F1778 Force PLAIN WASHER

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Left side engine view (typical example) (1) J500/P500 Injection Actuation Pressure Control Valve (IAPCV) connector (2) Injection Actuation Pressure (IAP) sensor (3) J2/P2 Engine Control Module (ECM) connector
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Left side engine view (typical example) (1) J500/P500 Injection Actuation Pressure Control Valve (IAPCV) connector (2) Injection Actuation Pressure (IAP) sensor (3) J2/P2 Engine Control Module (ECM) connectorTest Step 1. SymptomsThe following symptoms may occur if there is a problem with the HEUI fuel system:
The engine cranks but the engine will not start.
The engine runs rough.
The engine is erratic or unstable at idle or running.
Low power
The following fault codes might be currently active codes or logged event codes: 164-00, 164-02 and 164-11.Complete the following test steps. Circle the appropriate answers in the "Results" section of each test step and return the pages with the fuel system component.
Connect the Caterpillar Electronic Technician (ET) to the service tool connector.
Restore the electrical power to the ECM. DO NOT START THE ENGINE.
Print the "Lifetime Totals" and the "Configuration" screen.
Check for active diagnostic codes.Expected Result:There are no active diagnostic codes with the electrical power restored to the ECM and the engine OFF.Results:
OK - There are no active codes. Proceed to Test Step 2.
Not OK - Active codes are present.Repair: Refer to diagnostic functional tests Troubleshooting, "Engine Pressure Sensor Open or Short Circuit - Test" if 164-03 or 164-04 is active.Refer to diagnostic functional tests Troubleshooting, "Injection Actuation Pressure Sensor - Test" if 164-02 is active.Contact your Engine Technical Communicator (TC) if 164-00 or 164-11 is active.STOPTest Step 2. Check the Engine Oil Level
Check the engine oil level.
If the engine oil level is low add oil to the engine.
Try to start the engine.Expected Result:The engine starts.Results:
Yes - The engine starts. Proceed to Test Step 7.
No - The engine does not start. Proceed to Test Step 3.Test Step 3. The Engine Cranks but the Engine Will Not StartYour answer from the previous step indicated that the engine oil level is within specifications. Do not replace the injection actuation pressure sensor at this time.
Crank the engine. Observe the status for "Injection Actuation Pressure" and "Engine Speed" on Cat ET while the engine is cranking. Record the following data:________ Desired injection actuation pressure________ Actual injection actuation pressure________ Observed engine speed________ Engine coolant temperature________ Observed "Injection Actuation Output Percent"Expected Result:The desired injection actuation pressure and the actual injection actuation pressure are within 1 MPa (145 psi).Results:
OK - The desired injection actuation pressure and the actual injection actuation pressure are within 1 MPa (145 psi).Repair: The HEUI fuel system is functioning correctly. Refer to troubleshooting without a diagnostic code Troubleshooting, "Engine Cranks but Will Not Start".STOP
Not OK - The desired injection actuation pressure and the actual injection actuation pressure are not within 1 MPa (145 psi). Proceed to Test Step 4.Test Step 4. Use a Test Lamp to Check for the Presence of Current
Disconnect the J500/P500 IAPCV connector from the unit injector hydraulic pump.Note: Do not insert any wire that is larger than 18 AWG into the P500 harness connector. Do not insert the probe for the voltage test lamp into the P500 harness connector. These actions will spread the sockets of the connector which will damage the connector. Damaged connectors could cause intermittent connections.
Insert a 186-3735 Connector Pin into each of the harness connector sockets at connector P500.
Connect a voltage test lamp to the connector pins that are inserted in the P500 connector.
Crank the engine and watch the test lamp.Expected Result:The test lamp illuminates while the engine is cranking.Results:
OK - The test lamp illuminates while the engine is cranking. The ECM is operating correctly and the wiring harness to the pump is probably OK. Proceed to Test Step 5.
Not OK - The test lamp does not illuminate while the engine is cranking.Repair: Refer to diagnostic functional tests Troubleshooting, "Injection Actuation Pressure Control Valve Circuit - Test".STOPTest Step 5. Check the Oil Pressure at the Pump (Deadhead Test)
Escaping fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.Always use a board or cardboard when checking for a leak.
Disconnect the high pressure oil line from the unit injector hydraulic pump. Install a 8T-0852 Pressure Gauge onto the outlet port of the pump.Note: Ensure that the pump is supplying oil only to the gauge.Note: The pressure readings may vary between gauges.
Install a 224-9282 Adapter Cable As at the J500/P500 connectors. Connect one end of the adapter cable to the IAPCV and connect the other end to the harness connector.Note: There must be a continuous electrical connection between the ECM and the unit injector hydraulic pump. The improper connection or the incomplete connection of the adapter cable may provide incorrect results.
Connect a multimeter that is capable of measuring current that is 0 to 1,000 milliamperes in series with the adapter cable. Select the lowest current range for the multimeter that is greater than one amp.Note: If the multimeter is not set to the correct scale, the following measurement may provide misleading results.
Crank the engine and record the following data:________ Observed pressure reading from the pressure gauge________ Observed engine speed from Cat ET________ Observed "Injection Actuation Output Percent" from Cat ET________ Current reading from the ammeterExpected Result:The oil pressure is above 26.5 MPa (3840 psi) and the current is above 400 mA.Results:
OK - The oil pressure is above 26.5 MPa (3840 psi) and the current is above 400 mA. Return the system to the original configuration. Proceed to Test Step 6.
Not OK, Result 1 - The oil pressure is below 26.5 MPa (3840 psi) and the current is above 400 mA.Repair: Replace the unit injector hydraulic pump. If the drive gear on the pump is loose, do not attempt to tighten the drive gear and reuse the pump. Verify that the repair eliminates the problem. If the problem remains after the repair, contact your Engine Technical Communicator (TC).After the unit injector hydraulic pump has been