5033901 JOHNSON CAMSHAFT, INTAKE - 90HP

Recommended Actions
Table 1
Troubleshooting Test Steps Values Results
1. Check for Codes
A. Establish communication between Cat® Electronic Technician (ET) and the Electronic Control Module (ECM).
B. Monitor the diagnostic codes on Cat ET. Check for any active or logged codes.
Note: Wait at least 30 seconds for diagnostic codes to become active.
Codes
Result: A code is not active or logged.
Proceed to Test Step 2.
Result: A code is active or logged.
Repair: Troubleshoot any codes before continuing with this procedure.
Verify that the repair eliminated the problem. Return the unit to service.
2. Inspect the Electrical Connections
A. Check for the correct installation of the ECM J1/P1 and the J2/P2 connectors.
B. Check for correct installation of the fuel injector connectors.
Connectors
Result: There are no suspect connectors.
Proceed to Test Step 3.
Result: There are suspect connectors.
Repair: Repair or replace the suspect connectors. Perform the "Wiggle Test" on Cat ET.
Verify that the repair eliminated the problem. Return the unit to service.
3. Test the Fuel Injectors
A. Perform the "Injector Solenoid Test" on Cat ET to determine if all the injector solenoids are being energized by the ECM.
B. Perform the "Automatic Cylinder Cutout Test" on Cat ET.
Fuel Injector
Result: The test was successful.
Proceed to Test Step 4.
Result: The test was not successful.
Repair: Diagnose the problem and then repair the problem. Reset all active codes and clear all logged codes.
Verify that the repair eliminated the problem. Return the unit to service.
4. Check the Fuel Quality
A. Refer to Operation and Maintenance Manual for information on the proper characteristics of the fuel for the engine. If necessary, obtain a fuel analysis to confirm that the correct fuel is being used for the engine.
B. Refer to Testing and Adjusting, "Fuel Quality - Test" for the testing procedure.
Fuel
Result: The fuel quality is acceptable.
Proceed to Test Step 5.
Result: There is a problem with the fuel quality.
Repair: Replace the fuel.
Verify that the repair eliminated the problem. Return the unit to service.
5. Check for Proper Lubrication
A. Check for proper lubrication of the valve components. Check for sufficient lubrication between the injector tappets and the rocker arms.
B. Check for blocked oil passages. Clean any oil passages that are questionable. Refer to the Disassembly and Assembly manual for removal of any components.
C. Inspect the engine oil filters for ferrous material.
D. Obtain an S-O-S oil analysis.
Lubrication
Result: The oil passages are not blocked and the engine has proper lubrication.
Proceed to Test Step 6.
Result: The oil passages are blocked or the engine does not have proper lubrication.
Repair: Make the necessary repairs.
Verify that the repair eliminated the problem. Return the unit to service.
6. Isolate the Source of the Noise
A. If the source of the noise is the engine accessory, remove the suspect engine accessory.
B. Inspect the suspect engine accessory for any signs of damage or wear.
Engine Accessory
Result: An engine accessory is not the source of the noise.
Proceed to Test Step 7.
Result: An engine accessory is the source of the noise.
Repair: Repair the engine accessory and/or replace the engine accessory, if necessary.
Verify that the repair eliminated the problem. Return the unit to service.
7. Inspect the Valve Train Components
A. Check the valve lash. Refer to Troubleshooting, "Valve Lash Is Excessive".
B. Check for damage to valve train components. Remove the valve cover from the suspect cylinders. Check the following items for damage:
- Camshaft
- Valve rotocoil
- Valve springs
- Camshaft followers
- Rocker shaft
- Bridges
- Injectors
Refer to the Disassembly and Assembly for the appropriate procedure to remove engine components.
C. Check for valves that do not move freely. Remove the cylinder head and inspect the valves.
Valve Train
Result: The valve train components are not damaged.
Proceed to Test Step 8.
Result: The valve train components are damaged.
Repair: Make the necessary repairs.
Verify that the repair eliminated the problem. Return the unit to service.
8. Inspect the Gear Train and Components of the Lower End
Gear Train
Result: The gear train or lower end components are not damaged.
Proceed to Test Step 9.
Result: The gear train or lower end components are damaged.
Repair: Replace any damaged parts.
Verify that the repair eliminated the problem. Return the unit to service.
9. Inspect the Crankshaft and the Related Components
A. Look for worn thrust plates and wear on the crankshaft.
B. Inspect the connecting rod bearings and the bearing surfaces on the crankshaft. Make sure that the bearings are in the correct position.
Crankshaft
Result: The crankshaft or the related components are damaged or worn.
Repair: Repair or replace any damaged parts. Verify that the repair eliminated the problem.
Verify that the repair eliminated the problem. Return the unit to service.
If the procedure did not correct the issue, contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the Dealer Solutions Network (DSN).