30964-0200 Tohatsu BEVEL GEAR B

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. Active Codes and Logged Codes
A. Establish communication between Caterpillar Electronic Technician (ET) and the Electronic Control Module (ECM).
B. Download the "Product Status Report" from the engine ECM before performing any troubleshooting or clearing diagnostic trouble codes.
Codes
Result: A diagnostic trouble code is not active or logged.
Proceed to Test Step 2.
Result: A diagnostic trouble code is active or logged.
Troubleshoot the active or logged codes.
2. Check the Engine Oil Level and Obtain an Oil Sample
A. Check oil level.
B. If the oil level is high, take an oil sample to check for fuel dilution. Refer to Troubleshooting, Oil Contains Fuel.
Oil
Result: The engine oil sample shows action required.
Repair: Make necessary repairs.
Result: The engine oil sample and engine oil level are OK.
Proceed to Test Step 3.
Result: The engine oil is not at the correct level.
Repair: Determine root cause of why the oil level was high or low.
3. Low-Quality Fuel
A. Refer to Operation and Maintenance Manual for information on the proper characteristics of the fuel for the engine. If necessary, obtain a fuel analysis to confirm that the correct fuel is being used for the engine. Refer to Systems Operation/Testing and Adjusting, "Fuel System Quality Test" for the proper procedure.
Fuel
Result: The fuel quality is OK.
Proceed to Test Step 4.
Result: The fuel quality is not OK.
Replace the fuel. Verify that the repair eliminated the problem.
4. Fuel Injectors
A. If service has been performed on the engine fuel system recently, verify that the injector trim codes in the Engine ECM match the injector for each cylinder. If injectors were moved between cylinders or if an injector was replaced and the injector trim codes were not updated in the Engine ECM, this can cause an engine miss.
B. Access the "Cylinder Cutout Test" in the "Diagnostic Tests" under the "Diagnostics" menu. Cut out each cylinder one at a time to listen for improvements in the engine. If engine sound improves while cutting out a specific cylinder or cylinders, then check that the injector(s) are working properly by using 440-6907 Injector Kit .
Note: The injector deliver quantity is not a reliable indicator of a failed injector. It is not recommended to use that test in determining if an injector has failed.
Fuel Injector
Result: If injector(s) trim codes for each cylinder do not match what is in the Engine ECM, then refer to Special Instruction, REHS9707, for the procedure to install the new injector QR codes within the Engine ECM and on-line. Confirm that this resolves the issue.
Result: If injector(s) are found to be defective, then replace the injector(s). Refer to Disassembly and Assembly, Electronic Unit Injector - Remove and Install. Refer to Special Instruction, REHS9707, for the procedure to install the new injector QR codes within the Engine ECM and online. Confirm that this resolves the issue.
Note: If two or more injectors are not working properly, this is likely a result of water in the fuel, bad fuel, or contaminated fuel. Contaminated fuel can occur by pre-filling the fuel filter or contamination during a previous repair of the fuel system. The root cause needs tobe determinedto prevent a repeat occurrence.
Result: There are no previous known services on fuel system and there was no noticeable improvement during the cylinder cut out test. The customer could have ordered injectors through parts and did not change the injector trim codes in the Engine ECM. Visually confirm that the injector trim code for each cylinder matches what is in the Engine ECM. Refer to Special Instruction, REHS9707, for the procedure to install the new injector QR codes within the Engine ECM and online.
5. Low Compression
A. Perform a compression test. Refer to Systems Operation, Testing and Adjusting, Compression - Test.
B. Possible causes of low compression:
• Faulty piston
• Faulty piston rings
• Worn cylinder bores
• Worn valves
• Faulty cylinder head
• Damaged cylinder head
Compression
Result: Low compression is present. Make the necessary repairs. Verify that the repair eliminated the problem.
Result: Low compression is not present.
Proceed to Test Step 6.
6. Valve Train Components
Check the valve lash. Refer to Troubleshooting, "Valve Lash Is Excessive".
B. Check for damage to valve train components. Remove the valve cover from the suspect cylinders. Check the following items for damage:
1. Camshaft
2. Valve springs
3. Camshaft followers
4. Rocker shaft
5. Bridges
6. Pushrods
7. Injectors
Refer to the Disassembly and Assembly for additional information.
C. Check for valves that do not move freely. Remove the cylinder head and inspect the valves.
Refer to the Disassembly and Assembly for additional information.
Valve train
Result: The valve train components are not damaged.
Proceed to Test Step 7.
Result: The valve train components are damaged.
Make the necessary repairs, Verify that the repair eliminated the problem.
7. Gear Train and Components of the Lower End
A. Inspect the gear train and lower end components.
Gear train
Result: The gear train or lower end components are damaged.
Replace any damaged parts.
8. Pistons and Connecting Rods
A. Inspect the pistons and connecting rods for damage or wear.
Pistons and connecting rods
Result: The pistons or the connecting rods are worn or damaged. Replace any damaged parts. Verify that the repair has eliminated the noise.
Contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the Dealer Solutions Network (DSN).