5036985 JOHNSON HOLDER, CDI Unit

The following background information is related to this procedure:Electronically controlled wastegateThe engine has a turbocharger with an electronically controlled wastegate. Typically, the wastegate is a mechanical valve that is used in the turbocharger to regulate the intake manifold pressure to a set value.The control system for the electronically controlled wastegate precisely regulates the intake manifold pressure by using a wastegate regulator to control the wastegate.The required intake manifold pressure is calculated by the software that is contained in the ECM. The ECM uses the wastegate regulator to control the wastegate to provide the precise value of intake manifold pressure. The solenoid in the wastegate regulator is controlled by a PWM signal.Fuel metering valve for the high-pressure fuel pump:The high-pressure fuel pump is equipped with a fuel metering valve. The fuel metering valve precisely controls the amount of fuel that enters the high-pressure fuel pump.The amount of fuel that is required is calculated by the software that is contained in the ECM. The solenoid in the suction control valve is controlled by a PWM signal from the ECM.
Illustration 1 g06554549
Schematic diagram for the solenoid valves
Not all connectors are shown. Refer to the appropriate Electrical Schematic.
Illustration 2 g02351359
View of the pin locations on the P2 connector for the solenoid valves
(4) Wastegate regulator return
(15) Fuel metering valve supply
(60) Fuel metering valve return
Illustration 3 g03086696
View of the pin locations on the P1 connector
Table 2
Troubleshooting Test Steps Values Results
1. Inspect Electrical Connectors and Wiring
A. Check the fuses.
B. Thoroughly inspect the P2/J2 and P1/J1 ECM connectors and thoroughly inspect the connectors for the solenoid valves. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
C. Inspect the terminals on the P1/J1 ECM connector and all other connectors associated with the glow plug circuit.
D. Perform a 30 N (6.7 lb) pull test on each of the wires that are associated with the solenoid valves.
Damaged wire or connector
Result: A damaged wire or damaged connector was found. A fuse is blown.
Repair the damaged wire or the damaged connector. Replace any blown fuses
Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault.
Result: All connectors, pins, and sockets are correctly connected and/or inserted and the harness is free of corrosion, of abrasion or of pinch points.
Proceed to Test Step 2.
2. Check for Diagnostic Codes
A. Turn the keyswitch to the OFF position.
B. Connect the electronic service tool to the diagnostic connector.
C. Turn the keyswitch to the ON position.
D. Monitor the electronic service tool for active diagnostic codes and/or logged diagnostic codes.
Diagnostic codes
Result: A 1076-5 diagnostic code is active or recently logged.
Proceed to Test Step 3.
Result: A 1188-5 diagnostic code is active or recently logged.
Proceed to Test Step 4.
Result: A 1076-6 or 1188-6 diagnostic code is active or recently logged.
Proceed to Test Step 8.
Result: A 1076-2 diagnostic code is active or recently logged
An intermittent fault exists in the circuit for the fuel metering valve.
For intermittent faults, refer to Troubleshooting, "Electrical Connectors - Inspect".
3. Check the Power Supply to the ECM
A. Check that pin P1:1 is receiving the correct voltage. Refer to Troubleshooting, "Electrical Power Supply - Test".
Note: The power supply for the fuel pump metering valve is supplied through P1:1.
Power supply
Result: The power supply to P1:1 is faulty.
Perform any necessary repairs. Refer to Troubleshooting, "Electrical Power Supply - Test".
Result: The power supply to P1:1 is OK.
Proceed to Test Step 4.
4. Create a Short Circuit in the Harness at the Solenoid
A. Turn the keyswitch to the OFF position.
B. Disconnect the connector for the suspect solenoid.
C. Fabricate a jumper wire that is 150 mm (6 inch) long.
D. Install the wire between the two pins on the harness connector for the suspect solenoid to create a short circuit.
E. Turn the keyswitch to the ON position. Wait for 30 seconds. Cycle the keyswitch.
F. Check for active diagnostic codes on the electronic service tool.
G. Remove the jumper wire from the connector for the solenoid valve.
Diagnostic codes
Result: An XXXX-6 diagnostic code is active when the jumper is installed.
Temporarily connect a replacement for the suspect valve to the harness.
Turn the keyswitch to the ON position. Wait for 30 seconds. Cycle the keyswitch. Use the electronic service tool to check for active diagnostic codes.
If the fault is eliminated, reconnect the suspect valve. If the fault returns, permanently install the replacement valve. Refer to Disassembly and Assembly for the correct procedure.
Result: A 1076-5 diagnostic code is still active with the jumper installed.
Proceed to Test Step 5.
Result: A 1188-5 diagnostic code is still active with the jumper installed.
Proceed to Test Step 6.
5. Create a Short Circuit at the ECM Connector
A. Turn the keyswitch to