ELECTRONIC DIESEL ENGINE

DIAGNOSIS SPECIALIST TEST (L2)

MEDIUM/HEAVY COMPOSITE VEHICLE
PREPARATION/REFERENCE BOOKLET
INTERNET VERSION
1998 National Institute for AUTOMOTIVE SERVICE EXCELLENCE. All rights reserved.
This booklet is intended only for preparation and reference when taking the ASE Electronic
Diesel Engine Diagnosis Specialist (L2) Test. The medium/heavy composite vehicle control
system is based on designs common to many engine and vehicle manufacturers, but is not
identical to any actual production engine or vehicle.
ASE MEDIUM/HEAVY COMPOSI TE VEHI CLE PREPARATION/REFERENCE BOOKLET PAGE 1
ASE
ELECTRONIC DIESEL ENGINE DIAGNOSIS SPECIALIST TEST
MEDIUM/HEAVY COMPOSITE VEHICLE INFORMATION
GENERAL DESCRIPTION
This generic four cycle, in-line six cylinder diesel engine is equipped with a
turbocharger, charge air cooler, and electronic unit injectors. The engine rating is
330 hp at 1,800 rpm and develops a peak torque of 1150 lb. ft. at 1,200 rpm.
THE ELECTRONIC CONTROL MODULE (ECM)
The electronic control module is the microprocessor that receives electronic inputs
from sensors and switches, and is calibrated to control fuel metering, injection
timing, diagnostics, and engine protection. The ECM receives power from the
battery and ignition switch and provides a reference voltage for some sensors. The
software (instructions) contained in the ECM determine how the electronic diesel
engine control system operates. The ECM stores the calibration values that define
rated horsepower, torque curves, and rpm specifications. The ECM is mounted on
the engine.
FUEL SYSTEM
Fuel supply (transfer) is provided by a positive displacement, mechanically driven
pump. A regulating valve is used to maintain fuel pressure. Fuel delivery is provided
by electronically controlled unit injectors. The injector solenoids are energized by
the ECM.
PROGRAMMABLE PARAMETERS
Programmable parameters are the specifications that can be set within the ECM to
control operating functions. The parameters are stored in non-volatile memory. A
customer password is available for programing protection. A list of parameter
ranges and their settings are shown below.
Feature Range Setting Feature Range Setting
Max Vehicle Speed in Top Gear 35-99 mph 60 mph One Gear Down Ratio .5-1.5 1.0
Cruise Control Set Speed 35-99 mph 60 mph Min. Engine Cooling Fan On Time 0-999 sec. 240 sec.
Max Engine Speed with VSS Signal 1600-2500 rpm 2100 rpm PTO / Remote PTO:
Max Engine Speed w/o VSS Signal 1200-2500 rpm 1800 rpm max PTO speed 600-2500 rpm 1000 rpm
Idle Set Speed 600-850 rpm 700 rpm min PTO speed 600-2500 rpm 700 rpm
Gear Down Max Vehicle Speed: 35-99 mph 58 mph set PTO speed 600-2500 rpm 900 rpm
Cruise Control and Engine Brakes: mph above cruise set speed resume PTO speed 600-2500 rpm 900 rpm
engine brake low 1-20 mph 6 mph remote PTO speed 600-2500 rpm 1000 rpm
engine brake medium 1-20 mph 6 mph Idle Shutdown Timer 3-60 min. 5 min.
engine brake high 1-20 mph 8 mph Tire Revolutions per Mile 400-700 501
Road Speed Governor Droop 0-4 mph 2 mph Rear Axle Ratio 2.50-12.0 4.10
Max Progressive Shift Speed 1500-2500 rpm 1800 rpm # of VSS Wheel Teeth 5-16 16
Mph at Max Progressive Shift Speed 6-99 mph 18 mph
PAGE 2 ASE MEDIUM/HEAVY COMPOSI TE VEHI CLE PREPARATION/REFERENCE BOOKLET
ENGINE PROTECTION SYSTEM
The engine protection system monitors coolant temperature, coolant level, oil
temperature, intake manifold temperature, and oil pressure. The system has three
levels of protection: warning, derate, and shutdown.
In the warning mode, the yellow warning/diagnostic lamp alerts the operator of a
potential problem. In the derate (limp home) mode, the ECM will gradually reduce
engine power after lighting the red warning/diagnostic lamp. Power deration will
begin 30 seconds after the initial warning. The shutdown mode will activate for
engine coolant temperature, coolant level, or engine oil pressure failures only.
Shutdown will occur when the condition reaches a preset value, after the warning
and derate modes have been activated. The diagnostic on/off switch can be used to
temporarily override the shutdown mode.
High Engine Coolant Temperature Low Engine Oil Pressure
Engine Coolant Power Derate/ dependent on the relationship between
Temperature Shutdown oil pressure and engine speed. If the oil
210 EF 100% Power pressure falls below these specifications,
215 EF 75% Power power derate will begin, and shutdown
220 EF 50% Power will occur if oil pressure continues to
225 EF 25% Power decrease.
230 EF Shutdown
Low Engine Coolant Level
Power derate begins after an additional
20 second delay, and shutdown occurs
if the coolant level remains low.
High Intake Manifold Temperature
Power derate begins when the mani-
fold air temperature reaches 210 EF.
Power derate/shutdown set points are
Engine Oil Pressure
Engine Speed Begin Derate
Shutdown
2000 rpm 40 psi 20 psi
1800 rpm 35 psi 17 psi
1400 rpm 25 psi 12 psi
1000 rpm 15 psi 8 psi
600 rpm 5 psi 2 psi
High Engine Oil Temperature
Power derate begins when the oil
temperature reaches 260 EF.

ENGINE OPERATING SPECIFICATIONS
Fuel Pressure - Cranking: 20 psi. min. Engine Oil Pressure - Idle: 15-35 psi. min.
Rated rpm: 90-100 psi. Rated rpm: 50-70 psi.
Engine Coolant Temperature - 195EF Engine Oil Temperature - 210EF
Turbo Boost Pressure - Rated rpm: 20-30 psi.
ASE MEDIUM/HEAVY COMPOSI TE VEHI CLE PREPARATION/REFERENCE BOOKLET PAGE 3
SENSORS
Throttle Position Sensor (TPS)
The TPS is a potentiometer that senses the position of the accelerator pedal. A
reference voltage is sent to the TPS, and as the angle of the accelerator pedal
changes, the TPS varies the signal voltage to the ECM. This sensor includes an
integral idle validation switch (IVS). (PID 91)
Engine Oil Pressure Sensor (EOP)
The solid-state EOP sensor monitors engine oil pressure, and is installed in the
main lube oil gallery. The ECM uses this signal for engine protection. (PID 100)
Boost Pressure Sensor (BP)
The solid-state BP sensor monitors positive intake manifold pressure, and is
located on the intake manifold. The ECM uses this signal to control fuel metering
and injection timing and to limit smoke during acceleration. (PID 102)
Intake Manifold Temperature Sensor (IMT)
The IMT sensor monitors air temperature in the intake manifold. The ECM uses
this signal to control injection timing, fuel metering, and engine protection. (PID
105)
Barometric Pressure Sensor (BARO)
The solid-state BARO sensor monitors ambient air pressure, and is located on
the side of the engine block. The ECM uses this signal to adjust fuel timing and
metering based on altitude. (PID 108)
Engine Coolant Temperature Sensor (ECT)
The ECT sensor monitors coolant temperature in the engine block, and is
mounted in the engine coolant jacket. The ECM uses this signal to control
injection timing and fan clutch operation. During an overheating situation, it is
also used for engine protection. (PID 110)
Coolant Level Sensor (CL)
The CL sensor detects the presence or absence of coolant at the probe, and is
located in the radiator top tank. The ECM uses this signal for engine protection
when coolant is not detected. (PID 111)
Fuel Temperature Sensor (FT)
The FT sensor monitors fuel temperature, and is mounted on the secondary fuel
filter housing. The ECM uses this signal to adjust calculated fuel measurements
in order to compensate for fuel temperature changes. (PID 174)
Engine Oil Temperature Sensor (EOT)
The EOT sensor monitors engine oil temperature, and is installed in the main
lube oil gallery. The ECM uses this signal for the engine protection. (PID 175)
PAGE 4 ASE MEDIUM/HEAVY COMPOSI TE VEHI CLE PREPARATION/REFERENCE BOOKLET
SENSORS (CONTINUED)
Engine Position Sensor (EPS)
The EPS is a Hall-effect sensor that generates a digital signal whose frequency
varies with the speed of the engine. The ECM uses the frequency and
pulsewidth of this signal to determine engine speed and cylinder position for fuel
control and injector timing. The EPS is located in the engine front cover facing
the trigger wheel which is mounted on the camshaft gear. (PID 190)
Vehicle Speed Sensor (VSS)
The magnetic pick-up VSS measures vehicle speed at the transmission output.
The ECM uses this AC voltage signal for the speedometer, cruise control
operation, and vehicle (road) speed limiting. (PID 84)
SWITCHES
Engine Cooling Fan Manual Switch
This is a normally open switch that, when closed by the operator, requests that
the ECM deenergize the engine cooling fan solenoid. This will cause the cooling
fan to operate continuously.
Diagnostic On/Off Switch
This is a normally open momentary switch that, when pressed and released,
requests that the ECM enter diagnostic mode. The yellow warning/diagnostic
indicator lamp will come on and flash inactive fault codes. The red
warning/diagnostic indicator lamp will come on and flash active fault codes. If
both lights remain on only momentarily, no fault codes are present. The operator
may also override the engine protection system shutdown by depressing and
holding the switch on.
Air Conditioning High Pressure Switch
This normally closed pressure switch opens when the air conditioner high-side
pressure reaches a preset value. This signals the ECM to operate the engine
cooling fan. (SID 228)
Idle Validation Switch (IVS)
The IVS is an integral part of the throttle position sensor (TPS). This two-position
switch indicates idle position when one set of contacts is closed, and off-idle
position when the other set of contacts is closed. For safety, the ECM will
command idle speed whenever the off-idle position contacts are open,
regardless of the signal from the TPS. (SID 230)
Cruise Control On/Off Switch
This normally open switch enables cruise control operation when it is closed by
the operator. (SID 244)
ASE MEDIUM/HEAVY COMPOSI TE VEHI CLE PREPARATION/REFERENCE BOOKLET PAGE 5
SWITCHES (CONTINUED)
Cruise Set/Resume Switch
This switch has two momentary positions: set/coast and resume/accelerate.
Vehicle cruising speed can be set by pressing the set switch. Once a speed has
been set, and then disengaged using the brake or clutch, the ECM will return to
the previously set speed when the resume switch is pressed. (Set - SID 243,
Resume - SID 242)
Clutch Switch
This normally closed switch opens when the clutch pedal is depressed. This
signals the ECM to cancel cruise control, power take-off mode, and engine
braking, and to override the idle shutdown timer. (SID 245)
Service Brake Switch
This normally closed air pressure switch opens when the service brake pedal is
depressed. This signals the ECM to enable engine braking, cancel cruise control
and power take-off mode, and to override the idle shutdown timer. (SID 246)
Engine Brake On/Off Switch
This normally open switch enables engine brake operation when closed by the
operator. (PID 121)
Engine Brake Selector Switch
This three-position switch sets the level of engine braking (low, medium or high).
(Low/High - PID 121, Med/High - PID 122)
Power Take-Off (PTO) On/Off Switch
This normally open switch enables PTO mode operation when closed. In this
mode, the cruise control switches are used to set and hold engine speed. (PID
150)
Power Take-Off (PTO) Remote Switch
This normally open switch is mounted outside the cab and enables remote PTO
mode operation when closed. (PID 150)
ACTUATORS
Electronic Unit Injectors (EUI)
These electromechanical diesel fuel injectors contain a solenoid controlled by
the ECM to manage fuel timing and metering. The injector solenoid driver
circuitry in the ECM sends a high voltage signal to energize the injector
solenoid. (SID 1, 2, 3, 4, 5, 6)
Engine Cooling Fan Solenoid
When it is energized by the ECM, this normally closed solenoid supplies air
pressure to disengage the engine cooling fan clutch. (SID 33)
PAGE 6 ASE MEDIUM/HEAVY COMPOSI TE VEHI CLE PREPARATION/REFERENCE BOOKLET
DISPLAYED DATA
Engine Coolant Temperature (ECT) EF
Intake Manifold Temperature (IMT) EF
Engine Oil Temperature (EOT) EF
Fuel Temperature (FT) EF
Engine Oil Pressure (EOP) psi
Boost Pressure (BP) psi
Barometric Pressure (BARO) In.Hg
Throttle Position (TPS) %
Idle Validation Switch (IVS) On/Off
Engine Position (EPS) rpm
Vehicle Speed (VSS) mph
Battery Voltage (B+) Volts
Coolant Level (CL) Normal/Low
Cruise Control Set Speed mph
Cruise Control Switch On/Off
PTO Switch On/Off
Remote PTO Switch On/Off
Engine Cooling Fan Switch On/Off
A/C High Pressure Switch Open/Closed
Clutch Switch Depressed/Released
Service Brake Switch Depressed/Released
Engine Brake Switch On/Off
Engine Brake Selector Low/Med/High
Diagnostic Lamp - Yellow On/Off
- Red On/Off
Diagnostic Trouble Codes
Active:
Inactive:
ACTUATORS (CONTINUED)
Warning/Diagnostic Indicator Lamps
The Red "engine shutdown" lamp lights when the engine protection system is in
the derate and shutdown modes. The Red lamp can also be used to read active
fault flash codes in diagnostic mode. (SID 238)
The Yellow "warning" lamp lights when the engine protection system is in the
warning mode, or when electronic control system failures are occurring and an
active fault is present. The Yellow lamp can also be used to read inactive fault
flash codes in diagnostic mode. (SID 239)
Engine Brake Solenoids
These three solenoids can be energized by the ECM to provide engine braking
on two, four or all six cylinders. The engine brake can be operated in cruise
control (switch on) and will be energized after the set speed has been exceeded
or when the service brake pedal is depressed and the throttle pedal is released.
The ECM will not energize the solenoids when the clutch pedal is depressed.
(Low/High Solenoid - PID 121, Med/High Solenoids - PID 122)
DATA LINK CONNECTORS
The J1939 data link allows the ECM to communicate with other vehicle control
systems such as transmission, automatic traction control, and anti-lock brake
controllers. The J1939 data link connector is mounted on the engine. (SID 231)
The J1587 data link is used by an electronic Diagnostic Tool to communicate with
the ECM. This allows for diagnostic information retrieval and parameter calibration
setting. The J1587 data link connector is located in the cab. (SID 250)
DIAGNOSTIC EQUIPMENT
A Breakout Tool can be connected into a circuit to measure voltage signals and
resistance values with a DMM (Digital Multimeter). The Displayed Data chart below
shows how Diagnostic Tool data will be presented in some Composite Vehicle test
questions. If a range of values is given, the sensor reading is varying in that range.
ASE MEDIUM/HEAVY COMPOSI TE VEHI CLE PREPARATION/REFERENCE BOOKLET PAGE 7
IDENTIFIERS
Diagnostic Trouble Codes (DTC)
Trouble codes can be active or inactive. Active codes indicate that the problem currently
exists and inactive codes indicate that a problem once existed. Flash codes represent
digits assigned to diagnostic trouble codes, so that DTCs can be retrieved through the
diagnostic lamps. The DTC's are formatted under SAE J1587 standards. The first set of
numbers is the Parameter or Subsystem Identifier and the second set is the Failure Mode
Identifier. Both can be retreived from the ECM via the Data Link.
SubSystem Identifier (SID)
The SID is a one, two, or three digit code assigned to identify a section of a
control system without a related parameter identifier.
Parameter Identifier (PID)
The PID is a two or three digit code which is assigned to each component.
Failure Mode Identifier (FMI)
The FMI is a one or two digit code that describes the type of failure detected in the
system component.
FAILURE MODE IDENTIFIERS (FMI)
Number Description
0 Data valid but above normal operational range
1 Data valid but below normal operational range
2 Data erratic, intermittent, or incorrect
3 Voltage above normal or shorted high
4 Voltage below normal or shorted low
5 Current below normal or open circuit
6 Current above normal of grounded circuit
7 Mechanical system not responding properly
8 Abnormal frequency, pulse width, or period
9 Abnormal update rate
10 Abnormal rate of change
11 Failure mode not identifiable
12 Bad intelligent device or component
13 Out of calibration
14 Special instructions
PAGE 8 ASE MEDIUM/HEAVY COMPOSI TE VEHI CLE PREPARATION/REFERENCE BOOKLET
PID/SID CODE LISTING
Code Description Flash Code
S1 Cylinder 1 11
S2 Cylinder 2 12
S3 Cylinder 3 13
S4 Cylinder 4 14
S5 Cylinder 5 15
S6 Cylinder 6 16
S33 Engine Cooling Fan Solenoid 17
P71 Idle Shutdown 18
P84 Vehicle Speed Sensor 19
P91 Throttle Position Sensor 20
P100 Engine Oil Pressure Sensor 21
P102 Boost Pressure Sensor 22
P105 Intake Manifold Temperature Sensor 23
P108 Barometric Pressure Sensor 24
P110 Engine Coolant Temperature Sensor 25
P111 Engine Coolant Level Sensor 26
P121 Engine Brake Solenoid Lo/Hi 27
P122 Engine Brake Solenoid Med/Hi 28
P150 PTO On/Off Switch 29
P168 Battery Supply 30
P174 Fuel Temperature Sensor 31
P175 Engine Oil Temperature Sensor 32
P187 PTO 33
P190 Engine Position Sensor 34
S228 A/C High Pressure Switch 35
S230 Idle Validation Switch 36
S231 J1939 Data Link 37
S232 5 Volt Supply 38
S238 Warning/Diagnostic Lamp-Red 39
S239 Warning/Diagnostic Lamp-Yellow 40
S242 Cruise Control Resume Switch 41
S243 Cruise Control Set Switch 42
S244 Cruise Control On/Off Switch 43
S245 Clutch Switch 44
S246 Service Brake Switch 45
S250 J1587 Data Link 46
S252 Incorrect Engine Software 47
S253 Check System Parameters 48
S254 ECM 49
NOTE: S = System Identifier (SID)
P = Parameter Identifier (PID)
ASE MEDIUM/HEAVY COMPOSI TE VEHI CLE PREPARATION/REFERENCE BOOKLET PAGE 9
ELECTRICAL SPECIFICATIONS
Data Links (Vehicle and Control) All Shorts to External Voltage
Positive Wire to chassis ground: OK: if less than 1.5 VDC
2.5 to 5.0 VDC
Negative Wire to chassis ground: 5 V Reference Power Supply
0.0 to 2.5 VDC At ECM: 4.75 to 5.25 VDC
Fuel Injectors
0.5 to 5.0 ohms resistance
100 to 120 VDC supply voltage
ECM
9.0 to 16.0 VDC supply voltage
Maximum voltage drop on all
circuits (except injectors): 0.05 VDC
At Harness: 4.75 to 5.25 VDC
All Shorts to Ground
OK: If greater than 100 Kohms
(No short circuit)
All Continuity Checks
OK: if less than 10 ohms
(No open circuit)
SENSOR SPECIFICATIONS
Vehicle Speed Sensor Barometric Pressure Sensor
Coil Resistance: 1100 to 1500 ohms Pressure Altitude Voltage
Throttle Position Sensor 29.9 0 (sea level) 4.0 - 4.6
Potentiometer Resistance: 26.8 3000 3.6 - 4.4
Between supply and return wires: 24.0 6000 3.2 - 4.0
2000 to 3000 ohms 21.4 9000 3.0 - 3.8
Between supply and signal wires: 19.1 12000 2.6 - 3.4
released pedal -
1500 to 3000 ohms Engine Oil Pressure Sensor
depressed pedal - Pressure Voltage
200 to 1500 ohms kPa psi VDC
Released minus depressed: Must be 0 0 0.4 - 0.6
greater than 1000 ohms 172 25 1.4 - 1.6
Boost Pressure Sensor 517 75 3.4 - 3.6
Pressure Voltage 689 100 4.4 - 4.6
psi in. Hg VDC
0.0 0.0 0.42 - 0.58
12.5 25.45 1.42 - 1.58
25.0 50.90 2.42 - 2.58
37.5 76.35 3.42 - 3.58
50.0 101.80 4.42 - 4.58
Coolant Level Sensor
Coolant present: CL Normal signal =
5 VDC, CL Low signal near 0 VDC
Coolant NOT present: CL Low signal
= 5 VDC, CL Normal signal near 0 VDC
In. Hg. feet VDC
345 50 2.4 - 2.6
All Temperature Sensors
Temperature Voltage
EC EF VDC
-40 -40 0.50
0 32 0.75
32 90 1.50
54 130 2.50
82 180 3.60
120 248 4.50