804604 Mercury BOLT, (M6 x 20)

Table 1
Diagnostic Codes Table    
Code and Description    Conditions which Generate this Code    System Response    
1-5 Cylinder #1 Injector : Current Below Normal     The ECM detects a low current in the circuit for the injector solenoid.     The code is logged.
The ECM continues the attempt to energize the solenoid circuit until the circuit is repaired.    
2-5 Cylinder #2 Injector : Current Below Normal    
3-5 Cylinder #3 Injector : Current Below Normal    
4-5 Cylinder #4 Injector : Current Below Normal    
5-5 Cylinder #5 Injector : Current Below Normal    
6-5 Cylinder #6 Injector : Current Below Normal    
7-5 Cylinder #7 Injector : Current Below Normal    
8-5 Cylinder #8 Injector : Current Below Normal    
9-5 Cylinder #9 Injector : Current Below Normal    
10-5 Cylinder #10 Injector : Current Below Normal    
11-5 Cylinder #11 Injector : Current Below Normal    
12-5 Cylinder #12 Injector : Current Below Normal    
13-5 Cylinder #13 Injector : Current Below Normal    
14-5 Cylinder #14 Injector : Current Below Normal    
15-5 Cylinder #15 Injector : Current Below Normal    
16-5 Cylinder #16 Injector : Current Below Normal    
1-6 Cylinder #1 Injector : Current Above Normal     The ECM detects a high current in the circuit for the injector solenoid.     The code is logged.
The ECM disables this solenoid circuit. The ECM will periodically attempt to energize the solenoid circuit until the circuit is repaired.    
2-6 Cylinder #2 Injector : Current Above Normal    
3-6 Cylinder #3 Injector : Current Above Normal    
4-6 Cylinder #4 Injector : Current Above Normal    
5-6 Cylinder #5 Injector : Current Above Normal    
6-6 Cylinder #6 Injector : Current Above Normal    
7-6 Cylinder #7 Injector : Current Above Normal    
8-6 Cylinder #8 Injector : Current Above Normal    
9-6 Cylinder #9 Injector : Current Above Normal    
10-6 Cylinder #10 Injector : Current Above Normal    
11-6Cylinder #11 Injector : Current Above Normal    
12-6 Cylinder #12 Injector : Current Above Normal    
13-6 Cylinder #13 Injector : Current Above Normal    
14-6 Cylinder #14 Injector : Current Above Normal    
15-6 Cylinder #15 Injector : Current Above Normal    
16-6 Cylinder #16 Injector : Current Above Normal    Background InformationPerform this procedure during operating conditions that are identical to the operating conditions that exist when the problem occurs. Typically, problems with the injector solenoid occur when the engine is warmed up and/or when the engine is under vibration (heavy loads). The wiring and/or the connectors may have problems that only occur during vibration.These engines have fuel injectors that are electronically controlled. A solenoid is used to actuate the injector. The solenoid is mounted on top of the fuel injector body. The ECM sends a 105 V pulse to the injector solenoid. The pulse is sent at the proper time and for the correct duration for any given engine load and speed.Trim Files When an injector is replaced, program the new injector code into the ECM. Refer to Troubleshooting, "Injector Trim File - Install" for information that is related to trim files. If the ECM is replaced, all of the injector codes must be programmed into the new ECM. Refer to Troubleshooting, "ECM - Configure" for information that is related to the configuration of a new ECM.Diagnostic Tests that are Available on Caterpillar Electronic Technician (ET)Cat ET includes the following tests that will aid in troubleshooting injector solenoids:Note: Dual data link communications must be established between the service tool and the engine ECM prior to gaining access to some of the following tests. For information on dual data link communications, refer to Troubleshooting, "Electronic Service Tools" for details.Cylinder Cutout Test - The "Cylinder Cutout Test" is used on an engine in order to determine the individual cylinder performance while the engine is running. As one or more cylinders are cut out during the test, the "Cylinder Cutout Test" uses "Fuel Position" to evaluate the performance of the cylinders. As different cylinders are cut out, a comparison of the change in fuel injection delivery is used to identify cylinders that are weak or misfiring. When a malfunctioning injector is cut out, the increase in fuel delivery is less than the increase for a cylinder that is performing normally. One reason for a cylinder that is weak or misfiring is an injector that is malfunctioning.Injector Solenoid Test - This test identifies an open circuit or a short circuit in the circuits for the injector solenoids. The test is performed while the engine is not running. The "Injector Solenoid Test" briefly activates each solenoid. A good solenoid will create an audible click when the solenoid is activated. Cat ET indicates the status of the solenoid as "OK", "Open", or "Short".Fuel System Verification Test - This test evaluates the health of each injector. The test determines if an injector needs to be replaced. When the test is performed, Cat ET indicates the status of each injector as "Success" or "Failed". Perform this test immediately after an injector has been replaced. Also, perform this test if a -2 code or -7 code is active.Note: The "Fuel System Verification Test" test must be performed when the engine is running and the coolant temperature is above 65 °C (149 °F).Note: Two injector solenoids may share a common supply wire. For this reason, an open circuit or a short circuit in a supply wire could cause diagnostic codes for two cylinders. Refer to Illustration 2 for the schematic that is for the injector solenoids.
Illustration 1 g01270037
Schematic of the injector solenoids circuits (control assembly input connectors)
Illustration 2 g03320197
Location of the ECM connectors (top front engine view) (1) Right rail connector (2) J2/P2 ECM connector (3) Left rail connector
Illustration 3 g01270451
Terminal locations at the P2 ECM connector that are associated with the injector solenoids (P2-18) Injector cylinder 11 return (P2-22) Injector cylinder 7 return (P2-31) Injector cylinder 9 return (P2-50) Injector cylinder 5 return (P2-61) Injector cylinder 14, 16 supply (P2-67) Injector cylinder