0389821 JOHNSON LEVER,Throttle

Illustration 1 g01056784
Typical schematic
Illustration 2 g01092097
P1 ECM connector
(P1-41) Diagnostic reset switch
(P1-46) Droop
(P1-47) Low idle switch Test Step 1. Inspect Electrical Connectors and Wiring
Turn the Engine Control Switch (ECS) to the OFF/RESET position.
Thoroughly inspect the ECM connector J1/P1. Inspect all of the other connectors. Refer to Troubleshooting, "Electrical Connectors - Inspect" 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. Refer to Illustration 1.
Check the ECM connector J1/P1 for the proper torque of 6.0 N m (55 lb in).
Check the harness and wiring for abrasions and for pinch points. Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted, and the harness and wiring are free of corrosion, of abrasion and of pinch points.Results:
OK - The connectors and wiring are OK. Proceed to Test Step 2.
Not OK - There is a problem with the electrical 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.Repair CompleteTest Step 2. Verify the Negative Battery Connections
Locate the negative battery bus bars and verify that the connections are installed properly. Expected Result:The negative battery connections have been properly installed.Results:
OK - The connections for the negative battery bus bar have been installed properly. Proceed to Test Step 3.
Not OK - Repair: Make the necessary connections in order to ensure proper installation.STOPTest Step 3. Check the Status of the Switch
Connect the electronic service tool to the service tool connector.
Turn the ECS to the COOLDOWN/STOP position.
Monitor the status screen on the electronic service tool while each switch is cycled. Expected Result:Each switch is displayed as "ON" and "OFF" when the switch is cycled.Results:
OK - The switches are operating properly.Repair: The problem may be intermittent. If the problem is intermittent, refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - There is a problem with the wiring or the switch. Proceed to Test Step 4.Test Step 4. Bypass the Switch
Make a jumper wire that is 100 mm (4 inch) long. Use two 9W-0852 Connector Pin on the ends of the wire.
Turn the ECS to the OFF/RESET position.
Install the jumper wire across the switch that is suspect.
Turn the ECS to the COOLDOWN/STOP position.
Monitor the status screen on the electronic service tool for the suspect switch. Expected Result:The switch status changes for the suspect switch.Results:
OK - The switch status changed.Repair: Replace the switch.Verify that the repair solved the problem.STOP
Not OK - The switch status did not change. Proceed to Test Step 5.Test Step 5. Check the Negative Battery Wiring for the Suspect Switch
Turn the ECS to the OFF/RESET position.
Measure the resistance between the negative battery terminal on the suspect switch and a negative battery connection that is in close proximity. Check in order to ensure that the negative battery connection is good. Expected Result:The resistance is less than 5 Ohms.Results:
OK - The resistance is less than 5 Ohms. The wiring between the switch and the negative battery is OK. Proceed to Test Step 6.
Not OK - The resistance is greater than 5 Ohms.Repair: Replace the wire.Verify that the repair eliminates the problem.STOPTest Step 6. Check for an Open between the Switch and the ECM
Turn the ECS to the OFF/RESET position.
Disconnect the ECM connector P1 from the ECM.
Measure the resistance between the suspect switch input on the ECM connector P1 and the suspect switch. Wiggle the harness during the measurement. This will help reveal an intermittent condition.Expected Result:The resistance is less than 5 Ohms.Results:
OK - The resistance is less than 5 Ohms. Proceed to Test Step 7.
Not OK - The resistance is more than 5 Ohms. The resistance of the wire indicates an open or excessive resistance.Repair: Repair the wiring or replace the wiring.Verify that the repair eliminates the problem.STOPTest Step 7. Check for a Short Circuit between the Switch and the ECM
Disconnect the ECM connector P1 and the ECM connector P2.
Measure the resistance between the input for the suspect switch on the ECM connector P1 and every terminal on the P1 and P2 connector. Measure the resistance between the input for the suspect switch on the ECM connector P1 and engine ground. Expected Result:The resistance is more than 20,000 Ohms.Results:
OK - The resistance is more than 20,000 Ohms. There is not a short circuit. Proceed to Test Step 8.
Not OK - The resistance is less than 20,000 Ohms. There is a short circuit.Repair: Repair the wiring or replace the wiring.Verify that the repair eliminates the problem.STOPTest Step 8. Check the voltage at the ECM
Turn the ECS to the OFF/RESET position.
Remove the suspect switch wire from the P1 ECM connector. Install a wire jumper into the socket for the suspect switch wire.
Turn the ECS to the COOLDOWN/STOP position.
Alternately ground the wire jumper.
Monitor the status screen on the electronic service tool for the suspect switch. Expected Result:The switch status changes for the suspect switch.Results:
OK - The switch status changes for the suspect switch. The ECM is responding correctly.Repair: The problem may be intermittent. If the problem is intermittent, refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - The switch status does not change for the suspect switch. There may be a problem with the ECM.Repair: Perform the following procedure.
Temporarily connect a spare ECM.
Cycle the suspect switch and monitor the switch status on the electronic service tool.
If the problem is resolved with the spare ECM, then reconnect the suspect ECM.
If the problem returns with the suspect ECM, then replace the ECM. Refer to Troubleshooting, "Replacing the ECM" for additional information.STOP