3T9-72096-0 Tohatsu LABEL, CAUTION (CE-A)

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The connection of any electrical equipment and the disconnection of any electrical equipment may cause an explosion hazard which may result in injury or death. Do not connect any electrical equipment or disconnect any electrical equipment in an explosive atmosphere.
Test Step 1. Check for Active Diagnostic Codes
Connect the Caterpillar Electronic Technician (ET) to the service tool connector. Refer to Troubleshooting, "Electronic Service Tool".
Turn the keyswitch to the ON position.Note:
Observe the "Active Diagnostic" screen on Cat ET. Wait at least 15 seconds so that any codes may become active. Look for an active 164-02 diagnostic code.Note: If a 164-03 Injector Actuation Pressure voltage high or a 164-04 Injector Actuation Pressure voltage low is active, refer to Troubleshooting, "Engine Pressure Sensor Open or Short Circuit - Test".Expected Result:The 164-02 diagnostic code is not active.Results:
OK - No 164-02 diagnostic code is active. Proceed to Test Step 2.
Not OK - A 164-02 diagnostic code is active. Proceed to Test Step 3.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 Troubleshooting, "Electrical Inspectors - Inspect".STOP
Not OK - The engine does not start.Repair: Refer to Troubleshooting, "Engine Cranks but Will Not Start".STOPTest Step 3. Inspect Electrical Connectors and Wiring
Turn the keyswitch to the OFF position.
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Component locations (typical example) (1) Unit injector hydraulic pump (2) Injection actuation pressure sensor (3) Injection Actuation Pressure Control Valve (IAPCV) (4) High pressure supply line to cylinder head (5) Low pressure supply line to pump (6) ECM (7) J2/P2 ECM connector
Thoroughly inspect the J204/P204 injection actuation pressure sensor connector and the J2/P2 ECM connector. Refer to Troubleshooting, "Electrical Connectors - Inspect".
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P2 terminals that are associated with the injection actuation pressure sensor (P2-3) Return (P2-2) +5 VDC (P2-27) Injection Actuation pressure
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Connectors 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 in the ECM connector that are associated with the injection actuation pressure sensor.
Check the allen head screws on the ECM connectors for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque value.
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 and the harness and wiring are free of corrosion, of abrasion and of pinch points.Results:
OK - The wiring and the connectors appear to be OK. Proceed to Test Step 4.
Not OK - There is a problem with the wiring and/or the connectors.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 completely coupled.Verify that the repair eliminates the problem.STOPTest Step 4. Check the Status of the Sensor
Turn the keyswitch to the ON position.
Check the value of the "Injection Actuation Pressure" on Cat ET.Note: If a 164-03 code is active or a 164-04 code is active, the status for the injection actuation pressure will default to 17500 kPa (2538 psi).Expected Result:The value of the "Injection Actuation Pressure" is 0 kPa (0 psi).Results:
OK - The status for the injection actuation pressure is 0 kPa (0 psi). Proceed to Test Step 6.
Not OK - The status for 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
Turn the keyswitch to the OFF position.
Disconnect the J204/P204 connectors.
Connect a 3-terminal breakout T to the P204 harness connector only.
Turn the keyswitch to the ON position.
Measure the voltage between terminals A and B at the breakout T.Expected Result:The voltage reading is 5.0 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 Troubleshooting, "5 Volt Engine Pressure 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.
Turn the keyswitch to the OFF position.
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.