5032144 JOHNSON ROD, HANDLE

Probable Causes
Diagnostic codes
Throttle position sensor
Air intake and exhaust system
Air inlet heater starting aid (if equipped)
Glow plugs (if equipped)
Fuel supply
Low compression (cylinder pressure)
Individual malfunctioning cylinder
Fuel injection pump
Fuel injectorsRecommended Actions
Diagnostic Codes
Check for active diagnostic codes on the electronic service tool. Troubleshoot any active codes before continuing with this procedure.Throttle Position Sensor
Use the electronic service tool and observe the signal for the throttle position sensor. Make sure that the throttle reaches the 100% raw position and the calibrated position.
If the signal is erratic, refer to Troubleshooting, "Analog Throttle Position Sensor Circuit - Test" or Troubleshooting, "Digital Throttle Position Sensor Circuit - Test".
If the engine has a 10 position throttle switch refer to Troubleshooting, "Throttle Switch Circuit - Test".
If the repairs do not eliminate the fault proceed to "Air Intake and Exhaust System". Air Intake and Exhaust System
Check the air filter restriction indicator, if equipped.
Ensure that the air filter is clean and serviceable.
Check the air intake and exhaust systems for the following defects:
Blockages
Restrictions
Damage to lines or hoses
If the repairs do not eliminate the fault proceed to "Air Inlet Heater Starting Aid (if equipped)". Air Inlet Heater Starting Aid (if equipped)
Check for proper operation of the air inlet heater starting aid. Refer to Systems Operation, Testing and Adjusting, "Air Inlet Heater - Test".
If the repairs do not eliminate the fault refer to "Glow Plugs (if equipped)". Glow Plugs (if equipped)
Note: Faulty glow plugs will only affect engine starting when the ambient temperature is below 10 °C (50 °F).
Check the operation of the glow plugs. Refer to Systems Operation, Testing and Adjusting, "Glow Plugs - Test".
If necessary, replace faulty glow plugs. Refer to Disassembly and Assembly, "Glow Plug - Remove and Install".
If the repairs do not eliminate the fault, proceed to "Fuel Supply". Fuel Supply
Visually check the fuel tank for fuel. The fuel gauge may be faulty.
Ensure that the fuel supply valve (if equipped) is in the full OPEN position.
If the temperature is below 0 °C (32 °F), check for solidified fuel (wax).
Check the primary filter/water separator for water in the fuel.
Check for fuel supply lines that are restricted.
Check that the low pressure fuel lines are tight and secured properly.
Check the fuel filters.
Check the diesel fuel for contamination. Refer to Systems Operation, Testing and Adjusting, "Fuel Quality - Test".
Check for air in the fuel system. Refer to Systems Operation, Testing and Adjusting, "Air in Fuel - Test".
Ensure that the fuel system has been primed. Refer to Systems Operation, Testing and Adjusting, "Fuel System - Prime".
Check the fuel pressure. Refer to Systems Operation, Testing and Adjusting, "Fuel System Pressure - Test".
If the repair does not eliminate the fault refer to "Low Compression (Cylinder Pressure)". Low Compression (Cylinder Pressure)
Perform a compression test. Refer to Systems Operation, Testing and Adjusting, "Compression - Test ".
If low compression is noted on any cylinders, investigate the cause and rectify the cause. Possible causes of low compression are shown in the following list:
Loose glow plugs (if equipped)
Faulty piston
Faulty piston rings
Worn cylinder bores
Worn valves
Faulty cylinder head gasket
Damaged cylinder head
Perform all necessary repairs.
Ensure that the repairs have eliminated the faults.
If the repair does not eliminate the fault refer to "Individual Malfunctioning Cylinders". Individual Malfunctioning Cylinders
With the engine speed at a fast idle, loosen the high pressure fuel line to the fuel injector of number 1 cylinder. Note if there is any reduction in engine speed. Tighten the high pressure fuel line to the fuel injector.
Individually repeat this procedure for each fuel injector. If there is no reduction in the engine speed, investigate the cause of the malfunction.
If the repair does not eliminate the fault refer to "Fuel Injection Pump". Fuel Injection Pump
Note: The fuel injection pumps that are installed by the factory on the 1100 series engines are nonserviceable items. If any mechanical fault or any electrical fault occurs within the fuel injection pump then the fuel injection pump must be replaced.
Use the electronic service tool to select the correct screen display. Refer to Troubleshooting, "Troubleshooting with a Diagnostic Code".
If the repair does not eliminate the fault refer to "Fuel Injectors". Fuel Injectors
Remove the fuel injectors from the cylinder head. Refer to Disassembly and Assembly, "Fuel Injector - Remove".
Visually inspect the fuel injectors. If a fuel injector has a suspected fault, replace the fuel injector.
Install the fuel injectors into the cylinder head. Refer to Disassembly and Assembly, "Fuel Injector - Install".