Published: 21-Jul-2015

Exhaust System - INGENIUM I4 2.0L Diesel - Exhaust System

Description and Operation

COMPONENT LOCATION - SHEET 1 OF 2 - VEHICLES WITHOUT SELECTIVE CATALYST REDUCTION

(SCR) SYSTEM

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Item Description
A Vehicles with 5 seats
B Vehicles with 7 seats
1 Catalytic converter
2 Flexible coupling
3 Diesel Particulate Filter (DPF)
4 Mounting rubber
5 Rear silencer
6 Outlet pipe
7 Clamp

COMPONENT LOCATION - SHEET 2 OF 2 - VEHICLES WITH SELECTIVE CATALYST REDUCTION (SCR)

SYSTEM
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Item Description
A Vehicles with 5 seats
B Vehicles with 7 seats
1 Catalytic converter
2 Flexible coupling
3 Diesel Particulate Filter (DPF) and Selective Catalyst Reduction (SCR) catalytic converter assembly
4 Mounting rubber
5 Rear silencer
6 Outlet pipe
7 Clamp

OVERVIEW

The exhaust system is manufactured from stainless steel and is attached to the underside of the vehicle body with rubber
mountings which are located on hanger bars that are welded to the exhaust system. The rubber mountings locate on adjacent
hanger brackets which are bolted or welded to the underside of the vehicle body and the subframes.

The exhaust system comprises three separate sections:

A front section, including a catalytic converter.

A center section,
- incorporating the Diesel Particulate Filter (DPF) and a connecting pipe to the Low Pressure (LP) Exhaust Gas
Recirculation (EGR) valve on EU5 market vehicles.For additional information, refer to: Diesel Particulate Filter
(309-00C, Description and Operation).
- incorporating the Diesel Particulate Filter (DPF), the Selective Catalyst Reduction (SCR) catalytic converter and a
connecting pipe to the Low Pressure (LP) Exhaust Gas Recirculation (EGR) valve on EU6 market vehicles.For
additional information, refer to: Selective Catalyst Reduction (SCR) (309-00C, Description and Operation).
A rear section,
- comprising a single rear silencer with two outlet pipes on vehicles with 5 seats.
- comprising two rear silencers on vehicles with 7 seats.

DESCRIPTION

Front Section

The front section has an inlet flange which mates with the turbocharger outlet. The flange is sealed with a stainless metallic
gasket to the turbocharger and secured with a vee clamp onto the turbocharger housing.
An elbow from the flange is connected to the catalytic converter. The elbow contains a threaded boss for the installation of the
Heated Oxygen Sensor (HO2S).

A support bracket with a stud is welded to the elbow. A mounting bracket is secured to the front section with a nut. The
mounting bracket is connected to the top of the engine with three bolts, which secures the top of the front section to the
engine. A band clamp is attached to the catalytic converter with a bolt to hold the front section in its position.

The catalytic converter is connected to a flange which mates with the flexible coupling of the center section.

Center Section - Vehicles Without Selective Catalyst Reduction (SCR) system

The center section is connected to the front section by a flange. It is sealed with a metal gasket and secured with three studs
and nuts. The flange is connected to a flexible coupling with a pipe. The pipe comprises a threaded boss for the post-catalyst
exhaust gas temperature sensor. A curved pipe from the flexible coupling is connected to the Diesel Particulate Filter (DPF). A
threaded boss is welded to the pipe and provides the connection of the differential pressure sensor high pressure pipe. A
welded hanger bar with a rubber mounting is connected to a common bracket which in turn bolted to the front subframe, to
support the center section.

The DPF outlet pipe comprises threaded bosses for the post-DPF exhaust gas temperature sensor and the differential pressure
sensor low pressure pipe. An additional pipe is welded to the outlet pipe, which routes the exhaust gases from the outlet pipe
to the Low Pressure (LP) Exhaust Gas Recirculation (EGR) valve. A welded hanger bar with a rubber mounting is connected to
a common bracket which in turn bolted to the underside of the vehicle body, to support the center section.For additional
information, refer to: (309-00C)

Diesel Particulate Filter (Description and Operation),

Diesel Particulate Filter (Description and Operation).
Center Section - Vehicles With Selective Catalyst Reduction (SCR) system

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The center section is connected to the front section by a flange. It is sealed with a metal gasket and secured with three studs
and nuts. The flange is connected to a flexible coupling with a pipe. The pipe comprises a threaded boss for the post-catalyst
exhaust gas temperature sensor. A curved pipe from the flexible coupling is connected to the DPF and Selective Catalyst
Reduction (SCR) catalytic converter assembly. A threaded boss is welded to the pipe and provides the connection of the
differential pressure sensor high pressure pipe. A welded boss provides the attachment of the Diesel Exhaust Fluid (DEF)
injector. A mixer plate is located in the exhaust pipe downstream of the DEF injector. A welded hanger bar with a rubber
mounting is connected to a common bracket which in turn bolted to the front subframe, to support the center section.

The SCR outlet pipe comprises threaded bosses for the post-DPF exhaust gas temperature sensor, the differential pressure
sensor low pressure pipe and the post-SCR nitrogen oxide (NOx) sensor. An additional pipe is welded to the outlet pipe, which
routes the exhaust gases from the outlet pipe to the Low Pressure (LP) Exhaust Gas Recirculation (EGR) valve. A welded
hanger bar with a rubber mounting is connected to a common bracket which in turn bolted to the underside of the vehicle
body, to support the center section.For additional information, refer to: Selective Catalyst Reduction (SCR) (309-00C,
Description and Operation).

Rear Section - Vehicles With 5 Seats

If the vehicle is equipped with 5 seats, the exhaust system rear section comprises a single rear silencer. The rear section is
connected to the center section with a clamp. The rear silencer is connected by a pipe to the center section and secured with a
clamp.

The rear section inlet pipe comprises a flexible coupling and a welded hanger bar. A hanger bar is attached to the hanger
bracket with a rubber mounting. The hanger bracket is bolted to the underside of the vehicle body.

The rear section inlet pipe is routed in a central position under the vehicle, with a slight deviation around the Rear Drive Unit
(RDU), where it joins with the rear silencer. The rear silencer is supported by three rubber mountings. Two are attached to a
hanger bracket bolted to the left side of the rear subframe and the third is attached to a hanger bracket on the right side of
the rear subframe. The rear silencer has an outlet pipe at each end. Each outlet pipe is fitted with a stainless steel finisher.

Rear Section - Vehicles With 7 Seats

If the vehicle is equipped with 7 seats, the exhaust system rear section comprises two rear silencers. The rear section is
connected to the center section with a clamp. The rear silencers are connected by two individual pipes to a 'Y' piece which the
center section and secured with a clamp.

The rear section comprises a flexible coupling which is connected to the center section with a clamp. The flexible coupling
outlet pipe is separated into two outlet pipes and a hanger bar and an exhaust brace are welded to the pipes to retain the
system in position and reduce exhaust flexing. A hanger bar is attached to the hanger bracket with a rubber mounting. The
hanger bracket is bolted to the underside of the vehicle body. The left rear silencer inlet pipe is connected to the rear section
with a clamp. Inlet pipes to each rear silencer are routed with a slight deviation to each side of the RDU. Both inlet pipes have
a welded hanger bar where it connects to the appropriate rear silencer. Rubber mountings and hanger brackets are attached
to the hanger bars. The hanger brackets are bolted to the rear subframe on both side. Each rear silencer is connected to the
rear armature via a welded hanger bar and rubber mounting. Each rear silencer has an outlet pipe at each end. Each pipe is
fitted with a stainless steel finisher.

SYSTEM OPERATION

Catalytic Converter
The oxidizing catalytic converter is fitted in the front section of the exhaust system, after the Heated Oxygen Sensor (HO2S).
The catalytic converter assembly is common to vehicles with or without the DPF, however, the catalyst coating specification
varies depending on the market. The HO2S monitors the exhaust gases leaving the engine. The engine management system
uses this information to provide accurately metered quantities of fuel to the combustion chambers to ensure the most efficient
use of fuel and to minimise the exhaust emissions.For additional information, refer to: Electronic Engine Controls (303-14C,
Description and Operation).

The catalytic converter further reduces the carbon monoxide and hydrocarbons content of the exhaust gases. In the catalytic
converter the exhaust gases are passed through honeycombed ceramic elements coated with a special surface treatment
called a 'washcoat'. The washcoat increases the surface area of the ceramic elements by a factor of approximately 7000. On
top of the washcoat is a coating containing platinum, which is the active constituent for converting harmful emissions into
inert by-products. The platinum adds oxygen to the carbon monoxide and the hydrocarbons in the exhaust gases, to convert
them into carbon dioxide and water respectively.

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Published: 09-Sep-2016
Exhaust System - INGENIUM I4 2.0L Diesel - Diesel Particulate Filter
Diagnosis and Testing

Principle of Operation

For a detailed description of the exhaust system, refer to the relevant Description and Operation section of the workshop
manual.
REFER to: Diesel Particulate Filter (309-00B Exhaust System - INGENIUM I4 2.0L Diesel, Description and Operation).

Inspection and Verification

CAUTION: Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules does not
guarantee confirmation of a fault, and may also cause additional faults in the vehicle being tested and/or the donor vehicle.

NOTES:

If a control module or a component is suspect and the vehicle remains under manufacturer warranty, refer to the
Warranty Policy and Procedures manual, or determine if any prior approval programme is in operation, prior to the installation
of a new module/component.

Generic scan tools may not read the codes listed, or may read only 5-digit codes. Match the 5 digits from the scan tool
to the first 5 digits of the 7-digit code listed to identify the fault (the last 2 digits give extra information read by the

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manufacturer-approved diagnostic system).

When performing voltage or resistance tests, always use a digital multimeter accurate to three decimal places, and with
an up-to-date calibration certificate. When testing resistance always take the resistance of the digital multimeter leads into
account.

Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.

Inspect connectors for signs of water ingress, and pins for damage and/or corrosion.

If DTCs are recorded and, after performing the pinpoint tests, a fault is not present, an intermittent concern may be the
cause. Always check for loose connections and corroded terminals.

Check DDW for open campaigns. Refer to the corresponding bulletins and SSMs which may be valid for the specific
customer complaint and carry out the recommendations as required.

1. Verify the customer concern

2. Visually inspect for obvious signs of mechanical or electrical damage

Visual Inspection
Mechanical Electrical

Diesel particulate filter

Differential pressure sensor hoses
Differential pressure sensor
Differential pressure sensor metal pipes and unions
Differential pressure sensor connector
Differential pressure sensor mounting position integrity
Differential pressure sensor wiring harness
Metal fatigue
Electrical connector(s)
Joints
Sensor(s)
Mountings
Engine Control Module (ECM)
Clearance around components
Damaged diesel particulate filter

3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding
to the next step

4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart, alternatively check for
DTCs and refer to the DTC Index

Symptom Chart

Symptom Possible Causes Action

 Blocked
regeneration
Amber warning Customer If DTC is P246B-00 or AMBER DPF FULL REFER TO HANDBOOK message is
message on driving routine displayed with no other reported messages. No repair is required, if the vehicle
instrument cluster - does not allow is driven on a highway AS DIRECTED IN THE HANDBOOK then the light will be
DPF FULL REFER TO the system to extinguished and the system self healed, nothing more than this is required
HANDBOOK - clean the
particulate
filter

Air intake
system fault
Restricted
exhaust
system
Low fuel
pressure
Check the air intake system. Check for a blocked catalytic converter or muffler,
Exhaust Gas
Lack of power install new components as necessary. Check the fuel pressure. For EGR and
Recirculation
turbocharger tests, refer to the relevant section of the workshop manual
(EGR) valve(s)
fault
Turbocharger
fault
Diesel
Particulate
filter fault

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DTC Index

NOTES:

If the control module or a component is suspect and the vehicle remains under manufacturer warranty, refer to the
Warranty Policy and Procedures manual (section B1.2), or determine if any prior approval programme is in operation, prior to
the installation of a new module/component

Generic scan tools may not read the codes listed, or may read only 5-digit codes. Match the 5 digits from the scan tool
to the first 5 digits of the 7-digit code listed to identify the fault (the last 2 digits give extra information read by the
manufacturer approved diagnostic system)

Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests

Inspect connectors for signs of water ingress, and pins for damage and/or corrosion

If DTCs are recorded and, after performing the pinpoint tests, a fault is not present, an intermittent concern may be the
cause. Always check for loose connections and corroded terminals

DTC Description Possible Cause Action

Front heated Refer to the electrical circuit diagrams and check front
oxygen sensor heated oxygen sensor heater control circuit for short circuit
HO2S Heater Control heater control to ground
Circuit (Bank 1, circuit short Check and install a new front heated oxygen sensor as
P0031-11
Sensor 1) - Circuit circuit to ground required. Refer to the warranty policy and procedures
short to ground Front heated manual, or determine if any prior approval programme is
oxygen sensor in operation, prior to the installation of a new
failure module/component

Front heated Refer to the electrical circuit diagrams and check front
oxygen sensor heated oxygen sensor heater control circuit for short circuit
HO2S Heater Control heater control to power
Circuit (Bank 1, circuit short Check and install a new front heated oxygen sensor as
P0032-12
Sensor 1) - Circuit circuit to power required. Refer to the warranty policy and procedures
short to battery Front heated manual, or determine if any prior approval programme is
oxygen sensor in operation, prior to the installation of a new
failure module/component
 Front heated Refer to the electrical circuit diagrams and check the front
oxygen sensor heated oxygen sensor heater control circuit for high
HO2S Heater Control heater control resistance, open circuit
Circuit (Bank 1, circuit high Check and install a new front heated oxygen sensor as
P0030-29 Sensor 1) - Signal
resistance, open required. Refer to the warranty policy and procedures
Invalid circuit manual, or determine if any prior approval programme is
Front heated in operation, prior to the installation of a new
oxygen sensor module/component
failure

Exhaust system
Refer to the relevant section of the workshop manual and
leak
check for and rectify any exhaust leak between cylinder
Fuel control
head and catalytic converter. Check front heated oxygen
system fault
sensor is correctly installed in exhaust manifold
Front heated
Check fuel control system for related DTCs and refer to the
oxygen sensor
O2 Sensor Circuit Low relevant DTC index
circuit short
Voltage Bank 1 Refer to the electrical circuit diagrams and check the front
P0135-29 circuit to ground,
Sensor 1 - Signal heated oxygen sensor circuit for short circuit to ground,
short circuit to
Invalid short circuit to power, open circuit, high resistance
power, open
Check and install a new front heated oxygen sensor as
circuit, high
required. Refer to the warranty policy and procedures
resistance
manual, or determine if any prior approval programme is
Front heated
in operation, prior to the installation of a new
oxygen sensor
module/component
failure

Exhaust system Check for and rectify any exhaust leak between cylinder

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leak head and catalytic converter. Check front heated oxygen
Fuel control sensor is correctly installed in exhaust manifold
system fault Check fuel control system for related DTCs and refer to the
Front heated relevant DTC index
O2 Sensor Circuit Low
oxygen sensor to Refer to the electrical circuit diagrams and check front
Voltage (Bank 1
P0131-11 engine control heated oxygen sensor to engine control module wiring
Sensor 1) - Circuit
module wiring shield for high resistance
Short To Ground
shield high Check and install a new front heated oxygen sensor as
resistance required. Refer to the warranty policy and procedures
Front heated manual, or determine if any prior approval programme is
oxygen sensor in operation, prior to the installation of a new
failure module/component

Exhaust system
leak
Fuel control
Check for and rectify any exhaust leak between cylinder
system fault
head and catalytic converter
Front heated
Check front heated oxygen sensor is correctly installed in
oxygen sensor to
exhaust manifold
engine control
Check fuel control system for related DTCs and refer to the
module wiring
O2 Sensor Circuit relevant DTC index
shield high
High Voltage (Bank 1 Refer to the electrical circuit diagrams and check front
P0132-12 resistance
Sensor 1) - Circuit heated oxygen sensor to engine control module wiring
Front heated
Short To Battery shield for high resistance
oxygen sensor
Check and install a new front heated oxygen sensor as
failure
required. Refer to the warranty policy and procedures
Fuel control
manual, or determine if any prior approval programme is
system over
in operation, prior to the installation of a new
fuelling
module/component
Front heated
oxygen sensor
failure

Exhaust gas
Refer to the electrical circuit diagrams and check
temperature
connections are secure, exhaust gas temperature sensor
Exhaust Gas sensor circuit,
circuit, for short circuit to power, short circuit to ground,
Temperature Sensor short circuit to
open circuit
Circuit - Bank 1 power, short
P0544-22 Check and install a new exhaust gas temperature sensor as
Sensor 1 - Signal circuit to ground,
required. Refer to the warranty policy and procedures
Amplitude > open circuit
manual, or determine if any prior approval programme is
Maximum Exhaust gas
in operation, prior to the installation of a new
temperature
module/component
sensor failure
 Exhaust gas Refer to the electrical circuit diagrams and check
Exhaust Gas temperature connections are secure, exhaust gas temperature sensor
Temperature Sensor sensor circuit, circuit, for short circuit to power, short circuit to ground,
Circuit Low - Bank 1 short circuit to open circuit
P0545-16 Sensor 1 - Circuit power, short Check and install a new exhaust gas temperature sensor as
Voltage Below circuit to ground, required. Refer to the warranty policy and procedures
Threshold open circuit manual, or determine if any prior approval programme is
Exhaust gas in operation, prior to the installation of a new
temperature module/component
sensor failure

Exhaust gas Refer to the electrical circuit diagrams and check

Exhaust Gas temperature connections are secure, exhaust gas temperature sensor
Temperature Sensor sensor circuit, circuit, for short circuit to power
Circuit High - Bank 1 short circuit to Check and install a new exhaust gas temperature sensor as
P0546-17
Sensor 1 - Circuit power required. Refer to the warranty policy and procedures
Voltage Above Exhaust gas manual, or determine if any prior approval programme is
Threshold temperature in operation, prior to the installation of a new
sensor failure module/component

Fuel control Refer to the electrical circuit diagrams and check front
system fault heated oxygen sensor circuit for short circuit to power,
Front Heated short circuit to ground, open circuit
Internal Control
Oxygen sensor to Check front heated oxygen sensor harness for signs of
Module O2 Sensor
engine control damage caused by chaffing or heat
Processor
P064D-00 module wiring Check front heated oxygen sensor for damage
Performance Bank 1 -
shield high Check and install a new front heated oxygen sensor as

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No sub type
resistance required. Refer to the warranty policy and procedures
information
Front Heated manual, or determine if any prior approval programme is
Oxygen sensor in operation, prior to the installation of a new
failure module/component

Pre-catalyst
temperature
sensor
Check the pre-catalyst temperature sensor for
contaminated
contamination
Pre-catalyst
Refer to the electrical circuit diagrams and check the
Exhaust Gas temperature
pre-catalyst temperature sensor circuits for short circuit to
Temperature Sensor sensor circuit
power, short circuit to ground, open circuit, high resistance
P2031-22 Circuit Bank 1 Sensor short circuit to
Check and install a new pre-catalyst temperature sensor as
2 - Signal Amplitude power, short
required. Refer to the warranty policy and procedures
> Maximum circuit to ground,
manual, or determine if any prior approval programme is
open circuit, high
in operation, prior to the installation of a new
resistance
module/component
Pre-catalyst
temperature
sensor failure

Pre-catalyst
temperature Check the pre-catalyst temperature sensor for
sensor contamination
Exhaust Gas contaminated Refer to the electrical circuit diagrams and check the
Temperature Sensor Pre-catalyst pre-catalyst temperature sensor circuits for short circuit to
Circuit Low Bank 1 temperature ground
P2032-16
Sensor 2 - Circuit sensor circuit Check and install a new pre-catalyst temperature sensor as
Voltage Below short circuit to required. Refer to the warranty policy and procedures
Threshold ground manual, or determine if any prior approval programme is
Pre-catalyst in operation, prior to the installation of a new
temperature module/component
sensor failure

Pre-catalyst
temperature
sensor Check the pre-catalyst temperature sensor for
contaminated contamination
Exhaust Gas Pre-catalyst Refer to the electrical circuit diagrams and check the
Temperature Sensor temperature pre-catalyst temperature sensor circuits for short circuit to
Circuit High Bank 1 sensor circuit power
P2033-17 short circuit to
Sensor 2 - Circuit Check and install a new pre-catalyst temperature sensor as
Voltage Above power required. Refer to the warranty policy and procedures
Threshold
 Pre-catalyst manual, or determine if any prior approval programme is
temperature in operation, prior to the installation of a new
sensor failure module/component

Exhaust Gas
temperature
sensor
Check the Exhaust Gas temperature sensor for
contaminated
contamination
Exhaust Gas Exhaust Gas
Refer to the electrical circuit diagrams and check the
Temperature Sensor temperature
exhaust gas temperature sensor circuits for short circuit to
Circuit sensor circuit
power, short circuit to ground, open circuit, high resistance
P2080-62 Range/Performance short circuit to
Check and install a new exhaust gas temperature sensor as
Bank 1 Sensor 1 - power, short
required. Refer to the warranty policy and procedures
Signal Compare circuit to ground,
manual, or determine if any prior approval programme is
Failure open circuit, high
in operation, prior to the installation of a new
resistance
module/component
Exhaust Gas
temperature
sensor failure

Exhaust gas
Refer to the electrical circuit diagrams and check
temperature
Exhaust Gas connections are secure, exhaust gas temperature sensor
sensor circuit,
Temperature Sensor circuit, for short circuit to power, short circuit to ground,
short circuit to
Circuit open circuit
power, short
P2080-64 Range/Performance - Check and install a new exhaust gas temperature sensor as
circuit to ground,
Bank 1 Sensor 1 - required. Refer to the warranty policy and procedures
open circuit

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Signal plausibility manual, or determine if any prior approval programme is
Exhaust gas
failure in operation, prior to the installation of a new
temperature
module/component
sensor failure

Pre-catalyst
temperature
Exhaust Gas Refer to the electrical circuit diagrams and check
sensor circuit
Temperature Sensor connections are secure and wiring integrity
short circuit to
Circuit Check and install a new pre-catalyst temperature sensor as
power, short
P2084-62 Range/Performance required. Refer to the warranty policy and procedures
circuit to ground,
Bank 1 Sensor 2 - manual, or determine if any prior approval programme is
open circuit
Signal Compare in operation, prior to the installation of a new
Pre-catalyst
Failure module/component
temperature
sensor failure

Front heated Refer to the electrical circuit diagrams and check the front
oxygen sensor heated oxygen sensor circuit for open circuit, high
O2 Sensor Negative
circuit open resistance
Current Control
circuit, high Check and install a new front heated oxygen sensor as
P2251-13 Circuit / Open - Bank
resistance required. Refer to the warranty policy and procedures
1, Sensor 1 - Circuit
Front heated manual, or determine if any prior approval programme is
Open
oxygen sensor in operation, prior to the installation of a new
failure module/component

Exhaust Gas
temperature
sensor
Check the Exhaust Gas temperature sensor for
contaminated
contamination
Exhaust Gas
Exhaust Gas Refer to the electrical circuit diagrams and check the
temperature
Temperature Out of exhaust gas temperature sensor circuits for short circuit to
sensor circuit
Range - Bank 1 power, short circuit to ground, open circuit, high resistance
P2478-84 short circuit to
Sensor 1 - Signal Check and install a new exhaust gas temperature sensor as
power, short
Below Allowable required. Refer to the warranty policy and procedures
circuit to ground,
Range manual, or determine if any prior approval programme is
open circuit, high
in operation, prior to the installation of a new
resistance
module/component
Exhaust Gas
temperature
sensor failure

Exhaust Gas
temperature
Check the Exhaust Gas temperature sensor for
sensor
contamination
contaminated
Exhaust Gas
 Temperature Out of Exhaust Gas Refer to the electrical circuit diagrams and check the
Range - Bank 1 temperature exhaust gas temperature sensor circuits for short circuit to
Sensor 1- Signal sensor circuit power, short circuit to ground, open circuit, high resistance
P2478-85 Above Allowable short circuit to Check and install a new exhaust gas temperature sensor as
Range power, short required. Refer to the warranty policy and procedures
circuit to ground, manual, or determine if any prior approval programme is
open circuit, high in operation, prior to the installation of a new
resistance module/component
Exhaust Gas
temperature
sensor failure

Pre-catalyst
temperature
Refer to the electrical circuit diagrams and check
Exhaust Gas sensor circuit
connections are secure and wiring integrity
Temperature Out of short circuit to
Check and install a new pre-catalyst temperature sensor as
Range - Bank 1 power, short
P2479-22 required. Refer to the warranty policy and procedures
Sensor 2 - Signal circuit to ground,
manual, or determine if any prior approval programme is
Amplitude > open circuit
in operation, prior to the installation of a new
Maximum Pre-catalyst
module/component
temperature
sensor failure

Pre-catalyst
temperature
Refer to the electrical circuit diagrams and check
Exhaust Gas sensor circuit
connections are secure and wiring integrity
Temperature Out of short circuit to

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Check and install a new pre-catalyst temperature sensor as
Range - Bank 1 power, short
P2479-85 required. Refer to the warranty policy and procedures
Sensor 2 - Signal circuit to ground,
manual, or determine if any prior approval programme is
Above Allowable open circuit
in operation, prior to the installation of a new
Range Pre-catalyst
module/component
temperature
sensor failure

Post-catalyst
temperature
sensor Check the post-catalyst temperature sensor for
contaminated contamination
Post-catalyst Refer to the electrical circuit diagrams and check the
Exhaust Gas temperature post-catalyst temperature sensor circuits for short circuit
Temperature Sensor sensor circuit to power, short circuit to ground, open circuit, high
P242A-22 Circuit Bank 1 Sensor short circuit to resistance
3 - Signal Amplitude power, short Check and install a new post-catalyst temperature sensor
> Maximum circuit to ground, as required. Refer to the warranty policy and procedures
open circuit, high manual, or determine if any prior approval programme is
resistance in operation, prior to the installation of a new
Post-catalyst module/component
temperature
sensor failure

Catalyst damaged
Air leak intake air
system
Diesel particulate
Check the catalyst for damage
filter damaged
Check intake air system for leakage
Post-catalyst
Check the diesel particulate filter for damage
temperature
Exhaust Gas Check post-catalyst temperature sensor for contamination
sensor
Temperature Sensor Refer to the electrical circuit diagrams and check the
contaminated
Circuit post-catalyst temperature sensor circuits for short circuit
Post-catalyst
P242B-62 Range/Performance to power, short circuit to ground, open circuit, high
temperature
Bank 1 Sensor 3 - resistance
sensor circuit
Signal Compare Check and install a new post-catalyst temperature sensor
short circuit to
Failure as required. Refer to the warranty policy and procedures
power, short
manual, or determine if any prior approval programme is
circuit to ground,
in operation, prior to the installation of a new
open circuit, high
module/component
resistance
Post-catalyst
temperature
sensor failure
 Post-catalyst
temperature Refer to the electrical circuit diagrams and check the
sensor circuit post-catalyst temperature sensor circuits for short circuit
Exhaust Gas short circuit to to power, short circuit to ground, open circuit, high
Temperature Sensor power, short resistance
Circuit circuit to ground, Check post-catalyst temperature sensor for contamination
P242B-64 Range/Performance open circuit, high Check and install a new post-catalyst temperature sensor
Bank 1 Sensor 3 - resistance as required. Refer to the warranty policy and procedures
Signal plausibility Post-catalyst manual, or determine if any prior approval programme is
failure temperature in operation, prior to the installation of a new
sensor module/component
contaminated
Post-catalyst
temperature
sensor failure

Post-catalyst
temperature Check the post-catalyst temperature sensor for
sensor contamination
Exhaust Gas contaminated Refer to the electrical circuit diagrams and check the
Temperature Sensor Post-catalyst post-catalyst temperature sensor circuits for short circuit
Circuit Low Bank 1 temperature to ground
P242C-16
Sensor 3 - Circuit sensor circuit Check and install a new post-catalyst temperature sensor
Voltage Below short circuit to as required. Refer to the warranty policy and procedures
Threshold ground manual, or determine if any prior approval programme is
Post-catalyst in operation, prior to the installation of a new
temperature module/component

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sensor failure

Post-catalyst
temperature Check the post-catalyst temperature sensor for
sensor contamination
Exhaust Gas contaminated Refer to the electrical circuit diagrams and check the
Temperature Sensor Post-catalyst post-catalyst temperature sensor circuits for short circuit
Circuit High Bank 1 temperature to power
P242D-17
Sensor 3 - Circuit sensor circuit Check and install a new post-catalyst temperature sensor
Voltage Above short circuit to as required. Refer to the warranty policy and procedures
Threshold power manual, or determine if any prior approval programme is
Post-catalyst in operation, prior to the installation of a new
temperature module/component
sensor failure

Check that the hoses coming from the diesel particulate

filter to the sensor at the rear of the cylinder head are
installed correctly, secure and in good condition
Check differential pressure sensor hose lines are not frozen
Check differential pressure sensor hose lines are installed
correctly
Check differential pressure sensor hose lines for
mechanical integrity
Diesel Particulate Refer to the electrical circuit diagrams and check the
Diesel particulate
Filter Differential differential pressure sensor circuit for short circuit to
filter hose line
P244A-95 Pressure Too ground, short circuit to power, open circuit, high resistance
removed or
Low(Bank1) - Inspect connectors for signs of water ingress, and pins for
crossed over
Incorrect Assembly damage and/or corrosion
Check and install a new differential pressure sensor as
required
Using the manufacturer approved diagnostic system carry
out 'Diesel particulate filter differential pressure sensor
replacement' routine (perform routine - Reset Specified
Information )
Using the manufacturer approved diagnostic system clear
all stored DTCs using the Diagnosis Menu tab and retest

Refer to the workshop manual and check the particulate

filter and sensor for obvious signs of damage
Check the sensor harness for chaffing or heat damage
Harness fault - Refer to the electrical circuit diagrams and check the diesel
diesel particulate particulate filter, differential pressure sensor signal circuit
filter, differential for open circuit, short circuit to ground, short to other
Diesel Particulate pressure sensor circuits
Filter (DPF) Pressure Diesel particulate Check the sensor ground circuit for open circuit, short
P2452-08 Sensor A Circuit Low filter, differential circuit to power, high resistance
 - Bus Signal / pressure sensor Check the sensor power supply circuit for open circuit,
Message Failures failure. no longer short circuit to ground, high resistance
communicating Repair wiring as required, if there are no wiring faults.
with the engine Check and install a new diesel particulate filter, differential
control module pressure sensor as required. Refer to the warranty policy
and procedures manual, or determine if any prior approval
programme is in operation, prior to the installation of a
new module/component

Check engine control module for DPF related DTCs and

refer to relevant DTC index
Using the manufacturer approved diagnostic system carry
out a service regeneration procedure
Diesel Particulate
Check charge air system for leakage, split pipework, loose
Filter Restriction -
Maximum soot hose clips & damaged hoses
P2463-00 Soot Accumulation
mass Diagnosis of this DTC may require using the manufacturer
(Bank 1) - no sub
approved diagnostic system check datalogger signals
type information
0x0466 Turbocharger/Supercharger Boost Pressure A -
Desired
Using the manufacturer approved diagnostic system clear
all stored DTCs using the ‘Diagnosis Menu’ tab and retest

Post-catalyst
temperature Check the post-catalyst temperature sensor for
sensor contamination
Exhaust Gas contaminated Refer to the electrical circuit diagrams and check the
Temperature Out of Post-catalyst post-catalyst temperature sensor circuits for short circuit

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Range - Bank 1 temperature to ground
P247A-84
Sensor 3 - Signal sensor circuit Check and install a new post-catalyst temperature sensor
Below Allowable short circuit to as required. Refer to the warranty policy and procedures
Range ground manual, or determine if any prior approval programme is
Post-catalyst in operation, prior to the installation of a new
temperature module/component
sensor failure

Post-catalyst
temperature Check the post-catalyst temperature sensor for
sensor contamination
contaminated Refer to the electrical circuit diagrams and check the
Exhaust Gas Post-catalyst post-catalyst temperature sensor circuits for short circuit
Temperature Out of temperature to ground
P247A-85
Range - Bank 1 sensor circuit Check and install a new post-catalyst temperature sensor
Sensor 3 short circuit to as required. Refer to the warranty policy and procedures
ground manual, or determine if any prior approval programme is
Post-catalyst in operation, prior to the installation of a new
temperature module/component
sensor failure

Pinpoint Tests

PINPOINT TEST A : DTC CHECK

TEST DETAILS/RESULTS/ACTIONS
CONDITIONS
A1: CHECK FOR OTHER DTCS
1 Using the manufacturer approved diagnostic system, check engine control module for DPF related DTCs
Are any DTCs stored?
Yes
Refer to the relevant DTC Index and carry out the relevant repair procedure. Only after the repair, using
the manufacturer approved diagnostic system clear the DTC and re-test
No
Proceed to next step
A2: EXHAUST PIPE AND JOINTS
1 Check all exhaust pipes and joints for leaks
2 Check for external damage to the diesel particulate filter metalwork
Are any of the exhaust pipes leaking, or is there external damage to the diesel particulate filter metalwork?
Yes
Repair leaking exhaust joints as required
Check and install a new diesel particulate filter as requiredRefer to the warranty policy and procedures
manual, or determine if any prior approval programme is in operation, prior to the installation of a new
module/component
 No
Proceed to next step
A3: DIESEL PARTICULATE FILTER PRESSURE SENSOR PIPES
1 Check differential pressure sensor pipes for cracks, mis-routing or hoses crossed
Are any of the differential pressure sensor pipes cracked, mis-routed or hoses crossed?
Yes
Repair as required, clear DTC and retest
No
Proceed to next step
A4: HARNESS DIFFERENTIAL PRESSURE SENSOR
1 Check wiring harness to the differential pressure sensor, include any inline connectors
Was the wiring harness to the differential pressure sensor damaged?
Yes
Repair wiring harness as required, clear DTC and retest
No
Proceed to next step
A5: CONNECTOR INTEGRITY DIFFERENTIAL PRESSURE SENSOR
1 Check differential pressure sensor connector for damage and terminal corrosion
Was the differential pressure sensor connector damaged or terminal corrosion present?
Yes
Refer to the electrical circuit diagrams and check connections are secure and wiring integrity. Repair as
required, clear DTC and retest
No
Proceed to next step
A6: FUNCTIONAL CHECK DIFFERENTIAL PRESSURE SENSOR
NOTES:

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The Particulate Filter Differential Pressure Sensor measured voltage with the ignition on checks the sensor
output with no variation/pressure in the exhaust system, checking the Particulate Filter Differential Pressure
Sensor adaption is working. The measured voltages at engine idle and 4000 RPM will be considerably different
depending on the diesel particulate filter soot loading. The idle value tells us that the Particulate Filter
Differential Pressure Sensor is working if it goes up from the ignition on value. The 4000 RPM value tells us how
much soot is in the diesel particulate filter. A diesel particulate filter which is recoverable measures less than 1
Volt / 93mbar at 4000 RPM

If a new differential pressure sensor or hose lines have been installed, incorrectly routed, or any
differential pressure sensor circuit repairs carried out, the Engine Control Module must learn and store the new
differential pressure sensor offset value. The following conditions must be met to allow the differential pressure
sensor offset value to be learnt and stored: Using the manufacturer approved diagnostic system, clear DTCs
from Engine Control Module, then monitor the datalogger signal 'sump oil temperature - measured' ensuring a
minimum of 50 degrees C is achieved. Start engine, run above 500RPM for 2 minutes, then a further 30
seconds at idle. Ensure the engine cooling fan is not running. Set vehicle in park and set ignition status to off.
Wait 30 seconds for the Engine Control Module to power down, learn and store differential pressure sensor
offset value. This process must be carried out six times, to allow a large negative offset value to adapt back to
0 Hpa

1 Using the manufacturer approved diagnostic system check datalogger signal - Particulate Filter Differential
Pressure Sensor Voltage - Bank 1 - (0x03DB) under the conditions described below. Allow the voltage to
stabilize before recording the value for approximately 7 seconds

Ignition is ON and engine speed is 0 RPM

Engine idle speed

Engine speed is 4000 RPM

Was datalogger signal - Particulate Filter Differential Pressure Sensor Voltage - Bank 1 - (0x03DB) - value
approximately 0.4 Volts when ignition ON and engine speed is 0 RPM?Was datalogger signal - Particulate Filter
Differential Pressure Sensor Voltage - Bank 1 - (0x03DB) - value less than 1 Volt when engine speed at
idle?Was datalogger signal - Particulate Filter Differential Pressure Sensor Voltage - Bank 1 - (0x03DB) - value
less than 1 Volt when engine speed at 4000 RPM?
(0.5volt = 14mbar, 1 volt = 106mbar at 4000RPM)

Yes
Proceed to next step
No
Check and install a new differential pressure sensor as requiredRefer to the warranty policy and procedures
manual, or determine if any prior approval programme is in operation, prior to the installation of a new
module/componentUsing the manufacturer approved diagnostic system clear the DTC and re-test
NOTE: If a new differential pressure sensor or hose lines have been installed, incorrectly routed, or any
differential pressure sensor circuit repairs carried out, the Engine Control Module must learn and store the
new differential pressure sensor offset value. The following conditions must be met to allow the differential
pressure sensor offset value to be learnt and stored: Using the manufacturer approved diagnostic system,
 clear DTCs from Engine Control Module, then monitor the datalogger signal 'sump oil temperature -
measured' ensuring a minimum of 50 degrees C is achieved. Start engine, run above 500RPM for 2
minutes, then a further 30 seconds at idle. Ensure the engine cooling fan is not running. Set vehicle in park
and set ignition status to off. Wait 30 seconds for the Engine Control Module to power down, learn and
store differential pressure sensor offset value. This process must be carried out six times, to allow a large
negative offset value to adapt back to 0 Hpa
A7: ACCELERATION SMOKE TEST

NOTE: Ensure the engine is at normal operating temperature

1 Increase the engine speed momentarily to 4000RPM and allow the engine to settle back to idle
2 Carry out above step 3 times
3 Carry out visual check for excessive black smoke leaving the tailpipe during each of the 3 tests
Is excessive black smoke visible leaving the tailpipe during each of the 3 tests?
Yes
Note: Only install a new diesel particulate filter if black smoke is visible leaving the tailpipe
Check and install a new diesel particulate filter as requiredRefer to the warranty policy and procedures
manual, or determine if any prior approval programme is in operation, prior to the installation of a new
module/componentUsing the manufacturer approved diagnostic system clear the DTC and re-test. Return
vehicle to the customer
No
Check and install a new differential pressure sensor as requiredCarry out differential pressure sensor
adaption process
PINPOINT TEST B : RED WARNING MESSAGE DPF FULL VISIT DEALER IS DISPLAYED AND DTC P2463-00 IS
LOGGED

TEST DETAILS/RESULTS/ACTIONS

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CONDITIONS
B1: VIN INFORMATION
1 Record the full vehicle identification number for the vehicle under test, as this information may later be
required by dealer technical support
Has the vehicle identification number been recorded?
Yes
Proceed to the next step
No
Record the vehicle identification number and proceed to the next step
B2: VEHICLE MILEAGE
1 Record the full mileage for the vehicle under test, as this information may later be required by dealer
technical support
Has the mileage been recorded?
Yes
Proceed to the next step
No
Record the mileage and proceed to the next step
B3: VEHICLE SOFTWARE PART NUMBER
1 Using the manufacturer approved diagnostic system, record the software part number for the Engine
Control Module (ECM)
Has the software part number been recorded? Is the software installed to the vehicle to the latest relevant
level?
Yes
Proceed to the next step
No
Record the software part number and proceed to the next step
B4: RECORD ALL ENGINE CONTROL MODULE (ECM) DTCS
1 Using the manufacturer approved diagnostic system, check Engine Control Module (ECM), for related DTCs
Are other DTCs logged?
Yes
Proceed to the next step
No
Proceed to step 7
B5: DTC P2459-65 IS LOGGED
1 Using the manufacturer approved diagnostic system, the logged mileage for DTCs can be seen by viewing
the snapshot data
Was DTC P2459-65 logged at a mileage up to 625 miles (1000KM) before the diagnostic trouble P2463-00 was
logged?
Yes
Suspect the customer has ignored the AMBER DPF FULL REFER TO HANDBOOK message. The customer
should be advised of this and the repair may become chargeable
Proceed to step 7
No
Proceed to the next step
B6: OTHER RELATED ENGINE CONTROL MODULE (ECM) DTCS
 1 Related Engine Control Module (ECM) DTCs other than P2459-65 and P2463-00 are logged
Are related Engine Control Module (ECM) DTCs other than P2459-65 and P2463-00 logged?
Yes
Refer to the relevant DTC Index. Repair as required. Using the manufacturer approved diagnostic system
clear the DTCs and re-test
No
Proceed to step 7
B7: DIESEL PARTICULATE FILTER REGENERATION CYCLE

NOTE: Using the manufacturer approved diagnostic system begin to perform a service regeneration cycle,
DO NOT drive the cleaning cycle. Record the grams of soot only

1 With the engine at running temperature check the pre catalyst oxygen sensor operation as follows:-
2 Using the manufacturer approved diagnostic system check datalogger signals - Oxygen Sensor Voltage -
(0xF424)

Idle vehicle and record, should be (0.7 ~ 1 volt)

Idle to 100% pedal, during acceleration record, should be 0 ~ 0.2 volts
Accelerate to 4500RPM (stationary) and close throttle, should read 1.15 ~ 1.2 volts

Does the pre catalyst oxygen sensor meets this criteria?

Yes
Pre catalyst oxygen sensor is operating correctlyNote: DO NOT carry out the adaption process on the pre
catalyst oxygen sensor, as this resets the adaption to 0Proceed to step 8
No
Pre catalyst oxygen sensor adaption cycle is required
Pre catalyst oxygen sensor adaption cycle is NOT possible while DTCs are loggedUsing the manufacturer
approved diagnostic system, carry out FIT NEW PARTICULATE FILTER PROCESS only and clear the

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DTCsAfter completing FIT NEW PARTICULATE FILTER PROCESS continue with pre catalyst oxygen sensor
adaption cycle as follows:-1. Idle vehicle for 10 minutes2. Set car in command shift 3rd gear3. Accelerate
to 3800RPM (where achievable) and overrun / coastdown without braking until revs drop below 1500
RPM4. Repeat step 3 a further 3 times5. Check for any DTCs, if adaption failed a DTC will be evident and
the sensor will require replacement6. Check oxygen sensor adaption is now complete by returning to B7
item 27. Using the manufacturer approved diagnostic system clear the DTC and re-test. Return vehicle to
the customer
B8: SOOT ESTIMATOR IS ACCURATE AND THE DIFFERENTIAL PRESSURE SENSOR READING IS WORKING CORRECTLY
1 Using the manufacturer approved diagnostic system check datalogger signal - Particulate Filter Differential
Pressure Sensor Voltage - Bank 1 - (0x03DB)

Record value with ignition ON

Idle engine record value
Hold engine speed at 4000RPM and record value
Note: 0.7volt = 37mbar, 1 volt = 93mbar at 4000RPM

Have the values been recorded for each of the conditions?

Yes
Proceed to step 9
No
Record values for each of the conditions and proceed to step 9
B9: EXHAUST GAS TEMPERATURES
1 Using the manufacturer approved diagnostic system check datalogger signals

Exhaust Gas Temperature Bank 1 Sensor 2 - (0x03F5)

Exhaust Gas Temperature Bank 1 Sensor 1 - (0x03F4)
Exhaust Gas Temperature Bank 1 Sensor 2 - (0x03F5)
Exhaust Gas Temperature Bank 1 Sensor 3 - (0x03F6)

2 Hold engine speed at 2000RPM for 2 minutes and record values

(By doing this we are trying to establish if the system can recognize heat in the exhaust during regeneration)

Are all of the exhaust gas temperature sensors showing reasonable values between 120°C and 400°C?
Yes
Proceed to step 10
No
Check and install new exhaust gas temperature sensors as required. Refer to the new module/component
installation note at the top of the DTC Index
Using the manufacturer approved diagnostic system clear the DTCs and re-test
B10: COMPARISON OF SOOT MASS IN DIESEL PARTICULATE FILTER AND PARTICULATE FILTER DIFFERENTIAL PRESSURE
SENSOR VOLTAGE

NOTE: Using the results from steps 7 and 8 establish if the Soot Mass estimator and the differential pressure sensor
are aligned, in terms of their assessment of soot in the filter. If the soot mass is less than 35 grams the diesel particulate
filter is recoverable.

1 Using the results from step 7 check soot mass is less than 35 grams
 2 Using the results from step 8 check particulate filter differential pressure sensor voltage at 4000RPM is less
than 1 Volt (93mbar)
Is diesel particulate filter soot mass value less than 35 grams and particulate filter differential pressure sensor
voltage at 4000RPM less than 1 Volts (93mbar)?
Yes
If the diesel particulate filter soot mass value is greater than 35 grams and the differential pressure sensor
voltage is between 0.5Volts and 1 Volt then the diesel particulate filter is low on soot but has not been
driven to allow pressure correction of the diesel particulate filter, if other issue from the tests performed
are evident. Proceed to next step
No
If the diesel particulate filter soot mass value is greater than 35 grams and the differential pressure sensor
voltage greater than 1 Volt then the diesel particulate filter has a high soot contentIf no other issue from
the tests performed are evident then the vehicle has a soot generated fault not detected by DTCs. Refer to
the relevant section of the workshop manual and check for boost pressure leakage using the manufacturer
approved leak check toolContact dealer technical support for further advice
B11: SOOT MASS REDUCTION
1 With the vehicle fully up to temperature and in Park maintain 2500RPM for 3 minutes
2 Return to step 7, check diesel particulate filter soot mass value
Has the diesel particulate filter soot mass reduced from the original reading to less than 26 grams?
Yes
Proceed to next step
No
Proceed to step 13
B12: DRIVE VEHICLE

CAUTION: At all times during this procedure you should observe all relevant speed limits, laws, and
regulations

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1 Drive the vehicle until the engine reaches normal operating temperature. The engine should NOT be left
idling to achieve working temperature. Drive the vehicle for a further twenty minutes, keeping the vehicle
at a constant speed between 75 km/h (45 mph) and 120 km/h (75 mph). Keeping a constant speed
enables the diesel particulate filter to regenerate more efficiently. It is therefore recommended that cruise
control is used to achieve this, if possible
(Do NOT carry out diesel particulate filter service regeneration)

Is the diesel particulate filter soot mass less than 15 grams?

Yes
Using the manufacturer approved diagnostic system clear the DTC and re-test. Return vehicle to the
customer
No
Contact dealer technical support with all of the recorded values from the above tests
B13: CARRY OUT FIT NEW PARTICULATE FILTER PROCESS

WARNING: DO NOT carry out this process on any other occasion without first installing a new diesel
particulate filter

1 Using the manufacturer approved diagnostic system, select SPECIAL APPLICATIONS ~ POWERTRAIN ~
carry out FIT NEW PARTICULATE FILTER PROCESS
2 Carry out diesel particulate filter service regeneration. Record grams of soot following diesel particulate
filter service regeneration
Is the diesel particulate filter soot mass less than 15 grams?
Yes
Using the manufacturer approved diagnostic system clear the DTC and re-test. Return vehicle to the
customer
No
Contact dealer technical support with all of the recorded values from the above tests

Diesel particulate filter regeneration procedure

CAUTION: The regeneration procedure produces high temperatures in the diesel particulate filter. Heat can be felt
radiating from beneath the vehicle, which is normal and not a cause for concern. However, the vehicle should not be parked
over combustible material, particularly during dry weather. The heat generated could be sufficient to start a fire when in close
proximity to combustible material such as long dry grass, paper etc

If DPF FULL SEE HANDBOOK appears in the message center, carry out the following procedure

CAUTION: At all times during this procedure you should observe all relevant speed limits, laws, and regulations

1. Drive the vehicle until the engine reaches normal operating temperature. The engine should NOT be left idling to
achieve working temperature

2. Drive the vehicle for a further twenty minutes, keeping the vehicle at a constant speed between 75 km/h (45 mph)
and 120 km/h (75 mph)
 NOTE: The ideal speed and conditions for regeneration are 100 km/h (62 mph ) ~ 120 km/h (75 mph), in Drive.
Keeping a constant speed enables the diesel particulate filter to regenerate more efficiently. It is therefore recommended that
cruise control is used to achieve this, if possible

3. If regeneration is successful the warning message will be extinguished, once the message is extinguished please
keep driving for 10 minutes to ensure that the diesel particulate filter is completely clean

4. If the message remains repeat the process

NOTE: When driving off-road during the regeneration process, greater accelerator pedal use may be required

DTC Index

For a complete list of all diagnostic trouble codes that could be logged on this vehicle, please refer to Section 100-00.
REFER to: Diagnostic Trouble Code (DTC) Index - INGENIUM I4 2.0L Diesel, DTC: Engine Control Module (ECM) B10A2-07 to
P034B-76 (100-00 General Information, Description and Operation).

Published: 21-Jul-2015
Exhaust System - INGENIUM I4 2.0L Diesel - Diesel Particulate Filter - Component
Location
Description and Operation

COMPONENT LOCATION - SHEET 1 OF 3 - DIESEL PARTICULATE FILTER (DPF)

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Item Description
1 Differential pressure sensor
2 Pre-catalytic converter exhaust gas temperature sensor
3 Heated Oxygen Sensor (HO2S)
4 Diesel Particulate Filter (DPF)
5 Post-Diesel Particulate Filter (DPF) exhaust gas temperature sensor
6 Pre-Diesel Particulate Filter (DPF) exhaust gas temperature sensor
COMPONENT LOCATION - SHEET 2 OF 3 - DIFFERENTIAL PRESSURE SENSOR
 cardiagn.com
Item Description
1 Differential pressure sensor
2 Electrical connection
3 Differential pressure sensor pipe - low
4 Differential pressure sensor pipe - high
COMPONENT LOCATION - SHEET 3 OF 3 - EXHAUST GAS TEMPERATURE SENSOR

Item Description
1 Exhaust gas temperature sensor
2 Electrical connection
Published: 18-Aug-2015
Exhaust System - INGENIUM I4 2.0L Diesel - Exhaust System DTC: Selective
Catalytic Reduction (SCR)
Diagnosis and Testing

Principle of Operation

For a detailed description of the Exhaust System, refer to the relevant Description and Operation section of the workshop
manual.
REFER to: Selective Catalyst Reduction (309-00B Exhaust System - INGENIUM I4 2.0L Diesel, Description and Operation).

Inspection and Verification

CAUTION: Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules does not
guarantee confirmation of a fault, and may also cause additional faults in the vehicle being tested and/or the donor vehicle.

NOTES:

If a control module or a component is suspect and the vehicle remains under manufacturer warranty, refer to the
Warranty Policy and Procedures manual, or determine if any prior approval programme is in operation, prior to the installation
of a new module/component.

When performing voltage or resistance tests, always use a digital multimeter accurate to three decimal places, and with

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an up-to-date calibration certificate. When testing resistance always take the resistance of the digital multimeter leads into
account.

Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.

1. Verify the customer concern

2. Visually inspect for obvious signs of damage and system integrity

Visual Inspection
Mechanical Electrical

Leaks
Metal fatigue
Correct installation
Battery
Selective catalyst reduction muffler
Engine junction box
Muffler(s)
Rear junction box
Joints
Fuses
Mountings
Wiring harnesses and connectors
Clearance around components
Engine control module
Diesel exhaust fluid injector
Sensor(s)
Diesel exhaust fluid line
Actuator(s)
Diesel exhaust fluid tank
DEF relay
Diesel exhaust fluid filler assembly
Diesel exhaust fluid level
Diesel exhaust fluid quality

3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding
to the next step

4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart, alternatively check for
Diagnostic Trouble Codes (DTCs) and refer to the DTC Index

5. Check DDW for open campaigns. Refer to the corresponding bulletins and SSMs which may be valid for the specific
customer complaint and carry out the recommendations as required

Symptom Chart

Symptom Possible Causes Action

Using the manufacturer approved

diagnostic system check engine control
module for related DTCs and refer to
relevant DTC index
Check and correct the diesel exhaust
fluid level
 Selective catalyst reduction system failure Refer to the electrical circuit diagrams
Diesel exhaust fluid level too low and check connections are secure and
Power or ground failure wiring integrity
Diesel exhaust fluid pressure too low Refer to the workshop manual and the
Diesel exhaust fluid pressure too high battery care manual, inspect the vehicle
Engine Diesel exhaust fluid injection pump battery and ensure it is fully charged and
malfunction Diesel exhaust fluid injector serviceable before performing further
lamp Diesel exhaust fluid relay tests
illuminated Diesel exhaust fluid heater control unit Inspect connectors for signs of water
Pre selective catalytic reduction NOx sensor ingress, and pins for damage and/or
Pre selective catalyst reduction Nox sensor module corrosion
Post selective catalyst reduction NOx sensor Refer to the electrical circuit diagrams
Post selective catalyst reduction Nox sensor module and check sensor, relays/fuses and
Post selective catalyst reduction soot sensor control module power feeds and grounds
Post selective catalyst reduction soot sensor module Check system for correct installation of
Diesel sub net CAN communication bus components
Check system mechanical and fluid
integrity
Check system for mechanical integrity
Check system for leakage
Check system for blockage

Refer to the workshop manual and the

battery care manual, inspect the vehicle
battery and ensure it is fully charged and
serviceable before performing further
tests

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Engine Vehicle battery failure Inspect connectors for signs of water
will not Diesel exhaust fluid level too low ingress, and pins for damage and/or
crank Harness failure - Wiring integrity corrosion
Check and correct the diesel exhaust
fluid level
Using the manufacturer approved
diagnostic system carry out any required
routines

Selective catalyst reduction system failure Using the manufacturer approved

A monitor of the historical diesel exhaust fluid diagnostic system check engine control
Message consumption rate, allied with a direct reading of the module for related DTCs and refer to
warning diesel exhaust fluid level in the tank, predicts that relevant DTC index
the distance to emptying the tank is less than Check and correct the diesel exhaust
2400km fluid level

Control module cavity

Control Module Cavity Description DTC

P203B-02
P203B-16
P203B-17
P203B-31
P203C-00
Circuit reference RALS PWM input to the engine control module P203D-00
P205B-84
P205B-85
P205C-16
P205D-17
P205E-64

P208A-13
P208B-4B
Circuit reference RAPM PWM output from the engine control module
P208C-11
P208D-12

P202E-4B
P2047-13
Circuit reference RAMV_L PWM output from the engine control module
P2048-11
P2049-12

P202E-4B
P2047-13
Circuit reference RAMV_H PWM output from the engine control module P2048-11
P2049-12

P2200-13
P2200-14
P2201-28
P2201-2F
P2202-16
P2203-17
P2209-01
P220A-01
P220B-01
P225C-85
P225D-84
P225E-85
P225F-84
P229E-13
P229E-14
P229F-28
P229F-2F
Circuit reference CAN_3_H Diesel sub net CAN communication bus (High) P22A0-16
P22A1-17
P22A7-01
P22FA-27
P22FB-64
P22FB-84
P22FB-85

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P22FE-2A
P22FE-64
P22FE-84
P22FE-85
U029D-87
U029E-87
U02A5-87
U05A6-08
U3009-00
U300C-00
U300F-00

P2200-13
P2200-14
P2201-28
P2201-2F
P2202-16
P2203-17
P2209-01
P220A-01
P220B-01
P225C-85
P225D-84
P225E-85
P225F-84
P229E-13
P229E-14
P229F-28
P229F-2F
Circuit reference CAN_L_3 Diesel sub net CAN communication bus (Low) P22A0-16
P22A1-17
P22A7-01
P22FA-27
P22FB-64
P22FB-84
P22FB-85
P22FE-2A
P22FE-64
P22FE-84
P22FE-85
U029D-87
U029E-87
U02A5-87
U05A6-08
U3009-00
U300C-00
U300F-00
 P21C7-13
Circuit reference SCRMRLY PWM output from the engine control module P21C8-11
P21C9-12

P20FA-13
Circuit reference RAPP PWM output from the engine control module P20FC-11
P20FD-12

Diagnostic routines

Routine
Routine description Routine action
number
0x0406 Reset all adaptions Value 0x0F - To Reset Selective Catalyst Reductant (SCR) Inducement System Start Inhibit
Reset Specified
0x4026 Value 0x2C − To Reset Selective Catalyst Reductant (SCR) Quality Monitor
Information
Selective Catalytic
This routine forms part of the DEF prime routine to be carried out at end of line and in service if
0x4076 Reductant
components are replaced
Preparation
This routine carries out a leak and dosing quantity test by using inputs from the tool. If all
Selective Catalytic
inputs from the tool are zero, then the test is a visual inspection for leaks while under pressure,
0x4077 Reductant Dosing
quantity tests are done by comparing the reductant amount delivered with the amount
Measuring Test
requested
Selective Catalytic This routine empties/purges the hydraulic lines of the DEF system which will be necessary in
0x4078
Reductant Emptying service to renew aged diesel exhaust fluid
Test Reductant

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0x4092 This routine tests the integrity of the DEF lines at low pressure (1 - 2 bar)
System Lines
Test The Pump
Emptying The High This routine is used to test the back flow pump which empties the DEF lines when the system is
0x4093
Pressure Reductant drained
System
Test Dosing Valve This routine tests the quantity of DEF delivered with the injector opened for a given period of
0x4094
Dynamic Behavior time
Test Measured Static
0x4095 Reductant Dosing This routine tests the quantity of DEF delivered against an expected value
Quantity
Test Reductant This routine tests the pattern of DEF injected from the dosing module as there is often a
0x4096
Spray Pattern build-up of residue around the actual injector.
Prime Reductant This routine is used to prime the reductant system following component replacement and
0x4097
System For First Fill includes a short pressure test to confirm the integrity of the pipework
Reductant First Fill Selective reductant catalyst system end of line first fill and pressure test routine. This routine
0x409A
And Pressure Test will prime and test the system

Parameter Identifier (PID)

PID Description Action

Diagnosis may require using the manufacturer approved

diagnostic system check datalogger signals
- Signal is displayed in Deg C
0x043C Reductant Tank Temperature - Raw
- Circuit reference I_T_RALS
- Input to the engine control module PWM signal for
DEF tank temperature

Diagnosis may require using the manufacturer approved

diagnostic system check datalogger signals
- Signal is displayed in %
0x0441 Reductant Injector Duty Cycle
- Circuit reference O_T_RAMV_L
- Output from the engine control module PWM signal
to drive the DEF injector

Diagnosis may require using the manufacturer approved

diagnostic system check datalogger signals
- Signal is displayed in mm
0x05C1 Reductant Tank Fluid Level
- Circuit reference I_T_RALS
- Input to the engine control module PWM signal for
DEF tank level

Diagnosis may require using the manufacturer approved

diagnostic system check datalogger signals
0x05C2 Reductant Tank Sensor Duty Cycles - Signal is displayed in %
- Signal value is read from internal memory location
internal to engine control module over CAN
communication bus

Diagnosis may require using the manufacturer approved

diagnostic system check datalogger signals
- Signal is displayed in %
0x05CF Reductant Purge Pump Duty Cycle - Commanded
- Circuit reference O_T_RAPM
- Output from the engine control module PWM signal
to drive the DEF pump

Diagnosis may require using the manufacturer approved

diagnostic system check datalogger signals
- Signal is displayed in %
0x05D0 Reductant Pump Duty Cycle - Commanded
- Circuit reference O_T_RAPM
- Output from the engine control module PWM signal
to drive the DEF pump

Diagnosis may require using the manufacturer approved

diagnostic system check datalogger signals
Selective Catalyst Reductant Relay State - - Signal is displayed as off/on
0x05D1
Commanded - Circuit reference O_T_SCRMRLY
- Output from the engine control module PWM signal
to drive the DEF relay

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Diagnosis may require using the manufacturer approved
diagnostic system check datalogger signals
Learnt Heater Current Threshold For Heater Run
- Signal is displayed in mA
0x05FB Dry Detection - Frozen Cavity Detection In Urea
- Signal value is read from internal memory location
Tank
internal to engine control module over CAN
communication bus

Diagnosis may require using the manufacturer approved

diagnostic system check datalogger signals
- Signal is displayed in Kg
0x05FC Total Mass Of Fluid Injected By Urea Dosing System
- Signal value is read from internal memory location
internal to engine control module over CAN
communication bus

Diagnosis may require using the manufacturer approved

diagnostic system check datalogger signals
Total Time Of Urea Dosing Valve Exceeding Upper - Signal is displayed in s
0x05FD
Temperature Threshold - Signal value is read from internal memory location
internal to engine control module over CAN
communication bus

Diagnosis of these symptoms may require using the

manufacturer approved diagnostic system check
datalogger signals
0xDD02 Main ECU Voltage Supply - Signal is displayed in volts
- Signal value is read from internal memory location
internal to engine control module over CAN
communication bus

Diagnosis of these symptoms may require using the

manufacturer approved diagnostic system check
datalogger signals
Particulate Matter Sensor Meander Temperature −
0xD940 - Signal is displayed in Deg C
Raw
- Signal value is read from internal memory location
internal to engine control module over CAN
communication bus

Diesel Exhaust Fluid (DEF) Level

The level of DEF in the tank is checked via the Instrument Cluster (IC) menu. When selected the message center displays the
approximate amount of DEF remaining, providing an estimated km/miles figure remaining, prior to emptying the tank
The DEF tank is fitted with combined temperature/ultrasonic level sensors. Circuit continuity and plausibility of the signals
received are checked within the ECM. An ultrasonic “no echo malfunction” is set if no valid echo from the ultrasonic sensor is
detected during a predefined time. This typically happens when the ultrasonic signal of the sensor is blocked, or if the DEF
tank is overfilled (the air pocket at the top of the DEF tank is no longer present). The vehicle message center display's an
advisory/warning system, which activates in low DEF conditions. If no corrective action is made, the engine will eventually not
restart. The stages in the warning system are listed in the following tables

NOTE: None of the listed stages will activate the MIL. The stages are automatically cleared if the DEF level is increased

Stages Cause Warning Message Description

The DEF is running low. Fill DEF at the

Stage DEF range Message at earliest convenience
Low Diesel Exhaust Fluid
1 <1500mls/2400km engine start - The volumes of DEF are consumption
and DEF tank geometry dependant

The DEF is running low

Stage DEF range
Amber symbol Refill Diesel Exhaust Fluid - The volumes of DEF are consumption
2 <940mls/1500km
and DEF tank geometry dependant

The DEF is running low. Fill DEF

Stage DEF range No engine restart possible soon. immediately or engine will not start
Amber symbol
3 <515mls/830km Diesel Exhaust Fluid - The volumes of DEF are consumption
and DEF tank geometry dependant

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The DEF is running critically low. Fill DEF
Stage DEF range No engine restart possible soon. immediately or engine will not start
Amber symbol
4 <100mls/160km Diesel Exhaust Fluid - The volumes of DEF are consumption
and DEF tank geometry dependant

The DEF tank is empty. Fill DEF to the

Stage DEF range minimum restart level condition
Red symbol No engine restart possible
5 <0mls/0km - The volumes of DEF are consumption
and DEF tank geometry dependant

Diesel Exhaust Fluid (DEF) Quality

The DEF quality is monitored after refilling of the DEF tank. The monitoring begins when refilling is identified. In order to
recognize a poor quality DEF, the OBD system uses the SCR catalytic converter NOx efficiencies, returned by the passive SCR
catalytic converter monitoring, to build long and short term records of the average NOx conversion efficiencies. If the short
term record becomes significantly different to the long term record, the malfunction is attributed to the quality of the DEF.
The message center warning system is activated when such a malfunction is detected. Simultaneously, the MIL is directly
activated on the first occurrence of the malfunction detection

Stages Cause Warning Message Description

Incorrect DEF The DEF does not meet manufacturer specifications.
Stage Amber Incorrect Diesel Exhaust Fluid quality
quality is The system must be checked by a Jaguar Land Rover
1 symbol detected
detected service department
Incorrect DEF No engine restart possible in 515mls/ The DEF does not meet manufacturer specifications.
Stage Amber
quality is 830km. Incorrect Diesel Exhaust Fluid The system must be checked by a Jaguar Land Rover
2 symbol
detected quality detected service department
Incorrect DEF No engine restart possible soon. The DEF does not meet manufacturer specifications.
Stage Amber
quality is Incorrect Diesel Exhaust Fluid quality The system must be checked by a Jaguar Land Rover
3 symbol
detected detected service department
Incorrect DEF The DEF does not meet manufacturer specifications.
Stage Red No engine restart possible. Incorrect
quality is The system must be checked by a Jaguar Land Rover
4 symbol Diesel Exhaust Fluid quality detected
detected service department
Diesel Exhaust Fluid (DEF) Quality

Prior to the NOx sensor and the monitoring function becoming operational, the sensor must have reached its 'dew point'. This
is the point where the moisture content in the exhaust gas has evaporated and can no longer damage the NOx sensor. In
normal ambient conditions, this process typically takes around 6 to 10 minutes. If a malfunction is detected during the
operation of the NOx sensor, a reversible fault is stored. If a malfunction is detected over two (NAS variants) or three (EU6
variants) consecutive drive cycles, a permanent fault is stored and the MIL is activated

The following monitoring is performed on the NOx sensors

Signal plausibility and correction factor limits

Circuit continuity between the sensor control unit and probe element
 Operating temperature reached after a defined heating period

Private CAN Bus - Monitoring

The following components are connected to the ECM via a private CAN bus. The ECM provides a gateway, for communication
to the vehicle CAN bus

Heater control unit

NOx sensor control unit(s)

The following CAN communication monitoring applies to these components

Signal time-out
Signal check sum

The DEF injector, DEF pump, temperature and level sensors are hardwired to the ECM and do not involve CAN communication

Diesel Exhaust Fluid (DEF) Supply and Metering System Malfunctions

The OBD system monitors components and the functionality of the DEF supply and metering system. If a malfunction is
detected a message center warning is displayed. If no action is taken to rectify the warning malfunction, this will eventually
lead to a 'No engine restart' situation

Stages Cause Warning Message Description

Supply system or
No engine restart possible in The DEF supply system or component used for
Stage monitoring Amber
515mls/830km. Diesel Exhaust monitoring is malfunctioning. The system must be
1 component symbol
Fluid system malfunction checked by a Jaguar Land Rover service department
malfunction

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Supply system or
No engine restart possible. The DEF supply system or component used for
Stage monitoring Red
Diesel Exhaust Fluid system monitoring is malfunctioning. The system must be
2 component symbol
malfunction checked by a Jaguar Land Rover service department
malfunction
Diesel Exhaust Fluid (DEF) Supply and Metering System Malfunctions

The following DEF supply and metering system malfunctions may trigger the message center warning system

Pressure build up in the supply line

Metering/injection time to closed loop
Over pressure in supply line
Under pressure in supply line
Injection valve open circuit
SCR system relay open circuit
Solenoid pump(s) open circuit
Combined temperature/level sensor open circuit
Missing communication with upstream NOx sensor (NAS variants only)
Missing communication with downstream NOx sensor

Diesel exhaust fluid

DTC Description Purpose and Cause Action

NOTE: To monitor diesel

exhaust fluid heater control unit.
Diesel exhaust fluid heater control
unit under voltage

The engine control module Refer to the electrical circuit diagrams and check
measured a voltage below a diesel exhaust fluid heater control unit power and
specified range but not ground circuits for open circuit
necessarily a short circuit to Refer to the electrical circuit diagrams and check
Reductant Heater ground the diesel exhaust fluid heater control unit circuit
Control Module Diesel exhaust fluid heater for open circuit, high resistance
P05ED-16 Supply Voltage - control unit power and Inspect connectors for signs of water ingress, and
Circuit voltage ground circuits open circuit pins for damage and/or corrosion
below threshold Diesel exhaust fluid heater Check and install a new diesel exhaust fluid heater
control unit circuit short control unit as required
circuit to ground, short Using the manufacturer approved diagnostic
circuit to power, open system clear all stored DTCs using the ‘Diagnosis
circuit, high resistance Menu’ tab and retest
Connector is disconnected,
connector pin is backed out,
connector pin corrosion
Diesel exhaust fluid heater
control unit failure
 NOTE: To monitor diesel
exhaust fluid heater control unit.
Diesel exhaust fluid heater control
unit over voltage
Refer to the electrical circuit diagrams and check
The engine control module
diesel exhaust fluid heater control unit power and
measured a voltage above a
ground circuits for short circuit to ground, circuit
specified range but not
short circuit to power
necessarily a short circuit to
Refer to the electrical circuit diagrams and check
Reductant Heater power
the diesel exhaust fluid heater control unit circuit
Control Module Diesel exhaust fluid heater
for short circuit to ground, circuit short circuit to
P05ED-17 Supply Voltage - control unit power or ground
power
Circuit voltage circuit short circuit to
inspect connectors for signs of water ingress, and
above threshold ground, circuit short circuit
pins for damage and/or corrosion
to power
Check and install a new diesel exhaust fluid heater
Diesel exhaust fluid heater
control unit as required
control unit circuit short
Using the manufacturer approved diagnostic
circuit to ground, short
system clear all stored DTCs using the ‘Diagnosis
circuit to power, open
Menu’ tab and retest
circuit, high resistance
Connector is disconnected,
connector pin is backed out,
connector pin corrosion
Diesel exhaust fluid heater
control unit failure

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NOTE: To monitor diesel
exhaust fluid relay. Diesel exhaust
fluid relay stuck closed

The engine control module

has not detected any Refer to the electrical circuit diagrams and check
motion, upon commanding the diesel exhaust fluid tank module circuit for
the operation of a motor, short circuit to ground, short circuit to power, open
solenoid or relay to open circuit, high resistance
some piece of equipment Refer to the electrical circuit diagrams and check
Diesel exhaust fluid tank the diesel exhaust fluid relay circuit for short
Reductant Pump module circuit short circuit circuit to ground, short circuit to power, open
Supply Voltage to ground, short circuit to circuit, high resistance
P05F1-73 Circuit Stuck On - power, open circuit, high Inspect connectors for signs of water ingress, and
Actuator stuck resistance pins for damage and/or corrosion
closed Diesel exhaust fluid relay Check and install a new diesel exhaust fluid relay
circuit short circuit to as required
ground, short circuit to Check and install a new diesel exhaust fluid tank
power, open circuit, high module as required
resistance Using the manufacturer approved diagnostic
Connector is disconnected, system clear all stored DTCs using the ‘Diagnosis
connector pin is backed out, Menu’ tab and retest
connector pin corrosion
Diesel exhaust fluid relay
failure
Diesel exhaust fluid tank
module failure

NOTE: To monitor diesel

exhaust fluid relay. Diesel exhaust
fluid relay stuck open

The engine control module

has not detected any Refer to the electrical circuit diagrams and check
motion, upon commanding the diesel exhaust fluid tank module circuit for
the operation of a motor, short circuit to ground, short circuit to power, open
solenoid or relay to close circuit, high resistance
some piece of equipment Refer to the electrical circuit diagrams and check
Diesel exhaust fluid tank the diesel exhaust fluid relay circuit for short
Reductant Pump module circuit short circuit circuit to ground, short circuit to power, open
Supply Voltage to ground, short circuit to circuit, high resistance
P05F2-72 Circuit Stuck Off - power, open circuit, high Inspect connectors for signs of water ingress, and
Actuator stuck resistance pins for damage and/or corrosion
open Diesel exhaust fluid relay Check and install a new diesel exhaust fluid relay
circuit short circuit to as required
ground, short circuit to Check and install a new diesel exhaust fluid tank
power, open circuit, high module as required
resistance
 Connector is disconnected, Using the manufacturer approved diagnostic
connector pin is backed out, system clear all stored DTCs using the ‘Diagnosis
connector pin corrosion Menu’ tab and retest
Diesel exhaust fluid relay
failure
Diesel exhaust fluid tank
module failure

NOTE: To monitor diesel

exhaust fluid heater control unit.
Diesel exhaust fluid heater control
unit missing voltage

The engine control module Refer to the electrical circuit diagrams and check
has determined an open the diesel exhaust fluid heater control unit circuit
circuit via lack of bias for open circuit, high resistance
Reductant Heater voltage, low current flow, no Inspect connectors for signs of water ingress, and
Control Module change in the state of an pins for damage and/or corrosion
P05F8-13 input in response to an
Performance - Check and install a new diesel exhaust fluid heater
Circuit open output control unit as required
Diesel exhaust fluid heater Using the manufacturer approved diagnostic
control unit power or ground system clear all stored DTCs using the ‘Diagnosis
circuit open circuit, high Menu’ tab and retest
resistance
Connector is disconnected,
connector pin is backed out,
connector pin corrosion

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Diesel exhaust fluid heater
control unit failure

NOTE: To monitor diesel

exhaust fluid heater control unit.
Diesel exhaust fluid heater control
unit over temperature Refer to the electrical circuit diagrams and check
the diesel exhaust fluid heater control unit circuit
The engine control module for short circuit to power
Reductant Heater detected an internal Inspect connectors for signs of water ingress, and
Control Module temperature above the pins for damage and/or corrosion
P05F8-4B expected range
Performance - Over Check and install a new diesel exhaust fluid heater
temperature Diesel exhaust fluid heater control unit module as required
control unit circuit short Using the manufacturer approved diagnostic
circuit to power system clear all stored DTCs using the ‘Diagnosis
Connector is disconnected, Menu’ tab and retest
connector pin is backed out,
connector pin corrosion
Diesel exhaust fluid heater
control unit failure

NOTE: To monitor diesel

exhaust fluid heater control unit.
Diesel exhaust fluid heater control
unit non volatile memory error

The engine control module Refer to the electrical circuit diagrams and check
monitored a parameter over the diesel exhaust fluid heater control unit circuit
time within specified limits for short circuit to ground, short circuit to power,
Reductant Heater
and detected more than the open circuit, high resistance
Control Module
expected number of Inspect connectors for signs of water ingress, and
Performance -
P05F8-66 transitions pins for damage and/or corrosion
Signal has too
Diesel exhaust fluid heater Check and install a new diesel exhaust fluid heater
many transitions /
control unit circuit short control unit as required
events
circuit to ground, short Using the manufacturer approved diagnostic
circuit to power, open system clear all stored DTCs using the ‘Diagnosis
circuit, high resistance Menu’ tab and retest
Connector is disconnected,
connector pin is backed out,
connector pin corrosion
Diesel exhaust fluid heater
control unit failure

Diagnosis of this DTC may require using the

manufacturer approved diagnostic system check
datalogger signals
 Selective catalytic reduction - 0x05C1 Reductant Tank Fluid Level
dosing system prime routine - 0x043C Reductant Tank Temperature - Raw
failed during the empty - Check that the DEF tank has at least 25mm
phase of fluid (0x05C1)
Selective catalytic reduction - Check the DEF tank temperature is within -5
SCR System - EOL priming routine did not to + 70 °C (0x043C)
- Failure During complete successfully Refer to the electrical circuit diagrams and check
Emptying Test - No DEF back flow pump did not the diesel exhaust fluid tank module circuit for
P16A3-00
sub type empty the pressure line short circuit to ground, short circuit to power, open
information correctly circuit, high resistance
DEF pressure line leakage Check the DEF pressure line for leakage
Routine aborted at ignition Using the manufacturer approved diagnostic
off system carry out routine 0x409A - Reductant First
Fill And Pressure Test. Check that the ignition
stays on throughout the whole duration of the
routine
Using the manufacturer approved diagnostic
system clear all stored DTCs using the ‘Diagnosis
Menu’ tab and retest

Diagnosis of this DTC may require using the

manufacturer approved diagnostic system check
datalogger signals
- 0x05C1 Reductant Tank Fluid Level
- 0x043C Reductant Tank Temperature - Raw
- Check that the DEF tank has at least 25mm
Selective catalytic reduction
of fluid (0x05C1)
dosing system prime routine

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- Check the DEF tank temperature is within -5
failed during the first fill
to + 70 °C (0x043C)
SCR System - EOL phase
Refer to the electrical circuit diagrams and check
- Failure During Selective catalytic reduction
the diesel exhaust fluid tank module circuit for
P16A4-00 First Fill Test - No priming routine did not
short circuit to ground, short circuit to power, open
sub type complete successfully
circuit, high resistance
information Pressure and DEF back flow
Check the DEF pressure line for leakage
pump not activated correctly
Using the manufacturer approved diagnostic
Routine aborted at ignition
system carry out routine 0x409A - Reductant First
off
Fill And Pressure Test. Check that the ignition
stays on throughout the whole duration of the
routine
Using the manufacturer approved diagnostic
system clear all stored DTCs using the ‘Diagnosis
Menu’ tab and retest

Diagnosis of this DTC may require using the

manufacturer approved diagnostic system check
datalogger signals
- 0x05C1 Reductant Tank Fluid Level
- 0x043C Reductant Tank Temperature - Raw
Selective catalytic reduction
- Check that the DEF tank has at least 25mm
dosing system prime routine
of fluid (0x05C1)
failed during the pressure
- Check the DEF tank temperature is within -5
preparation phase
to + 70 °C (0x043C)
SCR System - EOL Selective catalytic reduction
Refer to the electrical circuit diagrams and check
- Failure During priming routine did not
the diesel exhaust fluid tank module circuit for
P16A5-00 Pressure Test - No complete successfully
short circuit to ground, short circuit to power, open
sub type Pressure pump is not
circuit, high resistance
information pressurizing the line
Check the DEF pressure line for leakage
correctly
Using the manufacturer approved diagnostic
DEF pressure line leakage
system carry out routine 0x409A - Reductant First
Routine aborted at ignition
Fill And Pressure Test. Check that the ignition
off
stays on throughout the whole duration of the
routine
Using the manufacturer approved diagnostic
system clear all stored DTCs using the ‘Diagnosis
Menu’ tab and retest

Diagnosis of this DTC may require using the

manufacturer approved diagnostic system check
datalogger signals
- 0x05C1 Reductant Tank Fluid Level
Selective catalytic reduction - 0x043C Reductant Tank Temperature - Raw
dosing system prime routine - Check that the DEF tank has at least 25mm
aborted during cycle of fluid (0x05C1)
SCR System - EOL
P16A6-00 - Unfinished Tests - Selective catalytic reduction - Check the DEF tank temperature is within -5
No sub type priming routine did not to + 70 °C (0x043C)
information complete successfully Using the manufacturer approved diagnostic
The routine has been system carry out routine 0x409A - Reductant First
aborted by the user Fill And Pressure Test. Check that the ignition
Routine aborted at ignition stays on throughout the whole duration of the
off routine
Using the manufacturer approved diagnostic
system clear all stored DTCs using the ‘Diagnosis
Menu’ tab and retest

Refer to the electrical circuit diagrams and check

Diesel exhaust fluid tank
the diesel exhaust fluid tank module circuit for
module circuit short circuit
short circuit to ground, short circuit to power, open
to ground, short circuit to
circuit, high resistance
SCR System - power, open circuit, high
- DEF pump circuit
Tampering At resistance
Inspect connectors for signs of water ingress, and
P16A7-00 Connector 1 - No - DEF pump circuit
pins for damage and/or corrosion
sub type Connector is disconnected,
Check and install a new diesel exhaust fluid tank
information connector pin is backed out,
module as required
connector pin corrosion
Using the manufacturer approved diagnostic
Diesel exhaust fluid tank
system clear all stored DTCs using the ‘Diagnosis
module failure
Menu’ tab and retest

Refer to the electrical circuit diagrams and check

Diesel exhaust fluid tank
the diesel exhaust fluid tank module circuit for
module circuit short circuit
short circuit to ground, short circuit to power, open

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to ground, short circuit to
circuit, high resistance
power, open circuit, high
- DEF heater
SCR System - resistance
- DEF level
Tampering At - DEF heater
- DEF relay circuit
P16A8-00 Connector 2 - No - DEF level
Inspect connectors for signs of water ingress, and
sub type - DEF relay circuit
pins for damage and/or corrosion
information Connector is disconnected,
Check and install a new diesel exhaust fluid tank
connector pin is backed out,
module as required
connector pin corrosion
Using the manufacturer approved diagnostic
Diesel exhaust fluid tank
system clear all stored DTCs using the ‘Diagnosis
module failure
Menu’ tab and retest

The engine control module

has determined an open
circuit via lack of bias
Refer to the electrical circuit diagrams and check
voltage, low current flow, no
the diesel exhaust fluid heater control unit circuit
change in the state of an
for open circuit, high resistance
input in response to an
Reductant Tank Inspect connectors for signs of water ingress, and
output
Heater Control pins for damage and/or corrosion
P202A-13 Diesel exhaust fluid heater
Circuit/Open - Check and install a new diesel exhaust fluid heater
control unit circuit open
Circuit open control unit as required
circuit, high resistance
Using the manufacturer approved diagnostic
Connector is disconnected,
system clear all stored DTCs using the ‘Diagnosis
connector pin is backed out,
Menu’ tab and retest
connector pin corrosion
Diesel exhaust fluid heater
control unit failure

The engine control module

has detected a ground
measurement for a period
Refer to the electrical circuit diagrams and check
longer than expected or has
the diesel exhaust fluid heater control unit circuit
detected a ground
short circuit to ground
Reductant Tank measurement when another
Inspect connectors for signs of water ingress, and
Heater Control value was expected
pins for damage and/or corrosion
P202B-11 Circuit Low - Diesel exhaust fluid heater
Check and install a new diesel exhaust fluid heater
Circuit short to control unit circuit short
control unit as required
ground circuit to ground
Using the manufacturer approved diagnostic
Connector is disconnected,
system clear all stored DTCs using the ‘Diagnosis
connector pin is backed out,
Menu’ tab and retest
connector pin corrosion
Diesel exhaust fluid heater
control unit failure
 NOTE: To monitor diesel
exhaust fluid heater for open
circuit, high resistance Refer to the electrical circuit diagrams and check
the diesel exhaust fluid heater control unit circuit
The engine control module for open circuit, high resistance
has determined an open Refer to the electrical circuit diagrams and check
circuit via lack of bias the CAN communication diesel exhaust fluid tank
voltage, low current flow, no module - DEF heater controller circuit for open
Reductant Tank change in the state of an circuit, high resistance
Heater Control input in response to an
P202B-13 Circuit Low - Inspect connectors for signs of water ingress, and
output pins for damage and/or corrosion
Circuit open Diesel exhaust fluid heater Check and install a new diesel exhaust fluid heater
control unit circuit open control unit as required
circuit, high resistance Using the manufacturer approved diagnostic
CAN communication diesel system clear all stored DTCs using the ‘Diagnosis
exhaust fluid tank module - Menu’ tab and retest
DEF heater controller circuit
open circuit, high resistance
Connector is disconnected,
connector pin is backed out,
connector pin corrosion
Diesel exhaust fluid heater
control unit failure

The engine control module

has detected a vehicle

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power measurement for a
Refer to the electrical circuit diagrams and check
period longer than expected
the diesel exhaust fluid heater control unit circuit
or has detected a vehicle
short circuit to power
Reductant Tank power measurement when
Inspect connectors for signs of water ingress, and
Heater Control another value was expected
pins for damage and/or corrosion
P202C-12 Circuit High - Diesel exhaust fluid heater
Check and install a new diesel exhaust fluid heater
Circuit short to control unit circuit short
control unit as required
battery circuit to power
Using the manufacturer approved diagnostic
Connector is disconnected,
system clear all stored DTCs using the ‘Diagnosis
connector pin is backed out,
Menu’ tab and retest
connector pin corrosion
Diesel exhaust fluid heater
control unit failure

The engine control module

has detected a power
measurement or open circuit
for a period longer than
Refer to the electrical circuit diagrams and check
expected or has detected a
the diesel exhaust fluid heater control unit circuit
power measurement or open
short circuit to power open circuit, high resistance
Reductant Tank circuit when another value
Inspect connectors for signs of water ingress, and
Heater Control was expected
pins for damage and/or corrosion
P202C-15 Circuit High - Diesel exhaust fluid heater
Check and install a new diesel exhaust fluid heater
Circuit short to control unit circuit short
control unit as required
battery or open circuit to power open circuit,
Using the manufacturer approved diagnostic
high resistance
system clear all stored DTCs using the ‘Diagnosis
Connector is disconnected,
Menu’ tab and retest
connector pin is backed out,
connector pin corrosion
Diesel exhaust fluid heater
control unit failure

The engine control module

detected an internal
temperature above the Refer to the electrical circuit diagrams and check
expected range the diesel exhaust fluid heater control unit circuit
Diesel exhaust fluid heater for open circuit, high resistance
control unit circuit open Refer to the electrical circuit diagrams and check
circuit, high resistance the CAN communication diesel exhaust fluid tank
Reductant Injection
CAN communication diesel module - DEF heater controller circuit for open
Valve Circuit
exhaust fluid tank module - circuit, high resistance
P202E-4B Range/Performance
DEF heater controller circuit Inspect connectors for signs of water ingress, and
Bank 1 Unit 1 -
open circuit, high resistance pins for damage and/or corrosion
Over temperature
Connector is disconnected, Check and install a new diesel exhaust fluid heater
connector pin is backed out, control unit as required
connector pin corrosion
 Diesel exhaust fluid heater Using the manufacturer approved diagnostic
control unit failure system clear all stored DTCs using the ‘Diagnosis
Menu’ tab and retest

NOTE: Monitoring of the

diesel exhaust fluid level sensor
(level)
NOTE: Key On. Tank unfrozen, drive for 10 Km
Diesel exhaust fluid tank
module level reading not Refer to the electrical circuit diagrams and check
possible the diesel exhaust fluid tank module circuit for
Reductant Level Diesel exhaust fluid tank short circuit to ground, short circuit to power, open
Sensor "A" Circuit module communication error circuit, high resistance
P203B-02 Range/Performance Diesel exhaust fluid tank Inspect connectors for signs of water ingress, and
- General signal module circuit short circuit pins for damage and/or corrosion
failure to ground, short circuit to Check and install a new diesel exhaust fluid tank
power, open circuit, high module as required
resistance Using the manufacturer approved diagnostic
Connector is disconnected, system clear all stored DTCs using the ‘Diagnosis
connector pin is backed out, Menu’ tab and retest
connector pin corrosion
Diesel exhaust fluid tank
module failure

NOTE: Monitoring of the

diesel exhaust fluid level sensor

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(level)

The engine control module

NOTE: Key On
measured a voltage below a
specified range but not
Refer to the electrical circuit diagrams and check
necessarily a short circuit to
the diesel exhaust fluid tank module circuit for
Reductant Level ground
short circuit to ground, short circuit to power, open
Sensor "A" Circuit Diesel exhaust fluid tank
circuit, high resistance
P203B-16 Range/Performance module level signal range
Inspect connectors for signs of water ingress, and
- Circuit voltage check too low
pins for damage and/or corrosion
below threshold Diesel exhaust fluid tank
Check and install a new diesel exhaust fluid tank
module circuit short circuit
module as required
to ground, short circuit to
Using the manufacturer approved diagnostic
power, open circuit, high
system clear all stored DTCs using the ‘Diagnosis
resistance
Menu’ tab and retest
Connector is disconnected,
connector pin is backed out,
connector pin corrosion
Diesel exhaust fluid tank
module failure

The engine control module

measured a voltage above a
specified range but not Refer to the electrical circuit diagrams and check
necessarily a short circuit to the diesel exhaust fluid tank module circuit for
power short circuit to ground, short circuit to power, open
Reductant Level Diesel exhaust fluid tank circuit, high resistance
Sensor "A" Circuit module circuit short circuit Inspect connectors for signs of water ingress, and
P203B-17 Range/Performance to ground, short circuit to pins for damage and/or corrosion
- Circuit voltage power, open circuit, high Check and install a new diesel exhaust fluid tank
above threshold resistance module as required
Connector is disconnected, Using the manufacturer approved diagnostic
connector pin is backed out, system clear all stored DTCs using the ‘Diagnosis
connector pin corrosion Menu’ tab and retest
Diesel exhaust fluid tank
module failure

NOTE: Monitoring of the

diesel exhaust fluid level sensor
(level)

The engine control module

NOTE: Key On. Tank unfrozen, drive for 10 Km
does not detect a signal
which ought to be present
Diesel exhaust fluid tank
module level reading not
Reductant Level possible
P203B-31 Sensor "A" Circuit Diesel exhaust fluid tank Refer to the electrical circuit diagrams and check
Range/Performance module communication error the diesel exhaust fluid tank module circuit for
- No signal Diesel exhaust fluid tank short circuit to ground, short circuit to power, open
module circuit short circuit circuit, high resistance
to ground, short circuit to Inspect connectors for signs of water ingress, and
power, open circuit, high pins for damage and/or corrosion
resistance Check and install a new diesel exhaust fluid tank
Connector is disconnected, module as required
connector pin is backed out, Using the manufacturer approved diagnostic
connector pin corrosion system clear all stored DTCs using the ‘Diagnosis
Diesel exhaust fluid tank Menu’ tab and retest
module failure

Refer to the electrical circuit diagrams and check

Diesel exhaust fluid tank
the diesel exhaust fluid tank module circuit for
module circuit short circuit
short circuit to ground, short circuit to power, open
to ground, short circuit to
circuit, high resistance
Reductant Level power, open circuit, high
Inspect connectors for signs of water ingress, and
Sensor, A, Circuit resistance
P203C-00 pins for damage and/or corrosion
Low - No sub type Connector is disconnected,
Check and install a new diesel exhaust fluid tank
information connector pin is backed out,
module as required
connector pin corrosion
Using the manufacturer approved diagnostic
Diesel exhaust fluid tank
system clear all stored DTCs using the ‘Diagnosis
module failure
Menu’ tab and retest

Refer to the electrical circuit diagrams and check

Diesel exhaust fluid tank
the diesel exhaust fluid tank module circuit for

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module circuit short circuit
short circuit to ground, short circuit to power, open
to ground, short circuit to
circuit, high resistance
Reductant Level power, open circuit, high
Inspect connectors for signs of water ingress, and
Sensor "A" Circuit resistance
P203D-00 pins for damage and/or corrosion
High - No sub type Connector is disconnected,
Check and install a new diesel exhaust fluid tank
information connector pin is backed out,
module as required
connector pin corrosion
Using the manufacturer approved diagnostic
Diesel exhaust fluid tank
system clear all stored DTCs using the ‘Diagnosis
module failure
Menu’ tab and retest

The engine control module

has determined an open
circuit via lack of bias
Refer to the electrical circuit diagrams and check
voltage, low current flow, no
the diesel exhaust fluid injector circuit for open
change in the state of an
circuit, high resistance
input in response to an
Reductant Injection Inspect connectors for signs of water ingress, and
output
Valve Circuit/Open pins for damage and/or corrosion
P2047-13 Diesel exhaust fluid injector
Bank 1 Unit 1 - Check and install a new diesel exhaust fluid
circuit open circuit, high
Circuit open injector as required
resistance
Using the manufacturer approved diagnostic
Connector is disconnected,
system clear all stored DTCs using the ‘Diagnosis
connector pin is backed out,
Menu’ tab and retest
connector pin corrosion
Diesel exhaust fluid injector
failure

The engine control module

has detected a ground
measurement for a period
Refer to the electrical circuit diagrams and check
longer than expected or has
the diesel exhaust fluid injector circuit for short
detected a ground
circuit to ground
Reductant Injection measurement when another
Inspect connectors for signs of water ingress, and
Valve Circuit Low value was expected
pins for damage and/or corrosion
P2048-11 Bank 1 Unit 1 - Diesel exhaust fluid injector
Check and install a new diesel exhaust fluid
Circuit short to circuit short circuit to
injector as required
ground ground
Using the manufacturer approved diagnostic
Connector is disconnected,
system clear all stored DTCs using the ‘Diagnosis
connector pin is backed out,
Menu’ tab and retest
connector pin corrosion
Diesel exhaust fluid injector
failure

The engine control module

has detected a vehicle
power measurement for a
 Reductant Injection period longer than expected Refer to the electrical circuit diagrams and check
Valve Circuit High or has detected a vehicle the diesel exhaust fluid injector circuit for short
Bank 1 Unit 1 - power measurement when circuit to power
P2049-12 Circuit short to another value was expected Inspect connectors for signs of water ingress, and
battery Diesel exhaust fluid injector pins for damage and/or corrosion
circuit short circuit to power Check and install a new diesel exhaust fluid
Connector is disconnected, injector as required
connector pin is backed out, Using the manufacturer approved diagnostic
connector pin corrosion system clear all stored DTCs using the ‘Diagnosis
Diesel exhaust fluid injector Menu’ tab and retest
failure

The engine control module

has determined failures
Refer to the electrical circuit diagrams and check
where some circuit quantity,
the diesel exhaust fluid tank module circuit for
reported via serial data, is
short circuit to ground, open circuit, high
below a specified range
Reductant Tank resistance
Diesel exhaust fluid tank
Temperature Inspect connectors for signs of water ingress, and
module circuit short circuit
P205B-84 Sensor "A" Circuit pins for damage and/or corrosion
to ground, open circuit, high
Low - Signal below Check and install a new diesel exhaust fluid tank
resistance
allowable range module as required
Connector is disconnected,
Using the manufacturer approved diagnostic
connector pin is backed out,
system clear all stored DTCs using the ‘Diagnosis
connector pin corrosion
Menu’ tab and retest
Diesel exhaust fluid tank
module failure

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The engine control module
has determined failures
Refer to the electrical circuit diagrams and check
where some circuit quantity,
the diesel exhaust fluid tank module circuit for
reported via serial data, is
short circuit to power
Reductant Tank above a specified range
Inspect connectors for signs of water ingress, and
Temperature Diesel exhaust fluid tank
pins for damage and/or corrosion
P205B-85 Sensor "A" Circuit module circuit short circuit
Check and install a new diesel exhaust fluid tank
Low - Signal above to power
module as required
allowable range Connector is disconnected,
Using the manufacturer approved diagnostic
connector pin is backed out,
system clear all stored DTCs using the ‘Diagnosis
connector pin corrosion
Menu’ tab and retest
Diesel exhaust fluid tank
module failure

The engine control module

measured a voltage below a
Refer to the electrical circuit diagrams and check
specified range but not
the diesel exhaust fluid tank module circuit for
necessarily a short circuit to
short circuit to ground, open circuit, high
Reductant Tank ground
resistance
Temperature Diesel exhaust fluid tank
Inspect connectors for signs of water ingress, and
Sensor "A" Circuit module circuit short circuit
P205C-16 pins for damage and/or corrosion
High - Circuit to ground, open circuit, high
Check and install a new diesel exhaust fluid tank
voltage below resistance
module as required
threshold Connector is disconnected,
Using the manufacturer approved diagnostic
connector pin is backed out,
system clear all stored DTCs using the ‘Diagnosis
connector pin corrosion
Menu’ tab and retest
Diesel exhaust fluid tank
module failure

The engine control module

measured a voltage above a
Refer to the electrical circuit diagrams and check
specified range but not
the diesel exhaust fluid tank module circuit for
necessarily a short circuit to
Reductant Tank short circuit to power
power
Temperature Inspect connectors for signs of water ingress, and
Diesel exhaust fluid tank
Sensor "A" Circuit pins for damage and/or corrosion
P205D-17 module circuit short circuit
Intermittent/Erratic Check and install a new diesel exhaust fluid tank
to power
- Circuit voltage module as required
Connector is disconnected,
above threshold Using the manufacturer approved diagnostic
connector pin is backed out,
system clear all stored DTCs using the ‘Diagnosis
connector pin corrosion
Menu’ tab and retest
Diesel exhaust fluid tank
module failure

The engine control module

Refer to the electrical circuit diagrams and check
detected plausibility failures
the diesel exhaust fluid tank module circuit for
 Reductant Tank Diesel exhaust fluid tank short circuit to ground, short circuit to power, open
Temperature module circuit short circuit circuit, high resistance
Sensor Circuit to ground, short circuit to Inspect connectors for signs of water ingress, and
P205E-64 Intermittent/Erratic power, open circuit, high pins for damage and/or corrosion
- Signal plausibility resistance Check and install a new diesel exhaust fluid tank
failure Connector is disconnected, module as required
connector pin is backed out, Using the manufacturer approved diagnostic
connector pin corrosion system clear all stored DTCs using the ‘Diagnosis
Diesel exhaust fluid tank Menu’ tab and retest
module failure

The engine control module

has determined an open
circuit via lack of bias
voltage, low current flow, no Refer to the electrical circuit diagrams and check
change in the state of an the diesel exhaust fluid tank module circuit for
input in response to an open circuit, high resistance
output - output from the ECM to DEF pump control
Reductant Pump
Diesel exhaust fluid tank Inspect connectors for signs of water ingress, and
"A" Control
P208A-13 module circuit open circuit, pins for damage and/or corrosion
Circuit/Open -
high resistance Check and install a new diesel exhaust fluid tank
Circuit open
- output from the ECM module as required
to DEF pump control Using the manufacturer approved diagnostic
Connector is disconnected, system clear all stored DTCs using the ‘Diagnosis
connector pin is backed out, Menu’ tab and retest
connector pin corrosion
Diesel exhaust fluid tank

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module failure

Refer to the electrical circuit diagrams and check

Diesel exhaust fluid tank
the diesel exhaust fluid tank module circuit for
module circuit short circuit
short circuit to ground, short circuit to power, open
to ground, short circuit to
circuit, high resistance
Reductant Pump power, open circuit, high
- DEF back flow pump
"A" Control resistance
Inspect connectors for signs of water ingress, and
P208B-00 Performance/Stuck - DEF back flow pump
pins for damage and/or corrosion
Off - No sub type Connector is disconnected,
Check and install a new diesel exhaust fluid tank
information connector pin is backed out,
module as required
connector pin corrosion
Using the manufacturer approved diagnostic
Diesel exhaust fluid tank
system clear all stored DTCs using the ‘Diagnosis
module failure
Menu’ tab and retest

The engine control module

detected an internal
Refer to the electrical circuit diagrams and check
temperature above the
the diesel exhaust fluid tank module circuit for
expected range
short circuit to power
Diesel exhaust fluid tank
Reductant Pump - output from the ECM to DEF pump control
module circuit short circuit
"A" Control Inspect connectors for signs of water ingress, and
to power
P208B-4B Performance/Stuck pins for damage and/or corrosion
- output from the ECM
Off - Over Check and install a new diesel exhaust fluid tank
to DEF pump control
temperature module as required
Connector is disconnected,
Using the manufacturer approved diagnostic
connector pin is backed out,
system clear all stored DTCs using the ‘Diagnosis
connector pin corrosion
Menu’ tab and retest
Diesel exhaust fluid tank
module failure

NOTE: To monitor for the

pump pressure. Diesel exhaust fluid
injection pump range performance Refer to the electrical circuit diagrams and check
the diesel exhaust fluid tank module circuit for
The engine control module short circuit to ground, short circuit to power, open
detected plausibility failures circuit, high resistance - monitor for the pump
Reductant Pump
Diesel exhaust fluid tank pressure build up
"A" Control
module circuit short circuit Inspect connectors for signs of water ingress, and
P208B-64 Performance/Stuck
to ground, short circuit to pins for damage and/or corrosion
Off - Signal
power, open circuit, high Check and install a new diesel exhaust fluid tank
plausibility failure
resistance module as required
Connector is disconnected, Using the manufacturer approved diagnostic
connector pin is backed out, system clear all stored DTCs using the ‘Diagnosis
connector pin corrosion Menu’ tab and retest
Diesel exhaust fluid injection
pump failure
 The engine control module
has detected a ground
measurement for a period
longer than expected or has Refer to the electrical circuit diagrams and check
detected a ground the diesel exhaust fluid tank module circuit for
measurement when another short circuit to ground
value was expected - output from the ECM to DEF pump control
Reductant Pump
Diesel exhaust fluid tank Inspect connectors for signs of water ingress, and
"A" Control Circuit
P208C-11 module circuit short circuit pins for damage and/or corrosion
Low - Circuit short
to ground Check and install a new diesel exhaust fluid tank
to ground
- output from the ECM module as required
to DEF pump control Using the manufacturer approved diagnostic
Connector is disconnected, system clear all stored DTCs using the ‘Diagnosis
connector pin is backed out, Menu’ tab and retest
connector pin corrosion
Diesel exhaust fluid tank
module failure

The engine control module

has detected a vehicle
power measurement for a
period longer than expected Refer to the electrical circuit diagrams and check
or has detected a vehicle the diesel exhaust fluid tank module circuit for
power measurement when short circuit to power
another value was expected - output from the ECM to DEF pump control
Reductant Pump
Diesel exhaust fluid tank Inspect connectors for signs of water ingress, and

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"A" Control Circuit
P208D-12 module circuit short circuit pins for damage and/or corrosion
High - Circuit short
to power Check and install a new diesel exhaust fluid tank
to battery
- output from the ECM module as required
to DEF pump control Using the manufacturer approved diagnostic
Connector is disconnected, system clear all stored DTCs using the ‘Diagnosis
connector pin is backed out, Menu’ tab and retest
connector pin corrosion
Diesel exhaust fluid tank
module failure

NOTE: To monitor diesel

exhaust fluid injector opening /
closing. Diesel exhaust fluid injector
is stuck closed
Reductant Injection Check and install a new diesel exhaust fluid
Valve Stuck Closed The engine control module injector as required
P208E-73 Bank 1 Unit 1 - has not detected any Using the manufacturer approved diagnostic
Actuator stuck motion, upon commanding system clear all stored DTCs using the ‘Diagnosis
closed the operation of a motor, Menu’ tab and retest
solenoid or relay to open
some piece of equipment
Diesel exhaust fluid injector
failure

NOTE: To monitor diesel

exhaust fluid heater control unit.
Diesel exhaust fluid heater control
unit voltage too low
Refer to the electrical circuit diagrams and check
The engine control module the diesel exhaust fluid heater control unit circuit
measured a voltage below a for open circuit, high resistance
Reductant Tank
specified range but not Inspect connectors for signs of water ingress, and
Heater Control
necessarily a short circuit to pins for damage and/or corrosion
P209F-16 Circuit Performance
ground Check and install a new diesel exhaust fluid heater
- Circuit voltage
Diesel exhaust fluid heater control unit as required
below threshold
control unit circuit open Using the manufacturer approved diagnostic
circuit, high resistance system clear all stored DTCs using the ‘Diagnosis
Connector is disconnected, Menu’ tab and retest
connector pin is backed out,
connector pin corrosion
Diesel exhaust fluid heater
control unit failure

NOTE: To monitor diesel

exhaust fluid heater control unit.
 Diesel exhaust fluid heater control
unit voltage too high
Refer to the electrical circuit diagrams and check
The engine control module the diesel exhaust fluid heater control unit circuit
measured a voltage above a for short circuit to ground, short circuit to power,
Reductant Tank specified range but not open circuit, high resistance
Heater Control necessarily a short circuit to Inspect connectors for signs of water ingress, and
P209F-17 Circuit Performance power pins for damage and/or corrosion
- Circuit voltage Diesel exhaust fluid heater Check and install a new diesel exhaust fluid heater
above threshold control unit circuit short control unit as required
circuit to ground, short Using the manufacturer approved diagnostic
circuit to power, open system clear all stored DTCs using the ‘Diagnosis
circuit, high resistance Menu’ tab and retest
Connector is disconnected,
connector pin is backed out,
connector pin corrosion
Diesel exhaust fluid heater
control unit failure

NOTE: To monitor diesel

exhaust fluid heater control unit.
Diesel exhaust fluid heater control
unit current too low Refer to the electrical circuit diagrams and check
the diesel exhaust fluid heater control unit circuit
The engine control module for short circuit to ground, short circuit to power,
Reductant Tank has measured current flow open circuit, high resistance
Heater Control below a specified range Inspect connectors for signs of water ingress, and

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P209F-18 Circuit Performance Diesel exhaust fluid heater pins for damage and/or corrosion
- Circuit current control unit circuit short Check and install a new diesel exhaust fluid heater
below threshold circuit to ground, short control unit as required
circuit to power, open Using the manufacturer approved diagnostic
circuit, high resistance system clear all stored DTCs using the ‘Diagnosis
Connector is disconnected, Menu’ tab and retest
connector pin is backed out,
connector pin corrosion
Diesel exhaust fluid heater
control unit failure

NOTE: To monitor diesel

exhaust fluid heater control unit.
Diesel exhaust fluid heater control
unit current too high Refer to the electrical circuit diagrams and check
the diesel exhaust fluid heater control unit circuit
The engine control module for short circuit to ground, short circuit to power,
Reductant Tank has measured current flow open circuit, high resistance
Heater Control above a specified range Inspect connectors for signs of water ingress, and
P209F-19 Circuit Performance Diesel exhaust fluid heater pins for damage and/or corrosion
- Circuit current control unit circuit short Check and install a new diesel exhaust fluid heater
above threshold circuit to ground, short control unit as required
circuit to power, open Using the manufacturer approved diagnostic
circuit, high resistance system clear all stored DTCs using the ‘Diagnosis
Connector is disconnected, Menu’ tab and retest
connector pin is backed out,
connector pin corrosion
Diesel exhaust fluid heater
control unit failure

The engine control module

has determined an open
circuit via lack of bias
Refer to the electrical circuit diagrams and check
voltage, low current flow, no
the diesel exhaust fluid tank module circuit for
change in the state of an
open circuit, high resistance
input in response to an
Reductant Heater Inspect connectors for signs of water ingress, and
output
"A" Control pins for damage and/or corrosion
P20B9-13 Diesel exhaust fluid tank
Circuit/Open - Check and install a new diesel exhaust fluid tank
module circuit open circuit,
Circuit open module as required
high resistance
Using the manufacturer approved diagnostic
Connector is disconnected,
system clear all stored DTCs using the ‘Diagnosis
connector pin is backed out,
Menu’ tab and retest
connector pin corrosion
Diesel exhaust fluid tank
module failure
 NOTE: To monitor diesel
exhaust fluid line heater
Refer to the electrical circuit diagrams and check
The engine control module the diesel exhaust fluid line heater circuit for open
measured a voltage below a circuit, high resistance
Reductant Heater specified range but not Inspect connectors for signs of water ingress, and
"A" Control Circuit necessarily a short circuit to pins for damage and/or corrosion
P20BA-16 Performance - ground Check and install a new diesel exhaust fluid line
Circuit voltage Diesel exhaust fluid line heater as required
below threshold heater circuit open circuit, Using the manufacturer approved diagnostic
high resistance system clear all stored DTCs using the ‘Diagnosis
Connector is disconnected, Menu’ tab and retest
connector pin is backed out,
connector pin corrosion
Diesel exhaust fluid line
heater failure

NOTE: To monitor diesel

exhaust fluid line heater

The engine control module Refer to the electrical circuit diagrams and check
measured a voltage above a the diesel exhaust fluid line heater circuit for short
specified range but not circuit to ground, short circuit to power, open
Reductant Heater necessarily a short circuit to circuit, high resistance
"A" Control Circuit power Inspect connectors for signs of water ingress, and
P20BA-17 Performance - Diesel exhaust fluid line pins for damage and/or corrosion

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Circuit voltage heater circuit short circuit to Check and install a new diesel exhaust fluid line
above threshold ground, short circuit to heater as required
power, open circuit, high Using the manufacturer approved diagnostic
resistance system clear all stored DTCs using the ‘Diagnosis
Connector is disconnected, Menu’ tab and retest
connector pin is backed out,
connector pin corrosion
Diesel exhaust fluid line
heater failure

NOTE: To monitor diesel

exhaust fluid line heater
Refer to the electrical circuit diagrams and check
The engine control module the diesel exhaust fluid line heater circuit for short
has measured current flow circuit to ground, short circuit to power, open
Reductant Heater below a specified range circuit, high resistance
"A" Control Circuit Diesel exhaust fluid line Inspect connectors for signs of water ingress, and
P20BA-18 Performance - heater circuit short circuit to pins for damage and/or corrosion
Circuit current ground, short circuit to Check and install a new diesel exhaust fluid line
below threshold power, open circuit, high heater as required
resistance Using the manufacturer approved diagnostic
Connector is disconnected, system clear all stored DTCs using the ‘Diagnosis
connector pin is backed out, Menu’ tab and retest
connector pin corrosion
Diesel exhaust fluid line
heater failure

NOTE: To monitor diesel

exhaust fluid line heater
Refer to the electrical circuit diagrams and check
The engine control module the diesel exhaust fluid line heater circuit for short
has measured current flow circuit to ground, short circuit to power, open
Reductant Heater above a specified range circuit, high resistance
"A" Control Circuit Diesel exhaust fluid line Inspect connectors for signs of water ingress, and
P20BA-19 Performance - heater circuit short circuit to pins for damage and/or corrosion
Circuit current ground, short circuit to Check and install a new diesel exhaust fluid line
above threshold power, open circuit, high heater as required
resistance Using the manufacturer approved diagnostic
Connector is disconnected, system clear all stored DTCs using the ‘Diagnosis
connector pin is backed out, Menu’ tab and retest
connector pin corrosion
Diesel exhaust fluid line
heater failure
 The engine control module
Refer to the electrical circuit diagrams and check
has detected a ground
the diesel exhaust fluid tank module circuit for
measurement for a period
short circuit to ground
longer than expected or has
Inspect connectors for signs of water ingress, and
Reductant Heater detected a ground
pins for damage and/or corrosion
"A" Control Circuit measurement when another
Check and install a new diesel exhaust fluid tank
P20BB-11 Low - Circuit short value was expected
module as required
to ground Diesel exhaust fluid tank
Using the manufacturer approved diagnostic
module circuit short circuit
system clear all stored DTCs using the ‘Diagnosis
to ground
Menu’ tab and retest
Connector is disconnected,
connector pin is backed out,
connector pin corrosion
Diesel exhaust fluid tank
module failure

The engine control module

has detected a vehicle
power measurement for a
Refer to the electrical circuit diagrams and check
period longer than expected
the diesel exhaust fluid tank module circuit for
or has detected a vehicle
short circuit to power
power measurement when
Reductant Heater Inspect connectors for signs of water ingress, and
another value was expected
"A" Control Circuit pins for damage and/or corrosion
P20BC-12 Diesel exhaust fluid tank
High - Circuit short Check and install a new diesel exhaust fluid tank
module circuit short circuit
to battery module as required
to power
Using the manufacturer approved diagnostic
Connector is disconnected,
system clear all stored DTCs using the ‘Diagnosis

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connector pin is backed out,
Menu’ tab and retest
connector pin corrosion
Diesel exhaust fluid tank
module failure

NOTE: If modelled pressure

falls below 2 bar system is purged
and pressure is built up again. If
this happens 12 times during
driving cycle error is set (Fast path
due to air bubbles)

The engine control module

has determined failures Check diesel exhaust fluid line for leakage
where some circuit quantity, Using the manufacturer approved diagnostic
reported via serial data, is system carry out diagnostic routine 0x4092
below a specified range Refer to the electrical circuit diagrams and check
DEF injector dosing too the diesel exhaust fluid tank module circuit for
"Reductant high. Diesel Exhaust Fluid short circuit to ground, short circuit to power, open
Pressure Too Low - injection pump delivers to circuit, high resistance
P20E8-84
Signal below much DEF Inspect connectors for signs of water ingress, and
allowable range Diesel exhaust fluid line pins for damage and/or corrosion
leakage Check and install a new diesel exhaust fluid tank
Diesel exhaust fluid line air module as required
bubbles Using the manufacturer approved diagnostic
Diesel exhaust fluid tank system clear all stored DTCs using the ‘Diagnosis
module circuit short circuit Menu’ tab and retest
to ground, short circuit to
power, open circuit, high
resistance
Connector is disconnected,
connector pin is backed out,
connector pin corrosion
Diesel exhaust fluid tank
module failure

NOTE: To monitor for diesel

exhaust fluid line under pressure
error. If modelled pressure falls
below 4.5 bar the system is purged
and pressure is built up again. If
this occurs during a drive cycle the
error is set

The engine control module Check Diesel exhaust fluid line for leakage
has determined failures
where some circuit quantity,
 reported via serial data, is Using the manufacturer approved diagnostic
above a specified range system carry out diagnostic routine 0x4092
"Reductant DEF injector dosing too Refer to the electrical circuit diagrams and check
Pressure Too Low - high. Diesel Exhaust Fluid the diesel exhaust fluid tank module circuit for
P20E8-85 injection pump delivers to short circuit to ground, short circuit to power, open
Signal above
allowable range much DEF circuit, high resistance
Diesel exhaust fluid line Inspect connectors for signs of water ingress, and
leakage pins for damage and/or corrosion
Diesel exhaust fluid line air Check and install a new diesel exhaust fluid tank
bubbles module as required
Diesel exhaust fluid tank Using the manufacturer approved diagnostic
module circuit short circuit system clear all stored DTCs using the ‘Diagnosis
to ground, short circuit to Menu’ tab and retest
power, open circuit, high
resistance
Connector is disconnected,
connector pin is backed out,
connector pin corrosion
Diesel exhaust fluid tank
module failure

NOTE: To monitor for over

pressure (slow). If modelled
pressure rises above 8,5 bar system
is purged and pressure is built up
again. If this happens 5 times Check diesel exhaust fluid line for blockage
during driving cycle error is set Check diesel exhaust fluid injector for blockage

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Check diesel exhaust fluid tank module for
The engine control module blockage
"Reductant has determined failures Check diesel exhaust fluid line is not frozen
Pressure Too High where some circuit quantity,
P20E9-84 Check diesel exhaust fluid injector is not frozen
- Signal below reported via serial data, is Check diesel exhaust fluid tank module is not
allowable range below a specified range frozen
Diesel exhaust fluid line Using the manufacturer approved diagnostic
frozen / blocked system clear all stored DTCs using the ‘Diagnosis
Diesel exhaust fluid line Menu’ tab and retest
heater frozen
Diesel exhaust fluid injector
frozen / blocked
Diesel exhaust fluid tank
module frozen

NOTE: To monitor for over

pressure (fast). If modelled
pressure rises above 10 bar,
system is purged and pressure is
built up again. If this happens 5
times during driving cycle error is Check diesel exhaust fluid line for blockage
set Check diesel exhaust fluid injector for blockage
Check diesel exhaust fluid tank module for
The engine control module blockage
"Reductant
has determined failures Check diesel exhaust fluid line is not frozen
Pressure Too High
P20E9-85 where some circuit quantity, Check diesel exhaust fluid injector is not frozen
- Signal above
reported via serial data, is Check diesel exhaust fluid tank module is not
allowable range
above a specified range frozen
Diesel exhaust fluid line Using the manufacturer approved diagnostic
frozen / blocked system clear all stored DTCs using the ‘Diagnosis
Diesel exhaust fluid line Menu’ tab and retest
heater frozen
Diesel exhaust fluid injector
frozen / blocked
Diesel exhaust fluid tank
module frozen

NOTE: Monitors SCR Nox

catalyst efficiency - reduced
catalyst Nox efficiency

SCR - reduced catalyst Nox

conversion efficiency
detected by passive
 monitoring but not detected
SCR NOx Catalyst
by active monitoring; on two NOTE: Drive vehicle at urban speeds until SCR
Efficiency Below
consecutive occasions catalyst warm and exhaust Nox sensors active. Ensure the
P20EE-00 Threshold Bank 1 -
The SCR device ammonia vehicle is not in DPF active regeneration and drive at
No sub type
storage capability is greatly urban speeds for 20min (50 / 60mph)
information
reduced or the device is
missing Check for damaged or removed SCR catalyst
Defective SCR catalyst Check for deposits on front face of SCR catalyst
(aged) Check diesel exhaust fluid injector for deposits or
Deficient DEF reagent corrosion
delivery Check exhaust metal work for damage
Diesel exhaust fluid injector Using the manufacturer approved diagnostic
partial delivery system clear all stored DTCs using the ‘Diagnosis
Damaged exhaust metal Menu’ tab and retest
work
SCR catalyst damage

NOTE: To monitor DEF back

flow pump for open circuit

The engine control module

has determined an open Refer to the electrical circuit diagrams and check
circuit via lack of bias the diesel exhaust fluid tank module circuit for
voltage, low current flow, no open circuit, high resistance - DEF back flow pump
Reductant Pump change in the state of an Inspect connectors for signs of water ingress, and
"B" Control input in response to an pins for damage and/or corrosion
P20FA-13 output
Circuit/Open - Check and install a new diesel exhaust fluid tank

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Circuit open Diesel exhaust fluid tank module as required
module circuit open circuit, Using the manufacturer approved diagnostic
high resistance - DEF back system clear all stored DTCs using the ‘Diagnosis
flow pump Menu’ tab and retest
Connector is disconnected,
connector pin is backed out,
connector pin corrosion
Diesel exhaust fluid tank
module failure

Refer to the electrical circuit diagrams and check

Diesel exhaust fluid tank
the diesel exhaust fluid tank module circuit for
module circuit short circuit
short circuit to ground, short circuit to power, open
to ground, short circuit to
circuit, high resistance
Reductant Pump power, open circuit, high
- DEF back flow pump
"B" Control resistance
Inspect connectors for signs of water ingress, and
P20FB-00 Performance/Stuck - DEF back flow pump
pins for damage and/or corrosion
Off - No sub type Connector is disconnected,
Check and install a new diesel exhaust fluid tank
information connector pin is backed out,
module as required
connector pin corrosion
Using the manufacturer approved diagnostic
Diesel exhaust fluid tank
system clear all stored DTCs using the ‘Diagnosis
module failure
Menu’ tab and retest

NOTE: To monitor DEF back

flow pump for short circuit to
ground

The engine control module

has detected a ground Refer to the electrical circuit diagrams and check
measurement for a period the diesel exhaust fluid tank module circuit for
longer than expected or has short circuit to ground - DEF back flow pump
Reductant Pump detected a ground Inspect connectors for signs of water ingress, and
"B" Control Circuit measurement when another pins for damage and/or corrosion
P20FC-11
Low - Circuit short value was expected Check and install a new diesel exhaust fluid tank
to ground Diesel exhaust fluid tank module as required
module circuit short circuit Using the manufacturer approved diagnostic
to ground - DEF back flow system clear all stored DTCs using the ‘Diagnosis
pump Menu’ tab and retest
Connector is disconnected,
connector pin is backed out,
connector pin corrosion
Diesel exhaust fluid tank
module failure
 NOTE: To monitor DEF back
flow pump for short circuit to power
Refer to the electrical circuit diagrams and check
The engine control module the diesel exhaust fluid tank module circuit for
has detected a vehicle short circuit to power - DEF back flow pump
power measurement for a Inspect connectors for signs of water ingress, and
Reductant Pump period longer than expected pins for damage and/or corrosion
"B" Control Circuit or has detected a vehicle Check and install a new diesel exhaust fluid tank
P20FD-12 module as required
High - Circuit short power measurement when
to battery another value was expected Using the manufacturer approved diagnostic
Diesel exhaust fluid tank system clear all stored DTCs using the ‘Diagnosis
module circuit short circuit Menu’ tab and retest
to power - DEF back flow
pump
Connector is disconnected,
connector pin is backed out,
connector pin corrosion
Diesel exhaust fluid tank
module failure

Monitors DEF reagent

delivery performance to the
SCR device
An active overdosing of the
SCR is performed following a
passive monitoring event NOTE: Drive vehicle at urban speeds until SCR
catalyst warm and exhaust Nox sensors active. Ensure the

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(lack of apparent SCR
efficiency). The reagent vehicle is not in DPF active regeneration and drive at
delivery provided by the urban speeds for 20min (50 / 60mph)
Reductant Metering dosing valve is monitored
Unit Performance - during this process Damaged/Removed dosing module
P20FE-00 Dosing module stuck closed / stuck by deposits
No sub type Defective DEF reagent
information delivery Deposits on SCR device front face
Defective SCR catalyst Damaged/Removed SCR catalyst
(aged) Deposits on front face of SCR catalyst
Deficient DEF reagent Check diesel exhaust fluid injector for deposits or
delivery corrosion
Diesel exhaust fluid injector Check exhaust metal work for damage
partial delivery
Damaged exhaust metal
work
SCR catalyst damage

The engine control module

has measured current flow Refer to the electrical circuit diagrams and check
above a specified range the diesel exhaust fluid tank module circuit for
Diesel exhaust fluid tank short circuit to ground, short circuit to power, open
module circuit short circuit circuit, high resistance
Reductant Pump
to ground, short circuit to - DEF pump circuit
"A" Current Too
power, open circuit, high Inspect connectors for signs of water ingress, and
P214E-19 High - Circuit
resistance pins for damage and/or corrosion
current above
- DEF pump circuit Check and install a new diesel exhaust fluid tank
threshold
Connector is disconnected, module as required
connector pin is backed out, Using the manufacturer approved diagnostic
connector pin corrosion system clear all stored DTCs using the ‘Diagnosis
Diesel exhaust fluid tank Menu’ tab and retest
module failure

The engine control module

Refer to the electrical circuit diagrams and check
detected plausibility failures
the diesel exhaust fluid tank module circuit for
Diesel exhaust fluid tank
short circuit to ground, short circuit to power, open
module circuit short circuit
circuit, high resistance
Reductant Level to ground, short circuit to
Inspect connectors for signs of water ingress, and
Sensor "A" Stuck - power, open circuit, high
P21C5-64 pins for damage and/or corrosion
Signal plausibility resistance
Check and install a new diesel exhaust fluid tank
failure Connector is disconnected,
module as required
connector pin is backed out,
Using the manufacturer approved diagnostic
connector pin corrosion
system clear all stored DTCs using the ‘Diagnosis
Diesel exhaust fluid tank
Menu’ tab and retest
module failure
 The engine control module
has determined an open
circuit via lack of bias Refer to the electrical circuit diagrams and check
voltage, low current flow, no the diesel exhaust fluid tank module circuit for
change in the state of an short circuit to ground, short circuit to power, open
input in response to an circuit, high resistance
output Refer to the electrical circuit diagrams and check
Diesel exhaust fluid tank the diesel exhaust fluid relay circuit for short
Reductant Control module circuit short circuit circuit to ground, short circuit to power, open
Module Power to ground, short circuit to circuit, high resistance
Relay/Relays power, open circuit, high Inspect connectors for signs of water ingress, and
P21C7-13 Control resistance pins for damage and/or corrosion
Circuit/Open - Diesel exhaust fluid relay Check and install a new diesel exhaust fluid relay
Circuit open circuit short circuit to as required
ground, short circuit to Check and install a new diesel exhaust fluid tank
power, open circuit, high module as required
resistance Using the manufacturer approved diagnostic
Connector is disconnected, system clear all stored DTCs using the ‘Diagnosis
connector pin is backed out, Menu’ tab and retest
connector pin corrosion
Diesel exhaust fluid relay
failure
Diesel exhaust fluid tank
module failure

The engine control module

has detected a ground

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measurement for a period
longer than expected or has
Refer to the electrical circuit diagrams and check
detected a ground
the diesel exhaust fluid tank module circuit for
measurement when another
short circuit to ground, short circuit to power, open
value was expected
circuit, high resistance
Diesel exhaust fluid tank
Refer to the electrical circuit diagrams and check
module circuit short circuit
the diesel exhaust fluid relay circuit for short
Reductant Control to ground, short circuit to
circuit to ground, short circuit to power, open
Module Power power, open circuit, high
circuit, high resistance
Relay/Relays resistance
P21C8-11 Inspect connectors for signs of water ingress, and
Control Circuit Low Diesel exhaust fluid relay
pins for damage and/or corrosion
- Circuit short to circuit short circuit to
Check and install a new diesel exhaust fluid relay
ground ground, short circuit to
as required
power, open circuit, high
Check and install a new diesel exhaust fluid tank
resistance
module as required
Connector is disconnected,
Using the manufacturer approved diagnostic
connector pin is backed out,
system clear all stored DTCs using the ‘Diagnosis
connector pin corrosion
Menu’ tab and retest
Diesel exhaust fluid relay
failure
Diesel exhaust fluid tank
module failure

The engine control module

has detected a vehicle
power measurement for a
period longer than expected
Refer to the electrical circuit diagrams and check
or has detected a vehicle
the diesel exhaust fluid tank module circuit for
power measurement when
short circuit to ground, short circuit to power, open
another value was expected
circuit, high resistance
Diesel exhaust fluid tank
Refer to the electrical circuit diagrams and check
module circuit short circuit
the diesel exhaust fluid relay circuit for short
Reductant Control to ground, short circuit to
circuit to ground, short circuit to power, open
Module Power power, open circuit, high
circuit, high resistance
Relay/Relays resistance
P21C9-12 Inspect connectors for signs of water ingress, and
Control Circuit High Diesel exhaust fluid relay
pins for damage and/or corrosion
- Circuit short to circuit short circuit to
Check and install a new diesel exhaust fluid relay
battery ground, short circuit to
as required
power, open circuit, high
Check and install a new diesel exhaust fluid tank
resistance
module as required
Connector is disconnected,
Using the manufacturer approved diagnostic
connector pin is backed out,
system clear all stored DTCs using the ‘Diagnosis
connector pin corrosion
Menu’ tab and retest
Diesel exhaust fluid relay
failure
Diesel exhaust fluid tank
module failure
 The engine control module
has determined an open
circuit via lack of bias
voltage, low current flow, no Refer to the electrical circuit diagrams and check
change in the state of an the pre selective catalytic reduction NOx sensor
input in response to an circuit for short circuit to ground, short circuit to
output power, open circuit, high resistance
NOx Sensor Circuit Pre selective catalytic Inspect connectors for signs of water ingress, and
P2200-13 Bank 1 Sensor 1 - reduction NOx sensor circuit pins for damage and/or corrosion
Circuit open short circuit to ground, short Check and install a new pre selective catalytic
circuit to power, open reduction NOx sensor as required
circuit, high resistance Using the manufacturer approved diagnostic
Connector is disconnected, system clear all stored DTCs using the ‘Diagnosis
connector pin is backed out, Menu’ tab and retest
connector pin corrosion
Pre selective catalytic
reduction NOx sensor failure

The engine control module

has detected a ground
measurement or open circuit
for a period longer than
Refer to the electrical circuit diagrams and check
expected or has detected a
the pre selective catalytic reduction NOx sensor
ground measurement or
circuit for short circuit to ground, short circuit to
open circuit when another
power, open circuit, high resistance
NOx Sensor Circuit value was expected
Inspect connectors for signs of water ingress, and
Bank 1 Sensor 1 - Pre selective catalytic
P2200-14 pins for damage and/or corrosion

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Circuit short to reduction NOx sensor circuit
Check and install a new pre selective catalytic
ground or open short circuit to ground, short
reduction NOx sensor as required
circuit to power, open
Using the manufacturer approved diagnostic
circuit, high resistance
system clear all stored DTCs using the ‘Diagnosis
Connector is disconnected,
Menu’ tab and retest
connector pin is backed out,
connector pin corrosion
Pre selective catalytic
reduction NOx sensor failure

Refer to the electrical circuit diagrams and check

Pre selective catalytic
the pre selective catalytic reduction NOx sensor
reduction NOx sensor circuit
circuit for short circuit to ground, short circuit to
NOx Sensor Circuit short circuit to ground, short
power, open circuit, high resistance
Range/Performance circuit to power, open
Inspect connectors for signs of water ingress, and
Bank 1 Sensor 1 - circuit, high resistance
P2201-28 pins for damage and/or corrosion
Signal bias level Connector is disconnected,
Check and install a new pre selective catalytic
out of range / zero connector pin is backed out,
reduction NOx sensor as required
adjustment failure connector pin corrosion
Using the manufacturer approved diagnostic
Pre selective catalytic
system clear all stored DTCs using the ‘Diagnosis
reduction NOx sensor failure
Menu’ tab and retest

Refer to the electrical circuit diagrams and check

Pre selective catalytic
the pre selective catalytic reduction NOx sensor
reduction NOx sensor circuit
circuit for short circuit to ground, short circuit to
short circuit to ground, short
power, open circuit, high resistance
NOx Sensor Circuit circuit to power, open
Inspect connectors for signs of water ingress, and
Range/Performance circuit, high resistance
P2201-2F pins for damage and/or corrosion
Bank 1 Sensor 1 - Connector is disconnected,
Check and install a new pre selective catalytic
Signal erratic connector pin is backed out,
reduction NOx sensor as required
connector pin corrosion
Using the manufacturer approved diagnostic
Pre selective catalytic
system clear all stored DTCs using the ‘Diagnosis
reduction NOx sensor failure
Menu’ tab and retest

The engine control module

measured a voltage below a
specified range but not
necessarily a short circuit to Refer to the electrical circuit diagrams and check
ground the pre selective catalytic reduction NOx sensor
Pre selective catalytic circuit for short circuit to ground, short circuit to
reduction NOx sensor circuit power, open circuit, high resistance
NOx Sensor Circuit short circuit to ground, short Inspect connectors for signs of water ingress, and
Low Bank 1 Sensor circuit to power, open
P2202-16 pins for damage and/or corrosion
1 - Circuit voltage circuit, high resistance Check and install a new pre selective catalytic
below threshold
reduction NOx sensor as required
 Connector is disconnected, Using the manufacturer approved diagnostic
connector pin is backed out, system clear all stored DTCs using the ‘Diagnosis
connector pin corrosion Menu’ tab and retest
Pre selective catalytic
reduction NOx sensor failure

The engine control module

measured a voltage above a
specified range but not Refer to the electrical circuit diagrams and check
necessarily a short circuit to the pre selective catalytic reduction NOx sensor
power circuit for short circuit to ground, short circuit to
NOx Sensor Circuit Pre selective catalytic power, open circuit, high resistance
High Bank 1 reduction NOx sensor circuit Inspect connectors for signs of water ingress, and
P2203-17 Sensor 1 - Circuit short circuit to ground, short pins for damage and/or corrosion
voltage above circuit to power, open Check and install a new pre selective catalytic
threshold circuit, high resistance reduction NOx sensor as required
Connector is disconnected, Using the manufacturer approved diagnostic
connector pin is backed out, system clear all stored DTCs using the ‘Diagnosis
connector pin corrosion Menu’ tab and retest
Pre selective catalytic
reduction NOx sensor failure

Refer to the electrical circuit diagrams and check

Pre selective catalytic
the pre selective catalytic reduction NOx sensor
reduction NOx sensor circuit
circuit for short circuit to ground, short circuit to
NOx Sensor Heater short circuit to ground, short
power, open circuit, high resistance
Sense Circuit circuit to power, open
Inspect connectors for signs of water ingress, and

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Range/Performance circuit, high resistance
P2209-01 pins for damage and/or corrosion
Bank 1 Sensor 1 - Connector is disconnected,
Check and install a new pre selective catalytic
General electrical connector pin is backed out,
reduction NOx sensor as required
failure connector pin corrosion
Using the manufacturer approved diagnostic
Pre selective catalytic
system clear all stored DTCs using the ‘Diagnosis
reduction NOx sensor failure
Menu’ tab and retest

Refer to the electrical circuit diagrams and check

Pre selective catalytic
the pre selective catalytic reduction NOx sensor
reduction NOx sensor circuit
circuit for short circuit to ground, short circuit to
short circuit to ground, short
NOx Sensor Supply power, open circuit, high resistance
circuit to power, open
Voltage Circuit Inspect connectors for signs of water ingress, and
circuit, high resistance
P220A-01 Bank 1 Sensor 1 - pins for damage and/or corrosion
Connector is disconnected,
General electrical Check and install a new pre selective catalytic
connector pin is backed out,
failure reduction NOx sensor as required
connector pin corrosion
Using the manufacturer approved diagnostic
Pre selective catalytic
system clear all stored DTCs using the ‘Diagnosis
reduction NOx sensor failure
Menu’ tab and retest

NOTE: Post selective catalytic

reduction NOx sensor heater circuit Refer to the electrical circuit diagrams and check
error the post selective catalytic reduction NOx sensor
circuit for short circuit to ground, short circuit to
NOx Sensor Supply Post selective catalytic power, open circuit, high resistance
Voltage Circuit reduction NOx sensor circuit Inspect connectors for signs of water ingress, and
P220B-01 Bank 1 Sensor 2 - short circuit to ground, short pins for damage and/or corrosion
General electrical circuit to power, open Check and install a new post selective catalytic
failure circuit, high resistance reduction NOx sensor as required
Connector is disconnected, Using the manufacturer approved diagnostic
connector pin is backed out, system clear all stored DTCs using the ‘Diagnosis
connector pin corrosion Menu’ tab and retest
Post selective catalytic
reduction NOx sensor failure

The engine control module

has determined failures
where some circuit quantity,
reported via serial data, is Refer to the electrical circuit diagrams and check
above a specified range the pre selective catalytic reduction NOx sensor
NOx Sensor Pre selective catalytic circuit for short circuit to ground, short circuit to
Performance - reduction NOx sensor circuit power, open circuit, high resistance
Signal short circuit to ground, short Inspect connectors for signs of water ingress, and
P225C-85 Biased/Stuck High circuit to power, open pins for damage and/or corrosion
circuit, high resistance Check and install a new pre selective catalytic
reduction NOx sensor as required
 Bank 1 Sensor 1 - Connector is disconnected, Using the manufacturer approved diagnostic
Signal above connector pin is backed out, system clear all stored DTCs using the ‘Diagnosis
allowable range connector pin corrosion Menu’ tab and retest
Pre selective catalytic
reduction NOx sensor failure

NOTE: Range check pre

selective catalytic reduction NOx
sensor. Pre selective catalytic NOTE: NOx sensor released, the dew point
reduction NOx sensor signal out of detection function is initiated (after engine start there is a
range at low load negative strategy to avoid activation if water is present in the
deviation exhaust, the function integrates the warmth quantity seen
by the sensor and then releases it, then the sensor is
NOx Sensor The engine control module heated and starts measuring)
Performance - has determined failures
Signal where some circuit quantity, Refer to the electrical circuit diagrams and check
P225D-84 Biased/Stuck Low reported via serial data, is the pre selective catalytic reduction NOx sensor
Bank 1 Sensor 1 - below a specified range circuit for short circuit to ground, short circuit to
Signal below Pre selective catalytic power, open circuit, high resistance
allowable range reduction NOx sensor circuit Inspect connectors for signs of water ingress, and
short circuit to ground, short pins for damage and/or corrosion
circuit to power, open Check and install a new pre selective catalytic
circuit, high resistance reduction NOx sensor as required
Connector is disconnected, Using the manufacturer approved diagnostic
connector pin is backed out, system clear all stored DTCs using the ‘Diagnosis
connector pin corrosion Menu’ tab and retest
Pre selective catalytic

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reduction NOx sensor failure

NOTE: Range check post

selective catalytic reduction NOx
NOTE: NOx sensor released, the dew point
sensor. Post selective catalytic
detection function is initiated (after engine start there is a
reduction NOx sensor signal out of
strategy to avoid activation if water is present in the
range at low load positive deviation
exhaust, the function integrates the warmth quantity seen
by the sensor and then releases it, then the sensor is
The engine control module
NOx Sensor heated and starts measuring)
has determined failures
Performance - where some circuit quantity,
Signal Refer to the electrical circuit diagrams and check
reported via serial data, is
P225E-85 Biased/Stuck High the post selective catalytic reduction NOx sensor
above a specified range
Bank 1 Sensor 2 - circuit for short circuit to ground, short circuit to
Post selective catalytic
Signal above power, open circuit, high resistance
reduction NOx sensor circuit
allowable range Inspect connectors for signs of water ingress, and
short circuit to ground, short
pins for damage and/or corrosion
circuit to power, open
Check and install a new post selective catalytic
circuit, high resistance
reduction NOx sensor as required
Connector is disconnected,
Using the manufacturer approved diagnostic
connector pin is backed out,
system clear all stored DTCs using the ‘Diagnosis
connector pin corrosion
Menu’ tab and retest
Post selective catalytic
reduction NOx sensor failure

NOTE: Range check post

selective catalytic reduction NOx
sensor. Post selective catalytic NOTE: NOx sensor released, the dew point
reduction NOx sensor signal out of detection function is initiated (after engine start there is a
range at low load negative strategy to avoid activation if water is present in the
deviation exhaust, the function integrates the warmth quantity seen
by the sensor and then releases it, then the sensor is
NOx Sensor The engine control module heated and starts measuring)
Performance - has determined failures
Signal where some circuit quantity, Refer to the electrical circuit diagrams and check
P225F-84 Biased/Stuck Low reported via serial data, is the post selective catalytic reduction NOx sensor
Bank 1 Sensor 2 - below a specified range circuit for short circuit to ground, short circuit to
Signal below Post selective catalytic power, open circuit, high resistance
allowable range reduction NOx sensor circuit Inspect connectors for signs of water ingress, and
short circuit to ground, short pins for damage and/or corrosion
circuit to power, open Check and install a new post selective catalytic
circuit, high resistance reduction NOx sensor as required
Connector is disconnected, Using the manufacturer approved diagnostic
connector pin is backed out, system clear all stored DTCs using the ‘Diagnosis
connector pin corrosion Menu’ tab and retest
Post selective catalytic
reduction NOx sensor failure
 The engine control module
has determined an open
circuit via lack of bias
Refer to the electrical circuit diagrams and check
voltage, low current flow, no
the post selective catalytic reduction NOx sensor
change in the state of an
circuit for open circuit, high resistance
input in response to an
Inspect connectors for signs of water ingress, and
NOx Sensor Circuit output
pins for damage and/or corrosion
P229E-13 (Bank 1 Sensor 2) Post selective catalytic
Check and install a new post selective catalytic
- Circuit open reduction NOx sensor circuit
reduction NOx sensor as required
open circuit, high resistance
Using the manufacturer approved diagnostic
Connector is disconnected,
system clear all stored DTCs using the ‘Diagnosis
connector pin is backed out,
Menu’ tab and retest
connector pin corrosion
Post selective catalytic
reduction NOx sensor failure

The engine control module

has detected a ground
measurement or open circuit
for a period longer than Refer to the electrical circuit diagrams and check
expected or has detected a the post selective catalytic reduction NOx sensor
ground measurement or circuit for short circuit to ground, open circuit, high
open circuit when another resistance
NOx Sensor Circuit
value was expected Inspect connectors for signs of water ingress, and
(Bank 1 Sensor 2)
P229E-14 Post selective catalytic pins for damage and/or corrosion
- Circuit short to
reduction NOx sensor circuit Check and install a new post selective catalytic
ground or open
short circuit to ground, open reduction NOx sensor as required

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circuit, high resistance Using the manufacturer approved diagnostic
Connector is disconnected, system clear all stored DTCs using the ‘Diagnosis
connector pin is backed out, Menu’ tab and retest
connector pin corrosion
Post selective catalytic
reduction NOx sensor failure

Refer to the electrical circuit diagrams and check

Post selective catalytic
the post selective catalytic reduction NOx sensor
reduction NOx sensor circuit
circuit for short circuit to ground, short circuit to
NOx Sensor Circuit short circuit to ground, short
power, open circuit, high resistance
Range/Performance circuit to power, open
Inspect connectors for signs of water ingress, and
(Bank 1 Sensor circuit, high resistance
P229F-28 pins for damage and/or corrosion
2)Signal bias level Connector is disconnected,
Check and install a new post selective catalytic
out of range / zero connector pin is backed out,
reduction NOx sensor as required
adjustment failure connector pin corrosion
Using the manufacturer approved diagnostic
Post selective catalytic
system clear all stored DTCs using the ‘Diagnosis
reduction NOx sensor failure
Menu’ tab and retest

Refer to the electrical circuit diagrams and check

Post selective catalytic
the post selective catalytic reduction NOx sensor
reduction NOx sensor circuit
circuit for short circuit to ground, short circuit to
short circuit to ground, short
power, open circuit, high resistance
NOx Sensor Circuit circuit to power, open
Inspect connectors for signs of water ingress, and
Range/Performance circuit, high resistance
P229F-2F pins for damage and/or corrosion
(Bank 1 Sensor 2) Connector is disconnected,
Check and install a new post selective catalytic
- Signal erratic connector pin is backed out,
reduction NOx sensor as required
connector pin corrosion
Using the manufacturer approved diagnostic
Post selective catalytic
system clear all stored DTCs using the ‘Diagnosis
reduction NOx sensor failure
Menu’ tab and retest

The engine control module

measured a voltage below a
specified range but not
necessarily a short circuit to Refer to the electrical circuit diagrams and check
ground the post selective catalytic reduction NOx sensor
Post selective catalytic circuit for short circuit to ground, short circuit to
NOx Sensor Circuit reduction NOx sensor circuit power, open circuit, high resistance
Low (Bank 1 short circuit to ground, short Inspect connectors for signs of water ingress, and
P22A0-16 Sensor 2) - Circuit circuit to power, open pins for damage and/or corrosion
voltage below circuit, high resistance Check and install a new post selective catalytic
threshold Connector is disconnected, reduction NOx sensor as required
connector pin is backed out, Using the manufacturer approved diagnostic
connector pin corrosion system clear all stored DTCs using the ‘Diagnosis
Menu’ tab and retest
 Post selective catalytic
reduction NOx sensor failure

The engine control module

measured a voltage above a
specified range but not Refer to the electrical circuit diagrams and check
necessarily a short circuit to the post selective catalytic reduction NOx sensor
power circuit for short circuit to ground, short circuit to
NOx Sensor Circuit Post selective catalytic power, open circuit, high resistance
High (Bank 1 reduction NOx sensor circuit Inspect connectors for signs of water ingress, and
P22A1-17 Sensor 2) - Circuit short circuit to ground, short pins for damage and/or corrosion
voltage above circuit to power, open Check and install a new post selective catalytic
threshold circuit, high resistance reduction NOx sensor as required
Connector is disconnected, Using the manufacturer approved diagnostic
connector pin is backed out, system clear all stored DTCs using the ‘Diagnosis
connector pin corrosion Menu’ tab and retest
Post selective catalytic
reduction NOx sensor failure

Refer to the electrical circuit diagrams and check

Post selective catalytic
the post selective catalytic reduction NOx sensor
reduction NOx sensor circuit
circuit for short circuit to ground, short circuit to
NOx Sensor Heater short circuit to ground, short
power, open circuit, high resistance
Sense Circuit circuit to power, open
Inspect connectors for signs of water ingress, and
Range/Performance circuit, high resistance
P22A7-01 pins for damage and/or corrosion
(Bank 1 Sensor 2) Connector is disconnected,
Check and install a new post selective catalytic
- General electrical connector pin is backed out,
reduction NOx sensor as required

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failure connector pin corrosion
Using the manufacturer approved diagnostic
Post selective catalytic
system clear all stored DTCs using the ‘Diagnosis
reduction NOx sensor failure
Menu’ tab and retest

The signal transitions more

quickly than is reasonably Refer to the electrical circuit diagrams and check
allowed the pre selective catalytic reduction NOx sensor
NOx Sensor Pre selective catalytic circuit for short circuit to ground, short circuit to
Performance - Slow reduction NOx sensor circuit power, open circuit, high resistance
Response High too short circuit to ground, short Inspect connectors for signs of water ingress, and
P22FA-27 low Bank 1 Sensor circuit to power, open pins for damage and/or corrosion
1 - Signal rate of circuit, high resistance Check and install a new pre selective catalytic
change above Connector is disconnected, reduction NOx sensor as required
threshold connector pin is backed out, Using the manufacturer approved diagnostic
connector pin corrosion system clear all stored DTCs using the ‘Diagnosis
Pre selective catalytic Menu’ tab and retest
reduction NOx sensor failure

The engine control module

Refer to the electrical circuit diagrams and check
detected plausibility failures
the pre selective catalytic reduction NOx sensor
Pre selective catalytic
circuit for short circuit to ground, short circuit to
NOx Sensor reduction NOx sensor circuit
power, open circuit, high resistance
Performance - short circuit to ground, short
Inspect connectors for signs of water ingress, and
Sensing Element circuit to power, open
P22FB-64 pins for damage and/or corrosion
Bank 1 Sensor 1 - circuit, high resistance
Check and install a new pre selective catalytic
Signal plausibility Connector is disconnected,
reduction NOx sensor as required
failure connector pin is backed out,
Using the manufacturer approved diagnostic
connector pin corrosion
system clear all stored DTCs using the ‘Diagnosis
Pre selective catalytic
Menu’ tab and retest
reduction NOx sensor failure

The engine control module

has determined failures
where some circuit quantity,
reported via serial data, is Refer to the electrical circuit diagrams and check
below a specified range the pre selective catalytic reduction NOx sensor
Pre selective catalytic circuit for short circuit to ground, short circuit to
NOx Sensor
reduction NOx sensor circuit power, open circuit, high resistance
Performance -
short circuit to ground, short Inspect connectors for signs of water ingress, and
Sensing Element
P22FB-84 circuit to power, open pins for damage and/or corrosion
Bank 1 Sensor 1 -
circuit, high resistance Check and install a new pre selective catalytic
Signal below
Connector is disconnected, reduction NOx sensor as required
allowable range
connector pin is backed out, Using the manufacturer approved diagnostic
connector pin corrosion system clear all stored DTCs using the ‘Diagnosis
Menu’ tab and retest
 Pre selective catalytic
reduction NOx sensor failure

The engine control module

has determined failures
where some circuit quantity, Refer to the electrical circuit diagrams and check
reported via serial data, is the pre selective catalytic reduction NOx sensor
above a specified range circuit for short circuit to ground, short circuit to
NOx Sensor
Pre selective catalytic power, open circuit, high resistance
Performance -
reduction NOx sensor circuit Inspect connectors for signs of water ingress, and
Sensing Element
P22FB-85 short circuit to ground, short pins for damage and/or corrosion
Bank 1 Sensor 1 -
circuit to power, open Check and install a new pre selective catalytic
Signal above
circuit, high resistance reduction NOx sensor as required
allowable range
Connector is disconnected, Using the manufacturer approved diagnostic
connector pin is backed out, system clear all stored DTCs using the ‘Diagnosis
connector pin corrosion Menu’ tab and retest
Pre selective catalytic
reduction NOx sensor failure

Refer to the electrical circuit diagrams and check

Post selective catalytic
the post selective catalytic reduction NOx sensor
reduction NOx sensor circuit
circuit for short circuit to ground, short circuit to
NOx Sensor short circuit to ground, short
power, open circuit, high resistance
Performance - circuit to power, open
Inspect connectors for signs of water ingress, and
Sensing Element circuit, high resistance
P22FE-2A pins for damage and/or corrosion
Bank 1 Sensor 2 - Connector is disconnected,
Check and install a new post selective catalytic
Signal stuck in connector pin is backed out,
reduction NOx sensor as required

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range connector pin corrosion
Using the manufacturer approved diagnostic
Post selective catalytic
system clear all stored DTCs using the ‘Diagnosis
reduction NOx sensor failure
Menu’ tab and retest

The engine control module

Refer to the electrical circuit diagrams and check
detected plausibility failures
the post selective catalytic reduction NOx sensor
Post selective catalytic
circuit for short circuit to ground, short circuit to
NOx Sensor reduction NOx sensor circuit
power, open circuit, high resistance
Performance - short circuit to ground, short
Inspect connectors for signs of water ingress, and
Sensing Element circuit to power, open
P22FE-64 pins for damage and/or corrosion
Bank 1 Sensor 2 - circuit, high resistance
Check and install a new post selective catalytic
Signal plausibility Connector is disconnected,
reduction NOx sensor as required
failure connector pin is backed out,
Using the manufacturer approved diagnostic
connector pin corrosion
system clear all stored DTCs using the ‘Diagnosis
Post selective catalytic
Menu’ tab and retest
reduction NOx sensor failure

The engine control module

has determined failures
Refer to the electrical circuit diagrams and check
where some circuit quantity,
the post selective catalytic reduction NOx sensor
reported via serial data, is
circuit for short circuit to ground, open circuit, high
NOx Sensor below a specified range
resistance
Performance - Post selective catalytic
Inspect connectors for signs of water ingress, and
Sensing Element reduction NOx sensor circuit
P22FE-84 pins for damage and/or corrosion
Bank 1 Sensor 2 - short circuit to ground, open
Check and install a new post selective catalytic
Signal below circuit, high resistance
reduction NOx sensor as required
allowable range Connector is disconnected,
Using the manufacturer approved diagnostic
connector pin is backed out,
system clear all stored DTCs using the ‘Diagnosis
connector pin corrosion
Menu’ tab and retest
Post selective catalytic
reduction NOx sensor failure

The engine control module

has determined failures
Refer to the electrical circuit diagrams and check
where some circuit quantity,
the post selective catalytic reduction NOx sensor
reported via serial data, is
NOx Sensor circuit for short circuit to power
above a specified range
Performance - Inspect connectors for signs of water ingress, and
Post selective catalytic
Sensing Element pins for damage and/or corrosion
P22FE-85 reduction NOx sensor circuit
Bank 1 Sensor 2 - Check and install a new post selective catalytic
short circuit to power
Signal above reduction NOx sensor as required
Connector is disconnected,
allowable range Using the manufacturer approved diagnostic
connector pin is backed out,
system clear all stored DTCs using the ‘Diagnosis
connector pin corrosion
Menu’ tab and retest
Post selective catalytic
reduction NOx sensor failure
 NOTE: With the inducement countdown at 0; stop
engine. Ignition off. Power latch. Ignition on (after power
latch). Carry out routine 0x0406 Value 0x0F - To Reset
Selective Catalyst Reductant (SCR) Inducement System
Start Inhibit to allow restart from this point onwards. The
routine can be used each time the mileage countdown
goes to 0

Diagnosis of this DTC may require using the

manufacturer approved diagnostic system check
datalogger signals
- 0x05C1 Reductant Tank Fluid Level
Engine restart is prevented. - Check that the DEF tank has at least 25mm
The inducement system of fluid (0x05C1)
countdown has run out Using the manufacturer approved diagnostic
SCR Inducement -
Final inducement - No system check engine control module for related
Forced Engine
P241D-00 engine restart is allowed DTCs and refer to relevant DTC index
Shutdown - No sub
Other related DTCs Re fill diesel exhaust fluid tank with correct
type information
Vehicle has run out of specification diesel exhaust fluid
inducement system allowed Using the manufacturer approved diagnostic
mileage system carry out the refill and bleed procedures
After repair, use routine 0x0406 Value 0x0F - To
Reset Selective Catalyst Reductant (SCR)
Inducement System Start Inhibit to allow a
temporary mileage allowance (50km / 31mi) in
order to run the vehicle and the OBD system to
confirm repair

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The inducement system will clear automatically
upon acknowledgment of repair by the OBD
system
Using the manufacturer approved diagnostic
system clear all stored DTCs using the ‘Diagnosis
Menu’ tab and retest

Other DEF related DTCs

DEF system for mechanical
integrity
Check engine control module for DEF related DTCs
- DEF tank module
and refer to relevant DTC index
- DEF line heater
Check DEF system for mechanical integrity
- DEF injector
- DEF tank module
- DEF injection pump
- DEF line heater
- DEF heater control unit
- DEF injector
- DEF line
- DEF injection pump
- DEF tank
- DEF heater control unit
- DEF filler assembly
- DEF line
Excessive Time To DEF system for electrical
- DEF tank
Enter Closed Loop integrity
- DEF filler assembly
P249C-00 Reductant Injection - Harness failure -
Check DEF system for electrical integrity
Control - No sub Wiring integrity short
- Refer to the electrical circuit diagrams and
type information circuit to ground,
check connections are secure and wiring
short circuit to power,
integrity
open circuit, high
- DEF tank module
resistance
- DEF line heater
- DEF tank module
- DEF injector
- DEF line heater
- DEF injection pump
- DEF injector
- DEF heater control unit
- DEF injection pump
Inspect connectors for signs of water ingress, and
- DEF heater control unit
pins for damage and/or corrosion
Connector is disconnected,
connector pin is backed out,
connector pin corrosion

NOTE: Selective catalytic

reduction, reduced catalyst Nox
conversion efficiency, dosing
system cannot reach dosing
setpoint. The system cannot reach Check for damaged or removed SCR catalyst
Closed Loop target efficiency Check for deposits on front face of SCR catalyst
Reductant Injection Check diesel exhaust fluid injector for deposits or
Control At Limit - Defective SCR catalyst corrosion
P249D-00 (aged)
Flow Too Low - No Check exhaust metal work for damage
sub type Deficient DEF reagent
information delivery
 Diesel exhaust fluid injector Using the manufacturer approved diagnostic
partial delivery system clear all stored DTCs using the ‘Diagnosis
Damaged exhaust metal Menu’ tab and retest
work
SCR catalyst damage

NOTE: Selective catalytic

reduction, reduced catalyst Nox
conversion efficiency, dosing
system cannot prevent ammonia
slip (ammonia is found at the back Check for damaged or removed SCR catalyst
Closed Loop of the selective catalytic reduction Check for deposits on front face of SCR catalyst
Reductant Injection catalyst) Check diesel exhaust fluid injector for deposits or
Control At Limit - corrosion
P249E-00 Defective SCR catalyst
Flow Too High - No Check exhaust metal work for damage
sub type (aged) Using the manufacturer approved diagnostic
information Deficient DEF reagent system clear all stored DTCs using the ‘Diagnosis
delivery Menu’ tab and retest
Diesel exhaust fluid injector
partial delivery
Damaged exhaust metal
work
SCR catalyst damage

The engine control module

has detected a voltage

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outside of the expected
Refer to the electrical circuit diagrams and check
range, but not identified as
the post selective catalyst reduction soot sensor
too high or too low
circuit for short circuit to ground, short circuit to
Post selective catalyst
power, open circuit, high resistance
reduction soot sensor circuit
Refer to the electrical circuit diagrams and check
short circuit to ground, short
the post selective catalyst reduction soot sensor
circuit to power, open
Particulate Matter circuit / diesel sub net CAN circuit for short circuit
circuit, high resistance
Sensor Circuit to ground, short circuit to power, open circuit, high
P24AE-1C Post selective catalyst
-Circuit voltage out resistance
reduction soot sensor circuit
of range Inspect connectors for signs of water ingress, and
/ diesel sub net CAN circuit
pins for damage and/or corrosion
short circuit to ground, short
Check and install a new post selective catalyst
circuit to power, open
reduction soot sensor as required
circuit, high resistance
Using the manufacturer approved diagnostic
Connector is disconnected,
system clear all stored DTCs using the ‘Diagnosis
connector pin is backed out,
Menu’ tab and retest
connector pin corrosion
Post selective catalyst
reduction soot sensor failure

The engine control module

has received an indication
about the component that
indicates a failure e.g. an Refer to the electrical circuit diagrams and check
intelligent actuator or sensor the post selective catalyst reduction soot sensor
is indicating an internal fault circuit for short circuit to ground, short circuit to
Post selective catalyst power, open circuit, high resistance
reduction soot sensor circuit Refer to the electrical circuit diagrams and check
short circuit to ground, short the post selective catalyst reduction soot sensor
Particulate Matter circuit to power, open circuit / diesel sub net CAN circuit for short circuit
Sensor Circuit - circuit, high resistance to ground, short circuit to power, open circuit, high
P24AE-96
Component Post selective catalyst resistance
internal failure reduction soot sensor circuit Inspect connectors for signs of water ingress, and
/ diesel sub net CAN circuit pins for damage and/or corrosion
short circuit to ground, short Check and install a new post selective catalyst
circuit to power, open reduction soot sensor as required
circuit, high resistance Using the manufacturer approved diagnostic
Connector is disconnected, system clear all stored DTCs using the ‘Diagnosis
connector pin is backed out, Menu’ tab and retest
connector pin corrosion
Post selective catalyst
reduction soot sensor failure

The value of the signal

measured by the engine
 control module is not Refer to the electrical circuit diagrams and check
plausible given the the post selective catalyst reduction soot sensor
operating conditions circuit for short circuit to ground, short circuit to
Post selective catalyst power, open circuit, high resistance
reduction soot sensor circuit Refer to the electrical circuit diagrams and check
Particulate Matter short circuit to ground, short the post selective catalyst reduction soot sensor
Sensor Circuit circuit to power, open circuit / diesel sub net CAN circuit for short circuit
P24AF-29 circuit, high resistance to ground, short circuit to power, open circuit, high
Range/Performance
- Signal invalid Post selective catalyst resistance
reduction soot sensor circuit Inspect connectors for signs of water ingress, and
/ diesel sub net CAN circuit pins for damage and/or corrosion
short circuit to ground, short Check and install a new post selective catalyst
circuit to power, open reduction soot sensor as required
circuit, high resistance Using the manufacturer approved diagnostic
Connector is disconnected, system clear all stored DTCs using the ‘Diagnosis
connector pin is backed out, Menu’ tab and retest
connector pin corrosion
Post selective catalyst
reduction soot sensor failure

The engine control module

has received an indication
about the component that
indicates a failure e.g. an Refer to the electrical circuit diagrams and check
intelligent actuator or sensor the post selective catalyst reduction soot sensor
is indicating an internal fault circuit for short circuit to ground, short circuit to
Post selective catalyst power, open circuit, high resistance

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reduction soot sensor circuit Refer to the electrical circuit diagrams and check
short circuit to ground, short the post selective catalyst reduction soot sensor
Particulate Matter
circuit to power, open circuit / diesel sub net CAN circuit for short circuit
Sensor Circuit
circuit, high resistance to ground, short circuit to power, open circuit, high
P24AF-96 Range/Performance
Post selective catalyst resistance
- Component
reduction soot sensor circuit Inspect connectors for signs of water ingress, and
internal failure
/ diesel sub net CAN circuit pins for damage and/or corrosion
short circuit to ground, short Check and install a new post selective catalyst
circuit to power, open reduction soot sensor as required
circuit, high resistance Using the manufacturer approved diagnostic
Connector is disconnected, system clear all stored DTCs using the ‘Diagnosis
connector pin is backed out, Menu’ tab and retest
connector pin corrosion
Post selective catalyst
reduction soot sensor failure

The engine control module

has received an indication
about the component that
indicates a failure e.g. an Refer to the electrical circuit diagrams and check
intelligent actuator or sensor the post selective catalyst reduction soot sensor
is indicating an internal fault circuit for short circuit to ground, short circuit to
Post selective catalyst power, open circuit, high resistance
reduction soot sensor circuit Refer to the electrical circuit diagrams and check
short circuit to ground, short the post selective catalyst reduction soot sensor
Particulate Matter circuit to power, open circuit / diesel sub net CAN circuit for short circuit
Sensor Circuit Low circuit, high resistance to ground, short circuit to power, open circuit, high
P24B0-96
- Component Post selective catalyst resistance
internal failure reduction soot sensor circuit Inspect connectors for signs of water ingress, and
/ diesel sub net CAN circuit pins for damage and/or corrosion
short circuit to ground, short Check and install a new post selective catalyst
circuit to power, open reduction soot sensor as required
circuit, high resistance Using the manufacturer approved diagnostic
Connector is disconnected, system clear all stored DTCs using the ‘Diagnosis
connector pin is backed out, Menu’ tab and retest
connector pin corrosion
Post selective catalyst
reduction soot sensor failure

The engine control module

has received an indication
about the component that Refer to the electrical circuit diagrams and check
indicates a failure e.g. an the post selective catalyst reduction soot sensor
intelligent actuator or sensor circuit for short circuit to ground, short circuit to
is indicating an internal fault power, open circuit, high resistance
Post selective catalyst Refer to the electrical circuit diagrams and check
reduction soot sensor circuit the post selective catalyst reduction soot sensor
 short circuit to ground, short circuit / diesel sub net CAN circuit for short circuit
Particulate Matter circuit to power, open to ground, short circuit to power, open circuit, high
Sensor Circuit High circuit, high resistance resistance
P24B1-96
- Component Post selective catalyst Inspect connectors for signs of water ingress, and
internal failure reduction soot sensor circuit pins for damage and/or corrosion
/ diesel sub net CAN circuit Check and install a new post selective catalyst
short circuit to ground, short reduction soot sensor as required
circuit to power, open Using the manufacturer approved diagnostic
circuit, high resistance system clear all stored DTCs using the ‘Diagnosis
Connector is disconnected, Menu’ tab and retest
connector pin is backed out,
connector pin corrosion
Post selective catalyst
reduction soot sensor failure

Post selective catalyst Refer to the electrical circuit diagrams and check
reduction soot sensor circuit the post selective catalyst reduction soot sensor
short circuit to ground, short circuit for short circuit to ground, short circuit to
circuit to power, open power, open circuit, high resistance
circuit, high resistance Refer to the electrical circuit diagrams and check
Particulate Matter Post selective catalyst the post selective catalyst reduction soot sensor
Sensor Heater reduction soot sensor circuit circuit / diesel sub net CAN circuit for short circuit
Control / diesel sub net CAN circuit to ground, short circuit to power, open circuit, high
P24B3-00
Circuit/Open - No short circuit to ground, short resistance
sub type circuit to power, open Inspect connectors for signs of water ingress, and
information circuit, high resistance pins for damage and/or corrosion
Connector is disconnected, Check and install a new post selective catalyst

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connector pin is backed out, reduction soot sensor as required
connector pin corrosion Using the manufacturer approved diagnostic
Post selective catalyst system clear all stored DTCs using the ‘Diagnosis
reduction soot sensor failure Menu’ tab and retest

The engine control module

has detected that the
component performance is
outside its expected range Refer to the electrical circuit diagrams and check
or operating in an incorrect the post selective catalyst reduction soot sensor
way circuit for short circuit to ground, short circuit to
Post selective catalyst power, open circuit, high resistance
reduction soot sensor circuit Refer to the electrical circuit diagrams and check
short circuit to ground, short the post selective catalyst reduction soot sensor
Particulate Matter
circuit to power, open circuit / diesel sub net CAN circuit for short circuit
Sensor Heater
circuit, high resistance to ground, short circuit to power, open circuit, high
P24B5-92 Control Circuit Low
Post selective catalyst resistance
- Performance or
reduction soot sensor circuit Inspect connectors for signs of water ingress, and
incorrect operation
/ diesel sub net CAN circuit pins for damage and/or corrosion
short circuit to ground, short Check and install a new post selective catalyst
circuit to power, open reduction soot sensor as required
circuit, high resistance Using the manufacturer approved diagnostic
Connector is disconnected, system clear all stored DTCs using the ‘Diagnosis
connector pin is backed out, Menu’ tab and retest
connector pin corrosion
Post selective catalyst
reduction soot sensor failure

The engine control module

has detected that the
component performance is
outside its expected range
or operating in an incorrect Refer to the electrical circuit diagrams and check
way the post selective catalyst reduction soot sensor
Post selective catalyst circuit for short circuit to ground, short circuit to
reduction soot sensor circuit power, open circuit, high resistance
short circuit to ground, short Refer to the electrical circuit diagrams and check
circuit to power, open the post selective catalyst reduction soot sensor
Particulate Matter circuit, high resistance circuit / diesel sub net CAN circuit for short circuit
Sensor Heater Post selective catalyst to ground, short circuit to power, open circuit, high
P24B6-92 Control Circuit High reduction soot sensor circuit resistance
- Performance or / diesel sub net CAN circuit Inspect connectors for signs of water ingress, and
incorrect operation short circuit to ground, short pins for damage and/or corrosion
circuit to power, open Check and install a new post selective catalyst
circuit, high resistance reduction soot sensor as required
 Connector is disconnected, Using the manufacturer approved diagnostic
connector pin is backed out, system clear all stored DTCs using the ‘Diagnosis
connector pin corrosion Menu’ tab and retest
Post selective catalyst
reduction soot sensor failure

Post selective catalyst Refer to the electrical circuit diagrams and check
reduction soot sensor circuit the post selective catalyst reduction soot sensor
short circuit to ground, short circuit for short circuit to ground, short circuit to
circuit to power, open power, open circuit, high resistance
circuit, high resistance Refer to the electrical circuit diagrams and check
Post selective catalyst the post selective catalyst reduction soot sensor
Particulate Matter
reduction soot sensor circuit circuit / diesel sub net CAN circuit for short circuit
Sensor
/ diesel sub net CAN circuit to ground, short circuit to power, open circuit, high
P24C6-00 Temperature
short circuit to ground, short resistance
Circuit - No sub
circuit to power, open Inspect connectors for signs of water ingress, and
type information
circuit, high resistance pins for damage and/or corrosion
Connector is disconnected, Check and install a new post selective catalyst
connector pin is backed out, reduction soot sensor as required
connector pin corrosion Using the manufacturer approved diagnostic
Post selective catalyst system clear all stored DTCs using the ‘Diagnosis
reduction soot sensor failure Menu’ tab and retest

The engine control module

has determined failures
where some circuit quantity,
Refer to the electrical circuit diagrams and check
reported via serial data, is

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the post selective catalyst reduction soot sensor
below a specified range
circuit for short circuit to ground, short circuit to
Post selective catalyst
power, open circuit, high resistance
reduction soot sensor circuit
Refer to the electrical circuit diagrams and check
short circuit to ground, short
Particulate Matter the post selective catalyst reduction soot sensor
circuit to power, open
Sensor circuit / diesel sub net CAN circuit for short circuit
circuit, high resistance
Temperature to ground, short circuit to power, open circuit, high
P24C6-84 Post selective catalyst
Circuit - Signal resistance
reduction soot sensor circuit
below allowable Inspect connectors for signs of water ingress, and
/ diesel sub net CAN circuit
range pins for damage and/or corrosion
short circuit to ground, short
Check and install a new post selective catalyst
circuit to power, open
reduction soot sensor as required
circuit, high resistance
Using the manufacturer approved diagnostic
Connector is disconnected,
system clear all stored DTCs using the ‘Diagnosis
connector pin is backed out,
Menu’ tab and retest
connector pin corrosion
Post selective catalyst
reduction soot sensor failure

NOTE: Monitoring of the

meander starting temperature for
plausibility. Power feed to the post
selective catalyst reduction soot
sensor module fell below 9 volts for
longer than 0.4 seconds
Refer to the electrical circuit diagrams and check
The engine control module the post selective catalyst reduction soot sensor
detected failure when circuit for short circuit to ground, short circuit to
comparing two or more power, open circuit, high resistance
input parameters for Refer to the electrical circuit diagrams and check
Particulate Matter
plausibility the post selective catalyst reduction soot sensor
Sensor
Post selective catalyst circuit / diesel sub net CAN circuit for short circuit
Temperature
reduction soot sensor circuit to ground, short circuit to power, open circuit, high
P24C7-62 Circuit
short circuit to ground, short resistance
Range/Performance
circuit to power, open Inspect connectors for signs of water ingress, and
- Signal compare
circuit, high resistance pins for damage and/or corrosion
failure
Post selective catalyst Check and install a new post selective catalyst
reduction soot sensor circuit reduction soot sensor as required
/ diesel sub net CAN circuit Using the manufacturer approved diagnostic
short circuit to ground, short system clear all stored DTCs using the ‘Diagnosis
circuit to power, open Menu’ tab and retest
circuit, high resistance
Connector is disconnected,
connector pin is backed out,
connector pin corrosion
Post selective catalyst
reduction soot sensor failure
 NOTE: Monitoring of the
dynamic meander temperature for NOTE: Monitor runs 220seconds after post selective
plausibility catalyst reduction soot sensor completes regeneration
(requires driving for around 20 minutes and regeneration
The engine control module end visible via temperature DID D940 drops from 785Deg
detected plausibility failures C down to ~ 200Deg C) - keep low rpm
Post selective catalyst
reduction soot sensor Check post selective catalyst reduction soot sensor
incorrectly installed for correct installation
Post selective catalyst Refer to the electrical circuit diagrams and check
reduction soot sensor circuit the post selective catalyst reduction soot sensor
short circuit to ground, short circuit for short circuit to ground, short circuit to
circuit to power, open power, open circuit, high resistance
Particulate Matter
circuit, high resistance Refer to the electrical circuit diagrams and check
Sensor
Post selective catalyst the post selective catalyst reduction soot sensor
Temperature
reduction soot sensor circuit circuit / diesel sub net CAN circuit for short circuit
P24C7-64 Circuit
/ diesel sub net CAN circuit to ground, short circuit to power, open circuit, high
Range/Performance
short circuit to ground, short resistance
- Signal plausibility
circuit to power, open Inspect connectors for signs of water ingress, and
failure
circuit, high resistance pins for damage and/or corrosion
Connector is disconnected, Check and install a new post selective catalyst
connector pin is backed out, reduction soot sensor as required
connector pin corrosion Refer to the electrical circuit diagrams and check
Post selective catalyst the DPF outlet temperature sensor circuit for short
reduction soot sensor failure circuit to ground, short circuit to power, open
DPF outlet temperature circuit, high resistance
sensor circuit short circuit to Check SCR catalyst for blockage

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ground, short circuit to Check exhaust system for mechanical integrity
power, open circuit, high Using the manufacturer approved diagnostic
resistance system clear all stored DTCs using the ‘Diagnosis
SCR catalyst blocked Menu’ tab and retest
Exhaust system mechanical
integrity

Post selective catalyst Refer to the electrical circuit diagrams and check
reduction soot sensor circuit the post selective catalyst reduction soot sensor
short circuit to ground, short circuit for short circuit to ground, short circuit to
circuit to power, open power, open circuit, high resistance
circuit, high resistance Refer to the electrical circuit diagrams and check
Post selective catalyst the post selective catalyst reduction soot sensor
Particulate Matter
reduction soot sensor circuit circuit / diesel sub net CAN circuit for short circuit
Sensor Supply
/ diesel sub net CAN circuit to ground, short circuit to power, open circuit, high
P24D0-00 Voltage Circuit Low
short circuit to ground, short resistance
- No sub type
circuit to power, open Inspect connectors for signs of water ingress, and
information
circuit, high resistance pins for damage and/or corrosion
Connector is disconnected, Check and install a new post selective catalyst
connector pin is backed out, reduction soot sensor as required
connector pin corrosion Using the manufacturer approved diagnostic
Post selective catalyst system clear all stored DTCs using the ‘Diagnosis
reduction soot sensor failure Menu’ tab and retest

NOTE: To monitor diesel

exhaust fluid level Diagnosis of this DTC may require using the
manufacturer approved diagnostic system check
NOx Exceedance - The engine control module datalogger signals
Empty Reagent has detected that a fluid - 0x05C1 Reductant Tank Fluid Level
P2BA7-7B level is too low for proper
Tank - Low fluid Check and correct diesel exhaust fluid level
level operation of the system Using the manufacturer approved diagnostic
Diesel exhaust fluid level is system clear all stored DTCs using the ‘Diagnosis
low Menu’ tab and retest
Diesel exhaust fluid tank is
empty

NOTE: To monitor the

selective catalytic reduction system
for sudden reduction in catalyst Nox
NOTE: With ignition on - run once routine 0x4026
conversion efficiency by passive
Value 0x2C − To Reset Selective Catalyst Reductant (SCR)
monitoring
Quality Monitor. Drive vehicle at urban speeds until SCR
catalyst warm and exhaust Nox sensors are active. Ensure
Selective catalytic reduction
the vehicle is not in DPF active regeneration and drive at
- Nox conversion efficiency
urban speeds for 20minutes (50 / 60mph)
is below threshold. The
diesel exhaust fluid quality
 NOx Exceedance - is reduced or the selective Using the manufacturer approved equipment
Insufficient catalytic reduction catalyst measure DEF quality to check it conforms to
P2BA9-00 Reagent Quality - is missing specification
No sub type Monitor to prioritize the Drain and refill DEF if not to specification
information diesel exhaust fluid Check for damaged or removed SCR catalyst
detection when a sudden Check for deposits on front face of SCR catalyst
drop in Nox conversion Check diesel exhaust fluid injector for
efficiency is detected blockage/failure
Diesel exhaust fluid quality Check for deposits on mixer
is reduced Check and install a new diesel exhaust fluid
Defective SCR catalyst injector as required
(missing) Using the manufacturer approved diagnostic
Deficient DEF reagent system clear all stored DTCs using the ‘Diagnosis
delivery Menu’ tab and retest
Diesel exhaust fluid injector
blockage/failure

NOTE: To monitor the

selective catalytic reduction system
for minimum catalyst Nox
conversion efficiency by passive
monitoring not met after function
reset NOTE: With ignition on - run once routine 0x4026
Value 0x2C − To Reset Selective Catalyst Reductant (SCR)
The engine control module Quality Monitor. Drive vehicle at urban speeds until SCR
has detected that the catalyst warm and exhaust Nox sensors are active. Ensure
component performance is the vehicle is not in DPF active regeneration and drive at

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outside its expected range urban speeds for 20minutes (50 / 60mph)
or operating in an incorrect
way Using the manufacturer approved equipment
NOx Exceedance - Selective catalytic reduction measure DEF quality to check it conforms to
Insufficient - the minimum conversion specification
P2BA9-92 Reagent Quality - efficiency of the catalytic Drain and refill DEF if not to specification
Performance or device is not met after Check for damaged or removed SCR catalyst
incorrect operation function reset Check for deposits on front face of SCR catalyst
The diesel exhaust fluid Check diesel exhaust fluid injector for
quality is not meeting blockage/failure
manufacturer specifications Check for deposits on mixer
or the SCR catalyst is Check and install a new diesel exhaust fluid
removed injector as required
Diesel exhaust fluid quality Using the manufacturer approved diagnostic
is reduced system clear all stored DTCs using the ‘Diagnosis
Defective SCR catalyst Menu’ tab and retest
(missing)
Deficient DEF reagent
delivery
Diesel exhaust fluid injector
blockage/failure

NOTE: The fault path responsible for the

inducement level may require driving cycle conditions

Stage 1 This monitor shows Diagnosis of this DTC may require using the
at the first level of the driver manufacturer approved diagnostic system check
advisory message - DEF low datalogger signals
NOx Exceedance -
Stage 2 This monitor shows - 0x05C1 Reductant Tank Fluid Level
NOx Control
at the second level of the Check and correct diesel exhaust fluid level
P2BAE-00 Monitoring System
driver advisory message - Check engine control module for related DTCs and
- No sub type
DEF low - Refill DEF now refer to relevant DTC index
information
Diesel exhaust fluid level is Using the manufacturer approved diagnostic
low system clear all stored DTCs using the ‘Diagnosis
Other related DTCs Menu’ tab and retest
The inducement system will clear automatically
upon acknowledgment of repair by the OBD
system

NOTE: The fault path responsible for the

inducement level may require driving cycle conditions
The DTC is set at first,
second and third levels of Diagnosis of this DTC may require using the
final driver warning for manufacturer approved diagnostic system check
inducement system datalogger signals
To monitor for low diesel - 0x05C1 Reductant Tank Fluid Level
NOx System Driver
exhaust fluid level
P2BAF-00 Inducement Active To monitor diesel exhaust Check and correct diesel exhaust fluid level
- No sub type fluid quality Check engine control module for related DTCs and
information To monitor selective catalyst refer to relevant DTC index
reduction system hardware Using the manufacturer approved diagnostic
Diesel exhaust fluid level is system clear all stored DTCs using the ‘Diagnosis
low Menu’ tab and retest
Other related DTCs The inducement system will clear automatically
upon acknowledgment of repair by the OBD
system

The engine control module

has not received the
expected CAN signal from
the pre selective catalytic Check pre and post NOx sensor connectors are not
reduction NOx sensor / crossed
diesel sub net CAN within Refer to the electrical circuit diagrams and check
the specified time interval the pre selective catalytic reduction NOx sensor /
Lost
Pre and post NOx sensor diesel sub net CAN circuit for short circuit to
Communication
connectors are crossed ground, short circuit to power, open circuit, high
U029D-87 With NOx Sensor
Pre selective catalytic resistance
"A" - Missing
reduction NOx sensor / Inspect connectors for signs of water ingress, and
message
diesel sub net CAN circuit pins for damage and/or corrosion
short circuit to ground, short Using the manufacturer approved diagnostic
circuit to power, open system clear all stored DTCs using the ‘Diagnosis
circuit, high resistance Menu’ tab and retest
Connector is disconnected,
connector pin is backed out,

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connector pin corrosion

The engine control module

has not received the
expected CAN signal from
the post selective catalytic Check pre and post NOx sensor connectors are not
reduction NOx sensor / crossed
diesel sub net CAN within Refer to the electrical circuit diagrams and check
the specified time interval the post selective catalytic reduction NOx sensor /
Lost
Pre and post NOx sensor diesel sub net CAN circuit for short circuit to
Communication
connectors are crossed ground, short circuit to power, open circuit, high
U029E-87 With NOx Sensor
Post selective catalytic resistance
"B" - Missing
reduction NOx sensor / Inspect connectors for signs of water ingress, and
message
diesel sub net CAN circuit pins for damage and/or corrosion
short circuit to ground, short Using the manufacturer approved diagnostic
circuit to power, open system clear all stored DTCs using the ‘Diagnosis
circuit, high resistance Menu’ tab and retest
Connector is disconnected,
connector pin is backed out,
connector pin corrosion

The engine control module

has determined an open
circuit via lack of bias
voltage, low current flow, no
change in the state of an
input in response to an
output
The engine control module Refer to the electrical circuit diagrams and check
has not received the the diesel exhaust fluid particulate matter soot
expected CAN signal from sensor / diesel sub net CAN circuit for short circuit
Lost the diesel exhaust fluid to ground, short circuit to power, open circuit, high
Communication particulate matter soot resistance
U02A3-13
With PM Sensor - sensor / diesel sub net CAN Inspect connectors for signs of water ingress, and
Circuit open within the specified time pins for damage and/or corrosion
interval Using the manufacturer approved diagnostic
Particulate matter soot system clear all stored DTCs using the ‘Diagnosis
sensor / diesel sub net CAN Menu’ tab and retest
circuit short circuit to
ground, short circuit to
power, open circuit, high
resistance
Connector is disconnected,
connector pin is backed out,
connector pin corrosion
 The engine control module
has not received the
expected CAN signal from
the diesel exhaust fluid Refer to the electrical circuit diagrams and check
particulate matter soot the diesel exhaust fluid particulate matter soot
sensor / diesel sub net CAN sensor / diesel sub net CAN circuit for short circuit
Lost within the specified time to ground, short circuit to power, open circuit, high
Communication interval resistance
U02A3-87 With PM Sensor - Particulate matter soot Inspect connectors for signs of water ingress, and
Missing message sensor / diesel sub net CAN pins for damage and/or corrosion
circuit short circuit to Using the manufacturer approved diagnostic
ground, short circuit to system clear all stored DTCs using the ‘Diagnosis
power, open circuit, high Menu’ tab and retest
resistance
Connector is disconnected,
connector pin is backed out,
connector pin corrosion

The engine control module

has not received the
expected CAN signal from
the diesel exhaust fluid
Refer to the electrical circuit diagrams and check
heater control unit / diesel
the diesel exhaust fluid heater control unit / diesel
Lost sub net CAN within the
sub net CAN circuit for short circuit to ground,
Communication specified time interval
short circuit to power, open circuit, high resistance
with Reductant Diesel exhaust fluid heater
U02A5-87 Inspect connectors for signs of water ingress, and
Heater Control control unit / diesel sub net
pins for damage and/or corrosion

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Module - Missing CAN circuit short circuit to
Using the manufacturer approved diagnostic
message ground, short circuit to
system clear all stored DTCs using the ‘Diagnosis
power, open circuit, high
Menu’ tab and retest
resistance
Connector is disconnected,
connector pin is backed out,
connector pin corrosion

The engine control module

has not received the
expected CAN signal from Check diesel exhaust fluid particulate matter soot
the diesel exhaust fluid sensor / diesel sub net CAN for related DTCs and
particulate matter soot refer to relevant DTC index
sensor / diesel sub net CAN Refer to the electrical circuit diagrams and check
within the specified time the diesel exhaust fluid particulate matter soot
interval sensor / diesel sub net CAN circuit for short circuit
Invalid Data
Particulate matter soot to ground, short circuit to power, open circuit, high
Received From PM
U04A4-02 sensor / diesel sub net CAN resistance
Sensor - General
circuit short circuit to Inspect connectors for signs of water ingress, and
signal failure
ground, short circuit to pins for damage and/or corrosion
power, open circuit, high Check and install a new post selective catalyst
resistance reduction soot sensor as required
Connector is disconnected, Using the manufacturer approved diagnostic
connector pin is backed out, system clear all stored DTCs using the ‘Diagnosis
connector pin corrosion Menu’ tab and retest
Post selective catalyst
reduction soot sensor failure

NOTE: To check CAN

communication between engine
control module and diesel exhaust
fluid heater control unit

The engine control module

Check diesel exhaust fluid heater control unit /
has not received the
diesel sub net CAN for related DTCs and refer to
expected CAN signal from
relevant DTC index
the diesel exhaust fluid
Refer to the electrical circuit diagrams and check
heater control unit / diesel
Invalid Data the diesel exhaust fluid heater control unit / diesel
sub net CAN within the
Received from sub net CAN circuit for short circuit to ground,
specified time interval
Reductant Heater short circuit to power, open circuit, high resistance
U05A6-08 Diesel exhaust fluid heater
Control Module - Inspect connectors for signs of water ingress, and
control unit / diesel sub net
Bus signal / pins for damage and/or corrosion
CAN circuit short circuit to
message failures Refer to the electrical circuit diagrams and check
ground, short circuit to
connections are secure and wiring integrity
power, open circuit, high
resistance
 Connector is disconnected, Using the manufacturer approved diagnostic
connector pin is backed out, system clear all stored DTCs using the ‘Diagnosis
connector pin corrosion Menu’ tab and retest
Harness failure - Diesel
exhaust fluid heater control
unit

NOTE: NOx sensor released, the dew point

NOTE: To monitor removal detection function is initiated (after engine start there is a
detection post selective catalytic strategy to avoid activation if water is present in the
reduction NOx sensor exhaust, the function integrates the warmth quantity seen
by the sensor and then releases it, then the sensor is
Post selective catalytic heated and starts measuring)
reduction NOx sensor not
installed in the exhaust Check post selective catalytic reduction NOx
Control Module system sensor is correctly installed in the exhaust system
Ground "B" - No Post selective catalytic Refer to the electrical circuit diagrams and check
U3009-00
sub type reduction NOx sensor circuit the post selective catalytic reduction NOx sensor
information short circuit to ground, short circuit for short circuit to ground, short circuit to
circuit to power, open power, open circuit, high resistance
circuit, high resistance Inspect connectors for signs of water ingress, and
Connector is disconnected, pins for damage and/or corrosion
connector pin is backed out, Check and install a new post selective catalytic
connector pin corrosion reduction NOx sensor as required
Post selective catalytic Using the manufacturer approved diagnostic
reduction NOx sensor failure system clear all stored DTCs using the ‘Diagnosis
Menu’ tab and retest

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NOTE: NOx sensor released, the dew point
NOTE: To monitor removal detection function is initiated (after engine start there is a
detection post selective catalytic strategy to avoid activation if water is present in the
reduction NOx sensor exhaust, the function integrates the warmth quantity seen
by the sensor and then releases it, then the sensor is
Post selective catalytic heated and starts measuring)
reduction NOx sensor not
installed in the exhaust Check post selective catalytic reduction NOx
Ignition Input system sensor is correctly installed in the exhaust system
Off/On/Start - No Post selective catalytic Refer to the electrical circuit diagrams and check
U300C-00
sub type reduction NOx sensor circuit the post selective catalytic reduction NOx sensor
information short circuit to ground, short circuit for short circuit to ground, short circuit to
circuit to power, open power, open circuit, high resistance
circuit, high resistance Inspect connectors for signs of water ingress, and
Connector is disconnected, pins for damage and/or corrosion
connector pin is backed out, Check and install a new post selective catalytic
connector pin corrosion reduction NOx sensor as required
Post selective catalytic Using the manufacturer approved diagnostic
reduction NOx sensor failure system clear all stored DTCs using the ‘Diagnosis
Menu’ tab and retest

NOTE: NOx sensor released, the dew point

NOTE: To monitor removal detection function is initiated (after engine start there is a
detection post selective catalytic strategy to avoid activation if water is present in the
reduction NOx sensor exhaust, the function integrates the warmth quantity seen
by the sensor and then releases it, then the sensor is
Post selective catalytic heated and starts measuring)
reduction NOx sensor not
installed in the exhaust Check post selective catalytic reduction NOx
Ignition Input system sensor is correctly installed in the exhaust system
U300F-00 Accessory - No sub Post selective catalytic Refer to the electrical circuit diagrams and check
type information reduction NOx sensor circuit the post selective catalytic reduction NOx sensor
short circuit to ground, short circuit for short circuit to ground, short circuit to
circuit to power, open power, open circuit, high resistance
circuit, high resistance Inspect connectors for signs of water ingress, and
Connector is disconnected, pins for damage and/or corrosion
connector pin is backed out, Check and install a new post selective catalytic
connector pin corrosion reduction NOx sensor as required
Post selective catalytic Using the manufacturer approved diagnostic
reduction NOx sensor failure system clear all stored DTCs using the ‘Diagnosis
Menu’ tab and retest

DTC Index
For a complete list of all diagnostic trouble codes that could be logged on this vehicle, please refer to Section 100-00.
REFER to: Diagnostic Trouble Code (DTC) Index - INGENIUM I4 2.0L Diesel, DTC: Engine Control Module (ECM) (100-00
General Information, Description and Operation).

Published: 21-Jul-2015
Exhaust System - INGENIUM I4 2.0L Diesel - Selective Catalyst Reduction
Description and Operation

COMPONENT LOCATION

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Item Description
1 Diesel Exhaust Fluid (DEF) filler assembly
2 Engine Control Module (ECM)
3 Diesel Exhaust Fluid (DEF) tank
4 Diesel Exhaust Fluid (DEF) tank module
5 Diesel Exhaust Fluid (DEF) heater control unit
6 Post - Selective Catalyst Reduction (SCR) nitrogen oxide (NOx) sensor
7 Diesel Exhaust Fluid (DEF) injector
8 Selective Catalyst Reduction (SCR) catalytic converter
9 Nitrogen oxide (NOx) sensor control module

OVERVIEW

The Selective Catalyst Reduction (SCR) system is an exhaust gas aftertreatment solution used to reduce the nitrogen oxides
within the exhaust gas.

For this purpose, a specified amount of Diesel Exhaust Fluid (DEF) is injected into the exhaust system, downstream of the
DPF. The injected DEF into the exhaust system is converted to ammonia (NH3) and carbon dioxide (CO2). The resulting
ammonia (NH3) is used within a special catalyst in the exhaust stream. The resulting reaction converts the unwanted nitrogen
oxides (NOx) into harmless nitrogen (N2) and water (H2O) vapor.

DESCRIPTION

Diesel Exhaust Fluid (DEF)

Diesel Exhaust Fluid (DEF) is a pure, odorless, colorless, synthetically manufactured, 32.5% aqueous solution of urea, used
for the aftertreatment of exhaust gases in a Selective Catalyst Reduction (SCR) catalytic converter.

The SCR catalytic converter can be contaminated by low quantities of metals and thus the quality of the DEF fluid is held to
closely controlled standards. DEF cannot be substituted by urea used in agriculture or diluted with any other fluid.

DEF is not categorized as a dangerous substance, it is non-flammable and non-toxic, and there is no danger in the event of
spills. DEF can be stored on board vehicles, despite the limitation that it crystallizes at temperatures below -11°C (12°F).

In Europe, DEF is also known as AdBlue®, the fluid is specified by ISO22241.

Diesel Exhaust Fluid (DEF) Tank

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The Diesel Exhaust Fluid (DEF) tank is blow molded from High Density Polyethylene (HDPE). The tank is located under the
right side of the fuel tank and it is secured to the underside of the vehicle in common with the fuel tank by the fuel tank
support strap and a bolt secures the DEF tank to the rear left side member. The DEF tank contains the DEF tank module which
is welded into the tank, and supplied as a unit. An additional shield protects the DEF tank module. The protection shield is
attached to the DEF tank and the fuel tank heatshield with four screws. The tank includes a 12% unusable volume to protect
the internal components as a result of fluid expansion under freezing conditions.

If the ambient temperature falls below -11°C (12°F), the DEF will freeze in the DEF tank, this will provide difficulty with the
refill procedure. In order to thaw the DEF in the DEF tank, place the vehicle in a warm place for up to 2 hours before
attempting to refill the tank.

The volume of the DEF tank is different on all JLR products, but has been designed so that refills are minimized outside of the
vehicle service intervals.

When the vehicle consumes more DEF than anticipated, for example extended vehicle use in extreme temperatures, 'at
altitude' or aggressive drive cycles, a warning message will be displayed in the Instrument Cluster (IC) message center to add
DEF to the tank.

Diesel Exhaust Fluid (DEF) Tank Module

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Item Description
1 Diesel Exhaust Fluid (DEF) level sensor
2 Diesel Exhaust Fluid (DEF) tank module electrical connection
3 Diesel Exhaust Fluid (DEF) pressure line connection
4 Diesel Exhaust Fluid (DEF) injection pump electrical connection
5 Diesel Exhaust Fluid (DEF) heater element
The Diesel Exhaust Fluid (DEF) tank module is located at the bottom of the DEF tank. The module is welded into the tank and
can only be replaced as a complete assembly. The DEF tank module includes a life-time fit filter, a fluid level and temperature
sensor and a heater element to defrost the DEF in extreme cold climates. The DEF level sensor is an ultrasonic device located
in the DEF tank module, which sends the DEF level value to the Engine Control Module (ECM) via Pulse Width Modulation
(PWM) signals. The ultrasonic cone angle is ±10° and the readings are most accurate when the vehicle is stationary and on
level ground.

The heater element is a Positive Temperature Coefficient (PTC) type heater, which provides safe operation to the system.
Increased heater element temperature results in decreased current drawn from the DEF heater control module, which
actuates the power supply of the heater element. Under normal operation the maximum current is 6A.

The DEF tank module has a fused power supply from the Battery Junction Box (BJB). The ECM controls the power supply of
the DEF tank module via the DEF control relay located in the Rear Junction Box (RJB).

Diesel Exhaust Fluid (DEF) Injection Pump

The Diesel Exhaust Fluid (DEF) tank module comprises a DEF injection pump which is an assembly of two solenoid pumps. The
DEF injection pump provides 6.5 bar operating pressure. The 6.5 bar pressure is required to maintain the complete DEF
atomization in the exhaust gas. The purge pump is used to purge the DEF from the DEF pressure line at engine shut-down to
prevent freezing in the DEF injector at low temperatures. The pumps have a fused power supply from the Rear Junction Box
(RJB). The ECM controls the ground connection of the pumps individually via hardwired connections.

Diesel Exhaust Fluid (DEF) Line

The Diesel Exhaust Fluid (DEF) line provides hydraulic connection between the DEF injection pump and the DEF injector. The
DEF line is manufactured from a plastic material which is specifically designed for use with DEF. A copper based resistor wire
DEF line heater is installed within the DEF line with an electrical connector. The DEF line heater enables electrical heating of

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the DEF at low-ambient temperatures. The DEF line heater has hardwired connections to the DEF heater control unit, which
actuates the power supply for the heater element, controlled by the ECM via the Private Controller Area Network (CAN) bus.

Diesel Exhaust Fluid (DEF) Injector

The Diesel Exhaust Fluid (DEF) injector is located in the exhaust system downstream of the catalytic converter and it is
secured to the S-shaped exhaust pipe with a clamp. Due to the position of the injector on the S-shaped exhaust pipe, the DEF
is injected axially to the exhaust gas flow direction ensuring the DEF is mixed well and distributed evenly within the exhaust
gas. The DEF injector consists of an injector and a passive cooling heat sink to protect the injector from overheating due to
the high exhaust temperatures.

The DEF injector works at high pressures to obtain the complete atomization of the injected DEF, this ensures the SCR
catalytic converter is working to its optimum performance. The DEF injector is controlled by the ECM with PWM signals.

Diesel Exhaust Fluid (DEF) Heater Control Unit

The Diesel Exhaust Fluid (DEF) heater control unit is located on the left side of the luggage compartment, behind the side trim
panel. The heater system enables rapid SCR system operation in the event of frozen DEF and ensures an adequate quantity of
defrosted DEF is available at all operating points. The DEF heater control unit has a fused power supply from the RJB and it
receives an ignition signal from the ECM relay located in the BJB. Operation of the ECM relay is controlled by the ECM.

The DEF heater control unit has hardwired connections to the DEF tank module and the DEF line heater. If the ambient air
temperature is below -7°C (19.4°F), the ECM switches on the DEF heater control unit via the Private CAN bus. The DEF heater
control unit energizes the DEF tank module heater element and the DEF line heater. The DEF heater control unit has on-board
diagnostics to detect and report faults to the ECM via the Private CAN bus.

Nitrogen Oxide (NOx) Sensor

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Item Description
1 Post - selective catalyst reduction (SCR) nitrogen oxide (NOx) sensor control module
2 Electrical connection
3 Post - selective catalyst reduction (SCR) nitrogen oxide (NOx) sensor
The Post - selective catalyst reduction (SCR) nitrogen oxide (NOx) sensor is located in the exhaust pipe downstream of the
SCR catalytic converter. The NOx sensor comprises a sensor element attached to a dedicated control module with a hardwired
connection.

The sensor and the control module are replaced as an assembly. The NOx sensor is an evolution of the wide band oxygen
sensor. The sensor element is constructed from special ceramics and contains two oxygen density detecting chambers that
work together to determine the NOx concentration in the exhaust gas. The control module sends a message via the Private
CAN bus to the ECM for monitoring the effectiveness of the SCR system.

OPERATION

Schematic Diagram - Selective Catalyst Reduction (SCR) System

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Item Description
1 Engine Control Module (ECM)
2 Diesel Exhaust Fluid (DEF) tank with Diesel Exhaust Fluid (DEF) tank module
3 Diesel Exhaust Fluid (DEF) injection pump
4 Diesel Exhaust Fluid (DEF) line
5 Post - Selective Catalyst Reduction (SCR) nitrogen oxide (NOx) sensor
6 Selective Catalyst Reduction (SCR) catalytic converter
7 Mixer plate
8 Diesel Exhaust Fluid (DEF) injector
9 Diesel Particulate Filter (DPF)
10 Catalytic converter
11 Engine
The SCR catalytic converter reaches the operating temperature at 150 °C (302°F). The temperature of the exhaust gas is
measured by the post DPF exhaust gas temperature sensor, which is connected to the ECM.

The DEF injection pump supplies the DEF from the DEF tank at a pressure of 6.5 bar to the DEF injector via the heated DEF
line. The DEF injector is controlled with a Pulse Width Modulation (PWM) signal by the ECM.

The injected DEF is carried along by the exhaust gas flow and is evenly distributed in the exhaust gas by the mixer plate. The
mixer plate is located in the exhaust pipe upstream of the SCR catalytic converter and downstream of the DEF injector. After
the injection, the DEF is converted into ammonia (NH3) and carbon dioxide (CO2) during chemical reactions.

In the SCR catalytic converter, the ammonia (NH3) reacts with the nitrogen oxides (NOx) to produce nitrogen (N2) and water
(H2O) vapor. The SCR system's efficiency is registered by the post SCR NOx sensor.

In order to optimise the SCR system's efficiency, the correct amount of ammonia (NH3) is required in the exhaust gas. The
ECM achieves this by operating in two modes:

Storage mode
On-line mode

For example, storage mode will operate during low speed driving condition; the on-line mode will operate at high speed
driving condition.

Storage Mode
When the system operates in storage mode, the ammonia (NH3) is stored on the SCR catalytic converter and used as a
function of the NOx feed. In this mode, the objective of the control system is to ensure that a pre-determined amount of NH3
is available on the SCR catalytic converter at any given time. As a consequence, it may be difficult to diagnose dosing system
problems when the system is in storage mode.

On-line Mode

When the system operates in on-line mode, the NOx is measured by the pre-SCR NOx sensor (or the model value) and the
amount of ammonia (NH3) is injected as a function of the NOx feed. In this mode, the dosing system is 'easy' to diagnose if it
is functioning correctly as the pulses from the DEF injector are frequent.

Warning Messages

It is a legal requirement for the driver to be informed of SCR system faults. If the performance of the SCR system is reduced a
message will be displayed in the Instrument Cluster (IC) message center. There are three possible routes to receive a fault
message on the IC:

Low DEF volume in the tank

Incorrect DEF quality supplied to the SCR System
Efficiency of the SCR System is reduced in the event of a system fault.

In case of low DEF level, a warning is given 800km (497 miles) ahead of any vehicle restriction in order to allow time to visit
an authorized Land Rover dealer to refill the DEF tank. If the DEF fluid is not replenished within this distance, and the engine
is turned off, the vehicle will fail to start. In this event customers can use two standard size refill bottles as a short term
solution to restart the vehicle, a complete refill of the DEF tank will still be required by an authorized Land Rover dealer.

INPUT/OUTPUT DIAGRAM

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 cardiagn.com
A = Hardwired; AL = Pulse Width Modulation (PWM); U = Private Controller Area Network (CAN) bus.
Item Description
1 Engine Control Module (ECM)
2 Post-Selective Catalyst Reduction (SCR) nitrogen oxide (NOx) sensor control module
3 Diesel Exhaust Fluid (DEF) heater control unit
4 Diesel Exhaust Fluid (DEF) tank module heater element
5 Diesel Exhaust Fluid (DEF) line heater
6 Diesel Exhaust Fluid (DEF) injection pump
7 Diesel Exhaust Fluid (DEF) injector
8 Ground
9 Power supply
10 Diesel Exhaust Fluid (DEF) level sensor
11 Post Selective Catalyst Reduction (SCR) NOx sensor
Published: 02-Mar-2015
Exhaust System - INGENIUM I4 2.0L Diesel - Exhaust System
Diagnosis and Testing

Principles of Operation

For a detailed description of the Exhaust System, refer to the relevant Description and Operation section in the workshop
manual.
REFER to: Exhaust System (309-00B Exhaust System - INGENIUM I4 2.0L Diesel, Description and Operation).

Inspection and Verification

CAUTION: Diagnosis by substitution from a donor vehicle is NOT acceptable. Substitution of control modules does not
guarantee confirmation of a fault and may also cause additional faults in the vehicle being checked and/or the donor vehicle.

NOTES:

If the control module or a component is suspect and the vehicle remains under manufacturer warranty, refer to the
Warranty Policy and Procedures manual, or determine if any prior approval programme is in operation, prior to the installation
of a new module/component.

When performing voltage or resistance tests, always use a digital multimeter accurate to three decimal places, and with
an up-to-date calibration certificate. When testing resistance always take the resistance of the digital multimeter leads into

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account.

Check DDW for open campaigns. Refer to the corresponding bulletins and SSMs which may be valid for the specific
customer complaint and carry out the recommendations as required.

Check and rectify basic faults before beginning diagnostic routines involving pinpoint tests.

1. Verify the customer concern

2. Visually inspect for obvious signs of damage and system integrity

Visual Inspection
Mechanical

Exhaust gas leaks

Restrictions or blockages
Metal fatigue
Pipes, mufflers and catalytic converters
Joints or gaskets
Exhaust mountings
Clearance around components
Heat shields

3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding
to the next step

4. If the cause is not visually evident, verify the symptom and refer to the Symptom Chart, alternatively check for
Diagnostic Trouble Codes (DTCs) and refer to the DTC Index

5. Check DDW for open campaigns. Refer to the corresponding bulletins and SSMs which may be valid for the specific
customer complaint and carry out the recommendations as required

Symptom Chart

Symptom Possible Causes Action

Exhaust system
Exhaust leaking
Check the exhaust system for leaks
excessively Exhaust system
Check the exhaust system for foul conditions
noisy fouling body,
transmission, etc

Exhaust system
Check the exhaust system for restrictions and blockages
restricted/blocked
Check the catalytic converter for blockage or damage
Loss of engine Catalytic converter Refer to the relevant section of the workshop manual and check the fuel
performance blocked or damaged system
Fuel system fault Using the manufacturer approved diagnostic system, check the engine
Ignition system fault control module for related DTCs and refer to the relevant DTC index
Engine system fault

DTC Index

For a list of Diagnostic Trouble Codes (DTCs) that could be logged on this vehicle, please refer to Section 100-00.
REFER to: Diagnostic Trouble Code (DTC) Index - INGENIUM I4 2.0L Diesel, DTC: Engine Control Module (ECM) (100-00,
Description and Operation).

Published: 21-Jul-2015
Exhaust System - INGENIUM I4 2.0L Diesel - Exhaust System
Description and Operation

COMPONENT LOCATION - SHEET 1 OF 2 - VEHICLES WITHOUT SELECTIVE CATALYST REDUCTION

(SCR) SYSTEM

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Item Description
A Vehicles with 5 seats
B Vehicles with 7 seats
1 Catalytic converter
2 Flexible coupling
3 Diesel Particulate Filter (DPF)
4 Mounting rubber
5 Rear silencer
6 Outlet pipe
7 Clamp

COMPONENT LOCATION - SHEET 2 OF 2 - VEHICLES WITH SELECTIVE CATALYST REDUCTION (SCR)

SYSTEM
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Item Description
A Vehicles with 5 seats
B Vehicles with 7 seats
1 Catalytic converter
2 Flexible coupling
3 Diesel Particulate Filter (DPF) and Selective Catalyst Reduction (SCR) catalytic converter assembly
4 Mounting rubber
5 Rear silencer
6 Outlet pipe
7 Clamp

OVERVIEW

The exhaust system is manufactured from stainless steel and is attached to the underside of the vehicle body with rubber
mountings which are located on hanger bars that are welded to the exhaust system. The rubber mountings locate on adjacent
hanger brackets which are bolted or welded to the underside of the vehicle body and the subframes.

The exhaust system comprises three separate sections:

A front section, including a catalytic converter.

A center section,
- incorporating the Diesel Particulate Filter (DPF) and a connecting pipe to the Low Pressure (LP) Exhaust Gas
Recirculation (EGR) valve on EU5 market vehicles.For additional information, refer to: Diesel Particulate Filter
(309-00C, Description and Operation).
- incorporating the Diesel Particulate Filter (DPF), the Selective Catalyst Reduction (SCR) catalytic converter and a
connecting pipe to the Low Pressure (LP) Exhaust Gas Recirculation (EGR) valve on EU6 market vehicles.For
additional information, refer to: Selective Catalyst Reduction (SCR) (309-00C, Description and Operation).
A rear section,
- comprising a single rear silencer with two outlet pipes on vehicles with 5 seats.
- comprising two rear silencers on vehicles with 7 seats.

DESCRIPTION

Front Section

The front section has an inlet flange which mates with the turbocharger outlet. The flange is sealed with a stainless metallic
gasket to the turbocharger and secured with a vee clamp onto the turbocharger housing.
An elbow from the flange is connected to the catalytic converter. The elbow contains a threaded boss for the installation of the
Heated Oxygen Sensor (HO2S).

A support bracket with a stud is welded to the elbow. A mounting bracket is secured to the front section with a nut. The
mounting bracket is connected to the top of the engine with three bolts, which secures the top of the front section to the
engine. A band clamp is attached to the catalytic converter with a bolt to hold the front section in its position.

The catalytic converter is connected to a flange which mates with the flexible coupling of the center section.

Center Section - Vehicles Without Selective Catalyst Reduction (SCR) system

The center section is connected to the front section by a flange. It is sealed with a metal gasket and secured with three studs
and nuts. The flange is connected to a flexible coupling with a pipe. The pipe comprises a threaded boss for the post-catalyst
exhaust gas temperature sensor. A curved pipe from the flexible coupling is connected to the Diesel Particulate Filter (DPF). A
threaded boss is welded to the pipe and provides the connection of the differential pressure sensor high pressure pipe. A
welded hanger bar with a rubber mounting is connected to a common bracket which in turn bolted to the front subframe, to
support the center section.

The DPF outlet pipe comprises threaded bosses for the post-DPF exhaust gas temperature sensor and the differential pressure
sensor low pressure pipe. An additional pipe is welded to the outlet pipe, which routes the exhaust gases from the outlet pipe
to the Low Pressure (LP) Exhaust Gas Recirculation (EGR) valve. A welded hanger bar with a rubber mounting is connected to
a common bracket which in turn bolted to the underside of the vehicle body, to support the center section.For additional
information, refer to: (309-00C)

Diesel Particulate Filter (Description and Operation),

Diesel Particulate Filter (Description and Operation).
Center Section - Vehicles With Selective Catalyst Reduction (SCR) system

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The center section is connected to the front section by a flange. It is sealed with a metal gasket and secured with three studs
and nuts. The flange is connected to a flexible coupling with a pipe. The pipe comprises a threaded boss for the post-catalyst
exhaust gas temperature sensor. A curved pipe from the flexible coupling is connected to the DPF and Selective Catalyst
Reduction (SCR) catalytic converter assembly. A threaded boss is welded to the pipe and provides the connection of the
differential pressure sensor high pressure pipe. A welded boss provides the attachment of the Diesel Exhaust Fluid (DEF)
injector. A mixer plate is located in the exhaust pipe downstream of the DEF injector. A welded hanger bar with a rubber
mounting is connected to a common bracket which in turn bolted to the front subframe, to support the center section.

The SCR outlet pipe comprises threaded bosses for the post-DPF exhaust gas temperature sensor, the differential pressure
sensor low pressure pipe and the post-SCR nitrogen oxide (NOx) sensor. An additional pipe is welded to the outlet pipe, which
routes the exhaust gases from the outlet pipe to the Low Pressure (LP) Exhaust Gas Recirculation (EGR) valve. A welded
hanger bar with a rubber mounting is connected to a common bracket which in turn bolted to the underside of the vehicle
body, to support the center section.For additional information, refer to: Selective Catalyst Reduction (SCR) (309-00C,
Description and Operation).

Rear Section - Vehicles With 5 Seats

If the vehicle is equipped with 5 seats, the exhaust system rear section comprises a single rear silencer. The rear section is
connected to the center section with a clamp. The rear silencer is connected by a pipe to the center section and secured with a
clamp.

The rear section inlet pipe comprises a flexible coupling and a welded hanger bar. A hanger bar is attached to the hanger
bracket with a rubber mounting. The hanger bracket is bolted to the underside of the vehicle body.

The rear section inlet pipe is routed in a central position under the vehicle, with a slight deviation around the Rear Drive Unit
(RDU), where it joins with the rear silencer. The rear silencer is supported by three rubber mountings. Two are attached to a
hanger bracket bolted to the left side of the rear subframe and the third is attached to a hanger bracket on the right side of
the rear subframe. The rear silencer has an outlet pipe at each end. Each outlet pipe is fitted with a stainless steel finisher.

Rear Section - Vehicles With 7 Seats

If the vehicle is equipped with 7 seats, the exhaust system rear section comprises two rear silencers. The rear section is
connected to the center section with a clamp. The rear silencers are connected by two individual pipes to a 'Y' piece which the
center section and secured with a clamp.

The rear section comprises a flexible coupling which is connected to the center section with a clamp. The flexible coupling
outlet pipe is separated into two outlet pipes and a hanger bar and an exhaust brace are welded to the pipes to retain the
system in position and reduce exhaust flexing. A hanger bar is attached to the hanger bracket with a rubber mounting. The
hanger bracket is bolted to the underside of the vehicle body. The left rear silencer inlet pipe is connected to the rear section
with a clamp. Inlet pipes to each rear silencer are routed with a slight deviation to each side of the RDU. Both inlet pipes have
a welded hanger bar where it connects to the appropriate rear silencer. Rubber mountings and hanger brackets are attached
to the hanger bars. The hanger brackets are bolted to the rear subframe on both side. Each rear silencer is connected to the
rear armature via a welded hanger bar and rubber mounting. Each rear silencer has an outlet pipe at each end. Each pipe is
fitted with a stainless steel finisher.

SYSTEM OPERATION

Catalytic Converter
The oxidizing catalytic converter is fitted in the front section of the exhaust system, after the Heated Oxygen Sensor (HO2S).
The catalytic converter assembly is common to vehicles with or without the DPF, however, the catalyst coating specification
varies depending on the market. The HO2S monitors the exhaust gases leaving the engine. The engine management system
uses this information to provide accurately metered quantities of fuel to the combustion chambers to ensure the most efficient
use of fuel and to minimise the exhaust emissions.For additional information, refer to: Electronic Engine Controls (303-14C,
Description and Operation).

The catalytic converter further reduces the carbon monoxide and hydrocarbons content of the exhaust gases. In the catalytic
converter the exhaust gases are passed through honeycombed ceramic elements coated with a special surface treatment
called a 'washcoat'. The washcoat increases the surface area of the ceramic elements by a factor of approximately 7000. On
top of the washcoat is a coating containing platinum, which is the active constituent for converting harmful emissions into
inert by-products. The platinum adds oxygen to the carbon monoxide and the hydrocarbons in the exhaust gases, to convert
them into carbon dioxide and water respectively.

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Published: 21-Jul-2015
Exhaust System - INGENIUM I4 2.0L Diesel - Diesel Particulate Filter - Component
Location
Description and Operation

COMPONENT LOCATION - SHEET 1 OF 3 - DIESEL PARTICULATE FILTER (DPF)

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Item Description
1 Differential pressure sensor
2 Pre-catalytic converter exhaust gas temperature sensor
3 Heated Oxygen Sensor (HO2S)
4 Diesel Particulate Filter (DPF)
5 Post-Diesel Particulate Filter (DPF) exhaust gas temperature sensor
6 Pre-Diesel Particulate Filter (DPF) exhaust gas temperature sensor
COMPONENT LOCATION - SHEET 2 OF 3 - DIFFERENTIAL PRESSURE SENSOR
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Item Description
1 Differential pressure sensor
2 Electrical connection
3 Differential pressure sensor pipe - low
4 Differential pressure sensor pipe - high
COMPONENT LOCATION - SHEET 3 OF 3 - EXHAUST GAS TEMPERATURE SENSOR

Item Description
1 Exhaust gas temperature sensor
2 Electrical connection
Published: 15-May-2015
Exhaust System - INGENIUM I4 2.0L Diesel - Diesel Particulate Filter - System
Operation and Component Description
Description and Operation

System Operation
DIESEL PARTICULATE FILTER (DPF)

Two processes are used to regenerate the DPF; passive and active.

Passive Regeneration

Passive regeneration requires no special engine management intervention and occurs during normal engine operation. The
passive regeneration involves a slow conversion of the particulate matter deposited in the DPF into carbon dioxide. This
process occurs when the DPF temperature exceeds 250°C (482°F) and is a continuous process when the vehicle is being
driven at higher engine loads and speeds.

During passive regeneration, only a portion of the particulate matter is converted into carbon dioxide. This is because the
chemical reaction, which utilises nitrogen dioxide, is slower than the rate of engine production of particulate matter and is
effective from 250°C (482°F).

Above 580°C the conversion efficiency of the particulates into carbon dioxide rapidly increases. These temperatures are
generally only be achieved using the active regeneration process.

Active Regeneration

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Active regeneration starts when the particulate loading of the DPF reaches a threshold as monitored or determined by the DPF
control software. The threshold calculation is based on driving style, distance travelled and back pressure signals from the
differential pressure sensor.

Active regeneration generally occurs every 250 miles (400 km) although this is dependant on how the vehicle is driven. For
example, if the vehicle is driven at low loads in urban traffic regularly, active regeneration will occur more often. This is due to
the rapid build-up of particulates in the DPF than if the vehicle is driven at high speeds when passive regeneration will have
occurred.

The DPF software incorporates a mileage trigger which is used as back-up for active regeneration. If active regeneration has
not been initiated by a back pressure signal from the differential pressure sensor, regeneration is requested based on distance
travelled.

Active regeneration of the DPF is commenced when the temperature of the DPF is increased to the combustion temperature of
the particles. The DPF temperature is raised by increasing the exhaust gas temperature. This is achieved by introducing
post-injection of fuel after the pilot and main fuel injections have occurred.

It is determined by the DPF software monitoring the signals from the two DPF temperature sensors to establish the
temperature of the DPF. Depending on the DPF temperature, the DPF software requests the Engine Control Module (ECM) to
perform either one or two post-injections of fuel:

The first post-injection of fuel is associated with retarded combustion to increase the temperature of the exhaust gas
and therefore allow the oxidation catalyst to reach it's operational temperature.
The second post-injection of fuel is injected late in the power stroke cycle. The fuel is not intended to combust in the
cylinder, and hence unburnt fuel passes into the exhaust where it creates an exothermic event within the catalytic
converter, further increasing the temperature of the DPF.

The active regeneration process takes up to 20 minutes to complete. The first phase increases the exhaust gas temperature to
ensure the catalytic converter is active. The second phase further increases the DPF temperature to the optimum temperature
for particle combustion. This temperature is then controlled for 15-20 minutes to ensure complete oxidation of the particles
within the DPF. The oxidation process converts the carbon particles to carbon dioxide.

The active regeneration temperature of the DPF is closely monitored by the DPF software to maintain a target temperature at
the DPF inlet. The temperature control ensures that the temperatures do not exceed the operational limits of the turbocharger
and the catalytic converter. The turbocharger inlet temperature must not exceed 830°C (1526°F), the catalytic converter brick
temperature must not exceed 800°C (1472°F) and the exit temperature must remain below 875°C (1382°F).

Air management control during DPF regeneration

The DPF air management function controls the following:

EGR control
Turbocharger boost pressure control
Intake mass air flow

During active regeneration, the EGR operation is disabled and the closed-loop activation of the turbocharger boost controller is
calculated. The air management function controls the air in the intake manifold to a predetermined mass flow. This control is
required to achieve the correct in-cylinder conditions for stable and robust combustion of the post injected fuel.
The function controls the intake mass air flow by actuating the throttle and by adjustment of the turbocharger boost pressure
control.

If, due to vehicle usage and/or driving style, the active regeneration process cannot take place or is unable to regenerate the
DPF, the dealer can force regenerate the DPF. This is achieved by driving the vehicle until the engine is at its normal operating
temperature and then driving for approximately a further 20 minutes at speeds between 60 km/h to 120 km/h (40 mph to 70
mph). It is possible that the regeneration process will occur at lower speeds, but the events may take longer at a 48 km/h (30
mph) average speed.

DPF Control

The DPF requires constant monitoring to ensure that it is operating at its optimum efficiency and does not become blocked.
The ECM contains DPF software which controls the monitoring and operation of the DPF system and also monitors other
vehicle data to determine regeneration periods and service intervals.

The DPF software can be divided into three separate control software functions; a DPF supervisor function, a DPF fuel
management function and a DPF air management function.

These three functions are controlled by a fourth software function known as the DPF co-ordinator function. The co-ordinator
function manages the operation of the other functions when an active regeneration is requested.

DPF Fuel Management Function

The DPF fuel management function controls the following:

Timing and quantity of the four split injections per stroke (pilot, main and two post injections).
Injection pressure and the transition between the three different calibration levels of injection.

The fuel management calculates the quantity and timing for the four split injections, for each of the three calibration levels for

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injection pressure, and also manages the transition between the levels.

The two post injections are required to separate the functionality of increasing in-cylinder gas temperatures and the
production of hydrocarbons. The first post injection is used to generate the higher in-cylinder gas temperature while
simultaneously retaining the same engine torque output produced during normal (non-regeneration) engine operation. The
second post injection is used to generate hydrocarbons by allowing unburnt fuel into the catalytic converter without producing
increased engine torque.

DPF Air Management Function

The DPF air management function controls the following:

EGR control
Turbocharger boost pressure control
Intake mass air flow

DPF Co-ordinator Fuction

The DPF co-ordinator function reacts to a regeneration request from the supervisor function by initiating and co-ordinating the
following DPF regeneration requests:

EGR cut-off - except for overrun condition

Turbocharger boost pressure control
Engine load increase
Control of mass air flow
Fuel injection control.

When the supervisor function issues a regeneration request, the co-ordinator function requests EGR cut-off and a regeneration
specific turbocharger boost pressure control. It then waits for a feedback signal from the EGR system confirming that the EGR
valve is closed.

When the EGR valve is closed, the co-ordinator function initiates requests to increase engine load by controlling the intake
mass air flow.

Once confirmation is received that intake conditions are controlled or a calibration time has expired, the co-ordinator function
then changes to a state awaiting an accelerator pedal release manoeuvre from the driver. If this occurs or a calibration time
has expired, the co-ordinator function generates a request to control fuel injections to increase exhaust gas temperature.

DIFFERENTIAL PRESSURE SENSOR

As the amount of particulates trapped by the DPF increases, the pressure at the inlet side of the DPF increases in comparison
to the DPF outlet. The DPF software uses this comparison, in conjunction with other data, to calculate the accumulated
amount of trapped particulates.

By measuring the pressure difference between the DPF inlet and outlet and the DPF temperature, the DPF software can
determine if the DPF is becoming blocked and requires regeneration.

Component Description
DIESEL PARTICULATE FILTER (DPF)

The DPF system reduces diesel particulate emissions to negligible levels to meet current standards for:

European stage 5 and 6 emissions

NAS LEV3 emissions

The particulate emissions are the black fumes emitted from the diesel engine under certain load conditions. The emissions are
a complex mixture of solid and liquid components with the majority of the particulates being carbon microspheres on which
hydrocarbons from the engine's fuel and lubricant condense.

The DPF system comprises the following components:

Diesel Particulate Filter (DPF)

DPF temperature sensors
DPF control software incorporated in the ECM
Differential pressure sensor.

The DPF is located in the exhaust system, downstream of the catalytic converter. Its function is to trap particulate matter in
the exhaust gases leaving the engine. A major feature of the DPF is its ability for regeneration. Regeneration is the burning of
particulates trapped by the filter to prevent obstruction to the free flow of exhaust gasses. The regeneration process takes
place at calculated intervals and is not noticeable by the driver of the vehicle.

Regeneration is most important, since an overfilled filter can damage the engine through excessive exhaust back pressure and
can itself be damaged or destroyed. The material trapped in the filter is in the most part carbon particles with some absorbed
hydrocarbons.

The DPF uses a filter technology based on a filter with a catalytic coating. The DPF is made from silicon carbide housed in a
steel container and has excellent thermal shock resistance and thermal conductivity properties. The DPF is designed for the

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engine's operating requirements to maintain the optimum back pressure requirements.

The porous surface of the filter consists of thousands of small parallel channels positioned in the longitudinal direction of the
exhaust system. Adjacent channels in the filter are alternately plugged at the end. This design forces the exhaust gasses to
flow through the porous filter walls, which act as the filter medium. Particulate matter which are too big to pass through the
porous surface are collected and stored in the channels.

The collected particulate matter, if not removed, can create an obstruction to exhaust gas flow. The stored particles are
removed by a regeneration process which incinerates the particles.

Diesel Particulate Filter Temperature Sensors

The sensors measure the temperature of exhaust gas exiting the turbocharger and before it passes through the DPF and
provides the information needed to calculate the DPF temperature.

The information is used, in conjunction with other data, to estimate the amount of accumulated particulates and to control the
DPF temperature.

Instrument Cluster (IC) Indications

For drivers who make regular short journeys at low speeds, it may not be possible to efficiently regenerate the DPF. In this
case, the DPF software will detect a blockage of the DPF from signals from the differential pressure sensor and will alert the
driver as follows:

The driver will be alerted to this condition by a message 'EXHAUST FILTER NEARLY FULL'. See 'HANDBOOK'. As detailed in the
Owners Handbook, the driver should drive the vehicle until the engine is at its normal operating temperature and then drive
for approximately a further 20 minutes at speeds between 60 km/h to 120 km/h (40 mph to 70 mph). It is possible that the
regeneration process will occur at lower speeds, but the events may take longer at a 48 km/h (30 mph) average speed.
Successful regeneration of the DPF is indicated to the driver by the 'EXHAUST FILTER NEARLY FULL' message no longer being
displayed. If the DPF software detects that the DPF is still blocked, the message will continue to be displayed or an additional
message 'EXHAUST FILTER FULL VISIT DEALER' will be displayed. The driver should take the vehicle to an authorized dealer
to have the DPF force regenerated using an approved diagnostic system.

If, due to vehicle usage and/or driving style, the active regeneration process cannot take place or is unable to regenerate the
DPF, the dealer can force regenerate the DPF. This is achieved by driving the vehicle until the engine is at its normal operating
temperature and then driving for approximately a further 20 minutes at speeds between 60 km/h to 120 km/h (40 mph to 70
mph). It is possible that the regeneration process will occur at lower speeds, but the events may take longer at a 48 km/h (30
mph) average speed.

Diesel Particulate Filter Side Effects

The following section details some side effects caused by the active regeneration process.

Engine Oil Dilution

Engine oil dilution can occur due to small amounts of fuel entering the engine crankcase during the post-injection phases. This
has made it necessary to introduce a calculation based on driving style to reduce oil service intervals if necessary. The driver
is alerted to the oil service by a message in the instrument cluster.
The DPF software monitors the driving style and the frequency of the active regeneration and duration. Using this information
a calculation can be made on the engine oil dilution. When the DPF software calculates the engine oil dilution has reached a
predetermined threshold (fuel being 7% of engine oil volume) a service message is displayed in the IC.

Depending on driving style, some vehicles may require an oil service before the designated interval. If a service message is
displayed, the vehicle will be required have a full service and the service interval counter will be reset.

Fuel consumption

During the active regeneration process of the DPF, there will be an increase in fuel consumption.

However, because active regeneration occurs infrequently, the overall effect on fuel consumption is approximately 2%. The
additional fuel used during the active regeneration process is accounted for in the instantaneous and average fuel
consumption displays in the instrument cluster.

DIFFERENTIAL PRESSURE SENSOR

The differential pressure sensor is used by the DPF software to monitor the condition of the DPF. Two pipe connections on the
sensor are connected by pipes to the inlet and outlet ends of the DPF. The pipes allow the sensor to measure the inlet and
outlet pressures of the DPF.

Aftermarket DPF cleaning fluids

Recent years have seen the introduction of 'DPF cleaning fluids' to (non JLR approved) aftermarket sales. These products
claim to reduce the temperature that the soot reaction takes place. It should be stressed that, during the vehicle development
activity, every effort is made to generate DPF regeneration temperatures whilst maintaining safe levels for all other vehicle
components. Unauthorized use of the aftermarket fluids produces a significant risk to soot burn rates and DPF peak
temperatures real world driving conditions. These fluids are not authorised for JLR use.

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Published: 21-Jul-2015
Exhaust System - INGENIUM I4 2.0L Diesel - Selective Catalyst Reduction
Description and Operation

COMPONENT LOCATION

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Item Description
1 Diesel Exhaust Fluid (DEF) filler assembly
2 Engine Control Module (ECM)
3 Diesel Exhaust Fluid (DEF) tank
4 Diesel Exhaust Fluid (DEF) tank module
5 Diesel Exhaust Fluid (DEF) heater control unit
6 Post - Selective Catalyst Reduction (SCR) nitrogen oxide (NOx) sensor
7 Diesel Exhaust Fluid (DEF) injector
8 Selective Catalyst Reduction (SCR) catalytic converter
9 Nitrogen oxide (NOx) sensor control module

OVERVIEW

The Selective Catalyst Reduction (SCR) system is an exhaust gas aftertreatment solution used to reduce the nitrogen oxides
within the exhaust gas.

For this purpose, a specified amount of Diesel Exhaust Fluid (DEF) is injected into the exhaust system, downstream of the
DPF. The injected DEF into the exhaust system is converted to ammonia (NH3) and carbon dioxide (CO2). The resulting
ammonia (NH3) is used within a special catalyst in the exhaust stream. The resulting reaction converts the unwanted nitrogen
oxides (NOx) into harmless nitrogen (N2) and water (H2O) vapor.

DESCRIPTION

Diesel Exhaust Fluid (DEF)

Diesel Exhaust Fluid (DEF) is a pure, odorless, colorless, synthetically manufactured, 32.5% aqueous solution of urea, used
for the aftertreatment of exhaust gases in a Selective Catalyst Reduction (SCR) catalytic converter.

The SCR catalytic converter can be contaminated by low quantities of metals and thus the quality of the DEF fluid is held to
closely controlled standards. DEF cannot be substituted by urea used in agriculture or diluted with any other fluid.
DEF is not categorized as a dangerous substance, it is non-flammable and non-toxic, and there is no danger in the event of
spills. DEF can be stored on board vehicles, despite the limitation that it crystallizes at temperatures below -11°C (12°F).

In Europe, DEF is also known as AdBlue®, the fluid is specified by ISO22241.

Diesel Exhaust Fluid (DEF) Tank

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The Diesel Exhaust Fluid (DEF) tank is blow molded from High Density Polyethylene (HDPE). The tank is located under the
right side of the fuel tank and it is secured to the underside of the vehicle in common with the fuel tank by the fuel tank
support strap and a bolt secures the DEF tank to the rear left side member. The DEF tank contains the DEF tank module which
is welded into the tank, and supplied as a unit. An additional shield protects the DEF tank module. The protection shield is
attached to the DEF tank and the fuel tank heatshield with four screws. The tank includes a 12% unusable volume to protect
the internal components as a result of fluid expansion under freezing conditions.

If the ambient temperature falls below -11°C (12°F), the DEF will freeze in the DEF tank, this will provide difficulty with the
refill procedure. In order to thaw the DEF in the DEF tank, place the vehicle in a warm place for up to 2 hours before
attempting to refill the tank.

The volume of the DEF tank is different on all JLR products, but has been designed so that refills are minimized outside of the
vehicle service intervals.

When the vehicle consumes more DEF than anticipated, for example extended vehicle use in extreme temperatures, 'at
altitude' or aggressive drive cycles, a warning message will be displayed in the Instrument Cluster (IC) message center to add
DEF to the tank.

Diesel Exhaust Fluid (DEF) Tank Module

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Item Description
1 Diesel Exhaust Fluid (DEF) level sensor
2 Diesel Exhaust Fluid (DEF) tank module electrical connection
3 Diesel Exhaust Fluid (DEF) pressure line connection
4 Diesel Exhaust Fluid (DEF) injection pump electrical connection
5 Diesel Exhaust Fluid (DEF) heater element
The Diesel Exhaust Fluid (DEF) tank module is located at the bottom of the DEF tank. The module is welded into the tank and
can only be replaced as a complete assembly. The DEF tank module includes a life-time fit filter, a fluid level and temperature
sensor and a heater element to defrost the DEF in extreme cold climates. The DEF level sensor is an ultrasonic device located
in the DEF tank module, which sends the DEF level value to the Engine Control Module (ECM) via Pulse Width Modulation
(PWM) signals. The ultrasonic cone angle is ±10° and the readings are most accurate when the vehicle is stationary and on
level ground.

The heater element is a Positive Temperature Coefficient (PTC) type heater, which provides safe operation to the system.
Increased heater element temperature results in decreased current drawn from the DEF heater control module, which
actuates the power supply of the heater element. Under normal operation the maximum current is 6A.

The DEF tank module has a fused power supply from the Battery Junction Box (BJB). The ECM controls the power supply of
the DEF tank module via the DEF control relay located in the Rear Junction Box (RJB).

Diesel Exhaust Fluid (DEF) Injection Pump

The Diesel Exhaust Fluid (DEF) tank module comprises a DEF injection pump which is an assembly of two solenoid pumps. The
DEF injection pump provides 6.5 bar operating pressure. The 6.5 bar pressure is required to maintain the complete DEF
atomization in the exhaust gas. The purge pump is used to purge the DEF from the DEF pressure line at engine shut-down to
prevent freezing in the DEF injector at low temperatures. The pumps have a fused power supply from the Rear Junction Box
(RJB). The ECM controls the ground connection of the pumps individually via hardwired connections.

Diesel Exhaust Fluid (DEF) Line

The Diesel Exhaust Fluid (DEF) line provides hydraulic connection between the DEF injection pump and the DEF injector. The
DEF line is manufactured from a plastic material which is specifically designed for use with DEF. A copper based resistor wire
DEF line heater is installed within the DEF line with an electrical connector. The DEF line heater enables electrical heating of

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the DEF at low-ambient temperatures. The DEF line heater has hardwired connections to the DEF heater control unit, which
actuates the power supply for the heater element, controlled by the ECM via the Private Controller Area Network (CAN) bus.

Diesel Exhaust Fluid (DEF) Injector

The Diesel Exhaust Fluid (DEF) injector is located in the exhaust system downstream of the catalytic converter and it is
secured to the S-shaped exhaust pipe with a clamp. Due to the position of the injector on the S-shaped exhaust pipe, the DEF
is injected axially to the exhaust gas flow direction ensuring the DEF is mixed well and distributed evenly within the exhaust
gas. The DEF injector consists of an injector and a passive cooling heat sink to protect the injector from overheating due to
the high exhaust temperatures.

The DEF injector works at high pressures to obtain the complete atomization of the injected DEF, this ensures the SCR
catalytic converter is working to its optimum performance. The DEF injector is controlled by the ECM with PWM signals.

Diesel Exhaust Fluid (DEF) Heater Control Unit

The Diesel Exhaust Fluid (DEF) heater control unit is located on the left side of the luggage compartment, behind the side trim
panel. The heater system enables rapid SCR system operation in the event of frozen DEF and ensures an adequate quantity of
defrosted DEF is available at all operating points. The DEF heater control unit has a fused power supply from the RJB and it
receives an ignition signal from the ECM relay located in the BJB. Operation of the ECM relay is controlled by the ECM.

The DEF heater control unit has hardwired connections to the DEF tank module and the DEF line heater. If the ambient air
temperature is below -7°C (19.4°F), the ECM switches on the DEF heater control unit via the Private CAN bus. The DEF heater
control unit energizes the DEF tank module heater element and the DEF line heater. The DEF heater control unit has on-board
diagnostics to detect and report faults to the ECM via the Private CAN bus.

Nitrogen Oxide (NOx) Sensor

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 cardiagn.com
Item Description
1 Post - selective catalyst reduction (SCR) nitrogen oxide (NOx) sensor control module
2 Electrical connection
3 Post - selective catalyst reduction (SCR) nitrogen oxide (NOx) sensor
The Post - selective catalyst reduction (SCR) nitrogen oxide (NOx) sensor is located in the exhaust pipe downstream of the
SCR catalytic converter. The NOx sensor comprises a sensor element attached to a dedicated control module with a hardwired
connection.

The sensor and the control module are replaced as an assembly. The NOx sensor is an evolution of the wide band oxygen
sensor. The sensor element is constructed from special ceramics and contains two oxygen density detecting chambers that
work together to determine the NOx concentration in the exhaust gas. The control module sends a message via the Private
CAN bus to the ECM for monitoring the effectiveness of the SCR system.

OPERATION

Schematic Diagram - Selective Catalyst Reduction (SCR) System

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Item Description
1 Engine Control Module (ECM)
2 Diesel Exhaust Fluid (DEF) tank with Diesel Exhaust Fluid (DEF) tank module
3 Diesel Exhaust Fluid (DEF) injection pump
4 Diesel Exhaust Fluid (DEF) line
5 Post - Selective Catalyst Reduction (SCR) nitrogen oxide (NOx) sensor
6 Selective Catalyst Reduction (SCR) catalytic converter
7 Mixer plate
8 Diesel Exhaust Fluid (DEF) injector
9 Diesel Particulate Filter (DPF)
10 Catalytic converter
11 Engine
The SCR catalytic converter reaches the operating temperature at 150 °C (302°F). The temperature of the exhaust gas is
measured by the post DPF exhaust gas temperature sensor, which is connected to the ECM.

The DEF injection pump supplies the DEF from the DEF tank at a pressure of 6.5 bar to the DEF injector via the heated DEF
line. The DEF injector is controlled with a Pulse Width Modulation (PWM) signal by the ECM.

The injected DEF is carried along by the exhaust gas flow and is evenly distributed in the exhaust gas by the mixer plate. The
mixer plate is located in the exhaust pipe upstream of the SCR catalytic converter and downstream of the DEF injector. After
the injection, the DEF is converted into ammonia (NH3) and carbon dioxide (CO2) during chemical reactions.

In the SCR catalytic converter, the ammonia (NH3) reacts with the nitrogen oxides (NOx) to produce nitrogen (N2) and water
(H2O) vapor. The SCR system's efficiency is registered by the post SCR NOx sensor.

In order to optimise the SCR system's efficiency, the correct amount of ammonia (NH3) is required in the exhaust gas. The
ECM achieves this by operating in two modes:

Storage mode
On-line mode

For example, storage mode will operate during low speed driving condition; the on-line mode will operate at high speed
driving condition.

Storage Mode
When the system operates in storage mode, the ammonia (NH3) is stored on the SCR catalytic converter and used as a
function of the NOx feed. In this mode, the objective of the control system is to ensure that a pre-determined amount of NH3
is available on the SCR catalytic converter at any given time. As a consequence, it may be difficult to diagnose dosing system
problems when the system is in storage mode.

On-line Mode

When the system operates in on-line mode, the NOx is measured by the pre-SCR NOx sensor (or the model value) and the
amount of ammonia (NH3) is injected as a function of the NOx feed. In this mode, the dosing system is 'easy' to diagnose if it
is functioning correctly as the pulses from the DEF injector are frequent.

Warning Messages

It is a legal requirement for the driver to be informed of SCR system faults. If the performance of the SCR system is reduced a
message will be displayed in the Instrument Cluster (IC) message center. There are three possible routes to receive a fault
message on the IC:

Low DEF volume in the tank

Incorrect DEF quality supplied to the SCR System
Efficiency of the SCR System is reduced in the event of a system fault.

In case of low DEF level, a warning is given 800km (497 miles) ahead of any vehicle restriction in order to allow time to visit
an authorized Land Rover dealer to refill the DEF tank. If the DEF fluid is not replenished within this distance, and the engine
is turned off, the vehicle will fail to start. In this event customers can use two standard size refill bottles as a short term
solution to restart the vehicle, a complete refill of the DEF tank will still be required by an authorized Land Rover dealer.

INPUT/OUTPUT DIAGRAM

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 cardiagn.com
A = Hardwired; AL = Pulse Width Modulation (PWM); U = Private Controller Area Network (CAN) bus.
Item Description
1 Engine Control Module (ECM)
2 Post-Selective Catalyst Reduction (SCR) nitrogen oxide (NOx) sensor control module
3 Diesel Exhaust Fluid (DEF) heater control unit
4 Diesel Exhaust Fluid (DEF) tank module heater element
5 Diesel Exhaust Fluid (DEF) line heater
6 Diesel Exhaust Fluid (DEF) injection pump
7 Diesel Exhaust Fluid (DEF) injector
8 Ground
9 Power supply
10 Diesel Exhaust Fluid (DEF) level sensor
11 Post Selective Catalyst Reduction (SCR) NOx sensor
Published: 07-Sep-2015
Exhaust System - INGENIUM I4 2.0L Diesel - Catalytic Converter and Diesel
Particulate Filter (DPF) Assembly
Removal and Installation

Removal

WARNING: Observe due care when working near a hot exhaust system.

NOTES:

Removal steps in this procedure may contain installation details.

Some components shown removed for clarity.

Some variation in the illustrations may occur, but the essential information is always correct.

1. Refer to: Engine Cover - INGENIUM I4 2.0L Diesel (501-05,

Removal and Installation).

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2.
WARNING: Make sure to support the vehicle with axle
stands.

Raise and support the vehicle.

3. Refer to: Exhaust System (309-00, Removal and Installation).

4. Torque: 25 Nm

5. Torque: 9 Nm
7.
6.

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8.

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9. Torque: 25 Nm
10. Torque: 10 Nm

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11.
NOTE: Do not disassemble further if the
component is removed for access only.

Torque: 35 Nm

12. Torque: 48 Nm
Installation

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1. To install, reverse the removal procedure.

2. If a new unit is installed, configure using the approved diagnostic

tool.
Published: 13-Oct-2016
Exhaust System - INGENIUM I4 2.0L Diesel - Catalytic Converter
Removal and Installation

Special Tool(s)
310-121
Wrench, H02S

Removal

WARNING: Observe due care when working near a hot exhaust system.

NOTES:

Some variation in the illustrations may occur, but the essential information is always correct.

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Removal steps in this procedure may contain installation details.

1.
WARNING: Make sure to support the vehicle with axle
stands.

Raise and support the vehicle.

2. Remove the engine acoustic cover.

Refer to: Engine Cover - INGENIUM I4 2.0L Diesel (501-05 Interior

Trim and Ornamentation, Removal and Installation).

3. Remove the right front fender splash shield.

Refer to: Fender Splash Shield (501-02 Front End Body Panels,
Removal and Installation).

4. Remove the front subframe.

Refer to: Front Subframe (502-00 Uni-Body, Subframe and Mounting

System, Removal and Installation).

5. Remove the Diesel Particulate Filter (DPF).

Refer to: Catalytic Converter and Diesel Particulate Filter (DPF)

Assembly (309-00B Exhaust System - INGENIUM I4 2.0L Diesel,
Removal and Installation).
Refer to: Catalytic Converter (309-00B Exhaust System - INGENIUM
I4 2.0L Diesel, Removal and Installation).

6.
NOTE: Remove and discard the gasket.
8.
7.

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 9.

11.
10.

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12.
NOTE: Remove and discard the gasket.

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13.
NOTE: Do not disassemble further if the
component is removed for access only.
 14. Special Tool(s): 310-121

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Installation

1. CAUTIONS:

Make sure the anti-seize compound does not

contact the catalyst monitor sensor tip.

If accidentally dropped or knocked install a new

sensor.

Special Tool(s): 310-121

Torque: 48 Nm
2.
CAUTION: Only tighten the bolts finger tight at
this stage

3. CAUTIONS:

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Take extra care not to damage the component.

Take extra care not to damage the surrounding

components.

4.
CAUTION: Only tighten the bolts finger tight at
this stage
5.
NOTE: Install a new gasket.

6. Torque: 10 Nm

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7. Torque: 24 Nm
8. Torque: 24 Nm

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9. Torque: 24 Nm

10. Torque: 24 Nm
11.

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12.
NOTE: Install a new gasket.

Torque: 24 Nm
 13. Install the Diesel Particulate Filter (DPF).

Refer to: Catalytic Converter and Diesel Particulate Filter (DPF)

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Assembly (309-00B Exhaust System - INGENIUM I4 2.0L Diesel,
Removal and Installation).
Refer to: Catalytic Converter (309-00B Exhaust System - INGENIUM
I4 2.0L Diesel, Removal and Installation).

14. Install the front subframe.

Refer to: Front Subframe (502-00 Uni-Body, Subframe and Mounting

System, Removal and Installation).

15. Install the engine acoustic cover.

Refer to: Engine Cover - INGENIUM I4 2.0L Diesel (501-05 Interior

Trim and Ornamentation, Removal and Installation).

16. Install the right front fender splash shield.

Refer to: Fender Splash Shield (501-02 Front End Body Panels,
Removal and Installation).

Published: 30-Jun-2015
Interior Trim and Ornamentation - Engine Cover INGENIUM I4 2.0L Diesel
Removal and Installation

Removal

NOTE: Removal steps in this procedure may contain installation details.

1.
 2.

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Installation

1. To install, reverse the removal procedure

Published: 18-Oct-2016
Uni-Body, Subframe and Mounting System - Front Subframe
Removal and Installation

Special Tool(s)
205-754A
Splitter, Ball Joints
 502-012
Alignment Pins, Subframe

General Equipment
Transmission jack

Removal

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CAUTION: Nuts and bolts must be tightened with the weight of the vehicle on the suspension.

NOTES:

Removal steps in this procedure may contain installation details.

LHD illustration shown, RHD is similar.

All vehicles

1.

2.
WARNING: Make sure that a new steering
column flexible coupling bolt is installed.

Torque: 25 Nm
 3.
WARNING: Make sure that new nuts are
installed.

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CAUTION: Make sure that the specified torque is
not exceeded, or the retaining studs may shear and
damage the body panel.

Torque: 2.2 Nm

4.
WARNING: Make sure to support the vehicle with axle
stands.

Raise and support the vehicle.

5. Refer to: Engine Undershield (501-02 Front End Body Panels,

Removal and Installation).

6. Torque: 10 Nm
7. Torque: 10 Nm

8.
NOTE: If equipped.
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9. Repeat the above step for the other side.

Refer to: Fender Splash Shield (501-02 Front End Body Panels,
Removal and Installation).

10.

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11. Torque: 12 Nm

12.
Vehicles with diesel particulate filter (DPF)

13.

All vehicles

14.
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WARNING: Make sure that a new nut is
installed.

CAUTION: Make sure that the ball joint ball does

not rotate.

Tie aside.
Torque:
Bolt 10 Nm
nut 55 Nm
Repeat the above step for the other side.
15.
WARNING: Make sure that a new nut is
installed.

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CAUTION: Make sure that the ball joint ball does
not rotate.

Torque: 133 Nm

16.
CAUTION: Make sure that the ball joint seal is
not damaged.

NOTES:

Some variation in the illustrations may occur, but

the essential information is always correct.

Repeat the step for the other side.

Special Tool(s): 205-754A

17.
CAUTION: Make sure that new bolts are
installed.

NOTE: Repeat the step for the other side.

Torque:
Vehicles fitted with 18'' brakes.
Stage 1:110 Nm
Stage 2:120°
M14 bolts 200 Nm
M12 bolts
Stage 1:90 Nm
Stage 2:120°

18.
CAUTION: Make sure that new bolts are
installed.

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NOTE: Repeat the step for the other side.

Torque:
Stage 1:80 Nm
Stage 2:180°

19.
 cardiagn.com
20. Torque: 110 Nm

21. General Equipment: Transmission jack

22. CAUTIONS:

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Remove and discard the M16 subframe retaining bolts.

Do not discard the M10 retaining bolts.

Torque: 45 Nm
Torque:
Stage 1:140 Nm
Stage 2:240°

23.
CAUTION: Remove and discard the M16
subframe retaining bolts.

Torque:
Stage 1:140 Nm
Stage 2:240°
 24.

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 cardiagn.com
26.
CAUTION: Make sure that new nuts and bolts
are installed.

Repeat for the other side.

(1) Lower control arm front bolt.

Torque:
Stage 1:140 Nm
Stage 2:45°
(2) Lower control arm rear nuts and bolts for
vehicles fitted with 18" brakes.

Torque:
Stage 1:115 Nm
Stage 2:240°
(2) Lower control arm rear nuts and bolts for
vehicles fitted with 17" brakes.

Torque: 175 Nm

27.
NOTE: Some components shown removed for clarity.
 28. Torque: 20 Nm

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29. Torque: 189 Nm
 30. Torque: 24 Nm

31. Using only four wheel alignment equipment approved by Land

Rover, check and adjust the wheel alignment.
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Refer to: Four-Wheel Alignment (204-00 Suspension System - General
Information, General Procedures).

Installation

All vehicles

1.
CAUTION: Use the special tool to align the components.

To install, reverse the removal procedure.

Special Tool(s): 502-012
Special Tool(s): 502-012
 Vehicles with dynamic suspension

2. Check the suspension system ride height.

cardiagn.com
Published: 07-Sep-2015
Exhaust System - INGENIUM I4 2.0L Diesel - Catalytic Converter and Diesel
Particulate Filter (DPF) Assembly
Removal and Installation

Removal

WARNING: Observe due care when working near a hot exhaust system.

NOTES:

Removal steps in this procedure may contain installation details.

Some components shown removed for clarity.

Some variation in the illustrations may occur, but the essential information is always correct.

1. Refer to: Engine Cover - INGENIUM I4 2.0L Diesel (501-05,

Removal and Installation).

2.
WARNING: Make sure to support the vehicle with axle
stands.

Raise and support the vehicle.

3. Refer to: Exhaust System (309-00, Removal and Installation).

4. Torque: 25 Nm
5. Torque: 9 Nm

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6.
8.
7.

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 cardiagn.com
9. Torque: 25 Nm

10. Torque: 10 Nm
 11.
NOTE: Do not disassemble further if the
component is removed for access only.

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Torque: 35 Nm

12. Torque: 48 Nm

Installation
 1. To install, reverse the removal procedure.

2. If a new unit is installed, configure using the approved diagnostic

tool.

Published: 13-Oct-2016
Exhaust System - INGENIUM I4 2.0L Diesel - Catalytic Converter
Removal and Installation

Special Tool(s)
310-121
Wrench, H02S

Removal

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WARNING: Observe due care when working near a hot exhaust system.

NOTES:

Some variation in the illustrations may occur, but the essential information is always correct.

Removal steps in this procedure may contain installation details.

1.
WARNING: Make sure to support the vehicle with axle
stands.

Raise and support the vehicle.

2. Remove the engine acoustic cover.

Refer to: Engine Cover - INGENIUM I4 2.0L Diesel (501-05 Interior

Trim and Ornamentation, Removal and Installation).

3. Remove the right front fender splash shield.

Refer to: Fender Splash Shield (501-02 Front End Body Panels,
Removal and Installation).

4. Remove the front subframe.

Refer to: Front Subframe (502-00 Uni-Body, Subframe and Mounting

System, Removal and Installation).

5. Remove the Diesel Particulate Filter (DPF).

Refer to: Catalytic Converter and Diesel Particulate Filter (DPF)

Assembly (309-00B Exhaust System - INGENIUM I4 2.0L Diesel,
Removal and Installation).
Refer to: Catalytic Converter (309-00B Exhaust System - INGENIUM
I4 2.0L Diesel, Removal and Installation).
6.
NOTE: Remove and discard the gasket.

7.

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8.
 9.

11.
10.

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12.
NOTE: Remove and discard the gasket.

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13.
NOTE: Do not disassemble further if the
component is removed for access only.
 14. Special Tool(s): 310-121

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Installation

1. CAUTIONS:

Make sure the anti-seize compound does not

contact the catalyst monitor sensor tip.

If accidentally dropped or knocked install a new

sensor.

Special Tool(s): 310-121

Torque: 48 Nm
2.
CAUTION: Only tighten the bolts finger tight at
this stage

3. CAUTIONS:

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Take extra care not to damage the component.

Take extra care not to damage the surrounding

components.

4.
CAUTION: Only tighten the bolts finger tight at
this stage
5.
NOTE: Install a new gasket.

6. Torque: 10 Nm

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7. Torque: 24 Nm
8. Torque: 24 Nm

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9. Torque: 24 Nm

10. Torque: 24 Nm
11.

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12.
NOTE: Install a new gasket.

Torque: 24 Nm
 13. Install the Diesel Particulate Filter (DPF).

Refer to: Catalytic Converter and Diesel Particulate Filter (DPF)

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Assembly (309-00B Exhaust System - INGENIUM I4 2.0L Diesel,
Removal and Installation).
Refer to: Catalytic Converter (309-00B Exhaust System - INGENIUM
I4 2.0L Diesel, Removal and Installation).

14. Install the front subframe.

Refer to: Front Subframe (502-00 Uni-Body, Subframe and Mounting

System, Removal and Installation).

15. Install the engine acoustic cover.

Refer to: Engine Cover - INGENIUM I4 2.0L Diesel (501-05 Interior

Trim and Ornamentation, Removal and Installation).

16. Install the right front fender splash shield.

Refer to: Fender Splash Shield (501-02 Front End Body Panels,
Removal and Installation).

Published: 30-Sep-2014
Front End Body Panels - Fender Splash Shield
Removal and Installation

Removal

NOTES:

Removal steps in this procedure may contain installation details.

RH illustration shown, LH is similar.

1.
WARNING: Make sure to support the vehicle with axle
stands.

Raise and support the vehicle.

2. Refer to: Wheel and Tire (204-04, Removal and Installation).

3.
CAUTION: Take extra care not to damage the
component.

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4.

5.
 6.

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Installation

1. To install, reverse the removal procedure.

Published: 28-Sep-2015
Exhaust System - INGENIUM I4 2.0L Diesel - Diesel Particulate Filter (DPF)
Differential Pressure Sensor
Removal and Installation

Removal

NOTES:

Removal steps in this procedure may contain installation details.

Some components shown removed for clarity.

Some variation in the illustrations may occur, but the essential information is always correct.

1. Refer to: Engine Cover - INGENIUM I4 2.0L Diesel (501-05 Interior

Trim and Ornamentation, Removal and Installation).

2.

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3.

4. Torque: 6 Nm
Installation

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1. To install, reverse the removal procedure.

2.
NOTE: This step is only necessary when installing a new
component.

Using the diagnostic tool, clear diagnostic trouble codes (DTCs)

from the engine control module (ECM).
Using the data logger, check the engine oil temperature.
Make sure the selector lever is in the 'P' position.
Start and run the engine.
Make sure that the engine oil is at a minimum temperature of 50
degrees C.
Allow the engine to idle for 2 minutes and 30 seconds.
Make sure that the engine cooling fan is not running.
Turn off the ignition.
Wait for 30 seconds.
Repeat steps 4 to 9, a further 5 times.
Disconnect the Jaguar approved diagnostic system.

Published: 30-Jun-2015
Interior Trim and Ornamentation - Engine Cover INGENIUM I4 2.0L Diesel
Removal and Installation

Removal

NOTE: Removal steps in this procedure may contain installation details.

1.
 2.

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Installation

1. To install, reverse the removal procedure

Published: 13-Mar-2015
Exhaust System - INGENIUM I4 2.0L Diesel - Rear Silencer
Removal and Installation

Removal

WARNING: Observe due care when working near a hot exhaust system.

NOTE: Removal steps in this procedure may contain installation details.

All vehicles

1.
WARNING: Make sure to support the vehicle with axle
stands.

Raise and support the vehicle.

Vehicles with petrol engine

2.
CAUTION: Make sure that the exhaust system is

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supported with suitable retaining straps.

NOTE: Right illustration shown, Left is similar

3.
NOTE: Right illustration shown, Left is similar

Torque: 55 Nm
Vehicles with diesel engine

4.

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CAUTION: Make sure that the exhaust system is
supported with suitable retaining straps.

5. Torque: 55 Nm
Vehicles with petrol engine

6.

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CAUTION: Make sure that a new bolt is
installed.

NOTES:

Right illustration shown, Left is similar

Do not disassemble further if the component is

removed for access only.

Torque: 22 Nm

Vehicles with diesel engine

7.
CAUTION: Make sure that new bolts are
installed.

Torque: 22 Nm
Installation

cardiagn.com
1. To install reverse the removal procedure.
Published: 26-May-2016
Exhaust System - INGENIUM I4 2.0L Diesel - Exhaust System Vehicles Without:
Diesel Exhaust Fluid
Removal and Installation

Removal

WARNING: Observe due care when working near a hot exhaust system.

NOTE: Removal steps in this procedure may contain installation details.

All vehicles

1.
WARNING: Make sure to support the vehicle with axle
stands.

Raise and support the vehicle.

2. Refer to: Engine Undershield (501-02 Front End Body Panels,

Removal and Installation).

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3. Torque: 30 Nm
NAS vehicles

5.

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All vehicles

6.
 7.
CAUTION: Make sure that the exhaust system is
supported with suitable retaining straps.

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8.
CAUTION: Make sure that the exhaust system is
supported with suitable retaining straps.

Torque: 40 Nm

9.
 10.
NOTE: Do not disassemble further if the

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component is removed for access only.

Torque: 48 Nm

NAS vehicles

11. Torque: 48 Nm
Installation

1. To install, reverse the removal procedure.

Published: 01-Oct-2013
Front End Body Panels - Engine Undershield
Removal and Installation

Removal

NOTES:

Some variation in the illustrations may occur, but the essential information is always correct.

Removal steps in this procedure may contain installation details.

1.
WARNING: Make sure to support the vehicle with axle
stands.

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Raise and support the vehicle.

2.
NOTE: Loosen the bolt, but do not fully remove.

Torque: 10 Nm

3. Torque: 10 Nm
 4.
NOTE: Do not disassemble further if the
component is removed for access only.

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Installation

1. To install, reverse the removal procedure.

Published: 30-Sep-2014
Bumpers - Rear Armature
Removal and Installation

Removal

NOTE: Removal steps in this procedure may contain installation details.

All vehicles

1.
WARNING: Make sure to support the vehicle with axle
stands.

Raise and support the vehicle.

2. Refer to: Rear Bumper Cover (501-19, Removal and Installation).

3.

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Vehicles with occasional rear seats

4.
WARNING: Observe due care when working near a hot
exhaust system.
 All vehicles

5. Torque: 30 Nm

Installation
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1. To install, reverse the removal procedure.