2019/01/25 Injection Actuation Pressure - Test (RENR2418-20)

SMCS - 1290, 1714, 1925 i07654629

Use the steps that follow to check the operation of the HEUI fuel system or

PSP
troubleshoot a 164-11 Injector Actuation Pressure : Other Failure Mode diagnostic code. Circle

202 -0003
the appropriate answers within the “Results” section of each step. Complete the pages. Provide
completed pages with any returned part. Return the parts through the normal channels.

4
22: /10/1 0640
Results from the test must be included in the claim for related repairs. Failure to follow the

4
proper sequence of this procedure may result in incorrect results. The standard warranty may

RE 6:51+ 3
not cover repairs that are performed while using this procedure incorrectly.

N
© 2 R24 07:00
Illustration 1
024 18 g01181491

Cat
Left side of engine (typical example)
(1) J500/P500 Connector for the injection actuation pressure control valve

erp
(2) Injection actuation pressure sensor

Table 1
illa
Troubleshooting Test Steps rI Values
nc.
Results

1. Check for Codes

A. Connect the Cat® Electronic Technician

(ET) to the data link connector.

B. Turn the keyswitch to the ON position. DO

NOT START THE ENGINE. Results: There are no active
codes or logged codes. Proceed
C. Print the "Lifetime Totals" and the to Test Step 2.
"Configuration" screen.
Results: Active codes or logged
D. Check for active diagnostic codes or logged Codes codes are present.
diagnostic codes. The diagnostic codes should
become active within 30 seconds. Repair: Troubleshoot the codes
as required.
E. Verify that the engine coolant temperature
sensor is operating properly. Verify through STOP
Cat ET. Refer to Testing and Adjusting, "Test
For The Water Temperature Gauge" for the
proper procedure.

Document all active diagnostic codes or

logged diagnostic codes.

2. Start the Engine Engine Results: The engine starts.

Proceed to Test Step 10.
A. Inspect the engine for oil leaks in the HEUI
oil rail. Repair leaks before proceeding. Clearly Results: The engine does not
mark all leaks on returned parts. start. Proceed to Test Step 3.

Note: Inspect the area near the high-pressure

oil rail and the unit injector hydraulic pump. If
leakage is found between the transfer pump
and the hydraulic pump, refer to Special
Instructions, REHS3830 for details. If leakage
is found between the hydraulic pump and the
front housing, refer to Special Instructions,
REHS3830 for details on replacing the seal.

B. Check the engine oil level. If the engine oil

level is low, add oil to the engine. Do not
overfill the engine.

C. Try to start the engine.

Results: The engine does not

start. Reconnect the connector
for the actuation pressure
sensor. Clear all diagnostic
3. Verify the Operation of the Injection codes. Proceed to Test Step 4.
Actuation Pressure Sensor
Results: The engine starts.
A. Disconnect the connector for the injection Injection
actuation pressure sensor. Check for evidence Actuation Repair: The injection actuation
of moisture in the connector. Refer to Pressure pressure sensor may be faulty.
Troubleshooting, "Electrical Connectors - Sensor Replace the sensor and
Inspect" for troubleshooting details. reconnect the connector. Clear
all diagnostic codes. Verify that
B. Try to start the engine. the repair eliminates the
problem.

If the problem still exists,

proceed to Test Step 4.

4. Observe the Readings in Cat ET 100 rpm at Results: The observed engine
6 MPa (870 speed is above 100 rpm and the
A. Observe the status for "Engine Speed", psi) actual injection actuation
"Actual Injection Actuation Pressure" and pressure is at least 6 MPa (870
"Engine Oil Pressure" on Cat ET while the psi) while the engine is cranking.
engine is cranking. Record the following data:
Repair: If a 94-11 code is active
· Engine Speed or logged, there is a problem
with the fuel supply system.
· Actual injection actuation pressure Refer to Testing and Adjusting,
"Fuel System Pressure - Test"
· Desired injection actuation pressure
If a 94-11 code is not active or
· Engine oil pressure logged, refer to Test Step 5.

· Fuel pressure Results: The observed engine

speed is below 100 rpm.
· Engine coolant temperature
 Repair: Refer to
· Observed "Injection Actuation Output Troubleshooting, "Engines
Percent" Cranks But Does Not Start".

STOP

Results: The observed engine

speed is above 100 rpm and the
observed engine oil pressure is
below 14 kPa (2 psi).
Repair: There is a problem with
the engine oil supply. Refer to
Testing and Adjusting, "Engine
Oil Pressure - Test".

STOP

Results: The observed engine

speed is above 100 rpm and the
observed engine oil pressure is
above 14 kPa (2 psi) and the
actual injection actuation
pressure is below 6 MPa (870
psi). Proceed to Test Step 7.

Electrical shock hazard. The electronic unit injector system uses

90-120 volts.
Illustration 2 g01330859
Location of the connectors for the injector solenoids (C7 engines)
(1) Connector at the valve cover
(2) J2/P2 ECM connectors
(3) Rubber grommet for the injector harness at the valve cover
Illustration 3 g01330939
Location of the connectors for the injector solenoids (C9 engines)
(1) Connector at the valve cover
(2) J2/P2 ECM connectors
Table 2

Troubleshooting Test Steps Values Results

5. Verify Communication Between Fuel Results: There are logged diagnostic codes
the ECM and the Fuel Injectors Injectors for injector solenoids in all cylinders. The
logged codes indicate communication
A. Turn the key to the "OFF" between the ECM and the fuel injectors. Turn
position. An electrical shock hazard the key to the OFF position. Reconnect the
is present if the key is not in the connector for the injector harness. Clear all
"OFF" position. diagnostic codes. Proceed to Test Step 6.

B. Disconnect the connector for the Results: At least one cylinder does not
injector harness at the valve cover. indicate a logged diagnostic code for the
Check for evidence of moisture in injector solenoid.
the connector. Refer to
Troubleshooting, "Electrical Repair: There may be a problem with the
Connectors - Inspect" for engine harness or ECM. Record the numbers
troubleshooting details. that do not indicate a logged diagnostic code
for the injector solenoid. Turn the key to the
C. Crank the engine for 15 seconds. OFF position. Reconnect the connector for
the injector harness. Clear any diagnostic
D. Check Cat ET for logged codes or event codes. Refer to
diagnostic codes that are related to Troubleshooting, "Injector Solenoid Circuit -
the injector solenoids. Test".
 STOP

Results: Observed fuel pressure is above

175 kPa (25 psi) while the engine is cranking.

Repair: Access the "Injector Solenoid Test" in

Cat ET. Activate the test. As each solenoid is
energized by the ECM an audible click can be
heard at the valve cover. Listen for a click at
the valve cover. Cat ET will indicate the
cylinder number as each solenoid is being
energized. Replace injectors that do not
produce an audible click. Verify the repair. If
6. Check the Pressure of the Low
all injectors produce an audible click and the
Pressure Fuel System
engine will not start, refer to Troubleshooting,
175 kPa "Engine Cranks but Will Not Start".
A. Observe the status for "Fuel
(25 psi)
Pressure" on Cat ET while the
STOP
engine is cranking. Record the fuel
pressure.
Results: Observed fuel pressure is below
175 kPa (25 psi) while the engine is cranking.

Repair: There is a problem with the fuel

supply system. Refer to System Operation,
Test and Adjusting, "Fuel System Pressure -
Test".

There is a problem with the fuel supply

system. Refer to System Operation, Test and
Adjusting, "Fuel System Pressure - Test".

7. Use a Test Lamp to Check for Test Results: The test lamp illuminates while the
the Presence of Current lamp engine is cranking. The ECM is operating
correctly and the wiring harness to the pump
A. Disconnect the J500/P500 IAPCV is OK. Proceed to Test Step 8.
connector from the unit injector
hydraulic pump. Results: The test lamp does not illuminate
while the engine is cranking.
Note: Do not insert any wire that is
larger than 18 AWG into the P500 Repair: Refer to Troubleshooting, "Injection
harness connector. Do not insert the Actuation Pressure Control Valve Circuit -
probe for the voltage test lamp into Test" for information on troubleshooting the
the P500 harness connector. These circuit.
actions will spread the sockets of the
connector which will damage the STOP
connector. Damaged connectors
could cause intermittent
connections.

B. Insert a 186-3735 Connector Pin

into each of the P500 harness
connector sockets .

C. Connect a voltage test lamp to

the connector pins that are inserted
in the P500 connector.

D. Crank the engine and watch the

test lamp.

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.

Electrical shock hazard. The electronic unit injector system uses

90-120 volts.

Table 3
Troubleshooting Test Steps Values Results

8. Check the High Pressure Oil System High Results: There are no excessive oil
for Leaks Pressure leaks around injector bores. Also,
Oil there is no excessive discharge of oil
A. Remove the valve cover and inspect the System from the spill ports of the injector.
high-pressure oil system for excessive oil
leaks or discharge. Repair: f the unit injector hydraulic
pump has not been replaced during
B. Look at the injector bores for any signs this procedure, replace the pump and
of oil leakage while the engine is being repeat steps "E" and "F". The engine
cranked. Inspect the spill ports on the will need to be cranked for a
injectors for an excessive discharge of oil. significant length of time in order to fill
All six injectors should discharge the same the pump with oil after the pump is
amount of oil. Excessive leakage or replaced. Clear all diagnostic codes.
discharge can cause issues with the
system pressure. If the unit injector hydraulic pump has
been replaced during this procedure,
C. Turn the key to the "OFF" position. An and the actual injection actuation
electrical shock hazard is present if the key pressure was at least 6 MPa (870 psi)
is not turned to the "OFF" position. in Step "E", proceed to Test Step 9.

D. Disconnect the connector for the Results: If the unit injector hydraulic
injector harness at the valve cover. Check pump has already been replaced
for evidence of moisture in the connector. during this procedure and the actual
Refer to Troubleshooting, "Electrical injection actuation pressure was
Connectors - Inspect" for troubleshooting below 6 MPa (870 psi) in Step "E",
details. consult your local technical
communicator for assistance.
E. Crank the engine. Observe the injector
bores for any signs of leakage. Inspect the Results: There are excessive oil
spill ports on the injectors for an excessive leaks around the injector bores or
discharge of oil. The injectors are now excessive discharge of oil out of the
disabled and the injectors should spill port of the injector.
discharge little oil, which is normal.
Observe the status for the "Actual Injection Repair: Replace the O-ring on the
Actuation Pressure" on Cat ET while the injector(s) that is leaking around the
engine is cranking. bore(s) or replace the damaged
injector(s) that is identified with
F. Clear any diagnostic codes that are excessive discharge out of the spill
logged. ports. Proceed to Test Step 9.

Results: The engine starts.

STOP

Results: The engine does not start

and actual injection actuation
pressure is above 6 MPa (870 psi).
9. Try to Start the Engine Proceed to Test Step 5.

A. Turn the key to the "OFF" position. An Results: The engine does not start
electrical shock hazard is present if the key and actual injection actuation
is not in the "OFF" position. pressure is below 6 MPa (870 psi).
B. Reconnect the connector for the injector
harness at the valve cover and install the Repair: If the unit injector hydraulic
Engine
valve cover. pump has not been replaced, replace
the pump and try to start the engine.
C. Try to start the engine. Observe the The engine will need to be cranked for
status for "Actual Injection Actuation a significant length of time in order to
Pressure" on Cat ET while the engine is fill the pump with oil after the pump
cranking. Record the actual injection has been replaced. Clear all
actuation pressure. diagnostic codes. If the engine does
not start, proceed to Test Step 5.

Results: If the unit injector hydraulic

pump has already been replaced in a
previous test, stop and consult your
local technical communicator for
assistance.

Extended oil drain intervals may cause elevated levels of soot in the engine oil. The elevated
levels of soot may also deplete the additive package of the oil. This can affect the operation of
the high-pressure oil system.

Refer to the engine's Operation and Maintenance Manual for the recommended engine oil
change interval and refill capacities.

Escaping fluid under pressure, even a pinhole size leak, can

penetrate body tissue, causing serious injury, and possible
death. If fluid is injected into your skin, it must be treated
immediately by a doctor familiar with this type of injury.

Always use a board or cardboard when checking for a leak.

Table 4

Troubleshooting Test Steps Values Results

 Results: The customer has not
exceeded the suggested oil change
interval.

Repair: Refer to Systems Operation,

Testing and Adjusting, "Fuel System
Pressure - Test" and Systems
Operation/Testing and Adjusting
, "Engine Oil Pressure - Test" in order to
verify that the observed fuel pressure
and engine oil pressures are
acceptable. If a 94-1 diagnostic code is
active or if a 94-1 diagnostic code is
10. Check the Low Pressure Fuel
logged, a problem in the fuel supply
and Oil System Pressures
system has occurred. Refer to Systems
Operation, Testing and Adjusting, "Fuel
A. Start the engine.
System Pressure - Test". Make
necessary repairs. Verify that the repair
B. Observe the status for "Fuel
eliminates the problem.
Pressure" and "Engine Oil Pressure" Low
on Cat ET while the engine is running. Pressure
If the problem still exists, proceed to
Record the following data: Fuel and
Test Step 11.
Oil System
· Observed fuel pressure from Cat ET Pressures
Results: The customer has exceeded
· Observed engine oil pressure from
the suggested oil change interval.
Cat ET
· Drain interval
Repair: If the customer has exceeded
the suggested oil change interval, ask
· Miles or Kilometers since the last oil
the customer to authorize an oil change
change
with a new filter. Oil changes are not
covered by the warranty. After the
engine oil and the oil filter have been
changed, operate the engine until
normal operating temperature has been
reached. Operate the engine at 1200 to
1500 rpm for 15 minutes. This will purge
any trapped air or debris that is in the
system.

If the problem still exists, or if the

problem reoccurs in a short period of
time, repeat Test Step 10.

11. Use "Injection Actuation 1379 kPa Results: The pressure that is measured
Pressure Test" on Cat ET to Check (200 psi) with the pressure gauge for each step
the System and the pressure that is displayed on
Cat ET for each step are within
A. Install the 8T-0852 Pressure Gauge 1379 kPa (200 psi). The injection
in an accessible port in the high- actuation pressure sensor is operating
pressure part of the injection actuation properly.
system.
Repair: Do not replace the sensor.
B. Start the engine. Proceed to Test Step 12.
C. Access the "Injection Actuation
Pressure Test" in the "Diagnostics Results: he pressure that is measured
Menu" of Cat ET and begin the test. with the pressure gauge for each step
and the pressure that is displayed on
Note: The "Injection Actuation Cat ET for each step are not within
Pressure Test" can be used to increase 1379 kPa (200 psi).
the injection actuation pressure. Also,
the "Injection Actuation Pressure Test" Repair: The injection actuation pressure
can be used to decrease the injection sensor may be faulty. Replace the
actuation pressure. The test adjusts sensor and repeat this test step.
the oil pressure of the injection
actuation system in predefined steps. If the problem still exists, verify the
Step forward through all predefined accuracy of the pressure gauge.
steps in the test. Next, step backward Reinstall the original sensor and
through all predefined steps in the test. proceed to Test Step 12.

D. Record the pressure readings from

the pressure gauge and from Cat ET in
Table 5.

Table 5
Manual pressure Actual injection actuation pressure from Cat
Step Difference
gauge ET
1
2
3
4
3
2
1

Table 6
Troubleshooting Test Steps Values Results

12. Perform the "Injection Actuation 1379 kPa Results: The actual injection actuation
Pressure Test" at Low Idle (200 psi) pressure is no more than 1379 kPa
(200 psi) above the desired injection
A. Start the engine. Run the "Injection actuation pressure for each step. Also,
Actuation Pressure Test" at low idle the actual injection actuation pressure
only. Step forward through all does not fluctuate more than ±1000 kPa
predefined steps in the test. Next, step (±145 psi). Proceed to Test Step 13.
backward through all the predefined
steps in the test. Results: One of the actual injection
actuation pressures is more than
Note: There may be a short lag in the 1379 kPa (200 psi) above the desired
reaction to the injection pressure. The injection actuation pressure on at least
pressure change should occur within one step, or the actual injection actuation
two seconds of each command. pressure fluctuates more than ±1000 kPa
(±145 psi)
B. Record the actual injection actuation
pressure, the desired injection Repair: Replace the unit injector hydraulic
actuation pressure and the percent pump. After the pump has been replaced,
output from Cat ET in Table 7. the engine will need to be cranked for a
significant length of time in order to fill the
pump with oil. Clear all diagnostic codes
or event codes. Verify that the repair
eliminates the problem.

If the problem still exists, proceed to Test

Step 13.

Table 7
Low Idle
Actual injection Desired injection Percent
Difference
Step actuation pressure from actuation pressure from Output from
(A-B)
Cat ET (A) Cat ET (B) Cat ET
1
2
3
4
3
2
1

Hot oil and components can cause personal injury.

Do not allow hot oil or components to contact skin.

Table 8
Troubleshooting Test Steps Values Results

13. Check the High Pressure Oil System for Excessive Results: There are no
Excessive Leaks discharge excessive oil leaks around
of oil injector bores. Also, there is
A. Remove the valve cover and inspect the high- no excessive discharge of oil
pressure oil system for excessive oil leaks or from the spill ports of the
discharge. injector. Proceed to Test
Step 14.
B. Start the engine and allow the engine to idle.
Look at the injector bores for any signs of oil Results: There are
leakage. Inspect the spill ports on the injectors for excessive oil leaks around
an excessive discharge of oil. All six injectors injector bores or there is an
should discharge the same amount of oil. excessive discharge of oil
Excessive leakage or discharge can cause issues from the spill ports of the
with the system pressure. injector.

C. While the engine is at low idle, perform the Repair: Replace the O-ring
"Injection Actuation Pressure Test" in Cat ET. Run on the injector(s) that is
the test at the highest pressure in order to leaking around the bore(s) or
maximize any possible leaks. Observe the status replace the damaged
for "Actual Injection Actuation Pressure" on Cat injector(s) that is identified
ET. Record the following data: with excessive discharge out
of the spill ports.
· Any injectors with excessive leakage or
discharge Verify that the repair
eliminates the problem. If the
· Actual injection actuation pressure at low idle problem remains after the
repair, proceed to Test Step
D. Turn the key to the "OFF" position. An electrical 14.
shock hazard is present if the key is not turned to
the "OFF" position.

E. Disconnect the connector for the injector

harness at the valve cover. Check for evidence of
moisture in the connector. Refer to
Troubleshooting, "Electrical Connectors - Inspect"
for troubleshooting details.

F. Crank the engine. Observe the injector bores for

any signs of leakage. Inspect the spill ports on the
injectors for an excessive discharge of oil. The
injectors are now disabled and the injectors should
discharge little oil, which is normal.
G. While the engine is cranking, perform the
"Injection Actuation Pressure Test" in Cat ET. Run
the test at the highest pressure in order to
maximize any possible leaks. Observe the status
for "Actual Injection Actuation Pressure" on Cat
ET. Record the following data:

· Any injectors with excessive leakage or

discharge

· Actual injection actuation pressure while the

engine is cranking
H. Clear any diagnostic codes that are logged.

Escaping fluid under pressure, even a pinhole size leak, can

penetrate body tissue, causing serious injury, and possible
death. If fluid is injected into your skin, it must be treated
immediately by a doctor familiar with this type of injury.

Always use a board or cardboard when checking for a leak.

Table 9

Troubleshooting Test Steps Values Results

14. Check the Oil Pressure at the 29.5 MPa Results: The oil pressure is above
Pump (High Pressure Pump (4278 psi) 29.5 MPa (4278 psi) and the current is
Test) and the above 400 mA. Leave the system in the
 current is present configuration and proceed to Test
A. Turn the key to the "OFF" above 400 Step 15.
position. mA
Results: The oil pressure is below
B. Reconnect the connector for the 29.5 MPa (4278 psi) and the current is
injector harness at the valve cover above 400 mA.
and install the valve cover.
Repair: Replace the unit injector hydraulic
C. Install the 8T-0852 Pressure pump. If the drive gear on the pump is
Gauge in an accessible port in the loose, do not attempt to tighten the drive
high-pressure portion of the gear and reuse the pump. After the pump
injection actuation system. has been replaced, the engine will need to
be cranked for a significant length of time
D. Disconnect the connector for the in order to fill the pump with oil. Clear all
injection actuation pressure sensor diagnostic codes or event codes. Verify
and plug a spare injection actuation that the repair eliminates the problem.
pressure sensor into the engine
harness. Allow the spare sensor to If the problem still exists, consult your local
hang on the side of the engine. technical communicator for assistance.

Note: This configuration allows the STOP

unit injector hydraulic pump to build
maximum pressure. The engine will Results: The current is below 400 mA.
not start in this configuration.
Repair: Refer to Troubleshooting,
E. Install a 224-9282 Adapter Cable "Injection Actuation Pressure Control Valve
As in series with the P500 - Test".
connector. Reconnect the
P500/J500 connector. STOP

Note: There must be a continuous

electrical connection between the
ECM and the unit injector hydraulic
pump. The improper connection or
the incomplete connection of the
adapter cable may provide
incorrect results.

F. Connect a multimeter that is

capable of measuring current that
is 0 to 1,000 milliampere in series
with the adapter cable. Select the
lowest current range for the
multimeter that is greater than one
amp.

Note: If the multimeter is not set to

the correct scale, the following
measurement may provide
misleading results.

G. Crank the engine and record the

following data:
· Observed pressure reading from
the pressure gauge

Note: If the gauge fluctuates use

the average.
· Observed engine speed from Cat
ET

· Observed "Injection Actuation

Output Percent" from Cat ET

· Current reading from the

multimeter

15. Use the "Cylinder Cutout

Test" on Cat ET to Check the
Fuel Injectors

The troubleshooting indicates that

the unit injector hydraulic pump is
working properly. Record the Results: The injectors are operating
following data: properly according to the "Injector
Solenoid Circuit - Test". Also, the engine
· Engine symptoms (misfire, symptoms are still present.
excessive smoke, low power, runs
rough) Repair: Consult your local technical
communicator for assistance.
· Conditions when the engine
Injector
symptom occurs, (high load, idle, STOP
Operation
cold start, acceleration, etc)
· The frequency of the engine Results: The"Injector Solenoid Circuit -
symptoms (intermittent, constant, Test" indicates faulty injectors.
etc)
Repair: Replace the faulty injectors. Verify
A. Perform a cylinder cutout that the repair eliminates the problem. If
procedure if the test has not the problem still exists, consult your local
already been performed or if any technical communicator for assistance.
other repairs have been completed
since the most recent cylinder
cutout procedure. Refer to
Troubleshooting, "Injector Solenoid
Circuit - Test" for troubleshooting
details.

PSP-00030640
2024/10/13
22:45:50+07:00
i05938635
© 2024 Caterpillar Inc.