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Test Procedure

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  1. KP1 CHECK FOR DIAGNOSTIC TROUBLE CODES (DTCS) 

    Are DTCs P00DF, P00E0, P00E1, P00E2, P023A, P023B, P023C, P026A, P026E, P2B83, P2BC1, P2BC3 or U02A9 present? 

    Yes No
    For DTC P00DF, P00E0, P00E1, P00E2, GO to  KP2.
    For all others, GO to  KP9.    		 For symptoms without DTCs, GO to  KP2.
    For all others, RETURN to SYMPTOM CHARTS for further direction.
  2. KP2 CHECK THE CAC COOLING SYSTEM 
    WARNING: TO AVOID PERSONAL INJURY DO NOT UNSCREW THE COOLANT PRESSURE RELIEF CAP WHILE THE ENGINE IS OPERATING OR HOT. THE COOLING SYSTEM IS UNDER PRESSURE. STEAM AND HOT LIQUID CAN COME OUT FORCEFULLY WHEN THE CAP IS LOOSENED SLIGHTLY. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN PERSONAL INJURY.
    NOTE: Verify cooling fan operation before proceeding with this test.
    • Check the CAC cooling system for any loss of coolant or overheating concerns.

    Is the CAC cooling system OK? 

    Yes No
    GO to  KP3. REFER to the appropriate Charge Air Cooling article, to continue CAC cooling system diagnosis.
  3. KP3 CHECK THE RESISTANCE OF THE CAC COOLANT TEMPERATURE SENSOR 
    NOTE: Refer to the chart at the beginning of this test for the resistance specifications.
    • Ignition OFF.
    • CACCT Sensor connector disconnected.
    • Measure the resistance between:
    (+) CACCT Sensor Connector, Component Side (-) CACCT Sensor Connector, Component Side
    CACCTS - Pin 1 SIGRTN - Pin 2

    Is the resistance within specification? 

    Yes No
    GO to  KP4. INSTALL a new Charge Air Cooler (CAC) Coolant Temperature sensor.
    REFER to the appropriate Electronic Engine Controls article. RESET the keep alive memory (KAM), REFER to ENGINE CONTROLS - DIAGNOSTIC METHODS (DIESEL) ,
    Clear the PCM DTCs. REPEAT the self-test.
  4. KP4 CHECK THE CAC COOLANT TEMPERATURE SENSOR CIRCUITS FOR AN OPEN 
    • PCM-B connector disconnected.
    • Measure the resistance between:
    (+) CACCT Sensor Connector, Harness Side (-) PCM-B Connector, Harness Side
    CACCTS - Pin 1 CACCTS - Pin 92
    SIGRTN - Pin 2 SIGRTN - Pin 63

    Are the resistances less than 5 ohms? 

    Yes No
    GO to  KP5. REPAIR the open circuit. Clear the PCM DTCs.
    REPEAT the self-test.
  5. KP5 CHECK THE CAC COOLANT TEMPERATURE SENSOR CIRCUITS FOR A SHORT TO GROUND 
    • Measure the resistance between:
    (+) CACCT Sensor Connector, Harness Side (-)
    CACCTS - Pin 1 Ground
    SIGRTN - Pin 2 Ground

    Are the resistances greater than 10K ohms? 

    Yes No
    GO to  KP6. REPAIR the short circuit. Clear the PCM DTCs.
    REPEAT the self-test.
  6. KP6 CHECK THE CAC COOLANT TEMPERATURE SENSOR CIRCUITS FOR A SHORT TO VOLTAGE 
    • Ignition ON, engine OFF.
    • Measure the voltage between:
    (+) CACCT Sensor Connector, Harness Side (-)
    CACCTS - Pin 1 Ground
    SIGRTN - Pin 2 Ground

    Is any voltage present? 

    Yes No
    REPAIR the short circuit. Clear the PCM DTCs.
    REPEAT the self-test.    		 GO to  KP7.
  7. KP7 CAC COOLANT TEMPERATURE SENSOR INTERMITTENT CHECK 
    • CACCT Sensor connector connected.
    • PCM-E connector connected.
    • Ignition ON, engine OFF.
    • Access the PCM and monitor the CACCT_V (VOLT) PID.
    • While observing the PID, wiggle, shake, and bend small sections of the wiring harness while working from the sensor to the PCM.
    • Lightly tap on the CAC coolant temperature sensor and wiggle the harness and connector to simulate road shock.

    Does the PID reading change? 

    Yes No
    REPAIR as necessary or INSTALL a new CAC coolant temperature sensor. REFER to the appropriate Electronic Engine Controls article. RESET the keep alive memory (KAM), REFER to ENGINE CONTROLS - DIAGNOSTIC METHODS (DIESEL) , GO to  KP8.
  8. KP8 CHECK THE CHARGE AIR COOLER COOLANT TEMPERATURE AND THE ENGINE COOLANT TEMPERATURE CORRELATION 
    NOTE: Check temperature values while engine is at ambient temperature, cold soak the engine for a minimum of 6 hours if necessary. Make sure the vehicle has not been in direct sun light.
    NOTE: All PIDs may not be available on all vehicles.
    • Access the PCM and monitor the CACCT (TEMP), ECT (TEMP) and ECT1 (TEMP) PIDs.

    Are the temperature readings within 16.6° C (30°F) of each other? 

    Yes No
    GO to PINPOINT TEST ZZ . INSTALL a new Charge Air Cooler (CAC) Coolant Temperature sensor.
    REFER to the appropriate Electronic Engine Controls article. RESET the keep alive memory (KAM). REFER to ENGINE CONTROLS - DIAGNOSTIC METHODS (DIESEL) ,
    Clear the PCM DTCs. REPEAT the self-test.
  9. KP9 CHECK THE PUMPPWR CIRCUIT FOR AN OPEN 
    • Ignition OFF.
    • CACCP Motor connector disconnected.
    • Ignition ON, engine OFF.
    • Measure the voltage between:
    (+) CACCP Motor Connector, Harness Side (-)
    VPWR - Pin 2 Ground

    Is the voltage greater than 10.5 V? 

    Yes No
    GO to  KP10. REPAIR the open circuit. Clear the PCM DTCs.
    REPEAT the self-test.
  10. KP10 CHECK THE GND CIRCUIT FOR AN OPEN 
    • Ignition OFF.
    • Measure the resistance between:
    (+) CACCP Motor Connector, Harness Side (-)
    GND - Pin 1 Ground

    Is the resistance less than 5 ohms? 

    Yes No
    GO to  KP11. REPAIR the open circuit. Clear the PCM DTCs.
    REPEAT the self-test.
  11. KP11 CHECK THE CAC CIRCUIT FOR AN OPEN 
    • PCM-E connector disconnected.
    • Measure the resistance between:
    (+) CACCP Motor Connector, Harness Side (-) PCM-B Connector, Harness Side
    CACCP - Pin 3 CACCP - Pin 100

    Is the resistance less than 5 ohms? 

    Yes No
    GO to  KP12. REPAIR the open circuit. Clear the PCM DTCs.
    REPEAT the self-test.
  12. KP12 CHECK THE CAC CIRCUIT FOR A SHORT TO GROUND 
    • Measure the resistance between:
    (+) CACCP Motor Connector, Harness Side (-)
    CACCP - Pin 3 Ground

    Is the resistance greater than 10K ohms? 

    Yes No
    GO to  KP13. REPAIR the short circuit. Clear the PCM DTCs.
    REPEAT the self-test.
  13. KP13 CHECK THE CAC CIRCUIT FOR A SHORT TO VOLTAGE 
    • Ignition ON, engine OFF.
    • Measure the voltage between:
    (+) CACCP Motor Connector, Harness Side (-)
    CACCP - Pin 3 Ground

    Is any voltage present? 

    Yes No
    REPAIR the short circuit. Clear the PCM DTCs.
    REPEAT the self-test.    		 INSTALL a new Charge Air Cooler (CAC) Pump. REFER to the appropriate Charge Air Cooling article.
    Clear the PCM DTCs. REPEAT the self-test.
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