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TIER II COMPLIANT
1. Fuel pressure sensor 2. Coolant temperature sensor 3. Engine oil pressure and temperature sensor 4. Crankshaft sensor 5. Electro-injector 6. Air pressure temperature sensor 7. Camshaft sensor 8. Fuel heater and fuel temperature sensor 9. Pressure regulator 10. EDC 7 control unit
Crankshaft Sensor Engine Harness Connector Face/Latch Up 1 2 3 1. Yellow boot, ground 2. Red boot, positive
Camshaft Sensor
Other observations: EST defaults to 710 bar at OL, pump solenoid energizes
when reconnecting the rail pressure, monitoring of pressure relief code on EST, OL error at key ON.
Coolant and Fuel Temperature Sensor Check Perform test on both sensors
1. Attach interface harness to sensor and to engine harness. 2. Sensor Function Check: Connect voltmeter to red and black clips. Readings should be Coolant 1.5 volts 0.2 at 65 degrees C. Fuel 2.5 volts 0.2 at 41 degrees C. 3. Reference Voltage Check: Connect the + voltmeter lead to the red clip and the voltmeter lead to ground. Voltage reading should be 4.75 volts. If not, go to step 5. 4. Sensor Resistance Check: Disconnect engine harness and connect ohmmeter lead to black and red clip. Sensor readings should be 0.55K ohms at 65C, and 1.1K at 41 degrees C. If not, replace the sensor. 5. If any readings are open, carefully remove the connector from the processor, install the Pin Sizing tool (380002416) in the appropriate processor terminal, install the Male Spade pigtail (380002415) in the appropriate sensor terminal,
and connect the ohmmeter lead to each end of the suspected wire and check for continuity. 6. The reading should be less than 5 ohms. If the reading is more than 5 ohms, check for a light drag on the Pin Sizing tool, moving the tool in and out of the terminal. If the Pin Sizing tool is loose in the terminal, the wiring harness must be replaced. If the circuit is OK, using the wiring diagram, check voltage and ground supply at the processor. If OK, processor replacement may be necessary. 7. If drag is felt on the Pin Sizing tool check for a damaged wire or terminal in the sensor connector. Repair as necessary Other observations: Both Ols default to 60 degrees C on the EST. OL errors at key ON.
Pressure 3. Red boot, voltage reference 4. Yellow boot, signal Oil Pressure Note: If diagnostic tests have indicated an oil pressure problem, perform a mechanical oil pressure test before proceeding with the electrical diagnosis. 1. Sensor Output Test: Attach interface harness to sensor and to engine harness and start the engine. Connect the + voltmeter lead to the yellow clip and the lead to the black clip. Yellow to black .82 volts at 1 bar, 3.5 volts at 4.65 bar (idle), 4.7 volts at 6 bar. (high idle) 2. Reference Voltage Check: Connect the + voltmeter lead to the red clip and the lead to the black clip, reading should be 5.0 volts. If the voltage reading is 0 volts check the voltage from the red clip to ground, it should be 5 volts. 3. If any readings are open, carefully remove the connector from the processor, install the Pin Sizing tool (380002416) in the appropriate processor terminal, install the Male Spade pigtail (380002415) in the appropriate sensor terminal, and connect the ohmmeter lead to each end of the suspected wire and check for continuity. 4. The reading should be less than 5 ohms. 5. If the reading is more than 5 ohms, check for a light drag on the Pin Sizing tool, moving the tool in and out of the terminal. If the Pin Sizing tool is loose in the terminal, the wiring harness must be replaced. If the circuit is OK, check voltage supply and ground at the processor. If voltage is OK, processor replacement may be necessary. 6. If drag is felt on the Pin Sizing tool check for a damaged wire or terminal in the sensor connector. Repair as necessary. 6
Oil Temperature 1. Attach interface harness to sensor and to engine harness, Key ON 2. Sensor Output Test: Connect voltmeter to green and black clips, Reading should be 3.18 volts 0.2 volts at 20 degrees C or 1.8 volts 0.2 at 63 degrees C. 3. Reference Voltage Test: connect the + voltmeter lead to the red clip and the voltmeter lead to the black clip. Voltage reading should be 4.75 volts. If not, connect the voltmeter to ground, voltage should be 4.75 volts If voltage is not present, go to step 5. 4. Sensor Resistance Test: Disconnect engine harness and connect ohmmeter leads to the black and red clips. Readings should be 5.9 K at 63 degrees C and 2.5 K at 20 degrees C. 5. If any readings are open, carefully remove the connector from the processor, install the Pin Sizing tool (380002416) in the appropriate processor terminal, install the Male Spade pigtail (380002415) in the appropriate sensor terminal, and connect the ohmmeter lead to each end of the suspected wire and check for continuity.
Engine Harness Connector Face/Latch up 1 Temperature 1. Green boot, signal 2. Black boot, ground AIR TEMPERATURE 1. Attach interface harness (380002414) to sensor and to engine harness. Turn the key switch ON. 2. Sensor Output Test: Connect voltmeter to green and black clips. Reading should be 1 volt at 49 degrees C, or 3.22 volts at 20 degrees C. 0.2volts. 3. Reference Voltage Test: Connect the + voltmeter lead to the red clip and the voltmeter lead to the black clip. Voltage reading should be 5.00 volts 0.2 v. If not, connect the voltmeter lead to ground. If voltage is not 5 volts, go to step 5. 4. Sensor Resistance Test: Disconnect engine harness and connect ohmmeter leads to black and green clips. Reading should be 2.5K ohms at 20 degrees C or 3.6 K at 50 degrees C. If not, replace the sensor. 5. If any readings are open, carefully remove the connector from the processor, install the Pin Sizing tool (380002416) in the appropriate processor terminal, install the Male Spade pigtail (380002415) in the appropriate sensor terminal, and connect the ohmmeter lead to each end of the suspected wire and check for continuity. Repair as necessary. 2 3 4
Pressure 3. Red boot, voltage reference 4. Yellow boot, sensor signal AIR PRESSURE 1. Sensor Output Test: Attach interface harness (380002414) to sensor and to engine harness and start the engine. Connect the + voltmeter lead to the yellow clip and the lead to the black clip. Voltage should be 1.0 volt at idle and 1.7 volts at high idle. 2. Reference Voltage Test: Connect the + lead of the voltmeter to the red clip and the lead to the black clip. The voltage reading should be 5 volts. If not, ground the negative voltmeter lead. If the voltage is 0, go to step 3. 3 If any readings are open, carefully remove the connector from the processor, install the Pin Sizing tool (380002416) in the appropriate processor terminal, install the Male Spade pigtail (380002415) in the appropriate sensor terminal, and connect the ohmmeter lead to each end of the suspected wire and check for continuity. 4. The reading should be less than 5 ohms. 5. If the reading is more than 5 ohms, check for a light drag on the Pin Sizing tool, moving the tool in and out of the terminal. If the Pin Sizing tool is loose in the terminal, the wiring harness must be replaced. If the circuit is OK check voltage supply and ground at the processor. If voltage is OK, processor replacement may be necessary. 6. If drag is felt on the Pin Sizing tool, check for a damaged wire or terminal in the sensor connector. Repair as necessary. 7
1 2
4 3
4 3
1 2 Male Connector
Female Connector Interface boot colors: 1 = Red 2 = Black 3 = Black 4 = Red 1. Attach the Interface harnesses to each of the plugs at the cylinder head spacer plate. (See illustration at bottom of page.) The black connector boots are the ground circuit and the red connector boots are positive. Note: Voltage is not at the injector unless the engine is running. 2. Connect the + lead of the voltmeter to the red clip and the lead to the black clip. 3. Start the engine, when the engine is first started the voltage should be about 30 volts. At normal operating temperature, the voltage at idle is about 29 volts and at WOT, no load, about 31 volts. Each injector should read the same voltage. 4. If the injector readings are not the same, do an ohmmeter check on the injectors. 5. Disconnect the engine harness, do an ohm-
meter test from terminal 1 to 2 and 3 and 4 on each harness. The reading should be .56 ohms. If not replace the injector. 6. A "click test" can be done on each injector with the Solenoid/Injector Pulse Tool (380002417) included in this kit. Connect the tool to a voltage supply (either 12 or 24 volts), Red lead to positive and Black lead to ground. 7. With the engine harness still disconnected, connect the injector tester harness connector to the black and red leads. Push button on Pulse Tool to activate injector. A distinct click should be heard at the injector. This test must be done without the engine running. This test indicates, if the click is heard, that electrically, the injector is O.K.
2 = Black
1. Attach the Interface Harness to the Fuel Solenoid (see A on the illustration below) and to the Engine Harness. 2. Connect the + voltmeter lead to the red clip and the voltmeter lead to the black clip. 3. Start the engine and the voltmeter should read system voltage. If not, attach the voltmeter lead to a good ground and retest. 4. If the voltmeter still reads 0 volts unplug the solenoid and connect the Solenoid/Injector Pulse Tool (380002417) to the solenoid and push button to activate.
5. If the solenoid clicks the problem is most likely in the processor. If the solenoid does not click, replace the solenoid. 6. If any readings are open, carefully remove the connector from the processor, install the Sizing Pin tool in the appropriate processor terminal and connect the ohmmeter lead to each end of the suspected wire and check for continuity. A pigtail with a male spade terminal is supplied allowing access to the sensor side of the harness.
TEMP SENSORS VOLTAGE V-Ref 4.75V Coolant Temp Air Temp Oil Temp Fuel Temp 3.36 3.22V 3.34V 3.34V OHMS 2.5K +/- 75 2.5K +/- 75 2.5K +/- 75 2.5K +/- 75 CONNECTOR C - 18 C - 36 C - 21 C - 29 C - 19 C - 33 C - 17
PRESSURE SENSORS STATIC - KEY ON V-Ref 5.00V Air 3.91V Common Rail Pressure 4.49V
CONNECTOR C - 10 C - 28 C - 12 C - 20 C - 27 C-9 C - 35
Oil Pressure
4.10V
.678V
.278V
MAGNETIC SENSORS @ ENGINE CRANKING SPEED VOLTAGE (1.5V MIN) OHMS Camshaft Sensor 1.76V AC 900 +/- 75 Crankshaft Sensor 1.856V AC 900 +/- 75
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REPAIR PROCEDURES
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TIER II COMPLIANT COMMON RAIL ENGINE DIAGNOSTIC/REPAIR KIT (New Engine Family NEF)
Part No. 380040185 Contents:
3 each 380002408 Fuel Injector Interface Harness 1 each 380002409 Coolant/Fuel Temperature Sensor 1 each 380002410 Fuel High Pressure Solenoid 1 each 380002411 Cam/Crank Sensor 1 each 380002412 Common Rail Pressure Sensor 1 each 380002413 Oil Pressure/ Temperature Sensor 1 each 380002414 Air Pressure/ Temperature 6 each 380002415 Male Spade to Clip Jumper Adapters 1 each 380002416 Pin Size/Probe Adapters 1 each 380002417 Solenoid/Injector Pulse Tool 1 each 380002418 Terminal Release Tool (AMP) 1 each 380002419 Terminal Release Tool (Deutsch) 4 each Connector Cap Removal Clips 1 each Instruction Booklet 1 each Carry/Storage Case (includes drawer assembly, dividers and frame) 1 each 380002427 Connector Pack 1 each 380002428 Pigtail Pack 1 each 380002429 Terminal Tool Pack 1 each 380002490 Crimper Tool Extra Drawer Assembly Order part number 380002424
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