Dodge Cummins Articles: OBDII Error Codes

P0008 - Engine Position System Performance

Sat, 19 Jan 2019 00:17:40 +0000

P0008 - Engine Position System Performance

Theory of Operation

The Powertrain Control Module (PCM) will turn on the MIL lamp immediately after this diagnostic runs and fails.
The PCM will turn off the MIL lamp after the diagnostic runs and passes in four consecutive drive cycles.

When Monitored and Set Conditions

When Monitored: This diagnostic runs continuously when the following conditions are met:
• With the engine running.

Set Conditions:

• The Powertrain Control Module (PCM) has detected that the Crank Position Sensor (CKP) and Cam
Position Sensor (CMP) signals are reversed.

Default Actions:

• The MIL will illuminate

Possible Causes

CRANK AND CAM POSITION SENSOR CONNECTORS REVERSED

Always perform the PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE before proceeding. (Refer to
28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

Diagnostic Test

1. ACTIVE DTC
1. Ignition on, engine not running.
2. With the scan tool, clear the DTC.
3. Start or crank the engine.
4. With the scan tool, read DTCs.

Did the DTC reset?
Yes
• Go To 2
No

• Perform the INTERMITTENT CONDITION diagnostic procedure. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

2. CRANK AND CAM SENSOR CONNECTORS REVERSED

1. This DTC indicates that the CKP and CMP Position Sensor signals are reversed.
2. Switch the CKP and CMP Position Sensor connectors.
3. With the scan tool, clear the DTC.
4. Start or crank the engine.
5. With the scan tool, read DTCs.

Did the DTC reset?

Yes
• Using the wiring diagram as a guide, check the connectors and wiring for proper configuration.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).
No
• Repair complete.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

P000F - Fuel System Over Pressure Relief Valve Activated

Sat, 19 Jan 2019 00:04:09 +0000

P000F - Fuel System Over Pressure Relief Valve Activated

When Monitored and Set Conditions

When Monitored: This diagnostic runs continuously when the following conditions are met:

With the engine running.

Set Conditions:

The Powertrain Control Module (PCM) has detects that the fuel pressure has deviated at a higher rate than the calibrated threshold. This DTC will cause active regeneration to be disabled.

Default Actions:

The MIL will illuminate.

Possible Causes

PRESSURE LIMITING VALVE
LIFT PUMP
HIGH PRESSURE PUMP
EXCESSIVE INJECTOR DRAINS

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 28 - DTCBased Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

CHECK THE FUEL DELIVERY SYSTEM
1. (Refer to 29 - Non-DTC Diagnostics/Drivability - Diesel - Diagnosis and Testing) and perform the CHECKING THE FUEL DELIVERY SYSTEM diagnostic procedure.

Were any problems found?

Yes
Repair as necessary.

Perform the INTERMITTENT CONDITION diagnostic procedure. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

P0016 - Crankshaft / Camshaft Timing Misalignment - Bank 1 Sensor 1

Sun, 20 Jan 2019 20:25:12 +0000

P0016 - Crankshaft / Camshaft Timing Misalignment - Bank 1 Sensor 1

Theory of Operation

The Crankshaft Position (CKP) and Camshaft Position (CMP) Sensors are hall effect type sensors. The Powertrain Control Module (PCM) provides a 5-Volt supply to the position sensor and return circuit. A notch on the crankshaft gear is used to determine the speed of the engine by the PCM. As the notch on the crankshaft speed ring or the windows in the back of the camshaft gear move past the position sensor, a signal is generated on the position sensor circuit. The PCM interprets this signal and converts it to an engine speed.

When Monitored and Set Conditions

When Monitored: This diagnostic runs continuously when the following conditions are met:
• With the engine running.

Set Conditions:

• The Powertrain Control Module (PCM) has detected that the CKP and CMP sensor values are not aligned and out of sync.

Default Actions:

• The MIL will illuminate.

Possible Causes

DAMAGE TO THE CRANKSHAFT POSITION SENSOR (CKP) OR CAMSHAFT POSITION SENSOR (CMP)

DAMAGED TONE WHEEL

MECHANICAL MISALIGNMENT OF THE CKP OR CMP

MECHANICAL MISALIGNMENT OF THE CRANKSHAFT AND CAMSHAFT GEARS

1.DAMAGE TO THE CKP OR CMP

1. Visually inspect the condition of the tone wheel, CKP, and CMP for damage. Are any of the components damaged?

Yes

• Repair or replace any damaged component.

• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

• Go To 2

2.MECHANICAL MISALIGNMENT OF THE CKP OR CMP

1. Verify the tone wheel is properly positioned relative to the locating pin in the front face of the crankshaft.

Is the tone wheel properly installed?

Yes

• Go To 3

• Repair the tone wheel installation. • Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

3.MECHANICAL MISALIGNMENT OF THE CRANKSHAFT AND CAMSHAFT GEARS

1. Check the mechanical alignment of the camshaft gear to the crankshaft gear. Refer to service manual for assistance.

Are the gear teeth in proper alignment?

Yes

• Perform the INTERMITTENT CONDITION diagnostic procedure. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

• Repair the gear alignment. • Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

P0046 - Turbocharger Boost Control Circuit Performance

Mon, 04 Feb 2019 01:24:57 +0000

P0046 - Turbocharger Boost Control Circuit Performance

Theory of Operation

The Variable Geometry Turbocharger (VGT) is electronically controlled by the Electronic Turbo Actuator. The Electronic Turbo Actuator is a smart device; it communicates information with the Powertrain Control Module (PCM) over the J1939 BUS. The Electronic Turbo Actuator performs its own internal diagnostics and reports failures back to the PCM. The PCM then decodes the error message and converts it to a fault code. The PCM lights the Malfunction Indicator Lamp (MIL) after the diagnostic runs and fails in two consecutive drive cycles. The PCM will turn off the MIL immediately after this diagnostic runs and passes in four consecutive drive cycles.

When Monitored and Set Conditions

When Monitored: This diagnostic runs continuously when the following conditions are met:
• With the engine running.

Set Conditions:
• The Electronic Turbo Actuator does not receive a valid J1939 BUS position message from the Powertrain Control Module (PCM).

Default Actions:
• The MIL will illuminate.

Possible Causes

ELECTRONIC TURBO ACTUATOR 12 VOLT SUPPLY
ELECTRONIC TURBO ACTUATOR RETURN
ELECTRONIC TURBO ACTUATOR POWERTRAIN CONTROL MODULE (PCM)

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 28 - DTCBased Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

Diagnostic Test

1. OTHER DTCs

1. Ignition on, engine not running.

2. With the scan tool, read DTCs. Is U010C active?

Yes

• Perform the Diagnostics for U010C first.

• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

• Go To 2

2. POWERTRAIN CONTROL MODULE

1. Turn ignition off.

2. Disconnect the Electronic Turbo Actuator harness connector. NOTE: Check connectors - Clean/repair as necessary.

3. Ignition on, engine not running.

4. After 75 seconds, monitor the system response with the scan tool. Is U010C active?

Yes

• Go To 3

• Replace the Powertrain Control Module in accordance with the Service Information.

• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

3. INTERMITTENT CONNECTION

1. Turn ignition off.

2. Reconnect the Electronic Turbo Actuator harness connector.

3. Ignition on, engine not running.

4. After 75 seconds, monitor the system response with the scan tool. Is P0046 active?

Yes

• Go To 4

No
• Perform the INTERMITTENT CONDITION - 6.7L diagnostic procedure. (Refer to 28 - DTC-Based
Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

4. PCM CONNECTION
1. Turn ignition off.
2. Disconnect the PCM harness connector.
NOTE: Check connectors - Clean/repair as necessary. Were their any dirty or damaged terminals?

Yes
• Repair/Replace as necessary.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Go To 5

5. INTERMITTENT CONNECTION
1. Turn ignition off.
2. Reconnect the Electronic Turbo Actuator harness connector.
3. Reconnect the PCM harness connector.
4. Ignition on, engine not running.
5. After 75 seconds, monitor the system response with the scan tool.I s P0046 active?

Yes
• Replace the Electronic Turbo Actuator in accordance with the Service Information.(Refer to 09 - Engine, 6.7L Diesel/Turbocharger System/ACTUATOR, Turbocharger/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

• Perform the INTERMITTENT CONDITION - 6.7L diagnostic procedure. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

P0049 Turbocharger Turbine Overspeed

Mon, 04 Feb 2019 01:44:50 +0000

P0049 Turbocharger Turbine Overspeed

Theory of Operation

The Turbocharger Speed Sensor is a variable reluctance speed sensor. It consists of a coil of wire and an iron core. The target on the turbocharger shaft is a ground flat surface in the center of the shaft. As the flat surface on the turbocharger shaft spins past the speed sensor, a signal is generated. The Powertrain Control Module (PCM) interprets this signal and converts it to a turbocharger speed reading. The PCM will illuminate the MIL lamp after the diagnostic runs and fails in two consecutive drive cycles. During this time the PCM uses an estimated turbocharger speed. An engine power derate may be experienced. The PCM turns off the MIL when the diagnostic runs and passes in four consecutive drive cycles.

When Monitored and Set Conditions

When Monitored: This diagnostic runs continuously when the following conditions are met:

• With the engine running.

• PCM detects a valid turbocharger speed.

Set Conditions:

• The PCM detects that the Turbocharger Speed Sensor is out of range.

Default Actions:

• The MIL will illuminate.

Possible Causes

TURBO SPEED SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
TURBO SPEED SENSOR SIGNAL CIRCUIT OPEN/HIGH RESISTANCE
TURBO SPEED SENSOR RETURN CIRCUIT OPEN/HIGH RESISTANCE
TURBOCHARGER SPEED SENSOR

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 28 - DTCBased Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

1. OTHER DTCS

1. With the scan tool, read DTCs.

Are any DTCs present for Inlet Air Pressure Sensor or Boost Pressure Sensor?

Yes
• Troubleshoot other DTCs first.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based
Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Go To 2

2. INTERMITTENT CONDITION
1. Start the engine.
2. Using the accelerator pedal, accelerate the engine speed to high idle and hold the engine speed at high
idle for at least 20 seconds.
Does DTC P0049 become active?

Yes
• Go To 3

No
• Perform the INTERMITTENT CONDITION diagnostic procedure. (Refer to 28 - DTC-Based
Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

3. TURBOCHARGER SPEED SENSOR
1. Turn Ignition off.
2. Disconnect the Turbocharger Speed Sensor connector. NOTE: Check connectors - Clean/repair as necessary.
3. Measure the resistance across the (K540) Turbocharger Speed Sensor Signal circuit and the (K541) Turbocharger Speed Sensor Return circuit at the Turbocharger Speed Sensor. Is the resistance between 600 and 1600 Ohms?

Yes

• Go To 4

No
• Replace the Turbocharger Speed Sensor in accordance with the Service Information.(Refer to 09 - Engine, 6.7L Diesel/Turbocharger System/SENSOR, Turbocharger Speed/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

4. CHECK THE (K540) TURBO SPEED SENSOR SIGNAL CIRCUIT FOR A SHORT TO GROUND
1. Measure the resistance between ground and the
(K540) Turbocharger Speed Sensor Signal circuit at the Turbocharger Speed Sensor connector. Is the resistance greater than 10k Ohms?

Yes
• Go To 5

No
• Repair the (K540) Turbocharger Speed Sensor Signal circuit for a short to ground.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

5. CHECK THE (K540) TURBO SPEED SENSOR SIGNAL CIRCUIT FOR AN OPEN/HIGH RESISTANCE
1. Disconnect the PCM C1 harness connector.
NOTE: Check connectors - Clean/repair as necessary.
2. Measure the resistance of the (K540) Turbocharger Speed Sensor Signal circuit between the Turbocharger Speed Sensor harness connector and the PCM C1 harness connector. Is the resistance below 5.0 Ohms?

Yes
• Go To 6

No
• Repair the (K540) Turbocharger Speed Sensor Signal circuit for an open or high resistance.

• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

6. CHECK THE (K541) TURBO SPEED SENSOR RETURN CIRCUIT FOR AN OPEN/HIGH RESISTANCE
1. Measure the resistance of the (K541) Turbocharger Speed Sensor Return circuit between the Turbocharger Speed Sensor harness connector and the PCM C1 harness connector. Is the resistance below 5.0 Ohms?

Yes
• Go To 7

No
• Repair the (K541) Turbocharger Speed Sensor Return circuit for an open or high resistance.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

7. POWERTRAIN CONTROL MODULE
1. Disconnect all PCM harness connectors.
2. Disconnect all related in-line harness connections (if equipped).
3. Disconnect the related component harness connectors.
4. Inspect harness connectors, component connectors, and all male and female terminals for the following conditions:
• Proper connector installation.
• Damaged connector locks.
• Corrosion.
• Other signs of water intrusion.
• Weather seal damage (if equipped).
• Bent terminals.
• Overheating due to a poor connection (terminal may be discolored due to excessive current draw).
• Terminals that have been pushed back into the connector cavity.
• Perform a terminal drag test on each connector terminal to verify proper terminal tension. Repair any conditions that are found.

5. Reconnect all PCM harness connectors. Be certain that all harness connectors are fully seated and the connector locks are fully engaged.
6. Reconnect all in-line harness connectors (if equipped). Be certain that all connectors are fully seated and the connector locks are fully engaged.
7. Reconnect all related component harness connectors. Be certain that all connectors are fully seated and the connector locks are fully engaged.
8. With the scan tool, erase DTCs.

9. Using the recorded Freeze Frame and Environmental Data, along with the When Monitored and Set Conditions above, operate the vehicle in the conditions that set the DTC.
10. With the scan tool, read PCM DTCs. Did the DTC return?

Yes
• Replace the Powertrain Control Module (PCM) in accordance with the Service Information. (Refer to 08 - Electrical/8E - Electronic Control Modules/MODULE, Powertrain Control/Removal) .
• Perform the PCM VERIFICATION TEST. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Test complete.
• Perform the PCM VERIFICATION TEST. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

P006E - Turbocharger Boost control Supply Voltage Circuit Low

Mon, 04 Feb 2019 15:55:21 +0000

P006E - Turbocharger Boost control Supply Voltage Circuit Low

Theory of Operation

When Monitored and Set Conditions

When Monitored: This diagnostic runs continuously when the following conditions are met:

• With the ignition on.

Set Conditions:
• The 12 Volt supplied voltage from the PCM to the VGT Actuator dropped below 9.0 Volts for a calibrated length of time.

Default Actions:
• The MIL will illuminate.

Possible Causes

VGT 12 VOLT SUPPLY CIRCUIT OPEN/HIGH RESISTANCE

TURBOCHARGER ACTUATOR

POWERTRAIN CONTROL MODULE (PCM)

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 28 - DTCBased Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

Diagnostic Test

1. ACTIVE DTC
1. Turn the ignition on.
2. With the scan tool, read DTCs. Is P006E active?

Yes

• Go To

No
• Perform the INTERMITTENT CONDITION - DIESEL diagnostic procedure. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

2. CHECK THE (N639) VGT 12 VOLT SUPPLY CIRCUIT FOR AN OPEN/HIGH RESISTANCE

1. Measure the resistance of the (N639) VGT 12 Volt Supply circuit between the VGT harness conector and the PCM C1 harness connector. Is the resistance above 5.0 Ohms?

Yes
• Repair the (N639) VGT 12 Volt Supply circuit for an open or high resistance.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure)

No
• Go To 3

3. TURBOCHARGER ACTUATOR
1. Reconnect the PCM C1 harness connector.
2. Turn the ignition on and wait 1 minute.
3. With a voltmeter connected to ground, measure the voltage of the (N639) VGT 12 Volt Supply circuit at the VGT harness conector. Is the voltage equal to battery voltage?

No
• Go To 4

4. POWERTRAIN CONTROL MODULE
1. Disconnect all PCM harness connectors.
2. Disconnect all related in-line harness connections (if equipped).
3. Disconnect the related component harness connectors.
4. Inspect harness connectors, component connectors, and all male and female terminals for the following conditions:
• Proper connector installation.
• Damaged connector locks.
• Corrosion.
• Other signs of water intrusion.
• Weather seal damage (if equipped).
• Bent terminals.
• Overheating due to a poor connection (terminal may be discolored due to excessive current draw).
• Terminals that have been pushed back into the connector cavity.
• Perform a terminal drag test on each connector terminal to verify proper terminal tension.
Repair any conditions that are found.
5. Reconnect all PCM harness connectors. Be certain that all harness connectors are fully seated and the connector locks are fully engaged.
6. Reconnect all in-line harness connectors (if equipped). Be certain that all connectors are fully seated and the connector locks are fully engaged.
7. Reconnect all related component harness connectors. Be certain that all connectors are fully seated and the connector locks are fully engaged.
8. With the scan tool, erase DTCs.
9. Using the recorded Freeze Frame and Environmental Data, along with the When Monitored and Set Conditions above, operate the vehicle in the conditions that set the DTC.
10. With the scan tool, read PCM DTCs. Did the DTC return?

Yes
• Replace the Powertrain Control Module (PCM) in accordance with the Service Information. (Refer to 08 - Electrical/8E - Electronic Control Modules/MODULE, Powertrain Control/Removal) .
• Perform the PCM VERIFICATION TEST. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Test complete.
• Perform the PCM VERIFICATION TEST. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure)

P006F - Turbocharger Boost Control Supply Voltage Circuit High

Mon, 04 Feb 2019 16:08:54 +0000

P006F - Turbocharger Boost Control Supply Voltage Circuit High

Theory of Operation

When Monitored and Set Conditions

When Monitored: This diagnostic runs continuously when the following conditions are met:
• With the ignition on.

Set Conditions:
• The 12 Volt supplied voltage from the PCM to the VGT Actuator is above a calibrated threshold for a calibrated length of time.

Default Actions:
• The MIL will illuminate.

Possible Causes

VGT 12 VOLT SUPPLY CIRCUIT SHORT TO VOLTAGE
VGT RETURN CIRCUIT OPEN/HIGH RESISTANCE
TURBOCHARGER ACTUATOR
POWERTRAIN CONTROL MODULE

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 28 - DTCBased Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

Diagnostic Test

1. ACTIVE DTC
NOTE: If there are any Coolant Temperature related DTCs active, perform those diagnostics and repair before performing this diagnostic tree.
1. Turn the ignition on.
2. With the scan tool, read DTCs. Is P006F active?

Yes
• Go To 2

No
• Perform the INTERMITTENT CONDITION - DIESEL diagnostic procedure. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

2. CHECK THE (N639) VGT 12 VOLT SUPPLY CIRCUIT FOR A SHORT TO VOLTAGE
1. Turn the ignition off.
2. Disconnect the VGT harness connector.
3. Disconnect the PCM C1 harness connector.
4. Turn the ignition on. Wait 1 minute.
5. Measure the voltage on the (N639) VGT 12 Volt Supply circuit at the VGT harness connector. Is there voltage present?

Yes
• Repair the (N639) VGT 12 Volt Supply circuit for a short to voltage.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure)

No
• Go To

3. CHECK THE (K639) VGT RETURN CIRCUIT FOR AN OPEN/HIGH RESISTANCE
1. Measure the resistance of the (K639) VGT Return circuit between the VGT harness conector and the PCM C1 harness connector. Is the resistance above 5.0 Ohms?

No
• Go To 4

4. TURBOCHARGER ACTUATOR
1. Reconnect the PCM C1 harness connector.
2. Turn the ignition on. Wait 1 minute.
3. While monitoring the scan tool, connect a jumper wire between ground and the (N639) VGT 12 Volt Supply circuit at the VGT harness connector.
Does DTC P006E become active?

• Go To 5

5. POWERTRAIN CONTROL MODULE
1. Disconnect all PCM harness connectors.
2. Disconnect all related in-line harness connections (if equipped).
3. Disconnect the related component harness connectors.
4. Inspect harness connectors, component connectors, and all male and female terminals for the following conditions:
• Proper connector installation.
• Damaged connector locks.
• Corrosion.
• Other signs of water intrusion.
• Weather seal damage (if equipped).
• Bent terminals.
• Overheating due to a poor connection (terminal may be discolored due to excessive current draw).
• Terminals that have been pushed back into the connector cavity.
• Perform a terminal drag test on each connector terminal to verify proper terminal tension. Repair any conditions that are found.
5. Reconnect all PCM harness connectors. Be certain that all harness connectors are fully seated and the connector locks are fully engaged.

6. Reconnect all in-line harness connectors (if equipped). Be certain that all connectors are fully seated and the connector locks are fully engaged.
7. Reconnect all related component harness connectors. Be certain that all connectors are fully seated and the connector locks are fully engaged.
8. With the scan tool, erase DTCs.
9. Using the recorded Freeze Frame and Environmental Data, along with the When Monitored and Set Conditions above, operate the vehicle in the conditions that set the DTC.
10. With the scan tool, read PCM DTCs. Did the DTC return?

No
• Test complete.
• Perform the PCM VERIFICATION TEST. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

P0071 - Ambient Air Temperature Sensor Performance

Fri, 08 Feb 2019 17:44:08 +0000

P0071 - Ambient Air Temperature Sensor Performance

Theory of Operation

The Ambient Air Temperature (AAT) Sensor is located in the driver's door mirror. The Driver's Door Module (DDM) receives the data from the AAT sensor and sends it to the Body Control Module (BCM). The BCM then passes the data on to the Powertrain Control Module (PCM). There are two rationality tests. The first test is: Ignition on/engine running. The second test is: After an eight hour cold soak, at key on the readings for the AAT, Charge Air Cooler (CAC) temperature (D2, DJ), Intake Manifold Temperature (DD, DP), and the Engine Coolant Temperature (ECT) Sensors are all compared. If the temperatures differ by more than a calibrated amount, then the appropriate sensor fault code would be recorded. The PCM rationality check looks at the temperature reading from the sensor over time and ensures that it changes with the engine running. If the sensor reading does not change over a calibrated time limit, the fault will be recorded.

When Monitored and Set Conditions

When Monitored: This diagnostic runs continuously when the following conditions are met:
• Ignition on/engine off, or while the engine is running.

Set Conditions:
• The Powertrain Control Module (PCM) detects a fault in the Ambient Air Temperature Sensor circuit or is
missing the signal.

Default Actions:
• The MIL is illuminated.

Possible Causes

AAT SIGNAL CIRCUIT SHORTED TO VOLTAGE
AAT SIGNAL CIRCUIT OPEN OR HIGH RESISTANCE
AAT SIGNAL CIRCUIT SHORTED TO GROUND
AAT SIGNAL CIRCUIT SHORTED TO HEATED MIRROR RETURN GROUND
AAT SENSOR GROUND CIRCUIT OPEN OR HIGH RESISTANCE
AMBIENT AIR TEMPERATURE (AAT) SENSOR
DRIVERS DOOR MODULE (DDM)

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 28 - DTCBased Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

Diagnostic Test

1. ACTIVE DTC

NOTE: Diagnose any CAN C Bus Communication DTCs before continuing.
NOTE: If there are any other DTC's related to the Engine Coolant Temperature (ECT) sensor, Charge Air
Temperature sensor, or Intake Manifold Temperature Sensor present in the PCM perform thr
Diagnostics for those DTCs before continuing with this one.
1. Turn the ignition one.
2. With the scan tool, select View DTCs. Is the DTC active?

Yes
• Go To 2

No
• Perform the INTERMITTENT DTC diagnostic procedure. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

2. CHECK THE (G31) AAT SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE
1. Turn the ignition off.
2. Disconnect the Ambient Air Temperature Sensor (AAT) harness connector.
3. Turn the ignition on, engine not running.
4. Measure the voltage on the (G31) AAT Signal circuit in the AAT Sensor harness connector. Is the voltage above 5.2 volts?

Yes
• Repair the (G31) AAT Signal circuit for a short to voltage.
• Perform the PCM VERIFICATION TEST. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

• Go To 3

3. CHECK THE (G31) AAT SIGNAL CIRCUIT FOR AN OPEN/HIGH RESISTANCE
1. Turn the ignition off.
2. Disconnect the Driver Door Module (DDM) C2 harness connector.

3. Measure the resistance of the (G31) AAT Signal circuit between the Ambient Air Temperature Sensor harness connector and the DDM C2 harness connector. Is the resistance below 5.0 Ohms?

Yes
• Go To 4

No
• Repair the (G31) AAT Signal circuit for an open or high resistance.
• Perform the POWERTRAIN VERIFICATION TEST. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

4. CHECK THE (C160) HEATED MIRROR RETURN CIRCUIT FOR AN OPEN/HIGH RESISTANCE
1. Measure the resistance of the (C160) Heated Mirror Return circuit between the Ambient Air Temperature
Sensor harness connector and the DDM C2 harness connector.
Is the resistance below 5.0 Ohms?

Yes
• Go To 5

No
• Repair the (C160) Heated Mirror Return for an open or high resistance.
• Perform the POWERTRAIN VERIFICATION TEST. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

5. CHECK THE (G31) AAT SIGNAL CIRCUIT FOR A SHORT TO GROUND
1. Measure the resistance between ground and the (G31) AAT Signal circuit in the AAT Sensor harness connector.
Is the resistance above 10k Ohms?

Yes
• Go To 6

No
• Repair the (G31) AAT Signal circuit for a short to ground.

• Perform the PCM VERIFICATION TEST. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

6. CHECK FOR THE (G31) AAT SIGNAL CIRCUIT SHORTED TO THE (C160) HEATED MIRROR RETURN CIRCUIT
1. Measure the resistance between the (G31) AAT Signal circuit and the (C160) Heated Mirror Return circuit
at the AAT Sensor harness connector. Is the resistance above 10k Ohms?

Yes
• Go To 7

No
• Repair the short between the (G31) AAT Signal circuit and the (C160) Heated Mirror Return circuit.
• Perform the PCM VERIFICATION TEST. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

7. AMBIENT AIR TEMPERATURE SENSOR
1. Turn the ignition off.
2. Replace the Ambient Air Temperature Sensor in accordance with the Service Information.(Refer to 24 - Heating and Air Conditioning/Controls/SENSOR, Ambient Temperature/Removal)
3. Turn the ignition on.
4. With the scan tool, read DTCs. Is the DTC still reporting active or pending?

Yes
• Go To 8

No
• Repair is complete.
• Perform the POWERTRAIN VERIFICATION TEST. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

8. DRIVERS DOOR MODULE (DDM)

1. Using the wiring diagram/schematic as a guide, inspect the wiring and connectors between the AAT Sensor and the Drivers Door Module (DDM).

2. Look for any chafed, pierced, pinched or partially broken wires.

3. Look for broken, bent, pushed out or corroded terminals. Verify that there is good pin to terminal contact in the AAT Sensor and Drivers Door Module connectors.

4. Perform any Technical Service Bulletins that may apply. Were there any problems found?

Yes

• Repair as necessary.

• Perform the BODY VERIFICATION TEST. (Refer to 28 - DTC-Based Diagnostics/MODULE, Body Control (BCM) /Standard Procedure).

• Replace the Drivers Door Module (DDM) in accordance with the Service Information.

• Perform the BODY VERIFICATION TEST. (Refer to 28 - DTC-Based Diagnostics/MODULE, Body Control (BCM) /Standard Procedure).

P0072 - Ambient Air Temperature Sensor Circuit Low

Fri, 15 Feb 2019 23:27:52 +0000

P0072 - Ambient Air Temperature Sensor Circuit Low

Theory of Operation

When Monitored and Set Conditions

When Monitored: This diagnostic runs continuously when the following conditions are met:
• With the ignition on.

Set Conditions:
• The Powertrain Control Module (PCM) detects that the Ambient Air Temperature (AAT) Signal circuit
has fallen below a calibrated threshold.

Default Actions:
• The MIL is illuminated.

Possible Causes

AAT SENSOR SIGNAL CIRCUIT SHORTED TO GROUND

AAT SENSOR SIGNAL CIRCUIT SHORTED TO DRIVER MIRROR HEATER RETURN CIRCUIT

AMBIENT AIR TEMPERATURE (AAT) SENSOR

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 28 - DTCBased Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

Diagnostic Test

1. ACTIVE DTC

NOTE: There is no direct circuit input from the Ambient Air Temperature Sensor to the PCM.

NOTE: If there are any Loss of Communication DTCs related to the DDM present in the Body Control Module or elsewhere, perform those diagnostics before continuing with this diagnostic tree.

NOTE: If there are any other DTCs related to the Ambient Air Temperature Sensor present in the BCM, DDM, or any other module, perform those diagnostics before continuing with this diagnostic tree.

1. Turn the ignition on.
2. With the scan tool, record all Freeze frame data.
3. With the scan tool, erase DTCs.
4. Turn the ignition off for 75 seconds.
5. Turn the ignition on.
6. With the scan tool, read DTCs.
Did DTC P072 reset?

Yes
• Go To 2

No
• Perform the INTERMITTENT CONDITION diagnostic procedure. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

2. CHECK THE (G31) AAT SIGNAL CIRCUIT FOR A SHORT TO GROUND

1. Turn the ignition off.
2. Disconnect the AAT Sensor harness connector.
NOTE: Check connectors - Clean/repair as necessary.
3. Measure the resistance between ground and the (G31) AAT Signal circuit.
Is the resistance below 10k Ohms?

Yes
• Repair the (G31) AAT Signal circuit for a short to ground.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based
Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Go To 3

3. CHECK FOR THE (G31) AAT SIGNAL CIRCUIT SHORTED TO THE (C160) DRIVER MIRROR HEATER RETURN CIRCUIT

1. Disconnect the Driver Door Module.

2. Measure the resistance between the (G31) AAT Signal circuit and the (C160) Driver Mirror Heater Return circuit at the AAT Sensor harness connector. Is the resistance below 10k Ohms?

Yes

• Repair the short between the ((G31) AAT Signal circuit and the (C160) Driver Mirror Heater Return circuit.

• Perform POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

• Replace the Ambient Air Temperature Sensor in accordance with the Service Information.(Refer to 24 - Heating and Air Conditioning/Controls/SENSOR, Ambient Temperature/Removal)

• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

P0073 - Ambient Air Temperature Sensor S

Fri, 15 Feb 2019 23:40:55 +0000

P0073 - Ambient Air Temperature Sensor Circuit High

Theory of Operation

When Monitored and Set Conditions

When Monitored: This diagnostic runs continuously when the following conditions are met:
• With the ignition on.

Set Conditions:
• The Powertrain Control Module (PCM) detects that the Ambient Air Temperature (AAT) Signal circuit value is above a calibrated threshold.

Default Actions:
• The MIL is illuminated.

Possible Causes

AAT SENSOR SIGNAL CIRCUIT OPEN/HIGH RESISTANCE
AAT SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
DRIVER MIRROR HEATER RETURN CIRCUIT OPEN/HIGH RESISTANCE
AMBIENT AIR TEMPERATURE (AAT) SENSOR

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 28 - DTCBased Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

Diagnostic Test

1. ACTIVE DTC

NOTE: There is no direct circuit input from the Ambient Air Temperature Sensor to the PCM. If there are any Loss of Communication DTCs related to the DDM present in the Body Control Module or elsewhere, perform those diagnostics before continuing with this diagnostic tree.

NOTE: If there are any other DTCs related to the Ambient Air Temperature Sensor present in the BCM, DDM, or any other module, perform those diagnostics before continuing with this diagnostic tree.

Yes
• Go To 2

No
• Perform the INTERMITTENT CONDITION diagnostic procedure. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

2. CHECK THE (G31) AAT SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE
1. Disconnect the AAT Sensor harness connector.
2. Measure the voltage of the (G31) AAT Signal circuit at the AAT Sensor harness connector.
NOTE: The voltage should read approximately 5.0 Volts with connector disconnected and key on.

Is the voltage above 5.2 Volts?

Yes
• Repair the (G31) Ambient Air Temperature Signal circuit for a short to voltage.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Go To 3
3. CHECK THE (G31) AAT SIGNAL CIRCUIT FOR AN OPEN/HIGH RESISTANCE

1. Disconnect the DDM harness connector.
2. Measure the resistance of the (G31) AAT Signal circuit between the AAT Sensor harness connector and the DDM harness connector.
Is the resistance below 5.0 Ohms?

Yes
• Go To 4

No
• Repair the (G31) Ambient Air Temperature Signal circuit for an open or high resistance.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

4. CHECK THE (C160) DRIVER MIRROR HEATER RETURN CIRCUIT FOR AN OPEN/HIGH RESISTANCE

1.
2. Measure the resistance of the (C160) Driver Mirror Heater Return circuit between the ECT Sensor harness
connector and the PCM C1 harness connector.
Is the resistance below 5.0 Ohms?

Yes
• Replace the Ambient Air Temperature Sensor in accordance with the Service Information.(Refer to 24 - Heating and Air Conditioning/Controls/SENSOR, Ambient Temperature/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Repair the (C160) Driver Mirror Heater Return circuit for an open or high resistance.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

P007B - Charge Air Cooler Temperature Sensor Circuit Performance

Mon, 04 Feb 2019 22:17:08 +0000

P007B - Charge Air Cooler Temperature Sensor Circuit Performance

Theory of Operation

The Charge Air Cooler Temperature Sensor circuit is represented as the Intake Manifold Temperature Sensor circuit on the Cab and Chassis. On the Regular Cab it is still called the Charge Air Cooler Temperature Sensor circuit. In both configurations, this DTC refers to the circuit that runs from the Powertrain Control Module (PCM) C1 harness connector / terminal 62 to the Temperature/Pressure MAP sensor / terminal 3. The Powertrain Control Module (PCM) supplies 5-Volts to the Charge Air Cooler Temperature signal circuit. The PCM monitors the change in voltage caused by changes in the resistance of the sensor to determine the Charge Air Cooler temperature. The PCM will illuminate the Malfunction Indicator Lamp (MIL) after the diagnostic runs and fails in two consecutive drive cycles. During this time the customer may notice periods of white smoke as well as the fan running more often. The MIL lamp is turned off once the diagnostic runs and passes in four consecutive drive cycles.

When Monitored and Set Conditions

When Monitored: This diagnostic runs continuously when the following conditions are met:
• With the ignition on.

Set Conditions:
• The Powertrain Control Module (PCM) detects that at key on engine off, the Intake Manifold
Temperature Sensor Signal reads differently than the EGR Orifice Temperature Sensor and Coolant
Temperature Sensor. Or, while the engine is running the Powertrain Control Module (PCM) does not
read a change in value on the Intake Manifold Temperature Sensor Signal over a pre-determined
amount of time.

Default Actions:
• The MIL is illuminated.

Possible Causes

AIR CLEANER BOX NOT SEALING PROPERLY TO THE INLET AIR TUBE
DIRT OR DEBRIS IN CHARGE AIR COOLING SYSTEM
TEMPERATURE/PRESSURE MAP SENSOR

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 28 - DTCBased Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

1. ACTIVE DTC
NOTE: If there are any 5-Volt supply DTCs present, repair those DTCs before proceeding with this test.
1. Turn the ignition on.

2. With the scan tool, record all Freeze frame data.
3. With the scan tool, erase DTCs.
4. Turn the ignition off for 75 seconds.
5. Turn the ignition on.
6. With the scan tool, read DTCs.
Did the DTC return?

Yes
• Go To 2

No
• Perform the INTERMITTENT CONDITION diagnostic procedure. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

2. CHECK THE AIR CLEANER BOX FOR PROPER SEALING
1. Check the connection between the Inlet Air Tube and the Air Cleaner Box to make sure that it is sealed properly. Is the Air Cleaner Box to Inlet Air Tube installed and sealed properly?

Yes
• Go To 3

No
• Repair the connection between the Air Cleaner Box and the Inlet Air Tube.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

3. CHECK THE CHARGE AIR COOLER AND SYSTEM FOR DIRT OR DEBRIS
1. Remove the hoses at the Charge Air Cooler and Turbo outlet and inspect the system for signs of excessive oil, dirt or debris. Does the Charge Air Cooling system show signs of excessive dirt or debris?

Yes
• Clean the Charge Air Cooling system in accordance with the service information

• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Go To 4

4. CHECK THE TEMPERATURE/PRESSURE MAP SENSOR
1. Let engine cold soak up to eight hours.
2. Turn the ignition on.
3. With the scan tool, monitor Temperature/Pressure MAP Sensor, EGR Orifice Temperature Sensor and Coolant Temperature Sensor.
NOTE: Make sure ambient air temperature is above -6.7°C (20°F) when performing this test.
NOTE: Make sure there is no external heat source, such as a block heater, operating during this test or within the 8 hour cold soak. Does the CAC Temperature Sensor read differently from the other sensors?

Yes
• Replace the Temperature/Pressure MAP Sensor in accordance with the Service Information.(Refer to 14
- Fuel System/Fuel Injection/SENSOR, TMAP-Intake Manifold/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Go To 5

5. TEMPERATURE/PRESSURE MAP SENSOR
1. Turn the ignition off.
2. Disconnect the Temperature/Pressure MAP Sensor harness connector.
3. Remove the Temperature/Pressure MAP Sensor and reconnect the wiring to the sensor.
4. Turn the ignition on.
5. With the scan tool in Sensors, monitor the Temperature/Pressure MAP Sensor while heating the sensor with an external heat source (DO NOT USE OPEN FLAME). Does the reading from the sensor increase at least 5°F on the scan tool?

Yes

• Go To 6

No
• Replace the Temperature/Pressure MAP Sensor in accordance with the Service Information.(Refer to 14 - Fuel System/Fuel Injection/SENSOR, TMAP-Intake Manifold/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

Repair any conditions that are found.
5. Reconnect all PCM harness connectors. Be certain that all harness connectors are fully seated and the connector locks are fully engaged.
6. Reconnect all in-line harness connectors (if equipped). Be certain that all connectors are fully seated and the connector locks are fully engaged.
7. Reconnect all related component harness connectors. Be certain that all connectors are fully seated and the connector locks are fully engaged.
8. With the scan tool, erase DTCs.
9. Using the recorded Freeze Frame and Environmental Data, along with the When Monitored and Set Conditions above, operate the vehicle in the conditions that set the DTC.
10. With the scan tool, read PCM DTCs.
Did the DTC return?

No
• Test complete.
• Perform the PCM VERIFICATION TEST. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

P007C - Charge Air Cooler Temperature Sensor Circuit Low

Mon, 04 Feb 2019 22:20:51 +0000

P007C - Charge Air Cooler Temperature Sensor Circuit Low

Theory of Operation

• When Monitored:
The PCM monitors the change in signal voltage and converts this to a temperature value.

• Set Condition:
The CAC Outlet Temperature Sensor Signal circuit goes below a calibrated threshold.

Possible Causes

CAC OUTLET TEMPERATURE SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
CAC OUTLET TEMPERATURE SENSOR SIGNAL CIRCUIT OPEN/HIGH RESISTANCE
TEMPERATURE/PRESSURE MAP SENSOR
POWERTRAIN CONTROL MODULE (PCM)

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 28 - DTCBased Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

Diagnostic Test

1. ACTIVE DTC
1. Turn the ignition on.
2. With the scan tool, record all Freeze frame data.
3. With the scan tool, erase DTCs.
4. Turn the ignition off for 75 seconds.
5. Turn the ignition on.
6. With the scan tool, read DTCs.

Did the DTC reset?

Yes
• Go To 2

No
• Perform the INTERMITTENT CONDITION diagnostic procedure. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

2. CHECK THE (K48) CAC OUTLET TEMPERATURE SENSOR SIGNAL CIRCUIT FOR A SHORT TO GROUND
1.
2. Turn the ignition off.
3. Disconnect the Temperature/Pressure Map Sensor harness connector.
4. Disconnect the PCM C1 harness connector.
NOTE: Check connectors - Clean/repair as necessary.
5. Measure the resistance between ground and the (K48) CAC Outlet Temperature Sensor Signal circuit at
the Temperature/Pressure MAP Sensor harness connector.
Is the resistance above 5.0 Ohms?

Yes
• Go To 3

No
• Repair the (K48) CAC Outlet Temperature Sensor Signal circuit for a short to ground.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

3. CHECK THE (K48) CAC OUTLET TEMPERATURE SENSOR SIGNAL CIRCUIT FOR AN OPEN/HIGH RESISTANCE
1. Measure the resistance of the (K48) CAC Outlet Temperature Sensor Signal circuit between the Temperature/Pressure Map Sensor harness connector and the PCM C1 harness connector. Is the resistance below 5.0 Ohms?

Yes

• Go To 4

No
• Repair the (K48) CAC Outlet Temperature Sensor Signal circuit for an open or high resistance.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

4. TEMPERATURE/PRESSURE MAP SENSOR
1. Replace the Temperature/Pressure MAP Sensor.(Refer to 14 - Fuel System/Fuel Injection/SENSOR,
TMAP-Intake Manifold/Removal)
2. Turn the ignition on.
3. With the scan tool, erase DTCs.
4. Turn the ignition off for 75 seconds.
5. Start the vehicle. It may be necessary to drive vehicle to reset DTC.
6. With the scan tool, read DTCs.
Did the DTC return?

Yes
• Go To 5

No
• Repair is complete.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based
Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

5. POWERTRAIN CONTROL MODULE
1. Disconnect all PCM harness connectors.
2. Disconnect all related in-line harness connections (if equipped).
3. Disconnect the related component harness connectors.
4. Inspect harness connectors, component connectors, and all male and female terminals for the following
conditions:
• Proper connector installation.
• Damaged connector locks.
• Corrosion.
• Other signs of water intrusion.
• Weather seal damage (if equipped).
• Bent terminals.
• Overheating due to a poor connection (terminal may be discolored due to excessive current draw).
• Terminals that have been pushed back into the connector cavity.

• Perform a terminal drag test on each connector terminal to verify proper terminal tension. Repair any conditions that are found.
5. Reconnect all PCM harness connectors. Be certain that all harness connectors are fully seated and the connector locks are fully engaged.
6. Reconnect all in-line harness connectors (if equipped). Be certain that all connectors are fully seated and the connector locks are fully engaged.
7. Reconnect all related component harness connectors. Be certain that all connectors are fully seated and the connector locks are fully engaged.
8. With the scan tool, erase DTCs.
9. Using the recorded Freeze Frame and Environmental Data, along with the When Monitored and Set Conditions above, operate the vehicle in the conditions that set the DTC.
10. With the scan tool, read PCM DTCs.
Did the DTC return?

No
• Test complete.
• Perform the PCM VERIFICATION TEST. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

P007D - Charge Air Cooler Temperature Sensor Circuit High

Fri, 08 Feb 2019 17:34:51 +0000

P007D - Charge Air Cooler Temperature Sensor Circuit High

Theory of Operation

The Charge Air Cooler Temperature Sensor circuit is represented as the Intake Manifold Temperature Sensor circuit on the Cab and Chassis. On the Regular Cab it is still called the Charge Air Cooler Temperature Sensor circuit. In both configurations, this DTC refers to the circuit that runs from the Powertrain Control Module (PCM) C1 harness connector / terminal 62 to the Temperature/Pressure MAP sensor / terminal 3. The Powertrain
Control Module (PCM) supplies 5-Volts to the Charge Air Cooler Temperature signal circuit. The PCM monitors the change in voltage caused by changes in the resistance of the sensor to determine the Charge Air Cooler temperature. The PCM will illuminate the Malfunction Indicator Lamp (MIL) after the diagnostic runs and fails in two consecutive drive cycles. During this time the customer may notice periods of white smoke as well as the fan running more often. The MIL lamp is turned off once the diagnostic runs and passes in four consecutive drive cycles.

• When Monitored: The PCM monitors the change in signal voltage and converts this to a temperature value.

• Set Condition: The CAC Outlet Temperature Sensor Signal circuit goes above a calibrated threshold.

Possible Causes

CAC OUTLET TEMPERATURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
CAC OUTLET TEMPERATURE SENSOR SIGNAL CIRCUIT OPEN/HIGH RESISTANCE
CAC OUTLET TEMPERATURE SENSOR RETURN CIRCUIT OPEN/HIGH RESISTANCE
TEMPERATURE/PRESSURE MAP SENSOR
POWERTRAIN CONTROL MODULE (PCM)

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 28 - DTCBased Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

Diagnostic Test

Did the DTC reset?

Yes
• Go To 2

No
• Perform the INTERMITTENT CONDITION diagnostic procedure. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

2. CHECK THE (K48) CAC OUTLET TEMPERATURE SENSOR SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE
1.
2. Ignition on.
3. Disconnect the Temperature/Pressure Map Sensor harness connector.
NOTE: Check connectors - Clean/repair as necessary.
4. With a voltmeter connected to ground, measure the voltage of the (K48) CAC Outlet Temperature Sensor Signal circuit at the Temperature/Pressure Map Sensor harness connector. Is the voltage above 5.1 Volts?

Yes
• Repair the (K48) CAC Outlet Temperature Sensor Signal circuit for a short to voltage.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Go To 3

3. CHECK THE TEMPERATURE/PRESSURE MAP SENSOR
1. Turn the ignition off.
2. Measure the resistance from the Sensor ground (K916) to the (K48) CAC Outlet Temperature Signal
circuit across the terminals at the Temperature/Pressure Map Sensor harness connector. Is the resistance between 300 and 90k Ohms?

Yes

• Go To 4

No
• Replace the Temperature/Pressure MAP Sensor in accordance with the Service Information.(Refer to 14
- Fuel System/Fuel Injection/SENSOR, TMAP-Intake Manifold/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

4. CHECK THE (K48) CAC OUTLET TEMPERATURE SENSOR SIGNAL CIRCUIT FOR AN OPEN/HIGH RESISTANCE

1. Disconnect the PCM C1 harness connector. NOTE: Check connectors - Clean/repair as necessary.
2. Measure the resistance of the (K48) CAC Outlet Temperature Sensor Signal circuit between the
Temperature/Pressure Map Sensor harness connector and the PCM C1 harness connector. Is the resistance below 5.0 Ohms?

Yes
• Go To 5

5. CHECK THE (K916) INTAKE MANIFOLD TEMPERATURE SENSOR RETURN CIRCUIT FOR AN OPEN/HIGH RESISTANCE
1. Measure the resistance of the (K916) Intake Manifold Temperature Sensor Ground circuit between the Temperature/Pressure Map Sensor harness connector and the PCM C1 harness connector. Is the resistance below 5.0 Ohms?

Yes
• Go To 6

No
• Repair the (K916) Temperature/Pressure MAP Sensor ground circuit for an open or high resistance.

• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

6. POWERTRAIN CONTROL MODULE
1. Disconnect all PCM harness connectors.
2. Disconnect all related in-line harness connections (if equipped).
3. Disconnect the related component harness connectors.
4. Inspect harness connectors, component connectors, and all male and female terminals for the following conditions:
• Proper connector installation.
• Damaged connector locks.
• Corrosion.
• Other signs of water intrusion.
• Weather seal damage (if equipped).
• Bent terminals.
• Overheating due to a poor connection (terminal may be discolored due to excessive current draw).
• Terminals that have been pushed back into the connector cavity.
• Perform a terminal drag test on each connector terminal to verify proper terminal tension. Repair any conditions that are found.
5. Reconnect all PCM harness connectors. Be certain that all harness connectors are fully seated and the connector locks are fully engaged.
6. Reconnect all in-line harness connectors (if equipped). Be certain that all connectors are fully seated and the connector locks are fully engaged.
7. Reconnect all related component harness connectors. Be certain that all connectors are fully seated and the connector locks are fully engaged.
8. With the scan tool, erase DTCs.
9. Using the recorded Freeze Frame and Environmental Data, along with the When Monitored and Set Conditions above, operate the vehicle in the conditions that set the DTC.
10. With the scan tool, read PCM DTCs. Did the DTC return?

No
• Test complete.
• Perform the PCM VERIFICATION TEST. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

P0087 - Fuel Rail Pressure Too Low

Fri, 15 Feb 2019 23:55:49 +0000

P0087 - Fuel Rail Pressure Too Low

Special Tools: Click to display a list of tools used in this procedure

When Monitored and Set Conditions

When Monitored: This diagnostic runs continuously when the following conditions are met:
• With the engine running.

Set Conditions:
• The Powertrain Control Module (PCM) detects that the actual fuel pressure reading is below a calibrated threshold. This DTC will cause active regeneration to be disabled.

Default Actions:
• The MIL is illuminated.

Possible Causes

P000F PRESENT
EXTERNAL FUEL LEAKS
GELLED FUEL
NO VOLTAGE AT CHASSIS MOUNTED FUEL HEATER
NO VOLTAGE AT ENGINE MOUNTED FUEL HEATER
CHASSIS MOUNTED FUEL HEATER-FUEL FILTER
ENGINE MOUNTED FUEL HEATER-FUEL FILTER
HIGH PRESSURE PUMP
INJECTOR LEAKAGE
IN TANK LIFT PUMP
FUEL PRESSURE LIMITING VALVE

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 28 - DTCBased Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

1. P000F PRESENT

1. Ignition on, engine not running.
2. With the scan tool, read DTCs.
Is DTC P000F active?

Yes
• Perform the Diagnostics for DTC P000F first.
• If DTC P0087 is still active or pending after the P000F Diagnostics is completed, begin this Diagnostic Tree again.

No
• Go To 2

2. CHECK FOR OTHER DTCS
1. With the scan tool, read DTCs.
Are any other injector/fuel pressure related DTCs present?

Yes
• Troubleshoot other injector/fuel pressure related DTCs first.

No
• Go To 3

3. CHECK FOR EXTERNAL FUEL LEAKS

1. Put on personal protective equipment.
2. Operate engine at idle when looking for fuel leaks.
3. Use the scan tool to operate engine at a variety of engine speeds.
Any external leaks detected?

Yes
• Repair or replace component with external fuel leak.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

• Go To 4

4. CHECK OPERATING CONDITIONS
1. Determine the environmental conditions at or near the time the DTC set.
Has the vehicle been operated or cold soaked in ambient temperatures below freezing?

Yes
• Go To 5

No
• Go To 7

5. CHECK FOR GELLED FUEL/PERFORM THE IN-TANK LIFT PUMP FLOW TEST

NOTE: Before performing the IN-TANK FUEL LIFT PUMP FLOW test, verify that the fuel level in the fuel tank is above 1/4 full. If fuel tank is not above 1/4 full the pump will take in air causing the test results to be inaccurate.

1. Disconnect the low pressure fuel supply line from the High Pressure Fuel Pump. Connect the Decay Tool,
Fuel 8978A to the low pressure fuel supply line.

WARNING: To reduce the risk of fire and serious possible serious or fatal injury, place the Reservoir Assembly 534960 (3) on the floor and out of the way so that it is not a trip hazard.

2. Perform the following to purge air from the system:
• With the scan tool, actuate the In-Tank Fuel Lift Pump Module.
• Open the Flow Test Valve and allow the fuel to flow into the Reservoir for 10 seconds, then close the Flow Test Valve.
• Turn the ignition off.
• Disconnect, empty, and then reconnect the Reservoir Assembly.
3. Perform the following three times to find the average flow rate:
• With the scan tool, actuate the In-Tank Fuel Lift Pump Module.
• Open the Flow Test Valve (1) for 10 seconds, then close the Valve.
• Turn the ignition off.
• Measure and record the amount of fuel in the Reservoir Assembly.
• Disconnect, empty, and then reconnect the Reservoir Assembly.
4. Add the three recorded measurements and then divide the total by three to calculate the average flow rate.

NOTE: The flow rate specification is 500 ml in 10 seconds.

Does the average flow rate meet or exceed the specification?

Yes
• If the vehicle exhibited symptoms related to fuel gelling such as hard start, start and stall, and/or low power, but no longer exhibits these symptoms, fuel gelling may have been present but corrected itself. The fuel temperature may have increased through normal operation or if the vehicle was parked inside a warm building. Verify both fuel heaters are receiving power with the ignition on, and also check for proper operation of the fuel heaters. (Refer to 14 - Fuel System/Fuel Delivery, 6.7L Diesel/HEATER, Fuel/Diagnosis and Testing) .
• Then, Go To 7

No
• Leave the Fuel Decay Tester installed. Remove both fuel filters and inspect for fuel gelling/wax build-up and other contaminants. If wax build-up is found, the fuel has gelled. Replace both fuel filters and correct the fuel gelling accordingly before any further testing. Verify both fuel heaters are receiving power with the ignition on, and also check for proper operation of the fuel heaters. (Refer to 14 - Fuel System/Fuel Delivery, 6.7L Diesel/HEATER, Fuel/Diagnosis and Testing) .
• If no wax build-up or signs of fuel gelling is found, replace both Fuel Filter/Water Separators in accordance with the Service Information.
• Then, Go To 6

6. RECHECK IN-TANK FUEL LIFT PUMP FLOW
1. Perform the following to purge air from the system:
• With the scan tool, actuate the In-Tank Fuel Lift Pump Module.
• Open the Flow Test Valve for 10 seconds, then close the Valve.
• Turn the ignition off.
• Disconnect, empty, and then reconnect the Reservoir Assembly.
2. Perform the following three times to find the average flow rate:
• With the scan tool, actuate the In-Tank Fuel Lift Pump Module.
• Open the Flow Test Valve for 10 seconds, then close the valve.
• Turn the ignition off.
• Measure and record the amount of fuel in the Reservoir Assembly.
• Disconnect, empty, and then reconnect the Reservoir Assembly.
3. Add the three recorded measurements and then divide the total by three to calculate the average flow rate.
NOTE: The flow rate specification is 500 ml in 10 seconds.

Does the average flow rate meet or exceed the specification?

Yes

• Repair complete.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Use the wiring diagram as a guide to check the In-Tank Fuel Lift Pump wiring for an open, high resistance, or short to ground. If the In-Tank Fuel Lift Pump wiring is okay, remove the fuel tank and replace the In-Tank Fuel Lift Pump Module in accordance with the Service Information.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

7. CHECK THE FUEL DELIVERY SYSTEM
1. (Refer to 29 - Non-DTC Diagnostics/Drivability - Diesel - Diagnosis and Testing) and perform the CHECKING THE FUEL DELIVERY SYSTEM diagnostic procedure.
Were any problems found?

Yes
• Repair as necessary.

No
• Perform the INTERMITTENT CONDITION diagnostic procedure. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

P0088 - Fuel Rail Pressure Too High - Bank 1

Mon, 18 Feb 2019 19:38:10 +0000

P0088 - Fuel Rail Pressure Too High - Bank 1

Theory of Operation

The Powertrain Control Module (PCM) provides the Fuel Rail Pressure Sensor with a 5-Volt supply and sensor
ground, and receives a signal voltage back from the Fuel Rail Pressure Sensor. This sensor signal voltage
changes based on the pressure in the fuel rail. The PCM will light the MIL lamp immediately after the diagnostic
runs and fails. During this time the customer may experience a power and or speed derate. The PCM will turn
off the MIL light after the diagnostic runs and passes in four consecutive drive cycles.

When Monitored and Set Conditions

When Monitored: This diagnostic runs continuously when the following conditions are met:
• With the engine running.

Set Conditions:
• The Powertrain Control Module (PCM) detects that the actual fuel pressure reading is above a calibrated threshold. This DTC will cause active regeneration to be disabled.

Default Actions:
• The MIL is illuminated.

Possible Causes

FUEL CONTROL ACTUATOR
CHECK VALVE DAMAGED OR BLOCKED
LOW PRESSURE FUEL SYSTEM SUPPLY
HIGH PRESSURE FUEL SYSTEM LEAKS
HIGH INLET RESTRICTION
FUEL FILTER
FUEL RAIL PRESSURE SENSOR
IN TANK LIFT PUMP

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 28 - DTCBased Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

1. OTHER DTCs

1. With the scan tool, read DTCs.

Are any other injector/fuel pressure related DTCs present?

Yes
• Troubleshoot other injector/fuel pressure related DTCs first.

No
• Go To 2

2. CHECK THE FUEL DELIVERY SYSTEM

1. Perform the CHECKING THE FUEL DELIVERY SYSTEM procedure. (Refer to 29 - Non-DTC Diagnostics/Drivability - Diesel - Diagnosis and Testing) .
Did vehicle pass the CHECKING THE FUEL DELIVERY SYSTEM TEST?

Yes
• Go To 3

No
• Perform the appropriate repair.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based
Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

3. CHECK THE FUEL RETURN LINE

1. Check the Fuel Return line between the Fuel Filter housing and the Fuel Tank for a kink, blockage, or other damage.
Was there any blockage or other damage found?

Yes
• Perform the appropriate repair.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based
Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Go To 4

4. FUEL CONTROL ACTUATOR

1. Check for a mechanically stuck Fuel Control Actuator (FCA). Using the scan tool, actuate the HPCR Duty Cycle Output.
NOTE: The Fuel Control Actuator will only click when cycled off.
Do you hear a click from the Fuel Control Actuator when you cycle the actuator off with the scan tool?

Yes
• Go To 5

No
• Replace the Fuel Control Actuator in accordance with the Service Information.(Refer to 14 - Fuel System/Fuel Injection, 6.7L Diesel/ACTUATOR, Fuel Control/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

5. CHECK VALVE DAMAGED OR BLOCKED

1. Check the fuel drain line check valve in the rear of the cylinder head for signs of damage, blockage, or debris.
Is the check valve damaged or blocked?

Yes
• Repair the cause of the damaged or blocked check valve or replace the valve.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Go To 6

6. FUEL RAIL PRESSURE SENSOR
1. Using the scan tool, monitor the fuel pressure reading from the Fuel Rail Pressure Sensor at idle and at 2000 RPM.
Is the fuel rail pressure reading higher at 2000 RPM than at idle?

Yes
• Repair Complete.

• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Replace the Fuel Rail Pressure Sensor in accordance with the Service Information.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

P008A - Low Fuel Pressure Fuel System Pressure - Too Low

Fri, 15 Feb 2019 23:46:18 +0000

P008A - Low Fuel Pressure Fuel System Pressure - Too Low

When Monitored and Set Conditions

When Monitored: This diagnostic runs continuously when the following conditions are met:
• With the engine running.

Set Conditions:
• The Powertrain Control Module (PCM) detects that the Low Pressure Fuel Delivery pressure is below a calibrated value for a calibrated amount of time.

Default Actions:
• The MIL is illuminated.

Possible Causes

HIGH PRESSURE FUEL DELIVERY
LOW PRESSURE FUEL DELIVERY

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 28 - DTCBased Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

Diagnostic Test

1. OTHER DTCS

1. Ignition on, engine not running.
2. With the scan tool, read DTCs.
Are there any other DTCs related to Fuel Pressure?

Yes
• Perform the diagnostics for those DTCs before proceeding with this one.

• Go To 2

2. ACTIVE DTC

1. With the scan tool, record all Freeze frame data.
2. With the scan tool, erase DTCs.
3. Turn the ignition off for 75 seconds.
4. Turn the ignition on.
5. With the scan tool, read DTCs.
Did DTC P008A reset?

Yes
• Go To 3

No
• Perform the INTERMITTENT CONDITION diagnostic procedure. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

3. CHECK THE FUEL DELIVERY SYSTEM

1. (Refer to 29 - Non-DTC Diagnostics/Drivability - Diesel - Diagnosis and Testing) and perform the CHECKING THE FUEL DELIVERY SYSTEM diagnostic procedure.
Were any problems found?

Yes
• Repairs are complete.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Perform the INTERMITTENT CONDITION diagnostic procedure. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

P0093 - Fuel System Leak Detected - Large Leak

Mon, 18 Feb 2019 19:46:45 +0000

P0093 - Fuel System Leak Detected - Large Leak

Theory of Operation

The Powertrain Control Module (PCM) determines that there is a leak in the Low Pressure Fuel Delivery
system based on inputs from the High Pressure Fuel system, Fuel Tank Level Signal, Emissions systems, and
other engine conditions. The PCM will turn on the MIL on after this diagnostic runs and fails for two consecutive
drive cycles. This DTC will cause active regeneration to be disabled.

When Monitored and Set Conditions

When Monitored: This diagnostic runs continuously when the following conditions are met:
• With the engine running.

Set Conditions:
• The Powertrain Control Module (PCM) has detected a leak in the Low Pressure Fuel system.

Default Actions:
• The MIL is illuminated.

Possible Causes

PRESSURE LIMITING VALVE
FUEL LEAK IN THE LOW PRESSURE FUEL DELIVERY SYSTEM
POWERTRAIN CONTROL MODULE (PCM)
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 28 - DTCBased Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

Diagnostic Test

1. OTHER DTCS

1. Turn the ignition on, engine not running.
2. With the scan tool, read DTCs.

Are any other injector/fuel pressure related DTCs present?

Yes
• Diagnose and repair all other injectors/fuel pressure related DTCs before performing this diagnostic tree.

• Go To 2

2. ACTIVE DTC

1. With the scan tool, record all Freeze frame data.
2. With the scan tool, erase DTCs.
3. Turn the ignition off for 75 seconds.
4. Operate the engine until the coolant temperature is above 82.2°C (180°F).
5. With the scan tool, read DTCs.
Did DTC P0093 reset?

Yes
• Go To 3

No
• Perform the INTERMITTENT CONDITION diagnostic procedure. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

3. EXTERNAL FUEL LEAKS

1. Put on personal protective equipment.
2. Operate engine at idle when looking for fuel leaks.
3. Use the scan tool to operate engine at a variety of engine speeds.

Any external leaks detected?

Yes
• Repair or replace component with external fuel leak.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based
Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

• Go To 4

4. CHECK THE FUEL DELIVERY SYSTEM

1. (Refer to 29 - Non-DTC Diagnostics/Drivability - Diesel - Diagnosis and Testing) and perform the CHECKING THE FUEL DELIVERY SYSTEM diagnostic procedure.
Were any problems found?

Yes
• Repair as necessary.

No
• Go To 5

5. POWERTRAIN CONTROL MODULE

1. Disconnect all PCM harness connectors.
2. Disconnect all related in-line harness connections (if equipped).
3. Disconnect the related component harness connectors.
4. Inspect harness connectors, component connectors, and all male and female terminals for the following conditions:
• Proper connector installation.
• Damaged connector locks.
• Corrosion.
• Other signs of water intrusion.
• Weather seal damage (if equipped).
• Bent terminals.
• Overheating due to a poor connection (terminal may be discolored due to excessive current draw).
• Terminals that have been pushed back into the connector cavity.
• Perform a terminal drag test on each connector terminal to verify proper terminal tension.
Repair any conditions that are found.
5. Reconnect all PCM harness connectors. Be certain that all harness connectors are fully seated and the connector locks are fully engaged.
6. Reconnect all in-line harness connectors (if equipped). Be certain that all connectors are fully seated and the connector locks are fully engaged.
7. Reconnect all related component harness connectors. Be certain that all connectors are fully seated andthe connector locks are fully engaged.
8. With the scan tool, erase DTCs.
9. Using the recorded Freeze Frame and Environmental Data, along with the When Monitored and Set Conditions above, operate the vehicle in the conditions that set the DTC.

10. With the scan tool, read PCM DTCs.
Did the DTC return?

No
• Test complete.
• Perform the PCM VERIFICATION TEST. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

P00AF - Turbocharger Boost Control Module Performance

Mon, 14 Jan 2019 14:41:42 +0000

P00AF - Turbocharger Boost Control Module Performance

Theory of Operation

When Monitored and Set Conditions

When Monitored: This diagnostic runs continuously when the following conditions are met:

• With the ignition on.

Set Conditions:

• The Electronic Turbo Actuator has detected an internal error in the Variable Geometry Turbocharger (VGT) smart device.

Default Actions:

• The MIL is illuminated.

Possible Causes

Electronic Turbo Actuator Wiring Harness
Electronic Turbo Actuator

Diagnostic Test

1. OTHER DTCS

1. Ignition on, engine not running.
2. With the scan tool, read DTCs.

Is U010C active?

Yes
• Repair U010C first.

• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

• Go To 2

2. ELECTRONIC TURBO ACTUATOR
1. Turn ignition off.
2. Disconnect the Electronic Turbo Actuator harness connector.
NOTE: Check connectors - Clean/repair as necessary. Are there dirty or damaged pins?

Yes
• Repair/Replace as necessary.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Replace the Turbocharger Actuator in accordance with the Service Information.(Refer to 09 - Engine, 6.7L Diesel/Turbocharger System/ACTUATOR, Turbocharger/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

P0101 - Mass Air Flow Sensor "A" Circuit Performance

Mon, 18 Feb 2019 20:06:12 +0000

P0101 - Mass Air Flow Sensor "A" Circuit Performance

Theory of Operation

The Mass Air Flow (MAF) Sensor is a frequency based device. A constant voltage is applied to a heated wire. This wire is positioned in the air stream and is heated by the electrical current that the voltage produces. As air flows across it, it cools down. The heated wire or film is a Positive Temperature Coefficient (PTC) resistor, which means that the resistance of it drops when the temperature drops. The drop in resistance allows more
current to flow through it in order to maintain the programmed temperature. The current flow is changed to a frequency, which is sent to the Powertrain Control Module (PCM) and interpreted as air flow. Adjustments for air temperature and humidity are taken into consideration, since they also affect the temperature of the heated wire or film. The engine running monitor compares an estimated fresh air flow value to the MAF Sensor reading.

When Monitored and Set Conditions

When Monitored: This diagnostic runs continuously when the following conditions are met:
• With the Engine running.

Set Conditions:
• The Powertrain Control Module (PCM) has set the EGR flow equal to zero, but the Mass Air Flow sensor
value does not equal the charge air flow estimate.

Default Actions:
• The MIL is illuminated.

Possible Causes

TURBOCHARGER, EGR OR INTAKE AIR SYSTEM RELATED DTCS
MASS AIR FLOW (MAF) SENSOR
AIR FILTER
AIR INTAKE LEAK

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 28 - DTCBased Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

1. ACTIVE DTC

NOTE: If there are any other EGR, Turbocharger, or Intake system DTCs present, repair those DTCs before proceeding.
1. Turn the ignition on.
2. With the scan tool, record all Freeze frame data.

3. With the scan tool, erase DTCs.
4. Turn the ignition off for 75 seconds.
5. Start the engine attempt to duplicate the conditions that set the DTC.
6. With the scan tool, read DTCs.
Did the DTC reset?

Yes
• Go To 2

No
• Perform the INTERMITTENT CONDITION diagnostic procedure. (Refer to 28 - DTC-Based
Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

2. CHECK THE MAF SENSOR

1. Start the engine. Warm the engine up to operating temperature and then let it idle for five minutes.
NOTE: This is how long it takes for the EGR Valve to close.
2. With the scan tool in Data Display, verify that the EGR Valve is at 0%.
3. With the scan tool, read the MAF Sensor value.
Does the Mass Air Flow Sensor read from 3.0 - 6.75 lb/min for an auto transmission, or 3.5 - 7.5 lb/min for a manual transmission?

Yes
• Go To 3

No
• Replace the Mass Air Flow Sensor in accordance with the Service Information.(Refer to 14 - Fuel System/Fuel Injection, Diesel/SENSOR, Mass Airflow (MAF) /Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

3. CHECK THE AIR FILTER

1. Remove lid from air filter box.
2. Remove air filter and inspect for excessive debris or filter media damage.
3. Make sure the filter was installed properly.

Was the air filter damaged or full of debris?

Yes
• Replace the Air Filter in accordance with the Service Information..(Refer to 09 - Engine/Air Intake System/AIR CLEANER/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Go To 4

4. CHECK THE MAF SENSOR

1. Turn the Ignition off.
2. Remove MAF sensor from the air filter box.
Is it free from debris?

Yes
• Go To 5

No
• Clean the Mass Air Flow Sensor using low pressure air and reinstall, repair complete.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Base Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

5. CHECK FOR AN AIR LEAK IN THE INTAKE SYSTEM

1. Perform the INTAKE AIR SYSTEM PRESSURE TEST procedure. (Refer to 29 - Non-DTC Diagnostics/Drivability - Diesel - Diagnosis and Testing) .
2. Any leak between the air box to the intake manifold could cause this fault.
Were there any Intake Air System leaks?

Yes
• Repair the leak in the Intake Air System.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure

No
• Replace the Mass Air Flow Sensor in accordance with the Service Information.(Refer to 14 - Fuel
System/Fuel Injection, Diesel/SENSOR, Mass Airflow (MAF) /Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

P0102 - Mass Air Flow Sensor "A" Circuit Low

Mon, 18 Feb 2019 20:38:34 +0000

P0102 - Mass Air Flow Sensor "A" Circuit Low

Theory of Operation

When Monitored and Set Conditions

When Monitored: This diagnostic runs continuously when the following conditions are met:
• With the ignition on.

Set Conditions:
• The Powertrain Control Module (PCM) has detected the Mass Air Flow (MAF) Sensor value is below a
calibrated threshold.

Default Actions:
• The MIL is illuminated.

Possible Causes

INTAKE OR EXHAUST SYSTEM LEAKING OR RESTRICTED
MAF SENSOR SIGNAL CIRCUIT OPEN
MAF SENSOR SIGNAL CIRCUIT SHORTED TO THE RETURN CIRCUIT
MAF SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
MASS AIR FLOW (MAF) SENSOR
POWERTRAIN CONTROL MODULE (PCM)
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 28 - DTCBased Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

1. ACTIVE DTC

1. Ignition on, engine not running.
2. With the scan tool, erase DTCs.
3. Start the engine and let idle for at least two minutes.

4. With the scan tool, read DTCs.
Did the DTC return?

Yes
• Go To 2

No
• Perform the INTERMITTENT CONDITION diagnostic procedure. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

2. CHECK THE (K188) MAF SUPPLY CIRCUIT

1. Turn the ignition off.
2. Disconnect the MAF harness connector.
3. Turn the ignition on, engine not running.
NOTE: Check connectors - Clean/repair as necessary.
4. Measure the voltage of the (K188) MAF Supply circuit at the MAF Sensor harness connector.
Is the voltage greater than 11.0 Volts?

Yes
• Go To 3

No
• Repair the (K188) Mass Air Flow Supply circuit for an open or short to ground.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

3. CHECK FOR THE (K188) MAF SUPPLY CIRCUIT SHORTED TO THE (K957) RETURN CIRCUIT

1. Turn the ignition off.
2. Disconnect the PCM C1 harness connector.
3. Measure the resistance between the (K188) MAF Supply circuit and (K957) Return circuit at the MAF Sensor harness connector.
Is the resistance below 10k Ohms?

Yes
• Repair the short between the (K188) Mass Air Flow Supply circuit and (K957) Return circuit.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Go To 4

4. CHECK FOR THE (K157) MAF SENSOR SIGNAL CIRCUIT SHORTED TO THE (K916) RETURN CIRCUIT

1. Measure the resistance between the (K157) MAF Sensor Signal circuit and (K957) Return circuit at the MAF Sensor harness connector.
Is the resistance below 10k Ohms?

Yes
• Repair the short between the (K157) MAF Sensor Signal Signal circuit and (K957) Return circuit.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Go To 5

5. CHECK THE (K157) MAF SENSOR SIGNAL CIRCUIT FOR AN OPEN/HIGH RESISTANCE
1. Measure the resistance of the (K157) MAF Sensor Signal circuit between the MAF Sensor harness connector and the PCM C1 harness connector.
Is the resistance below 5.0 Ohms?

Yes
• Go To 6

No
• Repair the (K157) MAF Sensor Signal circuit for an open or high resistance.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

6. CHECK THE (K157) MAF SENSOR SIGNAL CIRCUIT FOR A SHORT TO GROUND
1. Measure the resistance between ground and the (K157) MAF Sensor Signal circuit at the Mass Air Flow
Sensor harness connector.
Is the resistance below 10k Ohms?

Yes
• Repair the (K157) MAF Sensor Signal circuit for a short to ground.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Go To 7

7. CHECK THE INTAKE SYSTEM

1. Visually inspect the Intake System for any restrictions.
2. Perform the INTAKE AIR PRESSURE TEST diagnostic procedure. (Refer to 29 - Non-DTC Diagnostics/Drivability - Diesel - Diagnosis and Testing)
Were any leaks or restrictions found?

Yes
• Repair as necessary.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Go To 8

8. CHECK THE EXHAUST SYSTEM

1. Visually inspect the Exhaust System for any restrictions.
2. Perform the CHECKING THE EXHAUST SYSTEM FOR LEAKS diagnostic procedure. (Refer to 29 - NonDTC Diagnostics/Drivability - Diesel - Diagnosis and Testing)
Were any leaks or restrictions found?

Yes

• Repair as necessary.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Go To 9

9. CHECK THE MASS AIR FLOW SENSOR

1. Replace the MAF Sensor in accordance with the Service Information.(Refer to 14 - Fuel System/Fuel Injection, Diesel/SENSOR, Mass Airflow (MAF) /Removal)
2. Reconnect the PCM C1 harness connector.
3. Turn the ignition on.
4. With the scan tool, erase DTCs.
5. Start the engine and allow it to idle for one minute.
6. With the scan tool, read DTCs.
Does the DTC P0102 return?

Yes
• Go To 10.

No
• Test Complete.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

10. POWERTRAIN CONTROL MODULE

No
• Test complete.
• Perform the PCM VERIFICATION TEST. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

P0103 - Mass Air Flow Sensor "A" Circuit High

Mon, 18 Feb 2019 20:46:55 +0000

P0103 - Mass Air Flow Sensor "A" Circuit High

Theory of Operation

When Monitored and Set Conditions

When Monitored: This diagnostic runs continuously when the following conditions are met:
• With the ignition on.

Set Conditions:
• The Powertrain Control Module (PCM) has detected the Mass Air Flow (MAF) Sensor value is above a
calibrated threshold.

Default Actions:
• The MIL is illuminated.

Possible Causes

MAF SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
MAF SENSOR RETURN CIRCUIT OPEN/HIGH RESISTANCE
MASS AIR FLOW (MAF) SENSOR
POWERTRAIN CONTROL MODULE (PCM)

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 28 - DTCBased Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

1. ACTIVE DTC

NOTE: The MAF Sensor, EGR Cooler Bypass Valve and Turbocharger Actuator get a 12V power supply from the PCM.
1. Ignition on, engine not running.
2. Record freeze frame data and clear DTCs.

3. Turn the ignition off for one minute.
4. Turn the ignition on.
5. With the scan tool, read DTCs.
Did the DTC return?

Yes
• Go To 2

No
• Perform the INTERMITTENT CONDITION diagnostic procedure. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

2. CHECK THE (K157) MAF SENSOR SIGNAL CIRCUIT SHORT TO VOLTAGE

1. Turn the ignition off.
2. Disconnect the MAF Sensor harness connector.
3. Turn the ignition on.
4. Measure the voltage of the (K157) MAF Sensor Signal circuit in the MAF Sensor harness connector.
Is the voltage equal to battery voltage?

Yes
• Repair the short to battery in the (K157) MAF Sensor Signal circuit.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Go To 3

3. CHECK THE (K957) MAF SENSOR RETURN CIRCUIT FOR AN OPEN/HIGH RESISTANCE

1. Turn the ignition off.
2. Disconnect the PCM C1 harness connector.
3. Measure the resistance of the (K957) MAF Sensor Return circuit between the MAF Sensor harness
connector and the PCM C1 harness connector.

Is the resistance below 5.0 Ohms?

Yes

• Go To 4

No
• Repair the (K957) Mass Air Flow Sensor Return circuit for an open or high resistance.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

4. CHECK THE MASS AIR FLOW SENSOR

1. Turn the ignition off.
2. Reconnect the PCM C1 harness connector.
3. Reconnect the MAF Sensor harness connector.
4. Turn the ignition on, engine not running.
5. With the scan tool, clear DTCs.
6. Disconnect the MAF Sensor harness connector and read DTCs.
Does the scan tool display DTC P0102 as active?

Yes
• Replace the Mass Air Flow Sensor in accordance with the Service Information.(Refer to 14 - Fuel System/Fuel Injection, Diesel/SENSOR, Mass Airflow (MAF) /Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Go To 5

5. POWERTRAIN CONTROL MODULE

No
• Test complete.
• Perform the PCM VERIFICATION TEST. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

P0106 - Manifold Absolute Pressure Sensor Performance

Wed, 06 Mar 2019 20:45:24 +0000

P0106 - Manifold Absolute Pressure Sensor Performance

Theory of Operation

The Charge Air Cooler Temperature Sensor (CAC) and the Boost Pressure Sensor are combined in one sensor. This combination sensor is called the Temperature/Pressure MAP Sensor. It is located on the EGR Airflow Throttle Control Valve on the Regular Cab. For the Cab and Chassis, it is located on the Intake Manifold. The Cab and Chassis version also receives the Intake Manifold Temperature signal. The Regular Cab still has a separate Intake Manifold Temperature Sensor. The Boost Pressure Sensor is used to measure pressure in the intake manifold. The Powertrain Control Module (PCM) provides a 5-Volt supply and sensor ground for the Boost Pressure Sensor. The Boost Pressure Sensor provides a signal back to the PCM on the Boost Pressure Sensor Signal circuit. The PCM will detect a low signal voltage at operating conditions such as during an idle or a deceleration. The PCM will detect a high signal voltage during high engine load operating conditions. At key on, the readings for the Boost Pressure Sensor, Exhaust Gas Pressure Sensor, and Barometric Pressure Sensor are compared. This fault code occurs if the boost pressure reading is different from the others. During normal engine operation, the PCM estimates the Boost Pressure Sensor value using other fuel system related inputs. The PCM compares the actual Boost Pressure Sensor reading to this estimated value. If the two values are out of range for a calibrated period of time, an error is recorded.

When Monitored and Set Conditions

When Monitored: This diagnostic runs continuously when the following conditions are met:
• With the Engine running.

Set Conditions:
• The Powertrain Control Module (PCM) has detected the Inlet Air Pressure Sensor value or the boost pressure reading is not within a calibrated threshold.

Default Actions:
• The MIL is illuminated.

Possible Causes

INTAKE AIR SYSTEM LEAK
EGR AIRFLOW THROTTLE CONTROL VALVE
PLUGGED AIR FILTER
TEMPERATURE/PRESSURE MAP SENSOR

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 28 - DTCBased Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

1. ACTIVE DTC

NOTE: If DTCs P0107 or P0108 are present, repair those DTCs before proceeding.
NOTE: If there are any EGR Valve or EGR Airflow Control Valve DTCs present, repair those DTCs before proceeding.
NOTE: If customer states that there was an EVIC message "Service Air Filter", or if Freeze Frame Data shows "Air Filter Plugged Error equals ON", replace the Air Filter before continuing.
1. Turn the ignition on.
2. With the scan tool, record all Freeze frame data.
3. With the scan tool, erase DTCs.
4. Turn the ignition on for 75 seconds.
5. Start the engine and let idle.
6. With the scan tool, read DTCs.
Did the DTC return?

Yes
• Go To 2

No
• Perform the INTERMITTENT CONDITION diagnostic procedure. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

2. CHECK FOR AN INTAKE AIR SYSTEM LEAK

1. Perform the INTAKE AIR SYSTEM PRESSURE TEST. (Refer to 29 - Non-DTC Diagnostics/Drivability -
Diesel - Diagnosis and Testing)
Where any leaks found?

Yes
• Repair the leak and perform a Mobile Desoot of the aftertreatment system.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based
Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Leave the Air Inlet Tube disconnected. Go To 3

3. TURBOCHARGER

1. Inspect the impeller gear on the turbocharger for damage or broken teeth.
Was there any damage found?

Yes
• Replace the Turbocharger assembly in accordance with the service information.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Go To 4

4. CHECK THE EGR AIRFLOW THROTTLE CONTROL VALVE

1. Remove the boot from the EGR Airflow Throttle Control Valve.
2. Using a mirror, look at the butterfly valve on the inside of the EGR Airflow Throttle Control Valve.
3. Start the vehicle, let idle for 10 seconds.
4. Turn the ignition off.

NOTE: If functioning properly the EGR Airflow Throttle Control Valve will cycle closed immediately
after the engine is shut down.

Did the EGR Airflow Throttle Control Valve cycle closed immediately after the engine was shut down?

Yes
• Go To 5

No
• Replace the EGR Airflow Throttle Control Valve in accordance with the Service Information.(Refer to 25
- Emissions Control/Exhaust Gas Recirculation, Diesel/VALVE, Exhaust Gas Recirculation (EGR) Airflow Control/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

5. TEMPERATURE/PRESSURE MAP SENSOR

1. Turn ignition switch on. Wait five seconds after ignition switch is turned on.
2. Using the scan tool, read DTCs
Is P0106 stored?

Yes
• Go To 6

No
• Replace the Temperature/Pressure MAP Sensor in accordance with the Service Information.(Refer to 14
- Fuel System/Fuel Injection/SENSOR, TMAP-Intake Manifold/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

6. TEMPERATURE/PRESSURE MAP SENSOR

1. Erase the DTC with the scan tool.
2. Start the engine and let it idle for one minute.
3. With the scan tool, monitor the boost pressure reading.
Does the Boost Pressure Sensor fluctuate slightly, indicating the sensor is not stuck?

Yes
• Repair complete.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Replace the Temperature/Pressure MAP Sensor in accordance with the Service Information.(Refer to 14
- Fuel System/Fuel Injection/SENSOR, TMAP-Intake Manifold/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

P0107 - Manifold Absolute Pressure Sensor Circuit

Wed, 24 Apr 2019 15:00:44 +0000

P0107 - Manifold Absolute Pressure Sensor Circuit

Theory of Operation

The Charge Air Cooler Temperature Sensor (CAC) and the Boost Pressure Sensor are combined in one sensor. This combination sensor is called the Temperature/Pressure MAP Sensor. It is located on the EGR Airflow Throttle Control Valve on the Regular Cab. For the Cab and Chassis, it is located on the Intake Manifold. The Cab and Chassis version also receives the Intake Manifold Temperature signal. The Regular Cab still has a separate Intake Manifold Temperature Sensor. The Boost Pressure Sensor is used to measure pressure in the intake manifold. The Powertrain Control Module (PCM) provides a 5-Volt supply and sensor ground for the Boost Pressure Sensor. The Boost Pressure Sensor provides a signal back to the PCM on the Boost Pressure Sensor Signal circuit. The PCM will detect a low signal voltage at operating conditions such as
during an idle or a deceleration. The PCM will detect a high signal voltage during high engine load operating conditions. At key on, the readings for the Boost Pressure Sensor, Exhaust Gas Pressure Sensor, and Barometric Pressure Sensor are compared. This fault code occurs if the boost pressure reading is different from the others. During normal engine operation, the PCM estimates the Boost Pressure Sensor value using
other fuel system related inputs. The PCM compares the actual Boost Pressure Sensor reading to this estimated value. If the two values are out of range for a calibrated period of time, an error is recorded.

When Monitored and Set Conditions

When Monitored: This diagnostic runs continuously when the following conditions are met:
• With the ignition on.
• Battery voltage greater than 10.4 Volts.

Set Conditions:

• The Powertrain Control Module (PCM) has detected the Boost Pressure Sensor Signal circuit is below a
calibrated threshold.

Default Actions:

• The MIL is illuminated.

Possible Causes

5-VOLT SUPPLY CIRCUIT OPEN/HIGH RESISTANCE
BOOST PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO THE BOOST PRESSURE SENSOR
RETURN CIRCUIT
BOOST PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
BOOST PRESSURE SENSOR SIGNAL CIRCUIT OPEN/HIGH RESISTANCE
TEMPERATURE/PRESSURE MAP SENSOR
POWERTRAIN CONTROL MODULE (PCM)

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 28 - DTCBased Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

Diagnostic Test

1. ACTIVE DTC

NOTE: If there are any 5-Volt supply DTCs present, repair those DTCs before proceeding.
1. Turn the ignition on.
2. With the scan tool, record all Freeze frame data.
3. With the scan tool, erase DTCs.
4. Turn the ignition off for 75 seconds.
5. Turn the ignition on.
6. With the scan tool, read DTCs.
Did the DTC reset?

Yes
• Go To 2

• Perform to the INTERMITTENT CONDITION diagnostic procedure. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

2. CHECK THE (F857) 5-VOLT SUPPLY CIRCUIT FOR AN OPEN/HIGH RESISTANCE

1. Ignition on.
2. Disconnect the Temperature/Pressure MAP (T/P MAP) Sensor harness connector.
3. With a voltmeter, measure the voltage of the (F857) 5-Volt Supply circuit at the T/P MAP Sensor harness connector.
Is the voltage reading between 4.9 and 5.1 volts?

Yes
• Go To 3

No
• Repair the (F857) 5-Volt Supply circuit for an open or high resistance.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

3. CHECK THE BOOST PRESSURE SENSOR

1. While monitoring the scan tool, connect a jumper between the (F857) 5-Volt Supply circuit and the (K37) Boost Pressure Sensor Signal circuit at the T/P MAP Sensor harness connector.
Did the P0108 DTC set?

Yes
• Replace the Temperature/Pressure MAP Sensor in accordance with the Service Information.(Refer to 14
- Fuel System/Fuel Injection/SENSOR, TMAP-Intake Manifold/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based
Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Go To 4

4. CHECK FOR THE (K37) BOOST PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO THE (K916) BOOST PRESSURE SENSOR RETURN CIRCUIT

1. Turn the ignition off.
2. Disconnect the PCM C1 harness connector.
3. Measure the resistance between the (K37) Boost Pressure Sensor Signal circuit and (K916) Sensor Ground circuit at the T/P MAP Sensor harness connector.
Is the resistance below 10k Ohms?

Yes
• Repair the short between the (K37) Boost Pressure Sensor Signal circuit and (K916) Sensor Ground circuit.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Go To 5

5. CHECK THE (K37) BOOST PRESSURE SENSOR SIGNAL CIRCUIT FOR A SHORT TO GROUND

1. Measure the resistance between ground and the (K37) Boost Pressure Sensor Signal circuit.
Is the resistance below 10k Ohms?

Yes
• Repair the (K37) Boost Pressure Sensor Signal circuit for a short to ground.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Go To 6

6. CHECK THE (K37) BOOST PRESSURE SENSOR SIGNAL CIRCUIT FOR AN OPEN/HIGH RESISTANCE
1. Measure the resistance of the (K37) Boost Pressure Sensor Signal circuit between the T/P MAP Sensor and the PCM C1 harness connectors.
Is the resistance below 5.0 Ohms?

Yes
• Go To 7.

No
• Repair the (K37) Boost Pressure Sensor Signal circuit for an open or high resistance.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

• Bent terminals.
• Overheating due to a poor connection (terminal may be discolored due to excessive current draw).
• Terminals that have been pushed back into the connector cavity.
• Perform a terminal drag test on each connector terminal to verify proper terminal tension. Repair any conditions that are found.
5. Reconnect all PCM harness connectors. Be certain that all harness connectors are fully seated and the connector locks are fully engaged.
6. Reconnect all in-line harness connectors (if equipped). Be certain that all connectors are fully seated and the connector locks are fully engaged.
7. Reconnect all related component harness connectors. Be certain that all connectors are fully seated and the connector locks are fully engaged.
8. With the scan tool, erase DTCs.
9. Using the recorded Freeze Frame and Environmental Data, along with the When Monitored and Set Conditions above, operate the vehicle in the conditions that set the DTC.
10. With the scan tool, read PCM DTCs.
Did the DTC return?

No
• Test complete.
• Perform the PCM VERIFICATION TEST. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain
Control (PCM) - Standard Procedure).

P0108 - Manifold Absolute Pressure Sensor Circuit High

Wed, 24 Apr 2019 15:21:34 +0000

P0108 - Manifold Absolute Pressure Sensor Circuit High

Theory of Operation

The Charge Air Cooler Temperature Sensor (CAC) and the Boost Pressure Sensor are combined in one sensor. This combination sensor is called the Temperature/Pressure MAP Sensor. It is located on the EGR Airflow Throttle Control Valve on the Regular Cab. For the Cab and Chassis, it is located on the Intake Manifold. The Cab and Chassis version also receive the Intake Manifold Temperature signal. The Regular Cab still has a separate Intake Manifold Temperature Sensor. The Boost Pressure Sensor is used to measure pressure in the intake manifold. The Powertrain Control Module (PCM) provides a 5-Volt supply and sensor ground for the Boost Pressure Sensor. The Boost Pressure Sensor provides a signal back to the PCM on the Boost Pressure Sensor Signal circuit. The PCM will detect a low signal voltage at operating conditions such as
during an idle or a deceleration. The PCM will detect a high signal voltage during high engine load operating conditions. At key on, the readings for the Boost Pressure Sensor, Exhaust Gas Pressure Sensor, and Barometric Pressure Sensor are compared. This fault code occurs if the boost pressure reading is different from the others. During normal engine operation, the PCM estimates the Boost Pressure Sensor value using
other fuel system related inputs. The PCM compares the actual Boost Pressure Sensor reading to this estimated value. If the two values are out of range for a calibrated period of time, an error is recorded.

When Monitored and Set Conditions

When Monitored: This diagnostic runs continuously when the following conditions are met:
• With the ignition on.
• Battery voltage greater than 10.4 Volts.

Set Conditions:

• The Powertrain Control Module (PCM) has detected the Boost Pressure Sensor Signal circuit is above a
calibrated threshold.

Default Actions:

• The MIL is illuminated.

Possible Causes

5-VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE
BOOST PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
BOOST PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO THE 5-VOLT SUPPLY CIRCUIT
BOOST PRESSURE SENSOR RETURN CIRCUIT OPEN/HIGH RESISTANCE
TEMPERATURE/PRESSURE MAP SENSOR
POWERTRAIN CONTROL MODULE (PCM)
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 28 - DTCBased Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure

Diagnostic Test

1. ACTIVE DTC

Yes
• Go To 2

No
• Perform the INTERMITTENT CONDITION diagnostic procedure. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

2. CHECK THE (K37) BOOST PRESSURE SENSOR SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE

1. Turn the ignition off.
2. Disconnect the Temperature/Pressure MAP (T/P MAP) Sensor harness connector.
3. Turn the ignition on.
4. With a voltmeter, measure the voltage of the (K37) Boost Pressure Sensor Signal circuit at the
Temperature/Pressure MAP Sensor harness connector.
Is the voltage reading near battery voltage?

Yes
• Repair the (K37) Boost Pressure Sensor Signal circuit for a short to voltage.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based
Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

• Go To 3

3. CHECK FOR THE (K37) BOOST PRESSURE SENSOR SIGNAL CIRCUIT SHORTED TO THE (F857) 5-VOLT SUPPLY CIRCUIT

1. Turn the ignition off.

2. Disconnect the PCM C1 harness connector.

3. Measure the resistance between the (K37) Boost Pressure Sensor Signal circuit and (F857) 5-Volt Supply circuit at the Temperature/Pressure MAP Sensor harness connector. Is the resistance below 10k Ohms?

Yes

• Repair the short between the (K37) Boost Pressure Sensor Signal circuit and (F857) 5-Volt Supply circuit.

• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

• Go To 4

4. CHECK THE (K916) BOOST PRESSURE SENSOR RETURN CIRCUIT FOR AN OPEN/HIGH RESISTANCE

1. Measure the resistance of the (K916) Boost Pressure Sensor Return circuit between the Temperature/Pressure MAP Sensor and the PCM C1 harness connectors. Is the resistance below 5.0 Ohms?

Yes

• Go To 5

• Repair the (K916) Boost Pressure Sensor Return circuit for an open or high resistance.

• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

5. CHECK THE TEMPERATURE/PRESSURE MAP SENSOR

1. Reconnect the Temperature/Pressure MAP Sensor harness connector.

2. Reconnect the PCM C1 harness connector.
3. Turn the ignition on.
4. With the scan tool, erase DTCs.
5. Turn the ignition off and disconnect the T/P MAP Sensor harness connector.
6. Turn the ignition on.
7. With the scan tool, read DTCs.
Did the DTC P0107 set?

Yes
• Replace the Temperature/Pressure MAP Sensor in accordance with the Service Information.(Refer to 14
- Fuel System/Fuel Injection/SENSOR, TMAP-Intake Manifold/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based
Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Go To 6

6. POWERTRAIN CONTROL MODULE

1. Disconnect all PCM harness connectors.
2. Disconnect all related in-line harness connections (if equipped).
3. Disconnect the related component harness connectors.
4. Inspect harness connectors, component connectors, and all male and female terminals for the following conditions:
• Proper connector installation.
• Damaged connector locks.
• Corrosion.
• Other signs of water intrusion.
• Weather seal damage (if equipped).
• Bent terminals.
• Overheating due to a poor connection (terminal may be discolored due to excessive current draw).
• Terminals that have been pushed back into the connector cavity.
• Perform a terminal drag test on each connector terminal to verify proper terminal tension.
Repair any conditions that are found.
5. Reconnect all PCM harness connectors. Be certain that all harness connectors are fully seated and the connector locks are fully engaged.
6. Reconnect all in-line harness connectors (if equipped). Be certain that all connectors are fully seated and the connector locks are fully engaged.
7. Reconnect all related component harness connectors. Be certain that all connectors are fully seated and the connector locks are fully engaged.
8. With the scan tool, erase DTCs.

Yes
• Replace the Powertrain Control Module (PCM) in accordance with the Service Information. (Refer to 08 -
Electrical/8E - Electronic Control Modules/MODULE, Powertrain Control/Removal) .
• Perform the PCM VERIFICATION TEST. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain
Control (PCM) - Standard Procedure).

No
• Test complete.
• Perform the PCM VERIFICATION TEST. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain
Control (PCM) - Standard Procedure).

P0111 - Intake Air Temperature Sensor 1 Performance

Wed, 24 Apr 2019 15:29:23 +0000

P0111 - Intake Air Temperature Sensor 1 Performance

Theory of Operation

The Intake Manifold Temperature (IMT) Sensor is located on the intake manifold on the Regular Cab. For the Cab and Chassis, it is a part of the Temperature/Pressure MAP Sensor. The IMT Sensor is used to measure the temperature of the air in the intake manifold. The Powertrain Control Module (PCM) supplies 5-Volts to the intake manifold temperature signal circuit. The PCM monitors the change in voltage caused by changes in the
resistance of the sensor to determine the intake manifold temperature. The MIL lamp is illuminated immediately when the diagnostic runs and fails. During this time the customer may notice periods of white smoke as well as the fan running more often. The MIL lamp is turned off once the diagnostic runs and passes in four consecutive drive cycles.

When Monitored and Set Conditions

When Monitored: This diagnostic runs continuously when the following conditions are met:
• With the ignition on.
• With the Engine running.

Set Conditions:

• The Powertrain Control Module (PCM) has detected the Intake Air Temperature (IAT) Sensor reads
differently than the Engine Coolant Temperature (ECT) Sensor with the ignition on and Engine off. With
the ignition on and Engine running the PCM does not read a change in value from the Intake Air
Temperature circuit over a calibrated amount of time.

Default Actions:

• The MIL is illuminated.

Possible Causes

AIR CLEANER BOX NOT SEALING PROPERLY TO THE AIR INLET TUBE
DIRT OR DEBRIS IN CHARGE AIR COOLING SYSTEM
TEMPERATURE/PRESSURE MAP SENSOR

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 28 - DTCBased Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

1. OTHER DTCS

1. Ignition on, engine not running.
2. With the scan tool, read DTCs.
Are DTC P0112 or P0113 present?

Yes
• Repair those DTCs first.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Go To 2

2. CHECK THE CHARGE AIR COOLER AND SYSTEM FOR DIRT OR DEBRIS

1. Remove the hoses at the Charge Air Cooler and Turbo outlet and inspect the system for signs of excessive oil, dirt or debris.
Does the Charge Air Cooling system show signs of excessive dirt or debris?

Yes
• Clean the Charge Air Cooling system in accordance with the service information.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Go To 3

3. COMPARE THE INTAKE AIR TEMPERATURE CIRCUIT

1. After an eight hour cold soak, connect the scan tool and monitor intake air temperature, EGR orifice temperature, and engine coolant temperature.
NOTE: Make sure ambient air temperature is above -6.7°C (20°F) when performing this test.
NOTE: Make sure there is no external heat source, such as a block heater, operating during this test or within the eight hour cold soak.

Does the Intake Air Temperature circuit read differently from the other sensors?

Yes
• Replace the Temperature/Pressure MAP Sensor in accordance with the service information.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Perform the INTERMITTENT CONDITION diagnostic procedure. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).