5036204 JOHNSON *VALVE, FLOAT

Table 1
Diagnostic Trouble Codes for the Injector Electrical Circuits
J1939 Codes Description Notes
651-5 Engine Injector Cylinder #01 current below normal These codes relate to the electrical circuit that includes injector terminals 1 and 3.
651-6 Engine Injector Cylinder #01 current above normal
652-5 Engine Injector Cylinder #02 current below normal
652-6 Engine Injector Cylinder #02 current above normal
653-5 Engine Injector Cylinder #03 current below normal
653-6 Engine Injector Cylinder #03 current above normal
654-5 Engine Injector Cylinder #04 current below normal
654-6 Engine Injector Cylinder #04 current above normal
655-5 Engine Injector Cylinder #05 current below normal
655-6 Engine Injector Cylinder #05 current above normal
656-5 Engine Injector Cylinder #06 current below normal
656-6 Engine Injector Cylinder #06 current above normal
3659-5 Engine Injector Cylinder #1 Actuator 2 current below normal These codes relate to the electrical circuit that includes injector terminals 2 and 4.
3659-6 Engine Injector Cylinder #1 Actuator 2 current above normal
3660-5 Engine Injector Cylinder #2 Actuator 2 current below normal
3660-6 Engine Injector Cylinder #2 Actuator 2 current above normal
3661-5 Engine Injector Cylinder #3 Actuator 2 current below normal
3661-6 Engine Injector Cylinder #3 Actuator 2 current above normal
3662-5 Engine Injector Cylinder #4 Actuator 2 current below normal
3662-6 Engine Injector Cylinder #4 Actuator 2 current above normal
3663-5 Engine Injector Cylinder #5 Actuator 2 current below normal
3663-6 Engine Injector Cylinder #5 Actuator 2 current above normal
3664-5 Engine Injector Cylinder #6 Actuator 2 current below normal
3664-6 Engine Injector Cylinder #6 Actuator 2 current above normal Background InformationThese engines have Electronic Unit Injectors (EUI) that are electronically controlled. Each injector contains two solenoids. The Engine Control Module (ECM) sends 105 V pulses to each injector solenoid. The pulses are sent at the proper time and at the correct duration for a given engine load and speed.The ECM monitors the current flow through the circuit for each solenoid. If low current flow is detected, a diagnostic code is activated. The ECM continues to try to fire the injector.If high current flow is detected, a diagnostic code is activated. The ECM will disable the solenoid circuit in order to prevent damage from the high current flow. However, the ECM will periodically try to fire the injector. If the short circuit remains, this sequence of events will be repeated until the problem is corrected.Ensure that the fuel system is not restricted. A restricted fuel supply to the injectors will cause the injector solenoids to overheat and possibly fail. A sufficient fuel supply to the injector solenoids is necessary to cool the solenoids during operation.Typically, problems with an injector solenoid occur when the engine is warmed up and/or when the engine is under vibration (heavy loads). Perform this procedure when the engine is at normal operating temperature. Pay careful attention to the condition of the wiring and the connectors as you perform this procedure. The wiring and/or the connectors may have problems that only occur during vibration.Diagnostic Tests on the Caterpillar Electronic Technician (ET)Cat ET includes the following test that aids in troubleshooting injector solenoids:Injector Solenoid Test - The "Injector Solenoid Test" identifies an open circuit or a short circuit in the circuits for the injector solenoids. The test is performed while the engine is not running. The "Injector Solenoid Test" briefly activates each solenoid. A good solenoid will create an audible click when the solenoid is activated. Cat ET indicates the status of the solenoid as "OK", "Open", or "Short".Note: Refer to the following schematics. Two injector solenoids share a common supply wire. For this reason, an open circuit or a short circuit in a supply wire could cause diagnostic codes for two cylinders.
Illustration 1 g01373808
Schematic for the injectors on C13 engines
Illustration 2 g01373904
Schematic for the injector solenoids on C15 engines
Test Step 1. Test the Fuel Supply at Secondary Filter Base
Test the fuel supply at the sampling port located on the secondary fuel filter base. T Expected Result:The fuel supply pressure should not exceed 655 kPa (95 psi) at high idle.Results:
No - The fuel supply pressure does not exceed 655 kPa (95 psi). Proceed to Test Step 2.
Yes - The fuel supply pressure exceeds 655 kPa (95 psi).Repair: Replace the fuel filters and check the fuel system for restrictions.STOPTest Step 2. Determine if the Code is Active or Logged
Establish communication between Cat ET and the ECM . Refer to Troubleshooting, "Electronic Service Tools", if necessary.
Start the engine. Allow the engine to warm up to normal operating temperature 77 °C (171 °F).
Determine if the code is active or logged. Expected Result:The code is logged.Results:
Logged code - Do not turn off the engine. Proceed to Test Step 3.
Active code - Do not turn off the engine. Proceed to Test Step 6.Test Step 3. Check the External Engine Harness
Inspect the injector wiring harness between the ECM and the valve cover. Look for these problems:
Improper routing of the wire harness
Missing clamps or other hardware
Loose connectors or damaged connectors
Damage that is caused by excessive heat
Damage that is caused by chafing
Slowly wiggle the wiring harness and the connectors between the P2 connector and the valve cover. Pay particular attention to the wiring near each connector. As you wiggle the wiring, look for the code to become active. Continue with this procedure if the code does not become active. If the code becomes active, note the location of the problem. Proceed to the appropriate result for this Test Step.
Refer to the appropriate schematic diagram. Identify the wires at each connector that relate to the cylinder that has the code. Perform the following procedure for the wires at each connector:
Inspect the seal around each wire. Verify that the seal is sealing correctly, properly installed, and not damaged.
Pull on each wire in order to verify that the wire and the terminal are correctly installed. Expected Result:The code becomes active when the wiring is moved. Alternatively, there is a problem with a connector.Results:
Yes - There is a problem with the external engine harness.Repair: