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For cyph8r pacific la ca 92101
1996 Mitchell International, All Rights Reserved.
Wednesday, June 02, 2010 10:42AM
ARTICLE BEGINNING
DIESEL EMISSION CONTROLS
Navistar T444E Diesel Engine Electronic Engine Control System
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Fig. 4: Fuel Supply System
Courtesy of Navistar International Corp.
Injection Control System
The T444E uses a hydraulically actuated injector to
pressurize fuel inside the injector. The hydraulic fluid used to
actuate the injector is engine oil. Oil is drawn from the oil pan
through the pickup tube by the oil pump. The oil pump is a gerotor
type, driven by the crankshaft. Oil is fed through passages in the
front cover to an oil reservoir mounted on top of the front cover.
The reservoir makes available a constant supply of oil to a
high pressure hydraulic pump mounted in the engine V. The pump is a
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gear-driven seven plunger swash plate pump. High pressure oil is
delivered by the high pressure pump to oil galleries machined into the
cylinder heads, drilled intersecting passages supply high pressure oil
to the injector.
See Fig. 5.
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IPR Valve
In the engine off state, the IPR spool valve is held closed
(to the right) by the return spring and the drain ports are closed.
See Fig. 7.
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The exhaust back pressure device is a mechanism which applies
a restriction to the flow of exhaust gas exiting the turbocharger. See
Fig. 11. The increased restriction created by the closure of the
butterfly valve increases exhaust back pressure and causes the engine
to work harder to force the exhaust gasses out of the turbocharger.
This results in more heat transferred from the engine to the coolant,
which allows the cab to receive more heat in a shorter time.
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The ECM supplies a 5 volt reference signal to many of the
input sensors in the control system. On most circuits, the ECM
compares the regulated 5 volts sent to the sensors by the modified
returned signal and is able to determine temperature, pressure, speed,
position and many other variables that are important to engine and
vehicle functions. This 5 volt signal is current limited by a current
limiting resistor in the event of an external dead short to ground.
For some sensors like Camshaft Position, the 5 volt signal is a power
source that powers up the circuitry in the sensor.
Signal Conditioner
The signal conditioner conditions the input signals for the
internal microprocessor. This enables the microprocessor to interpret
the signals. Signal conditioning usually consists of converting analog
signals to digital signals, squaring up sine wave signals or
amplifying low intensity signals to a level the ECM microprocessor can
process.
Microprocessor
The ECM contains an internal microprocessor. This processor
stores operating instructions (control strategies) and tables of
values (calibration parameters). It compares these stored instructions
and values to sensed input values to determine the correct operating
strategy for any given engine condition. Calculations in the ECM occur
at two different levels, or speeds, referred to as the foreground and
the background calculations. These calculations are performed on a
continuous closed loop basis.
The foreground calculations occur at a much faster rate than
background calculations. These are normally the more critical
calculations. Diagnostic strategies are also programmed into the ECM.
Some instructions cause inputs or outputs to be monitored on a
continuous basis and will flag a code that will be set. Other
strategies will instruct the ECM to perform certain tests upon
operator demand.
The ECM's microprocessor is equipped with three types of
memory: Random Access Memory (RAM), Read Only Memory (ROM) and Keep
Alive Memory (KAM). They allow the processor to store necessary
instructions, calibration tables and input values to control the
engine.
Read Only Memory (ROM)
Read only memory is the memory where calibration tables and
operating strategies are stored. Information in the ROM is permanent.
It cannot be changed or lost by turning off the engine or
disconnecting the battery.
Random Access Memory (RAM)
Random access memory is a temporary storage memory for
current events such as engine speed, pedal position, etc. It is the
memory where temporary information can be stored so it can be compared
to information in the read only memory. Random access memory is lost
every time the key is turned off or power is interrupted to the ECM.
Keep Alive Memory (KAM)
Keep alive memory is permanent memory. It is used to store
diagnostic fault codes. Adaptive strategies (temporary operating
instructions) can also be written to it in the event of a system
failure or as a compensation for component wear. Uninterrupted power
must be supplied from the battery to the ECM on a continuous basis to
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keep the memory alive. All information in the memory is lost if the
ECM has a total power loss, such as when the batteries are
disconnected.
Actuator Control
The ECM controls the actuators by applying a low level signal
to the base of the transistor output drivers. These drivers, when
switched on, will complete the ground circuit of each actuator. The
actuators are controlled either through a duty cycle (percent of time
on and off), or controlled through a controlled pulse width, or simply
just switched on or off as determined by the type of actuator being
controlled.
Injection Driver Module Functions
The injection driver module is a device that controls four
major functions: Electronic Distributor For Injectors, Power Source
For Injectors, Output Driver For Injectors and Diagnostic For Itself
and Injectors.
Electronic Distributor For Injectors
The ECM senses the piston position of cylinder No. 1 from the
output signal of the Camshaft Position Sensor (CMP). The sensor is
located on the engine front cover. The CMP is a Hall effect sensor
which looks for a narrow vane on the timing disc. The disc is
precisely mounted and indexed on the camshaft gear in a relationship
that identifies the position of No. 1 piston. The ECM uses this signal
to determine correct injector firing sequence. The Cylinder
Identification circuit carries the information to the Injector Driver
Module. The IDM receives a Fuel Demand Command Signal (FDCS) from the
ECM to control injector timing and quantity of fuel delivered to each
injector. See Fig. 14.
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digital signal, generating a signal voltage or switching a 12 volt
signal. See Fig. 17. Reference voltage sensors are supplied with a
constant 5 volts regulated supplies by the ECM. A voltage regulator
supplies the reference voltage (VREF) to these sensors. This voltage
is changed by the sensor and the signal is relayed back to the ECM.
The ECM, by comparing the VREF to the returned signal can check its'
internal programmed tables to determine the value of the variable
being measured.
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The Hall effect sensor is an electronic device which
generates a voltage signal controlled the presence, absence or
strength of a magnetic field. The Camshaft Position Sensor is a Hall
effect sensor. It contains a transducer, permanent magnet, signal
conditioner and a switching transistor. The permanent magnet applies a
magnetic field around the transducer. The transducer senses the
strength of the magnetic field which is controlled by the vanes and
windows as they pass the sensor. A voltage signal is generated each
time a window passes the device. The signal is filtered and
conditioned by the signal conditioner. This signal is applied to the
switching transistor's base, which causes the transistor to switch ON
and ground the 12 volt line from the ECM. The ECM no longer senses the
12 volt reference signal. When a vane passes the device, no signal is
generated, the transistor shuts of and the ECM sees the 12 volt
reference signal. This quick switching action allows the ECM to
determine crankshaft position and engine speed, and allows the ECM to
control injector timing and injection duration.
Switch Sensors
Switch sensors are used to indicate position, levels or
pressures. The switch signal is a digital signal and is created by
opening or closing a switch. Switch sensors can be either voltage
input or a grounding type switch. A voltage input switch will supply
the ECM with a voltage when closed. A grounding switch is wired in
series with a current limiting resistor in the ECM and will cause a 0
voltage signal when grounded. Examples are; Idle Validation, Brake
Normally Open, Brake Normally Closed, Coolant Level and Driveline
Disengagement.
Magnetic Pickup
A magnetic pickup is a sensor used to generate an alternating
frequency that indicates speed. A two wire connection for signal
return and ground are used. The pickup is constructed with a permanent
magnetic core surrounded by a wire coil. The signal frequency is
generated by the rotation of gear teeth which make and break the
magnetic field. An example is the Vehicle Speed Sensor.
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start.
ATA Data Link Provision
An ATA data link connector is provided that allows
communication between the engine control system and the Pro-Link 9000
Electronic Service Tool (EST). The data link provides communication
capabilities for the following:
* Engine Parameter Data Transmission
* Diagnostics & Troubleshooting
* Customer Programming
* Production Line Programming
* Field Programming
Service Diagnostics
The electronic service tool (EST) provides means for
obtaining diagnostic information through the ATA data link. The ProLink 9000 EST can diagnose system faults. The engine control system
also provides service diagnostic information via flash codes emitted
through the engine warning lamp.
Electronic Tachometer/Speedometer Provisions
The engine control system calibrates vehicle speed using
pulses/mile. Dip switches no longer need to be changed when components
affecting speed calibration are changed. The new speed calibration can
be programmed using an EST.
Engine Over Temperature Protection
This system reduces fuel delivery when coolant temperature is
above the design target value. Fueling is reduced proportionally to
the extent the design limit is exceeded. The reduction is calibrated
to a maximum 20 percent before standard engine warning shutdown
systems engage. If system is activated, a fault code is stored to
explain low power complaints. This feature may be omitted on emergency
vehicle that require 100 percent power on demand.
Event Logging System
This system records if the engine was operated beyond maximum
RPM, over heated, low on coolant and/or had low oil pressure. This
information is stored in the ECM memory and can be accessed using an
EST.
Engine Crank Inhibit
This system will not allow the engine to crank unless the
automatic transmission is in Neutral and will not allow the starter to
engage when engine is running. It also facilitates using cruise
control and PTO options with automatic transmissions.
Electronic Accelerator Pedal
This eliminates the mechanical linkage on conventional
systems. An accelerator position sensor within the accelerator pedal
provides the ECM with a signal representing the driver's demand for
power.
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SELF-TEST OPERATION
Diagnostic Fault Code Detection
The T444E diagnostic system has the capability to detect
fault codes which indicate an operating malfunction. There are two
types of detection systems; Continuous Monitor Self-Tests and Engine
Diagnostic Tests. See Fig. 18.
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key is ON, if an input signal is out of its programmed range, the ECM
will record a Fault. It will also monitor the operation of systems and
will determine if the system is working within a normal range. If the
ECM detects that a system is operating out of range, it will record a
fault code. During normal engine operation, the ECM automatically
performs several tests to detect faults. When it has determined a
fault, the ECM will invoke a fault management strategy to allow
continued, though sometimes degraded, vehicle operation.
A Fault is an indication of a malfunction measured or
monitored electronically. Codes are three digit numbers assigned to
faults to indicate the source of the problem. Most codes will indicate
the Mode of failure. The Failure Mode will indicate the signal reading
is Out-Of-Range High, Out-Of-Range Low, or in Range Fault. When the
engine is running, the Vehicle Personality Module (VPM) memory will
record Event Engine Hours. This is the monitoring of engine operation
exceeding programmed parameters. The standard engine event is
Overspeed, referred to as Over RPM and excess coolant temperature. To
retrieve information on Engine Events, it is necessary to access them
with the Electronic Service Tool. If the engine is equipped with an
optional engine warning/shutdown system, low oil pressure and low
coolant level operation, it will also be monitored and recorded as
Engine Event Hours.
Engine OFF Standard Tests
Engine Off tests are standard tests performed by the ECM.
These tests are commanded by the technician using the Electronic
Service Tool (EST) or using the Self-Test Input (STI) push button
switch. Since injector driver module faults are not stored in the ECM,
it is necessary to perform a self-test to transmit faults to the ECM.
To use the EST, access the Engine menu and select Diagnostic
Tests. Then select Engine Off Tests. Depressing the Enter key will
initiate the test.
To use the STI diagnostic push button switch, depress the
switch and hold, while turning the ignition ON. Release the STI button
after engine is on. Do not start the engine. When the operator signals
the test to begin, the ECM will perform internal tests of its
processing components and memory. It will automatically proceed to
Output Circuit Check. This will operate the ECM output circuits. It
will measure each individual circuit's response. The following
circuits are checked by the ECM during the test.
* Cylinder Identification
* Exhaust Pressure Regulator
* Engine Crank Inhibit Relay
* Glow Plug Control Relay
* Injector Driver Module Relay
* Glow Plug Light
* Fuel Demand Command Signal
* Injection Pressure Regulator
* Engine-To-Transmission Data Line
The ECM will monitor the outputs and test the operation of
the output signals and actuators. If a circuit fails the test, a fault
code will be logged. When the test is complete, the EST will display
any faults that were found. If the STI diagnostic switch was used, the
fault codes will be transmitted a Flash Codes using the Oil Warning
and Engine Warning lights. The fault codes are read by counting the
number of light flashes. The following sequence will occur:
The OIL/WATER light will flash once. This indicates the
beginning of active fault codes. The WARN ENGINE light will flash
repeatedly signaling active fault codes. All codes are three digits.
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The number of flashes should be counted in sequence. At the end of
each digit of the code, there will be a pause. Three flashes and a
pause indicates code 3. Code 232 would be represented as two flashes,
a pause, three flashes, another pause then two final flashes.
If there is more than one code being sent, the OIL/WATER
light will flash once, indicating the start of another code. If code
111 flashes, it indicates there are no faults. If no further fault
codes exist, the OIL/WATER light will flash twice, indicating the
start of Inactive Codes. The WARN ENGINE light will then flash any
inactive codes present. If more than one inactive code is present, the
OIL/WATER light will flash once between each code.
When all stored fault codes have been sent, the OIL/WATER
light will flash 3 times, indicating end of message. If it is
necessary to repeat transmission of the codes, press the STI button
and all codes will be retransmitted.
Injector Buzz Test (Engine OFF)
The injector buzz test diagnoses electrical problems with the
fuel delivery components. This test can only be accessed with the EST
and only after the Engine Off test or Self-Test has been performed.
Before running this test, all fault codes should be noted and erased.
This will allow faults found in this test to appear as Active Codes.
During this test, the ECM will signal the Injector Driver
Module (IDM) to activate the injectors in numerical order, 1 through
8. The IDM will monitor each injector's electrical circuit operation.
The IDM will send feedback signals to the ECM which indicate the
status of injector performance and circuit operation. If an electrical
component in the fuel system fails, an inactive fault code will be
logged and transmitted to the EST at the end of the test. If the fault
codes were not erased before this test, the faults found in this test
will be displayed as Inactive Codes. To read the codes, access the
Diagnostic Codes menu and read both Active and Inactive codes.
Output State Test (Engine OFF)
The Output State Test diagnoses the output signals and
actuators. The EST must be used to perform this test. To run the test,
select Output State Test from the EST Engine Off Menu. The test
operates in two modes; Toggling outputs from high to low and toggling
outputs from low to high.
When in Outputs Are Low mode, the ECM will pull down the
output voltage to their low state. This will activate the output
components that are controlled by the ECM grounding the circuits.
During the test OUTPUTS ARE LOW will de displayed on the screen.
When in Outputs Are High mode, the ECM will pull up the
output voltage to their high state. This will activate the output
components that are controlled by the ECM energizing the control
circuits. During the test OUTPUTS ARE HIGH will de displayed on the
screen.
During this test, the output of the circuit in question can
be monitored using a DVOM. The DVOM will measure a high or low voltage
state as the outputs are toggled. The actual voltage will vary with
the circuit being tested. No faults will be set during this test.
Standard Test (Engine Running)
This test checks the operation of the Injection Pressure
Regulator (IPR) and Exhaust Backpressure Regulator (EPR). During the
test the ECM commands the IPR and EPR actuators through a preprogrammed testing sequence to determine actuator operation. The ECM
monitors the feedback signal values from the sensors and compares themEMISSIONS
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to expected values. At the end of the test, the ECM will return the
engine to normal operating mode and transmit any fault codes that were
found. This test can only be made using the EST. Before performing the
test, coolant must be warm, battery voltage must be at least 12.5
volts and no vehicle speed sensor signal should be present. If active
codes are present they must be repaired and cleared first.
Select Engine Running Test from the Diagnostic Test menu in
the EST. Press ENTER to start test. The ECM will begin to raise the
idle speed to a predetermined value. It will then command the IPR
value to set the injection control pressure to rated speed pressure.
If the IPR performance is acceptable, the ECM will control the IPR to
reduce pressure in stages while monitoring the performance.
At the completion of the test, the ECM will conduct a similar
test on the EPR calve. When testing is completed, the engine will
return to normal operation and any fault codes will transmitted.
Injector Cylinder Test (Engine Running)
The Injector Test detects problems with the injection and
combustion events. During the test the ECM will control fuel delivery
and determine each cylinder's power contribution. If a cylinder is not
performing satisfactorily, a fault code will be set. This test can
only be performed using the EST. The Engine Running Self-Test must be
performed first to gain access to the Injector Running test in the
EST.
Select injector Test from the Engine Running test menu. The
ECM will increase the normal amount of fuel delivery to the
injector/cylinder being tested and monitor the reduction of fuel
required to operate the remaining injectors to maintain engine speed.
If there is no reduction in the fuel delivery to the other cylinders,
the ECM will set a fault code identifying the faulty cylinder. When
the test is complete, normal operation will be restored and any fault
codes will be transmitted.
Wiggle Test
The purpose of the Wiggle Test is to troubleshoot
intermittent connections at sensors and actuators. It can be performed
with the engine off or running. The EST is used to monitor the various
sensors and actuator circuits during the test. Select Wiggle Test from
the Diagnostic Test menu in the EST. Press Enter key to start test.
The technician should wiggle connectors and wires at all suspected
problem points. The EST will beep if any circuit continuity is broken.
It will display all faults found during the test.
TROUBLE SHOOTING
SYMPTOM DIAGNOSIS
Camshaft Timing Incorrect
Possible Causes - Camshaft gear to crankshaft gear is
assembled out of time.
Correction - Bar engine over by hand until pointer on
Camshaft Position Sensor (CMP) is aligned with the machined timing
slot on the crankshaft damper. remove CMP and view timing disc through
hole in front cover. If engine is on compression stroke for No. 1
cylinder, a narrow sync vane will be seen directly in the middle of
the CMP opening. If camshaft timing is one tooth advanced or retarded,
the narrow vane will appear about 1/8 inch from either the upper or
lower edge of the hole. If no narrow vane is visible, the engine is
probably not on the No. 1 cylinder compression stroke. Rotate engine
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over 360 degrees until timing mark and pointer are aligned. Reinspect
location of narrow vane in CMP opening.
Combustion Leaks
Possible Causes - The most likely cause of combustion gas
leaking into the cooling system is past the lower nozzle sleeve in the
cylinder head. A blown head gasket or porous cylinder wall is
possible, but should not be suspected unless vehicle overheated or a
very high mileage engine has not had proper coolant conditioning.
Correction No. 1 - Plug in block heater to warm coolant.
Pressurize cooling system to 14 psi. Remove valve covers and glow
plugs. Observe glow plug holes while turning engine over by hand to
see if coolant is flooding the top of the piston and escaping out of
the glow plug hole. If the leak is slight, pressure may have to be
left on overnight to see coolant leak. When the suspected nozzle
sleeve is located, drain coolant and replace sleeve. Check system
operation to see is problem is corrected.
Correction No. 2 - Plug in block heater to warm coolant.
Remove valve covers and glow plugs. Remove cap from surge tank. Rotate
crankshaft on cylinder to be tested until valves are shut. Install
Compression Adapter (ZTSE-4292) in glow plug hole and adapt gauge end
to accept shop air pressure. Apply 100-160 psi shop pressure and
observe surge tank for escaping air. If nozzle sleeve is leaking air
bubbles will be seen in surge tank. When the suspected nozzle sleeve
is located, drain coolant and replace sleeve. Check system operation
to see is problem is corrected.
Coolant In Lube Oil
Possible Causes - Oil cooler bundle or O-ring failure; front
cover O-ring damage; front cover porosity; cylinder head porosity;
crankcase porosity; nozzle sleeve leakage.
Correction - Plug in block heater to warm coolant. Remove oil
pan plug, oil filter and glow plugs. Pressurize cooling system to 14
psi. Check rear of oil cooler at oil filter mounting for coolant or
air pressure escaping. If leaking is occurring from header at oil
filter mounting header, the oil cooler should be removed and tested.
Correct as necessary.
If coolant is escaping from oil pan drain plug, remove valve
covers and inspect cylinder head area under valve covers and welch
plugs in cylinder head for leakage. Correct as necessary.
If no leaks are found, remove engine and oil pan. Block off
all coolant connections. Pressurize cooling system with 14 psi of
regulated air pressure. Inspect bottom of crankcase for leaks. Repair
as necessary. If no leaks are found, remove front cover and inspect
gasket and sealing surfaces. Repair as necessary. When all corrections
are made, retest system.
Coolant Temperature Too High
Possible Causes - Gauge error; low coolant level; plugged
radiator; incorrect radiator; stuck thermostat; no thermostat;
defective water pump; broken belt; fan clutch slippage; wrong or
damaged fan blade.
Correction - Check for correct coolant level and correct.
Inspect for correct part numbers on fan blade, shroud, belt and
radiator. Monitor coolant temperature with Electronic Service Tool
(EST) and compare to dash reading of temperature. Manually check
temperature in coolant sender opening and confirm high temperature.
Check thermostat for correct opening temperature. Remove radiator and
check radiator flow.
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applied.
Remove, inspect and measure clearances in lube oil pump.
Inspect front mating surface for gouging or scratching. Inspect oil
pump for damage or wear. Measure clearance between gerotor and oil
pump housing. Clearance should be .028-.032" (72-81 mm). Measure
clearance between gerotor and housing surface. Clearance should be .
001-.03" (.02-.08 mm). Remove transmission and flywheel. Inspect rear
main plate for oil leaks. Massive oil leaks could indicate missing
main galley plug. Remove rear plate and inspect plugs. Remove oil pan
and inspect for missing piston cooling jets and bearing shells. Remove
front cover and check for cut or damaged O-rings or missing tappet
galley plugs. Correct any incorrect conditions found and recheck
system for proper operation.
No Start Because Of Dry Oil Reservoir
Possible Causes - The failure mode must be identified before
cause can be found. If engine Started, Ran For 15 Seconds And Stalled,
most likely cause is the lack of oil supply by the oil system. If
Engine Did Not Start And Reservoir Was Dry, most likely cause is
reservoir leak down. This can be caused by a leaking check valve in
high pressure oil pump, porous oil reservoir or reservoir pump down
which occurs during cranking and no start conditions caused by an
electronic circuit failure.
Correction - If engine started, ran and then stalled, refill
oil reservoir and verify start and stall condition. If condition still
exists, remove, inspect and measure clearances in oil pump. Inspect
front mating surface for gouging or scratching. Inspect oil pump for
damage or wear. Measure clearance between gerotor and oil pump
housing. Clearance should be .028-.032" (72-81 mm). Measure clearance
between gerotor and housing surface. Clearance should be .001-.03" (.
02-.08 mm).
If engine did not start and reservoir was dry, refill
reservoir and try to start engine. If engine does not start, perform
procedures on Navistar Hard Start/No Start Diagnostic form. This
checks if all essential elements required for starting are okay. If
engine starts, low reservoir problem may be caused by a reservoir leak
down after a long period of not running. Road test vehicle for 10
miles to purge all air from injection control system. Check oil level
to ensure it is full and let vehicle sit overnight.
Inspect oil level in the morning and determine if leak down
has occurred. The only leakage paths are past a check ball internal to
the pump or through a porous front cover. Leakage past a check ball
may be intermittent. The check ball is not serviceable. Replace oil
pump if it is suspect. If porosity through the front cover or oil pump
is suspected, replace reservoir first and check if problem is solved.
Replace front cover only as a last resort.
ECM Reset
ECM reset may result in the glow plug light cycling on, glow
plugs recycle, engine stumbles and/or dies, no acceleration pedal
authority until return to idle position.
The ECM reset occurs when the ECM momentarily reboots, or is
turned on and off while the engine is operating. If condition occurs a
single time, the engine will briefly stumble, and the ECM will go
through a normal key on cycle, including turning the glow plug light
and glow plugs on and will also attempt to validate the accelerator
pedal position. If pedal is not at idle, authority will not be allowed
by ECM until pedal is released and returned to idle.
Possible Causes - Momentary loss of power to the ECM or IDM EMISSIONS
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may be caused by defective power relays, shorted or open harnesses,
intermittent connectors or poor grounds, short to ground in VREF
circuits, short to ground in injector high side voltage.
Correction - Perform test Nos. 3, 4a and 4b on the Navistar
Performance Diagnostic Form. This will determine if the ECM has
detected a fault condition that will cause a ECM reset.
NOTE:
Check all power and ground connections for the ECM and IDM.
Monitor VREF and VPOWER circuits with a breakout box installed when
the fault occurs. Inspect the CMP harness connector and harness for a
VREF or signal short to ground condition. Remove and inspect the CMP
position sensor for possible timing disk to CMP sensor contact.
If the ECM reset condition is repeatable, disconnect sensors
one at a time and operate the engine to see if the condition will
reoccur. Inspect each harness and connector upon removal. Remove the
valve covers and inspect the under valve cover connectors for possible
pinching under the valve cover gasket or rub through against the push
tubes. Correct as necessary.
Rough Idle
Possible Causes - Engine oil problem, defective injectors,
injector short to ground, power cylinder problems, valve train
problems, low fuel pressure, aerated fuel, exhaust system problem,
engine mounts, loose/worn, electronic control system problem, poor
fuel quality, injection control pressure system problems.
Correction - Verify complaint. Operate vehicle under
complaint conditions and verify that rough idle is not present with
any other condition. Inspect exhaust system for contact with cab or
bed. Engine vibrations may be transmitted to the cab through the
exhaust system, which can be misinterpreted as a rough idle condition.
Check that engine oil is the correct grade and is full. Check ECM for
any fault codes that affect engine operation. Check that injectors are
operating properly. Check that fuel transfer pump has correct pressure
and pump inlet is not restricted. Check fuel return line for air
present in fuel. Check Injection Control Pressure and Exhaust
Backpressure system for proper function. Check individual cylinders
for a low power cylinder.
Check Injection Control Pressure (ICP) system. Monitor ICP
voltage signal using a DVOM with key on and engine off. Value should
be .15-.25 volts. If ICP is reading correct, check for air in engine
oil and that the oil has the correct quality. Check for low oil
pressure suction leaks.
Disconnect engine harness connector at ICP sensor with engine
at idle. If rough idle smoothes out, replace ICP sensor. If engine
still runs rough, check IPR and ICP system diagnostics. Check
crankcase pressure. Check ICP pressure between right and left cylinder
heads. Difference between cylinders should not exceed .2 volts. If
pressure differences are found, leakage is occurring in lower pressure
head. This may be caused by lose or cross threaded oil gallery drains,
injector O-rings or a bad injector. Check engine compression on each EMISSIONS
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cylinder to verify base engine condition. If no faults are found in
any of the possible corrections, replace injectors.
Black Smoke
Possible Causes - Air intake or exhaust restriction, exhaust
backpressure device closing, turbocharger failure, loose injector,
operation at high altitude, (very slight Black smoke on hard
acceleration is normal).
Correction - If engine has a fuel knock or there is evidence
of fuel in exhaust manifolds, remove exhaust manifolds and check for
fuel. Check for loose injectors, missing or damaged O-rings and Copper
gasket on bottom. Check air inlet system and exhaust system for
restrictions and leaks. Check if exhaust backpressure device (EPD) is
closing at wide open throttle. Monitor EPD signal with EST while
operating engine to see if backpressure is high.
White Smoke
Possible Causes - No glow plug operation, loose injectors,
cold engine, bent connecting rods, low compression, worn rings,
coolant leaking into combustion chambers past injector sleeves.
Correction - In cold temperatures some White smoke is normal
until engine reaches normal operating temperatures. If engine cannot
reach normal operating temperature, check thermostat. On a cold engine
the glow plug system may remain on for up to 2 minutes after engine
starts to aid in cold smoke clean-up. Verify proper glow plug
operation. If engine had a fuel knock, or fuel in exhaust, remove
exhaust manifolds and check for fuel in exhaust ports. Check for loose
injectors, missing or damaged O-rings and Copper gasket on bottom. If
air induction system shows evidence of water injection that can cause
hydraulic static lock and bend connecting rods, perform a compression
test on cylinders.
Blue Smoke/Fuel Odor
Possible Causes - Excessive oil consumption and/or loose
injectors.
Correction - If engine had a fuel knock, or fuel in exhaust,
remove exhaust manifolds and check for fuel in exhaust ports. Check
for loose injectors, missing or damaged O-rings and Copper gasket on
bottom.
TESTING
DIAGNOSTIC TOOLS
Testing Equipment
Specific testing equipment is required to fully diagnose the
T444E Electronic Control System. These tools will provide the most
accurate specifications needed to determine if the system is operating
properly. All manufacturers instructions contained in the tools should
be read and thoroughly understood before operating the tool. In the
diagnostic tests for specific codes used in the T444E control system,
references will be made to using these tools. It is assumed that the
technician understands how these tools operate and what they will
display when the test is run. Specific connections to harnesses,
terminal numbers, wire colors, etc., will be included in the test
charts. The following is a brief description of the tools required to
properly diagnose this system.
Pressure Test Kit
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The Beyers Model 200 Pressure Test Kit (part no. ZTSE-2239)
is used to measure intake manifold boost pressure, fuel pressure, air
cleaner restriction, fuel restriction, exhaust backpressure and
crankcase pressure.
Manometer
The manometer is used to measure low pressure or vacuum.
Orificed Restrictor & Adapter
The Orificed Restrictor (part no. ZTSE-4146A) and Adapter
(part no. ZTSE-4284) are used to measure combustion gas flow out of
the engine. It is also used to perform a crankcase pressure test.
Glow Plug/Injector Breakout
The Glow Plug/Injector Breakout (part no. ZTSE-4345) is used
to check injector solenoid continuity and glow plug resistance to
ground.
ICP/EBP Breakout "T"
The Injection Control Pressure (ICP)/Exhaust Backpressure
Sensor (EBP) Breakout "T" (part no. ZTSE-4347) is used to gain access
to injection control pressure and exhaust backpressure signal
voltages. The "T" enables the technician to quickly connect a
voltmeter to read voltage signals at each of the sensors.
Injection Control Pressure/Adapter Plug Kit
The injection control pressure/adapter plug kit (part no.
ZTSE-4359) is used in performing high pressure leakage tests on the
injection control pressure system. The adapter allows the ICP sensor
to be installed in either of the high pressure oil hoses during
testing.
Fluke 88 Digital Multimeter
The Fluke 88 Digital Multimeter (DVOM) (part no. ZTSE-4357)
is used to trouble shoot all electrical components. It can also
measure engine RPM when the EST is not available or is unable to
receive ATA data link information.
Breakout Box
The Breakout Box (part no. ZTSE-4346) is designed to allow
for testing of the electronic control system components without
disturbing connections or piercing wire insulation. See Fig. 19.
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Fig. 20:
Page 26 of 208
Courtesy of Navistar International Corp.
To retrieve diagnostic codes, turn all accessories and the
engine off. Connect the EST to the ATA data link at the lower left
kick panel inside the vehicle cab. When the tool is plugged in, the
Pro-Link screen will light up. Turn the ignition key ON, but do not
start the engine. The EST will receive data from the electronic
control components on the vehicle. The information received will be
the data as to the current status of the engine. For complete
operating instructions, refer to the manufacturers instructions, along
with the instructions described in the diagnostic code charts.
TESTING
DIAGNOSTIC TROUBLE CODES
DIAGNOSTIC TROUBLE CODE CHART
244
245
251
252
253
254
255
311
312
313
314
315
316
321
322
323
324
325
331
332
333
334
335
341
342
343
344
351
352
421
422
423
424
425
426
427
428
431
432
433
434
435
436
437
438
441
442
443
444
445
446
447
448
451
452
453
454
455
456
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EDL ....................... Eng.-To-Trans. Data Line OCC Fault
EPR ....................... EPR Regulator OCC Self-Test Failed
GPC ................ Glow Plug Controller OCC Self-Test Failed
GPC ...................... Glow Plug Lamp OCC Self-Test Failed
ECM/IDM .......... Fuel Inj. Sync Circuit OCC Self-Test Failed
ECM .............. OCC Self-Test ECM Circuit Out-of-range High
ECM ............... OCC Self-Test ECM Circuit Out-of-range Low
EOT .............................. EOT Signal Out-of-range Low
EOT ............................. EOT Signal Out-of-range High
EOP .................. Engine Oil Pressure Below Warning Level
EOP ................. Engine Oil Pressure Below Critical Level
....................... Engine Speed (Tach RPM) Limit Exceeded
ECT .................. ECT Unable To Reach Commanded Set Point
ECT .................................. ECT Above Warning Level
ECT ................................. ECT Above Critical Level
ECL ......................... ECL Below Warning/Critical Level
.................. Idle Shutdown Timer Enabled Engine Shutdown
ECT ..... Power Reduced, Matched To Cooling System Performance
IPR .................. IPR Pressure Above System Working Range
IPR ................. IPR Pressure Above Spec. With Engine Off
IPR ................... IPR Pressure Above/Below Desired Level
IPR .......................... ICP Unable To Achieve Set Point
IPR ............. ICP Unable To Build Pressure During Cranking
EBP .............................. EBP Signal Out-of-range Low
EBP ............................. EBP Signal Out-of-range High
EBR ........................... Excessive Exhaust Backpressure
EBP .......................... EBP Above Spec. With Engine Off
EPR ............ EBP Below Expected Level At High Engine Speed
EPR ......................... EBP Above Or Below Desired Level
INJ ........................ Low To High Side Open - Cyl No. 1
INJ ........................ Low To High Side Open - Cyl No. 2
INJ ........................ Low To High Side Open - Cyl No. 3
INJ ........................ Low To High Side Open - Cyl No. 4
INJ ........................ Low To High Side Open - Cyl No. 5
INJ ........................ Low To High Side Open - Cyl No. 6
INJ ........................ Low To High Side Open - Cyl No. 7
INJ ........................ Low To High Side Open - Cyl No. 8
INJ ....................... Low To High Side Short - Cyl No. 1
INJ ....................... Low To High Side Short - Cyl No. 2
INJ ....................... Low To High Side Short - Cyl No. 3
INJ ....................... Low To High Side Short - Cyl No. 4
INJ ....................... Low To High Side Short - Cyl No. 5
INJ ....................... Low To High Side Short - Cyl No. 6
INJ ....................... Low To High Side Short - Cyl No. 7
INJ ....................... Low To High Side Short - Cyl No. 8
INJ ....................... Low Side Short To VBAT - Cyl No. 1
INJ ....................... Low Side Short To VBAT - Cyl No. 2
INJ ....................... Low Side Short To VBAT - Cyl No. 3
INJ ....................... Low Side Short To VBAT - Cyl No. 4
INJ ....................... Low Side Short To VBAT - Cyl No. 5
INJ ....................... Low Side Short To VBAT - Cyl No. 6
INJ ....................... Low Side Short To VBAT - Cyl No. 7
INJ ....................... Low Side Short To VBAT - Cyl No. 8
INJ ..................... Low Side Short To Ground - Cyl No. 1
INJ ..................... Low Side Short To Ground - Cyl No. 2
INJ ..................... Low Side Short To Ground - Cyl No. 3
INJ ..................... Low Side Short To Ground - Cyl No. 4
INJ ..................... Low Side Short To Ground - Cyl No. 5
INJ ..................... Low Side Short To Ground - Cyl No. 6
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457 INJ ..................... Low Side Short To Ground - Cyl No. 7
458 INJ ..................... Low Side Short To Ground - Cyl No. 8
461 Perf. Diag. ...... Cyl. Contribution Test Failure - Cyl. No. 1
462 Perf. Diag. ...... Cyl. Contribution Test Failure - Cyl. No. 2
463 Perf. Diag. ...... Cyl. Contribution Test Failure - Cyl. No. 3
464 Perf. Diag. ...... Cyl. Contribution Test Failure - Cyl. No. 4
465 Perf. Diag. ...... Cyl. Contribution Test Failure - Cyl. No. 5
466 Perf. Diag. ...... Cyl. Contribution Test Failure - Cyl. No. 6
467 Perf. Diag. ...... Cyl. Contribution Test Failure - Cyl. No. 7
468 Perf. Diag. ...... Cyl. Contribution Test Failure - Cyl. No. 8
511 INJ ........................... Bank No. 1 Has Multiple Faults
512 INJ ........................... Bank No. 2 Has Multiple Faults
513 INJ ............................. High Side To Bank No. 1 Open
514 INJ ............................. High Side To Bank No. 2 Open
515 INJ ............. Bank No. 1 High Side Short To Ground Or VABT
521 INJ ............. Bank No. 2 High Side Short To Ground Or VABT
522 IDM PWR ................................. IDM Internal Failure
523 IDM PWR ............................. IDM Power Voltage Is Low
524 INJ ................. Both High Side Switches Shorted Together
531 ECM/IDM ................... Cylinder Identification Signal Low
532 ECM/IDM .................. Cylinder Identification Signal High
541 ECM/IDM ..................... IDM Feedback TOGGLE Not Detected
543 ECM/IDM .............................. IDM Faults Not Received
544 INJ ............................. Injector Fault In Bank No. 2
545 INJ ............................. Injector Fault In Bank No. 1
612 CMP ............. Incorrect ECM Installed For CMP Timing Wheel
613 VPM ............. Installed ECM Incompatible With VPM Software
614 VPM ............. Installed VPM Incompatible With ECM Software
615 ECM ................. Programmable Parameter KAM Corrupt Fault
621 VPM .......... Engine Using MFG. Default Rating Program Engine
622 VPM ........................ Engine Using Field Default Rating
623 VPM .......... Invalid Eng. Rating Code, Check VPM Programming
625 ECM .............. Module Software Background Process Inactive
631 ECM ...................................... ROM Self-Test Fault
632 ECM ........................... RAM Memory/CPU Self-Test Fault
633 DCL/ATA ............... VPM Communicating Incorrectly With ECM
634 VPM ................ Internal Fuel Meter Memory Location Error
635 VPM ................. Internal Hourmeter Memory Location Error
641 VPM .................. Internal Odometer Memory Location Error
642 VPM ................................. Internal Fuelmeter Fault
643 VPM ................................. Internal Hourmeter Fault
644 VPM .................................. Internal Odometer Fault
645 VPM .................... Internal EEPROM Memory Location Error
651 VPM .................. Feature Memory Data Content Interrupted
652 VPM ................ Engine/Fuel Memory Data Content Corrupted
653 VPM .............. Engine/Rating Memory Data Content Corrupted
654 VPM ......................................... Watchdog Timeout
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ground, preferably the negative battery cable, to determine if a short
to ground is present. During these tests, turn off all accessories,
including the dome light. Current in the system will affect resistance
readings. If a reading is fluctuating greatly, disconnect the battery
and measure to the negative battery cable. The signal ground on all
sensor harness connectors should measure less than 5 ohms. The VREF
and signal lines with the processor connected will normally measure
more than 100k ohms. The power ground on an actuator circuit should
measure less than 5 ohms. The control side of an actuator circuit
should measure more than 1000 ohms.
Connector Voltage Checks
Turn ignition key to the ON position and measure if the
expected voltages are present at the connector. On circuits with
expected voltages, this test will verify the integrity of the circuit.
On circuits without an expected voltage, this test will determine if
the circuit is shorted or miswired to a voltage source. The signal
ground on all connectors should measure less than .25 volts. VREF
circuits should measure 4.5-5.5 volts. If voltage is higher or lower
than expected, disconnect sensors one at a time to determine if a
sensor is biasing the circuit.
Sensor signal lines will measure 0-.25 volts. If the circuit
is designed to pull down when disconnected, or a higher voltage (4.6-5
or 12 volts), it is designed as a pull up circuit. A pull up signal
circuit that measures the expected value normally indicates a god
circuit.
Actuator circuits may either be On/Off type circuits (12
volts), or pulse width modulated circuit (12 volts controlled by a %
duty cycle).
Communication circuits between the ECM and Injector Driver
Module (IDM) are designed to pull up or down. This means that one end
of the communication circuit is normally at a high, or 12 volt level
and the signal is created by the low side toggling or switching the
high side to ground. Communication lines are best diagnosed with the
breakout box installed and measuring the expected voltage with the key
ON and engine off.
Harness Resistance Tests
Harness resistance checks are performed when a circuit is
suspected of being open or having high resistance. These tests are
performed with the breakout box installed and by measuring resistance
from the sensor connector end to the processor connector. If an open
circuit or high resistance is encountered, the problem is most easily
isolated by separating the circuit at the intermittent connectors and
measuring resistance through both halves of the circuit.
Operational Signal Checks
These checks are made with the breakout box installed and are
normally measuring a signal voltage or frequency. They are useful for
determining an in-range type fault or intermittent condition. In cases
of intermittent faults, monitoring a suspected circuit and recreating
the environmental or physical conditions that caused the complaint
will help verify if a problem is in a particular circuit. It is
critical when measuring the signal level of a circuit to understand
its function and whether it is a analog voltage, digital frequency,
sine wave or digital communication signal. A DVOM has certain
limitations in measuring any circuit that has a frequency.
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that indicates the driver demand for power. The idle validation switch
(IVS) is 0-12 volt signal that provides the ECM with a redundant
signal to verify the pedal is in the idle position.
Fault Detection Management
Any detected malfunction of the APS or IVS will illuminate
the WARN ENGINE light. An APS signal that is detected out-of-range
high or low by the ECM will cause the engine to ignore the signal and
only allow the engine to operate at low idle. If a disagreement in the
state of IVS and APS is detected by the ECM and the ECM determines
that it is an IVS fault, the ECM will only a maximum of 50 percent APS
to be commanded. If a disagreement in the state of IVS and APS is
detected by the ECM and the ECM cannot determine if it is an IVS or
APS fault, or if it is an APS fault, the engine will operate at low
idle only.
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see, a fault code is set. APS/IVS fault codes are as follows:
CODE 131 - ATA CODE PID 91 FMI 4; APS OUT-OF-RANGE LOW Perform Testing APS Circuits. See Fig. 26.
CODE 132 - ATA CODE PID 91 FMI 3; APS OUT-OF-RANGE HIGH Perform Testing APS Circuits. See Figs. 26 and 27.
CODE 133 - ATA CODE PID 91 FMI 2; APS IN RANGE FAULT Perform Testing IVS Circuits and Testing APS Circuits. See Figs. 25,
26 and 27.
CODE 134 - ATA CODE PID 91 FMI 7; APS/IVS DISAGREE - Perform
Testing IVS Circuits and Testing APS Circuits. See Figs. 25, 26 and
27.
CODE 135 - ATA CODE SID 230 FMI 11; IVS CIRCUIT FAULT Perform Testing IVS Circuits and Testing APS Circuits. See Figs. 25,
26 and 27.
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are as follows:
CODE 151 - ATA CODE PID 108 FMI 3; BARO SIGNAL OUT-OF-RANGE
HIGH - Perform Testing BARO Circuit. See Figs. 30 and 31.
CODE 152 - ATA CODE PID 108 FMI 4; BARO SIGNAL OUT-OF-RANGE
LOW - Perform Testing BARO Circuit. See Figs. 30 and 31.
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until the vehicle has been shut off and restarted. the Engine Warning
Light will not come on. Brake switch/relay fault code is as follows:
CODE 222 - ATA CODE SID 247 FMI 2; BRAKE SWITCH CIRCUIT FAULT
- Perform Air Brake Switch and Hydraulic Brake Switch Circuit tests
before performing Brake Switch Relay Circuit Test. See Figs. 35
through 39.
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2) Measure resistance between terminals No. 30 and 87. If
resistance is more than 100k ohms, go to next step. If resistance is
less than 100K ohms, replace relay.
Page 50 of 208
3) Connect positive battery lead to terminal No. 85 and
negative lead to terminal No. 86. Relay should energize with an
audible click. If relay energizes, go to next step. If relay does not
energize, replace relay.
4) With relay energized, measure resistance between terminals
No. 30 and 87A. If resistance is more than 100k ohms, go to next step.
If resistance is less than 100K ohms, replace relay.
5) With relay energized, measure resistance between terminals
No. 30 and 87. If resistance is less than 2 ohms, relay is good. If
resistance is more than 2 ohms, replace relay.
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effect engine operation a corresponding fault code will be set. The
engine will not operate without a functioning CMP signal.
ECM Diagnostics
Once the ECM has recognized the narrow vane it will
synchronize the engine firing order to the timing of the CMP signal.
Every 2 crankshaft revolutions it will verify that synchronization. If
the ECM receives too many or too few pulses for the number of engine
revolutions, it will set a fault code. CMP codes that are set will
become inactive codes if the key is turned off. These cods can be
retrieved using the Self-Test Input switch on the dashboard, or the
Electronic Service Tool. The following fault codes may be set:
CODE 143 - ATA CODE SID 21 FMI 2; WRONG NUMBER OF CMP SIGNAL
TRANSITIONS PER CAM REVOLUTION - Possible causes for code 143 are
intermittent CMP signal caused by an intermittent circuit, defective
CMP sensor, or incorrect CMP sensor to timing disc clearance. Perform
CMP Sensor Circuit Test. See Fig. 43.
CODE 144 - ATA CODE SID 21 FMI 2; CMP SIGNAL NOISE DETECTED Possible causes for code 144 are poor ground connections, wire harness
shielding missing or incorrectly installed or outside components that
could induce voltage signals. Perform CMP Sensor Circuit Test. See
Fig. 43.
CODE 145 - ATA CODE SID 21 FMI 12; CMP SIGNAL INACTIVE WHILE
ICP HAS INCREASED - Possible causes for code 145 are defective sensor,
faulty circuitry or improper air gap between sensor and timing disc.
Perform CMP Sensor Circuit Test. See Fig. 43.
CODE 612 - ATA CODE SID 21 FMI 7; INCORRECT ECM INSTALLED FOR
CMP TIMING DISC - Possible causes for code 612 are ECM accidentally
replaced with incorrect ECM, incorrect signal due to defective CMP
sensor or incorrect CMP sensor to timing disc air gap. Perform CMP
Sensor Circuit Test. See Fig. 43.
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Fig. 43: Camshaft Position Sensor Circuit Test
Courtesy of Navistar International Corp.
Page 55 of 208
Personality Module (VPM) and the ECM. It is used to communicate
diagnostic and calibration data.
The ATA Diagnostic Programming Link signal is 0-5 volt width
wave form signal that enables communication between the Vehicle
Personality Module (VPM) and the Electronic Service Tool (EST). It is
used to communicate diagnostic, programming and calibration data.
The Tachometer signal is when the ECM provides the VPM with a
0-12 volt tachometer signal. The frequency of the signal is one-fifth
the RPM.
Fault Detection Management
The VPM and ECM can detect on a continuous basis an open,
short or intermittent connection on the DCL and ATA lines.
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the service tool does not power up when connected, try the tool on
another vehicle to check the tool operation. If the tool is okay,
perform Testing EST Connector. See Fig. 46. If the service tool
displays NO DATA, the ATA data link circuit from the EST connector on
the VPM may be disrupted. Verify that the key in ON and then perform
Testing ATA Data Link Circuits. See Fig. 47. Data Link fault codes are
as follows:
CODE 223 - ATA CODE SID 252 FMI 7; VPM NOT COMMUNICATING WITH
ECM - Perform Testing DCL Circuits. See Fig. 50.
CODE 231 - ATA CODE SID 250 FMI 2; ATA COMMON FAULT - Perform
Testing ATA Data Links. See Fig. 47.
CODE 232 - ATA CODE SID 250 FMI 9; UNABLE TO FORWARD ECM
MESSAGE TO ATA DCL - Perform Testing ATA Data Links. See Fig. 47.
CODE 234 - ATA CODE SID 248 FMI 9; UNABLE TO FORWARD ATA
MESSAGE TO ECM - Perform Testing DCL Circuits. See Fig. 50.
CODE 235 - ATA CODE SID 248 FMI 2; VPM/ECM DCL FAULT Perform Testing DCL Circuits. See Fig. 50.
CODE 633 - ATA CODE SID 252 FMI 7; ECM/VPM COMMON FAULT Perform Testing DCL Circuits. See Fig. 50.
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Fig. 50: Testing DCL Data Link Circuits (1 Of 2)
Courtesy of Navistar International Corp.
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Fig. 52: Exhaust Backpressure Sensor Connector Check Values
Courtesy of Navistar International Corp.
ECM Diagnostics
The ECM continuously monitors the signal from the EBP sensor
to ensure the signal is within the correct operating range. If the
signal is lower or higher than required, the ECM will set a fault
code. If the key is turned off, the code will be stored as an inactive
code. EBP fault codes are as follows:
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CODE 341 - ATA CODE SID 34 FMI 20: EBP SIGNAL OUT-OF-RANGE
LOW - Possible causes for code 341 are an open VREF signal circuit or
a defective EBP sensor.
CODE 342 - ATA CODE SID 34 FMI 19: EBP SIGNAL OUT-OF-RANGE
HIGH - Possible causes for code 342 are an open signal return circuit,
a short to a voltage source or a defective EBP sensor.
CODE 344 - ATA CODE SID 34 FMI 29: EXHAUST BACKPRESSURE BELOW
WARNING LEVEL - Code 344 may be caused by a defective or plugged EBP
sensor or a restriction in the tube leading to the sensor. To confirm
this, remove the sensor and/or tube and inspect for carbon deposits.
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Diagnostics
terminals Nos. 10 and 35 are directly involved with
crank inhibit relay. The ECM and VPM are programmed
for automatic and manual transmissions.
Page 68 of 208
ECM terminal No. 10 receives input (0 or 12 volts) from
either the clutch switch (man. trans.) or neutral position switch
(auto. trans.). The ECM uses the input to determine the voltage signal
on terminal No. 35.
ECM terminal No. 35 is connected by a circuit to crank
inhibit relay terminal No. 5. Based on inputs to terminal No. 10 and
engine operating conditions, the ECM either applies 0.1-0.6 volts or
12 volts to terminal No. 35. If lower voltage is applied, the inhibit
relay is enabled. If higher voltage is applied, the relay is not
enabled.
There are no fault codes or ECM diagnostics for this system.
When troubleshooting make sure battery is fully charged. Ensure all
connections are clean and tight. Inspect all harness connectors for
corrosion, damage, etc. Testing is divided into test charts shown in
the following illustrations.
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Fig. 58: Engine Does Not Crank Part 2A, Wiring Diagram
Courtesy of Navistar International Corp.
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Fig. 61: Engine Does Not Crank Part 2B, Wiring Diagram
Courtesy of Navistar International Corp.
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Fig. 64: Engine Does Not Crank Part 2C, Wiring Diagram
Courtesy of Navistar International Corp.
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turn ON. If the engine shutdown feature has been selected and the outof-range condition go beyond the critical level, the ECM will initiate
the shutdown process.
Fault Detection Management
There are no ECM Diagnostics for this system. Flash Code 323
will be active when a low coolant condition is present and the PROLINK will indicate COOLANT LOW. After the coolant has been refilled,
code 323 will remain as an inactive code and the ECM will log the
engine hours of the occurrence. If the PRO-LINK indicates COOLANT LOW,
perform Testing For False Low Coolant Signal. See Figs. 74 and 75. If
the PRO-LINK indicates COOLANT FULL, perform Testing For False Full
Coolant Signal. See Figs. 76 and 77.
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ECM SELF-DIAGNOSTICS
Signal Functions
The ECM monitors and controls engine operation and
performance, vehicle features such a PTO and cruise control,
communicates information to the VPM and Injector Driver Module (IDM).
Fault Detection Management
The ECM is capable of internal fault detection and depending
upon the severity of the problem, can provide fault management
strategies to allow limited engine/vehicle operation.
ECM Diagnostics
During normal engine operation, the ECM automatically
performs several tests to detect faults. During normal operation the
ECM performs Start-Up KAM test and Continuous Diagnostics. The StartUp KAM test is used to validate the ECM keep alive memory once each
time the ECM resets. If an error is detected, codes 224 or 615 can be
set.
CODE 615 - ATA CODE SID 254 FMI 13: PROGRAMMABLE PARAMETER
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KAM CORRUPT -FAULT
- Code
615 can T444E
be setELEC
when ENG
code CTRL)Article
224 is set. If
224
is set, see KEEP ALIVE MEMORY POWER . If code 224 is not set, the ECM
RAM is effective. Replace ECM.
Continuous diagnostics are made by the ECM during vehicle
operation. Codes 112 and 113 may be set during this procedure. If
codes 112 and/or 113 are present, see ECM POWER SUPPLY .
Use the PRO-LINK EST to perform ECM internal self-tests. This
test may set the following codes:
Page 94 of 208
CODE 111 - ATA CODE PID 194 FMI 0: NO ERRORS DETECTED - Code
111 indicates the ECM has not found any errors.
CODE 625 - ATA CODE SID 254 FMI 9: ECM INACTIVE BACKGROUND Code 625 indicates the ECM software is faulty. Replace the ECM.
CODE 631 - ATA CODE SID 240 FMI 2: ROM TEST FAULT - If code
631 is present, replace the ECM.
CODE 632 - ATA CODE SID 254 FMI 12: RAM/CPU TEST FAULT - If
code 632 is present, replace the ECM.
During the ECM Output Circuit Check the following codes may
appear:
CODE 254 - ATA CODE SID 254 FMI 3: OCC ORH - If code 254 is
present, replace the ECM.
CODE 255 - ATA CODE SID 254 FMI 4: OCC ORL - If code 255 is
present, replace the ECM.
TESTING
ECM/IDM COMMUNICATIONS
Signal Functions
The Cylinder Identification (CI) signal is a 0 to 12 volt
wave form signal that communicates from the ECM to the Injector Driver
Module (IDM) the position of cylinder No. 1. The IDM uses this signal
to synchronize injector firing sequence.
The Fuel Demand Command (FDCS) signal is a 0 to 12 volt wave
form signal that communicates from the ECM to the Injector Driver
Module (IDM) the required engine timing and duration of injector
firing.
The IDM feedback signal is a 0 to 12 volt wave form signal
that communicates from the IDM to the ECM a mirror image of the FDCS
signal. Extensions of this signal can indicate to the ECM possible
problems with the injectors by the IDM as the engine is running.
Fault Detection Management
An intermittent or open or short to ground in the CI circuit
can be detected by the IDM through IDM Stuck High or Low Codes (531 &
532). Active faults can be detected by an on demand output circuit
check during Engine Off tests. The engine will not operate without an
active cylinder identification circuit.
Active faults in the fuel demand command circuit can be
detected by an on demand output circuit check during Engine Off tests.
The engine will not operate without an active fuel demand command
circuit.
Active faults in the IDM feedback circuit can be detected by
toggle sequence that the ECM looks for on start up. The WARN light
will be on if this is detected. IDM diagnostic fault codes will not be
transmitted if the EF line is not functioning. The engine will operate
normally.
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is running. When it detects a fault sent from the IDM, it will log the
transfer. It will be necessary to perform an Engine Off Standard test
to determine most fault codes stored in the IDM. The ECM continually
measures the communication signal voltage levels. If levels are lower
or higher than expected, a fault code will be set to identify the
circuit or component. The fault will automatically recorded as an
active code. If the key is turned off, the code will be stored as
inactive. The following codes may be set by the ECM/IDM:
CODE 242 - ATA CODE SID 154 FMI 11: FDCS CIRCUIT TO IDM OCC
SELF-TEST FAILED - Code 242 may be caused by a shorted high or low or
open FDCS circuit. If accompanied by other communication codes could
indicate the IDM is not powered up. The fault must be repaired for the
engine to operate.
CODE 253 - ATA CODE SID 153 FMI 11: FUEL INJ SYNC CIRCUIT OCC
SELF-TEST FAILED - Code 253 may be caused by a shorted high or low or
open CI circuit. If accompanied by other communication codes could
indicate the IDM is not powered up. The fault must be repaired for the
engine to operate.
CODE 531 - ATA CODE SID 153 FMI 4: FUEL INJ SYNC SIGNAL LOW Code 531 may be caused by a short to ground in the CI circuit. The
fault must be repaired for the engine to operate.
CODE 532 - ATA CODE SID 153 FMI 3: FUEL INJ SYNC SIGNAL HIGH
- Code 532 may be caused by a short to voltage or an open in the CI
circuit. The fault must be repaired for the engine to operate.
CODE 541 - ATA CODE SID 155 FMI 11: IDM FEEDBACK TOGGLE NOT
DETECTED BY ECM - Code 541 may be caused by a short or open EF circuit
if this is the only code present. If other IDM codes are present the
IDM may not be powered or operational. If displayed during an Engine
Off Standard test it will be accompanied by code 543. This code may
set due to other faults in the ECM due to a reset condition. If other
codes are present, repair them first in the order of importance for
engine operation. This code will not prevent the engine from
operating.
CODE 543 - ATA CODE SID 155 FMI 7: IDM FAULTS NOT RECEIVED Code 543 may be caused by a shorts or opens in the IDM/ECM
communications circuits or an IDM not powered. If other codes are
present, repair them first in the order of importance for engine
operation. This code will not prevent the engine from operating.
Also see Figs. 80 and 81 for further diagnostic information.
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ENGINE -COOLANT
TEMPERATURE
SENSOR
Signal Functions
The Engine Coolant Temperature Sensor (ECT) is a thermistor
type that has a variable resistance that changes when exposed to
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ENGINE DATA LINE WITH ALLISON TRANSMISSIONS
Signal Functions
The ECM is programmed with 2 shift schedules: Closed Throttle
Mode and Wide Open Throttle Mode. Closed throttle is used for moderate
engine loads. ECM terminal No. 32 will be 0 volts. This energizes the
relay, turning off power to the solenoid, causing the transmission to
shift at about 65 percent of engine load. The wide open throttle mode
is for heavy load conditions. ECM terminal No. 32 will be at 12 volts.
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ECM Diagnostics
The ECM continuously monitors the signal from the EOP sensor.
If the signal is higher or lower than expected, a fault code will be
set. The following fault codes may be set:
CODE 211 - ATA CODE PID 100 FMI 4: ENGINE OIL PRESS SIGNAL
OUT-OF-RANGE LOW - Code 211 may be set if the ECM detects a voltage
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ECM Diagnostics
The
ECM continuously
monitors
the signal
from the EOT Text
sensor.
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If the signal is higher or lower than expected, a fault code will be
set. The following fault codes may be set:
CODE 311 - ATA CODE PID 175 FMI 4: ENGINE OIL TEMP SIGNAL
OUT-OF-RANGE LOW - Code 311 may be set if the ECM detects a voltage
less than 0.20 volts for more than .10 seconds. The ECM will default
to a fixed value for engine operation. The ECM will turn on the Engine
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INJECTION
CONTROL
PRESSURE
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Signal Functions
The Injection Control Pressure (ICP) sensor is a variable
capacitance sensor that when supplied with a 5 volt reference signal
from the ECM produces a linear analog voltage signal that indicates
pressure. The ICP function is to provide a feedback signal to indicate
injection control pressure to enable the ECM to command the correct
Fig. 107:
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Signal Functions
There are two injector drive circuits, the High Side and the
Low Side. The High Side drive output function is to supply the
injectors a 115 volt DC power supply at a maximum of 10 amps. The
power supply is available on a continuous basis. The Low Side drive
outputs
control
the injector
on time
timing (in
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ELECquantity),
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Text (p. 143)For cyph8r pacific la ca 92101 1996 Mi
relation to TDC) and sequencing (firing order).
The IDM fires each individual injector by completing the
ground circuit to each injector solenoid. A valid Cylinder
Identification (CI) and Fuel Demand Command Signal (FDCS) must be sent
from the ECM to the IDM before an injector will be allowed to be
fired.
Fault Detection Management
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CODES 421 THRU 428 - ATA CODE SID 1 THRU 8 FMI 5: HIGH SIDE
TO LOW SIDE OPEN - Codes for High Side to Low Side Open indicate an
open circuit between the IDM high side driver and low side driver.
Possible causes are an open wire in the injector harness, open
injector return circuit or injector solenoid.
CODES 431 THRU 438 - ATA CODE SID 1 THRU 8 FMI 4: HIGH SIDE
SHORTED TO LOW SIDE - Codes for High Side to Low Side Short indicate
the return voltage is too high due to a short circuit between the high
side driver and return circuit. Possible causes are a shorted injector
solenoid or wiring harness.
CODES 441 THRU 448 - ATA CODE SID 1 THRU 8 FMI 3: LOW SIDE
SHORTED TO B+ - Low Side Shorted to battery power indicates the IDM
has detected continuous battery voltage on the signal return circuit.
A short circuit in the injector wiring harness will set these codes.
CODES 451 THRU 458 - ATA CODE SID 1 THRU 8 FMI 6: LOW SIDE
SHORTED TO GROUND - Low Side Shorted to ground indicates the return
circuit shorted to ground. A shorted injector solenoid or wiring
harness to ground will set these codes.
CODE 511 - ATA CODE SID 151 FMI 11: BANK 1 HAS MULTIPLE
FAULTS - Multiple faults indicate more than 1 fault was detected by
the IDM such as an open and a short in cylinder Nos. 1, 3, 5 and 7.
With code 511 active, the IDM will disable the opposite bank drivers.
CODE 512 - ATA CODE SID 152 FMI 11: BANK 2 HAS MULTIPLE
FAULTS - Multiple faults indicate more than 1 fault was detected by
the IDM such as an open and a short in cylinder Nos. 2, 4, 6 and 8.
With code 512 active, the IDM will disable the opposite bank drivers.
CODE 513 - ATA CODE SID 151 FMI 5: HIGH SIDE OPEN, RIGHT
GROUP - High side open indicates the IDM has detected an open circuit
to injectors on cylinder Nos. 1, 3, 5 and 7. With code 513 active, the
IDM will compensate for misfire to keep the engine operating and will
light the Engine Warning Light.
CODE 514 - ATA CODE SID 152 FMI 5: HIGH SIDE OPEN, LEFT GROUP
- High side open indicates the IDM has detected an open circuit to
injectors on cylinder Nos. 2, 4, 6 and 8. With code 514 active, the
IDM will compensate for misfire to keep the engine operating and will
light the Engine Warning Light.
CODE 515 - ATA CODE SID 151 FMI 6: HIGH SIDE BANK 1 SHORT TO
GROUND OR B+ - Code 515 indicates the IDM has detected excessive
current draw on cylinder Nos. 1, 3, 5 and 7. With code 515 active, the
IDM will compensate for misfire to keep the engine operating and will
light the Engine Warning Light.
CODE 521 - ATA CODE SID 152 FMI 6: HIGH SIDE BANK 2 SHORT TO
GROUND OR B+ - Code 521 indicates the IDM has detected excessive
current draw on cylinder Nos. 2, 4, 6 and 8. With code 521 active, the
IDM will compensate for misfire to keep the engine operating and
will
EMISSIONS
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The engine will not operate with an IPR circuit that is not
functioning.
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Fig. 121: Injection Control Pressure Regulator Circuit Wiring Diagram
Courtesy of Navistar International Corp.
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ECM Diagnostics
During normal operation the ECM performs certain tests. When
the ignition is ON, the ECM performs the Start-Up KAM test to test its
Keep Alive memory. This test is performed once each time the key is
turned on or when the ECM resets. The ECM performs a test to determine
if the memory is working properly, but a lack of battery power to ECM
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MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
Signal Functions
The MAP sensor is a variable capacitance sensor which
operates on a 5 volt reference signal from the ECM to produce a
digital frequency that indicates pressure. The MAP signal is used to
control smoke by limiting fuel quantity during acceleration until a
specified boost pressure is obtained. The MAP also optimizes injection
timing for boost pressure measured.
Fault Detection Management
A MAP signal that is detected by the ECM to be out-of-range
or at an incorrect value for specific conditions will cause the ECM to
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Fig. 129: Accelerator, MAP & BARO Sensor Circuits Wiring Diagram
Courtesy of Navistar International Corp.
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Fig. 135: Testing Speed Control Command Switches (1 Of 4)
Courtesy of Navistar International Corp.
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Fig. 140: Testing Remote PTO Preset & Variable Enable Circuits
(1 Of 2)
Courtesy of Navistar International Corp.
Fig. 141: Testing Remote PTO Preset & Variable Enable Circuits
(2 Of 2)
Courtesy of Navistar International Corp.
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Signal Functions
The Self-Test Input (STI) switch (or PRO-LINK EST) can be
used to run Key On Engine Off (KOEO) Standard tests. Faults detected
during this test result in active fault codes which are flashed
through the Engine Warning Light. If no codes are present, code 111
will flash, indicating no codes are present. ECM terminal No. 48 has 5
volts with the key ON and engine off. Depressing the STI switch
grounds terminal No. 48, causing it to change from 5 volts to 0 volts,
signaling the ECM to start the KOEO Standard test.
When the key is turned ON, the Engine Warning Light (EWL)
turns on and remains on while the ECM runs normal start up tests, and
then turns off. If the ECM detects a problem, the light remains on.
Ignition power from fuse No. F6 (fuse No. A2 with FBC) is applied to
the EWL. The ground side of the EWL is connected to ECM terminal No.
17, which is a ground switch. The ECM applies 12 volts to terminal No.
17 (light off) or 0 volts (light on), in response to engine
1996 Mi
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Fault Detection Management
There are no ECM diagnostics for the STI or EWL circuits.
Fig. 144: Self-Test Input & Engine Warning Light Connector Checks
Courtesy of Navistar International Corp.
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Fig. 145: Self-Test Input & Engine Warning Light Wiring Diagram
Courtesy of Navistar International Corp.
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ECM Diagnostics
If the Camshaft Position (CMP) signal is not received and
processed by the ECM, the engine will not start. If the engine is
running, but the tachometer does not operate, the problem could be in
the speedometer/tachometer unit. An open or high or low short circuit
condition in the tachometer buffer circuit may also cause the problem.
The only fault code set for the tachometer circuit is code 233.
CODE 233 - ATA CODE PID 190 FMI 2: VPM: TACHOMETER BUFFER
INOPERATIVE - This code is set during the Key On Engine Running Tach
Buffer test if engine speed is less than 1250 RPM, circuit 97D is open
or shorted between
the
ECM and VPM
or if
the ENG
VPM internal
buffering
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circuit is defective. Perform the appropriate tachometer testing to
isolate the problem.
See Figs. 151 through 153.
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Fig. 154: Two Speed Electric (Air) Axle Circuit Wiring Diagram
Courtesy of Navistar International Corp.
EMISSIONS - DIESEL (NAVISTAR T444E ELEC ENG CTRL)Article Text (p. 192)For cyph8r pacific la ca 92101 1996 Mi
Fig. 155: Two Speed Electric (Hydraulic) Axle Circuit Wiring Diagram
Courtesy of Navistar International Corp.
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END OF ARTICLE
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