0398361 JOHNSON CARB. ASSY., Lower, 200STL

Table 1
J1939 Code and Description CDL Code and Description Comments
5394-7
Aftertreatment DEF Dosing Valve : Not Responding Properly 3821-7
Aftertreatment #1 DEF Dosing Valve Actuator #1 : Not Responding Properly The Aftertreatment #1 Diesel Exhaust Fluid (DEF) injector #1 is not functioning properly.
The code is logged.
5394-14
Aftertreatment DEF Dosing Valve : Special Instruction 3821-14
Aftertreatment #1 DEF Dosing Valve Actuator #1 : Special Instruction The Aftertreatment #1 DEF injector #1 is not functioning properly.
The code is logged.
5974-7
Aftertreatment #2 DEF Dosing Valve 1 : Not Responding Properly 5020-7
Aftertreatment #2 DEF Dosing Valve Actuator #1 : Not Responding Properly The Aftertreatment #2 DEF injector #1 is not functioning properly.
The code is logged.
5974-14
Aftertreatment #2 DEF Dosing Valve #1 : Special Instruction 5020-14
Aftertreatment #2 DEF Dosing Valve Actuator #1 : Special Instruction The Aftertreatment #2 DEF injector #1 is not functioning properly.
The code is logged.
6324-7
Aftertreatment #1 DEF Dosing Valve #2 : Not Responding Properly 5017-7
Aftertreatment #1 DEF Dosing Valve Actuator #2 : Not Responding Properly The Aftertreatment #1 DEF injector #2 is not functioning properly.
The code is logged.
6324-14
Aftertreatment #1 DEF Dosing Valve #2 : Special Instruction 5017-14
Aftertreatment #1 DEF Dosing Valve Actuator #2 : Special Instruction The Aftertreatment #1 DEF injector #2 is not functioning properly.
The code is logged.
6325-7
Aftertreatment #2 DEF Dosing Valve #2 : Not Responding Properly 5021-7
Aftertreatment #2 DEF Dosing Valve Actuator #2 : Not Responding Properly The Aftertreatment #2 DEF injector #2 is not functioning properly.
The code is logged.
6325-14
Aftertreatment #2 DEF Dosing Valve #2 : Special Instruction 5021-14
Aftertreatment #2 DEF Dosing Valve Actuator #2 : Special Instruction The Aftertreatment #2 DEF injector #2 is not functioning properly.
The code is logged.
7488-7
Aftertreatment #1 DEF Dosing Valve #3 : Not Responding Properly 5018-7
Aftertreatment #1 DEF Dosing Valve Actuator #3 : Not Responding Properly The Aftertreatment #1 DEF injector #3 is not functioning properly.
The code is logged.
7488-14
Aftertreatment #1 DEF Dosing Valve #3 : Special Instruction 5018-14
Aftertreatment #1 DEF Dosing Valve Actuator #3 : Special Instruction The Aftertreatment #1 DEF injector #3 is not functioning properly.
The code is logged.
7489-7
Aftertreatment #2 DEF Dosing Valve #3 : Not Responding Properly 5022-7
Aftertreatment #2 DEF Dosing Valve Actuator #3 : Not Responding Properly The Aftertreatment #2 DEF injector #3 is not functioning properly.
The code is logged.
7489-14
Aftertreatment #2 DEF Dosing Unit #3 : Special Instruction 5022-14
Aftertreatment #2 DEF Dosing Valve Actuator #3 : Special Instruction The Aftertreatment #2 DEF injector #3 is not functioning properly.
The code is logged.
7546-7
Aftertreatment #1 DEF Dosing Valve #4 : Not Responding Properly 5019-7
Aftertreatment #1 DEF Dosing Valve Actuator #4 : Not Responding Properly The Aftertreatment #1 DEF injector #4 is not functioning properly.
The code is logged.
7546-14
Aftertreatment #1 DEF Dosing Valve #4 : Special Instruction 5019-14
Aftertreatment #1 DEF Dosing Valve Actuator #4 : Special Instruction The Aftertreatment #1 DEF injector #4 is not functioning properly.
The code is logged.
7547-7
Aftertreatment #2 DEF Dosing Valve #4 : Not Responding Properly 5023-7
Aftertreatment #2 DEF Dosing Valve Actuator #4 : Not Responding Properly The Aftertreatment #2 DEF injector #4 is not functioning properly.
The code is logged.
7547-14
Aftertreatment #2 DEF Dosing Valve #4 : Special Instruction 5023-14
Aftertreatment #2 DEF Dosing Valve Actuator #4 : Special Instruction The Aftertreatment #2 DEF injector #4 is not functioning properly.
The code is logged.
Table 2
Required Tools
Part Number Part Name Qty
372-5260 Test Lead Tool Group 1 Probable Causes
Codes
DEF lines
DEF injector
Wiring harness
DEF quality
RestrictionsRecommended Actions
Illustration 1 g06552831
The DEF injectors are on the inlet of the Clean Emissions Module (CEM). There are injectors on both inlets of the dual CEM applications.
(1) Aftertreatment #1 DEF pump #2 DEF injector #1 (green)
(2) Aftertreatment #1 DEF pump #1 DEF injector #2 (blue)
(3) Aftertreatment #1 DEF pump #1 DEF injector #3 (blue)
(4) Aftertreatment #1 DEF pump #2 DEF injector #4 (green)
(5) Aftertreatment #2 DEF pump #2 DEF injector #1 (red)
(6) Aftertreatment #2 DEF pump #1 DEF injector #2 (yellow)
(7) Aftertreatment #2 DEF pump #1 DEF injector #3 (yellow)
(8) Aftertreatment #2 DEF pump #2 DEF injector #4 (red)
Table 3
Troubleshooting Test Steps Values Results
1. Check for Codes
A. Connect Cat® Electronic Technician (ET) to the service tool connector.
B. Look for active codes that are associated with the system for the event code.
Codes
Result: An associated code is active.
Repair: Troubleshoot the associated code before continuing with this test.
Result: A -7 code is active or logged.
Proceed to Test Step 2.
Result: A -14 code is active or logged.
Repair: Replace the failed DEF injector.
Proceed to Test Step 10.
2. Check the Diesel Exhaust Fluid (DEF) Lines Routing
A. Turn the keyswitch to the OFF position.
B. Ensure that the DEF lines are routed from the appropriate DEF pump to the appropriate DEF injector.
Lines Routing
Result: The DEF lines are routed to the correct locations.
Proceed to Test Step 3.
Result: The DEF lines are not to the correct locations.
Repair: Route the DEF lines to the correct locations.
Proceed to Test Step 10.
3. Check the resistance of the DEF Injector
A. Turn the keyswitch to the OFF position. Allow 2 minutes to elapse before proceeding.
B. Disconnect the affected DEF injector from the wiring harness.
C. Inspect the connector for damage or debris.
D. Connect two 398-4987 Probes to the affected DEF injector wiring harness connector.
The probes must be used to prevent damage to the DEF injector connector.
E. Measure the resistance of the affected DEF injector.
Ohms
Result: The resistance of the DEF injector measured between 10 Ohms to 14 Ohms.
Proceed to Test Step 4.
Result: The resistance of the DEF injector did not measure between 10 Ohms to 14 Ohms. A failed DEF injector has been detected.
Repair: Replace failed DEF injector. Refer to the Disassembly and Assembly manual for additional information.
Proceed to Test Step 10.
4. Check for a Short Circuit in the Wiring Harness
A. Disconnect the affected DEF in