2017 International a26 Engine Diagnostic Manual

SCR - US, Canada, Mexico
2017 International® A26 Engine Diagnostic Manual

DIAGNOSTIC MANUAL
DIAGNOSTIC MANUAL
2017 International® A26 Engine Diagnostic Manual
0000876391
Navistar, Inc.
November 2019
Revision 21
2701 Navistar Drive, Lisle, IL 60532 USA
© 2019 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1915
Engine Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2283
Diagnostic Tools and Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2299
Engine Systems Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2303
Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2321
Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2331
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 International® A26
diesel engines.
Technical Service Literature

International® A26 Engine Operation and Maintenance Manual
International® A26 Engine Service Manual
International® A26 Engine and Aftertreatment Wiring Schematic 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
• Diagnostics Forms
• Engine Wiring Schematic Form
• Service Bulletins
DIAGNOSTIC MANUAL 3
Safety Information
This manual provides general and specific maintenance procedures essential for 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.
Disregard for Safety Instructions, Warnings, Cautions, and Notes in this manual can lead to injury, death or
damage to the engine, vehicle or property.
Safety Terminology
Three terms are used to stress your safety and safe operation of the vehicle and 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, vehicle or property.
Note: A note describes actions necessary for correct, efficient engine and vehicle diagnosis and repair.
Safety Instructions
Work Area
• Keep work area clean, dry, and organized.
• Keep tools and parts off the floor.
• Make sure work area is ventilated and well lit.
• Make sure a First Aid Kit is available.
Safety Equipment
• Use correct lifting devices.
• Use safety chocks 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
• Shift transmission to Park or Neutral, set parking brake, and install wheel chocks before diagnosing or
servicing vehicle.
4 DIAGNOSTIC MANUAL
• Clear area before starting engine.

Engine
• Engine should be operated and 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 with side protection.
• 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 electrical tools are properly grounded.
DIAGNOSTIC MANUAL 5
• Check for frayed power cords before using power tools.

Fluids Under Pressure
• Wear safety glasses or goggles with side protection.
• 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 vehicle when the engine is running.
Removal of Tools, Parts, and Equipment
• Reinstall all safety guards, shields, and covers after servicing the vehicle or 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 (DTC) List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
How To Use Symptom Based Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Operational Checkout Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

1.0 - Preliminary Vehicle Operational Checkout Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
2.0 - Engine Does Not Start Operational Checkout Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
3.0 - Engine Hard to Start Operational Checkout Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
4.0 - Engine Performance Problem Operational Checkout Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
5.0 - Cooling System Operational Checkout Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
6.0 - Engine Oil System Operational Checkout Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
7.0 - Fuel System Operational Checkout Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
8.0 - Engine Compression Brake Operational Checkout Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Engine Does Not Start Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

2.1 - Engine Cranks Fast, Slow or Does Not Crank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
2.2 - Engine Cranks But Does Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Engine Hard to Start Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

3.1 - Engine Hard to Start (Long Crank Time). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
3.2 - Engine Starts, Then Stalls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Engine Performance Problems Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

4.1 - Misfire / Rough Idle / Runs Rough. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
4.2 - Popping Noise from Intake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
4.3 - Low Power (Slow Acceleration). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
4.4 - Surge (Inconsistent Engine RPM During Steady State). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
4.5 - Turbocharger Noise / Whine / Whistle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Engine Coolant Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

5.1 - Coolant Overflow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
5.2 - Coolant Over Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
5.3 - Coolant Leak to Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
5.4 - Coolant Leak to Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Engine Lubrication Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

6.1 - Low Engine Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
6.2 - Oil Leak to Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Fuel System Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

7.1 - Metal in Fuel System / Noise from High-Pressure Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
7.2 - Fuel Gelling / Contamination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
7.3 - Fuel Leak to Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
7.4 - Fuel Leak to Exhaust. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
7.5 - Fuel Tanks Not Equalizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88
8 1 DIAGNOSTIC TROUBLESHOOTING PROCEDURES
Engine Brake Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

8.1 - Engine Compression Brake Inoperative. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
8.2 - Engine Compression Brake Engaged When Not Commanded. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Fault Code Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

Diagnostic Trouble Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Diagnostic Trouble Code (DTC) List

SPN FMI Condition Description
69 19 Two Speed Axle Switch : Received Network Data In Error (page 100)
70 19 Parking Brake Switch : Received Network Data In Error (page 101)
Wheel-Based Vehicle Speed : Data Valid But Above Normal Operational Range - Most Severe
84 0
Level (page 102)
Wheel-Based Vehicle Speed : Data Valid But Below Normal Operational Range - Most Severe Level
84 1
(page 108)
91 2 Accelerator Pedal Position 1 : Data Erratic, Intermittent Or Incorrect (page 114)
91 3 Accelerator Pedal Position 1: Voltage Above Normal, Or Shorted To High Source (page 123)
91 4 Accelerator Pedal Position 1 : Voltage Below Normal, Or Shorted To Low Source (page 127)
97 31 Water In Fuel Indicator 1 : Condition Exists (page 132)
98 3 Engine Oil Level : Voltage Above Normal, Or Shorted To High Source (page 134)
98 4 Engine Oil Level : Voltage Below Normal, Or Shorted To Low Source (page 138)
98 14 Engine Oil Level : Special Instructions (page 141)
98 17 Engine Oil Level : Data Valid But Below Normal Operating Range - Least Severe Level (page 142)
100 3 Engine Oil Pressure : Voltage Above Normal, Or Shorted To High Source (page 143)
100 4 Engine Oil Pressure : Voltage Below Normal, Or Shorted To Low Source (page 147)
100 14 Engine Oil Pressure : Special Instructions (page 152)
100 17 Engine Oil Pressure : Data Valid But Below Normal Operating Range - Least Severe Level (page 154)
Engine Intake Manifold #1 Pressure : Data Valid But Above Normal Operational Range - Most Severe
102 0
Level (page 156)
Engine Intake Manifold #1 Pressure : Data Valid But Below Normal Operational Range - Most Severe
102 1
Level (page 161)
102 2 Engine Intake Manifold #1 Pressure : Data Erratic, Intermittent Or Incorrect (page 165)
102 3 Engine Intake Manifold #1 Pressure : Voltage Above Normal, Or Shorted To High Source (page 171)
102 4 Engine Intake Manifold #1 Pressure : Voltage Below Normal, Or Shorted To Low Source (page 175)
102 10 Engine Intake Manifold #1 Pressure : Abnormal Rate Of Change (page 180)
Engine Intake Manifold #1 Pressure : Data Valid But Above Normal Operating Range - Moderately
102 16
Severe Level (page 184)
Engine Intake Manifold #1 Pressure : Data Valid But Below Normal Operating Range - Moderately
102 18
Engine Intake Manifold 1 Temperature : Data Valid But Above Normal Operational Range - Most
105 0
105 2 Engine Intake Manifold 1 Temperature : Data Erratic, Intermittent Or Incorrect (page 197)
105 3 Engine Intake Manifold 1 Temperature : Voltage Above Normal, Or Shorted To High Source (page 203)
105 4 Engine Intake Manifold 1 Temperature : Voltage Below Normal, Or Shorted To Low Source (page 209)
105 10 Engine Intake Manifold 1 Temperature : Abnormal Rate Of Change (page 211)

Engine Intake Manifold 1 Temperature : Data Valid But Below Normal Operating Range - Moderately
105 18
Barometric Pressure : Data Valid But Below Normal Operational Range - Most Severe Level (page
108 1
215)
108 2 Barometric Pressure : Data Erratic, Intermittent Or Incorrect (page 217)
108 3 Barometric Pressure : Voltage Above Normal, Or Shorted To High Source (page 219)
108 4 Barometric Pressure : Voltage Below Normal, Or Shorted To Low Source (page 221)
Engine Coolant Temperature : Data Valid But Above Normal Operational Range - Most Severe
110 0
Level (page 223)
110 2 Engine Coolant Temperature : Data Erratic, Intermittent Or Incorrect (page 225)
110 3 Engine Coolant Temperature : Voltage Above Normal, Or Shorted To High Source (page 230)
110 4 Engine Coolant Temperature : Voltage Below Normal, Or Shorted To Low Source (page 236)
110 10 Engine Coolant Temperature : Abnormal Rate Of Change (page 239)
110 14 Engine Coolant Temperature : Special Instructions (page 242)
Engine Coolant Temperature : Data Valid But Above Normal Operating Range - Least Severe Level
110 15
(page 244)
Engine Coolant Temperature : Data Valid But Above Normal Operating Range - Moderately Severe
110 16
Level (page 246)
Engine Coolant Temperature : Data Valid But Below Normal Operating Range - Moderately Severe
110 18
Level (page 247)
Engine Coolant Level 1 : Data Valid But Below Normal Operational Range - Most Severe Level
111 1
(page 249)
111 3 Engine Coolant Level 1 Circuit : Voltage Above Normal or Shorted to High Source (page 253)
111 4 Engine Coolant Level 1 Circuit : Voltage Below Normal or Shorted to Low Source (page 255)
Engine Intake Air Mass Flow Rate : Data Valid But Above Normal Operational Range - Most Severe
132 0
Level (page 257)
132 3 Engine Intake Air Mass Flow Rate : Voltage Above Normal, Or Shorted To High Source (page 263)
132 4 Engine Intake Air Mass Flow Rate : Voltage Below Normal, Or Shorted To Low Source (page 269)
132 13 Engine Intake Air Mass Flow Rate : Out Of Calibration (page 275)
Engine Intake Air Mass Flow Rate : Data Valid But Above Normal Operating Range - Moderately
132 16
Engine Intake Air Mass Flow Rate : Data Valid But Below Normal Operating Range - Moderately
132 18
132 20 Engine Intake Air Mass Flow Rate : Data Drifted High (page 283)
132 21 Engine Intake Air Mass Flow Rate : Data Drifted Low (page 285)
Engine Fuel 1 Injector Metering Rail 1 Pressure : Data Valid But Above Normal Operational Range -
157 0
Most Severe Level (page 288)
Engine Fuel 1 Injector Metering Rail 1 Pressure : Data Valid But Below Normal Operational Range -
157 1

Engine Fuel 1 Injector Metering Rail 1 Pressure : Voltage Above Normal, Or Shorted To High Source
157 3
(page 295)
Engine Fuel 1 Injector Metering Rail 1 Pressure : Voltage Below Normal, Or Shorted To Low Source
157 4
(page 302)
157 10 Engine Fuel 1 Injector Metering Rail 1 Pressure : Abnormal Rate Of Change (page 305)
Engine Fuel 1 Injector Metering Rail 1 Pressure : Data Valid But Above Normal Operating Range -
157 16
Moderately Severe Level (page 306)
Engine Fuel 1 Injector Metering Rail 1 Pressure : Data Valid But Below Normal Operating Range -
157 18
157 20 Engine Fuel 1 Injector Metering Rail 1 Pressure : Data Drifted High (page 312)
157 21 Engine Fuel 1 Injector Metering Rail 1 Pressure : Data Drifted Low (page 318)
Key Switch Battery Potential : Data Valid But Above Normal Operating Range - Moderately Severe
158 16
Level (page 321)
Key Switch Battery Potential : Data Valid But Below Normal Operating Range - Moderately Severe
158 18
Level (page 323)
Ambient Air Temperature : Data Valid But Above Normal Operational Range - Most Severe Level
171 0
(page 338)
171 2 Ambient Air Temperature : Data Erratic, Intermittent Or Incorrect (page 344)
171 3 Ambient Air Temperature : Voltage Above Normal, Or Shorted To High Source (page 348)
171 4 Ambient Air Temperature : Voltage Below Normal, Or Shorted To Low Source (page 354)
Engine Intake 1 Air Temperature : Data Valid But Above Normal Operational Range - Most Severe
172 0
Level (page 357)
172 2 Engine Intake 1 Air Temperature : Data Erratic, Intermittent Or Incorrect (page 359)
172 3 Engine Intake 1 Air Temperature : Voltage Above Normal, Or Shorted To High Source (page 364)
172 4 Engine Intake 1 Air Temperature : Voltage Below Normal, Or Shorted To Low Source (page 370)
Engine Exhaust Temperature : Data Valid But Above Normal Operational Range - Most Severe
173 0
Level (page 372)
173 2 Engine Exhaust Temperature : Data Erratic, Intermittent Or Incorrect (page 374)
173 3 Engine Exhaust Temperature : Voltage Above Normal, Or Shorted To High Source (page 379)
173 4 Engine Exhaust Temperature : Voltage Below Normal, Or Shorted To Low Source (page 385)
Engine Oil Temperature 1 : Data Valid But Above Normal Operational Range - Most Severe Level
175 0
(page 387)
175 2 Engine Oil Temperature 1 : Data Erratic, Intermittent Or Incorrect (page 389)
175 3 Engine Oil Temperature 1 : Voltage Above Normal, Or Shorted To High Source (page 394)
175 4 Engine Oil Temperature 1 : Voltage Below Normal, Or Shorted To Low Source (page 400)
175 14 Engine Oil Temperature 1 : Special Instructions (page 402)
Engine Oil Temperature 1 : Data Valid But Above Normal Operating Range - Least Severe Level
175 15
(page 404)
188 14 Engine Speed At Idle, Point 1 : Special Instructions (page 406)

Engine Speed At Idle, Point 1 : Data Valid But Above Normal Operating Range - Moderately Severe
188 16
Level (page 409)
Engine Speed At Idle, Point 1 : Data Valid But Below Normal Operating Range - Moderately Severe
188 18
Level (page 411)
191 2 Transmission Output Shaft Speed : Data Erratic, Intermittent Or Incorrect (page 413)
191 3 Transmission Output Shaft Speed : Voltage Above Normal, Or Shorted To High Source (page 419)
191 4 Transmission Output Shaft Speed : Voltage Below Normal, Or Shorted To Low Source (page 424)
191 19 Transmission Output Shaft Speed : Received Network Data In Error (page 430)
Engine Exhaust Gas Recirculation 1 Temperature : Data Valid But Above Normal Operational Range -
412 0
412 2 Engine Exhaust Gas Recirculation 1 Temperature : Data Erratic, Intermittent Or Incorrect (page 434)
Engine Exhaust Gas Recirculation 1 Temperature : Voltage Above Normal, Or Shorted To High
412 3
Source (page 440)
Engine Exhaust Gas Recirculation 1 Temperature : Voltage Below Normal, Or Shorted To Low Source
412 4
(page 446)
560 2 Transmission Driveline Engaged : Data Erratic, Intermittent Or Incorrect (page 448)
597 19 Brake Switch : Received Network Data In Error (page 449)
626 3 Engine Start Enable Device 1 : Voltage Above Normal, Or Shorted To High Source (page 450)
626 4 Engine Start Enable Device 1 : Voltage Below Normal, Or Shorted To Low Source (page 455)
626 5 Engine Start Enable Device 1 : Current Below Normal Or Open Circuit (page 460)
628 12 Program Memory : Bad Intelligent Device Or Component (page 464)
629 0 Controller #1 : Data Valid But Above Normal Operational Range - Most Severe Level (page 466)
629 2 Controller #1 : Data Erratic, Intermittent Or Incorrect (page 468)
629 8 Controller #1 : Abnormal Frequency Or Pulse Width Or Period (page 470)
629 12 Controller #1 : Bad Intelligent Device Or Component (page 472)
629 14 Controller #1 : Special Instructions (page 474)
629 15 Controller #1 : Data Valid But Above Normal Operating Range - Least Severe Level (page 476)
629 31 Controller #1 : Condition Exists (page 478)
Engine Fuel Actuator 1 Control Command : Voltage Above Normal, Or Shorted To High Source
633 3
(page 480)
Engine Fuel Actuator 1 Control Command : Voltage Below Normal, Or Shorted To Low Source
633 4
(page 484)
633 5 Engine Fuel Actuator 1 Control Command : Current Below Normal Or Open Circuit (page 488)
636 2 Engine Position Sensor : Data Erratic, Intermittent Or Incorrect (page 492)
636 8 Engine Position Sensor : Abnormal Frequency Or Pulse Width Or Period (page 499)
636 10 Engine Position Sensor : Abnormal Rate Of Change (page 506)
637 8 Engine Timing Sensor : Abnormal Frequency Or Pulse Width Or Period (page 513)

637 10 Engine Timing Sensor : Abnormal Rate Of Change (page 519)
639 14 J1939 Network #1, Primary Vehicle Network : Special Instructions (page 525)
639 19 J1939 Network #1, Primary Vehicle Network : Received Network Data In Error (page 544)
Engine Variable Geometry Turbocharger Actuator #1 : Data Erratic, Intermittent Or Incorrect (page
641 2
563)
Engine Variable Geometry Turbocharger Actuator #1 : Mechanical System Not Responding Or Out
641 7
Of Adjustment (page 569)
Engine Variable Geometry Turbocharger Actuator #1 : Bad Intelligent Device Or Component (page
641 12
572)
641 14 Engine Variable Geometry Turbocharger Actuator #1 : Special Instructions (page 575)
641 19 Engine Variable Geometry Turbocharger Actuator #1 : Received Network Data In Error (page 582)
651 3 Engine Fuel 1 Injector Cylinder 1 : Voltage Above Normal, Or Shorted To High Source (page 591)
651 4 Engine Fuel 1 Injector Cylinder 1 : Voltage Below Normal, Or Shorted To Low Source (page 598)
651 5 Engine Fuel 1 Injector Cylinder 1 : Current Below Normal Or Open Circuit (page 607)
651 13 Engine Fuel 1 Injector Cylinder 1 : Out Of Calibration (page 612)
Engine Fuel 1 Injector Cylinder 1 : Data Valid But Above Normal Operating Range - Moderately
651 16
Engine Fuel 1 Injector Cylinder 1 : Data Valid But Below Normal Operating Range - Moderately
651 18
652 16
652 18
653 16
653 18

654 16
654 18
655 16
655 18
656 3 Engine Fuel 1 Injector Cylinder 6: Voltage Above Normal, Or Shorted To High Source (page 725)
656 4 Engine Fuel 1 Injector Cylinder 6: Voltage Below Normal, Or Shorted To Low Source (page 732)
656 5 Engine Fuel 1 Injector Cylinder 6: Current Below Normal Or Open Circuit (page 741)
656 13 Engine Fuel 1 Injector Cylinder 6: Out Of Calibration (page 746)
Engine Fuel 1 Injector Cylinder 6: Data Valid But Above Normal Operating Range - Moderately
656 16
Engine Fuel 1 Injector Cylinder 6: Data Valid But Below Normal Operating Range - Moderately
656 18
724 2 O2 Sensor : Data Erratic, Intermittent Or Incorrect (page 752)
724 16 O2 Sensor : Data Valid But Above Normal Operating Range - Moderately Severe Level (page 754)
724 18 O2 Sensor : Data Valid But Below Normal Operating Range - Moderately Severe Level (page 756)
974 3 Remote Accelerator Pedal Position : Voltage Above Normal, Or Shorted To High Source (page 758)
974 4 Remote Accelerator Pedal Position : Voltage Below Normal, Or Shorted To Low Source (page 762)
974 19 Remote Accelerator Pedal Position : Received Network Data In Error (page 767)
1072 3 Engine Compression Brake Output #1 : Voltage Above Normal, Or Shorted To High Source (page 768)
1072 4 Engine Compression Brake Output #1 : Voltage Below Normal, Or Shorted To Low Source (page 770)
1072 5 Engine Compression Brake Output #1 : Current Below Normal Or Open Circuit (page 772)
1073 3 Engine Compression Brake Output #2 : Voltage Above Normal, Or Shorted To High Source (page 774)
1073 4 Engine Compression Brake Output #2 : Voltage Below Normal, Or Shorted To Low Source (page 776)
1073 5 Engine Compression Brake Output #2 : Current Below Normal Or Open Circuit (page 778)
1081 3 Engine Wait to Start Lamp : Voltage Above Normal, Or Shorted To High Source (page 780)
1081 4 Engine Wait to Start Lamp : Voltage Below Normal, Or Shorted To Low Source (page 784)
1081 5 Engine Wait to Start Lamp : Current Below Normal Or Open Circuit (page 788)
1110 31 Engine Protection System has Shutdown Engine : Condition Exists (page 793)

1135 3 Engine Oil Temperature 2 : Voltage Above Normal, Or Shorted To High Source (page 795)
1135 4 Engine Oil Temperature 2 : Voltage Below Normal, Or Shorted To Low Source (page 799)
Engine ECU Temperature : Data Valid But Above Normal Operational Range - Most Severe Level
1136 0
(page 802)
1136 3 Engine ECU Temperature : Voltage Above Normal, Or Shorted To High Source (page 803)
1136 4 Engine ECU Temperature : Voltage Below Normal, Or Shorted To Low Source (page 804)
1136 14 Engine ECU Temperature : Special Instructions (page 805)
Engine Exhaust Pressure 1 : Data Valid But Above Normal Operational Range - Most Severe Level
1209 0
(page 806)
Engine Exhaust Pressure 1 : Data Valid But Below Normal Operational Range - Most Severe Level
1209 1
(page 811)
1209 2 Engine Exhaust Pressure 1 : Data Erratic, Intermittent Or Incorrect (page 816)
1209 3 Engine Exhaust Pressure 1 : Voltage Above Normal, Or Shorted To High Source (page 821)
1209 4 Engine Exhaust Pressure 1 : Voltage Below Normal, Or Shorted To Low Source (page 825)
1244 5 Engine Fuel Actuator 2 Control Command : Current Below Normal Or Open Circuit (page 840)
1244 6 Engine Fuel Actuator 2 Control Command : Current Above Normal Or Grounded Circuit (page 844)
Engine Fuel Actuator 2 Control Command : Mechanical System Not Responding Or Out Of
1244 7
Adjustment (page 848)
1322 14 Engine Misfire for Multiple Cylinders : Special Instructions (page 852)
1322 31 Engine Misfire for Multiple Cylinders : Condition Exists (page 855)
1323 31 Engine Misfire Cylinder #1 : Condition Exists (page 858)
1378 31 Engine Oil Change Interval : Condition Exists (page 876)
Engine Protection Torque Derate : Data Valid But Above Normal Operational Range - Most Severe
1569 0
Level (page 877)
Engine Protection Torque Derate : Data Valid But Above Normal Operating Range - Least Severe
1569 15
Level (page 878)
Engine Protection Torque Derate : Data Valid But Above Normal Operating Range - Moderately
1569 16
1590 19 Adaptive Cruise Control Mode : Received Network Data In Error(page 881)
1659 14 Engine Coolant System Thermostat 1 : Special Instructions(page 883)
Engine Coolant System Thermostat 1 : Data Valid But Below Normal Operating Range - Moderately
1659 18

Aftertreatment 1 Diesel Exhaust Fluid Tank Volume : Data Valid But Below Normal Operational
1761 1
Range - Most Severe Level (page 888)
Aftertreatment 1 Diesel Exhaust Fluid Tank Volume : Voltage Above Normal, Or Shorted To High
1761 3
Source (page 890)
Aftertreatment 1 Diesel Exhaust Fluid Tank Volume : Voltage Below Normal, Or Shorted To Low
1761 4
Source (page 892)
1761 10 Aftertreatment 1 Diesel Exhaust Fluid Tank Volume : Abnormal Update Rate (page 894)
1761 12 Aftertreatment 1 Diesel Exhaust Fluid Tank Volume : Bad Intelligent Device Or Component (page 896)
1761 13 Aftertreatment 1 Diesel Exhaust Fluid Tank Volume : Out Of Calibration (page 898)
Aftertreatment 1 Diesel Exhaust Fluid Tank Volume : Data Valid But Below Normal Operating Range -
1761 17
Least Severe Level (page 900)
Aftertreatment 1 Diesel Exhaust Fluid Tank Volume : Data Valid But Below Normal Operating Range -
1761 18
1761 19 Aftertreatment 1 Diesel Exhaust Fluid Tank Volume : Received Network Data In Error (page 904)
2599 19 Fire Apparatus Pump Engagement : Received Network Data In Error (page 910)
2623 3 Accelerator Pedal #1 Channel 2 : Voltage Above Normal, Or Shorted To High Source (page 911)
2623 4 Accelerator Pedal #1 Channel 2 : Voltage Below Normal, Or Shorted To Low Source (page 915)
Engine Turbocharger 1 Compressor Outlet Temperature : Data Valid But Above Normal Operational
2629 0
Engine Turbocharger 1 Compressor Outlet Temperature : Data Erratic, Intermittent Or Incorrect
2629 2
(page 923)
Engine Turbocharger 1 Compressor Outlet Temperature : Voltage Above Normal, Or Shorted To
2629 3
High Source (page 929)
Engine Turbocharger 1 Compressor Outlet Temperature : Voltage Below Normal, Or Shorted To
2629 4
Low Source (page 935)
Engine Charge Air Cooler 1 Outlet Temperature : Data Valid But Above Normal Operational Range -
2630 0
2630 2 Engine Charge Air Cooler 1 Outlet Temperature : Data Erratic, Intermittent Or Incorrect (page 939)
Engine Charge Air Cooler 1 Outlet Temperature : Voltage Above Normal, Or Shorted To High Source
2630 3
(page 944)
Engine Charge Air Cooler 1 Outlet Temperature : Voltage Below Normal, Or Shorted To Low Source
2630 4
(page 950)
2634 3 Power Relay : Voltage Above Normal, Or Shorted To High Source (page 953)
2634 5 Power Relay : Current Below Normal Or Open Circuit (page 956)
2659 10 Engine Exhaust Gas Recirculation 1 Mass Flow Rate : Abnormal Update Rate (page 962)
Engine Exhaust Gas Recirculation 1 Mass Flow Rate : Data Valid But Above Normal Operating
2659 16
Range - Moderately Severe Level (page 966)
Engine Exhaust Gas Recirculation 1 Mass Flow Rate : Data Valid But Below Normal Operating
2659 18

Engine Exhaust Gas Recirculation 1 Valve 1 Control 1 : Data Erratic, Intermittent Or Incorrect
2791 2
(page 973)
Engine Exhaust Gas Recirculation 1 Valve 1 Control 1 : Voltage Above Normal, Or Shorted To
2791 3
High Source (page 975)
Engine Exhaust Gas Recirculation 1 Valve 1 Control 1 : Voltage Below Normal, Or Shorted To Low
2791 4
Source (page 979)
Engine Exhaust Gas Recirculation 1 Valve 1 Control 1 : Mechanical System Not Responding Or Out
2791 7
Engine Exhaust Gas Recirculation 1 Valve 1 Control 1 : Bad Intelligent Device Or Component
2791 12
(page 985)
2791 19 Engine Exhaust Gas Recirculation 1 Valve 1 Control 1 : Received Network Data In Error (page 987)
2797 11 Engine Fuel 1 Injector Group 1 : Root Cause Not Known (page 994)
2798 8 Engine Fuel 1 Injector Group 2 : Abnormal Frequency Or Pulse Width Or Period (page 1018)
2798 11 Engine Fuel 1 Injector Group 2 : Root Cause Not Known (page 1022)
Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature 1 : Data Erratic, Intermittent Or Incorrect
3031 2
(page 1046)
Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature 1 : Voltage Above Normal, Or Shorted
3031 3
To High Source (page 1048)
Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature 1 : Voltage Below Normal, Or Shorted
3031 4
To Low Source (page 1050)
3031 13 Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature 1 : Out Of Calibration (page 1052)
3031 20 Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature 1 : Data Drifted High (page 1054)
3061 31 Engine Cold Start Emission Reduction Strategy System Monitor : Condition Exists (page 1057)
3216 2 Aftertreatment 1 SCR Intake NOx 1 : Data Erratic, Intermittent Or Incorrect (page 1059)
3216 4 Aftertreatment 1 SCR Intake NOx 1 : Voltage Below Normal, Or Shorted To Low Source (page 1064)
3216 10 Aftertreatment 1 SCR Intake NOx 1 : Abnormal Rate Of Change (page 1066)
3216 13 Aftertreatment 1 SCR Intake NOx 1 : Out Of Calibration (page 1068)
Aftertreatment 1 SCR Intake NOx 1 : Data Valid But Above Normal Operating Range - Moderately
3216 16
Aftertreatment 1 SCR Intake NOx 1 : Data Valid But Below Normal Operating Range - Moderately
3216 18
Severe (page 1072)
3216 19 Aftertreatment 1 SCR Intake NOx 1 : Received Network Data In Error (page 1074)
3217 2 Aftertreatment 1 Intake Percent Oxygen 1 : Data Erratic, Intermittent Or Incorrect (page 1084)
Aftertreatment 1 Intake Gas Sensor 1 Power In Range : Data Erratic, Intermittent Or Incorrect (page
3218 2
1086)
3226 2 Aftertreatment 1 Outlet NOx 1 : Data Erratic, Intermittent Or Incorrect (page 1091)
3226 4 Aftertreatment 1 Outlet NOx 1 : Voltage Below Normal, Or Shorted To Low Source (page 1096)
3226 10 Aftertreatment 1 Outlet NOx 1 : Abnormal Rate Of Change (page 1098)
3226 11 Aftertreatment 1 Outlet NOx 1 : Root Cause Not Known (page 1100)

3226 13 Aftertreatment 1 Outlet NOx 1 : Out Of Calibration (page 1102)
Aftertreatment 1 Outlet NOx 1 - Data Valid But Above Normal Operating Range - Moderately Severe
3226 16
Level (page 1104)
Aftertreatment 1 Outlet NOx 1 : Data Valid But Below Normal Operating Range - Moderately Severe
3226 18
Level (page 1106)
3226 19 Aftertreatment 1 Outlet NOx 1 : Received Network Data In Error (page 1108)
Aftertreatment 1 Outlet Gas Sensor 1 Power In Range : Data Erratic, Intermittent Or Incorrect (page
3228 2
1117)
Aftertreatment 1 Diesel Particulate Filter Intake Temperature : Data Valid But Above Normal
3242 0
Operational Range - Most Severe Level (page 1122)
Aftertreatment 1 Diesel Particulate Filter Intake Temperature : Data Erratic, Intermittent Or Incorrect
3242 2
(page 1126)
Aftertreatment 1 Diesel Particulate Filter Intake Temperature : Voltage Above Normal, Or Shorted
3242 3
Aftertreatment 1 Diesel Particulate Filter Intake Temperature : Voltage Below Normal, Or Shorted
3242 4
Aftertreatment 1 Diesel Particulate Filter Intake Temperature : Bad Intelligent Device Or Component
3242 12
(page 1132)
Aftertreatment 1 Diesel Particulate Filter Intake Temperature : Data Valid But Above Normal Operating
3242 15
Range - Least Severe Level (page 1133)
Aftertreatment 1 Diesel Particulate Filter Intake Temperature : Data Valid But Above Normal Operating
3242 16
Aftertreatment 1 Diesel Particulate Filter Intake Temperature : Data Valid But Below Normal Operating
3242 18
3242 20 Aftertreatment 1 Diesel Particulate Filter Intake Temperature : Data Drifted High (page 1144)
3242 21 Aftertreatment 1 Diesel Particulate Filter Intake Temperature : Data Drifted Low (page 1146)
Aftertreatment 1 Diesel Particulate Filter Outlet Temperature : Data Valid But Above Normal
3246 0
Aftertreatment 1 Diesel Particulate Filter Outlet Temperature : Data Erratic, Intermittent Or Incorrect
3246 2
(page 1152)
Aftertreatment 1 Diesel Particulate Filter Outlet Temperature : Voltage Above Normal, Or Shorted
3246 3
Aftertreatment 1 Diesel Particulate Filter Outlet Temperature : Voltage Below Normal, Or Shorted
3246 4
Aftertreatment 1 Diesel Particulate Filter Outlet Temperature : Bad Intelligent Device Or Component
3246 12
(page 1157)
Aftertreatment 1 Diesel Particulate Filter Outlet Temperature : Data Valid But Above Normal Operating
3246 15
Range - Least Severe Level (page 1159)
Aftertreatment 1 Diesel Particulate Filter Outlet Temperature : Data Valid But Above Normal Operating
3246 16

Aftertreatment 1 Diesel Particulate Filter Outlet Temperature : Data Valid But Below Normal Operating
3246 18
3246 20 Aftertreatment 1 Diesel Particulate Filter Outlet Temperature : Data Drifted High (page 1170)
3246 21 Aftertreatment 1 Diesel Particulate Filter Outlet Temperature : Data Drifted Low (page 1172)
Aftertreatment 1 Diesel Particulate Filter Differential Pressure : Data Valid But Above Normal
3251 0
Aftertreatment 1 Diesel Particulate Filter Differential Pressure : Data Erratic, Intermittent Or Incorrect
3251 2
(page 1178)
Aftertreatment 1 Diesel Particulate Filter Differential Pressure : Voltage Above Normal, Or Shorted
3251 3
Aftertreatment 1 Diesel Particulate Filter Differential Pressure : Voltage Below Normal, Or Shorted
3251 4
3251 15
Operating Range - Least Severe Level (page 1193)
3251 16
Operating Range - Moderately Severe Level (page 1197)
3362 31 Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit 1 Input Lines : Condition Exists (page 1201)
Aftertreatment 1 Diesel Exhaust Fluid Tank Heater : Voltage Above Normal, Or Shorted To High
3363 3
Source (page 1213)
Aftertreatment 1 Diesel Exhaust Fluid Tank Heater : Voltage Below Normal, Or Shorted To Low
3363 4
Source (page 1218)
Aftertreatment 1 Diesel Exhaust Fluid Tank Heater : Data Valid But Above Normal Operating Range -
3363 16
Aftertreatment 1 Diesel Exhaust Fluid Tank Heater : Data Valid But Below Normal Operating Range -
3363 17
Aftertreatment 1 Diesel Exhaust Fluid Tank Heater : Data Valid But Below Normal Operating Range -
3363 18
3364 13 Aftertreatment 1 Diesel Exhaust Fluid Tank Quality : Out Of Calibration (page 1233)
3480 2 Aftertreatment 1 Fuel Pressure 1 : Data Erratic, Intermittent Or Incorrect (page 1235)
3480 3 Aftertreatment 1 Fuel Pressure 1 : Voltage Above Normal, Or Shorted To High Source (page 1237)
3480 4 Aftertreatment 1 Fuel Pressure 1 : Voltage Below Normal, Or Shorted To Low Source (page 1240)
Aftertreatment 1 Fuel Pressure 1 : Data Valid But Below Normal Operating Range - Least Severe
3480 17
Level (page 1245)
3480 20 Aftertreatment 1 Fuel Pressure 1 : Data Drifted High (page 1247)
3482 2 Aftertreatment 1 Fuel Enable Actuator : Data Erratic, Intermittent Or Incorrect (page 1250)
Aftertreatment 1 Fuel Enable Actuator : Voltage Above Normal, Or Shorted To High Source (page
3482 3
1253)
3482 4 Aftertreatment 1 Fuel Enable Actuator : Voltage Below Normal, Or Shorted To Low Source (page 1259)
Aftertreatment 1 Fuel Enable Actuator : Mechanical System Not Responding Or Out Of Adjustment
3482 7
(page 1262)

Aftertreatment 1 Fuel Enable Actuator : Data Valid But Above Normal Operating Range - Moderately
3482 16
3490 3 Aftertreatment 1 Purge Air Actuator : Voltage Above Normal, Or Shorted To High Source (page 1266)
3490 4 Aftertreatment 1 Purge Air Actuator : Voltage Below Normal, Or Shorted To Low Source (page 1272)
Aftertreatment 1 Purge Air Actuator : Mechanical System Not Responding Or Out Of Adjustment
3490 7
(page 1275)
3509 3 Sensor Supply Voltage 1 : Voltage Above Normal, Or Shorted To High Source (page 1277)
3509 4 Sensor Supply Voltage 1 : Voltage Below Normal, Or Shorted To Low Source (page 1280)
3509 6 Sensor Supply Voltage 1 : Current Above Normal Or Grounded Circuit (page 1283)
3509 14 Sensor Supply Voltage 1 : Special Instructions (page 1286)
3512 14 Sensor Supply Voltage 4: Special Instructions (page 1364)
Aftertreatment 1 Diesel Exhaust Fluid Temperature 2 : Voltage Above Normal, Or Shorted To High
3515 3
Source (page 1373)
Aftertreatment 1 Diesel Exhaust Fluid Temperature 2 : Voltage Below Normal, Or Shorted To Low
3515 4
Source (page 1375)
3515 10 Aftertreatment 1 Diesel Exhaust Fluid Temperature 2 : Abnormal Rate Of Change (page 1377)
3515 20 Aftertreatment 1 Diesel Exhaust Fluid Temperature 2 : Data Drifted High (page 1379)
Aftertreatment 1 Diesel Exhaust Fluid Concentration : Data Erratic, Intermittent Or Incorrect (page
3516 2
1381)
Aftertreatment 1 Diesel Exhaust Fluid Concentration : Voltage Above Normal, Or Shorted To High
3516 3
Source (page 1383)
Aftertreatment 1 Diesel Exhaust Fluid Concentration : Voltage Below Normal, Or Shorted To Low
3516 4
Source (page 1385)
3516 10 Aftertreatment 1 Diesel Exhaust Fluid Concentration : Abnormal Rate Of Change (page 1387)
Aftertreatment 1 Diesel Exhaust Fluid Concentration : Bad Intelligent Device Or Component (page
3516 12
1390)

Aftertreatment 1 Diesel Exhaust Fluid Concentration : Data Valid But Above Normal Operating Range
3516 15
- Least Severe Level (page 1392)
3516 19 Aftertreatment 1 Diesel Exhaust Fluid Concentration : Received Network Data In Error (page 1394)
3521 14 Aftertreatment 1 Diesel Exhaust Fluid Property : Special Instructions (page 1399)
3556 2 Aftertreatment 1 Hydrocarbon Doser 1 : Data Erratic, Intermittent Or Incorrect (page 1401)
3556 5 Aftertreatment 1 Hydrocarbon Doser 1 : Current Below Normal Or Open Circuit (page 1403)
Aftertreatment 1 Hydrocarbon Doser 1 : Data Valid But Below Normal Operating Range - Moderately
3556 18
ECU Power Output Supply Voltage #1 : Voltage Above Normal, Or Shorted To High Source (page
3597 3
1417)
3597 4 ECU Power Output Supply Voltage #1 : Voltage Below Normal, Or Shorted To Low Source (page 1422)
3598 3
1427)
3598 4
1431)
3599 3
1434)
Aftertreatment 1 Diesel Particulate Filter Outlet Pressure : Data Erratic, Intermittent Or Incorrect
3610 2
(page 1449)
Aftertreatment 1 Diesel Particulate Filter Outlet Pressure : Voltage Above Normal, Or Shorted To High
3610 3
Source (page 1455)
Aftertreatment 1 Diesel Particulate Filter Outlet Pressure : Voltage Below Normal, Or Shorted To Low
3610 4
Source (page 1460)
3610 10 Aftertreatment 1 Diesel Particulate Filter Outlet Pressure : Abnormal Rate Of Change (page 1465)
Aftertreatment 1 Diesel Particulate Filter Outlet Pressure : Data Valid But Above Normal Operating
3610 16
3695 2 Aftertreatment Regeneration Inhibit Switch : Data Erratic, Intermittent Or Incorrect (page 1474)
Diesel Particulate Filter Active Regeneration Inhibited Due to Inhibit Switch : Condition Exists (page
3703 31
1476)
Diesel Particulate Filter Active Regeneration Inhibited Due to System Timeout : Condition Exists
3713 31
(page 1477)
Aftertreatment 1 Diesel Particulate Filter Conditions Not Met for Active Regeneration : Condition
3750 31
Exists (page 1478)
3936 14 Aftertreatment Diesel Particulate Filter System : Special Instructions (page 1480)
Aftertreatment Diesel Particulate Filter System : Data Valid But Above Normal Operating Range -
3936 15
Aftertreatment Diesel Particulate Filter System : Data Valid But Above Normal Operating Range -
3936 16
4094 31 NOx limits exceeded due to Insufficient Diesel Exhaust Fluid Quality : Condition Exists (page 1489)

Engine Fuel Filter Water Level sensor : Voltage Above Normal, Or Shorted To High Source (page
4192 3
1491)
4192 4 Engine Fuel Filter Water Level sensor : Voltage Below Normal, Or Shorted To Low Source (page 1495)
Engine Crankcase Breather Oil Separator : Data Valid But Below Normal Operational Range - Most
4227 1
Engine Crankcase Breather Oil Separator : Abnormal Frequency Or Pulse Width Or Period (page
4227 8
1504)
Engine Variable Geometry Turbocharger Actuator 1 Temperature : Data Valid But Above Normal
4228 0
4228 14 Engine Variable Geometry Turbocharger Actuator 1 Temperature : Special Instructions (page 1512)
Engine Variable Geometry Turbocharger Actuator 1 Temperature : Data Valid But Above Normal
4228 15
Aftertreatment 1 Diesel Exhaust Fluid Actual Dosing Quantity : Data Valid But Above Normal
4331 16
Aftertreatment 1 Diesel Exhaust Fluid Actual Dosing Quantity : Data Valid But Below Normal
4331 18
Aftertreatment 1 Diesel Exhaust Fluid Doser 1 Absolute Pressure : Data Erratic, Intermittent Or
4334 2
Incorrect (page 1530)
Aftertreatment 1 Diesel Exhaust Fluid Doser 1 Absolute Pressure : Voltage Above Normal, Or
4334 3
Shorted To High Source (page 1533)
Aftertreatment 1 Diesel Exhaust Fluid Doser 1 Absolute Pressure : Voltage Below Normal, Or Shorted
4334 4
Aftertreatment 1 Diesel Exhaust Fluid Doser 1 Absolute Pressure : Mechanical System Not
4334 7
Responding Or Out Of Adjustment (page 1543)
Aftertreatment 1 Diesel Exhaust Fluid Doser 1 Absolute Pressure : Data Valid But Above Normal
4334 15
Aftertreatment 1 Diesel Exhaust Fluid Doser 1 Absolute Pressure : Data Valid But Above Normal
4334 16
Aftertreatment 1 Diesel Exhaust Fluid Doser 1 Absolute Pressure : Data Valid But Below Normal
4334 18
4334 20 Aftertreatment 1 Diesel Exhaust Fluid Doser 1 Absolute Pressure : Data Drifted High (page 1553)
Aftertreatment 1 Diesel Exhaust Fluid Line Heater 1 State : Voltage Above Normal, Or Shorted
4340 3
Aftertreatment 1 Diesel Exhaust Fluid Line Heater 1 State : Voltage Below Normal, Or Shorted
4340 4
4342 3
4342 4
4344 3

4344 4
4360 2 Aftertreatment 1 SCR Intake Temperature : Data Erratic, Intermittent Or Incorrect (page 1597)
4360 14 Aftertreatment 1 SCR Intake Temperature : Special Instructions (page 1599)
Aftertreatment 1 SCR Outlet Temperature : Data Valid But Above Normal Operational Range - Most
4363 0
4363 2 Aftertreatment 1 SCR Outlet Temperature : Data Erratic, Intermittent Or Incorrect (page 1607)
Aftertreatment 1 SCR Outlet Temperature : Voltage Above Normal, Or Shorted To High Source
4363 3
(page 1609)
Aftertreatment 1 SCR Outlet Temperature : Voltage Below Normal, Or Shorted To Low Source (page
4363 4
1611)
Aftertreatment 1 SCR Outlet Temperature : Data Valid But Above Normal Operating Range -
4363 16
4363 20 Aftertreatment 1 SCR Outlet Temperature : Data Drifted High (page 1617)
4363 21 Aftertreatment 1 SCR Outlet Temperature : Data Drifted Low (page 1620)
Aftertreatment 1 SCR Conversion Efficiency : Data Valid But Below Normal Operating Range -
4364 18
Aftertreatment 1 Diesel Exhaust Fluid Pump Drive Percentage : Data Erratic, Intermittent Or Incorrect
4375 2
(page 1625)
Engine Exhaust Gas Recirculation 1 Cooler Efficiency : Data Valid But Below Normal Operating
4752 18
Aftertreatment 1 Diesel Oxidation Catalyst Intake Temperature : Data Erratic, Intermittent Or Incorrect
4765 2
(page 1639)
Aftertreatment 1 Diesel Oxidation Catalyst Intake Temperature : Voltage Above Normal, Or Shorted
4765 3
Aftertreatment 1 Diesel Oxidation Catalyst Intake Temperature : Voltage Below Normal, Or Shorted
4765 4
Aftertreatment 1 Diesel Oxidation Catalyst Intake Temperature : Bad Intelligent Device Or Component
4765 12
(page 1646)
Aftertreatment 1 Diesel Oxidation Catalyst Intake Temperature : Data Valid But Above Normal
4765 16
Aftertreatment 1 Diesel Oxidation Catalyst Intake Temperature : Data Valid But Below Normal
4765 18
4765 20 Aftertreatment 1 Diesel Oxidation Catalyst Intake Temperature : Data Drifted High (page 1655)
4765 21 Aftertreatment 1 Diesel Oxidation Catalyst Intake Temperature : Data Drifted Low (page 1657)
4792 10 Aftertreatment 1 SCR System : Abnormal Rate Of Change (page 1659)
4795 31 Aftertreatment 1 Diesel Particulate Filter Missing : Condition Exists (page 1662)
5016 3
1665)

5024 10 Aftertreatment 1 Intake NOx Sensor Heater Ratio : Abnormal Rate Of Change (page 1673)
5031 10 Aftertreatment 1 Outlet NOx Sensor Heater Ratio : Abnormal Rate Of Change (page 1678)
Aftertreatment SCR Operator Inducement Severity : Data Valid But Above Normal Operational Range
5246 0
- Most Severe Level (page 1683)
Aftertreatment SCR Operator Inducement Severity : Data Valid But Above Normal Operating Range -
5246 15
Aftertreatment SCR Operator Inducement Severity : Data Valid But Above Normal Operating Range -
5246 16
Engine Charge Air Cooler 1 Efficiency : Data Valid But Below Normal Operating Range - Moderately
5285 18
Aftertreatment 1 Diesel Oxidation Catalyst Conversion Efficiency : Data Valid But Below Normal
5298 18
5319 31 Aftertreatment 1 Diesel Particulate Filter Incomplete Regeneration : Condition Exists (page 1692)
Aftertreatment 1 Diesel Exhaust Fluid Doser Valve 1 : Current Below Normal Or Open Circuit (page
5394 5
1696)
Aftertreatment 1 Diesel Exhaust Fluid Doser Valve 1 : Mechanical System Not Responding Or Out
5394 7
Engine Idle Fuel Quantity : Data Valid But Above Normal Operating Range - Moderately Severe
5395 16
Level (page 1715)
Engine Idle Fuel Quantity : Data Valid But Below Normal Operating Range - Moderately Severe
5395 18
Level (page 1717)
5397 31 Aftertreatment 1 Diesel Particulate Filter Regeneration too Frequent : Condition Exists (page 1720)
Aftertreatment 1 Diesel Exhaust Fluid Line Heater Relay 1 : Voltage Above Normal, Or Shorted
5491 3
Aftertreatment 1 Diesel Exhaust Fluid Line Heater Relay 1 : Current Below Normal Or Open Circuit
5491 5
(page 1724)
Engine Cold Start Fuel Igniter Command : Data Valid But Below Normal Operational Range - Most
5548 1
Engine Cold Start Fuel Igniter Command : Voltage Above Normal, Or Shorted To High Source (page
5548 3
1737)
Engine Cold Start Fuel Igniter Command : Voltage Below Normal, Or Shorted To Low Source (page
5548 4
1745)
5548 5 Engine Cold Start Fuel Igniter Command : Current Below Normal Or Open Circuit (page 1752)
5548 8 Engine Cold Start Fuel Igniter Command : Abnormal Frequency Or Pulse Width Or Period (page 1760)
Diesel Particulate Filter 1 Soot Sensor ECU Internal Temperature : Data Erratic, Intermittent Or
5569 2
Incorrect (page 1768)
Diesel Particulate Filter 1 Soot Sensor ECU Internal Temperature : Voltage Above Normal, Or
5569 3
Diesel Particulate Filter 1 Soot Sensor ECU Internal Temperature : Voltage Below Normal, Or Shorted
5569 4

Diesel Particulate Filter 1 Soot Sensor ECU Internal Temperature : Data Valid But Above Normal
5569 16
Engine Fuel 1 Injector Metering Rail 1 Cranking Pressure : Data Valid But Below Normal Operational
5585 1
Aftertreatment Diesel Particulate Filter Temperature Sensor Module : Voltage Above Normal, Or
5742 3
Aftertreatment Diesel Particulate Filter Temperature Sensor Module : Voltage Below Normal, Or
5742 4
Shorted To Low Source (page 1783)
Aftertreatment Diesel Particulate Filter Temperature Sensor Module : Bad Intelligent Device Or
5742 12
Component (page 1787)
Aftertreatment Diesel Particulate Filter Temperature Sensor Module : Data Valid But Above Normal
5742 16
Aftertreatment Diesel Particulate Filter Temperature Sensor Module : Received Network Data
5742 19
In Error (page 1791)
5743 19 Aftertreatment 1 SCR Temperature Sensor Module : Received Network Data In Error (page 1801)
Aftertreatment 1 Outlet Soot Sensor Heater : Voltage Above Normal, Or Shorted To High Source
5747 3
(page 1811)
Aftertreatment 1 Outlet Soot Sensor Heater : Voltage Below Normal, Or Shorted To Low Source
5747 4
(page 1813)
5747 5 Aftertreatment 1 Outlet Soot Sensor Heater : Current Below Normal Or Open Circuit (page 1815)
5747 10 Aftertreatment 1 Outlet Soot Sensor Heater : Abnormal Rate Of Change (page 1817)
Engine Exhaust Gas Recirculation 1 Actuator 1 Temperature : Data Valid But Above Normal
5765 0
5765 14 Engine Exhaust Gas Recirculation 1 Actuator 1 Temperature : Special Instructions (page 1821)
Engine Exhaust Gas Recirculation 1 Actuator 1 Temperature : Data Valid But Above Normal
5765 15
5835 3 Aftertreatment 1 Particulate Sensor : Voltage Above Normal, Or Shorted To High Source (page 1825)
5835 4 Aftertreatment 1 Particulate Sensor : Voltage Below Normal, Or Shorted To Low Source (page 1827)
5835 19 Aftertreatment 1 Particulate Sensor : Received Network Data In Error (page 1829)
5835 21 Aftertreatment 1 Particulate Sensor : Data Drifted Low (page 1838)
Engine Fuel 1 Injector Metering Rail 1 Cold Start Pressure : Data Valid But Above Normal Operating
6653 16
Engine Fuel 1 Injector Metering Rail 1 Cold Start Pressure : Data Valid But Below Normal Operating
6653 18
Aftertreatment 1 Particulate Sensor Regeneration State : Mechanical System Not Responding Or Out
6774 7
Aftertreatment 1 Particulate Sensor Power Supply : Voltage Above Normal, Or Shorted To High
6778 3
Source (page 1848)
Aftertreatment 1 Particulate Sensor Power Supply : Voltage Below Normal, Or Shorted To Low
6778 4
Source (page 1850)

Aftertreatment 1 Particulate Sensor Power Supply : Data Valid But Above Normal Operating Range -
6778 16
6780 2 Aftertreatment 1 Particulate Sensor Temperature : Data Erratic, Intermittent Or Incorrect (page 1854)
Aftertreatment 1 Particulate Sensor Temperature : Voltage Above Normal, Or Shorted To High
6780 3
Source (page 1856)
Aftertreatment 1 Particulate Sensor Temperature : Voltage Below Normal, Or Shorted To Low
6780 4
Source (page 1858)
Aftertreatment 1 Diesel Exhaust Fluid Pump : Voltage Above Normal, Or Shorted To High Source
7107 3
(page 1860)
Aftertreatment 1 Diesel Exhaust Fluid Pump : Voltage Below Normal, Or Shorted To Low Source
7107 4
(page 1865)
Aftertreatment 1 Particulate Sensor Heater Power Supply Diagnostic Status : Data Erratic, Intermittent
7330 2
Or Incorrect (page 1870)
Engine Cold Start Fuel Injection Timing for All Cylinders : Abnormal Frequency Or Pulse Width
7392 8
Or Period (page 1874)
7393 2 Aftertreatment 1 Particulate Sensor Current : Data Erratic, Intermittent Or Incorrect (page 1878)
7393 10 Aftertreatment 1 Particulate Sensor Current : Abnormal Rate Of Change (page 1883)
Aftertreatment 1 Diesel Exhaust Fluid Pump Power Relay : Voltage Above Normal, Or Shorted
7416 3
7712 3 Battery Potential / Power Input 3 : Voltage Above Normal, Or Shorted To High Source (page 1888)
7712 4 Battery Potential / Power Input 3 : Voltage Below Normal, Or Shorted To Low Source (page 1896)
7713 3 Battery Potential / Power Input 4 : Voltage Above Normal, Or Shorted To High Source (page 1903)
7713 4 Battery Potential / Power Input 4 : Voltage Below Normal, Or Shorted To Low Source (page 1907)
7854 2 Aftertreatment 1 Particulate Sensor Module : Data Erratic, Intermittent Or Incorrect (page 1911)
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.
Operational Checkout Procedures

1.0 - Preliminary Vehicle Operational Checkout Procedure
CAUTION:
To prevent engine damage, do not start or run engine if fuel system has contamination.
Step 1 Inspect fuel level, quality, and fuel system. Decision

A. Perform Fuel Level and System Inspection (page 2152) Yes: Go to Step 2.
B. Perform Fuel Quality Inspection (page 2156).
Is fuel level to specification, and is fuel system not damaged or leaking? No: Correct low fuel level.
Repair fuel system leaks or
damage. If fuel contamination is
found drain and replace fuel. If
engine was run with fuel gelling
or contamination, perform 7.0
- Fuel System Operational
Checkout Procedure (page 39).
After repairs are complete, retest
for original problem.
Step 2 Inspect batteries, electrical system, and connections. Decision

Perform Batteries and Electrical System Inspection (page 2198). 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 to 12.6 volts.
Step 3 Inspect air intake system for damage or restrictions. Decision

Perform Intake Air Inspection (page 2165). Yes: Repair air intake system
damage or restrictions. After
repairs are complete, retest for
original problem.
Are air intake system components damaged or restricted? No: Go to Step 4.
Step 4 Inspect exhaust system for damage or restrictions. Decision

Perform Exhaust and Aftertreatment System Inspection (page 2166). Yes: Repair exhaust system
damage or restrictions. After
original problem.
Are exhaust system components damaged or restricted? No: Go to Step 5.
Step 5 Inspect engine oil level. Decision

Perform Engine Oil Level and Quality Inspection (page 2158). Yes: Go to Step 6.
Is engine oil level and quality to specification? No: Go to 6.0 Engine Oil System
Operational Checkout Procedure
(page 37).
Step 6 Inspect engine coolant level and quality. Decision

Perform Coolant Level Inspection (page 2159) and Coolant Quality Inspection Yes: Go to Step 7.
(page 2160).
Are coolant level and quality to specification? No: Go to 5.0 Cooling System
(page 34).
Step 7 Verify Engine Control Module (ECM) communicates, obtain vehicle Decision
health report, and check for current ECM calibration.
Connect EST (page 1956) and log in to Navistar® Engine Diagnostics Yes: Go to Step 8.
Is EST communicating with ECM, and is ECM calibration current? No, EST not communicating with
ECM: Diagnose and repair EST,
Controller Area Network (CAN),
vehicle diagnostic connector,
ECM, or power/ground problem.
No, ECM calibration not current:
Ensure vehicle has latest ECM
calibration. After repairs are
complete, retest for original
problem.
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 30)
• 3.0 Engine Hard to Start Operational Checkout Procedure (page 31)
• 4.0 Engine Performance Problem Operational Checkout Procedure (page 32)
• 5.0 Cooling System Operational Checkout Procedure (page 34)
• 6.0 Engine Oil System Operational Checkout Procedure (page 37)
• 7.0 Fuel System Operational Checkout Procedure (page 39)

• 8.0 Engine Compression Brake Operational Checkout Procedure (page 41)
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 work and repairs.
Step 1 Perform preliminary operational checkout procedure. Decision

Yes: Go to Step 2.
Was 1.0 Preliminary Vehicle Operational Checkout Procedure (page 28) performed? No: Go to 1.0 Preliminary
Vehicle Operational Checkout
Procedure page 28.
Step 2 Check for no start related Diagnostic Trouble Codes (DTC). Decision
Use Electronic Service Tool with Navistar® Engine Diagnostics, check DTC list for: Yes: Go to Fault Code
Diagnostics for no start related
• SPN 636 Camshaft Position
SPN.
• SPN 637 Crankshaft Position
• SPN 108, 158, 628, 629, 1110 Engine Control Module
• SPN 1209 Exhaust Back Pressure
• SPN 3251 Diesel Particulate Filter Differential Pressure
• SPN 3610 Diesel Particulate Filter Outlet Pressure
• SPN 102 Intake Manifold Pressure
• SPN 2797, 2789 Injector
• SPN 157 Fuel Rail Pressure
• SPN 633 Engine Fuel Actuator 1
• SPN 2791 Exhaust Gas Recirculation Valve
Does EST DTC list have any active fault codes listed above? No: Go to Step 3.
Step 3 Record snapshot of engine cranking data. Decision

Perform Engine Cranking Test (page 2078). Yes: Go to 2.2 Engine Cranks
But Does Not Start (page 46).
It is normal for Fuel Rail Pressure sensor to read up to 1,000 psi at Key On Engine Off.
Is engine speed (rpm) within engine cranking specification? No: Go to 2.1 Engine Cranks
Fast, Slow or Does Not Crank
(page 43).
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

Yes: Go to Step 2.
Procedure page 28.
Step 2 Check for hard to start related Diagnostic Trouble Codes (DTC). Decision
Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics, check DTC Yes: Go to Fault Code
list for: Diagnostics for no start related
SPN.
• SPN 3055 and 157 Fuel Rail Pressure
• SPN 641, 2795 or 4228 Variable Geometry Turbocharger
Step 3 Determine specific hard to start symptom. Decision

A. Attempt to start engine. Yes: Go to 3.2 Engine Starts,
Then Stalls. (page 48)
B. Perform Engine Cranking Test (page 2078).
Does engine start and then stall? No, engine speed (rpm) out of
specification: Go to 2.1 Engine
Cranks Fast, Slow or Does Not
Crank (page 43).
No, long crank time: Go to
3.1 Engine Hard to Start (Long
Crank Time) (page 47).
4.0 - Engine Performance Problem Operational Checkout Procedure
Overview
The following steps direct technicians to systematically troubleshoot engine performance problems and avoid

Yes: Go to Step 2.
Procedure (page 28).
Step 2 Check for related Diagnostic Trouble Codes (DTCs). Decision

Use Electronic Service Tool (EST), with Navistar® Engine Diagnostics check DTC list. Yes: Go to Fault Code
Diagnostics for appropriate
SPN.
Does EST DTC list have SPN/FMI codes active or pending? No: Go to Step 3.
Step 3 Determine if engine has a misfire, rough idle, and/or runs rough. Decision
Yes: Go to 4.1 Misfire/Rough
Idle/Runs Rough (page 50).
Does vehicle have a misfire, rough idle, and/or runs rough? No: Go to Step 4.
Step 4 Determine if engine has popping noises coming from the engine intake. Decision
Yes: Go to 4.2 Popping Noise
from Intake (page 53).
Does vehicle have popping noises coming from the engine intake? No: Go to Step 5.
Step 5 Determine if a suspected turbocharger noise is coming from under the Decision
hood.
Yes: Go to 4.5 - Turbocharger
Noise / Whine / Whistle (page
60) .
Does vehicle make a noise that may be turbocharger noise / whine / whistle, No: Go to Step 6
especially when engine is under load?
Step 6 Determine if engine has low power or slow acceleration. Decision

Yes: Go to 4.3 Low Power (Slow
Acceleration) (page 55).
Does vehicle have low power or slow acceleration? No: Go to Step 7.
Step 7 Determine if engine has a surge or inconsistent rpm during steady state. Decision
Yes: Go to 4.4 Surge
(Inconsistent Engine RPM
During Steady State) (page 59).
Does engine surge or is engine speed (rpm) inconsistent during steady state? No: Review operator complaint.
5.0 - Cooling System Operational Checkout Procedure
Overview
The following steps direct technicians to systematically troubleshoot engine cooling system problems and avoid

Did you perform 1.0 Preliminary Vehicle Operational Checkout Procedure? Yes: Go to Step 2.
No: Go to 1.0 Preliminary
Vehicle Operational
Checkout Procedure
page 28.
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 radiator and other cooling Yes: Clear restrictions
package components. and clean debris from
cooling package. Repair
B. Inspect cooling fan blades, fan shroud, accessory drive belt(s), drive belt
damaged cooling system
tensioner(s), cooling package, and other cooling system components for damage.
components. After
Were restrictions or debris found, or are cooling system components damaged? repairs are complete,
retest for original
problem.
No: Go to Step 3.
Step 3 Determine if deaeration tank cap holds to rated pressure. Decision

Perform Deareation Tank Cap Test (page 2117). 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.
Step 4 Determine if engine or cooling system components are leaking externally or Decision
internally.
Perform Cooling System Pressure Test (page 2120). Yes: Go to Step 5.
No, external leaks:
Repair external cooling
system leaks. After
repairs are complete,
retest for original
problem.
Does cooling system hold pressure for 15 minutes? No, internal leaks: Go to
Step 7.
Step 5 Determine if cooling system overflows. Decision

A. Fill deaeration tank with coolant to proper level using Coolant Management System Yes: Go 5.1 Coolant
tool KL5007NAV. Overflow (page 62).
B. Install deaeration tank cap.
C. Start engine. Turn engine Off before any over temperature or overheating occurs.
D. Run engine to operating temperature at high idle.
Does coolant overflow out of deaeration tank? No: Go to Step 6.
Step 6 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 5.2 Coolant
concern. False results will occur due to lack of proper air flow across the cooling package. Over Temperature (page
65).
Does vehicle cooling system go over temperature or overheat (220°F [104°C])? No: Go to Step 7.
Step 7 Determine if coolant is in the engine oil. Decision

Perform Coolant to Oil Inspection (page 2162). Yes: Go 5.3 Coolant
Leak to Engine Oil (page
67).
Is engine oil contaminated with coolant? No: Go to Step 8.
WARNING:
To prevent personal injury or death, allow engine to cool before working with
components.
Step 8 Determine if EGR Cooler is leaking to exhaust. Decision

Perform EGR Cooler Leak Test (page 2126). Yes: Replace EGR
Cooler.
Is coolant seen leaking from the rear of the EGR Cooler? No: Go to Step 9.
Step 9 Determine if AFTHD is leaking coolant. Decision

Perform Coolant in Exhaust Inspection (page 2161). Yes: Go 5.4 Coolant
Leak to Exhaust (page
69).
Is coolant seen leaking into the exhaust? No: Review complaint.
6.0 - Engine Oil System Operational Checkout Procedure
Overview
The following steps direct technicians to systematically troubleshoot engine oil system problems and avoid

Vehicle Operational
Checkout Procedure
page 28.
Step 2 Determine if engine has external oil leaks. Decision

Inspect for engine oil leaks (oil fill tube, drive housing, valve cover, road draft tube, etc.). Yes: Repair engine oil
leaks as needed. After
retest for original
problem.
Is engine oil visibly leaking from the engine, does vehicle leave oil stains on the ground No: Go to Step 3.
where parked, or is road draft tube leaking excessively (a small amount of oil at road draft
tube is normal)?
Step 3 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 SPN 100
• SPN 100 / FMI 3, 4 Engine Oil Pressure (EOP)
/ FMI 3, 4.
Does EST DTC list have SPN 100 / FMI 3, 4 Active or Pending? No: Go to Step 4.
Step 4 Determine if engine oil pressure is low. Decision

A. Start engine. Yes: Go to 6.1 Low
Engine Oil Pressure
B. Read engine oil pressure gauge.
(page 71).
Is engine oil pressure lower then specification (page 2286)? No: Go to Step 5.
Step 5 Verify engine oil quality. Decision

Review results from previously performed Engine Oil Level and Quality Inspection (page Yes, fuel in engine oil:
2158). Go to 7.3 Fuel Leak to
Engine Oil (page 85).
Yes, coolant in engine oil:
Go to 5.3 Coolant Leak
to Engine Oil (page 67).
Is engine oil contaminated? No: Go to Step 6.
Step 6 Determine if oil is leaking into the exhaust. Decision

Disconnect exhaust inlet pipe from Diesel Oxidation Catalyst (DOC) inlet. Yes: Go to 6.2 Oil Leak
to Exhaust (page 75).
Is oil in the exhaust? No: Review concern.
End Diagnostic Test

After performing diagnostic steps, if fault remains, verify if step was completed correctly and proper decision was
made. Notify supervisor for further action.
7.0 - Fuel System Operational Checkout Procedure
Overview
The following steps direct technicians to systematically troubleshoot fuel system problems and avoid

Vehicle Operational
Checkout Procedure
page 28.
CAUTION:
CAUTION:
To prevent personal injury or death, keep fuel away from flames and sparks.
Step 2 Determine if fuel is gelled or contaminated. Decision

Review results from Fuel Quality Inspection (page 2156). Yes: Go to 7.2 Fuel
Gelling / Contamination
Is fuel gelled or contaminated (other than metal)?
(page 79).
No: Go to Step 3.
Step 3 Determine if metal is in fuel system and / or the high-pressure fuel pump is noisy. Decision
Inspect primary fuel filter and fuel tanks for metal debris. Yes: Go to 7.1 Metal
in Fuel System / Noise
Is metal in the fuel system and / or is the high-pressure fuel pump noisy?
from High-Pressure Fuel
Pump (page 77).
No: Go to Step 4.
Step 4 Check for fuel 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 fuel
• SPN 157 Fuel Rail Pressure
related Fault Code.
• SPN 5571 Fuel Rail Pressure System
• SPN 633 or 1244 Engine Fuel Actuators

• SPN 651-656, 2797-2798 Injector
Step 5 Determine if fuel is in the engine oil. Decision

Review results from Engine Oil Level and Quality Inspection (page 2158). Yes: Go to 7.3 Fuel Leak
Is fuel in the engine oil? No: Go to Step 6.
Step 6 Determine if fuel is in the exhaust. Decision

A. Remove exhaust down pipe after the Aftertreatment Fuel Injector. Yes: Go to 7.4 Fuel Leak
to Exhaust (page 87).
B. Look for raw fuel / diesel fuel smell. Fuel mixed with exhaust may look like black
engine oil.
Is fuel in the exhaust? No: Go to Step 7.
Step 7 Determine if fuel is in the air intake. Decision

A. Remove Charge Air Cooler (CAC) hose at the Mixer duct. Yes: Replace Intake air
heater fuel solenoid.
B. Inspect for fuel leaks at the intake air heater fuel igniter (if equipped).
After repairs are
complete, retest for
original problem.
Is fuel in the air intake? No: Go to Step 8.
Step 8 Determine if fuel tanks are not equal. Decision

Interview operator or customer complaint. Yes: Go to 7.5 - Fuel
Tanks Not Equalizing
• Is customer complaining about fuel tanks not returning equally and(or) not equalizing?
(page 88).
• Does vehicle run out of fuel in one of the two tanks and not the other?
Do the fuel tanks have unequal levels or does on of the tanks empty at a different rate No: End diagnostics,
than the other? retest for original
complaint.
8.0 - Engine Compression Brake Operational Checkout Procedure
Overview
The following steps direct technicians to systematically troubleshoot engine compression brake system problems
and avoid unnecessary work and repairs.

Vehicle Operational
Checkout Procedure
page 28.
Step 2 Check for 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
• SPN 91, 2623 Accelerator Pedal Position
appropriate SPN.
• SPN 100 Engine Oil Pressure
• SPN 191 Transmission Output Shaft Speed (TOSS) /Vehicle Speed Sensor
• SPN 1072 Engine Compression Brake 1
• SPN 1073 Engine Compression Brake 2
• SPN 1322 - 1328 Cylinder Balance
Does EST DTC list have any of the above listed SPN? No: Go to Step 3.
Step 3 Determine if engine runs rough after 30 seconds. Decision

A. Start engine. Yes, Cylinder Bank 1 (1,
2, and 3); OR Bank 2
B. Let engine run for more than 30 seconds.
(4, 5, and 6) low: Go to
C. Perform Cylinder Balance Test (page 2010). 8.2 Engine Compression
Brake Engaged When
Does engine run rough after 30 seconds?
Not Commanded (page
96).
Yes, one or two cylinders
low: Go to 4.0 Engine
Performance Problem
Operational Checkout
No: Go to Step 4.
NOTE: Verify customer settings match expected engine brake operation. Engine brake has many different
possible customer programmable parameters, and can operate in many different ways.
Step 4 Determine if engine compression brake engages and disengages properly Decision
when commanded, per customer settings.
Perform Engine Compression Brake Operational Test (page 2148). Yes: Review complaint.
Did engine brake engage and disengage properly per engine brake parameter settings?
No, engine brake did
not engage: Go to 8.1
Engine Compression
Brake Inoperative (page
93).
No, engine brake
engaged when Not
commanded: Go to 8.2
Engine Compression
Brake Engaged When
Not Commanded (page
96).
Engine Does Not Start Symptoms

2.1 - Engine Cranks Fast, Slow or Does Not Crank
Overview
Determine reason engine cranks too fast, 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 / high resistance in battery cable circuit
• Starting system faults
• Crank inhibit fault
• Charging system faults
• Internal engine damage
• 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

Did you perform 2.0 Engine Does Not Start Operational Checkout Procedure? Yes: Go to Step 2.
No: Go to 2.0 Engine
Does Not Start Operational
Checkout Procedure (page
30).
WARNING:
To prevent property damage, personal injury, and / or death, when working with batteries,
always wear 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

Review results from Batteries and Electrical System Inspection (page 2198). Yes: Go to Step 3.
Is voltage of each battery 12.5 volts or more?
No: Perform Electrical
System Test (page 2065).
Make repairs indicated
by test. After repairs are
problem.
Step 3 Determine if engine cranks too fast. Decision

Crank engine while observing engine rpm. Yes: Go to Step 4.
Does engine crank abnormally fast?
No: Go to Step 5.
Step 4 Determine if valve train components or engine timing problems are present. Decision
A. Remove valve cover (see Engine Service Manual) Yes: Repair engine damage.
After repairs are complete,
B. Inspect valves, valve bridges, camshaft lobes, rocker arms, and rocker shaft for
retest for original problem.
damage or improper operation.
C. Check engine timing.
Are any valves sitting too low or valve train components damaged? Is engine timing
out of specification?
No: Go to 2.2 Engine Cranks
But Does Not Start (page
46).
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
problem.
No: Go to Step 6.
Step 6 Determine if engine has internal damage or starter / flywheel gears are binding. Decision
Using torque wrench set to 120 lb-ft (162 N-m) rotate crankshaft (see Engine Service Yes: Go to Step 7.
Manual “Crankshaft Rotation Procedure”) by hand to determine if starter / flywheel gears
are binding or engine has internal damage.
Does crankshaft rotate appropriately?
No: Repair starter / flywheel
binding or internal engine
damage. See Engine
Service Manual. After
repairs are complete, retest
Step 7 Determine if batteries, Starting and Charging systems are working properly. Decision
Perform Electrical System Test (page 2065). Yes: Review complaint.
Did the vehicle pass test?
No. Make repair indicated
by test. After repairs are
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.
2.2 - Engine Cranks But Does Not Start
Overview
Determine reason engine will crank properly but will not start.
Possible Causes
• Low Fuel Rail Pressure (FRP)
Test Procedure
Step 1 Perform operational checkout procedure Decision

Did you perform 2.0 Engine Does Not Start Operational Checkout Procedure? Yes: Go to Step 2.
Does Not Start Operational
30).
Step 2 Determine if Over-the-Air (OTA) engine calibration update was initiated. Decision
Contact customer to determine if a recent OTA engine calibration was initiated. Yes: Charge and maintain
battery voltage over 12.5
Was an OTA engine calibration initiated?
volts to begin recovery
program. A key cycle may
or may not be needed.
Electronic Gauge Cluster
(EGC) will provide status of
completion. After repairs
symptom.
No: Go to Step 3.
Step 3 Determine if engine is able to build Fuel Rail Pressure (FRP). Decision
Review Engine Cranking Test (page 2078) data. Yes: Review complaint.
Is FRP in specification?
No: Go to SPN 157 FMI
1 Fault Code Diagnostics
(page 290).

Engine Hard to Start Symptoms

3.1 - Engine Hard to Start (Long Crank Time)
Overview
Diagnose reason extended crank time is required to start engine.
Possible Causes
• Loss of fuel prime
• Missing Engine Speed signal.
Test Procedure

Did you perform 3.0 Engine Hard to Start Operational Checkout Procedure? Yes: Go to Step 2.
No: Go to 3.0 Engine Hard to
Start Operational Checkout
Procedure (page 31) .
Step 2 Check for rpm signal. Decision

Review the results from the Engine Cranking test (page 2078). Yes: Go to SPN 157 FMI
1 Fault Code Diagnostics
(page 290).
Is an engine speed signal observed on EST? No: Go to SPN 636 FMI 2
(page 492).
3.2 - Engine Starts, Then Stalls
Overview
Engine is able to start (possibly briefly), but is not able to continue to run.
Possible Causes
• Intake restriction
• Exhaust restriction
• Loss of fuel prime
• Failed EGR Valve
Test Procedure

Did you perform 3.0 Engine Hard to Start Operational Checkout Procedure? Yes: Go to Step 2.
No: Go to 3.0 Engine Hard to
Start Operational Checkout
Procedure (page 31) .
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 start
• SPN 731 Knock Detected
related SPN.
• SPN 641 Variable Geometry Turbocharger

Does EST DTC list have any of the fault codes listed above? No: Go to Step 3.
Step 3 Determine if engine air intake is restricted. Decision

Perform Intake Air Inspection (page 2165). Yes: Repair intake
restriction. After repairs
original problem.
Are air intake duct and / or air filter restricted or damaged? No: Go to Step 4.
Step 4 Determine if exhaust is restricted. Decision

Review Engine Cranking Test data (page 2078). Yes: Go to Step 5.
Is Exhaust Back Pressure (EBP), within cranking specification (page 2285)? No: Perform Exhaust
Restriction Isolation Test
(page 2114). After repairs
original problem.
Step 5 Check for failed EGR valve. Decision

A. Key OFF. Remove EGR bellows tubes (see Engine Service Manual for additional Yes: Review complaint.
information).
B. Inspect EGR valve for damage or missing pieces.
C. Press on EGR butterfly valve, if it opens with light pressure, replace the EGR
valve.
D. Perform EGR Valve Position Test (page 1989). While test is active, watch to
determine if EGR valve shaft and butterfly rotate together, the valve can close
completely, and there is no debris or soot blocking or restricting valve motion.
Is the butterfly valve free of damage, does the butterfly valve move with its shaft when No: Replace EGR valve.
actuated, and does the butterfly valve stay in position when pressed with light pressure? After repairs are complete,
retest for original complaint.

Engine Performance Problems Symptoms

4.1 - Misfire / Rough Idle / Runs Rough
Overview
Diagnose reason engine has a misfire, idles rough, or runs rough.
Possible Causes
• Contaminated or aerated fuel
• Engine compression brake malfunction
• Improper valve or engine brake lash
• Mechanical engine damage
• Base engine compression imbalance
• Failed injector
• Exhaust Gas Recirculation (EGR) valve stuck or sticking
• Fuel Rail Pressure
• Failed EGR valve
Test Procedure

Did you perform 4.0 Engine Performance Problem Operational Checkout Procedure? Yes: Go to Step 2.
Performance Problem
Step 2 Check for contaminated fuel supply Decision

Perform Fuel Quality Inspection (page 2156). Yes: Drain and Flush fuel
tank, change both fuel filters,
and replace any fuel lines or
connections as needed. After
repairs are complete, perform
Fuel system priming (page 2026)
and retest for fault.
Is fuel contaminated? No: Go to Step 3.
Step 3 Check for stuck on Engine Brake Decision

If vehicle is equipped with an Engine Brake, perform Engine Compression Brake Yes: Go to Step 4.
Operational Test (page 2148). If not equipped, go to Step 4.
Do test results meet expected outcome? No: Perform Engine Brake
Inspection (page 2180) to
isolate and repair compression
brake failure. After repairs are
complete, retest for fault.
Step 4 Identify misfiring cylinder. Decision

Perform Multi-cylinder Cut-out Test (page 2018), manually cutting out 5 cylinders Yes: Go to Step 5.
at a time.
Do all 6 cylinders hold desired RPM independently during testing? No: Go to Step 6.

Perform Cylinder Balance Test (page 2010). Yes: Go to Step 9.
Are all 6 Cylinders within 0.6 of each other? No: Go to Step 6.
Step 6 Inspect for failed valve train components. Decision

A. Perform Valve Train Inspection (page 2188). Yes: Go to Step 7.
B. Inspect valves, valve keepers, and valve stems for damage.
C. Verify engine can be rotated by hand.
Did all valve train component(s) pass inspection and was engine able to be rotated No: Repair engine mechanical
by hand? failure (see Engine Service
Manual). Perform Crankshaft
Position Sensor Relearn
Procedure (page 1926). After
fault.
Step 7 Determine if valve lash or engine brake lash is out of adjustment. Decision
Perform Valve Lash Adjustment (see Engine Service Manual). Yes: After Valve Lash Adjustment
is complete, retest for fault.
Was valve lash or engine brake lash out of adjustment. No: Go to Step 8.
Step 8 Check for internal engine damage. Decision

Perform Internal Engine Damage Inspection (page 2184). Yes: Repair internal engine
mechanical damage (see Engine
Service Manual). After repairs
are complete, retest for fault.
Does inspection identify a failed or damaged engine component? No: Reassemble engine, and
replace injector on previously
identified misfiring cylinder(s)
(see Engine Service Manual).
Perform IQA Adjustment(page
1941) procedure. Perform
Crankshaft Position Sensor
Relearn Procedure (page 1926).
for fault.

A. Key OFF. Remove EGR bellows tubes (see Engine Service Manual for additional Yes: Go to Step 10.
information).
B. Inspect EGR Valve for damage or missing pieces.
valve.
Step 10 Determine if engine has a fuel rail pressure problem. Decision

Perform Fuel Aeration Test (page 2034). Yes: Repair problem
causing fuel aeration. After
Is fuel aerated?
No: Review complaint.

4.2 - Popping Noise from Intake
Overview
Engine cylinder compression popping back through the air intake.
Fault Facts
Possible Causes
If operator reports hearing a pop and then the vehicle has low power, go to 4.3 – Low Power (page 55).
• Sticking, damaged, or leaking intake or exhaust valve(s)
• Damaged rocker arm or shaft
• Failed camshaft
Test Procedure

Performance Problem
Step 2 Determine if valve train is damaged. Decision

A. Remove valve cover (see Engine Service Manual). Yes: Repair damaged valve
train components. After
B. Inspect valves, valve bridges, camshaft lobes, rocker arms, rocker shaft, for
damage or improper operation.
C. Bar engine over and inspect for sticking valves and proper operation of valve
train.
Are any valves sitting too low or is valve train damaged?
No: Go to Step 3.
Step 3 Determine if valves are sticking. Decision

Bar engine over and look for valves sticking down when rotating engine. Yes: Repair sticking valves.
NOTE: Missing injector hold down thrust washers from a previous repair, may cause
sticking valves.
Are one or more valves sticking?
No: Perform Valve Lash
Adjustment Procedure (see
Engine Service Manual).
retest for original problem. If
problem remains: Repair or
replace cylinder head. After

4.3 - Low Power (Slow Acceleration)
Overview
Diagnose reason vehicle or engine is not able to accelerate properly while under a load.
Fault Facts
A loud popping noise heard just before the low power symptom started may indicate a Charge Air Cooler (CAC)
hose failure.
Special Tools
Electronic Service Tools (EST)
Possible Causes
• Low boost or slow to boost (charge air leak or restriction, turbocharger, Variable Geometry Turbocharger
(VGT) actuator)
• Plugged Intake Manifold Pressure (IMP) sensor
• Plugged Exhaust Back Pressure (EBP) sensor
• Failed turbocharger
• Failed VGT actuator
• Failed Exhaust Gas Recirculation (EGR) valve
CAUTION:
To prevent damage, do not drive vehicle if Charge Air Cooler (CAC) hose or other boost
system leaks are present. Over fueling and damage to the exhaust aftertreatment may
occur.
Test Procedure

Performance Problem
Step 2 Determine if CAC hoses or charge air system are leaking. Decision
Perform Intake Air Inspection (page 2165). Yes: Go to Step 4.
Are CAC hoses and charge air system free of leaks? No: Repair CAC hose or
charge air system leaks, or
damage. After repairs are
complete, go to Step 3.
Step 3 Determine if the Diesel Particulate Filter (DPF) must be replaced. Decision
A. Using EST check Diagnostic Trouble Code (DTC) list. Yes: Perform DPF
Replacement After Boost
B. Determine if DPF Outlet Temperature went above 1550 °F (843 °C). Using
System Leak or Over
EST locate Programmable Parameters:
Temperature (page 2263).
• 55770, Max DPF Outlet Temperature – DOC Inlet Temperature After repairs are complete,
retest for original concern.
• 55780, Max DPF Outlet Temperature – DOC Outlet Temperature
• 55790, Max DPF Outlet Temperature – DPF Outlet Temperature
Is SPN 3936 FMI 16 Active, or did any MAX DPF Outlet Temperature go above 1550 No: Clear fault codes,
°F (843 °C)? Perform stationary DPF
Regeneration Procedure
original concern.
Step 4 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
damage.
Were restrictions or debris found, or are cooling system components damaged? No: Go to Step 5.
Step 5 Determine if Variable Geometry Turbocharger (VGT) is working properly. Decision

Perform VGT Position Test (page 1991). Yes: Go to Step 8.
Did VGT meet commanded position visually and in EST? No: Go to Step 6.
Step 6 Inspect VGT Actuator for proper motion. Decision

A. Key OFF. Yes: Go to Step 7.
B. Disconnect VGT Actuator connector.

C. Disconnect VGT linkage at VGT Actuator.
Important: Leave Key OFF and VGT actuator connector disconnected while
VGT Actuator linkage is disconnected from turbocharger.
D. Manually move VGT Actuator from fully open to fully closed and back to open.
Is VGT Actuator free from sticking or binding? No: Replace VGT actuator
only. After repairs are
complete, retest for retest
for original concern.
Step 7 Inspect VGT Vanes for proper motion. Decision

A. Key OFF. VGT Actuator connector and linkage still disconnected. Yes: End diagnostics,
retest for retest for original
Important: Leave Key OFF and VGT actuator connector disconnected while
concern.
VGT Actuator linkage is disconnected.
B. Manually move VGT vane side of turbocharger from fully open to fully closed
and back to open.
C. Reinstall VGT Actuator linkage on to turbocharger before reconnecting actuator
connector.
Are VGT vanes free from sticking or binding? No: Replace VGT assembly.
retest for retest for original
concern.
Step 8 Verify EGR system is working properly. Decision

Perform EGR Valve Position Test (page 1989). Yes: Go to Step 9.
Does EGRV meet expected commanded position of test? No: Replace EGRV. After
for original concern.
Step 9 Determine if air management system actuators and sensors are functioning Decision
properly.
Perform Air Management Test (page 2004). Yes: Go to Step 10.
Does IMP and EBP sensor signals react approximately the same as snapshot graphs No: Go to Step 12.
shown in the Air Management Test?
Step 10 Determine if air management system actuators and sensors are functioning Decision
properly.
Review results from Air Management Test (page 2004). Yes: End diagnostics.
Review concern.
Is MAF decrease difference percentage between 60% and 100%? No: Go to Step 11.
Step 11 Check EGR valve operation. Decision

A. Key OFF. Remove EGR bellows tubes. See Engine Service Manual for Yes: End diagnostics.
additional information. Review concern.
C. Press on EGR butterfly valve. If it opens with light pressure, replace the EGR
valve.
completely and there is no debris or soot blocking or restricting valve movement.
Step 12 Inspect IMP and / or EBP sensors for soot build up and damage. Decision
A. Remove IMP and / or EBP sensor from engine (see Engine Service Manual). Yes: Go to Step 13.
B. Inspect IMP and / or EBP sensor itself and sensor bore(s) for soot build up
or damage blocking sensor opening.
Are IMP and(or) EBP sensors and bores free of soot build up and damage? No: Remove soot build up or
repair damage as needed.
Only replace a sensor if the
opening on the sensor is
100% plugged. After repairs
original concern.
Step 13 Determine if turbochargers are damaged. Decision

Perform Turbocharger Radial Play Inspection (page 2183). Yes: Replace damaged
turbocharger. After repairs
original concern.
Is turbocharger damaged, cracked or leaking; turbine wheel rubbing in the housing; or No: Go to Step 14.
compressor impeller or turbine wheel blades bent, broken, or eroded?
Step 14 Determine if engine air intake (boost) leaks or restrictions are present. Decision
A. Perform Smoke Test (Air Intake System) (page 2093). Inspect hoses and Yes: End diagnostics.
clamps, and Charge Air Cooler (CAC).
B. Perform Charge Air Cooler (CAC) Pressure Test (page 2085).
Is CAC and air intake system free of leaks, restrictions and damage? No: Repair air intake
system leaks, damage, or
restrictions. After repairs
symptom.

After performing all diagnostic steps, if symptom remains, verify if each step was completed correctly and the proper
decision was made. Notify supervisor for further action.
4.4 - Surge (Inconsistent Engine RPM During Steady State)
Overview
Diagnose reason engine power varies unexpectedly under a load.
Possible Causes
• Viscous fan clutch (if equipped) electrical failure
• EGR valve sticking open or closed
• Intermittent engine wiring harness circuit problem (O2, EGR, ACV, EBP, IMP, FRP, CKP, CMP, etc.)
Test Procedure

Performance Problem
Step 2 Determine if EGR system is operating properly. Decision

Does EGR Valve meet commanded position in EST and visually?
No: Replace EGR Valve.
Step 3 Determine if intermittent engine wiring harness circuit problem exists. Decision
A. Check main engine to chassis grounds. Yes: Using results from
Continuous Monitor Test,
B. Connect Electronic Service Tool (EST) with Navistar® Engine Diagnostics.
repair appropriate circuit or
C. Start engine. harness. After repairs are
D. Start Continuous Monitor Test.
problem.
E. Attempt to recreate engine running problem. Wiggle sensor connectors and
engine wiring harness and view voltages.
Was concern duplicated when harness was wiggled?

4.5 - Turbocharger Noise / Whine / Whistle
Overview
Diagnose reason a noise / whine / whistle is heard from turbocharger area under load.
Possible Causes
• Leaking Charge Air Cooler (CAC) Inlet Pipe crimp clamps
• Leaking CAC
• Failed Turbocharger
Test Procedure

Performance Problem
Step 2 Determine if CAC inlet pipe has a crimp clamp. Decision

Inspect CAC Inlet Pipe clamps. Yes: Carefully remove
crimp clamps and install
constant tension clamps.
Is CAC inlet pipe connected with crimp clamps? No: Go to Step 3.
Step 3 Inspect for engine air intake (boost) leaks. Decision

Perform Smoke Test (Air Intake System) (page 2093). Yes: Go to Step 4.
Is air intake system free of leaks? No: Repair air intake system
leaks. After repairs are
problem.
Step 4 Determine if CAC is leaking. Decision

Perform Charge Air Cooler (CAC) Pressure Test (page 2085) . Yes: Go to Step 5.
Did air pressure in CAC drop less than 5 psi (34 kPa) in 15 minutes? No: Replace CAC. After
Step 5 Determine if turbocharger is visibly damaged. Decision

Perform Turbocharger Radial Play Inspection (page 2183) . Yes: Replace damaged
turbocharger. After repairs
original problem.
Is turbocharger damaged, cracked or leaking; turbine wheel rubbing in the housing; or No: Review operator
compressor impeller or turbine wheel blades bent, broken, or eroded? complaint.

Engine Coolant Symptoms

5.1 - Coolant Overflow
Overview
Determine reason coolant overflows out of deaeration tank with the deaeration tank cap installed.
WARNING:
Possible Causes
• Air compressor
• Exhaust Gas Recirculation (EGR) cooler
• Cracked cylinder sleeve
• Cylinder head cracked or leaking
• Incorrect cylinder sleeve protrusion
Test Procedure

Did you perform 5.0 Cooling System Operational Checkout Procedure? Yes: Go to Step 2.
No: Go to 5.0 Cooling
System Operational
34).
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 5.2 Coolant Over
Step 3 Determine if air compressor is causing coolant overflow. Decision

Perform Air Compressor Leaking Air to Coolant Test (page 2123). Yes: Go to Step 4.
Does coolant overflow occur with air tanks drained and valves open?
No: Repair or replace air
compressor. After repairs
original problem.
Step 4 Determine if Exhaust Gas Recirculation (EGR) cooler is leaking. Decision

Perform EGR Cooler Leak Test (page 2126). Yes: Replace leaking EGR
cooler per the Engine
Is EGR cooler leaking coolant?
No: Go to Step 5.
CAUTION:
To prevent engine damage, when replacing cylinder sleeves inspect piston cooling jets
for damage or obstructions.
Step 5 Inspect cylinder sleeves for leaks, staining, pinholes, and cracks. Decision
Perform Cylinder Sleeve Cavitation and Crack Inspection (page 2163). Yes: Go to Step 6.
Are all cylinder sleeves free of coolant leaks, coolant staining, pinholes, and cracks?
No: Replace leaking or
cracked cylinder sleeves.
Step 6 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 7.
ZTSE4825 and a dial indicator with magnetic base. See Engine Service Manual.
Is Sleeve protrusion in specification for all 6 cylinders?
No: Repair liner protrusion
according to Engine Service
Manual. After repairs are
problem.
Step 7 Determine if cylinder liner(s) are leaking. Decision

A. Remove all cylinder sleeves. See Engine Service Manual. Yes: Replace cylinder head.
B. Inspect cylinder sleeves inside and out for pin holes, cracks, and damage.
Are all cylinder sleeves free of pin holes, cracks, and damage?
No: Replace leaking or
cracked cylinder sleeves.
Ensure liner protrusion is
within specification. After

5.2 - Coolant Over Temperature
Overview
Determine reason engine cooling system goes over temperature or over heats.
WARNING:
Possible Causes
• Cooling package debris clogging
• Damaged fan belt
• Accessory belt tensioner failure
• Inoperative / slipping fan clutch
• Inoperative / damaged cooling fan or shroud
• Damaged water pump impeller
• Stuck closed thermostats
Test Procedure

System Operational
34).
Step 2 Determine if coolant is flowing in the deareation tank and coolant lines. Decision
A. Fill deaeration tank with coolant to proper level. Yes: Go to Step 3.
B. Run engine. No: Go to Step 6.
C. Observe deareation tank and coolant lines for coolant flow.
Is coolant circulating in the deaeration tank?
Step 3 Determine if fan clutch is operating properly. Decision

Perform Engine Fan Test (page 2013). Yes: Go to Step 4.
Does fan clutch operate properly? No: Repair fan clutch. After
Step 4 Determine if thermostats are stuck closed. Decision

Perform Thermostat Operational Test (page 2136). Yes: Go to Step 5.
With engine at operating temperature, is the upper radiator hose within 25°F (14°C) No: Replace thermostats.
of ECT1? After repairs are complete,
Step 5 Determine if radiator will not dissipate heat properly. Decision

A. Run engine to operating temperature at high idle with air conditioning off. Yes: Review complaint.
B. Using an Infrared Thermometer, target the upper and lower radiator hoses, and
record both readings.
C. Calculate the temperature difference (upper radiator temp – lower radiator temp).
NOTE: Greater temperature drop should occur in colder weather.
Is there an appropriate temperature drop between lower radiator hose and upper radiator No: Clean or replace
hose? radiator. After repairs are
problem.
Step 6 Determine if water pump and water distribution housing are operating Decision
properly
A. Remove water pump pulley. See Engine Service Manual. Yes: Replace water pump
and / or water distribution
B. Remove water pump.
housing. After repairs are
C. Inspect water pump and water distribution housing for damage / cavitation. See complete, retest for original
Engine Service Manual. problem.
Does the water pump or water distribution housing have damage or excess cavitation /
wear?
No: Review concern.

5.3 - Coolant Leak to Engine Oil
Overview
Determine component causing engine coolant to leak into engine oil.
Possible Causes
• Cracked cylinder liner
• Leaking cylinder liner O-ring(s)
• Leaking rear gear train freeze plug
• Failed air compressor
• Leaking oil cooler module or gaskets
NOTE: White condensation under the oil filler cap is normal.
Test Procedure

System Operational
34).
WARNING:
Step 2 Determine if coolant is leaking from cylinder liners. Decision

A. Remove engine oil pan. See Engine Service Manual. Yes, coolant leaking
between cylinder liner
B. Remove deaeration tank cap.
and crankcase: Replace
C. Install Radiator Pressure Testing Kit ZTSE2384 on deaeration tank. failed cylinder liner
O-ring(s). After repairs
D. Pressurize cooling system to 17 psi (117 kPa) for a minimum of 15 minutes.
E. Inspect for coolant leaking between cylinder liner and piston. original problem. Change
engine oil and filter.
F. Inspect for coolant leakage between cylinder liner and crankcase. Bar engine over
to inspect for coolant leaks on liners. Yes, coolant leaking
between piston and
cylinder liner: Replace
leaking cylinder liner(s)
and inspect cylinder head
for cracking. After repairs
original problem. Change
Is coolant leaking between piston and liner, or between cylinder liner and crankcase? No: Go to Step 3.
Step 3 Determine where coolant is leaking into crankcase. Decision

A. With cooling system pressurized to 17 psi (117 kPa). Yes, rear gear train area
leaking: Inspect and
B. Inspect for coolant at rear gear train area.
repair cylinder head
C. Inspect for coolant at air compressor drain. freeze plug leaks. After
D. Inspect for coolant at oil cooler drain.
retest for original
problem. Change engine
oil and filter.
Yes, leaking from air
compressor drain:
Replace air compressor.
After repairs are
complete, retest for
Yes, leaking from oil
cooler drain: Inspect
and repair leaking oil
cooler module and / or
gaskets. After repairs
Is coolant leaking at the gear train area, air compressor drain, or oil cooler drain? No: Review concern.

5.4 - Coolant Leak to Exhaust
Overview
Determine why engine coolant is leaking into the exhaust.
Possible Causes
• Failed Exhaust Gas Recirculation (EGR) cooler
• Failed Aftertreatment Hydrocarbon Doser (AFTHD)
• Failed Cylinder Head
Test Procedure

System Operational
34).
WARNING:
Step 2 Inspect AFTHD for coolant leakage. Decision

A. Remove AFTHD from exhaust (see Service Manual). Yes: Replace AFTHD. After
B. Install Radiator Pressure Test Kit ZTSE2384 (with appropriate adapter if
needed) onto deaeration tank.
C. Pressurize cooling system to 15 psi.
D. Inspect for coolant loss at AFTHD.
Is coolant leaking from AFTHD? No: Go to Step 3.

Perform EGR Cooler Leak Test (page 2126). Yes: Replace leaking EGR
cooler per the Engine
for original problem. Change
engine oil and oil filter.
Is EGR cooler leaking coolant? No: Replace Cylinder Head
per Engine Service Manual.

Engine Lubrication Symptoms

6.1 - Low Engine Oil Pressure
Overview
Determine reason engine oil pressure is low and / or oil pressure gauge reads low.
Possible Causes
• Instrument panel engine oil pressure gauge or circuit
• Engine Oil Pressure (EOP) sensor
• Collapsed oil filter / coolant saturated
• Oil pump / gear train
• Oil aeration / pickup tube or O-ring leak
• Piston cooling tubes
• Connecting rod and/or main bearing wear
• Missing / leaking cup plugs
• Oil pressure regulator
NOTE: Low viscosity engine oil will cause lower engine oil pressure in hot ambient temperatures and high engine
loads.
Test Procedure

Did you perform 6.0 Engine Oil System Operational Checkout Procedure? Yes: Go to Step 2.
Oil System Operational
37).
Step 2 Determine if instrument panel oil pressure gauge is working properly. Decision
Perform Instrument Panel Engine Oil Pressure Gauge Validation Test (page 2142). Yes: Go to Step 3.
Does EST Engine Oil Pressure (EOP) match oil pressure shown on instrument panel
oil pressure gauge?
No: Repair instrument panel
oil pressure gauge or circuit.
Step 3 Determine if Engine Oil Pressure (EOP) sensor is operating properly. Decision
Perform Oil Pressure Verification Test (page 2137). Yes: Replace EOP sensor.
Does pressure gauge read engine oil pressure in specification and EOP did not match?
No: Go to Step 4.
Step 4 Determine if engine oil filter is restricted. Decision

Remove and inspect engine oil filter. Yes: Go to 5.3 Coolant Leak
Is oil filter crushed and / or contaminated with coolant?
No: Go to Step 5.
Figure 1 Crankcase Cup Plug Near #7 Main Bearing

Step 5 Determine if oil suction tube, piston cooling tubes, cup plug, main or Decision
connecting rod bearings are causing low oil pressure.
A. Remove oil pan (see Engine Service Manual). Yes, oil suction tube
or O-ring damaged or
B. Perform Oil and Crankcase Inspection (page 2170).
restricted: Install new oil
C. Inspect for leaking or missing cup plug near #7 main bearing. suction tube and O-ring.
Is oil suction tube, O-ring, or piston cooling tubes cracked, damaged, or restricted (burnt
cylinder); or is cup plug near #7 main bearing leaking or missing; or are connecting
rod or main bearings damaged or spun?
Yes, piston cooling tube(s)
damaged or restricted (burnt
cylinder): Install new piston
cooling tubes (see Engine
Service Manual). After
Yes, cup plug near #7 main
bearing leaking or missing:
Install new cup plug. After
Yes, visual damage main
and / or connecting
rod bearing: Perform
Connecting Rod, Main
Bearing, and Journal
Inspection (page 2192).
No: Go to Step 6.
Step 6 Determine if leaking or missing cup plugs under the valve cover are causing Decision
low oil pressure.
A. Remove valve cover (see Engine Service Manual). Yes: Install new cup plug(s).
B. Perform Cylinder Head, Valve train, and Engine Brake Housing Oil Leak
Inspection (page 2174).
Are cup plugs under the valve cover leaking or missing?
No: Go to Step 7.
Step 7 Determine if oil pressure regulator valve is stuck. Decision

A. Remove oil module assembly (see Engine Service Manual). Yes: Go to Step 8.
B. Remove and inspect oil pressure regulator valve.
Is oil pressure regulator in good condition and not stuck or damaged?
No: Replace oil pressure
regulator. After repairs are
problem.
Step 8 Determine if oil pump, oil pump bushing, or cup plug(s) are causing low oil Decision
pressure.
Perform Oil Pump and Fan Drive Oil Leak Inspection (page 2172). Yes: Replace damaged,
leaking or excessively worn
Does oil pump, oil pump bushing, gear train or idle gear have damage or excessive
components. After repairs
wear; or are cup plugs leaking or missing?
original problem.
No: Review concern.

6.2 - Oil Leak to Exhaust
Overview
Determine cause of engine oil leaking into the exhaust.
Possible Causes
• Turbocharger failure
• Cylinder liner(s)
• Piston rings
Test Procedure

Did you perform 6.0 Engine Oil System Operational Checkout Procedure? Yes: Go to Step 2.
Oil System Operational
37).
Step 2 Determine if engine oil is in the Charge Air Cooler (CAC) piping. Decision
Disconnect piping to the CAC and inspect for oil. Yes: Repair or Replace
turbocharger. Perform
Is oil inside the CAC piping?
CAC Cleaning Procedure.
Inspect for DOC and
DPF for damage Refer
to Aftertreatment Reuse
guidelines. After repairs are
problem.
No: Go to Step 3.
Step 3 Determine if crankcase pressure is within specification. Decision

Perform Crankcase Pressure Test (page 2092). Yes: Go to Step 4.
Is crankcase pressure within specification?

No: Repair base engine
problem or air compressor
based on results. See
Engine Service Manual.
Step 4 Determine if base engine problem or turbocharger is leaking oil into the Decision
exhaust.
A. Remove turbocharger. See Engine Service Manual. Yes: Repair base engine
failure. See Engine Service
B. Inspect for oil coming from the engine(exhaust manifold) into the HP
Manual. After repairs are
turbocharger inlet.
C. Inspect HP turbocharger for leaks and damage. problem.
Is oil entering the exhaust from the engine (exhaust manifold)?
No: Repair or Replace
turbocharger. Inspect for
DOC and DPF for damage
Refer to Aftertreatment
Reuse guidelines. After
for original problem

Fuel System Symptoms

7.1 - Metal in Fuel System / Noise from High-Pressure Fuel Pump
Overview
If fuel pump fails, it may send debris into the low-pressure fuel lines and tank. Debris comes from the
low-pressure return and gets caught by the fuel filters. Do NOT replace fuel injectors, fuel rail, high-pressure
lines, or Aftertreatment Fuel Injector (AFTFI).
Possible Causes
• Failed fuel pump
• Debris in fuel system (normal from manufacturing or previous failure)
• Fuel aeration / inlet restriction
• Restricted fuel return
Test Procedure

Did you perform 7.0 Fuel System Operational Checkout Procedure? Yes: Go to Step 2.
No: Go to 7.0 Fuel System
CAUTION:
CAUTION:
Metal debris in fuel system may be residual from manufacturing or from a previous
failure.
Step 2 Determine if metal debris is currently coming from the fuel pump. Decision
A. Connect Clean Fuel Source Tool 15-637-01 to low-pressure fuel inlet and Yes: Go to Step 4.
high-pressure fuel return.
B. Put a magnet in the Clean Fuel Source Tool fuel tank.
C. Start engine and run at idle for 5 minutes, while checking the return line
discharge for metallic debris.
Is metallic debris present in the Clean Fuel Source Tool discharge and / or Clean Fuel
Source Tool fuel tank?
No: Go to Step 3.
Step 3 Determine if the high-pressure fuel pump is noisy. Decision

Is the high-pressure fuel pump noisy? Yes: Go to Step 5.
No: Review concern.
CAUTION:
To prevent engine damage, do not crank engine to prime fuel system.
Step 4 Drain fuel, flush low-pressure fuel system, install new fuel filters, and new high-pressure fuel pump.
A. Install new primary fuel filter and secondary fuel filter.
B. Install new high-pressure fuel pump
C. Use Fuel Priming Tool 12-992-01 to prime the fuel system.
D. After repairs are complete, retest for original problem.
E. Clean out Clean Fuel Source Tool.
Step 5 Determine if low-pressure fuel system is restricted. Decision

Perform Fuel Restriction Test (page 2038). Yes: Repair fuel restriction.
Is low-pressure fuel system restricted?
No: Go to Step 6.
Step 6 Determine if fuel return line is restricted. Decision

Perform HP Pump Fuel Return Pressure Test (page 2052). Yes: Go to Step 7.
Is pressure less than 13 psi?
No: Repair restriction in
fuel return line between
high-pressure fuel pump
and fuel tank. After repairs
original problem.
Step 7 Determine if low-pressure fuel system is aerated. Decision

Perform Fuel Aeration Test (page 2034). Yes: Repair low-pressure
fuel system aeration. After
Does low-pressure fuel system have aeration?
No: End Diagnostic Steps.

7.2 - Fuel Gelling / Contamination
Overview
Determine how to treat Diesel Exhaust Fluid (DEF), water, gelling, waxing, or other contaminates in the engine
fuel. Fuel gelling or contamination caused by incorrect servicing is not covered by Navistar® warranty.
Diesel fuel gelling occurs when the paraffin present in diesel fuel starts to solidify when the temperature is low
enough. The fuel reaches this stage whereby enough wax crystals have formed to prevent any flow of the fuel.
The gel point is the temperature at which diesel or biodiesel fuel freezes solid and can no longer flow by gravity
or be pumped through fuel lines.
Associated Faults
Possible Diagnostic Trouble Code(s) that may be present if gelling has occurred:
SPN 132 FMI 21 SPN 157 FMI 1,18 SPN 641 FMI 7,14 SPN 2798 FMI 8
SPN 3251 FMI 0,15,16 SPN 3482 FMI 7 SPN 6653 FMI 18
Fault Facts
Possible symptoms of diesel fuel gelling may include: loss of power while driving, crank no start, MIL, high soot
loading, and frequent aftertreatment regenerations.
Below is a listing of the most common diesel fuels used in on-highway truck engines.
• Diesel #2 (2-D) – Most common fuel used, also know as “summer fuel”. It is a heavier distillate fuel than
1-D. Recommended treating with Anti-Gel at temperatures below freezing.
• Diesel #1 (1-D) – This is a kerosene like or lighter distillate fuel, and has a lower wax content. Used in
applications running in extreme cold.
• BioDiesel – Typically a blend from 5 to 20% Bio (produced from organic materials such as vegetable oil)
and conventional diesel fuel.
• Winter Blend – Typically a blend of #1 and #2 fuels to help reduce (not eliminate) the risk of gelling.
Operating temperatures at or below 32° F recommendations:
• Use an Anti-Gel additive
• Consider using a “winter blend” fuel
• Educate driver to use the type of fuel that is correctly blended for the operating climate.
• Drain water separator frequently. If equipped, use the 120V block and fuel heaters when possible.
Operating temperatures at or below 15° F recommendations:
• Use a “winter blend” fuel with Anti-Gel additive.
• Use a winter front and an Artic Fox Tank Heater.
• Install Racor GreenMax Primary Fuel Water Separator (if not equipped)
Service Parts Information
Description Part Number Quantity Notes

Required
Davco 382 Primary Fuel Refer to Parts 1 25 Micron Rating

Filter Catalog
Racor Primary Fuel Filter (If Refer to Parts 1 30 Micron Rating
Equipped) Catalog
Secondary Engine Mounted Refer to Parts 1 5 Micron Rating
Fuel Filter Catalog
Racor GreenMax Refer to Parts 1 30 Micron Rating
Conversion Kit Catalog
Diesel Fuel System De-Icer Refer to Parts As 32oz. bottle used for emergency thaw ONLY. Treats
(Recommended) Catalog Needed up to 30 gallons when de-icing.
Diesel Fuel Anti-Gel Refer to Parts As 20oz. bottle prevents gelling to -40° F. Treats up to
(Recommended) Catalog Needed 125 gallons of fuel.
Possible Causes
• Incorrect servicing / operator adding coolant, DEF, or other incorrect fluid. Or operator neglecting to add
additives to fuel.
• Incorrect usage of diesel fuel type / blend.
• Failed block or fuel heaters (if equipped).
CAUTION:
CAUTION:
NOTE: If engine has been run with fuel contamination all high-pressure fuel system components may need to
be replaced.
Test Procedure

Step 2 Review results from Fuel Quality Inspection and determine if fuel shows signs Decision
of cloudiness, gelling, or waxing.
Did fuel show signs of gelling, waxing, or cloudiness? Yes: Replace Primary and
Secondary Fuel Filters.
Add recommended cold
weather fuel additive to
fuel tank depending on
fuel condition. See Service
Parts Information. (page 80)
Perform DPF Regeneration
No: Go to Step 3.
Step 3 Determine if engine was run with fuel contamination. Decision

Does engine run rough, have fuel or performance related fault codes (SPN 157, SPN Yes: Replace Primary and
651-656, SPN 1322-1328, SPN 2797, SPN 2798, SPN 6653), stumble, or have a no Secondary Fuel Filters.
start condition? Replace all fuel system
components:
• Aftertreatment Fuel
Injector (AFTFI)
• Fuel injectors
• High-pressure fuel
pump
• Aftertreatment fuel
doser module
• High-pressure fuel rail
system lines
• Low-pressure fuel lines
as needed.
• Both fuel filters

• If equipped, replace the
fuel heater.
• Flush the fuel tank.

Perform Fuel System
Priming (page 2026) and
No: Flush fuel tank, change
both fuel filters, and replace
any fuel lines or connections
as needed. After repairs
are complete, perform Fuel
System Priming (page
2026) and retest for original
problem.

After performing all diagnostic steps, if symptom remains, verify if each step was completed correctly and the proper
7.3 - Fuel Leak to Engine Oil
Overview
Determine reason fuel is in the engine oil.
Possible Causes
• Cracked or leaking fuel Injector(s)
• Failed fuel injector O-ring(s)
CAUTION:
Test Procedure

NOTE: Loose fuel injector hold down(s) or missing injector hold down thrust washer(s) can cause fuel to leak
into engine oil.
Step 2 Determine where fuel is leaking into engine oil. Decision

A. Connect Clean Fuel Source Tool 15-637-01 to low-pressure fuel inlet and fuel Yes, fuel leaking from top
return. of one or more injector:
Replace leaking injector(s)
B. Add fuel dye to Clean Fuel Source Tool fuel tank.
(see Engine Service
C. Run engine at high idle for 3 to 5 minutes. Manual). After repairs
D. Turn engine Off.
original problem.
E. Remove valve cover (see Engine Service Manual).
F. Inspect for oil leaks at and around each fuel injector.

Is fuel leaking from the top or around one or more fuel injector(s)?
Yes, fuel leaking around
base of one or more
injector: Replace failed
injector O-ring(s) and install
new injector combustion
washers (see Engine
Service Manual). After

7.4 - Fuel Leak to Exhaust
Overview
Determine reason fuel is leaking into the engine exhaust.
Possible Causes
• Leaking Aftertreatment Fuel Injector (AFTFI)
CAUTION:
Test Procedure

Step 2 Determine if Aftertreatment Fuel Injector (AFTFI) is leaking. Decision

Perform AFT Fuel Injector Leak Test (page 1996). Yes: Review complaint.
Did AFTFI meet expected outcome?
No: Replace AFTFI. After

7.5 - Fuel Tanks Not Equalizing
Overview
The following steps direct technicians to troubleshoot why fuel tank levels are not equalizing. Customer
observations may include vehicle running out of fuel in one tank, but not the other and fuel tanks not returning
fuel equally.
Fault Facts
None
Special Tools
None
Possible Causes
• Fuel tank vents / hoses restricted or damaged
• Fuel tank supply / return lines incorrect dimension, kinked, or routed improperly
• Fuel line end fittings / splitter tees damaged, leaking, or incorrect size
• Fuel tank supply / return tubes contaminated or incorrect dimensions
7
4 1
5
6 2
4
5
0000450076
Figure 2 Fuel Tank Flow

1. Fuel tank cap
2. Fuel tank vent / hose
3. Fuel tank splitter tee
4. Fuel tank supply draw tube
5. Fuel tank return draw tube
6. Fuel tank supply (RED)
7. Fuel tank return (BLUE)
WARNING:
To prevent personal injury or death, read all safety instructions in the “Safety
Information” section of this manual.
WARNING:
GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be hazard to
human health and environment. Handle all fluids and other contaminated materials
(such as filters and rags) in accordance with applicable regulations. Recycle or dispose
of engine fluids, filters, and other contaminated materials according to applicable
regulations.

Step 2 Determine if fuel tank vents / hoses are restricted. Decision

Perform Fuel Tank Vent Test (page 2116). Yes: Replace fuel tank
vent(s) / hose(s). After
for symptom.
Are fuel tank vents / hoses restricted or damaged? No: Go to Step 3.
Step 3 Inspect fuel tank supply and return lines. Decision

Verify the fuel supply and return lines meet the following criteria: similar dimension; Yes: Go to Step 4.
routed alike; free of bends or kinks; pass through or over frame rail with no obstructions;
and have proper heat shield sleeves installed.
Do fuel tank supply and return lines meet the outlined criteria? No: Replace components
as needed or reroute to
confirm both supply and
return lines are similar. After
for symptom.
Step 4 Inspect fuel line end fittings and splitter tees. Decision
Check fuel line end fittings and splitter tees for any damage, leaks, or unlike fittings. Yes: Go to Step 5.
Are fuel line end fittings and splitter tees in good condition with similar type fittings? No: Replace fuel line
end fitting(s) and / or
splitter tee(s). After repairs
symptom.
Step 5 Inspect fuel tank supply and return draw tubes. Decision
A. Key OFF. Remove drain plugs from fuel tanks and drain fuel. Yes: End diagnostics.
Fuel tank levels are
B. Using fuel tank drain holes, inspect fuel supply and return draw tubes for
approximately the same,
incorrect tube lengths, different tube diameters, or contamination.
retest for symptom.
C. Measure length from bottom of draw tubes to bottom of fuel tanks.
Are draw tubes approximately 1 inch from bottom of fuel tanks, have similar tube No: If serviceable (plastic
diameters in both tanks, and free of contamination? tubes), repair or replace
draw tube(s) as needed to
confirm both supply and
return tubes are similar.
If non–serviceable (metal
tubes), replace fuel tank(s).
retest for symptom.
End Diagnostic Tests

After performing diagnostic steps, if symptom remains, verify steps were completed correctly and proper decision was
made. Notify supervisor for further action.
Engine Brake Symptoms

8.1 - Engine Compression Brake Inoperative
Overview
Engine compression brake will not activate when commanded On.
Possible Causes
• Engine brake solenoid assembly
• Engine brake input inhibitors
• Misadjusted slave piston
• Brake housing leak
• Low oil pressure
Test Procedure

Did you perform 8.0 Engine Compression Brake Operational Checkout Procedure? Yes: Go to Step 2.
Compression Brake
Step 2 Determine if engine brake programmable parameter inputs or settings are Decision
inhibiting engine brake operation.
Perform Engine Compression Brake Inputs and Programmable Parameter Checks Yes: Correct engine brake
(page 2144). programmable parameter
inputs or settings problems.
Are engine brake programmable parameter inputs or settings inhibiting engine brake
operation?
No: Go to Step 3.
Step 3 Determine if one or both engine brake solenoid will not actuate. Decision
A. Connect Electronic Service Tool (EST) with Navistar® Engine Diagnostics, and Yes: Go to Step 4.
log in.
B. Select: Tests > KOEO Tests > Actuator Test
C. Start engine
D. In Control Panel tab, Actuator field, select: Engine Compression Brake 1.
E. Select On and click the Start Test button. Wait for test to complete.
F. Select: Engine Compression Brake 2.
G. Select On and click the Start Test button.
Did both engine brake solenoid assemblies fail to actuate?
No, one engine brake
solenoid did not actuate:
Determine which engine
brake solenoid did not
actuate. Go to Step 4.
Step 4 Determine if engine brake housings, injector harness assembly, and solenoid Decision
assemblies are damaged or not working; and verify slave piston clearances.
A. Remove valve cover. See Engine Service Manual. Yes: Replace failed engine
brake solenoid(s). After
B. Inspect engine compression brake housings for cracks and missing cup plugs,
injector harness assembly for rubbing and chafing, and inspect solenoid
assemblies for damage.
C. Measure slave piston clearances.
Are brake housings, injector harness assembly, and solenoid assemblies in good
condition and not damaged; and are slave piston clearances with specification?
No: Repair or replace
damaged components.
Replace failed engine
brake solenoid(s). Adjust
slave piston clearances to
specification. After repairs
original problem.

8.2 - Engine Compression Brake Engaged When Not Commanded
Overview
Engine compression brake engaged when Not commanded On.
Possible Causes
• Stuck open brake solenoid
• Engine brake related programmable parameter(s) not set correctly (Road speed limiting)
Test Procedure

Did you perform 8.0 Engine Compression Brake Operational Checkout Procedure? Yes: Go to Step 2.
Compression Brake
NOTE: Vehicles may have customer required road speed limiting programmable parameters set below some
operators desired vehicle speed.
Step 2 Determine if engine brake engages at customer programmed road speed limit. Decision
®
A. Connect Electronic Service Tool (EST) with Navistar Engine Diagnostics, and Yes: Normal operation.
log in. Inform operator of normal
customer programmed road
B. Select: Sessions > Programming.
speed limit.
C. Select the Engine Brake tab.
Does engine brake engage at customer programmed road speed limit and other
programmed times?
No: Go to Step 3.
Step 3 Determine if engine brake disengages when ECB harness is disconnected. Decision
A. Start engine. Yes: Replace engine brake
solenoids. After repairs are
B. Unplug 4-pin ECB harness connector.
Does engine brake disengage when ECB harness is disconnected? problem.
No: Go to Step 4.
Step 4 Determine if engine brake housings, injector harness assembly, and solenoid Decision
assemblies are damaged or not working; and verify slave piston clearances.
A. Remove valve cover. See Engine Service Manual. Yes: Replace failed engine
brake solenoid(s). After
B. Inspect engine compression brake housings for cracks and missing cup plugs,
injector harness assembly for rubbing and chafing, and inspect solenoid
assemblies for damage.
C. Measure slave piston clearances.
Are brake housings, injector harness assembly, and solenoid assemblies in good
condition and not damaged; and are slave piston clearances with specification?
No: Repair or replace
damaged components.
Replace failed engine
brake solenoid(s). Adjust
slave piston clearances to
specification. After repairs
original problem.

Fault Code Diagnostics

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)
SPN 69 FMI 19 – Two Speed Axle Switch : Received Network Data In Error
Fault Overview
Fault code sets when Engine Control Module (ECM) does Not detect Two Speed Axle Switch on Private J1939
CAN data link communications circuit.
Lamp Reaction
No Lamp reaction. This fault is only viewable in Electronic Service Tools (EST).
Associated Faults
None
Fault Facts
None
Drive Cycle to Determine Fault Status

Continuous
Possible Causes
• J1939 CAN circuit failure
Step 1 Check for active or pending fault codes. Decision

®
Use EST with Navistar Engine Diagnostics, check Diagnostic Trouble Codes (DTC) Yes: Go to Step 2.
list for SPN 69 FMI 19.
Is EST DTC list SPN 69 FMI 19 active? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure (page
1940).
Step 2 Check for J1939 CAN circuit failure. Decision

Perform J1939 Diagnostics (page 2112) at Body Controller (see appropriate Vehicle Yes: End diagnostics, retest for
Technician Manual for additional circuit and diagnostic information). SPN 69 FMI 19.
Were all checks within specification? No: Repair failed J1939 circuit.
for SPN 69 FMI 19.
End Diagnostic Test

After performing diagnostic steps, if SPN 69 FMI 19 remains, verify each step was completed correctly and proper
decision was made. Return to fault code diagnostics.
SPN 70 FMI 19 – Parking Brake Switch : Received Network Data In Error
Fault Overview
Fault code sets when Engine Control Module (ECM) detects the Parking Brake Switch signal has an error on
the Public J1939 CAN network.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes

®
1940).

for SPN 70 FMI 19.
End Diagnostic Test

SPN 84 FMI 0 – Wheel-Based Vehicle Speed : Data Valid But Above Normal Operational Range -
Most Severe Level
Fault Overview
Fault code sets when Engine Control Module (ECM) calculated vehicle speed is greater than 128 mph.
Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate immediately when this fault is detected.
Associated Faults
SPN 191 FMI 3, 4 and 19
Fault Facts
None

Continuous
Possible Causes
• TOSS sensor circuit OPEN
• TOSS-H shorted to TOSS-L
• TOSS sensor failure
• Excessive air gap between TOSS sensor and trigger wheel
• Damaged TOSS trigger wheel
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 102).
Is EST DTC list free of Associated Faults? No: Repair Associated Faults.
for SPN 84 FMI 0.
Step 2 Check for active fault codes. Decision

Use EST, Key On Engine Off (KOEO), check DTC list for SPN 84 FMI 0. Yes: Go to Step 3.
Is EST DTC listing SPN 84 FMI 0 active? No: Go to Intermittent or Inactive
1940).
Step 3 Inspect connections at Transmission Output Shaft Speed (TOSS) Decision

sensor.
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.
Is TOSS sensor connector, harness, and terminal clean and undamaged? No: Repair connector, harness,
or terminal damage. After repairs
are complete, retest for SPN 84
FMI 0.
Step 4 Check TOSS sensor circuit for OPEN. Decision

Perform Test 1 (page 105). Use DMM, measure voltage between TOSS sensor Yes: Go to Step 5.
pin-A to known good GND.
Is voltage 2.5 ± 0.25 volts? No: Repair short to GND
between ECM pin C1-91 and
TOSS sensor. After repairs are
complete, retest for SPN 84 FMI
0.

pin-B to known good GND.
0.
Step 6 Check for TOSS-H shorted to TOSS-L. Decision

Perform Test 3 (page 107). Use DMM, measure resistance between TOSS Yes: Go to Step 7.
connector pin-A and pin-B.
Is resistance greater than 1,000 Ohms? No: Repair short between
TOSS-H and TOSS-L circuits.
for SPN 84 FMI 0.
Step 7 Check for excessive air gap between TOSS sensor and trigger wheel Decision
or damaged trigger wheel.
Inspect trigger wheel on transmission and verify it is not damaged or missing. Yes: Replace TOSS sensor.
After repairs are correct retest for
SPN 84 FMI 0.
Is trigger wheel in good condition and undamaged? No: Check TOSS sensor air
gap or trigger wheel and repair
as necessary. After repairs are
0.

After performing diagnostic steps, if SPN 84 FMI 0 remains, verify if step was completed correctly and proper decision
was made. Return to fault code diagnostics.
Pin-Point Test SPN 84 FMI 0

Tools Required
• Terminal Test Kit ZTSE4435C
• Digital Multimeter (DMM)
Figure 3 TOSS Circuit Check
Test 1
A. Key Off.
C. Connect Terminal Test Kit ZTSE4435C to chassis harness and leave TOSS sensor disconnected.
D. Key On Engine Off (KOEO).
Test 2
A. Key Off.
D. KOEO.
Test 3
A. Key Off.
SPN 84 FMI 1 - Wheel-Based Vehicle Speed : Data Valid But Below Normal Operational Range - Most
Severe Level
Fault Overview
Fault code sets when Engine Control Module (ECM) calculated vehicle speed is less than 0.6 mph when engine
load is high and PTO mode is not engaged.
Lamp Reaction
Associated Faults
SPN 191 FMI 3, 4 and 19
Fault Facts
None

Continuous
Possible Causes
• TOSS sensor circuit OPEN
• Excessive air gap between TOSS sensor and trigger wheel

for SPN 84 FMI 1.

Is EST DTC listing SPN 84 FMI 1 active or pending? No: Go to Intermittent or Inactive
1940).

sensor.

connector housing.
FMI 1.

1.

1.

Perform Test 3 (page 112). Use DMM, measure resistance between TOSS connector Yes: Go to Step 7.
pin-A and pin-B.
for SPN 84 FMI 1.
Step 7 Check for excessive air gap between TOSS sensor and trigger wheel Decision
or damaged trigger wheel.
Inspect trigger wheel on transmission and verify it is not damaged or missing. Yes: Replace TOSS sensor.
After repairs are correct retest for
SPN 84 FMI 1.
Is trigger wheel in good condition and undamaged? No: Check TOSS sensor air
gap or trigger wheel and repair
1.


Tools Required
Test 1
A. Key Off.
Test 2
A. Key Off.
D. KOEO.
Test 3
A. Key Off.
SPN 91 FMI 2 - Accelerator Pedal Position 1 : Data Erratic, Intermittent Or Incorrect
Fault Overview
Fault codes sets when Engine Control Module (ECM) detects difference between APP1 signal value and APP2
signal value is greater than expected.
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 3509 SPN 3511
Fault Facts
None

Continuous
Possible Causes
• APP1 circuit high resistance
• APP2 circuit high resistance
• VREF 1 circuit high resistance
• APP1 SIG GND circuit high resistance
• APP2 SIG GND circuit high resistance
• Failed Accelerator Pedal Position (APP) sensor

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
for SPN 91 FMI 2.

Diagnostic Trouble Codes (DTC) list for SPN 91 FMI 2.
Is EST DTC list SPN 91 FMI 2 active or pending? No: Go to Intermittent or Inactive
Fault Diagnostic Procedure
(page 1940).
Step 3 Inspect connections at Accelerator Pedal Position (APP) connector. Decision

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,
FMI 2.
Step 4 Check VREF 1 circuit for Open or high resistance. Decision

Perform Test 1 (page 117). Use DMM, measure voltage between Breakout Harness Yes: Go to Step 5.
ZTSE4485A pin-C and known good GND.
Is voltage 5 ± 0.25 volts? No: Repair Open or high
resistance between APP pin-C
and ECM pin C1-36. After repairs
FMI 2.
Step 5 Check VREF 1 circuit for high resistance. Decision

ZTSE4485A pin-D and known good GND.
Is voltage 5 ± 0.25 volts? No: Repair high resistance
between APP pin-C and ECM
pin C1-06. After repairs are
2.
Step 6 Check APP1 circuit for high resistance. Decision

ZTSE4485A pin-A and pin-B.
Is voltage 1.15 ± 0.25 volts? No: Go to Step 7.
Step 7 Check APP1 SIG GND circuit for high resistance. Decision
Perform Test 4 (page 119). Use DMM, measure voltage between Breakout Harness Yes: Repair high resistance
ZTSE4485A pin-A and known good GND. between APP pin-B and ECM
2.
Is voltage 1.15 ± 0.25 volts? No: Repair high resistance
between APP pin-A and ECM
2.
Step 8 Check APP2 circuit for high resistance. Decision

Perform Test 5 (page 120). Use DMM, measure voltage between Breakout Harness Yes: Replace APP sensor. After
ZTSE4485A pin-F and pin-E. repairs are complete, retest for
SPN 91 FMI 2.
Is voltage 0.6 ± 0.25 volts? No: Go to Step 9.
Step 9 Check APP2 SIG GND circuit for high resistance. Decision
Perform Test 6 (page 121). Use DMM, measure voltage between Breakout Harness Yes: Repair high resistance
ZTSE4485A pin-F and known good GND. between APP pin-E and ECM
2.
between APP pin-F and ECM
2.


See latest version of vehicle Electrical Circuit Diagram on Service Portal for additional circuit information.
Tools Required
• Breakout Harness ZTSE4485A
Figure 9 VREF 1 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
Test 2
A. Key OFF.
D. Key ON
Figure 11 APP1 Circuit Check
Test 3
A. Key OFF.
C. Connect Breakout Harness ZTSE4485A between vehicle harness and APP sensor.
D. Key ON
Figure 12 APP1 SIG GND Circuit Check
Test 4
A. Key OFF.
D. Key ON
Test 5
A. Key OFF.
D. Key ON
Figure 14 APP2 SIG GND Circuit Check
Test 6
A. Key OFF.
D. Key ON
SPN 91 FMI 3 - Accelerator Pedal Position 1: Voltage Above Normal, Or Shorted To High Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Accelerator Pedal Position 1 (APP1) circuit
voltage greater than normal operating range.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• APP1 signal circuit short to PWR
• SIG GND circuit Open
• Failed APP sensor

®
(page 1940).

connector housing.
FMI 3.
Step 3 Check for short to power on APP1 circuit. Decision

ZTSE4485A pin-A and known good GND.
Is voltage 0 ± 0.5 volts? No: Repair short to PWR
between APP pin-A and ECM
3.
Step 4 Check for an Open on SIG GND circuit. Decision

ZTSE4485A pin-B and PWR. repairs are complete, retest for
SPN 91 FMI 3.
Is voltage B+ ± 0.5 volts? No: Repair Open between APP
pin-B and ECM pin C1-02. After
SPN 91 FMI 3.


Tools Required
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B-compliant supporting J1939 and J1708)
G91-3T1
Test 1
A. Key OFF.
D. Key ON.
G91-3T2
Figure 16 SIG GND Circuit Check
Test 2
A. Key OFF.
D. Key ON.
SPN 91 FMI 4 - Accelerator Pedal Position 1 : Voltage Below Normal, Or Shorted To Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Accelerator Pedal Position 1 (APP1) circuit
voltage less than normal operating range.
Lamp Reaction
Associated Faults
SPN 3509
Fault Facts
None

Continuous
Possible Causes
• APP1 circuit Open or short to GND
• VREF circuit Open or short to GND
Step 1 Check for Associated Faults. Decision

®
Diagnostic Trouble Codes (DTC) list for Associated Faults (page 127).
for SPN 91 FMI 4.

1940).

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 91 FMI 4.
Step 4 Check VREF circuit. Decision

Perform Test 1 (page 130). Use DMM, measure voltage between Breakout Yes: Go to Step 5.
Harness ZTSE4485A pin-C and known good GND.
Is voltage 5 ± 0.25 volts? No: Repair Open or short to GND
between APP pin-C and ECM pin
C1-06. After repairs are complete,
retest for SPN 91 FMI 4.
Step 5 Check APP1 circuit. Decision

A. Perform Test 2 (page 131). Yes: Replace APP sensor. After
B. Use EST, perform Continuous Monitor Test (page 1974).
SPN 91 FMI 4.
C. Monitor APP1 voltage in EST while test is active.
between APP pin-A and ECM pin


Tools Required
• Breakout Harness ZTSE4498
Test 1
A. Key OFF.
B. Disconnect APP sensor.
D. Key ON
Test 2
A. Key OFF.
D. Use Breakout Harness ZTSE4498 short Breakout Harness ZTSE4485A pin-A and pin-C together.
SPN 97 FMI 31 - Water In Fuel Indicator 1 : Condition Exists
Fault Overview
This fault sets when water is detected in the fuel.
Lamp Reaction
No lamp will illuminate, but the gauge cluster will display a water in fuel message.
Associated Faults
None
Fault Facts
None.

Continuous
Possible Causes
• Fuel system damage
• Fuel contaminated with water

Perform Fuel Level and System Inspection (page 2152). Yes: Repair fuel system
damage. Drain fuel
system and remove
water. Replace fuel
filters. After repairs are
complete, perform Fuel
system priming (page
2026) and retest for SPN
97 FMI 31.
Is fuel system damaged or leaking? No: Go to Step 2.

Perform Fuel Quality Inspection (page 2156). Yes: Go to Step 3.
Is fuel contaminated with water or Diesel Exhaust Fluid? No: End diagnostics.
Retest for SPN 97 FMI
31.
Step 3 Determine if engine was run with fuel contamination. Decision

Yes: Replace Primary
and Secondary Fuel
Filters. Replace all fuel
system components:
• Aftertreatment Fuel
Injector (AFTFI)
• Fuel injectors
pump
• Aftertreatment fuel
doser module
rail
system lines
• Low-pressure fuel
lines as needed.
• Both fuel filters
• If equipped, replace
the fuel heater.
• Flush the fuel tank.
Does engine run rough, have fuel or performance related fault codes (SPN 157, SPN No: Flush fuel tank,
651-656, SPN 1322-1328, SPN 2797, SPN 2798), stumble, or have a no start condition? change both fuel filters,
and replace any fuel
lines or connections as
needed. After repairs are
complete, perform Fuel
system priming (page
2026) and retest for SPN
97 FMI 31.

SPN 98 FMI 3 - Engine Oil Level : Voltage Above Normal, Or Shorted To High Source
Fault Overview
Fault codes sets when Engine Control Module (ECM) detects Engine Oil Level (EOL) sensor voltage is greater
than expected.
Lamp Reaction
No lamp will illuminate when this fault is detected. This fault code can only be viewed in Electronic Service Tools
(EST)
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• EOL circuit Open or short to PWR
• Failed Engine Oil Level (EOL) sensor

®
1940).
Step 2 Inspect connections at Engine Oil Level (EOL) sensor. Decision

B. Disconnect EOL sensor connector.
C. Check EOL sensor and connector terminals for: damaged or pinched

wires; moisture or corroded terminals; loose, bent, or broken pins; or
broken connector housing.
Are EOL sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
FMI 3.
Step 3 Check EOL circuit for Open or short to PWR. Decision

Perform Test 1 (page 136). Use Digital Multimeter (DMM), measure voltage from Yes: Go to Step 4.
Breakout Harness ZTSE4827 pin-1 and known good GND.
Is voltage 2.5 Volts ± 0.25 Volts? No: Repair Open or short to PWR
between EOL sensor pin-1 and
ECM pin E1-75. After repairs are
complete, retest fro SPN 98 FMI
3.
Step 4 Check SIG GND circuit for Open. Decision

Perform Test 2 (page 137). Use DMM, measure voltage from Breakout Harness Yes: Replace EOL sensor. After
ZTSE4827 pin-2 and B+. repairs are complete, retest fro
SPN 98 FMI 3.
Is voltage B+ ± 0.5 Volts? No: Repair Open between EOL
sensor pin-2 and ECM pin E1-61.
fro SPN 98 FMI 3.


Tools Required
Figure 19 EOL Circuit Check
Test 1
A. Key OFF.
B. Disconnect Engine Oil Level (EOL) sensor.
C. Connect Breakout Harness ZTSE4827 to engine harness and leave EOL sensor disconnected.
D. Key On, Engine Off (KOEO)
Test 2
A. Key OFF.
D. Key ON
SPN 98 FMI 4 - Engine Oil Level : Voltage Below Normal, Or Shorted To Low Source
Fault Overview
Fault codes sets when Engine Control Module (ECM) detects Engine Oil Level (EOL) sensor voltage is less than
expected.
Lamp Reaction
No lamp will illuminate when this fault is detected. This fault code can only be viewed in Electronic Service Tools
(EST)
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• EOL circuit short to GND

®
1940).
Step 2 Inspect connections at Engine Oil Level (EOL) sensor. Decision

A. Key Off. Yes: Go to Step 3.
B. Disconnect EOL sensor connector.
C. Check EOL sensor and connector terminals for: damaged or pinched
Are EOL sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
FMI 4.
Step 3 Check EOL circuit for Open or short to PWR. Decision

Perform Test 1 (page 136). Use Digital Multimeter (DMM), measure voltage from Yes: Replace EOL sensor. After
Breakout Harness ZTSE4827 pin-1 and known good GND. repairs are complete, retest fro
SPN 98 FMI 4.
Is voltage 2.5 Volts ± 0.25 Volts? No: Repair Open or short to PWR
complete, retest fro SPN 98 FMI
4.


Tools Required
Figure 21 EOL Circuit Check
Test 1
A. Key Off.
D. Key ON
SPN 98 FMI 14 - Engine Oil Level : Special Instructions
Fault Overview
This fault sets when the Engine Oil Level (EOL) sensor detects low engine oil level.
Lamp Reaction
Red Stop Lamp (RSL) will illuminate immediately when this fault is detected.
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Low Oil Level (Oil loss)
• Debris or Contamination in engine oil
• Failed Engine Oil Level sensor
Step 1 Check engine oil level. Decision

Was engine oil level within specification? No: Perform 6.0 - Engine Oil
System Operational Checkout
Procedure (page 37)to diagnose
and repair oil loss. After repairs
FMI 14.
Step 2 Inspect oil sensor for debris or contamination. Decision

Review results from Engine Oil Level and Quality Inspection performed in Step 1. Yes: Replace EOL sensor. After
Remove the EOL sensor from the crankcase. repairs are complete, retest for
SPN 98 FMI 14.
Is engine oil free of debris and contamination? No: Remove contamination or
debris. Repair source of debris
or contamination and change
engine oil. After repairs are
14.

SPN 98 FMI 17 - Engine Oil Level : Data Valid But Below Normal Operating Range - Least Severe Level
Fault Overview
This fault sets when the Engine Oil Level (EOL) sensor detects low engine oil level.
Lamp Reaction
Amber Warning Lamp (AWL) will illuminate immediately when this fault is detected.
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Low Oil Level (Oil loss)
• Debris or Contamination in engine oil
• Failed Engine Oil Level sensor
Step 1 Check engine oil level. Decision

Was engine oil level within specification? No: Perform 6.0 - Engine Oil
Procedure (page 37)to diagnose
and repair oil loss. After repairs
FMI 17.
Step 2 Inspect oil sensor for debris or contamination. Decision

Review results from Engine Oil Level and Quality Inspection performed in Step 1. Yes: Replace EOL sensor. After
Remove the EOL sensor from the crankcase. repairs are complete, retest for
SPN 98 FMI 17.
Is engine oil free of debris and contamination? No: Remove contamination or
debris. Repair source of debris
or contamination and change
17.

SPN 100 FMI 3 - Engine Oil Pressure : Voltage Above Normal, Or Shorted To High Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Engine Oil Pressure (EOP) signal voltage is
greater than normal range of operation.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• EOP signal circuit short to PWR
• Failed EOP sensor

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, Key ON, check Yes: Go to Step 2.
(page 1940).
Step 2 Inspect connections at Engine Oil Pressure (EOP) sensor. Decision

B. Disconnect EOP connector.
C. Check EOP and connector terminals for: damaged or pinched wires;
connector housing.
Are EOP connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. After
SPN 100 FMI 3.
Step 3 Check for failed EOP sensor. Decision

A. Perform Test 1 (page 145). Yes: Replace EOP sensor. After
B. Use EST with Navistar® Engine Diagnostics, perform Continuous Monitor
SPN 100 FMI 3.
Test (page 1974).
• During test, monitor EOP voltage with Navistar® Engine Diagnostics.
During test, monitor EOP voltage with EST.
Is voltage 0 volts ± 0.05 volts? No: Go to Step 4.
Step 4 Check for short to PWR in EOP circuit. Decision

A. Perform Test 2 (page 145) Yes: Repair Open between
ECM pin E1-60 and EOP pin-1.
Test (page 1974).
• During test, monitor EOP voltage with Navistar® Engine Diagnostics.
Is voltage 0 volts ± 0.05 volts? No: Repair short to PWR
between ECM pin E1-64 to
EOP pin-3. After repairs are
complete, retest for SPN 100
FMI 3.


Tools Required
Figure 22 Sensor Circuit Check
Test 1
A. Key OFF.
B. Disconnect Engine Oil Pressure (EOP) sensor.
C. Connect Breakout Harness ZTSE4850 to engine harness and leave EOP sensor disconnected.
D. Use Breakout Harness ZTSE4498 to short Breakout Harness ZTSE4850 pin-3 to pin-1.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1956).
F. Key ON, log in to EST with Navistar® Engine Diagnostics.
Figure 23 Sensor Circuit Check
Test 2
A. Key OFF.
B. Disconnect Engine Oil Pressure (EOP) sensor
C. Connect Breakout Harness ZTSE4850 to engine harness and leave EOP sensor disconnected.
D. Use Breakout Harness ZTSE4498 to short Breakout Harness ZTSE4850 pin-3 to known good GND.
SPN 100 FMI 4 - Engine Oil Pressure : Voltage Below Normal, Or Shorted To Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Engine Oil Pressure (EOP) signal voltage is
less than normal operating range.
Lamp Reaction
Associated Faults
SPN 3512 (VREF)
Fault Facts
None

Continuous
Possible Causes
• EOP signal circuit Open
• EOP signal circuit short to GND
Step 1 Check for associated faults Decision

®
for SPN 100 FMI 4.

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics, Key ON, check Yes: Go to Step 3.
(page 1940).

connector housing.
FMI 4.

Perform Test 1 (page 150). Use Digital Multimeter (DMM), measure voltage between Yes: Go to Step 5.
Breakout Harness ZTSE4850 pin-2 and known good GND
Is voltage 5 volts ± 0.25 volts? No: Repair Open or short to
GND between EOP pin-2 and
4.
Step 5 Check Sensor. Decision

A. Perform Test 2 (page 150). Yes: Replace EOP sensor. After
SPN 100 FMI 4.
C. During test, monitor EOP voltage with EST.
Is voltage 5 volts ± 0.25 volts? No: Repair Open or short to
GND between EOP pin-3 and
ECM pin E1-64. After repairs
FMI 4.


Tools Required
Test 1
A. Key OFF.
B. Connect Breakout Harness ZTSE4850 to vehicle harness and leave Engine Oil Pressure (EOP) sensor
disconnected.
C. Key ON.
Figure 25 EOP Circuit Check
Test 2
A. Key OFF.
B. Connect Breakout Harness ZTSE4850 to vehicle harness and leave EOP sensor disconnected.
C. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4850 pin-2 to pin-3.
D. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1956).
E. Key ON, log in to EST.
SPN 100 FMI 14 - Engine Oil Pressure : Special Instructions
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Oil Pressure (EOP) is below critical pressure.
Stop engine immediately when this fault code is active.
Lamp Reaction
Associated Faults
SPN 100 FMI 3, and 4

(EOP)
Fault Facts
Ensure engine oil level and quality are appropriate.

Continuous
Possible Causes
• Failed engine oil mechanical system
Step 1 Check for associated faults. Decision

®
Diagnostic Trouble Code (DTC) list for Associated Faults(page 152).
for SPN 100 FMI 14.
Step 2 nspect connections at Engine Oil Pressure (EOP) sensor. Decision

connector housing.
FMI 14.
Step 3 Check Engine Oil Pressure (EOP) use mechanical gauge. Decision
Perform Oil Pressure Verification Test (page 2137). Yes: Go to Step 4.
Is oil pressure within specification? No: Go to Low Oil Pressure
(page 71) symptom diagnostics.
Step 4 Check biased sensor / circuit Decision

Analyze results from Oil Pressure Verification Test. Yes: End Diagnostics. Retest for
SPN 100 FMI 14.
Is Navistar® Engine Diagnostics EOP reading within 5 psi of instrument panel gauge? No: Replace EOP sensor. After
SPN 100 FMI 14.

After performing diagnostic steps, if SPN 100 FMI 14 remains, verify if step was completed correctly and proper
SPN 100 FMI 17 - Engine Oil Pressure : Data Valid But Below Normal Operating Range - Least Severe
Level
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Oil Pressure (EOP) is below Warning
pressure.
Lamp Reaction
Associated Faults
SPN 100 FMI 3 and 4
Fault Facts
Ensure engine oil level and quality are appropriate.

Continuous
Possible Causes
• Failed engine oil mechanical system
• Failed EOP gauge

®
for SPN 100 FMI 17.

connector housing.
FMI 17.
Step 3 Check Engine Oil Pressure (EOP) use mechanical gauge. Decision
Perform Oil Pressure Verification Test (page 2137). Yes: Go to Step 4.
Is oil pressure within specification? No: Go to Low Oil Pressure
(page 71) symptom diagnostics.
Step 4 Check biased sensor / circuit Decision

Analyze results from Oil Pressure Verification Test. Yes: End Diagnostics. Retest for
SPN 100 FMI 17.
Is Navistar® Engine Diagnostics EOP reading within 5 psi of instrument panel gauge? No: Replace EOP sensor. After
SPN 100 FMI 17.

SPN 102 FMI 0 - Engine Intake Manifold #1 Pressure : Data Valid But Above Normal Operational
Range - Most Severe Level
Fault Overview
Fault code sets when Intake Manifold Pressure (IMP) sensor signal is valid but higher than the normal operating
range.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• IMP circuit failure
• SIG GND circuit failure
• Failed IMP sensor
Step 1 Check for active or pending fault code. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON, check DTC Yes: Go to Step 2.
No: Go to Intermittent or
Is EST DTC list SPN 102 FMI 0 active or pending? Inactive Fault Diagnostic
Step 2 Inspect connections at Intake Manifold Pressure (IMP) connector. Decision

B. Disconnect IMP connector.
C. Check IMP and connector terminals for: damaged or pinched wires; moisture or
corroded terminals; loose, bent, or broken pins; or broken connector housing.
Are IMP connector, harness, and terminals clean and undamaged? No: Repair connector,
harness, or terminal
damage. After repairs
SPN 102 FMI 0.
Step 3 Check for failed IMP sensor. Decision

A. Perform Test 1 (page 159). Yes: Replace IMP
sensor. After repairs are
complete, retest for SPN
C. During test, monitor IMP voltage with EST. 102 FMI 0.
Is voltage less than 0.05 volts? No: Go to Step 4.
Step 4 Check GND circuit for high resistance. Decision

A. Perform Test 2 (page 160). Yes: Repair high
resistance between
ECM pin E1-81 and IMP
C. During test, monitor IMP voltage with EST. pin-1. After repairs are
102 FMI 0.
Is voltage less than 0.05 volts? No: Repair high
resistance between
ECM pin E1-10 to IMP
pin-3. After repairs are
102 FMI 0.

After performing all tests, if no problem is found, verify if each step was completed correctly and the proper decision

Tools Required
Test 1 Setup
A. Key OFF.
B. Disconnect Intake Manifold Pressure (IMP) sensor.
C. Connect Breakout Harness ZTSE4850 to engine harness and leave IMP sensor disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4850 pin-3 to pin-1 together.
Test 2 Setup
A. Key OFF.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4850 pin-3 to a known good GND.
SPN 102 FMI 1 - Engine Intake Manifold #1 Pressure : Data Valid But Below Normal Operational
Fault Overview
Fault code sets when Intake Manifold Pressure (IMP) sensor signal is valid but lower than the normal operating
range.
Lamp Reaction
Associated Faults
None
Fault Facts
None.

Continuous
Possible Causes
• IMP signal circuit Open or short to GND

®
(page 1940).

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

connector housing.
Are IMP connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
FMI 1.

ZTSE4850 pin-2 and known good GND.
Is voltage 5.0 ± 0.25 volts? No: Repair Open or high
resistance between ECM pin
E1-78 and IMP pin-2. After
SPN 102 FMI 1.
Step 4 Check for Failed IMP sensor. Decision

A. Perform Test 2 (page 164). Yes: Replace IMP sensor. After
SPN 102 FMI 1.
C. During test, monitor IMP voltage with EST.
Is voltage 5.0 ± 0.25 volts? No: Repair Open or short to
GND between IMP pin-3 and
FMI 1.


Tools Required
Test 1
A. Key OFF.
C. Connect Breakout Harness ZTSE4850 to vehicle harness and leave IMP sensor disconnected.
D. Key ON.
Figure 29 IMP Circuit Check
Test 2
A. Key OFF.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4850 pin-3 to pin-2.
SPN 102 FMI 2 - Engine Intake Manifold #1 Pressure : Data Erratic, Intermittent Or Incorrect
Fault Overview
This fault code sets when Engine Control Module (ECM) detects Intake Manifold Pressure (IMP) voltage differes
from other pressure sensors more than expected.
Lamp Reaction
Associated Faults
• SPN 102 FMI 3 and 4 • SPN 3512 (VREF)

(IMP)
Fault Facts
None.

Continuous
Possible Causes
• VREF circuit failure
• IMP circuit failure

®
for SPN 102 FMI 2.

Use EST, Key ON, check DTC list for SPN 102 FMI 2. Yes: Go to Step 3.
(page 1940).

connector housing.
FMI 2.

Perform Test 1 (page 168). Use DMM; measure voltage between Breakout Harness Yes: Go to Step 5.
between ECM pin E1-78 and
IMP pin-2. After repairs are
FMI 2.
Step 5 Check for failed IMP sensor Decision

SPN 102 FMI 2.
Step 6 Check for Open or high resistance in IMP circuit. Decision

A. Perform Test 3 (page 169). Yes: Repair high resistance
between ECM pin E1-81 and IMP
pin-1. After repairs are complete,
C. During test, monitor IMP voltage with EST. retest for SPN 102 FMI 2.
Is voltage less than 0.05 volts? No: Repair high resistance
between ECM pin E1-10 to IMP


Tools Required
Test 1
A. Key OFF.
C. Connect Breakout Harness ZTSE4850 to IMP harness and leave sensor disconnected.
D. Key ON.
Test 2
A. Key OFF.
Test 3
A. Key OFF.
SPN 102 FMI 3 - Engine Intake Manifold #1 Pressure : Voltage Above Normal, Or Shorted To High Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Intake Manifold Pressure (IMP) signal voltage
greater than normal operating range.
Lamp Reaction
Associated Faults
None.
Fault Facts
None.

Continuous
Possible Causes
• IMP Circuit short to PWR

®
(page 1940).

connector housing.
SPN 102 FMI 3.
Step 3 Check for failed IMP sensor Decision

SPN 102 FMI 3.
Test (page 1974).
• During test, monitor IMP voltage with Navistar® Engine Diagnostics.
Step 4 Check for Open or short to PWR in IMP circuit. Decision

A. Perform Test 2 (page 173). Yes: Repair open between ECM
®
pin E1-81 and IMP pin-1. After
B. Use EST with Navistar Engine Diagnostics, perform Continuous Monitor
Test (page 1974).
SPN 102 FMI 3.
• During test, monitor IMP voltage with Navistar® Engine Diagnostics.
Is voltage less than 0.05 volts? No: Repair short to PWR
between ECM pin E1-10 to IMP


Tools Required
Test 1
A. Key OFF.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4850 pin-3 to pin-1 together.
Test 2
A. Key OFF.
E. Key ON, log in to EST with Navistar® Engine Diagnostics.
SPN 102 FMI 4 - Engine Intake Manifold #1 Pressure : Voltage Below Normal, Or Shorted To Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Intake Manifold Pressure (IMP) signal voltage less
than normal operating range.
Lamp Reaction
Associated Faults
SPN 3512
Fault Facts
None.

Continuous
Possible Causes
• IMP signal circuit Open or short to GND

®
for SPN 102 FMI 4.

(page 1940).

connector housing.
FMI 4.

Is voltage 5.0 ± 0.25 volts? No: Repair Open or high
E1-78 and IMP pin-2. After
SPN 102 FMI 4.
Step 5 Check for Failed IMP sensor. Decision

SPN 102 FMI 4.
GND between IMP pin-3 and
FMI 4.


Tools Required
Test 1
A. Key OFF.
D. Key ON.
Test 2
A. Key OFF.
SPN 102 FMI 10 - Engine Intake Manifold #1 Pressure : Abnormal Rate Of Change
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that actual Intake Manifold Pressure (IMP) deviates.
Lamp Reaction
Associated Faults
SPN 102 FMI 0, 1, 2, 3, and SPN 132 SPN 157 SPN 641
4
SPN 651–656 FMI 3,4,5, SPN 1322–1328 FMI 14 or SPN 1209 FMI 2, 3, and 4 SPN 4228
and 18 31
Fault Facts
Do not electrically power up the VGT Actuator if it is disconnected from the turbocharger.

Road Test
Possible Causes
• Failed Variable Geometry Turbocharger (VGT) Controller
• Restricted Intake Air or Charge Air Cooler (CAC) System
• CAC hose, clamp, or pipe leaking
• Failed EBP sensor pipe
CAUTION:
To prevent damage, do not drive vehicle if Charge Air Cooler (CAC) hose or other charge
air leaks are present. Over fueling and damage to the exhaust aftertreatment may occur.

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics, Key ON, Yes: Go to Step 2.
check Diagnostic Trouble Codes (DTC) list for Associated Faults (page 180).
for SPN 102 FMI 10.
WARNING:
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.
Are CAC hoses and charge air system free of leaks? No: Repair CAC hose or charge
air system leaks, or damage.
After repairs are complete, go to
Step 3.
A. Using EST check Diagnostic Trouble Code (DTC) list. Yes: Perform DPF Replacement
After Boost System Leak or Over
Temperature (page 2263). After
• 55770, Max DPF Outlet Temperature – DOC Inlet Temperature SPN 102 FMI 10.
Is SPN 3936 FMI 16 Active, or did any DPF Outlet Temperature go above 1550 No: Clear fault codes, Perform
°F (843 °C)? stationary DPF Regeneration
SPN 102 FMI 10.
Step 4 Determine if VGT can meet commanded position. Decision

Did VGT meet commanded position? No: Go to Step 5.

A. Key OFF. Disconnect VGT Actuator connector. Yes: Go to Step 6.
B. Disconnect VGT linkage at VGT Actuator.
Important: Leave Key OFF and VGT actuator connector disconnected
while VGT Actuator linkage is disconnected from turbocharger.
C. Manually move VGT Actuator from fully open to fully closed and back to
open.
Is VGT Actuator free from sticking or binding? No: Replace VGT Actuator Only.
for SPN 102 FMI 10.

A. Key OFF. VGT Actuator connector and linkage still disconnected. Yes: Go to Step 7.
while VGT Actuator linkage is disconnected.
B. Manually move VGT vane side of turbocharger from fully open to fully
closed and back to open.
C. Reinstall VGT Actuator linkage on to turbocharger before reconnecting
actuator connector.
Are VGT vanes free from sticking or binding? No: Replace entire VGT
assembly. After repairs are
10.

A. Key OFF. Remove EGR bellows tubes. See Engine Service Manual for Yes: Go to Step 8.
additional information.
C. Press on EGR butterfly valve. If it opens with light pressure, replace the
EGR valve.
D. Perform EGR Valve Position Test (page 1989). While test is active, watch
to determine if EGR valve shaft and butterfly rotate together, the valve
can close completely and there is no debris or soot blocking or restricting
valve movement.
Is the butterfly valve free of damage, does the butterfly valve move with its shaft No: Replace EGR valve. After
when actuated, and does the butterfly valve stay in position when pressed with repairs are complete, retest for
light pressure? SPN 102 FMI 10.
Step 8 Verify engine responds appropriately during the Air Management Decision
System test.
Perform Air Management Test (page 2004) while monitoring IMP, EBP, VGT Position, Yes: End Diagnostics. Retest for
and EGR position signals. SPN 102 FMI 10.
Was EBP always greater than IMP. And did IMP and EBP both increase as VGT No, EBP did not respond to
position is increased, and decrease as the EGR Valve is position is increased? changes in VGT and EGR
Positions: Go to Step 9.
No, IMP did not respond to
changes in VGT and EGR
Step 9 Inspect Exhaust Back Pressure (EBP) connector. Decision

A. Key OFF. Disconnect EBP connector. Yes: Go to Step 10.
B. Check EBP sensor and connector terminals for: damage or pinched wires;
connector housing.
Is EBP connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal. After repairs are
10.
Step 10 Inspect EBP sensor pipe. Decision

A. Inspect EBP sensor pipe for exhaust leaks or damage Yes: End Diagnostics. Retest for
SPN 102 FMI 10.
B. Remove and inspect EBP sensor and sensor pipe (see Engine Service
Manual).
Is line clear of damage, restriction, moisture, or soot buildup? No: Replace EBP sensor pipe.
for SPN 102 FMI 10.
Step 11 Check Intake system for large leaks. Decision

Perform Smoke Test (Air Intake System) (page 2093). Yes: Yes, If CAC was leaking,
Perform Charge Air Cooler (CAC)
Pressure Test (page 2085).
Replace CAC if failed. After
SPN 102 FMI 10.
Yes: Yes, Intake hoses and (or)
piping leaking, repair intake.
for SPN 102 FMI 10.
Were any leaks found in intake hose, piping or CAC? No: Go to step 12.
Step 12 Inspect turbocharger for damage. Decision

Perform Turbocharger Radial Play Inspection (page 2183). Yes: Replace turbocharger. After
SPN 102 FMI 10.
Does the turbocharger have signs of wear and / or excessive radial play? No: End diagnostics. Retest for
SPN 102 FMI 10.

After performing all tests, if no problem is found, verify if each step was completed correctly and the proper decision was
made. Return to SPN 102 FMI 10 fault code diagnostics.
SPN 102 FMI 16 - Engine Intake Manifold #1 Pressure : Data Valid But Above Normal Operating Range -
Moderately Severe Level
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Intake Manifold Pressure (IMP) is greater than
a predetermined value.
Lamp Reaction
Associated Faults
4
and 18 31
Fault Facts

Road Test
Possible Causes
• Variable Geometry Turbocharger (VGT) Actuator failure

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for Associated Yes: Go to Step 2.
Faults (page 184).
Is EST DTC list free of Associated Faults? No: Repair Associated
Faults. After repairs are
102 FMI 16.

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for SPN Yes: Go to Step 3.
102 FMI 16.
Is EST DTC list SPN 102 FMI 16 active or pending? No: Go to Intermittent or
Inactive Fault Diagnostic
Step 3 Determine if Variable Geometry Turbocharger (VGT) can meet commanded Decision
position.
Perform VGT Position Test (page 1991). Yes: End diagnostics,
retest for SPN 102 FMI
16.

Important: Leave Key OFF and VGT actuator connector disconnected while VGT
Actuator linkage is disconnected from turbocharger.
Is VGT Actuator free from sticking or binding? No: Replace VGT
Actuator Only. After
16.

16.
Actuator linkage is disconnected.
B. Manually move VGT vane side of turbocharger from fully open to fully closed and
back to open.
connector.
assembly. After repairs
SPN 102 FMI 16.

After performing all tests, if no problem is found, verify if each step was completed correctly and the proper decision was
SPN 102 FMI 18 - Engine Intake Manifold #1 Pressure : Data Valid But Below Normal Operating Range -
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Intake Manifold Pressure (IMP) is less than
desired for current operation.
Lamp Reaction
Associated Faults
4
and 18 31
Fault Facts

Road Test
Possible Causes
• Failed Variable Geometry Turbocharger (VGT) Controller
• Restricted Intake Air or Charge Air Cooler (CAC) System
• CAC hose, clamp, or pipe leaking
• Failed EBP sensor pipe

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, Key ON, Yes: Go to Step 2.
for SPN 102 FMI 18.
Step 2 Determine if engine air intake or CAC is leaking, damaged, restricted. Decision
Is air intake system, CAC, and air filter free of restrictions, leaks, and physical No: Repair intake, CAC, or air
damage? filter restriction, leak, or physical
damage. After repairs are
18
Step 3 Determine if VGT can meet commanded position. Decision


D. Manually move VGT Actuator from fully open to fully closed and back to
open.
for SPN 102 FMI 18.

A. Key OFF. VGT Actuator connector and linkage still disconnected. Yes: End diagnostics, retest for
SPN 102 FMI 18.

actuator connector.

7.

Perform EGR Valve Position Test (page 1989). Yes: Go to step 7.
Did EGR valve meet commanded position? No: Replace EGR Valve. After
SPN 102 FMI 18.
Step 7 Verify engine responds appropriately during the Air Management Decision
System test.
Perform Air Management Test (page 2004) while monitoring IMP, EBP, VGT Position, Yes: End Diagnostics. Retest for
and EGR position signals. SPN 102 FMI 18.
Was EBP always greater than IMP. And did IMP and EBP both increase as VGT No, EBP did not respond to
position is increased, and decrease as the EGR Valve is position is increased? changes in VGT and EGR
No, IMP did not respond to
changes in VGT and EGR
Step 8 Inspect Exhaust Back Pressure (EBP) connector. Decision

B. Disconnect EBP connector.
C. Check EBP sensor and connector terminals for: damage or pinched wires;
connector housing.
Is EBP connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal. After repairs are
18.
Step 9 Inspect EBP sensor pipe. Decision

A. Inspect EBP sensor pipe for exhaust leaks or damage Yes: End Diagnostics. Retest for
SPN 102 FMI 18.
B. Remove and inspect EBP sensor and sensor pipe (see Engine Service
Manual).
Is line clear of damage, restriction, moisture, or soot buildup? No: Replace EBP sensor pipe.
for SPN 102 FMI 18.
Step 10 Check Intake system for large leaks. Decision

Perform Smoke Test (Air Intake System) (page 2093). Yes: Yes, If CAC was leaking,
Perform Charge Air Cooler (CAC)
Pressure Test (page 2085).
Replace CAC if failed. After
SPN 102 FMI 18.
Yes: Yes, Intake hoses and (or)
piping leaking, repair intake.
for SPN 102 FMI 18.
Were any leaks found in intake hose, piping or CAC? No: Go to step 11.
Step 11 Inspect turbocharger for damage. Decision

Perform Turbocharger Radial Play Inspection (page 2183). Yes: Replace turbocharger. After
SPN 102 FMI 18.
Does the turbocharger have signs of wear and / or excessive radial play? No: End diagnostics. Retest for
SPN 102 FMI 18.

SPN 105 FMI 0 - Engine Intake Manifold 1 Temperature : Data Valid But Above Normal Operational
Fault Overview
Fault code sets when Intake Manifold Temperature (IMT) sensor signal is valid but higher than the normal
operating range.
Lamp Reaction
Associated Faults
SPN 105 FMI 4
Fault Facts
None

Continuous
Possible Causes
• IMT circuit failure
• Failed IMT sensor

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Diagnostic Yes: Go to Step 2.
Trouble Code (DTC) list for Associated Faults(page 191).
105 FMI 0.

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics. Key ON, check DTC Yes: Go to Step 3.
Step 3 Inspect connections at Intake Manifold Temperature (IMT) connector. Decision

B. Disconnect IMT connector.
C. Check IMT and connector terminals for: damaged or pinched wires; moisture or
Are IMT connector, harness, and terminals clean and undamaged? No: Repair connector,
SPN 105 FMI 0.
Step 4 Check IMT circuit for high resistance. Decision

B. Disconnect IMT sensor.

C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1956).
D. Key ON, log in to Navistar® Engine Diagnostics.

E. Perform Continuous Monitor Test
F. During test, monitor IMT voltage in EST.
Is voltage 5.0 ± 0.25 volts? No: Repair high
resistance between
ECM pin E1-36 and IMT
pin-B. After repairs are
105 FMI 0.
Step 5 Check for failed IMT sensor. Decision

Perform Test 1(page 195). Use EST, perform Continuous Monitor Test (page 1974). Monitor Yes: Replace IMT
IMT voltage while test is active. sensor. After repairs are
105 FMI 0.
Is voltage approximately 0 volts? No: Go to Step 6.

Perform Test 2(page 195). Use EST, perform Continuous Monitor Test (page 1974). Monitor Yes: Repair high
IMT voltage while test is active. resistance between
pin-A. After repairs are
105 FMI 0.
Is voltage approximately 0 volts? No: Repair high
resistance between
105 FMI 0.


Tools Required
4498
B 4782
0000415337
Figure 37 IMT Circuit Check
Test 1 Setup
A. Key OFF.
B. Disconnect Intake Manifold Temperature (IMT) sensor.
C. Connect Breakout Harness ZTSE4782 to engine harness and leave Intake Manifold Temperature (IMT) sensor
disconnected.
D. Use Breakout Harness ZTSE4498 short pin-A and pin-B of Breakout Harness ZTSE4782 together.
F. Key ON, log in to EST.
4498
4782
0000416048
Test 2 Setup
A. Key OFF.
disconnected.
D. Use Breakout Harness ZTSE4498, short pin-B to a known good GND.
SPN 105 FMI 2 – Engine Intake Manifold 1 Temperature : Data Erratic, Intermittent Or Incorrect
Fault Overview
Fault code sets when Intake Manifold Temperature (IMT) sensor temperature differs from other engine
temperature sensors by greater than 27°F (15°C) after a cold soak.
Lamp Reaction
Associated Faults
SPN 105 FMI 3 and 4
Fault Facts
None

Continuous
Possible Causes
• IMT circuit failure
• Block heater, Auxiliary Power Unit (APU) or other Auxiliary coolant heaters being used

®
105 FMI 2.

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics. Key ON, check DTC Yes: Go to Step 3.
Step 3 Check for Block heater, Auxiliary Power Unit (APU) or other Auxiliary coolant Decision
heaters being used.
Review customer complaint, interview vehicle operator and view fault code freeze frame data. Yes: Clear fault code
after all other faults have
been diagnosed. After
Was fault code set after using a Block heater, Auxiliary Power Unit (APU) or other Auxiliary No: Go to Step 4.
coolant heater overnight?

C. Check IMT and connector terminals for: damaged or pinched wires; moisture or
Are IMT connector, harness, and terminals clean and undamaged? No: Repair connector,
SPN 105 FMI 2.
Step 5 Check IMT circuit for short to GND. Decision

B. Disconnect IMT sensor.
E. Perform Continuous Monitor Test

between ECM pin E1-36
and IMT pin-B. After
2.
Step 6 Check for failed IMT sensor. Decision

Perform Test 1(page 201). Use EST, perform Continuous Monitor Test (page 1974). Monitor Yes: Replace IMT
IMT voltage while test is active. sensor. After repairs are
105 FMI 2.

Perform Test 2(page 201). Use EST, perform Continuous Monitor Test (page 1974). Monitor Yes: Repair high
IMT voltage while test is active. resistance between
pin-A. After repairs are
105 FMI 2.
Is voltage approximately 0 volts? No: Repair high
resistance between
105 FMI 2.


Tools Required
4498
B 4782
0000415337
Test 1 Setup
A. Key OFF.
disconnected.
D. Use Breakout Harness ZTSE4498 short pin-A and pin-B of Breakout Harness ZTSE4782 together.
4498
4782
0000416048
Test 2 Setup
A. Key OFF.
disconnected.
D. Use Breakout Harness ZTSE4498, short pin-B to a known good GND.
SPN 105 FMI 3 – Engine Intake Manifold 1 Temperature : Voltage Above Normal, Or Shorted To High
Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Intake Manifold Temperature (IMT) voltage is
Lamp Reaction
Malfunction Indicator Lamp (MIL) will immediately illuminate when this fault is detected.
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• IMT circuit Open
• IMT circuit short to PWR

®
(page 1940).

C. Check IMT and connector terminals for: damaged or pinched wires;
connector housing.
Are IMT connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
SPN 105 FMI 3.
Step 3 Check IMT circuit for short to PWR. Decision

Perform Test 1(page 206). Use DMM to measure voltage between Breakout Harness Yes: Repair short to PWR
ZTSE4782 pin-B and a known good GND. between IMT pin-B and Engine
Control Module (ECM) pin
E1-36. After repairs are
FMI 3.
Is voltage greater than 5 volts? No: Go to Step 4.
Step 4 Check for a failed IMT sensor. Decision

Perform Test 2(page 206). Use EST, perform Continuous Monitor Test (page 1974). Yes: Replace IMT sensor. After
Monitor IMT while test is active. repairs are complete, retest for
SPN 105 FMI 3.
Step 5 Check for IMT circuit failure. Decision

Perform Test 3(page 207). Use EST, perform Continuous Monitor Test (page 1974). Yes: Repair Open between IMT
Monitor IMT while test is active. pin-A and ECM pin E1-61. After
SPN 105 FMI 3.
Is voltage approximately 0 volts? No: Repair Open between IMT
pin-B and ECM pin E1-36. After
SPN 105 FMI 3.


Tools Required
B
4782
0000415343
Figure 41 IMT Circuit Voltage Check
Test 1
A. Key OFF.
C. Connect Breakout Harness ZTSE4782 to engine harness and leave IMT sensor disconnected.
D. Key ON.
4498
B 4782
0000415337
Figure 42 IMT Sensor Circuit Check
Test 2
A. Key OFF.
D. Use Breakout Harness ZTSE4498 short Breakout Harness ZTSE4782 pin-A and pin-B together.
4498
4782
0000416048
Test 3
A. Key OFF.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4782 pin-B to known good GND.
SPN 105 FMI 4 - Engine Intake Manifold 1 Temperature : Voltage Below Normal, Or Shorted To Low
Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Intake Manifold Temperature (IMT) voltage is
less than normal operating range.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• IMT circuit short to GND

®
(page 1940).

C. Check IMT and connector terminals for: damaged or pinched wires;
connector housing.
Are IMT connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
SPN 105 FMI 3.
Step 3 Check IMT circuit for high resistance. Decision

A. Key Off. Yes: Replace IMT sensor. After
B. Disconnect IMT sensor
SPN 105 FMI 4.
C. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector
(page 1956).
E. Perform Continuous Monitor Test (page 1974).

Is voltage 5 ± 0.25 volts? No: Repair short to GND
between IMT pin-B and Engine
Control Module pin E1-36. After
SPN 105 FMI 4.

SPN 105 FMI 10 - Engine Intake Manifold 1 Temperature : Abnormal Rate Of Change
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Intake Manifold Temperature (IMT) did not rise as
expected after the Cold Start System has run a full cycle.
Lamp Reaction
Associated Faults
SPN 105 FMI 2, 3, 4, and 18 SPN 171 FMI 2, 3, and 4 SPN 626 FMI 3, 4, and 5 SPN 5548
Fault Facts
None

Road Test
Possible Causes
• Damaged or restricted fuel lines to Cold Start Assist system
• PWR circuit to Cold Start Fuel Igniter Relay Open
• Failed Cold Start Assist Enable Device (Fuel Solenoid)
• Failed Cold Start Fuel Igniter (CSFI)

®
for SPN 105 FMI 10.
Step 2 Check for correct amperage draw while Cold Start Fuel Igniter (CSFI) Decision
is actuated.
Perform Cold Start Fuel Igniter Test (page 2058). While test is active, measure Yes: Go to Step 3.
the amperage draw at CSFI.
Does current draw drop below 15 amps during test? No: Go to Step 4.
Step 3 Check for failed Cold Start System PWR circuit. Decision
Perform Cold Start Fuel Igniter Test (page 2058). While test is active, use DMM, Yes: Replace Cold Start Fuel
measure voltage between CSFI stud and known good GND. Igniter. After repairs are
10.
Is voltage B+ ± 1.0 volts. No: Repair Open in Cold Start
System PWR circuit. After repairs
FMI 10.
Step 4 Check for correct fuel supply to Cold Start Enable Device. Decision
Perform Fuel Supply at Cold Start Enable Device Test (page 2060). Yes: Go to Step 5.
Is fuel supply pressure with specification? No: Replace damaged, leaking
or restricted fuel supply line to
Cold Start Enable Device (fuel
solenoid). After repairs are
10.
Step 5 Check for correct fuel supply Decision

Perform Fuel Supply at Cold Start Fuel Igniter Test (page 2063). Yes: Replace Cold Start Fuel
Igniter. After repairs are
10.
Is fuel supply pressure with specification? No: Go to Step 6.
Step 6 Check for fuel line damage or restriction to CSFI. Decision

Check CSFI fuel line and connections for damage, leaks or restrictions. Disconnect Yes: End Diagnostics. Retest for
both ends of fuel line and blow compressed air through line. SPN 105 FMI 10.
Is fuel line and connections in good condition and not damaged, leaking, or No: Replace damage, leaking
restricted? or restricted CSFI fuel line or
connections. After repairs are
10.

SPN 105 FMI 18 - Engine Intake Manifold 1 Temperature : Data Valid But Below Normal Operating
Range - Moderately Severe Level
Fault Overview
Fault code sets when Engine Control Module (ECM) detects difference between Key On Engine Running (KOER)
Intake Manifold Temperature (IMT) and Key On Engine Off (KOEO) IMT is less than expected after Cold Start
System has been activated.
Lamp Reaction
Associated Faults
SPN 105 FMI 2, 3, and 4 SPN 171 FMI 2, 3, and 4 SPN 626 FMI 3, 4, and 5 SPN 5548 FMI 3, 4, 5, and 8
Fault Facts
None.

Road Test
Possible Causes
• Damaged or restricted fuel lines to Cold Start system
• PWR circuit to Cold Start Fuel Ignitor (CSFI) Relay Open
• Failed Cold Start Enable Device (CSED) (fuel solenoid)
• Failed CSFI

®
Is EST DTC list free of Associated Faults? No: Go to Intermittent or Inactive
(page 1940).
Step 2 Check for correct amperage draw while Cold Start Fuel Igniter (CSFI) Decision
is actuated.
A. Check that engine coolant temperature is below 100°F (38°C). Yes: Go to Step 3.
B. When engine coolant temperature is below 100°F (38°C) perform Cold
Start Fuel Igniter Test (page 2058).
Does CSFI current drop below 15 amps during test? No: Go to Step 4.
Step 3 Check for Failed CSFI PWR circuit. Decision

Perform Actuator Test (page 1968). Select Eng Cold Start and Fuel Igniter tabs in Yes: Replace CSFI. After repairs
test session. During test, use DMM, measure voltage between CSFI PWR stud are complete, retest for SPN 105
and known good GND. FMI 18.
Is voltage between 10 and 13 volts. No: Repair Open in CSFI
PWR circuit. After repairs are
18.
Step 4 Check for correct fuel supply to Cold Start Enable Devise (CSED) Decision
(fuel solenoid).
Perform Fuel Supply at Cold Start Enable Device Test (page 2060). Yes: Go to Step 5.
Is fuel supply pressure with specification? No: Replace damaged, leaking
or restricted fuel supply line to
CSED (fuel solenoid). After
SPN 105 FMI 18.
Step 5 Check for correct fuel supply to CSFI. Decision

Perform Fuel Supply at Cold Start Fuel Igniter Test (page 2063). Yes: Replace CSFI. After repairs
FMI 18.
Is fuel supply pressure with specification? No: Go to Step 6.
WARNING:
To prevent personal injury or death, wear safety glasses with side shields. Limit
compressed air pressure to 30 psi (207 kPa).
Step 6 Check for fuel line damage or restriction to CSFI. Decision

Check CSFI fuel line and connections for damage, leaks or restrictions. Disconnect Yes: Replace CSED (fuel
both ends of CSFI fuel line and blow compressed air through line. solenoid). After repairs are
18.
Are fuel lines and connections in good condition and not damaged, leaking, or No: Replace damage, leaking
restricted? or restricted CSFI fuel line or
18.

SPN 108 FMI 1 - Barometric Pressure : Data Valid But Below Normal Operational Range - Most Severe
Level
Fault Overview
This fault code sets when Engine Control Module (ECM) internal Barometric Pressure (BARO) Sensor signal is
reading lower than expected range.
Lamp Reaction
Associated Faults
None
Fault Facts
BARO Sensor is installed inside ECM and is not serviceable separately.

Continuous
Possible Causes
• ECM Calibration Not Current
• Failed ECM
Step 1 Check for current Engine Control Module (ECM) calibration. Decision
View calibration scorecard on Service Portal. Yes: Go to Step 2.
Is ECM calibration current? No: Ensure vehicle has latest
ECM calibration. After repairs
FMI 1.

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics. Key On, Yes: Replace ECM, following
check Diagnostic Trouble Code (DTC) list for SPN 108 FMI 1. approved warranty procedures,
and perform Crankshaft Position
Sensor Relearn Procedure (page
1926). After repairs are complete,
Is SPN 108 FMI 1 active or pending? No: Repair other active codes
first. Retest for SPN 108 FMI 1.

SPN 108 FMI 2 - Barometric Pressure : Data Erratic, Intermittent Or Incorrect
Fault Overview
This fault code sets when Engine Control Module (ECM) internal Barometric Pressure (BARO) Sensor signal
differs from other pressure sensors more than expected.
Lamp Reaction
Associated Faults
None
Fault Facts

Continuous
Possible Causes
• Failed ECM
FMI 2.


SPN 108 FMI 3 - Barometric Pressure : Voltage Above Normal, Or Shorted To High Source
Fault Overview
This fault code sets when Engine Control Module (ECM) internal Barometric Pressure (BARO) Sensor voltage
is greater than normal operating range.
Lamp Reaction
Associated Faults
None
Fault Facts

Continuous
Possible Causes
• Failed ECM
FMI 3.


SPN 108 FMI 4 - Barometric Pressure : Voltage Below Normal, Or Shorted To Low Source
Fault Overview
This fault code sets when Engine Control Module (ECM) internal Barometric Pressure (BARO) Sensor voltage
is below normal operating range.
Lamp Reaction
Associated Faults
None
Fault Facts

Continuous
Possible Causes
• Failed ECM
FMI 4.


SPN 110 FMI 0 - Engine Cooling System above Critical Temperature
Fault Overview
Fault code sets when Electronic Control Module (ECM) detects that Engine Coolant Temperature (ECT) is is
Lamp Reaction
Associated Faults
SPN 110 FMI 3, and 4
Fault Facts
Air pockets in cooling system can interfere with coolant flow or prevent thermostats from opening when needed,
resulting in this fault.

Continuous
Possible Causes
• Cooling system overheating

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Ensure coolant level is at
Diagnostic Trouble Code (DTC) list for Associated Faults(page 223). normal operating level, go to Step
2 of Cooling System Operational
SPN 110 FMI 0.

SPN 110 FMI 2 - Engine Coolant Temperature : Data Erratic, Intermittent Or Incorrect
Fault Overview
Fault code sets when Engine Coolant Temperature (ECT) sensor temperature differs from other engine
temperature sensors by greater than 27°F (15°C) after a cold soak.
Lamp Reaction
Associated Faults
SPN 110 FMI 3 and 4 (ECT)
Fault Facts
None

Continuous
Possible Causes
• ECT circuit short to GND
• High resistance in ECT circuit
• High resistance in SIG GND circuit
• Failed ECT sensor

®
Is EST DTC list free of Associated Faults? No: Repair Associated Faults .
for SPN 110 FMI 2.

1940).
Step 3 Inspect connections at Engine Coolant Temperature 1 (ECT) connector. Decision

B. Disconnect ECT connector.
C. Check ECT and connector terminals for: damaged or pinched wires;
connector housing.
Are ECT connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
FMI 2.
Step 4 Check ECT circuit for short to GND. Decision

A. Perform Test 1 (page 228). Yes: Go to Step 5.
B. Perform Continuous Monitor Test (page 1974).
C. With test in progress, monitor ECT voltage with EST.
Is voltage 5.0 ± 0.25 volts? No: Repair short to GND between
ECM pin E1-87 and ECT pin-2.
for SPN 110 FMI 2.
Step 5 Check for a failed ECT censor. Decision

A. Perform Test 2 (page 228). Yes: Replace ECT sensor. After
SPN 110 FMI 2.
C. With test in progress, monitor ECT voltage with EST.

ECT pin-1. After repairs are
C. With test in progress, monitor ECT voltage with EST. complete, retest for SPN 110 FMI
2.
Is voltage approximately 0 volts? No: Repair high resistance
ECT pin-2. After repairs are
2.

Pin-Point Tests (SPN 110 FMI 2)

Tools Required
• 3-Banana Plug Harness ZTSE4498
Test 1
A. Key OFF.
B. Disconnect Engine Coolant Temperature (ECT) sensor.
Figure 44 ECT Circuit Check
Test 2
A. Key OFF.
C. Connect Breakout Harness ZTSE4602 to engine harness connector and leave ECT sensor disconnected.
D. Use Breakout Harness ZTSE4498 short pin-1 and pin-2 of Breakout Harness ZTSE4602 together.
E. Key ON. Log in to EST.
Figure 45 ECT Signal Circuit Check
Test 3
A. Key OFF.
C. Connect Breakout Harness ZTSE4602 to engine harness connector and leave ECT sensor disconnected.
D. Use Breakout Harness ZTSE4498, short pin-2 to a known good GND.
E. Key ON. Log in to EST.
SPN 110 FMI 3 - Engine Coolant Temperature : Voltage Above Normal, Or Shorted To High Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects ECT1 signal is greater than normal operating range.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• ECT1 signal circuit Open
• ECT1 signal circuit short to PWR
• ECT1 SIG GND circuit Open
• Failed ECT1 sensor

®
Diagnostic Trouble Code (DTC) list for SPN 110 FMI 3.
(page 1940).
Step 2 Inspect connections at Engine Coolant Temperature (ECT1) connector. Decision

B. Disconnect ECT1 sensor connector.
C. Check ECT1 sensor and connector terminals for damaged or pinched
wires; 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,
SPN 110 FMI 3.
Step 3 Check ECT1 circuit for short to PWR. Decision

Perform Test 1 (page 233). Use Digital Multimeter (DMM), measure voltage between Yes: Repair short to PWR
Breakout Harness ZTSE4782 pin-2 and known good GND. between ECT1 pin-2 and
Engine Control Module (ECM)
pin E1-87. After repairs are
FMI 3.
Step 4 Check for a failed ECT1 sensor. Decision

A. Perform Test 2 (page 233). Yes: Replace ECT1 sensor.
®
for SPN 110 FMI 3.
Test (page 1974).
• During test, monitor ECT1 voltage with EST with Navistar® Engine
Diagnostics.
Step 5 Check for ECT1 circuit failure. Decision

A. Perform Test 3 (page 234). Yes: Repair Open between
ECT1 pin-1 and ECM pin E1-61.
Test (page 1974).
for SPN 110 FMI 3.
Diagnostics.
Is voltage approximately 0 volts? No: Repair Open between ECT1
pin-2 and ECM pin E1-87. After
SPN 110 FMI 3.


Tools Required
Figure 46 ECT1 Sensor Circuit Check
Test 1
A. Key OFF.
B. Disconnect Engine Coolant Temperature 1 (ECT1) sensor
C. Connect Breakout Harness ZTSE4602 to engine harness and leave ECT1 sensor disconnected.
D. Key ON.
Test 2
A. Key OFF.
B. Disconnect Engine Coolant Temperature (ECT1) sensor.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4602 pin-1 and pin-2 together.
F. Key ON. Log in to EST with Navistar® Engine Diagnostics.
Test 3
A. Key OFF.
B. Disconnect Engine Coolant Temperature (ECT1) sensor.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4602 pin-2 to known good GND.
F. Key ON. Log in to EST with Navistar® Engine Diagnostics.
SPN 110 FMI 4 - Engine Coolant Temperature : Voltage Below Normal, Or Shorted To Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Engine Coolant Temperature 1 (ECT1) sensor
signal voltage is less than normal operating range.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• ECT1 circuit short to GND
• Failed ECT1 sensor

®
(page 1940).
Step 2 Inspect connections at Engine Coolant Temperature 1 (ECT1) sensor. Decision

B. Disconnect ECT1 sensor connector.
C. Check ECT1 sensor and connector terminals for damaged or pinched
housing.
Are ECT1 sensor, connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
SPN 110 FMI 4.
Step 3 Check for a failed ECT1 sensor. Decision

A. Perform Test 1 (page 238). Yes: Replace ECT1 sensor.
for SPN 110 FMI 3.
Test (page 1974).
Diagnostics.
Is voltage 5V ± 0.25 volts? No: Repair short to GND
between ECT1 pin-2 and ECM
FMI 4.


Tools Required
Test 1
A. Key OFF.
B. Disconnect Engine Coolant Temperature 1 (ECT1) sensor.
D. Key ON. Log in to EST with Navistar® Engine Diagnostics.
SPN 110 FMI 10 - Engine Coolant Temperature : Abnormal Rate Of Change
Fault Overview
Fault code sets when signal from Engine Coolant Temperature (ECT) is lower than the 122° F (50° C) when
Engine Control Module's (ECM) modeled coolant temperature based on operation is above 122° F (50° C).
Lamp Reaction
Associated Faults
SPN 111 FMI 1
Fault Facts
None

Continuous
Possible Causes
• Low coolant level
• Failed engine thermostats
• Failed Engine Fan solenoid
• Failed engine fan clutch.
Step 1 Decision
®
SPN 110 FMI 14.
Step 2 Inspect coolant level. Decision

Perform Coolant Level Inspection (page 2159). Yes: Go to step 2 of 5.0 - Cooling
Procedure (page 34) to diagnose
coolant loss. After repairs are
complete, retest SPN 110 FMI 14.
Is Coolant level low, is there evidence of coolant loss, or does operator complain of No: Go to Step 3.
coolant leaks or consumption?
Step 3 Check for failed Thermostats. Decision

Perform Thermostat Operational Test. (page 2136). Yes: Go to Step 4.
Did thermostats operate correctly and Open at specified temperature? No: Replace Thermostats. After
SPN 110 FMI 10.
Step 4 Determine if engine fans are operating properly. Decision

Perform Engine Fan Test (page 2013). Yes: End diagnostics, retest for
SPN 110 FMI 10.
Is engine fan operating properly? No: Go to step 5.
Step 5 Check air supply to Engine Fan Solenoid. Decision

Disconnect vehicle air supply at Engine Fan Solenoid, Listen for air pressure. Yes: Go to step 6.
Is vehicle air pressure available at Engine Fan Solenoid? No: Repair vehicle air supply
to Engine Fan Solenoid. After
SPN 110 FMI 10.
Step 6 Check Engine Fan Solenoid for proper operation. Decision

A. Key Off, disconnect air supply at Engine Fan clutch. Yes: Replace Engine Fan Clutch.
B. Key On, ensure vehicle air tanks are full.
for SPN 110 FMI 10.
C. Perform Actuator Test (page 1968) with Engine Fan selected in control
panel.
D. Cycle the Engine Fan On and Off while monitoring for air pressure at fan
clutch.
Is vehicle air pressure available at Engine Fan Clutch with Engine Fan Solenoid No: Replace Engine Fan
energized? Solenoid (EFS). After repairs are
10.

SPN 110 FMI 14 - Engine Coolant Temperature : Special Instructions
Fault Overview
Fault code sets when Electronic Control Module (ECM) detects that Engine Coolant Temperature is outside a
programmable parameter.
Lamp Reaction
Engine shutdown is commanded and Red Stop Lamp (RSL) will illuminate immediately when this fault is
detected.
Associated Faults
SPN 110 FMI 2, 3, and 4
Fault Facts

Continuous
Possible Causes

®
SPN 110 FMI 14.

SPN 110 FMI 15 - Engine Coolant Temperature : Data Valid But Above Normal Operating Range
- Least Severe Level
Fault Overview
Fault code sets when Electronic Control Module (ECM) detects that engine coolant at Engine Coolant
Temperature 1 (ECT1) is greater than 239°F (115°C).
Lamp Reaction
Amber Warning Lamp (AWL) will illuminate immediately with no buzzer when this fault is detected.
Associated Faults
SPN 110 FMI 3 and 4
Fault Facts

Continuous
Possible Causes

®
SPN 110 FMI 15.

SPN 110 FMI 16 - Engine Coolant Temperature : Data Valid But Above Normal Operating Range -
Fault Overview
Fault code sets when Electronic Control Module (ECM) detects that engine coolant at Engine Coolant
Temperature 1 (ECT1) is greater than 239°F (115°C) for more than 2 minutes.
Lamp Reaction
Associated Faults
None
Fault Facts

Continuous
Possible Causes

®
Diagnostic Trouble Code (DTC) list for SPN 110 FMI 16. normal operating level, go to Step
Is DTC SPN 110 FMI 16 Active or Previously Active with high counts? No: End diagnostics.

SPN 110 FMI 18 - Engine Coolant Temperature : Data Valid But Below Normal Operating Range -
Fault Overview
Fault code sets when signal from Engine Coolant Temperature (ECT) reads lower than expected.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Road Test
Possible Causes
• Failed engine cooling fan (stuck on)
• Failed thermostat (stuck open)
Step 1 Check for correct coolant level. Decision

Inspect coolant level. Perform Coolant Level Inspection (page 2159). Yes: Go to Step 2.
Is coolant filled to correct level? No: Fill engine coolant and Go
to Step 2 of Cooling System
(page 34). After repairs are
18.
Step 2 Check for stuck on engine cooling fans. Decision

Check for stuck on engine cooling fan. Use EST, perform Engine Fan Test (page Yes: Go to Step 3.
2013).
Is fan operating properly? No: Repair or replace radiator
fan assembly. After repairs are
18.
Step 3 Check for failed thermostat. Decision

Check for failed Thermostat. Perform Thermostat Operational Test (page 2136). Yes: End diagnostics, retest for
SPN 110 FMI 18.
Did thermostats operate correctly and Open at specified temperature? No: Replace thermostats. After
SPN 110 FMI 18.

SPN 111 FMI 1 - Engine Coolant Level 1 : Data Valid But Below Normal Operational Range - Most
Severe 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.
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Coolant loss or leak
• Failed ECL sensor or circuit
Step 1 Check coolant level. Decision

Perform Coolant Level Inspection (page 2159). Yes: Go to Step 2 in Cooling
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 Inspect connections at Engine Coolant Level (ECL) sensor. Decision

A. Key OFF. Yes: Go to Step 3
B. Disconnect ECL sensor connector.
C. Check ECL sensor and connector terminals for damaged or pinched wires;
wet or 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,
FMI 1.

®
1.
Step 4 Check for failed ECL sensor or circuit. Decision

A. Use EST, Key ON, clear codes. Yes: Replace engine coolant
level sensor. After repairs are
B. Key OFF, wait for ECM to power down.
C. Disconnect coolant level sensor. 1.
D. Wait 1 minute.
E. Key ON, check DTC list for SPN 111 FMI 1 to become Previously Active.
Did SPN 111 FMI 1 become Previously Active? No: Go to Step 5.
Step 5 Check for failed ECL circuit. Decision

Perform Test 1 (page 252). Using Digital Multimeter (DMM), measure voltage Yes: Repair open or high
between ECL sensor pin 1 and a known good GND. resistance between ECL pin
2 and ECM pin C1-63. After
SPN 111 FMI 1.
Is voltage B+ ± 0.5 volts? No: Repair open or high
resistance between ECL pin
1 and ECM pin C1-08. After
SPN 111 FMI 1.


Tools Required
• Engine Terminal Test Kit ZTSE4435C
Figure 49 Engine Coolant Level Sensor Check
Test 1
A. Key OFF.
B. Disconnect Engine Coolant Level (ECL) Sensor.
C. Use Engine Terminal Test Kit ZTSE4435C, insert proper terminal into ECL pin 1.
SPN 111 FMI 3 - Engine Coolant Level 1 Circuit : Voltage Above Normal or Shorted to High Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Coolant Level (ECL) Sensor Circuit signal
voltage is above normal or shorted to a high source.
Lamp Reaction
Amber Warning Light (AWL) will illuminate.
Associated Faults
None
Fault Facts
Fault codes will set if the wrong ECL sensor is installed.

Continuous
Special Tools
®
• Navistar Electronic Service Tool (EST)
• Breakout Harness 12-166-01
Possible Causes
• Open or high resistance in SIG GND circuit
• Open, high resistance, or short to voltage in Coolant Level circuit
• Incorrect ECL programmable parameter
• Failed ECL sensor

Key ON. Use EST, check Diagnostic Trouble Code (DTC) list for SPN 111 FMI 3. Yes: Go to Step 2.
Is SPN 111 FMI 3 active? No: Go to Intermittent or Inactive
(page 1940).
Step 2 Identify what color ECL sensor is installed. Decision

Determine what color ECL sensor is installed into deaeration tank. Yes: Go to Step 3.
Is ECL sensor connector Red? No: Update programmable
parameter 39070, Engine
Coolant Level Sensor Type to
value Grey or Brown connector,
Normally Open (Value 0). After
repairs are complete, reset for
fault.
Step 3 Inspect connections at ECL sensor. Decision

A. Key OFF. ECL sensor disconnected. Yes: Go to Step 4.
B. Check connector terminals for: damaged or pinched wires; moisture or
corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are ECL sensor connector, harness, and terminals clean and undamaged? No: Repair / replace connector,
harness, or terminal damage.
for fault.
Step 4 Check for a failed ECL sensor. Decision

A. Key OFF. ECL sensor disconnected. Yes: Replace ECL sensor, retest
for fault.
B. Connect Breakout Harness 12-166-01 to vehicle harness and leave ECL
sensor disconnected.
C. Key ON. Using DMM, measure voltage between pin-A and pin-B.
Is voltage 5 ± 0.25 volts? No: Go to Step 5.
Step 5 Check ECL signal circuit for an Open or short. Decision

A. Key OFF. ECL sensor disconnected. Yes: Repair Open or high
resistance between ECL pin-B
B. Connect Breakout Harness to vehicle harness and leave ECL disconnected.
C. Key ON. Measure voltage between pin-A and ground. are complete, retest for fault.
Is voltage 5 ± 0.25 volts? No: Repair Open or short to
voltage between ECL pin-A and
ECM pin C1-8. After repairs are

After performing diagnostic steps, if fault remains, verify steps were completed correctly and proper decision was
made. Retest for fault.
SPN 111 FMI 4 - Engine Coolant Level 1 Circuit : Voltage Below Normal or Shorted to Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Coolant Level (ECL) sensor circuit signal
voltage is below normal or shorted to low source.
Lamp Reaction
Amber Warning Light (AWL) will illuminate.
Associated Faults
None
Fault Facts
Fault codes will set if the wrong ECL sensor is installed.

Continuous
Special Tools
• Navistar® Electronic Service Tool (EST)
Possible Causes
• ECL circuit short to ground
• Failed ECL sensor

Key ON. Use EST, check Diagnostic Trouble Code (DTC) list for SPN 111 FMI 4. Yes: Go to Step 2.
(page 1940). Retest for fault.
Step 2 Inspect connections at ECL sensor. Decision

A. Key OFF. ECL sensor disconnected. Yes: Go to Step 3.
B. Inspect connector terminals for: damaged or pinched wires; moisture
or corroded terminals; loose, bent, or broken pins; or broken connector
housing.
Are ECL sensor connector, harness, and terminals clean and undamaged? No: Repair / replace connector,
harness, or terminal. After
fault.
Step 3 Check for a failed ECL sensor. Decision

A. Key OFF. ECL sensor disconnected. Yes: Replace ECL sensor. After
B. Connect Breakout Harness 12-166-01 to vehicle harness and leave ECL
fault.
C. Key ON. Using DMM, measure voltage between pin-A and pin-B.
Is voltage 5 ± 0.25 volts? No: Repair short to ground
between ECL pin-A and ECM pin
retest for fault.

After performing diagnostic steps, if fault remains, verify steps were completed correctly and proper decision was
made. Retest for fault.
SPN 132 FMI 0 - Engine Intake Air Mass Flow Rate : Data Valid But Above Normal Operational Range -
Most Severe Level
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Mass Air Flow (MAF) Sensor reading is within
range but greater than a normal operating value.
Lamp Reaction
Associated Faults
SPN 132 FMI 3
Fault Facts
None

Continuous
Possible Causes
• MAF circuit short to PWR
• Failed MAF/IAT sensor

®
for SPN 132 FMI 0.

Use EST with Navistar® Engine Diagnostics, Check DTC list for SPN 132 FMI 0. Yes: Go to Step 3.
(page 1940).
Step 3 Inspect connections at Mass Air Flow/Intake Air Temperature (MAF/IAT) Decision
sensor connector.
B. Disconnect MAF/IAT connector.
C. Check MAF/IAT and connector terminals for: damaged or pinched wires;
connector housing.
Are MAF/IAT connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
SPN 132 FMI 0.
Step 4 Check MAF Signal Circuit. Decision

Breakout Harness 12-163-02 Pin-1 and known good GND.
Is voltage 5 volts ± 0.25 volts? No: Repair short to PWR
between MAF/IAT Pin-1 and
FMI 0.
Step 5 Check VREF 2 Signal Circuit. Decision

12-163-02 Pin-2 and known good GND.
Is voltage 5 volts ± 0.25 volts? No: Repair open or short
between MAF/IAT Pin-2 and
ECM Pin E1-89. After repairs
are complete, retest for SPN
132 FMI 0.
Step 6 Check Signal GND Circuit. Decision

Perform Test 3 (page 261). Use DMM, measure voltage between Breakout Harness Replace MAF/IAT sensor. After
12-163-02 Pin-3 and battery power. repairs are complete, retest for
SPN 132 FMI 0.
Is voltage B+ ± 0.5V? No: Repair open or high
resistance between MAF/IAT
Pin-3 and ECM Pin E1-66. After
SPN 132 FMI 0.


Tools Required
12-163-02
0000424363
Figure 50 MAF/IAT Sensor Circuit Check
Test 1
A. Key OFF.
B. Disconnect Mass Air Flow/Intake Air Temperature (MAF/IAT) sensor.

C. Connect Breakout Harness 12-163-02 to vehicle harness and leave MAF/IAT sensor disconnected.
D. Key ON Engine OFF (KOEO).

12-163-02
0000424364
Test 2
A. Key OFF.
12-163-02
0000424365
Test 3
A. Key OFF.
SPN 132 FMI 3 - Engine Intake Air Mass Flow Rate : Voltage Above Normal, Or Shorted To High Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Mass Air Flow (MAF) Sensor voltage is greater
Lamp Reaction
Associated Faults
None
Fault Facts
MAF Sensor is combined sensor with Intake Air Temperature (IAT) sensor located in turbocharger air inlet pipe.

Continuous
Possible Causes
• MAF signal circuit short to PWR
• Failed IAT / MAF sensor

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, Key ON Engine Yes: Go to Step 2.
OFF (KOEO), check Diagnostic Trouble Codes (DTC) list for SPN 132 FMI 3.
(page 1940).
Step 2 Inspect connections at Mass Air Flow / Intake Air Temperature (MAF / Decision
IAT) sensor connector.
B. Disconnect MAF / IAT connector.
C. Check MAF / IAT and connector terminals for: damaged or pinched wires;
connector housing.
Are MAF / IAT connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
SPN 132 FMI 3.
Step 3 Check MAF Signal Circuit Decision

Is voltage 5 volts +/- 0.1 volts? No: Repair short to PWR
between MAF / IAT Sensor Pin-1
and Engine Control Module
(ECM) pin E1-71. After repairs
FMI 3.
Step 4 Check VREF 2 Signal Circuit Decision

Is voltage 5 volts +/- 0.1 volts? No: Repair open or short
between MAF / IAT Sensor
SPN 132 FMI 3.
Step 5 Check Signal GND Circuit Decision

Perform Test 3 (page 268). Use DMM, measure voltage between Breakout Harness Yes: Replace MAF / IAT Sensor.
12-163-02 Pin-3 and battery power. After repairs are complete, retest
for SPN 132 FMI 3.
resistance between MAF /
IAT Sensor Pin-3 and ECM
Pin E1-66. After repairs are
complete, reteset for SPN 132
FMI 3.


Tools Required
12-163-02
0000424363
Figure 53 MAF Signal Circuit Check
Test 1
A. Key OFF.
B. Disconnect Mass Air Flow / Intake Air Temperature (MAF / IAT) sensor.
C. Connect Breakout Harness 12-163-02 to vehicle harness and leave MAF / IAT sensor disconnected.
D. Key ON, Engine OFF (KOEO).
12-163-02
0000424364
Figure 54 VREF 2 Signal Circuit Check
Test 2
A. Key OFF.
12-163-02
0000424365
Figure 55 Signal GND Circuit Check
Test 3
A. Key OFF.
SPN 132 FMI 4 - Engine Intake Air Mass Flow Rate : Voltage Below Normal, Or Shorted To Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Mass Air Flow (MAF) Sensor voltage is less
Lamp Reaction
Associated Faults
SPN 3510
Fault Facts
MAF Sensor is combined sensor with Intake Air Temperature (IAT) sensor located in turbocharger air inlet pipe.

Continuous
Possible Causes
• MAF circuit short to GND
• MAF Signal open
• Failed IAT/MAF sensor

®
for SPN 132 FMI 4.
Step 2 Check for active fault code. Decision

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics, Key ON Engine Yes: Go to Step 3.
(page 1940).
Step 3 Inspect connections at Mass Air Flow/Intake Air Temperature (MAF / Decision
connector housing.
SPN 132 FMI 4.
Step 4 Check MAF Signal Circuit Decision

between MAF / IAT Sensor Pin-1
(ECM) pin E1-71. After repairs
FMI 4.
Step 5 Check VREF 2 Signal Circuit Decision

between MAF / IAT Sensor
SPN 132 FMI 4.
Step 6 Check Signal GND Circuit Decision

Perform Test 3 (page 274). Use DMM, measure voltage between Breakout Harness Yes: Replace MAF / IAT Sensor.
12-163-02 Pin-3 and battery power. After repairs are complete, retest
for SPN 132 FMI 4.
resistance between MAF /
IAT Sensor Pin-3 and ECM
complete, reteset for SPN 132
FMI 4.


Tools Required
12-163-02
0000424363
Figure 56 MAF Signal Circuit Check
Test 1
A. Key OFF.
12-163-02
0000424364
Figure 57 VREF 2 Signal Circuit Check
Test 2
A. Key OFF.
12-163-02
0000424365
Figure 58 Signal GND Circuit Check
Test 3
A. Key OFF.
SPN 132 FMI 13 - Engine Intake Air Mass Flow Rate : Out Of Calibration
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Mass Airflow (MAF) sensor calibration learning
routine is not complete.
Lamp Reaction
Associated Faults
SPN 132 FMI 0, 2, 3, and 4
Fault Facts
None

Continuous
Possible Causes
• MAF Sensor not Calibrated

®
for SPN 132 FMI 13.

Use EST with Navistar® Engine Diagnostics, Check DTC list for SPN 132 FMI 13. Yes: Go to Step 3.
(page 1940).
Step 3 Inspect connections at Mass Air Flow sensor connector. Decision

B. Disconnect MAF/IAT sensor connector.
C. Check MAF/IAT sensor and connector terminals for: damaged or pinched
wires; moisture 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,
SPN 132 FMI 13.
Step 4 Test intake system for leaks. Decision

Perform Smoke Test (Air Intake System) (page 2093). Perform MAF Sensor Calibration
procedure (page 1944). After
SPN 132 FMI 13.
Are Intake air system clamps, hoses, components, and piping free of major leaks? No: Repair Intake system leaks.
Perform MAF Sensor Calibration
procedure (page 1944) and

SPN 132 FMI 16 - Engine Intake Air Mass Flow Rate : Data Valid But Above Normal Operating Range -
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Mass Air Flow (MAF) Sensor signal is reading
high for current engine conditions.
Lamp Reaction
Associated Faults
SPN 641 SPN 724 SPN 2791 SPN 3216

SPN 5024
Fault Facts
None.

Continuous
Possible Causes
• Dirty MAF sensor
• MAF Signal open
• Failed MAF sensor

®
for SPN 132 FMI 16.

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics. Key ON, Yes: Go to Step 3.
check Diagnostic Trouble Codes (DTC) list for SPN 132 FMI 16.
Is EST DTC list SPN 132 FMI 16 active? No: Repair other active faults.
for SPN 132 FMI 16.
Step 3 Inspect connections at Mass Air Flow/Intake Air Temperature (MAF Decision
/ IAT) sensor connector.
connector housing.
FMI 16.

Perform Intake Air Inspection (page 2165) and Smoke Test (Air Intake System) Yes: Go to Step 5.
(page 2093).
Is intake system free of damage, restrictions, or leaks? No: Repair air intake system
damage, restrictions, or leaks.
for SPN 132 FMI 16.
Step 5 Validate Air Management System actuators and sensor signals. Decision
Does Engine Intake Air Mass Flow Rate decrease when EGR valve opens? No: Replace MAF / IAT sensor.
16.
Step 6 Calibrate Mass Airflow Sensor. Decision

Perform MAF Sensor Calibration (page 1944). Yes: End diagnostics. Retest for
SPN 132 FMI 16.
Did MAF Sensor Calibration complete successfully? No: Replace MAF / IAT sensor.
16.

SPN 132 FMI 18 - Engine Intake Air Mass Flow Rate : Data Valid But Below Normal Operating Range -
Fault Overview
low for current engine conditions.
Lamp Reaction
Associated Faults
SPN 641 SPN 724 SPN 2791 SPN 3216

SPN 5024
Fault Facts
None.

Continuous
Possible Causes
• MAF Signal open

®
for SPN 132 FMI 18.

for SPN 132 FMI 18.
connector housing.
FMI 18.

(page 2093).
for SPN 132 FMI 18.
18.

SPN 132 FMI 18.
18.

SPN 132 FMI 20 - Engine Intake Air Mass Flow Rate : Data Drifted High
Fault Overview
high for current engine conditions.
Lamp Reaction
Associated Faults
SPN 102 FMI 18 SPN 641 SPN 724 SPN 2791

SPN 3216 SPN 5024
Fault Facts
None.

Continuous
Possible Causes
• MAF Signal open

®
for SPN 132 FMI 20.

for SPN 132 FMI 20.
connector housing.
FMI 20.

(page 2093).
for SPN 132 FMI 20.
20.

SPN 132 FMI 20.
20.

SPN 132 FMI 21- Engine Intake Air Mass Flow Rate : Data Drifted Low
Fault Overview
low for current engine conditions.
Lamp Reaction
Associated Faults
SPN 641 SPN 724 SPN 2791 SPN 3216

SPN 5024
Fault Facts
None.

Continuous
Possible Causes
• MAF Signal open

®
for SPN 132 FMI 21.

for SPN 132 FMI 21.
connector housing.
FMI 21.

(page 2093).
for SPN 132 FMI 21.
21.

SPN 132 FMI 21.
21.

SPN 157 FMI 0 - Engine Fuel 1 Injector Metering Rail 1 Pressure : Data Valid But Above Normal
Operational Range - Most Severe Level
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Fuel Rail Pressure (EFRP) is above
maximum operating range.
Lamp Reaction
Associated Faults
SPN 157 FMI 3, 4, 20, and SPN 633 SPN 1244

21
Fault Facts
None

Road Test
Possible Causes
• Restricted High-Pressure Fuel Pump (HPFP) fuel return line
• EFRP sensor or circuit failure
• Failed EFA1 (on HP pump)
• Failed EFA2 (on HP fuel rail)
Step 1 Check for associated fault code. Decision

®
check Diagnostic Trouble Code (DTC) list for Associated Faults (page 288).
for SPN 157 FMI 0.
Step 2 Check for low fuel level or leaking fuel supply. Decision
Perform Fuel Level and System Inspection (page 2152). Yes: Go to Step 3.
Is fuel present and fuel tanks / lines not leaking? No: Repair fuel leaks and add
fuel. Perform Fuel System
Priming (page 2026) procedure.
After repairs are complete retest
for SPN 157 FMI 0.
Step 3 Check for restricted High-Pressure Fuel Pump (HPFP) fuel return line. Decision
Perform HP Pump Fuel Return Pressure Test (page 2052). Yes: Go to Step 4.
Is pressure less than 13 psi? No: Repair restriction in fuel
return line between HPFP and
fuel tank. After repairs are
0..
Step 4 Check for failed EFA2. Decision

Perform Fuel Rail Pressure (FRP) Return Flow Test 2 (page 2048). Yes: Replace fuel rail. After
SPN 157 FMI 0.
Does fuel flow from the rail during test? No: Go to Step 5.
Step 5 Check for high fuel delivery pressure. Decision

Perform HP Pump Inlet Pressure Test (page 2055). Yes: Repair secondary fuel filter
housing or return fuel lines for
restriction. After repairs are
0.
Did fuel delivery pressure meet expected outcome of test? No: Go to Step 6.
Step 6 Check for aerated fuel. Decision

Perform Fuel Aeration Test (page 2034). Yes: Repair cause of fuel aeration
in fuel supply. After repairs are
0.
Is fuel aerated? No: Go to Step 7.
Step 7 Check for failed EFA1. Decision

®
A. Use EST with Navistar Engine Diagnostics, record a snapshot in default Yes: Replace fuel rail. After
session with vehicle idling for 5 minutes. repairs are complete, retest for
SPN 157 FMI 0.
B. Review graph of recorded data.
C. Graph EFRP and desired EFRP.
Does difference between EFRP and desired EFRP remain less than 1160 psi (80 No: Replace EFA1 (on HP pump).
bar) during recording? After repairs are complete, retest
for SPN 157 FMI 0.

SPN 157 FMI 1 - Engine Fuel 1 Injector Metering Rail 1 Pressure : Data Valid But Below Normal
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Fuel Rail Pressure (FRP) does meet desired value
for current operating conditions.
Lamp Reaction
Associated Faults
SPN 97 FMI 31 SPN 157 FMI 3, 4, 20, and SPN 633 SPN 1244
21
Fault Facts
None

Road Test
Possible Causes
• Low fuel level
• Fuel contaminated with water or DEF
• Restricted fuel filter or fuel gelling
• Internal leak in high-pressure fuel system
• Leaking fuel pressure relief valve
• Leaking fuel filter check valve
• Restricted fuel return line
• Restricted fuel tank vent
• Failed High Pressure Fuel Pump

for SPN 157 FMI 1.
for SPN 157 FMI 1.
Step 3 Check fuel quality. Decision

Perform Fuel Quality Inspection (page 2156). Yes: Go to step 2 of 7.2 - Fuel
Contamination (page 79). After
repairs are complete retest for
SPN 157 FMI 1.
Is fuel contaminated with water, Diesel Exhaust Fluid, gelling, waxing, or cloudiness? No: Go to Step 4.
Step 4 Check if engine can reach minimum cranking rpm. Decision

A. Crank engine for maximum of 20 seconds. Yes: Go to Step 5.
B. Watch engine rpm in EST with Navistar® Engine Diagnostics while cranking
engine.
Does engine crank at a minimum of 130 rpm? No: Go to step 2 of 2.1 - Engine
Crank (page 43) symptom. After
SPN 157 FMI 1.
Step 5 Verify engine starts and maintains idle. Decision

Crank engine for maximum of 20 seconds. If engine does not start, wait 2 minutes Yes: Retest for SPN 157 FMI 1.
and try again. If starting complaint is present go
to step 2 of 3.1 - Engine Hard to
Start (Long Crank Time) (page
47) symptom.
Does engine start and maintain idle? No: Go to step 6.
Step 6 Check for aeration in low pressure fuel system. Decision

Perform Fuel Aeration Test (page 2034). Yes: Repair source of fuel
aeration. After repairs are
complete retest for SPN 157 FMI
1.
Was aeration found in fuel? No: Go to Step 7.
Step 7 Start Using Fuel System Priming Tool. Decision

A. Perform Fuel System Priming (page 2026). Yes: Go to Step 8.
B. Crank engine for a maximum of 20 seconds. If engine does not start, wait 2
minutes and try again.
Does engine start and maintain idle? No: Go to Step 10.

Remove Fuel System Priming Tool and reassemble. Crank engine for a maximum of Yes: Go to Step 14.
20 seconds.
Does engine start and maintain high idle for a minimum of 2 minutes? No: Go to Step 9.
Step 9 Check fuel supply system. Decision

Perform Start From Clean Fuel Source Test (page 2032). Yes: Go to Step 14.
Step 10 Check for restricted primary (engine mounted) fuel filter. Decision
Perform High-Pressure Pump Inlet Pressure Test (page 2055). Yes: Go to Step 11.
Did fuel delivery pressure meet expected outcome of test? No: Replace high-pressure fuel
pump. Perform Fuel System
Go to Step 18.
Step 11 Check for excessive fuel return. Decision

Perform Fuel Rail Pressure (FRP) Return Flow Test part 1 (page 2047). Yes: Go to Step 12.
Is line free of return fuel from cylinder head while cranking? No: Go to Step 13.
Step 12 Check for a failed fuel pressure relief valve. Decision

Perform Fuel Rail Pressure (FRP) Return Flow Test part 2 (page 2048). Yes: Replace high-pressure fuel
Go to Step 18.
Is line free of return fuel from fuel rail? No: Replace fuel rail. After
SPN 157 FMI 1.
Step 13 Check for an internal leak in high-pressure fuel system. Decision

Perform Fuel Rail Pressure (FRP) Leak Isolation Test (page 2043). Yes: Replace last capped injector
and all HP lines removed during
this test and perform Injector
Quantity Adjustment (IQA) (page
1941) and Crankshaft Position
Was a leaking injector identified? No: End diagnostics. Retest for
SPN 157 FMI 1.
Step 14 Check for restriction in low pressure fuel system. Decision

Perform Fuel Restriction Test (page 2038). Yes: Repair source of restriction.
for SPN 157 FMI 1.
Is fuel system restricted? No: Go to Step 15.
Step 15 Check fuel tank vent(s) for restriction. Decision

Perform Fuel Tank Vent Restriction Test (page 2116). Yes: Repair source of restriction.
for SPN 157 FMI 1.
Are the fuel tank vent(s) restricted? No: Go to Step 16.
Step 16 Identify type of chassis fuel filter. Decision

Yes: Go to Step 17.
®
Is the vehicle equipped with a Davco chassis mounted fuel filter. No: End diagnostics. For an
intermittent issue check for debris
in the fuel tank(s). Retest for SPN
157 FMI 1.
Step 17 Check Davco® fuel filter check valve. Decision

®
Perform Davco Fuel Filter Check Valve Inspection (page 2196). Yes: Replace check valve or
components as necessary. After
SPN 157 FMI 1.
Did the inspection find any leaking or damaged check valve components? No: End diagnostics. For an
157 FMI 1.
Step 18 Check for restricted high-pressure fuel pump return line. Decision
Perform HP Pump Fuel Return Pressure Test (page 2052). Yes: End diagnostics. Retest for
SPN 157 FMI 1.
return line between high-pressure
fuel pump and fuel tank. After
SPN 157 FMI 1.

SPN 157 FMI 3 - Engine Fuel 1 Injector Metering Rail 1 Pressure : Voltage Above Normal, or Shorted
to High Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Fuel Rail Pressure (EFRP) voltage is greater
Lamp Reaction
Associated Faults
SPN 3510 FMI 14
Fault Facts
None

Continuous
Possible Causes
• EFRP circuit short to PWR
• EFRP circuit open
• SIG GND circuit open
• VREF 2 circuit short GND
• VREF 2 circuit open
• Failed EFRP sensor

®
for SPN 157 FMI 3.

1940).
Step 3 Inspect connections at Engine Fuel Rail Pressure (EFRP) sensor. Decision
B. Disconnect EFRP connector.
C. Check EFRP and connector terminals for: damaged or pinched wires;
connector housing.
Are EFRP connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
FMI 3.
Step 4 Check for short to PWR on EFRP signal circuit. Decision

between EFRP pin-2 and ECM
3.
Step 5 Check for Open or short to GND in VREF circuit. Decision

GND between EFRP pin-3 and
FMI 3.
Step 6 Perform Continuous Monitor Test. Decision

A. Perform Test 3 (page 299). Yes: Replace fuel rail. After
SPN 157 FMI 3.
C. During test, monitor EFRP voltage with Navistar® Engine Diagnostics.
Is voltage 0.25 volts or less? No: Go to Step 7.
Step 7 Perform Continuous Monitor Test. Decision

EFRP pin-1 and ECM pin E1-13.
C. During test, monitor EFRP voltage with Navistar® Engine Diagnostics. for SPN 157 FMI 3.
Is voltage 0 ± 0.25 volts? No: Repair Open between EFRP
SPN 157 FMI 3.


Tools Required
2
6027
0000448541
Figure 59 FRP Circuit Check
Test 1
A. Key OFF.
B. Disconnect Engine Fuel Rail Pressure (EFRP) sensor.
C. Connect Breakout Harness ZTSE6027 to vehicle harness and leave EFRP sensor disconnected.
D. Key ON.
Figure 60 VREF Circuit Check
Test 2
A. Key OFF.
D. Key ON.
4498
2 6027
0000448545
Test 3
A. Key OFF.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE6027 pin-1 to pin-2
F. Key On, log in to Navistar® Engine Diagnostics.
4498
2
6027
0000448540
Test 4
A. Key OFF.
E. Connect EST to vehicle Diagnostic Connector (page 1956).
F. Key On, log in to Navistar® Engine Diagnostics.
SPN 157 FMI 4 - Engine Fuel 1 Injector Metering Rail 1 Pressure : Voltage Below Normal, or Shorted to
Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Fuel Rail Pressure (EFRP) voltage is lower than
0.19 volts.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• EFRP signal circuit short to GND

®
1940).
connector housing.
FMI 4.
Step 3 Check for short to GND. Decision

A. Perform Test 1 (page 304). Yes: Replace fuel rail. After
SPN 157 FMI 4.
C. During test, monitor EFRP voltage with EST.
Is voltage 5 ± 0.25 volts? No: Repair short to GND between
FRP pin-2 and ECM pin E1-63.
for SPN 157 FMI 4.


Tools Required
Test 1
A. Key OFF.
D. Key On, log in to Navistar® Engine Diagnostics.
SPN 157 FMI 10 - Engine Fuel 1 Injector Metering Rail 1 Pressure : Abnormal Rate Of Change
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Fuel Rail Pressure (EFRP) signal is erratic
or intermittent.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Road Test
Possible Causes
A. Key OFF. Yes: Replace fuel rail and pigtail
connector. After repairs are
C. Check EFRP and connector terminals for: damaged or pinched wires; 10..
connector housing.
FMI 10.

SPN 157 FMI 16 - Engine Fuel 1 Injector Metering Rail 1 Pressure : Data Valid But Above Normal
Operating Range - Moderately Severe Level
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Fuel Rail Pressure (FRP) is above maximum with
minimum command.
Lamp Reaction
Associated Faults
SPN 157 FMI 3, 4, 20 and SPN 633 FMI 3, 4 and 5 SPN 1244
21
Fault Facts
None

Road Test
Possible Causes
• Fuel system damage or leak

®
for SPN 157 FMI 16.
Is fuel present and fuel tanks not leaking? No: Repair fuel leaks and add
fuel. Prime fuel system. Perform
Fuel System Priming (page 2026)
procedure. After repairs are
16.
SPN 157 FMI 16.
16.

SPN 157 FMI 18 - Engine Fuel 1 Injector Metering Rail 1 Pressure : Data Valid But Below Normal
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Fuel Rail Pressure (FRP) is below minimum when
maximum is command.
Lamp Reaction
Associated Faults
21
Fault Facts
None

Road Test
Possible Causes
• Restricted fuel supply
• Restricted secondary (engine-mounted) fuel filter
• Aerated fuel delivery
• Low fuel level or leaking fuel supply
• Leaking EFA2 relief valve
• Stuck or sticking EFA1
• Engine Fuel Rail Pressure (EFRP) sensor or circuit fault

®
for SPN 157 FMI 18.
18.

SPN 157 FMI 18.
Step 4 Verify High-Pressure Fuel Pump (HPFP) is receiving fuel. Decision

Perform HP Pump Inlet Pressure Test (page 2055). Yes: Go to Step 8.
Was fuel pressure 68 ± 5 psi (469 ± 34 kPa) at low idle and 80 ± 5 psi (552 ± 34 No: Go to Step 5.
kPa) at high idle?
Step 5 Check for restricted secondary (engine-mounted) fuel filter. Decision

Remove secondary (engine-mounted) fuel filter. Inspect filter for gelling and Yes: Replace secondary
restrictions. (engine-mounted) fuel filter. After
SPN 157 FMI 18.
Is secondary (engine-mounted) fuel filter restricted? No: Go to Step 6.

Perform Fuel Aeration Test (page 2034). Yes: Repair cause of fuel
18.

for SPN 157 FMI 18.

Is fuel volume less than 60 ml? No: Go to Step 11.
Step 9 Check for a failed EFA2. Decision

SPN 157 FMI 18.
SPN 157 FMI 18.
18.

Perform Fuel Rail Pressure (FRP) Leak Isolation Test (page 2043). Yes: Go to Step 12.
Was a leaking injector identified? No: Replace last capped injector
Quantity Adjustment (page 1941)
18.
Step 12 Inspect connections at Fuel Rail Pressure (FRP) sensor. Decision

connector housing.
FMI 18.
Step 13 Check for failed EFRP sensor. Decision

Perform the Intermittent or Inactive Fault Diagnostic Procedure (page 1940) while Yes: Replace pig tail connector.
monitoring Engine Fuel Rail Pressure (EFRP). After repairs are complete, retest
for SPN 157 FMI 18.
Was the voltage >4.81V or less than 0.19V? No: Replace fuel rail. After
SPN 157 FMI 18.

SPN 157 FMI 20 - Engine Fuel 1 Injector Metering Rail 1 Pressure : Data Drifted High
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Fuel Rail Pressure (EFRP) voltage is greater
than 0.609 volts during after run cycle.
Lamp Reaction
Associated Faults
SPN 157 FMI 3 and 4 SPN 3510 FMI 14
Fault Facts
After shutdown, with enable conditions met, Engine Control Module (ECM) operates after run cycle (for 30 to
45 seconds) to do needed "house keeping" operations. After run cycle is processed ECM goes through to save
memory and shutdown.

Road Test
Possible Causes
• EFRP signal circuit Open or short to PWR
• VREF 2 circuit Open or high resistance
• SIG GND circuit Open or high resistance

®
OFF, check Diagnostic Trouble Code (DTC) list for Associated Faults (page 312).
for SPN 157 FMI 20.
Step 2 Inspect connections at Engine Fuel Rail Pressure (EFRP) sensor Decision
connector.
connector housing.
FMI 20.
Step 3 Check EFRP signal circuit for Open or short to PWR. Decision
PWR between EFRP pin-2 and
20.

resistance between EFRP pin-3
and ECM pin E1-88. After repairs
FMI 20.
Step 5 Check EFRP SIG GND circuit for Open or high resistance. Decision
Perform Test 3 (page 317). Use DMM, measure voltage between Breakout Harness Yes: Replace fuel rail and pigtail
ZTSE6027 pin-1 and pin-2. connector. After repairs are
FMI 20.
resistance between EFRP pin-1
FMI 20.


Tools Required
2
6027
0000448541
Figure 63 EFRP Circuit Check
Test 1
A. Key OFF.
C. Connect Breakout Harness ZTSE6027 to engine harness and leave EFRP sensor disconnected.
D. Key ON.
Test 2
A. Key OFF.
D. Key ON.
6027
2
0000413828
Figure 65 EFRP Circuit Check
Test 3
A. Key OFF.
D. Key ON.
SPN 157 FMI 21 - Engine Fuel 1 Injector Metering Rail 1 Pressure : Data Drifted Low
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Fuel Rail Pressure (EFRP) voltage is less
than 0.424 volts during ECM housekeeping.
Lamp Reaction
Associated Faults
SPN 157 FMI 2, 3, and 4 SPN 3510 FMI 14
Fault Facts
After shutdown, with enable conditions met, Engine Control Module (ECM) operates after run cycle (for 30 to
45 seconds) to do needed "house keeping" operations. After run cycle is process ECM goes through to save
memory and shutdown.

Road Test
Possible Causes
• EFRP signal circuit short to GND

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, Key On, check Yes: Go to Step 2.
for SPN 157 FMI 21.
Step 2 Inspect connections at Engine Fuel Rail Pressure (EFRP) sensor Decision
connector.
connector housing.
FMI 21.
Step 3 Check EFRP signal circuit for short to GND. Decision

Perform Test 1 (page 320). Use DMM, measure voltage between Breakout Harness Yes: Replace fuel rail and pigtail
ZTSE6027 pin-2 and known good GND. connector. After repairs are
21.
EFRP pin-2 and ECM pin E1-63.
for SPN 157 FMI 21.


Tools Required
Figure 66 EFRP Signal Circuit Check
Test 1
A. Key OFF.
D. Key ON.
SPN 158 FMI 16 - Key Switch Battery Potential : Data Valid But Above Normal Operating Range -
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that battery voltage greater than 15.9 volts
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Failed alternator
• Loose / corroded alternator wiring connections
• Incorrect battery pack wiring (series instead of parallel
Step 1 Check sense (S) terminal, if equipped. Decision

Verify S terminal wire IS running directly to battery pack. Measure voltage at S Yes: Perform Electrical System
terminal. Test (page 2065). If charging
system fails, replace alternator.
for SPN 158 FMI 16.
Is proper wire installed on S terminal, and reads B+ ± 0.5 Volts? No: Repair Circuit. After repairs
FMI 16.

SPN 158 FMI 18 - Key Switch Battery Potential : Data Valid But Below Normal Operating Range -
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that battery voltage less than 9.0 volts
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Low charging voltage
• Low battery voltage
• B+ circuits Open or high resistance
• SWBAT circuit Open or high resistance
• GND circuits Open or high resistance

®
1940).
Step 2 Check battery and electrical system. Decision

Perform Batteries and Electrical System Inspection (page 2198). Yes: Go to Step 3.
Are batteries and charging system operating properly? No: Repair or replace batteries
and/or charging system
components as necessary.
for SPN 158 FMI 18.
Step 3 Check voltage at alternator. Decision

With engine running, measure voltage at alternator main power terminal. Yes: Go to Step 6.
Does meter read 14V ±1 volt? No: Go to Step 4.
Step 4 Check alternator sense (S) terminal circuit for Open, high resistance Decision
or short to ground, if equipped.
A. Verify S terminal wire running directly to battery pack Yes: Go to Step 5.
B. Key ON. Using Digital Multimeter (DMM), measure voltage at S terminal.
Is wire properly installed on S terminal, and reads battery voltage ± 0.5 volts? No: Repair Open, high resistance
or short to ground in alternator
S circuit. After repairs are
18.
Step 5 Test charging and staring systems. Decision

Perform Electrical System Test (page 2065). Yes: End diagnostics and retest
for SPN 158 FMI 18.
Did charging and starting system pass tests? No: Repair or replace as directed
by test. . After repairs are
18.
Step 6 Check for failed SWBAT circuit to ECM. Decision

Perform Test 1 (page 328). Use DMM, measure voltage from Breakout Box pin Yes: Go to Step 7.
C1-17 to known good GND.
resistance between ECM C1-17
and battery PWR. After repairs
FMI 18.
Step 7 Check for failed PWR circuit to ECM. Decision

Perform Test 2 (page 328). Use DMM, measure voltage from Breakout Box Pin Yes: Go to Step 8.
FMI 18.

FMI 18.

FMI 18.

FMI 18.

FMI 18.
Step 12 Check for failed GND circuit to ECM. Decision

C2-04 to PWR.
and GND. After repairs are
18.

C2-10 to PWR.
No: Repair open or high
Is voltage B+ ± 0.5 volts? resistance between ECM C2-10
18.

C2-16 to PWR.
Is voltage B+ ± 0.5 volts? resistance between ECM C2-16
18.

Perform Test 10 (page 336). Use DMM, measure voltage from Breakout Box Pin Yes: Repair open or high
C2-13 to PWR. resistance between ECM C2-07
Is voltage B+ ± 0.5 volts?
18.
18.
End Diagnostic Test


Tools Required
• 180-pin Breakout Box 00-00956-08
• Breakout Harness 12-801-05-01
C1-17
0000415216
Figure 67 SWBAT Circuit Check
Test 1
A. Key OFF
B. Connect 180-pin Breakout Box 00-00956-08 to Breakout Harness 12-801-05-01.
C. Connect Breakout Harness 12-801-05-01 to vehicle harness, and leave ECM C1 and C2 connectors
disconnected
D. Key ON
C2-03
0000415219
Figure 68 B+ Circuit Check
Test 2
A. Key OFF
disconnected
D. Key ON
C2-09
0000415221
Test 3
A. Key OFF
disconnected
D. Key ON
C2-08
0000415220
Test 4
A. Key OFF
disconnected
D. Key ON
C2-14
0000415222
Test 5
A. Key OFF
disconnected
D. Key ON
C2-15
0000415223
Test 6
A. Key OFF
disconnected
D. Key ON
C2-04
0000415228
Figure 73 GND Circuit Check
Test 7
A. Key OFF
disconnected
D. Key ON
C2-10
0000415230
Test 8
A. Key OFF
disconnected
D. Key ON
C2-16
0000415232
Test 9
A. Key OFF
disconnected
D. Key ON
C2-13
0000415231
Test 10
A. Key OFF
disconnected
D. Key ON
SPN 171 FMI 0 - Ambient Air Temperature : Data Valid But Above Normal Operational Range - Most
Severe Level
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Ambient Air Temperature (AAT) voltage is
Lamp Reaction
Malfunction Indicator Lamp (MIL) will immediately when this fault is detected during to consecutive drive cycles.
Associated Faults
SPN 171 FMI 2, 3 and 4

Continuous
Fault Facts
AAT Sensor is located in Driver's view mirror.
Possible Causes
• AAT signal circuit Open
• AAT signal circuit short to PWR
• AAT SIG GND circuit Open
• Failed AAT sensor

®
for SPN 171 FMI 0.
Step 2 Inspect connections at Ambient Air Temperature (AAT) connector. Decision

B. Disconnect AAT connector.
C. Check AAT and connector terminals for: damaged or pinched wires;
connector housing.
Are AAT connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
FMI 0.
Step 3 Check AAT circuit for short to PWR. Decision

Perform Test 1 (page 341). Use Digital Multimeter (DMM) to measure voltage Yes: Repair short to PWR
between Breakout Harness ZTSE4871 pin-1 and a known good GND. between AAT pin-B and Engine
Control Module (ECM) pin C1-09.
for SPN 171 FMI 0.
Is voltage greater than 5 volts? No: Go to step 4.
Step 4 Check for a failed AAT sensor. Decision

A. Perform Test 2 (page 342). Yes: Replace AAT sensor. After
®
SPN 171 FMI 0.
Test (page 1974).
C. During test, monitor AAT voltage with EST.
Step 5 Decision
A. Perform Test 3 (page 343). Yes: Repair Open between AAT
pin-A and ECM pin C1-63. After
Test (page 1974).
SPN 171 FMI 0.
Is voltage approximately 0 volts? No: Repair Open between AAT
SPN 171 FMI 0.


Tools Required
Figure 77 AAT Circuit Voltage Check
Test 1
A. Key OFF.
B. Disconnect Ambient Air Temperature (AAT) sensor.

C. Connect Breakout Harness ZTSE4871 to engine harness and leave AAT sensor disconnected.
D. Key ON.
Figure 78 AAT Sensor Circuit Check
Test 2
A. Key OFF.
D. Use Breakout Harness ZTSE4498 short Breakout Harness ZTSE4871 pin-2 and pin-1 together.
F. Key ON, log in to Navistar® Engine Diagnostics.
Figure 79 AAT sensor circuit check
Test 3
A. Key OFF.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector.
SPN 171 FMI 2 - Ambient Air Temperature : Data Erratic, Intermittent Or Incorrect
Fault Overview
Fault code sets when Ambient Air Temperature (AAT) sensor temperature differs from other engine temperature
sensors by greater than 27°F (15°C) after cold soak. Diagnostic runs at initial Key ON after being shutdown for
a minimum of 8 hours to allow all temp sensors to be similar to each other.
Lamp Reaction
Associated Faults
SPN 171 FMI 3 and 4
Fault Facts
AAT sensor is located inside driver side-view mirror

Road Test
Possible Causes
• High resistance in AAT signal circuit
• High resistance in SIG GND circuit

®
for SPN 171 FMI 2.

Is SPN 171 FMI 2 active or pending? No: Go to Intermittent or Inactive
(page 1940).
Step 3 Inspect connections at Ambient Air Temperature (AAT) sensor Decision

connector.
B. Disconnect AAT sensor connector.
C. Check AAT sensor and connector terminals for: damaged or pinched wires;
connector housing.
Are AAT sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
FMI 2.
Step 4 Check for high resistance in AAT signal circuit. Decision

A. Key OFF. Yes: Go to step 5.
B. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector

(page 1956).
C. Key ON, log in to Navistar® Engine Diagnostics.
D. Use EST with Navistar® Engine Diagnostics, perform Continuous Monitor
Test (page 1974).
E. During test, monitor AAT voltage in EST.

Is voltage 5 volts ± 0.25 volts No: Repair high resistance in
AAT signal circuit between ECM
E1-42 to AAT pin-1. After repairs
FMI 2.
Step 5 Check for failed AAT sensor. Decision

SPN 171 FMI 2.
Test (page 1974).
C. During test, monitor AAT voltage in EST.

Is voltage 0 volts ± 0.25 volts No: Repair High resistance in
AAT Pin-2 and ECM Pin C1-63.
for SPN 171 FMI 2.

Figure 80 AAT Sensor Circuit Diagram
Tools Required
Test 1
A. Key OFF.

C. Connect Breakout Harness ZTSE4871 to vehicle harness and leave AAT sensor disconnected.
F. Key ON, log in to Navistar® Engine Diagnosticse.
SPN 171 FMI 3 - Ambient Air Temperature : Voltage Above Normal, Or Shorted To High Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Ambient Air Temperature (AAT) voltage is
Lamp Reaction
Associated Faults
None

Continuous
Fault Facts
AAT Sensor is located in Driver's view mirror.
Possible Causes
• AAT signal circuit Open
• AAT signal circuit short to PWR
• AAT SIG GND circuit Open

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON, check Yes: Go to Step 2.
(page 1940).

connector housing.
SPN 171 FMI 3.
Step 3 Check AAT circuit for short to PWR. Decision

Perform Test 1 (page 351). Use Digital Multimeter (DMM) to measure voltage Yes: Repair short to PWR
between Breakout Harness ZTSE4871 pin-1 and a known good GND. between AAT pin-B and Engine
C1-09. After repairs are
FMI 3.
Step 4 Check for a failed AAT sensor. Decision

®
SPN 171 FMI 3.
Test (page 1974).
Is voltage approximately 0 volts? No: Go to step 5.
Step 5 Check AAT circuit for Open or high resistance. Decision

A. Perform Test 3 (page 352). Yes: Repair Open between AAT
pin-A and ECM pin C1-63. After
Test (page 1974).
SPN 171 FMI 3.
Is voltage approximately 0 volts? No: Repair Open between AAT
SPN 171 FMI 3.


Tools Required
Figure 82 AAT Circuit Voltage Check
Test 1
A. Key OFF.
D. Key ON.
Test 2
A. Key OFF.
Figure 84 AAT sensor circuit check
Test 3
A. Key OFF.
E. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector.
SPN 171 FMI 4 - Ambient Air Temperature : Voltage Below Normal, Or Shorted To Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Ambient Air Temperature (AAT) voltage is less
Lamp Reaction
Associated Faults
None

Continuous
Fault Facts
The AAT Sensor is located in the Driver’s side view mirror.
Possible Causes
• AAT circuit short to GND

®
(page 1940).

connector housing.
SPN 171 FMI 4.
Step 3 Check AAT sensor operation. Decision

A. Key OFF. Yes: Replace AAT sensor. After
B. Disconnect Ambient Air Temperature (AAT) sensor
SPN 171 FMI 4.
(page 1956).
E. Use Navistar® Engine Diagnostics, perform Continuous Monitor Test (page

1974).
F. During test, monitor AAT voltage with EST.
between AAT pin-B and ECM
FMI 4.

SPN 172 FMI 0 - Engine Intake 1 Air Temperature : Data Valid But Above Normal Operational Range -
Most Severe Level
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Intake Air Temperature (IAT) is within range but
reading greater than expected.
Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected, during two consecutive drive cycles.
Associated Faults
SPN 172 FMI 2, 3, 4
Fault Facts
IAT sensor is integrated into the Mass Air Flow (MAF) sensor.

Continuous
Possible Causes
• Improperly installed / damaged air intake system.
• External heat source
• Air being drawn from under hood

for SPN 172 FMI 0.

®
1940).
Step 3 Inspect air filter and air intake assembly for restriction and/or damage. Decision
Is air intake assembly free of restriction and damage? No: Repair air intake system.
for SPN 172 FMI 0.
connector housing.
FMI 4.
Step 5 Check Mass Air Flow / Intake Air Temperature (MAF / IAT) sensor Decision
operation.
A. Key OFF. Yes: Replace MAF / IAT sensor.
B. Disconnect MAF / IAT sensor
for SPN 172 FMI 4.
(page 1956).
D. Key On Engine Off (KOEO), log in to Navistar® Engine Diagnostics.
1974).
• During test, monitor MAF / IAT voltage.
between IAT / MAF pin-4 and
4.

SPN 172 FMI 2 - Engine Intake 1 Air Temperature : Data Erratic, Intermittent Or Incorrect
Fault Overview
Fault sets when Engine Control Module (ECM) determines Intake Air Temperature (IAT) signal deviates from
absolute values of Intake Manifold Temperature (IMT), and Charge Air Cooler Outlet Temperature (CACOT)
after cold soak.
Lamp Reaction
Associated Faults
SPN 172 FMI 3 and 4
Fault Facts
IAT sensor is integrated into the Mass Air Flow (MAF) sensor.

Continuous
Possible Causes
• High resistance in IAT signal circuit
• High resistance in IAT ground circuit
• Failed MAF / IAT sensor

®
for SPN 172 FMI 2.

1940).
IAT) sensor.
connector housing.
FMI 2.
Step 4 Check for Failed MAF/IAT sensor. Decision

A. Perform Test 1 (page 362). Yes: Replace MAF / IAT sensor.
®
for SPN 172 FMI 2.
Test (page 1974).
C. During test, monitor IAT voltage.
Is IAT voltage less than 0.25 volts? No: Go to Step 5.
Step 5 Check for Open or high resistance in IAT circuit. Decision

between MAF/IAT sensor pin-3
Test (page 1974).
C. During test, monitor IAT voltage. FMI 2.
Is IAT voltage less than 0.25 volts? No: Repair high resistance
between MAF/IAT sensor pin-4
FMI 2.


Tools Required
4498
4 12-163-02
0000419495
Figure 85 IAT Circuit Check
Test 1
A. Key OFF.
B. Connect Breakout Harness 12-163-02 to vehicle harness and leave MAF / IAT sensor disconnected..
C. Use Breakout Harness ZTSE4498, short pin-4 and pin-3 of Breakout Harness 12-163-02 together.
D. Connect EST to vehicle Diagnostic Connector (page 1956).

E. Key On Engine Off (KOEO), log into Navistar® Engine Diagnostics.
4498
12-163-02
0000419496
Test 2
A. Key OFF.
B. Connect Breakout Harness 12-163-02 to vehicle harness and leave MAF / IAT sensor disconnected..
C. Use Breakout Harness ZTSE4498, short pin-4 of Breakout Harness 12-163-02 to a known good GND.
D. Connect EST to vehicle Diagnostic Connector (page 1956).
E. KOEO, log into Navistar® Engine Diagnostics.
SPN 172 FMI 3 - Engine Intake 1 Air Temperature : Voltage Above Normal, Or Shorted To High Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Intake Air Temperature (IAT) sensor voltage is
Lamp Reaction
Associated Faults
None
Fault Facts
IAT Sensor is combined sensor with Mass Airflow (MAF) sensor located in turbocharger air inlet pipe.

Continuous
Possible Causes
• IAT signal circuit Open
• IAT signal circuit short to PWR
• IAT SIG GND circuit Open
• Failed MAF / IAT sensor

®
(page 1940).
Step 2 Inspect connections at Mass Air Flow/Intake Air Temperature (MAF / Decision
connector housing.
SPN 172 FMI 3.
Step 3 Check MAF / IAT circuit for short to PWR. Decision

Perform Test 1 (page 367). Use DMM, measure voltage between Breakout Harness Yes: Repair short to PWR
12-163-02 Pin-4 and a known good GND. between MAF / IAT Pin-4 and
FMI 3.
Step 4 Check for failed MAF / IAT sensor. Decision

A. Perform Test 2 (page 367). Yes: Replace MAF / IAT sensor.
®
B. Use Navistar Engine Diagnostics, perform Continuous Monitor Test (page
for SPN 172 FMI 3.
1974).
• During test, monitor IAT voltage with EST.
Step 5 Check for IAT circuit failure. Decision

A. Perform Test 3 (page 368). Yes: Repair Open between MAF
/ IAT Pin-3 and ECM pin E1-66.
B. Use Navistar® Engine Diagnostics, perform Continuous Monitor Test (page
1974).
for SPN 172 FMI 3.
• During test, monitor IAT voltage with EST.
Is voltage approximately 0 volts? No: Repair Open between MAF
/ IAT Pin-4 and ECM pin E1-83.
for SPN 172 FMI 3.


Tools Required
12-163-02
0000415403
Test 1
A. Key OFF.
B. Disconnect Mass Air Flow/Intake Air Temperature (MAF / IAT) sensor.

4498
12-163-02
3
4
0000415404
Test 2
A. Key OFF.
D. Use Breakout Harness ZTSE4498, short Breakout Harness 12-163-02 pin-4 and pin-3 together.
4498
12-163-02
4
0000415405
Test 3
A. Key OFF.
B. Disconnect Mass Air Flow/Intake Air Temperature (MAF / IAT) sensor.
D. Use Breakout Harness ZTSE4498, short Breakout Harness 12-163-02 pin-4 to known good GND.
E. KOEO, log in to Navistar® Engine Diagnostics.
SPN 172 FMI 4 - Engine Intake 1 Air Temperature : Voltage Below Normal, Or Shorted To Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Intake Air Temperature (IAT) voltage is less
Lamp Reaction
Associated Faults
None
Fault Facts
IAT Sensor is combined sensor with Mass Airflow (MAF) sensor located in turbocharger air inlet pipe.

Continuous
Possible Causes
• IAT circuit short to GND
• Failed IAT / MAF sensor

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key On Engine Yes: Go to Step 2.
Off (KOEO), check Diagnostic Trouble Codes (DTC) list for SPN 172 FMI 4.
(page 1940).
connector housing.
SPN 172 FMI 4.
Step 3 Check Mass Air Flow / Intake Air Temperature (MAF / IAT) sensor Decision
operation.
A. Key OFF. Yes: Replace MAF / IAT sensor.
B. Disconnect MAF / IAT sensor
for SPN 172 FMI 4.
(page 1956).
D. Key On Engine Off (KOEO), log in to Navistar® Engine Diagnostics.
1974).
• During test, monitor MAF / IAT voltage.
between IAT / MAF pin-4 and
FMI 4.

SPN 173 FMI 0 - Engine Exhaust Temperature : Data Valid But Above Normal Operational Range -
Most Severe Level
Fault Overview
Fault code sets when Engine Control Module (ECM) determines Engine Exhaust Temperature (EET) is high.
Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected, during two consecutive drive cycles..
Associated Faults
SPN 173 FMI 2, 3 and 4
Fault Facts
None

Road Test
Possible Causes
• Engine overheating
• Failed EET sensor

®
for SPN 173 FMI 0.
Step 2 Inspect connections at Engine Exhaust Temperature (EET) connector. Decision

1940).

B. Disconnect EET connector.
C. Check EET and connector terminals for: damaged or pinched wires;
connector housing.
Are EET connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
FMI 0.
Step 4 Check for failed EET sensor Decision

A. Key OFF. Disconnect Engine Exhaust Temperature (EET) sensor electrical Yes: Replace EET sensor. After
connector. repairs are complete, retest for
SPN 173 FMI 0.
B. Perform Continuous Monitor Test (page 1974). Monitor EET voltage while
the test is active.
Is voltage 5V ± 0.25 volts? No: Repair short to GND between
EET pin-2 and ECM pin E1-62.
for SPN 173 FMI 0.

SPN 173 FMI 2 - Engine Exhaust Temperature : Data Erratic, Intermittent Or Incorrect
Fault Overview
Fault code sets when Engine Control Module (ECM) determines Engine Exhaust Temperature (EET) signal
deviates from average values of Intake Manifold Temperature (IMT), Intake Air Temperature (IAT), and Charge
Air Cooler Outlet Temperature (CACOT) after cold soak.
Lamp Reaction
Associated Faults
SPN 173 FMI 3 and 4
Fault Facts
None

Road Test
Possible Causes
• EET signal circuit Open
• EET signal circuit short to PWR
• EET SIG GND circuit Open

®
for SPN 173 FMI 2.
Step 2 Inspect connections at Engine Exhaust Temperature (EET) connector. Decision

1940).

connector housing.
FMI 2.
Step 4 Check EET circuit for short to PWR. Decision

Perform Test 1 (page 377). Use DMM; measure voltage between Breakout Harness Yes: Repair short to PWR
ZTSE4946 pin-2 and a known good GND. between EET pin-2 and Engine
Control Module (ECM) pin E1-62.
for SPN 173 FMI 2.
Step 5 Check for a failed EET sensor. Decision

A. Perform Test 2 (page 377). Yes: Replace EET sensor. After
SPN 173 FMI 2.
1974).
C. During test, monitor EET voltage.
Step 6 Check for EET circuit failure. Decision

A. Perform Test 3 (page 378). Yes: Repair Open between EET
Test (page 1974).
SPN 173 FMI 2.
Is voltage approximately 0 volts? No: Repair Open between EET
SPN 173 FMI 2.


Tools Required
Figure 90 EET Circuit Check
Test 1
A. Key OFF.
B. Connect Breakout Harness ZTSE4946 to engine harness and leave Engine Exhaust Temperature (EET)
C. Key ON.
Figure 91 EGT Circuit Check
Test 2
A. Key OFF.
B. Connect Breakout Harness ZTSE4946 to engine harness and leave EET sensor disconnected.
C. Use Breakout Harness ZTSE4498, short pin-2 and pin-1 of Breakout Harness ZTSE4946 together.
Test 3
A. Key OFF.
B. Connect Breakout Harness ZTSE4946 to engine harness and leave EET sensor disconnected.
C. Use Breakout Harness ZTSE4498, short pin-2 of Breakout Harness ZTSE4946 to a known good GND.
SPN 173 FMI 3 - Engine Exhaust Temperature : Voltage Above Normal, Or Shorted To High Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Engine Exhaust Temperature (EET) sensor
voltage is greater than normal operating range.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• EET signal circuit Open
• EET signal circuit short to PWR
• EET SIG GND circuit Open

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, Key On Engine Yes: Go to Step 2.
(page 1940).
Step 2 Inspect connections at Engine Exhaust Temperature (EET) sensor Decision

connector.
connector housing.
SPN 173 FMI 3.
Step 3 Check EET circuit for short to PWR. Decision

Perform Test 1 (page 382). Use DMM; measure voltage between Breakout Harness Yes: Repair short to PWR
ZTSE4946 pin-2 and a known good GND. between EET pin-2 and Engine
FMI 3.
Step 4 Check for failed EET sensor. Decision

A. Perform Test 2 (page 382). Yes: Replace EET sensor. After
®
SPN 173 FMI 3.
1974).
Step 5 Check for EET circuit failure. Decision

A. Perform Test 3 (page 383). Yes: Repair Open between EET
Test (page 1974).
SPN 173 FMI 3.
Is voltage approximately 0 volts? No: Repair Open between EGT
SPN 173 FMI 3.


Tools Required
Figure 93 EET Circuit Check
Test 1
A. Key OFF.
B. Disconnect Engine Exhaust Temperature (EET) sensor.
C. Connect Breakout Harness ZTSE4946 to engine harness and leave EET sensor disconnected.
Test 2
A. Key OFF.
B. Disconnect EET sensor.
C. Connect Breakout Harness ZTSE4946 to vehicle harness and leave EET sensor disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4946 pin-2 and pin-1 together.
Test 2
A. Key OFF.
B. Disconnect EET sensor.
C. Connect Breakout Harness ZTSE4946 to vehicle harness and leave EET sensor disconnected.
SPN 173 FMI 4 - Engine Exhaust Temperature : Voltage Below Normal, Or Shorted To Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Engine Exhaust Temperature (EET) sensor
voltage is less than normal operating range.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• EET circuit short to GND

®
(page 1940).
Step 2 Inspect connections at EET sensor connector. Decision

connector housing.
SPN 173 FMI 4.
Step 3 Check EET sensor operation. Decision

A. Key OFF. Yes: Replace EET sensor. After
B. Disconnect EET sensor
SPN 173 FMI 4.
(page 1956).
D. Key On, log in to Navistar® Engine Diagnostics.
1974).
F. During test, monitor EGT voltage.
between EGT pin-2 and ECM
FMI 4.

SPN 175 FMI 0 - Engine Oil Temperature 1 : Data Valid But Above Normal Operational Range - Most
Severe Level
Fault Overview
Fault code sets when signal from Engine Oil Temperature (EOT) is greater than normal operating range.
Lamp Reaction
Associated Faults
SPN 175 FMI 2, 3, 4, 14

and 15
Fault Facts
None

Continuous
Possible Causes
• EOT signal circuit Short to GND
• Failed EOT sensor

®
for SPN 175 FMI 0.

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics, Key On Yes: Go to Step 3.
Engine Off (KOEO), check Diagnostic Trouble Codes (DTC) list for SPN 175 FMI 0.
1940).
Step 3 Inspect connections at Engine Oil Temperature (EOT) connector. Decision

B. Disconnect EOT connector.
C. Check EOT and connector terminals for: damaged or pinched wires;
connector housing.
Are EOT connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
FMI 0.
Step 4 Check for failed EOT sensor. Decision

A. Key OFF. Yes: Replace EOT sensor. After
B. Disconnect Engine Oil Temperature (EOT) sensor.
SPN 175 FMI 0.
C. Perform Continuous Monitor Test (page 1974).
D. During test, monitor EOT voltage.
between EOT pin-2 and ECM
FMI 0.

After performing diagnostic steps, if SPN 175 FMI 0 remains, verify each step was completed correctly and the proper
SPN 175 FMI 2 - Engine Oil Temperature 1 : Data Erratic, Intermittent Or Incorrect
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Engine Oil Temperature (EOT) is too different
from Intake Manifold Temperature.
Lamp Reaction
Associated Faults
SPN 175 FMI 3 and 4
Fault Facts
None

Continuous
Possible Causes
• EOT signal circuit Open
• EOT SIG GND circuit Open

®
for SPN 175 FMI 2.

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics. Key ON, check Yes: Go to Step 3.
(page 1940).
Step 3 Inspect connections at Engine Oil Temperature (EOT) sensor Decision

connector.
Key OFF. Disconnect EOT connector. Check EOT and connector terminals for: Yes: Go to Step 4.
damaged or pinched wires; moisture or corroded terminals; loose, bent, or broken
pins; or broken connector housing.
FMI 2.
Step 4 Check for Failed EOT sensor. Decision

A. Perform Test 1 (page 392) . Yes: Replace EOT. After repairs
®
FMI 2.
1974).
C. During test, monitor EOT voltage in Navistar® Engine Diagnostics.
Is EOT voltage less than 0.25 volts? No: Go to step 5.
Step 5 Check for Open or high resistance in EOT circuit. Decision

1974).
C. During test, monitor EOT voltage in Navistar® Engine Diagnostics. 2.
Is EOT voltage less than 0.25 volts? No: Repair high resistance
between EOT sensor pin-2 and
2.


Tools Required
Figure 96 EOT Sensor Circuit Check
Test 1
A. Key OFF.
B. Connect Breakout Harness ZTSE4602 to engine harness and leave EOT sensor disconnected.
C. Use Breakout Harness ZTSE4498, short pin-2 and pin-1 of Breakout Harness ZTSE4602 together.
D. Connect EST to vehicle Diagnostic Connector.
E. Key ON, log in to Navistar® Engine Diagnostics.
Test 2
A. Key OFF.
B. Connect Breakout Harness ZTSE4602 to engine harness and leave EGT sensor disconnected.
C. Use Breakout Harness ZTSE4498, short pin-2 of Breakout Harness ZTSE4602 to a known good GND.
D. Connect EST to vehicle Diagnostic Connector.
F. Key-ON, log in to Navistar® Engine Diagnostics.
SPN 175 FMI 3 - Engine Oil Temperature 1 : Voltage Above Normal, Or Shorted To High Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Engine Oil Temperature (EOT) sensor voltage
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• EOT signal circuit Open
• EOT signal circuit short to PWR
• EOT SIG GND circuit Open

®
(page 1940).

connector housing.
FMI 3.
Step 3 Check EOT circuit for short to PWR. Decision

A. Perform Test 1 (page 397). Yes: Repair short to PWR
between EOT pin-2 and Engine
B. Use Digital Multimeter (DMM), measure voltage between Breakout Harness
FMI 3.
Step 4 Check for failed EOT sensor Decision

A. Perform Test 2 (page 397). Yes: Replace EOT sensor. After
®
SPN 175 FMI 3.
1974).
C. During test, monitor EOT voltage.
Is voltage approximately 0 volts? No: Go to step 5.
Step 5 Check for Open EOT signal circuit. Decision

A. Perform Test 3 (page 398). Yes: Repair Open between EOT
1974).
SPN 175 FMI 3.
C. During test, monitor EOT voltage.
Is voltage approximately 0 volts? No: Repair Open between EGT
SPN 175 FMI 3.


Tools Required
Figure 98 EOT Circuit Check
Test 1
A. Key OFF.
C. Connect Breakout Harness ZTSE4602 to engine harness and leave EOT sensor disconnected.
D. Key-ON.
Test 2
A. Key OFF.
C. Connect Breakout Harness ZTSE4602 to engine harness and leave EOT sensor disconnected.
Test 3
A. Key OFF.
C. Connect Breakout Harness ZTSE4602 to vehicle harness and leave EOT sensor disconnected.
SPN 175 FMI 4 - Engine Oil Temperature 1 : Voltage Below Normal, Or Shorted To Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Engine Oil Temperature (EOT) sensor voltage
is less than normal operating range.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• EOT signal circuit Short to GND

®
(page 1940).

connector housing.
SPN 175 FMI 4.
Step 3 Check for failed EOT sensor. Decision

A. Key OFF. Yes: Replace EOT sensor. After
SPN 175 FMI 4.
D. During test, monitor EOT voltage.
FMI 4.

SPN 175 FMI 14 - Engine Oil Temperature 1 : Special Instructions
Fault Overview
Fault code sets when signal from Engine Oil Temperature (EOT) is greater than the critical limit.
Lamp Reaction
Red Stop Lamp (RSL) will illuminate immediately when this fault is active.
Associated Faults
SPN 175 FMI 3 and 4
Fault Facts
None

Continuous
Possible Causes
• Low engine oil level and / or oil leak
• Failed oil cooler assembly
• Contaminated Engine Oil

for SPN 175 FMI 14.
Step 2 Inspect low engine oil level. Decision

Is engine oil level within specification and Not contaminated? No: Repair source of
contamination (see Symptom
Diagnostics portion of this
manual to isolate source of
contamination), then change
14.
Step 3 Inspect for engine oil leaks Decision

Key On Engine Running (KOER) inspect under vehicle for continuous drips or Yes: Go to Step 4.
continuous running of engine oil from vehicle.
Is engine free of major oil leaks No: Repair oil leaks. After repairs
FMI 14.
Step 4 Inspect for signs of engine oil in coolant. Decision

Perform Coolant Quality Inspection (page 2160). Yes: Retest for SPN 175 FMI 14.
Is coolant free of oil contamination? No: Go to Step 5.
Step 5 Check for leaking oil cooler. Decision

Perform Oil Cooler Pressure Test (see Engine Service Manual). Yes: End Diagnostic Steps.
Is oil cooler clean and free of leaks and debris? No: Replace oil cooler assembly.
Flush cooling system if needed.
Fill oil and coolant system to
specification with new fluids.
for SPN 175 FMI 14.

SPN 175 FMI 15 - Engine Oil Temperature 1 : Data Valid But Above Normal Operating Range - Least
Severe Level
Fault Overview
Fault code sets when signal from Engine Oil Temperature (EOT) is greater than the warning limit.
Lamp Reaction
Amber Warning Lamp (AWL) will illuminate immediately when this fault is active.
Associated Faults
SPN 175 FMI 3 and 4
Fault Facts
None

Continuous
Possible Causes
• Low engine oil level
• Failed oil cooler assembly
• Failed EOT

for SPN 175 FMI 15.
Step 2 Inspect low engine oil level. Decision

Is engine oil level within specification and Not contaminated? No: Repair source of
contamination (see Symptom
Diagnostics portion of this
manual to isolate source of
contamination), then change
15.
Step 3 Inspect for engine oil leaks Decision

Key On Engine Running (KOER) inspect under vehicle for continuous drips or Yes: Go to Step 4.
continuous running of engine oil from vehicle.
Is engine free of major oil leaks No: Repair oil leaks. After repairs
FMI 15.
Step 4 Inspect for signs of engine oil in coolant. Decision

Perform Coolant Quality Inspection (page 2160). Yes: Retest for SPN 175 FMI 15.
Is coolant free of oil contamination? No: Go to Step 5.
Step 5 Check for leaking oil cooler. Decision

Perform Oil Cooler Pressure Test (see Engine Service Manual). Yes: End Diagnostic Steps.
Is oil cooler clean and free of leaks and debris? No: Replace oil cooler assembly.
Flush cooling system if needed.
Fill oil and coolant system to
specification with new fluids.
for SPN 175 FMI 15.

SPN 188 FMI 14 - Engine Speed At Idle, Point 1 : Special Instructions
Fault Overview
Fault code sets when Electronic Control Module (ECM) detects vehicle is stationary and engine speed is higher
than 2600 rpm.
CAUTION:
To prevent engine damage, do not attempt to start engine until a full engine analysis and
all diagnostic steps have been completed.
Lamp Reaction
Red Stop Lamp (RSL) and Amber Warning Lamp (AWL) will illuminate immediately 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.

Continuous
Possible Causes
• Failed Injectors
• Oil leak to intake
• Failed Engine
Step 1 Check for excessive oil in turbo outlet and Charge Air Cooler (CAC) Decision
piping.
Perform Oil in Intake Inspection (page 2169). Yes: Go to Step 2.
Is there excessive oil in turbo outlet pipe or CAC piping? No: Go to Step 6.
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 DOC,
DPF, and SCR catalyst for Oil
contamination. After repairs are
14.
Is there any external engine block damage? No: Go to Step 3.
Step 3 Check Programmable Parameter (PP) 58071. Decision

A. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector Yes: Go to Step 4.
(page 1956).
B. Key ON, log into Navistar® Engine Diagnostics.
C. Open Programming Session.
D. Check value of PP 58070.

Is PP 58070 above 3200 rpm? No: Go to Step 5.
Step 4 Check for engine block or engine sleeve damage (engine speed Decision
greater than 3200 rpm).
Remove engine oil pan (see Engine Service Manual). Inspect for internal engine Yes: Repair or replace engine,
block or engine sleeve damage following warranty policies.
Inspect DOC, DPF, and SCR
catalyst for Oil contamination and
repair as needed. After repairs
FMI 14.
Is there any internal engine block or engine sleeve damage? No: Reinstall oil pan and refill oil.
Replace all 6 fuel injectors and
perform IQA Adjustment (page
1941) procedure. Inspect DOC,
DPF, and SCR catalyst for Oil
contamination. Clear trip report,
Step 5 Check for engine block or engine sleeve damage (engine speed less Decision
than 3200 rpm and greater than 2600 rpm).
Remove engine oil pan (see Engine Service Manual). Inspect for internal engine Yes: Repair or replace engine,
block or engine sleeve damage following warranty policies.
Inspect DOC, DPF, and SCR
catalyst for Oil contamination.
for SPN 188 FMI 14.
Is there any internal engine block or engine sleeve damage? No: Reinstall oil pan and refill oil.
Clear trip report, retest for SPN
188 FMI 14.
Step 6 Interview Driver. Decision

Interview Driver, ask following: Yes: Open Case File. Attach trip
report, freeze frame data and set
• When did fault occur?
condition information.
• Were shifts missed around this time?
• How was vehicle operating when fault occurred?
• Save Freeze Frame data from fault code.
• Save vehicle trip report.

Was vehicle operated in a way that over-sped the engine? No: End diagnostics, retest for
SPN 188 FMI 14.

SPN 188 FMI 16 - Engine Speed At Idle, Point 1 : Data Valid But Above Normal Operating Range -
Fault Overview
Fault sets only when a vehicle is stationary and engine speed exceeds desired set point.
Lamp Reaction
Associated Faults
SPN 5395 FMI 0
Fault Facts
None.

Continuous
Possible Cause
• External fuel source
• Engine oil leak to intake
• Fuel leak to intake
• Contaminated fuel
• Failed Fuel Injector

Is EST DTC list free of Associated Faults. No: Repair Associated Faults.
for SPN 188 FMI 16.
Step 2 Check for airborne combustibles (such as propane saturated air, ether) Decision
near engine.
Inspect air filter and intake system for stains, contaminants, odors / smells from Yes: Go to Step 3.
external fuel sources, and modifications.
Is engine intake system intact and free from any external fuel sources? No: Repair source of
combustibles. After repairs
FMI 16.
Step 3 Check for a engine oil leak to intake. Decision

Perform Oil in Intake Inspection (page 2169). Yes: Repair engine oil leak
to intake. After repairs are
16.
Is engine oil leaking to intake? No: Go to Step 4.
Step 4 Determine if fuel is in the air intake. Decision

With Charge Air Cooler (CAC) hose still removed from at mixer duct from previous Yes: Replace Cold Start Enable
step, inspect for fuel leaks at the intake air heater fuel igniter. Device (CSED) fuel solenoid.
for SPN 188 FMI 16.
Is fuel in the air intake? No: Go to Step 5.
Step 5 Check for contaminated fuel (alternate fuels other than Diesel fuel). Decision
Perform Fuel Quality Check (page 2156). Yes: Go to Step 6.
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,
Step 6 Determine if engine has a fuel injector problem. Decision

Perform Multiple Cylinder Cutout Test (page 2018). Yes: Replace fuel injector on
suspected cylinder and perform
IQA Adjustment(page 1941)
16.
Did one or more cylinders have significant speed difference(s) than others? No: End diagnostics. Retest for
SPN 188 FMI 16.

SPN 188 FMI 18 - Engine Speed At Idle, Point 1 : Data Valid But Below Normal Operating Range -
Fault Overview
Fault code sets when Engine Control Module (ECM) detects vehicle is stationary and engine speed is less than
expected.
Lamp Reaction
Associated Faults
SPN 157 SPN 641 SPN 651-656 SPN 1072-1073

SPN 1322-1328 SPN 2791
Fault Facts
None

Continuous
Possible Causes
• Low cylinder compression
• Base engine compression loss
• Clutch or Power Take Off (PTO) engagement without command
• Injector or injector circuit fault
• Valve train failure

Is EST DTC list free of Associated Faults. No: Repair Associated Faults.
for SPN 188 FMI 18.
Step 2 Determine if engine has a mechanical cylinder balance problem Decision

(compression loss).
Perform Crankcase Pressure Test (page 2092). Yes: Repair base engine
compression imbalance. After
SPN 188 FMI 18.
Does engine have excessive crankcase pressure? No: Go to Step 3.

Perform Multiple Cylinder Cutout Test (page 2018). Yes: Go to Step 4.
Did one or more cylinders have significant speed difference(s) than others? No: Go to Step 5.

Perform Valve Train Inspection (page 2188). Yes: Replace injector suspected
by Multiple Cylinder Cutout Test
and perform IQA Adjustment
(page 1941) procedure and
for SPN 188 FMI 18.
Did all valve train component(s) pass inspection? No: Repair failed valve train
components. After repairs are
18.
Step 5 Check for PTO engaged. Decision

Check for Power Take Off (PTO) engagement without command. KOER, monitor Yes: Repair PTO unit. After
PTO rotation. repairs are complete, retest for
SPN 188 FMI 18.
Is PTO rotating without command? No: End diagnostics. Retest for
SPN 188 FMI 18.

SPN 191 FMI 2 - Transmission Output Shaft Speed : Data Erratic, Intermittent Or Incorrect
Fault Overview
Fault code sets when Engine Control Module (ECM) detects non plausible signal from Transmission Output
Shaft Speed (TOSS) sensor.
Lamp Reaction
Associated Faults
SPN 191 FMI 3, 4 and 19
Fault Facts
None

Continuous
Possible Causes
• TOSS sensor circuit short PWR
• TOSS sensor circuit short to GND

for SPN 191 FMI 2.

1940).
Step 3 Inspect Transmission Output Shaft Speed (TOSS) Sensor and Trigger Decision
Wheel.
Inspect trigger wheel on transmission and verify it is not damaged or missing. Also Go to Step 4.
check that sensor is free of debris and metal shavings.
Is trigger wheel in good condition and undamaged? No: Repair damaged or missing
trigger wheel and remove debris
from sensor as necessary. After
SPN 191 FMI 2.

sensor.
connector housing.
FMI 2.

FMI 2.

2.

Perform Test 3 (page 417). Use DMM, measure resistance between TOSS Yes: Replace TOSS sensor.
connector pin-A and pin-B. After repairs are correct retest for
SPN 191 FMI 2.
for SPN 191 FMI 2.


See latest version of vehicle Electrical Circuit Diagram on Service Portal for additional circuit information. There
might be slight differences in 7600 connector end based on type of transmission used.
Tools Required
Test 1
A. Key Off.

Test 2
A. Key Off.
D. KOEO.
Test 3
A. Key Off.
SPN 191 FMI 3 - Transmission Output Shaft Speed : Voltage Above Normal, Or Shorted To High Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects TOSS/VSS speed sensor voltage is greater than
normal operating range.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Failed TOSS / VSS sensor
• Incorrect air gap between TOSS / VSS sensor and trigger wheel
• Damaged TOSS / VSS trigger wheel
• TOSS-H short to PWR
• TOSS-L short to PWR

®
(page 1940).
Step 2 Inspect connections at Transmission Output Speed Sensor/Vehicle Decision

Speed Sensor (TOSS / VSS) sensor.
B. Disconnect TOSS / VSS sensor.
C. Check TOSS / VSS sensor and connector terminals for: damaged or
pinched wires; wet or corroded terminals; loose, bent, or broken pins; or
Is TOSS / VSS sensor connector, harness, and terminal clean and undamaged? No: Repair connector, harness,
FMI 3.
Step 3 Check for failed TOSS / VSS circuit failure. Decision

B. Use DMM, measure voltage between TOSS pin-A to known good GND and
measure voltage between TOSS pin-B to known good GND.
Are both TOSS pin-A and pin-B to GND voltage 2.5 ± 0.25 volts? No: Repair short to PWR
between ECM and TOSS /
VSS sensor. After repairs are
3.
Step 4 Check TOSS / VSS sensor resistance. Decision

A. Perform Test 2 (page 422). Yes: Check TOSS / VSS sensor
air gap or trigger wheel and
B. Use DMM, measure resistance between TOSS pin-A and pin-B.
repair as necessary. After
SPN 191 FMI 3.
Is resistance between 600 and 800 ohms? No: Replace TOSS / VSS sensor.
for SPN 191 FMI 3.


Tools Required
• International® Electronic Engine Terminal Test Kit ZTSE4435C
• EZ-Tech® Electronic Service Tool (EST) with Navistar® Engine Diagnostics
• Interface cable (RP1210B compliant supporting J1939 and J1708)
Figure 104 TOSS / VSS Circuit Check
Test 1
A. Key OFF.
B. Disconnect TOSS / VVSS sensor.
C. Connect Terminal Test Kit ZTSE4435C to chassis harness and leave TOSS / VSS sensor disconnected.

Test 2
A. Key OFF.
C. Connect Terminal Test Kit 4435C to chassis harness and leave TOSS / VSS sensor disconnected.
SPN 191 FMI 4 - Transmission Output Shaft Speed : Voltage Below Normal, Or Shorted To Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects TOSS/VSS speed sensor voltage is less than
Lamp Reaction
Associated Faults
None
Fault Facts
None.

Continuous
Possible Causes
• TOSS / VSS sensor circuit short to GND
• TOSS-H circuit shorted to TOSS-L circuit
• TOSS / VSS sensor failure
• Excessive air gap between TOSS / VSS sensor and trigger wheel
• Damaged TOSS / VSS trigger wheel

®
(page 1940).
Step 2 Inspect connections at Transmission Output Speed Sensor (TOSS) / Decision

Vehicle Speed Sensor (VSS) sensor.
C. Check TOSS / VSS sensor and connector terminals for: damaged or
Is TOSS / VSS sensor connector, harness, and terminal clean and undamaged? No: Repair connector, harness,
FMI 4.
Step 3 Check for TOSS / VSS circuit shorted to GND. Decision

B. Use DMM, measure voltage between TOSS (7600) pin-A to known good
GND and measure voltage between TOSS (7600) pin-B to known good
GND.
Are both TOSS (7600) pin-A and pin-B to GND voltage 2.5 ± 0.25 volts? No: Repair short to GND between
ECM and TOSS / VSS sensor.
for SPN 191 FMI 4.
Step 4 Check for TOSS-H circuit shorted to TOSS-L circuit. Decision

B. Use DMM, measure resistance between TOSS/VSS connector pin-A and
pin-B.
Is resistance greater than 1,000 ohms? No: Repair short between
for SPN 191 FMI 4.
Step 5 Check for failed TOSS / VOSS. Decision

Inspect trigger wheel on transmission and verify it is not damaged or missing. Yes: Replace TOSS / VSS
4
Is the trigger wheel in good condition and undamaged? No: Check TOSS / VSS sensor
air gap or trigger wheel and repair
4.


See latest version of vehicle Electrical Circuit Diagram on Service Portal for additional circuit information. There
might be slight differences in 7600 connector end based on type of transmission used.
Tools Required
• International® Electronic Engine Terminal Test Kit ZTSE4435C
Test 1
A. Key OFF.
B. Disconnect TOSS / VSS (7600) sensor.
C. Connect Terminal Test Kit ZTSE4435C to chassis harness and leave TOSS/VSS (7600) sensor disconnected.
D. Key On Engine Off (KOEO)

Test 2
A. Key OFF.
B. Disconnect TOSS / VSS (7600) sensor.
C. Connect Terminal Test Kit 4435C to chassis harness and leave TOSS/VSS sensor disconnected.
D. Disconnect ECM C-1 connector.
SPN 191 FMI 19 - Transmission Output Shaft Speed : Received Network Data In Error
Fault Overview
Fault code sets when Engine Control Module (ECM) does Not detect Transmission Output Shaft Speed (TOSS)
on Private J1939 CAN data link communications circuit.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• J1939 TCM Module CAN circuit failure

®
(page 1940).
Step 2 Check for Transmission Control Module (TCM)faults. Decision

Review all vehicle fault codes either using the health report of EST. Yes: Diagnose and repair using
transmission OEM service
information. After repairs are
FMI 19.
Were any fault codes set in the TCM? No: Go to step 3.
Step 3 Check J1939 CAN circuit failure. Decision

Perform J1939 Diagnostics (page 2112). Yes: Repair failure indicated by
test. After repairs are complete,
Was a failure identified during the test? No: End Diagnostics, retest for
SPN 191 FMI 19

SPN 412 FMI 0 - Engine Exhaust Gas Recirculation 1 Temperature : Data Valid But Above Normal
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Exhaust Gas Recirculation Temperature
(EGRT) is within range but reading greater than expected.
Lamp Reaction
Associated Faults
SPN 110 FMI 0, 2, 3, 4, 15 SPN 111 FMI 1 SPN 412 FMI 2, 3, and 4
and 16
Fault Facts
None

Continuous
Possible Causes
• Engine overheating
• Failed EGR cooler
Step 1 Check for associated faults.. Decision

®
for SPN 412 FMI 0.

(page 1940).
Step 3 Check for low coolant condition. Decision

Perform Coolant Level Inspection (page 2159). Yes: Go to step 4.
Is coolant level within specification? No: Go to step 2 of 5.0 - Cooling
coolant loss. After repairs are
FMI 0.
Step 4 Check for engine overheating condition. Decision

A. Start engine, and run engine to normal operating temperature. Yes: Go to step 2 of 5.2 - Coolant
Over Temperature (page 65) to
B. After engine reaches normal operating temperature, monitor engine coolant
diagnose overheating condition.
temperature for an overheating condition for 5 minutes.
for SPN 412 FMI 0.
Does engine coolant temperature go above normal operating temperature? No:
Step Determine if Exhaust Gas Recirculation (EGR) cooler is leaking. Decision

Perform EGR Cooler Leak Test (page 2126). Yes: Replace EGR cooler. After
SPN 412 FMI 0.
Is EGR cooler leaking coolant? No: End diagnostics, retest for
SPN 4752 FMI 4.

SPN 412 FMI 2 - Engine Exhaust Gas Recirculation 1 Temperature : Data Erratic, Intermittent Or
Incorrect
Fault Overview
Fault sets when Engine Control Module (ECM) determines Exhaust Gas Recirculation Temperature (EGRT)
signal deviates from average values of Intake Manifold Temperature (IMT), Intake Air Temperature (IAT), and
Charge Air Cooler Outlet Temperature (CACOT) after cold soak.
Lamp Reaction
Associated Faults
SPN 412 FMI 3 and 4
Fault Facts
None

Road Test
Possible Causes
• High resistance in EGRT signal circuit
• High resistance in EGRT ground circuit
• Failed EGRT sensor

®
for SPN 412 FMI 2.

(page 1940).
Step 3 Inspect connections at Exhaust Gas Recirculation Temperature (EGRT) Decision

connector.
B. Disconnect EGRT connector.
C. Check EGRT and connector terminals for: damaged or pinched wires;
connector housing.
Are EGRT connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
FMI 2.
Step 4 Check EGRT circuit for high resistance. Decision

A. Key Off. Yes: Go to step 5.
B. Disconnect EGRT sensor

(page 1956).
F. During test, monitor EGRT voltage in EST.
Is voltage 5 ± 0.25 volts? No: Go to step 7
Step 5 Check for Failed EGRT sensor. Decision

A. Perform Test 1 (page 437). Yes: Replace EGRT. After
SPN 412 FMI 2.
C. During test, monitor EGRT voltage in EST.
Is EGRT voltage between 0 and 0.25 volts? No: Go to Step 6.
Step 6 Check for Failed EGRT circuit. Decision

between EGRT pin-1 and ECM
C. During test, monitor EGRT voltage in EST. complete, retest for SPN 412
FMI 2.
Is EGRT voltage between 0 and 0.25 volts? No: Go to Step 7.
Step 7 Check for Failed EGRT circuit. Decision

between EGRT pin-2 and 10-Pin
Engine Interface Connector
C. During test, monitor EGRT voltage in EST. pin-E on engine harness. After
SPN 412 FMI 2.
Is EGRT voltage between 0 and 0.25 volts? No: Repair high resistance
between 10-Pin Engine Interface
Connector pin-E and ECM pin
C1-31 on vehicle harness. After
SPN 412 FMI 2.


Tools Required
Figure 110 EGRT Circuit Check
Test 1
A. Key OFF.
B. Connect Breakout Harness ZTSE4760A to engine harness and leave EGRT sensor disconnected.
C. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4760A pin-1 to pin-2.
Test 2
A. Key OFF.
C. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4760A pin-1 to a known good GND.
E. Key ON.
4498
E
12-999-06
0000421981
Test 3
A. Key OFF.
B. Disconnect 10-Pin Engine Interface Connector
C. Connect Breakout Harness 12-999-06 to vehicle side harness and leave engine harness side disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness 12-999-06 pin-E to a known good GND.
F. Key ON.
SPN 412 FMI 3 - Engine Exhaust Gas Recirculation 1 Temperature : Voltage Above Normal, Or Shorted
To High Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Exhaust Gas Recirculation Temperature
(EGRT) voltage is greater than normal operating range.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• EGRT signal circuit Open
• EGRT signal circuit short to PWR
• EGRT SIG GND circuit Open

®
(page 1940).

connector.
connector housing.
SPN 412 FMI 3.
Step 3 Check for EGRT circuit short to PWR. Decision

between EGRT pin-2 and
B. Use DMM, measure voltage between Breakout Harness ZTSE4760A pin-2
and known good GND.
FMI 3.
Step 4 Check for failed EGRT sensor. Decision

A. Perform Test 2 (page 443). Yes: Replace EGRT sensor.
®
for SPN 412 FMI 3.
Test (page 1974).
C. During test, monitor EGRT voltage.
Step 5 Check for EGRGT circuit failure. Decision

EGRT pin-1 and ECM pin E1-61.
Test (page 1974).
for SPN 412 FMI 3.
C. During test, monitor EGRT voltage.
Is voltage approximately 0 volts? No: Repair Open between EGRT
pin-2 and ECM pin C1-31. After
SPN 412 FMI 3.


Tools Required
Figure 113 EGRT Circuit Voltage Check
Test 1
A. Key Off.
B. Disconnect Exhaust Recirculation Cooler Gas Temperature (EGRT) sensor.
C. Connect Breakout Harness ZTSE4760A to vehicle harness and leave EGRT sensor disconnected.
D. Key On, Engine Off (KOEO).
Figure 114 EGRT Sensor Circuit Check
Test 2
A. Key Off.
B. Disconnect Exhaust Gas Recirculation Cooler Temperature (EGRT) sensor.
D. Use Breakout Harness ZTSE4498 short pin-2 and pin-1 of Breakout Harness ZTSE4760A together.
F. KOEO, log in to Navistar® Engine Diagnostics.
Figure 115 EGRT Sensor Circuit Check
Test 3
A. Key Off.
B. Disconnect Exhaust Gas Recirculation Cooler Temperature (EGRT) sensor.
D. Use Breakout Harness ZTSE4498, short pin-2 of Breakout Harness ZTSE4760A to a known good GND.
F. KOEO, log in to Navistar® Engine Diagnostics.
SPN 412 FMI 4 - Engine Exhaust Gas Recirculation 1 Temperature : Voltage Below Normal, Or Shorted
To Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Exhaust Gas Recirculation Temperature
(EGRT) signal voltage is less than normal operating range.
Lamp Reaction
Associated Faults
None.
Fault Facts
None.

Continuous
Possible Causes
• EGRT circuit short to GND

®
1940).

connector.
connector housing.
FMI 4.
Step 3 Check for failed EGRT sensor. Decision

A. Key OFF Yes: Replace EGRT sensor.
B. Disconnect Exhaust Gas Recirculation Temperature (EGRT) sensor
for SPN 412 FMI 4.
electrical connector.
(page 1956).
D. Key ON.
E. Use EST with Navistar® Engine Diagnostics, perform Continuous Monitor
Test (page 1974).
F. During test, monitor EGRT voltage with EST.
between EGRGT pin-2 and ECM
4.

SPN 560 FMI 2 - Transmission Driveline Engaged : Data Erratic, Intermittent Or Incorrect
Fault Overview
Fault code sets when Engine Control Module (ECM) detects transmission drive-line engaged status is invalid.
Lamp Reaction
Associated Faults
None.
Fault Facts
None.

Continuous
Possible Causes
• Transmission Control Module (TCM) communication fault
• Body Controller communication fault
• Transmission driveline engaged switch or circuit fault
Step 1 Verify Transmission Control Module (TCM) is communicating. Decision

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check that Yes: Diagnose Transmission
TCM is listed in Sniffer Section of Default Session. Driveline engaged switch or
circuit fault (see appropriate
Transmission/Truck Service
Manual). After repairs are
completed, retest for SPN 560
FMI 2.
Is TCM listed? No: Diagnose Transmission
PWR or J1939 CAN circuit
failures (see appropriate
Transmission/Truck Service
Manual) After Repairs are
completed, retest for SPN 560
FMI 2.

SPN 597 FMI 19 - Brake Switch : Received Network Data In Error
Fault Overview
Fault code sets when Engine Control Module (ECM) detects the Brake Switch signal is not seen on the Public
J1939 CAN network.
Lamp Reaction
The Amber Warning Lamp (AWL) illuminates immediately when this fault is detected.
Associated Faults
None
Fault Facts
Ensure Body Controller (Source Address 33) SPN 597 faults are not Active. If Body Controller has active SPN
597 faults active, diagnose and repair these fault codes first using Diamond Logic Builder and the appropriate
Technician Manual.

Continuous
Possible Causes

®
1940).

for SPN 597 FMI 19.
End Diagnostic Test

SPN 626 FMI 3 - Engine Start Enable Device 1 : Voltage Above Normal, Or Shorted To High Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Cold Start Enable Device (CSED) fuel
solenoid current draw is greater than greater than normal operating range.
Lamp Reaction
Associated Faults
None.
Fault Facts
None.

Continuous
Possible Causes
• CSED fuel solenoid circuit short to PWR
• CSED fuel solenoid short to ECM PWR OUT 3
• Failed CSED fuel solenoid

®
(page 1940).
Step 2 Inspect connections at Engine Cold Start Enable Device (CSED) fuel Decision
solenoid connector.
B. Disconnect CSED fuel solenoid connector.
C. Check CSED fuel solenoid and connector terminals for: damaged or
pinched wires; moisture or corroded terminals; loose, bent, or broken pins;
or broken connector housing.
Are CSED fuel solenoid connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
FMI 3.
Step 3 KOEO Voltage Check. Decision

Is voltage B+ ± 0.5 volts? No: Repair short to GND
CSED fuel solenoid pin-2. After
SPN 626 FMI 3.
Step 4 Check for failed CSED fuel solenoid. Decision

Perform Test 2 (page 454). Use DMM measure resistance between Breakout Yes: Go to Step 5.
Harness ZTSE4827 pin-1 and pin-2.
Is resistance 8 ±1 ohm? No: Replace CSED fuel solenoid.
for SPN 626 FMI 3.
Step 5 Check for short to PWR in CSED fuel solenoid circuit. Decision
Perform Test 3 (page 454). Use DMM measure voltage between Breakout Harness Yes: End of Diagnostics, retest
ZTSE4827 pin-1 and known good GND. for SPN 626 FMI 3.
CSED fuel solenoid pin-1. After
SPN 626 FMI 3.


Tools Required
Figure 116 ECM PWR OUT 2 Circuit Check
Test 1
A. Key OFF.
B. Connect Breakout Harness ZTSE4827 to CSED fuel solenoid and leave vehicle harness disconnected.
C. Key ON.
Figure 117 CSED fuel solenoid Resistance Check
Test 2
A. Key OFF.
Figure 118 IAHFS Circuit Check
Test 3
A. Key OFF.
C. Key ON.
SPN 626 FMI 4 - Engine Start Enable Device 1 : Voltage Below Normal, Or Shorted To Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Cold Start Enable Device (CSED) fuel
solenoid circuit voltage less than a normal operating range.
Lamp Reaction
Associated Faults
SPN 3599
Fault Facts
None.

Continuous
Possible Causes
• ECM PWR OUT 3 circuit short to GND
• CSED fuel solenoid circuit short to GND
• Failed CSED fuel solenoid

for SPN 626 FMI 4.

®
(page 1940).
Step 3 Inspect connections at CSED fuel solenoid connector. Decision

B. Disconnect CSED fuel solenoid connector.
C. Check CSED fuel solenoid and connector terminals for: damaged or
Are CSED fuel solenoid connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
FMI 4.
Step 4 Check ECM PWR OUT 3 circuit for short to GND. Decision
Perform Test 1 (page 457). Use DMM, measure resistance between Breakout Yes: Go to Step 5.
Harness ZTSE4827 pin-2 and known good GND.
Is resistance greater than 1,000 ohms? No: Repair short to GND between
ECM pin C1-01 and CSED fuel
solenoid pin-2. After repairs are
4.
Step 5 Check CSED fuel solenoid circuit for short to GND. Decision
ECM pin C1-50 and CSED fuel
solenoid pin-1. After repairs are
4.
Step 6 Check for Failed CSED fuel solenoid. Decision

Perform Test 3 (page 459). Use DMM, measure resistance between Breakout Yes: End diagnostics, retest for
Harness ZTSE4827 pin-1 and pin-2. SPN 626 FMI 4.
Is resistance 8 ± 1 ohms? No: Replace CSED fuel solenoid.
for SPN 626 FMI 4.


Tools Required
Test 1
A. Key OFF.
B. Disconnect ECM E-1 connector.
C. Connect Breakout Harness ZTSE4827 to engine harness and leave Cold Start Enable Device (CSED) fuel
solenoid disconnected.
Figure 120 CSED fuel solenoid Circuit Check
Test 2
A. Key OFF.
B. Disconnect ECM E-1 connector.
C. Connect Breakout Harness ZTSE4827 to engine harness and leave CSED fuel solenoid disconnected.
Figure 121 CSED fuel solenoid Resistance Check
Test 3
A. Key OFF.
B. Connect Breakout Harness ZTSE4827 to CSED fuel solenoid and leave engine harness disconnected.
SPN 626 FMI 5 - Engine Start Enable Device 1 : Current Below Normal Or Open Circuit
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Cold Start Enable Device (CSED), or fuel solenoid,
circuit is open.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• ECM PWR OUT circuit Open
• CSED circuit Open
• Failed CSED

®
1940).
Step 2 Inspect connections at Cold Start Enable Device (CSED) connector. Decision
B. Disconnect CSED connector.
C. Check CSED and connector terminals for: damaged or pinched wires;
connector housing.
Are CSED connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
FMI 5.
Step 3 ECM PWR OUT circuit check. Decision

Is voltage B+ ± 0.25 volts? No: Repair OPEN in ECM PWR
OUT 3 circuit. After repairs are
5.
Step 4 Check for Failed CSED. Decision

Perform Test 2 (page 463). Use DMM, measure resistance between Breakout Yes: Repair open between ECM
Harness ZTSE4827 pin-1 and pin-2. pin C1-50 and CSED pin-1. After
SPN 626 FMI 5.
Is resistance 8 ± 1 ohms? No: Replace CSED. After repairs
FMI 5.


Tools Required
Figure 122 ECM PWR OUT Circuit Check
Test 1
A. Key OFF.
B. Connect Breakout Harness ZTSE4827 to engine harness and leave CSED disconnected.
C. Key On, Engine Off (KOEO).

Figure 123 CSED Resistance Check
Test 2
A. Key OFF.
B. Connect Breakout Harness ZTSE4827 to CSED and leave engine harness disconnected.
SPN 628 FMI 12 - Program Memory : Bad Intelligent Device or Component
Fault Overview
Fault Code sets when Engine Control Module (ECM) detects ECM memory error has occurred during the drive
cycle.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Failed ECM
• Out of date software
Step 1 Obtain vehicle health report and check for current Engine Control Decision
Module (ECM) calibration.
Perform Obtain Vehicle Health Report(page 1946). Yes: Go to Step 2.
FMI 12.

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics, Key ON, Yes: Replace ECM, following
check Diagnostic Trouble Codes (DTC) list for SPN 628 FMI 12. approved warranty procedures,
Sensor Relearn Procedure
12.
Is SPN 628 FMI 12 active or pending? No: Release vehicle to customer.

SPN 629 FMI 0 - ECM Error - Controller #1 : Data Valid But Above Normal Operational Range - Most
Severe Level
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that CPU load is excessively high
Lamp Reaction
The Malfunction Indicator Lamp will illuminate immediately when this fault is detected.
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Out of date software
• Failed ECM
FMI 0.

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics, Key ON, check Yes: Replace ECM, following
Diagnostic Trouble Codes (DTC) list for SPN 629 FMI 0. approved warranty procedures,
0.

SPN 629 FMI 2 - Controller #1 : Data Erratic, Intermittent Or Incorrect
Fault Overview
Fault code sets when Engine Control Module (ECM) detects and error-level 2 monitoring error.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• ECM software out of date
• Failed ECM
FMI 2.

2.

SPN 629 FMI 8 - Controller #1 : Abnormal Frequency Or Pulse Width Or Period
Fault Overview
Fault Code sets when Engine Control Module (ECM) detects that difference between engine OFF timer count
and ECM timer count is greater than 6%.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Failed ECM
FMI 8.

8.

SPN 629 FMI 12 - Controller #1 : Bad Intelligent Device Or Component
Fault Overview
Fault Code sets when Engine Control Module (ECM) detects an internal error within ECM.
Lamp Reaction
Associated Faults
SPN 157 FMI 0, 1, 3, 4, 15, SPN 633 FMI 3, 4, and 5 SPN 651 - 656 FMI 3, 4, SPN 651 - 656 FMI 13, 16,
17, 20, and 21 and 5 and 18
SPN 1244 SPN 2797 FMI 11 SPN 2798 FMI 11
Fault Facts
None

Continuous
Possible Causes
• Loose connections in electrical system

®
for SPN 629 FMI 12.

Use EST, Key ON, check Diagnostic Trouble Codes (DTC) list for SPN 629 FMI 12. Yes: Go to Step 3.
Is SPN 629 FMI 12 active? No: End diagnostics. Retest for
SPN 629 FMI 12.
Step 3 Check for failed batteries. Decision

Perform Batteries and Electrical System Inspection (page 2198). Yes: End diagnostics. Retest for
SPN 629 FMI 12.
Are batteries, wiring, electrical connections clean, tight, and free of damage? No: Repair batteries, wiring and
SPN 629 FMI 12.

SPN 629 FMI 14 - Controller #1 : Special Instructions
Fault Overview
Fault Code sets when Engine Control Module (ECM) detects an internal chip error within ECM.
Lamp Reaction
Associated Faults
SPN 157 SPN 633 SPN 651–656 SPN 1244

SPN 2797 FMI 11 SPN 2798 FMI 11
Fault Facts
None

Continuous
Possible Causes
• Failed ECM
FMI 14.

for SPN 629 FMI 14.

Use EST, Key ON, check Diagnostic Trouble Codes (DTC) list for SPN 629 FMI 14. Yes: Replace ECM, following
approved warranty procedures
14.

SPN 629 FMI 15 - Controller #1 : Data Valid But Above Normal Operating Range - Least Severe Level
Fault Overview
Fault code sets when Engine Control Module (ECM) detects internal temperature of ECM is too high.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Failed ECM
FMI 15.

15.

SPN 629 FMI 31 - Controller #1 : Condition Exists
Fault Overview
Fault code sets when Engine Control Module (ECM) detects an internal chip error.
Lamp Reaction
Associated Faults
• SPN 91 • SPN 2623
Fault Facts
None

Continuous
Possible Causes
• Failed ECM
FMI 31.

for SPN 629 FMI 31.

31.

SPN 633 FMI 3 - Engine Fuel Actuator 1 Control Command : Voltage Above Normal, Or Shorted To
High Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Fuel Actuator 1 (EFA1) high side circuit
voltage or low side circuit voltage is less than normal operating range.
Lamp Reaction
Associated Faults
None
Fault Facts
EFA1 is the electronic control valve mounted to the high-pressure fuel pump.

Road Test
Possible Causes
• EFA1 12V circuit short to GND
• EFA1 circuit Short to PWR
• Failed EFA1

®
(page 1940).
Step 2 Inspect connections at EFA1 connector. Decision

B. Disconnect EFA1 connector.
C. Check EFA1 and connector terminals for: damaged or pinched wires;
connector housing.
Are EFA1 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
FMI 3.
Step 3 Check EFA1 12V circuit for short to GND. Decision

Is voltage B+ ± 0.25 volts? No: Repair Short to GND
EFA1 pin-2. After repairs are
FMI 3.
Step 4 Check EFA1 circuit for short to PWR. Decision

Perform Test 2 (page 483). Use DMM, measure voltage between Breakout Harness Yes: Replace EFA1. After repairs
ZTSE6021 pin-1 and known good GND. are complete, retest for SPN 633
FMI 3.
Is voltage 4.0 ± 0.25 volts? No: Repair short to PWR
EFA1 pin-1. After repairs are
3.


Tools Required
Figure 124 EFA1 12V Circuit Check
Test 1
A. Key OFF.
B. Connect Breakout Harness ZTSE6021 to engine harness and leave Engine Fuel Actuator 1 (EFA1)
disconnected.
C. Key ON.
Figure 125 EFA1 Circuit Check
Test 2
A. Key OFF.
B. Connect Breakout Harness ZTSE6021 to engine harness and leave EFA1 sensor disconnected.
C. Key ON.
SPN 633 FMI 4 - Engine Fuel Actuator 1 Control Command : Voltage Below Normal, Or Shorted To
Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Fuel Actuator 1 (EFA1) high side circuit
voltage or low side circuit voltage is less than normal operating range.
Lamp Reaction
Associated Faults
None
Fault Facts
EFA1 is mounted on the high-pressure fuel pump.

Road Test
Possible Causes
• EFA1 12 volt circuit short to GND
• EFA1 circuit Short to GND
• Failed EFA1

®
(page 1940).
Step 2 Inspect connections at Engine Fuel Actuator 1 (EFA1) connector. Decision

connector housing.
FMI 4.
Step 3 Check EFA1 12 volt circuit for short to GND. Decision

Is voltage B+ ± 0.25 volts? No: Repair short to GND between
ECM pin E1-52 and EFA1 pin-2.
for SPN 633 FMI 4.
Step 4 Check EFA1 circuit for short to GND. Decision

FMI 4.
Is voltage 4.0 ± 0.25 volts? No: Repair short to GND between
for SPN 633 FMI 4.


Tools Required
Figure 126 EFA1 12V Circuit Check
Test 1
A. Key OFF.
B. Connect Breakout Harness ZTSE6021 to engine harness and leave Engine Fuel Actuator 1 (EFA1)
disconnected.
C. Key ON, Engine Off (KOEO).
Test 2
A. Key OFF.
B. Connect Breakout Harness ZTSE6021 to vehicle harness and leave EFA1 disconnected.
C. KOEO.
SPN 633 FMI 5 - Engine Fuel Actuator 1 Control Command : Current Below Normal Or Open Circuit
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Fuel Actuator 1 (EFA1) circuit is open.
Lamp Reaction
Associated Faults
None
Fault Facts
EFA1 is mounted to the high-pressure fuel pump.

Road Test
Possible Causes
• EFA1 12V circuit Open
• EFA1 circuit Open
• Failed EFA1

®
(page 1940).

connector housing.
FMI 5.
Step 3 Check EFA1 12V circuit for an Open. Decision

Is voltage B+ ± 0.25 volts? No: Repair Open circuit between
for SPN 633 FMI 5.
Step 4 Check EFA1 circuit for an Open. Decision

FMI 5.
Is voltage 4.0 ± 0.25 volts? No: Repair Open circuit between
for SPN 633 FMI 5.


Tools Required
Figure 128 EFA1 12 Volt Circuit Check
Test 1
A. Key OFF.
B. Connect Breakout Harness ZTSE6021 to vehicle harness and leave Engine Fuel Actuator 1 (EFA1) sensor
disconnected.
Test 2
A. Key OFF.
B. Connect Breakout Harness ZTSE6021 to vehicle harness and leave EFA1 sensor disconnected.
C. KOEO.
SPN 636 FMI 2 - Engine Position Sensor : Data Erratic, Intermittent Or Incorrect
Fault Overview
Fault code sets when Electronic Control Module (ECM) detects difference between camshaft and crankshaft
position signals is greater than 20 degrees or less than 20 degrees.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Road Test
Possible Causes
• Debris accumulation on Camshaft Position (CMP) sensor
• CMP-L Open or high resistance
• CMP-H Open or high resistance
• CMP-L short to GND
• CMP-H short to GND
• CMP-L shorted to CMP-H
• Camshaft and Crankshaft not synchronized
• Failed CMP

®
(page 1940).
Step 2 Inspect connections at Camshaft Position (CMP) sensor connector. Decision

B. Disconnect CMP connector.
C. Check CMP and connector terminals for: damaged or pinched wires;
connector housing.
Are CMP connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
or terminal damage. Perform
for SPN 636 FMI 2.
Step 3 Inspect CMP sensor and bore for damage or debris build up. Decision
Remove CMP sensor and inspect sensor and bore. Yes: Go to Step 4.
Is sensor and bore free of damage or debris? No: Clean CMP sensor with a rag
or towel and clean sensor bore,
replace CMP sensor as needed.
Perform Crankshaft Position
FMI 2.
Step 4 Check for a failed CMP sensor. Decision

Perform Test 1 (page 496). Use Digital Multimeter (DMM), measure resistance Yes: Go to Step 5.
between Breakout Harness ZTSE6021 pin-1 and pin-2 when sensor is at room
temperature.
Is CMP sensor resistance between 774 and 946 ohms at room temperature? No: Replace CMP sensor.
2.
Step 5 Check for short to GND in CMP-H circuit. Decision

CMP pin-2 and ECM pin E1-19.
FMI 2.
Step 6 Check for short to GND in CMP-L circuit. Decision

2.
Step 7 Check for OPEN or High resistance in CMP-H circuit. Decision

Perform Test 4 (page 498). Use DMM, measure voltage from Breakout Harness Yes: Go to Step 8.
ZTSE6021 pin-2 to known good GND.
Is voltage 2 ± 0.25 volts? No: Repair OPEN or high
E1-19 and CMP pin- 2. Perform
for SPN 636 FMI 2.
Step 8 Check for OPEN or High resistance in CMP-L circuit. Decision

E1-43 and CMP pin-1. Perform
for SPN 636 FMI 2.
Step 9 Check for correct camshaft /crankshaft synchronization Decision

Perform camshaft /crankshaft synchronization (see Engine Service Manual, Yes: End diagnostics. Perform
"Cylinder Head, Camshaft and Valve Train" section). Crankshaft Position Sensor
for SPN 636 FMI 2.
Are camshaft and crankshaft timed properly? No: Check for damage and
re-time camshaft and crankshaft.

2.

After performing all tests, if no problem is found, verify if each step was completed correctly and proper decision was

Tools Required
Figure 130 CMP Sensor Check
Test 1
A. Key OFF.
B. Connect Breakout Harness ZTSE6021 to engine harness and leave Camshaft Position (CMP) sensor
disconnected.
Figure 131 CMP-H Circuit Check
Test 2
A. Key OFF.
B. Connect Breakout Harness ZTSE6021 to engine harness and leave CMP sensor disconnected.
Figure 132 CMP-L Circuit Check
Test 3
A. Key OFF.
Test 4
A. Key OFF.
C. Key ON
Test 5
A. Key OFF.
C. Key ON
SPN 636 FMI 8 - Engine Position Sensor : Abnormal Frequency Or Pulse Width Or Period
Fault Overview
Fault code sets when Electronic Control Module (ECM) detects CMP signal is different than expected CMP
signal.
Lamp Reaction
Associated Faults
None
Fault Fact
None

Road Test
Possible Causes
• Failed CMP

®
(page 1940).

connector housing.
for SPN 636 FMI 8.
replace CMP sensor if needed.
8.

temperature.
Is CMP sensor resistance between 774 and 946 ohms? No: Replace CMP sensor.
8.

Is CMP sensor resistance between 774 and 946 ohms at room temperature? No: Repair short to GND between
8.

8.

Is voltage 2.65 ± 0.25 volts? No: Repair OPEN or high
for SPN 636 FMI 8.

Is voltage 2.45 ± 0.25 volts? No: Repair OPEN or high
for SPN 636 FMI 8.

Perform camshaft /crankshaft synchronization (see Engine Service Manual, Yes: End diagnostics. Perform
"Cylinder Head, Camshaft and Valve Train" section). Crankshaft Position Sensor
for SPN 636 FMI 8.

8.


Tools Required
Test 1
A. Key OFF.
B. Connect Breakout Harness ZTSE6021 to Camshaft Position (CMP) sensor and leave engine harness
disconnected.
Test 2
A. Key OFF.
B. Connect Breakout Harness ZTSE6021 to engine harness and leave Camshaft Position (CMP) sensor
disconnected.
Test 3
A. Key OFF.
Test 4
A. Key OFF.
Test 5
A. Key OFF.
C. KOEO.
SPN 636 FMI 10 - Engine Position Sensor : Abnormal Rate Of Change
Fault Overview
Fault code sets when Electronic Control Module (ECM) does not detect CMP signal.
Lamp Reaction
Associated Faults
None
Fault Fact
None

Road Test
Possible Causes
• Failed CMP

®
1940).

connector housing.
for SPN 636 FMI 10.
replace CMP sensor if needed.
Sensor Relearn Procedure.
(page 1926)After repairs are
10.

temperature.
Is CMP sensor resistance between 774 and 946 ohms at room temperature? No: Replace CMP sensor.
10.

10.

FMI 10.

resistance between CMP pin-2
and ECM pin E1-19. Perform
for SPN 636 FMI 10.

resistance between CMP pin-1
and ECM pin E1-43. Perform
for SPN 636 FMI 10.

Perform camshaft/crankshaft synchronization (see Engine Service Manual, "Cylinder Yes: End diagnostics. Perform
Head, Camshaft, and Valve Train" section). Crankshaft Position Sensor
for SPN 636 FMI 10.
FMI 10.


Tools Required
Test 1
A. Key OFF.
B. Connect Breakout Harness ZTSE6021 to Camshaft Position (CMP) sensor and leave engine harness
disconnected.
Test 2
A. Key OFF.
Test 3
A. Key OFF.
Test 4
A. Key OFF.
C. Key ON
Test 5
A. Key OFF.
C. Key ON
SPN 637 FMI 8 - Engine Timing Sensor : Abnormal Frequency Or Pulse Width Or Period
Fault Overview
Fault Code sets when Electronic Control Module (ECM) detects signal from Crankshaft Position (CKP) sensor
not reading properly after ECM synchronizes CKP and Camshaft Position (CMP) signals.
Lamp Reaction
Associated Faults
None
Fault Facts
None.

Road Test
Possible Causes
• Debris accumulation on Crankshaft Position (CKP) sensor
• CKP-L circuit intermittent short to GND
• CKP-H circuit intermittent short to GND
• CKP-L circuit intermittent short to CKP-H circuit
• Failed CKP sensor

®
(page 1940).
Step 2 Inspect connections at Crankshaft Position (CKP) sensor. Decision

B. Disconnect CKP connector.

C. Check CKP and connector terminals for: damaged or pinched wires;
connector housing.
Are CKP connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
for SPN 637 FMI 8.
Step 3 Inspect CKP sensor for debris build up. Decision

Remove CKP sensor. Inspect CKP sensor for debris build up on sensor. Yes: Go to Step 4.
Is sensor free of damage or debris on sensor surface? No: Clean CKP sensor with a
rag or towel. Perform Crankshaft
SPN 637 FMI 8.
Step 4 Check for failed CKP sensor. Decision

Harness ZTSE6021 pin-1 and pin-2 when sensor is at room temperature.
Is resistance between 774 and 946 Ohms at room temperature? No: Replace CKP sensor.
8.
Step 5 Check for short to GND in CKP-H circuit. Decision

CKP pin-1 and ECM pin E1-21.
FMI 8.
Step 6 Check for short to GND in CKP-L circuit. Decision

FMI 8.
Step 7 Check for short CKP-L to CKP-H. Decision

Harness ZTSE6021 pin-1 to pin-2.
Is resistance greater than 1,000 ohms? No: Repair short between CKP-L
and CKP-H circuits. Perform
for SPN 637 FMI 8.
Step 8 Check for incorrect output from CKP sensor. Decision

B. Set DMM to AC Volts - RPM2.
C. Measure rpm between Breakout Harness ZTSE6021 pin-1 and pin-2.
• During cranking.
• During low idle.
• During high idle.
Is RPM measured at 100 to 200 rpm for cranking, 600 rpm for low idle, and 1800 to No: Replace CKP sensor.
2000 rpm for high idle? Perform Crankshaft Position
FMI 8.

Review results from Step 8. Yes: Go to Step 2 of 2.1 - Engine
Crank (page 43). Make repairs
as directed from symptom.
FMI 8.
Is RPM measured below 100 RPM? No: End diagnostics. Perform
Retest for SPN 637 FMI 8.


Tools Required
Figure 145 CKP Sensor Resistance Check
Test 1
A. Key OFF.
B. Connect Breakout Harness ZTSE6021 to Crankshaft Position (CKP) sensor and leave engine harness
disconnected.
Figure 146 CKP-H Circuit Check
Test 2
A. Key OFF.
B. Connect Breakout Harness ZTSE6021 to engine harness and leave Crankshaft Position (CKP) sensor
disconnected.
Figure 147 CKP-L Circuit Check
Test 3
A. Key OFF.
B. Connect Breakout Harness ZTSE6021 to engine harness and leave Crankshaft Position (CKP) sensor
disconnected.
Figure 148 CKP Circuit Check
Test 4
A. Key OFF.
B. Disconnect Engine Control Module (ECM) E1 connector from ECM.
C. Connect Breakout Harness ZTSE6021 to engine harness and leave Crankshaft Position (CKP) sensor
disconnected.
Figure 149 CKP RPM Signal Check
Test 5
A. Key OFF.
B. Reconnect ECM E1 connector.
C. Connect Breakout Harness ZTSE6021 between vehicle harness and CKP sensor.
SPN 637 FMI 10 - Engine Timing Sensor : Abnormal Rate Of Change
Fault Overview
Fault code sets when Electronic Control Module (ECM) does not detect Crankshaft Position (CKP) signal.
Lamp Reaction
Associated Faults
None
Fault Facts
None.

Road Test
Possible Causes
• Debris accumulation on Crankshaft Position (CKP) sensor
• CKP-L circuit intermittent short to GND
• CKP-H circuit intermittent short to GND
• CKP-L circuit intermittent short to CKP-H circuit
• Failed CKP sensor
• Base engine timing

®
(page 1940).
Step 2 Inspect connections at Crankshaft Position (CKP) sensor. Decision

B. Disconnect CKP connector.
C. Check CKP and connector terminals for: damaged or pinched wires;

connector housing.
Are CKP connector, harness, and terminals clean and undamaged? No: Repair connector, harness,

for SPN 637 FMI 10.
Step 3 Check for a failed CKP sensor. Decision

Harness ZTSE6021 pin-1 and pin-2 when sensor is at room temperature..
Is resistance between 774 and 946 Ohms at room temperature? No: Replace CKP sensor.
10.
Step 4 Check for short to GND in CKP-H circuit. Decision

10.
Step 5 Check for short to GND in CKP-L circuit. Decision

10.
Step 6 Check for short CKP-L to CKP-H. Decision

Harness ZTSE6021 pin-1 to pin-2.
Is resistance greater than 1,000 ohms? No: Repair short between CKP-L
and CKP-H circuits. Perform
for SPN 637 FMI 10.

A. Perform Test 5 (page 518). Yes: End diagnostics. Perform
B. Set DMM to AC Volts - RPM2.
C. Measure rpm between Breakout Harness ZTSE6021 pin-1 and pin-2. Retest for SPN 637 FMI 10.
• During cranking.
• During low idle.
• During high idle.

Is RPM measured at 100 to 200 rpm for cranking, 600 to 750 rpm for low idle, and No: Go to Step 8.
1700 to 1900 rpm for high idle?
Step 8 Inspect CKP sensor for debri build up. Decision

Remove CKP sensor. Inspect CKP sensor for debris build up on sensor. Yes: Go to step 9.
Is sensor free of damage or debris on sensor surface? No: Clean CKP sensor with a
rag or towel. Perform Crankshaft
SPN 637 FMI 10.
Step 9 Verify base engine timing Decision

Verify base engine timing is correct. See Engine Service Manual to verify crankshaft Yes: Replace CKP sensor.
and camshaft are properly timed. Perform Crankshaft Position
FMI 10.
Are Crankshaft and Camshaft timed properly? No: Repair base engine timing.
FMI 10.


Tools Required
Figure 150 CKP Sensor Resistance Check
Test 1 Setup
A. Key OFF.
B. Connect Breakout Harness ZTSE6021 to Crankshaft Position (CKP) sensor and leave vehicle harness
disconnected.
Figure 151 CKP-H Circuit Check
Test 2
A. Key OFF.
B. Connect Breakout Harness ZTSE6021 to vehicle harness and leave Crankshaft Position (CKP) sensor
disconnected.
Figure 152 CKP-L Circuit Check
Test 3
A. Key OFF.
B. Connect Breakout Harness ZTSE6021 to vehicle harness and leave Crankshaft Position (CKP) sensor
disconnected.
Figure 153 CKP Circuit Check
Test 4
A. Key OFF.
B. Disconnect Engine Control Module (ECM) E1 connector.
C. Connect Breakout Harness ZTSE6021 to vehicle harness and leave Crankshaft Position (CKP) sensor
disconnected.
Figure 154 CKP RPM Signal Check
Test 5
A. Key OFF.
B. Connect ECM E1 connector.
C. Connect Breakout Harness ZTSE6021 between vehicle harness and CKP sensor.
SPN 639 FMI 14 - J1939 Network #1, Primary Vehicle Network : Special Instructions
Fault Overview
Fault code sets when Engine Control Module (ECM) detects public J1939 Controller Area Network (CAN) bus
circuit impedance is greater than or equal to 0.5 ohms.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Public CAN-H or CAN-L circuit fault
• Failed terminating resistor(s)
• Failed PWR or GND circuit to ECM
Step 1 Determine if Engine Control Module (ECM) can communicate with Decision
Electronic Service Tool (EST).
A. Connect EST to vehicle Diagnostic Connector (page 1956). Yes: Go to Step 2.
B. Key ON, log in to Navistar® Engine Diagnostics.
Is ECM able to communicate with EST? No: Go to Step 3.

Use EST, check Diagnostic Trouble Codes (DTC) list for SPN 639 FMI 14. Yes: Go to Step 3.
first. After repairs are complete,

B. Use Digital Multimeter (DMM), measure voltage from ECM pin C2-03 to
a known good GND.
Is voltage B+ ± 0.5 volts? No: Repair failed PWR circuit to
ECM. After repairs are complete,

a known good GND.

a known good GND.

a known good GND.

a known good GND.

a known good GND.

B. Use DMM, measure voltage from ECM pin C2-04 to B+.
Is voltage B+ ± 0.5 volts? No: Repair failed GND circuit to




Step 14 Check CAN-H circuit voltage. Decision

B. Use DMM, measure voltage between ECM pin C1-59 (CAN-L) and known
good GND.
Is voltage 2-3 volts? No: Repair Open, short to GND,
or short to PWR on CAN-H circuit.
for SPN 639 FMI 14.
Step 15 Check CAN-L circuit voltage. Decision

B. Use DMM, measure voltage between ECM pin C1-83 (CAN-H) and known
good GND.
or short to PWR on CAN-L circuit.
for SPN 639 FMI 14.
Step 16 Determine if CAN-H circuit is shorted to CAN-L circuit. Decision

B. Use DMM, measure resistance from Breakout Harness 00-01467-00 pin
C1-83 (CAN-H) to C1-59 (CAN-L).
Is resistance greater than 55 ohms? No: Repair short between
CAN-H and CAN-L, or remove
extra terminating resistor that
has been added. After repairs
FMI 14.
Step 17 Check for failed terminating resistor. Decision

A. Perform Test 14 (page 543). Yes: Repair Open circuit(s)
between ECM and other
B. Use DMM, measure resistance from Breakout Harness 00-01467-00 pin pin
modules on J1939 CAN bus.
C1-83 (CAN-H) to C1-59 (CAN-L).
for SPN 639 FMI 14.
Is resistance greater than 65 ohms? No: Repair failed terminating
resistor(s) or open between ECM
and terminating resistors. After
SPN 639 FMI 14.


Tools Required
C2-03
0000415219
Figure 155 ECM PWR circuit check
Test 1
A. Key OFF.
B. Disconnect ECM C1 and C2 connectors.
C. Connect 180-pin Breakout Box 00-0956-08 to Breakout Harness 12-801-05-01.

D. Connect Breakout Harness 12-801-05-01 between vehicle harness and ECM.
E. Key ON.
C2-08
0000415220
Test 2
A. Key OFF.
E. Key ON.
C2-09
0000415221
Test 3
A. Key OFF.
E. Key ON.
C2-14
0000415222
Test 4
A. Key OFF.
E. Key ON.
C2-15
0000415223
Test 5
A. Key OFF.
E. Key ON.
C1-17
0000415216
Test 6
A. Key OFF.
E. Key ON.
C2-04
0000415228
Figure 161 ECM GND circuit check
Test 7
A. Key OFF.
E. Key ON.
C2-07
0000415229
Test 8
A. Key OFF.
E. Key ON.
C2-10
0000415230
Test 9
A. Key OFF.
E. Key ON.
C2-13
0000415231
Test 10
A. Key OFF.
E. Key ON.
C2-16
0000415232
Test 11
A. Key OFF.
E. Key ON.
C1-59
0000415225
Figure 166 CAN-H circuit check
Test 12
A. Key OFF.
E. Key ON.
C1-83
0000415226
Figure 167 CAN-L circuit check
Test 13
A. Key OFF.
E. Key ON.
C1-59
C1-83
0000426187
Figure 168 CAN resistance check
Test 14
A. Key OFF.
D. Connect Breakout Harness 12-801-05-01 to vehicle harness and leave ECM disconnected.
SPN 639 FMI 19 - J1939 Network #1, Primary Vehicle Network : Received Network Data In Error
Fault Overview
Fault code sets when Engine Control Module (ECM) detects public J1939 Controller Area Network (CAN) bus
circuit impedance is less than or equal to 0.5 ohms.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Public CAN-H or CAN-L circuit fault
• Failed terminating resistor(s)
• Failed PWR or GND circuit to ECM
Step 1 Determine if Engine Control Module (ECM) can communicate with Decision
Electronic Service Tool (EST).
A. Connect EST to vehicle Diagnostic Connector (page 1956). Yes: Go to Step 2.
B. Key ON, log in to Navistar® Engine Diagnostics.
Is ECM able to communicate with EST? No: Go to Step 3.


a known good GND.

a known good GND.

a known good GND.

a known good GND.

a known good GND.

a known good GND.





Step 14 Check CAN-H circuit voltage. Decision

B. Use DMM, measure voltage between ECM pin C1-59 (CAN-L) and known
good GND.
or short to PWR on CAN-H circuit.
for SPN 639 FMI 19.
Step 15 Check CAN-L circuit voltage. Decision

B. Use DMM, measure voltage between ECM pin C1-83 (CAN-H) and known
good GND.
or short to PWR on CAN-L circuit.
for SPN 639 FMI 19.
Step 16 Determine if CAN-H circuit is shorted to CAN-L circuit. Decision

CAN-H C1-34 to CAN-L C1-47.
CAN-H and CAN-L, or remove
extra terminating resistor that
has been added. After repairs
FMI 19.

A. Perform Test 14 (page 562). Yes: Repair Open circuit(s)
between ECM and other
modules on J1939 CAN bus.
CAN-H C1-34 to CAN-L C1-47.
for SPN 639 FMI 19.
Is resistance greater than 65 ohms? No: Repair failed terminating
resistor(s) or open between ECM
and terminating resistors. After
SPN 639 FMI 19.


Tools Required
C2-03
0000415219
Test 1
A. Key OFF.

E. Key ON.
C2-08
0000415220
Test 2
A. Key OFF.
E. Key ON.
C2-09
0000415221
Test 3
A. Key OFF.
E. Key ON.
C2-14
0000415222
Test 4
A. Key OFF.
E. Key ON.
C2-15
0000415223
Test 5
A. Key OFF.
E. Key ON.
C1-17
0000415216
Test 6
A. Key OFF.
E. Key ON.
C2-04
0000415228
Test 7
A. Key OFF.
E. Key ON.
C2-07
0000415229
Test 8
A. Key OFF.
E. Key ON.
C2-10
0000415230
Test 9
A. Key OFF.
E. Key ON.
C2-13
0000415231
Test 10
A. Key OFF.
E. Key ON.
C2-16
0000415232
Test 11
A. Key OFF.
E. Key ON.
C1-59
0000415225
Figure 180 CAN-H circuit check
Test 12
A. Key OFF.
E. Key ON.
C1-83
0000415226
Figure 181 CAN-L circuit check
Test 13
A. Key OFF.
E. Key ON.
C1-59
C1-83
0000426187
Figure 182 CAN resistance check
Test 14
A. Key OFF.
SPN 641 FMI 2 - Engine Variable Geometry Turbocharger Actuator #1 : Data Erratic, Intermittent
Or Incorrect
Fault Overview
Fault sets when ECM detects Variable Geometry Turbocharger Actuator (VGTA) internal electrical error.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Failed VGT Actuator
• ECM PWR OUT Open or High Resistance
• VGT GND Open or high resistance

®
Is EST DTC list SPN 641 FMI 2 active or pending? No: Repair other active faults.
for SPN 641 FMI 2.
Step 2 Inspect connections at Variable Geometry Turbocharger (VGT) Decision

actuator connector.
B. Disconnect VGT actuator connector.
C. Check VGT actuator and connector terminals for: damaged or pinched

connector housing.
Are VGT actuator connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
FMI 2.
Step 3 Check VGT GND circuit Decision

Is voltage B+ ± 1.0 Volts? No: Repair Open or High
resistance between VGT pin-3
FMI 2.

Perform Test 2 (page 579). Use Digital Multimeter (DMM), measure voltage between Yes: Replace VGT Actuator. After
Breakout Harness ZTSE6016 pin-4 and B+. repairs are complete, retest for
SPN 641 FMI 2.
Is voltage B+ ± 1.0 Volts? No: Go to Step 5.

Breakout Harness 12–999–06 pin-G and B+.
resistance between 10-Pin
Engine Interface vehicle side
connector pin-G and GND. After
SPN 641 FMI 2.

Perform Test 4 (page 581). Use Digital Multimeter (DMM), measure voltage between Yes: Repair Open or High
Breakout Harness 12–999–06 pin-H and B+. resistance between VGT pin-4
and 10-Pin Engine Interface
engine side connector pin-G and
H. After repairs are complete,
resistance between 10-Pin
Engine Interface vehicle side
connector pin-H and GND. After
SPN 641 FMI 2.


See latest version of engine Electrical Circuit Diagram on Service Portal for additional circuit information.
Tools Required
Figure 183 VGT PWR circuit check
Test 1
A. Key OFF.
B. Disconnect Variable Geometry Turbocharger (VGT) actuator connector.
C. Connect breakout harness ZTSE6016 to engine harness and leave VGT disconnected.
D. Key ON.
Figure 184 VGT GND circuit check
Test 2
A. Key OFF.
D. Key ON.
12-999-06
0000427409
Test 3
A. Key OFF.
B. Reconnect VGT actuator connector.
C. Disconnect 10-Pin Engine Interface connector.
D. Connect breakout harness 12-999-06 to vehicle side harness and leave engine side harness disconnected.
E. Key ON.
12-999-06
0000427408
Test 4
A. Key OFF.
B. Disconnect 10-Pin Engine Interface connector.
C. Connect breakout harness 12-999-06 to vehicle side harness and leave engine side harness disconnected.
D. Key ON.
SPN 641 FMI 7 - Engine Variable Geometry Turbocharger Actuator #1 : Mechanical System Not
Responding Or Out Of Adjustment
Fault Overview
Fault sets when the Variable Geometry Turbocharger (VGT) actuator detects that the turbocharger cannot meet
commanded position or if the actuators span of travel is less than required.
Lamp Reaction
Associated Faults
SPN 641 FMI 19 SPN 4228 FMI 0 and 15
Fault Facts

Road Test
Possible Causes
• Low battery voltage supplied to VGT

Faults (page 569).
641 FMI 7.

Is EST DTC list SPN 641 FMI 7 active or pending? No: Repair other active
faults. After repairs are
641 FMI 7.
Step 3 Check excessively drained batteries. Decision

Interview operator or customer and(or) review the initial write up. View the freeze frame Yes: Perform Batteries
data for this SPN 641 FMI 7 in EST. and Electrical System
Inspection (page 2198)
and Electrical System
Test (page 2065).
Repair or replace
failed components as
641 FMI 7.
Is “V: Switch Battery” greater than 16 Volts or less than 8 Volts in the Freeze Frame data, or No: Go to Step 4.
is it possible the engine was cranked when battery voltage dropped below 8 Volts?
position.

7.

back to open.
connector.

SPN 641 FMI 7.

SPN 641 FMI 12 - Engine Variable Geometry Turbocharger Actuator #1 : Bad Intelligent Device Or
Component
Fault Overview
Fault sets when the Variable Geometry Turbocharger (VGT) actuator detects that the turbocharger cannot meet
commanded position or if the actuators span of travel is less than required during Cold Start Emissions Reduction
(CSER) mode.
Lamp Reaction
Associated Faults
SPN 641 FMI 19 SPN 4228 FMI 0 and 15
Fault Facts

Road Test
Possible Causes

Faults (page 572).
641 FMI 12.

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for SPN Yes: Go to Step 3.
641 FMI 12.
faults. After repairs are
641 FMI 12.

Interview operator or customer and(or) review the initial write up. View the freeze frame data Yes: Perform Batteries
for this SPN 641 FMI 12 in EST with Navistar® Engine Diagnostics. and Electrical System
Test (page 2065).
Repair or replace
641 FMI 12.
position.
12.

12.

12.
back to open.

connector.
SPN 641 FMI 12.

SPN 641 FMI 14 - Engine Variable Geometry Turbocharger Actuator #1 : Special Instructions
Fault Overview
Fault sets when the Variable Geometry Turbocharger (VGT) actuator voltage supply is above or below normal
operating range.
Lamp Reaction
Associated Faults
SPN 158 FMI 16 and 18 SPN 641 FMI 19 SPN 5016 FMI 3 and 4 SPN 7713 FMI 3 and 4
Fault Facts
Using a 24 Volt charger to start vehicle may cause this fault code to set and possibly major damage to electrical
system. Never attempt to start vehicle with a 24 Volt charger, always use a 12 Volt charger.

Road Test
Possible Causes
• ECM PWR OUT Open or High Resistance
• VGT GND Open or high resistance

Faults (page 572).
641 FMI 14.

Is EST DTC list SPN 641 FMI 14 active or pending? No: Go to Intermittent or
Procedure (page
1940). After repairs
SPN 641 FMI 14.

Interview operator or customer and(or) review the initial write up. View the freeze frame data Yes: Perform Batteries
for this SPN 641 FMI 14 in EST with Navistar® Engine Diagnostics. and Electrical System
Test (page 2065).
Repair or replace
641 FMI 14.
Step 4 Inspect connections at Variable Geometry Turbocharger (VGT) actuator Decision

connector.
C. Check VGT actuator and connector terminals for: damaged or pinched wires; wet
or corroded terminals; loose, bent, or broken pins; or broken connector housing.
Are VGT actuator connector, harness, and terminals clean and undamaged? No: Repair connector,
SPN 641 FMI 14.

Is voltage B+ ± 1.0 Volts? No: Repair Open or
High resistance between
VGT pin-3 and ECM pin
641 FMI 14.

Perform Test 2 (page 579). Use Digital Multimeter (DMM), measure voltage between Yes: End diagnostics.
Breakout Harness ZTSE6016 pin-4 and B+. Retest for SPN 641 FMI
14.
Is voltage B+ ± 1.0 Volts? No: Go to Step 7.

Breakout Harness 12–999–06 pin-G and B+.
10-Pin Engine Interface
vehicle side connector
pin-G and GND. After
14.

Perform Test 4 (page 581). Use Digital Multimeter (DMM), measure voltage between Yes: Repair Open or
Breakout Harness 12–999–06 pin-H and B+. High resistance between
VGT pin-4 and 10-Pin
Engine Interface engine
side connector pin-G
and H. After repairs are
641 FMI 14.
10-Pin Engine Interface
vehicle side connector
pin-H and GND. After
14.


Tools Required
Figure 187 VGT PWR circuit check
Test 1
A. Key OFF.
D. Key ON.
Test 2
A. Key OFF.
D. Key ON.
12-999-06
0000427409
Test 3
A. Key OFF.
B. Reconnect VGT actuator connector.
C. Disconnect 10-Pin Engine Interface connector.
D. Connect breakout harness 12-999-06 to vehicle side harness and leave engine side harness disconnected.
E. Key ON.
12-999-06
0000427408
Test 4
A. Key OFF.
B. Disconnect 10-Pin Engine Interface connector.
C. Connect breakout harness 12-999-06 to vehicle side harness and leave engine side harness disconnected.
D. Key ON.
SPN 641 FMI 19 - Engine Variable Geometry Turbocharger Actuator #1 : Received Network Data In Error
Fault Overview
Fault Code sets when Engine Control Module (ECM) detects a loss of communication with Variable Geometry
Turbocharger Actuator (VGTA) on Private J1939 CAN data link communication circuit.
Lamp Reaction
Associated Faults
SPN 5016 FMI 3 and 4 SPN 1761 FMI 19 SPN 2791 FMI 19 SPN 3216 FMI 19
SPN 3226 FMI 19 SPN 3516 FMI 19 SPN 5742 FMI 19 SPN 5743 FMI 19
SPN 5835 FMI 19
Fault Facts
If more than one of following sensor modules fail (or set a fault), suspect a common Private CAN circuit, common
power circuit, ground circuit, or switched ignition relay problem. The following components share power and
ground circuits: EGR Valve (EGRV), VGT Actuator (VGTA), AFT temperature sensor module, NOx OUT sensor
module, NOx IN sensor module, Particulate Matter (PM) sensor module and DEF Tank sensor module. Verify
batteries are fully charged and connections are clean before completing diagnostics.

Continuous
Possible Causes
• ECM PWR OUT circuit Open or high resistance
• VGTA GND circuit Open or high resistance
• CAN-H circuit Open
• CAN-H circuit short to GND
• CAN-H circuit short to PWR
• CAN-L circuit Open
• CAN-L circuit short to GND
• CAN-L circuit short to PWR
• CAN-H shorted to CAN-L
• Failed VGTA

®
Is EST DTC list free of Associated FMI 19 communication faults? No: Repair Private CAN circuit,
common sensor module(s)
power or ground circuit failure,
aftertreatment smart sensor
relay or aftertreatment PDM
problem. After repairs are
complete, perform SCR Fault
Reset Request (page 1955) and
retest for SPN 641 FMI 19

Is EST DTC list free of SPN 5016 FMI 3 or 4? No: Repair SPN 5016 FMI 3 or
4. After repairs are complete,

®
1940).
Step 4 Inspect VGTA connector and terminals. Decision

B. Disconnect VGTA sensor module.
C. Check VGTA sensor module and connector terminals for: damaged or
Are VGTA sensor module connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
FMI 19.
Step 5 Check voltage to VGTA. Decision

Breakout Harness ZTSE6016 pin-3 and pin-4.
Is voltage B+ ± 1.0 volts? No: Go to Step 6.
Step 6 Check ECM PWR OUT circuit for Open or short to ground. Decision
Perform Test 2 (page 587). Use DMM, measure voltage between Breakout Harness Yes: Repair Open or high
ZTSE6016 pin-3 and known good GND. resistance between VGTA pin-3
19.
Is voltage B+ ± 1.0 volts? No: Repair Open or high
resistance between VGTA pin-4
FMI 19.
Step 7 Check CAN-L circuit for Open or short to GND. Decision

Is voltage greater than 2 volt? No: Repair Open or short to
GND on CAN-L circuit between
VGTA pin-2 and all other Private
CAN modules (DEF Tank Sensor
Module, EGRV, NOx IN sensor
module, NOx OUT sensor
module, PM sensor module and
AFT Temp sensor module). After
SPN 641 FMI 19.
Step 8 Check CAN-L circuit for short to power. Decision

Is voltage less than 3 volts? No: Repair short to PWR on
CAN-L circuit between VGTA
pin-2 and all other Private CAN
modules (DEF Tank Sensor
SPN 641 FMI 19.
Step 9 Check CAN-H circuit for Open or short to GND. Decision

GND on CAN-H circuit between
VGTA pin-1 and all other Private
SPN 641 FMI 19.
Step 10 Check CAN-H circuit for short to PWR. Decision

CAN-H circuit between VGTA
SPN 641 FMI 19.
Step 11 Check CAN-L circuit for short to CAN-H. Decision

Perform Test 5 (page 590). Use DMM, measure resistance between Breakout Yes: Replace VGTA. After repairs
Harness ZTSE6016 pin-1 and pin-2. are complete, retest for SPN 641
FMI 19.
Is resistance between 55 and 65 ohms? No: Repair short between VGTA
pin-1 and pin-2 or missing
terminating resistor. After repairs
FMI 19.


Tools Required
6016 4
0000419478
Figure 191 PWR and GND Circuit Check
Test 1
A. Key OFF.
B. Disconnect Variable Geometry Turbocharger Actuator (VGTA) connector
C. Connect Breakout Harness ZTSE6016 to engine harness, and leave VGTA disconnected.
D. Key On, Engine Off.
Figure 192 PWR and GND Circuit Check
Test 2
A. Key OFF.
B. Connect Breakout Harness ZTSE6016 to engine harness, and leave VGTA disconnected.
C. Key On, Engine Off.
Figure 193 CAN-L Circuit Check
Test 3
A. Key OFF.
Figure 194 CAN-H Circuit Check
Test 4
A. Key OFF.
2 6016
0000419477
Figure 195 CAN-H to CAN-L Circuit Check
Test 5
A. Key OFF.
B. Connect Breakout Harness ZTSE6016 between vehicle harness and VGTA.
SPN 651 FMI 3 - Engine Fuel 1 Injector Cylinder 1 : Voltage Above Normal, or Shorted to High Score
Fault Overview
This fault code sets when Engine Control Module (ECM) detects short to PWR in Fuel Injector 1 (INJ1) Circuit
Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected during one drive cycle.
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• INJ1 H circuit short to PWR
• INJ1 L circuit short to PWR
• INJ1 H circuit shorted to INJ1 L circuit
• Failed fuel injector 1

®
Off (KOEO), check Diagnostic Trouble Code (DTC) list for SPN 651 FMI 3.
Does EST DTC list show SPN 651 FMI 3 active or pending? No: Go to Intermittent or Inactive
(page 1940).
Step 2 Inspect UVC harness and connections at fuel injector 1 under valve Decision
cover.
A. Key OFF. Yes: Replace injector harness
and install in proper routing. After
B. Remove upper valve cover and engine brake housing (see Engine Service
Manual).
SPN 651 FMI 3.
C. Disconnect fuel injector 1 connector.
D. Check fuel injector 1 and connector terminals for: damaged or pinched
E. Inspect UVC harness under valve cover for improper harness routing,
evidence of harness contacting rocker arms or brake housing, or other
signs of harness damage.
Is there evidence of harness or injector connector damage? No: Go to Step 3.
Step 3 Check for shorted fuel injector 1 coil. Decision

Perform Test 1 (page 594). Use Digital Multi-Meter (DMM), measure resistance Yes: Go to Step 4.
between fuel injector 1 H and L terminals.
Is resistance between 0.2 to 0.8 Ohms? No: Replace fuel injector 1
Procedure (page 1941) and
for SPN 651 FMI 3.
Step 4 Inspect connections at Electronic Control Module (ECM) E2 connector. Decision

B. Disconnect ECM E2 connector.
C. Check ECM E2 and connector terminals for: damaged or pinched wires;

connector housing.
Are ECM E2 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
FMI 3.
Step 5 Check for INJ1 H circuit short to PWR. Decision

Perform Test 2 (page 595). Use DMM, measure voltage between Breakout Box pin Yes: Go to Step 6.
E2–05 and a known good GND (wiggle test may be required).
between ECM pin E2–05 and
fuel injector 1. After repairs are
3
Step 6 Check for INJ1 L circuit short to PWR. Decision

3
Step 8 Check for INJ1 H circuit short to INJ1 L circuit. Decision

Perform Test 4 (page 597). Use DMM, measure resistance between Breakout Box Yes: End diagnostics and retest.
pins E2-05 and E2-12 (wiggle test may be required).
Is resistance greater than 1000 ohms? No: Repair short between INJ1
H circuit and INJ1 L circuit. After
SPN 651 FMI 3

Figure 196 Fuel Injector 1 circuit diagram
Tools Required
Figure 197 Fuel Injector 1 Circuit Check
Test 1
A. Key OFF
B. Disconnect fuel injector 1 H and L terminals

Figure 198 Fuel Injector High Side Circuit Check
Test 2
A. Key OFF
C. Connect Breakout Box 00-00956-08 to Breakout Harness 12-801-05-03.
E. Key ON
Figure 199 Fuel Injector Low Side Circuit Check
Test 3
A. Key OFF
E. Key ON
Test 4
A. Key OFF
SPN 651 FMI 4 - Engine Fuel 1 Injector Cylinder 1 : Voltage Below Normal, or Shorted to Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects a short to GND in Fuel Injector 1 (INJ1) circuit.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• INJ1 H circuit short to GND
• INJ1 L circuit short to GND
• Fuel injector shorted to engine brake housing

®
(page 1940).
cover.
Manual).
SPN 651 FMI 4.
Step 3 Inspect connections at fuel injector 1 connector. Decision

Verify proper fuel injector and terminal orientation. Remove upper valve cover and Yes: Go to Step 4.
engine brake housing (see Engine Service Manual). Verify fuel injector terminals are
installed parallel to avoid a short to ground on engine brake housings.
Are fuel injector 1 terminals oriented correctly and Not contacting engine brake No: Adjust connections so fuel
housing? injector 1 and injector terminals
will not contact engine brake
4.

for SPN 651 FMI 4.

connector housing.
FMI 4.
Step 6 Check for fuel injector 1 H terminal short to ground. Decision

Perform Test 2 (page 602). Use DMM, measure resistance between fuel injector 1 H Yes: Go to Step 7.
terminal and known good GND.
Is resistances greater than 1000 ohms? No: Replace fuel injector 1
for SPN 651 FMI 4.
Step 7 Check for fuel injector 1 L terminal short to ground. Decision

Perform Test 3 (page 603). Use DMM, measure resistance between fuel injector 1 L Yes: Go to Step 8.
for SPN 651 FMI 4.

Perform Test 4 (page 604). Use DMM, measure resistance between Breakout Box Yes: Go to Step 9.
SPN 651 FMI 4.
Step 9 Check INJ 1 H circuit for short to GND. Decision

Perform Test 5 (page 605). Use DMM, with fuel injector 1 disconnected, measure No: Repair short to GND
resistance between Breakout Box pin E2-05 and known good GND (wiggle test between E2-12 and fuel injector
may be required). 1. After repairs are complete,
Is resistance greater than 1000 Ohms? No: Repair short to GND
between E2-05 and fuel injector

Tools Required
Test 1
A. Key OFF

Figure 203 Fuel Injector 1 High Side Circuit Check
Test 2
A. Key OFF
B. Disconnect Fuel Injector 1 H and L terminals
C. Disconnect Engine Control Module (ECM) E2 connector.
Figure 204 Fuel Injector 1 Low Side Circuit Check
Test 3
A. Key OFF
Test 4
A. Key OFF.
B. Connect Breakout Box 00-00956-08 to Breakout Harness 12-801-05-03.
C. Connect Breakout Harness 12-801-05-03 to vehicle harness and leave ECM connector disconnected.
D. Disconnect Fuel Injector 1 H and L terminals
Test 5
A. Key OFF.
SPN 651 FMI 5 - Engine Fuel 1 Injector Cylinder 1 : Current Below Normal or Open Circuit
Fault Overview
Fault code sets when Engine Control Module (ECM) detects an Open in Fuel Injector 1 (INJ1) Circuit
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• INJ1 H circuit open or high resistance
• INJ1 L circuit open or high resistance

®
(page 1940).
cover.
Manual).
SPN 651 FMI 5.
Step 3 Check for a shorted fuel injector 1 coil. Decision

Perform Test 1 (page 610). Use DMM measure resistance between fuel injector 1 Yes: Go to Step 4.
H and L terminals.
andperform IQA Adjustment
for SPN 651 FMI 5.


connector housing.
FMI 5.
Step 5 Check INJ1 H circuit for open or high resistance Decision

Perform Test 2 (page 611). Use DMM, measure resistance between fuel injector 1 Yes: Repair open or high
INJ1 H ring terminal and Breakout Box pin E2-05. resistance between fuel injector
1 INJ1 L ring terminal and ECM
5.
Is resistance < 5 ohms? No: Repair open or high
resistance between fuel injector
1 INJ1 H ring terminal and ECM
5.

Tools Required
Test 1
A. Key OFF
Test 2
A. Key OFF
B. Disconnect Fuel Injector 1 H and L terminals.
C. Disconnect Engine Control Module (ECM) E2 connector
D. Connect Breakout Box 00–00956–08 to Breakout Harness 12–801–05–03
E. Connect Breakout Harness 12–801–05–03 to vehicle harness and leave ECM disconnected
SPN 651 FMI 13 - Engine Fuel 1 Injector Cylinder 1 : Out Of Calibration
Fault Overview
Fault code sets when Electronic Control Module (ECM) detects an incorrect Injector Quantity Adjustment (IQA)
has been programmed into ECM.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Incorrectly Programmed IQA
Step 1 Check that proper Injector Quantity Adjustment (IQA) is programed into Decision
Electronic Control Module (ECM).
1. Remove upper valve cover and engine brake housing (see Engine Service Yes: Clear fault code. Recheck
Manual). Document IQA code for all six injectors. IQA codes. After repairs are
2. Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics,
13.
perform IQA Adjustment (page 1941).
Do IQA codes displayed in EST match injectors in engine? No: Reprogram ECM with correct
IQA codes (follow on screen
instructions). After repairs are
13.

SPN 651 FMI 16 - Engine Fuel 1 Injector Cylinder 1 : Data Valid But Above Normal Operating Range -
Fault Overview
Fault code sets when Engine Control Module (ECM) detects fuel injector is energized longer than expected.
Lamp Reaction
Associated Faults
SPN 157 SPN 651 FMI 4, 5, and 13
Fault Facts
None.

Continuous
Possible Causes
• Contaminated Fuel
• Failed Injector (Mechanical)
• Base Engine Compression Imbalance
• Low Fuel Delivery Pressure (FDP)

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key On, check Yes: Go to Step 2.
for SPN 651 FMI 16.

Is gauge pressure between 68-80 psi (469-552 kPa)? No: Go to Step 2 of 7.0 - Fuel
and repair fuel system. After
SPN 651 FMI 16.
Step 3 Determine if engine has mechanical cylinder balance problem Decision

(compression loss).
Perform Crankcase Pressure Test (page 2092). Yes: Repair engine compression
imbalance. After repairs are
16.

Perform Valve Train Inspection (page 2188). Yes: Replace fuel injector 1 and
perform IQA Adjustment(page
1941) procedure and Crankshaft
SPN 651 FMI 16.
16.

SPN 651 FMI 18 - Engine Fuel 1 Injector Cylinder 1 : Data Valid But Below Normal Operating Range -
Fault Overview
Fault code sets when Electronic Control Module (ECM) detects fuel injector is energized shorter than expected.
Lamp Reaction
Associated Faults
SPN 157 SPN 651 FMI 4, 5, and 13
Fault Facts
None.

Continuous
Possible Causes

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostic. Key On, check Yes: Go to Step 2.
for SPN 651 FMI 18.

SPN 651 FMI 18.

(compression loss).
18.

SPN 651 FMI 18.
18.

SPN 652 FMI 3 - Engine Fuel 1 Injector Cylinder 2 : Voltage Above Normal, or Shorted to High Source
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostic, Key On Engine Yes: Go to Step 2.
(page 1940).
cover.
Manual).
SPN 652 FMI 3.

for SPN 652 FMI 3.


connector housing.
FMI 3.

3

3

SPN 652 FMI 3

Figure 210 Fuel Injector 2 Circuit Diagram
Tools Required
Test 1
A. Key OFF

Test 2
A. Key OFF
E. Key ON
Test 3
A. Key OFF
E. Key ON
Test 4
A. Key OFF
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes

®
(page 1940).
cover.
Manual).
SPN 652 FMI 4.

4.

for SPN 652 FMI 4.

connector housing.
FMI 4.

for SPN 652 FMI 4.

for SPN 652 FMI 4.

SPN 652 FMI 4.
Step 9 Check INJ 2H circuit for short to GND. Decision

Perform Test 5 (page 631). Use DMM, measure resistance between Breakout Box Yes: Repair short to GND
pin E2-06 and known good GND (wiggle test may be required). between E2-11 and fuel injector
Is resistance greater than 1000 Ohms? No: Repair short to GND between
E2-06 and fuel injector 2. After
SPN 652 FMI 4.

Tools Required
Test 1
A. Key OFF

Test 2
A. Key OFF
Test 3
A. Key OFF
C. Disconnect ECM E2 connector.
Test 4
A. Key OFF.
D. Disconnect fuel injector 2 H and L terminals
Test 5
A. Key OFF.
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• INJ2 H circuit Open or high resistance
• INJ2 L circuit Open or high resistance

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostic, Key On Engine Yes: Go to Step 2.
(page 1940).
cover.
Manual).
SPN 652 FMI 5.

H and L terminals.
for SPN 652 FMI 5.


connector housing.
FMI 5.

Perform Test 2 (page 637). Use DMM, measure resistance between fuel injector 2 Yes: Repair open or high
INJ2 H ring terminal and Breakout Box pin E2-11. resistance between fuel injector
5.
5.

Tools Required
Test 1
A. Key OFF
Test 2
A. Key OFF
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
13.
13.

Fault Overview
Lamp Reaction
Associated Faults
SPN 157 SPN 652 FMI 4, 5, and 13
Fault Facts
None.

Continuous
Possible Causes

®
for SPN 652 FMI 16.

SPN 652 FMI 16.

(compression loss).
16.

SPN 652 FMI 16.
16.

Fault Overview
Lamp Reaction
Associated Faults
SPN 157 SPN 652 FMI 4, 5, and 13
Fault Facts
None.

Continuous
Possible Causes

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostic. Key On, check Yes: Go to Step 2.
for SPN 652 FMI 18.

SPN 652 FMI 18.

(compression loss).
18.

SPN 652 FMI 18.
18.

Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes

®
(page 1940).
cover.
Manual).
SPN 653 FMI 3.

for SPN 653 FMI 3.

connector housing.
FMI 3.

3

3

SPN 653 FMI 3

Tools Required
Test 1
A. Key OFF
Test 2
A. Key OFF
E. Key ON
Test 3
A. Key OFF
E. Key ON
Test 4
A. Key OFF
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes

®
(page 1940).
cover.
Manual).
SPN 653 FMI 4.

4.

for SPN 653 FMI 4.

connector housing.
FMI 4.

for SPN 653 FMI 4.

for SPN 653 FMI 4.

00-00956-08 pins E2-04 and E2-13 (wiggle test may be required).
SPN 653 FMI 4.
Step 9 Check INJ 1 H circuit for short to GND. Decision

Perform Test 5 (page 658). Use DMM, with fuel injector 3 disconnected, measure No: Repair short to GND between
resistance between Breakout Box 00-00956-08 pin E2-04 and known good GND E2-13 and fuel injector 3. After
(wiggle test may be required). repairs are complete, retest for
SPN 653 FMI 4.
SPN 653 FMI 4.

Tools Required
Test 1
A. Key OFF

Test 2
A. Key OFF
Test 3
A. Key OFF
Test 4
A. Key OFF.
Test 5
A. Key OFF.
SPN 653 FMI 5 - Engine Fuel 1 Injector 3 : Current Below Normal or Open Circuit
Fault Overview
Fault code sets when Engine Control Module (ECM) detects an Open in Fuel Injector 3 (INJ3) Circuit.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes

®
(page 1940).
cover.
Manual).
SPN 653 FMI 5.

H and L terminals.
for SPN 651 FMI 5.


connector housing.
FMI 5.

Perform Test 2 (page 664). Use DMM, measure resistance between fuel injector Yes: Repair open or high
3 INJ3 H ring terminal and Breakout Box pin E2-04. resistance between fuel injector
5.
5.

Tools Required
Test 1
A. Key OFF
Test 2
A. Key OFF
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
13.
perform IQA Adjustment(page 1941).
13.

Fault Overview
Lamp Reaction
Associated Faults
SPN 157 SPN 653 FMI 4, 5, and 13
Fault Facts
None.

Continuous
Possible Causes

®
for SPN 653 FMI 16.

SPN 653 FMI 16.

(compression loss).
16.

SPN 653 FMI 16.
16.

Fault Overview
Lamp Reaction
Associated Faults
SPN 157 SPN 653 FMI 4, 5, and 13
Fault Facts
None.

Continuous
Possible Causes

®
for SPN 653 FMI 18.

SPN 653 FMI 18.

(compression loss).
18.

SPN 653 FMI 18.
18.

Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes

®
(page 1940).
cover.
Manual).
SPN 654 FMI 3.

for SPN 654 FMI 3.


connector housing.
FMI 3.

3

3

SPN 654 FMI 3

Tools Required
Test 1
A. Key OFF

Test 2
A. Key OFF
E. Key ON
Test 3
A. Key OFF
E. Key ON
Test 4
A. Key OFF
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostic Software, Yes: Go to Step 2.
Key-On Engine-Off (KOEO), check Diagnostic Trouble Code (DTC) list for SPN
654 FMI 4.
(page 1940).
cover.
Manual).
SPN 654 FMI 4.

4.

for SPN 654 FMI 4.

connector housing.
FMI 4.

for SPN 654 FMI 4.

for SPN 654 FMI 4.

SPN 652 FMI 4.
Step 9 Check INJ4 H circuit for short to GND. Decision

00-00956-08 pin E2-03 and known good GND (wiggle test may be required). between E2-14 and fuel injector
SPN 652 FMI 4.

Tools Required
• Electronic Service Tool (EST) with Navistar® Engine Diagnostic Software
Test 1
A. Key OFF

Test 2
A. Key OFF
Test 3
A. Key OFF
Test 4
A. Key OFF.
Test 5
A. Key OFF.
B. Connect Breakout Box 00-00956-08 to Breakout Harness 00-01468-00.
SPN 654 FMI 5 - Engine Fuel Injector 1 Cylinder 4 : Current Below Normal or Open Circuit
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes

®
654 FMI 5.
(page 1940).
cover.
Manual).
SPN 654 FMI 5.

H and L terminals.
for SPN 654 FMI 5.

connector housing.
FMI 5.

5.
5.

Tools Required
Test 1
A. Key OFF
Test 2
A. Key OFF
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
13.
13.

Fault Overview
Lamp Reaction
Associated Faults
SPN 157 SPN 654 FMI 4, 5, and 13
Fault Facts
None.

Continuous
Possible Causes

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostic Software. Yes: Go to Step 2.
Key-On, check Diagnostic Trouble Code (DTC) list for Associated Faults (page 694).
for SPN 654 FMI 16.

SPN 654 FMI 16.

(compression loss).
16.

SPN 654 FMI 16.
16.

Fault Overview
Lamp Reaction
Associated Faults
SPN 157 SPN 654 FMI 4, 5, and 13
Fault Facts
None.

Continuous
Possible Causes

®
for SPN 654 FMI 18.

SPN 654 FMI 18.

(compression loss).
18.

SPN 654 FMI 18.
18.

Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes

®
655 FMI 3.
(page 1940).
cover.
Manual).
SPN 655 FMI 3.

for SPN 655 FMI 3.


connector housing.
FMI 3.

3

3

SPN 655 FMI 3

Tools Required
Test 1
A. Key OFF

Test 2
A. Key OFF
E. Key ON
E2-15
0000415214
Test 3
A. Key OFF
E. Key ON
Test 4
A. Key OFF
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes

®
655 FMI 4.
(page 1940).
cover.
Manual).
SPN 655 FMI 4.

FMI 4.

for SPN 655 FMI 4.

connector housing.
FMI 4.

for SPN 655 FMI 4.

for SPN 655 FMI 4.

SPN 655 FMI 4.

Is resistance greater than 1000 Ohms? No: Repair short to GND
between E2-02 and fuel injector

Tools Required
Test 1
A. Key OFF

Test 2
A. Key OFF
Test 3
A. Key OFF
Test 4
A. Key OFF.
Test 5
A. Key OFF.
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes

®
655 FMI 5.
(page 1940).
cover.
Manual).
SPN 655 FMI 5.

H and L terminals.
for SPN 655 FMI 5.


connector housing.
FMI 5.

5.
5.

Tools Required
Test 1
A. Key OFF
Test 2
A. Key OFF
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
13.
13.

Fault Overview
Lamp Reaction
Associated Faults
SPN 157 SPN 655 FMI 4, 5, and 13
Fault Facts
None.

Continuous
Possible Causes

®
for SPN 655 FMI 16.

SPN 655 FMI 16.

(compression loss).
16.

SPN 655 FMI 16.
16.

Fault Overview
Lamp Reaction
Associated Faults
SPN 157 SPN 655 FMI 4, 5, and 13
Fault Facts
None.

Continuous
Possible Causes

®
for SPN 655 FMI 18.

SPN 655 FMI 18.

(compression loss).
18.

SPN 655 FMI 18.
18.

SPN 656 FMI 3 - Engine Fuel 1 Injector Cylinder 6 - Voltage Above Normal, or Shorted to High Source
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes

®
656 FMI 3.
(page 1940).
cover.
Manual).
SPN 656 FMI 3.

for SPN 656 FMI 3.


connector housing.
FMI 3.

3.

3.

SPN 656 FMI 3.

Tools Required
Test 1
A. Key OFF

Test 2
A. Key OFF
E. Key ON
E2-16
0000415215
Test 3
A. Key OFF
E. Key ON
Test 4
A. Key OFF
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes

®
656 FMI 4.
(page 1940).
cover.
Manual).
SPN 656 FMI 4.

4.

for SPN 656 FMI 4.

connector housing.
FMI 4.

for SPN 656 FMI 4.

for SPN 656 FMI 4.

SPN 656 FMI 4.

SPN 656 FMI 4.

Tools Required
Test 1
A. Key OFF

Test 2
A. Key OFF
Test 3
A. Key OFF
Test 4
A. Key OFF.
Test 5
A. Key OFF.
C. Connect Breakout Harness 12-801-05-03 to vehicle harness and leave ECM E2 connector disconnected.
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes

®
656 FMI 5.
(page 1940).
cover.
Manual).
SPN 656 FMI 5.

H and L terminals.
for SPN 656 FMI 5.


connector housing.
FMI 5.

5.
5.

Tools Required
Test 1
A. Key OFF
Test 2
A. Key OFF
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
13.
13.

Fault Overview
Lamp Reaction
Associated Faults
SPN 157 SPN 656 FMI 4, 5, and 13
Fault Facts
None.

Continuous
Possible Causes

®
for SPN 656 FMI 16.

SPN 656 FMI 16.

(compression loss).
16.

SPN 656 FMI 16.
16.

Fault Overview
Lamp Reaction
Associated Faults
SPN 157 SPN 656 FMI 4, 5, and 13
Fault Facts
None.

Continuous
Possible Causes

®
for SPN 656 FMI 18.

SPN 656 FMI 18.

(compression loss).
18.

SPN 656 FMI 18.
18.

SPN 724 FMI 2 - O2 Sensor : Data Erratic, Intermittent Or Incorrect
Fault Overview
This fault codes sets when the Engine Control Module (ECM) detects that the NOx IN sensor’s exhaust Oxygen
content signal is not respond to engine changes as expected.
Lamp Reaction
Associated Faults
SPN 641 FMI 19 SPN 1761 FMI 19 SPN 2791 FMI 2, 3, 4, 7, 12 SPN 3226 FMI 19
and 19
Fault Facts
The A26 engine is not equipped with an Oxygen (O2) Sensor. The function of the O2 sensor is incorporated into
the NOx IN sensor module.

Continuous
Possible Causes
• Failed Nitrogen Oxides In (NOxIN) sensor module

®
Is EST DTC list free of Associated FMI 19 communication faults? No: Repair common Engine/AFT
Private CAN circuit failure,
aftertreatment smart sensor relay,
or aftertreatment PDM problem.
After repairs are complete, and

Is EST DTC list free of remaining Associated Faults? No: Repair other Associated fault
codes. After repairs are complete,
and retest for SPN 724 FMI 2.

®
Step 4 Inspect Nitrogen Oxides In (NOxIN) sensor module and connector. Decision
A. Key Off. Yes: Replace NOx IN sensor
module. After repairs are
B. Disconnect NOx IN sensor module.
C. Check NOx IN sensor module and connector terminals for: damaged or 2.
Are NOx IN sensor module connector, harness, and terminals clean and No: Repair connector, harness,
undamaged? or terminal damage. After repairs
FMI 2.

SPN 724 FMI 16 - O2 Sensor : Data Valid But Above Normal Operating Range - Moderately Severe Level
Fault Overview
This fault codes sets when the Engine Control Module (ECM) detects that the NOx IN sensor’s adaptation value
is too high.
Lamp Reaction
Associated Faults
SPN 641 FMI 19 SPN 724 FMI 2 SPN 1761 FMI 19 SPN 2791 FMI 2, 3, 4, 7, 12
and 19
SPN 5835 FMI 19
Fault Facts

Continuous
Possible Causes

®


®
FMI 16.

SPN 724 FMI 18 - O2 Sensor : Data Valid But Below Normal Operating Range - Moderately Severe Level
Fault Overview
This fault codes sets when the Engine Control Module (ECM) detects that the NOx IN sensor’s adaptation value
is too low.
Lamp Reaction
Associated Faults
SPN 641 FMI 19 SPN 724 FMI 2 SPN 1761 FMI 19 SPN 2791 FMI 2, 3, 4, 7, 12
and 19
SPN 5835 FMI 19
Fault Facts

Continuous
Possible Causes

®


®
FMI 18.

SPN 974 FMI 3 - Remote Accelerator Pedal Position : Voltage Above Normal, Or Shorted To High Source
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
None.

Continuous.
Possible Causes
• RAPP circuit short to PWR
• Failed RAPP system component

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key ON, Yes: Go to Step 2.
1940).
Step 2 Inspect connections at Body Builder connector 2. Decision

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
Are Body Builder connector 2 connector, harness, and terminals clean and No: Repair connector, harness,
FMI 3.
Step 3 Check for short to PWR in RAPP circuit. Decision

Perform Test 1 (page 760). Use DMM, measure voltage from pin-A to GND. Yes: Go to Step 4.
Is voltage less than 5 volts? No: Repair short to PWR
Body Builder Connector 2 pin-A.
for SPN 974 FMI 3.
Step 4 Check for Open in SIG GND circuit. Decision

A. Perform Test 2 (page 760). Yes: Replace RAPP. After repairs
®
FMI 3
Test (page 1974).
C. During test, monitor RAPP voltage.
Is RAPP approximately 0 volts? No: Repair Open between ECM
pin C1-63 and Body Builder
Connector 2 pin-C. After repairs
FMI 3.


Tools Required
• Breakout Harness ZTSE4435C
Figure 280 RAPP Circuit Check
Test 1
A. Key OFF.
C. Insert correct pin from Terminal Test Kit ZTSE4435C into Body Builder connector 2 pin-A.
D. Key ON.
Test 2
A. Key OFF.
D. Insert correct pin from Terminal Test Kit ZTSE4435C into Body Builder connector 2 pin-C.
E. Use Breakout Harness ZTSE4498, short Body Builder connector 2 pin-A to pin-C.
F. Connect Electronic Service Tool (EST) with Navistar® Engine Diagnostics to vehicle Diagnostic Connector.
G. Key ON, log in to Navistar® Engine Diagnostics.
SPN 974 FMI 4 - Remote Accelerator Pedal Position : Voltage Below Normal, Or Shorted To Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Remote Accelerator Pedal Position (RAPP) signal
is less than expected.
Lamp Reaction
No Lamp.
Associated Faults
SPN 3512
Fault Facts
None.

Continuous.
Possible Causes
• RAPP signal circuit Open
• RAPP signal circuit short to GND
• VREF circuit Open
• Failed RAPP system component

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check for Yes: Go to Step 2.
associated faults (page 762).
Is EST DTC list free of associated faults? No: Repair associated faults.
for SPN 974 FMI 4.

Use EST with Navistar® Engine Diagnostics. Key ON, check Diagnostic Trouble Yes: Go to Step 3.
Codes (DTC) list for SPN 974 FMI 4.
(page 1940).
Step 3 Inspect connections at Body Builder connector 2. Decision

C. Check Body Builder connector 2 and connector terminals for: damaged
Are Body Builder connector 2 connector, harness, and terminals clean and No: Repair connector, harness,
FMI 4.
Step 4 Check for Open in RAPP 5 volt circuit. Decision

Perform Test 1 (page 764). Use DMM, measure voltage from pin-B to known good Yes: Go to Step 5.
GND.
Is voltage between 5 ± 0.25 volts? No: Repair Open between ECM
Connector 2 pin-B. After repairs
FMI 4.
Step 5 Check for failed RAPP. Decision

A. Perform Test 2 (page 764). Yes: Replace RAPP. After repairs
FMI 4.
Test (page 1974).
C. During test, monitor RAPP voltage with Navistar® Engine Diagnostics.
Is RAPP approximately 5 volts? No: Go to Step 6.
Step 6 Check for Open in RAPP circuit. Decision

A. Perform Test 3 (page 765). Yes: Repair short to GND
B. Key ON, clear codes.
Body Builder Connector 2 pin-A.
C. Key OFF, wait for ECM to shut down. After repairs are complete, retest
for SPN 974 FMI 4.
D. Key ON, check Diagnostic Trouble Codes (DTC) list for SPN 3512 (VREF
4).
Is EST DTC list SPN 3512 active or pending? No: Repair Open between ECM
Connector 2 pin-A. After repairs
FMI 4.


Tools Required
Test 1
A. Key OFF.
C. Insert correct pin from Terminal Test Kit ZTSE4435C into Body Builder connector 2 pin-B.
D. Key ON.
Test 2
A. Key OFF.
D. Insert correct pin from Terminal Test Kit ZTSE4435C into Body Builder connector 2 pin-B.
E. Use Breakout Harness ZTSE4498, short Body Builder connector 2 pin-A to pin-B.
Test 3
A. Key OFF.
D. Insert correct pin from Terminal Test Kit ZTSE4435C into Body Builder connector 2 pin-B.
E. Use Breakout Harness ZTSE4498, short Body Builder connector 2 pin-A to pin-B.
SPN 974 FMI 19 - Remote Accelerator Pedal Position : Received Network Data In Error
Fault Overview
Fault code sets when Engine Control Module (ECM) does Not detect Driveline on Private J1939 CAN data link
communications circuit.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes

®
1940).

for SPN 974 FMI 19.
End Diagnostic Test

SPN 1072 FMI 3 - Engine Compression Brake Output #1 : Voltage Above Normal, Or Shorted To High
Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Compression Brake 1 (ECB1) circuit is
shorted to power.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Failed 16-pin Engine Injector harness
• Failed ECB1 solenoid

®
(page 1940).
Step 2 Inspect connections on ECM Disconnect 16-pin Engine Injector Decision

harness.
B. Disconnect ECM 16-Pin E2 connector.
C. Check ECM 16-Pin E2 connector terminals for: damaged or pinched wires;
housing.
D. Remove valve cover and inspect UVC harness for damage.
Are ECM 16-Pin E2 connector, UVC harness, connectors, and terminals clean and No: Replace 16-pin Engine
undamaged? Injector harness. After repairs
1072 FMI 3.
Step 3 Check for failed ECB1. Decision

Disconnect 16-pin Engine Injector harness from ECB1 posts. Use DMM, Measure Yes: Go to Step 4.
resistance between both ECB1 posts.
Is resistance between 4 and 14 Ohms? No: Replace ECB1. After repairs
1072 FMI 3.
Step 4 Check for ECB1 body Short to GND. Decision

Disconnect 16-pin Engine Injector harness from ECB1 posts. Use DMM, Measure Yes: Replace 16-pin Engine
resistance between either ECB1 post and known good GND. Injector harness. After repairs
1072 FMI 3.
Is resistance greater than 1,000 Ohms? No: Replace ECB1. After repairs
1072 FMI 3.

SPN 1072 FMI 4 - Engine Compression Brake Output #1 : Voltage Below Normal, Or Shorted To Low
Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Compression Brake 1 (ECB1) circuit Short
to Ground
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes

®
(page 1940).

harness.
housing.
1072 FMI 4.

1072 FMI 4.

1072 FMI 4.
1072 FMI 4.

SPN 1072 FMI 5 - Engine Compression Brake Output #1 : Current Below Normal Or Open Circuit
Fault Overview
Fault code sets when Engine Control Module (ECM) detects an Open in the Engine Compression Brake 1 (ECB1)
circuit.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes

®
(page 1940).

harness.
housing.
1072 FMI 5.

1072 FMI 5.

1072 FMI 5.
1072 FMI 5.

SPN 1073 FMI 3 - Engine Compression Brake Output #2 : Voltage Above Normal, Or Shorted To High
Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Compression Brake 2 (ECB2) circuit is
shorted to power.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes

®
(page 1940).

harness.
housing.
1073 FMI 3.

1073 FMI 3.

1073 FMI 3.
1073 FMI 3.

SPN 1073 FMI 4 - Engine Compression Brake Output #2 : Voltage Below Normal, Or Shorted To Low
Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Compression Brake 2 (ECB2) circuit Short
to Ground
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes

®
(page 1940).

harness.
housing.
1073 FMI 4.

1073 FMI 4.

1073 FMI 4.
1073 FMI 4.

SPN 1073 FMI 5 - Engine Compression Brake Output #2 : Current Below Normal Or Open Circuit
Fault Overview
Fault code sets when Engine Control Module (ECM) detects an Open in the Engine Compression Brake 2 (ECB2)
circuit.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes

®
(page 1940).

harness.
housing.
1073 FMI 5.

1073 FMI 5.

1073 FMI 5.
1073 FMI 5.

SPN 1081 FMI 3 - Engine Wait to Start Lamp : Voltage Above Normal, Or Shorted To High Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Wait to Start Lamp (WTSL) circuit is shorted
to PWR.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• WTSL circuit short to PWR
• Failed WTSL
Step 1 Check for active or pending fault codes Decision

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostic Software, Key Yes: Go to step 2.
ON, check Diagnostic Trouble Codes (DTC) list for SPN 1081 FMI 3.
1940).
Step 2 Check for short to power in Wait to Start Lamp (WTSL) circuit. Decision
Perform Test 1 (page 783). Use Digital Multimeter (DMM), measure voltage between Yes: Replace WTSL. After
Breakout Harness ZTSE4435C pin-B and known good GND. repairs are complete, retest for
SPN 1081 FMI 3.
between WTSL (connector 1455)
SPN 1081 FMI 3.
End Diagnostic Test

Figure 285 WTSL Circuit Diagram
Tools Required
Figure 286 WTSL Circuit Check
Test 1
A. Key OFF.
B. Use Terminal Test Kit ZTSE4435C insert appropriate terminal into Wait to Start Lamp (WTSL) connector (1455)
pin-B and leave WTSL disconnected. See (vehicle Electrical Circuit Diagrams) for additional details.
C. Key ON
SPN 1081 FMI 4 - Engine Wait to Start Lamp : Voltage Below Normal, Or Shorted To Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects no current on Wait to Start Lamp (WTSL) driver
circuit when WTSL is commanded ON.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• WTSL circuit short to GND
• Failed WTSL

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostic Software, Key Yes: Go to Step 2.
(page 1940).
Step 2 Measure engine side of Wait to Start Lamp (WTSL) circuit for short Decision
to GND.
between Breakout Harness ZTSE4435C pin-B and known good GND.
Is resistance greater than 1000 ohms? No: Repair short to GND
between WTSL (connector 1455)
SPN 1081 FMI 4.
Step 3 Measure vehicle side of WTSL circuit for short to GND. Decision
Perform Test 2 (page 787). Use DMM, measure resistance between Breakout Yes: Replace WTSL. After
Harness ZTSE4435C pin-A and known good GND. repairs are complete, retest for
SPN 1081 FMI 4.
between WTSL (connector
1455) pin-A and vehicle wiring
(see WTSL Circuit Diagram
and vehicle Electrical Circuit
Diagrams for additional details).
for SPN 1081 FMI 4.
End Diagnostic Test

Tools Required
Test 1
A. Key OFF.
pin-B and leave WTSL disconnected. See( vehicle Electrical Circuit Diagrams) for additional details.
Test 2
A. Key OFF.
B. Use Terminal Test Kit ZTSE4435C insert appropriate terminal into WTSL connector (1455) pin-A and leave
WTSL disconnected. See( vehicle Electrical Circuit Diagrams) for additional details.
SPN 1081 FMI 5 - Engine Wait to Start Lamp : Current Below Normal Or Open Circuit
Fault Overview
Fault code sets when Engine Control Module (ECM) detects an Open in Wait To Start Lamp (WTSL) circuit.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• WTSL circuit Open or high resistance
• Failed WTSL

(page 1940).
Step 2 Check 15-amp fuse F10-D (464M). Decision

Check 15-amp fuse F10-D (464M) (see vehicle Electrical Circuit Diagrams for Yes: Go to Step 3.
additional details).
Is fuse in good condition and not blown? No: Replace 15-amp fuse
F10-D (464M). After repairs are
FMI 5.
Step 3 Check vehicle side of Wait To Start Lamp (WTSL) circuit for Open or Decision
high resistance.
ZTSE4435C pin-A and known good GND.
Is voltage 12 volts or greater while WTSL circuit is activated? No: Repair Open or high
resistance between WTSL
(connector 1455) pin-A and
vehicle wiring. After repairs are
FMI 5.
Step 4 Check Engine Control Module (ECM) side of WTSL circuit for Open or Decision
high resistance.
Perform Test 2 (page 792). Use DMM, measure resistance between ZTSE4435C Yes: Repair Open or high
pin-B and Breakout Box 00-00956-08 pin C2-15. resistance between WTSL
(connector 1455) pin-B and
ECM pin C2-15. After repairs
1081 FMI 5.
Is resistance greater than 5 ohms? No: Replace WTSL. After
SPN 1081 FMI 5.
End Diagnostic Test

Tools Required
Test 1
A. Key OFF.
pin-A and leave WTSL disconnected. See( vehicle Electrical Circuit Diagrams) for additional details.
C. Key ON
Test 2
A. Key OFF.
B. Use Terminal Test Kit ZTSE4435C insert appropriate terminal into WTSL connector (1455) pin-B and leave
WTSL disconnected. See( vehicle Electrical Circuit Diagrams) for additional details.
C. Connect 180-pin Breakout Box 00-0956-08 to Breakout Harness 00-01467-00.
D. Connect Breakout Harness 00-01467-00 to vehicle harness and leave Engine Control Module (ECM)
disconnected.
SPN 1110 FMI 31 - Engine Protection System has Shutdown Engine : Condition Exists
Fault Overview
Fault code sets when Engine Control Module (ECM) detects engine fueling without fuel injector driver demanding
fuel.
Lamp Reaction
Associated Faults
None
Fault Facts
None.

Continuous
Possible Causes
• Other modules intermittently requesting torque
• Failed ECM
1110 FMI 31.

(page 1940).
Step 3 Clear Fault Code then check for active or pending fault codes. Decision
®
A. Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, clear Yes: Replace ECM, following
fault codes. approved warranty procedures.
B. Run to operating temperature.
C. Check Diagnostic Trouble Codes (DTC) list for SPN 1110 FMI 31. (page 1926). After repairs are
FMI 31.
Is EST DTC list SPN 1110 FMI 31 active? No: End Diagnostics. Retest for
SPN 1110 FMI 31

SPN 1135 FMI 3 - Engine Oil Temperature 2 : Voltage Above Normal, Or Shorted To High Source
Fault Overview
Fault codes sets when Engine Control Module (ECM) detects Engine Oil Temperature 2 (EOT2) signal value is
above normal operating range. EOT2 sensor is a combined sensor with Engine Oil Level (EOL) sensor.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• EOT2 circuit Open or short to PWR

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostic Software, Yes: Go to Step 2.
1940).
Step 2 Check EOT2 circuit for Open or short to PWR. Decision

Perform Test 1 (page 797). Use Digital Multimeter (DMM), measure voltage from Yes: Go to Step 3.
Is voltage 5 ± 0.25 volts? No: Repair Open or short to PWR
complete, retest fro SPN 1135
FMI 3.

Perform Test 2 (page 797). Use DMM, measure voltage from Breakout Harness Yes: Replace EOL sensor. After
ZTSE4827 pin-4 and B+. repairs are complete, retest fro
SPN 1135 FMI 3.
Is voltage B+ ± 0.25 volts? No: Repair Open between EOL
sensor pin-4 and ECM pin E1-46.
fro SPN 1135 FMI 3.


Tools Required
Figure 293 EOT2 Circuit Checks
Test 1
A. Key OFF.
D. Key ON
Test 2
A. Key OFF.
D. Key ON
SPN 1135 FMI 4 - Engine Oil Temperature 2 : Voltage Below Normal, Or Shorted To Low Source
Fault Overview
Fault codes sets when Engine Control Module (ECM) detects Engine Oil Temperature 2 (EOT2) signal value is
less than normal operating range. EOT2 sensor is a combined sensor with Engine Oil Level (EOL) sensor.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• EOT2 signal circuit short to GND

1940).
Step 2 Check EOT2 circuit for short to GND. Decision

Perform Test 1 (page 801). Use Digital Multimeter (DMM), measure voltage from Yes: Replace EOL sensor. After
Breakout Harness ZTSE4827 pin-3 and known good GND. repairs are complete, retest fro
SPN 1135 FMI 4.
EOL sensor pin-3 and Engine
fro SPN 1135 FMI 4.


Tools Required
Figure 295 EOT2 Circuit Checks
Test 1
A. Key OFF.
D. Key ON
SPN 1136 FMI 0 - Engine ECU Temperature : Data Valid But Above Normal Operational Range - Most
Severe Level
Fault Overview
Fault code sets when Engine Control Module (ECM) detects its internal temperature sensor is greater than a
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Failed ECM

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, Key ON, check Yes: Replace ECM, following
FMI 0.
Is SPN 1136 FMI 0 active or pending? No: End diagnostics. Retest for
SPN 1136 FMI 0.

SPN 1136 FMI 3 - Engine ECU Temperature : Voltage Above Normal, Or Shorted To High Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects its internal temperature sensor is shorted to battery
voltage.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Failed ECM
Step 1 Check for active codes. Decision

®
FMI 3.
Is SPN 1136 FMI 3 active? No: End diagnostics, Retest for
SPN 1136 FMI 3.

SPN 1136 FMI 4 - Engine ECU Temperature : Voltage Below Normal, Or Shorted To Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects its internal temperature sensor is shorted to ground.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Failed ECM

®
FMI 4.
Is SPN 1136 FMI 4 active? No: End diagnostics. Retest for
SPN 1136 FMI 4.

SPN 1136 FMI 14 - Engine ECU Temperature : Special Instructions
Fault Overview
Fault code sets when Engine Control Module (ECM) detects its internal temperature sensor is reading an
unexpected value.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Failed ECM

®
FMI 14.
Is SPN 1136 FMI 14 active or pending? No: End diagnostics. Retest for
SPN 1136 FMI 14.

SPN 1209 FMI 0 - Engine Exhaust Pressure 1 : Data Valid But Above Normal Operational Range -
Most Severe Level
Fault Overview
Fault sets when Exhaust Back Pressure (EBP) signal is valid but greater than a normal operating range.
Lamp Reaction
Associated Faults
SPN 1209 FMI 2, 3 and 4
Fault Facts
EBP sensor shares common ground and 5V reference and ground circuits with FDP, AFTFP, and EOP sensors.
If more than one of these sensors set a fault, suspect a common 5V reference, or ground circuit.

Continuous.
Possible Causes
• EBP signal short to PWR
• Failed EBP sensor
• Open SIG GND

®
Diagnostic Trouble Code (DTC) list for Associated Faults. (page 806) Associated
Faults.
for SPN 1209 FMI 0.

FMI 0.
Step 3 Inspect connections at Exhaust Back Pressure (EBP) sensor. Decision

B. Disconnect EBP sensor connector.
C. Check EBP sensor and connector terminals for: damaged or pinched
housing.
Are EBP sensor, connector harness, and terminals clean and undamaged? No: Repair connector, harness,
1209 FMI 0.
Step 4 Check for failed EBP sensor. Decision

A. Perform Test 1 (page 809). Yes: Replace EBP sensor. After
®
SPN 1209 FMI 0.
Test (page 1974).
C. During test, monitor EBP voltage with Navistar® Engine Diagnostics.
Is voltage less than 0.25 volts? No: Go to step 5
Step 5 Check for short to PWR in EBP circuit. Decision

A. Perform Test 2 (page 810). Yes: Repair Open between ECM
pin E1-60 and EBP sensor pin-1.
Test (page 1974).
for SPN 1209 FMI 0.
between ECM pin E1-64 to EBP
sensor pin-3. After repairs are
FMI 0.


Tools Required
Figure 296 EBPV Sensor Check
Test 1
A. Key OFF.
B. Disconnect EBP sensor.
C. Connect Breakout Harness ZTSE4850 to engine harness and leave EBP sensor disconnected.
D. Using Breakout Harness ZTSE4498, short Breakout Harness ZTSE4850 pin-3 to pin-1.
E. Connect Electronic Service Tool (EST) with Navistar® Engine Diagnostics, to vehicle Diagnostic Connector
(page 1956).
Figure 297 EBP Circuit Check
Test 2
A. Key OFF.
D. Using Breakout Harness ZTSE4498, short Breakout Harness ZTSE4850 pin-3 to a known good GND.
(page 1956).
SPN 1209 FMI 1 - Engine Exhaust Pressure 1 : Data Valid But Below Normal Operational Range -
Most Severe Level
Fault Overview
Fault sets when Exhaust Back Pressure (EBP) signal is valid but less than a normal operating range.
Lamp Reaction
Associated Faults
SPN 1209 FMI 2, 3 and 4 SPN 3512
Fault Facts
None

Continuous
Possible Causes
• EBP signal circuit Open or short to GND

®
for SPN 1209 FMI 1.

1940).

C. Check EBP sensor and connector terminals for damaged or pinched wires;
housing.
1209 FMI 1.
Step 4 Check VREF circuit Open or short to GND. Decision

Perform Test 1 (page 814). Use DMM to measure voltage from ZTSE4850 Pin-2 Yes: Go to Step 5.
to a known good GND.
Is voltage 5.0 ± 0.25 volts? No: Repair Open or short to GND
between EBP sensor pin-2 and
ECM Pin E1-54. After repairs are
FMI 1.

SPN 1209 FMI 1.
C. During test, monitor EBP voltage with EST.
Is voltage 5.0 ± 0.25 volts? No: Repair Open or short to GND
between EBP sensor Pin-3 and
FMI 1.


Tools Required
Test 1
A. Key OFF.
B. Connect Breakout Harness ZTSE4850 to engine harness and leave EBP disconnected.
C. Key ON.
Figure 299 EBP Sensor Check
Test 2
A. Key OFF.
SPN 1209 FMI 2 - Engine Exhaust Pressure 1 : Data Erratic, Intermittent Or Incorrect
Fault Overview
Fault sets when Engine Control Module (ECM) determines Exhaust Back Pressure (EBP) signal deviates from
absolute values of Intake Manifold Pressure (IMP) sensor, and Barometric Pressure (BARO) sensor in post run
state.
Lamp Reaction
Associated Faults
SPN 1209 FMI 3 and 4 SPN 3512
Fault Facts
EBP sensor shares common ground and 5V reference circuit with FDP, AFTFP, and EOP sensors. If more than
one of these sensors set a fault, suspect a common 5V reference, or ground circuit.

Continuous
Possible Causes
• VREF 4 circuit Open
• EBP circuit failure

Use Electronic Service Tool (EST)s, check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Associated Faults (page 816).
for SPN 1209 FMI 2.

(page 1940).
Step 3 Inspect connections at Exhaust Back Pressure (EBP) connector. Decision

C. Check EBP and connector terminals for: damaged or pinched wires;
connector housing.
Are EBP connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
1209 FMI 2.

Perform Test 1 (page 818). Use DMM; measure voltage between Breakout Harness Yes: Go to step 5.
E1-54 and EBP pin-2. After
SPN 1209 FMI 2.
Step 5 Check for failed EBP sensor Decision

SPN 1209 FMI 2.
1974).
C. During test, monitor EBP voltage.
Step 6 Check for Open or high resistance in EBP circuit. Decision

®
EBP pin-1. After repairs are
1974).
C. During test, monitor EBP voltage. FMI 2.
EBP pin-3. After repairs are
FMI 2.


Tools Required
Test 1
A. Key OFF.
B. Connect Breakout Harness ZTSE4850 to engine harness and leave EBP sensor disconnected.
C. Key ON, Engine Off.

Test 2
A. Key OFF.
C. Using Breakout Harness ZTSE4498, short Breakout Harness ZTSE4850 pin-3 to pin-1.
Test 3
A. Key OFF.
C. Using Breakout Harness ZTSE4498, short Breakout Harness ZTSE4850 pin-3 to a known good GND.
SPN 1209 FMI 3 - Engine Exhaust Pressure 1 : Voltage Above Normal, Or Shorted To High Source
Fault Overview
Fault sets when Exhaust Back-Pressure (EBP) sensor signal voltage is greater than normal operating range.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• EBP signal short to PWR
• Open SIG GND

®
FMI 3.

B. EBP sensor connector.
C. Check EBP sensor and connector terminals for: damaged or pinched
housing.
1209 FMI 3.

SPN 1209 FMI 3.
Test (page 1974).
Step 4 Check for short to PWR in EBP circuit. Decision

A. Perform Test 2 (page 823). Yes: Repair Open between ECM
®
pin E1-60 and EOP pin-1. After
Test (page 1974).
SPN 1209 FMI 3.
between ECM pin E1-64 to EOP


Tools Required
Figure 303 EBPV Sensor Check
Test 1
A. Key OFF.
D. Using Breakout Harness ZTSE4498, short Breakout Harness ZTSE4850 pin-3 to pin-1.
(page 1956).
Test 2
A. Key OFF.
D. Using Breakout Harness ZTSE4498, short Breakout Harness ZTSE4850 pin-3 to a known good GND.
(page 1956).
SPN 1209 FMI 4 - Engine Exhaust Pressure 1 : Voltage Below Normal, Or Shorted To Low Source
Fault Overview
Fault sets when Exhaust Back-Pressure (EBP) sensor signal voltage is less than normal operating range.
Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate immediately when this fault is detected
Associated Faults
SPN 3512
Fault Facts
None

Continuous
Possible Causes
• EBP signal circuit open or short to GND
• VREF circuit open or short to GND

®
for SPN 1209 FMI 4.

1940).

C. Check EBP sensor and connector terminals for damaged or pinched wires;
housing.
1209 FMI 4.
Step 4 Check VREF circuit Open or short to GND. Decision

Perform Test 1 (page 828). Use DMM to measure voltage from ZTSE4850 Pin-2 Yes: Go to Step 5.
to a known good GND.
GND between EBP pin-2 and
FMI 4.

SPN 1209 FMI 4.
C. During test, monitor EBP voltage with EST.
GND between EBP Pin-3 and
FMI 4.


Tools Required
Test 1
A. Key OFF.
C. Key ON.
Figure 306 EBP Sensor Check
Test 2
A. Key OFF.
D. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector.
SPN 1213 FMI 3 - Malfunction Indicator Lamp : Voltage Above Normal, Or Shorted To High Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects hard-wired Malfunction Indicator Lamp (MIL) is
shorted to PWR.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• MIL circuit short to PWR

1940).
Step 2 Check Malfunction Indicator Lamp (MIL) operation. Decision

A. Key OFF, wait for Engine Control Module (ECM) to power down, check Yes: Repair short to PWR
MIL status. between ECM pin C1-57 and
MIL. After repairs are complete,
B. Key ON, wait for ECM to power up, check MIL status.
Is MIL ON with Key OFF, and OFF with Key ON? No: Go to Step 3.
Step 3 Check MIL circuit for short to PWR. Decision

Perform Test 1 (page 832). Use DMM, measure resistance between Breakout Box Yes: End diagnostics, retest for
00-00956-08 pin C1-57 and B+. SPN 1213 FMI 3.
Is resistance greater than 1,000 ohms? No: Repair short to PWR


Tools Required
Figure 307 MIL Circuit Check
Test 1
A. Key OFF
B. Disconnect Engine Control Module (ECM) C1 and C2 Connectors.
D. Connect Breakout Harness 00-01467-00 between ECM and chassis harness.

SPN 1213 FMI 4 - Malfunction Indicator Lamp : Voltage Below Normal, Or Shorted To Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects hard-wired Malfunction Indicator Lamp (MIL) is
shorted to GND.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• MIL circuit short to GND

1940).
Step 2 Check Malfunction Indicator Lamp (MIL) operation. Decision

Key ON, wait for Engine Control Module (ECM) to power up, check MIL status. Yes: Repair short to GND
Is MIL illuminated with Key ON? No: Go to Step 3.
Step 3 Check MIL circuit for short to PWR. Decision

Perform Test 1 (page 835). Use DMM, measure resistance between Breakout Box Yes: End diagnostics, retest for
00-00956-08 pin C1-57 and known good GND. SPN 1213 FMI 4.
Is resistance greater than 1,000 ohms? No: Repair short to GND


Tools Required
Test 1
A. Key OFF
B. Disconnect Engine Control Module (ECM) C1 and C2 Connectors.
D. Connect Breakout Harness 00-01467-00 between ECM and chassis harness.

SPN 1213 FMI 5 - Malfunction Indicator Lamp : Current Below Normal Or Open Circuit
Fault Overview
Fault code sets when Engine Control Module (ECM) detects hard-wired Malfunction Indicator Lamp (MIL) circuit
is Open.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• MIL circuit Open
• Failed MIL bulb
• B+ Open or short to GND to instrument cluster

1940).
Step 2 Check MIL circuit for Open. Decision

Perform Test 1 (page 838). Use DMM, measure voltage from connector 423M pin-13 Yes: Go to Step 3.
and known good GND.
Is voltage 3.7 ± 0.25 volts? No: Repair Open between
ECM pin C1-57 and connector
423M pin-13. After repairs are
FMI 5.
Step 3 Check for B+ to instrument cluster. Decision

Perform Test 2 (page 838). Use DMM, measure voltage from connector 423M pin-3 Yes: Replace MIL bulb. After
and known good GND. repairs are complete, retest for
SPN 1213 FMI 5.
Is voltage within B+ ± 0.5 volts? No: Repair Open or short to GND
in B+ circuit to instrument cluster.
for SPN 1213 FMI 5.


See latest version of International® A26 Engine Aftertreatment Wiring Schematic Form 0000009301 for additional
circuit information.
Tools Required
• Engine Terminal Test Kit ZTSE4435C
Test 1
A. Remove Left Side Cluster #2 from dashboard.
B. Key OFF.
C. Disconnect Left Side Cluster #2 connector 423M.
D. Use Engine Terminal Test Kit ZTSE4435C, insert proper terminal into connector 423M pin-13.
E. Key ON.
Figure 310 Power Supply Circuit Check
Test 2
A. Remove Left Side Cluster #2 from dashboard.
B. Key OFF.
C. Disconnect Left Side Cluster #2 connector 423M.
D. Use Engine Terminal Test Kit ZTSE4435C, insert proper terminal into connector 423M pin-3.
E. Key ON.
SPN 1244 FMI 5 - Engine Fuel Actuator 2 Control Command : Current Below Normal Or Open Circuit
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Fuel Actuator 2 (EFA2) high or low side
circuit voltage is above normal operating range.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• EFA2 12 volt circuit short to PWR
• EFA2 GND circuit short to PWR
• Failed EFA2

®
(page 1940).

connector housing.
1244 FMI 5.

Perform Test 1 (page 842). Use DMM, measure voltage between Breakout Harness Yes: Go to step 4.
Is voltage B+ ± 0.25 volts? No: Repair EFA 2 PWR between
ECM pin E1-24 and EFA 2 pin-1.
for SPN 1244 FMI 5.

Perform Test 2 (page 842). Use DMM, measure voltage between Breakout Harness Yes: Replace Fuel Rail. After
ZTSE6021 pin-2 and known good GND. repairs are complete, retest for
SPN 1244 FMI 5.
EFA 2 pin-2. After repairs are
FMI 5.


Tools Required
Test 1
A. Key OFF.
B. Connect Breakout Harness ZTSE6021 to engine harness and leave EFA2 disconnected.
Test 2
A. Key OFF.
SPN 1244 FMI 6 - Engine Fuel Actuator 2 Control Command : Current Above Normal Or Grounded
Circuit
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Fuel Actuator (EFA) 2 high side or low side
circuit is shorted to ground.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Failed EFA2

®
(page 1940).


connector housing.
1244 FMI 6.

for SPN 1244 FMI 6.

SPN 1244 FMI 6.
FMI 6.


Tools Required
Test 1
A. Key OFF.
Test 2
A. Key OFF.
SPN 1244 FMI 7 - Engine Fuel Actuator 2 Control Command : Mechanical System Not Responding
Or Out Of Adjustment
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Fuel Actuator 2 (EFA2) has an Open circuit.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Failed EFA2

®
(page 1940).

connector housing.
1244 FMI 7.

for SPN 1244 FMI 7.

SPN 1244 FMI 7.
FMI 7.


Tools Required
Test 1
A. Key OFF.
Test 2
A. Key OFF.
SPN 1322 FMI 14 - Engine Misfire for Multiple Cylinders : Special Instructions
Fault Overview
Fault code sets when Electronic Control Module (ECM) detects engine misfires more than 135 times in 1000
engine revolutions, more than three times in one drive cycle. This monitor runs during off idle operation.
Lamp Reaction
Associated Faults
SPN 97 FMI 31 SPN 111 FMI 1 SPN 157 SPN 636

SPN 637 SPN 651 - 656 SPN 1072 SPN 1073
Fault Facts
None

Road Test
Possible Causes
• Failed injector

Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
for SPN 1322 FMI 14.



at a time.

Perform Cylinder Balance Test (page 2010). Yes: End of diagnostics, retest
for fault.

fault.

for fault.

After performing diagnostic steps, if fault remains, verify steps were completed correctly and proper decision was made.
Return to Fault code diagnostics.
SPN 1322 FMI 31- Engine Misfire for Multiple Cylinders : Condition Exists
Fault Overview
Fault code sets when Electronic Control Module (ECM) detects multiple cylinder misfires based on crankshaft
acceleration.
Lamp Reaction
Associated Faults

SPN 637 SPN 651 - 656 SPN 1072 SPN 1073
Fault Facts
None

Road Test
Possible Causes
• Failed injector

for fault.



at a time.

for fault.

fault.

for fault.

SPN 1323 FMI 31- Engine Misfire Cylinder #1 : Condition Exists
Fault Overview
Fault code sets when Electronic Control Module (ECM) detects a cylinder 1 misfire from Crankshaft Position
(CKP) sensor.
Lamp Reaction
Associated Faults

SPN 637 SPN 651 - 656 SPN 1072 SPN 1073
Fault Facts
None

Road Test
Possible Causes
• Failed injector

for fault.



at a time.

for fault.

fault.

for fault.

Fault Overview
(CKP) sensor.
Lamp Reaction
Associated Faults

SPN 637 SPN 651 - 656 SPN 1072 SPN 1073
Fault Facts
None

Road Test
Possible Causes
• Failed injector

for fault.



at a time.

for fault.

fault.

for fault.

Fault Overview
(CKP) sensor.
Lamp Reaction
Associated Faults

SPN 637 SPN 651 - 656 SPN 1072 SPN 1073
Fault Facts
None

Road Test
Possible Causes
• Failed injector

for fault.



at a time.

for fault.

fault.

for fault.

Fault Overview
(CKP) sensor.
Lamp Reaction
Associated Faults

SPN 637 SPN 651 - 656 SPN 1072 SPN 1073
Fault Facts
None

Road Test
Possible Causes
• Failed injector

for fault.



at a time.

for fault.

fault.

for fault.

Fault Overview
(CKP) sensor.
Lamp Reaction
Associated Faults

SPN 637 SPN 651 - 656 SPN 1072 SPN 1073
Fault Facts
None

Road Test
Possible Causes
• Failed injector

for fault.



at a time.

for fault.

fault.

for fault.

Fault Overview
(CKP) sensor.
Lamp Reaction
Associated Faults

SPN 637 SPN 651 - 656 SPN 1072 SPN 1073
Fault Facts
None

Road Test
Possible Causes
• Failed injector

for fault.



at a time.

for fault.

fault.

for fault.

SPN 1378 FMI 31 - Engine Oil Change Interval : Condition Exists
Service Interval Messages Operation

Service interval messages are displayed on the instrument cluster message center and include engine oil and
fuel filter change reminders.
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.
Lamp Reaction
None
Possible Causes
• Change oil and re-set interval counter
SPN 1569 FMI 0 - Engine Protection Torque Derate : Data Valid But Above Normal Operational Range -
Most Severe Level
Fault Overview
Fault sets when DEF quality warning lamps and beeps have been ignored for 3 hours and the engine has idle
for another 60 minutes or a refueling event has been detected. This fault will induce a 40% torque derate and
limit vehicle speed to 5 mph.
Lamp Reaction
No Lamps directly related to this fault, but the DEF lamp, Amber Warning Lamp (AWL) and the Red Stop Lamp
(RSL) may be illuminated or flashing because of the SPN 4094 FMI 31.
Associated Faults
Any Aftertreatment or SCR

related faults
Fault Facts
All SCR faults must be repaired prior to performing the SCR fault reset. If the SCR reset is performed prior to
repairing the fault codes, the reset will not take.

Continuous
Possible Causes
• Programmable Parameter (PP) reset of "SCR Faults Reset Request" is needed to remove inducement
effects.

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics, check Yes: Repair Associated Faults.
Diagnostic Trouble Code (DTC) list for Associated Faults(page 877). After repairs are complete,
perform SCR Faults Reset
Request Procedure(page 1955).
Are Associated Faults active or previously active? No: Test drive vehicle and retest
for SPN 1569 FMI 0. If fault does
not return, perform SCR Faults
Reset Request Procedure(page
1955).

SPN 1569 FMI 15 - Engine Protection Torque Derate : Data Valid But Above Normal Operating Range
Fault Overview
Fault sets when a major aftertreatment component has failed or is disconnected, or bad Urea quality is detected
for at least one hour.
Lamp Reaction
Associated Faults

related faults
Fault Facts

Continuous
Possible Causes
effects.

Are Associated Faults active or previously active? No: Test drive vehicle and
retest for SPN 1569 FMI 15. If
fault does not return, perform
SCR Faults Reset Request
Procedure(page 1955).

SPN 1569 FMI 16 - Engine Protection Torque Derate : Data Valid But Above Normal Operating Range -
Fault Overview
Fault sets when DEF quality warning lamps and beeps have been ignored for 3 hours and will induce a 40%
torque derate.
Lamp Reaction
Associated Faults

related faults
Fault Facts

Continuous
Possible Causes
effects.

Are Associated Faults active or previously active? No: Test drive vehicle and
retest for SPN 1569 FMI 16. If
fault does not return, perform
Procedure(page 1955).

SPN 1590 FMI 19 - Adaptive Cruise Control Mode : Received Network Data In Error
Fault Overview
Fault code sets when Engine Control Module (ECM) has detected a loss of communication with Adaptive Cruise
Control (ACC) module.
Lamp Reaction
No Lamp
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• J1939 ACC Module CAN circuit failure

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostic Software, check Yes: Go to Step 2.
1940).

Perform J1939 Diagnostics (page 2112) at adaptive cruise control module (see Yes: End diagnostics, retest for
appropriate Vehicle Technician Manual for additional circuit and diagnostic SPN 1590 FMI 19.
information).
End Diagnostic Test

SPN 1659 FMI 14 - Engine Coolant System Thermostat 1 : Special Instructions
Fault Overview
Fault code sets When ECM detects Engine Coolant Temperature drops after initial warm-up.
Lamp Reaction
Associated Faults
SPN 110 FMI 0, 2, 3 and 4 SPN 111 FMI 1 SPN 1659 FMI 18 SPN 3599 FMI 3 and 4
Fault Facts
None

Road Test
Possible Causes
• Engine thermostats stuck open
• Engine fan stuck ON

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Go to Step 2.
Is EST DTC list free of Associated Faults? Repair Associated Faults. After
SPN 1659 FMI 14.
Step 2 Determine if thermostats are operating properly. Decision

Perform Thermostat Operational Test (page 2136). Go to step 3.
Does upper radiator hose temperature increase to within ± 25° F (14° C) of ECT? Replace thermostats. After
SPN 1659 FMI 14.

SPN 1659 FMI 14.
Is engine fan operating properly? No: Go to step 4

SPN 1659 FMI 14.

A. Key Off, disconnect air supply at Engine Fan clutch. Yes: Replace Engine Fan Clutch.
B. Key On, ensure vehicle air tanks are full.
C. Perform Actuator Test (page 1968) with Engine Fan selected in control
panel.
D. Cycle the Engine Fan On and Off while monitoring for air pressure a.t fen
clutch
Is vehicle air pressure available at Engine Fan Clutch with Engine Fan Solenoid No: Replace Engine Fan
energized? Solenoid (EFS). After repairs are
FMI 14.

After performing all tests, if no problem is found, verify if each step was completed correctly and proper decision
SPN 1659 FMI 18 - Engine Coolant System Thermostat 1 : Data Valid But Below Normal Operating
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Coolant Temperature (ECT) signal is below
a predetermined value when engine should be at operating temperature.
Lamp Reaction
Associated Faults
SPN 110 FMI 3 and 4
Fault Facts
This fault sets based off Engine Coolant Temperature. This fault may be inactive when it arrives at shop.

Road Test
Possible Causes
• Failed engine thermostats
• Cooling Package damage, blockage, or debris clogging
• Failed engine fan clutch or Engine Fan Solenoid (EFS)

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics, check Go to Step 2.
Are Associated Faults active? Repair Associated Faults. After
SPN 1659 FMI 18.
Step 2 Check thermostat operation. Decision

Perform Thermostat Operational Test (page 2136). Yes: Go to Step 4.
Does upper radiator hose temperature increase to within ± 25° F (14° C) of ECT1? No: Replace engine thermostats.

SPN 1659 FMI 18.
Is engine fan operating properly? No: Go to step 4

SPN 1659 FMI 18.

Perform Test 1 (page 887). Listen for air pressure at Engine Fan Clutch. Yes: Replace Engine Fan Clutch.
Is vehicle air pressure available at Engine Fan Clutch when NOT energized and no No: Replace Engine Fan
air pressure with Engine Fan Solenoid energized? Solenoid (EFS). After repairs are
FMI 18.


Tools Required
Figure 317 Engine Fan Solenoid Operation Check
Test 1
A. Key OFF.
B. Disconnect Engine Fan Solenoid.
C. Connect Breakout Harness ZTSE4871 between engine harness and Engine Fan Solenoid.
D. Use Breakout Harness ZTSE4498, Short Breakout Harness ZTSE4871 pin-1 to known good GND.
E. Key ON.
SPN 1761 FMI 1 - Aftertreatment 1 Diesel Exhaust Fluid Tank Volume : Data Valid But Below Normal
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Exhaust Fluid Tank Level (DEFTL) is equal
to 0%. Engine torque will be reduced if fault is active for a limited period of time. Engine torque will be severely
reduced after extended engine operation with fault code active. Five MPH Vehicle Speed Limit will be activated
on Key OFF/ON event OR Fuel Refill OR when idling for 60 minutes while DEF level equals 0%.
Lamp Reaction
Amber Warning Lamp (AWL) will illuminate immediately when this fault sets. Red Stop Lamp (RSL) will illuminate
after fault has been active for a set period of time.
Associated Faults
SPN 1761 FMI 3, 4, and 19

(DEFTLT)
Fault Facts
This fault indicates there is no DEF in DEF tank. Completely refilling DEF tank with approved DEF, will cause
this fault to go inactive and tank level to rise at real time. Because of tank sloshing that occurs during driving,
the level has filters to ensure accurate level readings. To over come this filter the tank must be filled to 100%
with DEF for the gauge to react and any engine derate to be turned off.

Road Test
Possible Causes
• Low DEF tank level

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostic Software, check Yes: Go to Step 2.
for SPN 1761 FMI 1.
Step 2 Check for damaged Diesel Exhaust Fluid (DEF) tank and DEF lines Decision
Inspect DEF tank and lines for damage and leaks. Yes: Turn Key Off for 60 seconds
or until ECM powers down.
Fill DEF tank to 100% using
approved DEF. After repairs are
FMI 1.
Are DEF tank and lines free of damage and not leaking? No: Repair damaged or leaking
DEF tank and lines. After repairs
1761 FMI 1.

SPN 1761 FMI 3 - Aftertreatment 1 Diesel Exhaust Fluid Tank Volume : Voltage Above Normal, Or
Shorted To High Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Exhaust Fluid Tank Level (DEFTL) signal
voltage is greater than expected for 10 second. Engine torque will be reduced if fault is active for a limited period
of time. Engine torque will be severely reduced after extended engine operation with fault code active.
Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected during first drive cycle.
Associated Faults
None
Fault Facts
If replacing a Float / Optical DEF head unit with Ultrasonic DEF head unit, submerge DEF head unit into DEF
two or three times at a rapid pace before installing into tank to initialize flow through the boot encapsulation.

Continuous
Possible Causes
• Poor electrical connections
• Failed DEF head unit

®
Is EST DTC list SPN 1761 FMI 3 active or pending? No: Repair other active fault
codes. After repairs are
Step 2 Inspect connections at DEF head unit. Decision

A. Key OFF. Yes: Replace DEF head unit.
B. Disconnect DEF head unit connector.
perform SCR Fault Reset
C. Check DEF head unit connector terminals for damaged or pinched wires; Request (page 1955) and retest
wet and corroded terminals; loose, bent, or broken pins; or broken for SPN 1761 FMI 3.
connector housing.
No: Repair connector, harness,
Are DEF head unit connector, harness, and terminal clean and undamaged? or terminal damage. After repairs
are complete, perform SCR Fault

SPN 1761 FMI 4 - Aftertreatment 1 Diesel Exhaust Fluid Tank Volume : Voltage Below Normal, Or
Shorted To Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Exhaust Fluid Tank Level (DEFTL) signal
voltage is less than expected for more than 10 seconds. Engine torque will be reduced if fault is active for a
limited period of time.
Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected during first drive cycle.
Associated Faults
None
Fault Facts

Continuous
Possible Causes

®
fault codes. After repairs
are complete, perform SCR
Maintenance Reset Procedure
(page 1955) and retest for SPN
1761 FMI 4.

perform SCR Maintenance Reset
C. Check DEF head unit and connector terminals for damaged or pinched Procedure (page 1955) and
wires; wet and corroded terminals; loose, bent, or broken pins; or broken retest for SPN 1761 FMI 4.
connector housing.
Are DEF head unit connector, harness, and terminal clean and undamaged? or terminal damage. After repairs
are complete, perform SCR
1761 FMI 4.

SPN 1761 FMI 10 - Aftertreatment 1 Diesel Exhaust Fluid Tank Volume : Abnormal Rate Of Change
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Exhaust Fluid Tank Level (DEFTL) signal is
invalid for an extended period of time.
Lamp Reaction
Associated Faults
SPN 1761 FMI 3, 4, and 19
Fault Facts
Fault code may set if vehicle was operated at an angle for a period of time.

Continuous
Possible Cause
• Low DEF
• Operated at an angle

®
Request (page 1955) and retest

Step 3 Check DEF tank level. Decision

Remove DEF tank cap and inspect DEF level in tank. Yes: Go to Step 4.
Is DEF tank level at least half full? No: Fill DEF tank with new
and/or known good DEF. After
SCR Fault Reset Request (page
1955) and retest for SPN 1761
FMI 10.
Step 4 Remove DEF head unit from tank. Decision

Remove DEF head unit from DEF tank. Submerge DEF head unit into DEF two or Yes: Replace DEF head unit.
three times at a rapid pace before installing into tank. Retest for SPN 1761 FMI 10. After repairs are complete, retest
Is SPN 1761 FMI 10 active? No: Removing air bubbles from
DEF head unit has corrected
fault condition. After repairs are

SPN 1761 FMI 12 - Aftertreatment 1 Diesel Exhaust Fluid Tank Volume : Bad Intelligent Device Or
Component
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Exhaust Fluid Tank Level (DEFTL) sensor,
within the DEF head unit, has failed.
Lamp Reaction
Associated Faults
SPN 1761 FMI 3, 4 and 19
Fault Facts

Continuous
Possible Causes

®

C. Check DEF Tank Head Unit sensor module and connector terminals for
damaged or pinched wires; wet and corroded terminals; loose, bent, or
broken pins; or broken connector housing.
Are DEF Tank head unit sensor module connector, harness, and terminal clean 1761 FMI 12.
and undamaged?

SPN 1761 FMI 13 - Aftertreatment 1 Diesel Exhaust Fluid Tank Volume : Out Of Calibration
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Exhaust Fluid Tank Level (DEFTL) sensor
module is out of calibration.
Lamp Reaction
Associated Faults
SPN 1761 FMI 3, 4, and 19

(DEFTLT)
Fault Facts

Road Test
Possible Causes
• Poor Electrical Connections


A. Key OFF. Yes: Replace DEFTLT sensor
C. CheckDEF head unit connector terminals for damaged or pinched wires; FMI 13.
housing.
Are DEF head unit connector, harness, and terminal clean and undamaged? No: Repair connector, harness,
1761 FMI 13.

Operating Range - Least Severe Level
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Diesel Exhaust Fluid Tank Level (DEFTL) is
greater than 2.2% and less than or equal to 5.6%.
Lamp Reaction
None
Associated Faults
SPN 1761 FMI 3, 4, and 19
Fault Facts

Road Test
Possible Causes

FMI 17.
1761 FMI 17.

Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Exhaust Fluid Tank Level (DEFTL) is less
than or equal to 2.2% and greater than 0% of being full. Engine torque will be reduced if fault is active for an
extended period of time.
Lamp Reaction
Amber Warning Lamp (AWL) will illuminate immediately when this fault sets.
Associated Faults
SPN 1761 FMI 3, 4, and 19

(DEFTLT)
Fault Facts

Road Test.
Possible Causes

FMI 18.
1761 FMI 18.

SPN 1761 FMI 19 - Aftertreatment 1 Diesel Exhaust Fluid Tank Volume : Received Network Data In Error
Fault Overview
This Fault sets when Engine Control Module (ECM) does not detect Diesel Exhaust Fluid (DEF) head unit
communication on private J1939 CAN bus. Engine torque will be reduced if fault is active for a limited period of
time. Engine torque will be severely reduced and vehicle speed will be limited after extended engine operation
with this fault code active.
Lamp Reaction
Associated Faults
SPN 5742 FMI 19 SPN 5743 FMI 19 SPN 5835 FMI 19
Fault Facts
module, NOx IN sensor module, Particulate Matter (PM) sensor module and DEF head unit. Verify batteries are
fully charged and connections are clean before completing diagnostics.

Continuous
Possible Cause
• AFTSS PWR circuit open or short to GND
• CAN-H circuit open or short to GND
• CAN-L circuit open or short to GND
• CAN-H circuit short to power
• CAN-L circuit short to power
• GND circuit open or high resistance
• CAN-H short to CAN-L

®
Is EST DTC list free of Associated Faults? No: Repair Private CAN circuit,
aftertreatment smart sensor relay
perform SCR Fault Reset Request
(page 1955), and retest for SPN
1761 FMI 19

Engine Off (KOEO), check Diagnostic Trouble Code (DTC) list for SPN 1761 FMI 19.
1761 FMI 19.
Step 3 Inspect DEF head unit and connector. Decision

C. Check DEF head unit and connector terminals for: damaged or pinched
connector housing.
Are DEF head unit connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
Reset Request (page 1955), and
Step 4 Check voltage drop across DEF head unit. Decision

C. Connect Breakout Harness 18-124-01 between vehicle harness and
DEF head unit.
E. Use DMM, measure voltage between Breakout Harness 18-124-01 pin-3
and pin-4.
Step 5 Check AFT Smart Sensor relay PWR circuit for Open or short to GND. Decision
A. Key Off. Yes: Repair Open or high
resistance between DEF head
unit pin-3 and GND. After repairs
C. Connect Breakout Harness 18-124-01 between vehicle harness and are complete, perform SCR Fault
DEF head unit. Reset Request (page 1955), and

and known good GND.
Is voltage B+ ± 0.5 volts? No: Repair Open, short to ground,
or high resistance between DEF
head unit pin-4 and AFT Smart
Sensor relay pin-30. After repairs
Step 6 Check Private CAN-H circuit. Decision

DEF head unit.

and known good GND.
Is voltage between 2.60 and 2.90 volts? No: Repair Open or short to GND
if voltage is less than 2.60 volts.
Repair short to PWR if voltage
is greater than 2.90 volts. After
repairs are complete, perform SCR
Fault Reset Request (page 1955),
Step 7 Check Private CAN-L circuit. Decision


DEF head unit.
and known good GND.
Step 8 Check for Private CAN-H shorted to Private CAN-L. Decision


C. Connect Breakout Harness 18-124-01 to vehicle harness and leave DEF
head unit disconnected.
D. Use DMM, measure resistance between Breakout Harness 18-124-01
pin-1 and pin-2.
Is resistance greater than 55 ohms? No: Repair short between CAN-H
and CAN-L, or remove extra
terminating resistor that has been
added. After repairs are complete,

1761 FMI 19.

A. Key Off. Yes: Repair failed terminating
resistor(s) or Open between CAN
circuit and terminating resistors.
C. Connect Breakout Harness 18-124-01 to vehicle harness and leave DEF After repairs are complete, perform
head unit disconnected. SCR Fault Reset Request (page
1955), and retest for SPN 1761
FMI 19.
pin-1 and pin-2.
Is resistance greater than 65 ohms? No: Go to Step 10.
Step 10 Check CAN-H on isolated DEF head unit. Decision


C. Connect Breakout Harness 18-124-01 to DEF head unit and leave
chassis harness disconnected.
D. Using jumper wires, supply B+ and ground to DEF head unit through
breakout harness. Leave CAN circuits disconnected.
E. Use DMM, measure voltage between pin-2 (CAN-H) and known good
GND.
Is voltage between 2.4 and 3.1 volts? No: Go to Step 12.
Step 11 Check CAN-L on isolated DEF head unit. Decision

A. Key Off. Yes: Reinstall DEF Head Unit. End
diagnostics. Retest for fault.

breakout harness. Leave CAN circuits disconnected
E. Use DMM, measure voltage between pin-1 (CAN-L) and known good
GND
Step 12 DEF Tank Heater Valve (DEFTHV) Coolant Flow Test. Decision
Perform DEFTHV Coolant Flow Test (page 2230). Yes: Replace DEFTHV and
DEF head unit. After repairs are
Is there a constant stream of coolant coming from DEF head unit return port? No: Replace DEF head unit. After

SPN 2599 FMI 19 - Fire Apparatus Pump Engagement : Received Network Data In Error
Fault Overview
Fault code sets when Engine Control Module (ECM) has detected a loss of communication with Fire Apparatus
Pump.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes

®
1940).

End Diagnostic Test

SPN 2623 FMI 3 - Accelerator Pedal #1 Channel 2 : Voltage Above Normal, Or Shorted To High Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Accelerator Pedal Position 2 (APP2) circuit voltage
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• APP2 circuit short to PWR

(page 1940).

connector housing.
2623 FMI 3.
Step 3 Check APP circuit for short to PWR. Decision

ZTSE4485A pin-F and known good GND.
Is voltage 0 volts? No: Repair short to PWR
between APP pin-F and ECM
FMI 3.

ZTSE4485A pin-E and PWR. repairs are complete, retest for
SPN 2623 FMI 3.
Is voltage B+ ± 0.5 volts? No: Repair Open between APP
pin-E and ECM pin C1-29. After
SPN 2623 FMI 3.


Tools Required
Test 1
A. Key OFF.
B. Disconnect Accelerator Pedal Position (APP) sensor
D. Key ON
Test 2
A. Key OFF.
B. Disconnect APP sensor
D. Key ON
SPN 2623 FMI 4 - Accelerator Pedal #1 Channel 2 : Voltage Below Normal, Or Shorted To Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Accelerator Pedal Position 2 (APP2) circuit voltage
is less than normal operating range.
Lamp Reaction
Associated Faults
• SPN 3511 (VREF)
Fault Facts
None

Continuous
Possible Causes
• APP2 circuit Open or short to GND

for SPN 2623 FMI 4.

1940).

connector housing.
2623 FMI 4.
Step 4 Check VREF circuit for Open or short to GND. Decision

ZTSE4485A pin-D and known good GND.
GND between APP pin-D and
FMI 4.
Step 5 Check for failed APP sensor. Decision

A. Perform Test 2 (page 919). Yes: Replace APP sensor. After
SPN 2623 FMI 4.
C. Monitor APP2 voltage in EST.
between APP pin-F and ECM pin


Tools Required
Test 1
A. Key OFF.
B. Disconnect APP sensor
D. Key ON
Figure 321 Check for failed APP sensor
Test 2
A. Key OFF.
D. Use Breakout Harness ZTSE4498 short Breakout Harness ZTSE4485A pin-F and pin-D together.
SPN 2629 FMI 0 - Engine Turbocharger 1 Compressor Outlet Temperature : Data Valid But Above
Normal Operational Range - Most Severe Level
Fault Overview
Fault code sets when ECM detects Turbocharger Compressor Outlet Temperature (TCOT) reading is within
range but greater than a normal operating value.
Lamp Reaction
Associated Faults
SPN 2629 FMI 2, 3 and 4
Fault Facts
None.

Road Test
Possible Causes
• TCOT circuit short to GND
• Failed TCOT sensor

®
for SPN 2629 FMI 0.

Use EST with Navistar® Engine Diagnostics, check DTC list for SPN 2629 FMI 0. Yes: Go to Step 3.
(page 1940).
Step 3 Inspect connections at TCOT sensor. Decision

B. Disconnect TCOT sensor.
C. Check TCOT sensor and connector terminals for: damaged or pinched
connector housing.
Is TCOT sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
2629 FMI 0.
Step 4 Inspect connections at 10-pin Engine Interface Connector. Decision

B. Disconnect 10-pin Engine Interface Connector.
C. Check connector terminals for: damaged or pinched wires; moisture or
housing.
Is connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
SPN 2629 FMI 0.
Step 5 Check for failed TCOT sensor. Decision

A. Key OFF. Yes: Replace TCOT sensor.
B. Disconnect TCOT sensor electrical connector.
for SPN 2629 FMI 0.
C. Use EST with Navistar® Engine Diagnostics, perform Continuous Monitor
Test (page 1974).
D. During test, monitor TCOT voltage.

between TCOT sensor pin-2 and
FMI 0.

SPN 2629 FMI 2 - Engine Turbocharger 1 Compressor Outlet Temperature : Data Erratic, Intermittent
Or Incorrect
Fault Overview
Fault sets when Engine Control Module (ECM) determines Turbocharger Compressor Outlet Temperature
(TCOT) signal deviates from average values of Intake Manifold Temperature (IMT), Intake Air Temperature
(IAT), and Charge Air Cooler Outlet Temperature (CACOT) after cold soak.
Lamp Reaction
Associated Faults
SPN 2629 FMI 3 and 4
Fault Facts
TCOT sensor is located on the outlet of the turbocharger compressor housing.

Road Test
Possible Causes
• High resistance in TCOT signal circuit
• High resistance in TCOT ground circuit

®
for SPN 2629 FMI 2.

(page 1940).
Step 3 Inspect connections at Turbocharger Compressor Outlet Temperature Decision

(TCOT) connector.
B. Disconnect TCOT connector.
C. Check TCOT and connector terminals for: damaged or pinched wires;
connector housing.
Are TCOT connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
2629 FMI 2.
Step 4 Check TCOT circuit for high resistance. Decision

A. Key Off. Yes: Go to step 5.
B. Disconnect TCOT sensor

(page 1956).
F. During test, monitor TCOT voltage in EST.
Is voltage 5 ± 0.25 volts? No: Go to step 7.
Step 5 Check for Failed TCOT sensor. Decision

A. Perform Test 1 (page 926). Yes: Replace TCOT. After
SPN 2629 FMI 2.
C. During test, monitor TCOT voltage in EST.
Is TCOT voltage between 0 and 0.25 volts? No: Go to Step 6.
Step 6 Check for Failed TCOT circuit. Decision

between TCOT pin-1 and ECM
C. During test, monitor TCOT voltage in EST. complete, retest for SPN 2629
FMI 2.
Is TCOT voltage between 0 and 0.25 volts? No: Go to Step 7.
Step 7 Check for Failed TCOT circuit. Decision

between TCOT pin-2 and 10-Pin
Engine Interface Connector
C. During test, monitor TCOT voltage in EST. pin-F on engine harness. After
SPN 2629 FMI 2.
Is TCOT voltage between 0 and 0.25 volts? No: Repair high resistance
between 10-Pin Engine Interface
Connector pin-F and ECM pin
C1-11 on vehicle harness. After
SPN 2629 FMI 2.


Tools Required
Figure 322 TCOT Circuit Check
Test 1
A. Key OFF.
C. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4760A pin-1 to pin-2.
Test 2
A. Key OFF.
C. Use Breakout Harness ZTSE4498, short Breakout Harness ZTSE4760A pin-1 to a known good GND.
E. Key ON.
4498
F
12-999-06
0000421982
Test 3
A. Key OFF.
B. Disconnect 10-Pin Engine Interface Connector
C. Connect Breakout Harness 12-999-06 to vehicle side harness and leave engine harness side disconnected.
D. Use Breakout Harness ZTSE4498, short Breakout Harness 12-999-06 pin-F to a known good GND.
F. Key ON.
SPN 2629 FMI 3 - Engine Turbocharger 1 Compressor Outlet Temperature : Voltage Above Normal,
Or Shorted To High Source
Fault Overview
Fault Code sets when Engine Control Module (ECM) detects Turbocharger Compressor Outlet Temperature
(TCOT) sensor voltage is greater than normal operating range.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• TCOT circuit Open or short to PWR

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostic Software. Yes: Go to Step 2.
Key-ON Engine-OFF (KOEO), check Diagnostic Trouble Codes (DTC) list for SPN
2629 FMI 3.
(page 1940).

B. Disconnect Turbocharger Compressor Outlet Temperature (TCOT) sensor.
connector housing.
Is TCOT sensor connector, harness, and terminal clean and undamaged? No: Repair connector, harness,
2629 FMI 3.
Step 3 Check TCOT circuit for short to PWR. Decision

between TCOT pin-2 and Engine
B. Use DMM, measure voltage between Breakout Harness ZTSE4760A pin-2
and known good GND.
for SPN 2629 FMI 3.

A. Perform Test 2 (page 932). Yes: Replace TCOT sensor.
for SPN 2629 FMI 3.
C. Monitor TCOT voltage during test.

TCOT pin-1 and ECM pin E1-61.
C. Monitor TCOT voltage during test. for SPN 2629 FMI 3.
Is voltage approximately 0 volts? No: Repair Open between TCOT
SPN 2629 FMI 3.


Tools Required
• 3-Banana Plug Harness
Figure 325 TCOT Short to PWR Check
Test 1
A. Key OFF.
C. Connect Breakout Harness ZTSE4760A to engine harness connector and leave TCOT sensor disconnected.
D. Key-ON.
Test 2
A. Key OFF.
C. Connect Breakout Harness ZTSE4760A to engine harness connector and leave TCOT disconnected.
D. Use 3-Banana Plug Harness ZTSE4498, short Breakout Harness ZTSE4760A pin-1 and pin-2 together.
Figure 327 TCOT GND to Open Check
Test 3
A. Key OFF.
C. Connect Breakout Harness ZTSE4760A to engine harness connector and leave TCOT disconnected.
D. Use 3-Banana Plug Harness ZTSE4498 short Breakout Harness ZTSE4760A pin-2 to a known good GND.
SPN 2629 FMI 4 - Engine Turbocharger 1 Compressor Outlet Temperature : Voltage Below Normal,
Or Shorted To Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Turbocharger Compressor Outlet Temperature
(TCOT) signal voltage is less than normal operating range.
Lamp Reaction
Associated Faults
None
Fault Facts
None.

Continuous
Possible Causes
• TCOT circuit short to GND

Key-ON Engine-OFF (KOEO), check Diagnostic Trouble Codes (DTC) list for SPN
2629 FMI 4.
(page 1940).

connector housing.
Is TCOT sensor connector, harness, and terminal clean and undamaged? No: Repair connector, harness,
2629 FMI 4.

A. Key OFF. Yes: Replace TCOT sensor.
for SPN 2629 FMI 4.
D. During test, monitor TCOT voltage.
between TCOT pin-2 and ECM
FMI 4.

SPN 2630 FMI 0 - Engine Charge Air Cooler 1 Outlet Temperature : Data Valid But Above Normal
Fault Overview
Fault sets when Engine Control Module (ECM) determines Charge Air Cooler Outlet Temperature (CACOT)
sensor reading is greater than a predetermined value. ECM uses vehicle speed and Ambient Air Temperature
(AAT) to determine CAC effectiveness
Lamp Reaction
Associated Faults
SPN 647 (EFC) SPN 2630 FMI 2, 3, and 4

(CACOT)
Fault Facts
Vehicles equipped with a snow plow application may set 2630-0 faults. Cruising at highway like speeds with
plow blade raised may cause enough reduction in air flow over the CAC to set a fault.

Continuous
Possible Causes
• Restricted charge air cooler (CAC)
• Engine fan and/or fan shroud failure
• Winter front installed outside of recommended temperature

for SPN 2630 FMI 0.
Step 2 Determine if a winter front (grill cover) is installed during warm Decision
temperatures.
Visually inspect vehicle grill area for installed winter front (grill cover). Yes: Go to Step 3.
Is winter front (grill cover) removed during warm temperatures outside recommended No: Remove winter front. After
range? repairs are complete, retest for
SPN 2630 FMI 0.
Step 3 Check for restricted Charge Air Cooler (CAC). Decision

Inspect CAC for damage, blockage, or anything that could prevent proper air flow Yes: Go to Step 4.
through CAC.
Is CAC undamaged, not blocked, and is air able to flow through CAC properly? No: Repair CAC damage or
blockage. After repairs are
FMI 0.
Step 4 Inspect engine cooling fan and shroud for damage. Decision
Visually inspect cooling fan blades and fan shroud for debris, cracks, and damage. Yes: Go to Step 5.
Are engine cooling fan and shroud in good condition and not damaged? No: Repair engine cooling fan or
shroud damage. After repairs are
made, retest for SPN 2630 FMI 0.
Step 5 Determine if engine fan is operating properly. Decision

SPN 2630 FMI 0.
Is engine fan operating properly? No: Repair or replace failed
engine fan clutch. After repairs
2630 FMI 0.

SPN 2630 FMI 2 - Engine Charge Air Cooler 1 Outlet Temperature : Data Erratic, Intermittent or Incorrect
Fault Overview
Fault code sets when Engine Control Module (ECM) detects difference of Engine Air Inlet Temperature (IAT)
with Charge Air Cooler Outlet Temperature (CACOT) and Intake Manifold Temperature (IMT) after 8 hour cold
soak is greater than 45°F (25°C).
Lamp Reaction
Associated Faults

(CACOT)
Fault Facts
None

Continuous
Possible Causes
• CACOT circuit open or high resistance
• Biased CACOT sensor

for SPN 2630 FMI 2.

Use EST check DTC list for SPN 2630 FMI 2. Yes: Go to Step 3.
(page 1940).
Step 3 Inspect connections at Charge Air Cooler Outlet Temperature (CACOT) Decision
connector.
B. Disconnect CACOT connector.
C. Check CACOT and connector terminals for: damaged or pinched wires;
connector housing.
Are CACOT connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
2630 FMI 2.
Step 4 Check for biased CACOT sensor. Decision

A. Perform Test 1 (page 942). Yes: Replace CACOT sensor.
for SPN 2630 FMI 2.
C. Monitor CACOT voltage during test.
Step 5 Check for CACOT circuit failure. Decision

CACOT sensor pin-A and ECM
C. Monitor CACOT voltage during test. complete, retest for SPN 2630
FMI 2.
resistance between CACOT
sensor pin-B and ECM pin E1-11.
for SPN 2630 FMI 2.

After performing diagnostic steps, if SPN 2630 FMI 2 remains, verify if each step was completed correctly and proper

Tools Required
4498
B 4782
0000415337
Figure 328 CACOT Sensor Check
Test 1
A. Key OFF.
B. Disconnect Charge Air Cooler Outlet Temperature (CACOT) sensor.
C. Connect Breakout Harness ZTSE4782 to engine harness and leave CACOT sensor disconnected.
D. Use 3-Banana Plug Harness ZTSE4498, short Breakout Harness ZTSE4782 pin-A to pin-B.
E. Connect Electronic Service Tool (EST) with Navistar® Engine Diagnostic Software to vehicle Diagnostic
Connector (page 1956).
F. Key ON, log into EST.
4498
4782
0000415339
Figure 329 CACOT Circuit Check
Test 2
A. Key OFF.
C. Connect Breakout Harness ZTSE4782 to engine harness and leave CACOT sensor disconnected.
D. Use 3-Banana Plug Harness ZTSE4498, short Breakout Harness ZTSE4782 pin-A to a known good GND.
SPN 2630 FMI 3 - CACOT Engine Charge Air Cooler 1 Outlet Temperature : Voltage Above Normal,
Fault Overview
Fault Code sets when Engine Control Module (ECM) detects Charge Air Cooler Temperature (CACOT) sensor
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• CACOT circuit Open or short to PWR
• Failed CACOT

®
Trouble Codes (DTC) list for SPN 2630 FMI 3.
Is EST DTC list SPN 2630 FMI 3 active? No: Go to Intermittent or
Step 2 Inspect connections at CACOT Decision

C. Check CACOT sensor and connector terminals for: damaged or pinched wires;
Are CACOT sensor connector, harness, and terminals clean and undamaged? No: Repair connector,
2630 FMI 3.
Step 3 Check CACOT circuit for short to PWR. Decision

between CACOT pin-B
B. Use DMM, measure voltage between Breakout Harness ZTSE4782 pin-B and
known good GND.
(ECM) pin E1-11. After
for SPN 2630 FMI 3.
Step 4 Check for failed CACOT sensor. Decision

A. Perform Test 2 (page 947). Yes: Replace CACOT
B. Use EST with Navistar® Engine Diagnostic Software, perform Continuous
Monitor Test (page 1974).
2630 FMI 3.
C. Monitor CACOT voltage during test.

CACOT sensor pin-A and
B. Use EST with Navistar® Engine Diagnostic Software, perform Continuous
Monitor Test (page 1974).
C. Monitor CACOT voltage during test. 2630 FMI 2.
resistance between CACOT
sensor pin-B and ECM pin
2630 FMI 2.


Tools Required
B
4782
0000415343
Figure 330 CACOT short to PWR Check
Test 1
A. Key OFF.
B. Disconnect Charge Air Cooler Temperature (CACOT) sensor
C. Connect Breakout Harness ZTSE4782 to engine harness connector and leave CACOT disconnected.
D. Key ON.
4498
B 4782
0000415337
Figure 331 CACOT Sensor Check
Test 2
A. Key OFF.
D. Use 3-Banana Plug Harness ZTSE4498 short Breakout Harness ZTSE4782 pin-A and pin-B together.
F. Key ON. Log in to EST with Navistar® Engine Diagnostic Software.
4498
4782
0000415339
Test 3
A. Key OFF.
D. Use 3-Banana Plug Harness ZTSE4498, short Breakout Harness ZTSE4782 pin-A to a known good GND.
F. Key ON. Log in to EST with Navistar® Engine Diagnostic Software.
SPN 2630 FMI 4 - CACOT Engine Charge Air Cooler 1 Outlet Temperature : Voltage Below Normal,
Fault Overview
Fault Code sets when Engine Control Module (ECM) detects Charge Air Cooler Outlet Temperature (CACOT)
signal is less than normal operating range.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• CACOT circuit short to GND
• Failed CACOT sensor

®
(page 1940).
Step 2 Inspect connections at Charge Air Cooler Outlet Temperature (CACOT) Decision
sensor.
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,
2630 FMI 4.

A. Key OFF. Yes: Replace CACOT sensor.
for SPN 2630 FMI 4.
C. Connect EST to vehicle Diagnostic Connector (page 1956).
D. Key ON. Log in to EST.
E. Use EST, perform Continuous Monitor Test (page 1974).
F. Monitor CACOT voltage during test.

Is voltage 4.85 ± 0.25 volts? No: Repair short to ground
between CACOT pin-2 and
FMI 4.

SPN 2634 FMI 3 - Power Relay : Voltage Above Normal, Or Shorted To High Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Aftertreatment Smart Sensor (AFTSS) Relay control
circuit is Short to Power.
Lamp Reaction
Associated Faults
None
Fault Facts
If more than one of the following smart sensor modules fail (or set an FMI 19 fault), suspect a common Private
J1939 CAN circuit, power circuit, ground circuit, or AFTSS Relay problem. The following components share
power and ground circuits: VGT Actuator, EGR Valve, DEF Head Unit, NOx IN sensor module, NOx OUT sensor
module, PM Sensor Module, and AFT Exhaust Temperature Module. Also, verify batteries are fully charged and
connections are clean.

Continuous
Possible Causes
• AFTSS Relay CTL circuit Short to PWR
• Failed AFTSS Relay

®
(page 1940).
Step 2 Check Aftertreatment Power Distribution Module (PDM) Decision

Check Aftertreatment Power Distribution Module (PDM) fuse(s) and relay(s) for Yes: Go to Step 3.
blown fuses; loose, missing, or intermittent connections.
Are all fuses and relays securely attached and in good condition? No: Secure or replace failed
fuse(s) or relay(s) to PDM
FMI 3.
Step 3 Check AFTSS Relay voltage supply circuit for Open or Short to GND. Decision
Perform Test 1 (page 955). Use DMM, Measure voltage between AFTSS Relay Yes: Repair Short to PWR
(R5) terminal 86 and a known good GND. between AFTSS Relay (R5)
SPN 2634 FMI 3..
Is Voltage greater than 0.5V? No: Replace AFTSS Relay. After
repairs are complete, Retest for
SPN 2634 FMI 3.


Tools Required
86 4435C
0000424370
Figure 333 Check AFTSS Relay voltage
Test 1
A. Key OFF.
B. Remove AFTSS Relay (R5) from AFT PDM.
C. Install Test Lead ZTSE443531 from Terminal Test Kit ZTSE4435C into AFTSS Relay terminal 86.
D. Key ON.
SPN 2634 FMI 5 - Power Relay : Current Below Normal Or Open Circuit
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Aftertreatment Smart Sensor (AFTSS) Relay control
circuit is Open or Short to GND.
Lamp Reaction
Associated Faults
None
Fault Facts
If more than one of the following smart sensor modules fail (or set an FMI 19 fault), suspect a common Private
J1939 CAN circuit, power circuit, ground circuit, or AFTSS Relay problem. The following components share
power and ground circuits: VGT Actuator, EGR Valve, DEF Head Unit, NOx IN sensor module, NOx OUT sensor
module, PM Sensor Module, and AFT Exhaust Temperature Module. Also, verify batteries are fully charged and
connections are clean.

Continuous
Possible Causes
• AFTSS Relay voltage supply circuit Open or Short to GND
• AFTSS Relay CTL circuit Open or Short to GND
• Failed AFTSS Relay

®
(page 1940).
Step 2 Check Aftertreatment Power Distribution Module (PDM) Decision

Check Aftertreatment Power Distribution Module (PDM) fuse(s) and relay(s) for Yes: Go to Step 3.
FMI 5.
Step 3 Check AFTSS Relay voltage supply circuit for Open or Short to GND. Decision
Perform Test 1 (page 959). Use DMM, Measure voltage between AFTSS Relay Yes: Go to Step 4.
(R5) terminal 85 and a known good GND.
Is Voltage B+ ± 0.5 Volts? No: Repair Open or Short to
GND and(or) blown fuse between
AFTSS Relay (R5) terminal 85
and vehicle battery, After repairs
2634 FMI 5.
Step 4 Check AFTSS Relay CTL circuit for Short to GND. Decision
Perform Test 2 (page 960). Use DMM, Measure resistance between AFTSS Relay Yes: Go to step 5.
(R5) terminal 86 and a known good GND.
Is Resistance greater than 1.000 Ohms? No: Repair Short to GND
between AFTSS Relay (R5)
SPN 2634 FMI 5.
Step 5 Check for Open in AFTSS Relay CTL circuit. Decision

Perform Test 3 (page 961). Use DMM, Measure voltage between AFTSS Relay (R5) Yes: Replace AFTSS Relay.
terminal 85 and AFTSS Relay (R5) terminal 86. After repairs are complete,
Is Voltage B+ ± 0.5 Volts? No: Repair Open between
AFTSS Relay (R5) pin-86 and
FMI 5.


Tools Required
85 4435C
0000424369
Test 1
A. Key OFF.
86 4435C
0000427394
Test 2
A. Key OFF.
4435C 4435C
85
86
0000428651
Test 3
A. Key OFF.
D. Install Test Lead ZTSE443531 from Terminal Test Kit ZTSE4435C into AFTSS Relay terminal 86.
E. Key ON.
SPN 2659 FMI 10 - Engine Exhaust Gas Recirculation 1 Mass Flow Rate : Abnormal Update Rate
Fault Overview
Fault code sets when Engine Control Module (ECM) detects feedback from Mass Air Flow (MAF) Sensor
indicating air flow through the engine is not meeting expected setpoint for given Exhaust Gas Recirculation
Valve (EGRV) position.
Lamp Reaction
Associated Faults
SPN 91 SPN 102 SPN 641 SPN 724

SPN 2623 SPN 2791 SPN 5298
Fault Facts
None

Road Test
Possible Causes
• Soot build up on EGRV
• Failed EGRV
• Soot build up in EGR Cooler

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics, check Diagnostic Yes: Go to Step 2.
Trouble Codes (DTC) list for Associated Faults (page 962).
2659 FMI 10.

C. Check EBP sensor and connector terminals for: damaged or pinched wires;
Are EBP sensor, connector harness, and terminals clean and undamaged? No: Repair connector,
SPN 2659 FMI 10.
Step 3 Verify Mass Air Flow (MAF) changes when Exhaust Gas Recirculation Valve Decision
(EGRV) is commanded ON.
Perform Air Management Test (page 2004). Yes: End diagnostics,
10.
Step 4 Verify EGRV can meet commanded position. Decision

10.
Step 5 Check if VGT can meet commanded position. Decision

Perform VGT Position Test (page 1991). Yes: Go to step 6.
Did VGT meet commanded position and did no fault codes set during test? No: Go to Step 9.
Step 6 Inspect cold side of EGR cooler for soot build up. Decision
A. Remove EGR cooler gas outlet hose from front of EGR cooler (see Engine Service Yes: Go to Step 7.
manual).
B. Inspect EGR cooler outlet for signs of carbon or soot build up inside the EGR cooler.
Is EGR cooler exhaust gas outlet free of soot build up? No: Replace EGR
cooler. After repairs are
2659 FMI 10.
Step 7 Inspect Exhaust Gas Recirculation Valve (EGRV) for soot build up. Decision
A. Remove EGR cooler bellow tubes (see Engine Service manual). Yes: Go to step 8.
B. Inspect EGRV butterfly, shaft and bore for soot build up blocking EGRV movement.
Is EGRV butterfly, shaft, and bore free of soot build up? No: Replace EGRV. After
10.
Step 8 Inspect EGR cooler inlet for soot build up. Decision
With EGR cooler bellow tubes removed, inspect exhaust gas inlet for signs of soot build up. Yes: End diagnostics.
10.
Is EGR cooler exhaust gas inlet free of soot build up? No: Replace EGR
2659 FMI 10.

10.

10.
back to open.
connector.
SPN 2659 FMI 10.

SPN 2659 FMI 16 - Engine Exhaust Gas Recirculation 1 Mass Flow Rate : Data Valid But Above Normal
Fault Overview
indicating air flow through the engine is below expected setpoint for given Exhaust Gas Recirculation Valve
(EGRV) position.
Lamp Reaction
Associated Faults

SPN 2623 SPN 2791 SPN 5298
Fault Facts
None

Road Test
Possible Causes
• Failed EGRV

®
2659 FMI 16.

SPN 2659 FMI 16.
16.

16.

16.
Does VGT meet commanded position? No: Go to Step 6.



16.

16.
back to open.
connector.
SPN 2659 FMI 16.

SPN 2659 FMI 18 - Engine Exhaust Gas Recirculation 1 Mass Flow Rate : Data Valid But Below Normal
Fault Overview
indicating air flow through the engine is above expected setpoint for given Exhaust Gas Recirculation Valve
(EGRV) position.
Lamp Reaction
Associated Faults

SPN 2623 SPN 2791 SPN 5298
Fault Facts
None

Road Test
Possible Causes
• Failed EGRV
• Internal coolant leak
• Soot build up in EGR cooler

®
2659 FMI 18.

SPN 2659 FMI 18.
18.

18.

Perform VGT Position Test (page 1991). Yes: Go to step 6.
Did VGT meet commanded position and did no fault codes set during test? No: Go to Step 9.
Step 6 Inspect cold side of EGR cooler for soot build up. Decision
A. Remove EGR cooler gas outlet hose from front of EGR cooler (see Engine Service Yes: Go to Step 7.
manual).
B. Inspect EGR cooler outlet for signs of carbon or soot build up inside the EGR cooler.
Is EGR cooler exhaust gas outlet free of soot build up? No: Replace EGR
2659 FMI 18.
Step 7 Inspect Exhaust Gas Recirculation Valve (EGRV) for soot build up. Decision
A. Remove EGR cooler bellow tubes (see Engine Service manual). Yes: Go to step 8.
B. Inspect EGRV butterfly, shaft and bore for soot build up blocking EGRV movement.
Is EGRV butterfly, shaft, and bore free of soot build up? No: Replace EGRV. After
18.
Step 8 Inspect EGR cooler inlet for soot build up. Decision
With EGR cooler bellow tubes removed, inspect exhaust gas inlet for signs of soot build up. Yes: End diagnostics.
18.
Is EGR cooler exhaust gas inlet free of soot build up? No: Replace EGR
2659 FMI 18.

18.

18.
back to open.
connector.
SPN 2659 FMI 18.

SPN 2791 FMI 2 - Engine Exhaust Gas Recirculation 1 Valve 1 Control 1 : Data Erratic, Intermittent
Or Incorrect
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Gas Recirculation Valve (EGRV) internal
circuit failure.
Lamp Reaction
Associated Faults
• SPN 2791 FMI 3, 4, 12

and 19
Fault Facts
None

Continuous
Possible Causes
• Failed EGRV
Step 1 Check for Associated Fault codes Decision

®
for SPN 4752 FMI 4.

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostic Software, check Yes: Go to step 3
1940).
Step 3 Inspect connector and terminals. Decision

B. Disconnect Exhaust Gas Recirculation Valve (EGRV).
C. Check EGRV and connector terminals for: damaged or pinched wires; wet
housing.
Are EGRV connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
2791 FMI 2.
Step 4 Verify Exhaust Gas Recirculation Valve (EGRV) can meet commanded Decision
Position.
Perform EGR Valve Position Test (page 1989). Yes: End diagnosics. Retest for
SPN 2791 FMI 2.
Does EGRV meet commanded position? No: Replace EGRV. After repairs
2791 FMI 2.

SPN 2791 FMI 3 - Engine Exhaust Gas Recirculation 1 Valve 1 Control 1 : Voltage Above Normal,
Fault Overview
Fault code sets when Engine Control Module (ECM) detects voltage supplied to Engine Gas Recirculation Valve
(EGRV) is greater than normal operating range.
Lamp Reaction
Associated Faults
• SPN 158 FMI 15 (ECM) • SPN 2791 FMI 19 (EGR) • SPN 3598 (ECM)
Fault Facts
None

Continuous
Possible Causes
• Excessive charging voltage
• Incorrect battery pack wiring
• Failed EGRV

check for Associated Faults (page 975).
for SPN 2791 FMI 3.

(page 1940).
Step 3 Inspect connections at Engine Gas Recirculation Valve (EGRV) Decision

connector.
B. Disconnect EGRV connector.
C. Check EGRV and connector terminals for: damaged or pinched wires;
connector housing.
2791 FMI 3.
Step 4 Check battery pack wiring. Decision

Check for correct parallel battery pack wiring. Check positive battery cable(s) Yes: Go to Step 5.
connected from positive battery terminal to positive 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.
for SPN 2791 FMI 3.
Step 5 Check EGRV PWR circuit for high voltage. Decision

Perform Test 1 (page 978). Use DMM, measure voltage between Breakout Harness Yes: Perform Electrical System
ZTSE4948 pin-4 and known good GND. Test (page 2065). If charging
system fails, replace alternator.
for SPN 2791 FMI 3.
Is voltage greater than 18 volts? No: Replace EGRV. After repairs
2791 FMI 3.

Tools Required
Test 1
A. Key OFF.
B. Connect Breakout Harness ZTSE4948 to vehicle harness and leave Engine Gas Recirculation Valve (EGRV)
C. Start engine and allow it to idle.

SPN 2791 FMI 4 - Engine Exhaust Gas Recirculation 1 Valve 1 Control 1 : Voltage Below Normal,
Fault Overview
Fault code sets when Engine Control Module (ECM) detects voltage supply to Engine Gas Recirculation Valve
(EGRV) is less than normal operating range.
Lamp Reaction
Associated Faults
SPN 158 FMI 17 SPN 2791 FMI 19 SPN 3598
Fault Facts
Verify batteries are fully charged and that terminals are clean and in good condition.

Continuous
Possible Causes
• ECM PWR Out circuit Open or short to GND
• EGRV GND circuit Open or high resistance
• Starting or Charging system failure

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check for Yes: Go to Step 2.
for SPN 2791 FMI 4.

(page 1940).

Interview operator or customer and(or) review the initial write up. View the freeze Yes: Perform Batteries and
frame data for this SPN 2791 FMI 4 in EST with Navistar® Engine Diagnostics. Electrical System Inspection
(page 2198) and Electrical
System Test (page 2065). Repair
or replace failed components
as needed. After repairs are
FMI 4.
Is “V: Switch Battery” greater than 16 Volts or less than 8 Volts in the Freeze Frame No: Go to Step 4.
data, or is it possible the engine was cranked when battery voltage dropped below
8 Volts?

connector.
connector housing.
2791 FMI 4.
Step 5 Check for Open or short to GND in PWR circuit. Decision

ZTSE4948 pin-4 and know good GND. resistance between EGRV pin-3
FMI 4.
Is voltage B+ ± 0.5 volts No: Repair Open or short to
GND between EGRV pin-4 and
ECM pin E1-01 and E1-02. After
SPN 2791 FMI 4.


Tools Required
• Digital Multimeter (DMM) Interface cable (RP1210B-compliant supporting J1939 and J1708)
Test 1
A. Key OFF.
B. Connect Breakout Harness ZTSE4948 to vehicle harness and leave Engine Gas Recirculation Valve (EGRV)
C. Key ON.
SPN 2791 FMI 7 - Engine Exhaust Gas Recirculation 1 Valve 1 Control 1 : Mechanical System Not
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Gas Recirculation Valve (EGRV) motor
varies from command by greater than 44 steps.
Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected in two consecutive drive cycles.
Associated Faults
SPN 2791 FMI 3, 4, and 19
Fault Facts
None.

Road Test
Possible Causes
• Failed EGRV

®
for Associated Faults (page 983).
for SPN 2791 FMI 7.
Step 2 Verify Engine Gas Recirculation Valve (EGRV) can meet commanded Decision
Position.
Perform EGR Valve Position Test (page 1989). Yes: End Diagnostics. Retest for
SPN 2791 FMI 7.
2791 FMI 7.

SPN 2791 FMI 12 - Engine Exhaust Gas Recirculation 1 Valve 1 Control 1 : Bad Intelligent Device
Or Component
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Engine Gas Recirculation Valve (EGRV) motor
varies from command by greater than 44 steps in Cold Start Emissions Reduction (CSER) mode.
Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected in two consecutive drive cycles.
Associated Faults
SPN 2791 FMI 3, 4 and 19
Fault Facts
None.

Road Test
Possible Causes
• Failed EGRV

®
for Associated Faults (page 985).
Step 2 Verify Engine Gas Recirculation Valve (EGRV) can meet commanded Decision
Position.
Perform EGR Valve Position Test (page 1989). Yes: End Diagnostics. Retest for
SPN 2791 FMI 12.
2791 FMI 12.

SPN 2791 FMI 19 - Engine Exhaust Gas Recirculation 1 Valve 1 Control 1 : Received Network Data In
Error
Fault Overview
Fault code sets when Engine Control Module (ECM) does Not detect Exhaust Gas Recirculation Valve (EGRV)
on J1939 CAN data link communications network.
Lamp Reaction
Associated Faults
SPN 3598 FMI 3 and 4 SPN 641 FMI 19 SPN 1761 FMI 19 SPN 3216 FMI 19
SPN 5835 FMI 19
Fault Facts

Continuous
Possible Causes
• ECM PWR OUT 2 circuit Open or short to GND
• EGRV GND circuit Open or high resistance
• CAN_H circuit Open
• CAN_H circuit short to GND
• CAN_H circuit short to PWR
• CAN_L circuit Open
• CAN_L circuit short to GND
• CAN_L circuit short to PWR
• CAN_H shorted to CAN_L
• Failed EGRV

®
Is EST DTC list free of Associated FMI 19 communication faults? No: Repair Private CAN circuit,

Is EST DTC list free of SPN 3598 FMI 3 or 4? No: Repair SPN 3598 FMI 3 or 4.

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostic Software, Key Yes: Go to Step 4.
(page 1940).
Step 4 Inspect connector and terminals. Decision

B. Disconnect Exhaust Gas Recirculation Valve (EGRV) sensor module.
C. Check EGRV sensor module and connector terminals for: damaged or
Are EGRV sensor module connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
2791 FMI 19.
Step 5 Check voltage to EGRV. Decision

Step 6 Check ECM PWR OUT 3 circuit for Open or short to ground. Decision
ZTSE4948 pin-4 and known good GND. resistance between EGRV pin-3
FMI 19.
resistance between EGRV pin-4
and ECM pin E1-01 and E1-02.

Is voltage greater than 2 volts? No: Repair Open or short to
EGRV pin-2 and all other Private
Module, VGTA, NOx IN sensor
SPN 2791 FMI 19.

CAN-L circuit between EGRV
SPN 2791 FMI 19.

EGRV pin-1 and all other Private
SPN 2791 FMI 19.

CAN-H circuit between EGRV
SPN 2791 FMI 19.

Perform Test 5 (page 993). Use DMM, measure resistance between Breakout Yes: Replace EGRV. After
Harness ZTSE4948 pin-1 and pin-2. repairs are complete, retest for
SPN 2791 FMI 19.
Is resistance 55 to 65 ohms? No: Repair short between EGRV
pin-1 and pin-2. After repairs are
FMI 19.


Tools Required
Figure 340 EGRV Voltage Check
Test 1
A. Key OFF.
B. Connect Breakout Harness ZTSE4948 to engine harness and leave Exhaust Gas Recirculation Valve (EGRV)
disconnected.
C. Key ON.
Figure 341 ECM PWR Out 3 Circuit Check
Test 2
A. Key OFF.
B. Connect Breakout Harness ZTSE4948 to engine harness and leave EGRV disconnected.
C. Key ON.
Test 3
A. Key OFF.
C. Key ON.
Test 4
A. Key OFF.
C. Key ON.
Figure 344 CAN Circuit Check
Test 5
A. Key OFF.
SPN 2797 FMI 11 - Engine Fuel 1 Injector Group 1 : Root Cause Not Known
Fault Overview
Fault codes sets when Engine Control Module (ECM) detects a short in fuel injector (INJ) 1, 2, or 3 circuits.
Lamp Reaction
Associated Faults
SPN 651 FMI 3, 4 and 5 SPN 652 FMI 3, 4 and 5 SPN 653 FMI 3, 4 and 5

Continuous.
Fault Facts
None.
Possible Causes
• INJ1 H short to INJ1 L
• Fuel injector 1 wiring terminals shorted to engine brake housing

Step 2 Inspect UVC harness and connections at fuel injectors under valve Decision
cover.
Manual).
SPN 2797 FMI 11.
C. Disconnect fuel injector connectors.
D. Check fuel injectors and connector terminals for: damaged or pinched
Step 3 Verify proper fuel injector wire terminal orientation. Decision

Remove upper valve cover and engine brake housing (see Engine Service Manual). Yes: Go to Step 4.
Verify fuel injector terminals are installed parallel so they do not short to ground on
engine brake housings or other components.
Are fuel injector wire terminals oriented correctly and Not contacting engine brake No: Adjust connections so fuel
housing? injectors wire terminals will not
contact engine brake housing.

B. Disconnect fuel injector 1 wiring terminals

C. Use Digital Multimeter (DMM), measure resistance across fuel injector
1 H and L terminals.


C. Use DMM, measure resistance across fuel injector 2 H and L terminals.

Step 7 Check fuel injector 1 H terminal for short to GND. Decision


C. Use DMM, measure resistance between fuel injector 1 H terminal and GND.
Is resistance greater than 10,000 ohms? No: Replace fuel injector 1
Step 8 Check fuel injector 1 L terminal for short to GND. Decision

C. Use DMM, measure resistance between fuel injector 1 L terminal and GND.




Step 13 Inspect connections at Engine Control Module (ECM) E2 connector. Decision

connector housing.
2797 FMI 11.
Step 14 Check for INJ1 H short to INJ1 L. Decision

Is resistance greater than 1000 ohms? No: Repair INJ1 H short to INJ1
L. After repairs are complete,



pin E2-05 and known good GND (wiggle test may be required).
FMI 11.
Step 18 Check INJ1 L circuit for short to GND. Decision

Is resistance greater than 1000 ohms? No: Repair short to GND between
ECM pin E2-12 and fuel injector




pin E2-13 and a known good GND (wiggle test may be required).
ECM pin E2-13 and fuel injector 3.
Step 23 Check INJ1 H circuit for short to PWR. Decision

Perform Test 10 (page 1011). Use DMM, measure voltage between Breakout Box Yes: Go to Step 24.
Is voltage less than 0.5 volts? No: Repair short to PWR between
ECM pin E2-05 and fuel injector 1.
Step 24 Check INJ1 L circuit for short to PWR. Decision

Is voltage less than 0.5 Volts? No: Repair short to PWR between

FMI 11.

FMI 11.

FMI 11.

Perform Test 15 (page 1017). Use DMM, measure voltage between Breakout Box Yes: End diagnostics. Retest for
pin E2-13 and known good GND (wiggle test may be required). SPN 2797 FMI 11.
FMI 11.

Pin-Point Test
Figure 345 Fuel Injector Circuit Diagram
Tools Required
Test 1
A. Key OFF.
B. Disconnect fuel injector 1 wiring terminals.
C. Connect Breakout Harness 00-01468-00 to 180-pin Breakout Box 00-00956-08.
D. Connect Breakout Harness 00-01468-00 to vehicle harness and leave ECM disconnected.
Test 2
A. Key OFF.
Test 3
A. Key OFF.
Test 4
A. Key OFF.
Test 5
A. Key OFF.
Test 6
A. Key OFF.
Test 7
A. Key OFF.
Test 8
A. Key OFF.
Test 9
A. Key OFF.
Test 10
A. Key OFF.
E. Key On, Engine Off (KOEO).
Test 11
A. Key OFF.
E. KOEO.
Test 12
A. Key OFF.
E. KOEO.
Test 13
A. Key OFF.
E. KOEO.
Test 14
A. Key OFF.
E. KOEO.
Test 14
A. Key OFF.
E. KOEO.
SPN 2798 FMI 8 - Engine Fuel 1 Injector Group 2 : Abnormal Frequency Or Pulse Width Or Period
Fault Overview
Fault codes sets Engine Control Module (ECM) detects a irregular shut off of the post injection cycle.
Lamp Reaction
Associated Faults
SPN 157 SPN 651 - 656 SPN 2797 FMI 11 SPN 2798 FMI 11
Fault Facts
None.

Continuous.
Possible Causes
• Loose or damaged fuel system electrical connector
• Fuel system failure
• Failed fuel injector

®
for SPN 2798 FMI 8.
for SPN 2798 FMI 8.

SPN 2798 FMI 8.
connector housing.
2798 FMI 8.
Step 5 Inspect connections at Engine Fuel Actuator 1 (EFA1) on high-pressure Decision

fuel pump.

connector housing.
2798 FMI 8.

fuel rail.
connector housing.
2798 FMI 8.
Step 7 Check for failed fuel injectors. Decision

Perform Multiple Cylinder Cutout Test (page 2018), manually cutting out 5 cylinders Yes: Go to Step 8.
at a time.
Do all 6 cylinders hold desired RPM independently during testing? No: Replace failed fuel injectors
indicated by test and perform
Injector Quantity Adjustment
(IQA) (page 1941). After repairs
2798 FMI 8.
Step 8 Identify an under or over fueling fuel injector. Decision

for SPN 2798 FMI 8.

Perform Valve Train Inspection (page 2188). Yes: Go to Step 11.
Did all valve train component(s) pass inspection? No: Go to Step 10.
Step 10 Verify fallen valve bridge did not damage valves, valve keepers, or valve Decision
stems.
Reinstall valve bridge and adjust lash (see Engine Service Manual). Verify engine Yes: Repair engine mechanical
can be rotated by hand. failure (see Engine Service
SPN 2798 FMI 8.
Was there valve damage or was engine Not able to be rotated by hand? No: Go to Step 12.

Remove oil pan and inspect cylinders for damage: such as bent rods, damage Yes: Repair damaged cylinders
to engine block, and/or engine sleeves. (see Engine Service Manual).
for SPN 2978 FMI 8.
Are any cylinders damaged? No: Go to Step 12.

Remove cylinder head and inspect cylinder(s) identified by Cylinder Balance Test for Yes: Clean and inspect Cylinder
a loss of compression. Such as bent valves, stuck rings, or a blown head gasket. head for reuse (see Engine
2798 FMI 8.
Is cylinder head and cylinders free of damage? No: Repair cylinder head and
cylinder damage (see Engine
2798 FMI 8.

SPN 2798 FMI 11 - Engine Fuel 1 Injector Group 2 : Root Cause Not Known
Fault Overview
Fault codes sets Engine Control Module (ECM) detects a short in fuel injector (INJ) 4, 5, or 6 circuit.
Lamp Reaction
Associated Faults
• SPN 654 FMI 3, 4 and 5 • SPN 655 FMI 3, 4 and 5 • SPN 656 FMI 3, 4 and 5
Fault Facts
None.

Continuous.
Possible Causes
• Fuel injector 4 shorted to engine brake housing

Step 2 Inspect UVC harness and connections at fuel injectors under valve Decision
cover.
Manual).
SPN 2798 FMI 11.
C. Disconnect fuel injector connectors.
D. Check fuel injectors and connector terminals for: damaged or pinched
Step 3 Verify proper fuel injector wire terminal orientation. Decision

Remove upper valve cover and engine brake housing (see Engine Service Manual). Yes: Go to Step 4.
Verify fuel injector terminals are installed parallel so they do not short to ground on
engine brake housings or other components.
Are fuel injector wire terminals oriented correctly and Not contacting engine brake No: Adjust connections so fuel
housing? injectors wire terminals will not
contact engine brake housing.


C. Use Digital Multimeter (DMM), measure resistance across fuel injector
4 H and L terminals.






Is resistance greater than 10,000 ohms? No: Replace fuel injector 4 and
IQA Adjustment Procedure (page
FMI 11.




Step 13 Inspect connections at Engine Control Module (ECM) E2 connector. Decision

connector housing.
2798 FMI 11.




FMI 11.

FMI 11.

FMI 11.


Perform Test 8 (page 1037). Use DMM measure resistance between Breakout Box Yes: Go to Step 22.


FMI 11.

FMI 11.

FMI 11.

FMI 11.

FMI 11.

Perform Test 15 (page 1045). Use DMM, measure voltage between Breakout Box Yes: End diagnostics. Retest for
pin E2-16 and known good GND (wiggle test may be required). SPN 2797 FMI 11.
FMI 11.

Figure 361 Fuel Injector Circuit Diagram
Tools Required
Test 1
A. Key OFF.
Test 2
A. Key OFF.
Test 3
A. Key OFF.
Test 4
A. Key OFF.
Test 5
A. Key OFF.
Test 6
A. Key OFF.
Test 7
A. Key OFF.
Test 8
A. Key OFF.
Test 9
A. Key OFF.
Test 10
A. Key OFF.
E. Key On Engine Off (KOEO).
Test 11
A. Key OFF.
E. KOEO.
Test 12
A. Key OFF.
E. KOEO.
E2-15
0000415214
Test 13
A. Key OFF.
E. KOEO.
Test 14
A. Key OFF.
E. KOEO.
E2-16
0000415215
Test 14
A. Key OFF.
E. KOEO.
SPN 3031 FMI 2 - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature 1 : Data Erratic, Intermittent
Or Incorrect
Fault Overview
Fault code sets when Engine Control Module (ECM) detects difference between Diesel Exhaust Fluid
Temperature (DEFT) Sensor and Intake Manifold Temperature (IMT) Sensor or Engine Coolant Temperature
1 (ECT1) Sensor is more than 72°F (40°C) at initial Key ON after engine has been shut down more than eight
hours.
Lamp Reaction
Associated Faults
SPN 105 SPN 110 SPN 1769 FMI 19 SPN 3031 FMI 3 and 4
SPN 3516 FMI 19
Fault Facts

Road Test
Possible Causes
• Block heater or auxiliary coolant heater being used

®
Key-On, check Diagnostic Trouble Code (DTC) list for Associated Faults (page
1046).
for SPN 3031 FMI 2.
Step 2 Check for Block Heater, Auxiliary Power Unit (APU) or other Auxiliary Decision
coolant heaters being used.
Review customer complaint, interview vehicle operator and view fault code freeze Yes: Clear fault code after all
frame data. other faults have been diagnosed
and repaired.
Was fault code set after using a Block heater, Auxiliary Power Unit (APU) or other No: Replace DEF head unit.
Auxiliary coolant heater overnight? After repairs are complete, retest
for SPN 3031 FMI 2.

SPN 3031 FMI 3 - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature 1 : Voltage Above Normal,
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Exhaust Fluid Temperature (DEFT) Sensor
signal is shorted to PWR.
Lamp Reaction
Associated Faults
SPN 1761 FMI 19 SPN 3516 FMI 19
Fault Facts

Continuous
Possible Causes

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key-On, check Yes: Go to Step 2.
for SPN 3031 FMI 3.
Step 2 Check for active fault code Decision

Key-On, check Diagnostic Trouble Codes (DTC) list for SPN 3031 FMI 3.
Is SPN 3031 FMI 3 active? No: Repair other active codes
for SPN 3031 FMI 3.
Step 3 Inspect connections at Diesel Exhaust Fluid head unit. Decision

C. Check DEF head unit and connector terminals for: damaged or pinched Request (page 1955) and retest
wires; wet or corroded terminals; loose, bent, or broken pins; or broken for SPN 3031 FMI 3.
connector housing.

SPN 3031 FMI 4 - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature 1 : Voltage Below Normal,
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Exhaust Fluid Temperature (DEFT) Sensor
signal is shorted to GND.
Lamp Reaction
Associated Faults
SPN 1761 FMI 19 SPN 3516 FMI 19
Fault Facts

Continuous
Possible Causes

®
Key-On, check Diagnostic Trouble Codes (DTC) list for Associated Faults (page
1050)
for SPN 3031 FMI 4.

for SPN 3031 FMI 4.
Step 3 Inspect connections at Diesel Exhaust Fluid Head Unit. Decision

A. Key OFF. Yes: Replace DEF Head Unit.
C. Check DEF head unit and connector terminals for: damaged or pinched Request (page 1955) and retest
wires; wet or corroded terminals; loose, bent, or broken pins; or broken for SPN 3031 FMI 4.
connector housing.

SPN 3031 FMI 13 - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature 1 : Out Of Calibration
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Exhaust Fluid Tank Temperature (DEFTT)
sensor module is out of calibration.
Lamp Reaction
Associated Faults
SPN 1761 FMI 19 SPN 3516 FMI 19
Fault Facts

Road Test
Possible Causes
• Incorrect DEF head unit installed

®

C. Check DEF head unit and connector terminals for damaged or pinched
housing.
Are DEF head unit connector, harness, and terminal clean and undamaged? No: Repair connector, harness,
3031 FMI 13.
Step 3 Check for correct DEF head unit. Decision

Use Parts catalog to verify correct DEF head unit is installed. Yes: Ensure ECM calibration
is current, then retest for SPN
3031 FMI 13.
Is correct DEF head unit installed? No: Install correct DEF head
unit. After repairs are complete,

SPN 3031 FMI 20 - Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature 1 : Data Drifted High
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Exhaust Fluid Tank Temperature (DEFTT)
is above a excessively high threshold.
Lamp Reaction
Associated Faults
SPN 1761 FMI 19 SPN 3031 FMI 2 and 19 SPN 3516 FMI 3, 4 and 19 SPN 3363
Fault Facts

Road Test
Possible Causes
• DEF Tank Coolant lines improperly routed
• DEFTHV improperly installed

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key-On, check Yes: Go to Step 2.

Step 3 Inspect connections at Diesel Exhaust Fluid head unit. Decision

connector housing.
3031 FMI 20.
Step 4 Check DEF quality and for debris. Decision

Perform DEF Quality Test (page 2228). Yes: Go to Step 5.
Is urea concentration between 30 and 34% and free of any debris? No: Drain DEF tank, flush with
distilled water, and fill with new
and / or known good DEF.
Confirm DEF concentration is
between 30 and 34% and go to
Step 5.
Step 5 Check DEF Tank Coolant lines for proper routing. Decision
Check DEF tank coolant lines routing for reverse flow. Flow from the engine should Yes: Go to Step 6.
go through the DEF Tank Heater Valve, DEF head unit, DEF supply module and
back to the engine.
Are DEF coolant lines routed correctly? No: Route coolant lines properly
to restore correct coolant flow
through DEF system. After
SPN 3031 FMI 20.
Step 6 Check for proper installation of DEFTHV. Decision

Verify that DEFTHV is installed correctly and coolant supply flow arrow is facing Yes: Replace DEF head unit.
inlet of DEF head unit. After repairs are complete, retest
Is DEFTHV installed correctly? No: Reposition DEFTHV. After
SPN 3031 FMI 20.

SPN 3061 FMI 31 - Engine Cold Start Emission Reduction Strategy System Monitor : Condition Exists
Fault Overview
Fault code sets when Engine Control Module (ECM) detects engine failed to warm-up during Cold Start
Emissions Reduction (CSER) monitoring period.
Lamp Reaction
Associated Faults
SPN 105 FMI 2, 3, and 4 SPN 157 SPN 171 FMI 2, 3, and 4 SPN 641
SPN 1659 SPN 2791 SPN 4228
Fault Facts
None.

Road Test
Possible Causes
• Auxiliary coolant heater or block heater installed


SPN 3061 FMI 31.
Does EST list SPN 3061 FMI 31 active or pending? No: Repair all other active faults.

Perform VGT Position Test (page 1991). Yes: End diagnostics, retest for
SPN 3061 FMI 31.
Does VGT approximately meet commanded position and were no fault codes set No: Go to Step 4.
during test?

D. Manually move VGT Actuator from fully open to fully closed and back to
open.

A. Key OFF. VGT Actuator connector and linkage still disconnected. Yes: End diagnostics, retest for
SPN 3061 FMI 31.
actuator connector.
FMI 31.

SPN 3216 FMI 2 - Aftertreatment 1 SCR Intake NOx 1 : Data Erratic, Intermittent or Incorrect
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Nitrogen Oxides In (NOxIN) sensor output is
in range, but is not changing with engine conditions.
Lamp Reaction
Associated Faults
SPN 3216 FMI 19 (NOx IN)
Fault Facts
Verify batteries are fully charged and connections are clean before performing step-based diagnostics.

Continuous
Possible Causes
• Failed NOx IN sensor module
• AFTSS PWR circuit Open or short to GND
• GND circuit Open or high resistance
• AFT Power Distribution Module (AFT PDM) loose fuse or relay

®
for SPN 3216 FMI 2.
Step 2 Check Aftertreatment Power Distribution Module (AFT PDM) fuse(s) Decision
and relay(s).
Check AFT PDM fuse(s) and relay(s) for blown fuses; loose, missing, or intermittent Yes: Go to Step 3.
connections.
fuse(s) or relay(s) to AFT PDM
FMI 2.
Step 3 Inspect connections at Nitrogen Oxides In (NOxIN) sensor module Decision

connector.
A. Key-Off. Yes: Go to Step 4.
B. Disconnect NOx IN connector.
C. Check NOx IN connector and connector terminals for: damaged or
Are NOx IN connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
FMI 2.
Step 4 Check voltage to NOx IN sensor module. Decision

A. Perform Test 1 (page 1062). Yes: Replace NOx IN sensor
B. Use Digital Multimeter (DMM), measure voltage between Breakout
Harness 18-648-01 pin-1 and pin-4.
2.
Step 5 Check AFTSS PWR circuit for Open or short to ground. Decision
A. Perform Test 2 (page 1062). Yes: Repair Open or high
resistance between NOx IN sensor
B. Use DMM, measure voltage between Breakout Harness 18-648-01 pin-1
module pin-4 and GND. After
and known good GND.
SPN 3216 FMI 2.
Is voltage B+ ± 0.5 volts? No: Repair Open or short to
ground between NOx IN sensor
module connector pin-1 and AFT
Smart Sensor Relay pin-87. After
SPN 3216 FMI 2.


Tools Required
Figure 377 NOx IN Sensor Module Circuit Check
Test 1
A. Key-Off.
B. Disconnect Nitrogen Oxides In (NOxIN) sensor module.
C. Connect Breakout Harness 18-648-01 between vehicle harness and leave NOx IN sensor module disconnected.
D. Key-On Engine-Off (KOEO).
Figure 378 AFTSS PWR Circuit Check
Test 2
A. Key-Off.
B. Disconnect Nitrogen Oxides In (NOxIN) sensor module.
C. Connect Breakout Harness 18-648-01 between vehicle harness and leave NOx IN sensor module disconnected.
SPN 3216 FMI 4 - Aftertreatment 1 SCR Intake NOx 1 : Voltage Below Normal, or Shorted to Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects an internal circuit error is detected in Nitrogen
Oxides In (NOxIN) sensor module. Diesel Exhaust Fluid (DEF) injection into aftertreatment system is disabled,
and engine torque is severely reduced.
Lamp Reaction
Associated Faults
SPN 3216 FMI 19 (NOx IN) SPN 3218 FMI 2 (NOx IN)
Fault Facts
None

Road Test
Possible Causes

3216 FMI 4.
A. Key-Off. Yes: Replace NOx IN sensor
C. Check NOx IN sensor module and connector terminals for: damaged or Reset Request (page 1955), retest
pinched wires; wet or corroded terminals; loose, bent, or broken pins; or for SPN 3216 FMI 4.
Reset Request (page 1955), retest
for SPN 3216 FMI 4.

SPN 3216 FMI 10 - Aftertreatment 1 SCR Intake NOx 1 : Abnormal Rate Of Change
Fault Overview
Fault code sets when Nitrogen Oxides In (NOxIN) sensor module reading is invalid.
Lamp Reaction
Associated Faults
Fault Facts
None

Road Test
Possible Causes
• Failed NOx IN Sensor Module

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics. Key On, Yes: Go to Step 2.

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key On, Yes: Go to Step 3.
check Diagnostic Trouble Code (DTC) list for SPN 3216 FMI 10.
Step 3 Inspect connections at Nitrogen Oxide (NOx) IN Sensor Module Decision

A. Key Off. Yes: Replace NOx IN Sensor
Module. After repairs are
B. Disconnect NOx IN Sensor Module connector.

C. Check NOx IN Senor Module and connector terminals for: damaged or FMI 10.
pinched wires; moisture or corroded terminals; loose, bent, or broken
Are NOx IN Sensor Module connector, harness, and terminals clean and No: Repair connector, harness,
FMI 10.

SPN 3216 FMI 13 - Aftertreatment 1 SCR Intake NOx 1 : Out Of Calibration
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Nitrogen Oxides In (NOxIN) sensor Module voltage
rating does not match engine's electrical system voltage.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Incorrect NOx IN sensor module installed

®
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 3216
FMI 13.
1940).
Step 2 Check for correct Nitrogen Oxides Inlet (NOx IN) sensor module. Decision
Verify correct NOx IN sensor module is installed. Yes: Replace NOx IN sensor
FMI 13.
Is correct NOx IN sensor module installed? No: Install correct NOx IN
sensor module. After repairs are
FMI 13.

SPN 3216 FMI 16 - Aftertreatment 1 SCR Intake NOx 1 : Data Valid But Above Normal Operating Range -
Fault Overview
This fault code sets when Engine Control Module (ECM) determines Nitrogen Oxides In (NOxIN) sensor signal
is in-range, but reading high during monitoring conditions.
Lamp Reaction
Associated Faults
SPN 641 SPN 2791 SPN 3216 FMI 19 SPN 3218 FMI 2
Fault Facts
None

Road Test
Possible Causes

®
1070).

Key-On, check Diagnostic Trouble Code (DTC) list for SPN 3216 FMI 16.
Does EST list SPN 3216 FMI 16 active? No: Repair all other active faults.

A. Key-Off. Yes: Replace NOx IN Sensor
FMI 16.

SPN 3216 FMI 18 - Aftertreatment 1 SCR Intake NOx 1 : Data Valid But Below Normal Operating Range -
Fault Overview
This fault code sets when Engine Control Module (ECM) determines Nitrogen Oxides In (NOxIN) sensor signal
is in-range, but reading low during monitoring conditions.
Lamp Reaction
Associated Faults
Fault Facts
None

Road Test
Possible Causes

®
1072).


A. Key-Off. Yes: Replace NOx IN Sensor
FMI 18.

SPN 3216 FMI 19 - Aftertreatment 1 SCR Intake NOx 1 : Received Network Data In Error
Fault Overview
Fault code sets when Engine Control Module (ECM) loses J1939 data link communications with Nitrogen Oxides
In (NOxIN) sensor module. Diesel exhaust Fluid (DEF) injection into aftertreatment system is disabled, and
engine torque will be severely reduced.
Lamp Reaction
Associated Faults
Fault Facts

Continuous
Possible Causes
• AFTSS PWR circuit short to GND or Open
• CAN-H circuit Open or short to GND
• CAN-L circuit Open or short to GND

®
After repairs are complete, perform
SCR Fault Reset Request(page
FMI 19.

(page 1955)and retest for SPN
3216 FMI 19.
C. Check NOx IN sensor module and connector terminals for: damaged or
Reset Request (page 1955)and

and pin-4.
resistance between NOx IN sensor
module pin-4 and GND. After
and known good GND.
1955)and retest for SPN 3216 FMI
19.
ground between NOx IN sensor
module connector pin-1 and AFT
Fault Reset Request (page 1955)

and known good GND.
Is voltage greater than 2 volts? No: Repair Open or short to GND
on CAN-H circuit between NOx IN
sensor module pin-3 and all other
Private CAN modules (VGTA,
DEF Tank Sensor Module, EGRV,
NOx OUT sensor module, PM
sensor module and AFT Temp
sensor module). After repairs

and known good GND.
Is voltage less than 3 volts? No: Repair short to power on
CAN-H circuit between NOx IN
sensor module). After repairs are
complete, perform SCR Fault Reset
Request (page 1955)and retest for
SPN 3216 FMI 19.

and known good GND.
ground on CAN-L circuit between
NOx IN sensor module pin-2 and
all other Private CAN modules
(VGTA, DEF Tank Sensor Module,
EGRV, NOx OUT sensor module,
PM sensor module and AFT Temp

and known good GND.
CAN-L circuit between NOx IN

A. Perform Test 5 (page 1082). Yes: Replace NOx IN sensor
B. Use DMM, measure resistance between Breakout Harness 18-648-01
pin-2 and pin-3.
Is resistance between 55 and 65 ohms? No: Repair short between NOx
IN sensor module connector
pin-2 and pin-3. After repairs


Tools Required
Figure 379 NOx IN Sensor Module Circuit Check
Test 1
A. Key-Off.
B. Disconnect Nitrogen Oxides In (NOxIN) sensor module
C. Connect Breakout Harness 18-648-01 to vehicle harness and leave Nitrogen Oxides In (NOxIN) sensor
module disconnected.
Test 2
A. Key-Off.
Test 3
A. Key-Off.
Test 4
A. Key-Off.
Figure 383 CAN-L and CAN-H Circuit Check
Test 5
A. Key-Off.
SPN 3217 FMI 2 - Aftertreatment 1 Intake Percent Oxygen 1 : Data Erratic, Intermittent Or Incorrect
Fault Overview
Fault code sets when Nitrogen Oxides In (NOxIN) sensor module detects the internal circuitry of the Internal
Oxygen sensor (O2S) has failed causing the sensor reading to be invalid.
Lamp Reaction
Associated Faults
Fault Facts
None

Continuous
Possible Causes

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics. Key On, Yes: Go to Step 2.
for SPN 3217 FMI 2.

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key On, Yes: Go to Step 3.
for SPN 3217 FMI 2.

A. Key Off. Yes: Replace NOx IN Sensor

FMI 2.

SPN 3218 FMI 2 - Aftertreatment 1 Intake Gas Sensor 1 Power In Range : Data Erratic, Intermittent
Or Incorrect
Fault Overview
Fault code sets when Engine Control Module (ECM) detects power supply to Nitrogen Oxides In (NOxIN) sensor
is too high or too low.
Lamp Reaction
Associated Faults
SPN 3216 FMI 19
Fault Facts
None

Continuous
Possible Causes
• AFTSS PWR circuit intermittent short to GND or open
• Aftertreatment Power Distribution Module (AFT PDM) loose fuse or relay
• Incorrect NOxIN sensor installed

®
ON, check Diagnostic Trouble Code (DTC) list for Associated Faults(page 1086).
Is EST DTC list clear of Associated Faults? No: Repair Associated Faults.
for SPN 3218 FMI 2.

ON, check Diagnostic Trouble Code (DTC) list for SPN 3218 FMI 2.
1940).
and relay(s)
B. Check AFT PDM fuse(s) and relay(s) for blown fuses; loose, missing,
or intermittent connections.
FMI 2.
Step 4 Inspect connections at Nitrogen Oxides In (NOxIN) sensor. Decision

B. Disconnect NOxIN sensor connector.
C. Check NOxIN sensor and connector terminals for damaged or pinched
housing.
Are NOxIN sensor, connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
FMI 2.
Step 5 Check voltage to NOxIN sensor module. Decision

and pin-4.
Step 6 Check AFTSS PWR circuit for open or short to ground. Decision
resistance between NOxIN
B. Use DMM, measure voltage between NOxIN sensor connector pin-1 and
sensor connector pin 4 and GND.
known good GND.
for SPN 3218 FMI 2.
Is voltage B+ ± 0.5 volts? No: Repair Open or short to GND
between NOxIN sensor connector
pin-1 and AFT Smart Sensor
Relay pin-87. After repairs are
FMI 2.
Step 7 Check for incorrect Nitrogen Oxides In (NOxIN) sensor installed. Decision
Check for incorrect NOxIN sensor installed. Yes: Check for intermittent
harness fault. Perform
Intermittent or Inactive Fault
Diagnostic Procedure (page
Is correct NOxIN sensor installed? No: Install correct NOxIN sensor.
for SPN 3218 FMI 2.

Pin-Point Tests SPN 3218 FMI 2

Tools Required
Figure 384 NOxIN Sensor Circuit Check
Test 1
A. Key-Off.
B. Disconnect NOxIN sensor.
C. Connect Breakout Harness 18-648-01 to vehicle harness connector and leave NOxIN sensor disconnected.

Figure 385 NOxIN Sensor Circuit Check
Test 2
A. Key-Off.
B. Disconnect NOxIN sensor.
C. Connect Breakout Harness 18-648-01 to vehicle harness connector and leave NOxIN sensor disconnected.
SPN 3226 FMI 2 - Aftertreatment 1 Outlet NOx 1 : Data Erratic, Intermittent or Incorrect
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Nitrogen Oxides (NOx) OUT sensor output is
in range, but is not changing with engine conditions.
Lamp Reaction
Associated Faults
SPN 3226 FMI 19
Fault Facts
Verify batteries are fully charged and connections are clean before performing step-based diagnostics.

Road Test
Possible Causes
• GND Circuit Open or high resistance
• AFTSS PWR Circuit Open or short to GND
• Failed NOx out sensor module

®
for SPN 3226 FMI 2.
and relay(s).
Check Aftertreatment Power Distribution Module (AFT PDM) fuse(s) and relay(s) for Yes: Go to Step 3.
FMI 2.
Step 3 Inspect Nitrogen Oxides (NOx) OUT sensor module and connector. Decision
B. Disconnect NOx OUT sensor module.
C. Check NOx OUT sensor and connector terminals for: damaged or pinched
connector housing.
Are NOx OUT sensor module connector, harness, and terminals clean and No: Repair connector, harness,
3226 FMI 2.
Step 4 Check voltage to NOx OUT sensor module. Decision

Perform Test 1(page 1094). Use DMM to measure voltage between Breakout Yes: Go to Step 6.
Perform Test 2(page 1094). Use DMM to measure voltage between Breakout Yes: Repair Open or high
Harness 18-649-01 pin-1 and known good GND. resistance between NOx OUT
sensor module pin-4 and GND.
for SPN 3226 FMI 2.
GND between NOx OUT sensor
module pin-1 and AFT Smart
Sensor Relay pin-87. After

SPN 3226 FMI 2.
Step 6 Check decomposition mixer for crystallization. Decision

Remove decomposition mixer from exhaust system (See appropriate Vehicle Yes: Clean decomposition mixer.
Technician Manual) and inspect for excessive DEF crystallization. After repairs are complete, retest
for SPN 3226 FMI 2.
Is excessive DEF crystallization present in decomposition mixer? No: Replace NOx OUT sensor
FMI 2.

SPN 3226 FMI 2 Pin-Point Test

Tools Required
Figure 386 NOx Out Sensor Module Circuit Check
Test 1
A. Key OFF.
B. Disconnect Nitrogen Oxides (NOx) OUT sensor module
C. Connect Breakout Harness 18-649-01 to vehicle harness and leave Nitrogen Oxides (NOx) OUT sensor
D. Key-ON, Engine-OFF (KOEO).
Figure 387 NOx Out Sensor Module Circuit Check
Test 2
A. Key OFF.
B. Disconnect Nitrogen Oxides (NOx) OUT sensor module
SPN 3226 FMI 4 - Aftertreatment 1 Outlet NOx 1 : Voltage Below Normal, Or Shorted To Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects an internal circuit error in Nitrogen Oxides (NOx)
Out Sensor Module. Engine torque will be reduced if engine is operated for limited period of time with fault code
active. Engine torque will be severely reduced and vehicle speed will be limited after extended engine operation
Lamp Reaction
Associated Faults
SPN 3226 FMI 19 SPN 3228 FMI 2
Fault Facts
None.

Road Test
Possible Causes
• Failed NOx Out Sensor Module

®
Perform SCR Fault Reset
Request (page 1955). After
SPN 3226 FMI 4.
Step 2 Inspect Nitrogen Oxides (NOx) Out Sensor Module and connector. Decision
A. Key OFF. Yes: Replace NOx Out Sensor
Module. Perform SCR Fault
B. Disconnect NOx Out Sensor Module.
Reset Request (page 1955).
C. Check NOx Out Sensor Module and connector terminals for: damaged or After repairs are complete, retest
pinched wires; wet or corroded terminals; loose, bent, or broken pins; or for SPN 3226 FMI 4.
Are NOx Out Sensor Module connector, harness, and terminals clean and No: Repair connector, harness,
undamaged? or terminal damage. Perform

SPN 3226 FMI 10 - Aftertreatment 1 Outlet NOx 1 : Abnormal Rate Of Change
Fault Overview
This fault code sets when Engine Control Module (ECM) detects that Nitrogen Oxides (NOx) Out Sensor Module
signal is invalid.
Lamp Reaction
Associated Faults
SPN 3226 FMI 19

Road Test
Possible Causes
• Failed NOx Out Sensor module

®
1098).

Step 3 Inspect connections at Nitrogen Oxide (NOx) Out Sensor Module Decision
A. Key-Off. Yes: Replace NOx Out Sensor
B. Disconnect NOx Out Sensor Module connector.
C. Check NOx Out Sensor Module and connector terminals for: damaged FMI 10.
FMI 10.

SPN 3226 FMI 11 - Aftertreatment 1 Outlet NOx 1 : Root Cause Not Known
Fault Overview
This fault code sets when Engine Control Module (ECM) detects that Nitrogen Oxides (Nox) Out Sensor Module
has an internal error.
Lamp Reaction
Associated Faults
SPN 3226 FMI 19
Fault Facts
None

Road Test
Possible Causes
• Failed Nox Out Sensor Module

®
1100).

C. Check NOx Out Senor Module and connector terminals for: damaged or FMI 11.
FMI 11.

SPN 3226 FMI 13 - Aftertreatment 1 Outlet NOx 1 : Out Of Calibration
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Nitrogen Oxides (NOx) OUT sensor module voltage
rating does not match engine's electrical system voltage.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Failed NOx OUT sensor module
• Incorrect NOx OUT sensor module installed

®
Engine-Off (KOEO), check Diagnostic Trouble Codes (DTC) list for SPN 3226
FMI 13.
(page 1940).
Step 2 Check for correct Nitrogen Oxides Outlet (NOx OUT) sensor module. Decision
Verify correct NOx OUT sensor module is installed. Yes: Replace NOx OUT sensor
FMI 13.
Is correct NOx OUT sensor module installed? No: Install correct NOx OUT
FMI 13.

SPN 3226 FMI 16 - Aftertreatment 1 Outlet NOx 1 - Data Valid But Above Normal Operating Range -
Fault Overview
This fault code sets when Engine Control Module (ECM) determines Nitrogen Oxides (NOx) Out Sensor signal
is in-range, but reading high during monitoring conditions.
Lamp Reaction
Associated Faults
Fault Facts
None

Road Test
Possible Causes

®
1104).

FMI 16.

SPN 3226 FMI 18 - Aftertreatment 1 Outlet NOx 1 : Data Valid But Below Normal Operating Range -
Fault Overview
This fault code sets when Engine Control Module (ECM) determines Nitrogen Oxides (NOx) Out Sensor signal
is in-range, but reading low during monitoring conditions.
Lamp Reaction
Associated Faults
Fault Facts
None

Road Test
Possible Causes

®
1106).

FMI 18.

SPN 3226 FMI 19 - Aftertreatment 1 Outlet NOx 1 : Received Network Data In Error
Fault Overview
Fault code sets when Engine Control Module (ECM) loses J1939 data link communications with Nitrogen Oxides
(NOx) OUT sensor module.
Lamp Reaction
Associated Faults
Fault Facts

Continuous
Possible Causes
• Failed Nitrogen Oxides (NOx) OUT sensor module

®


®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, check DTC list Yes: Go to Step 3.
are complete, Perform SCR
3226 FMI 19.
Step 3 Inspect Nitrogen Oxides (NOx) OUT sensor module and connector. Decision
B. Disconnect NOx OUT sensor module.
C. Check NOx OUT sensor module and connector terminals for: damaged or
Are NOx OUT sensor module connector, harness, and terminals clean and No: Repair connector, harness,
SCR Maintenance Reset
SPN 3226 FMI 19.
Step 4 Check voltage to NOx OUT sensor module. Decision

Perform Test 1(page 1112). Use DMM, measure voltage between Breakout Harness Yes: Go to Step 6.
18-649-01 pin-1 and pin-4.
Perform Test 2(page 1112). Use DMM, measure voltage between Breakout Harness Yes: Repair Open or high
18-649-01 pin-1 and known good GND. resistance between NOx OUT
sensor module pin-4 and ground.
Perform SCR Maintenance Reset
SPN 3226 FMI 19.
ground between NOx OUT
sensor module connector
Relay pin-30. Perform SCR

FMI 19.

18-649-01 pin-3 and known good GND.
Is voltage greater than 2 volt? No: Repair Open or short to GND
on CAN-H circuit between NOx
OUT sensor module pin-3 and
(VGTA, EGRV, NOx IN sensor
module, DEF Tank Sensor
Module, PM sensor module
and AFT Temp sensor module).
Perform SCR Maintenance
Reset Procedure (page 1955).

CAN-H circuit between NOx OUT
EGRV, NOx IN sensor module,
DEF Tank Sensor Module, PM
sensor module). Perform SCR
FMI 19.

Is voltage greater than 2 volts? No: Repair Open or short
to ground on CAN-L circuit
between NOx OUT sensor
module pin-2 and all other

FMI 19.

CAN-L circuit between NOx OUT
FMI 19.

Perform Test 5(page 1115). Use DMM, measure resistance between Breakout Yes: Replace NOx OUT
Harness 18-649-01 pin-2 and pin-3. sensor module. Perform SCR
FMI 19.
Is resistance between 55 and 65 ohms? No: Repair short between NOx
OUT sensor module connector
pin-2 and pin-3. Perform SCR
FMI 19.


Tools Required
Figure 388 NOx OUT Sensor Module Circuit Check
Test 1
A. Key OFF.
B. Disconnect Nitrogen Oxides (NOx) OUT sensor module.
Figure 389 SWBAT Circuit Check
Test 2
A. Key OFF.
C. Connect Breakout Harness 18-649-01 to engine harness and leave Nitrogen Oxides (NOx) OUT sensor
Test 3
A. Key OFF.
Test 4
A. Key OFF.
Figure 392 CAN-L and CAN-H Circuit Check
Test 5
A. Key OFF.
SPN 3228 FMI 2 - Aftertreatment 1 Outlet Gas Sensor 1 Power In Range : Data Erratic, Intermittent
Or Incorrect
Fault Overview
Fault code sets when Engine Control Module (ECM) detects power supply to Nitrogen Oxides Outlet (NOxOUT)
sensor is too high or too low.
Lamp Reaction
Associated Faults
SPN 3226 FMI 19
Fault Facts
None

Continuous
Possible Causes
• AFTSS PWR circuit intermittent short to GND or open
• Incorrect NOxOUT sensor installed

®
Using Electronic Service Tool (EST) with Navistar Engine Diagnostics, check Yes: Go to Step 2.
for SPN 3228 FMI 2.

1940).
Step 3 Check Aftertreatment Power Distribution Module ( AFT PDM) fuse(s) Decision
and relay(s)
B. Check AFT PDM fuse(s) and relay(s) for blown fuses; loose, missing,
or intermittent connections.
FMI 2.
Step 4 Inspect connections at Nitrogen Oxides Outlet (NOxOUT) sensor. Decision

B. Disconnect NOxOUT sensor.
C. Check NOxOUT sensor and connector terminals for damaged or pinched
housing.
Are NOxOUT sensor, connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
FMI 2.
Step 5 Check voltage to NOxOUT sensor module. Decision

and pin-4.
Step 6 Check AFTSS PWR circuit for open or short to ground. Decision
resistance between NOxOUT
sensor pin-4 and GND. After
and known good GND.
SPN 3228 FMI 2.
Is voltage B+ ± 0.5 volts? No: Repair Open or short to GND
between NOxOUT connector
FMI 2.
Step 7 Check for incorrect NOxOUT sensor installed. Decision

Check for incorrect NOxOUT sensor installed. Yes: Check for intermittent
harness fault. Perform
Intermittent or Inactive Fault
Diagnostic Procedure (page
Is correct NOxOUT sensor installed? No: Install correct NOxOUT
FMI 2.


Tools Required
Figure 393 NOxOUT Sensor Circuit Check
Test 1
A. Key-Off.
B. Disconnect Nitrogen Oxides Outlet (NOxOUT) sensor.

C. Connect breakout Harness 18-649-01 to vehicle harness connector and leave NOxOUT sensor disconnected.

Figure 394 NOxOUT Sensor Circuit Check
Test 2
A. Key-Off.
B. Disconnect NOxOUT sensor.
C. Connect breakout Harness 18-649-01 to vehicle harness connector and leave NOxOUT sensor disconnected.
SPN 3242 FMI 0 - Aftertreatment 1 Diesel Particulate Filter Intake Temperature : Data Valid But Above
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Particulate Filter Inlet Temperature (DPFIT)
reading is greater than critical limit.
Lamp Reaction
Associated Faults
SPN 731 SPN 1322-1328 FMI 31 SPN 2797 and 2798 FMI 11 SPN 3242 FMI 2, 3, and 4
SPN 5742 FMI 3, 4, 12, and SPN 5743 FMI 19
19
Fault Facts
If aftertreatment system has had excess fuel, oil, metal, or other contamination, inspect entire aftertreatment
system for causal damage before re-installing. Inspect for overheated aftertreatment components, cracked
exhaust system welds, leaking exhaust system seams, or other damage. This fault will go inactive after DPFIT
drops below warning limit, and will likely be inactive when vehicle is in shop. For this reason, these diagnostics
must be used for both active and inactive fault codes.

Road Test
Possible Causes
• Intake and / or charge air system leak
• Leaking fuel injector
• Fuel or engine oil leak to exhaust
• Leaking or stuck open Aftertreatment Hydrocarbon Doser (AFTHD)
• Leaking or stuck open Aftertreatment Fuel Enable Actuator (AFTFEA)
• Failed Aftertreatment temperature sensor module
• Failed valve train components
• Failed or soot loaded DOC and / or DPF
CAUTION:

®
for SPN 3242 FMI 0.
WARNING:
Step 3.
A. Using EST check Diagnostic Trouble Code (DTC) list. Yes: Perform DPF Replacement
Temperature (page 2263). After
• 55770, Max DPF Outlet Temperature – DOC Inlet Temperature SPN 3242 FMI 0.
Is SPN 3936 FMI 16 Active, or did any DPF Outlet Temperature go above 1550 No: Clear fault codes, Perform
°F (843 °C)? stationary DPF Regeneration
SPN 3242 FMI 0.
Step 4 Compare all Exhaust temperatures. Decision

Perform Hot Run Sensor Comparison Test (page 2267). Yes: Go to Step 5.
Is DOCIT, DPFIT, and DPFOT difference with in 77°F (43°C) of each other? No: Replace temperature sensor
FMI 0.

(compression loss).
mechanical damage. After
SPN 3242 FMI 0.


by Multiple Cylinder Cutout Test
(page 1941) procedure. After
SPN 3242 FMI 0.
complete retest for SPN 3242
FMI 0.
Step 8 Inspect turbocharger exhaust outlet for oil or fuel in aftertreatment Decision
system from engine.
Remove exhaust plumbing from turbocharger outlet. Yes: Go to Step 9.
Was turbocharger exhaust outlet free of oil and fuel contamination? No: Repair fuel or engine oil
leak to exhaust. See Fuel to
Exhaust (page 87), and see 6.2
Oil Leak to Exhaust (page 75).
for SPN 3242 FMI 0.
Step 9 Check for leaking or stuck open Aftertreatment Fuel Enable Actuator Decision
(AFTFEA).
Perform AFT Fuel Enable Actuator Leak Test (page 1995). Yes: Go to Step 10.
Is AFT Hydrocarbon Doser (AFTHD) dry and free of fuel? No: Replace AFTFEA. After
SPN 3242 FMI 0.
Step 10 Check for leaking or stuck open AFTHD. Decision

Perform AFT Hydrocarbon Doser Leak Test (page 1996). Yes: Go to Step 11.
Is AFTHD dry and free of fuel? No: Replace AFTHD. After
SPN 3242 FMI 0.
Step 11 Check for failed AFT fuel flow. Decision

Perform AFT Dosing System Test (page 1993). Yes: Go to Step 12.
Was 225 to 500 ml of fuel dispensed within 2.5 minutes? No: Replace AFTHD. Refer to
Fault Facts. After repairs are
FMI 0.
Step 12 Inspect Diesel Oxidation Catalyst (DOC) for soot accumulation, face Decision
plugging, or damage.
Remove DOC. Yes: Reinstall DOC and perform
a Parked Regeneration. After
SPN 3242 FMI 0.
Are less than 50% of cells on intake face completely blocked by soot? No: Clean or replace DOC. Refer
to Fault Facts. After repairs are
FMI 0.
End Diagnostic Test

After performing all diagnostic steps, if SPN 3242 FMI 0 remains, verify each step was completed correctly and proper
SPN 3242 FMI 2 - Aftertreatment 1 Diesel Particulate Filter Intake Temperature - Data Erratic,
Intermittent Or Incorrect
Fault Overview
Fault code sets when Engine Control Module (ECM) detects difference between Diesel Particulate Filter Inlet
Temperature (DPFIT) sensor and Diesel Particulate Filter Outlet Temperature (DPFOT) sensor and Diesel
Oxidation Catalyst Intake Temperature (DOCIT) readings do not match expected values for engine operating
conditions.
Lamp Reaction
Associated Faults
SPN 2791 - Engine Exhaust Gas Recirculation 1 Valve 1 Control 1
Fault Facts
None

Road Test
Possible Causes
• Failed Aftertreatment Temperature sensor module

®
Is EST DTC list SPN 3242 FMI 2 active or pending? No: Repair Active or Pending
faults first. After repairs are
FMI 2.

information).
valve.
Is the butterfly valve free of damage, does the butterfly valve move with its shaft when No: Replace EGR Valve.
Step 3 Aftertreatment Temperature sensor module and connector inspection. Decision

A. Key OFF. Disconnect Aftertreatment Temperature sensor module. Yes: Replace Aftertreatment
Temperature sensor module.
B. Check Aftertreatment Temperature sensor module and connector terminals
for: damaged or pinched wires; wet or corroded terminals; loose, bent, or
for SPN 3242 FMI 2.
Are Aftertreatment Temperature sensor module connector, harness, and terminals No: Repair connector, harness,
clean and undamaged? or terminal damage. After repairs
3242 FMI 2.

After performing all diagnostic steps, if SPN 3242 FMI 2 remains, verify if each step was completed correctly and proper
SPN 3242 FMI 3 - Aftertreatment 1 Diesel Particulate Filter Intake Temperature : Voltage Above Normal,
Fault Overview
sensor signal voltage is greater than expected.
Lamp Reaction
Associated Faults
SPN 5742
Fault Facts
None

Continuous
Possible Causes
Step 1 Check for Associated Faults Decision

®
for SPN 3242 FMI 3.
Step 2 Inspect connections at Aftertreatment temperature sensor module Decision

connector.
A. Key OFF. Yes: Replace Aftertreatment
temperature sensor module.
B. Disconnect Aftertreatment temperature sensor module.
C. Check Aftertreatment temperature sensor module and connector terminals for SPN 3242 FMI 3.
Are Aftertreatment temperature sensor module connector, harness, and terminals No: Repair connector, harness,
3242 FMI 3.

SPN 3242 FMI 4 - Aftertreatment 1 Diesel Particulate Filter Intake Temperature : Voltage Below Normal,
Fault Overview
sensor signal voltage is out of range low.
Lamp Reaction
Associated Faults
SPN 5742
Fault Facts
None

Continuous
Possible Causes

®
for SPN 3242 FMI 4.

connector.
C. Check Aftertreatment temperature sensor module and connector terminals for SPN 3242 FMI 4.
3242 FMI 4.

SPN 3242 FMI 12 - Aftertreatment 1 Diesel Particulate Filter Intake Temperature : Bad Intelligent Device
Or Component
Fault Overview
Fault sets when the Aftertreatment Temperature Sensor Module detects an internal communication error causing
no data to be received from the Diesel Particulate Filter Intake Temperature (DPFIT) sensor for more than 5
seconds in the key off state.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Cause
• Failed AFT Temperature Sensor Module

®
Step 2 Inspect connections at AFT temperature sensor module. Decision

A. Key OFF. Yes: Replace AFT Temperature
Sensor Module. After repairs are
B. Disconnect AFT temperature sensor module connector.
C. Check AFT temperature sensor module and connector terminals for FMI 12.
damaged or pinched wires; corroded terminals; loose, bent, or broken
Are AFT temperature sensor module connector, harness, and terminals clean and No: Repair connector, harness,
3242 FMI 12.

Normal Operating Range - Least Severe Level
Fault Overview
reading is in range but greater than expected for an extended period of time.
Lamp Reaction
Associated Faults
SPN 731 SPN 1322-1328 FMI 31 SPN 2791 (EGR) SPN 2797 and 2798 FMI 11
SPN 3242 FMI 2, 3, and 4 SPN 5742 FMI 3, 4, 12, and SPN 5743 FMI 19
19
Fault Facts
exhaust system welds, leaking exhaust system seams, or other damage. This fault will go inactive after DPFIT
drops below warning limit, and will likely be inactive when vehicle is in shop. For this reason, these diagnostics

Road Test
Possible Causes
• Failed or soot loaded DOC and/or DPF
CAUTION:

®
WARNING:
Step 3.
System Leak or Over
Is SPN 3936 FMI 16 Active, or did any DPF Outlet Temperature go above 1550 °F (843 No: Clear fault codes,
°C)? Perform stationary DPF
3242 FMI 15.

FMI 15.

information).
valve.
Is the butterfly valve free of damage, does the butterfly valve move with its shaft when No: Replace EGR Valve.

(compression loss).
SPN 3242 FMI 15.


by Multiple Cylinder Cutout
Test and perform IQA
Adjustment(page 1941)
FMI 15.
FMI 15.
system from engine.
Remove exhaust plumbing from turbocharger outlet (see Engine Service Manual). Yes: Go to Step 10.
(AFTFEA).
SPN 3242 FMI 15.

SPN 3242 FMI 15.

FMI 15.
Remove DOC (see appropriate Technician Manual). Yes: Reinstall DOC and perform
SPN 3242 FMI 15.
FMI 15.
End Diagnostic Test

Normal Operating Range - Moderately Severe Level
Fault Overview
reading is greater than expected for an extended period of time or greater than expected for an extended period
of time during regeneration.
Lamp Reaction
Associated Faults
SPN 651 - 656 SPN 731 FMI 16 and 18 SPN 1322 - 1328 FMI 31 SPN 2797 and 2798 FMI 11
SPN 3242 FMI 2, 3, and 4 SPN 5742 FMI 3, 4, 12, and
19
Fault Facts
If aftertreatment system has had excess fuel, oil, coolant, metal, or other contamination, inspect entire
aftertreatment system for causal damage before re-installing. Inspect for overheated aftertreatment
components, cracked exhaust system welds, leaking exhaust system seams, or other damage. This fault will
go inactive after DPFIT drops below warning limit, and will likely be inactive when vehicle is in shop. For this
reason, these diagnostics must be used for both active and inactive fault codes.

Road Test
Possible Causes
• Leaking fuel Injector
CAUTION:

®
1137).
WARNING:
Step 3.
System Leak or Over
3242 FMI 16.
Step 4 Compare Diesel Oxidation Catalyst Inlet Temperature (DOCIT) Sensor Decision
to Diesel Particulate Filter Inlet (DPFIT) and DPF Outlet Temperature
(DPFOT) Sensor temperatures.
Is DOCIT, DPFIT, and DPFOT difference with in 77°F (43°C) of each other? No: Replace AFT Temperature
FMI 16.

(compression loss).
SPN 3242 FMI 16.


Test, perform IQA Adjustment
FMI 16.
system from engine.
(AFTFEA).
SPN 3242 FMI 16.

SPN 3242 FMI 16.

FMI 16.
Remove DOC (see Appropriate Vehicle Technician Manual). Yes: Reinstall DOC and perform
SPN 3242 FMI 16.
FMI 16.
End Diagnostic Test

SPN 3242 FMI 18 - Aftertreatment 1 Diesel Particulate Filter Intake Temperature : Data Valid But Below
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Particulate Filter Intake Temperature (DPFIT)
signal value is lower than expected.
Lamp Reaction
Associated Faults
SPN 3480 SPN 3482 SPN 3556 SPN 5298 FMI 18

SPN 5742 SPN 5743
Fault Facts
go inactive after DPFIT drops below warning limit, and will likely be inactive when vehicle is in shop. For this

Road Test
Possible Causes
• Damaged or failed Diesel Oxidation Catalyst (DOC)
• Restricted DOC (soot accumulation)
• Exhaust system leak between turbocharger and DOC
• Aftertreatment Hydrocarbon Doser (AFTHD) stuck closed
• Aftertreatment Fuel Enable Actuator (AFTFEA) stuck closed
• Failed AFT temperature sensor module

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostic Software. Key Yes: Go to Step 2.
On, check Diagnostic Trouble Code (DTC) list for Associated Faults (page 1141).
Step 2 Compare all aftertreatment sensor temperatures. Decision

Are DOCIT, DPFIT, DPFOT, and SCROT within 77°F (25°C) of each other? No: Replace AFT temperature
FMI 18.
Step 3 Inspect exhaust system for leaks between the turbocharger outlet and Decision
Diesel Oxidation Catalyst (DOC) inlet.
KOER, check for cracked exhaust system welds, leaking exhaust system seams, Yes: Go to Step 4.
or other damage.
Is exhaust system between turbocharger outlet and DOC inlet sealed and No: Repair or replace damaged
undamaged? exhaust system components.
Step 4 Inspect for a restricted or damaged DOC. Decision

Remove DOC, Check DOC for restrictions from soot or oil contamination, cracks or Yes: Go to Step 5.
damage to cells in DOC, and soot restrictions at front face of DOC.
Is DOC unrestricted and free of damage? No: Replace DOC. Repair
source of damage or excessive
soot. After repairs are complete,
(AFTFEA).
Is AFT Hydrocarbon Doser (AFTHD) dry and free of fuel? No: Replace Aftertreatment Fuel
Supply Module. After repairs are
FMI 18.

SPN 3242 FMI 18.

Perform AFT Dosing System Test (page 1993). Yes: Replace DOC. After repairs
3242 FMI 18.
Was between 225 ml and 500 ml of fuel dispensed within 2.5 minutes? No: Replace AFTHD. After
SPN 3242 FMI 18.
End Diagnostic Test

SPN 3242 FMI 20 - Aftertreatment 1 Diesel Particulate Filter Intake Temperature : Data Drifted High
Fault Overview
is above a plausibly high threshold.
Lamp Reaction
Associated Faults
SPN 3242 FMI 0, 15, 16,

and, 18
Fault Facts
None.

Road Test
Possible Causes

Step 2 Desel Particulate Filter Intake Temperature (DPFIT) sensor and Decision
connector inspection.
B. Disconnect DPFIT sensor.
C. Check DPFIT sensor and connector terminals for: damaged or pinched
connector housing.
Are DPFIT sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
3242 FMI 20.
Step 3 Compare Diesel Oxidation Catalyst Inlet Temperature (DOCIT) sensor Decision
(DPFOT) sensor temperatures.
Perform Hot Run Sensor Comparison Test (page 2267). Yes: End Diagnostics. Retest for
SPN 3242 FMI 20.
Is DOCIT, DPFIT, and DPFOT difference with in 77°F (43°C) of each other? No: Replace AFT temperature
FMI 20.

SPN 3242 FMI 21 - Aftertreatment 1 Diesel Particulate Filter Intake Temperature : Data Drifted Low
Fault Overview
is below a plausibly low threshold.
Lamp Reaction
Associated Faults
SPN 3242 FMI 0, 15, 16,

and, 18
Fault Facts
None.

Road Test
Possible Causes

connector housing.
3242 FMI 21.
SPN 3242 FMI 21.
FMI 21.

SPN 3246 FMI 0 - Aftertreatment 1 Diesel Particulate Filter Outlet Temperature : Data Valid But Above
Fault Overview
Fault code sets when the Engine Control Module (ECM) detects Diesel Particulate Filter Outlet Temperature
(DPFOT) reading is greater than critical limit.
Lamp Reaction
Associated Faults
SPN 651 - 656 SPN 1322 - 1328 FMI 14 SPN 2197 and 2798 FMI 11 SPN 3242 FMI 2, 3, and 4
and 31
SPN 5742 FMI 19
Fault Facts
go inactive after DPFOT drops below warning limit, and will likely be inactive when vehicle is in shop. For this

Road Test
Possible Causes
• Leaking or stuck open Aftertreatment Hydrocarbon (AFTHD)
CAUTION:

®
for SPN 3246 FMI 0.
WARNING:
Step 3.
System Leak or Over
3246 FMI 0.
FMI 0.

(compression loss).
SPN 3246 FMI 0.


by Multiple Cylinder Cutout Test,
perform IQA Adjustment (page
FMI 0.
system from engine.
for SPN 3246 FMI 0.
(AFTFEA).
Is AFT Fuel Injector (AFTFI) dry and free of fuel? No: Replace AFTFEA. After
SPN 3246 FMI 0.

Is AFTFI dry and free of fuel? No: Replace AFTHD. After
SPN 3246 FMI 0.

FMI 0.
Remove DOC (see Exhaust Aftertreatment System with DPF and SCR Service Yes: Reinstall DOC and perform
Manual). a Parked Regeneration. After
SPN 3246 FMI 0.
FMI 0.
End Diagnostic Test

SPN 3246 FMI 2 - Aftertreatment 1 Diesel Particulate Filter Outlet Temperature : Data Erratic,
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Aftertreatment (AFT) temperature sensor module
reading is not changing with engine operating conditions.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Failed Aftertreatment (AFT) temperature sensor module

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostics. Key-On, Yes: Go to Step 2.
Is EST DTC list SPN 3246 FMI 2 active or pending? No: Repair all other active faults.
for SPN 3264 FMI 2.
Step 2 Perform sensor and connector inspection Decision

A. Key OFF. Yes: Replace AFT temperature
B. Disconnect AFT temperature sensor module.
C. Check AFT temperature sensor module and connector terminals for: FMI 2.
damaged or pinched wires; wet or corroded terminals; loose, bent, or
3246 FMI 2.

SPN 3246 FMI 3 - Aftertreatment 1 Diesel Particulate Filter Outlet Temperature : Voltage Above Normal,
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Particulate Filter Outlet Temperature
(DPFOT) sensor signal voltage is greater than normal operating range.
Lamp Reaction
Associated Faults
SPN 5742
Fault Facts
None

Continuous
Possible Causes

®
SPN 3246 FMI 3.

connector.
C. Check Aftertreatment temperature sensor module and connector terminals Request (page 1955). After
for: damaged or pinched wires; wet or corroded terminals; loose, bent, or repairs are complete, retest for
broken pins; or broken connector housing. SPN 3246 FMI 3.
clean and undamaged? or terminal damage. Perform

SPN 3246 FMI 4 - Aftertreatment 1 Diesel Particulate Filter Outlet Temperature : Voltage Below Normal,
Fault Overview
(DPFOT) sensor signal voltage is less than normal operating range.
Lamp Reaction
Associated Faults
SPN 5742
Fault Facts
None

Continuous
Possible Causes

®
SPN 3246 FMI 4.

connector.
C. Check Aftertreatment temperature sensor module and connector terminals Request (page 1955). After
for: damaged or pinched wires; wet or corroded terminals; loose, bent, or repairs are complete, retest for
broken pins; or broken connector housing. SPN 3246 FMI 4.
SCR Fault Reset Request
FMI 4.

SPN 3246 FMI 12 - Aftertreatment 1 Diesel Particulate Filter Outlet Temperature : Bad Intelligent Device
Or Component
Fault Overview
Fault sets when the Aftertreatment Temperature Sensor Module detects an internal communication error causing
no data to be received from the Diesel Particulate Filter Outlet Temperature Sensor for more than 5 seconds in
the key off state.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Failed Aftertreatment (AFT) temperature sensor module

®
Is EST DTC list SPN 3246 FMI 12 active? No: Repair all other active
faults. Perform SCR Fault Reset
SPN 3264 FMI 12.
Step 2 Inspect connections at AFT Temperature Sensor Module. Decision

sensor module. Perform SCR
B. Disconnect AFT temperature sensor module.
Fault Reset Request (page 1955).
C. Check AFT temperature sensor module and connector terminals for: After repairs are complete, retest
damaged or pinched wires; wet or corroded terminals; loose, bent, or for SPN 3246 FMI 12.

Fault Overview
(DPFOT) reading is in range and reading greater than expected for an extended period of time.
Lamp Reaction
Associated Faults
• SPN 731 • SPN 1322 - 1328 FMI 31 • SPN 2797 and 2798 FMI • SPN 3242 FMI 2, 3, and 4
11
• SPN 5742 FMI 3, 4, 12, SPN 5743 FMI 19
and 19
Fault Facts
exhaust system welds, leaking exhaust system seams, or other damage. This fault will go inactive after DPFOT
drops below warning limit, and will likely be not active when vehicle is in shop. For this reason, these diagnostics

Road Test
Possible Causes
CAUTION:

®
WARNING:
Step 3.
System Leak or Over
3246 FMI 15.

FMI 15.

(compression loss).
SPN 3246 FMI 15.


FMI 15.
FMI 15.
system from engine.
Was turbocharger exhaust outlet free of oil and fuel contamination? No: Repair fuel or engine oil leak
to exhaust. See Fuel to Exhaust
(page 87), or see 6.2 Oil Leak to
Exhaust (page 75). After repairs
3246 FMI 15.
(AFTFEA).
SPN 3246 FMI 15.

SPN 3246 FMI 15.

FMI 15.
Remove DOC (see appropriate Technician Manual). Yes: Reinstall DOC and perform
SPN 3246 FMI 15.
FMI 15.
End Diagnostic Test

Fault Overview
(DPFOT) reading is greater than 1269°F (687°C) for an extended period of time.
Lamp Reaction
Amber Warning Lamp (AWL) and Red Stop Lamp (RSL) will illuminate 10 seconds after this fault is detected.
Malfunction Indicator Lamp (MIL) will be illuminated 60 second after this fault is detected.
Associated Faults
SPN 651-656 FMI 3 and 4 SPN 1322 - 1328 FMI 31 SPN 2797 and 2798 FMI 8 SPN 3242 FMI 2, 3, and 4
and 11
SPN 5742 FMI 3, 4, 12, and
19
Fault Facts

Road Test
Possible Causes
• Leaking Fuel Injector
CAUTION:

®
1163).
WARNING:
Step 3.
System Leak or Over
3246 FMI 16.
Step 4 Compare Diesel Oxidation Catalyst Inlet Temperature (DOCIT) Sensor Decision
(DPFOT) Sensor temperatures.
Is DOCIT, DPFIT, and DPFOT difference with in 77°F (43°C) of each other? No: Replace AFT Temperature
FMI 16.

(compression loss).
SPN 3246 FMI 16.


from Multiple Cylinder Cutout
FMI 16.
system from engine.
3246 FMI 16.
(AFTFEA).
SPN 3246 FMI 16.

SPN 3246 FMI 16.

FMI 16.
Remove DOC (see Appropriate Vehicle Technician Manual). Yes: Reinstall DOC and perform
SPN 3246 FMI 16.
FMI 16.
End Diagnostic Test

SPN 3246 FMI 18 - Aftertreatment 1 Diesel Particulate Filter Outlet Temperature : Data Valid But Below
Fault Overview
(DPFOT) signal value is lower than expected.
Lamp Reaction
Associated Faults
SPN 3480 SPN 3482 SPN 3556 SPN 5298 FMI 18

SPN 5742 SPN 5743
Fault Facts

Road Test
Possible Causes
• Damaged or failed Diesel Oxidation Catalyst (DOC)
• Aftertreatment Hydrocarbon Doser (AFTHD) stuck closed
• Aftertreatment Fuel Enable Actuator (AFTFEA) stuck closed

®
On, check Diagnostic Trouble Code (DTC) list for Associated Faults (page 1167).

Are DOCIT, DPFIT, DPFOT, and SCROT within 77°F (25°C) of each other? No: Replace AFT temperature
FMI 18.
KOER, check for cracked exhaust system welds, leaking exhaust system seams, Yes: Go to Step 4.
or other damage.

Remove DOC, Check DOC for restrictions from soot or oil contamination, cracks or Yes: Go to Step 5.
Is DOC unrestricted and free of damage? No: Replace DOC. Repair
source of damage or excessive
soot. After repairs are complete,
(AFTFEA).
FMI 18.

SPN 3246 FMI 18.

3246 FMI 18.
SPN 3246 FMI 18.
End Diagnostic Test

SPN 3246 FMI 20 - Aftertreatment 1 Diesel Particulate Filter Outlet Temperature : Data Drifted High
Fault Overview
(DPFOT) is above a plausibly high threshold.
Lamp Reaction
Associated Faults
SPN 3246 FMI 0, 15, 16,

and, 18
Fault Facts
None.

Road Test
Possible Causes

connector housing.
3246 FMI 20.
SPN 3246 FMI 20.
FMI 20.

SPN 3246 FMI 21 - Aftertreatment 1 Diesel Particulate Filter Outlet Temperature : Data Drifted Low
Fault Overview
(DPFOT) is below a plausibly low threshold.
Lamp Reaction
Associated Faults
SPN 3246 FMI 0, 15, 16,

and, 18
Fault Facts
None.

Road Test
Possible Causes

connector housing.
3246 FMI 21.
SPN 3246 FMI 21.
FMI 21.

SPN 3251 FMI 0 - Aftertreatment 1 Diesel Particulate Filter Differential Pressure : Data Valid But Above
Fault Overview
Fault code sets when the Engine Control Module (ECM) detects Diesel Particulate Filter (DPF) soot load has
exceeded operating limits. DPF soot level 4.
Lamp Reaction
The Red Stop Lamp (RSL) will illuminate immediately when this fault is detected.
Associated Faults
SPN 102 SPN 157 SPN 651-656 SPN 2797–2798

SPN 3242 FMI 2, 3, and 4 SPN 3246 FMI 2, 3, and 4 SPN 3480 SPN 3482
SPN 3556 SPN 3610 SPN 4765 FMI 2, 3, and 4
Fault Facts
This DTC indicates the engine is not capable of reducing soot loads during current operating conditions. Parked
and Active regeneration is disable when this fault is active. The Electronic Service Tool (EST) must be used to
perform an aftertreatment regeneration.

Road Test
Possible Causes
• Regen inhibited
• Engine performance problem
• Restricted DPFDP hoses / tubes
• Excessive Idle time over 20 hours
• Soot build-up on Aftertreatment Hydrocarbon Injector (AFTHD)
• Failed AFTHD
• Failed Diesel Oxidation Catalyst (DOC)
• Failed DPF
• Charge Air Cooler (CAC) hose or charge air system leak
CAUTION:

After repairs are complete, return
to SPN 3251 FMI 0 diagnostics,
and go to Step 2.
WARNING:
Step 3.
System Leak or Over
3251 FMI 0.
Step 4 Check for long idle periods. Decision

Speak with operator or customer and ask if vehicle is allowed to idle for extended Yes: Using EST, perform DPF
periods of time. Regeneration Procedure (page
1936) until all soot load warnings
are inactive.
Was vehicle allowed to idle for 20 hours or more? No: Go to Step 5.
A. Use EST, locate Programmable Parameter 55770 Max DPF Outlet Yes: Go to Step 6.
Temperature – DOC Inlet Temperature, 55780 Max DPF Outlet
Temperature – DOC Outlet Temperature, and 55790 Max DPF Outlet
Temperature – DOC Outlet Temperature. Record values.
B. Use Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC)
Are all these Programmable Parameters below 1550°F (843°C) and is DTC list free No: Go to Step 14.
of SPN 3936 FMI 16?
Step 6 Check AFTHD for proper operation. Decision

Perform AFT Dosing System Test (page 1993). Watch spray pattern of AFTHD Yes: Go to Step 8.
for proper atomization. Spray pattern should be smooth, conical and free of large
dips or single streams.
Is AFTHD atomizing fuel properly? No: Go to Step 7.
Step 7 Clean AFTHD and re-check for proper operation. Decision

A. Clean AFTHD nozzle with carburetor cleaner and a brass brush. Yes: Go to Step 8.
B. Perform AFT Dosing System Test (page 1993)again.
C. Watch spray pattern of AFTHD for proper atomization. Spray pattern should
be smooth, conical and free of large dips or single streams.
Is AFTHD atomizing fuel properly? No: Replace AFTHD. After
SPN 3251 FMI 0.

Review results from AFT Dosing System Test. Yes: Go to Step 9.
Was injector volume within specification? No: Replace AFTHD. After
SPN 3251 FMI 0.
Step 9 Check DPFDP sensor tubes and hoses for restrictions or damage. Decision
Inspect DPFDP sensor hoses and tubes for kinks, improper hose routing, Yes: Go to Step 10.
restrictions, or damage.
Are DPFDP sensor hoses and tubes routed correctly, free of damage, and No: Repair or replace DPFDP
unrestricted? sensor hose(s). After repairs are
FMI 0.
Step 10 Check Regeneration performance. Decision

Using EST, perform DPF Regeneration Procedure (page 1936). Observe for DPF Yes: End diagnostics, retest for
Soot warning level reduction. SPN 3251 FMI 0.
Did DPF Soot Load warning level reduce or did the instrument cluster warning No: Go to Step 11.
routine change?
Step 11 Compare DPF regen snapshot to known good graph. Decision

Compare DPF Regeneration graphs to Normal Exhaust Gas Temp Graph (page Yes: End diagnostics, retest for
2022). SPN 3251 FMI 0.
Does DPF Regen snapshot meet expected outcome? No: Go to Step 12.
Step 12 Inspect DOC. Decision

Remove DOC and DPF. Compare DOC to DOC Inspection and Reuse Guidelines Yes: If DOC is 50% plugged or
(page 2240). more, perform DOC Cleaning
Procedure (page 2231). Go to
Step 14.
Is the DOC reusable? No: Replace DOC. After repairs
are complete, go to Step 13.
Step 13 Inspect DPF. Decision

Compare DPF to DPF Inspection and Reuse Guidelines (page 2247). Yes: Clean or replace as needed.
Is the DPF reusable? No: Replace DPF. After repairs
3251 FMI 0.
Step 14 Replace DPF and Inspect SCR catalyst Decision

A. Replace DPF, clean soot build-up from Decomp mixer and tailpipe. Yes: Perform DPF Regeneration
Procedure (page 1936). If
B. While DPF and Decomp mixer are removed, Inspect SCR Catalyst.
fault codes become active,
Compare to SCR Catalyst Inspection and Reuse Guidelines (page 2270).
go to appropriate fault code
diagnostics.
Is SCR free of melting or damage and is the catalyst reusable? No: Replace SCR catalyst. After
SPN 3251 FMI 0.

SPN 3251 FMI 2 - Aftertreatment 1 Diesel Particulate Filter Differential Pressure : Data Erratic,
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Particulate Filter Differential Pressure
(DPFDP) sensor signal is greater than 0.25 psi (1.5 kPa), is not changing with engine conditions, or signal
range since last monitor is less than 0.15 psi (1 kPa).
Lamp Reaction
Associated Faults
SPN 3511 FMI 4, 6 and 14
Fault Facts
None

Road Test
Possible Causes
• DPFDP SIG GND circuit high resistance
• Leaking or Restricted DPFDP / DPFOP sensor hoses
• Failed DPFDP / DPFOP sensor
• VREF 3 high resistance

®
for SPN 3251 FMI 2.
Step 2 Inspect hoses and tube connections at Diesel Particulate Filter Decision
Differential Pressure (DPFDP) / Diesel Particulate Filter Outlet
Pressure (DPFOP) sensor.
Check DPFDP / DPFOP sensor tubes, and passages for leaks, restrictions, and Yes: Go to Step 3.
damage.
Are DPFDP / DPFOP sensor tubes and connections free of leaks, restrictions, and No: Repair leaking, restricted,
damage? or damaged hoses, tubes and
FMI 2.
Step 3 Inspect connections at DPFDP / DPFOP sensor. Decision

B. Disconnect DPFDP / DPFOP sensor connector.
C. Check DPFDP / DPFOP sensor and connector terminals for: damaged or
pinched wires; corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are DPFDP / DPFOP sensor connector, harness, and terminals clean and No: Repair connector, harness,
3251 FMI 2.
Step 4 Check SIG GND circuit for high resistance. Decision

12-575-01 Pin-1 to PWR.
Is voltage between B+ ± 0.5 volts? No: Repair high resistance
between DPFDP / DPFOP
sensor Pin-1 and ECM pin C1-63.
for SPN 3251 FMI 2.
Step 5 Check DPFDP / DPFOP sensor operation. Decision

A. Perform Test 2 (page 1181). Yes: Replace DPFDP / DPFOP
B. Use Electronic Service Tool (EST), perform Continuous Monitor Test (page
1974).
FMI 2.
C. During test, monitor DPFDP voltage with EST.
Step 6 Check VREF circuit for high resistance. Decision

Perform Test 3 (page 1182). Use Digital Multimeter (DMM), measure voltage Yes: Repair Open between
between Breakout Harness 12-575-01 Pin-4 and known good GND. DPFDP / DPFOP sensor module
Pin-2 and ECM pin C1-10. After
SPN 3251 FMI 2.
GND between DPFDP / DPFOP
sensor module Pin-4 and ECM
FMI 2.

Pin Point Test SPN 3251 FMI 2

Tools Required
Test 1
A. Key OFF.
B. Disconnect Diesel Particulate Filter Differential Pressure (DPFDP) / Diesel Particulate Filter Outlet Pressure
(DPFOP) sensor module.
C. Connect Breakout Harness 12-575-01 to engine harness and leave DPFDP / DPFOP sensor disconnected.
D. Key ON.
Figure 396 DPFDP / DPFOP Sensor Circuit Check
Test 2
A. Key OFF.
B. Disconnect DPFDP / DPFOP sensor.
D. Use Breakout Harness ZTSE4498, short Breakout Harness 12-575-01 Pin-2 to Pin-4.
F. Key ON. Log in to Navistar® Engine Diagnostics software.
Test 3
A. Key OFF.
D. Key ON.
SPN 3251 FMI 3 - Aftertreatment 1 Diesel Particulate Filter Differential Pressure : Voltage Above
Normal, Or Shorted To High Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that aftertreatment Diesel Particulate Filter
Differential Pressure (DPFDP) signal voltage is greater than normal operating range.
Lamp Reaction
Associated Fault
None
Fault Facts
None

Continuous
Possible Causes
• DPFDP signal circuit short to PWR
• Failed DPFDP / DPFOP Sensor

®
Is EST DTC listing SPN 3251 FMI 3 active or pending? No: Go to Intermittent or
Step 2 Inspect connections at DPFDP/DPF Outlet Pressure (DPFOP) sensor. Decision

connector housing.
undamaged? or terminal damage. After
SPN 3251 FMI 3.
Step 3 Check for short to power. Decision

B. Disconnect Diesel Particulate Filter Differential Pressure (DPFDP) Sensor.
C. Key ON, Engine OFF (KOEO).
D. Connect (EST) with Navistar® Engine Diagnostics software, perform
Continuous Monitor Test (page 1974).
E. During test, monitor DPFDP voltage with EST.
Is voltage approximately 0 volts? No: Repair short to PWR on
sensor signal circuit between
ECM Pin C1-10 and DPFDP
/ DPFOP sensor pin-2. After
SPN 3251 FMI 3.
Step 4 Check for open or high resistance in DPFDP / DPFOP SIG GND circuit. Decision
Perform Test 1 (page 1187). Use DMM, measure voltage between Breakout Harness Yes: Replace DPFDP / DPFOP
12-575-01 pin-1 and PWR. Sensor. After repairs are
FMI 3.
resistance between ECM Pin
C1-63 and DPFDP / DPFOP
Sensor pin-1. After repairs are
FMI 3.


Tools Required
Figure 398 DPFDP SIG GND Circuit Check
Test 1
A. Key OFF
B. Disconnect DPFDP Sensor.
C. Connect Breakout Harness 12-575-01 to engine harness, and leave DPFDP Sensor disconnected.
D. Key ON.
SPN 3251 FMI 4 - Aftertreatment 1 Diesel Particulate Filter Differential Pressure : Voltage Below
Normal, Or Shorted To Low Source
Fault Overview
(DPFDP) signal voltage is less than normal operating range.
Lamp Reaction
Associated Faults
SPN 3511
Fault Facts
None

Continuous
Possible Causes
• DPFDP signal circuit open or short to GND
• DPFDP VREF circuit open or short to GND

®

Use EST with Navistar® Engine Diagnostic Software. Key-On, check DTC list for Yes: Go to Step 3.
SPN 3251 FMI 4.
Is SPN 3251 FMI 4 active? No: Go to Intermittent or
Step 3 Inspect connections at DPFDP / DPFOP Sensor. Decision

B. Disconnect DPFDP / DPFOP Sensor connector.
C. Check DPFDP / DPFOP Sensor and connector terminals for: damaged or
connector housing.
Are DPFDP / DPFOP Sensor connector, harness, and terminals clean and No: Repair connector, harness,
undamaged? or terminal damage. After
SPN 3251 FMI 4.

Is voltage 5 volts ± 0.25 volts? No: Repair open or short to
GND between DPFDP/DPFOP
pin 4 and ECM pin C1-36. After
SPN 3251 FMI 4.
Step 5 Check DPFDP/DPFOP Sensor Circuit. Decision

A. Perform Test 2 (page 1191). Yes: Replace DPFDP/DPFOP
Sensor. After repairs are
C. During test, monitor DPFDP voltage with EST. FMI 4.
Is voltage 5 ± 0.25 volts? No: Repair open or short to
GND between DPFDP/DPFOP
SPN 3251 FMI 4.


Tools Required
Test 1
A. Key OFF.
C. Connect Breakout Harness 12-575-01 to engine harness and leave DPFDP / DPFOP Sensor disconnected.
Figure 400 DPFDP / DPFOP Sensor Circuit Check
Test 2
A. Key OFF.
C. Connect Breakout Harness 12-575-01 to engine harness and leave DPFDP / DPFOP Sensor disconnected.
D. Connect Breakout Harness ZTSE4498 between Breakout Harness 12-575-01 pin-4 and pin-2.
Fault Overview
exceeded operating limits. DPF soot level 1 and 2.
Lamp Reaction
The DPF Indicator will illuminate when this fault is detected.
Associated Faults
SPN 102 SPN 157 SPN 651-656 SPN 2797–2798

Fault Facts
Perform an active or parked regeneration when this fault is active.

Road Test
Possible Causes
• Regen inhibited
• Failed Aftertreatment Hydrocarbon Injector (AFTHD)
• Failed Diesel Oxidation Catalyst (DOC)
• Face-Plugged DPF
• Soot in Aftertreatment Assembly
CAUTION:

After repairs are complete, return
to SPN 3251 FMI 15 diagnostics
and go to Step 2.
WARNING:
Step 3.
System Leak or Over
3251 FMI 15.

Speak with operator or customer and ask if vehicle is allowed to idle for extended Yes: Perform DPF Regeneration
periods of time. Procedure (page 1936) multiple
times if needed or until all soot
load warnings are inactive.
Are all these Programmable Parameters below 1550°F (843°C) and is DTC list free No: Go to Step 14.
of SPN 3936 FMI 16?

Perform DPF Regeneration Procedure (page 1936). Observe for DPF Soot warning Yes: Perform DPF Regeneration
level reduction. Procedure (page 1936) multiple
routine change?


SPN 3251 FMI 15.

SPN 3251 FMI 15.
FMI 15.

2022). SPN 3251 FMI 15.

Step 13.

Remove DOC and DPF. Compare DPF to DPF Inspection and Reuse Guidelines Yes: Clean or replace as needed.
(page 2247). Retest for SPN 3251 FMI 15.
3251 FMI 15.

Fault Overview
exceeded operating limits. DPF soot level 3.
Lamp Reaction
The DPF Indicator and Amber Warning Lamp (AWL) will illuminate immediately when this fault is detected.
Associated Faults
SPN 102 SPN 157 SPN 651-656 SPN 2797–2798

Fault Facts
Find a safe location to perform a parked regeneration. Active regeneration will be disable when this fault is
active.

Road Test
Possible Causes
• Regen inhibited
• Failed Aftertreatment Hydrocarbon Injector (AFTHD)
CAUTION:

WARNING:
Step 3.
System Leak or Over
3251 FMI 16.

Speak with operator or customer and ask if vehicle is allowed to idle for extended Yes: Perform DPF Regeneration
periods of time. Procedure (page 1936) multiple
Are all these Programmable Parameters below 1550°F (843°C) and is DTC list free No: Replace DPF. After repairs
of SPN 3936 FMI 16? are complete, retest for SPN 3251
FMI 16.

Perform DPF Regeneration Procedure (page 1936). Observe for DPF Soot warning Yes: Perform DPF Regeneration
level reduction. Procedure (page 1936) multiple
routine change?


SPN 3251 FMI 16.

SPN 3251 FMI 16.
FMI 16.

2022). SPN 3251 FMI 16.

Step 10.

Remove DOC and DPF. Compare DPF to DPF Inspection and Reuse Guidelines Yes: Clean or replace as needed.
(page 2247). Retest for SPN 3251 FMI 16.
3251 FMI 16.

SPN 3362 FMI 31 - Aftertreatment 1 Diesel Exhaust Fluid Dosing Unit 1 Input Lines : Condition Exists
Fault Overview
Fault code sets when Diesel Exhaust Fluid (DEF) system is unable to successfully build pressure or prime after
multiple attempts.
Lamp Reaction
Associated Faults
SPN 3363 FMI 3, 4, 16, 17 SPN 4334 FMI 2, 3, 4, 7 SPN 4340 FMI 3 and 4 SPN 4342 FMI 3 and 4
and 18 and 18
SPN 4344 FMI 3 and 4 SPN 5491 FMI 3 and 5
Fault Facts
None

Road Test
Possible Causes
• Debris in DEF system
• Failed DEF connection, line or fitting
• DEF supply Module PWR Open or short to GND
• DEF supply Module GND Open
• Failed DEFAP sensor or sensor circuit
• Aerated DEF
• Failed DEF Supply Module
• Failed DEF Doser Valve
• Low DEF Level

SPN 3362 FMI 31.
Step 2 Check Diesel Exhaust Fluid (DEF) tank level. Decision

Perform DEF Level Inspection(page 2217). Determine actual tank level. Yes: Fill DEF tank with
appropriate diesel exhaust
fluid. Perform SCR Fault Reset
SPN 3362 FMI 31.
Is DEF in DEF tank below 1/2 tank? No: Go to Step 3.
Step 3 Visually Inspect DEF lines and connections. Decision

Inspect all three DEF lines and the DEF line fittings on the DEF supply module for Yes: Go to step 4.
white DEF residue (indicating a leak), reversed lines, damage or restricted lines or
connections.
Are all DEF lines and connections free of leaks, damage, reversed connections or No: Repair failed DEF line or
restrictions? connection. Perform SCR Fault
Step 4 Visually inspect the DEF tank. Decision

Visually inspect the DEF tank vent for crystallization, clogging, damage or pinched Yes: Repair any damage or
hoses. pinched hoses. Clean DEF
crystallization with distilled water
and a soft bristle brush. Replace
the DEF level sensor ONLY if
the vent is damaged. Perform
FMI 31.
Is DEF tank vent clogged or blocked with DEF crystallization? No: Go to step 5.
Step 5 Check the DEF Supply module suction. Decision

Perform DEF Supply Module Suction Test (page 2224). Yes: Go to step 10.
Was vacuum gauge reading 7 in-Hg (177.8 mm-Hg) or greater? No: Go to step 6.
Step 6 Check for DEF Supply Module operation Decision

Review results form the DEF Supply Module Suction Test performed in step 5. Yes: Inspect the DEF Tank
filter, DEF Supply Module Inlet
screen, DEF Supply Module
filter and DEF Doser Valve Inlet
screen for debris. Replace
as needed if restricted. After
repairs are complete, go back
to step 5. If vehicle fails DEF
Supply Module Suction test a
second time, replace DEF Supply
Module. Perform SCR Fault
While performing the DEF Supply Module Suction Test was pump noise heard No: Go to step 7.
coming from the DEF Supply Module when the test was active?
Step 7 Inspect DEF Supply Module Connector for damage. Decision

B. Disconnect DEF Supply Module connector.
C. Check DEF Supply Module and connector terminals for: damaged or
Are DEF Supply Module connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
FMI 31.
Step 8 Check PWR circuit. Decision

Perform Test 1 (page 1208). Use Digital Multimeter (DMM), measure voltage Yes: Go to step 9
between Breakout Harness 18-648-01 Pin-2 and a known good GND.
Is voltage B+ ± 0.5 volts? No: Repair Open between
DEF Supply Module Relay
Pin-87 and DEF Supply Module
Pin-2. Perform SCR Fault Reset
SPN 3362 FMI 31.
Step 9 Check GND circuit. Decision

Perform Test 2 (page 1209). Use Digital Multimeter (DMM), measure voltage Yes: Replace the DEF Supply
between Breakout Harness 18-648-01 Pin-4 and PWR. Module. Perform SCR Fault
ECM pin C2-02 and DEF
Supply Module Pin-4. Perform
FMI 31.
Step 10 Check the Aftertreatment DEF Supply Module inlet restriction. Decision
Perform DEF Supply Module Inlet Restriction Test (page 2218). Yes: Go to step 11.
Was vacuum gauge reading less than 10 in-Hg (254 mm-Hg)? No: Repair the DEF tank filter or
DEF suction line as necessary for
a restriction. Drain the DEF tank,
flush with distilled water, and fill
with known good DEF. Perform
FMI 31.
Step 11 Check DEF supply for aeration Decision

Review the results of the DEF Supply Module Inlet Restriction Test performed in Yes: Repair leaks or cracks
step 10. in either the suction line or
DEF tank suction fitting/pick-up
tube. Perform SCR Fault Reset
SPN 3362 FMI 31.
Were bubbles approximately half or larger than the diameter of DEF diagnostic line, No: Go to step 12.
Part Number 5299833, tubing seen during the test?
Step 12 Check for biased DEFAP sensor. Decision

B. Wait 30 seconds for DEF system pressure to leak down

C. Disconnect DEF pressure line at DEF Doser Valve to ensure system
pressure is relieved.
D. Connect Electronic Service Tool (EST) with Navistar® Engine Diagnostic
Software
E. Key ON, log into Navistar® Engine Diagnostic Software.

F. Monitor DEFAP.
Is gauge reading less than 10 psi (69 kPa)? No: Go to step 13.
Step 13 Inspect DEF Dosing Valve Connector for damage. Decision

B. Disconnect DEF Dosing Valve connector.
C. Check DEF Dosing Valve and connector terminals for: damaged or pinched
connector housing.
Are DEF dosing Valve connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
FMI 31.
Step 14 Check DEFAP circuits. Decision

Perform Test 3 (page 1210). Use Digital Multimeter (DMM), measure resistance Yes: Go to step 15
between Breakout Harness 18-559-02 Pin-7 and ECM Pin C1-63.
Is resistance less than 10 Ohms? No: Repair Open between ECM
pin C1–63 and DEF Doser Valve
SPN 3362 FMI 31.

SPN 3362 FMI 31.

Perform Test 5 (page 1212). Use Digital Multimeter (DMM), measure resistance Yes: Replace DEF Doser Valve
between Breakout Harness 18-559-02 Pin-8 and ECM Pin C1-34. for failed DEFAP sensor. Perform
FMI 31.
SPN 3362 FMI 31.
Step 17 Check DEF pressure at DEF Doser Valve Inlet. Decision

Perform DEF Doser Valve Inlet Pressure Test (page 2209). Yes: Go to step 19.
Step 18 Check DEF pressure at DEF Doser Valve Outlet Decision

Perform DEF Doser Valve Outlet Pressure Test (page 2212). Yes: Inspect DEF Doser Valve
Inlet screen for debris and
replace as needed. If no debris
is found, replace the DEF
Doser. Perform SCR Fault Reset
SPN 3362 FMI 31.
Is gauge reading less than 10 psi (69 kPa)? No: Inspect DEF Return Line
and DEF Tank return fitting for
restriction. Repair as needed.
SPN 3362 FMI 31.
Step 19 Check DEF Pressure at DEF Supply Module Outlet. Decision

Perform DEF Supply Module Outlet Pressure Test (page 2221). Yes: Go to step 20.
Is gauge reading less than 137 psi (950 kPa)? No: Repair restricted DEF
Pressure line. Perform SCR
Fault Reset Request (page
1955). After repairs are
FMI 31.

Review the results from the DEF Supply Module Outlet Pressure Test performed in Yes: Go to step 21.
step 19.
Is gauge reading greater than 108 psi (750 kPa)? No: Inspect DEF Supply Module
outlet fitting and supply module
filter for signs of blockage or
build-up. Perform SCR Fault
Step 21 Determine if DEF system can provide proper amount of DEF. Decision
Perform DEF Dosing System Test (page 1978). Yes: Check the entire system for
restrictions, debris or air leaks.
Inspect the DEF Tank filter, DEF
Supply Module Inlet screen,
DEF Supply Module filter and
DEF Doser Valve Inlet screen
for debris. Replace or repair
as needed. Perform SCR Fault
Did the pressure drop below 94 psi (650 kPa) at any time during the test? No: Go to step 22.
Review results from DEF Dosing System Test performed in step 21. Yes: End Diagnostics. Perform
1955). Retest for SPN 3362 FMI
31.
Was the volume of DEF within specification during all three times the test was run? No: Replace DEF Doser Valve.
SPN 3362 FMI 31.


Tools Required
Figure 401 DEFSM PWR Check
Test 1
A. Key OFF.
B. Disconnect the DEF Supply Module connector.
C. Connect breakout harness 18-648-01 to the vehicle harness and leave the DEF Supply Module disconnected.
4
18-648-01
0000413990
Figure 402 DEFSM GND Check
Test 2
A. Key OFF.
C1-63
7
18-559-02
0000414113
Figure 403 DEFAP GND Circuit Check
Test 3
A. Key OFF.
B. Disconnect the DEF Dosing Valve connector.
C. Connect breakout harness 18-559-02 to the vehicle harness and leave the DEF Dosing Valve disconnected.
D. Disconnect ECM C1 and C2 Connectors.
E. Connect breakout harness 12-801-05-01 to the Chassis harness and leave the ECM disconnected.
F. Connect breakout harness 12-801-05-01 to the breakout box 00-00956-08.
C1-36
5
18-559-02
0000414111
Test 4
A. Key OFF.
C1-34
8
18-559-02
0000414157
Figure 405 DEFAP Signal Circuit Check
Test 5
A. Key OFF.
SPN 3363 FMI 3 - Aftertreatment 1 Diesel Exhaust Fluid Tank Heater : Voltage Above Normal, Or
Fault Overview
Fault code sets when Engine Control Module (ECM) detects voltage signal from Diesel Exhaust Fluid Tank
Heater CTL (DEFTHC) circuit is above normal operating range.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Road Test.
Possible Causes
• DEFTHC circuit short to PWR
• Failed Diesel Exhaust Fluid Tank Heater Valve (DEFTHV)

®
Step 2 Inspect connections at Diesel Exhaust Fluid Tank Heater Valve Decision
(DEFTHV) connector.
B. Disconnect DEFTHV connector.
C. Check DEFTHV and connector terminals for: damaged or pinched wires;
connector housing.
Are DEFTHV connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
Reset Request (page 1955),
Step 3 Check DEFTHC circuit for short to power. Decision

between DEFTHV pin-4 and
ECM C1-28. After repairs are
Reset Request (page 1955),
Step 5 Check for failed DEFTHV. Decision

A. Perform Test 2 (page 1217). Yes: Replace DEFTHV. After
B. Select Tests > KOEO Aftertreatment Tests > Actuator - DEF Tank Heater
(page 1987).
1955), retest for SPN 3363 FMI
C. Select start test. 3.
D. While DEF Tank Heater test is active, use DMM, measure voltage between
Is voltage B+ ± 0.5 volts? No: End diagnostics. Perform
3.


Tools Required
Test 1
A. Key OFF.
B. Disconnect Diesel Exhaust Fluid Tank Heater Valve (DEFTHV) connector.
C. Connect Breakout Harness ZTSE4827 to vehicle harness and leave DEFTHV disconnected.
D. Key ON.
Figure 407 DEFTHV Circuit Check
Test 2
A. Key OFF.
B. Disconnect Diesel Exhaust Fluid Tank Heater Valve (DEFTHV) connector.
D. Connect Electronic Service Tool (EST) with Navistar® Engine Diagnostics to vehicle Diagnostic Connector.
E. Key ON, log in to EST.
SPN 3363 FMI 4 - Aftertreatment 1 Diesel Exhaust Fluid Tank Heater : Voltage Below Normal, Or
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Exhaust Fluid Tank Heater Valve (DEFTHV)
circuit is shorted to ground or Open Load for a calibrated period of time.
Lamp Reaction
Associated Faults
Fault Facts
None

Road Test
Possible Causes
• ECM PWR OUT circuit short to GND
• DEFTHC circuit shorted to GND
• ECM PWR OUT shorted to DEFTHC circuit
• Failed DEFTHV

®
Request (page 1955)and retest
for SPN 3363 FMI 4.

Step 3 Inspect connections at Diesel Exhaust Fluid Tank Heater Valve Decision
(DEFTHV) connector.
C. Check DEFTHV and connector terminals for: damaged or pinched wires;
connector housing.
D. Check harness from DEFTHV to the ECM for proper routing, harness
rubbing or chafing.
Step 4 Check ECM PWR circuit for short to GND. Decision

between Breakout Harness ZTSE4827 pin-1 and known good GND.
DEFTH pin-1 and ECM C1-01.
for SPN 3363 FMI 4.
Step 5 Check DEFTHC circuit for Open or high resistance. Decision

between DEFTH pin-4 and
ECM C1-28. After repairs are
Step 6 Check DEFTC circuit short to ECM PWR OUT. Decision

Perform Test 3 (page 1223). Use DMM, measure resistance between Breakout Yes: Replace DEF Tank
Harness ZTSE4827 pin-4 and pin-1. Heater Valve. After repairs are
DEFTHV pin-1 and pin-4. After
1955)and retest for SPN 3363
FMI 4.


Tools Required
Test 1
A. Key OFF.
B. Disconnect Diesel Exhaust Fluid Tank Heater (DEFTHV) and Engine Control Module (ECM) C1 connectors.
4827
0000428088
Test 2
A. Key OFF.
B. Disconnect DEFTHV and ECM C1 connectors.
Test 3
A. Key OFF.
B. Disconnect DEFTHV and ECM C1 connectors.
SPN 3363 FMI 16 - Aftertreatment 1 Diesel Exhaust Fluid Tank Heater : Data Valid But Above Normal
Fault Overview
Fault code sets when Engine Control Module (ECM) determines Diesel Exhaust Fluid Tank Temperature
(DEFTT) is too high when commanded OFF.
Lamp Reaction
Associated Faults
None
Fault Facts
If there is a problem with Diesel Exhaust Fluid Tank Heater Valve (DEFTHV), such as valve stuck open, coolant
leaking past valve seat, or valve is incorrectly installed, it can take long periods of operation at high load before
tank temperature gradually increases to fault code threshold of 165°F (75°C). When temperature drops below
165°F (75°C) due to a stopped engine, overnight parking, or reduced coolant temperature, fault code will go
inactive while root cause of issue is not present. This fault will likely be inactive when in shop.

Road Test
Possible Causes
• DEFTHV installed incorrectly (missing, bypassed, or reversed)
• Auxiliary DEF Tank heater installed
• Failed DEFTHV (stuck open)

®
1940).
Step 2 Check for proper orientation of DEFTHV. Decision

Verify DEFTHV is correctly orientated. Flow arrow on valve body should be facing Yes: Go to Step 3.
inlet of DEF tank.
Is DEFTHV facing proper direction? No: Orient DEFTHV properly.
Hose pinchers may be used to
clamp hoses so coolant doesn’t
drain out. After repairs are
FMI 16.
Step 3 Check for an auxiliary Diesel Exhaust Fluid (DEF) coolant heater. Decision
Inspect vehicle for an auxiliary DEF coolant heater. If equipped, ensure lines are Yes: Go to Step 4.
routed correctly, and not sending coolant backward through the DEF system.
If coolant heater is equipped, is it routed correctly? No: Reroute hoses to auxiliary
DEF coolant heater. After repairs
3363 FMI 16.
Step 4 Check for failed DEF head unit. Decision

Use EST with Navistar® Engine Diagnostic Software, load signals session and Yes: Replace DEFTHV. After
monitor DEF Tank Temp signal. Using Infrared Thermometer ZTSE4799, measure repairs are complete, retest for
DEF temperature inside DEF tank. SPN 3363 FMI 16.
Is EST reading within 72°F (40°C) of Infrared Thermometer reading? No: Replace DEF head unit.

SPN 3363 FMI 17 - Aftertreatment 1 Diesel Exhaust Fluid Tank Heater : Data Valid But Below Normal
Fault Overview
Fault code sets when Engine Control Module (ECM) commands Diesel Exhaust Fluid Tank Heater Valve
(DEFTHV) ON and DEF Tank Temperature does not rise.
Lamp Reaction
Associated Faults
SPN 110 SPN 111 FMI 1 SPN 1659 FMI 14 and 18
Fault Facts

Road Test
Possible Causes
• Low Coolant
• Damaged, restricted or kinked Coolant hose
• Restricted DEF tank heating loop (DEF head unit)
• Failed DEFTHV
• Restricted DEF supply module

®
Step 2 Check for low engine coolant level. Decision

Perform Coolant Level Inspection (page 2159). Yes: Go to step 3.
Is engine coolant level within specification? No: Go to Step 2 of 5.0 - Cooling
SPN 3363 FMI 17.
Step 3 Check coolant lines to and from Diesel Exhaust Fluid Tank. Decision
Check all coolant lines from engine to DEFTHV, DEF tank, DEF Supply module, Yes: Go to Step 4.
and back to engine for leaks or damage; kinks or restrictions; loose connections;
and leaking seals or gaskets.
Are all coolant lines and connections unrestricted and in good condition? No: Repair or replace leaking or
damaged coolant line, fittings,
or seals. Check engine coolant
level and add as necessary.
Step 4 Check DEF tank coolant supply and return lines for restrictions. Decision
A. Use Hose clamp pliers on vehicle coolant supply and return hoses to stop Yes: Repair restriction in either
coolant from leaking when system is open. If any coolant is lost, top off coolant supply to the DEFTHV or
coolant after all testing is complete. coolant return to the engine from
the DEF supply module. After
B. Disconnect coolant hose at DEFTHV inlet.
C. Disconnect coolant return to engine at DEF supply module outlet. SPN 3363 FMI 17.
D. Perform DEF Tank Heater Test (page 1987) to actuate DEFTHV for flow
testing.
E. Use garden hose, supply water to DEFTHV and monitor flow exiting DEF
supply module outlet fitting while DEF Tank Heater Test is active.
Is water flow into DEFTHV consistent with DEF Supply Module outlet flow? No: Go to Step 5.
A. Use Hose clamp pliers on vehicle coolant supply and return hoses to stop Yes: Replace DEFTHV. After
coolant from leaking when system is open. If any coolant is lost, top off repairs are complete, retest for
coolant after all testing is complete. SPN 3363 FMI 17.
B. Disconnect DEF tank coolant supply hose at DEF Tank Head Unit inlet.
C. Disconnect coolant return to engine at the DEF supply module outlet.
D. Use garden hose, supply water to DEF head unit inlet and monitor flow
exiting DEF supply module outlet fitting.
Is water flow into DEF head unit consistent with DEF Supply Module outlet flow? No: Go to Step 6.
A. Use Hose clamp pliers on vehicle coolant supply and return hoses to stop Yes: Replace the DEF head unit.
coolant from leaking when system is open. If any coolant is lost, top off After repairs are complete, retest
coolant after all testing is complete. for SPN 3363 FMI 17.
B. Disconnect DEF tank coolant return hose at DEF head unit outlet.
C. Disconnect coolant return to engine at the DEF supply module outlet.
D. Use garden hose, supply water to DEF head unit inlet and monitor flow
exiting DEF supply module outlet fitting.
Is water flow into DEF tank coolant return hose consistent with DEF supply module No: Replace the DEF Supply
outlet flow? Module. After repairs are
FMI 17.

SPN 3363 FMI 18 - Aftertreatment 1 Diesel Exhaust Fluid Tank Heater : Data Valid But Below Normal
Fault Overview
Fault code sets when Engine Control Module (ECM) determines Diesel Exhaust Fluid Tank Heater (DEFTHV)
valve has been on long enough to thaw DEF, but DEF dosing system is unable to prime.
Lamp Reaction
Associated Faults
SPN 110 SPN 111 SPN 1659
Fault Facts

Road Test
Possible Causes
• Failed DEFTHV
• Coolant line from DEFTHV to DEF tank leaking, damaged, kinked, or restricted
• Coolant supply line to DEFTHV leaking, damaged, kinked, or restricted
• Low engine coolant level
• Restricted DEF head unit heating coil

®
1229).

Use EST with Navistar® Engine Diagnostic Software. Key-On, check Diagnostic Yes: Go to Step 3.
Trouble Code (DTC) list for SPN 3363 FMI 18.
(page 1940).
Step 3 Check for low engine coolant level Decision

Perform Coolant Level Inspection (page 2159). Yes: Go to Step 4.
Is engine coolant level within specification? No: Go to step 2 of 5.0 - Cooling
SPN 3363 FMI 18.
Step 4 Check for damaged coolant line from DEFTHV to DEF Tank. Decision
Check coolant line between DEFTHV and DEF tank for leaks or damage; kinks or Yes: Go to Step 5.
restrictions; loose connections; and leaking seals or gaskets.
Is coolant line between DEFTHV and DEF tank unrestricted and in good condition? No: Repair or replace leaking
or damaged coolant line from
DEFTHV to DEF tank, fittings,
or seals. Check engine coolant
level and add as necessary. After
SPN 3363 FMI 18.
Step 5 Check for damaged coolant supply line to DEFTHV. Decision

Check coolant supply line to DEFTHV for leaks or damage; kinks or restrictions; Yes: Go to Step 6.
loose connections; and leaking seals or gaskets.
Is coolant supply line to DEFTHV unrestricted and in good condition? No: Repair or replace leaking
or damaged coolant supply
line to DEFTH valve. Check
engine coolant level and add
FMI 18.
A. Drain engine coolant. Yes: End Diagnostics. Retest for
SPN 3363 FMI 18.
B. Disconnect DEF Tank coolant supply hose at DEFTHV inlet
C. Disconnect coolant return at Diesel Exhaust Fluid Supply Module (DEFSM)
coolant outlet
D. Use EST with Navistar® Engine Diagnostic Software, perform DEF Tank
Heater Test (page 1987) to open DEFTHV.
E. Use garden hose, supply water to DEFTHV inlet and monitor flow exiting
DEFSM.
Is water flow into DEFTHV consistent with water flow exiting DEFSM? No: Go to Step 7.
A. Drain engine coolant. Yes: Replace Restricted DEFSM.
B. Disconnect DEF Tank coolant supply hose at DEFTHV inlet
C. Disconnect coolant hose at Diesel Exhaust Fluid Supply Module (DEFSM)
coolant inlet.
E. Use garden hose, supply water to DEFTHV inlet and monitor flow exiting
coolant supply hose to DEFSM.
Is water flow into DEFTHV consistent with water flow exiting coolant hose to DEFSM? No: Go to Step 8.
A. Drain engine coolant. Yes: Repair restricted coolant
hose to DEFSM. After repairs are
B. Disconnect DEF Tank coolant supply hose at DEFTHV inlet.
C. Disconnect coolant hose at DEF Tank coolant outlet. FMI 18
E. Use garden hose to send water through DEFTHV and monitor for flow
exiting DEF Tank.
Is water flow into DEFTHV consistent with water flow exiting DEF Tank coolant No: Go to Step 9.
outlet?
Step 9 Check DEF head unit heating coil for restrictions. Decision
A. Drain engine coolant. Yes: Replace Restricted
DEFTHV. After repairs are
B. Disconnect DEF Tank heater valve outlet.
C. Disconnect coolant hose at DEF Tank coolant outlet. FMI 18.
D. Use garden hose, supply water to DEF Tank coolant supply inlet and
monitor for flow exiting DEF Tank.
Is water flow into DEF Tank consistent with water flow exiting DEF Tank? No: Replace DEF head unit.

SPN 3364 FMI 13 - Aftertreatment 1 Diesel Exhaust Fluid Tank Quality : Out Of Calibration
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Urea Quality sensing element is out of calibration.
Lamp Reaction
Associated Faults
SPN 1761 FMI 19 SPN 3516 FMI 19
Fault Facts

Road Test
Possible Causes
• Incorrect DEF head unit installed

®
Step 2 Inspect connections at Diesel Exhaust Fluid (DEF) head unit. Decision
A. Key OFF. Yes: Install correct DEF head
C. Check DEF Head Unit and connector terminals for damaged or pinched
housing.
Are DEF Head Unit connector, harness, and terminal clean and undamaged? No: Repair connector, harness,
3364 FMI 13.

SPN 3480 FMI 2 - Aftertreatment 1 Fuel Pressure 1 : Data Erratic, Intermittent Or Incorrect
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Aftertreatment Fuel Pressure (AFTFP) sensor is
stuck in-range. Diagnostics are only performed prior to starting an active regeneration of DPF, or at Key ON
if active regeneration is continuing across key cycles. If diagnostics fail, then regeneration request is aborted.
Active regeneration of aftertreatment DPF will be disabled until next key cycle. Engine torque will be reduced if
engine is operated for an extended period of time with this fault active.
Lamp Reaction
Associated Faults
SPN 108 (BARO) SPN 3512 FMI 14 (VREF 4)
Fault Facts
This fault is detected by comparing measured pressure at three pressure reference states to see if the measured
pressures are unique in all cases. Reference pressure states are 1): Ambient, 2) Air Supply Pressure, and 3)
Fuel Pressure.
1. Ambient pressure reading is taken when the AFTHD is open AND the AFTPAA and AFTFEA are closed.
2. Air supply pressure reading is taken when the AFTPAA is open AND the AFTFEA and AFTHD are
closed.
3. Fuel pressure reading is taken when the AFTFEA is open AND the AFTHD and AFTPAA are closed.
Also, individual measured pressures at each state are checked against their expected pressure range. A fault
is set if any measured value is outside expected range.

Regeneration
Possible Causes
• Aftertreatment Fuel Doser Module or AFT Hydrocarbon Doser (AFTHD) fuel lines or connections loose,
leaking, restricted, or damaged.
• Failed AFT Fuel Doser Module
Step 1 Check for Associated Fault Codes Decision

®
for SPN 3480 FMI 2.

1940).
Step 3 Check for leaks, restriction, or damage. Decision

Check AFT Fuel Doser Module and AFT Hydrocarbon Doser (AFTHD) fuel lines and Yes: Repair or replace leaking,
connections for: loose connections, leaks, restrictions, or damage. restricted, or damaged fuel line
or connection. After repairs are
FMI 2.
Are AFT Fuel Doser Module and AFT Hydrocarbon Doser fuel lines and connections No: Replace AFT Fuel Doser
leaking, restricted, or damaged? Module. After repairs are
FMI 2.
End Diagnostic Test

SPN 3480 FMI 3 - Aftertreatment 1 Fuel Pressure 1 : Voltage Above Normal, Or Shorted To High Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Aftertreatment Fuel Pressure (AFTFP) signal
Lamp Status
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• AFTFP circuit short to power
• Failed AFTFP sensor

®
1940).
Step 2 Inspect connections at AFT Fuel Pressure (AFTFP) Sensor. Decision

A. Key OFF Yes: Go to Step 3.
B. Disconnect AFTFP Sensor Connector.
C. Check AFTFP Sensor and connector terminals for: damaged or pinched
connector housing.
Are AFTFP Sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
3480 FMI 3.
Step 3 Check AFTFP circuit for short to PWR. Decision

B. Disconnect AFTFP sensor
Test (page 1974).
D. Monitor AFTFP voltage in Navistar® Engine Diagnostics while test is active.

between AFTFP sensor pin 3
3480 FMI 3.
Step 4 Check Signal GND circuit for Open. Decision

Perform Test 1 (page 1239). Use Digital Multimeter (DMM), measure voltage Yes: Replace AFTFP Sensor.
between Breakout Harness ZTSE4845 pin 2 and PWR. After repairs are complete, retest
for SPN 3480 FMI 3.
AFTFP Sensor pin 2 and ECM
FMI 3.


Tools Required
4845
0000424362
Test 1
A. Key OFF.
B. Disconnect Aftertreatment Fuel Pressure (AFTFP) sensor.
C. Connect Breakout Harness ZTSE4845 to engine harness and leave AFTFP sensor disconnected.
D. Key ON.
SPN 3480 FMI 4 - Aftertreatment 1 Fuel Pressure 1 : Voltage Below Normal, or Shorted to Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects signal from Aftertreatment Fuel Pressure Fuel
Pressure (AFTFP) sensor is less than normal operating range for 2 seconds. Active aftertreatment regeneration
disabled until next key cycle. Engine torque will be reduced if fault is active for an extended period of time.
Lamp Reaction
Associated Faults
SPN 3512 FMI 4, 6, and 14
Fault Facts
None

Continuous
Possible Causes
• AFTFP circuit Open or short to GND
• VREF 4 circuit Open or short to GND
• Failed AFT Fuel Doser Module
Step 1 Check for associated fault codes Decision

®
for SPN 3480 FMI 4.

1940).
Step 3 Inspect connections at Aftertreatment Fuel Pressure (AFTFP) Sensor. Decision

B. Disconnect AFTFP sensor connector.
C. Check AFTFP sensor and connector terminals for: damaged or pinched
connector housing.
Are AFTFP sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness, or
terminal damage. After repairs are
4.
Step 4 Check VREF 4 circuit for Open or short to GND. Decision

Perform Test 1 (page 1243). Use Digital Multimeter (DMM) to measure voltage Yes: Go to Step 5.
GND between AFTFP pin-1 and
FMI 4.
Step 5 Check for failed AFTFP Sensor. Decision

A. Perform Test 2 (page 1243). Yes: Replace AFT Fuel Doser
C. Monitor AFTFP voltage in EST. FMI 4.
Is voltage 5 ± 0.5 volts? No: Repair open or short to GND
between AFTFP pin-3 and ECM
pin E1–37. After repairs are
FMI 4.

decision was made. Return to fault code diagnostics

See latest version of vehicle Electrical Circuit Diagram on Service Portal for additional circuit information
Tools Required
Test 1
A. Key OFF.
C. Connect Breakout Harness ZTSE4845 to engine harness and leave AFTFP disconnected.
D. Key ON, Engine OFF (KOEO)
Figure 413 AFTFP Sensor Check
Test 2
A. Key OFF.
C. Connect Breakout Harness ZTSE4845 to engine harness and leave AFTFP disconnected.
SPN 3480 FM 17 - Aftertreatment 1 Fuel Pressure 1 : Data Valid But Below Normal Operating Range
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Aftertreatment Fuel Pressure (AFTFP) sensor signal
is valid but below normal operating range. This diagnostic runs during active regeneration of Diesel Particulate
Filter (DPF). When this fault is active, active regeneration of DPF will be disabled until next key cycle. Engine
torque will be reduced if engine is operated for an extended period of time with this fault active.
Lamp Reaction
Associated Faults
None
Fault Facts
Fuel restriction diagnostic runs when Aftertreatment Hydrocarbon Doser (AFTHD) is open, Aftertreatment Fuel
Enable Actuator (AFTFEA) is open, and Aftertreatment Purge Air Actuator (AFTPAA) is closed. When enable
conditions are met, a counter will count when fuel pressure is below the minimum to dose threshold. A fault will
set when failure monitor is triggered.

Road Test
Possible Causes
• Restricted, damaged, or leaking fuel line to the aftertreatment fuel doser module
• Restricted, damaged, or leaking aftertreatment fuel doser module
• Low Fuel Delivery Pressure
• Failed AFTHD (stuck open)

®
Is SPN 3480 FMI 17 active? No: Repair other active faults.
Step 2 Inspect AFT Fuel Doser Module for damage, restrictions, and leaks. Decision
Check AFT Fuel Doser module fuel supply line from the secondary fuel filter Yes: Go to step 3.
assembly to Aftertreatment Fuel Supply Module for damage, restrictions or leaks.
Is fuel supply line in good condition, not restricted or damaged? No: Replace Aftertreatment Fuel
Supply Module fuel supply line.
Step 3 Check Fuel Pressure to Aftertreatment Fuel Supply Module Decision

Perform Aftertreatment Fuel Supply Module Inlet Pressure Test (page 2203). Yes: Go to step 4.
Is fuel pressure 105 ± 10 psi at low idle and 150 ± 10 psi at high idle? No: Repair low-pressure fuel
system. After repairs are
FMI 17.
Step 4 Decision
Perform AFT Hydrocarbon Doser Leak Test (page 1996). Yes: Replace AFTHD. After
SPN 3480 FMI 17.
Did AFTHD leak more than 5 ml of Fuel during the test? No: Replace Aftertreatment Fuel
FMI 17.

After performing diagnostic steps, if 3480 FMI 17 remains, verify if step was completed correctly and proper decision
SPN 3480 FMI 20 - Aftertreatment 1 Fuel Pressure 1 : Data Drifted High
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Aftertreatment Fuel Pressure (AFTFP) signal
voltage is stuck in range, but above a normal value.
Lamp Status
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• AFTFP circuit short to power
• Failed AFTFP sensor

®
1940).
Step 2 Inspect connections at AFT Fuel Pressure (AFTFP) Sensor. Decision

B. Disconnect AFTFP Sensor Connector.
C. Check AFTFP Sensor and connector terminals for: damaged or pinched
connector housing.
Are AFTFP Sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
3480 FMI 20.
Step 3 Check AFTFP circuit for short to PWR. Decision

B. Disconnect AFTFP sensor
Test (page 1974).
D. Monitor AFTFP voltage in Navistar® Engine Diagnostics while test is active.

between AFTFP sensor pin 3
3480 FMI 20.
Step 4 Check Signal GND circuit for Open. Decision

Perform Test 1 (page 1249). Use Digital Multimeter (DMM), measure voltage Yes: Replace AFTFP Sensor.
between Breakout Harness ZTSE4845 pin 2 and PWR. After repairs are complete, retest
AFTFP Sensor pin 2 and ECM
FMI 20.


Tools Required
4845
0000424362
Test 1
A. Key OFF.
C. Connect Breakout Harness ZTSE4845 to engine harness and leave AFTFP sensor disconnected.
D. Key ON.
SPN 3482 FMI 2 - Aftertreatment 1 Fuel Enable Actuator : Data Erratic, Intermittent Or Incorrect
Fault Overview
Fault code sets when Engine Control Module (ECM) detects an internally leaking Aftertreatment Fuel Enable
Actuator (AFTFEA) or a stuck closed Aftertreatment Hydrocarbon Doser (AFTHD). AFTHD is commanded On
at start of test. This will purge pressure in fuel supply line. A pressure sample is then taken by AFTFP. An
AFTHD restricted, stuck closed or leaking AFTFEA, or leaking AFTPAA is detected if this pressure sample is
above expected ambient pressure.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Regen
Possible Causes
• AFTHD failed or restricted
• Restricted fuel line to AFTHD
• Failed AFTFP
• Failed AFTFEA
• Failed AFTPAA

®
Key-On Engine-Off (KOEO), check DTC list for SPN 3482 FMI 2.
Is SPN 3482 FMI 2 active or pending? No: Diagnose and repair all other
active faults. After repairs are
2.
Step 2 Check fuel supply line to Aftertreatment Hydrocarbon Doser (AFTHD). Decision
Inspect the line between the Aftertreatment fuel supply and the Aftertreatment Yes: Go to Step 3.
Hydrocarbon Doser (AFTHD).
Is AFT fuel supply line free from leaks, restrictions, or damage? No: Repair or replace AFT fuel
supply line. After repairs are
2.
Step 3 Check for failed Aftertreatment Purge Air Actuator (AFTPAA). Decision
Perform Aftertreatment Purge Air Actuator Test (page 1970). Yes: Go to Step 4.
Did AFTFP increase to approximately vehicle air pressure during test? No: Replace AFTPAA. After
SPN 3482 FMI 2.
(AFTFEA).
Was 5 ml or less of fuel dispensed? No: Replace the AFT Fuel Supply
Module for a failed AFTFEA. After
SPN 3482 FMI 2.

Was 5 ml or less of fuel dispensed? No: Replace AFTHD. After repairs
FMI 2.

Perform AFT Dosing System Test (page 1993). Yes: Replace the AFT Fuel Supply
Module for a failed AFTFP sensor.
for SPN 3482 FMI 2.
Was 225 to 500 ml of fuel dispensed within 2.5 minutes? No: Replace AFTHD. After repairs
FMI 2.

SPN 3482 FMI 3 - Aftertreatment 1 Fuel Enable Actuator : Voltage Above Normal, Or Shorted To High
Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects After treatment Fuel Enable Actuator (AFTFEA)
circuit is shorted to vehicle battery or open.
Lamp Reaction
Associated Faults
None

Continuous
Possible Causes
• AFTFEA circuit failure
• AFTFEA-GND circuit failure
• Failed AFTFEA

®
FMI 3.
Step 2 Inspect connections at Aftertreatment Fuel Enable Actuator (AFTFEA). Decision

B. Disconnect AFTFEA.
C. Check AFTFEA and connector terminals for: damaged or pinched wires;
housing.
Are AFTFEA connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
3482 FMI 3.
Step 3 Check AFTFEA circuit. Decision

Harness ZTSE4760A pin-1 and pin-2.
Step 4 Check AFTFEA circuit. Decision

Perform Test 2 (page 1256). Use DMM, measure voltage between Breakout Harness Yes: Repair Open, high
ZTSE4760A pin-1 and known good GND. resistance, or short to power
between AFTFEA pin-2 and
FMI 3.
resistance between AFTFEA
SPN 3482 FMI 3.
Step 5 Check AFTFEA resistance. Decision

Perform Test 3 (page 1257). Use DMM, measure resistance between Breakout Yes: Repair short to power
Harness ZTSE4760A pin-1 and pin-2. between AFTFEA pin-1 and ECM
FMI 3
Is resistance less than 5 ohms? No: Replace AFTFEA. After
SPN 3482 FMI 3.


Tools Required
4760A
2
0000422453
Figure 415 AFTFEA circuit check
Test 1
A. Key OFF.
B. Disconnect After treatment Fuel Enable Actuator (AFTFEA) connector.
C. Connect Breakout Harness ZTSE4760A between engine harness and AFTFEA connector.
D. Key ON
Test 2
A. Key OFF.
B. Disconnect After treatment Fuel Enable Actuator (AFTFEA) connector.
C. Connect Breakout Harness ZTSE4760A to engine harness and leave AFTFEA disconnected.
D. Key ON
Figure 417 AFTFEA resistance check
Test 3
A. Key OFF.
B. Disconnect After treatment Fuel Shutoff Valve (AFTFEA) connector.
C. Connect Breakout Harness ZTSE4760A to AFTFEA connector and leave engine harness disconnected.
SPN 3482 FM 4 - Aftertreatment 1 Fuel Enable Actuator : Voltage Below Normal, Or Shorted To Low
Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects a short to ground in After treatment Fuel Enable
Actuator (AFTFEA) circuit.
Lamp Reaction
Associated Faults
None

Continuous
Possible Causes
• AFTFEA short to GND
• Failed AFTFEA

®
Is EST DTC listing SPN 3482 FMI 4 active or pending? No: Diagnose other active or
pending fault codes first. After
SPN 3482 FMI 4.
Step 2 Inspect connections at Aftertreatment Fuel Enable Actuator (AFTFEA). Decision

B. Disconnect AFTFEA.
C. Check AFTFEA and connector terminals for: damaged or pinched wires;
housing.
Are AFTFEA connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
3482 FMI 4.
Step 3 Inspect connections at After treatment Fuel Enable Actuator Decision

(AFTFEA).
Perform Test 1 (page 1261). Use Digital Multimeter (DMM), measure resistance Yes: Repair short to ground
between Breakout Harness ZTSE4760A pin-1 and known good GND. between AFTFEA pin-1 and ECM
4.
Is resistance greater than 1000 ohms? No: Replace the AFTFEA. After
SPN 3482 FMI 4.

decision was made. Return to fault diagnostics.

Tools Required
Test 1
A. Key OFF.
B. Disconnect After treatment Fuel Shutoff Valve (AFTFEA) connector.
C. Connect Breakout Harness ZTSE4760A to engine harness and leave AFTFEA disconnected.
SPN 3482 FM 7 - Aftertreatment 1 Fuel Enable Actuator : Mechanical System Not Responding Or
Out Of Adjustment
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Aftertreatment Fuel Pressure (AFTFP) sensor is
reading lower than expected when Aftertreatment Fuel Enable Actuator (AFTFEA) is commanded open.
Lamp Reaction
Associated Faults
SPN 157
Fault Facts
None.

Regeneration
Possible Causes
• Leaking fuel supply line to AFT fuel doser module
• Low-pressure fuel system failure
• Restricted Aftertreatment Fuel Enable Actuator (AFTFEA)
• Failed AFT Fuel Pressure (AFTFP) sensor

®
for SPN 3482 FMI 7.
Step 2 Check for missing, leaking, or damaged fuel supply line to AFTFEA. Decision
Key On Engine Running (KOER), inspect fuel supply line to AFTFEA for restrictions Yes: Go to Step 3.
and leaks.
Is fuel supply line to AFTFEA present and in good condition? No: Repair or replace fuel supply
to AFTFEA. After repairs are
FMI 7.
Step 3 Check Fuel Pressure to Aftertreatment Fuel Supply Module. Decision

Perform Aftertreatment Fuel Supply Module Inlet Pressure Test (page 2203). Yes: Go to Step 4.
Is Fuel Delivery Pressure 105 ± 10 psi at low idle and 150 ± 10 psi at high idle? No: Repair low-pressure fuel
FMI 7.
Step 4 Check AFT fuel flow. Decision

Check for failed AFT fuel flow. Perform AFT Dosing System Test (page 1993). Yes: Replace AFT fuel supply
module for failed AFTFP sensor.
for SPN 3482 FMI 7.
Was 225 to 500 ml of fuel dispensed within 2.5 minutes? No: Replace AFT fuel supply
module for failed AFTFEA. After
SPN 3482 FMI 7.

SPN 3482 FM 16 - Aftertreatment 1 Fuel Enable Actuator : Data Valid But Above Normal Operating
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Aftertreatment Fuel Pressure (AFTFP) sensor
is not reading a pressure increase when aftertreatment fuel enable actuator (AFTFEA) is commanded open.
Lamp Reaction
Associated Faults
SPN 3480

Regeneration
Fault Facts
None.
Possible Causes
• Leaking fuel supply line to AFT fuel doser module
• Low-pressure fuel system failure
• Restricted Aftertreatment Fuel Enable Actuator (AFTFEA)
• Failed AFT Fuel Pressure (AFTFP) sensor

®
Step 2 Check for missing, leaking, or damaged fuel supply line to AFTFEA. Decision
Key On Engine Running (KOER), inspect fuel supply line to AFTFEA for restrictions Yes: Go to Step 3.
and leaks.
Is fuel supply line to AFTFEA present and in good condition? No: Repair or replace fuel supply
to AFTFEA. After repairs are
FMI 16.
Step 3 Check Fuel Pressure to Aftertreatment Fuel Supply Module. Decision

Perform Aftertreatment Fuel Supply Module Inlet Pressure Test (page 2203). Yes: Go to Step 4.
Is Fuel Delivery Pressure 105 ± 10 psi at low idle and 150 ± 10 psi at high idle? No: Repair low-pressure fuel
FMI 16.
Step 4 Check AFT fuel flow. Decision

Check for failed AFT fuel flow. Perform AFT Dosing System Test (page 1993). Yes: Replace AFTFP sensor.
Was 225 to 500 ml of fuel dispensed within 2.5 minutes? No: Replace AFTFEA. After
SPN 3482 FMI 16.

SPN 3490 FMI 3 - Aftertreatment 1 Purge Air Actuator : Voltage Above Normal, Or Shorted To High
Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects After treatment Purge Air Actuator (AFTPAA) circuit
is shorted to vehicle battery or open.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• AFTPAA circuit short to PWR
• AFTPAA circuit Open or high resistance
• Failed AFTPAA

®
Is EST DTC listing SPN 3490 FMI 3 active or pending? No: Repair connector, harness,
3490 FMI 3.
Step 2 Inspect connections at AFTPAA connector. Decision

B. Disconnect AFTPAA connector.
C. Check AFTPAA and connector terminals for: damaged or pinched wires;
housing.
Are AFTPAA connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
3490 FMI 3.
Step 3 Inspect connections at AFTPAA. Decision

Harness ZTSE4760A pin-1 and pin-2.
Step 4 Check AFTPAA circuit for Open or high resistance. Decision

Perform Test 2 (page 1269). Use DMM, measure voltage between Breakout Harness Yes: Repair Open, high
ZTSE4760A pin-1 and known good GND. resistance, or short to power
between AFTPAA pin-2 and
FMI 3.
Is voltage B+ ± 1.0 Volts? No: Repair Open or high
resistance between AFTPAA
SPN 3490 FMI 3.
Step 5 Decision
Perform Test 3 (page 1270). Use DMM, measure resistance between Breakout Yes: Repair short to power
Harness ZTSE4760A pin-1 and pin-2. between AFTPAA pin-1 and ECM
FMI 3.
Is Resistance between 7.9 and 8.9 Ohms? No: Replace AFTPAA . After
SPN 3490 FMI 3.


Tools Required
4760A
2
0000422453
Figure 419 AFTPAA Circuit Check
Test 1
A. Key OFF.
B. Disconnect After treatment Purge Air Actuator (AFTPAA) connector.
C. Connect Breakout Harness ZTSE4760A between engine harness and AFTPAA connector.
D. Key ON, Engine Off.
Test 2
A. Key OFF.
B. Disconnect After treatment Purge Air Actuator (AFTPAA) connector.
C. Connect Breakout Harness ZTSE4760A to engine harness and leave AFTPAA disconnected.
D. Key ON, Engine Off.
Test 3
A. Key OFF.
B. Disconnect After treatment Fuel Shutoff Valve (AFTPAA) connector.
C. Connect Breakout Harness ZTSE4760A to AFTPAA and leave engine harness disconnected.
SPN 3490 FM 4 - Aftertreatment 1 Purge Air Actuator : Voltage Below Normal, Or Shorted To Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects a short to ground in After treatment Purge Air
Actuator (AFTPAA) circuit.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• AFTPAA CTL-H short to GND
• Failed AFTPAA

®
Is EST DTC listing SPN 3490 FMI 4active or pending? No: Repair connector, harness,
3490 FMI 4.
Step 2 Inspect connections at AFTPAA connector. Decision

C. Check AFTPAA and connector terminals for: damaged or pinched wires;
housing.
Are AFTPAA connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
3490 FMI 4.
Step 3 Check AFTPAA CTL-H circuit for short to GND Decision

Perform Test 1 (page 1274). Use DMM, measure resistance between Breakout Yes: Replace AFTPAA. After
Harness ZTSE4760A pin-1 and known good GND. repairs are complete, retest for
SPN 3490 FMI 4.
Is resistance greater than 1000 ohms? No: Repair short to ground
between AFTPAA pin-1 and
FMI 4.


Tools Required
Test 1
A. Key OFF.
C. Connect Breakout Harness ZTSE4760A to engine harness and leave AFTPAV disconnected.
SPN 3490 FMI 7 - Aftertreatment 1 Purge Air Actuator : Mechanical System Not Responding Or Out Of
Adjustment
Fault Overview
Fault code sets when Engine Control Module (ECM) detects signal from Aftertreatment Fuel Pressure (AFTFP)
sensor is lower than expected when Aftertreatment Purge Air Actuator (AFTPAA) is commanded ON.
Lamp Reaction
Associated Faults
None

Regeneration
Possible Causes
• Missing or leaking air supply line to AFTPAA
• Missing or leaking air supply line to AFT Fuel Doser module
• Failed AFTPAA (stuck closed)

®
On Engine Off (KOEO), check DTC list for SPN 3490 FMI 7.
active faults. After repairs are
FMI 7.
Step 2 Check for missing, leaking, or damaged air supply line to Aftertreatment Decision
Purge Air Actuator (AFTPAA).
Key On Engine Running (KOER), inspect air supply line to AFTPAA for restrictions Yes: Go to Step 3.
and leaks. Supply line should be plumbed directly to the air dryer.
Is air supply line to AFTPAA present, in good condition and free of leaks? No: Repair or replace air supply
to AFTPAA. After repairs are
FMI 7.
Step 3 Check for missing, leaking, or damaged air supply line from AFTPAA to Decision
AFT Fuel Doser module.
Key On Engine Off (KOEO), inspect air supply line between AFTPAA and AFT Fuel Yes: Go to Step 4.
Doser Module for restrictions and leaks.
Is air supply line to AFT Fuel Doser Module present, in good condition and free No: Repair or replace air supply
of leaks? line to AFT Fuel Doser module.
for SPN 3490 FMI 7.
Step 4 Check AFTPAA proper operation. Decision

Perform Aftertreatment Purge Air Actuator Test (page 1970). Yes: End diagnostics, retest for
SPN 3490 FMI 7.
Did Aftertreatment Fuel Pressure (AFTFP) increase to approximately vehicle air No: Go to Step 5.
tank pressure when AFTPAA was commanded ON?
Step 5 Check AFTPAA proper operation. Decision

Using results from previously performed Aftertreatment Purge Air Actuator Test Yes: Replace AFT Fuel Doser
(page 1970). Module. After repairs are
FMI 7.
Was vehicle air pressure heard exiting the AFTPAA during the test? No: Replace AFT Purge Air
Actuator. After repairs are
FMI 7.

SPN 3509 FMI 3 - Sensor Supply Voltage 1 : Voltage Above Normal, Or Shorted To High Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that VREF 1 circuit voltage is greater than 5.1 volts.
Lamp Reaction
Associated Faults
None
Fault Facts
None.

Continuous
Possible Causes
• VREF 1 circuit short to PWR

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostic Software. Key Yes: Go to Step 2.
Is EST DTC list SPN 3509 FMI 3 active or pending? No: Repair all other Active faults.
for SPN 3509 FMI 3.

connector housing.
3509 FMI 3.
Step 3 Check VREF 1 Circuit for short to PWR. Decision

ZTSE4485A pin-C and known good GND. repairs are complete, retest for
SPN 3509 FMI 3.
Is voltage 5 ± 0.1 volts? No: Repair short to PWR or
GND between APP pin-C and
FMI 3.


Tools Required
Test 1
A. Key OFF.
C. Connect Breakout Harness ZTSE4485A to engine harness and leave APP sensor disconnected.
D. Key-On Engine-Off (KOEO)
SPN 3509 FMI 4 - Sensor Supply Voltage 1 : Voltage Below Normal, Or Shorted To Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that VREF 1 circuit shorted to ground.
Lamp Reaction
Associated Faults
None
Fault Facts
None.

Continuous
Possible Causes
• VREF 1 circuit short to GND

for SPN 3509 FMI 4.

connector housing.
3509 FMI 4.

SPN 3509 FMI 4.
FMI 4.


Tools Required
Test 1
A. Key OFF.
SPN 3509 FMI 6 - Sensor Supply Voltage 1 : Current Above Normal Or Grounded Circuit
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that VREF 1 circuit voltage is less than 4.9 volts.
Lamp Reaction
Associated Faults
None
Fault Facts
None.

Continuous
Possible Causes

for SPN 3509 FMI 6.

connector housing.
3509 FMI 6.

SPN 3509 FMI 6.
FMI 6.


Tools Required
Test 1
A. Key OFF.
SPN 3509 FMI 14 - Sensor Supply Voltage 1 : Special Instructions
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that VREF 1 circuit voltage is greater than 5.1 volts
or less than 4.9 volts.
Lamp Reaction
Associated Faults
None
Fault Facts
None.

Continuous
Possible Causes


connector housing.
3509 FMI 14.

SPN 3509 FMI 14.
FMI 14.


Tools Required
Test 1
A. Key OFF.
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None.

Continuous
Possible Causes
• Failed Intake Air Temperature/ Mass Air Flow (IAT/MAF) sensor
• Failed Engine Fuel Rail Pressure (EFRP) sensor

for SPN 3510 FMI 3.
Step 2 Inspect connections at Intake Air Temperature/ Mass Air Flow Decision
(IAT/MAF) sensor
B. Disconnect IAT/MAF connector.
C. Check IAT/MAF and connector terminals for: damaged or pinched wires;
connector housing.
Are IAT/MAF connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
3510 FMI 3.
connector housing.
3510 FMI 3.

Perform Test 1 (page 1292). Use DMM, measure voltage between Breakout Harness Yes: Replace IAT/MAF sensor.
12-163-02 pin-2 and known good GND. After repairs are complete, retest
for SPN 3510 FMI 3.
Step 5 Check VREF 2 Circuit for short to GND. Decision

Perform Test 2 (page 1293). Use DMM, measure voltage between Breakout Harness Yes: Repair short to PWR or
ZTSE4829 pin-2 and known good GND. GND in VREF 2. After repairs are
FMI 3.
Is voltage 5 ± 0.1 volts? No: Replace fuel rail. After
SPN 3510 FMI 3.


Tools Required
12-163-02
0000424364
Test 1
A. Key OFF.
B. Disconnect Intake Air Temperature/ Mass Air Flow (IAT/MAF) sensor.
C. Connect Breakout Harness 12-163-02 to engine harness and leave IAT/MAF sensor disconnected.
Test 2
A. Key OFF.
B. Disconnect IAT/MAF sensor.
C. Disconnect Engine Fuel Rail Pressure (EFRP) sensor
D. Connect Breakout Harness ZTSE4829 to engine harness and leave IAT/MAF sensor disconnected.
E. Key-On Engine-Off (KOEO)
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that VREF 2 circuit is shorted to ground.
Lamp Reaction
Associated Faults
None
Fault Facts
None.

Continuous
Possible Causes

for SPN 3510 FMI 4.
(IAT/MAF) sensor
connector housing.
3510 FMI 4.
connector housing.
3510 FMI 4.

for SPN 3510 FMI 4.

FMI 4.
SPN 3510 FMI 4.


Tools Required
12-163-02
0000424364
Test 1
A. Key OFF.
Test 2
A. Key OFF.
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None.

Continuous
Possible Causes

for SPN 3510 FMI 6.
(IAT/MAF) sensor
connector housing.
3510 FMI 6.
connector housing.
3510 FMI 6.

for SPN 3510 FMI 6.

FMI 6.
SPN 3510 FMI 6.


Tools Required
12-163-02
0000424364
Test 1
A. Key OFF.
Test 2
A. Key OFF.
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None.

Continuous
Possible Causes

(IAT/MAF) sensor
connector housing.
3510 FMI 14.
connector housing.
3510 FMI 14.


FMI 14.
SPN 3510 FMI 14.


Tools Required
12-163-02
0000424364
Test 1
A. Key OFF.
Test 2
A. Key OFF.
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None.

Continuous
Possible Causes
• Failed Diesel Exhaust Fluid (DEF) Doser Valve sensor
• Failed Diesel Particulate Filter Differential Pressure/ Diesel Particulate Filter Outlet Pressure
(DPFDP/DPFOP) sensor
• Failed Remote Accelerator Pedal Position (RAPP) sensor (if equipped)

(page 1940).
Step 2 Inspect connections at Diesel Exhaust Fluid (DEF) Doser Valve sensor Decision
B. Disconnect DEF Doser Valve connector.
C. Check DEF Doser Valve and connector terminals for: damaged or pinched
Are DEF Doser Valve connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
3511 FMI 3.
Step 3 Inspect connections at Diesel Particulate Filter Differential Pressure/ Decision

Diesel Particulate Filter Outlet Pressure (DPFDP/DPFOP) sensor
B. Disconnect DPFDP/DPFOP connector.
C. Check DPFDP/DPFOP and connector terminals for: damaged or pinched
Are DPFDP / DPFOP connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
3511 FMI 3.

A. Key OFF. Yes: If equipped with RAPP, go to
Step 5. If no RAPP is equipped,
go to Step 6.
connector housing.
3511 FMI 3.
Step 5 Inspect connections at Remote Accelerator Pedal Position (RAPP) Decision

connector.
B. Disconnect RAPP connector.
C. Check RAPP and connector terminals for: damaged or pinched wires;

connector housing.
Are RAPP connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
3511 FMI 3.

Perform Test 1 (page 1313). Use DMM, measure voltage between Breakout Harness Yes: Replace DEFDV. Perform
18-650-01 pin-5 and known good GND. SCR Fault Reset Request
FMI 3
Is voltage 5V ± 0.1 volts? No: Go to Step 7.

Perform Test 2 (page 1314). Use DMM, measure voltage between Breakout Harness Yes: Replace DPFDP/OP sensor.
for SPN 3511 FMI 3.

Perform Test 3 (page 1315) . Use DMM, measure voltage between Breakout Yes: Replace APP sensor. After
Harness ZTSE4485A pin-D and known good GND. repairs are complete, retest for
SPN 3511 FMI 3.
Is voltage 5 ± 0.1 volts? No: If equipped with RAPP, go to
repair short to PWR or GND
in VREF 3. After repairs are
FMI 3

Perform Test 4 (page 1316) . Use DMM, measure voltage between Body Builder Yes: Replace RAPP. After repairs
Connector 2 pin-B and known good GND. are complete, retest for SPN
3511 FMI 3.
Is voltage 5 ± 0.1 volts? No: Repair short to PWR or GND
FMI 3.


Tools Required
5
18-559-02
0000418908
Test 1
A. Key OFF.
B. Disconnect DEFDV
C. Connect Breakout Harness 18-559-02 to vehicle harness and leave DEFDV disconnected.

Test 2
A. Key OFF.
(DPFOP) sensor.
C. Connect Breakout Harness 12-575-01 to engine harness and leave DPFDP/DPFOP sensor disconnected.
D. Key ON.
Test 3
A. Key OFF.
Test 4
A. Key OFF.
B. Disconnect Body Builder Connector 2.
C. Use Engine Terminal Test Kit ZTSE4435C, insert proper terminal into Body Builder Connector 2 pin-B.
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None.

Continuous
Possible Causes

(page 1940).
3511 FMI 4.

3511 FMI 4.

go to Step 6.
connector housing.
3511 FMI 4.

connector.

connector housing.
3511 FMI 4.

FMI 4

for SPN 3511 FMI 4.

SPN 3511 FMI 4.
FMI 4

3511 FMI 4.
FMI 4.


Tools Required
5
18-559-02
0000418908
Test 1
A. Key OFF.
B. Disconnect DEFDV
Test 2
A. Key OFF.
(DPFOP) sensor.
D. Key ON.
Test 3
A. Key OFF.
Test 4
A. Key OFF.
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None.

Continuous
Possible Causes

(page 1940).

3511 FMI 6.


3511 FMI 6.

go to Step 6.
connector housing.
3511 FMI 6.

connector.
connector housing.
3511 FMI 6.

FMI 6

for SPN 3511 FMI 6.

SPN 3511 FMI 6.
FMI 6

3511 FMI 6.
FMI 6.


Tools Required
5
18-559-02
0000418908
Test 1
A. Key OFF.
B. Disconnect DEFDV
Test 2
A. Key OFF.
(DPFOP) sensor.
D. Key ON.
Test 3
A. Key OFF.
Test 4
A. Key OFF.
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None.

Continuous
Possible Causes

(page 1940).
3511 FMI 14.

3511 FMI 14.

go to Step 6.
connector housing.
3511 FMI 14.

connector.

connector housing.
3511 FMI 14.

FMI 14


SPN 3511 FMI 14.
FMI 14

3511 FMI 14.
FMI 14.


Tools Required
5
18-559-02
0000418908
Test 1
A. Key OFF.
B. Disconnect DEFDV
Test 2
A. Key OFF.
(DPFOP) sensor.
D. Key ON.
Test 3
A. Key OFF.
Test 4
A. Key OFF.
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Failed Intake Manifold Pressure (IMP) sensor
• Failed Engine Oil Pressure (EOP) sensor
• Failed Aftertreatment Fuel Pressure (AFTFP) sensor
• Failed Fuel Delivery Pressure (FDP) sensor
• Failed Engine Back Pressure (EBP) sensor

®
(page 1940).
Step 2 Inspect connections at Intake Manifold Pressure (Inspect connections Decision

at Intake Manifold Pressure (IMP) sensor) sensor

connector housing.
3512 FMI 3.
Step 3 Inspect connections at Aftertreatment Fuel Pressure (AFTFP) sensor. Decision

B. Disconnect AFTFP connector.
C. Check AFTFP and connector terminals for: damaged or pinched wires;
connector housing.
Are AFTFP connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
3512 FMI 3.
Step 4 Inspect connections at Engine Oil Pressure (EOP) sensor Decision

B. Disconnect Variable EOP connector.
C. Check Variable EOP and connector terminals for: damaged or pinched
Are Variable EOP connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
3512 FMI 3.
Step 5 Inspect connections at Engine Back Pressure (EBP) sensor. Decision

A. Key OFF. Yes: If equipped with a FDP
sensor, go to Step 6. If no FDP
sensor present, go to Step 7.
connector housing.
3512 FMI 3.
Step 6 Inspect connections at Fuel Delivery Pressure (FDP) sensor. Decision

B. Disconnect FDP connector.
C. Check FDP and connector terminals for: damaged or pinched wires;

connector housing.
Are FDP connector, harness, and terminals clean and undamaged? No: Repair connector, harness,

3512 FMI 3.
Step 7 Check VREF Circuit for short. Decision

Perform Test 1 (page 1343). Use DMM, measure voltage between Breakout Harness Yes: Replace IMP sensor. After
SPN 3512 FMI 3.
Step 8 Check VREF circuit for short. Decision

Perform Test 2 (page 1343). Use DMM, measure voltage between Breakout Harness Yes: Replace AFTFP sensor.
ZTSE4845 pin-1 and known good GND. After repairs are complete, retest
for SPN 3512 FMI 3.

Perform Test 3 (page 1344). Use DMM, measure voltage between Breakout Harness Yes: Replace EOP sensor. After
SPN 3512 FMI 3.

Perform Test 4 (page 1345). Use DMM, measure voltage between Breakout Harness Yes: Replace EBP sensor. After
SPN 3512 FMI 3.
Is voltage 5 ± 0.1 volts? No: If equipped with a FDP
sensor present, replace engine
sensor harness. After repairs are
FMI 3

Perform Test 5 (page 1346). Use DMM, measure voltage between Breakout Harness Yes: Replace FDP sensor. After
SPN 3512 FMI 3.
Is voltage 5 ± 0.1 volts? No: Replace engine sensor
harness. After repairs are
FMI 3.


Tools Required
Test 1
A. Key OFF.
B. Disconnect IMP sensor.
Test 2
A. Key OFF.
B. Leave previously disconnected sensors disconnected.
C. Disconnect AFTFP sensor.
D. Connect Breakout Harness ZTSE4845 to engine harness and leave AFTFP sensor disconnected.
E. Key On Engine Off (KOEO)
Test 3
A. Key OFF.
C. Disconnect EOP.
D. Connect Breakout Harness ZTSE4850 to engine harness and leave EOP sensor disconnected.
Test 4
A. Key OFF.
C. Disconnect EBP.
D. Connect Breakout Harness ZTSE4850 to engine harness and leave EBP sensor disconnected.
Test 5
A. Key OFF.
C. Disconnect FDP.
D. Connect Breakout Harness ZTSE4850 to engine harness and leave FDP sensor disconnected.
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes

®
(page 1940).


connector housing.
3512 FMI 4.

connector housing.
3512 FMI 4.

3512 FMI 4.

connector housing.
3512 FMI 4.


connector housing.

3512 FMI 4.

SPN 3512 FMI 4.

for SPN 3512 FMI 4.

SPN 3512 FMI 4.

SPN 3512 FMI 4.
FMI 4

SPN 3512 FMI 4.
FMI 4.


Tools Required
Test 1
A. Key OFF.
Test 2
A. Key OFF.
Test 3
A. Key OFF.
C. Disconnect EOP.
Test 4
A. Key OFF.
C. Disconnect EBP.
Test 5
A. Key OFF.
C. Disconnect FDP.
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes

®
(page 1940).


connector housing.
3512 FMI 6.

connector housing.
3512 FMI 6.

3512 FMI 6.

connector housing.
3512 FMI 6.


connector housing.

3512 FMI 6.

SPN 3512 FMI 6.

for SPN 3512 FMI 6.

SPN 3512 FMI 6.

SPN 3512 FMI 6.
FMI 6

SPN 3512 FMI 6.
FMI 6.


Tools Required
Test 1
A. Key OFF.
Test 2
A. Key OFF.
Test 3
A. Key OFF.
C. Disconnect EOP.
Test 4
A. Key OFF.
C. Disconnect EBP.
Test 5
A. Key OFF.
C. Disconnect FDP.
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes

®
(page 1940).


connector housing.

3512 FMI 14.

connector housing.
3512 FMI 14.

3512 FMI 14.

connector housing.
3512 FMI 14.

connector housing.
3512 FMI 14.

SPN 3512 FMI 14.


SPN 3512 FMI 14.

SPN 3512 FMI 14.
FMI 14

SPN 3512 FMI 14.
FMI 14.


Tools Required
Test 1
A. Key OFF.
Test 2
A. Key OFF.
Test 3
A. Key OFF.
C. Disconnect EOP.
Test 4
A. Key OFF.
C. Disconnect EBP.
Test 5
A. Key OFF.
C. Disconnect FDP.
SPN 3515 FMI 3 - Aftertreatment 1 Diesel Exhaust Fluid Temperature 2 : Voltage Above Normal, Or
Fault Overview
This Fault sets when temperature sensor in Diesel Exhaust Fluid (DEF) head unit is shorted to PWR or voltage
is too high.
Lamp Reaction
Associated Faults
SPN 1761 FMI 19 SPN 3516 FMI 19
Fault Facts

Continuous
Possible Causes

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostic Software. Yes: Go to Step 2
Key-On, check Diagnostic Trouble Code (DTC) list for Associated Faults(page
1373).
3515 FMI 3.

Is SPN 3515 FMI 3 active? No: Repair active faults. After
FMI 3.

C. Check DEF head unit connector terminals for: damaged or pinched wires; (page 1955) and retest for SPN
moisture or corroded terminals; loose, bent, or broken pins; or broken 3515 FMI 3.
connector housing.
End Diagnostic Test

SPN 3515 FMI 4 - Aftertreatment 1 Diesel Exhaust Fluid Temperature 2 : Voltage Below Normal, Or
Fault Overview
This fault sets when temperature sensor in Diesel Exhaust Fluid (DEF) head unit is shorted to GND or voltage
is too low.
Lamp Reaction
Associated Faults
SPN 1761 FMI 19 SPN 3516 FMI 19
Fault Facts

Continuous
Possible Causes
• Failed DEF Head Unit

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostic Software. Yes: Go to Step 2
1375).
3515 FMI 4.

Is SPN 3515 FMI 4 active? No: Repair active faults. After
FMI 4.

B. DEF head unit connector.
C. Check DEF head unit connector terminals for: damaged or pinched wires; (page 1955) and retest for SPN
moisture or corroded terminals; loose, bent, or broken pins; or broken 3515 FMI 4.
connector housing.
End Diagnostic Test

SPN 3515 FMI 10 - Aftertreatment 1 Diesel Exhaust Fluid Temperature 2 : Abnormal Rate of Change
Fault Overview
This Fault sets when temperature sensor in Diesel Exhaust Fluid (DEF) head unit is reading an unexpected
value.
Lamp Reaction
Associated Faults
SPN 110 FMI 2, 3, and 4 SPN 171 FMI 2, 3, and 4 SPN 1761 FMI 19 SPN 2630 FMI 2, 3, and 4
SPN 3516 FMI 19
Fault Facts

Road Test
Possible Causes
• Aftermarket engine block heater installed

®
check Diagnostic Trouble Code (DTC) list for Associated Faults(page 1377).

Use EST with Navistar® Engine Diagnostic Software, Key ON, check DTC list for Yes: Go to Step 3.
SPN 3515 FMI 10.
Is SPN 3515 FMI 10 active or pending? No: Repair other active faults.
Step 3 Check for failed DEF head unit. Decision

®
Use EST with Navistar Engine Diagnostic Software, load signals session and Yes: Go to Step 4.
monitor DEF Tank Temp signal. Using Infrared Thermometer ZTSE4799, measure
DEF temperature inside DEF tank.
Is EST reading within 72°F (40°C) of Infrared Thermometer reading? No: Replace DEF head unit. After
SPN 3515 FMI 10.
Step 4 Check for Block heater, Auxiliary Power Unit (APU) or other Auxiliary Decision
coolant heaters being used.
Review customer complaint, interview vehicle operator and view fault code freeze Yes: Clear fault code after all
frame data. other faults have been diagnosed.
Was fault code set after using a Block heater, Auxiliary Power Unit (APU) or other No: End diagnostics, retest for
Auxiliary coolant heater overnight? SPN 3515 FMI 10.
End Diagnostic Test

SPN 3515 FMI 20 - Aftertreatment 1 Diesel Exhaust Fluid Temperature 2 : Data Drifted High
Fault Overview
Fault code sets when Diesel Exhaust Fluid (DEF) head unit detects temperature sensor is reading in range, but
too high for current conditions.
Lamp Reaction
Associated Faults
SPN 1761 FMI 19 SPN 3031 FMI 2, 3, 4, and SPN 3515 SPN 3 and 4 SPN 3516
19
Fault Facts

Continuous
Possible Causes
• Incorrectly routed DEF Tank Coolant Lines
• Diesel Exhaust Fluid Tank Heater Valve (DEFTHV) installed incorrectly

Step 2 Verify coolant lines are routed properly. Decision

Perform DEF Head Unit Coolant Line Routing Inspection (page 2215). Yes: Go to Step 3.
through DEF system. After repairs
FMI 20.

Review results from DEF Head Unit Coolant Line Routing Inspection preformed Yes: Replace DEF head unit.
in Step 2. After repairs are complete, retest
Is DEFTHV installed correctly? No: Reposition DEFTHV properly.
End Diagnostic Test

SPN 3516 FMI 2 - Aftertreatment 1 Diesel Exhaust Fluid Concentration : Data Erratic, Intermittent
Or Incorrect
Fault Overview
Diesel Exhaust Fluid (DEF) head unit internal temperature sensor is above maximum operating temperature.
Lamp Reaction
Associated Faults
Fault Facts

Road Test
Possible Cause

for SPN 3516 FMI 2.

®
Use EST with Navistar Engine Diagnostics, Key ON Engine OFF (KOEO), check Yes: Go to Step 3.
DTC list for SPN 3516 FMI 2.
Is SPN 3516 FMI 2 active or pending? No: Repair Active faults. After
SPN 3516 FMI 2.
Step 3 Perform DEF head unit Coolant Line Routing Inspection. Decision
Perform DEF Head Unit Coolant Line Routing Inspection (page 2215). Check Yes: Go to Step 4.
DEF tank coolant lines routing for reverse flow. Flow from the engine should go
through the DEF Tank Heater Valve, DEF head unit, DEF supply module and back
to the engine.
FMI 2.

Verify that DEFTHV is installed correctly and coolant supply flow arrow is facing Yes: Replace DEF head unit.
inlet of DEF tank. After repairs are complete, retest
for SPN 3516 FMI 2.
for SPN 3516 FMI 2.
End Diagnostic Test

SPN 3516 FMI 3 - Aftertreatment 1 Diesel Exhaust Fluid Concentration : Voltage Above Normal, Or
Fault Overview
This fault code sets when Urea Quality Sensor (UQS) sensing element voltage is too high or is shorted to power.
Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is on first drive cycle.
Associated Faults
Fault Facts

Continuous
Possible Cause
• Failed DEFTHV
• Failed DEF Tank head unit

3516 FMI 3.

Use EST, Key ON Engine OFF (KOEO), check DTC list for SPN 3516 FMI 3. Yes: Go to Step 3.
FMI 3.

FMI 3.

Review results from DEF Head Unit Coolant Line Routing Inspection preformed Yes: Go to Step 5.
in Step 3.
3516 FMI 3.

Perform DEFTHV Coolant Flow Test (page 2230). Yes: If equipped with Ultrasonic
DEF head unit, ONLY replace
DEFTHV. If equipped with Float
/ Optical DEF head unit, replace
both DEFTHV and DEF head
3516 FMI 3.
Is there a steady, constant stream of coolant after allowing 30 seconds of residual No: Replace DEF head unit. After
coolant to exit? repairs are complete, perform
FMI 3.
End Diagnostic Test

SPN 3516 FMI 4 - Aftertreatment 1 Diesel Exhaust Fluid Concentration : Voltage Below Normal, Or
Fault Overview
This fault code sets when Urea Quality Sensor (UQS) sensing element voltage is too low or is shorted to ground.
Lamp Reaction
Associated Faults
Fault Facts

Continuous
Possible Cause
• Failed DEFTHV
• Failed DEF Tank head unit

3516 FMI 4.

Use EST, Key ON Engine OFF (KOEO), check DTC list for SPN 3516 FMI 4. Yes: Go to Step 3.
FMI 4.

FMI 4.

in Step 3.
3516 FMI 4.

3516 FMI 4.
FMI 4.
End Diagnostic Test

SPN 3516 FMI 10 - Aftertreatment 1 Diesel Exhaust Fluid Concentration : Abnormal Rate Of Change
Fault Overview
Fault code sets when Diesel Exhaust Fluid (DEF) head unit detects Urea Quality Sensor (UQS) is reading an
unexpected value.
Lamp Reaction
Associated Faults
SPN 1761 FMI 19 SPN 3031 FMI 19 SPN 3515 SPN 3, 4, 10, SPN 3516 FMI 2, 3, 4, 12,
and 20 and 19
Fault Facts

Continuous
Possible Causes
• Contaminated or degraded DEF
• Aerated DEF
• Failed DEFTHV

3516 FMI 10.

Perform DEF Quality Inspection (page 2228). Yes: Removing air bubbles from
boot has corrected fault condition.
Perform SCR Fault Reset Request
3516 FMI 10.
Was there air bubbles removed from DEF head unit silicone boot? No: Go to Step 3.

Review results from DEF Quality Test performed in Step 2. Yes: Go to Step 4.
Is urea concentration between 30 and 34% and free of contamination or debris? No: Drain DEF tank, flush with
and / or known good DEF. After
FMI 10.

Review results from DEF Quality Test performed in step 2. Yes: Go to Step 5.
Is the concentration signal displayed in the service tool matching Refractometer No: Replace DEF head unit. After
reading within 3%? repairs are complete, perform
FMI 10.


in Step 5.
3516 FMI 10.

3516 FMI 10.
FMI 10.
End Diagnostic Test

SPN 3516 FMI 12 - Aftertreatment 1 Diesel Exhaust Fluid Concentration : Bad Intelligent Device Or
Component
Fault Overview
This Fault sets when Engine Control Module (ECM) detects Diesel Exhaust Fluid (DEF) head unit has an internal
error.
Lamp Reaction
Associated Faults
SPN 1761 FMI 19 SPN 3031 FMI 19 SPN 3516 FMI 2, 3, 4, and
19
Fault Facts

Road test
Possible Causes

®

Use EST, Key On Engine Off (KOEO), check DTC list for SPN 3516 FMI 12. Yes: Replace DEF head unit.
Is SPN 3516 FMI 12 active or pending? No: Repair other Active faults.
End Diagnostic Test

SPN 3516 FMI 15 - Aftertreatment 1 Diesel Exhaust Fluid Concentration : Data Valid But Above Normal
Fault Overview
Fault code sets when Urea Quality Sensor (UQS) detects DEF is contaminated, degraded, or incorrect.
Lamp Reaction
Red Stop Lamp (RSL) will illuminate when this fault is detected during first drive cycle.
Associated Faults
and 20 and 19
Fault Facts

Continuous
Possible Causes
• Aerated DEF
• Failed DEF Tank Head Unit

3516 FMI 15.

Is urea concentration between 30 and 34% and free of any bubbles, contamination No: If air bubbles are present,
or debris? remove them. If debris or
contamination found, drain DEF
tank, flush with distilled water, and
fill with new and / or known good
DEF. After repairs are complete,
3516 FMI 15.

FMI 15.


in Step 4. After repairs are complete,
3516 FMI 15.
3516 FMI 15.
End Diagnostic Test

SPN 3516 FMI 19 - Aftertreatment 1 Diesel Exhaust Fluid Concentration : Received Network Data In
Error
Fault Overview
This Fault sets when Engine Control Module (ECM) does not detect Diesel Exhaust Fluid (DEF) head unit
communication on private J1939 CAN bus. Engine torque will be reduced if fault is active for a limited period of
time. Engine torque will be severely reduced and vehicle speed will be limited after extended engine operation
Lamp Reaction
Associated Faults
Fault Facts
power circuit, ground circuit, or switched ignition relay problem. The following components share J1939 CAN,
power and ground circuits: EGR Valve (EGRV), VGT Actuator (VGTA), AFT temperature sensor module, NOx
OUT sensor module, NOx IN sensor module, Particulate Matter (PM) sensor module and DEF head unit. Verify

Continuous
Possible Causes
• AFT Smart Sensor relay PWR circuit Open or short to GND
• Private CAN-H circuit Open or short to GND
• Private CAN-L circuit Open or short to GND
• Private CAN-H circuit short to PWR
• Private CAN-L circuit short to PWR
• Private CAN-H short to Private CAN-L

®
After repairs are complete, perform
FMI 19.

Engine Off (KOEO), check Diagnostic Trouble Code (DTC) list for SPN 3516
FMI 19.
3516 FMI 19.
Step 3 Inspect DEF head unit and connector. Decision

connector housing.
Step 4 Check voltage drop across DEF head unit. Decision


DEF head unit.


and pin-4.
Step 5 Check AFT Smart Sensor relay PWR circuit for Open or short to GND. Decision
A. Key Off. Yes: Repair Open or high
resistance between DEF head
unit pin-3 and GND. After repairs
C. Connect Breakout Harness 18-124-01 between vehicle harness and are complete, perform SCR Fault
DEF head unit. Reset Request (page 1955), and
and known good GND.
Is voltage B+ ± 0.5 volts? No: Repair Open, short to ground,
or high resistance between DEF
head unit pin-4 and AFT Smart
Sensor relay pin-30. After repairs

DEF head unit.
and known good GND.

DEF head unit.

and known good GND.
Step 8 Check for Private CAN-H shorted to Private CAN-L. Decision

C. Connect Breakout Harness 18-124-01 to vehicle harness and leave DEF
head unit disconnected.
pin-1 and pin-2.
Is resistance greater than 55 ohms? No: Repair short between CAN-H
and CAN-L, or remove extra
terminating resistor that has been
added. After repairs are complete,
3516 FMI 19.

A. Key Off. Yes: Repair failed terminating
resistor(s) or Open between CAN
circuit and terminating resistors.
C. Connect Breakout Harness 18-124-01 to vehicle harness and leave DEF After repairs are complete, perform
head unit disconnected. SCR Fault Reset Request (page
FMI 19.
pin-1 and pin-2.
Is resistance greater than 65 ohms? No: Go to Step 10.
Step 10 Check CAN-H on isolated DEF head unit. Decision


breakout harness. Leave CAN circuits disconnected.
E. Use DMM, measure voltage between pin-2 (CAN-H) and known good
GND.
Step 11 Check CAN-L on isolated DEF head unit. Decision

A. Key Off. Yes: Reinstall DEF Head Unit. End
diagnostics. Retest for fault.
breakout harness. Leave CAN circuits disconnected
E. Use DMM, measure voltage between pin-1 (CAN-L) and known good
GND
Step 12 DEF Tank Heater Valve (DEFTHV) Coolant Flow Test. Decision
Perform DEFTHV Coolant Flow Test (page 2230). Yes: Replace DEFTHV and
DEF head unit. After repairs are
Is there a constant stream of coolant coming from DEF head unit return port? No: Replace DEF head unit. After

SPN 3521 FMI 14 - Aftertreatment 1 Diesel Exhaust Fluid Property : Special Instructions
Fault Overview
Fault code sets when Urea Quality Sensor (UQS) detects the fluid in the DEF tank is something other than DEF.
Lamp Reaction
Associated Faults
and 20 and 19
Fault Facts

Continuous
Possible Causes
• Aerated DEF

3521 FMI 14.

3521 FMI 14.

FMI 14.


3521 FMI 14.
3521 FMI 14.
End Diagnostic Test

SPN 3556 FMI 2 - Aftertreatment 1 Hydrocarbon Doser 1 : Data Erratic, Intermittent Or Incorrect
Fault Overview
Fault code sets when Engine Control Module (ECM) detects leaking Aftertreatment Hydrocarbon Doser (AFTHD)
or an external leak. Fuel pressure is building in system as expected, but not holding.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Road Test
Possible Causes
• Leaking fuel line to AFTHD
• Leaking AFT Fuel Supply Module
• Failed AFTHD
• Failed Aftertreatment Fuel Enable Actuator (AFTEA)
Step 1 Check for active of pending fault codes. Decision

®
3556 FMI 2.
faults. After repairs are complete,
Step 2 Check for damaged or leaking Aftertreatment (AFT) fuel supply module. Decision
Inspect AFT fuel supply module for leaks or damage. Yes: Go to Step 2.
Is AFT fuel supply module free of leaks or damage? No: Replace AFT fuel supply
FMI 2.
Step 3 Check for leaking or damaged fuel supply line to Aftertreatment Decision
A. Key-On Engine-Running (KOER) Yes: Go to Step 4.
B. Inspect fuel supply line between AFT fuel supply module and AFTHD for
restrictions and leaks.
Is fuel supply line to AFTHD free of leaks or damage? No: Repair or replace fuel supply
line to AFTHD. After repairs are
FMI 2.
Step 4 Check for failed Aftertreatment Fuel Enable Actuator (AFTFEA). Decision
Perform AFT Fuel Enable Actuator Leak Test (page 1995). Yes: Replace AFTFEA. After
SPN 3556 FMI 2.
Was 5ml or more of fuel collected during test? No: Go to Step 5.
Step 5 Check for failed Aftertreatment Hydrocarbon Doser (AFTHD). Decision

Perform AFT Hydrocabon Doser Leak Test (page 1996). Yes: Replace AFTHD. After
SPN 3556 FMI 2.
Was 5ml or more of fuel collected during test? No: End diagnostics. Retest for
SPN 3556 FMI 2.

SPN 3556 FMI 5 - Aftertreatment 1 Hydrocarbon Doser 1 : Current Below Normal Or Open Circuit
Fault Overview
Fault codes sets when Engine Control Module (ECM) detects a fault in Aftertreatment Hydrocarbon Doser
(AFTHD) circuit. Active regeneration of aftertreatment diesel particulate filter will be disabled until next key
cycle. Engine torque will be reduced if engine is operated for an extended period of time with this fault active.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Road Test.
Possible Causes
• AFTHD CTL-H circuit Open or high resistance
• AFTHD CTL-H short to GND
• AFTHD CTL-H short to power
• AFTHD CTL-L short to GND
• AFTHD CTL-L short to power
• AFTHD CTL-H short to AFTHD CTL-L

®
1940).
Step 2 Inspect connections at Engine Control Module (ECM) connector. Decision

B. Disconnect ECM connector.
C. Check ECM and connector terminals for: damaged or pinched wires;
connector housing.
Are ECM connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
3556 FMI 5.
Step 3 Inspect connections at Aftertreatment Hydrocarbon Doser (AFTHD) Decision

connector.
B. Disconnect AFTHD connector.
C. Check AFTHD and connector terminals for: damaged or pinched wires;
connector housing.
Are AFTHD connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
3556 FMI 5.
Step 4 Check AFTHD-H circuit for Open or short to GND. Decision

Perform Test 1 (page 1407). Use DMM, measure resistance between ECM pin Yes: Go to Step 5.
E1-53 and known good GND.
Is resistance greater than 1000 ohms? No: Repair Open of short to
GND between AFTHD pin-1 and
FMI 5.
Step 5 Check AFTHD-L circuit for Open or short to GND. Decision

Perform Test 2 (page 1407). Use DMM, measure voltage between between ECM Yes: Go to Step 6.
pin E1-29 and known good GND.
Is resistance greater than 1000 ohms? No: Repair Open of short to
GND between AFTHD pin-2 and
FMI 5.
Step 6 Check for AFTHD-H short to AFTHD-L. Decision

Perform Test 3 (page 1408). Use DMM, measure resistance from ECM pin E1-53 Yes: Go to Step 7.
and ECM pin E1-29.
Is resistance greater than 1000 ohms? No: Repair short between ECM
pin E1-53 and ECM pin E1-29.
for SPN 3556 FMI 5.
Step 7 Check for AFTHD-H for short to PWR. Decision

ZTSE4760A pin-1 to known good GND.
AFTHD pin-1 and ECM pin E1-53.
for SPN 3556 FMI 5.
Step 8 Check for AFTHD-L for short to PWR. Decision

ZTSE4760A pin-2 to known good GND.
AFTHD pin-2 and ECM pin E1-29.
for SPN 3556 FMI 5.
Step 9 Check AFTHD-H circuit for Open or high resistance. Decision

Perform Test 6 (page 1411). Using DMM, measure resistance between Breakout Yes: Repair Open or high
Harness ZTSE4760A pin-1 and ECM pin E1-53. resistance between AFTHD pin-1
FMI 5.
Is resistance greater than 10 ohms? No: Go to Step 10
Step 10 Check AFTHD-L circuit for Open or high resistance. Decision

Perform Test 7 (page 1412). Using DMM, measure resistance between Breakout Yes: Repair Open or high
Harness ZTSE4760A pin-2 and ECM pin E1-29. resistance between AFTHD pin-2
FMI 5.
Is resistance greater than 10 ohms? No: Replace AFTHD. After repairs
FMI 5.


Tools Required
E1-53
0000415361
Figure 471 AFTHD-H Circuit Check
Test 1
A. Key OFF.
B. Disconnect Engine Control Module (ECM)
C. Connect Breakout Box 00-0956-08 and Breakout Harness 12-801-05-03 to ECM harness and leave ECM
disconnected.
D. Disconnect AFTHD.
E1-29
0000415364
Figure 472 AFTHD-L Circuit Check
Test 2
A. Key OFF.
disconnected.
E1-29
E1-29
0000415365
Figure 473 AFTHD Circuit Check
Test 3
A. Key OFF.
disconnected.
Test 4
A. Key OFF.
C. Disconnect AFTHD.
D. Connect Breakout Harness ZTSE4760A to engine harness and leave AFTHD disconnected.
E. Key ON Engine OFF (KOEO)
Test 5
A. Key OFF.
C. Disconnect AFTHD.
D. Connect Breakout Harness ZTSE4760A to engine harness and leave AFTHD disconnected.
E. Key ON Engine OFF (KOEO)
E1-53
E1
4760A E2
0000415368
Test 6
A. Key OFF.
disconnected.
E. Connect Breakout Harness ZTSE4760A to engine harness and leave AFTHD disconnected.
E1-29
E1
2
E2
4760A
0000415369
Test 7
A. Key OFF.
disconnected.
E. Connect Breakout Harness ZTSE4760A to engine harness and leave AFTHD disconnected.
SPN 3556 FMI 18 - Aftertreatment 1 Hydrocarbon Doser 1 : Data Valid But Below Normal Operating
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Aftertreatment Hydrocarbon Doser (AFTHD) can
not inject enough fuel for active regeneration of aftertreatment system.
Lamp Reaction
Associated Faults
SPN 3482 FMI 16
Fault Facts
None

Regeneration
Possible Causes
• Damaged or restricted supply line to AFTHD
• Failed AFTHD
• Exhaust leak or restriction
• Inefficient DOC

®
Step 2 Check for restricted or damaged fuel supply line to Aftertreatment Decision
A. Key-On Engine-Running (KOER) Yes: Go to Step 3.
B. Inspect fuel supply line between AFT Fuel Supply Module and AFTHD for
restrictions and leaks.
Is fuel supply line between AFT Fuel Supply Module and AFTHD in good condition No: Repair or replace fuel line
and not restricted? to AFTHD. After repairs are
FMI 18.
Step 3 Inspect exhaust system for leaks and physical damage. Decision
Inspect exhaust system for leaks and physical damage. Perform Exhaust and Yes: Go to Step 4.
Aftertreatment System Inspection (page 2166).
Is exhaust system free of leaks and physical damage? No: Repair or replace leaking or
damaged exhaust components.
Step 4 Check for damaged or restricted Aftertreatment Hydrocarbon Doser Decision

(AFTHD)
Perform Aftertreatment Hydrocarbon Doser (AFTHD) Inspection (page 2206). Yes: Clean or replace AFTHD.
Is AFTHD damaged or restricted? No: Go to Step 5.
Step 5 Check AFTHD operation. Decision

Was 225 to 500 ml of fuel dispensed within 2 minutes 30 seconds? No: Clean or replace AFTHD.
Step 6 Inspect DOC for damage or face plugging. Decision

Perform DOC Inspection (page 2240). Yes: Replace DOC. If DOC is
melted, diagnose and repair
cause of excessive heat. After
SPN 3556 FMI 18.
Is DOC damaged or restricted? No: End diagnostics, retest for
SPN 3556 FMI 18.

SPN 3597 FMI 3 - ECU Power Output Supply Voltage #1 : Voltage Above Normal, Or Shorted To High
Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects ECM PWR OUT 1 circuit voltage is greater than
Lamp Reaction
Associated Faults
None
Fault Facts
ECM PWR OUT 1 circuit is divided into two separate circuits. One circuit runs from ECM to Engine Compression
Brake 1 (ECB1) and the other runs to Engine Compression Brake 2 (ECB2).

Continuous
Possible Causes
• ECM Pin E2-08 shorted to PWR
• ECM Pin E2-09 shorted to PWR
Step 1 Check for active fault codes Decision

Use EST, Key ON, check Diagnostic Trouble Code (DTC) list for SPN 3597 FMI 3. Yes: Go to Step 2.
Is EST DTC list SPN 3597 FMI 3 active or pending? No: Diagnose other active or
SPN 3597 FMI 3.
Step 2 Check ECM voltage Pin E2-09 and GND. Decision

Perform Test 1 (page 1420). Use Digital Multimeter (DMM), measure voltage Yes: Go to Step 3.
between Pin E2-09 and a known good GND.
Is voltage B+? No: Go to Step 4.
Step 3 Check for ECB1 body Short to PWR. Decision

Disconnect 16-pin Engine Injector harness from ECB1 posts. Use DMM, Measure Yes: Replace under valve
voltage between either ECB1 post and known good GND. cover harness, After repairs are
FMI 3.
Is voltage B+? No: End Diagnostics. Retest for
SPN 3597 FMI 3.
Step 4 Check ECM voltage Pin E2-08 and GND. Decision

Perform Test 2 (page 1421). Use Digital Multimeter (DMM), measure voltage Yes: Replace under valve
between Pin E2-08 and a known good GND. cover harness, After repairs are
FMI 3.
Is voltage B+? No: End Diagnostics. Retest for
SPN 3597 FMI 3.


Tools Required
• 12-801-05-03 Breakout Harness
• 00-00956-08 Breakout Box
E2-09
0000429987
Test 1
A. Key OFF.
B. Connect Breakout harness 12-801-05-03 to ECM E2 connector and leave the ECM disconnected.
C. Connect Breakout Harness 12-801-05-03 to breakout box 00-00956-08.
E2-08
0000429986
Test 2
A. Key OFF.
B. Connect Breakout harness 12-801-05-03 to ECM E2 connector and leave ECM disconnected.
SPN 3597 FMI 4 - ECU Power Output Supply Voltage #1 : Voltage Below Normal, Or Shorted To Low
Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects ECM PWR OUT 1 circuit voltage is less than 0.3
volts.
Lamp Reaction
Associated Faults
None
Fault Facts
ECM PWR OUT 1 circuit is divided into two separate circuits. One circuit runs from ECM to Engine Compression
Brake 1 (ECB1) and the other runs to Engine Compression Brake 2 (ECB2).

Continuous
Possible Causes
• ECM Pin E2-08 shorted to GND
• ECM Pin E2-09 shorted to GND
• Failed Engine Compression Brake (ECB)

SPN 3597 FMI 4.
Step 2 Check ECM resistance Pin E2-09 and GND. Decision

between Pin E2-09 and a known good GND.
Is the resistance greater than 1 kΩ? No: Go to Step 4.
Step 3 Check ECM resistance Pin E2-08 and GND. Decision

Perform Test 2 (page 1426). Use Digital Multimeter (DMM), measure resistance Yes: End diagnostics. Retest for
between Pin E2-08 and a known good GND. SPN 3597 FMI 4.
Is the resistance greater than 1 kΩ? No: Go to Step 5.

resistance between either ECB1 post and known good GND. cover harness, After repairs are
FMI 4.
Is the resistance greater than 1 kΩ? No: Replace ECB1. After repairs
3597 FMI 4.

resistance between either ECB2 post and known good GND. cover harness, After repairs are
FMI 4.
Is the resistance greater than 1 kΩ? No: Replace ECB2. After repairs
3597 FMI 4.


Tools Required
• 12-801-05-03 Breakout Harness
• 00-00956-08 Breakout Box
E2-09
0000430241
Test 1
A. Key OFF.
B. Connect Breakout harness 12-801-05-03 to ECM E2 connector and leave the ECM disconnected.
E2-08
0000430240
Test 2
A. Key OFF.
B. Connect Breakout harness 12-801-05-03 to ECM E2 connector and leave ECM disconnected.
Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects ECM PWR OUT 2 circuit is shorted to power.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• ECM Power OUT 2 Shorted to PWR

®
1940).
Step 2 Inspect connections at Exhaust Gas Recirculation Valve (EGRV) Decision

connector.
housing.
3598 FMI 3.
Step 3 Check ECM Power OUT 2 for short to power. Decision

Perform Test 1 (page 1430). Use Digital Multimeter (DMM), measure voltage Yes: End diagnostics. Retest for
between breakout harness ZTSE4948 pin-4 and a known good GND. SPN 3598 FMI 3.
between EGRV pin-4 and ECM
Pin E1-01 and E1-02. After
SPN 3598 FMI 3.


Tools Required
Figure 482 ECM PWR OUT 2 circuit check
Test 1
A. Key OFF.
C. Connect Breakout harness ZTSE4948 to engine harness and leave EGRV disconnected.
Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects ECM PWR OUT 2 circuit is shorted to ground.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• ECM Power OUT 2 Shorted to GND
• Failed EGR Valve

Is EST DTC list SPN 3598 FMI 4 active? No: Diagnose other active fault
codes first. After repairs are
FMI 4.
Step 2 Inspect connections at Exhaust Gas Recirculation Valve (EGRV) Decision

connector.
housing.
3598 FMI 4.
Step 3 Check ECM PWR OUT for short to GND. Decision

Perform Test 1 (page 1433). Use Digital Multimeter (DMM), measure resistance Yes: Replace EGR Valve. After
between breakout harness ZTSE4948 pin-4 and a known good GND. repairs are complete, retest for
SPN 3598 FMI 4.
Is the resistance greater than 1,000 Ohms? No: Repair short to GND between
EGRV pin-4 and ECM Pin E1-01
and E1-02. After repairs are
FMI 4.


Tools Required
Test 1
A. Key OFF.
C. Connect Breakout harness ZTSE4948 to engine harness and leave EGRV disconnected.
Source
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
ECM PWR OUT 3 circuit is divided into three separate circuits. One circuit runs from ECM to control side of the
DEF Supply module relay. Another circuit runs from ECM to the Engine Fan Control (EFC) solenoid and to pin A
on the Body Builder Connector 1. The final branch runs from the ECM to the DEF Tank Heater Valve (DEFTHV)
and the Cold Start Fuel Solenoid (CSED).

Continuous
Possible Causes
• DEF Supply Module Relay control circuit Shorted to PWR
• Engine Fan Solenoid control circuit Shorted to PWR
• DEFTHV Control circuit Shorted to PWR
• CSED control circuit Shorted to PWR

®
1940).
Step 2 Check DEF Supply Module Relay control circuit for short to PWR. Decision
between Pin C2-11 and a known good GND.
Is the voltage less than 0.25 volts? No: Go to Step 5.
Step 3 Check DEFTHV and CSED circuits for short to PWR. Decision
Step 4 Check Engine Fan Solenoid and Body Builder Connector 1 circuits for Decision
short to PWR.
Perform Test 3 (page 1440). Use Digital Multimeter (DMM), measure voltage Yes: End Diagnostics. Retest for
between Pin C1-25 and a known good GND. SPN 3599 FMI 3.
Step 5 Check Aftertreatment Power Distribution Module. Decision

connections.
FMI 3.
Step 6 Check DEF Supply Module Relay supply circuit for short to PWR. Decision
Remove DEF Supply Module Relay (R$). Perform Test 1 (page 1438). Use Digital Yes: Repair the short to PWR
Multimeter (DMM), measure voltage between Pin C2-11 and a known good GND. between ECM pin C1-05 and
DEF Supply Module Relay Pin
Is the voltage less than 0.25 volts? No: Repair the short to PWR
between ECM C2-11 and Pin 85
on DEF Supply Module Relay.
for SPN 3599 FMI 3.
Step 7 Inspect connections at DEF Tank Heater Valve connector. Decision


C. Check DEFTHV connector and connector terminals for: damaged or
3599 FMI 3.
Step 8 Inspect connections at CSED connector. Decision

C. Check CSED connector and connector terminals for: damaged or pinched
connector housing.
3599 FMI 3.
Step 9 Check DEFTHV circuit for short to PWR. Decision

Disconnect the DEFTHV connector. Perform Test 2 (page 1439). Use Digital Yes: Repair the short to PWR
DEFTHV pin-4. After repairs are
FMI 3.
Is the voltage less than 0.25 volts? No: Go to step 10.
Step 10 Check DEFTHV and CSED supply circuit for short to PWR. Decision
Disconnect the CSED Connector. Perform Test 2 (page 1439). Use Digital Yes: Repair the short to PWR
CSED pin-1. After repairs are
FMI 3.
between ECM C1-01 and CSED
connector pin-2 or DEFTHV
Step 11 Inspect connections at Body Builder Connector 1. Decision

C. Check Body Builder Connector 1 and connector terminals for: damaged or
Are Body Builder Connector 1, harness, and terminals clean and undamaged? No: Repair connector, harness,
3599 FMI 3.
Step 12 Inspect connections at Engine Fan Solenoid connector. Decision

B. Disconnect Engine Fan Solenoid connector.
C. Check Engine Fan Solenoid connector and connector terminals for:
Are Engine Fan Solenoid connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
3599 FMI 3.
Step 13 Check Engine Fan Solenoid circuit for short to PWR. Decision
Disconnect the Engine Fan Solenoid. Perform Test 3 (page 1440). Use Digital Yes: Repair the short to PWR
Engine Fan Solenoid pin-B. After
SPN 3599 FMI 3.
Step 14 Check Engine Fan Solenoid and Body Builder Connector supply circuit Decision
for short to PWR.
Disconnect the Body Builder connector 1. Perform Test 3 (page 1440). Use Digital Yes: Repair short to PWR on
Multimeter (DMM), measure voltage between Pin C1-25 and a known good GND. chassis side of BBC1. After
SPN 3599 FMI 3.
between ECM C1-25 and EFS
connector pin-A or BBC1 pin-A.
for SPN 3599 FMI 3.


Tools Required
• Breakout Box 00-00956-08
C2-11
0000428100
Test 1
A. Key OFF.
B. Connect Breakout harness 12-801-05-01 in between ECM C1 and C2 chassis harness and ECM.
Test 2
A. Key OFF.
C1-25
0000428096
Test 3
A. Key OFF.
Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects ECM PWR OUT 3 circuit voltage is less than the
Lamp Reaction
Associated Faults
None
Fault Facts
ECM PWR OUT 3 circuit is divided into three separate circuits. One circuit runs from ECM to control side of DEF
Supply module relay. Another circuit runs from ECM to the Engine Fan Solenoid (EFS) solenoid and optional
Pin A on the Body Builder Connector 1. The final branch runs from the ECM to the DEF Tank Heater Valve
(DEFTHV) and optional Cold Start Fuel Solenoid (CSED).

Continuous
Possible Causes
• Failed DEFTHV
• Failed CSED if equipped
• Failed Engine Fan Solenoid
• Failed Body Builder wiring shorted to GND

®
1940).

connections.
FMI 4.
Step 3 Check ECM PWR OUT resistance to GND. Decision

Remove DEF Supply Module Relay. Perform Test 1 (page 1446). Use Digital Yes: Go to Step 4.
Multimeter (DMM), measure resistance between Pin C2-11 and a known good GND.
Is resistance greater than 1,000 Ohms? No: Repair short to GND between
ECM C2-11 and Pin 85 on DEF
Supply Module Relay. After
SPN 3599 FMI 4.
Step 4 Inspect connections at 14-Way DEF Tank Harness connector. Decision

B. Disconnect 14-Way DEF Tank Harness connector.
C. Check 14-Way DEF Tank Harness connector and connector terminals for:
Are 14-Way DEF Tank Harness connector, harness, and terminals clean and No: Repair connector, harness,
3599 FMI 4.
Step 5 Inspect connections at DEF Tank Heater Valve (DEFTHV) connector. Decision
A. Key OFF. Yes: If equipped with Cold Start
System, Go to Step 6. If Cold
Start System NOT equipped, Go
C. Check DEFTHV connector and connector terminals for: damaged or to Step 7.
3599 FMI 4.
Step 6 Inspect connections at Cold Start Enable Device (CSED) connector. Decision
connector housing.
3599 FMI 4.
Step 7 Check ECM PWR OUT circuit for short to GND. Decision
Is resistance greater than 1,000 Ohms? No: Go to Step 8.
Disconnect DEFTHV connector. Perform Test 2 (page 1447). Use Digital Multimeter Yes: Replace DEFTHV. After
(DMM), measure resistance between Pin C1-01 and a known good GND. repairs are complete, retest for
SPN 3599 FMI 4.
Is resistance greater than 1,000 Ohms? No: If equipped with Cold Start
System, go to Step 9 for further
testing. If Cold Start System is
NOT equipped, repair short to
GND between ECM Pin C1-01
and DEFTHV Pin-1. After repairs
3599 FMI 4.
Disconnect DEFTHV connector and CSED (fuel Solenoid) connector. Perform Test Yes: Replace CSED. After
2 (page 1447). Use Digital Multimeter (DMM), measure resistance between Pin repairs are complete, retest for
C1-01 and a known good GND. SPN 3599 FMI 4.
ECM C1-01 and DEFTHV Pin-1
or CSED Pin-2. After repairs are
FMI 4.

A. Key Off. Yes: If Body Builder Connector 1
is in use, Go to Step 11. If Body
B. Disconnect Engine Fan Solenoid connector.
Builder Connector 1 is not in use,
C. Check Engine Fan Solenoid connector and connector terminals for: Go to Step 12.
Are Engine Fan Solenoid connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
3599 FMI 4.

C. Check Body Builder Connector 1 and connector terminals for: damaged or
Are Body Builder Connector 1, harness, and terminals clean and undamaged? No: Repair connector, harness,
3599 FMI 4.
Perform Test 3 (page 1448). Use Digital Multimeter (DMM), measure resistance Yes: End Diagnostics. Retest for
Is resistance greater than 1,000 Ohms? No: Go to Step 13.
Disconnect Engine Fan Solenoid. Perform Test 3 (page 1448). Use Digital Yes: Replace Engine Fan
Multimeter (DMM), measure resistance between Pin C1-25 and a known good GND. Solenoid. After repairs are
FMI 4.
Is resistance greater than 1,000 Ohms? No: If Body Builder Connector
1 is in use, go to Step 14 for
further testing. If Body Builder
Connector 1 is NOT in use, repair
short to GND between ECM Pin
C1-25 and Engine Fan Solenoid
connector pin-A. After repairs are
FMI 4.
Disconnect Engine Fan Solenoid and Body Builder 1 Connector. Perform Test 3 Yes: Repair short to GND
(page 1448). Use Digital Multimeter (DMM), measure resistance between Pin C1-25 between Body Builder Connector
and a known good GND. 1 Pin-A and Chassis side body
builder wiring. After repairs are
FMI 4.
ECM Pin C1-25 and Engine Fan
Solenoid connector pin-A or Body
Builder Connector 1 Pin-A. After
SPN 3599 FMI 4.


Tools Required
C2-11
0000428095
Test 1
A. Key OFF.
B. Connect Breakout harness 12-801-05-01 to chassis harness and leave ECM disconnected.

C1-01
0000428089
Test 2
A. Key OFF.
C1-25
0000428091
Test 3
A. Key OFF.
SPN 3610 FMI 2 - Aftertreatment 1 Diesel Particulate Filter Outlet Pressure : Data Erratic, Intermittent
Or Incorrect
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Particulate Filter Outlet Pressure (DPFOP)
signal is in range but reading inappropriately high for current operating conditions.
Lamp Reaction
Associated Faults
SPN 3511
Fault Facts
None

Road Test
Possible Causes
• DPFOP circuit high resistance
• SIG GND circuit high resistance
• Leaking or restricted Diesel Particulate Filter / DPF Outlet Pressure (DPFDP/DPFOP) sensor tube or hoses
• Failed DPFDP/DPFOP sensor

for SPN 3610 FMI 2.
Differential Pressure/ DPF Outlet Pressure (DPFDP/DPFOP) sensor.
Check DPFDP/DPFOP sensor module, tubes, and passages for leaks, restrictions, Yes: Go to Step 3.
and damage.
Are DPFDP/DPFOP sensor module connections free of leaks, restrictions, and No: Repair leaking, restricted,
damage? or damaged hoses and
connections. After repairs
3610 FMI 2.
Step 3 Inspect connections at DPFDP/DPFOP sensor. Decision

B. Disconnect DPFDP/DPFOP sensor connector.
C. Check DPFDP/DPFOP sensor and connector terminals for: damaged or
connector housing.
Are DPFDP/DPFOP sensor connector, harness, and terminals clean and No: Repair connector, harness,
3610 FMI 2.

between DPFDP/DPFOP sensor
SPN 3610 FMI 2.
Step 5 Check DPFOP circuit for high resistance. Decision

C. During test, monitor DPFOP voltage with EST.
SPN 3610 FMI 2.

SPN 3610 FMI 2.
Step 7 Check Decomposition/Reactor for restriction. Decision

A. Perform Decomp Reactor Inspection (page 2208). Yes: Clean DPF crystals or repair
exhaust restriction after DPF.
B. Inspect exhaust from DPF to tailpipe for restrictions or damage.
for SPN 3610 FMI 2.
Were DEF crystals or other exhaust restrictions found in exhaust? No: Replace DPFDP/DPFOP
FMI 2.


Tools Required
Test 1
A. Key OFF.
B. Disconnect DPFDP/DPFOP sensor.

D. Key ON.
Figure 491 DPFOP Circuit Check
Test 2
A. Key OFF.
D. Use Breakout Harness ZTSE4498, short Breakout Harness 12-575-01 pin-3 to pin-4.
Test 3
A. Key OFF.
SPN 3610 FMI 3 - Aftertreatment 1 Diesel Particulate Filter Outlet Pressure : Voltage Above Normal,
Fault Overview
signal voltage is greater than normal operating range.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• SIG GND circuit open or high resistance
• DPFOP signal circuit short to PWR

®
1940).
Step 2 Inspect connections at Diesel Particulate Filter Differential Pressure Decision

(DPFDP) / Diesel Particulate Filter Outlet Pressure (DPFOP) sensor.
connector housing.
3610 FMI 3.
Step 3 Check DPFOP circuit for short to PWR. Decision

B. Disconnect Diesel Particulate Filter Differential Pressure (DPFDP) / Diesel
Particulate Filter Outlet Pressure (DPFOP) connector.
C. Connect Electronic Service Tool (EST) with Navistar® Engine Diagnostic

Software to vehicle Diagnostic Connector (page 1956).
D. Key ON. Log in to EST, perform Continuous Monitor Test(page 1974).
E. During test, monitor DPFOP voltage with EST.
between DPFDP/DPFOP pin-3
and ECM connector pin C1-07.
for SPN 3610 FMI 3.
Step 4 Check Signal GND for open or high resistance. Decision

Perform Test 1 (page 1459). Use DMM, measure voltage between Breakout Harness Yes: Replace DPFDP/DPFOP
12-575-01 pin-1 and B+. sensor module. After repairs are
FMI 3.
Is voltage B+ ± 0.5 volts? No: Repair open or
high resistance between
DPFDP/DPFOP pin-1 and ECM
FMI 3.


Tools Required
Figure 493 SIG GND Circuit Resistance Check
Test 1
A. Key OFF.
(DPFOP) sensor module
C. Connect Breakout Harness 12-575-01 to vehicle harness and leave DPFDP/DPFOP sensor module
disconnected.
D. Key ON.
SPN 3610 FMI 4 - Aftertreatment 1 Diesel Particulate Filter Outlet Pressure : Voltage Below Normal,
Fault Overview
signal voltage is less than normal operating range for more than 2 seconds.
Lamp Reaction
Associated Faults
SPN 3511
Fault Facts
None

Continuous
Possible Causes
• DPFOP signal circuit OPEN
• DPFOP signal circuit short to GND
• VREF circuit OPEN
• VREF circuit short to GND

®
for SPN 3610 FMI 4.

Is EST DTC list SPN 3610 FMI 4 active and pending? No: Go to Intermittent or Inactive
1940).
Step 3 Inspect Diesel Particulate Filter Differential Pressure / Diesel Particulate Filter Decision
Outlet Pressure (DPFDP/DPFOP) sensor connector.
pinched wires; wet or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
Are DPFDP / DPFOP sensor connector, harness, and terminals clean and undamaged? No: Repair connector,
3610 FMI 4.
Step 4 Check VREF circuit for Open or short to GND. Decision

between DPFDP / DPFOP pin-4
are complete retest for SPN 3610
FMI 4.
Step 5 Check for failed DPFOP sensor. Decision

A. Perform Test 2 (page 1463). Yes: Replace DPFDP / DPFOP
B. Use Electronic Service Tool (EST) with Navistar® Engine Diagnostic
Software, perform Continuous Monitor Test (page 1974).
FMI 4.
Is voltage 5 ± 0.25 volts? No: Repair Open or Short to
GND between DPFDP / DPFOP
pin 3 and ECM pin C1-07 After
SPN 3610 FMI 4.


Tools Required
Figure 494 VREF Circuit Voltage Check
Test 1
A. Key OFF.
(DPFOP) sensor.
D. Key ON.
Test 2
A. Key OFF.
SPN 3610 FMI 10 - Aftertreatment 1 Diesel Particulate Filter Outlet Pressure : Abnormal Rate Of Change
Fault Overview
is in range but reading inappropriately for current operating conditions.
Lamp Reaction
Associated Faults
SPN 3511
Fault Facts
None

Road Test
Possible Causes
• DPFOP circuit Open or high resistance
• VREF 3 circuit Open or high resistance
• SIG GND circuit Open or high resistance
• Leaking or restricted Diesel Particulate Filter / DPF Outlet Pressure (DPFDP/DPFOP) sensor tube or hoses
• Restricted exhaust

®
Differential Pressure/ DPF Outlet Pressure (DPFDP/DPFOP) sensor.
Check DPFDP/DPFOP sensor module, tubes, and passages for leaks, restrictions, Yes: Go to Step 3.
and damage.
Are DPFDP/DPFOP sensor module connections free of leaks, restrictions, and No: Repair leaking, restricted,
damage? or damaged hoses and
connections. After repairs
3610 FMI 10.
Step 3 Inspect connections at DPFDP/DPFOP sensor. Decision

connector housing.
3610 FMI 10.

Is voltage 5 ± 0.25 volts? No: Repair Open or
DPFDP/DPFOP sensor pin-4
3610 FMI 10.
Step 5 Check DPFOP circuit for high resistance. Decision

Is voltage 5 ± 0.25 volts? No: Repair Open or
DPFDP/DPFOP sensor pin-3
3610 FMI 10.


SPN 3610 FMI 10.
Step 7 Check Decomposition/Reactor Tube for restriction. Decision

A. Perform Decomp Tube Inspection (page 2208). Yes: Clean DPF crystals or repair
exhaust restriction after DPF.
B. Inspect exhaust from DPF to tailpipe for restrictions or damage.
Were DEF crystals or other exhaust restrictions found in exhaust? No: Replace DPFDP/DPFOP
FMI 10.


Tools Required
Test 1
A. Key OFF.
D. Key ON.
Test 2
A. Key OFF.
Test 3
A. Key OFF.
SPN 3610 FMI 16 - Aftertreatment 1 Diesel Particulate Filter Outlet Pressure : Data Valid But Above
Fault Overview
Fault code sets when Engine Control Module (ECM) detects aftertreatment Diesel Particulate Filter Outlet
Pressure (DPFOP) signal is in range but reading inappropriately.
Lamp Reaction
Associated Faults
SPN 132 SPN 3246 SPN 3251
Fault Facts
If aftertreatment system has had excess fuel, oil, coolant, metal, or other contamination; inspect entire
aftertreatment system for causal damage before reinstalling. Inspect for overheated aftertreatment components,
cracked exhaust system welds, leaking exhaust system seams, or other damage.

Continuous
Possible Causes
• Leaking or restricted Diesel Particulate Filter / DPF Outlet Pressure (DPFDP/DPFOP) sensor hoses
• Restricted exhaust
• Failed Mass Airflow (MAF) Sensor

®
Step 2 Perform Intake Air Inspection. Decision

Was intake system and Mass Airflow (MAF) Sensor free of damage, blockage, No: Repair damage or blockage.
or debris buildup? Replace MAF sensor if debris
build up is present. After repairs
3610 FMI 16.
Step 3 Inspect hoses and tube connections at Diesel Particulate Filter / DPF Decision
Outlet Pressure (DPFDP/DPFOP) sensor module.
Check DPFDP/DPFOP sensor, tubes, and passages for leaks, restrictions, Yes: Go to Step 4.
blockage, and damage. Also check for proper hose routing. Hoses should not
have excessive curving or low points.
Are DPFDP/DPFOP sensor connections free of leaks, restrictions, and damage? No: Repair leaking, restricted, or
damaged hoses and connections.
Step 4 Inspect connections at DPFDP/DPFOP sensor module. Decision

connector housing.
3610 FMI 16.
Step 5 Determine if exhaust is restricted Decision

Perform Exhaust Restriction Isolation Test (page 2114). Yes: Repair exhaust restriction
downstream of DPF. After repairs
3610 FMI 16.
Does DPFOP exceed specification? No: End diagnostics. Retest for
SPN 3610 FMI 16.

SPN 3695 FMI 2 - Aftertreatment Regeneration Inhibit Switch : Data Erratic, Intermittent Or Incorrect
Fault Overview
Fault code sets when Engine Control Module (ECM) detects DPF regen inhibit switch is ON, and active
regeneration of Aftertreatment system is needed.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Regeneration
Possible Causes
• DPF regen inhibit switch ON
• Failed DPF regen inhibit switch

®
3695 FMI 2.
for SPN 3695 FMI 2.
Step 2 Verify DPF regen inhibit switch is in correct position. Decision

Check DPF regen inhibit switch in correct position. Yes: Replace switch pack that
contains DPF regen inhibit switch.
for SPN 3695 FMI 2.
Is DPF regen inhibit switch OFF allowing for active regenerations of Aftertreatment No: Turn DPF regen inhibit
system? switch OFF and perform a parked
regeneration of Aftertreatment
FMI 2.
End Diagnostic Test

SPN 3703 FMI 31 - Diesel Particulate Filter Active Regeneration Inhibited Due to Inhibit Switch :
Condition Exists
Fault Overview
Fault code sets when Engine Control Module (ECM) detects regen inhibit switch is enabled when active
regeneration of the aftertreatment system is needed.
Lamp Reaction
Associated Faults
None

Regeneration
Fault Facts
This fault can indicate reason high soot load faults have been logged.
Possible Causes
• Regen Inhibit Switch enabled when active regeneration is needed.

Check DPF regen inhibit switch is in correct position. Yes: Run a parked regeneration of
aftertreatment system, and retest for
SPN 3703 FMI 31.
Is regen inhibit switch disabled allowing for active regenerations of aftertreatment No: Disable regen inhibit switch
system? and perform parked regeneration of
aftertreatment system. Retest for
SPN 3703 FMI 31.
End Diagnostic Test

SPN 3713 FMI 31 - Diesel Particulate Filter Active Regeneration Inhibited Due to System Timeout :
Condition Exists
Fault Overview
Fault code sets when Engine Control Module (ECM) detects regen inhibit switch is enabled when active
regeneration of the aftertreatment system is needed.
Lamp Reaction
Associated Faults
None

Regeneration
Fault Facts
This fault can indicate reason high soot load faults have been logged.
Possible Causes
• Regen Inhibit Switch enabled when active regeneration is needed.

Check DPF regen inhibit switch is in correct position. Yes: Run a parked regeneration of
aftertreatment system, and retest for
SPN 3713 FMI 31.
Is regen inhibit switch disabled allowing for active regenerations of aftertreatment No: Disable regen inhibit switch
system? and perform parked regeneration of
aftertreatment system. Retest for
SPN 3713 FMI 31.
End Diagnostic Test

SPN 3750 FMI 31 - Aftertreatment 1 Diesel Particulate Filter Conditions Not Met For Active Regeneration
: Condition Exists
Fault Overview
is less than required for active regeneration.
Lamp Reaction
Associated Faults
SPN 2791 SPN 3251 FMI 2, 3, and 4 SPN 3480 SPN 3556
SPN 3936 SPN 5298 FMI 18

Regeneration
Fault Facts
None
Possible Causes
• Failed Aftertreatment Temperature Sensor Module
• Degraded Diesel Oxidation Catalyst (DOC)
• Exhaust System Leak
• Damaged Diesel Particulate Filter (DPF)

®
1478).
Step 2 Inspect exhaust system for leaks and physical damage. Decision
Perform Exhaust and Aftertreatment System Inspection (page 2166). Yes: Go to Step 3.
Step 3 Compare Diesel Oxidation Catalyst Inlet Temperature (DOCIT), Diesel Decision
Particulate Filter Inlet (DPFIT) and DPF Outlet Temperature (DPFOT)
Temperatures.
Are the DOCIT, DPFIT, and DPFOT temperatures within 77°F (25°C) of each other? No: Replace Aftertreatment
Temperature Sensor Module.
Step 4 Check DOC condition. Decision

Perform DOC Inspection (page 2240). Yes: Go to Step 5.
Is DOC free of restrictions, contamination, and soot leakage, and is DOC not melted No: Replace DOC. If
or deformed? contaminated, also diagnose and
repair source of contamination.
Step 5 Check DPF condition. Decision

Perform DPF Inspection (page 2247). Yes: End diagnostics, retest for
SPN 3750 FMI 31.
Is DPF free of contamination, soot leakage, and filter damage, and were DPF No: Replace DPF. If
channels free of restrictions? contaminated, also diagnose and
repair source of contamination.
End Diagnostic Test

SPN 3936 FMI 14 - Aftertreatment Diesel Particulate Filter System : Special Instructions
Fault Overview
Fault code sets when Electronic Control Module (ECM) detects Aftertreatment (AFT) Temperature Sensor
Module part number does not match what is stored in ECM..
Lamp Reaction
Associated Faults
SPN 3226 FMI 19 SPN 3516 FMI 19 SPN 5016 FMI 3 and 4 SPN 5742 FMI 19
SPN 5743 FMI 19 SPN 5835 FMI 19
Fault Facts
This fault may rarely be caused by calibration or CAN communication issues. If part number is correct, verify
that the ECM has the proper calibration installed.

Continuous
Possible Causes
• Incorrect AFT Temperature Sensor Module installed

®

Is EST DTC list SPN 3936 FMI 14 active or pending? No: End Diagnostics and retest
Step 3 Aftertreatment Temperature sensor module and connector inspection. Decision

B. Disconnect Aftertreatment Temperature sensor module..
C. Check Aftertreatment Temperature sensor module and connector terminals
Are Aftertreatment Temperature sensor module connector, harness, and terminals No: Repair connector, harness, or
clean and undamaged? terminal damage. Install correct
Aftertreatment Temperature
Sensor Module if necessary.
Step 4 Check for failed Aftertreatment temperature sensor module. Decision

Test 1 (page 1483). Use DMM, measure voltage between Breakout Harness Yes: Replace Aftertreatment
18-801-01 pin-4 and pin-1. temperature sensor module.
Is voltage B+ ± 0.5 volts? No: Go to step 5.
Step 5 Check SWBAT circuit for Open or short to GND. Decision

Test 2 (page 1484). Use DMM, measure voltage between Breakout Harness Yes: Repair Open or
18-801-01 pin-1 and known good GND. high resistance between
Aftertreatment temperature
for SPN 3936 FMI 14
ground between Aftertreatment
temperature sensor module
pin-1 and Switched Ignition

FMI 14.

After performing diagnostic step if SPN 3936 FMI 14 remains, verify if step was completed correctly and proper decision

Tools Required
Figure 499 Aftertreatment Temperature Sensor Module Circuit Check
Test 1
A. Key OFF.
B. Connect Breakout Harness 18-801-01 between vehicle harness and Aftertreatment temperature sensor module.
C. Key ON
Test 2
A. Key OFF.
B. Connect Breakout Harness 18-801-01 to vehicle harness and leave Aftertreatment temperature sensor
C. Key ON
SPN 3936 FMI 15 - Aftertreatment Diesel Particulate Filter System : Data Valid But Above Normal
Fault Overview
(DPFDP) Sensor signal is in range but reading inappropriately high.
Lamp Reaction
Associated Faults
SPN 102 SPN 157 SPN 651-656 SPN 2797 - 2798

Fault Facts
None

Road Test
Possible Causes
• Damaged or restricted Diesel Particulate Filter (DPF)
• Restricted DPFDP hoses
• Restricted exhaust after DPF

Step 2 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 3.
damage.
Are DPFDP sensor hoses routed correctly, free of damage, and unrestricted? No: Repair or replace DPFDP
sensor hose(s). After repairs are
FMI 15.
Step 3 Inspect exhaust after DPF. Decision

Perform Exhaust Restriction Isolation Test (page 2114). Yes: Repair restriction. After
SPN 3936 FMI 15.
Is exhaust restricted after DPF? No: Go to Step 4.
Step 4 Perform DPF Regeneration. Decision

Perform DPF Regeneration Procedure (page 1936). Yes: End Diagnostics. Retest for
SPN 3936 FMI 15.
was soot load reduced and did the regeneration complete without fault codes No: Repair fault codes set during
setting? regeneration. After repairs are
FMI 15.

SPN 3936 FMI 16 - Aftertreatment Diesel Particulate Filter System : Data Valid But Above Normal
Fault Overview
Fault code sets when the Particulate Matter (PM) Sensor Module detects excessive soot or particulate matter
exiting the exhaust aftertreatment.
Lamp Reaction
Associated Faults
SPN 102 FMI 10 (IMP) SPN 5319 FMI 31 SPN 5397 FMI 31 SPN 5569 FMI 2, 3 and 4
SPN 5747 FMI 3, 4 and 5 SPN 5835 FMI 3, 4 and 21 SPN 6774 FMI 7 SPN 6778 FMI 4 and 16
SPN 6780 FMI 2, 3 and 4 SPN 7330 FMI 2 SPN 7393 FMI 2 and 10 SPN 7854 FMI 2, 3 and 4
Fault Facts
None

Road Test
Possible Causes
• Exhaust contaminated with Fuel or Oil
• Damaged or missing DPF
• Face-plugged DPF
• Soot in Aftertreatment Assembly

Use Electronic Service Tool (EST) , check Diagnostic Trouble Code (DTC) list for Yes: Go to Step 2.
Step 2.
Step 2 Check Exhaust system for major damage. Decision

Perform Exhaust and Aftertreatment System Inspection(page 2166). Yes: Go to DPF Replacement
Is exterior of exhaust and aftertreatment system free of damage and leaks? No: Repair damage or leaks
in exhaust and aftertreatment
FMI 16.

SPN 4094 FMI 31 - NOx limits exceeded due to Insufficient Diesel Exhaust Fluid Quality : Condition
Exists
Fault Overview
Fault code sets when Diesel Exhaust Fluid (DEF) Head unit detects DEF is contaminated, degraded, or incorrect.
Lamp Reaction
Associated Faults
and 20 and 19
Fault Facts
If multiple associated faults are present, use Health Report “Ranked Faults” section to determine what faults to
diagnose first.
DEF lines may need to be replaced on 5 and 15 gallon DEF tanks when replacing a Float / Optical DEF head
unit with an Ultrasonic DEF head unit for the first time.

Continuous
Possible Causes
• Aerated DEF
• Failed DEF Tank Head Unit

4094 FMI 31.

4094 FMI 31.

Is the concentration signal displayed in the service tool matching Refractometer No: Replace DEF Head Unit. After
FMI 31.


Review results from DEF Head Unit Coolant Line Routing Inspection preformed Yes: Replace DEF Head Unit.
4094 FMI 31.
4094 FMI 31.
End Diagnostic Test

SPN 4192 FMI 3 - Engine Fuel Filter Water Level sensor : Voltage Above Normal, Or Shorted To High
Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Water In Fuel (WIF) sensor signal voltage is above
a normal range.
Lamp Reaction
No Lamp. Fault will only be viewable through Electronic Service Tool (EST).
Associated Faults
None
Fault Facts
Water In Fuel (WIF) Sensor, Body Builder Connector 2, Engine Coolant Level Sensor, Ambient Air Temperature
Sensor, DPF Outlet / Differential Pressure Sensor, and DEF Doser Valve all share a common ground circuit. If
multiple faults are present, suspect a common ground circuit problem.

Continuous
Possible Causes
• WIF signal circuit Open or short to PWR
• WIF ground circuit Open
• Failed WIF sensor

®
1940).
Step 2 Inspect connections at Water In Fuel (WIF) sensor. Decision

B. Disconnect WIF sensor connector.

C. Check WIF sensor and connector terminals for: damaged or pinched
housing.
Are WIF sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
4192 FMI 3.

Perform Test 1 (page 1493). Use Digital Multimeter (DMM), measure voltage Yes: Replace WIF sensor. After
between Breakout Harness ZTSE6002 pin-1 and pin-2. repairs are complete, retest for
SPN 4192 FMI 3.
Is voltage 5 ± 0.25 volts? No: Go to step 4.
Step 4 Check WIF circuit for short to PWR. Decision

Perform Test 2 (page 1494). Use DMM, measure voltage between Breakout Harness Yes: Repair Open between ECM
ZTSE6002 pin-2 and known good GND. pin C1-63 and WIF sensor pin-1.
for SPN 4192 FMI 3.
PWR between ECM C1-55 and
WIF sensor pin-2. After repairs
4192 FMI 3.


Tools Required
Figure 501 WIF Circuit Check
Test 1
A. Key OFF.
C. Connect Breakout Harness ZTSE6002 to vehicle harness and leave WIF sensor disconnected.
D. Key ON.
Test 2
A. Key OFF.
D. Key ON.
SPN 4192 FMI 4 - Engine Fuel Filter Water Level sensor : Voltage Below Normal, Or Shorted To Low
Source
Fault Overview
Fault code sets when the Engine Control Module (ECM) detects Water In Fuel (WIF) sensor signal voltage is
less than a normal range.
Lamp Reaction
No Lamp. Fault will only be viewable through Electronic Service Tool (EST).
Associated Faults
None
Fault Facts
Water In Fuel (WIF) Sensor, Body Builder Connector 2, Engine Coolant Level Sensor, Ambient Air Temperature
Sensor, DPF Outlet / Differential Pressure Sensor, and DEF Doser Valve all share a common ground circuit. If
multiple faults are present, suspect a common ground circuit problem.

Continuous
Possible Causes
• WIF signal circuit short to GND
• Failed WIF sensor

®
1940).
Step 2 Inspect connections at Water In Fuel (WIF) sensor. Decision


C. Check WIF sensor and connector terminals for: damaged or pinched
housing.
Are WIF sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
4192 FMI 4.

Perform Test 1 (page 1497). Use Digital Multimeter (DMM), measure voltage Yes: Replace WIF sensor. After
between Breakout Harness ZTSE6002 pin-2 and known good ground. repairs are complete, retest for
SPN 4192 FMI 3.
between ECM C1-55 and WIF
sensor pin-2. After repairs are
FMI 3.


Tools Required
Test 1
A. Key OFF.
D. Key ON.
SPN 4227 FMI 1 - Engine Crankcase Breather Oil Separator : Data Valid But Below Normal Operational
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Crankcase Breather Oil Separator Speed
(CCBOSS) sensor value is less than expected based on Engine Speed and Engine Coolant Temperature 1
(ECT1) signal.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Road Test
Possible Causes
• Failed Crankcase Breather assembly
• Failed Crankcase Breather Oil Separator Speed (CCBOSS) sensor
• CCBOSS-H circuit Open, high resistance, or short to GND
• CCBOSS-L circuit Open, high resistance, or short to GND
• CCBOSS-H circuit shorted to CCBOSS-L circuit

®
for SPN 4227 FMI 1.

(page 1940).
Step 3 Inspect connections at Crankcase Breather Oil Separator (CCBOSS) Decision

sensor.
B. Disconnect CCBOSS sensor connector.
C. Check CCBOSS sensor and connector terminals for: damaged or pinched
connector housing.
Are CCBOSS sensor connectors, harness, and terminals clean and undamaged? No: Repair connector, harness,
4227 FMI 1.
Step 4 Check Crank Case Oil Separator (CCOS) operation. Decision

Perform Crankcase Breather Oil Separator Test (page 2083). Yes: Replace Crankcase
Breather assembly. After repairs
4227 FMI 1.
Was Crankcase Breather Oil Separator Speed at least 3000 rpm at low idle and at No: Go to Step 5.
least 8,500 rpm at high idle?
Step 5 Check CCBOSS-H circuit for Open or high resistance. Decision

Is voltage between 2.0 and 2.5 volts? No: Repair Open or high
resistance between CCBOSS
SPN 4227 FMI 1.
Step 6 Check CCOSS-L circuit for Open or high resistance. Decision

resistance between CCOS pin-2
4227 FMI 1.
Step 7 Check CCOSS-L circuit for short to CCOSS-H circuit. Decision

Perform Test 3 (page 1503). Use DMM, measure resistance from Breakout Harness Yes: Replace CCBOSS sensor.
ZTSE4951 pin-1 and pin-2. After repairs are complete, retest
for SPN 4227 FMI 1.
CCBOSS-L and CCBOSS-H
circuits. After repairs are
FMI 1.


Figure 504 CCBOSS-H Circuit Check
Test 1
A. Key OFF.
B. Disconnect Crankcase Breather Oil Separator Speed (CCBOSS) sensor.
C. Connect Breakout Harness ZTSE4951 to engine harness and leave CCBOSS sensor disconnected.
D. Key ON.
Figure 505 CCBOSS-L Circuit Check
Test 2
A. Key OFF.
D. Key ON.
Figure 506 CCBOSS-H to CCBOSS-L Circuit Check
Test 3
A. Key OFF.
SPN 4227 FMI 8 - Engine Crankcase Breather Oil Separator : Abnormal Frequency Or Pulse Width
Or Period
Fault Overview
Fault code sets when ECM detects Crankcase Breather Oil Separator Speed (CCBOSS) sensor frequency
exceeds a normal operating range.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Road Test
Possible Causes
• Failed Crankcase Breather Oil Separator Speed (CCBOSS) sensor
• CCBOSS-H circuit Open, high resistance, or short to GND
• CCBOSS-L circuit Open, high resistance, or short to GND
• CCBOSS-H circuit shorted to CCBOSS-L circuit

®
for SPN 4227 FMI 8.

(page 1940).
Step 3 Inspect connections at Crankcase Breather Oil Separator (CCBOSS) Decision

sensor.
B. Disconnect CCBOSS sensor connector.
C. Check CCBOSS sensor and connector terminals for: damaged or pinched
connector housing.
Are CCBOSS sensor connectors, harness, and terminals clean and undamaged? No: Repair connector, harness,
4227 FMI 8.
Step 4 Check CCBOSS-H circuit for Open or high resistance. Decision

resistance between CCBOSS
SPN 4227 FMI 8.
Step 5 Check CCOSS-L circuit for Open or high resistance. Decision

resistance between CCOS pin-2
4227 FMI 8.
Step 6 Check CCOSS-L circuit for short to CCOSS-H circuit. Decision

Perform Test 3 (page 1509). Use DMM, measure resistance from Breakout Harness Yes: Replace CCBOSS sensor.
ZTSE4951 pin-1 and pin-2. After repairs are complete, retest
for SPN 4227 FMI 8.
CCBOSS-L and CCBOSS-H
circuits. After repairs are
FMI 8.


Figure 507 CCBOSS-H Circuit Check
Test 1
A. Key OFF.
D. Key ON.
Figure 508 CCBOSS-L Circuit Check
Test 2
A. Key OFF.
D. Key ON.
Figure 509 CCBOSS-H to CCBOSS-L Circuit Check
Test 3
A. Key OFF.
SPN 4228 FMI 0 - Engine Variable Geometry Turbocharger Actuator 1 Temperature : Data Valid But
Above Normal Operational Range - Most Severe Level
Fault Overview
Fault code sets when ECM detects Variable Geometry Turbocharger Actuator internal temperature sensor
reading is valid but above normal operating range.
Lamp Reaction
Associated Faults
SPN 111 FMI 1 SPN 110 FMI 0, 2, 3, 4, 10, SPN 1659

15 and 16
Fault Facts
None

Road Test
Possible Causes
• VGT coolant flow restriction
• Failed engine thermostat
• Coolant contamination
• Exhaust leak
• Failed VGTA

for SPN 4228 FMI 0.

®
Use EST with Navistar Engine Diagnostics, check DTC list for SPN 4228 FMI 0. Yes: Go to Step 3.
(page 1940).
Step 3 Inspect for external heat source near or contacting VGTA. Decision
Check that VGTA is not in contact with hot exhaust components or other heat Yes: Remove/Repair external
sources. heat source. After repairs are
FMI 0.
Is VGTA near or contacting an external heat source? No: Go to step 4.
Step 4 Inspect Exhaust system for leaks and damage Decision

On engine exhaust system, inspect Exhaust Manifold flanges, EGR Valve Bellows, Yes: Go to step 5.
Tube Clamps, Turbocharger, and Turbo outlet pipe for damage, restrictions, and
leaks.
Is exhaust system free of leaks and damage causing excess heat to be applied No: Repair exhaust system
to the VGTA? leaks. After repairs are complete,

Is coolant level within specification? No: Go to step 6.
Step 6 Test cooling system for leaks. Decision

Perform Cooling System Pressure Test (page 2120). Inspect vehicle for coolant Yes: Go to step 7.
leaks.
Does cooling system hold cap rated pressure for 15 minutes, and is vehicle free No: Repair leaking cooling
of leaks? system component. After repairs
4228 FMI 0.
Step 7 Check engine thermostat operation. Decision

Perform Thermostat Operational Test (page 2136). Yes: Replace VGTA. After repairs
4228 FMI 0.
Are engine thermostats operating within specification? No: Replace both engine
thermostats. After repairs are
FMI 0.

SPN 4228 FMI 14 - Engine Variable Geometry Turbocharger Actuator 1 Temperature : Special
Instructions
Fault Overview
Lamp Reaction
Associated Faults

15 and 16
Fault Facts
None

Road Test
Possible Causes
• Exhaust leak
• Failed VGTA


®
(page 1940).
FMI 14.

leaks.


leaks.
4228 FMI 14.

4228 FMI 14.
FMI 14.

SPN 4228 FMI 15 - Engine Variable Geometry Turbocharger Actuator 1 Temperature : Data Valid But
Above Normal Operating Range - Least Severe Level
Fault Overview
Lamp Reaction
Associated Faults

15 and 16
Fault Facts
None

Road Test
Possible Causes
• Exhaust leak
• Failed VGTA


®
(page 1940).
FMI 15.

leaks.


leaks.
4228 FMI 15.

4228 FMI 15.
FMI 15.

SPN 4331 FMI 16 - Aftertreatment 1 Diesel Exhaust Fluid Actual Dosing Quantity : Data Valid But Above
Fault Overview
Fault code sets when Engine Control Module (ECM) detects calculated actual DEF flow is more than
commanded.
Lamp Reaction
Associated Faults
SPN 3362 FMI 31 SPN 4334 FMI 2, 3, 4, 7, SPN 5394 FMI 5 and 7
and 15
Fault Facts
None

Road Test
Possible Causes
• Failed DEF line or connection
• DEF tanks damaged or contaminated with debris
• DEF system screens, lines, fittings or filters restricted
• Failed DEF Supply Module (DEFSM)
• Failed DEF Supply module PWR or GND circuits
• Restricted DEF return line or DEF head unit return fitting
• Failed DEF Doser Valve (DEFDV)


®
1940).
Step 3 Visually inspect DEF lines and connections. Decision

Inspect DEF lines and DEF line fittings on the DEF Doser Valve, DEF Supply Yes: Go to Step 4.
Module, and DEF Tank for reversed lines, kinks, damage, blockage or restricted
lines or connections. Remove line connections to inspect for damaged fittings.
Are all DEF lines and connections free of damage, blockage, reversed connections No: Repair DEF failed line or
or restrictions? connection. After repairs are
FMI 16.

Looking through the DEF Tank fill port, visually inspect the DEF tank vent for Yes: Go to Step 5.
contamination, debris, crystallization, clogging, or damage. Check the DEF tank vent
for crystallization buildup and clogging.
DEF tank and vent clean and free of debris or damage? No: Drain the DEF tank.
Thoroughly flush with distilled
water. Repair any damage or
pinched hoses. Clean DEF
the DEF level sensor ONLY if the
vent is damaged. After repairs
4331 FMI 16.

Step 6 Check for DEF Supply Module operation. Decision

Review results from the DEF Supply Module Suction Test performed in step 5. Yes: Inspect the DEF Tank filter,
DEF Supply Module Inlet screen,
for debris. Replace as needed
if restricted. After repairs are
complete, go back to step 5. If
vehicle fails DEF Supply Module
Suction test a second time,
replace DEF Supply Module.

4331 FMI 16.

between Breakout Harness 18-648-01 pin-2 and a known good GND.
Is voltage B+ ± 0.5 volts? No: Repair Open between DEF
Supply Module Relay pin-87 and
DEF Supply Module Pin-2. After
SPN 4331 FMI 16.

between Breakout Harness 18-648-01 Pin-4 and PWR. Module. After repairs are
FMI 16.
Is voltage B+ ± 0.5 volts? No: Repair Open between ECM
pin C2-02 and DEF Supply
Module Pin-4. After repairs are
FMI 16.
DEF suction line as necessary
for a restriction. Drain the DEF
tank, flush with distilled water,
and fill with known good DEF.


Perform DEF Doser Valve Outlet Pressure Test (page 2212). Yes: Replace the DEF Doser.

Pressure line. After repairs are
FMI 16.

step 13.
build-up. Repair as needed. If
no signs of blockage or build-up,
replace the DEF Supply Module.
FMI 16.
Review results from DEF Dosing System Test performed in step 15. Yes: End Diagnostics. Retest for
SPN 4331 FMI 16.


Tools Required
Test 1
A. Key OFF.
4
18-648-01
0000413990
Test 2
A. Key OFF.
SPN 4331 FMI 18 - Aftertreatment 1 Diesel Exhaust Fluid Actual Dosing Quantity : Data Valid But Below
Fault Overview
Fault code sets when Engine Control Module (ECM) detects calculated actual DEF flow is less than commanded.
Lamp Reaction
Associated Faults
SPN 3362 FMI 31 SPN 4334 FMI 2, 3, 4, 7, SPN 5394 FMI 5 and 7
and 15
Fault Facts
None

Road Test
Possible Causes
• Failed DEF line or connection
• DEF tanks damaged or contaminated with debris
• DEF system screens, lines, fittings or filters restricted
• Failed DEF Supply Module (DEFSM)
• Failed DEF Supply module PWR or GND circuits
• Restricted DEF return line or DEF head unit return fitting
• Failed DEF Doser Valve (DEFDV)


®
1940).

Inspect DEF lines and DEF line fittings on the DEF Doser Valve, DEF Supply Yes: Go to Step 4.
Module, and DEF Tank for reversed lines, kinks, damage, blockage or restricted
lines or connections. Remove line connections to inspect for damaged fittings.
Are all DEF lines and connections free of damage, blockage, reversed connections No: Repair DEF failed line or
or restrictions? connection. After repairs are
FMI 18.

Looking through the DEF Tank fill port, visually inspect the DEF tank vent for Yes: Go to Step 5.
contamination, debris, crystallization, clogging, or damage. Check the DEF tank vent
for crystallization buildup and clogging.
DEF tank and vent clean and free of debris or damage? No: Drain the DEF tank.
Thoroughly flush with distilled
water. Repair any damage or
pinched hoses. Clean DEF
4331 FMI 18.



4331 FMI 18.

Supply Module Relay pin-87 and
DEF Supply Module Pin-2. After
SPN 4331 FMI 18.

between Breakout Harness 18-648-01 Pin-4 and PWR. Module. After repairs are
FMI 18.
Module Pin-4. After repairs are
FMI 18.
DEF suction line as necessary
for a restriction. Drain the DEF
tank, flush with distilled water,
and fill with known good DEF.


Perform DEF Doser Valve Outlet Pressure Test (page 2212). Yes: Replace the DEF Doser.

FMI 18.

step 13.
build-up. Repair as needed. If
no signs of blockage or build-up,
replace the DEF Supply Module.
FMI 18.
SPN 4331 FMI 18.


Tools Required
Test 1
A. Key OFF.
4
18-648-01
0000413990
Test 2
A. Key OFF.
SPN 4334 FMI 2 - Aftertreatment 1 Diesel Exhaust Fluid Doser 1 Absolute Pressure : Data Erratic,
Fault Overview
Fault code sets when Diesel Exhaust Fluid (DEF) system is holding DEF Doser Absolute Pressure (DEFDAP)
after the Diesel Exhaust Fluid Supply Module (DEFSM) is in the OFF state and system is purged.
Lamp Reaction
Associated Faults
SPN 4334 FMI 3, 4, 7 and SPN 4375 FMI 2 SPN 7107 SPN 7416
16
Fault Facts
DEFDAP sensor is located inside the DEF Doser Valve (DEFDV).

Continuous
Possible Causes
• Failed DEFDAP sensor
• Failed DEFDV
• Restricted DEF return line
• Restricted DEF head unit return passage

®
for SPN 4334 FMI 2.

Does EST DTC list SPN 4334 FMI 2 active or pending? No: Go to Intermittent or Inactive
(page 1940).
Step 3 Inspect connections at DEF Doser Valve (DEFDV) connector. Decision

B. Disconnect DEFDV connector.
C. Check DEFDV and connector terminals for: damaged or pinched wires;
connector housing.
Are DEFDV connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
4334 FMI 16.
Step 4 Check for biased DEFDAP sensor. Decision

B. Wait 30 seconds for DEF system pressure to leak down.
C. Disconnect the aftertreatment DEF pressure line at the DEF Doser Valve to
ensure system pressure is relieved.
D. Key ON, Engine Off (KOEO).

E. Use Electronic Service Tool (EST), monitor DEF Doser Absolute Pressure.
Is the pressure 0 ±10 psi (0 ±69 Kpa)? No: Replace DEF Doser Valve for
a failed DEFDAP sensor. After
SPN 4334 FMI 2.
Step 5 Check DEFDAP at the return line. Decision

Perform DEF Doser Valve Outlet Pressure Test (page 2212). Yes: Replace DEF Doser Valve.
for SPN 4334 FMI 2.
Is pressure less than 10 psi (69 kPa)? No: Go to Step 6.
Step 6 Check DEF return line for restrictions. Decision

Disconnect both ends of return line and blow regulated compressed air through Yes: Replace DEF head unit for
return line; blow regulated compressed air through removed fitting. return passage blockage. After
SPN 4334 FMI 2.
Does compressed air flow freely through return line? No: Replace DEF return line.
for SPN 4334 FMI 2.

SPN 4334 FMI 3 - Aftertreatment 1 Diesel Exhaust Fluid Doser 1 Absolute Pressure : Voltage Above
Normal, or Shorted to High Source
Fault Overview
Fault Code sets when Engine Control Module (ECM) detects Diesel Exhaust Fluid Absolute Pressure (DEFAP)
Signal is greater than specified operating range. DEF injection into aftertreatment system is disabled. Engine
torque will be reduced if fault is active for an extended period of time.
Lamp Reaction
Associated Faults
SPN 3511 FMI 4, 6, 14
Fault Facts
None.

Continuous.
Possible Causes
• DEFAP signal circuit short to PWR
• DEFAP signal circuit shorted to VREF 3
• SIG GND circuit open or high resistance
• Failed Diesel Exhaust Fluid Doser Valve (DEFDV)

®
ON, check Diagnostic Trouble Code (DTC) list for Associated Faults (page 1533).
SPN 4334 FMI 3.

Does EST DTC list SPN 4334 FMI 3 active? No: Go to Intermittent or Inactive
(page 1940). Perform SCR Fault
for SPN 4334 FMI 3.
Step 3 Inspect connections at Diesel Exhaust Fluid Doser Valve (DEFDV) Decision
connector.
connector housing.
FMI 3.
Step 4 Check SIG GND for open or high resistance Decision

Perform Test 1 (page 1536). Use DMM, measure voltage from breakout harness Yes: Go to Step 5.
18-559-02 pin-7 to Battery PWR.
resistance between DEFDV
pin-7 and ECM pin C1-63.
SPN 4334 FMI 3.
Step 5 Check DEFAP signal for short to PWR. Decision

Perform Test 2 (page 1537). Use DMM, measure voltage from breakout harness Yes: Replace DEFDV. Perform
18-559-02 pin-8 and a known good GND SCR Fault Reset Request
FMI 3.
Is voltage 0 volts? No: Repair short to PWR
between DEFDV pin 8 and PWR.
for SPN 4334 FMI 3. Perform
FMI 3.


Tools Required
7
18-559-02
0000419031
Test 1
A. Key OFF.
B. Disconnect DEFDV.
C. Connect Breakout Harness 18-559-02 to vehicle harness and leave DEFDV disconnected
D. Key ON
8
18-559-02
0000419032
Test 2
A. Key OFF.
D. Key ON
SPN 4334 FMI 4 - Aftertreatment 1 Diesel Exhaust Fluid Doser 1 Absolute Pressure : Voltage Below
Fault Overview
Fault Code sets when Engine Control Module (ECM) detects Diesel Exhaust Fluid Absolute Pressure (DEFAP)
Signal is lower than specified operating range. DEF injection into aftertreatment system is disabled. Engine
torque will be reduced if fault is active for an extended period of time
Lamp Reaction
Associated Faults
SPN 3511 FMI 4, 6, and 14
Fault Facts
None.

Continuous.
Possible Causes
• DEFAP signal circuit short to GND
• DEFAP signal circuit open or high resistance
• VREF 3 circuit open or high resistance
• Failed Diesel Exhaust Fluid Doser Valve (DEFDV)

®
SPN 4334 FMI 4.
Step 2 Check for active of pending fault codes Decision

®
Is EST DTC list SPN 4334 FMI 4 as active? No: Perform Intermittent
or Inactive Fault Diagnostic
Procedure (page 1940). Perform
FMI 4.
connector.
connector housing.
FMI 4.
Step 4 Check VREF 3 circuit for open or high resistance. Decision

Perform Test 1 (page 1541). Use DMM, measure voltage from breakout harness Yes: Go to Step 5..
18-559-02 pin-5 and a known good GND.
Is voltage 5V ± 0.1 volts? No: Repair open or high
resistance between DEFDV pin-5
and ECM pin C1-36. Perform
FMI 4.
Step 5 Check for failed DEFDV Decision

Perform Test 2 (page 1542). Use EST with Navistar® Engine Diagnostic Software, Yes: Replace DEFDV. Perform
clear Diagnostic Trouble Code (DTC) list. SCR Fault Reset Request
FMI 4
Does SPN 4334 FMI 3 set after DTC list is cleared? No: Repair open or high
resistance between DEFDV pin-8
and ECM pin C1-34. Perform

FMI 4.


Tools Required
5
18-559-02
0000418908
Test 1
A. Key OFF.
B. Disconnect DEFDV

4498
5
18-559-02
8
0000418911
Figure 517 DEFAP Circuit Check
Test 2
A. Key OFF.
D. Use Breakout Harness ZTSE4498 short Breakout Harness 18-559-02 pin-8 and pin-5 together.
E. Connect Electronic Service Tool (EST) with Navistar® Engine Diagnostic Software.
F. Key ON, log into Electronic Service Tool (EST) with Navistar® Engine Diagnostic Software.
SPN 4334 FMI 7 - Aftertreatment 1 Diesel Exhaust Fluid Doser 1 Absolute Pressure : Mechanical
System Not Responding Or Out Of Adjustment
Fault Overview
This fault code sets with the Engine Control Module (ECM) detects DEF Absolute Pressure is greater than 36psi
(250kPa) at Key OFF
Lamp Reaction
Associated Faults
None

Continuous
Possible Causes
• Restricted DEF Doser Valve (DEFDV) Inlet Screen
• Failed DEFDV

Inspect DEF lines and DEF line fittings on the DEFDV for reversed lines, kinks, Yes: Go to Step 2.
damage, blockage or restricted lines or connections.
Are all DEF lines and connections free of damage, reversed connections or No: Repair DEF line or
restrictions? connection. After repairs
4334 FMI 7.

Software.
F. Monitor DEFAP.
Is DEFAP Signal reading less than 10 psi (69 kPa)? No: Replace DEF Doser Valve
for failed DEFAP sensor. After
SPN 4334 FMI 7.
Step 3 Check DEF Pressure at DEF Doser Valve Outlet Decision

Inlet screen (See appropriate
vehicle technician manual) for
debris and replace as needed.
If no debris is found, replace
DEF Doser. After repairs are
FMI 7.
Is gauge reading less than 10 psi (70 kPa)? No: Inspect DEF return line
for SPN 4334 FMI 7.

SPN 4334 FMI 15 - Aftertreatment 1 Diesel Exhaust Fluid Doser 1 Absolute Pressure : Data Valid But
Above Normal Operating Range - Least Severe Level
Fault Overview
This fault code sets with the Engine Control Module (ECM) detects Diesel Exhaust Fluid Absolute Pressure
(DEFAP) is greater than 101 psi (700kPa) at Key OFF.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Failed DEFDV

4334 FMI 15.

Software.
F. Monitor DEFAP.
SPN 4334 FMI 15.

Inlet screen (see appropriate
FMI 15.

Above Normal Operating Range - Moderately Severe Level
Fault Overview
This fault code sets with the Engine Control Module (ECM) detects Diesel Exhaust Fluid Absolute Pressure
(DEFAP) is greater than 160 psi (1,100kPa).
Lamp Reaction
Associated Faults
None
Fault Facts
None.

Continuous
Possible Causes
• Failed DEFDV

4334 FMI 16.

Software.
F. Monitor DEFAP.
SPN 4334 FMI 16.

FMI 16.

Below Normal Operating Range - Moderately Severe Level
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Exhaust Fluid Supply Module (DEFSM) is
unable to build or maintain adequate pressure in dosing system.
Lamp Reaction
Associated Faults
None
Fault Facts
None.

Continuous
Possible Causes
• Debris in DEF tank / restricted DEF tank screen
• DEF tank, supply module, or doser line or connection loose, leaking, or damaged
• Restricted DEF supply line
• Failed Diesel Exhaust Fluid Supply Module (DEFSM)

fluid. After repairs are complete,

Visually inspect the DEF tank vent for crystallization, clogging, damage or pinched Yes: Repair any damage or
hoses. pinched hoses. Clean DEF
4334 FMI 18.
Is DEF tank vent clogged or blocked with DEF crystallization? No: Go to Step 3.

Inspect all three DEF lines and the DEF line fittings on the DEF supply module for Yes: Go to Step 4.
white DEF residue (indicating a leak), reversed lines, damage or restricted lines or
connections.
Are all DEF lines and connections free of leaks, damage, reversed connections or No: Repair failed DEF line or
restrictions? connection. After repairs are
FMI 18
Step 4 Check the DEF Supply Module Suction. Decision

Was vacuum gauge reading 7 in-Hg (177.8 mm-Hg) or greater? No: Inspect the DEF Tank, DEF
DEF Supply Module Filter and
complete, perform DEF Supply
Module Suction Test again. If
Step 5 Check DEF Supply Module Inlet Restriction. Decision

Was vacuum gauge reading less than 10 in-Hg (254 mm-Hg)? No: Repair or replace DEF tank
filter or DEF suction line as
necessary for a restriction. Drain
the DEF tank, flush with distilled
water, and fill with known good
Step 6 Check DEF Supply for Aeration Decision

Review the results of the DEF Supply Module Inlet Restriction Test perform in step 5. Yes: Repair leaks or cracks in
either the suction line or DEF
tank suction fitting/pick-up tube.
Were bubbles approximately half the size of DEF diagnostic line (Part Number No: Go to step 7.
5299833) tubing seen during the test?
Step 7 Check DEF Pressure at DEF Doser Valve Inlet. Decision


Is gauge reading between 108 psi (750kPa) and 137 psi (950 kPa)? No: Repair restricted DEF
FMI 18.

Vehicle Technician Manual) for
the DEF Doser. After repairs
4334 FMI 18. After repairs are
FMI 2.
Is gauge reading less than 10 psi (69 kPa)? No: Go to Step 10.
Perform DEF Dosing System Test (page 1978). Yes: Check the entire system
for debris or air leaks. Repair
as needed. After repairs are
FMI 18.
SPN 4334 FMI 18.

SPN 4334 FMI 20 - Aftertreatment 1 Diesel Exhaust Fluid Doser 1 Absolute Pressure : Data Drifted High
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that the DEF Pump has exceeded maximum
pressure.
Lamp Reaction
Associated Faults
SPN 4334 FMI 2, 3, and 4
Fault Facts
None.

Continuous.
Possible Causes
• Failed DEFDV


4334 FMI 20.

B. Wait 30 seconds for DEF system pressure to leak down

Software
F. Monitor DEFAP.
Is gauge reading less than 10 psi (69 kPa)? No: Replace DEF Doser Valve
SPN 4334 FMI 20.

replace as needed. If no debris is
found, replace DEF Doser. After
SPN 4334 FMI 20.

SPN 4340 FMI 3 - Aftertreatment 1 Diesel Exhaust Fluid Line Heater 1 State : Voltage Above Normal,
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Exhaust Fluid Line Heater 1 (DEFLH1), or
pressure line heater, voltage is open or short to power.
Lamp Reaction
Associated Faults
SPN 5491 FMI 5
Fault Facts
Diesel Exhaust Fluid Line Heaters share a common Ground circuit. If more than one DEF line heater fault is
set, suspect a common Ground circuit problem.

Continuous
Possible Causes
• DEFLH1 harness Open or Short to Power
• Failed DEFLH1
• Failed DEFLH1 Relay (R2)

®
for SPN 4340 FMI 3.
Step 2 Inspect connections at Diesel Exhaust Fluid Line Heater 1 (DEFLH1) Decision
connector.
B. Disconnect DEFLH1 connector.
C. Check DEFLH1 and connector terminals for: damaged or pinched wires;
housing.
Are DEFLH1 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
4340 FMI 3.
Step 3 Inspect connections at 14-way DEF Tank Harness connector. Decision

B. Disconnect 14–way DEF Tank Harness connector.
C. Check DEF Tank Harness connector terminals for: damaged or pinched
connector housing.
Are DEF Tank Harness connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
4340 FMI 3.
Step 4 Check DEFLH1 circuit for short to PWR. Decision

Perform Test 1 (page 1558). Use Digital Multimeter (DMM), measure voltage Yes: Go to step 7.
between Breakout Harness 18-047-01 pin-1 and pin-2.
Is voltage less than 0.5 volts? No: Go to step 5.

Remove DEFLH1 relay (R2) from AFT PDM, Perform Test 1 (page 1558). Use Yes: Replace DEFLH1 relay
Digital Multimeter (DMM), measure voltage between Breakout Harness 18–047–01 (R2). After repairs are complete,
pin-1 and pin-2. retest for SPN 4340 FMI 3.
Step 6 Check DEFLH1 for open. Decision

Perform Test 2(page 1558). Use Digital Multimeter (DMM), measure resistance Yes: Repair short to power
between Breakout Harness 18-047-01 pin-1 and pin-2. between DEFLH1 Relay (R2)
terminal 30, DEFLH1 pin-1 and
ECM Pin C1-64. After repairs are
FMI 3.
Is resistance between 2 and 15 Ohms? No: Replace DEFLH1. After
SPN 4340 FMI 3.
Step 7 Check DEFLH1 circuit for open. Decision

Perform Test 3 (page 1559). Use Digital Multimeter (DMM), measure voltage Yes: Repair open circuit between
between Breakout Harness 18-047-01 pin-1 and a known good GND. DEFLH1 pin-2 and GND. After
SPN 4340 FMI 3.
Is voltage B+ ± 1.0 volts? No: Repair open circuit between
ECM pin C1-64 and DEFLH1


Tools Required
Figure 518 DEFLH1 Circuit Check
Test 1
A. Key OFF.
C. Install Breakout Harness 18–047–01 between engine harness and DEFLH1.

D. Key ON.
2 18-047-01
0000424773
Figure 519 DEFLH1 Internal Resistance Check
Test 2
A. Key OFF.
C. Connect Breakout Harness 18–047–01 to DEFLH1 and leave vehicle harness disconnected.
Test 3
A. Key OFF.
C. Connect Breakout Harness 18–047–01 to vehicle harness and leave DEFLH1 disconnected.
D. Key ON.
SPN 4340 FMI 4 - Aftertreatment 1 Diesel Exhaust Fluid Line Heater 1 State : Voltage Below Normal,
Fault Overview
pressure line heater, voltage is open or Short to Ground for a calibrated period of time.
Lamp Reaction
Associated Faults
SPN 5491 FMI 5
Fault Facts
None

Continuous
Possible Causes
• DEFLH1 harness Open or Short to Ground
• DEFLH1 Relay control circuit Open or Short to Ground
• Failed DEFLH1

®
for SPN 4340 FMI 4.
Step 2 Check Power Distribution Module (PDM) Decision

Check Power Distribution Module (PDM) fuse(s) and relay(s) for blown fuses; loose, Yes: Go to Step 3.
missing, or intermittent connections.
FMI 4.
Step 3 Check DEFLH1 circuit for open or short to ground. Decision

Perform Test 1 (page 1564). Use Digital Multimeter (DMM), Measure voltage Yes: Go to Step 4.
between DEFLH Relay (R2) pin-30 and a known good GND.
Is voltage B+ ± 1.0 volts? No: Repair open or short to
ground between DEFLH1 Relay
(R2) terminal 30, DEFLH1 pin-1
and ECM Pin C1-64. After
SPN 4340 FMI 4.
Step 4 Check DEFLH1 for internal short. Decision

Perform Test 2 (page 1565). Use Digital Multimeter (DMM) to measure resistance Yes: Go to Step 5.
SPN 4340 FMI 4. After repairs
4340 FMI 4.
Step 5 Check DEFLH1 relay circuit for open or short to ground. Decision
Perform Test 3 (page 1565). Use Digital Multimeter (DMM), Measure voltage Yes: Go to step 6.
ground between DEFLH1 relay
(R2) pin-87 and vehicle battery.
for SPN 4340 FMI 4.
for SPN 4340 FMI 4.
Step 7 Check for open in DEFLH CTL/GND circuit. Decision

A. Perform Test 5 (page 1567). Yes: End diagnostics. Retest for
®
SPN 4340 FMI 4.
B. Use EST with Navistar Engine Diagnostics, perform DEF Line Heater
Test (page 1983).
C. While test is running, use DMM, measure voltage between DEFLH relay
pin-86 and a known good ground.
Is voltage less than 0.5 volts? No: Repair open between
DEFLH relay (R2) pin-86 and
FMI 4.


Tools Required
• Breakout Harness 18–047–01
30 4435C
0000422454
Figure 521 DEFLH Circuit Check
Test 1
A. Key OFF.
B. Disconnect DEFLH1.
C. Disconnect DEFLH1 Relay (R2).
D. Install Test Lead ZTSE443531 from Terminal Test Kit ZTSE4435C into DEFLH1 Relay terminal 30.
E. Key ON.
2 18-047-01
0000424773
Figure 522 DEFLH Resistance Check
Test 2
A. Key OFF.
C. Connect Breakout Harness 18–047–01 to DEFLH1 and leave engine harness disconnected.
87 4435C
0000424371
Test 3
A. Key OFF.
B. Disconnect DEFLH Relay (R2).
C. Install Test Lead ZTSE443531 from Terminal Test Kit ZTSE4435C into DEFLH1 Relay terminal 87.
85 4435C
0000424369
Figure 524 DEFLH Relay CTL Circuit Check
Test 4
A. Key OFF.
B. Disconnect DEFLH1 Relay (R2).
86 4435C
0000424370
Test 5
A. Key OFF.
D. Key ON.
Fault Overview
backflow line heater, voltage is open or short to power.
Lamp Reaction
Associated Faults
SPN 5491 FMI 5
Fault Facts

Continuous
Possible Causes
• Failed DEFLH2

®
Use EST with Navistar Engine Diagnostics. Check Diagnostic Trouble Code (DTC) Yes: Go to Step 2.
list for Associated faults (page 1569).
for SPN 4342 FMI 3.
Step 2 Inspect connections at Diesel Exhaust Fluid Line Heater 2(DEFLH2) Decision
connector.
housing.
4342 FMI 3.

connector housing.
4342 FMI 3.



Perform Test 2 (page 1572). Use Digital Multimeter (DMM), measure resistance Yes: Repair short to power
FMI 3.
SPN 4342 FMI 3.

SPN 4342 FMI 3.


Tools Required
Test 1
A. Key OFF.

D. Key ON.
2 18-046-01
0000424772
Test 2
A. Key OFF.
Test 3
A. Key OFF.
D. Key ON.
Fault Overview
backflow line heater, voltage is open or Short to Ground for a calibrated period of time.
Lamp Reaction
Associated Faults
SPN 5491 FMI 5
Fault Facts
None

Continuous
Possible Causes
• Failed DEFLH2

®
for SPN 4342 FMI 4.

FMI 4.

SPN 4342 FMI 4.

Perform Test 2 (page 1579). Use Digital Multimeter (DMM) to measure resistance Yes: Go to Step 5.
SPN 4342 FMI 4.
for SPN 4342 FMI 4.
for SPN 4342 FMI 4.

®
SPN 4342 FMI 4.
Test (page 1983).
FMI 4.


Tools Required
30 4435C
0000422454
Test 1
A. Key OFF.
E. Key ON.
2 18-046-01
0000424772
Test 2
A. Key OFF.
87 4435C
0000424371
Test 3
A. Key OFF.
85 4435C
0000424369
Test 4
A. Key OFF.
86 4435C
0000424370
Test 5
A. Key OFF.
D. Key ON.
Fault Overview
Suction line heater, voltage is open or short to power.
Lamp Reaction
Associated Faults
SPN 5491 FMI 5
Fault Facts

Continuous
Possible Causes
• Failed DEFLH3

®
Use EST with Navistar Engine Diagnostics. Check Diagnostic Trouble Code (DTC) Yes: Go to Step 2.
list for Associated faults (page 1583).
for SPN 4344 FMI 3.
Step 2 Inspect connections at Diesel Exhaust Fluid Line Heater 3 (DEFLH3) Decision
connector.
housing.
4344 FMI 3.

connector housing.
4344 FMI 3.



Perform Test 2 (page 1586). Use Digital Multimeter (DMM), measure resistance Yes: Repair short to power
FMI 3.
SPN 4344 FMI 3.

SPN 4344 FMI 3.


Tools Required
Test 1
A. Key OFF.

D. Key ON.
2 18-045-01
0000424771
Test 2
A. Key OFF.
Test 3
A. Key OFF.
D. Key ON.
Fault Overview
suction line heater, voltage is open or Short to Ground for a calibrated period of time.
Lamp Reaction
Associated Faults
SPN 5491 FMI 5
Fault Facts
None

Continuous
Possible Causes
• Failed DEFLH3

®
for SPN 4344 FMI 4.

FMI 4.

SPN 4344 FMI 4.

Perform Test 2 (page 1593). Use Digital Multimeter (DMM), Measure resistance Yes: Go to Step 5.
SPN 4344 FMI 4.
for SPN 4344 FMI 4.
for SPN 4344 FMI 4.
Step 7 Check for open in DEFLH relay CTL/GND circuit. Decision

®
SPN 4344 FMI 4.
Test (page 1983).
FMI 4.


Tools Required
30 4435C
0000422454
Test 1
A. Key OFF.
E. Key ON.
2 18-045-01
0000424771
Test 2
A. Key OFF.
87 4435C
0000424371
Test 3
A. Key OFF.
85 4435C
0000424369
Test 4
A. Key OFF.
86 4435C
0000424370
Test 5
A. Key OFF.
D. Key ON.
SPN 4360 FMI 2 - Aftertreatment 1 SCR Intake Temperature : Data Erratic, Intermittent or Incorrect
Fault Overview
Fault code sets when Engine Control Module (ECM) has determined AFT temperature sensor does not match
engine operating conditions for more than 5 minutes.
Lamp Reaction
Associated Faults
SPN 3246 FMI 3 and 4 SPN 5742 SPN 5743
Fault Facts
None

Continuous
Possible Causes

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostic software, check Yes: Go to Step 2.
Diagnostic Trouble Code list for Associated Faults (page 1597).
for SPN 4360 FMI 2.
Step 2 Inspect connections at Aftertreatment Temperature Sensor Module Decision

connector.
B. Disconnect AFT temperature sensor module sensor.
C. Check AFT temperature sensor module sensor and connector terminals
Are AFT temperature sensor module sensor connector, harness, and terminals No: Repair connector, harness,
4360 FMI 2.
Step 3 Compare AFT Temperature Sensors Decision

Perform Hot Run Sensor Comparison Test (page 2267). Yes: End diagnostics. Retest for
SPN 4360 FMI 2.
Were all sensors within 77°F (25°C) of each other? No: Replace AFT temperature
FMI 2.

SPN 4360 FMI 14 - Aftertreatment 1 SCR Intake Temperature : Special Instructions
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Selective Catalyst Reduction (SCR) mid bed
temperature signal value is greater than expected.
Lamp Reaction
Red Stop Lamp (RSL) will illuminate after this fault is detected.
Associated Faults
SPN 1322-1328 FMI 31 SPN 2797 and 2798 FMI 11 SPN 3242 FMI 2, 3, 4,12, SPN 3246 FMI 2, 3, 4,12,
20, 21 20, 21
SPN 4363 FMI 2, 3, and 4 SPN 4765 FMI 2, 3, 4,12, SPN 5743 FMI 19
20, 21
Fault Facts
components, cracked exhaust system welds, leaking exhaust system seams, or other damage.
If more than one DOC, DPF and/or SCR temperature sensor over temperature fault code(s) are present, check
for unregistered fuel or oil in exhaust.

Road Test
Possible Causes
• Contaminated Diesel Exhaust Fluid (DEF)
• Engine oil leak to exhaust
• Fuel leak to exhaust
• Leaking or stuck Open Aftertreatment Hydrocarbon Doser (AFTHD)
• Leaking or stuck Open Aftertreatment Fuel Enable Actuator (AFTFEA)
CAUTION:

®
WARNING:
Step 3.
System Leak or Over
4360 FMI 14.
Step 4 Check DEF quality. Decision

Is urea concentration between 30 and 34 percent and Not contaminated? No: Drain DEF tank, flush with
SPN 4360 FMI 14.
Step 5 Determine if engine performance problem is present. Decision

Check for engine misfire, rough idle, popping noise from intake, or low power (slow Yes: Go to 4.0 - Engine
acceleration) condition. Performance Problem
(page 32).
Is an engine performance problem present? No: Go to Step 6.
Step 6 Inspect turbocharger exhaust outlet for oil or fuel to aftertreatment Decision
system.
Was turbocharger exhaust outlet free of oil and fuel contamination? No: Repair engine oil or fuel leak
to exhaust. See 6.2 Oil Leak
to Exhaust (page 75), or See
Fuel to Exhaust (page 87). After
SPN 4360 FMI 14.
(AFTFEA).
SPN 4360 FMI 14.

SPN 4360 FMI 14.

FMI 14.
Step 10 Compare SCR Inlet, and SCR outlet temperatures. Decision

Is SCR inlet, and SCR outlet temperature sensors with in 77°F (43°C) of each other? No: Replace AFT temperature
sensor module. Refer to Fault
Facts. After repairs are complete,
Step 11 Remove Diesel Oxidation Catalyst (DOC). Decision

Perform DOC Inspection (page 2240). Yes: Reinstall DOC and perform
SPN 4360 FMI 14.
Is less than 50 percent of cells on intake face completely blocked by soot and No: Clean or replace DOC. Refer
undamaged? to Fault Facts. After repairs are
FMI 14.
End Diagnostic Testing

SPN 4363 FMI 0 - Aftertreatment 1 SCR Outlet Temperature : Data Valid But Above Normal Operational
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Selective Catalyst Reduction Outlet Temperature
(SCROT) signal value is greater than expected.
Lamp Reaction
Associated Faults
SPN 1322-1328 FMI 31 SPN 2197 and 2798 FMI 11 SPN 4363 FMI 2, 3, and 4 SPN 5742 FMI 19
SPN 5743 FMI 19
Fault Facts
None

Road Test
Possible Causes
• Leaking or stuck open Aftertreatment Fuel Enable (AFTFEA)
• Failed SCR temperature sensor module
CAUTION:

®
for SPN 4363 FMI 0.
WARNING:
Step 3.
System Leak or Over
4363 FMI 0.

Is urea concentration between 30 - 34 percent and Not contaminated? No: Drain DEF tank, flush with
SPN 4363 FMI 0.

FMI 0.
system.
SPN 4363 FMI 0.
Step 7 Check for leaking or stuck open AFTFEA. Decision

SPN 4363 FMI 0.

SPN 4363 FMI 0.

Was 225 to 500 ml of fuel dispensed within 2.5 minutes? No: Replace AFTHD. After
SPN 4363 FMI 0.

Are all temperature sensors with in 77°F (43°C) of each other? No: Replace SCR temperature

SPN 4363 FMI 0.
Is less than 50 percent of cells on intake face completely blocked by soot and No: Clean or replace DOC.
undamaged? Repair upstream source of
excessive heat (fuel and oil
in exhaust). After repairs are
FMI 0.

SPN 4363 FMI 2 - Aftertreatment 1 SCR Outlet Temperature : Data Erratic, Intermittent Or Incorrect
Fault Overview
(SCROT) sensor does not match engine operating conditions for more than 5 minutes.
Lamp Reaction
Associated Faults
SPN 4363 FMI 3 and 4 SPN 5742 FMI 19 SPN 5743 FMI 19
Fault Facts
None

Continuous
Possible Causes
Step 1 Check for associated fault codes Decision

®
for SPN 4363 FMI 2.
Step 2 Inspect connections at Aftertreatment (AFT) temperature sensor Decision

module connector.
C. Check AFT temperature sensor module sensor and connector terminals
4363 FMI 2.
Step 3 Check for failed AFT temperature sensor module. Decision

Perform Hot Run Sensor Comparison Test (page 2267). Yes: End diagnostics. Retest for
SPN 4363 FMI 2.
Was SCROT signal within 77 degrees F (25C) of other exhaust temperature signals? No: Replace AFT temperature
FMI 2.

SPN 4363 FMI 3 - Aftertreatment 1 SCR Outlet Temperature : Voltage Above Normal, or Shorted
to High Source
Fault Overview
(SCROT) sensor circuit is shorted to battery or open. Active and parked regeneration will be disabled and engine
torque reduced. Engine torque will be severely reduced and vehicle speed will be limited after extended engine
operation with this fault code active.
Lamp Reaction
Associated Faults
SPN 5742 (AFT Temp) SPN 5743 (AFT Temp)
Fault Facts
None

Continuous
Possible Causes

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostic software, check Yes: Go to Step 2.
SPN 4363 FMI 3.

Use EST with Navistar® Engine Diagnostic software. Key ON, check DTC list for Yes: Go to Step 3.
SPN 4363 FMI 3.
(page 1940). Perform SCR
FMI 3.
Step 3 Inspect connections at Aftertreatment Temperature Sensor Module Decision

connector.
sensor module. Perform
C. Check AFT temperature sensor module sensor and connector terminals (page 1955). After repairs are
for: damaged or pinched wires; wet or corroded terminals; loose, bent, or complete, retest for SPN 4363
broken pins; or broken connector housing. FMI 3.
FMI 3.

SPN 4363 FMI 4 - Aftertreatment 1 SCR Outlet Temperature : Voltage Below Normal, Or Shorted To
Low Source
Fault Overview
(SCROT) sensor circuit is shorted to GND.
Lamp Reaction
Associated Faults
SPN 5742 SPN 5743
Fault Facts
None

Continuous
Possible Causes
• Failed SCR temperature sensor module

SPN 4363 FMI 4.

®
Use EST with Navistar Engine Diagnostics. Key ON, check DTC list for SPN Yes: Go to Step 3.
4363 FMI 4.
Is EST DTC listing SPN 4363 FMI 4 active? No: Go to Intermittent or Inactive
(page 1940). Perform SCR
FMI 4.
Step 3 Inspect connections at Aftertreatment (AFT) temperature sensor Decision

module connector.
sensor module. Perform
C. Check AFT temperature sensor module sensor and connector terminals (page 1955). After repairs are
for: damaged or pinched wires; wet or corroded terminals; loose, bent, or complete, retest for SPN 4363
broken pins; or broken connector housing. FMI 4.
FMI 4.

SPN 4363 FMI 16 - Aftertreatment 1 SCR Outlet Temperature : Data Valid But Above Normal Operating
Fault Overview
(SCROT) signal value is greater than expected when not in regeneration mode.
Lamp Reaction
Associated Faults
SPN 1322-1328 FMI 31 SPN 2197 and 2798 FMI 11 SPN 3242 SPN 3246
SPN 4360 FMI 2, 3, and 4 SPN 4363 FMI 2, 3, and 4 SPN 4765 SPN 5743 FMI 3, 4, 12, and
19
Fault Facts
go inactive after SCROT drops below maximum limit, and will likely be inactive when vehicle is in shop. For this
If more than one DOC, DPF and/or SCR temperature sensor over temperature fault code(s) are present, check
for unregistered fuel or oil in exhaust.

Road Test
Possible Causes
CAUTION:

®
WARNING:
Step 3.
System Leak or Over
4363 FMI 16.

Is urea concentration between 30 and 34 percent and Not contaminated? No: Drain DEF tank, flush with
SPN 4363 FMI 16.

(page 32).
system.
SPN 4363 FMI 16.
(AFTFEA).
SPN 4363 FMI 16.

SPN 4363 FMI 16.

FMI 16.


SPN 4363 FMI 16.
Is less than 50 percent of cells on intake face completely blocked by soot and No: Clean or replace DOC. Refer
undamaged? to Fault Facts. After repairs are
FMI 16.

SPN 4363 FMI 20 - Aftertreatment 1 SCR Outlet Temperature : Data Drifted High
Fault Overview
(SCROT) signal value is greater than expected.
Lamp Reaction
Associated Faults
SPN 1322-1328 FMI 31 SPN 2197 and 2798 FMI 11 SPN 4363 FMI 2, 3, and 4 SPN 5742 FMI 19
SPN 5743 FMI 19
Fault Facts
None.

Continuous
Possible Causes


Obtain a sample of DEF. Visually inspect for contamination, and use special tool Yes: Go to Step 3.
DEF Refractometer 5025 to test urea concentration of DEF fluid.
SPN 4363 FMI 20.

SPN 4363 FMI 20.

(page 32).
system.
SPN 4363 FMI 20.
(AFTFEA).
SPN 4363 FMI 20.

SPN 4363 FMI 20.

SPN 4363 FMI 20.

Are all temperature sensors with in 77°F (43°C) of each other? No: Replace AFT temperature
FMI 20.
Step 9 Test for black smoke from exhaust. Decision

Perform Snap Acceleration Test (page 2281). Yes: Go to Step 10.
Is exhaust free of black smoke? No: Replace DPF. Repair
upstream source of excessive
heat (fuel and oil in exhaust).

SPN 4363 FMI 20.
Is less than 50 percent of cells on intake face completely blocked by soot and No: Clean or replace DOC.
undamaged? Repair upstream source of
excessive heat (fuel and oil
in exhaust). After repairs are
FMI 20.

SPN 4363 FMI 21 - Aftertreatment 1 SCR Outlet Temperature : Data Drifted Low
Fault Overview
(SCROT) signal value is lower than expected.
Lamp Reaction
Associated Faults
SPN 1322-1328 FMI 31 SPN 2197 and 2798 FMI 11 SPN 4363 FMI 2, 3, and 4 SPN 5742 19
SPN 5743 19
Fault Facts
None.

Continuous
Possible Causes

®

(page 32).

SPN 4363 FMI 21.

Perform Hot Run Sensor Comparison Test (page 2267). Yes: Perform a Parked
Regeneration. After repairs
4363 FMI 21.
FMI 21.

SPN 4364 FMI 18 - Aftertreatment 1 SCR Conversion Efficiency : Data Valid But Below Normal
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Nitrogen Oxides (NOx) conversion efficiency of
Selective Catalyst Reduction (SCR) catalyst is less than expected.
Lamp Reaction
Associated Faults
SPN 3216 SPN 3218 SPN 3226 SPN 3228

SPN 3362 FMI 31 SPN 3363 FMI 3, 4 SPN 4331 FMI 16 SPN 4334
SPN 4340 FMI 3 SPN 4342 FMI 3 SPN 4344 FMI 3 SPN 5394 FMI 5 and 7
SPN 5743
Fault Facts
A Diesel Exhaust Fluid Doser Valve (DEFDV) with a small leak (infrequent drips) can cause this fault to activate.

Road Test
Possible Causes
• Exhaust system leak(s) or damage
• Failed or leaking Diesel Exhaust Fluid (DEF) line or line connection
• Restricted DEF Supply Module (DEFSM) filter

Step 2 Inspect exhaust and intake air systems for leak(s) and damage. Decision
A. Perform Exhaust and Aftertreatment System Inspection (page 2166). Yes: Go to Step 3.
B. Perform Intake Air Inspection (page 2165).

Are exhaust and intake air systems free of leaks and damage? No: Repair exhaust or intake air
system leak(s) or damage. After
SPN 4364 FMI 18.
Step 3 Inspect Diesel Exhaust Fluid (DEF) tank, DEF Supply Module (DEFSM), Decision
DEF Doser Valve (DEFDV), lines and connections.
Inspect DEF tank, DEFSM, DEFDV, lines and connections for damage or cracks; Yes: Go to Step 4.
loose, leaking, or damaged connections; and restrictions.
Are DEF tank, DEFSM, DEFDV, lines and connections in good condition and not No: Repair or replace failed
leaking? component, line or connection.
Step 4 Determine if DEF Doser Valve (DEFDV) has appropriate flow and spray Decision
pattern, and tip is not corroded.
A. Perform DEF Dosing System Test (page 1978). Yes: Go to Step 5.
B. Inspect DEFDV tip.
Does DEFDV have appropriate flow and spray pattern, and is tip in good condition? No: Clean DEFDV tip with a
brass brush and retest. If volume
and spray pattern do not pass
test after cleaning, install a
new DEFDV. After repairs are
FMI 18.
Step 5 Determine if DEF Doser Valve (DEFDV) tip or system has leaks. Decision
Perform DEF System Leak Test (page 1985). DEFDV tip should not drip during the Yes: Replace DEFDV or leaking
DEF System Leak Test. component. Go to Step 6.
Does DEFDV tip or system have leaks? No: Go to Step 6.
Step 6 Determine if SCR catalyst is functioning properly Decision

A. Clear fault codes. Yes: Remove and inspect
SCR catalyst per SCR Catalyst
B. Perform DPF Regeneration Procedure.
Inspection and Reuse Guidelines
(page 2270). Install new SCR
Catalyst if it fails per guidelines.
Does SPN 4364 FMI 18 become active? No: Drive vehicle approximately
20 miles and determine if SPN
4364 FMI 18 becomes active. If
fault becomes active: Remove
and inspect SCR catalyst per
SCR Catalyst Inspection and
Reuse Guidelines (page 2270).
Install new SCR catalyst if it fails
per guidelines. After repairs are
FMI 18.

SPN 4375 FMI 2 - Aftertreatment 1 Diesel Exhaust Fluid Pump Drive Percentage : Data Erratic,
Fault Overview
The Engine Control Module (ECM) detected the Aftertreatment Diesel Exhaust Fluid (DEF) pump command is
erratic in its attempt to maintain system pressure.
Lamp Reaction
Associated Faults
SPN 3363 FMI 3, 4, 16, 17 SPN 1761 SPN 4334 FMI 2, 3, 4, 7 SPN 4340 FMI 3 and 4
and 18 and 18
SPN 4342 FMI 3 and 4 SPN 4344 FMI 3 and 4 SPN 5491 FMI 3 and 5
Fault Facts
None

Road Test
Possible Causes
• Debris in DEF system
• Failed DEF connection, line or fitting
• DEF Supply Module PWR Open or short to GND
• DEF Supply Module GND Open
• Failed DEFAP sensor or sensor circuit
• Aerated DEF
• Failed DEF Supply Module
• Failed DEF Doser Valve
• Low DEF Level

Perform SCR Faults Reset
Request Procedure (page 1955).

fluid. Perform SCR Faults Reset
for SPN 4375 FMI 2.

A. Perform DEF System Leak Test (page 1985). Yes: Go to step 4.
B. Check Diesel Exhaust Fluid (DEF) tank, DEF Supply Module (DEFSM), and
DEF Doser Valve (DEFDV) lines and connections for: cracks and pitting;
and loose, leaking, or damaged connections.
Are all DEF lines and connections free of leaks, damage, reversed connections or No: Repair failed DEF line
restrictions? or connection. Perform SCR
Faults Reset Request Procedure
FMI 2.

Visually inspect the DEF tank for debris and tank vent for crystallization, clogging, Yes: Repair any damage or
damage or pinched hoses. pinched hoses. Clean debris and
DEF crystallization with distilled
water and a soft bristle brush.
Replace the DEF level sensor
ONLY if the vent is damaged.
for SPN 4375 FMI 2.
Is DEF tank have debris or is tank vent clogged or blocked with DEF crystallization? No: Go to step 5.


for SPN 4375 FMI 2.

SPN 4375 FMI 2.

Supply Module Relay pin-87
and DEF Supply Module Pin-2.
for SPN 4375 FMI 2.

between Breakout Harness 18-648-01 Pin-4 and PWR. Module. Perform SCR Faults
Reset Request Procedure
FMI 2.
Module Pin-4. Perform SCR
FMI 2.
DEF suction line as necessary for
a restriction. Drain the DEF tank,
flush with distilled water, and fill
with known good DEF. Perform
SPN 4375 FMI 2.
Step 11 Check DEF supply for aeration. Decision

Review the results of the DEF Supply Module Inlet Restriction Test perform in Yes: Repair leaks or cracks in
step 10. either the suction line or DEF
tank suction fitting/pick-up tube.
for SPN 4375 FMI 2.
Were bubbles approximately half the size of DEF diagnostic line, Part Number No: Go to step 12.
5299833 tubing seen during the test?

D. Connect Electronic Service Tool (EST) with Navistar® Engine Diagnostics.

F. Monitor DEFAP.
Step 13 Inspect DEF Dosing Valve Connector for damage. Decision

B. Disconnect DEF Dosing Valve connector.
C. Check DEF Dosing Valve and connector terminals for: damaged or pinched
connector housing.
Are DEF Dosing Valve connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
SPN 4375 FMI 2.

Pin-7. Perform SCR Faults Reset
for SPN 4375 FMI 2.

for SPN 4375 FMI 2.

Perform Test 5 (page 1636). Use Digital Multimeter (DMM), measure resistance Yes: Replace DEF Doser Valve
between Breakout Harness 18-559-02 Pin-8 and ECM Pin C1-34. for failed DEFAP sensor. Perform
SPN 4375 FMI 2.
for SPN 4375 FMI 2.


replace as needed. If no debris
is found, replace the DEF Doser.
for SPN 4375 FMI 2.
for SPN 4375 FMI 2.

Pressure line. Perform SCR
FMI 2.

step 19.
build-up. Perform SCR Faults
Reset Request Procedure
FMI 2.
Perform DEF Dosing System Test (page 1978). Yes: Check the entire system
for restrictions, debris or air
leaks. Inspect the DEF Tank
filter, DEF Supply Module Inlet
screen, DEF Supply Module
filter and DEF Doser Valve Inlet
screen for debris. Replace or
repair as needed. Perform SCR
FMI 2.
Review results from DEF Dosing System Test performed in step 21. Yes: End Diagnostics. Perform
Procedure (page 1955). Retest
for SPN 4375 FMI 2.
for SPN 4375 FMI 2.


Tools Required
Test 1
A. Key OFF.
4
18-648-01
0000413990
Test 2
A. Key OFF.
C1-63
7
18-559-02
0000414113
Figure 544 DEFAP GND Circuit Check
Test 3
A. Key OFF.
C1-36
5
18-559-02
0000414111
Test 4
A. Key OFF.
C1-34
8
18-559-02
0000414157
Test 5
A. Key OFF.
SPN 4752 FMI 18 - Engine Exhaust Gas Recirculation 1 Cooler Efficiency : Data Valid But Below
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Exhaust Gas Recirculation Cooler Gas Temperature
(EGRGT) signal value is greater than expected for current amount of EGR flow.
Lamp Reaction
Associated Faults
SPN 110 FMI 0, 2, 3, 4, 10, SPN 111 FMI 1 SPN 412 FMI 2, 3, and 4
15 and 16
Fault Facts
None

Road Test
Possible Causes
• Engine Overheating
• Failed Exhaust Gas Recirculation (EGR) cooler


®
Fault Diagnostic Procedure.
(page 1940)
Step 3 Check a low coolant condition. Decision

Is Coolant Level within specification? No: Perform 5.0 - Cooling
SPN 4752 FMI 18.
Step 4 Check for an engine overheating condition. Decision

A. Start engine, and run engine to normal operating temperature. Yes: Go to Coolant Over
Temperature (page 65) symptom
B. After engine reaches normal operating temperature, monitor engine coolant
diagnostics. After repairs are
temperature for an overheating condition for 5 minutes.
FMI 18.
Does engine coolant temperature go above normal operating temperature? No: Go to Step 5.

Perform EGR Cooler Leak Test (page 2126). Yes: Replace EGR cooler. After
SPN 4752 FMI 18.
Is EGR cooler leaking coolant? No: End diagnostics, retest for
SPN 4752 FMI 18.

SPN 4765 FMI 2 - Aftertreatment 1 Diesel Oxidation Catalyst Intake Temperature : Data Erratic,
Fault Overview
Fault code sets when Engine Control Module (ECM) detects difference between Diesel Oxidation Catalyst Inlet
Temperature (DOCIT) and Diesel Particulate Filter Inlet Temperature (DPFIT) readings do not match expected
values for engine operating conditions.
Lamp Reaction
Associated Faults
SPN 5742 FMI 3, 4, 12, 16 SPN 5743 FMI 19

and 19
Fault Facts
None

Continuous
Possible Causes
• Face plugged Diesel Oxidation Catalyst (DOC)
• Failed DOC

Use Electronic Service Tool (EST), check Diagnostic Trouble Codes (DTC) list for Yes: Go to Step 2.
for SPN 4765 FMI 2.

Is EST DTC listing SPN 4765 FMI 2 active or pending? No: End diagnostics. Retest for
SPN 4765 FMI 2.
Step 3 Check Aftertreatment Temperature Sensor Module and connector. Decision

B. Disconnect AFT Temperature Sensor Module.
C. Check AFT Temperature Sensor Module and connector terminals for:
Are AFT Temperature Sensor Module connector, harness, and terminals clean and No: Repair connector, harness,
4765 FMI 2.

A. Use EST, Key ON, clear codes. Yes: Go to Step 5.
B. Start engine and allow engine to idle.
C. Use Electronic Service Tool (EST), to monitor DOC Inlet Temperature
(DOCIT), DPF Inlet Temperature (DPFIT), DPF Outlet Temperature
(DPFOT), and SCR Outlet temperature (SCROT) while engine is idling.
Is DOCIT within 43°F (24°C) of the other AFT temperature sensors? No: Replace AFT Temp sensor
FMI 2.
Step 5 Check DOC for face plugging or excessive fueling. Decision

Perform DOC Inspection and Reuse Guidelines(page 2240). Yes: Perform DOC Cleaning
Procedure(page 2231). After
SPN 4765 FMI 2.
Is DOC more than 50% face plugged with soot and reusable? No: Replace DOC. After repairs
4765 FMI 2.

SPN 4765 FMI 3 - Aftertreatment 1 Diesel Oxidation Catalyst Intake Temperature : Voltage Above
Normal, or Shorted to High Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Oxidation Catalyst Inlet Temperature
(DOCIT) sensor signal voltage is greater than expected.
Lamp Reaction
Associated Faults
SPN 5742 FMI 19 SPN 5743 FMI 19
Fault Facts
None

Continuous
Possible Causes

®
ON, check Diagnostic Trouble Codes (DTC) list for Associated Faults (page 1642).
for SPN 4765 FMI 3.

(page 1940).

C. Check AFT Temperature Sensor Module and connector terminals for: for SPN 4765 FMI 3.
Are Aftertreatment Temperature Sensor Module connector, harness, and terminals No: Repair connector, harness,
4765 FMI 3.

SPN 4765 FMI 4 - Aftertreatment 1 Diesel Oxidation Catalyst Intake Temperature : Voltage Below
Normal, or Shorted to Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Oxidation Catalyst Inlet Temperature
(DOCIT) sensor signal voltage is less than 1 volt for more than 2 seconds.
Lamp Reaction
Associated Faults
SPN 5742 FMI 19 SPN 5743 FMI 19
Fault Facts
None

Continuous
Possible Causes

®
ON, check Diagnostic Trouble Codes (DTC) list for Associated Faults (page 1644).
for SPN 4765 FMI 4.

(page 1940).

C. Check AFT Temperature Sensor Module and connector terminals for: for SPN 4765 FMI 4.
4765 FMI 4.

SPN 4765 FMI 12 - Aftertreatment 1 Diesel Oxidation Catalyst Intake Temperature : Bad Intelligent
Device Or Component
Fault Overview
Fault code sets when Engine Control Module (ECM) detects an internal communication error between
Aftertreatment Temperature Sensor Smart Module and Diesel Oxidation Catalyst Intake Temperature (DOCIT)
thermocouple.
Lamp Reaction
Associated Faults
SPN 5742 FMI 19 SPN 5743 FMI 19
Fault Facts
None

Continuous
Possible Causes


®
Is EST DTC list SPN 4765 FMI 12 active? No: Repair all other Active faults.

C. Check AFT temperature sensor module and connector terminals for:
damaged or pinched wires; moisture or corroded terminals; loose, bent, or
4765 FMI 12.

A. Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics. Key Yes: Replace AFT temperature
ON, clear codes. sensor module. After repairs are
B. Key OFF, wait for EST screens to clear.
FMI 12.
C. Key ON, check Diagnostic Trouble Codes (DTC) list for SPN 4765 FMI 12.
Is EST DTC list SPN 4765 FMI 12 active or pending? No: End of diagnostics, retest for
SPN 4765 FMI 12.

SPN 4765 FMI 16 - Aftertreatment 1 Diesel Oxidation Catalyst Intake Temperature : Data Valid But
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Aftertreatment (AFT) Temperature Sensor Module
signal value is greater than expected.
Lamp Reaction
Red Stop Lamp (RSL) will illuminate immediately after this fault is detected.
Associated Faults
SPN 651 - 656 SPN 1322 - 1328 SPN 2797 SPN 2798
SPN 3482 SPN 3556
Fault Facts
If aftertreatment system has had excess fuel, oil, coolant, metal, or other contamination; inspect entire
aftertreatment system for causal damage before reinstalling. Inspect for overheated aftertreatment components,
cracked exhaust system welds, leaking exhaust system seams, or other damage. This fault will go inactive
after DOCIT drops below warning limit, and will likely be not active when vehicle is in shop. For this reason,
these diagnostics must be used for both active and inactive fault codes.

Road Test
Possible Causes
CAUTION:

®
WARNING:
Step 3.
System Leak or Over
4765 FMI 16.

Is DOCIT, DPFIT, DPFOT, and SCROT difference within 77°F (25°C) of each other? No: Replace AFT temperature
FMI 16.

(compression loss).
SPN 4765 FMI 16.


(page 1926) procedure and
FMI 16.
system from engine.
4765 FMI 16.
(AFTFEA).
Supply Module (AFTFSM). After
SPN 4765 FMI 16.

SPN 4765 FMI 16.

FMI 16.
Remove DOC (see Exhaust Aftertreatment System with DPF and SCR Service Yes: Reinstall DOC and perform
Manual). a Parked Regeneration. After
SPN 4765 FMI 16.
FMI 16.
End Diagnostic Test

After performing all diagnostic steps, if SPN 4765 FMI 16 remains, verify each step was completed correctly and the
proper decision was made. Notify supervisor for further action.
SPN 4765 FMI 18 - Aftertreatment 1 Diesel Oxidation Catalyst Intake Temperature : Data Valid But
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Aftertreatment (AFT) Temperature Sensor Module
signal value is lower than expected.
Lamp Reaction
Associated Faults
SPN 3246 FMI 2, 3, and 4 SPN 3556 SPN 5742 FMI 19 SPN 5743 FMI 19
Fault Facts
None

Continuous
Possible Causes
• Damaged DOC


Is DOCIT, DPFIT, DPFOT, and SCROT difference within 77°F (25°C) of each other? No: Replace AFT temperature
FMI 18.
A. Key-On Engine-Running (KOER). Yes: Go to Step 4.
B. Check for cracked exhaust system welds, leaking exhaust system seams,
or other damage.

A. Remove DOC (see Exhaust Aftertreatment System with DPF and SCR Yes: Go to Step 5.
Service Manual).
B. Check DOC for restrictions from soot or oil contamination, cracks or
Is DOC unrestricted and free of damage? No: Refer to DPF Inspection
(page 2247). Repair source of
damage or excessive soot. After
SPN 4765 FMI 18.
(AFTFEA).
Supply Module (AFTFSM). After
SPN 4765 FMI 18.

SPN 4765 FMI 18.

4765 FMI 18.
SPN 4765 FMI 18.

SPN 4765 FMI 20 - Aftertreatment 1 Diesel Oxidation Catalyst Intake Temperature : Data Drifted High
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Oxidation Catalyst Intake Temperature
(DOCIT) is above a plausibly high threshold.
Lamp Reaction
Associated Faults
SPN 4765 FMI 0, 16, and 18
Fault Facts
None.

Road Test
Possible Causes


connector housing.
4765 FMI 20.
SPN 4765 FMI 20.
FMI 20.

SPN 4765 FMI 21 - Aftertreatment 1 Diesel Oxidation Catalyst Intake Temperature : Data Drifted Low
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Oxidation Catalyst Intake Temperature
(DOCIT) is below a plausibly low threshold.
Lamp Reaction
Associated Faults
SPN 4765 FMI 0, 16, and 18
Fault Facts
None.

Road Test
Possible Causes


connector housing.
4765 FMI 21.
SPN 4765 FMI 21.
FMI 21.

SPN 4792 FMI 10 - Aftertreatment 1 SCR System : Abnormal Rate Of Change
Fault Overview
Fault code sets when Engine Control Module (ECM) detects conversion of Nitrogen Oxides (NOx) is too low in
aftertreatment system with maximum compensation commanded.
Lamp Reaction
Associated Faults
SPN 3216 SPN 3218 SPN 3226 FMI 11. 16, 18, SPN 3362 FMI 31
and 19
SPN 3363 FMI 3, and 4 SPN 3516 SPN 4094 SPN 4334
SPN 5394 FMI 5 and 7 SPN 5491 SPN 7107
Fault Facts
None

Road Test
Possible Causes
• Exhaust system leak(s) or damage
• Failed or leaking Diesel Exhaust Fluid (DEF) line or line connection
• Restricted DEF Supply Module (DEFSM) filter
• Restricted decomposition reactor tube (DEF crystallization)
• Failed Diesel Exhaust Fluid Doser (DEFD)

Step 2 Inspect exhaust system for leak(s) and damage. Decision

Is exhaust system free of leaks and damage? No: Repair exhaust system
leak(s) or damage. After repairs
4792 FMI 10.
Step 3 Check Diesel Exhaust Fluid (DEF) tank, DEF Supply Module (DEFSM), Decision
and DEF Doser Valve (DEFDV) lines and connections for cracks and
pitting; loose, leaking, or damaged connections; and restrictions.
Perform KOEO DEF System Leak Test (page 1985). Yes: Go to Step 4.
Are DEF tank, DEFSM, and DEFDV lines and connections in good condition and No: Repair or replace failed line
not leaking? or connection. After repairs are
FMI 10.

Is urea concentration between 30 to 34 percent and Not contaminated? No: Drain DEF tank, flush with
SPN 4792 FMI 10.
Step 5 Verify correct Diesel Exhaust Fluid Doser Valve (DEFDV) operation. Decision
Perform DEF Dosing System Test (page 1978). Yes: Go to Step 6.
Was amount of collected DEF within specifications? No: Perform DEF Flushing
repair as needed. Repeat
Step 5. If system still does not
operate correctly, replace DEF
Doser Valve. After repairs are
FMI 10.
Step 6 Check decomposition mixer for DEF crystallization. Decision

Perform Decomp Mixer Inspection (page 2208). Yes: Perform DPF Regeneration
SPN 4792 FMI 10.
Is decomposition mixer free of DEF crystallization? No: Remove DEF crystallization
from decomposition mixer. After
SPN 4792 FMI 10.

SPN 4795 FMI 31 - Aftertreatment 1 Diesel Particulate Filter Missing : Conditions Exists
Fault Overview
(DPFDP) is below a minimum value, and exhaust flow rate is above a minimum flow rate. Active and parked
regeneration of DPF will be disabled. Exhaust Gas Recirculation (EGR) valve will be closed, and engine torque
will be reduced if fault is active for an extended period of time.
Lamp Reaction
Associated Faults
None
Fault Facts
This fault code is not caused by a failed DPFDP/DPFOP Sensor. Do NOT replace the Sensor unless SPN 3251
or SPN 3610 fault codes are present.

Road Test
Possible Causes
• Missing DPF
• DPF damaged or failed
• DPFDP/DPFOP sensor hoses reversed or damaged
• Exhaust leak or damage before DPF

®
Is SPN 4795 FMI 31 active or pending? No: Diagnose all other active
Step 2 Inspect exhaust system for leaks, damage, and missing Diesel Decision
Particulate Filter (DPF).
Is DPF installed, and is exhaust system free of leaks and damage? No: Install missing DPF or repair
exhaust system. After repairs are
FMI 31.
Step 3 Inspect connections at Diesel Particulate Filter Differential Pressure / Decision

DPF Outlet Pressure (DPFDP/DPFOP) sensor.
Are DPFDP/DPFOP connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
FMI 31.
Step 4 Check DPFDP/DPFOP sensor hoses for correct routing and Decision
restrictions.
Inspect DPFDP/DPFOP sensor hoses for kinks, improper hose routing, plugged Yes: Go to Step 5.
hoses, reversed hoses, debris, or other damage.
Are DPFDP/DPFOP sensor hoses routed correctly and free of damage and debris? No: Reroute or replace
DPFDP/DPFOP sensor hoses.
Step 5 Check DPF condition. Decision

Perform DPF Inspection (page 2247). Yes: Diagnose and repair cause
of excessive heat or damage,
then replace DPF. After repairs
FMI 31.
Is DPF melted or damaged? No: End diagnostics, retest for
SPN 4795 FMI 31.

Source
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None.

Continuous
Possible Causes
• ECM Power out 4 Shorted to PWR
Step 1 Check for active or pending fault codes.. Decision

®
SPN 5016 FMI 3.
Step 2 Inspect connections at Variable Geometry Turbo Actuator (VGTA) Decision

connector.
B. Disconnect VGTA connector.
C. Check VGTA and connector terminals for: damaged or pinched wires; wet
housing.
Are VGTA connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
5016 FMI 3.
Step 3 Check ECM Power Out 4 for short to power. Decision

between VGTA pin-3 and ECM
FMI 3.


Tools Required
Test 1
A. Key OFF.
C. Connect Breakout harness ZTSE6016 to engine harness and leave VGTA disconnected.
Source
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None.

Continuous
Possible Causes
• ECM Power out 4 Shorted to GND
Step 1 Check for active or pending fault codes.. Decision

®
SPN 5016 FMI 4.

connector.
housing.
5016 FMI 4.
Step 3 Check ECM Power Out 4 for short to ground. Decision

Is resistance greater than 1 kΩ? No: Repair short to GND between
VGTA pin-3 and ECM Pin E1-50.
for SPN 5016 FMI 4.


Tools Required
6016
0000428101
Test 1
A. Key OFF.
SPN 5024 FMI 10 - Aftertreatment 1 Intake NOx Sensor Heater Ratio : Abnormal Rate of Change
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Nitrogen Oxides In (NOxIN) sensor heater was
unable to maintain its normal operating temperature.
Lamp Reaction
Associated Faults
SPN 3216 FMI 19
Fault Facts
If more than one of the following sensor modules fail (or set a fault), suspect a common power circuit, ground
circuit, or AFT Smart Sensor Relay problem. The following components share power and ground circuits: DEF
Tank Sensor Module, NOx IN Sensor Module, NOx OUT Sensor Module, PM Sensor Module, and AFT Exhaust
Temperature Module.
Verify batteries are fully charged and connections are clean.

Continuous
Possible Causes
• AFTSS PWR circuit open or high resistance

®

Does EST list SPN 5024 FMI 10 as active? No: Diagnose all other active
Step 3 Inspect connections at Nitrogen Oxides In (NOxIN) sensor module. Decision

C. Check NOx IN sensor module and connector terminals for: damaged or
5024 FMI 10.

Perform Test 1 (page 1676). Use DMM, measure voltage between Breakout Yes: Replace NOx IN sensor
Harness 18-648-01 pin-1 and pin-4. module. After repairs are
FMI 10.
Step 5 Check AFTSS PWR circuit for Open or high resistance. Decision
18-648-01 pin-1 and known good GND. resistance between NOx IN
resistance between NOx IN
sensor module pin-1 and AFT
SPN 5024 FMI 10.


Tools Required
Figure 549 NOx IN Circuit Check
Test 1
A. Key OFF.
B. Disconnect Nitrogen Oxides In (NOxIN) sensor Module
Module disconnected.
Test 2
A. Key OFF.
B. Disconnect Nitrogen Oxides In (NOxIN) sensor Module
SPN 5031 FMI 10 - Aftertreatment 1 Outlet NOx Sensor Heater Ratio : Abnormal Rate Of Change
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Nitrogen Oxides (NOx) Out sensor heater was
unable to maintain its normal operating temperature.
Lamp Reaction
Associated Faults
SPN 3226 FMI 19
Fault Facts
If more than one of the following sensor modules fail (or set a fault), suspect a common power circuit, ground
circuit, or AFT Smart Sensor Relay problem. The following components share power and ground circuits: DEF
Tank Sensor Module, NOx IN Sensor Module, NOx OUT Sensor Module, PM Sensor Module, and AFT Exhaust
Temperature Module.
Verify batteries are fully charged and connections are clean.

Road Test.
Possible Causes

®

Does EST list SPN 5031 FMI 10 as active? No: Repair all other active faults.
Step 3 Inspect connections at Nitrogen Oxides (NOx) Out Sensor Module. Decision
B. Disconnect NOx Out Sensor Module.
C. Check NOx Out Sensor Module and connector terminals for: damaged or
5031 FMI 10.
Step 4 Check voltage to NOx Out Sensor Module. Decision

Perform Test 1 (page 1681). Use DMM, measure voltage between Breakout Harness Yes: Replace NOx Out Sensor
18-649-01 pin-1 and pin-4. Module. After repairs are
FMI 10.
Step 5 Check AFTSS PWR circuit for open or high resistance. Decision
Perform Test 2 (page 1681). Use DMM to measure voltage between Breakout Yes: Repair open or high
Harness 18-649-01 pin-1 and known good GND. resistance between NOx Out
Sensor Module pin-4 and GND.
resistance between NOx Out
Sensor Module pin-1 and AFT
Smart Sensor Relay pin-87.


Tools Required
Figure 551 NOx Out Circuit Check
Test 1
A. Key OFF.
B. Disconnect Nitrogen Oxides (NOx) Out Sensor Module connector.
C. Connect Breakout Harness 18-649-01 to vehicle harness and leave Nitrogen Oxides (NOx) Out Sensor
Test 2
A. Key OFF.
B. Disconnect Nitrogen Oxides (NOx) Out Sensor Module connector.
C. Connect Breakout Harness 18-649-01 to vehicle harness and leave NOx Out sensor module disconnected.
SPN 5246 FMI 0 - Aftertreatment SCR Operator Inducement Severity : Data Valid But Above Normal
Fault Overview
Fault sets when SCR Tamperproof warning lamps and beeps have been ignored for 5 hours or immediately after
any repeat SCR faults. This fault will induce 5 mph vehicle speed limit and 1000 rpm engine speed limit.
Lamp Reaction
Malfunction Indicator Lamp (MIL) and Amber Warning Lamp (AWL) will already be illuminated from related faults.
Associated Faults
Any aftertreatment open

circuit faults or DEF
concentration faults
Fault Facts
This fault is a notification indicating SCR Tamperproof Warning and Protection Inducement is in effect. Check
for any associated aftertreatment circuit faults. Once condition that caused original circuit fault has been
repaired, SCR Faults Reset Request Procedure will need to be performed to reset SCR Tamperproof Warning
and Protection Inducement. If no associated faults are present, check repair history for recent previous repair
to aftertreatment system. If there was recent repair SCR Faults Reset Request Procedure may just need to
be performed.

Continuous
Possible Causes
effects.

Diagnostic Trouble Code (DTC) list for Associated Faults (page 1683). After repairs are complete,
Are Associated Faults active or previously active? No: Perform SCR Faults Reset

Operating Range - Lease Severe Level
Fault Overview
Fault sets when any aftertreatment sensor or actuator is disconnected or a major SCR failure is detected. After
one hour (level 2) engine torque will be de-rated by 25%.
Lamp Reaction
Malfunction Indicator Lamp (MIL) and Amber Warning Lamp (AWL) will illuminate immediately when this fault is
detected.
Associated Faults

Fault Facts
be performed.

Continuous
Possible Causes
effects.

®
Use Electronic Service Tool (EST) with Navistar Engine Diagnostic Software, check Yes: Repair Associated Faults.

Fault Overview
Fault sets when SCR Tamperproof warning lamps and beeps have been ignored for 5 hours or immediately after
any repeat SCR faults. This fault will induce a 40% torque derate when it sets.
Lamp Reaction
Malfunction Indicator Lamp (MIL) and Amber Warning Lamp (AWL) will illuminate immediately when this fault is
detected.
Associated Faults

Fault Facts
be performed.

Continuous
Possible Causes
effects.


SPN 5285 FMI 18 - Engine Charge Air Cooler 1 Efficiency : Data Valid But Below Normal Operating
Fault Overview
Fault sets when Engine Control Module (ECM) determines Charge Air Cooler is not reducing temperature
properly. Charge Air Cooler Outlet Temperature (CACOT) sensor reading is greater than a predetermined
value.
Lamp Reaction
Associated Faults
SPN 2629 FMI 2, 3, and 4 SPN 2630 FMI 2, 3, and 4 SPN 3599
Fault Facts
Vehicles equipped with a snow plow application or a fully closed winter front may set 5285-18 faults. Cruising
at highway like speeds with plow blade raised or a fully closed winter front may cause enough reduction in air
flow over the Charge Air Cooler (CAC) to set a fault. Do not diagnose if fault was set while driving with snow
plow raised or while operating the vehicle with a fully closed winter front outside of recommended operating
temperatures. See Vehicle Owners Manual for more information.

Road Test
Possible Causes
• Restricted CAC
• Engine fan and/or engine fan shroud failure
• Winter front installed outside recommended temperatures

Step 2 Determine if a winter front (grill cover) is installed during warm Decision
temperatures.
Visually inspect vehicle grill area for installed winter front (grill cover). Yes: Go to Step 3.
Is winter front (grill cover) removed during warm temperatures outside recommended No: Remove winter front. After
range? repairs are complete, retest for
SPN 5285 FMI 18.
Step 3 Check for restricted Charge Air Cooler (CAC). Decision

Inspect CAC for damage, blockage, or anything that could prevent proper air flow Yes: Go to Step 4.
through CAC.
Is CAC undamaged, not blocked, and is air able to flow through CAC properly? No: Repair CAC damage or
blockage. After repairs are
FMI 18.
Step 4 Inspect engine cooling fan and shroud for damage. Decision
Visually inspect cooling fan blades and fan shroud for debris, cracks, and damage. Yes: Go to Step 5.
Are engine cooling fan and shroud in good condition and not damaged? No: Repair engine cooling fan or
shroud damage. After repairs are
made, retest for SPN 5285 FMI
18.
Step 5 Determine if engine fan is operating properly. Decision

SPN 5285 FMI 18.
Is engine fan operating properly? No: Repair or replace failed
engine fan clutch or Engine Fan
Solenoid (EFS). After repairs are
FMI 18.

SPN 5298 FMI 18 - Aftertreatment 1 Diesel Oxidation Catalyst Conversion Efficiency : Data Valid But
Fault Overview
Fault code sets when the Engine Control Module (ECM) detects temperature differential across Diesel Oxidation
Catalyst (DOC) during active regeneration does not indicate a temperature increase.
Lamp Reaction
Associated Faults
• SPN 3242 FMI 2, 3, and 4 • SPN 3246 FMI 2, 3, and 4 • SPN 3556 FMI 18 • SPN 4765 FMI 2, 3, and 4
Fault Facts
If Aftertreatment system has had excess fuel, oil, coolant, metal, or other contamination; inspect the
entire Aftertreatment system for causal damage before re-installing. Inspect for overheated Aftertreatment
components, cracked exhaust system welds, leaking exhaust system seams, or other damage.

Regeneration
Possible Causes
• Damaged or failed DOC
• Failed Aftertreatment Fuel Enable Actuator (AFTFEA)
• Failed valve train component(s) causing poor DOC efficiency

®

Diagnostic Trouble Code (DTC) list for SPN 1322 FMI 14 and / or 188 FMI 18?
Is EST DTC list free of SPN 1322 FMI 14 and SPN 188 FMI 18? No: Go to Step 6.
A. Key-On Engine-Running (KOER). Yes: Go to Step 4.
B. Check for cracked exhaust system welds, leaking exhaust system seams,
or other damage.
Step 4 Verify DOC operation. Decision

Perform DPF Regeneration Procedure (page 1936) in Navistar® Engine Diagnostics Yes: End diagnostics, retest for
and record snapshot. SPN 5298 FMI 18.
Did regeneration run successfully? No: Go to Step 5.
WARNING:
To prevent personal injury and / or death, allow exhaust to cool before removing
components.

A. Ensure DOC is cooled down. Yes: Go to Step 7.
B. Remove DOC (see appropriate Technician Manual).
C. Check DOC for restrictions from soot or oil contamination, cracks or
Is DOC unrestricted and free of damage? No: Go to Step 6.
Step 6 Inspect valve train components. Decision

Did all valve train component(s) pass inspection? No: Replace valve train
component(s). After repairs
5298 FMI 18.
Is Aftertreatment Hydrocarbon Doser (AFTHD) dry and free of fuel? No: Replace AFTFEA. After
SPN 5298 FMI 18.
Step 8 Check for failed AFTHD. Decision

SPN 5298 FMI 18.
Step 9 Check AFT fuel quantity. Decision

5298 FMI 18.
SPN 5298 FMI 18.
End Diagnostic Test

SPN 5319 FMI 31 - Aftertreatment 1 Diesel Particulate Filter Incomplete Regeneration : Condition Exists
Fault Overview
Fault code sets when Engine Control Module (ECM) detects soot load of Diesel Particulate Filter (DPF) is too
high following successful active regeneration of Aftertreatment system.
Lamp Reaction
Associated Faults
SPN 102 SPN 157 SPN 633 SPN 651-656

SPN 1244 SPN 1322–1328 SPN 2791 SPN 2797–2798
SPN 3556
Fault Facts
If Aftertreatment system has had excess fuel, oil, coolant, metal, or other contamination; inspect entire
Aftertreatment system for causal damage before re-installing. Inspect for overheated Aftertreatment
components, cracked exhaust system welds, leaking exhaust system seams, or other damage. Excessive ash
accumulation in Diesel Particulate Filter (DPF) will cause frequent regenerations of Aftertreatment system.

Regeneration
Possible Causes
• Fuel system failure causing Diesel Oxidation Catalyst (DOC) blockage
• Restricted DPFDP / DPFOP hose(s) and tubes
• Restricted or failed Diesel Particulate Filter (DPF)
• Oil leak to exhaust
• Failed AFTFEA
• Failed AFTHD

Use EST, check DTC list for Associated Faults (page 1692). Yes: Go to Step 2.
Step 2 Check for restricted DOC. Decision

Perform Engine Cranking Test (page 2078). Yes: Go to Step 8.
Is EBP reading within 0.1-0.3 psi (0.69-2.0 kPa) cranking and(or) 10-13 psi (69-90 No: Go to Step 3.
kPa) Low Idle No Load?
Step 3 Inspect Diesel Oxidation Catalyst (DOC) for restrictions, damage, or Decision
contamination.
Perform DOC Inspection (page 2240). Yes: Go to Step 8.
Is DOC free of restriction, contamination, soot leakage, and melted or deformed No: Clean or Replace DOC, then
cells? Continue to Step 4.
B. Disconnect EFRP sensor.
C. Check EFRP sensor and connector terminals for: damaged or pinched
connector housing.
Are EFRP sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
FMI 31.
Step 5 Inspect connections at Engine Fuel Actuator 1 (EFA1). Decision

B. Disconnect EFA1 sensor.
C. Check EFA1 and connector terminals for: damaged or pinched wires; wet
housing.
FMI 31.
Step 6 Inspect connections at Engine Fuel Actuator 2 (EFA2). Decision

B. Disconnect EFA2.
C. Check EFA2 and connector terminals for: damaged or pinched wires; wet
housing.
FMI 31.
Step 7 Inspect connections at Diesel Particulate Filter Differential Pressure / Decision

Diesel Particulate Filter Outlet Pressure (DPFDP / DPFOP) sensor.

FMI 31.
Step 8 Check DPFDP / DPFOP sensor hoses for correct routing and Decision
restrictions.
Inspect DPFDP / DPFOP sensor hoses for kinks, improper hose routing, Yes: Go to Step 9.
Are DPFDP / DPFOP sensor hoses routed correctly, free of damage, and No: Repair or replace DPFDP
unrestricted? / DPFOP sensor hose(s). After
SPN 5319 FMI 31.
Step 9 Check DPFDP. Decision

Perform Lug Down Test (page 2021) and review DPFDP. Yes: Go to Step 10.
Is DPFDP 0.7 PSI or greater? No: Go to Step 11.
Step 10 Inspect Diesel Particulate Filter for restrictions, damage, or Decision

contamination.
Perform DPF Inspection (page 2247). Yes: Go to Step 11.
Is DPF unrestricted, free of damage, and free of contamination? No: Clean or Replace DPF.
Continue to Step 11.
Step 11 Check for engine oil leak to exhaust. Decision

Perform 6.2 - Oil Leak to Exhaust (page 75). Yes: Go to Step 12.
Is exhaust free of engine oil contamination? No: Repair engine oil leak
to exhaust. After repairs are
FMI 31.
Step 12 Check for coolant leak to exhaust. Decision

Perform Coolant in Exhaust Inspection (page 2161). Yes: Go to Step 13.
Is exhaust free of engine coolant contamination? No: Repair engine coolant leak
to exhaust. After repairs are
FMI 31.
SPN 5319 FMI 31.
Step 14 Check for failed AFTFI. Decision

Is AFTHD dry and free of fuel? No: Replace AFTHD. After repairs
FMI 31.

Perform AFT Dosing System Test (page 1993). Yes: End Diagnostics. Perform
DPF Regeneration Procedure
(page 1936) in EST to retest for
SPN 5319 FMI 31.
FMI 31.

SPN 5394 FMI 5 - Aftertreatment 1 Diesel Exhaust Fluid Doser Valve 1 : Current Below Normal or
Open Circuit
Fault Overview
Fault codes sets when Engine Control Module (ECM) detects that Diesel Exhaust Fluid Doser Valve (DEFDV)
circuit is open or shorted. DEF injection into aftertreatment system is disabled, and engine torque will be reduced
if fault is active for a limited period of time. Engine torque will be severely reduced and vehicle speed limited
after extended engine operation with this fault code active.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Road Test
Possible Causes
• Failed DEFDV
• DEFDV CTL-L circuit Open or high resistance
• DEFDV CTL-L circuit short to GND
• DEFDV CTL-H circuit Open or high resistance
• DEFDV CTL-H circuit short to GND
• DEFDV CTL-H shorted to DEFDV CTL-L
• DEFDV CTL-L circuit short to PWR

®
Reset Request(page 1955).
5394 FMI 5.
connector.
housing.
Reset Request(page 1955),
Step 3 Check DEFDV-H circuit for short to GND. Decision

Harness 18-559-02 pin-2 and known good GND.
between DEFDV connector pin-2
Request(page 1955), retest for
SPN 5394 FMI 5.
Step 4 Check DEFDV-L circuit for short to GND. Decision

between DEFDV connector pin-1
Request(page 1955), retest for
SPN 5394 FMI 5.
Step 5 Inspect connections at ECM connector. Decision

B. Disconnect ECM connector.
C. Check ECM and connector terminals for: damaged or pinched wires; wet
housing.
Are ECM connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
Step 6 Check DEFDV-H circuit for Open or high resistance. Decision

Harness 18-559-02 pin-2 and ECM pin C2-01.
Is resistance less than 5 ohms? No: Repair Open or high
connector pin-2 and ECM
connector pin C2-01. After
1955), retest for SPN 5394 FMI 5.
Step 7 Check DEFDV-L circuit for Open or high resistance. Decision

Harness 18-559-02 pin-1 and ECM pin C2-06.
Is resistance less than 5 ohms? No: Repair Open or high
connector pin-1 and ECM
connector pin C2-06. After
Step 8 Check for DEFDV-L circuit shorted to DEFDV-H circuit. Decision

DEFDV-H and DEFDV-L. After
Step 9 Check DEFDV-L circuit for short to PWR. Decision

Perform Test 6 (page 1704). Use DMM, measure resistance between Breakout Yes: Replace DEFDV. After
Harness 18-559-02 pin-1 and PWR. repairs are complete, perform
Is resistance greater than 1000 ohms? No: Repair short to power
between DEFDV pin-1 and ECM
connector C2-06. After repairs


Tools Required
2
18-559-02
0000415386
Figure 553 DEFDV-H Circuit Check
Test 1
A. Key OFF.

18-559-02
0000415387
Figure 554 DEFDV-L Circuit Check
Test 2
A. Key OFF.
C2-01
2
18-559-02
0000415388
Figure 555 DEFDV-H Circuit Check
Test 3
A. Key OFF.
D. Disconnect Engine Control Module (ECM) connector.
E. Connect 180-pin Breakout Box 00-00956-08 and ECM Breakout Harness 12-801-05-01 to engine harness
and leave ECM disconnected.
1
C2-06
18-559-02
0000415389
Test 4
A. Key OFF.
E. Connect 180-pin Breakout Box 00-00956-08 and ECM Breakout Harness 12-801-05-01 to engine harness
and leave ECM disconnected.
18-559-02 2
0000415390
Figure 557 DEFDV-L and DEFDV-H Circuit Check
Test 5
A. Key OFF.
18-559-02
0000415391
Test 6
A. Key OFF.
SPN 5394 FMI 7 - Aftertreatment 1 Diesel Exhaust Fluid Doser Valve 1 : Mechanical System Not
Fault Overview
Fault code sets when Engine Control Module (ECM) detects a mechanical failure of Diesel Exhaust Fluid Doser
Valve (DEFDV). DEF injection into aftertreatment system is disabled, and engine torque will be reduced if fault
is active for an extended period of time.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Road Test
Possible Causes
• DEF line or connection loose, leaking, or damaged
• DEFDV mechanical failure (stuck open or closed)
• Faulty DEF Supply Module
• Restricted DEF Tank or Supply Module Filter
Step 1 Check Diesel Exhaust Fluid (DEF) tank, DEF Supply Module (DEFSM), Decision
and DEF Doser Valve (DEFDV) lines and connections for: cracks and
pitting; and loose, leaking, or damaged connections.
Perform KOEO DEF System Leak Test (page 1985). Yes: Go to Step 2.
Are DEF tank, DEFSM, and DEFDV lines and connections in good condition? No: Repair or replace failed
line or connection. Perform
FMI 7.
Step 2 Check DEFDV for damage, crystallization, or restriction. Decision

Remove inlet and outlet fittings from DEFDV and inspect for damaged O-rings, Yes: Repair DEFDV. Perform
clogged fittings, crystallization, and blockage. SCR Faults Reset Request
FMI 7.
Is DEF crystallization, damage, or restriction present on DEFDV? No: Go to Step 3.
Perform DEF Dosing System Test (page 1978). Yes: Go to Step 4.
Was volume of DEF dosed within specification? No: Replace DEFDV. Perform
SCR Faults Reset Request (page
7.
Step 4 Inspect exhaust for DEF crystallization. Decision

Disconnect decomposition mixer from exhaust system (see appropriate Vehicle Yes: Clean decomposition mixer.
Technician Manual) and inspect for excessive DEF crystallization. Perform SCR Faults Reset
SPN 5394 FMI 7.
Is excessive DEF crystallization present in decomposition mixer? No: Go to Step 5.
Perform DEF Supply Module (DEFSM) Flushing Procedure (page 1929). Yes: Replace failed component.
SPN 5394 FMI 7.
Does procedure identify a failed component? No: End diagnostics. Perform
SCR Faults Reset Request (page
7.

SPN 5395 FMI 0 - Engine unable to achieve desired idle torque (too high)
Fault Overview
Fault code sets when Engine Control Module (ECM) detects fuel quantity and engine speed is greater than
expected.
Lamp Reaction
Associated Faults
• SPN 94 (FDP) • SPN 157 (FRP) • SPN 188 FMI 1 (EWPS) • SPN 633 (FPCV)
• SPN 3055 (FRP System) • SPN 5571 (FRP System)

Continuous
Possible Causes
• Base engine mechanical failure
• Failed valve train component
• Aftermarket PTO system not installed correctly
• Aftermarket PTO system not programmed correctly
Module (ECM) Calibration.
Perform Obtain Vehicle Health Report (page 1946). Yes: Go to Step 2.
5395 FMI 0.

for SPN 5395 FMI 0.

(compression loss).
SPN 5395 FMI 0.
Does engine have excessive crankcase pressure? No: Go to Step 4


FMI 0.
FMI 0.
Step 6 Inspect for installation of aftermarket PTO system. Decision

Inspect for installation of aftermarket PTO system. Yes: End diagnostics, retest for
SPN 5395 FMI 0.
Was an aftermarket PTO system installed and programmed correctly? No: Repair PTO or reprogram
PTO. After repairs are complete,

SPN 5395 FMI 1 - Engine unable to achieve desired idle torque (too low)
Fault Overview
Fault code sets when Engine Control Module (ECM) detects an un-commanded load being placed on engine at
idle or detects fuel quantity is less than expected.
Lamp Reaction
Associated Faults
• SPN 188 FMI 0 (EWPS)

Continuous
• Engine mechanical failure
• Failed cylinder
• Fuel leak to intake

for SPN 5395 FMI 1.

(compression loss).
SPN 5395 FMI 1.


FMI 1.
FMI 1.
Step 5 Inspect for airborne combustibles (ex. propane saturated air, ether, Decision
etc.) near engine.
Is the engine intake system intact and free from any external fuel sources? No: Repair source of
5395 FMI 1.
Step 6 Inspect for a engine oil leak to intake. Decision

A. Inspect for oil leaks from turbochargers leaking into air intake. Yes: Repair engine oil leak
B. Perform Crankcase Pressure Test (page 2092), to help determine if
crankcase pressure is leaking into the air intake.
FMI 1.
Step 7 Inspect for contaminated fuel (alternate fuels other than Diesel fuel). Decision
Perform Fuel Quality Check (page 2156). Yes: End diagnostics, retest for
SPN 5395 FMI 1.
clean and/or known good diesel
fuel, and replace fuel filters. After
SPN 5395 FMI 1.

SPN 5395 FMI 16 - Engine Idle Fuel Quantity : Data Valid But Above Normal Operating Range -
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that engine idle fuel quantity is greater than
expected.
Lamp Reaction
Associated Faults
SPN 157 SPN 188 SPN 633 SPN 651–656

SPN 1322
Fault Facts
None

Continuous
Possible Causes
• Base engine mechanical failure
• Failed valve train component
• Aftermarket Power Take-Off (PTO) / Auxiliary Engine Speed Control (AESC) system not installed correctly
• Aftermarket PTO / AESC system not programmed correctly

®
Step 2 Inspect for installation of aftermarket PTO / AESC system. Decision

Inspect for installation of aftermarket PTO / AESC system. Yes: Go to Step 3.
Was an aftermarket PTO / AESC system installed and programmed correctly? No: Repair PTO / AESC
or reprogram PTO / AESC
Programmable parameters,

(compression loss).
SPN 5395 FMI 16.

Perform Multiple Cylinder Cutout Test (page 2018). Yes: Go to Step 5
Did one or more cylinders have significant speed difference(s) than others? No: End Diagnostics. Retest for
SPN 5395 FMI 16.

FMI 16.
FMI 16.

SPN 5395 FMI 18 - Engine Idle Fuel Quantity : Data Valid But Below Normal Operating Range -
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that engine idle fuel reading lower than expected
range.
Lamp Reaction
Associated Faults
SPN 157 SPN 188 SPN 633 SPN 651–656

SPN 1322
Fault Facts
None

Continuous
• Engine mechanical failure
• Failed cylinder

®

(compression loss).
SPN 5395 FMI 18.


FMI 18.
FMI 18.
Step 5 Inspect for airborne combustibles (ex. propane saturated air, ether, Decision
etc.) near engine.
Is the engine intake system intact and free from any external fuel sources? No: Repair source of
5395 FMI 18.
Step 6 Inspect for a engine oil leak to intake. Decision

Perform Oil in Intake Inspection (page 2169). Yes: Repair engine oil leak
FMI 18.
Step 7 Inspect for contaminated fuel (alternate fuels other than Diesel fuel). Decision
Perform Fuel Quality Inspection (page 2156). Yes: End diagnostics, retest for
SPN 5395 FMI 18
clean and/or known good diesel
fuel, and replace fuel filters. After
SPN 5395 FMI 18.

SPN 5397 FMI 31 - Aftertreatment 1 Diesel Particulate Filter Regeneration Too Frequent : Condition
Exists
Fault Overview
Fault code sets when Engine Control Module (ECM) detects time between completion of a successful active
regeneration and request for another active regeneration is less than 2.5 hours.
Lamp Reaction
Associated Faults
SPN 94 (FDP) SPN 102 (IMP) SPN 157 (FRP) SPN 633 (FPCV)
SPN 651 - 656 (INJ/CYL) SPN 1244 (PRV) SPN 1322 - 1328 (CYL SPN 2797 and SPN 2798
Balance) (CYL Balance)
SPN 3251 FMI 2, 3, and 4
(DPFDP)
Fault Facts
An excessive ash accumulation condition reduces soot holding capability of Diesel Particulate Filter (DPF) and
will cause frequent aftertreatment regenerations. This fault is NOT caused by a failed DPFDP/ DPFOP sensor.
Do not replace this sensor unless this fault is set with other sensor faults (SPN 3251 DPFDP 3601 DPFOP).

Regeneration
Possible Causes
• DPF Maintenance Required
• Restricted DPFDP hoses or tubes
• Failed Diesel Particulate Filter (DPF)
• Restricted DPF (soot accumulation)
Step 1 DPF Maintenance Interval check. Decision

Check vehicle maintenance records. Yes: Perform ash cleaning
maintenance and retest for SPN
5397 FMI 31.
If the DPF due for cleaning? (Refer to the Engine OMM for maintenance intervals). No: Go to Step 2.

Step 3 Check DPFDP sensor hoses and tubes for correct routing and Decision
restrictions.
Inspect DPFDP sensor hoses and tubes for kinks, improper hose or tube routing, Yes: Go to Step 4.
unrestricted? sensor hose(s) and/or tube(s).
Step 4 Check DPFDP. Decision

Perform Lug Down Test (page 2021) and review DPFDP. Yes: Go to Step 5.
Is DPFDP 0.7 PSI or greater? Yes: End Diagnostics. Perform
(page 1936) in Navistar® Engine
Diagnostics to retest for SPN 5397
FMI 31.
Step 5 Inspect Diesel Particulate Filter (DPF) for restrictions, damage, or Decision
contamination.
A. Remove DPF (see appropriate vehicle technician manual). Yes: End Diagnostics. Perform
B. Perform DPF Inspection (page 2247).
(page 1936) in Navistar® Engine
Diagnostics to retest for SPN 5397
FMI 31.
Is DPF unrestricted, free of damage, and free of contamination? No: Clean or replace DPF. After
SPN 5397 FMI 31.

SPN 5491 FMI 3 - Aftertreatment 1 Diesel Exhaust Fluid Line Heater Relay 1 : Voltage Above Normal,
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Exhaust Fluid Line Heater Relay Control
(DEFLH Relay CTL) circuit is short to power.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Failed DEFLH relay (R1, R2, or R3)
• DEFLH relay CTL/GND circuit short to PWR

®
SPN 5491 FMI 3.
Step 2 Check DEFLH1 Relay (R2) for short to PWR Decision

A. Remove DEFLH1 Relay (R2). Yes: Reinstall DEFLH1 relay into
PDM, and Go to step 3
B. Using Electronic Service Tool (EST) with Navistar Engine Diagnostics, clear
all active DTCs, and run DEF Line Heater (page 1983)test.
Does DTC SPN 5491 FMI 3 set? No: Install new DEFLH1 relay
into PDM and retest for SPN
5491 FMI 3.
Step 3 Check DEFLH2 Relay (R1) for short to PWR Decision

A. Remove DEFLH1 Relay (R1). Yes: Reinstall DEFLH2 relay into
PDM, and Go to step 4
5491 FMI 3.
Step 4 Check DEFLH CTL circuit for short to PWR. Decision

A. Remove DEFLH1 Relay (R3). Yes: Repair short to power
between relay R1, R2, R3 pin-86
and ECM pin C1-24
5491 FMI 3.
End Diagnostic Test

SPN 5491 FMI 5 - Aftertreatment 1 Diesel Exhaust Fluid Line Heater Relay 1 : Current Below Normal
Or Open Circuit
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Exhaust Fluid Line Heater Relay (DEFLH
Relay) control circuit is open or short to ground.
Lamp Reaction
Associated Faults
Fault Facts
None.

Continuous
Possible Causes
• DEFLH CTL/GND circuit open or short to GND
• Voltage supply circuit open or short to GND
• Failed DEF Line Heater Relays (DEFLH Relays)

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics, check Diagnostic Yes: Go to Step 2.
105 FMI 2.

®
Is EST DTC list SPN 5491 FMI 5 active? No: Diagnose other active or
SPN 5491 FMI 5.

FMI 5.
Step 4 Check for short to ground in DEFLH CTL/GND circuit. Decision

Perform Test 1 (page 1727). Using DMM, measure resistance between DEFLH Yes: Go to step 5.
relay pin-86 and a known good ground.
Is resistance greater than 1k Ohms? No: Repair short to ground
between relay R1, R2, R3 pin-86
and ECM pin C1-24.

A. Perform Test 2 (page 1728). Yes: Go to step 6.
B. Use EST with Navistar Engine Diagnostics to perform DEF line Heaters
test (page XXX).
Is voltage less than 0.5 volts? No: Repair open between relay
R1, R2, R3 pin-86 and ECM pin
C1-24.
Step 6 Check for open or short to ground in DEFLH supply circuit. Decision
Perform Test 3 (page 1729). Using DMM, measure voltage between DEFLH relay Yes: End diagnostics, retest for
pin-85 and a known good ground. SPN 5491 FMI 5.
GND between Relay pin-85 and
vehicle battery.


Tools Required
86 4435C
0000427394
Test 1
A. Key OFF.
B. Remove DEFLH relay R1
C. Install Test Lead ZTSE443531 from Terminal Test Kit ZTSE4435C into DEFLH Relay terminal 86.
86 4435C
0000424370
Test 2
A. Key OFF.
85 4435C
0000424369
Test 3
A. Key OFF.
SPN 5548 FMI 1 - Engine Cold Start Fuel Igniter Command : Data Valid But Below Normal Operational
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Cold Start Fuel Igniter (CSFI) Relay diagnostic
signal short to ground.
Lamp Reaction
Associated Faults
SPN 157 SPN 5548 FMI 3, 4, and 5
Fault Facts
None

Road Test
Possible Causes
• CSFI Relay Enable circuit short to GND
• CSFI Relay CTL circuit short to GND
• CSFI Relay Diag circuit short to GND
• CSFI Relay output short to GND
• Failed CSFI Relay
• Failed CSFI

®
for SPN 5548 FMI 1.

1940).
Step 3 Inspect connections at Cold Start Fuel Igniter (CSFI). Decision

B. Inspect CSFI ring terminal and harness.
C. Check CSFI ring terminal for: damaged or pinched wires; moist or corroded
terminals; loose, bent, or broken terminal.
Are CSFI harness, and terminal clean and undamaged? No: Repair connector, harness,
5548 FMI 8.
Step 4 Inspect connections at Cold Start Fuel Igniter (CSFI) Relay. Decision
B. Disconnect CSFI Relay.
C. Check CSFI Relay and connector terminals for: damaged or pinched wires;
moist or corroded terminals; spread female terminals, backed out terminals
and(or) wires, bent, or broken pins; or broken connector housing.
Are CSFI Relay connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
5548 FMI 8.
Step 5 Check CSFI Relay Enable circuit for short to GND. Decision
CSFI pin-6 and ECM pin E1-95.
for SPN 5548 FMI 1.
Step 6 Check CSFI Relay CTL circuit for short to GND. Decision
CSFI pin-7 and ECM pin E1-90.
for SPN 5548 FMI 1.
Step 7 Check CSFI Relay Diag circuit for short to GND. Decision
between CSFI Relay pin-8 and
FMI 1.
Step 8 Check CSFI Relay output 1 circuit for short to GND. Decision
CSFI ring terminal. After repairs
5548 FMI 1.
5548 FMI 1.
Step 10 Check CSFI for Open. Decision

A. Key OFF Yes: Replace CSFI. After repairs
B. Remove ring terminal from CSFI and isolate from GND.
5548 FMI 1.
C. Use DMM, measure resistance between CSFI stud and known good GND.
Is resistance greater than 10 ohms? No: Replace CSFI Relay. After
SPN 5548 FMI 1.


Tools Required
Figure 562 CSFI Relay Enable Circuit Check
Test 1
A. Key OFF.
B. Disconnect Cold Start Fuel Igniter (CSFI) Relay.
C. Connect Breakout Harness ZTSE4885 to vehicle harness and leave CSFI Relay disconnected.
Figure 563 CSFI Relay CTL Circuit Check
Test 2
A. Key OFF.
Figure 564 CSFI Relay Diag Circuit Check
Test 3
A. Key OFF.

Figure 565 CSFI Relay Output 1 Circuit Check
Test 4
A. Key OFF.
C. Disconnect CSFI and leave terminal disconnected and isolate it from GND.
D. Connect Breakout Harness ZTSE4885 to vehicle harness and leave CSFI Relay disconnected.
Test 5
A. Key OFF.
SPN 5548 FMI 3 - Engine Cold Start Fuel Igniter Command : Voltage Above Normal, Or Shorted To
High Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Cold Start Fuel Ignitor (CSFI) Relay shorted high.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Road Test
Possible Causes
• CSFI short to PWR
• CSFI Relay Enable circuit short to PWR
• Failed CSFI

®
1940).
Step 2 Inspect connections at Cold Start Fuel Ignitor (CSFI). Decision

B. Disconnect CSFI.
C. Check CSFI stud and ring terminal for: damaged or pinched wires; wet or
moist or corroded terminals; loose, bent, or broken pins; or broken housing.
Are CSFI harness, and terminals clean and undamaged? No: Repair connector, harness,
5548 FMI 3.
Step 3 Inspect connections at Cold Start Fuel Injector (CSFI) Relay. Decision
C. Check CSFI Relay and connector terminals for: damaged or pinched
wires; wet or moist or corroded terminals; loose, bent, or broken pins; or
5548 FMI 3.
Step 4 Check CSFI Relay Enable circuit for short to PWR. Decision
Perform Test 1 (page 1740). Use Digital Multimeter (DMM), measure voltage Yes: Repair short to PWR
between Breakout Harness ZTSE4885 pin-6 and known good GND. between CSFI Relay pin-6 and
FMI 3.
Is voltage greater than 1.75 volts? No: Go to Step 5.
Step 5 Check CSFI Relay CTL circuit for short to PWR. Decision
ZTSE4885 pin-7 and known good GND. between CSFI Relay pin-7 and
FMI 3.
Step 6 Check CSFI Relay Diag circuit for short to PWR. Decision
FMI 3.
Step 7 Check CSFI Relay output 1 circuit for short to PWR. Decision
5548 FMI 3.
Step 8 Check CSFI Relay output 2 circuit for short to PWR. Decision
5548 FMI 3.
Step 9 Check CSFI for Open Decision

A. Key OFF. Yes: Replace CSFI. After repairs
5548 FMI 3.
SPN 5548 FMI 3.


Tools Required
Test 1
A. Key OFF.
D. Key ON.
Test 2
A. Key OFF.
B. Disconnect Intake CSFI Relay.
D. Key ON.
Test 3
A. Key OFF.
D. Key ON.
Test 4
A. Key OFF.
D. Key ON.
Test 5
A. Key OFF.
D. Key ON.
SPN 5548 FMI 4 - Engine Cold Start Fuel Igniter Command : Voltage Below Normal, Or Shorted
To Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Cold Start Fuel Igniter (CSFI) circuit short to ground.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Road Test
Possible Causes
• CSFI Relay Enable circuit short to GND
• CSFI Relay CTL circuit short to GND
• CSFI Relay Diag circuit short to GND
• CSFI Relay output short to GND
• Failed CSFI

®
1940).

B. Disconnect CSFI.
C. Check CSFI and connector terminals for: damaged or pinched wires; moist
housing.
Are CSFI connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
SPN 5548 FMI 4.
wires; moist or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
SPN 5548 FMI 4.
FMI 4.
Step 5 Check CSFI Relay CTL circuit for short to GND. Decision
FMI 4.
Step 6 Check CSFI Relay Diag circuit for short to GND. Decision
FMI 4.
5548 FMI 4.
5548 FMI 4.
Step 9 Check CSFI for Open. Decision

A. Key OFF Yes: Replace CSFI. After repairs
5548 FMI 4.
SPN 5548 FMI 4.


Tools Required
Test 1
A. Key OFF.
Test 2
A. Key OFF.
Test 3
A. Key OFF.

Test 4
A. Key OFF.
Test 5
A. Key OFF.
SPN 5548 FMI 5 - Engine Cold Start Fuel Igniter Command : Current Below Normal Or Open Circuit
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Cold Start Fuel Igniter (CSFI) circuit has an open.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• CSFI Relay Enable circuit Open
• CSFI Relay CTL circuit Open
• CSFI Relay Diag circuit Open
• CSFI Relay Output circuit Open
• Failed CSFI

®
1940).

B. Disconnect CSFI.
C. Check CSFI and connector terminals for: damaged or pinched wires; moist
housing.
5548 FMI 5.
wires; moist or corroded terminals; loose, bent, or broken pins; or broken
connector housing.
5548 FMI 5.
Is voltage 1.5 ± 0.25 volts? No: Repair Open between CSFI
Relay pin-6 and ECM pin E1-95.
for SPN 5548 FMI 5.
Step 5 Check CSFI Relay CTL circuit for Open. Decision

for SPN 5548 FMI 5.
Step 6 Check CSFI Relay Diag circuit for Open. Decision

for SPN 5548 FMI 5.
Step 7 Check CSFI Relay PWR supply circuit for Open. Decision
Is voltage B+ ± 0.5 volts? No: Repair Open between CSFI
Relay pin-3 and under-hood
PDM. After repairs are complete,
Step 8 Check CSFI Relay output circuit for OPEN. Decision

A. Perform Actuator Test (page 1968) and select Eng Cold Start > Fuel Ignitor Yes: Replace CSFI. After repairs
from menu. are complete, retest for SPN
5548 FMI 5.
B. Using DMM, measure voltage between CSFI stud and known good GND
while test is active.
Step 9 Check CSFI Relay Output circuit for OPEN. Decision

A. Perform Test 5 (page 1758). Yes: Repair OPEN between
CSFI Relay pin-1 and/or pin-2
B. Perform Actuator Test (page 1968) and select Eng Cold Start > Fuel Ignitor
and CSFI stud. After repairs are
from menu.
C. During test, use DMM to measure voltage between Breakout Harness FMI 5.
D. During test, use DMM to measure voltage between Breakout Harness
Are both voltages B+ ± 0.5 volts? No: Replace CSFI Relay. After
SPN 5548 FMI 5.


Tools Required
Test 1
A. Key OFF.
B. Disconnect Cold Start Fuel Ignitor (CSFI) Relay.
Test 2
A. Key OFF.
D. KOEO.
Test 3
A. Key OFF.
D. KOEO.
Figure 580 CSFI Relay PWR Supply Circuit Check
Test 4
A. Key OFF.
D. KOEO.
Test 5
A. Key OFF.
C. Connect Breakout Harness ZTSE4885 between vehicle harness and CSFI Relay.
SPN 5548 FMI 8 - Engine Cold Start Fuel Igniter Command : Abnormal Frequency Or Pulse Width
Or Period
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Cold Start Fuel Ignitor (CSFI) command has
abnormal frequency or pulse width or period.
Lamp Reaction
Associated Faults
SPN 157 SPN 5548 FMI 3, 4, and 5
Fault Facts
None

Continuous
Possible Causes
• CSFI Relay Enable circuit Open
• CSFI Relay CTL circuit Open
• CSFI Relay Diag circuit Open
• CSFI Relay Output circuit Open
• Failed CSFI

®
for SPN 5548 FMI 8.

1940).

B. Inspect CSFI ring terminal and harness.
C. Check CSFI ring terminal for: damaged or pinched wires; moist or corroded
terminals; loose, bent, or broken terminal.
5548 FMI 8.
C. Check CSFI Relay and connector terminals for: damaged or pinched wires;
moist or corroded terminals; spread female terminals, backed out terminals
and(or) wires, bent, or broken pins; or broken connector housing.
5548 FMI 8.
for SPN 5548 FMI 8.
Step 6 Check CSFI Relay CTL circuit for Open. Decision

for SPN 5548 FMI 8.
Step 7 Check CSFI Relay Diag circuit for Open. Decision

for SPN 5548 FMI 8.
Step 8 Check CSFI Relay PWR supply circuit for Open. Decision
Is voltage B+ ± 0.5 volts? No: Repair Open between CSFI
Relay pin-3 and under-hood
PDM. After repairs are complete,
Step 9 Check CSFI Relay output circuit for OPEN. Decision

A. Perform Actuator Test (page 1968) and select Eng Cold Start > Fuel Ignitor Yes: Replace CSFI. After repairs
from menu. are complete, retest for SPN
5548 FMI 8.
B. Using DMM, measure voltage between CSFI stud and known good GND
while test is active.
Step 10 Check CSFI Relay Output circuit for OPEN. Decision

A. Perform Test 5 (page 1758). Yes: Repair OPEN between
CSFI Relay pin-1 and/or pin-2
B. Perform Actuator Test (page 1968) and select Eng Cold Start > Fuel Ignitor
and CSFI stud. After repairs are
from menu.
C. During test, use DMM to measure voltage between Breakout Harness FMI 8.
D. During test, use DMM to measure voltage between Breakout Harness
Are both voltages B+ ± 0.5 volts? No: Replace CSFI Relay. After
SPN 5548 FMI 8.


Tools Required
Test 1
A. Key OFF.

Test 2
A. Key OFF.
D. KOEO.
Test 3
A. Key OFF.
D. KOEO.
Figure 586 CSFI Relay PWR Supply Circuit Check
Test 4
A. Key OFF.
D. KOEO.
Test 5
A. Key OFF.

C. Connect Breakout Harness ZTSE4885 between vehicle harness and CSFI Relay.
SPN 5569 FMI 2 - Diesel Particulate Filter 1 Soot Sensor ECU Internal Temperature : Data Erratic,
Fault Overview
This fault sets when Engine Control Module (ECM) detects Particulate Matter (PM) sensor module's internal
circuit board temperature sensors are not consistent with each other.
Lamp Reaction
Associated Faults
SPN 6780
Fault Facts
None
Drive Cycles
Continuous
Possible Causes
• Failed PM sensor Module

®
for SPN 5569 FMI 2.

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics. Key-On Yes: Go to Step 3.
Engine-Off (KOEO), check Diagnostic Trouble Code (DTC) list for SPN 5569 FMI 2.
SPN 5569 FMI 2.
Step 3 Inspect connections at Particulate Matter (PM) sensor. Decision

A. Key-Off. Yes: Replace PM sensor. After
B. Disconnect PM sensor.
SPN 5569 FMI 2.
C. Check PM sensor and connector terminals for: damaged or pinched
connector housing.
Are PM sensor connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
FMI 2.
End Diagnostic Test

SPN 5569 FMI 3 - Diesel Particulate Filter 1 Soot Sensor ECU Internal Temperature : Voltage Above
Fault Overview
circuit board temperature sensor voltage is above a normal operating range.
Lamp Reaction
Associated Faults
Fault Facts
None

Continuous
Possible Causes
• Failed PM Sensor Module

for SPN 5569 FMI 3.

®
5569 FMI 3.
for SPN 5569 FMI 3.
Step 3 Inspect connections at PM sensor. Decision

A. Key-OFF. Yes: Replace PM sensor. After
SPN 5569 FMI 3.
C. Check PM sensor and connector terminals for: damaged or pinched wires;
housing.
5569 FMI 3.

SPN 5569 FMI 4 - Diesel Particulate Filter 1 Soot Sensor ECU Internal Temperature : Voltage Below
Fault Overview
circuit board temperature sensor voltage is below normal operating range.
Lamp Reaction
Associated Faults
Fault Facts
None

Continuous
Possible Causes

for SPN 5569 FMI 4.

®
5569 FMI 4.
for SPN 5569 FMI 4.
Step 3 Inspect connections at PM sensor. Decision

A. Key-OFF. Yes: Replace PM sensor. After
SPN 5569 FMI 4.
housing.
5569 FMI 4.

SPN 5569 FMI 16 - Diesel Particulate Filter 1 Soot Sensor ECU Internal Temperature : Data Valid But
Fault Overview
circuit board temperature is hotter than a safe temperature.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Road Test
Possible Causes
• PM sensor installed incorrectly or contacting hot exhaust components
• Failed PM sensor Module

®
1940).

connector.
B. Disconnect PM sensor module connector.
housing.
5569 FMI 16.
Step 3 Verify PM sensor module is installed correctly. Decision

Verify the aftertreatment particulate sensor module is properly mounted on its Yes: Replace PM sensor. After
bracket and not contacting hot exhaust components. repairs are complete, retest for
SPN 5569 FMI 16.
Is PM sensor module properly mounted and not contacting hot exhaust components? No: Mount PM sensor module to
bracket and ensure harness is
properly routed. After repairs are
FMI 16.
End Diagnostic Test

SPN 5585 FMI 1 - Engine Fuel 1 Injector Metering Rail 1 Cranking Pressure : Data Valid But Below
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Fuel Rail Pressure (FRP) does meet desired value
for current starting conditions and engine will not start.
Lamp Reaction
Associated Faults
SPN 97 FMI 31 SPN 157 FMI 3, 4, 20, and SPN 633 SPN 1244
21
Fault Facts
None

Road Test
Possible Causes
• Low fuel level
• Fuel contaminated with water or DEF
• Restricted fuel filter
• Leaking fuel pressure relief valve
• Leaking fuel filter check valve
• Restricted fuel return line
• Restricted fuel tank vent
• High Pressure Fuel Pump

for SPN 5585 FMI 1.
for SPN 5585 FMI 1.

SPN 5585 FMI 1.
Is fuel contaminated with water or Diesel Exhaust Fluid? No: Go to Step 4.
Step 4 Check if engine can reach minimum cranking rpm. Decision

A. Crank engine for maximum of 20 seconds. Yes: Go to Step 5.
B. Watch engine rpm in EST with Navistar® Engine Diagnostics while cranking
engine.
Does engine crank at a minimum of 130 rpm? No: Go to step 2 of 2.1 - Engine
Crank (page 43) symptom. After
SPN 5585 FMI 1.

Crank engine for maximum of 20 seconds. If engine does not start, wait 2 minutes Yes: Retest for SPN 157 FMI 1.
and try again. If starting complaint is present go
to step 2 of 3.1 - Engine Hard to
Start (Long Crank Time) (page
47) symptom.
Does engine start and maintain idle? No: Go to step 6.

Perform Fuel Aeration Test (page 2034). Yes: Repair source of fuel
FMI 1.
Was aeration found in fuel? No: Go to Step 7.
Step 7 Start Using Fuel System Priming Tool. Decision

A. Perform Fuel System Priming (page 2026). Yes: Go to Step 8.
B. Crank engine for a maximum of 20 seconds. If engine does not start, wait 2
minutes and try again.
Does engine start and maintain idle? No: Go to Step 10.

Remove Fuel System Priming Tool and reassemble. Crank engine for a maximum of Yes: Go to Step 14.
20 seconds.
Step 9 Check fuel supply system. Decision

Perform Start From Clean Fuel Source Test (page 2032). Yes: Go to Step 14.
Step 10 Check for restricted primary (engine mounted) fuel filter. Decision
Perform High-Pressure Pump Inlet Pressure Test (page 2055). Yes: Go to Step 11.
Did fuel delivery pressure meet expected outcome of test? No: Replace high-pressure fuel
Go to Step 18.

Is line free of return fuel from cylinder head while cranking? No: Go to Step 13.
Step 12 Check for a failed fuel pressure relief valve. Decision

Perform Fuel Rail Pressure (FRP) Return Flow Test part 2 (page 2048). Yes: Replace high-pressure fuel
Go to Step 18.
SPN 5585 FMI 1.

Perform Fuel Rail Pressure (FRP) Leak Isolation Test (page 2043). Yes: Replace last capped injector
Quantity Adjustment (IQA) (page
Was a leaking injector identified? No: End diagnostics. Retest for
SPN 5585 FMI 1.

for SPN 5585 FMI 1.
Step 15 Check fuel tank vent(s) for restriction. Decision

Perform Fuel Tank Vent Restriction Test (page 2116). Yes: Repair source of restriction.
for SPN 5585 FMI 1.
Are the fuel tank vent(s) restricted? No: Go to Step 16.
Step 16 Identify type of chassis fuel filter. Decision

Yes: Go to Step 17.
®
Is the vehicle equipped with a Davco chassis mounted fuel filter. No: End diagnostics. For an
5585 FMI 1.
Step 17 Check Davco® fuel filter check valve. Decision

®
Perform Davco Fuel Filter Check Valve Inspection (page 2196). Yes: Replace check valve or
components as necessary. After
SPN 5585 FMI 1.
Did the inspection find any leaking or damaged check valve components? No: End diagnostics. For an
5585 FMI 1.
Step 18 Check for restricted high-pressure fuel pump return line. Decision
SPN 5585 FMI 1.
return line between high-pressure
fuel pump and fuel tank. After
SPN 5585 FMI 1.

SPN 5742 FMI 3 - Aftertreatment Diesel Particulate Filter Temperature Sensor Module : Voltage Above
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Aftertreatment temperature sensor module
supply voltage is high.
Lamp Reaction
Associated Faults
None
Fault Facts
If SPN 5742 FMI 3 is set with any other voltage too high Diagnostic Trouble Codes (DTC), ensure batteries are
wired properly and that alternator charging voltage is within specification.

Continuous
Possible Causes
• Charging system voltage too high

®
Is only SPN 5742 FMI 3 active? No: Perform Electrical System
Test (page 2065). Follow repair
direction in test. After repairs are
FMI 3.
Step 2 Check for correct parallel battery pack wiring. Decision

Inspect battery pack wiring. Positive battery cable(s) should be connected from Yes: Go to Step 3.
positive battery terminal to positive battery terminal. 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.
for SPN 5742 FMI 3.
Step 3 Check for Overcharging Condition Decision

Perform Electrical System Test (page 2065). Yes: Follow repair direction in
test. After repairs are complete,
Was a failed component identified during the test? No: Replace Aftertreatment
for SPN 5742 FMI 3.
End Diagnostic Test

SPN 5742 FMI 4 - Aftertreatment Diesel Particulate Filter Temperature Sensor Module : Voltage Below
Fault Overview
Fault code sets when Engine Control Module (ECM) detects that Aftertreatment temperature sensor module
supply voltage is low.
Lamp Reaction
Associated Faults
Fault Facts
Verify batteries are fully charged and connections are clean before completing diagnostics. If other voltage faults
are present, troubleshoot main power feeds, ECM grounds circuits, and relay circuits and do not replace the
Aftertreatment temperature sensor module.

Continuous
Possible Causes
• AFTSS PWR circuit Open or short to GND

®
Is EST DTC list free of Associated Faults? No: Troubleshoot main power
feeds, ECM grounds circuits, and
relay circuits and do not replace
the Aftertreatment temperature
sensor module. Ensure batteries
are fully charged and in good
condition. Perform Electrical
System Test (page 2065). After
SPN 5742 FMI 4.

1940).

connector.
B. Disconnect Aftertreatment temperature sensor module connector.
C. Check Aftertreatment temperature sensor module and connector terminals

for: damaged or pinched wires; moisture or corroded terminals; loose, bent,
or broken pins; or broken connector housing.
5742 FMI 4.
Step 4 Check for failed Aftertreatment temperature sensor module. Decision

Perform Test 1 (page 1785). Use DMM, measure voltage between Breakout Harness Yes: End diagnostics. Retest for
18-801-01 pin-4 and pin-1. SPN 5742 FMI 4.
Step 5 Check SWBAT circuit for Open or short to GND. Decision

Perform Test 2 (page 1786). Use DMM, measure voltage between Breakout Yes: Repair Open or
Harness 18-801-01 pin-4 and known good GND. high resistance between
for SPN 5742 FMI 4
ground between Aftertreatment
temperature sensor module pin-4
and AFTSS Relay pin-87. After
SPN 5742 FMI 4.
End Diagnostic Test


Tools Required
Figure 589 Aftertreatment Temperature Sensor Module Circuit Check
Test 1
A. Key OFF.
B. Connect Breakout Harness 18-801-01 between vehicle harness and Aftertreatment temperature sensor module.
C. Key ON
Test 2
A. Key OFF.
C. Key ON
SPN 5742 FMI 12 - Aftertreatment Diesel Particulate Filter Temperature Sensor Module : Bad Intelligent
Device Or Component
Fault Overview
Fault code sets when the Engine Control Module (ECM) detects AFT temperature sensor module has
experienced internal module failures.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes

®
SPN 5742 FMI 12.
Step 2 Inspect connections at AFT temperature sensor module connector. Decision

C. Check AFT temperature sensor module and connector terminals for:
damaged or pinched wires; moisture or corroded terminals; loose, bent, or
5742 FMI 12.

®
A. Use Electronic Service Tool (EST) with Navistar Engine Diagnostics, Key Yes: Replace AFT temperature
ON, clear codes. sensor module. After repairs are
B. Key OFF, wait for EST screens to clear.
FMI 12
C. Key ON, check Diagnostic Trouble Codes (DTC) list for SPN 5742 FMI 12.
SPN 5742 FMI 12.
End Diagnostic Test

SPN 5742 FMI 16 - Aftertreatment Diesel Particulate Filter Temperature Sensor Module : Data Valid But
Fault Overview
The Smart Exhaust Gas Temperature Module has detetected an ECU temperature too high condition in the
internal module circuitry.
Lamp Reaction
Associated Faults
SPN 5742 FMI 19 SPN 5743 FMI 19
Fault Facts
None

Continuous.
Possible Causes
• External heat source too close to AFT temperature sensor module
• Damage or leaking exhaust system

Step 2 Inspect for external heat source around AFT temperature sensor Decision
module, or improper mounting.
Check that AFT temperature sensor module is properly installed on bracket, and that Yes: Repair mounting of AFT
the sensor is not in contact with hot exhaust components or other heat sources. temperature sensor module, or
remove external heat source.
Is AFT temperature sensor module near an external heat source or mounted No: Go to Step 3.
improperly?
Step 3 Inspect for a damaged exhaust system. Decision

Perform Exhaust and Aftertreatment System Inspection (page 2166). Yes: Replace AFT temperature
FMI 16.
Refer to Fault Facts. After repairs
5742 FMI 16.
End Diagnostic Test

SPN 5742 FMI 19 - Aftertreatment Diesel Particulate Filter Temperature Sensor Module : Received
Network Data In Error
Fault Overview
Fault code sets when Engine Control Module (ECM) loses J1939 data link communications with Aftertreatment
Lamp Reaction
Associated Faults
Fault Facts

Continuous
Possible Cause

®
Reset Request(page 1955), and


connector.
for: damaged or pinched wires; moisture or corroded terminals; loose,
bent, or broken pins; or broken connector housing.
Step 4 Check Aftertreatment Power Distribution Module (PDM) for damaged Decision
fuse(s) and/or relay(s).
Check Aftertreatment PDM fuse(s) and relay(s) for blown fuses; loose, missing, or Yes: Go to Step 5.
intermittent connections.
Are all fuses and relays securely attached and in good condition? No: Secure or replace
failed fuse(s) or relay(s) to
Aftertreatment PDM. After repairs

Step 5 Check voltage supply to Aftertreatment temperature sensor module. Decision

Perform Test 2 (page 1797). Use DMM, measure voltage between Breakout Yes: Repair Open or
Harness 18-801-01 pin-1 and known good ground. high resistance between
GND between Aftertreatment
and Aftertreatment Smart Sensor
(AFTSS) relay pin-30. After
FMI 19.

Harness 18-801-01 pin-2 and known good ground.
Is voltage greater than 2 volts? No: Repair Open or short to GND
on CAN-H circuit between AFT
Temp sensor module pin-2 and
(VGTA, DEF Tank sensor module,
NOx OUT sensor module, and
PM sensor module). After repairs

18-801-01 pin-2 and known good ground.
CAN-H circuit between AFT Temp
DEF Tank sensor module, EGRV,
NOx IN sensor module, NOx
OUT sensor module, and PM

AFT Temp sensor module
modules (VGTA, DEF Tank
sensor module, EGRV, NOx
IN sensor module, NOx OUT
sensor module, and PM sensor
module). After repairs are
Step 10 Check CAN-L circuit for short to PWR. Decision

CAN-L circuit between AFT Temp
DEF Tank sensor module, EGRV,
NOx IN sensor module, NOx
OUT sensor module, and PM

Perform Test 5 (page 1800). Use DMM, measure resistance between Breakout Yes: Replace Aftertreatment
Harness 18-801-01 pin-2 and pin-3. temperature sensor module.
Is resistance between 55 and 65 ohms? No: Repair short between
sensor module pin-2 and pin-3.


Tools Required
Figure 591 Aftertreatment Temperature Sensor Module Voltage Check
Test 1
A. Key OFF.
C. Key ON
Test 2
A. Key OFF.
C. Key ON
Test 3
A. Key OFF.
C. Key ON
Test 4
A. Key OFF.
C. Key ON
Figure 595 CAN-H shorted to CAN-L Circuit Check
Test 5
A. Key OFF.
SPN 5743 FMI 19 - Aftertreatment 1 SCR Temperature Sensor Module : Received Network Data In Error
Fault Overview
Fault code sets when Engine Control Module (ECM) loses J1939 data link communications with Aftertreatment
Lamp Reaction
Associated Faults
Fault Facts

Continuous
Possible Cause

®
Reset Request(page 1955), and

Fault Diagnostic Procedure(page
1940). After repairs are

connector.
for: damaged or pinched wires; moisture or corroded terminals; loose, bent,
or broken pins; or broken connector housing.
Step 4 Check Aftertreatment Power Distribution Module (PDM) for damaged Decision
fuse(s) and/or relay(s).
Check Aftertreatment PDM fuse(s) and relay(s) for blown fuses; loose, missing, or Yes: Go to Step 5.
Are all fuses and relays securely attached and in good condition? No: Secure or replace
failed fuse(s) or relay(s) to
aftertreatment PDM. After repairs

Step 5 Check voltage supply to Aftertreatment temperature sensor module. Decision

Perform Test 2 (page 1807). Use DMM, measure voltage between Breakout Harness Yes: Repair Open or
18-801-01 pin-1 and known good ground. high resistance between
GND between Aftertreatment
and Aftertreatment Smart Sensor
(AFTSS) relay pin-30. After
FMI 19.

Sensor Module, EGRV, NOx

CAN-H circuit between AFT Temp
DEF Tank Sensor Module,

Step 10 Check CAN-L circuit for short to PWR. Decision

CAN-L circuit between AFT Temp
DEF Tank Sensor Module,

Perform Test 5 (page 1810). Use DMM, measure resistance between Breakout Yes: Replace Aftertreatment
Harness 18-801-01 pin-2 and pin-3. temperature sensor module.
Is resistance between 55 and 65 ohms? No: Repair short between
sensor module pin-2 and pin-3.


Tools Required
Figure 596 Aftertreatment Temperature Sensor Module Voltage Check
Test 1
A. Key OFF.
C. Key ON
Test 2
A. Key OFF.
C. Key ON
Test 3
A. Key OFF.
C. Key ON
Test 4
A. Key OFF.
C. Key ON
Figure 600 CAN-H shorted to CAN-L Circuit Check
Test 5
A. Key OFF.
SPN 5747 FMI 3 - Aftertreatment 1 Outlet Soot Sensor Heater : Voltage Above Normal, Or Shorted
To High Source
Fault Overview
This fault sets when Engine Control Module (ECM) detects Particulate Matter (PM) sensor heater low side circuit
is Open or high side is shorted to PWR.
Lamp Reaction
Associated Faults
Fault Facts
None
Drive Cycles
Continuous
Possible Causes
• Failed PM sensor module

®
Is EST DTC list clear of Associated Faults? No: Repair associated faults.
for SPN 5747 FMI 3.

Use Electronic Service Tool (EST) with Navistar® Engine Diagnostics. Key On Yes: Go to Step 3.
SPN 5747 FMI 3.

A. Key Off. Yes: Replace PM sensor. After
SPN 5747 FMI 3.
connector housing.
FMI 3.
End Diagnostic Test

SPN 5747 FMI 4 - Aftertreatment 1 Outlet Soot Sensor Heater : Voltage Below Normal, Or Shorted
To Low Source
Fault Overview
This fault sets when Engine Control Module (ECM) detects Particulate Matter (PM) sensor heater high side
circuit is shorted to GND or there is an open in heater circuit.
Lamp Reaction
Associated Faults
Fault Facts
None
Drive Cycles
Continuous
Possible Causes

®
for SPN 5747 FMI 4.

SPN 5747 FMI 4.

SPN 5747 FMI 4.
connector housing.
FMI 4.
End Diagnostic Test

SPN 5747 FMI 5 - Aftertreatment 1 Outlet Soot Sensor Heater : Current Below Normal Or Open Circuit
Fault Overview
This fault sets when Engine Control Module (ECM) detects Particulate Matter (PM) sensor heater has an open
circuit.
Lamp Reaction
Associated Faults
Fault Facts
None

Continuous
Possible Causes

for SPN 5747 FMI 5.

®
Is SPN 5747 FMI 5 active? No: Repair Active faults. After
SPN 5747 FMI 5.

A. Key OFF. Yes: Replace PM sensor. After
SPN 5747 FMI 5.
housing.

5747 FMI 5.

SPN 5747 FMI 10 - Aftertreatment 1 Outlet Soot Sensor Heater : Abnormal Rate Of Change
Fault Overview
This fault code sets when Engine Control Module (ECM) detects Particulate Matter (PM) sensor has a positive
offset.
Lamp Reaction
Associated Faults
Fault Facts
None

Road Test.
Possible Causes


®
SPN 5747 FMI 10.

SPN 5747 FMI 10.
housing.

5747 FMI 10.
End Diagnostic Test

SPN 5765 FMI 0 - Engine Exhaust Gas Recirculation 1 Actuator 1 Temperature : Data Valid But Above
Fault Overview
Fault code sets when Engine Control Module (ECM) detects the Engine Exhaust Gas Recirculation Valve (EGRV)
has an issue.
Lamp Reaction
Associated Faults
SPN 110 FMI 0, 2, 3, 4, 10, SPN 111 FMI 1 SPN 2791

15 and 16
Fault Facts
None

Road Test
Possible Causes
• Failed EGRV

for SPN 5765 FMI 0.

Use EST with Navistar® Engine Diagnostics, check DTC list for SPN 5765 FMI 0. Yes: Go to Step 3.
(page 1940).

connector.
A. Key OFF. Yes: Replace EGRV. After
SPN 5765 FMI 0.
connector housing.
5765 FMI 0.

SPN 5765 FMI 14 - Engine Exhaust Gas Recirculation 1 Actuator 1 Temperature : Special Instructions
Fault Overview
Fault code sets when Engine Control Module (ECM) detects the Engine Exhaust Gas Recirculation Valve (EGRV)
has an issue.
Lamp Reaction
Associated Faults
SPN 110 FMI 0, 2, 3, 4, 10, SPN 111 FMI 1 SPN 2791

15 and 16
Fault Facts
None

Road Test
Possible Causes
• Failed EGRV


®
(page 1940).

connector.
A. Key OFF. Yes: Replace EGRV. After
SPN 5765 FMI 14.
connector housing.

5765 FMI 14.

SPN 5765 FMI 15 - Engine Exhaust Gas Recirculation 1 Actuator 1 Temperature : Data Valid But Above
Fault Overview
Fault code sets when Engine Control Module (ECM) detects the Engine Exhaust Gas Recirculation Valve internal
temperature is too high.
Lamp Reaction
Associated Faults

15 and 16
Fault Facts
None

Continuous
Possible Causes
• Failed EGRV

®
Step 2 Check coolant quality. Decision

Perform Coolant Quality Inspection (page 2160). Yes: Go to Step 3.
Is coolant clean and free of contamination? No: Repair source of coolant
contamination. Refill cooling
system with new coolant. After
SPN 5765 FMI 15.

Is coolant level within specification? No: Go to Step 2 of 5.0 - Cooling
SPN 5765 FMI 15.

Perform Thermostat Operational Test (page 2136). Yes: Clear DTCs. If active code
remains, replace EGRV. After
SPN 5765 FMI 15.
FMI 15.

SPN 5835 FMI 3 - Aftertreatment 1 Particulate Sensor : Voltage Above Normal, Or Shorted To High
Source
Fault Overview
This fault sets when Engine Control Module (ECM) detects Particulate Matter (PM) Sensor Module internal
sensing element voltage is too high.
Lamp Reaction
Associated Faults
SPN 5835 FMI 19
Fault Facts
None

Road Test
Possible Causes

®
1825).
for SPN 5835 FMI 3.

SPN 5835 FMI 3.
Does EST DTC list SPN 5835 FMI 3 active or pending? No: Repair other active faults.
for SPN 5835 FMI 3.
Step 3 Inspect connections at Particulate Matter (PM) Sensor Module. Decision

A. Key-Off. Yes: Replace PM Sensor Module.
B. Disconnect PM Sensor Module.
for SPN 5835 FMI 3.
C. Check PM Sensor Module and connector terminals for: damaged or
Are PM Sensor Module connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
FMI 3.
End Diagnostic Test

SPN 5835 FMI 4 - Aftertreatment 1 Particulate Sensor : Voltage Below Normal, Or Shorted To Low
Source
Fault Overview
This fault sets when Engine Control Module (ECM) detects Particulate Matter (PM) Sensor Module internal
sensing element voltage is too low.
Lamp Reaction
Associated Faults
SPN 5835 FMI 19
Fault Facts
None

Road Test
Possible Causes

®
1827).
for SPN 5835 FMI 4.

SPN 5835 FMI 4.
Does EST DTC list SPN 5835 FMI 4 active or pending? No: Repair other active faults.
for SPN 5835 FMI 4.

for SPN 5835 FMI 4.
FMI 4.
End Diagnostic Test

SPN 5835 FMI 19 - Aftertreatment 1 Particulate Sensor : Received Network Data In Error
Fault Overview
This fault sets when Engine Control Module (ECM) detects a loss of communication with Particulate Matter (PM)
Sensor Module on Private J1939 CAN.
Lamp Reaction
Associated Faults
Fault Facts

Road Test
Possible Causes
• AFTSS PWR circuit open or short to GND
• Private CAN-H circuit open or short to GND
• Private CAN-L circuit open or short to GND
• Private CAN-H circuit short to PWR
• Private CAN-L circuit short to PWR
• Private CAN-H short to Private CAN-L

®
for SPN 5835 FMI 19

®
Does EST DTC list SPN 5835 FMI 19 active or pending? No: Go to Intermittent or Inactive
1940).

FMI 19.
Step 4 Check AFTSS PWR Circuit to PM Sensor Decision

A. Perform Test 1(page 1833). Yes: Go to Step 5.
B. Use Digital Multimeter (DMM), measure voltage between Breakout
Is voltage B+ ± 0.5 volts? No: Repair open or high resistance
between PM Sensor Module pin-1
and AFT Smart Sensor Relay
Step 5 Check PM sensor GND circuits. Decision

Perform Test 2(page 1834). Use DMM, measure voltage between Breakout Yes: Go to Step 6.
Harness 18-651-01 pin-2 and B+.
FMI 19.

Is voltage between 2 and 3 volts? No, voltage is less than 2 volts:
repair Open or short to GND
on CAN-H circuit between PM
Sensor Module pin-3 and all other
NOx IN sensor module, NOx OUT
sensor module, and AFT Temp
FMI 19.
No, voltage is greater than 3
volts: repair short to PWR on
CAN-H circuit between PM Sensor
Module pin-3 and all other Private
CAN modules (VGTA, DEF Tank
FMI 19.

Is voltage between 2 and 3 volts? No, voltage is less than 2 volts:
repair Open or short to GND
on CAN-L circuit between PM
Sensor Module pin-4 and all other
NOx IN sensor module, NOx OUT
FMI 19.
No, voltage is greater than 3
volts: repair short to PWR on
CAN-L circuit between PM Sensor
Module pin-4 and all other Private
CAN modules (VGTA, DEF Tank

FMI 19.
Step 7 Check for short between Private CAN-H circuit and Private CAN-L Decision
circuit.
Perform Test 5(page 1837). Use DMM, measure resistance between Breakout Yes: Replace PM Sensor Module.
Harness 18-651-01 pin-3 and pin-4. After repairs are complete, retest
Is resistance between 55 and 65 Ohms? No: Repair short from CAN-H to
CAN-L if resistance is less than 55
ohms. Repair open in CAN-H or
CAN-L or replace missing or failed
terminating resistor if resistance
is greater than 65 ohms. After
SPN 5835 FMI 19.
End Diagnostic Test

Pinpoint Tests SPN 5835 FMI 19

Required Tools
18-651-01
0000415073
Test 1
A. Key-Off.
B. Disconnect Particulate Matter (PM) Sensor Module.
C. Connect Breakout Harness 18-651-01 to vehicle harness and leave PM Sensor Module disconnected.
2
18-651-01
0000415074
Figure 602 PM Sensor Module GND Circuit Check
Test 2
A. Key-Off.
3
18-651-01
0000419135
Test 3
A. Key-Off.
4
18-651-01
0000419136
Test 4
A. Key-Off.
18-651-01 4
0000419137
Figure 605 CAN-H to CAN-L Circuit Check
Test 5
A. Key-Off.
SPN 5835 FMI 21 - Aftertreatment 1 Particulate Sensor : Data Drifted Low
Fault Overview
Fault code sets when Engine Control Module (ECM) detects a clog in the protection tube of the Particulate Matter
(PM) sensor or improper installation of PM sensor in the exhaust.
Lamp Reaction
Associated Faults
Fault Facts
None

Continuous
Possible Causes
• Failed PM sensor
• Improperly installed PM sensor

®

Use EST with Navistar® Engine Diagnostics software. Key On Engine Off (KOEO), Yes: Go to Step 3.
check DTC list for SPN 5831 FMI 21.
SPN 5835 FMI 21.

A. Key Off. Yes: Replace PM sensor. After
SPN 5835 FMI 21.
housing.
5835 FMI 21.

SPN 6653 FMI 16 - Engine Fuel 1 Injector Metering Rail 1 Cold Start Pressure : Data Valid But Above
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Fuel Rail Pressure (FRP) is above maximum with
minimum command during Cold start Emissions Reduction (CSER) mode.
Lamp Reaction
Associated Faults
21
Fault Facts
None

Road Test
Possible Causes
• Fuel system damage or leak

®
FMI 16.
SPN 6653 FMI 16.
FMI 16.

SPN 6653 FMI 18 - Engine Fuel 1 Injector Metering Rail 1 Cold Start Pressure : Data Valid But Below
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Fuel Rail Pressure (FRP) is below minimum when
maximum is command during Cold Start Emissions Reduction (CSER) mode.
Lamp Reaction
Associated Faults
21
Fault Facts
None

Road Test
Possible Causes
• Restricted fuel supply
• Restricted secondary (engine-mounted) fuel filter
• Aerated fuel delivery
• Low fuel level or leaking fuel supply
• Leaking EFA2 relief valve
• Stuck or sticking EFA1
• Engine Fuel Rail Pressure (EFRP) sensor or circuit fault

®
FMI 18.

SPN 6653 FMI 18.

Was fuel pressure 68 ± 5 psi (469 ± 34 kPa) at low idle and 80 ± 5 psi (552 ± 34 No: Go to Step 5.
kPa) at high idle?
Step 5 Check for restricted secondary (engine-mounted) fuel filter. Decision

Remove secondary (engine-mounted) fuel filter. Inspect filter for gelling and Yes: Replace secondary
restrictions. (engine-mounted) fuel filter. After
SPN 6653 FMI 18.
Is secondary (engine-mounted) fuel filter restricted? No: Go to Step 6.

Perform Fuel Aeration Test (page 2034). Yes: Repair cause of fuel
FMI 18.


Is fuel volume less than 60 ml? No: Go to Step 11.
Step 9 Check for a failed EFA2. Decision

SPN 6653 FMI 18.
SPN 6653 FMI 18.
FMI 18.

Perform Fuel Rail Pressure (FRP) Leak Isolation Test (page 2043). Yes: Go to Step 12.
Was a leaking injector identified? No: Replace last capped injector
Quantity Adjustment (page 1941)
FMI 18.
Step 12 Inspect connections at Fuel Rail Pressure (FRP) sensor. Decision

B. Disconnect EFRP connector
connector housing.
6653 FMI 18.
Step 13 Check for failed EFRP sensor. Decision

Perform the Intermittent or Inactive Fault Diagnostic Procedure (page 1940) while Yes: Replace engine sensor
monitoring Engine Fuel Rail Pressure (EFRP). harness. After repairs are
FMI 18.
Was the voltage >4.81V or less than 0.19V? No: Replace fuel rail. After
SPN 6653 FMI 18.

SPN 6774 FMI 7 - Aftertreatment 1 Particulate Sensor Regeneration State : Mechanical System Not
Fault Overview
This fault codes sets when Engine Control Module (ECM) detects Particulate Matter (PM) heater sensor cannot
maintain sensor temperature.
Lamp Reaction
Associated Faults
Fault Facts
None
Drive Cycles
Road Test
Possible Causes

®
for SPN 6774 FMI 7.

SPN 6774 FMI 7.

SPN 6774 FMI 7.
connector housing.
FMI 7.
End Diagnostic Test

SPN 6778 FMI 3 - Aftertreatment 1 Particulate Sensor Power Supply : Voltage Above Normal, Or
Fault Overview
This fault codes sets when Engine Control Module (ECM) detects Particulate Matter (PM) Sensor boost circuit
is shorted to PWR.
Lamp Reaction
Associated Faults
SPN 5569 FMI 2
Fault Facts
None
Drive Cycles
Road Test
Possible Causes

®
1848).
for SPN 6778 FMI 3.

Is SPN 6778 FMI 3 active? No: Repair Active faults. After
SPN 6778 FMI 3.

B. Disconnect PM sensor connector.
SPN 6778 FMI 3.
connector housing.
FMI 3.
End Diagnostic Test

SPN 6778 FMI 4 - Aftertreatment 1 Particulate Sensor Power Supply : Voltage Below Normal, Or
Fault Overview
is shorted to GND.
Lamp Reaction
Associated Faults
SPN 5569 FMI 2
Fault Facts
None
Drive Cycles
Road Test
Possible Causes

®
1850).
for SPN 6778 FMI 4.

SPN 6778 FMI 4.
for SPN 6778 FMI 4.

SPN 6778 FMI 4.
connector housing.
FMI 4.
End Diagnostic Test

SPN 6778 FMI 16 - Aftertreatment 1 Particulate Sensor Power Supply : Data Valid But Above Normal
Fault Overview
is creating an excessive output voltage.
Lamp Reaction
Associated Faults
None
Fault Facts
None
Drive Cycles
Road Test
Possible Causes

®
Key-On, check DTC list for SPN 6778 FMI 16.
Is SPN 6778 FMI 16 active? No: Repair all other active faults.

SPN 6778 FMI 16.
connector housing.
FMI 16.
End Diagnostic Test

SPN 6780 FMI 2 - Aftertreatment 1 Particulate Sensor Temperature : Data Erratic, Intermittent or
Incorrect
Fault Overview
This fault codes sets when Engine Control Module (ECM) detects Particulate Matter (PM) sensor probe
temperature signal is not rational at key on and/or during the measurement phase.
Lamp Reaction
Associated Faults
SPN 5835 FMI 19 (AFT) SPN 7854 FMI 2 (PM)
Fault Facts
None
Drive Cycles
Road Test
Possible Causes

for SPN 6780 FMI 2.

Use EST with Navistar® Engine Diagnostic Software. Key-On Engine-Off (KOEO), Yes: Go to Step 3.
SPN 6780 FMI 2.

SPN 6780 FMI 2.
connector housing.
FMI 2.
End Diagnostic Test

SPN 6780 FMI 3 - Aftertreatment 1 Particulate Sensor Temperature : Voltage Above Normal, Or Shorted
To High Source
Fault Overview
This fault codes sets when Engine Control Module (ECM) detects Particulate Matter (PM) Sensor probe
temperature signal voltage is greater than normal operating range.
Lamp Reaction
Associated Faults
SPN 5835 FMI 19
Fault Facts
None
Drive Cycles
Road Test
Possible Causes

®
for SPN 6780 FMI 3.

Use EST with Navistar® Engine Diagnostics. Key-On, check DTC list for SPN Yes: Go to Step 3.
6780 FMI 3.
for SPN 6780 FMI 3.

SPN 6780 FMI 3.
connector housing.
FMI 3.
End Diagnostic Test

SPN 6780 FMI 4 - Aftertreatment 1 Particulate Sensor Temperature : Voltage Below Normal, Or Shorted
To Low Source
Fault Overview
This fault codes sets when the Engine Control Module (ECM) detects the Particulate Matter (PM) sensor probe
temperature is shorted to ground.
Lamp Reaction
Associated Faults
Fault Facts
None
Drive Cycles
Road Test
Possible Causes

for SPN 6780 FMI 4.

Use EST with Navistar® Engine Diagnostic Software. Key-On Engine-Off (KOEO), Yes: Go to Step 3.
SPN 6780 FMI 4.

SPN 6780 FMI 4.
connector housing.
FMI 4.
End Diagnostic Test

SPN 7107 FMI 3 - Aftertreatment 1 Diesel Exhaust Fluid Pump : Voltage Above Normal, Or Shorted
To High Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Exhaust Fluid Pump Control (DEFP CTL)
voltage is above normal operating range.
Lamp Reaction
Malfunction Indicator Lamp (MIL) will illuminate when this fault is detected after one trip.
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• DEFP CTL Short to PWR
Step 1 Inspect Aftertreatment Power Distribution Module (AFT PDM). Decision

B. Check AFT PDM fuse(s) and relay(s) for blown fuses; loose, missing, or
connector. Perform SCR Fault
for SPN 7107 FMI 4.
Step 2 Inspect connections at Diesel Exhaust Fluid (DEF) Supply Module Decision
connector.
Are DEF supply module connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
FMI 3.
Step 3 Inspect connections at Diesel Exhaust Fluid (DEF) Tank Harness 14-way Decision
connector.
B. Disconnect DEF Tank Harness 14-way connector.
C. Check DEF Tank Harness 14-way and connector terminals for: damaged
Are DEF Tank Harness 14-way connector, harness, and terminals clean and No: Repair connector, harness,
FMI 3.
Step 4 Check DEFP CTL for short to PWR. Decision

Perform Test 1 (page 1863). Use DMM, measure voltage from breakout harness Yes: Repair short to PWR
18-648-01 pin 3 and a known good GND. between DEFSM pin 3 and
PWR. Perform SCR Fault Reset
SPN 7107 FMI 3.
Step 5 Check for DEFP CTL shorted to DEFSM PWR Circuit. Decision
Perform Test 2 (page 1864). Use DMM, measure resistance between breakout Yes: End Diagnostics. Perform
harness 18-648-01 pin 2 and pin 3. SCR Fault Reset Request (page
3.
DEFSM pin 2 and DEFSM pin
3. Perform SCR Fault Reset
SPN 7107 FMI 3.


Tools Required
Figure 606 DEFP CTL Voltage Check
Test 1
A. Key OFF.
B. Disconnect Diesel Exhaust Fluid Supply Module (DEFSM) Connector.
C. Connect Breakout Harness 18-648-01 to vehicle harness and leave DEFSM disconnected.
Figure 607 DEFP CTL Short DEFSM PWR Check
Test 2
A. Key OFF.
B. Disconnect Engine Control Module (ECM).
C. Disconnect Diesel Exhaust Fluid Supply Module (DEFSM) Connector.
D. Connect Breakout Harness 18-648-01 to vehicle harness and leave DEFSM disconnected.
SPN 7107 FMI 4 - Aftertreatment 1 Diesel Exhaust Fluid Pump : Voltage Below Normal, Or Shorted
To Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Exhaust Fluid Supply Module (DEFSM)
Power Circuit voltage is below normal operating range.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• Failed DEFSM Relay or Fuse
• DEFSM Relay CTL circuit Open
• DEFSM power circuit Open or short to ground
• DEFP State circuit Open or short to ground
• DEFP CTL Open or short to ground
Step 1 Determine if fault code is active. Decision

®
Use Navistar Electronic Service Tool (EST), check Diagnostic Trouble Code (DTC) Yes: Go to Step 2.
Is SPN 7107 FMI 4 Active? No: End diagnostics. Retest for
SPN 7107 FMI 4.

A. Key OFF. Check AFT PDM fuse(s) and relay(s) for blown fuses; loose, Yes: Go to Step 3.
B. Inspect back of AFT PDM for: loose, missing, intermittent connections,

bad crimps, and corrosion.
Are all fuses and relays securely attached and in good condition, and are harness No: Repair or replace fuses,
terminals clean and undamaged? relays and If fuse blows, test for
short. Perform SCR Fault Reset
SPN 7107 FMI 4.
Step 3 Inspect connections at Diesel Exhaust Fluid (DEF) Tank Harness 14-way Decision
connector.
A. Key OFF. Disconnect DEF Tank Harness 14-way connector. Yes: Go to Step 4.
B. Check DEF Tank Harness 14-way and connector terminals for: damaged
Are DEF Tank Harness 14-way connector, harness, and terminals clean and No: Repair connector, harness,
FMI 4.
Step 4 Inspect connections at Diesel Exhaust Fluid (DEF) Supply Module Decision
connector.
A. Key OFF. Disconnect DEF Supply Module connector. Yes: Go to Step 5.
B. Check DEF Supply Module and connector terminals for: damaged or
Are DEF supply module connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
FMI 4.
Step 5 Check DEFSM power circuit for an Open. Decision

A. Key OFF. Disconnect Diesel Exhaust Fluid Supply Module (DEFSM) Yes: Go to Step 10.
Connector.
B. Connect Breakout Harness 18-648-01 between vehicle harness and
DEFSM.
C. Key ON. Using DMM, measure voltage between Breakout Harness
18-648-01 pin 2 and ground.
No. Voltage is B+ ± 0.5V and

does not return to less than 0.5V
after ten seconds: Repair Open
in DEFP State wire between ECM
pin C1-67 and DEFSM voltage
supply circuit splice. Perform
SCR Fault Reset Request. After
SPN 7107 FMI 4.
Is voltage B+ ± 0.5V for approximately 10 seconds after key is switched ON then No. Voltage is never B+ ± 0.5V:
return to less than 0.5V? Go to Step 6.
Step 6 Check for an Open in DEFSM relay control circuit. Decision

A. Key OFF. Remove DEFSM relay. Install Test Lead ZTSE443531 from Yes: Go to Step 8.
Terminal test kit ZTSE4435C into DEFSM relay terminal 85.
B. Install Test Lead ZTSE443531 into DEFSM relay terminal 86.
C. Key ON. Using DMM, measure voltage between DEFSM relay terminal
85 and terminal 86.
Is voltage B+ ± 0.5V for approximately 10 seconds after key is switched On then No: Go to Step 7.
return to less than 0.5V?
Step 7 Check for an Open in ECM PWR OUT 3 circuit. Decision

A. Key OFF. Remove DEFSM relay. Yes: Repair Open or high
resistance between DEFSM
B. Install Test Lead ZTSE443531 from Terminal test kit ZTSE4435C into
relay terminal 86 and ECM
DEFSM relay terminal 85.
C1-05. Perform SCR Fault Reset
C. Key ON. Using DMM, measure voltage between DEFSM relay terminal Request (page 1955). After
85 and ground. repairs are complete, retest for
SPN 7107 FMI 4.
DEFSM relay terminal 85 and
ECM C2-11. Perform SCR Fault
for SPN 7107 FMI 4.
Step 8 Check DEFSM relay circuit for an Open. Decision

A. Key OFF. Remove DEFSM relay. Yes: Go to Step 9.
C. Key ON. Using DMM, measure voltage between DEFSM relay terminal
87 and ground.
DEFSM relay terminal 87
and vehicle battery. Perform
FMI 4.
Step 9 Test for a failed DEFSM relay. Decision

A. Key OFF. Remove DEFSM relay. Yes: Replace DEFSM relay.
C. Install Test Lead ZTSE443531 into DEFSM relay terminal 30. SPN 7107 FMI 4.
D. Use Breakout Harness ZTSE4498 to jumper DEFSM relay terminal 87
to relay terminal 30.
E. Disconnect Diesel Exhaust Fluid Supply Module (DEFSM) Connector.
F. Connect Breakout Harness 18-648-01 to vehicle harness and leave DEFSM
disconnected.
G. Key ON. Using DMM, measure voltage between Breakout Harness
18-648-01 pin 2 and ground.
DEFSM relay terminal 30
and DEFSM pin 2. Perform
FMI 4.
Step 10 Check DEFP CTL Circuit for Open or short to GND. Decision
A. Key OFF. Disconnect DEFSM Connector. Yes: Repair Open, or short to
ground between DEFSM pin
B. Connect Breakout Harness 18-648-01 to vehicle harness and leave DEFSM
3 and ECM C1 connector pin
disconnected.
C1-04. Perform SCR Fault Reset
C. Key ON. Use DMM, measure voltage between Breakout Harness Request (page 1955). After
18-648-01 pin 3 and ground. repairs are complete, retest for
SPN 7107 FMI 4.
Step 11 Check DEFP CTL Circuit for high resistance. Decision

A. Key OFF. Disconnect DEFSM Connector. Yes: Repair high resistance
between DEFSM pin 3 and
B. Connect Breakout Harness 18-648-01 to vehicle harness and leave DEFSM
ECM C1 connector pin C1-04.
disconnected.
C. Disconnect ECM C1 connector. Request (page 1955). After
D. Connect Breakout Box 00-00956-08 to Breakout Harness 12-801-05-01.
SPN 7107 FMI 4.
E. Connect Breakout Harness 12-801-05-01 between ECM C1 connector
and vehicle harness.
F. Using DMM, measure resistance between Breakout Box 18-909-01 pin
C1-04 and Breakout Harness 18-648-01 pin 3. Remember to Zero out any
resistance in the DMM leads or breakout harness’.
Is resistance less than 0.5 ohms? No: Replace DEFSM. Perform

FMI 4.

SPN 7330 FMI 2 - Aftertreatment 1 Particulate Sensor Heater Power Supply Diagnostic Status : Data
Erratic, Intermittent Or Incorrect
Fault Overview
This fault code sets when the Engine Control Module (ECM) detects an intermittent power supply voltage drop
that results in an internal reset to the Particulate Matter (PM) sensor within a calibrated period of time.
Lamp Reaction
Associated Faults
SPN 5569 FMI 2, 3, 4, and SPN 7393 FMI 19 SPN 7854 FMI 2
16
Fault Facts
None
Drive Cycles
Road Test
Possible Causes
• Open or high resistance in SWBAT circuit
• Open or high resistance in GND circuit

®
for SPN 7330 FMI 2.

Use EST with Navistar® Engine Diagnostics. Key On Engine Off (KOEO), check Yes: Go to Step 3.
DTC list for SPN 7330 FMI 2.
for SPN 7330 FMI 2.

connector housing.
FMI 2.
Step 4 Check PM sensor B+ circuits Decision

resistance between PM sensor
FMI 2.

Perform Test 2 (page 1873). Use DMM, measure voltage between Breakout Yes: Replace PM sensor. After
Harness 18-651-01 pin-2 and B+. repairs are complete, retest for
SPN 7330 FMI 2.
pin-2 and GND. After repairs are
FMI 2.
End Diagnostic Test


Tools Required
18-651-01
0000415073
Figure 608 PM Sensor Circuit Check
Test 1
A. Key OFF.
B. Disconnect Particulate Matter (PM) sensor harness.
C. Connect Breakout Harness 18-651-01 to vehicle harness and leave PM sensor disconnected.
2
18-651-01
0000415074
Test 2
A. Key OFF.
SPN 7392 FMI 8 - Engine Cold Start Fuel Injection Timing for All Cylinders : Abnormal Frequency Or
Pulse Width Or Period
Fault Overview
Fault codes sets Engine Control Module (ECM) detects a irregular shut off of the post injection cycle.
Lamp Reaction
Associated Faults
SPN 157 SPN 651 - 656 SPN 2797 FMI 11 SPN 2798 FMI 11
Fault Facts
None.

Continuous.
Possible Causes
• Loose or damaged fuel system electrical connector
• Fuel system failure

®
for SPN 7392 FMI 8.
connector housing.
7392 FMI 8.

fuel pump.
connector housing.
7392 FMI 8.

fuel rail.

connector housing.
7392 FMI 8.
Step 5 Check for failed fuel injectors. Decision

Perform Multiple Cylinder Cutout Test (page 2018), manually cutting out 5 cylinders Yes: Go to Step 6.
at a time.
Do all 6 cylinders hold desired RPM independently during testing? No: Replace failed fuel injectors
indicated by test and perform
Injector Quantity Adjustment
(IQA) (page 1941). After repairs
7392 FMI 8.
Step 6 Identify an under or over fueling fuel injector. Decision

for SPN 7392 FMI 8.

Did all valve train component(s) pass inspection? No: Go to Step 8.
Step 8 Verify fallen valve bridge did not damage valves, valve keepers, or valve Decision
stems.
Reinstall valve bridge and adjust lash (see Engine Service Manual). Verify engine Yes: Repair engine mechanical
can be rotated by hand. failure (see Engine Service
SPN 7392 FMI 8.
Was there valve damage or was engine Not able to be rotated by hand? No: Go to Step 9.

Remove oil pan and inspect cylinders for damage: such as bent rods, damage Yes: Repair damaged cylinders
to engine block, and/or engine sleeves. (see Engine Service Manual).
for SPN 7392 FMI 8.
Are any cylinders damaged? No: Go to Step 10.

Remove cylinder head and inspect cylinder(s) identified by Cylinder Balance Test for Yes: Clean and inspect Cylinder
a loss of compression. Such as bent valves, stuck rings, or a blown head gasket. head for reuse (see Engine
7392 FMI 8.
Is cylinder head and cylinders free of damage? No: Repair cylinder head and
cylinder damage (see Engine
7392 FMI 8.

SPN 7393 FMI 2 - Aftertreatment 1 Particulate Sensor Current : Data Erratic, Intermittent Or Incorrect
Fault Overview
This fault code sets when Engine Control Module (ECM) detects Particulate Matter (PM) Sensor Module has
had an intermittent power supply voltage drop resulting in 3 or more internal reset events within 10 minutes.
Lamp Reaction
Associated Faults
SPN 5569 FMI 2 SPN 5835 FMI 19 SPN 6778 FMI 3 or 4
Fault Facts
None
Drive Cycles
Road Test
Possible Causes

®
1878).
for SPN 7393 FMI 2.

SPN 7393 FMI 2.
Does EST DTC list SPN 7393 FMI 2 active? No: Repair other active faults.
for SPN 7393 FMI 2.

FMI 2.
Step 4 Check AFTSS PWR Circuit to PM Sensor Decision

and known good GND.
and AFT Smart Sensor Relay
Step 5 Check PM Sensor Module GND circuits. Decision

A. Perform Test 2(page 1882). Yes: Replace PM Sensor Module.
for SPN 7393 FMI 2.
and B+.
FMI 2.
End Diagnostic Test

Pinpoint Tests SPN 7393 FMI 2

Required Tools
18-651-01
0000415073
Test 1
A. Key-Off.
2
18-651-01
0000415074
Figure 611 PM Sensor Module GND Circuit Check
Test 2
A. Key-Off.
SPN 7393 FMI 10 - Aftertreatment 1 Particulate Sensor Current : Abnormal Rate Of Change
Fault Overview
This fault code sets when the Engine Control Module (ECM) detects Particulate Matter (PM) Sensor Module
signal is not valid.
Lamp Reaction
Associated Faults
Fault Facts
None
Drive Cycles
Road Test
Possible Causes

®
1883).

SPN 7393 FMI 10.

FMI 10.
End Diagnostic Test

SPN 7416 FMI 3 - Aftertreatment 1 Diesel Exhaust Fluid Pump Power Relay : Voltage Above Normal,
Fault Overview
Fault code sets when Engine Control Module (ECM) detects Diesel Exhaust Fluid Supply Module (DEFSM)
Relay Control voltage is above normal operating range.
Lamp Reaction
Associated Faults
None
Fault Facts
None

Continuous
Possible Causes
• DEFSM Relay CTL Short to PWR.

B. Check AFT PDM fuse(s) and relay(s) for blown fuses; loose, missing, or
connector. Perform SCR Fault
for SPN 7416 FMI 3.
Step 2 Check DEFSM Relay CTL for short to PWR. Decision

Perform Test 1 (page 1887). Use DMM, measure voltage from Breakout Box pin Yes: Repair Short to PWR
C1-05 and a known good GND. between ECM pin C1-05 and
DEFSM Relay pin 85. Perform
FMI 3.
Is voltage B+ ± 0.5 volts? No: End diagnostics. Perform
FMI 3.


Tools Required
Figure 612 DEFSM Relay CTL Voltage Check
Test 1
A. Key OFF.
B. Disconnect Engine Control Module (ECM) C1 connector.
D. Connect Breakout Harness 12-801-05-01 between ECM C1 connector and vehicle harness.
E. Key On Engine Off (KOEO).
SPN 7712 FMI 3 - Battery Potential / Power Input 3 : Voltage Above Normal, Or Shorted To High Source
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts

Continuous
Possible Causes
• DEF Supply Module Relay control circuit Shorted to PWR
• Engine Fan Solenoid control circuit Shorted to PWR
• DEFTHV Control circuit Shorted to PWR
• CSED control circuit Shorted to PWR

®
SPN 7712 FMI 3.
Step 2 Check DEF Supply Module Relay control circuit for short to PWR. Decision
Step 3 Check DEFTHV and CSED circuits for short to PWR. Decision
Step 4 Check Engine Fan Solenoid and Body Builder Connector 1 circuits for Decision
short to PWR.

connections.
FMI 3.
Step 6 Check DEF Supply Module Relay supply circuit for short to PWR. Decision
Remove DEF Suply Module Relay, Perform Test 1 (page 1893). Use Digital Yes: Repair the short to PWR
DEF Supply Module Relay Pin
for SPN 7712 FMI 3.


7712 FMI 3.

connector housing.
7712 FMI 3.
Step 9 Check DEFTHV circuit for short to PWR. Decision

Disconnect the DEFTHV connector, Perform Test 2 (page 1894). Use Digital Yes: Repair the short to PWR
DEFTHV pin-4. After repairs are
FMI 3.
Is the voltage less than 0.5 volts? No: Go to step 10.
Step 10 Check DEFTHV and CSED supply circuit for short to PWR. Decision
Disconnect the CSED Connector, Perform Test 2 (page 1894). Use Digital Yes: Repair the short to PWR
CSED pin-1. After repairs are
FMI 3.

B. Disconnect BBC1 connector.
C. Check BBC1 connector and connector terminals for: damaged or pinched
connector housing.
Are BBC1 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
7712 FMI 3.

B. Disconnect EFS connector.
C. Check EFS connector and connector terminals for: damaged or pinched
connector housing.
Are EFS connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
7712 FMI 3.
Step 13 Check Engine Fan Solenoid circuit for short to PWR. Decision
Disconnect the Engine Fan Soleniod, Perform Test 3 (page 1895). Use Digital Yes: Repair the short to PWR
Engine Fan Solenoid pin-B. After
SPN 7712 FMI 3.
Step 14 Check Engine Fan Solenoid and Body Builder Connector supply circuit Decision
for short to PWR.
Disconnect the Body Builder connector 1, Perform Test 3 (page 1895). Use Digital Yes: Repair short to PWR on
Multimeter (DMM), measure voltage between Pin C1-25 and a known good GND. chassis side of BBC1. After
SPN 7712 FMI 3.
for SPN 7712 FMI 3.


Tools Required
C2-11
0000428100
Figure 613 DEF Supply Module Relay Circuit Check
Test 1
A. Key OFF.
B. Connect Breakout harness 12-801-05-01 in between ECM C1, C2 chassis harness and ECM.
Test 2
A. Key OFF.
B. Connect Breakout harness 12-801-05-01 in between ECM C1 chassis harness and ECM.
C1-25
0000428096
Test 2
A. Key OFF.
SPN 7712 FMI 4 - Battery Potential / Power Input 3 : Voltage Below Normal, Or Shorted To Low Source
Fault Overview
Fault code sets when Engine Control Module (ECM) detects ECM PWR OUT 3 circuit voltage is less than 0.2
volts.
Lamp Reaction
Associated Faults
None
Fault Facts

Continuous
Possible Causes

®
SPN 7712 FMI 4.

connections.
FMI 4.
Step 3 Check DEF Supply Module Relay control circuit for short to GND. Decision
Remove DEF Suply Module Relay, Perform Test 1 (page 1900). Use Digital Yes: Go to step 4.
Multimeter (DMM), measure resistance between Pin C2-11 and a known good GND.
Is the resistance greater than 1 kΩ? No: Repair the short to GND
for SPN 7712 FMI 4.

7712 FMI 4.

connector housing.
7712 FMI 4.
Step 6 Check DEFTHV and CSED supply circuit for short to GND. Decision
Disconnect the DEFTHV and CSED connectors, Perform Test 2 (page 1901). Use Yes: Go to Step 7.
Digital Multimeter (DMM), measure resistance between Pin C1-01 and a known
good GND.

B. Disconnect BBC1 connector.
C. Check BBC1 connector and connector terminals for: damaged or pinched
connector housing.
Are BBC1 connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
7712 FMI 4.

B. Disconnect EFS connector.
C. Check EFS connector and connector terminals for: damaged or pinched
connector housing.
Are EFS connector, harness, and terminals clean and undamaged? No: Repair connector, harness,
7712 FMI 4.
Step 9 Check Engine Fan Solenoid and Body Builder Connector 1 supply Decision
circuit for short to PWR.
Disconnect the Engine Fan Soleniod, Perform Test 3 (page 1902). Use Digital Yes: End Diagnostics. Retest for
Multimeter (DMM), measure resistance between Pin C1-25 and a known good GND. SPN 7712 FMI 4.
Is the resistance greater than 1 kΩ? No: Go to step 10.
Step 10 Check Engine Fan Solenoid and Body Builder Connector 1 supply Decision
circuit for short to PWR.
Disconnect the Body Builder connector 1, Perform Test 3 (page 1902). Use Digital Yes: Repair short to GND on
Multimeter (DMM), measure resistance between Pin C1-25 and a known good GND. chassis side of BBC1. After
SPN 7712 FMI 4.
for SPN 7712 FMI 4.


Tools Required
C2-11
0000428095
Test 1
A. Key OFF.
B. Connect Breakout harness 12-801-05-01 in between ECM C1, C2 chassis harness and ECM.
C1-01
0000428089
Figure 617 DEFTHV and CSED Supply Circuit Check
Test 2
A. Key OFF.
C1-25
0000428091
Figure 618 Engine Fan Solenoid and Body Builder Connector 1 Supply Circuit Check
Test 2
A. Key OFF.
SPN 7713 FMI 3 - Battery Potential / Power Input 4 : Voltage Above Normal, Or Shorted To High Source
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None.

Continuous
Possible Causes
• ECM Power out 4 Shorted to PWR

®
SPN 7713 FMI 3.

connector.
housing.
7713 FMI 3.
Step 3 Check ECM Power Out 4 for short to power. Decision

between VGTA pin-3 and ECM
FMI 3.


Tools Required
Test 1
A. Key OFF.
SPN 7713 FMI 4 - Battery Potential / Power Input 4 : Voltage Below Normal, Or Shorted To Low Source
Fault Overview
Lamp Reaction
Associated Faults
None
Fault Facts
None.

Continuous
Possible Causes
• ECM Power out 4 Shorted to GND

®
SPN 7713 FMI 4.

connector.
housing.
7713 FMI 4.
Step 3 Check ECM Power Out 4 for short to ground. Decision

Is resistance greater than 1 kΩ? No: Repair short to GND between
VGTA pin-3 and ECM Pin E1-50.
for SPN 7713 FMI 4.


Tools Required
6016
0000428101
Test 1
A. Key OFF.
SPN 7854 FMI 2 - Aftertreatment 1 Diesel Particulate Filter Soot Sensor Module Data Erratic,
Intermittent or Incorrect
Fault Overview
This fault codes sets when Engine Control Module (ECM) detects Particulate Matter (PM) sensor module voltage
is within range, but not equal to ECM voltage.
Lamp Reaction
Associated Faults
None
Fault Facts
None
Drive Cycles
Continuous
Possible Causes
• SWBAT circuit Open or short to GND
• Failed PM sensor

7854 FMI 2.
1940).

connector housing.
FMI 2.

and known good GND.
pin-1 and AFT PDM Switched
Ignition Relay pin-87. After repairs
FMI 2.
Step 4 Check PM sensor GND circuits. Decision

A. Perform Test 2(page 1914). Yes: Replace PM sensor. After
SPN 7854 FMI 2.
and B+.
pin-2 and GND. After repairs are
FMI 2.
End Diagnostic Test

Pinpoint Tests (SPN 7854 FMI 2)

Required Tools
18-651-01
0000415073
Test 1
A. Key-Off.
2
18-651-01
0000415074
Test 2
A. Key-Off.
2 ENGINE SYSTEM TESTS AND INSPECTIONS 1915
Table of Contents
Navistar® Engine Diagnostic Software Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1919

Check for DTCs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1919
Connection and Data Recording. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1920
Crankshaft Position Sensor Relearn Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1926
DEF System Decontamination Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1929
Diagnostic Trouble Code Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1932
DOC/DPF Replacement/Reset Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1934
DPF Regeneration Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1936
Intermittent or Inactive Fault Diagnostic Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1940
Injector Quantity Adjustment (IQA). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1941
MAF Sensor Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1944
Obtain Vehicle Health Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1946
Programmable Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1947
Record Snapshot of KOEO Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1948
Session Files. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1950
Viewing Graphs of Recorded Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1952
SCR Fault Reset Request. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1955
Connecting EST with Navistar® Engine Diagnostics to Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1956

Interface Device Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1956
Connecting Navistar® Engine Diagnostic Software. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1959
Pinpoint Diagnostic Graphic Legend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1960
Service Bay Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1968

Engine Off Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1968
Actuator Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1968
Aftertreatment Purge Air Actuator Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1970
Cold Start System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1972
Continuous Monitor Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1974
DEF Dosing System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1978
DEF Line Heater Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1983
DEF System Leak Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1985
DEF Tank Heater Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1987
EGR Valve Position Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1989
VGT Position Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1991
Engine Running Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1993
AFT Dosing System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1993
AFT Fuel Enable Actuator Leak Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1995
AFT Hydrocarbon Doser Leak Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1996
Aftertreatment Dosing System Test Preparatory Steps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1997
Air Management Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2004
Cylinder Balance Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2010
Engine Fan Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2013
High Pressure Pump Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2014
Multiple Cylinder Cutout Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2018
1916 2 ENGINE SYSTEM TESTS AND INSPECTIONS
Road Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2020

0-60 MPH Road Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2020
Lug Down Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2021
Normal Exhaust Gas Temp Graph. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2022
Low-Pressure Fuel System Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2026

Fuel System Priming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2026
Start From Clean Fuel Source Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2032
Fuel Aeration Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2034
Fuel Restriction Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2038
High-Pressure Fuel System Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2043

Fuel Rail Pressure (FRP) Leak Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2043
Fuel Rail Pressure (FRP) Return Flow Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2047
HP Pump Fuel Return Flow Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2050
HP Pump Fuel Return Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2052
HP Pump Inlet Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2055
Cold Start System Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2058

Cold Start Fuel Igniter Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2058
Fuel Supply at Cold Start Enable Device Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2060
Fuel Supply at Cold Start Fuel Igniter Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2063
General Test Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2065

Electrical System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2065
Engine Cranking Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2078
Cable Drop Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2079
Crankcase Breather Oil Separator Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2083
Charge Air Cooler (CAC) Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2085
Crankcase Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2092
Smoke Test (Air Intake System). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2093
Smoke Test (Exhaust System). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2100
Smoke Test (Aftertreatment System). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2105
J1939 Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2112
Exhaust Restriction Isolation Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2114
Fuel Tank Vent Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2116
Coolant Test Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2117

Deaeration Tank Cap Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2117
Cooling System Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2120
Air Compressor Leaking Coolant to Oil Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2122
Air Compressor Leaking Air to Coolant Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2123
Aftertreatment Hydrocarbon Doser (AFTHD) Coolant Leak Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2124
EGR Cooler Leak Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2126
Thermostat Operational Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2136
Engine Oil Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2137

Oil Pressure Verification Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2137
Power Steering Fluid Leak to Engine Oil Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2141
Instrument Panel Engine Oil Pressure Gauge Validation Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2142
Engine Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2144

Engine Compression Brake ECM Inputs and Programmable Parameter Checks. . . . . . . . . . . . . . .2144
Engine Compression Brake Operational Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2148
Engine System Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2151

Initial Key On Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2151
Fuel Level and System Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2152
Fuel Quality Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2156
Engine Oil Level and Quality Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2158
Coolant Level Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2159
Coolant Quality Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2160
Coolant in Exhaust Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2161
Coolant to Oil Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2162
Cylinder Sleeve Cavitation and Crack Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2163
Charge Air Cooler Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2164
Intake Air Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2165
Exhaust and Aftertreatment System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2166
Oil in Intake Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2169
Oil and Crankcase Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2170
Oil Pump and Fan Drive Oil Leak Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2172
Cylinder Head, Valve train, and Engine Brake Housing Oil Leak Inspection. . . . . . . . . . . . . . . . . . . . .2174
Engine Brake Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2180
Turbocharger Radial Play Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2183
Internal Engine Damage Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2184
Valve Train Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2188
Connecting Rod, Main Bearing, and Journal Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2192
Davco® Fuel Pro 382 Fuel Filter Check Valve Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2196
Batteries and Electrical System Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2198
Aftertreatment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2203
Aftertreatment Fuel Supply Module Inlet Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2203
Aftertreatment Hydrocarbon Doser (AFTHD) Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2206
Decomp Mixer Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2208
DEF Doser Valve Inlet Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2209
DEF Doser Valve Outlet Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2212
DEF Head Unit Coolant Line Routing Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2215
DEF Level Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2217
DEF Supply Module Inlet Restriction Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2218
DEF Supply Module Outlet Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2221
DEF Supply Module Suction Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2224
DEF Quality Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2228
DEFTHV Coolant Flow Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2230
DOC Cleaning Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2231
DOC Inspection and Reuse Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2240
DPF Inspection and Reuse Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2247
DPF Replacement After Boost System Leak or Over Temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2263
Hot Run Sensor Comparison Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2267
Forced Active Regeneration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2268
SCR Catalyst Inspection and Reuse Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2270
SCR Cleaning Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2277
Snap Acceleration Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2281
Navistar® Engine Diagnostic Software Procedures

Check for DTCs
Navistar® Engine Diagnostic Software displays Diagnostic Trouble Codes (DTC)s at the bottom of the screen.
Figure 623 DTC display
Procedure:
Navistar® Engine Diagnostic Software will update DTC status every 10 seconds and will check for DTCs as
soon as the Refresh DTC/Vehicle Events button (Figure 623) is pressed.
Connection and Data Recording
Overview
Navistar® Engine Diagnostic Software is an Engine Electronic Control System Diagnostic Tool. It is used to view
Diagnostic Trouble Codes (DTCs) stored in the Engine Control Module (ECM), perform various Service Bay
Tests, Procedures, and Program engine features. It can also monitor and record signals from the ECM.
Engine Auto-Detection
The International® A26 engine is able to auto-connect at KOEO or engine running. The only difference when
connecting with a running engine is most of the parameters will not load. You will also notice a 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.
Tools Required
Equipment Condition
None
Test Setup
Figure 624 Navistar® Engine Diagnostic Software Default Session
NOTE: Key-On Engine-Off (KOEO) will load signals and parameters.
Key-On Engine-Running (KOER) will load signals, but will not load parameters.
1. Connect Electronic Service Tool (EST) with Navistar® Engine Diagnostic Software to vehicle Diagnostic
Connector .
2. Start Navistar® Engine Diagnostic Software.
Figure 625 Engine Selection Window
NOTE: If Navistar® Engine Diagnostic Software displays the Engine selection window (Figure 625), 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.
Snapshot Recording Procedure
Figure 626 Start Signal Recording

1. Start logging watched signals to a log file button
1. Click on the Start logging watched signals to log a file button (Figure 626) (Item 1).
Figure 627 Stop Signal Recording

1. Stop logging watched signals to a log file button
2. Click on the Stop logging watched signals to a log file button (Figure 627) (Item 1) to stop the recording.
Figure 628 Snapshot folder
3. Snapshot recording will be saved in the Snapshot folder (Figure 628) located on your computers desktop.
Snapshot Playback Procedure
Figure 629 Snapshot Selection
1. Open previously recorded snapshot, Click on the Open Snapshot Recording File (Figure 629) from the File
Menu.
2. Select the desired recording you wish to open.
Figure 630 Snapshot Recording Playback
3. Once the recording is open, you can select any signal you wish to show up in the graph.
Crankshaft Position Sensor Relearn Procedure
Overview
After diagnosing and repairing Crankshaft Position (CKP) sensor, Camshaft Position (CMP) sensor, and base
engine concerns, CKP position parameter has to be reprogrammed.
Tools Required
Equipment Condition
None
Test Setup
1. Key On Engine Off (KOEO)
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector (page 1956).
3. Log in to Navistar® Engine Diagnostics.
4. Clear Diagnostic Trouble Codes (DTC) if any are displayed.
Test Procedure
Figure 631 Sessions Drop Down Menu
1. Select Sessions > Programming (Figure 631).

Figure 632 Service Interval Tab and Parameter Values
2. Select Service Interval Tab (Figure 632).

3. Change Parameter Value 95232 CKP Crankshaft Position Learning Reset Request (Figure 632) to Yes.
Figure 633 Program Engine Button
4. Click Program Engine Button (Figure 633).
Figure 634 Engine Parameters Programmed Successfully Popup Box
5. When Engine Parameters Programmed Successfully (Figure 634) pop up box appears, turn Key Off for a
minimum of 15 seconds.
6. Turn Key On.

7. Clear any Diagnostic Trouble Codes (DTC).
8. Road test vehicle. During road test several decelerations will be needed to ensure proper functionality of
vehicle. Increase engine speed to 1600 RPMs or greater then decelerate the engine speed below 1000
RPMs. Repeat 4 times.
9. Return back to the testing facility and let vehicle idle for 5 minutes.
Expected Outcome
Engine will program successfully.
Follow-On Procedure
None
DEF System Decontamination Procedure
Overview
DEF system decontamination procedure should be used any time contamination is found in the DEF system.
CAUTION:
Do not disconnect vehicle batteries, DEF Supply Module connector, or any DEF lines
until the DEF dosing system has completed its cool down and purge cycles. Wait will
be variable between 30 seconds and 15 minutes depending exhaust temperature at shut
down. Wait until no sound is heard coming from the DEF Supply Module after Key OFF
for the DEF dosing system to complete the cool down and purge cycles.
Tools Required
• Cap & Plug Set ZTSE4891
Equipment Condition
None
Test Setup
1. Remove DEF Supply Module from vehicle (see appropriate vehicle Technician Manual). Replace DEF
Supply Module if physical damage, cracks or external leaks are found.
2. Using Cap & Plug Set ZTSE4891, install protective caps on the fluid connector(s) and the electrical
connector on the DEF Supply Module.
Test Procedure
1. With DEF supply module removed, clean the DEF supply module using only warm water and a soft bristled
brush. Thoroughly clean the areas surrounding the inlet and outlet DEF connectors and main filter cap.
0000430081
Figure 635 DEF Supply Module Filter

1. DEF supply module
2. DEF supply module filter
3. DEF supply module filter cover
4. DEF supply module filter housing
2. Remove DEF Supply module filter from supply module.

3. Inspect the filter for signs that the contaminated fluid went through the dosing system.
• If the contaminated fluid did not go through the dosing system, drain the DEF tank and flush with distilled
water. Replace both DEF tank filter and supply module filter. After the DEF tank has been cleaned, fill
the tank with new and/or known good DEF.
• If the contaminated fluid did go through the dosing system, go to next step.
4. Drain the DEF tank. Thoroughly flush with distilled water.
5. Clean and flush the DEF head unit and filter with distilled water. Replace the DEF tank filter, if necessary.
6. Remove all of the aftertreatment DEF lines and flush with distilled water.
7. Remove the DEF supply module inlet screen (located behind the DEF supply module inlet fitting). Replace
both DEF supply module inlet screen and main filter.
Expected Outcome
DEF system contamination will be removed from system.
Follow-On Procedure
1. Reinstall the DEF supply module on vehicle.
2. Reinstall all DEF lines.
3. Fill the tank with new and/or known good DEF.
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 636 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.
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.
DOC/DPF Replacement/Reset Procedure
Overview
The Aftertreatment (AFT) maintenance provides the ability for a technician to install/reset maintenance
components. An example would be a new or clean Diesel Oxidation Catalyst (DOC) or Diesel Particulate Filter
(DPF). Once a DOC is considered by the Engine Control Module (ECM) to be “Face Plugged”, AFT dosing is
disabled. After the DOC is replaced, the technician would need to reset the value to clean in order to enable
dosing and re-initiate active regeneration. In order to prevent the misuse of this feature, the reset shall only be
available when most severe fault conditions exist on the particular AFT component that is being reset. The
DPF Replacement reset allows the user to reset ash accumulators within the ECM after the DPF has been
replaced or cleaned.
Tools Required
Equipment Condition
None
Test Setup
1. Key On Engine Off (KOEO).
2. Connect EST to Vehicle Diagnostic Connector (page 1956).
3. Key On, log into Navistar® Engine Diagnostics.
Procedure
1. Replace the failed part indicated by the diagnostics.
2. Verify that one of the following active Diagnostic Trouble Codes (DTCs) are present SPN 3556 FMI 18, SPN
3936 FMI 0 or SPN 5298 FMI 18
• If DTCs are present, go to Step 3.
• If DTCs are not present, go to Step 8.
•
3. Go to Procedures > KOEO Procedures > Service Diagnostic Resets.
4. Select AFT Maintenance tab.
5. Press the Reset - AFT Maintenance button.
6. Once Programming is complete, turn key OFF until ECM is fully powered down (approximately 30 seconds)
or until EST loses connection with ECM.
7. Key ON, clear DTCs and got to Step 8.
8. Go to Procedures > KOEO Procedures > Service Diagnostic Resets.
9. Select DPF Replacement tab.
10. Press the Reset - DPF Replacement button.
11. Once Programming is complete, turn key OFF until ECM is fully powered down (approximately 30 seconds)
or until EST loses connection with ECM.
12. Key ON, clear DTCs.
Expected Outcome
EST will reset DOC and DPF accumulators within the ECM software after parts have been replaced.
Follow-On Procedure
None
Overview
A parked Diesel Particulate Filter (DPF) regeneration cleans the DPF while monitoring Aftertreatment system
operation.
WARNING:
To prevent personal injury or death, set parking brake, shift transmission to park or
neutral, and block wheels.
Tools Required
Equipment Condition
1. Engine Speed (low idle).
2. Engine Coolant Temperature above 120° F (49° C).
3. Accelerator Pedal Position (APP) 0% (pedal released).
4. Brake switch released.
5. Parking break set.
6. No Inhibitors.
7. Vehicle Speed 0 MPH (Not Moving)
Test Setup
Procedure
1. Start engine and allow engine coolant temperature to reach above 120° F (49° C).
Figure 637 Select Test
2. Select Tests > KOER Aftertreatment Tests > DPF Regeneration. Follow on-screen instructions.
Figure 638 DPF Regeneration Inhibitors
3. Verify DPF Regeneration entry conditions are met and DPF regeneration inhibitors (Figure 638) are not
inhibited.
• If regen inhibitors are displayed as inhibited, refer to Check Regen Inhibitors (page 1938) table.
Check Regen Inhibitors

Check Expected Results Comment
AFT Regen Inhibit - PTO Not Inhibited If inhibited, ensure Power Takeoff control is
Active 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 120°F (49°C)
AFT Regen Inhibit - Inhibit Not Inhibited If inhibited, ensure Regen Inhibit Switch is in the
Switch OFF position and there are no active fault
codes with switch. Diagnose and repair active
fault codes before running DPF regeneration.
AFT Regen Inhibit - Out of Not Inhibited If inhibited, ensure transmission is in park or neutral.
Neutral
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.
AFT Regen Inhibit - Not Inhibited If inhibited, run engine until all exhaust temperatures
Low Exhaust Gas reach DPF regen target temperature.
Temperature
4. Select the “Start Recording” button when ready to begin test procedure.
Figure 639 Start DPF Regeneration

5. Select “Start DPF Regeneration”.

6. Engine Speed will ramp up to increase exhaust flow through DPF. Monitor all exhaust temperature readings
in EST. As exhaust temperatures rise Aftertreatment fuel injection will begin dosing fuel into the exhaust.
DPF soot load will begin to decrease as DPF temperatures rise.
7. When procedure completes, Select “Stop Recording”.
Expected Outcome
Exhaust temperature will rise and soot load will decrease. Exhaust temperatures should closely follow Normal
Exhaust Gas Temp Graph (page 2022).
Follow-On Procedure
None
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
• J1939–compliant interface cable
Equipment Condition
None
Test Setup
1. Key-On, Engine-Off (KOEO).
3. Log in to Navistar® Engine Diagnostic Software.
Procedure
1. Verify health report was saved. Clear fault codes.
2. Hit Record button in Navistar® Engine Diagnostic Software.
3. Continuous Monitor Test (page 1974) and view voltage signal for suspect sensor.
• The continuous monitor test will have you watch voltage signals for voltage spikes while wiggling affected
harness and connections.
• A voltage spike while performing continuous monitor wiggle test indicates a damaged harness and/or
connector pin.
4. Stop recording and review snapshot file.
5. If voltage spike or fault occurs during continuous monitor wiggle test start from point 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
Injector Quantity Adjustment (IQA)
Overview
Calibrate Engine Control Module (ECM) for newly installed injectors. Each injector is encrypted with an Injection
Quantity Adjustment (IQA) code that must be programmed into the ECM anytime an injector has been replaced.
IQA injects the correct amount of fuel for each individual injector throughout the operating range of the engine.
Injector mechanical tolerances, high flow, and low flow can be evenly balanced with the ECM calibration.
Special Tools
Equipment Condition
None
Test Setup
1. Turn ignition switch to ON, engine OFF.
2. Connect Electronic Service Tool (EST) to Vehicle Diagnostic Connector and launch Navistar® Engine
Diagnostic Software. (page 1956).
Procedure
Figure 640 Injector Quantity Adjustment procedure
1. Select Injection Quantity Adjustment (Figure 640) from Procedures drop-down menu.
Figure 641 Picture of IQA code location
2. Type in new IQA code (stamped on top portion of injector) (Figure 641) into proper cylinder location.
Figure 642 Injector Quantity Adjustment
3. When the Undo button appears, the Program Engine button becomes active. Press the Program Engine
(Figure 642) button.
4. Replace failed injector following procedures in the Engine Service Manual.
Expected Outcome
ECM will have correct fuel injector calibrations.
Follow-on Procedure
None
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 will calibrate the sensor.
Special Tools
• Electronic Service Tool (EST) with Navistar® Engine Diagnostics.
Equipment Condition
• Engine speed at low idle
• Accelerator Pedal Position (APP) at 0%
• Brake pedal released
• EGR Valve Position less than 100%
• Engine Coolant Temperature (ECT) between 160° F (71° C) and 248° F (120° C).
• Engine Oil Temperature (EOT) between 32° F (0° C) and 248° F (120° C)
• Intake Manifold Temperature (IMT) between 32° F (0° C) and 302° F (150° C)
• Parking Brake Set
• Vehicle Speed is 0 MPH
• Intake system is correctly installed and there is no leaks
• Vehicle’s hood closed and latched
• All front and rear HVAC systems turned Off
Test Setup
1. Ensure ECM has no fault codes besides the SPN 132 FMI 13.
2. Ensure entire intake system is correctly installed and there is no leaks. Perform Smoke Test (Air Intake
System) (page 2093) to check for leaks and repair as needed.
3. Close and latch the vehicle’s hood.
4. Ensure all Front and Rear HVAC systems are turned Off. Extra engine load caused by the HVAC system
or engine fan can skew the results of the MAF sensor calibration procedure.
5. Ensure shop exhaust hoses are not attached to vehicle during MAF Calibration. Shop exhaust fans can
skew the results of the MAF sensor calibration procedure. Perform this procedure outside if needed.
6. Connect Electronic Service Tool (EST) to Vehicle Diagnostic Connector (page 1956).
7. Key On Engine Off (KOEO), log into Navistar® Engine Diagnostics.
Procedure
1. Start engine and run to operating temperature of 160° F (71° C).
2. Select Procedures > KOER Procedures > MAF Sensor Calibration to load procedure session.
3. Record the values of Programmable Parameters (PP) 62210 MAF Trim Calibration A and 62220 MAF Trim
Calibration B BEFORE running procedure. Parameters are displayed in the upper right of the MAF Sensor
Calibration session under the Parameters tab.
4. When ready, Start Recording Snapshot.
5. Select “Start MAF Sensor Calibration”. Procedure will run through entire RPM range. Only one MAF
calibration attempt is allowed per key cycle. If test fails from a missed entry condition, key will need to be
cycled Off for 30 seconds, or until the ECM fully powers down before turning Key On and trying again.
6. When the procedure completes, select Stop Recording Snapshot.
7. Fault code SPN 132 FMI 13 should change status to Previously Active if present.
8. Record the values of PP 62210 MAF Trim Calibration A and 62220 MAF Trim Calibration B AFTER running
the procedure.
• If Parameters 62210 MAF Trim Calibration A and 62220 MAF Trim Calibration B do not change from
Step 3 to Step 8, open a case file for assistance in resetting the PPs.
9. Clear fault codes and turn key OFF. Allow ECM to fully power down.
Expected Outcome
MAF Sensor Calibration will run successfully and fault code SPN 132 FMI 13 status will change to Previously
Active and can be cleared after calibration is complete.
Follow-On Procedure
None
Obtain Vehicle Health Report
Overview
Connect Electronic Service Tool (EST) with Navistar® Engine Diagnostic Software 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 Navistar® 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 to vehicle Diagnostic Connector
(page 1956).
3. Use PocketMaxx™, EST, or EZ-tech Launcher to retrieve a vehicle Health Report.
4. Connect to internet and upload Health Report to Navistar® Service Portal.
5. Verify Health Report is visible on Navistar® Service Portal. Select Write Up > Vehicle Information.
Expected Outcome
Current vehicle Health Report is viewable on Navistar® Service Portal.
Follow-On Procedure
None
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 Diagnostic Software, load the Programming session.
Special Tools
Equipment Condition
None
Test Setup
1. Key-On Engine-Off (KOEO)
Procedure
1. Select Parameters to view all Parameters sorted into categories.
2. Click on the desired parameter value to be changed.
3. Press the Program Engine Button.
4. When programming is successful, turn Key OFF for minimum of 30 seconds or until the ECM powers down.
5. Turn Key ON.
6. Clear Diagnostic Trouble Code (DTC)s, if any.
Expected Outcome
None
Follow-On Procedure
None
Record Snapshot of KOEO Data
Overview
Record Key-On Engine-Off (KOEO) data to be referenced now, and in the future.
Special Tools
Equipment Condition
1. Do not crank or run engine for 3 minutes or more to allow fluid pressures to stabilize.
Test Setup
1. Key-On Engine-Off.
Procedure
Figure 645 Start Recording

1. Start Recording button
1. From the default Session, select Start Recording button.

2. Wiggle harness sensor and actuator connections and the Engine Control Module (ECM) connectors.
Figure 646 Stop Recording

1. Stop Recording button
3. Select Stop Recording when finished.
Expected Outcome
KOEO values will be within specification.
Follow-On Procedure
None
Session Files
Overview
Navistar® Engine Diagnostic Software has a variety of Sessions; Signal Monitoring, Engine Programming and
Service Bay Testing.
Service Bay Test and Procedures will automatically load pre-made default sessions. Users are not limited to
using pre-made default sessions. Sessions (Figure 647) can be built or modified, saved and loaded (Figure 648)
at any time. The operator can use their own saved session to run a Service Bay test as long as the check mark
is removed from the Load Test Specific Session (Figure 649) prior to running the test.
Figure 647 Menu – Save Session
Figure 648 Menu – Load Session

Figure 649 Menu – Load Test Specific Session

Viewing Graphs of Recorded Data
Overview
Graph data using Navistar® Engine Diagnostic Software. View recorded data, and save or print screenshots of
playback.
NOTE: ServieMaxx™ snapshots can be viewed at any time by selecting Open Recorded Signal File from the
File drop-down menu or through the desktop Snapshots folder.
Special Tools
• J1939-Compliant Interface Cable
Equipment Condition
Navistar® Engine Diagnostic snapshot is saved to Snapshot folder on desktop of EST.
Test Setup
Procedure
Figure 650 Menu – Open Snapshot Recording File
1. File > Open Snapshot Recording File.
Figure 651 Opening Snapshot File
2. Select a previously recorded file from the Open window.

Figure 652 Recorded Signal Playback
3. Select which signal(s) to view by clicking on the Graph boxes.

4. With parameters selected, there are multiple options to view the snapshot:
• Press Play
• Drag bar across to play snapshot at desired speed
• Utilize Play, Fast Forward, Rewind, or click Play again during snapshot viewing to Pause playback
5. Click Show Graphed Only box allows technician to view selected parameter(s) only, without other parameters
being displayed. Show Graphed Only box not checked will display all parameters again.
6. Click Save Screenshot as JPG button to save your screenshot as a picture file at any point during recording.
A dialog box will display showing location of saved screenshot picture file. Click OK to save.
7. Click Print Screenshot button to print. Choose printer and select OK.
Expected Outcome
Technician will be able to view captured graph data, and save or print screenshots.
Follow-On Procedure
None
Overview
After diagnosing and repairing Selective Catalytic Reduction (SCR) faults, SCR Faults Reset Parameter will
have to be reprogrammed to remove any warning lamps and derate conditions.
Special Tools
Equipment Condition
None
Test Setup
2. Connect Electronic Service Tool (EST) with Navistar® Engine Diagnostic Software (page 1956) to vehicle
Diagnostic Connector and log in.
Procedure
1. Select: Clear DTCs button.
2. Select: Sessions > Programming.
3. Select: Service Interval tab.
4. Change Programmable Parameter “SCR Faults Reset Request” value from 0 to 1.
5. Select: Program Engine Button.
6. When programming is successful, turn Key OFF for minimum of 30 seconds or until the ECM powers down.
7. Turn Key ON.
8. Clear any Diagnostic Trouble Codes (DTCs).
Expected Outcome
Engine will program successfully and SCR fault inducements will be reset.
Follow-On Procedure
None
Connecting EST with Navistar® Engine Diagnostics to Engine

Interface Device Selection
To connect Electronic Service Tool (EST) with Navistar® Engine Diagnostics to engine, the Interface cable
(RP1210B compliant supporting J1939 and J1708) must be connected between EST and vehicle diagnostic
connector. The vehicle diagnostic connector is located inside vehicle cab, above clutch pedal.
1. Using Interface cable, connect EST (Electronic Service Tool) to vehicle’s diagnostic connector.
2. Start Navistar® Engine Diagnostics.
Figure 653 Com Link Selection Drop Down Menu
3. Select Com Link (Figure 653).

Figure 654 Com Link Activation Drop Down Menu
4. Activate Com Link (Figure 654) for interface cable connection.

If Navistar® Engine Diagnostic Software fails to auto connect, use the following procedure:
5. From Tools drop-down menu, go to Select Com Link (Figure 653).
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 being used (provided from cable manufacturer).
If cable is not at fault, see J1939 Data Link Error (ECM unable to transmit) (page 525) in Fault Code Diagnostics
section of this manual.
Connecting Navistar® Engine Diagnostic Software

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), 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 655 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 656 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 section, above.

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 657 Breakout Harness

Figure 658 ZTSE4498 – 3–Banana Plug Harness

Figure 659 ZTSE4497 — 500 Ohm Resistor

Figure 660 Ohm Meter

Figure 661 Volt Meter

Figure 662 ECM (Engine Control Module) 180 Pin Breakout Harness Overlay
Figure 663 ACM (Aftertreatment Control Module) 180 Pin Breakout Harness Overlay
Figure 664 Battery

Service Bay Tests

Engine Off Tests
Actuator Test
Overview
The Key-On Engine-Off (KOEO) Actuator Test enables technicians to cycle any actuator to high or low states, and
some actuators have variable positions. Technicians can use a Digital Multimeter (DMM) to measure changes
in voltage or duty cycle, or visually monitor actuator movement while actuator is commanded. This test does not
display pass or fail results.
Tools Required
Test Setup
Test Procedure
Figure 665 Menu – Select Test
1. Select Tests > KOEO Tests > Actuator Test (Figure 665) .
Figure 666 Actuator Control Panel
2. Select desired actuator from control panel (Figure 666).

3. Adjust amount of duty cycle you wish to control.
4. Adjust delay test start time, if a delay start time is desired.
5. Press the Start Test button to begin the test.
6. Actuator will cycle to commanded position.
Expected Outcome
The test will complete successfully.
Follow-On Procedure
None
Aftertreatment Purge Air Actuator Test
Overview
This test check the function of the Aftertreatment Purge Air Actuator (AFTPAA).
Tools Required
Equipment Condition
Vehicle air tanks full.
Test Setup
2. Connect Electronic Service Tool (EST) with Navistar® Engine Diagnostics (page 1956).
Test Procedure
Figure 667 Selecting AFT Actuator Test
1. Before starting the test, AFT Fuel Pressure (AFTFP) must be lower than vehicle air pressure. Verify AFTFP
signal value is below 50 psi (345 kPa).
• To reduce AFTFP prior to running the test, select Tests > KOEO Aftertreatment Tests > AFT Actuator Test,
then select AFT Hydr Doser from top of menu screen. Select the Start Test button as many times as needed
to reduce the AFTFP below 50 psi (345 kPa).
2. Go to Tests > KOEO Aftertreatment Tests > AFT Actuator Test.
Figure 668 AFT Actuator Test Control Panel
3. Set desired delay time, and press Start Test button.

4. Monitor AFTFP signal value during test. AFTFP should increase to approximately vehicle air pressure.
• If AFTFP increased to approximately vehicle air pressure, AFTPAA and AFTFP are working properly.
• If AFTFP does not increase to approximately vehicle air pressure, go to step 5.
5. Disconnect air line between AFTPAA and AFT Fuel Doser Module.
6. Set desired delay time, and press Start Test button in Navistar® Engine Diagnostics.
7. Listen and(or) feel for vehicle air pressure exiting AFTPAA. When test is active vehicle air pressure will be
continuously leaking from AFTPAA.
Expected Outcome
AFTFP signal value should increase to approximately vehicle air tank pressure.
Follow-On Procedure
Reinstall any removed air lines
Cold Start System Test
Overview
The Cold Start System Test is used to activate the Cold Start System when ambient temperatures are above
normal Cold Start activation temperatures.
Tools Required
• Interface Cable (RP1210B-compliant, supporting J1939 and J1708)
Equipment Condition
None
Test Setup
Test Procedure
1. Select Tests > KOEO Tests > Cold Start System Test.
2. When ready, select the “Start Cold Start System Test”.

3. The Wait to Start Lamp (WTSL) will illuminate solid, start engine once WTSL begins to flash. The Lamp:
Wait to Start signal will switch to Off in the EST.
4. After engine has started, Cold Start Enable Device (Fuel Solenoid) will open allowing fuel flow to the Cold
Start Fuel Igniter (CSFI).
5. Monitor Intake Manifold Temperature (IMT) sensor signal for a rise in temperature during test.
Expected Outcome
On a cold engine, Intake Manifold Temperature should raise at least 10° F (6° C) before the test completes.
Follow-on Procedure
None
Continuous Monitor Test
Overview
The Key-On Engine-Off (KOEO) Continuous Monitor 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 momentary 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 too high or too
low. The Continuous Monitor Test will force all sensor voltage to display actual voltages. Signals that display N
/ A are not available or not enabled on selected engine.
Figure 671 KOEO Continuous Monitor Test Home Screen
Position Sensor Voltages are Monitored:

• Accelerator Pedal Position 1
• Accelerator Pedal Position 2
• Remote Pedal Sensor (If equipped)
• Diesel Exhaust Fluid (DEF) Tank Level
Pressure Sensor Voltages are Monitored:

• Aftertreatment (AFT) Fuel Pressure
• Barometric Absolute Pressure
• Diesel Particulate Filter (DPF) Differential Pressure
• DPF Outlet Pressure
• Engine Oil Pressure
• Fuel Delivery Pressure
• Fuel Rail Pressure
• Intake Manifold Pressure
• Exhaust Back Pressure
Temperature Sensor Voltages are Monitored:

• Ambient Air Temperature
• CAC Outlet Temperature
• Engine Coolant Temperature
• Engine Oil Temperature
• Exhaust Gas Recirculation Temperature
• Intake Air Temperature
• Intake Manifold Temperature
• Turbocharger Compressor Outlet Temperature
• Engine Exhaust Temperature
Other Voltage Signals Monitored:

• Switched Battery
Tools Required
Equipment Condition
None
Test Setup
2. Connect Electronic Service Tool (EST) with Navistar® Engine Diagnostic Software to Vehicle Diagnostic
Log in to Navistar® Engine Diagnostic Software.
Test Procedure
1. Select Continuous Monitor Test (Figure 672) from drop down menu.
Figure 673 Start Signal Recording

1. Start recording button
2. Select the Record button to record the test results.
Figure 674 Voltage Spike
3. Monitor suspect voltage signal while wiggling the wiring harness and connectors. If the circuit is interrupted,
the signal will spike.
Figure 675 Stop Test Button
4. Test will run until cancelled by pressing the Stop test button (Figure 675).
Figure 676 Stop Signal Recording

1. Stop recording button
5. Select the Stop recording button. Review the recorded signal file for voltage spikes.
Expected Outcome
No intermittent faults or voltage spikes detected.
Follow-on Procedure
None
DEF Dosing System Test
Overview
Validates performance of the Diesel Exhaust Fluid (DEF) dosing system, based on the amount of DEF flow for
a fixed amount of time.
Tools Required
• Diesel Exhaust Fluid (DEF) extension kit, Part Number 5299873 (Obtain from Cummins)
• Graduated cylinder (with individual milliliter or ounce markings)
• Air and Fuel Cap and Plug Kit ZTSE4891
Equipment Condition
DEF tank level above half full.
Test Setup
WARNING:
To prevent personal injury or death, avoid contact with Diesel Exhaust Fluid (DEF) / urea.
Do not get DEF in eyes. In case of eye contact, immediately flush eyes with large amounts
of water for a minimum of 15 minutes. Do not swallow. If DEF is ingested, contact a
physician immediately.
1. Key Off.
2. Check Diesel Exhaust Fluid (DEF) tank, DEF supply module, and DEF Doser Valve (DEFDV) lines and
connections for: cracks and pitting; loose, leaking, or damaged connections; and restrictions.
• If the DEF tank, DEF supply module, or DEFDV lines and connections are damaged or restricted,
repair or replace the failed component, line, or connection.
3. Perform the DEF Quality Test (page 2228).
• If DEF is contaminated or urea concentration is not between 30 – 34 percent, drain the DEF tank,
flush with distilled water, and fill with new and / or known good DEF.
4. Disconnect DEFDV electrical connector and both DEF pressure and DEF return lines.
1 2
7 6 5 4
0000419122
Figure 677 Test Setup

1. DEF Pressure line
2. DEF backflow line
3. Exhaust harness
4. Harness extension 5299874
5. DEFDV mounting location
6. DEF backflow line extension 5299912
7. DEF pressure line extension 5299875
5. Remove 3 cap screws and DEFDV from exhaust.

6. Using extension kit 5299873, connect part number 5299874 between vehicle harness and DEFDV.
7. Using extension kit 5299873, connect part number 5299875 between DEF pressure line and DEFDV.
8. Using extension kit 5299873, connect part number 5299912 between DEF backflow line and DEFDV.
3
5
0000419123
Figure 678 Test Setup

1. Harness extension 5299874
2. DEF backflow line extension 5299912
3. DEF pressure line extension 5299875
4. Graduated cylinder
5. DEFDV
9. Place DEFDV into a graduated cylinder. When the test is being performed, the Aftertreatment DEFDV
will spray a very fine mist of DEF. To prevent fine mist from escaping into the air and to make sure of an
accurate measurement, place a clean shop towel or cover over the valve and container.
Test Procedure
1. Key On Engine Off.
4. Record the ECM Software ID.
• If the 6th digit is J or later, Continue to Step 5.
• If the 6th digit is between A and H, update ECM software using NavKal, then continue to Step 5.
5. Go to Tests > KOEO Aftertreatment Tests > DEF Dosing System Test.
6. With the DEFDV in the graduated cylinder, Select “Start DEF Dosing System Test”.
7. While test is running, monitor DEFDV spray pattern. DEFDV spray pattern should be a fine mist. If larger
drops, dripping, or a non-symmetrical spray pattern is present, stop the test and clean the DEFDV tip (see
appropriate Technician Manual). After cleaning is completed, restart the test.
8. After test is complete, measure DEF in graduated cylinder. One test will dose 10.1 ± 0.8 fl-oz (300 ± 25 ml).
9. Inspect collected sample for contamination or debris. If debris is found in sample, flush DEF system and
replace all system filters. Then restart the test.
10. Perform the test three times. Average all 3 readings and compare to specification: 10.1 ± 0.8 fl-oz (300 ±
25 ml).
• If one or more of the test results is below specification, clean the DEFD Valve (see Exhaust System
Service Manual) and rerun test.
• If one or more of the test results is above specification, replace the DEFD Valve.
• If test results vary above and below specification, replace the DEFD Valve.
Expected Outcome
DEF system will dose between 10.1 ± 0.8 fl-oz (300 ± 25 ml) during each individual test. DEF spray pattern will
be a fine mist.
Follow-On Procedure
• Reinstall DEF Doser Valve.
DEF Line Heater Test
Overview
The Key-On Engine-Off (KOEO) Diesel Exhaust Fluid (DEF) Line Heater Test is used to command DEF Line
Heaters ON, allowing a service technician to measure voltage output to DEF Line heaters while confirming
system is working correctly.
Tools Required
Equipment Condition
None
Test Setup
Test Procedure
1. Select Tests > KOEO Aftertreatment Test > Actuator Test (Figure 681). Follow on-screen instructions.
Figure 682 Actuator Tab
2. From the actuator control panel (Figure 682) select DEF Line Heaters.
3. Set desired time delay if needed.
4. Press Begin Test button to begin test.
Expected Outcome
All three DEF Line heaters will activate to check circuits for voltage.
Follow-On Procedure
None
DEF System Leak Test
Overview
Diesel Exhaust Fluid (DEF) System Leak Test is used to prime DEF system and hold pressure so the system
can be checked for leaks. This test does not display pass or fail results.
Tools Required
Equipment Condition
None
Test Setup
4. Leaving DEF Line and coolant lines attached, remove DEF Doser Valve and discard gasket.
Test Procedure
Figure 683 Menu – Select Test
1. Select Tests > KOEO Aftertreatment Tests > DEF System Leak.
2. Using EST, monitor DEF Pump (ID: 400158) signal.
• If DEF Pump signal reads “Error”, go to Step 3.
• If DEF Pump signal reads anything but “error”, go to Step 4.
3. Key Off, disconnect DEF Supply Module connector. Wait 60 seconds or until ECM powers down. Reconnect
DEF Supply module connector and turn Key On, KOEO.
• If DEF Pump signal still reads “Error”, replace DEF Supply Module and go to Step 4.
• If DEF Pump signal now reads anything but “error”, go to Step 4.
4. From the DEF System Leak test session, select Begin Test button.
5. Listen for pump noise. Pump should begin spinning, making pump noise, and creating pressure within 15-30
seconds after commanding test.
• If pump is not spinning or making noise, verify DEF Supply module is receiving PWR at Pin-2 and GND
at Pin-4. Repair any circuit issues, command the test again and go to step 6.
• If pump is spinning and making noise, continue to Step 6.
6. Inspect DEF system for leaks.
7. Inspect Doser Valve nozzle for any signs of leakage.
8. Test will run for 20 minutes, but can be cancelled at any time if a leak is identified.
Expected Outcome
Technician will check DEF system for leaks while test is running and system is pressurized. DEF Doser Valve
nozzle will be free of leaks.
Follow-On Procedure
Reinstall DEF Doser Valve and new gasket into decomposition reactor tube.
DEF Tank Heater Test
Overview
The Key-On Engine-Off (KOEO) Diesel Exhaust Fluid (DEF) Tank Heater Test is used to command the DEF tank
heater on, allowing a technician to measure the voltage output to the DEF tank heater control valve confirming
the system is working correctly.
Tools Required
• Interface Cable (RP1210B-compliant supporting J1939 and J1708)
Equipment Condition
None
Test Setup
Test Procedure
Figure 684 Test Selection
1. Select Tests > KOEO Aftertreatment Tests > Actuator Test (Figure 684). Follow on-screen instructions.
2. From the actuator control panel (Figure 685) select DEF Tank Heater Valve.
3. Adjust the desired test delay amount (Figure 685), if any delay is needed.
4. Press the Begin Test button (Figure 685) to begin the test.
Expected Outcome
DEF Tank Heater Valve will activate to check circuits for voltage.
Follow-On Procedure
None
EGR Valve Position Test
Overview
Determine if Exhaust Gas Recirculation Valve (EGRV) can meet commanded position and if it is sticking due to
debris or carbon build-up.
Tools Required
Equipment Condition
None
Test Setup
1. Key On Engine Off (KOEO)
Diagnostics (page 1956).
Test Procedure
Figure 686 Selecting Actuator Test
1. Select Tests > KOEO Tests > Actuator Test. Follow on-screen instructions.
2. From the actuator control panel select EGR Valve and set duty cycle to 100%.
3. Press the Start Test button and monitor the EGR Position (EGRP) signal to see if EGRV can meet
commanded position.
4. Repeat steps 2 and 3 with duty cycle set to 50%.
Expected Outcome
EGRV position will meet Navistar® Engine Diagnostic Software commanded position.
Follow-On Procedure
None
VGT Position Test
Overview
Determine if Variable Geometry Turbocharger (VGT) can meet commanded position.
Tools Required
Equipment Condition
None
Test Setup
2. Connect Electronic Service Tool (EST) with Navistar® Engine Diagnostics (page 1956) to vehicle
Diagnostic Connector and log in.
Test Procedure
1. Select Tests: KOEO Tests > Actuator Test. Follow on-screen instructions.
Figure 689 VGT Actuator Test
2. From Actuator Test select VGT Actuator tab and set duty cycle to 100%.
3. Set desired time delay if needed.
4. Press "Start Test" button.
5. Monitor both VGT Actuator Control and VGT Actuator Position signals.
6. Run test a second time with duty cycle set to 100%. Watch VGT actuator linkage under hood. Ensure
actuator linkage is moving smoothly and not binding or sticking.
7. Repeat steps 3 through 6, but set Duty Cycle to 50%.
Expected Outcome
If VGT has failed, a fault code will set during the test. VGT position will meet approximately Navistar® Engine
Diagnostics commanded duty cycle. Also, physical movement of VGT actuator linkage will move smoothly
through its range of travel without sticking or binding.
Follow-On Procedure
None
Engine Running Tests

AFT Dosing System Test
Overview
Determines the amount of fuel dispensed from the Aftertreatment Hydrocarbon Doser (AFTHD). The test will
open the AFTHD and Aftertreatment Fuel Enable Actuator (AFTFEA), and inject 225 to 500 ml of fuel within 2
minutes 30 seconds.
WARNING:
Tools Required
Equipment Condition
None
Test Setup
1. Do Aftertreatment Fuel Dosing Test Preparatory Steps (page 1997).
2. Start the engine and allow it to reach operating temperature.
Diagnostic Software. (page 1956).
Test Procedure
1. Go to > KOER Aftertreatment Tests > AFT Dosing System Test.

2. Under Value heading, select System Test.

3. Set the desired Delay Time and select Start Test.
4. Perform the test 3 times, and average all three test results. Average amount of fuel collected per test should
be between 225 and 500 ml. If fuel collected is within specification, clean and install AFTHD. If fuel collected
is not within specification, clean AFTHD and perform AFT Dosing System Test a second time. If average
amount of fuel collected is still below specifications, replace AFTHD.
Expected Outcome
Test will dispense between 225 and 500 ml per test when averaged.
Follow-On Procedure
None
AFT Fuel Enable Actuator Leak Test
Overview
This Test determines if the Aftertreatment Fuel Enable Actuator (AFTFEA) is leaking. The first time to purge all
remaining fuel from the Aftertreatment Hydrocarbon Doser (AFTHD) supply line. This test will open the AFTHD
and close the AFTFEA.
Tools Required
Equipment Condition
None
Test Setup
3. Connect Electronic Service Tool to Vehicle Diagnostic Connector.
Test Procedure
1. Go to Tests > KOER Aftertreatment Tests > AFT Fuel Dosing Test.
2. Under the Test Mode drop down, select Fuel Enable Actuator Leak Test.
3. Set the desired Delay Time and select Start Test. The first test will purge the fuel from the AFTHD supply
line.
4. Run the test a second time to confirm results.
5. After second test is completed, record results.
Expected Outcome
Less than 5 ml of fuel will be collected.
Follow-On Procedure
None
AFT Hydrocarbon Doser Leak Test
Overview
This Test determines if the Aftertreatment Hydrocarbon Doser (AFTHD) is leaking. The first time to purge all
remaining fuel from the Aftertreatment Hydrocarbon Doser (AFTHD) supply line. This test will open the AFTFEA
and close the AFTHD.
Tools Required
Equipment Condition
None
Test Setup
3. Connect Electronic Service Tool to Vehicle Diagnostic Connector.
Test Procedure
1. Go to Tests > KOER Aftertreatment Tests > AFT Fuel Dosing Test.
2. Under the Test Mode drop down, select Hydrocarbon Doser Leak Test.
3. Set the desired Delay Time and select Start Test. The first test will purge the fuel from the AFTHD supply
line.
4. Run the test a second time to confirm results.
5. After second test is completed, record results.
Expected Outcome
Less than 5 ml of fuel will be collected.
Follow-On Procedure
None
Aftertreatment Dosing System Test Preparatory Steps
Overview
Validates performance of the Aftertreatment (AFT) fuel dosing system by measuring how much fuel comes
out of the Aftertreatment Fuel Injector (AFTHD) in approximately 2 minutes 30 seconds while the AFTHD and
Aftertreatment Fuel Enable Actuator (AFTFEA) are commanded Open. The AFT Fuel Dosing Test has three
different modes:
• AFT Dosing System Test
• AFT Hydrocarbon Doser Leak Test
• AFT Fuel Enable Actuator Leak Test
Tools Required
• Coolant Management Tool KL5007NAV
• Aftertreatment Injector Test Kit 12-559-01
• Graduated Cylinder
• Air and Fuel Cap and Plug Kit ZTSE4891
Test Setup
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 the radiator cap 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.
• Pause for a moment to avoid being scalded by steam.
• Continue to turn the cap counterclockwise to remove.
Figure 692 Coolant Management Tool Connections

1. Air valve (closed)
2. Vacuum Module
3. BLUE vent valve
4. Cap Adapter
5. Deaeration tank
WARNING:
1. Remove deaeration tank cap and install Cap Adapter KL5004NAV (Figure 692) (Item 4) onto the
deaeration tank (Figure 692) (Item 5).
2. Connect Vacuum Module KL5005NAV (Figure 692) (Item 2) to Cap Adapter.
3. Verify both valves on the Vacuum Module are in the closed position, and attach clean dry shop air.
Figure 693 Air Valve (Open)

1. Air valve (open)
Test Procedure
1. Open air valve (Figure 693) (Item 1) on Vacuum Module, and allow 5 to 10 in. Hg to be drawn on the cooling
system.
Figure 694 AFTHD Harness and Connections

1. Aftertreatment Hydrocarbon Doser (AFTHD) connector
2. AFTHD connector mounting bracket
3. AFTHD harness fasteners (3)
2. Press release tab to disconnect wiring harness lead from AFTHD connector (Figure 694) (Item 1).
3. Disconnect AFTHD connector from AFTHD connector mounting bracket (Figure 694) (Item 2).
4. Disconnect three AFTHD harness fasteners (Figure 694) (Item 3).
Figure 695 AFTHD Connections (Disconnected)

1. Fuel supply line
2. AFTHD M6 mounting bolts (2)
3. Aftertreatment Hydrocarbon Doser (AFTHD)
4. Coolant supply line
5. AFTHD Coolant Line Plugs (2)
6. Coolant return line
5. Disconnect AFTHD fuel supply line (Item 1) from AFTHD, and use Air and Fuel Cap and Plug Kit ZTSE4891
to cap line.
6. Disconnect AFTHD coolant supply line (Item 4) and coolant return line (Item 6) at the AFTHD. Discard
O-rings.
7. Install two AFTHD Coolant Line Plugs (Item 5) onto coolant supply and return line.
8. Open the BLUE vent valve on the Vacuum Module to release vacuum on the cooling system.
9. Remove two AFTHD M6 mounting bolts (Item 2).
10. Remove AFTHD as an assembly from turbocharger exhaust outlet pipe. Discard metal gasket and fibrous
insulator. Some carbon build up is normal, do not clean until instructed.
Figure 696 AFTHD Block Off Plate and Bolts

1. AFTHD Block Off Plate Bolt (2)
2. AFTHD Block Off Plate
11. Install AFTHD Block Off Plate 12-559-01-05 (Item 2) onto turbocharger exhaust outlet pipe using two AFTHD
Block Off Plate Bolts 12-55-01-04 (Item 1).
Figure 697 AFTHD In Graduated Cylinder

1. Graduated cylinder 2. AFTHD Fuel Supply Extension 3. AFTHD Harness Extension
Line 12-559-01 12-559-01-06
12. Connect AFTHD Fuel Supply Extension Line 12-559-01 (Item 2) between AFTHD fuel supply line and
AFTHD.
13. Connect AFTHD Harness Extension 12-559-01-06 (Item 3) between vehicle harness and AFTHD connector.
14. Place AFTHD into a clear graduated cylinder (Item 1), large enough to contain the AFTHD, and marked in
milliliters.
15. Cover the AFTHD and graduated cylinder so fuel spray is contained.
Expected Outcome
Technician has setup truck to perform AFT Dosing System Test, AFT Hydrocarbon Doser Leak Test, and AFT
Fuel Enable Actuator Leak Test.
Follow-On Procedure
None
Air Management Test
Overview
This test is used to validate the Air Management System by monitoring effects of actuators and sensor signals.
During the test, Exhaust Back Pressure (EBP) should always be greater than Intake Manifold Pressure (IMP).
As Variable Geometry Turbocharger (VGT) position increases, IMP and EBP should also increase and decrease
as Exhaust Gas Recirculation (EGR) valve position is increased. A calculation will determine if Engine Intake
Air Mass Flow Rate decrease according to EGR valve position is within specification.
Tools Required
Equipment Conditions
1. Engine Speed - Low Idle
2. Engine Coolant Temperature - Above 100° F (38° C)
3. Parameter: 8203(X) Maximum Standstill Engine Speed - Above 1,700 rpm
4. Accelerator Pedal Position - 0%
5. Brake Switch - Released
6. Parking Brake - Set
Test Setup
1. Key OFF.
3. Key ON Engine OFF (KOEO), log in to Navistar® Engine Diagnostics.
4. Start engine and warm engine coolant temperature above 100°F (38°C).
Test Procedure
1. Select Tests > KOER Tests > Air Management Test.
2. Select the Start Recording (page 1948)button.
3. When ready, select Start Air Management Test.
4. When the tests completes, select Stop Recording (page 1948)button.
5. Open the snapshot recording to View graphs of recorded data (page 1952).Graph the following signals:
• EGR Valve Position
• Engine Intake Air Mass Flow Rate
• Engine Speed
• Exhaust Back Pressure
• Intake Manifold Pressure
• VGT Actuator Position
6. Compare results to the following graphs:
1 2 3 4
5
0000422393
Figure 698 Good Air Management Test Graph

1. Engine Speed (RED)
2. Exhaust Back Pressure (EBP) (LIGHT BLUE)
3. VGT Position (PINK)
4. EGR Position (GREEN)
5. Intake Manifold Pressure (IMP) (DARK BLUE)
Exhaust Back Pressure (EBP) should always be greater than Intake Manifold Pressure (IMP). As Variable
Geometry Turbocharger (VGT) position increases, IMP and EBP should also increase and decrease as
Exhaust Gas Recirculation (EGR) valve position is increased.
Figure 699 Good Air Management Test Graph

1. VGT Actuator Position (GREEN)
2. Engine Intake Air Mass Flow Rate (BLUE)
3. EGR Valve Position (RED)
As EGR valve position increases to approximately 100%, Engine Intake Air Mass Flow Rate should decrease
to its lowest point during the test.
7. To calculate MAF decrease, graph the following signals:
• EGR Valve Position
• Engine Intake Air Mass Flow Rate
Figure 700 MAF Rate Value and EGR Valve Position (Closed) Graph
1. Engine Intake Air Mass Flow Rate
2. Cursor
3. Engine Intake Air Mass Flow Rate Value
4. EGR Valve Position (Closed)
8. Drag the cursor to the middle of Engine Intake Air Mass Flow Rate line when the EGR Valve position is at
0% (closed).
9. Record the Engine Intake Mass Air Flow Rate Value.
Figure 701 MAF Rate Value and EGR Valve Position (Open) Graph
1. EGR Valve Position (Open)
2. Cursor
3. Engine Intake Air Mass Flow Rate Value
4. Engine Intake Air Mass Flow Rate
10. Drag the cursor to the middle of Engine Intake Air Mass Flow Rate line when the EGR Valve position is at
approximately 100% (open).
11. Record the Engine Intake Mass Air Flow Rate Value.
12. Calculate decrease in MAF percentage:
((Engine Intake Air Mass Flow Rate Value with EGR Valve Closed - Engine Intake Air Mass Flow Rate Value with
EGR Valve Open) / Engine Intake Air Mass Flow Rate Value with EGR Valve Closed) x 100 = MAF decrease.
Example: ((1417 - 443) / 1417) x 100 = 69%
13. Engine Intake Air Mass Flow Rate Value with EGR Valve Closed ____.
14. Engine Intake Air Mass Flow Rate Value with EGR Valve Open ____.
15. Take the value from Step 13 and subtract by the value from Step 14 ____.
16. Take the value from Step 15 and divide it by the value from Step 13 ____.
17. Multiply the result of Step 16 ____ by 100.
18. Total MAF decrease percentage ____%.
Expected Outcome
Test will complete successfully and technician will interpret the recorded snapshot. EBP should be greater than
IMP. IMP and EBP should increase as VGT position is increased, and decrease as the EGR Valve position is
increased. Engine Intake Air Mass Flow Rate should drop to its lowest when the EGR Valve position reaches
100%. Calculated MAF decrease difference percentage should be between 60% and 100%. Engine Intake Air
Mass Flow Rate should also respond to changes in the VGT actuator position and Engine speed.
Follow-On Procedure
None
Cylinder Balance Test
Overview
Isolates a suspect cylinder(s) causing a misfire or rough running.
Tools Required
Equipment Condition
None
Test Setup
1. Key On, Engine Off (KOEO)
2. Connect Electronic Service Tool (EST) to Vehicle Diagnostic Connector (page 1956) and log into
Navistar® Engine Diagnostics.
Test Procedure
1. Select: Tests > KOER Tests > Cylinder Balance.
2. Select record snapshot button. Continue recording until testing is completed.
Figure 702 Cylinder Balance Test Signal Values

1. Actual Engine Torque
2. Cylinder (1–6) Crankshaft
Angular Velocity Data
3. Start engine and allow Cylinder (1–6) Crankshaft Angular Velocity Data signal values (Item 2) to stabilize
for 30 seconds.
4. After Cylinder (1–6) Angular Velocity Data signal values stabilize, compare signal values to each other.
• If signal values are within 0.6 of each other, continue to Step 5.
• If signal values are not within 0.6 of each other, suspect cylinder(s) has been identified and test is
complete. Cylinder Balance Test Signal Values shows Cylinder 1 is suspect for a failure.
5. Slowly increase engine speed to 1500 rpm while keeping Actual Engine Torque signal value (Item 1) below
150 lb-ft (203 N-m).
6. Hold engine speed at 1500 rpm for 2 minutes while comparing Cylinder (1–6) Angular Velocity Data signal
values.
• If signal values are within 0.6 of each other, test is complete.
• If signal values are not within 0.6 of each other, suspect cylinder(s) has been identified and test is
complete. Cylinder Balance Test Signal Values shows Cylinder 1 is suspect for a failure.
7. Stop snapshot recording.
Expected Outcome
All Cylinder (1–6) Angular Velocity Data signal values will be within 0.6 of each other.
Follow-On Procedure
None
Engine Fan Test
Overview
Validates performance of Engine Fan by commanding the fan Off and On to listen for change in fan noise. This
test is an audible test only.
Tools Required
• Parking brake set.
• Accelerator, Clutch, and Brake pedals released.
• AFT Regen Status Not Active.
• HVAC off (Front and Rear)
• Air tanks full (over 90 psi)
Test Setup
1. Key OFF
3. Key ON, Engine OFF (KOEO), log into Navistar® Engine Diagnostics.
4. Start engine and run to operating temperature.
Test Procedure
1. Select Tests > KOER Tests > Engine Fan Test.
2. Select Turn Fan Off from Controls tab. Listen for Engine Fan to get quieter. Wait the entire 1.5 minutes and
allow engine to return to idle before proceeding.
3. Select Turn Fan On from Controls tab. Listen for Engine Fan to get Louder. Wait the entire 1.5 minutes and
allow engine to return to idle before proceeding.
4. Verify fan operates as commanded. If fan is always On or always Off, ECM does not have control.
Expected Outcome
Fan will remain off when commanded off and engage when commanded on. This is an audible only test.
Follow-On Procedure
None
High Pressure Pump Test
Overview
Validates performance of the high-pressure fuel system’s ability to meet various commanded pressures at
different engine RPM levels.
Tools Required
Equipment Condition
• Engine Speed at low idle
• PP 8203 High Idle Engine Speed Set above 1650 rpm
• Accelerator Pedal Position (0%)
• Brake Pedal (Released)
• Engine Coolant Temperature above 140° F (60° C)
• Clutch Pedal (Release)
• Vehicle Speed (0 mph)
Test Setup
1. Connect EST to vehicle Diagnostic Connector (page 1956).
2. Log into Navistar® Engine Diagnostics.
3. Start Engine and warm engine coolant temperature above 140° F (60° C).
Test Procedure
1. Go to Tests > KOER Tests > High Pressure Pump Test.
2. Press the Record button.
3. When ready, select “Start High Pressure Pump Test”.
4. When the tests completes, select Stop Recording.
5. Open snapshot recording to View graphs of recorded data (page 1952). Graph the following signals into 2
separate graphs:
• Graph 1
1. Engine Speed
2. Engine Fuel Rail Pressure
3. Engine Fuel Rail Pressure Desired
• Graph 1
1. Engine Speed
2. Engine Fuel Actuator 1 Control (Pump)
3. Engine Fuel Actuator 2 Control (Rail)
6. Compare results to the following graphs:
Figure 703 Graph 1

1. Engine Speed (RED)
2. Engine Fuel Rail Pressure (BLUE)
3. Engine Fuel Rail Pressure Desired (GREEN)
Figure 704 Graph 2

1. Engine Speed (BLUE)
2. Engine Fuel Actuator 2 Control (Rail) (GREEN)
3. Engine Fuel Actuator 1 Control (Pump) (RED)
Expected Outcome
Test will complete and graph 1 and graph 2 will look similar to the graphs above.
Follow-on Procedure
None
Multiple Cylinder Cutout Test
Overview
The KOER Multiple Cylinder Cutout test is use to help diagnose rough idle or misfire symptoms. The test will
monitor engine load while disabling 3 cylinders at a time in a pre-determined sequence. Engine Load averages
are collected from each combination and used to calculating test results.
Tools Required
1. Engine Coolant Temperature 1 (ECT1) above 160°F (71°C)
2. Engine Speed at idle
3. Vehicle Not Moving (Parking Brake set)
4. Accelerator Pedal Position (0%)
5. Brake Pedal (Release)
6. Clutch Pedal (Release)
Test Setup
1. Key On Engine Off.
4. Start engine and warm engine coolant temperature above 160°F (71°C).
Test Procedure
1. Select Tests > KOER Tests > Multiple Cylinder Cutout Test.
2. The Multiple Cylinder Cutout Test Session will load.
3. This test has the following 2 options:
• Option 1 – Manual cylinder cutout test. User can select an injector (s) by clicking an X in the cylinder
location. Press Begin Test button will disable selected injector (s). To end test, press End Test button.
This is an audible test only, does not display test results.
• Option 2 – Automated Multiple Cylinder Cutout Test. Click on Auto Test button to begin the automated
test. This test will run for about 8 minutes before displaying Test results.
4. Click on Auto Test button for Automated Multiple Cylinder Cutout Test. Test will begin an 8 minute sequence
disabling cylinder combination while collecting data.
5. Test is complete when the results are displayed.
Expected Outcome
Test will complete successfully.
Follow-On Procedure
None
Road Tests
0-60 MPH Road Test
Overview
This procedure alone is not a diagnostic tool, but allows the technician to recreate a problem and record signals
for later analysis while operating the vehicle. 0-60 MPH Road Test is for vehicles with automatic transmissions
only. Vehicles with manual or automated manual with manual mode transmissions should use Lug Down Test
(page 2021).
WARNING:
To prevent personal injury or death, do not exceed local speed limit laws or drive too fast
for conditions.
Special Tools
Equipment Condition
None
Test Setup
3. Select the Default Session.
4. Find a suitable location to perform Road Test and pull over to the side of the road.
5. Ensure Engine Coolant Temperature (ECT) is above 158° F (70° C).
Test Procedure
1. When safe to do so, select Start Recording button and drive vehicle up to road speed.
2. Press accelerator pedal fully to the floor and accelerate to 60 mph.
3. Try to reproduce fault while recording.
4. After Lug Down Test is complete select Stop Recording button.
Expected Outcome
Signals values will be recorded for diagnostic analysis.
Follow-On Procedure
Use recorded signals to analyze graphs and make diagnosis.
Lug Down Test
Overview
This procedure alone is not a diagnostic tool, but allows the technician to recreate a problem and record signals
for later analysis while operating the vehicle. Lug Down Test is for vehicles with manual transmissions or
automatic transmissions with manual mode. Vehicles with automatic transmissions should use 0–60 MPH Road
Test (page 2020).
WARNING:
for conditions.
Special Tools
Equipment Condition
None
Test Setup
3. Select the Default Session.
4. Find a suitable location to perform Road Test and pull over to the side of the road.
5. Ensure Engine Coolant Temperature (ECT) is above 158° F (70° C).
Procedure
1. When safe to do so, select Start Recording button and drive vehicle up to road speed.
2. Select a suitable high range gear (Example: In a 10 Speed gearbox, select 8th gear).
3. Allow engine speed to drop to 1000 RPM.
4. Press accelerator pedal fully to the floor and accelerate to rated engine speed.
5. Shift to transmission to next gear. Press accelerator pedal fully to the floor and accelerate to rated engine
speed.
6. Try to reproduce fault while recording.
7. After Lug Down Test is complete select Stop Recording button.
Expected Outcome
Signals values will be recorded for diagnostic analysis.
Follow-On Procedure
Use recorded signals to analyze graphs and make diagnosis.
Normal Exhaust Gas Temp Graph
Overview
This graph shows an aftertreatment system operating as designed. It only allows the user to validate operation
of the aftertreatment system by monitoring exhaust gas temperatures.
Special Tools
Equipment Condition
None
Test Setup
1. Key On Engine Running (KOER).
2. Connect Electronic Service Tool (EST) with to Vehicle Diagnostic Connector.
4. View graph of recorded DPF Regeneration Procedure data (page 1952).
Test Procedure
1. Compare successfully completed DPF regeneration procedure snapshot data to graphs below.
• Successful regeneration procedure length may be longer or shorter depending on ECM calibration.
Figure 705 Normal Exhaust Gas Temperatures (Long Regeneration)

1. Diesel Particulate Filter Intake Temperature (DPFIT) (Dark Blue)
2. Diesel Particulate Filter Outlet Temperature (DPFOT) (Green)
3. Selective Catalyst Reduction Intake Temperature (SCRIT) (Black)
4. Selective Catalyst Reduction Outlet Temperature (SCROT) (Light Blue)
5. Diesel Oxidation Catalyst Intake Temperature (DOCIT) (Orange)
Figure 706 Normal Exhaust Gas Temperatures (Short Regeneration)

1. Diesel Particulate Filter Intake 3. Selective Catalyst Reduction 5. Selective Catalyst Reduction
Temperature (DPFIT) (Dark Intake Temperature (SCRIT) Outlet Temperature (SCROT)
Blue) (Grey) (Light Blue)
2. Diesel Particulate Filter Outlet 4. Diesel Oxidation Catalyst Intake
Temperature (DPFOT) (Green) Temperature (DOCIT) (Red)
Expected Outcome
Long Regeneration:
• After DOC reaches operating temperature and stabilizes, DPFIT signal value will remain approximately
200°F (104°C) below target temperature for soot load level (page 2288) for approximately one hour.
• After approximately one hour, DPFIT will rise to reach soot load level target temperature.
• DOCIT signal value is between 550°F (287°C) to 800°F (427°C).
Short Regeneration:
• DOC reaches operating temperature and stabilizes, DPFIT signal value will reach approximate target
temperature for soot load level (page 2288).
• DOCIT signal value is between 550°F (287°C) to 800°F (427°C).
Low-Pressure Fuel System Tests

Fuel System Priming
Overview
Prime the fuel system after a repair has been made or the engine has run out of fuel.
GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids 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.
WARNING:
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, store diesel fuel properly in an approved container
designed for and clearly marked DIESEL FUEL.
CAUTION:
To prevent damage to fuel system components, make sure pressure regulator handle is
in 50 psi (345 kPa) position when servicing International® A26 engines.
NOTE: Fuel Priming System 12–922–01 ball valves (on hose ends) should be in closed position, unless suction
ad pressure hoses are connected to vehicle fuel system.
Tools Required
Fuel Priming System 12–922–01
Equipment Condition
Fuel system is completely assembled and not leaking.
Test Setup
1. Verify Fuel Priming System 12–92201 pressure regulator handle is in 50 psi (345 kPa) position.
2. Put a fuel drain pan under primary fuel filter / water separator and verify it is full with clean diesel fuel.
Test Procedure
Figure 707 Filter Housing

1. Level Indicator
1. Fill Fuel Priming System 12-922-01 filter housing with approximately 1 gallon of clean diesel fuel up to level
indicator (Item 1). Do this the first time tool is used and any time there is no diesel fuel in filter housing.
2. Select suction adapter 12–922–01–2 and pressure adapter 12–922–01–3 from the adapter holding fixture
on the Fuel Priming System cart.
Figure 708 Fuel Supply Line to Engine

1. Fuel supply line to engine 2. Fuel supply line connector
3. Disconnect fuel supply line to engine (Item 1) from fuel supply line connector (Item 2) at primary fuel filter /
water separator (output to low-pressure fuel pump).
Figure 709 Connecting Suction and Pressure Hoses

1. Pressure hose 2. Suction hose
4. Connect Fuel Priming System suction hose (Item 2) to primary fuel filter / water separator output.
5. Connect Fuel Priming System pressure hose (Item 1) to fuel supply line to engine.
Figure 710 Ball Valves

1. Pressure valve 2. Suction valve
6. Open pressure and suction hose ball valves (Figure 710) (Items 1 and 2).
7. Connect electrical power to Fuel Priming System.
8. Move Fuel Priming System power button (located on outlet box on top of Fuel Priming System cart) to ON
position.
Figure 711 Sight Glass

1. Sight glass
9. Run Fuel Priming System for a minimum of 2 minutes after no bubbles are visible in sight glass (Item 1).
10. After the 2 minutes has passed, start engine with Fuel Priming System still running.
11. Run engine at 1200 rpm for a minimum of 2 minutes.
12. After the 2 minute run time, turn off engine.
13. Move Fuel Priming System power button to OFF position.
14. Close pressure and suction hose ball valves.
15. Disconnect Fuel Priming System pressure and suction hoses from adapters
16. Remove suction and pressure adapter from vehicle.
17. Re-connect fuel supply line to primary fuel filter / water separator.
18. Re-start vehicle to verify that no leaks are present.
Expected Outcome
Fuel system primed and free of air.
Follow-on Procedure
None
Start From Clean Fuel Source Test
Overview
Diagnose proper operation of the Low Pressure Fuel Pump by verifying operation of the Low-pressure Fuel
system using a known clean, unrestricted and dedicated fuel source.
CAUTION:
Ensure all fuel lines and dry break fittings are clear of dirt and heavy debris before
disconnecting any fittings. Failure to comply could cause contaminants to enter the
Low-pressure fuel system.
Tools Required
• Clean Fuel Source Tool – 15–637–01
• Air Cap, Fuel Cap and Plug Kit – ZTSE4891
Equipment Condition
None
Test Setup
1. With engine Off, disconnect fuel supply line at low-pressure fuel pump inlet fitting.
2. Use Air Cap, Fuel Cap and Plug Kit ZTSE4891 to cap disconnected fuel line.
Figure 712 Clean Fuel Source Connection

1. Low-Pressure Fuel Pump inlet fitting
3. Connect Clean Fuel Source Tool 15-637-01 to low-pressure fuel pump inlet fitting.
4. Prime fuel system by pumping primer bulb.
CAUTION:
Do not crank engine continuously for longer than 15 seconds. Failure to comply could
result in damage to engine starter motor.
Test Procedure
1. Crank the engine.
2. If engine starts, idle for 30 seconds before shutting down.
Expected Outcome
Engine will start and run with Clean Fuel Source Tool connected.
Follow-on Procedure
None
Fuel Aeration Test
Overview
Check for and diagnose cause of fuel aeration.
Tools Required
• 15-637-01 – Clean Fuel Source Tool
• ZTSE4886 – Fuel Inlet Restriction / Aeration Tool
• ZTSE4906 – Fuel Line Coupler
Equipment Condition
None
Test Setup 1
1 3
5 4
6
0000415022
Figure 713 Fuel Aeration Test 1

1. Low-pressure Fuel Pump
2. Primer Pump
3. Primer Pump inlet fitting
4. Fuel supply line to secondary fuel filter
5. Fuel Line Coupler ZTSE4906
6. Fuel Inlet Restriction/Aeration Tool ZTSE4886
7. Low-pressure Fuel Pump outlet fitting
1. Use Fuel Line Coupler ZTSE4906 to connect Fuel Inlet Restriction/Aeration Tool ZTSE4886 between
fuel supply line to secondary fuel filter and low-pressure fuel pump outlet.
2. Prime fuel system using primer pump.
Test Procedure 1
Start or crank engine. If possible, raise engine speed to high idle while visually monitoring for fuel aeration (air
bubbles passing through the clear line of the Restriction/Aeration Tool).
• If fuel is aerated, continue to Test 2.
Test Setup 2
1 3
5 4
6
0000415022
Figure 714 Fuel Aeration Test 2

1. Low-pressure Fuel Pump
2. Primer Pump
3. Primer Pump inlet fitting
4. Fuel supply line to secondary fuel filter
6. Fuel Inlet Restriction/Aeration Tool ZTSE4886
7. Low-pressure Fuel Pump outlet fitting
1. Retain Fuel Inlet Restriction/Aeration Tool from previous test.

2. Connect Clean Fuel Source Tool 15-637-01 to primer pump inlet fitting.
Test Procedure 2
Start or crank engine. If possible, raise engine speed to high idle while visually monitoring for fuel aeration (air
bubbles passing through the clear line of the Restriction/Aeration Tool).
• If fuel is not aerated, repair fuel supply line between fuel primer pump and fuel tank.
• If fuel is aerated, repair low-pressure fuel pump supply line or fuel primer pump.
Expected Outcome
No Air bubbles will be seen in the Fuel Inlet Restriction/Aeration Tool ZTSE4886.
Follow-On Condition
None
Fuel Restriction Test
Overview
Check for and diagnose cause of fuel supply restriction.
Tools Required
• ZTSE4526 – Coupler, Fuel/Oil Pressure Test
• 15-637-01 – Clean Fuel Source Tool
• ZTSE4409 – Mechanical or Fluke PV350 – digital vacuum gauge (Obtain locally)
Equipment Condition
None
Test Setup 1
2
3
6 5
0000415328
Figure 715 Fuel Restriction Test

1. Vacuum gauge 3. Compucheck test port 5. Primary fuel filter inlet
2. Coupler, Fuel/Oil Pressure test 4. Primer pump inlet 6. Primary fuel filter outlet
1. Connect Coupler, Fuel/Oil Pressure Test ZTSE4526 to vacuum gauge.

2. Connect vacuum gauge to Compucheck test port.
Test Procedure 1
Start or crank engine. If possible, raise engine speed to high idle while monitoring vacuum gauge.
• If restriction is above specification cranking: 8-12 inHg (203-305 mmHg), low idle: 13 - 17 inHg (330 - 432
mmHg), or high idle: <18 inHg (<480 mmHg), go to Test 2.
• If restriction is within specification cranking: 8-12 inHg (203-305 mmHg), low idle: 13 - 17 inHg (330 - 432
mmHg), or high idle: <18 inHg (<480 mmHg), retest for original complaint.
Test Setup 2
2
3
6 5
0000415328

1. Retain setup from previous test

2. Connect Clean Fuel Source Tool 15-637-01 to primer pump inlet.
Test Procedure 2
Start or crank engine. If possible, raise engine speed to high idle while monitoring vacuum gauge.
• If restriction is above specification cranking: 8-12 inHg (203-305 mmHg), low idle: 13 - 17 inHg (330 - 432
mmHg), or high idle: <18 inHg (<480 mmHg), go to Test 3.
• If restriction is within specification cranking: 8-12 inHg (203-305 mmHg), low idle: 13 - 17 inHg (330 - 432
mmHg), or high idle: <18 inHg (<480 mmHg), repair or replace failed fuel line connection or fuel primer
pump assembly.
Test Setup 3
2
3
6 5
0000415328

1. Retain setup from Test 2, but move Clean Fuel Source Tool 15-637-01 to primary filter inlet.
2. Restore any fuel line connections.
Test Procedure 3
1. Start or crank engine. If possible, raise engine speed to high idle while monitoring vacuum gauge.
2. If restriction is above specification cranking: 8-12 inHg (203-305 mmHg), low idle: 13 - 17 inHg (330 -
432 mmHg), or high idle: <18 inHg (<480 mmHg), repair restriction between primary fuel filter and fuel
tank.
3. If restriction is above specification cranking: 8-12 inHg (203-305 mmHg), low idle: 13 - 17 inHg (330
- 432 mmHg), or high idle: <18 inHg (<480 mmHg), replace primary fuel filter, clean fuel strainer, and
check fuel lines and fittings for damage.
Expected Outcome
Technician will verify there is no fuel restriction or diagnose cause of fuel restriction.
Follow-on Procedure
Connect low-pressure fuel lines that were disconnected.
High-Pressure Fuel System Tests

Fuel Rail Pressure (FRP) Leak Isolation
Overview
Isolate pressure loss or excessive fuel leakage from high-pressure fuel injector return passage in cylinder head.
WARNING:
The high-pressure fuel system may have extremely high pressure. Verify pressure is
below 500 psi before loosening a high-pressure line. Every time the engine is shut down
and the key is in the OFF position, the ECM commands a blank shot injection process
that drains the high-pressure fuel rail.
Tools Required
• Diesel fuel container measuring in milliliters
• High Pressure Rail Return Line Tester ZTSE4887
• High Pressure Rail Plugs ZTSE6098
Equipment Condition
If necessary, remove inner fenders as needed to gain access to all high-pressure fuel rail and injector pipes.
Test Setup
1. Key Off.
2. Disconnect fuel drain tube assembly at rear of cylinder head.
Figure 718 High Pressure (HP) Return Line Tester Connected to Cylinder Head
3. Connect HP Return Line Tester ZTSE4887-2 and ZTSE4887-3 to the cylinder head return port and drain
tube assembly. Use 2 banjo ring seals to cylinder head fuel drain tube fitting and torque banjo bolt to 22
lb-ft (30 N•m). Route hose end into a diesel fuel container.
Test Procedure
1. Disconnect cylinder six injector high-pressure fuel line.
Figure 719 High Pressure Rail Plug installed on injector six
2. Install a High Pressure Rail Plug ZTSE6098 on open fuel rail port. Tighten High Pressure Rail Plug to 30
lb•ft (40 N•m).
3. Crank engine for a maximum of 15 seconds or start engine and run at low idle.
• If engine does not start, go to Step 4.
• If engine starts, go to Step 9.
4. Repeat steps 1 through 3 on cylinder five injector. Leaving previously installed High Pressure Rail Plug on
engine.
5. Repeat steps 1 through 3 on cylinder four injector. Leaving previously installed High Pressure Rail Plugs on
engine.
6. Repeat steps 1 through 3 on cylinder three injector. Leaving previously installed High Pressure Rail Plugs
on engine. Monitor Fuel Rail Pressure in EST while cranking the engine and compare to Fuel Rail Pressure
Desired.
• If engine does not start and(or) Fuel Rail Pressure does not build above 3000 psi (20,000 kPa) and does
not build to within 2000 psi (13,790 kPa) of Fuel Rail Pressure Desired in EST, go to Step 7.
• If engine starts and(or) Fuel Rail Pressure now builds above 3000 psi (20,000 kPa) and builds to within
2000 psi (13,790 kPa) of Fuel Rail Pressure Desired in EST, cylinder three injector is suspect. Go to
step 9.
7. Repeat steps 1 through 3 on cylinder two injector. Leaving previously installed High Pressure Rail Plugs on
engine. Monitor Fuel Rail Pressure in EST while cranking the engine and compare to Fuel Rail Pressure
Desired.
• If Fuel Rail Pressure does not build above 3000 psi (20,000 kPa) and does not build to within 2000 psi
(13,790 kPa) of Fuel Rail Pressure Desired in EST, go to Step 8.
• If Fuel Rail Pressure now builds above 3000 psi (20,000 kPa) and builds to within 2000 psi (13,790 kPa)
of Fuel Rail Pressure Desired in EST, cylinder two injector is suspect.
8. Repeat steps 1 through 3 on cylinder one injector. Leaving previously installed High Pressure Rail Plugs on
engine. Monitor Fuel Rail Pressure in EST while cranking the engine and compare to Fuel Rail Pressure
Desired.
• If pressure now builds above 3000 psi (20,000 kPa) and builds to within 2000 psi (13,790 kPa) of Fuel
Rail Pressure Desired in EST, cylinder one injector is suspect.
9. With engine now running at low idle, wait until fuel flow is steady at cylinder head return port and fuel
volume reaches a good starting measurement point. Start timer and begin measurement. Measure fuel
return volume for 1 minute. Return from cylinder head should be less than 2.02 oz (60 ml) in 1 minute.
• If return flow from cylinder head is now in spec, suspect fuel injector is the last plugged cylinder.
• If return flow from cylinder is still out of specification, ensure all fuel injectors, high-pressure connector,
and retaining nuts are installed properly, free of damage and proper torque sequence was followed for
installation.
Expected Outcome
Technician will identify injector causing loss in fuel rail pressure.
Follow-on Procedure
Replace all removed high-pressure fuel lines with new parts once diagnosis is complete.
Fuel Rail Pressure (FRP) Return Flow Test
Overview
Verify return flow at cylinder head or fuel rail is within specifications.
Tools Required
• Diesel fuel container with measuring marks
• High Pressure Return Line Tester ZTSE4887
Equipment Condition
1. Low-Pressure (LP) fuel system is operating correctly and within specification.
Test Setup 1
1. Disconnect fuel drain tube assembly at rear of cylinder head.
Figure 720 High-Pressure (HP) Return Line Tester Connected to Cylinder Head
2. Connect HP Return Line Tester ZTSE4887 using 2 banjo ring seals to cylinder head fuel drain tube
fitting. Route the hose end into a diesel fuel container.
Test Procedure 1
1. Crank engine for a maximum of 15 seconds or start engine and run at low idle. If engine starts, wait
until fuel flow is steady and fuel volume reaches a good starting measurement point, then start timer
and begin measurement. Measure fuel return volume for 1 minute if the engine starts.
Expected Outcome Test Procedure 1

If engine starts, fuel return flow volume should be < 60 ml in 1 minute. If engine does not start, little to no fuel
returned.
Test Setup 2
1. Verify fuel drain tube is connected to the cylinder head.
Figure 721 High-Pressure (HP) Return Line Tester Connected to Fuel Rail
1. HP Return Line Tester ZTSE4887
2. Fuel rail return port
3. Fuel rail return line
2. Disconnect fuel rail return line (Item 3) at fuel rail.

3. Connect HP Return Line Tester ZTSE4887 (Item 1) using 2 banjo ring seals to fuel rail return port (Item
2) . Route the hose end into a diesel fuel container.
Test Procedure 2
1. Crank engine for a maximum of 15 seconds or start engine and run at low idle. If engine starts, wait until
fuel flow is steady and fuel volume reaches a good starting measurement point, start timer and begin
measurement. Measure fuel return volume for 1 minute if the engine starts.
Expected Outcome Test Procedure 2

No fuel return flow from fuel rail return port.
Follow-on Procedure
Reconnect fuel drain tube assembly and fuel rail return line.
HP Pump Fuel Return Flow Test
Overview
Verify return flow from the High-Pressure (HP) fuel pump is within specifications.
Tools Required
• Clean Fuel Source Tool 15-637-01
• Fuel Block Off Tool ZTSE4905
Equipment Condition
Low-Pressure (LP) fuel system is operating correctly.
Test Setup
0000419716
Figure 722 HP Fuel Pump

1. HP fuel pump return line
1. Disconnect High-Pressure (HP) fuel pump return line from HP fuel pump.
2. Connect Fuel Block Off Tool ZTSE4905 to HP fuel pump return line.
3. Connect Clean Fuel Source Tool 15-637-01 to the HP fuel pump fuel return port. Verify the shutoff valve is
Open.
Test Procedure
1. Start engine or crank engine for 15 seconds while monitoring fuel flow from HP fuel pump fuel return
port to Clean Fuel Source Tool.
Expected Outcome
No fuel flow from HP fuel pump fuel return port until engine starts.
Follow-on Procedure
None
HP Pump Fuel Return Pressure Test
Overview
Verify return fuel system pressure is within specifications.
Tools Required
• ZTSE4526 – Compucheck fitting
• ZTSE4681 – Fuel Pressure Gauge
Equipment Condition
None
Test Setup
1. Disconnect high-pressure fuel pump return line.
2 3
6 5 4
0000419717
Figure 723 High-pressure fuel pump return line connected to Fuel Pressure Gauge
1. Fuel Pressure Gauge ZTSE4681
2. Fuel Inlet Restriction / Aeration Tool ZTSE4886
3. HP Fuel Pump return fitting
4. Return fuel line
6. Compucheck fitting ZTSE4526
2. Use Fuel Line Coupler ZTSE4906 to connect Fuel Inlet Restriction/Aeration Tool ZTSE4886 between the
high-pressure fuel pump and return line.
3. Use Compucheck fitting ZTSE4526 to connect Fuel Inlet Restriction / Aeration Tool ZTSE4886 to Fuel
Pressure Gauge ZTSE4681.
Test Procedure
1. Start or crank engine. If the engine starts run at high idle while monitoring Fuel Pressure Gauge.
2. If the engine does not start, continue cranking for a maximum of 15 seconds while monitoring fuel
pressure gauge.
Expected Outcome
HP Fuel Pump return pressure should not exceed 13 psi (89.6 kPa).
Follow-on Procedure
None
HP Pump Inlet Pressure Test
Overview
Verify high-pressure fuel pump is receiving fuel.
Tools Required
• ZTSE4681 – Fuel Pressure Gauge
Equipment Condition
None
Test Setup
1. Connect Coupler, Fuel/Oil Pressure Test ZTSE4526 to the fuel pressure gauge ZTSE4681.
2. Disconnect The HP Pump inlet line from the HP pump.
3. Use Fuel Line Coupler ZTSE4906 to connect Fuel Inlet Restriction / Aeration Tool ZTSE4886 between the
HP pump inlet and the HP pump inlet line.
2
1
6 5
7
0000414979
Figure 724 Pressure Test Kit connected between HP Pump and HP Pump inlet line
1. Fuel Pressure Gauge
2. Fuel Inlet Restriction / Aeration Tool
3. High-Pressure Fuel Pump
4. High-pressure Fuel Pump inlet fitting
5. High-pressure Fuel Pump inlet line
6. Fuel Line Coupler
7. Coupler, Fuel/Oil Pressure Test
4. Connect ZTSE4681 Fuel Pressure Gauge to Fuel Inlet Restriction / Aeration Tool ZTSE4886.
Test Procedure
A. Start or crank engine. If possible, run at high idle. Monitor Fuel Pressure Gauge ZTSE4681. Wait for
gauge reading to stabilize before recording the pressure.
Expected Outcome
If engine does not start, the pump should be receiving a minimum of 30 psi (206.8 kPa) to start. If the engine
starts, fuel pressure will be 68 ± 5 psi (469 ± 34 kPa) at low idle and 80 ± 5 psi (552 ± 34 kPa) at high idle when
measured at the high-pressure fuel pump inlet. Fuel pressure will vary with engine speed. Higher engine speed
equals higher pressure.
Follow-on Procedure
None
Cold Start System Tests

Cold Start Fuel Igniter Test
Overview
This test will measure the current draw of the Cold Start Fuel Igniter (CSFI) to check for proper operation.
Tools Required
• EXP-1000 HD by Midtronics or Digital Multimeter (DMM) with amp clamp ZTSE4575
Equipment Condition
Engine coolant temperature is below 100°F (38°C).
Test Setup
Test Procedure
1. Ensure engine coolant temperature is below 100°F (38°C).
2. In Navistar® Engine Diagnostics select Tests > KOEO Tests > Actuator Test.
Figure 725 Current clamp on CSFI
3. Connect EXP-1000 HD by Midtronics current clamp or DMM with amp clamp ZTSE4575 around CSFI power
circuit.
4. Select “Eng Cold Start” tab from the top menu.
5. Select “Fuel Ingniter” from the sub-menu.
6. Select time delay if desired.
7. Press the Start Test button while monitoring current draw. Record results.
Expected Outcome
Cold Start Fuel Igniter (CSFI) current draw will be 15 Amps ± 2 amps.
Equipment Condition
None
Fuel Supply at Cold Start Enable Device Test
Overview
Verify sufficient fuel pressure is being supplied to the Cold Start Enable Device (CSED) fuel solenoid.
Tools Required
• Fuel Pressure Gauge ZTSE4681
• Solenoid Test Adapter ZTSE6059-1
Equipment Condition
No fault code(s) are active for LP fuel system.
Test Setup
1. Key Off.
2. Disconnect fuel supply to Cold Start Enable Device (CSED) fuel solenoid.
1 2
4
5
0000428498
Figure 726 Fuel Pressure Gauge connected to CSED fuel supply line
1. CSED (Fuel Solenoid)
2. Solenoid Test Adapter ZTSE6059-1
3. Fuel Pressure Gauge ZTSE4681
4. CSED fuel supply line
5. CSED fuel supply line Banjo bolt
3. Connect Fuel Pressure Gauge ZTSE4681 1/8 NPT hose fitting directly into Intake Air Heater Solenoid Test
Adapter ZTSE6059-1.
4. Connect CSED fuel supply line to Air Heater Solenoid Test Adapter ZTSE6059-1 using the banjo bolt and
two sealing washers.
Test Procedure
1. Crank engine for a maximum of 15 seconds while monitoring Fuel Pressure Gauge ZTSE4681.
2. Fuel Pressure Gauge ZTSE4681 may need to have the air bled from it to stabilize reading. Allow gauge
reading to stabilize before recording measurement.
Expected Outcome
Fuel pressure supplied to CSED will be 8 - 12 psi (55 - 82 kPa).
Follow-on Procedure
None
Fuel Supply at Cold Start Fuel Igniter Test
Overview
Verify sufficient fuel pressure is being supplied to the Cold Start Fuel Igniter (CSFI).
Tools Required
• Fuel Pressure Gauge ZTSE4681
• Test Adapter ZTSE6059-2
• Fuel Pressure Test Kit ZTSE4657
Equipment Condition
None
Test Setup
Test Procedure
1. Disconnect fuel supply to CSFI.
3
2
0000428497
Figure 727 Fuel Pressure Gauge connected to CSFI fuel supply line
1. Fuel pressure gauge ZTSE4681 2. Adapter from Fuel Pressure Test 3. Test Adapter ZTSE6059-2
Kit ZTSE4657 4. Fuel supply line to CSFI
2. Using Fuel Pressure Test Kit ZTSE4657 and Test Adapter ZTSE6059-2, connect Fuel Pressure Gauge
ZTSE4681 to CSFI fuel supply line.
3. In Navistar® Engine Diagnostics, select Tests > KOEO Tests > Cold Start System Test.
4. When Wait to Start lamp begins flashing, crank engine while monitoring Fuel Pressure Gauge ZTSE4681.
5. Fuel Pressure Gauge ZTSE4681 may need to have the air bled from it to stabilize reading. Allow gauge
reading to stabilize before recording measurement.
Expected Outcome
Fuel pressure to CSFI will be 8 - 12 psi (55 - 82 kPa).
Follow-on Procedure
Reconnect fuel supply line to CSFI.
General Test Procedures

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 728 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.
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 2198) 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.
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 729 Main Clamps A139

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 730 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.
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.
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 732 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.
Figure 733 Good Battery Pack Test Results (Typical)
Figure 734 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.
Figure 735 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 2072) 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 2065).
REPLACE BATTERY or BAD CELL – Replace failed battery then rerun Electrical System Test (page 2065).
REPLACE
19. Charge or replace individual batteries as needed.

20. Reconnect battery pack(s).
21. Rerun Electrical System Test (page 2065).
Starter System Test Procedure

22. Following a successful Battery Pack Test Procedure, press NEXT.
23. When prompted, start engine.
Figure 736 Starter System / Cranking Test Results (Typical)

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 2074).
LOW VOLTAGE Verify charging system is operating properly. Go to: Charging System
Test Procedure (page 2074). If Charging System Test Procedure
passes, do Cable Drop Test (page 2079) 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 2074). After
Charging System Test Procedure is complete: If symptom is, or
could be starter related, redo complete Electrical System Test (page
2065) 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 2074). If
Charging System Test Procedure passes, perform Cable Drop Test
(page 2079) 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 2074). If
Charging System Test Procedure passes, perform Cable Drop Test
(page 2079) on starter power circuit. If required, repair starter power
circuit. If starter power circuit tests good, replace starter.
Charging System Test Procedure
0000453023
Figure 737 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.
0000453103
Figure 738 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.
0000453123
Figure 739 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.
Figure 740 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 2079). 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.
Engine Cranking Test
Overview
Monitors engine systems as the engine is cranked to determine if systems are able to meet minimum starting
requirements.
Tools Required
Equipment Condition
None
Test Setup
Test Procedure
1. Select: Session > Default.
2. Select: Tool > Start Recording Snapshot.
3. Crank engine for 15 seconds.
4. Select: Tools > Stop Recording Snapshot.
5. Verify the following signals meet engine cranking specifications:
• Switch Battery (SWBAT)
• Engine Speed (RPM)
• Fuel Rail Pressure (FRP)
• Exhaust Back Pressure (EBP)
• Variable Geometry Turbocharger Actuator Position (VGTAP)
Expected Outcome
All signal values meet engine cranking specifications (page 2285).
Follow-on Procedure
None
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:
procedures.
WARNING:
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.
Test 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).
4. Select rated amperage or output of circuit.
Figure 742 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.
0000453063
Figure 743 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 744 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
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.
Crankcase Breather Oil Separator Test
Overview
Check if Crankcase Breather Oil Separator is rotating at the proper speeds.
Tools Required
• Ultrasonic Leak Detector ZTSE4800
Equipment Condition
• Engine at operating temperature, Engine Coolant Temperature is 180 to 190˚ F (82 to 88˚ C).
• Oil level and pressure are within specification.
Test Setup
Test Procedure
1. Start engine and run to operating temperature.
2. From the Default session, select All Signals and locate Crankcase Breather Oil Separator Speed signal.
3. Monitor Crankcase Breather Oil Separator Speed signal with engine at low and high idle. Allow speed signal
to stabilize before taking readings. At low idle speed should be at least 3,000 rpm. At high idle the speed
should be at least 8,500 rpm.
• If Crankcase Breather Oil Separator Speed is within specification, crankcase breather system is
operating correctly.
• If Crankcase Breather Oil Separator Speed is not within specification, continue to next step.
4. With engine running, place Ultrasonic Ear ZTSE4800 near Crankcase Breather Oil Separator Speed sensor.
5. Turn engine OFF and quickly monitor for centrifugal noise. The centrifuge will continue spinning for 15
seconds after engine is shut off.
• If Crankcase Breather Oil Separator centrifugal noise is NOT heard, replace Crankcase Breather Oil
Separator.
• If Crankcase Breather Oil Separator centrifugal noise is heard, check sensor for physical damage or debris.
Replace sensor if damaged.
Expected Outcome
At low idle speed should be at least 3,000 rpm. At high idle the speed should be at least 8,500 rpm. The
centrifuge will continue spinning for 15 seconds after engine is shut off.
Follow-on Condition
None
Charge Air Cooler (CAC) Pressure Test
Overview
Pressure test the Charge Air Cooler (CAC) to check for leaks.
WARNING:
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.
WARNING:
Tools Required
• CAC Pressure Test Kit ZTSE4341
• CAC Cleaning Adapter Kit 09–925–01
Equipment Condition
• Inlet (hot side) CAC pipes and hoses removed from CAC.
• Outlet (cold side) CAC pipes and hoses removed from CAC.
Test Setup
Figure 745 CAC Cleaning Adapter Kit 09-925-01 With CAC Pressure Test Kit ZTSE4341 Installed
1. CAC Pressure Test Kit ZTSE4341
WARNING:
To prevent personal injury or death, clean all hoses and other pressure test components
of oil, grease, or other lubricants before connecting.
Figure 746 CAC Pressure Test Kit Installed on CAC Outlet

1. Gauge / regulator assembly
2. Quick disconnect fitting
3. Gauge coupler
4. T-clamp (2)
5. Large hose
6. Charge Air Cooler (CAC) outlet
7. Safety cable
1. Install large hose (5) and T-clamp (4) onto CAC outlet (6). Tighten T-clamp (4) securing large hose to
CAC outlet to 55 lb·in (6.2 N·m).
2. Install gauge coupler (3) and T-clamp (4) onto large hose. Tighten T-clamp (4) securing gauge coupler
(3) to large hose (5) to 55 lb·in (6.2 N·m).
3. Connect safety cable (7) to a known good anchor point.
4. Attach gauge / regulator assembly (1) onto quick disconnect fitting (2).
5. Install large hose and T-clamp onto CAC inlet. Tighten T-clamp securing large hose to CAC outlet to 55
lb·in (6.2 N·m).
6. Install bleed-off coupler and T-clamp onto large hose. Tighten T-clamp securing gauge coupler to large
hose to 55 lb·in (6.2 N·m).
7. Connect safety cable to a known good anchor point.
Test Procedure
1. Visually inspect CAC for cracks, holes, and other damage. If cracked or damaged, replace CAC.
Figure 747 Gauge / Regulator Assembly Connections

1. Air valve
2. Air regulator knob
3. Gauge
WARNING:
To prevent personal injury or death, attach safety cables to Charge Air Cooler (CAC) or
a known good anchor point.
CAUTION:
Adjust air regulator valve to minimum setting before connecting shop air supply.
Accidentally applying high-pressure can damage tool components or the Charge Air
Cooler (CAC).
2. Connect filtered shop air supply to air valve (1) on gauge / regulator assembly.
WARNING:
To prevent personal injury or death, increase air pressure slowly to prevent coupler
blowing-out during testing.
3. Open air valve slightly, and slowly increase air pressure until gauge (3) reads 30 psi (205 kPa). If
needed, adjust air regulator knob (2) as follows until gauge reads 30 psi (205 kPa):
a. Pull air regulator knob outward to unlock.
b. Turn air regulator knob to adjust pressure to 30 psi (205 kPa).
c. Push air regulator knob inward back into locked position.
4. Close air valve and monitor gauge pressure for 15 seconds.

• If air pressure drops more than 5 psi (34 kPa) in 15 seconds, replace CAC.
• If air pressure drops 5 psi (34 kPa) or less in 15 seconds, perform cleaning procedure. See Charge
Air Cooler (CAC) Cleaning in Engine Service Manual.
5. Repeat steps 3 and 4 three times to verify results.
Expected Outcome
Air pressure in CAC will drop 5 psi (34 kPa) or less in 15 seconds.
Follow-on Procedure
Figure 748 Bleed-Off Coupler Components

1. Bleed-off coupler
2. Bleed-off valve
WARNING:
To prevent personal injury or death, relieve air pressure through bleed-off valve slowly
before removing test equipment.
1. Slowly turn bleed-off valve (Figure 748) (Item 2) on bleed-off coupler (Figure 748) (Item 1)
counterclockwise, and release air from system.
2. Disconnect filtered shop air supply from air valve on gauge / regulator assembly.
Figure 749 Bleed-Off Coupler Installed On CAC Intake

1. Safety cable
2. Bleed-off coupler
3. T-clamp (2)
4. Small hose
5. Charge Air Cooler (CAC) Intake
3. Disconnect safety cable (Figure 749) (Item 1) from anchor point.

4. Remove bleed-off coupler (Figure 749) (Item 2) and T-clamp (Figure 749) (Item 4) from small hose.
5. Remove large hose (Figure 749) (item 4) and T-clamp from CAC Intake (Figure 749) (item 5).
Figure 750 CAC Pressure Test Kit Installed on CAC Outlet

1. Gauge / regulator assembly
2. Quick disconnect fitting
3. Gauge coupler
4. T-clamp (2)
5. Large hose
6. Charge Air Cooler (CAC) outlet
7. Safety cable
6. Remove gauge / regulator assembly (item 1) from quick disconnect fitting (item 2).
7. Remove safety cable (item 7) from anchor point.
8. Remove gauge coupler (item 3) and T-clamp (Figure 750) (Item 4) from large hose (Figure 750) (Item
5).
9. Remove large hose and T-clamp from CAC outlet (item 6).
10. Reinstall the hot and cold side CAC hoses and pipes.
11.
12.
13.
Crankcase Pressure Test
Overview
Verify if engine is in need for a possible overhaul or repair due to cylinder or valve wear or damage. Verify
operation of air compressor or turbochargers for possible worn or damaged parts.
Tools Required
• Digital manometer or Water Manometer ZTSE2217A
• Crankcase Pressure Test Tool ZTSE4039
• Air Cap, Fuel Cap and Plug Kit ZTSE4891
Equipment Condition
None
Test Setup
1. Verify crankcase oil breather separator is functioning properly before running this test. See Crankcase
Oil Breather Separator Test (page 2083).
2. Disconnect breather outlet tube from 90 degree breather outlet elbow on top of oil separator.
3. Connect Crankcase Pressure Test Tool ZTSE4039 to breather outlet elbow.
4. Connect manometer to Crankcase Pressure Test Tool ZTSE4039.
5. Ensure engine is at or above 158° F (70° C).
Test procedure
1. Start engine and run at high idle. Allow manometer reading to stabilize before recording pressure reading.
2. Record crankcase pressure.
• If pressure is less than 8 in H2O, no repair is required.
• If pressure is above 8 in H2O, continue to next step.
3. Shut engine OFF. Drain vehicle air tanks until pressure is removed from air system.
4. Remove air compressor discharge line.
5. Start engine and run at high idle. Allow manometer reading to stabilize before recording pressure reading.
6. Record crankcase pressure.
Expected Outcome
Crankcase pressure will be less than < 8 in H2O.
Follow-on Procedure
None
Smoke Test (Air Intake System)
Overview
Determine if leaks are present in the air intake system. Pressurized smoke will pass through the Charge Air
Cooler (CAC), clamps, and air intake system hoses 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. The Exhaust Gas Recirculation (EGR) Valve has a weep hole behind a vent
shield. It is normal to see soot or smoke coming from the weep hole during smoke testing, do not replace the
EGR Valve.
WARNING:
To prevent personal injury and / 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.
Tools Required
• 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
NOTE: Engines may have different air cleaner assembly configurations. For units with engine mounted air
cleaner assemblies, start at Step 4.
1. Remove air intake piping.
1 2
0000448489
Figure 751 Navistar® Fixed Graduated Intake Adapter Installed In Air Intake Hose
1. Navistar® fixed graduated intake adapter
2. Air intake Hose
2. Install Navistar® fixed graduated intake adapter into air intake hose with clamp previously removed.
3. Connect Navistar® leak locator supply line to fixed graduated intake adapter.
4. Remove air cleaner assembly.
1 2
4 3
0000448487
Figure 752 Powersmoke™ 3.9 In Adapter Installed In Air Intake Duct

1. Powersmoke™ 3.9 in adapter
2. Air intake duct
3. Navistar® leak locator supply line
4. Schrader valve
5. Insert Powersmoke™ 3.9 in adapter into air intake duct and attach safety chain to a secure location.
6. Connect an air chuck to the schrader valve and inflate Powesmoke™ 3.9 in adapter until air intake duct
is fully sealed.
7. Connect Navistar® Leak Locator supply line to Powesmoke™ 3.9 in adapter.
Test Procedure
Figure 753 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 is in OFF position.

2. Pull adjustable Pressure Regulator knob out to unlock, and turn regulator until System Pressure gauge reads
5 psi (34 kPa).
3. Push Adjustable Pressure Regulator knob in to lock and set system pressure.
4. Press the Start / Stop switch, and turn Flow Control switch to ON position to begin 10 minute smoke cycle.
1 2 3 4 3 5
3 6
2
0000448488
Figure 754 Intake System Inspection (Right-Side)

1. Variable Geometry Turbocharger (VGT) air outlet duct
2. Hoses (3)
3. Clamps (6)
4. CAC inlet tube
5. Charge Air Cooler (CAC)
6. Air inlet piping
5. On the right-side of the engine, inspect six clamps, three hoses, CAC, CAC inlet tube, VGT air outlet duct
and air inlet piping for smoke trails produced by Navistar® Leak Locator.
2 3 4
0000448486
Figure 755 Intake System Inspections Points (Left-Side)

1. Charge Air Cooler (CAC)
2. Clamps (2)
3. Air mixer
4. CAC outlet hose
6. On the left-side of the engine, inspect CAC, CAC outlet hose, two clamps and air mixer for smoke trails
produced by Navistar® Leak Locator.
Expected Outcome
Intake system clamps, hoses, components and piping are free of major leaks.
Follow-On Procedure
1. Disconnect Navistar® Leak Locator supply line from Powersmoke™ adapter or Navistar® fixed graduated
intake adapter.
2. Deflate and remove Powersmoke™ adapter per Navistar® Leak Locator Operation Manual.
3. Install air cleaner assembly (if removed).
Smoke Test (Exhaust System)
Overview
Determine if leaks are present in the exhaust system. Pressurized smoke will pass through clamps, hoses,
components, and piping to help locate difficult to find leaks.
indicate a component has failed. The Exhaust Gas Recirculation (EGR) Valve has a weep hole behind a vent
shield. It is normal to see soot or smoke coming from the weep hole during smoke testing, do not replace the
EGR Valve.
WARNING:
To prevent personal injury and / 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.
Tools Required
• Navistar® Leak Locator Kit 19–700–01
Equipment Condition
Navistar® Leak Locator filled with smoke fluid 19–700–0102, connected to power supply, and connected to air
Test Setup
1. Disconnect Turbocharger exhaust outlet pipe from Diesel Oxidation Catalyst (DOC).
Figure 756 Powersmoke™ 2.9 In Adapter Installed In Turbocharger Exhaust Outlet Pipe
1. Turbocharger exhaust outlet Pipe
4. Schrader valve
2. Install Powersmoke™ 2.9 in adapter into turbocharger exhaust outlet pipe and connect safety chain to a
secure location.
3. Connect an air chuck to the schrader valve and inflate Powersmoke™ 2.9 in adapter until turbocharger
exhaust outlet pipe is fully sealed.
4. Block off Air Intake System, refer to Smoke Test (Air Intake System) (page 2093) Test Setup procedure.
5. Install block off coupler to Air Intake System Adapter.

6. Connect Navistar® Leak Locator supply line to Powersmoke™ 2.9 in adapter.
Test Procedure


2. Pull adjustable Pressure Regulator knob out to unlock, and turn regulator until System Pressure gauge reads
5 psi (34 kPa).
4. Press the Start / Stop switch, and turn Flow Control switch to ON position to begin 10 minute smoke cycle.
Figure 758 Exhaust System Inspection (Right Side)

1. Turbocharger exhaust outlet pipe
2. Exhaust Gas Recirculation Valve
3. Exhaust Manifold
4. EGR Cooler Assembly
5. Variable Geometry Turbocharger
5. On the right side of the engine, inspect the turbocharger exhaust outlet pipe, Exhaust Manifold, EGR Valve,
EGR Cooler and VGT.
Expected Outcome
Exhaust system clamps, hoses, components, and piping are free of major leaks.
Follow-On Procedure
1. Disconnect Navistar® Leak Locator supply line from Powersmoke™ adapter.
3. Install Turbocharger exhaust outlet pipe to DOC.
4. Install air cleaner assembly (if removed).
Smoke Test (Aftertreatment System)
Overview
Determine if leaks are present in the Aftertreatment system. Pressurized smoke will pass through Aftertreatment
system clamps, hoses, components, and piping to help locate difficult to find leaks.
indicate a component has failed.
The Aftertreatment system is tested separately upstream and downstream of the Diesel Particulate Filter (DPF).
This is done since smoke from Navistar® Leak Detector 19-00-1 may not be able to physically pass through a
properly functioning DPF. If smoke does pass through the DPF, this does not indicate the DPF has failed and it
should not be replaced.
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.
Tools Required
• Navistar® Leak Locator Kit 19-700-01
Equipment Condition
Navistar® Leak Locator filled with smoke fluid 19-700-0102, connected to power supply, and connected to air
Test Setup 1 (Downstream Of DPF)

1. Remove Turbocharger exhaust outlet pipe from Turbocharger outlet pipe.
0000450328
Figure 759 Powersmoke™ 2.9 In Adapter Installed In Turbocharger Exhaust Outlet Pipe
1. Turbocharger Exhaust Outlet Pipe
3. Schrader valve
2. Install Powersmoke™ 2.9 in adapter into turbocharger exhaust outlet pipe and connect safety chain to a
secure location.
3. Connect an air chuck to the schrader valve and inflate Powersmoke™ 2.9 in adapter until turbocharger
exhaust outlet pipe is fully sealed.
0000450329
Figure 760 Powersmoke™ 3.9 In Adapter Installed In Tailpipe

1. Tailpipe
2. Schrader valve
4. Install Powersmoke™ 3.9 in adapter into tail pipe with exhaust stack retention hoop and attached to
safety chain.
5. Connect an air chuck to the schrader valve and inflate Powersmoke™ 3.9 in adapter until tail pipe is fully
sealed.
6. Install block off coupler to Powersmoke™ 3.9 in adapter.
Test Procedure 1 (Downstream Of DPF)


2. Pull adjustable Pressure Regulator knob out to unlock, and turn regulator until System Pressure gauge
reads 5 psi (34 kPa).
4. Press the Start / Stop switch, and turn Flow Control switch to ON position to begin 10 minute smoke
cycle.
0000450327
Figure 762 SCR Catalyst Inspection Points (Downstream Of DPF)

1. Particulate Matter (PM) sensor
2. NOx Out Sensor
3. SCR Outlet temperature sensor
4. Clamp
5. Large clamp
6. DPF Outlet Temperature sensor
7. DPFDP/DPFOP Outlet sensor port
8. Large clamp
9. DEF Doser Valve (DEFDV)
5. Inspect eight sensor ports, flex pipe, two clamps, three large clamps, DEFDV and piping for smoke trails
Test Setup 2 (Upstream Of DPF)

2. Install block off coupler to Powersmoke™ 2.9 in adapter.
Test Procedure (Upstream Of DPF)


2. Pull adjustable Pressure Regulator knob out to unlock, and turn regulator until System Pressure gauge
reads 5 psi (34 kPa).
4. Press the Start / Stop switch, and turn Flow Control switch to ON position to begin 10 minute smoke
cycle.
0000450330
Figure 764 SCR Catalyst Inspection Points (Upstream Of DPF)

1. DPFDP/DPFOP Inlet sensor port
2. DPF Inlet Temperature sensor
3. Large clamps (1)
4. Clamps (1)
5. Diesel Oxidation Catalyst (DOC) Inlet Temperature sensor
5. Inspect flex pipe, DOC, three sensor ports, one clamp, one large clamp, and piping for smoke trails
Expected Outcome
Aftertreatment system clamps, hoses, components, and piping are free of major leaks.
Follow-On Procedure
1. Disconnect Navistar® Leak Locator supply line from Powersmoke™ adapter.
3. Install Turbocharger exhaust outlet pipe to Turbocharger outlet pipe.
J1939 Diagnostics
Overview
J1939 is an industry standard protocol providing for communications between Electronic Control Units (ECUs)
over a Controller Area Network (CAN) bus. Diagnostic tools can also use the bus to monitor the data between
ECUs and communicate with individual ECUs for troubleshooting, software updates, and programming. An ECU
may be a module such as the Engine Control Module (ECM), or a sensor such as the Diesel Exhaust Fluid Tank
Level and Temperature sensor (DEFTLT).
The J1939 datalink used in Navistar® vehicles uses two wires labeled High (H) and Low (L), twisted together at
regular spacing to create an unshielded twisted pair (UTP). UTP wiring provides a high degree of immunity to
electrical noise, which could interrupt communications. To further keep noise to a minimum, the total resistance
between the H and L wires is specified at 60 ohms. This is accomplished by having two 120 ohm resistors,
one near each end of the bus, between the H and L wires. The two 120 ohm resistors in parallel form a total
resistance of 60 ohms. The resistor may be an external, separate item, or internal to an ECU. Together, the H
and L wires form a communication bus. An ECU may have more than one bus. If the busses are independent,
such as the Public and Private busses found in the ECM, a fault in one bus will not affect the other bus.
Any fault in a communication bus will result in some loss of communication between ECUs. This can include
any of the following:
• Short to ground, to voltage, or H and L wires shorted together will result in total loss of communication, with
no ECUs able to communicate.
• Open anywhere along the bus will effectively result in two separate networks, with ECUs on one side of the
break being unable to communicate with ECUs on the other side. If the break results in the disconnection
of one of the terminating resistors, the ECUs still connected to each other may not be able to communicate
with each other as well. ECUs on one side of the break will set faults indicating that messages from ECUs
on the other side were not received.
• Loss of power to an individual ECU will result only in that ECU not sending messages, and no other
interruption will occur. Other ECUs will set a fault indicating that messages from the ECU without power
were not received.
Tools Required
• Terminal Test Kit ZTSE4435C or Breakout harness, as required
Equipment Condition
Vehicle batteries fully charged.
Test Setup
1. Disconnect vehicle harness at suspect connector.
Test Procedure
NOTE: See the latest version of Navistar® Engine and Aftertreatment Wiring Schematic Form 0000019042 for
additional circuit information.
1. Key-On Engine-Off (KOEO), use a DMM to measure voltage between the following connector locations:
Test Location Specification

Power pin(s) and ground pin(s) B+
Power pin(s) and a known good ground B+
J1939–H pin and a known good ground 2 to 4 V
J1939–L pin and a known good ground 2 to 4 V
2. Key OFF, wait 1 minute. Use a DMM to measure resistance between the following connector locations:
Test Location Specification

J1939–H pin and a known good ground > 1k Ω
J1939–L pin and a known good ground > 1k Ω
J1939–H pin and J1939–L pin 55 to 65 Ω
If > 65 Ω, Open circuit on J1939-H or J1939-L circuits or
a missing terminating resistor.
If < 55 Ω, Short circuit between J1939–H and J1939–L,
or extra terminating resistor has been added
(possible ECU added to network containing an
internal resistor)
J1939–H pin and any other J1939–H pin < 10 Ω
J1939–L pin and any other J1939–L pin < 10 Ω
Expected Outcome
All voltage and resistance tests will be within specifications. All ECU’s communicating on J1939 data bus.
Follow-On Procedure
1. Reconnect vehicle harness at suspect connector.
Exhaust Restriction Isolation Test
Overview
Record exhaust aftertreatment system pressures to help determine cause of restriction.
Tools Required
Equipment Condition
None
Test Setup
1. Key Off.
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector. (page 1956)
3. Key On Engine Off (KOEO), log into Navistar® Engine Diagnostics.
Test Procedure
1. Select: Session > Default > Pressure.
2. Select: Tool > Start Recording Snapshot.
3. Start or crank engine. If engine starts, allow engine to run for 30 seconds, then run engine at high idle for
30 seconds, and allow engine idle for 10-15 seconds before shutting down. If engine does not start, crank
engine for 15 seconds.
4. Select: Tools > Stop Recording Snapshot.
5. Review following signals from snapshot recording:
• DPF Differential Pressure (DPFDP)
• DPF Outlet Pressure (DPFOP)
• Exhaust Back Pressure (EBP)
6. Compare signals to their specification (page 2285).
7. Does DPFOP exceed specification?
• Yes: Inspect exhaust after the DPF for DEF crystallization or other exhaust damage causing a restriction.
• No: Got to step 8.
8. Does DPFDP and EBP exceed specification (page 2285)?
• Yes: Inspect DPF for damage or excessive ash and(or) soot.
• No: Got to Step 9.
9. Is EBP the only sensor out of specification (page 2285)?
• Repair exhaust restriction between exhaust manifold and DPF. Inspect turbocharger, DOC and piping
for restriction.
Expected Outcome
Record DPFDP, DPFOP, and EBP to be used to determine location of exhaust restriction.
Follow-on Procedure
None
Fuel Tank Vent Test
Overview
Determine source of air entering fuel system on suction side of fuel supply system (tank to engine).
Tools Required
• ZTSE2499 Hand Operated Vacuum Pump Tester, or equivalent.
Equipment Condition
None
Test Setup
CAUTION:
Do not pressurize fuel tanks.

1. Remove fuel fill cap from tank(s).
2. Obtain service tool (ZTSE2499 or similar).
Test Procedure
1. Attach test tool to open end of fuel tank vent line.
2. Apply vacuum to vent line.
3. Minimal vacuum should show on the gauge, readings in excess of 5” indicate restriction.
4. If restriction is found, remove extension hose from valve and retest at the valve as needed for multiple tanks.
5. Reinstall fuel tank caps before moving or releasing vehicle.
Expected Outcome
Fuel tank vent lines and valves will be free of restriction.
Equipment Condition
None
Coolant Test Procedures

Deaeration Tank Cap Test
Overview
Verify proper operation of the deaeration tank cap.
WARNING:
deaeration cap:
• Continue to turn the cap counterclockwise to remove.
Tools Required
• Coolant Cap Pressure Tester 09-040-01
Equipment Condition
None
Test Setup
1. Allow engine to cool and remove coolant cap from cooling system.
2. Check deaeration tank neck for cracks or warping.
Test Procedure
1. Turn air distribution valve to center (closed) position on the Coolant Cap Pressure Test Tool 09-040-01.
2. Install screw-on style coolant cap on correct adapter of the Coolant Cap Pressure Test Tool 09-040-01.
Figure 765 Screw-on style coolant cap on Pressure Test Tool

1. Screw-on style coolant cap
2. Air distribution valve
3. pressure regulator knob
4. Shop air hose
3. With air distribution valve closed, connect shop air hose to hose fitting on bottom of Coolant Cap Pressure
Test Tool 09-040-01.
CAUTION:
Do not exceed coolant cap manufacturer’s pressure rating. Doing so could result in
premature failure to coolant cap. If pressure is exceeded, replace coolant cap.
4. Turn pressure regulator knob counter clockwise until coolant cap manufacturer’s specified pressure rating
has been reached.
Figure 766 Air distribution Valve Open Position
5. Slowly turn (open) air distribution valve towards the coolant cap.
6. Close air distribution valve (center position). Monitor pressure regulator gauge for pressure decay. If
pressure drops rapidly, then replace coolant cap.
Expected Outcome
Cap will hold rated pressure.
Follow-on Procedure
None
Cooling System Pressure Test
Overview
Apply air pressure to cooling system to determine if system has leaks. The system should hold pressure
indicating there are no leaks.
WARNING:
WARNING:
To prevent personal injury or death, do following when removing radiator cap or

deaeration cap:
• Wrap a thick cloth around the radiator cap or deaeration cap.
• Loosen cap slowly a quarter to half turn to vent pressure.
• Continue to turn cap counter-clockwise to remove.
WARNING:
To prevent personal injury or death, ensure shop-air pressure is properly regulated.
Tools Required
• Radiator Pressure Test Kit ZTSE2384
Equipment Condition
Cooling system full.
Test Setup
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 on dearation tank.
5. Pressurize cooling system to cap rated pressure.
6. Check both sides of vehicle for coolant, leaks, and coolant on the ground.
7. If coolant is leaking, determine what component is leaking.
Test Procedure
1. Pump ZTSE2384 to pressurize the cooling system to the cap rated pressure.
2. Take note of gauge reading and check for pressure decay.
3. Watch gauge for 15 minutes to see if pressure decays.
4. Inspect vehicle for coolant leaks.
Expected Outcome
Cooling system will hold cap rated pressure for a minimum of 15 minutes.
Follow-on Procedure
Replace splash guards (if removed).
Air Compressor Leaking Coolant to Oil Test
Overview
This test is used to verify that the air compressor is not leaking engine coolant into the engine engine oil.
Tools Required
Equipment Condition
None
Test Setup
1. Drain engine engine oil and remove oil pan
2. Install Radiator Pressure Test Kit - ZTSE2384 on Deaeration Tank
3. Maintain 15 psi (103 kPa) of cooling system pressure throughout this test
4. Perform Coolant Leak - Visual Inspection (page 2120)
Test Procedure
1. With cooling system under 15 psi (103 kPa) of pressure, visually inspect engine oil return port from air
compressor inside crankcase
Expected Outcome
No engine coolant will be found leaking from engine oil return port from air compressor.
Follow-On Procedure
None
Air Compressor Leaking Air to Coolant Test
Overview
Determine if air compressor is aerating coolant or causing coolant to overflow by reducing pressure in vehicle
air system.
Tools Required
None
Equipment Condition
None
Test Setup
1. Fill deaeration tank with coolant to proper level.
2. Install deaeration tank cap.
3. Drain vehicle air tanks.
Test Procedure
1. Open air tank drain valves and prop them open.
2. Run engine to recreate overflow condition.
Expected Outcome
Determine if air compressor is causing coolant overflow.
Follow-on Procedure
Close air tank drain valves.
Aftertreatment Hydrocarbon Doser (AFTHD) Coolant Leak Test
Overview
Inspect inside of exhaust pipe at Aftertreatment Hydrocarbon Doser (AFTHD) for presence of coolant.
WARNING:
To prevent personal injury or death, allow engine to cool before removing components.
WARNING:
To prevent personal injury or death, do not let engine fluids stay on your skin. Clean skin
and nails using hand cleaner and wash with soap and water. Wash or discard clothing
and rags contaminated with engine fluids.
Tools Required
• Radiator Pressure Testing Kit ZTSE2384
Equipment Condition
WARNING:
deaeration cap:
• Continue to turn cap counterclockwise to remove.
Test Setup
1. Remove deaeration tank cap.
2. Connect Radiator Pressure Testing Kit ZTSE2384 with Surge Tank Cap Adaptor to deaeration tank.
Test Procedure
1. Disconnect exhaust pipe at the turbocharger outlet pipe after the AFTHD.
2. Pressurize cooling system to 117 kPa (17 psi) for 15 minutes.
3. Inspect inside of exhaust pipe at AFTHD nozzle for coolant leaks.
Expected Outcome
Technician will verify if coolant leak is present at AFTHD nozzle.
Follow-on Procedure
None
EGR Cooler Leak Test
Overview
Test Exhaust Gas Recirculation (EGR) cooler for coolant leakage.
Tools Required
• EGR Cooler Pressure Test Kit 12–892–07
• Spray bottle with soapy water solution
• Beaker of water
Equipment condition
EGR cooler removed from engine (see Engine Service Manual).
Test Setup
Figure 767 EGR Cooler Supply and Return Lines / Harness

1. Exhaust gas outlet hose 3. EGR valve harness
2. EGR valve coolant return line 4. EGR valve coolant supply 90
and deaeration fitting degree fitting
1. Remove EGR cooler exhaust gas outlet hose (1), EGR valve coolant return line and deaeration fitting
(2) (see Engine Service Manual).
2. Remove EGR valve coolant supply 90 degree fitting (4).
Figure 768 Exhaust Gas Inlet Adapter 12–892–07–02

1. Exhaust Gas Inlet Adapter
3. Install Exhaust Gas Inlet Adapter (1) into EGR cooler exhaust gas inlet port. Tighten knurled ring to seal.
Figure 769 Heater Core Supply Plug 12–892–07–03

1. Heater Core Supply Plug
4. Align and install Heater Core Supply Plug (1) into heater core supply port. Tighten knurled knob to seal.
Figure 770 Coolant Inlet Block-Off 12–892–07–06

1. Coolant Inlet Block-Off
5. Align and install Coolant Inlet Block-Off (1) into EGR cooler coolant inlet port. Tighten knurled knobs to
seal.
Figure 771 EGR Valve Coolant Supply Adapter 12–892–07–09

1. EGR Valve Coolant Supply
Adapter
6. Align and install EGR Valve Coolant Supply Adapter (1) into EGR valve coolant supply port.
Figure 772 Sleeper Cab Heat Block-Off 12–892–07–05

1. Sleeper Cab Heat Block-Off
7. If vehicle is equipped with bunk heater, align and install Sleeper Cab Heat Block-Off (1). Tighten knurled
knob to seal.
Figure 773 Front Pressure Test Adapters

1. Exhaust Gas Outlet Plug
12–892–07–01
2. EGR Valve Coolant Return,
Deaeration, and Coolant Filter
Supply Plug 12–892–07–10 (3)
3. Coolant Outlet Clamp Assembly
knurled knob
4. Coolant Outlet Clamp Assembly
12–892–07–07
8. Align and install Exhaust Gas Outlet Plug (1) into EGR cooler exhaust gas outlet port. Tighten knurled
ring to seal.
9. Align and install three EGR Valve Coolant Return, Deaeration, and Coolant Filter Supply Plugs (2) as
needed for vehicle configuration.
10. Align and install Coolant Outlet Clamp Assembly (4) into EGR cooler coolant return port. Tighten knurled
knob (3) to seal.
Figure 774 Bubble Test Hose Assembly 12–892–07–04

1. Bubble Test Hose Assembly
11. Install Bubble Test Hose Assembly (1) onto EGR Valve Coolant Supply Adapter.
Figure 775 Regulator Assembly Installed On Outlet Plug

1. Regulator Assembly
12–892–07–08
2. Exhaust Gas Outlet Plug
12–892–07–01
12. Install Regulator Assembly (1) onto Exhaust Gas Outlet Plug (2).
CAUTION:
Adjust air regulator knob on regulator assembly to minimum setting before connecting
filtered shop air supply. Applying high-pressure air can cause damage to tools or
components.
13. Connect filtered shop air supply to Regulator Assembly.
Test Procedure
Figure 776 Regulator Assembly

1. Air regulator knob 2. Gauge
1. Slowly turn air regulator knob (1) on Regulator Assembly clockwise until gauge (2) reads 40 psi (276 kPa).
2. Spray a soapy water solution on EGR cooler pressure test kit adapters and fittings. Look for leaks from
adapters and fittings.
Figure 777 Test Hose In Beaker of Water

1. Red marking 2. Test hose
3. Insert test hose (2) into a beaker of water to depth of 0.375 inches. Red marking (1) on test hose indicates
depth of 0.375 inches.
4. After inserting hose into water wait 30 seconds and then monitor for air bubbles for 5 minutes. Disregard
any air bubbles that appear during initial pressurization within the first 30 seconds, these do not indicate a
failure of the cooler.
• If no air bubbles present after 5 minutes, go to step 4.
• If air bubbles are present during 5 minutes, replace EGR cooler.
5. Remove shop air supply from Regulator Assembly and relieve air pressure from EGR cooler.
Figure 778 Bubble Test Hose and Regulator Assembly Switched

1. Bubble Test Hose Assembly 2. Regulator Assembly
6. Switch positions of Bubbles Test Hose Assembly (1) and Regulator Assembly (2).
7. Connect filtered shop air supply to Regulator Assembly.
8. Slowly turn air regulator knob on Regulator Assembly clockwise until gauge reads 40 psi (276 kPa).
Figure 779 Test Hose In Beaker of Water

1. Red marking 2. Test hose
9. Insert test hose (2) into a beaker of water to depth of 0.375 inches. Red marking (1) on test hose indicates
depth of 0.375 inches.
10. After inserting hose into water wait 30 seconds and then monitor for air bubbles for 5 minutes. Disregard
any air bubbles that appear during initial pressurization within the first 30 seconds, these do not indicate a
failure of the cooler.
• If no air bubbles present after 5 minutes, EGR cooler can be reused.
• If air bubbles are present during 5 minutes, replace EGR cooler.
Expected Outcome
No air bubbles coming from test hose for 5 minutes.
Follow-On Procedure
None
Thermostat Operational Test
Overview
Determine if engine thermostats open when engine reaches operating temperature by monitoring upper radiator
hose temperature.
Tools Required
• Infrared Thermometer ZTSE4799
Equipment Condition
1. Ensure Engine Coolant Temperature is below 120° F (49° C) before staring the test.
2. Perform Coolant Level Inspection (page 2159). Ensure Coolant is full before performing test.
Test Setup
Test Procedure
1. Select the Temperature tab in Navistar® Engine Diagnostic Software.
2. Start engine and raise engine RPM to warm coolant to operating temperature.
3. Monitor upper radiator hose temperature using Infrared Thermometer ZTSE4799.
4. Run engine at high idle to operating temperature. Upper radiator hose temperature should be less than ECT
while thermostat is closed. As ECT reaches approximately 181°F (83°C), a working thermostat will begin to
open, and the upper radiator hose should heat up to match ECT ± 25° F (14° C).
• If ECT continues to rise and upper radiator hose remains cooler, replace thermostat.
• If ECT never reaches 181° F (83° C), replace thermostat.
• If upper hose matches ECT after engine coolant temperature reaches approximately 181° F (83° C),
thermostat is working properly.
Expected Outcome
Upper radiator hose temperature will increase to within ± 25° F (14° C) of ECT after engine warms up past
thermostat opening temperature.
Follow-On Procedure
None
Engine Oil Tests

Oil Pressure Verification Test
Overview
Compare electronic signal from Engine Oil Pressure (EOP) sensor to actual oil pressure using mechanical
gauge.
Tools Required
• Pressure Test Kit ZTSE4409
• Oil Pressure Test Fitting 12–889–04
Equipment Condition
Engine at operating temperature at or above 181° F (83° C) .
Test Setup
A. Key OFF. Remove Engine Oil Pressure (EOP) sensor from oil filter module (see Engine Service Manual),
and install Oil Pressure Test Fitting 12–889–04 into oil filter module.
1 2 3 4 5 6
0000419708
Figure 780 Oil Pressure Verification Test Connection

1. Oil Pressure Test Fitting 12–889–04
B. Connect Pressure Test Kit ZTSE4409 to Oil Pressure Test Fitting (Figure 780) (Item 1).
C. Key On Engine Off (KOEO).
D. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector. (page 1956)
E. Log in to Navistar® Engine Diagnostics.
Test Procedure
1. Start engine.
2. Allow engine to idle until oil pressure reading is stabilized.
3. At low idle, monitor mechanical gauge for engine oil pressure reading; record value.
4. Increase engine speed to high idle.
5. At high idle, monitor mechanical gauge for engine oil pressure reading; record value.
6. Key OFF. Remove Oil Pressure Test Fitting 12–889–04 into oil filter module from oil filter module, and
re-install Engine Oil Pressure (EOP) sensor.
7. Start engine.
8. Allow engine to idle until oil pressure reading is stabilized.
Figure 781 Navistar® Engine Diagnostic Software Tools Menu – Start Recording
9. From the default Session, select Start Recording button.

11. Wait until oil pressure reading stabilizes and then return engine to low idle.

12. Stop signal recording by selecting Stop Recording button.

13. Compare mechanical gauge readings to the snapshot taken.
Expected Outcome
EOP reading on mechanical gauge, and EOP sensor signal value in Navistar® Engine Diagnostics will be within
specification (page 2286) and approximately the same.
Follow-On Procedure
Remove oil pressure test fitting 12–889–04 and re-install EOP sensor.
Power Steering Fluid Leak to Engine Oil Test
Overview
Verify Power Steering Fluid is not leaking to Engine Oil.
Tools Required
None
Equipment Condition
None
Test Setup
1. Adjust engine oil level to full operating range.
2. Adjust power steering fluid level to full operating range.
Test Procedure
1. Start engine, run for a minimum of 10 minutes.
2. Stop engine, inspect engine oil and power steering fluid levels.
• If power steering fluid level is decreasing and engine engine oil level is increasing, install a new power
steering pump (see Engine Service Manual).
• If power steering fluid level is not decreasing and engine oil level is not increasing, power steering fluid
is not leaking into engine oil.
Expected Outcome
Technician will verify Power Steering Fluid is not leaking to Engine Oil.
Follow-on Procedure
None
Instrument Panel Engine Oil Pressure Gauge Validation Test
Overview
Compare EOP sensor signal value in Navistar® Engine Diagnostics to instrument panel gauge reading.
Tools Required
Equipment Condition
Engine at operating temperature at or above 181° F (83° C) .
Test Setup
2. Connect Electronic Service Tool (EST) to vehicle Diagnostic Connector. (page 1956)
Test Procedure
1. Start engine.
Figure 783 Navistar® Engine Diagnostics Tools Menu – Start Recording

2. Start recording by selecting start recording button. Monitor instrument panel gauge during test.
3. Allow engine to idle for 5 – 10 seconds or until oil pressure reading is stabilized.
5. Wait until oil pressure reading stabilizes and then return engine to low idle.

6. Stop signal recording by selecting Stop recording button.

7. Compare Instrument panel gauge and Navistar® Engine Diagnostics Oil Pressure readings.
Expected Outcome
EOP sensor signal value in Navistar® Engine Diagnostics, and instrument panel gauge will be within High Idle
specification (page 2286), Low Idle specification (page 2286) and approximately the same.
Follow-On Procedure
None
Engine Brake
Engine Compression Brake ECM Inputs and Programmable Parameter Checks
Overview
Verify engine compression brake Engine Control Module (ECM) input and parameter values are within
specification
Tools Required
• Electronic Service Tool (EST) with Diamond Logic Builder™ software
• EST with Navistar® Engine Diagnostics
Equipment Condition
None
Test Setup
Test Procedure
1. Select: Sessions > Parameters.
2. Verify the following engine parameters are set to correct value using table below:
Parameter Value Possible Values Recommended Settings

Vehicle Retarder Control Mode • 0: Off • 1, 2, 3, or 4. A value of 0
(7000x) indicates the Engine Brake
• 1: Service Brake Latched
is disabled.
• Determines conditions
• 2: Coast
Engine Brake feature will
be functional. • 3: Latched
• 4: Smart Latched
Engine Retarder- Brake Pedal Delay • 0 to 300 seconds • 1 seconds
(7001x)
• Sets delay time for
(optional) service brake
pedal activated Engine
Brake.
• The Engine Brake mode
must be set to Service
Brake Latched or Coast
(Mode 1, 2, or 4).
Engine Retarder Minimum Vehicle • 0 to 130.5 mph • 15 mph - vehicle may

Speed (7002x) experience bucking or
jerking if set below 15 mph.
• Sets minimum vehicle
speed limit that Engine
Brake can be activated.
Cruise Control Engine Retarder Low • 0 to 130.5 mph • 4 mph - This should be
Speed (7003x) set higher than the PCC
Maximum Positive Offset
• This parameter sets the
(7619x) parameter value.
vehicle speed above the
cruise set speed at which
the Engine Brake will
activate at the programmed
Cruise Control Engine
Brake Low Activation
(7005x) parameter setting.
Cruise Control Engine Retarder High • 0 to 130.5 mph • 6 mph
Speed (7004x)
programmed speed (above
the cruise set speed) at
which the engine brake will
activate at 100%.
Cruise Control Engine Retarder High • 0 to 100% • 35%
Speed (7005x)
activation percent (%) that
the engine brake feature
starts at the Cruise Control
Engine Retarder Low
Speed (7003x) parameter
setting.
Cruise Control Engine Retarder • 0: Disabled • 1: Enabled
Enable (7006x)
• 1: Enabled
• This parameter enables
the cruise control related
Engine Brake functionality.
Engine Retarder- Accelerator Pedal • 0 to 300 seconds • 1 seconds - If this is set too
Delay (7008x) low, the engine brake may
activate while shifting gears
on a manual transmission.
delay time for (optional)
accelerator pedal activated
Engine Brake or Smart
Latched.
• The Engine Brake mode

must be set to Latched
(Mode 3) or Smart Latched
(Mode 4).
Road Speed Limit Engine Brake • 0: Disabled • 2: Enabled, accelerator
Activation Enable (7011x) pedal will NOT disable
• 1: Enabled, accelerator
brake
• When enabled the engine pedal will disable brake
brake will active when the
• 2: Enabled, accelerator
truck exceeds the maximum
pedal will NOT disable
programmed vehicle speed
brake
plus the (7003x) brake
enable low speed offset. It
also allows the customer to
determine if the driver can
disable the brake with the
accelerator pedal in vehicle
over speed situations.
Engine Brake Switch Override • 0: Switch off will allow • 1: Switch off will only
of CC/RSL Engine Brake CC/RSL brake activation disable CC brake activation
Activation (7012x)
• 1: Switch off will only
• This parameter determines disable CC brake activation
if the retarder on/off level
• 2: Switch off will only
switch will affect the
disable RSL brake
operation of the retarder
activation
during cruise control of
when the road speed • 3: Switch off will disable
limiting is active. both CC and RSL brake
activation
Smart Engine Brake Level Enable • 0: Disabled • 0: Disabled
(7013x)
• 1: Enabled
• When enabled level
2-Medium will switch to
an acceleration based
brake level. This allows the
driver to descend long hills
with varying grades and not
have to manually switch
brake levels to maintain the
vehicle speed. This feature
is optimized for Eaton AMT

transmissions.
Engine Brake Switch 1 Input • 0: Enabled with Hardwire • Customer Choice
Selection (99302) input
• This parameter selects how • 1: Enabled with CAN input
the ECM sees the switch for
setting Source addresses.
See Engine Feature Documentation on the Navistar Body Builder website for information.
3. Log off Navistar® Engine Diagnostics and log in to Diamond Logic Builder™ software.
4. Go to Features and select the Filter icon in the left hand corner of the Features window.
5. Type “Engine Brake” into the pop-up search window.
6. Click on appropriate feature code so it is highlighted. Lower half of window will now show applicable
parameters for that feature.
7. Verify the following parameter values:
• Clutch switch status in Engine Control Module (ECM) and Body Control Module (BCM)
• Brake switch status in ECM and BCM
• Engine Brake switch status in ECM
• Accelerator Pedal Position (APP) sensor 0.00% when released
Expected Outcome
Engine brake Engine Control Module (ECM) input and parameter values are within specification.
Follow-On Procedure
None
Engine Compression Brake Operational Test
Overview
Determines if engine compressions brake activates when commanded ON.
Tools Required
Equipment Condition
None.
Test Setup
2. Connect EST with Navistar® Engine Diagnostic Software to vehicle diagnostic connector (page 1956)
and log in.
Test Procedure
1. Run engine to operating temperature 180°F (82°C).
2. Select: Tests > KOEO Tests > Actuator Test.

Figure 786 Selecting Engine Compression Brake 1 Actuator Test
3. Select Engine Compression Brake 1 tab.

4. While the engine is running, click “Start Test” button (2) and monitor engine for a misfire on three cylinders.
If misfire does not occur, diagnose engine compression brake 1 problem.
Figure 787 Selecting Engine Compression Brake 2 Actuator Test
5. Select Engine Compression Brake 2 tab.

6. While the engine is running, click “Start Test” button and monitor engine for a misfire on three cylinders. If
misfire does not occur, diagnose engine compression brake 2 problem.
Expected Outcome
Each engine brake assembly will cause three cylinders to misfire when commanded ON. Engine should not
misfire when brakes are commanded OFF.
Follow-On Procedure
None.
Engine System Inspections

Initial Key On Check
Determine if Engine Control Module (ECM) is powered up and if water is in fuel supply.
Tools Required
None
Equipment Condition
None
Test Setup
1. Key-ON Engine-OFF (KOEO).
Test Procedure
1. Observe the following:
• Wait to Start lamp
• WATER IN FUEL indicator (Integral Digital Display)
2. Record results on Diagnostics Form.
• If WATER IN FUEL indicator stays ON, go to Fuel Quality Check (page 2156).
Expected Outcome
Technician will verify ECM is powered up and if water is in fuel supply.
Follow-on Procedure
None
Fuel Level and System Inspection
Overview
Verify instrument panel fuel gauge indicates correct fuel level, and fuel system is free of damage. Check primary
(chassis mounted) fuel filter for leaks, correct filters, contamination, and other damage.
WARNING:
sparks.
Tools Required
None
Equipment Condition
1. Vehicle parked on level ground.
Preliminary Inspection Procedure

1. Visually inspect the fuel tank(s) for leaks or damage.
2. Visually inspect level of fuel in fuel tank(s).
3. Inspect interior of fuel tanks and ensure fuel level is equal in both tanks if equipped with dual tanks.
4. Visually inspect fuel for waxing, gelling, and cloudiness.
5. Check instrument panel fuel gauge and verify indicated fuel level is consistent with actual fuel level.
6. Visually inspect all fuel lines and connections for leaks, damage, and proper routing.
7. Visually inspect secondary fuel filter for damage and leaks. Ensure seal on the bottom of filter is in place
and not damaged. Also, ensure filter standpipe is properly installed and not cracked or damaged.
8. If fuel filter is not a Navistar OEM part number, replace with OEM fuel filter. Non OEM filters can cause
performance and / or starting issues.
After Preliminary Inspection Procedure is complete, perform one of the following primary fuel filter inspections
based on style of filter equipped:
• Inspection Procedure Canister Style Filter (page 2153)
• Inspection Procedure Cartridge Style Filter (page 2154)
Inspection Procedure Canister Style Filter
Figure 788 Canister Style Filter (Typical)
1. Check fuel filter and filter housing for fuel leaks, large dents, or damage.
2. Verify fuel filter O-ring is installed properly and free of damage.
3. Check maintenance history for primary fuel filter replacement. Replace filter if beyond recommended
service interval (see Engine Operation and Maintenance Manual).
Inspection Procedure Cartridge Style Filter
Figure 789 Cartridge Style Filter (Typical)
1. Check fuel filter and filter housing for fuel leaks or damage.
2. Visually inspect fuel filter following the Primary Fuel Filter (Cartridge Style) Inspection) (page 2154).
Primary Fuel Filter (Cartridge Style) Inspection

Fuel Level Visual Indication Possible Solution
Fuel level below top of fuel filter. Normal - no repair necessary.
Fuel level above top of fuel Change primary fuel filter element.
filter. May cause loss of power
complaint.
Primary Fuel Filter (Cartridge Style) Inspection (cont.)

Fuel level is to top of fuel filter 1. Change primary fuel filter element
and looks to be full of wax.
2. Run engine for a minimum of 25 minutes at idle. Do not run at
high idle.
Excessive bubbles are seen 1. Check all fittings and lines from between fuel tank and chassis
flowing within fuel. fuel filter assembly.
2. Check upper and lower connector O-rings.
Loss of power complaint. Fuel 1. Check for missing grommet at lower end of filter.
level is below fuel filter housing
2. Check for missing or broken spring at top of primary fuel filter
collar.
element.
Water is seen (noticeable 1. Inspect fuel tank(s) for water contamination.

separation) in fuel filter
2. Drain a full cup of fuel from chassis fuel filter assembly.
assembly.
NOTE: Do not drain with engine running.
3. Restart engine. Shut off engine and drain chassis fuel filter
assembly.
4. Repeat step 3 until ALL water is removed.
Fuel drains back to fuel tank 1. Remove and inspect check valve assembly.
when changing fuel filter or
2. Repair (clean) or replace as necessary, and retest.
draining water separator.
Fuel Quality Inspection
Overview
Drain both fuel filter assembly and check fuel quality.
WARNING:
sparks.
NOTE: Ultra Low Sulfur Diesel (ULSD) fuel is required for Navistar® Diesel Engines used with advanced
aftertreatment systems.
NOTE: Do not continue diagnostic procedures if fuel is contaminated.
Tools Required
• 2 Clear diesel fuel container
• Clear plastic hose
Equipment Condition
None
Inspection Procedure
1. Take a sample from fuel tank. If sample shows signs of gelling, waxing, or cloudiness, end Fuel Quality
Inspection.
Figure 790 Fuel Sample
2. Install clear plastic hose on secondary fuel filter drain valve.

3. Place clear diesel fuel container under fuel-filter housing.
4. Route clear plastic hose into clear diesel fuel container.
5. Open drain valve and fill container.
6. Repeat Steps 2-4 at the frame rail mounted primary fuel filter.
7. Check all three samples for water, gelling, waxing, cloudiness, 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.
• Water, gasoline and kerosene will separate from diesel fuel.
• Gelling, waxing, cloudy fuel, or icing may prevent diesel fuel flowing from fuel-drain valve.
Expected Outcome
Fuel is free of water, gelling, waxing, cloudiness, icing, sediment, gasoline, kerosene, or Diesel Exhaust Fluid
(DEF).
Engine Oil Level and Quality Inspection
Overview
Inspection of engine oil level and engine oil quality.
Tools Required
None
Equipment Condition
None
Figure 791 Left Side of Engine — Dipstick Location

A. Oil level gauge (dipstick)
1. Use oil level gauge (dipstick) (1) to check engine oil level and quality.
Expected Outcome
Oil level should be within specification and free of dilution, coolant contamination, and improper servicing.
Coolant Level Inspection
Overview
Determine if coolant is at appropriate level.
Tools Required
None
Equipment Condition
1. Allow engine to cold soak.
Figure 792 Coolant Deaeration Tank

A. Deaeration Cap
B. Deaeration Tank
1. Inspect coolant level in deaeration tank.

2. Inspect coolant for debris and signs of contamination.
Expected Outcome
Coolant level should be between COLD MAX and COLD MIN lines and free of debris and contaminants.
Coolant Quality Inspection
Overview
Check coolant for proper freeze point, and for contamination.
Tools Required
• Coolant and Battery Refractometer ZTSE4796
Equipment Condition
• Park vehicle on level ground
1. Wrap a thick cloth around deaeration cap.
2. Loosen cap slowly a quarter to half turn to vent pressure.
3. After pressure has been released, remove cap.
4. Check coolant for signs of contamination.
5. Take a sample from the deaeration tank.
6. Examine sample for engine oil and Diesel Exhaust Fluid (DEF).
• Oil contamination may result in a dark sludge.
• DEF contamination may give 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.
Coolant in Exhaust Inspection
Overview
Determine if engine coolant is in the exhaust system.
WARNING:
To prevent personal injury and / or death, allow engine to cool 15 minutes or more before
working with components.
WARNING:
To prevent personal injury and / or death, do not let engine fluids stay on your skin.
Clean skin and nails using hand cleaner and wash with soap and water. Wash or discard
clothing and rags contaminated with engine fluids.
GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and other contaminated materials (e.g., filters rags)
in accordance with applicable regulation
Tools Required
Equipment Condition
2. Engine allowed to cool for 15 minutes or more.
1. 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 cap.
2. Install Radiator Pressure Test Kit ZTSE2384 (with appropriate adapter if needed) onto deaeration tank.
3. Disconnect exhaust pipe at after the Aftertreatment Fuel Injector (see Engine Service Manual).
4. Pressurize cooling system to 15 psi (103 kPa).
5. Inspect exhaust for engine coolant and engine coolant residue.
6. Inspect exhaust manifold joints / gaskets, turbocharger mounting flange, and other exhaust sealing points
for signs or coolant residue
Expected Outcome
Determine if coolant is in exhaust system.
Coolant to Oil Inspection
Overview
Inspect engine oil 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.
NOTE: Oil contaminated with coolant usually causes oil to thicken and turn light gray.
Tools Required
None
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.
Cylinder Sleeve Cavitation and Crack Inspection
Overview
Inspect cylinder sleeves for holes or cracks caused by cavitation (gas-filled bubbles formed in the coolant).
Tools Required
None
Equipment Condition
1. Remove cylinder head. See Engine Service Manual.
1. Inspect piston crowns for signs of coolant leaks. Lack of carbon indicates possible coolant leak into the
cylinder.
2. Using a torque wrench set to 120 lb-ft (162 N·m), bar engine over until pistons 1 and 6 are at Bottom Dead
Center (BDC).
3. Inspect cylinder sleeves 1 and 6 for coolant, coolant staining, pinholes, and cracks.
4. Repeat for cylinders pairs 2-5 and 3-4.
5. Repair as needed.
Expected Outcome
Carbon deposits should be present on piston crowns, indicating cylinder sleeves are free of holes and cracks.
Cylinder sleeves should not have coolant, coolant staining, pinholes, or cracks.
Charge Air Cooler Inspection
Overview
Inspect the Charge Air Cooler (CAC), hoses, clamps, and connections for leaks, wear, or damage.
Tools Required
• None
Equipment Condition
None
CAUTION:
To prevent damage to engine, do not hold engine at a high idle for a period longer than
20 seconds when performing this inspection.
1. Start engine. Raise engine speed to high idle for no longer than 20 seconds.
2. While engine is at high idle, on right side of engine inspect Charge Air Cooler (CAC), Turbocharger, CAC
hoses, CAC pipe, and clamps for leaks and worn or damaged parts.
3. While engine is at high idle, on left side of engine inspect clamps, CAC, and hose for leaks and worn or
damaged parts.
Expected Outcome
CAC, hoses, clamps, and connections are free of leaks, wear, or damage.
Intake Air Inspection
Overview
Inspect air filter, air intake and charge air systems for leaks, restrictions and / or damage.
Tools Required
None
Equipment Condition
None
WARNING:
If engine oil is found in the intake, do not start engine, as further damage may result.
Diagnose and repair cause of oil in the intake.
1. Inspect for loose or damaged intake and Charge Air Cooler (CAC) hoses and pipes.
• If loose or damaged air hoses or pipes are found, repair Intake or CAC.
2. Inspect for a dirty, damaged, or incorrectly installed air filter.
• If air filter is clean, undamaged, and correctly installed, go to next step.
• If air filter is dirty or damaged, replace air filter, go to next step.
3. Inspect turbocharger inlet pipe and Mass Air Flow (MAF) sensor for damage, blockage, or debris build-up.
• If turbocharger inlet pipe and MAF sensor free of damage, blockage, or debris build-up, go to next step.
• If turbocharger inlet pipe and MAF sensor are damaged, blocked, or have debris build-up, replace MAF
sensor or turbocharger inlet pipe as needed, go to next step.
4. Inspect for air flow restrictions in air intake and charge air tubing, tubing connections, and filter housing.
• If air flow is restricted repair air flow restrictions, go to next step.
• If no air flow restriction is found, no action is required, go to next step.
5. Inspect for signs of engine oil in intake piping.
• Check for oil seeping from joints.
Expected Outcome
Determine if air filter, air filter housing, air intake and charge air tubing have damage, leaks or restrictions. Intake
air restriction should be less than 25 in Hg (84.7 kPa) at full load and rated speed.
Exhaust and Aftertreatment System Inspection
Overview
Inspect exhaust and aftertreatment system for leaks, damage, and restrictions.
Tools Required
None
Equipment Condition
None
A
B
C D C
B B
B
0000413916
Figure 793 Exhaust and Aftertreatment System (Single Can)

A. V-Band Clamps C. Large V-Band Clamps
B. Sensor Ports (8) D. DEF Doser Valve (DEFDV)
1. Visually inspect DEFDV (Item D) for damage or leaking DEF.

2. Inspect all clamps (Items A and C) for soot leakage or damage.
3. Inspect all 8 sensor ports (Item B) for leakage or damage.
0000413918
Figure 794 Aftertreatment Hydrocarbon Doser (AFHD)

A. E. Aftertreatment Hydrocarbon
Doser (AFTHD)
4. Visually inspect AFTHD (Item E) for damage, coolant leaks and fuel leaks.
I 0000413920
Figure 795 Exhaust System (Engine)

A. F. Exhaust Manifold Flange (6) C. H. Exhaust manifold to Turbo D. I. Turbocharger Outlet Pipe
B. G. EGR Valve Bellows Tube gasket sealing flanges (2)
Clamps (4)
5. On engine exhaust system, check the following for damage, restrictions, and leaks:
• Exhaust Manifold flanges (Item F)
• EGR Valve Bellows Tube Clamps (Item G)
• Turbocharger (Item H)
• Turbo outlet pipe (Item I)
Expected Outcome
Technician will determine if exhaust and aftertreatment system is leaking, damaged, or restricted.
Oil in Intake Inspection
Overview
Check for engine oil in the intake system.
Tools Required
None.
Equipment Condition
Engine Off.
1. Remove Charge Air Cooler (CAC) inlet and outlet piping.
2. Inspect for wet or pooling engine oil.
Expected Outcome
Intake piping will be free of excessive engine oil.
Oil and Crankcase Inspection
Overview
Inspect for internal components leaking larger than normal amounts of oil or damaged internal parts.
Tools Required
• Regulator assembly
Equipment Condition
1. Oil drained.
2. Oil pan removed (see Engine Service Manual).
Figure 796 Oil Pump Pick-up Tube

A. Oil pump pick-up tube O-ring
1. Inspect oil pump pick-up tube and oil pump pick-up tube O-ring (A) for looseness, cracks, obstructions, and
other damage.
2. Visually inspect crankcase for missing, loose, or damaged cylinder sleeve O-rings.
3. Visually inspect bearing inserts for damaged or spun bearings.
Figure 797 Piston Cooling Jet

1. Cooling jet bolt (6) 2. Piston cooling tube (6)
4. Check six piston cooling jets for loose or missing cooling jet bolts (1), and six piston cooling tubes (2) for
damage.
Expected Outcome
No internal engine damage or excessive engine oil leaking will be found.
Oil Pump and Fan Drive Oil Leak Inspection
Overview
Inspect oil pump, gear driven fan drive, and cup plugs for oil leaks and damage.
Tools Required
• None
Equipment Condition
1. Engine front cover removed (see Engine Service Manual)
Figure 798 Fan Drive Supply Cup Plug

A. Cup Plug
See Fan Drive Supply Cup Plug (Figure 798) to perform step 3.
1. Verify oil supply to fan drive has cup plug (A) installed and is not leaking.
2. Remove Oil pump (see Engine Service Manual).
Figure 799 Oil Pump Exploded View

A. Cover D. Axle G. Ring Gear Bushing
B. Cup plug E. Pinion Gear H. Inlet O-ring
C. Axle O-ring F. Ring Gear
See Oil Pump Exploded View (Figure 799) to perform step 5.

3. Inspect oil pump Cup Plug (B), Cover (A), Axle O-Ring (C), Axle (D), Pinion Gear (E), Ring Gear (F), Ring
Gear Bushing (G), and Inlet O-ring (H) for damage or leaks.
4. Inspect all front gear train bearing studs for signs of oil leaks or damage. Inspect all gears for signs of
excessive wear.
Expected Outcome
Technician will determine if oil pump, gear driven fan drive, or cup plugs are damaged or leaking.
Cylinder Head, Valve train, and Engine Brake Housing Oil Leak Inspection
Overview
Inspect cylinder head, rocker arm shafts, rocker arms, and engine brake housings for oil leaks causing low oil
pressure.
Tools Required
• None
Equipment Condition
1. Valve cover removed (see Engine Service Manual).
Figure 800 Rocker Arm and Shaft Plugs

A. Oil cup plug (3 per rocker shaft)
1. Inspect end of rocker shafts and arms for 18 properly installed and not leaking oil cup plugs (Item A).
Figure 801 Cylinder Head (Front View)

A. Oil cup plug (2)
2. Inspect two oil cup plugs (Item A) ,on front of cylinder head near upper left of intake manifold inlet port, for
proper installation and free of leaks.
Figure 802 Cylinder Head (Rear View)

A. Oil cup plug (3)
3. Inspect three oil cup plugs (Item A), at rear of cylinder head near camshaft gear, for proper installation and
free of leaks.
Figure 803 Engine Brake Housing (Front View)

A. Oil Cup Plug (2 per housing)
4. Inspect two oil cup plugs (Item A), on front left of each engine brake housing, for proper installation and free
of leaks.
Figure 804 Engine Brake Housing (Right View)

A. Oil cup plug (11 per housing)
5. Inspect 11 oil cup plugs (Item A), on right side of each engine brake housing, for proper installation and free
of leaks.
Figure 805 Engine Brake Housing (Left View)

A. Oil cup plug (6 per housing)
6. Inspect six oil cup plugs (Item A), on left side of each engine brake housing, for proper installation and free
of leaks.
Expected Outcome
Cylinder head, engine brake housing, rocker arm, and rocker arm shaft oil cup plugs are properly installed and
free of leaks.
Engine Brake Inspection
Overview
Inspect engine brake.
Tools Required
None
Equipment Condition
Remove over-engine equipment such as air intake, and turbocharger crossover pipes. Follow procedures in the
Engine Service Manual.
Remove upper valve cover, following procedures in the Engine Service Manual.
Figure 806 Engine Brake Housing Assembly (Top View)

A. Hold-down bolt (6 per housing) C. Engine brake housing plug (21 E. Engine brake housing
B. Control valve assembly (3 per per housing) F. Slave piston adjustment screw
housing) D. Engine brake solenoid assembly (3 per housing)
1. Check for loose, damaged, brittle, or cracked wiring or connections at engine brake solenoid. Repair as
necessary.
2. Check for loose or damaged hold-down bolts (Figure 806) (Item A).
• If hold-down bolts are loose or damaged, tighten to specification or replace as necessary.
3. Check control valve assembly (Figure 806) (Item B) for binding in housing bore.
• If control valve assembly is binding, clean housing and control valve. If binding continues, replace
housing.
4. Remove engine brake solenoid assembly (Figure 806) (Item D) from engine brake housing (Figure 806)
(Item E) (see Engine Service Manual).
Figure 807 Engine Brake Solenoid Assembly

A. Hold-down bolt (6 per housing) D. Engine brake solenoid assembly G. O-ring (2 per solenoid)
B. Control valve assembly (3 per (1 per housing) H. Screen (1 per solenoid)
housing) E. Engine brake housing
C. Engine brake housing plug (21 F. Slave piston adjustment screw
per housing) (3 per housing)
5. Check engine brake solenoid assembly screens (Item H) and O-rings (Item G) for damage or restrictions.
Replace as necessary.
6. Remove engine brake assemblies from engine (see Engine Service Manual).
7. Check engine brake housing for cracks.
• If cracks are present, replace engine brake housing.
8. Check engine brake housing plugs (Figure 806) (Item C) for leaks.
• If leaks are present, remove plug and clean threads. After threads are cleaned, reinstall plug(s) and
tighten to 100 lbf-in (11 N·m).
Figure 808 Engine Brake Assembly (Bottom View)

A. Hold-down bolt (6 per housing) D. Engine brake solenoid assembly H. Screen
B. Control valve assembly (3 per E. Engine brake housing I. Master piston roller (3 per
housing) F. Slave piston adjustment screw housing)
C. Engine brake housing plug (21 (3 per housing) J. Slave piston (3 per housing)
per housing) G. O-ring (2)
9. Inspect master piston rollers (Item I) for damage or binding,

• If rollers are binding, clean housing and master piston. If binding continues, replace housing.
10. Check engine brake slave piston (Item J) setting of 0.8 mm and engine valve settings (see Engine Service
Manual) and adjust as necessary.
Expected Outcome
Engine brake housing should be free of cracks, engine brake solenoid and control valve assemblies in good
operating condition, and engine brake housing plugs should be free of leaks. Valve bridges and actuator pins in
place and free of damage. Engine brake slave piston adjustment will be within specification. Master and slave
pistons free of damage and binding.
Turbocharger Radial Play Inspection
Overview
Check Variable Geometry Turbocharger (VGT) for excessive radial play.
Tools Required
None
Equipment Condition
Remove Turbocharger Inlet Duct.
1. Inspect turbocharger compressor housing and compressor wheel for signs of contact including damage to
the compressor wheel and/or scarring to the compressor housing.
2. Inspect for turbocharger shaft failure. Gently spin the turbocharger compressor wheel and inspect turbine
wheel to ensure both rotate together.
Expected Outcome
Turbocharger compressor wheel does not have excessive play, does not contact the inside of the compressor
wheel housing, and shaft is free from damage.
Internal Engine Damage Inspection
Overview
Inspect lower crankcase, upper crankcase, cylinder head, and cylinder bore for damage.
Tools Required
• None
Equipment Condition
2. Negative battery cable disconnected.
3. Oil pan removed (see Engine Service Manual).
Figure 809 Lower Crankcase

A. Connecting rod (6) B. Oil pickup tube C. Crankshaft
1. Inspect six connecting rods (A) if bent or broken; oil pickup tube (B) if loose or damaged; and crankshaft
(C) for damage.
• If damage is found, refer to Engine Service Manual for proper repair procedures.
• If no components are damaged, go to step 2.
Figure 810 Upper Crankcase

D. Piston (6) E. Piston cooling jet (6) F. Cylinder liner (6)
2. Inspect six pistons (D) for cracks or damage, six piston cooling jets (E) for damage, and six cylinder liners
(F) for cracks or breaks.
3. Drain engine coolant.
4. Remove cylinder head (see Engine Service Manual).
Figure 811 Cylinder Head (Bottom View)

G. Cylinder head H. Valve (24) I. Valve seat (24)
5. Inspect cylinder head (G) for cracks or damage; 24 valves (H) if bent, burnt or broken; and 24 valve seats
(I) if dropped or broken.
Figure 812 Cylinder Bore

D. Piston (6) F. Cylinder liner (6)
6. Inspect six cylinder liners (F) for damage, six pistons (D) for damage; and if piston rings are stuck or
damaged.
7. Determine if a connecting rod is bent. Check piston protrusion (see Engine Service Manual).
Expected Outcome
Technician will determine if internal engine mechanical damage is present.
Valve Train Inspection
Overview
Inspect rocker arm roller pins, valve bridges, valve tips and camshaft lobes for signs of excessive wear and
damage.
Tools Required
None
Equipment Condition
• Valve Cover removed (see Engine Service Manual).
1. Inspect for fallen valve bridges and ensure no damage to valves, valve keepers and valve stems.
2. Rotate engine (see Engine Service Manual “Crankshaft Rotation Procedure”) until cylinder 1 rocker arms
are against base circle of camshaft, and both Intake and Exhaust valves are fully closed. Repeat this step
for all rockers being measured.
3. Spin each rocker arm roller by hand and check for binding, replace rocker arm if roller does not spin freely
and continue to next rocker arm.
4. Lightly apply downward pressure on roller and rocker arm.
Figure 813 Rocker Arm and Camshaft

1. Feeler gauge
2. Rocker arm casting fork
3. Base circle of camshaft
5. Using a feeler gauge, measure clearance between base circle of camshaft and rocker arm casting. Minimum
gap measurement should be no less than 0.090 inches or (2.3 mm). Do not measure between roller and
camshaft. Record all measurements.
6. If measurements are out of specification, only replace individual rocker arm as needed.
Figure 814 Rocker Arm and Camshaft Damage

1. Rocker arm
2. Camshaft Lobe
7. Inspect contact surfaces of camshaft lobes and rocker arm rollers for physical damage that can be felt with
a finger nail such as pitting, streaking and excessive wear.
Figure 815 Rocker Arm Roller and Camshaft Normal Wear

1. Rocker arm roller
2. Camshaft Lobe
8. Roller and camshaft lobe surfaces should be smooth, some discoloration and lines are normal.
9. If any failure is found, replace engine oil and filter.
Expected Outcome
Rocker arm rollers, valve bridges, valve tips and camshaft lobes will be free of physical damage or excessive
wear. Clearance between base circle of camshaft and rocker arm casting should not be less than 0.090 inches
or (2.3 mm). Replace any component(s) that show damage or excessive wear.
Connecting Rod, Main Bearing, and Journal Inspection
Overview
Inspect connecting rod and crankshaft bearings, journals, and caps for signs of excessive wear and damage.
Tools Required
• None.
Equipment Condition
• Oil Pan removed (see Engine Service Manual).
1. Remove connecting rod caps and main bearing caps from engine (see Engine Service Manual).
Figure 816 GOOD bearing examples

1. New bearing
2. Used bearing
Figure 817 BAD bearing examples

1. Copper showing
2. Excessive wear with metal transfer
2. Inspect bearing caps and bearings for streaking or pitting that a fingernail can be caught on, indicating
excessive wear.
Figure 818 GOOD crankshaft journal
Figure 819 BAD crankshaft journal — spun bearing damage

3. Inspect crankshaft journals for streaking or pitting that a fingernail can be caught on, indicating excessive
wear.
CAUTION:
To prevent engine damage, replace connecting rod if a connecting rod bearing is spun,
and replace the crankcase of a main bearing is spun.
4. Inspect connecting rod and main bearing caps for damage or excessive wear. Damaged rod or main bearing
caps are not reusable.
CAUTION:
To prevent engine damage, install new connecting rod and main bearing bolts.
Expected Outcome
Determine if connecting rod and crankshaft bearings, journals, and caps are reusable or damaged.
Davco® Fuel Pro 382 Fuel Filter Check Valve Inspection
Overview
Inspect check fuel filter valve for damage and debris.
Equipment Condition
None
Inspection Setup
1. Place container below fuel filter to catch any fuel that may drip during the procedure.
2. Without draining fuel from filter, remove fuel line supply line from fuel inlet port.
Figure 820 Davco® Fuel Filter

1. Vent Cap 3. Drain Valve
2. Fuel Inlet Port 4. Fuel Outlet Port
1. Open vent cap (1) located on top of clear filter cover.

• Fuel leaking steadily back out of inlet port (2) indicates a sticking check valve. A small amount of fuel
seepage is normal.
2. Drain fuel from filter into catch container, using fuel drain valve (3).
3. Remove Fuel Inlet Port from Filter assembly(4).
Figure 821
1. Fuel Inlet Port Fitting 3. Spring
2. Check Ball 4. Retaining Clip
4. Remove plastic retaining clip (4), spring (3), and check ball (2).
5. Inspect plastic retaining clip, spring, check ball, and check ball seat for damage, scratches, burrs, and debris
or sludge build up.
6. Inspect sealing O-ring on Fuel Inlet Port Fitting (1).
7. If no damage is found, clean components and reassemble.
• Replace damaged components as necessary.
Expected Outcome
Check valve assembly will be clean and free of damage.
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
WARNING:
procedures.
WARNING:
Figure 822 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.
D
E
0000414074
Figure 823 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).
A B
E
F
0000414024
Figure 824 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.
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.
Aftertreatment
Aftertreatment Fuel Supply Module Inlet Pressure Test
Overview
This test will measure Pressure at the Aftertreatment Fuel Supply Module inlet to confirm proper fuel supply to
the Aftertreatment system.
Tools Required
• ZTSE4409 – Mechanical or Fluke PV350 – digital pressure gauge (Obtain locally)
Equipment Condition
None
Test Setup
1. Key Off
6
7
0000415483
Figure 825 Tools installed at AFT fuel supply module inlet

1. Pressure gauge
2. High-pressure Fuel Pump
3. Fuel Filter Module
4. AFT fuel supply module inlet
5. AFT Fuel supply line
6. Coupler, Fuel/Oil Pressure Test ZTSE4526
7. Fuel Inlet Restriction / Aeration Tool ZTSE4886
2. Connect Coupler, Fuel/Oil Pressure Test ZTSE4526 to the pressure gauge.

3. Disconnect fuel supply at Aftertreatment Fuel Supply Module inlet.
4. Use Fuel Line Coupler ZTSE4906 to connect Fuel Inlet Restriction / Aeration Tool ZTSE4886 between
the Aftertreatment Fuel Supply Module and fuel supply line.
5. Connect Pressure Gauge to Fuel Inlet Restriction / Aeration Tool ZTSE4886.
Test Procedure
1. Start engine. Run at low and high idle. Monitor Pressure Gauge. Wait for gauge reading to stabilize before
recording both high idle and low idle pressures.
Expected Outcome
Fuel pressure will be 95-115 psi (655-793 kPa) during low idle, and 140-160 psi (965-1105 kPa) during high
idle when measured at the Aftertreatment Fuel Supply Module. Fuel pressure will vary with engine speed. The
higher the engine speed the higher the pressure.
Follow-On Procedure
None
Aftertreatment Hydrocarbon Doser (AFTHD) Inspection
Overview
Inspect Aftertreatment Hydrocarbon Doser (AFTHD) for leaks and damage.
Tools Required
None
Equipment Condition
None
1. Visually inspect AFTHD and exhaust pipe for leaks and damage.
2. Visually inspect Aftertreatment Hydrocarbon Doser (AFTHD) fuel supply line and coolant supply and return
lines for leaks, kinks, bends, or other damage.
Figure 826 Aftertreatment Hydrocarbon Doser (AFTHD)

1. AFTHD mounting bolt (2) 3. Ceramic insulator 5. Turbocharger exhaust outlet
2. AFTHD 4. AFTHD gasket pipe
3. Remove AFTHD (see Engine Service Manual) and discard gasket and insulator. Perform visual check of
the following:
• AFTHD and Turbocharger exhaust outlet pipe bore are unrestricted and free of carbon buildup.
• AFTHD tip is free of cracks and other visible damage.
4. Reinstall AFTHD (see Engine Service Manual) with new gasket and insulator.
Expected Outcome
Technician will determine if AFTHD is leaking and / or damaged. Determine if AFTHD fuel supply, and coolant
supply and return lines are leaking, kinked, bent, or damaged.
Decomp Mixer Inspection
Overview
Inspect decomposition mixer for blockage caused by Diesel Exhaust Fluid (DEF) deposits.
Tools Required
None
Equipment Condition
Decomposition mixer removed from exhaust.
1. Inspect decomposition mixer for blockage caused by DEF deposits.
• If the DEF deposits in the mixer area are blocking more than 50% of the decomposition mixer, the mixer
must be cleaned. Clean using warm water and a soft bristle brush.
2. Inspect the exhaust flanges for corrosion or other damage.
3. Inspect SCR Catalyst face for excessive DEF deposits. Some minor DEF deposits are normal.
Expected Outcome
Decomposition mixer and SCR inlet face should be free from restriction or blockage caused by DEF deposits.
DEF Doser Valve Inlet Pressure Test
Overview
This test will measure the DEF Pressure at the DEF Doser Valve (DEFDV) inlet using a mechanical or digital
gauge.
Tools Required
• DEF diagnostic line, Part Number 5394565 (Obtain from Cummins)
Equipment Condition
Flush DEF diagnostic line 5394565 with warm clean water to ensure the Compucheck fitting is clean and free
of DEF crystals.
Test Setup
1. Key OFF
4 5
1
0000415414
Figure 827 DEFDV Inlet Pressure

1. Pressure Gauge
2. DEF Pressure Line
3. DEF diagnostic line 5394565
4. DEF Backflow Line
5. DEFDV
6. DEFDV Inlet Fitting
7. Coupler, Fuel/Oil Pressure Test
2. Disconnect pressure line from the DEF Doser Valve inlet fitting. This fitting is marked with an arrow
pointing towards injector.
3. Connect DEF diagnostic line 5394565 between vehicle DEF pressure line and DEF Doser valve inlet
fitting.
4. Using Coupler, Fuel/Oil Pressure Test ZTSE4526, connect either a mechanical or digital pressure gauge
to the Compucheck fitting on DEF diagnostic line 5394565.
6. Connect Electronic Service Tool (EST) to vehicle diagnostic connector (page 1956)
7. Start and log in to Navistar® Engine Diagnostics.
Test Procedure
Figure 828 Selecting the DEF System Leak Test
1. Select Tests: KOEO Aftertreatment Tests > DEF System Leak Test. Follow on-screen instructions.
2. When ready, select “Start DEF System Leak Test” button.
3. Monitor installed pressure gauge. Allow pressure reading to stabilize. It may take 30-60 seconds for system
to prime and reading to stabilize.
Expected Outcome
The installed gauge will read between 108-137 psi (750-950 kPa) after system is primed and reading is stabilized.
Follow-On Procedure
Lubricate the O-rings inside of DEF fittings with a synthetic grease before reinstallation.
DEF Doser Valve Outlet Pressure Test
Overview
This test will measure the DEF Pressure at the DEF Doser Valve outlet using a mechanical or digital gauge.
Tools Required
Equipment Condition
Flush DEF diagnostic line 5394564 with warm clean water to ensure the Compucheck fitting is clean and free
of DEF crystals.
Test Setup
1. Key Off
4 5
1
0000415486
Figure 829 DEF Doser Valve Outlet Pressure Setup

1. Pressure gauge
2. DEF backflow (return) line
4. DEF Doser Valve outlet fitting
5. DEF Doser Valve
6. DEF Doser Valve Inlet fitting
2. Disconnect return line from DEF Doser Valve outlet fitting. This fitting is marked with an arrow pointing
away from the doser valve.
3. Connect DEF diagnostic line 5394564 between vehicle DEF return line and DEF Doser valve outlet
fitting.
to Compucheck fitting on the DEF diagnostic line 5394564.
6. Connect Electronic Service Tool (EST) to vehicle diagnostic connector (page 1956).
Test Procedure
2. When ready, select “Start DEF System Leak Test” button.
3. Monitor installed gauge. Allow pressure reading to stabilize. It may take 30-60 seconds for system to prime
and reading to stabilize.
Expected Outcome
Installed gauge will read less than 10 psi (70 kPa) after system is primed reading is stabilized.
Follow-On Procedure
DEF Head Unit Coolant Line Routing Inspection
Overview
Identify proper coolant line routing for DEF Tank.
Tools Required
None
Equipment Condition
None
1 2 3
0000429485
Figure 831 DEF Tank Coolant Line Routing

1. DEF head unit line to DEF supply module
2. DEF tank heater valve
3. DEF coolant return line tee fitting
4. Supply line
5. Return line
1. Verify that DEF head unit outlet line is routed properly to DEF supply module inlet.
2. Verify that supply line is routed properly to inlet of DEF Tank Heater Valve (DEFTHV).
3. Verify that DEFTHV is installed correctly and coolant supply flow arrow is facing inlet of DEF head unit.
4. Verify that return line is routed properly to outlet of DEF supply module.
2
1
0000429484
Figure 832 DEF Tank Coolant Return Line Tee Fitting

1. Supply Line
2. Plastic Coupler
3. Return Line
4. Tee Fitting
5. Verify that supply and return lines are not crossed at Tee fitting and plastic coupler.
Expected Outcome
Technician will determine proper DEF tank coolant line and DEFTHV routing.
DEF Level Inspection
Overview
Determine the approximate level of Diesel Exhaust Fluid (DEF) in the DEF tank and operation of the DEF level
gauge.
Tools Required
None
Equipment Condition
1. Park vehicle on level ground.
1. Remove Diesel Exhaust Fluid (DEF) cap.
2. Use shop light or flashlight to view DEF level in tank related to tank volume. Example: 1/4 full, 1/2 full.
3. Compare DEF tank level to gauge reading.
4. DEF level should be roughly equivalent to amount shown on DEF level Gauge.
5. Reinstall DEF cap.
Expected Outcome
Diesel Exhaust Fluid (DEF) in DEF tank close to level indicated on DEF level gauge.
DEF Supply Module Inlet Restriction Test
Overview
This test checks the DEF Supply Modules inlet restriction with the pump running at maximum capacity and the
DEF Pressure line routed into a bucket.
Tools Required
Equipment Condition
• Flush the DEF diagnostic line 5299833 with warm clean water to ensure the Compucheck fitting is clean
and free of DEF crystals.
• DEF tank level above half full.
Test Setup
1. Key OFF
6 5 4 3
0000415324
Figure 833 DEF Suction diagnostic line

1. Vacuum gauge
2. DEF Supply Module
3. DEF Supply Module inlet fitting
4. DEF diagnostic line, Part Number 5299833
6. DEF Suction Line
2. Disconnect suction line from DEF Supply Module “IN” fitting.

3. Connect the DEF diagnostic line 5299833 between the DEF Supply Module “IN” fitting and vehicle
suction line.
4. Open the valve on the DEF diagnostic line 5299833.
5. Using Coupler, Fuel/Oil Pressure Test ZTSE4526, connect either a mechanical or digital vacuum gauge
to the Compucheck fitting on the DEF diagnostic line 5299833.
6. Disconnect the DEF pressure line at the DEF Dosing Valve and route into a clean bucket. It is
recommended to use at least a 1 gal (3.8 L) bucket.

Test Procedure
2. When ready, select the “Start DEF System Leak Test” button.
3. Monitor the installed vacuum gauge. Allow the vacuum reading to stabilize. It may take 30-60 seconds for
the system to prime and the reading to stabilize.
4. Also monitor DEF diagnostic line 5299833 for aeration.
Expected Outcome
DEF Supply Module vacuum reading should be less than 10 in-Hg (254 mm-Hg) with the valve on the DEF
diagnostic line 529983 open. Air bubbles are normal as the system is priming itself. After the system is primed,
bubbles should NOT exceed half diameter of the tool’s hoses.
Follow-On Procedure
DEF Supply Module Outlet Pressure Test
Overview
This test will measure the DEF Pressure at the DEF Supply Module outlet using a mechanical or digital gauge.
Tools Required
Equipment Condition
Flush the DEF diagnostic line 5394564 with warm clean water to ensure the Compucheck fitting is clean and
free of DEF crystals.
Test Setup
1. Key OFF
5 4 3
7 6
0000415344
Figure 835 DEF Pressure diagnostic line

1. Pressure gauge
3. DEF Supply Module outlet fitting
4. DEF Supply Module inlet fitting
5. DEF diagnostic line, Part Number 5394564
7. DEF Pressure Line
2. Disconnect the pressure line from the DEF Supply Module outlet fitting. This fitting is marked with “OUT”
on the DEF supply module.
3. Connect the DEF diagnostic line 5394564 between the vehicle DEF pressure line and DEF Supply
Module outlet fitting.
7. Start and log into Navistar® Engine Diagnostic.
Test Procedure
1. Select Tests > KOEO Aftertreatment Tests > DEF System Leak Test. Follow the on screen instructions.
2. When ready, select “Start DEF System Leak” button.
3. Monitor the installed pressure gauge. Allow the pressure reading to stabilize. It may take 30-60 seconds
for the system to prime and reading to stabilize.
Expected Outcome
The installed gauge will read between 108-137 psi (750-950 kPa) after system is primed and reading is stabilized.
Follow-On Procedure
DEF Supply Module Suction Test
Overview
This test will measure the amount of vacuum or suction the DEF supply module is capable of creating with a
completely blocked supply hose.
Tools Required
Equipment Condition
Flush the DEF diagnostic line 5299833 with warm clean water to ensure the Compucheck fitting is clean and
free of DEF crystals.
Test Setup
1. Key OFF.
6 5 4 3
0000415305
Figure 837 DEF Supply Module Suction Test

1. Vacuum Gauge
3. DEF Supply Module “IN” fitting
6. Suction Line
2. Disconnect the suction line from the DEF Supply Module “IN” fitting.
3. Connect the DEF diagnostic line 5299833 between the DEF Supply module “IN” fitting and the vehicle
suction line.
4. Close the valve on the DEF diagnostic line 5299833. Valve is shown in off position above.
5. Using Coupler, Fuel/Oil Pressure Test ZTSE4526, connect either a mechanical or digital vacuum gauge
8. Start and log into Navistar® Engine Diagnostic.
Test Procedure
1. Select Tests > KOEO Aftertreatment Tests > DEF System Leak Test. Follow the on screen instructions.
2. When ready, select “Start DEF System Leak” button.
3. Monitor the installed vacuum gauge. Allow the vacuum reading to stabilize. It may take 30–60 seconds for
reading to stabilize.
Expected Outcome
DEF Supply Module should be able to pull a vacuum of 7 in-Hg (177.8 mm-Hg) with valve on the DEF diagnostic
line 5299833 closed.
Follow-On Procedure
DEF Quality Test
Overview
Inspect Diesel Exhaust Fluid (DEF) for contamination and proper urea concentration.
WARNING:
To prevent personal injury or death, avoid contact with Diesel Exhaust Fluid (DEF) / urea.
Do not get DEF in eyes. In case of eye contact, immediately flush eyes with large amounts
of water for a minimum of 15 minutes. Do not swallow. If DEF is ingested, contact a
physician immediately.
Tools Required
• Diesel Exhaust Fluid (DEF) Refractometer 5025
Equipment Condition
• Calibrate DEF Refractometer (see 5025 DEF Refractometer Operating Instructions included in tool kit).
1. Visually inspect inside of DEF tank for debris, bubbles, icing or other forms of contamination. If bubbles are
found on sensor, remove bubbles before continuing.
Figure 839 Ultrasonic Diesel Exhaust Fluid Head Unit

1. Concentration sensor silicone boot
2. Tie straps (2)
2. Using a clean uncontaminated rod, push down on boot (Item 1) to release any trapped air bubbles.
3. Obtain sample of Diesel Exhaust Fluid (DEF) from the DEF tank.
4. Visually inspect sample for fuel, oil or other forms of contamination.
5. Use DEF Refractometer 5025 to test urea concentration of DEF.
6. Use Electronic Service Tool (EST) to view DEF concentration signal. Refractometer reading and EST signal
should be within 3% of each other.
Expected Outcome
No air bubbles on concentration sensor or inside sensor boot. Diesel Exhaust Fluid (DEF) urea concentration
should be between 30 and 34%. Refractometer reading and EST signal should be within 3% of each other. DEF
and DEF tank should be free of contamination such as debris, bubbles, icing, fuel, and oil.
DEFTHV Coolant Flow Test
Overview
This test will identify a failed Diesel Exhaust Fluid Tank Heater Valve (DEFTHV).
Tools Required
None
Equipment Condition
None
Test Setup
None
Test Procedure
1. Key Off. DEFTHV is normally closed at Key Off.
2. Verify that coolant supply flow direction arrow on DEFTHV is pointing towards DEF head unit.
3. Using hose clamp pliers, pinch off DEF head unit coolant return line to restrict back flow.
4. Disconnect the coolant return line from the DEF head unit and watch coolant flow from return port of DEF
head unit.
5. Allow 30 seconds of residual coolant to exit DEF head unit coolant return port.
Expected Outcome
Replace DEFTHV if there is a constant stream of coolant coming from DEF head unit return port.
DOC Cleaning Procedure
Overview
General procedure for cleaning a face plugged DOC.
Special Tools
• Threaded Plug (Cummins tool number 4919495)
• Rubber pipe reducer for securing vacuum hose to DOC inlet (obtain locally)
• Shop vacuum with HEPA filtration system
1. DOC removed from vehicle (see Engine Service Manual).
WARNING:
To prevent personal injury and / or death, read all safety instructions in the “Safety
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 avoid personal injury and / or death, wear appropriate eye and face protection when
using compressed air.
Procedure
CAUTION:
To prevent component and / or property damage, do not use a grinder or abrasive air
tool to remove residual gasket material, as this can damage the flange and cause the
connection to leak.
1. Use a putty knife to remove any residual gasket material from the flanges on the DOC. Avoid dropping
fragments of gasket material into the aftertreatment diesel particulate filter and catalyst.
2. Inspect the exhaust gas temperature sensor boss threads for damage. If thread damage is found on the
exhaust gas temperature sensor boss threads, a thread repair insert must be used for repair.
3. Inspect the downpipe from the turbocharger outlet for oil and / or excessive fuel in exhaust. If a trail of engine
oil or fuel can be seen exiting the turbocharger outlet, steam clean the downpipe between the turbocharger
and the aftertreatment DOC.
4. Inspect the inlet and outlet faces of the aftertreatment DOC for signs of damage. See DOC Inspection and
Reuse Guidelines (page 2240). If the guidelines indicate DOC is damaged and cannot be reused, replace
DOC.
Figure 841 Vacuuming and Wiping DOC Catalyst

WARNING:
To prevent property damage, personal injury, and / or death, exhaust filter maintenance
must be completed only by appropriately trained personnel. The material captured in a
partial flow diesel particulate filter and/or a diesel particulate filter must be characterized,
handled, and disposed of according to applicable local regulations. The captured
material can contain elevated concentrations of regulated chemicals and metals that
may consist of: zinc, molybdenum, polynuclear aromatic hydrocarbons, oxides of
calcium, zinc, phosphorous, silicon, sulfur, and iron.
CAUTION:
To prevent component and / or property damage, do not use an open flame to burn off
soot accumulation from the face of the aftertreatment DPF.
CAUTION:
To prevent component and / or property damage, do not scrape off soot accumulation
from the face of the aftertreatment DPF.
CAUTION:
To prevent component and / or property damage, do not steam clean the inlet of the DOC.
5. Use a rag to wipe off soot from DOC outlet, and use a HEPA vacuum to remove any remaining loose debris.
Use a vacuum bag, such as a drywall dust bag, to capture the soot that is removed.
6. Install a threaded plastic plug, tool number 4919495, into the exhaust gas temperature sensor port on the
DOC to prevent air from escaping.
Figure 843 Rubber Pipe Reducer
7. Install the larger end of the rubber pipe reducer to the inlet of the DOC.
8. Attach the vacuum hose to the smaller end of the pipe reducer, and use tape to seal any open ports.
9. Regulate the air supply for a rubber-tipped air gun to 90 psi (621 kPa).
Figure 845 Blowing and Vacuuming DOC Catalyst
CAUTION:
To prevent component and / or property damage, use only a rubber-tipped air gun near
the catalyst material. Damage will result if a metal air gun strikes the catalyst material.
10. Switch vacuum ON, and use air gun to blow compressed air across the outlet face of the aftertreatment
DOC for approximately 5 minutes. Maintain a distance of 1/2 to 1 in (13 to 25 mm) between the air gun and
the DOC face. Use a sweeping motion across the entire face of the DOC and attempt to blow air through
every cell. Allow the vacuum to operate for 1 minute after blowing out the aftertreatment DOC.
11. Place an inspection mirror into the inlet of the DOC and shine a flashlight on the mirror to inspect the cells
of the inlet face. If less than 50 percent of the cells are blocked, the aftertreatment DOC can be reused. If
more than 50 percent of the cells remain blocked, repeat steps 5-10.
Expected Outcome
At least 50 percent of the DOC inlet face cells should be cleared of soot. If 50 percent of the cells remain blocked
after the second cleaning, replace the DOC.
Follow-On Procedure
None.
DOC Inspection and Reuse Guidelines
Overview
General inspection to determine if DOC is acceptable for reuse.
Special Tools
None
Equipment Condition
DOC removed.
WARNING:
WARNING:
procedures.
Figure 847 DOC Inspection

1. DOC housing 2. Temperature sensor 3. Mounting strap
1. Inspect DOC V-band clamp and mounting strap (3) for signs of overextension or damage.
2. Check DOC housing (1) for dents.
3. Examine DOC mounting flanges for dents, cracks, or gouges.
4. Inspect temperature sensor (2) threads in DOC for damage.
5. Check DOC inlet and outlet face for evidence of excessive coolant, oil, or fuel.
6. Check DOC inlet and outlet face for gouges.
7. Inspect DOC by looking through inlet face while shining light through outlet face to determine if more
than 50% of DOC cells are clear. If DOC has a side inlet configuration, insert shop light and inspection
mirror into inlet of DOC.
Reuse Guidelines
DOC Inlet New
Figure 848 New DOC
A. Verify new DOC face is clean and has no dents or gouges.

B. Make sure DOC media is correct type.
• Type A media is tan with writing on face.
• ReCon® type A media is pink.
• Type B media is dark grey with light grey joining cement and writing on face.
DOC Inlet / Outlet - Melted
Figure 849 DOC-Melted
A. Inspect DOC for melted or deformed cells caused by excessive fuel or oil in exhaust.
B. Check for fault codes related to aftertreatment system.
C. Investigate engine service history.
D. Inspect turbocharger turbine outlet and aftertreatment inlet for oil or fuel.
DOC Inlet - Face Plugged
Figure 850 DOC Inlet-Face Plugged
A. Inspect DOC inlet face for an accumulation of high amounts of soot plugging DOC inlet face.
B. Determine cause of inlet face plugging, and repair failed components.
DOC Inlet / Outlet Face Gouged
Figure 851 DOC Inlet / Outlet Face Gouged
A. Inspect DOC inlet and outlet face for gouges.

B. Check if gouge(s) in face is (are) greater than 1/8 in (3 mm) deep.
Expected Outcome
A. Verify DOC passes inspection. No melted or deformed cells are found. DOC passes inspection for
reuse.
B. If accumulation of soot is found, repair failed components before cleaning DOC for reuse. Common
causes include coolant entering exhaust system, light duty cycles, low exhaust temperatures, or
combustion malfunction creating excessive engine smoke.
C. If gouge(s) in face is (are) greater than 1/8 in (3 mm) deep, replace DOC.
D. If a malfunction (melted or deformed cells) resulted in oil, coolant, excessive fuel, and / or excessive
black smoke exiting the exhaust system, repair failed upstream components before replacing DOC.
Follow-On Procedure
A. Install DOC.
DPF Inspection and Reuse Guidelines
Overview
General inspection to determine if DPF is acceptable for reuse.
Special Tools
None
Equipment Condition
DPF removed.
WARNING:
WARNING:
procedures.
Figure 852 DPF Inspection

1. DPF housing 3. Pressure and temperature
2. Mounting straps (2) sensor threads (2)
A. Inspect DPF V-band clamp and mounting straps (2) for signs of overextension or damage.
B. Check DPF housing (1) for dents.
C. Examine DPF inlet and outlet mounting flange for dents, cracks, or gouges.
D. Inspect DPF pressure and temperature sensor threads (3) in DPF for damage.
E. Check DPF inlet and outlet face for evidence of excessive coolant, oil, or fuel.
F. Check DPF inlet and outlet face for gouges.
Reuse Guidelines
DPF Inlet - New
Figure 853 New DPF
A. Verify new DPF face is clean and has no dents or gouges.

B. Make sure DPF media is correct type.
• Type A media is tan with writing on face.
• ReCon® type A media is pink.
• Type B media is dark grey with light grey joining cement and writing on face.
DPF Inlet - Dirty and Useable
Figure 854 Light Soot Type A

Figure 855 Light Soot Type B
A. Inspect Type A DPF inlet for soot (black) or ash (grey) on face and within channels. Light or moderate
levels of soot or ash are typical of normal engine operation.
B. Inspect Type B DPF inlet for soot (black) or ash (grey) on face and within channels. Light or moderate
levels of soot or ash are typical of normal engine operation, unless soot or ash is blocking channel
openings.
C. Determine cause of soot or ash blocking DPF inlet channel openings, and repair failed components.
DPF Inlet - Dirty and Useable 2
Figure 856 Heavy Soot
A. Inspect DPF inlet for high levels of soot load (black) with face plugged (channel openings narrowed or
blocked), caused by normal use.
B. Follow troubleshooting steps for soot-related codes.
C. Determine cause of high level of soot plugging face, and repair failed components.
DPF Inlet - Clean
Figure 857 DPF Inlet After Cleaning
A. After normal engine operation followed by aftertreatment DPF cleaning machine, verify DPF inlet
contains very little soot (black) or ash (grey) on face or within channels.
DPF Inlet - Gouged
Figure 858 DPF Inlet-Gouged
A. Inspect DPF inlet face for gouges.

B. Check if gouge(s) in face is (are) greater than 1/8 in (3 mm) deep.
DPF Inlet - Ash
Figure 859 DPF Inlet-Ash

1. Concentrated white ash 2. Dark wet surrounding ring 3. Uneven soot streaks
A. Inspect DPF for concentrated white ash (1), dark wet surrounding ring (2), and uneven soot streaks (3)
across inlet, caused by excessive lubricating oil concentration in exhaust gases.
B. Inspect turbocharger turbine outlet and aftertreatment inlet for lubricating oil.
C. Investigate vehicle for engine component damage introducing excessive lubricating oil into exhaust.
D. Determine cause of excessive lubricating oil in exhaust gases, and repair failed components.
DPF Inlet - Dark Soot Rings
Figure 860 DPF Inlet-Dark Soot Rings

1. Dark soot rings
A. Inspect DPF for dark soot rings (1) caused by excessive water concentration in exhaust gases.
B. Check for active fault codes.
C. Investigate coolant consumption.
D. Investigate vehicle history for component damage that introduces excessive coolant into exhaust.
E. Determine cause of dark soot rings (1), and repair failed components.
DPF Outlet - Soot Stains
Figure 861 DPF Outlet-Soot Stains

1. Soot stain in filter channel walls 2. Soot stain on filter outlet face
A. Inspect DPF for black soot stains on filter outlet face (2) and in filter channel walls (1).
• Black soot stains in both areas indicates DPF has internal cracking or melting.
• Black soot stains only on filter outlet face (2) do not indicate a malfunction has occurred.
D. Inspect turbocharger turbine outlet and aftertreatment inlet for lubricating oil or fuel.
E. Check exhaust system outlet for excessive soot buildup.
• Normal operation of vehicle over its life will cause small amount of soot staining to appear in outlet
of exhaust, but excessive soot is an indication of a damaged DPF.
F. Check for black smoke during engine operation.
G. Determine cause of dark soot stains, and repair failed components.
DPF Outlet - Burn Marks from Welding
Figure 862 DPF Outlet-Burn Marks from Welding
A. Inspect DPF for brown staining on filter outlet caused by welding process during filter assembly.
B. Check filter for black soot stains in outlet cell walls.
DPF Outlet - Excessive Soot Stains
Figure 863 DPF Outlet-Excessive Soot Stains
A. Inspect DPF for excessive black soot stains on filter outlet caused by internal cracking or melting of filter
material.
D. Inspect turbocharger turbine outlet and aftertreatment inlet for lubricating oil or fuel.
E. Determine cause of dark soot stains, and repair failed components.
DPF Outlet - Face Cracked
Figure 864 DPF Outlet-Face Cracked
A. Inspect DPF for cracks across filter face caused by high soot load in aftertreatment DPF that reacted
rapidly with engine exhaust.
B. Determine cause of high soot load, and repair failed components.
DPF Outlet - Coolant Staining
Figure 865 DPF Outlet-Coolant Staining
A. Inspect DPF for dark streaks on face and coolant staining caused by excessive coolant concentration
in exhaust gases.
B. Check for active fault codes.
C. Investigate coolant consumption.
D. Investigate vehicle history for component damage that introduces excessive coolant into exhaust.
E. Determine cause of dark streaks and coolant staining, and repair failed components.
DPF Outlet - Melted
Figure 866 DPF Outlet-Melted
A. Inspect DPF for melted or deformed cells caused by excessive fuel or oil in exhaust.
D. Determine if fuel or oil has been introduced into exhaust from damage of another engine component.
E. Inspect turbocharger turbine outlet and aftertreatment inlet for oil or fuel.
Expected Outcome
• No face cracks are found. DPF passes inspection for reuse.
• If cracks are found across filter face, repair failed components before replacing DPF.
Follow-On Procedure
1. Install DPF.
DPF Replacement After Boost System Leak or Over Temperature
Overview
After a major boost system leak such as a Charge Air Cooler (CAC) hose failure, if the vehicle is driven, excessive
fuel may enter the exhaust aftertreatment system causing excessive heat, soot, Diesel Particulate Filter (DPF)
failure, Selective Catalyst Reduction (SCR) damage and damage to other aftertreatment components. This
procedure gives directions for replacing the DPF, inspecting and cleaning the Diesel Oxidation Catalyst (DOC),
inspecting and cleaning the SCR catalyst and other exhaust components. Only perform this procedure after
being directed here from symptom or fault code diagnostics.
Special Tools
• Exhaust aftertreatment assembly lifting equipment
• Marking pen
• Electronic Service Tool (EST)
1. Source of damage to DPF has been repaired: boost system leak, CAC hose failure, fuel or oil leak to
exhaust.
2. If hot, allow exhaust components to cool.
Test Setup
WARNING:
WARNING:
procedures.
WARNING:
To prevent property damage, personal injury, and / or death, before working on the
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. The exhaust and exhaust components can remain hot after the vehicle
has stopped moving.
1. Shift transmission to Park or Neutral, set parking brake and chock wheels.
Procedure
Figure 867 Single Can Aftertreatment

1. DEF hoses
2. DEF doser
3. Electrical connector
4. Exhaust pipe
5. Exhaust pipe clamp
6. Support strap
7. Exhaust aftertreatment assembly
8. Tail pipe clamp
9. Tail pipe
1. Disconnect aftertreatment electrical connectors, Diesel Exhaust Fluid (DEF) hoses, exhaust pipe and tail
pipe from the exhaust aftertreatment assembly.
WARNING:
To prevent property damage, personal injury, and / or death, use appropriate lifting
equipment to support aftertreatment assembly during removal and installation.
2. Using appropriate lifting equipment: support aftertreatment assembly, remove support straps, and lower
assembly.
4 3
0000428072
Figure 868 Exhaust Aftertreatment Assembly Components

1. SCR catalyst
2. Diesel Oxidation Catalyst (DOC)
3. Diesel Particulate Filter (DPF)
4. Decomposition mixer
3. Put permanent index marks on exhaust aftertreatment components: DOC, DPF, decomposition mixer, SCR
catalyst and V-band clamps to be used as reference for reassembly.
4. Apply lubricant on V-band clamp threads. Loosen clamps by hand. Do not use air tools to remove V-band
clamp nuts.
5. Separate the DOC, DPF, decomposition mixer and SCR catalyst. Discard gaskets from V-band joints and
remove residual gasket material from flanges with a scraping tool.
6. Remove old PM sensor module and PM sensor probe from the SCR catalyst.
7. Inspect V-band clamps. Replace V-band clamps if bent, damaged or threads are damaged.
8. Inspect aftertreatment sensors, hoses and wiring for overheating and melting. Replace overheated or melted
components if required.
9. Inspect DOC per DOC Inspection and Reuse Guidelines (page 2240) to determine if the DOC can be reused.
10. If DOC passes inspection, perform DOC Cleaning Procedure (page 2231).
11. Clean out decomposition mixer using warm water and a soft bristle brush.
12. Clean out tail pipe.
13. Inspect SCR catalyst per SCR Catalyst Inspection and Reuse Guidelines (page 2270) to determine if the
SCR catalyst can be reused.
• If SCR is face plugged with excessive soot, perform SCR Cleaning Procedure (page 2277) then
reinspect.
• If SCR catalyst passes inspection, perform SCR Cleaning Procedure (page 2277), if not already done.
14. Put permanent index marks on new DPF in same place as DPF removed.
15. Assemble DOC, new DPF, decomposition mixer housing and SCR catalyst. Align index marks and tighten
band clamps to 177 in•lb (20 N•m).
NOTE: Do not install new PM sensor probe until after the DPF Regeneration Procedure has been performed.
16. Install old PM sensor probe in the SCR assembly.
17. Install new PM sensor module on aftertreatment assembly and let new PM sensor probe hang.
18. Using appropriate lifting equipment, lift and install exhaust aftertreatment assembly. Install support straps
and tighten to 150 in•lb (17 N•m)
19. Connect aftertreatment electrical connectors, Diesel Exhaust Fluid (DEF) hoses, exhaust pipe and tail pipe
to the exhaust aftertreatment assembly. Tighten exhaust pipe clamp to 97 in•lb (11 N•m). Tighten tail pipe
clamp to 111 in•lb (12.5 N•m).
20. Perform stationary DPF Regeneration Procedure (page 1936).
21. Remove old PM sensor probe and install new PM sensor probe.
22. Using EST, Reset – DPF Replacement.
23. Key ON. Using EST, change “Time since last active regeneration” Service Interval Parameter 61550 to
104.000 hours, press Enter, and click Program Engine button. Key OFF.
Expected Outcome
New DPF and PM sensor will be installed and exhaust aftertreatment will be clean.
Follow-on Procedure
None
Hot Run Sensor Comparison Test
Overview
Check for failed aftertreatment system temperature sensor.
Special Tools
None
Test Setup
1. Key OFF
2. Disconnect Exhaust Gas Recirculation (EGR) valve connector
3. Key On, Engine Off (KOEO)
Procedure
1. Select Temperature tab.
2. Start and run engine at 1400 - 1500 rpm for 5 minutes.
3. After the five minutes at high idle, monitor the following signals in the Temperature tab and compare to each
other:
• DOC Intake Temp
• DPF Intake Temp
• DPF Outlet Temp
• SCR Inlet Temp
• SCR Outlet Temp
Expected Outcome
After 5 minutes, all signals should be within 77°F (25°C) of each other.
Follow-on Procedure
1. Reconnect the EGR valve connector.
2. Use EST with Navistar® Engine Diagnostics to clear Fault Codes that set during test.
Forced Active Regeneration
Overview
An active exhaust aftertreatment regeneration can automatically occur when the Service Interval requires it or
when the DPF soot load is determined to require a regeneration (DPF Indicator illuminated). When the engine
and aftertreatment are at the proper temperature and the vehicle is driven at the correct speed a regeneration
can occur automatically. An active regeneration can be forced by performing the Forced Active Regen procedure
using the Electronic Service Tool (EST) and then driving the vehicle at the correct speed for the required duration.
If the DPF Indicator is flashing or the Stop Engine lamp is illuminated an active regeneration is not possible until
after a parked regeneration has been performed. Only perform this procedure after being directed here from
diagnostics.
Special Tools
Electronic Service Tool (EST)
None
CAUTION:
Test Setup
If vehicle has recently had a Charge Air Cooler (CAC) hose failure or other charge air leaks: go to Low Power
(page 55) symptom.
Procedure
Figure 869 DPF Indicator
1. If the DPF Indicator is NOT illuminated, go to step 2 to force an active regeneration. If the DPF Indicator is
illuminated, an activate regeneration should start automatically when the vehicle is driven at proper speed
and DPF regeneration entry conditions are met, go to step 4.
2. Key ON. Using EST, open Forced Active Regen procedure, and click “Reset, before driving” button.
WARNING:
for conditions.
3. Start engine. Using EST, start a signal recording and begin road test. For Forced Active Regen, AFT
Regen Status should immediately be “Active” and AFT DPF Target Regen Temperature should exceed
800°F (430°C).
4. Drive vehicle at appropriate highway speeds and if performing a Forced Active Regen have an assistant
monitor AFT Regen Status.
5. After DPF Indicator turns OFF or AFT Regen Status changes to “Not active” indicating the regeneration
completed successfully, stop vehicle and stop recording.
Expected Outcome
Active aftertreatment regeneration will complete successfully.
Follow-On Procedure
None
SCR Catalyst Inspection and Reuse Guidelines
Overview
General inspection to determine if SCR Catalyst is acceptable for reuse.
Special Tools
None
Equipment Condition
SCR removed from vehicle.
WARNING:
WARNING:
procedures.
WARNING:
To prevent property damage, personal injury, and / or death, before working on the
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. The exhaust and exhaust components can remain hot after the vehicle has
stopped moving.
1 2 3
0000451064
Figure 870 SCR

1. SCR catalyst housing
2. Mounting strap
3. DEF doser
A. Inspect V-band clamp and mounting straps for signs of overextension or damage.
B. Check SCR catalyst housing for dents.
C. Examine SCR catalyst housing inlet and outlet mounting flange for dents, cracks, or gouges.
D. Inspect SCR catalyst housing sensor threads for damage.
E. Check SCR catalyst housing inlet and outlet face for evidence of excessive coolant, oil, or fuel.
F. Check SCR catalyst housing inlet and outlet face for gouges.
Reuse Guidelines
New Aftertreatment SCR
Figure 871 New Aftertreatment SCR
A. SCR inlet clean with no dents, gouges, or writing on face.

B. No action required. Ready for use.
Iron Deposits on SCR Inlet
Figure 872 Iron Deposits on SCR Inlet
A. Brown discoloration on aftertreatment SCR inlet surface.

B. Normal engine operation. No action required. SCR can be reused.
DEF Deposits on SCR Inlet
Figure 873 DEF Deposits on SCR Inlet
A. Inspect for white material build up on outer edge of aftertreatment SCR inlet.
B. Normal engine operation. Clean deposits from SCR inlet, taking care to not damage catalyst. SCR can
be reused.
Media Erosion on SCR Inlet
Figure 874 Media Erosion on SCR Inlet
A. Uneven wear on aftertreatment SCR inlet.

B. Normal engine operation. No action required. SCR can be reused.
Water Stains on SCR Inlet
Figure 875 Water Stains on SCR Inlet
A. Inspect for green coloring of SCR with dark stains on inlet indicating moisture in exhaust system.
B. Check SCR drain holes for plugging. Check for aftertreatment SCR conversion efficiency fault codes.
If fault code(s) are present, correct cause of fault code(s). SCR can be reused.
Expected Outcome
Determine if SCR catalyst is acceptable for reuse.
Follow-On Procedure
Reinstall SCR Catalyst
SCR Cleaning Procedure
Overview
General procedure for cleaning an SCR catalyst.
Special Tools
• Cap & Plug Set ZTSE4891
• Rubber pipe reducer for securing vacuum hose to SCR outlet (obtain locally)
• Shop vacuum with HEPA filtration system
• Rubber-tipped air gun
1. SCR catalyst removed from vehicle.
WARNING:
WARNING:
procedures.
WARNING:
To avoid personal injury and / or death, wear appropriate eye and face protection when
using compressed air.
Procedure
1. Inspect the inlet and outlet faces of the SCR catalyst for damage. See SCR Catalyst Inspection and Reuse
Guidelines (page 2270). If guidelines indicate SCR catalyst is damaged and cannot be reused, replace SCR
catalyst.
2. Clean flange for V-band clamp with a scraping tool.
Figure 876 Vacuuming and Wiping SCR Catalyst Surface
WARNING:
To prevent property damage, personal injury, and / or death, exhaust filter maintenance
must be completed only by appropriately trained personnel. The material captured in the
exhaust aftertreatment must be characterized, handled, and disposed of according to
applicable local regulations. The captured material can contain elevated concentrations
of regulated chemicals and metals that may consist of: zinc, molybdenum, polynuclear
aromatic hydrocarbons, oxides of calcium, zinc, phosphorous, silicon, sulfur, and iron.
CAUTION:
To prevent component and / or property damage, do not scrape off soot accumulation
from the face of the SCR catalyst.
CAUTION:
To prevent component and / or property damage, do not steam clean the SCR catalyst.
3. Use a rag to wipe off soot from SCR catalyst inlet, and use a HEPA vacuum to remove any remaining loose
debris. Use a vacuum bag, such as a drywall dust bag, to capture the soot that is removed.
4. Using the Cap & Plug Set, Install appropriate caps or plugs into the exhaust gas temperature sensor and
other ports of the SCR catalyst to seal open ports to prevent air from escaping.
Figure 877 Rubber Pipe Reducer
5. Install larger end of the rubber pipe reducer onto the outlet of the SCR catalyst.
6. Attach vacuum hose to smaller end of the pipe reducer.
7. Regulate air supply for a rubber-tipped air gun to 90 psi (621 kPa).
Figure 878 Blowing and Vacuuming SCR Catalyst
CAUTION:
To prevent component and / or property damage, use only a rubber-tipped air gun near
the catalyst material. Damage will result if a metal air gun strikes the catalyst material.
8. Switch vacuum ON, and use air gun to blow compressed air across the SCR catalyst inlet face for
approximately 5 minutes. Maintain a distance of 1/2 to 1 in (13 to 25 mm) between the air gun and SCR
catalyst face. Use a sweeping motion across the entire face of the catalyst and attempt to blow air through
every cell.
9. Remove plugs and blow out sensor holes while vacuuming. Allow the vacuum to operate for 1 minute after
blowing out the SCR catalyst.
Expected Outcome
Excessive soot and other debris has been removed from the SCR catalyst.
Follow-On Procedure
None.
Snap Acceleration Test
Overview
This test is used to check the Diesel Particulate Filter (DPF) for cracks or internal damage without removing it
from vehicle. The test checks for basic functionality of the DPF and should be done prior to removing it.
Special Tools
None
None
Test Setup
None
Procedure
1. The transmission must be in neutral and the parking brake applied.
2. Start and idle the engine.
3. Rapidly snap the 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
3 ENGINE SPECIFICATIONS 2283
Table of Contents
All Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2285

Key On Engine Off Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2285
Engine Cranking Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2285
Low Idle No Load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2286
High Idle No Load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2286
Full Load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2287
Engine Temperature Sensors and Actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2287
Soot Load Level versus Exhaust Gas Target Temperature Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2288
Other Component Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2288
International® A26 (12.4 L). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2290

365 HP @ 1700 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2290
370 HP @ 1700 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2291
390 HP @ 1700 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2292
400 HP @ 1700 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2293
410 HP @ 1700 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2294
430 HP @ 1700 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2295
450 hp @ 1700 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2296
475 hp @ 1700 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2297
2284 3 ENGINE SPECIFICATIONS
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
Intake manifold pressure 0 kPa (0 psi) / 1.06 V
Exhaust Back Pressure 1.72 kPa (0.25 psi)
Diesel particulate filter differential pressure 0 kPa (0 psi) / 0.5 V
Exhaust gas recirculation valve position 0 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
Variable Geometry Turbo Charger Position 0%
Engine Cranking Specifications
Battery voltage (min. based on ECM drop out) 10.5 V
Cranking rpm (min.) 130 rpm
15 seconds maximum crank time per attempt. Wait 2 to 3 minutes before repeating.
Fuel rail pressure 20 MPa (3000 psi) / 1 V
Fuel Intake restriction 203 - 305 mmHg (8 - 12 inHg)
High-pressure pump Inlet pressure > 207 kPa (> 30 psi)
Intake air heater fuel solenoid fuel supply pressure (Optional) 55 - 82 kPa (8 - 12 psi)
Intake air heater fuel igniter fuel supply pressure (Optional) 55 - 82 kPa (8 - 12 psi)
Diesel particulate filter differential pressure 0 kPa (0 psi) / 0.66 V
Exhaust Back Pressure

3.45 kPa (0.50 psi)
(Maximum pressure at cranking speed before engine starts)
Exhaust gas recirculation valve Position 0%
Variable Geometry Turbo Charger Position 0%

Low Idle No Load
Fuel delivery pressure (min.) 413 kPa (60 psi) / 1.8 V
Fuel rail pressure 80,250 kPa (11,639 psi)
Engine speed 600 - 650 rpm
Intake manifold pressure < 21 kPa (< 3 psi) / 1.026 V
Exhaust Back Pressure 69 - 83 kPa (10 - 12 psi) / 1.3 - 1.35 V
Fuel Intake restriction 330 - 432 mmHg (13 - 17 inHg)
High-pressure pump inlet pressure 482 - 896 kPa (70 - 130 psi)
High-pressure fuel return flow (from Cylinder head return fitting) < 60 ml
Crankcase oil separator speed 7000 to 8500 rpm
Engine coolant temperature 1 (at thermostat opening) 86° C (186° F) / 0.571 V
Engine coolant temperature 1 (max. before DTC is set) 111 °C (232 °F) / 0.64 V
Engine oil pressure (min. with gauge) 68 kPa (10 psi) / 1.5 V
Engine oil temperature 98 °C (208 °F) / 0.405 V
Intake manifold air temperature 53 °C (127 °F) / 1.329 V
High Idle No Load
Air cleaner restriction (max.) 3.7 kPa (15 in H2O)
Fuel intake restriction < 480 mmHg (1839 in Hg)
Fuel rail pressure 165 to 200 MPa (24,000 to 29,000 psi) / 4.01 V
Engine speed (high idle not governed speed) 2100 - 2200 rpm
Governed Speed can be adjusted by a Programmable Parameter in the ECM
Intake manifold pressure 90 - 110 kPa (13 - 16 psi)
Exhaust Back Pressure 137 - 165 kPa (20 - 24 psi) / 1.75 - 2.0 V @ 2100 rpm
High-pressure pump fuel return pressure (Max.) 90 kPa (13 psi)
Diesel particulate filter differential pressure (max. before DTC is set) 35 kPa (5 psi) / 1.9 V
Engine oil pressure (min. with gauge) 275 - 482 kPa (40 - 70 psi) / 4.7 V
Full Load
Air cleaner restriction (max.) 25 in H2O (6.2 kPa)
Fuel rail pressure 31900 psi (220 MPa) / 4.1 V
Engine speed 1700 rpm
Engine oil pressure (min. with gauge) 72 psi (500 kPa) / 3.9 V
Engine oil temperature (max.) 261°F (127°C)
Diesel particulate filter differential pressure (max. before DTC is set) 5 psi (35 kPa) / 1.9 V
Water temperature differential across radiator (Inlet to Outlet) 16°F (9°C)
Engine Temperature Sensors and Actuators
Temperature Sensors (Engine Coolant Temperature 1 [ECT1], Engine Oil Temperature [EOT], Intake Manifold Air
Temperature [IMAT])
Temperature at -18 °C (0 °F) 4.2 V / 14030 Ω
Temperature at 0 °C (32 °F) 3.6 V / 5876 Ω
Temperature Sensors (Intake Air Temperature [IAT])
Temperature at -18 °C (0 °F) 4.21 V / 13866 Ω
Other Components
Camshaft Position (CMP) sensor 860 Ω ± 10% @ 20 °C
Crankshaft Position (CKP) sensor 860 Ω ± 10% @ 20 °C
Crankcase Breather Oil Separator Speed (CCBOSS) sensor 860 Ω ± 10% @ 20 °C
Cold Start Enable Device (CSED) fuel solenoid 8 Ω ± 1 Ω @ room temperature
Cold Start Fuel Igniter (CSFI) current draw 15 A

Soot Load Level versus Exhaust Gas Target Temperature Chart
Soot Load (%) Target Temperature (Degrees Target Temperature (Degrees

Fahrenheit) Celsius)
0.0 212 100
11.1 212 100
22.2 212 100 (Regen Exits)
33.3 1040 560.0
44.4 1040 560.0
55.6 1035.5 557.5
66.7 1031 555
77.8 1026.5 552.5
87.8 1022 550
88.9 1004 540
100.0 990.5 532.5
111.1 977 525
122.2 977 525
133.3 977 525
146.7 977 525
147.8 932 500
163.6 932 500
Other Component Specifications
Actuator Output State
Exhaust Gas Recirculation (EGR) valve control Output state low – 0%
Output state high – 100 %
Exhaust Gas Recirculation Position (EGRP) Output state low – 5 %
Variable Geometry Turbocharger Position Output state low – 0%
Variable Geometry Turbocharger Position Desired Output state low – 0%
Aftertreatment Fuel Doser Control (AFTFD) Output state low – 5 %

Actuator Output State (cont.)
Cold Start Fuel Igniter (CSFI) Output state low – 5 %
Engine Fan Control (EFC) Output state low – 5 %
Crankcase Pressure
High idle no load - crankcase blow by flow < 8 in H2O

International® A26 (12.4 L)

365 HP @ 1700 rpm
International® A26 365 hp @ 1700 rpm / 1250 ft•lb @ 1000 rpm
Engine feature code 0012BDX
Injection timing Nonadjustable
High idle speed 2200 rpm
Low idle speed 600 rpm

370 HP @ 1700 rpm
Engine feature code 0012BDL, 0012BDY
High idle speed 2000 or 22000 rpm

390 HP @ 1700 rpm
Engine feature code 0012BDZ

400 HP @ 1700 rpm
International® A26 400 hp @ 1700 rpm / 1550-1750 ft•lb @ 975 rpm
Engine feature code 0012BDU

410 HP @ 1700 rpm
50 state 2010 Model Year (MY)
Engine model 0012BDM, 0012BDN, 0012BEA

430 HP @ 1700 rpm
Engine model 0012BDP, 0012BEB

450 hp @ 1700 rpm
Engine model 0012BDS, 0012BEC, 0012BDT, 0012BDW

475 hp @ 1700 rpm
Engine model 0012BED, 0012BEE

4 DIAGNOSTIC TOOLS AND ACCESSORIES 2299
Table of Contents
2300 4 DIAGNOSTIC TOOLS AND ACCESSORIES
4 DIAGNOSTIC TOOLS AND ACCESSORIES 2301
Please see Navistar® Tools Catalog located on Service Portal for latest International® A26 applicable tools.
2302 4 DIAGNOSTIC TOOLS AND ACCESSORIES
5 ENGINE SYSTEMS OVERVIEW 2303
Table of Contents
Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2305
Engine Emission Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2306
Engine Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2307
Engine Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2308
Engine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2309
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2310
Chassis Mounted Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2311
Engine Component Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2312
Aftertreatment Component Locator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2317

2304 5 ENGINE SYSTEMS OVERVIEW
Engine Serial Number
Figure 879 Engine Serial Number

1. Engine Serial Number (ESN) location
2. Engine emission label
3. Cylinder head
4. Flywheel housing
5. Crankcase
Engine Serial Number Examples

International® A26: 124KM2YXXXXXXX
Engine Serial Number Codes

124 – Engine displacement
K – Engine Type: Diesel, turbocharged, Charge Air Cooler (CAC), and electronically controlled
M2 – End Use Code: Motor truck
Y – Country-of-Origin: United States of America, Huntsville, Alabama
7 digit suffix – Engine serial number sequence
Engine Emission Label
Figure 880 U.S. Environmental Protection Agency (EPA) Exhaust Emissions Label (Example)
The U.S. Environmental Protection Agency (EPA) exhaust emission label is on top of the valve cover (front left
side). 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 (ESN)
• EPA, EURO, and reserved fields for specific applications
Engine Accessories
The following engine accessories may have manufacturer's labels or identification plates:
• Air compressor
• Air conditioning compressor
• Alternator
• Cooling fan clutch
• Engine Control Module (ECM)
• Power steering pump
• Starter motor
• Turbocharger
Engine Specifications
International® A26 Diesel Engine
Engine Configuration 4 stroke, inline six cylinder diesel
Advertised brake horsepower @ rpm See EPA exhaust emission label
Peak torque @ rpm See EPA exhaust emission label
Displacement 12.4 L (758 in³)
Compression ratio 18.5:1
Stroke 166 mm (6.54 in)
Bore (sleeve diameter) 126 mm (4.96 in)
Total engine weight (dry weight without trim or accessories) 1087 kgs (2392 lbs)
Firing order 1-5-3-6-2-4
Aspiration Variable Geometry Turbocharger (VGT)
Engine rotation direction (facing flywheel) Counterclockwise
Combustion system Direct injection turbocharged
Fuel system High-pressure common rail
Lube system capacity (including filter) 42 qts (40 L)
Lube system capacity (overhaul only, with filter) 46 qts (44 L)
Engine lubrication oil pressure at operating temperature
with SAE 10W-30 oil
• Low idle 10 psi (69 kPa) min
• High idle 40 - 70 psi (276 - 483 kPa)
Low Idle speed (no load) 600 rpm
Thermostat operating temperature 181°F - 203°F (83°C - 95°C)

Engine Description
The International® A26 diesel engine is designed for increased durability, reliability, and ease of maintenance.
The cylinder head has four valves per cylinder for increased airflow. The fuel injector is centrally located between
the four valves, directing fuel over the piston for improved performance and reduced emissions.
The overhead camshaft is supported by seven bearings in the cylinder head. The camshaft gear is driven from
the rear of the engine. The overhead valve train includes roller rocker arms and dual valves that open, using a
valve bridge.
International® A26 engines use one-piece steel pistons. All pistons use an offset piston axis and centered
combustion bowls. Crown markings show correct piston orientation in the crankcase.
The one-piece crankcase uses replaceable wet cylinder liners that are sealed by dual crevice seals.
The crankshaft has seven main bearings with fore and aft thrust controlled at the sixth bearing. One fractured
cap connecting rod is attached at each crankshaft journal. The 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 gerotor lube oil pump is mounted behind the front cover and is driven by the crankshaft. Pressurized oil is
supplied to various engine components. All International® A26 engines also use an engine oil cooler and a
cartridge-style engine oil filter, which are installed in the engine lube oil module.
The low-pressure fuel pump draws fuel from the fuel tank(s) through a chassis mounted filter/water separator.
The low-pressure fuel pump provides fuel for the engine mounted fuel filter module. Conditioned low-pressure
fuel is supplied from the engine mounted fuel filter module to the high-pressure fuel pump, optional Cold Start
Enable Device Solenoid, and the Aftertreatment (AFT) fuel supply module.
The high-pressure fuel system is a direct fuel injected common-rail system. The common-rail includes a
high-pressure fuel pump with integrated Engine Fuel Actuator (EFA), two fuel rail supply lines, fuel rail, six fuel
injectors, a rail mounted fuel rail pressure sensor and rail mounted electronic fuel pressure relief valve.
The fuel injectors are installed in the cylinder head under the valve cover and are electronically actuated by the
Engine Control Module (ECM).
The International® A26 engine uses a Variable Geometry Turbocharger (VGT) assembly and Charge Air Cooler
(CAC). The Charge Air Cooler (CAC) is mounted in front of the engine cooling package. The CAC is an air-to-air
type cooler, and requires no connections to the engine's cooling system.
The Exhaust Gas Recirculation (EGR) system circulates cooled exhaust into the air inlet duct. The EGR cooler
provides regulated cooling of the EGR gases before entering the air inlet duct. This cools the combustion
process, and reduces Oxides of Nitrogen (NOX) emissions.
The open crankcase breather system uses a centrifugal Crankcase Breather Oil Separator (CCBOS) to return
oil mist to the crankcase, and vent the cleaned crankcase gasses to the atmosphere. The CCBOS is part of
the oil module. The breather system has been redesigned, and uses an external breather hose. Blowby gases
enter the CCBOS through the side of the crankcase.
Optional Equipment
Optional cold climate features available are a cold start assist, oil pan heater and a coolant heater. Both heaters
use an electric element to warm engine fluids in cold weather.
The oil pan heater warms engine oil to ensure optimum oil flow to engine components.
The coolant heater warms the engine coolant surrounding the cylinders. Warmed engine coolant increases fuel
economy and aids start-up in cold weather.
The Cold Start system warms the incoming air supply during engine cranking and several minutes after cold
engine start up to help reduce emissions.
The Navistar® Engine Brake by Jacobs® is optional for International® A26 engine. The engine brake is a
compression release system that provides additional vehicle braking performance. The operator can control
the engine brake for different operating conditions.
Chassis Mounted Equipment

• The chassis mounted fuel filter/water separator and optional fuel heater removes a majority of the water and
foreign particles that may enter the fuel system from the supply tank(s). This filter works with the engine
mounted fuel module to eliminate foreign matter and moisture from the fuel before entering the fuel injection
system.
• The Charge Air Cooler (CAC) lowers temperature after the air is compressed by the turbocharger, and has
no connections to the engine cooling system. The CAC is an air-to-air cooler. The CAC is mounted in front
of the radiator cooling package.
• The Diesel Oxidation Catalyst (DOC) oxidizes hydrocarbons and carbon monoxide, provides heat for
exhaust system warm-up, aids in temperature management for the Diesel Particulate Filter (DPF), and
oxidizes NO into NO2 for passive DPF regeneration. The DOC is monitored by the Engine Control Module
(ECM) using one Diesel Oxidation Catalyst Inlet Temperature (DOCIT) sensor positioned at the DOC inlet,
and one Diesel Particulate Filter Inlet Temperature (DPFIT) sensor positioned at the DPF inlet.
• The DPF temporarily stores carbon-based particulates, oxidizes stored particulates, stores non-combustible
ash, and provides required exhaust back pressure for proper engine performance. The DPF is monitored by
the ECM using the AFT temperature sensor module installed on the DPF exhaust, and the Diesel Particulate
Filter Differential Pressure (DPFDP) / Diesel Particulate Filter Outlet Pressure (DPFOP) sensor installed
on the DPF. A Particulate Matter (PM) sensor is mounted at the outlet of the SCR catalyst and provides
feedback to the ECM as to how much soot or particulate matter is exiting the entire system to the tailpipe.
• The Selective Catalyst Reduction (SCR) catalyst oxidizes Oxides of Nitrogen (NOx) into Nitrogen gas and
water. The SCR catalyst is monitored by the ECM using a NOx IN sensor module installed in the turbocharger
outlet pipe, and a NOx OUT sensor module installed after the outlet of the SCR catalyst. The ECM monitors
the SCR catalyst temperatures using the AFT Temperature sensor module.
Engine Component Locator

Top View
Figure 881 Top View

1. Exhaust Gas Recirculation 4. Environmental Protection 6. EGR mixing duct
(EGR) cooler assembly Agency (EPA) emission label 7. Coolant outlet manifold
2. Rear coolant manifold location 8. EGR duct
3. Valve cover 5. Cold Start Fuel Igniter (CSFI)
(optional)
Front View
Figure 882 Front View

1. Water pump pulley 4. Oil fill connection 7. Vibration damper
2. Lifting eye 5. Coolant outlet manifold 8. Fan drive
3. EGR mixing duct 6. Accessory drive pulley
Left View
Figure 883 Left View

1. Fuel primer pump 5. Air compressor 11. High-Pressure Fuel Pump
2. Cold Start Enable Device 6. Oil pan (HPFP)
(CSED) Solenoid (optional) 7. Oil preheater (optional)
3. Engine Control Module (ECM) 8. Oil drain plug
4. Cold Start Fuel Igniter (CSFI) 9. Water drain valve
relay (optional) 10. Fuel filter housing
Right View
Figure 884 Right View

1. Exhaust Gas Recirculation 3. Air inlet duct 7. Coolant inlet
(EGR) valve 4. EGR cooler assembly 8. Turbo outlet pipe
2. Variable Geometry Turbocharger 5. Oil filter module 9. Aftertreatment Hydrocarbon
(VGT) 6. Coolant heater (optional) Doser (AFTHD) Assembly
Back View
Figure 885 Back View

1. Lifting eye (2) 3. Turbo outlet pipe 5. Flywheel housing
2. Rear coolant manifold 4. Flywheel
Aftertreatment Component Locator

Exhaust System
1 2 3 2
2
4
5
0000427422
Figure 886 Exhaust System

1. Tail pipe 3. Intermediate tail pipe 5. Exhaust Aftertreatment
2. Exhaust pipe clamp (4) 4. Turbo exhaust outlet pipe Assembly
Exhaust Aftertreatment Assembly Components
4 3
0000428072
Figure 887 Exhaust Aftertreatment Assembly Components

1. SCR Catalyst 3. Diesel Particulate Filter (DPF)
2. Diesel Oxidation Catalyst (DOC) 4. Decomp mixer housing
Exhaust Aftertreatment Sensors and Sensor Modules
2
1
4 5 6
7 8
9 10
13
12
11
0000428073
Figure 888 Exhaust Aftertreatment Sensors and Sensor Modules

1. Particulate Matter (PM) sensor 6. DPFDP/DPFOP Outlet sensor 10. DPF Inlet Temperature sensor
2. NOx Out Sensor port 11. DOC Inlet Temperature sensor
3. SCR Outlet temperature sensor 7. DPF Outlet Temperature sensor 12. AFT Temperature sensor
4. Particulate Matter (PM) sensor 8. DPFDP/DPFOP sensor module
module 9. DPFDP/DPFOP Inlet sensor 13. DEF doser valve
5. NOx Out sensor module port
6 ABBREVIATIONS AND ACRONYMS 2321
Table of Contents
Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2323

2322 6 ABBREVIATIONS AND ACRONYMS
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
ACM – Aftertreatment Control Module
ACV – Air Control Valve
AFTFI – Aftertreatment Fuel Injector
AFT – Aftertreatment
AFTFP1 – Aftertreatment Fuel Pressure 1
AFTFSV – Aftertreatment Fuel Shutoff Valve
AFTPAV – Aftertreatment Purge Air Valve
Amb – Ambient
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
ASTM – American Society for Testing and Materials
ATA – American Trucking Association
ATAH – American Trucking Association Link High
ATAL – 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
BBDC – Before Bottom Dead Center
BC – Body Controller
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

CAP – Cold Ambient Protection
CARB – California Air Resources Board
cc – Cubic centimeter
CCA – Cold Cranking Ampere
CCOSS – Crankcase Oil Separator Speed
CCS – Cruise Control Switches
CDR – Crankcase Depression Regulator
cfm – Cubic feet per minute
cfs – Cubic feet per second
CID – Cubic Inch Displacement
CKP – Crankshaft Position
CKPH – Crankshaft Position High
CKPL – Crankshaft Position Low
cm – Centimeter
CMP – Camshaft Position
CMPH – Camshaft Position High
CMPL – Camshaft Position Low
CO – Carbon Monoxide
COO – Cruise On / Off switch
CPU – Central Processing Unit
CTC – Coolant Temperature Compensation
Cyl – Cylinder
DC – Direct Current
DCA – Diesel Coolant Additive
DDI – Digital Direct Fuel Injection
DDS – Driveline Disengagement Switch
DEF – Diesel Exhaust Fluid
DEFSMH – Diesel Exhaust Fluid Supply Module Heater
DEFD – Diesel Exhaust Fluid Doser Valve
DEFLH Relay – Diesel Exhaust Fluid Line Heater Relay
DEFLP – Diesel Exhaust Fluid Line Pressure
DEFLT – Diesel Exhaust Fluid Line Temperature
DEFPLH – Diesel Exhaust Fluid Pressure Line Heater
DEFRLH – Diesel Exhaust Fluid Return Line Heater
DEFRV – Diesel Exhaust Fluid Reverting Valve
DEFSLH – Diesel Exhaust Fluid Supply Line Heater
DEFSP – Diesel Exhaust Fluid Supply Pump
DEFTHC – Diesel Exhaust Fluid Tank Heater Control Valve
DEFTL – Diesel Exhaust Fluid Tank Level
DEFTLT – Diesel Exhaust Fluid Tank Level and Temperature Sensor
DEFTT – Diesel Exhaust Fluid Tank Temperature
DEFSMH Relay – Diesel Exhaust Fluid Supply Module Heater Relay
DLC – Data Link Connector
DMM – Digital Multimeter
DOC – Diesel Oxidation Catalyst
DOCIT – Diesel Oxidation Catalyst Inlet Temperature
DPF – Diesel Particulate Filter
DPFDP – Diesel Particulate Filter Differential Pressure
DPFOP – Diesel Particulate Filter Outlet 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
EBC – Exhaust Brake Controller

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
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
EFA1 – Engine Fuel Actuator 1 (Pump)
EFA2 – Engine Fuel Actuator 2 (Rail)
EFAN – Engine Fan
EFANS – Engine Fan Speed
EFC – Engine Fan Control
EFRC – Engine Family Rating Code
EFS – Engine Fan Speed
EFT – Engine Fuel Temperature
EG – Ethylene Glycol
EGC – Electronic Gauge Cluster
EGR – Exhaust Gas Recirculation
EGRC – Exhaust Gas Recirculation Control
EGRH – Exhaust Gas Recirculation High control
EGRL – Exhaust Gas Recirculation Low control
EGRP – Exhaust Gas Recirculation Position
EGRT – Exhaust Gas Recirculation Temperature
EGT – Exhaust Gas Temperature
EMI – Electromagnetic Interference
EOL – Engine Oil Level
EOP – Engine Oil Pressure
EOT – Engine Oil Temperature
EOT2 – Engine Oil Temperature 2
EPA – Environmental Protection Agency
ESC – Electronic System Controller
ESN – Engine Serial Number
EST – Electronic Service Tool
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
gal/h – U.S. Gallons per hour
gal/min – U.S. Gallons per minute
GCW – Gross Combined Weight
GCWR – Gross Combined Weight Rating
GVW – Gross Vehicle Weight
H2O – Water
HC – Hydrocarbons
HEST – High Exhaust System Temperature
Hg – Mercury
hp – Horsepower
CAC – Charge Air Cooler
HPCR – High-Pressure Common Rail
HPFP – High-Pressure Fuel Pump
hr – Hour
Hyd – Hydraulic
IAH – Inlet Air Heater

IAHC – Inlet Air Heater Control
IAHD – Inlet Air Heater Diagnostic
IAHFI – Inlet Air Heater Fuel Igniter
IAHFS – Inlet Air Heater Fuel Solenoid
IAHR – Inlet Air Heater Relay
IAT – Inlet Air Temperature
IC – Integrated Circuit
ICP – Injection Control Pressure
ICG1 – Injector Control Group 1
ICG2 – Injector Control Group 2
ID – Inside Diameter
IGN – Ignition
ILO – Injector Leak Off
IMP – Intake Manifold Pressure
IMT – Intake Manifold Temperature
in – Inch
inHg – Inch of mercury
inH2O – Inch of water

INJs – Injectors
IPR – Injection Pressure Regulator
IPR PWR – Injection Pressure Regulator Power
IST – Idle Shutdown Timer
ITP – Internal Transfer Pump
J1939H – J1939 Data Link High

J1939L – 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
lbf – Pounds of force
lb/s – Pounds per second
lbf ft – Pounds of force per foot
lb in – Pounds of force per inch
lbm – Pounds of mass
LSD – Low Sulfur Diesel
m – Meter
m/s – Meters per second
MAF – Mass Air Flow
MAF GND – Mass Air Flow Ground
MAG – Magnetic
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
NH3 – Ammonia sensor
Nm – Newton meter
NO – Normally Open (electrical)
NOX – Nitrogen Oxides
NOX IN – Nitrogen Oxides Inlet sensor
NOX OUT – Nitrogen Oxides Outlet sensor
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
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

SART – Stand Alone Real Time Clock
SCA – Supplemental Cooling Additive
SCCS – Speed Control Command Switches
SCR – Selective Catalyst Reduction
SCRIT – Selective Catalyst Reduction Inlet Temperature
SCROT – Selective Catalyst Reduction Outlet Temperature
SCS – Speed Control Switch
SHD – Shield (electrical)
SID – Subsystem Identifier

SIG GND – Signal Ground
SIG GNDB – Signal Ground Body
SIG GNDC – Signal Ground Chassis
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
TCAPE – Truck Computer Analysis of Performance and Economy
TCM – Transmission Control Module
TCOT – Turbocharger Compressor Outlet Temperature
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
VREFB – Reference Voltage Body
VREFC – Reference Voltage Chassis
VREFE – Reference Voltage Engine
VSO – Vehicle Speed Output
VSO or VSS_CAL – Vehicle Speed Output
VSS – Vehicle Speed Sensor
VSS_CAL or VSO – Vehicle Speed Output
VSSH – Vehicle Speed Sensor High
VSSL – Vehicle Speed Sensor Low
WTSL – Wait to Start Lamp

WEL – Warn Engine Lamp
WIF – Water In Fuel
WIFL – Water In Fuel Lamp
WTEC – World Transmission Electronically Controlled automatic transmissions (Allison)
XCS – Transfercase
XMSN – Transmission
7 TERMINOLOGY 2331
Table of Contents
Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2333
2332 7 TERMINOLOGY
7 TERMINOLOGY 2333
Terminology
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.
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).
Aftertreatment Control Module (ACM) – An electronic processor that monitors and controls the aftertreatment
system.
Aftertreatment (AFT) fuel doser module – The AFT fuel doser module controls fuel flow to the AFTFI.
Aftertreatment Fuel Injector (FI) – Injects fuel into the exhaust system to increase temperature of the exhaust
gases.
Aftertreatment Purge Air Valve (AFTPAV) – Uses vehicle air to purge the AFT fuel doser module and AFTFI
of fuel following active or parked regeneration of the aftertreatment system.
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.
Air Control Valve (ACV) – Contains the HP turbocharger wastegate control port and the Exhaust Back Pressure
Valve (EBPV) control port. Although these components are integral to the ACV, each circuit is controlled by the
Engine Control Module (ECM). The ACV controls compressed air for each control valve.
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)
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.
American Trucking Association (ATA) Datalink – A serial datalink specified by the American Trucking
Association and the SAE.
Boost pressure – Pressure of charge air leaving the turbocharger.
Inlet manifold pressure greater than atmospheric pressure. Obtained by turbocharging.
Bottom Dead Center (BDC) – The lowest position of the piston during the stroke.
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.
2334 7 TERMINOLOGY
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)
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) – See Aftercooler.
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.
Cold Start Emissions Reduction (CSER) – A type of monitoring strategy used to monitor emission levels
during engine warm-up.
Controller Area Network (CAN) – A J1939 high-speed communication link.
Coolant – A fluid used to transport heat from one point to another.
Coolant level switch – A switch sensor used to monitor coolant level.
Continuous Monitor Test – An ECM function that continuously monitors the inputs and outputs to ensure that
readings are within set limits.
7 TERMINOLOGY 2335
Count – Number of events where a specific SPN / FMI setting criteria are meet. Example: 58 counts of 1000
cycles for misfire on cylinder #5.
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.
Current – The flow of electrons passing through a conductor. Measured in amperes.
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)
Decomposition reactor tube – Converts DEF to ammonia and CO2 and ensures even evaporation of DEF into
the exhaust stream.
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.
Diesel Exhaust Fluid (DEF) – Diesel Exhaust Fluid (DEF) is a nontoxic, nonflammable, colorless liquid that
delivers ammonia to the Selective Catalyst Reduction (SCR) system.
Diesel Exhaust Fluid Supply Module Heater (DEFSMH) – Maintains proper temperature and prevents freezing
of DEF in the DEF supply module.
Diesel Exhaust Fluid Doser Valve (DEFD) – Injects DEF into the Selective Catalyst Reduction (SCR) system.
Diesel Exhaust Fluid Line Heater Relay – Supplies power to the DEF line heaters when commanded ON by
the Aftertreatment Control Module (ACM).
Diesel Exhaust Fluid Line Pressure (DEFLP) Sensor – A variable capacitance sensor that measures DEF
pressure from the Diesel Exhaust Fluid Supply Pump (DEFSP).
Diesel Exhaust Fluid Pressure Line Heater (DEFPLH) – Maintains proper DEF temperature and prevents
freezing of the DEF pressure line.
Diesel Exhaust Fluid Return Line Heater (DEFRLH) – Maintains proper DEF temperature and prevents
freezing of the DEF return line.
Diesel Exhaust Fluid Return Valve (DEFRV) – Regulates DEF flow exiting the DEF supply module.
Diesel Exhaust Fluid Supply Line Heater (DEFSLH) – Maintains proper DEF temperature and prevents
freezing of the DEF suction line.
2336 7 TERMINOLOGY
Diesel Exhaust Fluid Supply Pump (DEFSP) – Pressurizes outgoing DEF to the Diesel Exhaust Fluid Doser
Valve (DEFDV).
Diesel Exhaust Fluid Tank Heater Control (DEFTHC) Valve – Controls coolant flow to the DEF tank heating
coil.
Diesel Exhaust Fluid Tank Level and Temperature (DEFTLT) sensor module – A combinations sensor that
monitors DEF tank level and temperature.
Diesel Exhaust Fluid Supply Module Heater Relay – Sends power to the Diesel Exhaust Fluid Dosing Unit
Heater (DEFDUH) when commanded ON by the Aftertreatment Control Module (ACM).
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 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.
The DOC can be used during an active regeneration to create higher exhaust temperatures, thereby reducing
soot in the DPF.
Diesel Oxidation Catalyst (DOC) / Diesel Particulate Filter (DPF) temperature sensor module – Monitors
signals from the Diesel Oxidation Catalyst Inlet Temperature (DOCIT) sensor, Diesel Particulate Filter
Inlet Temperature (DPFIT) sensor, and Diesel Particulate Filter Outlet Temperature (DPFOT) sensor and
communicates these signals to the Aftertreatment Control Module (ACM).
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.
Diesel Particulate Filter (DPF) / outlet pressure sensor – Measures the pressure differential across the Diesel
Particulate Filter (DPF) and communicates this back to the Aftertreatment Control Module (ACM).
Downstream Injection (DSI) metering unit – The DSI metering unit provides a metered amount of fuel to the
Aftertreatment Fuel Injector (FI).
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 Back Pressure Valve (EBPV) – The ECM commands the EBPV to control the Exhaust Brake.
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.
7 TERMINOLOGY 2337
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.
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 Warning Protection System (EWPS) – Safeguards the engine from undesirable operating conditions
to prevent engine damage and to prolong engine life.
Event – a condition where a fault threshold has set. Example: cylinder misfire event, an instance when the
cylinder misfired.
Exhaust Back Pressure (EBP) – The pressure present in the exhaust system during the exhaust period.
Exhaust Back Pressure Valve (EBPV) – A valve that regulates the amount of air pressure applied to the EBPV
pneumatic actuator.
Exhaust brake – A brake device using engine exhaust back pressure as a retarding medium.
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 Temperature (EGT) – The temperature of exhaust gases.
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 manifold – Exhaust gases flow through the exhaust manifold to the turbocharger exhaust inlet and
are directed to the EGR cooler.
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.
Failure Mode Indicator (FMI) – Identifies the fault or condition effecting the individual component.
2338 7 TERMINOLOGY
Filter restriction – A blockage, usually from contaminants, that prevents the flow of fluid through a filter.
Flash code – See Diagnostic Trouble Code (DTC).
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.
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.
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).
7 TERMINOLOGY 2339
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. 1 hp = 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).
Injection Pressure Regulator (IPR) valve – A valve that is used to maintain desired injection control pressure.
Injection Control Pressure (ICP) sensor – Provides a feedback signal to the ECM indicating injection control
pressure.
Inlet Air Heater (IAH) – Heats incoming air to help reduce cold start emissions.
Inlet Air Heater Fuel Igniter (IAHFI) – The IAHFI heats the intake air by vaporizing and igniting fuel in the air
inlet duct.
Inlet Air Heater Fuel Solenoid (IAHFS) – When the engine is cold and cranked, the ECM energizes the IAHFS
valve, allowing fuel into the IAHFI, which ignites and warms air drawn into the engine.
Inlet Air Heater Relay (IAHR) – The IAHR provides voltage to the IAHFI, and is controlled by the ECM.
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.
International NGV Tool Utilized for Next Generation Electronics (INTUNE) – The diagnostics software for
chassis related components and systems.
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.
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.
2340 7 TERMINOLOGY
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.
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.
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.
NOx IN sensor module – A smart device used to measure the NOx emission at the intake of the aftertreatment
system.
NOx OUT sensor module – A smart device used to measure the NOx emissions at the outlet of the SCR
catalyst.
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.
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.
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.
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)
7 TERMINOLOGY 2341
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.
Reserve capacity – Time in minutes that a fully charged battery can be discharged to 10.5 volts at 25 amperes.
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.
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.
Selective Catalyst Reduction (SCR) catalyst – Breaks down DEF into ammonia and CO2 and also converts
ammonia and NOx to Nitrogen gas and water.
Selective Catalyst Reduction Inlet Temperature (SCRIT) sensor – Monitors inlet temperature of the SCR
catalyst and sends a signal to the SCR temperature sensor module.
Selective Catalyst Reduction Outlet Temperature (SCROT) sensor – Monitors outlet temperature of the SCR
catalyst and sends a signal to the SCR temperature sensor module.
Selective Catalyst Reduction (SCR) temperature sensor module – Monitors signals from the Selective
Catalyst Reduction Inlet Temperature (SCRIT) sensor and Selective Catalyst Reduction Outlet Temperature
(SCROT) sensor, and communicates these signals to the Aftertreatment Control Module (ACM).
Navistar® Engine Diagnostic Software – Diagnostics software for engine and aftertreatment related
components and systems.
Setting criteria – Conditions required by a monitor to set a fault code. Once the setting criteria is met for the
required amount of time, the fault code will become either active or pending. Example: SPN 168 FMI 18 sets
when battery voltage supplied to the ACM is less than 6.5 volts (setting criteria) for 4 seconds (time required).
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 Take Off (PTO),
and remote hand throttle system.
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.
2342 7 TERMINOLOGY
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.
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.
Time required – The amount of time needed for a monitor to set a fault code when the setting criteria is met.
Example: SPN 168 FMI 18 sets when battery voltage supplied to the ACM is less than 6.5 volts (setting criteria)
for 4 seconds (time required).
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.
Trip (driving cycle) – Legal definition about what defines a drive cycle or trip to calculate the denominator
in the IUMPR (In-Use Monitoring Performance Ratio). For some faults a trip can be a key cycle (including
housekeeping time to reset the ECM). Example: out of range circuit checks for sensors. For other faults the trip
includes a warm up cycle, driving in certain conditions, etc. Example: thermostat monitor
Trip (MIL illumination and OBD executive) – Amount of trips when the fault must be present to illuminate the
MIL, latch the MIL, and store historic fault information. Most faults are two trip faults.
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 Compressor Outlet Temperature (TCOT) sensor – Thermistor installed in the outlet of the
turbocharger’s compressor housing used to measure temperature of the air entering the CAC. Used to calculate
CAC efficiency.
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.
7 TERMINOLOGY 2343
Vehicle Retarder Enable/Engage – Output from the ECM to a vehicle retarder.

Transmission Output Shaft Speed (TOSS) sensor – Normally a magnetic pickup sensor mounted in the
tailshaft housing of the transmission, used to indicate vehicle 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.
2344 7 TERMINOLOGY

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2017 International® A26 Engine Diagnostic Manual

2017 International® A26 Engine Diagnostic Manual

2701 Navistar Drive, Lisle, IL 60532 USA

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

Engine System Tests and Inspections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1915

Engine Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2283

Diagnostic Tools and Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2299

Engine Systems Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2303

Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2321

Technical Service Literature

• Clear area before starting engine.

• Check for frayed power cords before using power tools.

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

How To Use Symptom Based Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Operational Checkout Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Engine Does Not Start Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Engine Hard to Start Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Engine Performance Problems Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Engine Coolant Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Engine Lubrication Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Fuel System Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

Engine Brake Symptoms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Fault Code Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

Diagnostic Trouble Code (DTC) List

SPN FMI Condition Description

SPN FMI Condition Description

SPN FMI Condition Description

SPN FMI Condition Description

SPN FMI Condition Description

SPN FMI Condition Description

SPN FMI Condition Description

SPN FMI Condition Description

SPN FMI Condition Description

SPN FMI Condition Description

SPN FMI Condition Description

SPN FMI Condition Description

SPN FMI Condition Description

SPN FMI Condition Description

SPN FMI Condition Description

SPN FMI Condition Description

SPN FMI Condition Description

How To Use Symptom Based Diagnostics

Operational Checkout Procedures

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

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

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

Step 4 Inspect exhaust system for damage or restrictions. Decision

Step 5 Inspect engine oil level. Decision

Step 6 Inspect engine coolant level and quality. Decision

• 7.0 Fuel System Operational Checkout Procedure (page 39)

2.0 - Engine Does Not Start Operational Checkout Procedure

Step 1 Perform preliminary operational checkout procedure. Decision

Step 3 Record snapshot of engine cranking data. Decision

3.0 - Engine Hard to Start Operational Checkout Procedure

Step 1 Perform preliminary operational checkout procedure. Decision

Step 3 Determine specific hard to start symptom. Decision

4.0 - Engine Performance Problem Operational Checkout Procedure

Step 1 Perform preliminary operational checkout procedure. Decision