235 SY We "1 1 gradeViscosity oS 1 Aetnos ‘Chek Whe car oll f@servcir con paquallty oen- system to func- Scie an val grote, Crack ol level Novel Sang. it there is no oilor vary Giarhease the fl njectorswninst op. ee a, $2 vel 00 he gauge is cver ‘ut t's posable snare se have a just sor ‘while of indicatse is coolantceniacninatonand willhave a> ‘Check service recor for corveat bd typi ais * viscosiy- lar ne temperature {environment the + Yebicle operating n. Single weigh! or 124740 © “alls not ezeommendad for cold ambient tem- FerstLras. Oi that nas had extended drain in- terials vil “ave increased viscosity (become C1 i icie quality is poor after extended = _nnning, refer to test 13, "9 Oitlovelnigh ~incoredt servicing, tuo ct thie! and wil make engine cranking more ‘cul and staring ess ratabie at temperature 2 below roezing. Retertofube oi chartin th op- j Bators oF corice mafival for the comes of # + Selection for temperature conditions, = POSSIBLE CAUSES Ges Olleveltow = 01 ak, oi'censumetin ingen. ietaantong we from fit pump or Zetentve injector" rings © ot comariraon atti Gooian —O Cage head geste potty, (atentchiat = Giyiawowlora en sure ee rcored pd lok jalng heck we ten potas Ba TOOLS REQUIRED 2 41/4" drive raichst ar breaker bar to remous tien piug,TaaaE ENGINE SUFFICIENT CLEAN FUEL © Check at tank(s), drain sainple. from J {uel filler while cranking engine,” Method chee Viewal | PURPOSE | To determine ii the ue! sysiem is getting sullicient lean juel to start and operaie the engine, I TeST PROCEDURE + Route a hose from tne fuel draintube (Figure 2) toa clear container and open the drain, 2. Crank the engine and observe the fuel owing inte the container. Stop cranking the engine when the container is half full t Foe| flow out ofthe erin tube shouls be & steady stream, Insular ow could inscate lust supply i 2 fuel eystem proclem ORS ee SORE ca tree of air, contaminanis, wale, cing er elu: ing. The fusl shoud be straw colored. Fue! dyed red or blue indicates an off-highway fuel Check {uel odor {or the presence of other fuels Such as gasoline or kerosene, engine oils present inthe lvel, i may indicate an injector “0” ring leak and subsequent loss of injec- . tion controi pressure. if that is suspected, check in- ection control pressure during engine cranking. Use the Electronic Service Tool (EST) or fallow pro- cedure outlined in Test 9. NOTE: SOME SEDIMENT AND WATER MAY BE PRESENT IN THE FUEL SAMPLE IF THE FUEL. FILTER HAS NOT BEEN SERVICED OR \ DRAINED -OR A PROLONGED PERIOD OF TIME. A SECOND SAMPLE MAY BE REQUIRED TO DETERMINE FUEL QUALITY. i SSS LOW OR NO FUEL POSSIBLE CAUSES No tuel in iank © Irequipped with 2 iniine fuel valve, I could Be: shut off © Fuel supply line from tank(s) could be broken ar. crimped. ¢ Fuslcould be waxed or elied (mos! likely in co's weather with #2 ‘uel), the pickup tube in tank could be clogged or cracked. If there fe exces- sive water in the tank, it could freeze preventing the tue! from being drawn to the engine Il the vehicle is equipped with cupplemenial fiers or water separators, check for plugged iillers or leakage that could allow the engine to draw air. able grade for cold-temperatures. Excessive water Soe ocnray etre maces oes TOOLS REQUIRED Clear container approximately 1 quart - EGES-125 / Pac in sh Hoe! Canto mt Aameriem EanTaaaE ENGINE SUFFICIENT CLEAN FUEL © Check at tank(s), drain sainple. from J {uel filler while cranking engine,” Method chee Viewal | PURPOSE | To determine ii the ue! sysiem is getting sullicient lean juel to start and operaie the engine, I TeST PROCEDURE + Route a hose from tne fuel draintube (Figure 2) toa clear container and open the drain, 2. Crank the engine and observe the fuel owing inte the container. Stop cranking the engine when the container is half full t Foe| flow out ofthe erin tube shouls be & steady stream, Insular ow could inscate lust supply i 2 fuel eystem proclem ORS ee SORE ca tree of air, contaminanis, wale, cing er elu: ing. The fusl shoud be straw colored. Fue! dyed red or blue indicates an off-highway fuel Check {uel odor {or the presence of other fuels Such as gasoline or kerosene, engine oils present inthe lvel, i may indicate an injector “0” ring leak and subsequent loss of injec- . tion controi pressure. if that is suspected, check in- ection control pressure during engine cranking. Use the Electronic Service Tool (EST) or fallow pro- cedure outlined in Test 9. NOTE: SOME SEDIMENT AND WATER MAY BE PRESENT IN THE FUEL SAMPLE IF THE FUEL. FILTER HAS NOT BEEN SERVICED OR \ DRAINED -OR A PROLONGED PERIOD OF TIME. A SECOND SAMPLE MAY BE REQUIRED TO DETERMINE FUEL QUALITY. i SSS LOW OR NO FUEL POSSIBLE CAUSES No tuel in iank © Irequipped with 2 iniine fuel valve, I could Be: shut off © Fuel supply line from tank(s) could be broken ar. crimped. ¢ Fuslcould be waxed or elied (mos! likely in co's weather with #2 ‘uel), the pickup tube in tank could be clogged or cracked. If there fe exces- sive water in the tank, it could freeze preventing the tue! from being drawn to the engine Il the vehicle is equipped with cupplemenial fiers or water separators, check for plugged iillers or leakage that could allow the engine to draw air. able grade for cold-temperatures. Excessive water Soe ocnray etre maces oes TOOLS REQUIRED Clear container approximately 1 quart - EGES-125 / Pac in sh Hoe! Canto mt Aameriem EanCe. | a _/ PERFORMANCE DIAGNosTics ‘sana, ee Taub ENG x aE ENGINE SUFFICIENT CLEAN FUEL (Continy@d) ~—RES EERE Se ee Section 2 Page 36 PERFORMANCE DIAGNOSTics Soe ececins 2002 Oa EST TOOL-FAULT copes FROM FORM EGED-130 3. EST-TOOL FAULT CODES © Install Electronic Service Toot PURPOSE {0 determine it the Electronic Control Module (COM) has detected any fautteonchion ‘Patwouk! ERTO OPERATE THe EST. THE EST WILL aU. Cause an engine pertormance problem: FPMATICALLY POWER UP aS soon AS ITIS PLUGGED INTO THE Ata CONNECTOR. THe TEST PROCEDURE USE ONLY WHEN READING NON-VOLATILE ROTE. TURN ALL accrssonies AND THE MORY. IGNITION OFF, BEFORE CONNECTING =sT TOOL TO ATA DIAGNOSTIC CONNECTOR, Pein the ignition switch io the “ON” postion but do cave aettne engine, This wit allow the bern Ce Gonneet the Elecitonic Serviee Too! AEST) to the ceive data rom ye slectronic contro! componenis Zumerican Trucking Associaton (ara Seonostlc —onthstruck. todas ‘eoeived, press "ENTER Gepnastor. The connector is iocateti on tPelowerkell _ toreiy. Theinlomen received will be data show ‘tek Dane! (Figure 3) insice the cows ing the current status of the enginePERFORMANCE DIAGNOSTICS “eg 37 CL hn Se LL |. oan EST TOOL-FAULT CODES (Continued) ‘To access the fault codes press the "FUNC™ key to Switch to the main manu. NAVISTAR MRD SELECT DESIRED MENU [ENGINE] «+ PRO-LINK From the main menu select "ENGINE by pressing the "=" kay. This will cause the brackets to be placed arcund the “ENGINE” selection. Then press "ENTER", From the next menu select “DIAGNOSTIC CODES". The selection will have the *h* symbol onthe sereen.Thismeansthere are ctherselections available. Sy pressing the "J" key the other selec- lone wil display on the screen. Press "L" until "DIAGNOSTIC CODES” appears on the screen Noxtpress "ENTER". Youarenow inthe diagnostic codes selection of the tool, From this point, diag nostic codes ¢an be accessed, NAVISTAR MRD ENGINE MENU + DIAGNOSTIC. copes 4 The ‘tst option trat wil appear is “ACTIVE CODES", By sclecting this option, the faut codes ‘hat have occurred during thie Key"ON" eyeie wil be displayed. Press "ENTER". there are any"Active Codes" the lrstone wil appear onthe screan along witha desorption of he code. ifthere are any add tional codes *Actva" the" symbal wil appear on the screen. Press ‘L" key to access adkitional codes, I!thore sre nol any codes" Active". "NO AC- ‘TIVE CODES” wil appear on the screen. NAVISTAR MRD DIAGNOSTIC CODES t ACTIVE CODES zt ‘To access “Inactive Codes" prose the "FUNC" kay. ‘This will access the las prior soloction, Then pres the "L' key to salect "INACTIVE CODES” Pross the "ENTER" key. NAVISTAR MRD DIAGNOSTIC CODES + INACTIVECODES Inactive codes are faults that have occurred in the past, and are now stored in memory. An "Active Code" will Become an “Inactive” code Ifthe key Is ‘shut off even if the malfunction no longer exists (such as an intermittent problem). ecard all faut codes that are found. i there are any fault codes found, referto "Electronics Dlagros- Wes” section of the manual NOTE: ALL CURRENT FAULT CODES MUSTBE REPAIRED (CLEARED), BEFORE PROCEEDING WITH FURTHER DIAGNOSTIC TESTING, POSSIBLE CAUSES Electronic maifunctions whieh can be detected by the ECM cn a continuous monitor basi TOOLS REQUIRED PRO-LINK 9000 (ZTSE-43661) SUPPLEMENTAL DIAGNOSTICS HI fault codes are sot, reter to Electronic Diagnostic fom EGED=135 and fault code diagnosis,Bageaa PERFORMANCE DIAGNosTics } T444E ENGINE oa ee | EST TOOL-ENGINE OFF TESTS: FROM FORM EGED-139 4a. EST TOOL-ENGINE OFF TESTS © Select et 20 OF test or “Set Test” from Siagnostic lest menu —— Faulks Found PURPOSE Mer the “ENTER” key is pressed, the EST wil Fodetermine it there are any electrical! Canumetions — sommand the ECM 10 perterm a self test Uetcan be detected by the Electronic Conn ‘Moc | Ue ECM) during an on demand settiscr When the test is Complete, the screen wit! display. toy maar usfound inthe sees. tee, TEST PROCEDURE any additional faults found, Press "ENTER" and the IN EST ASSESS "DIAGNOSTIC CODES” weny STH wil be displayed. 1 there is more Fone DaND CLEAR ALL FAULT cope iN! wats found during thetest, thet ee FORE PERFORWING ENGINE OFF Soon: cose a nen onthe screen, Prescihe'dkestere Access the "ENGINE OFF TESTS” in the “DIAG- S888 any ational fauie NOSTIC Tests" Section of th tronic Service Tool (EST), arenes CapiMlet Cones were “py Fume the "FUNC ey rposicdy, Ul te wee. Mende BEFORE RUNNING ENGINE Oot | mont appears meee SPER, Unt hem Copey ALL IDM FAULTS AND associates | : : Be RORECORDED DURING THE Teor ATED | - EE STORED AS "INACTIVE" CODES Sy VE NAVISTAR MAD ACTS, READ THE CODES, accESS Te te | SELECT Desiaco | : wv. i MENU | Srenetrro-ine | save», Te pnoanan w THe esr vs OMY ALO ThE ENN Ory ESET LL TOBE ACCESSED ONCE. To REPEAT ENGINE: arcs Semen Pesers TOBE ACSEScED Gy "SELF TEST" NOS »? = THE ENGINE OFF TESTS. Next select the DIAGNOSTIC TESTS" menu by POSSIBLE CAUSES | Besa he" soy nt ounce meu BY the etn, on the Soreen. Prete “ENTER” Ie make this Selection, * Defective electrical components or chreuitry. } | asa aD ENGINE MENU > 3 Zz 2 m ° o o m = am 2 ee aS a mE infection Pressure Regulator (IPR) output cine uit check tauit, DIAGNOSTIC TESTS ° Fuel Demand Command Signal (FOS) and pryneer Identiication (Cl) output circu chon gaz ihe "1" key, unt ne “ENGINE OFF TESTS” fault ‘ | 3 8hown on the ‘Screen. At this point, Press "EN- ‘re 5R" TOOLS, REQUIRED | NAVISTAR BO PRO-LINK 8000 (ZTSE~413661) } DIAGNOSTIC Tests SUPPLEMENTAL DIAGNoSTics 4 t au codes aro set, reler to Electronic Di gnastic —Seeworrresrs 1] inate ne ‘nda cose a a | ——PERFORMANCE DIAGNOSTICS Section 2 Page 39 TA44E ENGINE EST-INJECTOR "BUZZ TEST” FROM FORM EGED-130 4b. EST-INJECTOR "BUZZ TEST” NOTE: Engine Off Test must be performed first In order to gain access to the In "Buzz Te ctor © Solect “Injector Test” trom diagnostic menu Faults Found PURPOSE ‘To determina ithe iniectors are electronically lune: tioning correctly, by energizing each injector in a programed sequence. The Electronic Contro! Module (ECA) and Injactor Drive Module (IDM) wil ‘moniter this tost and iranemittault codes it any injac- ‘oF(s) oF electrical cireutry are not functioning pron. aly sT PROCEDURE. MOTE 1: ACCESS "DIAGNOSTIC CODES” MENU IN EST AND CLEAR ALL FAULT CODES. NOTE 2: ENGINE OFF TEST MUST BE PER- FORMED FIRST IN ORDER TO ACCESS THE IN- JECTOR "BUZZ" TEST. After ino "Engine Off Tests "have been completed, rose ine”!" key to access ihe "INJECTOR TEST”. isplaying of faultcodes ete., press tho "FUNC key, This will ac~ “DIAGNOSTIC TESTS" menu. Press "ENTER" to begin the test, NNAVISTAR MAD. DIAGNosTIc Tests INJECTOR TEST NOTE: IF FAULT CODES WERE CLEARED BE- FORE THE INJECTOR “BUZZ” TEST, FAULT ‘CODES DISPLAYED WILL BE ACTUAL FAULTS FOUND DURING THE TEST. IF CODES WERE NOT CLEARED BEFORE TESTING, ACCESS “INACTIVE” FAULT CODES FROM EST MENU TO RETRIEVE FAULTS FOUND DURING THIS TEST. Altne completion of no injector Test, any faults thst have been detected wil be displayed. if thate io more than one faut the “tL” eymeoi wil be clo- Played. These adchionalfuits can be accessed by essing the “Uke Record any faulis iound ard refer to the Electronic Control System Diagnostics, Section 1 POSSIBLE CAUSES © Bad witing hares connection at injector solo- roid. © Cpenorshorter engine wiring hamess to|njec- tor(s) © Detective injectar solenoid(e), © Detective 1M, Toots REQUIRED PRO-LINK 9000 (ZTSE-43661) During tis est, tho injector solenoids wil proctuce es ‘an aucibie clicking sound when actuated. It is pos- Stree wie Sibi te detect a mallunctioning ijector(s)by sten- 1 fault codes are Sa, reer to Electronic Diagrosic ing the absence of the solanais clicking sound, _ Form EGED- 195, EGEs-125 ¥ Printed in the Untied State af Amatien‘Section 2 / Page 40 PERFORMANCE DIAGNOsTics T4445 ENGINE , Ao STIBUTTON-FLASH CopES FROM FORM EGED-130 5. STI BUTTON-FLASH CODES K © Deptess and hoid "Engine Diggnostics” suit, then tum the Ignition swith to the "ON postion x , Refer to Electronic Diagnostic torn ‘fault code(s) set i PURPOSE 2. The "WARN ENGINE" fight wit ach repeated- Teles acted oye Secon cong) WSOMRSNNGNE' HM ? eole (EOM), I tHe Electtonic Service Tool eee [ ® Remeereree cE sore arses reenay, Input” data due ton one ie mt AND CODE 111 INDICATES "No FAULTS" Have | (eh 82 due 10 communications of tempore BEEN Berea | AgsSel Test input STH switch stoSstedontheve- 3. Count the number of flashes in sequence. At | eessashoard (Figure 4) and is idengfied neko {he and of eacti digit of the coda there wil be a | ENGINE DIAGNOSTICS" swiicn Deptoos short pause. Three flashes anda niuse would ST Sartch on the dash while turning the | indicate the number 3, Therefore, two fashec Switch fo the "ON" position, will signal the a Pause, three flashes a pause, and wo lashoc Seine Bel Test input ciagrostics to check output 2 Pauise would indicate the cotle 259. Ittnevpie Grouits. Hany faults are deleted, he =CM wilften more than one taut code, the “olin ce i — oho indicate which fauts tight will lash once indicating the beginning af ave baer celetsee another active fault code NOTE: SELF TEST INPUT DIAGNOSTICS WiLL | NOT FLASH VPI :ODES. sMier all the active codes have been flashed, the TEST PROCEDURE POILAWATER” fight wil fash twice to indicate the | ee Pais beginning of INACTIVE codes. Coun: ihe ruins gan) Tumi graa omen ttendonvehcle begining the "WARN Ew hs mbet | ast). Tum the ignition switch to the "ON" postion : cone & more than one inactive cade, the "OALWAT Et pono! Start The Engine, The ECM will begin te Demedenee ea Perlorm the self test to cheek the output crear “oni wilfesh once in-between each feuit ode, Myfen the test is completed, the ECM wil fash tne Alter all codes have been sent, the "OM WAarzr" t TOILWATER" and WARN ENGINE” Nghts 10 Sig ight wil asm three times indicating "END GF MES- F nal the fautt endes, SAGE", | NOTE: FAULT CODES CAN BE ACCESSED aT } NYTMEBY DEPRESSING AND HOLDING THE To {epeal lransinission of fault codes, depress the j SUL SWITCH WHILE TURNING THE IGNITION -SNepua! DIAGNOSTICS" switch which wil signal SWAICH TO THE "ON" POSTON. (DO NOT ihe SANE tesend all stored fault codes, START ENGINE.) I fault codes are set, refer to Electronic Diagnos! F Tee8d the feullcodesitwilbeneccesearyiocount eal EGED-195 and fault code diagnons, Hes tmber ol times the "ENGINE WARN” ight = [RSs The following sequence of evente oun | POSSIBLE CAUSE. each ime the STI swich is depressedtoobianine Electronic component or circulty fatures, fault codes: , 1. The "OILAVATER? light willtlashonetimetoin. — TOOLS REQUIRED Sicate the beginning of Active fait codes, ‘None. EGEs-1; Print the Une States ct ameies ; eooa SS TrsurToMsUAsn cobeygonmaa @ ; “| ; si IGNITION DIAGNOSTIC SWITCH SWITCH Figure 4. Seif Test Input (STI) Dlagnostie Switen Location on Vehicle Dash EGES125 Printed in the United States of AmerionSection 2 Page 42 PERFORMANCE DIAGNOSTICS T 44a ENGINE = So INTAKE RESTRICTION __FROM FORM EGED-130 6. INTAKE RESTRICTION © Check fitter minder if equipped © Measure at High idle & no toad © Use manometer or magnehelic gauge Instrument Spec. Actual Filter Minder 25" H20 Magnehelic 12.57H20 Max. PURPOSE ‘To determine if an intake/air cleaner restriction ex- isis. Oflena low power and poor fuel economy com- plaint is simply due to a dirty air cleaner element. In this test, the gauge is inserted in the air cleaner housing. As the air cleaner element accumulales dir, restriction to air flowincreases. Iresiriction ex. ceeds specifications, replace the air cleaner ele- ment or elements. NOTE: A HIGH INTAKE RESTRICTION MAY CAUSE A CONSIDERABLE AMOUNT OF BLACK OR BLUE SMOKE WHEN STARTING THE ENGINE. INSPECT AIR INTAKE RESTRICTION INDICATOR 1. Reler to appropriate “Operation and Mainie- nance Manual” “Air Cleaner Restriction Gauge and Indicator’, for detailed information. ieHeUC Ss wae Lone NOTE: THE AIR CLEANERIS TO BE REPLACED WHEN THE RESTRICTION REACHES THE MAX- IMUM ALLOWABLE LIMIT, THE RESTRICTION CAN BE MEASURED BY A SERVICE INDICA- TOR, WATER MANOMETER OR MAGNEHELIC GAUGE. 2. inspect the element(s) ior damaged gaskets or dents. If they exhibit either they should be re- Placed, SINGLE ELEMENT AIR CLEANER Measure air cleaner restriction as follows: 1. Altach the restriction test gauge (Figure 5) at air cleaner housing tap location. 2. Run engine at high idle RPM. 3. Replace the air cleaner element when the test- gauge shows a restriction greater than 12.5 in. H20 (3.13 kPa). Figure 5. Restriction Test Location _—_——__*»Section 2 PERFORMANCE DIAGNOSTICS Same aaa ENGINE INTAKE RESTRICTION (Continued) NOTE 4: THE TRUE MAXIMUM AIR CLEANER, RESTRICTION CAN ONLY BE OBTAINED WHEN OPERATING THE ENGINE AT FULL LOAD AND RATED SPEED. THE VEHICLE MOUNTED INDI- CATOR OR VACUUM GAUGE WILL SENSE MAXIMUM RESTRICTION. WHEN 25 IN. H20 (6.22 KPA) IS SENSED ON THE VEHICLE MOUNTED GAUGES, REPLACE THE AiR CLEANER ELEMENT. FOR CONVIENENCE, AIR. CLEANER RESTRICTION CAN BE MEASURED ATHIGHIDLE (NO LOAD); HOWEVER, THE ELE- MENT MUST BE REPLACED WHEN 12.51N.H20 (3.19 KPA) IS MEASURED. NOTE 2: HIGH AIR CLEANER RESTRICTION CAN CAUSE TURBOCHARGER SEALS TO UN. SEAT, CAUSING OIL TO BE DRAWN THROUGH SEALS AND INTO ENGINE, DUAL ELEMENT CLEANER The cual element air cleaner provides a large pri ‘mary (outer filer element and a optional small sec- ondary (Inne) Titer element, The secondary ele- ment should be used in dusty environments. The dual element air cleaner assembly air eleanor restriction connection (Figures 6 and 7) is located between the primary anc the secondary elerrent in the bottom ofthe ai-cleanor housing, This arrange- rent allows oniy the primary (outer) element to be sensed by the restriction ineicator or dash mounted vacuum gauge, THE INNER ELEMENT IS NOT RECORDED ON THE RESTRICTIONINDICATOR ‘Of DASHMOUNTED VACUUM GAUGE. Visual Check Procedure ‘Visually inspect the restriction indicator buitintothe Inner element of inner sloment retaining nut. NOTE: TWo DIFFERENTINDICATORS ARE THE RESULT OF TWO DIFFERENT SUPPLIERS, RE- PLACE THE ELEMENT WHEN THE GREEN DOT DISAPPEARS FROM THE ELEMENT OR FROM ‘THE WINDOW IN THE RETAINING NUT. IMPORTANT EACH SUPPLIER'S RETAINING NUT REQUIRES: A DIFFERENT TORQUE. REFER TO FIGURES 5 AND 7. ToT Mra ‘rimany fouren SECONDARY — AIVGLEAWER Eo-2029 Figure 6, Duel Element Air Cleaner With Indicator in End Cap EGES-125 Painted in ta nile States of ArverienPageat PERFORMANCE DIAGNOSTics Ta ENGINE INTAKE RESTRICTION (Continued) ee" eee romance Ee ates Figure 7. Dual Element Air Cleaner Retaining Nut indicator POSSIBLE CAUSES © Diy air cleaner element * Snow, plasiic bags or other ioreign material May restrict air flow at the air engines recently repaired, ra may have been inasvertenty sysiom, leaner inlet. On 19S OF can plugs left in the intake TOOLS REQUIRED Mode! D-200 Pressure Test Kit (ZTSE-- 2299), mag. nehelic gauge or waler manomoter i a EGES-125 Pinko i toe United Guat 1s a BeBe ee ee ee ee ee ee| PERFORMANCE DIAGNOSTICS “Page 1g . Page 45 Ta44e ENGINE Fama at EXHAUST RESTRICTION FROM FoRM EGED- 7. EXHAUST RESTRICTION © Visually inspect exhaust cystem for damage ‘© Check if EBP device is closing at High idle With breakout box pins 49s and 46 — or "TEE" Green + and Biacx- © Measure at High idle Instrument Spee. ‘Astoal VOM < 2Volts PURPOSE 2. Woxtiaust system damage jg not present, start 7 determine it a restriction exiets in the exhaust engine and warm to operating temperatur, system which would cause an enging perlormancs exPaL problem, Run engine at high idle with no load, ‘The exhaust back pressure valve should be VISUAL INSPECTION open. Figures ilustrates position of tang on 1. Visually inspect entire exhaust system for ob bellerank of the back pressure device when the vious physical damage, ‘exhaust backpressure (buttery) vaive Is open, Figure 8. Checking Position of Exhaust Back Pressure (bullarlly) Valve At High tate EGES~125 Printed in the United Sites of AmarionBagene PERFORMANCE DIAGNOSTics Tae RNENE EXHAUST RESTRICTION (Continued) TEST, PROCEDURE POSSIBLE CAUSES 1+. he siapecie xia ° Closed Exhaust Back Proosure device, "Y. Installthe breakout box ge > oF "T" (Figure 8) in tine wit © Coltesed talpipe NOTE: APPLY PARKING By * Clogged catalytic convener, RAKE AND INSi logoed io lr, ‘THE TRANSMISSION Is my NEUTRAL. © Damaged muffier 2 Measure exhaust back preceure (voltage) at High tale engine speed.‘ Ronens meee arid TOOLS RecueD) Specification on diagnostic YOM and sensor breakou! “T* (27SE~4347), breakout box (ZTSE—aa46), EXHAUST BACK PRESSURE SENSOR or _BREBSEF RRR ERP eee eee anaSection 2 PERFORMANCE DIAGNOSTICS Page 47 Tae FUEL PRESSURE HIGH IDLE © Measure at regulator FROM FORM EGED-130 8. FUEL PRESSURE HIGH IDLE block. PURPOSE, ‘Todetermine tual prassureissulfcient io correctly operate the engine, ‘TEST PROCEDURE NOTE: IF FUEL FILTER IS EQUIPPED WITH A WATERIN-FUEL PROBE, CHECK WITH VE- HICLE OPERATOR To DETERMINE IF THE WA- TER-IN-FUEL LAMP HAS SEENILLUMINATED DURING VEHICLE OPERATION. 1. Remove 1/8" pipe plug located on me tual regu- lator biock. Figure 0, Instat 1/8 inch (3 mm) ipa fitting in place of the pipe plug. 2. Connect a line Figure 10 from the fting to the 9-180PS! gauge ol the Model D-200 Pressure Tost Kit (ZTSE-2239). Start engine and run at PIPE PLUG Tnsirument Shee. ‘Actual 30-85 0-160 Psi Psi Geuge ° High idle OM pressure is tow, change fiiter and re-toat Hf pressure still iow, proceed with stap 108. low idle tacheck fortuel teak inline o pressura gauge NOTE: BLEED AIR FROM THE FUEL LINE TO IN- SURE AN ACCURATE READING. 3. Measure fuel pressure at high idle and record (on diagnostic form. If pressure is not within Specifications, replace fuel filler and re— check {uel pressure at high idle. NOTE: IT MAY TAKE A NUMBER OF CRANK CYCLES TO PURGE THE AiR OUT OF THE FUEL SYSTEM AFTER REPLACING THE FUEL FiL- TER. 1 fuel pressure remains low atter replacing the filter, perform Transfor Pump Restriction Test 108. Figure 10. Fuel Pressure Tap Locatio EGES-125 Printed in the United Staten of AnarcieyPage aa PERFO! RMANCE DIAGNOSTICS ‘T44GE ENGINE FUEL PRESSURE HIGH IDLE {Continueg) POSSIBLE Causes ° Alualtiter could cause high restriction ;and iow {wel pressure because of dirt or iy A kinked or severely bent fue! Supply fine or Blockage a the pickup tube could cause restric. tion and therelore low fuel pressure, A lo088 fuel line on the 5: system could cau system and ction side of the fue! se air 0 be ingesied into the (Cause low fuel pressure, © Thetue! pump could have intemal }damage, e.g chek ePMeOM, ceized plunger or leaking check valves, TOOLS REQUIRED Mode! D-200 Pressure Test Kit (ZTSE~2238) (0 to Le Notuel Pressure gauge), appropriate irewh 1/8" NPT fiting,ea 4s = =— a Tasae ENGINE EST-ENGINE RUNNING Test FROM FORM EGED-130 ‘9a, EST-ENGINE RUNNING TEST Running” teat from NOSIS test men, "Engi * Select the Faults Found PURPOSE ‘Tevetty the ongine’s electronic sensors and actua- {cfs are operating proceriy within iheir specified op. rating ranges. The Electronic Service Tool (ES) @used to signal the Electronic Control Mogul (ECM) to perform tho "Engine Puncing Test”. The ECM ill exercise the actuators and monitor sensor feodback signals. If sensor of actuator prodem gusie, he ECM wil transmit faut code(s) to tne ST. TEST PROCEDURE IMPORTANT APPLY PARKING BRAKE AND INSURE THE TRANSMISSION IS IN NEUTRAL BEFORE RUN- NING TEST, 1. Startandnunengine untilt reaches 160° F mini mum. NOTE: ENGINE MUST BE ATLEAST 10°F TO ‘ALLOW THEECM TO PERFORM AN ACCURATE TEST OF THE ENGINE SENSORS AND ACTUA- TORS. IF ENGINE COOLANT TEMPERATURES BELOW SELF TEST RANGE, THE EST TOOL, MILL DISPLAY AN "ECT OUT OF SELF TEST RANGE” MESSAGE. 2. Access the "Engine Running Test” from the \GNOSTIC TESTS” menu by pressing ihe “L" key, untll “ENGINE RUNNING TEST” ap, Dearsonthescrean. Thenpressthe “ENTER' key. NAVISTAR MAD DIAGNOSTIC TESTS ENGINE RUNNING TEST The ECM will then concuet the "Engine Funning ‘Test’. It will commanc the engine to accelerate to @ pre-detarmined engine RPM and operate the In- ection Pressure Regulator IPA) valve and Exhaust Back Pressure Requlater (EPR) valve. The ECM will measure the effects of actuator move ment via the sensors. At the completion ofthe test, the EST screen will disslay "00 FAULTS". f no faults wore detected. |! EST indicates faults have been detected, press the "ENTER™ key to dieplay the faultcodes. Record ault codes and refer to the Electronic Diagnostic form EGED-135 for fault codes which were detected. POSSIBLE CAUSES © Defective or inoperative sensors or actuators Open or shorted winng harmess to sensors or actuators. © Loose or corraded engine wiring hamess con- nections at sensor or actuators. ee ee ol EGES-125 Print te tated Sintnef‘Section Page 50 2: PERFO! FROM FORM EGED-139 9b. EST TOOL4NJECTOR TEST (CYLINDER CONTRIBUTION) NOTE: Engine Running Test must be Pecrmed fist, in order to gain acceos to the Injector test, © Select Injector Test from Engine Running iest menu, NOTE! The engine will run rough uring the test. Diagnostic sheet it Refer to Electronic fault code(s) set. RMANCE DIAGNOSTICS ‘T444E ENGINE EST TOOL-INJECTOR ‘TEST PURPOSE {isctor in @ programed sequence and then mea- Sure power cylinder performance Te Xam thet all power eyincers are contributing equally, Pune completion atthe test, the EST sersen, wil dis- Bigy "00 FAULTS". ino injector feune occurred. It TEST PROCEDURE EST indicates jaunts have been Getecied, press the jENTER” key to dispiay the faun Odes. Record Be eg iHE "ENGINE RUNNING TesT= Jen (aultcodes andeter forte Electronic Diagnostic TECPERFORMED FIRST TO access THE IN: form EGED-135 fo, fault codes which were de. JECTOR TEST, tected. ° Alter th "Engine Running Test” has been com. pleted, press NING TEST” TEST”. Then NOTE: THE DIAGNOSTIC Tests ENGINE RUNNING Tests ENGINE WILL RUN ROUGH DUR- ING THE TEST, POSSIBLE Causes {het key rom the "ENGINE HUN prcen t© access the "INJECTOR Broken compression rings, Press the “ENTER” key, valves, bent pushtods or con * Open orshoried en, tor(s). INJECTOR Tes * Detective injector solenoids) TOOLS REQUIRED PRO-LINK 8000 (2TS=—43561) SUPPLEMENTAL DIAGNOSTICS ERe Electronic Service Too! (EST) wi waeect® — Beler to Electronic Contror System Diagnostics, Electronic Control Module (EM) io Sctumis each — Section 1, EGES-125 Printed in the United Saatew of America leaking of bent necting rods, ‘gine wiring hamess to injec- = oe Be ee He eS ee <2 a 4PERFORMANCE DIAGNOSTICS T4445 ENGINE FUEL PRESSURE (FULL LOAD) FROM FORM EGED~130 10a. FUEL PRESSURE (FULL LOAD) (© Measure at regulator block, © Measure at full oad Instrument | __ Spee, ‘Actual 30-66 0— 160 PSi Psi Gage e Full loag Ci it pressure is tow, change filter and retest Mt pressure still low, proceed with step 105, Section 2 Page st Nore: PURPOSE Tegeterminaitfuel pressure s sutfcienttoconectly ‘perate the engine at full load operating condition, NOTE: IF FUEL FILTER IS EQUIPPED WITH A WATERSIN-FUEL PROBE, CHECK WITH VE- HICLE OPERATOR TO DETERMINE IF THE WA. ‘TER-IN-FUEL LAMP HAS BEEN ILLUMINATED DURING VEHICLE OPERATION. ‘TEST PROCEDURE NOTE: FUEL PRESSURE MUST BE TAKEN AT FULL LOAD. FUEL PRESSURE MAY BE SUF- FICIENT AT HIGH IOLE, BUT MAY BE UNSATIS- FACTORY AT FULL LOAD OPERATING CONDI- TIONS, 1. Remove 1/2" pine plug located on the fuel regu: lator block. Figure 11, install 1/8 inch (3 mm) Pipe fitting in place ot the pipe plug, 2 Connect a line Figure 11 from the fitting to the 9-160 PSI gauge of the Mode! D-200 Pressure Test Kit (ZTSE-2299). Start engine and run at FULL LOAD FUEL PRESSURE AND BOOST PRESSURE ARE "ROAD TESTS”. THEY MAY BE PERFORMED AT THE SAME Tine, ‘owidle to checkforiuelleaks ining to pressure gauge. NOTE: BLEED AIR FROMTHE FUEL LINETOIN- SURE AN ACCURATE READING, IMPORTANT TO MEASURE FUEL PRESSURE AT FULL LOAD, VEHICLE MUST BE DRIVEN ON THE ROADINTHE HIGHEST GEAR (POSSIBLE) AND ACCELERATOR PEDAL DEPRESSED TO THE FLOOR (FULL DEPRESSION) OF THE CAB. IF A VEHICLE DYNOMOMETER IS AVAILABLE, OP- ERATE VEHICLE AT FULL RATED LOAD AND ‘SPEED. 3, Measure fue! pressure at full load and recordon diagnostic form. Mf pressure is not within specifications, repiace fuel filter and re check fuel pressure, EGes-125 ‘Print ln the United Staten of AmericaPOSSIBLE Causes PSIEM Could cause ab jo ingested into the 4 (uel iter could cause igh restriction and iow SYSIEM and cause ow fu *Pressu coe, e8sure because gin Felling in per ores me ae ss 2 ae © The "Vel pump could have Internal damage. ¢ 9g. endian Create diaphragrn, seize Plunger or leaking check valves, ° A kinked oF severo nt U6! SuDpIy line or re MP ae Pichun ape S2use restric. — TOOLS REQUIRED ton and therefore ion, {uel pressure Pressure Test kit (2738-2299) 0 16 160 Pg) Bur 4 lo08e fue! ine on the Suction Side of the tuo) lat line with, meres8ure gauge), mpropni VE'NPT iting.= . PERFORMANCE DIAGNOSTICS Rages Taaae ENGINE | ‘TRANSFER PUMP RESTRICTION FROM FORM EGED-130 0b, TRANSFER PUMP RESTRICTION © Measure at tue! pump iniat © Heasure at High ile Thevument Spee. ‘Actual vaouumGauge| — — = SSses =: = a = 7 ; = = : =——— Se = sas a a= 2 - Be ae] FS te = == > = = es = a~ CIRCUIT FUNCTIONS AND DIAGNOSTICS * ELECTRONIC CONTROL SYSTEM DIAGNOSTIC FORM EGED-1a5 (FRONT SIDE) 2 aS =e peemaeres ieee || oe] ee] 819 | |e} fa a EGES-125 Printed the United States of Amarin air |CIRCUIT FUNCTIONS AND DIAGNOSTICS Section 1 Page 4 (sl sunoud 44 «ante Soon oz = wauna ‘SunowD TWNoIs = NaIUD. no fn = ma a) ainouio aNnows = YONG SIIOAZeaay wa EGES-125 (rite in toe United Stains of Ameen58 af i al a i : - je | i a] i! i ae 3 cme? : el See at | e aa ze =a : <1g | Ste z |2 : ina 3 |; i Fle : : 3 : ie 3! = fe iP 5 |8 ii ye = fl | : | 3 El cm :y 4 3 Ss i ; = [a : ata Oolg t zn = aie a a ae | wo ome — fon | ree | oe = me wwe [aPoses’ CIRCUIT FUNCTIONS AND DIAGNOsTICS THIS PAGE INTENTIONALLY BLANK i i i 1 1 I 1 I I I | | | | | | gage, OE ee eT EGES-125 "inte ate Dated Ste of Amerinn ma be a a Se eeCIRCUIT FUNCTIONS AND DIAGNOSTICS “#2! CIRCUIT INDEX FAULT DESCRIPTION FLASH ENGINE TRUCK CODE SECTION SECTION MY vresccsessserescsssees Seecssees NO Fault Detected ~ Flash code only 112 Electrical System Vollage B+ out of range HIGH 113, Electrical System Voliage B+ out of range LOW wa Engine Coolant Temperature signal cut of range LOW 115 +» Engine Cootant Temperature signal out of range HIGH qai*. + Manilold Absolute Pressure Frequency Out of Range 122". ++ Manifold Absolute Pressure Signal is inactive 123 + Man Absolute Press (MAP) above spec, level allow idle tear +sscs++0+ Injestion Control Pressure Signal out of range LOW. 125 ssa... IOP + Injection Contro! Pressure Signal out of range HIGH 131°... APSIVS A + Accelerator Position Signal out o! range LOW 132 APSIVS . A Accelerator Position Signal out o! range HIGH 103"... APSIVS Assoc... Acselerator Position Signal in-range fault 138" APSINS «.......8......... Ascalerator Position and tole Validation disagree 198" <4. APBIIVE Au sccsees Idle Validation Switch circuit fault 144 L........ Vehicle Speed Signal out of range Low 142 . L 1... Vehicle Speed Signal out of range HIGH M48... CMP Wrong number of CMP signal transitions per car revolution 144000... CMP. sessssscs, OMP Signal noise detected 165... CMP. CMP Signal inactive while ICP has increased 1st BARO..f....-.-.......+ Baromettie Pressure Signal out of rango HIGH 182.42... BARO , Baromeitic Pressure Signai out of range LOW 136 2... AT Iniake Air Temperature Signal out of range LOW AES cia UAB Intake Air Temperature Signa’ out of range HIGH att ROP ie s+ Engine Oj Pressure Signal out of range LOW. ater FOP re Engine Oil Pressure Signal out of range HIGH 23. Oe Remote Throttle Signal out of range LOW 214 N 0... Remote Throttle Signal out of ange HIGH Bcmvigy Sa SCCS Switch or Circuit faut 222... é veel cose Brake Switch Circuit Fault 224, 8 spc sss VPM nol communicating with ECM “= Indicates WARN ENGINE LAMP on when fault is eet. EGES~125 Print in te Une Staten of Americ So@weee & 2 ee Se ee i oe ie oe jFase CIRCUIT FUNCTIONS AND DIAGNOSTICS ca nO area FLASH ENGINE ayy CODE SECTION —segry 24 Fc cei AM Comrupt 251... Bl Aa Eareemee 222. . Besos. Unable to forward ECM message ATA DCL 233. gin eee EAC Tasca bes ett hc a poner Unable to iomard ATA mecage to koa 235 oes. VPM. 8 : VPM /ECM OCL faut Inlection Pres.Regulator OCC Sel Test failed + FCS signal to 10M OCC Seif Tea fn !DM Pawer Relay Occ PBT ees IPA ey <+. ECMIDM est failed ola Linte (EDL) OCC Fauit Exhaust Pressure Regulator OCC Sell Test failed we E cv... Engine to Transiniscion 245 + EPR 251 Pe Glow Plug Continuity OCC Sell Test failed 288 oo. GBS ieee Glow Plug Lamp OCC Sell Test faileg 250.0... ECMMDM Fuel ini Syne Cireuit OCC Sell Test tailed 24 herein teens Bee ys, CGC Sel Tesl ECM test creut out of range HIGH ee ons ++ OGG Set! Tae: M test il Out of range Low Engine Oil Teinperaline Signal out of range Low Engine Oil Temporature Signal out of range HIGH Engine O# Pressure below warning level ~ Engine Gil Pressure below erica evel ~ Engine Speed (Tach RPRM) limit exceeded Engine Coolant Temperature above waming level + Engine Coolant Temperature above crical level ~ Engine Coolant Level below waming /rteal level Too rtrnecses, Power redueod, matched to Cooling System performance Inlection Controt Pressure above system working range: Inlection Control Prosoure above spec wih engine off Infection Coniol Pressure above/ below desired level ~ Exhaust Back Pressure signal out of range Low “+ Exhaust Back Pressure signal out of ange HIGH Excessive Exhaust Back Pressure 331"... IPR ‘Printed inthe United States of Armerico RCIRCUIT FUNCTIONS AND DIAGNOSTICS “92; CIRCUIT INDEX FAULT DESCRIPTION (Continued) FLASH ENGINE ‘TRUCK CODE SECTION SECTION ME case EBPs geosenenne +» Exhaust Back Pressure above Spec. with Engine OFF 251 - EPR ++ Exhaust Back Pressure below expecied level at high engine ‘speeds Exhaust Back Pressure above or below desired level ++ LOW to HIGH Side Open—Cyi1 » LOW to HIGH Side Open - oyi2 ++. LOW to HIGH Side Open —cyla LOW to HIGH Side Open — Oyl ¢ LOW to HIGH Side Open — cys --. LOW Io HIGH Side Open—Cyl6 ++ LOW to HIGH Side Opan-cy7 LOW to HIGH Side Open - cys LOW to HIGH Side Shon— cy LOW to HIGH Side Short Cyl 2 438 cess INI sess LOWIOHIGH Side Shont— cyl 494 IN 2 LOW to HIGH Side Short Cyi 4 435 os INS . sos+ LOWIOHIGH Side Short — Cyl 5 496. sesrs+ LOWIDHIGH Side Short — cyl 6 437. - LOW to HIGH Side Short ~ yi 7 438 -- LOW to HIGH Side Shon - Cys aes ++) LOW side short to veaT~ cyl 1 442 --+-+. LOW bide shott to VBAT— Cyl 2 403 LOW side short to VBaT —Cyi3 444 LOW side shor to VBAT— Cyl 4 445, LOW side shor to VBAT - Cyl 5 440. seoeesessssscse LOW side shor to VBAT - Cy 6 4a7. srssecey LOW side short to VBAT— Cy! 7 498.. « LOW side shor to VBAT—Cyia 451... LOW side shor to ground — Cy + 452 +++ LOW side short to ground ~ Cyi2 453 5 teecsesses LOW side short to ground = Cyl'3 456 seescu IN + LOW side short to ground — Oy! 4 2 455 ees IND, LOW side short to ground ~ Gy 5 8% IN LOW sido chor fo ground = Oy! 6 EGES-125 Pinte inthe Unie State of Arvin ee ee eeSection 1 Paget0 CIRCUIT FUNCTIONS AND DIAGNOSTICS CIRCUIT INDEX FAULT DESCRIPTION (Continued) FLASH ENGINE TRUCK CODE SECTION —secTION ABT eee IN : LOW side short to ground Cyt 7 458 ec IND = LOW side short to ground ~ Cy! 8 461.2... Pert Diag. . yl. Contribution Test Failure ~ Cyl 4 462......, Ped. Diag, Cyl. Contribution Test Failure - Gyi2 463. Perl. Diag. .... Cyl. Contribution Test Failure = Cyt 464........ Pert, Diag, 465 ....... Pert. Diag. sisvss+ Cyl Contribution Test Failure ~ Cy a ~ CVI, Contribution Test Failure— oy § 466 Pert. Diag, . CY. Contribution Test Failure — cy! 6 487 os... Pert. Diag... Cy|. Contribution Test Failure ~ Cyl 7 468 ....... Perf. Diag. . + Cyl. Contribution Test Failure — Cyl g St... IND Multiole Faults Bank 1 812" 4.4... IN As Multiple Faults Bank 2 BE acc sss High Side to Bank 1 Open sia, + High Side to Bank 2 Open 515". sar, Bank 1 High Side Short to Ground or VBAT Bank 2 High Side Short to Ground or VBAT 522°. IDM fauit Sass ‘ IDM power voltage is LOW BOR se NE 2 Both High Side Switches shorted together S31"... ECMMIOM ... ~ Fel Inf. Syne Signal Low: Cylinder identification Signal (C) 592" ...... ECMADM . “r++ Fuel Inj. Syne Signal High: Cylinder Identiication Signal (CI) 541°... ECMIDM... IDM Feedback TOGGLE not detected by ECM 849"... ECMIDM.......D 10M faults not received 544.4... 1DM..., ssseeesee+ Injector Fault in Bank 2 . 545 IDM. ~ Injector Fault in Bank 4 612" ...... CMP + Ineorreet ECM installed for CMP (timing) whee! Installed ECM not compatible with VPM Software | Installed VPM nct compatible with ECM sottware Programmable Parametor KAM Comupt fauit ~ Engine using MFG. Detaut rating Program Engino? ++++ Engine using Field Defauit rating + Invalid Engine Rating Code; Check VPM programming “x Indicates WARN ENGINE LAMP on when fault is set. EGES-125 = miei Printed I te Unioet Sina mt a earCIRCUIT FUNCTIONS AND DIAGNOSTICS “x2! ge 11 ~_ GIRCUTT INDEX FAULT DESCRIPTION (Continaegy FLASH ENGINE ‘TRUCK CODE SECTION — SECTION rir S........ Madule Sottware Background Procase was inactive + ROM (Read Only Memory) Selt Test fautt RAM Memory-CPU Sell Test Fault ‘VPM is communicating incorrectly with ECM, Internal Fuel meter memory location in error + Interal Hourmeter memory location In error ‘Internal Odometer memory location in error {ntemai Fusimeter Fault Internal Hourmeter Fault Internal Odometer Fault + Inlemel EEPROM memory location error ZEEZD OD = + Feature memory data content corupted Engina/Fual memory date content corrunted + Engine/Rating memory date ¢ontent corrupted Watchdog Timeout Toa omoze SermeBRmtiPRPePrteePPteen et & wmaSe ey | | Section 1 e Page 12 CUIT FUNCTIONS AND DIAGNOSTICS ‘SENSOR AND/ACTUATOR LOCATIONS (ENGINE) en nal) EOP ENGINE Of. PRESSURE SENSOR (Optio EPR EXHAUST BACK PRESSURE| REGULATOR Figure 1. Sensor and Actuator Locations On Engine. ~~ EGES-i25 ‘Printect i the United Steins of AmerenSection 1 CIRCUIT FUNCTIONS AND DIAGNOSTICS “Page's ELECTRONIC CONTROL SYSTEM COMPONENT LOCATIONS (VEHICLE) ELECTRONIC CONTROL SYSTEM VEHICLE/ENGINE INTERFACE rf el Figure 2. Electronic Contro! System Component Locations (Vehicle) EGES-125Pe’ CIRCUIT FUNCTIONS AND DIAGNOSTics ‘SENSOR AND ACTUATOR DIAGNOSTIC PROCEDURES: INSPECTION ‘The basic diagnostic procedure recommended for (INDICATES A VALUE Less THAN most Sensor and actuator circus is fo decone Sie harness atthe comector and inspect for comet () INDICATES VALUE EXAMPLE: <5 OHMS = LESS THAN 5 OHMS EXAMPLE: > 5 OHMS = MORE THAN 5 OHMS ‘© Power ground on an act lualor circuit should Figure 3. Removing Connector For inspection CONNECTOR CHECKS To GROUND (6-) ‘The second step is to measure the re: Wiring hamess connectors to, epalive battery cable) to sistance of all round (preferably the © Signal ground (marked “A= hamess conneciors shou! Sohms, (Signal ground o nectors vary). Figure 4, ‘. without an expected voltag Lee Re pee coure shorted of Nvehicle sensorcon- ures. : z g a : 2 © Signal retum (marked "A" on all engine sensor amess connectors should measure less than The V Rel and signal ines, with the Processor 25 volts. connected, will eormaly measure greater than 1000 ohms, sm * VRe! should measure 5.00 volts +.50 vols, 4 NOTE: THE SYMBOLS < & > ARE USED ON eer Sensors one ata time to detormine la son | peck SIAGNOSTIC CincUIT PAGE, THEY ARE Soris biasing the DEFINED AS FOLLOWS: EGES-125 Printed te United Sintme nt Amerie7 CIRCUIT FUNCTIONS AND DIAGNOSTICS ‘“Sase%5 ‘SENSOR AND ACTUATOR DIAGNOSTIC PROCEDURES (Continued) CONNECTOR VOLTAGE CHECKS (Continued) Figure 5. Measuring V Ref Voltage Sensor signal tines will measure 0 to 25 volts the circutt is designed to "pull down” when dis- connected, ora higher voltage (normally 4.610 5, oF 12 volts) if itis designed as a "pull up cuit". A”pull up"signal circuitthat measuresine expected value normally indieates a good cir- cut, © Actuator circuits may be either on/off type cir- cuits (nonaily 12 volts) or pulse wisth modu- lated circuits (12 volts controlled by a % duty oftle). © Communication circuits between the Electronic ‘Control Module (ECM) and the injector Driver Module (10M) ara dosignedt either “pullup" ot “pull down". That means that one end of the ‘communication circuitisnormally atahighor 12 volt level and the signal is created by the low ‘side toggling or switching the high side to round. Communication tines are best diag- esed with he breakoutboxinstaliedandmea- ‘suring the expected voltage with the Key in the “ONT position and the engine of HARNESS RESISTANCE TESTS Hamess resistance tasts are performed when acir- cuits suspected of having high resistance or being ‘open. Thess tests are performed withthe breakout tba connected and by measuring resistance from the sensor connector end fo the processor conn tor. if an open circuit or high resistance is eneoun- tered, the problem is most easily isolated by sepa- rating the cireuil atthe interim connectors (normally the Deutsch connector on the valve cover or the cow!) and measuring resistance through both halves of the ctreut. OPERATIONAL SIGNAL CHECKS These chacks are made with the breakout box Installed and ars normally measuring a signal volt- ‘age or irequency. They are usetul for determining anin-range type fault cran intermittent connection, Inthecase of an intermittent tauit, monitoring sus- pected circuit and recreating the environmental or physical conditions that caused the complaint will help very it a problem isin a particular circuit. Itis critical when measuring the signal level of s cir- cuit to understand its function and’ whether i's a analog voltage, digital frequancy, sine wave oF dich tal communication signal. standard Digital Volt ‘Ohm meter (DVOM) has certain imitations In mea- ‘suring any ofrcuft that has a frequency.Peet’ CIRCUIT FUNCTIONS AND DIAGNOSTICS APSAVS PEDAL POSITION SENSOR LE VALIDATION SWITCH ECM ELECTRONIC CONTROL MODULE IDM DRIVER, INJECTOR MODULE FUEL QUANTITY ‘AND. TIMING CONTROL, INJECTION CONTROL PRESSURE REGULATOR 5 Volts (100 %) WARN Lamp (0%) 2 0 Volts SIGNAL FUNCTIONS FAULT DETECTIONMANAGEMENT ‘he Accelerator Pedal Position Sensor (APS) is 2 potentiometer type sensor which, when supplied Nth a 5 volt reference signal trom the Electronic Control Module (ECM), provides @ linear analog voltage signal that indicates the driver's demand lee power. * The te Validation switch (VS) ie 0/12 vol euch that provides the ECM with a redundant signal 16 verily when the pedal is in the idle postion Aus! Quantity and Timing Control The APS sig. nel wood in calculating desired fuel quanity ar injector timing, Injection Control Preseure — Accelerator peda! Position is one ol the controling variables in the con, Culation Of desired injection contio! pressure, Any detetted malfunction of the APS or 1VS sensor ircull will Muminate the WARN ENGINE lamp, APS signal that is detected out of range high or {ow by the ECM wil cause the engine to gnors ne APS signal and willonly alow the engine \ooperais at low ide, Z It disagreement in the state of IVS and APS is de- jected by the ECM and the ECM determines that it 5 an IVS faul, tne ECM wil only alow a maxiinory 01 50% APS to be commanded. {fa disagreement inthe stale Of1VS and APS ie de- {ected by the ECM and the ECM can not disosin if itis an APS or IVS laut orif iis an APS fault the engine will be allowed to operate at iow idle only EGES-125 ‘Priced Wn ve Unter Steins of amneti-nTe EEE RRR Ree Accelerator Pedal Sensor & Idle CIRCUIT FUNCTIONS AND DIAGNOSTICS “22%! Fault Code 131 APS signal out of, 132 APS signal out of range high 193 APS signal in-range fault 134 APS and IVS disagree 195 idle validation switch olrcuit fault Validation switen (apsays) Fou Deutsch Connector Pin 447 C\ ee 19 a 1\=—@ Pin #46 VRer at 8 es () Pin #28 2 ce t © 2 o | Fx— Fa (tus) | & a") V IGN. F 1 je iy ‘Connector Checks to Chasels Ground {check wit Sensor Connector Osconnected and ignition hey tal accessories of) Test Fone | — Soe. ‘Commens Ao Grd._f> 1000 ohm | Ressiance iss than 1000 ohms heals a shor To Goan StoGrd. | ten fobs RAGGS oe Cio rc._[> 1000 atime | Resctanca ess then 1000 chime incicatee 9 shoo pred Dicer c._[> 1900 ohms | Resistance than 1000 ohm indicates a hort lo ground Sommestor Signal Checks (Check with Sensor Connector leeonnected and Ignition Key Gn) at Ponif — Ses AG a | 2 25 wots stealer than 25 vale Sahel round wie is sroned 0 V Ral bata. Bier rd] __O'voits| Signal ground ne vetiage expected, Clog Ka 3 = $vota[ Viel check key on If VAet nol prosanl check openlshan Ts WEB ToB seo VAT crea] 22 Gre 0~ 25 vols greatet than 25 volts signal ground wre js ahoried eV Berar Datlery Fito Grd. [515 vote] < 105 v check for poor Sonnaciion, Ov check lor panties 10 Grd Greull or Blown fuse, Harness Resistance Cheeks (Check with breakout box installed on a angine harness oni) TesiPomnts | Spec. ‘Commenis $i A_{< 5 dine | Resistace om 60 pn connacor io harmens conreiot APS Spar HES 8 {<3 ons [Resistance rom 60 pln congecioe to hacness conneciotSigral Geamaa #26 1 C | 1000 ohms | Resistance oes tan 1000 ohms iiales a hor to round il StoGrt [> 1200 otms | Resistane oss than 1000 ohms indleates a shor to groune Connector Voltage Checks (Check with sensor Connector Olaconnected and Ignition Key On) TeetPonte | Spe. Comments Bie Gd | Fate = 5] Val tech ay ON lage ms sc. Soe VTS SiGe [0-280 | talon tan 255, sna win chrodie Vil otaton Hamess Resistance Checks {Check with breakout box Installed on engine harness only) Test Pots | Spee. Comments #46 a A_| <5 ohme | Resistance fom sensor connecior to 60 pin Comedlar~ Signal ground [¥28 te 8 _[ 2061 106 Normal aimosaheric pressure al sea level. 17765 —| — so —| Roma amostonns posses SISO Fault Code Descriptions 151 = Signal voltage was greater then 4.95 volts for more than 1.0 seconds. 152 » Signal voltage was less than 1.0 volts for more than 1.0 seconds. EGEs-125 Printed tthe Unite States f Amerisn PPe PRESSE RE RB BER E REE EE SESection 4 Page 20 CIRCUIT FUNCTIONS AND DIAGNOSTICS CAMSHAFT POSITION (CMP) SENSOR ECM IDM INJECTOR DRIVER ELECTRONIC CONTROL EXHAUST PRESSURE REGULATOR BACK EXHAUST BACK oe PRESSURE VALVE mums wide WINDOW 44. NARROW WINDOW SIGNAL FUNCTIONS ‘The CMP (Camshaft Position) sensor is @ Hall Ef- fect type sensor that generates a digital frequency ‘as windows on the timing disk pass through its mag- Relic field. The Irequency of the windows passing by the sensor as well as the width of selected win- dows allows the ECM to delect engine speed and position, Engine Speed ~Is determined by counting 24 win- dows on the timing sensor disk each camshatt revo- lution, Fuel Timing Control - The position of oylinder #4 and #4 is determined by distinguishing @ narrow or ‘wide window on the camshaft timing sensor disk. Engine Mode Selection — Allows the ECM to dis- ‘ce when the engine is in the off, erank or run {1 REGULATOR SENSOR DISK s (LOCATED ON Face OF CAMSHAFT GEAR) FUEL QUANTITY ‘AND. TIMING CONTROL a. €_| pr INJECTION CONTROL Ip 8) ley (CMP Signal (digital frequency) 44 12 Volt Injection Control Pressure — Engine speedis one of the controling variables inthe calculation of de sired injection control pressure, Exhaust Back Pressure — Exhaust back pressure ‘control is a {unetion of engine speed and load. Fuel Quantity ControvTorque Limiting — Engine torque and fuel is controlled and is dependent on engine speed. Fusi quantity is determined by en gine speed. FAULT DETECTION/MANAGEMENT ‘An inactive GMP signal during cranking is detect- able by the ECM, An inactive CMP signal will cause anostert condition. Electrical nolse can also be de- tected by the ECM, ifthe level is sufficient to ellect engine operation a corresponding fault code will be sel. Theeagine will not operate without a func: mode, toning CMP signal, ee EGES-125 Printed tn te Unies Stare= ° -vten a ca a a ee ‘| me lac= wee eePeeE RB RE BRB RE RE E S CIRCUIT FUNCTIONS AND DIAGNOSTICS °2'34! Camshaft Position Fault Codes: Sensor 143 CMP/SYNC Counts incorrect (cM) 144 Nolee Rejection 145 Inactive CMP sensor 612 Incorrect ECM/Timing Wheel Bian 6 otis Ramieaa B Open: Bite Grd. [> 1000 ofr | Resistance less than 1000 ahma indeales a ahod lo Ground, [Brera [> 1000 ote | Rosistanes leas Than 1000 obms indeaies w shore Gourd. Connector Voltage Checks (Check with Sensor Connector Disconnected and Ignition Key On) Tea Par — Se. onal ie Gc | SE 5 vol |VBel che yon, Vet nt piben check cpa Tan TO Gd UB a Val a (eto Gras 18 vt wan 103 v hook lat peorsemwcton I Schock Io pore Harnoee Resistance Checks (Chock wit breakout bot htoieace Stine harness ony) Conant | eas | Ran ay rameas Gan y ak eas Spa TTP 11 0A | 1600 ons] CieGid Connector Voltage Checks 'Sor Connector Dieconnected and ignition Key On) Commenis Hel, check with key ON, I voltage not hn anee. ese V Ral creum greater than 025 vols signal wire I shor io V Rol of bafery (Check with 3 “Tesi Powis | Spee. BioGra | Svote ss CioGw. | 225 vals Hameas Resistance Cheeks {Check with breakout box installed on engine harness only) Tesi Pome | Seen r Comers AIST@ A <3 ols | Rentanee Wor sareor connector to 60 pin sounect = Sigal GORE FES to 8 _| 1000 chi Ci signal_| Less than 1000 ohms indeatea a shar lo ground oltier va Ihe Ramee or internal in oF connect the IDM an measure fo #229 446 | > 1000 ches] FOCS signal] Srmtemnal in the ECM of IDM. Disconnect the 1OM anc (ground. It shor sill present, disconnect the ECM and measure to £20 #46 [1000 chins] EF fescback| ground, If shor sill present, repair narroos Hameee Resistance Checks (Check with breakout bok etalied ignition key shoud be In me OFF postion) Test Fonta] Spee. ra Comments 1241010] comme | Clegnal “| Raslarce Tam BOM copmooor eB SSRIS Fazio [' 1000 ohms] lon key of, all sccessories off) ‘Cornments cise o cei ound, ches witn key OFF > Sab a haeSa SS Resistanea 6s than 1000 ohme indicates « shor io ground. (Check with sensor “Test Poinla | Sone SiG | 46-500 AwGd | o-av Putup age: 170 or ow vlog, creut has a5en G7 HGH eaMIaRGY ETT E I sreater han 25 vole, wire i shored to V Rel orbattoy Harness Resistance Checks {Sreck with breakout box installed om engin haees only) Comments Resstarce For hares comecior ta 60 ph comecar— Giana gounT Tea Faas | Spee F610 A | Ze oRR (eS sche Sestarcs fom narete sows 60 sn eamesio=eCr Ser Test Point Operational Signal Checks (67 et wa {hack win breakout box nelaign tag wth thw Sou) Votege_| Tere. *F [Tena | Posse Comme Oaay a8 | too ria Barv | aie | 100] seo Sv [6 | 20am Soy [2 0 |B675 Kahne : say} 3 | oe ult Code Descriptions smperalure Compensiation enabl Ii (Reduces tuel quantity 6% for each degree °C above 214° F (101°C) EGES-125 Print Ith Una totoSection 1 Page 28 CIRCUIT FUNCTIONS AND DIAGNOSTICS ENGINE OIL PRESSURE (EOP) SENSOR ECM ELECTRONIC CONTROL, MODULE ° EOP Signal (analog voltage) 5 Volts (More Pressure) | WARN ENGINE, WARN ENGINE EOP LAMP ENGINE OIL PRESSURE SENSOR SIGNAL FUNCTIONS ‘The Engine Ol Pressure (EOP) sensoris a variable capacitance sensor. that, when supplied with a volt reference signal from the ECM produces a lr ear analog voltage signal that incicates engine oll pressure. Engine Warning and Protection - An optionaliea- ture which, when enabled, will warn driver of owen- ‘ine oil pressure condition and can be programmed to shut the engine down. FAULT DETECTION/MANAGEMENT ‘An EOP signal that is detected ou! of range high or jow by the ECM will cause the engine to ignore the EOP signal and disable Engine Warning and Protection. EGES-125 Printed nthe United! Sto ef Amerioa —_1 CIRCUIT FUNCTIONS AND DIAGNOSTICS ‘“¢2ten, Page 29, Engine Oil Pressure Sensor (E0P) 211 Out of Range Low 212 Out of Range High 313 Eng. Oil Pres. Below Warn Level 314 Eng. Oil Pres. Below Critica ©) Connector Checks te Cre ie acrsck ith Sentor Connector ieconcewar Senne Kay otal accessories of) Test Points | — Spec. Comments Ae Ga | 7000 ohms eStore ise fan 1000 ohms ineoales a shat s gee Soca, [Re Connector Voltage checks (Check with sensor ct onnector Disconnected an ignition Key On) Test Ports | Stee Commenis BoGet | Svalss 5] V Rel check wit key ONT wollage not in spec. sea V Raf cor Cie Gea [=.25 vets [ge inal ground wire is shorted to V Mout box Instaled on engine harnees only) [Test Ponts | Spec. Comienes | 348 10 A [<3 ons | Resioanes To Sensor eanneclr 1 60 pin eowecar~ Sapa SORT W260 8 | 5 ohms tha aries pon StoGrd._[ > 1000 ohms | Resistance fess han 1000 cts incales a shor to aun. Connector Voltage Cheeks {Check with sensor Connecter Disconnected and ignition Key On) TestPons | Sree ‘Comments BioGrt ['4a—50v | Pualup volage, no or ow volage, creat has open oT AtoGra | 0-25v Tigh resistance or ahon ground. W greater than 25 volts; signal ground wie fa shorted 19 V Rel. or baton Harness Resistance Checks {Check with breakout box installed on engine harness only) TesiPoms | Spee] Comments arc 12 A_[<3 ches | Resistanco rom hamess connecioria 60 pin connecter Signal gourd (io [es one | Resistance irom hamess sonnecoris Socineomee eae Signal Tet Polede, Operational Voltage Checks 116 1012) 146 | (cna man onan eat WOLaES CES sen nea Votage [Tans F Png. ef naneee =o Ose | a8 ago [re a Cc 2K ote ise 18} — | -aa : ase) | oe Co ‘Ghcut Pmuttgee oly» 1 grave SUlREOde Descriptions 311 = Signal wes less nan.0.2 vote foe rear 0.1 soosids 312 = Signal votage was greater thain4:8 volts tor more than 0.1 seconds. EGES-i25 Print inthe Untied States of America—rT7 Section 1 Page 32 Vv CIRCUIT FUNCTIONS AND DIAGNOSTICS EXHAUST BACK PRESSURE (EPR) REGULATOR ECM 12 Volts ELECTRONIC 2 CONTROL MODULE Duty Cycte: EPR ‘ Exhaust Bock Pressure Regulator ‘Output Signal 20 Hz. Controlied Epp tar - ECT |, EXHAUST INTAKE AIR ENGINE: BACK PRESSURE TEMPERATURE COOLANT ‘SENSOR SENSOR TEMPERATURE SENSOR EXHAUST BACK PRESSURE] EXHAUST BACK PRESSURE VALE REGULATOR POWER f GROUND OUTPUT FUNCTIONS Exhaust Back Pressure Regulator — is 8 vaticble Position vaive that controls exhaust back pressure during cold ambient temperatures to increase cab heatand decrease the amountol time neededia ces {frost the windshield. The ECM Uses the measured ‘exhaust back pressure, (ambient) iniake airiemper- ature, engine coolant temperature and engine load to determine the desired exhaust back pressure. Vaive position is controlled by swiiching the output ‘signal circuit io 12 volts inside the ECM. On off ime is modulated from 010 99 % dependent upon theex- haust back pressure desired. FAULT DETECTION/MANAGEMENT An open or shorted to ground control circuit can be detected by an on demand output circull check per formed during the engine off lest. Problems with either the Exhaust Back Pressure Device of the tube between the exhaust manifold and the ESP sensor can be deteciad curing the ex- haust back pressure step test, in whieh the ECM commands and then measures a speciic prepro- rammed pressure then measures time for pres- Sure decay during the engine running test. the ECM detects an EBP or IAT sensor fauitit will disable the exhaust back pressure regulator. = EGES-125 Printed bathe United Staten of Amerien “ ae |BREEZE BRR ERB ER ERR HER EBEEE EG CIRCUIT FUNCTIONS AND DIAGNOSTICS "#322 Exhaust Back Pressure Fault Codes: Regulator 245 Output Circuit Check (EPR) ; 343 Excessive Back Pressure 351 EPR below expected oa 352 EPR Step Test Fail ceracter (Overlay Harness) “* Regulator Herness Regulator PWR Ground aay Connector _ (a) <———_f (Glow Plug Reiny SN Mounting Beit EPR Controt ecg Tm ©) Atter removing connector abvavs check lor damaged pins, corasian, loose lermhaln ta Connector Checks to Ch {check with Regulator Connector Diseannectes Tesi Ponte | — Spee. ‘Comments Ato Grd: |" tooo eames Ac is Ground nition off, a seceseorias oft.) Shen creak ar bad ground istance ess than 1000 ohms indvaies a shor fo ground. Harness Resistance Checks (Check with breakout box installed on engine hamees only) Comments cluding reguiaor, check wiregullor conmmclor [connectea (umedassary [9 check nex! Soints # ols Resistanca irom regular connector 19 Pwr. Ground. Resistance Irom regulator connector to 60 pin connector Test Powis | Spa Bur. Gra. to [2.5 too | Rasktance tough EPA aroun pint ‘rms AtoGra. | <3 ons Btomt [es one Circuit Faukt Code Descriptions 245 = Outoui circuit check detected curing Standard tes. indicates high or low reslatance in cicu Exhaust Back Pressure System Fault Code Descriptions Ser eer messure was Greater than 77 n, Hg. (250 kpaG) or 3 seconds. (3:3 vols) SSt-= Esaust backpressure is below 29.6 in. Hg, (20 KP3G) for 2.5 seconds (1.19 vot) at engine speeds greater han 2500 APM (possible plugged Ene) 352 = Indicates that EPR pressure of 23 in. Hg. (75 kPa) commanded during EBP engice Tunring ‘ostwas net obiained. (Plugged line or exhaust back pressure davies failure) EGEs-125 Printed inthe United States of Americn} | Section 1 Page 34 CIRCUIT FUNCTIONS AND DIAGNOSTICS GLOW PLUG CONTROL 7 Tha 7s = ECM ELECTRONIC CONTROL MODULE % JENGINE COOLANT TEMPERATURE SENSOR| BAROMETRIC PRESSURE SENSOR, (BARO) = LAMP BATTERY VOLTAGE BATTERY VOLTAGE (FROM STARTER SOLENOID) OUTPUT FUNCTIONS Glow Plug Relay — Controls the current flow io the glow plugs. Glow piug relay "ON" time is controlled bythe ECM andis a function of engine coolant ter= erature, barometric pressure and battery voltage. “ON” time normally varies between 10 10 120 se eonds. The glow plugs are self limiting glow plugs ‘and do not require to be cycled on andoott. (The glow plug relay will only cycle on and off repeatedly when there is 8 system vollage condition greater than 125 volts.) ‘Slow Plug Walt Lamp —Lamp that indicates fo the ‘operator when the glow plugs have been on long anough 10 crank the engine. itis controled by the ECM. Waitlight on time is 2 function of engine cool- ant temperature, barometne pressure and battery voltage. "ON" time normally varies between 2 to 10 seconds. (NOTE: Walt light on time Is indepent- ‘ent from glow plug relay on time). FAULT DETECTIONMANAGEMENT ‘An open or shorted to ground glow plug relay or wait lamp circuit can be detected by an on demand out- put circuit check performed during the engine otf fests, Glow plug and glow plug hamess problems can not be detected by the ECM, EGES-125 Printed inthe United States of America1 SPP eRR RB RB eEKR RB ERB ESE S| aa 2 4 CIRCUIT FUNCTIONS AND DIAGNOSTICS Glow Plug System Be 2a oy. 288 (eidics oye — 2 Steroesteetiine Deutsch Connector (On Valve Cover) Seotion 1 Page 35 Fault Codes: 251 GP Relay OCC Check 252 GP Lamp OCC Check Deutech Connector = (On Cow) eh tame if Conte Keven xerewn ECM > Connector CAUTION! DONOT PERFORM Engine VOLTAGE CHECKS Harness WITHTHE ENGINE Sonnector RUNNING on 8 INJECTOR SOLENOID fsieeney torte Valve OPERATING VOLTAGE C=== 51 oe M5V0¢. @ to amps CI Cennector(s) | PRESENT ON INJECTOR 3 erncurrs. Glow Fi z Glow Plig Helay Operation (Voltage Gheckay ‘TesiPonts | § Comments 4 sound [B+ [RSV SWiEh power Br shoud ba rosa at al nae TIGA WET sagee te ground. sto) Check connection at star or habe Inks tno power (/atage) presen Food i Bio Grouns | ae Be | Flow pita Ieed voltage shouldbe precent 10 fo 120 sec afer fey upon batery valtaga, barometric resaure(aliude) and erate eect [Relay soll ower. Voltage shoule Se rence [ivi Okan Fico, sched o (9) by ECU ating operation. Ov = lay ON, {2 = relay of Se Pgand Tees Option Sirsa ane SoRER ee ey eeturerendanca ot go see ed ea ‘Behemess connects: ‘ares (Giow Plog [ Pista Conrecir io | Relay Hames canes =; {Number | Ground (8-) Connector Spec <1 106 Om <8 Ohms: Rely to Hamees Connector = Beer a eed * feagavectasts 45 z oe High resistance could indicate ar open circult in the engine # | et Sorta et 3 Pia comesiaris songs a (ot ma aR SAE = Be Gert re Ne epg goveametusnestrenes thee ee depencen' wpon encina tempera 2st 206 Cok pertormed by ECU cur of fest. nea ae Performed by ECM curing angine of fet. indicates High or low resictance in GP coll cout. 2 SAK performed by ECM during onging of eal nekenee or ow resistance in GP lamp ect EGes-i25 3 ‘ Printed inthe United Staten of AmerieFeces’ CIRCUIT FUNCTIONS AND DIAGNOSTICS INTAKE AIR TEMPERATURE (AT) SENSOR ECM ELECTRONIC CONTROL MODULE iDM INJECTOR DRIVER MODULE EXHAUST {A Back BACK en PRESSURE PRESSURE TET) nr Signal analog voltage) | REGULATOR press Notte 7 (colder) 1aT (Warmer) EXHAUST © Volts SIGNAL FUNCTIONS ‘The Intake Air Temperature (IAT) sencor is @ therm- istor type sensor that has a variable resistance that changes when exposed to different temperatures. When interfacedwith the ECM it produces 0-Syolt ‘analog signal tha! will deduce temperature. Exhauat Bock Pressure Device - The IAT sen- 51's primary function is to measure intake air ter- perature in order to determine when the exhaust back pressure function is needed, FAULT DETECTION/MANAGEMENT An IAT signal that is detected out of range high or ow by the ECM will cause the engine to Ignore the AT signal, disable exhaust back pressure operation and assume an ambient temperature of 59° F (15° o. EGES-125 Printed inthe United States a America1 Injection Control Pressure ~ Fault Cots, . Soneor 124 Out of Range Low (cP) 125 Out of Range High 392 Signal Above Spec. w/Eng. Oft ECM Deutsch Connector Connector (eRe 0 Sener Ueriseele eae cocci Connector Signal Ground 2) Pin 45 0} 9 . ICP Signal Pine27 = Pin #26 © Me. ) tb) ‘Altec cemoving eon in Joese terminals atc, Connector Checks to Chassis Ground {Check with Seneor Connector Daconnocted and igition Ney of, ll accessories off) TesiFonis | Spee. Commer = Tic Ge [ han Sata Raneos SSE SS [_€ eG [> 1000 ons Restance os Ran TOHU sine naeaeesarer ees zl Connector Voltage Checks ar Connector Discannected and ignition Key On) ‘Comments Hage not in sp06., 608 V Ral cheat than 35 vis, signal wire ig shores to V Ret. or battery Harness Resistance Checks (Check with breakout box Insalied on engine hamese oniy) ‘Comments [Resistance from sensor connector to 60 pin connector = Sgral goon [Resisiance from sensor connector ta 60 pi conneeiar=V Rat [Resistance rom sensor connate To 60 pin connactor— CP aghal Tox Pome Operational Voltage Checks 1 127 1oC} Wa _| (Crack with breakout Bor netahedin She th the ECM) Psi | WPA. ‘Comments S20__|| 4 | Minimums required at engine cranking speed TSO PW 340780 |3.7-55 [Noel warm ide volago signa SSS high ile volage signal 2520 [17.4 | Sap accel or fal oad pressure Sonal (Check with sons TeaPans | Swe] | “BtoGrt | Svotts= 5 |v Ret Shock wih key ONT7a CioGra | <28y [ere Tost Ponte | Game How A |=sonme 28 19 Cf TORD=TiNs| injector power feed ngh de —codea STS'5°S21 ay beset ShoeTS > 1000 ohms] inector iow side — codes 451-450 may be set f shored to gr. ‘Valve Cover Gasket Connector to Chassis Ground (Check with pigtail connector installed on gaaieet conmector) i Comments > 1000 chime] Wjector ow ede — codes 45188 may be set Wahorted To get 5 1000,ohms | Wieclor power Teed high skie — codes SIS or S21 may be sot shonedTo gel ‘1000 ohms | jecicr low aide — codes 46)—a80 may be sail shorted to ork ‘Under Vaive Cover Hamess and ‘Solenoid Resistance Checks ‘ ~ (Check with pigtal connector ‘on gaaket connector). [escaie | ep Cormier. [Sezzanms] em ¥ open, codes 43128 may be presartf injector orhermees svoied ogohers = 57 Engine Hamessito 10M connector checks (measure to appropriate pin) Spec pease Gommenis:Pae43' CIRCUIT FUNCTIONS AND DIAGNOSTICS INJECTION PRESSURE REGULATOR (PA) EOT Engine Oll Temperature PR ECM ‘sjection Pressure Regulator !OP — Injection Control Pressure Output Signal siectronic | [12 Vote 400 Hz | CONTROL MODULE MAP — Ns Anson Pees C1 = BARO ~ Barometric Pressure ie ACCELERATOR POSITION / IDLE VALIDATION OUTPUT FUNCTIONS Injection Pressure Regulator ~ is a variable posle tion valve that controls injection control pressure, The ECM uses many input variables to determing the desired injection control pressure, Battery voltage is supplied to the IPR when the igni- tion Key Is in the on position, Valve position is con. trolled by switching the output signal circuit to ground inside the Elaetronie Control Module (ECM). On off time is modulated from 0-50% depencent upon the desired injection control pressure. FAULT DETECTIONMANAGEMENT. An open ot 2 shovt 1 ground control circuit can be etocted by anon demand output circuk check per. formed during the engine off test, Duty Cycle Controlled INJECTION CONTROL, PRESSURE REGULATOR | | Ea Sie age | | C {ee L [one ne The ECM Is capable of detecting, while the engine 's running, #.dasired injection control pressure Is ‘equal fo measuredinjection control pressure. ithe measured injection control pressure does not rea Sonably compare to the desired injection control Pressure, the ECM ignores the measured IGP sig- fal and attempts to control the engine with the de- sited value. (I!the problem was in he sensor crcul, this strategy causes ttle performance deteriora tion, ifthe problem is in the control circu, engine performance will probably stil be unsatistacior), A faully IPR or problem with the high pressure ol! ‘system cari be detected by the engine running test ‘uring the Injection control pressure step test. Dur- ing this test, the ECM commands and measures two Specific preprogrammed pressures, A faut code is Sel, ifthe pressures can no! be maintained. AOTE: THE ENGINE WILL NOT OPERATE WITH ANIC CIRCUIT THATIS NOT FUNCTIONING. EGES-125 Printed in the United States of AmericaInjection Pressure, Regulator (IPR), 241 Output Circuit CnesKn | ‘931 Excessive ICP Pressure |. 323 In-Range Fault Deuteen racer (On Vale Gover segues ta : Cains, Regulator Fe (a) A (b) ing con Joose terminals etc. | Connector Checks! 8 Ground (8) = (Geek vith 128 Connector Olasonnected anton heya, al accossoraa 3) [Test Poin “Spec. ‘Commanis 21000 chins [A shor io ground will command full IPH pressure, ode a3? Tay be sat rr = 1000 ohms | Resistance to chavsis ground, Wahorted o ginund iss PL ghega be 3101 { IPH Yoltage Check (Check with regulator connector disconnected) Comments = RAO Gis [Ss | Batery voltage tom Fa, check wih Key on (GP relay SOUS A Bio ids] 0= 25v [greater han 25 vols, signal wires shoned a V Ra [Test Pais [Spec ied rom seme se) Datiery. ci ee ae, ee : : = Se Ee sat | #2 200m | SOT meets FRIGA | 1000 ona Resistance ese han 1000 che Indcatoa a shor To groand [eters [= 00 one Roaistones eas han 1000 crs Inicates a sho To drara Connector Voltage Checks (Cheek with tensor Connector Disconnected nnd Ignition Key On) Fearon] Spee. Blo Gre. | vows = 5 | v Rat, shack with key ON StoGr. | 43-50% (sollage natin soec seo V REF Grout Pull up vollage ino oF tow volage ceeuit has ooen oF High resistance or shor lo ged | Harness Resistanes Checks (Check with breakout Sox Installed an engine harness only) Commenis Fiesslance fom sensor connecter 060 pin cannaciar Signal gone estianeo Irom sensor connector 60 pin connector =V Rel Fleelance rom sensor connector 60 pit cannactar — MAP aignal [LiestFons [Spe ets A [ 1000 onm | CCL-| 7900 chs indicales a shor to Gc. ether thea the hamess or ilemnel F2s10 Fas | > TOOT ohm | CLF] ime ECM or VPM and measure o orc again. I short stl present, dc FEE IGF [STOR ohm [TAGE] ceMMeSt ECM anc measie fo Gc. shat il present rapa haness. Harness Resistance Checks (Check with breakout box Installed, ignition key should be in the OFF position) ‘ectPaints | Spee. | Signal ‘Comment ‘#910 14 | Resistance irom VPM connecior lo EST connector ATA “'gnal Gips= | 5 ohme BARO | Sto P25 [> 5 ohms: <3 ‘pen in the V Fel euch esas. Comments = 1000 ohms | Resistance < 000 chms indcales a shor ia gud. Wa chon w gd cond 1000 ofr] ton is ideniied. remove af nonecr comocters inal are connected to Bs "0 determine shor is in a sensor, ECM or wie Pa Eee ey Ret ane EM a i sherk ech meee, > 1000 ome te shor i isontiiod nthe hdmess, remove the intermediate Dautech ST eons | = 1000 cans somrgchtand memauiny maniac at teen ee UBRRO | SieGed—|> 1000 arms] tw show Sines Harness Resistance Checks (Check with breakout Dox instaled om hamess oniy) ‘Sensor [Test Pants [Spee ‘Comments 1 | 316225 [> chins | The measurements taken form the sonsor connector he ECW BOA EBP_| S026 | > 5 ohms | Connector Resistance greater than Schima ecieates high @acvece sean EGES-125 Princ the United States af Ameen aSection A Page 50 APS AND IVS 1.0 DESCRIPTION ‘The Electronie Control Module (ECM) forthe engine determines the position of the acceleralor pede! by processing the input signals from the Accelerator Position Sensor (APS) and Idle Velidalian Switch (vs), Refertothe circuitdiagramlocaiedin this section the following discussion, 4-1 ACCELERATOR POSITION SENSOR (APS) ‘The EGM sends a regulated 5 volt signal through ECM connector (879) terminal 26 to APS connacior (982) terminal C. The APS then returns 2 variabie vollage signal (depending on pedal position) from, APS connector (382| terminal A to the ECMatjermi- nal 47. The APS is grounded trom connecior (382) lerminal B ia the ECM signel ground terminal 48, 1.1.1 APS AUTO-CALIBRATION ‘The ECM leams the lowest and highest pedal posi- tions by reading and storing the minimum and maxi- Tum voltage ievels itom the APS. in this manner the ECM" auto- calibrates” the sysiemtozllow max’ mum pedal sensitivity. The ECM auto-calibraies as) the key is ON, but when the keys turned OFF, the values are lost. When the key is turned on again, the. process staris over. When the pedal Is discon- nected (or New one installad), the pedal does not need to be calibrated, as the calibration happens: when the key is tuned on, 1.2 IDLE VALIDATION SWITCH (IVS) The ECM expects to receive one of two signals through ECM connector (379) terminal 8 from APS/ IVS connector (282) terminal D: + OVolls when the pedal is at the idle position, + 12 volts when the pedal is depressac The Idle Validation Switch receives 12 volt ignition voltage trom 10A {uso F4 (Ht with FBC), When the pedal is NOT in the idle position (\hroitle applied), the IVS sends a 12 volt signal to the ECM. ‘The ECM compares the inputs it receives at termi nals 47 and & from the APS/IVS to verily when the pedal is in the idle position, If ine APS signal at ter- minal 47 indicaies throttle is being applied, then the ECM expects (o see 12 volts al IVS terminal. Il the APS signal at terminal 47 indicates throttles nol ap= plied, then the ECM expects to see Ovolisat the IVS terminal 8. The timing process is critical between the APS and the IVS sensors. For this reason, itis very difficult to determine if the APS/IVS assembly. fs working properly using voll-ohmmeter. | ae : i re ; STAPSAVS CIRCUIT DIA APS AND IVS Sfaest (GRAM ~y 1a emisu, 7 oe ee ee ee oe ee oe | 12viaNTOvPM NELIAL GAFETY evaToH) Shane SWITCH LAY (m8 *Wronuase, Pro oR ENGINE BRAS APS/IVS (382) WOTE ISOPEN ATIOUE Figure 1.01 - APSJIVS Circuit DiagramSection A Page 52 APS AND IVS 20 ECM DIAGNOSTICS When the key is ON, the ECM continuously mont tors the APS/IVS circuits for expected voltages. ft also compares the APS and IVS signals for conflict. Ii the signals are not what the ECM expects to sea, Fault codes will be set. FLASH CODE 131/ ATA CODE PID 91 FMI 4 ECM: APS OUT OF RANGE LOW The OAL (out of range low) code 121 is set if the ECM detects a voltage lower than 0.152 volts at ter- minal 47. Possible causes inciude: a shortto ground cor an open in circuit 998. This code is displayed by either the Piolink EST or using the Engine Warn Light to flash codes. When code 131 is active, the ECM restricts engine spees to idle and turns the Engine Waring Light ON. Il the condition causing code 131 is intermittent an the condition is no longer present, the code wil become inactive and normal engine operation will resume, If code 131 is aclive, perform Test 5.1.2. FLASH CODE 132/ ATA CODE PID 91 FMI3 ECM: APS OUT OF RANGE HIGH “The ORH (out of range high) code 132 is set f the ECM detecis a voltage greater than 4.55 volts at ter- minal 47. Possible cause: short to VAEF ot? volts in circuit 99B. This code Is displayed by either the Prolink EST or using the Engine Warn Light to lash codes. When code 132 ié active, the ECM resiricis engine ‘speed to idle and turns the Engine Wam Light ON. the condition causing code 132 is intermitient and the condition is no longer present, the code will be~ come inactive and normal engine operation will sume, If code 132 is active, perform Test 3.1.2. FLASH CODES 133, 134 AND 195 - APS IN- RANGE FAULTS ‘The ECM checks the voltage output of the APS by ‘comparing the APS signal with the IVS signal. APS and IVS signals can disagree in two cases: + The APS signal indicates the pedal is presses down to accelerate, but the IVS signal ind cates idle position, * The APS signal indicates the pedal has been released to allow the engine to return to idle, bbul the IVS signal indicates off-idle position of the pedal Ii the ECM detects either of the above conditions, the ECM,attempts to isolate the source of conflict. It cade(s) 133, 134 andlor 135 ate ec.ive, perform tosis 3.1.1 and 3.1.2. FLASH CODE 133 / ATA CODE PID 91 FMI2 ECM: APS IN RANGE FAULT I the IVS signal is changing and the APS signal is constani, the ECM assumes APS is the conflict ‘source and sets code 133. Engine rpmis restricted 10 idle and the Engine War Light is tuned ON. FLASH CODE 134 / ATA CODE PID 91 FMIT ECM: APS/VS DISAGREEMENT Mt neither the APS or IVS is changing, or both are changing or the ECM cannot determine the faulty code in specified time, then code 134 is set, engine rpm is restricied to idle and the Engine Warn Light is turned ON. FLASH CODE 135 / ATA CODE SID 290 FMI 11 ECM: IVS CIRCUIT FAULT Ii the APS is changing and IVSis constant, he ECM ‘assumes IVS is the conflict source and sets flash code 185. Inthis case the ECM mits the APS signal to@ lower value..wnich provides less than full rm, but does not limit engine rpm to idle. The Engine Warn Light is not tumed ON. Note thal codes 133, 194 and 135 are caused by an Intermittent condition, the codes remain ACTIVE Until he vehicle has been shutdown and restarted. ‘They do not recover withaut cycling the key switch. EGES-125 Prieto te Unions Sse ot AmerieAPS AND IVS Section a Page $3 SOTROUBLESHOOTING a a = a ‘The APS and IVS circuits operate with ‘ow current levels. When troubloshooting, pay special attention to the connectors, 3.0.1 BEFORE PERFORMING ANY TEST ‘nspecteonnectors for pushed back, damaged, cor- foded or dity terminals, as well as making sur th the terminals and wires ara properly crimped. Make ure the connectors are property joined logethor ‘Aisa check for any damage to the wiring and make sure sysiom grounds are clean and tight. 3.1 TESTING ATANVS CIRCUITS Iflash codes 131 or 192 are present, perform Test 9.1.2. If flash codes 133, 134 of 135 are present, ferform Test 3.1.1, then perform Tes! 3.1 2 ‘These teats systematically check the APS and IVS circus for: AL Shot citouts to ground. BL Short circuits to unwanted vollage sources, C. Open circuits oF oxcessive circuit resis- D. Proper feeds and grouncs. (Call ofthe circuits between the ECM and the accel- ‘erator pedal assembly check good, then the accel- erator pedal is replaced, scors-405 Print i the United Staten of ArerienSection A Page 54 APS AND IVS 3.1.7 TESTING IDLE VALIDATION SWITCH (VS) CIRCUITS Refer to Circuit diagram 4.1 while performing this test. Check 10A fuse Fé (or Hi wiFBC) for open condition. ¥ [Locate cause of overioad condition, | _ NO then correct, Replace fuse. — a UP (idle), measure voltage al breakoul box between terminals 8 & 60, KEY OFF — install breakout box at ECM connector (379), Turn Key ON and with APS/IVS pedal Witt key OFF, disconnect APSIVS connector (382) from cab harness. ‘Turn key ON and at breakout box, measure voltage between terminals 6 and 60, Tocate shor to ies unwantec vohage source in circuit 99D, then correct, ¥ ves Rep APSAVS assembly. The 995 KEY OF F- Disconnect APS/IVS connector (382) Irom cab hamess. KE’ ON - Measure vol!age to veh. ground at (282), ierminal F. (382) Wile ee ee eee | vollage between breakout box terminals 8 and 60. T y Yes (“Pero 3.1.2 TESTING ‘Approximately APS SENSOR CIRCUITS 12 volls?, Locale cause of NO or LOW voltage in feed circuit 99E, then correct. Ignition valiage? F and terminal D. KEY ON - Jumper breakout box terminal & to ground (erminal 60). Al connector (982), measure vollage between terminal Locale open in circuit 98D between IVS connector (382) and ECM “Approximatoly connector (379), then correc! 12 volis? Yes [Replace APSnVS| pedal assembly. EGES-125 ried me tmitet Setee of America _— oeBORE ERR RRR Pee eee ee APS AND IVS ‘Page se 9.4.2 TESTING ACCELERATOR POSITION SENSOR (APS) CIRCUITS Fosfor to Cireuttclagram 4.1 while performing this test. Note: Periorm this tost codes 11 oF 132 CREGIN) 279 present. codes 153, 134 or 135 are present, perform Test 3.1.1 before per- forming this test. KEY OFF - Install breakoul Box te ECM hamriess connector (78), but do ‘not connect to ECM, Disconnect APS/IVS (982) trom cab hamess. y KEY ON - At breakout box, measure vollage belween Terminal 60 (GAD) and ter rrinals 8, 26, 46, 47. Tecate shor to unwanted votlage souroa in cteuit(s} where more than ‘volt ig prasont, then repair Voltage less than ‘voit at each terminal? yes KEY OFF and terminals 8, wfeaKout box, measure resistance between le7minal 60 (GAD) 46, and a7. Locale short ground in eweut where terminal resistance is tess |_NO than 100K ohms, then repair Resistance is 100K ohms or KEY OFF - Al breakout box, measure resistance belween lerminals 5, 26, 48, 47. Tocate short between any Circuits where resistance Is less than 100K ohms, then repai Fosistance Is 100K ohms or EGES-125 rine nthe atl Bin wf menicnSection A Page 58 APS AND IVS 5.1.2 TESTING ACCELERATOR POSITION SENSOR (APS) CIRCUITS (Continued) KEY OFF ~ instal! jumper Between breakout box terminals 46 and 47. AP connector (382), measure resisiance between terminals A and B, Locate open in creulisy 98NE7W/ 97X_ 0; 99B between connectors (378) and (382), then repair KEY OFF - At breakout box, install jumper between terminals 26 and 40 AT ‘connector (982), measuite resisiance between terminals and C. t (382) | Locate openin areue] x S89C(6V) oF S7AA(BV), then lo “Resistance | | fepait =< tess than 2 ohms? | s9Cisy) 998 | | Ye ‘KEY ON - At breakout box, install jUmparbeiween lerminals 46 & 6. AT ormectr Be] mente eosarbe Reneen enone Tosals open iy aroull) 89C(5¥) or 97AA(5V), then t I i Replace the APS i IVS assembly. \ I. | i i i EGES-125 Pitan te Vale? Se SeenAPS AND IVS 4.0 CIRCUIT DIAGRAM AND CONNECTOR END VIEWS 4.1 CIRCUIT DIAGRAM ROMY 23 Fa Ht soar (5) ey fon ETI sae STEM) > op sreven Se a WiFBc DASH CONN a mass (3 & 3A) 5 12vGNTo vem NEUTmAL SAFETY swToH BRAKE SWITCH RELAY (208) “Wucrlise, PTO OR ewan BRAKE ACcEL POS SENGOR APS/IVS (382) NOTE:1vS OPEN ATIOUE Sowoicares twsereo wine PAR EGES-125 Prine in the Unitea tates at Amerie.ati lea a acl lS SR SY Section A ? Page 80 APS AND IVS 4.2 CONNECTOR END VIEWS: = 31-PIN DASH CONNECTOR 383A GPMMESSSOE AN bLotHiMesSEDE. _lentnamtgaEaDE gs) cuonsammsosee cu = ow an ca a a aoe re a om PE adioed rue be lad = a) ee ree : or a aor wee —— nua = tee ica —_ 2 oot sree a ae rer ae ee ey Fe aaa oA ee a oo + incu mot cae Hannes wer OSE oro } C EGES~125APS AND IVS Seapes8 4.2 CONNECTOR END VIEWS (Continued) ELECTRONIC CONTROL MODULE ECan 60-PIN fe hae ‘CONNECTOR: S79) , eee Gey F ct | 8 = So se he een ua ay CAUTION Do not probe ECM connector with es meter lends ast wil camage he connector, Use breakout box to test circuits. iy cn cn ow a for ord mn 97-08 sae sue a ae aes nib = om “i ne oe 5.0 COMPONENT Locarions a Rafer to Section T for venicie/component A emt ee site 5:1 COMPONENT LOCATION CHART Po Ge cena GAS DAS Gaus ie sal CONNECTOR... LM DASH : ee on (373) Eom aaa : GONNEGTOR ....... LH DASH PANEL bs ou pe: (S82) APS/VS + ATACCELERATOR: =| = ears Ataccel ae se a so 50 s7Ac F4 FUSE, MAIN FUSE PANEL a | eh alan wrnues e se eo sete = Hr Fuse twain Fuse PANEL Ey ‘AZ o ~ Wi: a sh = So at ae = oe ees 125 Print in the Uted Sates ArmiesSection B Page 60 ATA AND DCL DATA COMMUNICATION LINKS TO DESCRIPTION ‘The Navistar engine control system consists of an Electronic Control Module (ECM), a Vehicle Per sonality Module (VPM), and an Injector Driver Mod wie (IDM). ‘The engine control system “alk” with the Eiectron- ie Service Tool through connector (384) as shown in Figure 1.01. The EST talks with the VPM using the American Trucking Associalion (ATA) dala ink lines! ‘The ECM talks with the VPM.and IDM through ¢ pro: Prietary data link channel (DCL). The Digital Cam- munications Link (DCL) channel shown in Figure 4.01 connects the ECM and the VPM. Both the ATA and DCL circuiis use twisied wire pairs. All repairs to these pairs must maintain one ‘complete twist per inch along the entire length o! ine ‘circuits. These circuits are polarized (one and one negative) and reversing the polar these circuits will disrupt communications. (1) - The ATA data link is defined by SAE recom: mended practices J1708 and J1887. This link and connector (384) were adopted by the Recom- mended Practices 1201 and 1202. 1.1 ATA COMMUNICATIONS: 1.1.1 ATA DATA LINK CONNECTOR (384) All communications between the EST (Protnk 2900" using the Navistar cartridge) and the engine Control system is done through the EST connector (84). This commanveations ink supports: + Dispiaying faut codes and operating condl- tions on the EST. + Performing proprietary diagnosiic tests programmed into the cartridge. + Clearing faull codes. * Programming performance parameter val- ues. EST connector (384) has sixpins, labeled A through F (Figure 1.02) thal provide the following: A. Fused BATTERY power is provided tv Pin “C" to provide battery power fot electronic service tools. Pin “E” ptovides a ballery ground for the EST. B. Connactor (384) terminal A is connected by cit- ‘cuit 98B(+) to the positive RED ATA bus and EST connector (984) arminal B is eonnectedby circuit 980(-) to ine negative BLUE (428) bus. ‘These two connections allow communication with all companents connected to the data link at these same two busses, ATA (+ and -) VPM ECM ga) Cos (273) DCL (+ and -) — —> Figure 1.01 — ATA And DCL Communication EGES-126 Print bathe Bet “me Amen =ATA AND DCL DATA COMMUNICATION LINKS Seetion Page 61 TO DESCRIPTION (Continucdy (eAW CIRCUIT s-oK EST.CONN. (384) | BLUE ATA AED ATA BUS (-) BUS (+) 2) XS ECM ars) DCE oct Figure 1.02~ ATA And DCL Data Communication Circult Diagram eGes-125 ‘rec itt United States of nsionSection B ATA AND DCL DATA Page 62 COMMUNICATION LINKS TODESCAPTION (Continent) pgp 1.1.2 POSITIVE AND NEGATIVE DATA LINKS The RED Positive and BLUE Negative Data Link Sussos connec! the EST connector (384) and the VPM (381). They are also the connection point for other electronic components (electronic transmis- sions, ABS brakes, etc.) that require access to the engine control system through the ATA communica- tions link. ‘The AED positive bus (427) is connected by circuit 98A(+) to the VPIM ai connector (381), terminal 11 ‘The BLUE negative bus (426) is connected by cir- cuit 9BC(-) fo the VPM at connector (381), terminal 12 1.2 DCL COMMUNICATION LINKS ‘The VPM is connecied to the rest of the engine con: trol system through the DCL. The DCL connection between the ECM and the VPM servesas a conduit for data senton the ATA to be shared with the ECM ‘Communications between the ECM and tne EST eonnector go through the VPM. 1.2.2 VPM - ECM COMMUNICATIONS The positive (+) DCL linkis circuit 97S, which con- necis ECM connector (379) terminal 28, othe VPM through connector (881), terminal 13, The nezative (¢) DCL tink is circuit S7AT, which connects ECM connector (379), terminal to the VPM through con- nector (384), terminal 14, These wo citeuts (O7AS ‘and STAT) are a twisted wire pair and pass throuah dash connector (3) at terminals 6 and 1. Both the ATA anc DCL circuits use twisted wire pairs. All repairs to these wire pairs must maintain ‘ne complete twist per inch along the entire length of the circuits. Both circuits are polarzed (one posi- tive and ona negative) and reversing the polarily of the circuit wil d'srupt communications, 2.0 DIAGNOSTICS Flash codes that can be caused by delects occur- fing in the ATA or DCL circuits are discussed in this Section. There are also Flash Codgs related 10 or caused by faulty communication (corrupt or invalid data transmities between the ECM and VPM), that are discussed in this section, 2.0.1 EST CONNECTOR (384) ‘The engine control system does not detect faults in the power or ground circuits to EST connector (384). If the service too does not power up when, connected, try the service tool en another vehicle if ne is available to determine i the service tool = working properly. Ifthe service too! is OK, then per- form 3.1 TESTING EST POWER-AND GROUND CIRCUITS located in this section 2.0.2 EST DISPLAYS [ NO DATA} Should the EST display NO DATA, the ATA data link Circuit trom the EST connector to the VPM may be disrupted. Verily thet the key is ON andthen perform 3.2 TESTING THE ATA DATA LINK CIRCUITS 2.1 FAULT CODES FLASH CODE 223 / ATA CODE SID 252 FMI 7 ECM: VPM NOT COMMUNICATING WITH ECM SYMPTOM: Flash code 223 causes the engine to Operate in Field Defaults, which tums the Engine Waring Light ON. When Field Detaults are being sed by the ECM, Flash Code 622 also is set. Ifthe condition causing code 223 is intermittent, and the Condition is no longer present, the code will change to an inactive code, and the engine wil resume no!- mal operation. WIRING CAUSES: A. DCL circuits 97AS and/or 97AT between the ECM and VPM: shories Lower High or Open. Wcode 223 is active 1. Perform 3.3 TESTING DCL CIRCUITS. A detect is found in DCL circu, correc do- lect. B, fhe DCL circuits (97AT and S7AS) check .900d, replace the VPM. FLASH CODE 231 / ATA CODE SID 250 FMI 2 VPM: ATA COMMON FAULT ‘SYMPTOM: Code 231 does nottum Engine Warn- ing light ON. This code can occur when the VPM can't access the ATA data link, I! this cesuts, there. will not be any ATA dala available al the electronic ‘service 100 (EST). The code can be “lashed” using the STI switch located on the instrument panel, EGES-125 Prt inthe thited States of Americ