5031911 JOHNSON *FUSE (25A)

Illustration 1 g01171623
Typical schematic for the 3500 engines
Illustration 2 g01152207
P2 terminals that are associated with the injector solenoids
(P2-1) Injector cylinder #1 signal
(P2-2) Injector cylinder #1 return
(P2-3) Injector cylinder #2 signal
(P2-4) Injector cylinder #2 return
(P2-40) Injector cylinder #3 signal
(P2-41) Injector cylinder #3 return
(P2-42) Injector cylinder #4 signal
(P2-43) Injector cylinder #4 return
(P2-14) Injector cylinder #5 signal
(P2-15) Injector cylinder #5 return
(P2-16) Injector cylinder #6 signal
(P2-17) Injector cylinder #6 return
(P2-48) Injector cylinder #7 signal
(P2-49) Injector cylinder #7 return
(P2-50) Injector cylinder #8 signal
(P2-51) Injector cylinder #8 return
(P2-24) Injector cylinder #9 signal
(P2-25) Injector cylinder #9 return
(P2-34) Injector cylinder #10 signal
(P2-35) Injector cylinder #10 return
(P2-58) Injector cylinder #11 signal
(P2-59) Injector cylinder #11 return
(P2-52) Injector cylinder #12 signal
(P2-62) Injector cylinder #12 return
(P2-32) Injector cylinder #13 signal
(P2-33) Injector cylinder #13 return
(P2-60) Injector cylinder #14 signal
(P2-61) Injector cylinder #14 return
(P2-5) Injector cylinder #15 signal
(P2-18) Injector cylinder #15 return
(P2-26) Injector cylinder #16 signal
(P2-27) Injector cylinder #16 return Test Step 1. Inspect the Electrical Connectors and Wiring
Turn the engine battery disconnect switch to the OFF position.
Turn the engine control to the OFF/RESET mode.
Thoroughly inspect the ECM connector J2/P2. Inspect all of the connectors that are associated with the circuit. 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 allen head screw on each ECM connector for the proper torque. Refer to Troubleshooting, "Inspecting Electrical Connectors" for the correct torque values.
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, and the harness and wiring are free of corrosion, of abrasion and of pinch points.Results:
OK - The connectors 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 Logged Diagnostic Codes
Connect Cat ET to the service tool connector.
Turn the engine battery disconnect switch to the ON position.
Turn the engine control to the STOP mode.
Check for logged diagnostic codes for the injector solenoids on Cat ET. Expected Result:No 1-05 to 16-05 or 1-06 to 16-06 are logged.Results:
OK - No 1-05 to 16-05 or 1-06 to 16-06 are logged. Proceed to Test Step 3.
Not OK - A 1-05 to 16-05 is logged. Proceed to Test Step 4.
Not OK - A 1-06 to 16-06 is logged. Proceed to Test Step 5.Test Step 3. Perform the "Cylinder Cutout Test"
Engine power is reduced when a properly functioning cylinder is cut out. Make sure that you will not damage auxiliary or driven equipment if the engine power is suddenly reduced.
Turn the engine battery disconnect switch to the OFF position.
Turn the engine control to the OFF/RESET mode.
Verify that the ECM connector J2/P2 and the injector connectors J301/P301 through J316/P316 are properly connected.
Turn the engine battery disconnect switch to the START position.
Turn the engine control to the STOP mode.
Start the engine.
Apply a load to the engine.
Perform the following steps on all suspect cylinders (solenoids).
Use the diagnostic tests on the Cat ET to initiate the "Cylinder Cutout Test".
Disconnect any suspect cylinders and run the "Cylinder Cutout Test". Expected Result:The results indicated that the remaining injectors used mor