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1 12 18-10

SUBJECT DATE
Fuel Injector Amplifier Diagnostics December, 2010

Additions, Revisions, or Updates

Publication Number / Title Platform Section Title Change

DDC-SVC-MAN-0084 SPN 3659/FMI 14

SPN 3660/FMI 14

SPN 3661/FMI 14 The fuel injector amplifier diagnostics have been modified for these
EPA07 DD
SPN 3662/FMI 14 SPNs.

SPN 3663/FMI 14

SPN 3664/FMI 14

All information subject to change without notice. 3

12-18-10 Copyright © 2011 DETROIT DIESEL CORPORATION
2 SPN 3659/FMI 14 - EPA07

2 SPN 3659/FMI 14 - EPA07

This diagnostic is typically fuel injector cylinder #1 amplifier control valve abnormal operation.
1. Check for multiple codes.
a. If SPN 168/FMI any are present along with any other faults, service SPN 168 first.
b. If SPN 168/FMI any is not present, Go to step 2.
2. Start and warm the engine until the coolant temperature is above 71°C (160°F).
3. Turn the ignition OFF (key OFF, engine OFF).
4. Disconnect the front fuel injector harness 14–pin connector.
5. Inspect the front fuel injector harness 14–pin connector for bent or spread pins, inspect the connector seal for damage
(signs of water or oil intrusion).
a. If water or oil intrusion, bent or spread pins are found, repair as necessary.
b. If connector shows no signs of damage, Go to step 6.

NOTE: Do NOT touch the metal ohm-meter leads with your hands while taking measurements.

NOTE: Ensure J-48671-10 ground strap is connected to the cylinder head.

6. Using the appropriate chart below, measure and record the resistance values between the corresponding pins on the valve
cover side of the front injector harness listed below. Are the resistances within range?
Front Injector Harness 14-Pin Connector Resistance Chart (Valve Cover Side)
Pins 5 and 8 * 0.5 – Pin 8 and ground *
Pins 5 and 2 * >20kΩ
Injector #1 Amplifier 2.0Ω >100kΩ
__________Ω __________Ω __________Ω
Pins 5 and 9 * 0.5 – Pin 9 and ground *
Pins 5 and 3 * >20kΩ
Injector #2 Amplifier 2.0Ω >100kΩ
__________Ω __________Ω __________Ω
Pins 5 and 12 * 0.5 – Pin 12 and ground *
Pins 5 and 4 * >20kΩ
Injector #3 Amplifier 2.0Ω >100kΩ
__________Ω __________Ω __________Ω
* = acceptable resistance

Front Injector Harness 14-Pin Connector Resistance Chart, Using J-48671-10 Injector Breakout Box
Pins 1 and 2 * 0.5 – Pins 2 and 3* >20kΩ Pin 1 and ground *
Injector #1 Amplifier 2.0Ω >100kΩ
__________Ω __________Ω __________Ω
Pins 1 and 2 * 0.5 – Pins 2 and 3 * >20kΩ Pin 1 and ground *
Injector #2 Amplifier 2.0Ω >100kΩ
__________Ω __________Ω __________Ω
Pins 1 and 2 * 0.5 – Pins 2 and 3 * >20kΩ Pin 1 and ground *
Injector #3 Amplifier 2.0Ω >100kΩ
__________Ω __________Ω __________Ω
* = acceptable resistance

a. Yes, Go to step 10.

4 All information subject to change without notice.

Copyright © 2011 DETROIT DIESEL CORPORATION 12-18-10
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b. No, Go to step 7.
7. Remove the rocker cover. Refer to section "Removal of the Rocker Cover"
8. Remove the front injector harness from the engine.Refer to section "Removal of the Two-Piece Fuel Injector Wiring
Harness"

NOTE: Do NOT touch the metal ohm-meter leads with your hands while taking measurements.

9. Using the chart below, measure and record the resistance values between the fuel injector pins listed below. Are the
resistances within range?
Injector Amplifier Resistance Chart (Injector Harness must be removed from engine)
Pins 1 and 2 * Pins 2 and 3 * >20kΩ Pin 1 and ground *
Injector #1 Amplifier 2.0Ω or less >100kΩ
__________Ω __________Ω __________Ω
Pins 1 and 2 * Pins 2 and 3 * >20kΩ Pin 1 and ground *
Injector #2 Amplifier 2.0Ω or less >100kΩ
__________Ω __________Ω __________Ω
Pins 1 and 2 * Pins 2 and 3 * >20kΩ Pin 1 and ground *
Injector #3 Amplifier 2.0Ω or less >100kΩ
__________Ω __________Ω __________Ω
* = acceptable resistance

a. Yes, replace the front injector harness.

b. No, replace the injector with the out-of-range resistance. Refer to section "Removal of the Fuel Injector"
10. Disconnect the Motor Control Module (MCM) 120-pin connector.

NOTE: Do NOT touch the metal ohm-meter leads with your hands while taking measurements.

11. Using the chart below, measure and record the resistance values between the engine side of the front valve cover 14-pin
connector and the MCM 120-pin connector. Are the resistances within range?

All information subject to change without notice. 5

12-18-10 Copyright © 2011 DETROIT DIESEL CORPORATION
2 SPN 3659/FMI 14 - EPA07

Engine Harness Injector Circuit Resistance Table

Front Engine Side Valve Front Engine Side Valve
MCM 120-Pin Harness Acceptable Resistance Acceptable Resistance
Cover 14-pin connector Cover 14 pin connector
Connector 1Ω or less 1KΩ or greater
# #
5 13 __________Ω 5 and ground __________Ω
8 14 __________Ω 8 and ground __________Ω
9 10 __________Ω 9 and ground __________Ω
12 12 __________Ω 12 and ground __________Ω
a. Yes, Go to step 12.
b. No, repair the engine side harness.

NOTE: The use of extension harness J49120 will ease installation of test MCM.

12. Install a test MCM.

13. Reconnect all connections and start engine. Bring to operating temperature 71°C (160°F). Does fault become active?
a. Yes, retain log file of active fault and the measured resistance values recorded in this procedure and contact the
Customer Support Center for further instructions.
b. No, replace the MCM. Refer to section "Removal of the Motor Control Module"

6 All information subject to change without notice.

Copyright © 2011 DETROIT DIESEL CORPORATION 12-18-10
 12 18-10

3 SPN 3660/FMI 14 - EPA07

This diagnostic is typically fuel injector cylinder #2 amplifier control valve abnormal operation.
1. Check for multiple codes.
a. If SPN 168/FMI any are present along with any other faults, service SPN 168 first.
b. If SPN 168/FMI any is not present,Go to step 2.
2. Start and warm the engine until the coolant temperature is above 71°C (160°F).
3. Turn the ignition OFF (key OFF, engine OFF).
4. Disconnect the front fuel injector harness 14–pin connector.
5. Inspect the front fuel injector harness 14–pin connector for bent or spread pins, inspect the connector seal for damage
(signs of water or oil intrusion).
a. If water or oil intrusion, bent or spread pins are found, repair as necessary.
b. If connector shows no signs of damage,Go to step 6.

NOTE: Do NOT touch the metal ohm-meter leads with your hands while taking measurements.

NOTE: Ensure J-48671-10 ground strap is connected to the cylinder head.

6. Using the appropriate chart below, measure and record the resistance values between the corresponding pins on the valve
cover side of the front injector harness listed below. Are the resistances within range?
Front Injector Harness 14-Pin Connector Resistance Chart (Valve Cover Side)
Pins 5 and 8 * Pin 8 and ground *
Pins 5 and 2 * >20kΩ
Injector #1 Amplifier 0.5 – 2.0Ω >100kΩ
__________Ω __________Ω __________Ω
Pins 5 and 9 * Pin 9 and ground *
Pins 5 and 3 * >20kΩ
Injector #2 Amplifier 0.5 – 2.0Ω >100kΩ
__________Ω __________Ω __________Ω
Pins 5 and 12 * Pin 12 and ground *
Pins 5 and 4 * >20kΩ
Injector #3 Amplifier 0.5 – 2.0Ω >100kΩ
__________Ω __________Ω __________Ω
* = acceptable resistance

Front Injector Harness 14-Pin Connector Resistance Chart, Using J-48671-10 Injector Breakout Box
Pins 1 and 2 * Pins 2 and 3* >20kΩ Pin 1 and ground *
Injector #1 Amplifier 0.5 – 2.0Ω >100kΩ
__________Ω __________Ω __________Ω
Pins 1 and 2 * Pins 2 and 3 * >20kΩ Pin 1 and ground *
Injector #2 Amplifier 0.5 – 2.0Ω >100kΩ
__________Ω __________Ω __________Ω
Pins 1 and 2 * Pins 2 and 3 * >20kΩ Pin 1 and ground *
Injector #3 Amplifier 0.5 – 2.0Ω >100kΩ
__________Ω __________Ω __________Ω
* = acceptable resistance

a. Yes, Go to step 10.

All information subject to change without notice. 7

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3 SPN 3660/FMI 14 - EPA07

b. No, Go to step 7.
7. Remove the rocker cover. Refer to section "Removal of the Rocker Cover"
8. Remove the front injector harness from the engine.Refer to section "Removal of the Two-Piece Fuel Injector Wiring
Harness"

NOTE: Do NOT touch the metal ohm-meter leads with your hands while taking measurements.

9. Using the chart below measure and record the resistance values between the fuel injector pins listed below. Are the
resistances within range?
Injector Amplifier Resistance Chart (Injector Harness must be removed from engine)
Pins 1 and 2 * Pins 2 and 3 * >20kΩ Pin 1 and ground *
Injector #1 Amplifier 2.0Ω or less >100kΩ
__________Ω __________Ω __________Ω
Pins 1 and 2 * Pins 2 and 3 * >20kΩ Pin 1 and ground *
Injector #2 Amplifier 2.0Ω or less >100kΩ
__________Ω __________Ω __________Ω
Pins 1 and 2 * Pins 2 and 3 * >20kΩ Pin 1 and ground *
Injector #3 Amplifier 2.0Ω or less >100kΩ
__________Ω __________Ω __________Ω
* = acceptable resistance

a. Yes, replace the front injector harness.

b. No, replace the injector with the out-of-range resistance. Refer to section "Removal of the Fuel Injector"
10. Disconnect the Motor Control Module (MCM) 120-pin connector.

NOTE: Do NOT touch the metal ohm-meter leads with your hands while taking measurements.

11. Using the chart below, measure and record the resistance values between the engine side of the front valve cover 14-pin
connector and the MCM 120-pin connector. Are the resistances within range?

8 All information subject to change without notice.

Copyright © 2011 DETROIT DIESEL CORPORATION 12-18-10
 12 18-10

Engine Harness Injector Circuit Resistance Table

Front Engine Side Valve Front Engine Side Valve
MCM 120-Pin Harness Acceptable Resistance Acceptable Resistance
Cover 14-pin connector Cover 14 pin connector
Connector 1Ω or less 1KΩ or greater
# #
5 13 __________Ω 5 and ground __________Ω
8 14 __________Ω 8 and ground __________Ω
9 10 __________Ω 9 and ground __________Ω
12 12 __________Ω 12 and ground __________Ω
a. Yes, Go to step 12.
b. No, repair the engine side harness.

NOTE: The use of extension harness J49120 will ease installation of test MCM.

12. Install a test MCM.

13. Reconnect all connections and start engine. Bring to operating temperature 71°C (160°F). Does fault become active?
a. Yes, retain log file of active fault and the measured resistance values recorded in this procedure and contact the
Customer Support Center for further instructions.
b. No, replace the MCM. Refer to section "Removal of the Motor Control Module"

All information subject to change without notice. 9

12-18-10 Copyright © 2011 DETROIT DIESEL CORPORATION
4 SPN 3661/FMI 14 - EPA07

4 SPN 3661/FMI 14 - EPA07

This diagnostic is typically fuel injector cylinder #3 amplifier control valve abnormal operation.
1. Check for multiple codes.
a. If SPN 168/FMI any are present along with any other faults, service SPN 168 first.
b. If SPN 168/FMI any is not present, Go to step 2.
2. Start and warm the engine until the coolant temperature is above 71°C (160°F).
3. Turn the ignition OFF (key OFF, engine OFF).
4. Disconnect the front fuel injector harness 14–pin connector.
5. Inspect the front fuel injector harness 14–pin connector for bent or spread pins, inspect the connector seal for damage
(signs of water or oil intrusion).
a. If water or oil intrusion, bent or spread pins are found, repair as necessary.
b. If connector shows no signs of damage, Go to step 6.

NOTE: Do NOT touch the metal ohm-meter leads with your hands while taking measurements.

NOTE: Ensure J-48671-10 ground strap is connected to the cylinder head.

6. Using the appropriate chart below, measure and record the resistance values between the corresponding pins on the valve
cover side of the front injector harness listed below. Are the resistances within range?
Front Injector Harness 14-Pin Connector Resistance Chart (Valve Cover Side)
Pins 5 and 8 *
0.5 – 2.0Ω Pin 8 and ground *
Pins 5 and 2 * >20kΩ
Injector #1 Amplifier >100kΩ
0.5 – 2.0Ω
__________Ω __________Ω __________Ω
Pins 5 and 9 * Pin 9 and ground *
Pins 5 and 3 * >20kΩ
Injector #2 Amplifier 0.5 – 2.0Ω >100kΩ
__________Ω __________Ω __________Ω
Pins 5 and 12 * Pin 12 and ground *
Pins 5 and 4 * >20kΩ
Injector #3 Amplifier 0.5 – 2.0Ω >100kΩ
__________Ω __________Ω __________Ω
* = acceptable resistance

Front Injector Harness 14-Pin Connector Resistance Chart, Using J-48671-10 Injector Breakout Box
Pins 1 and 2 * Pins 2 and 3* >20kΩ Pin 1 and ground *
Injector #1 Amplifier 0.5 – 2.0Ω >100kΩ
__________Ω __________Ω __________Ω
Pins 1 and 2 * Pins 2 and 3 * >20kΩ Pin 1 and ground *
Injector #2 Amplifier 0.5 – 2.0Ω >100kΩ
__________Ω __________Ω __________Ω
Pins 1 and 2 * Pins 2 and 3 * >20kΩ Pin 1 and ground *
Injector #3 Amplifier 0.5 – 2.0Ω >100kΩ
__________Ω __________Ω __________Ω
* = acceptable resistance

a. Yes; Go to step 10.

10 All information subject to change without notice.

Copyright © 2011 DETROIT DIESEL CORPORATION 12-18-10
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b. No; Go to step 7.
7. Remove the rocker cover. Refer to section "Removal of the Rocker Cover"
8. Remove the front injector harness from the engine. Refer to section "Removal of the Two-Piece Fuel Injector Wiring
Harness"

NOTE: Do NOT touch the metal ohm-meter leads with your hands while taking measurements.

9. Using the chart below, measure and record the resistance values between the fuel injector pins listed below. Are the
resistances within range?
Injector Amplifier Resistance Chart (Injector Harness must be removed from engine)
Pins 1 and 2 * Pins 2 and 3 * >20kΩ Pin 1 and ground *
Injector #1 Amplifier 2.0Ω or less >100kΩ
__________Ω __________Ω __________Ω
Pins 1 and 2 * Pins 2 and 3 * >20kΩ Pin 1 and ground *
Injector #2 Amplifier 2.0Ω or less >100kΩ
__________Ω __________Ω __________Ω
Pins 1 and 2 * Pins 2 and 3 * >20kΩ Pin 1 and ground *
Injector #3 Amplifier 2.0Ω or less >100kΩ
__________Ω __________Ω __________Ω
* = acceptable resistance

a. Yes, replace the front injector harness.

b. No, replace the injector with the out-of-range resistance. Refer to section "Removal of the Fuel Injector"
10. Disconnect the Motor Control Module (MCM) 120-pin connector.

NOTE: Do NOT touch the metal ohm-meter leads with your hands while taking measurements.

11. Using the chart below, measure and record the resistance values between the engine side of the front valve cover 14-pin
connector and the MCM 120-pin connector. Are the resistances within range?

All information subject to change without notice. 11

12-18-10 Copyright © 2011 DETROIT DIESEL CORPORATION
4 SPN 3661/FMI 14 - EPA07

Engine Harness Injector Circuit Resistance Table

Front Engine Side Valve Front Engine Side Valve
MCM 120-Pin Harness Acceptable Resistance Acceptable Resistance
Cover 14-pin connector Cover 14 pin connector
Connector 1Ω or less 1KΩ or greater
# #
5 13 __________Ω 5 and ground __________Ω
8 14 __________Ω 8 and ground __________Ω
9 10 __________Ω 9 and ground __________Ω
12 12 __________Ω 12 and ground __________Ω
a. Yes; Go to step 12.
b. No, repair the engine side harness.

NOTE: The use of extension harness J49120 will ease installation of test MCM.

12. Install a test MCM.

13. Reconnect all connections and start engine. Bring to operating temperature 71°C (160°F). Does fault become active?
a. Yes, retain log file of active fault and the measured resistance values recorded in this procedure and contact the
Customer Support Center for further instructions.
b. No, replace the MCM. Refer to section "Removal of the Motor Control Module"

12 All information subject to change without notice.

Copyright © 2011 DETROIT DIESEL CORPORATION 12-18-10
 12 18-10

5 SPN 3662/FMI 14 - EPA07

This diagnostic is typically fuel injector cylinder #4 amplifier control valve abnormal operation.
1. Check for multiple codes.
a. If SPN 168/FMI any are present along with any other faults, service SPN 168 first.
b. If SPN 168/FMI any is not present,Go to step 2.
2. Start and warm the engine until the coolant temperature is above 71°C (160°F).
3. Turn the ignition OFF (key OFF, engine OFF).
4. Disconnect the rear fuel injector harness 14–pin connector.
5. Inspect the rear fuel injector harness 14–pin connector for bent or spread pins, inspect the connector seal for damage (signs
of water or oil intrusion).
a. If the water or oil intrusion, bent or spread pins are found, repair as necessary.
b. If connector shows no signs of damage, Go to step 6.

NOTE: Do NOT touch the metal ohm-meter leads with your hands while taking measurements.

NOTE: Ensure J-48671-10 ground strap is connected to the cylinder head.

6. Using the appropriate chart below, measure and record the resistance values between the corresponding pins on the valve
cover side of the rear injector harness listed below. Are the resistances within range?
Rear Injector Harness 14-Pin Connector Resistance Chart (Valve Cover Side)
Pins 5 and 8 * Pin 8 and ground *
Pins 5 and 2 * >20kΩ
Injector #4 Amplifier 0.5 – 2.0Ω >100kΩ
__________Ω __________Ω __________Ω
Pins 5 and 9 * Pin 9 and ground *
Pins 5 and 3 * >20kΩ
Injector #5 Amplifier 0.5 – 2.0Ω >100kΩ
__________Ω __________Ω __________Ω
Pins 5 and 12 * Pin 12 and ground *
Pins 5 and 4 * >20kΩ
Injector #6 Amplifier 0.5 – 2.0Ω >100kΩ
__________Ω __________Ω __________Ω
* = acceptable resistance

Rear Injector Harness 14-Pin Connector Resistance Chart, Using J-48671-10 Injector Breakout Box
Pins 1 and 2 * Pins 2 and 3* >20kΩ Pin 1 and ground *
Injector #4 Amplifier 0.5 – 2.0Ω >100kΩ
__________Ω __________Ω __________Ω
Pins 1 and 2 * Pins 2 and 3 * >20kΩ Pin 1 and ground *
Injector #5 Amplifier 0.5 – 2.0Ω >100kΩ
__________Ω __________Ω __________Ω
Pins 1 and 2 * Pins 2 and 3 * >20kΩ Pin 1 and ground *
Injector #6 Amplifier 0.5 – 2.0Ω >100kΩ
__________Ω __________Ω __________Ω
* = acceptable resistance

a. Yes; Go to step 10.

All information subject to change without notice. 13

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5 SPN 3662/FMI 14 - EPA07

b. No; Go to step 7.
7. Remove the rocker cover. Refer to section "Removal of the Rocker Cover"
8. Remove the rear injector harness from the engine.Refer to section "Removal of the Two-Piece Fuel Injector Wiring
Harness"

NOTE: Do NOT touch the metal ohm-meter leads with your hands while taking measurements.

9. Using the chart below, measure and record the resistance values between the fuel injector pins listed below. Are the
resistances within range?
Injector Amplifier Resistance Chart (Injector Harness must be removed from engine)
Pins 1 and 2 * Pins 2 and 3 * >20kΩ Pin 1 and ground *
Injector #4 Amplifier 2.0Ω or less >100kΩ
__________Ω __________Ω __________Ω
Pins 1 and 2 * Pins 2 and 3 * >20kΩ Pin 1 and ground *
Injector #5 Amplifier 2.0Ω or less >100kΩ
__________Ω __________Ω __________Ω
Pins 1 and 2 * Pins 2 and 3 * >20kΩ Pin 1 and ground *
Injector #6 Amplifier 2.0Ω or less >100kΩ
__________Ω __________Ω __________Ω
* = acceptable resistance

a. Yes, replace the rear injector harness.

b. No, replace the injector with the out-of-range resistance. Refer to section "Removal of the Fuel Injector"
10. Disconnect the Motor Control Module (MCM) 120-pin connector.

NOTE: Do NOT touch the metal ohm-meter leads with your hands while taking measurements.

11. Using the chart below, measure and record the resistance values between the engine side of the rear valve cover 14-pin
connector and the MCM 120-pin connector. Are the resistances within range?

14 All information subject to change without notice.

Copyright © 2011 DETROIT DIESEL CORPORATION 12-18-10
 12 18-10

Engine Harness Injector Circuit Resistance Table

Rear Engine Side Valve Rear Engine Side Valve
MCM 120-Pin Harness Acceptable Resistance Acceptable Resistance
Cover 14-pin connector Cover 14 pin connector
Connector 1Ω or less 1KΩ or greater
# #
5 7 __________Ω 5 and ground __________Ω
8 4 __________Ω 8 and ground __________Ω
9 8 __________Ω 9 and ground __________Ω
12 6 __________Ω 12 and ground __________Ω
a. Yes, Go to step 12.
b. No, repair the engine side harness.

NOTE: The use of extension harness J49120 will ease installation of test MCM.

12. Install a test MCM.

13. Reconnect all connections and start engine. Bring to operating temperature 71°C (160°F). Does fault become active?
a. Yes, retain log file of active fault and the measured resistance values recorded in this procedure and contact the
Customer Support Center for further instructions.
b. No, replace the MCM. Refer to section "Removal of the Motor Control Module"

All information subject to change without notice. 15

12-18-10 Copyright © 2011 DETROIT DIESEL CORPORATION
6 SPN 3663/FMI 14 - EPA07

6 SPN 3663/FMI 14 - EPA07

This diagnostic is typically fuel injector cylinder #5 amplifier control valve abnormal operation.
1. Check for multiple codes.
a. If SPN 168/FMI any are present along with any other faults, service SPN 168 first.
b. If SPN 168/FMI any is not present, Go to step 2.
2. Start and warm the engine until the coolant temperature is above 71°C (160°F).
3. Turn the ignition OFF (key OFF, engine OFF).
4. Disconnect the rear fuel injector harness 14–pin connector.
5. Inspect the rear fuel injector harness 14–pin connector for bent or spread pins, inspect the connector seal for damage (signs
of water or oil intrusion).
a. If the water or oil intrusion, bent or spread pins are found, repair as necessary.
b. If connector shows no signs of damage, Go to step 6.

NOTE: Do NOT touch the metal ohm-meter leads with your hands while taking measurements.

NOTE: Ensure J-48671-10 ground strap is connected to the cylinder head.

6. Using the appropriate chart below, measure and record the resistance values between the corresponding pins on the valve
cover side of the rear injector harness listed below. Are the resistances within range?
Rear Injector Harness 14-Pin Connector Resistance Chart (Valve Cover Side)
Pins 5 and 8 * Pin 8 and ground *
Pins 5 and 2 * >20kΩ
0.5 – 2.0Ω >100kΩ
Injector #4 Amplifier
__________
__________Ω __________Ω
Ω
Pins 5 and 9 * Pin 9 and ground *
Pins 5 and 3 * >20kΩ
0.5 – 2.0Ω >100kΩ
Injector #5 Amplifier
__________
__________Ω __________Ω
Ω
Pins 5 and 12 Pin 12 and ground *
Pins 5 and 4 * >20kΩ
* 0.5 – 2.0Ω >100kΩ
Injector #6 Amplifier
__________
__________Ω __________Ω
Ω
* = acceptable resistance

Rear Injector Harness 14-Pin Connector Resistance Chart, Using J-48671-10 Injector Breakout Box
Pins 1 and 2 * Pins 2 and 3* >20kΩ Pin 1 and ground *
0.5 – 2.0Ω >100kΩ
Injector #4 Amplifier
__________ __________Ω __________Ω
Ω
Pins 1 and 2 * Pins 2 and 3 * >20kΩ Pin 1 and ground *
0.5 – 2.0Ω >100kΩ
Injector #5 Amplifier
__________ __________Ω __________Ω
Ω
Pins 1 and 2 * Pins 2 and 3 * >20kΩ Pin 1 and ground *
0.5 – 2.0Ω >100kΩ
Injector #6 Amplifier
__________ __________Ω __________Ω
Ω
* = acceptable resistance

16 All information subject to change without notice.

Copyright © 2011 DETROIT DIESEL CORPORATION 12-18-10
 12 18-10

a. Yes; Go to step 10.

b. No; Go to step 7.
7. Remove the rocker cover. Refer to section "Removal of the Rocker Cover"
8. Remove the rear injector harness from the engine.Refer to section "Removal of the Two-Piece Fuel Injector Wiring
Harness"

NOTE: Do NOT touch the metal ohm-meter leads with your hands while taking measurements.

9. Using the chart below, measure and record the resistance values between the injector pins listed below. Are the resistances
within range?
Injector Amplifier Resistance Chart (Injector Harness must be removed from engine)
Pins 1 and 2 * Pins 2 and 3 * >20kΩ Pin 1 and ground *
Injector #4 Amplifier 2.0Ω or less >100kΩ
__________Ω __________Ω __________Ω
Pins 1 and 2 * Pins 2 and 3 * >20kΩ Pin 1 and ground *
Injector #5 Amplifier 2.0Ω or less >100kΩ
__________Ω __________Ω __________Ω
Pins 1 and 2 * Pins 2 and 3 * >20kΩ Pin 1 and ground *
Injector #6 Amplifier 2.0Ω or less >100kΩ
__________Ω __________Ω __________Ω
* = acceptable resistance

a. Yes, replace the rear injector harness.

b. No, replace the injector with the out-of-range resistance. Refer to section "Removal of the Fuel Injector"
10. Disconnect the Motor Control Module (MCM) 120-pin connector.

NOTE: Do NOT touch the metal ohm-meter leads with your hands while taking measurements.

11. Using the chart below, measure and record the resistance values between the engine side of the rear valve cover 14-pin
connector and the MCM 120-pin connector. Are the resistances within range?

All information subject to change without notice. 17

12-18-10 Copyright © 2011 DETROIT DIESEL CORPORATION
6 SPN 3663/FMI 14 - EPA07

Engine Harness Injector Circuit Resistance Table

Rear Engine Side Valve Rear Engine Side Valve
MCM 120-Pin Harness Acceptable Resistance Acceptable Resistance
Cover 14-pin connector Cover 14 pin connector
Connector 1Ω or less 1KΩ or greater
# #
5 7 __________Ω 5 and ground __________Ω
8 4 __________Ω 8 and ground __________Ω
9 8 __________Ω 9 and ground __________Ω
12 6 __________Ω 12 and ground __________Ω
a. Yes; Go to step 12.
b. No, repair the engine side harness.

NOTE: The use of extension harness J49120 will ease installation of test MCM.

12. Install a test MCM.

13. Reconnect all connections and start engine. Bring to operating temperature 71°C (160°F). Does fault become active?
a. Yes, retain log file of active fault and the measured resistance values recorded in this procedure and contact the
Customer Support Center for further instructions.
b. No, replace the MCM. Refer to section "Removal of the Motor Control Module"

18 All information subject to change without notice.

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 12 18-10

7 SPN 3664/FMI 14 - EPA07

This diagnostic is typically fuel injector cylinder #6 amplifier control valve abnormal operation.
1. Check for multiple codes.
a. If SPN 168/FMI any are present along with any other faults, service SPN 168 first.
b. If SPN 168/FMI any is not present, Go to step 2.
2. Start and warm the engine until the coolant temperature is above 71°C (160°F).
3. Turn the ignition OFF (key OFF, engine OFF).
4. Disconnect the rear fuel injector harness 14–pin connector.
5. Inspect the rear fuel injector harness 14–pin connector for bent or spread pins, inspect the connector seal for damage (signs
of water or oil intrusion).
a. If the water or oil intrusion, bent or spread pins are found, repair as necessary.
b. If connector shows no signs of damage, Go to step 6.

NOTE: Do NOT touch the metal ohm-meter leads with your hands while taking measurements.

NOTE: Ensure J-48671-10 ground strap is connected to the cylinder head.

6. Using the appropriate chart below, measure and record the resistance values between the corresponding pins on the valve
cover side of the rear injector harness listed below. Are the resistances within range?
Rear Injector Harness 14-Pin Connector Resistance Chart (Valve Cover Side)
Pins 5 and 8 * Pin 8 and ground *
Pins 5 and 2 * >20kΩ
0.5 – 2.0Ω >100kΩ
Injector #4 Amplifier
__________
__________Ω __________Ω
Ω
Pins 5 and 9 * Pin 9 and ground *
Pins 5 and 3 * >20kΩ
0.5 – 2.0Ω >100kΩ
Injector #5 Amplifier
__________
__________Ω __________Ω
Ω
Pins 5 and 12 Pin 12 and ground *
Pins 5 and 4 * >20kΩ
* 0.5 – 2.0Ω >100kΩ
Injector #6 Amplifier
__________
__________Ω __________Ω
Ω
* = acceptable resistance

Rear Injector Harness 14-Pin Connector Resistance Chart, Using J-48671-10 Injector Breakout Box
Pins 1 and 2 * Pins 2 and 3* >20kΩ Pin 1 and ground *
Injector #4 Amplifier 0.5 – 2.0Ω >100kΩ
__________Ω __________Ω __________Ω
Pins 1 and 2 * Pins 2 and 3 * >20kΩ Pin 1 and ground *
Injector #5 Amplifier 0.5 – 2.0Ω >100kΩ
__________Ω __________Ω __________Ω
Pins 1 and 2 * Pins 2 and 3 * >20kΩ Pin 1 and ground *
Injector #6 Amplifier 0.5 – 2.0Ω >100kΩ
__________Ω __________Ω __________Ω
* = acceptable resistance

a. Yes; Go to step 10.

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7 SPN 3664/FMI 14 - EPA07

b. No; Go to step 7.
7. Remove the rocker cover. Refer to section "Removal of the Rocker Cover"
8. Remove the rear injector harness from the engine.Refer to section "Removal of the Two-Piece Fuel Injector Wiring
Harness"

NOTE: Do NOT touch the metal ohm-meter leads with your hands while taking measurements.

9. Using the chart below, measure and record the resistance values between the injector pins listed below. Are the resistances
within range?
Injector Amplifier Resistance Chart (Injector Harness must be removed from engine)
Pins 1 and 2 * Pins 2 and 3 * >20kΩ Pin 1 and ground *
Injector #4 Amplifier 2.0Ω or less >100kΩ
__________Ω __________Ω __________Ω
Pins 1 and 2 * Pins 2 and 3 * >20kΩ Pin 1 and ground *
Injector #5 Amplifier 2.0Ω or less >100kΩ
__________Ω __________Ω __________Ω
Pins 1 and 2 * Pins 2 and 3 * >20kΩ Pin 1 and ground *
Injector #6 Amplifier 2.0Ω or less >100kΩ
__________Ω __________Ω __________Ω
* = acceptable resistance

a. Yes, replace the rear injector harness.

b. No, replace the injector with the out-of-range resistance. Refer to section "Removal of the Fuel Injector"
10. Disconnect the Motor Control Module (MCM) 120-pin connector.

NOTE: Do NOT touch the metal ohm-meter leads with your hands while taking measurements.

11. Using the chart below, measure and record the resistance values between the engine side of the rear valve cover 14-pin
connector and the MCM 120-pin connector. Are the resistances within range?

20 All information subject to change without notice.

Copyright © 2011 DETROIT DIESEL CORPORATION 12-18-10
 12 18-10

Engine Harness Injector Circuit Resistance Table

Rear Engine Side Valve Rear Engine Side Valve
MCM 120-Pin Harness Acceptable Resistance Acceptable Resistance
Cover 14-pin connector Cover 14 pin connector
Connector 1Ω or less 1KΩ or greater
# #
5 7 __________Ω 5 and ground __________Ω
8 4 __________Ω 8 and ground __________Ω
9 8 __________Ω 9 and ground __________Ω
12 6 __________Ω 12 and ground __________Ω
a. Yes; Go to step 12.
b. No, repair the engine side harness.

NOTE: The use of extension harness J49120 will ease installation of test MCM.

12. Install a test MCM.

13. Reconnect all connections and start engine. Bring to operating temperature 71°C (160°F). Does fault become active?
a. Yes, retain log file of active fault and the measured resistance values recorded in this procedure and contact the
Customer Support Center for further instructions.
b. No, replace the MCM. Refer to section "Removal of the Motor Control Module"

All information subject to change without notice. 21

12-18-10 Copyright © 2011 DETROIT DIESEL CORPORATION