C13, C15, and C18 Tier 4 Interim Engines Injector Solenoid

Injector Solenoid - Test

C13, C15, and C18 Tier 4 Interim Engines [KENR6849]

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C13, C15, and C18 Tier 4 Interim Engines Diesel Particulate Filter Temperature Is Low

ELECTRICAL AND STARTING SYSTEM

SOLENOID GP

C13, C15, and C18 Tier 4 Interim Engines Injector Solenoid - Test

C13, C15, and C18 Tier 4 Interim Engines Cooling Fan Control - Test

System Operation Description:

This procedure covers the following diagnostic trouble codes.

Note: Refer to Troubleshooting, "Cat ET Service Features" for information about service features.

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Table 1
Diagnostic Trouble Codes
CDL Code	J1939 Code	Code Description	Comments
1-2	651-2	Cylinder #1 Injector : Erratic, Intermittent, or Incorrect	The code is logged. The engine Electronic Control Module (ECM) receives a signal from the injector solenoid that is invalid. Or, the ECM receives a signal from the injector solenoid that cannot be accurately interpreted. The ECM continues to energize the injector solenoid.
1-5	651-5	Cylinder #1 Injector : Current Below Normal	The code is logged. The ECM detects an open circuit. The ECM continues the attempt to energize the solenoid circuit until the circuit is repaired.
1-6	651-6	Cylinder #1 Injector : Current Above Normal	The code is logged. The ECM detects a short circuit. The ECM will disable the solenoid circuit in order to prevent damage to the circuit. The ECM disables this solenoid circuit. The ECM will periodically attempt to energize the solenoid circuit until the circuit is repaired.
1-7	651-7	Cylinder #1 Injector : Not Responding Properly	The code is logged. The ECM has determined that the mechanical wear for the injector is out of specifications. The ECM continues to energize the injector solenoid.
2-2	652-2	Cylinder #2 Injector : Erratic, Intermittent, or Incorrect	The code is logged. The engine ECM receives a signal from the injector solenoid that is invalid. Or, the ECM receives a signal from the injector solenoid that cannot be accurately interpreted. The ECM continues to energize the injector solenoid.
2-5	652-5	Cylinder #2 Injector : Current Below Normal	The code is logged. The ECM detects an open circuit. The ECM continues the attempt to energize the solenoid circuit until the circuit is repaired.
2-6	652-6	Cylinder #2 Injector : Current Above Normal	The code is logged. The ECM detects a short circuit. The ECM will disable the solenoid circuit in order to prevent damage to the circuit. The ECM disables this solenoid circuit. The ECM will periodically attempt to energize the solenoid circuit until the circuit is repaired.
2-7	652-7	Cylinder #2 Injector : Not Responding Properly	The code is logged. The ECM has determined that the mechanical wear for the injector is out of specifications. The ECM continues to energize the injector solenoid.
3-2	653-2	Cylinder #3 Injector : Erratic, Intermittent, or Incorrect	The code is logged. The engine ECM receives a signal from the injector solenoid that is invalid. Or, the ECM receives a signal from the injector solenoid that cannot be accurately interpreted. The ECM continues to energize the injector solenoid.
3-5	653-5	Cylinder #3 Injector : Current Below Normal	The code is logged. The ECM detects an open circuit. The ECM continues the attempt to energize the solenoid circuit until the circuit is repaired.
3-6	653-6	Cylinder #3 Injector : Current Above Normal	The code is logged. The ECM detects a short circuit. The ECM will disable the solenoid circuit in order to prevent damage to the circuit. The ECM disables this solenoid circuit. The ECM will periodically attempt to energize the solenoid circuit until the circuit is repaired.
3-7	653-7	Cylinder #3 Injector : Not Responding Properly	The code is logged. The ECM has determined that the mechanical wear for the injector is out of specifications. The ECM continues to energize the injector solenoid.
4-2	654-2	Cylinder #4 Injector : Erratic, Intermittent, or Incorrect	The code is logged. The engine ECM receives a signal from the injector solenoid that is invalid. Or, the ECM receives a signal from the injector solenoid that cannot be accurately interpreted. The ECM continues to energize the injector solenoid.
4-5	654-5	Cylinder #4 Injector : Current Below Normal	The code is logged. The ECM detects an open circuit. The ECM continues the attempt to energize the solenoid circuit until the circuit is repaired.
4-6	654-6	Cylinder #4 Injector : Current Above Normal	The code is logged. The ECM detects a short circuit. The ECM will disable the solenoid circuit in order to prevent damage to the circuit. The ECM disables this solenoid circuit. The ECM will periodically attempt to energize the solenoid circuit until the circuit is repaired.
4-7	654-7	Cylinder #4 Injector : Not Responding Properly	The code is logged. The ECM has determined that the mechanical wear for the injector is out of specifications. The ECM continues to energize the injector solenoid.
5-2	655-2	Cylinder #5 Injector : Erratic, Intermittent, or Incorrect	The code is logged. The engine ECM receives a signal from the injector solenoid that is invalid. Or, the ECM receives a signal from the injector solenoid that cannot be accurately interpreted. The ECM continues to energize the injector solenoid.
5-5	655-5	Cylinder #5 Injector : Current Below Normal	The code is logged. The ECM detects an open circuit. The ECM continues the attempt to energize the solenoid circuit until the circuit is repaired.
5-6	655-6	Cylinder #5 Injector : Current Above Normal	The code is logged. The ECM detects a short circuit. The ECM will disable the solenoid circuit in order to prevent damage to the circuit. The ECM disables this solenoid circuit. The ECM will periodically attempt to energize the solenoid circuit until the circuit is repaired.
5-7	655-7	Cylinder #5 Injector : Not Responding Properly	The code is logged. The ECM has determined that the mechanical wear for the injector is out of specifications. The ECM continues to energize the injector solenoid.
6-2	656-2	Cylinder #6 Injector : Erratic, Intermittent, or Incorrect	The code is logged. The engine ECM receives a signal from the injector solenoid that is invalid. Or, the ECM receives a signal from the injector solenoid that cannot be accurately interpreted. The ECM continues to energize the injector solenoid.
6-5	656-5	Cylinder #6 Injector : Current Below Normal	The code is logged. The ECM detects an open circuit. The ECM continues the attempt to energize the solenoid circuit until the circuit is repaired.
6-6	656-6	Cylinder #6 Injector : Current Above Normal	The code is logged. The ECM detects a short circuit. The ECM will disable the solenoid circuit in order to prevent damage to the circuit. The ECM disables this solenoid circuit. The ECM will periodically attempt to energize the solenoid circuit until the circuit is repaired.
6-7	656-7	Cylinder #6 Injector : Not Responding Properly	The code is logged. The ECM has determined that the mechanical wear for the injector is out of specifications. The ECM continues to energize the injector solenoid.

Background Information

Perform this procedure when the engine is at normal operating temperature. Pay careful attention to the condition of the wiring and the connectors as you perform this procedure. The wiring and/or the connectors may have problems that only occur during vibration.

Each injector for the common rail fuel system contains a solenoid. The ECM sends 105 V pulses to each injector solenoid. The pulses are sent at the proper time and at the correct duration for a given engine load and speed.

Cooling of the Injector Solenoids

Each injector solenoid is cooled by a stream of fuel.

Trim Files

When an injector is replaced, program the new injector code into the ECM. Refer to Troubleshooting, "Injector Trim File - Install" for information that is related to trim files. If the ECM is replaced, all of the injector codes must be programmed into the new ECM. Refer to Troubleshooting, "ECM - Configure" for information that is related to the configuration of a new ECM.

Diagnostic Tests on the AVSpare Electronic Technician (ET)

Cat ET includes the following test that aids in troubleshooting injector solenoids:

Injector Solenoid Test - This test identifies an open circuit or a short circuit in the circuits for the injector solenoids. The test is performed while the engine is not running. The "Injector Solenoid Test" briefly activates each solenoid. A good solenoid will create an audible click when the solenoid is activated. Cat ET indicates the status of the solenoid as "OK", "Open", or "Short".

Fuel System Verification Test - This test evaluates the health of each injector. This test will determine if an injector needs to be replaced. When the test is performed, Cat ET indicates the status of each injector as "Success" or "Failed". Perform the test immediately after replacing an injector. Also, perform this test if a -2 code or a -7 code is active.

Note: The "Fuel System Verification Test" must be performed when the engine is running and the coolant temperature is above 65° C (149° F).

Note: Refer to the following schematic. Two injector solenoids share a common supply wire. For this reason, an open circuit or a short circuit in a supply wire could cause diagnostic codes for two cylinders.

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Illustration 1	g01951596
Schematic for the injector solenoids on C9.3 engines

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Illustration 2	g02077734
Terminal locations at the P2 ECM connector (P2-99) Injector 5 & 6 supply (P2-104) Injector 1 & 2 supply (P2-105) Injector 6 return (P2-106) Injector 3 return (P2-107) Injector 5 return (P2-108) Injector 4 return (P2-115) Injector 3 & 4 supply (P2-116) Injector 1 return (P2-118) Injector 2 return

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Table 2
Troubleshooting Test Steps	Values	Results
1. Determine the Diagnostic Code A. Establish communication between Cat^® ET and the engine ECM. Refer to Troubleshooting, "Electronic Service Tools", if necessary. B. Download the "Warranty Report" from the engine ECM before performing any troubleshooting or clearing diagnostic trouble codes. C. Determine the diagnostic trouble code that relates to an injector.	Diagnostic Code	Result: A logged -5 code or a logged -6 code is present. Proceed to Test Step 3. Result: An active -5 code is present. Proceed to Test Step 4. Result: An active -6 code is present. Proceed to Test Step 5. Result: A -2 code or a -7 code is present. Proceed to Test Step 2.
2. Perform the "Fuel System Verification Test" Note: Do not clear the diagnostic trouble code. A. Perform the Fuel System Verification Test. Cat ET will clear the code when the test begins. If the injector passes the test, the injector is OK. If the injector fails the test, the injector is NOT OK.	Fuel System Verification Test	Result: The injector passes the test. STOP Result: The injector does not pass the test. Repair: Perform the following steps: 1. Replace the injector. 2. Flash program the injector trim file into the ECM. Refer to Troubleshooting, "Injector Trim File - Install", if necessary. 3. Perform the "Fuel System Verification Test". This test will clear the active diagnostic code for the new injector. 4. If the problem has been corrected, return the unit to service. 5. Troubleshoot any active codes. If a -5 injector code is present, proceed to Test Step 4. If a -6 injector code is present, proceed to Test Step 5
3. Check the Integrity of the External Engine Harness A. Inspect the injector wiring harness between the ECM and the valve cover. Look for these problems: · Improper routing of the wire harness · Missing clamps or other hardware · Loose connectors or damaged connectors · Damage that is caused by excessive heat · Damage that is caused by chafing B. Slowly wiggle the external wiring harness and the connectors. Pay particular attention to the wiring near each connector. Look for a logged code to become active as you wiggle the wiring.	Fuel System Verification Test	Result: The external engine harness is OK. A logged code does not become active. Proceed to Test Step 6. Result: A problem with the external engine harness has been identified. Repair: Stop the engine. Repair the wiring problem. Replace parts, if necessary. Start the engine. Verify that the problem is resolved.
4. Check the External Engine Harness for an Open Circuit A. Turn the keyswitch to the OFF position. A strong electrical shock hazard is present if the keyswitch is not turned off. B. Disconnect the harness connectors for the affected cylinder at the cylinder head. C. Fabricate a jumper wire to short circuit the different terminal locations at the connector for the injector harness at the valve cover. Crimp connector pins on both ends of the jumper wire. D. Connect the jumper wire between terminal locations 1 (supply) and 2 (return). This connection will effectively create a short circuit for the cylinder. E. Turn the keyswitch to the ON position. F. Perform the "Injector Solenoid Test" at least two times. G. Monitor the screens on Cat ET. H. Repeat this test for each suspect circuit. Stop the "Injector Solenoid Test" before handling the jumper wire. Restore the wiring to the original configuration.	Fuel System Verification Test	Result: "Short" is displayed for the cylinder with the jumper wire. The external engine harness is OK. Remove the jumper wire. Connect the harness connectors. Proceed to Test Step 6. Result: "Open" is displayed for the cylinder with the jumper wire. The ECM did not detect the jumper wire. There is an open circuit in the external engine harness. Repair: Repair the problem with the harness. Replace parts, if necessary. Start the engine. Verify that the problem is resolved.
5. Check the External Engine Harness for a Short Circuit A. Turn the keyswitch to the OFF position. A strong electrical shock hazard is present if the keyswitch is not turned off. B. Disconnect the connector at the valve cover. C. Turn the keyswitch to the ON position. D. Perform the "Injector Solenoid Test" at least two times. E. Turn the keyswitch to the ON position. F. Perform the "Injector Solenoid Test" at least two times. G. Monitor the screens on Cat ET.	Short Circuit	Result: All cylinders indicate "Open". The external engine harness does not have a short circuit. Proceed to Test Step 6. Result: One or more cylinders indicate "Short". Note the cylinders that indicate "Short". Repair: Repair the problem with the harness. Replace parts, if necessary. Start the engine. Verify that the problem is resolved.
6. Check the Injector Harness Under the Valve Cover for an Open Circuit or for a Short Circuit A. Turn the keyswitch to the OFF position. A strong electrical shock hazard is present if the keyswitch is not turned off. B. Remove the valve cover in order to gain access to the suspect injector. C. Disconnect the harness connector from the suspect injector. D. Thoroughly clean the terminals on the injector solenoid and on the harness connector. E. Use a jumper wire to short circuit the connector terminals for the suspect injector. This connection will effectively replace the injector solenoid with a short circuit. F. Turn the keyswitch to the ON position. G. Perform the "Injector Solenoid Test" at least two times. Note: The injector solenoid that shares the supply wire of the injector that is short circuited may indicate a false test result. Disregard this test result. Turn the keyswitch to the OFF position. Remove the jumper wire from the injector connector. Removing the jumper will effectively replace the injector solenoid with an open circuit. Turn the keyswitch to the ON position. Perform the "Injector Solenoid Test" at least two times. Monitor the screens on Cat ET. Turn the keyswitch to the OFF position.	Open or Short Circuit	Result: "Short" is displayed for the cylinder with the jumper wire and "Open" when the jumper wire is removed. The harness wiring is OK. Repair: Perform the following procedure: 1. Replace the suspect injector. 2. Program the injector trim file into the ECM. Refer to Troubleshooting, "Injector Trim File - Install", if necessary. 3. Perform the "Fuel System Verification Test". This test will clear the active diagnostic code for the new injector. 4. Return the unit to service. Result: O"Short" is not displayed for the cylinder with the jumper wire and "Open" is not displayed when the jumper wire is removed. There is a problem with the injector harness under the valve cover. There may be a problem with a connector. Repair: Repair the problem with the harness. Replace parts, if necessary. Start the engine. Verify that the problem is resolved.

Test Step 1.

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Electrical shock hazard. The injector for the common rail fuel system uses 90-120 volts.

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Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.

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NOTICE

Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training. Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information. Refer to Systems Operation, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.

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Electrical shock hazard. The injector for the common rail fuel system uses 90-120 volts.

Results:

The procedure corrected the issue. - STOP
The procedure did not correct the issue. -
Repair: Contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the Dealer Solutions Network (DSN).
STOP