0581392 JOHNSON LEAD ASSEMBLY, Ground

Illustration 1 g00621954
Test Step 1. Check for Connector Damage.
Turn the circuit breaker for the battery to the OFF position.
Turn the ECS to the OFF/RESET position.
Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors. Perform 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 ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the customer connector (allen head screw) for the proper torque of 2.25 0.25 N m (20 2 lb in).
Check the harness and the wiring for abrasion and pinch points.Expected Result:Ensure that all connectors, pins, and sockets have good electrical connections. The harness and wiring should be free of corrosion, abrasion or pinch points.Results:
OK - The connectors and wiring are okay. Proceed to test step 2.
Not OK - The connectors and/or wiring need repair.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Stop.Test Step 2. Check for LOGGED Diagnostic Codes.
Connect the Caterpillar Electronic Technician (ET).
Turn the circuit breaker for the battery to the ON position.
Turn the ECS to the STOP position.
Observe the diagnostic codes on the Cat ET.Expected Result:A CID-FMI from 1-05 to 12-05 or from 1-06 to 12-06 should not be logged.Results:
OK - A CID-FMI from 1-05 to 12-05 or from 1-06 to 12-06 is not logged. Proceed to test step 3.
Not OK - A CID-FMI from 1-05 to 12-05 or from 1-06 to 12-06 is logged. Proceed to test step 4.Test Step 3. Perform the Injector Solenoid Test.Note: This test will help the service technician verify that the ECM can fire the solenoids. DO NOT try to manually crank the engine during this test. The ECM will terminate the Injector Solenoid Test.
Perform this test on both Electronic Control Modules.
Turn the circuit breaker for the battery to the OFF position.
Turn the ECS to the OFF/RESET position.
Ensure that the ECM connector J2/P2 is connected. Ensure that the injector connectors J4/P4 through J15/P15 are connected.
Connect the Cat ET.
Turn the circuit breaker for the battery to the ON position.
Turn the ECS to the STOP position.
Use Diagnostic Tests on the Cat ET to initiate the Injector Solenoid Test.
As each solenoid is energized by the ECM an audible click can be heard at the valve cover. Listen for a click at each valve cover. A black square will appear over the cylinder number when the cylinder is being fired.Note: A false reading may result from the initial test. By the fourth consecutive test, the readings should become valid.
Perform this test on the Secondary ECM also.Expected Result:As each solenoid is energized by the ECM, an audible click of the solenoid should be heard. The solenoids will be energized one at a time in the following numerical order: 1-12. There will be momentary delay between each one.Results:
OK - As each solenoid is energized an audible click is heard. Proceed to test step 5.
Not OK - Verify that the ECM is receiving correct battery power.Repair: Perform the diagnostic functional test Troubleshooting, "Electrical Power Supply". Stop.Test Step 4. Check for a Short between Wires in the Harness.
This engine uses high voltage to control the fuel injectors.Disconnect the fuel enable circuit connector to prevent personal injury.Do not come in contact with the fuel injector terminals while the engine is running.
Turn the circuit breaker for the battery to the OFF position.
Turn the ECS to the OFF/RESET position.
Disconnect J2/P2 and J4/P4 through J15/P15.
Measure the resistance between the solenoid wire pairs at the ECM connector P2.For an engine with twelve cylinders, measure the resistance at the following points:
Measure the resistance for SOLENOID 1 at P2-16 and P2-5.
Measure the resistance for SOLENOID 2 at P2-40 and P2-11.
Measure the resistance for SOLENOID 3 at P2-26 and P2-5.
Measure the resistance for SOLENOID 4 at P2-34 and P2-11.
Measure the resistance for SOLENOID 5 at P2-32 and P2-17.
Measure the resistance for SOLENOID 6 at P2-28 and P2-21.
Measure the resistance for SOLENOID 7 at P2-38 and P2-17.
Measure the resistance for SOLENOID 8 at P2-22 and P2-21.
Measure the resistance for SOLENOID 9 at P2-37 and P2-27.
Measure the resistance for SOLENOID 10 at P2-18 and P2-33.
Measure the resistance for SOLENOID 11 at P2-31 and P2-27.
Measure the resistance for SOLENOID 12 at P2-12 and P2-33.Expected Result:The resistance should be greater than 20,000 Ohms.Results:
OK - The resistance is greater than 20,000 Ohms. Proceed to test step 6.
Not OK - The resistance is less than 20,000 Ohms. There is a problem in the wiring harness.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Stop.Test Step 5. 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 circuit breaker for the battery to the OFF position.
Turn the ECS to the OFF/RESET position.
Verify that the ECM connector J2/P2 and the injector connectors J4/P4 through J15/P15 are properly connected.
Turn the circuit breaker for the battery to the ON position.
Install the Cat ET.
Start the engine.
Apply a load to the engine.
Use the diagnostic tests on the Cat ET to initiate the injector solenoid test.
Check for a difference in the sound, feel, or power of the engine as each cylinder is cut out. The amount of change should be similar for all of the good cylinders. The amount of change should be minimal for a weak cylinder or a bad cylinder.
Disable the override. Repeat above steps for each cylinder (solenoid).Expected Result:The amount of change should be similar for all of the good cylinders. The amount of change should be minimal for a weak cylinder or a bad cylinder.Results:
OK - There was a similar change in the sound, feel, or power of the engine as each cylinder was cut out. The injectors are okay. Stop.
Not OK - There was no change in the sound, feel, or power of the engine as each cylinder was cut out. Proceed to test