IK1201196 - Diagnostics for SPN 3251 FMI 21 DPFDP excessively LOW (Sensor/circuit... Page 1 of 4

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IK1201196

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ISIS, Bus ISIS, FleetISIS, Body Builder

Revision:

8

Major System:
Current
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ENGINES

Created:
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8/22/2014

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English

3/31/2015
Aaron
Mimbs

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NONE

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Title : Diagnostics for SPN 3251 FMI 21 DPFDP excessively LOW (Sensor/circuit fault or missing DPF)
Applies To : 2013 HD-OBD V-8 Engine

CHANGE LOG
03/30/2015 - Fixed link to IK1201085
03/18/2015 - Updated Step 7 with the link to the V­8 DPF & DOC Catastrophic Failure Performance Assessment
02/23/2015 - Revised formatting
01/20/2015 - Fixed link to IK1201142
12/22/2014 - Author updated for feedback purposes.
12/17/2014 - Calibration level clarified, pressure test changed to follow IK1201142.
10/30/2014 - Added instruction to cap off BCS inlet & Breather inlet ports on the ITV.
10/21/2014 - Snap Throttle note added.
8/21/2014 Initial Article Release

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DESCRIPTION
This document will guide the user through necessary steps to properly diagnose active SPN 3251 FMI 21.

SYMPTOMS
Diagnostic Trouble Codes:

DTC/Light

Description

Status

SPN 3251 FMI 21

DPFDP excessively low

ANY

Customer Observations or Concerns:
- Check engine light - SPN 3251 FMI 21
­ Black Smoke
- Exhaust Fumes in Cab

SPECIAL TOOLS / SOFTWARE
Tool Description

Tool Number

ServiceMaxx
Navistar® LeakLocator

19­700­01

Comments

Instructions

SERVICE PARTS INFORMATION
Kit Description

Part Number

Qty

Notes

GASKET TAPE EXHAUST 3/4"X36YDS

2604051C91

1

Heat resistant exhaust flange tape

GASKET,EXH PIPE FLANGE

1891515C1

1­2

Turbo outlet and down pipe extension gaskets

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IK1201196 - Diagnostics for SPN 3251 FMI 21 DPFDP excessively LOW (Sensor/circuit... Page 2 of 4

GASKET V-BAND TURBO

1883660C1

1-2

Exhaust Up­Pipe to X­Pipe O­Gaskets

GASKET, EXHAUST SINGLE LAYER

1875808C1

1-2

Exhaust Manifold to Up­Pipe Gaskets

GASKET TURBO INLET

1878460C1

2

Turbo/EGR Cooler Inlet Gaskets

GASKET DUAL PORT

1877824C1

1

Center Exhaust Manifold Gasket (1 of 3)

GASKET SINGLE PORT

1877823C1

2

Outside Exhaust Manifold Gasket (2&3 of 3)

DPF ASSEMBLY

2510963C1

1

Terrastar DPF Assembly (Verify Specific Application Before Ordering)

DPF KIT REPLACEMENT 11.25X12

1892211C91

1

DPF Replacement Kit (4300) (Verify Specific Application Before
Ordering)

GASKET, FLANGE OFFSET 3 HOLE

2593986C1

1

DPF Outlet Gasket (4300)

GASKET, FLANGE 3 BOLT

2593998C1

1

DPF Inlet Gasket (4300)

DIAGNOSTIC STEPS
Step Action
Vehicle Health Report
1

STEP 2

Generate Vehicle Health Report and Upload to Navistar's System

Step Action
Perform Visual Inspections per the Diagnostic Manual and Performance
Diagnostic Sheet

2

Decision

Decision
Repair as required; STEP 3

1. Inspect Fuel System to Verify Fuel Level
2. Inspect Engine Oil Level (If severely over full see IK1201259)
3. Inspect Coolant Recovery Bottle for Coolant Level
4. Inspect Electrical Group for Poor or Loose Connections
5. Inspect Air Filter Minder and AMS for Leaks
6. Inspect Exhaust System
Were any issues found?

Step Action
Verify ECM Calibration Level
3

Decision
If required, update the ECM calibration;
STEP 4

Is the engine calibration current (PRS24LR2 or older)?
See IK1201085 if required.

Step Action
Snap Throttle Test
Perform the Aftertreatment Snap Throttle Test detailed in IK0700032.
4

Did the aftertreatment pass the Snap Throttle Test?

Step Action
5

DPFDP Sensor Inspection

Decision
Yes. STEP 5
No. iApproval: Record a video or take a
picture of the black smoke. Remove the
DOC and DPF take pictures of the inlet
and outlet of both. Open an iApproval
case file and attach all relative documents
and pictures. If approval for the DPF is
given, please continue with the rest of this
article.

Decision
Repair any noted issues and continue to
STEP 6

Remove the DPFDP inlet tube blow through it to clear it out. Resecure the tube and
inspect the rubber hoses for cracks.
Any defects or issues found?

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If the threads strip please see TL2900091
Step Action

Decision

Leak Locater Test
6

Repair leaks if required; STEP 7

Leak check the system using the procedure detailed in IK1201142 Leak Locater
Diagnostic Procedures.

Step Action

7

Decision

On Board Filter Cleanliness Evaluation

Yes. STEP 8

Perform an On Board Filter Cleanliness Test in ServiceMaxx and monitor the
MAF, DOCIT, DPFIT, and DPFOT sensor readings.

No. Rerun Test - If the results are the
same, open a Case File with Navistar's
Technical Support Team and submit
findings, work performed and recordings
for review. Await further instruction.

Review the V-8 DPF & DOC Catastrophic Failure Performance Assessment Sheet
located in IK1201251 and compare to the OBFCT result.
Does the system operate as required?

Step Action

Decision

Vehicle Repair Evaluation
8

Reset the fuel pressure adaptives, Recalibrate the MAF and clear the DTCs.

Yes. Open Case File and submit findings,
work performed and recordings for review.
Await further instruction.
No. Complete any other necessary work
and release to the customer

Road test and record, did SPN 3251 FMI 21 become Pending/Active?

WARRANTY INFORMATION
Warranty Claim Coding:
Group: 1200 Engine
Noun: 575 - Sensor, DPF Differential Pressure
577 - Tube DPF Differential Pressure Sensor
235 ­ Diesel Particulate Filter (DPF)
561 - Gasket DPF / DOC
358 - Gasket Exhaust Manifold
Use appropriate noun, relative to the actual repair made.
Standard Repair Times:
Due to the number of engine/vehicle combinations and possibilities for repairs, see appropriate SRT manual section, linked below.
Description
ECM Calibration
Visual Inspections
Check for DTCs & Reset Adaptives
DPFDP Sensor Replace
DPF/DOC Thread Repair, Perform
DOC R&R
DPF R&R
Stationary Recording
Road Test
Exhaust Manifold Gasket Replacement
Exhaust Clamp Replacement
Exhaust Up-Pipe Gasket Replacement
Turbo/EGR Cooler Inlet Gasket Replacement
On Board Filter Cleanliness Test

Manual Section
ELECTRONIC CONTROL MODULE (ECM OR ECM/IDM) - ENGINE PROGRAM
ELECTRONIC ENGINE PERFORMANCE, DIAGNOSE
ELECTRONIC ENGINE PERFORMANCE, DIAGNOSE
DPF DIFFERENTIAL PRESSURE SENSOR, REPLACE
DPF/DOC THREAD REPAIR PERFORM
DIESEL OXIDATION CATALYST (DOC) REPLACE
DIESEL PARTICULATE FILTER (DPF) R & R AND/OR REPLACE
STATIONARY SNAPSHOT, PERFORM
ELECTRONIC ENGINE PERFORMANCE, DIAGNOSE
EXHAUST MANIFOLD AND/OR GASKET, REPLACE
PIPE CLAMP/ REPLACE
MANIFOLD TO TURBO EXHAUST INLET PIPE(S) AND/OR SEAL, REPLACE
TURBOCHARGER AIR CROSSOVER DUCT, REPLACE
AFTERTREATMENT, MANUAL REGENERATION, PERFORM

OTHER RESOURCES
Master Service Information Site
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