C13 and C15 Engines for Combat and Tactical Vehicles Caterpillar

Intake Valve Actuator Circuit - Test

Usage:

C13 EMS

System Operation Description:

Note: Valid only if engine is equipped with an intake valve actuator.

Use this procedure to troubleshoot any suspect problems with the intake valve actuators.

Use this procedure for the following diagnostic codes:

285-05 Intake Valve Actuator #1 current low
285-06 Intake Valve Actuator #1 current high
286-05 Intake Valve Actuator #2 current low
286-06 Intake Valve Actuator #2 current high
287-05 Intake Valve Actuator #3 current low
287-06 Intake Valve Actuator #3 current high
288-05 Intake Valve Actuator #4 current low
288-06 Intake Valve Actuator #4 current high
289-05 Intake Valve Actuator #5 current low
289-06 Intake Valve Actuator #5 current high
290-05 Intake Valve Actuator #6 current low
290-06 Intake Valve Actuator #6 current high
You have been directed to this procedure from Troubleshooting, "Troubleshooting without a Diagnostic Code".

The intake valve actuators are used to hold down the rocker arms. This prevents the intake valves from closing. The intake valve actuator is a hydraulic system that uses the engine oil to operate. Oil is allowed to flow in and out of the intake valve actuator when the intake valve actuator is not activated. The intake valve actuator is activated by an electric solenoid. When the solenoid is energized the intake valve actuator traps the oil. This allows the actuator to hold the rocker arm down.

"Intake Valve Actuator Solenoid Test"

The "Intake Valve Actuator Solenoid Test" is a diagnostic test that is available on the Caterpillar Electronic Technician (ET). The test helps diagnose problems with the solenoid for the intake valve actuator. A small current is applied to the circuit at all times. This allows the Engine Control Module (ECM) to detect open circuits when the valve is not actuated. A short circuit will only be detected when the valve is actuated.

The following conditions must be met before the "Intake Valve Actuator Solenoid Test" will function:

Engine speed is 0.
Vehicle speed is 0.
The neutral switch is in the Neutral position.

Show/hide table




Illustration 1	g01099822
C15 schematic

Show/hide table




Illustration 2	g01099820
P2 ECM connector (P2-53) "Actuator 5 & 6 supply" (P2-61) "Actuator 3 & 4 supply" (P2-77) "Actuator 1 & 2 supply" (P2-100) "Actuator 6 return" (P2-101) "Actuator 3 return" (P2-102) "Actuator 5 return" (P2-103) "Actuator 4 return" (P2-111) "Actuator 1 return" (P2-113) "Actuator 2 return"

Show/hide table




Illustration 3	g01099864
Valve cover connectors for C15 engines (1) Terminal 9 Actuator 1 & 2 supply (2) Terminal 8 Actuator 2 return (3) Terminal 7 Actuator 1 return (4) Terminal 11 Actuator 5 & 6 supply (5) Terminal 10 Actuator 3 & 4 supply (6) Terminal 9 Actuator 6 return (7) Terminal 8 Actuator 5 return (8) Terminal 7 Actuator 4 return (9) Terminal 6 Actuator 3 return

Show/hide table




Illustration 4	g01105906
Location of components (1) Check valve (2) Acuator solenoid (3) Face seals (4) Intake valve actuation pressure sensor (5) Intake valve actuation pressure solenoid

Test Step 1. Inspect Electrical Connectors and Wiring

Thoroughly inspect the J2/P2 ECM connector and the front valve cover connector. Thoroughly inspect the valve cover connectors for the intake valve actuators.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector for the solenoids for the intake valve actuators.
Check the ECM connector (allen head screw) for the proper torque of 6 N·m (55.0 lb in).
Check the harness and wiring for abrasion and for pinch points.

Expected Result:

All connectors, pins, and sockets are completely coupled and/or inserted and the harness and the wiring are free of corrosion, of abrasion, or of pinch points.

Results:

OK - The harness and wiring are OK. Proceed to Test Step 2.
Not OK - There is a problem in the connectors and/or wiring.
Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.
Verify that the repair eliminates the problem.

STOP

Test Step 2. Check for Active Diagnostic Codes

Connect Cat ET to the service tool connector.
Turn the key switch to the ON position.
Check for active diagnostic codes that are related to the solenoids for the intake valve actuators.
Monitor the active diagnostic code screen on the electronic service tool. Check and record any active diagnostic codes.
Note: Wait at least 15 seconds in order for the diagnostic codes to become active.
Determine if the problem is related to a low current diagnostic code 05 or a high current diagnostic code 06.

Expected Result:

No diagnostic codes are active.

Results:

OK - No diagnostic codes are active.
Repair: The problem may have been related to a faulty connection in the harness. Carefully reinspect the connectors and wiring. Refer to Troubleshooting, "Electrical Connectors - Inspect".

STOP
Not OK - A low current diagnostic code (05) is active at this time. Proceed to Test Step 3.
Not OK - An high current diagnostic code (06) is active at this time. Proceed to Test Step 5.

Test Step 3. Short the Wires of the Suspect Solenoid for the Intake Valve Actuator at the Valve Cover Connector

Turn the key switch to the OFF position.
Disconnect the valve cover connector for the suspect solenoid for the intake valve actuator.
Fabricate a jumper wire in order to create a short between the supply and the return for the suspect solenoid for the intake valve actuator.
Turn the key switch to the ON position.
Access the "Special Tests" under the "Diagnostics" menu.
Start the "Intake Valve Actuator Solenoid Test" on Cat ET.
Once Cat ET displays the status of the solenoid for the intake valve actuator, stop the "Intake Valve Actuator Solenoid Test".

Expected Result:

The test indicated "Not Active: Device Short" with the jumper wire in place.

Results:

OK - The test indicated "Not Active: Device Short". The ECM recognized the short at the valve cover connector for the solenoid for the intake valve actuator. The harness wiring between the valve cover connector for the suspect solenoid for the intake valve actuator and ECM connector P2 is OK. Proceed to Test Step 7.
Not OK - The test indicated "Not Active: Device Open". The ECM did not see the short at the valve cover connector for the solenoid for the intake valve actuator. Proceed to Test Step 4.

Test Step 4. Create a Short Circuit at the ECM

Turn the key switch to the OFF position.
Disconnect the J2/P2 ECM connector.
Inspect the terminals on the J2 and P2 ECM connectors for damage.
Note: Refer to the Figure 2 for pin locations.
Remove the return wire and the supply wire for the suspect solenoid for the intake valve actuator from the P2 ECM connector.
Fabricate a jumper wire in order to short the two pins for the suspect solenoid for the intake valve actuator at the ECM. Crimp a socket to each end of the jumper wire. Insert the jumper wire into the P2 ECM connector.
Reconnect the P2 ECM connector.
Turn the key switch to the ON position.
Access the "Special Tests" under the "Diagnostics" menu.
Start the "Intake Valve Actuator Solenoid Test" on Cat ET.
Once Cat ET displays the status of the solenoid for the intake valve actuator, stop the "Intake Valve Actuator Solenoid Test".

Expected Result:

The test indicated "Not Active: Device Short" with the jumper wire in place.

Note: Disconnecting the supply wire for the suspect solenoid for the intake valve actuator will cause an "Open" in the solenoid for the intake valve actuator that shares the supply wire with the suspect solenoid for the intake valve actuator.

Results:

OK - The test indicated "Not Active: Device Short" with the jumper wire in place. The ECM recognized the short.
Repair: Check continuity of the supply wire for the suspect solenoid for the intake valve actuator between the valve cover connector for the suspect solenoid for the intake valve actuator and P2. If the wire is open, replace the wire.
Check continuity of the return wire for the suspect solenoid for the intake valve actuator between the valve cover connector for the suspect solenoid for the intake valve actuator and P2. If the wire is open, replace the wire.

STOP
Not OK - The test indicated "Not Active: Device Open" with the jumper wire in place. The ECM did not recognize the short circuit.
Repair: Replace the ECM. Refer to Troubleshooting, "Replacing the ECM". Verify that the problem is resolved.
Verify that the repair eliminates the problem.

STOP

Test Step 5. Open the Wires of the Suspect Solenoid for the Intake Valve Actuator at the Valve Cover Connector

Turn the key switch to the OFF position.
Disconnect the valve cover connector for the suspect solenoid for the intake valve actuator.
Turn the key switch to the ON position.
Access the "Special Tests" under the "Diagnostics" menu.
Start the "Intake Valve Actuator Solenoid Test" on Cat ET.
Once Cat ET displays the status of the solenoid for the intake valve actuator, stop the "Intake Valve Actuator Solenoid Test".

Expected Result:

The test indicates "Not Active: Device Open".

Results:

OK - The test indicates "Not Active: Device Open". The ECM recognized the open at the valve cover connector for the solenoid for the intake valve actuator. The harness wiring between the valve cover connector for the suspect solenoid for the intake valve actuator and ECM connector P2 is OK. Proceed to Test Step 8.
Not OK - The test indicates "Not Active: Device Short". The ECM did not see the open at the valve cover connector for the solenoid for the intake valve actuator. Proceed to Test Step 6.

Test Step 6. Create an Open at the ECM

Turn the key switch to the OFF position.
Disconnect the P2 ECM connector.
Inspect the terminals on the J2 and P2 ECM connectors for damage.
Note: Refer to the Figure 2 for pin locations.
Remove the return wire and the supply wire for the suspect solenoid for the intake valve actuator from the P2 ECM connector.
Reconnect the P2 ECM connector.
Turn the key switch to the ON position.
Access the "Special Tests" under the "Diagnostics" menu.
Start the "Intake Valve Actuator Solenoid Test" on Cat ET.
Once Cat ET displays the status of the solenoid for the intake valve actuator, stop the "Intake Valve Actuator Solenoid Test".

Expected Result:

The test indicates "Not Active: Device Open".

Results:

OK - The test indicates "Not Active: Device Open". The ECM recognized the open at the ECM.
Repair: Disconnect the P2 ECM connector. Measure the resistance between the supply wire for the suspect solenoid for the intake valve actuator and every terminal on ECM connector P1 and ECM connector P2. Measure the resistance between the supply wire for the suspect solenoid for the intake valve actuator and engine ground. If the wire is shorted, replace the wire.
Measure the resistance between the return wire for the suspect solenoid for the intake valve actuator and every terminal on ECM connector P1 and ECM connector P2. If the wire is shorted, replace the wire.

STOP
Not OK - The test indicates "Not Active: Device Short". The ECM did not recognize the open.
Repair: Replace the ECM. Refer to Troubleshooting, "Replacing the ECM". Verify that the problem is resolved.

STOP

Test Step 7. Create a Short Circuit at the Solenoid for the Intake Valve Actuator

Turn the key switch to the OFF position.
Reconnect the valve cover connector.
Remove the valve cover.
Disconnect the connector on the suspect solenoid for the intake valve actuator.
Inspect the terminals on the solenoid connector for damage.
Fabricate a jumper wire in order to short the two wires for the suspect solenoid on the solenoid connector. Crimp a pin to each end of the jumper wire.
Make sure that the solenoid connector securely holds the jumper wire.
Note: Worn terminals and/or damaged terminals on the solenoid connector could cause an intermittent "Open".
Turn the key switch to the ON position.
Access the "Special Tests" under the "Diagnostics" menu.
Start the "Intake Valve Actuator Solenoid Test" on Cat ET.
Once Cat ET displays the status of the solenoid for the intake valve actuator, stop the "Intake Valve Actuator Solenoid Test".

Expected Result:

The test indicated "Not Active: Device Short" with the jumper wire in place.

Results:

OK - The ECM recognized the short at the solenoid connector for the solenoid for the intake valve actuator. The harness wiring between the solenoid connector for the suspect solenoid for the intake valve actuator and ECM connector P2 is OK.
Repair: Temporarily connect a new solenoid for the intake valve actuator.
Temporarily connect a new solenoid for the intake valve actuator to the harness, but do not install the new solenoid for the intake valve actuator in the engine. Verify that there are no active diagnostic codes for the solenoid for the intake valve actuator. If there are no active diagnostic codes for the solenoid for the intake valve actuator, permanently install the new solenoid for the intake valve actuator. Clear any logged diagnostic codes.

STOP
Not OK - The test indicated "Not Active: Device Open" with the jumper wire in place. The ECM did not recognize the short circuit.
Repair: Repair the harness between the connector for the solenoid for the intake valve actuator and the valve cover connector for the suspect solenoid for the intake valve actuator.
Verify that the repair eliminates the problem.

STOP

Test Step 8. Create an Open Circuit at the Solenoid for the Intake Valve Actuator

Turn the key switch to the OFF position.
Reconnect the valve cover connector.
Remove the valve cover.
Disconnect the connector on the suspect solenoid for the intake valve actuator.
Inspect the terminals on the solenoid connector for damage.
Turn the key switch to the ON position.
Access the "Special Tests" under the "Diagnostics" menu.
Start the "Intake Valve Actuator Solenoid Test" on Cat ET.
Once Cat ET displays the status of the solenoid for the intake valve actuator, stop the "Intake Valve Actuator Solenoid Test".

Expected Result:

The test indicates "Not Active: Device Open".

Results:

OK - The test indicates "Not Active: Device Open". The ECM recognized the open at the solenoid for the intake valve actuator. The harness wiring between the solenoid connector for the suspect solenoid for the intake valve actuator and ECM connector P2 is OK.
Repair: Temporarily connect a new solenoid for the intake valve actuator.
Temporarily connect a new solenoid for the intake valve actuator to the harness, but do not install the new solenoid for the intake valve actuator in the engine. Verify that there are no active diagnostic codes for the solenoid for the intake valve actuator. If there are no active diagnostic codes for the solenoid for the intake valve actuator, permanently install the new solenoid for the intake valve actuator. Clear any logged diagnostic codes.

STOP
Not OK - The test indicates "Not Active: Device Short". The ECM did not recognize the open.
Repair: Repair the harness between the connector for the solenoid for the intake valve actuator and the valve cover connector for the suspect solenoid for the intake valve actuator.
Verify that the repair eliminates the problem.

STOP