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Title:
Accelerator Position Sensor / Idle Validation Switch APS / IVS Diagnostics MaxxForce® 11 and 13
engines
Applies To:
2008 - 2009 MaxxForce® 11 and 13 engine equipped WorkStar®, TranStar™, and ProStar™
vehicles.
DESCRIPTION
Two new APS sensors (Accelerator Position Sensor) have been developed and released for use with pre-
2010 emissions International Engines. The new sensors listed below contain "non-contact" hall-effect idle
validation sensors. This replaces the open/closed IVS switches in the old sensors. As a result of this new
design, the normal resistance measurements performed for the potentiometer and idle validation switch on
the previous "contact' sensor are no longer applicable. A technician can continue to perform resistance
measurement tests on the engine harness with the sensor unplugged (open circuit), but should rely solely
upon the voltage measurement tests, with a breakout harness installed, at the ECM and APS sensor, and
the new sensor connected.
SYMPTOMS
APS/ IVS fault codes present
Engine speed restricted to idle
Erratic automatic transmission operation
Engine warning lights illuminated
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POSSIBLE DIAGNOSTIC TROUBLE CODES
APS/IVS Diagnostic Trouble Code
DTC Condition Possible Causes
1131 APS signal out-of-range LOW APS signal OPEN or shorted to GND&
VREF circuit OPEN or shorted to GND
Failed sensor
1132 APS signal out-of-range APS signal shorted to PWR
HIGH Failed sensor
1133 APS signal in-range fault Circuit fault
Failed sensor
Open diagnostic resistor or circuit
1134 APS/IVS disagreement Circuit fault
Failed sensor
Open diagnostic resistor or circuit
1135 Idle validation switch fault IVS circuit OPEN or shorted to GND or PWR
Failed sensor
Open diagnostic resistor or circuit
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PARTS INFORMATION
Use the table below for identification of original APS sensor and cross over to the new hall affect sensor
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Old Sensor Part New Sensor
Model Engine
Number Part Number
All Pre-2004 Emissions Engines
1697269C92 2603895C91
2000,3400,3800,4000FBC,4000 and 8000 (T444E, DT466E, 530E)
All Pre-2004 Emissions Engines
(T444E, DT466E, 530E)
2587164C91 or
4200,4300,4400,7400,7500, 8500 and CF 2603893c91
2587575c92
All 2004-2007 Emissions
Engines
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ProStar™, TranStar™, DuraStar™, WorkStar® and All 2007 Emissions, 2587164C91 or
2603893C91
CityStar™ MaxxForce® Engines 2587575C92
All Pre-2004 Emissions Engines 1697269C92 2603895C91
All 2004-2007 Emissions
CE Bus, RE Bus, and FE Bus Engines 2587164C91 or
2603893C91
All 2007 Emissions 2587575C92
MaxxForce® Engines
FBC and CE Commercial Bus (Mexico and Latin 2587164C91 or
DT466 Non EGR 2603893C91
America built after March 2004) 2587575C92
All Pre-2004 Emissions Engines 1697269C92 2603895C91
All 2004-2007 Emissions
1552 and 1652 SC Engines 2587164C91 or
2603893C91
All 2007 Emission MaxxForce® 2587575C92
Engines
SFC Commercial Chassis All Pre-2004 Emissions Engines 1697269C92 2603895C91
5000's, PayStar® All Pre-2004 Emissions Engines 1697269C92 2603895C91
New sensors will NOT operate if installed with Cummins, Caterpillar, or 2010 MaxxForce® Engines
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DIAGNOSTICS
There can be various conditions that can cause APS/IVS related issues. As with any performance related
fault, a thorough description of the issue, from the operator are critical.
Is the fault sensitive to road conditions, such as rough terrain, hills, etc?
Is the fault temperature sensitive?
Does the fault occur, when coming to a stop, or when accelerating or cruising?
Do any other faults occur at the same time, such as loss of dash cluster, or other in cab accessories?
Are there other codes, that can be attributed to this issue such as loss of ignition related faults?
If any circuit issues are suspected, a thorough visual inspection of all circuitry for shorts, and opens
is critical, as intermittent issues are usually caused by wiring faults. Any harness mounting points should be
disassembled and inspected. Harnesses should be inspected and if damaged, repaired where they pass by
sharp edges, or possible points of abrasion. If harnesses are pulled too tight remount to provide a marginal
amount of slack, to prevent the connector or circuits from being pulled loose.
When inspecting connectors, be sure to verify that all connectors have been properly "locked" into place,
and a light coat of dielectric grease be applied to the terminals upon reinstallation.
If idle validation faults are an issue, testing of the ignition voltage supply to the sensor should be performed.
COMPONENT FUNCTION/DESCRIPTION
APS/IVS Circuit Operation
The APS/IVS is integrated into one component and mounted on the pedal. The APS/IVS switch can be
replaced without replacing the complete assembly.
The EIM determines accelerator pedal position by processing input signals from the APS and the IVS.
APS
The APS is a potentiometer sensor that is supplied with a 5Vreference voltage at Pin C from EIM Pin X4-4
and is grounded at Pin B from EIM Pin X4-24. The sensor returns a variable voltage signal from Pin A to
EIM Pin X4-18.
IVS
The IVS is an ON/OFF switch that is supplied B+ on Pin F from the PWR fuse. The switch sends an ON or
OFF idle voltage signal from Pin D to EIM Pin X4-23.
APS Auto-Calibration
The EIM auto-calibrates the APS signal every time the ignition key is turned on. The EIM learns the lowest
and highest pedal positions allowing for maximum pedal sensitivity. When the key is turned off, this
information is lost until the next key cycle where the process is repeated. No accelerator pedal adjustment
is needed with this feature.
Fault Detection / Management
When the key is on, the EIM continuously monitors the APS/IVS circuits for expected voltages. It also
compares the APS and IVS signals for conflict. If a conflict occurs, the EIM sets a DTC.
Any malfunction of the APS/IVS sensor circuit illuminates the amber engine lamp. If the EIM detects an
APS signal out of range HIGH or LOW, the engine ignores the APS signal and operates at low idle. If a
disagreement in the state of IVS and APS is detected by the EIM and the EIM determines that it is an IVS
fault, the EIM only allows a maximum of 50% APS to be commanded. If the EIM cannot discern if it is an
APS or IVS fault, the engine is allowed to operate at low idle only.
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NOTE:
The APS / IVS circuit for the MaxxForce® 11 and 13 is slightly different from other International Engine
APS / IVS circuits.
Note the 1150 ohm resistor in series with the IVS circuit and the 1150 ohm resistor in parallel with VREF
and the X4-15 Diag. These resistor values may vary in early built vehicles. These resistors can have a
direct inpact on the IVS/APS operation, so circuit diagnostics should be performed.
TROUBLESHOOTING
> 665?; 9 1: @
NOTE:
When performing diagnostic tests, be sure to refer to the correct circuit diagram manuals, found on
ISIS, for the vehicle you are working on.
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2//5; 2//4 AA 33 3- ) 9 1:
Connector Voltage Checks
(Disconnect sensor from harness. Connect breakout harness to chassis harness only. Turn ignition switch to ON. Use DMM to measure voltage.)
Test Points Specification Comments
A to GND 0V If > 0.25V, signal is shorted to PWR.
B to GND 0V If > 0.25 V, check for short to PWR.
If > 5.5 V, check VREF for short to PWR.
C to GND 5V
If < 4.5 V, check VREF for OPEN or short to GND. Do "Harness Resistance Checks"
D to GND 0V If > 0.25 V, check for short to PWR. Do "Harness Resistance Checks"
F to GND B+ If < B+, check for OPEN or blown fuse.
Harness Resistance Checks
(Turn ignition switch to OFF. Disconnect battery GND. Connect breakout box and breakout harness. Leave EIM and sensor disconnected. Use
DMM to measure resistance.)
Test Points Specification Comments
A to X4-18 < 5 ohm If > 5 ohm, check for APS signal circuit OPEN.
B to X4-24 < 5 ohm If > 5 ohm, SIG GND OPEN.
C to X4-4 < 5 ohm If > 5 ohm, VREF wire OPEN.
D to X4-23 < 5 ohm If > 5 ohm, IVS signal circuit OPEN.
F to Fuse < 5 ohm If > 5 ohm, IVS power circuit OPEN.
Note: MaxxForce® 11 and 13 liter engines are equipped with a diagnostic resistor between X4-4 and
X4 15. The resistance across these two pins should read 1-1.5k ohms. If not within specs, replace
the resistor.
Operational Voltage Checks
(Check with breakout tee installed and APS/IVS sensor connected)
APS Test Points IVS Test Points Operational Signal Checks
APS A or X4-18 to ground IVS D or X4-23 to ground (Check with breakout box installed on EIM and Engine Harness)
Position Voltage % APS Voltage % APS Comments
Low Idle 0.64 - 0.66V 0% 0V 0% IVS toggles just off idle.
High Idle 3.85 - 4.00 V 100% 12 ± 1.5 V 100%
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NOTE:
If all circuit and operational tests have been performed, and all wiring/components have been
inspected and are deemed to be satisfactory, yet the issue is still not resolved, open a tech service
case file for further diagnostic assistance.
ADDITIONAL RELATED IKNOW DOCUMENTS:
IK0800218 Accelerator Position Sensor/Idle Validation Switch APS /IVS Diagnostics, 3-Box equipped
engine control systems
IK0800219 DLC equipped vehicles Accelerator Position Sensor/IdleValidation Switch APS / IVS
Diagnostics NavPak™, CEC equipped engine control systems
IK0800223 DLCII equipped vehicles AcceIerator Position Sensor/Idle Validation Switch APS / IVS
Diagnostics DLCII equipped engine control systems
IK0800226 Accelerator Position Sensor/ Idle Validation Switch APS / IVS Diagnostics, MaxxForce®
equipped engine control systems
This article replaces IK0800165
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