827737 Mercury SEAL

Illustration 1 g01168791Test Step 1. Check for "Active" or "Logged" Diagnostic Codes
Connect Caterpillar Electronic Technician (ET) to the service tool connector.
Turn the engine control to the STOP mode.
Turn the engine battery disconnect switch to the ON position.
Monitor the diagnostic codes on Cat ET. Check and record any diagnostic codes. Note: Wait at least 15 seconds in order for the diagnostic codes to become active.
Determine if a diagnostic code has occurred several times. Note: A diagnostic code that is logged several times is an indication of an intermittent problem. Most intermittent problems are the result of a bad connection between a socket and a pin in a connector or a bad connection between a wire and terminal.
Determine if the problem is active and related to one of the following diagnostic codes:
03
04
08Expected Result:A diagnostic code has occurred several times.Results:
OK - A diagnostic code has occurred several times. Proceed to Test Step 2.
Not OK - 0-3 - An active 0-3 diagnostic code is present. Proceed to Test Step 3.
Not OK - 0-4 - An active 0-4 diagnostic code is present. Proceed to Test Step 5.
Not OK - 0-8 - An active 0-8 diagnostic code is present. Proceed to Test Step 8.Test Step 2. Perform the "Wiggle Test" on Caterpillar Electronic Technician (ET)
Select the "Wiggle Test" from the diagnostic tests on Cat ET.
Choose the appropriate group of parameters to monitor.
Press the "Start" button. Wiggle the wiring harness for the suspect sensor in order to reproduce an intermittent problem. If an intermittent problem exists, the status will be highlighted and an audible beep will be heard.Expected Result:No intermittent problems were indicated during the "Wiggle Test".Results:
OK - No intermittent problems were found. The harness and connectors appear to be OK. If a diagnostic code is still active, proceed to Test Step 1 and continue to troubleshoot the active diagnostic code.
Not OK - At least one intermittent problem was indicated.Repair: Repair the harness or the connector. Refer to the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors". Verify that the repair eliminates the problem.STOPTest Step 3. Check the Analog Supply Voltage at the Sensor Connectors
Turn the engine control to the OFF/RESET mode.
Turn the engine battery disconnect switch to the OFF position.
Disconnect the suspect sensor(s) at the sensor connector:
Turn the engine control to the STOP mode.
Turn the engine battery disconnect switch to the ON position.
Measure the voltage on the ECM side of the sensor connector between pin A and pin B for the suspect sensor(s). Expected Result:The supply voltage is 5.0 0.2 VDC.Results:
OK - The voltage is 5.0 0.2 VDC. Proceed to Test Step 6.
Not OK - The voltage is not 5.0 0.2 VDC. Proceed to Test Step 4.Test Step 4. Check the Analog Supply Voltage at the ECM
Turn the engine control to the OFF/RESET mode.
Turn the engine battery disconnect switch to the OFF position.
Check the supply voltage by removing the supply wires from P1-2 and P1-18. Note: The same 5 V supply provides power to both pins on ECM connector P1.
Install a 208-0059 Adapter Cable As (70-PIN BREAKOUT) at the J1/P1 ECM connector.
Turn the engine control to the STOP mode.
Turn the engine battery disconnect switch to the ON position.
Measure the voltage between terminal P1-2 and terminal P1-3 of the breakout T.
Turn the engine control to the OFF/RESET mode.
Turn the engine battery disconnect switch to the OFF position.
Remove the wire jumpers and replace all wires. Remove the breakout T. Reconnect ECM connector J1/P1. Expected Result:The supply voltage is 5.0 0.2 VDC.Results:
OK - The supply voltage is 5.0 0.2 VDC. The supply voltage at the ECM is correct. There is a problem in the wiring between the ECM and the suspect sensor.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOP
Not OK - The supply voltage is not 5.0 0.2 VDC. The voltage at the ECM is not correct.Repair: Replace the ECM. Refer to Troubleshooting, "Replacing the ECM". Verify that the problem is resolved.STOPTest Step 5. Create an Open at the Suspect Sensor Connector
Turn the engine control to the OFF/RESET mode.
Turn the engine battery disconnect switch to the OFF position.
Disconnect the sensor connector of the suspect sensor(s) with the active 04 diagnostic code.
Turn the engine control to the STOP mode. Wait at least 15 seconds for activation of the diagnostic codes.
Turn the engine battery disconnect switch to the ON position.
Access the "Active Diagnostic Code" screen on Cat ET. Check for an active 0-3 diagnostic code. Expected Result:The 03 diagnostic code is now active for the suspect sensor(s).Results:
OK - The 04 diagnostic code was active before disconnecting the sensor. The 03 diagnostic code became active after disconnecting the sensor.Repair: Temporarily connect a new sensor to the harness, but do not install the new sensor in the engine. Verify that there are no active diagnostic codes for the sensor. If there are no active diagnostic codes for the sensor, permanently install the new sensor. Clear any logged diagnostic codes.STOP
Not OK - The 04 diagnostic code is still active for the suspect sensor. There is a short circuit between the sensor harness connector and the ECM. Leave the sensor disconnected. Proceed to Test Step 7.Test Step 6. Check the Pull-up Voltage at the Sensor Connector
Turn the engine control to the STOP mode.
Turn the engine battery disconnect switch to the ON position.
Disconnect the suspect sensor.
Measure the voltage between terminal C (signal) and terminal B (sensor return) at the sensor connector.
Turn the engine control to the OFF/RESET mode.
Turn the engine battery disconnect switch to the OFF position. Expected Result:The voltage is 11 2 VDC.Results:
OK - The voltage is 11 2 VDC. The signal wire to the ECM from the sensor connector is OK.Repair: The open circuit is in the sensor or the wire between the sensor and the sensor connector. Replace the sensor. Do not install the sensor in the engine. Verify that no diagnostic codes are active for the suspect sensor before permanently installing the sensor.STOP
Not OK - The voltage is not 11 2 VDC. There is an open or a