Diagnosis Procedure

1. Turn ignition switch ON.
2. Connect CONSULT and check "ENGINE" diagnostic trouble codes for DTC P208D-00 being current.

Is applicable DTC current?

YES

GO TO 2 .

NO

Refer to Intermittent Incident .

Check the after treatment DEF control module mounting area for air flow obstructions. Restrictions or blockage of the air flow could cause the DEF control module to overheat. Check for the following:

1. Debris on or around the DEF control module.
2. Aftermarket shields, flaps, or brackets mounted too close to the DEF control module.
3. Exhaust leaks allowing exhaust to overheat the temperature sensor module.

Is the inspection result normal?

YES

GO TO 3 .

NO

• Repair or replace the cause of the restricted air flow.
• Remove any debris accumulated near the DEF control module.
• Relocate any aftermarket accessories that might be restricting air flow.
• Repair any causes of excessive heat to the DEF control module.
• GO TO 9 .

1. Turn ignition switch OFF.
2. Disconnect the DEF supply pump assembly connector.
3. Inspect connector for the following:
   • Loose connector.
   • Corroded pins.
   • Bent or broken pins.
   • Pushed back or expanded pins.
   • Moisture in or on the connector.
   • Missing or damaged connector seals.
   • Dirt or debris on or in the connector pins.
   • Connector shell broken.
   • Wire insulation damage.
   • Damaged connector locking tab.

Is the inspection result normal?

YES

GO TO 4 .

NO

Repair or replace error-detected parts.

1. Turn ignition switch OFF.
2. Disconnect the DEF control module.
3. Inspect both connectors for the following:
   • Loose connector.
   • Corroded pins.
   • Bent or broken pins.
   • Pushed back or expanded pins.
   • Moisture in or on the connector.
   • Missing or damaged connector seals.
   • Dirt or debris on or in the connector pins.
   • Connector shell broken.
   • Wire insulation damage.
   • Damaged connector locking tab.

Is the inspection result normal?

YES

GO TO 5 .

NO

Repair or replace error-detected parts.

1. Turn ignition switch ON.
2. Check for continuity between the pump motor A supply circuit and all other pins at the DEF control module harness connector.

Is the inspection result normal?

YES

GO TO 6 .

NO

Repair short circuit in harness or connectors.

1. Turn ignition switch ON.
2. Check for continuity between the pump motor B supply circuit and all other pins at the DEF control module harness connector.

Is the inspection result normal?

YES

GO TO 7 .

NO

Repair short circuit in harness or connectors.

1. Turn ignition switch ON.
2. Check for continuity between the pump motor C supply circuit and all other pins at the DEF control module harness connector.

Is the inspection result normal?

YES

GO TO 8 .

NO

Repair short circuit in harness or connectors.

1. Turn ignition switch OFF.
2. Connect DEF control module.
3. Turn ignition switch ON.
4. Wait 30 seconds.
5. Using CONSULT check for "ENGINE" diagnostic trouble codes.
   NOTE: Other DTCs will be set.

Is P208A-00 DTC current and P208D-00 DTC past?

YES

• Replace the DEF supply pump assembly. Refer to Removal and Installation .
• GO TO 9 .

NO

• Replace the DEF control module. Refer to Removal and Installation .
• GO TO 9 .

1. Turn ignition switch OFF.
2. Connect all harness connectors.
3. Turn ignition switch ON.
4. Using CONSULT erase "ENGINE" diagnostic trouble codes.
5. Operate the engine within the "Conditions for setting the DTC".
6. Check for "ENGINE" diagnostic trouble codes.

Is P208D-00 DTC current?

YES

Return to Diagnosis Procedure. Refer to DTC Description .

NO

Repair complete.