41492A 1 Mercury GUIDE ASSEMBLY

Illustration 1 g01325918
Schematic for sensor supplyTest Step 1. Inspect the Electrical Connectors and the Wiring
Turn the keyswitch to the OFF position.
Illustration 2 g01181787
Left side engine view (typical example) (1) Injection actuation pressure sensor (2) Boost pressure sensor (3) Fuel pressure sensor (4) Engine oil pressure sensor (5) J2/P2 ECM connector
Thoroughly inspect the connectors for pressure sensors (1), (2), (3), and (4). Also, thoroughly inspect connector (5). Refer to Troubleshooting, "Electrical Connectors - Inspect".
Illustration 3 g01325967
P1 ECM connector (P1-2) +5 V sensor supply (P1-3) Sensor return (P1-32) Engine cooling fan speed sensor
Illustration 4 g01181788
P2 ECM connector (P2-2) +5 V sensor supply (P2-3) Sensor return (P2-16) Fuel pressure (P2-24) Engine oil pressure (P2-27) Injection actuation pressure (P2-40) Boost pressure (P2-41) +5 V sensor supply (P2-42) Sensor return
Illustration 5 g01159881
Sensor connector (A) +5 V supply (B) Sensor return (C) Signal
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connectors that are associated with the circuit.
Check the allen head screw for each ECM connector for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
Check the harness and wiring for abrasion and for pinch points from the pressure sensors back to the ECM.Expected Result:All connectors, pins and sockets are completely coupled and/or inserted and the harness and wiring are free of corrosion, of abrasion and of pinch points.Results:
OK - The harness and connectors appear to be OK. Proceed to Test Step 2.
Not OK - There is a problem with the connectors and/or wiring.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.Verify that the repair eliminates the problem.STOPTest Step 2. Check for Active Diagnostic Codes
Connect Caterpillar Electronic Technician (ET) to the service tool connector. Refer to Troubleshooting, "Electronic Service Tools".
Turn the keyswitch to the ON position.
Observe the "Active Diagnostic" screen on Cat ET. Wait at least 30 seconds so that any codes may become active. Look for these codes:
262-03
262-04
Determine if the problem is related to a -03 diagnostic code or to a -04 diagnostic code.Expected Result:No diagnostic codes are active.Results:
OK - No diagnostic codes are active.Repair: If any of the above codes are logged and the engine is not running properly, refer to Troubleshooting, "Troubleshooting Without a Diagnostic Code".If the engine is running properly at this time, there may be an intermittent problem in a harness that is causing the codes to be logged. Refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Active -03 code - A -03 diagnostic code is active. Proceed to Test Step 3.
Active -04 code - A -04 diagnostic code is active. Proceed to Test Step 4.Test Step 3. Check the Supply Voltage at the Sensor Connector
Turn the keyswitch to the OFF position.
Disconnect the harness connectors for the following sensors:
Boost pressure sensor
Injection actuation pressure sensor
Fuel pressure sensor
Engine oil pressure sensor
Engine cooling fan speed sensor
Turn the keyswitch to the ON position.Note: Be sure to wiggle the harness during the following measurements in order to reveal an intermittent condition.
Measure the voltage between terminals A and B at each pressure sensor connector on the engine harness. Measure the voltage between terminals 2 and 5 at the connector for the engine cooling fan speed sensor.
Turn the keyswitch to the OFF position.
Connect all of the sensors.Expected Result:Each voltage measurement is 5.0 0.2 VDC.Results:
OK - Each voltage measurement is 5.0 0.2 VDC.Repair: Replace all wires to the original configuration. Clear all diagnostic codes. Check for active diagnostic codes. If the problem is intermittent, refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - At least one voltage measurement is not 5.0 0.2 VDC. There is a problem with the wiring or with the ECM. Proceed to Test Step 5.Test Step 4. Disconnect the +5 V Sensors and Check for Active Diagnostic Codes
Monitor the active diagnostic code screen on Cat ET. Check and record any active diagnostic codes.Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
Disconnect the following sensors one at a time at the sensor connector:
Boost pressure sensor
Injection actuation pressure sensor
Fuel pressure sensor
Engine oil pressure sensor
Engine cooling fan speed sensorExpected Result:The 262-04 diagnostic code deactivates when a particular sensor is disconnected.Results:
OK - The 262-04 diagnostic code deactivates when a particular sensor is disconnected.Repair: Connect the suspect sensor. If the code returns, replace the sensor.Connect all of the connectors. Verify that the problem is resolved.STOP
Not OK - The 262-04 diagnostic code remains after all of the sensors are disconnected. Leave the sensors disconnected. Proceed to Test Step 5.Test Step 5. Check the +5 V Supply at the ECM
Disconnect the J1/P1 ECM connector.
Remove terminal P1-2 (+5 V supply) from the P1 connector. Install a wire jumper with socket terminals on both ends into the P1-2 location.
Connect the J1/P1 ECM connectors.
Disconnect the J2/P2 ECM connector.
Remove terminal P2-2 (+5 V supply) from the P2 connector. Install a wire