0431889 JOHNSON CYLINDER & C'CASE ASSY.

Recommended Actions
Note: The procedures have been listed in order of probability. Complete the procedures in order.
Table 1
Troubleshooting Test Steps Values Results
1. Misreading Oil Level
A. Accurately measure the consumption of oil and fuel over a period of 50 engine hours.
Oil level
Result: The oil consumption is less than 0.1% of the fuel consumption.
Oil consumption is within specification. Return the unit to service
Result: The oil consumption is greater than 0.1% of the fuel consumption.
Proceed to Test Step 2.
2. Oil Leaks
A. Check for evidence of oil leaks on the engine.
B. Check for evidence of oil in the coolant.
Oil leaks
Result: An oil leak is identified.
Repair: Rectify the cause of the oil leak.
Result: Oil is present in the coolant.
Repair: Refer to Troubleshooting, "Coolant Contains Oil".
Result: No oil leaks are identified
Proceed to Test Step 3.
3. Engine Crankcase Breather
A. Check the engine crankcase breather for blockage or restrictions.
B. Check for excessive oil from the outlet of the breather.
Breather
Result: The engine crankcase breather is blocked or restricted.
Repair: Clear the blockage or restriction.
Result: Excessive oil is ejected from the outlet of the breather.
Repair: Investigate the cause of the excessive oil content in the breather flow. If the breather filter element is saturated with oil, replace the filter.
Result: No oil is ejected through the breather.
Proceed to Test Step 4.
4. Oil Level
A. Check for a high oil level in the engine.
Oil level
Result: The oil level in the engine is high.
Repair: Make sure that the oil is not contaminated with fuel. Refer to Troubleshooting, "Oil Contains Fuel".
Make sure that the oil is not contaminated with coolant. Refer to Troubleshooting, "Oil Contains Coolant".
Remove the excess oil.
Result: The oil level is OK.
Proceed to Test Step 5.
5. Air Intake and Exhaust System
A. Check the air filter restriction indicator, if equipped.
B. Check the air intake and exhaust systems for the following defects:
Blockages
Restrictions
Damage to lines or hoses
B. Check the air inlet and exhaust system for restrictions and/or leaks.
107-15: Engine Air Filter 1 Differential Pressure high - least severe (1)
107-16: Engine Air Filter 1 Differential Pressure high - moderate severity (2)
Air and Exhaust System restrictions
Result: The air filter is restricted.
Repair: Replace the air filter.
Result: There are system restrictions.
Repair: Refer to Systems Operation/Testing and Adjusting, "Air Inlet and Exhaust System" for additional information on the air inlet and exhaust systems.
Result: A 107-15 or 107-16 code is active
Repair: Refer to Troubleshooting, Inlet Air is Restricted.
Result: The air intake and exhaust system is OK.
Proceed to Test Step 6.
6. Turbocharger
Note: The turbocharger that is installed on this engine is a non-serviceable item. If any mechanical fault exists, then the turbocharger must be replaced.
A. Check that the oil drain for the turbocharger is not blocked or restricted.
B. Check the turbocharger for evidence of an internal oil leak.
Turbocharger
Result: The oil drain for the turbocharger is blocked or restricted.
Repair: Remove the blockage or restriction. If necessary, replace the oil drain line.
Result: The turbocharger has an internal oil leak.
Repair: Replace the turbocharger.
Check that the repairs have eliminated the faults.
Result: The turbocharger is OK.
Proceed to Test Step 7.
7. Low Compression (Cylinder Pressure)
A. Perform a compression test. Refer to Systems Operation, Testing, and Adjusting, "Compression - Test".
Cylinder compression
Result: The results of the compression test are outside the specifications.
Repair: Investigate the cause and rectify any faults.
Note: Possible causes of low compression are shown in the following list:
Loose glow plugs
Faulty piston
Faulty piston rings
Worn cylinder bores
Worn valves
Faulty cylinder head gasket
Damaged cylinder head
Result: The results of the compression test are OK.
Proceed to Test Step 8.
8. Clean the Fuel System
A. Following the instructions on the bottle, add Caterpillar Fuel System Cleaner 343-6210 to the fuel tank.
Electronic Unit Injectors
Result: Performance should be restored within 2-3 hours.
Return the unit to service, the fuel system will be cleaned during operation.
Result: Performance is not restored within 2-3 hours.
Contact the Dealer Solutions Network (DSN).