0398514 JOHNSON SERVICE REPAIR KIT, Fuel pump

Illustration 1 g01181491
Left side of engine (typical example)
(1) J500/P500 Connector for the injection actuation pressure control valve
(2) Injection actuation pressure sensor
Table 1
Troubleshooting Test Steps Values Results
1. Check for Codes
A. Connect the Cat® Electronic Technician (ET) to the data link connector.
B. Turn the keyswitch to the ON position. DO NOT START THE ENGINE.
C. Print the "Lifetime Totals" and the "Configuration" screen.
D. Check for active diagnostic codes or logged diagnostic codes. The diagnostic codes should become active within 30 seconds.
E. Verify that the engine coolant temperature sensor is operating properly. Verify through Cat ET. Refer to Testing and Adjusting, "Test For The Water Temperature Gauge" for the proper procedure.
Document all active diagnostic codes or logged diagnostic codes.
Codes
Results: There are no active codes or logged codes. Proceed to Test Step 2.
Results: Active codes or logged codes are present.
Repair: Troubleshoot the codes as required.
STOP
2. Start the Engine
A. Inspect the engine for oil leaks in the HEUI oil rail. Repair leaks before proceeding. Clearly mark all leaks on returned parts.
Note: Inspect the area near the high-pressure oil rail and the unit injector hydraulic pump. If leakage is found between the transfer pump and the hydraulic pump, refer to Special Instructions, REHS3830 for details. If leakage is found between the hydraulic pump and the front housing, refer to Special Instructions, REHS3830 for details on replacing the seal.
B. Check the engine oil level. If the engine oil level is low, add oil to the engine. Do not overfill the engine.
C. Try to start the engine.
Engine
Results: The engine starts. Proceed to Test Step 10.
Results: The engine does not start. Proceed to Test Step 3.
3. Verify the Operation of the Injection Actuation Pressure Sensor
A. Disconnect the connector for the injection actuation pressure sensor. Check for evidence of moisture in the connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for troubleshooting details.
B. Try to start the engine.
Injection Actuation Pressure Sensor
Results: The engine does not start. Reconnect the connector for the actuation pressure sensor. Clear all diagnostic codes. Proceed to Test Step 4.
Results: The engine starts.
Repair: The injection actuation pressure sensor may be faulty. Replace the sensor and reconnect the connector. Clear all diagnostic codes. Verify that the repair eliminates the problem.
If the problem still exists, proceed to Test Step 4.
4. Observe the Readings in Cat ET
A. Observe the status for "Engine Speed", "Actual Injection Actuation Pressure" and "Engine Oil Pressure" on Cat ET while the engine is cranking. Record the following data:
Engine Speed
Actual injection actuation pressure
Desired injection actuation pressure
Engine oil pressure
Fuel pressure
Engine coolant temperature
Observed "Injection Actuation Output Percent"
100 rpm at 6 MPa (870 psi)
Results: The observed engine speed is above 100 rpm and the actual injection actuation pressure is at least 6 MPa (870 psi) while the engine is cranking.
Repair: If a 94-11 code is active or logged, there is a problem with the fuel supply system. Refer to Testing and Adjusting, "Fuel System Pressure - Test"
If a 94-11 code is not active or logged, refer to Test Step 5.
Results: The observed engine speed is below 100 rpm.
Repair: Refer to Troubleshooting, "Engines Cranks But Does Not Start".
STOP
Results: The observed engine speed is above 100 rpm and the observed engine oil pressure is below 14 kPa (2 psi).
Repair: There is a problem with the engine oil supply. Refer to Testing and Adjusting, "Engine Oil Pressure - Test".
STOP
Results: The observed engine speed is above 100 rpm and the observed engine oil pressure is above 14 kPa (2 psi) and the actual injection actuation pressure is below 6 MPa (870 psi). Proceed to Test Step 7.
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
Illustration 2 g01330859
Location of the connectors for the injector solenoids (C7 engines)
(1) Connector at the valve cover
(2) J2/P2 ECM connectors
(3) Rubber grommet for the injector harness at the valve cover
Illustration 3 g01330939
Location of the connectors for the injector solenoids (C9 engines)
(1) Connector at the valve cover
(2) J2/P2 ECM connectors
Table 2
Troubleshooting Test Steps Values Results
5. Verify Communication Between the ECM and the Fuel Injectors
A. Turn the key to the "OFF" position. An electrical shock hazard is present if the key is not in the "OFF" position.
B. Disconnect the connector for the injector harness at the valve cover. Check for evidence of moisture in the connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for troubleshooting details.
C. Crank the engine for 15 seconds.
D. Check Cat ET for logged diagnostic codes that are related to the injector solenoids.
Fuel Injectors
Results: There are logged diagnostic codes for injector solenoids in all cylinders. The logged codes indicate communication between the ECM and the fuel injectors. Turn the key to the OFF position. Reconnect the connector for the injector harness. Clear all diagnostic codes. Proceed to Test Step 6.
Results: At least one cylinder does not indicate a logged diagnostic code for the injector solenoid.
Repair: There may be a problem with the engine harness or ECM. Record the numbers that do not indicate a logged diagnostic code for the injector solenoid. Turn the key to the OFF position. Reconnect the connector for the injector harness. Clear any diagnostic codes or event codes. Refer to Troubleshooting, "Injector Solenoid Circuit - Test".
STOP