0208076 JOHNSON SEAL, Motor cover

Table 1
Troubleshooting Test Steps Values Results
1. Inspect Electrical Connectors and Wiring
A. Turn the keyswitch to the OFF position. A strong electrical shock hazard is present if the keyswitch is not turned OFF.
B. Thoroughly inspect the connectors at the cylinder head. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
C. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with injector solenoids.
D. Check the screw for the ECM connector for the correct torque of 6 N m (53 lb in).
E. Check the harness and wiring for abrasion and for pinch points from the injectors to the ECM.
Loose connection or damaged wire
Result: There is a fault in a connector or the wiring.
Repair: Repair any faulty connectors or replace the wiring harness. Ensure that all of the seals are properly in place and ensure that the connectors are correctly coupled.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: All connectors, pins, and sockets are correctly coupled and/or inserted. The harness is free of corrosion, abrasion, and pinch points.
Proceed to Test Step 2.
2. Use the "Injector Solenoid Test"
A. Start the engine.
B. Allow the engine to warm up to the normal operating temperature.
C. Stop the engine.
D. Turn the keyswitch to the ON position.
E. Access the "Injector Solenoid Test" by accessing the following display screens in order:
"Diagnostics"
"Diagnostic Tests"
"Injector Solenoid Test"
F. Activate the test.
Note: Do not confuse the "Injector Solenoid Test" with the "Cylinder Cutout Test". The "Cylinder Cutout Test" is used to shut off fuel to a specific cylinder while the engine is running. The "Injector Solenoid Test" is used to actuate the injector solenoids while the engine is not running.
"OK", "OPEN", or "SHORT"
Result: All cylinders indicate "OK" - There is not an electronic fault with the injectors at this time.
Use the electronic service tool to clear all logged diagnostic codes. Return the engine to service.
Result: "OPEN"
Note the cylinders that indicate "OPEN".
Proceed to Test Step 3.
Result: "SHORT"
Note the cylinders that indicate "SHORT".
Proceed to Test Step 4.
3. Check the Harness between the ECM and the Cylinder Head for an Open Circuit
A. Turn the keyswitch to the OFF position. A strong electrical shock hazard is present if the keyswitch is not turned OFF.
B. Disconnect the connector for the suspect injector from the cylinder head.
C. Fabricate a jumper wire 100 mm (4 inch) long with terminals on both ends of the wire.
D. Insert one end of the jumper wire into the terminal for the supply to the suspect injector. Insert the other end of the jumper wire into the terminal for the return circuit for the suspect injector.
E. Turn the keyswitch to the ON position.
F. Perform the "Injector Solenoid Test" at least two times.
G. Repeat this test for each suspect injector. Stop the "Injector Solenoid Test" before handling the jumper wires.
Suspect injector indicates "SHORT"
Result: The electronic service tool displays "SHORT" for the cylinder with the jumper wire.
Proceed to Test Step 5.
Result: The electronic service tool does not display "SHORT" for the cylinder with the jumper wire.
Proceed to Test Step 6.
4. Check the Harness between the ECM and the Cylinder Head for a Short Circuit
A. Turn the keyswitch to the OFF position. A strong electrical shock hazard is present if the keyswitch is not turned OFF.
B. Disconnect the connector for the suspect injector from the cylinder head.
C. Turn the keyswitch to the ON position.
D. Perform the "Injector Solenoid Test" at least two times.
E. Repeat this test for each suspect injector. Stop the "Injector Solenoid Test" before handling the jumper wires.
Suspect injector indicates "OPEN"
Result: The electronic service tool displays "OPEN" for the suspect cylinder and the cylinder that shares the same connector.
Proceed to Test Step 5.
Result: The electronic service tool does not display "OPEN" for the suspect cylinder
Proceed to Test Step 7.
5. Exchange the Injector Harness Under the Valve Mechanism Cover
A. Turn the keyswitch to the OFF position. A strong electrical shock hazard is present if the keyswitch is not turned OFF.
B. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install" for the correct procedure.
C. Disconnect the connector for the suspect injector from the cylinder head. Disconnect the connector from the adjacent injector.
D. Exchange the two internal harnesses. Refer to Disassembly and Assembly, "Electronic Unit Injector - Remove" and refer to Disassembly and Assembly, "Electronic Unit Injector - Install" for the correct procedure.
E. Turn the keyswitch to the ON position.
F. Perform the "Injector Solenoid Test" at least two times.
G. Restore the wiring to the normal positions.
Fault moves to another injector
Result: Exchanging the harnesses causes the fault to move to another injector - There is a fault with the suspect injector harness under the valve mechanism cover.
Repair: Repair the suspect injector harness or replace the suspect injector harness under the valve mechanism cover.
Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault.
Result: The fault remains on the same injector when the harness is exchanged - the injector may be faulty.
Repair: Replace the faulty injector. Refer to Disassembly and Assembly, "Electronic Unit Injector - Remove" and Disassembly and Assembly, "Electronic Unit Injector - Install".
Perform the "Injector Solenoid Test".
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
6. Check the Wiring to the Cylinder Head for an Open Circuit
A. Turn the keyswitch to the OFF position. A strong electrical shock hazard is present if the keyswitch is not turned OFF.
B. Disconnect connector P2 from the ECM.
C. Thoroughly inspect the P2 connector. Refer to Troubleshooting, "Electrical Connectors - Inspect".
D. Disconnect the connector for the suspect injector from the cylinder head.
E. Use a multimeter to check the resistance between the terminals on the suspect cylinder head connector and the terminals on P2.
F. Install the removed connectors.
Less than 2 Ohms
Result: One or more of the measured resistances is greater than 2 Ohms. The fault is in the wiring between the ECM and the cylinder head