Use this procedure to troubleshoot the system when there is an active 42-11 Injection Actuation Control Valve open/short.
Note: Also use this procedure for an active 164-11 Injection Actuation Pressure system fault if you are directed by another test procedure.
The injection actuation pressure control valve (IAPCV) 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 IAPCV relieves excess high pressure oil back to the sump. The Electronic Control Module (ECM) controls the operation of the IAPCV by monitoring the engine speed and the injection actuation pressure sensor.
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| Illustration 1 | g01130408 |
Schematic for the Injection Actuation Pressure Control Valve | |
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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. |
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Test Step 1. Inspect Electrical Connectors And Wiring
- Thoroughly inspect the J500/P500 IAPCV connector and the J2/P2 ECM connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
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| Illustration 2 | g01130179 |
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 | |
- Perform a 45 N (10 lb) pull test on each of the wires that are associated with the IAPCV.
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| Illustration 3 | g01130409 |
P2 terminations for the IAPCV (P2-61) Control (P2-62) Return | |
- Check the allen head screw on the ECM connector for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
- Check the harness and wiring for abrasion and pinch points from the IAPCV back to the ECM.
Note: Ensure that the seal is installed on the harness connector for the injection actuation pressure control valve.
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 connectors and the wiring appear to be OK. Proceed to Test Step 2.
- Not OK - There is a problem with the connectors and/or the 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 completely coupled. Verify that the repair eliminates the problem.
STOP
Test Step 2. Measure the Resistance of the Injection Actuation Pressure Control Valve's Solenoid
- Turn the keyswitch to the OFF position.
- Disconnect the J500/P500 IAPCV connector.
Note: Ensure that the seal remains on the P500 connector when the connector is disconnected.
- Use a multimeter to measure the resistance between J500-1 IAPCV and J500-2 IAPCV Common on the IAPCV. Record the value that was measured.
Expected Result:
The solenoid resistance of the IAPCV is between 4 Ohms and 16 Ohms.
Results:
- OK - The resistance is between 4 Ohms and 16 Ohms. There is not a problem with the solenoid for the IAPCV. Reconnect the J500/P500 IAPCV connector. Proceed to Test Step 4.
- Not OK - The resistance is not between 4 Ohms and 16 Ohms. The solenoid for the IAPCV is faulty.
Repair: Replace the IAPCV. Start the engine and verify that the diagnostic code is no longer active.
STOP
Test Step 3. Measure the Resistance of the Solenoid Through the Engine Harness
- Disconnect the J2/P2 ECM connector.
- Check the resistance between P2-61 IAPCV and P2-62 IAPCV Common.
Expected Result:
The resistance should be within two Ohms of the value that was measured in the previous step.
Results:
- OK - The resistance is within two Ohms of the value that was measured in the previous step. The solenoid harness and the connector are OK. There may be a problem with the ECM. Proceed to Test Step 4.
- Not OK - The resistance is not within the acceptable range. One of the wires in the solenoid harness has an open or a short. There may be a problem with the solenoid connector.
Repair: Repair the wire and/or the connector, when possible. Replace parts, if necessary.
Verify that the repair has resolved the problem. Proceed to Test Step 5.
Test Step 4. Check the ECM with the "Injection Act Press Driver Test"
- Disconnect the J2/P2 ECM connector.
- Connect a 70-Terminal breakout T to the J2 ECM connector.
- Connect a voltage test lamp to P2-61 and P2-62 of the breakout.
- Turn the keyswitch to the ON position.
- Observe the test lamp while you activate the "Injection Act Press Driver Test" in CAT ET.
- Turn the keyswitch to the OFF position.
Expected Result:
The voltage test lamp illuminates when the test is active.
Results:
- OK - The voltage test lamp illuminates. The ECM is operating properly. Proceed to Test Step 5.
- Not OK - The voltage test lamp does not illuminate.
Repair: Replace the ECM. Refer to Troubleshooting, "Replacing the ECM". Verify that the repair resolves the problem.
STOP
Test Step 5. Perform "Injection Actuation Pressure Test"
- Disconnect the J500/P500 IAPCV connector.
- Crank the engine three times at 30 seconds intervals. This will ensure that air is purged from the high pressure fuel system.
- Reconnect the J500/P500 IAPCV connector.
- Start the engine and run the "Injection Actuation Pressure Test". Step through all of the pressure ranges of the test.
Expected Result:
The engine starts and the engine runs smoothly through all of the pressure ranges.
Results:
- OK - The engine runs smoothly.
Repair: The problem has been corrected.
STOP
- Not OK - The engine does not start or the engine does not run smoothly.
Repair: There is a problem with the IAPCV. Replace the IAPCV. Verify that the repair has resolved the problem.
STOP