2019 MY OBD SYSTEM OPERATION

SUMMARY FOR DIESEL ENGINES

Table of Contents
INTRODUCTION – OBD-II and HDOBD ............................................................................................................... 5
GENERAL DESCRIPTION DIESEL ENGINES .................................................................................................... 6
System Schematic 6.7L Chassis Certified ............................................................................................ 7
System Schematic 6.7L Dynamometer Certified .................................................................................. 8
System Schematic 3.2L Chassis Certified .......................................................................................... 12
System Schematic 1.5L Chassis Certified .......................................................................................... 13
System Schematic 3.0L Chassis Certified .......................................................................................... 15
NON-METHANE HYDROCARBON (NMHC) CONVERTING CATALYST MONITOR ...................................... 16
Diesel Oxidation Catalyst Efficiency Monitor - Functional ................................................................... 16
Diesel Oxidation Catalyst Efficiency Monitor – Intrusive ..................................................................... 17
Diesel Oxidation Catalyst DPF Regeneration Assistance Monitor ....................................................... 18
Diesel Oxidation Catalyst SCR Assistance Monitor ............................................................................ 18
OXIDES OF NITROGREN (NOx) CONVERTING CATALYST MONITORING.................................................. 19
Selective Catalyst Reduction – Catalyst Efficiency Monitor ................................................................ 19
Selective Catalyst Reduction – SCR System Fault ............................................................................. 22
Selective Catalyst Reduction Feedback Control Monitors................................................................... 23
Selective Catalyst Reduction Tank Level ........................................................................................... 24
MISFIRE MONITOR ............................................................................................................................................ 25
Misfire System Overview ................................................................................................................... 25
Misfire Algorithm Processing ............................................................................................................. 25
FUEL SYSTEM MONITOR .................................................................................................................................. 27
Fuel System Overview....................................................................................................................... 27
Fuel Rail Pressure Sensor Checks .................................................................................................... 27
Fuel Rail Pressure Controller Range Check: ...................................................................................... 29
Fuel Rail Temperature Sensor Checks .............................................................................................. 30
Fuel Volume Control Valve Checks.................................................................................................... 31
Fuel Pressure Control Valve Checks (6.7L only) ................................................................................ 32
Fuel Low Pressure Lift Pump Checks ................................................................................................ 33
Fuel Injector Checks .......................................................................................................................... 35
Fuel Injector Code Missing/Invalid: .................................................................................................... 37
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 Fuel Rail Pressure Monitors:.............................................................................................................. 38
Injection Timing / Injection quantity .................................................................................................... 40
Fuel Mass Observer (Global Fuel Bias) ............................................................................................ 42
Feedback control: .............................................................................................................................. 43
Zero Fuel Calibration: ........................................................................................................................ 43
EXHAUST GAS SENSOR MONITOR................................................................................................................. 48
Feedgas NOx Sensor – 3.2L and 6.7L F650-F750 ............................................................................. 48
Feedgas NOx Sensor – 3.0L and 6.7L F250-F550 ............................................................................. 55
Feedgas NOx Sensor Plausibility Monitors ........................................................................................ 60
Tailpipe NOx Sensor – 3.2L and 6.7L F650-F750 .............................................................................. 63
Tailpipe NOx Sensor – 6.7L F250-F550 ............................................................................................. 71
PARTICULATE MATTER SENSOR MONITOR ................................................................................................. 76
Exhaust Gas Particulate Matter Sensor (PMS)................................................................................... 76
Particulate Matter Sensor Sampling Monitor ...................................................................................... 82
Particulate Matter Sensor Regeneration Monitor ................................................................................ 83
Particulate Matter Filter Monitor Using PM Sensor ............................................................................. 84
EXHAUST GAS RECIRCULATION (EGR) SYSTEM MONITOR ....................................................................... 86
EGR Rate System Monitor ................................................................................................................ 86
EGR Cooler / EGR Cooler Bypass Monitor ........................................................................................ 89
EGR System Slow Response ............................................................................................................ 93
EGR Control Limits Monitor ............................................................................................................... 93
Mass Airflow Closed-loop Control Limits Monitor ............................................................................... 94
BOOST PRESSURE CONTROL SYSTEM MONITORING................................................................................ 95
Intrusive Turbo Position and Response Monitoring ............................................................................ 95
Overboost Monitoring ........................................................................................................................ 97
Threshold Overboost Monitoring ........................................................................................................ 98
Underboost Monitoring ...................................................................................................................... 99
Charge Air Cooler Monitoring .......................................................................................................... 101
PARTICULATE MATTER (PM) FILTER MONITORING ................................................................................... 102
DPF Filter Missing Substrate Monitor ............................................................................................... 102
DPF Frequent Regeneration Monitor ............................................................................................... 103
DPF Incomplete Regeneration Monitor ............................................................................................ 104
DPF Feedback Control Monitors ...................................................................................................... 105
DPF Restriction Monitor .................................................................................................................. 106
ENGINE COOLING SYSTEM MONITORING................................................................................................... 107
Thermostat Monitor ......................................................................................................................... 107
Primary Coolant Temp Rise Monitoring............................................................................................ 108
Secondary Coolant Temp Rise Monitoring ....................................................................................... 109
COLD START EMISSION REDUCTION STRATEGY MONITORING ............................................................. 110

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 Cold Start Emission Reduction Component Monitor ......................................................................... 110
CRANKCASE VENTILATION MONITOR ......................................................................................................... 114
ENGINE SENSORS .......................................................................................................................................... 115
Air Temperature Rationality Test ..................................................................................................... 115
Barometric Pressure and Manifold Absolute Pressure...................................................................... 122
Turbine Upstream Pressure Sensor Plausibility Checks ................................................................... 125
Upstream Turbine Pressure Sensor Signal Range Check ................................................................ 126
EGR Valve Position Sensor ............................................................................................................. 126
Throttle Position Sensor .................................................................................................................. 127
EGR Downstream Temperature Sensor Dynamic Plausibility Check ................................................ 127
Engine Coolant & Engine Oil Correlation ......................................................................................... 127
Cam and Crank Sensor: .................................................................................................................. 131
Mass Air Meter ................................................................................................................................ 133
MAF Rationality Check .................................................................................................................... 134
Air Path Leakage Check .................................................................................................................. 136
Turbocharger/Boost Sensor ............................................................................................................. 138
Turbocharger Position Sensor Signal Range Check (Turbocharger Position Sensor Equipped Only) 139
Engine Oil Pressure Sensor/Switch Signal Range Check (EOP Sensor Equipped Only) .................. 139
Engine Oil Pressure Sensor/Switch Circuit Plausibility Check (EOP Sensor Equipped Only) ............ 139
Engine Oil Pressure Too Low (EOP Sensor Equipped Only) ............................................................ 140
DEF Control and Delivery Systems – 3.2L Diesel ............................................................................ 140
DEF Control and Delivery Systems – 6.7L & 3.0L Diesel ................................................................. 149
DEF Control and Delivery Systems – 1.5L Diesel ............................................................................ 165
Exhaust Gas Temperature Sensor Rationality Test .......................................................................... 185
Diesel Particulate Filter Pressure Sensor ......................................................................................... 188
Diesel Particulate Filter Pressure Offset Test ................................................................................... 189
Diesel Particulate Filter Pressure Rationality Test ............................................................................ 190
DRIVER INPUT DEVICES................................................................................................................................. 191
Accelerator Pedal Diagnostics ......................................................................................................... 191
Brake Switch Diagnostics ................................................................................................................ 191
ENGINE OUTPUTS ........................................................................................................................................... 192
Turbocharger Actuator Jammed Detection (Turbocharger Position Sensor Equipped Only) .............. 192
Turbocharger Actuator Signal Range Check .................................................................................... 192
EGR Valve Actuator Signal Range Check ........................................................................................ 192
EGR Valve Offset Learn Limits ........................................................................................................ 193
EGR Valve Actuator Jammed Detection .......................................................................................... 194
Throttle Valve Actuator Signal Range Check ................................................................................... 194
Throttle Valve Offset Learn Limits .................................................................................................... 195
Throttle Valve Actuator Jammed Detection ...................................................................................... 195

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 ECB Valve Actuator Signal Range Check ........................................................................................ 196
Engine Over Speed Monitor ............................................................................................................ 197
Lack of Communication ................................................................................................................... 203
Active Grill Shutter Control – 3.0L and 1.5L Only ............................................................................. 205
GLOW PLUGS AND GLOW PLUG CONTROL MODULE (GPCM) FOR 6.7L AND 3.0L ............................... 208
DOWN STREAM INJECTION (DSI) SYSTEM .................................................................................................. 213
DSI Vaporizer Pump Circuit Continuity Check Monitor ..................................................................... 213
DSI Vaporizer Glow Plug Circuit Continuity Check Monitor .............................................................. 214
DSI Vaporizer Glow Plug Relay Plausibility Check Monitor .............................................................. 215
DSI Leakage Monitor ....................................................................................................................... 216
MISCELLANEOUS ECU MONITORS ............................................................................................................... 217
Fan Control Checks ......................................................................................................................... 217
ECU Temperature Sensor Checks ................................................................................................... 218
Vehicle Configuration Information .................................................................................................... 219
Transmission Park/Neutral Gear Check at Start-Up ......................................................................... 219
COMPREHENSIVE COMPONENT MONITOR - TRANSMISSION ................................................................. 220
Transmission Inputs ........................................................................................................................ 220
Transmission Outputs...................................................................................................................... 223
Transmission Control Module (TCM) ............................................................................................... 227
6R140 (RWD) TRANSMISSION WITH EXTERNAL PCM OR TCM ................................................................ 228
ON BOARD DIAGNOSTIC EXECUTIVE .......................................................................................................... 232
EXPONENTIALLY WEIGHTED MOVING AVERAGE ...................................................................................... 233
SERIAL DATA LINK MIL ILLUMINATION ......................................................................................................... 234
CALCULATED LOAD VALUE ........................................................................................................................... 235
I/M READINESS ................................................................................................................................................ 235
Power Take Off Mode ....................................................................................................................... 236
IN-USE MONITOR PERFORMANCE RATIO / MODE $09 RESULTS ............................................................ 237
MODE $06 RESULTS ....................................................................................................................................... 239

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 INTRODUCTION – OBD-II and HDOBD

OBD-II Systems

On Board Diagnostics II - Passenger Cars, Light-Duty Trucks, and Medium-Duty Vehicles and Engines
certified under title 13, CCR section 1968.2

California OBD-II applies to all California and "CAA Sec. 177 States" for gasoline engine vehicles up to 14,000 lbs.
Gross Vehicle Weight Rating (GVWR) starting in the 1996 MY and all diesel engine vehicles up to 14,000 lbs.
GVWR starting in the 1997 MY.

"CAA Sec. 177 States" or "California States" are states that have adopted and placed into effect the California Air
Resources Board (CARB) regulations for a vehicle class or classes in accordance with Section 177 of the Clean
Air Act.. At this time, “CAA Sec. 177 States" are Massachusetts, New York, Vermont and Maine for 2004, Rhode
Island, Connecticut, Pennsylvania for 2008, New Jersey, Washington, Oregon for 2009, Maryland for 2011,
Delaware for 2014 and New Mexico for 2016. These States receive California-certified vehicles for passenger cars
and light trucks, and medium-duty vehicles, up to 14,000 lbs. GVWR."

Federal OBD applies to all gasoline engine vehicles up to 8,500 lbs. GVWR starting in the 1996 MY and all diesel
engine vehicles up to 8,500 lbs. GVWR starting in the 1997 MY. US Federal only OBD-certified vehicles may use
the US Federal allowance to certify to California OBD II but then turn off/disable 0.020" evap leak detection).

Starting in the 2004 MY, Federal vehicle over 8,500 lbs. are required to phase in OBD-II. Starting in 2004 MY,
gasoline-fueled Medium Duty Passenger Vehicles (MDPVs) are required to have OBD-II. By the 2006 MY, all
Federal vehicles from 8,500 to 14,000 lbs. GVWR will have been phased into OBD-II.

Heavy Duty OBD Systems

Heavy Duty On-Board Diagnostics - Heavy-duty engines (>14,000 GVWR) certified to HD OBD under title
13, CCR section 1971.1(d)(7.1.1) or (7.2.2) (i.e., 2010 and beyond model year diesel and gasoline engines
that are subject to full HD OBD)

Starting in the 2010 MY, California and Federal gasoline-fueled and diesel fueled on-road heavy duty engines used
in vehicles over 14,000 lbs. GVWR are required to phase into HD OBD. The phase-in starts with certifying one
engine family to HD OBD in the 2010 MY. (2010 MY 6.8L 3V Econoline) By the 2015 MY, all engine families must
certify to the HD OBD requirements. Vehicles/engines that do not comply with HD OBD during the phase-in period
must comply with EMD+.

OBD-II system implementation and operation is described in the remainder of this document.

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 GENERAL DESCRIPTION DIESEL ENGINES

The 6.7L is a V8 engine designed to meet customer expectations of high horsepower and torque with exceptional
fuel economy and low NVH. It must do this while meeting the tough emissions standards set by the EPA and
CARB.

Some of the technologies employed to meet these diverse criteria include a Variable Geometry Turbocharger
(VGT), common rail fuel injection system, electronically controlled, cooled EGR, a diesel oxidation catalyst (DOC) ,
Selective Catalytic Reduction catalyst (SCR), Diesel Exhaust Fluid (DEF) injection system, and a diesel particulate
filter (DPF).

The system schematic on the next page shows the path of the air as it is compressed by the turbocharger, cooled
by the air-to-coolant intercooler, and mixed with the cooled EGR gases. The state of this compressed and heated
air is sensed by the manifold absolute pressure (MAP) sensor just before it enters the cylinders and the two
temperature sensors that represent Charge Air Cooler Outlet temperature (CACT1) and EGR Cooler outlet
temperature (EGRCOT). The exhaust gas pressure is measured by the exhaust backpressure (EP) sensor before
it exits through the turbocharger. The exhaust after treatment system consists of a DOC, a SCR, a DPF and a
muffler.

An electronic, proportional valve controls EGR rates with an integral position sensor (EGRP). Flows are
determined by valve position and the amount that backpressure exceeds boost pressure. An EGR throttle
(EGRTP) is used for regeneration control as well as to optimize the boost pressure vs. backpressure levels.

Fuel injection pressure is measured by the high-pressure fuel rail sensor (FRP). Injection pressure is controlled by
the high pressure pump and two regulating valves, a Pressure Control Valve (PCV), and a Fuel Metering Unit
(MeUn), formerly known as Volume Control Valve (VCV).

Engine speed (N) and crankshaft position are determined by the crankshaft position sensor (CKP) which senses a
60 minus 2 tooth target wheel. Camshaft position is determined by the camshaft position sensor (CMP), which
senses the profile of a multiple lobed camshaft.

Atmospheric pressure is determined by the Barometric Pressure sensor (BARO) mounted internally in the Engine
Control Module (ECM).

During engine operation, the ECM calculates engine speed from the crankshaft position sensor. The ECM
controls engine operation by controlling the piezo injector opening and closing times as well as the pressure at
which the fuel is injected, thereby controlling fuel quantity and timing. Simultaneously, airflow is modulated by
controlling the turbocharger vane position.

Fuel quantity is controlled by injector “on time” (pulse width) and the fuel rail pressure. Desired engine speed is
determined from the position of the accelerator pedal.

The 3.2L I5, 3.0L V6, and 1.5L I4 engines have the same technologies and engine layout employed on the 6.7L V8
engine with some exceptions. See engine diagrams below.

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System Schematic 6.7L Chassis Certified

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System Schematic 6.7L Dynamometer Certified

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 Actuators Acronym Sensors Acronym
DEF (Reductant) System
DEF Pump DEF Temp-Level Combination
Sensor
DEF Tank Heater Heater #1 DEF Pressure Sensor
DEF Line Heater Heater #2
DEF Pump Heater Heater #3
DEF Injector
NOx Sensor System
Feedgas NOx Sensor Controller NOx11 NOx “A” Sensor
Tailpipe NOx Sensor Controller NOx12 NOx “B” Sensor
Reductant Control Module RDCM
Reductant Quality Module RDQM
Boost System
Variable Geometry Turbo VGTC Manifold Pressure Sensor MAP
Control
Variable Geometry Turbo VGTP Charge Air Cooler Temperature CACT1
Position at Outlet
Variable Nozzle Turbocharger VNT Mass Airflow Sensor MAF
Motor
Intake Air Temperature IAT11
Exhaust Back Pressure EBP or P3
Exhaust Gas Recirculation System
Exhaust Gas Recirculation Valve EGRVC Exhaust Gas Recirculation Valve EGRVP
Control Position
Exhaust Gas Recirculation EGRCBV Exhaust Gas Recirculation EGRT_C/EGR_COT
Cooler Bypass Vacuum Control Cooler Gas Outlet Temperature
Solenoid
EGR CoolerGas Inlet EGRT_A / EGR_CIT/ T3
Temperature
EGR Throttle Control DIAFC EGR Throttle Position Sensor DIAFP
Fuel System
High Pressure Fuel Volume FVCV High Pressure Fuel Rail FRPS
Control Valve Pressure Sensor
High Pressure Fuel Pressure FRPRV Low Pressure Fuel Delivery FDPS
Relief Valve Switch
Fuel Injectors INJ 1-8 Low Pressure Fuel Temperature FTS
Sensor
Low Pressure Fuel Pump and DFCM
Filters

Water In Fuel Sensor WFS

Fuel Tank Level Sensor FLI
Glow Plug System
Glow Plugs
Glow Plug Control Module GPCM
Exhaust System
Particulate Matter Sensor PMS Diesel Oxidation Inlet DOC_IT or EGT11
Temperature
Reductant Level Sensor RDLV Diesel Oxidation Outlet DOC_OT or EGT12
Temperature
Selective Catalytic Reduction SCR_OT or EGT 13
Outlet Temperature
Upstream Catalyzed Diesel DPFP
Particulate Filter Pressure
Downstream Diesel Particulate DPF_OT or EGT 14
Filter Temperature
Single Pressure Gauge Sensor SPGS
Engine System
Electric Clutch Fan Controller FC-V Cam Shaft Position Sensor CMP
Engine Coolant Temperature ECT

Crank Shaft Position Sensor CKP

Engine Oil Temperature EOT
Engine Oil Pressure Switch EOP_SW
Low Temperature Coolant Loop ECT2
Temperature
Engine Fan Speed Sensor FSS
Environmental Temperature ENV_T
Sensor
Barometric Pressure Sensor BARO

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The dynamometer certified application of the 6.7L diesel engine has a similar layout to the chassis certified version.
The main difference is a change in the order of the aftertreatment systems.

Dynamometer certified 6.7L exhaust system layout.

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2019 MY 6.7L V8 Diesel Exhaust Features, Medium Duty, Chassis Cert

Tailpipe
cDPF
Cu-
Zeolite
DEF (urea) SCR
Injector
Engine 6.7 F-250
Out Superduty Diesel
Exhaust System
Architecture
Pt-Pd DOC

2019 MY 6.7L V8 Diesel Exhaust Features, Medium Duty, Dyno Cert

Tailpipe

Cu-
Zeolite
SCR

cDPF
Engine
Out 6.7 F-250
Superduty Diesel
Exhaust System
Architecture
Pt-Pd DOC

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System Schematic 3.2L Chassis Certified

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System Schematic 1.5L Chassis Certified

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2019 MY 1.5L Diesel Exhaust Features, Medium Duty, Chassis Cert

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System Schematic 3.0L Chassis Certified

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NON-METHANE HYDROCARBON (NMHC) CONVERTING CATALYST MONITOR

Diesel Oxidation Catalyst Efficiency Monitor - Functional

The Diesel Oxidation Catalyst (DOC) is monitored to ensure it is capable of converting hydrocarbons and carbon
monoxide. The monitor is only run during aftertreatment regeneration events. After entering regen, there is a short
delay to allow the DOC to achieve light-off temperature. Then the exotherm is monitored for a short period of time
and normalized versus an expected exotherm (a function of post-injection fuel quantity and ambient air temp). The
exotherm is defined as the DOC outlet temperature (EGT12) minus the DOC inlet temperature (EGT11). The
normalized exotherm is filtered for a short period of time, and then compared to a threshold. If the normalized
exotherm is below the threshold, a fault is indicated. No other preconditioning is required. This monitor is only used
on 6.7L F350-F750 chassis cab vehicles.

DOC Efficiency Monitor Summary:

DTCs P0420 – Catalyst System Efficiency Below Threshold
Monitor execution Once per driving cycle during which an active DPF regeneration occurs
Monitor Sequence None
Sensors OK EGT11, EGT12, ECT, MAF, IAT
Monitoring Duration 4 minutes

Typical DOC Efficiency Monitor Entry Conditions:

Entry condition Minimum Maximum
DPF regeneration event
Engine speed 1000 rpm 3000 rpm
Torque set point 100 Nm 1000 Nm
Engine coolant temperature 70 deg C
DOC inlet temperature 200 deg C 500 deg C
PTO inactive

Typical DOC Efficiency Monitor Malfunction Threshold:

Normalized exotherm is less than 40% of the expected exotherm for 60 seconds

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Diesel Oxidation Catalyst Efficiency Monitor – Intrusive

The Diesel Oxidation Catalyst (DOC) is monitored to ensure it is capable of converting hydrocarbons and carbon
monoxide. While entry conditions are met, a small quantity of fuel is post-injected late in the combustion cycle (similar
injection timing as DPF regen). The actual exothermic efficiency is calculated from the temperature rise across the
DOC and normalized by the expected exothermic efficiency (based on quantity of fuel injected), which results in a
ratio having values between 0-1. If the normalized exotherm is below the threshold, a fault is indicated. No other
preconditioning is required.

The Intrusive DOC Monitor is applicable to all 6.7L pickup vehicles and all 3.2L, 3.0L, and 1.5L products.

DOC Efficiency Monitor Summary:

DTCs P0420 – Catalyst System Efficiency Below Threshold
Monitor execution Once every 400 km
Monitor Sequence None
Sensors OK EGT11, EGT12, ECT, MAF, IAT
Monitoring Duration With valid entry conditions:
Monitor session: 75 sec (includes time to post-inject fuel and calculate
metric)
Total time: Approx. 8 minutes (3 sessions required in order to complete,
120 sec wait time between sessions)

Typical DOC Efficiency Monitor Entry Conditions:

Entry condition Minimum Maximum
Distance since last monitor completion 400 km
Time since entering normal Engine 300 sec (if transitioning from
Operating Mode (EOM0) EOM1/2 (Regen), EOM3
(Catalyst Warmup)
600 sec (if transitioning from
Aftertreatment Overheat mode
Pre-DOC Temp 210 deg C 280 deg C
Post-DOC Temp 210 deg C 1000 deg C
Exhaust Mass Flow Rate 70 kg/hr 1000 kg/hr
Post Injection Fuel (from requests other than -10 mg/stroke 10 mg/stroke
this monitor)
Engine coolant temperature 70 deg C
Ambient Air Temperature -6.7 deg C
Barometric Pressure 75.5 kPa
Engine speed 1000 rpm
Torque set point 50 Nm

Typical DOC Efficiency Monitor Malfunction Threshold:

Monitor requires 3 failing results in order to diagnose a failed DOC. (In the event of a failing result, the monitor
will immediately run again, bypassing the 400 km threshold above, until either a passing result or three
consecutive failing results are obtained.)
Normalized exotherm efficiency must be less than 30% of expected for all 3 monitor sessions.
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Diesel Oxidation Catalyst DPF Regeneration Assistance Monitor

The DOC is monitored to ensure it is capable of generating a sufficient exotherm to allow DPF regeneration events
by burning the soot which is stored in the Diesel Particulate Filter (DPF). This is accomplished with the same
diagnostic described above for the DOC Catalyst Efficiency Monitor.

Diesel Oxidation Catalyst SCR Assistance Monitor

The DOC in this system is not utilized to provide any changes in the feedgas constituency that would aid in the proper
SCR operation.

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OXIDES OF NITROGREN (NOx) CONVERTING CATALYST MONITORING

Selective Catalyst Reduction – Catalyst Efficiency Monitor

The SCR catalyst is monitored to ensure it is capable of NOx conversion. NOx concentrations upstream and
downstream of the SCR are measured with NOx sensors. While entry conditions are met, these concentrations are
used to calculate the cumulative efficiency of the SCR catalyst for a calibrated sample period (approx. 30 second
duration). The efficiency is then compared to a threshold.

If the efficiency is above the threshold, the test is considered a passing result and the monitor completes. If the
efficiency is below the threshold, then one of two results happen. During a particulate filter regeneration, all NH3 is
purged from the SCR catalyst, providing a good estimate to the model of ammonia storage. Over time, accumulated
errors reduce the accuracy of the ammonia storage model. If the SCR catalyst monitor efficiency is below the
threshold and the total DEF injection quantity since the conclusion of the previous particulate filter regeneration is
sufficiently small that the ammonia storage model has high confidence, then the monitor will immediately report a
failure. If the total DEF injection quantity is above the threshold where the ammonia storage model may be
inaccurate, then the monitor will intrusively adjust ammonia (NH3) storage in the SCR. The decision to
increase/decrease the NH3 storage is determined by an algorithm that uses the upstream/downstream NOx sensors
to assess whether the SCR is slipping NOx or ammonia:

 If the SCR is slipping NOx, the storage is increased. The adjustment quantity is determined by the
difference between the calculated efficiency and the threshold.
o If the efficiency is close to the threshold, a small adjustment (approx. 0.5 gram of NH3) is made.
o If the efficiency is substantially lower than the threshold, a larger adjustment (1-2 grams of NH3)
is made.
 If the SCR is slipping ammonia, the storage is decreased. The adjustment quantity is determined by the
time necessary for the NOx/NH3 slip algorithm to transition from NH3 back to NOx slip. If the SCR is
slipping NH3 for a long period of time, a larger adjustment can be made.

Typical time to make a storage adjustment is approximately 5 minutes. Once the storage adjustment has been
completed, the monitor will calculate NOx conversion across the SCR again and compare to the same failure
threshold. If the efficiency is above the threshold, the test is considered a passing result and the monitor completes.
If the efficiency is below the threshold, the test is considered failed, the fault is indicated, and the monitor is complete.

On the 3.2L Transit, the SCR conversion efficiency monitor uses a EWMA.

EWMA Specific Calibration Parameter Values for SCR conversion efficiency

Parameter Value Unit Description
Nominal Component/System (i.e.,
Healthy Component/System) 99 % 4K catalyst average result
Threshold is variable being a
function of space velocity and
temperature. Numbers here
are representative of
Malfunction Criteria Threshold 85 % conditions over the FTP cycle.
Mean Value WPA 97 % Full Useful Life Cat Mean
Mean Value BPU 80 % Threshold Cat Mean
The number of sample results
Maximum No. of Samples Per allowed during a driving cycle
Driving Cycle for Normal Monitoring for normal monitoring events
Events 1 - (i.e., not FIR or Step Change)
Manufacturers shall submit
data demonstrating the
No. of Samples During the FTP number of samples during the
Cycle for Normal Monitoring Events 1 - FTP cycle can be achieved

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 1=Number of samples
required to report readiness
after a code clear.
2=Number of samples
No. of Samples Required to Set required to report readiness
Readiness 1 or 2 - after a NVM clear
λ 0.2 - Normal EWMA filter constant
N/A, fast initial
response logic
uses unfiltered
results, no
initialization is Initialization EWMA value after
Fast Initial Response Initial Value needed. % code clear
N/A, no filtering
is applied if
using fast initial EWMA filter constant used
Fast Initial Response λ response - after code clear
Maximum No. of Samples Per
Driving Cycle for Fast Initial
Response Events 1 -
No. of Samples During the FTP
Cycle for Normal Monitoring Events 1 -
Step Change Enable Threshold 95 % FUL Mean - 2 sigma
N/A, step change
logic uses
unfiltered results,
no initialization is Initialization EWMA value after
Step Change Initial Value needed. % step change delta detected
Set to the max of (Threshold
Mean or Empty Can Mean + 3
Malfunction Threshold – SCL 80 % sigma)
N/A, no filtering
is applied if
using step EWMA filter constant used for
Step Change λ change logic - step change
Maximum No. of Samples Per
Driving Cycle for Step Change
Events 1 -
No. of Samples During the FTP
Cycle for Step Change Events 1 -

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Monitor Summary:
DTC P20EE – SCR NOx Catalyst Efficiency Below Threshold
Monitor execution P20EE - Once per driving cycle
Sensors OK NOx, EGT12, EGT13, ECT, DEF injection system, MAF, BARO, O2, EGR system
Monitoring Duration P20EE – 1 Minute (with no storage adjustment), 5 minutes with storage adjustment

Typical Entry Conditions:

Entry condition Minimum Maximum
Barometric Pressure 81.2 kPa 120 kPa
Ambient air temperature -6.7 degC
Engine coolant temperature 70 degC 120 degC
Engine Speed 1000 rpm 3000 rpm
Indicated Torque 150 800
Torque Transients -20 N-m/s 20 N-m/s
Feedgas NOx (upstream of SCR) 800 ppm
Exhaust gas flowrate 145 kg/hr 1800 kg/hr
DEF storage quantity 0.75 g 8g
Ratio of DEF storage (actual vs desired) 40% understored 10% overstored
SCR Inlet temp 200 degC 320 degC
SCR Outlet temp 180 degC 320 degC
Filtered rate of change of SCR inlet temp 10 deg/sec
NH3 dosing (ratio of NH3 vs FG NOx) 0.8 ppm NH3 / ppm NOx 3.0 ppm NH3 / ppm NOx
Engine Operating Mode Not in Regen, not in SCR warm-
up mode
Dosing not limited by AECD
No faults on pertinent sensors

Typical Malfunction Thresholds:

P20EE: If the cumulative efficiency of the SCR Catalyst is less than 55%, a fault is indicated.

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Selective Catalyst Reduction – SCR System Fault

The 3.2L diesel uses a Dosing Control Module (DCM) to control the DEF delivery system for the SCR catalyst.
This module detects certain fault codes directly. If it detects a fault that requires illumination of the Malfunction
Indicator Light (MIL) then it causes a P204F code to be reported by the ECU in addition to the specific pinpointing
code reported by the DCU.

Monitor Summary:
DTCs P204F – Reductant System Performance (Bank 1)
Monitor execution P204F - Continuously
Sensors OK None
Monitoring Duration P204F - Continuous

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Selective Catalyst Reduction Feedback Control Monitors

The SCR system is monitored to ensure the proper closed loop control of the reductant injection. As part of the
reductant injection control, a correction factor is adapted to account for long term drift of the system (injector, etc).
This correction factor is monitored continuously. If the correction factor reaches a threshold in the positive or negative
direction for a sufficient period of time, a fault will be indicated.

A SCR Time to Closed Loop monitor is implemented to ensure that SCR feedback occurs when expected. Once
entry conditions are met, a timer is incremented. If the fraction of time in closed loop control is less than a threshold,
a fault is indicated.

Additionally, the system has a temperature controller that increased the tailpipe temperatures under certain situations
to improve the function of the SCR system. This controller is also monitored.

Monitor Summary:
DTCs P249D – SCR Feedback at Minimum Limit
P249E – SCR Feedback at Maximum Limit
P249C – SCR Time to Closed Loop
Monitor execution Continuous
Monitor Sequence None
Sensors OK NOx, EGT12, EGT13, ECT, EGT11 EGT14, MAF, BARO, IAT,
DPFP, and EGR system
Monitoring Duration 5 minutes

Typical Entry Conditions:

Entry condition Minimum Maximum
For P249D/E:
Long Term Adaptation is enabled (SCR
catalyst is at acceptable and stable
operating temperature and has proper
ammonia storage, vehicle is in steady-
state operation
For P249C only:
Engine speed 800 rpm 3000 rpm
Torque set point 0 Nm 1000 Nm
Barometric pressure 74.5 kPa
Ambient temperature -6.7 deg C
Engine coolant temperature 70 deg C
Modeled SCR temperature 160 deg C 550 deg C

Typical Malfunction Thresholds:

P249D: If the correction factor is clipped at its minimum value for 30 seconds then a fault is indicated.

P249E: If the correction factor is clipped at its maximum value for 30 seconds then a fault is indicated.

P249C: The error is set as soon as the fraction of closed loop operation vs expected is less than the
threshold. The monitor needs to run for 300 seconds to call it complete.

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Selective Catalyst Reduction Tank Level

The SCR system is monitored to ensure the level of DEF in the reductant tank is sufficient to achieve system
performance. No fault codes are reported related to this system described below – information will be displayed on
the vehicle cluster only.

Reported Level Ford Example Cluster Information How?

8,500 mi EXHAUST FLUID Or
EXHAUST FLUID On Request: (System Check)

Oil Change LEVEL OK UNDER HALF FULL

Interval Appears at Threshold and Every Key Cycle After / DTE

RESET
EXHAUST FLUID Can be accessed by system check
800 mi RESET notes
RANGE: 800 Mi
the ability
to press the Appears at Threshold & Every Key Cycle After. Mileage
EXHAUST FLUID

RESET
Reset or Info shown will count-down. DTE Can be accessed by system
300 mi check, Solid Icon.
RANGE: 300 Mi or OK Button.
Appears at Threshold & Every Key Cycle After. Mileage

RESET
shown will count-down. DTE Can be accessed by system

RESET
99 mi SPEED LIMITED EXHAUST FLUID
check, Chime 4 times on key cycle, Solid Icon. Count
55 MPH IN 99Mi LOW Down tied to Odometer from 299 actual miles.

Appears at Threshold. Chime 4 times and repeat every 5

RESET

RESET
55 MPH MAX UPON EXHAUST FLUID
P203F 0 mi
RESTART EMPTY
minutes, Flashing Icon synchronized to chimes, re-
settable message.

Appears at Threshold. Chime 4 times and repeat every 5

RESET

RESET
SPEED LIMITED EXHAUST FLUID
restart TO 55 MPH EMPTY
minutes, Flashing Icon synchronized to chimes, re-
settable message.

0 mi
RESET

RESET
50 MPH MAX UPON EXHAUST FLUID Appears at Threshold. Chime 4 times and repeat every 5
minutes, Flashing Icon synchronized to chimes, re-
RESTART EMPTY settable message.

Appears at Threshold. Chime 4 times and repeat every 5

RESET
RESET

SPEED LIMITED EXHAUST FLUID minutes, Flashing Icon synchronized to chimes, re-
restart TO 50 MPH EMPTY settable message.

Appears at Threshold. Chime 4 times and repeat every 5

RESET RESET

EXHAUST FLUID minutes, Flashing Icon synchronized to chimes, re-

RESET RESET

ENGINE IDLED
settable message.
-100 mi EMPTY
UPON REFUEL
ENGINE IDLED X OVERRIDES Appears at Threshold. Chime 4 times and repeat every 5
refuel minutes, Flashing Icon synchronized to chimes, re-
SEE MANUAL AVAILABLE settable message.

DEF Override countdown 5-4-3-2-1-NO

FORD MOTOR COMPANY REVISION DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 24 OF 241

 MISFIRE MONITOR

Misfire System Overview

The 6.7L, 3.2L, 3.0L, and 1.5L Diesel engines utilize a Hall Effect sensor (CKP) that processes the edges of a 60-2
tooth stamped target wheel mounted on the crankshaft. The software gets an edge every 3 degrees and these edges
are used for fuel injection timing, fuel quantity control, and the calculation of engine speed. A software algorithm
corrects for irregularities of the teeth of the target wheel to improve crankshaft signal resolution. A second Hall effect
sensor is used to processes the edges of the three-lobed camshaft (CMP) target. The CMP signal and the window
of 2 missing teeth on the crankshaft target wheel indicate proper camshaft to crankshaft position for correct cylinder
timing.

Misfire Algorithm Processing

All engines use a misfire monitor that operates across much of the engine speed and torque range of the vehicle.
The misfire monitor evaluates crankshaft angular acceleration in terms of cylinder “segments” representing the arc
in which each cylinder fires. Each cylinder segment is, for example, 90° in length (720° / 8 cylinders = 90°) for the
6.7L, or 180° for the 1.5L I4. The monitor compares angular acceleration of the crankshaft from one cylinder event
to the next. For various powertrain configurations and transmissions statuses, there are threshold maps populated
of the minimum segment-to-segment response that indicates a misfire event. These maps are populated from real
misfire conditions throughout an engine map. Once a threshold is reached, it is flagged a misfire event and
counted. An interval is 4 complete segments of 1,000 crankshaft revolutions. If the summation of misfires reaches
5% of the total number of combustion events in any 4 complete segment interval, a fault is then set for misfire. In
the case of cold starting there is a special “no glow” function. This function evaluates the glow lamp status. In the
event that an end operator does not allow for sufficient time glow, the monitor threshold is expanded to account for
the reduced combustion stability that may result from failure to allow for sufficient glow time. Once the proper
thresholds are met after a no glow, the misfire monitor is reinstated to its normal operation.

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Misfire Monitor Operation:
DTCs P0300 – Random Misfire Detected
P0301 – Cylinder 1 Misfire Detected
P0302 – Cylinder 2 Misfire Detected
P0303 – Cylinder 3 Misfire Detected
P0304 – Cylinder 4 Misfire Detected
P0305 – Cylinder 5 Misfire Detected
P0306 – Cylinder 6 Misfire Detected
P0307 – Cylinder 7 Misfire Detected
P0308 – Cylinder 8 Misfire Detected

Monitor execution Continuous

Monitor Sequence None
Sensors OK Engine Coolant Temperature (ECT), Vehicle Speed (VSS), Crankshaft
Position Sensor (CKP) Injector Faults, Injector Bank Faults
Monitoring Duration 4000 revs

Typical Misfire Monitor Entry Conditions:

Entry condition Minimum Maximum
Engine Speed 500 rpm 3750 rpm
Engine Coolant Temperature (ECT) -7 deg C
Torque Gradient -2000 Nm/s 2000 Nm/s
Transmission Gear Change Not occurring
Engine Operating Mode Not in regeneration

FORD MOTOR COMPANY REVISION DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 26 OF 241

 FUEL SYSTEM MONITOR

Fuel System Overview

Fuel injection pressure is measured by the high-pressure fuel rail sensor (FRP). Injection pressure is controlled by
the high pressure pump and two regulating valves, a Pressure Control Valve (PCV), and a Fuel Metering Unit
(MeUn), formerly known as Volume Control Valve (VCV). (Note: the 1.5L and 3.2L diesel use a VCV only; they do
not have a PCV.)

LEAK OFF RAIL

INJECTORS 180 l/hr maximum at:

140 - 150oC Limit
PCV To 1.1 bar gage
FUEL RAIL

RETURN
FUEL DIESEL FUEL
COOLER CONDITIONING
MODULE (DFCM)
CONTAINS
LIFT PUMP
95 l/hr at: PRIMARY FILTER
SECONDARY
2 - 5oC above Inlet SUPPLY AND WIF
To 1.1 bar
FUEL
FILTER. CHASSIS FRAME
HP PUMP MOUNTED
ENGINE
(ITP)
MOUNTED

230 l/hr requirement at:

70oC Continuous
Fuel Rail 80oC Intermittent
90oC Limit
WATER
BLEED

INJECTORS
22 – 25 l/hr max.:
FUEL TANK
140 - 150oC
3 to 10 bar CHASSIS
FRAME
MOUNTED

Fuel Rail Pressure Sensor Checks

Fuel Rail Pressure ( FRP ) Sensor Circuit Check:

DTCs P0192 - Fuel Rail Pressure Sensor A Circuit Low Input
P0193 - Fuel Rail Pressure Sensor A Circuit High Input
Monitor Execution Continuous
Monitor Sequence None
Sensors OK Sensor Supply 1 OK (P06A6/P0642)
Typical Monitoring Duration 0.5 sec

Typical Fuel Rail Pressure Sensor Circuit Check Malfunction Thresholds:

FRP voltage < 0.13 V, or > 3.17 V

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Fuel Rail Pressure ( FRP ) Sensor Circuit Intermittent Check:
DTCs P0194 - Fuel Rail Pressure Sensor Circuit Intermittent/Erratic (Bank 1)
Monitor Execution Continuous
Monitor Sequence None
Sensors OK Sensor Supply Voltage 1 OK (P06A6)
FRP (P0192, P0193)
Typical Monitoring Duration 4 sec

Typical Fuel Rail Pressure Sensor Circuit Intermittent Malfunction Thresholds:

FRP gradient > 60 MPa

Fuel Rail Pressure ( FRP ) Rationality Check Operation:

DTCs P0191 - Fuel Rail Pressure Sensor "A" Circuit Range/Performance
Monitor Execution Immediately Prior to Crank and After Key-off (Key-off only for 6.7L products)

Monitor Sequence None

Sensors OK Sensor Supply Voltage 1 OK (P06A6), FRP OK (P0192, P0193), CKP OK

(P0335, P0336), CMP OK (P0016, P0341, P0342, P0343)
Typical Monitoring Duration 0.5 sec

Typical Fuel Rail Pressure Rationality Check Entry Conditions:

Entry condition Minimum Maximum
Pre-crank: engine coolant temperature -7 deg C
(6.7L)
Pre-crank: time engine off (6.7L) 600 sec

Pre-crank: change in engine coolant 35 deg C

temperature from previous key-off
(3.2L/1.5L)
After key-off: fuel temperature -40 deg C

After key-off: time since key off 12 sec

Typical Fuel Rail Pressure Rationality Malfunction Thresholds:

FRP voltage < 0.251 V (-40 bar) or > 0.384 V (68 bar).

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Fuel Rail Pressure Controller Range Check:

6.7L:
When fuel rail pressure is controlled by the Pressure Control Valve, the Pressure Control Valve signal needed to
maintain rail control is compared to an expected value. An adaptation factor for the Pressure Control Valve is
calculated from the difference between observed and expected control values. Inaccuracy in the Rail Pressure
Sensor Signal Slope is a potential cause of inaccuracy in the needed Pressure Control Valve signal along with
physical errors in the PCV itself. If the adaptation factor required for the Pressure Control Valve exceeds a
minimum or maximum control limit, then a code is set for rail pressure slope out of acceptable range.

3.2L:
The system attempts to correct for production variation in the VCV by learning an adapted flow through the
VCV.

Fuel Rail Pressure ( FRP ) Controller Range Check Operation:

DTCs P016D - Excessive Time To Enter Closed Loop Fuel Pressure Control
P228E - Fuel Pressure Regulator 1 Exceeded Learning Limits - Too Low
P228F - Fuel Pressure Regulator 1 Exceeded Learning Limits - Too High
Monitor Execution Continuous

Monitor Sequence None

Sensors OK (6.7L only) Sensor Supply Voltage 1 (P06A6), FRP (P0192, P0193)

Typical Monitoring Duration P016D – 30 sec (6.7L, 3.0L), P016D – 255 driving cycles (3.2L), P228E,
P228F - 10 sec

Typical Fuel Rail Pressure Controller Range Check Entry Conditions:

Entry condition Minimum Maximum
P016D (6.7L):
Requested rail pressure 500 bar 1200 bar
Fuel temperature 40 deg C
P016D (3.2L) none
P228E, P228F:
Rail pressure set point 500 bar 1200 bar
Fuel Temperature 40 deg C

Typical Fuel Rail Pressure Range Controller Check Malfunction Thresholds:

P016D (6.7L): If the system is within the adaptation operating conditions, but fails to learn a new adaptation factor
after 300 seconds, this DTC is set.
P016D (3.2L): If the system has not successfully learned an adaption value for the VCV after 255 driving cycles,
a DTC is set.
P228E, P228F: If the adaptation factor exceeds positive or negative thresholds which correspond to
approximately a 20% deviation in the Rail Pressure Sensor slope, a DTC is set.

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Fuel Rail Temperature Sensor Checks

The fuel temperature sensor on the 6.7L, 3.2L, and 3.0L applications is an analog sensor. On the 1.5L diesel, it is a
combined sensor with the low pressure fuel pressure sensor communicating on the SENT protocol.

Fuel Temperature Sensor Circuit Check Operation:

DTCs P0180 – Fuel Temperature Sensor “A” Circuit
P0181 – Fuel Temperature Sensor "A" Circuit Range/Performance
P0182 – Fuel Temperature Sensor "A" Circuit Low
P0183 – Fuel Temperature Sensor "A" Circuit High
U0603 – Lost Communication With Fuel Pressure Sensor "A"
Monitor Execution Continuous

Monitor Sequence None

Sensors OK None

Typical Monitoring Duration 0.5 sec

Typical Fuel Temperature Sensor Circuit Check Entry Conditions:

Entry condition Minimum Maximum
P0180:
Engine coolant temperature 65 deg C
P0181:
Engine Off Time 6 hours

Typical Fuel Temperature Sensor Circuit Check Malfunction Thresholds:

P0180: if after a 6 hour engine off soak, the difference in temperature between the fuel temperature sensor and
the ECU temperature sensor exceeds 20C, a DTC is set (3.2L only) or reported fuel temperature < -40 deg C or
> 150 deg C (1.5L only)
P0181: If after an 6 hour engine off soak, the difference in temperature between the fuel temperature sensor and
the charge air cooler outlet temperature sensor exceeds 40 deg C or if the difference in temperature between the
fuel temperature sensor and the charge air cooler outlet temperature sensor exceeds 20 deg C and no active
block heater is detected, a DTC is set (1,5L, 3.0L, 6.7L only)
P0182, P0183: FTS voltage < 0.0946 V (0.122.4 V = 150 deg C) or > 4.918 V (4.762 V = -40 deg C) (3.0L, 3.2L,
6.7L only)
U0603: Data from SENT sensor missing or invalid (1.5L only)

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Fuel Volume Control Valve Checks

Volume Control Valve (VCV) Monitor Operation:

DTCs P0001 - Fuel Volume Regulator Control Circuit / Open
P0002 - Fuel Volume Regulator Control Circuit Range/Performance
P0003 - Fuel Volume Regulator Control Circuit Low
P0004 - Fuel Volume Regulator Control Circuit High
Monitor Execution Continuous
Monitor Sequence None
Sensors OK None
Typical Monitoring Duration 0.3 sec

Typical Volume Control Valve Monitor Malfunction Thresholds:

P0001 – If the volume control valve is not energized and the voltage from the volume control valve control chip
is in the range 2.8 – 4.8 V (normal operation: 5V secondary voltage supply)
P0002 – Temperature of powerstage driver on ECM > 170 deg C (3.0L, 6.7L only)
P0003 – If the volume control valve is not energized and the observed voltage from the volume control valve
control chip is less than 2.8V (normal operation: 5V secondary voltage supply)
P0004 – If the volume control valve is energized and the current to the volume control valve exceeds 3.7A (normal
operation: 2.2A maximum)

Fuel Volume Regulator Control Valve (VCV) Monitor Operation:

DTCs P000E - Fuel Volume Regulator Control Exceeded Learning Limit
P228D - Fuel Pressure Regulator 1 Exceeded Control Limits - Pressure Too
High
Monitor Execution Continuous
Monitor Sequence None
Sensors OK P000E: None
P228D: VCV (P0001, P0003, P0004), FRP (P0191, P0192, P0193, P0194),
Sensor Reference Voltage “B” (P0652, P0653)
Typical Monitoring Duration P000E – 50 sec, P228D – 1 sec

Typical Volume Control Valve Monitor Malfunction Thresholds:

P000E – adaption value is outside of -99.90 and 1500 ml/mm, code is set (3.2L) or learned VCV pull-in time >
0.67 msec, code is set (1.5L)
P228D – Fuel rail pressure < 100 MPa and relative deviation of fuel pressure difference is 5%, code is set

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Fuel Pressure Control Valve Checks (6.7L only)

Fuel Pressure Control Valve (PCV) Monitor Operation:

DTCs P0089 - Fuel Pressure Regulator Performance
P0090 - Fuel Pressure Regulator Control Circuit
P0091 - Fuel Pressure Regulator Control Circuit Low
P0092 - Fuel Pressure Regulator Control Circuit High
Monitor Execution Continuous
Monitor Sequence None
Sensors OK None
Typical Monitoring Duration 0.3 sec

Typical Fuel Pressure Control Valve Monitor Malfunction Thresholds:

P0089 – Temperature of power stage driver on ECM is > 170 deg C
P0090 – The pressure control valve is not energized and the voltage from the pressure control valve control chip
is in the range 2.8 – 4.8 V (normal operation: 5V secondary voltage supply)
P0091 – The pressure control valve is not energized and the voltage from the pressure control valve control chip
is less than 2.8V (normal operation: 5V secondary voltage supply)
P0092 – The pressure control valve is energized and the observed current to the pressure control valve exceeds
5.1A (normal operation: 3.7A maximum)

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Fuel Low Pressure Lift Pump Checks

The 6.7L diesel in the F650-F750 chassis cab uses a fuel pump that is directly controlled from the PCM. The 6.7L
diesel in the F250-F550 pickup and chassis cab and all 3.2L and 3.0L products use a fuel pump that is controlled
from a fuel pump controller module.

Fuel Low Pressure Lift Pump Monitor Operation:

DTCs P0230 – Fuel Pump Primary Circuit
P0231 – Fuel Pump Secondary Circuit Low
P0232 – Fuel Pump Secondary Circuit High
P025A – Fuel Pump Module “A” Control Circuit/Open
P025B - Fuel Pump Module "A" Control Circuit Range/Performance
P025C – Fuel Pump Module “A” Control Circuit Low
P025D – Fuel Pump Module “A” Control Circuit High
P027A - Fuel Pump Module "B" Control Circuit/Open
P027C - Fuel Pump Module "B" Control Circuit Low
P027D - Fuel Pump Module "B" Control Circuit High
P0627 - Fuel Pump "A" Control Circuit / Open
P0628 - Fuel Pump "A" Control Circuit Low
P0629 - Fuel Pump "A" Control Circuit High
P062A – Fuel Pump "A" Control Circuit Range/Performance
P064A – Fuel Pump Control Module “A”
P1671 – Secondary Fuel Pump Relay
U0109 – Lost Communication With Fuel Pump Control Module “A”
Monitor Execution Continuous
Monitor Sequence None
Sensors OK None
Typical Monitoring Duration P0627, P0628, P0629 - 0.2 sec
P0230, P0231, P0232, P025A, P025B, P025C, P025D, P027A, P027C, P027D,
P062A, P064A, U0109 – 0.5 sec
P1671 - 0.3 sec

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Typical Fuel Low Pressure Lift Pump Monitor Malfunction Thresholds:
P0230 – If the lift pump duty cycle is outside the range 18-22%, this DTC is set. (3.2L)
P0231 – If the lift pump duty cycle is <5%, this DTC is set. (3.2L)
P0232 – If the lift pump duty cycle is >95%, this DTC is set. (3.2L)
P025A – The pump equipment module (PEM) detects an open circuit (6.7L F250-F550, 3.0L); the fuel pump
relay detects an open circuit (1.5L)
P025B – The fuel pump monitor line (FPM) reports a frequency outside the expected range (1.5L)
P025C – The PEM detects a short circuit to ground (6.7L F250-F550, 3.0L); the fuel pump relay detects a short
circuit to ground on either the high side or low side of the relay (1.5L)
P025D – The PEM detects a short circuit to power (6.7L F250-F550, 3.0L); the fuel pump relay detects a short
circuit to power on either the high side or low side of the relay (1.5L)
P0627 – Lift pump NOT energized and the voltage from the lift pump control chip is between 2.8 – 4.8V (normal
operation: 5V secondary voltage supply) (6.7L F650-F750)
P0628 – Lift pump NOT energized and the voltage from the lift pump control chip is less than 2.8V (normal
operation: 5V secondary voltage supply) (6.7L F650-F750)
P0629 – Lift pump energized and the current to the lift pump exceeds 3.7A (normal operation: 2.2A maximum)
(6.7L F650-F750)
P062A – One of the following must be true:
- The airbag deployment module sends a deployment signal and the fuel pump shows as energized via
the fuel pump monitor signal (6.7L F650-F750)
- The status of the energizing request to the fuel pump and the monitoring signal from the fuel pump
does not match (6.7L F650-F750)
- The frequency of the signal to the lift pump is outside the range 0.8 Hz to 1.1 Hz (3.2L)
- The fuel pump duty cycle feedback from the lift pump is outside the range 78-82% (1.5L, 6.7L F250-
F550, 3.0L)
P064A – The time period of the fuel pump monitoring signal is outside the range 0-1.2 sec OR the fuel pump
command duty cycle is implausible OR the fuel pump command duty cycle is outside the range 27.4-32.7% (1.5L,
3.0L, 6.7L F250-F550)
U0109 – Fuel pump command duty cycle <5% or >95% (1.5L, 3.0L, 6.7L F250-F550)

FORD MOTOR COMPANY REVISION DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 34 OF 241

Fuel Injector Checks

Fuel Injector Driver Circuit Monitor Operation:

DTCs P062D - Fuel Injector Driver Circuit Performance Bank 1
P062E - Fuel Injector Driver Circuit Performance Bank 2
P0A09 - DC/DC Converter Status Circuit Low
P0A10 - DC/DC Converter Status Circuit High
P1291 - Injector High Side Short To GND Or VBATT (Bank 1)
P1292 - Injector High Side Short To GND Or VBATT (Bank 2)
P1295 – Injector Multiple Faults (Bank 1)
Monitor Execution Continuous
Monitor Sequence None
Sensors OK None (6.7L)
Injector circuit checks OK (P0201-P0205, P1261-P1265), System voltage OK
(P2507, P2508) (3.2L)
Typical Monitoring Duration P062D, P062E, P0A09, P0A10 – 0.5 seconds
P1291, P1292, P1295 – 0.2 seconds

Typical Fuel Injector Driver Circuit Malfunction Thresholds:

P062D, P062E – Failure of injector driver of bank detected by IC Internal logic (3.0L, 6.7L); short circuit to ground
or battery of injector driver bank detected by IC internal logic (1.5L)
P0A09 – DC/DC converter output voltage <160V (3.2L)
P0A10 – DC/DC converter output voltage >300V (3.2L)
P1291, P1292 – Short to ground or battery of bank detected by IC internal logic
P1295 – One or more short to ground or battery faults detected (3.2L)

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Injection Circuits Monitor Operation:
DTCs P0201 - Injector Circuit / Open - Cylinder 1
P0202 - Injector Circuit / Open - Cylinder 2
P0203 - Injector Circuit / Open - Cylinder 3
P0204 - Injector Circuit / Open - Cylinder 4
P0205 - Injector Circuit / Open - Cylinder 5
P0206 - Injector Circuit / Open - Cylinder 6
P0207 - Injector Circuit / Open - Cylinder 7
P0208 - Injector Circuit / Open - Cylinder 8
P02EE – Cylinder 1 Injector Circuit Range/Performance
P02EF – Cylinder 2 Injector Circuit Range/Performance
P02F0 – Cylinder 3 Injector Circuit Range/Performance
P02F1 – Cylinder 4 Injector Circuit Range/Performance
P02F2 – Cylinder 5 Injector Circuit Range/Performance
P02F3 – Cylinder 6 Injector Circuit Range/Performance
P02F4 – Cylinder 7 Injector Circuit Range/Performance
P02F5 – Cylinder 8 Injector Circuit Range/Performance
P1201 – Cylinder #1 Injector Circuit Open/Shorted
P1202 – Cylinder #2 Injector Circuit Open/Shorted
P1203 – Cylinder #3 Injector Circuit Open/Shorted
P1204 – Cylinder #4 Injector Circuit Open/Shorted
P1205 – Cylinder #5 Injector Circuit Open/Shorted
P1206 – Cylinder #6 Injector Circuit Open/Shorted
P1207 – Cylinder #7 Injector Circuit Open/Shorted
P1208 – Cylinder #8 Injector Circuit Open/Shorted
P1261 – Cylinder #1 High To Low Side Short
P1262 – Cylinder #2 High To Low Side Short
P1263 – Cylinder #3 High To Low Side Short
P1264 – Cylinder #4 High To Low Side Short
P1265 – Cylinder #5 High To Low Side Short
P1266 – Cylinder #6 High To Low Side Short
P1267 – Cylinder #7 High To Low Side Short
P1268 – Cylinder #8 High To Low Side Short
P0261 – Cylinder 1 Injector "A" Circuit Low
P0262 – Cylinder 1 Injector "A" Circuit High
P0264 – Cylinder 2 Injector "A" Circuit Low
P0265 – Cylinder 2 Injector "A" Circuit High
P0267 – Cylinder 3 Injector "A" Circuit Low
P0268 – Cylinder 3 Injector "A" Circuit High
P0270 – Cylinder 4 Injector "A" Circuit Low
P0271 – Cylinder 4 Injector "A" Circuit High
P0273 – Cylinder 5 Injector "A" Circuit Low
P0274 – Cylinder 5 Injector "A" Circuit High
P126A – Cylinder 1 Injector Input Circuit
P126B – Cylinder 2 Injector Input Circuit
P126C – Cylinder 3 Injector Input Circuit
P126D– Cylinder 4 Injector Input Circuit
P126E – Cylinder 5 Injector Input Circuit
Monitor Execution Continuous
Monitor Sequence None
Sensors OK 6.7L
Typical Monitoring Duration P0201 – P0208 – 0.3 seconds, P02EE – P2F5 – 0.3 seconds.
P1201 – P1208 – 0.3 seconds, P1261 – P1268 – 0.3 seconds.
P126A – P126E – 5 seconds

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 Typical Injection Circuits Entry Conditions:
Entry condition Minimum Maximum
6.7L:
Injections requested
3.2L:
P02EE-P02F2:
Time since engine start 60 sec
Engine coolant temperature -5 deg C

Typical Injection Circuits Malfunction Thresholds:

P0201 – P0208 – Injector open circuit detected by IC internal logic
P02EE – P02F5 – Implausible injector response detected by IC internal logic
P1201 – P1208 – Injector short circuit detected by IC internal logic
P1261 – P1268 – Injector high side to low side short circuit detected by IC internal logic
P0261 – P0273 (Low): IC internal control > 10 mJ
P0262 – P0274 (High): IC internal control < -10 mJ
P126A – P126E: voltage is not within 210 and 240 v

Fuel Injector Code Missing/Invalid:

Injector Code Monitor Operation:

DTCs P268C – Cylinder 1 Injector Data Incompatible
P268D – Cylinder 2 Injector Data Incompatible
P268E – Cylinder 3 Injector Data Incompatible
P268F – Cylinder 4 Injector Data Incompatible
P2690 – Cylinder 5 Injector Data Incompatible
P2691 – Cylinder 6 Injector Data Incompatible
P2692 – Cylinder 7 Injector Data Incompatible
P2693 – Cylinder 8 Injector Data Incompatible
Monitor Execution Continuous
Monitor Sequence None
Sensors OK None
Typical Monitoring Duration 0.5 seconds

Typical Injector Code Monitor Malfunction Thresholds:

P268C – P2693: Each injector has a code stored in EEPROM that provides information to the ECU about
deviations of that injector from a theoretical average injector. If the injector code is missing or invalid (value
out of the acceptable range or the injector code checksum incorrect), a DTC is set.

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Fuel Rail Pressure Monitors:

The pressure in the fuel rail is controlled by a closed-loop control strategy that is always active during vehicle
operation. Two controllers may be used to control the rail pressure: the Pressure Control Valve and the Volume
Control Valve. The Pressure Control Valve is used to control pressure at engine start and when fuel temperature is
low. The Volume Control Valve is used to control fuel pressure under most other conditions. A third operation mode
allows fuel rail pressure to be controlled by a combination of the Pressure Control Valve and Volume Control Valve;
this mode is typically used to transition from control by one device to the other and in regimes where low fuel volume
is required.
The fuel rail pressure is controlled either with the Pressure Control Valve, the Volume Control Valve, or both,
depending upon engine operation condition. The high and low Fuel Rail Pressure Monitors detect when there is an
excessive deviation from the desired fuel pressure when the controller has reached a control limit or when the
minimum or maximum allowable rail pressures are exceeded.
Note: since the 3.2L diesel has only a VCV, it will always be in Volume Control Valve control.
Fuel Rail Pressure ( FRP ) Monitor Operation:
DTCs P0087 - Fuel Rail/System Pressure - Too Low
P0088 - Fuel Rail/System Pressure – Too High
P0093 – Fuel System Leak Detected – Large Leak
Monitor Execution Continuous

Monitor Sequence None

Sensors OK 1.5L, 6.7L: FRP (P0191, P0192, P0193)

3.2L: VCV (P0001, P0002, P0003), FRP (P0191, P0192, P0193, P0194),
Sensor Reference Voltage B (P0652, P0653)
Typical Monitoring Duration P0087, P0088 – 1.4 sec
P0093 – 2 sec

Typical Fuel Rail Pressure Monitor Malfunction Thresholds:

P0087: If the commanded rail pressure exceeds the measured rail pressure by 250 bar for 1.4 sec or if the
measured rail pressure drops below 140 bar for 0.3 sec
P0088: If the measured rail pressure exceeds the commanded rail pressure by 250 bar for 1.4 sec or if the
measured rail pressure exceeds 2150 bar for 0.3 sec
P0093: If the set point needed for the volume control valve to maintain desired rail pressure exceeds 13,500
mm3/sec at idle or if the set point needed for the volume control valve to maintain desired rail pressure is 40%
greater than the volume control valve set point as calculated from the requested injection quantity when not at idle

Low Fuel Rail Pressure Monitor Operation:

DTCs P008A - Low Pressure Fuel System Pressure - Too Low

Monitor Execution Continuous

Monitor Sequence None

Sensors OK none

Typical Monitoring Duration P008A – 5 sec

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Low Fuel Rail Pressure Switch Monitor Entry Conditions:
Entry condition Minimum Maximum
Fuel Temperature -40 deg C
Fuel in tank 10 liter
Engine coolant temperature -40 deg C
Airbag Not deployed
Battery 9v
Duration time since Low Fuel Rail 12 sec
Pressure indicated

Typical Fuel Rail Pressure Monitor Malfunction Thresholds:

P008A: If fuel filter pressure switch switching frequency > 5 or if indicated pressure in low pressure fuel
system is constantly < 51 psig, code is set

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Injection Timing / Injection quantity

Fuel Balancing Control:

Fuel Balancing Control (1.5L, 6.7L) is an algorithm designed to reduce differences in injected fuel quantity from
cylinder to cylinder. The increase in crankshaft speed due to individual cylinder combustion events is measured.
The amount of fuel injected to each cylinder is then adjusted up or down to minimize the difference in increase in
crankshaft speed from cylinder to cylinder. The total amount of fuel injected among all cylinders remains constant.
The concept is shown in the graphic below.

FBC operates in closed-loop control in an engine speed range of 500-3000 rpm, and a commanded injection
quantity of 3.5 – 90 mg/stroke. The maximum allowed correction in fuel quantity for an individual cylinder is given
by the following table.

Fuel Balancing Control (FBC) Control Limits:

Injection quantity requested before FBC correction (mg/stroke)

Maximum allowable FBC correction (mg/stroke): 3.5 7.5 15

4 7 14

The 3.2L engine uses a similar correction algorithm that operates at idle only.

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Fuel Balancing Control (FBC) Monitor Operation:
DTCs P0263 – Cylinder #1 Contribution/Balance
P0266 – Cylinder #2 Contribution/Balance
P0269 – Cylinder #3 Contribution/Balance
P0272 – Cylinder #4 Contribution/Balance
P0275 – Cylinder #5 Contribution/Balance
P0278 – Cylinder #6 Contribution/Balance
P0281 – Cylinder #7 Contribution/Balance
P0284 – Cylinder #8 Contribution/Balance
P029A - Cylinder 1 – Fuel Trim at Max Limit
P029B - Cylinder 1 – Fuel Trim at Min Limit
P029E - Cylinder 2 – Fuel Trim at Max Limit
P029F - Cylinder 2 – Fuel Trim at Min Limit
P02A2 - Cylinder 3 – Fuel Trim at Max Limit
P02A3 - Cylinder 3 – Fuel Trim at Min Limit
P02A6 - Cylinder 4 – Fuel Trim at Max Limit
P02A7 - Cylinder 4 – Fuel Trim at Min Limit
P02AA - Cylinder 5 – Fuel Trim at Max Limit
P02AB - Cylinder 5 – Fuel Trim at Min Limit
Monitor Execution Continuous

Monitor Sequence None

Sensors OK Injector circuit codes, CKP, CMP, BARO, sensor supply voltage

Typical Monitoring Duration 7.5 sec

Typical Fuel Balancing Control (FBC) Monitor Entry Conditions:

Entry condition Minimum Maximum
P0263-P0284 only:
Engine speed 500 rpm 3000 rpm
Injection quantity 3.5 mg/stroke 90 mg/stroke
Engine coolant temperature 15 deg C
Not In Regeneration
FBC wheel learn complete
P029A-P02AB only:
Engine coolant temperature 40 deg C

Typical Fuel Balancing Control (FBC) Monitor Malfunction Thresholds:

P0266 – P2084: If the current correction for the injector exceeds 90% of the allowable correction for current
operation conditions, the code is set.
P029A – P02AB: If specific cylinder balance quantity is >1.8 or <0.2 times normal fueling, a code is set.

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Fuel Mass Observer (Global Fuel Bias)

Fuel Mass Observer (FMO) is an algorithm used to detect deviations in performance of all injectors from nominal.
The oxygen percentage as measured by the tailpipe oxygen sensor is compared to a modeled oxygen percentage
based upon current fuel, boost, and EGR settings. Deviation between the observed and modeled oxygen
percentage is expressed in terms of the error in fueling required to explain the deviation. This calculated error in
fueling is then divided by the current requested fueling level to generate a ratio of percentage error in fueling. This
fueling ratio is then filtered over time. If the filtered error in fueling ratio exceeds minimum or maximum limits, then
a code is set.

Fuel Mass Observer (FMO) Monitor Operation:

DTCs P0170 – Fuel Trim (Bank 1)

Monitor Execution Continuous

Monitor Sequence None

Sensors OK

Typical Monitoring Duration P0170 - 45 sec

Typical Fuel Mass Observer (FMO) Monitor Entry Conditions:

Entry condition Minimum Maximum
Engine speed 1000 rpm 3000 rpm
Fuel injection quantity 20 mg/stroke 80 mg/stroke
Rate of change of fueling -2 mg/stroke/sec 2 mg/stroke/sec
Ambient pressure 700 hPa
Engine coolant temperature 70C 120C
System voltage 9V
Ambient temperature -7 C
Tailpipe oxygen sensor status Ready
Post injection Not occurring

Typical Fuel Mass Observer (FMO) Monitor Malfunction Thresholds:

P0170 : if the absolute value of the filtered ratio of error in fueling exceeds 0.15, this code is set.

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Feedback control:

Zero Fuel Calibration:

Zero Fuel Calibration (ZFC) is an algorithm used to compensate for deviations in individual injector performance
from nominal on the 1.5L and 6.7L diesel engines. In an overrun/decel fuel shut-off condition, fuel rail pressure is
set to 300 bar (6.7L) or 300 bar, 800 bar, and 1200 bar (1.5L) and small injections are made from a single injector.
The observed acceleration in crankshaft speed is detected and a regression line generated to predict the fueling
required to achieve the expected acceleration. If the calculated fueling required to generate the expected
acceleration in crankshaft speed falls outside the allowable control limits for the system, an addition routine is
called to very precisely learn the adjustment to injector energizing time required to achieve expected acceleration.
This information is then used to adjust all pilot injections on that injector to ensure correct fuel delivery. If the
absolute energizing time observed for the test injection to yield the expected acceleration exceeds minimum or
maximum limits, a code is set.

The 3.2L diesel uses a similar algorithm which operates at four injection pressures: 250 bar, 400 bar, 700 bar, and
1200 bar. It has two operating modes: a “fast” mode that operates quickly at only 400 bar to detect a “step
change” in injector performance, and a slower mode that is designed to optimize injection throughout vehicle life.
Separate faults with the same DTC exist for each mode.

Zero Fuel Calibration (ZFC) Monitor Operation:

DTCs P02CC – Cylinder 1 Fuel Injector Offset Learning at Min Limit
P02CD – Cylinder 1 Fuel Injector Offset Learning at Max Limit
P02CE – Cylinder 2 Fuel Injector Offset Learning at Min Limit
P02CF – Cylinder 2 Fuel Injector Offset Learning at Max Limit
P02D0 – Cylinder 3 Fuel Injector Offset Learning at Min Limit
P02D1 – Cylinder 3 Fuel Injector Offset Learning at Max Limit
P02D2 – Cylinder 4 Fuel Injector Offset Learning at Min Limit
P02D3 – Cylinder 4 Fuel Injector Offset Learning at Max Limit
P02D4 – Cylinder 5 Fuel Injector Offset Learning at Min Limit
P02D5 – Cylinder 5 Fuel Injector Offset Learning at Max Limit
P02D6 – Cylinder 6 Fuel Injector Offset Learning at Min Limit
P02D7 – Cylinder 6 Fuel Injector Offset Learning at Max Limit
P02D8 – Cylinder 7 Fuel Injector Offset Learning at Min Limit
P02D9 – Cylinder 7 Fuel Injector Offset Learning at Max Limit
P02DA – Cylinder 8 Fuel Injector Offset Learning at Min Limit
P02DB – Cylinder 8 Fuel Injector Offset Learning at Max Limit
P262A – Fuel Injector - Pilot Injection Not Learned
P2B11 – Cylinder 1 Injection Pulse Offset Exceeded Learning Limit
P2B13 – Cylinder 2 Injection Pulse Offset Exceeded Learning Limit
P2B15 – Cylinder 3 Injection Pulse Offset Exceeded Learning Limit
P2B17 – Cylinder 4 Injection Pulse Offset Exceeded Learning Limit
P2B19 – Cylinder 5 Injection Pulse Offset Exceeded Learning Limit
P2B1B – Cylinder 6 Injection Pulse Offset Exceeded Learning Limit
P2B1D – Cylinder 7 Injection Pulse Offset Exceeded Learning Limit
P2B1F – Cylinder 8 Injection Pulse Offset Exceeded Learning Limit

Monitor Execution Continuous

Monitor Sequence None

Sensors OK AAT, ECT, injectors, PCV

Typical Monitoring Duration all DTCs except P262A 30 sec

P262A: 30 events of 0.8+ seconds each

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Typical Zero Fuel Calibration (ZFC) Monitor Entry Conditions:
Entry condition (both) Minimum Maximum
P02CC, P02CD, P02CE, P02CF, P02D0, P02D1, P02D2, P02D3,
P02D4, P02D5, P02D6, P02D7, P02D8, P02D9, P02DA, P02DB,
P2B11, P2B13, P2B15, P2B17, P2B19, P2B1B, P2B1D, P2B1F:
Intake air temperature 0 deg C
Fuel temperature 10 deg C 75 deg C
Engine coolant temperature 50 deg C
System voltage 10 V
Time in overrun/decel fuel shut-off 30 sec
Engine speed 890 rpm 2400 rpm
Boost pressure 750 mbar
Accelerator pedal 2%
Transmission gear (no gear change) 4 th 6 th
Difference between requested and actual FRP 50 bar
Torque converter locked
Fuel Balance Control wheel learn complete
Time after start (3.2L) 0 sec
Vehicle speed (3.2L) 2 kph
Rate of change of torque (3.2L) 30 Nm/sec
Rate of change of RPM gradient (3.2L) -36 RPM/sec^2 36 RPM/sec^2
Indicated torque (3.2L) 3 Nm
Note: these are the entry conditions for the base function. The
monitor runs whenever the base function runs.

Typical Zero Fuel Calibration (ZFC) Monitor Malfunction Thresholds:

P02CC, P02CE, P02D0, P02D2, P02D4, P02D6, P02D8, P02DA:
If the observed energizing time for the test injection is 156 us or more lower than the target energizing time for the
given injector, the code is set.
P02CD, P02CF, P02D1, P02D3, P02D5, P02D7, P02D9, P02DB:
If the observed energizing time for the test injection is 254 us or more higher than the target energizing time for the
given injector, the code is set.
P262A: If after 30 instances, each of 0.8 seconds or longer duration, where all entry conditions have been met and
a pilot adaption value is not learned, this code is set.
P2B11, P2B13, P2B15, P2B17, P2B19, P2B1B, P2B1D, P2B1F:
If the observed energizing time for the test injection is 156 us or more lower or 254 us or more higher than the
target energizing time for the given injector, the code is set.

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Nominal Voltage Calibration:

Nominal Voltage Calibration (NVC) is a series of closed-loop controllers on the charge/discharge profile of
piezoelectric fuel injectors during an injection event. NVC is designed to compensate for changes due to aging of
the piezo stack and hydraulic control elements within individual injectors and of the injector charging circuitry to
maintain consistent operation of these components over the life of the injector. The injector charge/discharge
profile is shown in the figure below.

Energizing
injector voltage voltage at end
Time
after charging of energizing
Voltage

discharged
voltage

charge time discharge

(fixed at 100 us) time
Time

Nominal Voltage Calibration (NVC) Monitor Operation:

DTCs P1551 – Cylinder 1 Injector Circuit Range/Performance
P1552 – Cylinder 2 Injector Circuit Range/Performance
P1553 – Cylinder 3 Injector Circuit Range/Performance
P1554 – Cylinder 4 Injector Circuit Range/Performance
P1555 – Cylinder 5 Injector Circuit Range/Performance
P1556 – Cylinder 6 Injector Circuit Range/Performance
P1557 – Cylinder 7 Injector Circuit Range/Performance
P1558 – Cylinder 8 Injector Circuit Range/Performance
Monitor Execution continuous

Monitor Sequence None

Sensors OK Injector open circuit (P0201-0208), Injector performance (P02EE-02F5), Injector

short circuit (P1201-1208), Injector high to low short (P1261-1268), ECT (P0117,
P0118), RPS (P0191, P0192, P0193, P228E, P228F)
Typical Monitoring Duration 2 sec (set point voltage), 90 sec (other two tests)

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Typical Nominal Voltage Calibration (NVC) Monitor Entry Conditions:
Entry condition Minimum Maximum
Rail pressure (6.7L) 1200 bar 1600 bar
Engine coolant temperature 70 deg C 100 deg C
Injection duration (6.7L) 300 us
Time after engine start (3.2L) 60 sec

Typical Nominal Voltage Calibration (NVC) Monitor Malfunction Thresholds:

6.7L: If the set point voltage at end of energizing (yellow dot in figure) exceeds the allowable voltage given in the
chart below for the current rail pressure set point or if there exists a persistent deviation between set and measured
discharge time (yellow dot to blue dot in figure) or if there exists a persistent deviation between the set and
measured voltage at end of energizing (yellow dot in figure)
3.2L: If the charge of the piezo stack of the injector is <200 uA or >1200 uA, a DTC is set.

Maximum Allowable Voltage At End of Energizing (6.7L only):

Rail pressure (bar) 300 800 1200 2000

Maximum allowed voltage (V) 89 91 93 108

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Injector Leakage Check Operation:
DTCs P029D – Cylinder 1 – Injector Leaking
P02A1 – Cylinder 1 – Injector Leaking
P02A5 – Cylinder 1 – Injector Leaking
P02A9 – Cylinder 1 – Injector Leaking
P02AD – Cylinder 1 – Injector Leaking
Monitor Execution continuous

Monitor Sequence None

Sensors OK FRP

Typical Monitoring Duration 2 sec

Typical Injector Leakage Monitor Entry Conditions:

Entry condition Minimum Maximum
Engine speed 500 rpm 4000 rpm
Engine Torque 0
Engine operating mode Normal
FBC wheel learn complete True

Typical Injector Leakage Monitor Malfunction Thresholds:

Fuel rail pressure decay < threshold (based on fuel injection)

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 EXHAUST GAS SENSOR MONITOR

Feedgas NOx Sensor – 3.2L and 6.7L F650-F750

Feedgas NOx Sensor Control Module - 3.2L and 6.7L F650-F750

The sensor described below is used in all 2019 3.2L diesel Transit applications and in 2019 F650-F750 6.7L diesel
chassis cabs.

The NOx controller module is mounted to the vehicle frame under the body. It is used to control the combination
tailpipe NOx and O2 sensor mounted in diesel after-treatment exhaust system downstream of the SCR and DPF. It
communicates to the ECU via HSCAN to report NOx and O2 concentrations or OBDII errors.

The controller module consists of RAM, ROM, EEPROM, Ip1 circuit, Ip2 circuit, Rpvs circuit, heater driver,
microprocessor, and temperature sensor. The RAM temporarily stores information obtained from the sensing
element during operation. The ROM and EEPROM store sensor and controller module calibration coefficients
obtained during the manufacturing process. The Ip1 circuit consists of an ASIC (like that of a UEGO ASIC) that
adjusts pumping current in the sensing element’s Ip1 circuit for O2 detection. The Ip2 circuit adjusts the pumping
current in the sensing element’s Ip2 circuit for NOx detection. The Ip2 circuit consists of 2 bands: a wide range and
a narrow range. The Rpvs circuit is a measurement of the resistance of the Vs cell of the sensor element. This
measurement is used to estimate the temperature of the sensing element. The heater driver supplies a PWM voltage
to the heater portion of the sensing element to maintain the element’s target operational temperature. PID feedback
from Rpvs is used to control and maintain the element temperature. The microprocessor processes all of the inputs
from the sensing element and outputs to the CAN circuit. The temperature sensor in the controller module is used
for compensating the temperature dependency of circuit components and for OBD rationality checks.

The NOx controller module interfaces with the vehicle via a power source, signal ground, power ground, CAN-H and
CAN-L. The compensated O2 concentration compensated NOx concentration; Rpvs, pressure compensation
factors, sensor/module OBD (including monitor completion flags), module temperature, software ID, CALID, and
CVN are communicated via HSCAN to the vehicle PCM.

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 NOx Controller Module Malfunctions
DTCs P06EA NOx Sensor Processor Performance (Bank 1 Sensor 1)
U05A1 NOx Sensor "A" Received Invalid Data From ECM/PCM
P225A NOx Sensor Calibration Memory (Bank 1 Sensor 1)
Monitor execution Continuous
Monitor Sequence Ip2-N and Ip2-W range rationality – 50ppm < [NOx] < 100ppm
Sensors OK not applicable
Monitoring Duration 5 seconds to register a malfunction

Typical NOx Controller Malfunction Thresholds

P06EA RAM failure
ROM CRC check error
EEPROM CRC check error
Ip1 out of range – Ip1(VIP2.1) < 1.8V, Ip1(VIP2.1) > 2.2V, Ip1(VIP2.2) < 0.2V, or Ip1(VIP2.2) > 0.6V
Ip2-W out of range – Vs+ ≥ 5.35V and Ip2-W > 4.8V
Ip2-N out of range – Vs+ ≥ 5.35V and Ip2-N < 0.2V
Ip2-N and Ip2-W range rationality – Integral value of differential between Ip2-N & Ip2-W ≥ 250ppm
Vp2 circuit failure – Vp2 < 250mV or Vp2 > 650mV
Rpvs short to ground – Rpvs < 0.2V
Temperature sensor short to battery – Temp > 4.5V
Temperature sensor short to ground – Temp < 0.45V
Temperature sensor open – 0.45V ≤ Temp < 0.48V
NOx Module temperature within 40 deg. C of Exhaust Temperature Sensor (following 6 hour soak
only)
More than 33 aborted attempts to diagnose plausibility of feedgas NOx sensor.
U05A1 Erroneous Signal (Dew point reached with ignition off, etc.)
Timeout (>1 second before message received)
P225A Memory does not pass CRC check

Feedgas NOx and O2 Sensor Malfunctions – 3.2L and 6.7L F650-F750

The NOx sensor is primarily used to sense NOx concentrations in diesel exhaust gas. The sensor is mounted in a
vehicle’s exhaust pipe, perpendicular to exhaust gas flow. The sensor is typically mounted, in an aftertreatment-
equipped diesel exhaust system, upstream of the SCR and DPF on a Chassis Certified Vehicle and upstream of the
SCR only on a Dynamometer Certified Vehicle. The sensor interfaces to a NOx controller module that controls the
sensor element’s sense circuit and heater.

The Ip2 (NOx concentration) measurement takes place in a 2nd measurement chamber. Exhaust gas passes from
the 1st measurement chamber through a 2nd diffusion barrier into the 2nd measurement chamber. The NOx present
in the 2nd measurement chamber is dissociated into N2 and O2. The excess O2 is pumped out of the 2nd
measurement chamber by the pumping current, Ip2. Ip2 is proportional to the NOx concentration in the measured
gas.

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The NOx sensor is equipped with a memory component which stores unique sensor characteristics used to
compensate for part-to-part variation of the element during the manufacturing process. The memory stores Ip1 and
Ip2 gains/offsets for each individual sensor.

The NOx sensor interfaces the NOx controller module with the following:
Ip2 – pumping current for pumping out dissociated O2 from 2nd chamber
COM – virtual ground for Vs, Ip1, and Ip2 circuits
Vs – Nernst cell voltage, 425mV from COM. Also carries current for pumped reference.
TM – Touch memory which stores Ip1 and Ip2 gain/offset.
TM GND – Ground for touch memory reading
H+ – Heater voltage (High-side driver) – Duty cycle ON/OFF to control sensor temperature.
H- – Heater ground side

Cross section of element

Interface circuit
O2 2nd diffusion passage
Ip1
Ip1 drive
circuit
1st diffusion 1st Pumping Cell (Ip1) Gnd
Gnd
Ip+
Ip+
passage
GND
GND
Detecting
Detecting
Cell
Cell
(Vs Cell) Vs
Vs Vs signal Reference
detection 425mV
•Ip2+
•Ip2+ GND
GND Comparison
2nd Pumping Cell (Ip2)
O2 Icp Icp supply
Heater
Heater
Ip2 drive circuit
Ip2
Heater power supply

IP2 Open (FLO) OBD Algorithm

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IP2 Open (FLO) OBD Algorithm

NOx Sensor Malfunctions

DTCs P2200 NOx Sensor Circuit (Bank 1 Sensor 1)
P2201 NOx Sensor Circuit Range/Performance (Bank 1 Sensor 1)
P220E NOx Sensor Heater Control Circuit Range/Performance (Bank 1
Sensor 1)
P2209 NOx Sensor Heater Sense Circuit Range/Performance (Bank 1
Sensor 1)
P220A NOx Sensor Supply Voltage Circuit (Bank 1 Sensor 1)
Monitor execution Continuous
Monitor Sequence Ip2 Open – O2 ≥ 5% or F/C > 3 seconds and O2 ≥ 19%
Ip2 Crack – F/C > 5 seconds and O2 ≥ 19%

Sensors OK not applicable

Typical NOx Sensor Malfunctions Entry Conditions:

Entry condition Minimum Maximum
Sensor dewpoint reached
P2209:
Exhaust mass flow 110 g/sec
P2200 Ip2 crack detection only:
Fuel injection quantity 0 mg/stroke
Time at zero fuel quantity 5 seconds

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Typical NOx – O2 Sensor Malfunctions Thresholds
P2200 Vs, COM, Ip1 short to battery – ASIC Diag2=1 and Vs, COM, Ip1 ≥ 9V
Ip2 short to battery – Ip2 ≥ 4.8V
Vs, COM, Ip1 short to ground – ASIC Diag2=1 and Vs, COM, Ip1 < 9V
Ip2 short to ground – Ip2 ≤ 2V
Ip1 Open – Vs ≤ 225mV, Vs ≥ 625mV & -0.2mA ≤ Ip1 ≤ 0.2mA
Vs Open – Vs > 1.5V
COM Open – Rpvs > RpvsA (target Rpvs stored in sensor memory) or ASIC Diag1=1
Ip2 Open – Ip2-W ≤ 0.2V and Ip2-N ≤ 0.2V
Sensor Memory CRC check
Vs/Ip1 Cell Crack – Ip1 > 6.4mA
Ip2 Cell Crack – Ip2-W > 4.8V
P2201 NOx Sensor reading 50% Lower than expected (low threshold) during EGR Off
NOx Negative Offset – NOx Sensor greater than ~ - 20 ppm offset
NOx Positive Offset – NOx Sensor greater than ~50 ppm offset

P220E Heater control failure – Rpvs ≥ 0.2V and Rpvs < TRpvs - 30Ω or Rpvs > TRpvs + 30Ω
Heater Open – Heater current < 0.4A
Heater short to battery – Δ Heater Voltage > 0.2V
Heater short to ground – Δ Heater Voltage > 0.2V
Heater performance failure – Heater current ≥ 0.4A and Heater Resistance ≥ 11Ω
P2209 NOx Availability – > 1 PL (Healing mode) per cycle or > 9 sec of NOx not valid
P220A Battery failure – Battery > 17V or Battery < 10V

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NOx Sensor Operation Modes

Drive start Drive end

Engine OFF Engine OFF Engine ON Engine OFF Engine OFF

Key-OFF Key-ON Key-ON Key OFF Key-OFF
NA Mode NA Mode A Mode A Mode
- - Heater OFF A Mode & F/C Self Shut Down -
Vs No Active Vs Active under FLO After FLO
Failure occurred timing

②：In case of normal

① ③ ④ ⑤ ⑥ ⑦ ⑧ ⑩ ①
⑨：In case of engine stall

Mode 1 – No voltage supply to module or sensor. Non-operational.

Mode 2 – Voltage is supplied to module, yet voltage is not supplied to the sensor.
Mode 3 – Voltage is supplied to module, yet voltage is not supplied to the sensor. Dew-point waiting
period.
Mode 4 – Voltage is supplied to the module and to the sensor. The Vs cell of the sensor is not active.
Mode 5 – Voltage is supplied to the module and to the sensor. The Vs cell of the sensor is active.
Mode 6 – Voltage is supplied to the module and to the sensor. Sensor is in fast light-off to quickly heat
sensing element to operational temperature.
Mode 7 – Voltage is supplied to the module and to the sensor. The sensor has exited fast light-off and O2
and NOx will be available during this mode.
Mode 8 - Voltage is supplied to the module and to the sensor. The sensor has exited fast light-off and O2
and NOx will be available during this mode. During this mode a fuel cut condition is present, as
communicated by the PCM.
Mode 9 - Voltage is supplied to module, yet voltage is not supplied to the sensor.
Mode 10 - No voltage supply to module or sensor. Non-operational.

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FORD MOTOR COMPANY REVISION DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 54 OF 241
Feedgas NOx Sensor – 3.0L and 6.7L F250-F550

Feedgas NOx sensor Control Module – 3.0L and 6.7L F250-F550

The sensor and module described below are used in 2019 6.7L F250-F550 pickups and chassis cabs only and
2019 3.0L.

The NOx controller module (SCU) is mounted to the vehicle frame under the body. It is used to control the
combination tailpipe NOx and O2 sensor mounted in diesel after-treatment exhaust system downstream of the SCR
and DPF. It communicates to the ECU via HSCAN to report NOx and O2 concentrations or OBDII errors.

The controller module (non-detachable from the sensor) consists of RAM, ROM, EEPROM, Ip1 circuit (oxygen
measurement), Ip2 circuit (NOx measurement), Rpvs circuit (sensor heater control), heater driver, and
microprocessor. The RAM temporarily stores information obtained from the sensing element during operation. The
ROM and EEPROM store sensor and controller module calibration coefficients obtained during the manufacturing
process. The Ip1 circuit consists of an ASIC (like that of a UEGO ASIC) that adjusts pumping current in the sensing
element’s Ip1 circuit for O2 detection. The Ip2 circuit adjusts the pumping current in the sensing element’s Ip2 circuit
for NOx detection. The Ip2 circuit consists of 2 bands: a wide range and a narrow range. The Rpvs circuit is a
measurement of the resistance of the Vs cell of the sensor element. This measurement is used to estimate the
temperature of the sensing element. The heater driver supplies a PWM voltage to the heater portion of the sensing
element to maintain the element’s target operational temperature. PID feedback from Rpvs is used to control and
maintain the element temperature. The microprocessor processes all of the inputs from the sensing element and
outputs to the CAN circuit. The temperature sensor in the controller module is used for compensating the
temperature dependency of circuit components and for OBD rationality checks.

The NOx controller module interfaces with the vehicle via a power source, signal ground, power ground, CAN-H and
CAN-L. The compensated O2 concentration compensated NOx concentration; Rpvs, pressure compensation
factors, sensor/module OBD (including monitor completion flags), and module temperature, are communicated via
HSCAN to the vehicle PCM.

NOx Controller Module Malfunctions

DTCs P2200 NOx Sensor Circuit (Bank 1 Sensor 1)
U05A1 NOx Sensor "A" Received Invalid Data From ECM/PCM
Monitor execution continuous
Sensors OK not applicable
Monitoring Duration 5 seconds to register a malfunction

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 Typical NOx Controller Malfunction Thresholds
P2200 RAM failure
ROM CRC check error
EEPROM CRC check error
U05A1 Erroneous Signal (Dew point reached with ignition off, etc.)
Timeout (>1 second before message received)

Feedgas NOx and O2 Sensor Malfunctions – 3.0L and 6.7L F250-F550

The NOx sensor is primarily used to sense O2 and NOx concentrations in diesel exhaust gas. The sensor is mounted
in a vehicle’s tailpipe, perpendicular to exhaust gas flow. The sensor is typically mounted downstream of an SCR
and DPF in an aftertreatment-equipped diesel exhaust system. The sensor interfaces to a NOx controller module
that controls the sensor element’s sense circuit and heater.

The NOx Sensor operates similarly to a UEGO sensor for measuring Ip1 (O2 concentration). Exhaust gas enters
through a diffusion barrier into the 1st measurement chamber. The sensor infers an air fuel ratio relative to the
stoichiometric (chemically balanced) air fuel ratio by balancing the amount of oxygen pumped in or out of the 1st
measurement chamber. As the exhaust gasses get richer or leaner, the amount of oxygen that must be pumped in
or out to maintain a stoichiometric air fuel ratio in the 1st measurement chamber varies in proportion to the air fuel
ratio. By measuring the current required to pump the oxygen in or out, the O2 concentration can be estimated.

The Ip2 (NOx concentration) measurement takes place in a 2nd measurement chamber. Exhaust gas passes from
the 1st measurement chamber through a 2nd diffusion barrier into the 2nd measurement chamber. The NOx present
in the 2nd measurement chamber is dissociated into N2 and O2. The excess O2 is pumped out of the 2nd
measurement chamber by the pumping current, Ip2. Ip2 is proportional to the NOx concentration in the measured
gas.

The NOx sensor interfaces the NOx controller module with the following:
Ip1 – pumping current for maintaining the A/F ratio in the 1st chamber
Ip2 – pumping current for pumping out dissociated O2 from 2nd chamber
COM – virtual ground for Vs, Ip1, and Ip2 circuits
REF – Nernst cell voltage, also carries current for pumped reference.
H+ – Heater voltage (High-side driver) – Duty cycle ON/OFF to control sensor temperature.
H- – Heater ground side

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NOx – O2 Sensor Malfunctions
DTCs P0133 O2 Sensor Circuit Slow Response (Bank 1, Sensor 1)
P2A00 O2 Sensor Circuit Range/Performance (Bank 1, Sensor 1)
P2200 NOx Sensor Circuit (Bank 1 Sensor 1)
P2201 NOx Sensor Circuit Range/Performance (Bank 1 Sensor 1)
P2209 NOx Signal Readiness (Bank 1 Sensor 1)
P220A NOx Sensor Supply Voltage Circuit (Bank 1 Sensor 1)
P220E NOx Sensor Heater Control Circuit Range/Performance (Bank 1 Sensor
1)
Monitor execution continuous
Sensors OK not applicable
Monitoring Duration 1 event per trip

Typical NOx – O2 Sensor Malfunctions Thresholds

P0133 As shown in figure below, during a transition from load to overrun/decel fuel shutoff, one of the
following occurs:
The time for the observed O2 percentage to increase from the value under load by 30% of (21%-O2
percentage under load) exceeds 6 seconds
OR
The time for the observed O2 percentage to increase from the value under load + 30% of the
difference to the value under load + 60% of the difference exceeds 5 seconds
OR
The time for the observed O2 percentage to increase from the value under load to the value under
load + 60% of the difference exceeds 11 seconds. (Used to detect completely inert sensors.)

(monitor operates when the vehicle is not undergoing particulate filter regeneration)

P2A00 A calculated oxygen concentration is derived from fuel, boost, and EGR. Observed oxygen
concentration is evaluated within two speed/load/air mass ranges. Code is set if observed oxygen
concentration falls outside the range ((calculated O2 concentration – negative offset, calculated O2
concentration + positive offset). Ranges and allowable O2 concentration deviations are given in the table
below.
FORD MOTOR COMPANY REVISION DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 57 OF 241
OR
In an extended overrun/decel fuel shutoff condition, an adaption factor is calculated for the response
of the O2 sensor to ensure that the sensor reads 20.95% O2 in air. Code is set if adaption factor is outside
the range 0.95 – 1.22.

(monitor operates when the vehicle is not undergoing particulate filter regeneration)

P2200 Vs, COM, Ip1, Ip2 short to battery –Vs, COM, Ip1, Ip2 ≥ 5V
Vs, COM, Ip1 short to ground –Vs, COM, Ip1 ==0V
Ip2 short to ground – Ip2 ≤ 250mV
Vs, COM, Ip1, Ip2 Open – Open Circuit detected by hardware

P2201 NOx Negative Offset – Nox Sensor greater than ~20 ppm offset
NOx Positive Offset – Nox Sensor greater than ~40 ppm offset

P2209 NOx/O2 Signal Readiness – > Ratio of actual on time / expected on time > 90 %
P220A Supplied Voltage failure – Voltage supplied > 16.5V or < 8.5V

P220E Heater Open – Open circuit detected by hardware

Heater short to battery – Heater Voltage > 5V
Heater short to ground – Heater Voltage == 0V
Heater Rationality – Duty cycle of heater different than expected by > 20%

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 P0133 (O2 slow response) monitor operation

21% O2

60% of difference
percent O2

30% of difference
beginning
of overrun

0% of difference between
O2 at start of overrun and
21% O2

time

NOx Sensor Operation Modes

Drive start Drive end

Engine OFF Engine OFF Engine ON Engine OFF Engine OFF

Key-OFF Key-ON Key-ON Key OFF Key-OFF
NA Mode NA Mode A Mode A Mode
- - Heater OFF A Mode & F/C Self Shut Down -
Vs No Active Vs Active under FLO After FLO
Failure occurred timing

②：In case of normal

① ③ ④ ⑤ ⑥ ⑦ ⑧ ⑩ ①
⑨：In case of engine stall

Mode 1 – No voltage supply to module or sensor. Non-operational.

Mode 2 – Voltage is supplied to module, yet voltage is not supplied to the sensor.
Mode 3 – Voltage is supplied to module, yet voltage is not supplied to the sensor. Dew-point waiting
period.
Mode 4 – Voltage is supplied to the module and to the sensor. The Vs cell of the sensor is not active.
Mode 5 – Voltage is supplied to the module and to the sensor. The Vs cell of the sensor is active.
Mode 6 – Heating:
 Protective heating mode:
In order to prevent the formation of water condensation (sensor can be damaged if condensate
water gets in contact with the sensor element thermal shock) the NOx sensor is operated in this
mode with a low heating power (protective heating).
In this mode, the microcontroller and the complete circuit are in operation after power on. Also the
CAN interface is available.
The sensor pins consisting of Vs, COM and IP1 are set to a protection state (high ohmic), IP2 is
0.1 V [N] above COM to protect the electrode from oxidation.
Note: The sensor will change to the heat mode (to reach operational temperature) only after SCU
receives dew point end signal (DPE-signal) from ECU.
• Boost mode (Heating mode):
The heater control inside the SCU brings the sensor probe to the operating temperature by
adapting the duty cycle of the heater period with a defined heating strategy. In order to determine
the probe temperature, the resistance of the Nernstian cell is used (Rpvs).
The status of the heater-on flag is sent to the ECU (Engine Control Unit) via CAN message.
• Measurement mode (Normal operation mode):
In this state the temperature is controlled via Rpvs. In this stable condition the respective valid
flags for O2 and NOx are set.
Mode 8 - Voltage is supplied to module, yet voltage is not supplied to the sensor.
Mode 9 - No voltage supply to module or sensor. Non-operational.

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Feedgas NOx Sensor Plausibility Monitors

Feedgas NOx Sensor Plausibility Monitor – 3.0L

This monitor is used on the 3.0L engine variants only.

The feedgas NOx sensor plausibility monitor utilizes an intrusive self-diagnostic performed by the NOx sensor
controller, that compares a test result against a reference value stored in the sensor module. This value is normalized
and reported as a percentage to the stored value to the ECU. The self-diagnostic is commanded to run a number
of times by the ECU during key off/engine off conditions. Once all the events are completed the ECU will average
the final monitor result. This can be averaged over multiple key cycles, as the previous values are stored in NVRAM.
The ECU will make a final determination of a fault based on the average of all the events.

The stored reference value used is captured and stored in each NOx sensor and NOx sensor module pair at the
sensor manufacturer end-of-line factory.

The intrusive self-diagnostic performed by the NOx sensor controller is performed every time the ECU requests it.
The self-diagnostic is an intrusive test during which the NOx sensor is controlled intrusively to a setpoint to measure
the NOx value. It accomplishes this by flooding the O2 channel. Each time a normalized self-diagnostic result is
measured.

Once the self-diagnostic has completed, the NOx sensor controller will determine if the self-diagnostic result is used
to normalize the self-diagnostic test result at a sensor. There is also an internal compensation factor that will
compensate for sensor aging and normalizes the self-diagnostic test result over the life of the sensor to match actual
NOx output.

The ECU will determine if the normalized self-diagnostic test result should be included in the monitor metric
calculation based on the absolute O2 concentration of the exhaust gas during the self-diagnostic test and the drift in
the O2 during the self-diagnostic test.

FG NOx Plausibility Monitor

DTCs P2201 - NOx Sensor Circuit Range/Performance (Bank 1 Sensor 1)
Monitor execution During Key off/Engine Off conditions (can be over multiple key cycles)

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 Monitor Sequence Key off / Engine off
Sensors OK NOx Sensor
Monitoring Duration 0.1 s (each self-diagnostic event)

Typical Nominal FG NOx Plausibility Monitor Entry Conditions:

Entry condition Minimum Maximum
Exhaust temperature at NOx 69.96 deg C 299.96 deg C
Sensor
Engine Speed 0 rpm (or equal to) 10 rpm
Time since last DPF regen 300 s
Time in EOM0 30 s
Ambient Air Temperature -7.04 deg C
Ambient Air Pressure 740 hPa
Battery Voltage 11 V
Time since NOx module achieved
closed loop heater control
Vehicle Speed 1 kph
NOx Sensor Valid Status True

Typical NOx Controller Malfunction Thresholds

Averaged normalized self-diagnostic result is less than XXXXX AND
The number of completed self-diagnostic events is greater than 7

Feedgas NOx Sensor Plausibility Monitor – 3.2L and 6.7L

This monitor is used on the 6.7L and 3.2L engine variants only. The Feed Gas Low NOx Plausibility Monitor runs
once per drive cycle during an intrusive EGR shutoff, in which the calculated NOx value (using fuel quantity,
temperature and ambient pressure) is then compared to the threshold.

Max recorded Nox

4 Sec
Delay

Minimum Threshold

7 Sec
EGR Off

Test Start Test End

Entry Conditions met

FG NOx
RPM Plausibility
– idle speed Monitor 1.5 Sec fuel cut before idle
Pedal = 0MOTOR COMPANY
FORD 1 perREVISION
drive cycle
DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 61 OF 241
Fuel 7<>15 mg/stroke 2 trip MIL
Coolant > 70C 50% of expected for threshold
 DTCs P2201 - NOx Sensor Circuit Range/Performance (Bank 1 Sensor 1)
Monitor execution Once a drive cycle
Monitor Sequence When EGR is disabled at idle, for air mass adaptation, the monitor runs.
Sensors OK NOx Sensor, EGR system
Monitoring Duration 11 seconds to register a malfunction

Typical Nominal FG NOx Plausibility Monitor Entry Conditions:

Entry condition Minimum Maximum
Engine coolant temperature 70 deg C
Engine at idle
DOC (6.7L)/SBS (3.2L) status Degreened (see below)

In order to protect against potential false failures due to NOx conversion of an extremely active new or “green”
oxidation catalyst (for the 6.7L) or SBS (for the 3.2L), this monitor is disabled until the oxidation catalyst/SBS has
seen a minimum of 7200 seconds at an outlet temperature of 500 degrees C or higher.

Typical NOx Controller Malfunction Thresholds

Measured maximum NOx is less than 50% of expected amount from model.

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Tailpipe NOx Sensor – 3.2L and 6.7L F650-F750

Tailpipe NOx Sensor Control Module – 3.2L and 6.7L F650-F750

The sensor and module described below is used on all 2019 3.2L diesel Transit applications and in 2017 6.7L diesel
F650-F750 chassis cabs.

The NOx controller module is mounted to the vehicle frame under the body. It is used to control the combination
tailpipe NOx and O2 sensor mounted in diesel after-treatment exhaust system downstream of the SCR and DPF. It
communicates to the ECU via HSCAN to report NOx and O2 concentrations or OBDII errors.

The controller module consists of RAM, ROM, EEPROM, Ip1 circuit, Ip2 circuit, Rpvs circuit, heater driver,
microprocessor, and temperature sensor. The RAM temporarily stores information obtained from the sensing
element during operation. The ROM and EEPROM store sensor and controller module calibration coefficients
obtained during the manufacturing process. The Ip1 circuit consists of an ASIC (like that of a UEGO ASIC) that
adjusts pumping current in the sensing element’s Ip1 circuit for O2 detection. The Ip2 circuit adjusts the pumping
current in the sensing element’s Ip2 circuit for NOx detection. The Ip2 circuit consists of 2 bands: a wide range and
a narrow range. The Rpvs circuit is a measurement of the resistance of the Vs cell of the sensor element. This
measurement is used to estimate the temperature of the sensing element. The heater driver supplies a PWM voltage
to the heater portion of the sensing element to maintain the element’s target operational temperature. PID feedback
from Rpvs is used to control and maintain the element temperature. The microprocessor processes all of the inputs
from the sensing element and outputs to the CAN circuit. The temperature sensor in the controller module is used
for compensating the temperature dependency of circuit components and for OBD rationality checks.

The NOx controller module interfaces with the vehicle via a power source, signal ground, power ground, CAN-H and
CAN-L. The compensated O2 concentration compensated NOx concentration; Rpvs, pressure compensation
factors, sensor/module OBD (including monitor completion flags), module temperature, software ID, CALID, and
CVN are communicated via HSCAN to the vehicle PCM.

NOx Controller Module Malfunctions

DTCs P06EB NOx Sensor Processor Performance (Bank 1 Sensor 2)
U05A2 NOx Sensor "B" Received Invalid Data From ECM/PCM
P225B NOx Sensor Calibration Memory (Bank 1 Sensor 2)
Monitor execution Continuous
Monitor Sequence Ip2-N and Ip2-W range rationality – 50ppm < [NOx] < 100ppm

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 Sensors OK not applicable
Monitoring Duration 5 seconds to register a malfunction

Typical NOx Controller Malfunction Thresholds

P06EB RAM failure
ROM CRC check error
EEPROM CRC check error
Ip1 out of range – Ip1(VIP2.1) < 1.8V, Ip1(VIP2.1) > 2.2V, Ip1(VIP2.2) < 0.2V, or Ip1(VIP2.2) > 0.6V
Ip2-W out of range – Vs+ ≥ 5.35V and Ip2-W > 4.8V
Ip2-N out of range – Vs+ ≥ 5.35V and Ip2-N < 0.2V
Ip2-N and Ip2-W range rationality – Integral value of differential between Ip2-N & Ip2-W ≥ 250ppm
Vp2 circuit failure – Vp2 < 250mV or Vp2 > 650mV
Rpvs short to ground – Rpvs < 0.2V
Temperature sensor short to battery – Temp > 4.5V
Temperature sensor short to ground – Temp < 0.45V
Temperature sensor open – 0.45V ≤ Temp < 0.48V
NOx Module temperature within 40 deg. C of Exhaust Temperature Sensor (following 6 hour soak
only)
U05A2 Erroneous Signal (Dew point reached with ignition off, etc.)
Timeout (>1 second before message received)
P225B Memory does not pass CRC check

Tailpipe NOx and O2 Sensor Malfunction – 3.2L and 6.7L F650-F750

The NOx sensor is primarily used to sense O2 and NOx concentrations in diesel exhaust gas. The sensor is mounted
in a vehicle’s tailpipe, perpendicular to exhaust gas flow. The sensor is typically mounted downstream of an SCR
and DPF in an aftertreatment-equipped diesel exhaust system. The sensor interfaces to a NOx controller module
that controls the sensor element’s sense circuit and heater.

The NOx Sensor operates similarly to a UEGO sensor for measuring Ip1 (O2 concentration). Exhaust gas enters
through a diffusion barrier into the 1st measurement chamber. The sensor infers an air fuel ratio relative to the
stoichiometric (chemically balanced) air fuel ratio by balancing the amount of oxygen pumped in or out of the 1st
measurement chamber. As the exhaust gasses get richer or leaner, the amount of oxygen that must be pumped in
or out to maintain a stoichiometric air fuel ratio in the 1st measurement chamber varies in proportion to the air fuel
ratio. By measuring the current required to pump the oxygen in or out, the O2 concentration can be estimated.

The Ip2 (NOx concentration) measurement takes place in a 2nd measurement chamber. Exhaust gas passes from
the 1st measurement chamber through a 2nd diffusion barrier into the 2nd measurement chamber. The NOx present
in the 2nd measurement chamber is dissociated into N2 and O2. The excess O2 is pumped out of the 2nd
measurement chamber by the pumping current, Ip2. Ip2 is proportional to the NOx concentration in the measured
gas.

The NOx sensor is equipped with a memory component which stores unique sensor characteristics used to
compensate for part-to-part variation of the element during the manufacturing process. The memory stores Ip1
and Ip2 gains/offsets for each individual sensor.
The NOx sensor interfaces the NOx controller module with the following:
Ip1 – pumping current for maintaining the A/F ratio in the 1st chamber
Ip2 – pumping current for pumping out dissociated O2 from 2nd chamber
COM – virtual ground for Vs, Ip1, and Ip2 circuits
Vs – Nernst cell voltage, 425mV from COM. Also carries current for pumped reference.
TM – Touch memory which stores Ip1 and Ip2 gain/offset.
TM GND – Ground for touch memory reading
H+ – Heater voltage (High-side driver) – Duty cycle ON/OFF to control sensor temperature.
FORD MOTOR COMPANY REVISION DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 64 OF 241
 H- – Heater ground side

Cross section of element

Interface circuit
O2 2nd diffusion passage
Ip1
Ip1 drive
circuit
1st diffusion 1st Pumping Cell (Ip1) Gnd
Gnd
Ip+
Ip+
passage
GND
GND
Detecting
Detecting
Cell
Cell
(Vs Cell) Vs
Vs Vs signal Reference
detection 425mV
•Ip2+
•Ip2+ GND
GND Comparison
2nd Pumping Cell (Ip2)
O2 Icp Icp supply
Heater
Heater
Ip2 drive circuit

Ip2
Heater power supply

IP2 Open (FLO) OBD Algorithm

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IP2 Open (FLO) OBD Algorithm

NOx – O2 Sensor Malfunctions

DTCs P0139 O2 Sensor Circuit Slow Response (Bank 1 Sensor 2)
P0140 O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 2)
P2A01 O2 Sensor Circuit Range/Performance (Bank 1 Sensor 2)
P229E NOx Sensor Circuit (Bank 1 Sensor 2)
P229F NOx Sensor Circuit Range/Performance (Bank 1 Sensor 2)
P220F NOx Sensor Heater Control Circuit Range/Performance (Bank 1
Sensor 2)
P22A7 NOx Sensor Heater Sense Circuit Range/Performance (Bank 1
Sensor 2)
P220B NOx Sensor Supply Voltage Circuit (Bank 1 Sensor 2)
Monitor execution Continuous
Monitor Sequence Ip2 Open – 02 ≥ 5% or F/C > 3 seconds and O2 ≥ 19%
Ip2 Crack – F/C > 5 seconds and O2 ≥ 19%
Sensors OK not applicable

Typical NOx Sensor – O2 Sensor Malfunctions Entry Conditions:

Entry condition Minimum Maximum
Sensor dewpoint reached
P22A7:

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Exhaust mass flow 110 g/sec
P229E Ip2 crack detection only:
Fuel injection quantity 0 mg/stroke
Time at zero fuel quantity 5 seconds
P2A01:
Post injection status Not occurring
Fuel tank level 0L
System voltage 10.7V
Variation in O2 signal over 2 sec 1.5% O2
Engine speed 1000 rpm 2700 rpm
Injection quantity (zero fuel point) -0.5 mg/stroke 0.5 mg/stroke
Injection quantity (load point) 15 mg/stroke 40 mg/stroke

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Typical NOx – O2 Sensor Malfunctions Thresholds
P0139 As shown in figure below, during a transition from load to overrun/decel fuel shutoff, one of the
following occurs:
The time for the observed O2 percentage to increase from the value under load by 30% of (21%-O2
percentage under load) exceeds 6 seconds
OR
The time for the observed O2 percentage to increase from the value under load + 30% of the
difference to the value under load + 60% of the difference exceeds 5 seconds
OR
The time for the observed O2 percentage to increase from the value under load to the value under
load + 60% of the difference exceeds 11 seconds. (Used to detect completely inert sensors.)

(monitor operates when the vehicle is not undergoing particulate filter regeneration)

P0140 If there is no available O2 signal at 300 seconds after the sensor has achieved operating
temperature

P2A01 A calculated oxygen concentration is derived from fuel, boost, and EGR. Observed oxygen
concentration is evaluated within two speed/load/air mass ranges. Code is set if observed oxygen
concentration falls outside the range ((calculated O2 concentration – negative offset, calculated O2
concentration + positive offset). Ranges and allowable O2 concentration deviations are given in the table
below.
OR
In an extended overrun/decel fuel shutoff condition, an adaption factor is calculated for the response
of the O2 sensor to ensure that the sensor reads 20.95% O2 in air. Code is set if adaption factor is outside
the range 0.95 – 1.22.

(monitor operates when the vehicle is not undergoing particulate filter regeneration)

P229E Vs, COM, Ip1 short to battery – ASIC Diag2=1 and Vs, COM, Ip1 ≥ 9V
Ip2 short to battery – Ip2 ≥ 4.8V
Vs, COM, Ip1 short to ground – ASIC Diag2=1 and Vs, COM, Ip1 < 9V
Ip2 short to ground – Ip2 ≤ 2V
Ip1 Open – Vs ≤ 225mV, Vs ≥ 625mV & -0.2mA ≤ Ip1 ≤ 0.2mA
Vs Open – Vs > 1.5V
COM Open – Rpvs > RpvsA (target Rpvs stored in sensor memory) or ASIC Diag1=1
Ip2 Open – Ip2-W ≤ 0.2V and Ip2-N ≤ 0.2V
Sensor Memory CRC check
Vs/Ip1 Cell Crack – Ip1 > 6.4mA
Ip2 Cell Crack – Ip2-W > 4.8V

P229F NOx Negative Offset – NOx Sensor greater than ~ - 10 ppm offset
NOx Positive Offset – NOx Sensor greater than ~20 ppm offset
Tip-in – Filtered tailpipe NOx on tip-in delta > 0 ppm

P220F Heater control failure – Rpvs ≥ 0.2V and Rpvs < TRpvs - 30Ω or Rpvs > TRpvs + 30Ω
Heater Open – Heater current < 0.4A
Heater short to battery – Δ Heater Voltage > 0.2V
Heater short to ground – Δ Heater Voltage > 0.2V
Heater performance failure – Heater current ≥ 0.4A and Heater Resistance ≥ 11Ω
P22A7 NOx/O2 Availability – > 1 PL (Healing mode) per cycle or > 9 sec of NOx/O2 not valid
P220B Battery failure – Battery > 17V or Battery < 10V

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 Oxygen Sensor Plausibility Measurement (P2A01) Evaluation Ranges and Allowable Deviations:

Range 1 Overrun
Minimum Maximum Minimum Maximum
Engine speed (rpm) 1100 2700 100 4000
Fuel injection quantity 15 38 0 0.5
(mg/stroke)
Air mass (mg/stroke) 400 1000 100 1000
Allowable deviation (% O2) -7.0 5.5 -5.0 4.6

NOx Sensor Operation Modes

Drive start Drive end

Engine OFF Engine OFF Engine ON Engine OFF Engine OFF

Key-OFF Key-ON Key-ON Key OFF Key-OFF
NA Mode NA Mode A Mode A Mode
- - Heater OFF A Mode & F/C Self Shut Down -
Vs No Active Vs Active under FLO After FLO
Failure occurred timing

②：In case of normal

① ③ ④ ⑤ ⑥ ⑦ ⑧ ⑩ ①
⑨：In case of engine stall

Mode 1 – No voltage supply to module or sensor. Non-operational.

Mode 2 – Voltage is supplied to module, yet voltage is not supplied to the sensor.
Mode 3 – Voltage is supplied to module, yet voltage is not supplied to the sensor. Dew-point waiting
period.
Mode 4 – Voltage is supplied to the module and to the sensor. The Vs cell of the sensor is not active.
Mode 5 – Voltage is supplied to the module and to the sensor. The Vs cell of the sensor is active.
Mode 6 – Voltage is supplied to the module and to the sensor. Sensor is in fast light-off to quickly heat
sensing element to operational temperature.
Mode 7 – Voltage is supplied to the module and to the sensor. The sensor has exited fast light-off and O2
and NOx will be available during this mode.
Mode 8 - Voltage is supplied to the module and to the sensor. The sensor has exited fast light-off and O2
and NOx will be available during this mode. During this mode a fuel cut condition is present, as
communicated by the PCM.
Mode 9 - Voltage is supplied to module, yet voltage is not supplied to the sensor.
Mode 10 - No voltage supply to module or sensor. Non-operational.

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Tailpipe NOx Sensor – 6.7L F250-F550

Tailpipe NOx Sensor Control Module – 6.7L F250-F550

The sensor and module described below is used in 2019 6.7L diesel F250-F550 pickups and chassis cabs only.

The NOx controller module (SCU) is mounted to the vehicle frame under the body. It is used to control the
combination tailpipe NOx and O2 sensor mounted in diesel after-treatment exhaust system downstream of the SCR
and DPF. It communicates to the ECU via HSCAN to report NOx and O2 concentrations or OBDII errors.

The controller module (non-detachable from the sensor) consists of RAM, ROM, EEPROM, Ip1 circuit (oxygen
measurement), Ip2 circuit (NOx measurement), Rpvs circuit (sensor heater control), heater driver, and
microprocessor. The RAM temporarily stores information obtained from the sensing element during operation. The
ROM and EEPROM store sensor and controller module calibration coefficients obtained during the manufacturing
process. The Ip1 circuit consists of an ASIC (like that of a UEGO ASIC) that adjusts pumping current in the sensing
element’s Ip1 circuit for O2 detection. The Ip2 circuit adjusts the pumping current in the sensing element’s Ip2 circuit
for NOx detection. The Ip2 circuit consists of 2 bands: a wide range and a narrow range. The Rpvs circuit is a
measurement of the resistance of the Vs cell of the sensor element. This measurement is used to estimate the
temperature of the sensing element. The heater driver supplies a PWM voltage to the heater portion of the sensing
element to maintain the element’s target operational temperature. PID feedback from Rpvs is used to control and
maintain the element temperature. The microprocessor processes all of the inputs from the sensing element and
outputs to the CAN circuit. The temperature sensor in the controller module is used for compensating the
temperature dependency of circuit components and for OBD rationality checks.

The NOx controller module interfaces with the vehicle via a power source, signal ground, power ground, CAN-H and
CAN-L. The compensated O2 concentration compensated NOx concentration; Rpvs, pressure compensation
factors, sensor/module OBD (including monitor completion flags), and module temperature, are communicated via
HSCAN to the vehicle PCM.

NOx Controller Module Malfunctions

DTCs P229E NOx Sensor Processor Performance (Bank 1 Sensor 2)
U05A2 NOx Sensor "B" Received Invalid Data From ECM/PCM
Monitor execution continuous
Sensors OK not applicable
Monitoring Duration 5 seconds to register a malfunction

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 Typical NOx Controller Malfunction Thresholds
P06EB RAM failure
ROM CRC check error
EEPROM CRC check error
U05A2 Erroneous Signal (Dew point reached with ignition off, etc.)
Timeout (>1 second before message received)

Tailpipe NOx and O2 Sensor Malfunction – 6.7L F250-F550

The NOx sensor is primarily used to sense O2 and NOx concentrations in diesel exhaust gas. The sensor is mounted
in a vehicle’s tailpipe, perpendicular to exhaust gas flow. The sensor is typically mounted downstream of an SCR
and DPF in an aftertreatment-equipped diesel exhaust system. The sensor interfaces to a NOx controller module
that controls the sensor element’s sense circuit and heater.

The NOx Sensor operates similarly to a UEGO sensor for measuring Ip1 (O2 concentration). Exhaust gas enters
through a diffusion barrier into the 1st measurement chamber. The sensor infers an air fuel ratio relative to the
stoichiometric (chemically balanced) air fuel ratio by balancing the amount of oxygen pumped in or out of the 1st
measurement chamber. As the exhaust gasses get richer or leaner, the amount of oxygen that must be pumped in
or out to maintain a stoichiometric air fuel ratio in the 1st measurement chamber varies in proportion to the air fuel
ratio. By measuring the current required to pump the oxygen in or out, the O2 concentration can be estimated.

The Ip2 (NOx concentration) measurement takes place in a 2nd measurement chamber. Exhaust gas passes from
the 1st measurement chamber through a 2nd diffusion barrier into the 2nd measurement chamber. The NOx present
in the 2nd measurement chamber is dissociated into N2 and O2. The excess O2 is pumped out of the 2nd
measurement chamber by the pumping current, Ip2. Ip2 is proportional to the NOx concentration in the measured
gas.

The NOx sensor interfaces the NOx controller module with the following:
Ip1 – pumping current for maintaining the A/F ratio in the 1st chamber
Ip2 – pumping current for pumping out dissociated O2 from 2nd chamber
COM – virtual ground for Vs, Ip1, and Ip2 circuits
REF – Nernst cell voltage, also carries current for pumped reference.
H+ – Heater voltage (High-side driver) – Duty cycle ON/OFF to control sensor temperature.
H- – Heater ground side

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NOx – O2 Sensor Malfunctions
DTCs P0139 O2 Sensor Circuit Slow Response (Bank 1 Sensor 2)
P2A01 O2 Sensor Circuit Range/Performance (Bank 1 Sensor 2)
P229E NOx Sensor Circuit (Bank 1 Sensor 2)
P22A7 NOx Signal Readiness (Bank 1 Sensor 2)
P229F NOx Sensor Circuit Range/Performance (Bank 1 Sensor 2)
P220F NOx Sensor Heater Sense Circuit Range/Performance (Bank 1
Sensor 2)
P220B NOx Sensor Supply Voltage Circuit (Bank 1 Sensor 2)
Monitor execution continuous
Sensors OK not applicable
Monitoring Duration X events per trip

Typical NOx Sensor – O2 Sensor Malfunctions Entry Conditions:

Entry condition Minimum Maximum
Sensor dewpoint reached
P22A7:
Exhaust mass flow 110 g/sec
P229E Ip2 crack detection only:
Fuel injection quantity 0 mg/stroke
Time at zero fuel quantity 5 seconds
P2A01:
Post injection status Not occurring
Fuel tank level 0L
System voltage 10.7V
Variation in O2 signal over 2 sec 1.5% O2
Engine speed 1000 rpm 2700 rpm
Injection quantity (zero fuel point) -0.5 mg/stroke 0.5 mg/stroke
Injection quantity (load point) 15 mg/stroke 40 mg/stroke

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Typical NOx – O2 Sensor Malfunctions Thresholds
P0139 As shown in figure below, during a transition from load to overrun/decel fuel shutoff, one of the
following occurs:
The time for the observed O2 percentage to increase from the value under load by 30% of (21%-O2
percentage under load) exceeds 6 seconds
OR
The time for the observed O2 percentage to increase from the value under load + 30% of the
difference to the value under load + 60% of the difference exceeds 5 seconds
OR
The time for the observed O2 percentage to increase from the value under load to the value under
load + 60% of the difference exceeds 11 seconds. (Used to detect completely inert sensors.)

(monitor operates when the vehicle is not undergoing particulate filter regeneration)

P0140 If there is no available O2 signal at 300 seconds after the sensor has achieved operating
temperature

P2A01 A calculated oxygen concentration is derived from fuel, boost, and EGR. Observed oxygen
concentration is evaluated within two speed/load/air mass ranges. Code is set if observed oxygen
concentration falls outside the range ((calculated O2 concentration – negative offset, calculated O2
concentration + positive offset). Ranges and allowable O2 concentration deviations are given in the table
below.
OR
In an extended overrun/decel fuel shutoff condition, an adaption factor is calculated for the response
of the O2 sensor to ensure that the sensor reads 20.95% O2 in air. Code is set if adaption factor is outside
the range 0.95 – 1.22.

(monitor operates when the vehicle is not undergoing particulate filter regeneration)

P229E Vs, COM, Ip1 short to battery –Vs, COM, Ip1 ≥ 6.4V
Ip2 short to battery – Voltage rise between IP2 and REF circuits > 1V
Vs, COM, Ip1 short to ground –Vs, COM, Ip1 < 0.23V
Ip2 short to ground – Voltage drop between IP2 and REF circuits ≤ 230mV
Vs, COM, Ip1, Open – ==0V
IP2 Open – IP2 <1.35V

P229F NOx Negative Offset – Nox Sensor greater than ~30 ppm offset
NOx Positive Offset – Nox Sensor greater than ~50 ppm offset
Tip-in – Nox rise rate on tip-in < .01 ppm/sec

P220F Heater Open – Heater current < 0.4A

Heater short to battery – Δ Heater Voltage > 0.2V
Heater short to ground – Δ Heater Voltage > 0.2V
Heater Rationality – Duty cycle of heater different than expected by > 20%

P22A7 NOx/O2 Signal Readiness – > Ratio of actual on time / expected on time > 90 %
P220B Supplied Voltage failure – Voltage supplied > 16.5V or < 8.5V

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NOx Sensor Operation Modes

Drive start Drive end

Engine OFF Engine OFF Engine ON Engine OFF Engine OFF

Key-OFF Key-ON Key-ON Key OFF Key-OFF
NA Mode NA Mode A Mode A Mode
- - Heater OFF A Mode & F/C Self Shut Down -
Vs No Active Vs Active under FLO After FLO
Failure occurred timing

②：In case of normal

① ③ ④ ⑤ ⑥ ⑦ ⑧ ⑩ ①
⑨：In case of engine stall

Mode 1 – No voltage supply to module or sensor. Non-operational.

Mode 2 – Voltage is supplied to module, yet voltage is not supplied to the sensor.
Mode 3 – Voltage is supplied to module, yet voltage is not supplied to the sensor. Dew-point waiting
period.
Mode 4 – Voltage is supplied to the module and to the sensor. The Vs cell of the sensor is not active.
Mode 5 – Voltage is supplied to the module and to the sensor. The Vs cell of the sensor is active.
Mode 6 – Heating:
 Protective heating mode:
In order to prevent the formation of water condensation (sensor can be damaged if condensate
water gets in contact with the sensor element thermal shock) the NOx sensor is operated in this
mode with a low heating power (protective heating).
In this mode, the microcontroller and the complete circuit are in operation after power on. Also the
CAN interface is available.
The sensor pins consisting of Vs, COM and IP1 are set to a protection state (high ohmic), IP2 is
0.1 V [N] above COM to protect the electrode from oxidation.
Note: The sensor will change to the heat mode (to reach operational temperature) only after SCU
receives dew point end signal (DPE-signal) from ECU.
• Boost mode (Heating mode):
The heater control inside the SCU brings the sensor probe to the operating temperature by
adapting the duty cycle of the heater period with a defined heating strategy. In order to determine
the probe temperature, the resistance of the Nernstian cell is used (Rpvs).
The status of the heater-on flag is sent to the ECU (Engine Control Unit) via CAN message.
• Measurement mode (Normal operation mode):
In this state the temperature is controlled via Rpvs. In this stable condition the respective valid
flags for O2 and NOx are set.
Mode 8 - Voltage is supplied to module, yet voltage is not supplied to the sensor.
Mode 9 - No voltage supply to module or sensor. Non-operational.

PARTICULATE MATTER SENSOR MONITOR

Exhaust Gas Particulate Matter Sensor (PMS)

The particulate matter sensor (PMS) on diesel products is used to detect high levels of particulate emissions
resulting from a leak in the particulate filter. The sensor consists of an exhaust mounted probe and a sensor
control module. On chassis certified vehicles the probe is mounted in the highest point of the kick-up pipe routed
above the rear axle. On dyno certified vehicles the probe is mounted after the SCR near the NOx sensor and
EGT14 sensor. The sensor module is mounted to the vehicle frame under the body near the probe. The sensor
probe and the control module are permanently connected and cannot be serviced independently.

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The PMS interfaces to the vehicle via a power supply, power ground, CAN low and CAN high. The sensor specific
calibration factor, status of the sensor, temperature, electrode current, heater duty cycle, software ID, calibration ID,
and various sensor diagnostic results are communicated of HSCAN to the PCM.

PMS Control Module Checks:

DTCs P24D0 Particulate Matter Sensor Supply Voltage Circuit Low
U02A3 Lost Communication With PM Sensor
Monitor Execution Continuous
Monitor Sequence None
Sensors OK Not applicable
Typical Monitoring Duration P24D0 – 2 seconds
U02A3 – 7 seconds

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 PMS Control Module Checks Entry Conditions:
Entry condition Minimum Maximum
Battery voltage 11 V 16 V
P24D0 only:
Sensor heater duty cycle 35%

PMS Control Module Checks Malfunction Thresholds:

P24D0: If battery voltage is > 15 V, voltage drop > 1.1 V
if battery voltage is > 11.7 V, voltage drop > 2.1 V
if battery voltage is < 11.7 V, voltage drop > 3 V
U02A3: PMS CAN message missing for more than 7 seconds

The PMS probe consists of three internal parts: a heater, a temperature sensor and a set of particulate matter
measurement electrodes. The sensor operates by accumulating exhaust particles in the gap separating the
electrodes. As particles accumulate the resistance between the electrodes drops, and an electric current can flow
due to the voltage potential applied. The duration of accumulation to a certain current threshold determines the
leakage of the particulate filter. Because particles accumulate on the sensor, it must be regenerated occasionally
by activating the sensor heater. The temperature of the part is controlled with feedback from the temperature
sensor, and measurement of sensor temperature is used to correct sensor output for variation in resistivity of
particulate matter as a function of temperature.

The PMS module handles basic circuit checks for the sensor components. Standard open and short circuit
diagnostics are run on the temperature sensor and the heater by the PMS module and reported to the PCM via
CAN messages.

PMS Temperature Sensor Circuit Checks:

DTCs P24C6 Particulate Matter Sensor Temperature Circuit
Monitor Execution Continuous
Monitor Sequence None
Sensors OK Not applicable
Typical Monitoring Duration P24C6 – 2 seconds

PMS Temperature Sensor Circuit Checks Entry Conditions:

Entry condition Minimum Maximum
Battery voltage 11 V 16 V
Exhaust temperature -39 degC 800 degC

PMS Temperature Sensor Circuit Checks Malfunction Thresholds:

Temperature sensor circuit voltage is < 0.3 volts or > 3 volts

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 PMS Heater Circuit Checks:
DTCs P24B3 Particulate Matter Sensor Heater Control Circuit/Open
P24B4 Particulate Matter Sensor Heater Control Circuit Range/Performance
Monitor Execution P24B3: Continuous during PMS regeneration
P24B4: Continuous during PMS measuring
Monitor Sequence None
Sensors OK PMS Temperature
Typical Monitoring Duration 2 seconds

PMS Heater Circuit Checks Entry Conditions:

Entry condition Minimum Maximum
Battery voltage 11 V 16 V
For P24B3, PMS heating on
For P24B4, PMS heating off

PMS Heater Circuit Checks Malfunction Thresholds:

P24B3: PMS heater current < 0.2 amps
P24B4: PMS heater voltage > 7 volts

In addition to basic circuit checks the temperature sensor in the PMS is monitored for offset and plausibility compared
to other exhaust gas temperature sensors. The temperature offset check occurs at key-on after a long engine-off
soak to ensure all sensors have stabilized to ambient temperature. The PMS temperature is compared to the
average reading of three other exhaust temperature sensors. During PMS measurement, the sensor temperature
is compared to a model of the sensor temperature to check plausibility. The model estimates PMS temperature
based on exhaust gas temperature and exhaust pipe wall temperature. This monitor only runs while the PMS is not
actively heating and sufficient time has elapsed since the last heating event to ensure that the sensor temperature
has stabilized to the exhaust conditions.

PMS Temperature Plausibility Checks:

DTCs P24C7 Particulate Matter Sensor Temperature Circuit Range/performance
Monitor Execution - Offset test once per cold start
- Dynamic check during sensor measurement
Monitor Sequence None
Sensors OK EGT14
Typical Monitoring Duration - Cold start test, 10 sec
- Dynamic test, 120 sec

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 PMS Temperature Plausibility Checks Entry Conditions:
Entry condition Minimum Maximum
For dynamic test:
Battery voltage 11 V 16 V
EGT for offset check -40 degC 80 degC
Exhaust gas velocity 12 m/s 655 m/s
Vehicle speed 25 km/hr 250 km/hr
BARO 74.5 kPa
Modeled PMS temperature for -40 degC 400 degC
dynamic check
Modeled PMS temperature change 30 degC
during dynamic check
For cold start test:
EGT1, EGT2, EGT3 temperature -40 deg C 80 deg C
Time since PMS power-on 2.5 sec
Engine off time 6 hours

PMS Temperature Plausibility Checks Malfunction Thresholds:

- Difference between PM Sensor reported temperature and modeled temperature < -150 degC or > 60 degC
- Difference between PMS temperature and average of reference exhaust sensors > 45 degC
- PM sensor temperature at key-on < -40 degC

The resistance of the PMS heater is monitored as a surrogate for the performance of the heater. When the PMS is
powered up, two short pulses are sent to the heater during which the current through the heater is measured. Using
the measured supply voltage, the resistance of the heater can be calculated. The resistance is compared to a
threshold based on the sensor temperature and reported over CAN.

PMS Heater Checks:

DTCs P24B7 Particulate Matter Sensor Heater Resistance
Monitor Execution Once per drive at key on
Monitor Sequence None
Sensors OK PMS Temperature
Typical Monitoring Duration 10 seconds

PMS Heater Checks Entry Conditions:

Entry condition Minimum Maximum
Battery voltage 11 V 16 V
PMS Temperature -30 degC 150 degC
Change in PMS Temperature during 150 degC
monitor

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 PMS Heater Checks Malfunction Thresholds:
PMS heater resistance @ -30 degC < 1.06 Ohms or > 2.93 Ohms
PMS heater resistance @ 150 degC < 1.81 Ohms or > 4.12 Ohms

Because the sensor electrode is normally open circuit and can exhibit a short circuit in case it is heavily loaded with
PM, it poses unique challenges for on-board diagnostics. Monitoring the electrode for open circuit involves taking
advantage of movement of sodium ions through the hot ceramic substrate of the sensor electrode. At sensor
regeneration temperature, movement of the ions causes a current which is measured to ensure the integrity of the
sensor electrodes. This form of open circuit check takes place at the end of sensor regeneration while the electrode
is still hot. The check for short circuit takes place after the sensor has cooled below 425 °C immediately following
regeneration when the sensor is sure to be free of any PM. During sensor operation, the positive electrode of the
sensor is monitored to ensure the electrode supply voltage is in range. If the voltage drops due to a hardware failure
in the sensor, a fault will be set. If a short circuit occurs in the electrode and sensor regeneration will be performed
to ensure the short is not due to accumulation of soot, then a fault set.

PMS Electrode Checks:

DTCs P24AE Particulate Matter Sensor Circuit
P24AF Particulate Matter Sensor Circuit Range/Performance
P24B0 Particulate Matter Sensor Circuit Low
P24B1 Particulate Matter Sensor Circuit High
Monitor Execution P24AE – After each PMS regeneration
P24AF – After each PMS regeneration
P24B0 – Continuous during sensor measurement
P24B1 – Continuous during sensor measurement
Monitor Sequence None
Sensors OK EGT
Typical Monitoring Duration P24AE – 120 seconds
P24AF – 120 seconds
P24B0 – 1.6 seconds
P24B1 – 3 seconds

PMS Electrode Checks Entry Conditions:

Entry condition Minimum Maximum
Battery voltage 11 V 16 V
Key on
P24AE:
PMS state measure
PMS temperature: 200 deg C 425 deg C
P24AF:
PMS state Sensor regeneration
PMS temperature 770 deg C 800 deg C

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 PMS Electrode Checks Malfunction Thresholds:
P24AE: PMS current > 5 microamps after sensor regeneration
P24AF: PMS current during sensor regeneration less than 0.094 microamps
P24B0: PMS Voltage < 41.55 V
P24B1: PMS Current > 41 microamps

Particulate Matter Sensor Sampling Monitor

To operate correctly, the PMS must have unrestricted exposure to exhaust gas. A monitor for PM sensor sampling
checks the sensor once per drive for plugging with excessive soot and proper installation in the exhaust. The
monitor evaluates the change in voltage required to maintain a constant sensor heater temperature for changes in
exhaust gas velocity. In the event that the voltage, calculated from heater duty cycle, changes less than a
calibrated threshold for certain magnitude changes in exhaust gas flow, a fault for a PM sensor sampling error is
set. The sampling tube monitor runs during cold start before exhaust dewpoint is reached while the PMS is
operating at a low heating level for contamination protection.

PMS Sampling Error Check:

DTCs P24DA Particulate Matter Sensor Exhaust Sample Error Bank 1
Monitor Execution Once per drive
Monitor Sequence None
Sensors OK EGT14
Typical Monitoring Duration 3 minutes

PMS Sampling Error Check Entry Conditions:

Entry condition Minimum Maximum
PMS in protective heating mode
Exhaust gas acceleration 0.5 m/sec/sec 5 m/sec/sec
Time after engine start 10 sec
Exhaust gas temperature -3000 degC 3000 degC
Battery voltage 11 V 16 V
Engine running
Final EGT sensor temperature -40 deg C 180 deg C
PMS temperature at start -3550 deg C 120 deg C
Exhaust gas velocity 35 m/sec 50 m/sec

PMS Sampling Error Check Malfunction Thresholds:

Cumulative PM sensor voltage during exhaust gas velocity changes < 0.5 volts

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Particulate Matter Sensor Regeneration Monitor

To burn off accumulated particulates, the PMS must occasionally regenerate. This is accomplished by heating the
sensor element to 785 °C for a period of time. The success of sensor regeneration is monitored by evaluating if
the sensor is able to maintain the regeneration temperature for the time required to ensure all accumulated
material is removed. The monitoring only takes place if vehicle conditions are such that the sensor is capable of
regeneration. For example, the PMS may not be able to regenerate if the battery voltage is below normal and the
engine is at peak power. This is because at the reduced voltage, the PMS heater may not be capable of providing
the power required to reach the setpoint temperature.

PMS Regeneration Check:

DTCs P24D1 Particulate Matter Sensor Regeneration Incomplete
Monitor Execution After each PMS regeneration
Monitor Sequence None
Sensors OK EGT14
Typical Monitoring Duration 120 seconds

PMS Regeneration Check Entry Conditions:

Entry condition Minimum Maximum
Battery voltage 11 V 16 V
PMS heater power not exceeded

PMS Regeneration Check Malfunction Thresholds:

PMS unable to enter “measure” state

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Particulate Matter Filter Monitor Using PM Sensor

The DPF is monitored to ensure no leaks have developed in the substrate. The monitor runs anytime the filter is
not being regenerated and the exhaust is sufficiently warm to allow operation of the PMS. In addition, the NOx,
exhaust gas temperature and gas velocity must be at normal operating levels.
The DPF efficiency monitor compares the response of the tailpipe mounted PMS to a model of the expected PMS
response to a threshold leak DPF. If the sensor response exceeds the model response, the DPF is interpreted as
leaking more than the threshold and an error flag is set. The PMS response is a time required to a threshold
current, 12 microamps. The modeled sensor response provides the estimated time the PM sensor should reach
the threshold current as a function of the vehicle operating condition. The leakage rate of the DPF is indicated with
a metric derived from how close to the 12 microamp threshold the observed sensor current got at the point in time
the sensor model indicates the current threshold should have been reached for a sensor measuring an emission
threshold DPF.

Particle Deposition
Regen

Regen
Current threshold

Accumulation Time

The results of the DPF monitor are reported as a ratio of the PMS sensor current observed at the time of monitor
completion and the maximum sensor current possible for either an OK or failed DPF. The result is calculated as
𝑃𝑀𝑆𝐶𝑢𝑟𝑟𝑒𝑛𝑡
𝐷𝑃𝐹𝐿𝑒𝑎𝑘𝑅𝑎𝑡𝑒 = 2 − for an OK DPF, yielding a leak rate between 1 and 2. For a failed DPF, the
𝑀𝑎𝑥𝑂𝐾𝐷𝑃𝐹𝐶𝑢𝑟𝑟𝑒𝑛𝑡
𝑃𝑀𝑆𝐶𝑢𝑟𝑟𝑒𝑛𝑡−𝑀𝑎𝑥𝑃𝑀𝑆𝐶𝑢𝑟𝑟𝑒𝑛𝑡
leak rate is calculated as 𝐷𝑃𝐹𝐿𝑒𝑎𝑘𝑅𝑎𝑡𝑒 = yielding a value between 0 and 1. The
𝑀𝑎𝑥𝑂𝐾𝐷𝑃𝐹𝐶𝑢𝑟𝑟𝑒𝑛𝑡−𝑀𝑎𝑥𝑃𝑀𝑆𝐶𝑢𝑟𝑟𝑒𝑛𝑡
overall DPF leakage assessment is provided only after two or more results of the preceeding calculations has
completed and been averaged. An assessment of DPF leak is provided after the required number of sensor
measurements has been taken. The measurements may span one or more drive cycles.

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DPF Efficiency Check:
DTCs P2002 Particulate Filter Efficiency Below Threshold (Bank 1)
Monitor Execution Continuous while PMS can measure
Monitor Sequence None
Sensors OK PMS, EGT, ECT, MAF, NOx, IAT
Typical Monitoring Duration 10 minutes

DPF Efficiency Check Entry Conditions:

Entry condition Minimum Maximum
Dewpoint reached at PMS
Not currently in DPF regeneration or
catalyst heating mode
Time since DPF regeneration 600 sec
PMS temperature 400 degC
Estimated soot load on DPF 0g 300 g
Exhaust velocity 0 m/s 50 m/s
Exhaust pressure 74.5 kPa 135 kPa
EGT 65 degC 400 degC
Engine run time 300 sec
Tailpipe NOx 200 ppm
Ambient temperature -10 C 60 C
Barometric pressure 74.5 kPa
Battery voltage 11V 16V

DPF Efficiency Check Malfunction Thresholds:

Once a modeled amount of soot has been generated by the engine, if the current of the PMS > 12 uA,
measurement is failed.
Four measurements must be failed for a DTC to set.

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 EXHAUST GAS RECIRCULATION (EGR) SYSTEM MONITOR

EGR Rate System Monitor

The EGR system is a closed loop control system that controls percent of EGR in the cylinder using the EGR valve
and Throttle. The percent of EGR is calculated using two different methods and the difference between these two
calculations is used to determine if the system is operating corrected. First, the expected amount of EGR in the
cylinder is calculated using a model that is based on the commanded EGR and Throttle position. Second, the EGR
in the cylinder is measured by subtracting the mass air sensor (MAF) reading from a speed-density model of the air
charge into the cylinder. The speed-density model accounts for both fresh air and EGR and is based on the
volumetric efficiency of the engine. High or excessive EGR flow is detected when the measured amount of EGR is
greater than the expected amount of EGR. On the 6.7L engine, low or insufficient EGR flow is detected when the
measured amount of EGR is less than the expected amount of EGR. On the 3.2L engine, low or insufficient EGR
flow is detected when excessive use of the intake throttle is required to meet air path setpoints. On all engines, a
slow EGR system is detected using the excessive EGR flow system monitor.

The monitor compares the two calculations, when a set of entry conditions are met, and determines if the system is
operating correctly. The entry conditions are selected to ensure robust fault/non-fault detection. A summary of the
entry conditions is shown in the tables below. The fault must be detected for a minimum amount of time before being
reported. A timer counts up when the entry conditions are met and the fault is present. The timer counts down
when the entry conditions are met, the fault is not present, and the current count is greater than 0. When this timer
exceeds the time required detect a malfunction, the malfunction is reported.

EGR Flow Check Operation:

DTCs P0401 – Insufficient EGR Flow
P0402 – Excessive EGR Flow
Monitor Execution Continuous
Monitor Sequence None
Monitoring Duration High Flow 4 seconds required to detect a malfunction
Monitoring Duration Low Flow 8 seconds required to detect a malfunction

Typical EGR Flow Check Entry Conditions (High Flow Detection):

Entry Condition Minimum Maximum
Engine Torque Monitor is released in a speed/load region
as shown in the following figure.
Engine RPM
Engine Coolant Temperature 70 deg C 120 deg C
Engine Operating Mode Normal (no post
injection)
EGR Valve Position 0% 25%
Desired EGR Ratio -50% 25%
Intake Air Temperature 0 deg C 70 deg C
Ambient Pressure 74.5 kPa 110 kPa
EGR System in Closed Loop Control for >1.5 sec

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 1400

1200

1000

Release Region

Torque (Nm)
800 for Excessive EGR
Flow Monitoring

600

400

200

0
0 500 1000 1500 2000 2500 3000 3500 4000
Engine Speed (rpm)

Excessive EGR flow monitoring release area for 6.7L engine. 3.2L release region is similar but absolute torque
levels are lower.

Typical EGR High Flow Rate Malfunction Thresholds:

Expected EGR Ratio – Measured EGR Ratio < -15 (function of engine speed / torque)

Typical EGR Flow Check Entry Conditions (Low Flow Detection) (6.7L engine):
Entry Condition Minimum Maximum
Engine Torque Monitor is released in a speed/load region
as shown in the following figure.
Engine RPM
Engine Coolant Temperature 70 deg C 120 deg C
EGR Valve Position 40% 60%
Desired EGR Ratio 0% 100%
Intake Air Temperature 0 deg C 70 deg C
Ambient Pressure 74.5 kPa 110 kPa
EGR System in Closed Loop Control for > 1.5 sec

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 1400

1200

1000
Torque (Nm)

800

600

400

Release Region for

200 Insufficient EGR
Flow Monitoring

0
0 500 1000 1500 2000 2500 3000 3500 4000
Engine Speed (rpm)

Insufficient EGR flow monitoring release area for 6.7L engine. 3.2L release region is similar but
absolute torque levels are lower.

Typical EGR Low Flow Rate Malfunction Thresholds:

Expected EGR Ratio – Measured EGR Ratio > 10 (function of engine speed / torque)

Typical EGR Flow Check Entry Conditions (Low Flow Detection) (3.2L engine):
Entry Condition Minimum Maximum
Engine RPM 1000 2700
Rate of change of engine RPM -20 rpm/sec 150 rpm/sec
Engine torque 100 Nm 400 Nm
Rate of change of engine torque -5 Nm/sec 15 Nm/sec
MAF 0 kg/hr 500 kg/hr
Rate of change of MAF -10 (kg/hr)/sec 100 (kg/hr)/sec
Engine coolant temperature 65 deg C
Engine operating mode Normal (not in
particulate filter
regeneration)
Ratio of Exhaust Pressure to Intake Manifold Pressure 1.1
EGR System in Closed Loop Control for > 0.5 sec

Typical EGR Low Flow Rate Malfunction Thresholds (3.2L engine):

Average intake throttle actuator position > 44%

FORD MOTOR COMPANY REVISION DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 88 OF 241

EGR Cooler / EGR Cooler Bypass Monitor

The functionality of the EGR cooler system, including the bypass valve and temperature sensor, is monitored by
means of comparing measured EGR gas temperature downstream of the EGR cooler assembly with measured
coolant temperature in the main coolant loop when certain engine operating conditions exist. The operating
conditions in which this detection can occur are the monitor entry conditions. Following changes in engine operating
conditions, there is a delay before the changes are reflected in the EGR system temperatures. Because of this
delay the entry conditions include a number of timers which must complete before the monitor is released. When
a condition feeding a timer is no longer met, the timer resets. EGR undercooling is detected using this EGR cooler
monitor.

Monitor Entry Condition Timer Locations

Bypass Valve in Position

Bypass
Position
Closed Loop EGR Control Timer

Coolant Temperature in
Required Range

Monitor Entry
Engine Speed in
Required Range & & State
Combined
Engine Torque in Release
Required Range Timer

Exhaust Temperature in
Required Range
Exhaust
Temperature
Timer
EGR Flow in Required
Range
EGR Flow
Timer

Engine in Normal
Operating Mode
Engine Mode
Timer

The undercooling monitor can detect when EGR is not being cooled sufficiently, for example, when the EGR cooler
bypass is stuck in the bypass position. The entry conditions for EGR undercooling monitoring must be met for
monitoring to take place. Once the entry conditions are met and while they continue to be met, the measured EGR
temperature downstream of the EGR cooler assembly is compared to a threshold which is determined based on
measured coolant temperature. A typical value for this threshold is 70 deg C above engine coolant temperature.
If the measured EGR temperature downstream of the EGR cooler assembly is greater than the threshold, for a
predetermined amount of time, a fault is detected.

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EGR Cooler (Undercooling) Monitor:

DTCs P2457 – EGR Cooler Performance

Monitor execution Once per driving cycle , once entry conditions are met
Monitor Sequence None
Monitoring Duration 12 seconds to detected a malfunction

EGR Cooler/ECB Entry Conditions (Undercooling):

Entry Condition Minimum Maximum
EGR Cooler Bypass Valve Command Cooling Position
EGR System in Closed-Loop Control
Engine Coolant Temperature 70 deg C 130 deg C
Engine Speed 1100 rpm 3500 rpm
Engine Torque 200 Nm 1400 Nm
Exhaust Temperature 0 deg C 800 deg C
EGR Flow 0 g/s 42 g/s
Ratio of exhaust pressure to MAP 0 5
Engine Operating Mode Normal

EGR Cooler/ECB Entry Timers (Undercooling):

Timer Minimum Time
Bypass Position Timer 5 sec
Combined Release Timer 1 sec
Exhaust Temperature Timer 5 sec
EGR Flow Timer 5 sec
Engine Mode Timer 100 sec

Typical Undercooling Malfunction Thresholds:

Measured EGR temperature downstream of the EGR cooler assembly > Coolant Temperature + 70

FORD MOTOR COMPANY REVISION DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 90 OF 241

For overcooling, the 6.7L EGR cooling system is monitored by intrusively moving the bypass door from the cooling
position to the bypass position and looking at the response of the temperature out of the EGR cooler. The gradient
(slope) of the temperature is compared to a threshold, if the gradient is less than the threshold for the entire
monitoring duration, a fault is detected. In contrast, on a non-fault system, once the gradient exceeds the
threshold, the monitor pass is latched. Once the monitor pass is latched, the bypass door returns to the cooling
position to protect the engine hardware from overheating. The bypass door returns to the cooling position before
the monitor is complete but the monitor continues to be released as long as the entry conditions are met. The
monitor only completes once the monitor is released for the full monitoring duration, consecutively.

Monitoring is done during somewhat steady state operation at medium to high speed-load conditions with sufficient
EGR flow. Entry are selected so the monitor is released to run when the conditions are correct. The entry
conditions required to release the monitor are listed EGR Cooler (Intrusive) Entry Conditions table below. The
bypass door must be in the cooling position for a minimum calibrated time for the monitor to be released. The rest
of the entry conditions must be met for a different minimum calibrated time before the monitor is released.

To protect the hardware, the monitor is not allowed to re-release immediately if the release is lost because one of
more of the entry condition are no longer met.

The 3.2L uses a different overcooling monitor. The entry conditions for EGR overcooling monitoring must be met
for monitoring to take place. Once the entry conditions are met and while they continue to be met, the measured
EGR temperature downstream of the EGR cooler assembly is compared to a threshold which is determined based
on measured coolant temperature. A typical value for this threshold is 16 deg C below engine coolant temperature.
If the measured EGR temperature downstream of the EGR cooler assembly is less than the threshold, for a
predetermined amount of time, a fault is detected.

EGR Cooler (Intrusive) Monitor (6.7L):

DTCs P245A – Exhaust Gas Recirculation (EGR) Cooler Bypass Control Circuit (bank 1)
P245B – EGR Cooler Bypass Control Circuit Range/Performance (3.0L and 1.5L
Only)
Monitor execution Once per driving cycle, once entry conditions are met
Monitor Sequence None
Monitoring Duration P245A: 3 sec to detect a malfunction

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EGR Cooler (Intrusive) Entry Conditions:
Entry Condition Minimum Maximum
EGR Cooler Bypass Valve Command (only evaluated during Cooling Position
monitor pre-release)
EGR System in Closed-Loop Control
Engine Coolant Temperature 70 deg C 140 deg C
Engine Speed 575 rpm 900 rpm
Filtered Absolute Value of the Gradient of Engine Speed 150 rpm/s
Engine Torque 70 Nm 300 Nm
Filtered Absolute Value of the Gradient of Engine Torque 150 Nm/s
Exhaust Temperature 300 deg C 700 deg C
Filtered Absolute Value of the Gradient of Exhaust Temperature 8 deg C / s
Fuel Injection Quantity 0.1 g/rev 0.4 g/rev
Filtered Absolute Value of the Gradient of Fuel Injection Quantity 0.05 g/rev/s
EGR Flow 22 g/s 112 g/s
Filtered Absolute Value of the Gradient of EGR Flow 22 g/s/s
Modeled Intake Manifold Temperature 140 deg C

Engine Operating Mode Normal

Typical Malfunction Thresholds:

P245A: Measured Gradient of EGR Downstream Temperature < 3 deg C / s

EGR Cooler (Non-Intrusive) Monitor (3.2L):

DTCs P24A5 – Exhaust Gas Recirculation Cooler Bypass Control Stuck (Bank 1)
Monitor execution Once per driving cycle, once entry conditions are met
Monitor Sequence None
Monitoring Duration P24A5: 12 sec to detect a malfunction

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 EGR Cooler (Non-Intrusive) Entry Conditions:
Entry Condition Minimum Maximum
EGR Cooler Bypass Valve Command (only evaluated during Cooling Position
monitor pre-release)
EGR System in Closed-Loop Control
Engine Coolant Temperature 70 deg C 110 deg C
Engine Speed 575 rpm 1000 rpm
Engine Torque 40 Nm 200 Nm
Exhaust Manifold Temperature 165 deg C 650 deg C
Engine Operating Mode Normal (no post
injection)
Time in normal engine operating mode 100 sec
Time with EGR bypass valve in cooling position 15 sec
EGR Flow 5 g/s 28 g/s
Ratio of exhaust pressure to MAP 1 2.2

Typical Malfunction Thresholds:

P24A5: Measured EGR temperature downstream of the EGR cooler assembly < Coolant temperature +16C

EGR System Slow Response

Slow responding EGR systems are detected through the EGR rate system monitor.

EGR Control Limits Monitor

The control limit monitor functions continuously during normal (non-regen) closed-loop operation. The control limits
monitor compares the desired percent of EGR with the measured percent of EGR. If the error between these is
greater than the threshold for the required duration of time, a fault is set. Specifically, a timer counts up when the
entry conditions are met and the fault is present. The timer counts down when the entry conditions are met, the fault
is not present, and the current count is greater than 0. When this timer exceeds the time required detect a
malfunction, the malfunction is reported.
This monitor is only present on the 6.7L diesel engine.
EGR Closed-loop Control Limits Check Operation:
DTCs P04DA (Closed Loop EGR Control At Limit - Flow Too High)
P04D9 (Closed Loop EGR Control At Limit - Flow Too Low)
Monitor Execution Continuous
Monitor Sequence None
Monitoring Duration 20 seconds to detect a malfunction

Typical EGR Closed-loop Control Limits Check Entry Conditions:

No Air System Faults
EGR system in closed loop EGR control

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 Typical EGR Control Limits Malfunction Thresholds:
Desired EGR Ratio – Measured EGR Ratio < -60 (function of Engine Speed / Torque)
or
Desired EGR Ratio – Measured EGR Ratio > 45 (function of Engine Speed / Torque)

Mass Airflow Closed-loop Control Limits Monitor

During DPF regeneration the engine control system controls the mass of fresh air into the cylinder using the EGR
valve and throttle valve. In this operating mode, the desired mass of fresh air in the cylinder is compared to the
actual mass of air entering the cylinder. If the error is greater than the threshold for the required duration, a fault is
set. The monitor is released when the system is in closed loop control. Specifically, a timer counts up when the
entry conditions are met and the fault is present. The timer counts down when the entry conditions are met, the fault
is not present, and the current count is greater than 0. When this timer exceeds the time required detect a
malfunction, the malfunction is reported.

Mass Airflow Closed-loop Control Limits Check Operation:

DTCs P02EC - Diesel Intake Air Flow Control System - High Air Flow Detected
P02ED - Diesel Intake Air Flow Control System - Low Air Flow Detected
Monitor Execution Continuous
Monitor Sequence None
Monitoring Duration 20 seconds required to detect a malfunction

Typical Mass Air Flow Closed-loop Control Limits Check Entry Conditions:
No Air System Faults
EGR System in closed loop air mass control

Typical Air Mass Control Limits Malfunction Thresholds:

Desired Air Mass – Measure Air Mass > 400 (function of Engine Speed / Torque)
or
Desired Air Mass – Measure Air Mass < -400 (function of Engine Speed / Torque)

FORD MOTOR COMPANY REVISION DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 94 OF 241

BOOST PRESSURE CONTROL SYSTEM MONITORING

Intrusive Turbo Position and Response Monitoring

The 6.7L engine is equipped with an oil pressure actuated, variable vane turbocharger. The variable geometry turbo
(VGT) does not have a position sensor, so the position is inferred using a duty cycle to position transfer function. To
verify actual position based on the nominal transfer function, an intrusive monitor sweep is performed. When entry
conditions are met, the intrusive monitor for VGT closes the EGR valve, opens the throttle and then commands the
output PWM to open and closed position for a calibratable duration. Typical values are 85%, then 25%. The
minimum and maximum MAP values are saved and compared to a threshold. If the desired separation in MAP
pressure isn’t achieved, a fault is detected. If the desired separation in MAP is achieved, the test is considered a
pass.

In the example above, at 1871 seconds, the EGR valve is commanded closed, after 3 seconds with EGR off and
turbocharger at 85% position, the turbocharger is opened up to. 25% position. The 25% position is held for 4
seconds. If desired separation of 2kpa at sea level is achieved the test is considered a pass. If desired separation
isn’t achieved the test is completed and failed.

Note1: This monitor also serves to monitor for a slowly responding boost pressure system due to the time component
of the threshold.

Note2: On 3.2L engine, there is variable geometry turbo control and position.

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VGT Monitor:
DTCs P132B - Turbocharger/Supercharger Boost Control "A" Performance
P226C – Turbocharger Boost Control “A” Slow Response (3.0L and 1.5L Only)
Monitor Execution Once per driving cycle
Sensors OK ECT, MAP, VS, VGTP
Typical Monitoring Duration 7 seconds for full VGT monitoring cycle if pressure abort threshold hasn’t been
reached

Typical VGT Monitor Entry Conditions:

Entry Condition Minimum Maximum
Engine speed for learning 500 rpm 760 rpm
Pedal position allowed for learning 0.5 %
Engine coolant temperature for learning 70 deg C 124 deg C
Fuel quantity allowed for learning 20 mg/stoke
Vehicle speed for learning 3 mph
Time at idle 5 sec
Barometric Pressure 67 kPa 102 kPa
Time after engine start 120 seconds
Battery voltage 10V 16V
Engine operating mode Normal (no post
injection)

Typical VGT Monitor Malfunction Thresholds:

Response from 25% VGT position to 85% VGT position in 4 seconds results in a change in manifold pressure of
2 kPa or greater at sea level or 1.25 kPa at 8000 feet.

FORD MOTOR COMPANY REVISION DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 96 OF 241

Overboost Monitoring

The 6.7L engine utilizes a closed loop boost pressure controller to maintain desired boost pressure set point under
all temperature ranges and engine operating modes. The overboost monitor compares the desired vs. actual
measured boost pressure while in a specific range of closed loop boost pressure operation. If the boost pressure
governor deviation is greater than the calibrated threshold for 7 seconds, a fault is detected and the P-code is set.
The closed loop monitoring window is defined as any inner torque above 50 nm, and any engine speed above 1000
rpm. Torque window and threshold slightly different for dyno cert due to different turbocharger configuration,
calibration, and air path response.

This diagnostic will detect a turbo slowly responding or stuck in the primarily closed condition.

Overboost Monitor:
DTCs P0234 - Turbocharger/Supercharger "A" Overboost Condition
Monitor Execution Continuous
Monitor Sequence None
Sensors OK ECT, MAP, MAF,
Typical Monitoring Duration 7 seconds

Typical Overboost Monitor Entry Conditions:

Entry condition Minimum Maximum
Engine Torque 50 Nm
Engine Speed 1000 4000

Typical Overboost Monitor Malfunction Thresholds:

If desired boost pressure – actual boost pressure < -15.0 kPa

FORD MOTOR COMPANY REVISION DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 97 OF 241

Threshold Overboost Monitoring

For the pickup applications, use of the engine brake function can result in conditions where a momentary slow
response of the turbocharger vanes to movement can result in a transient high pressure condition that can be
erroneously detected as overboost by the pressure based monitor. Instead, a monitor of exhaust pressure above a
maximum threshold is used as the threshold overboost monitor.

Threshold Overboost Monitor:

DTCs P259F - Turbocharger "A" Boost Control Position At High Limit
Monitor Execution Continuous
Monitor Sequence None
Sensors OK ECT, MAP, MAF
Typical Monitoring Duration 2 sec

Typical Threshold Overboost Entry Conditions:

Entry condition Minimum Maximum
Key-on
Battery voltage (IVPWR) 9V 16.25 V

Typical Threshold Overboost Monitor Malfunction Thresholds:

If exhaust pressure > 5.5 bar

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Underboost Monitoring

The underboost monitor works in a similar fashion to the overboost monitor by comparing the desired vs. actual
measured boost pressure while in a specific range of closed loop boost pressure operation. If the boost pressure
governor deviation is greater than the calibrated threshold for 7 seconds, a fault is detected and the P-code is set.
The closed loop monitoring window is defined as any inner torque above 50 nm, and any engine speed above 1500
rpm. The threshold limit is wider for the underbooost monitor due to transient boost system response, compensation
for boost pressure lag, and short term (1-2 second) momentary torque truncation when air path torque is kept high,
but fueling is limited for component protection.

This diagnostic will detect a gross air path leak such as the turbo discharge or CAC discharge tube being blown off,
major pre-turbo exhaust leaks, or a turbo slowly responding or stuck in the open VGT position.

Underboost Monitor:
DTCs P1247 - Turbocharger Boost Pressure Low
P0299 – Turbocharger/Supercharger “A” Underboost Condition
P259E – Turbocharger "A" Boost Control Position At Low Limit
Monitor Execution Continuous
Monitor Sequence None
Sensors OK ECT, MAP, MAF, VGTP
Typical Monitoring Duration 7 sec

Typical Underboost Monitor Entry Conditions:

Entry condition Minimum Maximum
Closed-loop boost control enabled
P1247:
Engine Torque 50 Nm
Engine Speed 1000 rpm 4000 rpm
P259E:
Engine Torque 50 Nm
Engine Speed 1000 rpm 4000rpm
P0299:
Entry condition Minimum Maximum
Engine Torque 200 Nm 700 Nm
Engine coolant temperature -7 deg C
Ambient air temperature -7 deg C
Barometric Pressure 75 kPa 110 kPa
MAP steady state pressure 100 kPa
TOxiCatUs Temperature 99 deg C
Mass Air Flow 1300 kg/h
Not in Cold Start Warm-up Mode
Regeneration Status None

FORD MOTOR COMPANY REVISION DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 99 OF 241

Typical Underboost Monitor Malfunction Thresholds:
P1247: If desired boost pressure – actual boost pressure > 15 kPa
P0299: If control effort percent > threshold (see map below) for 4 seconds and exhaust lambda <1.33
P259E: If desired VGT position – actual VGT position < -25%

Typical Threshold Underboost monitor (P0299) Threshold Map

RPM/TRQ 600 750 1000 1200 1600 2000 2250 2500 2750 3000 3250 3500
0
50 50 50 50 50 50 50 50 50 50 50 50
100
50 50 50 50 50 50 50 50 50 50 50 50
150
50 50 50 50 50 50 50 50 50 50 50 50
200
50 50 20 12 12 12 12 12 12 25.5 25.5 25.5
250
50 50 20 12 12 12 12 12 12 27.5 27.5 25.5
300
50 50 20 12 12 12 12 12 12 27.5 27.5 25.5
350
50 50 20 12 12 12 12 12 12 27.5 27.5 25.5
400
50 50 20 12 12 12 12 15 15 25.5 25.5 25.5
450
50 50 20 12 12 12 12 15 16 25.5 25.5 25.5
500
50 50 20 12 12 12 12 18.5 18.5 25.5 25.5 25.5
600
50 50 20 12 12 12 12 18.5 22.5 25.5 25.5 25.5
700
50 50 20 12 12 12 12 18.5 22.5 25.5 25.5 25.5

FORD MOTOR COMPANY REVISION DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 100 OF 241
Charge Air Cooler Monitoring

The 6.7L engine is equipped with an air to water charge air intercooler. The CAC is on a secondary coolant loop,
independent from the main engine coolant system. The temperature at the outlet of the cooler is measured as
TCACDs, however the temperature going into the cooler is modeled. The 3.2L engine uses an air to air charge air
intercooler and no secondary coolant loop, but is otherwise similar.

To detect a CAC under cooling situation, the efficiency of the cooler is modeled at various speeds and airflows via a
3d speed/airflow multiplier table, providing a modeled cooler out temperature. Cooler efficiency * compressor out
temperature = modeled cooler out temp. This modeled cooler out temp is then compared to the measured coolant
out temp, if the difference is less than a threshold curve or greater than a threshold, a fault is detected and a p-code
is set.

Charge Air Cooler Monitor:

DTCs P026A - Charge Air Cooler Efficiency Below Threshold
P007E - Charge Air Cooler Temperature Sensor Intermittent/Erratic (Bank 1)
Monitor Execution Continuous
Monitor Sequence None
Sensors OK ECT, MAP, MAF
Typical Monitoring Duration 4 seconds for fault detection

Typical Charge Air Cooler Monitor Entry Conditions:

Entry condition Minimum Maximum
Engine speed 1100 rpm 3350 rpm
Engine coolant temperature 70 deg C
Ambient air temperature -7 deg C
Barometric Pressure 74.5 kPa 110 kPa
Ratio of Manifold Absolute Pressure to Barometric Pressure 1.2
Intake air temperature -7 deg C
Injection quantity 20mg/stk 85mg/stk

Typical Charge Air Cooler Monitor Malfunction Thresholds:

P026A - If the difference of measured temperature and modeled temperature is less than -15 deg C at 0 deg C
compressor out temp, or less than -10 deg C at 250 deg C compressor out temp, a fault is set.
P007E – If the difference of measured temperature and modeled temperature is greater than 35 deg C a fault is
set.

FORD MOTOR COMPANY REVISION DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 101 OF 241
 PARTICULATE MATTER (PM) FILTER MONITORING

DPF Filter Missing Substrate Monitor

The DPF is monitored to ensure that the filter has not been removed. The DPF Missing Substrate monitor compares
the measured pressure upstream of the DPF to a threshold (function of volumetric exhaust flow). A debounce
counter will increment when the pressure is below the threshold and decrement if the pressure is above the threshold
(clipped to a minimum of 0). When the debounce counter exceeds a threshold, a fault is indicated. This monitor is
only utilized for applications that utilize a pressure sensor. (All applications with a PM sensor will utilize the P2002
monitor to meet this requirement.)

Monitor Summary:
DTCs P244A – Diesel Particulate Filter Differential Pressure Too Low
Monitor execution P244A: Continuous while meeting entry conditions
Monitor Sequence None
Sensors OK EGT, DPFP, CKP, ECT (P0117, P0118), EGT13 EGT14, MAF, IAT
Monitoring Duration 90 sec

Typical Entry Conditions:

Entry condition Minimum Maximum
Exhaust volumetric flow 300 m3/hour 2400 m3/hour
Time after regeneration ended 30 sec
Intake air temperature -20 deg C
Engine coolant temperature -20 deg C
Torque 50 Nm
EGT1 temperature 150 deg C

Typical Malfunction Thresholds:

DPF Differential Pressure Test: (P244A)
Measured DPF inlet pressure is below a threshold (function of engine exhaust volumetric flow) for 90 seconds.
Typical values for threshold:

Flow (m^3/hr) 300 600 900 1200 1500 1800 2100 2500
Pressure (kPa) 7.99 15.02 27.94 47.13 72.80 104.94 143.45 204.61

FORD MOTOR COMPANY REVISION DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 102 OF 241
DPF Frequent Regeneration Monitor

The DPF Frequent Regeneration monitor calculates the distance between aftertreatment regeneration events. The
distance between successive regeneration events is calculated and the average distance is calculated for the two
most recent regeneration events. If the distance between regen events is below a threshold, a fault is indicated.

Monitor Summary:
DTC P2459 – Diesel Particulate Filter Regeneration Frequency
Monitor execution During each completed regeneration event
Monitor Sequence None
Sensors OK DPFP

Typical Entry Conditions:

Entry condition Minimum Maximum
Regeneration runs to completion (not aborted by customer input or drive cycle)
Not in “degraded regen” mode due to DPF pressure sensor error

Typical Malfunction Thresholds:

A fault is stored when the average distance between regeneration events is below a threshold. Typical
threshold is 42 km.

FORD MOTOR COMPANY REVISION DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 103 OF 241
DPF Incomplete Regeneration Monitor

The DPF Incomplete Regeneration monitor is used to detect an event where the DPF is not fully regenerated. If a
regeneration event is aborted due to duration and the restriction of the DPF is still above a threshold, a fault is
indicated. Upon the first occurrence of an incomplete regen, the system is put into a “degraded” regen
mode. Another regen will be forced in approximately 150 miles unless a normal regen is triggered by the soot load
first.

Monitor Summary:
DTC P24A2 – Diesel Particulate Filter Regeneration Incomplete
Monitor execution During each DPF regeneration cycle
Monitor Sequence None
Sensors OK EGT11, EGT12,EGT13, EGT14, DPFP, INJ
Monitoring Duration 30 minutes (maximum)

Typical Entry Conditions:

Entry condition Minimum Maximum
Monitor is activated during Aftertreatment regeneration events
Ambient air temperature -6.7 degC
Ambient pressure 74.5 kPa
Engine speed 1000 rpm 3500 rpm
Engine Indicated Torque 150 N-m 1500 N-m
Engine Coolant Temperature 70 degC
Minimum time with valid entry conditions (function of regen duration)
Time since last closed-loop soot update at beginning of 1200 sec
regeneration
Time since last closed-loop soot update at end of regeneration 300 sec

Typical Malfunction Thresholds:

If the restriction is above a threshold, a fault is indicated.

FORD MOTOR COMPANY REVISION DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 104 OF 241
DPF Feedback Control Monitors

The system is monitored to ensure that closed loop control of the regeneration event is initiated within a reasonable
period of time. The monitor runs during a regeneration event and compares the time in closed loop control to the
total time in regen. If the time in closed loop control is less than a threshold (a function of total time in regen), then a
fault is indicated.

If the closed loop controller is saturated at its limits and the temperature is not within the desired limit, a timer will
increment. If control is regained, the timer will decrement. At the end of the regeneration event, if this timer exceeds
a threshold (a function of total time in regen), a fault is indicated

Note: Ford Motor Company 2011+ 6.7L diesel programs are using in-cylinder post injection to achieve regeneration,
not external exhaust injection. The Post injection is monitored during this feedback monitor; there is no additional
monitor for "active / intrusive injection". 3.2L diesel programs use a downstream fuel injector which is monitored
separately.

Monitor Summary:
DTC P24A0 – DPF Temperature Control
P249F – Excessive Time To Enter Closed Loop DPF
Regeneration Control
Monitor execution During an active regeneration event
Monitor Sequence None
Sensors OK TIA, ECT, AMP, EGT11, EGT12, EGT13, EGT14
Monitoring Duration Once per regeneration event

Typical Entry Conditions:

Entry condition Minimum Maximum
Engine Operating Mode Particulate filter regeneration
Engine Speed 1200 rpm 3500 rpm
Indicated Torque Setpoint 200 Nm 1500 Nm
Ambient Temperature -6.7 deg C
Coolant Temperature 70 deg C
Barometric Pressure 74.5 kPa
Absolute value of transient torque 2047 Nm
difference
First EGT sensor temperature 525 deg C
HC desorb mode Not occurring

Typical Malfunction Thresholds:

P249F - If the time in closed loop operation is less than a threshold (function of total time in regen), a fault is
indicated.

P24A0 - If the difference between desired and actual temperature is greater than a threshold for a sufficient
period of time, a fault is indicated.

FORD MOTOR COMPANY REVISION DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 105 OF 241
DPF Restriction Monitor

The DPF is monitored for conditions where it may be overloaded. The monitor compares the calculated restriction
of the DPF to a threshold. If the threshold is exceeded for a sufficient period of time, a wrench light and a MIL will
be illuminated and engine output will be limited and EGR is disabled.

Monitor Summary:
DTCs P246C - Diesel Particulate Filter Restriction – Forced Limited Power
Monitor execution Continuous while meeting entry conditions
Monitor Sequence None
Sensors OK DPFP
Monitoring Duration 300 seconds

Typical Entry Conditions:

Entry condition Minimum Maximum
None

Typical Malfunction Thresholds:

Diesel Particulate Filter Restriction – Forced Limited Power (P246C) (Immediate MIL and Wrench Light)
Calculated normalized restriction is 2.0 times the normal value for soot load.

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 ENGINE COOLING SYSTEM MONITORING

Thermostat Monitor

The Thermostat Monitor checks that the thermostat is operating properly by modeling Engine Coolant Temperature
(ECT) based on engine fueling, engine speed, vehicle speed, and the ambient temperature. There are increment
and decrement portions to the model; the increment is based on engine speed and fuel quantity, while the decrement
is derived from calculated radiator efficiency based on coolant delta temp to ambient and vehicle speed. The model
is delayed by 60 seconds after engine start to negate potential errors due to block heater use. It is also suspended
while in catalyst warm-up mode due to errors in fuel quantity heat being contributed to the coolant.

Once that estimation reaches the thermostat start-to-open temperature, if the actual measured ECT has not reached
a minimum warm-up temperature and the driver has not spent too much time in part fuel cut off (over 30%), too low
load (over 70%), too high vehicle speed (over 70%), or too low vehicle speed (over 70%) - then the thermostat is
determined to be stuck open.

When ECT drops below 70 degrees C, the thermostat model and monitor are re-initialized.

Thermostat Monitor:
DTCs P0128 –Coolant Temp Below Thermostat Regulating Temperature
Monitor Execution Continuous
Monitor Sequence None
Sensors OK Engine Coolant Temperature (ECT), Intake Air Temperature (IAT), Vehicle
Speed (VS)
Typical Monitoring Duration Nominal time it takes for engine to warm up to thermostat "Start-To–Open"
temperature – see approximate times below. (Note: Unified Drive Cycle is 23.9
minutes long)
Ambient Temperature Drive Cycle Completion Time
-7 deg C Unified Drive Cycle x2 40 min
21 deg C Unified Drive Cycle 19 min
38 deg C Unified Drive Cycle 14 min

Typical Thermostat Monitor Entry Conditions:

Entry condition Minimum Maximum
Modeled engine coolant temperature 90 deg C
Engine coolant temperature at start -7 deg C 54 deg C
Intake air temperature at start -7 deg C
Ratio of time that the vehicle speed is above 85 km/hr, to the total monitoring time 70%
Ratio of time that the engine fueling is above 20 mg/str to the total monitoring time 35%
Ratio of time that the engine torque is below 60 n/m to the total monitoring time 70%
Ratio of time that the vehicle speed is below 45 km/hr to the total monitoring time 70%

Typical Thermostat Monitor Malfunction Thresholds:

Measured Engine Coolant Temperature < 70.2 deg C when modeled coolant temp > 90 deg C

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Primary Coolant Temp Rise Monitoring

To ensure the primary ECT sensor has not stuck below normal operating range, a simple rise check to verify a
minimum rise in coolant temperature over a calibratable time has been implemented. If coolant temperature at start
is greater than -35 deg C and less than 54 deg C, the monitor is enabled. At -35 deg C, the coolant is expected to
rise up to -7 deg C in 291 seconds or less. If -7 deg C coolant temp. is not achieved in the required 291 second
timeframe, a fault is detected. At a -7 deg C start temp, the coolant is expected to rise to 40 deg C in 5450 seconds-
assuming worst case with EGR off, vehicle idling in neutral with heater on. Again, if the minimum temperature is not
achieved in the required time, a fault is detected. This diagnostic is used in conjunction with the oil vs. coolant
plausibility check, thermostat model, and SRC checks to verify proper ECT operation and engine warm-up.

ECT Rise Monitor:

DTCs P0116 - Engine Coolant Temperature Sensor 1 Circuit Range/Performance
Monitor Execution Once per trip
Monitor Sequence None
Sensors OK ECT
Typical Monitoring Duration 291 seconds at -35 deg C start temp. idle only
5150 seconds at -7 deg C start temp, idle only

Typical ECT Rise Monitor Entry Conditions:

Entry condition Minimum Maximum
Engine coolant temperature -35 deg C 54 deg C
Engine speed 400 rpm
Fuel injection quantity 0 mg/stroke

Typical ECT Rise Monitor Malfunction Thresholds:

291 seconds at -35 deg C start temp to rise to -7 deg C
5150 seconds at -7 deg C start temp to rise to 40 deg C

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Secondary Coolant Temp Rise Monitoring

The 6.7L engine has a secondary coolant loop with two thermostats, a 20C thermostat for the charge air cooler and
fuel cooler, and a 45C thermostat for the EGR cooler and trans cooler. System schematic below:

The rise check to detect a stuck ECT2 sensor is identical in function to the rise check used for the primary coolant
loop. A minimum rise is expected over a calibratable amount of time,

ECT2 Rise Monitor:

DTCs P2183 - Engine Coolant Temperature Sensor 2 Circuit Range/Performance
Monitor Execution Once per trip
Monitor Sequence None
Sensors OK ECT2,
Typical Monitoring Duration 5750 sec at -35C, 200 at 25C

Typical ECT2 Rise Monitor Entry Conditions:

Entry condition Minimum Maximum
ECT2 -35 deg C 45 deg C
Torque 0 Nm 2000 Nm
Engine Speed 400 rpm

Typical ECT2 Rise Monitor Malfunction Thresholds:

within the time duration, must reach 25C

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 COLD START EMISSION REDUCTION STRATEGY MONITORING

Cold Start Emission Reduction Component Monitor

For all 2010 and subsequent model year vehicles that incorporate a specific engine control strategy to reduce cold
start emissions, the OBD ll system must monitor the components to ensure proper functioning. The monitor works
by validating the operation of the components required to achieve the cold start emission reduction strategy, namely
intake throttle and fuel balancing control. The 3.2L diesel does not use a cold start emission reduction strategy.

Cold Throttle Valve Actuator Jammed Detection

Duplicate fault storage of throttle valve jammed detection exists, which can only set/clear in EOM3.

Cold Throttle Actuator Jammed Valve Check Operation:

DTCs P02E1 – Diesel Intake Air Flow Control Performance,
Monitor execution Continuous
Monitor Sequence None
Monitoring Duration 5 seconds to register a malfunction

Typical Cold Throttle Jammed Valve Entry Conditions:

See Throttle Valve Actuator Jammed Detection
Engine Operating mode is EOM3

Typical Cold Throttle Jammed Valve Check (P02E1) Malfunction Thresholds:

A P02E1 is set in EOM3.

Cold EGR Valve Actuator Jammed Detection

Duplicate fault storage of EGR valve jammed detection exists, which can only set/clear in EOM3.

EGR Valve Jammed Check Operation:

DTCs P042E – Exhaust Gas Recirculation "A" Control Stuck Open
Monitor execution Continuous
Monitor Sequence None
Monitoring Duration 5 seconds to register a malfunction

Typical Actuator Jammed Valve Entry Conditions:

See EGR Valve Actuator Jammed Detection
Engine Operating mode is EOM3

Typical EGR Valve Jammed Check (P042E) Malfunction Thresholds:

A P042E is set in EOM3.

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Cold FBC (Only 6.7L Applications)

Fuel Balancing Control is an algorithm designed to reduce differences in injected fuel quantity from cylinder to
cylinder. The increase in crankshaft speed due to individual cylinder combustion events is measured. The amount
of fuel injected to each cylinder is then adjusted up or down to minimize the difference in increase in crankshaft speed
from cylinder to cylinder. The total amount of fuel injected among all cylinders remains constant. The Cold FBC
runs exactly the same as the normal FBC monitor, only difference is that it will run during EOM3 instead of EOM0.
The concept is shown in the graphic below.

FBC operates in closed-loop control in an engine speed range of 500-3000 RPM, and a commanded injection
quantity of 3.5 – 90 mg/stroke. The maximum allowed correction in fuel quantity for an individual cylinder is given
by the following table.

CSER Component Monitor: Cold FBC Control Limits:

Injection quantity requested before FBC correction (mg/stroke)

3.5 7.5 15
Maximum allowable FBC correction 4 7 14
(mg/stroke):

When the current correction for a given cylinder exceeds 90% of the allowable correction for the current conditions,
a code is set.

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CSER Component Monitor: Cold FBC Monitor Operation:
DTCs P0263 – Cylinder #1 Contribution/Balance
P0266 – Cylinder #2 Contribution/Balance
P0269 – Cylinder #3 Contribution/Balance
P0272 – Cylinder #4 Contribution/Balance
P0275 – Cylinder #5 Contribution/Balance
P0278 – Cylinder #6 Contribution/Balance
P0281 – Cylinder #7 Contribution/Balance
P0284 – Cylinder #8 Contribution/Balance
Monitor Execution P0263 – During EOM3 after a cold start
P0266 – During EOM3 after a cold start
P0269 – During EOM3 after a cold start
P0272 – During EOM3 after a cold start
P0275 – During EOM3 after a cold start
P0278 – During EOM3 after a cold start
P0281 – During EOM3 after a cold start
P0284 – During EOM3 after a cold start
Monitor Sequence None

Sensors OK Crankshaft Position Sensor "A" Circuit (P0335)

Crankshaft Position Sensor "A" Circuit Range/Performance (P0336)
Typical Monitoring Duration 7.5 sec

Typical CSER Component Monitor: Cold FBC Monitor Entry Conditions:

Entry condition Minimum Maximum
EOM3 Active
Engine speed 500 rpm 3000 rpm
Injection quantity 3.5 mg/stroke 90 mg/stroke
Engine Temperature
Barometric Pressure
FBC wheel learn complete

Typical CSER Component Monitor: Cold FBC Monitor Malfunction Thresholds:

If the current correction for the injector exceeds 90% of the allowable correction for current operation conditions,
the code is set.

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Monitoring of High Pressure Fuel System during start

At engine start, starting problems can occur due to insufficient rail pressure. Monitor runs during engine cranking.

Monitor Summary:
DTCs P2291 - Injector Control Pressure Too Low - Engine Cranking
Monitor execution During engine cranking
Monitor Sequence None
Sensors OK
Monitoring Duration P2291- 20 Sec

Typical Entry Conditions:

Entry condition Minimum Maximum
Fuel temperature -50 Deg C 150 Deg C
Engine Coolant Downstream -50 Deg C 150 Deg C
temperature
Rail pressure 14000 kPa
Fuel tank level -1 L
Inertia Switch Not set

Typical Malfunction Thresholds:

If the rail pressure is less than 14000 kPa within the entry condition for 20 sec, fault is set.

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CRANKCASE VENTILATION MONITOR

The 6.7L (F650-F750 chassis cabs only) and 3.2L diesel engines have a crankcase ventilation separator mounted
on the driver side rocker cover, with a tube connecting the separator to the fresh air inlet of the turbocharger. The
tube on the separator side has a tamper proof collar installed and is plastic welded to the separator. On the fresh
air inlet side, a hall effect sensor is present, to detect connection to the inlet casting assembly. The tube cannot
be disconnected on the separator side, and if it is disconnected from the inlet casting, a P04DB code is set, as
sensor output drops below a calibrated threshold. There are also circuit range checks, P04E2 and P04E3 to detect
shorts to ground, or short to battery/disconnected sensor, respectively. Note: F250-F550 pickups and chassis cabs
have tamper proof collars on the connections for both sides and, as a result, do not need these monitors.

Crankcase Ventilation Monitor

DTCs P04DB – Crankcase Ventilation System Disconnected
P04E2 – Crankcase Ventilation Hose Connection Sensor Circuit Low
P04E3 – Crankcase Ventilation Hose Connection Sensor Circuit High
Monitor Execution Once per driving cycle – P04DB
Continuous – P04E2, P04E3
Monitor Sequence None
Sensors OK P04DB - CVM (P04E2, P04E3)
Typical Monitoring Duration 2 sec

Typical Crankcase Ventilation Monitor Entry Conditions:

Entry Condition Minimum Maximum
Coolant Temperature 40C 112 deg C
Battery Voltage 9V 16.25V
Key is on

Crankcase Ventilation Monitor Disconnection Check Malfunction Thresholds:

P04DB – voltage below 2500 mv for 2 seconds (all other entry conditions met, heals if voltage rises above
3000mv)

Crankcase Ventilation Monitor Circuit Check Malfunction Thresholds:

No minimum coolant, ambient temp entry conditions, continuous monitor:
P04E2 – voltage less than 1000 mv for 2 seconds
P01E3 – voltage greater than 4900 mv for 2 seconds

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 ENGINE SENSORS

Air Temperature Rationality Test

An air temperature rationality test is performed once every drive cycle, after a long soak of 6 hours or greater. At
key on, a temperature sample is taken of each of the following sensors: Ambient Air (AAT), Intake Air (IAT), Charge
Air Cooler outlet (CACT1), EGR Cooler outlet (EGT COT), and Secondary Coolant Temperature (ECT2). Once a
cold start has been confirmed, the temperature samples are compared against each other, and the temperature
differences compared against a threshold. One sensor must fail plausibility with all four other sensors to set a fault
for the sensor in question. If one or more sensors fail plausibility with three or fewer sensors, a general temperature
plausibility fault is set. If a block heater has been detected, or if any sensor has been flagged for a pending signal
range malfunction, the plausibility check is not performed. Block heater detection is only attempted when
temperature sensors show larger than expected temperature difference at start. In this case, intake air temperature
is monitored for a temperature decrease of at least 5 degrees C following 60 seconds of driving at 20 kph or greater
speed. If this temperature decrease is observed, use of a block heater is inferred.

Figure : Air Temperature Plausibility Check Flow Chart

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Ambient Air Temperature (AAT) Sensor Circuit Check:
DTCs P0072 – Ambient Air Temperature Circuit Low
P0073 – Ambient Air Temperature Sensor Circuit High
Monitor Execution Continuous
Monitor Sequence None
Sensors OK Not applicable
Typical Monitoring Duration 2 sec.

Typical Ambient Air Temperature Sensor Circuit Check Entry Conditions:

Entry Condition Minimum Maximum
Battery Voltage 9V 16.25 V
Key On

Typical Ambient Air Temperature Sensor Circuit Check Malfunction Thresholds:

Voltage < 0.10 V (-40 deg C) or voltage > 4.99 V (108 deg C)

Ambient Air Temperature Rationality Check

DTCs P0071 – Ambient Air Temperature Sensor Range/Performance
Monitor Execution Once per driving cycle. The check is disabled if a block heater is in use.
Monitor Sequence None
Sensors OK AAT (P0072, P0073), IAT1 (P0112, P0113), EGT11 (P0548, P0549),
EGRCOT (P040D, P040C), ECT (P0117, P0118), EOT (P0197, P0198),
CACT1 (P007C, P007D)
Typical Monitoring Duration 0.5 sec

Typical Ambient Air Temperature Rationality Check Entry Conditions:

Entry Condition Minimum Maximum
Engine Off Time 6 hrs N/A
Engine coolant temperature -35 deg C 121 deg C

Typical Ambient Air Temperature Rationality Check Thresholds:

AAT Rationality is confirmed against 4 other sensors (absolute temperature difference thresholds):
CACT1 10 deg C
IAT1 15 deg C
EGRCOT 16 deg C
ECT2 20 deg C

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 Charge Air Cooler (CACT1) Sensor Circuit Check:
DTCs P007C – Charge Air Cooler Temperature Sensor Circuit Low
P007D – Charge Air Cooler Temperature Sensor Circuit High
Monitor execution Continuous
Monitor Sequence None
Sensors OK Not applicable
Typical Monitoring Duration 4 sec

Typical Charge Air Cooler Temperature Sensor Circuit Check Malfunction Thresholds:
Voltage < 0.092 V (161 deg C) or voltage > 4.90 V (-43 deg C)

Charge Air Cooler Temperature (CACT1) Rationality Check:

DTCs P007B - Charge Air Cooler Temperature Sensor Circuit
Range/Performance
Monitor Execution Once per drive cycle. The check is disabled if a block heater is in use.
Monitor Sequence None
Sensors OK AAT (P0072, P0073), IAT1 (P0112, P0113), EGT11 (P0548, P0549),
EGRCOT (P040D, P040C), ECT (P0117, P0118), EOT (P0197,
P0198), CACT1 (P007C, P007D)
Typical Monitoring Duration 0.5 sec

Typical Charge Air Cooler Temperature Rationality Check Entry Conditions:

Entry Condition Minimum Maximum
Engine Off Time 6 hrs
Coolant Temp -35 deg C 121 deg C

Typical Charge Air Cooler Temperature Functional Thresholds:

CACT1 Rationality is confirmed against 4 other sensors (absolute temperature difference thresholds):
AAT 10 deg C
IAT1 16 deg C
EGRCOT 19 deg C
ECT2 20 deg C

Intake Air Temperature (IAT) Sensor Circuit Check:

DTCs P0112 - Intake Air Temperature Sensor Circuit Low
P0113 - Intake Air Temperature Sensor Circuit High
Monitor Execution Continuous
Monitor Sequence None
Sensors OK Not applicable
Typical Monitoring Duration 4 sec.
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Typical Intake Air Temperature Sensor Circuit Check Malfunction Thresholds:
Voltage < 0.10 volts (137 deg C) or voltage > 4.91 volts (-25 deg C)

Intake Air Temperature Rationality Check

DTCs P0111 – Temperature Sensor Circuit Range/Performance
Monitor Execution Once per drive cycle. The check is disabled if a block heater is in use.
Monitor Sequence None
Sensors OK AAT (P0072, P0073), IAT1 (P0112, P0113), EGT11 (P0548, P0549),
EGRCOT (P040D, P040C), ECT (P0117, P0118), EOT (P0197,
P0198), CACT1 (P007C, P007D)
Typical Monitoring Duration 0.5 sec

Typical Intake Air Temperature Rationality Check Entry Conditions:

Entry Condition Minimum Maximum
Engine Off Time 6 hrs

Typical Intake Air Temperature Functional Thresholds:

IAT Rationality is confirmed against 4 other sensors (absolute temperature difference thresholds):
AAT 15 deg C
CACT1 16 deg C
EGTCOT 20 deg C
ECT2 20 deg C

EGR Cooler Downstream Temperature (EGR COT) Sensor Circuit Check (6.7L):
DTCs P041C – Exhaust Gas Recirculation Temperature Sensor “B” Circuit
Low
P041D – Exhaust Gas Recirculation Temperature Sensor “B” Circuit
High
Monitor execution Continuous
Monitor Sequence None
Sensors OK Not applicable
Typical Monitoring Duration 3 sec.

Typical EGR Cooler Downstream Temperature Sensor Circuit Check Malfunction Thresholds:
Voltage < 0.10 volts (961 deg C) or voltage > 4.90 volts (-46 deg C)

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EGR Cooler Downstream Temperature Rationality Check
DTCs P041B – Exhaust Gas Recirculation Temperature Sensor “B” Circuit
Range/Performance
Monitor Execution Once per drive cycle. The check is disabled if a block heater is in use.
Monitor Sequence None
Sensors OK AAT (P0072, P0073), IAT1 (P0112, P0113), EGT11 (P0548, P0549),
EGRCOT (P040D, P040C), ECT (P0117, P0118), EOT (P0197, P0198),
CACT1 (P007C, P007D)
Typical Monitoring Duration 0.5 sec

Typical EGR Cooler Downstream Temperature Rationality Check Entry Conditions:

Entry Condition Minimum Maximum
Engine Off Time 6 hrs
Ambient Temperature -40 deg C
Barometric Pressure 74.5 kPa

Typical EGR Cooler Downstream Temperature Functional Thresholds:

EGRCOT Rationality is confirmed against 4 other sensors (absolute temperature difference thresholds):
AAT 16 deg C
CACT1 19 deg C
IAT1 20 deg C
ECT2 20 deg C

EGR Inlet Temperature Sensor Rationality Check

DTCs P040B – Exhaust Gas Recirculation Temperature Sensor “A” Circuit
Range/Performance
Monitor Execution Once per drive cycle. The check is disabled if a block heater is in use.
Monitor Sequence None
Sensors OK AAT (P0072, P0073), IAT1 (P0112, P0113), EGT11 (P0548, P0549),
EGRCOT (P040D, P040C), ECT (P0117, P0118), EOT (P0197, P0198),
CACT1 (P007C, P007D)
Typical Monitoring Duration 0.5 sec

Typical EGR Inlet Temperature Sensor Rationality Check Entry Conditions:

Entry Condition Minimum Maximum
Engine Off Time 6 hrs
Coolant Temp -35 deg C 121 deg C

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EGR Temperature Check (3.2L):
DTCs P040C – EGR Temperature Sensor "A" Circuit Low
P040D – EGR Temperature Sensor "A" Circuit High
P041C – EGR Temperature Sensor "B" Circuit Low
P041D – EGR Temperature Sensor "B" Circuit High
Monitor execution Continuous
Monitor Sequence None
Sensors OK None
Typical Monitoring Duration 5 sec

Typical EGR Temperature Sensor Circuit Check Malfunction Thresholds:

P040C – EGR temperature “A” sensor voltage < 0.69V
P040D – EGR temperature “A” sensor voltage > 2.66V
P041C – EGR temperature “B” sensor voltage < 0.19V
P041D – EGR temperature “B” sensor voltage > 4.95V

EGR Temperature Sensor “A” to Plausibility Check:

DTCs P040A - EGR Temperature Sensor "A" Circuit
Monitor execution Continuous
Monitor Sequence None
Sensors OK P040C, P040D
Typical Monitoring Duration 20 sec

Typical EGR Temperature Sensor “A” Plausibility Check Entry Conditions:

Entry condition Minimum Maximum
EGR Temperature “A” Sensor 25C 500C
reading
Changes in EGR Temperature “A” 324C
Sensor reading in last 10 second is
not more than
Engine torque 1Nm
Engine operation mode EOM0
(not in DPF heat-up, regeneration,
or cool-down)
Engine Off Time 6Hrs

Typical EGR Temperature Sensor “A” Plausibility Check Malfunction Thresholds:

P040A – Delta between EGR temperature “A” and model value > 400C or <-400C.

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 Secondary Engine Coolant Temperature (ECT2) Sensor Circuit Check:
DTCs P2184 - Engine Coolant Temperature Sensor 2 Circuit Low
P2185 - Engine Coolant Temperature Sensor 2 Circuit High
Monitor execution Continuous
Monitor Sequence None
Sensors OK Not Applicable
Typical Monitoring Duration 2 sec.

Typical Secondary Engine Coolant Temperature Sensor Circuit Check Entry Conditions:
Entry condition Minimum Maximum
Key On
Battery Voltage 9V 16.25 V

Typical Secondary Engine Coolant Temperature Sensor Circuit Check Malfunction Thresholds:
Voltage < 0.10 (163 deg C) volts or voltage > 4.91 volts (-44 deg C)

Secondary Engine Coolant Temperature Rationality Check

DTCs P2182 – Engine Coolant Temperature Sensor 2 Circuit
P00DF – Charge Air Cooler Coolant Temperature Sensor “A” Circuit
Range/Performance (MY2019 1.5L only)
Monitor Execution Once per drive cycle. The check is disabled if a block heater is in use.
Monitor Sequence None
Sensors OK AAT (P0072, P0073), IAT1 (P0112, P0113), EGT11 (P0548, P0549),
EGRCOT (P040D, P040C), ECT (P0117, P0118), EOT (P0197,
P0198), CACT1 (P007C, P007D)
Typical Monitoring Duration 0.5 sec

Typical Secondary Engine Coolant Temperature Rationality Check Entry Conditions:

Entry Condition Minimum Maximum
Engine Off Time 6 hrs
Coolant Temp -35 deg C 121 deg C

Typical Secondary Engine Coolant Temperature Functional Thresholds:

ECT2 Rationality is confirmed against 4 other sensors (absolute temperature difference thresholds):
AAT 20 deg C
CACT1 20 deg C
IAT1 20 deg C
EGRCOT 20 deg C

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Barometric Pressure and Manifold Absolute Pressure

Barometric Pressure (BARO) Sensor Circuit Check:

DTCs P2227 – Barometric Pressure Sensor "A" Circuit Range/Performance
P2228 – Barometric Pressure Circuit Low Input
P2229 – Barometric Pressure Circuit High Input
Monitor Execution Continuous
Monitor Sequence None
Sensors OK Not applicable
Typical Monitoring Duration P2227 – 1 sec
P2228, P2229 –.5 sec.

Typical Barometric Pressure Sensor Circuit Check Entry Conditions:

Entry condition Minimum Maximum
Battery voltage (IVPWR) 9V 16.25 V

Typical Barometric Pressure Sensor Circuit Check Malfunction Thresholds:

P2227 – Observed pressure less than 50 kPa
P2228 - Voltage less than 0.25 V. (6.3 kPa)
P2229 - Voltage greater than 4.85 V. (115 kPa)

Manifold Absolute Pressure (MAP) Sensor Circuit Check:

DTCs P0107 - Manifold Absolute Pressure/BARO Sensor Low Input
P0108 - Manifold Absolute Pressure/BARO Sensor High Input
Monitor Execution Continuous
Monitor Sequence None
Sensors OK Not applicable
Typical Monitoring Duration P0107, P0108 - 2 sec.

Typical Manifold Absolute Pressure Sensor Circuit Check Entry Conditions:

Entry condition Minimum Maximum
Key-on
Battery voltage (IVPWR) 9V 16.25 V

Typical Manifold Absolute Pressure Sensor Circuit Check Malfunction Thresholds:

P0107 – Voltage less than .1 V (50 kPa)
P0108 – Voltage greater than 4.745 V (390 kPa)

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Manifold Absolute Pressure (MAP) Sensor Physical Range Check:
DTCs P0106 – Manifold Absolute Pressure/BARO Sensor Circuit
Monitor Execution Continuous
Monitor Sequence None
Sensors OK Not applicable
Typical Monitoring Duration 4s

Typical Manifold Absolute Pressure Sensor Physical Range Thresholds:

Manifold Absolute Pressure > 300 kPa

Manifold Absolute Pressure (MAP) Sensor Plausibility Check:

DTCs P0236 - Turbocharger/Supercharger Boost Sensor "A" Circuit
Range/Performance
Monitor Execution Continuous
Monitor Sequence None
Sensors OK Not applicable
Typical Monitoring Duration 2 sec.

Typical Manifold Absolute Pressure Sensor Circuit Check Entry Conditions:

Entry condition Minimum Maximum
Key-on
Battery voltage (IVPWR) 9V 16.25 V

Typical Manifold Absolute Pressure Sensor Circuit Check Malfunction Thresholds:

P0236 – if MAP > 3.5 bar absolute, this fault sets.

Manifold Absolute Pressure (MAP) / Barometric Pressure (BARO) Rationality Check:

DTCs P0069 – MAP/BARO Correlation
Monitor Execution Once per trip
Monitor Sequence None
Sensors OK BARO (P2228, P2229), MAP (P0107, P0108)
Typical Monitoring Duration 1.5 sec.

Typical MAP / BARO Rationality Check Entry Conditions:

Entry condition Minimum Maximum
P0069 - MAP / BARO Correlation:

Key-on
Battery voltage (IVPWR) 9V 16.25 V

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Engine Speed (N) 0 rpm 437.5 rpm

Engine off time 2 sec

Typical MAP / BARO Rationality Check Malfunction Thresholds:

P0069 - The difference between MAP and BARO is greater than 4.5 kPa, or less than -8 kPa.

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Turbine Upstream Pressure Sensor Plausibility Checks

The turbine upstream pressure sensor has two plausibility checks to determine if the sensor is operating correctly.
The first check looks for an offset in the turbine upstream pressure sensor when the engine is not running. This
check compares the absolute value of the difference between the measured turbine upstream pressure and the
measured environmental pressure under specific entry conditions. If the pressure difference exceeds the threshold,
for a predetermined amount of time while the entry conditions are met, a fault is set.

Turbine Upstream Pressure Sensor Offset Plausibility Check Operation:

DTCs P0471– Exhaust Pressure Sensor "A" Circuit Range /
Performance
Monitor execution Continuous in with engine off.
Monitor Sequence None
Monitoring Duration for stuck midrange 1.0 seconds to register a malfunction once entry conditions are
met.

Turbine Upstream Pressure Sensor Offset Entry Conditions

Entry Condition: Minimum Maximum
Turbine Upstream Pressure Sensor is not Frozen
Ambient Pressure 74.5 kPa
Ambient Air Temperature 5 deg C
Coolant Temperature 5 deg C
Engine Speed 0 rpm
Engine Off Time 10 sec.
No Turbine Upstream Pressure Sensor

Typical Upstream Turbine Pressure Sensor Plausibility Check Malfunction Thresholds:

| Turbine Pressure Sensor – Ambient Pressure Sensor | > 7.5 kPa

The second check compares the measured pressure upstream of the turbine to a model of the pressure upstream
of the turbine under specific entry conditions. If the difference between the measured and modeled pressure is
greater than a threshold, for a predetermined amount of time while the entry conditions are met, a fault is set.

Turbine Upstream Pressure Sensor -Model Plausibility Check Operation:

DTCs P0474– Exhaust Pressure Sensor "A" Circuit Intermittent / Erratic
Monitor execution Continuous when entry conditions are met.
Monitor Sequence None
Monitoring Duration for stuck midrange 2.0 seconds to register a malfunction once entry conditions are
met.

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 Turbine Upstream Pressure Sensor Offset Entry Conditions
Entry Condition: Minimum Maximum
Turbine Upstream Pressure Sensor is not Frozen
Coolant Temperature 50 deg C
Engine Speed 1300 rpm 2400 rpm
Engine Torque 500 Nm 1400 Nm
Ambient Air Temperature 5 deg C
Ambient Pressure 74.5 kPa
Modeled Exhaust Pressure 147.5 kPa 620.0 kPa
Air Flow Gradient 140 g/s/step

Typical Upstream Turbine Pressure Sensor Plausibility Check Malfunction Thresholds:

(Turbine Pressure Model – Turbine Pressure Sensor) > 90.0 kPa

Upstream Turbine Pressure Sensor Signal Range Check

Reductant Pressure Sensor Open/Short Check Operation:

DTCs P0472 - Exhaust Pressure Sensor "A" Circuit Low
P0473 - Exhaust Pressure Sensor "A" Circuit High
Monitor execution Continuous
Monitor Sequence none
Sensors OK none
Monitoring Duration 2 seconds to register a malfunction

Typical Reductant Pressure Sensor Check Malfunction Thresholds:

Pressure sensor voltage < 0.100 volts or Pressure sensor voltage > 4.8 volts

EGR Valve Position Sensor

Analog inputs checked for opens or shorts by monitoring the analog -to-digital (A/D) input voltage. The sensor range
is 0V to 5V, where 0V=-10% and 5V=140%. The typical normal operating range is 0.5V=5% to 4.5V=125%, where
5% is fully closed.

EGR Valve Position Sensor Check Operation:

DTCs P0405 (EGR Sensor "A" Circuit Low)
P0406 (EGR Sensor "A" Circuit High)
Monitor execution continuous
Monitor Sequence none
Sensors OK not applicable
Monitoring Duration 3 seconds to register a malfunction

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 Typical EGR Valve position sensor check malfunction thresholds (P0405,P0406):
Voltage < 0.30 volts or Voltage > 4.70 volts

Throttle Position Sensor

Analog inputs checked for opens or shorts by monitoring the analog -to-digital (A/D) input voltage.

Throttle Position Sensor Check Operation:

DTCs P02E9 (Diesel Intake Air Flow Position Circuit High),
P02E8 (Diesel Intake Air Flow Position Circuit Low).
Monitor execution continuous
Monitor Sequence none
Sensors OK not applicable
Monitoring Duration 3 seconds to register a malfunction

Typical TP sensor check malfunction thresholds (P02E8,P02E9):

Voltage < 0.08 volts or Voltage > 4.92 volts

EGR Downstream Temperature Sensor Dynamic Plausibility Check

Dynamic plausibility of the EGR downstream temperature sensor for the 6.7L diesel is checked using the EGR cooler
monitor.

Engine Coolant & Engine Oil Correlation

The engine coolant temperature sensor reading and engine oil temperature sensor readings are tested for plausibility
once per drive cycle after a long soak (6hrs or more). The values of the coolant and oil temperature sensor readings
are recorded at start up. Once it has been determined that the enable conditions have been achieved, upper and
lower thresholds are determined based on the engine-off time. The difference of the initial oil and coolant
temperatures are compared to this threshold. If the lower threshold is not achieved, a fault is reported. If the lower
threshold is met, but the upper threshold is not achieved and a block heater is not in use, a fault is reported. If a
block heater is detected and the difference is greater than 40C, a fault is reported.

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 ECT/EOT Plausibility Correlation Test Flow Chart

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 Engine Coolant Temperature (ECT) Sensor Circuit Check:
DTCs P0117 - Engine Coolant Temperature Sensor Circuit Low
P0118 - Engine Coolant Temperature Sensor Circuit High
Monitor execution Continuous
Monitor Sequence None
Sensors OK Not Applicable
Typical Monitoring Duration 2 sec.

Typical Engine Coolant Temperature Sensor Circuit Check Entry Conditions:

Entry condition Minimum Maximum
Key On
Battery Voltage 9V 16.25 V

Typical Engine Coolant Temperature Sensor Circuit Check Malfunction Thresholds:

Voltage < 0.10 (163 deg C) volts or voltage > 4.91 volts (-44 deg C)

Engine Coolant Temperature Rationality Check

DTCs P012F – Engine Coolant Temperature / Engine Oil Temperature
Correlation
Monitor Execution Once per drive cycle.
Monitor Sequence None
Sensors OK AAT (P0072, P0073), IAT1 (P0112, P0113), ECT (P0117, P0118), EOT
(P0197, P0198)
Typical Monitoring Duration Immediate when conditions exist

Typical Engine Coolant Temperature Rationality Check Entry Conditions:

Entry Condition Minimum Maximum
Engine Off Time 6 hrs
Intake Air Temp -7 deg C
Engine “Running” Time 2 sec

Typical Engine Coolant Temperature Functional Thresholds:

ECT Rationality is confirmed against EOT:
Absolute Temperature Difference > 15 deg C

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Engine Coolant Temperature in range Rationality Check
DTCs P0196 –Engine Oil Temperature Sensor Range/Performance
Monitor Execution Once per drive cycle where block heater is not detected.
Monitor Sequence None
Sensors OK ECT (P0117, P0118), EOT (P0197, P0198)
Typical Monitoring Duration Immediate when conditions exist

Typical Engine Coolant Temperature Rationality Check Entry Conditions:

Entry Condition Minimum Maximum
Engine Off Time 6 hrs
Engine Coolant Temp 70C
Block heater detection complete
Engine speed 500 rpm 4200 rpm

Typical Engine Coolant Temperature Functional Thresholds:

ECT Rationality is confirmed against EOT:
Absolute Temperature Difference 35 deg C

Engine Oil Temperature (EOT) Sensor Circuit Check:

DTCs P0197 - Engine Oil Temperature Sensor Circuit Low
P0198 - Engine Oil Temperature Sensor Circuit High
Monitor execution Continuous
Monitor Sequence None
Sensors OK Not Applicable
Typical Monitoring Duration 2 sec.

Typical Engine Oil Temperature Sensor Circuit Check Entry Conditions:

Entry condition Minimum Maximum
Key On
Battery Voltage 9V 16.25 V

Typical Engine Oil Temperature Sensor Circuit Check Malfunction Thresholds:

Voltage < 0.10 (163 deg C) volts or voltage > 4.91 volts (-44 deg C)

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 Engine Coolant System Leak Check:
DTCs P2560 - Engine Coolant Level Low
Monitor execution Continuous
Monitor Sequence None
Sensors OK ECT and OIL temp.
Typical Monitoring Duration 5 sec.

Typical Engine Oil Temperature Sensor Circuit Check Entry Conditions:

Entry condition Minimum Maximum
Engine Oil Temp 70C

Typical Engine Oil Temperature Sensor Circuit Check Malfunction Thresholds:

Oil Temperature is greater than coolant temperature by 50C

Cam and Crank Sensor:

TITLE: DRAWN BY:

Title: 6.7L Scorpion Cam Target / 60-2 Tooth Crank Target Timing Relationship Scorpion Cam / 60-2 Tooth Crank Timing Relationship Revision 2.0 B. Fulton
FILENAME: REVISED:

2010MY Cylinder Timing Plots 03/14/09

EDC 17 Reference Position of CKP for TDC Cylinder #1
Falling Edge Tooth 2 120o from falling edge of tooth 2

120 Crankº
Minus 60 Camº Minus Minus
2 Slot 2 Slot 2 Slot

59 60 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60

CKP Signal Direction of Rotation

Cylindering
Numbering 3 5
8 TDC Combustion
1 7 2 6 4

Crankshaft
630 Position 0 or 720 90 180 270 360 450 540
(Degrees)

Position of CMP for TDC

Cylinder #1 vs. CMP signal
-14 Crankº
118 Crankº 166 Crankº 350 Crankº 474 Crankº 530 Crankº
-7 Camº
59 Camº 83 Camº 175 Camº 237 Camº 265 Camº

CMP Signal
176 Crankº 48 Crankº 124 Crankº
88 Camº 24 Camº 62 Camº
132 Crankº 184 Crankº 56 Crankº
66 Camº 92 Camº 28 Camº

FBC / ZFC Segment Layout Tooth 9: Calculation for

main / post for cylinder 1 & 6
120 Crankº
60 Camº
EpmCrs_tiInc[14]
EpmCrs_tiInc[13]
EpmCrs_tiInc[12]
EpmCrs_tiInc[11]
EpmCrs_tiInc[10]
EpmCrs_tiInc[9]
EpmCrs_tiInc[8]
EpmCrs_tiInc[7]
EpmCrs_tiInc[6]
EpmCrs_tiInc[5]
EpmCrs_tiInc[4]
EpmCrs_tiInc[3]
EpmCrs_tiInc[2]
EpmCrs_tiInc[1]
EpmCrs_tiInc[0]

Tooth 24: Calculation for Tooth 39: Calculation for Tooth 54: Calculation for
main / post for cylinder 3 & 5 main / post for cylinder 7 & 4 main / post for cylinder 2 & 8
Minus
90o Minus
2 Slot 78o 45o 2 Slot

59 60 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
Minus
Pos Peak S0 S0 S0 S0 2 Slot S0 S0 S0 S0
Engine Speed
(RPM)

Nominal

8 1 3 7 2 6 5 4
Neg Peak
Segment 14 Segment 0 Segment 2 Segment 4 Segment 6 Segment 8 Segment 10 Segment 12 Segment 14
Segment 15 Segment 1 Segment 3 Segment 5 Segment 7 Segment 9 Segment 11 Segment 13
S1 S1 S1 S1 S1 S1 S1 S1
630 0 90 180 270 360 450 540
or
Tooth 2: Calculation for Tooth 17: Calculation for Tooth 32: Calculation for Tooth 47: Calculation for
720 pilot injections cylinder 1 & 6 pilot injections cylinder 3 & 5 pilot injections cylinder 7 & 4 pilot injections cylinder 2 & 8

Notes:
- S0 is scheduled starting at 78 deg (calibrate-able) before TDC of cylinder 1, S1 is 45 degrees after S0
- S0 and S1 will continue to be scheduled every 90 degrees from this point forward.
- During the call of the S0 interrupt, the S1 is scheduled on a segment selection calibration , so there will be an S0 or S1 every 45 deg interval.
- At each interrupt the FBC/ZFC algorithm will take a measurement of the Crank Signal buffer in the EDC module .
- Each interrupt is spaced by 45 degrees and each buffer entry for the crank signal is one tooth in distance (or 6 crank angle degrees).
- The FBC wheel learn / ZFC algorithm takes a look at the complete revolution of the crank signal by sampling the entire crank signal
- There are 16 total (0 – 15) segments between S0 and S1 interrupts, but INCA can only display the even numbered segments as they are between the S 0 points
- Teeth measured in each segment are counted backwards from the current segment to the previous segment from 0 – 14
- Injection timing and calculation points are shown on the plot

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Camshaft and Crankshaft Sensor Monitor Operation:
DTCs P0016 – Crankshaft Position - Camshaft Position Correlation (Bank 1 Sensor A)
P0315 – Crankshaft Position System Variation Not Learned
P0335 – Crankshaft Position Sensor "A" Circuit
P0336 – Crankshaft Position Sensor "A" Circuit Range/Performance
P0339 – Crankshaft Position Sensor "A" Circuit Intermittent
P0340 – Camshaft Position Sensor "A" Circuit (Bank 1 or single sensor)
P0341 – Camshaft Position Sensor "A" Circuit Range/Performance (Bank 1 or single
sensor)
P0342 – Camshaft Position Sensor “A” Circuit Low (Bank 1 or single sensor)
P0343 – Camshaft Position Sensor “A” Circuit High (Bank 1 or single sensor)
Monitor Execution P0016 – Continuous
P0315 – Continuous
P0335 – Continuous
P0336 – Continuous
P0339 – Continuous
P0341 – Continuous
P0342 – Continuous
P0343 – Continuous
Monitor Sequence None

Sensors OK P0016 – Sensor Supply Voltage 1 (P06A6), Sensor Supply Voltage 2 (P06A7)
P0315 – Sensor Supply Voltage 1 (P06A6), Crankshaft Sensor (P0335, P0336)
P0335 – Sensor Supply Voltage 1 (P06A6)
P0336 – Sensor Supply Voltage 1 (P06A6)
P0339 – CKP (P0016, P0335, P0336, P0339)
P0341 – Sensor Supply Voltage 2 (P06A7)
P0342 – None
P0343 – None

Typical Monitoring P0016 – 3.6 sec ,P0315 – 5000 sec of overrun/decel fuel shut-off
Duration P0335 – 1.8 sec, P0336 – 1.8 sec, P0341 – 1.2 sec, P0342 – 3 sec, P0343 – 3 sec

Typical Camshaft and Crankshaft Sensor Monitor Entry Conditions:

Entry condition Minimum Maximum
P0016 – Engine running or cranking
P0315 – Overrun/decel fuel shut-off
P0335 – Engine running or cranking
P0336 – Engine running or cranking
P0339 – Engine running or cranking
P0341 – Engine running or cranking
P0342 – Engine running or cranking
P0343 – Engine running or cranking

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Typical Camshaft Sensor Monitor Malfunction Thresholds:
P0016 – If the location of the gap on the crankshaft sensor wheel occurs at a location on the camshaft sensor
wheel that is more than 6 degrees from the expected location for two detection attempts, the code is set (larger
deviation permitted for 3.2L)
P0315 – If after 5000 total seconds of overrun/decel fuel shut-off, the system has been unable to learn crankshaft
wheel deviation corrections, the code is set
P0335 – If no signal is detected from the crankshaft sensor, the code is set (also if the incorrect number of teeth is
detected for the 3.2L)
P0336 – If the gap in the 60-2 tooth wheel is not detected for three revolutions, the code is set
P0339 – If a period error is detected in the crankshaft position sensor signal, the code is set
P0341 – If the segment profile detected does not match the segment profile shown in the figure above, the code
is set
P0342 – If the camshaft sensor signal is constantly low (0V) for 10+ revolutions of the crankshaft
P0343 – If the camshaft sensor signal is constantly high (system voltage) for 10+ revolutions of the crankshaft

Mass Air Meter

The 6.7L and 3.2L engines utilize a frequency-based hot film air meter. The digital output varies its period to indicate
a change in mass air flow. If the period is outside of a specified range, a fault is detected and the appropriate P-code
is set.

MAF Sensor Circuit Check:

DTCs P0100 – Mass or Volume Air Flow “A” Circuit
P0102 – Mass or Volume Air Flow “A” Circuit Low
P0103 – Mass or Volume Air Flow “A” Circuit High
Monitor Execution Continuous
Monitor Sequence None
Sensors OK Not applicable
Typical Monitoring Duration P0100 – 1.5 sec
P0102 – 2 sec
P0103 – 2 sec

MAF Sensor Circuit Check Entry Conditions:

Entry condition Minimum Maximum
Battery voltage 9V 16.25 V
Key on

MAF Sensor Circuit Check Malfunction Thresholds:

P0100 – hard coded, not visible in software
P0102 – period less than 62 us
P0103 – period greater than 1600 us

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MAF Rationality Check

For the 6.7L engine, a rationality check of the mass air flow sensor is performed each time an air mass adaption
(AMA) executes. (The 3.2L engine does not use AMA.) AMA adapts at two points- one at idle, the other at a specific
speed/load. The ratio between the mass air flow and the reference mass air flow is calculated with the EGR valve
commanded to the closed position. The release of this plausibility check occurs under strict engine operating and
environmental conditions to minimize the affect of outside influences on mass air flow. At each AMA event, the
corrected value is stored for each point. These stored values are compared to a threshold, if the stored values are
greater than a threshold a fault is detected, as the air meter has drifted outside of its nominal operating range. In
addition to the stored values, the corrected airflow is compared to directly to the modeled airflow during AMA. If the
ratio of the corrected airflow and the modeled airflow is less than the threshold, a fault is detected. The following
figure outlines the strategy for the rationality checks.

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Mass Air Flow Sensor Functional Check Operation:
DTCs P2073 – Manifold Absolute Pressure/Mass Air Flow - Throttle
Position Correlation at Idle
P2074 – Manifold Absolute Pressure/Mass Air Flow - Throttle
Position Correlation at Higher Load
P00BC – Mass or Volume (MAF/VAF) Air Flow “A” Circuit
Range/Performance – Air Flow Too Low
P0101 – Mass or Volume (MAF/VAF) Air Flow Sensor “A” Circuit
Range Performance
Monitor Execution Once per drive cycle
Monitor Sequence None.
Sensors OK MAF (P0100, P0101, P0102), BARO (P2228, P2229), EGRP (P0405,
P0406, P0404, P0042E, P042F, P1335),
Typical Monitoring Duration 5 Seconds

Typical Mass Air Flow Sensor Functional Check Entry Conditions:

Entry condition Minimum Maximum
Barometric Pressure 74.5 kPa 110 kPa
Engine Coolant Temperature 70 deg C 112 deg C
Throttle Valve 0% 20%

CAC Downstream Temperature -20 deg C 80 deg C

Ambient Air Temperature -20 deg C 80 deg C

Time engine running Normal 10 seconds

No Water Penetration Detected in Sensor

Engine Coolant Temperature at 1 second after key on 100 deg C

Difference in Barometric Pressure versus Pressure in Induction Volume 20 kPa

Engine Torque 20 Nm 200 Nm

Engine Speed 500 rpm 760 rpm

Typical Mass Air Flow Sensor Functional Check Malfunction Thresholds:

P2073, P2074 - If the final AMA stored value in either the idle or higher load cell is greater than 20% or less
than -20%, a fault is detected and the appropriate P-code is set.
P00BC - Corrected measured airflow / Modeled airflow < 0.7
P0101 - Corrected measured airflow / Modeled airflow < 0.7
P2074 – If the algorithm cannot learn a stable value for AMA within 20 learning events, this code is set.

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Air Path Leakage Check

Similar to the mass air flow sensor functional check diagnostics, a rationality check of the mass air flow sensor is
performed each time an air mass adaption (AMA) executes which is used to detect instantaneous problems with the
air path. (Note: the 3.2L engine does not use AMA.) At idle, the ratio between the mass air flow and the reference
mass air flow is calculated with the EGR valve in the closed position. This ratio is compared against a threshold
once AMA has been released. The release of this plausibility check occurs under strict engine operating and
environmental conditions to minimize the affect of outside influences on mass air flow. The ratio has an upper and
lower limit, and the monitor runs once per drive cycle. A ratio too high indicates a post-turbocharger compressor air
path leak, while a ratio too low indicates an EGR valve that is no longer sealing effectively.

Air Path Leakage Check Operation:

DTCs P00BC – Mass or Volume (MAF/VAF) Air Flow A Circuit
Range/Performance – Air Flow Too Low
P0101 – Mass or Volume (MAF/VAF) Air Flow Sensor “A” Circuit
Range Performance
P00BD - Mass or Volume (MAF/VAF) Air Flow A Circuit
Range/Performance – Air Flow Too High
Monitor Execution Once per drive cycle
Monitor Sequence None.
Sensors OK MAF (P0100, P0101, P0102), BARO (P2228, P2229), EGRP (P0405,
P0406, P0404, P0042E, P042F, P1335),
Typical Monitoring Duration 3 seconds

Typical Air Path Leakage Check Entry Conditions:

Entry condition Minimum Maximum
Engine Coolant Temperature 70 deg C 111 deg C
Turbocharger Position 75%
EGR Valve Position 5.1%

Typical Air Path Leakage Check Malfunction Thresholds:

If the ratio between modeled airflow and measured uncorrected airflow is greater than 1.18 or less than .76 a
fault is detected and the appropriate P-code is set.

Mass Air Flow Sensor Plausibility Check Operation:

DTCs P1102 – Mass Air Flow Sensor In Range But Lower Than Expected
P1103 – Mass Air Flow Sensor In Range But Higher Than Expected
Monitor Execution Continuous
Monitor Sequence None.
Sensors OK MAF (P0100, P0101, P0102), BARO (P2228, P2229), EGRP (P0405,
P0406, P0404, P0042E, P042F, P1335),
Typical Monitoring Duration 10 seconds

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Typical Mass Air Flow Sensor Plausibility Check Entry Conditions:
Entry condition Minimum Maximum
Barometric Pressure 75 kPa 110 kPa
Engine Coolant Temperature 70 deg C 121 deg C
Ambient Air Temperature -20 deg C 80 deg C

Time engine running Normal 5 seconds

Key On

Typical Mass Air Flow Sensor Plausibility Check Malfunction Thresholds:

If Mass Air Flow is greater than the maximum AFS threshold map,, or less than the minimum AFS threshold
map for 10 seconds, a fault is detected and a P-code is set.

Minimum AFS Threshold Map

RPM 400 600 1000 1500 2000 2500 3000 3500

Airflow 0 25 100 130 130 150 180 210

Maximum AFS Threshold Map

RPM 600 750 1000 1500 2000 2500 3000 3500

Airflow 300 400 540 850 1100 1350 1550 1550

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Turbocharger/Boost Sensor

Turbocharger/Boost Feedback Check Operation:

DTCs P0237 - Turbocharger/Supercharger Boost Sensor "A" Circuit Low
P0238 - Turbocharger/Supercharger Boost Sensor "A" Circuit High
P0047 - Turbocharger/Supercharger Boost Control "A" Circuit Low
P0048 - Turbocharger/Supercharger Boost Control "A" Circuit High
Monitor Execution Continuous
Monitor Sequence None
Sensors OK none
Typical Monitoring Duration 5 seconds

Typical Turbocharger/Boost Feedback Check Entry Conditions:

Entry condition Minimum Maximum
Battery voltage 9v 14 v

Typical Turbocharger/Boost Feedback Check Malfunction Thresholds:

P0237: sensor voltage < 0.2 v
P0238: sensor voltage > 4.8 v
P0047: Injector short circuit detected by IC internal logic
P0048: Injector open circuit detected by IC internal logic

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Turbocharger Position Sensor Signal Range Check (Turbocharger Position Sensor
Equipped Only)

If the engine is equipped with a turbocharger position sensor, then when the sensor voltage is out of range a fault
will set.

Turbocharger Position Sensor Signal Range Check Operation:

DTCs P2564 – Turbocharger Boost Control Position Sensor “A” Circuit Low
P2565 – Turbocharger Boost Control Position Sensor “A” Circuit High
Monitor execution Continuous
Monitor Sequence None
Monitoring Duration 2s

Typical Turbocharger Position Sensor Signal Range Check Malfunction Thresholds:

Voltage on turbocharger > 4.85V or < 0.15V

Engine Oil Pressure Sensor/Switch Signal Range Check (EOP Sensor Equipped Only)

If the engine is equipped with an engine oil pressure sensor/switch, then when the sensor voltage is out of range a
fault will set.

Engine Oil Pressure Sensor Signal Range Check Operation:

DTCs P0522 – Engine Oil Pressure Sensor/Switch “A” Circuit Low
P0523 – Engine Oil Pressure Sensor/Switch “A” Circuit High
Monitor execution Continuous
Monitor Sequence None
Monitoring Duration 5s

Typical Engine Oil Pressure Sensor Signal Range Check Malfunction Thresholds:
Voltage on turbocharger > 4.992V or < 0.018V

Engine Oil Pressure Sensor/Switch Circuit Plausibility Check (EOP Sensor Equipped Only)

If the engine is equipped with an engine oil pressure sensor/switch then if the engine oil pressure at start is compared
to the engine oil pressure at engine off. If the comparison is implausible a fault is set.

Engine Oil Pressure Sensor/Switch Plausibility Check Operation:

DTCs P0521 – Engine Oil Pressure Sensor/Switch “A” Circuit
Range/Performance
Monitor Execution At engine start
Monitor Sequence None
Sensors OK none
Typical Monitoring Duration Immediate

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 Typical Engine Oil Pressure Sensor/Switch Plausibility Check Entry Conditions:
Entry condition Minimum Maximum
Minimum engine on time 10 s
Number of engine off EOP Function of temperature
samples (maximum of 5 samples)

Typical Engine Oil Pressure Sensor/Switch Plausibility Check Malfunction Thresholds:

Minimum expected difference between average EOP during engine on and off < approximately 50 kPa
(function of temperature)
Maximum expected average EOP during engine off > 70 kPa

Engine Oil Pressure Too Low (EOP Sensor Equipped Only)

If the engine is equipped with an engine oil pressure sensor, and the engine oil pressure is too low during engine
running a fault will set.

Engine Oil Pressure Too Low Check Operation:

DTCs P0524 – Engine Oil Pressure Too Low
Monitor Execution At engine start
Monitor Sequence None
Sensors OK none
Typical Monitoring Duration 5s

Typical Engine Oil Pressure Too Low Check Entry Conditions:

Entry condition Minimum Maximum
Minimum engine on time 10 s

Typical Engine Oil Pressure Too Low Check Malfunction Thresholds:

EOP for engine protection < Function of engine speed and load (30…90 kPa)
EOP for engine protection < Function of EOT and engine speed (6.9 kPa)

DEF Control and Delivery Systems – 3.2L Diesel

The following sensors and monitors are used for the DEF injection system on all 3.2L diesel variants.

DEF Pressure Sensor

The DEF pressure control system uses the measured DEF pressure in a feedback control loop to achieve the desired
DEF pressure. The DEF injection algorithm uses actual DEF pressure in its computation of DEF injector pulse width.

The DEF sensor is a gauge sensor. Its atmospheric reference hole is near the electrical connector. The DEF
pressure sensor has a nominal range of 0 to 0.8 MPa (0 to 8 bar, 0 to 116 psi). This pressure range is above the
maximum intended operating pressure of 0.5 MPa. The sensor voltage saturates at slightly above 0.5 and slightly
below 4.5 volts.

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 DEF Pressure Sensor

DEF pressure is often a vacuum when the system purges after running. Vacuums cannot be measured by the
DEF pressure gauge sensor as voltages will not be lower than 0.5 Volts.

DEF Pressure Sensor Transfer Function

DEF Pump Pressure (PSI) = 29 * Voltage - 14.5
Volts Pressure, MPa (gauge) Pressure, psi (gauge)
5.00 0.8 116
4.50 0.8 116
3.50 0.6 87
2.50 0.4 58
1.00 0.1 14
0.500 0.0 0
0.250 0.0 0

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 Reductant Pressure Sensor Signal Range Check

Reductant Pressure Sensor Open/Short Check Operation:

DTCs P204C - Reductant Pressure Sensor Circuit Low
P204D - Reductant Pressure Sensor Circuit High
Monitor execution Continuous
Monitor Sequence none
Sensors OK none
Monitoring Duration 0.4 seconds to register a malfunction

Typical Reductant Pressure Sensor Check Malfunction Thresholds:

Pressure sensor voltage < 0.2 volts or Pressure sensor voltage > 4.85 volts

A reductant Pressure Sensor that is substantially in error results in a DEF system fault (over or under injection). If
actual DEF pressure exceeds measured pressure, more DEF than that which would be expected is injected and
vice versa. This error would show up in the long term adaption trim (DEF LTA).

Reductant Pressure Plausibility Check before Start-up

If the hydraulic circuit of the DEF system (pump, pressure line, & injector) is completely empty, i.e. purge cycle was
successfully completed during previous drive cycle, the DEF pressure is expected to read 0 kPa.
Based on sensor tolerances the deviation from zero is limited to 30 kPa.

Reductant Pressure Plausibility Check Operation:

DTCs P204B (SRC error for Reductant Pressure Sensor)
Monitor execution Continuous, prior to pressure build-up
Monitor Sequence P204B is inhibited by active P204C or P204D codes
Sensors/Actuators OK none
Monitoring Duration 0.6 seconds to register a malfunction

Typical Reductant Pressure Plausibility Check Entry Conditions:

Entry Condition Minimum Maximum
DEF pump and line not primed 0
DEF system not pressurized
DEF tank and pump not frozen True

Typical Reductant Pressure Plausibility Check Malfunction Thresholds:

P204B: > 50 kPa for 0.6 sec

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 DEF Pressure Build-up Check at Start-up

After the fill cycle is completed, the injector is closed and the system pressure is expected to rise.

Reductant Pressure Functional Check:

DTCs P20E8 – Reductant Pressure too Low
Monitor execution Once during pressure build-up
Monitor Sequence P20E8 is inhibited by active P204B, P204C or P204D codes
Sensors/Actuators OK Reductant pressure sensor, Reductant pump motor, injector
Monitoring Duration 1 event (3 times 15 seconds)

Typical Reductant Pressure Plausibility Check Entry Conditions:

Entry Condition Minimum Maximum
DEF pump and line not primed 0
DEF system not pressurized
DEF tank not frozen True

Typical Reductant Pressure Plausibility Check Malfunction Thresholds:

P20E8: pressure does not exceed 350 kPa after 45 sec with spinning pump

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 DEF System Pressure Control

DEF pressure is maintained via feedback knowledge of sensed pressure. Pressure control is closed loop based on
the voltage of the DEF pressure sensor. If a pressure increase is desired, the reductant pump motor speed is
increased by increasing the PWM output. Pressure decreases are analogous; as the system has a backflow throttle,
pressure will decrease to 0 unless the pump motor in run continuously. Once the set point pressure (500 kPa) is
reached the following diagnostics are enabled.

Reductant Pressure Control (Normal) Functional Check Operation:

DTCs P20E8 - Reductant Pressure Too Low
P20E9 - Reductant Pressure Too High
Monitor execution Continuous
Monitor Sequence P20E8 & P20E9 are inhibited by active P204b, P204C or P204D
codes
Sensors/Actuators OK reductant pump pressure sensor, reductant pump motor,
reductant injector
Monitoring Duration > 10 sec (resp. > 60 sec, see below)

Typical Reductant Pressure Control (Normal) Functional Check Entry Conditions:

Entry Condition Minimum Maximum
DEF system pressure in closed loop control previously True

Typical Reductant Pressure Control (Normal) Functional Check Malfunction Thresholds:

P20E8: < 400 kPa for 60 sec respectively < 300 kPa for 10 sec
P20E9: > 650 kPa for 10 sec respectively > 790 kPa for 1 sec

Reductant Metering Unit Functional Check Operation:

DTCs P20FE - Reductant Metering Unit Performance
P20FF - Reductant Control Module Performance
Monitor execution Continuous
Monitor Sequence P007C, P007D – P20FE
Sensors/Actuators OK CACT1 (P007C, P007D)
Monitoring Duration P20FE - 5 sec, P20FF - continuously

Typical Reductant Metering Unit Functional Check Entry Conditions:

Entry Condition Minimum Maximum
P20FE:
Engine Off time 6 hrs
CAC Downstream Temperature -20 deg C 80 deg C

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Typical Reductant Metering Unit Functional Check Malfunction Thresholds:
P20FE: If difference between reductant coil temperature and CAC temperature > 20 deg C, code is set.
P20FF: Non-volatile memory corruption detected or reductant pump motor controller temperature >130 deg
C

Reductant Purge Control Valve Functional Check Operation:

DTCs P20A0 - Reductant Purge Control Valve "A" Circuit /Open
P20A2 - Reductant Purge Control Valve "A" Circuit Low
P20A3 - Reductant Purge Control Valve "A" Circuit High
Monitor execution Continuous
Monitor Sequence none
Sensors/Actuators OK
Monitoring Duration continuously

Typical Reductant Purge Control Valve Functional Check Malfunction Thresholds:

P20A0: voltage > 4.9 v
P20A2: voltage < 0.1 v
P20A3 voltage > 4.9 v

FORD MOTOR COMPANY REVISION DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 145 OF 241
 Reductant Tank Level Sensor

For the 3.2L product, the task of the discrete level sensor is to measure the tank level at 3 different heights. The
determination of a reductant level is limited to liquid reductant. Frozen reductant cannot be detected. The measured
level will be used to update the calculation of remaining quantity in the reductant tank.

The level sensor consists of four high-grade stainless steel pins. The length of each pin defines the tank level (height)
which is to be checked. Only three pins can be used for level evaluation. The fourth pin is used as ground pin. Due
to the electrical conductivity of Urea the level sensor will determine whether the tank level is above or below the
respective level sensor position. This information will be directly evaluated by the ECU.

Reductant Tank Level Sensor:

Reductant Tank Level Sensor Circuit Tree

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 Reductant Tank Level Sensor Circuit Checks

Reductant Tank Level Sensor Open/Short Check Operation:

DTCs P203D - Reductant Level Sensor "A" Circuit High (SRC max – pin 1 & SCB)
P21AB - Reductant Level Sensor "B" Circuit High (SRC max – pin 2)
P21B0 - Reductant Level Sensor "C" Circuit High (SRC max – pin 3)
P203A - Reductant Level Sensor Circuit (OL)
P203C - Reductant Level Sensor Circuit Low (SCG)
Monitor execution Continuous, every 4 seconds (3x 1 sec to read from each individual pin,
1 sec for diagnosis)
Monitor Sequence None
Sensors OK None
Monitoring Duration 0.5 seconds to register a malfunction within diagnostic mode

Typical Tank Level Sensor Open/Short Check Malfunction Thresholds:

P203D, P21AB & P21B0: voltage > 3.24 Volts (Signal range check max. for pin 1, 2 & 3)
P203D: no calibration thresholds available, SCB fault information is sent directly from power stage
P203C: no calibration thresholds available, SCG fault information is sent directly from power stage
P203A: no calibration thresholds available, OL fault information is sent directly from power stage

The Reductant Tank Level Sensor and the Reductant Tank Temperature Sensor share the same ground wire.
Therefore an open load or short circuit to battery on the ground wire (reference pin) will set codes for both sensors.

Reductant Tank Level Sensor Plausibility Check

If a certain level pin is covered by liquid all pins below this level should be covered as well and send the same
information. If this is not the case, an error flag will be set.

Reductant Tank Level Sensor Plausibility Check Operation:

DTCs P203B – Reductant Level Sensor Circuit Range/Performance
Monitor execution Continuous
Monitor Sequence none
Sensors/Actuators OK Reductant Level sensor signal range checks
Monitoring Duration 60 seconds to register a malfunction

Typical Reductant Tank Level Sensor Plausibility Check Malfunction Thresholds:

no calibration thresholds available

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 Reductant Tank Temperature Sensor

The Reductant Tank Temperature sensor is mounted internal to the Reductant Tank Level Sensor. It is used to
control the activation of the Reductant Tank Heater as well as an enabler to the Level Sensor (which cannot read
level when the reductant is frozen).

Transfer Function
Temperature Resistance
Deg C (Ohms)

-40 336
-30 177
-20 97
-10 55
0 32
10 20
20 12
30 8
40 5.3
50 3.6
60 2.5
70 1.8
80 1.2

Reductant Tank Temperature Circuit Range Check

DTCs P205C Reductant Tank Temperature Sensor Circuit Low
P205D Reductant Tank Temperature Sensor Circuit High
Monitor execution continuous
Monitor Sequence none
Sensors OK not applicable
Monitoring Duration 0.4 seconds to register a malfunction

Typical Intake Reductant Tank Temperature Circuit Range Check Malfunction Thresholds
P205C: voltage < 0.097 Volts
P205D: voltage > 3.201 Volts

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 Reductant Tank Temperature Plausibility Check

On every cold start of the vehicle (min. soak time > 6 hours) the value of the tank temperature sensor is expected to
be close to the environmental temperature.

Reductant Tank Temperature Plausibility Check

DTCs P2043 Reductant Temperature Sensor Circuit Range/Performance
Monitor execution At cold start conditions / extended soak time
Monitor Sequence P2043 is inhibited by active P205C or P205D codes
Sensors OK Ambient temp sensor, exhaust gas temp. sensor upstream SCR catalyst, engine
coolant temperature sensor (downstream)
Monitoring Duration counts intermittent events per trip

Typical Reductant Tank Temperature Plausibility Check Entry Conditions:

Entry Condition Minimum Maximum
Engine off timer 6 hours
Reductant Tank Fluid level 10 % 100 %
Max (ambient temp, SCR catalyst temp., engine coolant temp.) 10 deg C
-
Min (ambient temp., SCR catalyst temp., engine coolant temp.)

Typical Reductant Tank Temperature Plausibility Check Malfunction Thresholds

Reductant tank temperature – ambient temperature > 20 deg C or < -20 deg C

Reductant Control Module Supply Check

Reductant Control Supply Voltage Check Operation:

DTCs P21CA - Reductant Control Supply Voltage Circuit
Monitor execution Continuous
Monitor Sequence none
Sensors OK none
Monitoring Duration 5 sec

Typical Reductant Pressure Sensor Check Malfunction Thresholds:

Battery voltage <= 10 volts or Battery voltage > 20 volts

DEF Control and Delivery Systems – 6.7L & 3.0L Diesel

The following sensors and monitors are used for the DEF injection system on all 6.7L and 3.0L diesel variants.

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 DEF System Pressure Control

Reductant pressure is maintained via feedback knowledge of sensed pressure. A set point pressure is determined
by engine operating conditions (500 kPa over exhaust backpressure). If a pressure increase is desired, the reductant
pump motor speed is increased by increasing the PWM output. Pressure decreases are analogous; as the system
has a backflow throttle, pressure will decrease to 0 unless the pump motor in run continuously.

DEF Pump Pressure Control (Normal) Functional Check Operation:

DTCs P20E8 (Reductant Pressure Too Low OR failure to build pressure)
P20E9 (Reductant Pressure Too High)
Monitor execution continuous
Monitor Sequence P204C and P204D must complete before setting P20E8 or P20E9
Sensors/Actuators OK DEF pump pressure sensor, DEF pump motor, DEF injector
Monitoring Duration > 60 sec

Typical DEF Pump Pressure Control (Normal) Functional Check Entry Conditions:
Entry Condition Minimum Maximum
Reductant system pressurized and ready to inject

Typical DEF Pump Pressure Control (Normal) Functional Check Malfunction Thresholds:
P20E8: Reductant pressure > 200 kPa below setpoint
Failed to build pressure / reach pressure control after 5 attempts
P20E9: Reductant pressure > 150 kPa above setpoint

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 Reductant Pump Motor and Pump Motor Controller (PMC)

The Reductant Pump is driven by a brushless DC electric 12 volt motor. The pump is a positive displacement
diaphragm design connected to the motor by a connecting rod and an eccentric on the motor shaft. The Pump
Motor Controller (PMC) is an electronic control module that that controls the pump motor to deliver pressurized
DEF to outlet port of the pump.

Reductant Pump Motor

Controller (PMC)

Reductant Pump Motor speed is controlled by a PWM driver in the PMC. Increasing the duty cycle of the PWM
increases the Pump Motor speed. PWM duty cycles between 43 and 95% are reserved for diagnostics.

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FORD MOTOR COMPANY REVISION DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 152 OF 241
 Reductant Pump Motor Circuit Checks

Reductant Pump Motor Open/Short Check Operation:

DTCs P208A – Reductant Pump Control Circuit Open
P208C – Reductant Pump Control Circuit Low
P208D – Reductant Pump Control Circuit High
Monitor execution Continuous – Open and Low with driver off / High with driver on
Monitor Sequence none
Sensors OK none
Monitoring Duration Circuit Open / Low: 8 seconds to register a malfunction
Circuit High: 2 seconds to register a malfunction

Typical Reductant Motor Check Malfunction Thresholds:

No calibration thresholds available, fault information is sent directly from power stage.
P208A – Reductant pump voltage in range 2.6 – 3.4V OR reductant PMC voltage < 6V
P208C – Reductant pump current > 5A or reductant PMC current > 15A
P208D – Reductant pump voltage > 16V or reductant PMC current > 5A

Reductant Pump Motor Functional Check

The functional check monitors the Pump Motor Speed Deviation. This test is run if the commanded pump speed is
within normal operating range, i.e. duty cycle 6 to 30 %. In this test if the internal RPM measurement of the Reductant
Pump Motor speed is not matching the commanded speed within a certain percentage, a fault is detected and the
system is shut down for this key cycle.

The functional check of the PMC will detect a fault, turn off the pump and transmit the duty cycle that corresponds to
the chart above. If there are multiple faults then the one with the highest priority shall be transmitted.

Reductant Pump Motor Control (Normal) Functional Check Operation:

DTCs P204C - Reductant Pressure Sensor Circuit Low
P204D - Reductant Pressure Sensor Circuit High
P208B – Reductant Pump Control Range/Performance
P20FF – Reductant Control Module Performance
P214E - Reductant Pump "A" Current Too High
P21CB - Reductant Control Module Supply Voltage Low
P21CC - Reductant Control Module Supply Voltage High
U040F - Invalid Data Received from Reductant Control Module
Monitor execution continuous
Monitor Sequence P208A , P208C, P208D must complete
Sensors/Actuators OK Reductant pump pressure sensor, Reductant injector
Monitoring Duration 5 sec for fault detection

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Typical Reductant Pump Motor Control (Normal) Functional Check Malfunction Thresholds:
P204C: Voltage < 0.2V
P204D: Voltage > 4.85V
P208B: Reductant pump speed deviation from setpoint > 300 RPM
Reductant pump speed control authority clipped at min or max for 30 sec.
P20FF: Reductant PMC temperature > 130°C OR internal error reported in PMC
P214E: Reductant PMC current > 15A
P21CB: Reductant PMC voltage < 8.5V
P21CC: Reductant PMC voltage >19V
U040F: Reductant PMC control signal duty cycle <4% or >96%

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 Reductant Dosing Valve (Injector)

The reductant dosing valve is used to meter and atomize the reductant liquid before it is mixed with the exhaust
gas. Normal operating frequency is 5 Hz. The cooling body contains heat sink fins to keep the injector and
reductant below the boiling point. If the sensed temperature is nearing the maximum temperature threshold,
reductant spray will be increased in quantity to actively cool the valve.

Reductant Dosing Valve Circuit Checks

Reductant Dosing Valve Circuit Check Operation:

DTCs P2047 – Reductant Injection Valve Circuit / Open (Bank 1 Unit 1)
P2048 – Reductant Injection Valve Circuit Low (Bank 1 Unit 1)
P2049 – Reductant Injection Valve Circuit High (Bank 1 Unit 1)
P2054 – Reductant Injection Valve Circuit Low (Bank 1 Unit 2)
P2055 - Reductant Injection Valve Circuit High (Bank 1 Unit 2)
Monitor execution Continuous
Monitor Sequence none
Sensors OK none
Monitoring Duration 2 seconds to register a malfunction

Typical Reductant Dosing Valve Circuit Check Malfunction Thresholds:

No calibration thresholds available, fault information is sent directly from power stage

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P2047 – Voltage in range 2.6 – 3.4V
P2048 – Current > 1.6A
P2049 – Current < 0.1A
P2054 – Resistance < -2 ohm
P2055 – Resistance > 2 ohm

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 Plausibility Check for Pump Motor Duty Cycle (Clogging)

The Pump Motor Duty Cycle is monitored depending on DEF dosing request.

Plausibility Check for Reductant Flow:

DTCs P218F - Reductant System Performance
Monitor execution continuous
Monitor Sequence P208A , P208C, P208D must complete
Sensors/Actuators OK DEF pump pressure sensor, DEF injector
Monitoring Duration 2 sec for fault detection – 3 events per drive cycle – Total duration
depending on customer drive cycle

Typical Plausibility Check for Pump Motor Duty Cycle Entry Conditions:
Entry Condition Minimum Maximum
SCR operating mode Dosing Dosing
Reductant pressure control error -0.5 bar 0.5 bar
Minimum time entry conditions met 5 seconds

Typical Plausibility Check for Pump Motor Duty Cycle Malfunction Thresholds:
P218F (Reductant no flow):
- no dosing: pump duty cycle < 6.75 %
- dosing: pump duty cycle increase < 5 % (dosing rate > 200 mg/sec)

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 Reductant Dosing Valve Functional Check

The functional check monitors the movement of the injector needle. When the injector needle reaches its upper
position (injector open, begin of injection period) a discontinuity in the slope of the dosing valve current occurs.

This functional check monitors the presence of this discontinuity. If it does not occur the injector is either stuck open
or stuck closed. In both case the system cannot be operated and will be shut down.

Reductant Injection Functional Check Operation:

DTCs P208E - Reductant Injection Valve Stuck Closed (Bank 1 Unit 1)
Monitor execution Once per injection stroke
Monitor Sequence P208E is inhibited by active P2047, P2048 or P2049
Sensors/Actuators OK Reductant pump motor, Reductant pressure sensor
Monitoring Duration 50 injection strokes for fault detection

Typical Reductant Injection Functional Check Malfunction Thresholds:

No calibration thresholds available, fault information is sent directly from power stage

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 Reductant Heaters

Aqueous urea water solution (Diesel Exhaust Fluid) freezes at -11°C (12 deg. F). In order to keep the fluid liquid at
low ambient temperatures, the system includes 2 heaters:
 tank heater (PTC heater element – self-regulating)
 pressure line heater (Resistance heater)
The heater power stages are located in the glow plug control module (GPCM). The tank heater is connected to
heater power stage #1. The pressure line is connected to heater power stage #2.
All SCR-heater related circuit checks are performed inside the GCU. The information is sent via CAN to the engine
control module (ECM).
Additionally the GCU sends the supply voltage and the actual heater current for each circuit to the ECM.
Based on this information the heater plausibility checks are performed on the ECM.

Reductant Heater Plausibility Checks

Based on the information of heater voltage and heater current, the actual conductance at peak power is calculated
for each heater circuit. This value is checked against the nominal value including tolerances.

Typical characteristic of PTC heater conductance:

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Reductant Heater Plausibility Check Operation:
DTCs P205B - Reductant Tank Temperature Sensor "A" Circuit
Range/Performance
P20BA – Reductant Heater "A" Control Performance
P20BE – Reductant Heater "B" Control Performance
P20C2 – Reductant Heater "C" Control Performance
P263D – Reductant Heater Driver Performance
Monitor execution Once per drive cycle (at peak heater power)
Monitor Sequence P20B9, P20BB, P20BC must complete for P20BA
P20BD, P20BF, P20C0 must complete for P20BE
Sensors/Actuators OK none
Monitoring Duration 1 event for fault detection

Typical Reductant Heater Plausibility Check Malfunction Thresholds:

P205B: Absolute value of difference between reductant tank temperature and reductant quality sensor
temperature at startup > 40C
P20BA: Powerstage on and heater circuit #1 current < 3A and heater circuit #1 output voltage <5V or
Powerstage off and heater circuit #1 current > 3A and heater circuit #1 output voltage >5V
P20BE: Powerstage on and heater circuit #2 current < 3A and heater circuit #2 output voltage <5V or
Powerstage off and heater circuit #2 current > 3A and heater circuit #2 output voltage >5V
P20C2: Heater supply voltage < 5V
P263D: Driver circuit temperatures > 125C

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 Additional plausibility check for heater circuit #2:

Pump heater & pressure line heater are connected in parallel to heater power stage #2. In order to be able to detect
a failure of just one of both heaters, the conductance of heater circuit #2 is continuously checked against a minimum
threshold. E.g. if the pressure line heater gets disconnected after peak conductance occurred, neither the plausibility
check nor the circuit checks inside the GCU can detect this error. Therefore this continuous check becomes
necessary.

Reductant Heater Plausibility Check Operation (Heater Circuit #2):

DTCs P20BE – Reductant Heater "B" Control Performance
P20C0 – Reductant Heater "B" Control Circuit High
P221C – Reductant Heater "B" Current Too Low
P221D – Reductant Heater "B" Current Too High
Monitor execution Continuously, if heater “B” is activated
Monitor Sequence P20BD, P20BF, P20C0 must complete for P20BE
Sensors/Actuators OK Pressure line heater
Monitoring Duration 2200 ms for fault detection

Typical Reductant Heater Plausibility Check Malfunction Thresholds (Heater Circuit #2):
P20BE: Conductance of heater circuit #2 < 0.3 Ω-1
P20C0: Powerstage off and heater circuit #2 current < 3A and heater circuit #2 voltage output > 5V
P20BF: Powerstage on and heater circuit #2 current > 15A
P221C: Heater circuit #2 current < 3A and Reductant line heater voltage supply > 5V or
Heater circuit #2 power lower than expected
P221C: Reductant heater line power < 1W or heater line power lower than expected
P221D: Reductant heater line power greater than expected

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 Reductant tank heater performance check (heater circuit #1):

The tank heater is located in close proximity to the tank temperature sensor. Therefore the tank temperature sensor
can be used to monitor the tank heater performance only when the heater is commanded on.

When the tank heater is activated, the tank temperature is expected to rise. If this is not the case a fault will be set.
If the vehicle is operated for several consecutive short drive cycles, the test may require more than one drive cycle
to complete.

Reductant Heater Performance Check Operation (Heater Circuit #1):

DTCs P205C - Reductant Tank Temperature Sensor "A" Circuit Low
P205D - Reductant Tank Temperature Sensor "A" Circuit High
P209F – Reductant Tank Heater Control Performance
P20BB - Reductant Heater "A" Control Circuit Low
P20BC - Reductant Heater "A" Control Circuit High
P214F - Reductant Heater "A" Current Too High
P21DD - Reductant Heater "A" Current Too Low
Monitor execution Once per heat cycle (after cold start)
Monitor Sequence P20B9, P20BB, P20BC must complete for P209F
Sensors/Actuators OK tank temperature sensor, tank heater
Monitoring Duration 2200 ms for fault detection

Typical Reductant Heater Performance Check Malfunction Thresholds (Heater Circuit #1):
P205C: Reductant tank temperature sensor voltage < 0.165V
P205D: Reductant tank temperature sensor voltage > 4.3V
P209F: Temperature increase < 0.5°C
P20BB: Powerstage on and heater circuit #1 current > 15A
P20BC: Powerstage off and heater circuit #1 current < 3A and heater circuit #1 voltage output > 5V
P214F: Reductant tank heater power greater than expected
P21DD: Heater circuit #1 current < 3A and Reductant line heater voltage supply > 5V or
Heater circuit #1 power lower than expected
Reductant Heater Power Control Relay Checks

The main relay that controls the power supply to the reductant heaters is checked for functionality and conductivity
continuously. When open circuit, short to ground, short to battery or a powerstage error is detected, a code will be
set.

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 Reductant Heater Control Relay Performance Check:
DTCs P21C2 – Reductant Heater Relay Control Circuit/Open
P21C3 – Reductant Heater Relay Control Circuit Low
P21C4 – Reductant Heater Relay Control Circuit High
P21C7 – Reductant Control Module Power Relay/Relays Control
Circuit/Open
Monitor execution Continuously when heaters are activated
Monitor Sequence N/A
Sensors/Actuators OK Reductant heater power control relay
Monitoring Duration Max. 5000 ms for fault detection

Typical Reductant Heater Control Relay Performance Check Malfunction Thresholds:

P21C2: Power stage on, heaters off and reductant heater current < 0.2A
P21C3: Power stage on, heaters off and reductant heater current > 6A
P21C4: Power stage off, heaters off and reductant heater voltage > 5V
P21C7: Power stage on, heaters off and reductant heater voltage 0V OR
Power stage off, heaters off and reductant heater voltage > 0V

Reductant Quality and Level Sensor

Reductant Quality and Level sensor use ultrasonic waves to determine the concentration and level. The sensor
transmits an ultrasonic signal via Piezo Ceramics to a known distance from 1st reference to 2nd reference points
and records the time delta to calculate the concentration. The sensor then transmits a ultrasonic signal to the top
of the reductant fluid and measures the time delta for this signal and uses the concentration value to get a height of
fluid. These calculations are performed within the Engine Control Module ECM.

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 Reductant Quality and Level Sensor:

DTCs P203B - Reductant Level Sensor "A" Circuit Range/Performance

P206C – Reductant Quality Sensor Low
P206D – Reductant Quality Sensor High
P21CD - Reductant Quality Module Supply Voltage Low
P206B – Reductant Quality Sensor Range / Performance
Monitor execution Continuous
Sensors/Actuators OK U02A2 – Lost Communication with RDQM
P2507, P2508
Monitoring Duration 15 sec – 900 sec

Typical Reductant Quality Sensor Range/Performance (P203B) Entry Conditions:

Entry condition Minimum Maximum
P203B:
Battery Voltage (min. 60 sec) 9V 20 V
Reductant temperature (min. 60 sec) 0°C
Environmental temperature (min. 60 sec) -3°C

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 Reductant mass in tank 3 kg

Typical Reductant Quality Sensor Range/Performance Monitor Malfunction Thresholds:

P203B: Reductant level could not be measured (0xFE) OR Reductant level sensor fault (0xFF) OR Reductant
level reading exceeds height of tank.

Typical Reductant Quality Sensor Low/High Entry Conditions:

Entry condition Minimum Maximum
P206C, P206D:
Reductant quality sensor temperature -3 Deg C
Ambient Air Temperature -20 Deg C
Acceleration pedal position 5%
Time since engine start 60 sec
Mass Of Reductant in Tank 3 kg
Reductant Concentration signal 5 sec
Filter Reductant Concentration 600 sec
stabilize time
Battery voltage 9V 20 V

Typical Reductant Quality Sensor Malfunction Thresholds:

P206C – Filter Reductant Concentration <= 28% for > 900 sec
P206D – Filter Reductant Concentration >= 60% for > 900 sec
P21CD – Reductant Quality Sensor supply voltage < 10 V OR >20V, for 15 sec
P206B – Internal Sensor Error

DEF Control and Delivery Systems – 1.5L Diesel

The following sensors and monitors are used for the DEF injection system on all 1.5L diesel variants.

DEF Pressure Sensor

DEF pressure is a calculated model and has removed the need for a pressure sensor.

DEF Pressure Build-up Check at Start-up

After the fill cycle is completed, the injector is closed and the system pressure is expected to rise.

Reductant Pressure Functional Check:

DTCs P20E8 – Reductant Pressure too Low
Monitor execution Once during pressure build-up
Monitor Sequence P20E8 is inhibited by active P2BAD, P2047 codes
Sensors/Actuators OK Reductant pump motor, injector, temperature, level

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 Monitoring Duration 1 event (3 times 50 seconds)

Typical Reductant Pressure Plausibility Check Entry Conditions:

Entry Condition Minimum Maximum
DEF tank defrost cycle complete True
DEF Sensors and actuators Circuit Checks
DEF Injector not Stuck
SCR Catalyst Temperature above threshold

Typical Reductant Pressure Plausibility Check Malfunction Thresholds:

P20E8: Exceeds number of pump lifts of 1700 over 150 seconds to achieve 3600 hpa

DEF System Pressure Control

DEF pressure is maintained through a pressure model. It looks at the current draw from the pump to correlate the
pressure in the urea line. The nominal pressure is 6300 kPa and the system will maintain pressure until required
dosing is activated, the pump will then supply added reductant to compensate for what has been dosed.

Reductant Pressure Control (Normal) Functional Check Operation:

DTCs P20E8 - Reductant Pressure Too Low
P20E9 - Reductant Pressure Too High
Monitor execution Continuous
Monitor Sequence P20E8 & P20E9 are inhibited by active P2BAD, P2047 codes
Sensors/Actuators OK reductant pump pressure model, reductant pump motor, reductant
injector, temperature, level
Monitoring Duration 1 event (3 times of 33 strokes) above or below threshold

Typical Reductant Pressure Control (Normal) Functional Check Entry Conditions:

Entry Condition Minimum Maximum
DEF system achieved nominal pressure build True

Typical Reductant Pressure Control (Normal) Functional Check Malfunction Thresholds:

P20E8: < 450 kPa for 3 times 33 strokes < 270 kPa for 10 times of 4 strokes
P20E9: > 850 kPa for 3 times of 33 strokes > 1000 kPa for 3 times of 4 strokes

Reductant Control Module Supply Check

Reductant Control Supply Voltage Check Operation:

DTCs P21CB - Reductant Control Module Supply Voltage Low
P21CC - Reductant Control Module Supply Voltage High
Monitor execution Continuous after engine start
Monitor Sequence None
Sensors OK None

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Monitoring Duration P21CB – 2 sec.
P21CC – 11 sec.

Reductant Control Supply Voltage Check Malfunction Thresholds:

Battery voltage < 10 volts
Battery voltage > 16 volts

Reductant Control Supply Plausibility Check Operation:

DTCs P1397 - System Voltage Out Of Self-Test Range
P1501 - Vehicle Speed Sensor Out Of Self-Test Range
P1726 - Insufficient Engine Speed Decrease During Self-Test
P20EA - Reductant Control Module Power Relay De-Energized Performance -
Too Early
P20EB - Reductant Control Module Power Relay De-Energized Performance -
Too Late
P20FF - Reductant Control Module Performance
U0100 - Lost Communication With ECM / PCM "A"
U0400 - Invalid Data Received
Monitor execution P1397, P1501, P1726 – Active only during end of line routine initiated by tool
P20EA – Engine on, valid after run completed
P20EB – ignition on
P20FF – ignition off
U0100, U0400 - Continuous after engine start
Monitor Sequence U0400 – U0100 tested
Sensors OK None
Monitoring Duration 0.7 sec

Reductant Control Supply Plausibility Check Malfunction Thresholds:

P1397 – < 10V, > 16V
P1501 – > 5kPh
P1726 - > 0RPM
P20EA – counter of 4 consecutive failed after run events
P20EB – DCU remains powered post after run
P20FF – 3 or more memory blocks (EEPROM) incorrectly read, memory block (EEPROM) fails to write 3
times consecutively,
U0100 - No CAN message received, or message stopped
U0400 – Wrong variant calibration sent from ECM

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 Reductant Pump Motor, Supply Pump and Back Flow Pump

The Reductant Supply and Backflow Pumps are driven by high frequency solenoid pumps.
The supply pump and back flow pumps are positive displacement pumps that use a diaphragm and solenoid
assembly to displace the reductant fluid to and from the urea line.

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Reductant Pump Motor speed is controlled by a PWM driver in the engine ECU. Increasing the duty cycle of the
PWM increases the Pump Motor speed. Below is a stroke volume/pressure curve.

Supply volume is a function of temperature. At 13.7V and temperatures above 20°C the nominal operating
pressure of 6.3 bar maintains appropriate quality as temperature increases. As temperatures decrease the
maximum volume also decreases (this limitation is greater than the maximum dosing amount of reductant).

The Back flow pump is used to empty the dosing valve and partial emptying of the pressure line. The backflow
volume target is to remove the dosing module and one meter of the pressure line.
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 Reductant Pump Motors (Supply and Backflow Pump) Circuit Checks

Reductant Pump Motors Open/Short Check Operation:

DTCs P208A – Reductant Pump Control Circuit Open
P208C – Reductant Pump Control Circuit Low
P208D – Reductant Pump Control Circuit High
P20A0 - Reductant Purge Control Valve "A" Circuit /Open
P20A2 – Reductant Purge Control Valve "A" Circuit Low
P20A3 - Reductant Purge Control Valve "A" Circuit High
Monitor execution Continuous – Open and Low with driver off / High with driver on
Additional circuit hi, circuit lo when power stage active
Monitor Sequence None
Sensors OK none
Monitoring Duration Circuit Open / Low: 2 seconds to register a malfunction
Circuit High: 2 seconds to register a malfunction
Circuit Lo Relay 250 milliseconds

Typical Reductant Motors Check Malfunction Thresholds:

P208A – 4.8 to 5.3V
P208C – 0 to 350 mv
P208D – 1944 to 2287 mV
P20A0 – 2.8 to 3.2V
P20A2 – 0 to 350 mv
P20A3 - 1944 to 2287 mV

Reductant Pump Motors Plausibility Operation:

DTCs P208B – Reductant Pump "A" Performance/Stuck Off
P20A5 - Reductant Purge Control Valve "A" Stuck Closed
Monitor execution Continuous
Monitor Sequence None
Sensors/Actuators OK reductant pump motor
Monitoring Duration Continuously

Reductant Pump Motors Plausibility Check Entry Conditions:

Entry Condition Minimum Maximum
Environment Pressure 635 hPa 1170 hPa
Pump Pressure 0 32000 hPa
Batt Voltage 9V 16V

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Reductant Pump Motors Plausibility Thresholds:
P208B – 10 x 3 missed MSP, 5 x 3 missed BMP (MSP, mechanical stop point BMP, begin movement point)
P20A5 – decrease 1300 hPa after 4.5 sec, 300 hpa pressure increase

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 Reductant Dosing Valve (Injector)

The reductant dosing valve is used to meter and atomize the reductant liquid before it is mixed with the exhaust
gas. Normal operating frequency is 3.3 Hz. The cooling body contains helps keep the injector and reductant
below the boiling point. If the modeled temperature is nearing the maximum temperature threshold, reductant
spray will be increased in quantity to actively cool the valve.

Reductant Dosing Valve Circuit Checks

Reductant Dosing Valve Circuit Check Operation:

DTCs P2047 – Reductant Injection Valve Circuit / Open (Bank 1 Unit 1)
P2048 – Reductant Injection Valve Circuit Low (Bank 1 Unit 1)
P2049 – Reductant Injection Valve Circuit High (Bank 1 Unit 1)
Monitor execution Continuous
Monitor Sequence none
Sensors OK none
Monitoring Duration P2047 – 5 sec
P2048, P2049 – 2 sec

Typical Reductant Dosing Valve Circuit Check Malfunction Thresholds:

P2047 – Current < 0.1A
P2048 – Current > 2A, or Voltage < 0.232V
P2049 – Current < 0.1A, or Voltage > 1.22V @ BattU 10V, Voltage > 1.952V @ BattU 16V

Reductant Dosing Valve Plausibility Check

Plausibility Check for Reductant Dosing Valve:

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 DTCs P208E - Reductant Injection Valve Stuck Closed (Bank 1 Unit 1)
P20FE - Reductant Metering Unit Performance
Monitor execution P208E – Once per injection stroke, continuous
P20FE – Cold Start
Monitor Sequence P208E is inhibited by active P2047, P2048 or P2049
P20FE – after valid U0100
Sensors/Actuators OK P208E - Reductant injector
P20FE - Reductant injector, voltage ok
Monitoring Duration P208E - 15 failed BIP events unless coil heating required
P20FE - <10 sec

Typical Plausibility Check for Reductant Dosing valve Entry Conditions:

Entry Condition Minimum Maximum
SCR operating mode Engine Running with Dosing
coil heating

Typical Plausibility Check Reductant Dosing Valve Malfunction Thresholds:

P208E – 15 measured BIP events <50 inductivity
P20FE - Difference of 40C between SCR cat temp and injector coil on cold start, or difference of 50C
between engine coolant and injector coil

Typical Reductant Metering Unit Functional Check Entry Conditions:

Entry Condition (P20FE) Minimum Maximum
Engine Off time 6 hrs
Environment Temperature --30 deg C N/A
BattU 10V 16V
Metering Unit Coil Temperature (<11V) <110C
Reductant Pressure (<11V) < 800kpa

Reductant Dosing Valve Functional Check

The functional check monitors the movement of the injector needle. When the injector needle reaches its upper
position (injector open, begin of injection period) a discontinuity in the slope of the dosing valve current occurs.

This functional check monitors the presence of this discontinuity. If it does not occur the injector is either stuck open
or stuck closed. In both case the system cannot be operated and will be shut down.

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 Reductant Dosing Valve Overtemperature Monitor

The reductant dosing valve over temperature diagnostic checks a modeled temperature to a threshold, when this
modeled temperature exceeds the threshold the monitor becomes active.

Reductant Dosing Valve Overtemperature Monitor:

DTCs P20AD - Reductant Metering Unit Temperature Sensor Circuit
Range/Performance
Monitor execution Continiuos
Monitor Sequence None
Sensors/Actuators OK None
Monitoring Duration 5 seconds

Typical Reductant Dosing Valve Overtemperature Monitor Entry Conditions:

Entry Condition Minimum Maximum
SCR State SCR initialization
Battery Voltage 10V 16V

Typical Reductant Dosing Valve Overtemperature Malfunction Thresholds:

Dosing valve current: < 0.1 Ohm

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 Reductant Heaters

Aqueous urea water solution (Diesel Exhaust Fluid) freezes at -11°C (12 deg. F). In order to keep the fluid liquid at
low ambient temperatures, the system includes 4 heaters:
 tank heater (PTC heater element – self-regulating)
 pressure line heater (Resistance heater)
 pump heaters (solenoid)
 dosing valve (solenoid)
The heater power stages are located in the dosing control unit (DCU). The tank heater is connected to heater power
stage #1. The pressure line to heater power stage #2. The pumps and dosing valve heater are on their own power
stage.
All SCR-heater related circuit checks and plausibility checks are performed inside the DCU. The diagnostic
information is sent via CAN to the engine control module (ECM) to flag DTC’s.

Reductant Heater Plausibility Checks

The cavity check diagnostic purpose is to detect an air cavity around the reductant tank heater. In the case of an
air cavity, reductant heating will be limited. This diagnostic checks the resistance of the heater. Such that when
the temperature increases, its resistance also increases, this lowers the current and reduces the heat quantity
supplied. If an air cavity has formed around the tank heater, the heat transfer to the environment will be reduced
considerably, the temperature of the heater will increase, and the heater will regulate the current. The function of
the monitor is to monitor the current of the tank heater, if current drops below a threshold a cavity will be detected.

Based on the information of heater voltage and heater current, the actual conductance at peak power is calculated
for heater 1 circuit and heater 2 circuit. This value is checked against the nominal value including tolerances.

Typical characteristic of PTC heater conductance:

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 Reductant Heater Plausibility Check Operation:
DTCs P2BAD – NOx Exceedance - Root Cause Unknown
P209F - Reductant Tank Heater Control Performance
Monitor execution P2BAD – Ambient temp below 0°C and tank heater active
P209F - Once per drive cycle (at peak heater power)
Monitor Sequence P2BAD, P209F - P20B9, P20BB, P20BC not active
Sensors/Actuators OK reductant heater
Monitoring Duration P2BAD, P209F – continuous

Typical Reductant Heater Plausibility Entry Conditions:

Entry Condition Minimum Maximum
Reductant Temperature 5 deg C
Environment Temperature 0 deg C
BattU 10V 16V
Heater Active (180 sec)

Typical Reductant Heater Plausibility Check Malfunction Thresholds:

P2BAD – < 4A for 300 sec
P209F – 150 sec, without heater release when heating requested

Additional plausibility checks for heater circuit #2:

Pressure line heater is checked for conductance and for circuit errors. The heating circuit and diagnostics are
conducted within the DCU and sent to the ECM via a status bit.

Reductant Heater Check Operation (Heater Circuit #2):

DTCs P20BE – Reductant Heater "B" Control Performance
P20BD – Reductant Heater "B" Control Circuit/Open
P20BF - Reductant Heater "B" Control Circuit Low
P20C0 - Reductant Heater "B" Control Circuit High
Monitor execution P20BD, P20BF– heater active
P20BE - heater active, engine off > 5min.
P20C0 – Power Stage inactive
Monitor Sequence P20BE - Non active P20BD, P20BF, P20C0
Sensors/Actuators OK Pressure line heater
Monitoring Duration P20BD, P20C0 – 2.0 sec
P20BE – 50 sec.
P20BF – 0.25 sec.

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 Typical Reductant Heater Check Malfunction Thresholds (Heater Circuit #2):
P20BE – 2.3V - 2.8V
P20BD – >0.73 conductance, < 0.31 conductance, based on peak current measured
P20BF - Reductant tank heater current > 17A, tank heater current > 8.8 to 10.1 @ power stage voltage 2.1 to
2.4V, power stage supply voltage < 2.1V
P20C0 - 3-5V powerstage, >4.3V measured

Reductant tank heater performance check (heater circuit #1):

Tank heater is checked for conductance and for circuit errors. The heating circuit and diagnostics are conducted
within the DCU and sent to the ECM via a status bit.

Reductant Heater Performance Check Operation (Heater Circuit #1):

DTCs P20B9 – Reductant Heater "A" Control Circuit/Open
P20BA – Reductant Heater "A" Control Performance
P20BB - Reductant Heater "A" Control Circuit Low
P20BC - Reductant Heater "A" Control Circuit High
Monitor execution P20B9, P20BB– heater active
P20BA - heater active, engine off > 5min.
P20BC – Power Stage inactive
Monitor Sequence P20BA - Non active P20B9, P20BB, P20BC
Sensors/Actuators OK tank temperature sensor, tank heater, Batt voltage
Monitoring Duration P20B9, P20BC – 2.0 sec.
P20BA – 50 sec.
P20BB – 0.25 sec
Typical Reductant Heater Performance Check Malfunction Thresholds (Heater Circuit #1):
P20B9 – 2.3V - 2.8V
P20BA – >1.35 to 1.148 conductance, < 0.168 to 0.24 conductance, based on peak current measured
P20BB - Reductant tank heater current > 17A, tank heater current > 8.8 to 10.1 @ power stage voltage 2.1 to
2.4V, power stage supply voltage < 2.1V, 0.2V measured
P20BC - 3-5V powerstage, > 4.3V measured

Reductant Tank Temperature Level and Concentration (TLC) Sensor

For the 1.5L product the reductant tank temperature level and concentration sensor is a SENT protocol. This data
is transmitted based on SENT standard according to SAE J2716 Rev3. This sensor internally regulates 5V from
12V input. The following information is transmitted from the SENT sensor to the DCU; Temperature + status, Level
+ status, concentration + status, speed of sound, SENT revision and CAL ID CVN every 100ms.

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Reductant Quality and Level sensor use ultrasonic waves to determine the concentration and level. The sensor
transmits an ultrasonic signal via Piezo Ceramics to a known distance from one reference point and records the
time delta to calculate the concentration. The sensor then transmits an ultrasonic signal to the top of the reductant
fluid and measures the time delta for this signal and uses the concentration value to get a height of fluid. These
calculations are performed within the Dosing Control Unit DCU and sends the signal to the ECU for functionality
checks. The temperature sensor is linear within the signal range.

The level sensor has a 10° sonic cone that improves accuracy of level measurement and reduces likelihood of
double reflections that may give inappropriate level values. The level sensor is 15mm above the base of the tank,
the use of a modeled level is used when the level is below this value.

Reductant Tank TLC (Temperature Level and Concentration) Sensor Checks

Circuit checks for Temperature level and concentration are within the TLC sensor Checks

Reductant Tank TLC Sensor Check Operation:

DTCs P2044 – Reductant Temperature Sensor "A" Circuit Low
P2045 – Reductant Temperature Sensor "A" Circuit High
P206B – Reductant Quality Sensor Range/Performance
P206C - Reductant Quality Sensor Low
P206D - Reductant Quality Sensor High
Monitor execution P2044 – Continuous when power stage relay active
P2045 – Continuous when power stage relay inactive
P206B, P206C, P206D - Continuous
Monitor Sequence P206B, P206C, P206D after sensor wakeup period

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 Sensors OK None
Monitoring Duration 2.5 seconds to register a malfunction within engine start

Typical Tank TLC Sensor Check Malfunction Thresholds:

P2044 – 0 to 350 mV
P2045 – 1944 to 2287 mV
P206B – SENT communication error including data consistency (120ms) or frame length(101.22 – 101.82).
P206C, P206D – No calibration threshold

Reductant Tank Temperature Sensor

The Reductant Tank Temperature sensor is mounted internal to the Reductant Tank TLC (temperature, level,
concentration) Sensor. It is used to control the activation of the Reductant Tank Heater as well as an enabler to the
Level Sensor (which cannot read level when the reductant is frozen).

Reductant Tank Temperature Plausibility Check

On every cold start of the vehicle (min. soak time > 6 hours) the value of the tank temperature sensor is expected to
be close to the environmental temperature.

Reductant Tank Temperature Plausibility Check

DTCs P2043 Reductant Temperature Sensor Circuit Range/Performance
P205C Reductant Tank Temperature Sensor Circuit Low
P205D Reductant Tank Temperature Sensor Circuit High
Monitor execution P2043 - At cold start conditions / extended soak time
P205C, P205D – Continuous once valid signal from SENT sensor
Monitor Sequence P2043 is inhibited by active P205C or P205D codes
P205C, P205D – Diagnosed after P206C and P206D test ok
Sensors OK P2043 - Ambient temp sensor, exhaust gas temp. sensor upstream SCR
catalyst, engine coolant temperature sensor (downstream)
P205C, P205D – Inhibited by P206B, P206C, P206D
Monitoring Duration P2043 – 1 sec, once per trip
P205C, P205D - 1sec

Typical Reductant Tank Temperature Plausibility Check Entry Conditions:

Entry Condition (P2043) Minimum Maximum
Engine off timer 6 hours
Reductant Tank Fluid level 3 kg 21 kg
Max (ambient temp, SCR catalyst temp., engine coolant temp.) -20°C Ambient 50°C (DEF)
-
Min (ambient temp., SCR catalyst temp., engine coolant temp.)

Typical Reductant Tank Temperature Plausibility Check Malfunction Thresholds

P2043 - Reductant tank temperature – ambient temperature > 50 deg C

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P205C – < - 60°C
P205D – > 89.96°C

Reductant Tank Level Sensor Plausibility Check

Reductant Tank Level Sensor Plausibility Check Operation:

DTCs P203B – Reductant Level Sensor "A" Circuit Range/Performance
P203C – Reductant Level Sensor "A" Circuit Low
P203D - Reductant Level Sensor "A" Circuit High
Monitor execution continuous once valid signal from SENT sensor
Monitor Sequence none
Sensors/Actuators OK Reductant Level sensor signal range checks
Monitoring Duration 60 seconds to register a malfunction

Typical Reductant Tank Level Plausibility Check Entry Conditions:

Entry Condition Minimum Maximum
Voltage 8V 20V
Reductant Tank Fluid level 0 kg 21 kg
Temperature, ambient/reductant 0°C 50°C

Typical Reductant Tank Level Sensor Plausibility Check Malfunction Thresholds:

P203C – < 0mm
P203D - > 200mm

Reductant Quality Sensor Plausibility Checks

Reductant Quality Sensor:

DTCs P206B – Reductant Quality Sensor Range/Performance
P206C – Reductant Quality Sensor Low
P206D – Reductant Quality Sensor High
P2BA9 - NOx Exceedance - Insufficient Reductant Quality
Monitor execution Voltage within bounds, and amb temp completes
Sensors/Actuators OK Key on, no CAN bus faults
Circuit faults completed, valid signal from SENT sensor
Monitoring Duration P206A – In plant or within 50km,
P206B, P206C, P206D – 900 sec
P2BA9 – 30 sec

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Typical Reductant Quality Sensor Range/Performance Entry Conditions:
Entry condition Minimum Maximum
Battery Voltage 9V 20 V
Reductant Tank Fluid level 0 kg 21 kg
Integrated Accelerations (mixing) 5
Temperature, ambient/reductant 0°C 50°C

Typical Reductant Quality Sensor Range/Performance Monitor Malfunction Thresholds:

P206B – > 60%
P206C – < 20%
P206D – > 75%
P2BA9 - < 29.5%

Reductant Quality Sensor Adaption Check

To improve production tolerances, the reductant sensor can utilize a single adaption (in plant or tank replacement).
To adapt to these tolerances there is an End of Line adaption routine that will adapt if the reductant is within +-4%
of 32.5%. This has a maximum correction of 2% towards 32.5% nominal. If greater than +-4% then a fault will be
set.

Reductant Quality Sensor Adaption:

DTCs P206A - Reductant Quality Sensor
Monitor execution Once in plant or new tank in service.
Sensors/Actuators OK Key on, no CAN bus faults
Circuit faults completed, valid signal from SENT sensor

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 Monitoring Duration P206A – no debounce

Typical Reductant Quality Sensor Adaption Entry Conditions:

Entry condition Minimum Maximum
Battery Voltage 10 V 16 V
Reductant Tank Fluid level 40 mm
Distance Traveled 0 km 50 km
Temperature Gradient (40 sec) 0.5°C
Temperature 5°C 35°C
Reductant Quality Signal 5 (high quality)
Reductant Sensor on Time 120 sec
First Fill Routine Complete

Typical Reductant Quality Sensor Adaption Monitor Malfunction Thresholds:

P206A - >+-4% concentration

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Exhaust Gas Temperature Sensor Rationality Test

Each EGT Sensor is checked continuously for proper circuit continuity and out of range high values. In addition, a
rationality test is performed once every drive cycle, after a soak of 6 hours or greater. The rationality test consists of
two components, the first being a comparison against modeled values, and the second being a key-on 4-way
temperature sensor comparison. At key-on, a temperature sample is taken of each of the following sensors: Exhaust
Gas Temperature (EGT11), Exhaust Gas Temperature (EGT12), Exhaust Gas Temperature (EGT13), and Exhaust
Gas Temperature (EGT14). Once the engine starts and a cold start has been confirmed, the model comparison
tests begin. The model comparison tests ensure that each sensor correlates with an expected modeled value, and
a fault is set if the difference is significant (greater than upper threshold or less than lower threshold) and persistent.
In the second rationality test, the temperature samples from 4 EGTs at key-on are compared against each other,
and the temperature differences are compared against a threshold. One sensor must fail key-on plausibility with
three other sensors to set a fault. If two or more sensors fail plausibility with the remaining sensors,, then appropriate
faults pointing to the faulty EGTs are set. The first (model versus sensor) rationality tests rely on entry conditions
that include engine on time, minimum modeled temperature, minimum engine coolant temperature, and minimum
engine torque. Once the entry conditions have been met, the model comparisons continue for several minutes to
ensure a robust detection. The modeled value for EGT11 is based on Modeled Turbo Temperatures. The modeled
value for EGT12 is based on EGT11. The modeled value for EGT13 is based on EGT12. The modeled value for
EGT14 is based on EGT13. In addition, both plausibility tests depend on minimum engine soak time of 6 hours or
more.

Exhaust Gas Temperature (EGT) Sensor Circuit Check:

DTCs P0545 – Exhaust Gas Temperature Circuit Low (Sensor 1)
P0546 – Exhaust Gas Temperature Sensor Circuit High (Sensor 1)
P2032 – Exhaust Gas Temperature Circuit Low (Sensor 2)
P2033 – Exhaust Gas Temperature Sensor Circuit High (Sensor 2)
P242C – Exhaust Gas Temperature Circuit Low (Sensor 3)
P242D – Exhaust Gas Temperature Sensor Circuit High (Sensor 3)
P2470 – Exhaust Gas Temperature Circuit Low (Sensor 4)
P2471 – Exhaust Gas Temperature Sensor Circuit High (Sensor 4)
P24C2 – Exhaust Gas Temperature Measurement System - Multiple
Sensor Correlation Bank 1
Monitor Execution Continuous
Monitor Sequence None
Sensors OK Not applicable
Typical Monitoring Duration 2 sec.

Typical Exhaust Gas Temperature Sensor Circuit Check Entry Conditions:

Entry Condition Minimum Maximum
Battery Voltage 9V 16.25 V
Key On

Typical Exhaust Gas Temperature Sensor Circuit Check Malfunction Thresholds:

Voltage < 0.10 volts or voltage > 2.66 volts

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The Exhaust Gas Temperature Sensor is a PTC Thermistor that provides an analog output voltage proportional to
the exhaust gas temperature. This EGT sensor is capable of being used anywhere in the exhaust gas stream.
Some possible applications are listed below:

EGT Exhaust Gas Temp

EGR_CIT EGR Cooler Inlet Exhaust Gas Temp
EGR_COT EGR Cooler Outlet Exhaust Gas Temp
DPF_IN Diesel Particualte Filter Inlet Exhaust Gas Temp
DPF_OUT Diesel Particulate Filter Outlet Exhaust Gas Temp
SCR_IN SCR Inlet Exhaust Gas Temp
SCR_OUT SCR Outlet Exhaust Gas Temp

EGT Sensor Transfer Function

Vout = (Vref * R sensor) / (1K + R sensor)
Response Time: 1 time constant = 15 sec for 300 deg C step @ 10m/sec gas flow
Volts A/D Counts in PCM Ohms Temperature, deg C
0.10 short circuit n/a
0.71 171 -40
0.82 202 0
1.06 277 100
1.27 350 200
1.45 421 300
1.61 490 400
1.75 556 500
1.88 619 600
1.99 691 700
2.09 740 800
2.14 768 850
2.34 1100
2.66 open circuit n/a

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Exhaust Gas Temperature Rationality Check
DTCs Sensor vs. Model Plausibility
P0544 – Exhaust Gas Temperature Sensor Circuit (Sensor 1)
P2031 – Exhaust Gas Temperature Sensor Circuit (Sensor 2)
P242A – Exhaust Gas Temperature Sensor Circuit (Sensor 3)
P246E – Exhaust Gas Temperature Sensor Circuit (Sensor 4)
Sensor to Sensor Plausibility
P2080 - Exhaust Gas Temperature Sensor Circuit Range/Performance
(Bank 1, Sensor 1)
P2084 - Exhaust Gas Temperature Sensor Circuit Range/Performance
(Bank 1, Sensor 2)
P242B - Exhaust Gas Temperature Sensor Circuit Range/Performance
(Bank 1, Sensor 3)
P246F - Exhaust Gas Temperature Sensor Circuit Range/Performance
(Bank 1, Sensor 4)
Monitor Execution Once per driving cycle.
Monitor Sequence Correlation Test completes after the Model Comparison Tests once the
cold start is detected.
Sensors OK
Typical Monitoring Duration Model Comparison Test Monitor Duration is 200 to 400 seconds.

Typical Exhaust Gas Temperature Rationality Check Entry Conditions:

Entry Condition Minimum Maximum
P2080, P2084, P242B, P246F:
Engine off time 6 hours
Ambient Temperature -40 deg C
Engine speed 10 RPM
P0544, P2031, P242A, P246F:
Engine operating mode Not in particulate filter regeneration
Temperature of sensor to be 25 deg C 500 deg C
diagnosed:
Change of temperature over 10 324 deg C
second period

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 Typical Exhaust Gas Temperature Rationality Check Thresholds:
Each EGT Rationality is confirmed against 3 other sensors (absolute temperature difference thresholds):
Key-On Comparison Threshold 50 deg C
Modeled Comparison Threshold 75 and -180 deg C for EGT11, ±80 deg C for EGT12, ±60 deg C for
EGT13, ±60 deg C for EGT14
Modeled Comparison Duration Comparison Test will run for 200 to 400 seconds. Fault must persist
for 20 seconds for robust detection.

Diesel Particulate Filter Over Temperature Check:

DTCs P200C– Diesel Particulate Filter Over Temperature (Bank1)
P200E – Catalyst System Over Temperature (Bank 1)
Monitor Execution Continuous
Monitor Sequence None
Sensors OK Not applicable
Typical Monitoring Duration 3 sec.
Thresholds P200C – Pre DPF > 830C or Post DPF > 950C or Post DPF Temp
Sensor Circuit failure
P200E - The conditions for P200C have been met for 3 seconds and
vehicle speed is less than 1 km/hr

Diesel Particulate Filter Pressure Sensor

All Ford diesel applications have a pressure sensor in the exhaust. For 6.7L F250-F550 applications and all 3.2L
applications, this sensor is a gage pressure sensor. For 6.7L F650-F750 applications, this sensor is a “delta-
pressure” sensor that measures the difference in pressure across the diesel particulate filter. Regardless of sensor
type, the fault codes described below are used for pressure sensor circuit and plausibility faults.

Diesel Particulate Filter Pressure (DPFP) Sensor Circuit Check:

DTCs P2454 – Particulate Filter Pressure Sensor "A" Circuit Low
P2455 – Particulate Filter Pressure Sensor "A" Circuit High
Monitor Execution Continuous
Monitor Sequence None
Sensors OK Not applicable
Typical Monitoring Duration 2 sec.

Typical Diesel Particulate Filter Pressure Sensor Circuit Check Entry Conditions:
Entry Condition Minimum Maximum
Battery Voltage 9V 16.25 V
Key On

Typical Diesel Particulate Filter Pressure Sensor Circuit Check Malfunction Thresholds:
Voltage < 0.10 volts or voltage > 4.90 volts

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 DPFP Sensor Transfer Function (6.7L F250-F550)
DPFP volts = 0.082 * kPaG Delta Pressure) + 0.45
Volts A/D Counts in PCM Delta Pressure, kPa Gauge
0.10 20 -4.3
0.45 92 0
1.27 260 10
2.09 428 20
2.91 595 30
3.73 763 40
4.55 931 50
4.90 1003 54.3

DPS Sensor Transfer Function (6.7L F650-F750)

DPFP volts = 0.082 * kPaG Delta Pressure) + 0.45
Volts Delta Pressure, kPa Gauge
0.5 0.0
1.0 4.4
1.6 9.6
2.0 13.1
2.6 18.4
3.0 21.9
3.6 27.1
4.0 30.6
4.6 35.9
4.8 37.6

Diesel Particulate Filter Pressure Offset Test

The DPFP Sensor is checked during after-run conditions (period where the key is turned off, however the ECU is
still powered), to verify that the sensor has not drifted from the ambient with no exhaust flow. This test is performed
by comparing the sensed pressure to a threshold (due the gauge sensor, this value should be 0)

Diesel Particulate Filter Pressure Sensor Offset Check

DTCs P2452 – Particulate Filter Pressure Sensor "A" Circuit
Monitor Execution Afterrun
Monitor Sequence None.
Sensors OK P2454, P2455
Typical Monitoring Duration 1 second.

Typical Diesel Particulate Filter Pressure Sensor Offset Check

Thresholds:
Exhaust Pressure Sensor value > 1 kPa

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Diesel Particulate Filter Pressure Rationality Test

Diesel Particulate Filter Pressure Sensor Rationality Check

DTCs P2453 – Particulate Filter Pressure Sensor "A" Circuit
Range/Performance
Monitor Execution Continuous.
Monitor Sequence None.
Sensors OK
Typical Monitoring Duration 2 seconds.

Typical Diesel Particulate Filter Pressure Sensor Rationality Check Entry Conditions:
Entry Condition Minimum Maximum
Exhaust Volume 500 m3/hour None.

Typical Diesel Particulate Filter Pressure Sensor Rationality Check

Thresholds:
Exhaust Pressure Sensor value < 1 kPa

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 DRIVER INPUT DEVICES

Accelerator Pedal Diagnostics

Accelerator Pedal Diagnostic Circuit and Plausibility Checks:

DTCs P2122 – Throttle/Pedal Position Sensor/Switch "D" Circuit Low
P2123 – Throttle/Pedal Position Sensor/Switch "D" Circuit High
P2127 – Throttle/Pedal Position Sensor/Switch "E" Circuit Low
P2128 – Throttle/Pedal Position Sensor/Switch "E" Circuit High
P2138 – Throttle/Pedal Position Sensor/Switch "D"/"E" Voltage Correlation
Monitor execution Continuous
Monitor Sequence None
Sensors OK
Monitoring Duration 0.3 seconds

Typical Accelerator Pedal Diagnostic Thresholds:

P2122 – Observed voltage on first pedal track <0.25V
P2123 – Observed voltage on first pedal track >4.75V
P2127 – Observed voltage on second pedal track <0.25V
P2128 – Observed voltage on second pedal track > 4.75V
P2138 – The absolute value of the difference between ((voltage on pedal track 1)/2 – voltage on pedal track 2)
exceeds a threshold dependent on pedal track 2 voltage (0.25V @ pedal track 2 voltage of 1.2V,
0.5V @ pedal track 2 voltage of 1.96V)

Brake Switch Diagnostics

Brake Switch Plausibility Checks:

DTCs P0504 – Brake Switch "A"/"B" Correlation
P0572 – Brake Switch "A" Circuit Low
P0573 – Brake Switch "A" Circuit High
Monitor execution Continuous
Monitor Sequence None
Sensors OK
Monitoring Duration Varies with driving conditions

Typical Brake Switch Diagnostic Thresholds:

P0504 – Brake switches disagree (pressed/not pressed) for 40 braking events
P0572 – No brake switch activation seen for 40 inferred braking events
P0573 – Brake switch activation seen for 40 inferred acceleration events

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 ENGINE OUTPUTS

Turbocharger Actuator Jammed Detection (Turbocharger Position Sensor Equipped Only)

If the engine is equipped with a turbocharger position sensor, and the turbocharger governor deviation is too positive
or negative, then a fault will be set indicating the turbocharger vanes are jammed.

Turbocharger Actuator Jammed Detection Operation:

DTCs P2598 – Turbocharger Boost Control Position Sensor “A”
Performance – Stuck Low
Monitor execution Continuous
Monitor Sequence None
Monitoring Duration 10 s

Typical Actuator Jammed Valve Entry Conditions:

Entry Condition Minimum Maximum
Engine speed 500 rpm
Adaptive Learning Not Active

Typical Turbocharger Valve Jammed Check (P042E) Malfunction Thresholds:

Desired turbocharger position – actual turbocharger position > 9.99% or Desired turbocharger position – actual
turbocharger position < -9.99%

Turbocharger Actuator Signal Range Check

The diagnostics for the circuit range check on the PWM signal to the turbocharger VGT actuator are internal to the
PWM power-stage. Open load, short-circuit to ground, and short-circuit to battery are detected on the single control
line to the actuator.

Turbocharger Control Circuit Open Load/Short to Ground/Short to Power:

DTCs P132A - Turbocharger/Supercharger Boost Control "A" Electrical
Monitor execution Continuous
Monitor Sequence None
Monitoring Duration 2 seconds to register a malfunction

EGR Valve Actuator Signal Range Check

The diagnostics for the circuit range check on the PWM signal to the EGR valve are internal to the h-bridge PWM
power-stage. Short-circuit to ground, and short-circuit to battery are detected on both the positive and negative
control lines to the actuator.

EGR Valve Actuator Short Circuit (P0489/P0490) Check Operation:

DTCs P0489 – EGR "A Control Circuit Low,
P0490 – EGR "A" Control Circuit High

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 Monitor execution Continuous; when Power-stage ON
Monitor Sequence None
Monitoring Duration 0.35 seconds to register a malfunction

EGR Valve Offset Learn Limits

When the engine is shut down with ECT > 70 C (typical) an offset learn is performed on the EGR valve. If the learned
values are outside the calibrated limits, a P0404 is set. Two offset learned values are generated due to lash in the
EGR valve gearset and the EGR valve position being measured at the motor side of the gearset. The “Min” learn is
the position where the motor is pressing the valve into the seat. The “Edge” learn is the position just before the valve
starts to lift off the seat where the lash in the gearset has been taken up.

EGR Valve Offset Learn Limits :

DTCs P0404 – Exhaust gas recirculation (EGR) “A” control circuit range
/ performance
P049D – EGR “A” Control Position Exceeded Learning Limit (3.0L
and 1.5L Only)
Monitor execution At completion of offset learn
Monitor Sequence None
Monitoring Duration Immediate at completion of offset learn

EGR Valve Offset Learn Limits Entry Conditions:

Entry Condition Minimum Maximum
EGR valve offset learning complete

EGR Valve Offset Learn Limits Malfunction Thresholds:

“Edge” Offset Learn < 7.5 or “Edge” Offset Learn >32.5 or “Min” Offset Learn < 0 or “Min” Offset Learn >25

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EGR Valve Actuator Jammed Detection

The EGR valve has a component level diagnostic to make sure that the valve is not stuck or sticking in a manner
such that it cannot reach the desired position. The monitor runs if a jammed valve is not already detected, position
control is in closed-loop control, and adaptive learning is not active. A minimum engine speed is used as an entry
condition.

If the position governor deviation is above a maximum calibrated threshold then counter starts to count up for the
detection of a permanent positive control fault. If the counter reaches a calibrated threshold then a jammed valve
malfunction is detected. Similarly, if the position governor deviation is below a minimum calibrated threshold then a
second counter starts to count up for the detection of permanent negative control deviation fault. If the counter
reaches a calibration threshold then a jammed valve is detected.

EGR Valve Jammed Check Operation:

DTCs P042E – Exhaust Gas Recirculation "A" Control Stuck Open
Monitor execution Continuous
Monitor Sequence None
Monitoring Duration 5 seconds to register a malfunction

Typical Actuator Jammed Valve Entry Conditions:

Entry Condition Minimum Maximum
Governor Active (closed-loop position control)
Adaptive Learning Not Active
Jammed Valve Fault Not Present on Actuator
RPM 700 rpm

Typical EGR Valve Jammed Check (P042E) Malfunction Thresholds:

Position Error > 8.60 or Position Error < -8.60

Throttle Valve Actuator Signal Range Check

The diagnostics for the circuit range check on the PWM signal to the throttle valve are internal to the h-bridge PWM
power-stage. Short-circuit to ground, and short-circuit to battery are detected on both the positive and negative
control lines to the actuator.

Throttle Valve Actuator Short Circuit (P02E2/P02E3) Check Operation:

DTCs P02E2- Diesel Intake Air Flow Control Circuit Low;
P02E3- Diesel Intake Air Flow Control Circuit High
Monitor execution Continuous; when power stage ON
Monitor Sequence None
Monitoring Duration 0.2 seconds to register a malfunction.

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Throttle Valve Offset Learn Limits

When the engine is shut down with ECT > 70 C (typical) an offset learn is performed on the Throttle valve. If the
learned value is outside the calibrated limits, a P0488 is set. The Throttle offset learn is for the open position of the
throttle.

Throttle Valve Offset Learn Limits:

DTCs P0488 – Exhaust gas recirculation throttle control “A” control
circuit range / performance
P02FA – Diesel Intake Air Flow Position Sensor
Minimum/Maximum Stop Performance (3.0L and 1.5L Only)
Monitor execution At completion of offset learn
Monitor Sequence None
Monitoring Duration Immediate at completion of offset learn

Throttle Valve Offset Learn Limits Entry Conditions:

Entry Condition Minimum Maximum
Throttle valve offset learning complete

Throttle Valve Offset Learn Limits Malfunction Thresholds:

“Min” Offset Learn < -11 or “Min” Offset Learn >10

Throttle Valve Actuator Jammed Detection

The throttle valve has a component level diagnostic to make sure that the valve is not stuck or sticking in a manner
such that it cannot reach the desired position. The monitor runs if a jammed valve is not already detected, position
control is in closed-loop control, and adaptive learning is not active.

If the position governor deviation is above a maximum calibrated threshold then counter starts to count up for the
detection of a permanent positive control fault. . If the counter reaches a calibrated threshold then a jammed valve
malfunction is detected. Similarly, if the position governor deviation is below a minimum calibrated threshold then a
second counter starts to count up for the detection of permanent negative control deviation fault. If the counter
reaches a calibration threshold then a jammed valve is detected.

A special case exists if the throttle is jammed in the closed position during crank. When the throttle is jammed in the
closed position the engine is unable to start. The counter counts up more quickly to allow for the fault to be detected
before the crank ends.

Actuator Jammed Valve Check Operation:

DTCs P02E1 – Diesel Intake Air Flow Control Performance,
P02E4 – Diesel Intake Air Flow “A” Control Stuck Open (3.0L and
1.5L Only)
Monitor execution Continuous
Monitor Sequence None
Monitoring Duration 5 seconds to register a fault during normal operation. 1 second to
register a malfunction during crank.

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 Typical Actuator Jammed Valve Entry Conditions:
Entry Condition

Governor Active (closed-loop position control)

Adaptive Learning Not Active
Jammed Valve Fault Not Present on Actuator

Typical Throttle Jammed Valve Check (P02E1) Malfunction Thresholds:

Position Governor Deviation > 12.5% or <-12.5 %

ECB Valve Actuator Signal Range Check

ECB Actuator Open-Load Check Operation:

DTCs P2425 - Exhaust Gas Recirculation Cooling Valve Control Circuit Open Load
Monitor execution Continuous;
Monitor Sequence None
Monitoring Duration 2 seconds to register a malfunction

ECB Actuator Short-Circuit (P2426/P2427) or (P245C/P245D) Check Operation:

DTCs P2426- Exhaust Gas Recirculation Cooling Valve Control Circuit Low, P2427-
Exhaust Gas Recirculation Cooling Valve Control Circuit High
P245C – EGR Cooler Bypass Control Circuit Low (Bank 1) - 1.5L only
P245D – EGR Cooler Bypass Control Circuit High (Bank 1) - 1.5L only
Monitor execution Continuous;
Monitor Sequence None
Monitoring Duration 2 seconds to register a malfunction.

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Engine Over Speed Monitor

Engine Over Speed check is performed continuously during each drive cycle. The function detects engine
overspeed when a certain calibratable engine−speed threshold has been exceeded for certain period of time; this
malfunction criteria sets. This monitor is set not to heal during same drive cycle.

Engine Over Speed Check:

DTCs P0219 - Engine Overspeed Condition
Monitor Execution Continuous
Monitor Sequence None
Sensors OK Not applicable
Typical Monitoring Duration 0.1 Sec to register a malfunction

Engine Over Speed Check Entry Conditions:

Key On

Engine Over Speed Check Malfunction Thresholds:

6.7L - If engine speed > 4200 rpm
3.2L – if engine speed > 5390 rpm

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Engine Control Unit (ECU) Monitor Operation:
DTCs P0600 - Serial Communication Link
P0601 - Internal Control Module Memory Checksum Error
P0603 – Internal Control Module Keep Alive Memory (KAM) Error
P0606 - Control Module Processor
P0607 - Control Module Performance
P060A - Internal Control Module Monitoring Processor Performance
P060B - Internal Control Module A/D Processing Performance
P060D - Internal Control Module Accelerator Pedal Position Performance
P0611 – Fuel Injector Control Module Performance
P061A - Internal Control Module Torque Performance
P061B - Internal Control Module Torque Calculation Performance
P061C - Internal Control Module Engine RPM Performance
P062B - Internal Control Module Fuel Injector Control Performance
P062F - Internal Control Module EEPROM Error
P06A6 - Sensor Reference Voltage "A" Circuit Range/Performance
P06A7 - Sensor Reference Voltage "B" Circuit Range/Performance
P06A8 - Sensor Reference Voltage "C" Circuit Range/Performance
P167F - Non-OEM Calibration Detected
P2507 - ECM / PCM Power Input Signal Low
P2508 - ECM / PCM Power Input Signal High
P0642 – Sensor Reference Voltage "A" Circuit Low
P0643 – Sensor Reference Voltage "A" Circuit High
P0652 – Sensor Reference Voltage "B" Circuit Low
P0653 – Sensor Reference Voltage "B" Circuit High
P119F – Internal Control Module Fuel Pressure Control Performance
P2610 – ECM / PCM Engine Off Timer Performance

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Monitor Execution P0600, P0603, P0606, P060A, P060B, P060D, P0611, P061A, P061B, P061C,
P062B, P062F, P06A6, P06A7, P06A8, P167F, P2507, P2508, P0642, P0643,
P0652, P0653, P119F, P2610 – Continuous
P0601 – Postdrive
P0607 – 20 sec
Monitor Sequence None
Sensors OK None
Typical Monitoring Duration P0600, P0601, P0603, P0606, P060A, P060B, P060D, P061B, P061C,
P062B, P062F, P06A6, P06A7, P06A8, P167F, P2507, P2508, P0611 – 5 sec
P061A – 0.1 sec , P2610 – 8 sec
P0642, P0643, P0652, P0653 – 0.5 sec
P119F – 0.5 sec

Typical Engine Control Unit (ECU) Monitor Entry Conditions:

Entry condition Minimum Maximum
P0600, P0603, P0606, P0607, P060A, P060B, P060D, P061A, P061B, P061C,
P062B, P062F, P06A6, P06A7, P06A8, P167F, P2507, P2508, P2610:
ECU energized (key-on, engine running, or post-drive before ECU shutdown)
Engine speed (as calculated by monitoring function) 1000 RPM
P0601: Post-drive
P0611: Engine running or cranking

Typical Internal Fuel Pressure Control Performance Entry Conditions:

Entry condition Minimum Maximum
P119F:
Fuel Pressure Sensor voltage 0.14 V 4.94 V
Fuel Pressure Sensor gradient 80 Mpa 120
Engine RPM 992

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Typical Engine Control Unit (ECU) Monitor Malfunction Thresholds:
P0600 – – A data transfer between chips in the ECU either is not possible or has invalid check bytes
OR Communication is interrupted between the CPU and the monitoring module
P0601 – An error is detected in the post-drive ROM test
P0603 – Voltage on the separate power supply for the ECU engine off timer chip (power supply used when the main
ECU is shut down) is < 0.25V (normal operation: battery voltage ~12V)
P0606 – A communications error exists between the powerstage controller chip and the CPU OR an internal chip
error has been detected within the voltage generation/monitoring system for the ECU OR voltage at 5V supply in
ECU is <4.7V or > 5.3V
P0607 – Five errors with internal ECU communication with the monitoring module chip are detected
P060A – An irreversible error occurs with an operating system function call OR An irreversible error occurs in the
test of the monitoring module
P060B – Failure on power-up calibration done for the A/D conversion module and A/D conversion time performed
on ECU start OR >249 mV reading in the cycle following grounding of a specific voltage OR Cyclical conversion of
a predetermined voltage results in <4727 mV or >4830 mV reading.
P060D – If either pedal voltage 1 or pedal voltage 2 < 742 mV and (pedal voltage 1) – 2 * (pedal voltage 2) > 547
mV OR If pedal voltage 1 and pedal voltage 2 >= 742 mV and (pedal voltage 1) – 2 * (pedal voltage 2) > 1055 mV
P0611 – If the raw voltage detected by an internal ECU voltage measurement for fuel system Nominal Voltage
Calibration falls below 0 mV or above 3300 mV for the monitoring duration
P061A – Commanded inner torque > permissible inner torque at current engine operating condition
P061B – The energizing time for Zero Fuel Calibration is <10 ms or > 850 ms (beyond limits for P02CC-P02DA) OR
The difference between programmed energizing time and actual energizing time exceeds 127.2 us or The requested
time for start of energizing of a given fuel injection is outside the crank angle regime permitted for that injection
OR The correction in requested fuel injection quantity due to transient pressure effects within the fuel injector as
calculated by the control software and as calculated by the monitor exceeds 5 mg for an injection
P061C – The engine speed calculated by the control software and the engine speed calculated by the monitor
deviate by more than 400 RPM
P062B – If an error is detected in a requested post injection OR If requested energizing time exceeds 200 us when
the controller is operating in overrun/decel fuel shut-off mode
P062F – An error is detected in an EEPROM read, write, or erase operation
P06A6 – Voltage output of sensor supply 1 is <4.7 V or >5.3 V
P06A7 – Voltage output of sensor supply 2 is <4.7 V or >5.3 V
P06A8 – Voltage output of sensor supply 3 <4.7 V or >5.3 V
P167F – a non-OEM calibration has been detected
P2507 – The 5V internal ECU supply is <4.2 V
P2508 – The 5V internal ECU supply is > 5.5 V
P0642 – The sensor reference “A” ECU voltage < 4.75V
P0643 – The sensor reference “A” ECU voltage > 5.25V
P0652 – The sensor reference “B” ECU voltage < 4.75V
P0653 – The sensor reference “B” ECU voltage > 5.25V
P2610 – If, during a key off event, engine coolant temperature decreases by 30 degrees and the engine off timer
has not incremented at least 1200 seconds OR If, while running for 1200 seconds as measured by ECU timer, the
timer used for engine off time and the time as determined by the secondary timer differ by at least 100 seconds OR
In afterrun, if a requested 8 second stop timer measurement is <7.52 seconds or >8.48 seconds

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Idle Speed and Fuel Monitor Operation:
DTCs P0506 - Idle Control System - RPM Lower Than Expected
P0507 - Idle Control System - RPM Higher Than Expected
P054E - Idle Control System - Fuel Quantity Lower Than Expected
P054F - Idle Control System - Fuel Quantity Higher Than Expected
Monitor Execution P0506, P0507, P054E, P054F – Continuous
Monitor Sequence None
Sensors OK ECT, CKP
Typical Monitoring Duration P0506 – 5 sec
P0507 – 5 sec
P054E – 5 sec
P054F – 5 sec

Typical Idle Speed and Fuel Monitor Entry Conditions:

Entry condition Minimum Maximum
P0506, P0507:
Engine idle speed governor active
Engine Coolant Temperature (°C) 0 120
Vehicle Speed (kph) 1
Engine RPM 300 (stall speed) 1500 (300 rpm above max
requestable idle speed)
P054E, P054F:
Engine running
Vehicle speed 0 mph
Difference between observed and 160 RPM
target idle speed
Accelerator pedal input 0%
RPM gradient 100 RPM/sec
Engine operating mode Normal (no post injection)
Time in normal operating mode 5 sec
Power Take off Not occurring
Transmission status Not in park/neutral
Gradient of fuel quantity requested 20 mg/stroke/sec
Total distance traveled over vehicle life 100 km
Barometric pressure 50 kPa
Engine coolant temperature 70 deg C

Typical Idle Speed and Fuel Monitor Malfunction Thresholds:

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P0506 – If observed idle speed is 100 or more RPM below requested idle speed
P0507 – If observed idle speed is 160 or more RPM above requested idle speed
P054E – If calculated torque required for idle < 50 Nm (less for 3.2L)
P054F – If calculated torque required for idle > 157 Nm (less for 3.2L)

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Lack of Communication

CAN Communications Error

The TCM receives information from the ECM via the high speed CAN network. If the CAN link or network fails, the
TCM no longer has torque or engine speed information available. The TCM will store a U0073 fault code and will
illuminate the MIL immediately (missing engine speed) if the CAN Bus is off. The TCM will store a U0100 fault code
and will illuminate the MIL immediately (missing engine speed) if it stops receiving CAN messages from the ECM.

ECU CAN Communication Malfunctions

DTCs U0073 - Control Module Communication Bus "A" Off
U0074 - Control Module Communication Bus "B" Off
U0101 - Lost Communication with TCM
U0102 - Lost Communication with Transfer Case Control Module
U0121 - Lost Communication With Anti-Lock Brake System (ABS) Control Module
U0151 - Lost Communication With Restraints Control Module
U0212 - Lost Communication With Steering Column Control Module
U029D - Lost Communication With NOx Sensor "A"
U029E - Lost Communication With NOx Sensor "B"
U0307 - Software Incompatibility with Glow Plug Control Module
U0407 - Invalid Data Received from Glow Control Module
U059E - Invalid Data Received from NOx Sensor "A"
U059F - Invalid Data Received from NOx Sensor "B"
U0002 - High Speed CAN Communication Bus Performance
U1013 – Invalid Internal Control Module Monitoring Data Received from TCM
U010E – Lost Communication with Reductant Control Module
U0140 – Lost Communication with Body Control Module
U02A2 – Lost Communication with Reductant Quality Module
U0155 – Lost Communication with Instrument Panel Cluster (IPC) Control
Monitor execution continuous
Monitor Sequence None
Sensors OK not applicable
Monitoring Duration continuous

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 Typical Malfunction Thresholds
U0073 – CAN Chip Driver detect CAN line short or open > 10 ms
U0074 – CAN Chip Driver detect CAN line short or open > 10 ms
U0101 – TCM master message not received > 1 sec
U0102 – TCCM master message not received > 5 sec
U0121 – ABS master message not received > 5 sec
U0151 – RCM master message not received > 10 sec
U0212 – SCCM master message not received > 5 sec
U029D – NOx Sensor "A" master message not received > 1 sec
U029E – NOx Sensor "B" master message not received > 1 sec
U0307 – Glow module reporting "safe glow" mode
U0407 - Calibration Verification Number not received by ECU
U059E - Calibration Verification Number not received by ECU
U0002 - ECM transmit CAN buffer overload > 5 sec
U1013 – invalid data received from TCM > 5 sec
U010E – RDCM master message not received > 5 sec
U0140 – BCM master message not received > 5 sec
U02A2 – RDQM master message not received > 5 sec
U0155 – IPC master message not received > 5 sec

Vehicle speed is received by the ECU over CAN from the ABS system or (if the ABS system is faulted on all 4
wheel speed sensors) the TCU through Output Shaft Speed calculation to wheel speed

VS Communication Plausibility Malfunctions

DTCs P0500 Vehicle Speed Sensor "A"
Monitor execution continuous
Monitor Sequence None
Sensors OK not applicable
Monitoring Duration continuous

Typical Malfunction Thresholds

VS signal is missing from the CAN system for 0.5 Seconds.

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Active Grill Shutter Control – 3.0L and 1.5L Only

The 3.0L and 1.5L engines are equipped with Active Grill Shutters (AGS) that are controlled by the ECU. For the
3.0L only there are two sets of grill shutters, upper “A” and lower “B”, and each has diagnostics related to endstop
detection, internal electrical faults, loss of communication with the AGS hardware, overtemperature, blockage/stuck,
under and over voltage of the actuator. The 1.5L has only one set of grill shutters and has the corresponding monitors
for it.

Figure above: This figure shows a grill shutter viewed from the outside grill for 3.0L only. The blue parts form a
duct keeping incoming air from flowing around the radiator.

Figure above: AGS actuator (top and bottom view)

Active Grill Shutter Endstop Detection will set a fault when the AGS does not detect an endstop when expected.
There are two scenarios under which the endstop is expected, during the self-calibration of the AGS or when it is
commanded via the ECU.

Active Grill Shutter Endstop Detection:

DTCs P05A1 – Active Grille Air Shutter “A” Position Sensor
Minimum/Maximum Stop
P05B0 – Active Grille Air Shutter “B” Position Sensor
Minimum/Maximum Stop
Monitor execution Continuous
Monitor Sequence None
Monitoring Duration 10 seconds.

Typical Active Grille Shutter Endstop Entry Conditions:

Entry Condition

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 Commanded to an endstop (Fully closed or fully open position)
AGS self-learning events > 5

Typical Active Grille Shutter Endstop Malfunction Thresholds:

Commanded vs. Actual final shutter position when calibrating AGS fully closed during self-cal > 40 deg
Commanded vs. Actual final shutter position when calibration AGS fully open during self-cal > 20 deg
Commanded vs. Actual final shutter position during normal operation towards fully closed/open position > 20
deg

Active Grille Air Shutter Control Circuit/Open monitor will detect a failure when there is an internal fault detected by
the AGS actuator.

Active Grill Shutter Control Circuit Open Detection:

DTCs P05A2 – Active Grille Air Shutter “A” Control Circuit/Open
P05B1 – Active Grille Air Shutter “B” Control Circuit/Open
Monitor execution Open coil check is performed once at the beginning and once
500ms after the end of each movement.
Short coil check is performed continuously.
Monitor Sequence None
Monitoring Duration 10 seconds.

Typical Active Grille Shutter Control Circuit Open Entry Conditions:

Entry Condition

Initiation of movement command

Typical Active Grille Shutter Control Circuit Open Malfunction Thresholds:

Shorted or open motor coil detected by the microcontroller inside the actuator = TRUE

Loss of communication faults with AGS can be set when the AGS controller is not communicating with the ECU.

Active Grill Shutter Loss of Communication Detection:

DTCs U0284 – Loss Communication with Active Grille Air Shutter
Module “A”
U0285 – Loss Communication with Active Grille Air Shutter
Module “B”
Monitor execution Continuous
Monitor Sequence None
Monitoring Duration Immediate

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 Typical Active Grille Shutter Supply Voltage Entry Conditions:
Entry Condition Minimum Maximum
Key on
Time since engine start 5s
Battery voltage 10.0V 16.26 V
Afterrun or pre-drive is not active

Typical Active Grille Shutter Loss of Communication Malfunction Thresholds:

Time signal is missing from AGS module > 10 sec

When the actuator has detected it is overtemperature a fault can be set. The junction temperature inside the ASIC
controller chip is normally 2-20 degrees higher than ambient temperature, depending on the motor-usage, during a
non-faulted event.

Active Grill Shutter Module Overtemperature Detection:

DTCs P05C0 – Active Grille Air Shutter Module “A” Over Temperature
P05C1 – Active Grille Air Shutter Module “B” Over Temperature
Monitor execution Continuous
Monitor Sequence None
Monitoring Duration 10 sec

Typical Active Grille Shutter Module Overtemperature Entry Conditions:

Entry Condition

None

Typical Active Grille Shutter Module Overtemperature Malfunction Thresholds:

Actuator junction temperature inside ASIC controller chip > 140 deg C

AGS is also monitored in case the shutter is stuck due to a blockage. This monitor will detect a blockage between
the open and closed position of the AGS or if the angle between the endstops after self-calibration is too small.

Active Grill Shutter Performance Detection:

DTCs P059F – Active Grille Air Shutter “A” Performance/Stuck Off
P05AE – Active Grille Air Shutter “B” Performance/Stuck Off
Monitor execution Continuous
Monitor Sequence None
Monitoring Duration 300 sec

Typical Active Grille Shutter Performance Entry Conditions:

FORD MOTOR COMPANY REVISION DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 207 OF 241
 Entry Condition

AGS self-learning events > 5

AGS freeze mode is active (AGS will enter freeze mode when ambient temperature is below 2 degC and
engine coolant temperature is below 110 degC)

Typical Active Grille Shutter Performance Malfunction Thresholds:

Command vs. Actual final shutter position when calibrating AGS fully open during self-learning event > 20 deg
Command vs. Actual final shutter position during normal operation conditions towards fully closed/open position
> 6 deg

When the AGS supply voltage is low the following faults can be set.

Active Grill Shutter Supply Voltage Detection:

DTCs P05A7 – Active Grille Air Shutter “A” Supply Voltage Circuit Low
P05B6 – Active Grille Air Shutter “B” Supply Voltage Circuit Low
Monitor execution Continuous
Monitor Sequence None
Monitoring Duration Instantaneous

Typical Active Grille Shutter Supply Voltage Entry Conditions:

Entry Condition Minimum Maximum
Key on
Time since engine start 5s
Battery voltage 9.0V 16.26 V

Typical Active Grille Shutter Supply Voltage Malfunction Thresholds:

Internal supply voltage measured by the ASIC controller chip < 6.9 V

GLOW PLUGS AND GLOW PLUG CONTROL MODULE (GPCM) FOR 6.7L AND
3.0L

The diesel engine uses glow plugs to assist with cold weather starting and combustion until the cylinder is warm
enough to operate normally. The glow plugs are duty cycle controlled and will overheat if constant 12V is applied.

The glow plugs are operated by the Glow Plug Control Module (GPCM). It contains 8 high current smart MOSFET
drivers, one for each glow plug. Glow time and intensity are calculated on the basis of CAN signals (rpm, torque,
engine coolant temp, air temp and BARO.) The module also contains 3 drivers for the DEF (NOx reductant) heating
and thawing system.

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 Glow Plug and Glow Plug Control Module (GPM)

The GPCM is connected to the ECU via Diesel high speed CAN. All data and diagnostics pass over this non-public
communication bus. The standard operating voltages for the GPCM are 6.5 volts to 16 volts. Limited operation
between 5.5v and 6.5v on the lower range and no operation below 5.5v. Glow function is disabled below 6.5v and
above 16.5v.

Glow Plug Module Operational Checks:

DTCs U0106 – Lost Communication with GPCM
P0381 – Glow Plug/Heater Indicator Circuit
P064C – Glow Plug Control Module
P06DF – Glow Plug Module Memory Checksum Error
P0384 – Glow Plug Module System Voltage
P052F – Glow Plug Module 1 System Voltage
P20C2 – Reductant Heater "C" Control Performance
P263C - Glow Plug Driver Performance
P06E5 - Glow Plug Control Module 1 Performance
P263E - Glow Plug Control Module 1 Over Temperature
Monitor execution P06DF, P0381 at power up, otherwise continuous
Monitor Sequence None
Sensors OK None
Monitoring Duration ~1 second to register a malfunction

Glow Plug Module: Malfunction Thresholds:

Communication lost for > 5 seconds
Cluster detects wait to start lamp in wrong state (off when commanded on)
Any internal driver circuits detect fault (not switching or over temp) > 1 sec (glow plugs, DEF heaters or relay)
RAM checksums do not match expected
GPCM main power feed voltage too low / too high / open circuit (< 6.5 volts or > 16 volts)
Low voltage detected on the Reductant Heater Circuit "C" < 5 volts
Glow plug module controller internal temperature > 150°C

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Glow Plug Circuit Open Load Check Operation:
DTCs P0671 – Cylinder 1 Glow Plug Circuit / Open
P0672 – Cylinder 2 Glow Plug Circuit / Open
P0673 – Cylinder 3 Glow Plug Circuit / Open
P0674 – Cylinder 4 Glow Plug Circuit / Open
P0675 – Cylinder 5 Glow Plug Circuit / Open
P0676 – Cylinder 6 Glow Plug Circuit / Open
P0677 – Cylinder 7 Glow Plug Circuit / Open (V8 Diesel Only)
P0678 – Cylinder 8 Glow Plug Circuit / Open (V8 Diesel Only)
P20B9 – Reductant Heater "A" Control Circuit / Open
P20BD – Reductant Heater "B" Control Circuit / Open
P20C1 – Reductant Heater "C" Control Circuit / Open
Monitor execution Glow plugs in heating mode. Heaters operational
Monitor Sequence None
Sensors OK None
Monitoring Duration ~1 second to register a malfunction

Glow Plug Circuit Open Load: Malfunction Thresholds:

Individual glow plug circuit current < 1 A, Individual reductant heater circuit current < .2 A

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Glow Plug Circuit Short to Battery Check Operation:
P066B – Cylinder 1 Glow Plug Circuit High
DTCs
P066D – Cylinder 2 Glow Plug Circuit High
P066F – Cylinder 3 Glow Plug Circuit High
P067B – Cylinder 4 Glow Plug Circuit High
P067D – Cylinder 5 Glow Plug Circuit High
P067F – Cylinder 6 Glow Plug Circuit High
P068D – Cylinder 7 Glow Plug Circuit High (V8 Diesel Only)
P068F – Cylinder 8 Glow Plug Circuit High (V8 Diesel Only)
P20BC – Reductant Heater "A" Control Circuit High
P20C0 – Reductant Heater "B" Control Circuit High
P20C4 – Reductant Heater "C" Control Circuit High
Monitor execution Glow plugs in heating mode. Heaters operational
Monitor Sequence None
Sensors OK None
Monitoring Duration ~1 second to register a malfunction for glow plugs
250 ms to register a malfunction for the reductant heaters

Glow Plug Circuit Short to Battery: Malfunction Thresholds:

Individual glow plug circuit = 0 Amps current, Individual reductant heater circuit = 0 Amps current

Glow Plug Circuit Short to Ground Check Operation:

DTCs P066A – Cylinder 1 Glow Plug Circuit Low
P066C – Cylinder 2 Glow Plug Circuit Low
P066E – Cylinder 3 Glow Plug Circuit Low
P067A – Cylinder 4 Glow Plug Circuit Low
P067C – Cylinder 5 Glow Plug Circuit Low
P067E – Cylinder 6 Glow Plug Circuit Low
P068C – Cylinder 7 Glow Plug Circuit Low (V8 Diesel Only)
P068E – Cylinder 8 Glow Plug Circuit Low (V8 Diesel Only)
P20BB – Reductant Heater "A" Control Circuit Low
P20BF – Reductant Heater "B" Control Circuit Low
P20C3 – Reductant Heater "C" Control Circuit Low
Monitor execution Glow plugs in heating mode. Heaters operational.
Monitor Sequence None
Sensors OK None
Monitoring Duration ~3 second to register a malfunction for glow plugs
250 ms to register a malfunction for the reductant heaters

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Glow Plug Circuit Short to Battery: Malfunction Thresholds:
Individual glow plug circuit > 20 Amps current > 1 second
Individual glow plug circuit > 70 Amps current for > .2 ms
Reductant heater relay (circuit "A" & "B") > 15 Amps current > 250 ms
Reductant heater relay (circuit "C") > 6 Amps current > 250 ms

Glow Plug Circuit Resistance Out of Range Check:

DTCs P06B9 – Cylinder 1 Glow Plug Circuit Range / Performance
P06BA – Cylinder 2 Glow Plug Circuit Range / Performance
P06BB – Cylinder 3 Glow Plug Circuit Range / Performance
P06BC – Cylinder 4 Glow Plug Circuit Range / Performance
P06BD – Cylinder 5 Glow Plug Circuit Range / Performance
P06BE – Cylinder 6 Glow Plug Circuit Range / Performance
P06BF – Cylinder 7 Glow Plug Circuit Range / Performance (V8 Diesel Only)
P06C0 – Cylinder 8 Glow Plug Circuit Range / Performance (V8 Diesel Only)
Monitor execution Glow plugs in heating mode.
Monitor Sequence After Open circuit, short to battery and short to ground testing
Sensors OK None
Monitoring Duration ~3 second to register a malfunction

Glow Plug Circuit Short to Battery: Malfunction Thresholds:

Individual circuit > 2 ohms resistance

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 DOWN STREAM INJECTION (DSI) SYSTEM

Down Stream Injection [DSI] system (that includes Vaporizer Pump and Glow Plug) is used to aid in DPF
regeneration on the 3.2L engine so as to reduce oil dilution associated with in-cylinder post injections.

Glow Plug

DSI monitoring strategy includes circuit continuity checks for vaporizer pump and vaporizer glow plug, plausibility
check for vaporizer glow plug relay, and DSI leakage monitor.

DSI Vaporizer Pump Circuit Continuity Check Monitor

Vaporizer pump circuit continuity check is performed continuously during each drive cycle. It compares the pump
voltage output with minimum/maximum allowable voltage threshold. If vaporizer pump voltage is detected outside of
the threshold range, it detects fault.

DSI Vaporizer Pump Circuit Continuity Check:

DTCs P20D7 - Exhaust Aftertreatment Fuel Supply Control Circuit/Open
P20D9 – Exhaust Aftertreatment Fuel Supply Control Circuit Low
P20DA – Exhaust Aftertreatment Fuel Supply Control Circuit High
Monitor Execution Continuous (while entry conditions are met)
Monitor Sequence None
Sensors OK Not applicable
Typical Monitoring Duration 5 sec.

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 Typical DSI Vaporizer Pump Circuit Continuity Check Entry Conditions:
Entry Condition Minimum Maximum
Battery Voltage 9.0 V 16.3 V
Key On

Typical DSI Vaporizer Pump Circuit Continuity Check Malfunction Thresholds:

Open Circuit Voltage Threshold:
If 2.9 V < Vaporizer Pump Volatge < 3.2 V for 5 seconds, the open circuit fault is detected.
Short to Ground Voltage Threshold:
If 1.95 V < Vaporizer Pump Volatge < 2.175 V for 5 seconds, the short to ground fault is detected.
Short to Positive/Battery Voltage Threshold:
If 10.9 V < Vaporizer Pump Volatge < 12.32 V for 5 seconds, the short to battery fault is detected.

DSI Vaporizer Glow Plug Circuit Continuity Check Monitor

Vaporizer Glow Plug circuit continuity check is performed continuously during each drive cycle. It compares the glow
plug voltage output with minimum/maximum allowable voltage threshold. If vaporizer glow plug voltage is detected
outside of the threshold range, it detects fault.

DSI Vaporizer Glow Plug Circuit Continuity Check:

DTCs P269B – Exhaust Aftertreatment Glow Plug Control Circuit/Open
P269D – Exhaust Aftertreatment Glow Plug Control Circuit Low
P269E – Exhaust Aftertreatment Glow Plug Control Circuit High
Monitor Execution Continuous (while entry conditions are met)
Monitor Sequence None
Sensors OK Not applicable
Typical Monitoring Duration 5 sec.

Typical DSI Vaporizer Glow Plug Circuit Continuity Check Entry Conditions:
Entry Condition Minimum Maximum
Battery Voltage 9.0 V 16.3 V
Key On

Typical DSI Vaporizer Glow Plug Circuit Continuity Check Malfunction Thresholds:
Open Circuit Voltage Threshold:
If 2.9 V < Vaporizer Glow Plug Volatge < 3.2 V for 5 seconds, the open circuit fault is detected.
Short to Ground Voltage Threshold:
If 1.95 V < Vaporizer Glow Plug Volatge < 2.175 V for 5 seconds, the short to ground fault is detected.
Short to Positive/Battery Voltage Threshold:
If 10.9 V < Vaporizer Glow Plug Volatge < 12.32 V for 5 seconds, the short to battery fault is detected.

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DSI Vaporizer Glow Plug Relay Plausibility Check Monitor

Vaporizer Glow Plug Relay plausibility check is performed continuously during each drive cycle. If vaporizer glow
plug relay feedback state doesn’t match the relay command state, it detects fault.

DSI Vaporizer Glow Plug Relay Plausibility Check:

DTCs P26A0 – Exhaust Aftertreatment Glow Plug Performance
Monitor Execution Continuous (while entry conditions are met)
Monitor Sequence None
Sensors OK DSI Glow Plug
Typical Monitoring Duration 60 sec.

Typical DSI Vaporizer Glow Plug Relay Plausibility Check Entry Conditions:
Entry Condition Minimum Maximum
Battery Voltage 9.0 V 16.3 V
Key On

Typical Vaporizer Glow Plug Relay Plausibility Check Malfunction Thresholds:

If Glow Plug Relay Feedback ≠ Glow Plug Relay Command for approx 60 seconds, the fault is detected.

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DSI Leakage Monitor

DSI leakage monitor addresses the detection of a leaking DSI system in normal lean condition when it is not
supposed to dispense fuel to exhaust pipe. DSI monitoring during normal operation is achieved through exhaust
temperature feedbacks. DSI leakage is detected by comparing measured post-SBS temperature with a modeled
post-SBS temperature value under enable conditions. If the difference between post-SBS temperature and model
temperature exceeds certain threshold, DSI system detects leakage fault.

DSI Leakage Monitor:

DTCs P2698 - Exhaust Aftertreatment Fuel Injector "A" Performance
Monitor Execution Continuous at Normal Operating Mode (while entry conditions are met)
Monitor Sequence None
Sensors OK Pre-SBS EGT, Post-SBS EGT.
Typical Monitoring Duration 10 seconds

Typical DSI Leakage Monitor Entry Conditions:

Entry Condition Minimum Maximum
Intake Air Mass Flow N/A 400 kg/hour
Engine Speed 0 RPM 2000 RPM
Engine Torque 0 N-m 350 N-m
Post SBS Exhaust Gas Temperature 200 Deg_C N/A
Pre SBS Exhaust Gas Temperature 190 Deg_C 550 Deg_C
Ambient Air Temperature 0 Deg_C N/A
Engine Temperature 10 Deg_C N/A
Ambient Air Pressure 800 hPa N/A
Engine Off Time 6 Hours N/A
Key On
Engine is Running

Typical DSI Leakage Monitor Malfunction Thresholds:

While all entry conditions met, if the difference between post SBS model temperature and actual temperature
exceeds 58 Deg_C for 10 seconds; DSI leakage fault is detected.

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 MISCELLANEOUS ECU MONITORS

Fan Control Checks

Fan Control Circuit Check Operation:

DTCs P0691 – Fan 1 Control Circuit Low
P0692 – Fan 1 Control Circuit High
P0693 – Fan 2 Control Circuit Low
P0694 – Fan 2 Control Circuit High
Monitor Execution Continuous

Monitor Sequence None

Sensors OK None

Typical Monitoring Duration 0.5 sec

Typical Fan Control Circuit Check Malfunction Thresholds:

P0691: The primary electric cooling fan relay detects an open circuit or short to ground
P0692: The primary electric cooling fan relay detects a short to power
P0693: The secondary electric cooling fan relay detects an open circuit or short to ground
P0694: The secondary electric cooling fan relay detects a short to power

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ECU Temperature Sensor Checks

ECU Temperature Sensor Circuit Check Operation:

DTCs P0667 – Control Module Internal Temperature Sensor "A" Range/Performance
P0668 – Control Module Internal Temperature Sensor "A" Circuit Low
P0669 – Control Module Internal Temperature Sensor "A" Circuit High
Monitor Execution Continuous

Monitor Sequence None

Sensors OK None

Typical Monitoring Duration 0.5 sec

Typical ECU Temperature Sensor Circuit Check Entry Conditions:

Entry condition Minimum Maximum
P0667:
Estimated ECU work since initialization 600 J
P0668, P0669 checks after cold soak:
Engine Off Time 6 hours
Engine Coolant Temperature 65 deg C

Typical ECU Temperature Sensor Circuit Check Malfunction Thresholds:

P0667: Observed ECU temperature increase is <1 deg C
P0668: ECU temperature sensor voltage < 0.14V OR fuel temperature > ECU temperature by 20+ degrees C at
key-on
P0669: ECU temperature sensor voltage > 4.98V or ECU temperature > fuel temperature by 20+ degrees C at
key-on

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Vehicle Configuration Information

Vehicle specific information is stored in two locations: within the ECU and within the body control module (BCM).
The following fault codes are immediate malfunction lamp codes (1 drive cycle) and reflect that the vehicle
configuration information has been improperly configured.

Vehicle Configuration
DTCs P0602 - Internal Control Module Keep Alive Memory (KAM) Error
P0610 - Control Module Vehicle Options Error
P0630 - VIN Not Programmed or Incompatible - ECM/PCM
P160A – Control Module Vehicle Options Reconfiguration Error
P1635 – Tire/Axle Out of Acceptable Range
P1639 - Vehicle ID Block Corrupted, Not Programmed
P164F – Fuel Tank Configuration Out of Acceptable Range
P264F - Engine Serial Number Not Programmed or Incompatible

ECU Main Relay

DTCs P0685 - ECM/PCM Power Relay Control Circuit/Open
P068A – ECM/PCM Power Relay De-Energized Too Early
Monitor execution Continuous
Monitor Sequence None
Monitoring Duration 0.5 seconds to register a malfunction.

Transmission Park/Neutral Gear Check at Start-Up

There are two inputs to the ECM for park/neutral gear determination, a hardwired input and a CAN
input. If the hardwired input does not agree with the CAN input when the starter motor is requested
(key in crank position), a DTC is set.

Transmission Park/Neutral Switch Plausibility Check:

DTCs P0850 – Park / Neutral Switch Input Circuit
Monitor execution Continuous
Monitor Sequence None
Monitoring Duration 1 second to register a malfunction.

Motor Slip Control Plausibility Check:

DTCs P1637 – CAN Link ECM/ABS Control Module Circuit/Network
U1012 – Invalid Internal Control Module Monitoring Data Received
from Anti-Lock Brake System (ABS) Control Module
Monitor execution Continuous
Monitor Sequence None
Monitoring Duration 1 second to register a malfunction.

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 COMPREHENSIVE COMPONENT MONITOR - TRANSMISSION

General
The MIL is illuminated for all emissions related electrical component malfunctions. For malfunctions attributable to
a mechanical component (such as a clutch, gear, band, valve, etc.), some transmissions are capable of not
commanding the mechanically failed component and providing the remaining maximum functionality (functionality
is reassessed on each power up)- in such case a non-MIL Diagnostic Trouble Code (DTC) will be stored and, if so
equipped, the Wrench" Light will flash.

Transmission Inputs

Transmission Range Sensor Check Operation:

DTCs P0706 - Out of range signal frequency for PWM TRS
P0707, P0708 - Low /High duty cycle for PWM TRS
Monitor execution Continuous
Monitor Sequence None
Sensors OK
Monitoring Duration 5 seconds of signal out of range

Typical TRS check entry conditions:

Auto Transmission Entry Conditions Minimum Maximum
battery voltage 7v 18v

Typical TRS malfunction thresholds:

PWM TRS: Frequency > 175 Hz or < 75 Hz, Duty Cycle > 90% or < 10%

Output Shaft Speed Sensor Functional Check Operation:

DTCs P0720 – OSS circuit
P0722 – OSS no signal
Monitor execution Continuous
Monitor Sequence None
Sensors OK TSS, Wheel Speed
Monitoring Duration 30 seconds

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Typical OSS functional check entry conditions:
Auto Transmission Entry Conditions Minimum Maximum
Gear selector position drive
Engine rpm (above converter stall speed) OR 3000 rpm
Turbine shaft rpm (if available) OR 1500 rpm
Output shaft rpm 300 - 650 rpm
Vehicle speed (if available) 12.5 - 15 mph

Typical OSS functional check malfunction thresholds:

Circuit/no signal - vehicle is inferred to be moving with positive driving torque and OSS < 100 to 200 rpm for 5
to 30 seconds

Turbine Shaft Speed Sensor Functional Check Operation:

DTCs P0715 – TSS circuit
P0717 – TSS no signal
Monitor execution Continuous
Monitor Sequence None
Sensors OK OSS, Wheel Speed
Monitoring Duration 30 seconds

Typical TSS functional check entry conditions:

Auto Transmission Entry Conditions Minimum Maximum
Gear selector position Forward range
Engine rpm (above converter stall speed) OR 3000 rpm
Output shaft rpm OR 600 - 650 rpm
Vehicle speed (if available) 12.5 - 15 mph

Typical TSS functional check malfunction thresholds:

Circuit/no signal - vehicle is inferred to be moving with positive driving torque and TSS < 200 rpm for 5 – 30
seconds

System voltage:
DTCs P0882 – voltage out of range low
P0883 – voltage out of range high
Monitoring execution electrical - continuous

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Transmission Fluid Temperature Sensor Functional Check Operation:
DTCs (non-MIL) P0712, P0713 or P0710 - Opens/shorts
P1711 – in range failures
P1783 – Transmission over temperature (non-MIL fault, TFT > 275 deg F
for 5 seconds)
Monitor execution continuous
Monitor Sequence none
Sensors OK ECT substituted if TFT has malfunction

Monitoring Duration 5 seconds for electrical, 600 seconds for functional check

Typical TFT Stuck Low/High check entry conditions:

Auto Transmission Entry Conditions Minimum Maximum
Engine Coolant Temp (hot or cold, not midrange) > 100 oF < 20 oF
Time in run mode 500 – 600 sec
Time in gear, vehicle moving, positive torque 150 sec
Vehicle Speed 15 mph
Time with engine off (cold start) OR 420 min
Engine Coolant Temp AND Trans Fluid Temp (inferred cold start) 122 oF

Typical TFT malfunction thresholds:

Opens/shorts: TFT voltage <0.05 or > 4.6 volts for 5 – 12 seconds
TFT Stuck low/high, i.e. TFT stuck at high temperature or stuck at low temperature):
Stores a fault code if TFT stabilizes (stops increasing if temperature < 70 deg F, stops decreasing if temperature
> 225 deg F) before reaching the temperature region where all MIL tests are enabled (70 to 225 deg F). If TFT
remains constant (+/- 2 deg F) for approximately 2.5 minutes of vehicle driving outside the 70 to 225 deg F
zone a P0711 fault code will be stored. Old logic used to indicate a "pass" for a single delta, and not test until
the normal operating region (70-225 deg F) was reached.

CAN:
DTCs U0073 – CAN bus off
U0100 – Lost communication with ECM
Monitoring execution Continuous
Monitoring sequence none

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Transmission Outputs

Transmission Solenoid Power Control (TSPC – provides power to all transmission solenoids:
DTCs P0657 – TSPC1 fault, impacts SSA, SSC, SSE
P2669 – TSPC2 fault, impacts SSB, SSD, TCC and LPC
Monitoring execution electrical - continuous
Monitor sequence Disables individual solenoid circuit fault detection if either above DTC
sets and power is removed from all solenoids (one relay, removes power
from both TSPC1 and TSPC2 wires)

Shift Solenoid Check Operation:

DTCs SS A - Electrical:
P0750 (Open), P0973 (short to ground), P0974 (short to power)
Functional:
P0751 (stuck off), P0752 (stuck on)
SS B - Electrical:
P0755 (Open), P0976 (short to ground), P0977 (short to power)
Functional:
P0756 (stuck off), P0757 (stuck on)
SS C - Electrical:
P0760 (Open), P0979 (short to ground), P0980 (short to power)
Functional:
P0761 (stuck off), P0762 (stuck on)
SS D - Electrical:
P0765 (Open), P0982 (short to ground), P0983 (short to power)
Functional:
P0766 (stuck off), P0767 (stuck on)
SS E - Electrical:
P0770 (Open), P0985 (short to ground), P0986 (short to power)
Functional:
P0771 (stuck off), P0772 (stuck on)
Monitor execution electrical - continuous, functional - continuous
Monitor Sequence None
Sensors OK TRS, TSS and OSS ok for functional diagnostics
Monitoring Duration 0.5 to 5 seconds for electrical checks, 3 clutch failed to apply (stuck off) or release
(stuck on) events for functional check

Typical Shift Solenoid mechanical functional check entry conditions:

Entry Conditions (with turbine speed) Minimum Maximum
Gear ratio calculated each gear
Throttle position positive drive torque

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Typical Shift Solenoid mechanical functional check entry conditions:
Entry Conditions (without turbine speed) Minimum Maximum
Rpm drop is obtained each shift
Throttle position positive drive torque

Typical Shift Solenoid malfunction thresholds:

Electrical circuit check: Output driver feedback indicates an open, short to ground or open circuit for 0.5 – 5.0
seconds

Gear Ratio Check Operation:

DTCs P0731 - incorrect gear 1 ratio
P0732 - incorrect gear 2 ratio
P0733 - incorrect gear 3 ratio
P0734 - incorrect gear 4 ratio
P0735 - incorrect gear 5 ratio
P0729 - incorrect gear 6 ratio
P0736 - incorrect reverse ratio 6
Monitor execution Continuous, in each gear
Monitor Sequence None
Sensors OK TSS, OSS, wheel speed
Monitoring Duration 12 seconds

Typical Forward Gear Ratio check entry conditions:

Entry Conditions Minimum Maximum
Gear selector position forward range,
> 8 seconds
Engine Torque 100 NM
Throttle position 10%
Not shifting > 0.5 seconds
Engine/input Speed 550 rpm
Output Shaft Speed 250 rpm 1350 rpm

Typical Neutral Gear Ratio check entry conditions:

Entry Conditions Minimum Maximum
Gear selector position forward range,
> 1 second
Absolute value of Engine rpm – Turbine rpm 150 rpm
Output Shaft Speed 500 rpm

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Typical Gear Ratio malfunction thresholds:
Forward gear check: > 20% error in commanded ratio for > 12 seconds

Typical Shift Completion check entry conditions:

Entry Conditions Minimum Maximum
Gear selector position forward range
Transmission Fluid Temp 50 oF
Engine/input Speed 1200 rpm
Output Shaft Speed 256 rpm

Typical Shift Completion malfunction thresholds:

Up-shift rpm check: rpm does not drop by > 30 rpm
Down-shift rpm check: rpm does not increase by > 30 rpm
Up-shift rpm check: rpm increases (flares) by > 300 rpm

Torque Converter Clutch Check Operation:

DTCs Electrical:
P0740 (open), P0742 (short to ground), P0744 (short to power)
Functional:
P0741 (stuck off), P2758 (stuck on)
Note: P2758 is non-MIL, all other TCC DTC's are MIL
Monitor execution electrical - continuous,
mechanical - TCC fails to apply 3 times (stuck off) or fails to release 3 times
(stuck on)
Monitor Sequence None
Sensors OK TSS, OSS
Monitoring Duration Electrical – 5 seconds, Functional - 3 lock-up or release events

Typical TCC mechanical functional check stuck off entry conditions:

Entry Conditions Minimum Maximum
Throttle Position steady
Engine Torque positive drive torque
Transmission Fluid Temp 70 oF 225 oF
Commanded TCC pressure (0 rpm slip) 55 psi none
Not shifting

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Typical TCC malfunction thresholds:
Electrical circuit check: Output driver feedback circuit does not match commanded driver state for 0.5 – 5.0
seconds
Mechanical check, stuck off: Slip across torque converter > 100 for 3 seconds after each of 3 lock events
Mechanical check, stuck on: Slip across torque converter < 20 rpm with converter commanded off in at least 3
different gears

Pressure Control Solenoid Check Operation:

DTCs P0960, P0962, P0963 - PC A opens/shorts
P0961 - PC A current range
Monitor execution Continuous
Monitor Sequence none
Sensors OK
Monitoring Duration Electrical: 5 seconds,

Typical Pressure Control Solenoid mechanical functional check entry conditions:

Entry Conditions Minimum Maximum
Gear ratio calculated each gear
Transmission Fluid Temperature 70 oF 225 oF
Throttle Position positive drive torque

Typical Pressure Control Solenoid malfunction thresholds:

Electrical circuit check: Output driver feedback circuit does not match commanded driver state for 0.5 – 5.0
seconds
Electrical current check: Feedback current out of range for 0.5 seconds

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Transmission Control Module (TCM)

TCM
DTCs P0604 – RAM fault present
P0605 – ROM fault present
P0607 – CPU reset fault
P06B8 – NVRAM error
Monitoring execution Once per driving cycle at start-up except reset monitoring which is
continuous
Monitor sequence non

ADLER (chip that controls the transmission solenoids):

DTCs P1636 – lost communication (over internal SPI network) with ADLER
chip
Monitoring execution electrical - continuous
Monitor sequence Transmission enters mechanical limp home (get P, R, N and 5M with
open TCC and max line) if the main micro cannot communicate with the
ADLER chip

Transmission ID (TRID) block (contains solenoid characterization data

DTCs P163E – programming error (checksum fault)
P163F – TRID data not programmed
Monitoring execution Start-up – TRID is a portion of flash memory, either it is present at start-
up or not
Monitor sequence Transmission solenoid data missing, enters limited operating mode (P,
R, N and 3rd gear with open TCC).

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 6R140 (RWD) TRANSMISSION WITH EXTERNAL PCM OR TCM

Transmission Control System Architecture

Starting in 2011 MY 6R140 replaces 5R110W in Super Duty truck applications.

The 6R140 is a 6-speed, step ratio transmission that is controlled by an external PCM (gas engine applications) or
TCM (Diesel engine applications). For Diesel the TCM communicates to the Engine Control Module (ECM), ABS
Module, Instrument Cluster and Transfer Case Control Module using the high speed CAN communication link. The
TCM incorporates a standalone OBD-II system. The TCM independently processes and stores fault codes, freeze
frame, supports industry-standard PIDs as well as J1979 Mode 09 CALID and CVN. The TCM does not directly
illuminate the MIL, but requests the ECM to do so. The TCM is located outside the transmission assembly. It is not
serviceable with the exception of reprogramming.

Transmission Inputs

Transmission Range Sensor

6R140 uses a Non-contacting Pulse Width Modulated Transmission Range Sensor (TRS) that provides a duty cycle
signal for each position. This signal is transmitted at a frequency of 125 Hz. The PCM / TCM decode the duty cycle
to determine the driver-selected gear position (Park, Rev, Neutral, OD, 3, 2, 1). This input device is checked for
frequency out of range (P0706), duty cycle out of range low (P0707) and duty cycle out of range high (P0708)

Speed Sensors

The Turbine Shaft Speed (TSS) sensor and Output Shaft Speed (OSS) sensor are Hall effect sensors.

The Turbine Shaft Speed sensor is monitored by a rationality test, if engine speed and output shaft speed are high
and a gear is engaged, it can be inferred that the vehicle is moving. If there is insufficient output from the TSS sensor
a fault is stored (P0715).

The Output Shaft Speed sensor is monitored by a rationality test. If engine speed and turbine speed are high and a
gear is engaged, it can be inferred that the vehicle is moving. If there is insufficient output from the OSS sensor a
fault is stored (P0720).

Transmission Fluid Temperature

The Transmission Fluid Temperature Sensor is checked for out of range low (P0712), out of range high (P0713),
and in-range failures (P0711). P1783 sets if TFT exceeds 275 deg F for 5 seconds, indicating transmission over
temperature (non-MIL failure).

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Transmission Outputs

Shift Solenoids (SS)

6R140 has 5 shift solenoids:

 SSA – a Variable Force Solenoid (VFS) that controls CB1234 (a brake clutch, grounds an element to the
case, that is on in 1st, 2nd, 3rd and 4th gear)

 SSB – a VFS that controls C35R (a rotating clutch on in 3rd, 5th and Reverse)

 SSC – a VFS that controls CB26 (a brake clutch on in 2nd and 6th gear)

 SSD – a VFS that controls CBLR (a brake clutch on in 1st gear with engine braking and Reverse)

 SSE – a VFS that controls C456 (a rotating clutch on in 4th, 5th and 6th gear)

Output circuits are checked for opens, short to ground and short to power faults (codes listed in that order) by the
"smart driver" (see ADLER below) that controls the solenoids (SSA P0750, P0973, P0974; SSB P0755, P0976,
P0977; SSC P0760, P0979, P0980; SSD P0765, P0982, P0983; SSE P0770, P0985, P0986).

The shift solenoids are also functional tested for stuck on and stuck off failures. This is determined by vehicle inputs
such as gear command, and achieved gear (based on turbine and output speed). In general the shift solenoid
malfunction codes actually cover the entire clutch system (solenoid, valves, seals and the clutch itself since using
ratio there is no way to isolate the solenoid from the rest of the clutch system)

For SSA thru SSE Diagnostics will isolate the fault into clutch functionally (non-electrical) failed off (SSA P0751, SSB
P0756, SSC P0761, SSD P0766. SSE P0771) and clutch functionally failed on (SSA: P0752, SSB: P0757, SSC:
P0762, SSD: P0767, SSE: P0772).

Gear ratio errors:

If ratio errors are detected that do not match an expected pattern for a failed solenoid then gear ratio error fault codes
(1st gear – P0731, 2nd gear – P0732, 3rd gear – P0733, 4th gear – P0734, 5th gear – P0735 or 6th gear – P0729) will
be stored.

Torque Converter Clutch

The Torque Converter Clutch (TCC) solenoid is a Variable Force Solenoid. TCC solenoid circuit is checked
electrically for open, short to ground and short to power circuit faults internally by the "smart driver" that controls the
solenoids (P0740, P0742, P0744).

The TCC solenoid is checked functionally for stuck off faults by evaluating torque converter slip under steady state
conditions when the torque converter is fully applied. If the slip exceeds the malfunction thresholds when the TCC is
commanded on, a TCC malfunction is indicated (P0741).

The TCC solenoid is monitored functionally for stuck on faults (P2758) by monitoring for lack of clutch slip when the
TCC is commanded off, but this code is non-MIL because while a stuck on TCC solenoid may cause driveability
complaints and/or cause engine stalls it does not impact emissions or fuel economy.

Electronic Pressure Control (EPC)

The EPC solenoid is a variable force solenoid that controls line pressure in the transmission. The EPC solenoid is
monitored for open, short to ground or short to power faults by the "smart driver" that controls the solenoid. If a short
to ground (low pressure) is detected, a high side switch will be opened. This switch removes power from all 7 VFSs,
providing Park, Reverse, Neutral, and 5M (in all forward ranges) with maximum line pressure based on manual lever
position. This solenoid is tested for open (P0960), short to ground (P0962), and short to power (P0963) malfunctions.

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Transmission Solenoid Power Control (TSPC)

6F140 PCM or TCM has an internal high side switch called TSPC that can be used to remove power from all 7
solenoids simultaneously. If the high side switch is opened, all 7 solenoids will be electrically off, providing Park,
Reverse, Neutral, and 5M (in all forward ranges) with maximum line pressure based on manual lever position.

Due to current limitations TSPC is split into 2 pins / wires at the PCM / TCM. TSPC A provides power to SSA, SSC
and SSE. TSPC B provides power to SSB, SSD, TCC and LPC. Each wire can be tested independently; P0657 sets
for an issue with TSPC-A, P2669 sets for an issue with TPSC-B.

Although there are 2 pins and wires between the PCM / TCM and the transmission bulkhead connector the PCM /
TCM contains only one TSPC internally – so the FMEM for either wire being failed is to open TSCP inside the PCM
/ TCM, which removes power from all 7 solenoids, providing P, R, N and 5th gear with open TCC and max line as
FMEM for any TPSC faults.

ADLER (chip that controls all 7 solenoids) diagnostics:

The solenoids are controlled by an ADLER chip. The main micro sends commanded solenoid states to the ADLER,
and receives back solenoid circuit fault information.

If communication with the ADLER is lost a P1636 fault code will be stored. If this failure is detected the states of the
solenoids are unknown, so the control system will open the high side switch (removes power from all the solenoids),
providing P, R, N and 5M with open TCC and max line pressure.

TRID Block

The TRID block is a portion of flash memory that contains solenoid characterization data tailored to the specific
transmission to improve pressure accuracy.

The TRID block is monitored for two failures:

 TRID block checksum error / incorrect version of the TRID (P163E)

 TRID block not programmed (P163F)

If the TRID block is unavailable FMEM action limits operation to P, R, N and 3rd gear based on manual lever position
until the issue is correct.

Transmission Control Module (TCM – Diesel only)

The TCM has the same module diagnostics as a PCM:

P0604 - Powertrain Control Module Random Access Memory (RAM) Error indicates the Random Access
Memory read/write test failed.

P0605 - Powertrain Control Module Read Only Memory (ROM) Error indicates a Read Only Memory
check sum test failed.

P0607 - Powertrain Control Module Performance indicates incorrect CPU instruction set operation, or
excessive CPU resets.

P06B8 - Internal Control Module Non-Volatile Random Access Memory (NVRAM) Error indicates
Permanent DTC check sum test failed

FORD MOTOR COMPANY REVISION DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 230 OF 241
.

CAN Communications Error

The TCM receives information from the ECM via the high speed CAN network. If the CAN link or network fails, the
TCM no longer has torque or engine speed information available. The TCM will store a U0073 fault code and will
illuminate the MIL immediately (missing engine speed) if the CAN Bus is off. The TCM will store a U0100 fault code
and will illuminate the MIL immediately (missing engine speed) if it stops receiving CAN messages from the ECM. A
U0401 fault codes will be stored if the ECM sends invalid/faulted information for the following CAN message items:
engine torque, pedal position.

TCM voltage

If the system voltage at the TCM is outside of the specified 9 to 16 volt range, a fault will be stored (P0882, P0883).

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 ON BOARD DIAGNOSTIC EXECUTIVE

The On-Board Diagnostic (OBD) Executive is a portion of the PCM strategy that manages the diagnostic
trouble codes and operating modes for all diagnostic tests. It is the "traffic cop" of the diagnostic system. The
Diagnostic Executive performs the following functions:

 Stores freeze frame and "similar condition" data.

 Manages storage and erasure of Diagnostic Trouble Codes as well as MIL illumination.
 Controls and co-ordinates the execution of the On-Demand tests:
o Key On Engine Off (KOEO)
o Key On Engine Running (KOER)
o Glow Plug Test
o Injector Electrical
o DPF service regeneration
o SCR system test
 Performs transitions between various states of the diagnostic and powertrain control system to
minimize the effects on vehicle operation.
 Interfaces with the diagnostic test tools to provide diagnostic information (I/M readiness, various J1979 test
modes) and responses to special diagnostic requests (J1979 Mode 08 and 09).
 Tracks and manages indication of the driving cycle which includes the time between two key on events
that include an engine start and key off.

The diagnostic executive also controls several overall, global OBD entry conditions.

 The battery voltage must fall between 9.0 and 16.25 volts to initiate monitoring cycles.
 The engine must be started to initiate the engine started, engine running, and engine off monitoring cycles.
 The Diagnostic Executive suspends OBD monitoring when battery voltage falls below 11.0 volts.

The diagnostic executive controls the setting and clearing of pending and confirmed DTCs.
 A pending DTC and freeze frame data is stored after a fault is confirmed on the first monitoring cycle. If the
fault recurs on the next driving cycle, a confirmed DTC is stored, freeze frame data is updated, and the MIL
is illuminated. If confirmed fault free on the next driving cycle, the pending DTC and freeze frame data is
erased on the next power-up.
 Pending DTCs will be displayed as long as the fault is present. Note that OBD-II regulations required a
complete fault-free monitoring cycle to occur before erasing a pending DTC. In practice, this means that a
pending DTC is erased on the next power-up after a fault-free monitoring cycle.
 After a confirmed DTC is stored and the MIL has been illuminated, three consecutive confirmed fault-free
monitoring cycles must occur before the MIL can be extinguished on the next (fourth) power-up. After 40
engine warm-ups, the DTC and freeze frame data is erased.

The diagnostic executive controls the setting and clearing of permanent DTCs.

 A permanent DTC is stored when a confirmed DTC is stored, the MIL has been illuminated, and there are
not yet six permanent DTCs stored.
 After a permanent DTC is stored, three consecutive confirmed fault-free monitoring cycles must occur before
the permanent DTC can be erased.
 After a permanent DTC is stored, one confirmed fault-free monitoring cycle must occur, following a DTC
reset request, before the permanent DTC can be erased. For 2010MY and beyond ISO 14229 programs
a driving cycle including the following criteria must also occur, following the DTC reset request, before a
permanent DTC can be erased:
o Cumulative time since engine start is greater than or equal to 600 seconds;
o Cumulative vehicle operation at or above 25 miles per hour occurs for greater than or equal
to 300 seconds (medium-duty vehicles with diesel engines certified on an engine
dynamometer may use cumulative operation at or above 15% calculated load in lieu of at or
above 25 miles per hour for purposes of this criteria); and
o Continuous vehicle operation at idle (i.e., accelerator pedal released by driver and vehicle speed
less than or equal to one mile per hour) for greater than or equal to 30 seconds.
FORD MOTOR COMPANY REVISION DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 232 OF 241
  A permanent DTC cannot be erased by a KAM clear (battery disconnect). Additionally, its confirmed DTC
counterpart will be restored after completion of the KAM reset (battery reconnect).

EXPONENTIALLY WEIGHTED MOVING AVERAGE

Exponentially Weighted Moving Averaging (EWMA) is a well-documented statistical data processing technique
that is used to reduce the variability on an incoming stream of data. Use of EWMA does not affect the mean of the
data; however, it does affect the distribution of the data. Use of EWMA serves to “filter out” data points that exhibit
excessive and unusual variability and could otherwise erroneously light the MIL.

The simplified mathematical equation for EWMA implemented in software is as follows:

New Average = [New data point * “filter constant”] + [( 1 - “filter constant” ) * Old Average]

This equation produces an exponential response to a step-change in the input data. The "Filter Constant"
determines the time constant of the response. A large filter constant (i.e. 0.90) means that 90% of the new data
point is averaged in with 10% of the old average. This produces a very fast response to a step change. Conversely,
a small filter constant (i.e. 0.10) means that only 10% of the new data point is averaged in with 90% of the old
average. This produces a slower response to a step change.

When EWMA is applied to a monitor, the new data point is the result from the latest monitor evaluation. A new
average is calculated each time the monitor is evaluated and stored in Keep Alive Memory (KAM). This normally
occurs each driving cycle. The MIL is illuminated and a DTC is stored based on the New Average store in KAM.

In order to facilitate repair verification and DDV demonstration, 2 different filter constants are used. A “fast filter
constant” is used after KAM is cleared or DTCs are erased and a “normal filter constant” is used for normal customer
driving. The “fast filter” is used for 5 driving cycles after KAM is cleared/DTCs are erased, and then the “normal
filter” is used. The “fast filter” allows for easy repair verification and monitor demonstration in 2 driving cycles, while
the normal filter is used to allow up to 6 driving cycles, on average, to properly identify a malfunction and illuminate
the MIL. This feature is called Fast Initial Response (FIR). The fast filter is always calibrated to 0.99 which means
that the EWMA is effectively disabled because the new average is 99% of the new data point. Since the EWMA is
effectively disabled, it takes two driving cycles to set the MIL. The first driving cycle with a fault will set a pending
DTC; the second driving cycle will set a confirmed code and illuminate the MIL.

The other unique feature used with EWMA is called Step Change Logic (SCL). This logic detects an abrupt change
from a no-fault condition to a fault condition. This is done by comparing the new data point to the EWMA old
average. If the two points differ by more than a calibrated amount (i.e. the new data point is outside the normal
distribution), it means that a catastrophic failure has occurred. The fast filter is then used in the same manner as
for the FIR feature above. Since the EWMA is effectively disabled, it takes two driving cycles to set the MIL. The
first driving cycle with a fault will set a pending DTC; the second driving cycle will set a confirmed code and illuminate
the MIL. The SCL becomes active after the 4th "normal" monitoring cycle to give the EWMA a chance to stabilize.

During "normal" EWMA operation, a slower filter constant is used. The "normal filer" allows the MIL to be illuminated
in 1 to 6 driving cycles. A confirmed code is set and the MIL is illuminated as soon as the EWMA crosses the
malfunction threshold. There is no pending DTC because EWMA uses a 1-trip MIL.

In order to relate filter constants to driving cycles for MIL illumination, filter constants must be converted to time
constants. The mathematical relationship is described below:

Time constant = [ ( 1 / filter constant ) - 1 ] * evaluation period

The evaluation period is a driving cycle. The time constant is the time it takes to achieve 68% of a step-change to
an input. Two time constants achieve 95% of a step change input.

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SERIAL DATA LINK MIL ILLUMINATION

The OBD-II diagnostic communication messages utilize an industry standard 500 kbps CAN communication link.

The instrument cluster on some vehicles uses the same CAN data link to receive and display various types of
information from the PCM. For example, the engine coolant temperature information displayed on the instrument
cluster comes from the same ECT sensor used by the PCM for all its internal calculations.

These same vehicles use the CAN data link to illuminate the MIL rather than a circuit, hard-wired to the PCM. The
PCM periodically sends the instrument cluster a message that tells it to turn on the MIL, turn off the MIL or blink the
MIL. If the instrument cluster fails to receive a message within a 5-second timeout period, the instrument cluster
itself illuminates the MIL. If communication is restored, the instrument cluster turns off the MIL after 5 seconds. Due
to its limited capabilities, the instrument cluster does not generate or store Diagnostic Trouble Codes.

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 CALCULATED LOAD VALUE

LOAD_PCT (PID $04) = Current Calculated Torque

Maximum Engine Torque at conditions

Where:

 Current Calculation of torque is derived from the injected quantity of torque producing fuel and engine speed.
 Maximum Engine Torque is derived from the maximum curve.

I/M READINESS

The readiness function is implemented based on the SAE J1979/ISO 15031-5 format. Clearing codes using a scan
tool results in the various I/M readiness bits being set to a “not-ready” condition. As each non-continuous monitor
completes a full diagnostic check, the I/M readiness bit associated with that monitor is set to a “ready” condition.
This may take one or two driving cycles based on whether malfunctions are detected or not. The readiness bit for
comprehensive component monitoring is immediately considered complete since they are continuous monitors.
The table below shows which monitors must complete for I/M readiness for MY2019 6.7L.

I/M Readiness bit Controlling Monitor

Boost Pressure P0299 P026A P132B P259F

CCM Always Ready

EGR P0401 P0402 P2457

Exhaust Gas Sensors P2201 P229F P0139 P2A01 P24AE

P0263 P0269 P0281 P0266 P0278 P0275 P0272

Fuel System
P0284 P0170 P0087 P0088

HC Catalyst P0420

P0301 P0303 P0307 P0302 P0306 P0305 P0304

Misfire
P0308 P0300

NOx Catalyst P20EE

PM Catalyst P244A P2002 P2459

FORD MOTOR COMPANY REVISION DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 235 OF 241
Power Take Off Mode

A Power Take-Off (PTO) unit refers to an engine driven output provision for the purposes of powering auxiliary
equipment (e.g., a dump-truck bed, aerial bucket, or tow-truck winch). The OBD-II regulations have historically
accommodated PTO by requiring the software to set all I/M readiness bits to "not complete" when PTO was
engaged and reset them to their previous state when PTO was disengaged.

The 2015 MY OBD-II regulations have changed the requirement for PTO mode. This is in reaction industry request
to accommodate PTO while the vehicle is stationary (stationary PTO) or while the vehicle is moving (mobile PTO).
In mobile PTO, some OBD monitors may not run or may run at reduced frequency. The changes to the OBD-II
regulations accommodate vehicles being I/M tested while PTO is engaged.

For the 2015 MY, the OBD II system is required to track the cumulative engine runtime with PTO active and set all
the OBD II I/M readiness bits to “not complete” if 750 minutes of cumulative engine runtime with PTO active has
occurred and all OBD monitors have not yet completed. The PTO timer pauses whenever PTO changes from
active to not active and resumes counting when PTO is re-activated. The PTO timer is reset to zero after all the
affected monitors have completed. If an OBD monitor is completely disabled by PTO mode, the affected IUMPR
numerator and denominator must also be disabled.

This new requirement provides a 750 minute allowance to run all OBD monitors before all the I/M readiness bits
are set to “not complete” in order to better accommodate vehicles that have monitors that run with reduced
frequency in PTO mode or have monitors that don’t run at all.

FORD MOTOR COMPANY REVISION DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 236 OF 241
IN-USE MONITOR PERFORMANCE RATIO / MODE $09 RESULTS

Manufacturers are required to implement software algorithms that track in-use performance for each of the following
components: NMHC catalyst, NOx catalyst monitor, NOx adsorber monitor, PM filter monitor, exhaust gas sensor
monitor, EGR/ VVT monitor, boost pressure monitor, and fuel system monitor. The numerator for each component
or system tracks the number of times that all conditions necessary for a specific monitor to detect a malfunction
have been encountered. The denominator for each component or system tracks the number of times that the
vehicle has been operated in the specified conditions.

Ignition Cycle Counter

Ignition cycle counter will increment after engine start >= 2 second

“Engine start” is defined as the point when the engine reaches a speed 150 rpm below the normal, warmed-up idle
speed (as determined in the drive position for vehicles equipped with an automatic transmission).

General Denominator Counter

General Denominator counter will increment if all the following conditions are met:

 Ambient Temperature >= -7 deg C (20 deg F)

 Barometric pressure >= 752 hPA (8,000 ft altitude)
 Time since engine start (or propulsion system active for hybrid) => 600 s
 If LD, Time with vehicle speed greater or equal to than 40 kph (25 mph) >= 300 s.
 If HD, Time with engine speed greater or equal to 1150 rpm >= 300 s.
 Continuous vehicle operation at idle time (i.e., accelerator pedal released with vehicle speed <= 1.6 kph
(1 mph)) >= 30 s
The table below shows which monitors must complete to increment each IUMPR numerator for MY2019 6.7L.

Monitor Group Monitor Fault Code(s)

NMHC Converting Catalyst

Monitoring P0420
NOx Converting Catalyst Monitoring P20EE
PM Filter Monitoring P2002
Exhaust Gas Sensor Monitoring
P2A01

P229F

P24AE

P2201
EGR System Monitoring
P0402

P2457
Boost Pressure Control System
P132B
Monitoring
P026A

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 Fuel System Monitoring
P0170

P0263
P0269
P0281
P0266
P0278
P0275
P0272
P0284

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MODE $06 RESULTS

OBD Test Data for MY2019 6.7L:

Test
Monitor ID
ID
Monitor ID Name TID Description Monitor
(MID) (TID)

Exhaust Gas Sensor

Monitor Bank 1 – Sensor 1 9A NOxPerform Low P2201
1
90 30% O2 rise P0139

91 30-60% O2 rise P0139

92 60% O2 rise P0139

94 O2 Conc Partial P2A01

Exhaust Gas Sensor
Monitor Bank 1 – Sensor 2 95 O2 Conc Coast P2A01
2
97 NOx Conc Error P229F
98 NOx Neg Adp Err P229F
99 NOx Pos Adp Err P229F
9C PM Sens IDE Cur P24AE
9D PM Sens ProTube P24DA
Catalyst Monitor Bank 1 21 90 DOC ExEff Regen P0420
90 EGR Low Flow P0401
91 EGR High Flow P0402
EGR Monitor Bank 1 31
92 EGR Over Temp P2457

99 OverallFuelTrim P0170
Cylinder #1 Fuel Balance Learned
A1 P0263
Limit
Cylinder #2 Fuel Balance Learned
A2 P0269
Limit
Cylinder #3 Fuel Balance Learned
A3 P0281
Fuel System Monitor Limit
81 Cylinder #4 Fuel Balance Learned
Bank 1 A4 P0266
Limit
9A FP Dev Positive P0088
9B FP Dev Negative P0087
9C FP Low Dev Lim P0088
9D FP High Dev Lim P0087
Fuel System Monitor Cylinder #5 Fuel Balance Learned
82 A5 P0278
Bank 2 Limit

FORD MOTOR COMPANY REVISION DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 239 OF 241
 Cylinder #6 Fuel Balance Learned
A6 P0275
Limit
Cylinder #7 Fuel Balance Learned
A7 P0272
Limit
Cylinder #8 Fuel Balance Learned
A8 P0284
Limit
92 Over Boost Cond P259F
Boost Pressure Control 96 CAC Temp Error P026A
85
Monitor Bank 1 97 TurboUnderboost P0299
90 Intrusive Boost P132B
NOx/SCR Catalyst
98 90 NOx Cat Con Eff P20EE
Monitor Bank 1

0B 10-trip RollAvg P0301

Misfire Cylinder 1 Data A2
0C Cur OBD Counts P0301

0B 10-trip RollAvg P0302

Misfire Cylinder 2 Data A3
0C Cur OBD Counts P0302

0B 10-trip RollAvg P0303

Misfire Cylinder 3 Data A4
0C Cur OBD Counts P0303

0B 10-trip RollAvg P0304

Misfire Cylinder 4 Data A5
0C Cur OBD Counts P0304
0B 10-trip RollAvg P0305
Misfire Cylinder 5 Data A6
0C Cur OBD Counts P0305
0B 10-trip RollAvg P0306
Misfire Cylinder 6 Data A7
0C Cur OBD Counts P0306
0B 10-trip RollAvg P0307
Misfire Cylinder 7 Data A8
0C Cur OBD Counts P0307
0B 10-trip RollAvg P0308
Misfire Cylinder 8 Data A9
0C Cur OBD Counts P0308
90 % Min Exp Press P244A
PM Filter Monitor Bank 91 Regen Frequency P2459
B2
1 92 RegenIncomplete P24A2
94 PartFilterEffic P2002

FORD MOTOR COMPANY REVISION DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 240 OF 241
REVISIONS

REVISION ID ITEMS MODIFIED

19.00.00.00 Original MY2019 Document

FORD MOTOR COMPANY REVISION DATE: DECEMBER 3, 2018 19.00.00.00-PAGE 241 OF 241