0438864 JOHNSON ENGINE COVER ASSY.

Illustration 1 g00674973
SchematicTest Step 1. Inspect Electrical Connectors and Wiring.
Turn the keyswitch to the OFF/RESET position.
Thoroughly inspect ECM connector J1/P1, ECM connector J2/P2, machine connector J3/P3, and all other connectors in the wiring harness. 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 abrasions, 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 circuit.Verify that the repair eliminates the problem.STOPTest Step 2. Check the Resistance of the Solenoids
Turn the keyswitch to the OFF/RESET position.
Disconnect the connectors to the solenoids for the system.
Use a multimeter to measure the resistance across each solenoid.Expected Result:The resistance across each solenoid is between 30 Ohms and 65 Ohms.Results:
OK - Proceed to Test Step 3.
Not OK - The suspect solenoid is faulty.Repair: Replace the suspect solenoid.Verify that the repair eliminates the problem.STOPTest Step 3. Check the Supply Voltage to Each of the Solenoids
Disconnect the connectors for the lower warm up solenoid and the upper warm up solenoid.
Start the engine.
Use a multimeter to measure the voltage between terminal 1 of the upper solenoid's connector and chassis ground. This must be performed when the warm-up is activated. Use a multimeter to measure the voltage between terminal 1 of the lower solenoid's connector and chassis ground when the system is activated.
Turn the keyswitch to the OFF/RESET position.Expected Result:The supply voltage to both connectors is 24.0 8.0 VDC.Results:
OK - Proceed to Test Step 4.
Not OK - The solenoids are not receiving the correct signal. Proceed to Test Step 5.
One OK and One Not OK - There is a problem in the wiring between the connector for the suspect warm up solenoid and the connection to E761-BU.Repair: Repair the circuit.Verify that the repair eliminates the problem.STOPTest Step 4. Check the Ground to the Solenoids
Disconnect the connectors for the lower warm up solenoid and the upper warm up solenoid.
Use a multimeter to check for continuity between the terminal 2 on the connector for the upper solenoid and chassis ground. Use a multimeter to check for continuity between terminal 2 on the connector for the lower solenoid and chassis ground.Expected Result:The resistance is less than 10 Ohms at both connectors.Results:
OK - The suspect solenoid is faulty.Repair: Replace the suspect solenoid.Verify that the repair eliminates the problem.STOP
Not OK - The ground for the solenoids is faulty.Repair: Repair the circuit.Verify that the repair eliminates the problem.STOP
One OK and One Not OK - There is a problem in the wiring between the connector for the suspect warm up solenoid and the connection to 200-BK.Repair: Repair the circuit.Verify that the repair eliminates the problem.STOPTest Step 5. Check the Resistance of the Relay
Illustration 2 g00675569
Connector for the relay
Turn the keyswitch to the OFF/RESET position.
Unplug the relay for the system's.
Use a multimeter to measure the resistance across terminal 87 (Solenoid Power) and terminal 85 (Solenoid Return).Expected Result:The resistance is between 250 Ohms and 500 Ohms.Results:
OK - Proceed to Test Step 6.
Not OK - The relay is faulty.Repair: Replace the relay.Verify that the repair eliminates the problem.STOPTest Step 6. Check the Output Voltage of the Relay
Illustration 3 g00675569
Relay connector
Ensure that all connectors are connected to the wiring harness.
Start the engine.
Use a multimeter to measure the voltage between terminal 87 (Solenoid Power) of the relay and chassis ground.
Turn the keyswitch to the OFF/RESET position.Expected Result:The voltage is 24.0 8.0 VDC.Results:
OK - There is a problem in the wiring between output of the relay and the solenoids.Repair: Repair the circuit.Verify that the repair eliminates the problem.STOP
Not OK - Proceed to Test Step 7.Test Step 7. Check the Power Supply to the Relay
Illustration 4 g00675569
Relay connector
Use a multimeter to measure the voltage across terminal 30 (+ Battery) and chassis ground.
Turn the keyswitch to the OFF/RESET position.Expected Result:The voltage is 24.0 8.0 VDC.Results:
OK - Proceed to Test Step 8.
Not OK - There is a problem in the wiring between the relay and the +Battery.Repair: Repair the circuit.Verify that the repair eliminates the problem.STOPTest Step 8. Check the Signal Voltage to the Relay
Illustration 5 g00675569
Relay connector
Ensure that all connectors are connected to the wiring harness.
Start the engine.
Use a multimeter to measure the voltage between terminal 86 (Control Valve Warm Up) of the relay and terminal 85 (Solenoid Return) of the relay.
Turn the keyswitch to the OFF/RESET position.Expected Result:The voltage is 24.0 8.0 VDC.Results:
OK - The relay is faulty.Repair: Replace the relay.Verify that the repair eliminates the problem.STOP
Not OK - Proceed to Test Step 9.Test Step 9. Check for Shorts in the Harness between the Relay and the ECM