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.

Set Conditions:

• The Powertrain Control Module (PCM) has detected the Intake Manifold Temperature Sensor circuit is
below a calibrated threshold.

Default Actions:

• The MIL is illuminated.

Possible Causes

INTAKE MANIFOLD TEMPERATURE SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
INTAKE MANIFOLD TEMPERATURE SENSOR SIGNAL CIRCUIT SHORTED TO THE SENSOR
GROUND CIRCUIT
TEMPERATURE/PRESSURE MAP SENSOR
POWERTRAIN CONTROL MODULE

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

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 INTAKE MANIFOLD TEMPERATURE CIRCUIT

1. Turn the ignition off.
2. Disconnect the T/P MAP sensor harness connector.
NOTE: Check connectors - Clean/repair as necessary.
3. Measure the resistance from the Sensor ground (K916) to the Intake Manifold Temperature circuit (K21) across the terminals at the T/P MAP sensor harness connector.
Is the resistance between 300 and 90k Ohms?

Yes
• Go To 3

No
• Replace the T/P 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).

3. CHECK THE (K21) INTAKE MANIFOLD TEMPERATURE SENSOR SIGNAL CIRCUIT FOR A SHORT TO GROUND

1.
2. Disconnect the PCM C1 harness connector.
NOTE: Check connectors - Clean/repair as necessary.
3. Measure the resistance between ground and the (K21) Intake Manifold Temperature Signal circuit at the T/P MAP sensor harness connector.  Is the resistance below 10k Ohms?

Yes
• Repair the (K21) Intake Manifold Temperature 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 4

4. CHECK FOR THE (K21) INTAKE MANIFOLD TEMPERATURE SIGNAL CIRCUIT SHORTED TO THE (K916) SENSOR GROUND CIRCUIT

1.
2. Measure the resistance between the (K21) Intake Manifold Temperature Signal circuit and the (K916)
Sensor Ground circuit at the T/P MAP sensor harness connector. Is the resistance below 10k Ohms?

Yes
• Repair the short between the (K21) Intake Manifold Temperature Signal circuit and the (K916) Sensor Ground circuit.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• 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).

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.

Set Conditions:

• The Powertrain Control Module (PCM) has detected the Intake Manifold Temperature Sensor circuit is
above a calibrated threshold.

Default Actions:

• The MIL is illuminated.

Possible Causes

INTAKE MANIFOLD TEMPERATURE SIGNAL CIRCUIT SHORTED TO VOLTAGE
INTAKE MANIFOLD TEMPERATURE SIGNAL CIRCUIT OPEN/HIGH RESISTANCE
INTAKE MANIFOLD TEMPERATURE 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

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 (K21) INTAKE MANIFOLD TEMPERATURE SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE

1.
2. Ignition on.
3. Disconnect the T/P MAP sensor harness connector.
NOTE: Check connectors - Clean/repair as necessary.
4. With a voltmeter connected to ground, measure the voltage of the (K21) Intake Manifold Temperature
Signal circuit at the T/P MAP sensor harness connector.
Is the voltage above 5.1 Volts?

Yes
• Repair the (K21) Intake Manifold 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 T/P MAP SENSOR

1. Turn the ignition off.
2. Measure the resistance across terminals 3 and 4 of the T/P 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.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

4. CHECK THE (K21) INTAKE MANIFOLD TEMPERATURE 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 (K21) Intake Manifold Temperature Signal circuit between the T/P MAP sensor harness connector and the PCM C1 harness connector.

Is the resistance below 5.0 Ohms?

Yes
• Go To 5

No
• Repair the (K21) Intake Manifold 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).

5. CHECK THE (K916) T/P MAP RETURN CIRCUIT FOR AN OPEN/HIGH RESISTANCE

1. Measure the resistance of the (K916) T/P MAP Return circuit between the T/P MAP sensor harness connector and the PCM C1 harness connector.
Is the resistance below 5.0 Ohms?

Yes
• 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).

No
• Repair the (K916)T/P MAP 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).

Theory of Operation

The Engine Coolant Temperature Sensor (ECT) is located near the thermostat housing and is used to measure the engine coolant temperature. The Engine Coolant Temperature Sensor receives 5-Volts and a sensor ground from the PCM. The PCM monitors the change in voltage to determine the coolant temperature. There are two parts to this fault code, a key on check and a rationality check. After an eight hour cold soak, at key on the readings for the Inlet Air Temperature, Intake Air Temperature and Engine Coolant Temperature Sensors are all compared. If the temperatures differ more than a calibrated amount, then the appropriate sensor fault code would be recorded. The key on monitor is disabled for ambient temperatures below 20°F. This monitor looks for all the sensors to be grouped on one temperature or, in the case that the monitor fails, two sensors grouped at one temperature and one outlier. In the case that all three sensor values are distributed over a range of temperatures this diagnostic will not run. A block heater is one possible cause of such a distribution. The PCM rationality check looks at the temperature reading from the sensor over time and ensures that it changes with engine running. If the sensor reading does not change over a calibrated time limit, the fault will be recorded. Both the key-on and rationality portions of this monitor require that the diagnostic fails in two consecutive drive cycles before the MIL lamp is lit. The ETC lamp will also be illuminated. During this time the PCM uses a default value for the Coolant Temperature Sensor. The PCM turns off the MIL lamp 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.

Set Conditions:

• The Powertrain Control Module (PCM) does not read a change in value from the Engine Coolant Temperature (ECT) Sensor over a calibrated amount of time.

Default Actions:

• The MIL is illuminated.

Possible Causes

LOW COOLANT LEVEL
ENGINE COOLANT TEMPERATURE (ECT) SENSOR
THERMOSTAT

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

1. CHECK THE COOLANT LEVEL

1. Turn the ignition off.
2. With the engine cold, verify the level of coolant in the cooling system.
Is the cooling system full of coolant?

Yes
• Go To 2

No
• Fill the cooling system to the proper level.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

2. THERMOSTAT

1. With the scan tool, check DTCs.
NOTE: If DTC P0117 or P0118 are present, repair those DTCs before proceeding with this test.
Is DTC P0128-Thermostat Rationality present?

Yes
• Replace the Thermostat in accordance with the Service Information..(Refer to 07 - Cooling/Engine/THERMOSTAT/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Go To 3

3. COOLANT TEMPERATURE SENSOR

1. Remove the Coolant Temperature Sensor and reconnect the wiring to the sensor.
2. Turn the ignition on. 

3. Monitor scan tool while heating the sensor with an external heat source (DO NOT USE OPEN FLAME).
Does the reading from the Coolant Temperature Sensor increase at least 5°F on the scan tool?

Yes
• Go To 4

No
• Replace the Coolant Temperature Sensor in accordance with the Service Information..(Refer to 07 - Cooling/Engine/SENSOR, Coolant Temperature/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

4. COOLANT TEMPERATURE SENSOR

1. Let vehicle cold soak for eight hours.
2. Turn the ignition on.
3. With a scan tool, monitor Inlet Air Temperature, EGR Temperature and Coolant Temperature Sensors.
NOTE: Make sure the Ambient Air Temperature is above 20°F.
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 Coolant Temperature Sensor read more than a 18°F (10°C) above or below the other sensors?

Yes
• Replace the Coolant Temperature Sensor in accordance with the Service Information..(Refer to 07 - Cooling/Engine/SENSOR, Coolant Temperature/Removal)
• 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).

Theory of Operation

The Engine Coolant Temperature Sensor (ECT) is located near the thermostat housing and is used to measure the engine coolant temperature. The Engine Coolant Temperature Sensor receives 5-Volts and a sensor ground from the PCM. The PCM monitors the change in voltage to determine the coolant temperature. There are two parts to this fault code, a key on check and a rationality check. After an eight hour cold soak, at key on the readings for the Inlet Air Temperature, Intake Air Temperature and Engine Coolant Temperature Sensors are all compared. If the temperatures differ more than a calibrated amount, then the appropriate sensor fault code would be recorded. The key on monitor is disabled for ambient temperatures below 20°F. This monitor looks for all the sensors to be grouped on one temperature or, in the case that the monitor fails, two sensors grouped at one temperature and one outlier. In the case that all three sensor values are distributed over a range of temperatures this diagnostic will not run. A block heater is one possible cause of such a distribution. The PCM rationality check looks at the temperature reading from the sensor over time and ensures that it changes with engine running. If the sensor reading does not change over a calibrated time limit, the fault will be recorded. Both the key-on and rationality portions of this monitor require that the diagnostic fails in two consecutive drive cycles before the MIL lamp is lit. The ETC lamp will also be illuminated. During this time the PCM uses a default value for the Coolant Temperature Sensor. The PCM turns off the MIL lamp 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 ignition on.
• Battery voltage greater than 10.4 Volts.

Set Conditions:

• The Powertrain Control Module (PCM) detects the Engine Coolant Temperature (ECT) Sensor Signal circuit is below a calibrated threshold.

Default Actions:

• The MIL is illuminated.

Possible Causes

ECT SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
ECT SENSOR SIGNAL CIRCUIT SHORTED TO ENGINE COOLANT TEMPERATURE SENSOR RETURN
CIRCUIT
ENGINE COOLANT TEMPERATURE (ECT) 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 COOLANT TEMPERATURE SENSOR

1. Turn the ignition off.
2. Disconnect the Engine Coolant Temperature Sensor (ECT) harness connector.
NOTE: Check connectors - Clean/repair as necessary.
3. Measure the resistance between ground and one of the terminals of the ECT Sensor.
Is the resistance below 10k Ohms?

Yes
• Replace the Coolant Temperature Sensor in accordance with the Service Information..(Refer to 07 -
Cooling/Engine/SENSOR, Coolant Temperature/Removal)
• 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 (K2) ENGINE COOLANT TEMPERATURE SENSOR SIGNAL CIRCUIT FOR A SHORT TO GROUND

1. Disconnect the PCM C1 harness connector.
NOTE: Check connectors - Clean/repair as necessary.
2. Measure the resistance between ground and the (K2) ECT Sensor Signal circuit at the ECT Sensor harness connector.
Is the resistance below 10k Ohms?

Yes
• Repair the (K2) ECT 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 4

4. CHECK FOR THE (K2) ENGINE COOLANT TEMPERATURE SENSOR SIGNAL CIRCUIT SHORTED TO THE (K914) ENGINE COOLANT TEMPERATURE SENSOR RETURN CIRCUIT
1. Measure the resistance between the (K2) ECT Sensor Signal circuit and the (K914) Sensor Ground circuit at the Coolant Temperature Sensor harness connector.
Is the resistance below 10k Ohms?

Yes
• Repair the short between the (K2) ECT Sensor Signal circuit and the (K914) Sensor Ground circuit.
• Perform 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

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).

Theory of Operation

The Engine Coolant Temperature Sensor (ECT) is located near the thermostat housing and is used to measure the engine coolant temperature. The Engine Coolant Temperature Sensor receives 5-Volts and a sensor ground from the PCM. The PCM monitors the change in voltage to determine the coolant temperature. There are two parts to this fault code, a key on check and a rationality check. After an eight hour cold soak, at key on the readings for the Inlet Air Temperature, Intake Air Temperature and Engine Coolant Temperature Sensors are all compared. If the temperatures differ more than a calibrated amount, then the appropriate sensor fault code would be recorded. The key on monitor is disabled for ambient temperatures below 20°F. This monitor looks for all the sensors to be grouped on one temperature or, in the case that the monitor fails, two sensors grouped at one temperature and one outlier. In the case that all three sensor values are distributed over a range of temperatures this diagnostic will not run. A block heater is one possible cause of such a distribution. The PCM rationality check looks at the temperature reading from the sensor over time and ensures that it changes with engine running. If the sensor reading does not change over a calibrated time limit, the fault will be recorded. Both the key-on and rationality portions of this monitor require that the diagnostic fails in two consecutive drive cycles before the MIL lamp is lit. The ETC lamp will also be illuminated. During this time the PCM uses a default value for the Coolant Temperature Sensor. The PCM turns off the MIL lamp 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 ignition on.
• Battery voltage greater than 10.4 Volts.

Set Conditions:

• The Powertrain Control Module (PCM) detects the Engine Coolant Temperature (ECT) Sensor Signal
circuit is above a calibrated threshold.

Default Actions:

• The MIL is illuminated.

Possible Causes

ECT SENSOR SIGNAL CIRCUIT OPEN/HIGH RESISTANCE
ECT SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
SENSOR RETURN CIRCUIT OPEN/HIGH RESISTANCE
ENGINE COOLANT TEMPERATURE (ECT) 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 (K2) ENGINE COOLANT TEMPERATURE SENSOR SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE

1. Ignition on.
2. Disconnect the Coolant Temperature Sensor harness connector.
3. Measure the voltage of the (K2) Engine Coolant Temperature Sensor (ECT) Signal circuit at the sensor harness connector.
NOTE: The voltage should read approximately 5.0 Volts with connector disconnected and key on.
Is the voltage above 5.1 Volts?

Yes
• Repair the (K2) ECT 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 ENGINE COOLANT TEMPERATURE SENSOR

1. Turn the ignition off.
NOTE: Check connectors - Clean/repair as necessary.
2. Measure the resistance across the terminals of the ECT Sensor. Is the resistance between 300 and 90k Ohms?

Yes
• Go To 4

No
• Replace the Coolant Temperature Sensor in accordance with the Service Information..(Refer to 07 - Cooling/Engine/SENSOR, Coolant Temperature/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

4. CHECK THE (K2) ENGINE COOLANT TEMPERATURE SENSOR SIGNAL CIRCUIT FOR AN OPEN/HIGH RESISTANCE

1. Disconnect the PCM C1 harness connector.
2. Measure the resistance of the (K2) ECT Sensor Signal circuit between the ECT Sensor harness connector and the PCM C1 harness connector.
Is the resistance below 5.0 Ohms?

Yes
• Go To 5

No
• Repair the (K2) ECT 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).

5. CHECK THE (K914) SENSOR RETURN CIRCUIT FOR AN OPEN/HIGH RESISTANCE

1.
2. Measure the resistance of the (K914) ECT Sensor Return circuit between the ECT Sensor harness
connector and the PCM C1 harness connector.

Is the resistance below 5.0 Ohms?

Yes
• Go To 6

No
• Repair the (K914) ECT 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).

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?

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)

Theory of Operation

The thermostat rationality diagnostic runs during a drive cycle that starts with the coolant temperature below 140°F. This diagnostic looks at the how cold the system is at start up, what the inlet air temperature is, and the amount of fuel burned during that drive cycle. The PCM estimates what the coolant temperature should be. If the coolant temperature is not above a calibrated threshold, the rationality fails. The PCM assumes that the thermostat is stuck open.

When Monitored:

While the engine is running.

Set Condition:

The coolant temperature does not rise above a calibrated amount over a calibrated amount of time.

Possible Causes

COOLANT LEVEL
COOLANT TEMPERATURE SENSOR
THERMOSTAT
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

1. CHECK THE COOLANT LEVEL
NOTE: If DTC P0116 is also present, repair the P0116 DTC before proceeding with this test.
NOTE: An engine block heater or oil heater can cause this DTC to set erroneously.
1. Turn the ignition off.
2. With the engine cold, verify the level of coolant in the cooling system. Is the cooling system full of coolant?

Yes
• Go To 2

No
• Fill the cooling system to the proper level.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

2. CHECK THE COOLANT TEMPERATURE SENSOR
1. Start the engine.
2. With the scan tool, monitor the coolant temperature for 10 minutes. Did the coolant temperature change over time while the engine was running?

Yes
• Replace the Thermostat in accordance with the Service Information.(Refer to 07 - Cooling/Engine/THERMOSTAT/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Replace the Coolant Temperature Sensor in accordance with the Service Information.(Refer to 07 - Cooling/Engine/SENSOR, Coolant Temperature/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).
 

Theory of Operation

There are two Water-In-Fuel (WIF) sensors attached to the two fuel filters. WIF 1 is attached to the fuel filter mounted on the engine. WIF 2 is attached to a 2nd fuel filter that can now be found mounted to the chassis. The Powertrain Control Module (PCM) provides a 5-Volt reference signal to each WIF sensor. When the water collected in the respective fuel filter covers the sensor probes, the sensor then pulls the 5-Volt reference voltage low indicating high water accumulation in that fuel filter.

When Monitored:

While the engine is running.

Set Condition:

Water-In-Fuel light was on for a calibrated amount of time.

Possible Causes

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

OTHER DTCS PRESENT

1. With the scan tool, read DTCs. Is P2269 displayed?

Yes
• Repair P2269 DTC first.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Drain water from both fuel filters.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

Theory of Operation

This DTC is mapped to an idle diagnostic, and runs only at idle. The key-on error monitors fuel pressure
voltage at key on after an eight hour cold soak. The Powertrain Control Module (PCM) varies fuel pressure and
monitors the final fueling and engine speed to determine if the rate of change of fueling with respect to rate of
change of pressure is with in the normal operation limits of the pressure sensor. The engine must be at
operating temperature and must not be in an active aftertreatment regeneration mode in order to run this
diagnostic. The idle monitor runs once per drive cycle and the PCM will light the MIL lamp after the diagnostic
runs and fails in two consecutive drive cycles. The PCM will turn off the MIL lamp after the diagnostic runs and
passes in four consecutive drive cycles.

When Monitored:

Engine running at idle.

Set Condition:

At idle, the rate of change in fueling with respect to the rate of change of pressure is below the calibrated fail high threshold or above the calibrated fail low threshold while the monitor was running.

Possible Causes

FUEL RAIL PRESSURE SENSOR
INJECTOR LEAKAGE

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 28 - DTC-Based 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 and let it idle for up to one minute.
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. FUEL RAIL PRESSURE SENSOR
1. With the scan tool, monitor the actual fuel pressure reading while the ignition is on and engine is not running. Is the actual fuel pressure reading above 870 psi?

Yes
• Go To 3

No
• Go To 4

3. VISUALLY INSPECT THE FUEL RAIL PRESSURE SENSOR
1. Visually inspect the fuel system components for signs of tampering, pay particular attention to the Fuel Pressure Sensor on the fuel rail and the Fuel Pressure Sensor wiring harness. Were any signs of tampering discovered?

Yes
• Replace the Fuel 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).

No
• Go To 4

4. CHECK THE INJECTOR RETURN FLOW
1. (Refer to 29 - Non-DTC Diagnostics/Drivability - Diesel - Diagnosis and Testing) and perform the INJECTOR RETURN FLOW TEST.
Does the injector drainage meet the test specification?

Yes
• Replace the Fuel 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).

No
• Repair cause of high Fuel Injector leakage.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

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:

With the ignition on and battery voltage greater than 10.4 Volts.

Set Condition:

One or both of the Fuel Rail Pressure Sensor Signals to the Powertrain Control Module (PCM) falls
below a calibrated threshold for a certain period of time.

Possible Causes

FRP SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
FRP SENSOR SIGNAL CIRCUIT SHORTED TO THE SENSOR RETURN
FRP SENSOR RETURN CIRCUIT OPEN/HIGH RESISTANCE
FRP SENSOR
POWERTRAIN CONTROL MODULE (PCM)
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

NOTE: If a 5-Volt reference DTC is present, repair that DTC 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 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 FUEL PRESSURE SENSOR

1. Turn the ignition off.
2. Disconnect the FRP Sensor harness connector.
3. Turn the ignition on. Does the DTC P0193 set?

Yes
• 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).

No
• Go To 3

3. CHECK THE (K181) FRP SENSOR SIGNAL 1 CIRCUIT FOR A SHORT TO GROUND

1. Turn the ignition off.
2. Disconnect the PCM C1 harness connector. NOTE: Check connectors - Clean/repair as necessary.
3. Measure the resistance between ground and the (K181) FRP Sensor Signal 1 circuit in the FRP Sensor harness connector.
Is the resistance below 10k Ohms?

Yes
• Repair the (K181) Fuel Rail Pressure Sensor Signal 1 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 4

4. CHECK FOR THE (K181) FRP SENSOR SIGNAL CIRCUIT SHORTED TO THE (K180) SENSOR RETURN

1. Measure the resistance between the (K181) FRP Sensor Signal 1 circuit and (K180) Sensor Return circuit at the FRP Sensor harness connector.
Is the resistance below 10k Ohms?

Yes
• Repair the short between the (K181) Fuel Rail Pressure Sensor Signal 1 circuit and (K180) Sensor 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 (K179) FRP SENSOR SIGNAL 2 CIRCUIT FOR A SHORT TO GROUND
1. Turn the ignition off.
2. Disconnect the PCM C1 harness connector. NOTE: Check connectors - Clean/repair as necessary.
3. Measure the resistance between ground and the (K179) FRP Sensor Signal 2 circuit in the FRP Sensor harness connector. Is the resistance below 10k Ohms?

Yes
• Repair the (K179) Fuel Rail Pressure Sensor Signal 2 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 FOR THE (K179) FRP SENSOR SIGNAL 2 CIRCUIT SHORTED TO THE (K180) SENSOR RETURN

1. Measure the resistance between the (K179) FRP Sensor Signal 2 circuit and (K180) Sensor Return circuit at the FRP Sensor harness connector.
Is the resistance below 10k Ohms?
 

Yes
• Repair the short between the (K179) Fuel Rail Pressure Sensor Signal 2 circuit and (K180) Sensor Return circuit.
• 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 (K180) SENSOR RETURN CIRCUIT FOR AN OPEN/HIGH RESISTANCE
1. Measure the resistance of the (K180) Sensor Return circuit between the FRP Sensor harness connector and the PCM C1 harness connector.
Is the resistance below 5.0 Ohms?

Yes
• Go To 8

No
• Repair the (K180) Sensor Return circuit for an open circuit or high resistance.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

8. 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).
 

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:

With the ignition on and battery voltage greater than 10.4 Volts.

Set Condition:

One or both of the Fuel Rail Pressure Sensor Signals to the Powertrain Control Module (PCM) is above a calibrated threshold for a certain period of time.

Possible Causes

5-VOLT SUPPLY CIRCUIT SHORTED TO VOLTAGE
FRP SENSOR SIGNAL 1 CIRCUIT SHORTED TO VOLTAGE
FRP SENSOR SIGNAL 2 CIRCUIT SHORTED TO VOLTAGE
FRP SENSOR SIGNAL 1 CIRCUIT OPEN/HIGH RESISTANCE
FRP SENSOR SIGNAL 2 CIRCUIT OPEN/HIGH RESISTANCE
FRP SENSOR SIGNAL 1 CIRCUIT SHORTED TO THE 5-VOLT SUPPLY CIRCUIT
FRP SENSOR SIGNAL 2 CIRCUIT SHORTED TO THE 5-VOLT SUPPLY CIRCUIT
SENSOR RETURN OPEN/HIGH RESISTANCE
FUEL RAIL PRESSURE SENSOR
POWERTRAIN CONTROL MODULE (PCM)

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
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

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

2. CHECK THE (K181) FRP SENSOR SIGNAL 1 CIRCUIT FOR A SHORT TO VOLTAGE

1. Turn the ignition off.
2. Disconnect the Fuel Rail Pressure Sensor harness connector.
3. Turn the ignition on.
4. Measure the voltage of the (K181) FRP Sensor Signal 1 circuit at the FRP Sensor harness connector. Is the reading above 5.2 volts?

Yes
• Repair the (K181) Fuel Rail Pressure Sensor Signal 1 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 FOR THE (K181) FRP SENSOR SIGNAL 1 CIRCUIT SHORTED TO THE (K350) 5-VOLT SUPPLY CIRCUIT
1. Turn the ignition off.
2. Disconnected PCM C1 harness connector.
3. Measure the resistance between the (K181) FRP Sensor Signal 1 circuit and the (K350) 5-Volt Supply circuit at the FRP Sensor harness connector.
Is the resistance below 10k Ohms?

Yes
• Repair the short between the (K181) Fuel Rail Pressure Sensor Signal 1 circuit and the (K350) 5-Volt Supply 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 THE (K181) FRP SENSOR SIGNAL 1 CIRCUIT FOR AN OPEN/HIGH RESISTANCE
1. Measure the resistance of the (K181) FRP Sensor Signal 1 circuit between the FRP Sensor harness connector and the PCM C1 harness connector. Is the resistance below 5.0 Ohms?

Yes
• Go To 5

No
• Repair the (K181) Fuel Rail Pressure Sensor Signal 1 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 (K179) FRP SENSOR 2 SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE
1. Turn the ignition off.
2. Disconnect the Fuel Rail Pressure Sensor harness connector.
3. Turn the ignition on.
4. Measure the voltage of the (K179) FRP Sensor 2 Signal circuit at the FRP Sensor harness connector. Is the reading above 5.2 volts?

Yes
• Repair the (K179) Fuel Rail Pressure Sensor Signal 2 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 6

6. CHECK FOR THE (K179) FRP SENSOR SIGNAL 2 CIRCUIT SHORTED TO THE (K350) 5-VOLT SUPPLY CIRCUIT
1. Turn the ignition off.
2. Disconnected PCM C1 harness connector.
3. Measure the resistance between the (K179) FRP Sensor Signal 2 circuit and the (K350) 5-Volt Supply circuit at the FRP Sensor harness connector.
Is the resistance below 10k Ohms?

Yes
• Repair the short between the (K179) Fuel Rail Pressure Sensor 2 Signal circuit and the (K350) 5-Volt Supply circuit.
• 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 (K179) FRP SENSOR SIGNAL 2 CIRCUIT FOR AN OPEN/HIGH RESISTANCE
1. Measure the resistance of the (K179) FRP Sensor Signal 2 circuit between the FRP Sensor harness connector and the PCM C1 harness connector.
Is the resistance below 5.0 Ohms?

Yes
• Go To 8

No
• Repair the (K1791) Fuel Rail Pressure Sensor Signal 2 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).

8. CHECK THE (K180) SENSOR RETURN FOR AN OPEN/HIGH RESISTANCE
1. Measure the resistance of the (K180) Sensor Return circuit between the FRP Sensor harness connector and the PCM C1 harness connector.
Is the resistance below 5.0 Ohms?

Yes
• Go To 9

No
• Repair the (K180) 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).

9. CHECK THE FUEL RAIL PRESSURE SENSOR
1. Turn the ignition off.
2. Reconnect the PCM C1 harness connector.
3. Reconnect the FRP Sensor harness connector.
4. Turn the ignition on.
5. With the scan tool, erase DTCs.
6. While monitoring scan tool, connect a jumper between the (K181) FRP Sensor Signal 1 circuit and the
(K180) Sensor Return circuit at the FRP Sensor harness connector. Does the DTC P0192 set?

Yes
• 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).

No
• Go To 10

10. 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).

Theory of Operation

The Powertrain Control Module (PCM) actuates the solenoid in the Fuel Injector causing the needle valve to rise and fuel flows through the spray holes in the nozzle tip into the combustion chamber. The PCM has a common internal driver circuit to all three Fuel Injectors on each bank. If any injector circuit on a given bank has a short to ground or a short to voltage, a DTC will be set for all three Fuel Injectors on that bank. Fuel Injectors 1,2,3 are grouped together on bank 1. Fuel Injectors 4,5,6 are grouped together on bank 2. The MIL will illuminate immediately after the diagnostic runs and fails twice. During this time the customer may experience engine surge or stumble. The MIL lamp will turn off once the diagnostic runs and passes in four consecutive drive cycles.

When Monitored:

Every 20 milliseconds when the ignition is on.

• Set Condition:

When the Fuel Injector current falls below a calibrated threshold.

Possible Causes

HIGH SIDE DRIVER CIRCUIT OPEN/HIGH RESISTANCE
LOW SIDE DRIVER CIRCUIT OPEN/HIGH RESISTANCE
HIGH SIDE DRIVER CIRCUIT SHORTED TO GROUND
LOW SIDE DRIVER CIRCUIT SHORTED TO GROUND
HIGH SIDE DRIVER CIRCUIT SHORTED TO VOLTAGE
LOW SIDE DRIVER CIRCUIT SHORTED TO VOLTAGE
DRIVER CIRCUITS SHORTED TOGETHER
VALVE COVER PASS THROUGH HARNESS
FUEL INJECTOR
POWERTRAIN CONTROL MODULE (PCM)– ONLY WHEN ALL INJECTOR WIRING TESTS GOOD AND
ALL 3 DTCS ON THE BANK ARE ACTIVE

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 check for active DTCs. Is the DTC active?

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 EACH FUEL INJECTOR CIRCUIT FOR AN OPEN/HIGH RESISTANCE
1. Turn the ignition off.
2. Disconnect the PCM C1 harness connector.
3. Measure the resistance between the:
• (K11) Fuel Injector 1 High Side Driver circuit and the (K611) Fuel Injector 1 Low Side Driver circuit at the PCM C1 harness connector.
• (K12) Fuel Injector 2 High Side Driver circuit and the (K612) Fuel Injector 2 Low Side Driver circuit at the PCM C1 harness connector.
• (K13) Fuel Injector 3 High Side Driver circuit and the (K613) Fuel Injector 3 Low Side Driver circuit at the PCM C1 harness connector.
NOTE: Be sure to zero out the Ohm meter prior to checking the Fuel Injector circuit. Resistance reading should be between 0-1 Ohm.
Is the resistance between 0-1 Ohm for each Fuel Injector circuit?

Yes
• Go To 3

No
• Go To 8

3. CHECK EACH FUEL INJECTOR CIRCUIT FOR A SHORT TO GROUND
1. Measure the resistance between ground and the:
(K11) Fuel Injector 1 High Side Driver circuit at the PCM C1 harness connector.
(K12) Fuel Injector 2 High Side Driver circuit at the PCM C1 harness connector.

(K13) Fuel Injector 3 High Side Driver circuit at the PCM C1 harness connector.
NOTE: There should be no continuity between the circuit and ground.

Is the resistance below 10k Ohms on any injector circuits?

Yes
• Go To 12

No
• Go To 4

4. CHECKING FOR INJECTOR CONTROL CIRCUITS SHORTED TOGETHER
1. Disconnect the valve cover pass through wires at each Bank 1 Fuel Injector terminal. NOTE: Do not disconnect the valve cover pass through harness from the engine harness.
2. At the PCM C1 harness connector, measure the resistance between ALL (Bank 1) Low AND High Side Control circuits: K11(High 1), K611(Low 1), K12(High 2), K612(Low 2), K13(High 3), and K613(Low 3).
Is the resistance below 10k ohms between any Injector Control circuits?

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

No
• Go To 5

5. ISOLATE CYLINDER 1 FUEL INJECTOR
1. Reconnect the PCM C1 harness connector to the PCM.
2. Leave the valve cover pass through wires disconnected at the Cylinder 1 Fuel Injector terminals.
3. Reconnect the valve cover pass through wires at the Cylinder 2 and 3 Fuel Injector terminals. NOTE: Torque the Injector terminal nuts to 8.8 in-lbs.

4. Place electrical tape on the ends of the disconnected valve cover pass through wires to prevent the Injector terminal nuts from coming in contact with each other or the engine block.
5. Place the valve cover on the engine. NOTE: It is not necessary to bolt the valve cover in place.
6. Ignition on, engine not running.
7. With the scan tool, erase all DTCs.
8. Start the engine and let idle for 1 minute.
9. Ignition on, engine not running.
10. With the scan tool, read DTCs. Are multiple bank 1 injector circuit DTCs (P0201, P0202, P0203) active?

Yes
• Go To 6

No
• Replace the Cylinder 1 Fuel Injector in accordance with the Service Information.(Refer to 14 - Fuel System/Fuel Inspection/INJECTOR(S) , Fuel/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

6. ISOLATE CYLINDER 2 FUEL INJECTOR
1. Reconnect the valve cover pass through wires at the Cylinder 1 Fuel Injector terminals. NOTE: Torque the Injector terminal nuts to 8.8 in-lbs.
2. Disconnect the valve cover pass through wires at the Cylinder 2 Fuel Injector terminals.
3. Place electrical tape on the ends of the disconnected valve cover pass through wires to prevent the injector terminal nuts from coming in contact with each other or the engine block.
4. Place the valve cover on the engine. NOTE: It is not necessary to bolt the valve cover in place.
5. Ignition on, engine not running.
6. With the scan tool, erase all DTCs.
7. Start the engine and let idle for 1 minute.
8. Ignition on, engine not running.
9. With the scan tool, read DTCs. Are multiple bank 1 injector circuit DTCs (P0201, P0202, P0203) active?

Yes
• Go To 7

No
• Replace the Cylinder 2 Fuel Injector in accordance with the Service Information.(Refer to 14 - Fuel System/Fuel Inspection/INJECTOR(S) , Fuel/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

7. ISOLATE CYLINDER 3 FUEL INJECTOR
1. Reconnect the valve cover pass through wires at the cylinder 2 fuel injector terminals. NOTE: Torque the injector terminal nuts to 8.8 in-lbs.
2. Disconnect the valve cover pass through wires at the cylinder 3 fuel injector terminals.
3. Place electrical tape on the ends of the disconnected valve cover pass through wires to prevent the injector terminal nuts from coming in contact with each other or the engine block.
4. Place the valve cover on the engine. NOTE: It is not necessary to bolt the valve cover in place.
5. Ignition on, engine not running.
6. With the scan tool, erase all DTCs.
7. Start the engine and let idle for 1 minute.
8. Ignition on, engine not running.
9. With the scan tool, read DTCs.
Are multiple bank 1 injector circuit DTCs (P0201, P0202, P0203) active?

Yes
• 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).

No
• Replace the Cylinder 3 Fuel Injector in accordance with the Service Information.(Refer to 14 - Fuel System/Fuel Inspection/INJECTOR(S) , Fuel/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

8. CHECK THE VALVE COVER PASS THROUGH HARNESS CIRCUIT
NOTE: Perform the following tests on the Fuel Injector circuit which was faulty.
1. Disconnect the Valve Cover Pass Through harness connector.
2. Measure the resistance between the Low Side Driver circuit and the High Side Driver circuit at the Valve Cover Pass Through connector terminals.
NOTE: Be sure to zero the Ohm meter prior to checking the Fuel Injector circuit.
Is the resistance between 0-1 Ohm?

Yes
• Go To 9

No
• Go To 11

9. CHECK THE HIGH SIDE CIRCUIT IN ENGINE HARNESS
1. Measure the resistance of the High Side Driver circuit between the Valve Cover Pass Through harness connector and the PCM C1 harness connector.
NOTE: Be sure to zero the Ohm meter prior to checking the Fuel Injector circuit.
Is the resistance between 0-1 Ohm?

Yes
• Go To 10

No
• Repair the High Side Driver 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).

10. CHECK THE LOW SIDE CIRCUIT IN ENGINE HARNESS
1.Measure the resistance of the Low Side Driver circuit between the Valve Cover Pass Through harness connector and the PCM C1 harness connector.
NOTE: Be sure to zero the Ohm meter prior to checking the Fuel Injector circuit.
Is the resistance between 0-1 Ohm?

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

No
• Repair the Low Side Driver 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).

11. CHECK THE FUEL INJECTORS
1. Disconnect all bank 1 Fuel Injector wires at the Fuel Injectors.
2. Measure the resistance across the terminals at the Fuel Injector.
NOTE: Be sure to zero the Ohm meter prior to checking the Fuel Injector circuit.
Is the resistance between 0-1 Ohm?

Yes
• Replace the Valve Cover Pass Through harness.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

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

12. CHECK FOR THE DRIVER CIRCUITS SHORTED TOGETHER
1. Disconnect all bank 1 Fuel Injector wires at the Fuel Injectors.
2. Measure the resistance between all bank 1 Driver circuits at the PCM C1 harness connector.

Is the resistance below 10k Ohms between any circuits?

Yes
• Go To 13

No
• Go To 14

13. CHECK THE VALVE COVER PASS THROUGH HARNESS CIRCUIT
1. Disconnect the Valve Cover Pass Through harness connector.
2. Measure the resistance between all bank 1 Driver circuits of the Valve Cover Pass Through connector terminals.
Is the resistance below 10k Ohms between any circuits?

Yes
• Replace the Valve Cover Pass Through harness 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
• Repair the short between the bank 1 Driver circuits in the engine harness.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

14. CHECK THE HIGH SIDE DRIVER CIRCUIT FOR A SHORT TO GROUND
NOTE: Perform the following tests on the Fuel Injector circuit which was faulty.
1. Disconnect the Valve Cover Pass Through harness connector.
2. Measure the resistance between ground and the High Side Driver circuit at the PCM C1 harness connector.
Is the resistance below 10k Ohms?

Yes

• Repair the High Side Driver 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 15

15. CHECK THE LOW SIDE DRIVER CIRCUIT FOR A SHORT TO GROUND
1. Measure the resistance between ground and the Low Side Driver circuit at the PCM C1 harness connector.
Is the resistance below 10k Ohms?

Yes
• Repair the Low Side Driver 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 16
 

16. CHECK THE FUEL INJECTORS
1. Measure the resistance between ground and one of the Fuel Injector terminals.
Is the resistance below 10k Ohms?

Yes
• Replace the Fuel Injector 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
• Replace the Valve Cover Pass Through harness 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).

Theory of Operation

The Powertrain Control Module (PCM) actuates the solenoid in the Fuel Injector causing the needle valve to rise and fuel flows through the spray holes in the nozzle tip into the combustion chamber. The PCM has a common internal driver circuit to all three Fuel Injectors on each bank. If any injector circuit on a given bank has a short to ground or a short to voltage, a DTC will be set for all three Fuel Injectors on that bank. Fuel Injectors 1,2,3 are grouped together on bank 1. Fuel Injectors 4,5,6 are grouped together on bank 2. The MIL will illuminate immediately after the diagnostic runs and fails twice. During this time the customer may experience engine surge or stumble. The MIL lamp will turn off once the diagnostic runs and passes in four consecutive drive cycles.

When Monitored:

Every 20 milliseconds when the ignition is on.

Set Condition:

When the Fuel Injector current falls below a calibrated threshold.

Possible Causes

HIGH SIDE DRIVER CIRCUIT OPEN/HIGH RESISTANCE
LOW SIDE DRIVER CIRCUIT OPEN/HIGH RESISTANCE
HIGH SIDE DRIVER CIRCUIT SHORTED TO GROUND
LOW SIDE DRIVER CIRCUIT SHORTED TO GROUND
HIGH SIDE DRIVER CIRCUIT SHORTED TO VOLTAGE
LOW SIDE DRIVER CIRCUIT SHORTED TO VOLTAGE
DRIVER CIRCUITS SHORTED TOGETHER
VALVE COVER PASS THROUGH HARNESS
FUEL INJECTOR
POWERTRAIN CONTROL MODULE (PCM)– ONLY WHEN ALL INJECTOR WIRING TESTS GOOD AND
ALL 3 DTCS ON THE BANK ARE ACTIVE
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. With the scan tool check for active DTCs.
Is the DTC active?

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 EACH FUEL INJECTOR CIRCUIT FOR AN OPEN/HIGH RESISTANCE

1. Turn the ignition off.
2. Disconnect the PCM C1 harness connector.
3. Measure the resistance between the:
• (K11) Fuel Injector 1 High Side Driver circuit and the (K611) Fuel Injector 1 Low Side Driver circuit at the PCM C1 harness connector.
• (K12) Fuel Injector 2 High Side Driver circuit and the (K612) Fuel Injector 2 Low Side Driver circuit at the PCM C1 harness connector.
• (K13) Fuel Injector 3 High Side Driver circuit and the (K613) Fuel Injector 3 Low Side Driver circuit at the PCM C1 harness connector.
NOTE: Be sure to zero out the Ohm meter prior to checking the Fuel Injector circuit. Resistance reading should be between 0-1 Ohm.
Is the resistance between 0-1 Ohm for each Fuel Injector circuit?

Yes
• Go To 3

No
• Go To 8

3. CHECK EACH FUEL INJECTOR CIRCUIT FOR A SHORT TO GROUND

1. Measure the resistance between ground and the:
• (K11) Fuel Injector 1 High Side Driver circuit at the PCM C1 harness connector.
• (K12) Fuel Injector 2 High Side Driver circuit at the PCM C1 harness connector.

(K13) Fuel Injector 3 High Side Driver circuit at the PCM C1 harness connector.
NOTE: There should be no continuity between the circuit and ground.
Is the resistance below 10k Ohms on any injector circuits?

Yes
• Go To 12

No
• Go To 4

4. CHECKING FOR INJECTOR CONTROL CIRCUITS SHORTED TOGETHER
1. Disconnect the valve cover pass through wires at each Bank 1 Fuel Injector terminal.
NOTE: Do not disconnect the valve cover pass through harness from the engine harness.
2. At the PCM C1 harness connector, measure the resistance between ALL (Bank 1) Low AND High Side Control circuits: K11(High 1), K611(Low 1), K12(High 2), K612(Low 2), K13(High 3), and K613(Low 3).
Is the resistance below 10k ohms between any Injector Control circuits?

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

No
• Go To 5

5. ISOLATE CYLINDER 1 FUEL INJECTOR
1. Reconnect the PCM C1 harness connector to the PCM.
2. Leave the valve cover pass through wires disconnected at the Cylinder 1 Fuel Injector terminals.
3. Reconnect the valve cover pass through wires at the Cylinder 2 and 3 Fuel Injector terminals.
NOTE: Torque the Injector terminal nuts to 8.8 in-lbs.

4. Place electrical tape on the ends of the disconnected valve cover pass through wires to prevent the Injector terminal nuts from coming in contact with each other or the engine block.
5. Place the valve cover on the engine.
NOTE: It is not necessary to bolt the valve cover in place.
6. Ignition on, engine not running.
7. With the scan tool, erase all DTCs.
8. Start the engine and let idle for 1 minute.
9. Ignition on, engine not running.
10. With the scan tool, read DTCs.
Are multiple bank 1 injector circuit DTCs (P0201, P0202, P0203) active?

Yes
• Go To 6

No
• Replace the Cylinder 1 Fuel Injector in accordance with the Service Information.(Refer to 14 - Fuel System/Fuel Inspection/INJECTOR(S) , Fuel/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

6. ISOLATE CYLINDER 2 FUEL INJECTOR
1. Reconnect the valve cover pass through wires at the Cylinder 1 Fuel Injector terminals.
NOTE: Torque the Injector terminal nuts to 8.8 in-lbs.
2. Disconnect the valve cover pass through wires at the Cylinder 2 Fuel Injector terminals.
3. Place electrical tape on the ends of the disconnected valve cover pass through wires to prevent the
injector terminal nuts from coming in contact with each other or the engine block.
4. Place the valve cover on the engine.
NOTE: It is not necessary to bolt the valve cover in place.
5. Ignition on, engine not running.
6. With the scan tool, erase all DTCs.
7. Start the engine and let idle for 1 minute.
8. Ignition on, engine not running.
9. With the scan tool, read DTCs.
Are multiple bank 1 injector circuit DTCs (P0201, P0202, P0203) active?

Yes
• Go To 7

No
• Replace the Cylinder 2 Fuel Injector in accordance with the Service Information.(Refer to 14 - Fuel System/Fuel Inspection/INJECTOR(S) , Fuel/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

7. ISOLATE CYLINDER 3 FUEL INJECTOR

1. Reconnect the valve cover pass through wires at the cylinder 2 fuel injector terminals.
NOTE: Torque the injector terminal nuts to 8.8 in-lbs.
2. Disconnect the valve cover pass through wires at the cylinder 3 fuel injector terminals.
3. Place electrical tape on the ends of the disconnected valve cover pass through wires to prevent the injector terminal nuts from coming in contact with each other or the engine block.
4. Place the valve cover on the engine.
NOTE: It is not necessary to bolt the valve cover in place.
5. Ignition on, engine not running.
6. With the scan tool, erase all DTCs.
7. Start the engine and let idle for 1 minute.
8. Ignition on, engine not running.
9. With the scan tool, read DTCs.
Are multiple bank 1 injector circuit DTCs (P0201, P0202, P0203) active?

Yes
• 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).
 

No
• Replace the Cylinder 3 Fuel Injector in accordance with the Service Information.(Refer to 14 - Fuel
System/Fuel Inspection/INJECTOR(S) , Fuel/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based
Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

8. CHECK THE VALVE COVER PASS THROUGH HARNESS CIRCUIT

NOTE: Perform the following tests on the Fuel Injector circuit which was faulty.
1. Disconnect the Valve Cover Pass Through harness connector.
2. Measure the resistance between the Low Side Driver circuit and the High Side Driver circuit at the Valve
Cover Pass Through connector terminals.
NOTE: Be sure to zero the Ohm meter prior to checking the Fuel Injector circuit.
Is the resistance between 0-1 Ohm?

Yes
• Go To 9

No
• Go To 11

9. CHECK THE HIGH SIDE CIRCUIT IN ENGINE HARNESS
1. Measure the resistance of the High Side Driver circuit between the Valve Cover Pass Through harness
connector and the PCM C1 harness connector.
NOTE: Be sure to zero the Ohm meter prior to checking the Fuel Injector circuit.
Is the resistance between 0-1 Ohm?

Yes
• Go To 10

No
• Repair the High Side Driver 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).

10. CHECK THE LOW SIDE CIRCUIT IN ENGINE HARNESS

1.Measure the resistance of the Low Side Driver circuit between the Valve Cover Pass Through harness connector and the PCM C1 harness connector.
NOTE: Be sure to zero the Ohm meter prior to checking the Fuel Injector circuit.
Is the resistance between 0-1 Ohm?

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

No
• Repair the Low Side Driver 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).

11. CHECK THE FUEL INJECTORS
1. Disconnect all bank 1 Fuel Injector wires at the Fuel Injectors.
2. Measure the resistance across the terminals at the Fuel Injector.
NOTE: Be sure to zero the Ohm meter prior to checking the Fuel Injector circuit.
Is the resistance between 0-1 Ohm?

Yes
• Replace the Valve Cover Pass Through harness.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

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

12. CHECK FOR THE DRIVER CIRCUITS SHORTED TOGETHER

1. Disconnect all bank 1 Fuel Injector wires at the Fuel Injectors.
2. Measure the resistance between all bank 1 Driver circuits at the PCM C1 harness connector.

Is the resistance below 10k Ohms between any circuits?

Yes
• Go To 13

No
• Go To 14
 

13. CHECK THE VALVE COVER PASS THROUGH HARNESS CIRCUIT

1. Disconnect the Valve Cover Pass Through harness connector.
2. Measure the resistance between all bank 1 Driver circuits of the Valve Cover Pass Through connector terminals.
Is the resistance below 10k Ohms between any circuits?

Yes
• Replace the Valve Cover Pass Through harness 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
• Repair the short between the bank 1 Driver circuits in the engine harness.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

14. CHECK THE HIGH SIDE DRIVER CIRCUIT FOR A SHORT TO GROUND
NOTE: Perform the following tests on the Fuel Injector circuit which was faulty.
1. Disconnect the Valve Cover Pass Through harness connector.
2. Measure the resistance between ground and the High Side Driver circuit at the PCM C1 harness connector.
Is the resistance below 10k Ohms?

Yes

• Repair the High Side Driver 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 15

15. CHECK THE LOW SIDE DRIVER CIRCUIT FOR A SHORT TO GROUND

1. Measure the resistance between ground and the Low Side Driver circuit at the PCM C1 harness
connector.
Is the resistance below 10k Ohms?

Yes
• Repair the Low Side Driver circuit for a short to ground.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-BasedDiagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Go To 16

16. CHECK THE FUEL INJECTORS

1. Measure the resistance between ground and one of the Fuel Injector terminals.
Is the resistance below 10k Ohms?

Yes
• Replace the Fuel Injector 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
• Replace the Valve Cover Pass Through harness 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).

Theory of Operation

The Powertrain Control Module (PCM) actuates the solenoid in the Fuel Injector causing the needle valve to rise and fuel flows through the spray holes in the nozzle tip into the combustion chamber. The PCM has a common internal driver circuit to all three Fuel Injectors on each bank. If any injector circuit on a given bank has a short to ground or a short to voltage, a DTC will be set for all three Fuel Injectors on that bank. Fuel Injectors 1,2,3 are grouped together on bank 1. Fuel Injectors 4,5,6 are grouped together on bank 2. The MIL will illuminate immediately after the diagnostic runs and fails twice. During this time the customer may experience engine surge or stumble. The MIL lamp will turn off once the diagnostic runs and passes in four consecutive drive cycles.

When Monitored:

Every 20 milliseconds when the ignition is on.

Set Condition:

When the Fuel Injector current falls below a calibrated threshold.

Possible Causes

HIGH SIDE DRIVER CIRCUIT OPEN/HIGH RESISTANCE
LOW SIDE DRIVER CIRCUIT OPEN/HIGH RESISTANCE
HIGH SIDE DRIVER CIRCUIT SHORTED TO GROUND
LOW SIDE DRIVER CIRCUIT SHORTED TO GROUND
HIGH SIDE DRIVER CIRCUIT SHORTED TO VOLTAGE
LOW SIDE DRIVER CIRCUIT SHORTED TO VOLTAGE
DRIVER CIRCUITS SHORTED TOGETHER
VALVE COVER PASS THROUGH HARNESS
FUEL INJECTOR
POWERTRAIN CONTROL MODULE (PCM)– ONLY WHEN ALL INJECTOR WIRING TESTS GOOD AND
ALL 3 DTCS ON THE BANK ARE ACTIVE

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 check for active DTCs.
Is the DTC active?

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 EACH FUEL INJECTOR CIRCUIT FOR AN OPEN/HIGH RESISTANCE

1. Turn the ignition off.
2. Disconnect the PCM C1 harness connector.
3. Measure the resistance between the:
• (K11) Fuel Injector 1 High Side Driver circuit and the (K611) Fuel Injector 1 Low Side Driver circuit at the PCM C1 harness connector.
• (K12) Fuel Injector 2 High Side Driver circuit and the (K612) Fuel Injector 2 Low Side Driver circuit at the PCM C1 harness connector.
• (K13) Fuel Injector 3 High Side Driver circuit and the (K613) Fuel Injector 3 Low Side Driver circuit at the PCM C1 harness connector.
NOTE: Be sure to zero out the Ohm meter prior to checking the Fuel Injector circuit. Resistance reading should be between 0-1 Ohm.
Is the resistance between 0-1 Ohm for each Fuel Injector circuit?

Yes
• Go To 3

No
• Go To 8

3. CHECK EACH FUEL INJECTOR CIRCUIT FOR A SHORT TO GROUND

1. Measure the resistance between ground and the:
• (K11) Fuel Injector 1 High Side Driver circuit at the PCM C1 harness connector.
• (K12) Fuel Injector 2 High Side Driver circuit at the PCM C1 harness connector.

(K13) Fuel Injector 3 High Side Driver circuit at the PCM C1 harness connector.

NOTE: There should be no continuity between the circuit and ground.
Is the resistance below 10k Ohms on any injector circuits?

Yes
• Go To 12

No
• Go To 4

4. CHECKING FOR INJECTOR CONTROL CIRCUITS SHORTED TOGETHER

1. Disconnect the valve cover pass through wires at each Bank 1 Fuel Injector terminal.
NOTE: Do not disconnect the valve cover pass through harness from the engine harness.
2. At the PCM C1 harness connector, measure the resistance between ALL (Bank 1) Low AND High Side Control circuits: K11(High 1), K611(Low 1), K12(High 2), K612(Low 2), K13(High 3), and K613(Low 3).
Is the resistance below 10k ohms between any Injector Control circuits?

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

No
• Go To 5

5. ISOLATE CYLINDER 1 FUEL INJECTOR

1. Reconnect the PCM C1 harness connector to the PCM.
2. Leave the valve cover pass through wires disconnected at the Cylinder 1 Fuel Injector terminals.
3. Reconnect the valve cover pass through wires at the Cylinder 2 and 3 Fuel Injector terminals.
NOTE: Torque the Injector terminal nuts to 8.8 in-lbs.

4. Place electrical tape on the ends of the disconnected valve cover pass through wires to prevent the Injector terminal nuts from coming in contact with each other or the engine block.
5. Place the valve cover on the engine.
NOTE: It is not necessary to bolt the valve cover in place.
6. Ignition on, engine not running.
7. With the scan tool, erase all DTCs.
8. Start the engine and let idle for 1 minute.
9. Ignition on, engine not running.
10. With the scan tool, read DTCs.
Are multiple bank 1 injector circuit DTCs (P0201, P0202, P0203) active?

Yes
• Go To 6

No
• Replace the Cylinder 1 Fuel Injector in accordance with the Service Information.(Refer to 14 - Fuel System/Fuel Inspection/INJECTOR(S) , Fuel/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

6. ISOLATE CYLINDER 2 FUEL INJECTOR

1. Reconnect the valve cover pass through wires at the Cylinder 1 Fuel Injector terminals.
NOTE: Torque the Injector terminal nuts to 8.8 in-lbs.
2. Disconnect the valve cover pass through wires at the Cylinder 2 Fuel Injector terminals.
3. Place electrical tape on the ends of the disconnected valve cover pass through wires to prevent the
injector terminal nuts from coming in contact with each other or the engine block.
4. Place the valve cover on the engine.
NOTE: It is not necessary to bolt the valve cover in place.
5. Ignition on, engine not running.
6. With the scan tool, erase all DTCs.
7. Start the engine and let idle for 1 minute.
8. Ignition on, engine not running.
9. With the scan tool, read DTCs.
Are multiple bank 1 injector circuit DTCs (P0201, P0202, P0203) active?

Yes
• Go To 7

No
• Replace the Cylinder 2 Fuel Injector in accordance with the Service Information.(Refer to 14 - FuelSystem/Fuel Inspection/INJECTOR(S) , Fuel/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

7. ISOLATE CYLINDER 3 FUEL INJECTOR

1. Reconnect the valve cover pass through wires at the cylinder 2 fuel injector terminals.
NOTE: Torque the injector terminal nuts to 8.8 in-lbs.
2. Disconnect the valve cover pass through wires at the cylinder 3 fuel injector terminals.
3. Place electrical tape on the ends of the disconnected valve cover pass through wires to prevent the injector terminal nuts from coming in contact with each other or the engine block.
4. Place the valve cover on the engine.
NOTE: It is not necessary to bolt the valve cover in place.
5. Ignition on, engine not running.
6. With the scan tool, erase all DTCs.
7. Start the engine and let idle for 1 minute.
8. Ignition on, engine not running.
9. With the scan tool, read DTCs.
Are multiple bank 1 injector circuit DTCs (P0201, P0202, P0203) active?

Yes
• 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).

No
• Replace the Cylinder 3 Fuel Injector in accordance with the Service Information.(Refer to 14 - Fuel System/Fuel Inspection/INJECTOR(S) , Fuel/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

8. CHECK THE VALVE COVER PASS THROUGH HARNESS CIRCUIT

NOTE: Perform the following tests on the Fuel Injector circuit which was faulty.
1. Disconnect the Valve Cover Pass Through harness connector.
2. Measure the resistance between the Low Side Driver circuit and the High Side Driver circuit at the Valve
Cover Pass Through connector terminals.
NOTE: Be sure to zero the Ohm meter prior to checking the Fuel Injector circuit.
Is the resistance between 0-1 Ohm?

Yes
• Go To 9

No
• Go To 11

9. CHECK THE HIGH SIDE CIRCUIT IN ENGINE HARNESS

1. Measure the resistance of the High Side Driver circuit between the Valve Cover Pass Through harness connector and the PCM C1 harness connector.
NOTE: Be sure to zero the Ohm meter prior to checking the Fuel Injector circuit.
Is the resistance between 0-1 Ohm?

Yes
• Go To 10

No
• Repair the High Side Driver 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).

10. CHECK THE LOW SIDE CIRCUIT IN ENGINE HARNESS

1.Measure the resistance of the Low Side Driver circuit between the Valve Cover Pass Through harness
connector and the PCM C1 harness connector.
NOTE: Be sure to zero the Ohm meter prior to checking the Fuel Injector circuit.
Is the resistance between 0-1 Ohm?

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

No
• Repair the Low Side Driver 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).

11. CHECK THE FUEL INJECTORS

1. Disconnect all bank 1 Fuel Injector wires at the Fuel Injectors.
2. Measure the resistance across the terminals at the Fuel Injector.
NOTE: Be sure to zero the Ohm meter prior to checking the Fuel Injector circuit.
Is the resistance between 0-1 Ohm?

Yes
• Replace the Valve Cover Pass Through harness.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based
Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

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

12. CHECK FOR THE DRIVER CIRCUITS SHORTED TOGETHER

1. Disconnect all bank 1 Fuel Injector wires at the Fuel Injectors.
2. Measure the resistance between all bank 1 Driver circuits at the PCM C1 harness connector.

Is the resistance below 10k Ohms between any circuits?

Yes
• Go To 13

No
• Go To 14

13. CHECK THE VALVE COVER PASS THROUGH HARNESS CIRCUIT
1. Disconnect the Valve Cover Pass Through harness connector.
2. Measure the resistance between all bank 1 Driver circuits of the Valve Cover Pass Through connector terminals.
Is the resistance below 10k Ohms between any circuits?

Yes
• Replace the Valve Cover Pass Through harness 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
• Repair the short between the bank 1 Driver circuits in the engine harness.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

14. CHECK THE HIGH SIDE DRIVER CIRCUIT FOR A SHORT TO GROUND

NOTE: Perform the following tests on the Fuel Injector circuit which was faulty.
1. Disconnect the Valve Cover Pass Through harness connector.
2. Measure the resistance between ground and the High Side Driver circuit at the PCM C1 harness connector.
Is the resistance below 10k Ohms?

Yes

• Repair the High Side Driver 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 15

15. CHECK THE LOW SIDE DRIVER CIRCUIT FOR A SHORT TO GROUND
1. Measure the resistance between ground and the Low Side Driver circuit at the PCM C1 harness connector.
Is the resistance below 10k Ohms?

Yes
• Repair the Low Side Driver 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 16

16. CHECK THE FUEL INJECTORS

1. Measure the resistance between ground and one of the Fuel Injector terminals. Is the resistance below 10k Ohms?

Yes
• Replace the Fuel Injector 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
• Replace the Valve Cover Pass Through harness 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).

Theory of Operation

The Powertrain Control Module (PCM) actuates the solenoid in the Fuel Injector causing the needle valve to rise and fuel flows through the spray holes in the nozzle tip into the combustion chamber. The PCM has a common internal driver circuit to all three Fuel Injectors on each bank. If any injector circuit on a given bank has a short to ground or a short to voltage, a DTC will be set for all three Fuel Injectors on that bank. Fuel Injectors 1,2,3 are grouped together on bank 1. Fuel Injectors 4,5,6 are grouped together on bank 2. The MIL will illuminate immediately after the diagnostic runs and fails twice. During this time the customer may experience engine surge or stumble. The MIL lamp will turn off once the diagnostic runs and passes in four consecutive drive cycles.

When Monitored:

Every 20 milliseconds when the ignition is on.

Set Condition:

When the Fuel Injector current falls below a calibrated threshold.

Possible Causes

HIGH SIDE DRIVER CIRCUIT OPEN/HIGH RESISTANCE
LOW SIDE DRIVER CIRCUIT OPEN/HIGH RESISTANCE
HIGH SIDE DRIVER CIRCUIT SHORTED TO GROUND
LOW SIDE DRIVER CIRCUIT SHORTED TO GROUND
HIGH SIDE DRIVER CIRCUIT SHORTED TO VOLTAGE
LOW SIDE DRIVER CIRCUIT SHORTED TO VOLTAGE
DRIVER CIRCUITS SHORTED TOGETHER
VALVE COVER PASS THROUGH HARNESS
FUEL INJECTOR
POWERTRAIN CONTROL MODULE (PCM)– ONLY WHEN ALL INJECTOR WIRING TESTS GOOD AND
ALL 3 DTCS ON THE BANK ARE ACTIVE
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 check for active DTCs.
Is the DTC active?

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 EACH FUEL INJECTOR CIRCUIT FOR AN OPEN/HIGH RESISTANCE

1. Turn the ignition off.
2. Disconnect the PCM C1 harness connector.
3. Measure the resistance between the:
• (K614) Fuel Injector 4 High Side Driver circuit and the (K14) Fuel Injector 4 Low Side Driver circuit at the PCM C1 harness connector.
• (K38) Fuel Injector 5 High Side Driver circuit and the (K638) Fuel Injector 5 Low Side Driver circuit at the PCM C1 harness connector.
• (K658) Fuel Injector 6 High Side Driver circuit and the (K58) Fuel Injector 6 Low Side Driver circuit at the PCM C1 harness connector.
NOTE: Be sure to zero out the Ohm meter prior to checking the Fuel Injector circuit. Resistance reading should be between 0-1 Ohm.
Is the resistance between 0-1 Ohm for each Fuel Injector circuit?

Yes
• Go To 3

No
• Go To 8

3. CHECK EACH FUEL INJECTOR CIRCUIT FOR A SHORT TO GROUND

1. Measure the resistance between ground and the:
• (K614) Fuel Injector 4 High Side Driver circuit at the PCM C1 harness connector.
• (K38) Fuel Injector 5 High Side Driver circuit at the PCM C1 harness connector.

• (K658) Fuel Injector 6 High Side Driver circuit at the PCM C1 harness connector.
NOTE: There should be no continuity between the circuit and ground.
Is the resistance below 10k Ohms on any injector circuits?

Yes
• Go To 12

No
• Go To 4

4. CHECKING FOR INJECTOR CONTROL CIRCUITS SHORTED TOGETHER

1. Disconnect the valve cover pass through wires at each Bank 2 Fuel Injector terminal.
NOTE: Do not disconnect the valve cover pass through harness from the engine harness.
2. At the PCM C1 harness connector, measure the resistance between ALL (Bank 2) Low AND High Side Control circuits: K614(High 4), K14(Low 4), K38(High 5), K638(Low 5), K658(High 6), and K58(Low 6).
Is the resistance below 10k ohms between any Injector Control circuits?

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

No
• Go To 5

5. ISOLATE CYLINDER 4 FUEL INJECTOR

1. Reconnect the PCM C1 harness connector to the PCM.
2. Leave the valve cover pass through wires disconnected at the Cylinder 4 Fuel Injector terminals.
3. Reconnect the valve cover pass through wires at the Cylinder 5 and 6 Fuel Injector terminals.
NOTE: Torque the Injector terminal nuts to 8.8 in-lbs.

4. Place electrical tape on the ends of the disconnected valve cover pass through wires to prevent the Injector terminal nuts from coming in contact with each other or the engine block.
5. Place the valve cover on the engine.
NOTE: It is not necessary to bolt the valve cover in place.
6. Ignition on, engine not running.
7. With the scan tool, erase all DTCs.
8. Start the engine and let idle for 1 minute.
9. Ignition on, engine not running.
10. With the scan tool, read DTCs.
Are multiple bank 2 injector circuit DTCs (P0204, P0205, P0206) active?

Yes
• Go To 6

No
• Replace the Cylinder 4 Fuel Injector in accordance with the Service Information.(Refer to 14 - Fuel System/Fuel Inspection/INJECTOR(S) , Fuel/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

6. ISOLATE CYLINDER 5 FUEL INJECTOR

1. Reconnect the valve cover pass through wires at the Cylinder 4 Fuel Injector terminals.
NOTE: Torque the Injector terminal nuts to 8.8 in-lbs.
2. Disconnect the valve cover pass through wires at the Cylinder 5 Fuel Injector terminals.
3. Place electrical tape on the ends of the disconnected valve cover pass through wires to prevent the injector terminal nuts from coming in contact with each other or the engine block.
4. Place the valve cover on the engine.
NOTE: It is not necessary to bolt the valve cover in place.
5. Ignition on, engine not running.
6. With the scan tool, erase all DTCs.
7. Start the engine and let idle for 1 minute.
8. Ignition on, engine not running.
9. With the scan tool, read DTCs.
Are multiple bank 2 injector circuit DTCs (P0204, P0205, P0206) active?

Yes
• Go To 7

No
• Replace the Cylinder 5 Fuel Injector in accordance with the Service Information.(Refer to 14 - Fuel System/Fuel Inspection/INJECTOR(S) , Fuel/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

7. ISOLATE CYLINDER 6 FUEL INJECTOR

1. Reconnect the valve cover pass through wires at the cylinder 5 fuel injector terminals.

NOTE: Torque the injector terminal nuts to 8.8 in-lbs.
2. Disconnect the valve cover pass through wires at the cylinder 6 fuel injector terminals.
3. Place electrical tape on the ends of the disconnected valve cover pass through wires to prevent the injector terminal nuts from coming in contact with each other or the engine block.
4. Place the valve cover on the engine.
NOTE: It is not necessary to bolt the valve cover in place.
5. Ignition on, engine not running.
6. With the scan tool, erase all DTCs.
7. Start the engine and let idle for 1 minute.
8. Ignition on, engine not running.
9. With the scan tool, read DTCs.
Are multiple bank 2 injector circuit DTCs (P0204, P0205, P0206) active?

Yes
• 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).

No
• Replace the Cylinder 6 Fuel Injector in accordance with the Service Information.(Refer to 14 - Fuel System/Fuel Inspection/INJECTOR(S) , Fuel/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

8. CHECK THE VALVE COVER PASS THROUGH HARNESS CIRCUIT

NOTE: Perform the following tests on the Fuel Injector circuit which was faulty.
1. Disconnect the Valve Cover Pass Through harness connector.
2. Measure the resistance between the Low Side Driver circuit and the High Side Driver circuit at the Valve Cover Pass Through connector terminals.
NOTE: Be sure to zero the Ohm meter prior to checking the Fuel Injector circuit.
Is the resistance between 0-1 Ohm?

Yes
• Go To 9

No
• Go To 11

9. CHECK THE HIGH SIDE CIRCUITS IN ENGINE HARNESS

1. Measure the resistance of the High Side Driver circuit between the Valve Cover Pass Through harness connector and the PCM C1 harness connector.
NOTE: Be sure to zero the Ohm meter prior to checking the Fuel Injector circuit. Is the resistance between 0-1 Ohm?

Yes
• Go To 10

No
• Repair the High Side Driver 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).

10. CHECK THE LOW SIDE CIRCUITS IN ENGINE HARNESS

1. Measure the resistance of the Low Side Driver circuit between the Valve Cover Pass Through harness connector and the PCM C1 harness connector.

NOTE: Be sure to zero the Ohm meter prior to checking the Fuel Injector circuit.
Is the resistance between 0-1 Ohm?

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

No
• Repair the Low Side Driver 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).

11. CHECK FUEL INJECTORS

1. Disconnect all bank 2 Fuel Injector wires at the Fuel Injectors.
2. Measure the resistance across the terminals at the Fuel Injector.
NOTE: Be sure to zero the Ohm meter prior to checking the Fuel Injector circuit.
Is the resistance between 0-1 Ohm?

Yes
• Replace the Valve Cover Pass Through harness 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
• Replace the Fuel Injector in accordance with the Service Information.(Refer to 14 - Fuel System/Fuel Inspection/INJECTOR(S) , Fuel/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

12. CHECK FOR THE DRIVER CIRCUITS SHORTED TOGETHER

1. Disconnect all bank 2 Fuel Injector wires at the Fuel Injectors.
2. Measure the resistance between all bank 2 Driver circuits at the PCM C1 harness connector. Is the resistance below 10k Ohms between any circuits?

Yes
• Go To 13

No
• Go To 14

13. CHECK THE VALVE COVER PASS THROUGH HARNESS CIRCUITS

1. Disconnect the Valve Cover Pass Through harness connector.
2. Measure the resistance between all bank 2 Driver circuits of the Valve Cover Pass Through connector terminals.
Is the resistance below 10k Ohms between any circuits?

Yes
• Replace the Valve Cover Pass Through harness 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
• Repair the short between the bank 2 Driver circuits in the engine harness.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

14. CHECK THE HIGH SIDE DRIVER CIRCUIT FOR A SHORT TO GROUND

NOTE: Perform the following tests on the Fuel Injector circuit which was faulty.
1. Disconnect the Valve Cover Pass Through harness connector .
2. Measure the resistance between ground and the High Side Driver circuit at the PCM C1 connector.
Is the resistance below 10k Ohms?

Yes
• Repair the High Side Driver 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 15

15. CHECK THE LOW SIDE DRIVER CIRCUIT FOR A SHORT TO GROUND

1. Measure the resistance between ground and the Low Side Driver circuit at the PCM C1 connector.
Is the resistance below 10k Ohms?

Yes
• Repair the Low Side Driver 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 16

16. CHECK THE FUEL INJECTORS
1. Measure the resistance between ground and one of the Fuel Injector terminals.
Is the resistance below 10k Ohms?

Yes
• Replace the Fuel Injector in accordance with the Service Information.(Refer to 14 - Fuel System/Fuel
Inspection/INJECTOR(S) , Fuel/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Replace the Valve Cover Pass Through harness 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).

Theory of Operation

The Powertrain Control Module (PCM) actuates the solenoid in the Fuel Injector causing the needle valve to rise and fuel flows through the spray holes in the nozzle tip into the combustion chamber. The PCM has a common internal driver circuit to all three Fuel Injectors on each bank. If any injector circuit on a given bank has a short to ground or a short to voltage, a DTC will be set for all three Fuel Injectors on that bank. Fuel Injectors 1,2,3 are grouped together on bank 1. Fuel Injectors 4,5,6 are grouped together on bank 2. The MIL will illuminate immediately after the diagnostic runs and fails twice. During this time the customer may experience engine surge or stumble. The MIL lamp will turn off once the diagnostic runs and passes in four consecutive drive cycles.

When Monitored:

Every 20 milliseconds when the ignition is on.

Set Condition:

When the Fuel Injector current falls below a calibrated threshold.

Possible Causes

HIGH SIDE DRIVER CIRCUIT OPEN/HIGH RESISTANCE
LOW SIDE DRIVER CIRCUIT OPEN/HIGH RESISTANCE
HIGH SIDE DRIVER CIRCUIT SHORTED TO GROUND
LOW SIDE DRIVER CIRCUIT SHORTED TO GROUND
HIGH SIDE DRIVER CIRCUIT SHORTED TO VOLTAGE
LOW SIDE DRIVER CIRCUIT SHORTED TO VOLTAGE
DRIVER CIRCUITS SHORTED TOGETHER
VALVE COVER PASS THROUGH HARNESS
FUEL INJECTOR
POWERTRAIN CONTROL MODULE (PCM)– ONLY WHEN ALL INJECTOR WIRING TESTS GOOD AND
ALL 3 DTCS ON THE BANK ARE ACTIVE

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 check for active DTCs.
Is the DTC active?

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 EACH FUEL INJECTOR CIRCUIT FOR AN OPEN/HIGH RESISTANCE

1. Turn the ignition off.
2. Disconnect the PCM C1 harness connector.
3. Measure the resistance between the:
• (K614) Fuel Injector 4 High Side Driver circuit and the (K14) Fuel Injector 4 Low Side Driver circuit at the PCM C1 harness connector.
• (K38) Fuel Injector 5 High Side Driver circuit and the (K638) Fuel Injector 5 Low Side Driver circuit at the PCM C1 harness connector.
• (K658) Fuel Injector 6 High Side Driver circuit and the (K58) Fuel Injector 6 Low Side Driver circuit at the PCM C1 harness connector.
NOTE: Be sure to zero out the Ohm meter prior to checking the Fuel Injector circuit. Resistance reading should be between 0-1 Ohm.
Is the resistance between 0-1 Ohm for each Fuel Injector circuit?

Yes
• Go To 3

No
• Go To 8

3. CHECK EACH FUEL INJECTOR CIRCUIT FOR A SHORT TO GROUND
1. Measure the resistance between ground and the:
• (K614) Fuel Injector 4 High Side Driver circuit at the PCM C1 harness connector.
• (K38) Fuel Injector 5 High Side Driver circuit at the PCM C1 harness connector.

• (K658) Fuel Injector 6 High Side Driver circuit at the PCM C1 harness connector.
NOTE: There should be no continuity between the circuit and ground.
Is the resistance below 10k Ohms on any injector circuits?

Yes
• Go To 12

No
• Go To 4

4. CHECKING FOR INJECTOR CONTROL CIRCUITS SHORTED TOGETHER

1. Disconnect the valve cover pass through wires at each Bank 2 Fuel Injector terminal.
NOTE: Do not disconnect the valve cover pass through harness from the engine harness.
2. At the PCM C1 harness connector, measure the resistance between ALL (Bank 2) Low AND High Side Control circuits: K614(High 4), K14(Low 4), K38(High 5), K638(Low 5), K658(High 6), and K58(Low 6).

Is the resistance below 10k ohms between any Injector Control circuits?

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

No
• Go To 5

5. ISOLATE CYLINDER 4 FUEL INJECTOR

1. Reconnect the PCM C1 harness connector to the PCM.
2. Leave the valve cover pass through wires disconnected at the Cylinder 4 Fuel Injector terminals.
3. Reconnect the valve cover pass through wires at the Cylinder 5 and 6 Fuel Injector terminals.
NOTE: Torque the Injector terminal nuts to 8.8 in-lbs.

4. Place electrical tape on the ends of the disconnected valve cover pass through wires to prevent the Injector terminal nuts from coming in contact with each other or the engine block.
5. Place the valve cover on the engine.
NOTE: It is not necessary to bolt the valve cover in place.
6. Ignition on, engine not running.
7. With the scan tool, erase all DTCs.
8. Start the engine and let idle for 1 minute.
9. Ignition on, engine not running.
10. With the scan tool, read DTCs.
Are multiple bank 2 injector circuit DTCs (P0204, P0205, P0206) active?

Yes
• Go To 6

No
• Replace the Cylinder 4 Fuel Injector in accordance with the Service Information.(Refer to 14 - Fuel System/Fuel Inspection/INJECTOR(S) , Fuel/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

6. ISOLATE CYLINDER 5 FUEL INJECTOR

1. Reconnect the valve cover pass through wires at the Cylinder 4 Fuel Injector terminals.
NOTE: Torque the Injector terminal nuts to 8.8 in-lbs.
2. Disconnect the valve cover pass through wires at the Cylinder 5 Fuel Injector terminals.
3. Place electrical tape on the ends of the disconnected valve cover pass through wires to prevent the injector terminal nuts from coming in contact with each other or the engine block.
4. Place the valve cover on the engine.
NOTE: It is not necessary to bolt the valve cover in place.
5. Ignition on, engine not running.
6. With the scan tool, erase all DTCs.
7. Start the engine and let idle for 1 minute.
8. Ignition on, engine not running.
9. With the scan tool, read DTCs.
Are multiple bank 2 injector circuit DTCs (P0204, P0205, P0206) active?

Yes
• Go To 7

No
• Replace the Cylinder 5 Fuel Injector in accordance with the Service Information.(Refer to 14 - Fuel System/Fuel Inspection/INJECTOR(S) , Fuel/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

7. ISOLATE CYLINDER 6 FUEL INJECTOR

1. Reconnect the valve cover pass through wires at the cylinder 5 fuel injector terminals.
NOTE: Torque the injector terminal nuts to 8.8 in-lbs.
2. Disconnect the valve cover pass through wires at the cylinder 6 fuel injector terminals.
3. Place electrical tape on the ends of the disconnected valve cover pass through wires to prevent the injector terminal nuts from coming in contact with each other or the engine block.
4. Place the valve cover on the engine.
NOTE: It is not necessary to bolt the valve cover in place.
5. Ignition on, engine not running.
6. With the scan tool, erase all DTCs.
7. Start the engine and let idle for 1 minute.
8. Ignition on, engine not running.
9. With the scan tool, read DTCs.
Are multiple bank 2 injector circuit DTCs (P0204, P0205, P0206) active?

Yes
• 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).

No
• Replace the Cylinder 6 Fuel Injector in accordance with the Service Information.(Refer to 14 - Fuel System/Fuel Inspection/INJECTOR(S) , Fuel/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

8. CHECK THE VALVE COVER PASS THROUGH HARNESS CIRCUIT

NOTE: Perform the following tests on the Fuel Injector circuit which was faulty.
1. Disconnect the Valve Cover Pass Through harness connector.
2. Measure the resistance between the Low Side Driver circuit and the High Side Driver circuit at the Valve Cover Pass Through connector terminals.
NOTE: Be sure to zero the Ohm meter prior to checking the Fuel Injector circuit.
Is the resistance between 0-1 Ohm?

Yes
• Go To 9

No
• Go To 11

9. CHECK THE HIGH SIDE CIRCUITS IN ENGINE HARNESS

1. Measure the resistance of the High Side Driver circuit between the Valve Cover Pass Through harness
connector and the PCM C1 harness connector.
NOTE: Be sure to zero the Ohm meter prior to checking the Fuel Injector circuit.
Is the resistance between 0-1 Ohm?

Yes
• Go To 10

No
• Repair the High Side Driver 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).

10. CHECK THE LOW SIDE CIRCUITS IN ENGINE HARNESS

1. Measure the resistance of the Low Side Driver circuit between the Valve Cover Pass Through harness connector and the PCM C1 harness connector.

NOTE: Be sure to zero the Ohm meter prior to checking the Fuel Injector circuit.
Is the resistance between 0-1 Ohm?

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

No
• Repair the Low Side Driver 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).

11. CHECK FUEL INJECTORS

1. Disconnect all bank 2 Fuel Injector wires at the Fuel Injectors.
2. Measure the resistance across the terminals at the Fuel Injector.
NOTE: Be sure to zero the Ohm meter prior to checking the Fuel Injector circuit.
Is the resistance between 0-1 Ohm?

Yes
• Replace the Valve Cover Pass Through harness 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
• Replace the Fuel Injector in accordance with the Service Information.(Refer to 14 - Fuel System/Fuel Inspection/INJECTOR(S) , Fuel/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

12. CHECK FOR THE DRIVER CIRCUITS SHORTED TOGETHER
1. Disconnect all bank 2 Fuel Injector wires at the Fuel Injectors.
2. Measure the resistance between all bank 2 Driver circuits at the PCM C1 harness connector.

Is the resistance below 10k Ohms between any circuits?

Yes
• Go To 13

No
• Go To 14

13. CHECK THE VALVE COVER PASS THROUGH HARNESS CIRCUITS

1. Disconnect the Valve Cover Pass Through harness connector.
2. Measure the resistance between all bank 2 Driver circuits of the Valve Cover Pass Through connector terminals.
Is the resistance below 10k Ohms between any circuits?

Yes
• Replace the Valve Cover Pass Through harness 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
• Repair the short between the bank 2 Driver circuits in the engine harness.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

14. CHECK THE HIGH SIDE DRIVER CIRCUIT FOR A SHORT TO GROUND

NOTE: Perform the following tests on the Fuel Injector circuit which was faulty.
1. Disconnect the Valve Cover Pass Through harness connector .
2. Measure the resistance between ground and the High Side Driver circuit at the PCM C1 connector.
Is the resistance below 10k Ohms?

Yes
• Repair the High Side Driver 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 15

15. CHECK THE LOW SIDE DRIVER CIRCUIT FOR A SHORT TO GROUND
1. Measure the resistance between ground and the Low Side Driver circuit at the PCM C1 connector.
Is the resistance below 10k Ohms?

Yes
• Repair the Low Side Driver 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 16

16. CHECK THE FUEL INJECTORS
1. Measure the resistance between ground and one of the Fuel Injector terminals.
Is the resistance below 10k Ohms?

Yes
• Replace the Fuel Injector in accordance with the Service Information.(Refer to 14 - Fuel System/Fuel Inspection/INJECTOR(S) , Fuel/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Replace the Valve Cover Pass Through harness 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).

Theory of Operation

The Powertrain Control Module (PCM) actuates the solenoid in the Fuel Injector causing the needle valve to rise and fuel flows through the spray holes in the nozzle tip into the combustion chamber. The PCM has a common internal driver circuit to all three Fuel Injectors on each bank. If any injector circuit on a given bank has a short to ground or a short to voltage, a DTC will be set for all three Fuel Injectors on that bank. Fuel Injectors 1,2,3 are grouped together on bank 1. Fuel Injectors 4,5,6 are grouped together on bank 2. The MIL will illuminate immediately after the diagnostic runs and fails twice. During this time the customer may experience engine surge or stumble. The MIL lamp will turn off once the diagnostic runs and passes in four consecutive drive cycles.

When Monitored:

Every 20 milliseconds when the ignition is on.

Set Condition:

When the Fuel Injector current falls below a calibrated threshold.

Possible Causes

HIGH SIDE DRIVER CIRCUIT OPEN/HIGH RESISTANCE
LOW SIDE DRIVER CIRCUIT OPEN/HIGH RESISTANCE
HIGH SIDE DRIVER CIRCUIT SHORTED TO GROUND
LOW SIDE DRIVER CIRCUIT SHORTED TO GROUND
HIGH SIDE DRIVER CIRCUIT SHORTED TO VOLTAGE
LOW SIDE DRIVER CIRCUIT SHORTED TO VOLTAGE
DRIVER CIRCUITS SHORTED TOGETHER
VALVE COVER PASS THROUGH HARNESS
FUEL INJECTOR
POWERTRAIN CONTROL MODULE (PCM)– ONLY WHEN ALL INJECTOR WIRING TESTS GOOD AND
ALL 3 DTCS ON THE BANK ARE ACTIVE

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 check for active DTCs.
Is the DTC active?

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 EACH FUEL INJECTOR CIRCUIT FOR AN OPEN/HIGH RESISTANCE

1. Turn the ignition off.
2. Disconnect the PCM C1 harness connector.
3. Measure the resistance between the:
• (K614) Fuel Injector 4 High Side Driver circuit and the (K14) Fuel Injector 4 Low Side Driver circuit at the PCM C1 harness connector.
• (K38) Fuel Injector 5 High Side Driver circuit and the (K638) Fuel Injector 5 Low Side Driver circuit at the PCM C1 harness connector.
• (K658) Fuel Injector 6 High Side Driver circuit and the (K58) Fuel Injector 6 Low Side Driver circuit at the PCM C1 harness connector.
NOTE: Be sure to zero out the Ohm meter prior to checking the Fuel Injector circuit. Resistance
reading should be between 0-1 Ohm.
Is the resistance between 0-1 Ohm for each Fuel Injector circuit?

Yes
• Go To 3

No
• Go To 8

3. CHECK EACH FUEL INJECTOR CIRCUIT FOR A SHORT TO GROUND

1. Measure the resistance between ground and the:
• (K614) Fuel Injector 4 High Side Driver circuit at the PCM C1 harness connector.
• (K38) Fuel Injector 5 High Side Driver circuit at the PCM C1 harness connector.

• (K658) Fuel Injector 6 High Side Driver circuit at the PCM C1 harness connector.
NOTE: There should be no continuity between the circuit and ground.
Is the resistance below 10k Ohms on any injector circuits?

Yes
• Go To 12

No
• Go To 4

4. CHECKING FOR INJECTOR CONTROL CIRCUITS SHORTED TOGETHER

1. Disconnect the valve cover pass through wires at each Bank 2 Fuel Injector terminal.
NOTE: Do not disconnect the valve cover pass through harness from the engine harness.
2. At the PCM C1 harness connector, measure the resistance between ALL (Bank 2) Low AND High Side
Control circuits: K614(High 4), K14(Low 4), K38(High 5), K638(Low 5), K658(High 6), and K58(Low 6).
Is the resistance below 10k ohms between any Injector Control circuits?

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

No
• Go To 5

5. ISOLATE CYLINDER 4 FUEL INJECTOR

1. Reconnect the PCM C1 harness connector to the PCM.
2. Leave the valve cover pass through wires disconnected at the Cylinder 4 Fuel Injector terminals.
3. Reconnect the valve cover pass through wires at the Cylinder 5 and 6 Fuel Injector terminals.
NOTE: Torque the Injector terminal nuts to 8.8 in-lbs.

4. Place electrical tape on the ends of the disconnected valve cover pass through wires to prevent the
Injector terminal nuts from coming in contact with each other or the engine block.
5. Place the valve cover on the engine.
NOTE: It is not necessary to bolt the valve cover in place.
6. Ignition on, engine not running.
7. With the scan tool, erase all DTCs.
8. Start the engine and let idle for 1 minute.
9. Ignition on, engine not running.
10. With the scan tool, read DTCs.
Are multiple bank 2 injector circuit DTCs (P0204, P0205, P0206) active?

Yes
• Go To 6

No
• Replace the Cylinder 4 Fuel Injector in accordance with the Service Information.(Refer to 14 - Fuel System/Fuel Inspection/INJECTOR(S) , Fuel/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

6. ISOLATE CYLINDER 5 FUEL INJECTOR

1. Reconnect the valve cover pass through wires at the Cylinder 4 Fuel Injector terminals.
NOTE: Torque the Injector terminal nuts to 8.8 in-lbs.
2. Disconnect the valve cover pass through wires at the Cylinder 5 Fuel Injector terminals.
3. Place electrical tape on the ends of the disconnected valve cover pass through wires to prevent the injector terminal nuts from coming in contact with each other or the engine block.
4. Place the valve cover on the engine.
NOTE: It is not necessary to bolt the valve cover in place.
5. Ignition on, engine not running.
6. With the scan tool, erase all DTCs.
7. Start the engine and let idle for 1 minute.
8. Ignition on, engine not running.
9. With the scan tool, read DTCs.
Are multiple bank 2 injector circuit DTCs (P0204, P0205, P0206) active?

Yes
• Go To 7

No
• Replace the Cylinder 5 Fuel Injector in accordance with the Service Information.(Refer to 14 - Fuel System/Fuel Inspection/INJECTOR(S) , Fuel/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

7. ISOLATE CYLINDER 6 FUEL INJECTOR

1. Reconnect the valve cover pass through wires at the cylinder 5 fuel injector terminals.
NOTE: Torque the injector terminal nuts to 8.8 in-lbs.
2. Disconnect the valve cover pass through wires at the cylinder 6 fuel injector terminals.
3. Place electrical tape on the ends of the disconnected valve cover pass through wires to prevent the
injector terminal nuts from coming in contact with each other or the engine block.
4. Place the valve cover on the engine.
NOTE: It is not necessary to bolt the valve cover in place.
5. Ignition on, engine not running.
6. With the scan tool, erase all DTCs.
7. Start the engine and let idle for 1 minute.
8. Ignition on, engine not running.
9. With the scan tool, read DTCs.
Are multiple bank 2 injector circuit DTCs (P0204, P0205, P0206) active?

Yes
• 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).

No
• Replace the Cylinder 6 Fuel Injector in accordance with the Service Information.(Refer to 14 - Fuel System/Fuel Inspection/INJECTOR(S) , Fuel/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

8. CHECK THE VALVE COVER PASS THROUGH HARNESS CIRCUIT

NOTE: Perform the following tests on the Fuel Injector circuit which was faulty.
1. Disconnect the Valve Cover Pass Through harness connector.
2. Measure the resistance between the Low Side Driver circuit and the High Side Driver circuit at the Valve Cover Pass Through connector terminals.
NOTE: Be sure to zero the Ohm meter prior to checking the Fuel Injector circuit.
Is the resistance between 0-1 Ohm?

Yes
• Go To 9

No
• Go To 11

9. CHECK THE HIGH SIDE CIRCUITS IN ENGINE HARNESS

1. Measure the resistance of the High Side Driver circuit between the Valve Cover Pass Through harness connector and the PCM C1 harness connector.
NOTE: Be sure to zero the Ohm meter prior to checking the Fuel Injector circuit.
Is the resistance between 0-1 Ohm?

Yes
• Go To 10

No
• Repair the High Side Driver 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).

10. CHECK THE LOW SIDE CIRCUITS IN ENGINE HARNESS

1. Measure the resistance of the Low Side Driver circuit between the Valve Cover Pass Through harness connector and the PCM C1 harness connector.

NOTE: Be sure to zero the Ohm meter prior to checking the Fuel Injector circuit.
Is the resistance between 0-1 Ohm?

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

No
• Repair the Low Side Driver 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).

11. CHECK FUEL INJECTORS

1. Disconnect all bank 2 Fuel Injector wires at the Fuel Injectors.
2. Measure the resistance across the terminals at the Fuel Injector.
NOTE: Be sure to zero the Ohm meter prior to checking the Fuel Injector circuit.
Is the resistance between 0-1 Ohm?

Yes
• Replace the Valve Cover Pass Through harness 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
• Replace the Fuel Injector in accordance with the Service Information.(Refer to 14 - Fuel System/Fuel Inspection/INJECTOR(S) , Fuel/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

12. CHECK FOR THE DRIVER CIRCUITS SHORTED TOGETHER

1. Disconnect all bank 2 Fuel Injector wires at the Fuel Injectors.
2. Measure the resistance between all bank 2 Driver circuits at the PCM C1 harness connector.

Is the resistance below 10k Ohms between any circuits?

Yes
• Go To 13

No
• Go To 14

13. CHECK THE VALVE COVER PASS THROUGH HARNESS CIRCUITS

1. Disconnect the Valve Cover Pass Through harness connector.
2. Measure the resistance between all bank 2 Driver circuits of the Valve Cover Pass Through connector terminals.
Is the resistance below 10k Ohms between any circuits?

Yes
• Replace the Valve Cover Pass Through harness 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
• Repair the short between the bank 2 Driver circuits in the engine harness.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

14. CHECK THE HIGH SIDE DRIVER CIRCUIT FOR A SHORT TO GROUND

NOTE: Perform the following tests on the Fuel Injector circuit which was faulty.
1. Disconnect the Valve Cover Pass Through harness connector .
2. Measure the resistance between ground and the High Side Driver circuit at the PCM C1 connector.
Is the resistance below 10k Ohms?

Yes
• Repair the High Side Driver 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 15

15. CHECK THE LOW SIDE DRIVER CIRCUIT FOR A SHORT TO GROUND

1. Measure the resistance between ground and the Low Side Driver circuit at the PCM C1 connector.
Is the resistance below 10k Ohms?

Yes
• Repair the Low Side Driver 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 16

16. CHECK THE FUEL INJECTORS

1. Measure the resistance between ground and one of the Fuel Injector terminals.
Is the resistance below 10k Ohms?

Yes
• Replace the Fuel Injector in accordance with the Service Information.(Refer to 14 - Fuel System/Fuel Inspection/INJECTOR(S) , Fuel/Removal)
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

No
• Replace the Valve Cover Pass Through harness 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).

Theory of Operation

The Coolant Temperature Sensor is a variable resistor sensor and is used to measure the temperature of the coolant of the engine. The PCM supplies 5-Volts to the Engine Coolant Temperature Sensor (ECT) Signal circuit. The PCM monitors the change in voltage caused by changes in the resistance of the sensor to determine the coolant temperature. The engine coolant temperature value is used by the PCM for the engine protection system and engine emissions control. The Engine Coolant Temperature Sensor is located near the thermostat housing. This fault becomes active when the PCM detects a coolant temperature higher than a calibrated limit for a calibrated amount of time. The PCM illuminates the MIL lamp after the diagnostic runs and fails once. During this time the customer may experience an engine power derate, and regeneration mode will be disabled. The PCM will turn off the MIL lamp after the diagnostic runs and passes in four consecutive drive cycles.

When Monitored:

While the engine is running.

Set Condition:

The engine coolant temperature is above a calibrated value for a calibrated amount of time.

Possible Causes

COOLING SYSTEM FAILURE
ECT SENSOR
MECHANICAL FAILURE

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

1. COOLING SYSTEM FAILURE

NOTE: If other cooling system DTCs are present, repair those DTCs before proceeding.

1. Check the engine cooling system operation. Refer to cooling, Diagnosis and Testing, Preliminary check.
(Refer to 07 - Cooling - Diagnosis and Testing) . Is the Cooling system operating normally?

Yes

Go To 2

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

2. CHECK THE ECT SENSOR

1. Allow the engine to reach normal operating temperature.
2. Use a temperature probe and measure the engine temperature near the ECT Sensor.
3. With the scan tool, read the Engine Coolant Temperature.
4. Compare the temperature probe reading with the scan tool reading.
Are the readings within 10°F of each other?

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

No
Replace the Engine Coolant Temperature Sensor in accordance with the Service Information.(Refer to 07 - Cooling/Engine/SENSOR, Coolant Temperature/Removal)
Perform the POWERTRAIN VERIFICATION TEST - 6.7L. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

Theory of Operation

The DTC is intended as an informational DTC to aid the technician in determining the root cause of a customer dirveability issue. The DTC is also intended to alert the technician to determine if a cooling system malfunction has occurred or if an additional transmission air to oil cooler is needed to support the customers driving behavior.

When Monitored and Set Conditions

When Monitored:

• This diagnostic runs continuously when the Engine is running.

Set Conditions:

• Transmission temperature exceeds 116° C or 240° F

Default Actions:

• Overheat shift schedule is activated.

Possible Causes

HIGH TEMPERATURE OPERATION ACTIVATED
TORQUE CONVERTER CLUTCH SLIPPING / NOT ACTIVATING
OPERATING VEHICLE WITH TRANSMISSION IN LIMP-IN MODE FOR AN EXTENDED PERIOD OF TIME
RESTRICTED TRANSMISSION COOLER OR COOLER LINE
TRANSMISSION BYPASS COOLER VALVE (THERMOSTAT)
EXCESSIVE TIME IDLING IN GEAR

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

HIGH TEMPERATURE OPERATION

NOTE: This DTC is an informational DTC designed to aid the Technician in diagnosing shift quality complaints.
NOTE: This DTC indicates that the transmission has been operating in the "Overheat" shift schedule which may generate a customer complaint.
NOTE: The customer driving patterns may indicate the need for an additional transmission oil cooler.
NOTE: If the Transmission has experienced a catastrophic failure, the Transmission Cooler must be replaced.
1. Verify proper Engine cooling system operation which would affect proper transmission operation.
2. Verify proper operation of the Transmission Bypass Cooler Valve (Thermostat). (Refer to 07 - Cooling/Transmission/COOLER, Transmission Oil/Operation) .
3. Verify the Transmission Cooler and Cooler Lines are not restricted.
4. Verify proper torque converter clutch operation.
5. With the scan tool, check the Event Data to help identify the conditions in which the DTC was set.

Were any of the above problems identified as the probable cause?

Yes
• Repair the cause of transmission overheating. Perform the PRELIMINARY CHECKS procedure. (Refer to 07 - Cooling - Diagnosis and Testing) . Make sure to check for any Service Bulletins pertaining to this problem.
• Perform the TRANSMISSION VERIFICATION TEST. (Refer to 28 - DTC-Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

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

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:

While the engine is running.

Set Condition:

The Powertrain Control Module (PCM) detects engine speed is above a calibrated threshold.

Possible Causes

MECHANICAL OVERSPEED OF ENGINE

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

1. OTHER DTCS

1. Turn the ignition on.
2. With the scan tool, read and record the freeze frame data.
3. With the scan tool, read the Engine DTCs.

Are there other Crankshaft Position Sensor DTCs set?

Yes
Repair any other Crankshaft Position Sensor DTCs.

No
Go To 2

2. MECHANICAL OVERSPEED OF ENGINE

NOTE: The most likely cause of this DTC is a mechanical overspeed. Examples of this could be downshifting into to low of a gear on a manual transmission or pulling a heavy load on a steep downgrade.

1. Visually inspect the engine for signs of mechanical overspeed. Such as, bent push rod, broken rocker arms, bent valves, flywheel bolts backing out, etc.

Did you notice any overspeed damage?

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

No
• Test Complete.

Theory of Operation

The Exhaust Gas Recirculation (EGR) Airflow Control Valve is controlled by the Powertrain Control Module (PCM) and is actuated by an electric motor. A spring internal to the actuator assembly attempts to drive the valve to the fully-open position. The electric motor works to overcome the spring force when the engine control module commands the valve to close. Position feedback from the valve is sent to the PCM to allow for closed-
loop control. Discrepancy in position feedback sent to the PCM, and commanded position sent to the EGR Airflow Control Valve by more than a prescribed amount will result in failure of device rationality diagnostics. Failure to properly actuate the EGR Airflow Control Valve can result in poor engine performance. This may cause active Exhaust Aftertreatment regenerations to last longer.

When Monitored:

With the ignition on.

Set Condition:

The Powertrain Control Module (PCM) detects that the EGR Airflow Control Valve is sticking or out of calibration.

Possible Causes

AIR INTAKE THROTTLE MOTOR (-) CIRCUIT OPEN/HIGH RESISTANCE
AIR INTAKE THROTTLE MOTOR (-) CIRCUIT OPEN/HIGH RESISTANCE
EGR AIRFLOW CONTROL VALVE
POWERTRAIN CONTROL MODULE (PCM)

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

1. DTC ACTIVE

1. Turn the ignition on.
2. With the scan tool, record all Freeze frame data.
NOTE: If DTC P02E2 or P02E3 are active, perform diagnosis and repair on those DTCs before continuing with this diagnostic tree.
3. With the scan tool, erase DTCs.
4. Turn the ignition off for 75 seconds.
5. Start the engine and let idle for one minute.
6. With the scan tool, read DTCs.

Is DTC P02E1 active?

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 (K674) AIR INTAKE THROTTLE MOTOR (-) CIRCUIT FOR HIGH RESISTANCE

1.
2. Turn the ignition off.
3. Disconnect the EGR Airflow Control Valve harness connector.
4. Disconnect the PCM C1 harness connector.
NOTE: Check connectors - Clean/repair as necessary.
5. Measure the resistance of the (K674) Air Intake Throttle Motor (-) circuit between the EGR Airflow Control Valve harness connector and the PCM C1 harness connector.

Is the resistance below 5.0 Ohms?

Yes
• Go To 3

No
• Repair the (K674) Air Intake Throttle Motor (-) 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 (K673) AIR INTAKE THROTTLE MOTOR (+) CIRCUIT FOR HIGH RESISTANCE

1.
2. Measure the resistance of the (K673) Air Intake Throttle Motor (+) circuit between the EGR Airflow Control
Valve harness connector and the PCM C1 harness connector.

Is the resistance below 5.0 Ohms?

Yes
• Go To 4

No
• Repair the (K673) Air Intake Throttle Motor (+) 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. EGR AIRFLOW CONTROL VALVE

1. Turn the ignition off.
2. Reconnect the PCM C1 harness connector.
3. Ignition on, engine not running.
4. Using a voltmeter connected to ground, measure the voltage on the:
• (K673) Air Intake Throttle Motor (+) circuit at the EGR Airflow Control Valve harness connector.
• (K674) Air Intake Throttle Motor (-) circuit at the EGR Airflow Control Valve harness connector.
NOTE: The voltage on the control circuits should read approximately battery voltage.
Are both measurements equal to battery voltage?

Yes
• Replace the EGR Airflow 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).

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 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).

Theory of Operation

The Exhaust Gas Recirculation (EGR) Airflow Control Valve is controlled by the Powertrain Control Module (PCM) and is actuated by an electric motor. A spring internal to the actuator assembly attempts to drive the valve to the fully-open position. The electric motor works to overcome the spring force when the engine control module commands the valve to close. Position feedback from the valve is sent to the PCM to allow for closed-
loop control. Discrepancy in position feedback sent to the PCM, and commanded position sent to the EGR Airflow Control Valve by more than a prescribed amount will result in failure of device rationality diagnostics. Failure to properly actuate the EGR Airflow Control Valve can result in poor engine performance. This may cause active Exhaust Aftertreatment regenerations to last longer.

When Monitored:

With the ignition on.

Set Condition:

The Powertrain Control Module detects that the control circuit voltage for the EGR Airflow Control Valve is below the calibrated threshold.

Possible Causes

AIR INTAKE THROTTLE MOTOR (-) CIRCUIT SHORTED TO GROUND
AIR INTAKE THROTTLE MOTOR (+) CIRCUIT SHORTED TO GROUND
EGR AIRFLOW CONTROL VALVE
POWERTRAIN CONTROL MODULE (PCM)

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

1. DTC ACTIVE

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 and let idle for one minute.
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 (K674) AIR INTAKE THROTTLE MOTOR (-) CIRCUIT FOR A SHORT TO GROUND

1. Turn the ignition off.
2. Disconnect the EGR Airflow Control Valve harness connector.
3. Disconnect the PCM C1 harness connector.
4. Measure the resistance between ground and the (K674) Air Intake Throttle Motor (-) circuit at the EGR
Airflow Control Valve harness connector.
Is the resistance below 10k Ohms?

Yes
• Repair the (K674) Air Intake Throttle Motor (-) 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 THE (K673) AIR INTAKE THROTTLE MOTOR (+) CIRCUIT FOR A SHORT TO GROUND

1. Measure the resistance between ground and the (K673) Air Intake Throttle Motor (+) circuit at the EGR Airflow Control Valve harness connector.
Is the resistance below 10k Ohms?

Yes
• Repair the (K673) Air Intake Throttle Motor (+) 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 4

4. EGR AIRFLOW CONTROL VALVE

1. Replace the EGR Airflow 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)
2. Reconnect the EGR Airflow Control Valve harness connector.
3. Reconnect the PCM C1 harness connector.
4. Turn the ignition on.
5. With the scan tool, erase DTCs.
6. Start the engine and allow it to idle for one minute.
7. With the scan tool, read DTCs.

Did the DTC return?

Yes
• Go To 5

No
• Repair 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?

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).

Theory of Operation

The Exhaust Gas Recirculation (EGR) Airflow Control Valve is controlled by the Powertrain Control Module (PCM) and is actuated by an electric motor. A spring internal to the actuator assembly attempts to drive the valve to the fully-open position. The electric motor works to overcome the spring force when the engine control module commands the valve to close. Position feedback from the valve is sent to the PCM to allow for closed-
loop control. Discrepancy in position feedback sent to the PCM, and commanded position sent to the EGR Airflow Control Valve by more than a prescribed amount will result in failure of device rationality diagnostics. Failure to properly actuate the EGR Airflow Control Valve can result in poor engine performance. This may cause active Exhaust Aftertreatment regenerations to last longer.

When Monitored:

With the ignition on.

Set Condition:

The Powertrain Control Module detects that the control circuit voltage for the EGR Airflow Control Valve is above the calibrated threshold.

Possible Causes

AIR INTAKE THROTTLE MOTOR (-) CIRCUIT OPEN/HIGH RESISTANCE
AIR INTAKE THROTTLE MOTOR (-) CIRCUIT SHORT TO VOLTAGE
AIR INTAKE THROTTLE MOTOR (+) CIRCUIT OPEN/HIGH RESISTANCE
AIR INTAKE THROTTLE MOTOR (+) CIRCUIT SHORT TO VOLTAGE
EGR AIRFLOW CONTROL VALVE
POWERTRAIN CONTROL MODULE (PCM)

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

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. Start the engine and let idle for one minute.
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 (K673) AIR INTAKE THROTTLE MOTOR (+) CIRCUIT FOR A SHORT TO VOLTAGE

1. Disconnect the PCM C1 harness connector.
2. Disconnect the EGR Airflow Control Valve harness connector.
3. Measure the voltage on the (K673) Air Intake Throttle Motor (+) circuit at the EGR Airflow Control Valve harness connector.
Is there voltage present?

Yes
• Repair the (K673) Air Intake Throttle Motor (+) 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 (K673) AIR INTAKE THROTTLE MOTOR (+) CIRCUIT FOR A SHORT TO THE (K834) 5 VOLT SUPPLY CIRCUIT

1. Measure the resistance between the (K673) Air Intake Throttle Motor (+) circuit and the (K834) 5 Volt Supply circuit.
Is the resistance below 5.0 Ohms?

Yes
• Repair the short between the (K673) Air Intake Throttle Motor (+) circuit and the (K834) 5 Volt Supply 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 THE (K674) AIR INTAKE THROTTLE MOTOR (-) CIRCUIT FOR A SHORT TO VOLTAGE

1. Measure the voltage on the (K674) Air Intake Throttle Motor (-) circuit at the EGR Airflow Control Valve harness connector.
Is there voltage present?

Yes
• Repair the (K674) Air Intake Throttle Motor (-) 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 5

5. CHECK THE (K674) AIR INTAKE THROTTLE MOTOR (-) CIRCUIT FOR A SHORT TO THE (K834) 5 VOLT SUPPLY CIRCUIT

1. Measure the resistance between the (K674) Air Intake Throttle Motor (-) circuit and the (K834) 5 Volt Supply circuit.
Is the resistance below 5.0 Ohms?

Yes
• Repair the short between the (K674) Air Intake Throttle Motor (-) circuit and the (K834) 5 Volt Supply circuit.
• 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 (K674) AIR INTAKE THROTTLE MOTOR (-) CIRCUIT FOR AN OPEN/HIGH RESISTANCE

1. Measure the resistance of the (K674) Air Intake Throttle Motor (-)circuit between the EGR Airflow Control
Valve harness connector and the PCM C1 harness connector.

Is the resistance below 5.0 Ohms?

Yes
• Go To 7

No
• Repair the (K674) Air Intake Throttle Motor (-) 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. CHECK THE (K673) AIR INTAKE THROTTLE MOTOR (+) CIRCUIT FOR AN OPEN/HIGH RESISTANCE

1. Measure the resistance of the (K673) Air Intake Throttle Motor (+) circuit between the EGR Airflow Control Valve harness connector and the PCM C1 harness connector.
Is the resistance below 5.0 Ohms?

Yes
• Go To 8

No
• Repair the (K673) Air Intake Throttle Motor (+) 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).

8. EGR AIRFLOW CONTROL VALVE

1. Replace the EGR Airflow 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)
2. Reconnect the EGR Airflow Control Valve harness connector.
3. Reconnect the PCM C1 harness connector.
4. Turn the ignition on.
5. With the scan tool, erase DTCs.
6. Start the engine and allow it to idle for one minute.
7. With the scan tool, read DTCs.

Did the DTC return?

Yes
• Go To 9

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

9. 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).

h2> Theory of Operation

The Exhaust Gas Recirculation (EGR) Airflow Control Valve is controlled by the Powertrain Control Module (PCM) and is actuated by an electric motor. A spring internal to the actuator assembly attempts to drive the valve to the fully-open position. The electric motor works to overcome the spring force when the engine control module commands the valve to close. Position feedback from the valve is sent to the PCM to allow for closed-loop control. Discrepancy in position feedback sent to the PCM, and commanded position sent to the EGR Airflow Control Valve by more than a

prescribed amount will result in failure of device rationality diagnostics. Failure to properly actuate the EGR Airflow Control Valve can result in poor engine performance. This may cause active Exhaust Aftertreatment regenerations to last longer.

When Monitored:

With the engine running.

Set Condition:

Actual EGR Airflow Control Valve position differs from Commanded EGR Airflow Control Valve position
by more than 8% on average, over a 15 second diagnostic window.

Possible Causes

HIGH RESISTANCE IN THE AIR INTAKE THROTTLE SENSOR SIGNAL CIRCUIT
EGR AIRFLOW CONTROL VALVE OBSTRUCTED/STICKING
EGR AIRFLOW CONTROL VALVE
POWERTRAIN CONTROL MODULE (PCM)

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

1. ACTIVE DTC

1. Start the engine and allow it to idle.
2. With the scan tool, read DTCs.
Is the DTC active?

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 EGR AIRFLOW THROTTLE CONTROL VALVE

1. Remove the boot from the EGR Throttle Control Valve. Using a mirror, look at the butterfly valve on the inside of the EGR Throttle Control Valve.
2. Start the vehicle, let idle for 10 seconds.
3. Turn ignition off.
NOTE: If functioning properly the EGR Throttle Control Valve will close immediately after the engine is shut down.
Did the EGR Throttle Control Valve close immediately after the engine was shut down?

Yes
• Go To 4

No
• Go To 3

3. CHECK THE EGR AIRFLOW CONTROL VALVE FOR BINDING OR STICKING

1. Turn the ignition off.
2. Check the butterfly valve for signs of a physical obstruction. Was there an obstruction 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
• Replace the EGR Airflow Control Valve 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).

4. CHECK THE (K672) AIR INTAKE THROTTLE SENSOR SIGNAL CIRCUIT FOR AN OPEN/HIGH RESISTANCE

1. Disconnect the EGR Airflow Control Valve harness connector.
2. Disconnect the PCM C1 harness connector.
3. Measure the resistance of the (K672) Air Intake Throttle Sensor Signal circuit between the Air Intake Throttle Sensor and the PCM C1 harness connector.

Is the resistance below 3.0 Ohms?

Yes
• Go To 5

No
• Repair the (K672) Air Intake Throttle 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).

5. CHECK THE EGR AIRFLOW CONTROL VALVE

1. Turn the ignition off.
2. Reconnect the PCM harness connector.
3. Reconnect the EGR Airflow Control Valve harness connector.
4. Ignition on, engine not running.
5. With the scan tool, erase DTCs.
6. While monitoring the scan tool, disconnect the EGR Airflow Control Valve harness connector.
7. With the scan tool, read DTCs.
Is DTC P02E9 active?

Yes
• Replace the EGR Airflow 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).

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.
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).

Theory of Operation

The Exhaust Gas Recirculation (EGR) Airflow Control Valve is controlled by the Powertrain Control Module (PCM) and is actuated by an electric motor. A spring internal to the actuator assembly attempts to drive the valve to the fully-open position. The electric motor works to overcome the spring force when the engine control module commands the valve to close. Position feedback from the valve is sent to the PCM to allow for closed-loop control. Discrepancy in position feedback sent to the PCM, and commanded position sent to the EGR Airflow Control Valve by more than a prescribed amount will result in failure of device rationality diagnostics. Failure to properly actuate the EGR Airflow Control Valve can result in poor engine performance. This may cause active Exhaust Aftertreatment regenerations to last longer.

When Monitored:

Ignition on.

Set Condition:

The PCM detects that the Air Intake Throttle Sensor Signal circuit is below a calibrated threshold for a calibrated amount of time.

Possible Causes

AIR INTAKE THROTTLE SENSOR SIGNAL CIRCUIT SHORTED TO GROUND
AIR INTAKE THROTTLE SENSOR SIGNAL CIRCUIT OPEN/HIGH RESISTANCE
EGR AIRFLOW CONTROL VALVE
POWERTRAIN CONTROL MODULE (PCM)
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 28 - DTC- Based Diagnostics/MODULE, Powertrain Control (PCM) - Standard Procedure).

1. ACTIVE DTC
NOTE: If there are Mass Airflow Sensor and Turbocharger DTCs present with this DTC, repair the 12-volt Supply circuit for an open or short to ground condition.

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 and let idle.
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 (K672) AIR INTAKE THROTTLE SENSOR SIGNAL CIRCUIT FOR A SHORT TO GROUND

1. Ignition on.
2. Disconnect the EGR Airflow Control Valve harness connector.
3. Disconnect the PCM C1 harness connector.
4. Measure the resistance between ground and the (K672) Air Intake Throttle Sensor Signal circuit at the EGR Airflow Control Valve harness connector.

Is the resistance below 10k Ohms?

Yes
• Repair the (K672) Air Intake Throttle 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 3

3. CHECK THE (K672) AIR INTAKE THROTTLE SENSOR SIGNAL CIRCUIT FOR AN OPEN/HIGH RESISTANCE

1. Measure the resistance of the (K672) Air Intake Throttle Sensor Signal circuit between the EGR Airflow
Control Valve harness connector and the PCM C1 harness connector.
Is the resistance above 5.0 Ohms?

Yes
• Repair the (K672) Air Intake Throttle 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).

No
• Go To 4

4. CHECK THE EGR AIRFLOW CONTROL VALVE

1. Turn the ignition off.
2. Reconnect the PCM harness connector.
3. Reconnect the EGR Airflow Control Valve harness connector.
4. Ignition on, engine not running.
5. With the scan tool, erase DTCs.
6. While monitoring the scan tool, disconnect the EGR Airflow Control Valve harness connector.
7. With the scan tool, read DTCs.
Is DTC P02E9 active?

Yes
• Replace the EGR Airflow 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).

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 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).

Theory of Operation

The Exhaust Gas Recirculation (EGR) Airflow Control Valve is controlled by the Powertrain Control Module (PCM) and is actuated by an electric motor. A spring internal to the actuator assembly attempts to drive the valve to the fully-open position. The electric motor works to overcome the spring force when the engine control module commands the valve to close. Position feedback from the valve is sent to the PCM to allow for closed-loop control. Discrepancy in position feedback sent to the PCM, and commanded position sent to the EGR Airflow Control Valve by more than a prescribed amount will result in failure of device rationality diagnostics. Failure to properly actuate the EGR Airflow Control Valve can result in poor engine performance. This may cause active Exhaust Aftertreatment regenerations to last longer.

When Monitored:

Ignition on.

Set Condition:

The PCM detects that the Air Intake Throttle Sensor Signal circuit is above a calibrated threshold for a calibrated amount of time.

Possible Causes

AIR INTAKE THROTTLE SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE
AIR INTAKE THROTTLE SENSOR SIGNAL CIRCUIT SHORTED TO THE 5-VOLT SUPPLY CIRCUIT
AIR INTAKE THROTTLE SENSOR SIGNAL CIRCUIT OPEN/HIGH RESISTANCE
SENSOR GROUND CIRCUIT OPEN/HIGH RESISTANCE
EGR AIRFLOW CONTROL VALVE
POWERTRAIN CONTROL MODULE (PCM)

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

1. ACTIVE DTC

NOTE: If there are Mass Airflow Sensor and Turbocharger DTCs present with this DTC, repair the 12-
volt Supply circuit for an open or short to ground condition.

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 and let idle.
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 (K672) AIR INTAKE THROTTLE SENSOR SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE

1. Turn the ignition off.
2. Disconnect the EGR Airflow Control Valve harness connector.
3. Measure the voltage on the (K672) Air Intake Throttle Sensor Signal circuit at the EGR Airflow Control
Valve harness connector.
Is the voltage reading above 5.1 Volts?

Yes
• Repair the (K672) Air Intake Throttle 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 FOR THE (K672) AIR INTAKE THROTTLE SENSOR SIGNAL CIRCUIT SHORTED TO THE (K834) 5-VOLT SUPPLY CIRCUIT

1. Disconnect the PCM C1 harness connector.
2. Measure the resistance between the (K672) Air Intake Throttle Sensor Signal circuit and the (K834) 5-Volt Sensor Supply Circuit at the EGR Airflow Control Valve harness connector.
Is the resistance below 10k Ohms?

Yes

• Repair the short between the (K672) Air Intake Throttle Sensor Signal circuit and the (K834) 5-Volt Sensor Supply 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 THE (K672) AIR INTAKE THROTTLE SENSOR SIGNAL CIRCUIT FOR AN OPEN/HIGH RESISTANCE

1. Measure the resistance of the (K672) Air Intake Throttle Sensor Signal circuit between the EGR Airflow
Control Valve harness connector and the PCM C1 harness connector.
Is the resistance above 5.0 Ohms?

Yes
• Repair the (K672) Air Intake Throttle 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).

No
• Go To 5

5. CHECK THE (K934) SENSOR GROUND CIRCUIT FOR AN OPEN/HIGH RESISTANCE
1. Measure the resistance of the (K934) Sensor Ground circuit between the EGR Airflow Control Valve harness connector and the PCM C1 harness connector.
Is the resistance above 5.0 Ohms?

Yes
• Repair the (K934) 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).

No
• Go To 6

6. CHECK THE EGR AIRFLOW CONTROL VALVE

1. Turn the ignition off.
2. Reconnect the PCM harness connector.
3. Reconnect the EGR Airflow Control Valve harness connector.
4. Ignition on, engine not running.
5. With the scan tool, erase DTCs.
6. While monitoring the scan tool, disconnect the EGR Airflow Control Valve harness connector.
7. With the scan tool, read DTCs.
Is DTC P02E9 active?

Yes
• Replace the EGR Airflow 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).

No
• Go To 7

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).