16219 1 Mercury SEAL

Illustration 1 g01121315
Schematic for the injection actuation pressure control valve
Illustration 2 g01121264
Left side view
(1) Connector for the IAPCV
(2) J2/P2 connectors
Illustration 3 g01121316
P2 terminations for the IAPCV
(P2-10) Control
(P2-20) Return
Table 1
Troubleshooting Test Steps Values Results
1. Inspect the Electrical Connectors and the Wiring
A. Turn the keyswitch to the OFF position.
B. Thoroughly inspect connectors (1) and (2). Refer to Troubleshooting, "Electrical Connectors - Inspect".
C. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the IAPCV.
D. Check the allen head screw on the ECM connector for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect".
E. Check the harness and wiring for abrasion and for pinch points from the IAPCV back to the ECM.
Note: Ensure that the seal is installed on the harness connector for the injection actuation pressure control valve.
Electrical Connectors and Wiring
Results: The connectors and the wiring are OK. Proceed to Test Step 2.
Results: There is a problem with the connectors and/or the 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 coupled. Verify that the repair eliminates the problem.
STOP
2. Check for Codes
A. Connect the Cat® Electronic Technician (ET) to the service tool connector.
B. Observe the "Active Diagnostic" screen on Cat ET. Wait at least 15 seconds so that any codes may become active. Look for these codes:
42-05
42-06
Codes
Results: One of the codes is active. Proceed to Test Step 3.
Results: None of the above 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
3. Measure the Resistance of the Injection Actuation Pressure Control Valve Solenoid
A. Turn the keyswitch to the OFF position.
B. Disconnect the J204/P204 connectors.
Note: Ensure that the seal on the P204 connector remains on the connector when the connector is disconnected.
C. Measure the resistance between terminals P204-1 (Control) and P204-2 (Return) on the IAPCV. Record the value of the resistance measurement
6.5 and 10.5 Ohms.
Results: The resistance measurement is between 6.5 and 10.5 Ohms. Connect the J204/P204 connectors. Proceed to Test Step 4.
Results: The resistance measurement is not between 6.5 and 10.5 Ohms. The solenoid resistance is not within the specification.
Repair: Replace the unit injector hydraulic pump. Verify that the problem is resolved.
STOP
4. Check the Wiring for an Open Circuit
A. Turn the keyswitch to the OFF position.
B. Disconnect the J2/P2 connectors.
C. Measure the resistance between terminals J2-10 (Control) and J2-20 (Return).
2 Ohms
Results: The resistance measurement is within two Ohms of the value that was measured in the previous Test Step. Proceed to Test Step 5.
Results: The resistance measurement is not within two Ohms of the value that was measured in the previous Test Step. There is a problem with the wiring harness. There may be a problem with a connector.
Repair: Repair the wiring and/or the connector. Replace parts, if necessary. Verify that the problem is resolved.
STOP
5. Check the Wiring for a Short Circuit
A. Disconnect the J204/P204 connectors.
Note: Ensure that the seal on the P204 connector remains on the connector when the connector is disconnected.
B. Disconnect the P1 connector.
C. Measure the resistance between the points that are listed in Table 2. Be sure to wiggle the wires in the harnesses as you make each resistance measurement.
Resistance
Results: All of the resistance measurements indicate an open circuit. Proceed to Test Step 6.
Results: At least one resistance measurement does not indicate an open circuit. There is a problem with a wiring harness. There may be a problem with a connector.
Repair: Repair the wiring and/or the connector. Replace parts, if necessary. Verify that the problem is resolved.
STOP
Table 2
Resistance Measurements for the Wiring Harness
Connector and Terminal Terminal
P2-10 (Control) All of the other terminals on the P2 connector
All of the terminals on the P1 connector
Engine ground
P2-20 (Return) All of the other terminals on the P2 connector
All of the terminals on the P1 connector
Engine ground
Table 3
Troubleshooting Test Steps Values Results
6. Check the ECM by Cranking the Engine