NUMBER: 12–17–10 S.M. REF.: Listed in Table … · NUMBER: 12–17–10 S.M. REF.: Listed in Table ENGINE: EPA07 Series 60 DATE: December 2010 SUBJECT: EGR DIAGNOSIS ADDITIONS,

NUMBER: 12–17–10 S.M. REF.: Listed in Table ENGINE: EPA07 Series 60 DATE: December2010

SUBJECT: EGR DIAGNOSIS

ADDITIONS, REVISIONS, OR UPDATES

Publication Number Platform Section Title Change Page Number(s)

DDC-SVC-MAN-0009 EPA07 Series 60 20.1 SPN 27/FMI 320.2 SPN 27/FMI 420.3 SPN 27/FMI 7

97.1 SPN 2791/FMI 397.2 SPN 2791/FMI 497.3 SPN 2791/FMI 597.4 SPN 2791/FMI 7



All of the followingprocedures have beenmodified for betterserviceability of theEGR system.

Insert as stated.

NOTE: Page numbers are based on the most recent version of the individual publication and may be adjusted throughout the annual print cycle.

SPN 27/FMI 3

This diagnostic condition is typically the EGR valve position circuit failed high.

EGR VALVE POSITION CIRCUIT CHECK

Check as follows:

NOTE:Verify the MCM has release 62.4 or newer software.

1. Disconnect the EGR valve.

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

3. Measure for voltage between pin 4 of the EGR connector harness and ground.

[a] If voltage is present, repair the short to power between pin 4 of the EGR connector harnessand pin 60 of the 120–pin MCM connector. Refer to section .

[b] If no voltage is present, go to step 4.

4. Measure for voltage between pin 3 of the EGR connector harness and ground.

[a] If voltage is present, repair the short to power between pin 3 of the EGR connector harnessand pin 67 of the 120–pin MCM connector. Refer to section .

[b] If no voltage present, go to step 5.

5. Turn the ignition OFF.

6. Disconnect the MCM 120–pin connector.

7. Measure the resistance from pin 3 of the EGR connector harness and pin 67 of the 120–pinMCM connector.

[a] If the resistance is greater than 3 Ω, repair the open between pin 3 of the EGR connectorharness and pin 67 of the 120–pin MCM connector. Refer to section .

[b] If the resistance is less than 3 Ω, replace the EGR valve. Refer to section .

VERIFY REPAIRS

Verify repairs as follows:

1. Turn ignition OFF.

2. Reconnect any electrical connections that were disconnected to perform the diagnosis.

3. Clear codes with DDDL 7.0 or latest version.

4. Start and bring engine up to operating temperature above 60°C (140°F).

5. Verify operation is satisfactory and no warning lamps illuminate. If warning lamps illuminate,troubleshoot the codes. If assistance is required, call the Detroit Diesel Customer SupportCenter at 313–592–5800.

SPN 27/FMI 4

This diagnostic condition is typically a Circuit Failed High.

NOTE:If the EGR valve is commanded via the service tool to any position more than three times per ignitioncycle, SPN 2791 FMI 7 (EGR Valve Position Incorrect) will set. This is normal and no diagnosticsshould be performed on a tool-induced fault.


Check as follows:

1. Check for multiple codes.

[a] If 27/4, 2791/5 and 1073/4 are present, repair open between pin 62 of the MCM 120–pinconnector and the EGR valve or pin 62 of the MCM 120–pin connector and the frontJake Brake® solenoid.

[b] If 27/4 only, go to step 2.

[c] If 27/4 and 1073/4 are present go to step 6.

[d] If 27/4 and 3482/4 are present go to step 11.

[e] If 27/4 and 3471/4 are present go to step 14.

[f] If 27/4 and 3598/4 are present go to step 17.

2. Disconnect the EGR Valve harness connector.


4. Measure the resistance between pin 4 of the EGR Valve harness connector and ground.

[a] If the resistance is less than 3 ohms, repair the wire between pin 4 of the EGR Valveharness connector and pin 60 of the MCM 120–pin connector.

[b] If the resistance is greater than 3 ohms, go to step 5.

5. Measure the resistance between pin 4 of the EGR Valve harness connector and pin 60 of theMCM 120–pin connector.

[a] If the resistance is less than 3 ohms, replace the EGR Valve.

[b] If the resistance is greater than 3 ohms, repair the wire between pin 4 of the EGR Valveharness connector and pin 60 of the MCM 120–pin connector.

6. Disconnect the front valve cover injector harness.

7. Inspect the front injector harness 12–pin connector for signs of oil intrusion.

[a] If contamination is found, replace the under valve cover injector harness.

[b] If no contamination is found, go to step 8.

8. Remove the valve cover.

9. Disconnect the front Jake Brake solenoid.

10. Measure the resistance between either Jake Brake solenoid terminal and ground.

[a] If the resistance is less than 3 ohms, replace the front Jake Brake solenoid.

[b] If the resistance is greater than 3 ohms, replace the front injector harness.


12. Disconnect the Fuel Cutoff Valve harness connector.

13. Measure the resistance between pin 1 of the Fuel Cutoff Valve harness connector and ground.

[a] If the resistance is less than 3 ohms, repair wire between pin 1 of the Fuel Cutoff Valveharness connector and pin 69 of the MCM 120–pin connector.

[b] If the resistance is greater than 3 ohms, replace the Doser Block Assembly.


15. Disconnect the Electronic Dosing Valve harness connector.

16. Measure the resistance between pin 1 of the Electronic Dosing Valve harness connector andground.

[a] If the resistance is less than 3 ohms, repair wire between pin 1 of the Electronic DosingValve harness connector and pin 65 of the MCM 120–pin connector.



18. Measure the resistance between pin 62 of the MCM 120–pin connector and ground.

[a] If the resistance is less than 3 ohms, go to step 19.

[b] If the resistance is greater than 3 ohms, go to step 21.

19. Disconnect the EGR Valve harness connector.


[a] If the resistance is less than 3 ohms, repair wire between pin 2 of the EGR Valve harnessconnector and pin 62 of the MCM 120–pin connector.

[b] If the resistance is greater than 3 ohms, reconnect valve. Go to step 24.


[a] If the resistance is less than 3 ohms, go to step 22.

[b] If the resistance is greater than 3 ohms, note resistance measurements taken duringprocedure and contact the Detroit Diesel Customer Support Center at 313–592–5800 forfurther instruction.

22. Disconnect the Electronic Dosing Valve.


[a] If the resistance is less than 3 ohms, repair the wire between pin 2 of the Electronic DosingValve harness connector and pin 64 of the MCM 120–pin connector.


24. Turn Ignition switch ON (key ON, engine OFF).

25. Using DDDL monitor EGR Actual Position while activating PWM1 to 50%.

26. Is EGR Actual Position reading between 40 and 60%?

[a] Yes; go to step 27.

[b] No; go to step 5.

27. Command PWM1 to 90% while monitoring EGR Actual Position. Does EGR Actual Positionread between 75-100%?

[a] Yes; repeat steps 24 through 27. If results are repeated, clear fault and release vehicle.

[b] No; replace EGR valve and verify repair.

VERIFY REPAIRS







SPN 27/FMI 7

This diagnostic condition is typically the EGR Valve Stuck Open.

NOTE:If the EGR valve is commanded via the service tool to any position more than three times per ignitioncycle, SPN 2791/FMI 7 (EGR Valve Position Incorrect) will set. This is normal and no diagnosticsshould be performed on a tool-induced fault.


Check as follows:


2. Using DDDL, monitor EGR Actual Position while activating PWM1 to 30%.





[a] Yes; repeat steps 2 through 4. If results are repeated, clear fault and release vehicle. Ifresults are not repeated, go to step 5.


5. Disconnect EGR Valve harness connector.

6. Inspect harness connector for bent, spread or corroded pins.

[a] If connector damage is found, repair as necessary.

[b] If no damage is found, go to step 7.

7. Remove the EGR Valve.

8. Inspect the EGR Valve butterfly for signs of excessive soot or white residue.

[a] If white residue is found, repair cause of coolant contamination or a possible EGR coolerfailure. Repair source of coolant contamination and replace the EGR Valve.

[b] If excessive soot residue is found, correct cause of soot contamination or a possible CACsystem leak(s). Repair source of soot contamination and replace the EGR Valve.

[c] If no contamination is found, replace the EGR Valve.

VERIFY REPAIRS







SPN 2791 – EGR VALVE (AUX PWM #1) FAILED OR OPEN CIRCUIT

SPN 2791/FMI 3

This diagnostic condition is typically a short to power fault.

Check as follows:

1. Disconnect the EGR valve connector.


3. Measure the voltage between pin 1 of the EGR valve connector and ground.

[a] If the voltage is greater than 11.5 volts, repair the short to power between pin 1 of the EGRvalve connector and pin 61 of the 120–pin MCM connector.

[b] If the voltage is less than 11.5 volts, replace the EGR valve.

VERIFY REPAIRS







SPN 2791/FMI 4

This diagnosis is typically short to ground.

Check as follows:

1. Disconnect EGR valve connector.

2. Disconnect 120–pin MCM connector.

3. Measure the resistance between pin 1 of the EGR valve connector and ground.

[a] If the resistance is less than 3 Ω, repair the short circuit between pin 1 of the EGR valveconnector and ground.

[b] If the resistance is greater than 3 Ω, replace the EGR valve.

VERIFY REPAIRS







SPN 2791/FMI 5

This diagnostic condition is typically an open circuit fault.

Check as follows:

1. Check for multiple codes.

[a] If 2791/5, 27/4, and 1073/4 are present, repair the open between pin 62 of the 120–pinMCM connector and EGR valve and front Jake Brake solenoid.

[b] If only 2791/5 is present, go to step 2.

2. Disconnect the EGR valve.

3. Disconnect the 120–pin MCM connector.

4. Measure the resistance between pin 1 of the EGR valve harness connector and pin 61 of the120–pin MCM connector.

[a] If the resistance is greater than 3 Ω, repair the open between pin 1 of the EGR valveharness connector and pin 61 of the 120–pin MCM connector.

[b] If the resistance is less than 3 Ω, replace the EGR valve.

VERIFY REPAIRS







SPN 2791/FMI 7

This diagnosis is typically the EGR Valve is in an Incorrect Position.

NOTE:If the EGR valve is commanded via the service tool to any position more than three times per ignitioncycle, SPN 2791/FMI 7 (EGR Valve Position Incorrect) will set. This is normal and no diagnosticsshould be performed on a tool-induced fault.


Check as follows:


2. Using DDDL monitor EGR Actual Position while activating PWM1 to 50%.





[a] Yes; repeat steps 2 through 4. If results are repeated, clear fault and release vehicle. Ifresults are not repeated, go to step 5.


5. Disconnect EGR Valve harness connector.

6. Inspect harness connector for bent, spread or corroded pins.

[a] If connector damage is found, repair as necessary and verify repair. Refer to section .

[b] If no damage is found, go to step 7.

7. Remove the EGR Valve.

8. Inspect the EGR Valve butterfly for signs of excessive soot or white residue.

[a] If white residue is found, repair cause of coolant contamination or possible EGR coolerfailure and verify repair.Refer to section .

[b] If excessive soot residue is found, correct cause of soot contamination or possible ChargeAir Cooler (CAC) system leaks and verify repair. Refer to section .

[c] If no contamination is found, go to step 9.

9. Using DDDL, monitor EGR Actual Position while activating PWM1 to 50%.



[b] No; replace EGR valve and verify repair. Refer to section .

11. Command PWM1 to 90% and monitor EGR Actual Position. Does EGR Actual Position readbetween 75-100%?

[a] Yes; road test vehicle. If fault code becomes active, replace EGR valve. If not, thenrelease truck.


VERIFY REPAIRS







SPN 2659/FMI 0

The code is typically EGR High Flow.

NOTE:If the EGR valve is commanded via the service tool to any position more than three times per ignitioncycle, SPN 2791 FMI 7 (EGR Valve Position Incorrect) will set. This is normal and no diagnosticsshould be performed on a tool-induced fault.


Check as follows:

1. Connect DDDL 7.3 or higher.

2. Is the vehicle equipped with a Series 60 engine?


[b] No, go to step 4.

3. Using DDDL 7.x, perform Turbo Hysteresis test.

[a] If Hysteresis test passes, go to step 4.

[b] If Hysteresis test fails, refer to the EPA07 Series 60 Workshop Manual(DDC-SVC-MAN-0005) for turbo diagnostics.

4. Check EGR Valve Operation. Command PWM1 to 50% while monitoring EGR ActualPosition. Does EGR Actual Position read between 40-60%?



5. Command PWM1 to 90% while monitoring EGR Actual Position. Does EGR Actual Positionread between 75-100 %?



6. Turn the ignition OFF (key OFF, engine OFF).

7. Disconnect EGR Valve Harness connector.

8. Inspect connector for damaged, corroded pins.

[a] If damage is found, repair as necessary and verify repair. Refer to section .

[b] If no damaged pins are found, go to step 11.

9. Remove and inspect air filter for plugging.

[a] If plugged, replace air filter.

[b] If air filter checks OK, go to step 10.

10. Inspect entire Intake Air system for leaks or blockage.

[a] If leaks or blockage are found, repair Intake Air system as necessary.

[b] If no issues are found with intake air system, obtain DDDL log file of failure and contactthe Detroit Diesel Customer Support Center at 313–592–5800 for further instruction.





[a] Yes; road test truck. If fault code becomes active, replace EGR valve; if not, release truck.


VERIFY REPAIRS







SPN 2659/FMI 1

The code is typically an EGR flow target error (low flow).

Reflash the MCM to 62.4 or newer software and verify repairs.

VERIFY REPAIRS







SPN 2659/FMI 17

The code is typically an EGR Flow Target Error (Low Flow).

NOTE:If the EGR valve is commanded via the service tool to any position more than 3 times per ignitioncycle, SPN 2791 FMI 7 (EGR Valve Position Incorrect) will set. This is normal and no diagnosticsshould be performed on a tool induced fault.


Check as follows:

1. Connect DDDL 7.3 SP3 or higher.


3. Is the vehicle equipped with a Series 60 engine?



4. Using DDDL 7.x, perform Turbo Hysteresis test.

[a] If Hysteresis test passes, go to step 5.

[b] If Hysteresis test fails, refer to EPA07 Series 60 Workshop Manual (DDC-SVC-MAN-0005)for turbo diagnostics.







7. Turn the ignition OFF (key OFF, engine OFF).



[a] If damage is found, repair as necessary. Go to step 12.

[b] If no damaged pins are found, go to step 12.

10. Remove and inspect air filter for plugging.

[a] If plugged, replace air filter.

[b] If air filter checks OK, go to step 11.

11. Inspect all EGR delivery pipes for leaks.

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

[b] If no issues are found with EGR delivery pipes, obtain DDDL log file of failure and contactthe Detroit Diesel Customer Support Center at 313–592–5800 for further instruction.







VERIFY REPAIRS







SPN2659/FMI 18

This code is typically EGR Low Flow (System Restriction Detected).

NOTE:If the EGR valve is commanded via the service tool to any position more than three times per ignitioncycle, SPN 2791/FMI 7 (EGR Valve Position Incorrect) will set. This is normal and no diagnosticshould be performed on a tool-induced fault.


Check as follows:


2. Using DDDL 7.X, perform Turbo Hysteresis test.

[a] If the Turbo Hysteresis test fails, refer to the EPA07 Series 60 Workshop Manual(DDC-SVC-MAN-0005) for turbo diagnostics.

[b] If the Turbo Hysteresis test passes, go to step 3.

3. Check EGR valve operation. Command PWM1 to 50% while monitoring EGR Actual Position.Does EGR Actual Position read between 40-60%?

[a] Yes, go to step 4.





5. Turn the ignition OFF.



[a] If damage is found, repair as necessary and verify repairs. Refer to section .

[b] If no damaged pins are found, go to step 20. Reconnect the valve and repeat steps 3 and 4.If valve fails to respond, replace the EGR Valve.

8. Check the Inlet Manifold Pressure Sensor; using DDDL 7.X, compare inlet manifold pressureto barometric pressure. Is the inlet manifold pressure within 0.6 psi of barometric pressure?



9. Substitute a known good Inlet Manifold Pressure Sensor. Is the inlet manifold pressure nowwithin 0.6 psi of barometric pressure?

[a] Yes, replace the Inlet Manifold Pressure Sensor.

[b] No, replace the MCM.

10. Access the Voltage Service Routine.

11. Select “Start Acquiring.”

12. Monitor P_DPF_IN voltage.

13. Is the voltage between 0.44 to 0.56 volts?


[b] No. If voltage is not within the range above, inspect electrical connections upstream to theMCM (sensor, ATD harness 10–pin, 31–pin VIH and the 120–pin MCM) for corrosionspread pins. If connector damage is found, repair as necessary. If no corrosion or damageis found, replace the suspect sensor.

14. Start the engine.

15. Increase engine to 1500 RPM while monitoring DPF Inlet Pressure.

16. Is DPF Inlet Pressure greater than 2 psi?



17. Inspect DOC Inlet face for soot contamination, or DOC Push Out; also inspect DPF Outlet forsoot contamination. Replace contaminated/damaged component(s); re-install and performparked regeneration.

18. Turn the engine OFF.

19. Remove the EGR valve and inspect the butterfly for physical damage.

[a] If butterfly damage is found, replace the EGR Valve.

[b] If no damage is found, replace the EGR cooler.

20. Check EGR valve operation. Command PWM1 to 50% while monitoring EGR Actual Position.Does EGR Actual Position read between 40-60%?





[b] No, replace EGR valve and verify repair. Refer to section .

VERIFY REPAIRS







SPN 411/FMI 0

This diagnosis is typically EGR differential pressure failed high (High Box).

EGR DELTA P SENSOR CHECK

Check as follows:

Reflash MCM to 62.4 or newer software and verify repair.

VERIFY REPAIRS







SPN 411/FMI 3

This diagnosis is typically EGR Delta P Sensor circuit failed high.

OPEN CIRCUIT CHECK

Check as follows:


VERIFY REPAIRS







SPN 411/FMI 4

This diagnosis is typically EGR Delta P Sensor short to ground.

SHORT TO GROUND CHECK

Check as follows:


VERIFY REPAIRS







SPN 411/FMI 13

This diagnosis is typically EGR Delta P Sensor out of calibration.

EGR DELTA P SENSOR CHECK

Check as follows:


VERIFY REPAIRS







ADDITIONAL SERVICE INFORMATION

Additional service information is available in Power Service Literature.

Detroit Diesel®, DDC®, Series 60® and the spinning arrows design are registered trademarks of Detroit Diesel Corporation.© Copyright 2010 Detroit Diesel Corporation. All rights reserved. Printed in U.S.A.

Documents

NUMBER: 12–17–10 S.M. REF.: Listed in Table … · NUMBER: 12–17–10 S.M. REF.: Listed in Table ENGINE: EPA07 Series 60 DATE: December 2010 SUBJECT: EGR DIAGNOSIS ADDITIONS,