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Electronic Control System Outputs

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All numbers and specifications listed in this program are used for illustration purposes only. Current information can be found in
the Service Manuals located on QuickServe Online.

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After completing this course, you should be able to:
• Recognize and interpret fault code readings
• Explain the relationship and interaction between the ECM and the various outputs
• Understand how to test and troubleshoot components
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A single output can supply multiple sensors. This is referred to as a supply.
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The ECM provides output power to:
Solenoids and actuators for fueling.
Turbocharger wastegates and engine brakes.
Motors for fuel priming pumps.
EGR valves and variable geometry turbocharger actuators.
Relays for control of high current items such as intake air heaters and fuel pumps.
And lamps to warn the operator of conditions that need attention.
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The output voltage from the ECM can be either a steady voltage
or Pulse Width Modulated (PWM).
On/off actuators, relays and some motors can use either type of signal.
Variable position actuators must use a PWM signal.
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Pulse width modulation is based on a pulsed output at a
constant frequency and
varying pulse width to obtain the desired results.
The time from the start of a pulse to the start of the next pulse is the period of the cycle. The pulse width is adjusted by
changing the on-time as compared with the off-time within each of the periods. Each of the cycles shown here has a period of
60 hertz. However, the on-time percentage is expressed as duty cycle.
In the examples shown here, the duty cycle varies from 25% to
50% and on
up to 75%. The higher duty cycle results in a higher effective voltage applied to the actuator.

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For example, when PWM is used to control a variable position normally open valve, a 25% duty cycle results in a relatively
small effective voltage applied which closes the valve a small amount.
Applying a larger duty cycle closes the valve further. The position of the valve varies with the percent of duty cycle input that
A PWM output can also be used to control an on/off actuator. A PWM signal is used with this type of actuator to provide a
constant output voltage regardless of the voltage input.

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One possible test of ECM function is to check these supply signals.
When the fault code is for a circuit containing an active sensor, the troubleshooting tree will contain a test for the 5 volt supply
signal on the appropriate wire. If the supply signal at the sensor is not within the 4.75 to 5.25 volt range,
it is important to test at the output pin of the ECM, since poor connections or broken wires can interrupt the supply to the
sensor even though the ECM is working properly.

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The ECM driver can output directly to components that have low current requirements such as indicator lamps.
The ECM controls other higher current devices, such as grid heaters, through output to relays that then control the component's
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The ECM delivers voltage to solenoids or actuators to control the opening and closing of valves at the appropriate time.
These actuators control the flow of various fluids, such as:
Fuel actuators for metering fuel
Wastegate actuators for controlling the flow of exhaust gas
and Engine brake solenoids for controlling oil flow.
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A solenoid is a device that converts an electrical signal into mechanical movement. In the example shown here,
the ECM supplies power to the coil in the solenoid creating a magnetic field. This field attracts a rod in the solenoid pushing the
valve closed
and stopping fuel from flowing into the high pressure fuel pump.
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Actuators are tested several
ways. Actuators can
be tested with an ohm meter.
For testing fueling actuators INSITE contains performance tests that allow shorting of cylinders individually or in groups as an
aid to the diagnosis.
In the case of an engine like the ISX, the fueling actuators can be switched to see if the performance problem moves with the
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The variable geometry turbocharger actuator on heavy duty engines
is also controlled by a solenoid actuated valve.
INSITE provides a turbocharger actuator test for this system.

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The ECM also controls various motors. These motors may position valves to control flow volume or to drive pumps. Examples
fuel priming pumps on various engines,
EGR valve motors,
ISB variable geometry turbocharger actuators and
throttle control motors in the gas fueled engines.
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A stepper motor positions the throttle plate on some gas fueled engines. When the ECM shuts off current to coil 1 and sends
current to coil 2 the
magnet inside the motor rotates slightly and faces coil 2.
By sequentially supplying current to the coils, the magnet moves in either direction through a series of steps. In this way the
ECM opens and closes the throttle in small precise increments.

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Stepper motors, such as the electronic throttle control actuator on B and C Gas Plus engines contain an integral position sensor.
This allows the technician, using INSITE, to monitor the commanded and measured throttle positions to ensure that they agree.
More than a 5% difference between the two indicates a failure of the unit.

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With many circuits, the ECM verifies proper voltage in the circuit. If the voltage is not in the specified range, the ECM sets a
fault code.
the recommended test is to check the pump resistance. A high reading indicates a faulty pump.
When the detected voltage is below normal, the test is to
disconnect the pump and watch the circuit response.
Since this creates a high resistance, the high voltage fault code should become active.
Reconnecting the pump causes the low voltage code to become active. A circuit that responds correctly indicates a faulty
priming pump. If the circuit doesn't respond properly, the fault must be elsewhere in the circuit.

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The variable geometry turbocharger actuator on ISB CM850 engines is an electric motor.
The motor can be tested with an ohmmeter.
INSITE can also be used to test these actuators when they incorporate a position sensor. Using INSITE compare the commanded
and measured positions of the actuator to determine that the actuator is functioning correctly.

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Relays are devices that use electrical current to open and close circuits upon demand.
Relays provide the ability to use a small current flow through the control circuit to move the relay to provide a path for the
higher current flow to the load. This is accomplished by passing current through a coil to create a magnetic field and
move a lever in the relay from one contact position to another. Substantially less current flow is needed through the coil to
move the lever than is used to supply power to the load.
Relays are typically used in intake air heater grid circuits,
lift pump circuits, and
fan control circuits.

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 Electronic Control System Outputs
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Since the ECM controls only the signal to the relay coil, only problems with the relay coil portion of the circuit will log a fault
The relay coil can be resistance tested and with some ECMs the circuit response can be checked by connecting and disconnecting
the relay coil circuit.

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Indicator lamps are mounted within the operator's view and are used to notify the operator of service or diagnostic information.
These lamps may include a maintenance, stop, warning, or wait-to-start lamps. Using the diagnostic switch, the lamps can also
be used to access the active fault codes.

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In addition to the bulb check at key on; some engines, such as the B Gas Plus, check the diagnostic lamp circuit for proper
voltage. When the ECM detects high or low voltage, it activates a fault code.
The circuit is a simple bulb circuit. Since this wiring is the OEM's responsibility, you must check the proper vehicle service
literature for the proper ECM
pins to test.
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Which of the following is an acceptable way to test fuel actuators?
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What type of signal must be used with variable position actuators?
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Using the mouse, click on the device that is stepper motor controlled.
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What portion of a relay circuit does the ECM control?
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A PWM signal is said to have a 60% duty cycle. What does this mean?

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Which of the following can cause a voltage above normal fault code for the lift pump circuit?

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