3126B and 3126E On-highway Engines Caterpillar

Use this procedure under the following situation:

Use the following information in order to troubleshoot the system when there is an active code:

• 42-11 Injection Actuation Pressure Control Valve Driver (18)

Note: Do not use this procedure for an active diagnostic code of 164-11 Injection Actuation Pressure System unless you are directed to this procedure from the "Injection Actuation Pressure - Test". If the diagnostic code of 164-11 Injection Actuation Pressure System is active, refer to Troubleshooting, "Injection Actuation Pressure - Test".

The following background information is related to the following procedure:

The injection actuation pressure control valve regulates the high pressure oil to the injectors through a high pressure rail. The high pressure oil manifold is used to actuate the injectors and the high pressure oil manifold is used to control the fuel injection pressure. The injection actuation pressure control valve relieves excess high pressure oil back to the sump. The ECM controls the operation of the injection actuation pressure control valve by monitoring the engine rpm and the injection actuation pressure sensor.

Illustration 1	g00724789
Location of the injection actuation pressure control valve

Illustration 2	g00724834
Schematic for the injection actuation pressure control valve

Illustration 3	g00724865
Locations for the ECM terminals

Test Step 1. Use the Electronic service Tool to Check for Active Diagnostic Codes.

1. Connect the electronic service tool to the cab data link connector.

2. Start the Engine.

3. Monitor the "Active Diagnostic Code" screen on the electronic service tool. Check and record active diagnostic codes.

   Note: Wait at least 15 seconds in order for the diagnostic codes to become active.

Expected Result:

42-11 Injection Actuation Pressure Valve Driver is active.

Results:

• Yes - Proceed to Test Step 2.

• No -

  Repair: Refer to Troubleshooting, "Troubleshooting Without a Diagnostic Code".

  STOP

Test Step 2. Inspect Electrical Connectors and Wiring.

1. Thoroughly inspect the connector J500/P500 for the injection actuation pressure control valve and inspect the ECM engine harness connector J2/P2. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.

2. 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 (terminals 61 and terminal 62).

3. Check the ECM connector (allen head screw) for the proper torque of 6.0 N·m (55 lb in).

4. Check the harness and wiring for abrasion and pinch points from the sensors back to the ECM.

Expected Result:

All connectors, pins and sockets should be completely coupled and/or inserted and the harness and wiring should be free of corrosion, abrasion or pinch points.

Results:

• OK - Proceed to Test Step 3.

• Not OK -

  Repair: Perform the following 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.

  STOP

Test Step 3. Measure the Solenoid Resistance of the Injection Actuation Pressure Control Valve.

1. Turn the ignition key switch to the OFF position.

2. Disconnect the connector for the injection actuation pressure control valve J500/P500.

   Note: Ensure that the seal on the connector P500 remains on P500 when the connector is disconnected.

3. Use a multimeter to measure the resistance between the two terminals of the section of the harness for the injection actuation pressure control valve. Record the value that was measured.

4. Reverse the leads of the multimeter and measure the resistance again.

Expected Result:

The solenoid resistance of the injection actuation pressure control valve should be between 4.0 and 16.0 Ohms.

Results:

• Yes - Record the measured resistance. Reconnect the harness connector for the injection actuation pressure control valve. Proceed to Test Step 4.

• No -

  Repair: Replace the injection actuation pressure control valve. Start the engine and verify that the fault is no longer active.

  STOP

Test Step 4. Measure the Solenoid Resistance through the Engine Harness.

1. Turn the ignition key switch to the OFF position.

2. Disconnect the ECM engine harness connector J2/P2.

3. Check the electrical resistance from the ECM engine harness connector P2 terminal 61 to P2 terminal 62. The resistance should be within 2 ohms of the previous test results.

4. Check the electrical resistance from the ECM engine harness connector P2 terminal 62 to the surrounding terminals for a short circuit:
   • Terminal 51

   • Terminal 52

   • Terminal 63

5. Check the resistance from the ECM engine harness connector P2 terminal 61 to the surrounding terminals for a short circuit:
   • Terminal 50

   • Terminal 51

   • Terminal 52

   • Terminal 60

   Note: The resistance should be greater than 10k ohms.

6. Check the resistance from the ECM engine harness connector P2 terminal 61 to the engine ground stud and from P2 terminal 62 to the engine ground stud. The resistance should be greater than 10k ohms.

Expected Result:

The resistance measurements are within the proper range.

Results:

• Yes - Proceed to Test Step 5.

• No -

  Repair: Replace the harness for the injection actuation pressure control valve.

  STOP

Test Step 5. Use the "Injection Actuation Pressure Driver Test" on the Electronic Service Tool to Check the Harness.

1. Connect the electronic service tool to the cab data link connector.

2. Turn the ignition key switch to the ON position.

3. Access the "Injection Act Press Driver Test".

4. Disconnect the injection actuation pressure control valve from the engine harness.

   Note: Do not insert any wire that is larger than 18 AWG into the harness connector (P500). Do not insert the probe for the voltage test lamp into the harness connector (P500). These actions will spread the sockets of the connector which will damage the connector. Damaged connectors could cause intermittent connections.

5. Insert a 9X-7200 ECM Pin Terminal into each of the harness connector sockets P500 for the injection actuation pressure driver.

6. Connect a voltage test lamp to the ECM pin terminals that are inserted in the P500 connector and start the "Injection Act Press Driver Test" with the electronic service tool. Then stop the "Injection Act Press Driver Test" with the electronic service tool.

   Note: This test procedure may cause a 42-11 Injection Actuation Pressure Control Valve Driver (18). This is normal.

Expected Result:

The voltage test lamp should come on when the test is active.

Note: Personality Modules with a manufactured date before JUNE 99 require an electrical connector for the injection actuation pressure sensor to be disconnected in order for the "Injection Actuation Pressure Control Valve Driver Special Test" to turn off the driver for the injection actuation pressure control valve. If the connector J204/P204 for the injection actuation pressure sensor is not disconnected, the voltage test lamp will remain on when the special test is not active.

Results:

• Yes - Proceed to Test Step 6.

• No - Proceed to Test Step 7.

Test Step 6. Perform "Injection Actuation Pressure Test".

1. Disconnect the injection actuation pressure control valve from the engine harness at connector J500/P500.

2. Crank the engine for 30 seconds. Crank the engine three times. This will purge the air from the system.

3. Connect the injection actuation pressure control valve to the engine harness at connector J500/P500.

4. Start the engine and run the "Injection Actuation Pressure Test". The "Injection Actuation Pressure Test" is located in the "Diagnostics" menu of the electronic service tool. Step through all of the pressure ranges.

   Note: This is not the "Injection Act Press Driver Test".

5. After performing the "Injection Actuation Pressure Test", check for active diagnostic codes or logged diagnostic codes 42-11.

Expected Result:

The engine should start and the engine should run without triggering any diagnostic codes.

Results:

• Yes - The problem has been corrected.STOP

• No -

  Repair: Replace the injection actuation pressure control valve. Verify that the problem is resolved.

  STOP

Test Step 7. Use the "Injection Act Press Driver Test" on the Electronic Service Tool to Check the ECM.

1. Disconnect the ECM engine harness connector J2/P2.

2. Turn the ignition key switch to the ON position.

3. Access the "Injection Act Press Driver Test" in the "Diagnostics" menu of the electronic service tool.

4. Connect a breakout T to the ECM engine harness connector J2.

5. Connect a voltage test lamp to the engine harness connector for the injection actuation pressure control valve, terminal 61 and terminal 62 of the breakout T.

6. Start and stop the "Injection Act Press Driver Test".

   Note: This test procedure may cause a 42-11 Injection Actuation Pressure Control Valve Driver (18). This is normal.

Expected Result:

The voltage test lamp should come on when the test is active.

Note: Personality Modules with a manufactured date before JUNE 99 require an electrical connector for the injection actuation pressure sensor to be disconnected in order for the "Injection Actuation Pressure Control Valve Driver Special Test" to turn off the driver for the injection actuation pressure control valve. If the connector J204/P204 for the injection actuation pressure sensor is not disconnected, the voltage test lamp will remain on when the special test is not active.

Results:

• Yes -

  Repair: Replace the harness for the injection actuation pressure control valve.

  STOP

• No -

  Repair: Temporarily install a test ECM. Repeat the test step. If this corrects the problem, then reinstall the old ECM and verify that the problem reoccurs. Replace the ECM if the problem reoccurs with the old ECM.

  STOP