0282198 JOHNSON ENGINE COVER ASSY., 185

Illustration 1 g01366881
Typical switch inputs and wiringTest Step 1. Check the Electrical Connectors and the Wiring
Remove the electrical power from the Electronic Control Module (ECM).
Illustration 2 g02164341
Location of the connectors that are for the switch circuits (typical left side engine view) (1) J1/P1 ECM connectors
Thoroughly inspect connectors (1) and the engine interface connectors. Thoroughly inspect the connections for the suspect switch. Refer to Troubleshooting, "Electrical Connectors - Inspect".
Illustration 3 g02219135
Terminal locations at the J1/P1 ECM connectors that are for the switch circuits (P1-22) Start aid manual override switch (P1-40) Start/Run/Stop switch (P1-41) Engine ECM reset switch
Illustration 4 g02219137
Terminals at the engine interface connector that are for the switch circuits (Terminal 9) Start aid manual override switch (Terminal 16) Start/Run/Stop switch
Perform a 45 N (10 lb) pull test on each of the wires in the circuit for the suspect switch.
Check the allen head screw on each ECM connector for the proper torque. Also, check the allen head screw on the customer connector for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
Check the harness and wiring for abrasions and for pinch points from the battery to the ECM.Expected Result:All connectors, pins, and sockets are coupled and/or inserted, and the harness and wiring are free of corrosion, of abrasion and of pinch points.Results:
OK - The wiring and connectors appear to be OK. Proceed to Test Step 2.
Not OK - There is a problem with the wiring and/or a connector.Repair: Repair the wiring and/or the connector. Replace parts, if necessary. Ensure that all of the seals are properly connected. Verify that the repair eliminates the problem.STOPTest Step 2. Test the Switch for Proper Operation
Disconnect the P1 connector.
Refer to Table 1. Determine the P1 terminal for the suspect switch.
Table 1
Terminals for the Switch Inputs    
Name of the Switch     Terminal Locations at the J1/P1 ECM Connectors     Terminal Locations at the Engine Interface Connector    
Start aid manual override switch     22     9    
Start/Run/Stop switch     40     16    
Engine ECM reset switch     41     N/A    
Connect one lead of a multimeter to the P1 terminal for the suspect switch. Connect the other lead of the multimeter to negative ground.Note: Wiggle the harnesses during the following measurements in order to reveal any intermittent short condition.
Measure the resistance between the P1 terminal for the suspect switch and negative ground.
Activate the switch and measure the resistance again.Expected Result:One resistance measurement indicates an open circuit. The other resistance measurement indicates that a short circuit exists.Results:
OK - One resistance measurement indicates an open circuit. The other resistance measurement indicates that a short circuit exists.Repair: The switch is operating correctly. The wiring does not have a short circuit or an open circuit. Operate the engine and check the switch for proper operation.If the switch does not operate correctly, there may be a short circuit between the circuit for the suspect switch and another circuit. Carefully reinspect the components. Refer to Troubleshooting, "Electrical Inspectors - Inspect". Locate the short circuit and perform repairs.STOP
Not OK - Both resistance measurements indicate an open circuit or both resistance measurements indicate a short circuit.Repair: There is a problem with the circuit for the switch. The problem could be in the switch, in the wiring, or in a connector.Carefully reinspect the components. Refer to Troubleshooting, "Electrical Inspectors - Inspect" for information that relates to troubleshooting suspect electrical problems in the harness.If the inspection does not identify the faulty component, replace the switch and test the switch again.If the problem is not resolved, repair the wiring or the connector. Replace parts, if necessary. Verify that the problem is resolved.STOP