0209038 JOHNSON OWNER'S MANUAL, Evnirude

Illustration 1 g01325334
Schematic for the active analog inputs
Test Step 1. Inspect the Electrical Connectors and Wiring
Remove the electrical power from the engine. Note: For the following steps, refer to Troubleshooting, "Electrical Connectors - Inspect".
Thoroughly inspect each of the following connectors:
J1/P1 connectors
J5/P5 connectors
J6/P6 connectors
J7/P7 connectors
J9/P9 connectors
Check the torque of the allen head screws on the Electronic Control Module (ECM).
If you are troubleshooting a problem with an analog sensor, perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the analog sensors.
If you are troubleshooting a problem with an analog sensor, check the harness and wiring for abrasion and for pinch points from the analog sensors to the ECM.
If you are troubleshooting a problem with the input for fuel quality, perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the fuel quality.
If you are troubleshooting a problem with the input for fuel quality, check the harness and wiring for abrasion and for pinch points from the gas chromatograph to the ECM. Expected Result:All connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points.Results:
OK - All connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points. The components are in good condition with proper connections. If you are troubleshooting a problem with an analog sensor, proceed to Test Step 2. If you are troubleshooting a 2449-5 code, proceed to Test Step 9. If you are troubleshooting a 2449-6 code, proceed to Test Step 12. If you are troubleshooting a 102-8 code, proceed to Test Step 4.
Not OK - At least one of the connectors, pins, and/or sockets are not connected properly. At least one of the connectors and/or the wiring has corrosion, abrasion, or pinch points.Repair: Perform the necessary repairs and/or replace parts, if necessary.STOPTest Step 2. Check for Diagnostic Codes for the Power Supply
Connect Cat ET to the service tool connector. Refer to Troubleshooting, "Electronic Service Tools".
Observe the "Active Diagnostic" screen on ET. Allow a minimum of 30 seconds for any codes to activate. Look for these codes:
262-3
262-4Expected Result:The 262-3 code or the 262-4 code is not active.Results:
No codes - There are no diagnostic codes for the sensor supply. If you are troubleshooting a -3 code, proceed to Test Step 4. If you are troubleshooting a -4 code or a -8 code, proceed to Test Step 3.
Active code - There is an active diagnostic code for the sensor supply. This procedure will not work when this type of code is active.Repair: Refer to Troubleshooting, "Sensor Supply - Test".If necessary, return to this functional test in order to troubleshoot the analog input after the diagnostic code for the sensor supply has been resolved.STOPTest Step 3. Create an Open Circuit for the Sensor
Disconnect the sensor that has the "voltage below normal" diagnostic code.
Observe the "Active Diagnostic" screen on Cat ET. Allow a minimum of 30 seconds for any codes to activate. Look for an active -3 diagnostic code. Expected Result:There is an active -3 diagnostic code for the disconnected sensor.Results:
Yes - Before the suspect sensor was disconnected, there was an active -4 diagnostic code or an active -8 diagnostic code for the sensor. After the suspect sensor was disconnected, there was an active -3 diagnostic code for the sensor.Repair: Connect the sensor. If the active -4 diagnostic code or the active -8 diagnostic code recurs, replace the original sensor.Verify that the code does not activate when the new sensor is installed. Clear the logged codes from the ECM.STOP
No - Before the suspect sensor was disconnected, there was an active -4 diagnostic code or an active -8 diagnostic code for the sensor. After the suspect sensor was disconnected, the active -4 diagnostic code or the active -8 diagnostic code remained. Proceed to Test Step 4.Test Step 4. Check the Supply Voltage at the Sensor Connector
Verify that the suspect sensor is disconnected from the engine harness.
Illustration 2 g00889729
Harness connectors for the various sensors
(A) 5 volt supply
(B) Return
(C) Signal
At the harness connector for the suspect sensor, measure the voltage between terminals (A) and (B). Expected Result:The voltage is between 4.5 VDC and 5.5 VDC.Results:
OK - The voltage between terminals A and B is between 4.5 VDC and 5.5 VDC. The 5 volt supply is present at the sensor connector. Proceed to Test Step 5.
Not OK - The voltage between terminals A and terminal B is not between 4.5 VDC and 5.5 VDC. The 5 volt supply is not present at the sensor connector. The 5 volts must be present at the sensor in order to continue this procedure.Repair: Verify that the wiring and/or connectors are OK. Repair any faulty wiring and/or connectors, when possible. Replace parts, if necessary.STOPTest Step 5. Check the Pull-Up Voltage at the Sensor
Verify that the suspect sensor's connector is disconnected from the engine harness.
Illustration 3 g01303723
Harness connectors for the various sensors
(A) 5 volt supply
(B) Return
(C) Signal