F438754 Force FUEL LINE W/CLAMPS

Illustration 1 g00802897
+5 V Sensor locations (typical example)
Illustration 2 g00890083
Schematic
Illustration 3 g00890154
Terminal locations J2/P2Test Step 1. Inspect Electrical Connectors And Wiring.
Thoroughly inspect the ECM engine harness connectors J2/P2 and J1/P1. Also check the individual sensor connectors. Refer to Troubleshooting, "Electrical Connectors-Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connectors that are associated with the analog sensor supply. Refer to illustration 3 for pin locations.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the harness and wiring for abrasion and pinch points from the sensors back to the ECM.Expected Result:All connectors, pins and sockets should be completely coupled and/or inserted and the harness and wiring should be free of corrosion, abrasion or pinch points.Results:
OK - Proceed to test step 2.
Not OK - Repair: Perform the following repair:Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.Verify that the repair eliminates the problem. Stop.Test Step 2. Connect the Caterpillar Electronic Technician (Cat ET) and Check for Active Diagnostic Codes.
Connect Cat ET to the service tool connector.
Turn the keyswitch to the ON position.
Monitor the active diagnostic code screen of Cat ET. Check and record active diagnostic codes.Note: Wait at least 15 seconds in order for the diagnostic codes to become active.Expected Result:Select the condition of the following codes:
CID 262-FMI 03 5 Volt Sensor DC power supply short to +batt
CID 262-FMI 04 5 Volt Sensor DC power supply short to groundResults:
Active - Proceed to test step 3.
Logged ONLY - Proceed to test step 5.
Not Active or Logged - The +5 V Supply is operating correctly at this time. Stop.Test Step 3. Disconnect The ECM Engine Harness Connector From The ECM.
Connect Cat ET to the service tool connector.
Turn the ignition key switch to the OFF position.
Disconnect ECM engine harness connector J2/P2.
Turn the ignition key switch to the ON position.
Access the active diagnostic code screen on Cat ET. Check for one of the following active diagnostic codes:
CID 262-FMI 03 5 Volt Sensor DC power supply short to +batt
CID 262-FMI 04 5 Volt Sensor DC power supply short to groundNote: When ECM engine harness connector J2/P2 is disconnected and the ignition key switch is in the ON position, open circuit diagnostic codes will be active or logged for all of the engine sensors. This is normal. The codes for the 5 Volt supply should not be active.Expected Result:The +5 V diagnostic code is active when the ECM engine harness connector is disconnected.Results:
Yes - Disconnecting the engine harness does not eliminate the active +5 V sensor diagnostic code. Repair: Perform the following diagnostic procedure:
Temporarily connect a test ECM. Only connect ECM harness J1/P1.
Recheck for an +5 V diagnostic code when the engine harness is disconnected.
If the problem is resolved with the test ECM, reconnect the suspect ECM.
If the problem returns with the suspect ECM, replace the ECM. Stop.
No - The +5 V diagnostic code is no longer active when the harness is disconnected. Either the harness or a sensor that is attached to the harness is causing the problem. Reconnect the ECM engine harness connector. Proceed to test step 4.Test Step 4. Disconnect The +5 V Sensors While Active Diagnostic Codes Are Being Monitored.
Connect Cat ET to the service tool connector.
Turn the ignition key switch to the ON position.
Access the active diagnostic code screen on Cat ET. Verify that one of the following diagnostic codes is active:
CID 262-FMI 03 5 Volt Sensor DC power supply short to +batt
CID 262-FMI 04 5 Volt Sensor DC power supply short to ground
Disconnect the following sensors one at a time:
J200/P200 Turbocharger Outlet Pressure Sensor
J201/P201 Oil Pressure Sensor
J203/P203 Atmospheric Pressure Sensor
J204/P204 Injector Actuation Pressure Sensor
J209/P209 Fuel Pressure Sensor
Wait for 30 seconds after each pressure sensor is disconnected while Cat ET is being monitored in order to verify that the disconnection of a specific sensor deactivates the +5 V diagnostic code.Note: When the sensors are disconnected and the "Ignition Key Switch" is in the ON position, open circuit diagnostic codes will be active or logged when the +5 V diagnostic codes are no longer active. This is normal. Clear these diagnostic codes after this test step is completed.Expected Result:The original +5 V diagnostic code remains active.Results:
Yes - The +5 V diagnostic code is still active. The harness is the cause of the problem. Leave the sensors disconnected. Proceed to test step 5.
No - Disconnecting a specific sensor makes the +5 V diagnostic code no longer active.Repair: Perform the following diagnostic procedure:
Reconnect the sensor that is suspected of causing the problem.
If the problem returns after the reconnection of the sensor, disconnect the sensor.
If the problem disappears after the disconnection of the sensor, replace the sensor.
Clear all diagnostic codes.
Verify that the repair eliminates the problem. Stop.Test Step 5. Check the Engine Harness.
Turn the ignition key switch to the OFF position.
Disconnect ECM Engine Harness Connector J2/P2. Verify that ALL of the analog pressure sensors that are attached to the ECM engine harness connector are disconnected.
J200/P200 Turbocharger Outlet Pressure Sensor
J201/P201 Oil Pressure Sensor
J203/P203 Atmospheric Pressure Sensor
J204/P204 Injector Actuation Pressure Sensor
J209/P209 Fuel Pressure Sensor
Set a multimeter in order to measure the resistance on the range that is close to 20,000 Ohms, but not less than 20,000 Ohms.
Measure the resistance from P2:2 Analog Sensor Power (+5V) to each of the following terminals.
P2:14 Atmospheric Pressure Sensor
P2:16 Fuel Pressure Sensor
P2:24 Oil Pressure Sensor
P2:27 Injector Actuation Pressure Sensor
P2:4