5033629 JOHNSON CLIP

Illustration 1 g00925335
Left side view of the engine
Illustration 2 g00925337
Top view of the engine
Illustration 3 g00942365
Circuit schematic for the injectorsTest Step 1. Inspect Electrical Connectors and Wiring
Illustration 4 g00925669
Pin locations for ECM connector P2
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
Turn the key switch to the OFF position. A strong electrical shock hazard is present if the key switch is not turned OFF.
Thoroughly inspect the ECM engine harness connector J2/P2 and the solenoid connector for the injector J300/P300. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector and the solenoid connector for the injector J300/P300 that are associated with injector solenoids.Refer to Illustration 4.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the solenoid connector for the injector J300/P300 in order to ensure the proper mating of the connector.
Check the harness and wiring for abrasion and pinch points from the injectors to the ECM.Expected Result:All connectors, pins and sockets should be completely coupled and/or inserted and the harness and wiring should be free of corrosion, abrasion or pinch points.Results:
OK - Proceed to Test Step 2.
Not OK - Repair: Perform the following repair:Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.Verify that the repair eliminates the problem. Stop.Test Step 2. Use the Caterpillar Electronic Technician (Cat ET) to Check for Logged Diagnostic Codes
Connect Cat ET to the data link connector.
Turn the key switch to the ON position.
Monitor the "Logged Diagnostic Code" screen of Cat ET.Expected Result:One or more of the listed codes have been logged:
1-11 Cylinder #1 Injector current fault (72)
2-11 Cylinder #2 Injector current fault (72)
3-11 Cylinder #3 Injector current fault (73)
4-11 Cylinder #4 Injector current fault (73)
5-11 Cylinder #5 Injector current fault (74)
6-11 Cylinder #6 Injector current fault (74)Results:
Yes - Proceed to Test Step 4.
No - Proceed to Test Step 3.Test Step 3. Check the Variation of the Injectors From Engine Cylinder to Engine Cylinder
Connect Cat ET to the data link connector.
When possible, put the vehicle on a dynamometer.
Start the engine.
Allow the engine to warm up to normal operating temperature.
After the engine is warmed to operating temperature, access the "Cylinder Cutout Test" by accessing the following display screens in order:
"Diagnostics"
"Diagnostic Tests"
"Cylinder Cutout Test"
Enable the cooling fan, if the fan is not controlled by the ECM. If the ECM controls the cooling fan, the cooling fan will start automatically when the test begins.
Shut off all parasitic loads such as the air conditioning and the air compressors which could affect the results of the test.
Cut out each cylinder and watch the "Fuel Position" of all of the other cylinders.
Verify that cutting out a specific cylinder causes only a slight change to the Fuel Position of the other cylinders in comparison to the change to the Fuel Position that occurs when other cylinders are cut out. If a cylinder is cut out and only a slight change occurs to the Fuel Position of the other cylinders, a mechanical problem with the injector or a mechanical problem with the cylinder may exist.
After the test is finished, use Cat ET to check for active diagnostic codes or for logged diagnostic codes that are new.Expected Result:An active diagnostic code for a cylinder fault results from running the Cylinder Cutout Test.Results:
Yes - Proceed to Test Step 4.
No - Perform the following repair:Repair: If a cylinder is cut out and only a slight change occurs to the Fuel Position of the other cylinders, a mechanical problem with the injector or a mechanical problem with the cylinder may exist. If the engine is misfiring or if the engine has low power, refer to Troubleshooting, "Engine Misfires, Runs Rough or Is Unstable" and Troubleshooting, "Low Power/Poor or No Response to Throttle". If a diagnostic code for a cylinder fault results from running the Cylinder Cutout test, proceed to Test Step 4.Test Step 4. Use the Injector Solenoid Test to Test the Injector Solenoids
Start the engine.
Allow the engine to warm up to the normal operating temperature.
Turn the key switch to the OFF position.
Connect Cat ET to the data link connector.
Turn the key switch to the ON position.
After the engine is warmed to operating temperature, access the "Injector Solenoid Test" by accessing the following display screens in order:
"Diagnostics"
"Diagnostic Tests"
"Injector Solenoid Test"
Activate the test.Note: Do not confuse the Injector Solenoid Test with the Cylinde