804081 Mercury SPRING

Table 1
Diagnostic Codes Table    
Code and Description    Conditions which Generate this Code    System Response    
41-3
8 Volt DC Supply : Voltage Above Normal     The digital sensor supply voltage is above normal for 2 seconds.     The code is logged.
All sensors are set to default values.    
41-4
8 Volt DC Supply : Voltage Below Normal     The digital sensor supply voltage is below normal for 2 seconds.    
262-3
5 Volt Sensor DC Power Supply : Voltage Above Normal     The analog sensor supply voltage is above normal for 2 seconds.     The code is logged.
All sensors are set to default values.    
262-4
5 Volt Sensor DC Power Supply : Voltage Below Normal     The analog sensor supply voltage is below normal for 2 seconds.    
678-3
ECU 8 Volts DC Supply : Voltage Above Normal     The digital sensor supply voltage is above normal for 2 seconds.     The code is logged.
All sensors are set to default values.    
678-4
ECU 8 Volts DC Supply : Voltage Below Normal     The digital sensor supply voltage is below normal for 2 seconds.    
3509-3
Sensor Supply Voltage 1 : Voltage Above Normal     The analog sensor supply voltage is above normal for 2 seconds.     The code is logged.
All sensors are set to default values.    
3509-4
Sensor Supply Voltage 1 : Voltage Below Normal     The analog sensor supply voltage is below normal for 2 seconds.    
3510-3
Sensor Supply Voltage 2 : Voltage Above Normal     The analog sensor supply voltage is above normal for 2 seconds.     The code is logged.
All sensors are set to default values.    
3510-4
Sensor Supply Voltage 2 : Voltage Below Normal     The analog sensor supply voltage is below normal for 2 seconds.    System OperationThe Electronic Control Module (ECM) supplies a regulated voltage of 5.0 0.2 VDC to the following sensors:
Atmospheric pressure sensor
Crankcase pressure sensor
Jacket water coolant pressure sensor
Filtered engine oil pressure sensor
Unfiltered engine oil pressure sensor
Filtered fuel pressure sensor
Unfiltered fuel pressure sensor
Intake manifold pressureThe ECM supplies a regulated voltage of 8.0 0.4 VDC to the following sensors:
Left turbocharger turbine inlet temperature sensor
Right turbocharger turbine inlet temperature sensorIf applicable, when a -10 code is logged, this code indicates that the 5 V supply is not available at the sensor connector. During normal engine operation, each of the signals from the pressure sensors fluctuate slightly. When the 5 V supply becomes unavailable at the pressure sensor connector, the signal from that sensor floats to a midrange value. The signal will not fluctuate. If the signal from the sensor remains abnormally steady for more than 30 seconds, the ECM will activate this code.Note: The sensors are not protected from overvoltage. A short from the supply line to the +Battery may damage the sensors. Repair the sensor supply and check for any active sensor diagnostic codes in order to determine if a sensor has failed.
Illustration 1 g03366146
Schematic for the analog sensors
Illustration 2 g03366147
Schematic for the PWM sensors
Illustration 3 g03284981
Terminal locations at the P2 ECM connector for the analog sensors (P2-15) Intake manifold pressure (P2-16) Fuel transfer pressure (unfiltered) (P2-27) Fuel transfer pressure (filtered) (P2-28) Filtered oil pressure (P2-29) Digital supply (P2-30) Analog return (P2-33) Crankcase pressure (P2-65) Left turbocharger turbine inlet temperature (P2-66) Unfiltered oil pressure (P2-70) Jacket water pressure (P2-72) Analog sensor supply (P2-73) Right turbocharger turbine inlet temperature (P2-78) Barometric pressure (P2-81) Analog sensor supply (P2-83) Analog return (P2-92) Digital return (P2-93) Analog return )
Illustration 4 g01240891
Sensor connector (Terminal 1) Sensor supply (Terminal 2) Sensor return (Terminal 3) Signal
Table 2
Troubleshooting Test Steps    Values    Results    
1. Inspect the Electrical Connectors and the Wiring
A. Turn the main disconnect switch to the OFF position.
B. Thoroughly inspect connectors (1) through (7) . Inspect all of the connectors that are associated with the circuit. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
C. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connectors that are associated with the circuit.
D. Check the allen head screw for each of the ECM connectors for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
E. Check the harness and wiring for abrasion and for pinch points from the sensors back to the ECM.
   
Connectors    
Results: The harness and connectors appear to be OK.
Proceed to Test Step 2
Results: 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 coupled.
Verify that the repair eliminates the problem.
   
2. Check for Diagnostic Codes that are Active or Logged
A. Connect Caterpillar Electronic Technician (ET) to the service tool connector.
B. Restore the electrical power to the ECM.
C. Monitor the active diagnostic code screen on Cat ET. Check and record any diagnostic codes that are active or logged. Look for the following diagnostic codes:
- 678-3
- 678-4
- 3509-3
- 3509-4
- 3510-3
- 3510-4
Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
D. Turn the main disconnect switch to the OFF position.
   
Codes    
Results: No diagnostic codes are active or logged.
Repair: There does not appear to be an electrical problem with the sensor supply at this time. If the problem is intermittent, refer to Troubleshooting, "Electrical Connectors - Inspect".
Results: Either the 678-3 or 678-4 diagnostic code is active or logged at this time.
There is an electrical problem with the digital sensor supply.
Proceed to Test Step 6