0395103 EVINRUDE GEARCASE ASSY., Long

Illustration 1 g00903452
Note: The Engine Control Switch (ECS) is mounted within an instrument panel that is located on the right side of the engine. The ECS is locked into the AUTO position with a pin. The pin must be removed in order to perform this test. After performing this test, ensure that the ECS is placed in the AUTO position and that the locking pin has been reinstalled.Test Step 1. Check for Connector Damage.
Verify that the circuit breakers are not tripped.
Turn the circuit breaker for the battery to the OFF position.
Turn the ECS to the OFF/RESET position.
Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors. Refer to the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connectors that are associated with the circuit.
Check the ECM connectors (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the customer connectors (allen head screw) for the proper torque of 2.25 0.25 N m (20 2 lb in).
Check the harness and the wiring for abrasion and pinch points.Expected Result:All connectors, pins, and sockets are coupled and/or inserted, and the harness and wiring should be free of corrosion, of abrasion or of pinch points.Results:
OK - The connectors and wiring are okay. Proceed to test step 2.
Not OK - The connectors and/or wiring are not okay.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 2. Check the Cat Data Link.
Turn the ECS to the OFF/RESET position.
Connect the Cat ET.
Turn the circuit breaker for the battery to the ON position.
Turn the ECS to the STOP position.
Check for any LOGGED diagnostic codes.
Start the engine and read the status information on the Cat ET.
Observe the engine oil pressure and the coolant temperature on the Electronic Monitoring System.Note: If some of the parameters, but not all of the parameters were displayed, the Cat Data Link is okay. Check the component that is associated with any missing parameter.Expected Result:The Cat ET should display the status information. The Electronic Monitoring System should display engine parameters.Results:
OK - The Cat Data Link is operating correctly at this time.Repair: If the problem is intermittent, perform the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors".STOP
No Parameter Displayed - There is a problem with the Cat Data Link. Proceed to test step 3.
Service Tool Did Not Power ON - The Cat ET or the Communication Adapter did not power up. Proceed to test step 4.Test Step 3. Check Communication with the Cat ET and the Communication Adapter.
Turn the ECS to the OFF/RESET position.
Disconnect the service tool connector J60.
Connect the Cat ET.
Turn the ECS to the STOP position.
Read LOGGED diagnostic codes and status information on the Cat ET.Expected Result:Status information should appear on the Cat ET.Results:
OK - Status information appears on the Cat ET. Proceed to test step 7.
Not OK - Status information does not appear on the Cat ET. Proceed to test step 8.Test Step 4. Check Supply Voltage to the Cat Data Link.
Turn the ECS to the OFF/RESET position.
Ensure that all connectors are connected.
Turn the ECS to the STOP position.
Measure the voltage between pin A and pin B at service tool connector J60.Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC. Proceed to test step 7.
Not OK - The voltage does not measure 24 3 VDC. Verify that the wire 200-BK has continuity to the − Battery terminal. Proceed to test step 5.Test Step 5. Check the Voltage at the ECS.
Turn the ECS to the STOP position.
Measure the voltage between the wire 103-RD on Pin 3 of the ECS and the − Battery terminal.Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC.Repair: Repair the wire that is between the ECS and Pin A of the service tool connector.STOP
Not OK - The voltage does not measure 24 3 VDC. Proceed to test step 6.Test Step 6. Check the Voltage to the ECS.
Turn the ECS to the STOP position.
Measure the voltage between the wire 110-RD on Pin 1 of the ECS and the − Battery terminal.Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC.Repair: Perform the diagnostic functional test Troubleshooting, "Engine Control Switch (ECS)".STOP
Not OK - The voltage does not measure 24 3 VDC.Repair: Check the breakers and the wiring between the ECS and the Battery.STOPTest Step 7. Check for Shorts in the Harness
Turn the ECS to the OFF/RESET position.
Disconnect ECM connector J1/P1 from the primary ECM and from the secondary ECM. Disconnect the service tool connector J60/P60. Disconnect the Electronic Monitoring System.
Ensure that the connector J3A/P3A is connected.
Measure resistance from P1-3 to P1-9.
Check the resistance at the following points of the primary ECM and the secondary ECM:
P1-3 to P1-5
P1-9 to P1-5
P1-3 to P1-6
P1-3 to P1-4
P1-9 to P1-4
P1-3 to P1-11
P1-9 to P1-11
Measure the resistance from P99-5 to P99-14.Expected Result:Resistance should read more than 20,000 Ohms for each measurement.Results:
OK - The resistance is greater than 20,000 Ohms. The harness is free of shorts. Proceed to test step 9.
Not OK - The resistance is less than 20,000 Ohms.Repair: Repair the connectors and/or wiring or replace the connectors and/or wiring.STOPTest Step 8. Check the Operation of the Cat ET.Verify proper operation of the Cat ET on another engine.Expected Result:The Cat ET and the communication adapter work on a different engine.Results:
OK - The Cat ET and the communication adapter work on a different engine. Proceed to test step 7.
Not OK - The Cat ET and the communications adapter did not work on another engine. There is a problem with the Cat ET, cables, or the communication adapter.Repair: Repair the Cat ET, cables, or the communication adapter.STOPTest Step 9. Check the Resistance through the Harness.
Turn the ECS to the OFF/RESET position.
Disconnect the ECM connectors J1/P1 on the primary ECM and the secondary ECM. Disconnect the service tool connector J60/P60. Disconnect the connector J99/P99 for