881545 Mercury PLUNGER

Table 1
Diagnostic Codes Table
Code and Description Conditions which Generate this Code System Response
651-2 Engine Injector Cylinder #01 : Erratic, Intermittent, or Incorrect The Electronic Control Module (ECM) receives a signal from the injector solenoid that is invalid or that cannot be accurately interpreted.
The code is logged.
The ECM continues to energize the injector solenoid.
652-2 Engine Injector Cylinder #02 : Erratic, Intermittent, or Incorrect
653-2 Engine Injector Cylinder #03 : Erratic, Intermittent, or Incorrect
654-2 Engine Injector Cylinder #04 : Erratic, Intermittent, or Incorrect
655-2 Engine Injector Cylinder #05 : Erratic, Intermittent, or Incorrect
656-2 Engine Injector Cylinder #06 : Erratic, Intermittent, or Incorrect
657-2 Engine Injector Cylinder #07 : Erratic, Intermittent, or Incorrect
658-2 Engine Injector Cylinder #08 : Erratic, Intermittent, or Incorrect
659-2 Engine Injector Cylinder #09 : Erratic, Intermittent, or Incorrect
660-2 Engine Injector Cylinder #10 : Erratic, Intermittent, or Incorrect
661-2 Engine Injector Cylinder #11 : Erratic, Intermittent, or Incorrect
662-2 Engine Injector Cylinder #12 : Erratic, Intermittent, or Incorrect
663-2 Engine Injector Cylinder #13 : Erratic, Intermittent, or Incorrect
664-2 Engine Injector Cylinder #14 : Erratic, Intermittent, or Incorrect
665-2 Engine Injector Cylinder #15 : Erratic, Intermittent, or Incorrect
666-2 Engine Injector Cylinder #16 : Erratic, Intermittent, or Incorrect
651-7 Engine Injector Cylinder #01 : Not Responding Properly The engines ECM has determined that the mechanical wear for the injector is out of specifications.
The code is logged.
The ECM continues to energize the injector solenoid.
652-7 Engine Injector Cylinder #02 : Not Responding Properly
653-7 Engine Injector Cylinder #03 : Not Responding Properly
654-7 Engine Injector Cylinder #04 : Not Responding Properly
655-7 Engine Injector Cylinder #05 : Not Responding Properly
656-7 Engine Injector Cylinder #06 : Not Responding Properly
657-7 Engine Injector Cylinder #07 : Not Responding Properly
658-7 Engine Injector Cylinder #08 : Not Responding Properly
659-7 Engine Injector Cylinder #09 : Not Responding Properly
660-7 Engine Injector Cylinder #10 : Not Responding Properly
661-7 Engine Injector Cylinder #11 : Not Responding Properly
662-7 Engine Injector Cylinder #12 : Not Responding Properly
663-7 Engine Injector Cylinder #13 : Not Responding Properly
664-7 Engine Injector Cylinder #14 : Not Responding Properly
665-7 Engine Injector Cylinder #15 : Not Responding Properly
666-7 Engine Injector Cylinder #16 : Not Responding Properly Background InformationA -2 code is activated when injector response to ECM current is not detected. Malfunctioning injectors can cause engine smoke and power issues.A -7 code is activated when injector response time to ECM current exceeds acceptable threshold. Injectors that are no longer responding correctly cause low power.Trim Files When an injector is replaced, program the new injector code into the ECM. Refer to Troubleshooting, "Injector Trim File - Install" for information that is related to trim files. If the ECM is replaced, all of the injector codes must be programmed into the new ECM. Refer to Troubleshooting, "ECM - Configure" for information that is related to the configuration of a new ECM.Note: Dual data link communications must be established between the service tool and the engine ECM prior to gaining access to some of the following tests. For information on dual data link communications, refer to Troubleshooting, "Electronic Service Tools" for details.Fuel System Verification Test - This test evaluates the health of each injector. The test determines if an injector needs to be replaced. When the test is performed, Cat ET indicates the status of each injector as "OK", "Not OK", or "Aborted".Double click for more information on error codes and why the test aborted:
0002 Active diagnostic present
10A7 Coolant temperature too low
10D0 Engine has not been running long enough
1100 Fuel rail pressure too high
1101 Fuel rail pressure too low
1108 Excessive engine RPM change
111D Fuel rail pressure high decay too high
111E Fuel rail pressure low decay too high
111F Fuel pump flow too low
1120 Fuel Pump Timing IncorrectIf any of these codes appear, fix the condition creating the code. Rerun the test until none of these conditions exist and a good test can be performed. Perform this test immediately after an injector has been replaced. Also, perform this test if a -2 code or -7 code is active.Note: The "Fuel System Verification Test" test must be performed when the engine is running and the coolant temperature is above 65 °C (149 °F). The FSVT will set the engine speed to rated speed.
Electrical Shock Hazard. The unit injector system uses 90 - 120 volts. The ECM sends this signal to the unit injectors. Do not come in contact with the unit injector harness connector while the engine is operating. Failure to follow this instruction could resulting in personal injury or death.
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
Ensure that all adjustments and repairs that are carried out to the fuel system are performed by authorized personnel that have the correct training.Before beginning ANY work on the fuel system, refer to Operation and Maintenance Manual, "General Hazard Information and High Pressure Fuel Lines" for safety information.Refer to Systems Operation, "Cleanliness of Fuel System Components" for detailed information on the standards of cleanliness that must be observed during ALL work on the fuel system.
Table 2
Troubleshooting Test Steps Values Results
1. Check for Diagnostic Codes
A. Establish communication between Cat ET and the engine ECM. Cat ET must be configured for Dual Data Link Communications in order to perform this procedure. Refer to Troubleshooting, "Electronic Service Tools", if necessary.
B. Determine the diagnostic code that relates to an injector.
Codes
Results: A -2 code or a -7 code is present.
Repair: Perform the following procedure:
1. Do not clear the diagnostic code.
2. Access the Fuel System Verification Test by accessing the following display screens:
- Diagnostics
- Diagnostic Tests
- Fuel System Verification Test
3. Perform the Fuel System Verification Test.
If the injector passes the test, the injector is OK. Cat ET will clear the code.
Results: If the injector fails the test, perform the following procedure:
a. Replace the injector.
b. Flash program the trim file for the new injector into the ECM. Refer to Troubleshooting, "Injector Trim File - Install", if necessary.
c. Perform the Fuel System Verification Test again. This test will clear the active