0383001 JOHNSON GEARCASE ASSEMBLY,Complete

Illustration 1 g01423833
Typical example of the electronic unit injector
Test Step 1. Check for Diagnostic Codes that are Related to this Procedure
Connect the electronic service tool to the diagnostic connector.
Turn the keyswitch to the ON position.
Check for logged diagnostic codes that are related to this procedure.
Make a note of the logged diagnostic codes. Expected Result:Expected Result 1One or more of the following diagnostic codes are logged:
1-2 Cylinder #1 Injector erratic, intermittent, or incorrect
2-2 Cylinder #2 Injector erratic, intermittent, or incorrect
3-2 Cylinder #3 Injector erratic, intermittent, or incorrect
4-2 Cylinder #4 Injector erratic, intermittent, or incorrect
5-2 Cylinder #5 Injector erratic, intermittent, or incorrect
6-2 Cylinder #6 Injector erratic, intermittent, or incorrect Expected Result 2On six cylinder engines, three injectors that share a common supply indicate a diagnostic code.Note: Injectors 1, 2 and 3 share a common injector driver circuit in the ECM. Injectors 4, 5 and 6 share a common driver circuit in the ECM. If three injectors that share a common supply indicate a diagnostic code then this is probably caused by a faulty ECM.Results:
OK - Result 1 One or more diagnostic codes are logged. Proceed to Test Step 2.
OK - Result 2 Three injectors that share a common supply indicate a diagnostic code. Proceed to Test Step 3.
Not OK - No related diagnostic codes are logged.STOPTest Step 2. Check the Faulty Cylinder Numbers
Use the electronic service tool in order to make a note of the logged diagnostic codes.
Use the noted diagnostic codes in order to check the cylinders for faulty injectors. Expected Result:The diagnostic codes indicate the cylinder numbers that have faulty injectors.Results:
OK - No related diagnostic codes are logged.STOP
Not OK - The diagnostic codes indicate the cylinder numbers that have faulty injectors.Repair: Replace the faulty injectors.Use the electronic service tool in order to program the trim file for the replacement injector. Refer to Troubleshooting, "Injector Trim File" for further information.Use the electronic service tool in order to clear the logged codes.Turn the keyswitch to the ON position.Start the engine.Use the electronic service tool in order to perform the "Fuel System Verification Test". If the cylinders indicate "PASS", then the fault has been cleared.STOPTest Step 3. Check the ECM
Make sure that the latest flash file for the application is installed in the ECM. Refer to Troubleshooting, "Flash Programming".
Use the electronic service tool in order to perform the "Fuel System Verification Test". Verify that the test eliminates the fault. Note: The "Fuel System Verification Test" will indicate if the cylinder has a "Pass" or "Fail". If the cylinders indicate "Pass" then the fault has been cleared.Expected Result:The test ECM clears the fault. The "Fuel System Verification Test" with the suspect ECM indicates a "FAIL" condition.Results:
OK - A new flash file eliminates the fault.STOP
Not OK - A new flash file did not eliminate the fault.Repair: Perform the following procedure:
Use the electronic service tool to check for active diagnostic codes.
If diagnostic codes are still active, contact the technical communicator at the Caterpillar dealer. Note: This consultation can greatly reduce the repair time.
If necessary, install a test ECM. Refer to Troubleshooting, "Replacing the ECM".
Use the electronic service tool in order to perform the "Fuel System Verification Test".
If the fault is eliminated with the test ECM, reconnect the suspect ECM. Verify that the active diagnostic code returns.
If the active diagnostic code returns with the suspect ECM, replace the ECM. STOP