5033080 JOHNSON *GASKET, INLET MANIFOLD

Illustration 1 g01075602
Schematic of the circuit for the throttle actuator
Test Step 1. Inspect the Electrical Connectors and WiringNote: This Test Step is important for troubleshooting a problem with instability.
Illustration 2 g01075604
Terminal box
(1) J2/P2 connectors for the ECM
(2) 16 amp circuit breaker
(3) J10/P10 connectors for the harness from the throttle actuator
Set the engine control to the OFF/RESET mode. Switch 16 amp circuit breaker (2) to the OFF position. Note: For the following steps, refer to Troubleshooting, "Inspecting Electrical Connectors".
Thoroughly inspect the following connectors:
J2/P2 connectors
J10/P10 connectors on the terminal box
Check the torque of the allen head screw for the ECM connector. The proper torque is 6 1 N m (55 9 lb in).
Illustration 3 g01075606
Harness side of the P2 connector
(P2-63) High side wire for the throttle actuator
(P2-64) Low side wire for the throttle actuator
Illustration 4 g00895202
Harness side of the P10 connector
(P10-C) High side wire for the throttle actuator
(P10-D) Low side wire for the throttle actuator
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the throttle actuator.
Illustration 5 g01075607
Throttle actuator
(4) Throttle actuator
(5) Connectors for the throttle actuator
Thoroughly inspect the connectors for the throttle actuator for moisture and for contamination. Check the harness and wiring for abrasion and for pinch points from the throttle actuator to the ECM. Expected Result:All of the connectors and terminals are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points.Results:
OK - The components are in good condition with proper connections. If you are troubleshooting a 1440-05 diagnostic code, proceed to Test Step 2. If you are troubleshooting a 1440-06 diagnostic code, proceed to Test Step 8.
Not OK - The components are not in good condition and/or at least one connection is improper.Repair: Perform the necessary repairs and/or replace parts, if necessary.STOPTest Step 2. Check the Solenoid and Harnesses for an Open Circuit
Set the engine control to the OFF/RESET mode. Switch the 16 amp circuit breaker OFF.
Disconnect the P2 connector.
Measure the resistance between terminals P2-63 and P2-64. During this measurement, wiggle the harnesses in order to check for an intermittent problem with the harness. Be sure to wiggle the harnesses near each of the connectors. Expected Result:The resistance is between 5.0 and 20.6 Ohms.Results:
OK - The resistance is between 5.0 and 20.6 Ohms. The solenoid and wiring appear to be OK. The low side wire may have a short to ground, or the ECM may have a problem. Proceed to Test Step 3.
Not OK - The resistance is higher than 20.6 Ohms. There is a problem with a connector and/or with the wiring for the solenoid, or the solenoid may have a problem. Proceed to Test Step 6.Test Step 3. Check All of the Low Side Wiring for a Short to Ground
Verify that the P2 connector is disconnected from the ECM.
Measure the resistance between the ground strap for the ECM and P2-64. During this measurement, wiggle the harnesses in order to check for an intermittent problem with the harness. Be sure to wiggle the harnesses near each of the connectors. Expected Result:The resistance is greater than 20,000 Ohms.Results:
OK - The resistance measurement is greater than 20,000 Ohms. The low side wire for the throttle actuator appears to be OK. Proceed to Test Step 12.
Not OK - The resistance measurement is less than 20,000 Ohms. There is a problem with the low side wire for the throttle actuator. Proceed to Test Step 4.Test Step 4. Check the Low Side Wiring inside the Engine Harness for a Short to Ground
Disconnect the P10 connector from the terminal box.
Measure the resistance between the ground strap for the ECM and terminal P10-D. During this measurement, wiggle the engine harness in order to check for an intermittent problem with the harness. Be sure to wiggle the harness near each of the connectors. Expected Result:The resistance is greater than 20,000 Ohms.Results:
OK - The resistance is greater than 20,000 ohms. The low side wire inside the engine harness appears to be OK. The low side wire inside the terminal box may have a problem. There may be a problem with a connector.Repair: Repair the harness and/or the connector, when possible. Replace parts, if necessary.STOP
Not OK - The resistance is less than 20,000 Ohms. The low side wire inside the engine harness may have a problem, or there may be a problem with the solenoid. Proceed to Test Step 5.Test Step 5. Check the Solenoid for an Internal Short Circuit
Disconnect the connector from the throttle actuator.
Illustration 6 g00895288
Throttle actuator
(1) Connector's shell
(2) Terminal B
Measure the resistance between the connector's shell and terminal B. Expected Result:The resistance is greater than 20,000 Ohms.Results:
OK - The resistance is greater than 20,000 Ohms. The solenoid does not have an internal short circuit. The low side wire inside the engine harness has a short to ground.Repair: Repair the engine harness or connectors, when possible. Replace parts, if necessary.STOP
Not OK - The resistance is less than 20,000 Ohms. The solenoid has an internal short circuit.Repair: Replace the solenoid. Refer to Operation and Maintenance Manual, "Electrohydraulic Actuator - Recondition".STOP