0323522 JOHNSON HOSE

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Schematic for analog sensors
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Terminal locations for ECM connector J2/P2
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Terminal locations for ECM connector J1/P1Test Step 1. Inspect Electrical Connectors and Wiring
Place the engine control in the OFF/RESET mode.
Thoroughly inspect the J1/P1 ECM connector and the J2/P2 ECM connector. Thoroughly inspect the connectors for each analog sensor.Refer to the diagnostic functional test 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:
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 for pinch points from the sensors back to the ECM.Expected Result:All connectors, pins and sockets are completely coupled and/or inserted and the harness and wiring are free of corrosion, of abrasion and of pinch points.Results:
OK - The harness and connectors appear to be OK. Proceed to Test Step 2.
Not OK - The connectors and/or wiring are not OK.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.STOPTest Step 2. Check for Active Diagnostic Codes
Connect CaterpillarElectronic Technician (ET) to the service tool connector.
Place the engine control in the ON mode.
Monitor the active diagnostic code screen on the electronic service tool. Check and record any active diagnostic codes.Note: Wait at least 15 seconds in order for the diagnostic codes to become active.Expected Result:One of the following diagnostic codes is active:
262-03
262-04 Results:
OK - A 262-03 diagnostic code is active. Proceed to Test Step 3.
OK - A 262-04 diagnostic code is active. Proceed to Test Step 4.Test Step 3. Check the Voltage on the +5 V Supply Wire
Place the engine control in the OFF/RESET mode.
Disconnect all of the following analog sensors at the sensor connector one at a time:
Fuel pressure sensor J209/P209
Engine oil pressure sensor J201/P201
Atmospheric pressure sensor J203/P203
Turbocharger outlet pressure sensor J200/P200
Injection actuation pressure sensor J204/P204
Auxiliary pressure sensor J220/P220
Place the engine control in the ON mode.
Measure the voltage between pin A and pin B at the sensor connectors.Expected Result:The voltage is 5.0 0.2 VDC.Results:
OK - The voltage is correct.Repair: Replace all wires to the original configuration. Clear all diagnostic codes. Check for active diagnostic codes. If the problem is intermittent, refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - The voltage is incorrect. Proceed to Test Step 5.Test Step 4. Disconnect the +5 V Pressure Sensors while you Monitor the Active Diagnostic Codes
Monitor the active diagnostic code screen on CatET. Check and record any active diagnostic codes.Note: Wait at least 15 seconds in order for the diagnostic codes to become active.
Disconnect the following sensors one at a time:
Fuel pressure sensor J209/P209
Engine oil pressure sensor J201/P201
Atmospheric pressure sensor J203/P203
Turbocharger outlet pressure sensor J200/P200
Injection actuation pressure sensor J204/P204
Auxiliary pressure sensor J220/P220
Wait for 15 seconds after each pressure sensor is disconnected. Check for an active diagnostic code.Expected Result:The 262-04 diagnostic code deactivates.Results:
OK - The 262-04 diagnostic code deactivates. The diagnostic code is not active after a specific sensor is disconnected.Repair: 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. Replace all wires to the original configuration. Clear all diagnostic codes. Verify that the repair eliminates the problem.STOP
Not OK - The 262-04 diagnostic code stays active. Leave the sensors disconnected. Proceed to Test Step 5.Test Step 5. Check the +5 V Supply Wire for a Short to Engine Ground or a Short to another Wire in the Harness
Place the engine control in the OFF/RESET mode.
Disconnect the J2/P2 ECM connector. Disconnect the J1/P1 ECM connector.
Leave the analog sensors disconnected at the sensor connectors.Note: Wiggle the harness during the following measurements in order to reveal any intermittent short condition.
Measure the resistance from the ECM connector P2:2 (+5 V Supply) to every pin on ECM connector P2.
Measure the resistance from the ECM connector P2:2 to the ECM ground strap.
Measure the resistance from the ECM connector P1:2 (+5 V Supply) to every pin on ECM connector P1.
Measure the resistance from the ECM connector P1:2 to the ECM ground strap.Expected Result:Each resistance measurement is more than 20,000 Ohms.Results:
OK - The resistance check does not indicate a short in the engine harness or a short to engine ground. Proceed to Test Step 6.
Not OK - A resistance measurement is less than 20,000 Ohms. The +5 V supply wire is shorted in the engine harness or the +5 V supply wire is shorted to engine ground.Repair: Repair the wire or replace the wire. Clear all logged diagnostic codes. Replace all wires to the original configuration. Verify that the repair eliminates the problem.STOPTest Step 6. Check the +5 V Supply at the ECM
Remove the wire G828-WH from ECM connector P2:2 (+5 V Supply). Install a wire jumper with socket terminals on both ends into P2:2.
Reconnect ECM connector J2/P2.
Remove the wire 125-OR from ECM connector P1:2 (+5 V Supply). Install a wire jumper with socket terminals on both ends into P1:2.
Reconnect ECM connector J1/P1.
Place the engine control in the ON mode.
Measure the voltage between the wire jumper in P1:2 and the engine ground.
Measure the voltage between the wire jumper in P2:2 and the engine ground.
Place the engine control in the OFF/RESET mode.
Replace all wires to the original configuration.Expected Result:The voltage is 5.0 0.2 VDC.Results:
OK - The voltage is correct.Repair: Clear all diagnostic codes. Check for active diagnostic codes. If the problem is intermittent, refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - The voltage is incorrect.Repair: Replace the ECM. Refer to the diagnostic procedure Troubleshooting, "Replacing the ECM".STOP