PLUNGER 9R8538 - Caterpillar

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J1/P1 ECM Connectors
Thoroughly inspect connectors (1). Inspect the connectors for the throttle position sensor. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
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Terminal locations at the P1 ECM connector for the digital sensor supply
(P1-4) 8 VDC supply
(P1-5) Digital return
(P1-66) Throttle position
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Terminal locations at the sensor connector for the digital sensor supply
(Terminal A) 8 VDC supply
(Terminal B) Digital return
(Terminal C) Throttle position
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the digital sensor supply.
Check the allen head screw from each ECM connector for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque value.
Check the harness and wiring for abrasions and for pinch points from the throttle position sensor to the ECM. Expected Result:All of the connectors, pins, and sockets are completely coupled and/or inserted, and the harness and wiring are free of corrosion, of abrasion or of pinch points.Results:
OK - The harness and connectors appear to be OK. Proceed to Test Step 2.
Not OK - There is a problem with a connector and/or the wiring.Repair: Repair the connector and/or the wiring. Replace parts, if necessary. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled. Verify that the problem is resolved.STOPTest Step 2. Check for Active Diagnostic Codes
Connect the Caterpillar Electronic Technician (ET) to the service tool connector. Refer to Troubleshooting, "Electronic Service Tools".
Restore electrical power to the engine ECM.
Monitor the active diagnostic code screen on Cat ET. Check and record any active diagnostic codes that are related to the digital supply. Note: Wait at least 30 seconds in order for the diagnostic codes to become active.Expected Result:There are no active diagnostic codes for the digital supply.Results:
OK - No diagnostic code for the digital supply is active. A problem is suspected with a sensor output signal. In order to verify that the sensor is receiving the correct supply voltage, proceed to Test Step 3.
Active 41-03 code - A 41-03 diagnostic code is active. The ECM is detecting a short to the +Battery in the wiring for the digital supply. Proceed to Test Step 3.
Active 41-04 code - A 41-04 diagnostic code is active. The ECM is detecting a short to ground in the wiring for the digital supply. Proceed to Test Step 4.Test Step 3. Check the Supply Voltage at the Sensor Connector
Remove electrical power from the engine ECM.
Disconnect the harness connectors for the throttle position sensor.
Restore electrical power to the engine ECM.
Measure the voltage between terminals A (8 V digital supply) and terminal B (digital return) at the sensor connector. Expected Result:The voltage measurement is 8.0 0.4 VDC.Results:
OK -