0322409 EVINRUDE SPACER, Housing 5" EXTENSION KIT

The following conditions must exist before any of the above codes will become active:
There are no active 3509 codes.
There are no active 168 codes.The following background information is related to this procedure:The 5 V sensor supply provides power to all 5 V sensors. The ECM supplies 5.0 0.1 V to each of the pressure sensor connectors. The sensor supply is output short circuit protected. A short circuit to the battery will not damage the circuit inside the ECM.
Illustration 1 g03732081
Schematic diagram for the exhaust gas pressure sensor
Illustration 2 g03732082
View of the pin locations on the 62-pin connector for the exhaust gas pressure sensor
(21) Exhaust gas pressure sensor 5 V supply
(22) Exhaust gas pressure sensor ground
(23) Exhaust gas pressure sensor signal
Illustration 3 g03732083
View of the pin locations on the P1 connector for the exhaust gas pressure sensor
(18) Exhaust gas pressure sensor 5 V supply
(37) Exhaust gas pressure sensor ground
(57) Exhaust gas pressure sensor signal
Table 2
Troubleshooting Test Steps Values Results
1. Inspect Electrical Connectors and Wiring
A. Thoroughly inspect the terminal connections on the P2/J2 ECM connector. Refer to Troubleshooting, "Electrical Connectors - Inspect".
B. Thoroughly inspect the connector for the exhaust gas pressure sensor. Refer to Troubleshooting, "Electrical Connectors - Inspect".
C. Perform a 30 N (6.7 lb) pull test on each of the wires in the ECM connector and the sensor connectors that are associated with the exhaust gas pressure sensor.
D. Check the harness for abrasions and for pinch points from the exhaust gas pressure sensor back to the ECM.
Damaged wire or connector
Result: A damaged wire or damaged connector was found.
Repair: Repair the damaged wire or the damaged connector.
Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault.
Result: All connectors, pins, and sockets are correctly connected and/or inserted and the harness is free of corrosion, of abrasion or of pinch points.
Proceed to Test Step 2.
2. Check For Active Diagnostic Codes
A. Turn the keyswitch to the ON position. Wait at least 10 seconds for activation of the diagnostic codes.
B. Verify if any of the diagnostic codes that are listed in Table 1 are active.
Diagnostic codes
Result: None of the preceding diagnostic codes are active.
Repair: If the codes in Table 1 are logged, an intermittent condition may be causing the logged codes. Refer to Troubleshooting, "Electrical Connectors - Inspect".
Result: A 1209-3 or a 1209-4 diagnostic code is active.
Proceed to Test Step 3.
3. Check the Supply Voltage at the Sensor Connector
A. Turn the keyswitch to the OFF position.
B. Disconnect the connector for the exhaust gas pressure sensor.
C. Turn the keyswitch to the ON position. Do not start the engine.
D. Measure the voltage between terminal 1 and terminal 2 on the harness connector for the exhaust gas pressure sensor. The voltage measurement should be 5.0 0.1 VDC.
E. Turn the keyswitch to the OFF position.
F. Reconnect the sensor.
4.9 V to 5.1 V
Result: The voltage measurement is not within the expected range.
Proceed to Test Step 4.
Result: The voltage measurement is within the expected range.
Proceed to Test Step 5.
4. Check the Supply Voltage at the 62-Pin Connector
A. Turn the keyswitch to the OFF position.
B. Disconnect the 62-pin connector.
C. Turn the keyswitch to the ON position. Do not attempt to start the engine.
D. Measure the voltage between terminal 21 and terminal 22 on the 62-pin connector on the harness between the engine and the ECM. The voltage measurement should be 5.0 0.1 V.
E. Turn the keyswitch to the OFF position.
F. Reconnect the 62-pin connector.
4.9 V to 5.1 V
Result: The voltage measurement is 5.0 0.1 V.
The fault is in the 5 V supply wire or the ground wire between the 62-pin engine interface connector and the sensor.
Repair: Replace the faulty wiring.
Use the electronic service tool to verify that the repair eliminates the fault.
Result: The voltage measurement is not 5.0 0.1 V.
The fault is in the 5 V supply wire or the ground wire between the 62-pin engine interface connector and the ECM.
Repair: Replace the faulty wiring.
Use the electronic service tool to verify that the repair eliminates the fault.
5. Verify the Type of Active Diagnostic Code
A. Turn the keyswitch to the ON position. Wait at least 10 seconds for activation of the diagnostic codes.
B. Use the electronic service tool to check for active diagnostic codes. Record all active diagnostic codes.
C. Determine if the fault is related to an open circuit diagnostic code or a short circuit diagnostic code.
Diagnostic codes
Result: A 1209-3 diagnostic code is active.
Proceed to Test Step 6.
Result: A 1209-4 diagnostic code is active.
Proceed to Test Step 8.
Result: Neither of the preceding diagnostic codes are active.
An intermittent fault may exist.
Repair: Refer to Troubleshooting, "Electrical Connectors - Inspect" in order to identify intermittent faults.
6. Create An Open Circuit at the Sensor Connector
A. Turn the keyswitch to the OFF position.
B. Disconnect the connector for the exhaust gas pressure sensor.
C. Turn the keyswitch to the ON position. Wait for at least 10 seconds for activation of the diagnostic codes.
D. Use the electronic service tool to check the "Active Diagnostic Code" screen. Check for an active 1209-4 diagnostic code.
Diagnostic codes
Result: A 1209-4 diagnostic code became active after disconnecting the sensor.
Repair: Temporarily connect a new exhaust gas pressure sensor to the harness, but do not install the new sensor in the engine. Use the electronic service tool in order to verify that the repair eliminates the fault and then permanently in