0582044 JOHNSON JUNCTION BOX & COVER

The following background information is related to this procedure:Injector codes are seven digit alphanumeric codes that are supplied with each injector. The code is printed on each injector. The code is used by the ECM to balance the performance of the injectors.Refer to Troubleshooting, "Injector Code - Calibrate" for further information.
Illustration 1 g02738616
Typical example of an electronic unit injector
(1) Location of the injector code
Table 2
Troubleshooting Test Steps Values Results
1. Check for Diagnostic Codes That Are Related to this Procedure
A. Connect the electronic service tool to the diagnostic connector.
B. Turn the keyswitch to the ON position.
C. Check for any active diagnostic codes that are listed in Table 1.
D. Make a note of the active diagnostic codes.
Diagnostic codes
Result: A 630-2 diagnostic code is active.
Proceed to Test Step 2.
Result: An XXX-20 or XXX-21 diagnostic code is active.
Proceed to Test Step 4.
2. Enter the Injector Codes Using the Electronic Service Tool
A. Connect the electronic service tool to the diagnostic connector. Refer to Troubleshooting, "Electronic Service Tools".
B. Turn the keyswitch to the ON position.
C. Manually enter the injector codes using the electronic service tool. Refer to Troubleshooting, "Injector Code - Calibrate".
D. Use the electronic service tool to clear all active diagnostic codes.
E. Start the engine.
F. Use the electronic service tool to check for active diagnostic codes.
G. Turn the keyswitch to the OFF position.
Diagnostic codes
Result: The 630-2 diagnostic code is no longer active.
Return the engine to service.
Result: The 630-2 diagnostic code is still active.
Proceed to Test Step 3.
3. Re-Flash the ECM
A. Reflash the ECM. Refer to Troubleshooting, "ECM Software - Install".
B. Ensure that all of the injector codes are programmed. Refer to Troubleshooting, "Injector Code - Calibrate".
C. Use the electronic service tool to clear all active diagnostic codes.
D. Start the engine.
E. Use the electronic service tool to check for active diagnostic codes.
Diagnostic codes
Result:The 630-2 diagnostic code is no longer active.
Return the engine to service.
Result: The 630-2 diagnostic code is still active
Proceed to Test Step 7.
4. Check the Oxygen Sensor for Faults
A. Connect the electronic service tool to the diagnostic connector.
B. Turn the keyswitch to the ON position.
C. Check for active or recently logged diagnostic codes for the oxygen sensor.
10 V to 14 V
Result: There are no diagnostic codes for the oxygen sensor.
Proceed to Test Step 5.
Result: There are diagnostic codes for the oxygen sensor
Troubleshoot the oxygen sensor before returning to this procedure. Refer to Troubleshooting, "Oxygen Level - Test".
5. Enter the Injector Code for the Suspect Cylinder
A. Connect the electronic service tool to the diagnostic connector. Refer to Troubleshooting, "Electronic Service Tools".
B. Turn the keyswitch to the ON position.
C. Manually enter the injector code for the suspect cylinder using the electronic service tool. Refer to Troubleshooting, "Injector Code - Calibrate".
D. Use the electronic service tool to clear all active diagnostic codes.
E. Start the engine.
F. Use the electronic service tool to check for active diagnostic codes.
G. Turn the keyswitch to the OFF position.
Diagnostic codes
Result: There are no active XXX-20 or XXX-21 diagnostic codes for the injectors.
Return the engine to service.
Result: The XXX-20 or XXX-21 diagnostic code is still active.
Proceed to Test Step 6.
6. Replace the Suspect Injector
A. Replace the injector for the cylinder with the XXX-20 or XXX-21 diagnostic code. Refer to Disassembly and Assembly, "Electronic Unit Injector - Remove" and refer to Disassembly and Assembly, "Electronic Unit Injector - Install".
B. Use the electronic service tool to input the code for the new injector. Refer to Troubleshooting, "Injector Code - Calibrate".
C. Use the electronic service tool to check for active diagnostic codes.
Diagnostic Codes
Result: There are no active XXX-20 or XXX-21 diagnostic codes for the injectors.
Return the engine to service.
Result: The XXX-20 or XXX-21 diagnostic code is still active.
Proceed to Test Step 7.
7. Check if a Replacement ECM Eliminates the Fault
A. Contact the Dealer Solution Network (DSN).
B. If the DSN recommends the use of a replacement ECM, install a replacement ECM. Refer to Troubleshooting, "Replacing the ECM".
C. Use the electronic service tool to recheck the system for active diagnostic codes.
Diagnostic codes
Result: There are no active diagnostic codes with the replacement ECM.
Reconnect the suspect ECM. If the fault returns with the suspect ECM, replace the ECM.
Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault.
Result: The diagnostic code is still present with the replacement ECM.
Contact the DSN.