0321580 JOHNSON T-SEAL,Piston,trim cylinder

Recommended Actions
Note: The procedures have been listed in order of probability. Complete the procedures in order.
Table 1
Troubleshooting Test Steps Values Results
1. Ground Level Shut-down Switch (If Equipped)
A. Ensure that the ground level shutdown switch has not been activated.
Shutdown switch
Result: The ground level shutdown switch has been activated.
Repair: Deactivate the ground level shutdown switch.
Result: The ground level shutdown switch has not been activated.
Proceed to Test Step 2.
2. Diagnostic Codes
A. Connect the electronic service tool to the diagnostic connector.
B. Crank the engine for 30 seconds.
C. Turn the keyswitch to the ON position.
D. Use the electronic service tool to check for active diagnostic codes.
Diagnostic codes
Result: There are active diagnostic codes.
Repair: Troubleshoot all active diagnostic codes before continuing with this procedure. Refer to Troubleshooting, "Diagnostic Trouble Codes".
Result: There are no active diagnostic codes.
Proceed to Test Step 3.
3. Visible Faults
A. Visually inspect the engine for the following faults:
Missing components
Damaged components
Damaged electrical cables or loose electrical cables
Oil leaks
Fuel leaks
B. Check for the correct levels of fuel, oil, and coolant.
C. If the ambient temperature is below 0 °C (32 °F), make sure that the correct specification of engine oil is used.
D. Check that the battery voltage is correct.
E. Use the electronic service tool to check the average cranking speed of the engine. If the cranking speed is less than 150 rpm, investigate the cause of the low cranking speed.
F. Make sure that all fuel filters are correctly installed.
G. Drain any water from the primary fuel filter/water separator.
Visible faults
Result: Faults found during engine inspection.
Repair: Make any repairs, as necessary.
Attempt to start the engine. If the engine will not start, proceed to Test Step 4.
Result: No faults found.
Proceed to Test Step 4.
4. Air Intake and Exhaust System
A. Check the air filter restriction indicator.
B. Ensure that the air filter is clean and serviceable
C. Check the air intake and exhaust systems for the following defects:
Blockages
Restrictions
Damage to lines or hoses
Defects
Result: A defect was found in the air intake or exhaust system.
Repair: Make any necessary repairs.
Attempt to start the engine. If the engine will not start, proceed to Test Step 5.
Result: No defects found in the air intake or exhaust systems.
Proceed to Test Step 5.
5. Fuel System Inspection
A. Check that the fuel shut-off valve is in the OPEN position.
B. If the temperature is below 0 °C (32 °F), check for solidified fuel (wax).
C. Check for fuel supply lines that are restricted.
D. Check that the low-pressure fuel lines are correctly installed.
E. Check the pressures in the fuel system. Refer to Systems Operation, Testing, and Adjusting, "Fuel System Pressure - Test"
F. Check the diesel fuel for contamination. Refer to Systems Operation, Testing, and Adjusting, "Fuel Quality - Test".
G. Check for air in the fuel system. Refer to Systems Operation, Testing, and Adjusting, "Air in Fuel - Test".
H. Ensure that the fuel system has been primed. Refer to Systems Operation, Testing, and Adjusting, "Fuel System - Prime".
Fuel System
Result: A defect was found in the fuel system.
Repair: Make any necessary repairs.
Attempt to start the engine. If the engine will not start, proceed to Test Step 6.
Result: No defects found.
Proceed to Test Step 6.
6. Fuel Filters
A. Replace the primary fuel filter and the secondary fuel filter. Refer to the Operation and Maintenance Manual, "Fuel System Primary Filter (Water Separator) Element - Replace".
B. Attempt to start the engine.
Engine start
Result: The engine starts.
Return the engine to service.
Result: The engine does not start.
Proceed to Test Step 7.
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
Illustration 1 g03705140
View of the fuel manifold (typical example)
Table 2
Troubleshooting Test Steps Values Results
7. Fuel Rail Pressure Relief Valve (PRV)
A. Turn the keyswitch to the OFF position.
B. Disconnect plastic tube assembly (4) from fuel manifold (1). Refer to Disassembly and Assembly, "Fuel Manifold (Rail) - Remove and Install".
C. Securely seal the end of plastic tube assembly (4).
Note: Plastic tube assembly (4) must be sealed to prevent air ingress into the fuel system.
D. Attach a length of hose to fuel manifold (1) and secure with a clip at position (3).
E. Place the other end of the hose into a container that is suitable for fuel. Ensure that the hose is secure and will not come out of the container while the engine is running.
F. Turn the keyswitch to the ON position.
G. Crank the engine for a maximum of 30 seconds.
H. After the engine has stopped, check the container for fuel.
Fuel in container
Result: Fuel is present in the container.
Repair: Install a replacement fuel Pressure Relief Valve (PRV). Refer to Disassembly and Assembly, "Fuel Manifold (Rail) - Remove and Install". When the PRV has been replaced, use the electronic service tool to perform the "Rail Pressure Valve Learn Reset".
Result: No fuel is present in the container.
Proceed to Test Step 8.
8. Fuel Pump Timing
A. Check the timing of the high-pressure fuel pump. Refer to Systems Operation, Testing, and Adjusting, "Fuel Injection Timing - Check".
Fuel pump timing
Result: The fuel pump timing is incorrect.
Repair: Make any necessary adjustments.
Attempt to start the engine. If the engine will not start, proceed to Test Step 9.
Result: The fuel pump timing is OK.
Proceed to Test Step 9.
9. Low Compression (Cylinder Pressure)
A. Perform a compression test. Refer to Systems Operation, Testing, and Adjusting, "Compression - Test".
Low compression
Result: Low compression is recorded on one or more cylinders.
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
Repair: Make any repairs, as necessary.
Attempt to start the