C7.1 Engines Caterpillar

NOx Conversion Is Low

Usage:

C7.1 881

This procedure covers the following diagnostic codes.

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Table 1
Diagnostic Trouble Codes for NOx Conversion Is Low
J1939 Code	CDL Code	Code Description (code descriptions may vary)	Comments
3516-16	E1365 (2)	Aftertreatment 1 Diesel Exhaust Fluid Concentration : High - moderate severity (2)	The Diesel Emissions Fluid (DEF) has a high concentration.
3516-18	E1364 (2)	Aftertreatment 1 Diesel Exhaust Fluid Concentration : Low - moderate severity (2)	The Diesel Emissions Fluid (DEF) has a low concentration.
4364-2	E1410 (2)	Aftertreatment #1 SCR Catalyst Conversion Efficiency : Erratic, Intermittent, or Incorrect	The Engine Out and Tailpipe Out NOx Sensors are installed in the incorrect locations.
4364-18	E1309 (2)	Aftertreatment #1 SCR Catalyst Conversion Efficiency : Low - moderate severity (2)	The SCR System is not able to reduce NOx in the exhaust system.
Follow the troubleshooting procedure to identify the root cause of the problem.

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Table 2
Required Tools
Tool	Part Number	Part Description	Qty
A	441-0451	Kit - Test	1

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Table 3
Associated Diagnostic Trouble Codes
J1939 Code	CDL Code
412-15	E1092 (1)
412-16	E1092 (2)
4360-17	E947 (1)
4360-18	E947 (2)
4765-17	E2165 (1)
5298-17	E2180 (1)

Complete the procedure in the order in which the steps are listed.

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Table 4
Troubleshooting Test Steps	Values	Results
1. Determine the Code A. Establish communication between the electronic service tool and the Electronic Control Module (ECM). Refer to Troubleshooting, "Electronic Service Tools", if necessary. B. Download the "Warranty Report" from the ECM before troubleshooting or clearing diagnostic trouble codes. C. Determine the diagnostic trouble code that is active.	Diagnostic trouble code	Result: An associated code is active or logged. Note: Troubleshoot associated codes before continuing with this procedure. Refer to Troubleshooting, "Diagnostic Trouble Codes" for further information. Result: A 4364-2 (E1410 (2)) code is active or logged. Proceed to Test Step 2. Result: A 3516-16 (E1365 (2)), 3516-18 (E1364 (2)) or 4364-18 (E1309 (2)) code is active or logged. Proceed to Test Step 3.
2. Check the NOx sensors for proper installation. A. Turn the keyswitch to the OFF position. B. Verify that the sensors are located in the correct position. Note : The "Engine Out NOx" sensor wiring has a black sheath. The "Tailpipe Out NOx" sensor wiring has a gray sheath. C. If the sensors are installed in the wrong positions, install the sensors in the correct positions. Refer to Special Instruction, "REHS8151" for the correct handling procedures. D. Use the electronic service tool to perform the "Aftertreatment System Functional Test".	NOx sensors	Result : The "Aftertreatment System Functional Test" completed successfully. Return the unit to service. Result : The "Aftertreatment System Functional Test" did not complete successfully and other codes were logged. Repair: Troubleshoot the logged codes. Refer to Troubleshooting, "Diagnostic Trouble Codes" for the code that became active during the test.
3. Check the Diesel Exhaust Fluid (DEF) Quality A. Measure the DEF quality. Refer to Systems Operation, Testing and Adjusting, Diesel Exhaust Fluid Quality - Test for the correct procedure.	DEF	Result : The DEF is not contaminated and the concentration is not within the acceptable range. Repair: Drain the DEF from the tank. Refill the tank with DEF that meets ISO 22241 quality standards. Proceed to Test Step 13. Result : The DEF is not contaminated and the concentration is within the acceptable range. Proceed to Test Step 4. Result : The DEF is contaminated. Contact the Dealer Solutions Network (DSN) for further information.
4. Determine the DEF Quality Sensor Installation Status A. Use the electronic service tool to check the status of Configuration Parameter "Aftertreatment #1 DEF Quality Sensor Installation Status".	Parameter status	Result : Configuration Parameter "Aftertreatment #1 DEF Quality Sensor Installation Status" is set to "Installed". Proceed to Test Step 5. Result : Configuration Parameter "Aftertreatment #1 DEF Quality Sensor Installation Status" is set to "Not Installed" or the parameter is not listed. Proceed to Test Step 6.
5. Determine the Diagnostic Code A. Use the electronic service tool to check active or logged diagnostic codes.	Diagnostic codes	Result : A or 3516-16 (E1365 (2)) or 3516-18 (E1364 (2)) code is active or logged. Repair: Replace the DEF tank header assembly. Refer to Disassembly and Assembly, Manifold (DEF Heater) - Remove and Install for the correct procedure. Proceed to Test Step 13. Result : A 4364-18 (E1309 (2)) code is active or logged. Proceed to Test Step 6.
6. Check the Turbocharger Actuator Rod Note: There have been isolated instances where the turbocharger wastegate actuator rod has become detached, causing low CEM inlet temperature. This situation can prevent the correct operation of the SCR filter. A. Check that the turbocharger wastegate actuator rod is securely attached to the wastegate. B. Check the operation of the wastegate actuator. Refer to Systems Operation, Testing and Adjusting, Turbocharger - Inspect.	Turbocharger wastegate actuator rod	Result : The turbocharger wastegate actuator rod is securely attached to the wastegate. The retaining clip is securely installed. The wastegate actuator is operating to specification. Proceed to Test Step 7. Result : The turbocharger wastegate actuator rod is detached from the wastegate. The retaining clip is missing. Contact the Dealer Solutions Network (DSN) for further information. Result: The wastegate actuator is not operating to specification. Repair: Install a replacement turbocharger. Refer to Disassembly and Assembly, Turbocharger - Remove and Disassembly and Assembly, Turbocharger - Install. Proceed to Test Step 13.
7. Inspect All the DEF Lines for Leaks A. Use the electronic service tool to perform the "Aftertreatment System Functional Test". Note: This test clears any diagnostic codes. B. Cycle the keyswitch to the ON position. Do not start the engine. C. Use the electronic service tool to perform the "DEF Dosing System Verification Test" to pressurize the system. Refer to Troubleshooting, "Service Tool Features" for more information. D. Visually inspect all DEF lines from the DEF tank to the DEF injector. Look for pinched, damaged, or disconnected lines. E. Inspect the lines for leakage. F. Turn the keyswitch to the OFF position.	Leaks	Result: The lines are leaking, damaged, pinched, or disconnected. Repair: Make the necessary repairs. Proceed to Test Step 13. Result: The lines are not leaking, damaged, pinched, or disconnected. Proceed to Test Step 8.
8. Perform a DEF Dosing System Accuracy Test A. Perform the "DEF Dosing System Accuracy Test". Refer to Testing and Adjusting, "Aftertreatment SCR System Dosing Test" for the correct procedure.	DEF dosing system accuracy test	Result: The amount of DEF collected is within specification. Install the DEF injector. Refer to Disassembly and Assembly, "DEF Injector and Mounting - Remove and Install". Proceed to Test Step 12. Result: The amount of DEF collected is below specification. Proceed to Test Step 9. Result: The amount of DEF collected is above specification. Repair: Install a replacement DEF injector. Refer to Disassembly and Assembly, "DEF Injector and Mounting - Remove and Install". Proceed to Test Step 13.
9. Check the DEF Pressure Line A. Turn the keyswitch to the OFF position for 2 minutes. Note: The keyswitch must be OFF for 2 minutes to allow the DEF pump to purge, reset the code, and reset the DEF Control Unit (DCU). B. Remove the DEF pressure line between the DEF pump and the DEF injector. Refer to Disassembly and Assembly, Diesel Exhaust Fluid Lines - Remove and Install. C. Inspect the line for obstructions. Flush the line with water or low-pressure air, if necessary. Possible obstructions are ice, DEF deposits, or debris.	Restrictions, obstructions, or leaks	Result: There are restrictions in the lines. Repair: Replace the line. Proceed to Test Step 11. Result: There are no restrictions in the lines. Proceed to Test Step 10.
10. Replace the DEF injector A. Turn the keyswitch to the OFF position. B. Remove the DEF injector. Refer to the Disassembly and Assembly, DEF Injector and Mounting - Remove and Install. C. Connect the replacement DEF injector to the DEF pressure line and the electrical connector. Note : Do not install the injector until Step 11 has been completed.	DEF Injector	Result: The DEF injector was replaced. The DEF injector was connected to the DEF pressure line and the electrical connector, but the injector was not installed. Proceed to Test Step 11.
11. Perform a DEF Dosing System Accuracy Test A. Perform the "DEF Dosing System Accuracy Test". Refer to Testing and Adjusting, "Aftertreatment SCR System Dosing Test" for the correct procedure.	DEF dosing system accuracy test	Result: The amount of DEF collected is within specification. Install the DEF injector. Refer to Disassembly and Assembly, "DEF Injector and Mounting - Remove and Install". Proceed to Test Step 13. Result: The amount of DEF collected is below specification. Install the DEF injector. Refer to Disassembly and Assembly, "DEF Injector and Mounting - Remove and Install". Install a replacement DEF pump. Refer to Disassembly and Assembly, "Diesel Exhaust Fluid Pump - Remove and Install". Proceed to Test Step 13.
12. Check for High Sulfur Fuel A. Ensure that the correct specification of fuel is being used. Refer to the Operation and Maintenance Manual for the correct specification. Note: If fuel with a high sulfur content is used, this fault will reoccur and a replacement CEM may be required.	Fuel quality	Result: High sulfur fuel is in use. Repair: Refer to Special Instruction, M0077352, Soot Antennae Check for C7.1 Engines to check for damage to the aftertreatment system. Drain the fuel tank, flush the fuel lines, and replace the fuel filters. Refill the fuel system with fuel of the correct specification. Proceed to Test Step 13. Result: High Sulfur fuel is not in use. Proceed to Test Step 13.
13. Perform the Aftertreatment Recovery Procedure A. Connect to the electronic service tool. B. Perform the "Aftertreatment Recovery Procedure".	Aftertreatment Recovery Procedure	Result: The Aftertreatment Recovery Procedure completed successfully. Proceed to Test Step 14. Result: The Aftertreatment Recovery Procedure was not successful. Contact the Dealer Solutions Network (DSN).
14. Perform an Aftertreatment System Functional Test A. Start the engine. B. Connect to the electronic service tool. C. Use the electronic service tool to perform the "Aftertreatment System Functional Test".	Aftertreatment System Functional Test	Result: The test completed successfully. Return the unit to service. Result: A 4364-18 (E1309 (2)) with no ETI code is active. Proceed to Test Step 15. Result: A 4364-18 (E1309 (2)) with an ETI code of 1 is active. Proceed to Test Step 16.
15. Replace both NOx sensors A. Turn the keyswitch to the OFF position. B. Allow time for the exhaust system to cool down. C. Replace both NOx sensors. Refer to Special Instruction, REHS8151 for the correct handling procedures. D. Use the electronic service tool to perform the "Aftertreatment System Functional Test".	NOx Sensors	Result : The test completed successfully. Return the unit to service. Result : The test did not complete successfully. Contact the Dealer Solutions Network (DSN).
16. Check the Coolant Level A. Check the coolant level in the engine cooling system. Refer to the Operation and Maintenance Manual, Coolant Level - Check.	Coolant level	Result : The coolant level is low and a leak is identified. Repair: Repair the coolant leak and fill the coolant system to the correct level. Result : The coolant level is low and no leaks are identified. Repair: Fill the coolant system to the correct level. Result : The coolant level is correct. Proceed to Test Step 17.
17. Inspect the NRS Cooler A. Perform a leak test on the NRS cooler. Refer to Systems Operation, Testing and Adjusting, Exhaust Cooler (NRS) - Test.	NRS cooler	Result : An internal leak is identified in the NRS cooler. Repair:Install a replacement NRS cooler. Refer to Disassembly and Assembly, Exhaust Cooler (NRS) - Remove and Install. Use the electronic service tool to perform the "Aftertreatment System Functional Test". If the "Aftertreatment System Functional Test" is passed, return the unit to service. If the "Aftertreatment System Functional Test" fails, contact the Dealer Solutions Network (DSN). Result : The NRS cooler does not have any internal leaks and the fault is still present. Contact the Dealer Solutions Network (DSN).

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