5005042 EVINRUDE DIAPHRAGM & HOSE Assy, Exhaust

Illustration 1 g01458702
Typical schematic of the digital throttle position sensor
Illustration 2 g01458703
Typical example of the pin locations on connector P1
(33) Sensor return
(43) Sensor supply (8 Volts)
(53) Sensor input Test Step 1. Inspect Electrical Connectors and Wiring
Inspect the P1/J1 connector, OEM harness and the OEM connectors. Thoroughly inspect the digital throttle position sensor connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the digital throttle position sensor:
P1:33
P1:43
P1:53
Check the screw for the ECM connector for the correct torque of 5.0 N m (44 lb in).
Check the harness for abrasion and pinch points from the digital throttle position sensor to the ECM. Expected Result:All connectors, pins and sockets are completely coupled and/or inserted and the harness is free of corrosion, of abrasion or of pinch points.Results:
OK - Proceed to Test Step 2.
Not OK - Repair: Perform the following repair:Repair the connectors or the harness and/or replace the connectors or the harness. Ensure that all of the seals are correctly in place and ensure that the connectors are completely coupled.Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault.STOPTest Step 2. Check for Active Diagnostic Codes
Connect the electronic service tool to the diagnostic connector.
Turn the keyswitch to the ON position.
Monitor the active diagnostic code screen on the electronic service tool. Check and record active diagnostic codes. Note: When the ECM automatically calibrates new duty cycle values for the low idle throttle position and the high idle throttle position, the ECM assumes 22 percent duty cycle at low idle and 75 percent duty cycle at high idle. As a result, you may notice that the throttle position status reaches 100 percent well before the throttle pedal is fully depressed. This is normal. After some cycling of the throttle pedal to the high idle position, the ECM will adjust the calibration automatically, provided that the high idle stop position is within the 75 to 90 percent duty cycle range, and the low idle is in the 10 to 22 percent duty cycle range. During normal operation, you may also notice that more movement of the throttle pedal is required for the throttle position status to increase above three percent. You may also observe that the status reaches the 100 percent value prior to the limit of the high idle position. This is done in order to ensure that the throttle reaches these two critical points for engine operation.Expected Result:Result 1 Diagnostic code 91-8 or 91-12 is active.Result 2 Diagnostic code 41-3, 41-4, 91-3 or 91-4 is active.Result 3 There are no active diagnostic codes that are related to the sensor circuit for the position of the digital throttle pedal at this time, but a fault is suspected with operation of the sensor circuit.Results:
Result 1 - Proceed to Test Step 3.
Result 2 - Proceed to Test Step 5.
Result 3 - Proceed to Test Step 3.Test Step 3. Check the Duty Cycle of the Digital Throttle Position Sensor
Verify that the keyswitch is in the ON position.
Monitor the duty cycle of the throttle sensor on the display screen of the electronic service tool. Expected Result:The duty cycle is between 10 and 22 percent with the throttle pedal assembly in the low idle position, and the duty cycle is between 75 and 90 percent with the throttle pedal assembly in the high idle position.Results:
OK - The digital throttle position sensor is operating correctly. Proceed to Test Step 6.
Not OK - The digital throttle position sensor circuit is not operating correctly. Proceed to Test Step 4.Test Step 4. Check the Supply Voltage at the Digital Throttle Position Sensor
Turn the keyswitch to the OFF position.
Install a breakout "T" with 3 terminals at the digital throttle position sensor connector J403/P403.
Turn the keyswitch to the ON position.
Measure the voltage at terminal "A" (+8 Volts) with reference to terminal "B" (digital throttle position sensor ground). Expected Result:The measured voltage is between 7.5 Volts DC and 8.5 Volts DC for the digital throttle position sensor.Results:
OK - Proceed to Test Step 8.
Not OK - The sensor is not receiving the correct voltage. Proceed to Test Step 5.Test Step 5. Monitor the Electronic Service Tool while the Digital Throttle Position Sensor is Being Disconnected
Access the active diagnostic code screen on the electronic service tool. Ensure that one of the following diagnostic code is active before proceeding:
41-3
41-4
91-3
91-4
Monitor the active diagnostic code screen while the digital throttle position sensor is being disconnected and reconnected. Expected Result:One of the following diagnostic codes is still active after the digital throttle position sensor has been disconnected:
41-3
41-4
91-3
91-4Results:
OK - Ensure that the digital throttle position sensor has been reconnected before continuing. Proceed to Test Step 7.
Not OK - Repair: Perform the following diagnostic procedure:Temporarily install another digital throttle position sensor. Use the electronic service tool in order to check for an active +8 Volt diagnostic code. Replace the digital throttle position sensor if both of the following conditions occur:
The fault is corrected with the new digital throttle position sensor.
The fault returns after the old digital throttle position sensor has been reconnected.STOPTest Step 6. Check the Status of the Power Train Data Link with the Electronic Service Tool
Start the engine. Use the electronic service tool in order to monitor the throttle position status. While the throttle position status is being monitored, fully depress the throttle pedal and release the throttle pedal. The throttle position status and the engine should respond to