803663A99 Mercury GASKET SET, Powerhead

Table 1
Associated Codes
E198
E390
E398
E583
107-15
107-16
157-17
5580-18
5584-0
5584-15
5584-16 Probable Causes
Codes
Parameters
Throttle Signal
Air Inlet and Exhaust System
Fuel System
Engine Load
Valve LashRecommended Actions
Note: If the problem only occurs under certain conditions, test the engine under those conditions.
Table 2
Troubleshooting Test Steps Values Results
1. Check for Engine Derate or Codes
A. Certain codes may cause poor performance. Refer to the histogram information for engine derates in Cat ET. Check for the following histograms:
1. High Exhaust Temperature Prevention Derate Time Histogram
2. High Turbo Speed Prevention Derate Time Histogram
B. If the histograms contain derates and no codes are present, then the engine is operating normally. The following list contains conditions that can cause derates:
1. Elevated altitude
2. Elevated inlet air temperature
3. Elevated ambient temperature
Engine Derate or Codes
Result: A code is not present.
Proceed to Test Step 2.
Result: A code is present.
Repair: Troubleshoot the code and then reset the histogram.
2. Check for Incorrect Parameters
A. Use Cat ET to verify that the correct parameters are being used. Refer to Troubleshooting, "Configuration Parameters" for additional information.
Parameters
Result: The parameters are correct.
Proceed to Test Step 3.
Result: The parameters are not correct.
Repair: Input the correct parameters. Refer to Troubleshooting, "Configuration Parameters" for additional information.
3. Monitor the Throttle Signal
A. Monitor the status for "Throttle Position" on Cat ET. Verify that the status for "Throttle Position" is stable and that the engine is able to reach high idle speed.
Throttle Signal
Result: The throttle signal is stable.
Proceed to Test Step 4.
Result: The throttle signal is not stable.
Repair: Make the necessary repairs. Refer to the appropriate procedure.
4. Inspect for Restrictions in the Air Inlet and Exhaust System
A. Check for an air filter restriction indicator. Replace any plugged air filters. Refer to the Operation and Maintenance Manual.
B. Check the air inlet and exhaust system for restrictions and/or leaks.
Restrictions
Result: There are no restrictions in the air inlet or exhaust system.
Proceed to Test Step 5.
Result: There are restrictions in the air inlet or exhaust system.
Repair: Make the necessary repairs, Refer to Systems Operation/Testing and Adjusting, "Air Inlet and Exhaust System - Inspect" for additional information.
5. Check the Fuel System
A. Visually check the fuel level in the fuel tank. Do not rely on the fuel gauge only.
B. Ensure that the vent in the fuel cap is not filled with debris.
C. Ensure that the fuel supply valve (if equipped) is in the full OPEN position.
D. Inspect the fuel system. Refer to Systems Operation/Testing and Adjusting, "Fuel System - Inspect" for additional information.
E. Cold weather adversely affects the characteristics of the fuel. Refer to the engines Operation and Maintenance Manual for information on improving the characteristics of the fuel during cold-weather operation. Cold mode (if applicable) is activated whenever the engine coolant temperature falls below a predetermined value. Monitor the status screen on Cat ET to verify that the engine has exited cold mode. Observe the reading for coolant temperature on the Cat ET.
Refer to "Cold Mode Operation" within the Systems Operation, "General Information".
F. Check fuel quality. Refer to Systems Operation/Testing and Adjusting, "Fuel Quality - Test" for the proper procedure. Check the fuel tank for debris or foreign objects which may block the fuel supply.
G. Check for the proper operation of the fuel transfer pump. Refer to Systems Operation/Testing and Adjusting, "Fuel System" for test information.
Fuel system Result: The fuel pressure is OK.
Proceed to Test Step 6.
Result: The fuel pressure is Not OK.
Repair: Replace the fuel filters. Clean the primary filter/water separator of debris. Refer to the Operation and Maintenance Manual for details.
6. Monitor the Engine Load
A. Check accessories and parasitic loads on the engine.
Engine load Result: There is not a parasitic load.
Proceed to Test Step 7.
Result: There is a parasitic load.
Repair: Remove the parasitic load.
7. Inspect the Valve Lash
Note: The valve lash can affect the performance of the engine.
Valve lash Result: The valve lash is not set correctly.
Repair: Set the valve lash. Refer to Testing and Adjusting, "Engine Valve Lash - Inspect/Adjust" for the correct procedure.
If the procedure did not correct the issue, contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the Dealer Solution Network (DSN).