good GND.
Is voltage 5 +/- 1 volt? No: Repair short to GND between
AFTFIS pin-4 and DCU pin-22.
After repairs are complete, retest
for SPN 3480 FMI 4.

End Diagnostic Tests

After performing diagnostic steps, if SPN 3480 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.

Pin-Point Tests (SPN 3480 FMI 4)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4830
• Breakout Harness ZTSE4498
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) withNavistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1037

Figure 304 VREF 5 Circuit Check

Test 1
A. Key OFF.
B. Disconnect Aftertreatment Fuel Inlet Sensor (AFTFIS) connector.
C. Connect Breakout Harness ZTSE4830 to vehicle harness and leave AFTFIS connector disconnected.
D. Key-On Engine-Off (KOEO).

Figure 305 AFTFP1 Circuit Check

Test 2
A. Key OFF.

B. Disconnect Aftertreatment Fuel Inlet Sensor (AFTFIS) connector.

C. Connect Breakout Harness ZTSE4830 to vehicle harness and leave AFTFIS connector disconnected.

D. Key-On Engine-Off (KOEO).

1038 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3482 FMI 3 - AFT Fuel Shutoff Valve short to PWR

Fault Overview
Fault Code sets when Doser Control Unit (DCU) Module detects a circuit fault for Aftertreatment Fuel Shutoff
(AFTFSO) circuit.

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

Associated Faults
None.

Fault Facts
DCU deactivates circuits when a circuit fault is present, NOID Lamp is needed to simulate correct circuit
operation. Fault is latched for a key cycle, ECM must be reset by a Key OFF cycle

Drive Cycle to Determine Fault Status

Key ON when energized.
Possible Causes
• AFTFSO CTL-H circuit Open or high resistance
• AFTFSO CTL-L circuit Open or high resistance
• AFTFSO CTL-H circuit short to GND
• AFTFSO CTL-L circuit short to GND
• Failed AFTFSO

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for Yes: Go to Step 2.
SPN 3482 FMI 3.
Is SPN 3482 FMI 3 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Inspect connections at AFTFSO sensor connector. Decision

A. Key OFF. Yes: Go to Step 3.

B. Disconnect AFTFSO sensor connector.

C. Check AFTFSO sensor connector terminals for damaged or pinched wires;

wet or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are AFTFSO sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3482
FMI 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1039

Step 3 Check vehicle harness/NOID Lamp illumination. Decision

A. Key OFF. Yes: Replace AFTSO. After
repairs are complete, retest for
B. Connect NOID Lamp 15-909-01 to engine harness and leave AFTFSO
SPN 3482 FMI 3.
disconnected.

C. Key ON Engine OFF (KOEO).

D. Perform KOEO DCU Actuator Test - Actuator Output High and Low
Diagnostics(page 1368).
Did NOID Lamp 15-909-01 illuminate? No: Go to Step 4.

Step 4 Inspect connections at 24-pin Engine to Chassis connector. Decision

A. Key OFF. Yes: Go to Step 5.
B. Disconnect 24-pin Engine to Chassis connector.
C. Check 24-pin connector and connector terminals for damaged or pinched
wires, wet or corroded terminals; loose, bent or broken pins; or broken
connector housing.
Is 24-pin connector harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3482
FMI 3.

Step 5 Check for Open in Aftertreatment Fuel Shutoff (AFTFSO) CTL-H Decision
circuit.
A. Perform Test 1 (page 1041). Yes: Go to Step 6.
B. Use DMM, measure resistance between Breakout Harness ZTSE4602
pin-1 and Breakout Harness ZTSE6020 pin-18.
Is resistance less than 5 ohms? No: Repair Open between 24-pin
connector pin-18 and AFTFSO
pin-1. After repairs are complete,
retest for SPN 3482 FMI 3.

Step 6 Check for short to GND in AFTFSO CTL-H circuit. Decision

A. Perform Test 2 (page 1042). Yes: Go to Step 7
B. Use DMM, measure resistance between Breakout Harness ZTSE4602
pin-1 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
24-pin connector pin-18 and
AFTFSO pin-1. After repairs are
complete, retest for SPN 3482 FMI
3.
1040 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 7 Check for Open in AFTFSO CTL-L circuit. Decision

A. Perform Test 3 (page 1043). Yes: Go to Step 8.
B. Use DMM, measure resistance between Breakout Harness ZTSE4602
pin-2 and Breakout Harness ZTSE6020 pin-19.
Is resistance less than 5 ohms? No: Repair Open between 24-pin
connector pin-19 and AFTFSO
pin-2. After repairs are complete,
retest for SPN 3482 FMI 3.

Step 8 Check for short to GND in AFTFSO CTL-L circuit. Decision

A. Perform Test 4 (page 1044). Yes: Go to Step 9
B. Use DMM, measure resistance between Breakout Harness ZTSE4602
pin-2 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
24-pin connector pin-19 and
AFTFSO pin-2. After repairs are
complete, retest for SPN 3482
FMI 3.

Step 9 Inspect connections at 86-pin Doser Control Unit (DCU). Decision

A. Key OFF. Yes: Go to Step 10.
B. Disconnect DCU.
C. Check DCU and connector terminals for damaged or pinched wires, wet
or corroded terminals; loose, bent or broken pins; or broken connector
housing.
Is 86-pin DCU module connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3482
FMI 3.

Step 10 Check for Open in AFTFSO CTL-L circuit. Decision

A. Perform Test 5 (page 1045). Yes: Go to Step 11.
B. Use DMM, measure resistance between Breakout Harness ZTSE6020
pin-19 and Terminal Test Kit ZTSE4435C pin-11
Is resistance less than 5 ohms? No: Repair Open between 24-pin
connector pin-19 and DCU Module
pin-11. After repairs are complete,
retest for SPN 3482 FMI 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1041

Step 11 Check for short to GND in AFTFSO CTL-L circuit. Decision

A. Perform Test 6 (page 1046). Yes: Step 12.
B. Use DMM, measure resistance between Breakout Harness ZTSE6020
pin-19 and known good engine GND.
Is resistance greater than 1000 ohms? No: Repair short to ground
between 24-pin connector pin-19
and DCU Module pin-11. After
repairs are complete, retest for
SPN 3482 FMI 3.

Step 12 Check for Open in AFTFSO CTL-H circuit. Decision

A. Perform Test 7 (page 1047). Yes: Repair short to ground
between 24-pin connector pin-18
B. Use DMM, measure resistance between Breakout Harness ZTSE6020
and DCU Module pin-31. After
pin-18 and Terminal Test Kit ZTSE4435C pin-31.
repairs are complete, retest for
SPN 3482 FMI 3.
Is resistance less than 5 ohms? No: Repair Open between 24-pin
connector pin-18 and DCU Module
pin-31. After repairs are complete,
retest for SPN 3482 FMI 3.

End Diagnostic Tests

After performing diagnostic steps, if SPN 3482 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.

Pin-Point Tests (SPN 3482 FMI 3)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4602
• Breakout Harness ZTSE6020
• Digital Multimeter (DMM)
• Terminal Test Kit ZTSE4435C
1042 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 306 AFTFSO CTL-H Circuit Check

Test 1
A. Key OFF.
B. Disconnect Aftertreatment Fuel Shutoff (AFTFSO).
C. Connect Breakout Harness ZTSE4602 to engine harness and leave AFTFSO disconnected.
D. Disconnect 24-pin Engine to Chassis connector.
E. Connect Breakout Harness ZTSE6020 to 24-pin connector and leave DCU Module side disconnected.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1043

Figure 307 AFTFSO CTL-H Circuit Check

Test 2
A. Key OFF.
B. Disconnect AFTFSO.
C. Disconnect 24-pin connector.
D. Connect Breakout Harness ZTSE4602 to engine harness and leave AFTFSO disconnected.
1044 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 308 AFTFSO CTL-L Circuit Check

Test 3
A. Key OFF.
B. Disconnect AFTSO.
C. Disconnect 24-pin connector.
D. Connect Breakout Harness ZTSE4602 to engine harness and leave AFTFSO disconnected.
E. Connect Breakout Harness ZTSE6020 to 24-pin connector and leave DCU Module side disconnected.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1045

Figure 309 AFTFSO CTL-L Circuit Check

Test 4
A. Key OFF.
B. Disconnect AFTSO.
C. Disconnect 24-pin connector.
D. Connect Breakout Harness ZTSE4602 to engine harness and leave AFTFSO disconnected.
1046 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 310 AFTFSO CTL-L Circuit Check

Test 5
A. Key OFF.
B. Disconnect 24-pin connector.
C. Disconnect DCU 86-pin connector.
D. Connect Breakout Harness ZTSE6020 to vehicle harness and leave AFTFSO side disconnected.
E. Use Terminal Test Kit ZTSE4435C insert appropriate terminal into 86-pin connector pin-11.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1047

Figure 311 AFTFSO CTL-L Circuit Check

Test 6
A. Key OFF.
B. Disconnect 24-pin connector.
C. Disconnect DCU 86-pin connector.
D. Connect Breakout Harness ZTSE6020 to vehicle harness and leave AFTFSO side disconnected.
1048 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 312 AFTFSO CTL-H Circuit Check

Test 7
A. Key OFF.
B. Disconnect 24-pin connector.
C. Disconnect DCU 86-pin connector.
D. Connect Breakout Harness ZTSE6020 to vehicle harness and leave AFTFSO side disconnected.
E. Use Terminal Test Kit ZTSE4435C insert appropriate terminal into 86-pin connector pin-31.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1049

SPN 3482 FMI 4 - AFT Fuel Shutoff Valve open or short to GND

Fault Overview
Fault Code sets when Doser Control Unit (DCU) Module detects signal from Aftertreatment Fuel Shutoff
(AFTFSO) actuator is shorted to ground.

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

Associated Faults
None

Fault Facts
Doser Control Unit (DCU) deactivates circuits when a circuit fault is present, so NOID light is needed to simulate
correct circuit. Fault is latched for a key cycle, so Engine Control Module (ECM) must be reset by a Key OFF
cycle.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• AFTFSO CTL-H circuit Open or high resistance
• AFTFSO CTL-L circuit Open or high resistance
• AFTFSO CTL-H circuit short to ground
• AFTFSO CTL-L circuit short to ground
• Failed AFTFSO

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for Yes: Go to Step 2.
SPN 3482 FMI 4.
Is SPN 3482 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Inspect connections at AFTFSO sensor connector. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect AFTFSO sensor connector.

C. Check AFTFSO sensor connector terminals for damaged or pinched

wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are AFTFSO sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3482
FMI 4.
1050 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Check vehicle harness/NOID Lamp illumination. Decision

A. Key OFF. Yes: Replace AFTSO. After
repairs are complete, retest for
B. Connect NOID Lamp 15-909-01 to vehicle harness and leave AFTSO
SPN 3482 FMI 4.
disconnected.

C. Key ON Engine OFF (KOEO).

D. Perform KOEO DCU Actuator Test - Actuator Output High and Low
Diagnostics(page 1368).
Did NOID Lamp 15-909-01 Lamp illuminate? No: Go to Step 4.

Step 4 Inspect connections at 24-pin Engine to Chassis connector. Decision

A. Key OFF. Yes: Go to Step 5.
B. Disconnect 24-pin connector.
C. Check 24-pin connector and connector terminals for damaged or pinched
wires, wet or corroded terminals; loose, bent or broken pins; or broken
connector housing.
Is 24-pin connector harness, and terminals clean and undamaged? No: Repair connector, harness, or
terminal damage. After repairs are
complete, retest for SPN 3482 FMI
4.

Step 5 Check for Open in AFTFSO CTL-H circuit. Decision

A. Perform Test 1 (page 1052). Yes: Go to Step 6.
B. Use DMM, measure resistance between Breakout Harness ZTSE4602
pin-1 and Breakout Harness ZTSE6020 pin-18.
Is resistance less than 5 ohms? No: Repair Open between 24-pin
connector pin-18 and AFTFSO
pin-1. After repairs are complete,
retest for SPN 3482 FMI 4.

Step 6 Check for short to GND in AFTFSO CTL-H circuit. Decision

A. Perform Test 2 (page 1053). Yes: Go to Step 7
B. Use DMM, measure resistance between Breakout Harness ZTSE4602
pin-1 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
24-pin connector pin-18 and
AFTFSO pin-1. After repairs are
complete, retest for SPN 3482 FMI
4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1051

Step 7 Check for Open in AFTFSO CTL-L circuit. Decision

A. Perform Test 3 (page 1054). Yes: Go to Step 8.
B. Use DMM, measure resistance between Breakout Harness ZTSE4602
pin-2 and Breakout Harness ZTSE6020 pin-19.
Is resistance less than 5 ohms? No: Repair Open between 24-pin
connector pin-19 and AFTFSO
pin-2. After repairs are complete,
retest for SPN 3482 FMI 4.

Step 8 Check for short to GND in AFTFSO CTL-L circuit. Decision

A. Perform Test 4 (page 1055). Yes: Go to Step 9
B. Use DMM, measure resistance between Breakout Harness ZTSE4602
pin-2 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
24-pin connector pin-19 and
AFTFSO pin-2. After repairs are
complete, retest for SPN 3482 FMI
4.

Step 9 Inspect connections at 86-pin Doser Control Unit (DCU). Decision

A. Key OFF. Yes: Go to Step 10.
B. Disconnect DCU.
C. Check DCU and connector terminals for damaged or pinched wires, wet
or corroded terminals; loose, bent or broken pins; or broken connector
housing.
Is 86-pin DCU module connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3482
FMI 4.

Step 10 Check for Open in AFTFSO CTL-L circuit. Decision

A. Perform Test 5 (page 1056). Yes: Go to Step 11.
B. Use DMM, measure resistance between Breakout Harness ZTSE6020
pin-19 and Terminal Test Kit ZTSE4435C pin-11
Is resistance less than 5 ohms? No: Repair Open between 24-pin
connector pin-19 and DCU Module
pin-11. After repairs are complete,
retest for SPN 3482 FMI 4.
1052 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 11 Check for short to GND in AFTFSO CTL-L circuit. Decision

A. Perform Test 6 (page 1057). Yes: Step 12.
B. Use DMM, measure resistance between Breakout Harness ZTSE6020
pin-19 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to ground
between 24-pin connector pin-19
and DCU Module pin-11. After
repairs are complete, retest for
SPN 3482 FMI 4.

Step 12 Check for Open in AFTFSO CTL-H circuit. Decision

A. Perform Test 7 (page 1058). Yes: Repair short to ground
between 24-pin connector pin-18
B. Use DMM, measure resistance between Breakout Harness ZTSE6020
and DCU Module pin-31. After
pin-18 and Terminal Test Kit ZTSE4435C pin-31.
repairs are complete, retest for
SPN 3482 FMI 4.
Is resistance less than 5 ohms? No: Repair Open between 24-pin
connector pin-18 and DCU Module
pin-31. After repairs are complete,
retest for SPN 3482 FMI 4.

End Diagnostic Tests

After performing diagnostic steps, if SPN 3482 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.

Pin-Point Tests (SPN 3482 FMI 4)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4602
• Breakout Harness ZTSE6020
• Digital Multimeter (DMM)
• Terminal Test Kit ZTSE4435C
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1053

Figure 313 AFTFSO CTL-H Circuit Check

Test 1
A. Key OFF.
B. Disconnect Aftertreatment Fuel Shutoff (AFTFSO).
C. Disconnect 24-pin Engine to Chassis connector.
D. Connect Breakout Harness ZTSE4602 to engine harness and leave AFTFSO disconnected.
E. Connect Breakout Harness ZTSE6020 to 24-pin connector and leave DCU Module side disconnected.
1054 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 314 AFTFSO CTL-H Circuit Check

Test 2
A. Key OFF.
B. Disconnect AFTFSO.
C. Disconnect 24-pin connector.
D. Connect Breakout Harness ZTSE4602 to engine harness and leave AFTFSO disconnected.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1055

Figure 315 AFTFSO CTL-L Circuit Check

Test 3
A. Key OFF.
B. Disconnect AFTSO.
C. Disconnect 24-pin connector.
D. Connect Breakout Harness ZTSE4602 to engine harness and leave AFTFSO disconnected.
E. Connect Breakout Harness ZTSE6020 to 24-pin connector and leave DCU Module side disconnected.
1056 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 316 AFTFSO CTL-L Circuit Check

Test 4
A. Key OFF.
B. Disconnect AFTSO.
C. Disconnect 24-pin connector.
D. Connect Breakout Harness ZTSE4602 to engine harness and leave AFTFSO disconnected.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1057

Figure 317 AFTFSO CTL-L Circuit Check

Test 5
A. Key OFF.
B. Disconnect 24-pin connector.
C. Disconnect DCU 86-pin connector.
D. Connect Breakout Harness ZTSE6020 to vehicle harness and leave AFTFSO side disconnected.
E. Use Terminal Test Kit ZTSE4435C insert appropriate terminal into DCU connector pin-11.
1058 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 318 AFTFSO CTL-L Circuit Check

Test 6
A. Key OFF.
B. Disconnect 24-pin connector.
C. Disconnect DCU 86-pin connector.
D. Connect Breakout Harness ZTSE6020 to vehicle harness and leave AFTFSO side disconnected.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1059

Figure 319 AFTFSO CTL-H Circuit Check

Test 7
A. Key OFF.
B. Disconnect 24-pin connector.
C. Disconnect DCU 86-pin connector.
D. Connect Breakout Harness ZTSE6020 to vehicle harness and leave AFTFSO side disconnected.
E. Use Terminal Test Kit ZTSE4435C insert appropriate terminal into 86-pin connector pin-31.
1060 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3509 FMI 3 - VREF 1 voltage above maximum

Fault Overview
Fault sets when Engine Control Module (ECM) senses VREF 1 sensor supply voltage is greater than 5.498 volts.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Short to PWR in engine harness
• Short to PWR in UVC harness (if equipped with ECB)
• Short to PWR in ETV
• Short to PWR in EBPC
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1061

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 3509 FMI 3.
Is EST DTC list SPN 3509 FMI 3 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Measure VREF voltage at Air Control Valve (ACV). Decision

A. Perform Test 1(page 1063). Yes: Go to Step 3.
B. Use DMM, measure voltage between Breakout Harness ZTSE4850 pin-2
and known good GND.
Is voltage greater than 5.5 volts? No: Replace ACV. After repairs
are complete, retest for SPN 3509
FMI 3.

Step 3 Measure VREF 1 voltage at ACV with Engine Control Module (ECM) Decision
disconnected.
A. Perform Test 2(page 1063). Yes: Go to Step 5.
B. Use DMM, measure voltage between Breakout Harness ZTSE4850 pin-2
and known good GND.
Is voltage greater than 5.5 volts? No: Go to Step 4.

Step 4 Measure VREF 1 voltage with Under Valve Cover 1 (UVC1) harness Decision
disconnected.
A. Perform Test 3(page 1064). Yes: Repair engine harness for
Short between ECM pin D-13 and
B. Use DMM, measure voltage between Breakout Harness ZTSE4952 pin-8
PWR. After repairs are complete,
and known good GND.
retest for SPN 3509 FMI 3.
Is voltage greater than 5.5 volts? No: Repair UVC harness for
Short between pin-5 and pin-8 OR
pin-5 and pin-3. After repairs are
complete, retest for SPN 3509 FMI
3.

Step 5 Measure VREF 1 voltage with Turbocharger 1 Turbine Outlet Pressure Decision
(TC1TOP) sensor disconnected.
A. Perform Test 4(page 1065). Yes: Replace ACV which contains
TC1TOP sensor. After repairs are
B. Use DMM, measure voltage between Breakout Harness ZTSE4850 pin-2
complete, retest for SPN 3509 FMI
and known good GND.
3.
Is voltage greater than 5.5 volts? No: Go to Step 6.
1062 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 6 Measure VREF 1 voltage with Engine Throttle Valve (ETV) sensor Decision
disconnected.
A. Perform Test 5(page 1066). Yes: Replace ETP sensor. After
repairs are complete, retest for
B. Use DMM, measure voltage between Breakout Harness ZTSE4850 pin-2
SPN 3509 FMI 3.
and known good GND.
Is voltage greater than 5.5 volts? No: Repair Short to PWR in engine
harness to pin E-35. After repairs
are complete, retest for SPN 3509
FMI 3.

End Diagnostic Test

After performing diagnostic steps, if SPN 3509 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.

Pin-Point Tests (SPN 3509 FMI 3)

Figure 320 VREF circuit diagram

 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1063

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4850
• Breakout Harness ZTSE4952
• Digital Multimeter (DMM)

Figure 321 EBP Circuit Check

Test 1
A. Key-Off.
B. Disconnect Exhaust Back Pressure (EBP) sensor connector.
C. Connect breakout harness ZTSE4850 to vehicle harness and reconnect EBP sensor connector.
D. Key-On Engine-Off (KOEO).
1064 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 322 EBP Circuit Check

Test 2
A. Key-Off.
B. Disconnect Engine Control Module (ECM) 36-pin driver connector.
C. Disconnect Exhaust Back Pressure (EBP) sensor connector.
D. Connect breakout harness ZTSE4850 to vehicle harness, reconnect EBP sensor connector, and leave ECM
36-pin connector disconnected.
E. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1065

Figure 323 UVC Circuit Check

Test 3
A. Key-Off.
B. Reconnect Engine Control Module (ECM) 36-pin driver connector.
C. Disconnect Under Valve Connector (UVC) connector.
D. Connect breakout harness ZTSE4952 to vehicle harness and leave UVC connector disconnected.
E. Key-On Engine-Off (KOEO).
1066 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 324 EBP Circuit Check

Test 4
A. Key-Off.
B. Disconnect Turbocharger 1 Turbine Outlet Pressure (TC1TOP) connector.
C. Disconnect Exhaust Back Pressure (EBP) sensor connector.
D. Connect breakout harness ZTSE4850 to vehicle harness, reconnect EBP sensor connector, and leave
TC1TOP connector disconnected.
E. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1067

Figure 325 EBP Circuit Check

Test 5
A. Key-Off.
B. Disconnect Engine Throttle Valve Position (ETP) connector. Reconnect Turbocharger 1 Turbine Outlet
Pressure (TC1TOP) connector.
C. Disconnect Exhaust Back Pressure (EBP) sensor connector.
D. Connect breakout harness ZTSE4850 to vehicle harness, reconnect EBP sensor connector, and leave ETP
connector disconnected.
E. Key-On Engine-Off (KOEO).
1068 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3509 FMI 4 - VREF 1 voltage below minimum

Fault Overview
Fault sets when Engine Control Module (ECM) senses VREF 1 sensor supply voltage is less than 4.5 volts.

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

Associated Faults
None

Fault Facts
Wiring harness routing to all sensors is very important. Make sure that wiring harnesses are routed properly to
avoid contact with serpentine belt or pulleys.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Short to GND in engine harness
• Short to GND in UVC harness
• Failed ETV
• Failed EBPC
• Failed: EOP, IMP, EBP, FDP, ICP, or ECBP (optional) sensors
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1069

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 3509 FMI 4.
Is EST DTC list SPN 3509 FMI 4 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 2 Measure VREF 1 voltage at Exhaust Back Pressure (EBP) sensor. Decision
A. Perform Test 1 (page 1072). Yes: Go to Step 3.
B. Use Digital Multimeter (DMM), measure voltage between Breakout
Harness ZTSE4850 pin-2 and known good GND.
Is voltage less than 4.5 volts? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 3 Measure VREF 1 voltage at EBP sensor with Engine Control Module Decision
(ECM) driver harness disconnected.
A. Perform Test 2 (page 1073). Yes: Go to Step 7.
B. Use DMM, measure voltage between Breakout Harness ZTSE4850 pin-2
and known good GND.
Is voltage less than 4.5 volts? No: Go to Step 4.

Step 4 Measure VREF 1 voltage at Under Valve Cover (UVC) connector 1. Decision
A. Perform Test 3 (page 1074). Yes: Repair short to GND
between ECM pin D-13 and GND.
B. Use DMM, measure voltage between Breakout Harness ZTSE4952 pin-8
After repairs are complete, retest
and known good GND.
for SPN 3509 FMI 4.
Is voltage less than 4.5 volts? No: Go to Step 5.

Step 5 Measure VREF 1 voltage at UVC 1 with Injector Control Pressure Decision
(ICP) disconnected.
A. Perform Test 4 (page 1075). Yes: Go to Step 6.
B. Use DMM, measure voltage between Breakout Harness ZTSE4952 pin-8
and known good GND.
Is voltage less than 4.5 volts? No: Replace ICP sensor. After
repairs are complete, retest for
SPN 3509 FMI 4.
1070 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 6 Measure VREF 1 voltage at UVC 1 with Engine Compression Brake Decision
Pressure (ECBP) disconnected.
A. Perform Test 5 (page 1076). Yes: Repair UVC harness. After
repairs are complete, retest for
B. Use DMM, measure voltage between Breakout Harness ZTSE4952 pin-8
SPN 3509 FMI 4.
and known good GND.
Is voltage less than 4.5 volts? No: Replace ECBP sensor. After
repairs are complete, retest for
SPN 3509 FMI 4.

Step 7 Measure VREF 1 voltage with Turbocharger 1 Turbine Outlet Pressure Decision
(TC1TOP) sensor disconnected.
A. Perform Test 6 (page 1077). Yes: Go to Step 8.
B. Use DMM, measure voltage between Breakout Harness ZTSE4850 pin-2
and known good GND.
Is voltage less than 4.5 volts? No: Replace TC1TOP sensor.
After repairs are complete, retest
for SPN 3509 FMI 4.

Step 8 Measure VREF 1 voltage with Engine Throttle Valve (ETV) sensor Decision
disconnected.
A. Perform Test 7 (page 1078). Yes: Go to Step 9.
B. Use DMM, measure voltage between Breakout Harness ZTSE4850 pin-2
and known good GND.
Is voltage less than 4.5 volts? No: Replace ETV sensor. After
repairs are complete, retest for
SPN 3509 FMI 4.

Step 9 Measure VREF 1 voltage with Fuel Delivery Pressure (FDP) sensor Decision
disconnected.
A. Perform Test 8 (page 1079). Yes: Go to Step 10.
B. Use DMM, measure voltage between Breakout Harness ZTSE4850 pin-2
and known good GND.
Is voltage less than 4.5 volts? No: Replace FDP sensor. After
repairs are complete, retest for
SPN 3509 FMI 4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1071

Step 10 Measure VREF 1 voltage with Engine Oil Pressure (EOP) sensor Decision
disconnected.
A. Perform Test 9 (page 1080). Yes: Go to Step 11.
B. Use DMM, measure voltage between Breakout Harness ZTSE4850 pin-2
and known good GND.
Is voltage less than 4.5 volts? No: Replace EOP sensor. After
repairs are complete, retest for
SPN 3509 FMI 4.

Step 11 Measure VREF 1 voltage with Intake Manifold Pressure (IMP) sensor Decision
disconnected.
A. Perform Test 10 (page 1081). Yes: Go to Step 12.
B. Use DMM, measure voltage between Breakout Harness ZTSE4850 pin-2
and known good GND.
Is voltage less than 4.5 volts? No: Replace IMP sensor. After
repairs are complete, retest for
SPN 3509 FMI 4.

Step 12 Measure VREF 1 voltage with EBP sensor disconnected. Decision

A. Perform Test 11 (page 1082). Yes: Repair short to GND in
engine harness to Pin E-35. After
B. Use DMM, measure voltage between Breakout Harness ZTSE4850 pin-2
repairs are complete, retest for
and known good GND.
SPN 3509 FMI 4.
Is voltage less than 4.5 volts? No: Replace EBP sensor. After
repairs are complete, retest for
SPN 3509 FMI 4.

End Diagnostic Tests

After performing diagnostic steps, if SPN 3509 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1072 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 3509 FMI 4)

Figure 326 VREF circuit diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4850
• Breakout Harness ZTSE4952
• Digital Multimeter (DMM)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1073

Figure 327 EBP Circuit Check

Test 1
A. Key-Off.
B. Disconnect Exhaust Back Pressure (EBP) sensor connector.
C. Connect breakout harness ZTSE4850 to vehicle harness and reconnect EBP sensor connector.
D. Key-On Engine-Off (KOEO).
1074 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 328 EBP Circuit Check

Test 2
A. Key-Off.
B. Disconnect Engine Control Module (ECM) 36-pin driver connector.
C. Disconnect EBP sensor connector.
D. Connect breakout harness ZTSE4850 to vehicle harness and reconnect EBP sensor connector.
E. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1075

Figure 329 UVC 1 Circuit Check

Test 3
A. Key-Off.
B. Reconnect ECM 36-pin driver connector.
C. Disconnect Under Valve Connector 1 (UVC 1) connector.
D. Connect breakout harness ZTSE4952 to vehicle harness and leave UVC 1 connector disconnected.
E. Key-On Engine-Off (KOEO).
1076 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 330 UVC 1 Circuit Check

Test 4
A. Key-Off.
B. Remove valve cover.
C. Disconnect Under Valve Cover (UVC) connector 1.
D. Connect Breakout Harness ZTSE4952 to vehicle harness and leave UVC connector 1 disconnected.
E. Disconnect Injection Control Pressure (ICP) connector.
F. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1077

Figure 331 UVC 1 Circuit Check

Test 5
A. Key-Off.
B. Remove valve cover
C. Disconnect UVC 1 connector.
D. Connect Breakout Harness ZTSE4952 to vehicle harness and leave UVC 1 connector disconnected.
E. Reconnect ICP connector. Disconnect Engine Compression Brake Pressure (ECBP) connector.
F. Key-On Engine-Off (KOEO).
1078 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 332 TC1TOP Circuit Check

Test 6
A. Key-Off.
B. Disconnect Turbocharger 1 Turbine Outlet Pressure (TC1TOP) connector.
C. Disconnect EBP sensor connector.
D. Connect breakout harness ZTSE4850 to vehicle harness, reconnect EBP sensor connector, and leave
TC1TOP disconnected.
E. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1079

Figure 333 ETV Circuit Check

Test 7
A. Key-Off.
B. Disconnect Engine Throttle Valve (ETV) connector. Reconnect TC1TOP connector.
C. Disconnect EBP sensor connector.
D. Connect breakout harness ZTSE4850 to vehicle harness, reconnect EBP sensor connector, and leave ETP
disconnected.
E. Key-On Engine-Off (KOEO).
1080 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 334 FDP Circuit Check

Test 8
A. Key-Off.
B. Disconnect Fuel Delivery Pressure (FDP) connector. Reconnect ETV connector.
C. Disconnect EBP sensor connector.
D. Connect breakout harness ZTSE4850 to vehicle harness, reconnect EBP sensor connector, and leave FDP
disconnected.
E. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1081

Figure 335 EOP Circuit Check

Test 9
A. Key-Off.
B. Disconnect Engine Oil Pressure (EOP) connector. Reconnect FDP connector.
C. Disconnect EBP sensor connector.
D. Connect breakout harness ZTSE4850 to vehicle harness, reconnect EBP sensor connector, and leave EOP
disconnected.
E. Key-On Engine-Off (KOEO).
1082 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 336 IMP Circuit Check

Test 10
A. Key-Off.
B. Disconnect Intake Manifold Pressure (IMP) connector. Reconnect EOP connector.
C. Disconnect EBP sensor connector.
D. Connect breakout harness ZTSE4850 to vehicle harness, reconnect EBP sensor connector, and leave IMP
disconnected.
E. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1083

Figure 337 EBP Circuit Check

Test 11
A. Key-Off.
B. Disconnect EBP sensor connector. Reconnect IMP connector.
C. Connect breakout harness ZTSE4850 to vehicle harness and leave EBP sensor disconnected.
D. Key-On Engine-Off (KOEO).
1084 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3510 FMI 3 - VREF 2 voltage above maximum

Fault Overview
Fault sets when Engine Control Module (ECM) senses VREF 2 sensor supply voltage is greater than 5.498 volts.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• VREF circuit short to PWR
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1085

Step 1 Check for active or pending fault codes. Decision

Using Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Repair short to PWR
SPN 3510 FMI 3. between APP pin-C and ECM pin
C-63. After repairs are complete,
retest for SPN 3510 FMI 3.
Is EST DTC list SPN 3510 FMI 3 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

End Diagnostic Tests

After performing diagnostic steps, if SPN 3510 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1086 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3510 FMI 4 - VREF 2 voltage below minimum

Fault Overview
Fault sets when Engine Control Module (ECM) senses VREF 2 sensor supply voltage is less than 4.502 volts.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• VREF circuit short to GND
• Failed sensor
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1087

Step 1 Check for active or pending fault codes. Decision

Using Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 3510 FMI 4.
Is EST DTC list SPN 3510 FMI 4 active or pending? No: Go to Intermittent or Not Active
Fault Diagnostic Procedure (page
1344).

Step 2 Measure VREF voltage for APP sensor. Decision

A. Perform Test 1 (page 1088). Yes: Replace APP sensor. After
repairs are complete, retest for
B. Use DMM, measure voltage between Breakout Harness ZTSE4485A
SPN 3510 FMI 4.
pin-C and known good GND.
Is voltage 5V ± 0.25V? No: Repair short to GND between
ECM pin C-63 and APP sensor
pin-C. After repairs are complete,
retest for SPN 3510 FMI 4.

End Diagnostic Tests

After performing diagnostic steps, if SPN 3510 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1088 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 3510 FMI 4)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4485A
• Digital Multimeter (DMM)

Figure 338 APP Circuit Check

Test 1
A. Key-Off.
B. Disconnect Accelerator Pedal Position (APP) sensor connector.
C. Connect Breakout Harness ZTSE4485A to vehicle harness and reconnect APP connector.
D. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1089

SPN 3511 FMI 3 - VREF 3 voltage above maximum

Fault Overview
Fault sets when Engine Control Module (ECM) senses VREF 3 sensor supply voltage is greater than 5.498 volts.

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• VREF circuit short to PWR
• Short to PWR in body builder connection
• Short to PWR in chassis harness
1090 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

Using Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 3511 FMI 3.
Is EST DTC list SPN 3511 FMI 3 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 2 Measure VREF voltage for APP sensor. Decision

A. Perform Test 1 (page 1091). Yes: Go to Step 3.
B. Use DMM, measure voltage between Breakout Harness ZTSE4485A
pin-D and known good GND.
Is voltage greater than 5.5 volts? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 3 Measure VREF voltage for APP sensor. Decision

A. Perform Test 2 (page 1091). Yes: Repair short to PWR
between 42-pin connector pin-30
B. Use DMM, measure voltage between Breakout Harness 00-00979-01
and APP pin-D. After repairs are
pin-30 and known good GND.
complete, retest for SPN 3511
FMI 3.
Is voltage greater than 5.5 volts? No: Repair short to PWR between
ECM pin C-27 and body builder
harness. After repairs are
complete, retest for SPN 3511
FMI 3.

End Diagnostic Tests

After performing diagnostic steps, if SPN 3511 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1091

Pin-Point Tests (SPN 3511 FMI 3)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4485A
• 42-pin Engine to Chassis Interface Cable 00-00979-01
• 180-pin Breakout Box 00-00956-08
• Digital Multimeter (DMM)

Figure 339 APP Circuit Check

Test 1
A. Key-Off.
B. Disconnect APP sensor.

C. Connect Breakout Harness ZTSE4485A to vehicle harness and leave APP connector disconnected.
D. Key-On Engine-Off (KOEO).
1092 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 340 APP Circuit Check

Test 2
A. Key-Off.
B. Disconnect 42-pin IP/Engine connector.
C. Connect Breakout Box 00-00956-08 to Breakout Harness 00-00979-01.
D. Connect Breakout Harness 00-00979-01 to vehicle harness (ECM side of connector) and leave vehicle side
disconnected.
E. Disconnect ECM 76-pin Chassis connector.
F. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1093

SPN 3511 FMI 4 - VREF 3 voltage below minimum

Fault Overview
Fault sets when Engine Control Module (ECM) senses VREF 3 sensor supply voltage is less than 4.502 volts.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• VREF circuit short to GND
• VREF 3 circuit for Body Builder short to GND
• Body Builder components short to GND
• Failed sensor causing short to GND on VREF circuit
1094 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: go to Step 2.
SPN 3511 FMI 4.
Is EST DTC list SPN 3511 FMI 4 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 2 Inspect connections at Accelerator Pedal Position (APP) connector. Decision

A. Key-Off. Yes: Go to Step 3.
B. Disconnect APP connector.
C. Check APP and connector terminals for: damaged or pinched wires;
moisture or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are APP connector, harness, and terminals clean and undamaged? No: Repair connector, harness, or
terminal damage. After repairs are
complete, retest for SPN 3511 FMI
4.

Step 3 Measure VREF voltage for Accelerator Pedal Position (APP) sensor. Decision
A. Perform Test 1 (page 1096). Yes: Go to Step 4.
B. Use DMM, measure voltage between Breakout Harness ZTSE4485A
pin-D and known good GND.
Is voltage less than 4.5 volts? No: Replace APP sensor. After
repairs are complete, retest for
SPN 3511 FMI 4.

Step 4 Inspect connections at 42-pin IP/Engine connector. Decision

A. Key-Off. Yes: Go to Step 5.
B. Disconnect 42-pin IP/Engine connector.
C. Check 42-pin IP/Engine and connector terminals for: damaged or pinched
wires; moisture or corroded terminals; loose, bent, or broken pins; or
broken connector housing.
Are 42-pin IP/Engine connector, harness, and terminals clean and undamaged? No: Repair connector, harness, or
terminal damage. After repairs are
complete, retest for SPN 3511 FMI
4.

Step 5 Check for short to GND between 42-pin connector and APP. Decision
A. Perform Test 2 (page 1096). Yes: Repair short to GND between
APP pin-D and 42-pin connector
B. Use DMM, measure voltage between Breakout Harness ZTSE4485A
pin-30. After repairs are complete,
pin-D and PWR.
retest for SPN 3511 FMI 4.
Is voltage within B+ ± 0.5 volts? No: Go to Step 6
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1095

Step 6 Check for short to GND between ECM and 42-pin connector. Decision
A. Perform Test 3 (page 1097). Yes: Repair short to GND between
42-pin connector pin-30 and
B. Use DMM, measure voltage between Breakout Harness 00-00979-01
ECM pin C-9. After repairs are
pin-30 and PWR.
complete, retest for SPN 3511 FMI
4.
Is voltage within B+ ± 0.5 volts? No: Go to Step 7.

Step 7 Check for short to GND between ECM and DPF sensor. Decision
A. Perform Test 4 (page 1098). Yes: Go to Step 8.
B. Use DMM, measure voltage between Breakout Harness ZTSE4761A
Pin-3 and a known good GND.
Is voltage 5V +/- 0.25V? No: Repair Short to GND between
DPF sensor Pin-3 and ECM pin
C-51. After repairs are complete,
retest SPN 3511 FMI 4.

Step 8 Check for short to GND on Body Builder VREF. Decision

A. Perform Test 5 (page 1099). Yes: End Diagnostics and retest
for SPN 3511 FMI 4.
B. Use DMM, measure voltage between ECM pin C-27 and a known good
GND.
Is voltage 5V +/- 0.25V? No: Repair short to GND between
ECM pin C-27 and Body Builder
Cut Wires. After repairs are
complete, retest SPN 3511 FMI 4.

End Diagnostic Tests

After performing diagnostic steps, if SPN 3511 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1096 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 3511 FMI 4)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• 180-pin Breakout Box 00-00956-08
• Breakout Harness 00-00959-01
• Breakout Harness 00-00979-01
• Breakout Harness ZTSE4485A
• Digital Multimeter (DMM)
• Pinout kit 4435C ZTSE4761A

Figure 341 APP Circuit Check

Test 1
A. Key-Off.
B. Disconnect Accelerator Pedal Position (APP) sensor.

C. Connect Breakout Harness ZTSE4485A to vehicle harness and leave APP connector disconnected.
D. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1097

Figure 342 APP Circuit Check

Test 2
A. Key-Off.
B. Disconnect APP sensor.
C. Connect Breakout Harness ZTSE4485A to vehicle harness and leave APP connector disconnected.
D. Disconnect 42-pin IP/Engine connector.
E. Key-On Engine-Off (KOEO).
1098 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 343 APP Circuit Check

Test 3
A. Key-Off.
B. Disconnect 42-pin IP/Engine connector between engine and chassis.
C. Connect Breakout Harness 00-00979-01 to vehicle harness ECM side of connector and leave 42-pin IP/Engine
chassis side of connector disconnected.
D. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1099

Figure 344 APP Circuit Check

Test 4
A. Key-Off.
B. Disconnect Diesel Particulate Filter Differential Pressure (DPFDP) sensor.
C. Connect Breakout Harness ZTSE4761A to chassis harness and leave DPFDP sensor disconnected.
D. Key-On Engine-Off (KOEO).
1100 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

C-27

0000415056

Figure 345 APP Circuit Check

Test 5
A. Key-Off.
B. Disconnect ECM Chassis 76-pin connector.
C. Connect Breakout Harness 00-00959-01 between vehicle harness and ECM Chassis connector.
D. Connect Breakout Harness 00-00959-01 to 180-pin Breakout Box 00-00956-08.
E. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1101

SPN 3512 FMI 14 - DCU VREF 1 or 2 Voltage Above or Below Normal

Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Doser Control Unit (DCU) VREF 1 or VREF 2
circuit voltage is greater than 5.1 volts or less than 4.9 volts.

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

Associated Faults
None

Fault Facts
The Aftertreatment Fuel Inlet sensor is a combination sensor that monitors Aftertreatment Fuel Pressure 1 and
Aftertreatment Fuel Temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• DCU VREF circuit short to PWR
• DCU VREF circuit short to GND
• Failed Aftertreatment Fuel Inlet (AFTFI) sensor
• Failed Aftertreatment Fuel Pressure 1 (AFTP1) sensor
1102 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list Yes: Go to Step 2.
for SPN 3512 FMI 14.
Is SPN 3512 FMI 14 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at Aftertreatment Fuel Inlet Sensor (AFTFIS). Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect AFTFIS connector.
C. Check AFTFIS connector terminals for damaged or pinched wires; wet
or corroded terminals; loose, bent, or broken pins; or broken connector
housings.
Are AFTFIS connectors, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for 3512 FMI
14.

Step 3 Inspect connections at Aftertreatment Fuel Pressure 2 (AFTFP2) Decision

sensor.
A. Key OFF. Yes: Go to Step 4.
B. Disconnect AFTFP2 connector.
C. Check AFTFP2 connector terminals for: damaged or pinched wires; wet
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are AFTFP2 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for 3512 FMI
14.

Step 4 Check voltage for DCU VREF circuit. Decision

Perform Test 1 (page 1104). Use Digital Multimeter (DMM), measure voltage Yes: End diagnostics. Retest for
between ZTSE6027 pin-1 and ground. SPN 3512 FMI 14.
Is voltage 5 ± 0.1 volts? No: Go to Step 5.

Step 5 AFTFP 2 sensor check. Decision

Perform Test 2 (page 1105). Use DMM, measure voltage between ZTSE6027 pin-1 Yes: Replace AFTFP2 sensor.
and ground. After repairs are complete, retest
for SPN 3512 FMI 14.
Is voltage 5 ± 0.1 volts? No: Go to Step 6.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1103

Step 6 Check for short in VREF circuit. Decision

Perform Test 3 (page 1106). Use DMM, measure voltage between ZTSE4830 pin-3 Yes: Replace AFTFIS sensor.
and ground. After repairs are complete, retest
for SPN 3512 FMI 14.
Is voltage 5 ± 0.1 volts? No: Repair short between AFTFIS
pin-3 and DCU pin-23 or AFTFP2
pin-1 and DCU pin-43. After
repairs are complete, retest for
SPN 3512 FMI 14.

End Diagnostic Tests

After performing diagnostic steps, if SPN 3512 FMI 14 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1104 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 3512 FMI 14)

Figure 346 DCU PWR circuit diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1105

Figure 347 VREF Circuit Check

Test 1
A. Key OFF.
B. Disconnect AFTFP2 connector.
C. Connect Breakout Harness ZTSE6027 between AFTFP2 sensor and engine harness.
D. Key-On Engine-Off (KOEO).
1106 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 348 VREF Circuit Check

Test 2
A. Key OFF.
B. Disconnect AFTFP2 connector.
C. Connect Breakout Harness ZTSE6027 to engine harness and leave AFTFP2 sensor disconnected.
D. Key-On Engine-Off (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1107

Figure 349 VREF Circuit Check

Test 3
A. Key OFF.
B. Disconnect Aftertreatment Fuel Inlet Sensor (AFTFIS) connector.
C. Connect Breakout Harness ZTSE4830 to engine harness and leave AFTIS disconnected.
D. Key-On Engine-Off (KOEO).
1108 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3556 FMI 0 - AFT Fuel Pressure 2 excessively high (Restricted injection)

Fault Overview
Fault sets when Aftertreatment Control Module (ACM) detects Aftertreatment Fuel Doser (AFTFD) is not
responding.

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

Associated Faults
• SPN 3479 FMI 3, 4, and 6 • SPN 4077 FMI 3 and 4
(AFTFD) (AFTFP2)

Fault Facts
None

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• Carbon deposits on Aftertreatment Fuel Injector (AFI)
• Restricted or leaking fuel line to AFI
• Cracked or damaged AFI
• Incorrect AFI gasket

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 1108).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 3556 FMI 0.

Step 2 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 3556 FMI 0. Yes: Go to Step 3.
Is EST SPN 3556 FMI 0 active or pending? No: Repair Active fault codes.
After repairs are complete, retest
for SPN 3556 FMI 0.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1109

Step 3 Inspect AFI fuel line. Decision

A. Inspect fuel line from DSI metering unit to AFI. Yes: Go to Step 4.
B. Look for cracks, bends and or breaks in fuel line.
C. Inspect for leaking fuel from fuel line.
Is AFI fuel line in good condition, clear of damage, and clear of leaks? No: Replace AFI fuel line. After
repairs are complete, retest for
SPN 3556 FMI 0.

Step 4 Inspect AFI bore. Decision

Remove AFI, see Engine Service Manual. Yes: Use chisel to break carbon
loose. Remove debris with
a vacuum. After repairs are
complete, retest for SPN 3556
FMI 0.
Is AFI opening of exhaust pipe restricted with carbon build up? No: Go to Step 5.

Step 5 Inspect AFI for carbon. Decision

With AFI still removed. Yes: Clean AFI tip with ZTSE4301
brass brush. Then go to Step 6.
Is there carbon build up on AFI tip? No: Go to Step 6.

Step 6 Inspect AFI and gasket. Decision

A. With AFI still removed. Yes: Go to Step 7.
B. Inspect for correct gasket, cracks in AFI body and cracks in AFI tip.
C. Discard removed gasket and bolts after inspection.
Is AFI clear of cracks and is correct gasket installed? No: Obtain new gasket and bolts.
Replace AFI as needed. After
repairs are complete, go to Step 7.

Step 7 Install and test AFI. Decision

A. Install AFI with new gasket and new bolts, see Engine Service Manual. Yes: End diagnostics. Retest for
SPN 3556 FMI 0.
B. Run KOER DSI Deaeration Procedure twice(page 1388), to purge Down
Stream Injection (DSI) system of air.
C. Perform Onboard Filter Cleanliness Test (OBFCT) (page 1331).
Did OBFCT run successfully without setting fault codes or aborting? No: See 0000003081
Aftertreatment Symptom-Based
Diagnostic and Service Manual for
further diagnostics.
1110 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

End Diagnostic Steps

After performing all diagnostic steps, if SPN 3556 FMI 0 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1111

SPN 3556 FMI 1 - AFT Fuel Pressure 2 below desired (Possible system leak)

Fault Overview
Fault code sets when Doser Control Unit (DCU) detects Aftertreatment Fuel Pressure 2 (AFTFP2) is below
desired pressure indicating a possible system leak.

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

Associated Faults
SPN 94 SPN 3479 SPN 3480 SPN 4077
SPN 5456

Fault Facts
None

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• VREF high resistance
• SIG GND high resistance
• AFTFP2 circuit high resistance
• System Leak
• Faulty AFTFP2

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 1111).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 3556 FMI 1.

Step 2 Inspect for system leak between Down Stream Injection (DSI) unit and Decision
Aftertreatment Fuel Injector (AFTFI).
Check DSI module and AFTFI fuel supply line for damage, restrictions, or leaks. Yes: Go to Step 3.
Is fuel supply line and DSI module in good condition and not restricted, leaking, No: Repair or replace damaged or
or damaged? leaking component. After repairs
are complete, retest for SPN 3556
FMI 1.
1112 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Check for Down Stream Injection (DSI) system leaks. Decision
Perform KOER DSI System Test (page 1385) to check DSI system for leaks. Yes: Repair leak. After repairs
are complete, retest for SPN 3556
FMI 1.
Does DSI system test indicate a leak? No: Go to Step 4.

Step 4 Check for VREF. Decision

A. Key OFF. Disconnect Aftertreatment Fuel Pressure 2 (AFTFP2) sensor. Yes: Go to Step 6.
B. Connect Breakout Harness ZTSE6027 to vehicle harness and leave
AFTFP2 sensor disconnected.
C. Key ON Engine OFF (KOEO).
D. Use DMM, measure voltage between Breakout Harness ZTSE6027 pin-1
and pin-2.
Is voltage within 5.0 ± 0.1 volts? No: Go to Step 5.

Step 5 Check for high resistance in SIG GND circuit. Decision

A. Breakout Harness ZTSE6027 connected to vehicle harness and AFTFP2 Yes: Repair Open or high
sensor disconnected. resistance in VREF circuit. After
repairs are complete, retest for
B. KOEO. Measure voltage between Breakout Harness pin-2 and B+.
SPN 3556 FMI 1.
Is voltage within B+ ± 0.5 volts? No: Repair high resistance in SIG
GND circuit. After repairs are
complete, retest for SPN 3556
FMI 1.

Step 6 Test AFTFP2 circuit. Decision

A. Using Navistar Engine Diagnostics, perform the Continuous Monitor Test Yes: Replace AFTFP2 sensor.
(page 1361). After repairs are complete, retest
for SPN 3556 FMI 1.
B. Monitor AFTFP2 voltage while shorting Breakout Harness pin-3 to pin-1.
Did AFTFP2 voltage change appropriately? No: Repair AFTFP2 circuit. After
repairs are complete, retest for
SPN 3556 FMI 1.

End Diagnostic Steps

After performing all diagnostic steps, if SPN 3556 FMI 1 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1113

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

Fault Overview
Fault sets when the Aftertreatment Control Module (ACM) detects the Aftertreatment Fuel Injector (AFI) is not
responding as expected.

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

Associated Faults
• SPN 94 FMI 17 (FDP) • SPN 3479 (AFTFD) • SPN 3480 (AFTFIS) • SPN 3482 (AFTFSV)

Fault Facts
None

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• System Leak
• Restricted AFI

Step 1 Check for associated fault codes Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 1113).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 3556 FMI 7.

Step 2 Inspect for system leak between Down Stream Injection (DSI) unit and Decision
Aftertreatment Fuel Injector (AFI).
Check DSI module and AFI fuel supply line for damage, restrictions, or leaks. Yes: Go to Step 3.
Is fuel supply line and DSI module in good condition and not restricted, leaking, No: Repair or replace damaged or
or damaged? leaking component. After repairs
are complete, retest for SPN 3556
FMI 7.

Step 3 Check for Down Stream Injection (DSI) system leaks. Decision
Perform KOER DSI System Test (page 1385) to check DSI system for leaks. Yes: Repair leaking or restricted
component. After repairs are
complete, retest for SPN 3556
FMI 7.
Does DSI system test indicate a leak? No: Clear fault and retest for SPN
3556 FMI 7.
1114 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

End Diagnostic Steps

After performing all diagnostic steps, if SPN 3556 FMI 7 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1115

SPN 3659 FMI 4 - Injector 1 close coil - short circuit

Fault Overview
Fault is set when short circuit is detected on injector 1 Close coil.

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

Associated Faults
None

Fault Facts
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed Injector
• Close H shorted to Close L
• Closed H shorted to GND
• Closed L shorted to GND
• Failed Engine Control Module (ECM)
1116 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 350 Injector 1 Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 3659 FMI 4.
Is EST DTC list SPN 3659 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at Under Valve Connector (UVC) connector 2. Decision

A. Key-Off. Yes: Go to Step 3.
B. Disconnect UVC 2
C. Check UVC 2 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 2 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3659
FMI 4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1117

Step 3 Inspect UVC harness under valve cover. Decision

A. Key-Off. Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 3659 FMI 4.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 4.

Step 4 Check for failed injectors. Decision

A. Key-Off. Yes: Go to Step 5.
B. Remove valve cover.
C. Disconnect Injector 1 through 6 connectors from UVC harness.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to each
Injector pin-1 and pin-4, leave UVC harness disconnected.
E. Use DMM, measure resistance between each individual Injector pin-1
and pin-4.
Is resistance 1.0 ± 0.5 ohms for each injector? No: Replace Failed Injector(s)
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 3659
FMI 4.

Step 5 Check Injector 1 for short to GND. Decision

A. Key-Off. Yes: Go to Step 6.
B. Disconnect Injector 1 from Under Valve Cover (UVC) harness.
C. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector
pin-1, leave UVC harness disconnected.
D. Use DMM, measure resistance between Injector pin-1 and known good
GND.
Is resistance greater than 1000 ohms? No: Replace Injector 1 and
perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 3659
FMI 4.
1118 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 6 Check Injector 1 Closed Coil H circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 7.
B. Disconnect Injector 1 from UVC harness.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-8, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-8 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to ground
between ECM D-8 and Injector 1.
After repairs are complete, retest
for SPN 3659 FMI 4.

Step 7 Check Injector 1 Closed Coil L circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 8.
B. Disconnect Injector 1 from UVC harness.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-7, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-7 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to ground
between ECM D-7 and Injector 1.
After repairs are complete, retest
for SPN 3659 FMI 4.

Step 8 Check for short between Closed H and Closed L circuits in Under Decision
Valve Cover (UVC) harness.
A. Key-Off. Yes: Go to Step 9.
B. Disconnect Injector 1 from UVC harness.

C. Disconnect UVC harness connector 2 from engine harness.

D. Connect Breakout Harness ZTSE4793 to UVC harness connector 2,
leave engine harness disconnected.

E. Use DMM, measure resistance between Breakout Harness ZTSE4793

pin-1 and pin-2.
Is resistance greater than 1000 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 3659 FMI 4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1119

Step 9 Check for short between Closed H and Closed L circuits in engine Decision
harness.
A. Key-Off. Yes: Go to Step 10.
B. Disconnect UVC harness connector 2 from engine harness

C. Disconnect ECM - Driver 36-pin connector.

D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pins D-7 and D-8, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pins D-7 and D-8.
Is resistance greater than 1000 ohms? Replace engine harness. After
repairs are complete, retest for
SPN 3659 FMI 4.

Step 10 Check for failed Engine Control Module (ECM). Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 3659
B. Install Test ECM.
FMI 4.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).
D. Key-On Engine-Off (KOEO), log in to Navistar® Engine Diagnostics.
E. Key-On Engine-Running (KOER).
F. Check DTC list for SPN 3659 FMI 4.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decisions were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 3659 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1120 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3659 FMI 5 - Injector 1 close coil - open circuit

Fault Overview
Fault is set when Engine Control Module (ECM) detects an Open circuit in Injector 1 Close coil circuit.

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected during one drive cycle.

Associated Faults
None

Fault Facts
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed Injector
• Open in Close H circuit
• Open in Close L circuit
• Failed Engine Control Module (ECM)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1121

Figure 351 Injector 1 Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 3659 FMI 5.
Is EST DTC list SPN 3659 FMI 5 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at Under Valve Connector (UVC) connector 2. Decision

A. Key-Off Yes: Go to Step 3.
B. Disconnect UVC 2.
C. Check UVC 2 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 2 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3659
FMI 5.
1122 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Inspect Under Valve Cover (UVC) harness under valve cover. Decision
A. Key-Off. Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 3659 FMI 5.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 4.

Step 4 Check for failed injectors. Decision

A. Key-Off. Yes: Go to Step 5.
B. Remove valve cover
C. Disconnect Injector 1 through 6 connectors from UVC harness.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to each
Injector pin-1 and pin-4, leave UVC harness disconnected.
E. Use DMM, measure resistance between each individual Injector pin-1
and pin-4.
Is resistance 1.0 ± 0.5 ohms for each injector? No: Replace Failed Injector(s)
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 3659
FMI 5.

Step 5 Check for Open in Closed H circuit in UVC harness. Decision

A. Key-Off. Yes: Go to Step 6.

B. Disconnect Under Valve Connector (UVC) Connector 2.

C. Connect Breakout Harness ZTSE4793 to UVC connector 2, leave engine
harness disconnected.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector
pin-1, leave injector disconnected.

E. Use DMM, measure resistance between Breakout Harness ZTSE4793

pin-1 and Injector pin-1.
Is resistance less than 0.5 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 3659 FMI 5.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1123

Step 6 Check for Open in Closed L circuit in UVC harness. Decision

A. Key-Off. Yes: Go to Step 7.

B. Disconnect Under Valve Connector (UVC) Connector 2.

C. Connect Breakout Harness ZTSE4793 to UVC connector 2, leave engine
harness disconnected.

D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector

pin-4, leave injector disconnected.
E. Use DMM, measure resistance between Breakout Harness ZTSE4793
pin-2 and Injector pin-4.
Is resistance less than 0.5 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 3659 FMI 5.

Step 7 Check for Open in Closed H circuit in engine harness. Decision

A. Key-Off. Yes: Go to Step 8.

B. Disconnect Under Valve Connector (UVC) connector 2.

C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-8 and UVC connector 2 pin-1, leave ECM and
UVC harness disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector pin
D-8 and UVC harness connector 2 pin-1.
Is resistance less than 0.5 ohms? No: Replace engine harness.
After repairs are complete, retest
for SPN 3659 FMI 5.

Step 8 Check for Open in Closed L circuit in engine harness. Decision

A. Key-Off. Yes: Go to Step 9.

B. Disconnect Under Valve Connector (UVC) connector 2.

C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-7 and UVC connector 2 pin-2, leave ECM and UVC
harness disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-7 and UVC connector 2 pin-2.
Is resistance less than 0.5 ohms? Replace engine harness. After
repairs are complete, retest for
SPN 3659 FMI 5.
1124 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 9 Check for failed Engine Control Module (ECM). Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 3659
B. Install Test ECM.
FMI 5.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).

D. Key-On Engine-Off (KOEO), log in to Navistar® Engine Diagnostics.

E. Key-On Engine-Running (KOER).

F. Check DTC list for SPN 3659 FMI 5.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decisions were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 3659 FMI 5 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1125

SPN 3660 FMI 4 - Injector 2 close coil - short circuit

Fault Overview
Fault is set when short circuit is detected on injector 2 Close coil.

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

Associated Faults
None

Fault Facts
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed Injector
• Close H shorted to Close L
• Closed H shorted to GND
• Closed L shorted to GND
• Failed Engine Control Module (ECM)
1126 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 352 Injector 2 Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 3660 FMI 4.
Is EST DTC list SPN 3660 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at Under Valve Connector (UVC) connector 2. Decision

A. Key-Off. Yes: Go to Step 3.
B. Disconnect UVC 2
C. Check UVC 2 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 2 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3660
FMI 4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1127

Step 3 Inspect UVC harness under valve cover. Decision

A. Key-Off. Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 3660 FMI 4.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 4.

Step 4 Check for failed injectors. Decision

A. Key-Off. Yes: Go to Step 5.
B. Remove valve cover.
C. Disconnect Injector 1 through 6 connectors from UVC harness.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to each
Injector pin-1 and pin-4, leave UVC harness disconnected.
E. Use DMM, measure resistance between each individual Injector pin-1
and pin-4.
Is resistance 1.0 ± 0.5 ohms for each injector? No: Replace Failed Injector(s)
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 3660
FMI 4.

Step 5 Check Injector 2 for short to GND. Decision

A. Key-Off. Yes: Go to Step 6.
B. Disconnect Injector 2 from Under Valve Cover (UVC) harness.
C. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector
pin-1, leave UVC harness disconnected.
D. Use DMM, measure resistance between Injector pin-1 and known good
GND.
Is resistance greater than 1000 ohms? No: Replace Injector 2 and
perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 3660
FMI 4.
1128 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 6 Check Injector 2 Closed Coil H circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 7.
B. Disconnect Injector 2 from UVC harness.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-12, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-12 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to ground
between ECM D-12 and Injector 2.
After repairs are complete, retest
for SPN 3660 FMI 4.

Step 7 Check Injector 2 Closed Coil L circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 8.
B. Disconnect Injector 2 from UVC harness.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-11, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-11 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to ground
between ECM D-11 and Injector 2.
After repairs are complete, retest
for SPN 3660 FMI 4.

Step 8 Check for short between Closed H and Closed L circuits in Under Decision
Valve Cover (UVC) harness.
A. Key-Off. Yes: Go to Step 9.
B. Disconnect Injector 2 from UVC harness.

C. Disconnect UVC harness connector 2 from engine harness.

D. Connect Breakout Harness ZTSE4793 to UVC harness connector 2,
leave engine harness disconnected.

E. Use DMM, measure resistance between Breakout Harness ZTSE4793

pin-5 and pin-6.
Is resistance greater than 1000 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 3660 FMI 4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1129

Step 9 Check for short between Closed H and Closed L circuits in engine Decision
harness.
A. Key-Off. Yes: Go to Step 10.
B. Disconnect UVC harness connector 2 from engine harness

C. Disconnect ECM - Driver 36-pin connector.

D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pins D-11 and D-12, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pins D-11 and D-12.
Is resistance greater than 1000 ohms? Replace engine harness. After
repairs are complete, retest for
SPN 3660 FMI 4.

Step 10 Check for failed Engine Control Module (ECM). Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 3660
B. Install Test ECM.
FMI 4.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).
D. Key-On Engine-Off (KOEO), log in to Navistar® Engine Diagnostics.
E. Key-On Engine-Running (KOER).
F. Check DTC list for SPN 3660 FMI 4.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decisions were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 3660 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1130 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3660 FMI 5 - Injector 2 close coil - open circuit

Fault Overview
Fault is set when Engine Control Module (ECM) detects an Open circuit in Injector 2 Close coil circuit.

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected during one drive cycle.

Associated Faults
None

Fault Facts
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous.
Possible Causes
• Failed Injector
• Open in Close H circuit
• Open in Close L circuit
• Failed Engine Control Module (ECM)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1131

Figure 353 Injector 2 Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 3660 FMI 5.
Is EST DTC list SPN 3660 FMI 5 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Inspect connections at Under Valve Connector (UVC) connector 2. Decision

A. Key-Off Yes: Go to Step 3.
B. Disconnect UVC 2.
C. Check UVC 2 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 2 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3660
FMI 5.
1132 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Inspect Under Valve Cover (UVC) harness under valve cover. Decision
A. Key-Off. Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 3660 FMI 5.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 4.

Step 4 Check for failed injectors. Decision

A. Key-Off. Yes: Go to Step 5.
B. Remove valve cover
C. Disconnect Injector 1 through 6 connectors from UVC harness.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to each
Injector pin-1 and pin-4, leave UVC harness disconnected.
E. Use DMM, measure resistance between each individual Injector pin-1
and pin-4.
Is resistance 1.0 ± 0.5 ohms for each injector? No: Replace Failed Injector(s)
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 3660
FMI 5.

Step 5 Check for Open in Closed H circuit in UVC harness. Decision

A. Key-Off. Yes: Go to Step 6.

B. Disconnect Under Valve Connector (UVC) Connector 2.

C. Connect Breakout Harness ZTSE4793 to UVC connector 2, leave engine
harness disconnected.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector
pin-1, leave injector disconnected.

E. Use DMM, measure resistance between Breakout Harness ZTSE4793

pin-5 and Injector pin-1.
Is resistance less than 0.5 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 3660 FMI 5.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1133

Step 6 Check for Open in Closed L circuit in UVC harness. Decision

A. Key-Off. Yes: Go to Step 7.

B. Disconnect Under Valve Connector (UVC) Connector 2.

C. Connect Breakout Harness ZTSE4793 to UVC connector 2, leave engine
harness disconnected.

D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector

pin-4, leave injector disconnected.
E. Use DMM, measure resistance between Breakout Harness ZTSE4793
pin-6 and Injector pin-4.
Is resistance less than 0.5 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 3660 FMI 5.

Step 7 Check for Open in Closed H circuit in engine harness. Decision

A. Key-Off. Yes: Go to Step 8.

B. Disconnect Under Valve Connector (UVC) connector 2.

C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-12 and UVC connector 2 pin-5, leave ECM and
UVC harness disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-12 and UVC harness connector 2 pin-5.
Is resistance less than 0.5 ohms? No: Replace engine harness.
After repairs are complete, retest
for SPN 3660 FMI 5.

Step 8 Check for Open in Closed L circuit in engine harness. Decision

A. Key-Off. Yes: Go to Step 9.

B. Disconnect Under Valve Connector (UVC) connector 2.

C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-11 and UVC connector 2 pin-6, leave ECM and
UVC harness disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector pin
D-11 and UVC connector 2 pin-6.
Is resistance less than 0.5 ohms? Replace engine harness. After
repairs are complete, retest for
SPN 3660 FMI 5.
1134 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 9 Check for failed Engine Control Module (ECM). Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 3660
B. Install Test ECM.
FMI 5.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).

D. Key-On Engine-Off (KOEO), log in to Navistar® Engine Diagnostics.

E. Key On Engine Running (KOER).

F. Check DTC list for SPN 3660 FMI 5.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decisions were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 3660 FMI 5 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1135

SPN 3661 FMI 4 - Injector 3 close coil - short circuit

Fault Overview
Fault is set when short circuit is detected on injector 3 Close coil.

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

Associated Faults
None

Fault Facts
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed Injector
• Close H shorted to Close L
• Closed H shorted to GND
• Closed L shorted to GND
• Failed Engine Control Module (ECM)
1136 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 354 Injector 3 Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 3661 FMI 4.
Is EST DTC list SPN 3661 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at Under Valve Connector (UVC) connector 3. Decision

A. Key-Off. Yes: Go to Step 3.
B. Disconnect UVC 3
C. Check UVC 3 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 3 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3661
FMI 4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1137

Step 3 Inspect UVC harness under valve cover. Decision

A. Key-Off. Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 3661 FMI 4.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 4.

Step 4 Check for failed injectors. Decision

A. Key-Off. Yes: Go to Step 5.
B. Remove valve cover.
C. Disconnect Injector 1 through 6 connectors from UVC harness.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to each
Injector pin-1 and pin-4, leave UVC harness disconnected.
E. Use DMM, measure resistance between each individual Injector pin-1
and pin-4.
Is resistance 1.0 ± 0.5 ohms for each injector? No: Replace Failed Injector(s)
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 3661
FMI 4.

Step 5 Check Injector 3 for short to GND. Decision

A. Key-Off. Yes: Go to Step 6.
B. Disconnect Injector 3 from Under Valve Cover (UVC) harness.
C. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector
pin-1, leave UVC harness disconnected.
D. Use DMM, measure resistance between Injector pin-1 and known good
GND.
Is resistance greater than 1000 ohms? No: Replace Injector 3 and
perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 3661
FMI 4.
1138 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 6 Check Injector 3 Closed Coil H circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 7.
B. Disconnect Injector 3 from UVC harness.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-10, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-10 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to ground
between ECM D-10 and Injector 3.
After repairs are complete, retest
for SPN 3661 FMI 4.

Step 7 Check Injector 3 Closed Coil L circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 8.
B. Disconnect Injector 3 from UVC harness.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-9, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-9 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to ground
between ECM D-9 and Injector 3.
After repairs are complete, retest
for SPN 3661 FMI 4.

Step 8 Check for short between Closed H and Closed L circuits in Under Decision
Valve Cover (UVC) harness.
A. Key-Off. Yes: Go to Step 9.
B. Disconnect Injector 3 from UVC harness.

C. Disconnect UVC harness connector 3 from engine harness.

D. Connect Breakout Harness ZTSE4793 to UVC harness connector 3,
leave engine harness disconnected.

E. Use DMM, measure resistance between Breakout Harness ZTSE4793

pin-1 and pin-2.
Is resistance greater than 1000 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 3661 FMI 4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1139

Step 9 Check for short between Closed H and Closed L circuits in engine Decision
harness.
A. Key-Off. Yes: Go to Step 10.
B. Disconnect UVC harness connector 3 from engine harness

C. Disconnect ECM - Driver 36-pin connector.

D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pins D-9 and D-10, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pins D-9 and D-10.
Is resistance greater than 1000 ohms? Replace engine harness. After
repairs are complete, retest for
SPN 3661 FMI 4.

Step 10 Check for failed Engine Control Module (ECM). Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 3661
B. Install Test ECM.
FMI 4.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).
D. Key-On Engine-Off (KOEO), log in to Navistar® Engine Diagnostics.
E. Key-On Engine-Running (KOER).
F. Check DTC list for SPN 3661 FMI 4.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decisions were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 3661 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1140 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3661 FMI 5 - Injector 3 close coil - open circuit

Fault Overview
Fault is set when Engine Control Module (ECM) detects an Open circuit in Injector 3 Close coil circuit.

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected during one drive cycle.

Associated Faults
None

Fault Facts
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed Injector
• Open in Close H circuit
• Open in Close L circuit
• Failed Engine Control Module (ECM)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1141

Figure 355 Injector 3 Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 3661 FMI 5.
Is EST DTC list SPN 3661 FMI 5 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at Under Valve Connector (UVC) connector 3. Decision

A. Key-Off Yes: Go to Step 3.
B. Disconnect UVC 3.
C. Check UVC 3 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 3 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3661
FMI 5.
1142 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Inspect Under Valve Cover (UVC) harness under valve cover. Decision
A. Key-Off. Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 3661 FMI 5.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 4.

Step 4 Check for failed injectors. Decision

A. Key-Off. Yes: Go to Step 5.
B. Remove valve cover
C. Disconnect Injector 1 through 6 connectors from UVC harness.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to each
Injector pin-1 and pin-4, leave UVC harness disconnected.
E. Use DMM, measure resistance between each individual Injector pin-1
and pin-4.
Is resistance 1.0 ± 0.5 ohms for each injector? No: Replace Failed Injector(s)
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 3661
FMI 5.

Step 5 Check for Open in Closed H circuit in UVC harness. Decision

A. Key-Off. Yes: Go to Step 6.

B. Disconnect Under Valve Connector (UVC) Connector 3.

C. Connect Breakout Harness ZTSE4793 to UVC connector 3, leave engine
harness disconnected.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector
pin-1, leave injector disconnected.

E. Use DMM, measure resistance between Breakout Harness ZTSE4793

pin-1 and Injector pin-1.
Is resistance less than 0.5 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 3661 FMI 5.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1143

Step 6 Check for Open in Closed L circuit in UVC harness. Decision

A. Key-Off. Yes: Go to Step 7.

B. Disconnect Under Valve Connector (UVC) Connector 3.

C. Connect Breakout Harness ZTSE4793 to UVC connector 3, leave engine
harness disconnected.

D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector

pin-4, leave injector disconnected.
E. Use DMM, measure resistance between Breakout Harness ZTSE4793
pin-2 and Injector pin-4.
Is resistance less than 0.5 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 3661 FMI 5.

Step 7 Check for Open in Closed H circuit in engine harness. Decision

A. Key-Off. Yes: Go to Step 8.

B. Disconnect Under Valve Connector (UVC) connector 3.

C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-10 and UVC connector 3 pin-1, leave ECM and
UVC harness disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-10 and UVC harness connector 3 pin-1.
Is resistance less than 0.5 ohms? No: Replace engine harness.
After repairs are complete, retest
for SPN 3661 FMI 5.

Step 8 Check for Open in Closed L circuit in engine harness. Decision

A. Key-Off. Yes: Go to Step 9.

B. Disconnect Under Valve Connector (UVC) connector 3.

C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-9 and UVC connector 3 pin-2, leave ECM and UVC
harness disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-9 and UVC connector 3 pin-2.
Is resistance less than 0.5 ohms? Replace engine harness. After
repairs are complete, retest for
SPN 3661 FMI 5.
1144 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 9 Check for failed Engine Control Module (ECM). Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 3661
B. Install Test ECM.
FMI 5.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).

D. Key-On Engine-Off (KOEO), log in to Navistar® Engine Diagnostics.

E. Key-On Engine-Running (KOER).

F. Check DTC list for SPN 3661 FMI 5.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decisions were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 3661 FMI 5 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1145

SPN 3662 FMI 4 - Injector 4 close coil - short circuit

Fault Overview
Fault is set when short circuit is detected on injector 4 Close coil.

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

Associated Faults
None

Fault Facts
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed Injector
• Close H shorted to Close L
• Closed H shorted to GND
• Closed L shorted to GND
• Failed Engine Control Module (ECM)
1146 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 356 Injector 4 Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 3662 FMI 4.
Is EST DTC list SPN 3662 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at Under Valve Connector (UVC) connector 3. Decision

A. Key-Off. Yes: Go to Step 3.
B. Disconnect UVC 3
C. Check UVC 3 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 3 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3662
FMI 4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1147

Step 3 Inspect UVC harness under valve cover. Decision

A. Key-Off. Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 3662 FMI 4.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 4.

Step 4 Check for failed injectors. Decision

A. Key-Off. Yes: Go to Step 5.
B. Remove valve cover.
C. Disconnect Injector 1 through 6 connectors from UVC harness.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to each
Injector pin-1 and pin-4, leave UVC harness disconnected.
E. Use DMM, measure resistance between each individual Injector pin-1
and pin-4.
Is resistance 1.0 ± 0.5 ohms for each injector? No: Replace Failed Injector(s)
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 3662
FMI 4.

Step 5 Check Injector 4 for short to GND. Decision

A. Key-Off. Yes: Go to Step 6.
B. Disconnect Injector 4 from Under Valve Cover (UVC) harness.
C. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector
pin-1, leave UVC harness disconnected.
D. Use DMM, measure resistance between Injector pin-1 and known good
GND.
Is resistance greater than 1000 ohms? No: Replace Injector 4 and
perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 3662
FMI 4.
1148 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 6 Check Injector 4 Closed Coil H circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 7.
B. Disconnect Injector 4 from UVC harness.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-36, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-36 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-36 and Injector 4. After
repairs are complete, retest for
SPN 3662 FMI 4.

Step 7 Check Injector 4 Closed Coil L circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 8.
B. Disconnect Injector 4 from UVC harness.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-35, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-35 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to ground
between ECM D-35 and Injector 4.
After repairs are complete, retest
for SPN 3662 FMI 4.

Step 8 Check for short between Closed H and Closed L circuits in Under Decision
Valve Cover (UVC) harness.
A. Key-Off. Yes: Go to Step 9.
B. Disconnect Injector 4 from UVC harness.

C. Disconnect UVC harness connector 3 from engine harness.

D. Connect Breakout Harness ZTSE4793 to UVC harness connector 3,
leave engine harness disconnected.

E. Use DMM, measure resistance between Breakout Harness ZTSE4793

pin-5 and pin-6.
Is resistance greater than 1000 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 3662 FMI 4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1149

Step 9 Check for short between Closed H and Closed L circuits in engine Decision
harness.
A. Key-Off. Yes: Go to Step 10.
B. Disconnect UVC harness connector 3 from engine harness

C. Disconnect ECM - Driver 36-pin connector.

D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pins D-35 and D-36, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pins D-35 and D-36.
Is resistance greater than 1000 ohms? Replace engine harness. After
repairs are complete, retest for
SPN 3662 FMI 4.

Step 10 Check for failed Engine Control Module (ECM). Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 3662
B. Install Test ECM.
FMI 4.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).
D. Key On Engine Off (KOEO), log in to Navistar® Engine Diagnostics.
E. Key-On Engine-Running (KOER).
F. Check DTC list for SPN 3662 FMI 4.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decisions were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 3662 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1150 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3662 FMI 5 - Injector 4 close coil - open circuit

Fault Overview
Fault is set when Engine Control Module (ECM) detects an Open circuit in Injector 4 Close coil circuit.

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected during one drive cycle.

Associated Faults
None

Fault Facts
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed Injector
• Open in Close H circuit
• Open in Close L circuit
• Failed Engine Control Module (ECM)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1151

Figure 357 Injector 4 Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 3662 FMI 5.
Is EST DTC list SPN 3662 FMI 5 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at Under Valve Connector (UVC) connector 3. Decision

A. Key-Off Yes: Go to Step 3.
B. Disconnect UVC 3.
C. Check UVC 3 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 3 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3662
FMI 5.
1152 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Inspect Under Valve Cover (UVC) harness under valve cover. Decision
A. Key-Off. Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 3662 FMI 5.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 4.

Step 4 Check for failed injectors. Decision

A. Key-Off. Yes: Go to Step 5.
B. Remove valve cover
C. Disconnect Injector 1 through 6 connectors from UVC harness.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to each
Injector pin-1 and pin-4, leave UVC harness disconnected.
E. Use DMM, measure resistance between each individual Injector pin-1
and pin-4.
Is resistance 1.0 ± 0.5 ohms for each injector? No: Replace Failed Injector(s)
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 3662
FMI 5.

Step 5 Check for Open in Closed H circuit in UVC harness. Decision

A. Key-Off. Yes: Go to Step 6.

B. Disconnect Under Valve Connector (UVC) Connector 3.

C. Connect Breakout Harness ZTSE4793 to UVC connector 3, leave engine
harness disconnected.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector
pin-1, leave injector disconnected.

E. Use DMM, measure resistance between Breakout Harness ZTSE4793

pin-5 and Injector pin-1.
Is resistance less than 0.5 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 3662 FMI 5.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1153

Step 6 Check for Open in Closed L circuit in UVC harness. Decision

A. Key-Off. Yes: Go to Step 7.

B. Disconnect Under Valve Connector (UVC) Connector 3.

C. Connect Breakout Harness ZTSE4793 to UVC connector 3, leave engine
harness disconnected.

D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector

pin-4, leave injector disconnected.
E. Use DMM, measure resistance between Breakout Harness ZTSE4793
pin-6 and Injector pin-4.
Is resistance less than 0.5 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 3662 FMI 5.

Step 7 Check for Open in Closed H circuit in engine harness. Decision

A. Key-Off. Yes: Go to Step 8.

B. Disconnect Under Valve Connector (UVC) connector 3.

C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-36 and UVC connector 3 pin-5, leave ECM and
UVC harness disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-36 and UVC harness connector 3 pin-5.
Is resistance less than 0.5 ohms? No: Replace engine harness.
After repairs are complete, retest
for SPN 3662 FMI 5.

Step 8 Check for Open in Closed L circuit in engine harness. Decision

A. Key-Off. Yes: Go to Step 9.

B. Disconnect Under Valve Connector (UVC) connector 3.

C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-35 and UVC connector 3 pin-6, leave ECM and
UVC harness disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector pin
D-35 and UVC connector 3 pin-6.
Is resistance less than 0.5 ohms? Replace engine harness. After
repairs are complete, retest for
SPN 3662 FMI 5.
1154 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 9 Check for failed Engine Control Module (ECM). Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 3662
B. Install Test ECM.
FMI 5.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).

D. Key On Engine Off (KOEO), log in to Navistar® Engine Diagnostics.

E. Key On Engine Running (KOER).

F. Check DTC list for SPN 3662 FMI 5.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decisions were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 3662 FMI 5 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1155

SPN 3663 FMI 4 - Injector 5 close coil - short circuit

Fault Overview
Fault is set when short circuit is detected on injector 5 Close coil.

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

Associated Faults
None

Fault Facts
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed Injector
• Close H shorted to Close L
• Closed H shorted to GND
• Closed L shorted to GND
• Failed Engine Control Module (ECM)
1156 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 358 Injector 5 Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 3663 FMI 4.
Is EST DTC list SPN 3663 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at Under Valve Connector (UVC) connector 4. Decision

A. Key-Off. Yes: Go to Step 3.
B. Disconnect UVC 4
C. Check UVC 4 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 4 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3663
FMI 4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1157

Step 3 Inspect UVC harness under valve cover. Decision

A. Key-Off. Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 3663 FMI 4.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 4.

Step 4 Check for failed injectors. Decision

A. Key-Off. Yes: Go to Step 5.
B. Remove valve cover.
C. Disconnect Injector 1 through 6 connectors from UVC harness.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to each
Injector pin-1 and pin-4, leave UVC harness disconnected.
E. Use DMM, measure resistance between each individual Injector pin-1
and pin-4.
Is resistance 1.0 ± 0.5 ohms for each injector? No: Replace Failed Injector(s)
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 3663
FMI 4.

Step 5 Check Injector 5 for short to GND. Decision

A. Key-Off. Yes: Go to Step 6.
B. Disconnect Injector 5 from Under Valve Cover (UVC) harness.
C. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector
pin-1, leave UVC harness disconnected.
D. Use DMM, measure resistance between Injector pin-1 and known good
GND.
Is resistance greater than 1000 ohms? No: Replace Injector 5 and
perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 3663
FMI 4.
1158 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 6 Check Injector 5 Closed Coil H circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 7.
B. Disconnect Injector 5 from UVC harness.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-32, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-32 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-32 and Injector 5. After
repairs are complete, retest for
SPN 3663 FMI 4.

Step 7 Check Injector 5 Closed Coil L circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 8.
B. Disconnect Injector 5 from UVC harness.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-31, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-31 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to ground
between ECM D-31 and Injector 5.
After repairs are complete, retest
for SPN 3663 FMI 4.

Step 8 Check for short between Closed H and Closed L circuits in Under Decision
Valve Cover (UVC) harness.
A. Key-Off. Yes: Go to Step 9.
B. Disconnect Injector 5 from UVC harness.

C. Disconnect UVC harness connector 4 from engine harness.

D. Connect Breakout Harness ZTSE4793 to UVC harness connector 4,
leave engine harness disconnected.

E. Use DMM, measure resistance between Breakout Harness ZTSE4793

pin-1 and pin-2.
Is resistance greater than 1000 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 3663 FMI 4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1159

Step 9 Check for short between Closed H and Closed L circuits in engine Decision
harness.
A. Key-Off. Yes: Go to Step 10.
B. Disconnect UVC harness connector 4 from engine harness

C. Disconnect ECM - Driver 36-pin connector.

D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pins D-31 and D-32, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pins D-31 and D-32.
Is resistance greater than 1000 ohms? Replace engine harness. After
repairs are complete, retest for
SPN 3663 FMI 4.

Step 10 Check for failed Engine Control Module (ECM). Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 3663
B. Install Test ECM.
FMI 4.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).
D. Key On Engine Off (KOEO), log in to Navistar® Engine Diagnostics.
E. Key On Engine Running (KOER).
F. Check DTC list for SPN 3663 FMI 4.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decisions were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 3663 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1160 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3663 FMI 5 - Injector 5 close coil - open circuit

Fault Overview
Fault is set when Engine Control Module (ECM) detects an Open circuit in Injector 5 Close coil circuit.

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected during one drive cycle.

Associated Faults
None

Fault Facts
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed Injector
• Open in Close H circuit
• Open in Close L circuit
• Failed Engine Control Module (ECM)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1161

Figure 359 Injector 5 Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 3663 FMI 5.
Is EST DTC list SPN 3663 FMI 5 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at Under Valve Connector (UVC) connector 4. Decision

A. Key-Off Yes: Go to Step 3.
B. Disconnect UVC 4.
C. Check UVC 4 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 4 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3663
FMI 5.
1162 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Inspect Under Valve Cover (UVC) harness under valve cover. Decision
A. Key-Off. Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 3663 FMI 5.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 4.

Step 4 Check for failed injectors. Decision

A. Key-Off. Yes: Go to Step 5.
B. Remove valve cover
C. Disconnect Injector 1 through 6 connectors from UVC harness.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to each
Injector pin-1 and pin-4, leave UVC harness disconnected.
E. Use DMM, measure resistance between each individual Injector pin-1
and pin-4.
Is resistance 1.0 ± 0.5 ohms for each injector? No: Replace Failed Injector(s)
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 3663
FMI 5.

Step 5 Check for Open in Closed H circuit in UVC harness. Decision

A. Key-Off. Yes: Go to Step 6.

B. Disconnect Under Valve Connector (UVC) Connector 4.

C. Connect Breakout Harness ZTSE4793 to UVC connector 4, leave engine
harness disconnected.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector
pin-1, leave injector disconnected.

E. Use DMM, measure resistance between Breakout Harness ZTSE4793

pin-1 and Injector pin-1.
Is resistance less than 0.5 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 3663 FMI 5.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1163

Step 6 Check for Open in Closed L circuit in UVC harness. Decision

A. Key-Off. Yes: Go to Step 7.

B. Disconnect Under Valve Connector (UVC) Connector 4.

C. Connect Breakout Harness ZTSE4793 to UVC connector 4, leave engine
harness disconnected.

D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector

pin-4, leave injector disconnected.
E. Use DMM, measure resistance between Breakout Harness ZTSE4793
pin-2 and Injector pin-4.
Is resistance less than 0.5 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 3663 FMI 5.

Step 7 Check for Open in Closed H circuit in engine harness. Decision

A. Key-Off. Yes: Go to Step 8.

B. Disconnect Under Valve Connector (UVC) connector 4.

C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-32 and UVC connector 4 pin-1, leave ECM and
UVC harness disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-32 and UVC harness connector 4 pin-1.
Is resistance less than 0.5 ohms? No: Replace engine harness.
After repairs are complete, retest
for SPN 3663 FMI 5.

Step 8 Check for Open in Closed L circuit in engine harness. Decision

A. Key-Off. Yes: Go to Step 9.

B. Disconnect Under Valve Connector (UVC) connector 4.

C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-31 and UVC connector 4 pin-2, leave ECM and
UVC harness disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector pin
D-31 and UVC connector 4 pin-2.
Is resistance less than 0.5 ohms? Replace engine harness. After
repairs are complete, retest for
SPN 3663 FMI 5.
1164 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 9 Check for failed Engine Control Module (ECM). Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 3663
B. Install Test ECM.
FMI 5.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).

D. Key On Engine Off (KOEO), log in to Navistar® Engine Diagnostics.

E. Key On Engine Running (KOER).

F. Check DTC list for SPN 3663 FMI 5.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decisions were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 3663 FMI 5 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1165

SPN 3664 FMI 4 - Injector 6 close coil - short circuit

Fault Overview
Fault is set when short circuit is detected on injector 6 Close coil.

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

Associated Faults
None

Fault Facts
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed Injector
• Close H shorted to Close L
• Closed H shorted to GND
• Closed L shorted to GND
• Failed Engine Control Module (ECM)
1166 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 360 Injector 6 Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 3664 FMI 4.
Is EST DTC list SPN 3664 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at Under Valve Connector (UVC) connector 4. Decision

A. Key-Off. Yes: Go to Step 3.
B. Disconnect UVC 4
C. Check UVC 4 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 4 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3664
FMI 4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1167

Step 3 Inspect UVC harness under valve cover. Decision

A. Key-Off. Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 3664 FMI 4.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 4.

Step 4 Check for failed injectors. Decision

A. Key-Off. Yes: Go to Step 5.
B. Remove valve cover.
C. Disconnect Injector 1 through 6 connectors from UVC harness.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to each
Injector pin-1 and pin-4, leave UVC harness disconnected.
E. Use DMM, measure resistance between each individual Injector pin-1
and pin-4.
Is resistance 1.0 ± 0.5 ohms for each injector? No: Replace Failed Injector(s)
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 3664
FMI 4.

Step 5 Check Injector 6 for short to GND. Decision

A. Key-Off. Yes: Go to Step 6.
B. Disconnect Injector 6 from Under Valve Cover (UVC) harness.
C. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector
pin-1, leave UVC harness disconnected.
D. Use DMM, measure resistance between Injector pin-1 and known good
GND.
Is resistance greater than 1000 ohms? No: Replace Injector 6 and
perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 3664
FMI 4.
1168 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 6 Check Injector 6 Closed Coil H circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 7.
B. Disconnect Injector 6 from UVC harness.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-34, leave ECM disconnected.

E. Use DMM, measure resistance between ECM - Driver 36-pin connector

pin D-34 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM D-34 and Injector 6. After
repairs are complete, retest for
SPN 3664 FMI 4.

Step 7 Check Injector 6 Closed Coil L circuit for short to GND. Decision
A. Key-Off. Yes: Go to Step 8.
B. Disconnect Injector 6 from UVC harness.
C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pin D-33, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-33 and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to ground
between ECM D-33 and Injector 6.
After repairs are complete, retest
for SPN 3664 FMI 4.

Step 8 Check for short between Closed H and Closed L circuits in Under Decision
Valve Cover (UVC) harness.
A. Key-Off. Yes: Go to Step 9.
B. Disconnect Injector 6 from UVC harness.

C. Disconnect UVC harness connector 4 from engine harness.

D. Connect Breakout Harness ZTSE4793 to UVC harness connector 4,
leave engine harness disconnected.

E. Use DMM, measure resistance between Breakout Harness ZTSE4793

pin-5 and pin-6.
Is resistance greater than 1000 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 3664 FMI 4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1169

Step 9 Check for short between Closed H and Closed L circuits in engine Decision
harness.
A. Key-Off. Yes: Go to Step 10.
B. Disconnect UVC harness connector 4 from engine harness

C. Disconnect ECM - Driver 36-pin connector.

D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM -
Driver 36-pin connector pins D-33 and D-34, leave ECM disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pins D-33 and D-34.
Is resistance greater than 1000 ohms? Replace engine harness. After
repairs are complete, retest for
SPN 3664 FMI 4.

Step 10 Check for failed Engine Control Module (ECM). Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 3664
B. Install Test ECM.
FMI 4.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).
D. Key On Engine Off (KOEO), log in to Navistar® Engine Diagnostics.
E. Key On Engine Running (KOER).
F. Check DTC list for SPN 3664 FMI 4.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decisions were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 3664 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1170 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3664 FMI 5 - Injector 6 close coil - open circuit

Fault Overview
Fault is set when Engine Control Module (ECM) detects an Open circuit in Injector 6 Close coil circuit.

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected during one drive cycle.

Associated Faults
None

Fault Facts
It may be necessary to perform the pin point circuit diagnostics tests with the engine at or near normal operating
temperature.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed Injector
• Open in Close H circuit
• Open in Close L circuit
• Failed Engine Control Module (ECM)
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1171

Figure 361 Injector 6 Circuit Diagram

See latest version of MaxxForce® DT, 9 and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 3664 FMI 5.
Is EST DTC list SPN 3664 FMI 5 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at Under Valve Connector (UVC) connector 4. Decision

A. Key-Off Yes: Go to Step 3.
B. Disconnect UVC 4.
C. Check UVC 4 and connector terminals for: damaged or pinched wires;
moisture in terminals; wet or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
Are UVC 4 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 3664
FMI 5.
1172 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Inspect Under Valve Cover (UVC) harness under valve cover. Decision
A. Key-Off. Yes: Replace UVC harness and
install in proper routing. After
B. Remove valve cover.
repairs are complete, retest for
C. Inspect UVC harness under valve cover for improper harness routing, SPN 3664 FMI 5.
evidence of harness contacting rocker arms, or other signs of harness
damage.
Is there evidence of harness damage? No: Go to Step 4.

Step 4 Check for failed injectors. Decision

A. Key-Off. Yes: Go to Step 5.
B. Remove valve cover
C. Disconnect Injector 1 through 6 connectors from UVC harness.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to each
Injector pin-1 and pin-4, leave UVC harness disconnected.
E. Use DMM, measure resistance between each individual Injector pin-1
and pin-4.
Is resistance 1.0 ± 0.5 ohms for each injector? No: Replace Failed Injector(s)
and perform Injector Coil End of
Motion (CEOM) Reset Procedure
(page 1334) and Injector Coking
Accumulation Reset Procedure
(page 1338). After repairs are
complete, retest for SPN 3664
FMI 5.

Step 5 Check for Open in Closed H circuit in UVC harness. Decision

A. Key-Off. Yes: Go to Step 6.

B. Disconnect Under Valve Connector (UVC) Connector 4.

C. Connect Breakout Harness ZTSE4793 to UVC connector 4, leave engine
harness disconnected.
D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector
pin-1, leave injector disconnected.

E. Use DMM, measure resistance between Breakout Harness ZTSE4793

pin-5 and Injector pin-1.
Is resistance less than 0.5 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 3664 FMI 5.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1173

Step 6 Check for Open in Closed L circuit in UVC harness. Decision

A. Key-Off. Yes: Go to Step 7.

B. Disconnect Under Valve Connector (UVC) Connector 4.

C. Connect Breakout Harness ZTSE4793 to UVC connector 4, leave engine
harness disconnected.

D. Connect correct terminals from Terminal Test Kit ZTSE4435C to Injector

pin-4, leave injector disconnected.
E. Use DMM, measure resistance between Breakout Harness ZTSE4793
pin-6 and Injector pin-4.
Is resistance less than 0.5 ohms? No: Replace UVC Harness. After
repairs are complete, retest for
SPN 3664 FMI 5.

Step 7 Check for Open in Closed H circuit in engine harness. Decision

A. Key-Off. Yes: Go to Step 8.

B. Disconnect Under Valve Connector (UVC) connector 4.

C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-34 and UVC connector 4 pin-5, leave ECM and
UVC harness disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector
pin D-34 and UVC harness connector 4 pin-5.
Is resistance less than 0.5 ohms? No: Replace engine harness.
After repairs are complete, retest
for SPN 3664 FMI 5.

Step 8 Check for Open in Closed L circuit in engine harness. Decision

A. Key-Off. Yes: Go to Step 9.

B. Disconnect Under Valve Connector (UVC) connector 4.

C. Disconnect ECM - Driver 36-pin connector.
D. Use Terminal Test Kit ZTSE4435C, insert proper terminal into ECM - Driver
36-pin connector pin D-33 and UVC connector 4 pin-6, leave ECM and
UVC harness disconnected.
E. Use DMM, measure resistance between ECM - Driver 36-pin connector pin
D-33 and UVC connector 4 pin-6.
Is resistance less than 0.5 ohms? Replace engine harness. After
repairs are complete, retest for
SPN 3664 FMI 5.
1174 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 9 Check for failed Engine Control Module (ECM). Decision

A. Key-Off. Yes: Replace ECM. After repairs
are complete, retest for SPN 3664
B. Install Test ECM.
FMI 5.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1345).

D. Key On Engine Off (KOEO), log in toNavistar® Engine Diagnostics.

E. Key On Engine Running (KOER).

F. Check DTC list for SPN 3663 FMI 5.
Has original concern been resolved? No: Reinstall original ECM. Verify
each step was completed correctly
and proper decisions were made.

End Diagnostic Steps

After performing diagnostic steps, if SPN 3664 FMI 5 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1175

SPN 3719 FMI 0 - DPF soot load - highest (level 3/3)

Fault Overview
This fault sets when Level 3 Diesel Particulate Filter (DPF) soot loading is over 100% full and engine de-rate
has been enabled. DPF regeneration is required.

Step 1 Action Decision

See Aftertreatment Symptom-Based Diagnostic and Service Manual 0000003081.
1176 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3719 FMI 15 - DPF Soot Load - Lowest (level 1/3)

Fault Overview
This fault sets when Level 1 Diesel Particulate Filter (DPF) soot loading is above 80% full and a DPF regeneration
is required.

Step 1 Action Decision

See Aftertreatment Symptom-Based Diagnostic and Service Manual 0000003081.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1177

SPN 3719 FMI 16 - DPF Soot Load - Moderate (level 2/3)

Fault Overview
This fault sets when Level 2 Diesel Particulate Filter (DPF) soot loading is 100% full and a DPF regeneration is
required.

Step 1 Action Decision

See Aftertreatment Symptom-Based Diagnostic and Service Manual 0000003081.
1178 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3936 FMI 0 - DPF Soot Load - Severe De-Rate

Fault Overview
This fault sets when Level 4 DPF soot loading is overfull and engine shutdown is enabled. DPF regeneration
functionality has been disabled.

Step 1 Action Decision

See Aftertreatment Symptom-Based Diagnostic and Service Manual 0000003081.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1179

SPN 3936 FMI 2 - DPF System Feedback Control Fault

Fault Overview
This fault sets when Level 4 DPF soot loading is overfull and engine shutdown is enabled. DPF regeneration
functionality has been disabled.

Step 1 Action. Decision

See Aftertreatment Symptom-Based Diagnostic and Service Manual 0000003081.
1180 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 3936 FMI 8 - DPF regenerations are occurring too frequently

Fault Overview
This fault sets when Engine Control Module (ECM) determines DPF regenerations are occurring too frequently.

Step 1 Action Decision

SPN 3936 FMI 8 sets when Aftertreatment Regenerations are occurring too often. See Aftertreatment Symptom-Based
Diagnostic and Service Manual 0000003081.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1181

SPN 3936 FMI 14 - DPF, Regen duration above limit

Fault Overview
This fault code sets when the Engine Control Module (ECM) detects regeneration of the Diesel Particulate Filter
(DPF) has run for longer than expected and soot load cannot be effectively reduced.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Engine unable to build enough heat to DOC
• DOC failure
• DSI failure to inject fuel into exhaust
• DPF failure
1182 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault code. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Install correct DOC/DPF
SPN 3936 FMI 14. temperature sensor module. After
repairs are complete, retest for
SPN 3936 FMI 14.
Is EST DTC list SPN 3936 FMI 14 active or pending? No: Clear codes and retest for
SPN 3936 FMI 14.

End Diagnostic Steps

After performing diagnostic step if SPN 3936 FMI 14 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1183

SPN 3936 FMI 20 - DPF Feedback Adaptive Limits Reached

Fault Overview
Fault sets when Engine Control Module (ECM) determines pressure in DPF adaptive limits have been reached.

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

Associated Faults
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Biased or Failed DPFIT sensor or circuit,
• Biased or Failed Inlet Air Temperature (IAT) Sensor or circuit
• Exhaust leaks
• DSI Fault
• DSI System Leak
• Hydrocarbon Injection (HCI) or HCI housing Plugged
• DOC failed or missing
1184 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Decision
Check calibration scorecard or use NavKal to check is ECM has latest calibration. Yes: Go to Step 2.
Is calibration up to date? No: Re-calibrate ECM. After
re-calibration is complete, retest
for SPN 3936 FMI 20.

Step 2 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list Yes: Go to Step 3.
for SPN 3936 FMI 20.
Is SPN 3936 FMI 20 active or pending? No: Repair other active fault
codes. After repairs are complete,
retest for SPN 3936 FMI 20.

Step 3 Determine if exhaust system has restrictions, leaks or damage. Decision

Inspect exhaust system restrictions, leaks, or physical damage. Inspect fuel system Yes: Go to Step 4.
from fuel tank to Hydrocarbon Injector (HCI) port for leaks or physical damage.
Is exhaust system and fuel system clear of restrictions, leaks, and physical damage? No: Repair restrictions, leaks, fuel
leaks, or physical damage. For
restricted HCI, go to Step 7. After
repairs are complete, retest for
SPN 3936 FMI 20.

Step 4 Inspect connections at Diesel Particulate Filter Inlet Temperature Decision

(DPFIT) and Mass Air Flow/Inlet Air Temperature (MAF/IAT) sensor.
A. Key OFF. Yes: Go to Step 5.
B. Disconnect DPFIT and MAF/IAT sensor.
C. Check DPFIT and MAF/IAT sensor and connector for: damaged or
pinched wires; wet or corroded terminals; loose, bent, or broken pins; or
broken connector housing.
Are DPFIT and MAF/IAT sensor connectors, harnesses, and terminals clean and No: Repair connector, harness,
undamaged? or terminal damage. After repairs
are complete, retest for SPN 3936
FMI 20.

Step 5 Test DPFIT and MAF/IAT for intermittent circuit operation. Decision
A. Key OFF. Yes: Go to Step 6.

B. Connect EST to vehicle Diagnostic Connector. (page 1345).

C. Key-On Engine-Off (KOEO), log in to Navistar® Engine Diagnostics.

D. Do Continuous Monitor Test (page 1361).

E. Verify sensor voltages are within specifications.
Are sensor voltages within specification? No: Locate specific circuit
component causing erratic or
intermittent operation. Perform
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1185

voltage and resistance checks

in this section. Repair circuits
as required. After repairs are
complete, retest for SPN 3936 FMI
20.

Step 6 Action Decision

Remove Hydrocarbon Injection (HCI) assembly (see Engine Service Manual). Yes: Go to Step 7.
Is HCI clean? No: Clean HCI assembly. After
repairs are complete, retest for
SPN 3936 FMI 20.

WARNING:

To prevent personal injury or death, do not perform an On Board Filter Cleanliness Test
(OBFCT) or Parked Regeneration if liquid oil or fuel is present or suspected in DPF.
Liquid oil or fuel will ignite during an OBFCT causing fires or damage to vehicle or other
equipment.

Step 7 Decision
Perform On Board Filter Cleanliness Test (OBFCT) (page 1331). Yes: Go to Step 8.
Is OBFCT running without an Abort Message in EST? No: Correct parked regen
inhibitors and redo Step 8.

Step 8 Decision
While running OBFCT, inspect for exhaust system for leaks or physical damage. Yes: Go to Step 9.
Is exhaust system clear of leaks and physical damage? No: Repair leaks and/or physical
damage. After repairs are
complete, retest for SPN 3936 FMI
20.

Step 9 Action Decision

After OBFCT is complete. Yes: After doing all diagnostic
steps, if SPN 3936 FMI 20 remains,
verify each step was completed
correctly and proper decisions
were made. Notify supervisor for
further action.
Des Diesel Particulate Filter Differential Pressure (DPFDP) signal measure below No: Remove DPF and inspect for
0.5 psi (3 kPa) at high idle? restrictions. If restricted, have DPF
cleaned using appropriate DPF
cleaning equipment. After repairs
are complete, retest for SPN 3936
FMI 20.
1186 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

End Diagnostic Test

After performing diagnostic steps, if SPN 3936 FMI 20 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1187

SPN 4077 FMI 3 - AFTFP2 Signal Out of Range HIGH

Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Aftertreatment Fuel Pressure 2 Sensor
(AFTFP2) signal voltage is greater than 4.75 volts.

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

Associated Faults
SPN 3512 FMI 14 (VREF)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• AFTFP2 circuit short to PWR
• AFTFP2 circuit Open
• SIG GND circuit Open
• Failed AFTFP2 sensor

Step 1 Check for associated faults. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults(page 1187)
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 4077 FMI 3.

Step 2 Check for active fault code. Decision

Use EST, check DTC list for SPN 4077 FMI 3. Yes: Go to Step 3.
Does EST DTC list show SPN 4077 FMI 3 as Active or Pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).
1188 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Inspect connections at Aftertreatment Fuel Pressure 2 (AFTFP2) Decision

sensor connector.
A. Key OFF Yes: Go to Step 4.
B. Disconnect AFTFP2 sensor connector.

C. Check AFTFP2 sensor and connector terminals for: damaged or pinched

wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are AFTFP2 sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 4077
FMI 3.

Step 4 Check for Short to Power Decision

A. Perform Test 1 (page 1189). Yes: Repair short to PWR between
AFTFP2 sensor pin-3 and DCU
B. Use DMM, measure voltage between Breakout Harness ZTSE6027 pin-3
pin-42. After repairs are complete,
and known good GND.
retest for SPN 4077 FMI 3.
Is voltage greater than 6 volts? No: Go to Step 5.

Step 5 Check for Short to Power Decision

A. Perform Test 2 (page 1190). Yes: Repair short to PWR between
AFTFP2 sensor pin-1 and DCU
B. Use DMM, measure voltage between Breakout Harness ZTSE6027 pin-1
pin-43. After repairs are complete,
and known good GND.
retest for SPN 4077 FMI 3.
Is voltage greater than 6 volts? No: Go to Step 6.

Step 6 Check for Failed Sensor Decision

A. Perform Test 3 (page 1191). Yes: Replace AFTFP2 sensor.
After repairs are complete, retest
B. Use EST, clear DTC list.
for SPN 4077 FMI 3.
Does SPN 4077 FMI 4 set after DTC is cleared? No: Go to Step 7.

Step 7 Check for Open Circuit Decision

A. Perform Test 4 (page 1192). Yes: Repair Open or Short to PWR
between AFTFP2 sensor pin-2
B. Use EST, clear DTC list.
and DCU pin-41. After repairs are
complete, retest for SPN 4077 FMI
3.
Does SPN 4077 FMI 4 set after DTC is cleared? No: Repair Open between AFTFP2
sensor pin-3 and DCU pin-42.
After repairs are complete, retest
for SPN 4077 FMI 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1189

End Diagnostic Tests

After performing diagnostic steps, if SPN 4077 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.

Pin-Point Tests (SPN 4077 FMI 3)

Figure 362 AFTFP2 Sensor Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4498
• Breakout Harness ZTSE6027
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP-1210B-compliant supporting J1939 and J1708)
1190 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 363 AFTFP2 Sensor Circuit Check

Test 1
A. Key OFF.
B. Disconnect Aftertreatment Fuel Pressure 2 (AFTFP2) sensor.
C. Connect Breakout Harness ZTSE6027 to vehicle harness connector and leave AFTFP2 sensor disconnected.
D. Key ON Engine OFF (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1191

Figure 364 AFTFP2 Sensor Circuit Check

Test 2
A. Key OFF.
B. Disconnect Aftertreatment Fuel Pressure 2 (AFTFP2) sensor.
C. Connect Breakout Harness ZTSE6027 to vehicle harness connector and leave AFTFP2 sensor disconnected.
D. Key ON Engine OFF (KOEO).
1192 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 365 AFTFP2 Sensor Circuit Check

Test 3
A. Key OFF.
B. Disconnect Aftertreatment Fuel Pressure 2 (AFTFP2) sensor.
C. Connect Breakout Harness ZTSE6027 to vehicle harness connector and leave AFTFP2 sensor disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE6027 pin-2 and pin-3 together.
E. Connect Electronic Service Tool (EST) to Vehicle Diagnostic Connector (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1193

Figure 366 AFTFP2 Sensor Circuit Check

Test 4
A. Key OFF.
B. Disconnect Aftertreatment Fuel Pressure 2 (AFTFP2) sensor.
C. Connect Breakout Harness ZTSE6027 to vehicle harness connector and leave AFTFP2 sensor disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE6027 pin-3 to known good GND.
E. Connect EST to Vehicle Diagnostic Connector .
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
1194 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 4077 FMI 4 - AFTFP2 Signal Out of Range LOW

Fault Overview
Fault code sets when Engine Control Module (ECM) detects AFTFP2 signal is less than 0.25 volt.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• AFTFP2 Signal circuit short to GND
• Failed AFTFP2 sensor
• Voltage VREF 5 circuit Open

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 4077 FMI 4.
Does EST DTC list show SPN 4077 FMI 4 as Active or Pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at Aftertreatment Fuel Pressure 2 (AFTFP2) Decision

sensor connector
A. Key OFF. Yes: Go to Step 3.
B. Disconnect AFTFP2 sensor connector.
C. Check AFTFP2 sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are AFTFP2 sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 4077
FMI 4.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1195

Step 3 Check VREF5 for Open Circuit. Decision

A. Key OFF. Yes: Repair Open or Short to GND
between AFTFP2 connector pin-1
B. Disconnect AFTFP2 sensor connector and leave sensor disconnected.
and DCU connecter pin-43. After
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector repairs are complete, retest for
(page 1345). SPN 4077 FMI 4.
D. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.

E. Use DMM, measure voltage between Pin 1 (VREF5) and known good
ground.
Does voltage measure less than 5 V +-.25 V? No: Go to Step 4.

Step 4 Check for Failed Sensor. Decision

A. Key OFF. Yes: Replace AFTFP2 sensor.
After repairs are complete, retest
B. Disconnect AFTFP2 sensor connector and leave sensor disconnected.
for SPN 4077 FMI 4.
C. Connect EST to vehicle Diagnostic Connector. (page 1345).
D. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
E. Use EST, clear DTC list.
Does SPN 4077 FMI 3 set after DTC is cleared? No: Repair short to GND between
AFTFP2 sensor connector pin-3
and DCU connector pin-42. After
repairs are complete, retest for
SPN 4077 FMI 4.

End Diagnostic Tests

After performing diagnostic steps, if SPN 4077 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1196 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 4192 FMI 3 - WIF signal Out of Range HIGH

Fault Overview
This fault sets when the ECM detects an short to power in the Water In Fuel (WIF) sensor circuit.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• WIF circuit Short to PWR
• SIG GND circuit Short to PWR
• Failed WIF sensor

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 4192 FMI 3.
Is SPN 4192 FMI 3 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at WIF sensor connector. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect WIF sensor connector.

C. Check WIF sensor and connector terminals for: damaged or pinched

wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are WIF sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 4192
FMI 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1197

Step 3 Check WIF circuit for Open. Decision

A. Key OFF. Disconnect WIF sensor. Yes: Go to Step 4.
B. Connect Breakout Harness ZTSE6002 to chassis harness and leave WIF
sensor disconnected.

C. Key ON. Use Digital Multimeter (DMM), measure voltage from Breakout
harness ZTSE6002 pin-1 to known good GND.
Does voltage measure 5 ± 0.25 volts? No: Repair short to PWR between
WIF pin-1 and ECM pin E-7. After
repairs are complete, retest for
SPN 4192 FMI 3.

Step 4 Check WIF GND circuit for Open. Decision

A. Key OFF. Disconnect WIF sensor. Yes: Replace WIF sensor. After
repairs are complete, retest for
B. Connect Breakout Harness ZTSE6002 to chassis harness and leave WIF
SPN 4192 FMI 3.
sensor disconnected.
C. Key ON. Use Digital Multimeter (DMM), measure voltage from Breakout
harness ZTSE6002 pin-2 to B+.
Does voltage measure B+ ± 0.5 volts? No: Repair short to PWR between
WIF pin-2 and ECM pin E-28.
After repairs are complete, retest
for SPN 4192 FMI 3.

End Diagnostic Test

After performing diagnostic steps, if SPN 4192 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1198 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 4192 FMI 4 - WIF Signal Out of Range LOW

Fault Overview
Fault code sets when Engine Control Module (ECM) detects Water In Fuel (WIF) sensor signal voltage is lower
than expected.

Lamp Reaction
No Lamp

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• WIF circuit short to GND
• Failed WIF sensor
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1199

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 4192 FMI 4.
Is SPN 4192 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at WIF sensor connector. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect WIF sensor connector.
C. Check WIF sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are WIF sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 4192
FMI 4.

Step 3 Check WIF signal circuit for short to GND. Decision

Perform Test 1 (page 1200). Use Digital Multimeter (DMM), measure voltage from Yes: Replace WIF sensor. After
Breakout harness ZTSE6002 pin-1 to known good GND. repairs are complete, retest for
SPN 4192 FMI 4.
Does voltage measure 5 ± 0.25 volts? No: Repair short to GND between
WIF sensor connector Pin-1 and
Engine Control Module (ECM)
76-pin engine connector pin E-7.
After repairs are complete, retest
for SPN 4192 FMI 4.

End Diagnostic Test

After performing diagnostic steps, if SPN 4192 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1200 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Diagnostics (SPN 4192 FMI 4)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools
• Breakout Harness ZTSE6002
• DMM

Figure 367 WIF Circuit Check

Test 1
A. Key OFF
B. Disconnect WIF sensor.
C. Connect Breakout Harness ZTSE6002 to chassis harness and leave WIF sensor disconnected.
D. Key ON, Engine OFF (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1201

SPN 4192 FMI 5 - WIF Signal Open or Short to PWR

Fault Overview
This fault sets when the ECM detects an open circuit in the Water In Fuel (WIF) sensor circuit.

Lamp Reaction
No Lamp

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• WIF circuit Open
• SIG GND circuit Open
• Failed WIF sensor

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 4192 FMI 5.
Is SPN 4192 FMI 5 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at WIF sensor connector. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect WIF sensor connector.

C. Check WIF sensor and connector terminals for: damaged or pinched

wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are WIF sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 4192
FMI 5.
1202 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Check WIF circuit for Open. Decision

A. Key OFF. Disconnect WIF sensor. Yes: Go to Step 4.
B. Connect Breakout Harness ZTSE6002 to chassis harness and leave WIF
sensor disconnected.

C. Key ON. Use Digital Multimeter (DMM), measure voltage from Breakout
harness ZTSE6002 pin-1 to known good GND.
Does voltage measure 5 ± 0.25 volts? No: Repair Open between WIF
pin-1 and ECM pin E-7. After
repairs are complete, retest for
SPN 4192 FMI 5.

Step 4 Check WIF GND circuit for Open. Decision

A. Key OFF. Disconnect WIF sensor. Yes: Replace WIF sensor. After
repairs are complete, retest for
B. Connect Breakout Harness ZTSE6002 to chassis harness and leave WIF
SPN 4192 FMI 5.
sensor disconnected.
C. Key ON. Use Digital Multimeter (DMM), measure voltage from Breakout
harness ZTSE6002 pin-2 to B+.
Does voltage measure B+ ± 0.5 volts? No: Repair Open between WIF
pin-2 and ECM pin E-28. After
repairs are complete, retest for
SPN 4192 FMI 5.

End Diagnostic Test

After performing diagnostic steps, if SPN 4192 FMI 5 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1203

SPN 4192 FMI 31 - Water in Fuel Detected

Fault Overview
Fault code sets when Engine Control Module (ECM) receives indication water in fuel is detected.

Lamp Reaction
No Lamp

Associated Faults
None

Fault Facts
Water In Fuel (WIF) text message in instrument cluster is displayed and remains on when water in fuel is
detected. During initial Key ON, WIF text message may be briefly flash. WIF text message may remain on
for approximately 10 seconds at Key OFF.

Drive Cycle to Determine Fault Status

Continuous

Possible Causes
• Water detected in primary fuel filter housing.
1204 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Drain water from fuel (see
SPN 4192 FMI 31. Engine Service Manual). After
repairs are complete, retest for
SPN 4192 FMI 31.
Is EST DTC list SPN 4192 FMI 31 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

End Diagnostic Steps

After performing diagnostic steps, if SPN 4192 FMI 31 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1205

SPN 4227 FMI 7 - CC Oil Separator: Not spinning

Fault Overview
Fault code sets when the Engine Control Module (ECM) detects Crankcase Oil Separator Speed (CCOSS)
sensor speed is less than 230 rpm.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Open or short to GND in CCOSS-H circuit
• Open or short to GND in CCOSS-L circuit
• Failed CCOSS sensor
• Failed crankcase oil breather / separator assembly

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 4227 FMI 7.
Is SPN 4227 FMI 7 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Crankcase Oil Separator Speed (CCOSS) sensor connector inspection. Decision
A. Key OFF. Yes: Go to Step 3.

B. Disconnect CCOSS sensor.

C. Check CCOSS sensor connector terminals for: damaged or pinched wires;
wet or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are CCOSS sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 4227
FMI 7.
1206 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Measure Crankcase Oil Separator Speed (CCOSS) resistance. Decision

A. Perform Test 1 (page 1207). Yes: Go to Step 4.
B. Use DMM, measure resistance between Breakout Harness ZTSE4951
pin-1 and pin-2.
Is resistance between 280 and 560 ohms? No: Replace CCOSS sensor.
After repairs are complete, retest
for SPN 4227 FMI 7.

Step 4 Verify operation of centrifugal oil breather separator. Decision

Perform Crankcase Oil Seperator (CCOS) Speed Test (page 1572). Yes: Go to Step 5.
Did Oil breather meet RPM Specifications? No: Replace crankcase oil
breather / separator assembly.
After repairs are complete, retest
for SPN 4227 FMI 7.

Step 5 Check for Open or short to GND in CCOSS - H circuit. Decision

A. Perform Test 2 (page 1207). Yes: Go to Step 6.
B. Use DMM, measure voltage between Breakout Harness ZTSE4951 pin-1
and known good GND.
Is voltage 2.5 volts ± 0.5 volts? No: Repair Open or short to
GND between CCOSS pin-1 and
ECM pin E-34. After repairs are
complete, retest for SPN 4227
FMI 7.

Step 6 Check for Open or short to GND in CCOSS - L circuit. Decision

A. Perform Test 3 (page 1208). Yes: End diagnostics. Retest for
SPN 4227 FMI 7.
B. Use DMM, measure voltage between Breakout Harness ZTSE4951 pin-2
and known good GND.
Is voltage 2.5 volts ± 0.5 volts? No: Repair Open or short to
GND between CCOSS pin-2 and
ECM pin E-17. After repairs are
complete, retest for SPN 4227
FMI 7.

End Diagnostic Steps

After performing all diagnostic steps, if SPN 4227 FMI 7 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1207

Pin-Point Tests (SPN 4227 FMI 7)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4951.
• Digital Multimeter (DMM)

Figure 368 CCOSS Circuit Check

Test 1
A. Key OFF.
B. Disconnect Crankcase Oil Separator Speed (CCOSS).
C. Install Breakout Harness ZTSE4951 to CCOSS sensor and leave engine harness disconnected.
1208 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 369 CCOSS Circuit Check

Test 2
A. Key OFF.
B. Disconnect Crankcase Oil Separator Speed (CCOSS).
C. Install Breakout Harness ZTSE4951 to vehicle harness and leave CCOSS sensor disconnected.
D. Key ON Engine OFF (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1209

Figure 370 CCOSS - L Circuit Check

Test 3
A. Key OFF.
B. Disconnect Crankcase Oil Separator Speed (CCOSS).
C. Install Breakout Harness ZTSE4951 to vehicle harness and leave CCOSS sensor disconnected.
D. Key ON Engine OFF (KOEO).
1210 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 4257 FMI 7 - Injector Coking Compensation Factor Reached Maximum Authority

Fault Overview
Fault code sets when Engine Control Module (ECM) determines injector coking compensation has reached
its maximum level. Cumulative coking compensation value estimated by injector coking compensation factor
accumulator model greater than 16%.

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

Associated Faults
None

Fault Facts
Coking is buildup of deposits on tip of Injector.

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Aged Injectors
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1211

Step 1 Inspect injectors for coking. Decision

Remove Injectors. Inspect injectors for coking on tip of Injectors. Yes: Replace all Injectors. Reset
programmable parameter for
coking compensation (Mode 1, 2,
and 3 - Time Factor for Coking
Accumulation). After repairs are
complete, retest for SPN 4257
FMI 7.
Are Injector tips coked? No: Retest for SPN 4257 FMI 7.

End Diagnostic Steps

After performing diagnostic steps, if SPN 4257 FMI 7 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1212 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 4257 FMI 16 - Multiple Injector High Flow fault

Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Exhaust Gas Temperature (EGT) temperature
is higher than expected for current operating conditions, indicating an issue with fuel flow.

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

Associated Faults
• SPN 27 FMI 0, 3, 4, 7, and • SPN 651 - 656 FMI 14 • SPN 1209 FMI 0, 2, 3, 4, • SPN 3251 FMI 0, 2, 10,
11 7, and 31 and 14
• SPN 3387 - 3392 FMI 20 • SPN 3387 - 3392 FMI 21

Fault Facts
None

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• Restricted exhaust
• Restricted intake
• Mechanical cylinder imbalance
• Failed fuel Injector
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1213

Step 1 Check for calibration update. Decision

Check calibration scorecard to see if calibration is up to date. Use NavCal can Yes: Go to Step 2.
also be used to check calibration status.
Is calibration up to date? No: Re-calibrate ECM. After
re-calibration is complete, retest
for SPN 4257 FMI 16.

Step 2 Check for associated faults Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 3.
Associated Faults(page 1212).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 4257 FMI 16.

Step 3 Check for active or pending fault Decision

Use EST, check DTC list for SPN 4257 FMI 16. Yes: Go to Step 4.
Is EST DTC list SPN 4257 FMI 16 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 4257 FMI 16.

Step 4 Inspect intake air system for leaks, restrictions, and damage. Decision
Perform Intake Air Inspection (page 1648). Yes: Go to Step 5.
Is intake air system free of leaks, restrictions, and damage? No: Repair leaks, restrictions,
and damage. After repairs are
complete, retest for SPN 4257
FMI 16.

Step 5 Exhaust system inspection. Decision

Perform Exhaust and Aftertreatment System Inspection(page 1651). Yes: Go to Step 6.
Is exhaust system free of leaks, restrictions, and physical damage? No: Repair or replace leaking or
damaged exhaust components.
Refer to Fault Facts. After repairs
are complete, retest for SPN 4257
FMI 16.
1214 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 6 Check Diesel Particulate Filter Differential Pressure (DPFDP). Decision

A. Key OFF. Yes: Go to Step 7.
B. Connect EST to vehicle Diagnostic Connector. (page 1345).
C. Key ON Engine OFF (KOEO), log into Navistar® Engine Diagnostics.
D. Start engine, run engine at high idle for 5 minutes.

E. Use EST, check DPFDP.

Is DPFDP less than 0.5 psi at high idle? No: Perform Onboard Filter
Cleanliness Test (OBFCT) (page
1331). After repairs are complete,
retest for SPN 4257 FMI 16.

Step 7 Check mechanical cylinder imbalance. Decision

Determine if engine has a mechanical cylinder balance problem (compression Yes: Repair engine compression
loss). Perform Crankcase Pressure Test (page 1567). imbalance. After repairs are
complete, retest for SPN 4257
FMI 16.
Does engine have excessive crankcase pressure? No: Go to Step 8.

Step 8 Check CPA Misfire diagnostics. Decision

Determine if engine has fuel injector problem. Yes: Go to Step 9.
A. Perform CPA Signal check(page 1413)
B. and CPA Cold Idle Test(page 1407).
Was a problem found with any cylinders? No: End Diagnostics. Retest for
SPN 4257 FMI 16.

Step 8 Perform misfire diagnostics. Decision

A. Inspect for failed valve train components. Remove valve cover (see Yes: Replace fuel injector
Engine Service Manual). suspected by CPA Test. After
repairs are complete, retest for
B. Inspect for bent valves, fallen bridges, and valves out of adjustment.
SPN 4257 FMI 16.
Is valve train free of failed valve train components? No: Repair failed valve train
components. After repairs are
complete retest for SPN 4257 FMI
16.

End Diagnostic Steps

After performing diagnostic steps, if SPN 4257 FMI 16 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1215

SPN 4257 FMI 18 - Multiple Injector Low Flow fault

Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Exhaust Gas Temperature (EGT) temperature
is lower than expected for current operating conditions, indicating an issue with fuel flow.

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

Associated Faults
• SPN 27 (EGR) • SPN 51 FMI 3, 4, and 7 • SPN 94 FMI 3 and 4 (FDP) • SPN 102 FMI 3, 4, and 7
(ETP) (IMP)
• SPN 105 FMI 2, 3, and 4 • SPN 108 FMI 3 and 4 • SPN 110 FMI 2, 3, and 4 • SPN 164 FMI 0, 3, 4, 16,
(IMT) (BARO) (ECT) and 18 (ICP)
• SPN 172 (IAT) • SPN 173 (EGT) • SPN 175 FMI 2, 3, and 4 • SPN 188 FMI 0 and 1
(EOT) (Eng)
• SPN 651 - 656 FMI 4 and • SPN 679 FMI 3 and 4 • SPN 1173 FMI 16 • SPN 1189 FMI 3 and 4
5 (INJ) (IPR) (TC2CIT) (TC2WC)
• SPN 1322 - 1328 FMI 31 • SPN 2630 (CACOT) • SPN 2659 FMI 20 and 21 • SPN 2791 FMI 2, 3, 4, 7,
(Engine) (AMS) 8, and 14 (EGR)
• SPN 3055 FMI 2 (INJ) • SPN 3464 FMI 31 (ETP) • SPN 3471 FMI 1 and 7 • SPN 3479 (AFTPC)
(AFTPC)
• SPN 3480 FMI 3 and 4 • SPN 3482 FMI 3 and 4 • SPN 3556 FMI 1 and 7 • SPN 4257 FMI 7 (INJ)
(AFTFIS) (AFTFSV) (AFTFP2)
• SPN 5543 FMI 3, 4, and 5
(EBPV)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Fuel restriction
• Degraded diesel fuel
• Failed Electric Fuel Pump (EFP)
• Failed Injector
1216 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for associated faults. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 1215).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 4257 FMI 18.

Step 2 Check for active or pending fault. Decision

Use EST, check DTC list for SPN 4257 FMI 18. Yes: Go to Step 3.
Is EST DTC list SPN 4257 FMI 18 active or pending? No: Go to Intermittent or Not
Active Fault Diagnostic Procedure
(page 1344).

Step 3 Do fuel system inspection. Decision

Perform Fuel System Inspection (page 1631). Yes: Go to Step 4.
Are fuel lines, fuel filter, fuel strainer, and fuel connections clean and Not damaged? No: Repair Fuel lines, fuel strainer,
and fuel connections. After repairs
are complete, retest for SPN 4257
FMI 18.

Step 4 Do fuel quality inspection. Decision

Perform Fuel Quality inspection (page 1632). Yes: Go to Step 5.
Is fuel free of water, waxing, icing, sediment, gasoline, kerosene, or Diesel Exhaust No: Drain fuel tank and fill with
Fluid (DEF)? new and/or known good fuel. After
repairs are complete, retest for
SPN 4257 FMI 18.

Step 5 Do fuel delivery pressure test. Decision

Perform Fuel Delivery Pressure (FDP) Test (page 1554). Yes: Go to Step 7.
Is FDP within specification? No: Go to Step 6.

Step 6 Do clean fuel source test. Decision

Perform Clean Fuel Source Test (page 1559). Yes: Repair Fuel restriction in
fuel system. After repairs are
complete, retest for SPN 4257
FMI 18.
Is FDP within specification? No: Replace Electric Fuel Pump
(EFP). After repairs are complete,
retest for SPN 4257 FMI 18.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1217

Step 7 Check for low compression. Decision

Perform Relative Compression Test Plus (RCT+) (page 1465). Yes: Repair mechanical problem
with cylinder(s) indicating low
performance. After repairs are
complete, retest for SPN 4257
FMI 18.
Does CPA Tool indicate a problem or generate a warranty authorization code No: Go to Step 8.
(WAC)?

Step 8 Do CPA misfire test. Decision

A. Perform CPA Signal Check (page 1413), Yes: Replace injector on cylinders
with a misfire. Perform Injector
B. CPA Cold Idle Test (page 1407),
Coil End of Motion (CEOM)
C. and CPA Hot Idle Test (page 1421). Reset Procedure (page 1334)
and Injector Coking Accumulation
Reset Procedure (page 1338).
After repairs are complete, retest
SPN 4257 FMI 18.
Was a misfire identified on any cylinders? No: End Diagnostics. Retest for
SPN 4257 FMI 18.

End Diagnostic Tests

After performing diagnostic steps, if SPN 4257 FMI 18 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1218 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 4287 FMI 0 - ECBP above desired level

Fault Overview
Fault code sets when the Engine Control Module (ECM) detects the Brake Control Pressure (BCP) signal is
greater than expected.

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

Associated Faults
SPN 164 (ICP) SPN 679 FMI 3 and 4 (IPR) SPN 4287 FMI 3 and 4 SPN 5543 FMI 3, 4, and 5
(ECBP) (EBPV)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Biased Brake Control Pressure (BCP) sensor
• Failed Engine Compression Brake 1 (ECB1) valve
• Failed Relief valve
• Failed Injection Pressure Regulator (IPR) valve

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 1218).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN yy FMI yy.

Step 2 Check Brake Control Pressure (BCP) offset. Decision

A. Key-On Engine-Off (KOEO) Yes: Replace BCP sensor. After
repairs are complete, retest for
B. Using Navistar® Engine Diagnostics, check Brake Control Pressure (BCP).
SPN 4287 FMI 0.
Is BCP greater than 145 psi (1.0 MPa)? No: Go to Step 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1219

Step 3 Check for leaking Engine Compression Brake (ECB1) valve assembly Decision
A. Key OFF. Yes: Replace ECB1 valve
assembly. After repairs are
B. Connect EST to vehicle Diagnostic Connector. (page 1345).
complete, retest for SPN 4287
C. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics. FMI 0.
D. Start Engine, Key ON Engine Running (KOER).

E. Use EST Navistar® Engine Diagnostics, monitor Brake Control Pressure

(BCP).
Is BCP greater than 145 psi (1.0 MPa) with engine running (engine compression No: Go to Step 4.
brake commanded Off)?

Step 4 Operate engine and test engine brake. Decision

A. Key OFF. Yes: Replace relief valve. After
repairs are complete, retest for
B. Connect EST to vehicle Diagnostic Connector. (page 1345).
SPN 4287 FMI 0.
C. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
D. Start Engine, Key ON Engine Running (KOER).
E. Use EST, record a snapshot recording of engine brake operation, activate
engine brake.
a. Command brake ON
b. Command brake OFF
Is BCP at normal operating pressure when commanded On, and less than 145 psi No: Go to Step 5.
(1.0 MPa) after brake is commanded OFF?

Step 5 Operate engine and test engine brake. Decision

Review snapshot. Yes: Replace Injection Pressure
Regulator (IPR) valve. After
repairs are complete, retest for
SPN 4287 FMI 0.
Is the difference between Brake Control Pressure (BCP) and Brake Control No: Retest for SPN 4287 FMI 0.
Pressure Desired greater than 653 psi (-4.5 MPa)?

End Diagnostic Steps

After performing all diagnostic steps, if SPN 4287 FMI 0 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1220 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 4287 FMI 1 - ECBP below desired level

Fault Overview
Fault sets when engine Exhaust Valve Actuation System Oil Pressure is lower than expected. Injection control
pressure minus measured retarder pressure is greater than 580.3 psi (4.001 MPa) for greater than 20 seconds.

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

Associated Faults
• SPN 164 (ICP) • SPN 679 FMI 3 and 4 (IPR) • SPN 4287 FMI 3 and 4

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Failed ECBP sensor
• Failed ECB Valve
• Failed brake pressure relief valve
• Failed brake pistons and/or high-pressure oil rail
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1221

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults(page 1220).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 4287 FMI 1.

Step 2 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 4287 FMI 1. Yes: Go to Step 3.
Is EST DTC list SPN 4287 FMI 1 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 4287 FMI 1.

Step 3 Check ECBP at KOEO Decision

A. Key-Off. Yes: Go to Step 4.
B. Connect EST to vehicle Diagnostic Connector. (page 1345).
C. Key On Engine Off (KOEO), log in to Navistar® Engine Diagnostics.
D. Use Navistar® Engine Diagnostics, monitor ECBP.
Is ECBP approximately 0 psi (0 MPa)? No: Replace ECBP sensor. After
repairs are complete, retest for
SPN 4287 FMI 1.

Step 4 Operate engine and test engine brake. Decision

A. Key-Off. Yes: Go to Step 5.
B. Connect EST to vehicle Diagnostic Connector. (page 1345).
C. Key On Engine Off (KOEO), log in to Navistar® Engine Diagnostics.
D. Use Navistar® Engine Diagnostics, record a snapshot recording of engine
brake operation (brake commanded ON and brake commanded OFF).
E. Activate engine brake.
F. Use Navistar® Engine Diagnostics, record a snapshot and graph ECBP
and ECB signals.
Does ECBP increase when ECB is activated? No: Replace ECB Valve. After
repairs are complete, retest for
SPN 4287 FMI 1.

Step 5 Operate engine and test engine brake. Decision

Open snapshot recording from Step 4 and graph ECBP, ICP, and ECB signals. Yes: End diagnostics. Retest for
SPN 4287 FMI 1.
Does ECBP stay within 580 psi (4 MPa) of ICP when brake is activated? No: Go to Step 6.
1222 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 6 Inspect brake pistons for leaks. Decision

A. Remove valve cover and high-pressure oil rail (see Engine Service Yes: Replace brake pressure
Manual). relief valve. After repairs are
complete, retest for SPN 4287
B. Remove brake pistons and inspect pistons and bores for damage and
FMI 1.
scoring.
Are brake pistons and bore free of damage and scoring? No: Replace brake pistons and/or
high-pressure oil rail as needed.
After repairs are complete, retest
for SPN 4287 FMI 1.

End Diagnostic Tests

After performing diagnostic steps, if SPN 4287 FMI 1 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1223

SPN 4287 FMI 3 - ECBP Signal Out of Range HIGH

Fault Overview
Fault sets when Engine Control Module (ECM) senses Brake Control Pressure (BCP) sensor signal is out of
range high.

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

Associated Faults

• SPN 3509 FMI 3 & 4

(VREF1)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• BCP circuit Open or short to PWR
• VREF 1 circuit Open or high resistance
• SIG GND circuit Open or high resistance
• Damaged Under Valve Cover (UVC) harness
• Failed BCP sensor

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 1223).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 4287 FMI 3.

Step 2 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 3.
SPN 4287 FMI 3.
Is SPN 4287 FMI 3 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).
1224 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Inspect Under Valve Cover (UVC 1) connector 1. Decision

A. Key OFF. Yes: Go to Step 4.
B. Disconnect UVC 1 connector.
C. Check UVC 1 connector terminals for damaged or pinched wires; corroded
terminals; loose, bent, or broken pins; or broken connector housing.
Are UVC 1 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 4287
FMI 3.

Step 4 Check BCP circuit for short to PWR. Decision

Perform Test 1 (page 1226). Use Digital Multimeter (DMM), measure voltage Yes: Repair short to PWR between
between Breakout Harness ZTSE4952 pin-1 and known good GND. UVC pin-1 and ECM pin D-21.
After repairs are complete, retest
for SPN 4287 FMI 3.
Is voltage greater than 5 volts? No: Go to Step 5.

Step 5 Check VREF 1 circuit for Open or high resistance. Decision

Perform Test 2 (page 1226). Use DMM, measure voltage between Breakout Yes: Go to Step 6.
Harness ZTSE4952 pin-3 and known good GND.
Is voltage 5 ± 0.25 volts? No: Repair Open or high
resistance between UVC pin-3
and ECM pin D-13. After repairs
are complete, retest for SPN 4287
FMI 3.

Step 6 Check SIG GND circuit for Open or high resistance. Decision
Perform Test 3 (page 1227). Use EST, clear DTC list. Yes: Go to Step 8.
Does SPN 4287 FMI 4 set after DTC list is cleared? No: Go to Step 7.

Step 7 Check SIG GND circuit for Open or high resistance. Decision
Perform Test 4 (page 1228). Use EST, clear DTC list. Yes: Repair Open between UVC
pin-2 and ECM pin D-14. After
repairs are complete, retest for
SPN 4287 FMI 3.
Does SPN 4287 FMI 4 set after DTC list is cleared? No: Repair Open between UVC
pin-1 and ECM pin D-21. After
repairs are complete, retest for
SPN 4287 FMI 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1225

Step 8 Check for broken locking tab or damage to harness connector. Decision
A. Key OFF. Yes: Go to Step 9.
B. Remove Valve Cover. (See engine service manual)
C. Check BCP sensor connector terminals for damaged or pinched wires; wet
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are BCP sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 4287
FMI 3.

Step 9 UVC harness resistance check. Decision

Perform Test 5 (page 1229). Use DMM, measure resistance between Breakout Yes: Go to Step 10.
Harness ZTSE4952 pin-1 and Breakout Harness ZTSE4686 pin-3.
Is resistance less than 5 ohms? No: Replace UVC harness. After
repairs are complete, retest for
SPN 4287 FMI 3.

Step 10 UVC harness resistance check. Decision

Perform Test 6 (page 1230). Use DMM, measure resistance between Breakout Yes: Go to Step 11.
Harness ZTSE4952 pin-3 and Breakout Harness ZTSE4686 pin-2.
Is resistance less than 5 ohms? No: Replace UVC harness. After
repairs are complete, retest for
SPN 4287 FMI 3.

Step 11 Check for failed BCP sensor. Decision

Perform Test 7 (page 1231). Use DMM, measure resistance between Breakout Yes: Replace BCP sensor. After
harness ZTSE4952 pin-2 and Breakout Harness ZTSE4686 pin-1. repairs are complete, retest for
SPN 4287 FMI 3.
Is resistance less than 5 ohms? No: Replace UVC harness. After
repairs are complete, retest for
SPN 4287 FMI 3.

End Diagnostic Test

After performing diagnostic steps, if SPN 4287 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1226 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Test (SPN 4287 FMI 3)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools
• Breakout Harness ZTSE4952
• Breakout Harness ZTSE4498
• Breakout Harness ZTSE4686
• Digital Multimeter (DMM)
• EST with Navistar® Engine Diagnostics

Figure 371 BCP Circuit Check

Test 1
A. Key OFF.

B. Disconnect Under Valve Cover (UVC) harness.

C. Connect Breakout Harness ZTSE4952 to engine harness and leave UVC harness disconnected.
D. Key ON, Engine OFF (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1227

Figure 372 BCP Circuit Check

Test 2
A. Key OFF.
B. Disconnect Under Valve Cover (UVC) harness.
C. Connect Breakout Harness ZTSE4952 to engine harness and leave UVC harness disconnected.
D. Key ON, Engine OFF (KOEO).
1228 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 373 BCP Circuit Check

Test 3
A. Key OFF.
B. Disconnect Under Valve Cover (UVC) harness.
C. Connect Breakout Harness ZTSE4952 to engine harness and leave UVC harness disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4952 pin-1 and pin-2 together.
E. Connect EST to vehicle Diagnostic Connector. (page 1345).
F. Key ON, Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1229

Figure 374 BCP Circuit Check

Test 4
A. Key OFF.
B. Disconnect Under Valve Cover (UVC) harness.
C. Connect Breakout Harness ZTSE4952 to engine harness and leave UVC harness disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4952 pin-1 to known good GND.
E. Connect EST to vehicle Diagnostic Connector. (page 1345).
F. Key ON, Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
1230 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 375 BCP Circuit Check

Test 5
A. Key OFF.
B. Disconnect Under Valve Cover (UVC) harness.
C. Remove valve cover.
D. Connect Breakout Harness ZTSE4952 to engine harness and leave UVC harness disconnected.
E. Connect Breakout Harness ZTSE4686 to UVC harness leave BCP sensor disconnected.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1231

Figure 376 BCP Circuit Check

Test 6
A. Key OFF.
B. Disconnect Under Valve Cover (UVC) harness.
C. Remove valve cover.
D. Connect Breakout Harness ZTSE4952 to engine harness and leave UVC harness disconnected.
E. Connect Breakout Harness ZTSE4686 to UVC harness leave BCP sensor disconnected.
1232 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 377 BCP Circuit Check

Test 7
A. Key OFF.
B. Disconnect Under Valve Cover (UVC) harness.
C. Remove valve cover.
D. Connect Breakout Harness ZTSE4952 to engine harness and leave UVC harness disconnected.
E. Connect Breakout Harness ZTSE4686 to UVC harness leave BCP sensor disconnected.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1233

SPN 4287 FMI 4 - ECBP signal Out of Range LOW

Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Compression Brake Pressure (ECBP)
sensor signal is out of range low.

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

Associated Faults
SPN 3509 FMI 3 and 4

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• ECBP signal circuit is short to GND
• Failed Under Valve Cover (UVC) harness
• Failed ECBP sensor

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults(page 1233).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 4287 FMI 4.

Step 2 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 4287 FMI 4. Yes: Go to Step 3.
Is SPN 4287 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).
1234 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Inspect UVC 1 connector. Decision

A. Key OFF. Yes: Go to Step 4.
B. Disconnect UVC 1 connector.
C. Check UVC 1 connector terminals for damaged or pinched wires; corroded
terminals; loose, bent, or broken pins; or broken connector housing.
Are UVC 1 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 4287
FMI 4.

Step 4 Isolate fault to engine harness or Under Valve Cover (UVC) harness. Decision
A. Key OFF. Disconnect UVC 1 harness connector. Yes: Correct short circuit to GND
between UVC connector pin-1 and
B. Connect EST to vehicle Diagnostic Connector. (page 1345).
ECM pin D-21. After repairs are
C. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics. complete, retest for SPN 4287
FMI 4.
D. Clear codes, check Diagnostic Trouble Code (DTC) list for SPN 4287
FMI 4.
Is SPN 4287 FMI 4 still active after clearing codes? No: Go to Step 5.

Step 5 Check UVC Harness and connectors for damage. Decision

A. Key OFF. Yes: Go to Step 6.
B. Remove Valve Cover. (See engine service manual)
C. Disconnect ECBP sensor
D. Check UVC harness for damaged or pinched wires; wet or corroded
terminals; loose, bent, or broken pins; or broken connector housing.
Is UVC harness clean and undamaged? No: Replace UVC harness. After
repairs are complete, retest for
SPN 4287 FMI 4.

Step 6 Check UVC harness for short to GND. Decision

A. Reconnect UVC1 connector and leave ECBP sensor disconnected. Yes: Replace UVC harness. After
repairs are complete, retest for
B. Key ON, Clear codes and check DTC) list for SPN 4287 FMI 4 to return.
SPN 4287 FMI 4.
Is SPN 4287 FMI 4 still active after clearing codes? No: Replace ECBP sensor. After
repairs are complete, retest for
SPN 4287 FMI 4.

End Diagnostic Steps

After performing all diagnostic steps, if SPN 4287 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1235

SPN 4752 FMI 4 - EGR Cooler Efficiency: EGR Outlet Temperature above expected

Fault Overview
Fault sets when Engine Control Module (ECM) determines EGR outlet temperature is above normal operating
range.

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

Associated Faults
• SPN 110 FMI 0, 15, 16, • SPN 111 FMI 1 and 2 • SPN 1209 FMI 0 • SPN 2630 FMI 16
and 18

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• External Coolant leak
• Failed EGR cooler
• Plugged EGR cooler coolant side
• Coolant contamination of gas side
• Low coolant level
• Failed water pump
• Stuck bypass circuit
• Excessive exhaust temperature
• Biased Charge Air Cooler Outlet Temperature (CACOT) sensor
• Biased Mass Air Flow (MAF) sensor
• Biased temperature sensor
• Restricted exhaust
• MAF sensor auto-calibration
• Incorrect MAF configuration Programmable Parameters (PP)
• Intake Manifold Temperature (IMT) sensor biased
1236 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults(page 1235).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 4752 FMI 4.

Step 2 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 4752 FMI 4. Yes: Go to Step 3.
Is SPN 4752 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 3 Check for Exhaust Gas Recirculation (EGR) cooler leaks. Decision
• Perform Coolant Leak Visual Inspection(page 1643). Yes: Go to Step 4.
• Inspect EGR cooler for any external coolant.
• Inspect EGR cooler for any external exhaust gas leaks.
Are there no external leaks? No: Repair external coolant
and/or exhaust leak(s), retest for
SPN 4752 FMI 4.

Step 4 Test EGR cooler integrity. Decision

Perform On-Engine EGR Cooler Leak Test (page 1616). Yes: Go to Step 5.
Did EGR cooler pass pressure tests? No: Replace EGR cooler. After
repairs are complete, retest for
SPN 4752 FMI 4.

Step 5 Check EGR internal condition. Decision

A. Refer to Engine Service Manual, and remove EGR cooler for inspection. Yes: Go to Step 6.
B. Inspect EGR cooler for plugged coolant and gas passages and internal
coolant and exhaust gas leaks.
Is EGR cooler free of obstructions and internal leaks? No: Replace EGR cooler. After
repairs are complete, retest for
SPN 4752 FMI 4.

Step 6 Determine if MAF Sensor Calibration will pass. Decision

Perform MAF Sensor Calibration (page 1539). Yes: After doing all diagnostic
steps, if SPN 4752 FMI 4 remains,
verify each step was completed
correctly and proper decision was
made.
Did MAF Sensor Calibration pass? No: Go to MAF fault code
diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1237

End Diagnostic Test

After performing diagnostic steps, if SPN 4752 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1238 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 4765 FMI 2 - DOCIT signal erratic, intermittent, or incorrect

Fault Overview
Fault code sets when the Engine Control Module (ECM) detects a difference between the Diesel Oxidation
Catalyst Intake Temperature (DOCIT) and Diesel Particulate Filter Intake Temperature (DPFIT) signals that do
not match expected values for 300 seconds. Active and parked regeneration of Diesel Particulate Filter (DPF)
will be disabled. Engine torque may be reduced if engine is operated for an extended period of time with this
fault active.

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

Associated Faults
SPN 4765 FMI 3 and 4
(DOCIT)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• High resistance in DOCIT circuit
• High resistance in SIG GND circuit
• Failed Diesel Oxidation Catalyst Inlet Temperature (DOCIT) sensor
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1239

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults(page 1238).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 4765 FMI 2.

Step 2 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 4765 FMI 2. Yes: Go to Step 3.
Is SPN 4765 FMI 2 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 3 Check connections at Diesel Oxidation Catalyst Inlet Temperature Decision

(DOCIT) sensor.
A. Key-Off. Yes: Go to Step 4.
B. Disconnect DOCIT sensor connector.
C. Inspect DOCIT sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are DOCIT sensor, connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 4765
FMI 2.

Step 4 DOCIT voltage check. Decision

A. Perform Test 1(page 1241). Yes: Go to Step 5.
B. Use DMM, measure voltage between Breakout Harness ZTSE4760A
pin-1 and PWR.
Is voltage B+ ± 0.5 volts? No: Repair high resistance
between DOCIT pin-1 and ECM
pin C-37. After repairs are
complete, retest for SPN 4765
FMI 2.
1240 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 5 DOCIT voltage check. Decision

A. Perform Test 2(page 1241). Yes: Replace DOCIT sensor.
After repairs are complete, retest
B. Use DMM, measure voltage from Breakout harness pin-2 to known good
for SPN 4765 FMI 2.
GND.
Is voltage 5.0 ± 0.5 volts? No: Repair high resistance
between DOCIT pin-2 and
ECM pin C-8. After repairs are
complete, retest for SPN 4765
FMI 2.

End Diagnostic Test

After performing diagnostic steps, if SPN 4765 FMI 2 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1241

Pin-Point Tests (SPN 4765 FMI 2)

Figure 378 DOCIT Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools
• Breakout Harness ZTSE4760A
• Digital Multimeter (DMM)

Figure 379 DOCIT Circuit Check

Test 1
A. Key OFF

B. Disconnect Diesel Oxidation Catalyst Inlet Temperature (DOCIT) sensor.

C. Connect Breakout Harness ZTSE4760A to DOCIT chassis harness and leave DOCIT sensor disconnected.

D. Key ON Engine OFF (KOEO).

1242 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 380 DOCIT Circuit Check

Test 2
A. Key OFF
B. Disconnect Diesel Oxidation Catalyst Inlet Temperature (DOCIT) sensor.
C. Connect Breakout Harness ZTSE4760A to DOCIT chassis harness and leave DOCIT sensor disconnected.
D. Key ON Engine OFF (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1243

SPN 4765 FMI 3 - DOCIT signal Out of Range HIGH

Fault Overview
Fault code sets when the Doser Control Unit (DCU) detects DOCIT sensor signal voltage is greater than
expected. Active and parked regeneration of Diesel Particulate Filter (DPF) will be disabled. Engine torque will
be reduced if engine is operated for an extended period of time with this fault active.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• DOCIT signal circuit OPEN or short to PWR
• SIG GND circuit OPEN
• Failed Diesel Particulate Filter Inlet Temperature (DPFIT) sensor
1244 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for Yes: Go to Step 2.
SPN 4765 FMI 3.
Is SPN 4765 FMI 3 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Check connections at Diesel Oxidation Catalyst Inlet Temperature Decision

(DOCIT) sensor.
A. Key OFF. Yes: Go to Step 3.
B. Disconnect DOCIT sensor connector.
C. Inspect DOCIT sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are DOCIT sensor, connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 4765
FMI 3.

Step 3 DOCIT sensor check. Decision

A. Key OFF. Disconnect DOCIT sensor connector. Yes: Replace DOCIT sensor. After
repairs are complete, retest for
B. Connect Breakout Harness ZTSE4760A to vehicle harness and leave
SPN 4765 FMI 3.
DOCIT sensor disconnected.
C. Use ZTSE4498 to short Breakout Harness ZTSE4760A pin-1 to pin-2.
D. Key ON. Engine OFF (KOEO). Connect EST to vehicle Diagnostic
Connector.
E. Perform the Continuous Monitor Test (page 1361).
F. Monitor DOCIT voltage while shorting Breakout Harness pin-1 to pin-2.
Clear DTC’s.
Did DOCIT voltage change to 0.0 ± 0.25 volts or did SPN 4765 FMI 4 set? No: Go to Step 4.

Step 4 DOCIT circuit check. Decision

A. Key OFF. Breakout Harness connected to vehicle harness and DOCIT Yes: Repair Open between DOCIT
sensor disconnected. pin-1 and ECM pin C-37. After
repairs are complete, retest for
B. Use ZTSE4498 to short Breakout Harness ZTSE4760A pin-2 to known
SPN 4765 FMI 3..
good GND.

C. Perform the Continuous Monitor Test.

D. Monitor DOCIT voltage while shorting Breakout Harness pin-2 to GND.

Clear DTC’s.
Did DOCIT voltage change to 0.0 ± 0.25 volts or did SPN 4765 FMI 4 set? No: Repair Open or short to PWR
in between DOCIT pin-2 and
ECM pin C-08. After repairs are
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1245

complete, retest for SPN 4765 FMI

3.

End Diagnostic Test

After performing diagnostic steps, if fault remains, verify steps were completed correctly and proper decision was
made. Retest for fault.
1246 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 4765 FMI 4 - DOCIT Signal Out of Range LOW

Fault Overview
Fault sets when the Engine Control Module (ECM) determines the Diesel Oxidation Catalyst Inlet Temperature
(DOCIT) value is lower than expected.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• DOCIT signal circuit short to GND
• Failed DOCIT sensor
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1247

Step 1 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 4765 FMI 4. Yes: Go to Step 2.
Is SPN 4765 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 2 Check connections at DOCIT sensor. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect DOCIT sensor connector.
C. Inspect DOCIT sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are DOCIT sensor, connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 4765
FMI 4.

Step 3 DOCIT connector voltage check. Decision

Perform Test 1 (page 1248). Use Digital Multimeter (DMM), measure voltage from Yes: Replace DOCIT sensor.
Breakout harness pin-2 to known good GND. After repairs are complete, retest
for SPN 4765 FMI 4.
Is voltage 5 ± 0.25 volts? No: Repair short to GND between
DOCIT pin-2 and ECM pin C-8.
After repairs are complete, retest
for SPN 4765 FMI 4.

End Diagnostic Steps

After performing all diagnostic steps, if SPN 4765 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1248 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 4765 FMI 4)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools
• Breakout Harness ZTSE4760A
• DMM

Figure 381 DOCIT Voltage Check

Test 1
A. Key OFF
B. Disconnect DOCIT sensor.
C. Connect Breakout Harness ZTSE4760A to DOCIT chassis harness and leave DOCIT sensor disconnected.
D. Key ON, Engine OFF (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1249

SPN 4765 FMI 7 - DOCIT not increasing with engine temperature

Fault Overview

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

Associated Faults
SPN 4765 FMI 3 and 4
(DOCIT)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• High resistance in DOCIT circuit
• High resistance in SIG GND circuit
• Failed DOCIT sensor

Step Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 1249).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 4765 FMI 7.

Step 2 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 4765 FMI 7. Yes: Go to Step 3.
Is SPN 4765 FMI 7 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 4765 FMI 7.

Step 3 Check connections at Diesel Oxidation Catalyst Inlet Temperature Decision

(DOCIT) sensor.
A. Key-Off. Yes: Go to Step 4.

B. Disconnect DOCIT sensor connector.

C. Inspect DOCIT sensor and connector terminals for: damaged or pinched

wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are DOCIT sensor, connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
1250 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

are complete, retest for SPN 4765

FMI 7.

Step 4 DOCIT voltage check. Decision

A. Perform Test 1 (page 1251). Yes: Go to Step 5.

B. Use DMM, measure voltage from Breakout harness pin-1 to B+.

Is voltage B+ ± 0.5 volts? No: Repair high resistance
between DOCIT pin-1 and ECM
pin C-37. After repairs are
complete, retest for SPN 4765
FMI 7.

Step 5 DOCIT voltage check. Decision

A. Perform Test 2 (page 1251). Yes: Replace DOCIT sensor.
After repairs are complete, retest
B. Use DMM, measure voltage from Breakout harness pin-2 to known good
for SPN 4765 FMI 7.
GND.
Is voltage 5.0 ± 0.5 volts? No: Repair high resistance
between DOCIT pin-2 and
ECM pin C-8. After repairs are
complete, retest for SPN 4765
FMI 72.

End Diagnostic Test

After performing diagnostic steps, if SPN 4765 FMI 7 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1251

Pin-Point Tests (SPN 4765 FMI 7)

Figure 382 DOCIT Circuit Diagram

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools
• Breakout Harness ZTSE4760A
• Digital Multimeter (DMM)

Figure 383 DOCIT Circuit Check

Test 1
A. Key OFF

B. Disconnect Diesel Oxidation Catalyst Inlet Temperature (DOCIT) sensor.

C. Connect Breakout Harness ZTSE4760A to DOCIT chassis harness and leave DOCIT sensor disconnected.

D. Key ON Engine OFF (KOEO).

1252 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 384 DOCIT Circuit Check

Test 2
A. Key OFF
B. Disconnect Diesel Oxidation Catalyst Inlet Temperature (DOCIT) sensor.
C. Connect Breakout Harness ZTSE4760A to DOCIT chassis harness and leave DOCIT sensor disconnected.
D. Key ON Engine OFF (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1253

SPN 4765 FMI 20 - DOCIT Signal Drifted HIGH

Fault Overview
Fault sets when Engine Control Module (ECM) determines DOCIT sensor is measuring temperature greater
than 842°F (450°C).

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

Associated Faults
SPN 1322 - 1328 FMI 31

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Alternate fuel source
• Unburned hydrocarbons in exhaust system
1254 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults(page 1253).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 4765 FMI 20.

Step 2 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 3.
SPN 4765 FMI 20.
Is SPN 4765 FMI 20 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 4765 FMI 20.

Step 3 Decision
A. Do Hot Run Sensor Compare Check (page 1322). Yes: Go to Step 4.
B. Compare Diesel Particulate Filter (DPF) Inlet Temperature (DPFIT), Diesel
Oxidation Catalyst (DOC) Inlet Temperature (DOCIT), and DPF Outlet
Temperature (DPFOT). All sensors should be within 68°F (38°C) of each
other.
Are all temperature sensors within 68°F (38°C) other sensors? No: Replace failed temperature
sensor. After repairs are
complete, retest for SPN 4765
FMI 20.

Step 4 Use terminal test kit inspect connections at DOCIT sensor. Decision
A. Key OFF. Yes: Go to Step 5.
B. Disconnect DOCIT sensor connector.
C. Check DOCIT sensor and connector for: damaged or pinched wires; wet
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are DOCIT sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 4765
FMI 20.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1255

Step 5 Test DOCIT sensor. Decision

A. Connect breakout harness ZTSE4760A between DOCIT sensor and Yes: Go to Step 6.
DOCIT sensor connector.
B. Do KOEO voltage check of DOCIT sensor between DOCIT signal and
ground.
Is voltage within specification? No: Replace DOCIT sensor. After
repairs are complete, retest for
SPN 4765 FMI 20.

Step 6 Check engine for oil ingestion. Decision

Do Charge Air Cooler (CAC) System checks (page 1646). Yes: Go to Step 7.
Is CAC system free of engine oil? No: Repair oil ingestion condition.
After repairs are complete, retest
for SPN 4765 FMI 20.

Step 7 Check Hydrocarbon Injection (HCI) assembly clean. Decision

Remove HCI assembly (AFI Plugging) (see Engine Service Manual and IK1200753 Yes: After doing all diagnostic
Hydrocarbon Injector Housing Cleaning Procedure). steps, if SPN 4765 FMI 20
remains active, verify each step
was completed correctly and
proper decision was made. Notify
supervisor for further action.
Is HCI assembly clean? No: Replace HCI assembly. After
replacement is complete, retest
for SPN 4765 FMI 20.

End Diagnostic Test

After performing diagnostic steps, if SPN 4765 FMI 20 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1256 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 4765 FMI 21 - DOCIT signal drifted LOW

Fault Overview
Fault sets when Engine Control Module (ECM) determines Diesel Oxidation Catalyst Inlet Temperature (DOCIT)
sensor is measuring temperature less than 446°F (230°C).

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

Associated Faults
SPN 4765 FMI 2, 3, and 4
(DOCIT)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
• Damaged or missing exhaust components
• Failed DOCIT sensor

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 1256).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 4765 FMI 21.

Step 2 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 4765 FMI 21. Yes: Go to Step 3.
Is SPN 4765 FMI 21 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 4765 FMI 21.

Step 3 Check connections at Diesel Oxidation Catalyst Inlet Temperature Decision

(DOCIT) sensor.
A. Key OFF. Yes: Go to Step 4.
B. Disconnect DOCIT sensor connector.

C. Inspect DOCIT sensor and connector terminals for: damaged or pinched

wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are DOCIT sensor, connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1257

are complete, retest for SPN 4765

FMI 21.

WARNING:

To prevent property damage, personal injury, and/or death, before working on exhaust
system, allow sufficient time for cool down. During regeneration, exhaust gas
temperature could reach 1500°F (800°C), and exhaust system surface temperature could
exceed 1300°F (700°C), which is hot enough to ignite or melt common materials, and to
burn skin. Exhaust and exhaust components can remain hot after vehicle has stopped
moving.

Step 4 Sensor compare check. Decision

Compare Diesel Particulate Filter (DPF) Inlet Temperature (DPFIT), Diesel Yes: Go to Step 5.
Oxidation Catalyst (DOC) Inlet Temperature (DOCIT), and DPF Outlet Temperature
(DPFOT) with engine cold.
Is DOCIT sensor within 68°F (38°C) of other sensors? No: Replace DOCIT sensor. After
repairs are complete, retest for
SPN 4765 FMI 21.

Step 5 Inspect exhaust system (engine and vehicle) for missing equipment, Decision
damage, or leaks.
Perform Exhaust and Aftertreatment System Inspection (page 1651). Yes: End diagnostics. Retest for
SPN 4765 FMI 21.
Is exhaust system undamaged and sensor installed? No: Repair exhaust or install
sensor as needed. After repairs
are complete, retest for SPN 4765
FMI 21.

End Diagnostic Test

After performing diagnostic steps, if SPN 4765 FMI 21 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1258 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 4766 FMI 10 - Catalyst System Efficiency Below Threshold

Fault Overview
Fault sets when Engine Control Module (ECM) determines Diesel Oxidation Catalyst (DOC) is not working
efficiently.

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

Associated Faults
SPN 4765 FMI 2, 7, and 20

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Exhaust leaks or damage
• Restricted air filter
• Fuel leaks or damage
• Failed DOC
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1259

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 1258).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 4766 FMI 10.

Step 2 Check for Intake and Exhaust systems for leaks and/or damage. Decision
• Perform Intake Air Inspection (page 1648), Yes: Go to Step 3.
• Charge Air Cooler Inspection (page 1646),
• Exhaust and Aftertreatment System Inspection(page 1651).
Are all items checked in good condition and clear of leaks and damage? No: Repair leaks or damage to
intake and exhaust. After repair
are complete, retest for SPN 4766
FMI 10.

Step 3 Check fuel system for leaks and/or damage. Decision

• Perform Fuel System Inspection(page 1631), Yes: Go to Step 4.
• Fuel Quality Inspection (page 1632),
• and Fuel Level Inspection (page 1634).
Are all items checked in good condition and clear of leaks and damage? No: Repair leaks or damage
to fuel system. After repair are
complete, retest for SPN 4766
FMI 10.

Step 4 Inspect connections at Diesel Oxidation Catalyst Inlet Temperature Decision

(DOCIT), Diesel Particular Filter Inlet Temperature (DPFIT), and DPF
Outlet Temperature (DPFOT) sensors.
A. Key OFF, disconnect DOCIT, DPFIT, and DPFOT sensor connectors. Yes: Go to Step 5.

B. Check sensor and connector terminals for: damaged or pinched wires; wet
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are DOCIT, DPFIT, and DPFOT sensor connectors, harnesses, and terminals clean No: Repair damaged connector,
and undamaged? harness, or terminal. After repairs
are complete, retest for SPN 4766
FMI 10.
1260 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 5 Check for regen inhibitors. Decision

A. Key OFF. Yes: Go to Step 6.
B. Connect EST to vehicle Diagnostic Connector. (page 1345).
C. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
D. Perform Onboard Filter Cleanliness Test (OBFCT) (page 1331).
Is DPF Regeneration running without an Abort Message in EST. No: Correct parked regen
inhibitors and redo Step 5.

Step 6 Inspect for exhaust leaks during DPF Regeneration procedure. Decision
While running DPF Regeneration procedure, inspect exhaust system for leaks or Yes: Go to Step 7.
physical damage.
Is exhaust system clear of leaks and physical damage? No: Repair leaks and/or physical
damage. After repairs are
complete, retest for SPN 4776
FMI 10.

Step 7 DPF Regeneration procedure results. Decision

After OBFCT is complete with no Abort Message in EST. Yes: End diagnostics, retest for
SPN 4766 FMI 10.
Does Diesel Particulate Filter Differential Pressure (DPFDP) signal measure below No: Remove DOC and inspect
0.5 psi (3 kPa) at high idle? for contamination and re-use refer
to Aftertreatment Diagnostic and
Service Manual 3081. Repair
source of contamination as
needed. Clean or replace per
re-use guidelines. After repairs
are complete, retest for SPN 4766
FMI 10.

End Diagnostic Test

After performing diagnostic steps, if SPN 4766 FMI 10 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1261

SPN 5319 FMI 31 - DPF incomplete Regeneration

Fault Overview
Fault sets when Engine Control Module (ECM) determines soot load of the DPF is still too high after active
regeneration has completed.

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

Associated Faults
SPN 3251 FMI 2 and 14
(DPFDP)

Drive Cycle to Determine Fault Status

Road Test
Possible Causes
• Biased DPFDP sensor or circuit
• High DPFDP after DPF regeneration
• DPFDP hoses damaged or restricted
• Boost below spec
• Exhaust leaks
• High ash levels in DPF
1262 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2
Associated Faults (page 1261).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 5319 FMI 31.

Step 2 Inspect connections at Diesel Particulate Filter Differential Pressure Decision

(DPFDP) / DPF Outlet Pressure (DPFOP) sensor.
A. Key OFF. Yes: Go to Step 3.
B. Disconnect DPFDP / DPFOP sensor.
C. Check DPFDP / DPFOP sensor and connector terminals for: damaged or
pinched wires; wet or corroded terminals; loose, bent, or broken pins; or
broken connector housing.
Are DPFDP / outlet pressure sensor connector, harness, and terminals clean and No: Repair connector, harness,
undamaged? or terminal damage. After repairs
are complete, retest for SPN 5319
FMI 31.

Step 3 Monitor DPFDP signal. Decision

A. Key OFF. Yes: Go to Step 5.

B. Connect EST to vehicle Diagnostic Connector. (page 1345).

C. Key On Engine Off (KOEO), log in to Navistar® Engine Diagnostics.
D. Key ON Engine Running (KOER).
E. Use EST, load Signals session.
F. Bring engine to high idle.
G. Monitor DPFDP.
Is DPFDP below 0.5 psi (3.45 kPa)? No: Go to Step 4.

Step 4 Check DPFDP sensor hoses for correct routing and restrictions. Decision
Inspect DPFDP sensor hoses for kinks, improper hose routing, restrictions, or Yes: Go to Step 5.
damage.
Are DPFDP sensor hoses routed correctly, clear of damage, and unrestricted? No: Repair or replace DPFDP
sensor hose(s). After repairs are
complete, retest for SPN 5319
FMI 31.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1263

Step 5 Exhaust Back Pressure Valve Test. Decision

Perform Exhaust Back Pressure Valve (EBPV) Test (page 1531). Yes: Repair failed component.
After repairs are complete, retest
for SPN 5319 FMI 31.
Did the test identify any failed components or issues? No: Go to Step 6.

Step 6 Inspect for oil in exhaust. Decision

A. Remove turbocharger down pipe. Yes: Go to Engine Oil Leak to
Exhaust (Step 2) (page 107). After
B. Inspect for oil leaking into exhaust.
repairs are complete, retest for
SPN 5319 FMI 31.
Was oil found leaking into exhaust? No: Go to Step 7.

Step 7 Check for failed fuel injector. Decision

Perform Cylinder Performance Analyzer (CPA) Test to check for misfires. Yes: Check injector(s) on
identified cylinder(s) and repair
A. Perform Connect Cylinder Performance Analyzer (CPA) Tool (page 1402).
as necessary. After repairs are
B. Perform CPA Signal Check (page 1413). complete, retest for SPN 5319
FMI 31.
C. Perform CPA Cold Idle Test (page 1407).
D. Perform CPA Hot Idle Test (page 1421).
Did CPA Tests identify a cylinder misfire? No: Go to Step 8.

Step 8 Check for restricted Diesel Particulate Filter (DPF). Decision

Perform Diesel Particulate Filter (DPF) Inspection (page 1653) . Yes: Clean DPF, reinstall on
vehicle, and reset DPF Soot Load.
In Navistar® Engine Diagnostics
go to: Parameters > CDPF Reset
Request > Yes > Program Engine.
Perform a parked regeneration.
After repairs are complete, retest
for SPN 5319 FMI 31.
Was DPF clear of contamination, soot leakage, and filter damage, and DPF No: Replace DPF, reinstall on
channels free of restrictions? vehicle, and reset DPF Soot Load.
In Navistar® Engine Diagnostics
go to: Parameters > CDPF Reset
Request > Yes > Program Engine.
After repairs are complete, retest
for SPN 5319 FMI 31.

End Diagnostic Test

After performing diagnostic steps, if SPN 5319 FMI 31 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1264 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 5395 FMI 0 - Engine unable to achieve desired idle torque (too high)

Fault Overview
Fault sets when Engine Control Module (ECM) monitoring idle fueling is greater than 199 mg/stroke for 60
seconds or more.

Time Requirement
Immediate

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

Associated Faults
• SPN 651 - 656 (INJ) • SPN 4257 (INJ) • SPN 1322 - 1328 FMI 31
(Engine)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Non-Controller Area Network (CAN) Power Take Off (PTO)
• Aftermarket PTO installed
• Aftermarket PTO programmed incorrectly
• PTO engaged without command
• Intake restriction
• Exhaust restriction
• Base engine compression issue
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1265

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults(page 1264).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 5395 FMI 0.

Step 2 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 5395 FMI 0. Yes: Go to Step 3.
Is SPN 5395 FMI 0 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 3 Check for Intake air restriction. Decision

Perform Intake Air Inspection(page 1648). Yes: Go to Step 4.
Is intake air restriction less than 25 in-Hg (84.7 kPa) at full load and at rated speed? No: Repair intake air restrictions.
After repairs are complete, retest
for SPN 5395 FMI 0.

Step 4 Check for exhaust system restriction. Decision

Inspect exhaust system for damage and restrictions(page 1651). Yes: Go to Step 5.
Is exhaust system free of any damage or restrictions? No: Repair exhaust damage and
restrictions. After repairs are
complete, retest for SPN 5395 FMI
0.

Step 5 Check for aftermarket Power Take Off (PTO). Decision

Inspect for installation of aftermarket PTO system. Yes: Go to Step 6.
Was an aftermarket PTO system installed correctly? No: Go to Step 7.

Step 6 Check for correctly programmed Power Take Off (PTO). Decision
A. Key OFF. Yes: Go to Step 7.

B. Connect EST to vehicle Diagnostic Connector. (page 1345).

C. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.

D. Check Programmable Features PP75270(page 1325) to verify aftermarket

PTO system was programed correctly.
Was Aftermarket PTO system programmed correctly? No: After inspection is complete,
notify supervisor with results for
further action. After repairs are
complete, retest for SPN 5395 FMI
0.
1266 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 7 Check for Power Take Off (PTO) engagement without command. Decision
A. Key-Off. Yes: Repair PTO unit. After repairs
are complete, retest for SPN 5395
B. Verify aftermarket PTO system programed correctly.
FMI 0.
C. Key-On Engine-Running (KOER).
D. Monitor PTO output shaft for rotation.
Is PTO output shaft rotating without throttle? No: Retest for SPN 5395 FMI 0.

End Diagnostic Tests

After performing diagnostic steps, if SPN 5395 FMI 0 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1267

SPN 5395 FMI 1 - Engine unable to achieve desired idle torque (too low)

Fault Overview
Fault sets when Engine Control Module (ECM) monitoring idle fueling is less than 1 mg/stroke for 60 seconds
or more.

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

Associated Faults
• SPN 651 - 656 (INJ) • SPN 4257 (INJ) • SPN 1322 - 1328 FMI 31
(Engine)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Contaminated fuel
• Engine oil leak to intake
• Alternate fuel source
• Engine mechanical failure
1268 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults(page 1267).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 5395 FMI 1.

Step 2 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 5395 FMI 1. Yes: Go to Step 3.
Is EST DTC list SPN 5395 FMI 1 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

Step 3 Check for airborne combustibles. Decision

A. Inspect for airborne combustibles (ex. propane saturated air, ether, etc.) Yes: Go to Step 4.
near engine.
B. Perform Intake Air Inspection(page 1648), inspect for stains,
concentrations of contaminants, odors/smells from external fuel sources,
and modifications.
Is engine intake system intact and free from any external fuel sources? No: Repair source of
combustibles. After repairs
are complete, retest for SPN 5395
FMI 1.

Step 4 Check for contaminated fuel. Decision

A. Inspect for contaminated fuel (alternate fuels other than Diesel fuel). Yes: Go to Step 5.
B. Perform Fuel System Inspection(page 1631).
C. Perform Fuel Quality Inspection (page 1632).
Is diesel fuel in good condition and Not contaminated? No: Drain fuel tank, and fill with
clean and/or known good diesel
fuel. After repairs are complete,
retest for SPN 5395 FMI 1.

Step 5 Determine if high-pressure turbocharger is causing oil leak. Decision

Remove high-pressure turbocharger center section (see Engine Service Manual). Yes: Go to Step 6.
Is oil pooling in high-pressure turbocharger turbine housing? No: Go to Step 7.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1269

Step 6 Determine if high-pressure turbocharger turbine housing is damaged. Decision

With high-pressure turbocharger center section removed, inspect inside of turbine Yes: Replace entire
housing (exhaust side) for evidence of contact with turbine wheel. high-pressure turbocharger
assembly with turbine housing.
• Indications of contact can include bright spots of bare metal, nicks, or gouges
After repairs are complete, retest
on turbine housing inner surface.
for original problem.
• Turbocharger end play does not indicate a failure.
Is turbine housing damaged or are there signs that turbine wheel has contacted No: Replace only high-pressure
turbine housing? turbocharger center section.
After repairs are complete, retest
for original problem.

Step 7 Determine if low-pressure turbocharger is causing oil leak. Decision

Remove low-pressure turbocharger center section (see Engine Service Manual). Yes: Go to Step 8.
Is oil pooling in low-pressure turbocharger turbine housing? No: Go to Step 9.

Step 8 Determine if low-pressure turbocharger turbine housing is Decision

damaged.
With low-pressure turbocharger center section removed, inspect inside of turbine Yes: Replace entire low-pressure
housing (exhaust side) for evidence of contact with turbine wheel. turbocharger assembly with
turbine housing. After repairs
• Indications of contact can include bright spots of bare metal, nicks, or gouges
are complete, retest for original
on turbine housing inner surface.
problem.
• Turbocharger end play does not indicate a failure.
Is turbine housing damaged or are there signs that turbine wheel has contacted No: Replace only low-pressure
turbine housing? turbocharger center section.
After repairs are complete, retest
for original problem.

Step 9 Check for mechanical failure. Decision

Determine if engine has a mechanical cylinder balance problem (compression Yes: Retest for SPN 5395 FMI 1.
loss). Perform Crankcase Pressure Test(page 1567).
Is crankcase pressure within specification? No: Repair base engine
compression imbalance. After
repairs are complete, retest for
SPN 5395 FMI 1.

End Diagnostic Tests

After performing diagnostic steps, if SPN 5395 FMI 1 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1270 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 5456 FMI 2 - AFTFT signal erratic, intermittent, or incorrect

Fault Overview
Fault sets when Engine Control Module (ECM) detects difference between Aftertreatment Fuel Temperature
(AFTFT) and other temperature sensors is greater than 27°F (15°C) after a cold soak.

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

Associated Faults
SPN 5456 FMI 3 and 4

Fault Facts
None

Drive Cycle
Continuous
Possible Causes
• Incorrect DCU for ECM.
• AFTFT circuit high resistance
• SIG GND circuit high resistance
• Failed AFTFT

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 1270).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 5456 FMI 2.

Step 2 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 5456 FMI 2. Yes: Go to Step 3.
Is EST DTC list SPN 5456 FMI 2 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344)

Step 3 Check for correct Doser Control Unit (DCU) part number. Decision
Use EST, check for correct DCU part number. Yes: Go to Step 4.
Does DCU match correct part number for model year of engine? No: Install correct DCU for model
year of engine. After repairs are
complete, retest for SPN 5456 FMI
2.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1271

Step 4 Inspect connections at Aftertreatment Fuel Inlet Sensor (AFTFIS) Decision

connector
A. Key OFF Yes: Go to Step 5.
B. Disconnect AFTFIS connector.

C. Check AFTFIS sensor and connector terminals for damaged or pinched

wires, wet or corroded terminals; loose, bent or broken pins; or broken
connector housing.
Are AFTFIS sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness, or
terminal damage. After repairs are
complete, retest for SPN 5456 FMI
2.

Step 5 Check for failed AFTFIS Decision

A. Perform Test 1 (page 1272). Yes: Replace AFTFIS. After
repairs are complete, retest for
B. Use EST, check AFTFT signal voltage.
SPN 5456 FMI 2.
Is voltage less than 0.5 volts? No: Go to Step 6.

Step 6 Check for Open or high resistance in AFTFT circuit. Decision

A. Perform Test 2 (page 1272). Yes: Repair Open between AFTFIS
pin-1 and DCU Module pin-21.
B. Use EST, check AFTFT signal voltage.
After repairs are complete, retest
for SPN 5456 FMI 2.
Is voltage less than 0.5 volts? No: Repair Open between AFTFIS
pin-2 and DCU Module pin-80.
After repairs are complete, retest
for SPN 5456 FMI 2.

End Diagnostic Tests

After performing diagnostic steps, if SPN 5456 FMI 2 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1272 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 5456 FMI 2)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• International® Electronic Engine Terminal Test Kit ZTSE4435C
• Breakout Harness ZTSE4830
• Digital Multimeter (DMM)
• 3-Banana Plug Harness ZTSE4498

Figure 385 AFTFIS Circuit Check

Test 1
A. Key OFF
B. Disconnect Aftertreatment Fuel Inlet Sensor (AFTFIS).
C. Connect Breakout Harness ZTSE4830 to vehicle harness and leave AFTFIS disconnected.
D. Use Breakout Harness ZTSE4498 short Breakout Harness ZTSE4830 pin-1 and pin-2 together.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1273

Figure 386 AFTFIS Circuit Check

Test 2
A. Key OFF
B. Disconnect Aftertreatment Fuel Inlet Sensor (AFTFIS).
C. Connect Breakout Harness ZTSE4830 to vehicle harness and leave AFTFIS disconnected.
D. Use Breakout Harness ZTSE4498 short Breakout Harness ZTSE4830 pin-2 to a known good GND.
1274 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 5456 FMI 3 - AFTFT signal Out of Range HIGH

Fault Overview
Fault code sets when Electronic Control Module (ECM) detects that Aftertreatment Fuel Temperature (AFTFT)
sensor is reading greater than 4.75 volts.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Aftertreatment (AFT) signal short to PWR
• AFTFT signal circuit Open
• Signal ground Open
• Failed Aftertreatment Fuel Inlet Sensor (AFTFIS) (Open)

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 5456 FMI 3.
Does EST DTC list show 5456 FMI 3 as active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344)

Step 2 Inspect connections at Aftertreatment Fuel Inlet Sensor (AFTFIS) Decision

connector.
A. Key OFF. Yes: Go to Step 3.
B. Disconnect AFTFIS connector.

C. Check AFTFIS sensor and connector terminals for: damaged or pinched

wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are AFTFIS sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 5456
FMI 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1275

Step 3 Check AFTFIS for short to PWR. Decision

A. Perform Test 1(page 1275). Yes: Repair short to power
between AFTFIS pin-2 and DCU
B. Use DMM, measure voltage between Breakout Harness ZTSE4830 pin-2
86-pin connector pin-80. After
and known good GND.
repairs are complete, retest for
SPN 5456 FMI 3.
Is voltage greater than 6 volts? No: Go to Step 4.

Step 4 Check AFTFIS for open circuit. Decision

A. Perform Test 2(page 1276). Yes: Replace AFTFIS. After
repairs are complete, retest for
B. Use EST, clear DTC list.
SPN 5456 FMI 3.
Does SPN 5456 FMI 4 set after DTC is cleared? No: Go to Step 5.

Step 5 Check for open in SIG GND circuit. Decision

A. Perform Test 3(page 1277). Yes: Repair Open in SIG to
ground GND circuit. After repairs
B. Use EST, clear DTC list.
are complete, retest for SPN 5456
FMI 3.
Does SPN 5456 FMI 4 set after DTC is cleared? No: Repair open in signal circuit.
After repairs are complete, retest
for SPN 5456 FMI 3.

End Diagnostic Tests

After performing diagnostic steps, if SPN 5456 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.

Pin-Point Tests (SPN 5456 FMI 3)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4830
• Breakout Harness ZTSE4498
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP-1210B-compliant supporting J1939 and J1708)
• Electronic Engine Terminal Test Kit
1276 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 387 AFTFIS Circuit Check

Test 1
A. Key OFF.
B. Disconnect Aftertreatment Fuel Inlet Sensor (AFTFIS) connector.
C. Connect Breakout Harness ZTSE4830 to engine harness connector and leave AFTFIS connector disconnected.
D. Key ON Engine OFF (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1277

Figure 388 AFTFIS Circuit Check

Test 2
A. Key OFF.
B. Disconnect Aftertreatment Fuel Inlet Sensor (AFTFIS) connector.
C. Connect Breakout Harness ZTSE4830 to engine harness connector and leave AFTFIS sensor disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4830 pin-1 and pin-2 together.
E. Connect EST to vehicle Diagnostic Connector. (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
1278 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 389 AFTFIS Circuit Check

Test 3
A. Key OFF.
B. Disconnect Aftertreatment Fuel Inlet Sensor (AFTFIS) connector.
C. Connect Breakout Harness ZTSE4830 to engine harness connector and leave AFTFIS sensor disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4830 pin-2 to known good GND.
E. Connect EST to vehicle Diagnostic Connector. (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1279

SPN 5456 FMI 4 - AFTFT Signal Out of Range LOW

Fault Overview
Fault code sets when Electronic Control Module (ECM) detects that Aftertreatment Fuel Temperature (AFTFT)
sensor is reading less than 0.25 volts.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• AFTFT short to GND
• Failed AFTFIS sensor

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 5456 FMI 4.
Does EST DTC list show 5456 FMI 4 as active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344)

Step 2 Inspect connections at Aftertreatment Fuel Inlet Sensor (AFTFIS) Decision

connector.
A. Key OFF. Yes: Go to Step 3.
B. Disconnect AFTFIS sensor connector.
C. Check AFTFIS sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are AFTFIS sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 5456
FMI 4.
1280 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 3 Check for failed sensor. Decision

A. Key OFF. Yes: Replace AFTFIS module.
After repairs are complete, retest
B. Disconnect Aftertreatment Fuel Inlet Sensor (AFTFIS) connector.
for SPN 5456 FMI 4.
C. Connect EST to vehicle Diagnostic Connector. (page 1345).
D. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.

E. Use EST, clear DTC list.

Does SPN 5446 FMI 3 set after DTC is cleared? No: Repair short circuit to GND
between pin-2 and DCU pin-80.
After repairs are complete, retest
for SPN 5456 FMI 4.

End Diagnostic Tests

After performing diagnostic steps, if SPN 5456 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1281

SPN 5541 FMI 1 - TC1TOP pressure below minimum

Fault Overview
Fault set when comparison of Turbocharger 1 Turbine Outlet Pressure (TC1TOP) to Intake Manifold Pressure
(IMP), Barometric Absolute Pressure (BARO), or Exhaust Back Pressure (EBP) has an absolute pressure value
difference of greater than 3.6 psi (25 kPa).

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected during one drive cycle.

Associated Faults
SPN 5543 FMI 3, 4, and 5

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Damaged or restricted TC1TOP sensor Tube
• Failed TC1TOP sensor
1282 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults(page 1281).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 5541 FMI 1.

Step 2 Check TC1TOP Key ON Engine OFF (KOEO) value. Decision

A. Key OFF. Yes: Replace Air Control Valve
(ACV), which contains the
B. Connect EST to vehicle Diagnostic Connector. (page 1345).
TC1TOP sensor. After repairs are
C. KOEO, log into EST with Navistar® Engine Diagnostics. complete, retest for SPN 5541
FMI 1.
D. Use EST, monitor TC1TOP value.
Is TC1TOP KOEO pressure 0 psi? No: Go to Step 3.

Step 3 Inspect Turbocharger 1 Turbine Outlet Pressure (TC1TOP) sensor Decision

tube for damage between ACV and turbocharger outlet pipe.
A. Remove TC1TOP sensor tube. Yes: Replace ACV. After repairs
are complete, retest for SPN 5541
B. Inspect TC1TOP sensor tube for cracks, kinks, soot plugging, or other
FMI 1.
damage.
Is TC1TOP sensor tube in good condition and free of damage or plugging? No: Replace sensor tube. After
repairs are complete, retest for
SPN 5541 FMI 1.

End Diagnostic Tests

After performing all diagnostic steps, if SPN 5541 FMI 2 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1283

SPN 5541 FMI 2 - TC1TOP signal erratic, intermittent, or incorrect

Function
Fault set when comparison of Turbocharger 1 Turbine Outlet Pressure (TC1TOP) to Intake Manifold Pressure
(IMP), Barometric Absolute Pressure (BARO), or Exhaust Back Pressure (EBP) has an absolute pressure value
difference of greater than 3.6 psi (25 kPa).

Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected during one trip.

Associated Faults
SPN 102 FMI 3 and 4 (IMP) SPN 108 FMI 3 and 4 SPN 1209 FMI 3 and 4 (EBP) SPN 3509 FMI 3 and 4
(BARO) (VREF 1)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Biased TC1TOP sensor

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 1283).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 5541 FMI 2.

Step 2 Check for active or pending fault code. Decision

Use EST, check DTC list for SPN 5541 FMI 2. Yes: Replace Air Control Valve
that contains TC1TOP sensor.
After repairs are complete, retest
for SPN 5541 FMI 2.
Is EST DTC list SPN 5541 FMI 2 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1344).

End Diagnostic Tests

After performing all diagnostic steps, if SPN 5541 FMI 2 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1284 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 5541 FMI 3 - TC1TOP signal Out of Range HIGH

Fault Overview

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

Associated Faults
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• TC1TOP signal circuit OPEN or short to GND
• TC1TOP Sensor Failure

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 5541 FMI 3.
Is SPN 5541 FMI 3 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect connections at Turbocharger 1 Turbine Outlet Pressure Decision

(TC1TOP).
A. Key OFF. Yes: Go to Step 3.
B. Disconnect TC1TOP sensor connector.
C. Check TC1TOP sensor and connector for: damaged or pinched wires; wet
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are TC1TOP sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 5541
FMI 3.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1285

Step 3 Test TC1TOP sensor. Decision

Connect breakout harness between TC1TOP sensor and TC1TOP sensor Yes: After doing all diagnostic
connector. Do KOEO voltage check of TC1TOP sensor between TC1TOP signal steps, if SPN 5541 FMI 3 remains
and ground. active, verify each step was
completed correctly and proper
decision was made. Notify
supervisor for further action.
Is voltage within specification? No: Replace TC1TOP sensor.
After repairs are complete, retest
for SPN 5541 FMI 3.

End Diagnostic Test

After performing diagnostic steps, if SPN 5541 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1286 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

SPN 5541 FMI 4 - TC1TOP signal Out of Range LOW

Fault Overview
Fault is set when Engine Control Module (ECM) detects Turbocharger 1 Turbine Outlet Pressure (TC1TOP)
signal is out of range LOW.

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

Associated Faults
SPN 3509 FMI 3 and 4
(VREF 1)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Signal Open
• Signal short to ground
• VREF Open
• Failed TC1TOP sensor
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1287

Step 1 Check for associated fault codes Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 1286).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 5541 FMI 4.

Step 2 Inspect connections at Air Control Valve (ACV). Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect ACV control.
C. Check ACV control and connector terminals for: damaged or pinched
wires; corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are ACV control connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 5541
FMI 4.

Step 3 Check VREF 1 circuit from EBPV to ECM. Decision

A. Perform Test 1 (page 1289). Yes: Go to Step 4.
B. Use DMM, measure voltage between Breakout Harness ZTSE4834 pin-2
and known good GND.
Is voltage 5.0 ± 0.5 volts? No: Repair Open or short to GND
in VREF 1 between ECM pin E-35
and ACV pin-2. After repairs are
complete, retest for SPN 5541
FMI 4.

Step 4 Check TC1TOP circuit from EBPV and ECM. Decision

A. Perform Test 2 (page 1289). Yes: Replace ACV which contains
the failed TC1TOP sensor. After
B. Use EST, clear DTC list.
repairs are complete, retest for
SPN 5541 FMI 4.
Does SPN 5541 FMI 3 set after DTC list is cleared? No: Go to Step 5.
1288 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 5 Check TC1TOP circuit from EBPV and ECM. Decision

A. Perform Test 2 (page 1289). Yes: Repair short to GND in
TC1TOP circuit between ECM pin
B. Use EST, clear DTC list.
E-45 and ACV pin-5. After repairs
are complete, retest for SPN 5541
FMI 4.
Does SPN 3509 FMI 4 set after DTC list is cleared? No: Repair open in TC1TOP
circuit between ECM pin E-45
and ACV pin-5. After repairs are
complete, retest for SPN 5541
FMI 4.

End Diagnostic Tests

After performing diagnostic steps, if SPN 5541 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1289

Pin-Point Tests (SPN 5541 FMI 4)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4834
• Breakout Harness ZTSE4498
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Figure 390 VREF 1 Circuit Check

Test 1
A. Key OFF.
B. Disconnect ACV connector.
C. Connect Breakout Harness ZTSE4834 to vehicle harness and leave ACV disconnected.
D. Key ON Engine OFF (KOEO).
1290 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Figure 391 Circuit Check

Test 2
A. Key OFF.
B. Disconnect ACV connector.
C. Connect Breakout Harness ZTSE4834 to vehicle harness and leave ACV disconnected.
D. Use Breakout Harness ZTSE4498 jumper between Breakout Harness ZTSE4834 pin-2 and pin-5.
E. Connect EST to vehicle Diagnostic Connector. (page 1345).
F. Key ON Engine OFF (KOEO). Log in to Navistar® Engine Diagnostics.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1291

SPN 5543 FMI 3 - EBPC short to PWR

Fault Overview

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• EBPC circuit short to PWR
• Failed EBPC valve
1292 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 5543 FMI 3.
Is SPN 5543 FMI 3 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect Air Control Valve (ACV) and connector. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect ACV sensor.
C. Check ACV sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are ACV sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 5543
FMI 3.

Step 3 Test EBP sensor. Decision

Connect breakout harness between EBP sensor and EBP sensor connector. Do Yes: After doing all diagnostic
KOEO voltage check of EBP sensor between EBP signal and ground. steps, if SPN 5543 FMI 3 remains
active, verify each step was
completed correctly and proper
decision was made. Notify
supervisor for further action.
Is voltage within specification? No: Replace EBP sensor. After
repairs are complete, retest for
SPN 5543 FMI 3.

End Diagnostic Test

After performing diagnostic steps, if SPN 5543 FMI 3 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1293

SPN 5543 FMI 4 - EBPC short to GND

Fault Overview
Fault sets when Engine Control Module (ECM) detects Exhaust Back Pressure Valve (EBPV) Control circuit is
shorted to ground.

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

Associated Faults
None

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• EBPC circuit short to GND
• Failed EBPC valve
1294 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for active or pending fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
SPN 5543 FMI 4.
Is SPN 5543 FMI 4 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure(page
1344).

Step 2 Inspect Air Control Valve (ACV) connector. Decision

A. Key OFF. Yes: Go to Step 3.
B. Disconnect ACV sensor.
C. Check ACV sensor and connector terminals for: damaged or pinched
wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are ACV sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 5543
FMI 4.

Step 3 Decision
Test EBP sensor. Connect breakout harness between EBP sensor and EBP sensor Yes: After doing all diagnostic
connector. Do KOEO voltage check of EBP sensor between EBP signal and ground. steps, if SPN 5543 FMI 4 remains
active, verify each step was
completed correctly and proper
decision was made.
Notify supervisor for further action.
Is voltage within specification? No: Replace EBP sensor.
After repairs are complete, retest
for SPN 5543 FMI 4.

End Diagnostic Test

After performing diagnostic steps, if SPN 5543 FMI 4 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1295

SPN 5543 FMI 5 - EBPC open load/circuit

Fault Overview
Fault sets when Exhaust Back Pressure Control (EBPC) is less than 25 mA for 100 microseconds when enabled.

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

Associated Faults
SPN 158 FMI 15 and 17
(ECM)

Fault Facts
None

Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• Exhaust Back Pressure Control (EBPC) circuit Open
• ACT GND circuit Open
• Failed Air Control Valve (ACV)
1296 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Step 1 Check for associated fault codes. Decision

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 1295).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
After repairs are complete, retest
for SPN 5543 FMI 5.

Step 2 Check for active or pending fault codes. Decision

Use EST, check DTC list for SPN 5543 FMI 5. Yes: Go to Step 3.
Is SPN 5543 FMI 5 active or pending? No: Repair Active faults. After
repairs are complete, retest for
SPN 5543 FMI 5.

Step 3 Inspect connections at Air Control Valve (ACV) connector. Decision

A. Key OFF. Yes: Go to Step 4.
B. Disconnect ACV
C. Check ACV and connector terminals for: damaged or pinched wires;
moisture in terminals; corroded terminals; loose, bent, or broken pins; or
broken connector housing.
Are ACV connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 5543
FMI 5.

Step 4 Checking for Open in ACT GND circuit. Decision

A. Perform Test 1(page 1298). Yes: Go to Step 5.
B. Use DMM, measure voltage between Breakout Harness ZTSE4834 pin-3
and PWR.
Is voltage B+ ± 0.5 volts? No: Repair Open between ACV
pin-3 and ACT GND. After repairs
are complete, retest for SPN 5543
FMI 5.

Step Check EBPV circuit for Open. Decision

A. Perform Test 2(page 1298). Yes: Replace ACV. After repairs
are complete, retest for SPN 5543
B. Use DMM, measure voltage between Breakout Harness ZTSE4834 pin-6
FMI 5.
and known good GND.
Is voltage 2.5 ± 0.5 volts? No: Repair Open between ACV
pin-6 and ECM pin E-56. After
repairs are complete, retest for
SPN 5543 FMI 5.
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1297

End Diagnostic Steps

After performing diagnostic steps, if SPN 5543 FMI 5 remains, verify each step was completed correctly and proper
decision was made. Notify supervisor for further action.
1298 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES

Pin-Point Tests (SPN 5543 FMI 5)

See latest version of MaxxForce® DT, 9, and 10 Engine and Aftertreatment Wiring Schematic Form 0000003221
for additional circuit information.
Tools Required
• Breakout Harness ZTSE4834
• Digital Multimeter (DMM)

Figure 392 EBPV Circuit Check

Test 1
A. Key OFF.
B. Disconnect ACV connector.
C. Connect Breakout Harness ZTSE4834 to vehicle harness and leave ACV connector disconnected.
D. Key ON Engine OFF (KOEO).
 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES 1299

Figure 393 EBPV Circuit Check

Test 2
A. Key OFF.
B. Disconnect ACV connector.
C. Connect Breakout Harness ZTSE4834 to vehicle harness and leave ACV connector disconnected.
D. Key ON Engine OFF (KOEO).
1300 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1301

Table of Contents

Navistar® Engine Diagnostics Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1305

CPA Snapshot Viewer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1305
Navistar® Engine Diagnostics Connection and Data Recording. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1311
Diagnostic Trouble Code Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1317
Check for DTCs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1319
Session Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1320
Hot Run Sensor Comparison Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1322
Obtain Vehicle Health Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1324
Programmable Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1325
Record Snapshot of KOEO Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1330
Onboard Filter Cleanliness Test (OBFCT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1331
Injector Coil End of Motion (CEOM) Reset Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1334
Injector Coking Accumulation Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1338
Fuel Pressure Adaptation Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1341
Intermittent or Inactive Fault Diagnostic Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1344

Connecting EST with Navistar® Engine Diagnostics Software to Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1345

Interface Device Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1345
Connecting Navistar® Engine Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1348
Pinpoint Diagnostic Graphic Legend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1349

Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1357
KOEO Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1357
KOEO Standard Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1357
Output State High or Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1359
Continuous Monitor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1361
Injector Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1365
KOEO DCU Actuator Test – Actuator Output High and Low Diagnostics. . . . . . . . . . . . . . .1368
Relative Compression Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1371
Engine Cranking Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1374
Engine Running Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1376
Air Management Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1376
KOER Standard Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1380
Low to High Idle Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1383
KOER DSI System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1385
KOER DSI Deaeration Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1388
Connecting CPA Tool for HPOP Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1391
Connecting CPA Tool for Misfire Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1402
Injector Misfire Detection Cold Idle Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1407
Injector Misfire Detection Signal Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1413
Injector Misfire Detection Hot Idle Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1421
Injector Misfire Detection Full Load to Highway Speed Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1427
CPA Advanced Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1433
CPA High-Pressure Oil Pump (HPOP) Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1440
CPA HPOP Signal Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1447
Record Snapshot of Engine Running Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1464
1302 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Base Engine Analysis Module (BEAM) Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1465

Relative Compression Test Plus (RCT+). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1465
Blow By Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1486
Pressure Plus Module and CPA Signal Functionality Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1501

Road Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1514

0 to 60 MPH Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1514
0 to 60 MPH ICP and ICPD Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1518
0 to 60 MPH, RPM, Load, IMP, EBP, and APP1 Graph. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1520
Normal Exhaust Gas Temperature Graph. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1523
Erratic Exhaust Gas Temperatures Graph. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1526
Low Exhaust Gas Temperatures Graph. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1528

Air Management System Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1531

Exhaust Back Pressure Valve (EBPV) Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1531
Boost Control System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1533
MAF Sensor Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1539
Exhaust Gas Recirculation Valve (EGRV) Operational Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1543
High-Pressure Charge Air Cooler (HPCAC) Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1545
Interstage Cooler (ISC) Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1551

Low-Pressure Fuel System Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1554

Fuel Delivery Pressure (FDP) Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1554
Fuel Pump Voltage Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1557
Clean Fuel Source Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1559

General Test Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1563

Cable Drop Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1563
Crankcase Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1567
Crankcase Oil Separator (CCOS) Speed Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1572
Coolant Heater Assembly Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1575
Electrical System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1577
Intake Air Heater (IAH) System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1590
Oil Pan Heater Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1593
Piston Height Measurement Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1595
Smoke Test (Air Intake System). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1598

Coolant Test Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1600

Deaeration Tank Cap Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1600
Cooling System Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1603
Coolant Over-Flow / Over-Temperature Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1607
Thermostat Operational Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1608
Engine Cooling Fan Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1609
Air Compressor Coolant Leak Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1611
Air Compressor Overflow Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1613
Combustion in Cooling System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1614
On-Engine EGR Cooler Leak Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1616
Instrument Cluster Temperature Gauge Validation Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1619

Engine Oil Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1621

Oil Cooler Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1621
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1303

Oil Pressure Verification Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1625

Instrument Cluster Engine Oil Pressure Gauge Validation Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1628

Engine System Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1631

Fuel System Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1631
Fuel Quality Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1632
Fuel Level Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1634
Engine Oil Level and Quality Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1635
Coolant Level Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1637
Coolant Quality Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1638
Coolant in Exhaust Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1639
Interstage Cooler (ISC) Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1640
Coolant Leak Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1643
Coolant To Intake Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1644
Charge Air Cooler Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1646
Intake Air Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1648
Front Gear Train Coolant Leak Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1650
Exhaust and Aftertreatment System Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1651
Diesel Particulate Filter (DPF) Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1653
Diesel Oxidation Catalyst (DOC) Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1656
Coolant to Engine Oil Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1658
Oil Pressure Regulator Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1659
Cylinder Sleeve Cavitation and Crack Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1661
Oil and Crankcase Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1662
High-Pressure (HP) Turbocharger Radial Play Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1665
Batteries and Electrical System Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1666

Aftertreatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1671
Snap Acceleration Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1671
Downstream Injection System Operation Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1672
1304 2 ENGINE SYSTEM TESTS AND INSPECTIONS
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1305

Navistar® Engine Diagnostics Procedures

CPA Snapshot Viewer

Overview
This procedure will guide technicians on how to upload and analyze a recorded snapshot using Cylinder
Performance Analyzer (CPA) Snapshot Viewer (SSV).

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Cylinder Performance Analyzer software
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Equipment Condition
None

Procedure
1. Key ON Engine OFF (KOEO).
2. Connect EST to vehicle Diagnostic Connector. (page 1345).
3. Log in to Navistar® Engine Diagnostics.

Figure 394 Navistar® Engine Diagnostics Menu

4. Start CPA software in Navistar® Engine Diagnostics by selecting Tests > Cylinder Performance Analyzer.
1306 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 395 Information Text Fields

5. Fill in Dealer location, operator/technician Information and Customer Complaint text fields.
6. Verify Vehicle Data matches information in text fields, then select proceed.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1307

Figure 396 CPA Platform Category Selection

1. Navistar® Medium Duty Engine

7. Select Navistar® Medium Duty Engine (1).

1308 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 397 CPA Medium Duty Test Selection

1. Snapshot Viewer (SSV)

8. Select Snapshot Viewer (SSV) (1), then select “Launch Test”.

 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1309

Figure 398 Snapshot Viewer Folder Selection

1. Snapshot File Folder icon
2. Recorded Test file

9. Select Snapshot File folder icon (1), locate desired recorded test file (2) and click OK.
10. Under the Test Type List, select Medium Duty, select corresponding test type, then select “Analyze
Snapshot”.
NOTE: Selecting the incorrect Engine Type and Torque rating will produce false results.
1310 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 399 CPA Snapshot Viewer Data Analyzer

1. Error Name
2. Error Description
3. YELLOW curser
4. Numeric value

11. Analyze the data by clicking the fault under Error Name (1) and read the Error Description (2) for further
instruction if fault was found.
NOTE: YELLOW curser (3) can be adjusted and numeric value (4) will displayed.

Expected Outcome
Test will complete successfully and will automatically stop when necessary data has been recorded. Review
test results and return to step-based diagnostics.

Follow-on Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1311

Navistar® Engine Diagnostics Connection and Data Recording

Overview
Navistar® Engine Diagnostics is an Electronic Service Tool (EST) used to run Tests, Procedures, and to Program
features. It can also monitor and record signals from the Engine Control Module (ECM), Doser Control Unit
(DCU), and Aftertreatment Control Module (ACM).

Engine Auto-Detection
Pre 2007 engines can only Auto-Detect at Key-On, Engine-Off (KOEO). The only difference when connecting
with a running engine is most of the parameters will not load. You will notice lot of missing values in the Vehicle
Information window.

Connection (Sniffer)
This area will display all the modules communicating on the Public Controller Area Network (CAN) Network.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Equipment Condition
None
1312 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Test Setup

Figure 400 Navistar® Engine Diagnostics Home Screen

1. Key On, Engine Off (KOEO) will load signals and parameters.
2. Key On, Engine-Running (KOER) will load signals, but will not load parameters.
3. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector .
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1313

4. Start Navistar® Engine Diagnostics.

Figure 401 Engine Selection Window

NOTE: If Navistar® Engine Diagnostics displays the Engine selection window (Figure 401), it was unable
to Auto- Detect. The Engine Control Module (ECM) or the Public Controller Area Network (CAN) to the
Data Link connector maybe at fault.
1314 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Snapshot Recording Procedure:

Figure 402 Start Signal Recording

1. Click on the Start Logging Watched Signals button (Figure 402).

Figure 403 Stop Signal Recording

2. Click on the Stop Logging Watched Signals button (Figure 403) to stop the recording.

Figure 404 Snapshot folder

3. Snapshot recording will be saved in the Snapshot folder (Figure 404) located on your computers desktop.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1315

Snapshot Playback Procedure

Figure 405 Snapshot

1. Open previously recorded snapshot, Click on the Open Snapshot Recording File (Figure 405) from the
File Menu.
2. Select the desired recording you wish to open.
1316 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 406 Snapshot Recording Playback

3. Once the recording is open (Figure 406), you can select any signal you wish to show up in the graph.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1317

Diagnostic Trouble Code Overview

Beginning in 2010, a Diagnostic Trouble Code (DTC) consists of two parts: the Suspect Parameter Number
(SPN) and Failure Mode Indicator (FMI). The SPN identifies a component or system with a fault, and the FMI
identifies what that fault or condition is. And beginning in 2013, all heavy duty diesel engines must adhear to
Heavy Duty Onboard Diagnostic (HD-OBD) standards for fault code setting and clearing.

Figure 407 Fault Code Display

DTC Type:
The fault type, or fault status, will consist of one of the following: Pending, Active, or Previously Active. HD-OBD
software monitors the system many times during a drive cycle or trip. Continuously monitoring the system allows
for trouble codes to be viewed at different status levels. When a 2 trip failure is detected once, a freeze frame
is stored, and the code status is displayed as Pending. Malfunction Indicator Light (MIL) will be illuminate when
the failure is detected a second time, and the code status will change to Active. The code status will remain
Active until the 3 consecutive trips happen without a fault detected. After the three trips are completed, the MIL
will turn off and the code status will change to Previously Active. It will take 40 trips to remove the Previously
Active code and freeze frame from the vehicles history. If at any time during Previously Active status, the system
monitor detects a failure again, the code status will immediately change to Active and clearing process begins
again.

Pending DTC
Pending Diagnostic Trouble Codes (DTC)s are possible faults that were detected on the first trip. Pending
HD-OBD faults do not turn on the MIL.

Active DTC
There are 3 types of Active DTCs: Non HD-OBD faults, 1 trip and 2 trip HD-OBD.
• Active Non HD-OBD faults go active on the first trip and do not turn on the MIL. Non HD-OBD faults may
not illuminate any lamps or may illuminate the Red Stop Lamp (RSL) or Amber Warning Lamp (AWL). Non
HD-OBD faults require only require 1 trip without detecting the fault code to clear.
• Active HD-OBD 1 trip faults turn on the Malfunction Indicator Lamp (MIL) immediately when the fault is
detected. HD-OBD 1 Trip faults require a specific drive cycle to monitor for the fault code.
• Active HD-OBD 2 drive cycle faults turn on the MIL after detecting a fault on 2 consecutive drive cycles.
HD-OBD 2 Trip faults require a specific drive cycle to monitor for the fault code.
1318 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Previously Active DTC

Previously Active DTCs are historical Active faults that were detected in a previous trip. If the fault code is not
detected for 3 consecutive trips, the fault code status will change from Active to Previously Active. Previously
Active DTCs do not illuminate the MIL.

DTC Count
DTC Count logs the amount of times the fault was detected.

Freeze Frame
Freeze Frame data is a snapshot of the engines operating condition at the time the fault was detected.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1319

Check for DTCs

Navistar® Engine Diagnostics displays Diagnostic Trouble Codes (DTC) at the bottom of the screen.

Figure 408 DTC display

Procedure:
Navistar® Engine Diagnostics will update DTC status every 10 seconds and will check for DTCs as soon as the
Refresh DTC / Vehicle Events button (Figure 408) is pressed.
1320 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Session Files

Overview
Navistar® Engine Diagnostics has a variety of Sessions; Signal Monitoring, Engine Programming and Testing.
Tests and Procedures will automatically load pre-made default sessions. Technicians are not limited to using
pre-made default sessions. Sessions (Figure 409) can be built or modified, saved and loaded (Figure 410) at
any time. A saved session can be use to run a Test as long as the check mark is removed from the Load Test
Specific Session (Figure 411) before running the test.

Figure 409 Menu – Save Session

Figure 410 Menu – Load Session

 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1321

Figure 411 Menu – Load Test Specific Session

1322 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Hot Run Sensor Comparison Test

Purpose
Check for failed aftertreatment system temperature sensor.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B compliant supporting J1939 and J1708)
This test is not dependent on engine temperature.
1. Turn ignition switch to ON position.
2. Connect Electronic Service Tool (EST) with Navistar® Engine Diagnostics to vehicle’s diagnostic connector.

Figure 412 Default Session

1. Temperature tab 2. All Signals tab
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1323

3. Go to Default Session: Sessions > Default > Temperature tab.

WARNING:

To prevent personal injury or death, shift transmission to park or neutral, set parking
brake, and block wheels before doing diagnostic or service procedures.
4. Start and run engine at 1400 to 1500 rpm for 10 minutes.
5. Monitor the following signals in the All Signals tab:
Compare the following three signals:
• Diesel Oxidation Catalyst (DOC) Inlet Temperature
• Diesel Particulate Filter (DPF) Inlet Temperature
• DPF Outlet Temperature
After 10 minutes, if any of these three aftertreatment temperature sensors are not within 77°F (43°C) of each
other, diagnose appropriate sensor and / or circuit.
1324 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Obtain Vehicle Health Report

Overview
Connect Electronic Service Tool (EST) to vehicle and generate a Health Report of current vehicle information:
• Vehicle Identification Number (VIN) validation
• Vehicle mileage
• Engine hours
• Diagnostic Trouble Codes (DTC)
• Engine Control Module (ECM) calibration
• Fuel economy data

Special Tools
PocketMaxx™, EST with International Graphical User Interface, or International® EZ-Tech Launcher

Equipment Condition
None

Test Setup
None

Procedure
1. Key-On, Engine-Off (KOEO).
2. Connect interface cable between PocketMaxx™, EST, or EZ-tech Launcher and to vehicle Diagnostic
Connector (page 1345).
3. Use PocketMaxx™, EST, or EZ-tech Launcher to retrieve a vehicle Health Report.
4. Connect to internet and upload Health Report to International® Service Portal.
5. Verify Health Report is visible on International® Service Portal. Select: Write Up > Vehicle Information.

Expected Outcome
Current vehicle Health Report is viewable on International® Service Portal.

Follow-On Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1325

Programmable Features

Overview
Many features can be programmed into the Engine Control Module (ECM) to fit many different applications. To
make programming changes using Navistar® Engine Diagnostics, load the Programming session.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Equipment Condition
None
1326 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 413 Programmable Feature

Test Setup
1. Key-On, Engine-Off (KOEO)
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Log in to Navistar® Engine Diagnostics.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1327

Procedure

Figure 414 Select Parameters or Programming

1. Select Programming (Figure 414) from the Session drop-down menu.

• Select Parameters to view all Parameters
• Select Programming to view Parameters sorted into categories.
1328 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 415 Change Parameter Value

2. Click on the desired parameter value (Figure 415) to be changed.

Figure 416 Program Engine

3. Press the Program Engine Button (Figure 416).

Figure 417 Program Engine

4. Turn ignition Key-Off for 15 seconds, so new value change be saved into the module (Figure 417).
5. Turn Key-On.
6. Clear Diagnostic Trouble Code (DTC)s, if any.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1329

Expected Outcome
None

Follow-On Procedure
None
1330 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Record Snapshot of KOEO Data

Overview
Record Key-On, Engine-Off (KOEO) data to be referenced now, and in the future.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Equipment Condition
Do not crank or run engine for 3 minutes or more. This will allow Injection Control Pressure (ICP) to bleed off.

Test Setup
1. Key-On.
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Log in to Navistar® Engine Diagnostics.

Procedure
1. Select: Sessions > Default.
2. Cycle ignition Key Off, then On.
NOTE: Fuel pump will run for 10 seconds after the ignition key is cycled.
3. Select: Tools > Start Recording Snapshot.
4. Wiggle harness connections on the Under Valve Cover (UVC) harness for ICP connector, ICP harness, and
36-pin Engine Control Module (ECM) connector.
5. Select: Tools > Stop Recording Snapshot.

Expected Outcome
KOEO values will be within specification.

Follow-On Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1331

Onboard Filter Cleanliness Test (OBFCT)

Overview
An Onboard Filter Cleanliness Test (OBFCT) cleans the DPF while allowing monitoring of the the Aftertreatment
system.

WARNING:

To prevent personal injury or death, set parking brake, shift transmission to park or
neutral, and block wheels.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Equipment Condition
1. Regen Inhibit switch Off.
2. Engine Coolant Temperature above 122°F (50°C).
3. Accelerator Pedal Position (APP) 0% (pedal released).
4. Break switch released.
5. Parking break set.
6. Clutch switch released.

Test Setup
1. Key-On Engine-Off (KOEO).
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Log in to Navistar® Engine Diagnostics.

Procedure
1. Start engine and allow engine coolant temperature to reach above 158°F (70°C).
2. Perform KOER Standard Test.
3. Select KOER Aftertreatment Tests > Onboard Filter Cleanliness Test from Test drop down menu.
1332 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 418 DPF Regeneration Inhibitors

4. Verify DPF Regeneration Procedure entry conditions are met and DPF regeneration inhibitors (Figure 418)
are not inhibited.
If regen inhibitors are displayed as inhibited, refer to Check Regen Inhibitors (page 1333) table.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1333

Check Regen Inhibitors

Check Expected Results Comment
AFT Regen Inhibit - AESC Not Inhibited If inhibited, ensure auxiliary engine speed control
Active is disabled.
AFT Regen Inhibit - Not Inhibited If inhibited, ensure accelerator pedal is released,
Accelerator OFF Idle and there are no active fault codes for APP
sensor. Diagnose and repair active fault codes
before running DPF regeneration.
AFT Regen Inhibit - Clutch Not Inhibited If inhibited, ensure clutch pedal is released, and
Disengaged there are no active fault codes for clutch switch.
Diagnose and repair active fault codes before
running DPF regeneration.
AFT Regen Inhibit - Engine Not Inhibited If inhibited, run engine until Engine Coolant
Not Warmed UP Temperature (ECT1) is above 150°F (66°C)
AFT Regen Inhibit - Inhibit Not Inhibited If inhibited, ensure Regen Inhibit Switch is in OFF
Switch position and there are no active fault codes
with switch. Diagnose and repair active fault
codes before running DPF regeneration.
AFT Regen Inhibit - Park Not Inhibited If inhibited, ensure park brake is set.
Brake not Set
AFT Regen Inhibit - Service Not Inhibited If inhibited, ensure service brake is released.
Brake Active
AFT Regen Inhibit - System Not Inhibited if inhibited, ensure no active faults listed in DTC list.
Fault Active Diagnose and repair active fault codes before
running DPF regeneration.
AFT Regen Inhibit - Vehicle Not Inhibited If inhibited, ensure vehicle speed is 0 mph, and
Speed too High no active TOSS fault codes. Diagnose and
repair active fault codes before running DPF
regeneration.
AFT Regen Inhibit Status Not Inhibited If inhibited, ensure other regen inhibitors are
corrected and reading not inhibited.

5. Engine Speed will ramp up to increase exhaust flow through DPF. Procedure will run for 20 minutes and will
not display pass or fail results.

Expected Outcome
Exhaust temperature will rise and soot load will decrease.

Follow-On Procedure
None
1334 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Injector Coil End of Motion (CEOM) Reset Procedure

Overview
Injector Coil End Of Motion (CEOM) corrects aging effect of fuel injector on fuel quantity. Over time injectors
inject less fuel due to injectors wearing. CEOM measures this wear and adds fuel back in to make it work like
new. When a new injector is installed in the engine, CEOM should be reset so it does not add too much fuel to
the engine.
NOTE: Only reset CEOM of injector being replaced.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Equipment Condition
Key-On Engine-Off (KOEO)
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1335

Test Setup

Figure 419 Injector Reset

1. Key-On Engine-Off (KOEO).

2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Start Navistar® Engine Diagnostics.
1336 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Procedure

Figure 420 Menu – Select Procedure

1. Select Injector CEOM Reset (Figure 420) from the KOEO Procedures drop-down menu.

Figure 421 Injector reset panel

2. Only reset the injector (Figure 421) that was replaced to prevent any injection imbalance.

Expected Outcome
Results
• Not Properly Measured: Displayed after selected injector has been reset and vehicle needs to be run to set
new values.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1337

• Properly Measured: Displayed after engine has run long enough to calculate proper fuel quantity for the
new injector.
1338 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Injector Coking Accumulation Reset

Overview
This procedure is used to reset the Engine Control Module’s (ECM) injector coking compensation strategy after
replacing injectors.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Equipment Condition
None.

Test Setup
1. Key-On Engine-Off (KOEO).
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Start and log in to Navistar® Engine Diagnostics.

Procedure

Figure 422 Sessions Menu

1. Go to Sessions > Programming.

2. Click on Service Interval tab.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1339

Figure 423 Coking Accumulation Parameters

3. Change value of 63001 Mode 1: Time factor for coking accumulation, 63011 Mode 2: Time factor for coking
accumulation, 63021 Mode 3: Time factor for coking accumulation to zero.

Figure 424 Program Engine Button

4. Click Program Engine Button.

5. When programming is successful, turn Key OFF for minimum of 30 seconds.
1340 2 ENGINE SYSTEM TESTS AND INSPECTIONS

6. Turn Key ON.

7. Clear any Diagnostic Trouble Codes (DTCs).

Expected Outcome
Engine will program successfully and the injector coking accumulation will reset.

Follow-On Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1341

Fuel Pressure Adaptation Reset

Overview
Engine Control Module (ECM) maintains reliability of Fuel Rail Pressure (FRP) system as parts age by storing
Fuel Pressure Adaptation (FPA) values.When any fuel system part is replaced: [Engine Injection Pressure
Regulator (IPR) valve, Injection Control Pressure (ICP) sensor, high-pressure pump, high-pressure rail, or ECM],
this parameter must be reset.
NOTE: For vehicles equipped with a 405HP MaxxForce 10, the Fuel Pressure Adaptation Reset must be
performed by a Navistar dealer with the assistance of Navistar Technician Services. PP99502 is not available
and cannot be programmed by any access level of NED users on vehicles with a 405HP calibration.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (J1939 - compliant)

Equipment Condition
One of the following components was replaced:
1. Engine Injection Control Pressure Regulator (IPR)
2. Injection Control Pressure (ICP) sensor
3. High-pressure pump
4. High-pressure rail
5. Engine Control Module (ECM)
1342 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 425 Fuel Pressure Adaptation Reset Screen

Test Setup
1. Key-On, Engine-Off (KOEO).
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Start Navistar® Engine Diagnostics.

Procedure
1. Replace failed part.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1343

Figure 426 Fuel Pressure Adaptation Rest Drop-Down Menu

2. Select Fuel Pressure Adaptation Reset from KOEO Procedure (Figure 426) drop down menu.

Figure 427 Reset Button

3. Press Fuel Pressure Adaptation Reset button (Figure 427).

Figure 428 Example of on-screen Instructions

4. Follow on-screen instructions (Figure 428).

5. For vehicles equipped with a 405HP MaxxForce 10, the Fuel Pressure Adaptation Reset must be performed
by a Navistar dealer with the assistance of Navistar Technician Services. PP99502 is not available and
cannot be programmed by any access level of NED users on vehicles with a 405HP calibration.

Follow-On Procedure
None
1344 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Intermittent or Inactive Fault Diagnostic Procedure

Overview
Use this test to diagnose inactive and/or intermittent faults. Inactive and/or intermittent faults are currently
healing, previously active, or inactive.
NOTE: For component faults that are pending or active, follow specific step based diagnostics for fault.
NOTE: Permanent faults are historic faults and are used for reporting purposes only. They should never be
treated as a current issue or used for diagnostics.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• J1939–compliant interface cable

Equipment Condition
None

Test Setup
1. Key-On, Engine-Off (KOEO).
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Log in to Navistar® Engine Diagnostics.

Procedure
1. Verify health report was saved. Clear fault codes.
2. Perform Continuous Monitor Test (page 1361)and view voltage signal for suspect sensor.
• The Continuous Monitor Test will have you watch for voltage signal spikes while wiggling affected
harness and connections.
• A voltage spike while performing continuous monitor wiggle test indicates a damaged harness and/or
connector pin.
NOTE: During continuous monitor wiggle test, if a fault code sets (high or low), voltage will latch high or low. To
continue performing continuous monitor wiggle test, faults will need to be cleared.
3. If a voltage spike or fault occurs during continuous monitor wiggle test start from the point the voltage spike
occurred and inspect harness for rubbing, and inspect nearby connectors for pin damage, corrosion, fretting,
etc.

Expected Outcome
The source of the intermittent / inactive fault will be isolated.

Follow-On Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1345

Connecting EST with Navistar® Engine Diagnostics Software to Engine

Interface Device Selection
To connect Electronic Service Tool (EST) with Navistar® Engine Diagnostics to an engine, an interface cable
(RP1210B compliant supporting J1939 and J1708) must be connected between EST and vehicle diagnostic
connector. The vehicle diagnostic connector is located inside the vehicle cab, above the clutch pedal.
1. Using Interface cable, connect EST (Electronic Service Tool) to vehicle’s diagnostic connector.
2. Start Navistar® Engine Diagnostics.

Figure 429 Com Link Selection Drop Down Menu

3. Select: Tools > Com Link (Figure 429).

1346 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 430 Com Link Activation Drop Down Menu

4. Activate Com Link (Figure 430) for interface cable connection.

If Navistar® Engine Diagnostics fails to autoconnect, use the following procedure:
5. Select: Tools > Select Com Link (Figure 429).
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1347

6. Select cable / interface device.

a. NEXIQ Technologies USB-Link
— USB-Link
• J1939
• J1708
• KWP2000
— Bluetooth USB-Link
• J1939
• J1708
• KWP2000
— USB-Link ATEC 160–Baud
• J1939
• J1708
• KWP2000
— BT USB-Link ATEC 160–Baud
• J1939
• J1708
• KWP2000
NOTE: If software is still unable to connect, see troubleshooting documentation provided for specific interface
cable (provided from cable manufacturer).

If cable is not at fault, see J1939 Data Link Error (ECM unable to transmit) (page 518) .
1348 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Connecting Navistar® Engine Diagnostics

1. Turn ignition switch to ON. Do not start engine.
2. Using interface cable, connect EST to vehicle’s diagnostic connector.
3. Start Navistar® Engine Diagnostics. After starting Navistar® Engine Diagnostics and selecting appropriate
interface device, (Interface Device Selection) (page 1345), a detection process will begin and should connect
automatically.
NOTE: If Navistar® Engine Diagnostics cannot detect Engine Serial Number (ESN), then it may be necessary
for user to select engine by clicking on Select Engine from File drop-down menu. Then select engine from
pop-up box.

Figure 431 ECM Connected Icon

NOTE: If software has connected to the ECM, active signals will populate startup screen, and ECM
connected icon in bottom right corner will show connected.

Figure 432 ECM Disconnected Icon

NOTE: When software is unable to connect to ECM, signals and vehicle information will not be displayed,
and ECM disconnected icon in bottom right corner will show disconnected.

If software is unable to connect to ECM, go to Interface Device Selection (page 1345) section, above.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1349

Pinpoint Diagnostic Graphic Legend

This defines the graphic depictions of tools required for Pin Point Tests in the Fault Code Diagnostics section of
this manual.

Figure 433 Breakout Harness

1350 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 434 ZTSE4498 – 3–Banana Plug Harness

 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1351

Figure 435 ZTSE4497 — 500 Ohm Resistor

1352 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 436 Ohm Meter

 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1353

Figure 437 Volt Meter

1354 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 438 ECM (Engine Control Module) 180 Pin Breakout Harness Overlay
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1355

Figure 439 ACM (Aftertreatment Control Module) 180 Pin Breakout Harness Overlay
1356 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 440 Battery

 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1357

Tests
KOEO Tests
KOEO Standard Test

Overview
The Key-On, Engine-Off (KOEO) Standard Test will command Engine Control Module (ECM) actuators to their
high state and low state. This test must be run before running other KOEO Tests: Output State Test High, Low,
and Intake Air Heater Test.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Equipment Condition
None

Test Setup
1. Key-On, Engine-Off (KOEO).
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Start and log in to Navistar® Engine Diagnostics.

Procedure

Figure 441 Menu — Select Test

1. Select: Tests > KOEO Tests > Standard Test. (Figure 441).
NOTE: This test does not display pass or fail results and will display test complete when finished.
1358 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 442 KOEO Standard Test Complete

Expected Outcome
Test will complete without fault codes setting or problems occurring.

Follow-On Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1359

Output State High or Low

Overview
The Key-On, Engine-Off (KOEO) Output State Test High or Low will command actuators to their high or low
position. This test allows users to diagnose actuator movement by commanding actuators high or low and
monitoring signals in Navistar® Engine Diagnostics or using a multimeter to measure circuits and also to visually
monitor movement on some actuators. This test does not display pass or fail results and user will need to cancel
test before running any other test. The KOEO Standard Test must be performed before this test is allowed to
run.

Actuators that cycle during this test:

• Exhaust Gas Recirculation (EGR) Valve
• Engine Throttle Valve Position (ETP)
• Turbocharger 2 Wastegate Control (TC2WC) solenoid
• Engine Injection Control Pressure Regulator (IPR)
• Electric Fuel Pump (EFP)

Special Tools
• Digital Multimeter (DMM)
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Equipment Condition
None

Test Setup
1. Key-On, Engine-Off (KOEO).
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Log in to Navistar® Engine Diagnostics

Procedure
1. Perform KOEO Standard Test (page 1357).
1360 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 443 Menu – Select Test

Figure 444 Menu – Select Test

2. Once test is complete, select Tests > KOEO Tests > Output State High Test (Figure 444) or select Tests >
KOEO Tests > Output State Low Test (Figure 443).
3. Monitor signals, verify visual movement or make measurements as needed.
4. Allow test to run for a minimum of 30 seconds before stopping testing.

Expected Outcome
Actuators will cycle to their high or low state as commanded; signals will show the command to high or low state
and remain steady while test is active.

Follow-On Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1361

Continuous Monitor Test

Overview
The Continuous Monitoring – Intermittent Sensor Diagnostics test is used to detect sensor intermittent faults.
During this test, sensor voltages are continuously monitored. This test provides a graphical view of all signals
and allows the technician to detect intermittent spiking or monetary loss of signal. Perform this test while wiggling
connectors, wiring, and harnesses of the suspected faulty component.
NOTE: A sensor fault that goes out of range high or low will cause the voltage signal to display Error. The
Continuous Monitor Test will force all sensor voltage to display actual voltages.
NOTE: This test does not work on early calibrations. Out of Range HIGH and Out of Range LOW faults will
display during this test until early 2015.

Figure 445 Continuous Monitor Test Home Screen

1362 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Position Sensor Voltages are Monitored:

• Accelerator Pedal Position 1
• Accelerator Pedal Position 2
• Engine Throttle Position
• Remote Pedal Sensor (If equipped)

Pressure Sensor Voltages are Monitored:

• Aftertreatment (AFT) Fuel Pressure 1
• AFT Fuel Pressure 2
• Barometric Absolute Pressure
• Diesel Fuel Particulate (DPF) Differential Pressure
• DPF Outlet Pressure
• Engine Control Brake Pressure
• Engine Oil Pressure
• Exhaust Back Pressure
• Fuel Delivery Pressure
• Injection Control Pressure
• Intake Manifold Pressure
• Turbocharger 2 (TC2) Compressor Outlet Pressure

Temperature Sensor Voltages are Monitored:

• AFT Fuel Temperature
• Ambient Air Temperature
• Engine Coolant Temperature 1
• Engine Oil Temperature
• Exhaust Gas Temperature
• Intake Air Temperature
• Intake Manifold Temperature

Other Voltage Signals Monitored:

Switched Battery

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Equipment Condition
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1363

Test Setup
1. Key-On, Engine-Off (KOEO).
2. Connect Electronic Service Tool (EST) to Vehicle Diagnostic Connector (page 1345).
3. Log in to Navistar® Engine Diagnostics.

Procedure

Figure 446 Menu – Select Test

1. Select: Tests > KOEO Tests > Continuous Monitor Test (Figure 446) from drop down menu.

Figure 447 Voltage Spike

2. Monitor suspect voltage signal while wiggling the wiring harness and connectors. If the circuit is interrupted,
the signal will spike.

Figure 448 Stop Test Button

1364 2 ENGINE SYSTEM TESTS AND INSPECTIONS

3. Test will run until cancelled by pressing the Stop test button (Figure 448).

Follow-on Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1365

Injector Test

Overview
Verify all 6 injectors are being electronically activated by the Engine Control Module (ECM). This test will activate
all injectors at the same time, then active each individual injector in order (1, 2, 3, 4, 5 and 6) for 2 seconds with
a 1 second pause in between. This is an audible test only (audible buzz sound) and will not activate any other
codes.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Equipment Condition
None

Test Setup
1. Key-On, Engine-Off (KOEO).
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Log in to Navistar® Engine Diagnostics.

Procedure
NOTE: The Key-On, Engine-Off (KOEO) Standard Test must be run before running this test.

Figure 449 Menu — Select Test

1. Select: Tests > KOEO Tests > Standard Test (Figure 449) .
1366 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 450 Menu – Select Test

NOTE: This is an audible test only and does not load a special session.
2. Select: Injector Test (Figure 450) from drop-down menu.
3. Check fuel injectors for the following while test is active:
• Do not rapidly cycle (buzz)
• Make a single or few “clicks” and stop
• Are faint in sound as compared to other 5 injectors
• Exhibit an irregular or inconsistent rhythm
• Are activated out of order (correct order is 1 through 6 sequentially)
If any of the above conditions are present, go to next step.
If none of the above conditions are present, end diagnostic steps.

Figure 451 Menu – Test Complete

NOTE: This test does not display pass or fail results and will display test complete (Figure 451) when finished.
4. Remove valve cover (see Engine Service Manual).
5. Unplug first injector of suspect bank.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1367

6. Cycle ignition key, and then select Injector Test from drop-down menu to repeat test.
• If two remaining injectors in suspect bank buzz, the unplugged injector has failed.
• If no injectors buzz, go to next step.
7. Reconnect first injector and disconnect next injector in same bank.
8. Cycle key, and then select Injector Test from drop-down menu to repeat test.
• Repeat steps 7 through 8 until failed injector is found.

Expected Outcome
Test will complete successfully, and audible buzz will be heard from each injector.

Follow-on Procedure
None
1368 2 ENGINE SYSTEM TESTS AND INSPECTIONS

KOEO DCU Actuator Test – Actuator Output High and Low Diagnostics

Overview
The Key-On, Engine Off (KOEO) Doser Control Unit (DCU) Actuator test will enable the technician to cycle any
actuator high or low. Some actuators have variable positions. A technician can use a Digital Multimeter (DMM) to
measure changes in voltage or duty cycle, or visually monitor actuator movement while actuator is commanded.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics.
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Figure 452 Actuator Test

Test Setup
1. Key-On, Engine-Off (KOEO).
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1369

2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Start Navistar® Engine Diagnostics.

Procedure

Figure 453 Menu – Select Test

1. Select: Tests > KOEO Aftertreatment Tests > Actuator > DCU Actuators (Figure 453).

Figure 454 Actuator Control Panel

1. Actuator selection
2. Actuator Delay Start Time
3. Actuator Duty Cycle control

2. Select desired actuator from control panel (Figure 454).

3. Steps 3-5 refer to Actuator Control Panel (Figure 454).
4. Adjust amount of duty cycle you wish to control.
5. Adjust delay test start time, if a delay start time is desired.
1370 2 ENGINE SYSTEM TESTS AND INSPECTIONS

6. Press the Start Test button to begin the test.

Figure 455 Test Complete

7. Actuator will cycle to commanded position for 5 seconds, before the Test Completed Successful (Figure
455) notification is displayed.
NOTE: This test does not display pass or fail results.

Expected Outcome
The test will complete successfully.

Follow-On Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1371

Relative Compression Test

Overview
Measures cylinder balance to determine cylinder integrity. Test results are presented in graphical or numerical
displays. Graphs or numbers should be approximately the same, indicating well balanced and equal cylinders.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Figure 456 Relative Compression Test

Test Setup
1. Key-On, Engine-Off (KOEO).
1372 2 ENGINE SYSTEM TESTS AND INSPECTIONS

2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Log in to Navistar® Engine Diagnostics.
4. Batteries must be charged (Use Battery charger if necessary).

Procedure

Figure 457 Menu — Select Test

1. Select: Tests > KOEO Tests > Relative Compression Test (Figure 457).

Figure 458 Test Instructions Popup Panel

2. Follow the instructions on the popup test panel (Figure 458) .

 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1373

Figure 459 Test Results

3. Results are measured on the down travel of each cylinder's power stroke (Figure 459). A cylinder with low
compression will be significantly lower then the others.

Figure 460 Test Complete

4. When test is complete (Figure 460), review test results.

Expected Outcome
Test will complete successfully

Follow-On Procedure
None
1374 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Engine Cranking Test

Overview
Monitors engine systems as engine is cranked to determine if systems are able to meet minimum starting
requirements.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface Cable (RP1210B compliant supporting J1939 and J1708)

Equipment Condition
None

Test Setup
1. Key On, Engine Off (KOEO).
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Log in to Navistar® Engine Diagnostics.

Procedure
1. Select Sessions > Default.
2. Select Start Recording Snapshot.
3. Crank engine for 10 seconds.
4. Select Stop Recording Snapshot.
5. Verify the following signals meet specification:
Signals:
• Diesel Particulate Filter Differential Pressure (DPFDP)
• Engine Speed (RPM)
• Exhaust Back Pressure (EBP)
• Exhaust Gas Recirculation (EGR) Position
• Fuel Delivery Pressure (FDP)
• Injection Control Pressure (ICP)
• Injection Pressure Regulator (IPR) Control (Ctrl)
• Turbocharger 1 Turbine Outlet Pressure (TC1TOP)
• Switch Battery (SWBAT)

Expected Outcome
All signal values meet specification.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1375

Follow-on Procedure
None
1376 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Engine Running Tests

Air Management Test

Overview
Evaluates air management system by monitoring effects Exhaust Gas Recirculation (EGR) valve position
changes have on Intake Manifold Pressure (IMP). IMP is normally 2 psi (14 kPa) or more during Air
Management Test engine ramp up (EGR valve closed). If the air management system is not operating
properly, IMP and Mass Air Flow (MAF) Mean Value will not change properly when changes in EGR valve
position are commanded. When this occurs, excess soot will be generated causing frequent regeneration of
the aftertreatment system. The recorded snapshot of the Air Management Test can also be analyzed using
Cylinder Performance Analyzer (CPA) Snapshot Viewer (SSV).

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Equipment Conditions
None

Test Setup
1. Key-On, Engine-Running (KOER).
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Log in to Navistar® Engine Diagnostics.
4. Run engine until Engine Coolant Temperature 1 (ECT1) is above 158°F (70°C).

Procedure
1. Select: Tests > KOER Tests > Standard Test (page 1380).
2. After Standard Test is complete, select: Tests > KOER Tests > Air Management Test.
3. Select: Start Recording Snapshot.
4. After Air Management Test is complete select: Stop Recording Snapshot.
5. If CPA software is available, go to CPA Snapshot Viewer (page 1305) to use SSV to analyze the snapshot.
6. Select: Open Snapshot Recording File.
7. Select and Open Air Management Test previously recorded.
8. Select the Graph box for: EGR position, Intake Manifold Pressure, and MAF Mean Value.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1377

Figure 461 Air Management System Graph (Bad)

1. Intake Manifold Pressure (psi) 2. MAF Mean Value (mg) 3. EGR Position (percent)

NOTE: EGR valve position will never read less than 35% and is considered closed.
9. Compare Air Management System Graph (Bad) (Figure 461) and Air Management System Graph (Good)
(Figure 462) with recorded snapshot.
10. Determine if Intake Manifold Pressure (1) and MAF Mean Value (2) drop when the EGR valve is commanded
open. In Air Management System Graph (Bad) Intake Manifold Pressure and MAF Mean Value do not drop
when the EGR valve is commanded open.
1378 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 462 Air Management System Graph (Good)

1. EGR Position (percent)
2. MAF Mean Value (mg)
3. Intake Manifold Pressure (psi)
4. MAF Mean Value high point (EGRV closed)
5. Intake Manifold Pressure (EGRV closed)
6. IMP spike (EGRV closed to open)
7. MAF Mean Value low point (EGRV open)

11. Determine if intake manifold pressure is appropriate. Is Intake Manifold Pressure (EGRV closed) (5) 2 psi or
more, and is IMP spike (EGRV closed to open) (6) 1.5 psi or more above Intake Manifold Pressure (EGRV
closed)?
12. Determine vehicles Rated Power listed in Navistar® Engine Diagnostics Vehicle Information tab on the default
page.
13. Determine if MAF Mean Value difference is within specification: subtract MAF Mean Value low point (EGRV
open) (7) from MAF Mean Value high point (EGRV closed) (4) and compare to MAF Mean Value Difference
table.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1379

MAF Mean Value Difference

Engine MAF Mean Value Difference (mg)
®
MaxxForce DT (below 245 hp) 690 or greater
®
MaxxForce DT (245 hp and above) 740 or greater
MaxxForce® 9 and 10 850 or greater

Expected Outcome
Determine if IMP and MAF Mean Value change appropriately when EGR valve is commanded open.
A. Determine if Intake Manifold Pressure is appropriate.
B. Determine if MAF Mean Value Difference is within specification.

Follow-On Procedure
None
1380 2 ENGINE SYSTEM TESTS AND INSPECTIONS

KOER Standard Test

Overview
The Key-On, Engine-Running (KOER) Standard Test verifies performance of the Injection Control Pressure
(ICP) System. During this test, engine speed increases to 1500 RPM and the Engine Control Module (ECM)
commands the Injection Pressure Regulator (IPR) valve to control ICP. The ECM will command 4000 psi, then
1000 psi thru the ICP Desired signal. The ECM monitors the ICP sensor (Actual pressure) to validate the
system’s ability to meet ICP desired.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• J1939-Compliant Interface Cable

Equipment Conditions
1. Engine speed at low idle (700 rpm)
2. Engine Coolant Temperature 1 (above 158°F 70°C)
3. Vehicle Not Moving
4. Accelerator Pedal Position (0%)
5. Brake Pedal (Released)
6. Clutch Pedal (Released)
7. Engine brake switch (OFF)
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1381

Test Setup

Figure 463 KOER Standard Test

1. Key On, Engine Running (KOER).

2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Log in to Navistar® Engine Diagnostics.
4. Start engine and warm Engine Coolant Temperature (ECT) above 158°F (70°C).
1382 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Procedure

Figure 464 Menu — Select Test

1. Select: Tests > KOER Tests > Standard Test (Figure 464).

Figure 465 Test Complete

2. This test does not display pass or fail results and will display test complete (Figure 465) when finished.

Expected Outcome
Test will complete successfully.

Follow-On Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1383

Low to High Idle Test

Overview
This test is used to validate engine performance throughout its full rpm range. By monitoring specific signals,
this test helps identify which systems are not performing as expected. Using information gathered, it assists
with further diagnostics.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Equipment Condition
None

Test Setup
1. Key On, Engine Off (KOEO).
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Log in to Navistar® Engine Diagnostics.

Procedure
1. Select Sessions > Default.
2. Press accelerator pedal to floor while monitoring the Accelerator Pedal Position (APP) signal value.
3. If APP signal consistently reads from 0 to approximately 99.6% continue test. If APP system is not consistent,
repair APP system as needed before continuing test.
4. In Navistar® Engine Diagnostics software, select Start Recording.
5. Start engine and idle for 20 seconds.
6. Press and hold accelerator pedal to floor for 20 seconds while listening and feeling for engine problems
such as:
• Engine does not accelerate smoothly
• Imbalance or vibrations
• Cylinders not firing or cylinders misfiring
7. Return to low idle.
8. Select Stop Recording and check the following signals against specifications:
• Fuel Delivery Pressure (FDP)
• Injection Control Pressure (ICP)
• Exhaust Back Pressure (EBP)
• Intake Manifold Pressure (IMP)
• Diesel Particulate Filter Differential Pressure (DPFDP)
9. If any signal does not meet specifications, diagnose that system in appropriate section or manual.
1384 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Expected Outcome
Engine will accelerate smoothly, all signals will be within specifications, and no imbalance or misfire will be
detected.

Follow-On Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1385

KOER DSI System Test

Overview
The Key-On, Engine-Running (KOER) Down Stream Injection (DSI) System Test can be used to validate
performance of the DSI system.

Figure 466 KOER DSI System Test

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant, supporting J1939 and J1708)
1386 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Equipment Conditions
NOTE: The conditions below are shown how they should be displayed on Navistar® Engine Diagnostics screen.
1. Engine speed (below 700 RPM).
2. Engine speed (below 700 RPM).
3. Accelerator pedal position (0%).
4. Brake pedal (Release).
5. Clutch pedal (Release).

Test Setup
1. Key On, Engine Off (KOEO).
2. Connect Electronic Service Tool (EST) to Vehicle Diagnostic Connector (page 1345).
3. Start and log in to Navistar® Engine Diagnostics.

Procedure

Figure 467 Menu – Select Test

1. Select: KOER Aftertreatment Tests > DSI System Test (Figure 467).
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1387

Figure 468 Test Results

2. This test will help validate DSI system performance (Figure 468), by cycling the AFT Fuel Shutoff (AFTFSO)
and Aftertreatment Fuel Doser (AFTFD), while monitoring effects on Aftertreatment Fuel Pressure 1
(AFTFP1) and Aftertreatment Fuel Pressure 2 (AFTFP2) sensors.

Expected Outcome
Determine if DSI systems are operating properly.

Follow-On Procedure
None
1388 2 ENGINE SYSTEM TESTS AND INSPECTIONS

KOER DSI Deaeration Procedure

Overview
The Key-On, Engine-Running (KOER) Down Stream Injection (DSI) Deaeration Procedure can be used to purge
air from the system after the fuel system was opened from a previous repair.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Equipment Condition
NOTE: The conditions below are shown as they should be displayed on the Navistar® Engine Diagnostics screen.
1. Engine speed (below 700 RPM)
2. Vehicle not moving
3. Accelerator Pedal Position (APP) (0%)
4. Brake pedal released
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1389

5. Clutch pedal released

Figure 469 DSI System Deaeration Procedure

Test Setup
1. Key-On, Engine-Off (KOEO).
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Key-On. Log in to Navistar® Engine Diagnostics.
1390 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Procedure

Figure 470 Menu – Select Procedure

1. Select: KOER Aftertreatment Procedures > DSI System De-Aeration (Figure 470) .
2. The procedure will cycle the AFT Fuel Shutoff (AFTFSO) and Aftertreatment Fuel Doser (AFTFD) to purge
air from the system.

Figure 471 Test Complete

3. This procedure does not display pass or fail results and will display Test Completed, Successful (Figure 471)
when finished.

Expected Outcome
Key-On, Engine-Running (KOER) test will complete without any problems occurring.

Follow-On Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1391

Connecting CPA Tool for HPOP Testing

Overview
The Cylinder Performance Analyzer (CPA) Tool is a four-channel oscilloscope used to detect faults in various
electronically controlled components. This section describes connecting the CPA Tool for High-Pressure Oil
Pump (HPOP) system testing.

WARNING:

To prevent damage to property, personal injury and / or death, never allow metal sensor
tee harness connectors (BNC Connector) or CPA tool ports to contact metal, other sensor
tee harness connectors, or ground.

CAUTION:

To prevent damage to property, do not store CPA tool in the engine compartment.
Exterior damage may adversely affect tool functionality and cause flawed test results.

CAUTION:

To prevent damage to property, secure Cylinder Performance Analyzer (CPA) tool and
test cables away from hot or moving parts and sources of radio frequency interference
with cable ties while performing tests.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics and CPA software (V7.1.8.12 or higher).
• Interface cable (RP1210B-compliant supporting J1939 and J1708)
• Cylinder Performance Analyzer (CPA) Tool Kit 12-999-01
• Engine Oil Temperature (EOT) Breakout Harness ZTSE4602
• IPR Blockoff Adapter with Integrated ICP Sensor Kit 12-999-01-07
• IPR Valve Breakout Harness 12-800-02 or ZTSE4484
• IPR Valve Socket 12-800-01

Equipment Condition
Depending on truck model, it may be necessary to remove the following to properly connect and safely route
test cables into cab.
1. Driverside inner fender
2. Quarter fenders
3. Passenger-side inner fender
1392 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Test 1: IPR ECM Powered Test Setup

Figure 472 Camshaft Position (CMP) Sensor

1. Yellow Cam Sensor Harness 2. CMP Sensor
12-999-01-02

1. Connect CPA Module 12-999-01-01 to Electronic Service Tool (EST) using supplied USB cable.
2. Disconnect engine harness from CMP sensor (2) and install Yellow Cam Sensor Harness (1) between
CMP sensor and engine harness.

WARNING:

To prevent damage to property, personal injury and / or death, do not drive vehicle with
CPA Tool attached unless CPA cables are attached to CPA Tool. Doing so may cause the
engine to stall without warning.

WARNING:
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1393

To prevent damage to property, personal injury and / or death, do not disturb, unplug,
or ground BNC connectors while vehicle is moving. Doing so may cause engine to stall
without warning.

WARNING:

To prevent damage to property, personal injury and / or death, never allow BNC
connectors or metal CPA ports to contact metal or ground. Doing so may cause engine
to stall without warning.

Figure 473 CPA Tool

1. CPA extension harness
12-999-01-05
2. CPA Module CAM SENSOR
Port
3. CPA Module 12-999-01-01

3. If equipped, turn both CPA Module signal adjustment knobs as far clockwise as possible.
4. Connect Yellow Cam Sensor Harness 2-pin connector to CPA module CAM SENSOR port (2) of CPA
Module (3) using CPA extension harness 12-999-01-05 (1). Route cable safely and securely behind
main drive belt on driver-side of vehicle to prevent damage.
5. Disconnect engine harness from Engine Oil Temperature (EOT) sensor and install EOT Breakout
Harness ZTSE4602 between engine harness and EOT sensor.
6. Connect 2-pin CPA banana jack Breakout Harness 12-999-01-06 to EOT Breakout Harness (EOT pin-1
to black end of banana jack and EOT pin-2 to red end of banana jack.)
7. Connect CPA Extension Harness to 2-pin CPA banana jack.
1394 2 ENGINE SYSTEM TESTS AND INSPECTIONS

8. Connect Extension Harness to CRANK SENSOR port on CPA Module.

9. Disconnect engine harness from Engine Oil Pressure (EOP) sensor connector. When disconnecting
EOP sensor, WHITE plastic lock from engine harness may separate from harness and lodge in EOP
sensor. If breakout harness will not connect to EOP sensor, inspect sensor for plastic lock and remove
it.

Figure 474 High-Pressure Oil Pump (HPOP) Test Breakout Harness 12-999-01-04
1. Engine Oil Pressure (EOP)
Signal to CPA Extension
Harness (BLUE)
2. Connection to EOP Sensor
Engine Harness Connector
3. ICP UCV signal to CPA
extension harness (RED)
4. Connection to UVC Connector
(EPA 2010 MaxxForce® DT, 9
and 10, N9, and N10)
5. Connection to UVC Connector
(EPA 2007 MaxxForce® DT, 9
and 10)
6. Connection to Test ICP Sensor
(only used during high-pressure
pump dead-head test)
7. Connection to EOP Sensor
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1395

10. Connect HPOP Test Breakout harness between EOP Sensor (7) and EOP engine harness connector
(2).
11. Use Extension Harness 12-999-01-05 to connect EOP signal cable (BLUE) (1) to SENSOR 4 port of
CPA Tool.

Figure 475 ICP UVC Connector (BEIGE)

1. ICP UVC Engine Harness
Connector (BEIGE)
2. Injection Control Pressure
(ICP) Under valve Cover (UVC)
Connector

12. Disconnect BEIGE ICP UVC engine harness connector (1) from ICP UVC connector (2).
13. Connect HPOP Test Breakout Harness to IPC UVC connector (2) and leave engine harness (1)
disconnected.
1396 2 ENGINE SYSTEM TESTS AND INSPECTIONS

14. Use Extension Harness 12-999-01-05 to connect ICP UVC signal cable (RED) (3) to SENSOR 3 port
of CPA Tool.

Figure 476 Under Valve Cover (UVC) Connections

1. UVC Injector Connectors

15. Disconnect either remaining three IPC UVC injector connectors (1) or ECM 36-pin connector, whichever
is more accessible by truck configuration. Injectors will remain disconnected for HPOP tests.
16. Return to CPA High-Pressure Oil Pump (HPOP) Test (page 1440) and continue testing.

Test 2: IPR Full Fielded Test Setup

1. Retain test setup from previous HPOP test and continue to Step 2.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1397

2. Disconnect engine harness from injection pressure regulator (IPR) valve.

Figure 477 IPR Breakout Harness ZTSE4484

Figure 478 IPR Breakout Harness 12-800-02

3. Compare IPR valve connector configuration to ZTSE4484 and 12-800-02 connector ends and select
appropriate breakout harness.
1398 2 ENGINE SYSTEM TESTS AND INSPECTIONS

4. Connect correct IPR Breakout Harness to IPR valve and leave engine harness disconnected.

CAUTION:

To prevent damage to property, do not leave IPR fully fielded for more than 5 minutes.

CAUTION:

To prevent damage to property, do not connect engine harness to IPR Breakout Tee.
5. Connect 12 volts and ground to IPR Breakout Harness.
6. Return to CPA High-Pressure Oil Pump (HPOP) Test (page 1440) and follow CPA tool on-screen
instructions to perform Test 2: IPR Full Fielded.

Test 3: IPR Blockoff Adaptor Installed Test Setup

1. Retain test setup from previous HPOP test and continue to Step 2.

Figure 479 IPR Valve Socket 12-800-01

 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1399

2. Use IPR Valve Socket to remove IPR valve.

3. Verify IPR Blockoff Adaptor O-ring and back-up seal are in good condition to avoid false results. Install
IPR Blockoff Adaptor with integrated ICP Sensor 12-999-01-07B into high-pressure oil pump (HPOP).
Leave IPR Blockoff Adaptor in HPOP for remaining HPOP test steps.
4. Connect IPR Blockoff Harness 12-999-01-07A (Green) between IPR Blockoff Adaptor and ICP sensor
connector on HPOP Test Breakout Harness.
5. Disconnect Extension Harness from EOP signal cable (Blue) 2–pin connector and connect it to IPR
Blockoff Harness 12-999-01-07A (GREEN) 2–pin connector. Leave Extension Harness connected to
SENSOR 4 port on CPA Module.
6. Return to CPA High-Pressure Oil Pump (HPOP) Test (page 1440) and follow CPA tool on-screen
instructions to perform Test 3: IPR Blockoff Adaptor Installed.

Test 4: Pump Deadhead Test Setup

1. Retain test setup from previous HPOP test and continue to Step 2.
2. Disconnect high-pressure oil hose from cylinder head.
1400 2 ENGINE SYSTEM TESTS AND INSPECTIONS

3. Verify Dead Head Plug O-ring is in good condition.

Figure 480 High-Pressure Oil Hose

1. High-pressure Oil Hose
2. Dead Head Plug 12-999-01-07C

4. Install Dead Head Plug (2) onto high-pressure oil hose (1).
• Oil leaks at high-pressure oil hose will cause test errors.
5. Return to CPA High-Pressure Oil Pump (HPOP) Test (page 1440) and follow CPA tool on-screen
instructions to perform Test 4: Pump Deadhead.

Expected Outcome
Cylinder Performance Analyzer (CPA) tool will be properly connected to perform HPOP testing.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1401

Follow-on Procedure
Perform CPA High-Pressure Oil Pump (HPOP) Test (page 1440).
1402 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Connecting CPA Tool for Misfire Diagnostics

Overview
Cylinder Performance Analyzer (CPA) Tool is a four-channel oscilloscope used to detect faults in various
electronically controlled components. This section describes connecting CPA Tool for misfire diagnostics
system testing.

WARNING:

To prevent damage to property, personal injury and / or death, never allow the metal
sensor tee harness connectors (BNC Connector) or the Cylinder Performance Analyzer
(CPA) tool ports to contact metal, other sensor tee harness connectors, or ground.

CAUTION:

To prevent property damage, do not store the CPA tool in the engine compartment. Any
exterior damage may adversely affect the functionality of the tool and cause flawed test
results.

CAUTION:

To prevent property damage, secure the Cylinder Performance Analyzer (CPA) tool
and test cables away from hot or moving parts and any sources of radio frequency
interference with cable ties while performing tests.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)
• Cylinder Performance Analyzer (CPA) Tool Kit 12-999-01

Equipment Condition
Depending on truck model, it may be necessary to remove the following to properly connect and safely route
test cables into cab.
1. Driverside inner fender
2. Quarter fenders
3. Passenger-side inner fender
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1403

Test Setup

Figure 481 Cylinder Performance Analyzer (CPA) Tool

1. Camshaft Position (CMP) 2. Crankshaft Position (CKP) 3. CPA BNC Connector
Sensor Tee Harness BNC Sensor Tee Harness BNC 4. CPA Tool (Most Current Version
Connector Connector does not have adjusting knobs)

1. Key-Off.
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
1404 2 ENGINE SYSTEM TESTS AND INSPECTIONS

3. Key-On Engine-Off (KOEO), log in to Navistar® Engine Diagnostics.

Figure 482 Camshaft Position Sensor 1

1. Camshaft Position (CMP)
Sensor Tee Harness
2. CMP Sensor

4. Connect Yellow Tee Harness 12-999-01-02 (1) between Camshaft Position (CMP) sensor (2) and engine
harness, making sure to tie it back from hot or moving parts.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1405

5. Securely connect metal end to connector on Cylinder Performance Analyzer (CPA) tool labeled Cam
Sensor.

Figure 483 Crankshaft Position Sensor

1. Crankshaft Position (CKP)
Sensor Tee Harness
2. CKP Sensor

6. Connect Black Tee Harness 12-999-01-03 (1) between Crankshaft Position (CKP) sensor (2) and engine
harness, making sure to tie it back from hot or moving parts.
7. Securely connect metal end to connector on CPA Tool labeled Crank Sensor.
8. Connect USB cable from CPA Tool to Electronic Service Tool (EST) with Navistar® Engine Diagnostics.
• Ensure light on CPA Tool (Figure 481) is flashing.
9. Recheck test cable connections and routing to ensure they do not come in contact with hot or moving
parts or radio frequency interference.

Expected Outcome
Cylinder Performance Analyzer (CPA) tool will be properly connected to perform misfire diagnostics.
1406 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Follow-on Procedure
Perform CPA misfire diagnostics.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1407

Injector Misfire Detection Cold Idle Test

Overview
Cylinder performance analyzer (CPA) injector misfire detection (IMD) cold idle test detects faults with cylinder
combustion during idle speed, and is usually performed if customer complaint includes a misfire during cold idle.
When required, IMD cold idle test should be performed before signal check.

Special Tools
• Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)
• Cylinder Performance Analyzer (CPA) Tool Kit 12-999-01

Equipment Condition
Depending on truck model, it may be necessary to remove the following to properly connect and safely route
test cables into cab.
1. Driverside inner fender
2. Quarter fenders
3. Passenger-side inner fender

Test Setup
1. Key Off.
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Key On Engine Off (KOEO). Log in to Navistar® Engine Diagnostics.
4. Connect Cylinder Performance Analyzer (CPA) (page 1402) tool for misfire diagnostics.

Figure 484 Navistar® Engine Diagnostics Menu

1408 2 ENGINE SYSTEM TESTS AND INSPECTIONS

5. Start CPA software in Navistar® Engine Diagnostics by selecting Tests > Cylinder Performance Analyzer.

Figure 485 Information Text Fields

6. Fill in Dealer location, operator/technician Information and Customer Complaint text fields.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1409

7. Verify Vehicle Data matches information in text fields, then select Proceed.

Figure 486 CPA Platform Category selection

1. Navistar® Medium Duty Engine
1410 2 ENGINE SYSTEM TESTS AND INSPECTIONS

8. Select Navistar® Medium Duty Engine (1).

Figure 487 CPA Medium Duty Test selection

1. Injector Misfire Detection (IMD)

9. Select Injector Misfire Detection (IMD) (1), then select “Launch Test”.

Figure 488 Test Description Text Fields

1. Detailed Test Description/Test
Comments Field
2. Brief Test Description Text Field
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1411

10. Enter information into Brief Test Description (2) and Detailed Test Description/Test Comments (1) text
fields.

Procedure

Figure 489 Test List

1. Select Cold Idle from Test List.

2. Start engine.
1412 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 490 Start Test Window

3. Click button on bottom left corner to Start Test.

4. Follow on screen instructions to complete test.
5. When End of Test text field appears, enter any final details about test.
6. Click Return button to return to Home screen and view test results.

Expected Outcome
Test will run successfully, return to step based diagnostics with test information, or continue Cylinder
Performance Analyzer (CPA) diagnostics as needed. Green cylinders indicate no defects were found; a red
cylinder indicates problem with that cylinder (may or may not be an injector); and light blue cylinders indicates
high engine speed fluctuations, but no problem with particular cylinder

Follow-on Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1413

Injector Misfire Detection Signal Check

Overview
Signal check ensures information from Crankshaft Position (CKP) sensor and Camshaft Position (CMP) sensor
are being read properly by the Cylinder Performance Analyzer (CPA) program and are not distorted. Signal
check must be performed before the full load to highway speed test, or any other test involving the vehicle being
driven. CPA software will only recognize, for a limited time, that Signal Check has been completed before it
resets and inhibits any test involving the vehicle being driven.

Special Tools
• Cylinder Performance Analyzer (CPA) Tool Kit 12-999-01
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Equipment Condition
Depending on truck model, it may be necessary to remove the following to properly connect and safely route
test cables into cab.
1. Driverside inner fender
2. Quarter fenders
3. Passenger-side inner fender

Test Setup
1. Key Off.
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector(page 1345).
3. Key On Engine Off (KOEO). Log in to Navistar® Engine Diagnostics.
1414 2 ENGINE SYSTEM TESTS AND INSPECTIONS

4. Connect Cylinder Performance Analyzer (CPA) (page 1402) tool for misfire diagnostics.

Figure 491 Navistar® Engine Diagnostics Menu

5. Start CPA software in Navistar® Engine Diagnostics by selecting Tests > Cylinder Performance Analyzer.

Figure 492 Information Text Fields

6. Fill in Dealer location, operator/technician Information and Customer Complaint text fields.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1415

7. Verify Vehicle Data matches information in text fields, then select Proceed.

Figure 493 CPA Platform Category selection

1. Navistar® Medium Duty Engine
1416 2 ENGINE SYSTEM TESTS AND INSPECTIONS

8. Select Navistar® Medium Duty Engine (1).

Figure 494 CPA Medium Duty Test selection

1. Injector Misfire Detection (IMD)

9. Select Injector Misfire Detection (IMD) (1), then select “Launch Test”.

Figure 495 Test Description Text Fields

1. Detailed Test Description/Test
Comments Field
2. Brief Test Description Text Field
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1417

10. Enter information into Brief Test Description (2) and Detailed Test Description/Test Comments (1) text
fields.

Figure 496 Cylinder Performance Analyzer

11. Later generations of CPA tool do not have adjusting knobs. If using a tool with adjusting knobs, proper
calibration is rotated fully to right (clockwise).
1418 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Procedure

Figure 497 Test List

1. Select Signal Check from Test List.

2. Start engine.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1419

Figure 498 Start Test Window

3. Click button on bottom left corner to start test.

Figure 499 Signal Test Instructions

4. Follow on-screen instructions to complete test.

5. When End of Test text field appears, enter any final details about the test.
6. Click Return button to return to home screen and view test results.
1420 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Expected Outcome
Test will run successfully, signal adjustment will be made, and any road test can be performed after test is run.
Return to step based diagnostics or continue with Cylinder Performance Analyzer (CPA) diagnostics as needed.

Follow-on Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1421

Injector Misfire Detection Hot Idle Test

Overview
Detects faults with cylinder combustion during idle speed with engine at or above operating temperature, and is
usually performed if customer complaint includes a misfire during hot idle.

Special Tools
• Cylinder Performance Analyzer (CPA) Tool Kit 12-999-01
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Equipment Condition
Depending on truck model, it may be necessary to remove the following to properly connect and safely route
test cables into cab.
1. Driverside inner fender
2. Quarter fenders
3. Passenger-side inner fender

Test Setup
1. Key Off.
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Key On Engine Off (KOEO). Log in to Navistar® Engine Diagnostics.
4. Connect Cylinder Performance Analyzer (CPA) (page 1402) tool for misfire diagnostics.

Figure 500 Navistar® Engine Diagnostics Menu

1422 2 ENGINE SYSTEM TESTS AND INSPECTIONS

5. Start CPA software in Navistar® Engine Diagnostics by selecting Tests > Cylinder Performance Analyzer.

Figure 501 Information Text Fields

6. Fill in Dealer location, operator/technician Information and Customer Complaint text fields.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1423

7. Verify Vehicle Data matches information in text fields, then select proceed.

Figure 502 CPA Platform Category selection

1. Navistar® Medium Duty Engine
1424 2 ENGINE SYSTEM TESTS AND INSPECTIONS

8. Select Navistar® Medium Duty Engine (1).

Figure 503 CPA Medium Duty Test selection

1. Injector Misfire Detection (IMD)

9. Select Injector Misfire Detection (IMD) (1), then select “Launch Test”.

Figure 504 Test Description Text Fields

1. Detailed Test Description/Test
Comments Field
2. Brief Test Description Text Field
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1425

10. Enter information into Brief Test Description (2) and Detailed Test Description/Test Comments (1) text
fields.

Procedure

Figure 505 Test List

1. Select Hot Idle from Test List.

2. If engine is not running, start engine.
1426 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 506 Start Test Window

3. Click button on bottom left corner to start test.

4. Follow on-screen instructions to complete this test.
5. When End of Test text field appears, enter any final details about test.
6. Click Return button to go back to home screen and view test results.

Expected Outcome
Test will run successfully. Return to step based diagnostics with test information or continue Cylinder
Performance Analyzer (CPA) diagnostics as needed.
1. Green cylinders indicate no defects were found
2. Red cylinder indicates a problem with that cylinder (may or may not be an injector)
3. Light blue cylinders indicates high engine speed fluctuations, but no problem with a particular cylinder

Follow-on Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1427

Injector Misfire Detection Full Load to Highway Speed Test

Overview
The Full Load to Highway Speed Test is used to detect faults with cylinder combustion during acceleration, under
a load. Signal check must be performed before this test. Testing will stop automatically once vehicle reaches
highway speed and/or all necessary data has been collected. Cylinder Performance Analyzer (CPA) software
will only recognize for a limited time that signal check has been completed before it will reset and inhibit any test
that involves vehicle being driven.

WARNING:

To prevent personal injury or death, do not exceed local speed limits, disobey traffic laws
or drive too fast for conditions while performing this test.

Special Tools
• Cylinder Performance Analyzer (CPA) Tool Kit 12-999-01
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Equipment Condition
Depending on truck model, it may be necessary to remove the following to properly connect and safely route
test cables into cab.
1. Driverside inner fender
2. Quarter fenders
3. Passenger-side inner fender

Test Setup
1. Key Off.
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Key On Engine Off (KOEO). Log in to Navistar® Engine Diagnostics.
1428 2 ENGINE SYSTEM TESTS AND INSPECTIONS

4. Connect Cylinder Performance Analyzer (CPA) (page 1402) tool for misfire diagnostics.

Figure 507 Navistar® Engine Diagnostics Menu

5. Start CPA software in Navistar® Engine Diagnostics by selecting Tests > Cylinder Performance Analyzer.

Figure 508 Information Text Fields

6. Fill in Dealer location, operator/technician Information and Customer Complaint text fields.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1429

7. Verify Vehicle Data matches information in text fields, then select proceed.

Figure 509 CPA Platform Category selection

1. Navistar® Medium Duty Engine
1430 2 ENGINE SYSTEM TESTS AND INSPECTIONS

8. Select Navistar® Medium Duty Engine (1).

Figure 510 CPA Medium Duty Test selection

1. Injector Misfire Detection (IMD)

9. Select Injector Misfire Detection (IMD) (1), then select “Launch Test”.

Figure 511 Test Description Text Fields

1. Detailed Test Description/Test
Comments Field
2. Brief Test Description Text Field
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1431

10. Enter information into Brief Test Description (2) and Detailed Test Description/Test Comments (1) text
fields.

Procedure

Figure 512 Test List

1. Select Full Load to Highway Speed test from Test List.

2. Start engine.
1432 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 513 Start Test Window

3. Click button on the bottom left corner to start test.

4. Follow on-screen instructions to complete test.
5. When End of Test text field appears, enter any final details about test.
6. Click Return button to return to home screen and view test results.

Expected Outcome
Test will complete successfully and will automatically stop when necessary data has been recorded. Review
test results and return to step-based diagnostics or continue with Cylinder Performance Analyzer (CPA) testing
as needed.

Follow-on Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1433

CPA Advanced Testing

Overview
Cylinder Performance Analyzer (CPA) advanced testing can be used with or without the guidance of
International® Technical Services. This allows the user to test other sensor signals to perform a wider variety of
diagnostics. Technician can not view data taken on sensor ports 3 and 4 without contacting tech central support.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)
• Cylinder Performance Analyzer (CPA) Tool Kit 12-999-01

Equipment Condition
Depending on truck model, it may be necessary to remove the following to properly connect and safely route
test cables into cab.
1. Driverside inner fender
2. Quarter fenders
3. Passenger-side inner fender

Test Setup
1. Key Off.
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Key On Engine Off (KOEO). Log in to Navistar® Engine Diagnostics.
4. Connect Cylinder Performance Analyzer (CPA) (page 1402) tool.
1434 2 ENGINE SYSTEM TESTS AND INSPECTIONS

5. Connect Extension Harness 12-999-01-05 and 2-pin Banana Plug 12-999-01-06 to sensor(s) to monitor
and to CPA tool, ensuring to route away from hot or moving parts.

Figure 514 Navistar® Engine Diagnostics Menu

6. Start CPA software in Navistar® Engine Diagnostics by selecting Tests > Cylinder Performance Analyzer.

Figure 515 Information Text Fields

 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1435

7. Fill in dealer location, operator/technician information and customer complaint text fields.
8. Verify vehicle data matches information in text fields, then select Proceed.

Figure 516 CPA Platform Category selection

1. Navistar® Medium Duty Engine
1436 2 ENGINE SYSTEM TESTS AND INSPECTIONS

9. Select Navistar® Medium Duty Engine (1).

Figure 517 CPA Medium Duty Test selection

1. Injector Misfire Detection (IMD)

10. Select Injector Misfire Detection (IMD) (1), then select “Launch Test”.

Figure 518 Test Description Text Fields

1. Detailed Test Description/Test
Comments Field
2. Brief Test Description Field
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1437

11. Enter information into Brief Test Description (2) and Detailed Test Description/Test Comments (1) text
fields.

Procedure

1. Add data for sensor(s) connected in field for Sensor 3 and Sensor 4, if needed.
1438 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 520 Test List

2. Select User Defined in drop-down list of Tests.

3. Start engine.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1439

Figure 521 Start Test Window

4. Click button on bottom left corner to Start Test.

5. Follow on screen instructions to complete test.
6. When End of Test text field appears, enter any final details about test.
7. Click Return button to return to Home screen and view test results.

Expected Outcome
Test will run successfully, return to step based diagnostics with test information, or continue Cylinder
Performance Analyzer (CPA) diagnostics as needed.
1. Green cylinders indicate no defects were found
2. Red cylinder indicates a problem with that cylinder (may or may not be an injector)
3. Light blue cylinders indicates high engine speed fluctuations, but no problem with particular cylinder

Follow-on Procedure
None
1440 2 ENGINE SYSTEM TESTS AND INSPECTIONS

CPA High-Pressure Oil Pump (HPOP) Test

Overview
Cylinder Performance Analyzer (CPA) - High-Pressure Oil Pump (HPOP) Test is a group of tests used to
diagnose defects in high-pressure oil system consisting of the Injection Pressure Regulator (IPR) Engine
Control Module (ECM) Powered test, IPR (Full Fielded) test, IPR Blockoff Adaptor Installed test, and Pump
Deadheaded test. It may not be necessary to perform all tests in CPA HPOP Test. If software detects a fault
in high-pressure oil system during any test, a Warranty Authorization Code (WAC) will be generated. Other
faults will be displayed in Summary Text Box. If no fault is found, software will recommend performing next
test in series.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)
• Cylinder Performance Analyzer (CPA) Tool Kit 12-999-01
• Breakout Harness ZTSE4602
• IPR Blockoff Adaptor with Integrated ICP Sensor Kit 12-999-01-07
Avoid using laptop chargers, vehicle chargers, power supplies, or power inverters during test as these may
cause interference with CPA tool.

Equipment Condition
1. hEST and vehicle batteries are fully charged.
2. 20+ mile break-in drive has been performed if a new IPR valve was recently installed,
3. Depending on truck model, it may be necessary to remove the following to properly connect and safely
route test cables into cab.
a. Driverside inner fender
b. Quarter fenders
c. Passenger-side inner fender

Test Setup
1. Disconnect battery charger and EST power cord.
2. Key Off.
3. Connect EST to vehicle diagnostic connector (page 1345).
4. Key On Engine Off (KOEO). Log in to Navistar® Engine Diagnostics.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1441

5. Perform connecting CPA tool for HPOP testing (page 1391) procedure.

Figure 522 Navistar® Engine Diagnostics Menu

6. Start CPA software in Navistar® Engine Diagnostics by selecting: Tests > Cylinder Performance
Analyzer.

Figure 523 Information Text Fields

1442 2 ENGINE SYSTEM TESTS AND INSPECTIONS

7. Fill in Dealer location, operator / technician Information and Customer Complaint text fields.
8. Verify Vehicle Data matches information in text fields, then select “Proceed.”

Figure 524 CPA Platform Category selection

1. Navistar® Medium Duty Engine
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1443

9. Select Navistar® Medium Duty Engine (1).

Figure 525 CPA Medium Duty Test selection

1. High Pressure Oil Pump Module
1444 2 ENGINE SYSTEM TESTS AND INSPECTIONS

10. Select High Pressure Oil Pump Module (1), then select “Launch Test”.

Figure 526 Enter Symptom Screen

11. Select appropriate symptom.

12. Review notes from selected symptom, then select “Proceed.”
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1445

Procedure

Figure 527 Instructions to Set-up and Perform Tests

NOTE: Hold down Shift and click summary text box for instructions and setup pictures.
1. Follow on-screen instructions to prepare to run this group of tests.
2. Click Start Test button on bottom left corner.
3. If CPA Software indicates an error with CPA signals, perform CPA HPOP signal test (page 1447).
4. Follow on-screen instructions to complete each test.
5. When prompted to continue to next HPOP test, return to connecting CPA tool for HPOP testing (page 1402)
and perform test setup for given HPOP test.
6. When End of Test text field appears, enter any final details about test.

Expected Outcome
Tests will run successfully, identifying a failed component or sending user to the next test in the sequence. When
this series is complete, return to step-based diagnostics.
1446 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Follow-on Procedure
CPA software automatically records completed HPOP tests to a .zip file starting with the last 8 digits of VIN.
Files are located in: C:\Engine Cylinder Performance Analyzer\
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1447

CPA HPOP Signal Test

Overview
CPA high-pressure oil pump (HPOP) signal test is used to diagnose signal errors that may occur during the
HPOP test. This test is considered part of tool maintenance and will not be considered part of a warranty claim.

Special Tools
• Cylinder Performance Analyzer (CPA) Tool Kit 12-999-01
• IPR Blockoff Adapter with Integrated ICP Sensor Kit 12-999-01-07
• Digital Multimeter (DMM)
• Terminal test Kit ZTSE4435C
• Breakout Harness ZTSE4602
• Breakout Harness ZTSE4850
• Breakout Harness ZTSE4951
Avoid using laptop chargers, vehicle chargers, power supplies, or power inverters during test as these may
cause interference with CPA tool.

Equipment Condition
None

Test Setup
1. Retain test set up from unsuccessful HPOP test. All CPA cables must be installed on vehicle during
testing.
2. Ensure all equipment and cable connections are not visibly damaged.
3. Ensure all equipment and connections are secured and making full contact when connected.
4. Ensure there are no engine circuit fault codes caused by test set-up, pending or active. Diagnose and
repair circuit fault codes before continuing to test CPA signals.

Procedure
1. If you know what signal has issues based on CPA software error message or analyzing graph data, proceed
to that particular signal test below. If not, proceed to Step 2.
• engine oil temperature (EOT) sensor signal test (page 1447)
• camshaft position sensor (CMP) signal test (page 1449)
• injection control pressure (ICP) under valve cover (UVC) signal test (page 1452)
• injection pressure regulator (IPR) breakout harness signal test (page 1456)
• engine oil pressure (EOP) sensor signal test (page 1461)

Engine Oil Temperature Sensor Signal Test

2. Key Off. Disconnect CPA extension harness from CPA module CRANK SENSOR port and leave CPA
extension harness connected to Engine Oil Temperature (EOT) sensor.
1448 2 ENGINE SYSTEM TESTS AND INSPECTIONS

4
0000431941

Figure 528 CPA Extension Harness Circuit Test

1. CPA extension harness center terminal
2. Outer grounding shell
3. Negative DMM lead
4. Positive DMM lead

Engine Oil Temperature Spec Chart

Temperature at -18 °C (0 °F) 4.62 V / 247 kΩ

Temperature at 0 °C (32 °F) 4.37 V / 96 kΩ
Temperature at 21 °C (70 °F) 3.78 V / 36 kΩ
Temperature at 65 °C (150 °F) 1.93 V / 6.3 kΩ
Temperature at 93 °C (200 °F) 0.99 V / 2.6 kΩ

3. Key On. Using DMM, measure voltage between CPA extension harness center terminal and outer grounding
shell. Compare to Engine Oil Temperature Chart Specs. If voltage is within specification, inspect CPA
Module for possible defect or loose connection, then go to Step 10. If voltage is not within specification, go
to Step 4.
4. Key Off. Disconnect CPA extension harness from CPA banana jack breakout harness and leave CPA banana
jack breakout harness connected to Engine Oil Temperature Sensor breakout harness ZTSE4602.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1449

0000432083

Figure 529 CPA Banana Jack Breakout Harness Circuit Test

5. Using Terminal Test Kit ZTSE4435C, insert proper terminals into CPA banana jack breakout harness.
6. Key On. Using DMM, measure voltage between CPA banana jack breakout harness (both pins of the 2–pin
connector). Compare to Engine Oil Temperature Specs Chart. If voltage is within specification, replace CPA
extension harness and go to Step 9. If voltage is not within specification, go to Step 7.
7. Key Off. Disconnect CPA banana jack breakout harness from EOT breakout harness ZTSE4602 and leave
breakout harness ZTSE4602 connected to Engine Oil Temperature sensor and engine harness.
8. Key On. Using DMM, measure voltage between EOT breakout harness ZTSE4602 pin-1 and pin-2.
Compare to Engine Oil Temperature Specs Chart. If voltage is within specification, replace CPA banana
jack breakout harness and go to Step 9. If voltage is not within specification, reconnect engine harness
to EOT and test for EOT sensor circuit fault codes.
9. Reconnect the EOT sensor to the CRANK sensor port of the CPA module using CPA banana jack breakout
harness and CPA extension harness, and return to appropriate CPA HPOP test.

Camshaft Position Sensor Signal Test

10. Key Off. Disconnect CPA extension harness from CPA module CAM SENSOR port and leave CPA extension
harness connected to Camshaft Position (CMP) sensor.
1450 2 ENGINE SYSTEM TESTS AND INSPECTIONS

4
0000431941

Figure 530 CPA Extension Harness Circuit Test

1. CPA extension harness center terminal
2. Outer grounding shell
3. Negative DMM lead
4. Positive DMM lead

11. Using DMM, measure resistance between CPA extension harness center terminal and outer grounding shell.
Compare to specification 300 to 400 Ohms. If resistance is within specification, inspect CPA Module for
possible defect or loose connection then go to Step 18. If resistance is not within specification, proceed to
Step 12.
12. Key Off. Disconnect CPA extension harness from CPA CAM sensor breakout harness and leave CPA CAM
sensor breakout harness connected to Camshaft Position (CMP) sensor.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1451

0000431940

Figure 531 CPA CAM Sensor Breakout Harness Circuit Test

13. Using Terminal Test Kit ZTSE4435C, insert proper terminals into CAM sensor breakout harness.
14. Using DMM, measure resistance between CPA CAM sensor breakout harness (both pins of the 2–pin
connector). Compare to specification 300 - 400 Ohms. If resistance is within specification, replace CPA
extension harness and go to Step 17. If resistance is not within specification, go to Step 15.
15. Disconnect CPA CAM sensor breakout harness from CMP sensor. Connect ZTSE4951 to CMP sensor and
leave engine harness and CPA CAM breakout harness disconnected.
16. Using DMM, measure resistance between breakout harness ZTSE4951 pin-1 and pin-2. Compare to
specification 300 - 400 Ohms. If resistance is within specification, replace CPA CAM breakout harness and
go to Step 17. If resistance is not within specification, reconnect engine harness to CMP sensor and test
for CMP sensor circuit fault codes.
17. Reconnect the CMP sensor to the CAM sensor port of the CPA module using CPA CAM sensor breakout
harness and CPA extension harness, and return to appropriate CPA HPOP test.
1452 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Injection Control Pressure (ICP) Under Valve Cover (UVC) Signal Test
18. If error with CPA signals occurred during CPA high-pressure oil pump (HPOP) Test 1 - IPR ECM powered
or Test 2 - IPR full fielded, go to Step 19. If error occurred during Test 3 - IPR blockoff adapter installed or
Test 4 - Pump deadhead, go to Step 34.
19. Key Off. Disconnect CPA extension harness from CPA Module Sensor 3 port and leave CPA extension
harness connected to CPA HPOP breakout harness.

4
0000431941

Figure 532 CPA Extension Harness Circuit Test

1. CPA extension harness center terminal
2. Outer grounding shell
3. Negative DMM lead
4. Positive DMM lead

20. Key On. Using DMM, measure voltage between CPA extension harness center terminal and outer grounding
shell. Compare to specification 0.25V ± 0.1V. If voltage is within specification, inspect CPA Module for
possible defect or loose connection, then go to Step 34. If voltage is not within specification, proceed to
Step 21.
21. Disconnect CPA extension harness from CPA HPOP breakout harness.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1453

0000432083

Figure 533 RED CPA HPOP Breakout Harness Circuit Test

22. Using Terminal Test Kit ZTSE4435C, insert proper terminals into RED CPA HPOP breakout harness 2-pin
connector.
23. Key On. Using DMM, measure voltage between both pins of CPA HPOP 2-pin connector. Compare to
specification 0.25V ± 0.1V. If voltage is within specification, replace CPA extension harness and go to Step
33. If voltage is not within specification, proceed to step 24.
24. Key Off. Disconnect CPA HPOP breakout harness from Under Valve Cover (UVC) connector.
1454 2 ENGINE SYSTEM TESTS AND INSPECTIONS

7 2

4 1

8 5
1 2

0000432149

Figure 534 CPA HPOP UVC Connector and RED CPA HPOP 2-Pin Connector Continuity Test

25. Using Terminal Test Kit ZTSE4435C, insert proper terminal into CPA HPOP 2010 MaxxForce UVC BEIGE
connector pin-7 and RED CPA HPOP breakout harness 2-pin connector pin-2.
26. Using DMM, measure resistance between both pins. Compare to specification of less than 0.5 Ohms. If
resistance is within specification, proceed to Step 27. If resistance is not within specification, repair or
replace CPA HPOP breakout harness as needed and go to Step 33.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1455

6 1

4 1

8 5
1 2

0000432150

Figure 535 CPA HPOP UVC Connector and RED CPA HPOP 2-Pin Connector Continuity Test

27. Using Terminal Test Kit ZTSE4435C, insert proper terminal into CPA HPOP 2010 MaxxForce UVC BEIGE
connector pin-6 and RED CPA HPOP breakout harness 2-pin connector pin-1.
28. Using DMM, measure resistance between both pins. Compare to specification of less than 0.5 ohms. If
resistance is within specification, proceed to Step 29. If resistance is not within specification, repair or
replace CPA HPOP breakout harness as needed and got to Step 33.
1456 2 ENGINE SYSTEM TESTS AND INSPECTIONS

4 1

8 5

7
0000432146

Figure 536 CPA HPOP Connector VREF Test

29. Using Terminal Test Kit ZTSE4435C, insert proper terminals into pin-8 and pin-7 of CPA HPOP 2010
MaxxForce UVC BEIGE connector.
30. Key On. Using DMM measure voltage between pin-8 and pin-7. Compare specification of 5.0V ± 0.5V.
If voltage is within specification, reconnect engine harness to UVC and test for ICP circuit fault codes. If
voltage is not within specification, go to Step 31.
31. Key Off. Disconnect CPA HPOP breakout harness from EOP sensor and engine harness, install ZTSE4850
between engine harness and EOP sensor.
32. Key On. Using DMM measure voltage between VREF and GND. Compare to specification 5.0V ± 0.5V. If
voltage is within specification, repair or replace CPA HPOP breakout harness as needed then go to Step
33. If voltage is not within specification, reconnect engine harness to EOP sensor and test for EOP sensor
circuit fault codes.
33. Reconnect the CPA HPOP breakout harness to the CPA extension and reconnect CPA extension harness
to CPA Module Sensor 3 port, and return to appropriate CPA HPOP test.

Injection Pressure Regulator Breakout Harness Signal Test

34. Key Off. Disconnect CPA extension harness from CPA Module Sensor 4 port.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1457

4
0000431941

Figure 537 CPA Extension Harness Circuit Test

1. CPA extension harness center terminal
2. Outer grounding shell
3. Negative DMM lead
4. Positive DMM lead

35. Key On. Using DMM measure voltage between CPA extension harness center terminal and outer grounding
shell. Compare to specification 0.25V ± 0.1V. If voltage is within specification, inspect CPA Module for
possible defect or loose connection then go to Step 47. If voltage is not within specification, proceed to Step
36.
36. Key Off. Disconnect CPA extension harness from GREEN IPR blockoff harness.
1458 2 ENGINE SYSTEM TESTS AND INSPECTIONS

0000432083

Figure 538 GREEN IPR Blockoff Breakout Harness Circuit Test

37. Using Terminal Test Kit ZTSE4435C, insert proper terminals into GREEN IPR blockoff harness 2-pin
connector.
38. Key On. Using DMM, measure voltage between GREEN IPR blockoff harness 2-pin connector. Compare
to specification to 0.25V ± 0.1V. If voltage is within specification, replace CPA extension harness then go to
Step 46. If voltage is not within specification, go to Step 39.

0000432145

Figure 539 GREEN IPR Blockoff Breakout Harness Connector

1. Terminal Lock
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1459

39. Key Off. Disconnect GREEN IPR blockoff harness from IPR adaptor and CPA HPOP breakout harness.
Inspect connector for missing terminal lock, replace IPR blockoff breakout harness if defect found.

3 2

3 1

1 2

0000432151

Figure 540 GREEN IPR Blockoff Breakout Harness Connector and 2-Pin Connector Continuity Test

40. Using Terminal Test Kit ZTSE4435C, insert proper terminal into GREEN IPR block-off breakout harness
connector pin-3 and 2-pin connector pin-2.
41. Using DMM, measure resistance between both pins. Compare to specification of less than 0.5 ohms. If
resistance is within specification, go to Step 42. If resistance is not within specification, replace GREEN IPR
blockoff breakout harness and go to Step 46.
1460 2 ENGINE SYSTEM TESTS AND INSPECTIONS

1 1

3 1

1 2

0000432152

Figure 541 GREEN IPR Blockoff Breakout Harness Connector and 2-Pin Connector Continuity Test

42. Using Terminal Test Kit ZTSE4435C, insert proper terminal into GREEN IPR blockoff breakout harness
connector pin-1 and 2-pin connector pin-1.
43. Using DMM, measure resistance between both pins. Compare to specification of less than 0.5 ohms. If
resistance is within specification, go to Step 44. If resistance is not within specification, replace GREEN IPR
blockoff breakout harness and go to Step 46.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1461

3
3 1

0000432148

Figure 542 CPA HPOP Injector Control Pressure Sensor Connector VREF Test

44. Using Terminal Test Kit ZTSE4435C, insert proper terminals into pin-1 and pin-2 of ICP sensor connector of
CPA HPOP breakout harness.
45. Key On. Using DMM measure voltage between pin-1 and pin-2 on ICP sensor connector. Compare
specification of 5.0V ± 0.5V. If voltage is within specification, replace GREEN IPR blockoff breakout harness
and go to Step 46. If voltage is not within specification, go to Step 47.
46. Reconnect IPR block-off breakout harness to IPR block-off adaptor and CPA extension harness to CPA
Module Sensor 4 port.

Engine Oil Pressure Signal Test

47. Disconnect CPA extension harness from CPA Module Sensor port 4.
1462 2 ENGINE SYSTEM TESTS AND INSPECTIONS

4
0000431941

Figure 543 CPA Extension Harness Circuit Test

1. CPA extension harness center terminal
2. Outer grounding shell
3. Negative DMM lead
4. Positive DMM lead

48. Key On. Using DMM measure voltage between CPA extension harness center terminal and outer grounding
shell. Compare to specification 0.5V ± 0.1V. If voltage is within specification, inspect CPA Module for possible
defect or loose connection then go to Step 54. If voltage is not within specification, proceed to Step 49.
49. Disconnect CPA extension harness from CPA HPOP breakout harness.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1463

0000432083

Figure 544 BLUE CPA HPOP Breakout Harness Circuit Test

50. Key on. Using DMM, measure voltage at BLUE EOP output voltage 2-Pin connector. Compare to
specification 0.5V ± 0.1V. If voltage is within specification, replace CPA extension harness then go to Step
53. If voltage is not within specification, go to Step 51.
51. Disconnect CPA HPOP breakout harness from engine harness and install ZTSE4850 between EOP sensor
and engine harness.
52. Key On. Using DMM, measure voltage between Signal and GND. Compare to specification of 0.5V ± 0.1V.
If voltage is within specification, repair or replace CPA HPOP breakout harness as needed and go to Step
53. If voltage is not within specification, reconnect engine harness into EOP sensor and test for EOP sensor
circuit fault codes.
53. Reconnect CPA HPOP breakout harness to engine harness and connect CPA extension harness to CPA
Module Sensor 4 port.
54. If all voltage and resistance readings are within specification and issue is not resolved, please open a Tools
case file for further instructions.

Expected Outcome
All voltage and resistance readings should be within given specification.

Follow-on Procedure
None
1464 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Record Snapshot of Engine Running Data

Overview
Record engine running data to be referenced now and in the future. Recreate engine running problem during
the test if possible.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Equipment Condition
None

Test Setup
1. Key On, Engine Running (KOER).
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Log into Navistar® Engine Diagnostics.

Procedure
1. Select: Sessions > Default.
2. Select: Start Recording Snapshot.
3. Recreate engine running problem.
4. Select: Stop Recording Snapshot.

Expected Outcome
Engine running values will be within specification. Save Snapshot for reference later in diagnostic procedures.

Follow-On Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1465

Base Engine Analysis Module (BEAM) Tests

Relative Compression Test Plus (RCT+)
Overview
This test will identify a weak contributing power cylinder, valve train issues, or other engine mechanical problems
by performing three 10 to 15 second engine cranking sessions.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics and CPA (V7.1.8.12 or higher) software
• Interface cable (RP1210B-compliant supporting J1939 and J1708)
• Cylinder Performance Analyzer (CPA) Tool Kit 12-999-01
• Pressure Plus Module (Medium) Kit 12-999-05M
• 1 inch Rubber Cap 09-889-02-30 (from Coolant Flushing Adapter kit)

Equipment Condition
1. Verify engine coolant temperature is > 150°F (65°C). If engine does not start, test may still be performed.
Cold engine RCT+ testing can give a false "weak cylinder" result. WAC’s resulting from cold RCT+ tests
are invalid.
2. Verify battery voltage is > 12.5 volts.
1466 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Test Setup

Figure 545 Graphic 1 Plugging the Breather outlet tube

1. Breather outlet tube
2. Rubber Cap 09-889-02-30 installed
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1467

Figure 546 Graphic 2 Plugging the Breather outlet tube

1. Breather Outlet Elbow
2. Breather Cap 12-999-05-10 installed
3. Pugged Turbocharger inlet hose

1. If equipped an Open Breather, install Rubber Cap 09-889-02-30 (Graphic 1, Item 2) into breather outlet
tube (Graphic 1, Item 1). If equipped with a closed breather, plug hose attached to Turbocharger inlet
(Graphic 2, Item 3) and install Breather Cap 12-999-05-10 (Graphic 2, Item 2) onto breather outlet elbow
(Graphic 2, Item 1) and tighten securely.
1468 2 ENGINE SYSTEM TESTS AND INSPECTIONS

2. Connect CPA module 12–999–01–01 to Electronic Service Tool (EST).

Figure 547 CPA Tool connected to CKP and CMP

1. Crankshaft Position (CKP) sensor
2. Camshaft Position (CMP) Sensor

3. Connect CPA yellow sensor harness 12–999–01–02 between “CAM SENSOR” channel and Camshaft
Position (CMP) sensor.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1469

4. Connect CPA black sensor harness 12–999–01–03 between “CRANK SENSOR” channel and
Crankshaft Position (CKP) sensor.

Figure 548 12–999–05–04 Cap Adapter

1. Wingnut (2)
2. Adapter

5. Remove oil fill cap.

6. Install adapter (Item 2) onto oil fill tube. Tighten wingnuts (Item 1) securely.
1470 2 ENGINE SYSTEM TESTS AND INSPECTIONS

7. Connect power cord 12-999-05-07 alligator clips either directly to battery or B+ and GND connections
on vehicle cowl panel.

Figure 549 Pressure Plus Module Connected to B+

8. Connect power cord 12-999-05-07 to Pressure Plus Module 12-999-05-01.

Figure 550 Pressure Plus Module Connected to Cap Adapter

1. Cap Adapter
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1471

9. Using Pressure Relief Valve Assembly 12-999-05-02, connect Pressure Plus Module 12-999-05-01 to
Cap Adapter 12-999-05-04.

Figure 551 Complete RCT+ set-up

1. Cap Adapter
2. Camshaft Position (CMP) Sensor
3. Crankshaft Position (CKP) Sensor

10. Using extension harness 12-999-01-05, connect “Pressure Signal” port on Pressure Plus Module to
“SENSOR 3” port of CPA tool 12-999-01-01.
11. Using another extension harness 12-999-01-05, connect “BATT Signal” port on Pressure Plus Module
to “SENSOR 4” port of CPA tool 12-999-01-01.
12. Key Off, disconnect Engine Control Module (ECM) 36–pin Injector Driver connector from ECM.
13. Key-On Engine-Off (KOEO).
14. Connect EST to vehicle Diagnostic Connector.
1472 2 ENGINE SYSTEM TESTS AND INSPECTIONS

15. Log in to Navistar® Engine Diagnostics.

Figure 552 Navistar® Engine Diagnostics Menu

 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1473

16. Start CPA software in Navistar® Engine Diagnostics by selecting Tests > Cylinder Performance Analyzer.

17. Fill in Dealer Name & Location, Operator, and Customer Complaints text fields.
1474 2 ENGINE SYSTEM TESTS AND INSPECTIONS

18. Verify vehicle data matches information in text fields, then select “Proceed”.

Figure 553 CPA Platform Category selection

1. Navistar® Medium Duty Engine
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1475

19. Select Navistar® Medium Duty Engine (1).

Figure 554 CPA Medium Duty Test selection

1. Base Engine Analysis Module (BEAM)

20. Select Base Engine Analysis Module (BEAM) (1), then select “Launch Test”.
1476 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Procedure

Figure 555 Test List

1. Customer Complaint & Test Notes text field
2. RCT with Crankcase Pressure Analysis (RCT+)
3. Start Test Button

1. Enter information into Customer Complaint & Test Notes text field (Item 1).
2. Select RCT with Crankcase Pressure Analysis (RCT+) (Item 2) from Test list.
3. Ensure vehicle is not connected to a battery charger.
4. Key-ON Engine-OFF (KOEO), select Start Test button (Item 3).
5. Follow on screen instructions. They will have you perform three cranking session lasting 15 seconds each
with a period of inactivity in-between each session to allow built up pressure to bleed off. If CPA Software or
data from test results indicate an error with signals or PPM, perform Pressure Plus Module and CPA Signal
Functionality Test (page 1501).
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1477

Figure 556 Show Results

1. Drop down menu

6. Once test is complete, review data by selecting "Show Results" (Item 1) from Test Summary drop down at
top of screen, and compare results to RCT+ Graph Analysis (page 1478) section.

Expected Outcome
Test will complete and give results on mechanical health of the engine. If a WAC is generated, repair given
component.

Follow-on Procedure
1. Key OFF, reconnect ECM 36–pin injector driver connector to ECM.
2. Clear any active fault codes set from disconnecting ECM.
1478 2 ENGINE SYSTEM TESTS AND INSPECTIONS

RCT+ Graph Analysis

Figure 557 Good Engine

1. Battery signal
2. CKP / CMP signal
3. Engine Speed (RPM)
4. Processed battery signal
5. Processed crankcase pressure signal
6. CMP signal
7. Crankcase pressure
8. CKP signal

Graph Analysis
This graph shows a good engine.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1479

Figure 558 Good Engine

1. Pressure rise duration
2. Pressure decay duration
3. Relative compression based off engine speed
4. Relative compression based off battery voltage
5. Crankcase pressure contribution per cylinder
6. Cylinder 1 cranking session 3
7. Cylinder 1 cranking session 2
8. Cylinder 1 cranking session 1

Graph Analysis
This graph shows a good engine. Each cylinder shows three bars, one for each cranking session, which are all
within specification. Green indicates a good cylinder, while orange at the top of each bar indicates the standard
deviation occurred during testing. Standard deviation is a measurement of variation in the data values collected.
1480 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 559 Bad: Power Cylinder 6

1. Failed pressure rise
2. Cylinder 6 weak based off engine speed
3. Cylinder 6 with weaker compression based off battery voltage
4. Cylinder 6 contributing excessive crankcase pressure

Graph Analysis
This graph shows a weak number six cylinder. Both engine speed and battery voltage relative compression
shows cylinder 6 to have lower compression. There is no engine speed rise (Item 2) or battery voltage rise (Item
3) while cranking. Also, cylinder six is contributing too much pressure into the crankcase during the compression
stroke (Item 4). This means cylinder 6 has compression loss and it is going into the crankcase indicating a power
cylinder failure or a scored cylinder wall.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1481

Figure 560 Bad: Power Cylinder 2

1. Failed pressure rise
2. Cylinder 2 weak based off engine speed
3. Cylinder 2 with weaker compression based off battery voltage
4. Cylinder 2 contributing excessive crankcase pressure

Graph Analysis
This graph shows a dead number two cylinder. Both engine speed and battery voltage relative compression
shows cylinder 2 to have low compression. There is no engine speed rise (Item 2) or battery voltage rise (Item
3) while cranking. Also, cylinder 2 is contributing too much pressure into the crankcase during the compression
stroke (Item 2). This means cylinder 2 has compression loss and it is going into the crankcase indicating a power
cylinder failure or a scored cylinder wall.
1482 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 561 Bad: Possible Dead Battery

1. Battery voltage drops too low

Graph Analysis
This graph shows a vehicle with a dead or dying battery. When battery voltage drops too low, it will skew the test
results. A low battery message will indicate voltage is too low and stop the test. Diagnose and repair starting or
charging system before retesting.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1483

Figure 562 Bad: Possible Dead Battery

1. Skewed battery results

Graph Analysis
This graph shows a vehicle with a dead or dying battery. When battery voltage drops too low, it will skew the test
results. A low battery message will indicate voltage is too low and stop the test. Diagnose and repair starting or
charging system before retesting.
1484 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 563 Bad: Crankcase not sealed

1. Crankcase pressure never builds above 30 in H2O

Graph Analysis
This graph shows crankcase pressure never building above 30 in H2O (Item 1). If crankcase pressure never
builds above 30 in H2O, the crankcase is not sealed properly. The results will not be accurate and an error
message will be displayed. This will prevent a Warranty Authorization Code (WAC) from generating. Check the
following for proper installation: breather cap, dipstick tube, and oil fill cap.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1485

Figure 564 Bad: Crankcase not sealed

1. Rise and fall data does not calculate

Graph Analysis
This graph shows crankcase pressure never building above 30 in H2O (Item 1). If crankcase pressure never
builds above 30 in H2O, the crankcase is not sealed properly. The results will not be accurate and an error
message will be displayed. This will prevent a Warranty Authorization Code (WAC) from generating. Check the
following for proper installation: breather cap, dipstick tube, and oil fill cap.
1486 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Blow By Test
Overview
This test will identify an engine with excessive blow by monitoring crankcase pressure (in of H2O) at the breather
outlet tube during a high idle event.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics and CPA (V7.1.8.12 or higher) software
• Interface cable (RP1210B-compliant supporting J1939 and J1708)
• Cylinder Performance Analyzer (CPA) Tool Kit 12-999-01
• Pressure Plus Module (Medium) Kit 12-999-05M
• Crankcase Pressure Test Orifice Tool ZTSE4039

Equipment Condition
1. Verify engine coolant temperature is > 150°F (65°C).
2. Verify battery voltage is > 12.5 volts.
3. Fan must be OFF when the reading is taking at high idle (WOT). Readings taken with fan ON are invalid.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1487

Test Setup

Figure 565 Graphic 1 ZTSE4039 installed on breather outlet tube

1. Breather outlet tube
2. Crankcase Pressure Test Orifice Tool ZTSE4039
1488 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 566 Graphic 2 ZTSE4039 installed on breather outlet tube

1. Plugged Turbo Inlet Tube
2. Crankcase Pressure Test Orifice Tool ZTSE4039
3. Breather outlet elbow

1. For Open Breather, connect ZTSE4039 (Graphic 1, Item 2) to breather outlet tube (Graphic 1, Item 1)
using hose clamps to seal the connection. For closed breather, plug turbo inlet tube (Graphic 2, Item 1)
and install ZTSE4039 (Graphic 2, Item 2) onto crankcase breather outlet elbow (Graphic 2, Item 3) with
hose clamps..
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1489

2. Connect CPA module 12–999–01–01 to Electronic Service Tool (EST).

Figure 567 CPA Tool connected to CKP and CMP

1. Crankshaft Position (CKP) sensor
2. Camshaft Position (CMP) Sensor

3. Connect CPA black sensor harness 12–999–01–03 between “CRANK SENSOR” channel and
Crankshaft Position (CKP) sensor.
4. Connect CPA yellow sensor harness 12–999–01–02 between “CAM SENSOR” channel and Camshaft
Position (CMP) sensor.
1490 2 ENGINE SYSTEM TESTS AND INSPECTIONS

5. Connect power cord 12-999-05-07 alligator clips either directly to battery or B+ and GND connections
on vehicle cowl panel.

Figure 568 Pressure Plus module connected to B+

 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1491

6. Connect power cord 12-999-05-07 to Pressure Plus Module 12-999-05-01.

Figure 569 Pressure Plus module connected to ZTSE4039

1. Crankcase Pressure Test Orifice Tool ZTSE4039

NOTE: black threaded fitting will need to be removed from Tube, Crankcase Breather Adapter
12-999-05-06 hose to be used with ZTSE4039.
1492 2 ENGINE SYSTEM TESTS AND INSPECTIONS

7. Using Tube, Crankcase Breather Adapter 12-999-05-06, Connect Pressure Plus Module 12-999-05-01
to Crankcase Pressure Test Orifice Tool ZTSE4039.

Figure 570 Complete Blow by Test set-up

1. Crankcase Pressure Test Orifice Tool ZTSE4039
2. Camshaft Position (CMP) Sensor
3. Crankshaft Position (CKP) Sensor

8. Using extension harness 12-999-01-05, connect “Pressure Signal” port on Pressure Plus Module to
“SENSOR 3” port of CPA tool 12-999-01-01.
9. Using another extension harness 12-999-01-05, connect “Batt Signal” port on Pressure Plus Module to
“SENSOR 4” port of CPA tool 12-999-01-01.
10. Key-On Engine-Off (KOEO).
11. Connect EST to vehicle Diagnostic Connector.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1493

12. Log in to Navistar® Engine Diagnostics.

Figure 571 Navistar® Engine Diagnostics Menu

1494 2 ENGINE SYSTEM TESTS AND INSPECTIONS

13. Start CPA software in Navistar® Engine Diagnostics by selecting Tests > Cylinder Performance Analyzer.

Figure 572 Information Text Fields

14. Fill in Dealer Name & Location, Operator, and Customer Complaints text fields.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1495

15. Verify vehicle data matches information in text fields, then select “Proceed”.

Figure 573 CPA Platform Category selection

1. Navistar® Medium Duty Engine
1496 2 ENGINE SYSTEM TESTS AND INSPECTIONS

16. Select Navistar® Medium Duty Engine (1).

Figure 574 CPA Medium Duty Test selection

1. Base Engine Analysis Module (BEAM)

17. Select Base Engine Analysis Module (BEAM) (1), then select “Launch Test”.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1497

Procedure

Figure 575 Test List

1. Customer Complaint & Test Notes
2. Blow By Test (BBT)
3. Save to file when test starts
4. Start Test

1. Enter information into Customer Complaint & Test Notes text field (Item 1).
2. Select Blow By Test (BBT) (Item 2) from Test list.
3. Verify Save to file when test starts box is unchecked (Item 3).
4. Key-ON Engine-OFF (KOEO), select Start Test button (Item 4).
5. Follow on screen instructions. Perform KOER Standard test in Navistar® Engine Diagnostics followed by two
5-10 seconds sessions of high-idle with accelerator pedal fully depressed. Ensure fan is OFF during both
high idle events. If engine cannot perform Navistar® Engine Diagnostics Standard test (that CPA requests)
continue to next Step, otherwise go to Step 9. If CPA Software or data from test results indicate an error
with signals or PPM, perform Pressure Plus Module and CPA Signal Functionality Test (page 1501).
6. box at Item 3 should be checked.
7. When CPA requests Navistar® Engine Diagnostics Standard test, rev engine to high idle (WOT) for 5 seconds
and return to low idle. Repeat for 5 seconds at high idle, then return to low idle.
8. Select STOP TEST and review results.
1498 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 576 Show Results

1. Drop down menu

9. Once test is complete, review data by selecting "Show Results" (Item 1) from Test Summary drop down at
top of screen, and compare results to Blow By Test Graph Analysis (page 1499) section.

Expected Outcome
Test will complete and give results on mechanical health of the engine. If a WAC is generated, repair given
component.

Follow-on Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1499

Blow By Test Graph Analysis

Figure 577 Good Engine

1. First high idle event maximum pressure reading
2. Second high idle event maximum pressure reading

Graph Analysis
This graph shows an engine with blow by within specification.
1500 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 578 Excessive Crankcase Pressure

1. First high idle event maximum pressure reading
2. Second high idle event maximum pressure reading

Graph Analysis
This graph shows an engine with blow by out of specification. This indicates a worn or damaged power cylinder
or an air compressor leaking to crankcase.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1501

Pressure Plus Module and CPA Signal Functionality Test

Overview
This test will identify a failed Pressure Plus Module (PPM) and CPA signal errors. This test is considered part
of tool maintenance and will not be considered part of a warranty claim.

Tools Required
• Pressure Plus Module (Medium) Kit 12-999-05M
• CPA Complete Tester Kit 12-999-01
• Terminal Test Kit ZTSE4435C
• Breakout Harness ZTSE4950
• Breakout Harness ZTSE4951
• Digital Multimeter (DMM)

Equipment Condition
Verify battery voltage is > 12.5 volts.

Test Setup
1. Perform Test Setup from either Relative Compression Test Plus (RCT+) (page 1465) or Blow By Test
(page 1486).
2. Ensure all equipment and cable connections are not visibly damaged.
3. Ensure all equipment and connections are secured and making full contact when connected.
4. Ensure there are no engine circuit fault codes pending or active. Diagnose and repair circuit fault codes
before continuing to test PPM and CPA signals.
1502 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Procedure

Figure 579 Pressure Plus module connected to B+

1. Verify LED light is illuminated. If LED On light is not illuminated or LED Fault light is illuminated, open Tools
Case File.
2. If graph data or CPA software indicates an error with a specific signal, proceed to that specific signal test
below. If not, proceed to Step 3.
• Camshaft Position Sensor Signal Test (page 1502)
• Crankshaft Position Sensor Signal Test (page 1504)
• PPM BATT Signal Test (page 1507)
• PPM Pressure Signal Test (page 1508)

Camshaft Position Sensor Signal Test

3. Key Off, disconnect CPA extension harness from CPA module CAM SENSOR port and leave CPA extension
harness connected to Camshaft Position (CMP) sensor.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1503

4
0000431941

Figure 580 CPA Extension Harness Circuit Test

1. CPA extension harness center terminal
2. Outer grounding shell
3. Negative DMM lead
4. Positive DMM lead

4. Using DMM, measure resistance between CPA extension harness center terminal (1) and outer grounding
shell (2). Compare to specification 300 to 400 Ohms. If resistance is within specification, inspect CPA
Module for possible defect or loose connection then go to Step 11. If resistance is not within specification,
proceed to Step 5.
5. Disconnect CPA extension harness from CPA CAM sensor breakout harness and leave CPA CAM sensor
breakout harness connected to Camshaft Position (CMP) sensor.
1504 2 ENGINE SYSTEM TESTS AND INSPECTIONS

0000431940

Figure 581 CPA CAM sensor breakout harness circuit test

6. Using Terminal Test Kit ZTSE4435C, insert proper terminals into CAM sensor breakout harness (both pins
of 2-pin connector).
7. Using DMM, measure resistance between CPA CAM sensor breakout harness (1) (both pins of 2-pin
connector). Compare to specification 300 - 400 Ohms. If resistance is within specification, replace CPA
extension harness, and go to Step 10. If resistance is not within specification, proceed to Step 8.
8. Disconnect CPA CAM sensor breakout harness from CMP sensor. Connect ZTSE4951 to CMP sensor and
leave engine harness and CPA CAM breakout harness disconnected.
9. Using DMM, measure resistance between breakout harness ZTSE4951 pin-1 and pin-2. Compare to
specification 300 - 400 Ohms. If resistance is within specification, replace CPA CAM breakout harness and
go to Step 10. If resistance is not within specification, reconnect engine harness to CMP sensor and test
for CMP sensor circuit fault codes.
10. Reconnect CMP sensor to CAM SENSOR port of CPA module using CPA CAM sensor breakout harness
and CPA extension harness, and return to appropriate BEAM Test.

Crankshaft Position Sensor Signal Test

11. Key Off, disconnect CPA extension harness from CPA module CRANK SENSOR port and leave CPA
extension harness connected to Crankshaft Position (CKP) sensor.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1505

4
0000431941

Figure 582 CPA Extension Harness Circuit Test

1. CPA extension harness center terminal
2. Outer grounding shell
3. Negative DMM lead
4. Positive DMM lead

12. Using DMM, measure resistance between CPA extension harness center terminal (1) and outer grounding
shell (2). Compare to specification 616-1275 Ohms. If resistance is within specification, inspect CPA Module
for possible defect or loose connection then go to Step 19. If resistance is not within specification, proceed
to Step 13.
13. Disconnect CPA extension harness from CPA CRANK sensor breakout harness and leave CPA CRANK
sensor breakout harness connected to Crankshaft Position (CKP) sensor.
1506 2 ENGINE SYSTEM TESTS AND INSPECTIONS

0000431940

Figure 583 CPA CRANK sensor breakout harness circuit test

0000431940

Figure 584 CPA CRANK sensor breakout harness circuit test

14. Using Terminal Test Kit ZTSE4435C, insert proper terminals into CRANK sensor breakout harness (both
pins of 2-pin connector).
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1507

15. Using DMM, measure resistance between CPA CRANK sensor breakout harness (1) (both pins of 2-pin
connector). Compare to specification 616-1275 Ohms. If resistance is within specification, replace CPA
extension harness, and go to Step 18. If resistance is not within specification, proceed to Step 16.
16. Disconnect CPA CRANK sensor breakout harness from CKP sensor. Connect ZTSE4950 to CKP sensor
and leave engine harness and CPA CRANK breakout harness disconnected.
17. Using DMM, measure resistance between breakout harness ZTSE4950 pin-1 and pin-2. Compare to
specification 616-1275 Ohms. If resistance is within specification, replace CPA CRANK breakout harness
and go to Step 18. If resistance is not within specification, reconnect engine harness to CKP sensor and
test for CKP sensor circuit fault codes.
18. Reconnect CKP sensor to CRANK SENSOR port of CPA module using CPA CRANK sensor breakout
harness and CPA extension harness, and return to appropriate BEAM Test.

PPM BATT Signal Test

19. Key Off, disconnect CPA extension harness from CPA module Sensor 4 port and leave CPA cable connected
to PPM BATT Signal port.

4
0000431941

Figure 585 CPA Extension Harness Circuit Test

1. CPA extension harness center terminal
2. Outer grounding shell
3. Negative DMM lead
4. Positive DMM lead

20. Using DMM, measure voltage between CPA extension harness center terminal (1) and outer grounding shell
(2). Voltage reading should be 5.9 ± 0.25 volts. If voltage is within specification, inspect CPA Module for
possible defect or loose connection then go to Step 25. If voltage is not within specification, proceed to Step
21.
1508 2 ENGINE SYSTEM TESTS AND INSPECTIONS

21. Disconnect CPA extension harness from PPM BATT Signal port.

Pressure Port

12V Batt IN

On Pressure Signal

Fault Batt Signal

0000432085

Figure 586 PPM BATT Signal Voltage Check

22. Use Terminal Test Kit ZTSE4435C, insert proper terminals into PPM BATT Signal port (both pins of 2-pin
connector).
23. Using DMM with correct test lead orientation, measure voltage between BATT Signal pins. Voltage reading
should be 5.9 ± 0.25 volts. If voltage is within specification, replace CPA extension harness, and continue
to Step 24. If voltage is not within specification, open a Tools case file for further instructions.
24. Reconnect PPM BATT Signal port to CPA module Sensor 4 port using new CPA extension harness, and
return to appropriate BEAM Test.

PPM Pressure Signal Test

25. Key Off, disconnect CPA extension harness from CPA module Sensor 3 port and leave CPA cable connected
to PPM Pressure Signal port.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1509

4
0000431941

Figure 587 CPA Extension Harness Circuit Test

1. CPA Extension harness center terminal
2. Outer grounding shell
3. Negative DMM lead
4. Positive DMM lead

26. Using DMM, measure voltage between CPA extension harness center terminal (1) and outer grounding
shell (2). Voltage reading should be 0.5 ± 0.1 volts. If voltage is within specification, inspect CPA Module
for possible defect or loose connection then go to Step 31. If voltage is not within specification, proceed to
Step 27.
27. Disconnect CPA extension harness from PPM Pressure Signal port.
1510 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Pressure Port

12V Batt IN

On Pressure Signal

Fault Batt Signal

0000432086

Figure 588 PPM Pressure Signal Voltage Check

28. Use Terminal Test Kit ZTSE4435C. Insert proper terminals into PPM Pressure Signal port (both pins of 2-pin
connector).
29. Using DMM with correct test lead orientation, measure voltage between Pressure Signal pins. Voltage
reading should be 0.5 ± 0.1 volts. If voltage is within specification, replace CPA extension harness, and
continue to Step 30. If voltage is not within specification, open a Tools case file for further instructions.
30. Reconnect PPM Pressure Signal port to CPA module Sensor 3 port using new CPA extension harness, and
return to appropriate BEAM Test.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1511

PPM 5V Output Test

Pressure Port

12V Batt IN

On Pressure Signal

Fault Batt Signal

0000432084

Figure 589 PPM 5V Output Voltage Check

31. Using DMM with correct test lead orientation, measure voltage between 5V Output pins. Voltage reading
should be 4.9 ± 0.1 volts. If voltage is within specification, proceed to Step 32. If voltage is not within
specification, open a Tools case file for further instructions.
1512 2 ENGINE SYSTEM TESTS AND INSPECTIONS

PPM Internal Pressure Sensor Test

2
3
1 4

Pressure Port

12V Batt IN

On Pressure Signal

Fault Batt Signal

0000432087

Figure 590 PPM Internal Pressure Sensor Check

1. Pressure Relief Valve Assembly 2. Regulator knob 4. Filtered shop air supply
12-999-05-02 3. Air valve

NOTE: Gold threaded T-fitting may need to be removed from Pressure Relief Valve Assembly 12-999-05-02 (1)
hose to be used with an air pressure regulator.
32. Connect air pressure regulator to PPM “Pressure Port” using Pressure Relief Valve Assembly 12-999-05-02
(1).

CAUTION:

Adjust air regulator valve to minimum setting before connecting shop air supply.
Accidentally applying high-pressure can damage tool components
33. Connect filtered shop air supply (4) to air valve (3) on air pressure regulator assembly.

WARNING:

To prevent personal injury or death, increase air pressure slowly to prevent fittings and
couplings from blowing-out during testing.

CAUTION:

To prevent damage to internal sensor, do not exceed 20 PSI when applying regulated air
to PPM “Pressure Port”.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1513

34. Open air valve (3) slightly, and slowly increase air pressure until gauge reads between 0.0 and 7.0 PSI. If
needed, adjust regulator knob (2) as follows until gauge reads between 0.0 and 7.0 PSI.
a. Pull air regulator knob (2) outward to unlock.
b. Turn air regulator knob (2) to adjust pressure to between 0.0 and 7.0 PSI.
c. Push air regulator knob (2) inward back into locked position.
35. Inspect regulated air supply adapters and fittings for leaks.
36. Use Terminal Test Kit ZTSE4435C. Insert proper terminals into PPM Pressure Signal port (both pins of 2-pin
connector).
37. Using DMM with correct test lead orientation, measure voltage between Pressure Signal pins.
38. Use regulator knob (2) to vary pressure applied to PPM “Pressure Port” from 0.0 to 7.0 PSI and monitor
voltage reading. Voltage reading should vary proportionally to amount of pressure applied. If Voltage reading
does not vary as expected, open a Tools case file for further instructions.

Expected Outcome
All voltage and resistance readings should be within given specification.

Follow-on Procedure
With air pressure at 0 PSI, disconnect Regulated Air Pressure Supply from Pressure Port.
1514 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Road Test
0 to 60 MPH Test

Overview
This test checks for unacceptable performance under a load at rated speed, and requires operation of the vehicle.
Use record feature in Navistar® Engine Diagnostics while driving on an open stretch of road trying to reproduce
complaint. Signals are recorded so they can be analyzed to determine which system is causing faults.

WARNING:

To prevent personal injury or death, do not exceed local speed limit laws or drive too fast
for conditions when performing 0 to 60 MPH Test.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface Cable (RP1210B compliant supporting J1939 and J1708)

Equipment Condition
None

Test Setup
1. Key-On, Engine-Running (KOER).
2. Connect Electronic Service Tool (EST) to Vehicle Diagnostic Connector (page 1345).
3. Log in to Navistar® Engine Diagnostics.
4. Run engine until Engine Coolant Temperature (ECT) is above 158°F (70°C).

Procedure
1. Drive vehicle to a suitable and safe location to perform test.
2. Pull over to side of road.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1515

Figure 591 Menu – Select Performance

3. Select: Sessions > Default.

1516 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 592 Menu – Select Start Recording Snapshot

4. Select Tools > Start Recording Snapshot (Figure 592).

5. When it is safe to do so, accelerate from 0 MPH to maximum allowed highway speed.
6. Repeat as necessary to reproduce complaint.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1517

Figure 593 Menu – Select Stop Recording Snapshot

7. After test is complete, Select Tools > Stop Recording Snapshot (Figure 593) and save snapshot in EST.
8. Return to shop and review snapshot data.

Expected Outcome
Safely perform road test and record data for analysis.

Follow-on Procedure
None
1518 2 ENGINE SYSTEM TESTS AND INSPECTIONS

0 to 60 MPH ICP and ICPD Graph

Overview
This graph shows an Injection Control Pressure (ICP) system operating as designed, and is a representation only,
no two graphs will be exactly alike. This test does not give pass or fail results, it only allows the user to validate
ICP and Injection Control Pressure Desired (ICPD) signal values under load. As engine rpm increases, ICP
should steadily increase. Low ICP will cause low Intake Manifold Pressure (IMP). Diagnose low ICP concerns
before diagnosing low IMP concerns.
NOTE: Analyze 0 to 60 MPH test signal values only during acceleration, and not during deceleration or shifting.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface Cable (RP1210B-compliant, supporting J1939 and J1708)

Equipment Condition
None

Test Setup
1. Key-On, Engine-Off (KOEO).
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Log in to Navistar® Engine Diagnostics
4. If not done previously, perform 0 to 60 MPH Test (page 1514) and save recording.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1519

Procedure

Figure 594 Injection Control Pressure and Injection Control Pressure Desired Graph
1. Injection Pressure Regulator 2. Injection Control Pressure 4. Injection Control Pressure (ICP)
(IPR) Valve control (percent) Desired (ICPD) [Green] [Purple]
[Blue] 3. Engine Speed (RPM) [Orange]

1. Verify if ICP is within 150 psi (1,034 kPa) of ICPD signal value during acceleration.
2. Verify if Injection Pressure Regulator (IPR) valve control is less than 80 percent.
3. Compare graph information with recorded data from test.

Expected Outcome
A properly-operating ICP system will closely resemble this graph.

Follow-On Procedure
None
1520 2 ENGINE SYSTEM TESTS AND INSPECTIONS

0 to 60 MPH, RPM, Load, IMP, EBP, and APP1 Graph

Overview
This graph shows the Intake Manifold Pressure (IMP) signal value operating as designed, and is a representation
only, no two graphs will be exactly alike. This test does not give pass or fail results, it only allows the user to
validate the IMP signal value under load. Accelerator Pedal Position 1 (APP1) signal value must be 99.6% to
successfully reach peak boost during this test. Low IMP can be the result of low Injection Control Pressure (ICP).
Diagnose low ICP concerns before diagnosing low IMP concerns. IMP can vary based on ECM calibration and
vehicle weight. Using Electronic Service Tool (EST) with Navistar® Engine Diagnostics, monitor turbocharger
wastegate operation to verify low boost; IMP signal value may be as low as 29 psi (200 kPa) on lower horsepower
configurations; Analyze 0 to 60 MPH Test signal values only during acceleration, not deceleration or shifting.

Special Tools
• Navistar® Engine Diagnostics
• Interface Cable (RP1210B-compliant, supporting J1939 and J1708)

Equipment Condition
None

Test Setup
1. Key-On, Engine-Off (KOEO).
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Log in to Navistar® Engine Diagnostics
4. If not done previously, perform 0 to 60 MPH Test (page 1514) and save recording.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1521

Procedure

Figure 595 Intake Manifold Pressure Graph

1. Accelerator Pedal Position 1 (APP1) (percent) [Orange]
2. Exhaust Back Pressure (EBP) (psi) [Red]
3. Engine Load (percent) [Blue]
4. Engine Speed (RPM) [Green]
5. Intake Manifold Pressure (IMP) (psi) [Purple]

1. Verify IMP signal value is between 29 psi (200 kPa) to 42 psi (289 kPa), with APP1 signal value at 99.6 %,
and engine speed between 1800 rpm to 2200 rpm.
2. Verify Exhaust Back Pressure (EBP) is less than 70 psi (482 kPa), with APP1 signal value at 99.6 %, and
engine speed between 1800 rpm to 2200 rpm.
3. Compare graph information with recorded data from test.

Expected Outcome
Properly operating system signals will closely resemble this graph.
1522 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Follow-On Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1523

Normal Exhaust Gas Temperature Graph

Overview
This graph shows an aftertreatment system operating as designed, and does not give pass or fail results. It only
allows the user to validate operation of the aftertreatment system by monitoring exhaust gas temperatures.
NOTE: It is normal to see Diesel Oxidation Catalyst Intake Temperature (DOCIT), Diesel Particulate Filter Intake
Temperature (DPFIT), and Diesel Particulate Filter Outlet Temperature (DPFOT) signal values fluctuate at the
beginning and end of the Onboard Filter Cleanliness Test (OBFCT). A snapshot is recorded below with Diesel
Particulate Filter (DPF) soot load level 1.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface Cable (RP1210B-compliant, supporting J1939 and J1708)

Equipment Condition
None

Test Setup
1. Key-On, Engine-Off (KOEO).
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Log in to Navistar® Engine Diagnostics.
4. Perform Onboard Filter Cleanliness Test (OBFCT) (page 1331) if not already done and saved.
1524 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Procedure

Figure 596 Normal Exhaust Gas Temperatures

1. Diesel Oxidation Catalyst Intake 2. Diesel Particulate Filter Intake 3. Diesel Particulate Filter Outlet
Temperature (DOCIT) (degrees Temperature (DPFIT) (degrees Temperature (DPFOT) (degrees
Fahrenheit) Fahrenheit) Fahrenheit)

1. Compare graph information with recorded data from test.

2. After Diesel Oxidation Catalyst (DOC) reaches operating temperature and stabilizes, verify DPFIT signal
value is at approximate target temperature for current soot load level (see Soot Load Level vs. Exhaust Gas
Target Temperature Chart).
3. Verify DOCIT signal value is between 550°F (287°C) to 800°F (427°C).

Expected Outcome
An aftertreatment system that is working properly will have signals that will be close to this graph.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1525

Follow-On Procedure
None
1526 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Erratic Exhaust Gas Temperatures Graph

Overview
This graph shows erratic exhaust gas temperatures. Erratic temperatures in the exhaust stream occur when
the Diesel Oxidation Catalyst (DOC) becomes contaminated, or an issue with the Aftertreatment Fuel Injector
(AFI) is present. This test does not give pass or fail results. It only allows the user to validate operation of the
aftertreatment system by monitoring exhaust gas temperatures.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface Cable (RP1210B-compliant, supporting J1939 and J1708)

Equipment Condition
None

Test Setup
1. Key-On, Engine-Off (KOEO).
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Log in to Navistar® Engine Diagnostics.
4. Perform Onboard Filter Cleanliness Test (OBFCT) (page 1331) if not already done and saved.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1527

Procedure

Figure 597 Graph Information Identification

1. Diesel Particulate Filter Intake Temperature (DPFIT) (degrees Fahrenheit)
2. Diesel Particulate Filter Outlet Temperature (DPFOT) (degrees Fahrenheit)
3. Diesel Oxidation Catalyst Intake Temperature (DOCIT) (degrees Fahrenheit)

1. Compare graph information with recorded data from test.

2. After Diesel Oxidation Catalyst (DOC) reaches operating temperature, verify Diesel Particulate Filter Intake
Temperature (DPFIT) and Diesel Particulate Filter Outlet Temperature (DPFOT) signal values do not
fluctuate more than 50°F (28°C) within 2 minutes. In this graph, DPFIT and DPFOT fluctuate more than
50°F (28°C) within 2 minutes.

Expected Outcome
Exhaust gas temperatures that fluctuate more than specified will have signal values that match this graph.

Follow-On Procedure
None
1528 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Low Exhaust Gas Temperatures Graph

Overview
This graph shows low exhaust gas temperatures indicating a restricted Aftertreatment Fuel Injector (AFI). Low
temperatures in the exhaust stream occur when fuel flow from the AFI is restricted, resulting in less fuel burning
in the exhaust stream. This test does not give pass or fail results. It only allows the user to validate operation of
the aftertreatment system by monitoring exhaust gas temperatures.
NOTE: It is normal to see Diesel Oxidation Catalyst Intake Temperature (DOCIT), Diesel Particulate Filter Intake
Temperature (DPFIT), and Diesel Particulate Filter Outlet Temperature (DPFOT) signal values fluctuate at the
beginning and end of the Onboard Filter Cleanliness Test (OBFCT). A snapshot is recorded below with Diesel
Particulate Filter (DPF) soot load level 1.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface Cable (RP1210B-compliant, supporting J1939 and J1708)

Equipment Condition
None

Test Setup
1. Key-On, Engine-Off (KOEO).
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Log in to Navistar® Engine Diagnostics.
4. Perform Onboard Filter Cleanliness Test (OBFCT) (page 1331) if not already done and saved.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1529

Procedure

Figure 598 Low Exhaust Gas Temperatures

1. Diesel Particulate Filter Intake 2. Diesel Particulate Filter Outlet 3. Diesel Oxidation Catalyst Intake
Temperature (DPFIT) (degrees Temperature (DPFOT) (degrees Temperature (DOCIT) (degrees
Fahrenheit) Fahrenheit) Fahrenheit)

1. Compare graph information with recorded data from test.

2. After Diesel Oxidation Catalyst (DOC) reaches operating temperature and stabilizes, verify DPFIT signal
value is at approximate target temperature for current soot load level (see Soot Load Level vs. Exhaust Gas
Target Temperature Chart).
3. Verify DOCIT signal value is between 550°F (287°C) to 800°F (427°C).

Expected Outcome
An aftertreatment system with low exhaust gas temperatures indicative of a restricted AFI, will have signal values
that match this graph .
1530 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Follow-On Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1531

Air Management System Tests

Exhaust Back Pressure Valve (EBPV) Test

Overview
This test measures performance of the Exhaust Back Pressure Valve (EBPV). This visual and functional test
uses pre-programmed actions of the Engine Control Module (ECM) to cycle the EBPV three times after the key
is turned Off. In recent calibration releases EBPV only cycles at or above an ECT of 140°F (60°C).

Special Tools
None

Equipment Condition
Remove truck-mounted components as necessary to have a clear view, and to allow access to EBPV.

Test Setup
1. Key-On, Engine-Off (KOEO).
2. Ensure air tanks are full.

Procedure

Figure 599 Exhaust Back Pressure Valve (EBPV)

1. Start engine and warm above 140°F (60°C).

2. Shut engine off and visually monitor EBPV (Figure 599) for movement (if necessary, use a helper):
• If EBPV cycles fully open and fully closed, it is working.
• If EBPV does not cycle, go to next step.
3. Disconnect air supply to EBPV.
4. Start engine and let it idle for a minimum of 5 seconds.
5. Shut engine off and check for airflow to the EBPV (if necessary, use a helper):
• If airflow cannot be heard or felt, go to Step 6.
• If airflow can be heard or felt go to Step 7.
1532 2 ENGINE SYSTEM TESTS AND INSPECTIONS

6. Disconnect vehicle air supply to Air Control Valve (ACV) and check for air supply to the valve.
• If airflow cannot be heard or felt, diagnose vehicle air system.
• If airflow is heard or felt, replace the Air Control Valve (ACV).
7. Check EBPV and linkage for binding and sticking.

Expected Outcome
The EBPV will cycle fully open and closed three times when the ignition key is turned Off. In recent calibration
releases EBPV only cycles at or above an ECT of 140°F (60° C).

Follow-on Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1533

Boost Control System Test

Overview
Verify operation of Turbocharger 2 Wastegate Control (TC2WC) solenoid, turbocharger wastegate actuator,
turbocharger wastergate, and air lines. Determine root cause of boost control system failures. All steps may
not need to be performed. If a step identifies a failed component, replace that component and retest for original
problem.

WARNING:

To prevent personal injury or death, wear safety glasses with side shields.

CAUTION:

Limit supply air pressure to 21.5 psi (148 kPa) to prevent damage to system lines, hoses,
and Turbocharger 2 Wastegate Control (TC2WC) solenoid.

Special Tools
• Pressure Test Kit ZTSE4409
• Ruler or tape measure

Equipment Condition
None

Test Setup
Remove components as necessary to access TC2WC solenoid and turbocharger wastegate actuator.
1534 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Procedure

Figure 600 Boost Control System Lines - Shown with Interstage Cooler (ISC) Removed for Clarity
1. Supply line 3. Turbocharger wastegate
2. Dump line actuator line

1. Perform visual inspection of Turbocharger 2 Wastegate Control (TC2WC) solenoid supply lines, wastegate
actuator and dump lines (Figure 600).
2. Using Pressure Test Kit ZTSE4409, apply 21.5 psi (148 kPa) air pressure to all three Boost control lines one
at a time. Check for leaking hoses. Repair broken or damaged lines as needed.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1535

Figure 601 Turbocharger 2 Wastegate Control (TC2WC) Solenoid

1. Boost Supply from throttle inlet (supply)
2. Electrical connector
3. To wastegate actuator
4. Vent / Dump to Turbocharger Air Inlet Duct

3. Check electrical connector (2) for bent, loose, damaged, or corroded pins. Repair as needed.
4. Turn ignition Key-Off.
5. Disconnect line from TC2WC solenoid to Vent / Dump (4) and Wastegate Actuator (3).
6. Using Pressure Test Kit ZTSE4409, apply 21.5 psi (148 kPa) air to TC2WC supply (1). With Key-Off, air
should pass from Boost Supply (1) to Wastegate Actuator (3), and no air should be exiting the Vent / Dump
(4). If air flows thru the vent / dump (4) at Key-Off, replace the TC2WC solenoid.
7. Start engine and run at low idle.
8. Apply 21.5 psi (148 kPa) air thru the supply line (1). No air should pass to either Wastegate Actuator (3) or
Vent / Dump (4). If air flows through TC2WC solenoid to either Wastegate Actuator (3) or vent / dump (4) at
idle, replace TC2WC solenoid.
1536 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 602 Pressure Test Kit ZTSE4409 Installed on Turbocharger Wastegate Actuator
1. Turbocharger Wastegate
Actuator

9. Install Pressure Test Kit on wastegate actuator (1), and connect to regulated air pressure.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1537

Figure 603 Turbocharger Actuator Rod Measurement

1. Actuator rod mark

10. Mark actuator rod (1) at base of actuator.

11. Apply 21.5 psi (148 kPa) of regulated air pressure to wastegate actuator.
12. Measure turbocharger actuator rod movement and compare to specification 0.51 in (13 mm). Relieve air
pressure from actuator. If actuator rod does not move properly, go to Step 14. If actuator rod moves per
specification, go to Step 13.
13. Apply 8 psi (55 kPa) of regulated air pressure to wastegate actuator. If actuator rod moves replace wastegate
actuator. If actuator rod does not move end testing.
1538 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 604 Turbocharger Actuator Rod Removal

14. Remove turbocharger actuator rod from turbocharger wastegate arm.

15. Move turbocharger wastegate lever by hand. If turbocharger wastegate lever moves without binding, install
a new wastegate actuator. If turbocharger wastegate lever sticks or binds, repair of replace turbocharger.

Expected Outcome
Determine if Turbocharger 2 Wastegate Control (TC2WC) solenoid, turbocharger wastegate actuator,
turbocharger wastergate, and air lines are operating properly.

Follow-On Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1539

MAF Sensor Calibration

Overview
The Mass Air Flow (MAF) sensor monitors and calculates the amount and density of air entering the engine.
The Engine Control Module (ECM) uses this information to calculate the amount of Exhaust Gas Recirculation
(EGR) flow during engine operation. This test displays pass, fail or abort results.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics.
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Equipment Condition
1. Engine speed at low idle (700 RPM)
2. Key-On, Engine-Running (KOER) Standard Test run.
3. Engine Coolant Temperature 1 (ECT1) at or above 176°F (80°C)
4. Engine Oil Temperature (EOT) above 176°F (80°C)
5. Vehicle not moving
6. Accelerator Pedal Position (APP) at 0%
7. Brake pedal released
8. Clutch pedal released

MAF Calibration Requirements

NOTE: Only run MAF Calibration Procedure if one of following conditions have occurred:
• SPN 132 FMI 13 is set
• Engine Control Module (ECM) replacement
• Repair or replacement of MAF sensor or circuit
• Repair or replacement of Intake Manifold Pressure (IMP) sensor or circuit
• Repair or replacement of Intake Manifold Temperature (IMT) sensor or circuit
• Repair or replacement of intake air system
• Repair or replacement of Charge Air Cooler (CAC) system
• Repair or replacement of turbocharger
• Repair or replacement of Engine Throttle Valve (ETV)
• Repair or replacement of Exhaust Gas Recirculation (EGR) valve
• Repair of base engine (cylinder head, pistons, camshaft)
• Engine replacement or rebuild

MAF Calibration Pre-Checks

• No active fault codes, other than SPN 132 FMI 13.
1540 2 ENGINE SYSTEM TESTS AND INSPECTIONS

• Diesel Particulate Filter (DPF) Status = regeneration not needed.

• No leaks in intake air system.
• No leaks in exhaust system.
• No shop exhaust hose attached.
• No engine performance issues.
• No engine misfire issues.
• Vehicle hood is closed.
• Transmission in Park or Neutral.
• Clutch pedal released
• Engine Fan OFF.
• Park Brake Applied.
• Power Takeoff (PTO) disabled.
• Direct Drive Power Takeoff (PTO) disconnected
• Air conditioning OFF.
• Accelerator pedal not pressed
• Mass Air Flow (MAF) sensor within Key-On, Engine-Off (KOEO) specification.
• Intake Manifold Pressure (IMP) sensor within KOEO specification.
• Intake Manifold Temperature (IMT) sensor within -22°F (-30°C) and 257°F (125°C)
• Snow Valve Off
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1541

Figure 605 MAF Sensor Calibration

Test Setup
1. Key On, Engine Off (KOEO).
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Perform KOER Standard Test (page 1380).

Procedure

Figure 606 Menu – Select Test

1542 2 ENGINE SYSTEM TESTS AND INSPECTIONS

1. Start engine and run to operating temperature of 176°F (80°C) or more.

2. Select Procedures > KOER Procedures > MAF Sensor Calibration (Figure 606).
3. Select: Tools > Start Recording Snapshot.

Figure 607 Test Abort Temperature Out of Range

Figure 608 Test Complete

4. Click OK (Figure 608) when the test is complete to return to Navistar® Engine Diagnostics homescreen.
5. Select: Tools > Stop Recording Snapshot.

Expected Outcome
Test will run successfully and give pass results.

Follow-On Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1543

Exhaust Gas Recirculation Valve (EGRV) Operational Test

Overview
This test commands the Exhaust Gas Recirculation (EGR) valve to perform a self-diagnostic routine and
broadcast a fault code if there is a problem. The test commands the EGR valve completely open, waits for
a significant dwell time, commands the EGR valve completely closed, waits for a significant dwell time, and
repeats the test multiple times. Long dwell times and repeating tests are important. A stuck EGR valve will
broadcast an SPN 2791 FMI 7 fault code. Allowing at least 30 seconds between Output State tests is critical.
Output State tests will not finish without a minimum of 30 seconds between them. This is a manually-controlled
test.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant, supporting J1939 and J1708)

Equipment Condition
None

Test Setup
1. Key-On, Engine-Off (KOEO)
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Log in to Navistar® Engine Diagnostics.
4. Perform KOEO Standard Test (page 1357).

Procedure

Figure 609 Tests – Output State Low

1. Select: Tests > KOEO Tests > Output State Low Test (Figure 609) and wait 30 seconds for test to run.
1544 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 610 Tests – Output State High

2. Select Tests > KOEO Tests > Output State High Test (Figure 610) and wait 30 seconds for test to run.
3. Repeat step 2 and step 3 in sequence three more times, waiting 30 seconds for each test to run.

Expected Outcome
A good EGR valve will not set SPN 2791 FMI 7 during the EGRV Operational Test.

Follow-On Maintenance
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1545

High-Pressure Charge Air Cooler (HPCAC) Pressure Test

Overview
Verifies High-Pressure Charge Air Cooler (HPCAC) integrity using compressed air to check for leaks.

WARNING:

To prevent personal injury or death, wear safety glasses with side shields.

WARNING:

To prevent personal injury or death, keep hoses and mating surfaces clear of oil and
grease.

Special Tools
Charge Air Cooler Pressure Test Kit – (ZTSE4341)

Equipment Condition
Remove piping, hump hoses and clamps from turbocharger and Engine Throttle Valve (ETV) or intake manifold.
1546 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Test Setup

Figure 611 Bleed-Off Coupler Installed on HPCAC Inlet

1. Safety cable
2. Bleed-off coupler
3. hose clamp (2)
4. Small hose
5. High-Pressure Charge Air Cooler (HPCAC) Inlet

NOTE: Charge Air Cooler (CAC) can remain in chassis for this test.
1. Install Charge Air Cooler Pressure Test Kit onto HPCAC using existing hump hoses and clamps.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1547

2. Double clamp hump hose connections and tighten hose clamps to 100 in-lbs.

WARNING:

To prevent possible injury or death, secure test adaptors with safety cables, and stay
clear while system is pressurized.

Figure 612 CAC Pressure Test Kit Installed on HPCAC Outlet

1. Air pressure gauge / regulator assembly
2. Quick disconnect fitting
3. Gauge coupler
4. Hose clamp (2)
5. Large hose
6. High-Pressure Charge Air Cooler (HPCAC) Outlet
7. Safety cable
1548 2 ENGINE SYSTEM TESTS AND INSPECTIONS

3. Close air pressure regulator and drain valve.

CAUTION:

Adjust air regulator valve to minimum setting before connecting shop air supply.
Accidentally applying high-pressure can damage tool components or HPCAC.
4. Attach shop air to valve on gauge / regulator assembly.

Procedure

WARNING:

Do not exceed 30 psi air pressure on CAC system during testing.

1. Slowly open air pressure regulator valve until pressure reaches 30 psi (207 kPa).
2. Close air pressure regulator when pressure reaches 30 psi (207 kPa).
3. Monitor pressure gauge and measure the rate of pressure decay. System should not drop more than 5 psi
in 15 seconds.
4. If a leaking connection is found, tighten or repair connection and repeat Steps 1 thru 3.
5. Repeat Steps 1 thru 4 at least 3 times to confirm readings.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1549

Figure 613 Bleed-off Coupler

1. Bleed-off coupler 2. Bleed-off valve

6. Open bleed-off valve slowly to release compressed air.

Expected Outcome
Determine if High-Pressure Charge Air Cooler (HPCAC) system will hold air pressure. If HPCAC system drops
more than 5 psi in 15 seconds during test, determine component(s) that are leaking.
1550 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Follow-On Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1551

Interstage Cooler (ISC) Pressure Test

Overview
Test Interstage Cooler (ISC) for air leaks using compressed air.

WARNING:

To prevent personal injury or death, tighten pressure test kit properly before testing.

WARNING:

To prevent personal injury or death, keep mating surfaces and hoses clear of oil and
grease.

WARNING:

To prevent personal injury or death, wear safety glasses with side shields.

WARNING:

Warning: Limit compressed air pressure to 30 psi (207 kPa).

Tools Required
• Air pressure regulator
• Interstage Cooler Test Kit ZTSE4937
• Spray bottle with soapy water

Equipment Condition
None
1552 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Test Setup

Figure 614 ISC Test Kit Setup

1. Air Inlet Disc Plug 3. Air pressure regulator assembly 4. Air Inlet Disc Plug Retaining
2. Air Outlet Cover Bracket

1. Cover ISC air inlet with Air Inlet Disc Plug (Item 1).
2. Install Air Inlet Disc Plug Retaining Bracket (Item 4) on top of Air Inlet Disc Plug and tighten clamping
bolt to seal ISC air inlet.
3. Attach Air Outlet Cover (Item 2) to ISC air outlet, and tighten bolts.
4. Connect air pressure regulator assembly (Item 3) to Air Outlet Cover, and turn air regulator valve to
lowest setting.

Procedure
1. Connect shop air supply to air pressure regulator assembly.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1553

2. Slowly turn air regulator valve till pressure reaches 30 psi (207 kPa).
3. Close air regulator valve and monitor gauge for 15 seconds.
• If air pressure drops 5 psi (34 kPa) or more after 15 seconds, spray connections and ISC with a soapy
water to determine location of leak.
4. Repeat steps 2 and 3 twice to verify reading.
• If air pressure still drops 5 psi (34 kPa) or more after 15 seconds, replace ISC.

Expected Outcome
Technician will determine if ISC is leaking.

Follow-On Procedure
None
1554 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Low-Pressure Fuel System Tests

Fuel Delivery Pressure (FDP) Test

Overview
Verifies proper operation of the Fuel Delivery Pressure (FDP) system. FDP must be within specification to ensure
proper performance of engine.

WARNING:

To prevent personal injury or death, wear safety glasses with side shields.

WARNING:

To prevent personal injury or death, do not smoke and keep fuel away from flame and
sparks.

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

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Fuel Pressure Gauge ZTSE4681
• Fuel / Oil Pressure Test Coupler (Compucheck) ZTSE4526
• Fuel Pressure Test Kit ZTSE4657
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Equipment Condition
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1555

Test Setup

Figure 615 Fuel Pressure Gauge to Fuel Filter Module Connection

1. Fuel Pressure Gauge ZTSE4681
2. Fuel Pressure Test Kit ZTSE4657
3. Fuel / Oil Pressure Test Coupler ZTSE4526

1. Key-Off.
2. Fuel Pressure Gauge ZTSE4681 (Figure 615) (Item 1) connected to Fuel Filter Module test port.
3. Valve closed on fuel gauge.
4. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
5. Log into Navistar® Engine Diagnostics.
1556 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Procedure

Figure 616 Fuel Pressure Gauge ZTSE4681

1. Turn Key-On, Engine-Off (KOEO) to energize fuel pump (pump will run for 10 to 20 seconds).
2. Monitor and record fuel pressure displayed on gauge.
3. Turn key Off for a minimum of 30 seconds, allowing Engine Control Module (ECM) to reset.
4. Electric Fuel Pump can also be commanded on by using Output State High Test in Navistar® Engine
Diagnostics.
5. Perform Output State High Test (page 1359) and monitor gauge and sensor signal in Navistar® Engine
Diagnostics.
6. Repeat as necessary to get an accurate and steady pressure reading.

Expected Outcome
Fuel Delivery Pressure (FDP) will be within specifications (page 1677).

Follow-On Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1557

Fuel Pump Voltage Test

Overview
This test is used to determine if the Engine Control Module (ECM) is commanding the Electric Fuel Pump (EFP)
by measuring supply voltage to the EFP.
NOTE: Output state high test can be used to activate fuel pump.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Digital Multimeter (DMM)
• Electric Fuel Pump (EFP) Breakout Harness ZTSE6023
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Equipment Condition
None

Test Setup
1. Key-Off.
2. Install Breakout Harness ZTSE6023 between Electric Fuel Pump (EFP) and EFP harness connector.
3. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
4. Log into Navistar® Engine Diagnostics.

Procedure

Figure 617 Pin-Point Test 1

1. Use Navistar® Engine Diagnostics and the Output State Test HIGH (page 1359) to command fuel pump On.
1558 2 ENGINE SYSTEM TESTS AND INSPECTIONS

2. While Electric Fuel Pump (EFP) is energized, use Digital Multimeter (DMM) to measure voltage between
Breakout Harness ZTSE6023 pin-6 and pin-1. Record measurement.

Figure 618 Pin-Point Test 2

3. While EFP is energized, use Digital DMM to measure voltage between Breakout Harness ZTSE6023, pin-4,
and pin-1. Record measurement.
4. Repeat steps 1 through 3 as necessary.

Expected Outcome
Voltage reading between pin-6 and pin-1 and voltage reading between pin-4 and pin-1 are B+ ± 0.5 volts.

Follow-On Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1559

Clean Fuel Source Test

Overview
Test verifies fuel supply system is not restricted (fuel tank, lines, and chassis-mounted filter (if equipped)), by
providing a clean unrestricted fuel source.

WARNING:

To prevent personal injury or death, do not smoke and keep fuel away from flames and
sparks.

WARNING:

To prevent personal injury or death, wear safety glasses with side shields.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)
• Clean Fuel Source Tool – 15–637–01
• Fuel Pressure Gauge – ZTSE4681
• Fuel Pressure Test Kit – ZTSE4657
• Fuel / Oil Pressure Test Coupler (Compucheck) – ZTSE4526

Equipment Condition
None

Test Setup
1. Key-On, Engine-Off (KOEO)
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Log into Navistar® Engine Diagnostics
1560 2 ENGINE SYSTEM TESTS AND INSPECTIONS

4. Disconnect fuel inlet dry-break fitting from the fuel filter module.

Figure 619 Fuel Filter Module

1. Fuel Supply Line/Clean Fuel Source Dry Break Fitting
2. Fuel inlet
3. Fuel Filter Module
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1561

5. Connect Clean Fuel Source Tool 15-637-01 (item 1) to fuel inlet (item 2) of fuel filter module (item 3)
(Figure 619) and prime using primer bulb

Figure 620 Fuel Pressure Gauge to Fuel Filter Module Connection

1. Fuel Pressure Gauge ZTSE4681
2. Fuel Pressure Test Kit ZTSE4657
3. Fuel/Oil Pressure Test Coupler ZTSE4526

6. Connect Fuel Pressure Gauge (Item 1) to Fuel Filter Module test port using Fuel Pressure Test Kit (item
2) and Fuel/Oil Pressure Test Coupler (item 3).

Procedure
1. Select Tests > KOEO Tests > Output State High Test (page 1359) to energize Electric Fuel Pump (EFP).
2. Observe fuel pressure reading while EFP is energized.
3. Activate EFP as many times as needed to record a consistent and accurate pressure reading.

Expected Outcome
Fuel pressure reading will be within specification.
1562 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Follow-on Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1563

General Test Procedures

Cable Drop Test

Overview
This test sends electrical current through both the positive and negative sides of the circuit being tested to
calculate voltage drop. A voltage drop reduces a circuits ability to pass current.

Special Tools
EXP-1000-HD-NAV, Handheld Battery and Electrical Diagnostic Tool with Wi-Fi

Equipment Condition
• Good batteries, fully charged.
• Battery terminals and electrical connections clean and tight.

Test Setup

WARNING:

To prevent property damage, personal injury, and / or death, shift transmission to Park or
Neutral, set parking brake, and install wheel chocks before doing diagnostic or service
procedures.

WARNING:

To prevent personal injury or death, always wear approved safe eye protection when
performing vehicle diagnostic or service procedures.
Connect Main Clamps connector to EXP-1000 HD NAV tool. Connect red clamp to battery positive (+) terminal
or adapter, and connect black clamp to battery negative (–) terminal or adapter.

Procedure
NOTE: This test requires a complete circuit. If you are testing a system with a remote solenoid, you can test
from battery to solenoid, but not from battery to starter.

0000453003

1. Highlight Cable Drop Test icon and press SELECT.

2. Select type of circuit being tested (Starter, Alternator, Chassis or Accessory).
3. Select battery pack configuration (Single or Dual).
1564 2 ENGINE SYSTEM TESTS AND INSPECTIONS

4. Select rated amperage or output of circuit.

Figure 622 Cable Drop Test Clamp Connections

5. Connect Main Clamps to positive and negative wires of component under test, as close to component as
possible. Rock clamps back and forth to ensure good connection.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1565

0000453063

Figure 623 DMM Clamps A028

6. Connect EXP-1000 HD DMM Clamps to positive and negative battery terminals. Rock clamps back and
forth to ensure good connection.

3
0000453163

Figure 624 Voltage Drop Test Results (Typical)

1. Total circuit voltage drop
2. Voltage drop across positive (+) side of circuit
3. Voltage drop across negative (-) side of circuit
1566 2 ENGINE SYSTEM TESTS AND INSPECTIONS

7. When finished testing tool will display:

• Total circuit voltage drop
• Voltage drop across positive (+) side of circuit
• Voltage drop across negative (-) side of circuit

Expected Outcome
Technician will determined if voltage drop is in specification: positive (+) side of circuit less than 0.5V AND
negative (-) side of circuit less than 0.5V.

Follow-On Procedure
None.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1567

Crankcase Pressure Test

Overview
Determines if crankcase pressure is within specification to help determine worn or damaged internal engine
parts.

WARNING:

To prevent personal injury or death, when routing test line, do not crimp line, run line too
close to moving parts, or let line touch hot engine. Secure manometer and test line to
not obstruct vehicle operation.

Special Tools
• Crankcase Pressure Test Tool ZTSE4039
• Digital Manometer ZTSE2217
• Slack Tube® Manometer ZTSE2217A
• Standard shop bolt (to plug intake tube)

Equipment Condition
Remove necessary truck-mounted components to access breather tubes and install test equipment.

Test Setup

Figure 625 ZTSE4039 (0.406 in. diameter)

1. To magnehelic gauge or manometer
2. To valve cover
1568 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 626 Digital Manometer

 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1569

Figure 627 Slack Tube® Manometer (ZTSE2217A)

1. Perform Crankcase Oil Separator (CCOS) Speed Test. (page 1572)

NOTE: Ensure Engine Coolant Temperature (ECT) is at or above 158°F (70°C) and fan is OFF when
reading is taken at high idle (WOT). Readings taken with fan ON are invalid.
1570 2 ENGINE SYSTEM TESTS AND INSPECTIONS

2. Turn engine OFF.

Figure 628 Crankcase Pressure Test Adapter Installed

1. Breather elbow
2. Crankcase breather outlet tube
3. Digital Manometer
4. Crankcase Pressure Test Tool

3. Disconnect breather outlet tube from breather elbow.

4. Plug tube to prevent dirt ingestion.
5. Install crankcase pressure test adapter on breather outlet tube.
6. Install manometer to crankcase pressure test adapter.

Procedure
1. Start engine.
2. Press accelerator pedal to the floor and hold. While pedal is pressed to the floor, allow manometer reading
to stabilize then record pressure reading and fan is OFF when reading is taken at high idle (WOT). Readings
taken with fan ON are invalid.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1571

3. Turn engine OFF.

4. If pressure is above specification and engine has an air compressor, disconnect compressor discharge line
and repeat steps 1 through 3.

Expected Outcome
Determine if crankcase pressure is in specification. If pressure is above specification, determine if air compressor
or internal engine damage / wear are the cause.

Follow-on Procedure
None
1572 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Crankcase Oil Separator (CCOS) Speed Test

Purpose
Determine if engine mounted crankcase breather is operating at correct speeds. A poorly operating breather
system can lead to excessive oil carryover into the air intake system which can eventually lead to turbocharger
coking.
Special Tools
• Digital Multimeter (DMM) - Hz Setting
• Camshaft Position (CMP) sensor (Dealer sourced) or existing CCOSS sensor
• CMP Breakout Harness ZTSE4951

Procedure

WARNING:

To prevent personal injury or death, shift transmission to park or neutral, set parking
brake, and block wheels before running engine.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1573

Figure 629 Crankcase Breather / Oil Separator (No Speed Sensor)

1. Sensor provision

1. If engine mounted crankcase breather / oil separator does not have a speed sensor installed (Figure 629),
locate sensor provision on top of crankcase breather / oil separator. Obtain CMP sensor. If needed, wrap
electrical tape around base of sensor to ensure a snug fit, and insert CMP sensor into sensor provision.
2. Connect Breakout Harness ZTSE4950 to sensor and leave harness disconnected.
3. Connect DMM to breakout harness and set to measure Hz (Hertz).
4. Warm engine to operating temperature of 176˚F before collecting data. Take DMM reading and then multiply
by 30 to get breather RPM.
NOTE: Oil: Viscosity, temperature, pressure and age (miles and hours) can affect breather operational speeds.
5. If crankcase breather spins slower then minimum rpm specification, do the following:
• Verify engine oil level, condition, miles and hours since last oil change are within specification.
• Verify engine oil pressure is in specification.
• Inspect crankcase breather / oil separator for excessive rotational resistance, sludge, or other
abnormalities.
• Verify good oil flow from the breather oil jet in lower housing.
1574 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Engine RPM Hz Reading Minimum CCOS RPM

Idle 150 Hz 4,500 RPM
High Idle 267 Hz 8,000 RPM

Expected Outcome
Determine if crankcase breather spins above minimum rpm.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1575

Coolant Heater Assembly Test

Overview
Verify operation of the Engine Coolant Heater.

Special Tools
Digital Multimeter (DMM)

Equipment Condition
None

Test Setup
Engine must be cold to perform this test.

Procedure

Figure 630 Engine Coolant Heater

1. Heater element
2. Cord adapter
3. O-ring
1576 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 631 External Plug Shown with Lid Removed for Clarity

1. Measure resistance at external plug for Oil Pan / Coolant Heater.

• Reading should be approximately 12 ohms. If unit is equipped with both coolant and oil pan heater,
they are wired on the same plug and the reading should be approximately 8.5 ohms. If reading is within
specifications, go to step 3.
• If reading is not within specifications, go to step 2.
2. Disconnect cord from coolant heater on the left side of the engine block and take resistance reading at the
terminals on the heater itself. See information below for further direction.
• If the reading is approximately 12 ohms, replace cord.
• If the reading is not approximately 12 ohms, install cord and go to step 3.
3. Connect standard extension cord between wall outlet and truck-mounted plug (Figure 631).
4. Wait 2 to 3 minutes, and then check if coolant heater is heating up by feeling cord adapter.

Expected Outcome
Resistance checks will be within specification and coolant heater will heat when plugged in.

Follow-On Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1577

Electrical System Test

Overview
This test consists of a Battery Pack Test, Starter System Test Procedure, and Charging System Test Procedure
that run consecutively. Not all tests may need to be run, but must be run in order. Perform this test after being
directed from Starting and Charging System Operational Checkout Procedure or fault codes.

3
5

4
0000453143

Figure 632 EXP-1000-HD-NAV Handheld Battery and Electrical Diagnostic Tool with Wi-Fi
1. MAIN MENU selection area
2. Arrow keys
3. Alphanumeric keys
4. POWER key
5. Voltmeter

The EXP-1000-HD-NAV Handheld Battery and Electrical Diagnostic Tool with Wi-Fi can communicate to the
Battery Management Information System (BMIS). BMIS is a web-based application that collects test data and
can produce reports.
1578 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Special Tools
• EXP-1000-HD-NAV, Handheld Battery and Electrical Diagnostic Tool with Wi-Fi
• Inductive Amp Clamp A018

Equipment Condition
1. Batteries and Electrical System Inspection (page 1666) has been performed.
2. Battery terminals clean.
3. Batteries fully charged.
4. Transmission in Park or Neutral
5. Parking brake set.
6. Wheel chocks installed.
7. Left side skirt removed to access batteries, if required.

Test Setup

WARNING:

To prevent property damage, personal injury, and / or death, shift transmission to Park or
Neutral, set parking brake, and install wheel chocks before doing diagnostic or service
procedures.

WARNING:

To prevent personal injury or death, always wear approved safe eye protection when
performing vehicle diagnostic or service procedures.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1579

NOTE: Keep all generated testing information to be submitted later for warranty claim, if warranty
applies.
1. All vehicle accessory loads OFF and ignition key OFF.

0000453043

Figure 633 Main Clamps A139

1580 2 ENGINE SYSTEM TESTS AND INSPECTIONS

2. Connect Main Clamps connector to EXP-1000-HD-NAV tool. See tags on Main Clamps cable for
additional information.
NOTE: Attach Lead Stud Adapters if battery has threaded studs. Do not attach Main Clamps to
battery threaded studs.

0000453083

Figure 634 Lead Stud Adapters A008

3. Connect red clamp to battery positive (+) post closest to the starter wire and connect black clamp to
battery negative (–) post closest to the chassis ground wire.
4. Rock clamps back and forth. Both clamps must be firmly connected before testing. If CHECK
CONNECTION message appears, clean terminals and / or reconnect clamps.

Battery Pack Test Procedure

1. If required, power ON the EXP-1000-HD-NAV tool. If this is the first time the tool is connected, see tool
setup documentation.
2. Select USER ID, NEXT and enter your PIN. If this is the first time you have used this tool, select + ADD
USER.

0000452963

3. Highlight the System Test icon and press SELECT.

4. At the MANUFACTURER screen, select YES for testing a Navistar® truck and press NEXT. Selecting YES
is required if Navistar warranty will be processed.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1581

5. Enter last eight digits or full Vehicle Identification Number (VIN) and press NEXT. Pressing alphanumeric
keys more than once will scroll thru the possible numbers and letters for that key.
6. Select battery pack configuration. Select DUAL PACK if vehicle has auxiliary batteries.
7. Select number of batteries in pack.
8. If required, select correct BATTERY VOLTS.

CAUTION:

Each battery in the battery pack should be the same type, chemistry and rating.
9. Select BATTERY TYPE. See battery label. For Fleetrite / Navistar battery description, enter battery part
number into Parts Catalog web site Search field and click Part Number. Usually Group 31.

Battery Type Description

GROUP 31 Heavy duty commercial truck battery. Common dimensions: 12.9” x 6.75”
x 9.27”. Most commonly used battery group type in Navistar vehicles.
COMMERCIAL 4D, 8D Larger than group 31 batteries. Common dimensions:
• (4D) 20.5” x 8.13” x 10.0”
• (8D) 20.75” x 11.0” x 11.0”
AUTOMOTIVE Regular 12-volt passenger vehicle battery. Usually smaller than Group
31 batteries.
1582 2 ENGINE SYSTEM TESTS AND INSPECTIONS

10. Select BATTERY CHEMISTRY.

Battery Chemistry Description

REGULAR FLOODED Conventional, “wet”, liquid lead-acid filled with electrolyte.
Fleetrite / Exide batteries part number starting with FLTBTRF.
AGM – SPIRAL Absorbed Glass Mat (AGM) spiral-wound cells. Will look like a six pack.
May have “AGM” labeled on battery. Lead – dry acid.
AGM - OTHER Will be shaped like a conventional battery. May have “AGM” labeled on
battery. Lead – dry acid
East Penn batteries part number prefix FEP followed by a number and
the letter A.
GEL Lead - gel acid

11. Select battery RATINGS UNITS. See battery label. For Fleetrite / Navistar batteries, go to Navistar Parts
Catalog to find rating. Enter last eight digits of VIN in the Chassis / VIN Number field of the Navistar Service
Portal and click View. Select the Components tab, and the feature code for the battery system. Select
Batteries, components.
12. Enter BATTERY RATING. Scroll to correct rating and press NEXT to begin test.

Figure 636 Measuring Ambient Battery Temperature

1. Battery case
2. IR temperature sensor

13. Measure ambient battery temperature by aiming IR temperature sensor at battery case. Press NEXT and
the Battery Pack Test will start.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1583

Figure 637 Good Battery Pack Test Results (Typical)

Figure 638 Failed Battery Pack Test Results (Typical)

14. If RESULTS display GOOD PACK, press NEXT to continue and skip steps 15 through 21. If RESULTS
display CHECK BATTERY PACK, press NEXT and go to step 15.
15. At PACK OPTIONS select BREAK PACK DOWN and NEXT.
NOTE: The EXP-1000-HD-NAV tool has a two minute timer that resets every time an alphanumeric or
arrow key is pressed. If the EXP-1000-HD-NAV is disconnected from battery power after the two minute
timer, the tool will power off in approximately 5 seconds. Pressing any alphanumeric or arrow key will
reset the timer and give the user two minutes to transfer Main Clamps.
16. Before transferring Main Clamps to another battery, press any alphanumeric or arrow key to reset the 2
minute timer. Attach EXP-1000-HD-NAV Main Clamps to one battery while disconnecting other batteries.
Disconnect battery cables from each battery, then select NEXT to continue.
NOTE: Attach Lead Stud Adapters if battery has threaded studs. Do not attach Main Clamps to battery
threaded studs.
17. Before transferring Main Clamps to another battery, press any alphanumeric or arrow key to reset the 2
minute timer. Connect to and test each battery when prompted.
1584 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 639 Individual Battery Test Results (Typical)

18. After testing last battery, use arrow keys to scroll through individual battery test RESULTS across multiple
screens.

Individual Battery Test RESULTS Recommended Action

GOOD BATTERY or GOOD - Continue to: Starter System Test Procedure (page 1584) after all
RECHARGE individual batteries pass test.
CHARGE & RETEST Recharge battery. After battery is fully charged, test battery. After all
individual batteries pass test, reconnect battery pack then rerun
Electrical System Test (page 1577).
REPLACE BATTERY or BAD CELL – Replace failed battery then rerun Electrical System Test (page 1577).
REPLACE

19. Charge or replace individual batteries as needed.

20. Reconnect battery pack(s).
21. Rerun Electrical System Test (page 1577).

Starter System Test Procedure

22. Following a successful Battery Pack Test Procedure, press NEXT.
23. When prompted, start engine.

Figure 640 Starter System / Cranking Test Results (Typical)

 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1585

24. After testing, scroll through RESULTS of CRANKING and BATTERY tests across multiple screens using
arrow keys.
25. Starting System RESULTS and Recommended Action(s):

Starting System RESULTS Recommended Action

CRANKING NORMAL Go to: Charging System Test Procedure (page 1586).
LOW VOLTAGE Verify charging system is operating properly. Go to: Charging System
Test Procedure (page 1586). If Charging System Test Procedure
passes, do Cable Drop Test (page 1563) on starter power circuit. If
required, repair starter power circuit. If starter power circuit tests
good, replace starter.
NO START Go to Starting System in appropriate Technician Manual.
CRANKING SKIPPED Continue to Charging System Test Procedure (page 1586). After
Charging System Test Procedure is complete: If symptom is, or
could be starter related, redo complete Electrical System Test (page
1577) and do not skip cranking.
CHARGE BATTERY If batteries were tested properly, verify charging system is operating
properly. Go to Charging System Test Procedure (page 1586). If
Charging System Test Procedure passes, perform Cable Drop Test
(page 1563) on starter power circuit. If required, repair starter power
circuit. If starter power circuit tests good, replace starter.
REPLACE BATTERY If batteries were tested properly, verify charging system is operating
properly. Go to Charging System Test Procedure (page 1586). If
Charging System Test Procedure passes, perform Cable Drop Test
(page 1563) on starter power circuit. If required, repair starter power
circuit. If starter power circuit tests good, replace starter.
1586 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Charging System Test Procedure

0000453023

Figure 641 Inductive Amp Clamp and Main Clamps Attached to EXP-1000-HD-NAV

CAUTION:

Use care when handling the amp clamp. Internal magnet may break if dropped.
26. At AMP CLAMP screen select AVAILABLE.
27. Attach Amp Clamp cable to EXP-1000-HD–NAV tool. Do not attach Amp Clamp to vehicle at this time.
28. Start engine, if not already running.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1587

0000453103

Figure 642 Zeroing Amp Clamp

NOTE: Do not press NEXT until reading and doing the following:
29. At AMP CLAMP ZERO screen, hold the Amp Clamp approximately 1 inch from the wire to be tested, then
press NEXT.
1588 2 ENGINE SYSTEM TESTS AND INSPECTIONS

0000453123

Figure 643 Amp Clamp Installed around Alternator Cable (Typical)

1. Amp Clamp A018

30. When prompted, install amp clamp around the positive cable between the alternator and the battery, closer
to the battery, then press NEXT.
31. At TESTING screen, follow prompts to turn electrical loads ON and OFF and to raise and lower engine
speed.
32. When prompted, turn OFF loads, and engine. Press NEXT to get RESULTS.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1589

Figure 644 Charging System Test RESULTS (Typical)

33. After testing, scroll through RESULTS of charging, cranking and battery tests across multiple screens using
arrow keys. Excessive alternator diode ripple usually means one or more diodes have failed in the alternator
or there is stator damage.

RESULTS Recommended Action

NO PROBLEMS Normal alternator output. No problem found.
NO VOLTAGE, or LOW VOLTAGE Check alternator belt, and electrical connections. If belt and connections
are good, perform Cable Drop Test (page 1563). If Cable Drop Test
passes, replace the alternator.
HIGH VOLTAGE Check alternator electrical connections. If connections are good, replace
the alternator. For regular flooded batteries, check battery electrolyte
level. Add distilled water if required.
EXCESSIVE RIPPLE Check alternator belt, mounting, and electrical connections. If belt,
mounting and connections are good, replace the alternator.
OPEN PHASE, OPEN DIODE, Replace alternator.
SHORTED DIODE

Expected Outcome
Technician will determine condition of battery pack, starting system, and charging system.

Follow-On Procedure
None.
1590 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Intake Air Heater (IAH) System Test

Overview
Verify operation of Intake Air Heater (IAH) system components and circuits. The IAH is commanded on by the
Engine Control Module (ECM) when Engine Coolant Temperature (ECT) is below threshold temperature. The
ECM controls the IAH relay with the IAH control and ACT GND circuits.

WARNING:

To prevent personal injury or death, wear safety glasses with side shields.

CAUTION:

Performing multiple IAH Tests with Navistar® Engine Diagnostics will cause element to
overheat. Overheating element will cause damage.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface Cable (RP1210B-compliant, supporting J1939 and J1708)
• Digital Multimeter (DMM)
• Breakout Harness ZTSE6025

Equipment Condition
None

Test Setup
1. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
2. Log in to Navistar® Engine Diagnostics.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1591

Procedure

Figure 645 Intake Air Heater (IAH) Circuit Diagram

1. Check IAH electrical connections for damage and corrosion. Repair as needed.
2. Measure voltage at heater element terminal connected to the relay output, while IAH heater is activated.
Activate IAH heater using Electronic Service Tool (EST) with Navistar® Engine Diagnostics. Select: Tests >
KOEO Tests > Intake Air Heater Test. Is voltage within 0.5 V of battery voltage (B+)?
• Yes: Replace IAH heater element.
• No: Go to Step 3.
3. Measure voltage at IAH relay supply terminal (from Junction post). Is voltage within 0.5 V of B+?
• Yes: Go to Step 4.
• No: Repair IAH relay power circuit, from B+ at starter motor post.
4. Disconnect IAH control circuit connector. Connect Breakout Harness 6025 and leave relay disconnected.
Activate IAH heater and measure voltage between pins 1 and 2. Is voltage within 0.5 V of B+?
• Yes: Connect IAH control circuit connector. Go to Step 5.
• No: Go to Step 6.
5. Activate IAH system and measure voltage between IAH relay output terminal and ground. Is voltage within
0.5 V of B+?
• Yes: Repair or replace relay output bus bar.
• No: Replace IAH relay.
6. Activate IAH heater and measure voltage between pin 2 and ground. Is voltage within 0.5 V of B+?
• Yes: Repair ACT GND circuit.
1592 2 ENGINE SYSTEM TESTS AND INSPECTIONS

• No: Repair IAH control circuit.

Expected Outcome
Determine if IAH system components and circuits are operate properly.

Follow-On Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1593

Oil Pan Heater Test

Overview
Verify operation of the Engine Oil Pan Heater.

Special Tools
Digital Multimeter (DMM)

Equipment Condition
None

Test Setup
Ensure engine is cold performing this test.

Procedure

Figure 646 Oil Pan Heater

1. O-ring
2. Oil heater element
3. AC power cord
1594 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 647 Oil Pan Heater Plug (Shown with Cover Removed for Clarity)

1. Measure resistance at external plug for oil pan / coolant heater (Figure 647).
• Reading should be approximately 12 ohms. If unit is equipped with both a coolant and oil pan heater,
they are wired on the same plug and reading should be approximately 8.5 ohms. If reading is within
specifications, go to step 3.
• If reading is not within specifications, go to step 2.
2. Disconnect cord from oil pan heater (Figure 646) on left side of engine oil pan. Measure resistance at
terminals on heater itself.
• If reading is approximately 12 ohms, cord needs to be replaced.
• If reading is not approximately 12 ohms, install cord and go to step 3.
3. Connect standard extension cord between wall outlet and (Figure 647).
4. Wait 2 to 3 minutes, and check to see if engine oil pan heater is heating up by feeling the area where cord
attaches.

Expected Outcome
Resistance checks will be within specification and oil pan heater will heat when plugged in.

Follow-On Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1595

Piston Height Measurement Test

Overview
Measure height of each piston at Top Dead Center (TDC) to help determine if one or more connecting rod is
bent. Use a vernier caliper depth probe to measure distance between bottom of each injector cup to top of piston
crown when piston is at TDC. Excess liquid (fuel / coolant / oil) in a cylinder can cause extremely high cylinder
pressure (hydro lock) and a bent connecting rod. A hydro locked cylinder causes damage to components in
that cylinder, replacing conning rod or other components in cylinders that have normal piston height may not be
covered by warranty.

Special Tools
Vernier caliper

Equipment Condition
None

Test Setup
Remove fuel injectors. See Engine Service Manual.
1596 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Procedure

Figure 648 Vernier Caliper Depth Probe Measuring Piston Height

 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1597

1. Extend vernier caliper depth probe and place it inside injector cup. Main scale rests against bottom of injector
cup and depth probe extends into cylinder.
2. Hold caliper while an assistant slowly bars over engine by hand to TDC.
3. Continue slowly barring engine until piston moves past TDC. Piston will push depth probe to shortest
measurement.

Cylinder # 1 2 3 4 5 6
Measurement 1
Measurement 2
Measurement 3
Total
Total / 3 =
Average

Piston Height Measurements and Average Calculations

4. Record Measurement 1 in table above.
5. Repeat Step 1 thru Step 3 two more times for that cylinder and record measurements in table.
6. Perform Steps 1 thru 5 for all six cylinders.
7. Calculate average of measurements for each cylinder. Add Measurements 1, 2, and 3 for each cylinder,
and divide by 3. Record calculations in table.
8. Compare each Average to other cylinders Averages. A difference of 0.007 in (0.18 mm) or more indicates
a possible bent connecting rod.

Expected Outcome
Determine if one or more cylinders piston height difference is 0.007 in (0.18 mm) or more when compared to
other cylinder averages.
1598 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Smoke Test (Air Intake System)

Overview
Determine if leaks are present in the air intake system. Pressurized smoke will pass through the air intake
system to help locate difficult to find leaks.
During smoke test, tiny “pinhole” leaks may be seen at some sealing surfaces. This is normal and does not
indicate a component has failed.

WARNING:

To prevent personal injury or death, allow engine to cool before removing components
or testing.
NOTE: Do not exceed 5 psi (34 kPa) system pressure when using Navistar® Leak Detector 19–700–01.
Operating the system at higher pressures will obscure test results, and make leaks more difficult to locate.
Lower system pressures will allow smoke trails to be more visible.

Special Tools
Navistar® Leak Locator Kit 19–700–01

Equipment Condition
Navistar® Leak Locator filled with smoke fluid 19–700–01–02, connected to power supply, and connected to air
supply (see Navistar® Leak Locator Operation Manual).

Test Setup
1. Remove air cleaner assembly.
2. Install Navistar® fixed graduated intake adapter into air intake piping with clamp previously removed
from air cleaner assembly.
3. Connect Navistar® Leak Locator supply line to intake adapter.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1599

Procedure

Figure 649 Navistar® Leak Locator Controls

1. Flow Control switch 3. Start / Stop switch 4. Adjustable Pressure Regulator
2. System Pressure gauge knob

1. Verify Flow Control switch (Item 1) is in OFF position

2. Pull Adjustable Pressure Regulator knob (Item 4) out to unlock, and turn regulator until System Pressure
gauge (Item 2) reads 5 psi (34 kPa) or less.
3. Push Adjustable Pressure Regulator knob in to lock and set system pressure.
4. Press the Start / Stop switch (Item 3), and turn Flow Control switch to ON position to begin 10 minute smoke
cycle.
5. Inspect intake air system piping, hoses, clamps and components for smoke trails.

Expected Outcome
Intake air system clamps, hoses, components, and piping are free of major leaks.

Follow-On Procedure
1. Disconnect Navistar® Leak Locator supply line from Powersmoke™ adapter.
2. Deflate and remove Powersmoke™ adapter per Navistar® Leak Locator Operation Manual.
3. Install air cleaner assembly.
1600 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Coolant Test Procedures

Deaeration Tank Cap Test

Overview
Verify proper operation of the deaeration tank cap.

WARNING:

To avoid possible injury or death, use care when working around hot coolant.

WARNING:

To prevent personal injury or death, do the following when removing the radiator cap or
deaeration cap:
• Allow engine to cool for 15 minutes.
• Wrap a thick cloth around radiator cap or deaeration cap.
• Loosen cap slowly a quarter to half turn counterclockwise to vent pressure.
• Pause for a moment to avoid being scalded by steam.
• Continue to turn the cap counterclockwise to remove.

Special Tools

Figure 650 ZTSE2384 Radiator Pressure Testing Kit

 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1601

Figure 651 09–040–01 Coolant Cap Pressure Tester

ZTSE2384 Radiator Pressure Testing Kit or 09–040–01 Coolant Cap Pressure Tester

Equipment Condition
None
1602 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Test Setup

Figure 652 Deaeration Tank and Cap (Typical)

1. Remove cap from deaeration tank (Figure 652).

2. Check deaeration tank neck (Figure 652) for cracks and warping.

Procedure
1. Determine rated pressure of deaeration tank cap.
2. Test dearation cap following the tool instructions for the tester being used.
3. Replace cap if not within specification.

Expected Outcome
Cap will hold rated pressure.

Follow-on Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1603

Cooling System Pressure Test

Overview
Determine engine cooling system integrity by pressurizing system and looking for leaks or pressure decay.

WARNING:

To prevent personal injury or death, wear safety glasses with side shields.

WARNING:

To prevent personal injury or death, do the following when removing radiator cap or
deaeration cap:
• Allow engine to cool for 15 minutes or more.
• Wrap a thick cloth around the deaeration cap.
• Loosen cap slowly a quarter to half turn to vent pressure.
• Pause for a moment to avoid being scalded by steam.
• Continue to turn cap counter-clockwise to remove.

WARNING:

To prevent personal injury or death, ensure shop-air pressure is properly regulated.

Special Tools
Coolant Management Tool KL5007NAV.

Equipment Condition
1. Remove splash guards (as necessary).
2. Cooling system full.
1604 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Test Setup

Figure 653 Coolant Management Tool (KL5007NAV)

1. Coolant Supply Tank 3. Pressure Module 5. Cap Adapter
2. Cart 4. Vacuum Module

1. Replace deaeration cap with Cap Adapter (Figure 653) (Item 5) from Coolant Management Tool.
2. Connect Pressure Module (Figure 653) (Item 3) to Cap Adapter (Figure 653) (Item 5).
3. Apply shop air to Pressure Module (Figure 653) (Item 3).
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1605

Procedure

Figure 654 Cap Adapter and Pressure Module

1. Pressure Module 3. Air Valve (Open)
2. Cap Adapter (KL5004NAV) 4. Air Valve (Closed)

1. Turn coolant supply tank (Figure 653) (Item 1) to CLOSED position.

2. Open air valve (Figure 654) (Item 3) on Pressure Module (Figure 654) (Item 1) making sure not to exceed
cap pressure on system.
3. Close air valve (Figure 654) (Item 4). System is now pressurized with air.
4. Monitor gauge reading for 15 minutes and check for pressure decay.
5. If decay is evident, check cooling system for leak(s), external and internal.
6. Disconnect compressed air, and remove pressure module (Figure 654) (Item 1).
7. Slowly open air valve (Figure 654) (Item 3) on pressure module to vent the pressure in the cooling system.

Expected Outcome
Engine cooling system holds steady air pressure.
1606 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Follow-on Procedure
Replace splash guards (if removed).
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1607

Coolant Over-Flow / Over-Temperature Test

Overview
Determine if cooling system over heats or forces coolant out of overflow tube on deaeration tank.

WARNING:

To prevent personal injury or death, be aware of hot coolant may be expelled from the
deaeration tank during this test.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)

Equipment Condition
None

Test Setup
1. Key-On, Engine-Off (KOEO).
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Log in to Navistar® Engine Diagnostics.

Procedure
1. Use Navistar® Engine Diagnostics to view Engine Coolant Temperature 1 (ECT1).
2. Start engine. Turn engine Off before any over temperature or overheat occurs.
3. Raise engine speed to high idle. Check for coolant overflowing from deaeration tank.
4. Run engine to operating temperature and attempt to reproduce concern.
5. Monitor ECT1 and stop engine if temperature exceeds normal operating temperature. Check for coolant
overflowing out of deaeration tank overflow hose.

Expected Outcome
Coolant will not exceed normal operating temperature, and coolant will not be expelled from overflow hose on
deaeration tank.

Follow-On Procedure
None
1608 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Thermostat Operational Test

Overview
Determine if engine thermostat opens when engine reaches operating temperature by monitoring upper radiator
hose temperature.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)
• Infrared Thermometer ZTSE4799

Equipment Condition
1. Allow engine to cold soak.
2. Perform Coolant Level Inspection (page 1637).

Test Setup
1. Key-On, Engine-Off (KOEO).
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345) and log in.

Procedure
1. Using Navistar® Engine Diagnostics, select > Sessions > Default > Temperature tab.
2. Start engine.
3. Monitor upper radiator hose temperature using Infrared Thermometer.
4. Run engine to operating temperature. Upper radiator hose temperature should be less than ECT1 while
thermostat is closed. As ECT1 reaches approximately 190°F (88°C), a working thermostat will begin to
open, and the upper radiator hose should heat up.
Does upper radiator hose temperature increase to ECT1 ±25°F after engine warms up past thermostat opening
temperature specification?
• No: ECT1 value continues to rise and upper radiator hose remains cooler. Replace thermostat and retest.
• No: ECT1 never reaches 190°F (88°C). Replace thermostat and retest.
• Yes: thermostat is working properly.

Expected Outcome
Upper radiator hose temperature will increase to within ±25°F of ECT1 after engine warms up past thermostat
opening temperature specification.

Follow-On Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1609

Engine Cooling Fan Test

Overview
This test is used to check the engine cooling fan for proper operation.

Special Tools
• Breakout Harness ZTSE4908
• Digital Multimeter (DMM)

Equipment Condition
None

Test Setup
Remove Engine Fan Relay

Procedure
1. Key-Off.
2. Using DMM, measure resistance between relay terminals 30 and 87.
• If resistance is > 1000 ohms, continue.
• If resistance is < 1000 ohms, replace relay

Figure 655 Engine Fan Relay Control Circuit Voltage Check

3. Connect Breakout Harness ZTSE4908 to relay vehicle harness connector and leave Engine Fan Relay
disconnected.
4. Key-On.
1610 2 ENGINE SYSTEM TESTS AND INSPECTIONS

5. Use DMM to measure voltage between Breakout Harness ZTSE4908 pin-85 and PWR.
• If voltage is < 0.5 volts, continue.
• If voltage is > 0.5 volts, repair short to GND in Engine Fan Control (EFC) circuit between ECM pin C-58 and
Engine Fan Relay.
6. Use DMM to measure voltage between Breakout Harness ZTSE4908 pin-87 and a known good ground.
• If voltage is < 0.5 volts, perform Engine Fan Clutch tests. See appropriate truck service manual.
• If voltage is > 0.5 volts, repair short in vehicle wiring harness between engine fan power feed and engine
fan switched power circuits.

Expected outcome
Engine Fan Relay is not stuck closed, no circuit shorts are present, and fan clutch is not mechanically stuck on.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1611

Air Compressor Coolant Leak Test

Overview
Determine if the air compressor is leaking air into the cooling system.

Special Tools
None

Equipment Condition
None

Test Setup

Figure 656 Radiator Pressure Test Kit ZTSE2384

1. Perform Coolant Leak – Visual Inspection. (page 1643).

2. Maintain a cooling system pressure of 15 psi (103 kPa).
1612 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Procedure

Figure 657 Air Compressor Oil Return Hose

1. Disconnect oil return hose from bottom of compressor (Figure 657).

2. Monitor any fluid coming from hose and check for coolant.

Expected Outcome
No coolant will leak from oil return hose.

Follow-on Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1613

Air Compressor Overflow Test

Overview
To determine if cooling system over heats or forces coolant out of overflow tube on deaeration tank due to a
faulty air compressor.

Special Tools
None

Equipment Condition
None

Test Setup
Disconnect discharge tube from air compressor housing.

Procedure
1. Start engine and run until reaching normal operating temperature.
2. Raise engine speed to high idle. Check for coolant overflow out of deaeration tank.
3. Run engine to above 225°F / radiator intake temperature above 200°F.
4. Check for coolant overflow out of deaeration tank overflow hose.

Expected Outcome
Air Compressor will not cause coolant to be expelled from overflow hose on deaeration tank.

Follow-on Procedure
None
1614 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Combustion in Cooling System Test

Overview
Check for combustion gasses and/or compressed air in the cooling system.

Special Tools
Combustion in Cooling System Test Kit – 09-889-01

Equipment Condition
None

Test set-up
1. Remove cap from deaeration tank and if necessary, fill coolant to proper level.

Figure 658 Deaeration Tank with Test Kit Adapter Installed

1. Deaeration Tank
2. Cap Adapter
3. Combustion Tester with Tube
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1615

2. Install Cap Adapter (item 2) and Combustion Tester (item 3) onto deaeration tank (item 1) (Figure 658).

Figure 659 Test Beaker

1. Test Beaker
2. Tester Tube

3. Fill test beaker (item 1) (Figure 659) to half way mark with clean tap water and place on a stable surface.
4. Insert combustion tester tube (item 2) (Figure 659) into water.

Procedure
1. Start Engine
2. Run engine to operating temperature.
3. Observe tester tube in water for air bubbles escaping.
4. Slowly increase engine speed to high idle while observing tester tube in water for air bubbles escaping.
5. Return engine speed to low idle and turn engine off.

Expected Outcome
There will not be a steady flow of air bubbles escaping from tester tube.

Follow-On Procedure
None
1616 2 ENGINE SYSTEM TESTS AND INSPECTIONS

On-Engine EGR Cooler Leak Test

Overview
Tests Exhaust Gas Recirculation (EGR) cooler for coolant leakage.

Special Tools
• Coolant Management Tool KL5007NAV
• EGR Cooler Leak Detection Kit KL20030NAV

Equipment Condition
None

Test Setup
1. Chock wheels and disconnect battery.
2. Drain cooling system using Coolant Management Tool KL5007NAV.
3. Remove passenger side inner fender.
4. Remove alternator.
5. Remove alternator mounting bracket.
6. Remove coolant supply and coolant return tubes from front of Exhaust Gas Recirculation (EGR) cooler.
7. Make sure all connection points on EGR cooler and tools are clean and free of debris.

Figure 660 Deaeration Fitting with EGR Leak Detection Kit KL20030NAV
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1617

8. Attach plug 20020-1 from EGR Cooler Leak Detection Kit KL20030NAV onto deaeration fitting Figure
(Figure 660).

Figure 661 Coolant Ports and Coolant Port Plug Assembly 20020-2

9. Attach coolant port plug assembly 20020-2 into coolant ports, Figure (Figure 661).

Figure 662 Air Hose Fitting with Extension

1618 2 ENGINE SYSTEM TESTS AND INSPECTIONS

10. Attach a pressure regulator with a shut-off valve to air hose fitting (an extension hose may be necessary
to reach, Figure (Figure 662)). Ensure air hose and fittings are free of any leaks, as they will appear as
false EGR cooler leaks.
11. While pressure testing the EGR Cooler, spray sealing surfaces / connections of tool and EGR Cooler to
ensure tool, hoses, and fittings are leak free.

Procedure
1. Pressurize Exhaust Gas Recirculation (EGR) cooler to 55 psi (379 kPa) and shut off air valve.
2. Monitor pressure gauge for 10 minutes.

Expected Outcome
EGR cooler should hold pressure. Pressure should not drop more than 5 psi in 10 minutes.

Follow-On Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1619

Instrument Cluster Temperature Gauge Validation Test

Overview
Verifies that the instrument cluster gauge is functioning properly. The gauge reading and sensor signal value
are compared to ensure proper operation and proper reading for the operator to monitor.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant, supporting J1939 and J1708)

Equipment Condition
None

Test Setup
1. Key-On, Engine-Off (KOEO).
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Log in to Navistar® Engine Diagnostics.
4. Check for any active or inactive code(s) relating to coolant temperature (repair these first).

Procedure

Figure 663 Monitoring Test

1. Engine Coolant Temperature 1
(ECT1) signal

1. Start engine.
1620 2 ENGINE SYSTEM TESTS AND INSPECTIONS

2. Monitor and compare ECT1 sensor signal (Figure 663) and instrument cluster engine coolant temperature
gauge.
3. Bring ECT up to operating temperature and continue to monitor readings for consistency.

Expected Outcome
Instrument Cluster Temperature Gauge and Engine Coolant Temperature (ECT1) sensor signal value will read
approximately the same.

Follow-On Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1621

Engine Oil Tests

Oil Cooler Pressure Test

Overview
Verifies internal integrity of engine oil cooler. This test uses special tools and compressed air to ensure coolant
and lube oil do not mix in the assembly.

WARNING:

To prevent personal injury or death, wear safety glasses with side shields.

CAUTION:

To prevent damage to oil cooler assembly, regulate compressed air to 30 psi (207 kPa).

Special Tools
• Oil Cooler Test Plate ZTSE4654
• Air Pressure Regulator
• Spray Bottle and Soapy Water

Equipment Condition
1. Remove any truck mounted components to gain access to engine oil cooler assembly.
2. Remove engine oil cooler (refer to Engine Service Manual).
1622 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Test Setup

Figure 664 ZTSE4654 Oil Cooler Test Plate

 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1623

Figure 665 Oil Cooler

1. Air Pressure Regulator Connector
2. Port Valve
3. Engine Oil Cooler Housing
4. Oil Cooler Test Plate — ZTE4654

1. Attach oil cooler test plate (Item 4) to engine oil cooler assembly (Item 3).
2. Install port valve in oil cooler test plate (Item 4) in coolant port; close valve.
3. Fill oil ports up to 1 / 4 - in. from the top with soapy water.
4. Attach regulated shop air to port valve (Item 2). Do not exceed 30 psi (207 kPa).

Procedure
1. Open port valve to allow regulated air to enter oil cooler housing.
2. Observe oil cooler housing ports for bubbles.
3. Spray oil cooler housing and test plate with soapy water to ensure air is not leaking.
4. Close valve, and remove and vent compressed air.
5. Disassemble test plate and drain water.
6. Use compressed air to dry inside and outside of oil cooler assembly (if re-using).
1624 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Expected Outcome
Oil cooler assembly will not have bubbles in oil ports or on outside of cooler assembly.

Follow-on Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1625

Oil Pressure Verification Test

Overview
Verifies the electronic signal for Engine Oil Pressure (EOP) sensor by comparing a mechanical oil pressure
gauge to EOP sensor output.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)
• Pressure Test Kit ZTSE4409

Equipment Condition
None

Test Setup
1. Key-On, Engine-Off (KOEO).
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
1626 2 ENGINE SYSTEM TESTS AND INSPECTIONS

3. Log in to Navistar® Engine Diagnostics.

Figure 666 Oil Pressure Verification Test Connection

1. Engine Oil Pressure sensor connection

4. Connect Pressure Test Kit ZTSE4409 to test port on Engine Oil Pressure (EOP) sensor (Figure 666) as
shown above (if engine is equipped with an air compressor, an in-line adapter should be used here).

Procedure
1. Start the engine.
2. At low idle, monitor mechanical gauge for engine oil pressure reading; compare this reading to EOP value
in Navistar® Engine Diagnostics.
3. Increase engine speed to high idle.
4. At high idle, monitor mechanical gauge for engine oil pressure reading; compare this reading to EOP value
in Navistar® Engine Diagnostics.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1627

Expected Outcome
The Engine Oil Pressure (EOP) reading on mechanical gauge and EOP sensor signal value in Navistar® Engine
Diagnostics should be within specification and approximately the same.

Follow-on Procedure
None
1628 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Instrument Cluster Engine Oil Pressure Gauge Validation Test

Overview
Verifies the electronic signal to and from the readout of the instrument cluster engine oil pressure gauge
approximately matches the actual mechanical reading. This test uses a mechanical gauge and Navistar®
Engine Diagnostics to simultaneously read Engine Oil Pressure (EOP).

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)
• Pressure Test Kit ZTSE4409

Equipment Condition
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1629

Test Setup

Figure 667 Pressure Test Kit ZTSE4409

1. Engine Oil Pressure Sensor

1. Key-On, Engine-Off (KOEO).

2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
3. Log in to Navistar® Engine Diagnostics.
4. Connect Pressure Test Kit ZTSE4409 to the test port on the EOP sensor (Figure 667) (if engine is
equipped with an air compressor, an in-line adapter should be used here).

Procedure
1. Start the engine.
1630 2 ENGINE SYSTEM TESTS AND INSPECTIONS

2. At low idle, monitor the mechanical gauge for the engine oil pressure reading. Compare this reading to the
value displayed in Navistar® Engine Diagnostics, as well as the value displayed on the instrument panel
gauge.
3. Increase engine speed to high idle.
4. At high idle, monitor the mechanical gauge for the engine oil pressure reading. Compare this reading to the
value displayed in Navistar® Engine Diagnostics, as well as the value displayed on the instrument cluster
gauge.

Expected Outcome
The mechanical gauge, Navistar® Engine Diagnostics, and the instrument cluster gauge will all read
approximately the same, indicating the sensor and gauge are working correctly.

Follow-On Procedure
None
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1631

Engine System Inspections

Fuel System Inspection

Overview
Verify the fuel system is clean and free of damage.

WARNING:

To prevent personal injury or death, do not smoke and keep fuel away from flames and
sparks.

Special Tools
None

Equipment Condition
None

Procedure
1. Visually inspect the condition and routing of fuel lines and connections.
• If fuel lines or connections are damaged or routed incorrectly, repair or replace as necessary.
• If fuel lines and connections are in good condition and routed correctly, go to step 2.
2. Remove fuel pump and fuel strainer. Inspect fuel strainer, fuel pump, and O-ring seals for cleanliness and
damage.
• If fuel pump, fuel strainer, or O-ring seals are dirty or damaged, replace as required.
• If fuel pump, fuel strainer, or O-ring seals are clean and not damaged, go to step 3.
3. Remove fuel filter and inspect for: sediments, gasoline, kerosene, waxing, or icing.
• If fuel filter is dirty or damaged, replace fuel filter.
• If fuel filter is clean, go to next test.
4. Inspection is complete.

Expected Outcome
Fuel lines, fuel filter, fuel strainer, and fuel connections are clean and not damaged.
1632 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Fuel Quality Inspection

Overview
Drain fuel filter assembly and check fuel quality.

WARNING:

To prevent personal injury or death, do not smoke and keep fuel away from flames and
sparks.
NOTE: Ultra Low Sulfur Diesel (ULSD) fuel is required for MaxxForce® Diesel Engines used with advanced
aftertreatment systems.

CAUTION:

To prevent engine damage, do not start engine.

Special Tools
Clear fuel container
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1633

Procedure

Figure 669 Fuel Filter Assembly

A. Fuel strainer B. Fuel drain valve

1. Place clear diesel fuel container under fuel-filter housing.

2. Open drain valve (Figure 669) (Item B) and fill container.
3. Check for water, waxing, icing, sediment, gasoline, kerosene, or Diesel Exhaust Fluid (DEF) by shaking fuel
sample container and letting contents settle.
• Sediments will fall to bottom of fuel sample container.
• Gasoline and kerosene will separate from diesel fuel.
• Waxing or icing will prevent diesel fuel flowing from fuel-drain valve.
4. Inspect fuel strainer (Figure 669) (Item A) for debris.

Expected Outcome
Fuel is free of water, waxing, icing, sediment, gasoline, kerosene, or Diesel Exhaust Fluid (DEF).
1634 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Fuel Level Inspection

Overview
Verify instrument panel fuel gauge indicates the correct fuel level in fuel tanks.

WARNING:

To prevent personal injury or death, do not smoke and keep fuel away from flames and
sparks.

Special Tools
None

Equipment Condition
None

Procedure
1. Inspect interior of fuel tanks and ensure fuel level is equal in both tanks.
2. Check instrument panel fuel gauge and verify that indicated fuel level is consistent with actual fuel level.

Expected Outcome
Fuel gauge should function properly and indicate correct fuel level in fuel tanks.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1635

Engine Oil Level and Quality Inspection

Overview
Determine if engine oil is to proper level, quality is correct, and oil is not aerated.

Special Tools
None

Equipment Condition
None

Procedure

Figure 670 Engine Oil Level Gauge (Dipstick)

1. Use oil level gauge (dipstick) (A) to check engine oil level.
• If engine oil level is below specification, inspect engine for leaks, oil consumption, or improper servicing.
Repair cause of low engine oil, and fill to proper level.
1636 2 ENGINE SYSTEM TESTS AND INSPECTIONS

• If engine oil level is above specification, inspect for fuel dilution (fuel smell), coolant contamination, or
improper servicing. If engine oil level is above specification, drain to proper level and diagnose cause
of dilution, contamination, or improper servicing.
2. Inspect engine oil level gauge for bubbles (aeration) in engine oil.

Expected Outcome
Determine if engine oil is to proper level, quality is correct, and if oil is aerated.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1637

Coolant Level Inspection

Overview
The following procedure is to inspect that coolant in the deaeration tank is at appropriate level and free of
contamination.

Special Tools
None

Equipment Condition
None

Procedure

Figure 671 Deareation Tank Location (Typical)

A. Maximum level indicator
B. Add coolant indicator

1. Inspect coolant level in deaeration tank.

Expected Outcome
Coolant level should be within specification and free of contaminants.
1638 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Coolant Quality Inspection

Overview
Check coolant for proper freeze point, and for contamination.

Special Tools
Coolant and Battery Refractometer ZTSE4796

Equipment Condition
• Park the vehicle on level ground.
• If engine was running, allow engine to cool for 15 minutes or more.

Procedure
1. Wrap a thick cloth around the deaeration cap.
2. Loosen cap slowly a quarter to half turn to vent pressure.
3. After pressure has been released, remove the cap.
4. Check coolant appearance for signs of contamination.
5. Take a sample from the deaeration tank.
6. Examine sample for lube oil and Diesel Exhaust Fluid (DEF).
• Oil contamination will result in a dark sludge.
• DEF contamination will give the coolant a dark yellow/brown color with a strong ammonia smell.
7. If coolant is not contaminated, check freeze point.

Expected Outcome
Coolant should be free of contamination, and at the correct freeze point.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1639

Coolant in Exhaust Inspection

Overview
Determine if engine coolant is in the exhaust system.

Special Tools
Radiator Pressure Test Kit ZTSE2384

Procedure
1. Park the vehicle on level ground. If engine was running, allow engine to cool for 15 minutes or more.
2. Wrap a thick cloth around the deaeration cap. Slowly turn cap counter-clockwise one-quarter to one-half
turn to vent pressure. After pressure has been released, remove the cap.
3. Install the Radiator Pressure Test Kit ZTSE2384 (with appropriate adapter if needed) onto the deaeration
tank.
4. Disconnect the exhaust pipe at the Exhaust Back Pressure Valve (EBPV) (see Engine Service Manual).
5. Pressurize cooling system to rated pressure for a minimum of 15 minutes.
6. Inspect exhaust pipe and brake housing for engine coolant.

Expected Outcome
Exhaust system will not have engine coolant present.
1640 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Interstage Cooler (ISC) Inspection

Overview
Inspect Interstage Cooler (ISC) and the High-Pressure (HP) turbocharger intake elbow for evidence of coolant.

WARNING:

To prevent personal injury or death, allow engine to cool before removing components.

WARNING:

To prevent personal injury or death, do the following when removing radiator or

deaeration cap:
• Allow engine to cool for 15 minutes or more.
• Wrap a thick cloth around radiator cap or deaeration cap.
• Loosen cap slowly a quarter to half turn counterclockwise to vent pressure.
• Continue to turn cap counterclockwise to remove.

Special Tools
Radiator Pressure Test Kit ZTSE2384
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1641

Equipment Condition

Figure 672 HP Turbocharger / ISC Assembly

1. High-Pressure (HP) 2. Intake elbow clamp
turbocharger compressor 3. Interstage Cooler (ISC)
housing 4. Intake elbow

1. Install the Radiator Pressure Test Kit ZTSE2384, with appropriate adapter if needed, on the deaeration
tank.
2. Pressurize cooling system to 15 psi (103 kPa).
3. Remove HP turbocharger intake elbow clamp (Figure 672) (Item 2).
4. Remove intake elbow (Figure 672) (4) from HP Turbocharger compressor housing (1) and ISC (3) (see
Engine Service Manual).
1642 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Procedure

Figure 673 ISC Assembly

A. Intake elbow B. Interstage Cooler (ISC)

Check intake elbow (Figure 673) (A) and ISC (B) for wet coolant and the residue of coolant.

Expected Outcome
No evidence of coolant or coolant residue will be found in the ISC or the HP-Turbocharger intake elbow.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1643

Coolant Leak Visual Inspection

Overview
Check engine cooling system for proper level and leaks.

Special Tools
Radiator Pressure Test Kit ZTSE2384

Equipment Condition
None

Procedure
1. Park vehicle on level ground. If engine was running, allow engine to cool for 15 minutes or more.
2. Wrap a thick cloth around the deaeration cap. Loosen cap slowly a quarter to half turn to vent pressure.
After pressure has been released, remove the cap.
3. Check coolant level. Compare coolant level to level indicators on the deaeration tank. If coolant level is low,
add coolant.
4. Install Radiator Pressure Test Kit ZTSE2384 and Surge Tank Cap Adaptor on deaeration tank.
5. Pressurize cooling system for a minimum of 15 minutes.
6. Check both sides of vehicle for coolant, leaks, and coolant on the ground. Inspect cooling package, hoses,
water pump, and engine for coolant leaks.
7. If coolant is leaking, determine what component is leaking.

Expected Outcome
Coolant should be at the correct level. There should be no visible coolant leaks, and cooling system should hold
pressure.
1644 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Coolant To Intake Inspection

Overview
Inspect the High-Pressure (HP) Turbocharger and intake elbow for evidence of coolant.

Special Tools
Radiator Pressure Test Kit ZTSE238

Equipment Condition

Figure 674 HP Turbocharger / ISC Assembly

1. High-Pressure (HP) 2. Intake elbow clamp
Turbocharger compressor 3. Interstage Cooler (ISC)
housing 4. Intake elbow

1. Install the Radiator Pressure Test Kit ZTSE2384, with appropriate adapter if needed, on the deaeration
tank.
2. Pressurize cooling system to 15 psi (103 kPa).
3. Remove intake elbow (Figure 674) (Item 4) from HP Turbocharger compressor housing (Figure 674)
(Item 1) and ISC (Figure 674) (Item 3) (see Engine Service Manual).
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1645

Procedure

Figure 675 Coolant To Intake Inspection

A. HP Turbocharger housing intake
B. Intake elbow

Inspect HP Turbocharger housing intake (Figure 675) (Item A) and intake elbow (Figure 675) (Item B) for coolant
and coolant residue.

Expected Outcome
No evidence of coolant or coolant residue will be found in the HP Turbocharger housing intake and intake elbow.
1646 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Charge Air Cooler Inspection

Overview
Inspect the High-Pressure Charge Air Cooler (CAC), Interstage Cooler (ISC), and CAC piping for leaking, worn,
or damaged parts.

Special Tools
None

Equipment Condition
None

Procedure

Figure 676 Right Side Engine View (Typical)

A. Interstage Cooler (ISC) D. High-Pressure Charge Air
B. Hose Cooler (HPCAC)
C. Clamp E. Connection point
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1647

1. On right side of engine inspect High-Pressure Charge Air Cooler (HPCAC) (Figure 676) (D), associated
hoses (Figure 676) (B), and clamps (Figure 676) (C) for leaks and worn or damaged parts.

Figure 677 Left Side Engine View (Typical)

A. Interstage Cooler (ISC) D. High-Pressure Charge Air
B. Hose Cooler (HPCAC)
C. Clamp E. Connection point

2. Inspect HPCAC (Figure 677) (D), Interstage Cooler (ISC) (Figure 677) (A), associated hoses (Figure 677)
(B), clamps (Figure 677) (C) and connections (Figure 677) (E) for leaks, worn or damaged parts.

Expected Outcome
HPCAC, ISC, hoses, clamps and connections are free of leaks, excessive wear, or damage.
1648 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Intake Air Inspection

Overview
Inspect air filter and air intake system for boost leaks, restrictions, and damage.

Special Tools
None

Equipment Condition
None

Procedure
1. Inspect for a dirty, damaged, incorrectly installed or non-Origional Equipment Manufactures (OEM) air filter.
• If air filter is clean, undamaged, correctly installed and is an OEM part: go to next step.
• If air filter is dirty, damaged or is non-OEM: replace air filter.
2. With Air filter removed, inspect the mesh screen below the filter and the Mass Airflow (MAF) sensor. Ensure
the screen and MAF sensor are not damaged or covered with debris.
• Repair torn, leaking, restricted or damaged components.
3. Inspect engine air intake piping, hoses, clamps, air filter housing, screen under air filter, Charge Air Cooler
(CAC), and Interstage Cooler (ISC) (if equipped) for leaks, damage, or restrictions
• Repair torn, leaking, restricted or damaged components.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1649

Figure 678 Engine Throttle Valve (ETV) Boot Split

4. Ensure ETV boot is not split at clamp, and clamp is installed 0.16 in (4 mm) away from end of boot.

Expected Outcome
Air intake components are free of leaks, damage and restrictions. Intake air restriction should be less than 25
in Hg (84.7 kPa) at full load and at rated speed.
1650 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Front Gear Train Coolant Leak Inspection

Overview
This test is used to check for signs of coolant leakage into front gear train.

Special Tools
None

Equipment Condition
1. Remove necessary components for removal of front cover.
2. Remove front cover.

Procedure

Figure 679 Front Gear Train Cover

A. Front cover C. Sealing surface
B. Gasket D. Coolant passage

1. Inspect gasket (Figure 679) (Item B), sealing surface (Figure 679) (Item C), and coolant passages (Figure
679) (Item D).
2. Check front cover (Figure 679) (Item A) and crankcase with straight edge and feeler gauge.

Expected Outcome
Gasket is in good condition, and there is no evidence of coolant leakage. Cover straightness is within
specification.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1651

Exhaust and Aftertreatment System Inspection

Overview
Inspect exhaust aftertreatment system and sensors for leaks and damage.
Black staining in the exhaust tailpipe can occur and is normal. Do not replace the Diesel Particulate Filter (DPF)
for black staining in the tailpipe.

Special Tools
None

Equipment Condition
None

Procedure

Figure 680 Exhaust and Aftertreatment System (Typical)

1. Diesel Oxidation Catalyst (DOC)
2. Diesel Particulate Filter (DPF)

1. Inspect DOC, DPF, exhaust system piping, and clamps (engine and vehicle) for restrictions, leaks, and
damage.
2. Inspect aftertreatment temperature sensors, connections and wiring for damage.
3. Inspect Diesel Particulate Filter Differential Pressure (DPFDP) sensor and tubes for damage or restrictions.
1652 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Figure 681 Exhaust and Aftertreatment System

A. Coolant supply and return lines C. AFTFI
B. Aftertreatment Fuel Injector D. AFTFI gasket
(AFTFI) fuel supply lines E. AFTFI bore

4. Inspect AFTFI fuel supply lines (B) and coolant supply and return lines (A) for leaks, kinks, bends, or other
damage.

Expected Outcome
Determine if exhaust system and sensors (engine and vehicle) have restrictions, leaks, or damage; and
determine if AFTFI fuel supply or coolant supply return lines have leaks, kinks, bends, or damage.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1653

Diesel Particulate Filter (DPF) Inspection

Overview
Inspect Diesel Particulate Filter (DPF) channels for restriction, contamination, soot leakage, and filter damage.
Inspect exterior for container damage.

Special Tools
None

Equipment Condition
Index and mark components to show direction of exhaust flow. Mark Diesel Particulate Filter (DPF) to ensure
proper installation after filter has been cleaned or replaced.
1. DPF may need to be removed for inspection. There are several variations of exhaust systems depending
on the specific truck series. All variations have the similar components, and removal / installation
procedures are similar for the different variations. Follow procedures in the Exhaust Aftertreatment
System Service Manual.
1654 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Procedure

Figure 682 New Diesel Particulate Filter (DPF) - face is clear and all channels are visible

1. Inspect the exterior of the Diesel Particulate Filter (DPF).

2. If the DPF shows signs of exterior damage such as dents or cracks, replace DPF.
3. Inspect the DPF intake and outlet.
4. If all channels are visible (Figure 682) and the light soot coating over the whole face is easily wiped away
with a finger, system is working correctly. No action is required.
5. If the DPF is plugged with ash, remove DPF and clean or replace.
6. If filter is cracked or melted, the source of the excessive soot that caused the cracking or melting must be
investigated and the filter must be replaced.
7. Follow Diesel Oxidation Catalyst (DOC) and DPF Reuse Guidelines in the Exhaust Aftertreatment System
Service Manual.
8. If DPF was cleaned or replaced, reset DPF Soot Load. In Navistar® Engine Diagnostics, go to: Parameters
> CDPF Reset Request > Yes > Program Engine.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1655

Expected Outcome
Diesel Particulate Filter (DPF) should be free of contamination, soot leakage, and filter damage. DPF channels
should be free of restrictions.
1656 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Diesel Oxidation Catalyst (DOC) Inspection

Overview
Inspect Diesel Oxidation Catalyst (DOC) for restriction, contamination, soot leakage, and melted or deformed
cells.

Special Tools
None

Equipment Condition
Before removal, mark the DOC to show the direction of exhaust flow. Marking the DOC ensures proper
installation after the DOC has been cleaned or replaced.
1. The Diesel Oxidation Catalyst (DOC) may need to be removed to be inspected. There are several
variations of exhaust systems depending on the specific truck series. All of the variations have the
same components and the removal/installation procedures are similar for the different variations. Follow
procedures in the Exhaust Aftertreatment System Service Manual.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1657

Procedure

Figure 683 Diesel Oxidation Catalyst (DOC) Outlet

A. DOC separation between the
substrate and housing

1. Inspect DOC.
2. If black soot or gray ash is visible on the face of the DOC, the system is working properly. The DOC can be
reused.
3. If inspection shows separation between the substrate and housing (Item A), the DOC can be reused.
4. If DOC cells are melted or deformed, determine the cause of excessive exhaust gas temperatures.
5. Repair cause of excessive exhaust gas temperatures. Replace the DOC. Follow procedure in the Exhaust
Aftertreatment System Service Manual.

Expected Outcome
DOC should be free of restriction, contamination, soot leakage, and melted or deformed cells.
1658 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Coolant to Engine Oil Inspection

Overview
Inspect oil in oil pan for coolant contamination.
NOTE: Oil cooler coolant leakage to oil will occur only when coolant pressure is higher than oil pressure.
Diagnosis and repairs will not be authorized based solely on oil analysis.

Special Tools
None

Procedure
1. Remove engine oil level gauge (dipstick) and inspect for coolant contamination. An overfilled crankcase can
be due to coolant in the engine oil.
2. Remove drain plug from oil pan and obtain an oil sample.
3. Inspect oil sample for signs of coolant.

Expected Outcome
Determine if engine oil is contaminated with coolant or not.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1659

Oil Pressure Regulator Inspection

Overview
Check oil pressure regulator for damage, binding, or sticking.

Special Tools
None

Equipment Condition

Figure 684 Oil Filter / Oil Filter Housing Assembly

1. Oil filter regulator 2. Oil filter housing 3. Oil filter

Remove regulator valve spring and piston (see Engine Service Manual).
1660 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Procedure

Figure 685 Oil Pressure Regulator

A. Regulator valve spring B. Regulator piston C. Bore

1. Check regulator valve spring (Figure 685) (Item A) for collapsed, damaged, and broken coils.
2. Check regulator piston (Figure 685) (Item B) and bore (Figure 685) (Item C) for scoring.

Expected Outcome
Oil pressure regulator will have no broken parts, will not bind or stick, and surfaces will show no signs of scoring
or excessive wear.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1661

Cylinder Sleeve Cavitation and Crack Inspection

Overview
Inspect cylinder sleeves for holes or cracks caused by cavitation (gas-filled bubbles formed in the coolant).

Special Tools
None

Equipment Condition
Remove cylinder head. See Engine Service Manual.

Procedure
1. Inspect piston crowns for signs of coolant leaks. Lack of carbon on piston crowns indicates possible coolant
leak into the cylinder.
2. Using engine barring tool ZTSE6072, rotate crankshaft to put one cylinders 1 and 6 to Bottom Dead Center
(BDC).
3. Inspect cylinder sleeves 1 and 6 for coolant, coolant staining, pinholes, and cracks in cylinder sleeve.
4. Repeat steps 2 and 3 for cylinders pairs 2-5 and 3-4.

Expected Outcome
Carbon deposits should be present on piston crowns, indicating cylinder sleeves are free of holes and cracks.
1662 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Oil and Crankcase Inspection

Overview
Inspect for internal engine damage and excessive engine oil leaks.

WARNING:

To prevent personal injury or death, wear safety glasses with side shields. Limit
compressed air pressure to 30 psi (207 kPa).

Special Tools
Air pressure regulator assembly

Equipment Condition
1. Drain engine oil.
2. Remove oil pan (see Engine Service Manual).

Procedure
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1663

Figure 687 Oil Pump Suction Tube (Typical)

A. Oil pump suction tube gasket
B. Oil pump suction tube

1. Remove oil pump suction tube (Figure 687) (Item B).

2. Check tube and gasket (Figure 687) (Item A).

Figure 688 Piston Cooling Tube

C. Piston cooling tube (6)
1664 2 ENGINE SYSTEM TESTS AND INSPECTIONS

3. Check for six missing or broken piston cooling tubes (Figure 688) (Item C).
4. Use regulated shop air to check for loose connecting rod or main bearings, camshaft bushings, or excessive
flow from regulator valve return port.

Expected Outcome
Technician will determine if internal engine damage is present, or if excessive engine oil is leaking.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1665

High-Pressure (HP) Turbocharger Radial Play Inspection

Overview
Check High-Pressure (HP) Turbocharger for excessive radial play.

Special Tools
None

Equipment Condition
Remove compressor housing from High Pressure (HP) Turbocharger.

Procedure
Inspect high pressure turbocharger compressor housing and compressor wheel for signs of contact including
damage to the compressor wheel and/or scaring to the compressor housing.

Expected Outcome
High-Pressure (HP) Turbocharger compressor wheel does not have excessive play, and does not contact the
inside of the compressor wheel housing, and is free from damage.
1666 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Batteries and Electrical System Inspection

Overview
Inspection of batteries, cables, starter, alternator, and associated wiring. Components and connections should
be tight and not corroded. Alternator drive belt should be in good condition, have proper tension and associated
drive pulleys should be operating properly.

Special Tools
None.

Equipment Condition
• Hood open
• Battery covers removed
• Fuse panel and power distribution covers removed

Procedure

WARNING:

To prevent property damage, personal injury, and / or death, shift transmission to Park or
Neutral, set parking brake, and install wheel chocks before doing diagnostic or service
procedures.

WARNING:

To prevent personal injury or death, always wear approved safe eye protection when
performing vehicle diagnostic or service procedures.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1667

Figure 689 Battery Box (Typical)

A. Negative jumper
B. Battery hold-down
C. Negative cable
D. Positive cable
E. Cube fuse
F. Positive jumper

1. Inspect battery terminal connections for looseness and corrosion.

2. Inspect battery case, tray, and hold-downs for cracks or damage. Verify each battery is the same type,
battery chemistry (flooded, AGM, etc.), and battery rating.
3. Check electrolyte level, if applicable. If low add distilled water.
4. If equipped, inspect cube fuse (E). Verify starter power cable is installed directly to positive terminal, NOT
on top of cube fuse.
5. Inspect battery wiring (A, C, D, F) for fraying, insulation integrity, and proper routing.
6. Inspect fuse panel. Verify fuses are not Open and circuit breakers are depressed and are in non-tripped
position.
7. Inspect power distribution module. Verify fuses are not Open.
1668 2 ENGINE SYSTEM TESTS AND INSPECTIONS

D
E

0000414074

Figure 690 Starter (Typical)

A. Positive cable
B. Cable connection
C. IMS
D. Negative Cable
E. Starter motor input cable
F. Negative connection

8. Inspect battery connections (B and F).

9. Inspect wiring (D, A, E) for fraying, insulation integrity, and proper routing.
10. If equipped, inspect integrated magnetic switch (IMS) connections and wiring (C).
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1669

A B

E
F
0000414024

Figure 691 Accessory Drive (Typical)

A. Alternator connections and wiring
B. Belt
C. Fan pulley
D. Crank pulley
E. Belt tensioner
F. Water pump pulley
G. Alternator pulley

11. Inspect alternator connections (A) for looseness and corrosion.

12. Inspect alternator wiring (A) for fraying, insulation integrity, and proper routing.
13. Inspect accessory drive belt (B) for excessive cracks, wear, and contamination.
14. Inspect accessory belt tensioner (E) for spring tension through full range of movement.
15. Inspect alternator and accessory drive pulleys (C, D, F, G) for damage and looseness, and that they spin
freely.
1670 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Expected Outcome
Determine if batteries, cables, starter, alternator, and associated wiring are tight and not corroded, and if
alternator drive belt is in good condition, has proper tension and associated drive pulleys are operating properly.

Follow-On Procedure
None.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1671

Aftertreatment
Snap Acceleration Test

Overview
Tests Diesel Particulate Filter (DPF) for cracks, internal damage, and basic functionality without removing it from
vehicle.

Special Tools
None

Equipment Condition
None

Test Setup
None

Procedure
1. Shift transmission to neutral, and set parking brake.
2. Start and idle engine.
3. Rapidly snap accelerator to full throttle (this can be done multiple times).
4. During the engine accelerations, visually monitor the exhaust pipe for heavy black smoke. Use assistant if
necessary.

Expected Outcome
There will not be heavy clouds of black smoke exiting the exhaust pipe. Black smoke is an indication of a failure
in the Aftertreatment (AFT) system, specifically the DPF.

Follow-On Procedure
None
1672 2 ENGINE SYSTEM TESTS AND INSPECTIONS

Downstream Injection System Operation Test

Overview
This test uses a special tool and a system test to determine if a faulty downstream injector is due to an electronic
control malfunction and / or wiring or a Downstream Injection (DSI) Assembly fault. Separating the command
circuit and DSI Assembly allows for proper diagnosis of the Downstream Injection System.

CAUTION:

Do NOT disconnect the Downstream Injection (DSI) Assembly harnesses or plug in the
NOID Light with the ignition Key-On. Doing so will give false test results.

Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B compliant supporting J1939 and J1708)
• NOID Light – 15-909-01

Equipment Condition
None

Test Setup
1. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1345).
2. Log in to Navistar® Engine Diagnostics.
 2 ENGINE SYSTEM TESTS AND INSPECTIONS 1673

3. Key OFF.

Figure 692 Downstream Injection (DSI) Assembly with Connectors

1. Engine wiring harness
2. Aftertreatment Fuel Doser (AFTFD) connector
3. Downstream Injection (DSI) assembly
4. AFT Fuel Shutoff (AFTFSO) connector

4. Disconnect Aftertreatment Fuel Doser (AFTFD) connector (Figure 692) (Item 2) from Downstream
Injection (DSI) Assembly (Figure 692) (Item 3).
5. Plug NOID Light (15-909-01) into AFTFD connector on engine wiring harness (Item 1).

Procedure
1. Key-On.
2. Perform KOEO DCU Actuator Test(page 1368).
• Select Tests > KOEO Aftertreatment Tests > Actuator - DCU Actuators.
• In the drop down menu select "AFT Fuel Pressure CTL".
1674 2 ENGINE SYSTEM TESTS AND INSPECTIONS

• Ensure "On (95% Duty Cycle)" is selected.

• Click "Start Test".
3. Observe NOID Light during test.
• Steady on or Flashing light indicates the electrical control and wiring for the DSI Assembly is working
properly.
• No light indicates an electrical circuit or control fault.
4. If light indicates a properly functioning command circuit and control for AFTFD, turn Key OFF.
5. Unplug NOID Light, and plug AFTFD connector back into DSI Assembly.
6. Unplug AFT Fuel Shutoff (AFTFSO) connector (Item 4) from DSI Assembly.
7. Plug NOID Light into AFTFSO connector on engine wiring harness.
8. Key–On.
9. Perform KOEO DCU Actuator Test(page 1368).
• Select Tests > KOEO Aftertreatment Tests > Actuator - DCU Actuators.
• In the drop down menu select "AFT Fuel Enable CTL".
• Ensure "On" is selected.
• Click "Start Test".
10. Observe NOID Light during test.
• Steady on or Flashing light indicates the electrical control and wiring for the DSI Assembly is working
properly.
• No light indicates an electrical circuit or control fault.

Expected Outcome
NOID Light will indicate if command signals and wiring are working properly for the Downstream Injection (DSI)
Assembly.

Follow-on Procedure
None
 3 ENGINE SPECIFICATIONS 1675

Table of Contents

All Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1677

Key-On, Engine-Off Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1677
Engine Cranking Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1679
Low Idle, no load, stabilized engine operating temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1680
High Idle No Load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1681
Full load, ECM rated speed at highway, stabilized operating temperature. . . . . . . . . . . . . . . . . . . . . . .1682
Other Component Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1683

MaxxForce® DT (7.6L). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1684

215 hp @ 2200 rpm (12NUK). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1684
230 hp @ 2200 rpm (12NUL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1686
230 hp @ 2200 rpm (12NUM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1687
245 hp @ 2200 rpm (12NUN). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1688
260 hp @ 2200 rpm (12NUP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1689
270 hp @ 2200 rpm (12NUR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1690
285 hp @ 2200 rpm (12NUS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1691
300 hp @ 2200 rpm (12NUT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1692

MaxxForce® 9 (9.3L). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1693

300 hp @ 2000 rpm (12NUU). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1693
315 hp @ 2000 rpm (12NUV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1695
330 hp @ 2000 rpm (12NUW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1696

MaxxForce® 10 (9.3L). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1698

310 hp @ 2000 rpm (12NUX). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1698
330 hp @ 2000 rpm (12NUY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1700
350 hp @ 2000 rpm (12NUZ). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1701

Signal Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1703

1676 3 ENGINE SPECIFICATIONS
 3 ENGINE SPECIFICATIONS 1677

All Ratings
Key-On, Engine-Off Specifications

Barometric pressure (500 ft. above sea level) 99.01 kPa (14.36 psi) / 3.91 V

Fuel rail pressure 0 kPa (0 psi) / 0.5 V

Turbocharger 1 turbine outlet pressure 0 kPa (0 psi) / 0.84 V

Fuel pump OFF, pressure bled down -2.34 to 2.34 psi (-16.10 to 16.10 kPa)

Fuel delivery pressure with fuel pump on and using a mechanical gauge. 60 to 100 psi (413 to 689 kPa)

Intake manifold pressure 0 kPa (0 psi) / 1.06 V

Diesel particulate filter differential pressure 0 kPa (0 psi) / 0.47 to 0.91 V

Exhaust gas recirculation valve position 4.5 to 5.5 %

Engine throttle valve position 4.5 to 5.5 %

Accelerator pedal position sensor (at idle) 0.7 V / 0 %

Accelerator pedal position sensor (depressed to floor) 3.75 V / 99.6 %

Engine oil pressure 0 kPa (0 psi) / 0.5 V

Exhaust back pressure 0 kPa (0 psi)

Example TC1TOP (Actual) Calculations

Maximum TC1TOP Signal Value TC1TOP KOEO Signal Value Maximum - TC1TOP Signal Value
During Cranking During Cranking TC1TOP KOEO
Signal Value = TC1TOP (Actual)
15.7 psi (108 kPa) 14.7 psi (101 kPa) 15.7 psi (108 kPa) - 14.7 psi (101 kPa)
= 1 psi (7 kPa)
1 psi (7 kPa) 0 psi (0 kPa) 1 psi (7 kPa) - 0 psi (0 kPa) = 1 psi (7
kPa)
-13 psi (-89 kPa) -14 psi (-96 kPa) -13 psi (-89 kPa) - (-14) psi (-96 kPa)
= 1 psi (7 kPa)
1678 3 ENGINE SPECIFICATIONS

Accelerator Pedal Position 1 (APP1) (Not Depressed) 0 % Nominal

Accelerator Pedal Position 2(APP2) (Not Depressed) 0 % Nominal

Accelerator Pedal Position 1 (APP1) (Not Depressed) 1.10 volt Nominal

Accelerator Pedal Position 1 (APP1) (Not Depressed) 0.56 volt Nominal

Accelerator Pedal Position 1 (APP1) (Fully Depressed) 100 % Nominal

Accelerator Pedal Position 2 (APP2) (Fully Depressed) 100 % Nominal

Accelerator Pedal Position 1 (APP1) (Fully Depressed) 4.30 volt Nominal

Accelerator Pedal Position 2 (APP2) (Fully Depressed) 2.14 volt Nominal

35% = Closed
EGR Valve Control
90% = Open

35% = Closed
EGR Position
90% = Open

Engine Throttle Position 0 % Nominal

 3 ENGINE SPECIFICATIONS 1679

Engine Cranking Specifications

Cranking rpm (min) 130 rpm

20 seconds maximum crank time per attempt. Wait 2 to 3 minutes before repeating.

Battery voltage (min based on ECM drop out) 9V

Injection control pressure (min to start engine) 5 MPa (725 psi) / 0.95 V

EGR control 35 %

Fuel delivery pressure with fuel pump on and using a mechanical gauge.
60 to 100 psi (413 to 689 kPa)
1680 3 ENGINE SPECIFICATIONS

Low Idle, no load, stabilized engine operating temperature

Engine coolant temperature (at thermostat opening) 85 °C (185 °F) ± 2.78 °C (5 °F)

1.26 V ± 0.4 V

Engine oil temperature should not go 5.5 °C (10 °F) above engine coolant temperature.

Intake Manifold Temperature 66 °C (150 °F) ± 5.5 °C (10 °F)

Low Idle, no load, stabilized engine operating temperature

Engine oil pressure 214 kPa (31 psi) / 2.19 V

Fuel delivery pressure (gauge) 621 kPa (90 psi) ± 10 psi

Mass air flow sensor 3140 Hz ± 100 Hz

 3 ENGINE SPECIFICATIONS 1681

High Idle No Load

High Idle, Parasitic load, at stabilized operating temperature

Fuel delivery pressure (gauge) 621 kPa (90 psi) ± 10 psi

Engine oil pressure 276 kPa (40 psi) minimum

Mass air flow sensor 7064 Hz ± 100 Hz

1682 3 ENGINE SPECIFICATIONS

Full load, ECM rated speed at highway, stabilized operating temperature

Air cleaner restriction (max) 6.2 kPa (25 in H2O)

Fuel delivery pressure (gauge) 621 kPa (90 psi) ± 10 psi

Mass air flow sensor 4612 Hz (min)

8138 Hz (max)
 3 ENGINE SPECIFICATIONS 1683

Other Component Specifications

Actuator Output State

Injector pressure regulator valve Output state LOW – 0%

Output state HIGH – 90%

Exhaust gas recirculation valve Output state LOW – 35%

Output state HIGH – 80 to 90%

Engine throttle valve Output state LOW – 0%

Output state HIGH – 50%

Engine throttle valve position Output state LOW – 1.12 V

Output state HIGH – 2.9 V

Air Control Valve Solenoid Output state LOW – 0%

Output state HIGH – 100%

Crankcase Pressure

High idle no load - max. using ZTSE4039 1.5 kPa (6 in. H2O)

Intake Air heater Current Draw

Intake Air heater Current Draw Current draw 125 +/- 30 Amps

TC2WC Rod Extension

Full travel 13 mm
1684 3 ENGINE SPECIFICATIONS

MaxxForce® DT (7.6L)
215 hp @ 2200 rpm (12NUK)

MaxxForce® DT/215 hp @ 2200 rpm / 560 ft•lb @ 1300 rpm

50 state 2010 Model Year (MY)

Engine unit code 12NUK

Engine model MaxxForce® DT/215

Engine Family Rating Code (EFRC) 1121

Injection timing Nonadjustable

High idle speed - manual transmission 2600 rpm

High idle speed - automatic transmission 2600 rpm

Low idle speed 700 rpm

Low Idle, no load, stabilized engine operating temperature

Intake manifold pressure 0 kPa (0 psi)

Exhaust back pressure 2 kPa (0.29 psi) / 0.74 V

Injection control pressure 5.9 MPa (859 psi) / 1.07 V

EGR Control 35 % to 80 %

Engine Throttle Position 0%

High Idle, no load, stabilized engine operating temperature

Intake Manifold Pressure 69 to 97 kPa (10 to 14 psi)

Exhaust back pressure 179 kPa (26 psi) / 2.16 V

Injection control pressure 10.69 MPa (1550 psi) / 1.72 V

EGR Control 35 % to 80 %

Engine Throttle Position 0%

Torque converter stall (automatic transmission) 2000 rpm or greater @ 5 seconds or less

Full load, ECM rated speed at highway, stabilized engine operating temperature

Intake manifold pressure 207 kPa (30 psi)

Exhaust back pressure 290 kPa (42 psi)

Injection control pressure 31 MPa (4525 psi)

 3 ENGINE SPECIFICATIONS 1685

EGR control 35% to 80%

Engine Throttle Position 0%

1686 3 ENGINE SPECIFICATIONS

230 hp @ 2200 rpm (12NUL)

MaxxForce® DT/230 hp @ 2200 rpm / 620 ft•lb @ 1300 rpm

50 state 2010 Model Year (MY)

Engine unit code 12NUL

Engine model MaxxForce® DT/230

Engine Family Rating Code (EFRC) 1141

Injection timing Nonadjustable

High idle speed - manual transmission 2600 rpm

High idle speed - automatic transmission 2600 rpm

Low idle speed 700 rpm

Low Idle, no load, stabilized engine operating temperature

Intake manifold pressure 0 kPa (0 psi)

Exhaust back pressure 1.3 kPa (0.19 psi) / 0.74 V

Injection control pressure 6 MPa (877 psi) / 1.07 V

EGR control 35% to 80%

Engine Throttle Position 0%

High Idle, no load, stabilized engine operating temperature

Intake manifold pressure 60 kPa (8.7 psi)

Exhaust back pressure 118 kPa (17.1 psi) / 2.16 V

Injection control pressure 12.2 MPa (1777 psi) / 2.62 V

EGR control 35% to 80%

Engine Throttle Position 0%

Torque converter stall (automatic transmission) 2000 rpm or greater @ 5 seconds or less

Full load, ECM rated speed at highway, stabilized engine operating temperature

Intake manifold pressure 207 kPa (30 psi)

Exhaust back pressure 247 kPa (35.85 psi)

Injection control pressure 30.3 MPa (4401 psi)

EGR control 35% to 80%

Engine Throttle Position 0%

 3 ENGINE SPECIFICATIONS 1687

230 hp @ 2200 rpm (12NUM)

MaxxForce® DT/230 hp @ 2200 rpm / 660 ft•lb @ 1300 rpm

50 state 2010 Model Year (MY)

Engine unit code 12NUM

Engine model MaxxForce® DT/230

Engine Family Rating Code (EFRC) 1151

Injection timing Nonadjustable

High idle speed - manual transmission 2600 rpm

High idle speed - automatic transmission 2600 rpm

Low idle speed 700 rpm

Low Idle, no load, stabilized engine operating temperature

Intake manifold pressure 0 kPa (0 psi)

Exhaust back pressure 2 kPa (0.29 psi) / 0.74 V

Injection control pressure 5.9 MPa (859 psi) / 1.07 V

EGR Control 35% to 80%

Engine Throttle Position 0%

High Idle, no load, stabilized engine operating temperature

Intake manifold pressure 97 kPa (14 psi)

Exhaust back pressure 179 kPa (26 psi) / 2.16 V

Injection control pressure 17 MPa (2518 psi) / 2.62 V

EGR Control 35% to 80%

Engine Throttle Position 0%

Torque converter stall (automatic transmission) 2000 rpm or greater @ 5 seconds or less

Full load, ECM rated speed at highway, stabilized engine operating temperature

Intake manifold pressure 207 kPa (30 psi)

Exhaust back pressure 290 kPa (42 psi)

Injection control pressure 31 MPa (4525 psi)

EGR Control 35% to 80%

Engine Throttle Position 0%

1688 3 ENGINE SPECIFICATIONS

245 hp @ 2200 rpm (12NUN)

MaxxForce® DT/245 hp @ 2200 rpm / 660 ft•lb @ 1300 rpm

50 state 2010 Model Year (MY)

Engine unit code 12NUN

Engine model MaxxForce® DT/245

Engine Family Rating Code (EFRC) 2111

Injection timing Nonadjustable

High idle speed - manual transmission 2600 rpm

High idle speed - automatic transmission 2600 rpm

Low idle speed 700 rpm

Low Idle, no load, stabilized engine operating temperature

Intake manifold pressure 0 kPa (0 psi)

Exhaust back pressure 2 kPa (0.32 psi) / 0.74 V

Injection control pressure 7 MPa (1005 psi) / 1.21 V

EGR Control 35% to 80%

Engine Throttle Position 0%

High Idle, no load, stabilized engine operating temperature

Intake manifold pressure 76 kPa (11 psi)

Exhaust back pressure 186 kPa (27 psi) / 2.22 V

Injection control pressure 9 MPa (1244 psi) / 1.43 V

EGR Control 35% to 80%

Engine Throttle Position 0%

Torque converter stall (automatic transmission) 2000 rpm or greater @ 5 seconds or less

Full load, ECM rated speed at highway, stabilized engine operating temperature

Intake manifold pressure 221 kPa (32 psi)

Exhaust back pressure 393 kPa (57 psi)

Injection control pressure 30 MPa (4337 psi)

EGR Control 35% to 80%

Engine Throttle Position 0%

 3 ENGINE SPECIFICATIONS 1689

260 hp @ 2200 rpm (12NUP)

MaxxForce® DT/260 hp @ 2200 rpm / 660 ft•lb @ 1300 rpm

50 state 2010 Model Year (MY)

Engine unit code 12NUP

Engine model MaxxForce® DT/260

Engine Family Rating Code (EFRC) 2121

Injection timing Nonadjustable

High idle speed - manual transmission 2600 rpm

High idle speed - automatic transmission 2600 rpm

Low idle speed 700 rpm

Low Idle, no load, stabilized engine operating temperature

Intake manifold pressure 0 kPa (0 psi)

Exhaust back pressure 2 kPa (0.32 psi) / 0.74 V

Injection control pressure 7 MPa (1005 psi) / 1.21 V

EGR Control 35% to 80%

Engine Throttle Position 0%

High Idle, no load, stabilized engine operating temperature

Intake manifold pressure 76 kPa (11 psi)

Exhaust back pressure 193 kPa (28 psi) / 2.2 V

Injection control pressure 17 MPa (2480 psi) / 1.4 V

EGR Control 35% to 80%

Engine Throttle Position 0%

Torque converter stall (automatic transmission) 2000 rpm or greater @ 5 seconds or less

Full load, ECM rated speed at highway, stabilized engine operating temperature

Intake manifold pressure 221 kPa (32 psi)

Exhaust back pressure 386 kPa (56 psi)

Injection control pressure 31 MPa (4496 psi)

EGR Control 35% to 80%

Engine Throttle Position 0%

1690 3 ENGINE SPECIFICATIONS

270 hp @ 2200 rpm (12NUR)

MaxxForce® DT/270 hp @ 2200 rpm / 860 ft•lb @ 1300 rpm

50 state 2010 Model Year (MY)

Engine unit code 12NUR

Engine model MaxxForce® DT/270

Engine Family Rating Code (EFRC) 2131

Injection timing Nonadjustable

High idle speed - manual transmission 2600 rpm

High idle speed - automatic transmission 2600 rpm

Low idle speed 700 rpm

Low Idle, no load, stabilized engine operating temperature

Intake manifold pressure 0 kPa (0 psi)

Exhaust back pressure 2 kPa (0.32 psi) / 0.74 V

Injection control pressure 7 MPa (1005 psi) / 1.21 V

EGR Control 35% to 80%

Engine Throttle Position 0%

High Idle, no load, stabilized engine operating temperature

Intake manifold pressure 76 kPa (11 psi)

Exhaust back pressure 207 kPa (30 psi) / 2.39 V

Injection control pressure 9 MPa (1306 psi) / 1.4 V

EGR Control 35% to 80%

Engine Throttle Position 0%

Torque converter stall (automatic transmission) 2000 rpm or greater @ 5 seconds or less

Full load, ECM rated speed at highway, stabilized engine operating temperature

Intake manifold pressure 248 kPa (36 psi)

Exhaust back pressure 393 kPa (57 psi)

Injection control pressure 32 MPa (4569 psi)

EGR Control 35% to 80%

Engine Throttle Position 0%

 3 ENGINE SPECIFICATIONS 1691

285 hp @ 2200 rpm (12NUS)

MaxxForce® DT/280 hp @ 2200 rpm / 860 ft•lb @ 1300 rpm

50 state 2010 Model Year (MY)

Engine unit code 12NUS

Engine model MaxxForce® DT/280

Engine Family Rating Code (EFRC) 2141

Injection timing Nonadjustable

High idle speed - manual transmission 2600 rpm

High idle speed - automatic transmission 2600 rpm

Low idle speed 700 rpm

Low Idle, no load, stabilized engine operating temperature

Intake manifold pressure 0 kPa (0 psi)

Exhaust back pressure 2 kPa (0.32 psi) / 0.74 V

Injection control pressure 7 MPa (1005 psi) / 1.21 V

EGR Control 35% to 80%

Engine Throttle Position 0%

High Idle, no load, stabilized engine operating temperature

Intake manifold pressure 83 kPa (12 psi)

Exhaust back pressure 214 kPa (31 psi) / 2.4 V

Injection control pressure 9 MPa (1305 psi) / 1.5 V

EGR Control 35% to 80%

Engine Throttle Position 0%

Torque converter stall (automatic transmission) 2000 rpm or greater @ 5 seconds or less

Full load, ECM rated speed at highway, stabilized engine operating temperature

Intake manifold pressure 248 kPa (36 psi)

Exhaust back pressure 386 kPa (56 psi)

Injection control pressure 32 MPa (4609 psi)

EGR Control 35% to 80%

Engine Throttle Position 0%

1692 3 ENGINE SPECIFICATIONS

300 hp @ 2200 rpm (12NUT)

MaxxForce® DT/280 hp @ 2200 rpm / 860 ft•lb @ 1300 rpm

50 state 2010 Model Year (MY)

Engine unit code 12NUT

Engine model MaxxForce® DT/280

Engine Family Rating Code (EFRC) 2151

Injection timing Nonadjustable

High idle speed - manual transmission 2600 rpm

High idle speed - automatic transmission 2600 rpm

Low idle speed 700 rpm

Low Idle, no load, stabilized engine operating temperature

Intake manifold pressure 0 kPa (0 psi)

Exhaust back pressure 2 kPa (0.32 psi) / 0.74 V

Injection control pressure 7 MPa (1005 psi) / 1.21 V

EGR Control 35% to 80%

Engine Throttle Position 0%

High Idle, no load, stabilized engine operating temperature

Intake manifold pressure 76 kPa (11 psi)

Exhaust back pressure 193 kPa (28 psi) / 2.27 V

Injection control pressure 9 MPa (1307 psi) / 1.5 V

EGR Control 35% to 80%

Engine Throttle Position 0%

Torque converter stall (automatic transmission) 2000 rpm or greater @ 5 seconds or less

Full load, ECM rated speed at highway, stabilized engine operating temperature

Intake manifold pressure 248 kPa (36 psi)

Exhaust back pressure 386 kPa (56 psi)

Injection control pressure 32 MPa (4588 psi)

EGR Control 35% to 80%

Engine Throttle Position 0%

 3 ENGINE SPECIFICATIONS 1693

MaxxForce® 9 (9.3L)
300 hp @ 2000 rpm (12NUU)

MaxxForce® 9/300 hp @ 2000 rpm / 860 ft•lb @ 1200 rpm

50 state 2010 Model Year (MY)

Engine unit code 12NUU

Engine model MaxxForce® 9/300

Engine Family Rating Code (EFRC) 5121

Injection timing Nonadjustable

High idle speed - manual transmission 2400 rpm

High idle speed - automatic transmission 2400 rpm

Low idle speed 700 rpm

Low Idle, no load, stabilized engine operating temperature

Intake manifold pressure 0 kPa (0 psi)

Exhaust back pressure 4 kPa (0.6 psi) / 0.75 V

Injection control pressure 6 MPa (853 psi) / 1.09 V

EGR Control 35% to 80%

Engine Throttle Position 0%

High Idle, no load, stabilized engine operating temperature

Minimum intake manifold pressure 69 kPa (10 psi)

Exhaust back pressure 352 kPa (51 psi) / 3.55 V

Injection control pressure 15 MPa (2228 psi) / 2.35 V

EGR Control 35% to 80%

Engine Throttle Position 0%

Torque converter stall (automatic transmission) 2000 rpm or greater @ 5 seconds or less

Full load, ECM rated speed at highway, stabilized engine operating temperature

Intake manifold pressure 248 kPa (36 psi)

Exhaust back pressure 365 kPa (53 psi)

Injection control pressure 32 MPa (4640 psi)

1694 3 ENGINE SPECIFICATIONS

EGR Control 35% to 80%

Engine Throttle Position 0%

 3 ENGINE SPECIFICATIONS 1695

315 hp @ 2000 rpm (12NUV)

MaxxForce® 9/315 hp @ 2000 rpm / 950 ft•lb @ 1200 rpm

50 state 2010 Model Year (MY)

Engine unit code 12NUV

Engine model MaxxForce® 9/315

Engine Family Rating Code (EFRC) 5131

Injection timing Nonadjustable

High idle speed - manual transmission 2400 rpm

High idle speed - automatic transmission 2400 rpm

Low idle speed 700 rpm

Low Idle, no load, stabilized engine operating temperature

Intake manifold pressure 0 kPa (0 psi)

Exhaust back pressure 4 kPa (0.6 psi) / 0.75 V

Injection control pressure 6 MPa (853 psi) / 1.09 V

EGR Control 35% to 80%

Engine Throttle Position 0%

High Idle, no load, stabilized engine operating temperature

Minimum intake manifold pressure 69 kPa (10 psi)

Exhaust back pressure 352 kPa (51 psi) / 3.55 V

Injection control pressure 15 MPa (2228 psi) / 2.35 V

EGR Control 35% to 80%

Engine Throttle Position 0%

Torque converter stall (automatic transmission) 2000 rpm or greater @ 5 seconds or less

Full load, ECM rated speed at highway, stabilized engine operating temperature

Intake manifold pressure 248 kPa (36 psi)

Exhaust back pressure 365 kPa (53 psi)

Injection control pressure 32 MPa (4640 psi)

EGR Control 35% to 80%

Engine Throttle Position 0%

1696 3 ENGINE SPECIFICATIONS

330 hp @ 2000 rpm (12NUW)

MaxxForce® 9/315 hp @ 2000 rpm / 950 ft•lb @ 1200 rpm

50 state 2010 Model Year (MY)

Engine unit code 12NUW

Engine model MaxxForce® 9/330

Engine Family Rating Code (EFRC) 5151

Injection timing Nonadjustable

High idle speed - manual transmission 2400 rpm

High idle speed - automatic transmission 2400 rpm

Low idle speed 700 rpm

Low Idle, no load, stabilized engine operating temperature

Intake manifold pressure 0 kPa (0 psi)

Exhaust back pressure 4 kPa (0.6 psi) / 0.75 V

Injection control pressure 6 MPa (853 psi) / 1.09 V

EGR Control 35% to 80%

Engine Throttle Position 0%

High Idle, no load, stabilized engine operating temperature

Minimum intake manifold pressure 69 kPa (10 psi)

Exhaust back pressure 352 kPa (51 psi) / 3.55 V

Injection control pressure 15 MPa (2228 psi) / 2.35 V

EGR Control 35% to 80%

Engine Throttle Position 0%

Torque converter stall (automatic transmission) 2000 rpm or greater @ 5 seconds or less

Full load, ECM rated speed at highway, stabilized engine operating temperature

Intake manifold pressure 248 kPa (36 psi)

Exhaust back pressure 365 kPa (53 psi)

Injection control pressure 32 MPa (4640 psi)

EGR Control 35% to 80%

Engine Throttle Position 0%

1697 3 ENGINE SPECIFICATIONS
1698 3 ENGINE SPECIFICATIONS

MaxxForce® 10 (9.3L)
310 hp @ 2000 rpm (12NUX)

MaxxForce® 10/310 hp @ 2000 rpm / 1050 ft•lb @ 1200 rpm

50 state 2010 Model Year (MY)

Engine unit code 12NUX

Engine model MaxxForce® 10/310

Engine Family Rating Code (EFRC) 6121

Injection timing Nonadjustable

High idle speed - manual transmission 2400 rpm

High idle speed - automatic transmission 2400 rpm

Low idle speed 700 rpm

Low Idle, no load, stabilized engine operating temperature

Intake manifold pressure

0 kPa (0 psi)

Exhaust back pressure 4 kPa (0.6 psi) / 0.75 V

Injection control pressure 6 MPa (853 psi) / 1.09 V

EGR Control 35% to 80%

Engine Throttle Position 0%

High Idle, no load, stabilized engine operating temperature

Minimum intake manifold pressure 69 kPa (10 psi)

Exhaust back pressure 352 kPa (51 psi) / 3.55 V

Injection control pressure 15 MPa (2228 psi) / 2.35 V

EGR Control 35% to 80%

Engine Throttle Position 0%

Torque converter stall (automatic transmission) 2000 rpm or greater @ 5 seconds or less

Full load, ECM rated speed at highway, stabilized engine operating temperature

Intake manifold pressure 248 kPa (36 psi)

Exhaust back pressure 365 kPa (53 psi)

Injection control pressure 32 MPa (4640 psi)

 3 ENGINE SPECIFICATIONS 1699

EGR Control 35% to 80%

Engine Throttle Position 0%

1700 3 ENGINE SPECIFICATIONS

330 hp @ 2000 rpm (12NUY)

MaxxForce® 10/330 hp @ 2000 rpm / 1150 ft•lb @ 1200 rpm

50 state 2010 Model Year (MY)

Engine unit code 12NUY

Engine model MaxxForce® 10/330

Engine Family Rating Code (EFRC) 6131

Injection timing Nonadjustable

High idle speed - manual transmission 2400 rpm

High idle speed - automatic transmission 2400 rpm

Low idle speed 700 rpm

Low Idle, no load, stabilized engine operating temperature

Minimum intake manifold pressure 69 kPa (10 psi)

Exhaust back pressure 4 kPa (0.6 psi) / 0.75 V

Injection control pressure 6 MPa (853 psi) / 1.09 V

EGR Control 35% to 80%

Engine Throttle Position 0%

High Idle, no load, stabilized engine operating temperature

Intake manifold pressure 159 kPa (23 psi)

Exhaust back pressure 352 kPa (51 psi) / 3.55 V

Injection control pressure 15 MPa (2228 psi) / 2.35 V

EGR Control 35% to 80%

Engine Throttle Position 0%

Torque converter stall (automatic transmission) 2000 rpm or greater @ 5 seconds or less

Full load, ECM rated speed at highway, stabilized engine operating temperature

Intake manifold pressure 248 kPa (36 psi)

Exhaust back pressure 365 kPa (53 psi)

Injection control pressure 32 MPa (4640 psi)

EGR Control 35% to 80%

Engine Throttle Position 0%

 3 ENGINE SPECIFICATIONS 1701

350 hp @ 2000 rpm (12NUZ)

MaxxForce® 10/350 hp @ 2000 rpm / 1150 ft•lb @ 1200 rpm

50 state 2010 Model Year (MY)

Engine unit code 12NUZ

Engine model MaxxForce® 10/350

Engine Family Rating Code (EFRC) 6151

Injection timing Nonadjustable

High idle speed - manual transmission 2400 rpm

High idle speed - automatic transmission 2400 rpm

Low idle speed 700 rpm

Low Idle, no load, stabilized engine operating temperature

Intake manifold pressure 0 kPa (0 psi)

Exhaust back pressure 4 kPa (0.6 psi) / 0.75 V

Injection control pressure 6 MPa (853 psi) / 1.09 V

EGR Control 35% to 80%

Engine Throttle Position 0%

High Idle, no load, stabilized engine operating temperature

Minimum intake manifold pressure 69 kPa (10 psi)

Exhaust back pressure 352 kPa (51 psi) / 3.55 V

Injection control pressure 15 MPa (2228 psi) / 2.35 V

EGR Control 35% to 80%

Engine Throttle Position 0%

Torque converter stall (automatic transmission) 2000 rpm or greater @ 5 seconds or less

Full load, ECM rated speed at highway, stabilized engine operating temperature

Intake manifold pressure 248 kPa (36 psi)

Exhaust back pressure 365 kPa (53 psi)

Injection control pressure 32 MPa (4640 psi)

EGR Control 35% to 80%

Engine Throttle Position 0%

1702 3 ENGINE SPECIFICATIONS
 3 ENGINE SPECIFICATIONS 1703

Signal Values
1704 3 ENGINE SPECIFICATIONS

NOTE: Voltage measurements were taken with the ignition Key ON, Engine OFF (KOEO) and the breakout
connected between the Engine Control Module (ECM) and engine harness. See “APPENDIX A: PERFORMANCE
SPECIFICATIONS” (page 1677) for actuator output voltages, sensor values, and component specifications in a wide
range of conditions.

Chassis 76 Pin Connector

ECM Pin Abbreviation Circuit Name KOEO
C-1, 3, 5 ECM PWR ECM Power B+
C-2, 4, 6 ECM GND ECM Ground 0V
C-7 ECI Engine Crank Inhibit 0V
C-8 DOCIT DOC Inlet Temperature 0.90 V
C-9, 51, 63 VREF-C Voltage Reference 5.00 V
C-10 ATA-L ATA Communication Link Low 0.77 V – 1.30 V
C-11 XCS Transfercase 2.75 V
C-16 RPRE Remote Preset PTO 0V
C-17 DOCOT DOC Outlet Temperature 0.90 V
C-19 DPFDP DPF Differential Pressure 0.72 V
C-21 OWL Oil Warn Lamp 4.41 V
C-22 WEL Warn Engine Lamp 4.41 V
C-25 ATA-H ATA Communication Link High 3.05 V – 4.00 V
C-26 EGRP Exhaust Gas Recirculation Position 1.79 V
C-27 VREF-B Voltage Reference Body 5.00 V
C-29 AIT Air Inlet Temperature 2.47 V
C-31 SWBAT Switch Battery B+
C-33 APP1 Accelerator Pedal Position 1 1.10 V
C-34, 36 SIG GND-C Signal Ground Chassis 0V
C-35 SIG GND-B Signal Ground Body 0V
C-42 ECL Engine Coolant Level 0V
C-45 IPR PWR IPR Power B+
C-48 APP2 Accelerator Pedal Position 2 0.53 V
C-49 RAS Resume Accel Switch 0V
C-50 RAPP Remote Accelerator Pedal Position 0V
C-53 VSS-L Vehicle Speed Signal Low 2.75 V
C-54 VSS-H Vehicle Speed Signal High 2.75 V
C-58 EFC Engine Fan Control 4.41 V
C-60 RVAR Remote Variable PTO 0V
C-61 J1939-H J1939 Data Link High 2.57 V
C-62 J1939-L J1939 Data Link Low 2.39 V
 3 ENGINE SPECIFICATIONS 1705

Chassis 76 Pin Connector

ECM Pin Abbreviation Circuit Name KOEO
C-65 TDE Transmission Driveline Engaged 0V
C-67 DPFOT DPF Outlet Temperature 0.92 V
C-70 MPR Main Power Relay 0.76 V
C-71 TACH Tachometer B+
C-72 VSO Vehicle Speed Output B+
C-76 FPC Fuel Pump Control B+
1706 3 ENGINE SPECIFICATIONS

NOTE: Voltage measurements were taken with the ignition Key ON, Engine OFF (KOEO) and the breakout
connected between the Engine Control Module (ECM) and engine harness. See “APPENDIX A: PERFORMANCE
SPECIFICATIONS” (page 1677) for actuator output voltages, sensor values, and component specifications in a wide
range of conditions.

Engine 76 Pin Connector

ECM Pin Abbreviation Circuit Name KOEO
E-7 WIF Water In Fuel 4.66 V
E-12 MAF GND Mass Airflow Ground 0V
E-13 EOP Engine Oil Pressure 0.56 V
E-15 IMT Intake Manifold Temperature 2.67 V
E-20 EBP Exhaust Back Pressure 0.74 V
E-24 CMP-H Camshaft Position High 2.48 V
E-25 CKP-H Crankshaft Position High 2.50 V
E-28 SIG GND-E Signal Ground Engine 0V
E-32 FDP Fuel Delivery Pressure 0.73 V
E-33 ECT1 Engine Coolant Temperature 1 3.27 V
E-41 CKP-L Crankshaft Position Low 2.50 V
E-42 CMP-L Camshaft Position Low 2.28 V
E-43 IPR Injection Pressure Regulator B+
E-45 TC1TOP Turbocharger 1 Turbine Outlet Pressure 0.52 V
E-48 IMP Intake Manifold Pressure 0.73 V
E-50 EGT Exhaust Gas Temperature 4.65 V
E-56 EBPC Exhaust Back Pressure Control 0V
E-57, 75 ETC-L Engine Throttle Control Low B+
E-58, 76 ETC-H Engine Throttle Control High B+
E-59 IAH-C Intake Air Heater Control 2.86 V
E-66 EOT Engine Oil Temperature 3.44 V
E-67 MAF Mass Airflow 2.69 V
E-68 ETP Engine Throttle Position 1.12 V
E-69 FPM Fuel Pump Monitor 0V
E-71 EGRC Exhaust Gas Recirculation Control 3.95 V
E-73 TC2WC Turbocharger 2 Wastegate Control B+
 3 ENGINE SPECIFICATIONS 1707

NOTE: Voltage measurements were taken with the ignition Key ON, Engine OFF (KOEO) and the breakout harness
connected between the gray valve cover connector and engine harness.

Gray 8 Pin UVC Connector

ECM Pin Abbreviation Circuit Name KOEO
1 ECBP Engine Compression Brake Pressure 0.27 V
2, 7 SIG GND-E Signal Ground Engine 0V
3, 8 VREF-E Voltage Reference Engine 5.00 V
4 ECB1 Engine Compression Brake 1 0V
6 ICP Injection Control Pressure 0.27 V

NOTE: Voltage measurements were taken with the ignition Key ON, Engine OFF (KOEO) and the 24-pin breakout
harness connected between the 24-pin connector and engine harness.

Downstream Injection (DSI) System

24-Pin Abbreviation Circuit Name KOEO
5 AFTFIT AFT Fuel Inlet Temperature 5.44 V
6, 15 AFT VREF AFT Voltage Reference 5.00 V
7 AFTFP1 AFT Fuel Pressure 1 4.79 V
8, 16 AFT SIG GND AFT Signal Ground 0V
9 AFTFD-H AFT Fuel Doser High 6.07 V
10 AFTFD-L AFT Fuel Doser Low 0V
17 AFTFP2 AFT Fuel Pressure 2 5.44 V
18 AFTFS-H AFT Fuel Shutoff High 6.08 V
19 AFTFS-L AFT Fuel Shutoff Low -0.35 V
1708 3 ENGINE SPECIFICATIONS
 4 DIAGNOSTIC TOOLS AND ACCESSORIES 1709

Table of Contents

Electrical Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1711

24-Pin IP Engine Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1711
Radiator Pressure Test Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1711
36-Pin Injector Driver Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1712
42-Pin Engine to Chassis Interface Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1712
76-Pin Engine and Chassis Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1713
180-Pin Breakout Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1714
Amp Clamp ZTSE4575. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1715
Digital Multimeter (DMM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1716
EXP-1000 HD by Midtronics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1717
EZ-Tech® Electronic Service Tool (EST). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1718
Navistar® Engine Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1718
Electronic Engine Terminal Test Kit ZTSE4435C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1719
Interface cable (RP1210B compliant supporting J1939 and J1708). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1720
3-Banana Plug Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1720
500-Ohm Resistor Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1721
Breakout Harness ZTSE4484 (IPR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1721
Breakout Harness ZTSE4485A (APP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1722
Breakout Harness ZTSE4602 (EOT, ECT1, and AFTFSV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1722
Breakout Harness ZTSE4674 (ECM and ACT PWR Relays). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1723
Breakout Harness ZTSE4735A (ETV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1723
Breakout Harness ZTSE4760A (DOCIT, DPFIT, and DPFOT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1724
Breakout Harness ZTSE4761A (DPFDP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1724
Breakout Harness 4793 (UVC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1724
Breakout Harness ZTSE4830 (AFTFIS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1725
Breakout Harness ZTSE4831 (TC2WC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1725
Breakout Harness ZTSE4834 (ACV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1726
Breakout Harness ZTSE4850 (IMP, ICP, EOP, FDP, and EBP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1726
Breakout Harness ZTSE4908 (EFAN). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1727
Breakout Harness ZTSE4946 (EGT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1727
Breakout Harness ZTSE4948 (EGR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1728
Breakout Harness ZTSE4950 (CKP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1728
Breakout Harness ZTSE4951 (CMP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1729
Breakout Harness ZTSE4952 (ICP, ECB, and ECBP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1729
Breakout Harness 4960 (MAF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1730
Breakout Harness ZTSE4993 (IMT). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1730
Breakout Harness ZTSE6002 (WIF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1730
Breakout Harness ZTSE6020 (24-pin). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1731
Breakout Harness ZTSE6021 (AFTFD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1731
Breakout Harness ZTSE6023 (EFP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1732
Breakout Harness ZTSE6025 (IAH). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1732
Breakout Harness ZTSE6027 (AFTFP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1733

Mechanical Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1734

Charge Air Cooler Test Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1734
Clean Fuel Tank Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1734
1710 4 DIAGNOSTIC TOOLS AND ACCESSORIES

Combustion in Cooling System Tester. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1735

Crankcase Pressure Test Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1735
Digital Manometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1736
EGR Cooler Leak Detection Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1737
EGR Mixing Bowl Guide Pins. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1738
EGR Valve Puller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1738
Fuel Inlet Restriction and Aeration Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1739
Fuel/Oil Pressure Test Coupler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1739
Fuel Pressure Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1740
Fuel Pressure Test Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1741
Fuel Test Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1741
High Pressure Test Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1742
Pressure Test Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1743
CAC Block Off Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1744
Oil Cooler Test Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1745
High Pressure Test Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1746
ICP Adapter Pressure Test Fitting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1746
ICP Test Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1747
Inline Shut-off Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1747
IPR Plug Tester. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1748
Pressure Vacuum Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1748
Turbo Lifting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1749
Slack Tube® Manometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1750
UV Leak Detection Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1752
Vacuum Analyzer and Fuel Pump Tester. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1753
 4 DIAGNOSTIC TOOLS AND ACCESSORIES 1711

Electrical Tools
24-Pin IP Engine Cable

Figure 693 ZTSE6020

The 24-pin IP Engine Cable is used to test the 24-pin connector circuits.

Radiator Pressure Test Kit

Figure 694 ZTSE2384

The Radiator Pressure Test Kit is used to check pressure caps and cooling systems. The pressure gauge
indicates if the pressure cap holds the correct pressure and whether the cooling system has leaks or holds
pressure.
1712 4 DIAGNOSTIC TOOLS AND ACCESSORIES

36-Pin Injector Driver Cable

Figure 695 3036

The 36-Pin Injector Driver Cable with breakout box overlay (pin identifier) sheet is used with the 180-Pin Breakout
Box to test the injector circuits to the ECM with no ECM connection.

42-Pin Engine to Chassis Interface Cable

Figure 696 00–00979–01

The 42-pin Engine to Chassis Interface Cable with breakout box overlay (pin identifier) sheet is used with the
180-pin Breakout Box to test the 42-pin connector circuits.
 4 DIAGNOSTIC TOOLS AND ACCESSORIES 1713

76-Pin Engine and Chassis Cables

Figure 697 3152-N4-8\3

The 76-pin Engine and Chassis Cables (2 cables) with breakout box overlay (pin identifier) sheet are used with
the 180-Pin Breakout Box. These jumpers are used to test the circuits going to the engine and chassis 76-pin
connectors on the ECM.
1714 4 DIAGNOSTIC TOOLS AND ACCESSORIES

180-Pin Breakout Box

Figure 698 00–00956–08

The 180-Pin Breakout Box allows testing of electronic control system components without disturbing connections
or piercing wire insulation to access various signal voltages in the electronic control system.

CAUTION:

To prevent damage to the breakout box, the breakout box is used for measurement only,
not to activate or control circuits. High current levels passing through the breakout box
will burn out the internal circuitry.
This box is universal and can adapt to any control system by means of a unique jumper harness. Each jumper
harness is a separate part, complete with a breakout box overlay (pin identifier) sheet.
The standard box layout is as follows:
• Two 90-pin connectors, which feed 90 banana plug probing points.
• Each 90-pin section of the box is basically a stand-alone box.
• The top row is all fuse protected circuits, the second row is all twisted pair circuits.
 4 DIAGNOSTIC TOOLS AND ACCESSORIES 1715

Amp Clamp ZTSE4575

Figure 699 ZTSE4575

The Amp Clamp ZTSE4575 is used to measure amperage draw for the Intake Air Heater (IAH).
1716 4 DIAGNOSTIC TOOLS AND ACCESSORIES

Digital Multimeter (DMM)

Figure 700 ZTSE4357

The DMM is used to troubleshoot electrical components, sensors, injector solenoids, relays, and wiring
harnesses. The DMM has a high input impedance that allows testing of sensors while the engine is running,
without loading the circuit being tested. This ensures the signal voltage measurement will not be affected by
the voltmeter.
 4 DIAGNOSTIC TOOLS AND ACCESSORIES 1717

EXP-1000 HD by Midtronics

Figure 701 EXP-1000 HD INTL

The EXP-1000 HD by Midtronics is used to measure amperage draw for the intake air heater.
1718 4 DIAGNOSTIC TOOLS AND ACCESSORIES

EZ-Tech® Electronic Service Tool (EST)

Figure 702 3114492C1

The EST is used to run Navistar® Engine Diagnostics for diagnosing and troubleshooting engine and vehicle
problems.
The EZ-Tech® Interface Kit cables are included with the EST.

Navistar® Engine Diagnostics

Navistar® Engine Diagnostics, loaded to an EST or laptop computer, is used to check performance of engine
systems, diagnose engine problems, and store troubleshooting history for an engine.
 4 DIAGNOSTIC TOOLS AND ACCESSORIES 1719

Electronic Engine Terminal Test Kit ZTSE4435C

Figure 703 ZTSE4435C

The Electronic Engine Terminal Test Kit ZTSE4435C is used to access circuits in the connector harness and
allows for the use of a Digital Multimeter (DMM) without damaging the harness connectors. The probes may
also be used as a guide to determine whether the harness connector is retaining correct tension on the mating
terminal.
1720 4 DIAGNOSTIC TOOLS AND ACCESSORIES

Interface cable (RP1210B compliant supporting J1939 and J1708)

Figure 704 Interface cable (RP1210B compliant supporting J1939 and J1708)

The Interface cable (RP1210B compliant supporting J1939 and J1708) is used to connect the EST to ECM. The
Interface cable (RP1210B compliant supporting J1939 and J1708) is an alternative to the NAVCoM Interface Kit.

3-Banana Plug Harness

Figure 705 ZTSE4498

The 3-Banana Plug Harness is used for sensor end diagnostics of sensor circuits.
 4 DIAGNOSTIC TOOLS AND ACCESSORIES 1721

500-Ohm Resistor Harness

Figure 706 ZTSE4497

The 500-Ohm Resistor Harness is used for sensor end diagnostics of sensor circuits.

Breakout Harness ZTSE4484 (IPR)

Figure 707 ZTSE4484

Breakout Harness ZTSE4484 is used to measure the voltage and resistance on circuits that go to the Engine
Injection Control Pressure Regulator (IPR).
1722 4 DIAGNOSTIC TOOLS AND ACCESSORIES

Breakout Harness ZTSE4485A (APP)

Figure 708 ZTSE4485A

Breakout Harness ZTSE4485A is used to measure voltage and resistance on circuits that go to the Accelerator
Pedal Position (APP) sensor.

Breakout Harness ZTSE4602 (EOT, ECT1, and AFTFSV)

Figure 709 ZTSE4602

Breakout Harness ZTSE4602 is used to measure voltage and resistance on circuits that go to the Engine Oil
Temperature (EOT), Engine Coolant Temperature 1 (ECT1), and Aftertreatment Fuel Shutoff Valve (AFTFSV).
 4 DIAGNOSTIC TOOLS AND ACCESSORIES 1723

Breakout Harness ZTSE4674 (ECM and ACT PWR Relays)

Figure 710 ZTSE4674

Breakout Harness ZTSE4674 is used to measure voltage and resistance on circuits that go to the Engine Control
Module (ECM) and Actuator (ACT) PWR relays.

Breakout Harness ZTSE4735A (ETV)

Figure 711 ZTSE4735A

Breakout Harness ZTSE4735A is used to measure voltage and resistance on circuits connected to the Engine
Throttle Valve (ETV).
1724 4 DIAGNOSTIC TOOLS AND ACCESSORIES

Breakout Harness ZTSE4760A (DOCIT, DPFIT, and DPFOT)

Figure 712 ZTSE4760A

Breakout Harness ZTSE4760A is used to measure voltage and resistance on circuits that go to the Diesel
Oxidation Catalyst Intake Temperature (DOCIT), Diesel Particulate Filter Intake Temperature (DPFIT), and
Diesel Particulate Filter Outlet Temperature (DPFOT) sensors.

Breakout Harness ZTSE4761A (DPFDP)

Figure 713 ZTSE4761A

Breakout Harness ZTSE4761A is used to measure voltage and resistance on circuits that go to the Diesel
Particulate Filter Differential Pressure (DPFDP) sensor.

Breakout Harness 4793 (UVC)

 4 DIAGNOSTIC TOOLS AND ACCESSORIES 1725

Breakout Harness 4793 is used to measure voltage and resistance on circuits connected to the Under Valve
Cover (UVC) Wiring-Injector solenoids.

Breakout Harness ZTSE4830 (AFTFIS)

Figure 715 ZTSE4830

Breakout Harness ZTSE4830 is used to measure voltage and resistance on circuits connected to the
Aftertreatment Fuel Inlet Sensor (AFTFIS).

Breakout Harness ZTSE4831 (TC2WC)

Figure 716 ZTSE4831

Breakout Harness ZTSE4831 is used to measure voltage and resistance on circuits connected to the
Turbocharger 2 Wastegate Control Actuator (TC2WC).
1726 4 DIAGNOSTIC TOOLS AND ACCESSORIES

Breakout Harness ZTSE4834 (ACV)

Figure 717 ZTSE4834

Breakout Harness ZTSE4834 is used to measure voltage and resistance on circuits connected to the Air Control
Valve (ACV).

Breakout Harness ZTSE4850 (IMP, ICP, EOP, FDP, and EBP)

Figure 718 ZTSE4850

Breakout Harness ZTSE4850 is used to measure voltage and resistance on circuits connected to the Intake
Manifold Pressure (IMP), Injection Control Pressure (ICP), Engine Oil Pressure (EOP), Fuel Delivery Pressure
(FDP), and Exhaust Back Pressure (EBP) sensors.
 4 DIAGNOSTIC TOOLS AND ACCESSORIES 1727

Breakout Harness ZTSE4908 (EFAN)

Figure 719 ZTSE4908

Breakout Harness ZTSE4908 is used to measure voltage and resistance on circuits to the Starter Relay and
Engine Fan (EFAN) relay.

Breakout Harness ZTSE4946 (EGT)

Figure 720 ZTSE4946

Breakout Harness ZTSE4946 enables the technician to quickly connect a voltmeter and read voltage signals for
the Exhaust Gas Temperature (EGT) sensor.
1728 4 DIAGNOSTIC TOOLS AND ACCESSORIES

Breakout Harness ZTSE4948 (EGR)

Figure 721 ZTSE4948

Breakout Harness ZTSE4948 is used to measure voltage and resistance on circuits that go to the Exhaust Gas
Recirculation (EGR) valve.

Breakout Harness ZTSE4950 (CKP)

Figure 722 ZTSE4950

Breakout Harness ZTSE4950 is used to measure voltage and resistance on circuits connected to the Crankshaft
Position (CKP) sensor.
 4 DIAGNOSTIC TOOLS AND ACCESSORIES 1729

Breakout Harness ZTSE4951 (CMP)

Figure 723 ZTSE4951

Breakout Harness ZTSE4951 is used to measure voltage and resistance on circuits connected to the Camshaft
Position (CMP) sensor and the Crankcase Oil Separator Speed (CCOSS) sensor.

Breakout Harness ZTSE4952 (ICP, ECB, and ECBP)

Figure 724 ZTSE4952

Breakout Harness ZTSE4952 is used to measure continuity of the Injection Control Pressure (ICP) sensor,
Engine Compression Brake (ECB), and the Engine Compression Brake Pressure (ECBP) sensor.
1730 4 DIAGNOSTIC TOOLS AND ACCESSORIES

Breakout Harness 4960 (MAF)

Figure 725 ZTSE4960

Breakout Harness 4960 is used to measure voltage and resistance on circuits that go to the Mass Air Flow (MAF)
sensor.

Breakout Harness ZTSE4993 (IMT)

Figure 726 ZTSE4993

Breakout Harness ZTSE4993 is used to measure voltage and resistance on circuits that go to the Intake Manifold
Temperature (IMT), Charge Air Cooler Outlet Temperature (CACOT) Sensor and High Pressure Turbo Intake
Temperature (HPCIT) sensor.

Breakout Harness ZTSE6002 (WIF)

Figure 727 ZTSE6002

 4 DIAGNOSTIC TOOLS AND ACCESSORIES 1731

Breakout Harness ZTSE6002 is used to measure voltage and resistance on circuits that go to the Water In Fuel
(WIF) sensor.

Breakout Harness ZTSE6020 (24-pin)

Figure 728 ZTSE6020

Breakout Harness ZTSE6020 is used to measure voltage and resistance on circuits that go to the 24-pin Engine
/ IP connector.

Breakout Harness ZTSE6021 (AFTFD)

Figure 729 ZTSE6021

Breakout Harness ZTSE6021 is used to measure voltage and resistance on circuits connected to the
Aftertreatment Fuel Doser (AFTFD).
1732 4 DIAGNOSTIC TOOLS AND ACCESSORIES

Breakout Harness ZTSE6023 (EFP)

Figure 730 ZTSE6023

Breakout Harness ZTSE6023 is used to measure voltage and resistance on circuits that go to the Electronic
Fuel Pump (EFP).

Breakout Harness ZTSE6025 (IAH)

Figure 731 ZTSE6025

Breakout Harness ZTSE6025 is used to measure voltage and resistance on circuits that go to the Intake Air
Heater (IAH) relay.
 4 DIAGNOSTIC TOOLS AND ACCESSORIES 1733

Breakout Harness ZTSE6027 (AFTFP)

Figure 732 ZTSE6027

Breakout Harness ZTSE6027 is used to measure voltage and resistance on circuits that go to the Aftertreatment
(AFT) Fuel Pressure (AFTFP) sensor.
1734 4 DIAGNOSTIC TOOLS AND ACCESSORIES

Mechanical Tools
Charge Air Cooler Test Kit

Figure 733 ZTSE4341

The Charge Air Cooler Test Kit is used to pressurize the charge air cooler and piping to check for leaks.

Clean Fuel Tank Tool

Figure 734 TBD

The Clean Fuel Tank Tool is used to provide a clean, alternative fuel source to aid in the diagnosis of the fuel
system.
 4 DIAGNOSTIC TOOLS AND ACCESSORIES 1735

Combustion in Cooling System Tester

The Combustion in Cooling System Tester is used in testing for signs of combustion gas present in coolant
system.

Crankcase Pressure Test Tool

Figure 736 ZTSE4039 (0.406 in. diameter)

1. To magnehelic gauge or manometer
2. To valve cover

The Crankcase Pressure Test Tool is used to measure combustion gas flow from the valve cover and may be
used with the magnehelic gauge or Slack Tube® manometer.
Use the pressure readings obtained with this adapter as the main source of engine condition. Use oil
consumption trend data if the pressure readings are over the specified limits. Neither changes in oil
consumption trends nor crankcase diagnostic pressure trends can establish a specific problem. These changes
only indicate that a problem exists.
1736 4 DIAGNOSTIC TOOLS AND ACCESSORIES

Digital Manometer

Figure 737 Obtain locally

The Digital Manometer is used to measure low vacuum due to intake restriction or low crankcase pressure. A
variety of digital manometers are available for purchase locally. The Water Manometer kit (ZTSE2217A) is an
alternative to the Digital Manometer
 4 DIAGNOSTIC TOOLS AND ACCESSORIES 1737

EGR Cooler Leak Detection Kit

Figure 738 KL 20030 NAV

1. KL 20040 NAV (2010 MaxxForce® 7)
2. KL 20020 NAV (2007 MaxxForce® DT, 9, and 10)
3. KL 20030 NAV (2010 MaxxForce® DT, 9, and 10)

The EGR Cooler Leak Detection Test Kit is used to pressure test the Exhaust Gas Recirculation (EGR) cooler
for leaks. KL 20020 NAV contains the plastic case with the EGR Cooler Leak Detection Test Kit for the 2007
MaxxForce® DT, 9, and 10. KL 20040 NAV is an add-on kit that contains the EGR Cooler Leak Detection Test
Kit for the 2010 MaxxForce® 7. KL 20030 NAV is an add-on kit that contains the EGR Cooler Leak Detection
Test Kit the 2010 MaxxForce® DT, 9, and 10. The three test kits can be purchased separately.
1738 4 DIAGNOSTIC TOOLS AND ACCESSORIES

EGR Mixing Bowl Guide Pins

Figure 739 ZTSE4945

The EGR mixing Bowl guide pins are used while installing the EGR mixing bowl to not damage the gasket.

EGR Valve Puller

Figure 740 ZTSE4941

The EGR valve puller is used to removed the EGR valve without damaging the valve.
 4 DIAGNOSTIC TOOLS AND ACCESSORIES 1739

Fuel Inlet Restriction and Aeration Tool

Figure 741 ZTSE6009

The Fuel Inlet Restriction and Aeration Tool is used to check for pressure and aerated fuel in the low-fuel pressure
system.

Fuel/Oil Pressure Test Coupler

Figure 742 ZTSE4526

The Fuel / Oil Pressure Test Coupler is used with the fuel pressure test fitting for an easy connection to measure
fuel pressure.
1740 4 DIAGNOSTIC TOOLS AND ACCESSORIES

Fuel Pressure Gauge

Figure 743 ZTSE4681

1. Quick disconnect check valve
2. Fuel test line
3. Fuel Pressure Gauge
4. Inline shut-off valve
5. Clear test line

The Fuel Pressure Gauge is used to check for fuel pressure and aerated fuel in the low-fuel pressure system.
 4 DIAGNOSTIC TOOLS AND ACCESSORIES 1741

Fuel Pressure Test Kit

Figure 744 ZTSE4657

1. Compression fitting 1/8 NPT
2. 90° elbow
3. Quick disconnect check valve
4. Fuel pressure test adapter

The Fuel Pressure Test Kit includes a quick disconnect check valve and fittings that can be used to make a test
line to check fuel pressure at the high-pressure fuel rail.

Fuel Test Fitting

Figure 745 ZTSE4692

The fuel test fitting is used to measure fuel inlet restriction or fuel pressure.
1742 4 DIAGNOSTIC TOOLS AND ACCESSORIES

When measuring fuel inlet restriction, the fitting is installed at the diagnostic port (inlet-side) of the fuel filter
housing.
When measuring fuel pressure, the fitting can be installed on the fuel rail instead of the Shrader valve.
The Fuel/Oil Pressure Test Coupler can then be connected to the fuel test fitting to measure fuel pressure or
fuel inlet restriction.

High Pressure Test Gauge

Figure 746 ZTSE4954

The High Pressure Test Gauge is used with the ICP Adapter Pressure Test Fitting (ZTSE4927) to measure
injection control pressure coming out of the high-pressure pump.
 4 DIAGNOSTIC TOOLS AND ACCESSORIES 1743

Pressure Test Kit

Figure 747 ZTSE4409

The Pressure Test Kit is used to measure intake manifold (boost) pressure, fuel system inlet restriction, fuel
pressure, oil pressure, air cleaner intake restriction, and crankcase pressure.
• 0 to 200 kPa (0 to 30 psi) measures intake manifold pressure.
• 0-30 in Hg vacuum /0 to 200 kPa (0 to 30 psi) compound gauge measures fuel system inlet restriction and
intake manifold pressure.
0-30 in H2O 0 to 7.5 kPa (0 to 1 psi) maximum pressure magnehelic gauge measures crankcase pressure
and air inlet restriction.
• 60 to 1100 kPa (0 to 160 psi) gauge may be used to check the fuel pressure and oil pressure.
1744 4 DIAGNOSTIC TOOLS AND ACCESSORIES

CAC Block Off Kit

Figure 748 ZTSE4937

1. Test plate
2. Seal Remover
3. Test plug
4. Seal installer
5. Test cap

The CAC Block Off Kit is used to pressure test the interstage cooler (if available) and check for leaks.
 4 DIAGNOSTIC TOOLS AND ACCESSORIES 1745

Oil Cooler Test Plate

Figure 749 ZTSE4939

The Oil Cooler Test Plate is used to test the integrity of the oil cooler.
1746 4 DIAGNOSTIC TOOLS AND ACCESSORIES

High Pressure Test Gauge

Figure 750 ZTSE4954

The High Pressure Test Gauge is used with the ICP Adapter Pressure Test Fitting (ZTSE4927) to measure
injection control pressure coming out of the high-pressure pump.

ICP Adapter Pressure Test Fitting

Figure 751 ZTSE4927

 4 DIAGNOSTIC TOOLS AND ACCESSORIES 1747

The ICP Adapter Pressure Test Fitting is used with the High Pressure Test Gauge (ZTSE4954) to measure
injection control pressure coming out of the high-pressure pump.

ICP Test Kit

Figure 752 ZTSE4655

1. Fitting 13/16 - 16 NPT
2. ICP sensor adapter

NOTE: Sensor for test has to be acquired locally.

The ICP Test Kit is used to check ICP system diagnostics. The ICP adapter is used with an ICP sensor and the
Under Valve Cover (UVC) gasket breakout harness to check the integrity of the high-pressure pump and IPR.
The fitting is adapted to an air line to pressurize the UVC components and check for leaks.

Inline Shut-off Valve

Figure 753 Part No. 221406

The Inline Shut-off Valve is used to make a test line to check for aerated oil, specifically at the EOT sensor port.
The Shut-Off valve can also be used to make a test line assembly to check for aerated fuel.
1748 4 DIAGNOSTIC TOOLS AND ACCESSORIES

IPR Plug Tester

Figure 754 ZTSE4816

The IPR Plug Tester is used to check the high-pressure pump for inability to reach maximum injection control
pressure.

Pressure Vacuum Module

Figure 755 Locally available

The Pressure Vacuum Module is used for pressure and vacuum measurements. A variety of pressure vacuum
modules are available for purchase locally.
 4 DIAGNOSTIC TOOLS AND ACCESSORIES 1749

Turbo Lifting Bracket

Figure 756 ZTSE4942

The Turbo Lifting Bracket is used to aid in the removal of the turbo assembly.
1750 4 DIAGNOSTIC TOOLS AND ACCESSORIES

Slack Tube® Manometer

Figure 757 ZTSE2217A

The Slack Tube® Manometer is a U-shaped tube with a scale mounted between the legs of the tube. When the
portability of the Pressure Test Kit is not required, this manometer is used to measure low vacuum for intake
restriction, low pressure for crankcase, or exhaust back pressure.
Filling
Fill the manometer with water before checking pressure. Use only distilled water. Add some colored water
vegetable dye so the scale can be read more easily. With both legs of the manometer open to the atmosphere,
fill the tube until the top of the fluid column is near the zero mark on the scale. Shake the tube to eliminate any
air bubbles.
Installing, Reading, and Cleaning
1. Support the manometer vertically. Make sure the fluid level is in line with the zero indicator on the graduated
scale.
2. Connect one leg of the manometer to the source of the pressure or vacuum. Leave the other leg open to
atmospheric pressure.
3. Start the engine and allow it to reach normal operating temperature. Then run the engine to high idle. The
manometer can be read after 10 seconds.
 4 DIAGNOSTIC TOOLS AND ACCESSORIES 1751

4. Record the average position of the fluid level when it is above and below the zero indicator. Add the two
figures together. The sum of the two is the total column of fluid (distance A). This represents the crankcase
pressure in inches of water (in-H2O).
At times, both columns of the manometer will not travel the same distance. This is no concern if the leg is
not connected to the pressure or the vacuum source is open to the atmosphere.
5. Compare the manometer reading with engine specifications.
6. When the test is done, clean the tube thoroughly using soap and water. Avoid liquid soaps and solvents.
1752 4 DIAGNOSTIC TOOLS AND ACCESSORIES

UV Leak Detection Kit

Figure 758 ZTSE4618

The UV Leak Detection Kit is used with fuel dye to quickly identify leaks. The fuel dye combines with fuel
and migrates out at the leak. The ultraviolet lamp illuminates the leaking fuel dye, which appears fluorescent
yellow-green in color.
 4 DIAGNOSTIC TOOLS AND ACCESSORIES 1753

Vacuum Analyzer and Fuel Pump Tester

Figure 759 ZTSE2499

The Vacuum Analyzer and Fuel Pump Tester is used to test the operation of the fuel pump.
1754 4 DIAGNOSTIC TOOLS AND ACCESSORIES
 5 COMPONENT LOCATOR 1755

Table of Contents

Engine Component Locations (245 hp and above). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1757

1756 5 COMPONENT LOCATOR
 5 COMPONENT LOCATOR 1757

Engine Component Locations (245 hp and above)

Figure 760 Component location – top

1. Alternator bracket 6. Air Control Valve (ACV) 12. Interstage cooler (245 hp and
2. High-pressure turbocharger 7. Valve cover above)
outlet 8. Intake Air Heater (IAH) relay 13. Interstage cooler inlet elbow
3. Low-pressure turbocharger 9. Air and EGR mixer duct (245 hp and above)
4. Exhaust back pressure valve 10. EGR valve 14. Interstage cooler inlet duct (245
5. Hydrocarbon injector 11. Fuel filter cap hp and above)
1758 5 COMPONENT LOCATOR

Figure 761 Component location – front

1. Deaeration hose elbow 6. Vibration damper 11. High-pressure turbocharger
2. Front cover 7. Water inlet elbow outlet
3. Fan drive pulley 8. Water pump pulley 12. Water outlet tube
4. Air compressor 9. Automatic belt tensioner
5. Front engine mounting bracket 10. Turbo air inlet duct
 5 COMPONENT LOCATOR 1759

Figure 762 Component location – exhaust side

1. Turbocharger heat shield 6. Breather outlet tube 12. Oil cooler
2. Dual stage turbocharger 7. Coolant return tube (high fin 13. Oil filter assembly
assembly density EGR cooler) 14. Exhaust Back Pressure Valve
3. Lifting eye 8. Breather inlet tube (EBPV)
4. Coolant supply housing 9. Crankcase breather with turbine 15. EGR cooler
(refrigerant compressor mount) 10. Coolant return tube 16. Turbo oil supply tube
5. Coolant supply tube (high fin 11. M16 plug (coolant drain under 17. Air Control Valve (ACV)
density EGR cooler) oil cooler module)
1760 5 COMPONENT LOCATOR

Figure 763 Component location – intake side

1. Electric fuel pump 8. Downstream Injection (DSI) feed 15. Oil pan
2. Fuel filter cap tube 16. Air compressor
3. Water drain valve 9. Injection unit inlet tube 17. Oil supply hose (air compressor)
4. Exhaust Gas Recirculation 10. Intake manifold 18. Coolant supply hose (air
(EGR) valve 11. Engine Control Module (ECM) compressor)
5. Air and EGR mixer duct 12. Coolant return hose (air 19. High pressure oil pump
6. Downstream Injection (DSI) compressor) 20. Fuel filter assembly with heater
metering unit 13. Power steering pump 21. Electric fuel pump inlet
7. Lifting eye 14. Oil drain hose (air compressor)
 5 COMPONENT LOCATOR 1761

Figure 764 Component location – rear

1. Deaeration hose elbow 6. Air Control Valve (ACV) to 10. Flywheel
2. Interstage cooler (245 actuator hose 11. EGR crossover duct
horsepower and above) 7. Exhaust pipe 12. Oil filler tube
3. Valve cover 8. Rear engine mounting bracket
4. Cylinder head assembly (2)
5. Injection unit inlet tube assembly 9. Flywheel housing
1762 5 COMPONENT LOCATOR
 6 ENGINE SYSTEMS OVERVIEW 1763

Table of Contents

Engine Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1765

Engine Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1765
Engine Emission Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1766
Engine Accessory Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1767
Engine Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1768
Standard Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1769
Optional Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1771
Chassis Mounted Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1772

Air Management System (AMS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1773

Air Flow – Pre Combustion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1774
Air Flow – Post Combustion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1774
Air Management Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1774
Turbochargers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1774
Interstage Cooler (ISC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1776
High-pressure Charge Air Cooler (HPCAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1777
Turbocharger 2 Wastegate Control (TC2WC) Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1778
Exhaust Gas Recirculation (EGR) System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1779
Crankcase Ventilation System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1782
Aftertreatment (AFT) System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1783

Fuel Management System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1787

ICP System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1788
High-Pressure Oil Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1789
ICP Closed Loop System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1790
ICP Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1791
Fuel Injector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1792

Fuel Supply System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1795

Fuel Supply System Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1796

Engine Lubrication System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1799

Oil Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1800

Engine Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1802

Cooling System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1802
Cooling System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1804
Coolant Heater (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1804
Thermostat Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1805
Low Temperature Radiator (LTR) Thermostat Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1807

Electronic Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1808

Electronic Control System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1808
Operation and Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1809
Reference Voltage (VREF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1809
Microprocessor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1809
1764 6 ENGINE SYSTEMS OVERVIEW

Actuator Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1809

Actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1809
Exhaust Gas Recirculation (EGR) Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1810
Intake Air Heater (IAH) Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1811
Engine Throttle Valve (ETV) and Position Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1812
Turbocharger 2 Wastegate Control (TC2WC) valve (turbocharger wastegate
actuator). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1813
Exhaust Back Pressure Valve (EBPV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1814
Engine Compression Brake (ECB) valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1815
Injection Pressure Regulator (IPR) valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1816
Engine and Vehicle Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1816
Temperature Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1816
Variable Capacitance Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1818
Magnetic Pickup Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1820
High-pressure Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1821
Potentiometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1822
Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1823
Engine Throttle Valve Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1824

Exhaust and Engine Brake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1825

Exhaust Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1825
Engine Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1826
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1828
Operation Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1830
 6 ENGINE SYSTEMS OVERVIEW 1765

Engine Identification
Engine Serial Number

Figure 765 Engine serial number

The engine serial number is in two locations:

• Stamped on the right side of the crankcase, just above the oil filter header
• On the engine emission label on the valve cover

Engine Serial Number Examples

MaxxForce® DT: 466HM2UXXXXXXX
MaxxForce® 9 and 10: 570HM2UXXXXXXX
Engine Serial Number Codes
466 – Engine displacement
570 – Engine displacement
H – Diesel, turbocharged, Charge Air Cooler (CAC) and electronically controlled
M2 – Motor truck
U – United States
7 digit suffix – Engine serial number sequence beginning with 3300001
1766 6 ENGINE SYSTEMS OVERVIEW

Engine Emission Label

Figure 766 U.S. Environmental Protection Agency (EPA) exhaust emission label (example)

The U.S. Environmental Protection Agency (EPA) exhaust emission label is attached on top of the valve cover.
The EPA label typically includes the following:
• Model year
• Engine family, model, and displacement
• Advertised brake horsepower and torque rating
• Emission family and control systems
• Valve lash specifications
• Engine serial number
• EPA, EURO, and reserved fields for specific applications
 6 ENGINE SYSTEMS OVERVIEW 1767

Engine Accessory Labels

The following engine accessories may have manufacturer's labels or identification plates:
• Air compressor
• Air conditioning compressor
• Alternator
• Cooling fan clutch
• Power steering pump
• Starter motor
1768 6 ENGINE SYSTEMS OVERVIEW

Engine Description

MaxxForce® DT, 9, and 10 Diesel Engines

Engine configuration 4 stroke, inline six cylinder diesel
®
MaxxForce DT displacement 466 in3 (7.6 L)
MaxxForce® 9 and 10 displacement 570 in3 (9.3 L)
Bore (sleeve diameter) 4.59 in (116.6 mm)
Stroke
• MaxxForce® DT 4.68 in (119 mm)
®
• MaxxForce 9 and 10 5.75 in (146 mm)
Compression ratio
• MaxxForce® DT 16.9 : 1
• MaxxForce® 9 and 10 16.5 : 1
Aspiration Dual turbocharged and charge air cooled
Advertised brake horsepower @ rpm See EPA exhaust emission label
Peak torque @ rpm See EPA exhaust emission label
Engine rotation (facing flywheel) Counterclockwise
Combustion system Direct injection turbocharged
Fuel system Electro-hydraulic injection
Total engine weight (oil and accessories)
• MaxxForce® DT 1816 lbs (824 kg)
• MaxxForce® 9 and 10 1864 lbs (845 kg)
Cooling system capacity (engine only) 13.5 qts US (12.8 L)
Lube system capacity (including filter) 30 qts US (28 L)
Lube system capacity (overhaul only, with filter) 34 qts US (32 L)
Firing order 1-5-3-6-2-4
 6 ENGINE SYSTEMS OVERVIEW 1769

Standard Features
MaxxForce® DT, 9, and 10 diesel engines are designed for increased durability, reliability, and ease of
maintenance.
The cylinder head has four valves per cylinder with centrally located fuel injectors directing fuel over the pistons.
This configuration provides improved performance and reduces emissions.
The camshaft is supported by four insert bushings pressed into the crankcase. The camshaft gear is driven from
the front of the engine. A thrust flange is located between the camshaft and the drive gear. The overhead valve
train includes mechanical roller lifters, push rods, rocker arms, and dual valves that open using a valve bridge.
MaxxForce® DT engines use one-piece aluminum alloy pistons. MaxxForce® 9 and 10 engines use one-piece
steel pistons. All pistons have zero pin offset and centered combustion bowls; therefore, pistons can be installed
safely without orientation: there is NO front-of-engine arrow or “CAMSIDE” marking on the piston crown to
indicate a necessary piston direction.
The one piece crankcase uses replaceable wet cylinder sleeves that are sealed by a single crevice seal ring.
Some applications include a crankcase ladder which is designed to support heavier loads and reduce engine
noise.
The crankshaft has seven main bearings with fore and aft thrust controlled at the rear bearing. One fractured
cap connecting rod is attached at each crankshaft journal. A piston pin moves freely inside the connecting rod
and piston. Piston pin retaining rings secure the piston pin in the piston. The rear oil seal carrier is part of the
flywheel housing.
A lube oil pump is mounted on the front cover and is driven by the crankshaft. Pressurized oil is supplied to
engine components and the high-pressure injection system. All MaxxForce® DT, 9, and 10 engines use an
engine oil cooler and spin-on engine oil filter.
The coolant supply housing serves as the mounting bracket for the refrigerant compressor. Mounting capabilities
for a dual refrigerant compressor are available as an option. The pad mounting design of the alternator and
refrigerant compressor brackets provide easy removal and improved durability.
The electric low-pressure fuel supply pump draws fuel from the fuel tank through the fuel filter assembly. The
assembly includes a strainer, filter, drain valve, Water in Fuel (WIF) sensor, and Fuel Delivery Pressure (FDP)
sensor. If equipped, an optional fuel heater element is installed in the fuel filter assembly. Conditioned fuel is
pumped through the intake manifold and cylinder head to the fuel injectors.
The WIF sensor detects water in the fuel system. When water reaches the level of the sensor located in the fuel
filter assembly, the instrument panel's amber FUEL FILTER lamp will illuminate. The collected water must be
removed immediately. Water is drained by opening the drain valve on the fuel filter assembly.
The fuel injection system is electro-hydraulic. The system includes an under-valve-cover high-pressure oil
manifold, fuel injectors, and a high-pressure oil pump. The injectors are installed in the cylinder head, under the
high-pressure oil manifold.
MaxxForce® DT, 9, and 10 engines use dual turbochargers with an air-to-air High Pressure Charge Air Cooler
(HPCAC) after the second stage. An interstage cooler is used after the first stage for applications with 245 hp
and above.
The Intake Air Heater (IAH) system warms the incoming air to aid cold engine starting and to reduce white smoke
and engine noise. The IAH system will initially illuminate the WAIT TO START lamp located on the instrument
panel. When the lamp turns off, the engine can be started.
The Exhaust Gas Recirculation (EGR) system circulates cooled exhaust into the intake air stream in the intake
manifold. This cools the combustion process and reduces the formation of NOX engine emissions.
1770 6 ENGINE SYSTEMS OVERVIEW

A closed crankcase breather system uses an engine mounted oil separator to return oil to the crankcase and
vent crankcase pressure into the intake system.
The Down Stream Injection (DSI) system aides in controlling emissions by injecting fuel into the exhaust stream.
The fuel causes an exothermic reaction which increases the temperature of the exhaust gas. This increase in
temperature allows for more efficient conversion of soot into ash within the Diesel Particulate Filter (DPF). Along
with DSI, the Diesel Oxidation Catalyst (DOC) aids in creating the required exothermic reaction. DSI consists
of the Doser Control Unit (DCU), Downstream Injection (DSI) assembly, hydrocarbon injector assembly, fuel
lines, and coolant lines. The Electronic Control Module (ECM) communicates with the DCU to control the timing
and quantity of fuel sprayed from the hydrocarbon injector assembly. The ECM signals the Air Control Valve
assembly to control the position of the Exhaust Back Pressure Valve (EBPV) to increase or decrease the exhaust
gas back pressure and temperature to allow the DOC and DPF to function efficiently.
The EBPV acts as an aftertreatment device to manage exhaust temperature. The resulting rise in back pressure,
increases exhaust temperature.
 6 ENGINE SYSTEMS OVERVIEW 1771

Optional Features
Optional features include the following:
• Air compressor
• Hydraulic pump
• Engine brake
• Exhaust Back Pressure Valve (EBPV)
An air compressor is available for applications that require air brakes or air suspension.
A hydraulic power steering pump can be used with or without the air compressor.
Engine brake and EBPV systems are available for applications that could benefit from added speed reduction
capability.

Optional Cold Climate Features

Optional cold climate features include the following:
• Oil pan heater
• Coolant heater
• Fuel heater
All three heaters use an electric element to warm engine fluids in cold weather.
The oil pan heater warms engine oil to ensure optimum oil flow.
The coolant heater warms engine coolant surrounding the cylinders. Warmed engine coolant aids in cold engine
start-up and performance.
The fuel heater is installed in the fuel filter assembly and warms the supply fuel. Warmed supply fuel prevents
waxing, and improves performance and fuel economy during cold weather start-up.
1772 6 ENGINE SYSTEMS OVERVIEW

Chassis Mounted Features

A Charge Air Cooler (CAC) is an air-to-air heat exchanger, which increases the density of the air charge.
The Aftertreatment System, part of the larger exhaust system, processes engine exhaust to meet tailpipe
emission requirements.
• The Pre-Diesel Oxidation Catalyst (PDOC) aids in creating the required exothermic reaction before the
exhaust gas enters the Diesel Oxidation Catalyst (DOC).
• The Diesel Oxidation Catalyst (DOC) oxidizes carbon monoxide, hydrocarbons, and small amounts of
nitrogen oxide in the exhaust stream.
• The Diesel Particulate Filter (DPF) captures and oxidizes particulates in the exhaust stream and stores
non-combustible ash.
 6 ENGINE SYSTEMS OVERVIEW 1773

Air Management System (AMS)

Figure 767 Air Management System (AMS)

The AMS includes the following:

• Air filter assembly
• Low-pressure turbocharger
• Interstage Cooler (ISC) (245 hp and above)
• High-pressure turbocharger
• High-pressure Charge Air Cooler (HPCAC)
• Engine Throttle Valve (ETV)
1774 6 ENGINE SYSTEMS OVERVIEW

• Air and EGR mixer duct

• Exhaust and intake valves
• Exhaust Gas Recirculation (EGR) system
• Exhaust system
• Exhaust back pressure valve
• Exhaust – aftertreatment

Air Flow – Pre Combustion

Fresh air from the air filter enters the low-pressure compressor where it is compressed and directed into the
ISC (245 hp and above ratings), if equipped. If not equipped with ISC, compressed air from the low-pressure
compressor is piped directly to the high-pressure compressor inlet. The high-pressure turbocharger further
increases the intake air pressure. The hot compressed air flows into the HPCAC where it is cooled, then through
the Engine Throttle Valve (ETV) on the air and EGR mixer duct.
If the EGR valve is open, exhaust gas enters the high fin density EGR cooler from the rear of the exhaust
manifold and is transferred to the intake manifold via the EGR crossover duct. The exhaust gas then passes
through a port in the intake manifold to the air and EGR mixer duct where it is mixed with filtered intake air. This
mixture then flows through the intake manifold and into the cylinder head.
If the EGR valve is closed, only filtered intake air flows through the ETV, air and EGR mixer duct, and into the
intake manifold.

Air Flow – Post Combustion

After combustion, gases exit through the cylinder head exhaust valves and ports. Exhaust gas is forced through
the exhaust manifold where, depending on the EGR valve position, it is split between the EGR system and the
high-pressure turbocharger, low-pressure turbocharger and the exhaust back pressure valve assembly.
The exhaust back pressure valve acts as an aftertreatment device to regulate exhaust temperatures.
Exhaust gases flow from the engine through the vehicle aftertreatment system to the exhaust tail pipe.

Air Management Components

Turbochargers
MaxxForce® DT, 9, and 10 engines are equipped with an electronically controlled two stage turbocharging
system. This system provides high levels of charge air pressure to improve engine performance and to help
reduce emissions. Because of its ability to generate very high charge air pressure levels, and to avoid Charge
Air Cooler (CAC) overloading conditions, the system is fitted with a spring loaded turbocharger wastegate.
The turbocharger wastegate is actuated by charge air pressure. The air pressure to the turbocharger wastegate
actuator is controlled by the Turbocharger 2 Wastegate Control (TC2WC) valve. The TC2WC valve is controlled
by Pulse Width Modulation (PWM) signals from the Electronic Control Module (ECM).
The high and low-pressure turbochargers are installed as an assembly on the exhaust manifold, on right side
of engine.
 6 ENGINE SYSTEMS OVERVIEW 1775

Figure 768 Low and high-pressure turbocharger components (below 245 hp shown)
1. High-pressure turbine housing 7. Breather outlet tube 13. High-pressure turbine inlet
2. High-pressure turbocharger 8. High-pressure turbo oil drain 14. Low-pressure turbine housing
outlet tube 15. Low-pressure bearing housing
3. Turbo wastegate actuator 9. Low-pressure turbo oil drain 16. Low-pressure compressor
4. Turbocharger 2 Wastegate tube housing
Control (TC2WC) valve 10. Turbo oil supply tube assembly 17. Air crossover duct
5. Turbo air inlet duct 11. Low-pressure turbine outlet
6. Low-pressure compressor 12. High-pressure compressor
housing housing

The high-pressure turbocharger is connected to the exhaust manifold through the high-pressure turbine inlet.
The high-pressure turbocharger is equipped with a wastegate that regulates the turbocharger boost by controlling
the amount of exhaust gases that pass through the high-pressure turbine. When demand for power is low, such
as during cruising speed, the turbocharger wastegate opens allowing part of the exhaust gas flow to bypass the
high-pressure turbine.
The low-pressure turbine is attached directly to the output of the high-pressure turbine. The exhaust gas enters
the low-pressure turbocharger through the low-pressure turbine housing and exits through the low-pressure
turbine outlet.
1776 6 ENGINE SYSTEMS OVERVIEW

Interstage Cooler (ISC)

The ISC is installed between the low-pressure and the high-pressure compressor housings for applications
with 245 hp and above. The ISC air inlet is connected to the low-pressure compressor outlet and uses engine
coolant to regulate the charge air temperature. The ISC air outlet is connected to the compressor inlet on the
high-pressure turbocharger.
 6 ENGINE SYSTEMS OVERVIEW 1777

High-pressure Charge Air Cooler (HPCAC)

The HPCAC is installed between the high-pressure turbocharger and the Engine Throttle Valve (ETV). The
HPCAC air inlet is connected to the high-pressure compressor outlet and uses air-to-air to regulate the charge
air temperature. The HPCAC air outlet is connected directly to the ETV body.
1778 6 ENGINE SYSTEMS OVERVIEW

Turbocharger 2 Wastegate Control (TC2WC) Valve

The TC2WC valve controls the turbocharger wastegate actuator by regulating the amount of charge air pressure
supplied to the wastegate actuator. The Pulse Width Modulated (PWM) signals sent to the TC2WC valve by the
Electronic Control Module (ECM) are based on input signals from the Exhaust Back Pressure (EBP) sensor.
When demand for power is high, such as during acceleration, the TC2WC valve opens the wastegate which
allows exhaust gas to enter the HP turbocharger in addition to the LP turbocharger. Once the vehicle reaches
cruising speed, the TC2WC valve will close the wastegate and direct exhaust gas away from the HP turbocharger
and only through the LP turbocharger.
 6 ENGINE SYSTEMS OVERVIEW 1779

Exhaust Gas Recirculation (EGR) System

Figure 769 EGR system

1. EGR crossover duct 5. Intake manifold assembly 9. Coolant return tube
2. Air and EGR mixer duct 6. Exhaust manifold assembly
assembly 7. High fin density EGR cooler
3. EGR valve assembly assembly
4. Engine throttle valve 8. Coolant supply tube
1780 6 ENGINE SYSTEMS OVERVIEW

The EGR system includes the following:

• Air and EGR mixer duct assembly
• Engine throttle valve
• EGR valve assembly
• Coolant supply tube
• Coolant return tube
• EGR cooler assembly
• EGR crossover duct
The EGR system reduces Nitrogen Oxide (NOX) engine emissions. NOX forms during a reaction between
nitrogen and oxygen at high temperatures during combustion. Combustion starts when fuel is injected into the
compressed combustion chamber.

EGR Flow
When EGR is commanded, the EGR valve opens and allows exhaust gas from the exhaust manifold to flow into
the EGR cooler for cooling. This cooled exhaust gas is directed through the EGR crossover duct into a port in
the intake manifold and directed to the air and EGR mixer duct where it is mixed with filtered intake air.

EGR Valve
The EGR valve consists of three major components, a valve, an actuator motor, and an Integrated Circuit (IC).
The EGR valve is installed in the air and EGR mixer duct assembly on the intake side of the engine.
The EGR valve uses a DC motor to control position of the valve assembly. The motor pushes directly on the
valve stem to open. The valve assembly has two poppets on a common shaft.
The IC has three hall effect position sensors to monitor valve movement.

EGR Closed Loop System

Figure 770 EGR closed loop system

The ECM commands EGR valve position based on engine speed and load conditions. The EGR control valve
provides feedback to the ECM on current valve position.
 6 ENGINE SYSTEMS OVERVIEW 1781

Figure 771 EGR control

1782 6 ENGINE SYSTEMS OVERVIEW

Crankcase Ventilation System

Figure 772 Crankcase ventilation system

1. Valve cover 4. Housing assembly (breather) 7. Breather outlet tube
2. Turbocharger air inlet duct 5. Housing assembly (turbine) 8. High-pressure turbo drain tube
3. Crankcase breather inlet tube 6. Low-pressure turbo drain tube
 6 ENGINE SYSTEMS OVERVIEW 1783

The crankcase ventilation system uses an engine mounted oil separator to return oil to the crankcase. The
excess crankcase pressure is vented back into the intake system.
Oil extracted blow-by gases flow from the valve cover through the crankcase breather inlet tube into the breather
housing assembly.
A high-speed centrifugal oil separator, driven by engine oil pressure, separates and directs oil to the side of
housing assembly. The separated oil drains into the oil separator turbine housing, through the crankcase, and
into the oil pan. The oil separator is located inside and towards the top of the housing assembly.
The turbine housing also provides oil drainage from the low-pressure and high-pressure turbochargers. The
low-pressure and high-pressure turbo oil drain tubes direct turbocharger drain oil into the turbine housing. The
oil drains out of the turbine housing, through the crankcase, and into the oil pan.
Blow-by gases are directed through the breather outlet tube and into the turbocharger air inlet duct.

Aftertreatment (AFT) System

Figure 773 Aftertreatment (AFT) system

The AFT System, part of the larger exhaust system, processes engine exhaust to meet emissions requirements.
The AFT system traps particulate matter (soot) and prevents it from leaving the tailpipe.
1784 6 ENGINE SYSTEMS OVERVIEW

AFT Control System

The control system performs the following functions:
• Monitors exhaust gases, the aftertreatment system, and controls engine operating parameters for emission
processing and failure recognition
• Cancels regeneration in the event of catalyst or sensor failure
• Monitors exhaust pressure before and after the Diesel Particulate Filter (DPF) and adapts engine operating
characteristics to compensate for increased back pressure
• Controls engine operating parameters to make regeneration automatic
• Maintains vehicle and engine performance during regeneration

Sensors
Sensors output an electronic signal based on temperature or pressure. The signals are used by the control
system to regulate the aftertreatment function.
The sensors measure the temperature and pressure at the center of the exhaust flow.

Exhaust Back Pressure Valve

The exhaust back pressure valve also acts as an aftertreatment device to manage exhaust temperatures. The
ECM will signal the exhaust back pressure valve to change the amount of air passing through the valve into
the exhaust and through the DOC and DPF. The ECM interprets the increased back pressure as an increased
load. In response to the increased pressure / load, the engine increases speed to meet the demand, resulting
in increased exhaust temperature.

Pre-Diesel Oxidation Catalyst (PDOC)

The PDOC does the following:
• Aids in creating an exothermic reaction to improve exhaust emissions
• Allows for more efficient operation of the aftertreatment system

Diesel Oxidation Catalyst (DOC)

The DOC does the following:
• Oxidizes hydrocarbons and carbon monoxide (CO) in exhaust stream
• Provides heat for exhaust system warm-up
• Aids in system temperature management for the DPF

Diesel Particulate Filter (DPF)

The DPF does the following:
• Captures and temporarily stores carbon-based particulates in a filter
• Allows for oxidation (regeneration) of stored particulates once back pressure increases to a predetermined
level
• Stores noncombustible ash
 6 ENGINE SYSTEMS OVERVIEW 1785

AFT Conditions and Responses

The operator is alerted audibly or with instrument panel indicators of system status. Automatic or manual
regeneration is required when levels of soot exceed acceptable limits. For additional information see the
applicable Vehicle Operator Manual and the vehicle visor placard.

Downstream Injection System

Figure 774 Aftertreatment (AFT) system

1. Downstream Injection (DSI) 3. Hydrocarbon injector assembly 6. Downstream Injection (DSI) feed
assembly 4. Injector coolant outlet tube tube assembly
2. Injection unit inlet tube assembly 5. Injector coolant inlet tube

The downstream injection system includes the following:

• Doser Control Unit (DCU)
• Hydrocarbon injector assembly
• Downstream Injection (DSI) assembly
• Coolant lines
• Fuel lines
The Doser Control Unit (DCU) is mounted on the chassis of the vehicle. The DCU receives signals from the
ECM and then signals the DSI assembly.
The DSI assembly is installed on the left rear of the engine above the intake manifold.
When the DCU signals the shutoff valve to open, fuel pressure increases in the upstream cavity of the DSI
assembly housing. The upstream pressure sensor immediately signals the DCU that pressure is increased by
available fuel. The DCU then signals the dosing valve to open, allowing a specific amount of fuel to be injected
into the injector unit inlet tube assembly to the hydrocarbon injector assembly.
Fuel is injected into the exhaust stream from the hydrocarbon injector assembly which increases the temperature
inside the Diesel Particulate Filter (DPF) in order to convert soot to ash more efficiently.
1786 6 ENGINE SYSTEMS OVERVIEW

The hydrocarbon injector assembly is cooled with engine coolant from the EGR cooler assembly.
 6 ENGINE SYSTEMS OVERVIEW 1787

Fuel Management System

Figure 775 Fuel management system

The fuel management system includes the following:

• Lubrication system
• Injection Control Pressure (ICP) system
• Engine Compression Brake (ECB)
• Fuel supply system
• Fuel injectors
• Electronic control system
1788 6 ENGINE SYSTEMS OVERVIEW

ICP System

Figure 776 Injection Control Pressure (ICP) system

1. Engine Compression Brake 5. High-pressure oil manifold 11. Injection Pressure Regulator
Pressure (ECBP) sensor 6. Injector oil inlet from (IPR) valve
2. O-ring (2) high-pressure oil manifold 12. Oil inlet from front cover reservoir
3. Engine Compression Brake 7. Oil outlet (2) 13. High-pressure oil pump
(ECB) valve 8. Fuel inlet port (4) assembly
4. Injection Control Pressure (ICP) 9. 70 degree elbow 14. Fuel injector assembly (6)
sensor 10. High-pressure oil hose
 6 ENGINE SYSTEMS OVERVIEW 1789

High-Pressure Oil Flow

The lubrication system supplies the oil reservoir located in the front cover. The reservoir provides oil for the
high-pressure oil pump. The pump is mounted on the backside of the front cover and is gear driven by the upper
idler gear.
High-pressure oil is directed to the high-pressure oil hose, cylinder head passage, and high-pressure oil manifold.
High-pressure oil is used by the fuel injectors to pressurize and inject fuel in the cylinders. This occurs when the
OPEN coil for each fuel injector is energized.
Excess high-pressure oil is directed to the crankcase sump by the Injection Pressure Regulator (IPR) valve. The
IPR valve is controlled by the Electronic Control Module (ECM) to maintain a desired injection control pressure.
If equipped with the optional engine brake, some high-pressure oil is directed internally to the engine brake
pistons when the engine compression brake is activated. Since these two systems share a common gallery,
a problem with the engine compression brake system can adversely affect injection control pressure and vise
versa.
1790 6 ENGINE SYSTEMS OVERVIEW

ICP Closed Loop System

Figure 777 ICP closed loop system

The ICP (Injection Control Pressure) system is a closed loop system that uses the ICP sensor to continuously
provide feedback to the ECM. The ECM commands the IPR duty cycle to adjust pressure to match engine
requirements.
 6 ENGINE SYSTEMS OVERVIEW 1791

ICP Control System

Figure 778 ICP control system

The IPR valve receives a Pulse Width Modulated (PWM) signal from the ECM. This controls the on and off time
the IPR valve is energized. The on/off time is controlled by the ECM to meet calibrated desired values.
The IPR valve is mounted in the body of the high-pressure pump. The IPR valve maintains desired ICP by
dumping excess oil back into the crankcase sump.
As demand for ICP increases, the ECM increases the current to the IPR valve solenoid. When demand for ICP
decreases, the duty cycle to the IPR valve decreases and more oil is allowed to flow back to the crankcase
sump.
When the ICP electrical signal is out-of-range, the ECM sets a fault code.
When ICP signals are out-of-range, the ECM ignores them and goes into open loop operation. The IPR valve
will operate from programmed default values.
The ICP sensor is installed in the high-pressure oil manifold under the valve cover.
1792 6 ENGINE SYSTEMS OVERVIEW

Fuel Injector

Figure 779 Fuel injector

1. Upper O-ring
2. Lower O-ring
3. Nozzle gasket
4. Injector nozzle
5. Fuel inlet port

Fuel Injector Features

Two 50 volt, 25 amp coils control a spool valve that directs oil flow in and out of the injector. Each injector has
a single four pin connector that connects to the valve cover gasket assembly.

Injector Coils and Spool Valve

An OPEN coil and a CLOSE coil on the injector move the spool valve from side to side using magnetic force.
The spool has two positions:
• When the spool valve is open, oil flows into the injector from the high-pressure oil manifold.
• When the spool valve is closed, oil exits from the top of the fuel injector and drains back to the crankcase.

Intensifier Piston and Plunger

When the spool valve is open, high-pressure oil enters the injector, pushing down the intensifier piston and
plunger. Since the intensifier piston is 10 times greater in surface area than the plunger, the fuel injection
pressure is also 10 times greater than injection control pressure on the plunger.
 6 ENGINE SYSTEMS OVERVIEW 1793

Plunger and Barrel

Fuel pressure builds at the base of the plunger in the barrel. When the intensifier piston pushes the plunger
down, the plunger increases fuel pressure in the barrel 10 times greater than injection control pressure. The
plunger has a hardened coating to resist scuffing.

Injector Needle
The injector needle opens inward when fuel pressure overcomes the Valve Opening Pressure (VOP). Fuel is
atomized at high-pressure through the nozzle tip.

Fuel Injector Operation

The injector operation has three stages:
• Fill stage
• Injection
• End of injection

Figure 780 Fuel injector cross section

Fill Stage
During the fill stage, both coils are de-energized and the spool valve is closed. High-pressure oil from the
high-pressure oil manifold is stopped at the spool valve.
Low-pressure fuel fills the four ports and enters through the edge filter on its way to the chamber beneath the
plunger. The needle control spring holds the needle onto its seat to prevent fuel from entering the combustion
chamber.
1794 6 ENGINE SYSTEMS OVERVIEW

Injection
1. A pulse-width controlled current energizes the OPEN coil. Magnetic force moves the spool valve open.
High-pressure oil flows past the spool valve and onto the top of the intensifier piston. Oil pressure
overcomes the force of the intensifier piston spring and the intensifier starts to move down. An increase
in fuel pressure under the plunger seats the fuel inlet check ball, and fuel pressure starts to build on the
needle.
2. The pulse-width controlled current to the OPEN coil is shut off, but the spool valve remains open.
High-pressure oil from the high-pressure oil manifold continues to flow past the spool valve. The
intensifier piston and plunger continue to move and fuel pressure increases in the barrel. When fuel
pressure rises above the VOP, the needle lifts off its seat and injection begins.

End of Injection
1. When the ECM determines that the correct injector on-time has been reached (the correct amount of fuel
has been delivered), the ECM sends a pulse-width controlled current to the CLOSE coil of the injector.
The current energizes the CLOSE coil and magnetic force closes the spool valve. High-pressure oil is
stopped against the spool valve.
2. The pulse-width controlled current to close the coil is shut off, but the spool valve remains closed. Oil
above the intensifier piston flows past the spool valve through the exhaust ports. The intensifier piston
and plunger return to their initial positions. Fuel pressure decreases until the needle control spring forces
the needle back on its seat.
 6 ENGINE SYSTEMS OVERVIEW 1795

Fuel Supply System

Figure 781 Low-pressure fuel system

1. Cylinder Head 8. Water In Fuel (WIF) sensor 13. Low pressure fuel rail (cast in
2. Fuel injector assembly (6) 9. 250 watt heater assembly intake manifold)
3. Fuel filter cap (optional)
4. M8 x 75 stud bolt (3) 10. Voss® Stop Flow adapter
5. Diagnostic coupling assembly assembly (fuel inlet)
and dust cap 11. Fuel filter assembly (with
6. Water drain valve assembly optional heater)
7. M8 x 75 bolt 12. Electric fuel pump assembly
1796 6 ENGINE SYSTEMS OVERVIEW

Fuel Supply System Flow

Figure 782 Fuel flow

The electric fuel pump draws fuel through the fuel lines from the fuel tank. Fuel enters the fuel filter assembly
and passes through the 100 micron strainer.
An optional 250 watt electric heating element is available to warm incoming fuel to prevent waxing and optimize
cold weather performance. The heater is installed in the fuel filter assembly, below the electric fuel pump.
Fuel flows from the strainer through the electric fuel pump to the fuel filter for further conditioning.
If water is in the fuel, the fuel filter element repels the water. The water is collected at the bottom of the main
filter element cavity in the fuel filter assembly.
Fuel flows through the 5 micron filter element and the standpipe. The filter element removes debris from the
fuel. The standpipe prevents fuel from draining from the fuel rail during service.
 6 ENGINE SYSTEMS OVERVIEW 1797

Figure 783 Fuel filter assembly components

1. M5 x 25 screw (3) 14. Fuel filter assembly with heater 26. O-ring seal
2. Electric fuel pump 15. M8 x 75 stud bolt (3) 27. Water In Fuel (WIF) sensor
3. Pump cover and housing O-ring 16. Fuel pressure regulator valve 28. 250 watt heater assembly
(2) assembly (optional)
4. Pump adapter 17. Fuel pressure regulator spring 29. Heater plug O-ring gasket
5. 3.53 x 40.87 ID O-ring 18. Cover plate seal 30. Dust cap
6. Pump strainer 19. Bottom cover plate 31. Diagnostic coupling
7. M6 screw (3) 20. Sensor O-ring 32. #906 O-ring
8. Port cover 21. Fuel Delivery Pressure (FDP) 33. M8 x 75 bolt
9. Port cover seal sensor 34. Voss® Stop Flow adapter
10. Fuel filter cap 22. M6 screw (7) assembly (fuel inlet)
11. O-ring gasket 23. O-ring 35. Gasket
12. Fuel filter element 24. Water drain valve assembly
13. Irregular molded gasket 25. M5 x 18 Torx® screw (2)
1798 6 ENGINE SYSTEMS OVERVIEW

When the maximum amount of water is collected in the element cavity, the WIF sensor sends a signal to the
Electronic Control Module (ECM). The ECM turns on the amber Water In Fuel lamp located on the instrument
panel.
A water drain valve is located on the fuel filter assembly and can be opened to drain contaminants (usually
water) from the assembly.
A fuel pressure regulator valve is built into the fuel filter assembly. The regulator valve is calibrated to relieve
excessive fuel pressure. Excess fuel is sent through a fuel return line back to the fuel tank. Return fuel is not
filtered.
Fuel continuously flows from the top of the filter element cavity, through a 0.2 mm air bleed orifice (filter center
tube feature), and into the return fuel line. This aids in removing trapped air from the element cavity as a result
of servicing.
When the fuel filter is removed, a drain-to-tank port valve is opened. Fuel present in the filter assembly then
drains out and back to the tank to provide improved cleanliness during servicing. When fuel lines are removed,
a check valve eliminates spillage and ensures fuel line cleanliness.
The Fuel Delivery Pressure (FDP) sensor detects low fuel pressure caused by a fuel restriction or dirty fuel filter.
The FDP sensor sends a signal to the ECM when pressure is below programmed values for various engine
conditions. The ECM turns on an amber FUEL FILTER lamp located on the instrument panel.
Filtered fuel flows from the fuel filter assembly into the fuel rail. The fuel rail is an integral part of the intake
manifold. Fuel flows into six cylinder head passages to each fuel injector.
When the fuel injectors are activated, fuel flows from the fuel passages through the injector inlet ports and into
the fuel injectors.
 6 ENGINE SYSTEMS OVERVIEW 1799

Engine Lubrication System

Figure 784 Lubrication system

1800 6 ENGINE SYSTEMS OVERVIEW

1. Unfiltered oil 10. Dual stage turbocharger 18. Piston cooling tube (6)
2. Cooled unfiltered oil 11. Oil cooler 19. Main filtered oil gallery
3. Filtered oil 12. Oil filter 20. Camshaft
4. Crankcase breather assembly 13. Oil cooler module assembly 21. Crankcase
5. Oil pump 14. Oil pressure regulator relief 22. Vertical gallery
6. Front cover valve 23. Cylinder head
7. Reservoir for high-pressure oil 15. Regulator relief valve drain to 24. Valve cover
pump sump 25. Rocker arm assembly oil gallery
8. Unfiltered oil gallery 16. Oil pan assembly 26. Air compressor (optional)
9. Pick-up tube 17. Crankshaft

Oil Flow

Figure 785 Lubrication system

Unfiltered oil is drawn from the oil pan through the pickup tube and front cover passage by the crankshaft driven
oil pump. Pressurized oil is forced through a front cover passage, into the crankcase gallery, and to the oil
system module assembly. Oil flow into the oil cooler is controlled by the thermal bypass valve.
The thermal bypass valve allows unfiltered oil to bypass the oil cooler when the oil temperature is cold, and flow
directly to the oil filter. As the oil temperature begins to warm, the thermal bypass valve begins to open. This
allows unfiltered oil to flow into the oil cooler and oil filter.
When the oil temperature is hot, the thermal bypass valve is fully open. This allows all unfiltered oil to flow
through the oil cooler before entering the oil filter.
Unfiltered oil moves through plates in the oil cooler heat exchanger. Engine coolant flows around the plates to
cool the surrounding oil.
Oil that exits or bypasses the oil cooler mixes and enters the spin-on oil filter. Oil flows from outside the filter
element towards the inside to remove debris. When the filter is restricted, the oil filter bypass (located in the oil
 6 ENGINE SYSTEMS OVERVIEW 1801

filter can) opens and allows oil to bypass the filter to maintain engine lubrication. The filter bypass valve opens
when pressure reaches 60 psi (414 kPa).
After passing through the filter, the oil travels past the oil pressure regulator. The regulator directs excess oil
back to the oil pan to maintain oil pressure at a maximum of 57 psi (393 kPa).
Clean regulated oil enters the main oil gallery of the engine to lubricate the crankshaft, camshaft, and tappets.
The crankshaft has cross-drillings that direct oil to the connecting rods.
Oil is also provided to the high-pressure reservoir through a passage in the front cover.
Piston cooling jets continuously direct cooled oil to the bottom of the piston crowns.
Oil is provided to the cylinder head from the rear cam bearing through a passage at the rear of the crankcase.
Oil flows through a passage in the cylinder head and rear rocker shaft support, then enters the hollow rocker
shaft, which lubricates the rocker arms.
The crankcase breather assembly oil separator is driven by unfiltered oil pressure taken from the right side of
the crankcase. Oil flows from the crankcase into the breather assembly oil separator. Passages direct the oil
through a pressed brass nozzle that controls oil flow into the drive oil separator wheel. Oil drains into the base
and mixes with oil from the breather system. The collected oil drains into the crankcase and then into the oil pan.
The turbocharger is lubricated with filtered oil from a supply tube assembly that connects the oil cooler module
assembly to the center housing of each turbocharger. Oil drains back to the crankcase through drain tubes
connected to the base of the breather housing assembly.
The optional air compressor is lubricated with filtered engine oil through a flexible hose. The hose is connected to
a tee on the left side of the crankcase near the Engine Oil Pressure (EOP) sensor. Oil drains into the front cover
and to the oil pan. Oil can also drain from the bottom of the air compressor through a tube into the crankcase.
The front gear train is splash lubricated with oil that drains from the high-pressure reservoir and the optional air
compressor.
1802 6 ENGINE SYSTEMS OVERVIEW

Engine Cooling System

Figure 786 Cooling system components and flow

Cooling System Description

The engine cooling system includes the following:
• Chassis mounted radiator
• Low temperature radiator (if equipped)
• Low temperature radiator thermostat (if equipped)
• Interstage cooler (if equipped)
• Coolant fan
• Water inlet elbow
• Front engine cover
• Water pump
• Crankcase
• Cylinder sleeves
• Cylinder head
• Oil cooler module assembly
• Air compressor
• Thermostat
• Coolant supply housing / coolant port
 6 ENGINE SYSTEMS OVERVIEW 1803

• EGR cooler
• Coolant surge tank
• Coolant heater (if equipped)
The water pump pushes coolant into the crankcase, low temperature radiator, and EGR cooler.
Coolant flows to the crankcase and through the water jackets from front to rear. Coolant flows around the cylinder
liners to absorb heat from combustion. Coolant may also pass by the optional engine coolant heater.
Swirling coolant flow in the cylinder liner jackets directs coolant through passages in the cylinder head gasket
and upwards into the cylinder head.
Coolant flows through the cylinder head water jackets towards the thermostat cavity at the front of the cylinder
head. When the thermostat is closed, coolant is directed through the bypass port, crankcase, front cover, and
into the water pump. When the thermostat is open, the bypass port is blocked, and coolant is directed through
the radiator.
Coolant passes through the radiator and is cooled by moving air from the coolant fan. Coolant returns to the
engine through the inlet elbow and front cover.
The air compressor is cooled with engine coolant supplied by a hose from the left side of the crankcase. Coolant
passes through the air compressor and returns to the cylinder head through a passage in the crankcase.
The oil cooler module assembly receives coolant from a passage in the crankcase. Coolant passes between
the oil cooler plates and returns through a tube connected to the coolant supply housing.
The EGR cooler receives coolant from the water pump through a supply tube at the rear of the front cover.
Coolant passing through the EGR cooler, flows through the cooler plates, cools the exhaust gas, and exits
through a tube to the rear of the front cover that returns coolant to the pump inlet. The hydrocarbon injector
assembly receives and returns coolant to the EGR cooler.
The EGR coolant supply tube also branches off to the low temperature radiator and to the interstage cooler
(above 245 hp), if equipped. For engines with ratings above 245 hp, the coolant is routed through the low
temperature thermostat, then through the low temperature radiator to the interstage cooler. Coolant is regulated
by the low temperature radiator thermostat. Warm coolant is directed to the low temperature radiator and into
the interstage cooler. Cold coolant bypasses the low temperature radiator and moves directly into the interstage
cooler.
The interstage cooler uses coolant to lower the charged air temperature that exits from the turbocharger
low-pressure compressor and enters the turbocharger high-pressure compressor.
The surge tank provides expansion space for coolant and deaerates the cooling system. The following four
vents provide coolant to the tank:
• Engine vent (top of coolant supply housing)
• EGR vent (top of EGR cooler)
• Main radiator vent (top of radiator)
• Interstage cooler vent (top of interstage cooler)
The surge tank returns coolant through the surge line, back to the water pump inlet.
Cab heat is provided by the heater core, which receives warmed coolant from the coolant supply housing.
1804 6 ENGINE SYSTEMS OVERVIEW

Cooling System Components

Coolant Heater (optional)
An optional coolant heater is available to warm engine coolant in cold weather. The coolant heater warms the
coolant surrounding the cylinders. Warmed engine coolant aids in cold engine start-up and performance. The
coolant heater is installed on the left side of the crankcase, in front of the Electronic Control Module (ECM).
 6 ENGINE SYSTEMS OVERVIEW 1805

Thermostat Operation
Coolant travels through two ports after it passes through the thermostat. One port directs coolant to the radiator
when the engine is at operating temperature. The other port directs coolant to the water pump until the engine
reaches operating temperature. The thermostat begins to open at 190°F (88°C) and is fully open at 205°F
(96°C).

Figure 787 Thermostat closed

1. Coolant flow to heater port
2. Coolant in from engine
3. Bypass to water pump

When engine coolant is below 190°F (88°C), the thermostat is closed, blocking flow to the radiator. Coolant is
forced to flow through a bypass port back to the water pump.
1806 6 ENGINE SYSTEMS OVERVIEW

Figure 788 Thermostat open

1. Coolant out to radiator
2. Coolant flow to heater port
3. Coolant in from engine

When coolant temperature reaches the nominal opening temperature of 190°F (88°C), the thermostat opens
allowing some coolant to flow to the radiator. When coolant temperature exceeds 205°F (96°C), the lower seat
blocks the bypass port directing full coolant flow to the radiator.
 6 ENGINE SYSTEMS OVERVIEW 1807

Low Temperature Radiator (LTR) Thermostat Operation

Figure 789 LTR thermostat

1. Thermostat outlet to low temperature radiator
2. Thermostat inlet
3. Thermostat bypass to ISC

Engines equipped with Interstage Cooler (ISC) will also have a Low Temperature Radiator (LTR) and LTR
thermostat. The LTR thermostat is a wax element thermostat in a housing with one inlet port and two outlet
ports. During cold engine operation (thermostat closed), coolant is directed to the ISC directly, through the
bypass port. At normal operating temperature (thermostat open), coolant is directed to the LTR first and then to
the ISC. The thermostat begins to open at 194°F (90°C) and is fully open at 209°F (98°C). The LTR thermostat
is installed on the chassis near the LTR.
1808 6 ENGINE SYSTEMS OVERVIEW

Electronic Control System

Electronic Control System Components

Figure 790 Electronic Control System

 6 ENGINE SYSTEMS OVERVIEW 1809

Operation and Function

The Electronic Control Module (ECM) monitors and controls engine performance to ensure maximum
performance and adherence to emissions standards. The ECM performs the following functions:
• Provides Reference Voltage (VREF)
• Conditions input signals
• Processes and stores control strategies
• Controls actuators

Reference Voltage (VREF)

The ECM internal Power supply generates 5.0 V (Vcc) for the internal components, a reference voltage of 5.0
V for the A/D converters and also three independent short circuit protected 5.0 V tracking voltages (V_REF_1,
V_REF_2, V_REF_3) for external devices.
• VREF 1 supplies 5 volts to engine sensors
• VREF 2 supplies 5 volts to vehicle aftertreatment and pedal
• VREF 3 supplies 5 volts to body builder and pedal

Microprocessor
The ECM microprocessor stores operating instructions (control strategies) and value tables (calibration
parameters). The ECM compares stored instructions and values with conditioned input values to determine
the correct strategy for all engine operations.

Actuator Control
The ECM controls the actuators by applying a low level signal (low side driver) or a high level signal (high side
driver). When switched on, the drivers complete a ground or power circuit to an actuator.
Actuators are controlled in one of the following ways, depending upon type of actuator:
• Duty cycle (percent time on / off)
• Controlled pulse width
• Switched on or off

Actuators
The ECM controls engine operation with the following:
• Exhaust Gas Recirculation (EGR) valve
• Intake Air Heater (IAH) relay
• Engine Throttle Valve (ETV) and position sensor
• Turbocharger 2 Wastegate Control (TC2WC) valve (turbocharger wastegate actuator)
• Exhaust Back Pressure Valve (EBPV)
• Engine Compression Brake (ECB) valve
• Injection Pressure Regulator (IPR) valve
1810 6 ENGINE SYSTEMS OVERVIEW

Exhaust Gas Recirculation (EGR) Valve

The EGR valve controls the flow of exhaust gases to the air and EGR mixer duct.
The EGR valve receives the desired valve position from the ECM for exhaust gas recirculation.
Sensors within the EGR valve provide feedback to the ECM on valve position and temperature. A fault code will
be set if the ECM detects an error.
 6 ENGINE SYSTEMS OVERVIEW 1811

Intake Air Heater (IAH) Relay

The IAH system warms the incoming air supply prior to cranking to aid cold engine starting.
The ECM is programmed to energize the IAH element through the IAH relay while monitoring certain
programmed conditions for engine coolant temperature, engine oil temperature, and atmospheric pressure.
The ECM activates the IAH relay. The relay supplies battery voltage to the heater elements for a set time,
depending on engine coolant temperature and altitude.
1812 6 ENGINE SYSTEMS OVERVIEW

Engine Throttle Valve (ETV) and Position Sensor

The engine throttle valve controls the flow of inlet air to regulate operating temperature for exhaust aftertreatment
and base engine operation.
The integral throttle actuator controls the engine throttle valve.
The throttle actuator receives the desired engine throttle valve position from the ECM to activate the throttle
valve. The throttle position sensor provides feedback to the ECM on the throttle valve position.
 6 ENGINE SYSTEMS OVERVIEW 1813

Turbocharger 2 Wastegate Control (TC2WC) valve (turbocharger wastegate actuator)

The turbocharger wastegate actuator regulates the charge air pressure by controlling the amount of exhaust
gases that pass through the high-pressure turbine.
The TC2WC valve receives the command signal from the ECM. When the charge air pressure demand is low, the
TC2WC valve opens, allowing control air to the turbocharger wastegate actuator. The actuator opens allowing
part of the exhaust gas flow to bypass the high-pressure turbine.
1814 6 ENGINE SYSTEMS OVERVIEW

Exhaust Back Pressure Valve (EBPV)

The Exhaust Back Pressure Valve (EBPV) controls the position of the exhaust valve increasing or decreasing
exhaust gas back pressure and temperature to allow the DOC and DPF to function efficiently.
 6 ENGINE SYSTEMS OVERVIEW 1815

Engine Compression Brake (ECB) valve

The Engine Compression Brake (ECB) valve controls pressure entering the brake oil gallery from the injector
oil gallery. This activates the brake actuator pistons and opens the exhaust valves. The ECB valve is installed
in the center of the high-pressure oil manifold.
1816 6 ENGINE SYSTEMS OVERVIEW

Injection Pressure Regulator (IPR) valve

The Injection Pressure Regulator (IPR) valve is used to maintain desired injection control pressure. Excess
high-pressure oil is directed to the crankcase sump by the IPR valve.

Engine and Vehicle Sensors

Temperature Sensors

Thermistor Sensors

Figure 791 Thermistor sensor

A thermistor sensor varies electrical resistance with changes in temperature. Resistance in the thermistor
decreases as temperature increases and increases as temperature decreases. Thermistors have a resistor
that limits current in the ECM to a voltage signal matched with a temperature value.
The top half of the voltage divider is the current limiting resistor inside the ECM. A thermistor sensor has two
electrical connectors, signal return and ground. The output of a thermistor sensor is a nonlinear analog signal.
Thermistor type sensors include the following:
• Engine Coolant Temperature (ECT) sensor
• Engine Oil Temperature (EOT) sensor
• Inlet Air Temperature (IAT) sensor
• Intake Manifold Temperature (IMT) sensor
• Charge Air Cooler Outlet Temperature (CACOT) sensor
• Turbocharger 2 Compressor Inlet Temperature (TC2CIT) sensor

ECT Sensor
The ECM monitors the ECT signal and uses this information for the instrument panel temperature gauge, coolant
compensation, Engine Warning Protection System (EWPS), and IAH operation. The ECT is a backup, if the EOT
is out-of-range. The ECT sensor is installed in the coolant supply housing (refrigerant compressor bracket).
 6 ENGINE SYSTEMS OVERVIEW 1817

EOT Sensor
The ECM monitors the EOT signal and uses this information to control fuel quantity and timing. The EOT signal
allows the ECM to compensate for differences in oil viscosity for temperature changes. The EOT sensor is
installed in the rear of the front cover, to the left of the high-pressure pump assembly.

IAT Sensor
The IAT sensor is integral to the Mass Air Flow (MAF) sensor. The ECM monitors the IAT signal to control
injector timing and fuel rate during cold starts. The ECM also uses the IAT signal to control EGR position and
engine throttle control.

IMT Sensor
The IMT sensor monitors the air temperature in the intake manifold. The ECM monitors the IMT signal for EGR
operation. The IMT sensor is installed in the intake manifold, to the right of the IMP sensor.

CACOT Sensor
The CACOT sensor monitors the temperature of the air leaving the CAC. The ECM monitors the CACOT signal
to evaluate the effectiveness and condition of the CAC.

TC2CIT Sensor
The TC2CIT sensor monitors the temperature of the air entering the Turbocharger 2 compressor. The ECM
monitors the TC2CIT signal to evaluate the effectiveness and condition of the interstage cooler.

Exhaust Gas Temperature (EGT) sensors

The Aftertreatment System and exhaust manifold use the following sensors:
• Exhaust Gas Temperature (EGT) sensor
• Diesel Oxidation Catalyst Intake Temperature (DOCIT) sensor
• Diesel Particulate Filter Intake Temperature (DPFIT) sensor
• Diesel Particulate Filter Outlet Temperature (DPFOT) sensor
The Exhaust Gas Temperature (EGT) sensor used in the exhaust manifold provides a feedback signal to the
ECM indicating exhaust gas temperature.
The DOCIT sensor provides a feedback signal to the ECM indicating Diesel Oxidation Catalyst (DOC) intake
temperature. The DOCIT sensor is the first temperature sensor installed past the turbocharger and just before
the DOC.
The DPFIT sensor provides a feedback signal to the ECM indicating Diesel Particulate Filter Intake (DPF) intake
temperature. The DPFIT sensor is the second temperature sensor installed past the turbocharger and just after
the DOC.
The DPFOT sensor provides a feedback signal to the ECM indicating DPF outlet temperature. The DPFOT
sensor is the third temperature sensor installed past the turbocharger and just after the DPF.
During a catalyst regeneration, the ECM monitors all three sensors along with the Exhaust Gas Recirculation
(EGR) System and Engine Throttle Valve (ETV).
1818 6 ENGINE SYSTEMS OVERVIEW

Variable Capacitance Sensors

Figure 792 Variable capacitance sensor

Variable capacitance sensors measure pressure. The pressure measured is applied to a ceramic diaphragm.
Pressure forces the ceramic material closer to a thin metal disk. This action changes the capacitance and
subsequently the voltage output of the sensor.
This type of sensor has three wires: VREF, ground, and a signal wire.
The sensor receives the VREF and returns an analog signal voltage to the ECM. The ECM compares the voltage
with pre-programmed values to determine pressure.
The operational range of a variable capacitance sensor is linked to the thickness of the ceramic disk. The thicker
the ceramic disk, the more pressure the sensor can measure.
Variable capacitance sensors include the following:
• Fuel Delivery Pressure (FDP) sensor
• Engine Oil Pressure (EOP) sensor
• Exhaust Back Pressure (EBP) sensor
• Mass Air Flow (MAF) sensor
• Intake Manifold Pressure (IMP) sensor

FDP Sensor
The ECM uses the FDP sensor signal to monitor engine fuel pressure and give an indication when the fuel filter
needs to be changed. The FDP sensor is installed in the fuel filter assembly on the intake side of the crankcase.

EOP Sensor
The ECM monitors the EOP signal, and uses this information for the instrument panel pressure gauge and
EWPS. The EOP sensor is installed in the intake side of the crankcase, below the fuel filter assembly.

EBP Sensor
The ECM monitors the exhaust pressure to control the EGR and intake throttle systems. The EBP sensor is
installed in a tube mounted on the coolant supply housing (refrigerant compressor bracket).
 6 ENGINE SYSTEMS OVERVIEW 1819

MAF Sensor
The MAF sensor is used for closed loop control of the EGR valve and ETV. The ECM monitors the MAF signal
to control the EGR and intake throttle systems. The MAF sensor also sends air temperature information to the
ECM. The MAF sensor is installed in the intake air duct or air cleaner housing.

IMP Sensor
The ECM monitors the IMP signal to control the EGR and intake throttle systems. The IMP sensor is installed
in the intake manifold, left of the IMT sensor.
1820 6 ENGINE SYSTEMS OVERVIEW

Magnetic Pickup Sensors

Figure 793 Magnetic pickup sensors

A magnetic pickup sensor contains a permanent magnet core that is surrounded by a coil of wire. The sensor
generates a voltage signal through the collapse of a magnetic field that is created by a moving metal trigger.
The movement of the trigger then creates an AC voltage in the sensor coil.
Magnetic pickup sensors used include the following:
• Crankshaft Position (CKP) sensor
• Camshaft Position (CMP) sensor
• Vehicle Speed Sensor (VSS)

CKP Sensor
The CKP sensor provides the ECM with a signal that indicates crankshaft speed and position. As the crankshaft
turns, the CKP sensor detects a 60-tooth timing disk on the crankshaft. Teeth 59 and 60 are missing. By
comparing the CKP signal with the CMP signal, the ECM calculates engine rpm and timing requirements. The
CKP sensor is installed in the top left side of the flywheel housing.

CMP Sensor
The CMP sensor provides the ECM with a signal that indicates camshaft position. As the cam rotates, the sensor
identifies the position of the cam by locating a peg on the cam. The CMP sensor is installed in the front cover,
above and to the right of the water pump pulley.

VSS
The VSS provides the ECM with transmission tail shaft speed by sensing the rotation of a 16-tooth gear on the
rear of the transmission. The detected sine wave signal (AC), received by the ECM, is used with tire size and
axle ratio to calculate vehicle speed. The VSS is on the left side of the transmission.
 6 ENGINE SYSTEMS OVERVIEW 1821

High-pressure Sensors

Figure 794 High-pressure sensor

High-pressure sensors convert pressure to a linear analog voltage output of 0 to 5 volts. Pressure to be
measured exerts force on a diaphragm with a strain gauge bonded to it. This diaphragm stretches and
compresses to change mechanical motion into an electrical signal.
This type of sensor has three wires: VREF, ground, and a signal wire.
The sensor is powered by VREF from the ECM and is grounded through the ECM to a common sensor ground.
The ECM compares the voltage with pre-programmed values to determine pressure.
High-pressure sensors include the following:
• Diesel Particulate Filter Differential Pressure (DPFDP) sensor
• Engine Compression Brake Pressure (ECBP) sensor
• Injection Control Pressure (ICP) sensor

DPFDP Sensor
The DPFDP sensor provides a feedback signal to the ECM indicating the pressure difference between the inlet
and outlet of the Diesel Particulate Filter (DPF). During a catalyst regeneration, the ECM monitors this sensor
along with three Aftertreatment System thermistor sensors, the EGR System, and the Engine Throttle Valve
(ETV).

ECBP
The ECM monitors the ECBP signal to determine oil pressure in the brake gallery of the high-pressure oil
manifold. The ECBP sensor is under the valve cover, forward of the No. 2 fuel injector in the high-pressure
oil manifold.

ICP
The ECM monitors the ICP sensor to determine injection control pressure for engine operation. The ICP sensor
is used to control the IPR valve. It provides feedback to the ECM for Closed Loop IPR control. The ICP sensor
is located under the valve cover, forward of the No. 6 fuel injector in the high-pressure oil manifold.
1822 6 ENGINE SYSTEMS OVERVIEW

Potentiometer

Figure 795 Potentiometer

A potentiometer is a variable voltage divider that senses the position of a mechanical component. A reference
voltage is applied to one end of the potentiometer. Mechanical rotary or linear motion moves the wiper along
the resistance material, changing voltage at each point along the resistive material. Voltage is proportional to
the amount of mechanical movement.

APP
The APP provides the ECM with a feedback signal (linear analog voltage) that indicates the operator's demand
for power. There are two potentiometers within the APP sensor. The APP is installed in the cab on the accelerator
pedal.
 6 ENGINE SYSTEMS OVERVIEW 1823

Switches

Figure 796 Switch

Switch sensors indicate position, level, or status. They operate open or closed, regulating the flow of current. A
switch sensor can be a voltage input switch or a grounding switch. A voltage input switch supplies the ECM with
a voltage when it is closed. A grounding switch grounds the circuit when closed, causing a zero voltage signal.
Grounding switches are usually installed in series with a current limiting resistor.
Switches include the following:
• Driveline Disengagement Switch (DDS)
• Engine Coolant Level (ECL)
• Water In Fuel (WIF)

DDS
The DDS determines if a vehicle is in gear. For manual transmissions, the clutch switch serves as the DDS. For
automatic transmissions, the neutral indicator switch or datalink communication functions as the DDS.

ECL
ECL is part of the Engine Warning Protection System (EWPS). The ECL switch is used in plastic deaeration
tanks. When a magnetic switch is open, the tank is full.
If engine coolant is low, the switch closes and the red ENGINE lamp on the instrument panel is illuminated.

WIF
A Water In Fuel (WIF) sensor in the fuel filter assembly is used to detect water in the fuel. The resistance of the
WIF sensor circuit changes when the water level in the fuel filter assembly reaches the sensor. The ECM then
sends a message to illuminate the amber water in fuel lamp, alerting the operator. The WIF is installed in the
side of the fuel filter assembly.
1824 6 ENGINE SYSTEMS OVERVIEW

Engine Throttle Valve Control System

Figure 797 Engine throttle valve control system

The Engine Throttle Valve (ETV) is controlled to limit inlet air. As part of the air management system, the ETV is
controlled by the ECM (closed loop) based on input from the Mass Air Flow (MAF) sensor for proper emissions
control.
The ETV is also used to help control inlet air during a Diesel Particulate Filter (DPF) regeneration process of the
aftertreatment system. It maintains vehicle and engine performance during regenerations.
 6 ENGINE SYSTEMS OVERVIEW 1825

Exhaust and Engine Brake System

Exhaust Brake

Figure 798 Exhaust brake system

The exhaust brake is available for all ratings and aids in the deceleration rate of vehicles.
The exhaust brake is an exhaust back pressure brake system that provides improved braking performance. The
operator can enable the brake function by toggling an instrument panel mounted switch ON or OFF.
1826 6 ENGINE SYSTEMS OVERVIEW

Engine Brake

Figure 799 Engine brake system

1. Exhaust Back Pressure (EBP) 4. Brake pressure relief valve 7. Engine Compression Brake
sensor 5. High-pressure oil manifold (ECB) valve
2. Switch 6. Engine Compression Brake 8. Injection Control Pressure (ICP)
3. Electronic Control Module Pressure (ECBP) sensor sensor
(ECM) 9. Front of engine

ECBP
The ECM monitors the ECBP signal during engine normal and braking operation to determine if the engine
brake system is working without fault. The ECBP sensor provides a feedback signal to the ECM indicating
brake control pressure. The ECBP sensor is installed in the high-pressure oil manifold, under the valve cover.

ECB
The ECB valve controls pressure entering the brake oil gallery from the injector oil gallery. This activates
the brake actuator pistons and opens the exhaust valves. The ECB valve is installed in the center of the
high-pressure oil manifold.

Brake Pressure Relief Valve

The brake pressure relief valve vents excess pressure under the valve cover. Residual brake gallery pressure
initially bleeds from the actuator bore. When brake gallery pressure reaches a set point, the brake pressure
relief valve opens and oil drains back to the sump.
 6 ENGINE SYSTEMS OVERVIEW 1827

EBP
The EBP sensor is an input to the ECM for control of the Turbocharger 2 Wastegate Control (TC2WC) valve. The
TC2WC valve controls the turbocharger wastegate actuator. The EBP sensor is mounted on a tube plumbed to
the exhaust manifold on the exhaust side of the engine.

High-pressure Oil Manifold

The high-pressure oil manifold has two internal separated oil galleries. The manifold supplies high-pressure oil
to each fuel injector during normal operation. High-pressure oil is directed to the brake pistons during engine
brake operation.
1828 6 ENGINE SYSTEMS OVERVIEW

Operation
During engine brake operation, The ECB valve opens to supply high-pressure oil to each brake actuator piston.
These brake actuator pistons hold the exhaust valves partially open.
During normal engine operation, oil in the high-pressure manifold goes to the fuel injectors only. The engine
compression brake valve, mounted in the high-pressure oil manifold, is closed to prevent oil from entering the
brake gallery.

Figure 800 Engine compression brake valve and brake actuator – OFF
1. High-pressure oil manifold 4. Engine compression brake valve 7. Valve lash (actuator retracted)
2. High-pressure oil gallery 5. Brake actuator piston assembly 8. Oil inlet
3. Brake oil gallery 6. Exhaust valve bridge
 6 ENGINE SYSTEMS OVERVIEW 1829

Figure 801 Engine compression brake valve and brake actuator – ON

1. High-pressure oil manifold 4. Engine compression brake valve 8. Normal oil seepage
2. High-pressure oil flow to brake 5. Brake actuator piston assembly 9. Oil inlet
oil gallery 6. Exhaust valve bridge
3. Brake oil gallery 7. Valve lash (actuator deployed)

The ECM monitors the following criteria to make sure certain conditions are met:
• Anti-lock Brake System (ABS) (inactive)
• RPM (greater than 1200)
• APP (less than 5%)
• EOT (greater than or equal to 140°F [60°C])
• Operator input switches (On / Off)
If On is selected, and the preceding criteria are met, the engine brake will activate.
When the engine brake is activated, the ECM provides the power to activate the Engine Compression Brake
(ECB) valve to allow oil from the injector oil gallery to flow to the brake oil gallery. High oil pressure activates the
brake actuator pistons to open the exhaust valves.
Vehicle momentum is absorbed by the resulting compression release of the engine power cylinders when pistons
are near the top of their stroke.
During an ABS event, the engine brake is deactivated. The engine brake is reactivated once the ABS event is
over.
The ECM removes the power source from the ECB valve to deactivate the engine brake. Residual brake gallery
pressure initially bleeds from the actuator bore. When brake gallery pressure bleeds down the brake pressure
relief valve opens, and oil drains back to sump.
1830 6 ENGINE SYSTEMS OVERVIEW

Operation Modes
The engine brake system provides three programmable modes of operation based on terrain, driving conditions,
or driver preference.

Coast Mode
When the coast mode is programmed, the brake system will activate only when the driver applies the vehicle
service brake. The coast mode allows the vehicle to coast without automatic brake system activation.

Latched Mode
When the latch mode is programmed, the brake system will activate when the driver releases the accelerator
pedal. The brake system will deactivate when the driver depresses the accelerator or clutch pedals. The brake
system will also deactivate when the engine speed is below a pre-programmed rpm.

Cruise Mode
When the cruise mode is programmed, the brake system performs similar to latch mode under normal driving
conditions. When cruise control is used the brake system will activate when the vehicle travels down a grade.
The brake system helps the cruise control system maintain the set vehicle speed.
 7 ENGINE AND VEHICLE FEATURES 1831

Table of Contents

Standard Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1833

Electronic Governor Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1833
SAE J1939 Communication Datalink. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1833
American Trucking Association (ATA) Datalink. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1833
Service Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1833
Event Logging System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1834
Electronic Speedometer and Tachometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1834
Aftertreatment System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1834
Engine Fuel Pressure (EFP) Monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1834
Intake Air Heater (IAH). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1834
Fast Idle Advance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1834
Cold Ambient Protection (CAP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1834
Coolant Temperature Compensation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1835
Engine Crank Inhibit (ECI). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1835

Optional Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1836

Road Speed Limiting (RSL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1836
Cruise Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1836
Traction Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1836
Exhaust Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1836
Engine Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1836
Engine Warning Protection System (EWPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1836
Idle Shutdown Timer (IST). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1837
Electronic Fan (EFAN). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1837
Radiator Shutter Enable (RSE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1837
In Cab Power Take Off (PTO) Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1838
Remote Accelerator Pedal Position (RAPP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1838
Change Engine Oil Interval Message. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1838
Fuel Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1838
1832 7 ENGINE AND VEHICLE FEATURES
 7 ENGINE AND VEHICLE FEATURES 1833

Standard Features
Electronic Governor Control
The governor controls engine rpm within a safe and stable operating range.
The low idle governor prevents engine rpm from dropping below a stable speed to prevent stalling when various
loads are demanded on the engine.
The high idle governor prevents engine rpm from going above a safe speed that would cause engine damage.

SAE J1939 Communication Datalink

Vehicles are equipped with the SAE J1939 connector for communication between the Engine Control Module
(ECM) and the Electronic Service Tool (EST).
The SAE J1939 datalink supports:
• Transmission of engine parameter data.
• Transmission and clearing of Suspect Parameter Number / Failure Mode Indicator (SPN / FMI) codes.
• Diagnostics and troubleshooting.
• Programming performance parameter values.
• Programming engine and vehicle features.
• Programming calibrations and strategies in the ECM.

American Trucking Association (ATA) Datalink

This link is supported for legacy diagnostic purposes only. It is no longer the programming link, nor does it
support the aftertreatment.

Service Diagnostics
NOTE: Model year 2010 vehicles no longer utilize DTC identification by number. DTCs are now identified
using the SPN and FMI identifiers only. These two identifiers, known as the Suspect Parameter Number (SPN)
and the Failure Mode Indicator (FMI), are displayed in the Electronic Service Tool (EST) with Navistar® Engine
Diagnostics in the DTC Window for model year 2010 vehicles and DTC for pre-2010 vehicles.
The EST provides diagnostic information using the SAE J1939 datalink. The recommended EST is the EZ-Tech®
with Navistar® Engine Diagnostics provided by Navistar®.
Faults from sensors, actuators, electronic components, and engine systems are detected by the ECM and sent
to the EST as codes. Effective engine diagnostics require and rely on codes.
Identification is accomplished using two fault code identifiers. These two identifiers, known as the Suspect
Parameter Number (SPN) and the Failure Mode Indicator (FMI) are displayed in the DTC window on model year
2010 or newer. On pre-2010 vehicles DTC may still be displayed in the ETC window.
• Suspect Parameter Number (SPN) The Suspect Parameter Number (SPN) identifies the individual
component causing the DTC.
• Failure Mode Indicator (FMI) The Failure Mode Indicator (FMI) identifies the fault or condition effecting the
individual component.
1834 7 ENGINE AND VEHICLE FEATURES

Event Logging System

The event logging system records engine operation above maximum rpm (overspeed), low coolant level, high
coolant temperature, or low oil pressure. The readings for the odometer and hourmeter are stored in the ECM
memory at the time of an event and can be retrieved using the EST.

Electronic Speedometer and Tachometer

The engine control system calibrates vehicle speed up to 157 pulses per mile. Any new speed calibration
information must be programmed with an EST.
The tachometer signal is generated by the ECM, by computing signals for the Camshaft position (CMP) sensor
and Crankshaft Position (CKP) sensor. Calculations for each sensor are sent to the instrument panel and to the
EST.

Aftertreatment System
The engine and vehicle exhaust piping includes an Aftertreatment System to capture soot and other particulates
before they exit the exhaust pipe. The soot is captured by the Diesel Particulate Filter (DPF) and is periodically
converted to ash by a Regeneration (Regen) process.

Engine Fuel Pressure (EFP) Monitor

The EFP monitors fuel pressure and indicates when the fuel filter needs to be serviced by illuminating the fuel
filter indicator lamp on the Instrument Panel.

Intake Air Heater (IAH)

The Intake Air Heater (IAH) system warms the incoming air supply to aid cold engine starting and reduce white
smoke during warm-up. The ECM controls the intake air heater and monitors the engine temperature. When
the engine is ready for cranking, the ECM sends a message to shut off the WAIT TO START lamp.

Fast Idle Advance

Fast idle advance increases engine idle speed up to 875 rpm for faster warm up to operating temperature. This
occurs when the ECM monitors ECT sensor input and adjusts the fuel injector operation accordingly.
Low idle speed is increased proportionally when the engine coolant temperature is below 158°F (70°C) at 700
rpm to below 14°F (-10°C) at 875 rpm maximum.

Cold Ambient Protection (CAP)

CAP safeguards the engine from damage caused by prolonged idle at no load during cold weather. CAP also
improves cab warm-up.
CAP maintains engine coolant temperature by increasing engine rpm to a programmed value when ambient air
temperature is below 68°F (20°C), coolant temperature is below 158°F (70°C), and engine has been idling at
no load for over five minutes.
Engine speed will ramp up to 1400 rpm and will maintain at 1400 rpm until coolant temperature has reached
167°F (75°C).
• Engine load is greater than 45%
• Brake pedal is applied or brake switch fault is detected
 7 ENGINE AND VEHICLE FEATURES 1835

• Clutch pedal is depressed or clutch pedal switch fault is detected (manual transmissions, if equipped with a
clutch switch)
• Shift selector is moved from neutral (automatic transmissions). Shift selector must be in neutral for CAP to
work
• Power Takeoff (PTO) switch, also used for electric hand throttle, is turned on and actively controls engine
speed
• Accelerator pedal is depressed or Accelerator Pedal Sensor (APS) fault is detected
• Idle Shutdown Timer (IST) is enabled
• Engine Coolant Temperature (ECT) sensor fault is detected
• Intake Air Temperature (IAT) ambient temperature sensor fault is detected

Coolant Temperature Compensation

Coolant temperature compensation reduces fuel delivery if the engine coolant temperature is above cooling
system specifications.
Before standard engine warning or optional warning / protection systems engage, the ECM begins reducing fuel
delivery when the engine coolant temperature reaches approximately 225°F (107°C). A rapid reduction of 20
percent is commanded when engine coolant temperature reaches approximately 230°F (110°C).
NOTE: Coolant temperature compensation is disabled in emergency vehicles and school buses that require 100
percent power on demand.
Engine Crank Inhibit (ECI)
ECI will not allow the starting motor to crank when the engine is running or the automatic transmission is in gear.
1836 7 ENGINE AND VEHICLE FEATURES

Optional Features
Road Speed Limiting (RSL)
Road Speed Limiting (RSL) is a feature designed to regulate the maximum vehicle speed as controlled by the
accelerator pedal.
Customer programmable parameters within the ECM provide vehicle speed governor related options that can
be adjusted to suit the customer’s needs. A parameter is used to set the maximum accelerator controlled vehicle
speed.
Additional programming flexibility is included to allow a trade-off to be made between performance and fuel
economy.

Cruise Control
The ECM controls the cruise control feature. The cruise control system functions similarly for all electronic
engines. Maximum and minimum allowable cruise control speeds will vary based on model. To operate cruise
control, see appropriate truck model Operator's Manual.

Traction Control
Traction control is a system that identifies when a wheel is going faster than the other wheels during acceleration.
When a traction control condition occurs, a datalink message is sent to the ECM to limit fuel for the purpose of
reducing engine torque.
Vehicles must have a transmission and an Antilock Braking System (ABS) that supports traction control.

Exhaust Brake
The exhaust brake increases exhaust back-pressure to aid in the deceleration rate of the vehicle. This option is
placed in the exhaust piping after the turbochargers. This option cannot be combined with the engine brake.

Engine Brake
The engine brake is a compression release brake system to aid in the deceleration rate of the vehicle. This
option is built into the high-pressure oil manifold under the engine valve cover. This option cannot be combined
with the exhaust brake.

Engine Warning Protection System (EWPS)

The EWPS safeguards the engine from undesirable operating conditions to prevent engine damage and to
prolong engine life. The ECM will illuminate the red ENGINE lamp and sound the warning buzzer when the
ECM detects:
• High coolant temperature
• Low oil pressure
• Low coolant level (3-way system only)
When the protection feature is enabled and a critical engine condition occurs, the on-board electronics will shut
the engine down (3-way protection). An event logging feature will record the event in engine hours and odometer
readings. After the engine has shutdown, and the critical condition remains, the engine can be started for a
30-second run time.
 7 ENGINE AND VEHICLE FEATURES 1837

Idle Shutdown Timer (IST)

GOVERNMENT REGULATION: State and local regulations may limit engine idle time. The
vehicle owner or operator is responsible for compliance with those regulations.

The IST allows the Engine Control Module (ECM) to shut down the engine during extended engine idle times.
Thirty seconds before IST-defined engine shutdown, a vehicle instrument panel indicator activates. There are
two types of indicators:
• Amber flashing idle shutdown indicator for multiplex electrical systems
• Red flashing indicator with audible alarm for non-multiplex electrical systems
This continues until the engine shuts down or the low idle shutdown timer is reset

IST for California ESS Compliant Engines

Beginning in 2008 MY, all MaxxForce® engines certified for sale in the state of California will conform to mandatory
California Air Resources Board (CARB) Engine Shutdown System (ESS) regulations.
Engine idle duration is limited for California Engine Shutdown System (ESS) compliant engines as follows:
• When vehicle parking brake is set, the idle shutdown time is limited to the California Air Resources Board
(CARB) requirement of five minutes
• When vehicle parking brake is released, the idle shutdown time is limited to the CARB requirement of 15
minutes
The duration of CARB mandated values can be reduced by programming the customer IST programmable
parameter to a value lower than 15 minutes.

Engine Idle Shutdown Timer (IST for Federal – Optional)

Idle time can be programmed from 5 to 120 minutes. While the EST is installed, the IST function will be active
with the programmed shutdown time in effect. Parking brake transitions reset the idle timer. If the IST is enabled,
the Cold Ambient Protection (CAP) will not function.

Electronic Fan (EFAN)

Engine electronics allow for the operation of an electronic fan or an air fan solenoid. The electronic fan
commands higher airflow through the radiator when the Air Conditioner (A/C) is on or when the coolant or inlet
air temperature goes above a set temperature.

Radiator Shutter Enable (RSE)

The Radiator Shutter Enable (RSE) feature provides a signal to open or close the radiator shutters. Closing the
shutters will keep the engine warm during cold weather operation. This provides faster warm up of the passenger
cab and enables faster windshield defrosting.
1838 7 ENGINE AND VEHICLE FEATURES

In Cab Power Take Off (PTO) Control

The engine speed control feature, commonly referred to as Power Take-off (PTO), provides a method for an
operator to set and maintain a constant engine speed without using the accelerator pedal. It is commonly used
for powering auxiliary devices.
Customer programmable parameters within the ECM provide in-cab engine speed control related options that
can be adjusted to suit the customer’s needs. Choosing whether the operator is allowed to increase the engine
speed using the accelerator pedal without disengaging the PTO is an example.

Remote Accelerator Pedal Position (RAPP)

This engine speed control feature, commonly referred to as PTO, provides a method for an operator to set and
maintain engine speed without using the accelerator pedal. It is commonly used for powering auxiliary devices.
When control over engine speed is required from outside the vehicle’s cab, remote mounted switches must be
used to turn on PTO engine speed control and select the desired engine speed. This functionality is referred to
as remote engine speed control (RESC).
The engine speed can be ramped up and down with RESC similar to the way the in-cab PTO feature works,
however, the RESC feature includes two additional switches (remote preset and remote variable), which allow
the operator to choose the mode of engine speed control operation.
Customer programmable parameters within the ECM provide RESC related options that can be adjusted to suit
the customer’s needs. Choosing whether a remote throttle pedal is used for PTO operation is an example.

Change Engine Oil Interval Message

The service interval feature is designed to provide a visual reminder to the operator that the oil change interval
has expired and that routine maintenance procedures should be performed.
The term “interval” in this case is used to describe the distance, time, or fuel used between the last maintenance
performed on the vehicle and the next maintenance, which is due.
It is essential that operators are trained to know the maintenance schedules and instructions regarding the
operation and reset functionality of the service interval for the feature to be effective.
The change engine oil interval message can be programmed with the EST for mileage, hours, or amount of fuel
used. The change oil message timer can be reset using the CRUISE ON and RESUME/ACCEL switches or the
EST.

Fuel Heater
The fuel heater is installed in the fuel filter assembly. The heater warms the supply fuel to prevent waxing during
cold conditions.
 8 ABBREVIATIONS AND ACRONYMS 1839

Table of Contents

Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1841

1840 8 ABBREVIATIONS AND ACRONYMS
 8 ABBREVIATIONS AND ACRONYMS 1841

Abbreviations and Acronyms

A or amp – Ampere
AAT – Ambient Air Temperature
ABDC – After Bottom Dead Center
ABS – Antilock Brake System
AC – Alternating Current
A/C – Air Conditioner
ACC – Air Conditioner Control
ACCEL – Accelerator
ACD – Air Conditioner Demand
ACT PWR GND – Actuator Power Ground
ACV – Air Control Valve
A/F – Air to Fuel ratio
AFD – Aftertreatment Fuel Drain
AFI – Aftertreatment Fuel Injector
AFP – Aftertreatment Fuel Pressure
AFS – Aftertreatment Fuel Supply
AFT – Aftertreatment
AFTFD – Aftertreatment Fuel Doser
AFTFD-H – Aftertreatment Fuel Doser High
AFTFD-L – Aftertreatment Fuel Doser Low
AFTFIT – Aftertreatment Fuel Inlet Temperature
AFTFIS – Aftertreatment Fuel Inlet Sensor
AFTFP – Aftertreatment Fuel Pressure
AFTFP1 – Aftertreatment Fuel Pressure 1
AFTFP2 – Aftertreatment Fuel Pressure 2
AFTFS-H – Aftertreatment Fuel Shutoff High
AFTFS-L – Aftertreatment Fuel Shutoff Low
AFTFSV – Aftertreatment Fuel Shutoff Valve
Amb – Ambient
amp or A – Ampere
AMS – Air Management System
API – American Petroleum Institute
APP – Accelerator Pedal Position
APP1 – Accelerator Pedal Position 1
APP2 – Accelerator Pedal Position 2
APS – Accelerator Position Sensor
APS/IVS – Accelerator Position Sensor / Idle Validation Switch
ASTM – American Society for Testing and Materials
ATA – American Trucking Association
ATA-H – American Trucking Association Link High
ATA-L – American Trucking Association Link Low
ATDC – After Top Dead Center
AWG – American Wire Gauge
AWL – Amber Warning Lamp

B+ or VBAT – Battery Voltage

BAP or BARO – Barometric Absolute Pressure
BARO or BAP – Barometric Absolute Pressure
BBDC – Before Bottom Dead Center
BC – Body Controller
1842 8 ABBREVIATIONS AND ACRONYMS

BCP – Brake Control Pressure

BCS – Boost Control Solenoid
BDC – Bottom Dead Center
bhp – Brake Horsepower
BNO – Brake Normally Open
BOO – Brake On / Off
BPP – Brake Pedal Position
BPS – Brake Pressure Switch
BSV – Brake Shut-off Valve
BTDC – Before Top Dead Center
BTU – British Thermal Unit

C – Celsius
CAC – Charge Air Cooler
CACOT – Charge Air Cooler Outlet Temperature
CAN – Controller Area Network
CAN-H – Controller Area Network High
CAN-L – Controller Area Network Low
CAP – Cold Ambient Protection
CARB – California Air Resources Board
cc – Cubic centimeter
CCA – Cold Cranking Ampere
CCV – Coolant Control Valve
CCOSS – Crankcase Oil Separator Speed
CCPS – Crankcase Pressure Sensor
CCS – Cruise Control Switches
CDR – Crankcase Depression Regulator
cfm – Cubic feet per minute
cfs – Cubic feet per second
CFV – Coolant Flow Valve
CID – Cubic Inch Displacement
CKP – Crankshaft Position
CKP-H – Crankshaft Position High
CKP-L – Crankshaft Position Low
CKPO – Crankshaft Position Out
cm – Centimeter
CMP – Camshaft Position
CMP-H – Camshaft Position High
CMP-L – Camshaft Position Low
CMPO – Camshaft Position Out
CMV – Coolant Mixer Valve
CO – Carbon Monoxide
COO – Cruise On / Off switch
CPU – Central Processing Unit
CSFI – Cold Start Fuel Igniter
CSFS – Cold Start Fuel Solenoid
CSR – Cold Start Relay
CSS – Cold Start Solenoid
CTC – Coolant Temperature Compensation
Cyl – Cylinder
 8 ABBREVIATIONS AND ACRONYMS 1843

DB – Decibel
DC – Direct Current
DCA – Diesel Coolant Additive
DCU – Doser Control Unit
DDI – Digital Direct Fuel Injection
DDS – Driveline Disengagement Switch
DLC – Data Link Connector
DME – Dimethyl Ether
DMM – Digital Multimeter
DOC – Diesel Oxidation Catalyst
DOCIT – Diesel Oxidation Catalyst Inlet Temperature
DOCOT – Diesel Oxidation Catalyst Outlet Temperature
DPF – Diesel Particulate Filter
DPFDP – Diesel Particulate Filter Differential Pressure
DPFIT – Diesel Particulate Filter Inlet Temperature
DPFOT – Diesel Particulate Filter Outlet Temperature
DSI – Down Stream Injection
DT – Diesel Turbocharged
DTC – Diagnostic Trouble Code
DTCs – Diagnostic Trouble Codes
DTRM – Diesel Thermo Recirculation Module

EBP – Exhaust Back Pressure

EBPD – Exhaust Back Pressure Desired
EBPV – Exhaust Back Pressure Valve
ECB – Engine Compression Brake
ECB1 – Engine Compression Brake 1
ECB2 – Engine Compression Brake 2
ECB3 – Engine Compression Brake 3
ECBP – Engine Compression Brake Pressure
ECI – Engine Crank Inhibit
ECL – Engine Coolant Level
ECM – Engine Control Module
ECM GND – Engine Control Module Ground
ECM PWR – Engine Control Module Power
ECS – Engine Coolant System
ECSR – Engine Controlled Shutdown Request
ECT – Engine Coolant Temperature
ECT1 – Engine Coolant Temperature 1
ECT2 – Engine Coolant Temperature 2
EFAN – Engine Fan
EFANS – Engine Fan Speed
EFC – Engine Fan Control
EFP – Engine Fuel Pressure
EFRC – Engine Family Rating Code
EFS – Engine Fan Speed
EFT – Engine Fuel Temperature
EG – Ethylene Glycol
EGC – Electronic Gauge Cluster
EGBP – Exhaust Gas Back Pressure
EGDP – Exhaust Gas Differential Pressure
1844 8 ABBREVIATIONS AND ACRONYMS

EGR – Exhaust Gas Recirculation

EGRC – Exhaust Gas Recirculation Control
EGRH – Exhaust Gas Recirculation High control
EGRL – Exhaust Gas Recirculation Low control
EGROT – Exhaust Gas Recirculation Outlet Temperature
EGRP – Exhaust Gas Recirculation Position
EGRT – Exhaust Gas Recirculation Temperature
EGT – Exhaust Gas Temperature
EGT1 – Exhaust Gas Temperature 1
EGT2 – Exhaust Gas Temperature 2
EGT3 – Exhaust Gas Temperature 3
EIM – Engine Interface Module
ELS – Exhaust Lambda Sensor
EMI – Electromagnetic Interference
EMP – Exhaust Manifold Pressure
EMT – Exhaust Manifold Temperature
EOL – Engine Oil Level
EOP – Engine Oil Pressure
EOT – Engine Oil Temperature
EPA – Environmental Protection Agency
EPR – Engine Pressure Regulator
ESC – Electronic System Controller
ESN – Engine Serial Number
EST – Electronic Service Tool
ETC – Engine Throttle Control
ETC-H – Engine Throttle Control High
ETC-L – Engine Throttle Control Low
ETP – Engine Throttle Position
ETV – Engine Throttle Valve
ETV-H – Engine Throttle Valve High
ETV-L – Engine Throttle Valve Low
EVB – Exhaust Valve Brake
EWPS – Engine Warning Protection System

F – Fahrenheit
FCV – Fuel Coolant Valve
FDP – Fuel Delivery Pressure
FEL – Family Emissions Limit
fhp – Friction horsepower
FMI – Failure Mode Indicator
FPC – Fuel Pump Control
FPCV – Fuel Pressure Control Valve
fpm – Feet per minute
FPM – Fuel Pump Monitor
fps – Feet per second
FRP – Fuel Rail Pressure
ft – Feet
FVCV – Fuel Volume Control Valve

GND – Ground (electrical)

gal – Gallon
 8 ABBREVIATIONS AND ACRONYMS 1845

gal/h – U.S. Gallons per hour

gal/min – U.S. Gallons per minute
GCW – Gross Combined Weight
GCWR – Gross Combined Weight Rating
GPC – Glow Plug Control
GPD – Glow Plug Diagnostic
GPR – Glow Plug Relay
GVW – Gross Vehicle Weight

H2O – Water
HC – Hydrocarbons
HCI – Hydrocarbon Injection
HEST – High Exhaust System Temperature
HFCM – Horizontal Fuel Conditioning Module
Hg – Mercury
hp – Horsepower
HPCAC – High-Pressure Charge Air Cooler
HPCR – High-Pressure Common Rail
HPFP – High-Pressure Fuel Pump
hr – Hour
HS – Humidity Sensor
Hyd – Hydraulic

IAH – Intake Air Heater

IAHC – Intake Air Heater Control
IAHD – Intake Air Heater Diagnostic
IAHR – Intake Air Heater Relay
IAT – Intake Air Temperature
IC – Integrated Circuit
ICP – Injection Control Pressure
ICPR – Injection Control Pressure Regulator
ICG1 – Injector Control Group 1
ICG2 – Injector Control Group 2
ID – Inside Diameter
IDM – Injector Driver Module
IGN – Ignition
ILO – Injector Leak Off
IMP – Intake Manifold Pressure
IMT – Intake Manifold Temperature
in – Inch
inHg – Inch of mercury
inH2O – Inch of water
IAT – Inlet Air Temperature
INJs – Injectors
IPR – Injection Pressure Regulator
IPR PWR – Injection Pressure Regulator Power
ISC – Interstage Cooler
IST – Idle Shutdown Timer
ITP – Internal Transfer Pump
ITV – Intake Throttle Valve
ITV-H – Intake Throttle Valve High control
1846 8 ABBREVIATIONS AND ACRONYMS

ITV-L – Intake Throttle Valve Low control

ITVP – Intake Throttle Valve Position
IVS – Idle Validation Swtich

J1939-H – J1939 Data Link High

J1939-L – J1939 Data Link Low
JCT – Junction (electrical)

kg – Kilogram
km – Kilometer
km/h – Kilometers per hour
km/l – Kilometers per liter
KOEO – Key-On Engine-Off
KOER – Key-On Engine-Running
kPa – Kilopascal

L – Liter
L/h – Liters per hour
L/m – Liters per minute
L/s – Liters per second
lb – Pound
lb – Pounds of force
lb/s – Pounds per second
lb ft – Pounds of force per foot
lb in – Pounds of force per inch
lbm – Pounds of mass
LPCAC – Low-pressure Charge Air Cooler
LSD – Low Sulfur Diesel

m – Meter
m/s – Meters per second
MAF – Mass Air Flow
MAF GND – Mass Air Flow Ground
MAG – Magnetic
MAP – Manifold Absolute Pressure
MAP / IAT – Manifold Absolute Pressure / Intake Air Temperature
MAT – Manifold Air Temperature
mep – Mean effective pressure
mi – Mile
MIL – Malfunction Indicator Lamp
mm – Millimeter
mpg – Miles per gallon
mph – Miles per hour
MPR – Main Power Relay
MSDS – Material Safety Data Sheet
MSG – Micro Strain Gauge
MSM – Multiplex System Module
MY – Model Year

NC – Normally Closed (electrical)

NETS – Navistar® Electronics Technical Support
 8 ABBREVIATIONS AND ACRONYMS 1847

N·m – Newton meter

NO – Normally Open (electrical)
NOX – Nitrogen Oxides

O2S – Oxygen Sensor

O2SH – Oxygen Sensor Heater
OAT – Organic Acid Technology
OCC – Output Circuit Check
OCP – Overcrank Protection
OD – Outside Diameter
OL – Over Limit
ORH – Out-of-Range High
ORL – Out-of-Range Low
OSHA – Occupational Safety and Health Administration
OWL – Oil/Water Lamp

PID – Parameter Identifier

P/N – Part Number
PDOC – Pre-Diesel Oxidation Catalyst
ppm – Parts per million
PROM – Programmable Read Only Memory
psi – Pounds per square inch
psia – Pounds per square inch absolute
psig – Pounds per square inch gauge
pt – Pint
PTO – Power Takeoff
PWM – Pulse Width Modulate
PWR – Power (voltage)

qt – Quart

RAM – Random Access Memory

RAPP – Remote Accelerator Pedal Position
RAS – Resume / Accelerate Switch (speed control)
REPTO – Rear Engine Power Takeoff
RFI – Radio Frequency Interference
rev – Revolution
rpm – Revolutions per minute
RPRE – Remote Preset
RSE – Radiator Shutter Enable
RVAR – Remote Variable

SAE – Society of Automotive Engineers

SCA – Supplemental Cooling Additive
SCCS – Speed Control Command Switches
SCS – Speed Control Switch
SHD – Shield (electrical)
SID – Subsystem Identifier
SIG GND – Signal Ground
SIG GNDB – Signal Ground Body
SIG GNDC – Signal Ground Chassis
1848 8 ABBREVIATIONS AND ACRONYMS

SIG GNDE – Signal Ground Engine

S/N – Serial Number
SPEEDO – Speedometer
SPN – Suspect Parameter Number
SW – Switch (electrical)
SWBAT – Switch Battery
SYNC – Synchronization

TACH – Tachometer output signal

TBD – To Be Determined
TC2CIS – Turbocharger 2 Compressor Inlet Sensor
TC2CIT – Turbocharger 2 Compressor Inlet Temperature
TC1TOP – Turbocharger 1 Turbine Outlet Pressure
TC2TOP – Turbocharger 2 Turbine Outlet Pressure
TC2WC – Turbocharger 2 Wastegate Control
TCAPE – Truck Computer Analysis of Performance and Economy
TCM – Transmission Control Module
TDC – Top Dead Center
TDE – Transmission Driving Engaged
TOP – Transmission Oil Pressure
TOSS – Transmission Output Shaft Speed
TOT – Transmission Oil Temperature
TTS – Transmission Tailshaft Speed

ULSD – Ultra-Low Sulfur Diesel

UVC – Under Valve Cover

V – Volt
VBAT or B+ – Battery Voltage
VC – Volume Control
VEPS – Vehicle Electronics Programming System
VGT – Variable Geometry Turbo
VIGN – Ignition Voltage
VIN – Vehicle Identification Number
VOP – Valve Opening Pressure
VRE – Vehicle Retarder Enable
VREF – Reference Voltage
VREF1 – Reference Voltage Engine
VREF2 – Reference Voltage Chassis
VREF3 – Reference Voltage Chassis
VREF4 – Reference Voltage Aftertreatment
VSO – Vehicle Speed Output
VSO or VSS_CAL – Vehicle Speed Output
VSS – Vehicle Speed Sensor
VSS_CAL or VSO – Vehicle Speed Output
VSS-H – Vehicle Speed Sensor High
VSS-L – Vehicle Speed Sensor Low

WTSL – Wait to Start Lamp

WEL – Warn Engine Lamp
WIF – Water In Fuel
 8 ABBREVIATIONS AND ACRONYMS 1849

WIFL – Water In Fuel Lamp

WTEC – World Transmission Electronically Controlled automatic transmissions (Allison)

XCS – Transfercase
XMSN – Transmission
1850 8 ABBREVIATIONS AND ACRONYMS
 9 TERMINOLOGY 1851

Table of Contents

Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1853
1852 9 TERMINOLOGY
 9 TERMINOLOGY 1853

Terms
Accelerator Pedal Position (APP) sensor – A potentiometer sensor that indicates the position of the throttle
pedal.
Accessory work – The work per cycle required to drive engine accessories (normally, only those essential to
engine operation).
Actuator – A device that performs work in response to an input signal.
Actuator Control – The ECM controls the actuators by applying a low-level signal (low-side driver) or a high-level
signal (high side driver). When switched on, both drivers complete a ground or power circuit to an actuator.
Aeration – The entrainment of air or combustion gas in coolant, lubricant, or fuel.
Aftercooler – See Charge Air Cooler.
Aftertreatment (AFT) system – A part of the exhaust system that processes engine exhaust to meet emission
requirements and traps particulate matter (soot) to prevent it from leaving the tailpipe.
Aftertreatment Fuel Doser (AFTFD) – A part of the Downstream Injection (DSI) unit that sends pressurized
fuel to the Aftertreatment Fuel Injector (AFI) to inject fuel into the exhaust pipe.
Aftertreatment Fuel Inlet Sensor (AFTFIS) – A sensor that monitors fuel temperature in the DSI system and
provides constant feedback to the ECM.
Aftertreatment Fuel Pressure 2 Sensor (AFTP2) – A sensor that monitors fuel pressure in the DSI system
and provides constant feedback to the ECM.
Aftertreatment Fuel Shutoff Valve (AFTFSV) – A valve used to prevent fuel flow to the Aftertreatment Fuel
Injector (AFI), and prevents all uncontrolled fuel delivery for the Aftertreatment system during an AFTFD valve
malfunction.
Air Control Valve (ACV) – Contains the EBPV control port and the TC1TOP port. Although these components
are integral to the ACV, each circuit is controlled by the ECM. The ACV controls compressed air for each EBPV.
Ambient Air Temperature (AAT) sensor – A sensor that sends an ambient air temperature signal to the ECM.
Ambient temperature – The environmental air temperature in which a unit is operating. In general, the
temperature is measured in the shade (no solar radiation) and represents the air temperature for other engine
cooling performance measurement purposes. Air entering the radiator may or may not be the same ambient
due to possible heating from other sources or recirculation. (SAE J1004 SEP81)
American Trucking Association (ATA) Datalink – A serial datalink specified by the American Trucking
Association and the SAE.
Ampere (amp) – The standard unit for measuring the strength of an electrical current. The flow rate of a charge
in a conductor or conducting medium of one coulomb per second. (SAE J1213 NOV82)
Analog – A continuously variable voltage.
Analog to digital converter (A/D) – A device in the ECM that converts an analog signal to a digital signal.
Barometric Absolute Pressure (BAP) sensor – A sensor built into the ECM that provides barometric pressure
information to the ECM.
Boost pressure – 1. The pressure of the charge air leaving the turbocharger.
2. Inlet manifold pressure that is greater than atmospheric pressure. Obtained by turbocharging.
Bottom Dead Center (BDC) – The lowest position of the piston during the stroke.
1854 9 TERMINOLOGY

Brake Horsepower (bhp) – The power output from an engine, not the indicated horsepower. The power output
of an engine, sometimes-called flywheel horsepower, is less than the indicated horsepower by the amount of
friction horsepower consumed in the engine.
Brake Horsepower (bhp) net – Net brake horsepower is measured with all engine components. The power of
an engine when configured as a fully equipped engine. (SAE J1349 JUN90)
Brake On/Off (BOO) switch – A switch located on the brake pedal lever, that provides a brake pedal position
signal to the ECM.
Brake Pressure Switch (BPS) – A switch located in the brake pressure line that provides a brake pedal position
signal to the ECM.
Calibration – ECM programming strategy to solve engine performance equations and make decisions.
Calibration values are stored in ROM and put into the processor during programming to allow the engine to
operate within certain parameters.
Camshaft Position (CMP) sensor – A magnetic pickup sensor that provides the ECM with a camshaft speed
and position signal.
Carbon Monoxide (CO) – A colorless, odorless, highly poisonous gas that is formed by the incomplete
combustion of carbon burning diesel engine. It is present in the exhaust gases of diesel engines.
Catalyst – A substance that produces a chemical reaction without undergoing a chemical change itself.
Catalytic converter – An antipollution device in the exhaust system that contains a catalyst for chemically
converting some pollutants in the exhaust gases (carbon monoxide, unburned hydrocarbons, and oxides of
nitrogen) into harmless compounds.
Cavitation – A dynamic condition in a fluid system that forms gas-filled bubbles (cavities) in the fluid.
Cetane number – 1. The auto-ignition quality of diesel fuel.
2. A rating applied to diesel fuel similar to octane rating for gasoline.
3. A measure of how readily diesel fuel starts to burn (self-ignites) at high compression temperature.
Diesel fuel with a high cetane number self-ignites shortly after injection into the combustion chamber. Therefore,
it has a short ignition delay time. Diesel fuel with a low cetane number resists self-ignition. Therefore, it has a
longer ignition delay time.
Charge air – Dense, pressurized, heated air discharged from the turbocharger.
Charge Air Cooler (CAC) – A heat exchanger mounted in the charge air path between the turbocharger and
engine intake manifold. The charge air cooler reduces the charge air temperature by transferring heat from the
charge air to a cooling medium (usually air).
Charge Air Cooler Outlet Temperature (CACOT) sensor – A thermistor sensor that monitors the temperature
of charge air entering the intake air duct.
Closed crankcase – A crankcase ventilation that recycles crankcase gases through a breather, then back to
the clean air intake.
Closed loop operation – A system that uses sensors to provide feedback to the ECM. The ECM uses the
sensor input to continuously monitor variables and adjust actuators to match engine requirements.
Cloud point – The point when wax crystals occur in fuel, making fuel cloudy or hazy. Usually below -12°C
(10°F).
Cold cranking ampere rating (battery rating) – The sustained constant current (in amperes) needed to
produce a minimum terminal voltage under a load of 7.2 volts per battery after 30 seconds.
 9 TERMINOLOGY 1855

Cold Start Fuel Igniter (CSFI) – The CSFI heats the intake air by vaporizing and igniting fuel in the air inlet duct.
Cold Start Fuel Solenoid (CSFS) – As the engine is cranked, the ECM energizes the CSFS valve, introducing
fuel into the CSFI, which ignites and warms the air being drawn into the engine.
Cold Start Relay (CSR) – The CSR provides voltage to the CSFI, and is controlled by the ECM.
Controller Area Network (CAN) – A J1939 high-speed communication link.
Coolant – A fluid used to transport heat from one point to another.
Coolant Flow Valve (CFV) – The CFV is ECM controlled and redirects coolant through the fuel cooler, based
on EFT, when directed.
Coolant level switch – A switch sensor used to monitor coolant level.
Coolant Mixer Valve (CMV) – Controls coolant flow through the low-temperature radiator.
Continuous Monitor Test – An ECM function that continuously monitors the inputs and outputs to ensure that
readings are within set limits.
Crankcase – The housing that encloses the crankshaft, connecting rods, and allied parts.
Crankcase breather – A vent for the crankcase to release excess interior air pressure.
Crankcase Oil Separator Speed (CCOSS) sensor – The CCOSS sensor sends the ECM information about
the speed of the crankcase oil separator internal components.
Crankcase pressure – The force of air inside the crankcase against the crankcase housing.
Crankshaft Position (CKP) sensor – A magnetic pickup sensor that determines crankshaft position and speed.
Cruise Control Switches (CCS) – A set of switches used for cruise control, Power TakeOff (PTO), and remote
hand throttle system.
Current – The flow of electrons passing through a conductor. Measured in amperes.
Cylinder Balance – An ECM control strategy to even-out the power contributions of each power cylinder.
Damper – A device that reduces the amplitude of torsional vibration. (SAE J1479 JAN85)
Deaeration – The removal or purging of gases (air or combustion gas) entrained in coolant or lubricating oil.
Deaeration tank – A separate tank in the coolant system used for one or more of the following functions:
• Deaeration
• Coolant reservoir (fluid expansion and afterboil)
• Coolant retention
• Filling
• Fluid level indication (visible)
Diagnostic Trouble Code (DTC) – 2010 model year vehicles no longer utilize DTC identification by number.
DTCs are now identified using the Suspect Parameter Number (SPN) and Failure Mode Indicator (FMI) identifiers
only.
Diamond Logic Builder (DLB) – The diagnostics software for chassis related components and systems.
Diesel Oxidation Catalyst (DOC) – A DOC is part of the diesel exhaust Aftertreatment system. DOCs
are devices that use a chemical process to break down pollutants in the exhaust stream into less harmful
components. More specifically, DOCs utilize rare metals such as palladium and platinum to reduce hydrocarbon
based Soluble Organic Fraction (SOF) and carbon monoxide content of diesel exhaust by simple oxidation.
1856 9 TERMINOLOGY

The DOC can be used during an active regeneration to create higher exhaust temperatures, thereby reducing
soot in the DPF.
Diesel Oxidation Catalyst Inlet Temperature sensor (DOCIT) – A sensor that provides DOC inlet temperature
signal to the ECM.
Diesel Particulate Filter (DPF) – A diesel particulate filter, sometimes called a DPF, is a device designed to
remove diesel particulate matter or soot from the exhaust gas of a diesel engine.
Diesel Particulate Filter Differential Pressure (DPFDP) sensor – A sensor that measures pressure difference
between the inlet and outlet of the DPF and provides feedback to the ECM.
Diesel Particulate Filter Inlet Temperature sensor (DPFIT) – A sensor that provides DOC inlet temperature
signal to the ECM.
Diesel Particulate Filter Outlet Temperature sensor (DPFOT) – A sensor that provides DOC outlet
temperature signal to the ECM.
Digital Multimeter (DMM) – An electronic meter that uses a digital display to indicate a measured value.
Preferred for use on microprocessor systems because it has a very high internal impedance and will not load
down the circuit being measured.
Disable – A computer decision that deactivates a system and prevents operation of the system.
Displacement – The stroke of the piston multiplied by the area of the cylinder bore multiplied by the number of
cylinders in the engine.
Down Stream Injection (DSI) – The DSI system injects fuel into the exhaust system to increase temperature
of the exhaust gases, and is necessary for DPF regeneration.
Driver (high side) – A transistor within an electronic module that controls the power to an actuator circuit.
Driver (low side) – A transistor within an electronic module that controls the ground to an actuator circuit.
Dual Stage Turbocharger – An assembly of two turbochargers (low-pressure and high-pressure) in series to
provide a wide range of charge air pressures efficiently.
Duty cycle – A control signal that has a controlled on/off time measurement from 0 to 100%. Normally used to
control solenoids.
EGR Cooler – A cooler that allows heat to dissipate from the exhaust gasses before they enter the intake
manifold.
Engine Compression Brake (ECB) valve – The ECB valve controls pressure entering the brake oil gallery
from the high-pressure oil rail gallery. This activates the brake actuator pistons and opens the exhaust valves.
Engine Compression Brake 1 (ECB1) solenoid – The ECB1 solenoid controls pressure entering the brake oil
gallery from the high-pressure oil rail gallery.
Engine Compression Brake 2 (ECB2) solenoid – The ECB2 solenoid controls pressure entering the brake oil
gallery from the high-pressure oil rail gallery.
Engine Compression Brake Pressure (ECBP) sensor – A high-pressure sensor that provides a feedback
signal to the ECM indicating brake control pressure.
Engine Control Module (ECM) – An electronic processor that monitors and controls the engine.
Engine Coolant Level (ECL) sensor – A switch sensor that monitors coolant level.
Engine Coolant Temperature 1 (ECT1) sensor – A thermistor sensor that detects engine coolant temperature.
Engine Coolant Temperature 2 (ECT2) sensor – A thermistor sensor that detects engine coolant temperature.
 9 TERMINOLOGY 1857

Engine Fuel Temperature (EFT) sensor – A thermistor sensor that measures fuel temperature.
Engine lamp – An instrument panel lamp that comes on when DTCs are set. DTCs can be read as flash codes
(red and amber instrument panel lamps).
Engine OFF tests – Tests that are done with the ignition switch ON and the engine OFF.
Engine Oil Pressure (EOP) sensor – A variable capacitance sensor that measures oil pressure.
Engine Oil Temperature (EOT) sensor – A thermistor sensor that measures oil temperature.
Engine rating – Engine rating includes Rated hp and Rated rpm.
Engine RUNNING tests – Tests done with the engine running.
Engine Throttle Valve (ETV) and Engine Throttle Position Sensor – The ETV valve is used to control airflow
during a regeneration process of the aftertreatment system. The ETV valve is also used to ensure a smooth
engine shut down by restricting airflow to the engine at shut down.
Engine Warning Protection System (EWPS) – Safeguards the engine from undesirable operating conditions
to prevent engine damage and to prolong engine life.
Exhaust Back Pressure (EBP) – The pressure present in the exhaust system during the exhaust period.
Exhaust Back Pressure Valve (EBPV) – A valve that regulates back pressure in the exhaust system.
Exhaust Gas Recirculation (EGR) – A system used to recirculate a portion of the exhaust gases into the power
cylinder in order to reduce oxides of nitrogen.
Exhaust Gas Recirculation Temperature (EGRT) sensor – A thermistor sensor that detects the exhaust gas
temperature entering the EGR cooler.
Exhaust Gas Recirculation (EGR) valve – The EGRV controls the flow of exhaust gases to the intake manifold.
The EGRV is integrated with an EGR Position (EGRP) sensor.
Exhaust Gas Temperature (EGT) – The temperature of exhaust gases.
Exhaust manifold – Exhaust gases flow through the exhaust manifold to the turbocharger exhaust inlet and
are directed to the EGR cooler.
Exhaust Manifold Pressure (EMP) sensor – A variable capacitance sensor used to indicate air pressure in
the exhaust manifold.
Exhaust Manifold Temperature (EMT) sensor – A thermistor style sensor used to indicate air temperature in
the exhaust manifold.
Failure Mode Indicator (FMI) – Identifies the fault or condition effecting the individual component.
Fault detection/management – An alternate control strategy that reduces adverse effects that can be caused
by a system failure. If a sensor fails, the ECM substitutes a good sensor signal or assumed sensor value in its
place. A lit amber instrument panel lamp signals that the vehicle needs service.
Filter restriction – A blockage, usually from contaminants, that prevents the flow of fluid through a filter.
Flash code – See Diagnostic Trouble Code (DTC).
Fuel Cooler Control Valve – A valve used to redirect coolant through the fuel cooler.
Fuel Delivery Pressure (FDP) sensor – A variable capacitance sensor that monitors fuel pressure coming from
the fuel tank and sends a signal to the ECM.
Fuel inlet restriction – A blockage, usually from contaminants, that prevents the flow of fluid through the fuel
inlet line.
1858 9 TERMINOLOGY

Fuel pressure – The force fuel exerts on the fuel system as it is pumped through the fuel system.
Fuel Pressure Control Valve (FPCV) – The FPCV controls the fuel pressure to the fuel rails and is controlled
by the ECM. FPCV control depends on fuel pressure and fuel temperature.
Fuel Rail Pressure (FRP) – The amount of pressure in the fuel rail.
Fuel Rail Pressure (FRP) sensor – A variable capacitance sensor that monitors fuel pressure in the fuel rail
and sends a signal to the ECM.
Fuel strainer – A pre-filter in the fuel system that keeps larger contaminants from entering the fuel system.
Fuel Volume Control Valve (FVCV) – The FVCV regulates the volume of flow sent to the HPFP. The FVCV
allows a sufficient quantity of fuel to be delivered to the HPFP depending on engine load, speed, injector quantity,
fuel temperature, and number of injections per cycle.
Fully equipped engine – A fully equipped engine is an engine equipped with only those accessories necessary
to perform its intended service. A fully equipped engine does not include components that are used to power
auxiliary systems. If these components are integral with the engine or, for any reason are included on the test
engine, the power absorbed may be determined and added to the net brake power. (SAE J1995 JUN90)
Fusible link (fuse link) – A fusible link is a special section of low tension cable designed to open the circuit
when subjected to an extreme current overload. (SAE J1156 APR86)
Gradeability – The maximum percent grade, which the vehicle can transverse for a specified time at a specified
speed. The gradeability limit is the grade upon which the vehicle can just move forward. (SAE J227a)
Gross Combined Weight Rating (GCWR) – Maximum combined weight of towing vehicle (including
passengers and cargo) and the trailer. The GCWR indicates the maximum loaded weight that the vehicle is
allowed to tow.
Gross brake horsepower – The power of a complete basic engine, with air cleaner, without fan, and alternator,
and air compressor not charging.
H-Bridge Circuit – An H-Bridge (bipolar) circuit operates like putting a power source on one side of a motor and
connecting the other side of the motor to a ground. This turns the motor. By shifting the leads on the motor, it
will turn in the opposite direction.
Hall effect – The development of a transverse electric potential gradient in a current-carrying conductor or
semiconductor when a magnetic field is applied.
Hall effect sensor – Transducer that varies its output voltage in response to changes in a magnetic field.
Commonly used to time the speed of wheels and shafts.
High-pressure Fuel Pump (HPFP) assembly – The HPFP is a volumetric pump that supplies fuel at
high-pressure. The HPFP is mounted in the rear valley on the top of the engine and is driven by the camshaft.
High-pressure Piezo Common Rail (HPCR) – The HPFP pumps fuel through separate tubes to each fuel rail.
Each fuel rail has four fuel tubes, one for each injector, that maintain constant pressure from the high-pressure
pump to each injector.
High-speed digital inputs – Inputs to the ECM from a sensor that generates varying frequencies (engine speed
and vehicle speed sensors).
Horsepower (hp) – Horsepower is the unit of work done in a given period of time, equal to 33,000 pounds
multiplied by one foot per minute. 1hp = 33,000 lb x 1 ft /1 min.
Humidity Sensor (HS) – A sensor that measures the moisture content of filtered air entering the intake system.
Hydrocarbons – Organic compounds consisting of hydrogen and carbon (fuel and oil).
 9 TERMINOLOGY 1859

Hydrocarbon Injector – Injects fuel into the exhaust system to increase temperature of the exhaust gases.
Idle Shutdown Timer (IST) – An engine calibration that allows the ECM to shut down the engine during extended
engine idle times.
Injection Control Pressure (ICP) sensor – Provides a feedback signal to the ECM indicating injection control
pressure.
Injection Pressure Regulator (IPR) valve – A valve that is used to maintain desired injection control pressure.
Inlet Air Temperature (IAT) sensor – A thermistor sensor that monitors intake air temperature.
Intake Air Heater (IAH) – The IAH is primarily used to assist in starting the engine during cold weather. In
addition, it helps to reduce white smoke emissions by heating the incoming air.
Intake manifold – Engine component that evenly supplies air to each intake port in the cylinder head(s).
Intake Manifold Pressure (IMP) sensor – A variable capacitance sensor used to indicate air pressure in the
intake manifold.
Intake Manifold Temperature (IMT) sensor – A thermistor sensor used to indicate air temperature in the intake
manifold.
Internal Transfer Pump (ITP) – The ITP is part of the HPFP assembly and driven off the same shaft as the
HPFP assembly. The ITP supplies fuel at a slightly higher pressure and flow to the HPFP though the Fuel Volume
Control Valve (FVCV). The ITP also provides fuel for cooling and lubrication of the HPFP. Fuel is rerouted as
pump return flow through the HPFP cooling and lubrication valve. Pressure is maintained at the inlet of the
HPFP piston pump by an ITP regulator.
Interstage Cooler (ISC) – Uses cooled coolant to lower the charged air temperature that exits from the
turbocharger low-pressure compressor and enters the turbocharger high-pressure compressor.
Low speed digital inputs – Switched sensor inputs that generate an on/off (high/low) signal to the ECM. The
input to the ECM from the sensor could be from a high input source switch (usually 5 or 12 volts) or from a
grounding switch that grounds the signal from a current limiting resistor in the ECM that creates a low signal (0
volts).
Low temperature radiator thermostat – Coolant flow to the low temperature radiator is regulated by the low
temperature radiator thermostat.
Lubricity – Lubricity is the ability of a substance to reduce friction between solid surfaces in relative motion
under loaded conditions.
Lug (engine) – A condition when the engine is run at an overly low RPM for the load being applied.
Malfunction Indicator Lamp (MIL) – An indicator lamp in the Electronic Instrument Cluster that will illuminate
when a detected emissions fault occurs.
Manifold Absolute Pressure (MAP) – Boost pressure in the manifold that is a result of the turbocharger.
Manifold Absolute Pressure (MAP) sensor – A variable capacitance sensor that measures boost pressure.
Manometer – A double-leg liquid-column gauge, or a single inclined gauge, used to measure the difference
between two fluid pressures. Typically, a manometer records in inches of water.
Mass Air Flow – The intake airflow in an engine.
Mass Air Flow (MAF) sensor – The MAF sensor is used for closed loop control of the EGR valve and ITV. The
ECM monitors the MAF signal so that the ECM can control the EGR and intake throttle systems.
Magnehelic Gauge – A gauge that measures pressure in inches of water.
1860 9 TERMINOLOGY

Magnetic Pickup Sensor – A magnetic pickup sensor generates an alternating frequency that indicates speed.
Magnetic pickups have a two-wire connection for signal and ground. This sensor has a permanent magnetic
core surrounded by a wire coil. The signal frequency is generated by the rotation of the gear teeth that disturb
the magnetic field.
Metering unit valve assembly – The Metering unit valve assembly provides a metered amount of fuel to the
Aftertreatment Fuel Injector (AFI).
Microprocessor – An integrated circuit in a microcomputer that controls information flow.
Micro Strain Gauge (MSG) Sensor – A MSG sensor measures pressure. Pressure exerts force on a pressure
vessel that stretches and compresses to change resistance of strain gauges bonded to the surface of the
pressure vessel. Internal sensor electronics convert the changes in resistance to a ratiometric voltage output.
Nitrogen Oxides (NOx) – Nitrogen oxides form by a reaction between nitrogen and oxygen at high temperatures
and pressures in the combustion chamber.
Normally closed – Refers to a switch that remains closed when no control force is acting on it.
Normally open – Refers to a switch that remains open when no control force is acting on it.
Ohm (Ω) – The unit of electrical resistance. One ohm is the value of resistance through which a potential of one
volt will maintain a current of one ampere. (SAE J1213 NOV82)
On demand test – A self-test the technician initiates using the EST that is run from a program in the software.
Output Circuit Check (OCC) – An on-demand test done during an Engine OFF self-test to check the continuity
of selected actuators.
Output Shaft Speed (OSS) sensor – A sensor mounted to the rear of the transmission that supplies a vehicle
speed signal to the ECM. The ECM uses this signal to control PTO, road speed limiting, and cruise control.
Automatic transmissions use this signal for shift scheduling.
Oxides of Nitrogen (NOx) – Nitrogen oxides formed by a reaction between nitrogen and oxygen at high
temperatures.
Oxygen Sensor (O2S) – A sensor that monitors oxygen levels in the exhaust.
pH – A measure of the acidity or alkalinity of a solution.
Particulate matter – Particulate matter includes mostly burned particles of fuel and engine oil.
Piezometer – An instrument for measuring fluid pressure.
Power – Power is a measure of the rate at which work (force x distance) is done during a specific time. Compare
with Torque.
Power TakeOff (PTO) – Accessory output, usually from the transmission, used to power a hydraulic pump for
a special auxiliary feature (garbage packing, lift equipment, etc).
Pulse Width Modulation (PWM) – Succession of digital electrical pulses, rather than an analog signal. Efficient
method of providing power between fully on and fully off.
Radiator Shutter Enable (RSE) – A feature that uses various input signals to open or close radiator shutters
by energizing or de-energizing a solenoid that controls an air or hydraulic cylinder.
Random Access Memory (RAM) – Computer memory that stores information. Information can be written to and
read from RAM. Input information (current engine speed or temperature) can be stored in RAM to be compared
to values stored in Read Only Memory (ROM). All memory in RAM is lost when the ignition switch is turned off.
Rated gross horsepower – Engine gross horsepower at rated speed as declared by the manufacturer. (SAE
J1995 JUN90)
 9 TERMINOLOGY 1861

Rated horsepower – Maximum brake horsepower output of an engine as certified by the engine manufacturer.
The power of an engine when configured as a basic engine. (SAE J1995 JUN90)
Rated net horsepower – Engine net horsepower at rated speed as declared by the manufacturer. (SAE J1349
JUN90)
Rated speed – The speed, as determined by the manufacturer, at which the engine is rated. (SAE J1995
JUN90)
Rated torque – Maximum torque produced by an engine as certified by the manufacturer.
Ratiometric Voltage – In a Micro Strain Gauge (MSG) sensor, pressure to be measured exerts force on a
pressure vessel that stretches and compresses to change resistance of strain gauges bonded to the surface
of the pressure vessel. Internal sensor electronics convert the changes in resistance to a ratiometric voltage
output.
Reference voltage (VREF) – A 5 volt reference supplied by the ECM to operate the engine sensors.
Regeneration – Oxidation of accumulated soot (carbon-based particulates) in the Diesel Particulate Filter (DPF).
The soot is reduced to ash and stored in the PDF.
Remote Accelerator Pedal Position (RAPP) – A feature that allows the operator to set and maintain a constant
engine speed from outside the vehicle cab. This feature may also be known as Remote Engine Speed Control
(RESC). Control over engine speed is accomplished by using remote mounted switches to turn on the RESC
and select the desired engine speed.
Remote Engine Speed Control (RESC) – See Remote Accelerator Pedal Position.
Reserve capacity – Time in minutes that a fully charged battery can be discharged to 10.5 volts at 25 amperes.
Return Fuel System – The return fuel system moves unused fuel from the fuel injectors to the fuel cooler.
Excess fuel out of the FVCV and the FPCV mix with fuel from the fuel injectors on the way to the fuel cooler.
Navistar® Engine Diagnostics – Diagnostics software for engine related components and systems.
Signal Conditioner – The signal conditioner in the internal microprocessor converts analog signals to digital
signals, squares up sine wave signals, or amplifies low-intensity signals to a level that the ECM microprocessor
can process.
Signal ground – The common ground wire to the ECM for the sensors.
Speed Control Command Switches (SCCS) – A set of switches used for cruise control, Power TakeOff (PTO),
and remote hand throttle system.
Starter Motor Control (SMC) – An ECM function that prevents starter engagement while the engine is running
(above a set calibrated rpm), when the automatic transmission is in gear, or when the manual transmission
clutch pedal is not depressed.
Steady state condition – An engine operating at a constant speed and load and at stabilized temperatures and
pressures. (SAE J215 JAN80)
Strategy – A plan or set of operating instructions that the microprocessor follows for a desired goal. Strategy
is the computer program itself, including all equations and decision making logic. Strategy is always stored in
ROM and cannot be changed during calibration.
Stroke – The movement of the piston from Top Dead Center (TDC) to Bottom Dead Center (BDC).
Substrate – Material that supports the wash coating or catalytic materials.
1862 9 TERMINOLOGY

Suspect Parameter Number (SPN) – A 19-bit number used to identify the item for which diagnostics are being
reported. The SPN is used for multiple purposes, some that are specific to diagnostics are as follows;
• Identify the least repairable subsystem that has failed.
• Identify subsystems or assemblies that may not have hard failures but may be exhibiting abnormal operating
performance.
• Identify a particular event or condition that will be reported.
• Report a component and non-standard failure mode.
System restriction (air) – The static pressure differential that occurs at a given airflow from air entrance through
air exit in a system. Usually measured in inches (millimeters) of water. (SAE J1004 SEP81)
Tachometer output signal – Engine speed signal for remote tachometers.
Thermistor – A semiconductor device. A sensing element that changes resistance as the temperature changes.
Thermistor Sensor – Changes electrical resistance with changes in temperature. Resistance in the thermistor
decreases as temperature increases, and increases as temperature decreases. Thermistors work with a resistor
that limits current to form a voltage signal matched with a temperature value.
Thrust load – A thrust load pushes or reacts through a bearing in a direction parallel to the shaft.
Top Dead Center (TDC) – The uppermost position of the piston during the stroke.
Torque – A force having a twisting or turning effect. For a single force, the cross product of a vector from some
reference point to the point of application of the force within the force itself. Also known as moment of force or
rotation moment. Torque is a measure of the ability of an engine to do work.
Truck Computer Analysis of Performance and Economy (TCAPE) – A computer program that simulates the
performance and fuel economy of trucks.
Turbocharger – A turbine driven compressor mounted on the exhaust manifold. The turbocharger increases
the pressure, temperature and density of intake air to charge air.
Turbocharger 1 Turbine Outlet Pressure (TC1TOP) sensor – A variable capacitance sensor that monitors
exhaust back-pressure after the turbochargers.
Turbocharger 2 Compressor Inlet (TC2CIS) sensor – The TC2CIS sensor includes a thermistor sensor that
monitors the temperature of charge air entering the HP turbocharger. This sensor also monitors boost pressure
for the LP turbocharger.
Turbocharger 2 Compressor Inlet Temperature (TC2CIT) sensor – The TC2CIT sensor is a thermistor-based
sensor that monitors the temperature of charge air entering the HP turbocharger.
Turbocharger Outlet Temperature (TCOT) sensor – A sensor that provides a turbocharger outlet temperature
signal to the ECM.
Turbocharger 2 Wastegate Control (TC2WC) solenoid – Controls the turbocharger 2 wastegate by regulating
the amount of charge air pressure supplied to the wastegate actuator. The TC2WC solenoid is controlled by
signals from the ECM in response to engine speed, required fuel quantity, boost, exhaust back-pressure, and
altitude.
Variable capacitance sensor – A variable capacitance sensor measures pressure. The pressure forces a
ceramic material closer to a thin metal disc in the sensor, changing the capacitance of the sensor.
Vehicle Electronic System Programming System – The computer system used to program electronically
controlled vehicles.
Vehicle Retarder Enable/Engage – Output from the ECM to a vehicle retarder.
 9 TERMINOLOGY 1863

Vehicle Speed Output (VSO) – A vehicle speed signal sent to the EGC through the J1939 network.
Vehicle Speed Sensor (VSS) – Normally a magnetic pickup sensor mounted in the tailshaft housing of the
transmission, used to indicate ground speed.
Viscosity – The internal resistance to the flow of any fluid.
Viscous fan – A fan drive that is activated when a thermostat, sensing high air temperature, forces fluid through
a special coupling. The fluid activates the fan.
Volt (v) – A unit of electromotive force that will move a current of one ampere through a resistance of one Ohm.
Voltage – Electrical potential expressed in volts.
Voltage drop – Reduction in applied voltage from the current flowing through a circuit or portion of the circuit
current multiplied by resistance.
Voltage ignition – Voltage supplied by the ignition switch when the key is ON.
Washcoat – A layer of alumina applied to the substrate in a monolith-type converter.
Water In Fuel (WIF) sensor – A switch sensor that measures the amount of water in the fuel.
1864 9 TERMINOLOGY