0437536 JOHNSON THROTTLE BODY ASSY., Stbd., 90

Illustration 1 g00931861
Test Step 1. Check for Connector Damage.
Turn the keyswitch to the OFF position.
Thoroughly inspect the ECM connector J1/P1. Thoroughly inspect the machine connector J2/P2. Inspect the operator monitor panel plug. Refer to the diagnostic functional test 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 2.25 0.25 N m (20 2 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 for pinch points.Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted. 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 are not okay.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Stop.Test Step 2. Check the Operation of the High Coolant Temperature Lamp.
Connect the Cat ET to the ECM through the J31 cab service tool connector.
Turn the keyswitch to the ON position. The engine should be off.
Access the diagnostic test on the Cat ET.
Activate the override for the high coolant temperature lamp.
Monitor the high coolant temperature lamp.
Deactivate the override for the high coolant temperature lamp.Expected Result:The high coolant temperature lamp is not ON before the override is activated. The high coolant temperature lamp is ON after the override is activated. The high coolant temperature lamp turns OFF after the override is deactivated.Results:
OK - The high coolant temperature lamp was ON during the override. The high coolant temperature lamp turned OFF after the override was deactivated.Repair: The high coolant temperature lamp is operating correctly. Stop.
Not OK - The high coolant temperature lamp did not turn ON. Proceed to Test Step 3.
Not OK - The high coolant temperature lamp turned ON. The high coolant temperature lamp did not turn OFF after the override was deactivated. Proceed to Test Step 4.Test Step 3. Check the Harness for a Short to Ground Condition.
Turn the keyswitch to the OFF position.
Disconnect ECM connector J1/P1.
Disconnect the operator monitor panel plug.
Measure the resistance between the following pins on the ECM connector:
P1-49 and P1-23
P1-49 and P1-13
P1-49 and P1-9Expected Result:The resistance is greater than 20,000 Ohms for each measurement.Results:
OK - The resistance is greater than 20,000 Ohms for each measurement. Proceed to Test Step 4.
Not OK - The resistance is less than 20,000 Ohms for one of the measurements.Repair: The wire 438-YL is shorted to ground through one of the three wires in the engine harness. If the short is to wire 229-BK, wire 438-YL could be shorted to the engine block or the chassis. If the short is not to wire 229-BK, locate the short in the engine harness or locate the short in the machine harness. Repair the connectors or wiring and/or replace the connectors or wiring. Stop.Test Step 4. Check the Harness for a Short to Battery Condition.
Turn the keyswitch to the OFF position.
Disconnect ECM connector J1/P1.
Disconnect the operator monitor panel plug.
Measure the resistance between the following pins on the ECM connector:
P1-49 and P1-70
P1-49 and P1-65
P1-49 and P1-51
P1-49 and P1-37Expected Result:The resistance is greater than 20,000 Ohms for each measurement.Results:
OK - The resistance is greater than 20,000 Ohms for each measurement. Proceed to Test Step 5.
Not OK - The resistance is less than 20,000 Ohms for one of the measurements.Repair: The wire 438-YL is shorted to power through one of the four wires in the engine harness. Locate the short in the engine harness or in the machine harness. Repair the connectors or wiring and/or replace the connectors or wiring. Stop.Test Step 5. Check for an Open in the Harness.
Turn the keyswitch to the OFF position.
Disconnect ECM connector J1/P1.
Disconnect the operator monitor panel plug.
Connect a wire jumper between wire P1-49 (438-YL) and wire P1-2 (201-BK) at the operator monitor panel plug.
Measure the resistance between P1-49 and P1-13 at ECM connector P1.
Remove the wire jumper.
Reconnect all connectors.Expected Result:The resistance is less than 5 Ohms.Results:
OK - The resistance is less than 5 Ohms. Proceed to Test Step 6.
Not OK - The resistance is more than 5 Ohms.Repair: There is an open or excessive resistance in the wiring and/or in the connectors between ECM connector P1 and the operator monitor panel plug. Repair the connectors or wiring and/or replace the connectors or wiring. Stop.Test Step 6. Check the Voltage to the Operator Monitor Panel Plug for the High Coolant Temperature Lamp.
Turn the keyswitch to the OFF position.
Turn the keyswitch to the ON position. The engine should be off.
Measure the voltage between P1-49 and P1-13 at ECM connector J1/P1.
Access the diagnostic test on the Cat ET.
Activate the override for the high coolant temperature lamp.
Measure the voltage between P1-49 and P1-13 at ECM connector J1/P1.
Deactivate the override for the high coolant temperature lamp.
Turn the keyswitch to the OFF position.Expected Result:The voltage is 7.5 0.5 VDC when the override is OFF. The voltage is 0.5 0.5 VDC when the override is ON.Results:
OK - The voltage was 7.5 0.5 VDC when the override was OFF. The voltage was 0.5 0.5 VDC when the override was ON. There is a problem in the wiring between the ECM and the operator monitor panel plug.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Stop.
Not OK - The voltage was not 7.5 0.5 VDC when the override was OFF. The voltage was not 0.5 0.5 VDC when the override was ON.Repair: The sinking driver on the ECM is not working properly. Replace the ECM. Refer to the diagnostic procedure Troubleshooting, "Replacing the ECM" before proceeding further. Stop.