0439083 JOHNSON POWERHEAD GASKET SET

Illustration 1 g00803894
Installation of the TC probe on the 3176C Engine
Illustration 2 g00798969
Installation of the TC probe on the 3406E Engine
Table 1
Required Special Tools
Part Number Description
6V-2197 Transducer
7X-1695 Cable As
7X-1171 Transducer Adapter
9S-9082 Engine Turning Tool Test Step 1. Install the 7X-1171 Transducer Adapter
Turn the keyswitch to the OFF/RESET position.
Use the 9S-9082 Engine Turning Tool to put either the No. 1 piston or the No. 6 piston at top center. After the top center position has been located, rotate the crankshaft in the opposite direction of normal rotation for 60 degrees.Note: Normal engine rotation is counterclockwise as the engine is viewed from the flywheel end. Refer to Illustration 1.
Remove the timing calibration plug from the cylinder block. If the3176C engine is viewed from the flywheel side of the engine, the timing calibration plug is on the right side. The timing calibration plug is located in the No. 4 cylinder rod pocket. Refer to Illustration 1. If the3406E engine is viewed from the flywheel side of the engine, the timing calibration plug is on the left side. The timing calibration plug is located in the No. 2 cylinder rod pocket. Refer to Illustration 2.
Install the 7X-1171 Transducer Adapter into the hole for the plug.Expected Result:The 7X-1171 Transducer Adapter is installed into the hole for the plug.Results:
OK - The 7X-1171 Transducer Adapter is installed into the hole for the plug. Proceed to Test Step 2.Test Step 2. Install the 6V-2197 Transducer
If the crankshaft is not in the correct position when the 6V-2197 Timing Calibration Probe is installed, the probe will be damaged.
Put the 2D-6392 O-Ring Seal on the end of the transducer.Note: A small amount of clean engine oil will allow the seal to slide onto the sensor more easily.
Push the transducer through the adapter until the transducer comes in contact with the outermost portion of the crankshaft counterweight. Move the O-ring seal downward against the adapter.
Withdraw the transducer 1.0 mm (0.04 inch) and hand tighten the nut on the adapter sleeve to secure the transducer in place.
Connect the 6V-2197 Transducer to the 7X-1695 Cable As.Expected Result:The 6V-2197 Transducer is installed on the engine.Results:
OK - The 6V-2197 Transducer is installed on the engine. Proceed to Test Step 3.Test Step 3. Start the Engine and Allow the Coolant to Reach Operating Temperature
Start the engine and run at low idle until the engine is at correct operating temperature.
Check for active diagnostic codes. Use the procedures in this manual for troubleshooting. Repair any active diagnostic codes before you check the calibration. The engine must not have any diagnostic fault conditions that are present during the timing calibration except the following condition:
261-13Expected Result:The engine is at the correct operating temperature.Results:
OK - The engine is at the correct operating temperature. Proceed to Test Step 4.Test Step 4. Connect the Electronic Service Tool
Connect Cat ET to the service tool connector.
Access the "Timing Calibration" screen on Cat ET. Access the following display screens in order:
"Service"
"Calibrations"
"Timing Calibration Screen"
Connect the 7X-1695 Cable As to the P26 timing calibration connector that is located near the ECM.
Ensure that all the following connections are made correctly:
Timing calibration probe
Cables for Cat ET and the communication adapterExpected Result:The necessary connections are correct.Results:
OK - The necessary connections are correct. Proceed to Test Step 5.Test Step 5. Calibrate the Speed/Timing SensorNote: The engine speed might have to be set manually if it is not automatically set by Cat ET.
Set the engine speed to 1100 50 rpm. The engine speed must remain stable in order for the calibration to be successful.
To calibrate the timing to the correct setting, select "Continue" on Cat ET. Wait until Cat ET indicates that the timing is "CALIBRATED".Note: If the display reads "CALIBRATION UNSUCCESSFUL", the electronic injection timing has not been set. Recheck the tool installation and tool operation and try again to calibrate electronic injection timing. If the crankshaft and camshaft gears have been reassembled incorrectly, the engine will not calibrate.Expected Result:The timing calibration procedure was completed successfully.Results:
OK - The timing calibration procedure was completed successfully.Repair: Disconnect the timing calibration probe before you exit the "Timing Calibration" screen on Cat ET.STOP
Not OK - The timing calibration procedure was not completed successfully.Repair: Perform the following procedure:
Verify that the engine speed was stable during the testing ( 50 rpm). If the engine speed was unstable or the engine speed could not be controlled within 50 rpm because of mechanical factors or electrical factors, refer to Troubleshooting, "Engine Misfires, Runs Rough or Is Unstable".
If all the problems have been corrected but the timing cannot be calibrated, check the cable of the 6V-2197 Timing Calibration Probe. And check the 6V-2197 Timing Calibration Probe to verify that the probe is not bent. Verify that the probe is installed correctly before restarting this procedure.STOP