C4.4 and C6.6 Engines Caterpillar

Solenoid Valve - Test

Usage:

C4.4 448

This procedure covers the following diagnostic codes:

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Table 1
Diagnostic Codes for the Solenoid Valves
J1939 Code	CDL Code	Code Description (code descriptions may vary)	Comments
1076-5	18-5	Engine Fuel Injection Pump Fuel Control Valve : Current Below Normal	The Electronic Control Module (ECM) detects the following conditions: Low current in the output from the ECM to the fuel pump solenoid for 0.6 seconds There are no active 168 diagnostic codes. The ECM has been powered for at least 0.25 seconds. The warning lamp will come on. The ECM will log the diagnostic code. This diagnostic code detects a fault in the circuit for the fuel pump solenoid.
1076-6	18-6	Engine Fuel Injection Pump Fuel Control Valve : Current Above Normal	The ECM detects the following conditions: High current in the output from the ECM to the fuel pump solenoid for 0.6 seconds. There are no active 168 diagnostic codes. The ECM has been powered for at least 0.25 seconds. The warning lamp will come on. The ECM will log the diagnostic code. This diagnostic code detects a fault in the circuit for the fuel pump solenoid. This fault is most likely to be caused by a high side short to ground or a low side short to power.
1188-3	526-3	Engine Turbocharger 1 Wastegate Drive : Voltage Above Normal	The ECM detects the following conditions: A high voltage condition in the output from the ECM to the solenoid for the wastegate regulator. There are no active 168 diagnostic codes. The ECM has been powered for at least 2 seconds. The warning lamp will come on once the diagnostic code has been active for 30 seconds. The diagnostic code will be logged. The engine will be derated while this diagnostic code is active. After the engine derate has been activated, the electronic service tool will indicate "Turbo Protection Derate Active". This diagnostic code detects a fault in the wastegate regulator that is most likely to be an open circuit.
1188-5	526-5	Engine Turbocharger 1 Wastegate Drive : 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. There are no active 168 diagnostic codes. The ECM has been powered for at least 2 seconds. The warning lamp will come on once the diagnostic code has been active for 30 seconds. The diagnostic code will be logged. The engine will be derated while this diagnostic code is active. After the engine derate has been activated, the electronic service tool will indicate "Turbo Protection Derate Active". This diagnostic code detects a fault in the wastegate regulator that is most likely to be an open circuit.
1188-6	526-6	Engine Turbocharger 1 Wastegate Drive : 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 There are no active 168 diagnostic codes. The ECM has been powered for at least 2 seconds. The warning lamp will come on once the diagnostic code has been active for 30 seconds. The diagnostic code will be logged. The engine will be derated while this diagnostic code is active. After the engine derate has been activated, the electronic service tool will indicate "Turbo Protection Derate Active". This diagnostic code detects a fault in the circuit for the wastegate regulator. This fault is most likely to be caused by a high side short to ground or a low side short to power.
Follow the troubleshooting procedure to identify the root cause of the fault.

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 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 to provide the precise value of intake manifold pressure. The solenoid in the wastegate regulator is controlled by a PWM signal from the ECM.

Suction Control Valve for the High-Pressure Fuel Pump

The high-pressure fuel pump is equipped with a suction control valve. The suction control 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	g06104371
Schematic for the solenoid valves

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Illustration 2	g06104394
(1) Typical wastegate regulator

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Illustration 3	g03714642
Typical example of the high-pressure fuel pump (2) Solenoid for the Suction Control Valve (SCV)

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Illustration 4	g01971875
Connector for the wastegate regulator (1) Signal (2) Return

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Table 2
Troubleshooting Test Steps	Values	Results
1. Inspect Electrical Connectors and Wiring A. Thoroughly inspect the terminal connections on the P2/J2 ECM connector and the solenoids. Refer to Troubleshooting, "Electrical Connectors - Inspect". B. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector and the solenoid connectors that are associated with the active diagnostic code. C. Check the screw for the ECM connector for the correct torque of 6 N·m (53 lb in). D. Check the harness for corrosion, abrasion, and pinch points from the solenoids to the ECM.	Loose connection or damaged wire	Result: There is a fault in a connector or the wiring. Repair: Repair any faulty connectors or replace the wiring harness. Ensure that all the seals are properly in place and ensure that the connectors are correctly coupled. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: All connectors, pins, and sockets are correctly coupled and/or inserted. The harness is free of corrosion, abrasion, and pinch points. Proceed to Test Step 2.
2. Check for Active 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. Wait at least 20 seconds for activation of the diagnostic codes. D. Verify if any of the diagnostic codes that are listed in Table 1 are active. E. Turn the keyswitch to the OFF position.	Diagnostic codes	Result: A -5 diagnostic code is active. Proceed to Test Step 3. Result: A -6 diagnostic is active. Proceed to Test Step 5.
3. Create a Short Circuit at the Harness Connector for 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 to create a short circuit. E. Turn the keyswitch to the ON position. Wait for 10 seconds. Check for active diagnostic codes on the electronic service tool. F. Remove the jumper wire from the connector for the solenoid valve.	Open circuit	Result: An -5 diagnostic code was active before installing the jumper. An -6 diagnostic code is active when the jumper is installed - There is a fault in the solenoid. Repair: Temporarily connect a replacement for the suspect valve to the harness. Turn the keyswitch to the ON position. Use the electronic service tool 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 -5 diagnostic code is still active with the jumper installed. Proceed to Test Step 4.
4. Check the Wiring for an Open Circuit A. Turn the keyswitch to the OFF position. B. Disconnect the P2 connector and the connector for the suspect valve. C. Use a multimeter to check the resistance between the signal terminal on P2 and the signal terminal on the valve connector. Refer to Illustration 1. D. Use a multimeter to check the resistance between the return terminal on P2 and the return terminal on the valve connector. Refer to Illustration 1. E. Reconnect the connectors.	Less than 2 Ohms	Result: One of the measured resistances is greater than 2 Ohms - There is a fault in the engine wiring harness Repair: Repair the engine wiring harness or replace the engine wiring harness. Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault. Result: All measured resistances are less than 2 Ohms. Contact the Dealer Solutions Network (DSN).
5. 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. Wait for 10 seconds. Check for active diagnostic codes on the electronic service tool.	Short circuit	Result: An -6 diagnostic code was active before disconnecting the valve. An -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 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 6.
6. Check the Wiring for a Short Circuit A. Turn the keyswitch to the OFF position. B. Disconnect the P2 connector and the connector for the suspect valve. C. Use a multimeter to check the resistance between the suspect signal terminal on P2 all other terminals on P2. Refer to Illustration 1. D. Use a multimeter to check the resistance between the suspect return terminal on P2 and all other terminals on P2. Refer to Illustration 1. E. Reconnect the connectors.	Greater than 100 Ohms	Result: At least one of the resistance measurements is less than 100 Ohms - The fault is in the engine harness. Repair: Repair the faulty harness or replace the faulty harness. Use the electronic service tool to verify that the repair eliminates the fault. Result: All resistance measurements are greater than 100 Ohms. Contact the Dealer Solutions Network (DSN).