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 POWERTRAIN VERIFICATION TEST - 6.7L .

   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 POWERTRAIN VERIFICATION TEST - 6.7L .

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.
   • Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to POWERTRAIN VERIFICATION TEST - 6.7L .

   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.
   • Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to POWERTRAIN VERIFICATION TEST - 6.7L .

   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.
   NOTE:

   The Refractometer test is only done to test the general quality of the fluid. It will not identify any specific contaminants that may be present.

4. Test the quality of the DEF using the DEF/UREA Refractometer (16-5025) available through MoparEssentialTools.com. Then, ENTER EQUIPMENT CATALOG. Or call (855)-298-2687.
   NOTE:

   The DEF should register approximately 32.5 percent using the Refractometer.

5. To test for hydrocarbons in the DEF tank use Hydroscopic test paper (223-44-863) available through MoparEssentialTools.com. Then, ENTER EQUIPMENT CATALOG. Or call (855)-298-2687. The test strip must 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 test paper from the package and inspect for color consistency. If the 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 test paper directly into the DEF fluid in the tank. If the light blue paper turns dark blue, that is an indication that oil or hydrocarbon contamination is present.

   Is the Diesel Exhaust Fluid (DEF) quality within specification and free of debris, hydrocarbons, or other contamination?

   Yes 

   • Go To  6

   No 

   • If the DEF fails the Refractometer quality test, but passes the Hydroscopic test paper test and shows no other signs of hydrocarbons or other contaminants: Just drain the Diesel Exhaust Fluid (DEF) and replace it with fresh fluid.
   • If the DEF fails the Hydroscopic test paper test or shows signs of other contaminants: Drain the Diesel Exhaust Fluid (DEF). Replace the DEF Tank, DEF Supply Pump Assembly, DEF Injector, DEF Supply Tube, DEF Filler Tube, and DEF Filler Cap in accordance with the service information.
   • Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to POWERTRAIN VERIFICATION TEST - 6.7L .

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 POWERTRAIN VERIFICATION TEST - 6.7L .

   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 POWERTRAIN VERIFICATION TEST - 6.7L .

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 POWERTRAIN VERIFICATION TEST - 6.7L .

No 

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