TIER II COMPLIANT

COMMON RAIL ENGINE

DIAGNOSTIC/REPAIR KIT
(New Engine Family — NEF)
Part No. 380040185
 Part No. 380040185
TIER II COMPLIANT COMMON RAIL ENGINE (NEF)
Harness Diagnostic and Repair Kit
STRUCTURAL AND NON-STRUCTURAL APPLICATIONS

The 380040185 Harness Diagnostic Kit allows
you to quickly, accurately and safely diagnose
harness, sensor and actuator faults by connect-
ing in-line to run system checks with the engine
running or in static, key-on condition. The inter-
face harnesses give you the ability to connect
your DVOM in-line without damaging connectors
or harness terminals. Other adapters in this kit
allow you to check harness integrity at the Engine
Control Unit without damaging the delicate pins in
the ECU connectors. Also included are replace-
ment connectors and pigtails for repair of dam-
aged harnesses.

1. Fuel pressure sensor 2. Coolant temperature sensor 3. Engine oil pressure and
temperature sensor 4. Crankshaft sensor 5. Electro-injector 6. Air pressure -
temperature sensor 7. Camshaft sensor 8. Fuel heater and fuel temperature sen-
sor 9. Pressure regulator 10. EDC 7 control unit

2
 CAM/CRANKSHAFT SENSOR DIAGNOSTICS
Interface Harness Part # 380002411

Crankshaft Sensor Camshaft Sensor

Engine Harness Connector

Face/Latch Up

1 2 3 1 2 3
1. Yellow boot, ground 2. Red boot, positive 3. Black boot, ground shield

Camshaft and Crankshaft Sensor Check

Perform test on both sensors.

1. Attach interface harness (380002411) to
sensor but not to engine harness.
2. Sensor Resistance Test: Connect ohm-
meter to yellow and red clips. Reading
should be 900 ohms ± 75 ohms at 20
degrees C. If not, replace the sensor.
3. Connect engine harness to interface har-
ness.
4. Circuit Ground Test: Connect ohmmeter
to black and yellow clips. Reading should
be less than 5 ohms. If reading is not
less than 5 ohms, go to line 6.
5. Sensor Output Test: Connect an AC
voltmeter to the yellow and red clips.
Reading should be a minimum of .50
volts AC while cranking engine. Voltage
will be higher with engine running. If not,
replace the sensor.
6. If any readings are open, carefully remove
the connector from the processor, install
the Pin Sizing/Probe Adapter
(380002416) in the appropriate processor
terminal and the Male Pigtail Spade
(380002415) to the appropriate terminal
of the sensor. Connect the ohmmeter lead
to each end of the suspected wire and
check for continuity.
7. The reading should be less than 5 ohms.
If the reading is more than 5 ohms, check
for a light drag on the pin sizing tool mov-
ing the tool in and out of the terminal. If
the pin sizing tool is loose in the terminal,
repair as necessary.
8. If drag is felt on the pin sizing tool check
for a damaged wire or terminal in the sen-
sor connector. Repair as necessary.

3
 COMMON RAIL PRESSURE SENSOR DIAGNOSTICS
Interface Harness Part # 380002412
Common Rail Pressure Sensor
Engine Harness Connector Face/Latch up

Attach interface harness to sensor

1 2 3
1. Black boot, Ground 2. Yellow boot, Signal 3. Red boot, Reference Voltage
Common Rail Pressure Sensor Check

1. Attach interface harness to sensor and to the 6. The reading should be less than 5 ohms. If
engine harness the reading is more than 5 ohms, check for a
2. Reference Voltage Check: Connect light drag on the Pin Sizing tool, moving the
Voltmeter + to the red clip and the — to the tool in and out of the terminal. If the Pin Sizing
black clip. Turn the key switch to the ON tool is loose in the terminal, the wiring har-
position. Reading should be 5 volts ± 0.5v. ness must be replaced. If the circuit is OK,
If not, connect the voltmeter lead to a good use the wiring schematic and check the
ground. If the voltmeter reading now is 5 voltage and ground supply at the processor.
volts ± 0.5v, repair the ground return circuit to If voltage is OK, processor replacement may
the processor. be necessary.
3. Sensor Voltage Check: Connect the volt- 7. If drag is felt on the Pin Sizing tool check for a
meter + to the yellow clip and the voltmeter damaged wire or terminal in the sensor con-
— to the black clip. nector. Repair as necessary
4. Start engine , the voltage should be 1.15
volts at 800 RPM (300 bar) and 2.30 volts
at 2120 RPM. (790 bar)
5. If any readings are open, carefully remove
the connector from the processor, install the
Pin Sizing tool (380002416) in the appropri-
ate processor terminal, install the Male
Spade Pigtail (380002415) in the appropriate
sensor terminal, and connect the ohmmeter
lead to each end of the suspected wire and
check for continuity.

Other observations: EST defaults to 710 bar at OL, pump solenoid energizes
when reconnecting the rail pressure, monitoring of pressure relief code on EST, OL
error at key ON.

4
 COOLANT/FUEL TEMPERATURE SENSOR DIAGNOSTICS
Interface Harness Part # 380002409.
Coolant Temperature Sensor Fuel Temperature Sensor

1 2 1 2
1. Black boot, ground 2. Red boot, reference volts

Coolant and Fuel Temperature Sensor Check

Perform test on both sensors

1. Attach interface harness to sensor and to engine
harness.
2. Sensor Function Check: Connect voltmeter to
red and black clips. Readings should be —
Coolant 1.5 volts ± 0.2 at 65 degrees C.
Fuel 2.5 volts ± 0.2 at 41 degrees C.
3. Reference Voltage Check: Connect the + volt-
meter lead to the red clip and the — voltmeter
lead to ground. Voltage reading should be 4.75
volts. If not, go to step 5.
4. Sensor Resistance Check: Disconnect engine
harness and connect ohmmeter lead to black
and red clip. Sensor readings should be
0.55K ohms at 65C, and 1.1K at 41 degrees C.
If not, replace the sensor.
5. If any readings are open, carefully remove the
connector from the processor, install the Pin Siz-
ing tool (380002416) in the appropriate proces-
sor terminal, install the Male Spade pigtail
(380002415) in the appropriate sensor terminal,
and connect the ohmmeter lead to each end of
the suspected wire and check for continuity.
6. The reading should be less than 5 ohms. If the
reading is more than 5 ohms, check for a light
drag on the Pin Sizing tool, moving the tool in
and out of the terminal. If the Pin Sizing tool is
loose in the terminal, the wiring harness must
be replaced. If the circuit is OK, using the wiring
diagram, check voltage and ground supply at the
processor. If OK, processor replacement may be
necessary.
7. If drag is felt on the Pin Sizing tool check for a
damaged wire or terminal in the sensor connec-
tor. Repair as necessary
Other observations: Both Ols default to 60
degrees C on the EST. OL errors at key ON.

5
 OIL PRESSURE/TEMPERATURE SENSOR DIAGNOSTICS
Interface Harness Part # 380002413
Oil Temperature/Pressure Sensor
Engine Harness Connector Face/Latch up
Temperature
1. Green boot, signal 2. Black boot, ground
Oil Temperature
1. Attach interface harness to sensor and to engine
harness, Key ON
2. Sensor Output Test: Connect voltmeter to
green and black clips, Reading should be 3.18
volts ± 0.2 volts at 20 degrees C or 1.8 volts
± 0.2 at 63 degrees C.
3. Reference Voltage Test: connect the + volt-
meter lead to the red clip and the — voltmeter
lead to the black clip. Voltage reading should be
4.75 volts. If not, connect the voltmeter to
ground, voltage should be 4.75 volts If voltage is
not present, go to step 5.
4. Sensor Resistance Test: Disconnect engine
harness and connect ohmmeter leads to the
black and red clips. Readings should be 5.9 K at
63 degrees C and 2.5 K at 20 degrees C.
5. If any readings are open, carefully remove the
connector from the processor, install the Pin Siz-
ing tool (380002416) in the appropriate proces-
sor terminal, install the Male Spade pigtail
(380002415) in the appropriate sensor terminal,
and connect the ohmmeter lead to each end of
the suspected wire and check for continuity.
6
1 2 3 4
Pressure
3. Red boot, voltage reference 4. Yellow
boot, signal
Oil Pressure
Note: If diagnostic tests have indicated an oil
pressure problem, perform a mechanical oil
pressure test before proceeding with the electri-
cal diagnosis.
1. Sensor Output Test: Attach interface harness to
sensor and to engine harness and start the
engine. Connect the + voltmeter lead to the yel-
low clip and the — lead to the black clip. Yellow
to black .82 volts at 1 bar, 3.5 volts at 4.65 bar
(idle), 4.7 volts at 6 bar. (high idle)
2. Reference Voltage Check: Connect the + volt-
meter lead to the red clip and the — lead to the
black clip, reading should be 5.0 volts. If the volt-
age reading is 0 volts check the voltage from the
red clip to ground, it should be 5 volts.
3. If any readings are open, carefully remove the
connector from the processor, install the Pin Siz-
ing tool (380002416) in the appropriate proces-
sor terminal, install the Male Spade pigtail
(380002415) in the appropriate sensor terminal,
and connect the ohmmeter lead to each end of
the suspected wire and check for continuity.
4. The reading should be less than 5 ohms.
5. If the reading is more than 5 ohms, check for a
light drag on the Pin Sizing tool, moving the tool
in and out of the terminal. If the Pin Sizing tool is
loose in the terminal, the wiring harness must be
replaced. If the circuit is OK, check voltage sup-
ply and ground at the processor. If voltage is
OK, processor replacement may be necessary.
6. If drag is felt on the Pin Sizing tool check for a
damaged wire or terminal in the sensor connec-
tor. Repair as necessary.
 AIR PRESSURE/TEMPERATURE SENSOR DIAGNOSTICS
Sensor Interface Harness Part # 380002414
Air Pressure Sensor
Engine Harness Connector Face/Latch up
Temperature
1. Green boot, signal
2. Black boot, ground
AIR TEMPERATURE
1. Attach interface harness (380002414) to sen-
sor and to engine harness. Turn the key
switch “ON.”
2. Sensor Output Test: Connect voltmeter to
green and black clips. Reading should be 1
volt at 49 degrees C, or 3.22 volts at 20
degrees C. ± 0.2volts.
3. Reference Voltage Test: Connect the + volt-
meter lead to the red clip and the —volt-
meter lead to the black clip. Voltage reading
should be 5.00 volts ± 0.2 v. If not, connect
the voltmeter lead to ground. If voltage is not
5 volts, go to step 5.
4. Sensor Resistance Test: Disconnect engine
harness and connect ohmmeter leads to
black and green clips. Reading should be
2.5K ohms at 20 degrees C or 3.6 K at 50
degrees C. If not, replace the sensor.
5. If any readings are open, carefully remove
the connector from the processor, install the
Pin Sizing tool (380002416) in the appropri-
ate processor terminal, install the Male
Spade pigtail (380002415) in the appropriate
sensor terminal, and connect the ohmmeter
lead to each end of the suspected wire and
check for continuity. Repair as necessary.
Air Temperature Sensor
1 2 3 4
Pressure
3. Red boot, voltage reference
4. Yellow boot, sensor signal
AIR PRESSURE
1. Sensor Output Test: Attach interface har-
ness (380002414) to sensor and to engine
harness and start the engine. Connect the +
voltmeter lead to the yellow clip and the —
lead to the black clip. Voltage should be 1.0
volt at idle and 1.7 volts at high idle.
2. Reference Voltage Test: Connect the + lead
of the voltmeter to the red clip and the —
lead to the black clip. The voltage reading
should be 5 volts. If not, ground the negative
voltmeter lead. If the voltage is 0, go to
step 3.
3 If any readings are open, carefully remove
the connector from the processor, install the
Pin Sizing tool (380002416) in the appropri-
ate processor terminal, install the Male
Spade pigtail (380002415) in the appropriate
sensor terminal, and connect the ohmmeter
lead to each end of the suspected wire and
check for continuity.
4. The reading should be less than 5 ohms.
5. If the reading is more than 5 ohms, check for
a light drag on the Pin Sizing tool, moving the
tool in and out of the terminal. If the Pin Siz-
ing tool is loose in the terminal, the wiring
harness must be replaced. If the circuit is OK
check voltage supply and ground at the
processor. If voltage is OK, processor
replacement may be necessary.
6. If drag is felt on the Pin Sizing tool, check for
a damaged wire or terminal in the sensor
connector. Repair as necessary.
7
 FUEL INJECTOR INTERFACE HARNESS
Fuel Injector Interface Harness Part # 380002408

The Fuel Injector Interface Harness allows access to the processor controlled fuel
injector system. The processor controls voltage and the ground circuit for the injector
“ON” time resulting in precise fuel control to the engine.

1 4 4 1

2 3 3 2

Female Connector Male Connector

Interface boot colors: 1 = Red 2 = Black 3 = Black 4 = Red

1. Attach the Interface harnesses to each of the
plugs at the cylinder head spacer plate. (See
illustration at bottom of page.) The black con-
nector boots are the ground circuit and the
red connector boots are positive. Note:
Voltage is not at the injector unless the
engine is running.
2. Connect the + lead of the voltmeter to the
red clip and the — lead to the black clip.
3. Start the engine, when the engine is first
started the voltage should be about 30 volts.
At normal operating temperature, the voltage
at idle is about 29 volts and at WOT, no load,
about 31 volts. Each injector should read the
same voltage.
4. If the injector readings are not the same, do
an ohmmeter check on the injectors.
5. Disconnect the engine harness, do an ohm-
meter test from terminal 1 to 2 and 3 and 4
on each harness. The reading should be .56
ohms. If not replace the injector.
6. A "click test" can be done on each injector
with the Solenoid/Injector Pulse Tool
(380002417) included in this kit. Connect the
tool to a voltage supply (either 12 or 24
volts), Red lead to positive and Black lead to
ground.
7. With the engine harness still disconnected,
connect the injector tester harness connector
to the black and red leads. Push button on
Pulse Tool to activate injector. A distinct
click should be heard at the injector. This test
must be done without the engine running.
This test indicates, if the click is heard,
that electrically, the injector is O.K.

8
 FUEL HIGH PRESSURE SOLENOID INTERFACE HARNESS
Part #380002410

The Fuel High Pressure Solenoid Interface Harness allows access to the processor
controlled Fuel High Pressure Solenoid. This solenoid allows fuel to the injectors when
a cranking signal or an engine running signal is present at the processor.

Fuel High Pressure Solenoid

Connector Face/Latch up

Interface harness boot colors: 1 = Red 2 = Black

1. Attach the Interface Harness to the Fuel
Solenoid (see A on the illustration below) and
to the Engine Harness.
2. Connect the + voltmeter lead to the red clip
and the — voltmeter lead to the black clip.
3. Start the engine and the voltmeter should
read system voltage. If not, attach the —
voltmeter lead to a good ground and retest.
4. If the voltmeter still reads 0 volts unplug the
solenoid and connect the Solenoid/Injector
Pulse Tool (380002417) to the solenoid and
push button to activate.
5. If the solenoid clicks the problem is most like-
ly in the processor. If the solenoid does not
click, replace the solenoid.
6. If any readings are open, carefully remove
the connector from the processor, install the
Sizing Pin tool in the appropriate processor
terminal and connect the ohmmeter lead to
each end of the suspected wire and check
for continuity.
A pigtail with a male spade terminal is sup-
plied allowing access to the sensor side of
the harness.

9
 ENGINE QUICK REFERENCE CHART
(NOTE: Voltage readings based on actual test of 721
D loader — info needs validation)
Sensor Readings Taken at 20 degreees C (68°F.)

TEMP SENSORS
VOLTAGE OHMS CONNECTOR
V-Ref — 4.75V
Coolant Temp 3.36 2.5K +/- 75 C - 18
C - 36
Air Temp 3.22V 2.5K +/- 75 C - 21
C - 29
Oil Temp 3.34V 2.5K +/- 75 C - 19
C - 33
Fuel Temp 3.34V 2.5K +/- 75 C - 17

PRESSURE SENSORS
STATIC - KEY ON IDLE FAST IDLE CONNECTOR
V-Ref — 5.00V
Air 3.91V 3.91V 3.18V C - 10
C - 28
Common Rail Pressure 4.49V 3.43V 2.46V C - 12
C - 20
C - 27
Oil Pressure 4.10V .678V .278V C-9
C - 35

MAGNETIC SENSORS @ ENGINE CRANKING SPEED

VOLTAGE (1.5V MIN) OHMS CONNECTOR
Camshaft Sensor 1.76V AC 900 +/- 75 C-5
PIN 1
Crankshaft Sensor 1.856V AC 900 +/- 75 C - 25
PIN 1

SENSORS CONNECTOR (C)

TERMINAL LOCATIONS

10
 REPAIR PROCEDURES

TERMINAL TOOLS

Tool Number 380002418, For All

Sensor Connectors
Push wire towards the front of the connector,
install the terminal tool into the two slots on the
face of the connector to release terminal locking
tabs and pull the wire out of the back of the con-
nector.

Tool Number 380002419, For All

Injector Harness Connectors
Remove the orange locking plug from the inside
of the connector with a needle nose or small pli-
ers. Push the wire towards the front of the con-
nector, place the terminal tool on the locking tab
inside of the connector and release the terminal.
Pull the wire out of the back of the connector.

89 Pin Processor Connector Latch

Release Tools
Part No. 380002429
Use this Release Tool to release the latches on
the cover to access the terminals. There are four
different size tools for these connectors.

11
Butt Splice Connector Procedure
Part No. 380002490
Use the appropriate wire crimper as shown in
the illustration. After crimping the connector,
apply heat to the splice connector until a small
amount of glue is seen coming out of the con-
nection. This will waterproof the splice.

Jumper Wires and

Pin Size/Probe Adapter
Part No. 380002416 Pin Size Adapter
Place the Pin Size/Probe Adapter into the 89 pin
processor adapter and the Male Spade Adapter
into the sensor connector. Connect the meter
leads to the Male Spade Adapter wire and Pin
Size adapter and read the resistance on the
ohmmeter. The reading should be less than 5
ohms.

Male Spade Adapter

Solenoid/Injector Pulse Tool

Part No. 380002417
Connect the Red (Bat+) and Black (Bat —) leads
to the battery. The small clips are connected to
the injector harness (part no. 380002408) red
and black clips. Push the button on the Pulse
Tool and listen for a "click" at the injector. If the
injector doesn't click, test the resistance of the
injector, the reading should be .57 ohms. If not,
bench check or replace the injector. The same
test should be performed on the high pressure
fuel solenoid. Use the adapter harness
380002410 to access the solenoid. Connect the
tester to the battery and to the solenoid adapter
leads the same as described on the 380002408
harness. A distinct click should be heard when
activating the tester.
12
 TIER II COMPLIANT
COMMON RAIL ENGINE
DIAGNOSTIC/REPAIR KIT
(New Engine Family — NEF)
Part No. 380040185

Contents: 1 each — 380002418 Terminal Release Tool

3 each — 380002408 Fuel Injector Interface
Harness
1 each — 380002409 Coolant/Fuel
Temperature Sensor
1 each — 380002410 Fuel High Pressure
Solenoid
1 each — 380002411 Cam/Crank Sensor
1 each — 380002412 Common Rail Pressure
Sensor
1 each — 380002413 Oil Pressure/
Temperature Sensor
1 each — 380002414 Air Pressure/
Temperature
6 each — 380002415 Male Spade to Clip
Jumper Adapters
1 each — 380002416 Pin Size/Probe Adapters
1 each — 380002417 Solenoid/Injector Pulse
Tool
(AMP)
1 each — 380002419 Terminal Release Tool
(Deutsch)
4 each — Connector Cap Removal Clips
1 each — Instruction Booklet
1 each — Carry/Storage Case (includes drawer
assembly, dividers and frame)
1 each — 380002427 Connector Pack
1 each — 380002428 Pigtail Pack
1 each — 380002429 Terminal Tool Pack
1 each — 380002490 Crimper Tool
Extra Drawer Assembly — Order part number
380002424
REPLACEMENT PARTS ARE
AVAILABLE FROM
CNH PARTS

13