PDF Diagnostics Manual MAXXFORCE 7 Engine - 713 KB
Effectively troubleshoot and diagnose issues with the MAXXFORCE 7 engine using this electronic control systems diagnostics manual.
This guide is specifically designed for technicians, providing detailed fault code charts, wiring diagrams, and testing procedures.
It is an indispensable tool for accurately identifying and resolving electronic and sensor-related problems.
Reduce diagnostic time and ensure accurate repairs with this specialized manual.
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--- Page 1 ---
7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 151
Table of Contents
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Section Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Electronic Control System Diagnostics Form. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
EGED-365 Diagnostic Form Example. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
Diagnostic Procedure Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
Diagnostics with Electronic Service Tool (EST). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
Diagnostics without Electronic Service Tool (EST). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
Sensor End Diagnostics (with MasterDiagnostics®). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Sensor End Diagnostics (2-Wire). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Sensor End Diagnostics (3-Wire). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
Pin-point Diagnostics (without MasterDiagnostics®). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
Actuator Operational Voltage Check - Output State Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
Harness Resistance Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
Operational Voltage Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
Circuit Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
AFT System (Aftertreatment). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
AFT System Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
AFT System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
AMS (Air Management System). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
AMS Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
APS/IVS (Accelerator Position Sensor and Idle Validation Switch). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
APS/IVS Sensor End Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
APS/IVS Pin-point Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
APS/IVS Circuit Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188
ATA Data Link (American Trucking Association). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
ATA Pin-point Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
ATA Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
Brake Switch Circuits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
Brake Switch Circuits Pin-point Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
Brake Switch Circuit Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
CAN Communications (Controller Area Network). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
CAN (Public) Pin-point Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
CAN (Public) Circuit Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
CCS (Cruise Control System). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
Cruise Control System Pin-point Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
CKP Sensor (Crankshaft Position). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
CKP Pin-point Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202
CKP Circuit Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
CMP Sensor (Camshaft Position). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
CMP Pin-point Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205
CMP Circuit Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207
Cylinder Balance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208
EGES-350-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© May 2009 Navistar, Inc.
--- Page 3 ---
7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 161
Sensor End Diagnostics (3-Wire) 5. Monitor the sensor voltage and verify an active
Diagnostic Trouble Code (DTC) is present.
1. Connect the Electronic Service Tool (EST) to the
EST connector. NOTE: If sensor signal circuit is shorted or open,
the Parameter Identifier (PID) value reads NA or
2. Turn the ignition switch to ON. Leave engine off.
Error.
3. Start MasterDiagnostics® software.
• If the DTC is inactive, monitor the PID
4. Run Continuous Monitor session. (This session while wiggling the connector and all wires
lists all engine sensors.) at suspected locations.
If the circuit is interrupted, the signal spikes.
Isolate the fault and repair.
• If the DTC is active, continue to the next step.
6. Disconnect the sensor. Inspect the connector for
damaged pins. Repair as necessary.
Figure 132 Sensor voltage
EGES-350-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© May 2009 Navistar, Inc.
--- Page 4 ---
7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 171
Alert Levels of DPF Soot Loading
There are four levels indicating the DPF is accumulating a level of soot and needs to be cleaned, each
with an increasing urgency for action.
Levels Conditions Action
Regeneration lamp on solid Exhaust regeneration required Drive on highway at highway
speeds so the system
can auto-regenerate.
OR
Start a parked regeneration to
prevent loss of power.
Regeneration lamp flashing DPF is full Pull vehicle safely off roadway
and start a parked regeneration to
prevent loss of power.
Regeneration lamp flashing DPF is full Pull vehicle safely off roadway
WEL solid engine performance is limited and start a parked regeneration to
Audio alarm beeps five prevent engine stopping.
times every minute
Regeneration lamp flashing DPF is overfull Pull vehicle safely off roadway
Engine STOP lamp on solid engine may shutdown soon turn on flashers, place warning
Audio alarm beeps continuously devices and stop engine, do not
use parked regeneration. Call for
service.
When the High Exhaust System Temperature lamp is illuminated, the exhaust is above 400° C (750° F)
and a regeneration could be in process.
EGES-350-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© May 2009 Navistar, Inc.
--- Page 5 ---
7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 181
DTC 3348 - AMT - EBP too high during EGR test
DTC sets when EBP does not meet expected response during the EGR portion of the AMS test.
Pin-point AMS Fault
1. Check for other active or inactive EBP, MAP, VGT, or EGR DTCs. Repair any fault before continuing
with this procedure.
2. Check for biased sensor. Verify BAP, MAP and EBP are within KOEO specification. See Key-On
Engine-Off for the applicable engine horsepower in “Performance Specifications” section of this
manual.
3. Check EGR operation. Monitor EGRP PID, Run KOEO Output State HIGH and LOW. See EGR
Actuator (page 258) in this section.
4. Check intake and exhaust system for leaks.
AMS Operation NOTE: Although commanding the EGR to close, it
may be stuck partially open and cause EBP values
The AMS test checks the operation of the VGT and
to be lower than expected. This would cause the
EGR by actuating each component open and closed
VGT portion of the test to fail. If this is suspected,
while monitoring the effect it has on exhaust back
the operation of the EGR valve should be visually
pressure using the EBP sensor. The test sequence
inspected while doing the Output State tests.
is carried out as follows.
If the VGT portion of the test completes without fault,
The ECM monitors the BAP sensor as a baseline for
no DTC sets, and the test continues for the EGR
zeroing the MAP and EBP signals.
portion.
VGT portion
EGR portion
The ECM commands the EGR valve to close, then
The EGR valve and VGT vanes are still closed,
increases engine idle speed to 950 rpm. The VGT
the ECM increases engine idle speed to 1200 rpm
vanes are commanded to open and EBP is allowed
and EBP is allowed to stabilize (EBP is expected to
to stabilize (EBP is expected to drop). The VGT
increase). The EGR is then commanded open and
vanes are then commanded to close and EBP is
EBP is allowed to stabilize (EBP is expected to drop).
allowed to stabilize (EBP is expected to increase). If
The EGR is then commanded closed and EBP is
pressure results do not match expected values for
allowed to stabilize (EBP is expected to increase). If
either condition, DTC 3345 sets, the engine returns
pressure results do not match expected values for
to 700 rpm, and the test completes without running
either position, DTC 3346 sets, the engine returns to
the EGR portion.
700 rpm, and the test is complete.
EGES-350-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© May 2009 Navistar, Inc.
--- Page 6 ---
7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 191
ATA Operation • Speedometer
• Tachometer
EST Connector
• Odometer/hourmeter
The fuse protected B+ signal is supplied to the EST
connector through Pin B and ground is through Pin • Change oil message
A. American Trucking Association High (ATAH) signal
• Oil pressure gauge
runs from ECM Pin C-25 and EST connector Pin F.
American Trucking Association Low (ATAL) signal • Engine oil temperature gauge
runs from ECM Pin C-10 and EST connector Pin G.
• Engine coolant temperature gauge
Electronic Gauge Cluster (EGC)
Fault Detection/Management
There are two types of EGC modules, one uses
There are no engine DTCs for ATA communication
Controller Area Network (CAN) communication and
faults. See Chassis Electrical Circuit Diagram Manual
the other uses ATA communication. The following
and Electrical System Troubleshooting Guide.
information is sent through data communication:
• Warn Engine Lamp (WEL) Repair Information
• Malfunction Indicator Lamp (MIL) The ATA circuits use a twisted wire pair. All repairs
must maintain one complete twist per inch along the
• Coolant level lamp
entire length of the circuit. This circuit is polarized,
• Wait to start lamp one positive and one negative. Reversing the polarity
of this circuit will disrupt communication.
• Oil/Water Lamp (OWL)
EGES-350-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© May 2009 Navistar, Inc.
--- Page 7 ---
7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 201
CKP Sensor (Crankshaft Position)
DTC SPN FMI Condition
1144 8021 8 CKP signal noise detected
1146 8064 12 CKP signal inactive
1147 8064 2 CKP incorrect signal signature
4553 8022 12 CKP signal inactive
4554 8022 7 CKP loss of sync
4555 8064 8 CKP signal noise detected
4556 8022 8 CKP period too short
4611 8021 13 CKP signature one tooth off
Figure 145 Function diagram for the CKP sensor
The CKP sensor function diagram includes the Sensor Location
following:
The CKP sensor is installed in the lower front right side
• Crankshaft Position (CKP) sensor of the crankcase.
• Electronic Control Module (ECM) Tools
• Fuel injectors (INJ) • Electronic Service Tool (EST) with
MasterDiagnostics® software
• Warn Engine Lamp (WEL)
• EZ-Tech® Interface Kit
Function
• Digital Multimeter (DMM)
The CKP sensor provides the ECM with a crankshaft
• 180-Pin Breakout Box
speed and position signals. The ECM uses this signal
with the Camshaft Position (CMP) signal to calculate • Terminal Test Adapter Kit
crankshaft speed and position.
EGES-350-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© May 2009 Navistar, Inc.
--- Page 8 ---
7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 211
EBP Sensor (Exhaust Back Pressure)
DTC SPN FMI Condition
3341 1209 4 EBP signal out-of-range LOW
3342 1209 3 EBP signal out-of-range HIGH
Figure 151 Function diagram for the EBP sensor
The EBP sensor function diagram includes the Sensor Location
following:
The EBP sensor is installed in a bracket mounted
• Exhaust Back Pressure (EBP) sensor above and behind the right valve cover.
• Electronic Control Module (ECM) with integrated Tools
Barometric Absolute Pressure (BAP) sensor
• Electronic Service Tool (EST) with
• Variable Geometry Turbocharger (VGT) MasterDiagnostics® software
• Exhaust Gas Recirculation (EGR) valve • EZ-Tech® Interface Kit
• Malfunction Indicator Lamp (MIL) • Digital Multimeter (DMM)
• 3-Banana Plug Harness
Function
• 180-Pin Breakout Box
The EBP sensor measures exhaust back pressure.
The ECM uses the EBP signals to control the VGT • Pressure Sensor Breakout Harness
and EGR systems.
• Terminal Test Adapter Kit
EGES-350-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© May 2009 Navistar, Inc.
--- Page 9 ---
7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 221
ECL Pin-point Diagnostics
DTC Condition Possible Causes
1236 ECL in-range circuit fault • ECL circuit OPEN or short to GND or PWR
• Failed switch
Figure 157 ECL circuit diagram
Connector Voltage Check
Disconnect ECL switch. Turn ignition switch to ON. Use DMM to measure voltage.
Test Point Spec Comment
A to GND 0V If > 0.25 V, check for short to PWR.
B to GND 4.6 V to 5 V If < 4.5 V, check for OPEN or short to GND. Do Harness Resistance Check
(page 222).
Connector Resistance Check to GND
Turn ignition switch to OFF. Connect breakout harness. Leave switch disconnected. Use DMM to measure
resistance.
Test Point Spec Comment
A to GND <5Ω If > 5 Ω, check for OPEN circuit.
B to GND > 1 kΩ If < 1 kΩ, check for short to GND.
EGES-350-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© May 2009 Navistar, Inc.
--- Page 10 ---
7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 231
DTC 4519 - Fuel Injector Driver Circuit Performance Bank B
Pin-point ECM Self-Diagnostic Fault
1. Clear DTC, cycle ignition switch.
2. If DTC is still active, replace ECM.
DTC 5382 - ECM over temperature
Pin-point ECM Self-Diagnostic Fault
1. Correct any abnormal condition of ECM overheating.
2. If DTC sets in cool conditions, then replace ECM.
DTC 5618 - SPI-BUS error 1
Pin-point ECM Self-Diagnostic Fault
1. Clear DTC, cycle ignition switch.
2. If DTC is still active, replace ECM.
DTC 5619 - SPI-BUS error 2
Pin-point ECM Self-Diagnostic Fault
1. Clear DTC, cycle ignition switch.
2. If DTC is still active, replace ECM.
DTC 5627 - Checksum program
Pin-point ECM Self-Diagnostic Fault
1. Clear DTC, cycle ignition switch.
2. If DTC is still active, replace ECM.
DTC 5628 - Checksum dataset
Pin-point ECM Self-Diagnostic Fault
1. Clear DTC, cycle ignition switch.
2. If DTC is still active, replace ECM.
DTC 5633 - CPU Load above maximum
Pin-point ECM Self-Diagnostic Fault
1. Clear DTC, cycle ignition switch.
2. If DTC is still active, replace ECM.
EGES-350-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© May 2009 Navistar, Inc.
--- Page 11 ---
7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 241
Voltage Check at Relay - Output State Test
Connect breakout harness between relay and relay socket. Connect EFAN and turn the ignition switch
to ON. Use DMM to measure voltage.
Test Point Spec Comment
30 to GND B+ If < B+, check power circuit to relay switch for OPEN or short to GND, or
blown fuse.
86 to GND B+ If < B+, check power circuit to relay coil for OPEN or short to GND, or
blown fuse.
Run Output State Test HIGH.
85 to GND B+ If < B+, check EFAN control circuit for short to GND. Do Harness Resistance
Check (page 241).
Run Output State Test LOW.
85 to GND 0.06 V to 2 V If > 2 V, check EFAN control circuit for OPEN. Do Harness Resistance
Check (page 241).
87 to GND B+ If < B+, replace relay.
Harness Resistance Check
Turn ignition switch to OFF. Connect breakout box and relay harness. Leave ECM and relay disconnected.
Test Point Spec Comment
C-58 to 85 <5Ω If > 5 Ω, check for OPEN circuit between ECM and relay terminal.
87 to A (fan) <5Ω If > 5 Ω, check for OPEN circuit between relay terminal and A (fan).
30 to C-1, 3 <5Ω If > 5 Ω, check ACT PWR for OPEN in circuit.
and 5
30 to GND > 1 kΩ If < 1 kΩ, check ACT PWR for short to GND.
86 to C-1, 3 <5Ω If > 5 Ω, check ACT PWR for OPEN in circuit.
and 5
86 to GND > 1 kΩ If < 1 kΩ, check ACT PWR for short to GND.
See truck Chassis Electrical Circuit Diagram Manual and Electrical System Troubleshooting Guide for
fuse information.
EFAN Circuit Operation 85. ACT PWR powers the other side of the relay coil,
Pin 86. ACT PWR is sent through the relay switch,
The default state of the EFAN is ON. B+ is needed to
which deactivates the EFAN.
turn the fan off.
ECM Pin C-58 controls the EFAN to shut off by
supplying a ground path to the EFAN relay coil Pin
EGES-350-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© May 2009 Navistar, Inc.
--- Page 12 ---
7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 251
EFT Pin-point Diagnostics
Figure 171 EFT circuit diagram
Connector Voltage Check
Connect breakout harness. Leave sensor disconnected. Turn ignition switch to ON. Use DMM to measure
voltage.
Test Point Spec Comment
1 to GND 0V If > 0.25 V, check for short to PWR.
2 to GND 4.6 V to 5 V If < 4.5 V, check for OPEN or short to GND. Do Harness Resistance Check
(page 251).
Connector Resistance Check to GND
Turn ignition switch to OFF. Connect breakout harness. Leave sensor disconnected. Use DMM to measure
resistance.
Test Point Spec Comment
1 to GND <5Ω If > 5 Ω, check for OPEN circuit.
2 to GND > 1 kΩ If < 1 kΩ, check for short to GND.
Harness Resistance Check
Turn ignition switch to OFF. Connect breakout box and breakout harness. Leave ECM and sensor
disconnected. Use DMM to measure resistance.
Test Point Spec Comment
1 to E-28 <5Ω If > 5 Ω, check for OPEN circuit.
2 to E-17 <5Ω If > 5 Ω, check for OPEN circuit.
EGES-350-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© May 2009 Navistar, Inc.
--- Page 14 ---
7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 261
3. Monitor sensor voltage. Verify an active 4. Disconnect engine harness from sensor.
Diagnostic Trouble Code (DTC) for the sensor.
NOTE: Inspect connectors for damaged pins,
• If DTC is inactive, monitor the Parameter corrosion, or loose pins. Repair if necessary.
Identifier (PID) while wiggling the connector
5. Connect breakout harness to engine harness.
and all wires at suspected location. If the
Leave sensor disconnected.
circuit is interrupted, the PID spikes and the
DTC goes active.
• If DTC is active, proceed to the next step.
EGES-350-2
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© May 2009 Navistar, Inc.
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7 ELECTRONIC CONTROL SYSTEMS DIAGNOSTICS 271
Tools
• Electronic Service Tool (EST) with
MasterDiagnostics® software
• EZ-Tech® Interface Kit
• Digital Multimeter (DMM)
• 3-Banana Plug Harness
• 180-Pin Breakout Box
• Exhaust Temperature Breakout Harness
• Terminal Test Adapter Kit
EGT2 Sensor End Diagnostics
DTC Condition Possible Causes
1741 EGT2 signal out-of-range LOW • EGT2 signal circuit short to GND
• Failed sensor
1742 EGT2 signal out-of-range HIGH • EGT2 signal OPEN or short to PWR