System Operation Description:
Use this procedure to troubleshoot any suspect problems with the following sensors:
- Engine oil pressure sensor
- Injection actuation pressure sensor
- Turbocharger outlet pressure sensor
- Atmospheric pressure sensor
- Right turbocharger inlet pressure sensor
This procedure covers the following open circuit diagnostic codes and short circuit diagnostic codes:
- 100-03 Engine Oil Pressure open/short to +batt
- 100-04 Engine Oil Pressure short to ground
- 164-03 Injector Actuation Pressure open/short to +batt
- 164-04 Injector Actuation Pressure short to ground
- 273-03 Turbo Outlet Pressure open/short to +batt
- 273-04 Turbo Outlet Pressure short to ground
- 274-03 Atmospheric Pressure open/short to +batt
- 274-04 Atmospheric Pressure short to ground
- 275-03 Right Turbo Inlet Pressure open/short to +batt
- 275-04 Right Turbo Inlet Pressure short to ground
The troubleshooting procedures for the diagnostic codes of each pressure sensor are identical. The Electronic Control Module (ECM) supplies 5 ± 0.2 VDC to terminal A of each sensor. The sensor common connection is connected to terminal B of each sensor. The signal voltage from terminal C of each sensor is sent to the appropriate terminal on the ECM.
Pull-up Voltage
The ECM continuously outputs a pull-up voltage on the circuit for the sensor signal wire. The ECM uses this pull-up voltage in order to detect an open in the signal circuit. When the ECM detects the presence of a voltage that is above a threshold on the signal circuit, the ECM will generate an open circuit diagnostic code (03) for the sensor.
If the sensor is disconnected at the sensor connector, the presence of pull-up voltage at the sensor connector indicates that the wires from the sensor connector to the ECM are not open or shorted to ground. If the sensor is disconnected at the sensor connector, the absence of pull-up voltage at the sensor connector indicates an open in the signal wire or a short to ground. If the sensor is disconnected at the sensor connector and the voltage at the sensor connector is different from pull-up voltage, the signal wire is shorted to another wire in the harness.
The ECM performs an automatic calibration of these sensors whenever the ECM is powered and the engine is off for at least five seconds. During an automatic calibration, the ECM calibrates pressure sensors against the atmospheric pressure sensor and an acceptable offset pressure range.
Note: Refer to Troubleshooting, "5 Volt Engine Pressure Sensor Supply Circuit - Test" if the ECM has detected a problem with the analog sensor supply voltage.
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Illustration 1 | g01087948 |
Schematic for ECM with serial number suffix IF |
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Illustration 2 | g01087832 |
Schematic for ECM with serial number suffix KD, KH, or IE |
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Illustration 3 | g01095114 |
Sensor locations (1) Injection actuation pressure sensor (2) Turbocharger outlet pressure sensor (3) Oil pressure sensor (4) Atmospheric pressure sensor (5) Turbocharger inlet pressure sensor |
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Illustration 4 | g01087857 |
P1 ECM connector (P1-2) +5 V Analog sensor power (P1-3) Analog sensor common (P1-15) Turbocharger inlet pressure sensor (ECM suffix IF) (P1-17) Turbocharger inlet pressure sensor (ECM suffix KD, KH, IE) |
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Illustration 5 | g01087858 |
P2 ECM connector (P2-2) +5 V Analog sensor power (P2-3) Analog sensor common (P2-14) Atmospheric pressure sensor (P2-24) Oil pressure sensor (P2-27) Injection actuation pressure sensor (P2-40) Turbocharger outlet pressure sensor (P2-41) +5 V Oil pressure sensor (P2-42) common |
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Illustration 6 | g01094844 |
Terminals for pressure sensors |
Test Step 1. Inspect Electrical Connectors and Wiring
- Turn the keyswitch to the OFF position.
- Thoroughly inspect the J1/P1 ECM connector and the J2/P2 ECM connector. Thoroughly inspect the connectors for each analog sensor.
Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
- Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector and the sensor connectors that are associated with the active diagnostic code.
- Check the ECM connector (allen head screw) for the proper torque of 6.0 N·m (55 lb in).
- Check the J61/P61 customer connector (allen head screw) for the proper torque of 2.25 ± 0.25 N·m (20 ± 2 lb in).
- Check the harness and wiring for abrasions and for pinch points from the sensors back to the ECM.
Expected Result:
All connectors, pins, and sockets are completely coupled and/or inserted. The harness and wiring are free of corrosion, of abrasion, and of pinch points.
Results:
- OK - The harness and wiring are OK. Proceed to Test Step 5.
- Not OK - There is a problem in the connectors and/or wiring.
Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.Verify that the repair eliminates the problem.
STOP
Test Step 2. Check the Supply Voltage at the Sensor Connector
- Turn the keyswitch to the OFF position.
- Disconnect all of the following analog sensors at the sensor connector:
- Engine oil pressure sensor
- Injection actuation pressure sensor
- Turbocharger outlet pressure sensor
- Atmospheric pressure sensor
- Right turbocharger inlet pressure sensor
- Engine oil pressure sensor
- Turn the keyswitch to the ON position.
- Measure the voltage between terminal A (5 V analog supply) and terminal B (sensor return) at the sensor connectors.
- Turn the keyswitch to the OFF position.
- Reconnect all sensors.
Expected Result:
The voltage is 5.0 ± 0.2 VDC.
Results:
- OK - The voltage is 5.0 ± 0.2 VDC. The voltage is correct. Proceed to Test Step 3.
- Not OK - The voltage is not 5.0 ± 0.2 VDC. The voltage is incorrect.
Repair: Perform the diagnostic functional test Troubleshooting, "5 Volt Engine Pressure Sensor Supply Circuit - Test".
STOP
Test Step 3. Check for Active Diagnostic Codes
- Connect the electronic service tool to the service tool connector.
- Turn the keyswitch to the ON position.
- Monitor the active diagnostic code screen on the electronic service tool. Check and record any active diagnostic codes.
Note: Wait at least 15 seconds in order for the diagnostic codes to become active.
- Determine if the problem is related to an open circuit diagnostic code 03 or a short circuit diagnostic code 04.
Expected Result:
No diagnostic codes are active.
Results:
- OK - No diagnostic codes are active.
Repair: The problem may have been related to a faulty connection in the harness. Carefully reinspect the connectors and wiring. Refer to Troubleshooting, "Electrical Connectors - Inspect".
STOP
- Not OK - A short circuit diagnostic code (04) is active at this time. Proceed to Test Step 4.
- Not OK - An open circuit diagnostic code (03) is active at this time. Proceed to Test Step 5.
Test Step 4. Disconnect the Suspect Sensor in Order to Create an Open Circuit
- Turn the keyswitch to the OFF position.
- Disconnect the sensor connector of the sensor with the short circuit diagnostic code (04).
- Turn the keyswitch to the ON position. Wait at least 15 seconds for activation of the diagnostic codes.
- Access the "Active Diagnostic Code" screen on the electronic service tool. Check for an active open circuit diagnostic code (03).
- Turn the keyswitch to the OFF position.
Expected Result:
An open circuit diagnostic code 03 is now active for the disconnected sensor.
Results:
- OK - A short circuit diagnostic code (04) was active before disconnecting the sensor. An open circuit diagnostic code (03) became active after disconnecting the sensor.
Repair: Temporarily connect a new sensor to the harness, but do not install the new sensor in the engine. Verify that there are no active diagnostic codes for the sensor. If there are no active diagnostic codes for the sensor, permanently install the new sensor. Clear any logged diagnostic codes.
STOP
- Not OK - There is a short circuit between the sensor harness connector and the ECM. Leave the sensor disconnected. Proceed to Test Step 8.
Test Step 5. Check the Pull-up Voltage at the Sensor Connector
- Turn the keyswitch to the ON position.
- Disconnect the suspect sensor.
- Measure the voltage between terminal C (signal) and terminal B (sensor return) at the sensor connector.
- Turn the keyswitch to the OFF position.
Expected Result:
The voltage is 11 ± 2 VDC.
Results:
- OK - The voltage is 11 ± 2 VDC. The signal wire to the ECM from the sensor connector is okay.
Repair: The open circuit is in the sensor or the wire between the sensor and the sensor connector. Replace the sensor. Do not install the sensor in the engine. Verify that no diagnostic codes are active for the suspect sensor before permanently installing the sensor.
STOP
- Not OK - The voltage is not 11 ± 2 VDC. The voltage is incorrect. Proceed to Test Step 6.
Test Step 6. Check the Signal Wire for a Short Circuit
- Turn the keyswitch to the OFF position.
- Disconnect ECM connectors P1 and P2.
- Disconnect the connector for the sensor.
- Measure the resistance between the terminal for the sensor signal wire at the ECM and every terminal on ECM connector P1 and ECM connector P2.
- Turn the keyswitch to the OFF position.
- Reconnect ECM connector P1 and ECM connector P2.
Expected Result:
The resistance is greater than 20,000 Ohms.
Results:
- OK - The resistance is greater than 20,000 Ohms. Proceed to Test Step 7.
- Not OK - The resistance is less than 20,000 Ohms.
Repair: The resistance measurement indicates a low resistance between two or more wires. Repair the connectors or wiring and/or replace the connectors or wiring.
STOP
Test Step 7. Create a Short at the Suspect Sensor Connector
- Turn the keyswitch to the OFF position.
- Install a jumper wire with Deutsch sockets on each end between terminal B and terminal C on the connector for the suspect sensor. Connect the jumper on the harness side of the connector.
- Turn the keyswitch to the ON position.
- Wait at least 15 seconds for activation of the short circuit diagnostic code 04.
Note: Monitor the "Active Diagnostic Codes" screen on the electronic service tool before installing the jumper wire and after installing the jumper wire.
- Remove the jumper wire.
- Turn the keyswitch to the OFF position.
Expected Result:
A short circuit diagnostic code 04 is active when the jumper wire is installed. An open circuit diagnostic code 03 is active when the jumper wire is removed.
Results:
- OK - The engine harness and the ECM are okay.
Repair: Temporarily connect a new sensor to the harness, but do not install the new sensor in the engine. Verify that there are no active diagnostic codes for the sensor. If there are no active diagnostic codes for the sensor, permanently install the new sensor. Clear any logged diagnostic codes.
STOP
- Not OK - The open circuit diagnostic code 03 remains active with the jumper in place. The open circuit is between the ECM and the sensor connector. Proceed to Test Step 8.
Test Step 8. Check the Operation of the ECM
- Turn the keyswitch to the OFF position.
- Check the operation of the ECM by creating an open at the ECM.
- Remove the signal wire for the suspect sensor from either the J1/P1 or the J2/P2 ECM connector.
- Remove the sensor return for the suspect sensor from either the J1/P1 or the J2/P2 ECM connector.
Note: Disconnecting the sensor return from the ECM will generate an open circuit diagnostic code for all sensors that are connected to the sensor return. Troubleshoot the original diagnostic code. Delete the logged diagnostic codes when you are finished.
- Turn the keyswitch to the ON position. Monitor the "Active Diagnostic Code" screen on the electronic service tool. Wait at least 15 seconds for activation of the code.
An open circuit diagnostic code (03) should be active for the suspect sensor.
- Check the operation of the ECM by creating a short at the ECM.
- Install a wire jumper between the two terminals for the sensor signal and the sensor return.
- Monitor the "Active Diagnostic Code" screen on the electronic service tool. Wait at least 15 seconds for activation of the code.
A short circuit diagnostic code (04) should be active when the wire jumper is installed.
- Remove the wire jumper and reconnect all wires.
Expected Result:
An open circuit diagnostic code 03 is active when the sensor signal wire is removed from the ECM connector. A short circuit diagnostic code 04 is active when the signal wire is connected to the sensor return.
Results:
- OK - The ECM is operating properly. The problem is in the wiring between the ECM and the sensor connector.
Repair: If the code is active for more than one sensor, the problem is most likely in the return wire for the sensor. Repair the return wire for the sensor or replace the harness.If the code is only active for one sensor, the problem is most likely in the signal wire for the sensor. Repair the signal wire for the sensor.
STOP
- Not OK - One of the following conditions exists: The open circuit diagnostic code 03 is not active when the sensor signal wire is disconnected. The short circuit diagnostic code 04 is not active when the wire jumper is installed.
Repair: Replace the ECM. Refer to Troubleshooting, "Replacing the ECM". Verify that the problem is resolved.
STOP