0335657 JOHNSON PLUG,FILL

Table 1
Diagnostic Trouble Codes for Excessive Soot Load
J1939 Code Code Description Comments
3251–16 Aftertreatment #1 DPF Differential Pressure High: Moderate Severity (2) The ECM detects a high accumulation of ash within the DPF.
3714–31 Diesel Particulate Filter Active Regeneration Inhibited Due to Temporary System Lockout Automatic regeneration is disabled.
The electronic service tool must be used to recover the aftertreatment system.
3715–31 Diesel Particulate Filter Active Regeneration Inhibited Due to Permanent System Lockout The estimated soot load is too high for safe recovery of the aftertreatment.
3719-16 DPF #1 Soot Loading Percent : High - moderate severity (2) The estimated soot load is high.
Engine power is gradually derated as the soot load increases.
3719-0 DPF #1 Soot Loading Percent : High - most severe (3) The estimated soot load is high.
Engine operation is limited to 60 second intervals when the electronic service tool is not communicating with the ECM.
An excessive accumulation of soot in the DPF can be caused by the following faults:
Oil in the exhaust system
A mechanical fault in a cylinder
Faulty injectors
Low exhaust gas pressure
A faulty engine intake throttle
A fault in the NOx Reduction System (NRS)
Fuel with a high sulfur contentEngine operation must be kept to a minimum to minimize the amount of soot that is created. Follow the troubleshooting procedure to minimize the amount of engine operation.Complete the procedure in the order in which the steps are listed.
Table 2
Troubleshooting Test Steps Values Results
1. Check for Active Diagnostic Trouble Codes
A. Turn the keyswitch to the ON position.
B. Connect the electronic service tool.
C. Check for active diagnostic trouble codes.
Diagnostic trouble codes
Result: A 3719-xx, 3714–31, or 3251–16 code is active.
Proceed to Test Step 2.
Result: A 3715–31 code is active.
Contact the Dealer Solutions Network (DSN).
Result: A code other than 3719-xx, 3714–31, 3715–31, or 3251–16 is active.
Diagnose and rectify the fault before continuing with this procedure. Refer to Troubleshooting, "Diagnostic Trouble Codes".
2. Check for Oil in the Exhaust System
A. Remove the flexible exhaust pipe. Refer to Disassembly and Assembly, "Flexible Exhaust Pipe - Remove and Install".
B. Inspect the exhaust system and Clean Emissions Module (CEM) inlet for oil deposits.
Exhaust system
Result: Oil deposits are present in the exhaust system.
Refer to Troubleshooting, "Exhaust System Contains Oil".
Result: No oil deposits are found in the exhaust system.
Proceed to Test Step 3.
3. 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 4.
4. Electronic Unit Injectors
A. Use the electronic service tool to perform the automatic "Cylinder Cutout Test". Refer to Troubleshooting, Service Tool Features for more information on understanding the results of the "Cylinder Cutout Test".
Note: If the compression test that was performed in Test Step 4 was satisfactory, the "Cylinder Cutout Test" will identify any faulty injectors.
Electronic Unit Injectors
Result: A faulty injector is indicated.
Repair: Remove any faulty electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit Injector - Remove".
Install new electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit Injector - Install".
Repeat the automatic "Cylinder Cutout Test". If the fault is still apparent, remove the replacement electronic unit injector and install the original electronic unit injector. Refer to Disassembly and Assembly, "Electronic Unit Injector - Remove" and Disassembly and Assembly, "Electronic Unit Injector - Install".
Result: All injectors are OK.
Proceed to Test Step 5.
5. Check the Engine Intake Throttle Valve and the NRS system
A. Use the Electronic service tool to perform the "Air System Motor Valve Verification Test".
Diagnostic codes
Result: The "Air System Motor Valve Verification Test" failed. A diagnostic code is present that is associated with the engine intake throttle valve or the NRS system.
Refer to Troubleshooting, "Diagnostic Trouble Codes" for information on troubleshooting the code.
Result: The "Air System Motor Valve Verification Test" passed. There are no diagnostic codes present for the engine intake throttle valve or the NRS system.
Proceed to Test Step 6.
6. Check for High Sulfur Fuel
A. Ensure that the correct specification of fuel is being used. Refer to the Operation and Maintenance Manual for the correct specification.
Note: If fuel with a high sulfur content is used, this fault will reoccur and a replacement CEM may be required.
Fuel
Result: High sulfur fuel is in use.
Repair: Drain the fuel tank, flush the fuel lines, and replace the fuel filters.
Refill the fuel system with fuel of the correct specification.
Proceed to Test Step 7.
Result: The fuel is the correct specification.
Contact the Dealer Solutions Network (DSN).
7. Recover the Aftertreatment System
A. Start the engine and use the electronic service tool to perform the "Aftertreatment Recovery Procedure".
DPF
Result: The soot content of the DPF returns to normal.
Use the electronic service tool to clear all related diagnostic codes. Operate the engine to ensure that the fault has been eliminated.
Return the unit to service.
Result: The soot content of the DPF remains high.
Contact the Dealer Solutions Network (DSN).