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1 12 16-10

SUBJECT DATE
SPN 2791/FMI 7, 8, 9, 14 December, 2010

Additions, Revisions, or Updates

Publication Number / Title Platform Section Title Change

DDC-SVC-MAN-0084 SPN 2791/FMI 7


SPN 2791/FMI 8
DD This SPN has a new sections for FMI 7, 8, 9, and 14.
SPN 2791/FMI 9
SPN 2791/FMI 14

All information subject to change without notice. 3


12-16-10 Copyright © 2011 DETROIT DIESEL CORPORATION
2 SPN 2791/FMI 7 - ALL YEARS

2 SPN 2791/FMI 7 - ALL YEARS

This diagnostic is typically the Exhaust Gas Recirculation (EGR) actuator, failsafe mode, motor on.

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.

Reserved for Extreme Parameter Action to take


3 Go to step 3.
8,11 Go to step 9.
3. Turn the ignition OFF (key OFF, engine OFF).
4. Disconnect the EGR valve actuator pull rod. Inspect the ball sockets on the pull rod for free movement. For DD13, ensure
part number is A4711401646 or higher; for DD15/16, ensure part number is A4721400646 or higher.

4 All information subject to change without notice.


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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 DD13 Exhaust Gas Recirculation Valve Actuator Pull Rod"
For the DD15 and DD16, Refer to section "Removal of the DD15 and DD16 Exhaust Gas Recirculation Valve
Actuator Pull Rod"
b. If the ball sockets move freely and the part number is recent, Go to step 5.
5. With the EGR valve actuator pull rod disconnected, physically sweep the EGR actuator throughout its travel.

NOTE: Some resistance is normal; however, the actuator should not bind in any particular spots.

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 and monitor SRA3 status using DDDL.
SRA3 Status Value Action to Take
EPA07 EPA10
9 or 10 “Learn: Span too large, using initial value” Do not replace the actuator. Cycle ignition 2
OR “Learn: Stops invalid using initial value.” 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 (key OFF, engine 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 3 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 3 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.

All information subject to change without notice. 5


12-16-10 Copyright © 2011 DETROIT DIESEL CORPORATION
2 SPN 2791/FMI 7 - ALL YEARS

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.

6 All information subject to change without notice.


Copyright © 2011 DETROIT DIESEL CORPORATION 12-16-10
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3 SPN 2791/FMI 8 - ALL YEARS

This diagnostic is typically the Exhaust Gas Recirculation (EGR) actuator, failsafe mode, motor off.

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. Replace the EGR valve actuator.
For the DD13; Refer to section "Removal of the DD13 Exhaust Gas Recirculation Valve Actuator"
For the DD15 and DD16; Refer to section "Removal of the DD15 and DD16 Exhaust Gas Recirculation Valve Actuator"
3. Turn 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”, contact the Customer Support Center at 313-592-5800.

All information subject to change without notice. 7


12-16-10 Copyright © 2011 DETROIT DIESEL CORPORATION
4 SPN 2791/FMI 9 - ALL YEARS

4 SPN 2791/FMI 9 - ALL YEARS

This diagnostic is typically the Exhaust Gas Recirculation (EGR) actuator (failsafe mode, motor off).

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. Is fault code SPN 2791 FMI 9 active or inactive?
a. If active, Go to step 3.
b. If inactive, Go to step 4.
3. Using DDDL 7.x, monitor the SRA3 status code.
SRA Status Code Action to take
EPA07 EPA10
5 Fault Condition Detected - Motor Replace the EGR valve actuator and
Go to step 10.
23 Reference Sensor Fault - Motor Go to step 4.
4. Turn the ignition OFF (key OFF, engine OFF).
5. Disconnect EGR valve actuator rod and inspect ball sockets on linkage for free movement. For DD13, ensure part number
is A4711401646 or higher; for DD15/16, ensure part number is A4721400646 or higher.
a. If the sockets do not rotate or move freely or the rod is not the most recent part number, replace the EGR valve
actuator pull rod and Go to step 10.
For the DD13: Refer to section "Removal of the DD13 Exhaust Gas Recirculation Valve Actuator Pull Rod"
For the DD15 and DD16: Refer to section "Removal of the DD15 and DD16 Exhaust Gas Recirculation Valve
Actuator Pull Rod"
b. If sockets move freely and the part number is recent, Go to step 6.
6. With the EGR valve actuator pull rod disconnected, physically sweep the EGR actuator throughout its travel.

NOTE: Some resistance is normal; however, the actuator should not bind in any particular spot.

8 All information subject to change without notice.


Copyright © 2011 DETROIT DIESEL CORPORATION 12-16-10
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a. If actuator binds at any point in its travel, replace the EGR actuator. Go to step 10.
For DD13: Refer to section "Removal of the DD13 Exhaust Gas Recirculation Valve Actuator"
For DD15 and DD16: Refer to section "Removal of the DD15 and DD16 Exhaust Gas Recirculation Valve Actuator"
b. If EGR actuator does not bind, Go to step 7.
7. With the EGR valve actuator pull rod disconnected, turn the ignition ON and monitor SRA3 status using DDDL.
SRA3 Status Value Actions to Take
9 or 10 “Learn: Span too large, using initial value” or Do not replace the actuator. Cycle ignition 2
“Learn: Stops invalid using initial value” more times and continue to monitor SRA3
status; if SRA3 status continues to be the
same, Go to step 8.
Any other value Any other value Replace the EGR valve actuator and Go to
step 10.
8. Turn the ignition OFF.
9. With the EGR valve actuator pull rod disconnected, physically move EGR 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 10.
For DD13: Refer to section "Removal of the DD13 Exhaust Flanged Manifold"
For 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 pull rod to the EGR valve and EGR actuator.
Go to step 10.
10. 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”, contact the Customer Support Center at 313-592-5800.

All information subject to change without notice. 9


12-16-10 Copyright © 2011 DETROIT DIESEL CORPORATION
5 SPN 2791/FMI 14 - ALL YEARS

5 SPN 2791/FMI 14 - ALL YEARS

This diagnostic is typically the Exhaust Gas Recirculation (EGR) valve actuator (failsafe mode, motor on).

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. Check for additional fault code SPN 2791 FMI 9.
a. If SPN 2791 FMI 9 is present, Go to step 15.
b. If SPN 2791 FMI 9 is not present, Go to step 3.
3. Check for additional fault code SPN 1073 FMI 4.
a. If SPN 1073 FMI 4 is present, Go to step 23.
b. If SPN 1073 FMI 4 is not present, Go to step 4.
4. Turn ignition OFF and disconnect the EGR actuator connector.
5. 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, Go to step 12.
b. If the resistance is not between 55 and 65 ohms, Go to step 6.
6. Disconnect the MCM 120-pin connector.
7. Measure the resistance between pins 3 and 4 of the EGR actuator connector (engine harness side).
a. If the resistance is less than 3 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 3 ohms, Go to step 8.
8. 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 9.
9. Measure the resistance between pin 4 of the EGR actuator connector harness and pin 75 of the MCM 120-pin connector.

10 All information subject to change without notice.


Copyright © 2011 DETROIT DIESEL CORPORATION 12-16-10
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a. If the resistance is greater than 3 ohms, repair wire between pin 4 of the EGR actuator connector harness and pin
75 of the MCM 120-pin connector.
b. If the resistance is less than 3 ohms, Go to step 10.
10. Install test MCM; 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 11.
b. If SRA3 status is not “0” or “OK”, replace the EGR valve actuator.
For the DD13: Refer to section "Removal of the DD13 Exhaust Gas Recirculation Valve Actuator"
For the DD15 and DD16: Refer to section "Removal of the DD15 and DD16 Exhaust Gas Recirculation Valve
Actuator"
11. Clear codes, cycle ignition, and turn 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. Refer to section "Removal of the Motor Control Module"
12. Turn the ignition ON.
13. Measure voltage between pins 1 and 2 of the EGR actuator connector (engine harness side).
a. If voltage is greater than 11 volts, replace the EGR valve actuator. Go to step 28.
For the DD13: Refer to section "Removal of the DD13 Exhaust Gas Recirculation Valve Actuator"
For the DD15 and DD16: Refer to section "Removal of the DD15 and DD16 Exhaust Gas Recirculation Valve
Actuator"
b. If the voltage is less than 11 volts, Go to step 14.
14. Measure the voltage between pin 1 of the EGR actuator connector (harness side) and ground.
a. If voltage is less than 11 volts, repair the wiring between pin 1 of the EGR harness connector and pin 62 of the MCM
120-pin connector.
b. If voltage is greater than 11 volts, repair the wiring between the EGR harness connector pin 2 and pin 67 of the
MCM 120-pin connector.
15. Is fault code SPN 2791 FMI 9 active or inactive?
a. If active, Go to step 16.
b. If inactive, Go to step 17.
16. Using DDDL 7.x, monitor the SRA3 status code.
SRA3 Status Action to Take
EPA07 EPA10
5 Fault Condition Detected - Motor Replace EGR valve actuator. Go to step 28.
23 Reference Sensor Fault - Motor Go to step 17.
17. Turn the ignition OFF (key OFF, engine OFF).
18. Disconnect EGR valve actuator pull rod and inspect ball sockets for free movement. For DD13, ensure part number is
A4711401646 or newer; for DD15/16, ensure part number is A4721400646 or newer.
a. If 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 "Installation of the DD13 Exhaust Gas Recirculation Valve Actuator Pull Rod"
For the DD15 and DD16: Refer to section "Installation of the DD15 and DD16 Exhaust Gas Recirculation Valve
Actuator Pull Rod"
b. If sockets move freely and the part number is recent, Go to step 19.
19. With the EGR valve actuator pull rod disconnected, physically sweep the EGR actuator from stop to stop to check for full
travel.

NOTE: Some resistance is normal; however, the actuator should not bind in any particular spots.

a. If actuator binds at any point in its travel, replace the EGR actuator.
For the DD13: Refer to section "Removal of the DD13 Exhaust Gas Recirculation Valve Actuator"
For the DD15 and DD16: Refer to section "Removal of the DD15 and DD16 Exhaust Gas Recirculation Valve
Actuator"

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12-16-10 Copyright © 2011 DETROIT DIESEL CORPORATION
5 SPN 2791/FMI 14 - ALL YEARS

b. If EGR actuator does not bind, Go to step 20.


20. With the EGR valve actuator pull rod disconnected, turn the ignition ON and monitor SRA3 status using DDDL.
SRA3 Status Value Action to Take
EPA07 EPA10
9 or 10 “Learn: Span too large, using initial value” or Do not replace the actuator. Cycle ignition 2
“Learn: Stops invalid using initial value” more times and continue to monitor SRA3
status; if SRA3 status continues to be the
same. Go to step 21.
Any other value Any other value Replace the EGR valve actuator. Go to step
28.
21. Turn the ignition OFF.
22. With the EGR valve actuator pull rod disconnected, physically move 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 28.
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 pull rod to the EGR valve and EGR actuator.
Go to step 28.
23. Turn the ignition OFF.
24. Disconnect the EGR actuator connector and the MCM 120-pin connector.
25. Measure the resistance between MCM pin 62 and pin 1 of the EGR actuator connector (engine harness side).
a. If resistance is greater than 3 ohms, repair wire between MCM pin 62 and pin 1 of the EGR actuator connector.
b. If resistance is less than 3 ohms, Go to step 26.
26. Disconnect the rear injector harness connector.
27. Measure resistance between MCM pin 62 and pin 14 of the rear injector harness connector.
a. If resistance is greater than 3 ohms, repair wire between MCM pin 62 and pin 14 of the rear injector harness connector.
b. If resistance is less than 3 ohms, replace the MCM. Refer to section "Removal of the Motor Control Module" Go
to step 28.
28. Clear codes, cycle 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”, contact the Customer Support Center at 313-592-5800.

12 All information subject to change without notice.


Copyright © 2011 DETROIT DIESEL CORPORATION 12-16-10