0285028 EVINRUDE ENGINE COVER ASSY., 200

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Schematic
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P1 and P2 ECM connectorsTest Step 1. Inspect Electrical Connectors and Wiring
Turn the keyswitch to the OFF/RESET position.
Thoroughly inspect the J1/P1 ECM connector, the J20/P20 primary engine speed/timing sensor connector, and the J44/P44 secondary engine speed/timing sensor connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Check the harness and wiring for abrasion and pinch points from the engine speed/timing sensors to the ECM.Expected Result:All connectors, pins, and sockets should be completely inserted and coupled. The harness and wiring should be free of corrosion, abrasion, and pinch points.Results:
OK - Proceed to Test Step 2.
Not OK - Repair: Repair the circuit. Verify that the repair eliminates the problem. Stop.Test Step 2. Check for Diagnostic Codes
Connect the electronic service tool to the service tool connector.
Turn the keyswitch to the ON position.
Observe logged diagnostic codes on the electronic service tool.Expected Result:The electronic service tool should indicate one of the following diagnostic codes as being active or recently logged:
190-02 Loss of Engine RPM Signal
190-08 Engine Speed Signal abnormal
342-02 Loss of Backup Engine RPM Signal
342-08 Backup Engine Speed Signal abnormalResults:
OK - One of the above diagnostic codes is active or recently logged.Repair: If 190-02 Loss of Engine RPM Signal and/or 190-08 Engine Speed Signal abnormal is present, disconnect the secondary engine speed/timing sensor (bottom).If 342-02 Loss of Backup Engine RPM Signal and/or 342-08 Backup Engine Speed Signal abnormal is present, disconnect the primary engine speed/timing sensor (top). Proceed to Test Step 3.
Not OK - None of the above diagnostic codes is active or recently logged. Proceed to Test Step 3.Test Step 3. Check the Engine Speed/Timing Sensor
Turn the keyswitch to the OFF/RESET position.
The flange of the sensor should be flush against the engine in order to ensure proper operation.
Inspect the bracket in order to ensure that the installation allows the flange of the sensor to be flush against the engine.Verify that the bracket is not bent.Note: The bracket cannot be replaced separately.
Ensure that the O-ring has been installed on the sensor, and ensure that the O-ring is free of damage.Expected Result:The flange of the sensor should be flush against the engine in order to ensure proper orientation. The sensor mounting bracket should not be bent.Results:
OK - The engine speed/timing sensor is seated properly and the bracket is not bent. Proceed to Test Step 4.
Not OK - The engine speed/timing sensor is not seated properly or the bracket is bent.Repair: Perform the following procedure in order to properly install the sensors and the bracket:
Loosen the bolt that holds the sensor mounting bracket to the engine.
Seat the sensor and tighten the bolt.If the sensor will not seat, repair the sensor or replace the sensor, as required.Note: The sensor must not be removed from the bracket.
Ensure that the sensor is properly oriented and that the harness is secured in the proper location.
Verify that the repair eliminates the problem. Stop.Test Step 4. Check Engine Speed on the Electronic Service Tool
Turn the keyswitch to the ON position and crank the engine.
Observe the engine speed on the electronic service tool while you crank the engine.Expected Result:The electronic service tool should display a steady engine speed between 100 and 250 rpm while the engine is cranking and the engine should start.Results:
OK - The engine speed/timing sensor is operating normally at this time.Repair: Reconnect the known good engine speed/timing sensor.If you are troubleshooting an intermittent problem, refer to Troubleshooting, "Electrical Connectors - Inspect". Stop.
No Engine Speed - The engine does not start and the engine speed does not appear on the electronic service tool. Proceed to Test Step 5.
Engine Speed OK/Engine Will Not Start - The engine will not start. Engine speed appears on the electronic service tool.Repair: Reconnect the known good engine speed/timing sensor.Proceed to Troubleshooting, "Engine Cranks But Will Not Start". Stop.Test Step 5. Check for a Short Circuit in the Wiring Harness
Turn the keyswitch to the OFF/RESET position.
Disconnect the ECM connector that contains the wiring for the suspect sensor and the connector for the suspect engine speed/timing sensor.
Measure the following resistances at the connector for the suspect engine speed/timing sensor on the engine harness.
Terminal 1 (Speed/Timing -) and Terminal 2 (Speed/Timing +)
Terminal 1 (Speed/Timing -) and engine ground
Terminal 2 (Speed/Timing +) and engine groundExpected Result:The resistance should be greater than 20,000 Ohms for each measurement.Results:
OK - Proceed to Test Step 6.
Not OK - There is a short circuit in the harness or connectors.Repair: Repair the circuit.Verify that the repair eliminates the problem. Stop.Test Step 6. Check the Resistance through the Harness
Fabricate a jumper wire with Deutsch pins at both ends.
Use the jumper wire to short P1:12 (Primary Engine Speed/Timing -) and P1:18 (Primary Engine Speed/Timing +).
Measure the resistance between J20:1 (Primary Engine Speed/Timing -) and J20:2 (Primary Engine Speed/Timing +).
Use the jumper wire to short P2:4 (Secondary Engine Speed/Timing -) and P2:39 (Secondary Engine Speed/Timing +) together.
Measure the resistance between J44:1 (Secondary Engine Speed/Timing -) and J44:2 (Secondary Engine Speed/Timing +).
Remove the jumper wire and reconnect all of the connectors.Expected Result:The resistance should read less than 10 Ohms when the jumper wire is installed.Results:
OK - The harness resistance is within acceptable limits. Proceed to Test Step 7.
Not OK - There is an open circuit or excessive resistance in the harness or connectors.Repair: Repair the circuit.Verify that the repair eliminates the problem. Stop.Test Step 7. Measure the Resistance at the Sensor
Turn the keyswitch to the OFF position.
Check the harness and the wiring for abrasion and pinch points from the sensor back to the ECM.
Disconnect the suspect sensor from the engine harness.
Thoroughly inspect the connector for the suspect sensor. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Primary engine speed/timing sensor
Measure the sensor resistance (Ohms) from J20:1 (Primary engine speed/timing -) to J20:2 (Primary engine speed/timing +).Resistance ... 75.0 to 230.0 Ohms
Secondary engine speed/timing sensor
Measure the sensor resistance (Ohms) from J44:1 (Secondary engine speed/timing -) to J44:2 (Secondary engine speed/timing +).Resistance ... 600 to 1800 OhmsExpected Result:The readings agree with the values that are listed above.Results: