0209597 JOHNSON OWNER'S MANUAL,Evinrude

Illustration 1 g01121181
Schematic for the engine temperature sensors
Illustration 2 g01121203
Left side view
(1) Engine coolant temperature sensor
(2) Intake manifold air temperature sensor
(3) J61/P61 Customer connector
(4) J2/P2 connectors
(5) J1/P1 connectors
Illustration 3 g01120360
P2 terminations for the engine temperature sensors
(P2-13) Engine coolant temperature
(P2-30) Return
(P2-56) Intake manifold air temperature
Illustration 4 g01121228
J1/P1 terminals that are associated with the engine temperature sensors
(3) Return
(16) Auxiliary temperature
Illustration 5 g01121234
J61/P61 terminals that are associated with the engine temperature sensors
(11) Auxiliary temperature
(15) Return
Illustration 6 g01120369
Harness connector for the temperature sensors
(1) Signal
(2) Return
Table 1
Troubleshooting Test Steps Values Results
1. Inspect the Electrical Connectors and the Wiring
A. Turn the keyswitch to the OFF position.
B. Thoroughly inspect connectors (3), (4), and (5). Inspect the sensor connectors. Refer to Troubleshooting, "Electrical Connectors - Inspect".
C. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the temperature sensors.
D. Check the allen head screw on the ECM connectors for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect".
E. Check the allen head screw on the customer connectors for the proper torque of 2.25 .25 N m (20 2 lb in).
F. Check the harness and wiring for abrasions and for pinch points from each sensor to the ECM.
Electrical Connectors and Wiring
Results: The connectors and wiring are OK. Proceed to Test Step 2.
Results: There is a problem in the connectors and/or wiring.
Repair: Repair the wiring and/or the connectors. Replace parts, if necessary. Ensure that all of the seals are properly in place and ensure that the connectors are coupled. Verify that the repair eliminates the problem.
STOP
2. Check for Codes
A. Connect the Cat® Electronic Technician (ET) to the service tool connector.
B. Turn the keyswitch to the ON position.
C. Monitor the active diagnostic code screen on Cat ET. Check and record any active diagnostic codes.
Note: Wait at least 15 seconds in order for the diagnostic codes to become active.
D. Look for an 03 diagnostic code or an 04 diagnostic code.
Codes
Results: No diagnostic codes are active.
Repair: he problem may have been related to a faulty connection in the harness. Carefully reinspect the connectors and wiring. Refer to Troubleshooting, "Electrical Connectors - Inspect" for additional information.
STOP
Results: An 04 diagnostic code is active at this time. Proceed to Test Step 3.
Results: An 03 diagnostic code is active at this time. Proceed to Test Step 4.
3. Disconnect the Suspect Sensor in Order to Create an Open Circuit
A. Turn the keyswitch to the OFF position.
B. Disconnect the suspect sensor from the engine harness.
C. Turn the keyswitch to the ON position. Wait at least 15 seconds for activation of the diagnostic codes.
D. Access the "Active Diagnostic Codes" screen on Cat ET and check for an active 03 diagnostic code for the suspect sensor.
E. Turn the keyswitch to the OFF position.
03 diagnostic code
Results: An 04 diagnostic code was active before disconnecting the sensor. An 03 diagnostic code became active after the sensor was disconnected.
Repair: Temporarily connect a new sensor to the harness, but do not install the new sensor in the engine. Verify that there are no active diagnostic codes for the sensor. If there are no active diagnostic codes for the sensor, permanently install the new sensor. Clear any logged diagnostic codes. Verify that the repair eliminates the problem.
STOP
Results: The 04 diagnostic code is still present. Leave the sensor disconnected. Proceed to Test Step 7.
4. Check the Pull-up Voltage at the Sensor Connector
A. Disconnect the suspect sensor at the sensor connector.
B. Turn the keyswitch to the ON position.
C. Measure the voltage between terminal 1 (signal) and terminal 2 (return) at the harness connector.
D. Turn the keyswitch to the OFF position.