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2005 Kenworth T800 CATERPILLAR C-11 ADEM A4/ACERT EPA04

Repair: CATERPILLAR - C-11, C-13, & C-15 (BXS) - EPA04 Print Date: 18/08/2017
- TROUBLESHOOTING
DIAGNOSTIC TESTS > INTAKE VALVE ACTUATION SYSTEM OIL PRESSURE
CIRCUIT > STEP 1. INSPECT ELECTRICAL CONNECTORS & WIRING

1. Place ignition switch to OFF position. Inspect J2/P2 ECM connector and solenoid
connector.

2. Perform a 10 lb (45 N) pull test on each of wires in ECM connector and solenoid connector.

3. Inspect ECM connector (Allen head screw) for correct torque specification .

4. Inspect harness and wiring for abrasion/pinch points.

Expected Result: All connectors, terminals, and sockets are completely coupled and/or inserted.
Harness and wiring are free of corrosion/abrasion/pinch points.

Results:

If okay - electrical connectors and wiring are okay. Determine condition that is present .

Not okay - Problem exists in electrical connectors and/or in wiring.

Repair: Repair connectors or wiring and/or replace connectors or wiring. Ensure all seals are
properly in place and ensure connectors are completely coupled. Verify repair eliminates
problem.

DIAGNOSTIC TESTS > INTAKE VALVE ACTUATION SYSTEM OIL PRESSURE

CIRCUIT > STEP 2. DETERMINE CONDITION THAT IS PRESENT

1. Connect Electronic Service Tool (EST) to data link connector.

2. Place ignition switch to ON position.

3. Get access to "Special Tests" under "Service" menu.

4. Start "Intake Valve Actuation Pressure Solenoid Test" on EST.

5. Once EST displays intake valve actuation pressure solenoid status, stop "Intake Valve
Actuation Pressure Solenoid Test".

Expected Result: Test indicated "Not Active: Device Open" or "Not Active: Device Short".

Results:

Open - Test indicated "Not Active: Device Open". Short wires at solenoid .

Short - Test indicated "Not Active: Device Short". Create an open at solenoid .

DIAGNOSTIC TESTS > INTAKE VALVE ACTUATION SYSTEM OIL PRESSURE

CIRCUIT > STEP 3. SHORT WIRES AT SOLENOID

1. Place ignition switch to OFF position.

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NOTE: When "Intake Valve Actuation Pressure Solenoid Test" is used it is

important to cycle ignition switch between steps.

2. Disconnect intake valve actuation pressure solenoid at solenoid connector.

3. Fabricate a jumper wire to short terminal 1 and terminal 2 of connector for solenoid on
engine harness.

4. Place ignition switch to ON position.

5. Get access to "Special Tests" under "Service" menu.

6. Start "Intake Valve Actuation Pressure Solenoid Test" on EST.

7. Once EST displays intake valve actuation pressure solenoid status, stop "Intake Valve
Actuation Pressure Solenoid Test".

Expected Result: Test indicated "Not Active: Device Short" with jumper in place.

Results:

If okay - Test indicated "Not Active: Device Short". Inspect solenoid resistance .

Not okay - Test indicated "Not Active: Device Open".

Repair: Reconnect solenoid to solenoid connector. Short circuit at ECM .

DIAGNOSTIC TESTS > INTAKE VALVE ACTUATION SYSTEM OIL PRESSURE

CIRCUIT > STEP 4. INSPECT SOLENOID RESISTANCE

1. Place ignition switch to OFF position.

2. Measure resistance between 1-2 terminals of intake valve actuation pressure solenoid
using a multimeter.

Expected Result: Resistance is less than 15 Ohms for 12 Volt systems and less than 50 Ohms for 24
Volt systems.

Results:

If okay - Resistance is within specifications.

Repair: Inspect solenoid connector/terminals/wiring. Verify all connectors, terminals, and wiring
are okay.

If problem is intermittent, inspect electrical connectors .

Not okay - Resistance is not within specifications.

Repair: Temporarily connect a NEW solenoid. If problem is fixed with NEW solenoid, reconnect
suspect solenoid. If problem recurs, replace solenoid permanently. Verify repair eliminates
problem.

DIAGNOSTIC TESTS > INTAKE VALVE ACTUATION SYSTEM OIL PRESSURE

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CIRCUIT > STEP 5. SHORT CIRCUIT AT ECM

1. Place ignition switch to OFF position.

NOTE: When "Intake Valve Actuation Pressure Solenoid Test" is used, it is

important to cycle ignition switch between steps.

2. Disconnect P2 ECM connector.

3. Remove wires from P2:31 (Intake valve acutation pressure solenoid) and P2:53 (Solenoid
common).

4. Fabricate a jumper to short P2:31 (Intake valve acutation pressure solenoid) and P2:53
(Solenoid common).

5. Reconnect P2 ECM connector.

6. Place ignition switch to ON position.

7. Get access to "Special Tests" under "Service" menu.

8. Start "Intake Valve Actuation Pressure Solenoid Test" on EST.

9. Once EST displays intake valve actuation pressure solenoid status, stop "Intake Valve
Actuation Pressure Solenoid Test".

Expected Result: Test indicated "Not Active: Device Short" with jumper wire in place.

Results:

If okay - Test indicated "Not Active: Device Short" with jumper wire in place. Bypass harness .

Not okay - Test indicated "Not Active: Device Open" with jumper wire in place.

Repair: Temporarily connect a test ECM. If problem is fixed through test ECM, reconnect
suspect ECM. If problem recurs, replace ECM permanently. Verify repair eliminates problem.

DIAGNOSTIC TESTS > INTAKE VALVE ACTUATION SYSTEM OIL PRESSURE

CIRCUIT > STEP 6. CREATE AN OPEN AT SOLENOID

1. Place ignition switch to OFF position.

NOTE: When "Intake Valve Actuation Pressure Solenoid Test" is used, it is

important to cycle ignition switch between steps.

2. Disconnect intake valve actuation pressure solenoid at solenoid connector.

3. Place ignition switch to ON position.

4. Get access to "Special Tests" under "Service" menu.

5. Start "Intake Valve Actuation Pressure Solenoid Test" on EST.

6. Once EST displays intake valve actuation pressure solenoid status, stop "Intake Valve
Actuation Pressure Solenoid Test".

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Expected Result: Test indicates "Not Active: Device Open".

Results:

If okay - Test indicates "Not Active: Device Open". Inspect solenoid resistance .

Not okay - Test indicates "Not Active: Device Short". Create an open at ECM .

DIAGNOSTIC TESTS > INTAKE VALVE ACTUATION SYSTEM OIL PRESSURE

CIRCUIT > STEP 7. INSPECT SOLENOID RESISTANCE

1. Place ignition switch to OFF position.

2. Measure resistance between 1-2 terminals of intake valve actuation pressure solenoid
using multimeter.

Expected Result: Resistance is more than 6 Ohms for 12 Volt systems and more than 23 Ohms for
24 Volt systems.

Results:

If okay - Resistance is within specifications.

Repair: Inspect for corrosion and moisture in solenoid connector. If problem is intermittent,
inspect electrical connectors .

Not okay - Short circuit exists in solenoid.

Repair: Temporarily connect a NEW solenoid. If problem is fixed with NEW solenoid, reconnect
suspect solenoid. If problem recurs, replace solenoid permanently. Verify repair eliminates
problem.

DIAGNOSTIC TESTS > INTAKE VALVE ACTUATION SYSTEM OIL PRESSURE

CIRCUIT > STEP 8. CREATE AN OPEN AT ECM

1. Place ignition switch to OFF position.

NOTE: When "Intake Valve Actuation Pressure Solenoid Test" is used, it is

important to cycle ignition switch between steps.

2. Disconnect P2 ECM connector.

3. Remove wires from P2:31 (Intake valve actuation pressure solenoid) and P2:53 (Solenoid
common).

4. Reconnect P2 ECM connector.

5. Place ignition switch to ON position.

6. Get access to "Special Tests" under "Service" menu.

7. Start "Intake Valve Actuation Pressure Solenoid Test" on EST.

8. Once EST displays intake valve actuation pressure solenoid status, stop "Intake Valve

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Actuation Pressure Solenoid Test".

Expected Result: Test indicates "Not Active: Device Open".

Results:

If okay - test indicates "Not Active: Device Open". Bypass harness .

Not okay - test indicates "Not Active: Device Short".

Repair: Temporarily connect a test ECM. If problem is fixed with test ECM, reconnect suspect
ECM. If problem recurs, replace ECM permanently. Verify repair eliminates problem.

DIAGNOSTIC TESTS > INTAKE VALVE ACTUATION SYSTEM OIL PRESSURE

CIRCUIT > STEP 9. BYPASS HARNESS

1. Place ignition switch to OFF position.

NOTE: When "Intake Valve Actuation Pressure Solenoid Test" is used, it is

important to cycle ignition switch between steps.

2. Disconnect P2 ECM connector and P701 Intake valve actuation pressure solenoid
connector.

3. Remove wire from P2:31 (Intake valve acutation pressure solenoid) and P701:1 (Intake
valve acutation pressure solenoid).

4. Fabricate 2 jumper wires between ECM to intake valve actuation pressure solenoid.

5. Place one of jumper into P2:31 and P701:1.

6. Place ignition switch to ON position.

7. Get access to "Special Tests" under "Service" menu.

8. Start "Intake Valve Actuation Pressure Solenoid Test" on EST.

9. Once EST displays intake valve actuation pressure solenoid status, stop "Intake Valve
Actuation Pressure Solenoid Test".

10. Place ignition switch to OFF position.

NOTE: When "Intake Valve Actuation Pressure Solenoid Test" is used, it is

important to cycle ignition switch between steps.

11. Disconnect P2 ECM connector and P701 Intake valve actuation pressure solenoid
connector.

12. Remove wire from P2:53 (Solenoid common) and P701:2 (Solenoid common).

13. Place other jumper into P2:53 and P701:2.

14. Place ignition switch to ON position.

15. Get access to "Special Tests" under "Service" menu.

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16. Start "Intake Valve Actuation Pressure Solenoid Test" on EST.

17. Once EST displays intake valve actuation pressure solenoid status, stop "Intake Valve
Actuation Pressure Solenoid Test".

Expected Result: Test indicates "Active" with one or both of jumper in place.

Results:

If okay - Bypass harness repaired problem.

Repair: Repair suspect wires or replace suspect wires. Verify repair eliminates problem.

Not okay - Bypass harness did not repair problem.

Repair: Verify bypass harness is properly connected. Inspect for damage and/or moisture in
ECM and solenoid connectors. If problem is intermittent, inspect electrical connectors .

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