0386802 JOHNSON BELLCRANK ASSY

Illustration 1 g00750162
Test Step 1. Check the Electrical Connectors and the Wiring.
Turn the Battery switch for the ECM to the OFF position.
Turn the breaker at the battery to the OFF position.
Thoroughly inspect the ECM connector J1/P1. Inspect all of the other connectors. Refer to Troubleshooting, "Inspecting Electrical Connectors" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the circuit.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the customer connector (allen head screw) for the proper torque of 2.25 0.25 N m (20 2 lb in).
Check the harness and the wiring for abrasion and pinch points.Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted, and the harness and wiring should be free of corrosion, abrasion or pinch points.Results:
OK - The wiring and connectors are okay. Proceed to Test Step 2.
Not OK - Repair the wiring and connectors or replace the wiring or the connectors. Ensure that all of the seals are properly connected. Verify that the repair eliminates the problem.STOPTest Step 2. Check the Status of the Start/Run/Stop Switch.
Connect the ET to the service tool connector.
Turn the breaker at the battery to the ON position.
Turn the Battery switch for the ECM to the ON position.
Monitor the parameter for the Start/Run/Stop Switch on the ET.
Activate the Start/Run/Stop Switch. Be sure that none of the other switches have been activated.Expected Result:The parameter for the Start/Run/Stop Switch should read "ON".Results:
OK - The parameter for the Start/Run/Stop Switch reads "ON". Proceed to test step 3.
Not OK - The parameter for the Start/Run/Stop Switch does not read "ON". Proceed to test step 4.Test Step 3. Check the Status of the Start/Run/Stop Switch.
Monitor the parameter for the Start/Run/Stop Switch on the ET.
Deactivate the Start/Run/Stop Switch.Expected Result:The parameter for the Start/Run/Stop Switch should read "OFF".Results:
OK - The parameter for the Start/Run/Stop Switch reads "OFF". The Start/Run/Stop Switch is functioning correctly. The ECM is receiving the signal from the Start/Run/Stop Switch.STOP
Not OK - The parameter for the Start/Run/Stop Switch does not read "OFF". Proceed to test step 4.Test Step 4. Check the Input to the ECM.
Turn the Battery switch for the ECM to the OFF position.
Disconnect J1/P1.
Install a Breakout T at the ECM connector P1/J1.
Remove socket 29 from the Breakout T that is connected to P1.
Remove socket 24 from the Breakout T that is connected to P1.
Turn the Battery switch for the ECM to the ON position.
Monitor the parameter for the switch on the ET.
Connect the ends of the wires that were removed from the Breakout T together.
Monitor the parameter for the switch on the ET.
Turn the Battery switch for the ECM to the OFF position. Disconnect the Breakout T. Reinstall all wires, and reconnect J1/P1.Expected Result:When the wires from the Breakout T are not connected together the switch status should read "OFF". When the wires from the Breakout T are connected together the switch status should read "ON".Results:
OK - The parameter for the Start/Run/Stop Switch is displaying the proper states. The problem is not with the ECM. Proceed to test step 5.
Not OK - The parameter for the Start/Run/Stop Switch does not show the correct states.Repair: Reconnect all connectors and wiring. Replace the ECM. Refer to Troubleshooting, "Replacing the ECM".STOPTest Step 5. Check the Start/Run/Stop Switch.
Turn the Battery switch for the ECM to the OFF position.
Disconnect the ECM connector J1/P1.
Remove the wires from the Start/Run/Stop Switch.
Ensure that the Start/Run/Stop Switch is not activated.
Measure the resistance between the terminals on the Start/Run/Stop Switch.
Activate the Start/Run/Stop Switch.
Measure the resistance between the terminals on the Start/Run/Stop Switch.Expected Result:The resistance should be greater than 20,000 Ohms when the Start/Run/Stop Switch is not activated. The resistance should be less than 10 Ohms when the Start/Run/Stop Switch is activated.Results:
OK - The resistance measurements are correct. Proceed to test step 6.
Not OK - The resistance measurements are not correct.Repair: Replace the Start/Run/Stop Switch. Reconnect all connectors and wiring. Verify that the problem is no longer present.STOPTest Step 6. Check for Shorts in the Wiring to the Start/Run/Stop Switch.
Measure the resistance between wire 998-BR from the Start/Run/Stop Switch and the engine ground.
Measure the resistance between wire F720-GN and wire 998-BR from the Switch.Expected Result:The resistance should be greater than 20,000 Ohms.Results:
OK - The resistance is greater than 20,000 Ohms. Proceed to test step 7.
Not OK - The resistance is less than 20,000 Ohms.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Reconnect all connectors and wiring. Verify that the problem is no longer present.STOPTest Step 7. Check for Opens in the Wiring to the Start/Run/Stop Switch.
Connect wire F720-GN and wire 998-BR from the Start/Run/Stop Switch together at the Start/Run/Stop Switch.
Measure the resistance between P1-29 and P1-24 at the ECM connector P1.Expected Result:The resistance should be less than 10 Ohms.Results:
OK - The resistance is less than 10 Ohms. The wiring is okay. Repair: Reconnect all connectors and wiring. There may be an intermittent problem in the circuit. Verify that the problem is no longer present.STOP
Not OK - The resistance is more than 10 Ohms.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Reconnect all connectors and wiring. Verify that the problem is no longer present.STOP