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4016-E61TRS Diagnostic Manual, May 2000 45
Functional test
TEST STEP RESULT DIAGNOSIS/ACTION
Step 1: Check Connector Mating
• MS Style Connectors
• Make sure the receptacle (jack) coupling is turned clockwise as much as possible and very little, if any, threading on the plug is visible. Make sure the connection is not cross threaded.
• Deutsch HD Style Connectors
• Make sure the plug and receptacle are aligned using index markings. Check that the receptacle coupling is fully turned clockwise and has clicked into locked position. Make sure the two halves cannot be pulled apart.
The connector will securely lock. The connector and locking mechanism is without cracks or breaks.
OK ⇒ Proceed to next step.
NOT OK ⇒ Repair or replace as necessary. STOP.
Step 2: Check ECM Connector “Allen Screw”
• Ensure the Connector Bolt is properly tightened, but be careful not to over tighten and break the bolt.
• Do not exceed 6.0 N·m (4.4 lb ft) of torque on the ECM Connector Bolt when mating the 70-Terminal “AMP”
connector to the ECM.
The ECM Connector is secure and the ECM Connector Bolt is properly torqued.
OK ⇒ Proceed to next step.
NOT OK ⇒ Repair or replace as necessary. STOP.
Step 3: Perform 45 N (10 Pound) Pull Test On Each Terminal/Wire
• Each terminal and connector should easily withstand 45 N (10 lb) of pull, and remain in the connector body. This test checks whether the wire was properly crimped in the terminal and whether the terminal was properly inserted into the connector.
Note: Terminals should ALWAYS be crimped onto the wires using an appropriate tool (1U5804 Deutsch Crimp Tool recommended). Do not solder terminals.
Each terminal and connector easily withstands 45 N (10 Pound) of pull, and remains in the connector body.
OK ⇒ Proceed to next step.
NOT OK ⇒ Repair or replace as necessary. STOP.
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46 4016-E61TRS Diagnostic Manual, May 2000
Step 4: Monitor Electronic Service Tool While Tugging On Wiring And Connectors
Warning!
There is a Strong Electrical Shock Hazard while the engine is turning. Do not touch wires associated with the Ignition Transformer circuit while the engine is cranking or running.
• If there is an Active Diagnostic Code pertaining to the circuit:
• Monitor the Perkins Diagnostic Tool TIPPS Active Code Screen while tugging on all harnesses and connectors that connect to the component with the Active
Diagnostic Code. If the Active Diagnostic Code disappears while tugging on the harness, there is a problem in the wiring or connector.
• If there are no Active Diagnostic codes:
• Monitor the TIPPS Display Status Screen for the component while tugging on the harnesses. If the reading changes erratically while tugging, there is a problem in the wiring or connector.
• If there are no Active Diagnostic codes and there are complaints about sudden intermittent engine speed changes or cutouts:
• Run the engine and listen for burps or cutouts while pulling on the wiring or connectors. If the engine speed changes cuts out while tugging on the harness, there is a problem in the wiring or connector.
The problem appears to be external to the harnesses and connectors. Tugging on the harnesses and connectors has no affect on the Active Diagnostic Code, component status, or engine performance.
OK ⇒ Proceed to next step.
NOT OK ⇒ Repair or replace as necessary STOP.
Step 5: Check Wires For Insulation Nicks Or Abrasion
• Carefully inspect each wire for signs of abrasion, nicks, or cuts. Likely locations to check are anywhere the
insulation is exposed, points where the wire rubs against the engine or a sharp point.
• Check all harness hold down clamps to verify the harness is properly clamped and the clamp is not compressing the harness. Pull the harness sleeves away to check for flattened wires where the clamp holds the harness.
The wires are free of abrasion, nicks, or cuts and the harness is properly clamped.
OK ⇒ Proceed to next step.
NOT OK ⇒ Repair or replace as necessary. STOP.
TEST STEP RESULT DIAGNOSIS/ACTION
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4016-E61TRS Diagnostic Manual, May 2000 47
Step 6: Check Connectors For Moisture Or Corrosion
• Ensure the connector seals and white sealing plugs are in place. If any of the seals or plugs are missing, replace the seal, plug, or if necessary, the connector.
• Check all wiring harnesses to verify the harness does not make a sharp bend out of a connector. This will deform the connector seal and create a moisture entry path.
• Thoroughly inspect ECM Connectors J1/P1 and J2/P2 for evidence of moisture entry.
Note: It is normal to see some minor seal abrasion on the ECM Connector seals. Minor seal abrasion will not allow moisture entry.
• If moisture or corrosion is evident in the connector, the source of the moisture entry must be found and repaired or the problem will reoccur. Simply drying the connector will not fix the problem. Likely moisture entry paths are missing or improperly installed seals, nicks in exposed insulation, or unmated connectors. Moisture can also travel or “wick” from one connector through the inside of a wire to the ECM Connector. If moisture is found in the ECM connector, thoroughly check all connectors and wires on the harness that connect to the ECM. The ECM is not the source of the moisture. Do not replace an ECM if moisture is found in either ECM connector.
Note: If corrosion is evident on pins, sockets or the connector itself, use only denatured alcohol to clean/remove the corrosion with a cotton swab or a soft brush. Do not use any cleaners that contain 1,1,1 trichloro-ethylene because it may damage the connector.
All connectors/seals should be completely
mated/inserted, and the harness/wiring should be free of corrosion, abrasion or pinch points.
OK ⇒ Proceed to next step.
NOT OK ⇒ Repair or replace wiring or connectors as necessary. Ensure all seals are properly in place and connectors completely mated. Verify the repair eliminates the problem by running the engine for several minutes and check again for moisture. If moisture reappears, it is wicking into the connector. Even if the moisture entry path is repaired, it may be necessary to replace the wires that have moisture wicking through them as the wires may have moisture trapped inside the insulation. Verify the repair eliminates the problem. STOP.
Step 7: Inspect The Connector Terminals
• Verify the terminals are not damaged. Verify proper alignment and location of terminals in the connector.
The terminals are properly aligned and appear undamaged.
OK ⇒ Proceed to next step.
NOT OK ⇒ Repair or replace as necessary. STOP.
Step 8: Check Individual Pin Retention Into The Socket
• This is especially important for intermittent problems.
Using a new pin, insert the pin into each socket (one at a time) to check for a good grip on the pin by the socket.
Repeat for each pin on the mating side of the connector, using a new socket for the test. The terminal contact (pin or socket) should stay in place when the connector is held upside down.
The pins and sockets appear to be OK.
OK ⇒ STOP.
NOT OK ⇒ Repair or replace as necessary. STOP.
TEST STEP RESULT DIAGNOSIS/ACTION
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48 4016-E61TRS Diagnostic Manual, May 2000