804109T 4 Mercury CYLINDER HEAD

Illustration 1 g03424167
Illustration 2 g03424835
Table 1
Diagnostic Codes
J1939 Code and Description Conditions which Generate the Code System Response
52-3
Engine Intercooler Temperature : Voltage Above Normal The Electronic Control Module (ECM) detects signal voltage that is not in the acceptable range. The code is logged.
The value of the parameter is set to a default value.
52-4
Engine Intercooler Temperature : Voltage Below Normal
105-3
Engine Intake Manifold #1 Temperature : Voltage Above Normal The Electronic Control Module (ECM) detects signal voltage that is not in the acceptable range. The code is logged.
The value of the parameter is set to a default value.
105-4
Engine Intake Manifold #1 Temperature : Voltage Below Normal
110-3
Engine Coolant Temperature : Voltage Above Normal The Electronic Control Module (ECM) detects signal voltage that is not in the acceptable range. The code is logged.
The value of the parameter is set to a default value.
110-4
Engine Coolant Temperature : Voltage Below Normal
175-3
Engine Oil Temperature 1 : Voltage Above Normal The Electronic Control Module (ECM) detects signal voltage that is not in the acceptable range. The code is logged.
The value of the parameter is set to a default value.
175-4
Engine Oil Temperature 1 : Voltage Below Normal System Operation (Secondary ECM)This engine utilizes a redundant control system in the case of an ECM failure. If the primary ECM fails, the secondary ECM provides for engine control and engine system monitoring. The secondary ECM utilizes several additional active sensors to monitor engine operation.When troubleshooting these sensors, ensure that the secondary ECM is controlling the engine. Each secondary sensor utilizes the same diagnostic code as the primary version of the sensor. The troubleshooting procedure for each secondary passive sensor is the same as the troubleshooting for the primary passive sensors.Schematics (Secondary ECM)The sensor signal for all of the passive sensors is routed to terminal 1 of each sensor connector. The sensor return for the passive sensors is routed from the ECM terminal 2 of each sensor connector.
Illustration 3 g01218763
Terminal locations at the sensor connector for the analog sensors
(Terminal 1) Sensor signal
(Terminal 2) Analog return
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.
Logged Diagnostic Codes
Or
Active Diagnostic Codes
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 -3 diagnostic code is active.
Proceed to Test Step 2.
Results: A -4 diagnostic code is active.
Proceed to Test Step 6.
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.
-3 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. Check for Battery Voltage on the Signal Wire
A. At the sensor harness connector, measure the voltage between the signal terminal and the return terminal.
B. Record the result.
-3 code
(+) Battery voltage
Results: The voltage is OK. The voltage measurement is less than the +Battery voltage. The signal wire is not shorted to the +Battery.
Proceed to Test Step 4.
Note: The following Results: will cause a -3 code.
Results: The voltage is NOT OK. The voltage measurement is approximately the +Battery voltage. The signal wire is shorted to the +Battery.
Repair: Repair the wiring, when possible. Replace parts, if necessary. Verify that the problem is resolved.
4. Determine if the Sensor has an Open Circuit Condition by Creating a Short Circuit at the Sensor Connector
A. Using appropriate terminals, fabricate a jumper wire.
B. At the sensor harness connector, connect the signal terminal and the return terminal with the jumper wire. The jumper will replace the sensor with a short circuit.
Note. Wait at least 30 seconds in order for the diagnostic codes to become active.
C. Record the resulting diagnostic code.
-3 Code
Results: A -3 diagnostic code is active when the connector is disconnected. A -4 diagnostic code is active when the jumper wire is shorting the circuit.
The sensor is NOT OK.
The open is in the sensor.
Repair: Perform the following procedure:
1. Temporarily connect a new sensor.
2. Recheck the circuit in order to ensure that the original problem is resolved with the connection of the new the sensor.
3. If the problem is resolved with the new sensor, reconnect the suspect sensor. If the problem returns with the connection of the suspect sensor, permanently install the new sensor.
4. Before returning the engine to service, clear the logged diagnostic codes.
Results: The -3 diagnostic code remains active when the jumper wire is shorting the circuit.
The sensor is OK.
The open is in the remainder of the circuit.
Proceed to Test Step 5.
5. Check the Operation of the ECM by Creating a Short Circuit at the ECM Connector
A. At the ECM harness connector, remove the signal wire and the return wire.
B. Using appropriate terminals, fabricate a jumper wire.
C. At the ECM harness connector, install the jumper wire between the signal terminal location and the return terminal location. The jumper will replace the engine wiring with a short circuit.
Note. Wait at least 30 seconds in order for the diagnostic codes to become active.
D. Record the resulting diagnostic code.
-3 code
Results: A -3 diagnostic code is active when the wires are removed. A -4 diagnostic code is active when th