804607 9 Mercury ADJUSTING PAD

Illustration 1 g03478740
Schematic for the air shutoff circuit
Illustration 2 g03480376
Schematic for the waste gate circuit
Note: Refer to Troubleshooting, "Component Location" of this manual, in order to locate the components listed in this procedure.
Table 2
Troubleshooting Test Steps Values Results
1. Check for Active Diagnostic Codes and Check for Logged Diagnostic Codes
A. Connect Caterpillar Electronic Technician (ET) to the service tool connector. Refer to Troubleshooting, "Electronic Service Tools", if necessary.
B. Download the "Product Status Report" from the engine ECM before performing any troubleshooting or clearing diagnostic trouble codes.
C. Monitor the active diagnostic code screen on Cat ET. Record any active diagnostic codes.
Note. Wait at least 30 seconds in order for diagnostic codes to become active.
D. Select diagnostic tests from Cat ET.
E. Select the "Override Parameters" screen on Cat ET.
F. Activate the override for the circuit that is being tested.
G. Monitor the active diagnostic code screen on Cat ET. Record any active diagnostic codes.
Note: Wait at least 30 seconds in order for the diagnostic code to become active.
H. Deactivate the override.
I. Monitor the active diagnostic code screen on Cat ET. Record any active diagnostic codes.
Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
Logged Diagnostic Codes
Or
Active Diagnostic Codes
677-5
677-6
Results: A diagnostic code is logged but is not active.
Repair: Do not troubleshoot a logged code unless the code relates to an operator complaint. If the code is logged and the code does not relate to an operator complaint, clear the code.
If the logged code relates to this procedure, inspect the electrical connectors and the wiring for the circuit. Refer to Troubleshooting, "Electrical Connectors - Inspect"
Results: A -5 diagnostic code is active at this time.
Proceed to Test Step 2.
Results: A -6 diagnostic code is active at this time.
Proceed to Test Step 5.
2. Inspect the Electrical Connectors and the Wiring
A. Check the harness and the wiring for abrasion and for pinch points.
B. Thoroughly inspect all connectors that are in the circuit. Refer to Troubleshooting, "Electrical Connectors - Inspect " for details.
-5 code
Results: The connectors and wiring are OK.
Proceed to Test Step 3.
Results: The connectors and/or wiring are Not OK.
Repair: Repair the connectors or wiring and/or replace the connectors or wiring.
3. Determine if the Solenoid Valve has an Open Circuit Condition
A. Remove the electrical power from the ECM.
B. Disconnect the electrical connector from the solenoid valve of the circuit being tested.
C. Using appropriate terminals, fabricate a jumper wire and short the harness connector.
D. Restore the electrical power to the ECM.
E. Monitor the active diagnostic code screen on Cat ET. Record any active diagnostic codes.
Note. Wait at least 30 seconds in order for the diagnostic codes to become active.
F. Select diagnostic tests from Cat ET.
G. Select the "Override Parameters" screen on Cat ET.
H. Activate the override for the circuit that is being tested.
I. Monitor the active diagnostic code screen on Cat ET. Record any active diagnostic codes.
Note: Wait at least 30 seconds in order for the diagnostic code to become active.
J. Deactivate the override.
K. Monitor the active diagnostic code screen on Cat ET. Record any active diagnostic codes.
Note: Wait at least 30 seconds in order for the diagnostic code to become active.
L. Remove the electrical power from the ECM.
M. Restore the wiring to the original configuration.
-5 code
Results: A -5 diagnostic code is active when the connector is disconnected. A -6 diagnostic code is active when the jumper wire is shorting the circuit.
Repair: The wiring harness and the ECM are OK. The open circuit is in the solenoid for the valve. Perform the following repair:
Note. Some solenoid valve assemblies have a solenoid that can be serviced separately. The solenoid may be called out as a coil in the parts book.
1. Temporarily connect a new solenoid valve.
2. Recheck the circuit in order to ensure that the original problem is resolved with the installation of the new the solenoid valve.
3. If the problem is resolved with the new solenoid valve, reinstall the suspect solenoid valve. If the problem returns with the installation of the suspect solenoid valve, permanently install the new solenoid valve.
4. Before returning the engine to service, clear the logged diagnostic codes that are associated with this test.
Results: The -5 diagnostic code remains active when the jumper wire is shorting the circuit.
The solenoid for the valve is OK.
The open is in the remainder of the circuit.
Proceed to Test Step 5
4. Check the Operation of the ECM by Creating a Short Circuit at the ECM Connector
A. Remove the electrical power from the ECM.
B. Remove the "Solenoid Valve (+)" wire, for the circuit being tested, from the ECM connector.
C. Using appropriate terminals, fabricate a jumper wire and replace the removed wire with the jumper wire.
D. Short the jumper wire to -Battery.
E. Restore the electrical power to the ECM.
F. Monitor the active diagnostic code screen on Cat ET. Record any active diagnostic codes.
Note: Wait at least 30 seconds in order for the diagnostic code to become active.
G. Select diagnostic tests from Cat ET.
H. Select the "Override Parameters" screen on Cat ET.
I. Activate the override for the circuit that is being tested.
J. Monitor the active diagnostic code screen on Cat ET. Record any active diagnostic codes.
Note: Wait at least 30 seconds in order for the diagnostic code to become active.
K. Deactivate the override.
L. Monitor the active diagnostic code screen on Cat ET. Record any active diagnostic codes.
Note: Wait at least 30 seconds in order for the diagnostic code to become active.
M. Remove the electrical power from the ECM.
N. Restore the wiring to the original configuration.
-5 code
Results: A -5 diagnostic code was active before shorting the wire to -Battery. A -6 diagnostic code became active after shorting the wire to -Battery.
Repair: The ECM is OK. There is an open in the wiring that is between the ECM and the