0387939 JOHNSON THRU BOLT PACKAGE

Complete the procedure in the order in which the steps are listed.
Table 2
Troubleshooting Test Steps Values Results
1. Check for Associated Diagnostic Trouble Codes
A. Download the "Warranty Report" from the engine ECM before troubleshooting or clearing diagnostic trouble codes.
B. Use the electronic service tool to confirm if a diagnostic code is present.
Diagnostic Trouble Codes
Result: A diagnostic code other than those codes listed in Table 1 is active.
Repair: Troubleshoot the associated code. Refer to Troubleshooting, "Diagnostic Trouble Codes".
Result: One of the diagnostic codes listed in Table 1 is active.
Proceed to Test Step 2.
2. Check the Coolant Level of the Engine
A. Determine if the engine coolant level is full.
Coolant Level
Result: The coolant level is full.
Proceed to Test Step 3.
Result: The coolant level is not full.
Repair: Add coolant to the system.
Determine the cause of low coolant. Refer to Troubleshooting, "Low Coolant Level" for additional information.
If adding coolant does not correct the fault, proceed to Test Step 3.
3. Check the Engine Coolant Temperature
A. Start the engine. Allow the engine to warmup to normal operating temperature.
B. Connect to the electronic service tool.
C. Select the Status Parameters tab.
D. Check the coolant temperature.
The temperature should be greater than 50° C (122° F).
Coolant temperature
Result: The coolant temperature is greater than 50° C (122° F).
Proceed to Test Step 4.
Result: The coolant temperature is less than 50° C (122° F).
Repair: Refer to Troubleshooting, "Coolant Temperature Is Low" for troubleshooting information.
4. Check for Coolant Leaks
A. Check for coolant leaks in the supply and return lines to the DEF tank header.
Leaks
Result: There are no leaks in the supply or return lines.
Proceed to Test Step 5.
Result: There are leaks in the supply or return lines.
Repair: Repair the leaks and refill the coolant system.
If the fault is still present, proceed to Test Step 5.
5. Inspect the Coolant Lines for Restrictions and Obstructions
A. Disconnect the coolant lines between the engine and the DEF tank.
B. Check for a restriction or obstruction in the coolant lines.
Restrictions
Result: There is a restriction in a line.
Repair: Repair or replace the lines with the restrictions.
Proceed to Test Step 8.
Result: The coolant lines are OK.
Reconnect the coolant lines.
Proceed to Test Step 6.
6. Check the Electrical Connection at the DEF Tank Header
A. Inspect electrical connector for DEF tank header . Refer to Troubleshooting, "Electrical Connectors - Inspect" for further information.
Check for corrosion or loose wires.
Electrical connections
Result: The electrical connector is not corroded or loose.
Proceed to Test Step 7.
Result: The electrical connector is corroded and/or loose.
Repair:Make the necessary repairs to the connectors. Cycle the keyswitch.
Use the electronic service tool to perform the "Aftertreatment System Functional Test" to verify that the repair eliminates the fault.
Proceed to Test Step 8.
Illustration 1 g03701177
(1) Coolant diverter valve
Table 3
Troubleshooting Test Steps Values Results
7. Check the DEF Coolant Diverter Valve Solenoid Operation
A. Turn the keyswitch to the ON position.
B. Start the engine.
C. Connect to the electronic service tool.
D. Set the status of the coolant diverter valve to OPEN using the "DEF Coolant Diverter Valve Solenoid Override" for 20 minutes.
Note: The DEF tank temperature must be within 5° C (9° F) of ambient air temperature prior to performing this override.
E. Monitor the "DEF Tank Temperature" and make sure that there is a temperature increase of at least 3° C (5.4° F).
Temperature rise
Result: The DEF tank temperature increased by at least 3° C (5.4° F).
Return the unit to service.
Result: The DEF tank temperature did not increase by at least 3° C (5.4° F).
Repair: Replace coolant diverter valve.
Proceed to Test Step 8.
8. Check the DEF Coolant Diverter Valve Solenoid Operation
A. Turn the keyswitch to the ON position.
B. Start the engine.
C. Connect to the electronic service tool.
D. Set the status of the coolant diverter valve to OPEN using the "DEF Coolant Diverter Valve Solenoid Override" for 20 minutes.
Note: The "DEF Coolant Diverter Valve Solenoid Override" will run for 5 minutes. Repeat the override four times.
Note: The DEF tank temperature must be within 5° C (9° F) of ambient air temperature prior to performing this override.
E. Monitor the "DEF Tank Temperature" and make sure that there is an increase of at least 3° C (5.4° F).
Temperature rise
Result: The DEF tank temperature increased by at least 3° C (5.4° F).
Return the unit to service.
Result: The DEF tank temperature did not increase by at least 3° C (5.4° F).
Repair : Repair the DEF Tank header sensor with the DEF Manifold Sensor Kit. Refer to Disassembly and Assembly, Manifold (DEF Heater) Sensor - Disassemble (Temperature, Level, Quality DEF Manifold Sensor) and Manifold (DEF Heater) Sensor -Assemble (Temperature, Level, Quality DEF Manifold Sensor).
Repeat this Test Step.
If the fault is still present, contact the Dealer Solutions Network (DSN).