0387933 JOHNSON THRU BOLT PACKAGE

Recommended Actions
Active Engine Derate
Use ET to check for logged engine derates and/or active engine derates. A derate status flag will appear on ET if an active engine derate is occurring. The engine may be derated due to one of the following conditions: high altitude, dirty air filters and other factors.Cold Mode
Use ET to verify that the engine has exited cold mode. Cold mode operation may cause the engine to run rough and engine power may be limited.
Observe the coolant temperature on the ET status screen. Verify that the reading is valid.Throttle Signal
Monitor "Throttle Position" on ET. Verify that the throttle position is stable and that the engine is able to reach high idle speed. Refer to Troubleshooting, "Throttle Position Sensor Circuit - Test" for the proper troubleshooting procedure.Direct Fuel Control
Monitor "Throttle Position" on ET. Verify that the throttle position is stable and that the engine is able to reach high idle speed. Refer to Troubleshooting, "Throttle Position Sensor Circuit - Test" for the proper troubleshooting procedure.Injection Actuation Pressure
Check the engine oil level. Engine oil supplies the injection actuation pressure circuit. The engine oil must be kept at the proper level for fuel injection.Note: If the oil has been drained from the unit injector hydraulic pump, the pump must be primed. Refer to Disassembly and Assembly, "Unit Injector Hydraulic Pump - Install" for the correct procedure.
If service has recently been performed on the engine, air may be present in the injection actuation pressure circuit. Allow the engine to fully warm up and operate the engine under load in order to purge the air from the injection actuation pressure circuit.
Use ET to check for diagnostic codes. If there is an active diagnostic code for injection actuation pressure, refer to the appropriate topic in Troubleshooting with a Diagnostic Code in this manual.
Compare actual injection actuation pressure and desired actuation pressure on the ET status screen. If these readings agree within 2000 kPa (290 psi) during the symptom, the problem is not in the injection actuation pressure circuit.
Check the seals on the injection actuation pressure control valve. If the seals are faulty, replace the seals and repeat Step 4.
Check the wiring harness to the injection actuation pressure control valve for opens and/or shorts.
Measure the coil resistance on the injection actuation pressure control valve. If the coil resistance is not within 10 5 Ohms, replace the injection actuation pressure control valve.
Escaping fluid under pressure, even a pinhole size leak, can penetrate body tissue, causing serious injury, and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury.Always use a board or cardboard when checking for a leak.
Use ET to perform the Injection Actuation Pressure Override Test. If the injection actuation pressure is low, the high pressure oil supply circuit may have a leak.
Unplug the injection actuation pressure control valve and the unit injector connectors.
Disable the unit injectors with ET and/or the engine shutdown switch.
Remove the valve mechanism covers.
Crank the engine while you check the drain holes in the unit injector adapter and the jumper block seals for leaks.
Repair any leaks and repeat Step 4.
If the injection actuation pressure during cranking remains low, there may be a problem with the pump compensator displacement control. Replace the pump compensator control assembly and repeat Step 4.Electrical Connectors
Check for correct installation of ECM connectors J1/P1 and J2/P2 and the unit injector connectors. Refer to Troubleshooting, "Electrical Connectors - Inspect".Unit Injectors
Use ET to determine if there are any active diagnostic codes for the unit injectors.
Perform the Injector Solenoid Test on ET in order to determine if all of the injector solenoids are being energized by the ECM.
Perform the Cylinder Cutout Test on ET in order to identify any misfiring cylinder(s). Refer to Troubleshooting, "Injector Solenoid Circuit - Test" for more information.Turbocharger Outlet Pressure Sensor
Monitor the status of "Fuel Position", "Rated Fuel Limit", and "FRC Fuel Limit" on ET while the engine is operating under full load. These parameters should reflect the information below.
Table 1
"Fuel Position" = "Rated Fuel Limit"    
AND    
"Fuel Position" < "FRC Fuel Limit"    If "Fuel Position" equals "Rated Fuel Limit" and "Fuel Position" is less than "FRC Fuel Limit", the electronics are operating correctly. Otherwise, proceed with the next Step.
Monitor the status of "Boost Pressure" and "Atmospheric Pressure" for normal operation on ET. When the engine is not running, "Boost Pressure" should be 0 kPa (0 psi).Air Inlet and Exhaust System
Inspect the air filter for a restriction. Clean plugged air filters or replace plugged air filters. Refer to the Operation and Maintenance Manual.
Check the air inlet and exhaust system for restrictions and/or leaks. Refer to Testing and Adjusting, "Air Inlet and Exhaust System".Parameters
If the ECM has been replaced, compare the values on the engine information plate to following parameters from ET:
FRC Offset
Full Load Setting (FLS)
Full Torque Setting (FTS)Fuel Supply
Check the fuel lines for the following problems: restrictions, collapsed lines and pinched lines. If problems are found with the fuel lines, repair the lines and/or replace the lines.
Check the fuel tank for foreign objects which may block the fuel supply.
Check for air in the low pressure fuel supply system if any of the following procedures have been performed:
Replacement of the fuel filters
Service on the low pressure fuel supply circuit
Replacement of unit injectorsNote: A sight glass in the low pressure supply line is helpful in diagnosing air in the fuel. Refer to Testing and Adjusting for more information.
Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.
Purge air from the low pressure fuel supply circuit. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure.
Check fuel quali