826278T09 Mercury CHAP, Long - Starboard - Camouflage

Illustration 1 g01182300
Left side engine view (typical component locations)
(1) Injection Actuation Pressure Control Valve (IAPCV)
(2) Injection actuation pressure sensor
(3) J2/P2 ECM connector
(4) Fuel injection pump outlet port
(5) Line for low pressure oil 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 powerThe following diagnostic codes might be currently active or logged:
164-00 High Injectuation Actuation Pressure
164-02 Injectuation Actuation Pressure signal irratic
164-11 Injectuation Actuation Pressure system fault
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 to the ECM restored while the engine is off.Results:
OK - None of these codes are active with the electrical power to the ECM restored while the engine is off. Proceed to Test Step 2.
Not OK - 164-03 or 164-04 is active with the electrical power to the ECM restored while the engine is off.Repair: Refer to Troubleshooting, "Analog Sensor Open or Short Circuit - Test".STOP
Not OK - A 164-02 diagnostic code is active with the electrical power to the ECM restored while the engine is off.Repair: Refer to Troubleshooting, "Injection Actuation Pressure Sensor - Test".STOP
Not OK - 164-00 or 164-11 is active with the electrical power to the ECM restored while the engine is off.Repair: Contact your Engine Technical Communicator (TC).STOPTest Step 2. Check the Engine Oil Level
Check the engine oil level. Refer to Operation and Maintenance Manual, "Engine Oil Level - Check".
If the engine oil level is low add oil to the engine.
Try to start the engine. Expected Result:The engine has started.Results:
OK - The engine starts. Proceed to Test Step 9.
Not OK - The engine does not start. Proceed to Test Step 3.Test Step 3. Crank the Engine and Record the Engine Data From Cat ETYour answer indicated that the engine oil level is satisfactory.
Crank the engine and observe the "Injection Actuation Pressure" and "Engine RPM". ________ Record the actual injection actuation pressure.________ Record the engine speed.Expected Result:The injection actuation pressure is above 6 MPa (870 psi).Results:
OK - The injection actuation pressure is above 6 MPa (870 psi).Repair: The HEUI system is functioning correctly. Refer to Troubleshooting, "Engine Cranks but Will Not Start" which is located in the "Troubleshooting without a Diagnostic Code" section.STOP
Not OK - The injection actuation pressure is below 6 MPa (870 psi). Proceed to Test Step 4.Test Step 4. Check the Oil Pressure at the Fuel Injection Pump Outlet PortLocate the high pressure oil line that supplies high pressure oil to the cylinder head. Remove the oil line and install the 8T-0852 Pressure Gauge to the line or to the high pressure port at the pump. Crank the engine and record the oil pressure that is indicated on the gauge.Note: The pressure readings may vary between gauges. ________ Observed pressure reading________ Observed RPM________ Observed "Injection Actuation Output Percent"Expected Result:The oil pressure is above 27.5 MPa (4000 psi).Results:
OK - The oil pressure is above 27.5 MPa (4000 psi).Repair: Remove the pressure gauge from the engine.Proceed to Test Step 8.
Not OK - The oil pressure is below 27.5 MPa (4000 psi). Proceed to Test Step 5.Test Step 5. Install a Test Plug and Recheck the Oil Pressure
Remove the Injection Actuation Pressure Control Valve (IAPCV).
Install a 219-2368 Plug (DIAGNOSTIC) and 9X-1484 Seal Kit and perform the pressure test at the fuel injection pump outlet port. Crank the engine and record the results. ________ Observed pressure readingNote: If the 219-2368 Plug (DIAGNOSTIC) is not available, proceed to "Install a New IAPCV and Check the Oil Pressure".Expected Result:The oil pressure is above 27.5 MPa (4000 psi).Results:
OK - The oil pressure is above 27.5 MPa (4000 psi).Repair: The HEUI pump is OK. Replace the IAPCV and recheck the oil pressure. If the problem continues contact technical support.STOP
Not OK - The oil pressure is below 27.5 MPa (4000 psi). Remove the pressure gauge from the engine. Proceed to Test Step 7.Test Step 6. Install a New IAPCV and Check the Oil PressureNote: Use this Test Step only if the 219-2368 Plug (DIAGNOSTIC) is not available.
Install a new IAPCV onto the high pressure oil pump. Refer to Disassembly and Assembly, "Injection Actuation Pressure Control Valve - Remove and Install".
Check the oil pressure at the fuel injection pump outlet port. Record the pressure reading. ________ Observed pressure readingExpected Result:The oil pressure measures above 27.5 MPa (4000 psi).Results:
OK - The oil pressure is above 27.5 MPa (4000 psi).Repair: The replacement of the IAPCV has corrected the problem. Remove the test equipment from the engine. Verify that the repair has resolved the problem.STOP
Not OK - The oil pressure is below 27.5 MPa (4000 psi). Remove the new IAPCV and reinstall the original IAPCV. Proceed to Test Step 7.Test Step 7. Check the Fuel Injection Pump Drive Gear
Remove the high pressure oil pump. Refer to Disassembly and Assembly, "Unit Injector Hydraulic Pump - Remove".
Check for any physical damage to the drive gear.
Verify that the drive gear and the retaining bolt are properly tightened. Also verify that the