0438562 JOHNSON FUEL PUMP ASSY.

Illustration 1 g00896642
Typical exampleTest Step 1. Check for Connector Damage.
Turn the keyswitch to the OFF position.
Turn the breaker for the engine to the OFF position.
Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors. Refer to the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the circuit.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the customer connector (allen head screw) for the proper torque of 2.25 0.25 N m (20 2 lb in).
Check the harness and the wiring for abrasion and for pinch points.Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted. The harness and wiring should be free of corrosion, of abrasion or of pinch points.Results:
OK - The connectors and wiring are okay. Proceed to test step 2.
Not OK - The connectors and/or wiring are not okay.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Stop.Test Step 2. Check for "ACTIVE" Diagnostic Codes.
Connect the Caterpillar Electronic Technician (ET) to the ECM through the J60/P60 service tool connector.
Turn the breaker for the engine to the ON position.
Turn the keyswitch to the STOP position. The engine should be off.
Wait for 15 seconds for the CID-FMI.Expected Result:Determine the failure mode identifier (FMI). Determine if the diagnostic codes 262-03 5 Volt Sensor DC Power Supply short to +batt or 262-04 5 Volt Sensor DC Power Supply short to ground are present. Determine if the diagnostic codes 263-03 Digital Sensor Supply short to +batt or 263-04 Digital Sensor Supply short to ground are present.Results:
FMI 03 - A diagnostic code with a FMI of 03 is present. Proceed to test step 3.
FMI 04 - A diagnostic code with a FMI of 04 is present. Proceed to test step 4.
FMI 00 or 08 - A diagnostic code with a FMI of 00 or of 08 is present. Proceed to test step 11.
262-03 or 262-04 Active Code - A diagnostic code of 262-03 or of 262-04 is present.Repair: Perform the diagnostic functional test Troubleshooting, "Analog Sensor Supply". Stop.
263-03 or 263-04 Active Code - A diagnostic code of 263-03 or 263-04 is present.Repair: Perform the diagnostic functional test Troubleshooting, "Digital Sensor Supply". Stop.Test Step 3. Check the Sensor Supply Voltage at the Sensor Connector if the Diagnostic Code FMI-03 is Present.
Turn the keyswitch to the OFF position.
Disconnect the suspect sensor.Note: Disconnecting the sensor will generate an open circuit diagnostic code for any sensor that is disconnected. Troubleshoot the original diagnostic code. Reset the system. Delete the logged diagnostic codes when you are finished.
Turn the keyswitch to the STOP position. The engine should be off.
Measure the voltage on the ECM side of the sensor connector between pin A and pin B for the suspect sensor.Expected Result:The supply voltage should be 5.0 0.2 VDC for all analog sensors and 8.0 0.4 VDC for all digital sensors.Results:
OK - The voltage is 5.0 0.2 VDC for all analog sensors and 8.0 0.4 VDC for all digital sensors. Proceed to test step 5.
Not OK - The voltage is not 5.0 0.2 VDC for all analog sensors and 8.0 0.4 VDC for all digital sensors. Proceed to test step 7.Test Step 4. Check the Sensor Supply Voltage at the Sensor Connector if the Diagnostic Code FMI-04 is Present.
Turn the keyswitch to the OFF position.
Disconnect the suspect sensor.Note: Disconnecting the sensor will generate an open circuit diagnostic code for any sensor that is disconnected. Troubleshoot the original diagnostic code. Reset the system. Delete the logged diagnostic codes when you are finished.
Turn the keyswitch to the STOP position. The engine should be off.
Measure the voltage on the ECM side of the sensor connector between pin A and pin B for the suspect sensor.Expected Result:The supply voltage should be 5.0 0.2 VDC for all analog sensors and 8.0 0.4 VDC for all digital sensors.Results:
OK - The voltage is 5.0 0.2 VDC for all analog sensors and 8.0 0.4 VDC for all digital sensors. Proceed to test step 8.
Not OK - The voltage is not 5.0 0.2 VDC for all analog sensors and 8.0 0.4 VDC for all digital sensors. Proceed to test step 7.Test Step 5. Check for a Short to the + Battery.
Turn the keyswitch to the OFF position.
Disconnect the suspect sensor.Note: Disconnecting the sensor will generate an open circuit diagnostic code for any sensor that is disconnected. Troubleshoot the original diagnostic code. Reset the system. Delete the logged diagnostic codes when you are finished.
Turn the keyswitch to the STOP position. The engine should be off.
Measure the voltage on the ECM side of the sensor connector between pin B and the engine ground.
Measure the voltage on the ECM side of the sensor connector between pin C and the engine ground.
Turn the keyswitch to the OFF position.Expected Result:The voltage will measure 24 3 VDC when a short to the + Battery is present.Results:
OK - The voltage measures 24 3 VDC. A short to the + Battery is present.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Stop.
Not OK - The voltage on pin B should measure 0 VDC. The voltage on pin C may measure approximately 6.5 VDC. The voltage on pin C is a pull up voltage. The ECM provides the pull up voltage to the signal input when the ECM senses an open circuit in the incoming input signal. Frequency sensors do not receive a pull up voltage. The sensor common and signal wire are not shorted to the + Battery. Proceed to test step 6.Test Step 6. Create a Short at the Sensor Connector.
Turn the keyswitch to the OFF position.
Use a wire jumper to connect pin B and pin C together on the sensor connector.
Turn the keyswitch to the STOP position. The engine should be off.
Check if the CID-FMI has changed from 03 to