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SUBJECT

DATE

SPN 2791/FMI 7 – ALL YEARS

May 2013

Additions, Revisions, or Updates
Publication Number / Title
DDC-SVC-MAN-0084

Platform

Section Title

Change

DD Platform

SPN 2791/FMI 7

Deleted part numbers from step 4. Added graphics showing the
different pull rods.

All information subject to change without notice.

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2 SPN 2791/FMI 7 - ALL YEARS

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SPN 2791/FMI 7 - ALL YEARS

This diagnostic is typically the Exhaust Gas Recirculation (EGR) Actuator, Failsafe Mode, Motor On.

Check as follows:
1. Check for additional voltage fault codes SPN/168 FMI (any).
a. If fault codes are present, troubleshoot and repair them first.
b. If no additional voltage fault codes are present, Go to step 2.
2. Using DDDL 7.x, check SPN 2791/FMI 7 extended data record #3 “physical data;” refer to chart below for the
"Reserved for Extreme Parameter" value.

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Table 1.
Reserved for Extreme Parameter

Action to take

3

Go to step 3.

8,11

Go to step 9.

3. Turn the ignition OFF.
4. Disconnect the EGR valve actuator pull rod. Inspect the ball sockets on the pull rod for free movement.
a. If the ball sockets do not rotate/move freely or the rod is not the most recent part number, replace the EGR valve
actuator pull rod.
For the DD13, Refer to section "Removal of the Exhaust Gas Recirculation Valve Actuator Pull Rod".
Before engine serial number HDE108907, the pull rods (1 and 2) were used. Beginning with engine serial
number HDE108907, pull rod (3) is used. The pull rods are not interchangeable.

All information subject to change without notice.

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2 SPN 2791/FMI 7 - ALL YEARS

For the DD15 and DD16, Refer to section "Removal of the Exhaust Gas Recirculation Valve Actuator Pull Rod".
Before engine serial number HDE172591, the pull rod (1) was used. Beginning with engine serial number
HDE172591, pull rod (2) is used. The pull rods are not interchangeable.

b. If the ball sockets move freely and the part number is recent, Go to step 5.
NOTE: Some resistance is normal; however, the actuator should not bind in any particular spots.

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5. With the EGR valve actuator pull rod disconnected, physically sweep the EGR actuator throughout its travel.
a. If actuator binds at any point in its travel, replace the EGR actuator.
For the DD13, Refer to section "Removal of the Exhaust Manifold".
For the DD15 and DD16, Refer to section "Removal of the DD15 and DD16 Exhaust Gas Recirculation Valve".
b. If EGR actuator does not bind, Go to step 6.
6. With the EGR valve actuator pull rod disconnected, turn the ignition ON (key ON, engine OFF) and monitor SRA3
status using DDDL.
Table 2.
SRA3 Status Value

Action to Take

EPA07

EPA10

9 or 10

“Learn: Span too large, using initial value”
OR “Learn: Stops invalid using initial
value.”

Do not replace the actuator. Cycle ignition
2 more times and continue to monitor
SRA3 status; if SRA3 status continues to
be the same, Go to step 7.

Any other value.

Any other value.

Replace the EGR valve actuator and Go to
step 16.

7. Turn the ignition OFF.
8. With the EGR actuator pull rod disconnected, physically move the EGR valve butterfly from stop to stop to check for
full travel (some drag is normal).
a. If EGR butterfly does not move fully from stop to stop, replace the EGR valve. Go to step 16.
For the DD13, Refer to section "Removal of the Exhaust Manifold".
For the DD15 and DD16, Refer to section "Removal of the DD15 and DD16 Exhaust Gas Recirculation Valve".
b. If EGR butterfly moves stop to stop, reconnect the EGR valve actuator rod to the EGR valve and EGR actuator.
Go to step 16.
9. Turn the ignition OFF and disconnect the EGR actuator harness connector.
10. Measure the resistance between pins 3 and 4 of the EGR actuator connector (engine harness side).
a. If the resistance is between 55 and 65 ohms, replace the EGR actuator.
b. If the resistance is not between 55 and 65 ohms, Go to step 11.
11. Disconnect the MCM 120-pin connector.
12. Measure the resistance between pins 3 and 4 of the EGR valve actuator connector (engine harness side).
a. If the resistance is less than 10K ohms, repair short between pins 3 and 4 of the EGR actuator harness connector
and MCM pins 74/75.
b. If the resistance is greater than 10K ohms, Go to step 13.
13. Measure the resistance between pin 3 of the EGR actuator connector harness and pin 74 of the MCM 120-pin
connector.
a. If the resistance is greater than 3 ohms, repair wire between pin 3 of the EGR actuator connector harness and pin
74 of the MCM 120-pin connector.
b. If the resistance is less than 3 ohms, Go to step 14.
14. Measure the resistance between pin 4 of the EGR valve actuator connector harness and pin 75 of the MCM 120-pin
connector.
a. If the resistance is greater than 3 ohms, repair wire between pin 4 of the EGR valve actuator connector harness
and pin 75 of the MCM 120-pin connector.
b. If the resistance is less than 3 ohms, Go to step 15.
15. Install test MCM; reconnect the EGR actuator harness connector. Turn the ignition ON and monitor SRA3 status using
DDDL.
a. If SRA3 status is “0” or “OK,” reprogram the original MCM with the latest settings on the server. Go to step 16.
b. If SRA3 status is not “0” or “OK,” replace the EGR valve actuator.
16. Clear codes, cycle the ignition ON and monitor SRA3 status using DDDL.
a. If SRA3 status is “0” or “OK,” clear the codes and release the vehicle.
b. If SRA3 status is not “0” or “OK,” replace the MCM.

All information subject to change without notice.

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