IK1201245 ­ 2010+ DT/9/10 EGR Valve Diagnostics

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PUERTO RICO

Document ID: IK1201245

Availability:

ISIS, Bus ISIS, FleetISIS

Revision:

5

Major System:
Current
Language:

ENGINES

Created:
Last
Modified:

11/25/2014

English

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Author:

5/7/2015
Michael
Sokolowski

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Title : 2010+ DT/9/10 EGR Valve Diagnostics
Applies To : 2010+ MaxxForce DT/9/10

CHANGE LOG
12/4/2014: Initial Draft
12/10/2-14: Step based diagnostics added
1/15/15: Corrected linking for 2659-14
3/26/15: Added 2659-10 information

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

DESCRIPTION
This document provides users with Exhaust Gas Recirculation (EGR) Valve diagnostics and repair information for the most likely fault codes. It covers all
2010 and newer DT, 9 and 10 engines
To the Top

SYMPTOMS
Diagnostic Trouble Codes & Dashboard Indicator Lights:

Fault Code Fault Description

Action

27-0

EGRP fault: over temperature

Replace EGR Valve- No diagnostics
needed

27-3

EGRP signal Out of Range HIGH

Replace EGR Valve- No diagnostics
needed

27-4

EGRP signal Out of Range LOW

Replace EGR Valve- No diagnostics
needed

27-7

EGRP does not agree with commanded
position

Replace EGR Valve- No diagnostics
needed

27­14

EGR internal circuit failure

Replace EGR Valve- No diagnostics
needed

2791­2

EGR valve communication fault

Continue to diagnostics below

2791­8

EGR valve not receiving ECM PWM signal

Continue to diagnostics below

2791-12

EGR valve stuck in position monitor

Replace EGR Valve­ No diagnostics
needed

2659- 10

EGR Slow Response Fault

Continue to diagnostics below

2659­14

KOER AMT - EGR test failure

Continue to diagnostics below

2659­20

EGR High Flow Rate Detected

Continue to diagnostics below

2659­21

EGR Low Flow Rate Detected

Continue to diagnostics below

• If NO EGR Valve Faults are present DO NOT replace the EGR Valve. No repairs are required for the
EGR system.
To the Top

DIAGNOSTICS
Select the active code:

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IK1201245 ­ 2010+ DT/9/10 EGR Valve Diagnostics

2791­2

2791­8

2659-14

2659-20

2659-21

2659-10

Page 2 of 9

Diagnostic Steps when Fault 2791-2 is present:
Step Action
1
Using terminal test kit, inspect connections at the Exhaust Gas Recirculation (EGR) valve.
With key OFF, disconnect EGR valve connector. Check EGR valve and connector for the
following:
Damaged or pinched wires
Corroded terminals
Loose, bent, or broken pins
Broken connector housing.

Decision
Yes: Continue to Step 2.
No: Repair connector, harness, or terminal
damage.
After repairs are complete, clear the code,
and retest for the fault.

Are the EGR valve connector, harness, and terminals clean and undamaged?

Step Action
2
Use DMM to measure the voltage of the following circuit:

Decision
Yes: Repair circuit between Pin 1 of the EGR
valve and Pin C-26 of the 76-Pin Chassis
(Gray) connector at the ECM.

Pin 1 of the EGR Connector to Ground
Is Voltage less than 1.79V +/­ .5V?

Step Action
3
Use DMM to measure the voltage of the following circuit:

No: Continue to Step 3.

Pin 2 of the EGR Connector to Ground

Decision
Yes: Repair circuit between Pin 2 of the EGR
valve and Pin E-71 of the 76-Pin Engine
(Black) connector at the ECM.

Is Voltage less than 3.95V +/­ .5V?

No: Continue to Step 4

Step Action
4
Use DMM to measure the resistance of the following circuit:
Pin 3 of the EGR Connector to Battery Ground

Decision
Yes: Repair circuit between Pin 3 and Pin
C2, 4 & 6 of the 76-Pin Chassis (Gray)
connector at the ECM.

Is Resistance greater than 5 Ω?

No: Continue to Step 5

Step Action
5
Use DMM to measure the voltage of the following circuit:

Decision
Yes: Repair actuator power circuit.

Pin 4 of the EGR Connector to Ground
Is Voltage less than 9V?

No: After performing diagnostic steps, if the
fault remains, verify each step was completed
correctly and proper decision was made. Notify
supervisor for further action.

Diagnostic Steps when Fault 2791-8 is present:
Step Action
1
Using terminal test kit, inspect connections at the Exhaust Gas Recirculation (EGR) valve.
With key OFF, disconnect EGR valve connector. Check EGR valve and connector for the
following:
Damaged or pinched wires
Corroded terminals
Loose, bent, or broken pins
Broken connector housing.

Decision
Yes: Continue to Step 2.
No: Repair connector, harness, or terminal
damage.
After repairs are complete, clear the code,
and retest for the fault.

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IK1201245 ­ 2010+ DT/9/10 EGR Valve Diagnostics

Page 3 of 9

Are the EGR valve connector, harness, and terminals clean and undamaged?

Step Action
2
Use DMM to measure the voltage of the following circuit:

Decision
Yes: Repair circuit between Pin 1 of the EGR
valve and Pin C-26 of the 76-Pin Chassis
(Gray) connector at the ECM.

Pin 1 of the EGR Connector to Ground
Is Voltage less than 1.79V +/­ .5V?

Step Action
3
Use DMM to measure the voltage of the following circuit:
Pin 2 of the EGR Connector to Ground

No: Continue to Step 3.

Decision
Yes: Repair circuit between Pin 2 of the EGR
valve and Pin E-71 of the 76-Pin Engine
(Black) connector at the ECM.

Is Voltage less than 3.95V +/­ .5V?
No: Continue to Step 4

Step Action
4
Use DMM to measure the resistance of the following circuit:
Pin 3 of the EGR Connector to Battery Ground

Decision
Yes: Repair circuit between Pin 3 and Pin
C2, 4 & 6 of the 76-Pin Chassis (Gray)
connector at the ECM.

Is Resistance greater than 5 Ω?

No: Continue to Step 5

Step Action
5
Use DMM to measure the voltage of the following circuit:
Pin 4 of the EGR Connector to Ground
Is Voltage less than 9V?

Decision
Yes: Repair actuator power circuit.
No: After performing diagnostic steps, if the
fault remains, verify each step was completed
correctly and proper decision was made.
Notify supervisor for further action.

Diagnostic Steps when Fault 2659-20 is present:
Step Action
1
Using Electronic Service Tool (EST) with ServiceMaxx™ software, check for other fault
codes.
Is SPN 2659 FMI 20 the only fault code active?

Step Action
2
Inspect connections at the Exhaust Gas Recirculation (EGR) valve. With key OFF,
disconnect EGR valve connector. Check EGR valve and connector for: damaged or pinched
wires; corroded terminals; loose, bent, or broken pins; or broken connector housing.

Decision
Yes: Continue to Step 2.
No: Correct any other active fault codes,
and retest for SPN 2659 FMI 20(clear code
before retesting)

Decision
Yes: Continue to step 3
No: Repair as needed, clear the code, then
retest for SPN 2659 FMI 20.

Are the EGR Valve connector, harness, and terminals clean and undamaged?

Step Action
3
Visually inspect intake air system for leaks.
Were any leaks identified?

Decision
Yes: Repair leaks. After repairs are complete,
retest for SPN 2659 FMI 20.
No: Continue to Step 4

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IK1201245 ­ 2010+ DT/9/10 EGR Valve Diagnostics

Step Action
4
Perform EGR Operational Test 5 times.

Page 4 of 9

Decision
Yes: Replace the EGR Valve, clear the
code, then retest for SPN 2659 FMI 20