5033701 JOHNSON HOSE, FUEL

Illustration 1 g00902222
SchematicNote: There are two types of solenoids. The connector for one of the solenoids is integral to the solenoid. The connector for the other solenoids is at the end of a pigtail that is connected to the solenoid.
Illustration 2 g00916561
P2 ECM connector
Illustration 3 g00910291
Engine viewsTest Step 1. Check for Diagnostic Codes
Turn the key switch to the OFF position.
Connect the Caterpillar Electronic Technician (Cat ET) to the data link connector.
Turn the key switch to the ON position. Access the "Special Tests" under the "Diagnostics" menu on Cat ET. Activate the "Turbo Wastegate Solenoid Output" on Cat ET. Wait at least 15 seconds for activation of the diagnostic codes.
Monitor Cat ET for active diagnostic codes and/or logged diagnostic codes.Expected Result:One or more diagnostic codes are active or logged.Results:
32-05, 32-06, or 32-11 is active and/or logged - Proceed to Test Step 2.
102-01, 102-02, or 102-07 is logged - Proceed to Test Step 9.
No Codes - STOPTest Step 2. Inspect Electrical Connectors and Wiring
Thoroughly inspect the J2/P2 ECM connector and the J511/P511 Wastegate solenoid connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the wastegate solenoid.
Check the ECM connector for the proper torque of 6.0 N m (55 lb in).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 3.
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 3. Determine the Diagnostic Code that is Active
Turn the key switch to the ON position. Access the "Special Tests" under the "Diagnostics" menu on Cat ET. Activate the "Turbo Wastegate Solenoid Output" on Cat ET. Wait at least 15 seconds for activation of the diagnostic codes.
Check for active diagnostic codes on Cat ET.
Determine if the problem is related to a "current low" diagnostic code (open circuit) or a "current high" diagnostic code (short circuit).Expected Result:A "current low" diagnostic code (open circuit) or a "current high" diagnostic code (short circuit) is active.Results:
Current Low (Open) - A "current low" diagnostic code (open circuit) is active at this time. Proceed to Test Step 4.
Current High (Short) - A "current high" diagnostic code (short circuit) is active at this time. Proceed to Test Step 6.
Current Mismatch - The ECM detects a short circuit to the + Battery.Repair: Perform the following procedure:
Inspect the J2/P2 ECM connector for moisture that could cause a short circuit.
Inspect the wiring harness for signs of tampering.
Repair any problems with the circuit. Verify that the repair eliminates the problem.Note: Factory Passwords are required to clear the 32-11 diagnostic code.STOPTest Step 4. Create a Short Circuit in the Harness at the Solenoid
Turn the key switch to the OFF position.
Disconnect the J511/P511 Turbo Wastegate Solenoid connector.
Fabricate a jumper wire between J511:1 and J511:2 in order to create a short circuit.
Turn the key switch to the ON position. Access the "Special Tests" under the "Diagnostics" menu on Cat ET. Activate the "Turbo Wastegate Solenoid Output" on Cat ET. Wait at least 15 seconds for activation of the diagnostic codes.
Check for active diagnostic codes on Cat ET.Expected Result:32-06 Turbo Wastegate Solenoid current high is now active.Results:
OK - There is an open circuit in the solenoid.Repair: Perform the following procedure:
Temporarily connect a new solenoid.
If the problem is fixed reconnect the suspect solenoid. If the problem returns, permanently install the new solenoid.Note: The solenoid coil can be replaced independently of the valve. If the problem is with the coil replace only the coil. Refer to the Parts Manual for more information.STOP
Not OK - The "current low" diagnostic code (open circuit) is still active. Proceed to Test Step 5.Test Step 5. Create a Short Circuit at the ECM
Turn the key switch to the OFF position.
Remove the wires from P2:61 and P2:62.
Fabricate a jumper wire between P2:61 and P2:62 of the ECM connector in order to create a short circuit.Note: The J2/P2 ECM connector must be connected during this step.
Turn the key switch to the ON position. Access the "Special Tests" under the "Diagnostics" menu on Cat ET. Activate the "Turbo Wastegate Solenoid Output" on Cat ET. Wait at least 15 seconds for activation of the diagnostic codes.
Check for active diagnostic codes on Cat ET.Expected Result:32-06 Turbo Wastegate Solenoid current high is now active.Results:
OK - There is a problem in the harness between the ECM and the solenoid. Proceed to Test Step 8.
Not OK - There is still a "current low" diagnostic code (open circuit).Repair: Perform the following procedure:
Temporarily connect a test ECM. Refer to Troubleshooting, "Programming Parameters" before replacing the ECM.
If the test ECM fixes the problem, reconnect the suspect ECM. If the problem returns, permanently install the new ECM.Note: The solenoid coil can be replaced independently of the valve. If the problem is with the coil only replace the coil. Refer to the Parts Manual for more information.STOPTest Step 6. Disconnect the Solenoid in order to Create an Open Circuit
Turn the key switch to the OFF position.
Disconnect the J511/P511 Turbo Wastegate Solenoid connector in order to create an open circuit.
Turn the key switch to the ON position. Access the "Special Tests" under the "Diagnostics" menu on Cat ET. Activate the "Turbo Wastegate Solenoid Output" on Cat ET. Wait at least 15 seconds for activation of the diagnostic codes.