0302493 JOHNSON "O"RING,Gearcase head

Illustration 1 g01459083
Schematic for engine temperature sensors
Illustration 2 g01459099
Pin locations for the temperature sensors on the P2 connector
(37) Ground (GND) Intake Manifold Air Temperature Sensor
(37) Ground (GND) Coolant Temperature Sensor
(42) Signal (SIG) Intake Manifold Air Temperature Sensor
(43) Signal (SIG) Coolant Temperature Sensor
Illustration 3 g01170313
Engine coolant temperature sensor and intake manifold air temperature sensor
(1) Signal (SIG)
(2) Ground (GND) Test Step 1. Verify All Active Diagnostic Codes
Connect the electronic service tool to the diagnostic connector.
Turn the keyswitch to the ON position. Note: Wait at least 30 seconds for activation of the diagnostic codes.
Use the electronic service tool in order to verify if any of the following diagnostic codes are active or recently logged:
110-3 Engine Coolant Temperature Sensor voltage above normal
110-4 Engine Coolant Temperature Sensor voltage below normal
172-3 Intake Manifold Air Temperature Sensor voltage above normal
172-4 Intake Manifold Air Temperature Sensor voltage below normalExpected Result:One or more of the preceding diagnostic codes are active or recently logged.Results:
Yes - Proceed to Test Step 2.
No - The fault is intermittent. Proceed to Test Step 8.Test Step 2. Inspect Electrical Connectors And Wiring
Thoroughly inspect ECM engine harness connector P2 and the suspect sensor connector. Refer to Troubleshooting, "Electrical Connectors - Inspect".
Perform a 45 N (10 lb) pull test on each of the wires in the sensor connector and the ECM connector that are associated with the active diagnostic code. Refer to illustration 2.
Verify that the latch tab of the connector is correctly latched. Also verify that the latch tab of the connector has returned to the fully latching position.
Check the screw for the ECM connector for the correct torque of 5.0 N m (44 lb in).
Check the harness for abrasions and for pinch points from the sensor to the ECM. Expected Result:All connectors, pins, and sockets should be completely coupled and/or inserted. The harness should be free of corrosion, abrasion, and pinch points.Results:
OK - Proceed to Test Step 3.
Not OK - Repair the connectors or the harness and/or replace the connectors or the harness. Ensure that all of the seals are correctly in place and ensure that the connectors are completely coupled. Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair has eliminated the fault. If the fault has not been eliminated, proceed to Test Step 3.Test Step 3. Verify That The Diagnostic Code Is Still Active
Turn the keyswitch to the ON position. Note: Wait at least 10 seconds for activation of the diagnostic codes.
Access the "Active Diagnostic Code" screen on the electronic service tool and check for active diagnostic codes.
Determine if the fault is related to a Voltage Above Normal diagnostic code or a Voltage Below Normal diagnostic code. Expected Result:A Voltage Below Normal diagnostic code or an Voltage Above Normal diagnostic code is active.Results:
OK - SHORT Circuit - A Voltage Below Normal diagnostic code is active at this time. Proceed to Test Step 4.
OK - OPEN Circuit - An Voltage Above Normal diagnostic code is active at this time. Proceed to Test Step 5.
Not OK - A Voltage Below Normal diagnostic code is not active. An Voltage Above Normal diagnostic code is not active. An intermittent fault may exist.Repair: Use the electronic service tool to perform a "Wiggle Test". If faults are indicated then go to the appropriate procedure. STOPTest Step 4. Disconnect The Sensor In Order To Create An Open Circuit
Turn the keyswitch to the OFF position.
Disconnect the sensor connector of the sensor with the Voltage Below Normal diagnostic code.
Turn the keyswitch to the ON position. Note: Wait at least 10 seconds for activation of the diagnostic codes.
Access the "Active Diagnostic Code" screen of the electronic service tool. Check for an active Voltage Above Normal diagnostic code. Expected Result:A Voltage Above Normal diagnostic code for the disconnected sensor is now active.Results:
OK - A Voltage Below Normal diagnostic code was active before disconnecting the sensor. An Voltage Above Normal diagnostic code became active after disconnecting the sensor.Repair: Refer to Troubleshooting, "Electrical Connectors - Inspect".Inspect the seals of the connectors for damage.Connect the sensor and verify that the fault returns. If the fault returns, the sensor is faulty.Replace the sensor.Use the electronic service tool in order to clear all logged diagnostic codes.STOP
Not OK - There is a short circuit between the sensor harness connector and the ECM. Leave the sensor disconnected. Proceed to Test Step 6.Test Step 5. Create a Short Circuit Between the Signal and the Common Terminals at the Sensor Harness Connector
Disconnect the suspect sensor connector P100 for the coolant temperature sensor or disconnect P103 for the inlet manifold temperature sensor.
Turn the keyswitch to the ON position. Note: Wait at least 10 seconds for the activation of any diagnostic fault codes.
Fabricate a