Service Training

QSM 11 engine sensor positions & diagnostics

1. Ambient air pressure sensor

The ambient air pressure sensor is located below the engine ECM.

The ambient air pressure sensor monitors the atmospheric pressure & passes the
information to the electronic control module (ECM) through the engine harness.

1.1. Check the ECM ambient air pressure sensor supply voltage

Caution: To reduce the possibility of pin or harness damage, use the following test
lead when taking measurements: P/N 3824774 - breakout cable.

Condition
● Install breakout cable, P/N
3824774, between the sensor and
the sensor harness connector.
● Turn ignition key ON.

Action
Check the ECM ambient air
pressure sensor supply voltage.

● Measure the supply voltage

from pin A to pin B of the breakout
cable.

OK: NOT OK:

+4.75 to 5.25 VDC ● Check voltage supply from the ECM between
pin 31 (GND) and pin 17 (Positive)

1
 Service Training

1.2. If the sensor voltage supply is not correct to the voltage test in step 1.1, measure
voltage supply at the ECM connector

Caution: To reduce the possibility of pin or harness damage, use the following test
lead when taking measurements: P/N 3822917 - female DEUTSCH/AMP/Metri-Pack test
lead.

Condition
● Disconnect the sensor harness
from the ECM.
● Turn ignition key ON

Action
Measure the voltage out of the
ECM.
● Measure the voltage at the ECM
from pin 17 (Positive) to pin 31
(GND) of the ECM sensor
connector port.

OK: NOT OK:

+4.75 to 5.25 VDC ● Replace the ECM
● Repair or replace the engine
harness
1.3. Check the ECM ambient air pressure sensor signal voltage

Caution: To reduce the possibility of pin or harness damage, use the following test
lead when taking measurements: P/N 3824774 - breakout cable.

Condition
● Install breakout cable, P/N
3824774, between the sensor and
the sensor harness connector.
● Turn ignition key ON.

Action
Check the ECM ambient air
pressure signal voltage
● Measure the signal voltage from
pin C to pin B of the breakout cable.

OK: NOT OK:

Altitude (m) = Voltage (VDC) ● Check harness for corroded, bent,
- 0m (sea level) = 3.4 to 4.5 VDC broken, pushed back or expanded pins
- 1000 m = 2.8 to 3.8 VDC Or
- 1800 m = 2.2 to 3.25 VDC ● Replace the ambient air pressure sensor
- 2700 m = 1.7 to 2.7 VDC
- 3600 m = 1.2 to 2.2 VDC 2
 Service Training

2. Coolant level switch

The coolant level sensor is located in the radiator top tank.

The coolant level sensor monitors the coolant level within the coolant system and passes
information to the electronic control module (ECM) through the sensor harness. This sensor
is very complex. Do not use a multimeter to check the coolant level sensor. If the radiator
coolant level drops below a certain level, a power derate will occur and become greater as
time goes by.

3. Coolant temperature sensor

The coolant temperature sensor is located at the front of the engine near the water pump.

The coolant temperature sensor is used by the ECM to monitor the temperature of the engine
coolant. The coolant temperature is used by the ECM for the engine protection system,
timing, and fuel control.

3
 Service Training

3.1. Check the resistance of the coolant temperature sensor

Do not remove the pressure cap from the radiator. Wait until coolant temperature is
below 50°C [122°F] before removing the pressure cap. Heated coolant water might
spray or steam can cause personal injury.

Caution: To reduce the possibility of pin or harness damage, use the following test
leads when taking measurements:
P/N 3822758 - male DEUTSCH/AMP/Metri-Pack test lead
P/N 3823256 - 2-way Metri-Pack test lead.

Condition
● Turn ignition key OFF
● Disconnect the harness from the
coolant temperature sensor.

Action
Check the resistance of the
coolant temperature sensor.
● Measure the resistance from pin
A (or 1) to pin B (or 2) of the
coolant temperature sensor.

OK: NOT OK:

300Ω to 90kΩ ● Replace the temperature sensor

The resistance of the sensor varies with temperature. Compare your readings to this table:

Temperature (°C) Temperature (°F) Resistance (ohms)

0 32 30kΩ to 36kΩ
25 77 9kΩ to 11kΩ
50 122 3kΩ to 4kΩ
75 167 1350Ω to 1500Ω
100 212 600Ω to 675Ω

4
 Service Training

3.2. Inspect the sensor harness and the ECM connector pins
Condition
● Turn ignition key OFF
● Disconnect the sensor harness
connector from the ECM.

Action
Inspect the sensor harness and
the ECM connector pins for the
following:
● Corroded, bent, broken pushed
back or expanded pins
●.Moisture in or on the connector
● Missing or damaged connector
seals
● Dirt or debris in or on the
connector pins

NOT OK:
OK:
● Repair or replace the engine
No damaged pins
harness, or replace the ECM,
whichever has the damaged pins
3.3. Check sensor harness for a short circuit from pin to pin
Caution: To reduce the possibility of pin or harness damage, use the following test
leads when taking measurements: P/N 3822758 - male DEUTSCH/AMP/Metri-Pack test
lead.
Condition
● Turn ignition key OFF
● Disconnect the engine harness
from the coolant temperature
sensor.
● Disconnect the sensor harness
connector from the ECM.

Action
Check for a short circuit from pin
to pin.
● Measure the resistance from pin
2 of the sensor harness to all
other pins in the connector
● Measure the resistance from pin
3 of the sensor harness to all
other pins in the connector

OK: NOT OK:

More the 100k ohms ● Repair or replace the engine harness 5
 Service Training

4. Engine position sensor

The engine position sensor is located above the accessory drive of the fuel pump.

The engine position sensor monitors the engine speed and the engine position, then passes
this information to the ECM through the sensor harness.

4.1. Check the resistance of the engine speed sensor

Caution: To reduce the possibility of pin or harness damage, use the following test
leads when taking measurements: P/N 3823996 - female Weather-Pack test lead.
Condition
● Turn ignition key OFF
● Disconnect the engine harness
from the engine position sensor.

Action
Check the resistance of the
engine position sensor.
● Measure the resistance from pin
A to pin D of the position sensor.
● Measure the resistance from pin
B to pin C of the position sensor.

OK: NOT OK:

1000 to 2000 ohms ● Replace the engine position sensor

6
 Service Training

5. Engine oil pressure / temperature sensor

The oil pressure / temperature sensor is located on the engine block, behind the fuel pump.

The oil pressure / temperature sensor is used by the ECM to monitor the lubrication oil
pressure. The ECM monitors the voltage signal on the signal pin and converts this to a
pressure value. The oil pressure value is used by the ECM for the engine protection system.

5.1. Check the resistance of the oil pressure / temperature sensor

Caution: To reduce the possibility of pin or harness damage, use the following test
leads when taking measurements: P/N 3822917 - female Deutsch/AMP/Metri-Pack test
lead.
Condition
● Turn ignition key OFF
● Disconnect the engine harness
from the oil pressure/temperature
sensor.

Action
Check the resistance of the oil
pressure/temperature sensor.

● Measure the resistance from pin

4 to pin 2 of the oil
pressure/temperature sensor.

OK: NOT OK:

300Ω to 90kΩ ● Replace the oil pressure/temperature sensor

7
 Service Training

The resistance of the sensor varies with temperature. Compare your readings to this table:

Temperature (°C) Temperature (°F) Resistance (ohms)

0 32 30kΩ to 36kΩ
25 77 9kΩ to 11kΩ
50 122 3kΩ to 4kΩ
75 167 1350Ω to 1500Ω
100 212 600Ω to 675Ω

5.2. Inspect the sensor harness and the ECM connector pins

Condition
● Turn ignition key OFF
● Disconnect the sensor harness
connector from the ECM.

Action
Inspect the sensor harness and
the ECM connector pins for the
following:
● Corroded, bent, broken pushed
back or expanded pins
●.Moisture in or on the connector
● Missing or damaged connector
seals
● Dirt or debris in or on the
connector pins

OK: NOT OK:

No damaged pins ● Repair or replace the engine
harness, or replace the ECM,
whichever has the damaged pins

8
 Service Training

5.3. Check sensor harness for a short circuit from pin to pin

Caution: To reduce the possibility of pin or harness damage, use the following test
leads when taking measurements: P/N 3822758 - female Deutsch/AMP/Metri-Pack test
lead.
Condition
● Turn ignition key OFF
● Disconnect the engine harness
from the oil pressure/temperature
sensor.
● Disconnect the sensor harness
connector from the ECM.

Action
Check for a short circuit from pin
to pin.
● Measure the resistance from pin
42 of the sensor harness to all
other pins in the connector
● Measure the resistance from pin
43 of the sensor harness to all
other pins in the connector

OK: NOT OK:

More the 100k ohms ● Repair or replace the engine harness

9
 Service Training

6. Injectors

There are two pieces to a QSM actuator harness- one internal and the other external
harness. The external portion of the actuator harness extends from the ECM to the backside
of the rocker lever housing. The external harness connects to the internal harness with a 15-
pin connector at the backside of the rocker lever housing. The internal actuator harness runs
along the inside of the rocker lever housing on the right side. It has six connectors spaced
along its length - on for each injector solenoid. These connectors attach to the pigtail
connector on each injector.

The injector solenoid valves are actuated by the ECM to control fuel metering and timing.
Each injector solenoid is connected to the ECM by a supply and return wire. An electrical
pulse is sent to the injector from the ECM on the supply wire and returns to the ECM wire
after actuating the solenoid. Each solenoid valve is normally open, and it is only closed by an
electrical pulse from the ECM during fuel injection and metering.

(The electric circuits for the cylinder # 2 to 6 are the same, apart from the pin numbers in the
15-pin plug and the ECM)

6.1. Check resistance of the injector solenoids

The injector solenoids receive high voltage when the engine is operating. To reduce
the possibility of personal injury or death from electrical shock, do not wear jewelry or
damp cloths, and do not touch the injector solenoids or the solenoid wires when the
engine is operating.

10
 Service Training

Condition
● Turn ignition key OFF
● Disconnect the internal actuator A
harness from the injector solenoid. B

Action
Check the resistance of the
injector solenoid.
● Measure the resistance from pin
A to pin B of the injector solenoid.

OK: NOT OK:

0.5 to 1.5 ohms ● Replace the injector

6.2. Inspect the actuator harness, pass-through connector, and ECM connector pins.

Condition
● Turn ignition key OFF
● Disconnect the actuator harness
connector from the ECM.
● Disconnect the actuator harness
from the 15-pin connector.

Action
Inspect the actuator harness, the
actuator harness 15-pin
connector, and the ECM
connector pins for the following:
● Corroded, bent, broken pushed
back or expanded pins
●.Moisture in or on the connector
● Missing or damaged connector
seals
● Dirt or debris in or on the
connector pins

OK: NOT OK:

No damaged pins ● Repair the damaged pins
● Repair or replace the engine harness or replace
the ECM, whichever has the damaged pins

11
 Service Training

6.3. Check external actuator harness for a short circuit from pin to pin

Caution: To reduce the possibility of pin or harness damage, use the following test
leads when taking measurements: P/N 3822758 - male Deutsch/AMP/Metri-Pack test
lead.

Condition
● Turn ignition key OFF
● Disconnect the actuator harness from the ECM.
● Disconnect the sensor harness connector from
the ECM.
● Disconnect the actuator harness from the 15-
pin connector

Action
Check for a short circuit from pin to pin.
● Measure the resistance from pin 9 in the
actuator harness connector to all other pins in the
actuator harness
● Measure the resistance from pin 9 in the
actuator harness connector to all other pins in the
sensor harness
● Measure the resistance from pin 10 in the
actuator harness connector to all other pins in the
actuator harness
● Measure the resistance from pin 10 in the
actuator harness connector to all other pins in the
sensor harness

OK: NOT OK:

More the 100k ohms ● Repair or replace the defect harness

12
 Service Training

7. Intake manifold temperature sensor

The intake manifold temperature sensor is located on the top half of the intake manifold, at
the front.

The intake manifold temperature sensor monitors the temperature of the engine intake air for
the ECM. The ECM uses the intake manifold temperature signal for the engine protection
system, timing and fueling control.

7.1. Check the resistance of the intake manifold temperature sensor

Caution: To reduce the possibility of pin or harness damage, use the following test
leads when taking measurements:
P/N 3822758 - male Deutsch/AMP/Metri-Pack test lead.
P/N 3823256 - 2-way Metri-Pack connector
Condition
● Turn ignition key OFF
● Disconnect the sensor harness
from the intake manifold
temperature sensor.

Action
Check the resistance of the intake
manifold temperature sensor.
● Measure the resistance from pin
A to pin B of the intake manifold
temperature sensor.

OK: NOT OK:

175Ω to 244kΩ ● Replace the intake manifold temperature sensor

13
 Service Training

The resistance of the sensor varies with temperature. Compare your readings to this table:

Temperature (°C) Temperature (°F) Resistance (ohms)

0 32 30kΩ to 36kΩ
25 77 9kΩ to 11kΩ
50 122 3kΩ to 4kΩ
75 167 1350Ω to 1500Ω
100 212 600Ω to 675Ω

7.2. Inspect the intake manifold temperature sensor and the sensor harness connector
pins

Condition
● Turn ignition key OFF
● Disconnect the sensor harness
connector from the intake
manifold temperature sensor.

Action
Inspect the intake manifold
temperature sensor and the
sensor harness connector pins for
the following:
● Corroded, bent, broken pushed
back or expanded pins
●.Moisture in or on the connector
● Missing or damaged connector
seals
● Dirt or debris in or on the
connector pins

OK: NOT OK:

No damaged pins ● Repair the damaged pins
● Repair or replace the engine harness or replace
the intake manifold temperature sensor, whichever
has the damaged pins.

14
 Service Training

7.3. Check sensor harness for a short circuit from pin to pin

Caution: To reduce the possibility of pin or harness damage, use the following test
leads when taking measurements: P/N 3822758 - male Deutsch/AMP/Metri-Pack test
lead.

Condition
● Turn ignition key OFF
● Disconnect the sensor harness
from the intake manifold
temperature sensor.
● Disconnect the sensor harness
connector from the ECM.

Action
Check for a short circuit from pin
to pin.
● Measure the resistance from pin
40 of the sensor harness to all
other pins in the connector
● Measure the resistance from pin
38 of the sensor harness to all
other pins in the connector

OK: NOT OK:

More the 100k ohms ● Repair or replace the engine harness

8. Intake manifold pressure sensor

The intake manifold pressure sensor is located in the air intake manifold toward the front to
the engine.

The intake manifold pressure sensor monitors intake manifold pressure and passes this
information to the ECM through the engine harness. If the intake manifold pressure becomes
to high, it will cause a derate condition.

15
 Service Training

8.1. Check the ECM intake manifold pressure sensor voltage supply.

Caution: To reduce the possibility of pin or harness damage, use the following test
lead when taking measurements: P/N 3824774 - breakout cable.
Condition
● Install breakout cable, P/N
3824774, between the sensor and
the sensor harness connector.
● Turn ignition key ON.

Action
Check the intake manifold
pressure sensor supply voltage.

● Measure the supply voltage

from pin A to pin B of the breakout
cable.

NOT OK:
OK: ● Check voltage supply from ECM between pin
+4.75 to 5.25 VDC 40 (GND) and pin 37 (Positive)

8.2. If the sensor voltage supply is not correct to the voltage test in step 8.1, measure
voltage supply at the ECM connector

Caution: To reduce the possibility of pin or harness damage, use the following test
lead when taking measurements: P/N 3822917 - female DEUTSCH/AMP/Metri-Pack test
lead.
Condition
● Disconnect the sensor harness
from the ECM.
● Turn ignition key ON

Action
Measure the voltage out of the
ECM.
● Measure the voltage at the ECM
from pin 37 (Positive) to pin 40
(GND) of the ECM sensor
connector port.

OK: NOT OK:

+4.75 to 5.25 VDC ● Replace the ECM
● Repair or replace the engine
harness
16
 Service Training

8.3. Check the ECM intake manifold pressure sensor signal voltage

Caution: To reduce the possibility of pin or harness damage, use the following test
lead when taking measurements: P/N 3824774 - breakout cable.
Condition
● Install breakout cable, P/N
3824774, between the sensor and
the sensor harness connector.
● Turn ignition key ON.

Action
Check the intake manifold pressure
sensor signal voltage
● Measure the signal voltage from
pin C to pin B of the breakout cable.

OK: NOT OK:

+ 0.42 to 0.58 VDC ● Check harness for corroded, bent,
broken, pushed back or expanded pins
Or
● Replace the ambient air pressure sensor

9. Water-in-fuel (WIF) sensor

The WIF sensor is installed in the fuel filter and is located in the battery compartment.

The WIF sensor is attached to the fuel filter. The WIF sensor sends a signal to the ECM
when a set volume of water has accumulated in the fuel filter. The WIF circuit contains two
wires: A return ground (pin 10) and a signal wire (pin 9).

17
 Service Training

9.1. Check the sensor voltage supply

Caution: To reduce the possibility of pin or harness damage, use the following test
lead when taking measurements: P/N 3822758 - male Deutsch/AMP/Metri-Pack test
lead.

Condition
● Disconnect the sensor harness
from the WIF sensor.
● Connect the sensor harness to
the ECM
● Turn ignition key ON.

Action
Check the WIF sensor supply
voltage.

● Measure the supply voltage

from pin B on the harness side of
the WIF sensor connector to
engine block ground.

NOT OK:
OK: ● Does not meet specification  Replace WIF
+4.75 to 5.25 VDC sensor
9.2. If the sensor voltage supply is not correct to the voltage test in step 9.1, measure
voltage supply at the ECM connector

Caution: To reduce the possibility of pin or harness damage, use the following test
lead when taking measurements: P/N 3822917 - female DEUTSCH/AMP/Metri-Pack test
lead.

Condition
● Disconnect the sensor harness
from the ECM.
●Disconnect the sensor harness
from the ECM
● Turn ignition key ON
Action
Measure the voltage out of the
ECM.
● Measure the voltage at the ECM
from pin 9 (Positive) to pin 10
(GND) of the ECM sensor
connector port.
OK: NOT OK:
+4.75 to 5.25 VDC ● Replace the ECM

18
 Service Training

9.3. Check sensor harness for a short circuit from pin to pin

Caution: To reduce the possibility of pin or harness damage, use the following test
leads when taking measurements: P/N 3822758 - male DEUTSCH/AMP/Metri-Pack test
lead.

Condition
● Turn ignition key OFF
● Disconnect the engine harness
from the WIF sensor.
● Disconnect the sensor harness
connector from the ECM.

Action
Check for a short circuit from pin
to pin.
● Measure the resistance from pin
9 of the sensor harness to all
other pins in the connector

OK: NOT OK:

More the 100k ohms ● Repair or replace the engine harness

19