Troubleshooting

1204E-E44TA, 1204E-E44TTA  and

1206E-E66TA Industrial Engines

BK1 (Engine)

MK1 (Engine)

ML1 (Engine)

This document is printed from SPI². Not for RESALE

Important Safety Information

Most  accidents    tha t involve  produc  t  op eration,  ma intena nc e and   repair   are  caus  ed  by  failure  to

ob serve  basic   safety   rules  or  precautions  .  An accident    can   often  be  avoided   by  recog nizing  pote ntially

ha za rdous  situations   before   an  accident    oc curs . A person    mus t be  alert   to pote ntial  ha za rds.  This

person   should   also  ha ve  the  ne cessary   training,  skills  and   tools  to perform   the se  func tions properly.

Improper operation, lubrication, maintenance or repair  of this product can be dangerous and

could result in injury  or death.

Do not operate or perform any lubrication, maintenance or repair on this  product, until you have

read and understood the operation, lubrication, maintenance and repair information.

Sa fety precautions     and  warning s  are   provided   in this  ma nua l and   on  the  produc t.  If the se  ha za rd

warning s  are  not  he eded,   bod ily injury  or death   could   oc cur to  you  or to  othe r persons  .

The  ha za rds are   identified   by  the  “Safety  Alert  Symb ol”  and  followed  by  a  “Signa l  Word” suc h  as

“DANGER”, “WARNING”  or “CAUTION”.  The Sa fety  Alert  “WARNING” label  is  shown   below.

The  me aning  of  this safety   alert   symb ol is  as  follows:

Attention! Become Alert! Your Safety is  Involved.

The  me ssage   tha t appears     und er the   warning  explains    the  ha za rd and   can  be   either  written  or

pictorially   presente  d.

Op erations  tha t  ma y caus e  produc  t dama  ge  are  identified   by  “NOTICE” labels   on  the  produc  t and   in

this  pub lication.

Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The

warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,

work method or operating technique that is not specifically recommended by Perkins is used,

you must satisfy yourself that it is safe  for you and for others. You should also ensure that the

product will not be damaged or be  made unsafe by the operation, lubrication, maintenance or

repair procedures that you choose.

The  informa tion, specifications   ,  and  illustrations   in  this  pub lication  are   on the  basis    of informa tion tha t

was  available    at  the  time  tha t the  pub lication   was  written.   The  specifications   , torque  s,  pressure  s,

me asure me nts , adjustme  nts , illustrations ,  and  othe r  items  can  cha  ng e at  any  time.  These  cha ng es  can

affect   the  service   tha t is given   to the  produc  t.  Ob tain the  comp  lete  and  mos t current   informa tion before

you  start any   job. Pe  rkins  dealers   or   Pe rkins  distributors     ha ve  the  mos t current   informa tion  available.

When  replacement  parts  are  required  for  this

product Perkins recommends using Perkins

 replacement  parts.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or

death.

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KENR9116-01

3

Table of  Contents

Table of Contents

Engine Stalls at Low RPM .................................... 94

Engine Top Speed Is Not Obtained ......................  96

Engine Vibration Is Excessive ............................  101

Exhaust Has Excessive Black Smoke ................  102

Exhaust Has Excessive White Smoke ................ 104

Fuel Consumption Is Excessive .......................... 106

Fuel Contains Water ...........................................  108

Fuel Rail Pressure Problem ................................ 109

Fuel Temperature Is High .................................... 117

Inlet Air Is Restricted ............................................ 119

Inlet Air Temperature Is High ..............................  120

Intake Manifold Air Pressure Is High ..................  121

Intake Manifold Air Pressure Is Low ................... 122

Intake Manifold Air Temperature Is High ............. 123

NRS Exhaust Gas Temperature Is High  ............ 124

NRS Mass Flow Rate Problem ........................... 127

Oil Consumption Is Excessive ............................  130

Oil Contains Coolant ........................................... 132

Oil Contains Fuel ................................................  133

Oil Pressure Is Low ............................................. 134

Power Is Intermittently Low  or Power Cutout Is

Troubleshooting Section

Electronic Troubleshooting

Welding Precaution ................................................. 5

System Overview .................................................... 5

Glossary ................................................................ 12

Electronic Service Tools ........................................ 16

Indicator Lamps ....................................................  18

Replacing the ECM ............................................... 21

Self-Diagnostics .................................................... 22

Sensors and Electrical Connectors ....................... 22

Engine Wiring Information ....................................  31

ECM Harness Connector Terminals .....................  36

Programming Parameters

Programming Parameters ..................................... 37

Test ECM Mode ....................................................  37

Factory Passwords ...............................................  37

Flash Programming ..............................................  38

Injector Code - Calibrate ....................................... 39

Mode Switch Setup ............................................... 40

Throttle Setup .......................................................  41

Multiposition Switch Setup .................................... 44

Intermittent ........................................................  136

Valve Lash Is Excessive .....................................  141

Troubleshooting with a Diagnostic Code

Diagnostic Trouble Codes ................................... 142

Diagnostic Code Cross Reference .....................  147

No Diagnostic Codes Detected ........................... 151

Customer Specified Parameters

Customer Specified Parameters ........................... 45

Customer Specified Parameters Table .................  51

Customer Specified Parameters Worksheet ......... 54

Troubleshooting with an Event Code

Event Codes  ......................................................  152

Diagnostic Functional  Tests

System Configuration Parameters

System Configuration Parameters ........................ 58

5 Volt Sensor Supply Circuit - Test .....................  154

Analog Throttle Position Sensor Circuit - Test .... 163

CAN Data Link Circuit - Test ............................... 168

Data Link Circuit - Test ........................................ 172

Diesel Particulate Filter  Identification Signal -

Symptom Troubleshooting

Acceleration Is Poor  or Throttle Response Is

Poor ....................................................................  60

Alternator Is Noisy ................................................  66

Alternator Problem ................................................ 66

Battery Problem ....................................................  66

Coolant Contains Oil ............................................. 67

Coolant Level Is Low ............................................  67

Coolant Temperature Is High ................................ 68

Crankcase Breather Ejects Oil .............................. 71

Crankcase Fumes  Disposal Tube Has  Oil

Draining ............................................................... 72

Cylinder Is Noisy ................................................... 73

Diesel Particulate Filter Collects Excessive Soot .. 74

Diesel Particulate Filter Temperature Is Low ........ 75

ECM Does  Not Communicate with  Other

Modules ..............................................................  76

ECM Will Not Accept Factory Passwords ............. 76

Electronic Service Tool Does Not Communicate .. 77

Engine Cranks but Does Not Start ........................ 78

Engine Does Not Crank ........................................ 84

Engine Has Early Wear ........................................  85

Engine Has Mechanical Noise (Knock) ................  85

Engine Misfires, Runs Rough or Is Unstable ........ 86

Engine Overspeeds ..............................................  91

Engine Shutdown Occurs Intermittently  ............... 92

Engine Speed Does Not Change .......................... 93

Test ...................................................................  179

Digital Throttle Position Sensor Circuit - Test .....  183

ECM Memory - Test ............................................ 192

Electrical Connectors - Inspect ........................... 193

Engine Pressure Sensor Open or Short  Circuit -

Test ...................................................................  197

Engine Speed/Timing Sensor Circuit - Test ........ 204

Engine Temperature Sensor Open or Short Circuit -

Test ...................................................................  212

Engine Temperature Sensor Open or Short Circuit -

Test ...................................................................  217

Ether Starting Aid - Test ...................................... 224

Fuel Pump Relay Circuit - Test ........................... 228

Glow Plug Starting Aid - Test .............................. 236

Idle Validation Switch Circuit - Test ..................... 242

Ignition Keyswitch Circuit and Battery Supply Circuit -

Test ...................................................................  248

Indicator Lamp Circuit - Test ............................... 255

Injector Data Incorrect - Test ............................... 258

Injector Solenoid Circuit - Test ............................ 260

Mode Selection Cir, cuit - Test .............................. 267

Motorized Valve - Test ........................................  271

PTO Switch Circuit - Test .................................... 276

Sensor Calibration Required - Test ..................... 279

Solenoid Valve - Test ..........................................  282

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KENR9116-01

Table of  Contents

Soot Sensor - Test ..............................................  288

Throttle Switch Circuit - Test ............................... 291

Valve Position Sensor - Test ............................... 295

Water In Fuel Sensor - Test ................................ 301

Index Section

Index ...................................................................  306

This document is printed from SPI². Not for RESALE

KENR9116-01

5

Troubleshooting Section

Troubleshooting Section

Electronic Troubleshooting

i04029202

Welding Precaution

Correct welding procedures are necessary in order to

avoid damage to the following components:

•  Electronic Control Module (ECM) on the engine

•  Clean Emissions Module (CEM)

•  Sensors

g01143634

Illustration 1

•  Associated components

Service welding guide (typical diagram)

Components for the driven equipment should also be

considered. When possible, remove the component

that requires welding. When welding on an engine

that is equipped with an ECM and  removal of the

component is not possible, the following procedure

must be followed. This procedure minimizes the risk

to the electronic components.

5.  When possible, connect the ground clamp for

the welding equipment directly  to the engine

component that will be welded. Place the clamp

as close as possible to the weld. Close positioning

reduces the risk of welding current damage to the

engine bearings, to the electrical components,

and to other components.

1.  Stop the engine. Remove the electrical power

from the ECM.

6.  Protect the wiring harnesses from welding debris

and/or from welding spatter.

2.  Ensure that the fuel supply to the engine is turned

off.

7.  Use standard welding procedures to weld the

materials together.

3.  Disconnect the negative battery cable from the

battery. If a battery disconnect switch is installed,

open the switch.

i04155807

System Overview

4.  Disconnect all electronic components from

the wiring harnesses.  Include the following

components:

The engine has an electronic control system. The

system also monitors the Diesel Particulate Filter

(DPF) and the NOx Reduction System (NRS).

•  Electronic components for the driven equipment

•  ECM

The control system  consists of the following

components:

•  Sensors

•  Electronically controlled valves

•  Relays

•  Electronic Control Module (ECM)

•  Software (flash file)

•  Wiring

•  Aftertreatment ID module

NOTICE

•  Sensors

Do not use electrical components (ECM or ECM sen-

sors)  or electronic  component grounding  points  for

grounding the welder.

•  Actuators

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6

KENR9116-01

Troubleshooting Section

The following information  provides a general

description of the control system. Refer to Systems

Operation, Testing, and  Adjusting for detailed

information about the control system.

Electronic Control Circuit Diagram

g02476570

Illustration 2

Electronic control circuit diagram for the  1204E-E44 engine

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KENR9116-01

7

Troubleshooting Section

g02476572

Illustration 3

Electronic control circuit diagram for the  1206E-E66 engine

Block Diagram

Refer to Illustration 4 and  Illustration 5 for block

diagrams of the control system.

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KENR9116-01

Troubleshooting Section

g02477761

Illustration 4

Block diagram for the 1204E and 1206E  engines with a single turbocharger

(1) Air cleaner

(13) Air-to-air aftercooler

(25) Oil pressure sensor

(2) Air inlet temperature sensor

(3) NRS cooler

(14) Wastegate regulator

(15) NRS outlet pressure sensor

(16) Engine

(17) Coolant temperature sensor

(18) Primary speed/timing sensor

(19) Fuel injectors

(26) Barometric pressure sensor

(27) ECM

(28) Electric fuel lift pump

(29) Primary fuel filter

(4) Exhaust back pressure valve

(5) Diesel Oxidation Catalyst (DOC)  and

Diesel Particulate Filter (DPF)

(6) DPF inlet temperature sensor

(7) Soot sensor

(8) Turbocharger

(9) NRS valve

(10) NRS temperature sensor

(11) NRS inlet pressure sensor

(12) NRS mixer

(30) In-line fuel strainer

(31) Intake manifold pressure sensor

(32) Intake manifold air temperature sensor

(33) Transfer pump inlet regulator

(34) Secondary fuel filter

(35) Fuel tank

(20) Return fuel cooler

(21) Return fuel pressure relief valve

(22) Secondary speed/timing sensor

(23) High-pressure fuel  pump/transfer

pump/fuel temperature sensor

(24) Fuel rail pressure sensor

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KENR9116-01

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Troubleshooting Section

g02477778

Illustration 5

Block diagram for the 1204E-E44TTA engine  with twin turbochargers

(1) Air cleaner

(13) Air-to-air aftercooler

(25) Oil pressure sensor

(2) Air inlet temperature sensor

(3) Exhaust back pressure valve

(4) Diesel Oxidation Catalyst (DOC)  and

Diesel Particulate Filter (DPF)

(5) DPF inlet temperature sensor

(6) Soot sensor

(7) NRS cooler

(8) Turbochargers

(9) NRS valve

(14) Wastegate regulator

(15) NRS outlet pressure sensor

(16) Engine

(17) Coolant temperature sensor

(18) Primary speed/timing sensor

(19) Fuel injectors

(26) Barometric pressure sensor

(27) ECM

(28) Electric fuel lift pump

(29) Primary fuel filter

(30) In-line fuel strainer

(31) Intake manifold pressure sensor

(32) Intake manifold air temperature sensor

(33) Transfer pump inlet regulator

(34) Secondary fuel filter

(35) Fuel tank

(20) Return fuel cooler

(21) Return fuel pressure relief valve

(22) Secondary speed/timing sensor

(23) High-pressure fuel  pump/transfer

pump/fuel temperature sensor

(24) Fuel rail pressure sensor

(10) NRS temperature sensor

(11) NRS inlet pressure sensor

(12) NRS mixer

System Operation

Engine Governor

The ECM governs the engine. The ECM determines

the timing, the injection pressure, and the amount

of fuel that is delivered  to each cylinder. These

factors are based on the actual conditions and on the

desired conditions at any given time during starting

and operation.

The governor uses the throttle position sensor  to

determine the desired engine speed. The governor

compares the desired engine speed to the  actual

engine speed. The actual engine speed is determined

through interpretation of the signals that are received

by the ECM from the engine speed/timing sensors. If

the desired engine speed is greater than the actual

engine speed, the governor injects more fuel in order

to increase engine speed.

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KENR9116-01

Troubleshooting Section

Fuel Injection

The ECM sends a high voltage signal to the injector

solenoids in order to energize  the solenoids. By

controlling the timing and the duration of  the high

voltage signal, the ECM can control the  following

aspects of injection:

•  Injection timing

•  Fuel delivery

The flash file inside the ECM  establishes certain

limits on the amount of fuel  that can be injected.

The FRC Fuel Limit is a limit that  is based on the

intake manifold pressure. The FRC Fuel Limit is used

to control the air/fuel ratio for control of emissions.

When the ECM senses a  higher intake manifold

pressure, the ECM increases the FRC Fuel Limit. A

higher intake manifold pressure indicates that there

is more air in the cylinder. When the ECM increases

the FRC Fuel Limit, the ECM allows more fuel into

the cylinder.

g01860934

Illustration 6

Typical example

The Rated Fuel Limit is a limit that is based on the

power rating of the engine and on the engine rpm.

The Rated Fuel Limit is like the rack stops and the

torque spring on a mechanically governed engine.

The Rated Fuel Limit provides  the power curves

and the torque curves for a specific engine  family

and a specific engine rating. All of these limits are

determined at the factory. These limits cannot  be

changed.

The desired engine speed is typically determined by

one of the following conditions:

•  The position of the throttle

•  The desired engine speed in Power Take-Off (PTO)

Timing Considerations

Once the governor has determined the amount of

fuel that is required, the governor must determine

the timing of the fuel injection. Fuel injection timing is

determined by the ECM after considering input from

the following components:

Customer Parameters and Engine Speed

Governing

A unique feature with electronic engines is customer

specified parameters. These parameters allow the

owner of the machine to fine-tune the ECM for engine

operation. Fine-tuning the ECM allows the machine

owner to accommodate the typical  usage of the

machine and the power train of the machine.

•  Coolant temperature sensor

•  Intake manifold air temperature sensor

•  Intake manifold pressure sensor

•  Barometric pressure sensor

Many of the customer parameters provide additional

restrictions on the actions that will be performed by

the ECM in response to input from the operator. The

PTO Top Engine Limit is an engine rpm limit that is

used by the ECM to limit the fuel during operation of

the PTO. The ECM will not fuel the injectors above

this rpm.

The ECM adjusts  timing for optimum engine

performance and fuel economy. Actual timing and

desired timing cannot be viewed with the electronic

service tool. The ECM determines the  location of

top center of the  number one cylinder from the

signals that are provided by the engine speed/timing

sensors. The ECM determines when injection should

occur relative to top center position. The ECM then

provides the signal to the injector at the desired time.

Some parameters are intended to notify the operator

of potential engine damage  (engine monitoring

parameters). Some parameters  enhance fuel

economy (machine speed, engine  speed limit,

and idle shutdown). Other parameters are used to

enhance the engine installation into the machine.

Other parameters are used to  provide operating

information to the owner of the machine.

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KENR9116-01

11

Troubleshooting Section

Other ECM  Functions for

Performance

“Lifetime Total Engine Revolutions”  is the total

number of revolutions that have been completed by

the engine crankshaft.

The ECM can also provide enhanced control of the

engine for machine functions such as controlling the

cooling fan. Refer to Troubleshooting, “Configuration

Parameters” for supplemental information about the

systems that can be monitored by the ECM in order

to provide enhanced machine performance,  fuel

economy, and convenience for the operator.

“Average Load Factor” provides  relative engine

operating information. “Average  Load Factor”

compares actual operating information of the engine

to the maximum engine operation that is available.

“Average Load Factor” is determined by using “Total

Max Fuel”, “Total Idle Fuel”, and “Total Fuel”. All of

these parameters are available with the electronic

service tool. These parameters are available within

the menu for “Current Totals”.

ECM Lifetime Totals

The ECM maintains total data of the engine for the

following parameters:

Programmable Parameters

Certain parameters that affect engine  operation

may be changed with the electronic  service tool.

The parameters are stored in  the ECM, and the

parameters are protected from unauthorized changes

by passwords. These parameters are either system

configuration parameters or customer parameters.

•  “Total Operating Hours”

•  “Engine Lifetime Hours”

•  “Total Idle Time”

•  “Total Idle Fuel”

System configuration parameters are  set at the

factory. System configuration parameters  affect

emissions or power ratings within an engine family.

Factory passwords must be obtained and factory

passwords must be used  to change the system

configuration parameters.

•  “Total Fuel”

•  “Total Max Fuel”

•  “Engine Starts”

Customer parameters are  variable. Customer

parameters affect the following characteristics within

the limits that are set by the factory, by the monitoring

system, and by PTO operation:

•  “Lifetime Total Engine Revolutions”

•  “Average Load Factor”

The “Total Operating Hours” is the operating hours of

the engine. The operating hours do not include the

time when the ECM is powered but the engine is not

running.

•  Rpm ratings

•  Power ratings

Customer passwords may be required to change

customer specified parameters.

The “Engine Lifetime Hours” is the number of hours

when electrical power has  been applied to the

engine. These hours will include the time when the

ECM is powered but the engine is not running.

Some of the parameters may affect engine operation

in an unusual way. An operator might  not expect

this type of  effect. Without adequate training,

these parameters may lead to power  complaints

or performance complaints  even though the

performance of the engine is to the specification.

“Total Idle Time” and “Total Idle Fuel” can  include

operating time when the engine  is not operating

under a load.

Fuel Information can be displayed in US gallons or

in liters.

Refer to Troubleshooting, “Configuration Parameters”

for additional information on this subject.

“Total Fuel” is  the total amount of  fuel that is

consumed by the engine during operation.

Passwords

“Total Max Fuel” is the maximum amount of fuel that

could have been consumed by the engine  during

operation.

System configuration parameters are protected by

factory passwords. Factory passwords are calculated

on a computer system  that is available only to

Perkins Distributors. Since factory passwords contain

alphabetic characters, only the electronic service

tool may change system configuration parameters.

System configuration parameters affect the power

rating family or emissions.

“Engine Starts” is the total number of times when the

engine has been started.

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KENR9116-01

Troubleshooting Section

Customer parameters can  be protected by

customer passwords. The customer passwords are

programmed by the customer. Factory passwords

can be used to  change customer passwords if

customer passwords are lost.

Communication Adapter  Tool  –  The

communication adapter provides a communication

link between the ECM and the electronic service tool.

Coolant Temperature Sensor  – The coolant

temperature sensor detects the  engine coolant

temperature for all normal operating conditions and

for engine monitoring.

Refer to Troubleshooting, “Factory Passwords” for

additional information on this subject.

Data Link  – The data link is a serial communication

port that is used for communication with other devices

such as the electronic service tool.

i04156374

Glossary

Derate  – Certain engine conditions will generate

event codes. Also, engine may be derated. The map

for the engine derate is programmed into the ECM

software. The type of derate can be one or more of

three types: reduction of rated power, reduction of

rated engine speed, and reduction of rated machine

speed for OEM products.

Active Diagnostic Code  – An active diagnostic

code alerts the operator or the service technician that

an electronic system malfunction is currently present.

Refer to the term “Diagnostic Code” in this glossary.

Aftertreatment  – Aftertreatment is a system that is

used to remove pollutants from exhaust gases. The

system consists of a Diesel Oxidation Catalyst (DOC)

and a Catalyzed Diesel Particulate Filter (CDPF).

Desired Engine Speed  – The desired engine speed

is input to the electronic governor within the ECM.

The electronic governor uses the signal  from the

throttle position sensor, the engine speed/timing

sensor, and other sensors in order to determine the

desired engine speed.

Alternating Current (AC)  – Alternating current is an

electric current that reverses direction at a regular

interval that is reoccurring.

Diagnostic Trouble Code  – A diagnostic trouble

code is sometimes referred to as a fault code. These

codes indicate an electronic system malfunction.

Before Top Center (BTC) – BTC is the 180 degrees

of crankshaft rotation before the piston reaches the

top center position in the normal direction of rotation.

Diagnostic Lamp  – The diagnostic lamp is also

called the warning lamp. The diagnostic lamp is used

to warn the operator of the presence  of an active

diagnostic code. The lamp may not be included in

all applications.

Breakout Harness  – A breakout harness is  a

test harness that is designed to  connect into the

engine harness. This connection allows a normal

circuit operation and the connection simultaneously

provides a Breakout T  in order to measure the

signals.

Diesel Oxidation Catalyst   – The Diesel Oxidation

Catalyst is also known as the (DOC). The DOC is a

device in the exhaust system that oxidizes certain

elements in the exhaust gases. These elements can

include carbon monoxide (CO), hydrocarbons and

the soluble organic fractions (SOF) of  particulate

matter.

Bypass Circuit  – A bypass circuit is a circuit that is

used as a substitute circuit for an existing circuit. A

bypass circuit is typically used as a test circuit.

CAN Data Link (see also J1939 CAN Data Link) –

The CAN Data Link  is a serial communications

port that is used  for communication with other

microprocessor-based devices.

Digital Sensor Return  – The common line (ground)

from the ECM is  used as ground for the digital

sensors.

Catalyzed Diesel Particulate Filter – The Catalyzed

Diesel Particulate Filter (CDPF) filters particulates

from the exhaust gases. A coating on the  internal

surfaces reacts with the hot exhaust gases in order

to burn off the particulates. This process prevents the

CDPF from becoming blocked with soot.

Digital Sensors  – Digital sensors produce a pulse

width modulated signal. Digital sensors are supplied

with power from the ECM.

Digital Sensor Supply  – The power supply for the

digital sensors is provided by the ECM.

Clean Emissions Module  – The Clean Emissions

Module (CEM) includes all the components of the

aftertreatment system.

Direct Current (DC)  – Direct current is the type of

current that flows consistently in only one direction.

DT, DT Connector, or Deutsch DT – This design is

a type of connector that is used on this engine. The

connectors are manufactured by Deutsch.

Code  – Refer to “Diagnostic Trouble Code”.

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