C7.1 Industrial Engine and Generator Set Caterpillar

System Operation Description:

This procedure covers the following diagnostic trouble codes.

Table 1

Diagnostic Trouble Codes for the ARD Nozzle Heater
J1939 Code	Description	Notes
4301-5	Aftertreatment #1 Fuel Injector #1 Heater Control : Current Below Normal	The Electronic Control Module (ECM) detects the following conditions: A low current condition (open circuit) in the circuit for the Aftertreatment Regeneration Device (ARD) nozzle heater relay circuit for one second. The ECM has been powered for at least one second. The ECM is not attempting to power the ARD nozzle heater relay.
4301-6	Aftertreatment #1 Fuel Injector #1 Heater Control : Current Above Normal	The ECM detects the following conditions: A high current condition (short circuit) in the circuit for the ARD nozzle heater circuit for at least one second. The ECM has been powered for at least one second. The ECM is attempting to power the ARD nozzle heater relay.

The ARD nozzle can become plugged with carbon or with debris. The engine is equipped with a system that cleans the nozzle. The ECM periodically tests the condition of the nozzle. The ARD combustion head contains an electric heating element. The heating element operates periodically in order to clean the nozzle.

ARD Nozzle Heater Circuit Test

The electronic service tool includes the "ARD Nozzle Heater Circuit Test". This override will assist the analysis of the ARD nozzle heater circuit. The override can be used to control the operation of the ARD nozzle heater while the engine is not running.

Illustration 1	g02453041
Schematic for the ARD nozzle heater

Illustration 2	g02041053
Pin locations on the P2 connector for the ARD nozzle heater (41) ARD nozzle heater relay return (43) ARD nozzle heater relay control

Illustration 3	g02169813
Pin locations on the 31-pin connector and the 40-pin connector for the ARD nozzle heater circuit

Illustration 4	g02326973
Typical example of a control panel for the Clean Emissions Module (CEM) (1) Relay for the ARD nozzle heater (2) Connector for the ARD nozzle heater relay (hidden) (3) 2-pin connector for the ARD nozzle heater

Test Step 1. Inspect Electrical Connectors And Wiring

1. Check that the fuses are not blown.

2. Check the harness for abrasion and pinch points from the ARD nozzle heater back to the ECM. Check the harness for abrasion and pinch points from the ARD nozzle heater back to the battery.

3. Inspect the connectors for the ARD heater and the ARD heater relay. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.

4. Thoroughly inspect the 31-pin connector and the 40-pin connector. Refer to Troubleshooting, "Electrical Connectors - Inspect".

5. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector and the connectors that are associated with the ARD nozzle heater.

6. Check the screw for the ECM connector for the correct torque of 6 N·m (53 lb in).

7. Check the harness for abrasions and for pinch points from the heating element back to the ECM.

Results:

• All connectors, pins, and sockets are correctly coupled and/or inserted. The harness is free of corrosion, abrasion, and pinch points. The fuses are not blown. - Proceed to Test Step 2.

• There is a fault with the harness and connectors -

  Repair: Repair the connectors or the harness and/or replace the connectors or the harness. Ensure that all of the seals are correctly in place and ensure that the connectors are correctly connected. Replace blown fuses.

  1. Start the engine. Wait for the engine to reach operating temperature.

  2. Use the electronic service tool to check for active diagnostic codes.

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  NOTICE
  Do not energize the heater for more than 30 seconds. If the heater is energized more than 30 seconds, damage to the heater can occur. Allow the heating element to cool for 2 minutes between power cycles.

  3. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater. Check for active diagnostic codes.

  4. Confirm that the fault has been eliminated.

     Note: If a fuse is replaced and the fault reoccurs, continue with this procedure.

  STOP

Test Step 2. Check for Active Diagnostic Codes

1. Connect the electronic service tool to the diagnostic connector.

2. Turn the keyswitch to the ON position.

3. Download the following items before performing any troubleshooting or clearing any diagnostic codes:
   • Warranty Report

   • Aftertreatment Regeneration Trigger History

   • Product Status Report with Histograms

4. Start the engine. Wait for the engine to reach operating temperature.

5. Check for an active 4301-5 diagnostic code.

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NOTICE
Do not energize the heater for more than 30 seconds. If the heater is energized more than 30 seconds, damage to the heater can occur. Allow the heating element to cool for 2 minutes between power cycles.

6. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater. Check for an active 4301-6 diagnostic code.

7. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

Results:

• A 4301-5 diagnostic code is active or recently logged. - Proceed to Test Step 3.

• A 4301-6 diagnostic code is active or recently logged. - Proceed to Test Step 6.

• There are no active 4301 diagnostic codes. - There may be a fault with the switched power circuit for the ARD nozzle heater. The ECM does not monitor the status of this condition. Proceed to Test Step 11.

Test Step 3. Create a Short at the ARD Nozzle Heater Relay

1. Turn the keyswitch to the OFF position.

2. Disconnect the connector for the ARD nozzle heater relay.

3. Fabricate a jumper wire that is 150 mm (6 inch) long.

4. Use the jumper to connect terminal 1 to terminal 4 on the harness connector for the relay.

5. Start the engine. Wait for the engine to reach operating temperature.

6. Check for an active 4301-5 diagnostic code.

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NOTICE
Do not energize the heater for more than 30 seconds. If the heater is energized more than 30 seconds, damage to the heater can occur. Allow the heating element to cool for 2 minutes between power cycles.

7. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater. Check for an active 4301-6 diagnostic code.

8. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

9. Remove the jumper.

Results:

• A 4301-5 diagnostic code is active with the jumper installed. - The relay is OK. Reconnect the ARD nozzle heater relay connector. Proceed to Test Step 4.

• A 4301-6 diagnostic code is active with the jumper installed. - The relay is faulty.

  Repair: Perform the following repair:

  1. Replace the ARD nozzle heater relay. Refer to Disassembly and Assembly, "Relay (ARD Nozzle Heater) - Remove and Install".

  2. Start the engine. Wait for the engine to reach operating temperature.

  3. Check for an active 4301-5 diagnostic code.

  Show/hide table

  NOTICE
  Do not energize the heater for more than 30 seconds. If the heater is energized more than 30 seconds, damage to the heater can occur. Allow the heating element to cool for 2 minutes between power cycles.

  4. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater. Check for an active 4301-6 diagnostic code.

  5. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

  6. Confirm that the fault has been eliminated.

  Proceed to Test Step 23.

Test Step 4. Create a Short at the 40-Pin Connector

1. Turn the keyswitch to the OFF position.

2. Disconnect the 40-pin connector.

3. Fabricate a jumper wire that is 150 mm (6 inch) long.

4. Insert one end of the jumper into socket 10 on the 40-pin connector on the harness between the engine and the Clean Emissions Module (CEM). Insert the other end of the jumper into socket 19 on the 40-pin connector on the harness between the engine and the CEM.

5. Start the engine. Wait for the engine to reach operating temperature.

6. Check for an active 4301-5 diagnostic code.

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NOTICE
Do not energize the heater for more than 30 seconds. If the heater is energized more than 30 seconds, damage to the heater can occur. Allow the heating element to cool for 2 minutes between power cycles.

7. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater. Check for an active 4301-6 diagnostic code.

   Note: While the 40-pin connector is disconnected, diagnostic codes for the other components that are connected to the 40-pin connector will be active. Disregard the diagnostic codes for all the other components. Only address the 4301 diagnostic codes.

8. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

9. Remove the jumper.

Results:

• A 4301-5 diagnostic code is active with the jumper installed. - The CEM harness is OK. Reconnect the 40-pin connector and proceed to Test Step 5.

• A 4301-6 diagnostic code is active with the jumper installed. - The fault is in the CEM harness between the 40-pin connector and the relay.

  Repair: Perform the following repair:

  1. Repair the faulty wiring or replace the faulty wiring.

  2. Reconnect the 40-pin connector. Use the electronic service tool to clear all logged diagnostic codes.

  3. Start the engine. Wait for the engine to reach operating temperature.

  4. Check for an active 4301-5 diagnostic code.

  Show/hide table

  NOTICE
  Do not energize the heater for more than 30 seconds. If the heater is energized more than 30 seconds, damage to the heater can occur. Allow the heating element to cool for 2 minutes between power cycles.

  5. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater. Check for an active 4301-6 diagnostic code.

  6. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

  7. Confirm that the fault has been eliminated.

  Proceed to Test Step 23.

Test Step 5. Create a Short at the 31-Pin Connector

1. Turn the keyswitch to the OFF position.

2. Disconnect the 31-pin connector.

3. Fabricate a jumper wire that is 150 mm (6 inch) long.

4. Insert one end of the jumper into socket 10 on the 31-pin connector on the engine harness. Insert the other end of the jumper into socket 19 on the 31-pin connector on the engine harness.

5. Start the engine. Wait for the engine to reach operating temperature.

6. Check for an active 4301-5 diagnostic code.

7. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater. Check for an active 4301-6 diagnostic code.

   Note: While the 31-pin connector is disconnected, diagnostic codes for the other components that are connected to the 31-pin connector will be active. Disregard the diagnostic codes for all the other components. Only address the 4301 diagnostic codes.

8. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

9. Remove the jumper.

Results:

• A 4301-5 diagnostic code is active with the jumper installed. - The harness between the 31-pin connector and the 40-pin connector is OK. Leave the 31-pin connector disconnected and proceed to Test Step 9.

• A 4301-6 diagnostic code is active with the jumper installed - The fault is in the harness between the 31-pin connector and the 40-pin connector.

  Repair: Perform the following repair:

  1. Repair the faulty wiring or replace the faulty wiring.

  2. Reconnect the 31-pin connector. Use the electronic service tool to clear all logged diagnostic codes.

  3. Start the engine. Wait for the engine to reach operating temperature.

  4. Check for an active 4301-5 diagnostic code.

  Show/hide table

  NOTICE
  Do not energize the heater for more than 30 seconds. If the heater is energized more than 30 seconds, damage to the heater can occur. Allow the heating element to cool for 2 minutes between power cycles.

  5. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater. Check for an active 4301-6 diagnostic code.

  6. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

  7. Confirm that the fault has been eliminated.

  Proceed to Test Step 23.

Test Step 6. Create an Open Circuit at the Relay Connector

1. Turn the keyswitch to the OFF position.

2. Disconnect the connector for the ARD nozzle heater relay.

3. Start the engine. Wait for the engine to reach operating temperature.

4. Check for an active 4301-5 diagnostic code.

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NOTICE
Do not energize the heater for more than 30 seconds. If the heater is energized more than 30 seconds, damage to the heater can occur. Allow the heating element to cool for 2 minutes between power cycles.

5. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater. Check for an active 4301-6 diagnostic code.

6. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

Results:

• A 4301-6 diagnostic code is active with the relay connector disconnected - The relay is OK. Reconnect the relay connector. Proceed to Test Step 7.

• A 4301-5 diagnostic code becomes active with the relay connector disconnected - The relay is faulty

  Repair: Perform the following repair:

  1. Replace the ARD nozzle heater relay. Refer to Disassembly and Assembly, "Relay (ARD Nozzle Heater) - Remove and Install".

  2. Start the engine. Wait for the engine to reach operating temperature.

  3. Check for an active 4301-5 diagnostic code.

  Show/hide table

  NOTICE
  Do not energize the heater for more than 30 seconds. If the heater is energized more than 30 seconds, damage to the heater can occur. Allow the heating element to cool for 2 minutes between power cycles.

  4. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater. Check for an active 4301-6 diagnostic code.

  5. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

  6. Confirm that the fault has been eliminated.

  Proceed to Test Step 23.

Test Step 7. Create an Open Circuit at the 40-Pin Connector

1. Turn the keyswitch to the OFF position.

2. Disconnect the 40-pin connector.

3. Start the engine. Wait for the engine to reach operating temperature.

4. Check for an active 4301-5 diagnostic code.

5. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater. Check for an active 4301-6 diagnostic code.

   Note: While the 40-pin connector is disconnected, diagnostic codes for the other components that are connected to the 40-pin connector will be active. Disregard the diagnostic codes for all the other components. Only address the 4301 diagnostic codes.

6. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

Results:

• A 4301-6 diagnostic code is active with the 40-pin connector disconnected - The CEM harness is OK. Reconnect the 40-pin connector and proceed to Test Step 8.

• A 4301-5 diagnostic code becomes active with the 40-pin connector disconnected. - The fault is in the CEM harness between the 40-pin connector and the relay.

  Repair: Perform the following repair:

  1. Repair the faulty wiring or replace the faulty wiring.

  2. Reconnect the 40-pin connector. Use the electronic service tool to clear all logged diagnostic codes.

  3. Start the engine. Wait for the engine to reach operating temperature.

  4. Check for an active 4301-5 diagnostic code.

  Show/hide table

  NOTICE
  Do not energize the heater for more than 30 seconds. If the heater is energized more than 30 seconds, damage to the heater can occur. Allow the heating element to cool for 2 minutes between power cycles.

  5. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater. Check for an active 4301-6 diagnostic code.

  6. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

  7. Confirm that the fault has been eliminated.

  Proceed to Test Step 23.

Test Step 8. Create an Open Circuit at the 31-Pin Connector

1. Turn the keyswitch to the OFF position.

2. Disconnect the 31-pin connector.

3. Start the engine. Wait for the engine to reach operating temperature.

4. Check for an active 4301-5 diagnostic code.

5. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater. Check for an active 4301-6 diagnostic code.

   Note: While the 31-pin connector is disconnected, diagnostic codes for the other components that are connected to the 31-pin connector will be active. Disregard the diagnostic codes for all the other components. Only address the 4301 diagnostic codes.

6. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

Results:

• A 4301-6 diagnostic code is active with the 31-pin connector disconnected. - The harness between the 31-pin connector and the 40-pin connector is OK. Reconnect the 31-pin connector. Proceed to Test Step 9.

• A 4301-5 diagnostic code becomes active with the 31-pin connector disconnected. - The harness between the 31-pin connector and the 40-pin connector is faulty.

  Repair: Perform the following repair:

  1. Repair the faulty wiring or replace the faulty wiring.

  2. Reconnect the 31-pin connector. Use the electronic service tool to clear all logged diagnostic codes.

  3. Start the engine. Wait for the engine to reach operating temperature.

  4. Check for an active 4301-5 diagnostic code.

  Show/hide table

  NOTICE
  Do not energize the heater for more than 30 seconds. If the heater is energized more than 30 seconds, damage to the heater can occur. Allow the heating element to cool for 2 minutes between power cycles.

  5. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater. Check for an active 4301-6 diagnostic code.

  6. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

  7. Confirm that the fault has been eliminated.

  Proceed to Test Step 23.

Test Step 9. Bypass the Engine Harness

1. Turn the keyswitch to the OFF position.

2. Disconnect the P2 connector.

3. Inspect the P2/J2 connector. Refer to Troubleshooting, "Electrical Connectors - Inspect".

4. Remove the wires from P2:41 and P2:43.

5. Remove the wires from socket 10 and socket 19 on the 31-pin connector on the engine harness.

6. Fabricate two jumper wires that are long enough to reach from the ECM to the 31-pin connector.

7. Insert one end of a jumper into P2:41. Insert the other end of the jumper into socket 10 on the 31-pin connector on the engine harness.

8. Insert one end of the other jumper into P2:43. Insert the other end of the jumper into socket 19 on the 31-pin connector on the engine harness.

9. Reconnect the P2 connector. Reconnect the 31-pin connector.

10. Start the engine. Wait for the engine to reach operating temperature.

11. Check for an active 4301-5 diagnostic code.

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NOTICE
Do not energize the heater for more than 30 seconds. If the heater is energized more than 30 seconds, damage to the heater can occur. Allow the heating element to cool for 2 minutes between power cycles.

12. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater. Check for an active 4301-6 diagnostic code.

13. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

Results:

• OK - There are no active 4301 diagnostic codes at this time. The fault is in the engine harness between the ECM and the 31-pin connector.

  Repair: Perform the following repair:

  1. Repair the faulty wiring or replace the faulty wiring.

  2. Reconnect the 31-pin connector. Reconnect the P2 connector. Use the electronic service tool to clear all logged diagnostic codes.

  3. Start the engine. Wait for the engine to reach operating temperature.

  4. Check for an active 4301-5 diagnostic code.

  Show/hide table

  NOTICE
  Do not energize the heater for more than 30 seconds. If the heater is energized more than 30 seconds, damage to the heater can occur. Allow the heating element to cool for 2 minutes between power cycles.

  5. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater. Check for an active 4301-6 diagnostic code.

  6. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

  7. Confirm that the fault has been eliminated.

  Proceed to Test Step 23.

• Not OK - A 4301 diagnostic code is still active at this time. Return all wires to the original configuration and proceed to Test Step 10.

Test Step 10. Check the ECM

1. Make sure that the latest flash file for the application is installed in the ECM. Refer to Troubleshooting, "Flash Programming".

2. Contact the Technical Communicator at a Caterpillar dealer.

   Note: This consultation can greatly reduce the repair time.

3. If the Technical Communicator recommends the use of a test ECM, install a test ECM. Refer to Troubleshooting, "Replacing the ECM".

4. Use the electronic service tool in order to clear all logged diagnostic codes.

5. Start the engine. Wait for the engine to reach operating temperature.

6. Check for an active 4301-5 diagnostic code.

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NOTICE
Do not energize the heater for more than 30 seconds. If the heater is energized more than 30 seconds, damage to the heater can occur. Allow the heating element to cool for 2 minutes between power cycles.

7. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater. Check for an active 4301-6 diagnostic code.

8. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

Results:

• There are no active 4301 diagnostic codes. - The replacement ECM functions correctly.

  Repair: Perform the following procedure:

  1. Reconnect the suspect ECM.

  2. If the fault returns with the suspect ECM, replace the ECM.

  3. Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault.

  Proceed to Test Step 23.

• Not OK - The fault is still present with the replacement ECM. Do not use the replacement ECM.

  Repair: Repeat this test procedure from Test Step 1.

  STOP

Test Step 11. Check the Fuse

1. Start the engine. Wait for the engine to reach operating temperature.

2. Check for an active 4301-5 diagnostic code.

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NOTICE
Do not energize the heater for more than 30 seconds. If the heater is energized more than 30 seconds, damage to the heater can occur. Allow the heating element to cool for 2 minutes between power cycles.

3. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater. Check for an active 4301-6 diagnostic code.

4. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

5. Turn the keyswitch to the OFF position. Check the fuse for the ARD nozzle heater. Refer to Illustration 1.

Results:

• The fuse is blown. - There is a short in the circuit for the ARD nozzle heater.

  Repair: Replace the fuse. Do not turn the keyswitch ON at this stage.

  Proceed to Test Step 12.

• The fuse is not blown. - There may be an open circuit in the circuit for the nozzle heater. Proceed to Test Step 17.

Test Step 12. Disconnect the 40-Pin Connector

1. Disconnect the 40-pin connector.

2. Turn the keyswitch to the ON position. Wait for at least 5 seconds.

3. Turn the keyswitch to the OFF position. Check the fuse for the ARD nozzle heater. Refer to Illustration 1.

Results:

• The fuse is not blown. - The wiring between the fuse and the 40-pin connector is OK. Reconnect the 40-pin connector and proceed to Test Step 13.

• The fuse is blown. - The fault is in the wiring between the fuse and the 40-pin connector.

  Repair: Perform the following repair:

  1. Repair the faulty wiring or replace the faulty wiring.

  2. Replace the fuse.

  3. Turn the keyswitch to the ON position and verify that the repair eliminates the fault.

  Proceed to Test Step 23.

Test Step 13. Disconnect the Connector for the Relay

1. Disconnect the connector for the ARD nozzle heater relay.

2. Turn the keyswitch to the ON position. Wait for at least 5 seconds.

3. Turn the keyswitch to the OFF position. Check the fuse for the ARD nozzle heater. Refer to Illustration 1.

Results:

• The fuse is not blown. - The wiring between the 40-pin connector and the relay connector is OK. Reconnect the relay connector and proceed to Test Step 14.

• The fuse is blown. - The fault is in the wiring between the 40-pin connector and the relay connector.

  Repair: Perform the following repair:

  1. Repair the faulty wiring or replace the faulty wiring.

  2. Replace the fuse.

  3. Turn the keyswitch to the ON position and verify that the repair eliminates the fault.

  Proceed to Test Step 23.

Test Step 14. Check the Relay for a Short Circuit

1. Disconnect the connector for the ARD nozzle heater relay.

2. Remove the wire from terminal 2 on the CEM harness connector for the relay.

3. Reconnect the connector for the relay.

4. Start the engine. Wait for the engine to reach operating temperature.

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NOTICE
Do not energize the heater for more than 30 seconds. If the heater is energized more than 30 seconds, damage to the heater can occur. Allow the heating element to cool for 2 minutes between power cycles.

5. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater. Wait for 5 seconds.

6. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

7. Turn the keyswitch to the OFF position. Check the fuse for the ARD nozzle heater. Refer to Illustration 1.

Results:

• The fuse is not blown. - The ARD nozzle heater relay is OK. Return all wires to the original configuration and proceed to Test Step 15.

• The fuse is blown. - The relay is faulty.

  Repair: Perform the following repair:

  1. Replace the ARD nozzle heater relay. Refer to Disassembly and Assembly, "Relay (ARD Nozzle Heater) - Remove and Install".

  2. Replace the fuse.

  3. Start the engine. Wait for the engine to reach operating temperature.

  4. Check for an active 4301-5 diagnostic code.

  Show/hide table

  NOTICE
  Do not energize the heater for more than 30 seconds. If the heater is energized more than 30 seconds, damage to the heater can occur. Allow the heating element to cool for 2 minutes between power cycles.

  5. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater. Check for an active 4301-6 diagnostic code.

  6. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

  7. Verify that the repair eliminates the fault.

  Proceed to Test Step 23.

Test Step 15. Disconnect the 2-Pin Connector for the Heater

1. Disconnect the 2-pin connector for the ARD nozzle heater.

2. Start the engine. Wait for the engine to reach operating temperature.

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NOTICE
Do not energize the heater for more than 30 seconds. If the heater is energized more than 30 seconds, damage to the heater can occur. Allow the heating element to cool for 2 minutes between power cycles.

3. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater.

4. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

5. Turn the keyswitch to the OFF position. Check the fuse for the ARD nozzle heater. Refer to Illustration 1.

Results:

• The fuse is not blown. - The CEM harness is OK. Replace all wires to the original configuration and proceed to Test Step 16.

• The fuse is blown. - The fault is in the CEM harness between the relay connector and the 2-pin connector for the ARD nozzle heater.

  Repair: Perform the following repair:

  1. Repair the faulty wiring or replace the faulty wiring.

  2. Replace the fuse.

  3. Start the engine. Wait for the engine to reach operating temperature.

  4. Check for an active 4301-5 diagnostic code.

  Show/hide table

  NOTICE
  Do not energize the heater for more than 30 seconds. If the heater is energized more than 30 seconds, damage to the heater can occur. Allow the heating element to cool for 2 minutes between power cycles.

  5. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater. Check for an active 4301-6 diagnostic code.

  6. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

  7. Verify that the repair eliminates the fault.

  Proceed to Test Step 23.

Test Step 16. Disconnect the Heater at the ARD Head

Illustration 5	g02231954
Overview of the ARD combustion head (4) Port for the heated nozzle (5) Retaining screw (6) Retaining clip

1. Remove retaining screw (5) and remove retaining clip (6) from the ARD nozzle heater.

2. Disconnect the wire to the ARD nozzle heater.

3. Start the engine. Wait for the engine to reach operating temperature.

4. Check for an active 4301-5 diagnostic code.

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NOTICE
Do not energize the heater for more than 30 seconds. If the heater is energized more than 30 seconds, damage to the heater can occur. Allow the heating element to cool for 2 minutes between power cycles.

5. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater. Wait for 5 seconds.

6. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

7. Turn the keyswitch to the OFF position. Check the fuse for the ARD nozzle heater. Refer to Illustration 1.

Results:

• The fuse is not blown. - The fault is in the ARD combustion head.

  Repair: Perform the following repair:

  1. Replace the ARD combustion head. Refer to Disassembly and Assembly, "Combustion Head Group (ARD) - Remove and Install".

  2. Start the engine. Wait for the engine to reach operating temperature.

  3. Check for an active 4301-5 diagnostic code.

  Show/hide table

  NOTICE
  Do not energize the heater for more than 30 seconds. If the heater is energized more than 30 seconds, damage to the heater can occur. Allow the heating element to cool for 2 minutes between power cycles.

  4. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater. Check for an active 4301-6 diagnostic code.

  5. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

  6. Verify that the repair eliminates the fault.

  Proceed to Test Step 23.

• The fuse is blown. - The fault is in the harness between the 2-pin connector for the ARD nozzle heater and the ARD head.

  Repair: Perform the following repair:

  1. Repair the faulty wiring or replace the faulty wiring.

  2. Replace the fuse.

  3. Start the engine. Wait for the engine to reach operating temperature.

  4. Check for an active 4301-5 diagnostic code.

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  NOTICE
  Do not energize the heater for more than 30 seconds. If the heater is energized more than 30 seconds, damage to the heater can occur. Allow the heating element to cool for 2 minutes between power cycles.

  5. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater.

  6. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

  7. Verify that the repair eliminates the fault.

  Proceed to Test Step 23.

Test Step 17. Check the Current Flow to the ARD Nozzle Heater

1. Turn the keyswitch to the OFF position.

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Illustration 6	g02231993
Typical view of the ARD combustion head (7) Insulated part of the heater wire

2. Connect a suitable clamp-ammeter around the insulated part of the heater wire (7) .

3. Start the engine. Wait for the engine to reach operating temperature.

4. Check for an active 4301-5 diagnostic code.

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NOTICE
Do not energize the heater for more than 30 seconds. If the heater is energized more than 30 seconds, damage to the heater can occur. Allow the heating element to cool for 2 minutes between power cycles.

5. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater. Check for an active 4301-6 diagnostic code.

6. Record the current reading on the ammeter.

7. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

Expected Result:

The ammeter should read at least 7 amps for a 12 V system or 3.5 Amps for a 24 V system.

Results:

• OK - The current is correct for the system. The ARD nozzle heater is operating correctly. Proceed to Test Step 23.

• Not OK - The current is below the expected level for the system. Proceed to Test Step 18.

Test Step 18. Check for Voltage at the ARD Head

1. Turn the keyswitch to the OFF position.

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Illustration 7	g02231954
Overview of the ARD combustion head (4) Port for the heated nozzle (5) Retaining screw (6) Retaining clip

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Illustration 8	g02173450
Wire for the ARD Nozzle Heater (8) Connector for the heated nozzle (9) Point of measurement on the wire

2. Remove retaining screw (5) and remove retaining clip (6) from the ARD nozzle heater.

3. Disconnect the wire to the ARD nozzle heater.

4. Start the engine. Wait for the engine to reach operating temperature.

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NOTICE
Do not energize the heater for more than 30 seconds. If the heater is energized more than 30 seconds, damage to the heater can occur. Allow the heating element to cool for 2 minutes between power cycles.

5. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater.

6. Measure the voltage at measurement point (9) to a suitable ground.

7. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

Expected Result:

The voltage should be ±3 VDC of battery voltage.

Results:

• OK - The voltage is within the expected range. The fault is inside the ARD combustion head.

  Repair: Perform the following repair:

  1. Replace the ARD combustion head. Refer to Disassembly and Assembly, "Combustion Head Group (ARD) - Remove and Install".

  Proceed to Test Step 17 in order to confirm that the repair eliminates the fault.

• Not OK - The voltage is not within the expected range. The ARD combustion head is OK. Reconnect the wire to the ARD nozzle heater. Proceed to Test Step 19.

Test Step 19. Check the Voltage at the 2-Pin Nozzle Heater Connector

1. Turn the keyswitch to the OFF position.

2. Disconnect the 2-pin connector for the ARD nozzle heater.

3. Start the engine. Wait for the engine to reach operating temperature.

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NOTICE
Do not energize the heater for more than 30 seconds. If the heater is energized more than 30 seconds, damage to the heater can occur. Allow the heating element to cool for 2 minutes between power cycles.

4. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater.

5. Measure the voltage at terminal 1 of the 2-pin connector to a suitable ground.

6. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

Expected Result:

The voltage should be ±3 VDC of battery voltage.

Results:

• OK - The voltage is within the expected range. The fault is in the wiring between the ARD combustion head and the 2-pin connector for the ARD nozzle heater.

  Repair: Perform the following repair:

  1. Repair the faulty wiring or replace the faulty wiring.

  Proceed to Test Step 17 in order to confirm that the repair eliminates the fault.

• Not OK - The voltage is not within the expected range. The wiring between the ARD combustion head and the 2-pin connector for the ARD nozzle heater is OK. Reconnect the 2-pin connector. Proceed to Test Step 20.

Test Step 20. Check for Voltage at the Output of the Relay

1. Turn the keyswitch to the OFF position.

2. Disconnect the connector for the ARD nozzle heater relay.

3. Remove the wire from terminal 2 on the CEM harness connector for the relay.

4. Reconnect the connector for the relay.

5. Start the engine. Wait for the engine to reach operating temperature.

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NOTICE
Do not energize the heater for more than 30 seconds. If the heater is energized more than 30 seconds, damage to the heater can occur. Allow the heating element to cool for 2 minutes between power cycles.

6. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater.

7. Measure the voltage from terminal 2 on the harness connector for the relay to a suitable ground.

8. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

Expected Result:

The voltage should be ±3 VDC of battery voltage.

Results:

• OK - The voltage is within the expected range. The fault is in the CEM harness between the 2-pin connector and the connector for the relay.

  Repair: Perform the following repair:

  1. Repair the faulty wiring or replace the faulty wiring.

  Proceed to Test Step 17 in order to confirm that the repair eliminates the fault.

• Not OK - The voltage is not within the expected range. The CEM harness between the 2-pin connector and the connector for the relay is OK. Return all wires to the original configuration. Proceed to Test Step 21.

Test Step 21. Measure the Voltage at the Input to the Relay

1. Turn the keyswitch to the OFF position.

2. Disconnect the connector for the ARD nozzle heater relay.

3. Start the engine. Wait for the engine to reach operating temperature.

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NOTICE
Do not energize the heater for more than 30 seconds. If the heater is energized more than 30 seconds, damage to the heater can occur. Allow the heating element to cool for 2 minutes between power cycles.

4. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater.

5. Measure the voltage from terminal 3 on the CEM harness connector for the relay to a suitable ground.

6. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

Expected Result:

The voltage should be ±3 VDC of battery voltage.

Results:

• OK - The voltage is within the expected range. The relay is faulty.

  Repair: Perform the following repair:

  1. Turn the keyswitch to the OFF position.

  2. Replace the ARD nozzle heater relay. Refer to Disassembly and Assembly, "Relay (ARD Nozzle Heater) - Remove and Install".

  Proceed to Test Step 17 in order to confirm that the repair eliminates the fault.

• Not OK - The voltage is not within the expected range. The relay is OK. Reconnect the connector for the relay. Proceed to Test Step 22.

Test Step 22. Check for Voltage at the 40-Pin Connector

1. Turn the keyswitch to the OFF position.

2. Disconnect the 40-pin connector.

3. Start the engine. Wait for the engine to reach operating temperature.

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NOTICE
Do not energize the heater for more than 30 seconds. If the heater is energized more than 30 seconds, damage to the heater can occur. Allow the heating element to cool for 2 minutes between power cycles.

4. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch on the ARD nozzle heater.

5. Measure the voltage at pin 18 on the 40-pin connector on the application harness to a suitable ground.

6. Use the "ARD Nozzle Heater Circuit Test" in the electronic service tool to switch off the ARD nozzle heater.

Expected Result:

The voltage should be ±3 VDC of battery voltage.

Results:

• OK - The voltage is within the expected range. The fault is in the CEM harness between the 40-pin connector and the connector for the relay.

  Repair: Perform the following repair:

  1. Repair the faulty wiring or replace the faulty wiring.

  Proceed to Test Step 17 in order to confirm that the repair eliminates the fault.

• Not OK - The voltage is not within the expected range. The fault is in the wiring between the 40-pin connector and switched battery+.

  Repair: Perform the following repair:

  1. Repair the faulty wiring or replace the faulty wiring.

  Proceed to Test Step 17 in order to confirm that the repair eliminates the fault.

Test Step 23. Perform a "Service Regeneration"

Note: This test must be performed through the electronic service tool. The electronic service tool enhances the diagnostics during the service test.

1. Start a "service regeneration" by selecting the following menus on the electronic service tool:
   • "Service"

   • "Service Procedures"

   • "Manual DPF Regeneration"

   The electronic service tool will display a "Waiting On Requirements" window. The ECM will automatically elevate the engine speed.

   The duration of the regeneration depends on the soot load in the diesel particulate filter. The ECM will automatically return the engine speed to low idle after the regeneration is complete.

Results:

• The manual DPF regeneration completes successfully. - Return the engine to service.
  STOP

• The manual DPF regeneration does not complete successfully. -

  Repair: Troubleshoot diagnostic codes that became active during the "service regeneration".

  STOP