5035590 JOHNSON PIN, COTTER

Illustration 1 g01001876
Typical example
Test Step 1. Check for Connector Damage.
Turn the circuit breaker for the battery to the OFF position.
Turn the Engine Control Switch (ECS) to the OFF/RESET position.
Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors. Refer to 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 connectors (allen head screw) for the proper torque of 6 1 N m (53 9 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 are 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 Harness for Shorts.
Disconnect the primary ECM connector J1/P1. Disconnect all of the analog sensors.
Measure the resistance between the analog supply P1-02 and the analog return P1-03.
Measure the resistance between P1-18 and P1-35.
Measure the resistance between P1-02 and engine ground.
Measure the resistance between P1-03 and engine ground.
Measure the resistance between P1-18 and engine ground.
Measure the resistance between P1-35 and engine ground. Expected Result:The resistance is more than 20,000 Ohms for each measurement.Results:
OK - The resistance is more than 20,000 Ohms for each measurement. Proceed to Test Step 3.
Not OK - The resistance is less than 20,000 Ohms for each measurement.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 3. Check the Analog Sensor Supply Voltage at the Primary ECM.
Disconnect the primary ECM connector J1/P1.
Remove the wire 997 from the primary ECM connector P1-02. Remove the wire 993 from the primary ECM connector P1-03. Install wire jumpers into P1-02 and into P1-03.
Remove the wire A997 from the primary ECM connector P1-18. Remove the wire A993 from the primary ECM connector P1-35. Install wire jumpers into P1-18 and into P1-35. Note: If you remove the sensor common from the ECM, an open circuit diagnostic code will be generated for all sensors that use the sensor common. Troubleshoot the original code. Delete the logged diagnostic codes when you are finished.
Reconnect ECM connector J1/P1.
Turn the circuit breaker for the battery to the ON position.
Turn the ECS to the STOP position. The engine should be off.
Measure the voltage between the wire jumper in the analog supply P1-02 and the wire jumper in the analog return P1-03.
Measure the voltage between the wire jumper in the analog supply P1-18 and the wire jumper in the analog return P1-35.
Turn the ECS to the OFF/RESET position.
Remove the wire jumpers. Replace the wires that were removed above. Reconnect ECM connector J1/P1. Expected Result:The supply voltage is 5.0 0.2 VDC.Results:
OK - The supply voltage is 5.0 0.2 VDC. Proceed to Test Step 4.
Not OK - The supply voltage is not 5.0 0.2 VDC.Repair: Perform the diagnostic functional test Troubleshooting, "Electrical Power Suply".STOPTest Step 4. Check the Analog Sensor Supply Voltage at the Sensor Connector.
Turn the ECS to the STOP position. The engine should be off.
Measure the voltage between socket-A and socket-B on the harness side of all analog sensor connectors.
Turn the ECS to the OFF/RESET position. Expected Result:The supply voltage is 5.0 0.2 VDC.Results:
OK - The supply voltage is 5.0 0.2 VDC. Proceed to Test Step 5.
Not OK - The supply voltage is not 5.0 0.2 VDC.Repair: There is an open circuit in the harness or connectors. Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 5. Check the Analog Sensors for Short Circuits.
Turn the ECS to the STOP position. The engine should be off.
Measure the voltage between socket-A and socket-B on the harness side of an analog sensor connector. Leave this sensor disconnected.
Connect one sensor at a time. Note: If the sensor is disconnected from the harness, an open circuit diagnostic code will be generated for that sensor. Troubleshoot the original diagnostic code. Delete the logged diagnostic codes when you are finished.
Repeat this step with all of the analog sensors. For the last sensor, move the voltmeter to another sensor connector. Check the last sensor, as described above.
Turn the ECS to the OFF/RESET position.
Reconnect all sensors. Expected Result:The supply voltage is 5.0 0.2 VDC after each analog sensor is connected.Results:
OK - The supply voltage is 5.0 0.2 VDC after each analog sensor is connected.Repair: The problem may be intermittent. If the problem is intermittent, perform the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors".STOP
Not OK - The voltage is okay before the sensor is connected. The voltage is not okay after the sensor is connected. The sensor may be internally shorted.Repair: Temporarily replace the sensor. Verify that the new sensor solves the problem before permanently installing the new sensor.STOP