0382468 JOHNSON WATER PUMP REPAIR KIT

Table 1
Wiring Faults and the Combinations of Cylinders that are Affected
Wiring Fault Cylinders
Open on the driver side Only one cylinder is affected.
Return side open
Return side short to ground
Cylinder 1 or 15
Short to +Battery on the driver side 1 and 15
Cylinder 2 or 16
Short to +Battery on the driver side 2 and 16
Cylinder 3 or 13
Short to +Battery on the driver side 3 and 13
Cylinder 4 or 14
Short to +Battery on the driver side 4 and 14
Cylinder 5 or 11
Short to +Battery on the driver side 5 and 11
Cylinder 6 or 12
Short to +Battery on the driver side 6 and 12
Cylinder 7 or 9
Short to +Battery on the driver side 7 and 9
Cylinder 8 or 10
Short to +Battery on the driver side 8 and 10
Return side short to +Battery 1, 3, 5, and 9
2, 4, 6, and 10
7, 11, 13, and 15
8, 12, 14, and 16 Because the circuits are in pairs or groups, multiple diagnostic codes can be activated for a single problem. If multiple diagnostic codes are active for the primary ignition, troubleshooting the circuits one at a time is an effective way to find the root cause.Logged diagnostic codes provide a historical record. Before you begin this procedure, use the Caterpillar Electronic Technician (ET) to print the logged codes to a file.The most likely causes of the diagnostic code are a poor electrical connection or a problem in a wiring harness. The next likely cause is a problem with an ignition transformer. The least likely cause is a problem with the ECM.
Illustration 1 g01106046
Schematic for the primary ignition
Test Step 1. Inspect the Electrical Connectors and Wiring
Illustration 2 g01074915
Terminal box
(1) J2/P2 connectors
(2) 16 amp circuit breaker
Set the engine control to the OFF/RESET mode. Switch 16 amp circuit breaker (2) to the OFF position. Note: For the following steps, refer to Troubleshooting, "Inspecting Electrical Connectors".
Thoroughly inspect the J2/P2 connectors.
Check the torque of the allen head screw for the ECM connectors. The proper torque is 6 1 N m (55 9 lb in).
Illustration 3 g01057571
Harness side of the P2 connector
(P2-1) Number 1 transformer's circuit driver
(P2-2) Number 1 transformer's return
(P2-3) Number 2 transformer's circuit driver
(P2-4) Number 2 transformer's return
(P2-24) Number 3 transformer's circuit driver
(P2-25) Number 3 transformer's return
(P2-26) Number 4 transformer's circuit driver
(P2-27) Number 4 transformer's return
(P2-14) Number 5 transformer's circuit driver
(P2-15) Number 5 transformer's return
(P2-16) Number 6 transformer's circuit driver
(P2-17) Number 6 transformer's return
(P2-5) Number 7 transformer's circuit driver
(P2-18) Number 7 transformer's return
(P2-52) Number 8 transformer's circuit driver
(P2-62) Number 8 transformer's return
(P2-32) Number 9 transformer's circuit driver
(P2-33) Number 9 transformer's return
(P2-34) Number 10 transformer's circuit driver
(P2-35) Number 10 transformer's return
(P2-48) Number 11 transformer's circuit driver
(P2-49) Number 11 transformer's return
(P2-50) Number 12 transformer's circuit driver
(P2-51) Number 12 transformer's return
(P2-58) Number 13 transformer's circuit driver
(P2-59) Number 13 transformer's return
(P2-60) Number 14 transformer's circuit driver
(P2-61) Number 14 transformer's return
(P2-40) Number 15 transformer's circuit driver
(P2-41) Number 15 transformer's return
(P2-42) Number 16 transformer's circuit driver
(P2-43) Number 16 transformer's return
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit of the ignition system.
Illustration 4 g00719936
Bulkhead connector on the front housing
Inspect the bulkhead connector for the ignition harness.
Check the ignition harness and wiring for abrasion and for pinch points from the bulkhead connector to the ECM. Expected Result:All of the connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points.Results:
OK - The components are in good condition with proper connections. Proceed to Test Step 2.
Not OK - The components are not in good condition and/or at least one connection is improper.Repair: Perform the necessary repairs and/or replace parts, if necessary.STOPTest Step 2. Check for Diagnostic Codes for the Primary Circuit
Connect Cat ET to the service tool connector. Refer to Troubleshooting, "Electronic Service Tools".
Switch the 16 amp circuit breaker ON. Set the engine control to the STOP mode.
Attempt to start the engine and use Cat ET. Determine if the following codes are active or logged:
301-05 Cylinder 1 Transformer Primary open circuit through 316-05 Cylinder 16 Transformer Primary open circuit
301-06 Cylinder 1 Transformer Primary short through 316-06 Cylinder 16 Transformer Primary shortNote: If a diagnostic code for the primary circuit is logged but not currently active, attempt to repeat the condition that generated the code. Run the engine to full operating temperature.Expected Result:None of the above diagnostic codes are active.