C4.4 and C6.6 Engines Caterpillar


Sensor Signal (Analog, Passive) - Test

Usage:

C4.4 448
This procedure covers the following diagnostic codes:

Table 1
Diagnostic Trouble Codes for Analog Passive Sensors 
J1939 Code  CDL Code  Code Description
(code descriptions may vary) 
Comments 
105-3  172-3  Engine Intake Manifold #1 Temperature : Voltage Above Normal  The Electronic Control Module (ECM) detects the following conditions:

The signal voltage from the intake manifold air temperature sensor is greater than 4.95 VDC for more than 8 seconds.

Engine coolant temperature is above −10 °C (15.0 °F).

The ECM will use the default value of 70 °C (158 °F) for the intake manifold air temperature. "Voltage High" will be displayed next to the status for "Intake Manifold Air Temperature" on the electronic service tool.
The engine may show the following symptoms:
Poor stability
Poor cold running
Poor acceleration under load
White smoke 
105-4  172-4  Engine Intake Manifold #1 Temperature : Voltage Below Normal  The ECM detects the following conditions:

The signal voltage from the intake manifold air temperature sensor is less than 0.2 VDC for more than 8 seconds.

The ECM will use the default value of 70 °C (158°F) for the intake manifold air temperature. "Voltage Low" will be displayed next to the status for "Intake Manifold Air Temperature" on the electronic service tool.
The engine may show the following symptoms:
Poor stability
Poor cold running
Poor acceleration under load
White smoke 
110-3  110-3  Engine Coolant Temperature : Voltage Above Normal  The ECM detects the following conditions:

The signal voltage from the engine coolant temperature sensor is greater than 4.95 VDC for more than 8 seconds.
An active diagnostic code will be generated after 8 seconds.
The ECM will default to 90 °C (194 °F) for engine coolant temperature. "Voltage Above Normal" will be displayed next to the status for "Engine Coolant Temperature" on the electronic service tool.
The engine may show the following symptoms:
Poor stability
Poor cold running
White smoke 
110-4  110-4  Engine Coolant Temperature : Voltage Below Normal  The ECM detects the following conditions:

The signal voltage from the engine coolant temperature sensor is less than 0.2 VDC for more than 8 seconds.

An active diagnostic code will be generated after 8 seconds. The diagnostic code will be logged if the engine has been operating for more than 7 minutes.
The ECM will default to 90 °C (194 °F) for engine coolant temperature. "Voltage Below Normal" will be displayed next to the status for "Engine Coolant Temperature" on the electronic service tool.
The engine may show the following symptoms:
Poor stability
Poor cold running
White smoke 
172-3  2526-3  Engine Air Inlet Temperature : Voltage Above Normal  The ECM detects the following conditions:

The signal voltage from the air inlet temperature sensor is greater than 4.95 VDC for at least 8 seconds. 
172-4  2526-4  Engine Air Inlet Temperature : Voltage Below Normal  The ECM detects the following conditions:

The signal voltage from the air inlet temperature sensor is less than 0.2 VDC for at least 8 seconds. 
174-3  174-3  Engine Fuel Temperature 1 : Voltage Above Normal  The ECM detects the following conditions:

The signal voltage from the fuel temperature sensor is greater than 4.95 VDC for more than 8 seconds.

The ECM will default to 40° C (104° F) for fuel temperature. "Voltage Above Normal" will be displayed next to the status for "Engine Fuel Temperature" on the electronic service tool. 
174-4  174-4  Engine Fuel Temperature 1 : Voltage Below Normal  The ECM detects the following conditions:

The signal voltage from the fuel temperature sensor is less than 0.2 VDC for more than 8 seconds.

The ECM will default to 40° C (104° F) for fuel temperature. "Voltage Below Normal" will be displayed next to the status for "Engine Fuel Temperature" on the electronic service tool. 
412-3  3386-3  Engine Exhaust Gas Recirculation Temperature : Voltage Above Normal  The ECM detects the following conditions:

The signal voltage from the Nox Reduction System (NRS) temperature sensor is greater than 4.975 VDC for more than 8 seconds. 
412-4  3386-4  Engine Exhaust Gas Recirculation Temperature : Voltage Below Normal  The ECM detects the following conditions:

The signal voltage from the NRS temperature sensor is less than 0.2 VDC for more than 8 seconds. 
441-3  1836-3  Auxiliary Temperature #1 : Voltage Above Normal  The ECM detects the following conditions:

The signal voltage from the auxiliary temperature sensor is greater than 4.95 VDC for more than 8 seconds.

An active diagnostic code will be generated after 8 seconds. The diagnostic code will be logged if the engine has been operating for more than 7 minutes.
"Voltage Above Normal" will be displayed next to the status for "Auxiliary Temperature" on the electronic service tool. 
441-4  1836-4  Auxiliary Temperature #1 : Voltage Below Normal  The ECM detects the following conditions:

The signal voltage from the auxiliary temperature sensor is less than 0.2 VDC for more than 8 seconds.

An active diagnostic code will be generated after 8 seconds. The diagnostic code will be logged if the engine has been operating for more than 7 minutes.
"Voltage Below Normal" will be displayed next to the status for "Auxiliary Temperature" on the electronic service tool. 
2630-3  3372-3  Engine Charge Air Cooler Outlet Temperature : Voltage Above Normal  The ECM detects the following conditions:

The signal voltage from the ATAAC outlet temperature sensor is greater than 4.95 VDC for more than 8 seconds.
 
2630-4  3372-4  Engine Charge Air Cooler Outlet Temperature : Voltage Below Normal  The ECM detects the following conditions:

The signal voltage from the ATAAC outlet temperature sensor is less than 0.2 VDC for more than 8 seconds.
 
Follow the troubleshooting procedure to identify the root cause of the fault. 

Note: The following conditions must exist before any of the above codes will become active:

  • The ECM has been powered for at least 2 seconds.

  • There are no active 168-X diagnostic codes.

The ECM will log the diagnostic code. If equipped, the warning light will come on.

This procedure covers open circuit diagnostic codes and short circuit diagnostic codes that are associated with the following sensors that are connected to the ECM:

  • Coolant temperature sensor

  • Intake manifold air temperature sensor

  • Fuel temperature sensor

  • Air inlet temperature sensor

  • Auxiliary temperature sensor (if equipped)

  • NRS inlet temperature sensor

The following background information is related to this procedure:

The troubleshooting procedures for the diagnostic codes of each temperature sensor are identical. The temperature sensors have two terminals. The signal line is connected to each sensor connector terminal 1. Terminal 2 is the return line. The signal voltage from terminal 1 of each sensor is supplied to the appropriate terminal in the ECM.

Pull-up Voltage

The ECM continuously outputs a pull-up voltage on the circuit for the sensor signal wire. The ECM uses this pull-up voltage to detect an open in the signal circuit. When the ECM detects a voltage above a threshold on a signal circuit, an open circuit diagnostic code (XXX-3) is communicated to the engine ECM.

If the sensor is disconnected, pull-up voltage at the connector indicates that the wires are not open or shorted to ground. If the sensor is disconnected, the absence of pull-up voltage indicates an open in the signal wire or a short to ground. If the sensor is disconnected and the voltage is different from pull-up voltage, the signal wire is shorted to another wire in the harness.



Illustration 1g06272953
Schematic for passive engine temperature sensors on the P1 connector
Not all connectors are shown. Refer to the appropriate Electrical Schematic.


Illustration 2g06114240
Schematic for passive engine temperature sensors on the P2 connector


Illustration 3g01170313
Typical view of an engine temperature sensor
(1) Signal
(2) Ground

Table 2
Troubleshooting Test Steps  Values  Results 

1. Check for Diagnostic Trouble Codes

A. Connect to the electronic service tool.

B. Turn the keyswitch to the ON position.

C. Access the "Active Diagnostic Code" screen on the electronic service tool.

Wait at least 30 seconds in order for the diagnostic codes to become active.

D. Look for one of the diagnostic codes that are listed in Table 1.
 

Codes 

Result: A -3 diagnostic code is active.

Proceed to Test Step 2.

Result: A -4 diagnostic code is active.

Proceed to Test Step 3.

Result: For a diagnostic code that is logged but not currently active, Proceed to Test Step 4.
 

2. Create a Short at the Sensor Connector

A. Turn the keyswitch to the OFF position.

B. Disconnect the suspect sensor.

C. Install the jumper wire between terminal 1 (sensor signal) and terminal 2 (sensor return) at the sensor connector.

D. Turn the keyswitch to the ON position.

E. Monitor the diagnostic codes on the electronic service tool. Check for an active -4 diagnostic code for the suspect sensor.

Wait at least 30 seconds in order for the diagnostic codes to become active.

F. Turn the keyswitch to the OFF position.
 

Short Circuit Recognized 

Result: The -3 diagnostic code remains active for the suspect sensor.

Repair: There is an open in the harness. Repair the wiring or replace the harness.

Verify that the problem is resolved.

Result: A -4 diagnostic code became active after creating the short at the sensor connector.

Repair: The wiring is OK. Replace the sensor.

Verify that the problem is resolved.
 

3. Create an Open at the Suspect Sensor Connector

A. Turn the keyswitch to the OFF position.

B. Disconnect the sensor connector of the suspect sensor with the active -4 or -20 diagnostic code.

C. Turn the keyswitch to the ON position.

D. Monitor the diagnostic codes on the electronic service tool. Check for an active -3 diagnostic code for the suspect sensor.

Wait at least 30 seconds in order for the diagnostic codes to become active.
· For a 110-3 code, start the engine and let the engine idle for 7 minutes. The engine must be running for at least 7 minutes in order for the diagnostic to run.

E. Turn the keyswitch to the OFF position.
 

Open Circuit Recognized 

Result: The -4 or -20 diagnostic code remains active for the suspect sensor.

Repair: There is an open in the harness. Repair the wiring or replace the harness.

Verify that the problem is resolved.

Result: A -3 diagnostic code became active after disconnecting the sensor.

Repair: The wiring is OK. Replace the sensor.

Verify that the problem is resolved.
 

4. Perform the Wiggle Test

Carefully following this procedure is the best way to identify the root cause of an intermittent problem.

A. Turn the keyswitch to the ON position.

B. Use the electronic service tool to run the "Wiggle Test".

C. Slowly wiggle the wiring and the connectors between the P2 connector and the sensor. Slowly wiggle the wiring and the connectors between the P1 connector and the sensor. Pay particular attention to the wiring near each connector. Be sure to wiggle all the wiring.

D. As you wiggle the wiring look for these problems.

1. Loose connectors or damaged connectors

2. Moisture on the connectors or the wiring

3. Damage that is caused by excessive heat

4. Damage that is caused by chafing

5. Improper routing of wiring

6. Damaged insulation
 
Wiggle test 
Result: The wiring failed the Wiggle Test.

Repair: There is a problem with the wiring. Repair the wiring or replace the wiring.

Verify that the problem is resolved.

Result: The wiring passed the Wiggle Test.

Repair: The problem may be intermittent. Inspect the wiring. Refer to Troubleshooting, "Electrical Connectors - Inspect".

If the wiring appears to be OK, perform the following procedure.

1. Turn the keyswitch to the OFF position.

2. Disconnect the connectors. Carefully inspect the terminals for proper installation. Make sure that each terminal is clean and dry.

3. Insert a pin into each socket. Verify that each socket grips the pin firmly. Repair any problems.

4. Connect all connectors.

5. Verify that the problem is resolved.

6. If the procedure did not correct the fault, contact the Dealer Solutions Network (DSN).
 

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