0396258 EVINRUDE CYLINDER & C'CASE ASSY.

Illustration 1 g02303039
Test Step 1. Inspect the Electrical Connectors and Wiring
Remove the electrical power from the engine.Note: For the following steps, refer to Troubleshooting, "Electrical Connectors - Inspect".
Thoroughly inspect each of the following connectors:
J1/P1 connectors
J3/P3 connectors
J11, J6/P6 and J7/P7 connectors
Connectors for the 24 VDC power supply
Connectors for the engine control
Check the torque of the allen head screw for the ECM connectors.
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the electrical power supply.
Check the harness and wiring for abrasion and for pinch points from the power supply to the master ECM and from the engine control to the master ECM.Expected Result: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. Ensure that all of the seals are properly installed. Make sure that the connectors are properly fastened. Verify that the repair has eliminated the problem.STOPTest Step 2. Check the Voltage at the Power Supply, at the Master ECM, and at the Slave ECM.
Make sure that the engine will not crank during this procedure. For an engine with an air starting motor, make sure that the pressurized air supply is OFF. Make sure that the air is purged from the system.Note: If a power supply is used instead of batteries, the minimum voltage for the power supply is 22 VDC. Troubleshoot the power supply if the voltage is less than 22 VDC or more than 29 VDC.
Measure the voltage at the terminals for the power supply. Record the measurement.
Insert two 7X-1710 Multimeter Probes into the harness side of the P1 connector. Insert the first probe into terminal 52. Insert the second probe into terminal 63. Connect a multimeter to the probes.
Switch the 35 amp circuit breaker ON.
Measure the power supply voltage at the P1 connector. During the measurement, wiggle the harness in order to check for an intermittent problem. Be sure to wiggle the harness near each of the connections. Record the measurement.
Switch the 35 amp circuit breaker OFF. Remove the probes from the P1 connector.
Insert two 7X-1710 Multimeter Probes into the harness side of the P3 connector. Insert the first probe into terminal 52. Insert the second probe into terminal 63. Connect a multimeter to the probes.
Switch the 35 amp circuit breaker ON.
Measure the power supply voltage at the P3 connector. During the measurement, wiggle the harness in order to check for an intermittent problem. Be sure to wiggle the harness near each of the connections. Record the measurement.Expected Result:The voltage that is measured at the terminals for the power supply is at least 22 VDC. The voltage that is measured at each connector is within one volt of the voltage that was measured at the terminals for the power supply. The voltage measurements are constant.Results:
OK - Each ECM is receiving the correct voltage.Repair: Perform the following procedure:Switch the 35 amp circuit breaker OFF.Remove the probes from the P3 connector. Proceed to Test Step 3.
Not OK - An ECM is not receiving the correct voltage.Repair: Perform the following procedure:
Switch the 35 amp circuit breaker OFF.
Remove the probes from the P3 connector.
Use a voltmeter to check the wiring. Refer to the schematic for the electrical system. Locate the source of the voltage drop.Note: If an open circuit is suspected in the circuit between the power supply and the powered component also inspect the power distribution box for the following conditions:
Abrasion of the insulation on the wiring within the box
Damage to the posts for the wiring to the circuit breakers
Damage to the internal parts of the circuit breakers
Make repairs, as needed.STOPTest Step 3. Check the Engine Control Switch
Make sure that the engine will not crank during this procedure. For an engine with an air starting motor, make sure that the pressurized air supply is OFF. Make sure that the air is purged from the system.
Connect Cat ET to the service tool connector. Refer to Troubleshooting, "Electronic Service Tools".
Switch the 35 amp circuit breaker ON.Note: A E225 and/or E233 event code may be generated during this step. After you have completed this step, clear the events from the "Logged Events" screen of Cat ET.
Observe the "Active Diagnostic" screen on Cat ET and set the engine control to the STOP mode, the START mode, and the AUTO mode. Look for an active 336-2 Engine Control Switch : Erratic, Intermittent, or Incorrect diagnostic code. Repeat this step several times.Expected Result:A 336-2 diagnostic code was not activated when the engine control was set to the STOP mode, the START mode, and the AUTO mode.Results:
OK - A 336-2 diagnostic code was not activated. The inputs from the engine control are correct. The problem seems to be resolved.Repair: The problem may be intermittent. Refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - A 336-2 diagnostic code was activated. The master ECM has detected an invalid pattern of inputs from the engine control switch. Proceed to Test Step 4.Test Step 4. Check the Circuit of the Engine Control Switch
Make sure that the engine will not crank during this procedure. For an engine with an air starting motor, make sure that the pressurized air supply is OFF. Make sure that the air is purged