BOLT 4532845 - Caterpillar

System Operation Description:Use this procedure to troubleshoot the system when the following diagnostic code is active:
164-02 Injection Actuation Pressure Signal Erratic (15)Note: This procedure can check the accuracy of the injection actuation pressure sensor against a pressure gauge.The following background information is related to the following procedure:The injection actuation pressure sensor measures the pressure of the oil in the high pressure oil manifold. The high pressure oil in the manifold is used to actuate the injectors and the high pressure oil is used to control the fuel injection pressure. Fuel injection pressure is based on inputs from the sensors. The inputs are used by the ECM for calculating the fuel injection pressure. The ECM uses the reading from the injection actuation pressure sensor in order to control the operation of the injection actuation pressure control valve.
Illustration 1 g00862894
Location of the injection actuation pressure control valve
Illustration 2 g00725355
Schematic for the injection actuation pressure sensor
Illustration 3 g00725426
Locations for the ECM terminals on connector P2Test Step 1. Check for Active Diagnostic Codes
Connect the Caterpillar Electronic Technician (Cat ET) to the data link connector.
Turn the key switch to the ON position.Note: If the 164-02 Injection Actuation Pressure Signal Erratic (15) is not active or logged, try to start the engine.Note: If 164-03 Injection Actuation Pressure Voltage High (15) or 164-04 Injection Actuation Pressure Voltage Low (15) is active, refer to Troubleshooting, "Engine Pressure Sensor Open or Short Circuit-Test".Expected Result:164-02 Injection Actuation Pressure Signal Erratic is active.Results:
Yes - The engine will not start. 164-02 Injection Actuation Pressure Signal Erratic is active. Proceed to Test Step 2.
No - The engine will not start. 164-02 Injection Actuation Pressure Signal Erratic is not active. Proceed to Test Step 2.
No - 164-02 is not active. The engine starts. The system is operating correctly at this time.STOPTest Step 2. Disconnect the Injection Actuation Pressure Sensor and Start the Engine
Turn the key switch to the OFF position.
Disconnect the electrical connector J204/P204 for the injection actuation pressure sensor from the engine harness.
Try to start the engine.Expected Result:The engine starts.Results:
Yes - Proceed to Test Step 3.
No - Repair: Reconnect the electrical connector J204/P204 for the injection actuation pressure sensor to the engine harness. Refer to Troubleshooting, "Engine Cranks but Will Not Start".STOPTest Step 3. Inspect Electrical Connectors and Wiring
Thoroughly inspect the connector J204/P204 for the injection actuation pressure sensor and inspect the ECM engine harness connector J2/P2. Refer to Troubleshooting, "Electrical Connectors-Inspect" for details.
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 (P2:61 and P2:62).
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the harness and wiring for abrasion and for 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 4.
Not OK - Repair: Perform the following repair:Repair