5032241 JOHNSON HOSE, WATER RETURN

Illustration 1 g01222822
Schematic for the injector solenoids
Test Step 1. Inspect the Electrical Connectors and the Wiring
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
Remove the electrical power from the ECM.
Illustration 2 g01200438
Left side engine view (typical example)
(1) J2/P2 ECM connector
(2) J300/P300 Injector valve cover entry connector
Thoroughly inspect connectors (1) and (2). Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".
Illustration 3 g01099568
Terminal locations at the P2 ECM connector
(P2-99) Injector 5 & 6 supply
(P2-104) Injector 1 & 2 supply
(P2-105) Injector 6 return
(P2-106) Injector 3 return
(P2-107) Injector 5 return
(P2-108) Injector 4 return
(P2-115) Injector 3 & 4 supply
(P2-116) Injector 1 return
(P2-118) Injector 2 return
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector and each of the wires that are associated with injector solenoids.
Check the allen head screw on each ECM connector for the proper torque. Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".
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. The harness and wiring are free of corrosion, of abrasion, and of pinch points.Results:
OK - The connectors and the wiring appear to be OK. Proceed to Test Step 2.
Not OK - There is a problem with 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 for the Injector Solenoids
Connect Cat ET to the data link connector. Refer to electronic troubleshooting Troubleshooting, "Electronic Service Tools".
Restore the electrical power to the ECM.
Check for logged diagnostic codes for the injector solenoids on Cat ET. Expected Result:There are no logged diagnostic codes for the injector solenoids.Results:
OK - No diagnostic codes have been logged. The injector solenoids are operating correctly. There may be a mechanical problem with the injector's fuel delivery. Proceed to Test Step 3.
Not OK - One or more diagnostic codes have been logged. There may be an electrical problem in the circuit for the injector. Proceed to Test Step 4.Test Step 3. Perform the "Cylinder Cutout Test"
Start the engine.
Allow the engine to warm up to normal operating temperature (approximately 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"
"Diagnostic Tests"
"Cylinder Cutout Test"
Shut off all parasitic loads such as the air conditioning and the air compressors which could affect the results of the test.
Select the start button at the bottom of the screen for the cylinder cutout test on Cat ET.
Follow the instructions that are provided in the cylinder cutout test. The cylinder cutout tests are interactive so the procedure is guided to the finish. The cylinder cutout test will set the correct engine speed for the application. Expected Result:The variation of the fuel rate for all cylinders is within specifications.Results:
OK - The cylinder cutout test indicates that all of the injectors are operating correctly.Repair: If a problem with the fuel system is suspected and diagnostic codes are not active