0392405 EVINRUDE SPARK PLUG,Champion L86

Illustration 1 g03694451
Schematic for the solenoid valves
Illustration 2 g03323799
Typical view of the pin locations on the P2 connector for the solenoid valves
(1) Fuel rack solenoid supply
(21) Fuel rack solenoid return
Illustration 3 g03323806
View of the connector for the fuel rack solenoid
(1) Fuel solenoid power
(2) Fuel solenoid ground
Table 2
Troubleshooting Test Steps Values Results
1. Inspect Electrical Connectors and Wiring
A. Thoroughly inspect the terminal connections on the P2/J2 ECM connectors.
B. Thoroughly inspect the connector for the fuel rack solenoid. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
C. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector and the sensor connectors that are associated with the fuel rack solenoid.
D. Check the screw for the ECM connector for the correct torque of 6 N m (53 lb in).
E. Check the harness for abrasions and for pinch points from the solenoid back to the ECM.
F. Verify that the latch tab of the connector is correctly latched. Also verify that the latch tab of the connector has returned to the fully latching position.
Loose connection or damaged wire
Result: There is a fault in a connector or the wiring.
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 correctly connected.
Use the electronic service tool to clear all logged diagnostic codes and 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 and of pinch points.
Proceed to Test Step 2.
2. Check for Diagnostic Codes
A. Turn the keyswitch to the OFF position.
B. Connect the electronic service tool to the diagnostic connector.
C. Turn the keyswitch to the ON position.
D. Monitor the electronic service tool for active diagnostic codes and/or logged diagnostic codes.
Diagnostic codes
Result: A 638-6 diagnostic code is active or recently logged.
Proceed to Test Step 3.
Result: No codes
There may be an open circuit in the circuit for the fuel rack solenoid.
Proceed to Test Step 5.
3. Disconnect the Solenoid in order to Create an Open Circuit
A. Turn the keyswitch to the OFF position.
B. Disconnect the connector for the fuel rack solenoid in order to create an open circuit.
C. Turn the keyswitch to the ON position. Check for active diagnostic codes on the electronic service tool. Wait at least 30 seconds in order for the codes to be displayed.
Diagnostic codes
Result: The 638-6 diagnostic code is no longer active.
There is a short in the solenoid.
Temporarily connect a replacement fuel rack solenoid to the harness.
If the fault is eliminated, reconnect the suspect solenoid. If the fault returns, permanently install the replacement solenoid. Refer to Disassembly and Assembly for the correct procedure.
Result: The 638-6 diagnostic code is still active.
Proceed to Test Step 4.
4. Create an Open Circuit at the ECM Connector
A. Turn the keyswitch to the OFF position.
B. Disconnect the P2 connector from the ECM.
C. Turn the keyswitch to the ON position. Do not attempt to start the engine.
D. Check for active diagnostic codes on the electronic service tool. Wait at least 30 seconds in order for the codes to be displayed.
Note: Diagnostic codes for other engine components will be active with the P2 connector disconnected. Ignore all other codes and only look for a 638-6 diagnostic code.
E. Turn the keyswitch to the OFF position.
Diagnostic codes
Result: The 638-6 diagnostic code is no longer active with the P2 connector disconnected.
The fault is in the wiring for the fuel rack solenoid.
Replace the faulty wiring.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: The 638-6 diagnostic code is still active with the P2 connector disconnected.
Proceed to Test Step 8.
5. Create a Short Circuit at the Solenoid Connector
A. Turn the keyswitch to the OFF position.
B. Disconnect the connector for the fuel rack solenoid.
C. Fabricate a jumper wire. Install the wire between the two pins on the harness connector for the solenoid in order to create a short circuit.
D. Turn the keyswitch to the ON position. Check for active diagnostic codes on the electronic service tool. Wait at least 30 seconds for activation of the diagnostic codes.
E. Remove the jumper wire from the connector for the fuel rack solenoid.
Diagnostic codes
Result: Diagnostic code 638-6 is active when the jumper wire is installed.
Proceed to Test Step 6.
Result: Diagnostic code 638-6 is not active with the jumper installed.
Proceed to Test Step 7.
6. Check the Resistance of the Solenoid Coil
A. Turn the keyswitch to the OFF position.
B. Disconnect the connector for the fuel rack solenoid.
C. Use a suitable multimeter to measure the resistance between the two terminals on the fuel rack solenoid.
Less than 4.5 Ohms
Result: The measured resistance is greater than 4.5 Ohms
There is an open circuit or high resistance in the solenoid coil.
Replace the fuel rack solenoid. Refer to Disassembly and Assembly for the correct procedure.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: The measured resistance is less than 4.5 Ohms.
The fuel rack solenoid coil is OK
The circuit for the fuel rack solenoid is OK. If you were directed here from another procedure, return and complete that procedure.
7. Check the Wiring for an Open Circuit
A. Turn the keyswitch to the OFF position.
B. Disconnect the connector for the fuel rack solenoid. Disconnect the P2 connector from the ECM.
C. Use a suitable multimeter to take the following resistance measurements:
P2:1 to terminal 1 on the harness connector for the fuel rack solenoid
P2:21 to terminal 2 on the harness connector for the fuel rack solenoid
Less than 5 Ohms
Result: At least one of the resistance measurements is greater than 5 Ohms.
The fault is in the wiring between the fuel rack solenoid connector and the P2 connector.
Replace the faulty wiring.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: All resistance measurements are less than 5 Ohms.
Proceed to Test Step 8.
8. Check the ECM
A. Make sure that the latest f