C3.4B Engines Caterpillar

Solenoid Valve - Test

Usage:

CCS7 4B2

This procedure covers the following codes:

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Table 1
Diagnostic Trouble Codes for the Solenoid Valves
J1939 Code	Description	Notes
1076-2	Engine Fuel Injection Pump Fuel Control Valve : Erratic, Intermittent, or Incorrect	The Electronic Control Module (ECM) detects an intermittent open or short circuit error in the control circuit for the fuel metering valve on the high-pressure fuel pump. This diagnostic code will not be active if a continuous fault in the circuit is detected. The warning lamp will come on.
1076-5	Engine Fuel Injection Pump Fuel Control Valve : Current Below Normal	The ECM detects the following conditions: A low current condition in the output from the ECM to the solenoid for the fuel metering valve on the high-pressure fuel pump for at least 0.01 seconds. The battery voltage is at least 9.5 VDC. The warning lamp will flash. The engine will be derated.
1076-6	Engine Fuel Injection Pump Fuel Control Valve : Current Above Normal	The ECM detects the following conditions: A high current condition in the output from the ECM to the solenoid for the fuel metering valve on the high-pressure fuel pump for at least 0.01 seconds. The battery voltage is at least 9.5 VDC. The warning lamp will flash. The engine will be derated.
1188-5	Engine Turbocharger Wastegate Actuator 1 Position : Current Below Normal	The ECM detects the following conditions: A low current condition in the output from the ECM to the solenoid for the wastegate regulator for at least 0.2 seconds. The battery voltage is at least 10 VDC. The warning lamp will flash. The engine will be derated.
1188-6	Engine Turbocharger Wastegate Actuator 1 Position : Current Above Normal	The ECM detects the following conditions: A high current condition in the output from the ECM to the solenoid in the wastegate regulator for at least 0.2 seconds. The battery voltage is at least 10 VDC. The warning lamp will flash. The engine will be derated.

The following background information is related to this procedure:

Electronically controlled wastegate

The engine has a turbocharger with an electronically controlled wastegate. Typically, the wastegate is a mechanical valve that is used in the turbocharger in order to regulate the intake manifold pressure to a set value.

The control system for the electronically controlled wastegate precisely regulates the intake manifold pressure by using a wastegate regulator to control the wastegate.

The required intake manifold pressure is calculated by the software that is contained in the ECM. The ECM uses the wastegate regulator to control the wastegate in order to provide the precise value of intake manifold pressure. The solenoid in the wastegate regulator is controlled by a PWM signal.

Fuel metering valve for the high-pressure fuel pump:

The high-pressure fuel pump is equipped with a fuel metering valve. The fuel metering valve precisely controls the amount of fuel that enters the high-pressure fuel pump.

The amount of fuel that is required is calculated by the software that is contained in the ECM. The solenoid in the suction control valve is controlled by a PWM signal from the ECM.

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Illustration 1	g03732763
Schematic diagram for the solenoid valves

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Illustration 2	g02351359
View of the pin locations on the P2 connector for the solenoid valves (4) Wastegate regulator return (15) Fuel metering valve supply (60) Fuel metering valve return

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Illustration 3	g03086696
View of the pin locations on the P1 connector (1) Battery (+) (28) Main relay control

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Table 2
Troubleshooting Test Steps	Values	Results
1. Inspect Electrical Connectors and Wiring A. Check the fuses. B. Thoroughly inspect the P2/J2 and P1/J1 ECM connectors and thoroughly inspect the connectors for the solenoid valves. Refer to Troubleshooting, "Electrical Connector - Inspect" for details. C. Thoroughly inspect the 62-pin connector . Refer to Troubleshooting, "Electrical Connectors - Inspect" for details. D. Perform a 30 N (6.7 lb) pull test on each of the wires that are associated with the solenoid valves.	Damaged wire or connector	Result: A damaged wire or damaged connector was found. A fuse is blown. Repair: Repair the damaged wire or the damaged connector. Replace any blown fuses Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault. Result: All connectors, pins, and sockets are correctly connected and/or inserted and the harness is free of corrosion, of abrasion or of pinch points. Proceed to Test Step 2.
2. Check for Diagnostic Codes A. Turn the keyswitch to the OFF position. B. Connect the electronic service tool to the diagnostic connector. C. Turn the keyswitch to the ON position. D. Monitor the electronic service tool for active diagnostic codes and/or logged diagnostic codes.	Diagnostic codes	Result: A 1076-5 diagnostic code is active or recently logged. Proceed to Test Step 3. Result: A 1188-5 diagnostic code is active or recently logged. Proceed to Test Step 4. Result: A 1076-6 or 1188-6 diagnostic code is active or recently logged. Proceed to Test Step 9. Result: A 1076-2 diagnostic code is active or recently logged Repair: An intermittent fault exists in the circuit for the fuel metering valve. For intermittent faults, refer to Troubleshooting, "Electrical Connectors - Inspect".
3. Check the Power Supply to the ECM A. Check that pin P1:1 is receiving the correct voltage. Refer to Troubleshooting, "Electrical Power Supply - Test". Note: The power supply for the fuel pump metering valve is supplied through P1:1.	Power supply	Result: The power supply to P1:1 is faulty. Repair: Perform any necessary repairs. Refer to Troubleshooting, "Electrical Power Supply - Test". Result: The power supply to P1:1 is OK. Proceed to Test Step 4.
4. Create a Short Circuit in the Harness at the Solenoid A. Turn the keyswitch to the OFF position. B. Disconnect the connector for the suspect solenoid. C. Fabricate a jumper wire that is 150 mm (6 inch) long. D. Install the wire between the two pins on the harness connector for the suspect solenoid in order to create a short circuit. E. Turn the keyswitch to the ON position. Check for active diagnostic codes on the electronic service tool. F. Remove the jumper wire from the connector for the solenoid valve.	Diagnostic codes	Result: An -6 diagnostic code is active when the jumper is installed. Repair: Temporarily connect a replacement for the suspect valve to the harness. Turn the keyswitch to the ON position. Use the electronic service tool in order to check for active diagnostic codes. Wait at least 30 seconds in order for the codes to be displayed. If the fault is eliminated, reconnect the suspect valve. If the fault returns, permanently install the replacement valve. Refer to Disassembly and Assembly for the correct procedure. Result: An XXXX-5 diagnostic code is still active with the jumper installed. Proceed to Test Step 5.
5. Create a Short Circuit at the 62-Pin Connector A. Turn the keyswitch to the OFF position. B. Disconnect the 62-pin connector. C. Fabricate a jumper wire that is 150 mm (6 inch) long. Install the jumper wire between the supply and return terminals on the 62-pin connector on the harness between the engine and the ECM. D. Turn the keyswitch to the ON position. Check for active diagnostic codes on the electronic service tool. Wait at least 30 seconds for activation of the diagnostic codes. Note: Diagnostic codes for all of the engine sensors will be active with the 62-pin connector disconnected. Ignore all other codes and only look for codes that relate to the suspect valve. E. Turn the keyswitch to the OFF position. F. Remove the jumper wire.	Diagnostic codes	Result: A -6 diagnostic code is active when the jumper is installed. The fault is in the supply wire or the return wire for the suspect valve between the valve and the 62-pin connector. Repair: Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: A 1076-5 diagnostic code is still active with the jumper installed. Proceed to Test Step 6. Result: A 1188-5 diagnostic code is still active with the jumper installed. Proceed to Test Step 7.
6. Create a Short Circuit at the ECM Connector A. Turn the keyswitch to the OFF position. B. Disconnect the P2 connector from the ECM. C. Fabricate a jumper wire and install the jumper wire between J2:15 and J2:60. D. Turn the keyswitch to the ON position. E. Use the electronic service tool to check for an active 1076 diagnostic code. Wait at least 30 seconds for activation of the diagnostic codes. F. Turn the keyswitch to the OFF position. G. Remove the jumper wire. H. Reconnect the connectors.	Diagnostic codes	Result: A 1076-6 diagnostic code is active with the jumper installed. The fault is in the harness between the 62-pin connector and the ECM. Repair: Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: The 1076-5 diagnostic code is still active with the jumper installed. Proceed to Test Step 12.
7. Measure the Voltage at the Wastegate Regulator Connector A. Turn the keyswitch to the OFF position. B. Disconnect the wastegate regulator. C. Turn the keyswitch to the ON position. D. Use a multimeter to measure the voltage between terminal 1 on the harness connector for the wastegate regulator and a suitable ground.	10 V to 14 V	Result: The measured voltage is not within the expected range. Repair: Check the fuse. If the fuse is blown, there is a short circuit in the switched battery supply to the wastegate regulator connector. If the fuse is not blown, there is an open circuit in the switched battery supply to the wastegate regulator connector. Repair the faulty wiring or replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: The measured voltage is within the expected range. Proceed to Test Step 8.
8. Check the Wastegate Regulator Return Wire for an Open Circuit A. Turn the keyswitch to the OFF position. B. Disconnect the wastegate regulator and the P2 connector. C. Use a suitable multimeter to measure the resistance between P2:4 and pin 27 on the 62-pin connector on the harness between the engine and the ECM.	Less than 5 Ohms	Result: The measured resistance is greater than 5 Ohms. The fault is in the wiring between terminal 27 on the 62-pin connector and P2:4. Repair: Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: The measured resistance is less than 5 Ohms. Proceed to Test Step 12.
9. Create an Open Circuit at the Solenoid A. Turn the keyswitch to the OFF position. B. Disconnect the connector for the suspect solenoid valve. C. Turn the keyswitch to the ON position. Check for active diagnostic codes on the electronic service tool. Wait at least 30 seconds for activation of the diagnostic codes. D. Turn the keyswitch to the OFF position.	Diagnostic codes	Result: A -5 diagnostic code is active with the valve disconnected. Repair: Temporarily connect a replacement for the suspect valve to the harness. Turn the keyswitch to the ON position. Use the electronic service tool in order to check for active diagnostic codes. Wait at least 30 seconds in order for the codes to be displayed. If the fault is eliminated, reconnect the suspect valve. If the fault returns, permanently install the replacement valve. Refer to Disassembly and Assembly for the correct procedure. Result: A -6 diagnostic code is still active with the valve disconnected. Proceed to Test Step 10.
10. Create an Open Circuit at the 62-Pin Connector A. Turn the keyswitch to the OFF position. B. Disconnect the 62-pin connector. C. Turn the keyswitch to the ON position. Check for active diagnostic codes on the electronic service tool. Note: Diagnostic codes for all of the engine sensors will be active with the 62-pin connector disconnected. Ignore all other codes and only look for codes that relate to the suspect valve.	Diagnostic codes	Result: A -5 diagnostic code is active with the 62-pin connector disconnected. The fault is in the wiring for the suspect valve between the valve and the 62-pin connector. Repair: Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: A -6 diagnostic code is still active with the 62-pin connector disconnected. Proceed to Test Step 11.
11. Create an Open Circuit at the ECM A. Turn the keyswitch to the OFF position. B. Disconnect the P2 connector from the ECM. C. Turn the keyswitch to the ON position. Wait at least 30 seconds for activation of the diagnostic codes. D. Use the electronic service tool to check for active diagnostic codes. Note: Diagnostic codes for all of the engine sensors will be active with the P2 connector disconnected. Ignore all other codes and only look for codes that relate to the suspect valve. E. Turn the keyswitch to the OFF position.	Diagnostic codes	Result: A -5 diagnostic code is active with the P2 connector disconnected. The fault is in the wiring between the 62-pin connector and the P2 connector. Repair: Replace the faulty wiring. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: The -6 diagnostic code is still active with the P2 connector disconnected. Proceed to Test Step 12.
12. Check if a Replacement ECM Eliminates the Fault A. Contact the Dealer Solution Network (DSN). B. If the DSN recommends the use of a replacement ECM, install a replacement ECM. Refer to Troubleshooting, "Replacing the ECM". C. Use the electronic service tool to recheck the system for active diagnostic codes.	Diagnostic codes	Result: There are no active diagnostic codes with the replacement ECM. Repair: Reconnect the suspect ECM. If the fault returns with the suspect ECM, replace the ECM. Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault. Result: The diagnostic code is still present with the replacement ECM. Contact the DSN.