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4374/0 UNDER PRESSURIZED DIESEL EXHAUST FLUID SYSTEM

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EPA07/10/GHG14 DDEC VI/10 Electronics and Troubleshooting Manual (DDC-SVC-MAN-0084) | 505 SPN 4374 (ACM) (GHG14) | 505.1 SPN 4374/FMI 0 – GHG14

Description This Code Sets When the Diesel Exhaust Fluid (DEF) Pump Speed is Higher than Normal For a Given DEF Pressure
Monitored Parameter DEF Pump Speed, DEF Pressure
Monitor Sequence None
Execution Frequency Continuous When Enabling Conditions Met
Typical Duration Continuous Until Resolved
Dash Lamps MIL, CEL
Engine Reaction Derate 25%
Verification SCR ADS Self-Check

Possible causes:

  • Restriction in the DEF line between the DEF tank and the DEF pump
  • Restriction in the DEF line between the DEF pump and the DEF dosing unit
  • Air in the DEF line between the DEF tank and the DEF pump
  • Restriction in the DEF pump
  • Failed DEF pump

Check as follows:

NOTICE:

Customers in colder climates where winter ambient air temperatures generally stay below -11° C (12°F) need to verify that the DEF is not frozen before troubleshooting this fault code.

    1. Connect DiagnosticLink® .

    1. Turn the ignition ON (key ON, engine OFF).

    1. Check for multiple codes. Are codes SPN 4334/FMI 3, 4, SPN 4375/FMI 3, 4, or SPN 3361/FMI 3, 4, 5 also present?
        1. Yes; diagnose and repair the other fault codes first. Verify repair.

      1. No; Go to step 4.

    1. Turn the ignition OFF.

    1. Inspect the DEF tank vent tube. Is there any blockage or restriction?
        1. Yes; clear the restricted vent tube. Go to step 6.

      1. No; Go to step 6.

    1. Using DEF test strip A0005850202, check for diesel fuel or oil contamination of the DEF fluid. Does the test strip indicate contamination?
        1. Yes; replace the following components and refill the system with new DEF:
          • DEF tank
          • DEF tank header
          • DEF supply line from the DEF tank to the DEF pump
          • DEF line from the DEF pump to the DEF dosing unit
          • DEF return line from the DEF dosing unit to the DEF tank
          • DEF pump
          • DEF dosing unit

      1. No; Go to step 7.

    1. Inspect the DEF line that runs from the DEF pump to the DEF dosing unit. Is the DEF line damaged, pinched, or kinked?
        1. Yes; replace the DEF line from the DEF pump to the DEF dosing unit.

      1. No; Go to step 8.

    1. Inspect the DEF line that runs from the DEF tank to the DEF pump. Is the DEF line damaged, pinched, or kinked?
        1. Yes; replace the DEF line from the DEF tank to the DEF pump.

      1. No; Go to step 9.

    1. Disconnect the DEF supply line at the dosing unit. Fill the graduated cylinder supplied in DEF test kit (P/N: W060589001900) with water. Place the end of the DEF line into the graduated cylinder as far as possible.
NOTE: Place the graduated cylinder in a secondary container to catch over flowing DEF fluid, making sure you still have clear sight of the end of the DEF line.

    1. Using DiagnosticLink, perform the Selective Catalyst Reduction Airless Dosing System (SCR ADS) Self-Check routine. When the service routine is running, visually inspect the DEF line for continuous air bubbles coming from the line and DEF flow.

    1. Were any bubbles coming from the DEF pump supply line indicating a crack in the DEF pump feed line?
        1. Yes; replace the DEF supply line from the DEF tank to the DEF pump. Verify repair.

      1. No; Go to step 12.
NOTICE:

The RS SUPPLY KIT contains all the necessary parts for steps 12-15.

    1. Using the DEF/Doser Kit , replace the DEF pump module filter. Go to step 13.

    1. Replace the DEF pump inlet screen. Go to step 14.

    1. Replace DEF Pressure Relief Valve (PRV).  Go to step 15.

    1. Replace DEF dosing unit inlet screen. Go to step 16.
NOTE: If air pressure is greater than 827 kPa (120 psi), use a pressure regulator.

    1. Prime pump with shop air. Using a rubber tipped air gun to seal around the DEF pump inlet fitting, apply clean regulated shop air to the DEF pump inlet fitting for three to five seconds.
      d140723a

    1. Connect all DEF lines and electrical connections. Go to step 18.

  1. Perform Selective Catalytic Reduction Airless Dosing System (SCR ADS) Self-Check Routine to prime the system. Did the SCR ADS test pass?
      1. Yes; clear the codes and release the vehicle.

    1. No; replace the DEF pump. 

3556/18 EPA10 DIESEL OXIDATION CATALYST OUTLET TEMPERATURE LOW

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EPA07/10/GHG14 DDEC VI/10 Electronics and Troubleshooting Manual (DDC-SVC-MAN-0084) | 372 SPN 3556 (ACM) (EPA10) | 372.2 SPN 3556/FMI 18 – EPA10

Description This code sets when the exhaust temperature does not increase above the modeled threshold when the low temp regeneration is enabled.
Monitored Parameter Diesel Oxidation Catalyst (DOC) outlet temperature sensor
Typical Enabling Conditions Low temperature regeneration enabled, 1100 to 2050 rpm, 50% to 100% engine load.
Monitor Sequence None
Execution Frequency Continuous When Enabling Conditions Met
Typical Duration 20 seconds
Dash Lamps MIL, CEL
Engine Reaction None
Verification Low Temp Regeneration

Check as follows:

    1. Connect DiagnosticLink® . Go to step 2.

    1. Turn the key ON (Key ON, Engine OFF). Go to step 3.

    1. Check for multiple codes. Are there DOC outlet temperature sensor stuck fault codes or DOC outlet temperature sensor circuit fault codes present?
        1. Yes; diagnose the other fault codes first. Verify repair.

      1. No; Go to step 4.

    1. Are there any Hydrocarbon (HC) doser low pressure fault codes present?
        1. Yes; diagnose HC doser low pressure fault codes first. Verify repair.

      1. No; Go to step 5.

    1. Perform the low temperature Aftertreatment Device (ATD) regeneration; Go to step 6.

    1. After the low temp ATD regeneration has run for 20 minutes, monitor the DOC outlet temperature sensor reading. Is the DOC outlet temperature sensor reading within 25°C (45°F) of the other exhaust temperature sensor readings?
        1. Yes; Go to step 7.

      1. No; replace the DOC outlet temperature sensor. Verify repair.

  1. Visually inspect the exhaust system for leaks. Are there exhaust leaks present?

      1. Yes; repair the exhaust leaks. Verify repair.

     

    1. No; replace the HC doser block. Verify repair.

5488/4 DIESEL EXHAUST FLUID LINE HEATER 5 CIRCUIT FAILED LOW

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GHG17 Heavy Duty Troubleshooting Manual (DDC-SVC-MAN-0191) | 347 SPN 5488 (ACM) (GHG17) | 347.2 SPN 5488/FMI 4 – GHG17

Description Line Heater 5 Circuit Failed Low
Monitored Parameter Line Heater 5 Circuit
Typical Enabling Conditions Always on
Monitor Sequence None
Execution Frequency Continuous when enabling conditions met
Typical Duration 2 Seconds
Dash Lamps MIL, CEL
Engine Reaction None
Verification Output Component Test

TROUBLESHOOTING:

  1. Turn the ignition OFF.
  2. Disconnect the line heater/Dosing Unit 8-pin connector.
  3. Inspect the sensor harness for bent, spread or corroded pins.
    1. If the pins are bent, spread or corroded, repair as necessary.
    2. If the connector shows no signs of damage, Go to step 4.
  4. Disconnect the ACM 120-pin connector.
  5. Measure the resistance between pin 3 on the harness side of the line heater 8-pin connector and ground.
    1. If the resistance is less than 10K ohms, repair the wire between pin 3 of the line heater 8-pin connector and pin 22 of the ACM 120-pin connector.
    2. If the resistance is greater than 10K ohms, replace the Dosing Unit.

DOSING UNIT

5016/3 EPA10 COOLANT VALVE SUPPLY VOLTAGE FAILED HIGH

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Description High Side Digital Output Circuit Shorted to Power
Monitored Parameter High Side Digital Output
Typical Enabling Conditions Always on
Monitor Sequence None
Execution Frequency Continuous when enabling conditions met
Typical Duration 2 Seconds
Dash Lamps MIL, CEL
Engine Reaction None
Verification Key Cycle

TROUBLESHOOTING:

  1. Check for multiple codes. Is fault code SPN 3216/FMI 13 or SPN 3490/FMI (any) present along with SPN 5016/FMI 3?
    1. Yes; repair the other fault code first.COOLANT VALVE DIAGRAM
  2. Turn the ignition OFF.
  3. Disconnect the Aftertreatment Control Module (ACM) 120-pin connector.
  4. Inspect the ACM 120-pin harness connector for bent, spread or corroded pins. Is any damage found?
    1. Yes; repair as necessary. Verify repair.
    2. No; Go to step 5.
  5. NOTE:  Multiple fault codes will set with the ACM 120-pin connector disconnected. Disregard other fault codes at this time.
  6. Turn the ignition ON (key ON, engine OFF) and clear fault codes. Does SPN 5016/FMI 3 become active?
    1. Yes; replace the ACM. Refer to OEM procedures.
    2. No; Go to step 6.
  7. Measure the voltage between pin 19 of the 120-pin ACM connector, harness side, and battery ground. Is any voltage present?
    1. Yes; repair the short to power between pin 19 of the 120-pin ACM connector and pin 2 of the DEF coolant valve connector. Verify repair.
    2. No; Go to step 7.
  8. Measure the voltage between pin 50 of the 120-pin ACM connector, harness side, and battery ground. Is any voltage present?
    1. Yes; repair the short to power between pin 50 of the 120-pin ACM connector and pin 1 of the NOx inlet sensor connector. Verify repair.
    2. No; Go to step 11.
  9. Is the vehicle equipped with a purge-in-process indicator?1. Yes; Go to step 9.
  10. Measure the voltage between pin 106 of the 120-pin ACM connector, harness side, and battery ground. Is any voltage present?
    1. Yes; repair the short to power between pin 106 of the 120-pin ACM connector and pin 2 of the DEF Purge-in-Process indicator. Verify repair.
    2. No; Go to step 10.
  11. NOTE:  ACM Pin 110 is not populated from the factory. The 120-pin ACM connector should be equipped with a cavity plug in the 120-pin connector cavity #110.
  12. Inspect connector cavity#110 of the 120-pin ACM connector, harness side. Is a wire populated in cavity #110?
    1. Yes; repair the short to power on pin 110 of the 120-pin ACM connector. Repair connector as needed. Verify repair.
    2. No; replace the ACM. Repair the connector as needed. Verify repair.
  13. Inspect connector cavity #106 of the 120-pin ACM connector, harness side. Is a wire populated in connector cavity #106?
    1. Yes; repair the short to power on pin 106 of the 120-pin ACM connector. Repair connector as needed. Verify repair.
    2. No; Go to step 12.
  14. Inspect connector cavity#110 of the 120-pin ACM connector, harness side. Is a wire populated in cavity #110?
    1. Yes; repair the short to power on pin 110 of the 120-pin ACM connector. Repair connector as needed. Verify repair.
    2. No; replace the ACM. Verify repair.

3480/2 EPA 07/10/GHG14 HYDROCARBON DOSER FUEL LINE PRESSURE LOW

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Hydrocarbon Doser Fuel Line Pressure Low SPN 3480/FMI 2

Description Hydrocarbon (HC) Doser Fuel Line Pressure Low

Monitored Parameter HC Doser Fuel Line Pressure

Typical Enabling Conditions Dosing Enabled

Execution Frequency Continuous When Enabling Conditions Met

Typical Duration One Minute

Dash Lamps MIL, CEL

Engine Reaction Derate 10%

Verification Parked Regeneration

TROUBLESHOOTING:

  1. Are there any fuel system faults present?
    1.     Yes; repair fault with the highest priority listed below. Verify repair. 3480/3, or 4 4077/3, or 4 3480/1, 4077/14
    2. No; Go to step 4.
  2. Start the engine.
  3. Using DiagnosticLink, perform two back-to-back “Purge Hydrocarbon Doser” service routines to help improve the chances of identifying a leak.
  4. Turn the ignition OFF.
  5. Visually inspect the fuel line between the HC doser block assembly and fuel doser injector valve for any sign of external fuel leaks. Are any external leaks present?
    1. 1. Yes; replace the HC doser injector valve fuel supply line. Go to step 8.
    2. No; replace the HC fuel doser injector valve. Refer to section “Removal of the Hydrocarbon Doser Fuel Injector Valve” . Go to step 8.
  6. Turn the ignition ON and start the engine.
  7. Clear fault codes.
  8. Perform a parked regeneration to verify the repair. Did SPN 3480/FMI 2 become active during regeneration?
    1.      Yes; replace doser block. Refer to section “Removal of the Hydrocarbon Doser Fuel Injector Valve” . Verify repair.
    2.    No; release vehicle.

Coolant in Oil

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NOTE:  Appearance of oil will be brown and have a milky-like state. Oil may be above recommended level as well.

  1. Pressurize the cooling system. Does the system hold pressure?
    1. Yes, the system holds pressure; Go to step 7.
    2. No; the system leaks down; Go to step 2.
  1. Remove the oil pan. Pressurize the cooling system. Where is coolant leaking from?
    1. Between the piston and liner; Go to step 3.
    2. Between the liner and block; Go to step 4.
    3. From the gear train or an oil return passage; Go to step 5.
    4. No coolant leaks are found present; Go to step 7.
  1. Remove the cylinder head and inspect for a failed cylinder kit. Was a failed cylinder kit found?
    1. Yes; replace lower end bearing kit, make necessary repairs, flush cooling system, and change engine oil.
    2. No; Go to step 4.
  1. Remove the cylinder liner where the leak was found. Was damage found?
    1. Yes; replace lower end bearing kit, make necessary repairs, flush cooling system, and change engine oil.
    2. No; Go to step 7.
  1. Pressure test the Oil Cooler. Were leaks found?
    1. Yes, leaks are found. Replace lower end bearing kit, make necessary repairs, flush cooling system, and change engine oil.
    2. No, leaks are not found; Go to step 6.
  1. Remove the cylinder head and inspect the cylinder head gasket for torn or debonded grommets.
    1. If damage is found, replace lower end bearing kit, make necessary repairs, flush cooling system, and change engine oil.
    2. If no damage is found, Go to step 7.
  1. Is fault code SPN 100/FMI 1 Low Engine Oil Pressure present?
    1. Yes; Inspect the Main and Connecting Rod Bearings.
    2. No; troubleshooting complete.