GASKET 5I7657 - 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 Engine Control Module (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 g00925013
Typical schematic for the injection actuation pressure sensor
The return wire may be connected to P1-3, P1-5, or P1-18.
Illustration 2 g01151734
Pin locations on ECM connector
(P1-2) Engine pressure sensor +5V
(P1-3) Engine pressure sensor common
(P1-25) Engine injection actuation pressure Test Step 1. Check for Active Diagnostic Codes
Connect the Caterpillar Electronic Technician (ET) to the data link connector.
Turn the key switch to the ON position. Note: If the 164-02 diagnostic code is not active or logged, try to start the engine.Note: If a 164-03 diagnostic code or a 164-04 code is active, refer to Troubleshooting, "Engine Pressure Sensor Open or Short Circuit-Test".Expected Result:164-02 diagnostic code is active.Results:
Yes - The engine will not start. 164-02 is active. Proceed to Test Step 2.
No - The engine will not start. 164-02 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/RESET 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 - The engine starts. Proceed to Test Step 3.
No - The engine does not start.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. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
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 are completely coupled and/or inserted and the harness and wiring are free of corrosion, of abrasion or of pinch points.Results:
OK - Proceed to Test Step 4.
Not OK - Repair: Perform