Diagnostic Test

1. Start the engine and allow it to idle long enough for the DEF system become operational.
2. With the scan tool, read DTCs.

   Is the DTC active?

   Yes 

   • If this DTC is present along with any DEF Injector, NOx Sensors, DEF Pump Assembly or DEF Dosing Control Unit, repair those DTCs before proceeding.
   • Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to STANDARD PROCEDURE .

   No 

   • Go To  2

Are there any other DEF Dosing system (not including SCR system DTCs) DTCs set as active along with the P249E DTC?

Yes 

• Perform the diagnostic procedure for the other active DTC before continuing with this test procedure.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to STANDARD PROCEDURE .

No 

• Go To  3

1. Visually inspect the entire exhaust system for signs of a leak.

   Were any exhaust leaks found?

   Yes 

   • Perform the appropriate repair. Refer to appropriate service information.
   • Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to STANDARD PROCEDURE .

   No 

   • Go To  4

1. Turn the engine off.
2. Visually inspect the DEF Supply Pump Assembly and DEF Pressure Line for signs of a fluid leak.

   Are there any leaks in the DEF System?

   Yes 

   • Perform the appropriate repair. Refer to appropriate service information.
   • Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to STANDARD PROCEDURE .

   No 

   • Go To  5

1. Turn the ignition off.
2. Collect a sample of diesel exhaust fluid from the system.
3. Visually inspect the fluid for signs of contamination or debris.
4. Test the quality of the DEF using the DEF/UREA Refractometer 94-F-OOK-108-456 available through Pentastar Service Equipment (PSE).
   NOTE:

   The DEF should register approximately 32.5 percent using a refractometer.

5. To test for hydrocarbons in the DEF tank use hydroscopic test paper (PSE part number. 223-44-863). The test strip come in contact with the DEF fluid in the tank in order to get a valid reading for hydrocarbons present in tank
6. Remove the oil/hydrocarbon detection paper from packing, inspect for color consistency. If color is not consistent replace strip.
7. Disconnect the DEF fill pipe from tank and try to get a sample or remove the DEF tank.
8. Place the detection paper directly into the DEF fluid in the tank. If the light blue paper turns dark blue, oil or hydrocarbon contamination exist.

   Is the diesel exhaust fluid quality within specification and free of debris and contamination?

   Yes 

   • Go To  6

   No 

   • Drain the diesel exhaust fluid from the tank and fill the system. If the fluid is contaminated, follow the cleaning procedure. Refer to TANK, DIESEL EXHAUST FLUID, CLEANING .
   • Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to STANDARD PROCEDURE .

1. Remove the DEF Injector from the Decomposition Tube. Refer to INJECTOR, DIESEL EXHAUST FLUID, REMOVAL .
2. Visually inspect the Decomposition Tube for diesel exhaust fluid deposits.

   Were any deposits found?

   Yes 

   • Clean the deposits from the Decomposition Tube.
   • Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to STANDARD PROCEDURE .

   No 

   • Go To  7

1. Reconnect the DEF Injector harness connector.
2. Place the DEF Injector in a container to capture the fluid sprayed.
3. Turn the ignition on.
4. With the scan tool, navigate to Systems Tests and actuate the Diesel Exhaust Fluid Doser Pump Override Test.
   NOTE:

   This Test will run for six minutes before timing out. The amount of flow may fluctuate through out the test, therefore the test must be allowed to run completely in order for the results to be accurate. The fluid should spray out as a mist. There should be no dripping from the holes in the DEF Injector at any time during the duration of the test procedure.

5. Measure the amount of fluid sprayed after the test times out.

   Does the fluid sprayed measure between 85 ml and 115 ml?

   Yes 

   • Go To  8

   No 

   • Replace the DEF Injector in accordance with the service information. Refer to INJECTOR, DIESEL EXHAUST FLUID, REMOVAL .
   • Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to STANDARD PROCEDURE .

Were any SCR Catalyst system DTCs present?

Yes 

• Replace the SCR Catalyst in accordance with the service information.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to STANDARD PROCEDURE .

No 

• Replace the Ammonia Sensor in accordance with the service information.
• Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to STANDARD PROCEDURE .