0438324 JOHNSON ENGINE COVER ASSY.

Illustration 1 g00671263
SchematicTest Step 1. Inspect Electrical Connectors and Wiring
Turn the keyswitch to the OFF/RESET position.
Thoroughly inspect the J2/P2 ECM connector, the J3/P3 machine connector, and the J113/P113 power shift solenoid connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Inspect the following components for damage, corrosion, and incorrect attachment:
Battery posts
Alternator
Breaker
Engine ground
Chassis groundExpected Result:All connectors, pins, and sockets are completely inserted and coupled. The harness and wiring are free of corrosion, of abrasion, and of pinch points. All connections and grounds are tight and free of corrosion.Results:
OK - Proceed to Test Step 2.
Not OK - Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and that the connectors are completely coupled.Verify that the repair eliminates the problem. Stop.Test Step 2. Perform the "Power Shift Pressure Solenoid Test"
Turn the keyswitch to the OFF/RESET position.
Disconnect the J113/P113 Power shift solenoid connector.
Connect Cat ET to the data link connector.
Turn the keyswitch to the ON position.
Activate the "Power Shift Pressure Solenoid Test" on Cat ET.
Use a voltage test lamp between the two terminals of the J113/P113 Power shift solenoid connector.Expected Result:The voltage test lamp illuminated when the "Power Shift Pressure Solenoid Test" was activated on Cat ET.Results:
OK - The voltage test lamp illuminated. Proceed to Test Step 3.
Not OK - The voltage test lamp did not illuminate. Proceed to Test Step 4.Test Step 3. Check the Solenoid for an Internal Short or Open
Disconnect the J113/P113 Power shift solenoid connector.
Measure the resistance between P113:1 and P113:2.Expected Result:The resistance is between 7 Ohms and 17 Ohms.Results:
OK - Proceed to Test Step 4.
Not OK - The solenoid is faulty.Repair: Replace the solenoid.Verify that the repair eliminates the problem. Stop.Test Step 4. Check the Resistance Through the Harness
Illustration 2 g00671736
ECM connector P2 (wire side)
Disconnect the J2/P2 ECM connector.
Use a suitable piece of wire to short P2:13 (Power Shift Solenoid) to P2:7 (Solenoid Return).
Measure the resistance between J113:1 and J113:2.
Remove the wire short.Expected Result:The resistance is less than 10 Ohms.Results:
OK - Proceed to Test Step 5.
Not OK - There is an open circuit or there is excessive resistance in the harness.Repair: Repair the circuit.Verify that the repair eliminates the problem. Stop.Test Step 5. Check For Shorts In Harness
Turn the keyswitch to the OFF/RESET position.
Disconnect the J2/P2 ECM connector and the J113/P113 Power shift solenoid connector.
Measure the resistance between engine ground and each terminal of J113 Power shift solenoid connector.
Measure the resistance between both terminals of J113 Power shift solenoid connector.Expected Result:Resistance is greater than 20,000 Ohms for each reading.Results:
OK - Proceed to Test Step 6.
Not OK - There is a short in the harness between the ECM and the power shift solenoid.Repair: Repair the circuit.Verify that the repair eliminates the problem. Stop.Test Step 6. Check the Voltage for the Solenoid at the ECM
Reconnect all connectors.
Connect Cat ET to the data link connector.
Start the engine.
Ensure that the keyswitch is in the ON position.
Check for any active diagnostic codes.Expected Result:The following diagnostics are not active:
581:05 Power Shift Solenoid open circuit
581:06 Power Shift Solenoid short to groundResults:
OK - The solenoid and the harness are OK.Repair: If the system does not function properly refer to Troubleshooting, "Unstable Hydraulic Function". Stop.
Not OK - The ECM is faulty.Repair: Replace the ECM. Refer to Troubleshooting, "Replacing the ECM".Verify that the repair eliminates the problem. Stop.