821571A 1 Mercury GUIDE TOOL, Water Pump Alignment Pins

Illustration 1 g01230041
Schematic for the injection actuation pressure sensorTest Step 1. Check for Active Diagnostic Codes
Connect the Caterpillar Electronic Technician (ET) to the service tool connector. Refer to electronic troubleshooting Troubleshooting, "Electronic Service Tools".
Restore the electrical power to the ECM.
Observe the "Active Diagnostic" screen on Cat ET. Wait at least 30 seconds so that any codes may become active. Look for an active 164-02 diagnostic code.Note: If one of the following diagnostic codes is active, refer to the diagnostic functional test Troubleshooting, "Engine Pressure Sensor Open or Short Circuit - Test".
164-03 Injector Actuation Pressure voltage high
164-04 Injector Actuation Pressure voltage lowExpected Result:The 164-02 diagnostic code is active.Results:
Active code - The 02 diagnostic code is active. Proceed to Test Step 3.
No active code - The 02 diagnostic code is not active. Proceed to Test Step 2.Test Step 2. Try to Start the Engine Try to start the engine.Expected Result:The engine starts.Results:
OK - The engine starts. There are no active codes for the injection actuation pressure sensor and the engine starts.Repair: There may be an intermittent problem in a harness that is causing the code to be logged. Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - The engine does not start.Repair: Refer to troubleshooting without a diagnostic code Troubleshooting, "Engine Cranks but Will Not Start".STOPTest Step 3. Inspect the Electrical Connectors and the Wiring
Remove the electrical power from the ECM.
Illustration 2 g01180781
Typical left side view (1) Injection actuation pressure sensor
Thoroughly inspect the J2/P2 ECM connectors. Thoroughly inspect the connector for the injection actuation pressure sensor. Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".
Illustration 3 g01180788
P2 terminals that are associated with the injection actuation pressure sensor (P2-17) Return (P2-72) +5 VDC (P2-85) Injection Actuation pressure
Illustration 4 g01123211
Harness connector for the injection actuation pressure sensor (A) Supply (B) Return (C) Signal
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the injection actuation pressure sensor.
Check the torque of the allen head screws for the ECM connectors. Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".
Check the harness and wiring for abrasion and for pinch points from the sensor back to the ECM.Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted. The harness and wiring are free of corrosion, of abrasion, and of pinch points.Results:
OK - The connectors and wiring are OK. Proceed to Test Step 4.
Not OK - There is a problem in the wiring and/or a connector.Repair: Repair the wiring and/or the connector. Replace parts, if necessary. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.Verify that the problem is resolved.STOPTest Step 4. Check the Status of the Sensor
Restore the electrical power to the ECM.
Check the value of the "Injection Actuation Pressure" on Cat ET.Note: The following codes will cause the value of the "Injection Actuation Pressure" to revert to a default value.
03 Injector Actuation Pressure voltage high
04 Injector Actuation Pressure voltage lowExpected Result:The value of the "Injection Actuation Pressure" is 0 kPa (0 psi).Results:
OK - The value of the "Injection Actuation Pressure" is 0 kPa (0 psi). Proceed to Test Step 6.
Not OK - The value of the "Injection Actuation Pressure" is above 0 kPa (0 psi). Proceed to Test Step 5.Test Step 5. Check the Voltage Supply to the Injection Actuation Pressure Sensor
Remove the electrical power from the ECM.
Disconnect the injection actuation harness connector.
Connect a 3-terminal breakout T to the injection actuation harness connector only.
Restore the electrical power to the ECM.
Measure the voltage between terminals A and B at the breakout T.Expected Result:The voltage reading is 5 0.2 VDC.Results:
OK - The voltage is within the specified range. Proceed to Test Step 6.
Not OK - The voltage is not within the specified range.Repair: Refer to the diagnostic functional test Troubleshooting, "Analog Sensor Supply Circuit - Test".STOPTest Step 6. Compare the Sensor's Output to a Pressure Gauge
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.
Remove the electrical power from the ECM.
Install a 8T-0852 Pressure Gauge to an oil port on the side of the cylinder head or to the port on the top of the fuel transfer pump.
Start the engine.
Go to the "Injection Actuation Pressure Test" on the diagnostic menu of Cat ET.
Start the "Injection Actuation Pressure Test".
Refer to Table 1. Observe the value of the "Injection Actuation Pressure" on Cat ET. Vary the engine speed in order to obtain each "Injection Actuation Pressure" value that is listed in the Table. For each pressure value, observe the reading on the pressure gauge.
Table 1
Comparison of Pressure Readings    
"Injection Actuation Pressure" Values on Cat ET     Range of Acceptable Pressure Values on the Pressure Gauge    
6000 kPa (870 psi)     4000-7800 kPa (580-1130 psi)    
10000 kPa (1450 psi)     800