0316484 JOHNSON THRUST WASHER,Shifter dog,rev.

Operator Information
* What happened, and when?* Under what conditions? Was the engine rpm (speed) high or low?Was the engine under load?* Are there any customer or dealer installed systems that could cause this symptom?* What else occurred?* When did the symptoms begin (and what else happened at that time)?Logged Diagnostic Codes
* Do they correlate to probable causes?* Did they occur at the same time as the symptoms?* Are some codes Logged repeatedly?Other Symptoms
* Are they related to this symptom?* Do they have common probable causes?Finally, test each probable cause using the tests suggested by the procedure. Be sure to check connectors, especially on intermittent problems! Refer to Section 5: P-501: Inspecting Electrical Connectors for details.P-301: Engine Will Not Crank
This is NOT an electronic system problem. Refer to the Systems Operation, Testing & Adjusting Manual for additional information on the following tests. Probable root causes:* Battery Cables/Batteries* E-Stop Switch* Starting motor solenoid or circuit problem (in system wiring)* Starting motor/flywheel ring gear* Engine accessory* Hydraulic cylinder lock* Internal engine problem Perform the following tests in order:1. Check battery post and battery cables for loose connections and corrosion. If corroded, remove and clean cables and connections. Check optional Battery disconnect switch.2. Load test batteries, Refer to Special Instruction, SEHS9249 Use Of 4C-4911 Battery Load Tester. If necessary, charge the batteries. Refer to Special Instruction, SEHS7633 Battery Test Procedure.3. Verify that the optional E-Stop switch is not engaged.4. Test starting motor solenoid operation. Check the system wiring to starting mortor solenoid.5. Test starting mortor operation. Refer to Systems Operation, Testing & Adjusting Manual. Inspect starting motor pinion and ring gear for damage.6. Ensure free movement of driveline. Refer to the Systems Operation, Testing & Adjusting Manual. Check transmission neutral gear indicator for proper operation and adjustment, repair or replace as required.7. Verify timing pin was not left in the flywheel housing after setting valve lash. Use the 9S-9082 Engine Turning Tool and attempt to manually turn the engine. If unable to turn the engine, remove and inspect engine accessories that can lock up the engine (air compressor, oil pump, etc). Repair or replace as necessary. Refer to the Systems Operation, Testing & Adjusting Manual.8. Remove injectors and check for fluid in the cylinders.9. Disassemble engine to inspect for internal components that may be seized, broken, bent, out of alignment, etc. Refer to the Disassembly & Assembly Manual.P-302: Engine Cranks But Will Not Start
Probable root causes:* Starting aids/fuel gel (cold temperature operation)* Electrical Connectors and Wiring* Personality Module or ECM* Engine Speed/Timing Signal* Electrical connections to the unit injector solenoids* Fuel supply* Combustion problem Perform the following tests in order:1. If cold ambient conditions exist, check operation of starting aids. Check cylinder block jacket water heater for malfunction and replace if required. Check for presence of congealed fuel (wax). Repair as required.2. Check for correct installation of the ECM connectors J1/P1 and J2/P2, Engine Speed/Timing Sensor connector J44/P44, and Unit Injector connectors J91/P91. Verify that the ECM is receiving the correct voltage. Turn the keyswitch to the ON position, the warning lamps should turn ON for five seconds then turn OFF. If the lamps do not turn ON, refer to P-346: Electrical Power Supply to the ECM. Aftermarket engine protection devices usually interrupt power to the ECM and prevent communications with the Electronic Service Tool. Check for correct installation and operation of Aftermarket engine protection devices. Aftermarket devices may need to be bypassed to continue.3. If the ECM has an unprogrammed Personality Module the engine will crank but will not start. Access ECM Status in the FLASH PC Program and follow the request to program the personality module. Refer to Section 2: Programming Parameters. Failure to program the personality module will cause the engine to not start or communicate. Cycling the ignition key will allow access to the FLASH PC Program. If the ECM has a serial number ending in CA, ensure that the Personality Module Chip has been installed properly. It should be completely snapped into the ECM Personality Module Socket.4. Connect an Electronic Service Tool and verify that a 190-00 Engine Overspeed Warning has not recently occurred. If an Overspeed condition has occurred, (even an Overspeed Verify Test) the Air Shutoff Solenoid will have to be manually reset.5. Verify there is not an Active 252-11 Incorrect Engine Software Diagnostic Code. If the diagnostic code is present, Refer to Section 5: P-513 ECM Personality Module.6. Observe the engine speed on an Electronic Service Tool Status screen while cranking the engine. If the Electronic Service Tool displays 0 rpm while cranking the engine, there is a problem in the Engine Speed/Timing Sensor circuit. Refer to P-514: Engine Speed/Timing Sensor. If the engine speed is greater than 50 rpm the Engine Speed/Timing circuitry appears to be operating correctly. Verify that the timing reference gear is installed correctly and keyed to the camshaft by means of the locating dowel. If the gear was installed backwards or flipped over during assembly, the engine will not start.7. Check calibration of timing sensor, recalibrated if required. Refer to P-614: Engine Speed/Timing Sensor Calibration. Check for proper orientation between crankshaft and camshaft drive gears, repair as required. Refer to procedure in Disassembly & Assembly Manual.8. Make sure the Unit Injector connectors are properly installed. Refer to P-515: Injector Solenoids and perform the Injector Solenoid Test as a quick check to confirm that the ECM can energize the unit injector solenoids.9. Check for a fuel supply problem and verify fuel pressure. Verify that the fuel pressure sensor P49/J49 is installed. Refer to P-339: Engine Has A Fuel Supply Problem.10. Check for combustion problems.P-303: Engine Misfires, Runs Rough Or Is Unstable
If the problem is intermittent and cannot be re-created, Refer to P-306: Intermittent Low Power Or Power Cutouts. If the problem is consistent and can be re-created, continue with this procedure. Probable root causes:* Cold Mode Operation (Normal Operation, if the problem occurs only after start-up)* Battery Cables, Battery* Electrical Connections to the ECM* Loss of