5033612 JOHNSON *OIL SEAL

Illustration 1 g00735975
Electronic Unit Injector
Illustration 2 g00927316
Schematic for the electronic unit injectors
Illustration 3 g01000770
P2 ECM connector
Illustration 4 g01001203
Harness connector for the injectors
Illustration 5 g00706830
P300 Injector harness connectorTest Step 1. Inspect Electrical Connectors and Wiring
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
Turn the key switch to the OFF position. A strong electrical shock hazard is present if the key switch is not turned off.
Thoroughly inspect the J2/P2 ECM connector and the J300/P300 injector harness connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector. Perform the pull test on the J300/P300 injector harness connector that are associated with injector solenoids.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the J300/P300 injector harness connector in order to ensure the proper mating of the connector.
Check the harness and wiring for abrasion and pinch points from the injectors to the ECM.Expected Result:All connectors, pins, and sockets are coupled and/or inserted and the harness and wiring should be free of corrosion, abrasion, or pinch points.Results:
OK - Proceed to Test Step 2.
Not OK - Repair: Perform the following repair:Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are coupled.Verify that the repair eliminates the problem.STOPTest Step 2. Check for Logged Diagnostic Codes Regarding Injector Solenoids
Connect Cat ET to the data link connector.
Turn the key switch to the ON position.
Check for logged diagnostic codes that are related to the injector solenoids on Cat ET.Expected Result:One or more diagnostic codes that are related to the injector solenoids have been logged:Results:
OK - One or more diagnostic codes have been logged. Proceed to Test Step 4.
Not OK - No diagnostic codes have been logged. Proceed to Test Step 3.Test Step 3. Check the Variation of the Injectors between Cylinders
When possible, put the truck on a dynamometer.
Start the engine.
Allow the engine to warm up to normal operating temperature 77 °C (171 °F).
After the engine is warmed to operating temperature, access the "Cylinder Cutout Test". Open the following display screens in order:
"Diagnostics"
"Diagnostic Tests"
"Cylinder Cutout Test"
Enable the cooling fan, if the fan is not controlled by the ECM. If the ECM controls the cooling fan, the cooling fan will start automatically when the test begins.
Shut off all parasitic loads such as the air conditioning and the air compressors which could affect the results of the test.
Set the engine speed to 1000 20 rpm.
Select the start button at the bottom of the screen for the Cylinder Cutout test on Cat ET.
Select the "4 Cylinder Cutout Test".
Follow the instructions that are provided in the Cylinder Cutout test. The Cylinder Cutout tests are interactive so the procedure is guided to the finish.Note: The "Manual Cylinder Cutout Test" is also available. Access the manual test by selecting the "Change" button on the screen for the Cylinder Cutout test. The recommended starting procedure is the "4 Cylinder Cutout Test". The automated tests run twice collecting data. The two sets of data are analyzed. The result is displayed as "OK" or "Not OK".
Check for active diagnostic codes and logged diagnostic codes that are related to t