5000500 JOHNSON ENGINE COVER ASSY.

Recommended Actions
Perform the following diagnostic procedures in order:
Check the vehicle harness and the connectors. Refer to Troubleshooting, "Inspecting Electrical Connectors".
Check the parameters for engine monitoring.
Connect an electronic service tool.
Check for diagnostic codes that can derate the engine when the engine monitoring is programmed to "Derate" or "Shutdown".
110-00 High Coolant Temperature Warning (61)
110-11 Very High Coolant Temperature (61)
111-11 Very Low Coolant Level (62)
100-11 Very Low Oil Pressure (46)
Check the battery power or ground to the ECM.
Ensure that the following connectors have been installed correctly:
ECM connectors (J1/P1 and J2/P2) with 70 pins
Injector connector (J300/P300)
Crankshaft Position Sensor connector (J401/P401)
Camshaft Position Sensor connector (J402/P402)
Use the electronic service tool to check for a 168-02 Intermittent Battery (51) diagnostic code. Check the power connections for the ECM and the ground connections for the ECM. If a problem is suspected, wire a bypass. Refer to Troubleshooting, "Ignition Key Switch Circuit and Battery Supply Circuit - Test".
Check for an electronic system problem.
Connect an electronic service tool.
Monitor the Fuel Position, the Rated Fuel Limit, and the FRC Fuel Limit.While the vehicle is operating under full load, the parameters should meet the following conditions:
The Fuel Position is equal to the Rated Fuel Limit.
The Fuel Position is less than the FRC Fuel Limit.If the Fuel Position is equal to the Rated Fuel Limit and the Fuel Position is less than the FRC Fuel Limit, the electronics are operating correctly. Go to Step 6.
If the Fuel Position is not equal to the Rated Fuel Limit and/or the Fuel Position is not less than the FRC Fuel Limit, perform the following tests in order:
When the engine is off, turn the ignition key switch to the ON position but do not start the engine. Check the boost pressure on the Status screen.When the engine is off, the boost pressure should be 0 kPa (0 psi).
Monitor the status of the accelerator pedal position sensor. Operate the engine at high idle with the vehicle in neutral.If the engine cannot reach the programmed Top Engine Limit, check the duty cycle of the accelerator pedal position sensor. Ensure that the duty cycle is within the calibration of 75 to 90 percent at high idle.The accelerator pedal position sensor is within calibration when both of the following conditions are met:
10 to 22 percent at low idle
75 to 90 percent at high idleAlso, ensure that the duty cycle changes as the pedal position moves. If a problem with the accelerator pedal position sensor is suspected, refer to Troubleshooting, "Accelerator Pedal (Throttle) Position Sensor Circuit - Test".Note: If the engine exceeds the Top Engine Limit, the "Top Engine Limit with Droop" is programmed to "Yes".
Monitor the vehicle speed signal. Ensure the accuracy of the vehicle speed signal by comparing the vehicle speed signal to the actual vehicle speed.If the vehicle speed is greater than the "VSL", the power is limited. If a problem is discovered, refer to Troubleshooting, "Vehicle Speed Circuit - Test".
Check the "Power Train Data Link". Ensure that the SAE J1922 or the SAE J1939 Power Train Data Link is not limiting the power.
Connect an electronic service tool.
Monitor the "Power Train Data Link" status screen while the vehicle is experiencing problems.If the "Power Train Data Link" status screen indicates that the "Power Train Data Link" is limiting the power or the rpm, verify that the limit is not normal operation. If the limit is not normal operation, refer to the vehicle OEM for repairs.
Check the fuel supply.
Monitor the exhaust for smoke while the engine is being cranked.If no smoke is present, there may be a problem with the fuel quality or there may be a problem with the fuel supply.
Check the fuel quality. Refer to Testing and Adjusting, "Fuel Quality - Test".
Check the fuel pressure. Refer to Testing and Adjusting, "Fuel System Pressure - Test".
Ensure that the fuel system has been primed. Refer to Testing and Adjusting, "Fuel System - Prime".
Check for fuel supply lines that are restricted.
Check the fuel filters.
If the temperature is below 0 °C (32 °F), check for solidified fuel (wax).
Check for air in the fuel system. Refer to Testing and Adjusting, "Air in Fuel - Test".
Check the torque limit switch.
Connect an electronic service tool.
Check the setting for the customer parameter for the "Torque Limit".If the "Torque Limit" is programmed below 3400 N m (2500 lb ft), check the status screen for the torque limit switch. Ensure that the status screen indicates that the switch is OFF. If the status of the switch is ON and a torque limit is programmed, the system is operating correctly. If the switch that is connected to this signal input is not switching ON and switching OFF, refer to Troubleshooting, "PTO Switch Circuit - Test".