0320247 JOHNSON PLATE, Leaf

Illustration 1 g00850406
Test Step 1. Check for Connector Damage
Turn the engine control to the OFF position.
Turn the breaker at the battery to the OFF 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 connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the customer connector (allen head screw) for the proper torque of 2.25 0.25 N m (20 2 lb in).
Check the harness and the wiring for abrasion and pinch points.Expected Result:The connectors and wiring should be free of the following problems: damage, corrosion, abrasion and incorrect attachment.Results:
OK - The connectors and wiring are okay. Proceed to test step 2.
Not OK - The connectors and/or wiring are not okay.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Stop.Test Step 2. Check the Engine Prelube Pressure Switch.
Disconnect the main power.
Disconnect ECM connector J1/P1.
Measure the resistance between the engine prelube pressure switch P1-19 and the Digital Return P1-29.
Reconnect the ECM connector J1/P1.Expected Result:The resistance should be greater than 20,000 Ohms.Results:
OK - The resistance is greater than 20,000 Ohms. The engine prelube pressure switch is not active. Proceed to test step 3.
Not OK - The resistance is less than 20,000 Ohms. The engine prelube pressure switch is active. Verify that the engine does not have a residual oil pressure that is high enough to activate the switch. If there is no residual oil pressure the switch is not operating correctly or there is a problem with the wiring. Proceed to test step 4.Test Step 3. Check the Status of the Prelube Switch on ET.
Activate a Normal Stop.
Disconnect the main power.
Connect the ET to the service tool connector.
Connect the main power.
Observe the parameters for the engine prelube and for the ignition switch.Expected Result:The parameter for the engine prelube should display "OFF". The parameter for the ignition switch should display "OFF".Results:
OK - The status parameters are correct. Proceed to test step 5.
Prelube Disabled - The parameter for the engine prelube displays "DISABLED".Repair: Set the engine prelube duration to a value that is greater than zero. Restart this test. Stop.
Ignition Switch NOT OFF - The parameter for the ignition switch does not display "OFF".Repair: There is a problem in the wiring to the Start Switch. Repair the switch or wiring or replace the switch or wiring. Stop.Test Step 4. Check the Engine Prelube Pressure Switch.
Disconnect the main power.
Disconnect the wires from terminal 1 and terminal 2 of the engine prelube pressure switch.
Measure the resistance between terminal 1 and terminal 2 of the engine prelube pressure switch.Expected Result:The resistance should be greater than 20,000 Ohms.Results:
OK - The resistance is greater than 20,000 Ohms. Proceed to test step 5.
Not OK - The resistance is less than 20,000 Ohms.Repair: There is a problem with the engine prelube pressure switch. Install a new switch. Determine if the problem no longer exists. If the problem is no longer present, reinstall the old switch. If the problem returns, replace the switch. Stop.Test Step 5. Check the Status of the Engine Prelube Pressure Switch.
Deactivate all engine stops and activate the start switch.
View the parameters for the engine prelube pressure switch and the ignition switch. View the parameters before the engine prelube duration expires and before the switch activates.Note: If necessary, program the engine prelube duration to 60 seconds.
If the engine prelube displays "COMPLETED", the engine prelube duration is reached. Reset the system and troubleshoot any active diagnostic code.Expected Result:When the engine is in the start up mode the Engine Prelube should display "ON".Results:
OK - The Engine Prelube displays "ON". Proceed to test step 6.
Not OK - The Engine Prelube does not display "ON".Repair: There is a problem in the wiring to the Start Switch. Repair the switch or wiring or replace the switch or wiring. Stop.Test Step 6. Check the Prelube Relay.
Activate a Normal Stop.
Access the override on the Electronic Service Tool.
Connect a voltage test lamp across the coil of the prelube relay.
Turn the override for the prelube to "ON".
Monitor the voltage test lamp across the coil of the prelube relay.Expected Result:The voltage test lamp should illuminate. The motor should run.Results:
OK - The voltage test lamp illuminated. The prelube motor operates.Repair: The system is operating correctly. Stop.
Not OK - The voltage test lamp did not illuminate. The prelube relay did not activate. Proceed to test step 8.
Prelube Motor Does Not Run - The voltage test lamp illuminated. The relay activates but the motor does not run. Proceed to test step 7.Test Step 7. Check the Normally Open Contacts on the Prelube Relay.
Activate a Normal Stop.
Access the override on the Electronic Service Tool.
Measure the voltage across the normally open contacts of the prelube relay.
Turn the override for the prelube to "ON".
Measure the voltage across the normally open contacts of the prelube relay.Expected Result:The voltage should measure 24 3 VDC before the override is activated. The voltage should measure 0.0 VDC after the override is activated. The prelube motor should run.Results:
OK - The voltage measurements are correct. The prelube motor should run.Repair: The system is operating correctly. Stop.
Not OK - The voltage measurements are correct. The prelube motor did not run.Repair: The problem is in the wiring between the prelube relay and the assembly for the prelube motor. To troubleshoot the assembly for the prelube motor, refer to the "OEM Manual". Stop.
Not OK - The voltage measurements are not correct.Repair: Check the power to the prelube relay if the voltage does not measure 24 3 VDC before activation of the prelube override. Replace the prelube relay if the voltage does not measure 0.0 VDC after activation of the prelube override. Stop.Test Step 8. Check the Signal to the Prelube Relay from the ECM.
Disconnect the main power.
Disconnect ECM connector J2/P2.
Remove wire A268-BK from ECM connector P2-35. Install a wire jumper into the socket for P2-35.
Remove