0438793 JOHNSON FUEL CONNECTOR ASSY.

Illustration 1 g00947900
Schematic
Illustration 2 g01095180
Top view of engine (typical example) (1) Connector for injector 1 J301/P301 (2) Connector for injector 2 J302/P302 (3) Connector for injector 3 J303/P303 (4) Connector for the injector harness J300/P300 (5) Connector for injector 4 J304/P304 (6) Connector for injector 5 J305/P305 (7) Connector for injector 6 J306/P306
Illustration 3 g01094158
P2 ECM connectorTop view of engine (typical example) (P2-36) "Injector cylinder 1" (P2-37) "Injector cylinder 2" (P2-38) "Injector cylinder 3" (P2-39) "Injector cylinder 4" (P2-44) Injector Return for Cylinder 1 (P2-45) Injector Return for Cylinder 2 (P2-46) Injector Return for Cylinder 3 (P2-47) Injector Return for Cylinder 4 (P2-54) "Injector cylinder 5" (P2-55) "Injector cylinder 6" (P2-57) Injector Return for Cylinder 5 (P2-58) Injector Return for Cylinder 6Test Step 1. Inspect Electrical Connectors and Wiring
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
Turn the keyswitch to the OFF position. A strong electrical shock hazard is present if the keyswitch is not turned OFF.
Thoroughly inspect the J2/P2 Electronic Control Module (ECM) connector and the J300/P300 injector harness connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector and the J300/P300 injector harness connector that are associated with the injector solenoids.
Check the allen head screw on each ECM connector and the customer connector for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
Check the J300/P300 injector harness connector for proper mating of the connector.
Check the harness and wiring for abrasions and for pinch points from the injectors to the ECM.Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted, and the harness and wiring are free of corrosion, of abrasion and of pinch points.Results:
OK - The harness and wiring are OK. Proceed to Test Step 2.
Not OK - There is a problem in the connectors and/or wiring.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.Verify that the repair eliminates the problem.STOPTest Step 2. Check for Diagnostic Codes Regarding Injector Solenoids
Connect Cat ET to the service tool connector.
Turn the keyswitch to the ON position.
Monitor the "Logged Diagnostic Codes" screen on Cat ET.Expected Result:One or more of the listed codes have been logged:
1-11
2-11
3-11
4-11
5-11
6-11Results:
OK - One or more of the codes that are listed above are logged. Proceed to Test Step 4.
Not OK - None of the codes that are listed above are logged. Proceed to Test Step 3.Test Step 3. Check the Variation of the Injectors between Cylinders
Start the engine.
Allow the engine to warm up to normal operating temperature (77 °C (171 °F)).
After the engine is warmed to operating temperature, access the "Cylinder Cutout Test" by accessing the following display screens in order:
"Diagnostics"
"Special Tests"
"Cylinder Cutout Test"
Shut off all parasitic loads such as the air compressors which could affect the results of the test.
Set the engine speed at low idle.
Use the cylinder cutout test in order to cut out individual cylinders.
Monitor the "Fuel Position" on the service tool display.
Perform the test three times.
Verify that cutting out a specific cylinder causes only a slight change to the "Fuel Position" of the other cylinders.
Compare the results that are found when other cylinders are cut out.Note: A mechanical problem with the injector or the cylinder may exist if a specific cylinder is cut out and only a slight change occurs to the "Fuel Position" of the other cylinders.
Check Cat ET for any active diagnostic codes or any logged diagnostic codes that are new after the test.Expected Result:One or more diagnostic codes for the injectors are active or logged as a result of the cylinder cutout test.Results:
OK - One or more diagnostic codes for the injectors are active or logged as a result of the cylinder cutout test. Proceed to Test Step 4.
Not OK - The injectors are OK electronically.Repair: Refer to Testing and Adjusting, "Fuel System" for additional information.STOPTest Step 4. Use the "Injector Solenoid Test" to Test the Injector Solenoids
Start the engine.
Allow the engine to warm up to normal operating temperature (77 °C (171 °F)).
Turn the keyswitch to the OFF position.
Turn the keyswitch to the ON position.
After the engine is warmed to operating temperature, access the "Injector Solenoid Test" by accessing the following display screens in order:
"Diagnostics"
"Diagnostic Tests"
"Injector Solenoid Test"
Activate the test.Note: The test is in the "Diagnostic Tests". Do not confuse the "Injector Solenoid Test" with the cylinder cutout test. The cylinder cutout test is used to shut off fuel to a specific cylinder while the engine is running. The injector solenoid test is used in order to actuate the injector solenoids. This allows the click of the injector solenoids to be heard when the engine is not running in order to determine that the circuit is functioning properly.
As each solenoid is energized by the ECM an audible click can be heard at the valve cover. Listen for a click at each valve cover. A black square will appear over the cylinder number when the cylinder is being fire