821945A54 Force CABLE ASSEMBLY-Hi Tension (RFI)

P-201: Inspecting Electrical Connectors
Many of the Operational Procedures and Diagnostic Code Procedures in this troubleshooting guide will direct you to check a specific electrical connector. Use the following steps to help determine if the connector is the cause of the problem. If a problem is found in the electrical connector, repair the connector and continue the test procedure.1. Check connector lock ring. Make sure that connector was properly locked and that the lock ring is capable of locking connector together.2. Perform 10 pound pull test on each pin/wire. Each pin and connector should easily withstand 10 pounds of pull, and remain in the connector body. This test checks whether the wire was properly crimped in the pin, and whether the pin was properly inserted into the connector. Repair as needed. Any time a wire is removed from a connector for testing purposes, do a 10 pound pull test after reinserting the wire. Pins should ALWAYS be crimped onto the wires; NEVER soldered. Use 1U5804 Crimping Tool (part of 4C3406 Connector Repair Kit).3. Visually inspect wiring. Look for worn or abraded wires. Check for pinched or damaged harnesses, especially on OEM wiring and early PEEC engines.4. Visually inspect connectors. Verify that pins and sockets are not corroded or damaged. Verify proper alignment and location of pins in the connector.5. Check individual pins and sockets. This is especially important for intermittent problems. Using a new pin, insert the pin into each socket one at a time to check for a good grip on the pin by the socket. Repeat for each pin on the mating side of the connector, using a new socket for the test.P-210: Electrical Power Supply To PEEC Test
The PEEC ECM receives electrical power (battery voltage) through wiring supplied by the vehicle manufacturer. In typical applications, PEEC receives power whenever the key is turned on.Some vehicles may be equipped with an engine protection shutdown system (such as a Kysor or Vigil shutdown system) or an idle time shutdown system (external to PEEC) that interrupts electrical power to the ECM to shut the engine down. Some of these will not supply power to PEEC until the engine is cranked, until oil pressure comes up to acceptable limits, or until an override button is pressed. Keep in mind that these devices may be the cause of no (or intermittent) power to the ECM.This procedure tests whether proper voltage is being supplied by the vehicle wiring. Detailed tests to identify specific failures in the vehicle wiring are the responsibility of the vehicle manufacturer.Note that the ECAP or DDT is supplied with electrical power through direct connections inside the ECM. Therefore, if the ECAP or DDT has power, so does the ECM.For intermittent problems that could be caused by vehicle wiring (such as intermittent shutdowns), temporarily bypassing the vehicle wiring may be an effective means of determining the root cause. If symptoms vanish with the wiring bypassed, vehicle wiring was the cause. A means of bypassing vehicle wiring is explained below. Step 1. Check Electrical Connectors And WiringCheck vehicle connector (J2/P2) and battery power and grounds to J2/P2, being sure to: * Check Connector lock rings.* Perform 10 pound pull test on each pin or wire.* Inspect wiring for damage or abrasion.* Inspect connectors for damage or corrosion. Refer to P-201: Inspecting Electrical Connectors for details. Repair any damage, then continue with the next step.* Visually and physically check grounds for looseness or corrosion. If a problem is found, disconnect, clean, and reconnect the connectorStep 2. Check Battery Voltage Coming To ECMA. Connect a 9-pin 'T' at the ECM vehicle connector (J2/P2).B. Turn key ON, engine OFF.C. Measure the voltage between + Battery (Pin A) and ground (Pin B). The voltage at Pin A should be between 11.5 and 13.5 VDC. OK: The ECM is currently receiving the correct voltage. If intermittent problems with battery voltage may be occurring, consider temporarily bypassing vehicle wiring as shown in Step 4. Otherwise, Stop. NOT OK: The ECM is NOT receiving the correct voltages. Continue with the next step.Step 3. Check BatteriesA. Measure battery voltage at the battery posts.B. Load test the batteries using the 4C4911 Battery Load Tester. Make reference to Operation Manual, Form No. SEHS9249 for more complete information for use of the 6V4930 Battery Load Tester. The voltage at the batteries should be at least 11.5 VDC, and the batteries should pass the load test. OK: The batteries are not the problem. Wiring or components between the batteries and PEEC are preventing voltage from reaching PEEC. Refer to the service manual for the vehicle for instructions on how to troubleshoot the vehicle wiring. Stop. NOT OK: The batteries are defective. Replace the defective batteries. Stop.Step 4. Bypass Vehicle Wiring For Testing This bypass is for TEST PURPOSES ONLY. It may be left on the vehicle temporarily to test whether intermittent problems are due to interruptions in battery power to the ECM. Since this will also bypass any engine protection devices, obtain approval from the owner before releasing a truck with this bypass installed. The bypass switch is installed in parallel with the ignition switch. Either one will turn power ON, and both must be OFF to turn power OFF and shutdown the engine.A. Build a bypass circuit as shown in the illustration below, using #14 AWG wire. B. Connect the battery end of the bypass DIRECTLY to the battery posts.C. Remove Pins A (+ Battery) and B (-Battery) from J2 (Vehicle connector - vehicle side).D. Insert the other end of the bypass into J2 Pins A and B (as shown below).E. Connect the wire that was formerly in J2 Pin B into the socket spliced into the bypass.F. Connect the wire that was formerly in J2 Pin A into the socket that is spliced into the bypass. (This supplies power to the throttle sensor and vehicle speed buffer through the bypass rather than the vehicle wiring). Tape this connection to keep it clean, prevent shorting, and prevent loosening during