Section 10 Chapter 24 - dmcpubs.com 10 Chapter 24 7-92610NH 24 Valve, ... Fault Code 381 or 382 ... SID(S): P190 SPN: 190 FMI: 2 Lamp: Yellow

Section 10 Chapter 24

7-92610NH

24 Valve, 8.3 Liter Engine

Fuel System Troubleshooting And Repair

Troubleshooting Fault Codes

Note: All coding used in the 8.3 Liter and 9 Liter engine manuals are Cummins engine codes. These engine codes have no meaning to New Holland warranty codes and should only be used for procedure

steps.

24 Valve, 8.3 Liter Engine Fault CodeTroubleshooting Fault Codes Page a

7-92610NH Section 10 Chapter 24 Issued 8-2001

Troubleshooting Fault Codes

Contents

Fault Code 111 ........................................................................................................................................................................................... 1ECM Microprocessor ................................................................................................................................................................................... 1

Fault Code 115 ........................................................................................................................................................................................... 4Engine Speed Sensor (ESS) Circuit ............................................................................................................................................................ 4

Fault Code 121 ......................................................................................................................................................................................... 15Engine Position Sensor (EPS) Circuit ........................................................................................................................................................ 15

Fault Code 122 or 123 .............................................................................................................................................................................. 25Intake Manifold Pressure Sensor Circuit .................................................................................................................................................... 25

Fault Code 124 ......................................................................................................................................................................................... 36Intake Manifold Pressure Sensor Circuit .................................................................................................................................................... 36

Fault Code 131 or 132 .............................................................................................................................................................................. 39Accelerator Position Sensor Circuit ........................................................................................................................................................... 39

Fault Code 135 or 141 .............................................................................................................................................................................. 54Oil Pressure Sensor Circuit ........................................................................................................................................................................ 54

Fault Code 143 ......................................................................................................................................................................................... 64Oil Pressure Sensor Circuit ........................................................................................................................................................................ 64

Fault Code 144 or 145 .............................................................................................................................................................................. 67Coolant Temperature Sensor Circuit ......................................................................................................................................................... 67

Fault Code 146 ......................................................................................................................................................................................... 77Coolant Temperature Sensor Circuit ......................................................................................................................................................... 77

Fault Code 151 ......................................................................................................................................................................................... 80Coolant Temperature Sensor Circuit ......................................................................................................................................................... 80

Fault Code 153 or 154 .............................................................................................................................................................................. 83Intake Manifold Air Temperature Sensor Circuit ........................................................................................................................................ 83

Fault Code 155 ......................................................................................................................................................................................... 94Intake Manifold Air Temperature Sensor Circuit ........................................................................................................................................ 94

Fault Code 221 or 222 .............................................................................................................................................................................. 97Ambient Air Pressure Sensor Circuit ......................................................................................................................................................... 97

Fault Code 234 ....................................................................................................................................................................................... 108Engine Overspeed Circuit ........................................................................................................................................................................ 108

Fault Code 235 ....................................................................................................................................................................................... 114Engine Coolant Level - Engine Protection ............................................................................................................................................... 114

Fault Code 263 or 265 ............................................................................................................................................................................ 120

Fault Code 24 Valve, 8.3 Liter EnginePage b Troubleshooting Fault Codes


Fuel Temperature Sensor Circuit ..............................................................................................................................................................120

Fault Code 268 ........................................................................................................................................................................................129Fuel Pressure Sensor Circuit ....................................................................................................................................................................129

Fault Code 271 or 272 .............................................................................................................................................................................132Front Pumping Valve Circuit .....................................................................................................................................................................132

Fault Code 273 or 274 .............................................................................................................................................................................142Rear Pumping Valve Circuit ......................................................................................................................................................................142

Fault Code 275 ........................................................................................................................................................................................152Front Pumping Element of the CAPS Fuel Pump .....................................................................................................................................152

Fault Code 276 or 279 .............................................................................................................................................................................155Injection Control Valve Circuit ...................................................................................................................................................................155

Fault Code 277 ........................................................................................................................................................................................164Injection Control Valve ..............................................................................................................................................................................164

Fault Code 278 ........................................................................................................................................................................................167Lift Pump Circuit .......................................................................................................................................................................................167

Fault Code 281 or 282 .............................................................................................................................................................................176Pumping Element .....................................................................................................................................................................................176

Fault Code 283 or 284 .............................................................................................................................................................................179Engine Speed Sensor ...............................................................................................................................................................................179

Fault Code 328 ........................................................................................................................................................................................189Rear Pumping Element .............................................................................................................................................................................189

Fault Code 329 ........................................................................................................................................................................................192CAPS Injection Pump ...............................................................................................................................................................................192

Fault Code 352 or 386 .............................................................................................................................................................................195Sensor Supply Circuit ...............................................................................................................................................................................195

Fault Code 381 or 382..............................................................................................................................................................................201Intake Air Heater Relay Circuit ..................................................................................................................................................................201

Fault Code 385 or 444 .............................................................................................................................................................................208Remote Accelerator Control Circuit ..........................................................................................................................................................208

Fault Code 387 or 443 .............................................................................................................................................................................218Accelerator Position Sensor Circuit ..........................................................................................................................................................218

Fault Code 415 ........................................................................................................................................................................................228Oil Pressure Sensor Circuit ......................................................................................................................................................................228

Fault Code 418 ........................................................................................................................................................................................231WIF Sensor Circuit ....................................................................................................................................................................................231

Fault Code 422 ........................................................................................................................................................................................234

24 Valve, 8.3 Liter Engine Fault CodeTroubleshooting Fault Codes Page c


Coolant Level Sensor Circuit ................................................................................................................................................................... 234

Fault Code 429 ................................................................................................................................................................................... 246WIF Sensor Circuit ............................................................................................................................................................................... 246

Fault Code 431 or 551 ........................................................................................................................................................................ 253Idle Validation Switch Circuit ................................................................................................................................................................ 253

Fault Code 432 ................................................................................................................................................................................... 265Accelerator Pedal Circuit ..................................................................................................................................................................... 265

Fault Code 433 ................................................................................................................................................................................... 279Intake Manifold Pressure Sensor Circuit .............................................................................................................................................. 279

Fault Code 434 ................................................................................................................................................................................... 287Unswitched Battery Supply Circuit ....................................................................................................................................................... 287



Fault Code 449 ................................................................................................................................................................................... 314Fuel Pressure Sensor Circuit ............................................................................................................................................................... 314

Fault Code 451 or 452 ........................................................................................................................................................................ 317Fuel Pressure Sensor Circuit ............................................................................................................................................................... 317

Fault Code 488 ................................................................................................................................................................................... 327Intake Manifold Air Temperature Sensor Circuit .................................................................................................................................. 327

Fault Code 515 or 516 ............................................................................................................................................................................ 330Coolant Level Sensor Circuit ................................................................................................................................................................... 330

Fault Code 24 Valve, 8.3 Liter EnginePage d Troubleshooting Fault Codes


THIS PAGE LEFT BLANK

24 Valve, 8.3 Liter Engine Fault Code 111Troubleshooting Fault Codes Page 1


Fault Code 111

ECM Microprocessor

Circuit Description:The ECM is a computer that is responsible for engine control, diagnostics and user features.

Component Location:The ECM is located on the left side of the engine block, behind the fuel filter.

Shop Talk:This fault code can be caused only by an internal ECM problem. Repairs are not possible for the ECM.

Electronic Control Module (ECM) Microprocessor CODES REASON EFFECT

Fault Code: 111PID(P), SID (S): S254SPN:FMI: 12Lamp: Yellow

ECM internal hardware error. Possible no effect or engine may run rough or not start.

Fault Code 111 24 Valve, 8.3 Liter EnginePage 2 Troubleshooting Fault Codes


TROUBLESHOOTING SUMMARY

� CAUTION��To avoid damaging a new ECM, all other active fault codes must be investigated prior to replacing the ECM.

TROUBLESHOOTING STEP

STEPS SPECIFICATIONS SRT CODE

STEP 1: Check the fault codes. STEP 1A: Read the fault codes. Fault Code 111 inactive.

STEP 1B: Check the inactive counts of Fault Code 111.

Fault is inactive and no performance related complaints are associated with this fault

STEP 2: Clear the fault codes. STEP 2A: Disable the fault code. Fault Code 111 inactive STEP 2B: Clear the inactive fault codes. All faults cleared

STEP 1: Check the fault codes. STEP 1A: Read the fault codes.

��CAUTION �To avoid damaging a new ECM, all other active fault codes must be investigated prior to replacing the ECM.Condition:• Key switch in the “ON” position.

Action Specification/Repair Next StepRead the fault codes.• Read the fault codes using an electronic

service tool

OKFault Code 111 Inactive

1B

NOT OKReplace the ECMRefer to Procedure 019-031.

2A

STEP 1B: Check the inactive counts of Fault Code 111.� CAUTION��

To avoid damaging a new ECM, all other active fault codes must be investigated prior to replacing the ECM. Condition:• Key switch in the "ON" position.

Action Specifications/Repair Next StepCheck the inactive counts of Fault Code 111.• Read the inactive counts of Fault Code 111

using an electronic service tool

OKLess than 3 counts

2A


2A



STEP 2: Clear the fault codes. STEP 2A: Disable the fault code. Condition: • Connect all components.

Action Specifications/Repair Next StepDisable the fault code.• Start the engine and let idle for one minute. • Verify that Fault Code 111 is inactive.

OKFault Code 111 inactive

2B

NOT OKReturn to the troubleshooting steps or contact the Techni-cal Services Group (if all the steps have been completed and checked again).

1A

STEP 2B: Clear the inactive fault codes.Condition: • Connect all components.

Action Specifications/Repair Next StepClear the inactive fault codes.• Erase the inactive fault code using an elec-

tronic service tool.

OKAll fault codes cleared

Repair complete

NOT OKTroubleshoot any remaining active fault codes.

Appropriate troubleshooting chart



Fault Code 115

Engine Speed Sensor (ESS) Circuit

Circuit Description:The engine speed/position sensor provides engine speed and position information to the electronic control module (ECM). The sensor must be powered by 5 VDC to operate. The sensor generates it's signals by sensing the movement of target teeth cut into a steel ring fastened to the backside of the cam gear. This ring has 71 teeth and a gap where the 72nd tooth would be placed. This missing tooth indicates that cylinder 1 (and 6) is at top dead center.

Component Location:The engine speed/position sensor is located on the back side of the gear housing, between the fuel injection pump and the air compressor.

Engine Speed Sensor (ESS) Circuit 115CODES REASON EFFECT

Fault Code: 115PID(P), SID(S): P190SPN: 190FMI: 2 Lamp: Yellow

No engine speed or position signal detected at pin 17 of the engine harness.

Engine power derate. Possible white smoke.



TROUBLESHOOTING SUMMARY� CAUTION��

To avoid damaging a new ECM, all other active fault codes must be investigated prior to replacing the ECM.

� CAUTION��To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead.

STEPS SPECIFICATIONS SRT CODESTEP 1: Check the engine harness. STEP 1A: Inspect the engine harness and the ECM connectors.

No damaged pins

STEP 1B: Check for an open circuit. Less than 10 ohms STEP 1C: Check for short circuit to ground.

More than 100k ohms

STEP 1D: Check for a short circuit from pin to pin.

More than 100k ohms

STEP 2: Check the ESS. STEP 2A: Inspect the ESS and engine harness connectors.

No damaged pins

STEP 2B: Check ESS supply voltage. 4.5 to 5.25 VDC STEP 2C: Check for signal from the ESS.

Signal present

STEP 2D: Inspect nose of sensor. No damage or debrisSTEP 3: Clear the fault codes. STEP 3A: Disable the fault codes. Fault Code 115 inactive STEP 3B: Clear the inactive fault codes.

All fault codes cleared




STEP 1: Check the engine harness. STEP 1A: Inspect the engine harness and the ECM connectors.

� CAUTION �To avoid damaging a new ECM, all other active fault codes must be investigated prior to replacing the ECM.Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the ECM.

Action Specifications/Repair Next StepInspect the engine harness and the ECM con-nector pins for:• bent or broken pins • pushed back or expanded pins• corroded pins• moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

1B

NOT OKRepair the damaged pinsRepair or replace the engine harness or ECM, whichever has the damaged pins • Repair the engine harness. • Replace engine harness. Refer to Procedure 019-

043. • Replace ECM. Refer to Procedure 019-031.

3A



STEP 1B: Check for an open circuit. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead. Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the ECM. • Disconnect the engine harness from the ESS.

Action Specifications/Repair Next StepCheck for an open circuit in the +5 VDC supply wire and the signal wire.• Measure the resistance from pin 8 of the

engine harness connector to pin A on the harness side of the ESS connector.

• Measure the resistance from pin 17 of the engine harness connector to pin C on the harness side of the ESS connector.

OKLess than 10 ohms

1C

NOT OKReplace the engine harnessRefer to Procedure 019-043.

3A



STEP 1C: Check for a short circuit to ground.� CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement: Tool No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead. Conditions:• Key switch in the "OFF" position. • Disconnect the engine harness from the ECM. • Disconnect the engine harness from the ESS.

Action Specifications/Repair Next StepCheck for a short circuit to ground in the +5 VDC supply wire and the signal wire.• Measure the resistance from pin 8 of the

engine harness connector to engine block ground.

• Measure the resistance from pin 17 of the engine harness connector to engine block ground.

OKMore than 100k ohms

1D


3A



STEP 1D: Check for a short circuit from pin to pin. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead.Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the ECM. • Disconnect the engine harness from the ESS.

Action Specifications/Repair Next StepCheck for a short circuit from pin to pin in the +5 VDC supply wire and the signal wire.• Measure resistance from pin 8 and 17 of

the engine harness connector to all other pins in the connector.


2A


3A



STEP 2: Check the ESS. STEP 2A: Inspect the ESS and the engine harness connectors.Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the ESS. • Connect the engine harness to the ECM.

Action Specifications/Repair Next StepInspect the ESS and the engine harness con-nector pins for:"• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

2B

NOT OKRepair the damaged pinsRepair or replace the engine harness or sensor, whichever has the damaged pins • Repair the engine harness. • Replace the engine harness. Refer to Procedure 019-

043. • Replace the ESS. Refer to Procedure 019-042.

3A



STEP 2B: Check ESS supply voltage.� CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3823996 - female Weather-Pack test lead.Condition:• Key switch in the "ON" position. • Disconnect the engine harness from the ESS. • Connect the engine harness to the ECM.

Action Specifications/Repair Next StepCheck ESS supply voltage.• Measure the voltage from pin A to pin B on

the harness side of the ESS connector.

OK4.5 to 5.25 VDC

2C

NOT OKReplace the ECMRefer to Procedure 019-031

3A



STEP 2C: Check for signal from the ESS. Condition:• Key switch in the "ON" position. • Install breakout cable, Tool No. 3824775, between the ESS and the engine harness.

Action Specifications/Repair Next StepCheck for signal from the ESS.• Measure the voltage from pin C to pin B on

the breakout cable while barring the engine over.

OKSignal Present

2D

NOT OKReplace the ESSRefer to Procedure 019-042.



STEP 2D: Inspect the nose of sensor.Condition: • Key in the “OFF” position • Remove sensor from engine.

Action Specifications/Repair Next StepInspect nose of sensor for damage or debris.• Inspect for metal debris on sensor tip. • Inspect for damage on sensor caused by

camshaft gear. • Inspect for sensor swelling.

OKNo damage found

3A

NOT OK Replace the Engine Speed Sensor Refer to Procedure 019-042.

3A

STEP 3: Clear the fault codes. STEP 3A: Disable the fault codes. Condition:• Connect all the components. • Key switch in the “ON” position.

Action Specifications/Repair Next StepDisable the fault codes.• Start the engine and let idle for one minute.• Using an electronic service tool, verify Fault

Code 115 is inactive.


3B


1A



STEP 3B: Clear the inactive fault codes. Condition: • Connect all the components. • Key switch in the “ON” position.

Action Specification/Repair Next StepClear the inactive fault codes. • Erase the inactive fault codes using an

electronic service tool.

OK All fault codes cleared

Repair complete

NOT OK Troubleshoot any remaining active fault codes.

Appropriate troubleshooting charts



Fault Code 121

Engine Position Sensor (EPS) Circuit

Circuit Description:The engine position sensor provides engine position information to the electronic control module (ECM). The sensor must be pow-ered by 5 VDC to operate. The sensor generates it's signals by sensing the movement of target teeth cut into a steel ring fastened to the backside of the cam gear. This ring has 71 teeth and a gap where the 72nd tooth would be placed. This missing tooth indi-cates that cylinder 1 (and 6) is at top dead center.

Component Location:The engine position sensor is located on the back side of the gear housing, between the fuel injection pump and the air compres-sor.

Engine Position Sensor (EPS) CircuitCODES REASON EFFECT

Fault Code: 121 PID(P), SID(S) P190SPN: 190 FMI: 2 Lamp: Yellow

No engine speed or position signal detected at pin 9 of the engine harness.

No engine speed and position backup for main speed/position sensor.



TROUBLESHOOTING SUMMARY� CAUTION��


� CAUTION��To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead.




No damaged pins

STEP 1B: Check for an open circuit. Less than 10 ohms STEP 1C: Check for short circuit to ground. More than 100k ohms STEP 1D: Check for a short circuit from pin to pin. More than 100k ohms STEP 2: Check the EPS. STEP 2A: Inspect the EPS and engine harness connectors.

No damaged pins

STEP 2B: Check EPS supply voltage. 4.5 to 5.25 VDC STEP 2C: Check for signal from the EPS. Signal present STEP 2D: Inspect the nose of sensor. No damage or debrisSTEP 3: Clear the fault codes. STEP 3A: Disable the fault codes. Fault Code 121 inactive STEP 3B: Clear the inactive fault codes. All fault codes cleared



Action Specifications/Repair Next StepInspect the engine harness and the ECM con-nector pins for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seal.

OKNo damaged pins

1B

NOT OKRepair the damaged pinsRepair or replace the engine harness or ECM, whichever has the damaged pins. • Repair the engine harness. • Replace the engine harness. Refer to Procedure 019-

043.• Replace ECM. Refer to Procedure 019-031.

3A




To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead. Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the ECM. • Disconnect the engine harness from the EPS.


engine harness connector to pin C on the harness side of the EPS connector.

• Measure the resistance from pin 10 of the engine harness connector to pin A on the harness side of the EPS connector.

OKLess than 10 ohms

1C


3A



STEP 1C: Check for a short circuit to ground.� CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead.Conditions:• Key switch in the "OFF" position. • Disconnect the engine harness from the ECM. • Disconnect the engine harness from the EPS.





1D


3A




To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead. Condition: • Key switch in the "OFF" position. • Disconnect the engine harness from the ECM. • Disconnect the engine harness from the EPS.

Action Specifications/Repair Next StepCheck for a short circuit from pin to pin in the +5 VDC supply wire and the signal wire.• Measure resistance from pin 9 and 10 of

the engine harness connector to all other pins in the connector.


2A


3A



STEP 2: Check the EPS. STEP 2A: Inspect the EPS and the engine harness connectors. Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the EPS. • Connect the engine harness to the ECM.

Action Specifications/Repair Next StepInspect the EPS and the engine harness con-nector pins for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals

OKNo damaged pins

2B

NOT OKRepair the damaged pinsRepair or replace the engine harness or sensor, whichever has the damaged pins • Repair the engine harness. • Replace the engine harness. Refer to Procedure 019-

043. • Replace the EPS. Refer to Procedure 019-038.

3A



STEP 2B: Check EPS supply voltage. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead.Condition: • Key switch in the "ON" position. • Disconnect the engine harness from the EPS. • Connect the engine harness to the ECM.

Action Specifications/Repair Next StepCheck EPS supply voltage. • Measure the voltage from pin A to pin B on

the harness side of the EPS connector.

OK4.5 to 5.25 VDC

2C


3A



STEP 2C: Check for signal from the EPS.Condition:• Key switch in the "ON" position. • Install breakout cable, Tool No. 3824775, between the EPS and the engine harness.

Action Specifications/Repair Next StepCheck for signal from the EPS.• Measure the voltage from pin C to pin B on

the breakout cable while barring the engine over.

OKSignal present

2D

NOT OKReplace the EPSRefer to Procedure 019-038.

3A



STEP 2D: Inspect the nose of sensor.Condition:• Key in the “OFF” position • Remove sensor from engine.

Action Specifications/Repair Next StepInspect nose of sensor for damage or debris.• Inspect for metal debris on sensor tip.• Inspect for damage on sensor caused by

camshaft gear. • Inspect for sensor swelling.

OKNo damage found

3A

NOT OKReplace the Engine Speed SensorRefer to Procedure 019-042.

3A

STEP 3: Clear the fault codes. STEP 3A: Disable the fault codes.Condition: • Connect all the components. • Key switch in the “ON” position.

Action Specifications/Repair Next StepDisable the fault codes.• Start the engine and let idle for one minute. • Using an electronic service tool, verify Fault



3B


1A



STEP 3B: Clear the inactive fault codes.Condition:• Connect all the components. • Key switch in the “ON” position.

Action Specifications/Repair Next StepClear the inactive fault codes.• Erase the inactive fault codes using an



Repair complete


Appropriate trou-ble-shooting charts

24 Valve, 8.3 Liter Engine Fault Code 122 or 123Troubleshooting Fault Codes Page 25


Fault Code 122 or 123

Intake Manifold Pressure Sensor Circuit

Circuit Description: The intake manifold pressure sensor monitors intake manifold pressure and passes information to the electronic control module (ECM) through the sensor harness. If the intake manifold pressure becomes too high it will cause a derate condition.

Component Location: The intake manifold pressure sensor is located on the rear of the intake air manifold in the second port on the side of the head to the right of the fuel filter.

Shop Talk:• Determine if engine is being over-fueled.• Confirm that the correct intake manifold pressure sensor part number is being used.• Confirm that the correct turbocharger is being used.• If it is suspected that cold intake air is the cause of the high intake manifold pressure, test the engine with warm intake air.• Inspect the intake manifold pressure sensor circuit for signs of tampering. Remove any extra wires from the circuit.• Check for high restriction in the intake air manifold due to a shutdown device in the manifold (if the vehicle is equipped with

one). Do not remove this device. If the engine is operated in a flammable atmosphere, the device is an essential safety fea-ture.

Intake Manifold Pressure Sensor Circuit 122 or 123CODES REASON EFFECT

Fault Code: 122 or 123PID(P), SID(S): P102SPN: 102FMI: 3 or 4 Lamp: Yellow

FC122: High voltage detected at the boost pres-sure sensor signal pin 45 of the engine harness.

FC123: Low voltage detected at the boost pres-sure sensor signal pin 45 of the engine harness.

Engine will derate to no-boost fueling.

Fault Code 122 or 123 24 Valve, 8.3 Liter EnginePage 26 Troubleshooting Fault Codes


TROUBLESHOOTING SUMMARY� CAUTION �

To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/Cannon/Metri-Pack test leadTool No. 3822917 - female AMP/Metri-Pack/Deutsch test lead.

� CAUTION �To avoid damaging a new ECM, all other active fault codes must be investigated prior to replacing the ECM.


STEP 1: Check for multiple fault codes. STEP 1A:. 1A Read the fault codes. Fault Codes 135, 141, 144, 145, 153, 154, and

352 are not active STEP 2: Check for mechanical failure. STEP 2A: Make sure of proper turbocharger operation.

Positive intake manifold pressure from turbo-charger and wastegate not stuck closed

STEP 3:Check the intake manifold pressure sensor. STEP 3A: Inspect the intake manifold pressure sensor and engine harness connector pins.

No damaged pins

STEP 3B: Check the intake manifold pressure supply voltage.

4.5 to 5.25 VDC

STEP 3C: Check the intake manifold pressure signal voltage.

0.44 to 0.56 VDC

STEP 4: Check the engine harness. STEP 4A: Inspect the engine harness and the ECM connector pins.

No damaged pins

STEP 4B: Check for an open circuit. Less than 10 ohms STEP 4C: Check for a short circuit to ground. More than 100k ohms STEP 4D:Check for a short circuit from pin to pin. More than 100k ohms STEP 5: Clear the fault codes. STEP 5A: Disable the fault code. Fault Code 122 or 123 inactive STEP 5B:Clear the inactive fault codes. All faults codes cleared




STEP 1: Check for multiple fault codes. STEP 1A: Read the fault codesCondition:• Key switch in the "ON" position.

Action Specifications/Repair Next StepRead the fault codes. • Read fault codes using an electronic ser-

vice tool.NOTE: If multiple temperature or pressure fault codes exist, this procedure should not be followed.

OKFault Codes 135, 141, 144, 145, 153, 154, and 352 are not active

2A

NOT OKPossible sensor failure. Short circuit to ground in sensor +5 VDC common supply, or short circuit from pin to pin.

Multiple fault code tree A

STEP 2: Check for mechanical failure. STEP 2A: Make sure of proper turbocharger operationCondition:• Key switch in the “OFF” position.

Action Specifications/Repair Next StepMake sure of proper turbocharger operation.• Check for positive intake manifold pressure

using a mechanical gauge.

OKPositive intake manifold pressure from turbocharger and wastegate not stuck closed

3A

NOT OKLow intake manifold pressureCorrect the base engine malfunction.Low intake manifold pressureRefer to in the Troubleshooting and Repair Manual for CDC 24 Valve 8.3 Liter Engine.

5A



STEP 3: Check the intake manifold pressure sensor. STEP 3A: Inspect the intake manifold pressure sensor and engine harness connector pins.Condition: • Key switch in the "OFF" position. • Disconnect the engine harness from the intake manifold pressure sensor.

Action Specifications/Repair Next StepInspect the engine harness and the sensor con-nector for:• bent or broken pins • pushed back or expanded pins• corroded pins• moisture in or on the connector• missing or damaged seals.

OKNo damaged pins

3B

NOT OKRepair the damaged pinsRepair or replace the intake manifold pressure sensor or the engine harness, whichever has damaged pins. • Repair the engine harness. • Replace the engine harness. Refer to Procedure 019-

043.• Replace the intake manifold pressure sensor. Refer to

Procedure 019-061.

5A



STEP 3B: Check the intake manifold pressure supply voltage. Condition:• Key switch in the "ON" position. • Connect the intake manifold pressure sensor breakout cable, Tool No. 3824776, between the sensor and the engine har-

ness. Action Specifications/Repair Next Step

Check the intake manifold pressure supply voltage. • Measure the voltage from pin A to pin B of

the intake manifold pressure sensor circuit.

OK4.5 to 5.25 VDC

3C


5A



STEP 3C: Check the intake manifold pressure signal voltage.Condition: • Key switch in the "ON" position. • Connect the intake manifold pressure sensor breakout cable, Tool No. 3824776, between the sensor and the engine har-

ness. Action Specifications/Repair Next Step

Check the intake manifold pressure signal volt-age. • Measure the voltage from pin B to pin C of

the intake manifold pressure sensor circuit.

OK0.44 to 0.56 VDC

4A

NOT OKReplace the intake manifold pressure sensorRefer to Procedure 019-061.

5A




� CAUTION �To avoid damaging a new ECM, all other active fault codes must be investigated prior to replacing the ECM.Condition:• Key switch in the "OFF" position.• Disconnect the engine harness from the ECM. • Disconnect the engine harness from the intake manifold pressure sensor.

Action Specifications/Repair Next StepInspect the engine harness and the ECM con-nector pins for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

4B


043.• Replace the ECM. Refer to Procedure 019-031.

5A



STEP 4B: Check for an open circuit.��CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead. Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the intake manifold pressure sensor.• Disconnect the engine harness from the ECM.

Action Specifications/Repair Next StepCheck for an open circuit.• Measure the resistance from pin 45 on the

engine harness connector to pin C on the harness side of the intake manifold pres-sure sensor connector.

OKLess than 10 ohms

4C


5A



STEP 4C: Check for a short circuit to ground. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead.Condition: • Key switch in the “OFF” position. • Disconnect the engine harness from the intake manifold pressure sensor. • Disconnect the engine harness from the ECM.

Action Specifications/Repair Next StepCheck for a short circuit to ground.• Measure the resistance from pin 45 on the

harness side of the engine harness con-nector to engine block ground.


4D


5A




To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead. Condition:• Key switch in the "OFF" position.• Disconnect the engine harness from the ECM. • Disconnect the engine harness from the intake manifold pressure sensor.

Action Specifications/Repair Next StepCheck for a short circuit from pin to pin.• Measure the resistance from pin 45 on the

harness side of the engine harness con-nector to all other pins in the engine har-ness.


5A


5A



STEP 5: Clear the fault codes. STEP 5A: Disable the fault code.Condition:• Connect all components. • Key switch in the “ON” position.

Action Specifications/Repair Next StepDisable the fault code.• Start the engine and let idle for 1 minute. • Using an electronic service tool, verify that

Fault Code 122 and 123 is inactive.

OKFault Code 122 and 123 inactive

5B

NOT OKReturn to troubleshooting steps or contact the Technical Services Group (if all steps have been completed and checked again).

1A

STEP 5B: Clear the inactive fault codes.Condition:• Connect all components. • Key switch in the “ON” position.



OKAll faults codes cleared

Repair complete





Fault Code 124


Circuit Description:The intake manifold pressure sensor is used by the electronic control module (ECM) to monitor the engine intake manifold pres-sure. The ECM monitors the voltage on the signal pin 45 and converts this to a pressure value. The intake manifold pressure value is used by the ECM for the engine protection system.

Component Location:The intake manifold pressure sensor is located on the rear of the intake manifold in the second port on the side of the head to the right of the fuel filter.

Possible causes:• malfunctioning turbo waste gate. Refer to Procedure 010-050 in Section 10 Chapter 17 of the CDC 24 Valve 8.3 Liter Engine

Repair Manual.• waste gate tampering. Refer to Procedure 010-100 in Section 10 Chapter17 of the CDC 24 Valve 8.3 Liter Engine Repair

Manual.wrong turbo tampering. Refer to Procedure 010-101 through 010-107 in Section 10 Chapter 17 of the CDC 24 Valve 8.3 Liter Engine Repair Manual.

Intake Manifold Pressure - Engine ProtectionCODES REASON EFFECT

Fault Code: 124 PID(P), SID(S): P102 SPM: 102FMI: 0Lamp: Yellow

Intake manifold pressure signal indicates intake manifold pressure has exceeded the maximum limit for the given engine rating.

Engine will derate to no boost fueling.






STEP 1: Check the sensor accuracy. STEP 1A: Verify the sensor accuracy with a mechanical gauge.

Sensor reading is correct within 5 in Hg

STEP 2: Clear the fault code. STEP 2A: Disable the fault code. Fault Code 124 inactive STEP 2B: Clear the inactive fault codes. All faults cleared

STEP 1: Check the sensor accuracy. STEP 1A: Verify the sensor accuracy with a mechanical gauge.Condition:• Key switch in the "ON" position.

Action Specifications/Repair Next StepVerify the sensor accuracy with a mechanical gauge.• Connect a mechanical intake manifold pres-

sure gauge to the engine. • Connect an electronic service tool to the

vehicle data bus. • Start the engine and compare the intake

manifold pressure sensor reading on an electronic service tool monitor screen to the reading on the mechanical intake manifold pressure gauge.

Note: The engine must be revved up to make it easier to see differences in read-ings.

OKSensor reading is correct within 5 in HgLocate and repair the cause of high intake manifold pressure.

2A

NOT OKFault Code 123 is active

Fault Code 123

STEP 2: Clear the fault code. STEP 2A: Disable the fault code.Condition:• Connect all the components. • Key switch in the “ON” position.

Action Specifications/Repair Next StepDisable the fault code.• Start the engine and let idle for one minute.• Using an electronic service tool, verify Fault



2B


1A






OKAll faults cleared

Repair complete






Accelerator Position Sensor Circuit

Circuit Description:The accelerator position sensor is attached to the accelerator pedal. The accelerator position sensor sends a signal to the elec-tronic control module (ECM) when the driver pushes on the accelerator pedal. The accelerator position circuit contains three wires: a +5 VDC supply wire (pin 29), a return ground (pin 19), and a signal wire (pin 30).

NOTE: The connector pin letters shown for the accelerator pedal wiring in these troubleshooting steps are examples of represen-tative sensors. The connector pin assignments may vary with equipment manufacturer, but the base troubleshooting logic will still apply.

Component Location:The accelerator position sensor is located on the accelerator pedal.

Shop Talk:If all wiring and sensor checks look good, then replace the accelerator position sensor and the idle validation switch circuit wires between the accelerator pedal and the ECM with new wires. Run the wires through, or around, the bulkhead without using the bulkhead connector. Test the vehicle with the test wires in place. If the fault goes away, replace the vehicle harness. Seal the open-ings in the bulkhead around the connector and wires to prevent toxic and noxious fumes from entering the operator area.

NOTE: The three wires in the accelerator position sensor circuit must be twisted together. Depending on ground location, IVS may only be two wires.

Accelerator Position Sensor CircuitCODES REASON EFFECT

Fault Code: 131 or 132PID(P), SID(S): P091SPN: 091 FMI: 3 or 4 Lamp: Yellow

FC 131: High voltage detected at accelerator position signal pin 30 of the vehicle harness.

FC 132: Low voltage detected at accelerator position signal pin 30 of the vehicle harness.

Engine idles when idle validation switch indicates idle and operates at a default set speed when idle validation switch indicates off-idle.




To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/Cannon/Metri-Pack test leadTool No. 3823995 - male Weather-Pack test leadTool No. 3823996 - female Weather-Pack test lead.


STEP 1: Check the accelerator pedal. STEP 1A: Verify that the accelerator position sen-sor is connected to the vehicle harness.

Sensor is connected

STEP 1B: Inspect the harness and the accelerator position sensor connector pins.

No damaged pins

STEP 1C: Check the accelerator position resis-tance.

2000 to 3000 ohms

STEP 1D: Check the resistance between sensor pins.

Released: 1500 to 3000 ohmsDepressed: 250 to 1500 ohms

STEP 1E: Check for a short circuit to ground in the sensor +5 VDC supply.

More than 100k ohms

STEP 1F: Check for a short circuit to ground in the sensor signal wire.

More than 100k ohms

STEP 2: Check the vehicle harness. STEP 2A: Inspect the harness and the ECM con-nector pins.

No damaged pins

STEP 2B: Check for an open circuit in the supply, signal, and return wires of the vehicle harness.

Less than 10 ohms

STEP 2C: Check for a short circuit between the +5 VDC supply wire and any other wire in the vehicle harness.

More than 100k ohms

STEP 2D: Check for a short circuit between the accelerator position signal wire and any other wire in the vehicle harness.

More than 100k ohms

STEP 2E: Check for a short circuit to ground in the accelerator position sensor +5 VDC supply circuit. (Fault Code 132 only)

More than 100k ohms

STEP 2F: Check for a short circuit to ground in the accelerator position sensor signal circuit. (Fault Code 132 only)

More than 100k ohms

STEP 3: Check the ECM.STEP 3A: Check the accelerator position supply voltage.

4.75 to 5.25 VDC

STEP 4: Clear the fault code.STEP 4A: Disable the fault code. Fault Code 131 or 132 inactive STEP 4B: Clear the inactive fault codes. All faults cleared




STEP 1: Check the accelerator pedal. STEP 1A: Verify the accelerator position sensor is connected to the vehicle harness.Condition:• Key switch in the "OFF" position.

Action Specifications/Repair Next StepVerify that the accelerator position sensor is con-nected to the vehicle harness.

OK Sensor Connected

1B

NOT OK Connect the vehicle harness

4A

STEP 1B: Inspect the harness and the accelerator position sensor connector pinsCondition:• Key switch in the “OFF” position.• Disconnect the vehicle harness from the accelerator position sensor.

Action Specifications/Repair Next StepInspect the harness and the accelerator position sensor connector pins for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

1C

NOT OKRepair the damaged pinsRepair or replace the vehicle harness or sensor, whichever has the damaged pins. • Repair the engine harness. • Replace the vehicle harness. Refer to vehicle manu-

facturer's instructions. • Replace the throttle position sensor. Refer to manu-

facturer's instructions.

4A



STEP 1C: Check the accelerator position sensor resistance. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3823996 - female Weather-Pack test lead.Condition:• Key switch in the "OFF" position.• Disconnect the vehicle harness from the accelerator position sensor.

Action Specifications/Repair Next StepCheck for an open or short circuit between pins in the accelerator position sensor.• Measure the resistance from pin 4 [pin A] to

pin 5 [pin C] on the sensor side of the accel-erator position sensor when the accelerator pedal is released and when it is depressed.

NOTE: The pin letters shown above are for the integrated sensor switch (ISS) and letters shown in brackets are for pedals with separate idle vali-dation and accelerator sensors.

OK2000 to 3000 ohms

1D

NOT OKReplace the accelerator position sensor Refer to the equipment manufacturer's troubleshooting and repair manual.

4A



STEP 1D: Check the resistance between sensor pins. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3823996 - female Weather-Pack test lead. Condition:• Key switch in the "OFF" position. • Disconnect the vehicle harness from the accelerator position sensor.

Action Specifications/Repair Next StepCheck the resistance between sensor pins. NOTE: Measure when the pedal is depressed and released.• Measure the resistance from pin 4 [pin A] to

pin 5 [pin C] on the sensor side of the accel-erator position sensor. NOTE: The pin letters shown above are for the integrated sensor switch (ISS) and the letters shown in brackets are for pedals with separate idle validation and accelerator sensors.

OKReleased: 1500 to 3000 ohmsDepressed: 250 to 1500 ohmsNOTE: Released resistance must be at least 1000 ohms more than depressed resistance.

1E

NOT OKReplace the accelerator position sensorRefer to the equipment manufacturer's troubleshooting and repair manual.

4A



STEP 1E: Check for a short circuit to ground in the sensor +5 volt supply.� CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3823996 - female Weather-Pack test lead.Condition:• Key switch in the “OFF” position. • Disconnect the vehicle harness from the accelerator position sensor.

Action Specifications/Repair Next StepCheck for a short circuit to ground in the sensor +5 volt supply.• Measure the resistance from pin 5 [pin C]

on the sensor side of the accelerator posi-tion sensor to engine block ground.

NOTE: The pin letters shown above are for the integrated sensor switch (ISS) and the letters shown in brackets are for pedals with separate idle validation and accelerator sensors.


1F


4A



STEP 1F: Check for a short circuit to ground in the signal wire. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3823996 - female Weather-Pack test lead.Condition:• Key switch in the “OFF” position.• Disconnect the vehicle harness from the accelerator position sensor.

Action Specifications/Repair Next StepCheck for a short circuit to ground in the signal wire.• Measure the resistance from pin 3 [pin B]

on the sensor side of the accelerator posi-tion sensor to engine block ground.

NOTE: The pin letters shown above are for the integrated sensor switch (ISS) and let-ters shown in brackets are for pedals with separate idle validation and accelerator sensors.


2A


4A



STEP 2: Check the vehicle harness. STEP 2A: Inspect the vehicle harness and the ECM connector pins.Condition:• Key switch in the "OFF" position. • Disconnect the vehicle harness from the ECM.

Action Specifications/Repair Next StepInspect the harness and the ECM connector pins for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

2B

NOT OKRepair the damaged pinsRepair or replace the vehicle harness or ECM, whichever has damaged pins. • Repair the vehicle harness. • Replace the vehicle harness. Refer to Procedure 019-


4A



STEP 2B: Check for an open circuit in the supply, signal, and return wires of the vehicle harness. � CAUTION �

To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/Cannon/Metri-Pack test leadTool No. 3823995 - male Weather-Pack test lead.Condition:• Key switch in the “OFF” position. • Disconnect the vehicle harness from the accelerator position sensor. • Disconnect the vehicle harness from the ECM.

Action Specifications/Repair Next StepCheck for an open circuit in the supply, signal and return wires of the vehicle harness.• Measure the resistance from pin 29 of the

vehicle harness connector to the throttle (+) 5 VDC supply pin 5 [pin C] on the harness side of the accelerator position sensor.

• Measure the resistance from pin 30 of the vehicle harness connector to the accelera-tor position signal pin 3 [pin B] on the har-ness side of the accelerator position sensor.

• Measure the resistance from pin 19 of the vehicle harness connector to the throttle return pin 4 [pin A] on the harness side of the accelerator position sensor.

OKLess than 10 ohms

2C

NOT OKReplace the vehicle harnessRefer to Procedure 019-071.

4A



STEP 2C: Check for a short circuit between +5 volt supply wire and any other wire in the vehicle harness.

� CAUTION �To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead. Condition:• Key switch in the "OFF" position. • Disconnect the vehicle harness from the accelerator position sensor. • Disconnect the vehicle harness from the ECM.

Action Specifications/Repair Next StepCheck for a short circuit from the +5 VDC supply wire to any other wire in the vehicle harness.• Measure the resistance from pin 29 to all

other pins in the vehicle harness connector.


2D


4A



STEP 2D: Check for a short circuit between accelerator position signal wire and any other wire in the vehicle harness.


Action Specifications/Repair Next StepCheck for a short circuit between the accelerator position signal wire and any other wire in the vehicle harness.• Measure the resistance from pin 30 to all

other pins in vehicle harness connector.


2E


4A



STEP 2E: Check for a short circuit to ground of the accelerator position sensor +5 VDC supply circuit. (Fault Code 132 only)


Action Specifications/Repair Next StepCheck for a short circuit to ground of the acceler-ator position signal sensor supply circuit.• Measure the resistance from pin 29 of the

vehicle harness connector to engine block ground.


2F

NOT OKRefer to Procedure 019-071. Replace the vehicle harness

4A



STEP 2F: Check for a short circuit to the ground in the accelerator position sensor signal circuit. (Fault Code 132 only)

� CAUTION �To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead.Condition:• Key switch in the "OFF" position. • Disconnect the vehicle harness from the ECM. • Disconnect the vehicle harness from the accelerator position sensor.

Action Specifications/Repair Next StepCheck for a short circuit to ground of the acceler-ator position sensor signal circuit.• Measure the resistance from pin 30 of the

vehicle harness connector to engine block.


3A


4A



STEP 3: Check the ECM STEP 3A: Check the accelerator position supply voltageCondition: • Connect the vehicle harness to the accelerator position sensor. • Disconnect the vehicle harness from the ECM.• Key switch in the “ON” position.

Action Specifications/Repair Next StepCheck the accelerator position supply voltage.• Measure the voltage from pin 19 to pin 29 in

the vehicle port of the ECM.

OK4.75 to 5.25 VDC

4A


4A


Action Specifications/Repair Next StepDisable the fault code.• Turn the key switch "ON" and depress the

accelerator pedal to full position. • Release the pedal and turn the key switch

to the "OFF" position • Wait for 15 seconds Key switch in the “ON”

position • Using an electronic service tool, verify that

the Fault Code 131 or 132 is inactive.

OKFault Code 131 or 132 inactive

4B


1A



STEP 4B: Clear the inactive fault codes.Condition:• Connect all the components.• Key switch in the “ON” position.




Repair complete






Oil Pressure Sensor Circuit

Circuit Description:The oil pressure sensor is used by the electronic control module (ECM) to monitor the lubricating oil pressure. The ECM monitors the voltage on the signal pin and converts this to a pressure value. The oil pressure value is used by the ECM for the engine pro-tection system.

Component Location:The oil pressure sensor is located on the engine block, below and to the right of the ECM.

Shop Talk:If Fault Code 143 or 415 are not present, the problem is not related to the engine lubrication system. an electronic service tool can be used to monitor the oil pressure signal voltage going into the ECM.

Oil Pressure Sensor CircuitCODES REASON EFFECT


FC135: High voltage detected at oil pressure sensor signal pin 33 of the engine harness.

FC141: Low voltage detected at oil pressure sensor signal pin 33 of the engine harness.

Default value used for oil pressure.No engine protection for oil pressure.






STEP 1: Check for multiple fault codes. STEP 1A: Read the fault codes. Fault Codes 145, 154, 213, 222, 352, and 422

are not active STEP 2: Check the oil pressure sensor STEP 2A: Inspect the engine harness and sensor connector.

No damaged pins

STEP 2B: Check the oil pressure sensor supply voltage.

4.5 to 5.25 VDC

STEP 2C: Check the oil pressure sensor signal voltage.

0.42 to 0.58 VDC

STEP 3: Check the engine harness. STEP 3A: Inspect harness and ECM connector pins. No damaged pins STEP 3B: Check for open circuit. Less than 10 ohms STEP 3C: Check for short circuit to ground. More than 100k ohms STEP 3D: Check for short circuit from pin to pin. More than 100k ohms STEP 4: Clear fault codes. STEP 4A: Disable the fault code. Fault Code 135 or 141 inactive STEP 4B: Clear the inactive fault codes. All faults cleared

STEP 1:Check for multiple fault codes. STEP 1A: Read the fault codes. CONDITION:• Key switch in the "ON" position.

Action Specifications/Repair Next StepRead the fault codes.• Read the fault codes using an electronic

service tool.

Note: If multiple temperature or pressure fault codes exist, this procedure should not be fol-lowed.

OKFault Codes 145, 154, 213, 222, 352, and 422 are not active

2A

NOT OKPossible sensor failure, a short circuit to ground in the sen-sor +5 VDC common supply, or a short circuit from pin to pin.


STEP 2: Check the oil pressure sensor. STEP 2A: Inspect the engine harness and the oil pressure sensor connector pins.Condition:• Key switch in the "OFF" position.• Disconnect the engine harness from the oil pressure sensor.

Action Specifications/Repair Next Step



Inspect the oil pressure sensor and the engine harness connector pins for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

2B

NOT OKRepair the damaged pinsRepair or replace the oil pressure sensor or the engine harness, whichever has damaged pins. • Repair the engine harness. • Replace the engine harness. Refer to Procedure 019-

043. • Replace the oil pressure sensor. Refer to Procedure

019-066.

4A

STEP 2: Check the oil pressure sensor. STEP 2A: Inspect the engine harness and the oil pressure sensor connector pins.



STEP 2B: Check the oil pressure sensor supply voltage. Condition:• Key switch in the "ON" position.• Disconnect the engine harness from the oil pressure sensor.• Install oil pressure sensor breakout cable (Tool No. 3824775).

Action Specifications/Repair Next StepCheck the oil pressure sensor supply voltage. • Measure the voltage from pin A to pin B on

the harness side of the oil pressure sensor connector.

OK4.5 to 5.25 VDC

2C

NOT OKReplace engine harnessRefer to Procedure 019-043.

4A



STEP 2C: Check the oil pressure sensor signal voltage.Condition:• Key switch in the "ON" position; engine not running. • Install oil pressure sensor breakout cable (Tool No. 3824775).

Action Specifications/Repair Next StepCheck the oil pressure sensor signal voltage.• Measure the voltage from pin C to pin B of

the breakout cable.

OK0.42 to 0.58 VDC

3A

NOT OKReplace the oil pressure sensorRefer to Procedure 019-066.

4A






OKNo damaged pins

3B


043. • Replace the ECM. Refer to Procedure 019-031.

4A



STEP 3B: Check for an open circuit.� CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead. Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the oil pressure sensor. • Disconnect the engine harness from the ECM.

Action Specifications/Repair Next StepCheck for an open circuit.• Measure the resistance from pin 33 of the

engine harness connector to pin C on the harness side of the oil pressure sensor con-nector.

OKLess than 10 ohms

3C


4A



STEP 3C: Check for a short circuit to ground. � CAUTION��

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male AMP/Metri-Pack/Deutsch test lead. Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the oil pressure sensor. • Disconnect the engine harness from the ECM.

Action Specifications/Repair Next StepCheck for a short circuit to ground.• Measure the resistance from pin 33 of the



3D


4A




To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead.Condition:• Key switch in the "OFF" position.• Disconnect the engine harness from the ECM. • Disconnect the engine harness from the oil pressure sensor.

Action Specifications/Repair Next StepCheck for a short circuit from pin to pin.• Measure the resistance from pin 33 of the

engine harness connector to all other pins in the engine harness connector.


4A


4A

STEP 4: Clear the fault codes. STEP 4A: Disable the fault code. • Condition: • Connect all the components. • Key switch in the “ON” position.

Action Specifications/Repair Next StepDisable the fault code.• Start the engine and let idle for 1 minute. • Using an electronic service tool, verify Fault

Code 135 and 141 is inactive and did not reoccur.


4B


1A



STEP 4B: Clear the inactive fault codes. Condition:• Connect all the components. • Key switch in the “ON” position.

Action Specifications/Repair Next StepClear the inactive fault codes. • Erase the inactive fault code using an elec-


OK All faults codes cleared

Repair complete

NOT OK Troubleshoot any remaining active fault codes.

Appropriate trou-bleshooting charts



Fault Code 143


Circuit Description: The oil pressure sensor is used by the electronic control module (ECM) to monitor the lubricating oil pressure. The ECM monitors the voltage on the signal pin and converts this to a pressure value. The oil pressure value is used by the ECM for the engine pro-tection system.

Component Location: The oil pressure sensor is located on the engine block below and to the right of the ECM.

Shop Talk: • Confirm that the oil pressure sensor supply voltage is between 4.5 and 5.25 VDC at the sensor.• Verify with the driver the engine speed at which the fault occurs. If the engine is being operated at too low of a speed under

load, the oil pressure can drop below the engine protection limits.

Oil Pressure - Engine Protection CODES REASON EFFECT

Fault Code: 143 PID(P), SID(S): P100SPN: 100 FMI: 1 Lamp: Yellow

Oil pressure signal indicates oil pressure below the low engine protection limit.

Power derate and possible engine shutdown if engine protection shutdown feature enabled.





STEPS SPECIFICATIONS SRT CODESTEP 1: Check the sensor accuracy. STEP 1A: Verify the sensor accuracy with a mechanical gauge.

Sensor reading is correct


STEP 1: Check the sensor accuracy. STEP 1A: Verify the sensor accuracy with a mechanical gauge.Condition:• Key switch in the "ON" position.

Action Specifications/Repair Next StepVerify the sensor accuracy with a mechanical gauge.• Connect a mechanical oil pressure gauge

to the engine. • Connect an electronic service tool to vehi-

cle data bus. • Start the engine and compare the oil pres-

sure reading on the service tool monitor screen to the reading on the mechanical oil pressure gauge.

Note: If necessary, rev the engine up to make it easier to see differences in the readings.

OKThe sensor reading is correct.Refer to the Troubleshooting and Repair Manual for CDC 24 Valve 8.3 Liter Engine.

2A

NOT OKFault Code 141 is active.

Fault Code 141

STEP 2: Clear the fault code STEP 2A: Disable the fault code Condition:• Connect all the components. • Key switch in the “ON” position.

Action Specifications/Repair Next StepDisable the fault code.• Start the engine and let it idle for one

minute.• Using an electronic service tool, verify Fault

Code 143 is inactive. Note: If the fault was at a particular speed, run the engine at that speed to verify the problem is corrected.


2B


1A







Repair complete


Appropriate trou-bleshooting chart




Coolant Temperature Sensor Circuit

Circuit Description:The coolant temperature sensor is used by the electronic control module (ECM) to monitor the temperature of the engine coolant. The coolant temperature is used by the ECM for the engine protection system, timing, and fueling control.

Component Location: The coolant temperature sensor is located below the thermostat housing.

Shop Talk:The resistance of the sensor varies with the temperature. Use a volt-ohm meter and read the fuel temperature using an electronic service tool. Compare the resistance value measured with the following table to verify that the sensor is functioning properly.

Coolant Temperature Sensor CircuitCODES REASON EFFECT

Fault Code: 144 or 145PID(P), SID (S): P110SPN: 110 FMI: 3 or 4 Lamp: Yellow

FC144: High voltage detected at the coolant temperature signal pin 23 of the engine harness.

FC145: Low voltage detected at the coolant temperature signal pin 23 of the engine harness.

Default value used for engine coolant temperature.No engine protection for coolant temperature.

Temperature (�C� Temperature [�F� Resistance (ohms)

0 32 30k to 36k

25 77 9k to 11k

50 122 3k to 4k

75 167 1350 to 1500

100 212 600 to 675



TROUBLESHOOTING SUMMARY� WARNING �

Wait until the coolant temperature is below 50� C [120�F] before removing the coolant system pressure cap or the cool-ant temperature sensor. Failure to do so can cause personal injury from heated coolant spray.

� CAUTION �To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/Cannon/Metri-Pack test leadTool No. 3824803 - female Metri-Pack test lead.

STEPS SPECIFICATIONS SRT CODESTEP 1: Check the fault codes. STEP 1A: Read the fault codes. Fault Code 441 not active STEP 1B: Read the fault codes. Fault Codes 122, 135, 153, 221, 263, and 451

are not active STEP 2: Check the coolant temperature sensor. STEP 2A: Inspect the engine harness and sensor connector.

No damaged pins

STEP 2B: Check the resistance of the coolant temperature sensor.

175 ohms to 244k ohms

STEP 2C: Check for short circuit to ground in coolant temperature sensor.

More than 100k ohms

STEP 3: Check the engine harness. STEP 3A: Inspect the harness and the ECM connector.

No damaged pins

STEP 3B: Check for open circuit. Less than 10 ohms STEP 3C: Check for short circuit to ground.

More than 100k ohms

STEP 3D: Check for short circuit from pin to pin.

More than 100k ohms

STEP 4: Clear fault codes. STEP 4A: Disable the fault code. Fault Code 144 and 145 inactive STEP 4B: Clear the inactive fault codes. All faults cleared




STEP 1: Check for multiple fault codes. STEP 1A: Read the fault codes.Condition:• Key switch in the “ON” position.


service tool.

OKFault Code 441 not active.

1B


Fault Code 441

STEP 1B: Read the fault codes. Condition:• Key switch in the “ON” position.


service tool.

OKFault Codes 122, 135, 153, 221, 263, and 451 are not active.

2A

NOT OKPossible sensor failure, short circuit to ground in the sen-sor +5 VDC common supply, or a short circuit from pin to pin, or an open circuit in the sensor common ground.

Multiple fault code Tree A

STEP 2: Check the coolant temperature sensor. STEP 2A: Inspect the coolant temperature sensor and engine harness connector pins. Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the coolant temperature sensor.

Action Specifications/Repair Next StepInspect the harness and the sensor connector pins for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

2B

NOT OKRepair the damaged pinsRepair or replace the engine harness or the coolant tem-perature sensor, whichever has the damaged pins. • Repair the engine harness. • Replace the engine harness. Refer to Procedure 019-

043.• Replace the coolant temperature sensor. Refer to

Procedure 019-019.

4A



STEP 2B: Check the resistance of the coolant temperature sensor.� CAUTION �

To avoid pin and harness damage, use female Metri-Pack test leads when taking a measurement.Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the coolant temperature sensor.

Action Specifications/Repair Next StepCheck the resistance of the Coolant Tempera-ture Sensor. • Measure the resistance from pin A to pin B

of the coolant temperature sensor.

OK 175 ohms to 244k ohms

2C

NOT OK Replace the coolant temperature sensorRefer to Procedure 019-019.

4A




To avoid pin and harness damage, use female Metri-Pack test leads when taking a measurement:Condition:• Key switch in the “OFF” position.• Disconnect the engine harness from the coolant temperature sensor.

Action Specifications/Repair Next StepCheck for a short circuit to ground.• Measure the resistance from pin A of the

coolant temperature sensor to engine block ground.


3A

NOT OKReplace the coolant temperature sensorRefer to Procedure 019-019.

4A



STEP 3:Check the engine harness. STEP 3A: Inspect the engine harness and the ECM connector pins.



OKNo damaged pins

3B

NOT OKRepair the damaged pinsRepair or replace the engine harness or ECM, whichever has the damaged pins. Repair the engine harness. Replace the engine harness. Refer to Procedure 019-043.Replace the ECM. Refer to Procedure 019-031.

4A



STEP 3B:Check for an open circuit.� CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead. Condition:• Key switch in the “OFF” position.• Disconnect the engine harness from the coolant temperature sensor. • Disconnect the engine harness from the ECM.


engine harness to pin A on the harness side of the coolant temperature sensor con-nector.

• Measure the resistance from pin 23 of the engine harness to pin B on the harness side of the coolant temperature sensor con-nector.

OKLess than 10 ohms

3C


4A




To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead. Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the coolant temperature sensor. • Disconnect the engine harness from the ECM.


engine harness to engine block ground. • Measure the resistance from pin 19 of the

engine harness to engine block ground.


3D


4A




To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead.Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the coolant temperature sensor. • Disconnect the engine harness from the ECM.


engine harness to all other pins in the engine harness.

• Measure the resistance from pin 19 of the engine harness to all other pins in the engine harness.


4A


4A


Action Specifications/Repair Next StepDisable the fault code.• Start the engine and let idle for one minute. • Verify that Fault Code 144 or 145 is inactive

using an electronic service tool.

OKFault Code 144 and 145 is inactive

4B


1A







Repair Complete





Fault Code 146


Circuit Description:The coolant temperature sensor (CTS) is used by the electronic control module (ECM) to monitor the temperature of the engine coolant. The coolant temperature is used by the ECM for the engine protection system, and the timing and fueling control.

Component Location:The coolant temperature sensor is located below the thermostat housing.

Shop Talk:Make sure the air flow through the radiator is not obstructed.

Coolant Temperature - Engine ProtectionCODES REASON EFFECT

Fault Code: 146PID(P), SID(S): P110SPN: 110FMI: 0 Yellow

Coolant temperature signal indicates coolant temperature has exceeded the engine protection limit.

Power derate and possible engine shutdown, if engine protection shut-down feature is enabled.





STEPS SPECIFICATIONS SRT CODESTEP 1: Check the sensor accuracy. STEP 1A: Verify the sensor accuracy with a thermocouple or similar temperature probe.



STEP 1: Check the sensor accuracy. STEP 1A: Verify the sensor accuracy with a thermocouple or similar temperature probe.Condition:• Key switch in the "ON" position.

Action Specifications/Repair Next StepVerify the sensor accuracy with a thermocouple or similar temperature probe. • Connect the temperature probe to the

engine near the coolant temperature sen-sor.

• Connect an electronic service tool to the vehicle data bus.

• Compare the coolant temperature reading on the service tool monitor screen to the reading from the temperature probe.

Note: If a temperature measuring device is not available then answer "OK" to this step.

OKSensor reading is correctRefer to the Troubleshooting and Repair Manual for CDC 24 Valve 8.3 Liter Engine

2A

NOT OK Sensor reading incorrect. Replace the coolant temperature sensor. Refer to Proce-dure 019-019.

2A





2B


1A







Repair complete





Fault Code 151


Circuit Description:The coolant temperature sensor (CTS) is used by the electronic control module (ECM) to monitor the temperature of the engine coolant. The coolant temperature is used by the ECM for the engine protection system, and the timing and fueling control.

Component Location:The coolant temperature sensor (CTS) is located below the thermostat housing.

Shop Talk:Make sure the air flow through the radiator is not obstructed.

Coolant Temperature - Engine ProtectionCODES REASON EFFECT

Fault Code: 151 PID(P), SID(S): P110SPN: 110FMI: 0Lamp: Red

Coolant temperature signal indicates coolant temperature has exceeded the engine protection limit.

Speed derate and possible engine shutdown if engine protection shutdown feature is enabled.








STEP 1: Check the sensor accuracy. STEP 1A: Verify the sensor accuracy with a thermocouple or similar temperature probe.Condition:• Key switch in the "ON" position.

Action Specifications/Repair Next StepVerify the sensor accuracy with a thermocouple or similar temperature probe.• Connect the temperature probe to the

engine near the coolant temperature sen-sor.

• Connect an electronic service tool to the vehicle data bus.

• Compare the coolant temperature reading on the service tool monitor screen to the reading from the temperature probe.Note: If a temperature measuring device is not available then answer "OK" to this step.

OKSensor reading is correct.Refer to the Troubleshooting and Repair Manual for CDC 24 Valve 8.3 Liter Engine.

2A

NOT OKSensor reading is incorrect.Replace the coolant temperature sensor. Refer to Proce-dure 019-019.

2A





2B


1A







Repair complete






Intake Manifold Air Temperature Sensor Circuit

Circuit Description:The intake manifold air temperature sensor is used by the electronic control module (ECM) to monitor the temperature of the engine intake air. The intake manifold air temperature signal is used by the ECM for the engine protection system, injection timing, and fueling control.

Component Location:The intake manifold air temperature sensor is located on the side of the intake manifold near the middle of the cylinder head.

Shop Talk:The resistance of the sensor varies with the temperature. Use a multimeter and read the air temperature using an electronic ser-vice tool. Compare the resistance value measured with the following table to verify the sensor is functioning properly.

Intake Manifold Air Temperature Sensor Circuit CODES REASON EFFECT


FC153: High voltage detected at intake manifold air temperature signal pin 34 of the engine har-ness.FC154: Low voltage detected at intake manifold air temperature signal pin 34 of the engine har-ness.

Default value used for intake manifold air tem-perature.No engine protection for intake manifold air tem-perature.




0 32 30k to 36k

25 77 9k to 11k

50 122 3k to 4k

75 167 1350 to 1500

100 212 600 to 675





STEPS SPECIFICATIONS SRT CODESTEP 1: Check for multiple fault codes. STEP 1A: Read the fault codes. Fault Code 441 is not active STEP 1B: Check for active fault codes. Fault Codes 122, 135, 144, 221, 263, and 451 are

not activeSTEP 2: Check the intake manifold temperature sensor. STEP 2A: Inspect engine harness and sensor connector.

No damaged pins

STEP 2B: Check the sensor resistance. 175 ohms to 244k ohms STEP 2C: Check for short circuit to ground.

More than 100k ohms

STEP 3: Check engine harness. STEP 3A: Inspect harness and ECM connector.

No damaged pins

STEP 3B: Check for open circuit. Less than 10 ohms STEP 3C: Check for short circuit to ground.

More than 100k ohms

STEP 3D: Check for a short circuit from pin to pin.

More than 100k ohms

STEP 4: Clear fault codes. STEP 4A: Disable the fault code. Fault Code 153 or 154 inactive STEP 4B: Clear the inactive fault codes. All faults cleared

STEP 1: Check for multiple fault codes. STEP 1A: Read the fault codes.Condition:• Key switch in the “ON” position.


service tool.

OKFault Code 441 is not active.

1B


Fault Code 441



STEP 1B: Check for active fault codes. Condition:• Key switch in the “ON” position.

Action Specifications/Repair Next StepCheck for active fault codes.Read the fault codes using an electronic service tool.

OKFault Codes 122, 135, 144, 221, 263, and 451 are not active.

2A

NOT OKPossible sensor failure, a short circuit to ground in the sen-sor +5 VDC common supply, a short circuit from pin to pin, or an open circuit on the sensor common ground.


STEP 2: Check the intake manifold air temperature sensor. STEP 2A: Inspect the intake manifold air temperature sensor and the engine harness connector pins. Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the intake manifold air temperature sensor.

Action Specifications/Repair Next StepInspect the intake manifold air temperature sen-sor and the engine harness connector pins for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

2B

NOT OKRepair the damaged pins.Repair or replace the intake manifold air temperature sen-sor or the engine harness, whichever has the damaged pins. • Repair the engine harness. • Replace the engine harness. Refer to Procedure 019-

043.• Replace the intake manifold air temperature sensor.

Refer to Procedure 019-059.

4A



STEP 2B: Check the sensor resistance. � CAUTION �

To avoid pin and harness damage, use female Metri-Pack test leads when taking a measurement:Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the intake manifold air temperature sensor.

Action Specifications/Repair Next StepCheck the resistance of the intake manifold air temperature sensor.• Measure the resistance from pin A to pin B

of the intake manifold temperature sensor.

OK175 ohms to 244k ohms

2C

NOT OKReplace the intake manifold air temperature sensor. Refer to Procedure 019-059.

4A




To avoid pin and harness damage, use female Metri-Pack test leads when taking a measurement:Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the intake manifold air temperature sensor.


intake manifold air temperature sensor to engine block ground.


3A

NOT OKReplace the intake manifold air temperature sensor. Refer to Procedure 019-059.

4A





Action Specifications/Repair Next StepInspect the intake manifold air temperature sen-sor and the engine harness connector pins for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

3B

NOT OKRepair the damaged pins.Repair or replace the intake manifold air temperature sen-sor or the engine harness, whichever has the damaged pins. • Repair the engine harness. • Replace the engine harness. Refer to Procedure 019-

043.• Replace the intake manifold air temperature sensor.

Refer to Procedure 019-031.

4A




To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead.Condition:• Key switch in the “OFF” position.• Disconnect the engine harness from the intake manifold temperature sensor. Disconnect the engine harness from the ECM.

Action Specifications/Repair Next Step• Check for an open circuit.• Measure the resistance from pin 19 of the

engine harness to pin A on the harness side of the intake manifold temperature sen-sor connector.

• Measure the resistance from pin 34 of the engine harness to pin B on the harness side of the intake manifold temperature sen-sor connector.

OKLess than 10 ohms

3C


4A



STEP 3C: Check for a short circuit to the ground. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead. Condition:• Key switch in the “OFF” position.• Disconnect the engine harness from the intake manifold air temperature sensor. • Disconnect the engine harness from the ECM.





3D


4A




To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead. Condition:• Key switch in the "OFF" position.• Disconnect the engine harness from the intake manifold air temperature sensor. • Disconnect the engine harness from the ECM.





4A


4A

STEP 4: Clear the fault code. STEP 4A: Disable the fault code. Condition:• Connect all the components.• Key switch in the “ON” position.

Action Specifications/Repair Next StepDisable the fault code.• Start the engine and let idle for one minute.• Using an electronic service tool, verify that

Fault Code 153 or 154 is inactive.


4B

NOT OKReturn to the troubleshooting steps or contact the Techni-cal Services Group (if all steps have been completed and checked again).

1A



STEP 4B: Clear the inactive fault codes.Condition:• Connect all the components.• Key switch in the “ON” position.



OKAll the faults cleared

Repair complete





Fault Code 155


Circuit Description:The intake manifold air temperature sensor is used by the electronic control module (ECM) to monitor the temperature of the engine intake air. The intake air temperature is used by the ECM for the engine protection system, timing, and fueling control.

Component Location:The intake manifold temperature sensor is located on the side of the intake manifold near the middle of the cylinder head.

Shop Talk:• Make sure the engine compartment temperature does not get too high (above 93.3�C [200�F]).• Make sure the intake manifold temperature sensor is not located near any extreme heat sources.• Possible causes:

– clogged, dirty, inadequate capacity air cleaner element. Refer to Procedures 010-060 thru 010-063 in Section 10 Chapter 17 of the CDC 24 Valve 8.3 Liter Engine Repair Manual.– intake restriction. Refer to Procedure 010-059 in Section 10 Chapter17 of the CDC 24 Valve 8.3 Liter Engine Repair Man-ual.

Intake Manifold Air Temperature Sensor - Engine ProtectionCODES REASON EFFECT

Fault Code: 155 PID(P), SID(S): P105SPN: 105FMI: 0Lamp: Red

Intake manifold air temperature signal indicates the intake manifold air temperature is above the engine protection limit.

Speed derate and possible engine shutdown if engine protection shutdown feature is enabled.








STEP 1: Check the sensor accuracy. STEP 1A: Verify the sensor accuracy with a thermocouple or similar temperature probe. Condition:• Key switch in the "ON" position.


engine near the intake manifold air temper-ature sensor.

• Connect an electronic service tool to the engine data bus.

• Run the engine and compare the intake manifold temperature sensor reading on an electronic service tool monitor screen to the reading from the temperature probe. Note: If a temperature measuring device is not available then answer "OK" to this step.Note: Readings may need to be checked while engine is operating at normal temper-ature conditions [180�F coolant].

OKSensor reading is correctLocate and repair the cause of high intake manifold air temperature. (Refer to the Shop Talk section of this fault code for the correct procedure.)

2A

NOT OKSensor reading is incorrect.

Fault Code 154



STEP 2: Clear the fault code. STEP 2A: Disable the fault code. Condition:• Connect all the components. • Key switch in the “ON” position.

Action Specifications/Repair Next StepDisable the fault code.• Start the engine and let idle for one minute. • Load and operate engine to typical operat-

ing temperature (180�F coolant). • Using an electronic service tool, verify Fault

Code 155 is inactive and did not reoccur.


2B


1A





Repair complete






Ambient Air Pressure Sensor Circuit

Circuit Description:The ambient air pressure sensor monitors atmospheric pressure and passes information to the electronic control module (ECM) through the sensor harness.

Component Location:• The ambient air pressure sensor is located below the fuel transfer pump.

Shop Talk:Monitor the ambient air pressure reading with a service tool to confirm that the pressure reading matches the actual air pressure.

Ambient Air Pressure Sensor Circuit CODES REASON EFFECT

Fault Code: 221 or 222PID(P), SID(S): P108SPN: 108FMI: 3 or 4Lamp: Yellow

FC221: High voltage detected at the ambient air pres-sure sensor signal pin 32 of the engine harness.

FC222: Low voltage detected at the ambient air pres-sure sensor signal pin 32 of the engine harness.

Power derate by 15%.




To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead.Tool No. 3822917 - female Metri-Pack test lead.

STEPS SPECIFICATIONS SRT CODESTEP 1: Check for multiple fault codes. STEP 1A: Read the fault codes. Fault Code 352 is not active STEP 2: Check the ambient air pressure sensor. STEP 2A: Inspect the ambient air pressure sensor and sensor harness connector pins.

No damaged pins

STEP 2B: Check the ECM ambient air pressure supply voltage. 4.5 to 5.25 VDC STEP 2C: Check the ECM ambient air pressure signal voltage.

Altitude (ft) Voltage0 (sea level) - 4.00 to 4.583000 - 3.60 to 4.406000 - 3.20 to 4.009000 - 3.00 to 3.8012000 - 2.60 to 3.40

STEP 3: Check the engine harness. STEP 3A: Inspect the engine harness and the ECM connector for damaged pins.

No damaged pins

STEP 3B: Check for an open circuit. Less than 10 ohms STEP 3C: Check for a short circuit to ground. More than 100k ohms STEP 3D: Check for a short circuit from pin to pin.

More than 100k ohms

STEP 4: Check for the ECM response. STEP 4A: Check for the appropriate ECM response.

Fault Code 222 is inactive and Fault Code 221 is active

STEP 5: Clear the fault codes. STEP 5A: Disable the fault code. Fault Code 221 and 222 inactive STEP 5B: Clear the inactive fault codes. All faults codes cleared




STEP 1: Check for multiple fault codes. STEP 1A: Read the fault codes. Condition:• Key switch in the "ON" position.


service tool.

OKFault Code 352 is not active

2A

NOT OK• Possible sensor failure, a short circuit to ground in the

sensor +5 VDC common supply, or a short circuit from pin to pin.

Multiple Fault Code Tree A

STEP 2: Check the ambient air pressure sensor. STEP 2A: Inspect the ambient air pressure sensor and engine harness connector pins. Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the ambient air pressure sensor.

Action Specifications/Repair Next StepInspect the ambient air pressure sensor and engine harness connector pins for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

2B

NOT OKRepair the damaged pins• Replace the ambient air pressure sensor if the sensor

connector pins are damaged.Refer to Procedure 019-004.

• Replace the sensor connector if it is oversized or damaged.

5A



STEP 2B: Check the ECM ambient air pressure supply voltage.Condition:• Install breakout cable, (Part # 3824775), between the sensor and the sensor harness connector.• Key switch in the "ON" position.

Action Specifications/Repair Next StepCheck the ECM ambient air pressure supply voltage with breakout cables.• Measure the supply voltage from pin A to

pin B of the breakout cable.

OK4.5 to 5.25 VDC

2C


5A



STEP 2C: Check the ECM ambient air pressure signal voltage. Condition:• Install the breakout cable, (Part #3824775), between the sensor and the sensor harness connector. • Key switch in the "ON" position.

Action Specifications/Repair Next StepCheck the ECM ambient air pressure signal volt-age.• Measure the signal voltage from pin B to pin

C of the breakout cable.

OKAltitude (ft) - Voltage (volts)0 (sea level) - 4.00 to 4.583000 - 3.60 to 4.406000 - 3.20 to 4.009000 - 3.00 to 3.8012000 - 2.60 to 3.40

3A

NOT OKReplace the ambient air pressure sensorRefer to Procedure 019-004.

5A



STEP 3: Check the engine harness. STEP 3A: Inspect the engine harness and the ECM connector for damaged pins.



OKNo damaged pins

3B

NOT OKRepair the damaged pinsRepair or replace the engine harness, connector, or ECM, whichever has the damaged pins. • Repair or replace the connector on the harness. • Replace the engine harness. Refer to Procedure 019-


5A




To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead.Condition:• Key switch in the "OFF" position.• Disconnect the ambient air pressure sensor from the engine harness. • Disconnect the engine harness from the ECM.

Action Specifications/Repair Next StepCheck for an open circuit in the ambient air pres-sure signal wire.• Measure the resistance from the engine

harness connector pin 32 to the ambient air pressure sensor signal pin C.

OKLess than 10 ohms

3C


5A




To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead.Condition:• Key switch in the "OFF" position. • Disconnect the ambient air pressure sensor from the engine harness.• Disconnect the engine harness from the ECM.

Action Specifications/Repair Next StepCheck for a short circuit to ground.• Measure the resistance from engine har-

ness connector pin 32 to the chassis ground.


3D


5A




To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead.Condition:• Key switch in the "OFF" position.• Disconnect the engine harness from the ambient air pressure sensor. Disconnect the engine harness from the ECM.

Action Specifications/Repair Next StepCheck for a short circuit from pin to pin.• Measure the resistance from engine har-

ness connector pin 32 to all other pins in the engine harness.


3E


5A

STEP 3E: Clear and check the fault codes.Condition:• Connect all the components. • Key switch in the “ON” position.

Action Specifications/Repair Next StepClear and check the fault codes.• Start the engine and let it idle for one

minute.• Snap the throttle lever. • Read the fault codes with the service tool.

OKNo reoccurrence of Fault Code 222

5A

NOT OKFault Code 222 still occurredIf Fault Code 222 is inactive, replace the ambient air pres-sure sensor. Refer to Procedure 019-004. If Fault Code 222 is active go to Step 4A.

4A



STEP 4: Check for the ECM response. STEP 4A: Check for the appropriate ECM response.

� CAUTION �To avoid damaging a new ECM, all other active fault codes must be investigated prior to replacing the ECM.Condition:• Key switch in the "ON" position. • Disconnect the engine harness from the ECM.

Action Specifications/Repair Next StepCheck for the appropriate ECM response.• Install a jumper wire between ECM engine

port connector pin 10 and pin 32. • Read the fault codes using an electronic

service tool.

OKFault Code 222 is inactive and Fault Code 221 is active.

5A


5A

STEP 5: Clear the fault codes. STEP 5A: Disable the fault code. Condition:• Connect all the components. • Key switch in the “ON” position.


minute.• Using an electronic service tool, verify that



5B

NOT OKReturn to troubleshooting steps or contact the Technical Services Group (if all the steps have been completed and checked again).

1A







Repair complete





Fault Code 234

Engine Overspeed Circuit

Circuit Description:The engine speed sensor provides engine speed information to the electronic control module (ECM). The sensor must be pow-ered by 5 VDC to operate. The sensor generates a signal by sensing the movement of target teeth cut into a steel ring fastened to the backside of the camshaft gear. This ring has 71 teeth and a gap where the 72nd tooth would be placed. This missing tooth indicates that cylinder 1 (and 6) is at top dead center.

Component Location:The engine speed sensor is located on the back side of the gear housing, between the CAPS fuel pump and the air compressor.

Engine Overspeed CircuitCODES REASON EFFECT

Fault Code: 234 PID(P), SID(S): P190SPN: 190 FMI: 0 Lamp: Red

Engine speed signal indicates engine speed has exceeded the overspeed limit.

Fuel to the injectors disabled until the engine speed falls below the overspeed limit.




If flammable vapors are detected, shut down the engine, ventilate the area, and do NOT restart the engine until the source of the vapors is located and repaired.

� CAUTION �If the engine speed stays above 2800 rpm, the engine must be shut off immediately.



STEPS SPECIFICATIONS SRT CODESTEP 1: Identify the reason for overspeed. STEP 1A: Check for proper operating condi-tions.

Proper vehicle operation

STEP 1B: Check for an alternate fuel source. No alternate fuel source STEP 1C: Check transmission operation Transmission functions properly STEP 1D: Inspect the harness and the sensor connector.

No damaged pins

STEP 1E: Check the vehicle speed sensor. Vehicle speed sensor OK STEP 1F: Check the vehicle speed sensor circuit for signs of tampering.

No tampering

STEP 1G: Check the rpm with an electronic ser-vice tool service tool monitor mode.

Correct rpm reading

STEP 1H: Check for an active fault at low rpm. Inactive fault at low rpm. STEP 2: Clear the fault code. STEP 2A: Disable the fault code. Fault Code 234 inactive STEP 2B: Clear the inactive fault codes. All faults cleared

STEP 1: Identify the reason for overspeed. STEP 1A: Check for proper operating conditions. Condition: • Key switch in the "OFF" position.

Action Specifications/Repair Next StepVerify with operator for the following:• Check if the engine was motoring downhill

when the fault was logged.

OKProper vehicle operation

1B

NOT OKCheck the engine for damageElectronics are OK. Inspect the base engine for damage due to overspeed condition.

2A



STEP 1B: Check for an alternate fuel source. � WARNING �

If flammable vapors are detected, shut down the engine, ventilate the area, and do NOT restart the engine until the source of the vapors is located and repaired.Condition:• Key switch in the "OFF" position.

Action Specifications/Repair Next StepCheck for an alternate fuel source.• Check if the operator reported a fuel con-

trolled event where the engine rapidly accelerated to or past overspeed limit with-out accelerator input to cause speed increase then followed by a sharp engine cutout.

• Check the intake manifold for sources of flammable vapors and check the turbo-charger seals to verify there are no oil leaks.

OKNo alternate fuel source

1C

NOT OKLocate the alternate fuel source• Locate any alternate fuel sources, such as operating

the engine near flammable vapors, blown turbo-charger seals, etc.

• Inspect the base engine for damage due to the over-speed condition.

2A

STEP 1C: Check transmission operation. Condition:• Inspect transmission speed sensor.

Action Specifications/Repair Next StepTest drive vehicle to check for proper operation of transmission.

OKTransmission functions properly

1D

NOT OKInstruct operator of proper operation.Repair transmission.Refer to original equipment manufacturer's manual.

2A



STEP 1D: Inspect the harness and the sensor connector pins. Condition:• Key switch in the "OFF" position. • Disconnect the vehicle harness from the vehicle speed sensor.

Action Specifications/Repair Next StepInspect the harness and the sensor connector pins for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

1E

NOT OKRepair the damaged pinsRepair or replace the vehicle harness or the VSS, which-ever has the damaged pins. • Repair the vehicle harness.• Replace the vehicle harness. Refer to the Procedure

019-071. • Replace the VSS. Refer to Procedures 019-090 or

019-091. • Inspect the base engine for damage due to the over-

speed condition.

2A

STEP 1E: Check the vehicle speed sensor. Condition:• Key switch in the "OFF" position.

Action Specifications/Repair Next StepCheck the vehicle speed sensor.• Verify vehicle speed sensor meets manu-

facturer's specifications.

OKVehicle speed sensor OK

1F

NOT OKReplace the vehicle speed sensorRefer to Procedures 019-090 or 019-091.Inspect the base engine for damage due to overspeed con-dition.

2A

STEP 1F: Check the vehicle speed sensor circuit for signs of tampering. Condition:• Key switch in the "OFF" position.

Action Specifications/Repair Next StepCheck the vehicle speed sensor circuit for signs of tampering such as:• extra wires spliced into the vehicle speed

sensor wiring. • cut braiding in the wires. • signs of unnecessary sensor removal and

installation.

OKNo tampering

1G

NOT OKRepair the vehicle speed sensor circuit• Magnetic pick-up VSS. Refer to Procedure 019-091. • Digital input VSS [mini-gen]. Refer to Procedure 019-

090.• Inspect the base engine for damage due to the over-

speed condition.

2A



STEP 1G: Check the rpm with the monitor mode. � CAUTION �

If the engine speed stays above 2800 rpm, the engine must be shut off immediately.Condition:• Engine running. • Key switch in the “ON” position.

Action Specifications/Repair Next StepCheck the rpm with the monitor mode.• Monitor the engine rpm using an electronic

service tool. Note: Compare the engine speed reading on an electronic service tool to a mechani-cal tachometer or the dash tachometer.

OKCorrect rpm reading

1H

NOT OKInspect engine speed sensorCheck the engine speed sensor as outlined for Fault Code 115. Inspect the base engine for damage due to the over-speed condition.

2A

STEP 1H: Check for an active fault at low rpm. � CAUTION �

To avoid damaging the new ECM, all other active fault codes must be investigated prior to replacing the ECM.Condition:• Key switch in the "ON" position.

Action Specifications/Repair Next StepCheck for an active fault code at low rpm.• Using an electronic service tool, check for

fault codes. • Check for active Fault Code 234 when the

engine is not running above 2800 rpm.

OKInactive fault code at low rpm

2A


2A


Action Specifications/Repair Next StepDisable the fault code.• Start the engine and let idle for one minute.• Using an electronic service tool, read the

fault codes.

OKFault Code 234 is inactive

2B


1A







Repair Complete





Fault Code 235

Engine Coolant Level - Engine Protection

Circuit Description:The coolant level sensor monitors the coolant level within the coolant system and passes information to the electronic control mod-ule (ECM) through the engine harness. Because this sensor is so complex, do not use a multimeter to check it. If the radiator cool-ant level drops below a certain level, a progressive power and/or speed derate will occur. Engine may shutdown if the engine protection shutdown feature is enabled.

Component Location:The coolant level sensor is located in the radiator top tank or surge tank.

Shop Talk:This is an application specific component and can vary in location.• If a shorting plug is used in the coolant level circuit, verify that it is wired correctly. • Inspect the wiring harness between the Weather-Pack 4-Way connector and the coolant level sensor for damage. • Make sure the coolant level sensor is located in the middle of the tank rather that off to one side where the coolant level can

change when the vehicle turns a corner.

Engine Coolant Level - Engine ProtectionCODES REASON EFFECT

Fault Code: 235 PID(P), SID(S): P111SPN: 111FMI: 1Lamp: Maintenance

Coolant level signal at pin 27 and pin 37 of the engine harness indicates coolant level is low.

Power and/or speed derates and possible engine shutdown if engine protection shutdown feature is enabled.





STEPS SPECIFICATIONS SRT CODESTEP 1: Verify the coolant level. STEP 1A: Check the coolant level. Coolant level is normal STEP 2: Check the coolant level sensor. STEP 2A: Confirm the fault is still active with the engine running.

Fault is still active

STEP 3: Check engine harness. STEP 3A: Inspect the engine harness, coolant level sensor, and ECM connectors.

No damaged pins

STEP 3B: Check for open circuit. Less than 10 ohms STEP 3C: Check sensor supply voltage. 4.5 to 5.25 VDCSTEP 4: Clear the fault code. STEP 4A: Disable the fault code. Fault Code 235 inactive STEP 4B: Clear the inactive fault codes. All faults cleared

STEP 1: Verify the coolant level. STEP 1A: Check the coolant level.

� WARNING �Wait until the coolant temperature is below 50�C [120�F] before removing the coolant system pressure cap or the cool-ant temperature sensor. Failure to do so can cause personal injury from heated coolant spray.

� CAUTION �Do not add cold coolant to a hot engine. Castings can be damaged. Allow engine to cool to below 50�C [120�F] before adding coolant.Condition:

Action Specifications/Repair Next StepCheck coolant level. • Remove the radiator cap and inspect cool-

ant level.

OK Coolant level is normal

2A

NOT OK Add coolant to the radiator Note: Make sure the coolant has the proper ratio of anti-freeze and water.

4A



STEP 2: Check the coolant level sensor. STEP 2A: Confirm the fault is still active with the engine running.Condition:• Key switch in the "ON" position.

Action Specifications/Repair Next StepConfirm the fault is still active with the engine running.• Start the engine and let idle for at least one

minute. • Read the fault codes using an electronic

service tool.

OKFault Code 235 is still active.

3A

NOT OKFault Code 235 is inactive.

4A

STEP 3: Check engine harness. STEP 3A: Inspect the engine harness, coolant level sensor, and ECM connectors.

� WARNING �Clear all faults before replacing ECM.Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the engine control module (ECM). • Disconnect the engine harness from the coolant level sensor.

Action Specifications/Repair Next StepInspect the engine harness, coolant level sensor, and ECM connectors for:• bent or broken pins • pushed back or expanded pins• corroded pins• moisture in or on the connector• missing connector seal.

OKNo damaged pins

3B

NOT OKRepair damaged pinsRepair or replace the engine harness, ECM, or coolant level sensor, whichever has the damaged pins. • Repair the engine harness.• Replace the engine harness. Refer to Procedure 019-

043.• Replace the ECM. Refer to Procedure 019-031. • Replace the coolant level sensor. Refer to Procedure

019-017.

4A



STEP 3B: Check for open circuit. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead. Condition:• Key switch in the “OFF” position.• Disconnect the engine harness from the ECM. • Disconnect the engine harness from the coolant level sensor.

Action Specifications/Repair Next StepCheck for open circuit in the coolant level sensor circuit.• Measure the resistance from pin B on the

harness side of the coolant level sensor cir-cuit to pin 19 of the engine harness connec-tor.

• Measure the resistance from pin D on the harness side of the coolant level sensor cir-cuit to pin 27 of the engine harness connec-tor.

• Measure the resistance from pin A on the harness side of the coolant level sensor cir-cuit to pin 37 of the engine harness connec-tor.

• Measure the resistance from pin C on the harness side of the coolant level sensor cir-cuit to pin 49 of the engine harness connec-tor.

OKLess than 10 ohms

3C


4A



STEP 3C: Check sensor supply voltage. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead.Condition:• Key switch in the “ON” position. • Disconnect the engine harness from the coolant level sensor. • Connect the engine harness to the ECM.

Action Specifications/Repair Next StepCheck sensor supply voltage.• Measure the voltage from pin C of the sen-

sor connector, harness side, to engine block ground.

OK4.5 to 5.25 VDC

4A


4A






4B


1A







Repair complete.

NOT OKTroubleshoot any remaining active fault codes





Fuel Temperature Sensor Circuit

Circuit Description:The fuel pressure/temperature sensor is used by the electronic control module (ECM) to monitor the fuel temperature in the accu-mulator. The ECM monitors the voltage on the signal pin and converts this to a temperature value.

Component Location:The fuel pressure/temperature sensor is located on the rear of the CAPS fuel pump accumulator.

Shop Talk:The resistance of the sensor varies with the temperature. Use a volt-ohmmeter and read the fuel temperature using an electronic service tool. Compare the resistance value measured with the following table to verify that the sensor is functioning properly.

Fuel Temperature Sensor Circuit CODES REASON EFFECT


FC263: High voltage detected at the fuel temper-ature signal pin 35 of the engine harness.

FC265: Low voltage detected at the fuel temper-ature signal pin 35 of the engine harness.

Default value used for engine fuel temperature.

Possible low power and no engine protection for fuel temperature.


0 32 30k to 36k

25 77 9k to 11k

50 122 3k to 4k

75 167 1350 to 1500

100 212 600 to 675




To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male AMP/Cannon Metri-Pack Deutsch test leadTool No. 3162982 - fuel pressure/temperature sensor break-out cable.


STEPS SPECIFICATIONS SRT CODESTEP 1: Check the fault codes. STEP 1A: Read the fault codes. Fault Codes 122, 135, 144, 153, 221, 263, 352, and

451 are not activeSTEP 2: Check the fuel temperature sensor. STEP 2A: Inspect the engine harness and sensor connector.

No damaged pins

STEP 2B: Check the resistance of the fuel temperature sensor.

175 to 244k ohms

STEP 2C: Check for short circuit to ground in fuel temperature sensor.

More than 100k ohms

STEP 3: Check the engine harness. STEP 3A: Inspect the harness and the ECM connector.

No damaged pins

STEP 3B: Check for open circuit. Less than 10 ohms STEP 3C: Check for short circuit to ground. More than 100k ohms STEP 3D: Check for short circuit from pin to pin.

More than 100k ohms

STEP 4: Clear fault codes. STEP 4A: Disable the fault code. Fault Code 263 and 265 inactive STEP 4B: Clear the inactive fault codes. All faults cleared

STEP 1: Check for multiple fault codes. STEP 1A: Read the fault codes. Condition: • Key switch in the “ON” position.


service tool.

OKFault Codes 122, 135, 144, 153, 221, 263, 352, and 451, are not active

2A

NOT OKPossible sensor failure, short circuit to ground in the sen-sor +5 VDC common supply, or a short circuit from pin to pin, or an open circuit in the sensor common ground.




STEP 2: Check the fuel temperature sensor. STEP 2A: Inspect the fuel temperature sensor and engine harness connector pins.Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the fuel temperature sensor.

Action Specifications/Repair Next StepInspect the harness and the sensor connector pins for: • bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OK No damaged pins

2B

NOT OK Repair the damaged pinsRepair or replace the engine harness or the fuel tempera-ture sensor, whichever has the damaged pins. • Repair the engine harness. • Replace the engine harness. Refer to Procedure 019-

043. • Replace the fuel temperature sensor. Refer to Proce-

dure 019-153.

4A

STEP 2B: Check the resistance of the fuel temperature sensor.Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the fuel temperature sensor. • Install the fuel pressure/temperature sensor break-out cable, Tool No. 3162982.

Action Specifications/Repair Next StepCheck the resistance of the fuel temperature sensor.• Measure the resistance from pin B to pin D

of the fuel temperature sensor.

OK175 to 244k ohms

2C

NOT OKReplace the fuel temperature sensorRefer to Procedure 019-153.

4A



STEP 2C: Check for a short circuit to ground in the fuel temperature sensor. Condition:• Key switch in the “OFF” position.• Disconnect the engine harness from the fuel temperature sensor.


fuel temperature sensor to engine block ground.


3A

NOT OKReplace the fuel pressure/temperature sensorRefer to Procedure 019-153.

4A






OKNo damaged pins

3B



4A




To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male AMP/Cannon Metri-Pack Deutsch test lead. Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the fuel temperature sensor.• Disconnect the engine harness from the ECM.


engine harness to pin D on the harness side of the fuel temperature sensor.

• Measure the resistance from pin 19 of the engine harness to pin B on the harness side of the fuel temperature sensor.

OKLess than 10 ohms

3C


4A




To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male AMP/Cannon Metri-Pack Deutsch test lead.Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the fuel temperature sensor. Disconnect the engine harness from the ECM.


engine harness to engine block ground. • Measure the resistance from pin 19 of the



3D


4A




To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male AMP/Cannon Metri-Pack Deutsch test lead.Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the fuel temperature sensor. Disconnect the engine harness from the ECM.





4A


4A



Fault Codes 263 and 265 are inactive.

OKFault Codes 263 and 265 are inactive

4B


1A







Repair complete





Fault Code 268

Fuel Pressure Sensor Circuit

Circuit Description:The fuel pressure/temperature sensor is used by the electronic control module (ECM) to monitor the fuel pressure in the accumu-lator. The ECM monitors the voltage on the signal pin and converts this voltage to a pressure value.

Component Location:The fuel pressure/temperature sensor is located on the rear of the CAPS accumulator.

Fuel Pressure Sensor Circuit CODES REASON EFFECT

Fault Code: 268PID(P), SID(S): P094SPPN: 94FMI: 2 Lamp: Yellow

Fuel Pressure in the accumulator is not changing with engine operating conditions.

Power and/or Speed derate, engine may run rough.






STEP 1: Check fuel pressure/temperature sensor. STEP 1A: Inspect the fuel pressure/temperature sensor and engine harness connector.

No damaged pins

STEP 1B: Monitor the fuel pressure. Fuel pressure changes as expected STEP 2: Clear the fault codes. STEP 2A: Disable the fault code. Fault Code 268 inactive STEP 2B: Clear the inactive fault codes. All fault codes cleared

STEP 1: Check fuel pressure/temperature sensor. STEP 1A: Inspect the fuel pressure/temperature sensor and engine harnessCondition:• Key switch in the “OFF” position. • Disconnect the engine wiring harness from the ECM. • Disconnect the engine wiring harness from the fuel pressure/temperature sensor.

Action Specifications/Repair Next StepInspect the engine harness, fuel pressure/tem-perature sensor and ECM connectors for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

1B

NOT OKRepair the damaged pinsRepair or replace the engine harness or sensor, whichever has the damaged pins. • Repair the engine harness. • Replace the engine harness. Refer to Procedure 019-

043.• Replace the fuel pressure/temperature sensor. Refer

to Procedure 019-153.

2A

STEP 1B: Monitor fuel pressure. Condition:• Key switch in the “ON” position. • Connect engine harness to the sensor.

Action Specifications/Repair Next StepStart engine, monitor the fuel pressure.• Check the fuel pressure using an electronic

service tool during engine operation. NOTE: Fuel pressure should fluctuate as engine is accelerated and decelerated.

• Fuel pressure at idle: 5,000 psi. • Maximum fuel pressure: 15,000 psi.

OKFuel pressure changes as expected

2A


2A




Action Specifications/Repair Next StepDisable the fault code.• Start the engine and let idle for 1 minute. • Using an electronic service tool, verify Fault



2B


1A

STEP 2B: Clear the inactive fault codes. Condition:• Connect all the components.• Key switch in the “ON” position.




Repair complete






Front Pumping Valve Circuit

Circuit Description:The pumping control valve of the CAPS fuel pump regulates the quantity of fuel that is pumped into the accumulator. The Elec-tronic Control Module (ECM) commands the valve to close based on several different parameters including fuel pressure, engine load and throttle position.

Component Location:The pumping control valves are located on the fuel pump on the top of the accumulator.

Front Pumping Valve CircuitCODES REASON EFFECT

Fault Code: 271 or 272PID(P), SID(S): S151SPN: 1347 FMI: 5 or 6 Lamp: Yellow

FC271: Low or no current detected at the front pumping valve pin 21 of the engine harness.

FC272: High current detected at the front pump-ing valve pin 21 of the engine harness.

Engine power will derate.






STEP 1: Check the front pumping valve. STEP 1A: Inspect the pumping valve connector for damaged pins.

No damaged pins

STEP 1B: Check the resistance of the pumping valve solenoid coil.

0.5 to 1.5 ohms

STEP 1C: Check for short circuit to ground in the pumping valve coil.

More than 100k ohms

STEP 1D: Check for open circuit in pumping control valve harness.

Less than 10 ohms

STEP 2: Check the engine harness. STEP 2A: Inspect the engine harness, pumping valve connector, and the ECM connector pins.

No damaged pins


More than 100k ohms

STEP 3: Clear fault codes. STEP 3A: Disable the fault code. Fault Code 271 or 272 inactive STEP 3B: Clear the inactive fault codes. All fault cleared

STEP 1: Check the front pumping valve. STEP 1A: Inspect front pumping valve and connector for damaged pins. Condition:• Key switch in the “OFF” position. • Disconnect the pumping control valve harness from the pumping control valve at the terminals.• Disconnect the engine harness from the front pumping control valve at the four pin connector.

Action Specifications/Repair Next StepInspect the front pumping valve four pin connec-tor and pumping control valve terminals for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

1B

NOT OKRepair the damaged pinsRepair or replace the pumping control valve harness or fuel injection pump, whichever has damaged pins.• Replace the pumping control valve harness. Refer to

Procedure 005-016 in Section 10 Chapter 12 of the CDC 24 Valve 8.3 Liter Engine Repair Manual.

• Replace the fuel injection pump. Refer to Procedure 005-016 in Section 10 Chapter 12 of the CDC 24 Valve 8.3 Liter Engine Repair Manual.

3A



STEP 1B: Check the resistance of the front pumping valve. Condition:• Key switch in the “OFF” position. • Disconnect the pumping control valve harness from the front pumping control valve.

Action Specifications/Repair Next StepCheck resistance of front pumping control valve.• Measure the resistance between the termi-

nals on top of the front pumping control valve.

OK0.5 to 1.5 ohms

1C

NOT OKReplace accumulator moduleRefer to Procedure 005-085 in Section 10 Chapter 12 of the CDC 24 Valve 8.3 Liter Engine Repair Manual.

3A



STEP 1C: Check for short circuit to ground in front pumping control valve. Condition:• Key switch in the “OFF” position. • Disconnect the pumping control valve harness from the front pumping valve coil.

Action Specifications/Repair Next StepCheck for short to ground in front pumping con-trol valve.• Measure the resistance between one of the

terminals of the front pumping control valve connector and chassis ground.


1D


3A



STEP 1D: Check for open circuit in pumping control valve harness. � CAUTION �

To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3823993 - male Deutsch/Metri-Pack test lead.Condition:• Key switch in the “OFF” position. • Connect the pumping control valve harness to the front pumping control valve.• Disconnect the engine harness from the pumping control valve at the four pin connector.

Action Specifications/Repair Next StepCheck for an open circuit in the control valve har-ness.• Measure the resistance from pin 1 to the

appropriate ring terminal of the pumping control valve harness.

• Measure the resistance from pin 2 to the appropriate ring terminal of the pumping control valve harness.

OKLess than 10 ohms

2A

NOT OKReplace the pumping control valve harness.Refer to Procedure 005-016 in Section 10 Chapter 12 of the CDC 24 Valve 8.3 Liter Engine Repair Manual.

3A



STEP 2: Check the engine harness. STEP 2A: Inspect the harness, pumping control valve connector and ECM connector pins. Condition:• Key switch in the “OFF“ position.• Disconnect the engine harness from the ECM. • Disconnect the engine harness from the pumping control valve at the 4-pin connector.

Action Specifications/Repair Next StepInspect the engine harness, pumping control valve connector, and ECM connector pins for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

2B

NOT OKRepair the damaged pinsRepair or replace the engine harness or ECM, whichever has damaged pins. • Repair the engine harness. • Replace the engine harness. Refer to Procedure 019-


3A



STEP 2B: Check for an open circuit. Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the ECM. • Disconnect the engine harness from the pumping control valve at the four pin connector.

Action Specifications/Repair Next StepCheck for an open circuit in the front pumping control valve.• Measure the resistance from pin 31 of the

engine harness to pin 2 of the front pump-ing control valve connector on the engine harness side.

• Measure the resistance from pin 21 of the engine harness to pin 1 of the front pump-ing control valve connector on the engine harness side.

OKLess than 10 ohms

2C


3A



STEP 2C: Check for short circuit to ground. Condition:• Key switch in the “OFF” position.• Disconnect the engine harness from the ECM.• Disconnect the engine harness from the pumping control valve at the four pin connector.

Action Specifications/Repair Next StepCheck for a short circuit to ground.• Measure the resistance from pins 21 and

31 of the engine harness connector to chassis ground.


2D

NOT OKReplace engine harness.Refer to Procedure 019-043.

3A



STEP 2D: Check for short circuit from pin to pin.Condition:• Key switch in the “OFF” position.• Disconnect the engine harness from the ECM. • Disconnect the engine harness from the pumping control valve at the four pin connector.

Action Specifications/Repair Next StepCheck for short circuit from pin to pin.• Measure the resistance from pin 21 of the

engine harness connector to all other pins in the connector.

• Measure the resistance from pin 31 of the engine harness connector to all other pins in the connector.


3A


3A

STEP 3: Clear fault codes. STEP 3A: Disable the fault code. Condition:• Connect all the components. • Key switch in the “ON” position.


Codes 271 and 272 are inactive.

OKFault Codes 271 and 272 inactive

3B


1A







Repair complete






Rear Pumping Valve Circuit

Circuit Description:The pumping control valve of the CAPS fuel pump regulates the quantity of fuel that is pumped into the accumulator. The Elec-tronic Control Module (ECM) commands the valve to close based on several different parameters including fuel pressure, engine load and throttle position.

Component Location:The pumping control valves are located on the fuel pump on the top of the accumulator.

Rear Pumping Valve Circuit CODES REASON EFFECT

Fault Code: 273 or 274PID(P), SID(S): S152SPN: 1348 FMI: 5 or 6 Lamp: Yellow

Fault Code 273: Low or no current detected at the rear pumping valve pin 15 of the engine har-ness.Fault Code 274: High current detected at the rear pumping valve pin 15 of the engine harness.

Engine power will derate.





STEPS SPECIFICATIONS SRT CODESTEP 1: Check the rear pumping valve. STEP 1A: Inspect the pumping valve connector for damaged pins.

No damaged pins

STEP 1B: Check the resistance of the pumping valve solenoid coil.

0.5 to 1.5 ohms

STEP 1C: Check for short circuit to ground in the pumping valve coil.

More than 100k ohms

STEP 1D: Check for open circuit in pumping control valve harness.

Less than 10 ohms

STEP 2: Check the engine harness. STEP 2A: Inspect the engine harness, pumping valve connector, and the ECM connector pins.

No damaged pins


More than 100k ohms

STEP 3: Clear fault codes. STEP 3A: Disable the fault code. Fault Codes 273 and 274 inactive STEP 3B: Clear the inactive fault codes. All faults cleared

STEP 1: Check the rear pumping valve. STEP 1A: Inspect rear pumping valve and connector for damaged pins.Condition:• Key switch in the “OFF” position.• Disconnect the engine harness from the pumping control valve at the four pin connector • Disconnect the pumping control valve harness from the rear pumping control valve.

Action Specifications/Repair Next StepInspect the rear pumping control valve connector for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

1B

NOT OKRepair the damaged pinsRepair or replace the pumping control valve harness or fuel injection pump, whichever has damaged pins.• Replace the pumping control valve harness. Refer to

Procedure 005-016 in Section 10 Chapter 12 of the CDC 24 Valve 8.3 Liter Engine Repair Manual.

• Replace the fuel injection pump. Refer to Procedure 005-016 in Section 10 Chapter 12 of the CDC 24 Valve 8.3 Liter Engine Repair Manual.

3A



STEP 1B: Check the resistance of the pumping control valve. Condition:• Key switch in the “OFF” position. • Disconnect the pumping control valve harness from the rear pumping control valve.

Action Specifications/Repair Next StepCheck resistance of rear pumping control valve.• Measure the resistance between the termi-

nals on top of the rear pumping control valve.

OK0.5 to 1.5 ohms

1C


3A



STEP 1C: Check for short circuit to ground in rear pumping valve.Condition:• Key switch in the “OFF” position. • Disconnect the pumping control valve harness from the rear pumping control valve.

Action Specifications/Repair Next StepCheck for short to ground in the rear pumping control valve.• Measure the resistance between one of the

terminals of the rear pumping control valve and chassis ground.


1D


3A



STEP 1D: Check for open circuit in control valve harness. � CAUTION �

To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3823993 - male Deutsch/Metri-Pack test lead.Condition:• Key switch in the “OFF” position. • Disconnect the pumping control valve harness from the rear pumping control valve. • Disconnect the engine harness from the pumping control valve at the four pin connector.

Action Specifications/Repair Next StepCheck for an open circuit in the control valve har-ness.• Measure the resistance from pin 3 to the

appropriate ring connector of the pumping control valve harness.

• Measure the resistance from pin 4 to the appropriate ring connector of the pumping control valve harness.

OKLess than 10 ohms

2A

NOT OKReplace the pumping control valve harness.Refer to the Procedure 005-016 in Section 10 Chapter 12 of the CDC 24 Valve 8.3 Liter Engine Repair Manual.

3A



STEP 2: Check the engine harness. STEP 2A: Inspect the harness, pumping control valve connector, and ECM connector pins.Condition:• Key switch in the “OFF“ position. • Disconnect the engine harness from the ECM. • Disconnect the engine harness from the pumping control valve at the four pin connector.

Action Specifications/Repair Next StepInspect the engine harness, pumping control valve connector, and ECM connector pins for: • bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OK No damaged pins

2B

NOT OK Repair the damaged pinsRepair or replace the engine harness or ECM, whichever has damaged pins. • Repair the engine harness. • Replace the engine harness. Refer to Procedure 019-

043. • Replace the ECM. Refer to Procedure 019-031.

3A



STEP 2B: Check for an open circuit. Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the ECM. • Disconnect the engine harness from the pumping control valve at the four pin connector.

Action Specifications/Repair Next StepCheck for an open circuit in the rear pumping control valve.• Measure the resistance from pin 15 of the

engine harness to pin 4 of the rear pumping control valve connector on the engine har-ness side.

• Measure the resistance from pin 25 of the engine harness to pin 3 of the rear pumping control valve connector on the engine har-ness side.

OKLess than 10 ohms

2C


3A



STEP 2C: Check for short circuit to ground. Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the ECM. • Disconnect the engine harness from the pumping control valve at the four pin connector.

Action Specifications/Repair Next StepCheck for a short circuit to ground.• Measure the resistance from pins 15 and

25 of the engine harness connector to chassis ground.


2D


3A



STEP 2D: Check for a short circuit from pin to pin. Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the ECM. • Disconnect the engine harness from the rear pumping control valve at the four pin connector.





3A


3A

STEP 3: Clear fault codes. STEP 3A: Disable the fault code.Condition:• Connect all the components. • Key switch in the “ON” position.


Codes 273 and 274 are inactive.


3B


1A







Repair complete





Fault Code 275

Front Pumping Element of the CAPS Fuel Pump

Circuit Description:The front pumping element CAPS Fuel Pump consists of the front barrel and plunger, front pumping control valve and the front check valve in the accumulator. These components are part of the accumulator module. The pumping element is responsible for pumping fuel into the accumulator and maintaining the desired pressure in the accumulator.

Component Location:The front pumping element is part of the CAPS fuel pump in the accumulator module.

Shop Talk:• A plugged fuel filter can cause both Fault Code 275 and Fault Code 328 to be logged intermittently. • If Fault Code 275 and Fault Code 328 are both present, check fuel filter restriction. • A failed engine harness could also cause this fault code to be active. • If Fault Code 271 or Fault Code 272 are active, troubleshoot them first.

Front Pumping ElementCODES REASON EFFECT

Fault Code: 275PID(P), SID(S): S151SPN: 1347FMI: 7Lamp: Yellow

The Electronic Control Module (ECM) has detected a failure in the front pumping element.

Derate in power output of the engine.





STEPS SPECIFICATIONS SRT CODESTEP 1: Check for fault codes. STEP 1A: Read fault codes. Fault Code 328 is not present STEP 2: Check for pumping element failure. STEP 2A: Verify pumping valve solenoid performance.

Solenoid clicks when activated

STEP 2A-1: Check fault codes. Fault Code 271 inactive STEP 2B: Verify pumping element performance. Pumping elements performing equally STEP 3: Clear fault codes. STEP 3A: Disable the fault code. Fault Code 275 inactive STEP 3B: Clear the inactive fault codes. All faults cleared

STEP 1: Check fault codes. STEP 1A: Read the fault codes.Condition:• Key switch in the “ON” position.


service tool. Verify that Fault Code 328 is not present.

OKFault Code 328 is not present

2A

NOT OKFault Code 328 is presentIf present, verify that the fuel filter is not plugged. Refer to Procedure 006-011 in Section 10 Chapter 13 of the CDC 24 Valve 8.3 Liter Engine Repair Manual.

3A

STEP 2: Verify pumping valve solenoid performance. STEP 2A: Check pumping valve circuit performance. Condition:• Key switch in the “ON” position.

Action Specifications/Repair Next StepVerify pumping valve solenoid circuit perfor-mance.• Using an electronic service tool, run the

Solenoid Click Test on the front pumping valve solenoid. Listen for an audible click when activating the test to verify that the solenoid is operating.

OKSolenoid clicks when activated

2B

NOT OKSolenoid does not click when activated

2A-1

STEP 2A-1: Check fault codes. Condition:• Key switch in the “ON” position.



Action Specifications/Repair Next StepRead fault codes.• Read fault codes using an electronic ser-

vice tool.


3A


Refer to Fault Code 271

STEP 2B: Verify pumping element performance. Condition:• Key switch in the ”ON” position with the engine operating.

Action Specifications/Repair Next StepVerify pumping element performance.• Using an electronic service tool, run the

Pumping Plunger Cutout Test on each pumping plunger. Observe VCA, Accumula-tor Pressure, Accumulator Pressure Set-point and engine speed for each pumping plunger as the other is cutout.

OKPumping element performs equally

3A

NOT OKReplace the accumulator moduleRefer to Procedure 005-085 in Section 10 Chapter 12 of the CDC 24 Valve 8.3 Liter Engine Repair Manual.

3A

STEP 3: Clear the fault codes. STEP 3A: Disable the fault code. Condition:• Connect all the components.• Key switch in the “ON” position.



Fault Code 275 is inactive.


3B


1A

STEP 3B: Clear the inactive fault code. Condition:• Connect all the components. • Key switch in the “ON” position.




Repair complete



STEP 2A-1: Check fault codes.




Injection Control Valve Circuit

Circuit Description:The injection control valve regulates both the quantity of fuel that is injected into each cylinder as well as the timing of the injection event. The electronic control module (ECM) commands the injection control valve to open based on several different parameters including fuel pressure, engine load, engine speed and throttle position.

Component Location:The injection control valve is located on the CAPS fuel injection pump on the top of the distributor.

Injection Control Valve CircuitCODES REASON EFFECT


FC276: Low or no current detected at the injec-tion control valve pin 07 of the engine harness.FC279: High current detected at the injection control valve pin 07 of the engine harness

Fueling to injectors disabled, engine may die, engine power derate.




To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male AMP/Deutsch/Metri-Pack test leadTool No. 3823993 - male Deutsch/Metri-Pack test lead.


STEPS SPECIFICATIONS SRT CODESTEP 1: Check the injection control valve. STEP 1A: Inspect the injection control valve connector for damaged pins.

No damaged pins

STEP 1B: Check the resistance of the injection control valve.

0.08 to 0.12 ohms

STEP 1C: Check for short circuit to ground in the injection control valve.

More than 100k ohms


No damaged pins


More than 100k ohms

STEP 3: Clear fault codes. STEP 3A: Disable the fault code. FC 276 or 279 inactive STEP 3B: Clear the inactive fault codes. All fault cleared

STEP 1: Check the injection control valve. STEP 1A: Inspect injection control valve and connector for damaged pins. Condition:• Key switch in the “OFF” position.• Disconnect the engine harness from the injection control valve.

Action Specifications/Repair Next StepInspect the injection control valve connector for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

1B

NOT OKRepair the damaged pinsRepair or replace the engine harness or injection control valve, whichever has damaged pins. • Repair the engine harness. • Replace the engine harness. Refer to Procedure 019-

043.• Replace the fuel injection pump. Refer to Procedure

005-016 in Section 10 Chapter 12 of the CDC 24 Valve 8.3 Liter Engine Repair Manual.

3A



STEP 1B: Check the resistance of the injection control valve. � CAUTION �

To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3823993 - male Deutsch/Metri-Pack test lead.Condition:• Key switch in the “OFF” position.• Disconnect the engine wiring harness from the injection control valve.

Action Specifications/Repair Next StepCheck resistance of injection control valve.• Measure the resistance between pin 1 and

pin 2 of the injection control valve connec-tor.

OK0.08 to 0.12 ohms

1C

NOT OKReplace the distributor/injector control valve module.Refer to Procedure 005-086 and 005-087 in Section 10 Chapter 12 of the CDC 24 Valve 8.3 Liter Engine Repair Manual.

3A



STEP 1C: Check for short circuit to ground in injection control valve. � CAUTION �

To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3823993 - male Deutsch/Metri-Pack test lead.Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the injection control valve coil.

Action Specifications/Repair Next StepCheck for short to ground in injection control valve.• Measure the resistance between pin 1 of

the injection control valve connector to chassis ground.

• Measure the resistance between pin 2 of the injection control valve connector to chassis ground.


2A

NOT OKReplace the distributor/injector control valve module.Refer to Procedure 005-086 and 005-087 in Section 10 Chapter 12 of the CDC 24 Valve 8.3 Liter Engine Repair Manual.

3A



STEP 2: Check the engine harness. STEP 2A: Inspect the harness and ECM connector pins. Condition:• Key switch in the “OFF“ position. • Disconnect the engine harness from the ECM.

Action Specifications/Repair Next StepInspect the engine harness and ECM connector pins for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

2B



3A




To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male AMP/Deutsch/Metri-Pack test lead Tool No. 3823993 - male Deutsch/Metri-Pack test lead. Condition:• Key switch in the “OFF” position.• Disconnect the engine harness from the ECM. Disconnect the engine harness from the injection control valve.

Action Specifications/Repair Next StepCheck for an open circuit in the injection control valve.• Measure the resistance from pin 7 of the

engine harness to pin 1 of the injection con-trol valve connector.

• Measure the resistance from pin 6 of the engine harness to pin 2 of the injection con-trol valve connector.

OKLess than 10 ohms

2C


3A



STEP 2C: Check for short circuit to ground. � CAUTION �

To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male AMP/Deutsch/Metri-Pack test lead.Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the ECM. • Disconnect the engine harness from the injection control valve solenoid.

Action Specifications/Repair Next StepCheck for a short circuit to ground.• Measure the resistance from pins 6 of the

engine harness connector to chassis ground.

• Measure the resistance from pins 7 of the engine harness connector to chassis ground.


2D


3A



STEP 2D: Check for short circuit from pin to pin. � CAUTION �

To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male AMP/Deutsch/Metri-Pack test lead. Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the ECM.





3A


3A

STEP 3: Clear fault codes. STEP 3A: Disable the fault code. Condition:• Connect all the components. • Key switch in the “ON” position.


Code 276 or 279 is inactive.


3B


1A



STEP 3B:Clear the inactive fault codes. Condition:• Connect all the components.• Key switch in the “ON” position.




Repair complete





Fault Code 277

Injection Control Valve

Circuit Description:The injection control valve regulates both the quantity of fuel that is injected into each cylinder as well as the timing of the injection event. The Electronic Control Module (ECM) commands the injection control valve to open based on several different parameters including fuel pressure, engine speed and throttle position.

Component Location:The injection control valve is located on the fuel injection pump on the top of the distributor.

Injection Control ValveCODES REASON EFFECT

Fault Code: 277PID(P), SID(S): P018SPN: 633FMI: 7Lamp: Yellow

The Electronic Control Module (ECM) has detected a failure in the injection control valve.

Engine loses power or dies.





STEPS SPECIFICATIONS SRT CODESTEP 1: Check injection control valve. STEP 1A: Verify injection control valve performance.

Solenoid clicks when activated and no faults present

STEP 1A-1: Check fault codes. Fault Code 276, 279, and 329 inactive STEP 2: Clear the fault codes. STEP 2A: Disable the fault codes. Fault Code 277 inactive STEP 2B: Clear the inactive fault codes. All faults cleared

STEP 1: Check injection control valve performance. STEP 1A: Verify injection control valve performance.Condition:• Key switch in the “ON” position.

Action Specifications/Repair Next StepVerify injection control valve performance.• Using an electronic service tool, run the

Solenoid Click Test on the injection control valve. Listen for an audible click when acti-vating the test to verify that the solenoid is operating.


2A


1A-1



service tool. • Check that Fault Codes 276, 279 and 329

are inactive.

OKFault Codes 276, 279, and 329 are inactive

2A

NOT OKFault Code 276 or 279 or 329 is active.

Refer to Fault Code 276, 279 or 329



STEP 2: Clear the fault codes. STEP 2A: Disable the fault codes.Condition:• Connect all the components. • Key switch in the “ON” position.Disable the fault code.• Start the engine and let idle for one minute.• Using an electronic service tool, verify that



2B


1A





Repair complete





Fault Code 278

Lift Pump Circuit

Circuit Description:The electronic control module (ECM) enables the lift pump by sending a signal directly to the lift pump. The ECM cycles the lift pump on for 30 seconds after turning on the key switch.

Component Location:The lift pump is mounted to the engine block on the intake side towards the rear of the engine.

Lift Pump CircuitCODES REASON EFFECT


Error detected in lift pump circuit at pin 11 and 22 of the engine harness.

Possible low power, engine may die, run rough, or be difficult to start.




To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male AMP/Metri-Pack/Deutsch test leadTool No. 3823993 - male Deutsch test lead.


STEP 1: Check the lift pump. STEP 1A: Inspect the engine harness and lift pump connectors.

No damaged pins

STEP 1B: Check resistance of lift pump. 1.0 to 1.2 ohms STEP 1C: Check for a short to ground. More than 100k ohmsSTEP 2: Check engine harness. STEP 2A: Inspect harness and ECM connector pins.

No damaged pins

STEP 2B: Check for open circuit. Less than 10 ohms STEP 2C: Check for short circuit to ground. More than 100k ohms STEP 2D: Check for short from pin to pin. More than 100k ohms STEP 2E: Measure voltage at the lift pump. 11 to 13 VDC

on 12 VDC systems23 to 25 VDCon 24 VDC systems

STEP 3: Clear the fault codes. STEP 3A: Disable the fault code. Fault Code 278 inactive STEP 3B: Clear the inactive fault codes. All faults cleared

STEP 1: Check the lift pump. STEP 1A: Inspect the engine harness and lift pump connectors. Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the lift pump.

Action Specifications/Repair Next StepInspect the engine harness and lift pump con-nectors for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

1B

NOT OKRepair the damaged pinsRepair or replace the engine harness or lift pump, which-ever has damaged pins. • Repair the engine harness.• Replace the engine harness. Refer to Procedure 019-

043.• Repair or replace the lift pump. Refer to Procedure

005-045.

3A



STEP 1B: Check resistance of lift pump. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3823993 - male Deutsch test lead. Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the lift pump.

Action Specifications/Repair Next StepCheck resistance of lift pump.• Measure the resistance from pin 1 to pin 2

of the lift pump harness.

OK1.0 to 1.2 ohms

1C

NOT OKReplace lift pumpRefer to Procedure 005-045.

3A



STEP 1C: Check for a short to ground. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3823993 - male Deutsch test lead.Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the lift pump.

Action Specifications/Repair Next StepCheck for a short to ground in the lift pump.• Measure the resistance from pin 1 of the lift

pump connector, pump side, to engine block ground.

• Measure the resistance from pin 2 of the lift pump connector, pump side, to engine block ground.


2A

NOT OKReplace the lift pumpRefer to Procedure 005-045.

3A



STEP 2: Check engine harness. STEP 2A: Inspect engine harness and ECM connectors. Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the ECM.


OKNo damaged pins

2B



3A




To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male AMP/Metri-Pack/Deutsch test leadTool No. 3823993 - male Deutsch test lead. Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the ECM. • Disconnect the lift pump connector from the engine harness.

Action Specifications/Repair Next StepCheck for an open circuit in the lift pump supply pin.• Measure the resistance from pin 2 of the lift

pump connector, harness side, and engine block ground.

• Measure the resistance from pin 11 of the engine harness connector to pin 1 of the lift pump connector.

• Measure the resistance from pin 22 of the engine harness connector to pin 1 of the lift pump connector.

OKLess than 10 ohms

2C


3A



STEP 2C: Check for short circuit to ground. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male AMP/Metri-Pack/Deutsch test lead. Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the ECM. Disconnect the engine harness from the lift pump.

Action Specifications/Repair Next StepCheck for a short circuit to ground.• Measure resistance from pin 11 of the

engine harness to engine block ground.• Measure resistance from pin 22 of the


OKMore the 100k ohms

2D


3A



STEP 2D: Check for short from pin to pin. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male AMP/Metri-Pack/Deutsch test lead.Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the ECM.


engine harness connector to all other pins in the connector except pin 22.

• Measure the resistance from pin 22 of the engine harness connector to all other pins in the connector except pin 11.

OKMore the 100k ohms

2E


3A

STEP 2E: Measure voltage at the lift pump. � WARNING �

Check and clear all active fault codes before replacing the ECM.Condition:• Connect all components.• Key switch in the “ON” position. • Connect an electronic service tool.

Action Specifications/Repair Next StepMeasure voltage at the lift pump.• Measure the voltage from the terminals on

the underside of the pump with the lift pump connected to the engine harness.

OK11 to 13 VDC on 12 VDC systems23 to 25 VDC on 24 VDC systems

3A


3A



STEP 3: Clear the fault codes. STEP 3A: Disable the fault code.Condition:• Connect all the components. • Key switch in the “ON” position.

Action Specifications/Repair Next StepDisable the fault code.• Start the engine and let idle for one minute.• Read the fault codes using an electronic

service tool.


3B


1A





Repair complete






Pumping Element

Circuit Description:These faults are due to a failure internal to the CAPS fuel pump. The pump must be sent to New Holland ReCon for repairs. Blow-shut is a condition caused when the fuel being moved, as the pumping plunger travels upwards, causes the PCV to close before the ECM commands the PCV to close.

Component Location:The pumping element is part of the CAPS fuel injection pump.

Pumping ElementCODES REASON EFFECT

Fault Code: 281 or 282PID(P) SID(S): S151 or S152SPN: 1347 or 1348FMI: 7 Lamp: Yellow

FC281: Engine ECM has detected a failure in the front pumping element.

FC282: Engine ECM has detected a failure in the rear pumping element.

Possible no effect or engine power derate.





STEPS SPECIFICATIONS SRT CODESTEP 1: Check fault codes. STEP 1A: Read fault codes. 281 or 282 inactive STEP 2: Clear the fault codes. STEP 2A: Disable the fault code. Fault Code 281 or 282 inactive STEP 2B: Clear the inactive fault codes. All faults cleared

STEP 1: Check fault codes. STEP 1A: Read fault codes.Condition:• Key switch in the “ON” position.


service tool.

OK281 or 282 inactive

2A

NOT OKReplace accumulator module.Refer to Procedure 005-085 in Section 10 Chapter 12 of the CDC 24 Valve 8.3 Liter Engine Repair Manual.

2A

STEP 2: Clear the fault code. STEP 2A: Disable the fault code.Condition:• Connect all the components.• Key switch in the “ON” position.


Fault Codes 281 or 282 are inactive.

OKFault Codes 281 or 282 are inactive.

2B


1A







Repair complete






Engine Speed Sensor

Circuit Description:The engine speed sensor provides engine speed and position information to the electronic control module (ECM). The sensor must be powered by 5 VDC to operate. The sensor generates it's signals by sensing the movement of target teeth cut into a steel ring fastened to the backside of the camshaft gear. This ring has 71 teeth and a gap where the 72nd tooth would be placed. This missing tooth indicates that cylinder 1 (and 6) is at top dead center.

Component Location:The engine speed sensor is located on the back side of the gear housing, between the CAPS fuel pump and the air compressor. The engine speed sensor is the outboard sensor.

Engine Speed Sensor CODES REASON EFFECT


FC283: High voltage detected at main engine speed sensor voltage supply pin 8 of the engine harness.FC284: Low voltage detected at main engine speed sensor voltage supply pin 8 of the engine harness.

The electronic control module (ECM) will use the engine speed sensor signal as a backup.Possible white smoke.




To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male AMP/Metri-Pack test lead.


STEPS SPECIFICATIONS SRT CODESTEP 1: Check the fault codes. STEP 1A: Read the fault codes. Fault Code 441 is not active STEP 2: Check the engine speed sensor. STEP 2A: Inspect the connector pins. No damaged pins STEP 2B: Check for short circuit to ground. More than 100k ohms STEP 3: Check engine harness. STEP 3A: Inspect the engine harness and ECM connector pins.

No damaged pins

STEP 3B: Check for an open circuit. Less than 10 ohm STEP 3C: Check for a short circuit to ground. More than 100k ohms STEP 3D: Check for a short circuit from pin to pin.

More than 100k ohms

STEP 3E: Check sensor supply voltage. 4.5 to 5.25 VDCSTEP 4: Clear the fault codes. STEP 4A: Disable the fault code. Fault Codes 283 or 284 are inactive STEP 4B: Clear the inactive fault codes. All faults cleared

STEP 1: Check the fault codes. STEP 1A: Read the fault codes.Condition:• Key switch in the “ON” position.


service tool.

OKFault Code 441 is not active

2A


Fault Code 441



STEP 2: Check the engine speed sensor. STEP 2A: Inspect the harness and sensor pins. Condition:• Key switch in the “OFF” position. • Disconnect the harness from the engine speed sensor.

Action Specifications/Repair Next StepInspect the engine harness and sensor connec-tors for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

2B

NOT OKRepair the damaged pinsRepair or replace the engine harness or engine speed sensor, whichever has the damaged pins. • Repair the engine harness. • Replace the engine harness. Refer to Procedure 019-

043.• Replace the engine speed sensor. Refer to Procedure

019-042.

4A



STEP 2B: Check for a short circuit to ground. Condition:• Key switch in the “OFF” position. • Disconnect the harness from the engine speed sensor. • Connect the Break-out cable, Tool No. 3824775 to engine speed sensor.


engine speed sensor connector to ground. • Measure the resistance from pin B of the

engine speed sensor connector to ground. • Measure the resistance from pin C of the

engine speed sensor connector to ground.


3A

NOT OKReplace the engine speed sensorRefer to Procedure 019-042.

4A



STEP 3: Check engine harness. STEP 3A: Inspect the engine harness and ECM connectors. Condition:• Key switch in the “OFF” position. • Disconnect engine harness from the ECM.

Action Specifications/Repair Next StepInspect the engine harness and ECM connec-tors for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

3B



4A




To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead.Condition:• Key switch in the “OFF” position.• Disconnect the engine harness from the ECM. • Disconnect the engine harness from the engine speed sensor.


engine harness connector to pin A on the harness side of the engine speed sensor.

• Measure the resistance from pin 18 of the engine harness connector to pin B on the harness side of the engine speed sensor.

• Measure the resistance from pin 17 of the engine harness connector to pin C on the harness side of the engine speed sensor.

OKLess than 10 ohm

3C


4A




To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead.Condition:• Key switch in the “OFF” position.• Disconnect the engine harness from the ECM. • Disconnect the engine harness from the engine speed sensor.

Action Specifications/Repair Next StepCheck for short circuit to ground.• Measure the resistance from pin 8 of the

engine harness connector to ground. • Measure the resistance from pin 18 of the

engine harness connector to ground. • Measure the resistance from pin 17 of the

engine harness connector to ground.


3D


4A




To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead. Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the ECM. • Disconnect the engine harness from the engine speed sensor.

Action Specifications/Repair Next StepCheck for a short circuit from pin to pin.• Measure the resistance from pin 8 to all

other pins on the harness side of the engine harness connector.

• Measure the resistance from pin 18 to all other pins on the harness side of the engine harness connector.

• Measure the resistance from pin 17 to all other pins on the harness side of the engine harness connector.


3E


4A



STEP 3E: Check sensor supply voltage. � CAUTION �

To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead. Condition:• Connect the engine harness to the ECM. • Disconnect the engine harness from the engine speed sensor. • Key switch in the “ON” position.

Action Specifications/Repair Next StepCheck sensor supply voltage.• Measure voltage from pin A on the harness

side of the engine speed sensor connector to engine block ground.

OK4.5 to 5.25 VDC

4A


4A





OKFault Codes 283 or 284 are inactive

4B


1A







Repair complete





Fault Code 328

Rear Pumping Element

Circuit Description:The rear pumping element consists of the rear barrel and plunger, rear pumping control valve and the rear check valve in the accu-mulator. These components are part of the accumulator module. The pumping element is responsible for pumping fuel into the accumulator and maintaining the desired pressure in the accumulator.

Component Location:The rear pumping element is part of the CAPS fuel pump in the accumulator module.

Shop Talk:• A plugged fuel filter can cause both Fault Code 275 and Fault Code 328 to be logged intermittently. • If Fault Code 275 and Fault Code 328 are both present, check fuel filter restriction. • A failed engine harness could also cause this fault code to be active. • If Fault Code 273 or Fault Code 274 are active, troubleshoot them first.

Rear Pumping Element CODES REASON EFFECT


The Electronic Control Module (ECM) has detected a failure in the rear pumping element.

Derate in power output of the engine.





STEPS SPECIFICATIONS SRT CODESTEP 1: Check for fault codes. STEP 1A: Read fault codes. Fault Code 275 is not present STEP 2: Check for pumping element failure. STEP 2A: Verify pumping valve solenoid performance.

Solenoid clicks when activated

STEP 2A-1: Check fault codes. Fault Code 273 inactive STEP 2B: Verify pumping element performance. Pumping elements performing equally STEP 3: Clear fault codes. STEP 3A: Disable the fault code. Fault Code 328 inactive STEP 3B: Clear the inactive fault codes. All faults cleared

STEP 1: Check fault codes. STEP 1A: Read the fault codes. Condition:• Key switch in the “ON” position.


service tool. • Verify that Fault Code 275 is not present.

OKFault Code 275 is not present

2A

NOT OKFault Code 275 is presentIf present, verify that the fuel filter is not plugged. Refer to Procedure 006-011 in Section 10 Chapter 13 of the CDC 24 Valve 8.3 Liter Engine Repair Manual.

3A

STEP 2: Verify pumping valve solenoid performance. STEP 2A: Check pumping valve circuit performance. Condition:• Key switch in the “ON” position.

Action Specifications/Repair Next StepVerify pumping valve solenoid circuit perfor-mance.• Using an electronic service tool, run the

Solenoid Click Test on the rear pumping valve solenoid. Listen for an audible click when activating the test to verify that the solenoid is operating.


2B


2A-1




Action Specifications/Repair Next StepRead fault codes.• Read fault codes using an electronic ser-

vice tool.


3A


Refer to Fault Code 273 for repair.

STEP 2B: Verify pumping element performance. Condition:• Key switch in the ”ON” position with the engine operating.

Action Specifications/Repair Next StepVerify pumping element performance.• Using an electronic service tool, run the

Pumping Plunger Cutout Test on each pumping plunger. Observe VCA, Accumula-tor Pressure, Accumulator Pressure Set-point and engine speed for each pumping plunger as the other is cutout.

OKPumping element performs equally

3A

NOT OKReplace the fuel accumulator moduleRefer to Procedure 005-085 in Section 10 Chapter12 of the CDC 24 Valve 8.3 Liter Engine Repair Manual.

3A






3B


1A





Repair complete



STEP 2A-1: Check fault codes.



Fault Code 329

CAPS Injection Pump

Circuit Description:The electronic control module (ECM) monitors several variables; including accumulator pressure, VCA, and injection control valve open-time; to determine if the pump has failed.

Component Location:The CAPS fuel injection pump is located on the intake manifold side of the engine.

Fuel Injection Pump CODES REASON EFFECT

Fault Code: 329PID(P), SID(S): S233SPN: 1077FMI: 12Lamp: Red

Engine ECM has detected an overpumping fail-ure in the CAPS pump.

Engine power derate, engine may die.





STEPS SPECIFICATIONS SRT CODESTEP 1: Check for fault codes. STEP 1A: Read the fault codes. Fault Code 329 inactive STEP 2: Clear the fault codes. STEP 2A: Disable fault codes. Fault Code 329 inactive STEP 2B: Clear the inactive fault codes. All faults cleared

STEP 1: Check for fault codes. STEP 1A: Read the fault codes. Condition:• Key switch in the “ON” position.


service tool.

OKFault Codes 268, 277, or 328 are inactiveReplace the fuel injection pumpRefer to Procedure 005-016 in the Troubleshooting & Repair Manual for CDC 24 Valve 8.3 Liter Engine.

2A

NOT OKFault Code 268, 277, or 328 are active

Appropriate fault tree.

STEP 2: Clear fault codes. STEP 2A: Disable fault codes. Condition:• Connect all the components. • Key switch in the “ON” position.

Action Specifications/Repair Next StepDisable fault codes. • Start the engine and let it idle for one

minute. • Using an electronic service tool, verify that


OK Fault Code 329 is inactive

2B

NOT OK Return to troubleshooting steps or contact the Technical Services Group (if all steps have been completed and checked again).

1A




Action Specifications/Repair Next StepClear the inactive fault codes. • Erase the inactive fault codes using an


OK All faults cleared

Repair complete

NOT OK Troubleshoot any remaining active fault codes





Sensor Supply Circuit

Circuit Description:All of the sensors are powered by the same +5 VDC source and the same return in the electronic control module (ECM).

Component Location:The +5 VDC sensor supply circuit is located in the sensor harness.

Shop Talk:If it is determined that the problem lies in the sensor +5 VDC supply, start unplugging the pressure sensors, engine position sen-sor, and ambient air pressure sensor one at a time. When the fault goes inactive, investigate that particular circuit or sensor for a problem.

Sensor Supply Circuit CODES REASON EFFECTFault Code: 352 or 386PID(P), SID(S): S232SPN: 620FMI: 4 or 3Lamp: Yellow

FC352: Low voltage detected at engine position sensor +5 VDC supply, pin 10 of the engine har-ness.FC386: High voltage detected at engine position sensor +5 VDC supply, pin 10 of the engine har-ness.

Default value used for sensors connected to this +5 VDC supply. Engine will derate to no-boost fueling and loss of engine protection for oil pres-sure, intake manifold pressure, ambient air pres-sure, and fuel pressure.




To avoid damaging a new ECM, all other fault codes must be investigated prior to replacing the ECM.

� CAUTION �To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead.


STEPS SPECIFICATIONS SRT CODESTEP 1: Check the engine harness. STEP 1A: Inspect the engine harness and ECM connectors.

No damaged pins

STEP 1B: Check for a short circuit to ground. More than 100k ohms STEP 1C: Check for a short circuit from pin to pin.

More than 100k ohms

STEP 1D: Check sensor supply voltage. 4.5 to 5.25 VDC STEP 2: Clear the fault codes. STEP 2A: Disable the fault codes. Fault Code 352 and 386 inactive STEP 2B: Clear the inactive fault codes. All faults cleared

STEP 1: Check the engine harness. STEP 1A: Inspect the engine harness and ECM connectors.Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the ECM.

Action Specifications/Repair Next StepInspect the engine harness and the ECM con-nectors for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

1B



2A

STEP 1B: Check for a short circuit to ground. Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the ECM. • Disconnect the engine position sensor from the engine harness. • Disconnect the oil pressure sensor from the engine harness. • Disconnect the intake manifold pressure sensor from the engine harness. • Disconnect the ambient air pressure sensor from the engine harness.



Action Specifications/Repair Next StepCheck for a short circuit to ground in the engine harness.• Measure the resistance from pin 10 of the



1C


2A

STEP 1B: Check for a short circuit to ground.



STEP 1C: Check for a short circuit from pin to pin. Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the ECM. • Disconnect the engine position sensor from the engine harness. • Disconnect the oil pressure sensor from the engine harness. • Disconnect the intake manifold pressure sensor from the engine harness. • Disconnect the ambient air pressure sensor from the engine harness. Check for a short circuit from pin to pin.• Measure the resistance from pin 10 of the

engine harness connector to all the other pins in the connector.


1D


2A



STEP 1D: Check sensor supply voltage. Condition:• Connect the engine harness to the ECM. • Disconnect the engine position sensor from the engine harness. • Disconnect the oil pressure sensor from the engine harness. • Disconnect the intake manifold pressure sensor from the engine harness. • Disconnect the ambient air pressure sensor from the engine harness. • Key switch in the “ON” position.

Action Specifications/Repair Next StepCheck for sensor +5 VDC supply voltage.• Measure the voltage from pin A on the har-

ness side of the engine speed sensor to engine block ground.

• Measure the voltage from pin A on the har-ness side of the oil pressure sensor to engine block ground.

• Measure the voltage from pin A on the har-ness side of the intake manifold pressure sensor to engine block ground.

• Measure the voltage from pin A on the har-ness side of the ambient air pressure sen-sor to engine block ground.

OK4.5 to 5.25 VDC

2A


2A



STEP 2: Clear the fault code. STEP 2A: Disable the fault code.Condition:Connect all the components. Key switch in the “ON” position.


Fault Code 352 and 386 are inactive.


2B


1A





Repair complete






Intake Air Heater Relay Circuit

Circuit Description:The intake air heater improves starting and white smoke control in cold ambient conditions. The ECM controls relays that switch power to the air heater. There are two heating coils in the heater which are individually controlled by the ECM.

Component Location:The intake air heater is located under the air inlet coverplate on the intake manifold. The location of the heater relays will vary with application.

Intake Air Heater Relay Circuit CODES REASON EFFECTFault Code: 381 or 382PID(P), SID(S): S237SPN: 626FMI: 2Lamp: Yellow

FC 381: Error detected in the cold start air relay 1 enable circuit at pin 41 of the vehicle harness.FC 382: Error detected in the cold start air relay 2 enable circuit at pin 31 of the vehicle harness. Intake air heater cannot be energized by the electronic control module (ECM).

Possible white smoke and/or hard starting in cold ambient conditions.




To avoid damaging a new ECM, all other fault codes must be investigated prior to replacing the ECM.

� CAUTION �To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male AMP/Metri-Pack/Deutsch test lead.


STEPS SPECIFICATIONS SRT CODESTEP 1: Check vehicle harness. STEP 1A: Inspect the vehicle harness, intake air heater relay, and ECM connectors.

No damaged pins

STEP 1B: Check for an open circuit. Less than 10 ohms STEP 1C: Check for an open circuit. Refer to Vehicle Service Manual STEP 1D: Check for a short circuit to ground. More than 100k ohms STEP 1E: Check for a short circuit from pin to pin.

More than 100k ohms

STEP 2: Clear the fault codes. STEP 2A: Disable the fault code. Fault Code 381 and 382 inactive STEP 2B: Clear the inactive fault codes. All faults cleared

STEP 1: Check vehicle harness. STEP 1A: Inspect the vehicle harness, intake air heater relay, and ECM connectors. Condition:• Key switch in “OFF” position. • Disconnect the vehicle harness from the ECM. • Disconnect the intake air heater relay.

Action Specifications/Repair Next StepInspect the vehicle harness, intake air heater relay, and ECM connectors for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

1B

NOT OKRepair damaged pinsRepair or replace the vehicle harness, ECM, or intake air heater relay, whichever has damaged pins. • Repair the vehicle harness. • Replace the vehicle harness. Refer to Procedure 019-

071.• Replace the ECM. Refer to Procedure 019-031. • Replace the intake air heater relay. Refer to the Trou-

bleshooting and Repair Manual for CDC 24 Valve 8.3 Liter Engine.

2A




To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male AMP/Metri-Pack/Deutsch test leadTool No. 3823996 - female Weather-Pack test lead. Condition:• Key switch in “OFF” position. • Disconnect the vehicle harness from the ECM. • Disconnect the vehicle harness from the intake air heater relay connector.

Action Specifications/Repair Next StepCheck for an open circuit in the relay enable cir-cuit.• Measure the resistance from the intake air

heater relay pin in the vehicle harness con-nector to the harness side of the heater relay connector.

Refer to the following to determine the cor-rect pins to check for each fault:FC 381: vehicle harness connector pin 41 to heater relay 1 (pin A).FC 382: vehicle harness connector pin 31 to heater relay 2 (pin C).

OKLess than 10 ohms

1C


2A



STEP 1C: Check for an open circuit in the relay and relay ground. Condition:• Key switch in the “OFF” position. • Disconnect the vehicle harness from the intake air heater relay connector.

Action Specifications/Repair Next StepCheck for an open circuit in the relay and relay ground.• Measure the resistance of the relay and its

ground on the pull-in coil side of the relay.

OKRefer to Troubleshooting and Repair Manual for CDC 24 Valve 8.3 Liter Engine for specification.

1D

NOT OKReplace relay or ground circuitRefer to Troubleshooting and Repair Manual for CDC 24 Valve 8.3 Liter Engine.

2A



STEP 1D: Check for a short circuit to ground. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male AMP/Metri-Pack/Deutsch test lead. Condition:• Key switch in the “OFF” position.• Disconnect the vehicle harness from the intake air heater relay connector. • Disconnect the vehicle harness connector from the ECM.

Action Specifications/Repair Next StepCheck for a short circuit to ground in the intake air heater relay circuit.• Measure the resistance from the intake air

heater relay pin in the vehicle harness con-nector to engine block ground. Refer to the following to determine the cor-rect pins to check for each fault:FC 381: vehicle harness connector pin 41.FC 382: vehicle harness connector pin 31.


1E


2A



STEP 1E: Check for a short circuit from pin to pin. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male AMP/Metri-Pack/Deutsch test lead. Condition:• Key switch in the “OFF” position. • Disconnect the vehicle harness connector from the ECM. • Disconnect the intake air heater relay connector from the vehicle harness.

Action Specifications/Repair Next StepCheck for a short circuit from pin to pin in the intake air heater relay circuit.• Measure the resistance from the intake air

heater relay pin in the vehicle harness to all other pins in the vehicle harness connector. Refer to the following to determine the cor-rect pins to check for each fault:FC 381: vehicle harness connector pin 41.FC 382: vehicle harness connector pin 31.


2A


2A







2B


1A





Repair complete

NOT OKTroubleshooting any remaining active fault codes.

Appropriatetroubleshooting chart




Remote Accelerator Control Circuit

Circuit Description:The remote accelerator control assembly contains the remote accelerator position sensor. This sensor sends the accelerator per-centage requested by the operator to the electronic control module (ECM). Remote accelerator is used by the ECM to determine fueling. In order for the remote accelerator position sensor to function properly, it is necessary that a good +5 VDC supply voltage is available.

NOTE: The connector pin letters shown for the accelerator pedal wiring in these troubleshooting steps are examples of represen-tative sensors. The connector pin assignments may vary with equipment manufacturer, but the base troubleshooting logic will still apply.

Component Location:The remote accelerator position sensor is located on the remote accelerator control assembly somewhere outside the cab.

Remote Accelerator Control Circuit CODES REASON EFFECTFault Code: 385 or 444PID(P), SID(S): S232SPN: 620FMI: 3 or 1Lamp: Yellow

FC385: High voltage detected at remote acceler-ator position sensor supply pin 10 of the vehicle harness.FC444: Low voltage detected at remote acceler-ator position sensor supply pin 10 of the vehicle harness.

Sensors connected to this +5 VDC supply will not function.




To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male AMP/Metri-Pack/Deutsch test leadTool No. 3823996 - female Weather-Pack test lead.

STEPS SPECIFICATIONS SRT CODESTEP 1: Check the remote accelerator position sensor. STEP 1A: Inspect the vehicle harness and sensor connectors.

No damaged pins

STEP 1B: Check for active fault codes. Fault Code 385, 441 or 444 remains active STEP 2: Check the vehicle harness. STEP 2A: Inspect the vehicle harness and ECM connectors.

No damaged pins


More than 100k ohms

STEP 2E: Check for a short circuit to a voltage source.

Less than 1.0 VDC

STEP 3: Check the ECM voltage. STEP 3A: Measure the sensor supply voltage from the ECM.

4.75 to 5.25 VDC

STEP 4: Clear the fault codes. STEP 4A: Disable the fault code. Fault Code 385 or 444 inactive STEP 4B: Clear the inactive fault codes. All faults cleared




STEP 1: Check the remote accelerator position sensor. STEP 1A: Inspect the vehicle harness and sensor connectors. Condition:• Key switch in the “OFF” position. • Disconnect the vehicle harness from the remote accelerator position sensor.

Action Specifications/Repair Next StepInspect the vehicle harness and the sensor con-nectors for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

1B

NOT OKReplace the damaged pinsRepair or replace the vehicle harness or the remote accel-erator position sensor, whichever has damaged pins. • Repair the vehicle harness. • Replace the vehicle harness. Refer to Procedure 019-

071.• Repair or replace the remote accelerator position

sensor. Refer to the vehicle troubleshooting and repair manual.

4A

STEP 1B: Check for active fault codes. Condition:• Key switch in the “ON” position. • Disconnect the vehicle harness from the remote accelerator position sensor.

Action Specifications/Repair Next StepRead the fault codes using an electronic service tool.

OK Fault Code 385 or 444 remains active

2A

NOT OK Replace the accelerator pedal assembly or the accelerator position sensorRefer to the vehicle troubleshooting and repair manual.

4A



STEP 2: Check the vehicle harness. STEP 2A: Inspect the vehicle harness and ECM connectors. Condition:• Key switch in the “OFF” position. • Disconnect the vehicle harness from the ECM.

Action Specifications/Repair Next StepInspect the vehicle harness and the ECM con-nectors for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

2B

NOT OKRepair the damaged pinsRepair or replace the vehicle harness or ECM, whichever has the damaged pins. • Repair the vehicle harness. • Replace the vehicle harness. Refer to Procedure 019-


4A




To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male AMP/Metri-Pack/Deutsch test leadTool No. 3823996 - female Weather-Pack test lead. Condition:• Key switch in the “OFF” position. • Disconnect the vehicle harness from the remote accelerator position sensor. • Disconnect the vehicle harness from the ECM.


vehicle harness connector to pin C on the harness side of the remote accelerator position sensor connector.

• Measure the resistance from pin 20 of the vehicle harness connector to pin A on the harness side of the remote accelerator position sensor connector.

OKLess than 10 ohms

2C


4A




To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male AMP/Metri-Pack/Deutsch test lead. Condition:• Key switch in the “OFF” position. • Disconnect the vehicle harness from the remote accelerator position sensor. • Disconnect the vehicle harness from the ECM.

Action Specifications/Repair Next StepCheck for a short circuit to a chassis ground.• Measure the resistance from pin 10 in the


• Measure the resistance from pin 20 in the vehicle harness connector to engine block ground.


2D


4A




To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male AMP/Metri-Pack/Deutsch test lead. Condition:• Key switch in the “OFF” position. • Disconnect the vehicle harness from the remote accelerator position sensor. • Disconnect the vehicle harness from the ECM.

Action Specifications/Repair Next StepCheck for a short circuit from pin to pin in the vehicle harness.• Measure the resistance from pin 10 to all

other pins in the vehicle harness. • Measure the resistance from pin 20 to all

other pins in the vehicle harness.


2E


4A



STEP 2E: Check for a short circuit to a voltage source. � CAUTION �

To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male AMP/Metri-Pack/Deutsch test lead.Condition:• Key switch in the “ON” position. • Disconnect the vehicle harness from the ECM. • Connect the vehicle harness to the remote accelerator position sensor.

Action Specifications/Repair Next StepCheck for a short circuit to a voltage source.• Measure the voltage from pin 10 in the vehi-

cle harness connector to engine block ground.

• Measure the voltage from pin 20 in the vehi-cle harness connector to engine block ground.

OKLess than 1.0 VDC

3A


4A




� CAUTION �To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822917 - female AMP/Metri-Pack/Deutsch test lead. Condition:• Key switch in the “ON” position. • Disconnect the vehicle harness from the ECM.

Action Specifications/Repair Next StepMeasure the voltage out of the ECM. • Measure the voltage from pin 10 to pin 20

on the ECM vehicle connector.

OK 4.75 to 5.25 VDC

4A

NOT OK Replace the ECMRefer to Procedure 019-031.

4A


Action Specifications/Repair Next StepDisable the fault codes.• Start the engine and let idle for one minute.• Depress and release the accelerator pedal

several times to be sure the ECM is getting a accelerator signal.

• Using an electronic service tool, verify Fault Code 385 or 444 is inactive.


4B


1A







Repair complete






Accelerator Position Sensor Circuit

Circuit Description:The accelerator pedal assembly with accelerator position sensor relays the accelerator percentage requested by the operator to the electronic control module (ECM). Percent accelerator is used by the ECM to determine fueling. In order for the accelerator position sensor to function properly, it is necessary that a good +5 VDC supply voltage is available.

Component Location:The accelerator position sensor is located on the accelerator pedal inside the vehicle cab.

Accelerator Position Sensor Circuit CODES REASON EFFECTFault Code: 387 or 443PID(P), SID(S): P091 or S23SPN: 2091 or 620FMI: 3 or 1 Lamp: Yellow

FC387: High voltage detected at accelerator position sensor supply pin 29 of the vehicle har-ness.FC443: Low voltage detected at accelerator position sensor supply pin 29 of the vehicle har-ness.

Engine idles when accelerator idle validation switch indicates idle and ramps up to a default set speed when idle validation switch indicates off-idle.




To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male AMP/Metri-Pack test leadTool No. 3822917 - female AMP/Metri-Pack test leadTool No. 3823996 - female Weather-Pack test lead.

STEPS SPECIFICATIONS SRT CODESTEP 1: Check the accelerator position sensor. STEP 1A: Inspect vehicle harness and sensor connectors.

No damaged pins

STEP 1B: Check for active fault code. 387 or 443 remains active STEP 2: Check the vehicle harness. STEP 2A: Inspect the vehicle harness and ECM connectors.

No damaged pins


More than 100k ohms

STEP 2E: Check for a short circuit to a voltage source.

Less than 1.0 VDC


4.75 to 5.25 VDC

STEP 4: Clear the fault codes. STEP 4A: Disable the fault code. Fault Code 387 or 443 inactive STEP 4B: Clear the inactive fault codes. All faults cleared




STEP 1: Check the accelerator position sensor. STEP 1A: Inspect the vehicle harness and sensor connectors. Condition:• Key switch in the “OFF” position. • Disconnect the vehicle harness from the accelerator position sensor.

Action Specifications/Repair Next StepInspect the harness and the sensor connectors for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

1B

NOT OKReplace the damaged pinsRepair or replace the vehicle harness or the accelerator position sensor, whichever has damaged pins. • Repair the vehicle harness. • Replace the vehicle harness. Refer to Procedure 019-

071.• Repair or replace the accelerator position sensor.

Refer to the vehicle troubleshooting and repair man-ual.

4A

STEP 1B: Check for active fault code. Condition:• Key switch in the “ON” position. • Disconnect the vehicle harness from the accelerator position sensor.

Action Specifications/Repair Next StepRead the fault codes using an electronic service tool.

OKFault Code 387 or 443 remains active

2A

NOT OKReplace the accelerator pedal assembly or the acceler-ator position sensor

4A



STEP 2: Check the vehicle harness. STEP 2A: Inspect the vehicle harness and the ECM connectors.Condition:• Key switch in the “OFF” position.• Disconnect the vehicle harness from the ECM.


OKNo damaged pins

2B



4A




To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male AMP/Metri-Pack test leadTool No. 3823996 - female Weather-Pack test lead. Condition:• Key switch in the “OFF” position.• Disconnect the vehicle harness from the accelerator position sensor. • Disconnect the vehicle harness from the ECM.


vehicle harness connector to pin C on the harness side of the accelerator position sensor connector.

• Measure the resistance from pin 19 of the vehicle harness connector to pin A on the harness side of the accelerator position sensor connector.

OKLess than 10 ohms

2C


4A




To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male AMP/Metri-Pack test lead. Condition:• Key switch in the “OFF” position. • Disconnect the vehicle harness from the accelerator position sensor. • Disconnect the vehicle harness from the ECM.

Action Specifications/Repair Next StepCheck for a short circuit to a chassis ground.• Measure the resistance from pin 29 in the


• Measure the resistance from pin 19 in the vehicle harness connector to engine block ground.

OKMore than 100k ohms.

2D


4A




To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male AMP/Metri-Pack test lead.Condition:• Key switch in the “OFF” position. • Disconnect the vehicle harness from the accelerator position sensor. • Disconnect the vehicle harness from the ECM.


other pins in the vehicle harness connector. • Measure the resistance from pin 19 to all

other pins in the vehicle harness connector.


2E


4A



STEP 2E: Check for a short circuit to a voltage source. � CAUTION �

To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male AMP/Metri-Pack test lead. Condition:• Key switch in the “ON” position. • Disconnect the vehicle harness from the ECM. • Connect the vehicle harness to the accelerator position sensor.

Action Specifications/Repair Next StepCheck for a short circuit to a voltage source.• Measure the voltage from pin 29 in the vehi-

cle harness connector to engine block ground.

• Measure the voltage from pin 19 in the vehi-cle harness connector to engine block ground.

OKLess than 1.0 VDC

3A

NOT OKReplace the vehicle harness.Refer to Procedure 019-071.

4A




� CAUTION �To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822917 - female AMP/Metri-Pack test lead. Condition:• Key switch in the “ON” position. • Disconnect the vehicle harness from the ECM.

Action Specifications/Repair Next StepMeasure the voltage out of the ECM.• Measure the voltage from pin 29 to pin 19

on the ECM vehicle connector port.

OK4.75 to 5.25 VDC

4A


4A

STEP 4: Clear the fault codes. STEP 4A: Disable the fault code. Condition:• Connect all the components. • Key switch in the “ON” position. a

Action Specifications/Repair Next StepDisable the fault code.• Start the engine and let idle for one minute.• Depress and release the accelerator pedal

several times to be sure the ECM is getting an accelerator signal.

• Using an electronic service tool, verify Fault Code 387 or 443 inactive.


4B


1A







Repair completed





Fault Code 415


Circuit Description:The oil pressure sensor is used by the electronic control module (ECM) to monitor the lubricating oil pressure. The ECM monitors the voltage on the signal pin and converts this to a pressure value. The oil pressure value is used by the ECM for the engine pro-tection system.

Component Location:The oil pressure sensor is located on the engine block below the ECM.

Shop Talk:• Verify with the driver the engine speed at which the fault occurs. If the engine is being operated at too low of a speed, the oil

pressure may drop below the engine protection limits. • Possible causes:

– low oil level.– low operation speeds.

Oil Pressure - Engine ProtectionCODES REASON EFFECT

Fault Code: 415PID(P), SID(S): P100SPN: 100FMI: 1Lamp: Red

Oil pressure signal indicates oil pressure below the very low engine protection limit.

Power and/or speed derate and possible engine protection shutdown if feature is enabled.





STEPS SPECIFICATIONS SRT CODESTEP 1: Check the sensor accuracy. STEP 1A: Verify the sensor accuracy with a mechanical gauge.



STEP 1: Check the sensor accuracy. STEP 1A: Verify the sensor accuracy with a mechanical gauge. Condition:• Key switch in the "ON" position.

Action Specifications/Repair Next StepVerify the sensor accuracy with a mechanical gauge.• Connect a mechanical oil pressure gauge

to the engine. • Connect an electronic service tool to the

vehicle data bus.• Start the engine and compare the oil pres-

sure reading on the service tool monitor screen to the reading on the mechanical oil pressure gauge.

Note: The engine must be revved up to make it easier to see differences in readings.

OKSensor reading is correct within 5 PSI. Locate and repair the cause of low oil pressure. Refer to Procedure 007-048 in Section 10 Chapter 14 of the CDC 24 Valve 8.3 Liter Engine Repair Manual.

2A

NOT OKSensor reading incorrect

Fault Code135 or 141





2B


1A







Repair complete





Fault Code 418

WIF Sensor Circuit

Circuit Description:The WIF sensor is attached to the fuel filter. The WIF sensor sends a signal to the electronic control module (ECM) when a set vol-ume of water has accumulated in the fuel filter. The WIF circuit contain two wires: A return ground (pin 20), and a signal wire (pin 40).

Component Location:The WIF sensor is installed in the bottom of the fuel filter which is located on the side of the cylinder head approximately mid-engine.

Water-In-Fuel (WIF) Sensor CircuitCODES REASON EFFECTFault Code: 418PID(P), SID(S): P097SPN: 097FMI: 0Lamp: WIF

Water-in-fuel signal indicates the water in the fuel filter needs to be drained.

Excessive water in the fuel can lead to severe fuel system damage.

Not the right graphic





STEPS SPECIFICATIONS SRT CODESTEP 1: Check the fuel filter. STEP 1A: Drain the water from the fuel filter. Fault Code 418 is inactive STEP 2: Clear the fault codes. STEP 2A: Disable the fault code. Fault Code 418 inactive STEP 2B: Clear the inactive fault codes. All faults cleared

STEP 1: Check the fuel filter. STEP 1A: Drain the water from the fuel filter. Condition:• Key switch in the “ON” position.

Action Specifications/Repair Next StepDrain the water from the fuel filter.• Read fault codes using an electronic ser-

vice tool.


2A

NOT OKDrain water from the fuel filterRefer to Procedure 006-050 in Section 10 Chapter 13 of the CDC 24 Valve 8.3 Liter Engine Repair Manual.

2A



the Fault Code 418 is inactive.


2B


1A







Repair complete





Fault Code 422

Coolant Level Sensor Circuit

Circuit Description:The coolant level sensor monitors the coolant level within the coolant system and passes information to the electronic control mod-ule (ECM) through the engine harness. This sensor is very complex. Do not use a multimeter to check the coolant level sensor. If the radiator coolant level drops below a certain level, a progressive power derate with increasing time after alert will occur.


Shop Talk:This is an application specific component and will vary in sensor location.• If a shorting plug is used in the coolant level circuit, verify that it is wired correctly. • Inspect the wiring harness between the Weather-Pack 4-Way connector and the coolant level sensor for damage. • Make sure the coolant level sensor is located in the middle of the tank rather than off to one side where the coolant level can

change when the vehicle makes a turn.

Coolant Level Sensor Circuit CODES REASON EFFECTFault Code: 422PID(P), SID(S): P111SPN: 111FMI: 2 Yellow

Voltage detected simultaneously on both the coolant level high and low signal pins 27 and 37 of the engine harness --OR-- no voltage detected on either pin.

No engine protection for coolant level.




Wait until the coolant temperature is below 50�C [120�F] before removing the coolant system pressure cap or the coolant temperature sensor. Failure to do so can cause personal injury from heated coolant spray.

� CAUTION �To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test leadTool No. 3823993 - male Deutsch test leadTool No. 3823995 - male Weather-Pack test lead.

STEPS SPECIFICATIONS SRT CODESTEP 1: Check for multiple fault codes and presence of a coolant level switch. STEP 1A: Read the fault codes. Fault Codes 123, 141, 145, 154 and 352 are not

active STEP 1B: Check if the vehicle has a coolant level switch.

Coolant level switch present

STEP 1B-1: Check if a shorting plug is installed.

Shorting plug installed

STEP 2: Check the coolant level sensor jumper harness. STEP 2A: Inspect the coolant level sensor and the coolant level sensor jumper harness connector pins.

No damaged pins

STEP 2B: Check for an open circuit. Less than 10 ohms STEP 2C: Check for a short circuit to ground. More than 100k ohms STEP 2D: Check for a short circuit pin to pin. More than 100k ohms STEP 3: Check the engine harness. STEP 3A: Inspect the engine harness and ECM connector pins.

No damaged pins

STEP 3B: Check for an open circuit. Less than 10 ohms STEP 3C: Check for a short circuit to ground. More than 100k ohms STEP 3D: Check for a short circuit pin to pin. More than 100k ohmsSTEP 4: Clear the fault code. STEP 4A: Disable the fault code. Fault Code 422 inactive STEP 4B: Clear the inactive fault codes. All faults cleared




STEP 1: Check for multiple fault codes and presence of coolant level switch. STEP 1A: Read the fault codes.

� WARNING �Wait until the coolant temperature is below 50�C [120�F] before removing the coolant system pressure cap or the cool-ant temperature sensor. Failure to do so can cause personal injury from heated coolant spray.Condition:• Key switch in the "ON" position.


service tool.

OKFault Codes 123, 141, 145, 154, and 352 are not active

1B

NOT OKFault codes are active


STEP 1B: Check if the vehicle has a coolant level switch. � WARNING �

Wait until the coolant temperature is below 50�C [120�F] before removing the coolant system pressure cap or the cool-ant temperature sensor. Failure to do so can cause personal injury from heated coolant spray. Condition:• Key switch in the "OFF" position.

Action Specifications/Repair Next StepCheck if the vehicle has a coolant level switch. OK

Coolant level switch present2A

NOT OKNo coolant level switch present

1B-1

STEP 1B-1: Check if a shorting plug is installed. � WARNING �

Wait until the coolant temperature is below 50�C [120�F] before removing the coolant system pressure cap or the cool-ant temperature sensor. Failure to do so can cause personal injury from heated coolant spray. Condition:• Key switch in the "OFF" position.

Action Specifications/Repair Next StepCheck if a shorting plug is installed in place of the coolant level switch harness connection.

OKShorting plug installed

2A

NOT OKInstall the shorting plug

4A



STEP 2: Check the coolant level sensor jumper harness. STEP 2A: Inspect the coolant level sensor and the coolant level sensor jumper harness connector pins.Condition:• Key switch in the "OFF" position. • Disconnect the coolant level sensor jumper harness from the coolant level sensor.Inspect the coolant level sensor and the coolant level sensor jumper harness connector pins for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

2B

NOT OKRepair the damaged pinsRepair or replace the coolant level sensor jumper harness or the coolant level sensor, whichever has the damaged pins. • Repair the coolant level sensor jumper harness.• Replace the coolant level sensor jumper harness.

Refer to the Troubleshooting and Repair Manual for CDC 24 Valve 8.3 Liter Engine.

• Replace the coolant level sensor. Refer to the Trou-bleshooting and Repair Manual for CDC 24 Valve 8.3 Liter Engine.

4A



STEP 2B: Check for an open circuit. � WARNING �

Wait until the coolant temperature is below 50� C [120�F] before removing the coolant system pressure cap or the cool-ant temperature sensor. Failure to do so can cause personal injury from heated coolant spray.

� CAUTION �To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3823993 - male Deutsch test leadTool No. 3823995 - male Weather-Pack test lead.Condition:• Key switch in the "OFF" position.• Disconnect the engine harness from the coolant level sensor jumper harness. • Disconnect the coolant level sensor jumper harness from the coolant level sensor.

Action Specifications/Repair Next StepCheck for an open circuit.• Measure the resistance from pin A to pin A

on the coolant level sensor jumper harness connectors.

• Measure the resistance from pin B to pin B on the coolant level sensor jumper harness connectors.

• Measure the resistance from pin C to pin C on the coolant level sensor jumper harness connectors.

• Measure the resistance from pin D to pin D on the coolant level sensor jumper harness connectors.

OKLess than 10 ohms

2C

NOT OKRepair or replace the coolant level sensor jumper har-ness.Refer to the Troubleshooting and Repair Manual for CDC 24 Valve 8.3 Liter Engine.

4A



STEP 2C: Check for a short circuit to ground. � WARNING �

Wait until the coolant temperature is below 50�C [120�F] before removing the coolant system pressure cap or the cool-ant temperature sensor. Failure to do so can cause personal injury from heated coolant spray.

� CAUTION �To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3823993 - male Deutsch test lead.Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the coolant level sensor jumper harness. Check for a short circuit to ground.• Measure the resistance from pin A on the

coolant level sensor jumper harness con-nector to engine block ground.

• Measure the resistance from pin B on the coolant level sensor jumper harness con-nector to engine block ground.

• Measure the resistance from pin C on the coolant level sensor jumper harness con-nector to engine block ground.

• Measure the resistance from pin D on the coolant level sensor jumper harness con-nector to engine block ground.


2D

NOT OKReplace the coolant level sensor jumper harnessRefer to the Troubleshooting and Repair Manual for CDC 24 Valve 8.3 Liter Engine.

4A



STEP 2D: Check for a short circuit from pin to pin. � WARNING �


� CAUTION �To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3823993 - male Deutsch test lead. Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the coolant level sensor jumper harness. • Disconnect the coolant level sensor jumper harness from the coolant level sensor.Check for a short circuit from pin to pin.• Measure the resistance from pin A on the

coolant level sensor jumper harness con-ductor to all other pins in the connector.

• Measure the resistance from pin B on the coolant level sensor jumper harness con-ductor to all other pins in the connector.

• Measure the resistance from pin C on the coolant level sensor jumper harness con-ductor to all other pins in the connector.

• Measure the resistance from pin D on the coolant level sensor jumper harness con-ductor to all other pins in the connector.


3A

NOT OKReplace the coolant level sensor jumper harnessRefer to the Troubleshooting and Repair Manual for CDC 24 Valve 8.3 Liter Engine.

4A



STEP 3: Check the engine harness. STEP 3A: Inspect the harness and the ECM connector pins. Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the ECM.

Action Specifications/Repair Next StepInspect the engine harness and the ECM con-nector pins for: • bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

3B

NOT OKRepair the damaged pinsRepair or replace the engine harness or the ECM which-ever has the damaged pins. • Repair the engine harness. • Replace the engine harness. Refer to Procedure 019-


4A



STEP 3B: Check for an open circuit. � WARNING �


� CAUTION �To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3823993 - male Deutsch test lead Tool No. 3822917 - female AMP test lead.Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test leadCondition:• Key switch in the "OFF" position. • Disconnect the engine harness from the coolant level sensor jumper harness. • Disconnect the engine harness from the ECM.

Action Specifications/Repair Next StepCheck for an open circuit.• Measure the resistance from pin 37 in the

engine harness connector to pin A on the engine harness side of the coolant level sensor jumper harness connector.

• Measure the resistance from pin 19 in the engine harness connector to pin B on the engine harness side of the coolant level sensor jumper harness connector.

• Measure the resistance from pin 49 in the engine harness connector to pin C on the engine harness side of the coolant level sensor jumper harness connector.

• Measure the resistance from pin 27 in the engine harness connector to pin D on the engine harness side of the coolant level sensor jumper harness connector.

OKLess than 10 ohms

3C

NOT OKRepair or replace the engine harnessRefer to Procedure 019-043.

4A



STEP 3C: Check for a short circuit to ground. � WARNING �


� CAUTION �To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead.Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the coolant level sensor jumper harness. • Disconnect the engine harness from the ECM.

Action Specifications/Repair Next StepCheck for a short circuit to ground in the coolant level sensor signal wires.• Measure the resistance from pin 49 of the





3D


4A



STEP 3D: Check for a short circuit from pin to pin. � WARNING �


� CAUTION �To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead.Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the coolant level sensor jumper harness. • Disconnect the engine harness from the ECM.

Action Specifications/Repair Next StepCheck for a short circuit from pin to pin.• Measure the resistance from pin 27 in the


• Measure the resistance from pin 37 in the engine harness connector to all other pins in the connector.


4A


4A








4B


1A

STEP 4B: Clear the inactive fault codes. Condition:• Connect all the components.• Key switch in the “ON” position.Clear the inactive fault codes. • Erase the inactive fault codes using an



Repair complete





Fault Code 429

WIF Sensor Circuit

Circuit Description:The WIF sensor is attached to the fuel filter. The WIF sensor sends a signal to the electronic control module (ECM) when a set vol-ume of water has accumulated in the fuel filter. The WIF circuit contain two wires: A return ground (pin 20), and a signal wire (pin 40).

Component Location:The WIF sensor is installed in the bottom of the fuel filter and is located on the side of the cylinder head approximately mid-engine.

Shop Talk:The WIF sensor uses the same internal ECM power supply as sensors on engine harness. If Fault Code 352 is also active, use its troubleshooting logic and tree.

Water-In-Fuel (WIF) Sensor CircuitCODES REASON EFFECT


Low voltage detected at WIF signal pin 40 of the vehicle harness.

No water-in-fuel detection.

Not the right graphic




To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead.


STEPS SPECIFICATIONS SRT CODESTEP 1: Check for sensor supply fault code. STEP 1A: Read fault codes. Fault Code 441 not active STEP 2: Check vehicle harness. STEP 2A: Inspect the vehicle harness, WIF sen-sor, and ECM connectors.

No damaged pins


More than 100k ohms

STEP 2D: Check sensor supply voltage. 4.75 to 5.25 VDC STEP 3: Clear the fault codes. STEP 3A: Disable the fault code. Fault Code 429 inactive STEP 3B: Clear the inactive fault codes. All faults cleared

STEP 1: Check for sensor supply fault code. STEP 1A: Read the fault codes.Condition:• Key switch in the “ON” position. • Connect all components.

Action Specifications/Repair Next StepRead the active fault codes.• Read fault codes using an electronic ser-

vice tool.

OKFault Code 441 not active

2A

NOT OKFault Code 441 active

Fault Code 441



STEP 2: Check vehicle harness. STEP 2A: Inspect the vehicle harness, WIF sensor, and ECM connectors. Condition:• Key switch in the “OFF” position. • Disconnect the vehicle harness from the WIF sensor. Disconnect the vehicle harness from the ECM.

Action Specifications/Repair Next StepInspect the vehicle harness, WIF sensor, and ECM connectors for:• bent of broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

2B

NOT OKRepair the damaged pinsRepair or replace the ECM, WIF sensor, or vehicle har-ness, whichever has the damaged pins. • Repair vehicle harness. • Replace the vehicle harness. Refer to Procedure 019-

071.• Replace the WIF sensor. Refer to the Procedure 006-

050 in Section 10 Chapter13 of the CDC 24 Valve 8.3 Liter Engine Repair Manual.

• Repair or replace the ECM. Refer to Procedure 019-031.

3A



STEP 2B: Check for short circuit to ground. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead. Condition:• Key switch in the “OFF” position. • Disconnect the vehicle harness from the WIF sensor. • Disconnect the vehicle harness from the ECM.




2C


3A



STEP 2C: Check for a short circuit from pin to pin. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead. Condition:• Key switch in the “OFF” position. • Disconnect the vehicle harness from the WIF sensor. • Disconnect the vehicle harness from the ECM.


other pins on the harness side of the vehi-cle harness connector.


2D


3A



STEP 2D: Check sensor supply voltage. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead. Condition:• Key switch in “ON” position. • Disconnect the vehicle harness from the WIF sensor. • Connect the vehicle harness to the ECM.

Action Specifications/Repair Next StepCheck sensor supply voltage.• Measure the voltage from pin B on the har-

ness side of the WIF sensor connector to engine block ground.

OK4.75 to 5.25 VDCReplace WIF sensor. Refer to Procedure 006-050 in Sec-tion 10 Chapter 13 of the CDC 24 Valve 8.3 Liter Engine Repair Manual.

3A


3A





the Fault Code 429 is inactive.


3B


1A





Repair complete






Idle Validation Switch Circuit

Circuit Description:The idle validation switch (IVS) is used by the electronic control module (ECM) to indicate when the accelerator pedal is released (on-idle) or depressed (off-idle). The switch is adjusted by the accelerator pedal manufacturers to switch from on-idle to off-idle at the correct accelerator pedal position.

Component Location:The IVS is located on the accelerator pedal assembly.

Shop Talk:This fault code is usually caused by a loose connection, uncalibrated accelerator pedal, or miswired IVS.A bad ground on pin A of the IVS can also cause this fault.

Idle Validation Switch (IVS) CircuitCODES REASON EFFECT


FC431: Idle validation signals on pins 25 and 26 of the vehicle harness indicate no voltage simul-taneously detected on both pins OR no voltage detected on either pin.FC551: Idle validation signals on pins 25 and 26 of the vehicle harness indicate voltage detected simultaneously on both pins.

FC431: No effect on performance but loss of idle validation.FC551: Engine will only idle.




Set the service brake using the trailer brake hand valve. Make sure there is enough air pressure to activate the brake pressure switch. Securely chock the wheels. Truck movement during troubleshooting can cause severe equipment dam-age, personal injury, or death.

� CAUTION �To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test leadTool No. 3823995 - male Weather-Pack test leadTool No. 3822917 - female AMP/Metri-Pack test leadTool No. 3823996 - female Weather-Pack test lead.

STEPS SPECIFICATIONS SRT CODESTEP 1: Check the accelerator pedal. STEP 1A: Verify the IVS is connected to the vehi-cle harness.

IVS connected

STEP 1B: Calibrate the accelerator pedal. Fault code 431 or 551 inactive STEP 1C: Inspect the harness and the IVS connector.

No damaged pins

STEP 1D: Check for an open circuit. Less than 10 ohms STEP 1E: Check for a short circuit from pin to pin. More than 100k ohms STEP 2: Check the vehicle harness. STEP 2A: Inspect the vehicle harness and ECM connectors.

No damaged pins

STEP 2B: Check the ECM supply. 4.75 to 5.25 VDC STEP 2C: Check for a short circuit from pin to pin.

More than 100k ohms

STEP 2D: Check for an open circuit. Less than 10 ohms STEP 2E: Check for a short circuit to ground. More than 100k ohms STEP 3: Clear the fault codes. STEP 3A: Disable the fault code. Fault code 431 or 551 inactive STEP 3B: Clear the inactive fault codes. All faults cleared




STEP 1: Check the accelerator pedal. STEP 1A: Verify the IVS is connected to the vehicle harness.Condition:• Key switch in the "OFF" position.

Action Specifications/Repair Next StepVerify the IVS is connected to the vehicle har-ness.

OKIVS connected

1B

NOT OKConnect the IVSConnect the vehicle harness to the IVS. Refer to the Trou-bleshooting and Repair Manual for CDC 24 Valve 8.3 Liter Engine.

3A

STEP 1B: Calibrate the accelerator pedal. Condition:• Key switch in the "ON" position.

Action Specifications/Repair Next StepCalibrate the accelerator pedal.• Depress the accelerator pedal to the full

fuel position. • Release the accelerator pedal. • Repeat this procedure two more times.

OKFault Code 431 or 551 active

1C

NOT OKPedal was not calibratedFault Code 431 or 551 is inactive.

3A



STEP 1C: Inspect the vehicle harness and the IVS connectors. Condition:• Key switch in the "OFF" position. • Disconnect the vehicle harness from the IVS.

Action Specifications/Repair Next StepInspect the vehicle harness and the IVS connec-tors for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

1D

NOT OKRepair the damaged pinsRepair or replace the IVS or vehicle harness, whichever has the damaged pins. • Repair the vehicle harness. • Replace the vehicle harness. Refer to Procedure 019-

071.• Repair or replace the IVS. Refer to the Troubleshoot-

ing and Repair Manual for CDC 24 Valve 8.3 Liter Engine.

3A



STEP 1D: Check for an open circuit. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3823995 - male Weather-Pack test lead. Condition:• Key switch in the "OFF" position. • Disconnect the vehicle harness from the IVS. Check for an open circuit in the IVS.• Measure the resistance from pin B to pin A

on the switch side of the IVS connector with the accelerator pedal released.

• Measure the resistance from pin C to pin A on the switch side of the IVS connector with the accelerator pedal depressed.

OKLess than 10 ohms

1E

NOT OKReplace the IVSRefer to the Troubleshooting and Repair Manual for CDC 24 Valve 8.3 Liter Engine.

3A



STEP 1E: Check for a short circuit from pin to pin. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3823995 - male Weather-Pack test lead. Condition:• Key switch in the “OFF” position. • Disconnect the vehicle harness from the IVS.

ACTION SPECIFICATIONS/REPAIR NEXT STEPCheck for a short circuit from pin to pin in the IVS.• Measure the resistance from pin B to pin C

on the switch side of the IVS connector with the accelerator pedal released and depressed.


2A

NOT OKReplace the IVSRefer to the Troubleshooting and Repair Manual for CDC 24 Valve 8.3 Liter Engine.

3A



STEP 2: Check the vehicle harness. STEP 2A: Inspect the vehicle harness and ECM connectors. Condition:• Key switch in the "OFF" position. • Disconnect the vehicle harness from the ECM. • Disconnect the vehicle harness from the IVS.

Action Specifications/Repair Next StepInspect the vehicle harness and ECM connec-tors for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

2B



3A



STEP 2B: Check the ECM supply. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822917 - female AMP/Metri-Pack test lead. Condition:• Key switch in the "ON" position.• Disconnect the vehicle harness from the ECM.Check the ECM supply.• Measure the voltage from pin 25 on the

ECM side of the vehicle harness connector to engine block ground.

• Measure the voltage from pin 26 on the ECM side of the vehicle harness connector to engine block ground.

OK4.75 to 5.25 VDC

2C


3A



STEP 2C: Check for a short circuit from pin to pin. � CAUTION �

To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead.Condition:• Key switch in the “OFF” position. • Disconnect the vehicle harness from the ECM. • Disconnect the vehicle harness from the IVS. Check for a short circuit from pin to pin.• Measure the resistance from pins 25 and

26 of the vehicle harness connector to all other pins in the connector.


2D


3A



STEP 2D: Check for an open circuit. � CAUTION �

To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test leadTool No. 3823996 - female Weather-Pack test lead. Condition:• Key switch in the "OFF" position. • Disconnect the vehicle harness from the ECM. • Disconnect the vehicle harness from the IVS.

Action Specifications/Repair Next StepCheck for an open circuit.• Measure the resistance from pin 26 on the

harness side of the vehicle harness con-nector to pin B on the harness side of the IVS connector.

• Measure the resistance from pin 25 on the harness side of the vehicle harness con-nector to pin C on the harness side of the IVS connector.

• Measure the resistance from pin A on the harness side of the IVS connector to engine block ground.

OKLess than 10 ohms

2E


3A



STEP 2E: Check for a short circuit to ground. � CAUTION �

To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead.Condition:• Key switch in the "OFF" position. • Disconnect the vehicle harness from the ECM. • Disconnect the vehicle harness to the IVS.

Action Specifications/Repair Next StepCheck for a short circuit from pin to ground.• Measure the resistance from pin 25 on the

harness side of the vehicle connector to engine block ground.

• Measure the resistance from pin 26 on the harness side of the vehicle connector to engine block ground.


3A


3A




Action Specifications/Repair Next StepDisable the fault code.• Turn the key switch to the "ON" position and

completely depress and release the accel-erator pedal four to five times.

• Turn the key switch to the "OFF" position for 5 seconds.

• Start the engine and let idle for one minute.• Using an electronic service tool, verify that



3B


1A





Repair complete





Fault Code 432

Accelerator Pedal Circuit

Circuit Description:The accelerator pedal assembly relays the accelerator percentage requested by the operator to the electronic control module (ECM). Percent accelerator is used to determine fueling. The accelerator position sensor and the idle validation switch on the accelerator pedal are adjusted at the factory to provide the correct output signals.NOTE: The connector pin letters shown for the accelerator pedal wiring in these troubleshooting steps are examples of represen-tative sensors. The connector pin assignments may vary with accelerator manufacturer, but the base troubleshooting logic will still apply.

Component Location:The accelerator position sensor and the idle validation switch are located on the accelerator pedal in the cab.

Shop Talk:Confirm that the idle validation switch (IVS) is properly calibrated. Refer to the accelerator pedal manufacturer's instructions for adjustment information.NOTE: The three wires in the accelerator position sensor circuit must be twisted together. Depending on ground location, IVS may only have two wires.

Accelerator Pedal Circuit (ISS) CODES REASON EFFECT


No voltage detected at pin 26 of the vehicle har-ness indicates the accelerator is at the idle posi-tion when the accelerator position signal at pin 30 of the vehicle harness indicates the accelera-tor is not at the idle position OR idle validation signal at pin 26 of the vehicle harness indicates the accelerator is not at the idle position when the accelerator position signal pin 30 of the vehi-cle harness indicates the accelerator is at the idle position.

No effect on engine.




To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test leadTool No. 3823995 - male Weather-Pack test leadTool No. 3823996 - female Weather-Pack test lead.

STEPS SPECIFICATIONS SRT CODESTEP 1: Check the fault status. STEP 1A: Perform the fault code disable procedure.

Fault Code 432 still active

STEP 1B: Check for idle validation fault codes. Fault Code 431 and 551 inactive STEP 2: Check the vehicle harness. STEP 2A: Inspect the vehicle harness and the ECM connectors.

No damaged pins

STEP 2B: Check the resistance of the accelerator position sensor circuit.

1500 to 3000 ohms (released)250 to 1500 ohms (depressed)

STEP 2B-1: Check the resistance of the accelerator position sensor.

1500 to 3000 ohms (released)250 to 1500 ohms (depressed)

STEP 2B-2: Check the resistance in the vehicle harness.

Less than 10 ohms

STEP 2C: Check for an open circuit. 2000 to 3000 ohms STEP 2C-1: Check for an open circuit of the accelerator position sensor supply and return circuit.

2000 to 3000 ohms

STEP 2C-2: Check for an open circuit in the vehicle harness.

Less than 10 ohms

STEP 2D: Check for a short circuit to ground. More than 100k ohms STEP 2D-1: Check for a short circuit to ground in the accelerator position sensor.

More than 100k ohms

STEP 2D-2: Check for a short circuit to ground in the vehicle harness.

More than 100k ohms

STEP 2E: Check for a short circuit from pin to pin in the vehicle harness.

More than 100k ohms





STEP 1: Check the fault status. STEP 1A: Perform the fault code disable procedure.Condition:• Key switch in the "ON" position. • All components connected.

Action Specifications/Repair Next StepPerform the fault code disable procedure. • Slowly depress the accelerator pedal to the

full fuel position and release it completely three times.

• Read the inactive fault codes using an elec-tronic service tool.

OK Fault Code 432 still active

1B

NOT OK Replace the accelerator pedal assemblyRefer to the equipment manufacturer's troubleshooting and repair manual.

3A

STEP 1B: Check for idle validation fault codes. Condition:• Key switch in the "ON" position. • All the components connected

Action Specifications/Repair Next StepRead the fault codes.Read the fault codes using an electronic service tool.

OKFault Code 431 and 551 are inactive

2A

NOT OKFault codes are active.


STEP 2: Check the vehicle harness. STEP 2A: Inspect the vehicle harness and the ECM connector pins. Condition:• Key switch in the "OFF" position. • Disconnect the vehicle harness from the ECM.


OKNo Damaged Pins

2B



3A



STEP 2B: Check the resistance of the accelerator position sensor circuit. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead. Condition:• Key switch in the "OFF" position. • Disconnect the vehicle harness from the ECM.

Action Specifications/Repair Next StepCheck the resistance.• Measure the resistance from pin 29 to pin

30 of the vehicle harness connector with the accelerator pedal in the released (idle) position.

• Repeat the measurement with the accelera-tor pedal in the depressed (full fuel) posi-tion.NOTE: Resistance with the pedal released must be at least 1000 ohms greater than when it is depressed.

OK1500 to 3000 ohms (released)250 to 1500 ohms (depressed)Released value must be at least 1000 ohms greater than depressed value

2C

NOT OK 2B-1



STEP 2B-1: Check the resistance of the accelerator position sensor. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3823995 - male Weather-Pack test lead.Condition:• Key switch in the "OFF" position. • Disconnect the vehicle harness from the accelerator position sensor. • Disconnect the vehicle harness from the ECM.

Action Specifications/Repair Next StepCheck the resistance of the throttle position sen-sor.• Measure the resistance from pin C to pin B

on the sensor side of the accelerator posi-tion sensor connector with the accelerator pedal in the released (idle) position.

• Repeat the above measurement with the accelerator pedal in the depressed (full fuel) position.Note: Resistance when the pedal is released must be at least 1000 ohms greater than when it is depressed.

OK1500 to 3000 ohms (released)250 to 1500 ohms (depressed)Released value at least 1000 ohms greater than depressed value

2B-2

NOT OKReplace the accelerator pedal assemblyRefer to the Troubleshooting and Repair Manual for CDC 24 Valve 8.3 Liter Engine.

3A



STEP 2B-2Check the resistance in the vehicle harness. � CAUTION �

To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead Tool No. 3823995 - male Weather-Pack test lead. Condition:• Key switch in the "OFF" position. • Disconnect the vehicle harness from the accelerator position sensor. • Disconnect the vehicle harness from the ECM.

Action Specifications/Repair Next StepCheck the resistance in the vehicle harness.• Measure the resistance from pin 29 of the


• Measure the resistance from pin 30 of the vehicle harness connector to pin B on the harness side of the accelerator position sensor connector.

OKLess than 10 ohms

2C

NOT OKRepair or replace the vehicle harnessRefer to the Troubleshooting and Repair Manual for CDC 24 Valve 8.3 Liter Engine.

3A



STEP 2C: Check for an open circuit. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead. Condition:• Key switch in the "OFF" position. • Connect the vehicle harness to the accelerator position sensor. • Disconnect the vehicle harness from the ECM.Check for an open circuit.• Measure the resistance from pin 29 to pin

19 of the vehicle harness connector (the accelerator pedal can be either released or depressed).

OK2000 to 3000 ohms

2D

NOT OK 2C-1



STEP 2C-1: Check for an open circuit of the accelerator position sensor supply and return circuit.

� CAUTION �To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3823995 - male Weather-Pack test lead.Condition:• Key switch in the "OFF" position. • Disconnect the vehicle harness from the accelerator position sensor. • Disconnect the vehicle harness from the ECM. Check for an open circuit of the accelerator posi-tion sensor supply and return circuit.• Measure the resistance from pin C to pin A

on the sensor side of the accelerator posi-tion sensor connector (the accelerator pedal can be either released or depressed).

OK2000 to 3000 ohms

2C-2


3A



STEP 2C-2: Check for an open circuit in the vehicle harness. � CAUTION �

To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test leadPart No 3823995 - male Weather-Pack test lead.Condition:• Key switch in the “OFF” position. • Disconnect the vehicle harness from the accelerator position sensor. • Disconnect the vehicle harness from the ECM.

Action Specifications/Repair Next StepCheck the resistance in the vehicle harness from the ECM.• Measure the resistance from pin 29 of the


• Measure the resistance from pin 19 of the vehicle harness connector to pin A on the harness side of the accelerator position sensor connector.

OKLess than 10 ohms

2D


3A



STEP 2D: Check for a short circuit to ground. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead. Condition:• Key switch in the "OFF" position.• Connect the vehicle harness to the accelerator position sensor. • Disconnect the vehicle harness from ECM.

Action Specifications/Repair Next StepCheck for a short circuit to ground.• Measure the resistance from pin 29 in the

vehicle harness to the engine block ground. • Measure the resistance from pin 30 in the

vehicle harness to the engine block ground.

OK More than 100k ohms

2E

NOT OK 2D-1



2D-1Check for a short circuit to ground in the accelerator position sensor. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3823996 - female Weather-Pack test lead. Condition:• Key switch in the "OFF" position.• Disconnect the vehicle harness from the accelerator position sensor.• Disconnect the vehicle harness from the ECM.

Action Specifications/Repair Next StepCheck for a short circuit to ground in the acceler-ator position sensor.• Measure the resistance from pin B on the

sensor side of the accelerator position sen-sor connector to the engine block ground.

• Measure the resistance from pin C on the sensor side of the accelerator position sen-sor connector to the engine block ground.


2D-2


3A



STEP 2D-2: Check for a short circuit to ground in the vehicle harness. � CAUTION �

To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead.Condition:• Key switch in the "OFF" position. • Disconnect the vehicle harness from the accelerator position sensor. • Disconnect the vehicle harness from the ECM.

Action Specifications/Repair Next StepCheck for a short circuit to ground in the vehicle harness.• Measure the resistance from pin 29 of the

vehicle harness to the engine block ground. • Measure the resistance from pin 30 of the

vehicle harness to the engine block ground.


2E


3A



STEP 2E: Check for a short circuit from pin to pin in the vehicle harness. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead. Condition:• Key switch in the "OFF" position. • Disconnect the vehicle harness from the accelerator position sensor. • Disconnect the vehicle harness from the ECM.

Action Specifications/Repair Next StepCheck for short circuit from pin to pin in the vehi-cle harness.• Measure the resistance from pin 29 in the

vehicle harness to all other pins in the con-nector.

• Measure the resistance from pin 30 in the vehicle harness to all other pins in the con-nector.

• Measure the resistance from pin 19 in the vehicle harness to all other pins in the con-nector.


3A


3A




Action Specifications/Repair Next StepDisable the fault code.• Depress the accelerator pedal to the full

fuel position and release it completely three times.

• Start the engine and let idle for one minute.• Drive the vehicle. • Using an electronic service tool, verify Fault



3B


1A

STEP 3B: Clear the inactive fault codes. Condition:• Connect all the components. • Key switch in the “ON” position. Clear the inactive fault codes.• Erase the inactive fault code using an elec-



Repair complete





Fault Code 433


Circuit Description:The intake manifold pressure sensor monitors intake manifold pressure and passes information to the electronic control module (ECM) through the engine harness. If intake manifold pressure becomes too high it will cause a derate condition.

Component Location:The intake manifold pressure sensor is located in the rear of the intake manifold, in the second port on the side of the cylinder head to the right of the fuel filter.

Shop Talk:The ECM checks for this fault only at idle speed. If the intake manifold pressure shows too high of a value at this time, the ECM will log a fault code.

Intake Manifold Pressure Sensor CircuitCODES REASON EFFECT

Fault Code: 433PID(P), SID(S): S102FMI: 2Lamp: Yellow

Boost pressure signal indicates boost pressure is high when other engine parameters (i.e. speed and load) indicate boost pressure should be low or boost pressure is low when other engine parameters indicate it should be high.

Engine will derate to no-boost fueling.




To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead.


STEPS SPECIFICATIONS SRT CODESTEP 1: Check the intake manifold pressure sensor. STEP 1A: Inspect the sensor circuit for tampering.

No tampering

STEP 1B: Inspect the engine harness and the sensor connectors.

No damaged pins

STEP 2: Check the engine harness. STEP 2A: Inspect the harness and the ECM connectors.

No damaged pins

STEP 2B: Check for a short circuit from pin to pin.

More than 100k ohms

STEP 2C: Check for a short circuit to ground. More than 100k ohms STEP 2D: Check for an open circuit in the return line.

Less than 10 ohms

STEP 3: Clear the fault codes. STEP 3A: Disable the fault code. Fault Code 433 inactive STEP 3B: Clear the inactive fault code. All faults cleared




STEP 1: Check the intake manifold pressure sensor. STEP 1A: Inspect the sensor circuit for tampering.Condition:• Key switch in the “OFF” position.

Action Specifications/Repair Next StepInspect the sensor circuit for tampering.Check the intake manifold pressure sensor and the engine harness for external wires or dam-aged harness braiding.

OKNo tampering

1B

NOT OKRemove and record tamperingIf tampering has occurred, repair the circuit and record the tampering.

3A



STEP 1B: Inspect the engine harness and the sensor connectors. Condition:• Key switch in the “OFF” position.• Disconnect the engine harness from the intake manifold pressure sensor.

Action Specifications/Repair Next StepInspect the harness and the sensor connectors for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

2A


043.• Replace the intake manifold pressure sensor. Refer to

Procedure 019-061.

3A

STEP 2: Check the engine harness. STEP 2A: Inspect the harness and the ECM connectors.

� CAUTION �To avoid damaging a new ECM, all other active fault codes must be investigated prior to replacing the ECM.Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the ECM. Inspect the harness and the ECM connectors for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

2B



3A



STEP 2B: Check for a short from pin to pin. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/Cannon/Metri-Pack test lead. Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the intake manifold pressure sensor. • Disconnect the engine harness from the ECM.

Action Specifications/Repair Next StepCheck for a short from pin to pin.• Measure the resistance from pin 45 in the

engine harness connector to all other pins in the engine harness connector.


2C


3A




To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead.Condition:• Key switch in the “ON” position. • Disconnect the engine harness from the intake manifold pressure sensor. • Disconnect the engine harness from the ECM.

Action Specifications/Repair Next StepCheck for a short circuit to ground.• Measure the voltage from pin 45 in the



2D


3A



STEP 2D: Check for an open circuit in the return line. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead. Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the intake manifold pressure sensor. • Disconnect the engine harness from the ECM.

Action Specifications/Repair Next StepCheck for an open circuit in the return line• Measure the resistance from pin 19 of the

engine harness connector to pin B of the intake manifold pressure sensor connector on the harness side.

OKLess than 10 ohmsReplace the intake manifold pressure sensor.Refer to Procedure 019-061.

3A


3A





3B


1A



STEP 3B: Clear the inactive fault codes Condition:• Connect all the components.• Key switch in the “ON” position.

Action Specifications/Repair Next StepClear the inactive fault code.• Erase the inactive fault code using an elec-


OKAll faults cleared.

Repair complete





Fault Code 434

Unswitched Battery Supply Circuit

Circuit Description:The ECM receives constant voltage from the batteries through the unswitched battery wires that are connected directly to the pos-itive (+) battery post. There is one 30 amp fuse in the unswitched battery wire to protect the engine harness from overheating. The ECM receives switched battery input through the vehicle key switch wire, when the vehicle key switch is turned on.

Component Location:The ECM is connected to the battery by the engine harness. This direct link provides a constant power supply for the ECM. The location of the battery will vary with the vehicle. Refer to the vehicle repair manual.

Shop Talk:If the ECM unswitched battery supply is taken from the starter, check for low voltage during cranking. Low voltage during cranking can cause the ECM power supply to drop below specifications and log Fault Code 434.

Unswitched Battery Supply CircuitCODES REASON EFFECT


All data gathered by the electronic control mod-ule (ECM) since the last key-on (i.e. faults, trip information data, etc.) was not stored to perma-nent memory at the last key off.

None on performance.Fault code table, trip information data and main-tenance monitor data may be inaccurate.





� CAUTION �To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test leadTool No. 3822917 - female AMP/Metri-Pack test lead.

STEPS SPECIFICATIONS SRT CODESTEP 1: Check the batteries and the power connector. STEP 1A: Inspect the 4 pin power connector. No damaged pins or loose connections STEP 1B: Check the resistance of the battery supply circuit.

Less than 10 ohms

STEP 1C: Check the battery voltage. Normal conditions:At least 12 VDC (12 VDC system)At least 24 VDC (24 VDC system)During cranking: At least 6.2 VDC (12 VDC system)At least 12 VDC (24 VDC system)

STEP 1D: Check the battery connections. Connections are tight and corrosion free STEP 2: Check the fuse. STEP 2A: Check if the 30 amp fuse is installed correctly.

Fuse installed correctly

STEP 2B: Check if the fuse is blown. Fuse not blown STEP 3: Check the engine harness. STEP 3A: Inspect the harness and the ECM connector pins. No damaged pins STEP 3B: Check for an open circuit in the battery power circuits.

10 to 15 VDC (12 VDC system)22 to 27 VDC (24 VDC system)

STEP 3C: Check for a short circuit in the battery return wires.

More than 100k ohms

STEP 3D: Check the add-on or the accessory wiring at "+" terminal of the battery.

No damaged wires





STEP 1: Check the batteries and the power connector. STEP 1A: Inspect the 4 pin power connector. Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the battery supply at the 4 pin connector.

Action Specifications/Repair Next StepInspect the 4 pin connector on both the battery side and harness side for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins or loose connections

1B

NOT OKRepair or replace the damaged pins

4A



STEP 1B: Check the resistance of the battery supply circuit. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/Cannon/AMP/Metri-Pack test lead.Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the 4 pin connector.

Action Specifications/Repair Next StepCheck the resistance of the battery supply cir-cuit.• Measure the resistance from pins A, B, C,

and D of the 4 pin power connector to the positive battery terminal.

• Measure the resistance from pins A, B, C, and D of the 4 pin ground connector to the negative battery terminal.

OKLess than 10 ohms

1C

NOT OKRepair or replace the harnessRefer to the Troubleshooting and Repair Manual for CDC 24 Valve 8.3 Liter Engine.

4A



STEP 1C: Check the battery voltage.Condition:• Key switch in the "ON" position. • Connect the engine harness to the three 4 pin and one 2 pin connectors.

Action Specifications/Repair Next StepCheck the battery voltage.Connect the engine harness to the 4 pin connector. • Place positive (+) probe of multimeter on

the positive battery terminal and touch neg-ative (-) probe to the negative battery termi-nal. Connect the engine harness to the 4 pin battery supply connector. Measure the voltage before and during cranking.

OKNormal conditions: at least 12 VDC (12 VDC system)at least 24 VDC (24 VDC system)During cranking: at least 6.2 VDC (12 VDC system)at least 12 VDC (24 VDC system)

1D

NOT OKCharge or replace the batteryRefer to the Troubleshooting and Repair Manual for CDC 24 Valve 8.3 Liter Engine

4A



STEP 1D: Check the battery connections. Condition:• Key switch in the "ON" position. • Connect the engine harness to the three 4 pin and one 2 pin connectors.

Action Specifications/Repair Next StepCheck the battery connections. OK

Connections are tight and corrosion free2A

NOT OKTighten the connectionsTighten the loose connections and clean the terminals. Refer to the Troubleshooting and Repair Manual for CDC 24 Valve 8.3 Liter Engine.

4A

STEP 2: Check the fuses. STEP 2A: Check if the 30 amp fuse is installed correctly. Condition:• Key switch in the "ON" position. • Connect the engine harness to the three 4 pin and one 2 pin connectors. Check if the 30 amp fuse is installed correctly.• Inspect the 30 amp fuse for correct installa-

tion.

OKFuse installed correctly

2B

NOT OKInstall the fuse correctly

4A



STEP 2C: Check if the fuse is blown. Condition:• Key switch in the "ON" position. • Connect the engine harness to the three 4 pin and one 2 pin connectors.

Action Specifications/Repair Next StepCheck if the 30 amp fuse is blown. OK

Fuse not blown3A


4A

STEP 3: Check the engine harness. STEP 3A: Inspect the harness and the ECM connector pins.

� CAUTION �To avoid damaging the ECM, all other active fault codes must be investigated prior to replacing the ECM.Condition:• Key switch in the "OFF" position.• Connect the engine harness to the three 4 pin and one 2 pin connectors. • Disconnect the engine harness from the ECM.


OKNo damaged pins

3B

NOT OKRepair the damaged pinsRepair or replace the engine harness or ECM, whichever has the damaged pins. • Repair the engine harness.• Replace the engine harness. Refer to Procedure 019-


4A



STEP 3B: Check for an open circuit in the battery power circuits. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead. Condition:• Key switch in the "OFF" position. • Connect the engine harness to the three 4 pin and one 2 pin connectors. • Disconnect the engine harness from the ECM.

Action Specifications/Repair Next StepCheck for an open circuit in the battery power and return circuits.• Measure the voltage from pin 38 to pins 20,

28, 29 and 30. • Measure the voltage from pin 39 to pins 20,



28, 29 and 30.

OK10 to 15 VDC (12 VDC system)22 to 27 VDC (24 VDC system)

3C


4A



STEP 3C: Check for a short circuit. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead. Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the three 4 pin and one 2 pin connectors. • Disconnect the engine harness from the ECM.

Action Specifications/Repair Next StepCheck for a short circuit.• Measure the resistance from pin 38 to all

other pins in the engine harness. • Measure the resistance from pin 39 to all







other pins in the engine harness.


3D


4A



STEP 3D: Check the add-on or accessory wiring at "+" terminal of the battery. Condition:• Key switch in the "OFF" position.

Action Specifications/Repair Next StepCheck the add-on or the accessory wiring at "+" terminal of the battery.• Starting at the "+" terminal, follow any add-

on or accessory wiring and examine wire(s) for damaged insulation or an installation error that can cause the supply wire to be shorted to the engine block ground.

OKNo damaged wires

4A

NOT OKRepair or replace the damaged wiringRefer to the Troubleshooting and Repair Manual for CDC 24 Valve 8.3 Liter Engine.

4A





4B


1A







Repair complete





Fault Code 441


Circuit Description:The ECM receives unswitched battery input through the engine harness. There is one 30 amp fuse in the unswitched battery wire of the engine harness to protect it from overheating.

Component Location:The ECM is connected to the battery by the engine harness. This direct link provides a constant power supply for the ECM. The location of the battery will vary with the vehicle. Refer to the vehicle repair manual for the battery location.

Shop Talk:Make sure the ECM unswitched battery supply is coming directly from the battery and not the starter.

Unswitched Battery Supply CircuitCODES REASON EFFECT


Voltage detected at electronic control module (ECM) power supply pins 38, 39, 40 and 50 of the engine harness indicates ECM supply volt-age fell below 6 VDC.

Engine may not start.




To avoid pin and harness damage, use the following test leads when taking a measurement:Tool No. 3822758 - male AMP/Cannon Metri-Pack Deutsch test leadTool No. 3822917 - female AMP/Cannon Metri-Pack Deutsch test lead.


STEPS SPECIFICATIONS SRT CODESTEP 1: Check the equipment battery system. STEP 1A: Inspect the battery cable connections. No damaged connections STEP 1B: Check the battery voltage. Normal conditions:

at least 12 VDC (12 VDC system)at least 24 VDC (24 VDC system)During cranking: at least 6.2 VDC (12 VDC system)at least 12 VDC (24 VDC system)

STEP 2: Check the vehicle harness. STEP 2A: Inspect the fuse connections. Fuses installed correctly STEP 2B: Check the fuse. Fuses not blown or loose connections STEP 2C: Inspect the 4 pin power connector. No damaged pins STEP 2D: Check for an open circuit in the unswitched battery supply circuit.

Less than 10 ohms

STEP 2E: Check for an add-on or accessory wiring at the “+” terminal of the battery.

No damaged wires

STEP 3: Check the engine harness. STEP 3A: Check for short circuit from pin to pin. More than 100k ohms STEP 3B: Check for an open circuit. Less than 10 ohms STEP 3C: Check for a short circuit to ground. More than 100k ohms STEP 4: Clear the fault code. STEP 4A: Disable the fault code. Fault Code 441 inactive STEP 4B: Clear the inactive fault codes. All faults cleared




STEP 1: Check the equipment battery system. STEP 1A: Inspect the battery cable connections.Condition:• Key switch in the "OFF" position.

Action Specifications/Repair Next StepInspect the battery cable connections for:• corrosion loose connection.

OKNo damaged connections

1B

NOT OKRepair the damaged connectionsTighten the battery connections and clean the battery ter-minals. Refer to the Troubleshooting and Repair Manual for CDC 24 Valve 8.3 Liter Engine.

4A



STEP 1B: Check the battery voltage.Condition:• Key switch in the "OFF" position.

Action Specifications/Repair Next StepCheck the battery voltage.• Measure the battery voltage from the posi-

tive (+) terminal to the negative (-) terminal. • Measure the battery voltage from the posi-

tive (+) terminal to the negative (-) terminal while trying to start the engine.

OKNormal conditions: at least 12 VDC (12 VDC system)at least 24 VDC (24 VDC system)During cranking: at least 6.2 VDC (12 VDC system)at least 12 VDC (24 VDC system)

2A

NOT OKCharge or replace the batteryRefer to the Troubleshooting and Repair Manual for CDC 24 Valve 8.3 Liter Engine.

4A



STEP 2: Check the vehicle harness. STEP 2A: Inspect the fuse connections.Condition:• Key switch in the "OFF" position. • Disconnect the 30 amp fuse from the engine harness.

Action Specifications/Repair Next StepCheck if the 30 amp fuse is installed correctly. OK

Fuse installed correctly.2B

NOT OKInstall fuse correctly

4A

STEP 2B: Check the fuse. Condition:• Key switch in the "OFF" position. • Disconnect the 30 amp fuse from the engine harness.

Action Specifications/Repair Next StepCheck if the 30 amp fuse is blown. OK

Fuse not blown2C

NOT OKReplace the fuse

4A



STEP 2C: Inspect the 4 pin power connector. Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the battery at the 4 pin connector.

Action Specifications/Repair Next StepInspect the 4 pin connectors on the both battery side and the harness side for:• bent or broken pins• pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins or loose connections.

2D

NOT OKRepair or replace the 4 pin connector

4A

STEP 2D: Check for an open circuit in the unswitched battery supply circuit. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement;Inspect connector on engine to determine which test lead to use:Tool No. 3823998 - Weatherpack - male test leadTool No. 3823999 - Weatherpack - female test lead.Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the battery supply at the 4 pin supply connector.

Action Specifications/Repair Next StepCheck for an open circuit in the battery supply and return circuits.• Measure the resistance from pins A, B, C,

and D to the positive terminal of the battery. • Measure the resistance from pins A, B, C,

and D to the negative battery terminal.

OKLess than 10 ohms

2E

NOT OKRepair or replace the harnessRefer to the Troubleshooting and Repair Manual for CDC 24 Valve 8.3 Liter Engine.

4A



STEP 2E: Check the add-on or accessory wiring at the “ +” terminal of the battery.Condition:• Key switch in the "OFF" position.

Action Specifications/Repair Next StepCheck the add-on or accessory wiring at the "+" terminal of the battery.• Starting at the “+” terminal follow any add-

on or accessory wiring and examine the wire(s) for damaged insulation or installa-tion error that can cause supply wire to be shorted to the engine block ground.

OKNo damaged wires

3A

NOT OKRepair the damaged wiringRefer to the Troubleshooting and Repair Manual for CDC 24 Valve 8.3 Liter Engine.

4A



STEP 3: Check the engine harness STEP 3A: Check for a short circuit from pin to pin.

� CAUTION �To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male AMP/Cannon Metri-Pack Deutsch test leadTool No. 3822917 - female AMP/Cannon Metri-Pack Deutsch test lead. Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the ECM. • Disconnect the engine harness from the three 4 pin and one 2 pin connectors.

Action Specifications/Repair Next StepCheck for a short circuit.• Measure the resistance from pin 38 to all








other pins in the engine harness.


3B

NOT OKReplace the engine harnessReplace the engine harness. Refer to Procedure 019-043.

4A



STEP 3B: Check for an open circuit.Condition:• Key switch in the “OFF” position. • Disconnect engine harness from the ECM. • Disconnect engine harness from the three 4 pin and one 2 pin connectors.

Action Specifications/Repair Next StepCheck for an open circuit.• Measure the resistance, on the engine har-

ness side, from pin 38 of the ECM connec-tor to pin A of the 4 pin supply connector.

• Measure the resistance, on the engine har-ness side, from pin 39 of the ECM connec-tor to pin B of the 4 pin supply connector.

• Measure the resistance, on the engine har-ness side, from pin 40 of the ECM connec-tor to pin C of the 4 pin supply connector.

• Measure the resistance, on the engine har-ness side, from pin 50 of the ECM connec-tor to pin D of the 4 pin supply connector.

• Measure the resistance, on the engine har-ness side, from pin 20 of the ECM connec-tor to pin A of the 4 pin ground connector.

• Measure the resistance, on the engine har-ness side, from pin 28 of the ECM connec-tor to pin B of the 4 pin ground connector.

• Measure the resistance, on the engine har-ness side, from pin 29 of the ECM connec-tor to pin C of the 4 pin ground connector.

• Measure the resistance, on the engine har-ness side, from pin 30 of the ECM connec-tor to pin D of the 4 pin ground connector.

OKLess than 10 ohms

3C

NOT OKReplace the engine harness.Refer to Procedure 019-043.

4A



STEP 3C: Check for a short circuit. Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the ECM. • Disconnect the engine harness from the three 4 pin and one 2 pin connectors.

Action Specifications/Repair Next StepCheck for a short circuit.• Measure the resistance from pin 38 of the

ECM connector on the engine harness to chassis ground.

• Measure the resistance from pin 39 of the ECM connector on the engine harness to chassis ground.








4A

NOT OKReplace the engine harnessReplace the engine harness. Refer to Procedure 019-043.

4A



STEP 4: Clear the fault code. STEP 4A: Disable the fault Code. Condition:• Connect all the components. • Key switch in the “ON” position.




4B


1A


Action Specifications/Repair Next StepClear the inactive Fault codes.• Erase the inactive fault code using an elec-



Repair complete





Fault Code 442


Circuit Description:The ECM receives unswitched battery input through the engine harness. There is a 30 amp fuse in the unswitched battery wire to protect the engine harness from overheating. The battery return wires are connected directly to the negative (-) battery post.

Component Location:The ECM is connected to the battery by the engine harness. This direct link provides a constant power supply for the ECM. The location of the battery will vary with the application. Refer to the vehicle service manual for battery location.

Shop Talk:Disconnect all aftermarket devices from the battery supply circuit. Make sure the proper size fuse is being used (30 amp fuse).

Unswitched Battery Supply Circuit CODES REASON EFFECT


Voltage detected at electronic control module (ECM) power supply pins 38, 39, 40 and 50 of the engine harness indicates ECM supply volt-age is above the maximum system voltage level.

Possible ECM damage.




To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3823995 - male Weather-Pack test lead.

STEPS SPECIFICATIONS SRT CODESTEP 1: Check the equipment battery system. STEP 1A: Check the battery voltage. Less than 32 VDC STEP 1B: Check the battery ground. Less than 10 ohms STEP 1C: Check the alternator. Alternator functioning normally STEP 2: Clear the fault code. STEP 2A: Disable the fault code. Fault Code 442 inactive STEP 2B: Clear the inactive fault codes. All faults cleared




STEP 1: Check the equipment battery system. STEP 1A: Check the battery voltage.

� CAUTION �To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3823995 - male Weather-Pack test lead. Condition:• Key switch in the "OFF" position. • Disconnect all aftermarket devices from the battery supply circuit. • Disconnect the engine harness from the battery at the positive 4 pin connector.

Action Specifications/Repair Next StepCheck the battery voltage.• Measure the battery voltage from pin A of

the positive lead of the power connector to engine block ground.

• Measure the battery voltage from pin B of the positive lead of the power connector to engine block ground.

• Measure the battery voltage from pin C of the positive lead of the power connector to engine block ground.

• Measure the battery voltage from pin D of the positive lead of the power connector to engine block ground.

OKLess than 32 VDC

1B

NOT OKInstall the battery system correctlyRefer to the Troubleshooting and Repair Manual for CDC 24 Valve 8.3 Liter Engine.

2A



STEP 1B: Check the battery ground. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3823995 - male Weather-Pack test lead.Condition:• Key switch in the “OFF” position. • Disconnect all aftermarket devices from the battery supply circuit. • Disconnect the engine harness from the battery at the 4 pin connector.

Action Specifications/Repair Next StepCheck the battery ground.• Measure the resistance from pin A of the

negative lead of the power connector to ground.

• Measure the resistance from pin B of the negative lead of the power connector to ground.

• Measure the resistance from pin C of the negative lead of the power connector to ground.

• Measure the resistance from pin D of the negative lead of the power connector to ground.

OKLess than 10 ohms

1C

NOT OKInstall the battery system correctlyRefer to the Troubleshooting and Repair Manual for CDC 24 Valve 8.3 Liter Engine.

2A



STEP 1C: Check the alternator. Condition:• Key switch in the "OFF" position.

Action Specifications/Repair Next StepInspect the alternator for normal operation. OK

Alternator functioning normally2A

NOT OKRepair or replace the alternatorRefer to the Troubleshooting and Repair Manual for CDC 24 Valve 8.3 Liter Engine.

2A





2B


1A





Repair complete





Fault Code 449


Circuit Description:The fuel pressure/temperature sensor is used by the ECM to monitor the fuel pressure in the accumulator. The ECM monitors the voltage on the signal pin and converts this to a pressure value.

Component Location:The fuel pressure/temperature sensor is located on the rear of the accumulator.

Shop Talk:A missing weather seal on the four pin fuel pressure sensor connector can cause this fault to log intermittently.



Fuel pressure signal indicates that fuel pressure has exceeded the maximum limit for the given engine rating.

Power and/or speed derate, engine may die.





STEPS SPECIFICATIONS SRT CODESTEP 1: Check for tampering. STEP 1A: Inspect fuel pressure sensor circuit for signs of tampering.

No tampering

STEP 2: Check fault codes. STEP 2A: Read fault codes. Fault Code 449 inactiveSTEP 3: Clear the fault codes. STEP 3A: Disable the fault codes. Fault Code 449 inactive STEP 3B: Clear the inactive fault code. All faults cleared

STEP 1: Check the fuel pressure sensor circuit. STEP 1A: Inspect the fuel pressure sensor circuit for signs of tampering.Condition:• Key switch in the “OFF” position.

Action Specifications/Repair Next StepCheck the fuel pressure sensor circuit for signs of tampering; such as:• extra wires spliced into the fuel pressure

sensor wiring. • cut braiding in the wire harness. • signs of unnecessary sensor removal and

installation. • missing weather seal on fuel pressure con-

nector.

OKNo tampering

2A

NOT OKRemove extra wires or replace missing weather seal.

3A

STEP 2: Check fault codes. STEP 2A: Read fault codes. Condition:• Connect all components.• Key switch in the “ON” position.

Action Specifications/Repair Next StepRead the fault codes.• Operate engine from low to high idle several

times or test drive the vehicle before read-ing fault codes.

• Using an electronic service tool, read the fault codes.


3A

NOT OKReplace the accumulator moduleRefer to Procedure 005-085 in Section 10 Chapter 12 of the CDC 24 Valve 8.3 Liter Engine Repair Manual.

3A



STEP 3: Clear the fault codes. STEP 3A: Disable the fault codes. Condition:• Connect all the components.• Key switch in the “ON” position.

Action Specifications/Repair Next StepDisable the fault code.• Start engine and let idle for one minute. • Using an electronic service tool, verify that

fault code 449 is inactive and did not reoc-cur.


3B


1A


Action Specifications/Repair Next StepClear all the inactive fault codes.• Erase the inactive fault codes using an



Repair complete


Appropriatetroubleshooting charts





Circuit Description:The fuel pressure/temperature sensor is used by the ECM to monitor the fuel pressure in the accumulator. The ECM monitors the voltage on the signal pin and converts this to a pressure value.

Component Location:The fuel pressure/temperature sensor is located on the rear of the accumulator.


Fault Code: 451 or 452PID(P), SID(S): P094SPN: 94 FMI: 3 or 4Lamp: Yellow

FC451: High voltage detected at fuel pressure sensor signal pin 46 of the engine harness.FC452: Low voltage detected at fuel pressure sensor signal pin 46 of the engine harness.

Power and/or speed derate, engine may run rough.




To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male AMP/Deutsch/Metri-Pack test leadTool No. 3162982 - fuel pressure breakout cable.

� CAUTION �To avoid damaging the new ECM, all other active fault codes must be investigated prior to replacing the ECM.


STEPS SPECIFICATIONS SRT CODESTEP 1: Check for multiple fault codes. STEP 1A: Read fault codes. Fault Codes 122, 123, 135, 141, 144, 145, 153,

154, 263, 265, and 352 inactive STEP 2: Check the fuel pressure sensor. STEP 2A: Inspect the fuel pressure sensor and engine harness connector.

No damaged pins

STEP 2B: Check the fuel pressure supply voltage.

4.5 to 5.25 VDC

STEP 2C: Check the fuel pressure signal voltage. 0.31 to 0.69 VDC STEP 3: Check the engine harness. STEP 3A: Inspect the engine harness and the ECM connector pins.

No damaged pins

STEP 3B: Check for open circuit. Less than 10 ohms STEP 3C: Check for a short circuit to ground. More than 100k ohms STEP 3D: Check for a short circuit from pin to pin.

More than 100k ohms

STEP 4: Clear the fault code. STEP 4A: Disable the fault code. Fault Code 451 and 452 inactive STEP 4B: Clear the inactive fault codes. All fault codes cleared

STEP 1: Check for multiple fault codes. STEP 1A: Read the fault codes.Condition:• Key switch in the "ON" position. • All components connected.

Action Specifications/Repair Next StepRead the fault codes.• Read active fault codes using an electronic

service tool.

OKFault Code 122, 123, 135, 141, 144, 145, 153, 154, 263, 265, and 352 inactive

2A

NOT OKFault codes are active

4A



STEP 2: Check the fuel pressure sensor. STEP 2A: Inspect the fuel pressure sensor and engine harness. Condition:• Key switch in the "OFF" position. • Disconnect the engine wiring harness from the ECM. • Disconnect the engine wiring harness from the fuel pressure sensor.

Action Specifications/Repair Next StepInspect the engine harness, fuel pressure sensor and ECM connectors for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

2B


043.• Replace the fuel pressure/temperature sensor. Refer

to Procedure 019-153.

4A



STEP 2B: Check the fuel pressure supply voltage. � CAUTION �

To avoid pin and harness damage, use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test leadTool No. 3162982 - fuel pressure breakout cable. Condition:• Key switch in the "OFF" position.• Disconnect the engine harness from the fuel pressure sensor. • Install fuel pressure breakout cable Tool No. 3162982. • Key switch in the “ON” position.

Action Specifications/Repair Next StepCheck the fuel pressure supply voltage. • Measure the voltage from pin A to pin B of

the fuel pressure sensor breakout cable.

OK4.5 to 5.25 VDC

2C


4A



STEP 2C: Check the fuel pressure signal voltage.Condition:• Key switch in the “ON” position. • Connect the fuel pressure sensor breakout cable, Tool No. 3162982, between the sensor and the engine harness.

Action Specifications/Repair Next StepCheck the fuel pressure signal voltage.• Measure the voltage from pin B to pin C of

the fuel pressure sensor breakout cable.

OK0.31 to 0.69 VDC

3A


4A




� CAUTION �To avoid damaging the new ECM, all other fault codes must be investigated prior to replacing the ECM.Condition:• Key switch in the "OFF" position. • Disconnect the engine wiring harness from the ECM.


OKNo damaged pins

3B

NOT OKRepair the damaged pinsRepair or replace the engine harness or the ECM, which-ever has the damaged pins. • Repair the engine harness. • Replace the engine harness. Refer to Procedure 019-


4A




To avoid pin and harness damage use the following test lead when taking a measurement:Tool No. 3822758 - male AMP/Deutsch/Metri-Pack test lead.Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the fuel pressure sensor. Disconnect the engine harness from the ECM.

Action Specifications/Repair Next StepCheck for a open circuit.• Measure the resistance from pin 46 of the

engine harness to pin C on the harness side of the fuel pressure sensor.

• Measure the resistance from pin 19 of the engine harness to pin B on the harness side of the fuel pressure sensor.

OKLess than 10 ohms

3C


4A




To avoid pin and harness damage use the following test lead when taking a measurement:Tool No. 3822758 - male AMP/Deutsch/Metri-Pack test lead.Condition:• Key switch in the “OFF” position.• Disconnect the engine harness from the fuel pressure sensor. • Disconnect the engine harness from the ECM.




OKMore than 100K ohms

3D

NOT OKReplace the engine harnessRefer to procedure 019-043.

4A




To avoid pin and harness damage use the following test lead when taking a measurement:Tool No. 3822758 - male AMP/Deutsch/Metri-Pack test lead.Condition:• Key switch in the “OFF” position. • Disconnect the engine harness from the fuel pressure sensor. • Disconnect the engine harness from the ECM.





4A


4A



Fault Code 451 and 452 are inactive and did not reoccur.

OKFault Code 451 and 452 is inactive

4B

NOT OKReturn to the troubleshooting steps or contact your local New Holland Authorized Repair Location, if all steps have been completed and checked again.

1A







Repair complete





Fault Code 488


Circuit Description:The intake manifold air temperature sensor is used by the electronic control module (ECM) to monitor the temperature of the engine intake air. The intake air temperature is used by the ECM for the engine protection system, and the timing and fueling con-trol.

Component Location:The intake manifold temperature sensor is located on the side of the intake manifold towards the rear of the cylinder head.

Shop Talk:• Make sure the engine compartment temperature does not get too high (above 93.3�C [200�F]).• Make sure the intake manifold temperature sensor is not located near any extreme heat sources. Possible causes:

– clogged, dirty, inadequate capacity air cleaner element. Refer to Procedures 010-060 thru 010-063 in Section 10 Chapter 17 of the CDC 24 Valve 8.3 Liter Engine Repair Manual.– intake restriction. Refer to Procedure 010-059 in Section 10 Chapter 17 of the CDC 24 Valve 8.3 Liter Engine Repair Man-ual.

Intake Manifold Air Temperature Sensor - Engine Protection Circuit CODES REASON EFFECT


Intake manifold air temperature signal indicates the intake manifold air temperature is above the engine protection limit.

Power derate and possible engine shutdown if engine protection shutdown feature is enabled.








STEP 1: Check the sensor accuracy. STEP 1A: Verify the sensor accuracy with a thermocouple or similar temperature probe. Condition:Key switch in the "ON" position.


engine near the intake manifold air temper-ature sensor.

• Connect an electronic service tool to the data bus.

• Run the engine and compare the intake manifold temperature sensor reading on an electronic service tool monitor screen to the reading from the temperature probe. Note: If a temperature measuring device is not available then answer "OK" to this step.Note: Readings may need to be checked while engine is operating at normal temper-ature conditions [180�F coolant].

OKSensor reading is correct within 5�FLocate and repair the cause of high intake manifold air temperature.(Refer to the Shop Talk section of this fault code for the correct procedure).

2A

NOT OKSensor not reading within 5�F.

Fault Code 154




Action Specifications/Repair Next StepDisable the fault code.• Start the engine and let idle for one minute. • Load and operate engine to typical operat-

ing temperature (180�F coolant). • Using an electronic service tool, verify Fault



2B


1A





Repair complete






Coolant Level Sensor Circuit

Circuit Description:The coolant level sensor monitors the coolant level within the coolant system and passes information to the electronic control mod-ule (ECM) through the engine harness.


Shop Talk:This is an application specific component and will vary in sensor location.• If a shorting plug is used in the coolant level circuit, verify that it is wired correctly. • Inspect the wiring harness between the Weather-Pack 4-Way connector and the coolant level sensor for damage. • Make sure the coolant level sensor is located in the middle of the tank rather than off to one side where the coolant level can

change when the vehicle makes a turn.

Coolant Level Sensor Circuit CODES REASON EFFECT


FC515: High voltage detected at the auxiliary +5 VDC sensor supply voltage pin 49 of the engine harness.FC516: Low voltage detected at the auxiliary +5 VDC sensor supply voltage pin 49 of the engine harness.

No engine protection for coolant level.




Wait until the coolant temperature is below 50�C [120�F] before removing the coolant system pressure cap or the coolant level sensor. Failure to do so can cause personal injury from heated coolant spray.

� CAUTION �To avoid pin and harness damage use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test leadTool No. 3823995 - male Weather-Pack test leadTool No. 3823996 - female Weather-Pack test lead.

STEPS SPECIFICATIONS SRT CODESTEP 1: Check the coolant level sensor. STEP 1A: Inspect the engine harness and coolant level sensor connector pins.

No damaged pins

STEP 1B: Check for active fault codes. Fault Code 515 or 516 remains active STEP 2: Check the engine harness. STEP 2A: Inspect the harness and the ECM connector pins.

No damaged pins


More than 100k ohms

STEP 2D: Check for a short circuit to a voltage source.

Less than 1.0 VDC

STEP 3: Check the ECM supply voltage. STEP 3A: Measure the sensor supply voltage from the ECM.

4.5 to 5.25 VDC

STEP 4: Clear the fault code. STEP 4A: Disable the fault code. Fault Code 515 or 516 inactive STEP 4B: Clear the inactive fault codes. All faults cleared




STEP 1: Check the coolant level sensor. STEP 1A: Inspect the engine harness and the coolant level sensor connector pins.

� WARNING �Wait until the coolant temperature is below 50�C [120�F] before removing the coolant system pressure cap or the cool-ant level sensor. Failure to do so can cause personal injury from heated coolant spray. Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the coolant level sensor.

Action Specifications/Repair Next StepInspect the engine harness and the coolant level sensor connector pins for:• bent or broken pins • pushed back or expanded pins • corroded pins • moisture in or on the connector • missing or damaged seals.

OKNo damaged pins

1B

NOT OKRepair the damaged pinsRepair or replace the engine harness or the coolant level sensor, whichever has damaged pins. • Repair the engine harness. • Replace the engine harness. Refer to Procedure 019-

043.• Replace the coolant level sensor. Refer to Procedure

019-017.

4A

STEP 1B: Check for active fault codes. Condition:• Key switch in the “ON” position.

Action Specifications/Repair Next StepCheck for active fault codes.• Using an electronic service tool, read the

fault codes.

OKFault Code 515 or 516 remains active

2A

NOT OK 4A




� WARNING �Wait until the coolant temperature is below 50�C [120�F] before removing the coolant system pressure cap or the cool-ant level sensor. Failure to do so can cause personal injury from heated coolant spray.Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the ECM.


OKNo damaged pins

2B

NOT OKRepair the damaged pinsRepair or replace the engine harness or the ECM, which-ever has the damaged pins. • Repair the engine harness. • Replace the engine harness. Refer to Procedure 019-


4A



STEP 2B: Check for a short circuit to ground. � WARNING �

Wait until the coolant temperature is below 50�C [120�F] before removing the coolant system pressure cap or the cool-ant level sensor. Failure to do so can cause personal injury from heated coolant spray.

� CAUTION �To avoid pin and harness damage use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead.Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the ECM. • Disconnect the engine harness from the coolant level sensor.







2C


4A



STEP 2C: Check for a short circuit from pin to pin. � WARNING �

Wait until the coolant temperature is below 50�C [120�F] before removing the coolant system pressure cap or the cool-ant level sensor. Failure to do so can cause personal injury from heated coolant spray.

� CAUTION �To avoid pin and harness damage use the following test lead when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead.Condition:• Key switch in the "OFF" position.• Disconnect the engine harness from the ECM.• Disconnect the engine harness from the coolant level sensor.






2D


4A



STEP 2D: Check for a short circuit to a voltage source. � CAUTION �

To avoid pin and harness damage use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead.Condition:• Key switch in the "OFF" position. • Disconnect the engine harness from the ECM. • Disconnect the engine harness from the coolant level sensor.

Action Specifications/Repair Next StepCheck for a short circuit to a voltage source.• Measure the voltage from pin 37 of the


• Measure the voltage from pin 27 of the engine harness connector to engine block ground.

• Measure the voltage from pin 49 of the engine harness connector to engine block ground.

OKLess than 1.0 VDC

3A


4A



STEP 3: Check for the ECM voltage. STEP 3A: Measure the sensor supply voltage from the ECM.

� WARNING �Wait until the coolant temperature is below 50�C [120�F] before removing the coolant system pressure cap or the cool-ant level sensor. Failure to do so can cause personal injury from heated coolant spray.

� CAUTION �To avoid pin and harness damage use the following test leads when taking a measurement:Tool No. 3822758 - male Deutsch/AMP/Metri-Pack test lead. Condition:• Connect the engine harness to the ECM. • Disconnect the engine harness from the coolant level sensor. • Key switch in the "ON" position.

Action Specifications/Repair Next StepMeasure the sensor supply voltage from the ECM.• Measure the voltage from pin C of the cool-

ant level sensor, harness side, to engine block ground.

OK4.5 to 5.25 VDC

4A


4A



STEP 4: Clear the fault code. STEP 4A: Disable the fault code. Condition:• Connect all components. • Key switch in the “ON” position.




4B

NOT OKReturn to troubleshooting steps or contact the Technical Services Group (if all the steps have been completed and checked again).

1A

STEP 4B: Clear the inactive fault codes. Condition:• Connect all components. • Key switch in the “ON” position.




Repair complete



Documents

Section 10 Chapter 24 - dmcpubs.com 10 Chapter 24 7-92610NH 24 Valve, ... Fault Code 381 or 382 ... SID(S): P190 SPN: 190 FMI: 2 Lamp: Yellow