Sensor and ECM

Diagnostics

LEE Weng Kong

CSTC
Discussion Topics
 Pressure and temperature sensor theory of
operation.
 ECM reaction to open circuits and short circuits.
 Troubleshooting using the ‘fault code state
change’ method.
 Walk though a troubleshooting tree to see how
‘fault code state change’ is used.
 Answer any ‘diagnostic’ or ‘fault code’ questions
you may have.
Quiz Question #1
 What fault code will you get when you unplug
the boost pressure sensor on a ISX’02, ISB’02,
ISC/ISL ‘04?
– A. Fault code 122 - Intake Manifold 1
Pressure Sensor Circuit - Voltage Above
Normal, or Shorted to High Source
– B. Fault code 123 - Intake Manifold 1
Pressure Sensor Circuit - Voltage Below
Normal, or Shorted to Low Source

 Answer is B
Quiz Question #2
 What fault code will you get when you unplug
the ambient air pressure sensor on a ISX’02,
ISB’02, ISC/ISL ‘04?
– A. Fault code 221 - Barometric Pressure
Sensor Circuit - Voltage Above Normal, or
Shorted to High Source
– B. Fault Code 222 - Barometric Pressure
Sensor Circuit - Voltage Below Normal, or
Shorted to Low Source
 Answer is B
Quiz Question #3
 What fault code will you get when you unplug the
coolant temperature sensor on a ISX’02, ISB’02,
ISC/ISL ‘04?
– A. Fault code 144 - Engine Coolant
Temperature 1 Sensor Circuit - Voltage Above
Normal, or Shorted to High Source
– B. Fault Code 145 - Engine Coolant
Temperature 1 Sensor Circuit - Voltage Below
Normal, or Shorted to Low Source
 Answer is A
Quiz Question #4
 What fault code will you get when you unplug the
intake manifold temperature sensor on a ISX’02,
ISB’02, ISC/ISL ‘04?
– A. Fault code 153 - Intake Manifold 1
Temperature Sensor Circuit - Voltage Above
Normal, or Shorted to High Source
– B. Fault Code 154 - Intake Manifold 1
Temperature Sensor Circuit - Voltage Below
Normal, or Shorted to Low Source
 Answer is A
Quiz Question #5
 What fault code will you get when you unplug
the lift pump on a ISB’02 or ISC/ISL ‘04?
– A. Fault code 2265 - Electric Lift Pump for
Engine Fuel Supply Circuit - Voltage Above
Normal, or Shorted to High Source
– B. Fault Code 2266 - Electric Lift Pump for
Engine Fuel Supply Circuit - Voltage Below
Normal, or Shorted to Low Source

 Answer is A
Quiz Question Answers
 Why do pressure sensors go out-of-range low
when they are disconnected?
 Why do temperature sensors go out-of-range
high when they are disconnected?
 Why does this really matter? How can this help
the troubleshooting process?
– Understanding this logic can make sensor
and ECM troubleshooting very easy.
– Eliminates the use of a multi-meter in most
cases.
– Can eliminate ‘No trouble found’ components.
Temperature Sensor Operation

 As temperature increases, the signal voltage decreases.

 As temperature decreases, the signal voltage increases.
Pressure Sensor Operation

 As pressure increases, the signal voltage increases.

 As pressure decreases, the signal voltage decreases.
Sensor Voltage Range Operation

5.0V
Out-of-Range High
4.75V
Out-of-Range
High Fault Code

Normal Sensor
Operating Range
0.25V Out-of-Range
Low Fault Code
Out-of-Range Low
0.0 V
What is ‘Fault Code State Change’?

 ‘Fault Code State Change’ is the process of

creating the ‘opposite’ fault code to troubleshoot
sensors, harnesses, and ECM’s.

 Understanding the ‘fault code state change’ logic

can make troubleshooting as easy as
disconnecting a sensor or unplugging the engine
harness from the ECM.
 Fault Code 122
Troubleshooting Example

 If a pressure sensor out-of-range high fault code is

active, you can force a fault code state change by
unplugging the sensor connector and/or the ECM
connector.
Out-of Range High Fault Code
 Greater than 4.75 volts on the signal wire.
– Shorted sensor
– Wiring harness short
– Open return wire Greater than
4.75 volts
 Always Use the
Correct Test Leads

Damaged Pins

 Not using the proper test leads can cause pin damage.
These expanded pins were causing intermittent fault
code in a test cell engine.
 A multimeter probe was jammed into the connector.
 Never use a paper clip as a test lead!!!!!
Out-of Range High Fault Code
 If a sensor is causing the short, unplugging the sensor will cause fault
code 122 to go inactive and fault code 123 (out-of-range low) will go
active.
Disconnect the Sensor
from the Wiring Harness

 If there is a short in the sensor, fault code 122

will go inactive and fault code 123 will go active.
Out-of Range High Fault Code
 If a harness is causing the short, unplugging the harness from the ECM
will cause fault code 122 to go inactive and fault code 123 will go active.
Disconnect the Wiring
Harness from the ECM

 If there is a short in the harness (5 volt supply to

the signal wire), fault code 122 will go inactive
and fault code 123 will go active.
 If fault code 122 does not go inactive when
the engine harness is disconnected from
the ECM, the short is internal to the ECM.
Out-of Range Low Fault Code
 Less than .25 volts on the signal wire.
– Open signal wire
– Shorted signal wire to ground
– Open 5 volt supply wire Less
than .25
volts
Using Test Leads to Change
the Fault Code State
Using Test Leads to Change
the Fault Code State
Temperature Sensor Diagnostics
Jumper the signal wire to the
return wire to create an out-
of-range low fault code on
temperature sensors.
Pressure Sensor Diagnostics

Jumper the 5 volt supply to the

signal wire to create an out-of-range
high fault code on pressure sensors.
‘Fault Code State Change’
troubleshooting can be used
on all CM8XX Series ECM’s.
Can also be applied to other
ECM’s, depending on datalink
and keyswitch location in the
engine harness.
Temperature Sensor Operation - Review
Pressure Sensor Operation - Review
Pressure/Temperature Sensor
Fault State Change Review
Questions ??