0584120 JOHNSON LEAD ASSEMBLY, Ground

Illustration 1 g00983926
Illustration 2 g00725481
Throttle Position Versus PWM Input
Illustration 3 g00725482
Stops for the throttle position sensor
Test Step 1. Check for Connector Damage.
Disconnect the main power.
Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors. Refer to 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 2.25 0.25 N m (20 2 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 for pinch points. Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted, and the harness and wiring should be free of corrosion, of abrasion or of 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.STOPTest Step 2. Check the Throttle Position Sensor Supply Voltage at the Sensor.
Turn the ECS to the STOP position. The engine should be OFF.
Disconnect the throttle position sensor.
Measure the voltage at J35-A with reference to J35-B. Expected Result:The voltage should be approximately 24 3 VDC.Results:
OK - The voltage is approximately 24 3 VDC. The throttle position sensor is receiving the correct voltage. Proceed to Test Step 3.
Not OK - The voltage is not 24 3 VDC. The sensor is not receiving the correct voltage. Proceed to Test Step 6.Test Step 3. Check the Throttle Position Sensor Duty Cycle at the Sensor Connector.
Illustration 4 g00725507
Remove the signal wire for the throttle position sensor from connector J35/P35.
Remove pin C from the connector P35. Place the red probe of the multimeter on pin C. Place the black probe of the multimeter on the − Battery terminal.
Set the multimeter to "VDC".
Press the "HZ" button twice so the % symbol is displayed.
Measure the percent duty cycle of the throttle position sensor. Move the throttle from LOW idle position to HIGH idle position. Expected Result:The duty cycle should be 5 to 10 percent at the low idle position. The duty cycle should be 90 to 95 percent when the handle is fully activated.Results:
OK - The duty cycle is 5 to 10 percent at the low idle position. The duty cycle is 90 to 95 percent when the handle is fully activated. Proceed to Test Step 4.
Not OK - The duty cycle is 0 percent or the duty cycle does not change smoothly.Repair: Replace the throttle position sensor. Perform the diagnostic functional test Troubleshooting, "Throttle Position Sensor - Calibrate" after you replace the sensor.STOP
Not OK - The duty cycle is changing but the duty cycle does not reach the low idle and/or the high idle positions.Repair: Recalibrate the sensor so that the duty cycle is 5 to 10 percent at the low idle stop and the duty cycle is 90 to 95 percent at the high idle stop. Refer to the diagnostic functional test Troubleshooting, "Throttle Position Sensor - Calibrate".STOPTest Step 4. Check the Throttle Position Sensor Duty Cycle at the J3 Customer Connector.
Reinsert pin C into the connector for the throttle position sensor P35.
Remove pin J3-03 from the customer connector J3 for the port engine.
Use a multimeter and place the red probe on J3-03. Place the black probe on the − Battery terminal.
Measure the percent duty cycle of the throttle position sensor. Move the throttle from LOW idle position to HIGH idle position. Expected Result:The duty cycle should be 5 to 10 percent at the low idle position. The duty cycle should be 90 to 95 percent at the high idle stop.Results:
OK - The duty cycle is 5 to 10 percent at the low idle position. The duty cycle is 90 to 95 percent at the high idle stop. Proceed to Test Step 5.
Not OK - The duty cycle is 0 percent or the duty cycle does not change smoothly.Repair: Replace the wire from P35-C to J3-03.STOPTest Step 5. Check the Throttle Position Sensor Duty Cycle at the ECM Connector.
Turn the ECS to the OFF position.
Remove the ECM connector P2 from the primary ECM. Remove the signal wire P2-24 for the throttle position sensor from the ECM connector P2.
Reconnect the ECM connector J2/P2.
Place the red probe on the wire that was removed from P2-24 of the ECM connector P2. Place the black probe on the − Battery terminal.
Measure the percent duty cycle of the throttle position sensor. Move the throttle from LOW idle position to HIGH idle position.
Replace all connectors and wires. Expected Result:The duty cycle should be 5 to 10 percent at the low idle stop. The duty cycle should be 90 to 95 percent at the high idle stop.Results:
OK - The Duty Cycle and Throttle Position readings are correct.Repair: Temporarily replace the ECM and perform the test again. If the problem is resolved, the ECM is faulty. Permanently replace the ECM. Refer to the diagnostic procedure Troubleshooting, "Replacing the ECM".STOP
Not OK - The duty cycle reading is not correct. The throttle position signal is not reaching the ECM.Repair: Replace the wire from J3-03 to J2-24. Verify that the repair eliminates the problem.STOPTest Step 6. Check the Voltage from the "EMS relay" to the Throttle Position Sensor.
Turn the ECS to the STOP position.
Measure the voltage between terminal 30 on the "EMS relay" and the − Battery terminal. Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC.Repair: Repair the connectors or wiring and/or replace the connectors or wiring between the "EMS relay" and the throttle position sensor. Check for voltage at TB-18 and the connector for the instrument box. Refer to Illustration 1 as a reference.STOP
Not OK - The voltage does not measure 24