0387787 JOHNSON RETAINER SET

Illustration 1 g01181491
Left side of engine (typical example)
(1) "J500/P500" Connector for the injection actuation pressure control valve
(2) Injection actuation pressure sensor Test 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 diagnostic codes might be active codes or logged codes: 164-00, 164-02, 164-03, 164-04, 164-11, 42-11, 94-1 and 94-11.
Connect the Caterpillar Electronic Technician (ET) to the data link connector.
Turn the keyswitch to the ON position. DO NOT START THE ENGINE.
Print the "Lifetime Totals" and the "Configuration" screen.
Check for active diagnostic codes or logged diagnostic codes. The diagnostic codes should become active within 30 seconds.
Verify that the engine coolant temperature sensor is operating properly. Verify through CAT ET. Refer to Testing and Adjusting, "Cooling System - Test" or Testing and Adjusting, "Test For The Water Temperature Gauge" for the proper procedure. Document all active diagnostic codes or logged diagnostic codes.________Expected Result:Diagnostic codes are not active or logged when electrical power is restored to the ECM and the engine is not running.Results:
OK - There are no active codes or logged codes. Proceed to Test Step 2.
Not OK - Active codes or logged codes are present.Repair: Refer to Troubleshooting, "Engine Pressure Sensor Open or Short Circuit - Test" if 164-03 or 164-04 is active or logged.Refer to Troubleshooting, "Injection Actuation Pressure Sensor - Test" if 164-02 is active or logged.Refer to Troubleshooting, "Injection Actuation Pressure Control Valve Circuit - Test" if 42-11 is active or logged. Refer to System Operation, Test and Adjusting, "Fuel System Pressure - Test" if 94-1 is active or logged. Proceed to Test Step 2 if 164-00, 164-11 or 94-11 is active or logged.STOPTest Step 2. Start the Engine
Inspect the engine for oil leaks in the HEUI oil rail. Repair leaks before proceeding. Clearly mark all leaks on returned parts. Note: Inspect the area near the high pressure oil rail and the unit injector hydraulic pump. If leakage is found between the transfer pump and the hydraulic pump, refer to Special Instruction, REHS3830 for details. If leakage is found between the hydraulic pump and the front housing, refer to Special Instruction, REHS3830 for details on replacing the seal.
Check the engine oil level. If the engine oil level is low, add oil to the engine. Do not overfill the engine.
Try to start the engine. Expected Result:The engine starts.Results:
OK - The engine starts. Proceed to Test Step 10.
Not OK - The engine does not start. Proceed to Test Step 3.Test Step 3. Verify the Operation of the Injection Actuation Pressure Sensor
Disconnect the connector for the injection actuation pressure sensor. Check for evidence of moisture in the connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for troubleshooting details.
Try to start the engine. Expected Result:The engine does not start.Results:
OK - The engine does not start. Reconnect the connector for the actuation pressure sensor. Clear all diagnostic codes. Proceed to Test Step 4.
Not OK - The engine starts.Repair: The injection actuation pressure sensor may be faulty. Replace the sensor and reconnect the connector. Clear all diagnostic codes. Verify that the repair eliminates the problem. If the problem still exists, proceed to Test Step 4.Test Step 4. The Engine Cranks but the Engine Will not Start
Observe the status for "Engine Speed", "Actual Injection Actuation Pressure" and "Engine Oil Pressure" on Cat ET while the engine is cranking. Record the following data: ________ Engine Speed________ Actual injection actuation pressure________ Desired injection actuation pressure________ Engine oil pressure________ Fuel pressure________ Engine coolant temperature________ Observed "Injection Actuation Output Percent"Expected Result:The observed engine speed is above 100 rpm and the actual injection actuation pressure is at least 6 MPa (870 psi) while the engine is cranking.Results:
OK - The observed engine speed is above 100 rpm and the actual injection actuation pressure is at least 6 MPa (870 psi) while the engine is cranking. Repair: If a 94-11 code is active or logged, there is a problem with the fuel supply system. Refer to System Operation, Test and Adjusting, "Fuel System Pressure - Test".If a 94-11 code is not active or logged, refer to Test Step 5.
Not OK - The observed engine speed is below 100 rpm.Repair: Refer to Troubleshooting, "Engine Cranks but Will Not Start".STOP
Not OK - The observed engine speed is above 100 rpm and the observed engine oil pressure is below 14 kPa (2 psi).Repair: There is a problem with the engine oil supply. Refer to System Operation, Test and Adjusting, "Engine Oil Pressure - Test".STOP
Not OK - The observed engine speed is above 100 rpm and the observed engine oil pressure is above 14 kPa (2 psi) and the actual injection actuation pressure is below 6 MPa (870 psi). Proceed to Test Step 7.Test Step 5. Verify Communication Between the ECM and the Fuel Injectors
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
Illustration 2 g01330859
Location of the connectors for the injector solenoids (C7 engines)
(1) Connector at the valve cover
(2) J2/P2 ECM connectors
(3) Rubber grommet for the injector harness at the valve cover
Illustration 3 g01330939
Location of the connectors for the injector solenoids (C9 engines)
(1) Connector at the valve cover
(2) J2/P2 ECM connectors
Turn the key to the "OFF" position. An electrical shock hazard is present if the key is not in the "OFF" position.
Disconnect the connector for the injector harness at the valve cover. Check for evidence of moisture in the connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for troubleshooting details.
Crank the engine for 15 seconds.
Check Cat ET for logged diagnostic codes that are related to the injector solenoids. Expected Result:There are logged diagnostic codes for injector solenoids in all cylinders.Results:
OK - There are logged diagnostic codes for injector solenoids in all cylinders. The logged codes indicate communication between the ECM and the fuel injectors. Turn the key to the "OFF" position. Reconnect the connector for the injector harness. Clear all diagnostic codes. Proceed to Test Step 6.
Not OK - At least one cylinder does not indicate