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EPA98 04 Series 60 EGR Technician's Manual (DDC-SVC-MAN-0078)

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1 Introduction
- 1.1 Basics
- 1.2 Operator Information
2 Ddec Iv Components
- 2.1 Functionality of the Egr Components
  - 2.1.1 DDEC IV Electronic Control Module
  - 2.1.2 Variable Pressure Output Device (VPOD)
  - 2.1.3 Variable Nozzle Turbocharger
  - 2.1.4 Turbocharger Boost Sensor
  - 2.1.5 EGR Valve
  - 2.1.6 EGR Valve Actuator
  - 2.1.7 EGR Cooler
  - 2.1.8 Delta P Sensor
  - 2.1.9 Venturi Tube/Delivery Pipe
  - 2.1.10 EGR Temperature Sensor
  - 2.1.11 EGR Mixer
  - 2.1.12 Charge Air Cooler
  - 2.1.13 Turbocharger Compressor Inlet Temperature Sensor
  - 2.1.14 High Flow Water Pump
3 Operational Modes
- 3.1 Boost Mode
- 3.2 Boost Mode Operation
  - 3.2.1 TRANSITION FROM BOOST MODE TO EGR MODE
- 3.3 Egr Mode
4 Ddec Iv Diagnostic Codes
- DDEC IV CODE DESCRIPTIONS
- LOGIC CODES (MECHANICAL FAILURES)
  - Diagnosing Flash Code 39
  - Diagnosing Flash Code 49
  - Sensor Codes
  - Protection Codes
5 Ddec Iv Testing
- - Intermittent Black Smoke
  - Power Loss Under Heavy Pull
  - Low Boost Under Cold Ambient Conditions
  - Flash Codes 14 and 29
  - Flash Code 39
  - Exhaust Fumes
  - Slobbering
  - Engine Vibration
  - Engine Backfire, Engine Misfire, Intermittent Exhaust Smoke
- TESTING PROCEDURES
  - Test A
  - Test B
- Exhaust Gas Recirculation System Basic Checks
  - Check Delta P Sensor and Barometric Sensor
  - Check VPOD Output Pressure
  - Check Variable Output Pressure Device Input Pressure
  - Check Variable Output Pressure Device Part Number and Supply Voltage
  - Check VPOD Wiring
  - Check for Active Codes
  - Verification
6 Dddl/Snapshots
- WORKING WITH DDDL SNAPSHOTS
- USING SNAPSHOT REPLAY CONTROLS
7 Snapshot Examples
- SNAPSHOT EXAMPLES
  - Normal Engine Operation as Viewed With DDDL Snapshots
  - EGR Flow at Idle
  - Delta P Sensor and Piping
  - Stuck or Sticking VNT or EGR Valve Actuator
  - Turbocharger Speed Sensor Faults
  - VPOD
  - Relative Humidity/Turbo Compressor Inlet Temperature Sensor
  - Turbo Compressor Outlet Temperature
  - EGR Flow Troubleshooting Tips
- 7.1 Snapshot Examples
  - 7.1.1 Normal Engine Operation as Viewed With DDDL Snapshots
- 7.2 Examples
8 Ddec V Components
- 8.1 Overview of the Ddec V Egr System
  - 8.1.1 EGR System
  - 8.1.2 Detailed Views of the DDEC V EGR Components
  - 8.1.3 DDEC V Electronic Control Unit
  - 8.1.4 EGR Valve and Related Components
  - 8.1.5 Top Right Side View of EGR Components
- 8.2 Functionality of Egr Components
  - 8.2.1 DDEC V Electronic Control Unit
  - 8.2.2 Turbocharger Compressor Inlet Temperature Sensor
  - 8.2.3 Venturi Tube
  - 8.2.4 EGR Cooler
  - 8.2.5 Charge Air Mixer
  - 8.2.6 Charge Air Cooler
  - 8.2.7 Variable Nozzle Turbocharger
  - 8.2.8 Variable Pressure Output Device
  - 8.2.9 Hydraulically Actuated EGR Valve
  - 8.2.10 EGR Temperature Sensor
  - 8.2.11 Delta P Sensor
  - 8.2.12 Intake Manifold Pressure Sensor
9 Ddec V Codes
- LOGIC CODES (MECHANICAL FAILURES)
  - Diagnosing Flash Code 13
  - EGR Valve Electric Current
10 Ddec V Testing
- 10.1 Probable Complaints
- 10.2 Testing Procedures
- 10.3 Troubleshooting Tasks
  - 10.3.1 FLASH CODE 13 (SID 146/FMI 6) EGR VALVE CURRENT TOO HIGH
  - 10.3.2 Flash Code 16 (SID 146/FMI5) EGR VALVE CURRENT TOO LOW
  - 10.3.3 FLASH CODE 39
  - 10.3.4 FLASH CODE 61
  - 10.3.5 BLACK SMOKE
  - 10.3.6 BLACK FUEL
  - 10.3.7 ENGINE MISFIRE, ENGINE BACKFIRE, INTERMITTENT SMOKE ISSUES
  - 10.3.8 SLOBBERING FROM EXHAUST PIPE
  - 10.3.9 POOR ENGINE PERFORMANCE
  - 10.3.10 CAB ODORS
  - 10.3.11 LOSS OF ENGINE COOLANT
- 10.4 Tests
  - 10.4.1 TEST A
  - 10.4.2 TEST B
  - 10.4.3 TEST C
    - 10.4.3.1 Delta P Sensor Test
    - 10.4.3.2 VPOD Output Pressure Test
    - 10.4.3.3 VPOD Input Pressure Test
    - 10.4.3.4 VPOD Part Number and Supply Voltage Test and Part Number Check
    - 10.4.3.5 VPOD Wiring Test
    - 10.4.3.6 Active Codes Test
    - 10.4.3.7 Final Test
  - 10.4.4 TEST D
  - 10.4.5 TEST E
  - 10.4.6 TEST F
  - 10.4.7 TEST G
11 Exhaust Gas Recirculation (Egr) Diagnostics
- 11.1 Exhaust Gas Recirculation Valve Diagnostics
- 11.2 Checking Exhaust Gas Recirculation Temperature Sensor
- 11.3 Checking Delta P Sensor
- 11.4 Checking Wires Between Exhaust Gas Recirculation Valve and Ecm
- 11.5 Checking Exhaust Gas Recirculation Turbocharger Speed Sensor Operation
12 List of Acronyms
13 Ddec Iv Wiring Schematics
14 Engine Diagnostic Questionnaire
15 Service Information Letters
16 Ddec Iv Ecm Overview and Vehicle Interface Harness

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