Cummins ISX11.9 CM2250 – Service Manual 019-043   Engine Wiring Harness

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Disconnect the batteries. Refer to the OEM service manual.

Replace the engine harness if there is an open or short circuit found under the protective covering of the harness body.

Disconnect the coolant temperature sensor.

Disconnect the EGR differential pressure sensor.

Disconnect the EGR temperature sensor (1), the compressor intake temperature sensor (2), and the EGR orifice pressure sensor (3) from the engine wiring harness.

Remove the two wiring harness retaining clips from the EGR system bracket (1) and the EGR mass measurement flow assembly (2).

Remove the turbocharger actuator electrical connector.

Disconnect the aftertreatment fuel injector electrical connector.

Remove the wiring harness retaining clip from the EGR system bracket.

Remove the EGR valve electrical connector.

Disconnect the exhaust gas pressure sensor.

Disconnect the turbocharger speed sensor.

Disconnect the aftertreatment intake NOx sensor electrical connector.

Remove the two wiring harness retaining clips from the engine block.

Disconnect the crankshaft position sensor.

Remove the wiring harness retaining clip from the camshaft gear cover plate.

Remove the wiring harness retaining clip from the cylinder head.

Disconnect the crankcase pressure sensor.

Disconnect the injector pass-through connector.

Disconnect the fuel pump actuator electrical connector.

Disconnect the aftertreatment purge air actuator from the engine harness.

Remove the wiring harness retaining clip from the aftertreatment doser air purge actuator body.

Disconnect the aftertreatment fuel pressure sensor (1) and the aftertreatment fuel shutoff valve (2) from the engine wiring harness.

Disconnect the intake manifold pressure/temperature sensor.

Disconnect the fuel rail pressure sensor.

Disconnect the oil temperature sensor (1) and the oil pressure sensor (2).

If equipped, disconnect the fuel lift pump electrical connector.

Disconnect the camshaft position sensor.

Disconnect the ECM 60-pin engine connector 1 (1) and the ECM 60-pin engine connector 2 (2).

Disconnect the 14-pin OEM crossover connector (3).

Disconnect the 2-pin relay power connector (4).

Remove the wiring harness.

Install the wiring harness.

Connect the ECM 60-pin engine connector 1 (1) and the ECM 60-pin engine connector 2 (2).

Connect the 14-pin OEM crossover connector (3).

Connect the 2-pin relayed power connector (4).

Tighten the two 60-pin connectors.

Connect the oil temperature sensor (1) and the oil pressure sensor (2).

If equipped, connect the fuel lift pump electrical connector.

Connect the camshaft position sensor.

Connect the fuel rail pressure sensor.

Connect the intake manifold pressure/temperature sensor.

Connect the aftertreatment fuel pressure sensor (1) and the aftertreatment fuel shutoff valve (2) to the engine wiring harness.

Connect the aftertreatment purge air actuator to the engine harness.

Install the wiring harness retaining clips onto the aftertreatment doser air purge actuator body. Use the following procedure for torque specifications. Refer to Procedure 011-065 in Section 11.

Connect the fuel pump actuator electrical connector.

Connect the injector pass-through connector.

Connect the crankcase pressure sensor.

Connect the crankshaft position sensor.

Install the wiring harness retaining clip onto the camshaft gear cover plate. Use the following procedure for torque specifications. Refer to Procedure 001-011 in Section 1.

Install the wiring harness retaining clip onto the cylinder head.

Connect the aftertreatment intake NOx sensor electrical connector.

Install the wiring harness retaining clips onto the engine block.

Connect the turbocharger speed sensor.

Connect the aftertreatment fuel injector electrical connector.

Connect the exhaust pressure sensor.

Connect the EGR valve electrical connector.

Connect the turbocharger actuator electrical connector.

NOTE: To prevent the turbocharger actuator wiring harness from experiencing heat damage, the harness must be secured away from nearby heat sources.

Secure the turbocharger actuator wiring harness. Use the following procedure for routing instructions. Refer to Procedure 010-134 in Section 10.

Install the wiring harness retaining clip onto the EGR system bracket.

Connect the EGR temperature sensor (1), the compressor intake temperature sensor (2), and the EGR orifice pressure sensor (3) electrical connectors.

Install the two wiring harness retaining clips from the EGR system bracket (1) and the EGR mass measurement flow assembly (2).

Connect the EGR differential pressure sensor.

Connect the coolant temperature sensor.

WARNING  Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arching, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

• Connect the batteries. Refer to the OEM service manual.
• Operate the engine and check for active fault codes.