0433123 JOHNSON ENGINE COVER ASSY., 90

Probable Causes
Diagnostic codes
Electrical connectors
ECM connection
Intake manifold pressure
Fuel supplyRecommended Actions
Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.
Note: The procedures have been listed in order of probability. Complete the procedures in order.
Table 1
Troubleshooting Test Steps Values Results
1. Diagnostic Codes
A. Establish communication between the electronic service tool and the Electronic Control Module (ECM). Refer to Troubleshooting, "Electronic Service Tools", if necessary.
B. Download the Product Status Report (PSR) with Histograms before performing any troubleshooting or clearing any diagnostic codes.
Note: The downloaded information will be required by the Dealer Solutions Network (DSN) if troubleshooting assistance is needed.
C. Use the electronic service tool to check for active or logged codes.
Diagnostic codes
Result: There are active or logged codes.
Repair: Troubleshoot any codes before continuing with this procedure.
Result: There are no active or logged codes.
Proceed to Test Step 2.
2. Electrical Connectors
A. Check all electrical connectors for damage. Refer to Troubleshooting, "Electrical Connectors - Inspect".
B. Make sure that all the connector seals are in place and that the connectors have been correctly installed.
Electrical connectors
Result: An electrical connector is damaged.
Repair: Repair the electrical connector or replace the electrical connector.
Result: A connector seal is displaced or missing or an electrical connector is not correctly installed.
Repair: Repair the electrical connector or replace the electrical connector.
Result: All electrical connectors are OK.
Proceed to Test Step 3.
3. ECM Connection
A. Check that the P2/J2 and P1/J1 connectors are correctly installed.
Note: If a fault is suspected with the ECM power or ground connections, refer to Troubleshooting, "Electrical Power Supply - Test".
ECM connection
Result: An ECM connector is not correctly installed.
Repair: Repair the electrical connector or replace the electrical connector.
Result: Both ECM connectors are correctly installed.
Proceed to Test Step 4.
4. Intake Manifold Pressure
A. Use the electronic service tool to verify the intake manifold pressure.
Turn the start switch to the ON position.
The intake manifold pressure must read 0 0.5 kPa (0 0.07 psi).
Intake manifold
Result: The intake manifold pressure does not read 0 0.5 kPa (0 0.07 psi).
Repair: Refer to Troubleshooting, "Intake Manifold Air Pressure Is Low".
Result: The intake manifold pressure reads 0 0.5 kPa (0 0.07 psi).
Proceed to Test Step 5.
5. Fuel Supply
A. Visually check the fuel level in the fuel tank. Do not rely on the fuel gauge only.
B. Ensure that the vent in the fuel cap is not filled with debris.
C. Ensure that the fuel supply valve (if equipped) is in the full OPEN position.
D. If the temperature is below 0 °C (32 °F), check for solidified fuel (wax).
E. Check the primary filter/water separator for water in the fuel.
F. Check for fuel supply lines that are restricted.
G. Check that the low-pressure fuel lines are tight and secured properly.
H. Check that the Electric Priming Pump (EPP) is operating correctly.
I. Replace any filters and/or screens in the fuel system. Refer to Operation and Maintenance Manual for further information.
J. Check the diesel fuel for contamination. Refer to Systems Operation, Testing and Adjusting, "Fuel Quality - Test".
K. Check for air in the fuel system. Refer to Systems Operation, Testing and Adjusting, "Air in Fuel - Test".
L. Ensure that the fuel system has been primed. Refer to Systems Operation, Testing and Adjusting, "Fuel System - Prime".
Fuel system
Result: The fuel supply is not OK.
Repair: Repair the fuel system or replace the fuel system components, as necessary.
Result: The fuel supply is OK.
Proceed to Test Step 6.