4/13/2021 SIS 2.

2005/10/13 5 Volt Engine Pressure Sensor Supply Circuit - Test (RENR9881)

SMCS - 1439 i02427773

System Operation Description:

Use this procedure to troubleshoot any suspect problems with the +5 V sensor supply.

Use this procedure to troubleshoot the system when one of the following diagnostic
codes is active or easily repeated:

262-03 5 Volt Sensor DC Power Supply short to +batt

262-04 5 Volt Sensor DC Power Supply short to ground

The Electronic Control Module (ECM) supplies a regulated voltage of 5.0 ± 0.2 VDC to
the following sensors:

Atmospheric pressure sensor

Injector actuation pressure sensor

Intake manifold (boost) pressure sensor

Engine oil pressure sensor

Fuel pressure sensor

The supply for the +5 V engine pressure sensor is routed from the ECM to terminal A of
each pressure sensor connector. The sensor return from the ECM connector goes to
terminal B of each sensor connector. The 5 V sensor supply is output short circuit
protected. A short circuit to the battery will not damage the circuit inside the ECM.

Note: The sensors are not protected from overvoltage. A short from the supply line to the
+Battery may damage the sensors. If the CID-FMI 03 is logged, it is possible that all of
the sensors have been damaged. Repair the 5 V sensor supply and check for any active
diagnostic codes for the sensor in order to determine if a sensor has failed.

A +5 V diagnostic code is probably caused by a short circuit to ground or a short circuit to

another voltage source in the harness. The next likely cause is a problem with a sensor.
The least likely cause is a problem with the ECM.

Illustration 1 g01213367
Schematic for the pressure sensor supply

Test Step 1. INSPECT THE ELECTRICAL CONNECTORS AND THE WIRING

A. Remove the electrical power from the ECM.

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4/13/2021 SIS 2.0

Illustration 2 g01213397
Typical sensor locations
(1) Intake manifold (boost) pressure sensor
(2) Injector actuation pressure sensor
(3) Fuel pressure sensor
(4) Atmospheric pressure sensor
(5) Engine oil pressure sensor
(6) J2/P2 ECM connectors

B. Thoroughly inspect connectors (6). Also, thoroughly inspect the connectors for
sensors (1), (2), (3), (4), and (5).
Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors -
Inspect" for details.

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4/13/2021 SIS 2.0

Illustration 3 g01213410
P2 ECM connector
(P2-15) Intake manifold (boost) pressure sensor
(P2-17) Sensor return
(P2-28) Engine oil pressure sensor
(P2-40) Fuel pressure sensor
(P2-57) Atmospheric pressure sensor
(P2-72) Sensor supply
(P2-85) Injector actuation pressure sensor

Illustration 4 g01159881
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4/13/2021 SIS 2.0

Sensor connector
(A) Sensor supply
(B) Sensor return
(C) Sensor signal

C. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector and on
each of the wires in the pressure sensor connectors.

D. Check the allen head screw for each of the ECM connectors and the machine
connectors for the proper torque. Refer to the diagnostic functional test
Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.

E. Check the harness and wiring for abrasions and for pinch points from each of the
pressure sensors back to the ECM.

Expected Result:

All connectors, pins and sockets are completely coupled and/or inserted and the harness
and wiring are free of corrosion, of abrasion or of pinch points.

Results:

OK - The harness and connectors appear to be OK. Proceed to Test Step 2.

Not OK - There is a problem with the connectors and/or wiring.

Repair: Repair the connectors or wiring and/or replace the connectors or wiring.
Ensure that all of the seals for each of the connectors are properly in place and
ensure that the connectors are completely coupled. Verify that the repair eliminates
the problem.

STOP

Test Step 2. CHECK FOR ACTIVE DIAGNOSTIC CODES

A. Connect Caterpillar Electronic Technician (ET) to the service tool connector.

B. Restore the electrical power to the ECM.

C. Monitor the active diagnostic code screen on Cat ET. Check for an active 03 code
or an active 04 code.
Note: Wait at least 30 seconds in order for the diagnostic codes to become active.

D. Remove the electrical power from the ECM.

Expected Result:

No diagnostic codes are active.

Results:

OK - No diagnostic codes are active.

Repair: If any of the above codes are logged and the engine is not running
properly, refer to Troubleshooting, "Troubleshooting Without a Diagnostic Code".

If the engine is running properly at this time, there may be an intermittent problem in
a harness that is causing the codes to be logged. Refer to the diagnostic functional
test Troubleshooting, "Electrical Connectors - Inspect".

STOP

Not OK - Either the 03 or 04 diagnostic code is active at this time. Proceed to Test
Step 3.

Test Step 3. DISCONNECT THE PRESSURE SENSORS AND CHECK FOR ACTIVE
DIAGNOSTIC CODES

A. Restore the electrical power to the ECM.

B. Monitor the active diagnostic code screen on Cat ET while you disconnect each
pressure sensor connector. Check for an active 03 code or an active 04 code.
Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
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4/13/2021 SIS 2.0

a. Disconnect the following sensors one at a time:

Engine oil pressure sensor

Injector actuation pressure sensor

Intake manifold (boost) pressure sensor

Fuel pressure sensor

Atmospheric pressure sensor

Expected Result:

The diagnostic code deactivates when a particular sensor is disconnected.

Results:

OK - The 03 or 04 diagnostic code deactivates when a particular sensor is

disconnected.
Repair: Connect the suspect sensor. If the code returns, replace the sensor.
Connect all of the connectors. Verify that the problem is resolved.

STOP

Not OK - The 03 or 04 diagnostic code remains active after all of the sensors are
disconnected. Leave the sensors disconnected. The sensors are not the cause of
the diagnostic code. Remove electrical power from the ECM. Proceed to Test Step
4.

Test Step 4. CHECK THE SUPPLY VOLTAGES AT THE ECM

A. Disconnect the J2/P2 ECM connectors.

B. Fabricate two jumper wires that are long enough to be used to measure the supply
voltage at the ECM connectors. Crimp connector sockets to one end of each
jumper wire.

C. Remove the wires from terminal locations P2-72 (5 V sensor supply) and P2-17
(sensor return). Install a jumper wire into each of these terminal locations.

D. Connect the J2/P2 ECM connectors.

E. Restore the electrical power to the ECM.

F. Measure the voltage between the jumper wire in P2-72 (5 V sensor supply) and the
jumper wire in P2-17 (sensor return).

G. Remove the electrical power from the ECM.

Expected Result:

Each voltage measurement is 5.0 ± 0.2 VDC.

Results:

OK - The voltage measurement is 5.0 ± 0.2 VDC. The ECM is operating correctly.
Repair: The ECM is operating correctly. There is a problem with the supply wires in
the engine harness. Repair the harness wiring and/or the connector. Replace parts,
if necessary. Verify that the problem is resolved.

STOP

Not OK - The voltage measurement is not 5.0 ± 0.2 VDC.

Repair: There is a problem with the ECM. Replace the ECM. Refer to electronic
troubleshooting Troubleshooting, "Replacing the ECM".

STOP

C9E1-UP, LN91-UP, LT91-UP, LX91-UP, NBP1-UP, NGP1-UP, NTX1-UP, RZ91-UP,

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4/13/2021 SIS 2.0

PIP-10231166
2021/04/14
02:34:10-05:00
i02427773
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