Components Needed To Start

#5 Speed sensor
#1 POWER PEEC has 8
+ Battery #2 ECM #6 Shut-off solenoid
- Battery
#3 P.M.
#7 BTM
#4 Parameters
#8 Rack position sensor
 Components Needed To Start

#5 Speed/Timing sensor
#1 POWER EUI has 6
+ Battery #2 ECM #6 Good Injectors
#3 P.M.
- Battery
#4 Parameters
 Components Needed To Start

#5 Speed/Timing sensor
#1 POWER HEUI has 7
+ Battery #2 ECM #6 Good Injectors
#3 P.M.
- Battery #7 IAPCV
#4 Parameters
 The Diagnostic Process

 Gather information
– Driver Questionnaire
– Questionnaire response
– Performance effect of active diagnostic codes
– Check the repair history
– What happened, in what order
 The Diagnostic Process

 Verify operational problems

– Is the complaint due to misunderstanding of
parameters
– Is the complaint due to a change of parameters
– Is the engine performing as expected
– Is the problem repeatable
 The Diagnostic Process

 Determine probable causes

– Repair “ACTIVE” diagnostic codes first
– What subsystem could cause the problem
– What subsystem does the troubleshooting guide
suggest
 The Diagnostic Process

 Narrow the list of causes

– Use driver information
– Check “LOGGED” diagnostic codes
– Check “STATUS SCREENS”
– If more than one symptom, look for common
causes
– Avoid “PRE-CONCEIVED IDEAS”
 The Diagnostic Process

 Test subsystems
– Use procedure in manual
– Connector checks are extremely important
– Check every pin, socket, and wire
 Troubleshooting Manual

 Electronic system overview

 Programming parameters
 Troubleshooting without a diagnostic code
 Troubleshooting with a diagnostic code
(functional tests)
 Diagnostic code listing
 Troubleshooting Manual

 Electronic system overview

– Brief explanation of component operation
– Component diagrams
– Sensor and connector locations
– Engine and vehicle wiring harness diagrams
– Service tools
 Troubleshooting Manual

 Programming parameters
– Overview of parameters
– Customer and factory passwords
– Programming a new ECM
– Programming or changing a personality module
– How to use ECM information
 Troubleshooting Manual

 Troubleshooting without a diagnostic code

– Section designation
– General description of symptom
– Page number to begin troubleshooting procedure
 Example:
– PA-19: Engine cranks, but will not start …. Page 65
 Troubleshooting Manual

 Troubleshooting with a diagnostic code

(functional tests)
– Section designation
– General description of subsystems and circuits
– Page number to begin troubleshooting procedure
 Example:
– PC-31: Engine speed/timing circuit test …. Page 233
 Troubleshooting Manual

 Diagnostic code listing

– Diagnostic code
– Code description
– Flash code
– Page number to begin troubleshooting procedure
 Example:
– 232-04: 5 volt supply below normal (21) …. Page 265
 Troubleshooting Manual

 Troubleshooting Without a diagnostic code

– Step by step elimination of all systems that could
cause symptom
 Troubleshooting with a diagnostic code or
functional tests
– Beginning of section on a specific subsystem
– Begins with System operation overview
 Diagnostic code listing
– Step 1 for that item
 Engine Cranks, But Will
3406E
Not Start
 Troubleshooting Without a diagnostic code
 A-19 page 65
 Probable root causes
– Connect an electronic service tool
– Will the ECM communicate
– Electrical connection to injectors
– Engine speed/timing signal
– Incorrect engine software
– Theft deterrent active
 Engine Cranks, But Will
Not Start
Example 1

EUI has 6
#1 POWER #2 ECM #5 Speed/Timing sensor
+ Battery #3 P.M.
#6 Good Injectors
- Battery #4 Parameters

Not an electronic problem

 Engine Cranks, But Will
Not Start
Example 2

EUI has 6
#1 POWER #2 ECM #5 Speed/Timing sensor
+ Battery #3 P.M.
#6 Good Injectors
- Battery #4 Parameters

No speed
 Engine Cranks, But Will
Not Start
 Find no speed or ……
 Have code 190-02 loss of engine RPM signal
– Referred to page 233 or 234 (PC-31)
– Page 233 is systems operation
 Read several steps to see where your going
Step 1 - Check all connectors, pins, and sockets
Step 2 - Check for active code
Step 3 - Connect service tool
 Engine Cranks, But Will
Not Start
 Step 4 – Install a 3 - pin breakout T at the harness side
of the sensor connector, J9 only
P9 J9

A A A
Speed timing sensor B B B
C C C
ECM

A
B
C
 Engine Cranks, But Will
Not Start
 Step 4 – Measure voltage at J9 pin A, with reference to
J9 pin B
P9 J9

A A A
Speed timing sensor B B B
C C C
ECM

A
B
C
+V
Com
 Engine Cranks, But Will
Not Start
 Step 4 – Is voltage between 11.5 and 13.5 volts DC
YES
P9 J9

A A A
Speed timing sensor B B B
C C C
ECM

Sensor is
A
receiving the B + 13.32 v
correct voltage C
+V
Com
 Engine Cranks, But Will
Not Start
 Step 5 – Connect sensor to the breakout T

P9 J9

A A A A
Speed timing sensor B B B B
C C C C
ECM
 Engine Cranks, But Will
Not Start
 Step 5 – Measure the voltage at pin A with reference to
pin B
P9 J9

A A A A
Speed timing sensor B B B B
C C C C
ECM

+V
Com
 Engine Cranks, But Will
Not Start
 Step 5 – Is the voltage still between 11.5 and 13.5 volts
YES
P9 J9

A A A A
Speed timing sensor B B B B
C C C C
ECM

The sensor is receiving the + 12.75 v

correct voltage +V
Com
 Engine Cranks, But Will
Not Start
 Step 6 – Remove the signal wire (pin C) from the engine
harness connector J9 to isolate the sensor signal wire
P9 J9

A A A A
Speed timing sensor B B B B
C C C C
ECM
 Engine Cranks, But Will
Not Start
 Step 6 – Measure the voltage from breakout pin-C to
breakout pin-B, before and while cranking
P9 J9

A A A A
Speed timing sensor B B B B
C C C C
ECM

+V
Com
 Engine Cranks, But Will
Not Start
 Step 6 – Is the voltage less than 2.0 volts DC or more
than 10.0 volts with key on, before cranking
P9 J9

A A A A
Speed timing sensor B B B B
C C C C
ECM

+ .162v
+V
Com
 Engine Cranks, But Will
Not Start
 Step 6 – During cranking is the voltage between 2.0
volts DC and 9.0 volts DC
P9
NO J9

A A A A
Speed timing sensor B B B B
C C C C
ECM

There is no output signal + .162 v

or it is out of limits +V
Com
 Speed Timing Sensor
Step 7
 Remove the existing
speed/timing sensor
 Pull the slip head out

Reinstall the
speed/timing sensor

Position the timing wheel in a place not

allowing the slip head to fill a slot
Component Diagram
 5 volt Active Sensors
3176B, C-10,
+ 5V
Ground
(36) +5v C-12, & 3406E
Oil Pressure (30) Sensor common
(8) Oil pressure
Data link Diagnostic
Tool
Fuel Temp
(3) Fuel Temp

ECM
Boost Pressure
(23) Boost pressure

Coolant Temp
(14) Coolant Temp
Signal
Diagnostic Codes
 Diagnostic Codes
A + 5V
100 Oil Pressure B Ground
C
Data link Diagnostic
Tool
174 Fuel Temp

ECM
Boost Pressure
102

110 Coolant Temp

Signal
03 = Open 04 = Short
 Diagnostic Codes
A + 5V
100 Oil Pressure B Ground
C
Data link Diagnostic
Tool
174 Fuel Temp
102 – 03

ECM
Boost Pressure
102

110 Coolant Temp

Signal
03 = Open 04 = Short
 Diagnostic Codes
A + 5V
“A” shorted to “B”
100 Oil Pressure B Ground
C
Data link Diagnostic
Tool
174 Fuel Temp
232 – 04

ECM
Boost Pressure
102

110 Coolant Temp

Signal
03 = Open 04 = Short
 Troubleshooting
A + 5V
“A” shorted to “B”
100 Oil Pressure B Ground
C
Data link Diagnostic
Tool
174 Fuel Temp
232 – 04

ECM
Boost Pressure
102

110 Coolant Temp

Unplug
Signal
03 = Open 04 = Short
 Troubleshooting
A + 5V
“A” shorted to “B”
100 Oil Pressure B Ground
C
Data link Diagnostic
Tool
174 Fuel Temp
232 – 04

ECM
Boost Pressure
102 Unplug

110 Coolant Temp

Unplug
Signal
03 = Open 04 = Short
 Troubleshooting
A + 5V
“A” shorted to “B”
100 Oil Pressure B Ground
C
Data link Diagnostic
Tool
174 Fuel Temp
Unplug 232 – 04

ECM
Boost Pressure
102 Unplug

110 Coolant Temp

Unplug
Signal
03 = Open 04 = Short
 Troubleshooting
A + 5V
“A” shorted to “B”
100 Oil Pressure B Ground
Unplug
C
Data link Diagnostic
Tool
174 Fuel Temp
Unplug 100-03
174-03
ECM
Boost Pressure 102-03
102 Unplug
110-03

110 Coolant Temp

Unplug
Signal
03 = Open 04 = Short
 Troubleshooting
A + 5V
100 Oil Pressure B Ground
C
Data link Diagnostic
Tool
174 Fuel Temp
102 – 03

ECM
Boost Pressure
102

110 Coolant Temp

Signal
03 = Open 04 = Short
 Troubleshooting
A + 5V
100 Oil Pressure B Ground
C
Data link Diagnostic
Tool
174 Fuel Temp
232 – 04

ECM
Boost Pressure
102

110 Coolant Temp

Signal
03 = Open 04 = Short
 Troubleshooting
A + 5V
“A” shorted to “B”
100 Oil Pressure B Ground
Unplug
C
Data link Diagnostic
Tool
174 Fuel Temp
Unplug 232 – 04

ECM
Boost Pressure
102 Unplug

110 Coolant Temp

Unplug
?
Signal
03 = Open 04 = Short
 5 volt Active Sensors
ECM - Battery
ECM
ECM + Battery

5 V + 0.25 V
A +5 volt
Any 3 wire,
5 volt
Common
B Pressure
Ground
or temp.
Sensor Signal C Signal
sensor
 “C” Wire Signal Output Voltage
“- 04” Short
120

100

80
2.5 volts = 60 PSI
PSI 60
40 “- 04”
Short
20
0
“- 04”
Short

0 Volt 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0V
 5 volt Active Sensors
ECM - Battery
ECM
ECM + Battery

5 V + 0.25 V
A +5 volt
Any
3 wire
Common
B 5 volt
Ground
Pressure
Sensor Signal C Signal
or temp.
sensor

“B” to “C” short

 “C” Wire Signal Output Voltage
“- 04” Short
120

100

80
2.5 volts = 60 PSI
PSI 60
40 “- 04”
Short
20
“B” to “C” short
0
“- 04” Code 100-04
Short
X
0 Volt 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0V
 5 volt Active Sensors
ECM - Battery
ECM
ECM + Battery

5 V + 0.25 V
A +5 volt
Any
3 wire
Common
B 5 volt
Ground
Pressure
Sensor Signal C Signal
or temp.
sensor

“C” to “A” short

 “C” Wire Signal Output Voltage
“- 04” Short
120

100

80
2.5 volts = 60 PSI
PSI 60
40 “- 04”
Short
20
“C” to “A” short
0
“- 04” 100-04
Short
X
0 Volt 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0V
 5 volt Active Sensors
ECM - Battery
ECM
ECM + Battery

5 V + 0.25 V
A +5 volt
Any
3 wire
Common
B 5 volt
Ground
Pressure
Sensor Signal C Signal
or temp.
sensor

“C” Open What code? 100-03

 “C” Wire Signal Output Voltage
“- 04” Short
120

100 What’s the voltage on the “C” wire?

80 6v+
2.5 volts = 60 PSI
PSI 60
40 “- 04”
Short
20
0
“- 04”
Short

0 Volt 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0V
 “C” Wire Signal Output Voltage
Battery +
100 volt DC EUI
Battery -

13.2 v speed timing sensor

8 v throttle position sensor

6.4 v pull up

A 5 v sensor supply
B
C Micro-processor
 5 volt Active Sensors
ECM - Battery “B” to “C” swap
ECM
ECM + Battery

5 V + 0.25 V
A +5 volt
Any
3 wire
B 5 volt
Ground
Pressure
C Signal
or temp.
sensor

What code? No code

 “C” Wire Signal Output Voltage
“- 04” Short
120

100

80
2.5 volts = 60 PSI
PSI 60
Look at status “- 04”
40
screen – low oil Short
20 pressure or
0 “B” to “C” swap temp – etc.
“- 04”
Short

0 Volt 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0V
 5 volt Active Sensors
ECM - Battery “A” to “C” swap
ECM
ECM + Battery

5 V + 0.25 V
A +5 volt
Any
A 3 wire
B 5 volt
Ground
B Pressure
C Signal
or temp.
C sensor

What code? No code

 “C” Wire Signal Output Voltage
“- 04” Short
120

100

80
2.5 volts = 60 PSI
PSI 60
Look at status “- 04”
40
screen – High oil Short
20 pressure or
0 temp – etc.
“- 04”
Short “A” to “C” swap

0 Volt 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0V
Electronics Class

Questions so
far?