275731 Volvo.Penta Repair kit

Table 1
J1939 Code and Description CDL Code and Description Comments
5394-7
Aftertreatment DEF Dosing Valve : Not Responding Properly 3821-7
Aftertreatment #1 Diesel Exhaust Fluid Dosing Valve Actuator : Not Responding Properly The aftertreatment #1 Diesel Exhaust Fluid (DEF) injector #1 is not functioning properly.
The code is logged.
5394-14
Aftertreatment DEF Dosing Valve : Special Instruction 3821-14
Aftertreatment #1 DEF Dosing Valve Actuator #1 : Special Instruction The aftertreatment DEF Dosing Valve Actuator is not functioning properly.
The code is logged.
6324-7
Aftertreatment #1 DEF Dosing Valve #2 : Not Responding Properly 5017-7
Aftertreatment #1 Diesel Exhaust Fluid Dosing Valve Actuator #2 : Not Responding Properly The aftertreatment #1 DEF injector #2 is not functioning properly.
The code is logged.
6324-14
Aftertreatment #1 DEF Dosing Valve #2 : Special Instruction 5017-14
Aftertreatment #1 DEF Dosing Valve Actuator #2 : Special Instruction The aftertreatment DEF Dosing Valve Actuator is not functioning properly.
The code is logged.
7488-7
Aftertreatment #1 DEF Dosing Valve #3 : Not Responding Properly 5018-7
Aftertreatment #1 Diesel Exhaust Fluid Dosing Valve Actuator #3 : Not Responding Properly The aftertreatment #1 DEF injector #3 is not functioning properly.
The code is logged.
7488-14
Aftertreatment #1 DEF Dosing Valve #3 : Special Instruction 5018-14
Aftertreatment #1 DEF Dosing Valve Actuator #3 : Special Instruction The aftertreatment DEF Dosing Valve Actuator is not functioning properly.
The code is logged.
7546-7
Aftertreatment #1 DEF Dosing Valve #4 : Not Responding Properly 5019-7
Aftertreatment #1 Diesel Exhaust Fluid Dosing Valve Actuator #4 : Not Responding Properly The aftertreatment #1 DEF injector #4 is not functioning properly.
The code is logged.
7546-14
Aftertreatment #1 DEF Dosing Valve #4 : Special Instruction 5019-14
Aftertreatment #1 DEF Dosing Valve Actuator #4 : Special Instruction The aftertreatment DEF Dosing Valve Actuator is not functioning properly.
The code is logged.
Table 2
Required Tools
Part Number Part Name Qty
372-5260 Test Lead Tool Group 1 Probable Causes
Codes
DEF lines
DEF injector
Wiring harness
DEF quality
RestrictionsRecommended Actions
Table 3
Troubleshooting Test Steps Values Results
1. Check for Codes
A. Connect Cat® Electronic Technician (ET) to the service tool connector.
B. Look for active codes that are associated with the system for the event code.
Codes
Result: An associated code is active.
Repair: Troubleshoot the associated code before continuing with this test.
Result: A code is active or logged.
Proceed to Test Step 2.
Result: A -14 code is active or logged.
Repair: Replace the failed DEF injector, Proceed to Test Step 10.
Illustration 1 g06027315
The DEF injectors are on the inlet of the Clean Emissions Module (CEM).
(1) DEF injector 2 (DEF pump 1)
(2) DEF injector 3 (DEF pump 1)
(3) DEF injector 1 (DEF pump 2)
(4) DEF injector 4 (DEF pump 2)
Table 4
Troubleshooting Test Steps Values Results
2. Check the Diesel Exhaust Fluid (DEF) Lines Routing
A. Turn the keyswitch to the OFF position.
B. Ensure that the DEF lines are routed from the appropriate DEF pump to the appropriate DEF injector.
Lines Routing
Result: The DEF lines are routed to the correct locations.
Proceed to Test Step 3.
Result: The DEF lines are not to the correct locations.
Repair: Route the DEF lines to the correct locations.
Proceed to Test Step 10.
3. Check the resistance of the DEF Injector
A. Turn the keyswitch to the OFF position. Allow 2 minutes to elapse before proceeding.
B. Disconnect the affected DEF injector from the wiring harness.
C. Inspect the connector for damage or debris.
D. Connect two 398-4987 Probes to the affected DEF injector wiring harness connector.
The probes must be used to prevent damage to the DEF injector connector.
E. Measure the resistance of the affected DEF injector.
Ohms
Result: The resistance of the DEF injector measured between 10 Ohms to 14 Ohms.
Proceed to Test Step 4.
Result: The resistance of the DEF injector did not measure between 10 Ohms to 14 Ohms. A failed DEF injector has been detected.
Repair: Replace failed DEF injector. Refer to the Disassembly and Assembly manual for additional information.
Proceed to Test Step 10.
4. Check for a Short Circuit in the Wiring Harness
A. Disconnect the affected DEF injector from the wiring harness.
B. Connect two 398-4985 Probes to the affected DEF injector.
The probes must be used to prevent damage to the DEF injector connector.
C. Measure the resistance between the affected DEF injector positive wire and DEF injector negative wire at the DEF injector wiring harness connector.
Note: The reading will measure the resistance in the wiring harness between the DEF injector connector and the Diesel Exhaust Fluid Control Unit (DCU).
Ohms
Result: The resistance of the DEF injector wiring harness measured greater than 10k Ohms.
Reconnect the DEF injector to the wiring harness. Proceed to Test Step 5.
Result: The resistance of the DEF injector wiring harness did not measure greater than 10k Ohms.
Repair: There is a short circuit in the wiring harness between the DEF injector connector and the DCU. Repair or replace the wiring harness.
If the problem is not resolved, proceed to Test Step 5.
5. Check the DEF Quality
A. Measure the DEF quality. Refer to Testing and Adjusting, Diesel Exhaust Fluid Quality - Test for additional information.
DEF
Result: The DEF is not contaminated.
Proceed to Test Step 6.
Result: The DEF is contaminated.
Repair: Contact the Dealer Solutions Network (DSN) for further information.
6. Perform the "DEF Dosing System Accuracy Test"
A. Connect Cat ET.
B. Select the appropriate DCU.
C. Use Cat ET to perform the following diagnostic test on the appropriate DEF injector:
- "Aftertreatment DEF Dosing Injector Accuracy Test"
Refer to Testing and Adjusting, DEF Dosing System Accuracy Test for additional information.
Test
Result: The amount of DEF collected is below 170 ml.
Proceed to T