0211445 JOHNSON OWNERS MANUAL, 90

Probable Causes
Diagnostic codes
Air intake system or exhaust system
Fuel system cleaning required
Valve lash
Turbocharger
Low compression (cylinder pressure)
Electronic unit injectors
Individual malfunctioning cylinderRecommended Actions
Note: Complete the procedure in the order in which the steps are listed.
Table 1
Troubleshooting Test Steps Values Results
1. Diagnostic Codes
A. Download the Product Status Report before troubleshooting or clearing any diagnostic codes.
Note: The downloaded information will be required by the DSN if troubleshooting assistance is needed.
B. Use the electronic service tool to check for active or logged codes.
Engine Derate or Diagnostic Codes
Result: A diagnostic code is present.
Repair: Troubleshoot the code.
Result: A diagnostic code is not present.
Proceed to Test Step 2.
2. Air Intake and Exhaust System
A. Observe the check engine lamp. Check for an air filter restriction indicator, if equipped. Replace a plugged air filter. Refer to the Operation and Maintenance Manual.
B. Check the air inlet and exhaust system for restrictions and/or leaks.
C. Check for ECM codes for inlet air restriction:
107-15: Engine Air Filter 1 Differential Pressure high - least severe (1)
107-16: Engine Air Filter 1 Differential Pressure high - moderate severity (2)
Restrictions
Result: There are restrictions in the air inlet or exhaust system.
Repair: Make the necessary repairs, Refer to Systems Operation/Testing and Adjusting, "Air Inlet and Exhaust System - Inspect" for additional information.
Result: A 107-15 or 107-16 code is active
Repair: Refer to Troubleshooting, Inlet Air is Restricted.
Result: There are no restrictions in the air inlet or exhaust system.
Proceed to Test Step 3.
3. 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.
Proceed to Test Step 4.
4. Valve Lash
A. Check the valve lash.
Valve lash
Result: The valve lash is incorrect.
Repair: Check the valve lash. Refer to Systems Operation, Testing, and Adjusting, "Engine Valve Lash - Inspect/ Adjust" for the correct procedure.
Result: The valve lash is correct.
Proceed to Test Step 5.
5. Turbocharger
Note: The turbocharger that is installed on the engine is a non-serviceable item. If any mechanical fault exists, then the faulty turbocharger must be replaced.
A. Ensure that the mounting bolts for the turbocharger are tight.
B. Check that the oil drain for the turbocharger is not blocked or restricted.
C. Check that the compressor housing for the turbocharger is free of dirt and debris. Make sure that the housing is not damaged.
D. Check that the turbine housing for the turbocharger is free of dirt and debris. Make sure that the housing is not damaged.
E. Check that the turbine blades rotate freely in the turbocharger.
F. Ensure that the wastegate on the turbocharger is adjusted correctly. Refer to Systems Operation, Testing, and Adjusting, "Turbocharger - Inspect". If the wastegate actuator is faulty, replace the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove" and Disassembly and Assembly, "Turbocharger - Install".
Turbocharger
Note: Some oil residue/pooling may be seen, but this is not an indication that the turbo has failed. If the compressor and turbine blades are undamaged and rotate freely, it is likely the turbocharger is fault free.
Result: There is a fault in the turbocharger.
Repair: Replace the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove" and Disassembly and Assembly, "Turbocharger - Install".
Result: The turbocharger is OK.
Proceed to Test Step 6.
6. 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 7.
7. Electronic Unit Injectors
A. Use the electronic service tool to perform the automatic "Cylinder Cut Out Test".
Note: If the compression test that was performed in Test Step 5 was satisfactory, the "Cylinder Cut Out 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 Cut Out 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 8.
8. Individual Malfunctioning Cylinders
A. With the engine speed at a fast idle, use the electronic service tool to perform the manual "Cylinder Cut Out Test".
As each cylinder is cut out, listen for a change in the sound from the engine. When a cylinder is cut out, there should be a noticeable change in the sound of the engine.
If a change in the sound of the engine is not noted, the isolated cylinder is not operating under normal conditions. If the isolation of a cylinder results in a change in the sound that is less noticeable, the cylinder may be operating below normal performance.
Cylinders
Result: The test indicates a faulty cylinder.
Repair: Investigate the cause of the fault on any cylinder that is not operating. Investigate the cause of the fault on any cylinder that is operating below normal performance.
Result: The test indicates that all cylinders are OK.
Contact the Dealer Solutions Network (DSN).