0386657 EVINRUDE STARTER MOTOR ASSY

Illustration 1 g00676128
Schematic
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P2 ECM connectorTest Step 1. Check for Active Diagnostic Codes
Connect the Caterpillar Electronic Technician (ET) to the data link connector.
Start the engine.
Check for active diagnostic codes.Expected Result:One of the following diagnostic codes is present:
42-05 Injection Actuation Valve open circuit
42-06 Injection Actuation Valve short to groundResults:
OK - Proceed to Test Step 2.
Not OK - There may be a mechanical problem with the high pressure oil system.Repair: Repair the problem. Refer to the appropriate topic in the "Troubleshooting Without A Diagnostic Code" section of this manual.Verify that the repair eliminates the problem.STOPTest Step 2. Inspect Electrical Connectors and Wiring
Turn the keyswitch to the OFF/RESET position.
Thoroughly inspect the J2/P2 ECM connector and J46/P46 IAPCV connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.Expected Result:All connectors, pins, and sockets are completely inserted and coupled. The harness and wiring are free of corrosion, of abrasions, and of pinch points. All connections and grounds are tight and free of corrosion.Results:
OK - Proceed to Test Step 3.
Not OK - Repair: Repair the circuit.Verify that the repair eliminates the problem.STOPTest Step 3. Check the Solenoid for an Internal Open or Short
Disconnect J46/P46 IAPCV connector.
Measure the resistance between J46:1 (IAPCV Supply) and J46:2 (IAPCV Return).Expected Result:The resistance is between 5.0 Ohms and 15.0 Ohms.Results:
OK - Proceed to Test Step 4.
Not OK - The IAPCV is faulty.Repair: Replace the IAPCV.Verify that the repair eliminates the problem.STOPTest Step 4. Check for Shorts in the Harness from the IAPCV to the ECM
Disconnect the J2/P2 ECM connector.
Disconnect J46/P46 IAPCV connector.
Measure the resistance between P2:29 (IAPCV Supply) and engine ground. Also, measure the resistance between P2:29 (IAPCV Supply) and all the other pins.
Measure the resistance between P2:35 (IAPCV Return) and engine ground. Also, measure the resistance between P2:35 (IAPCV Return) and all the other pins.Expected Result:The resistance for each measurement is greater than 20,000 Ohms.Results:
OK - Proceed to Test Step 5.
Not OK - There is a short in the wiring between the ECM and the IAPCV.Repair: Repair the circuit.Verify that the repair eliminates the problem.STOPTest Step 5. Check for Open Circuits in the Harness from the IAPCV to the ECM
Turn the keyswitch to the OFF position and install a 7X-1715 Adapter Cable (40-PIN BREAKOUT) at the J2/P2 ECM connector.
Use a suitable piece of wire to short P2:29 (IAPCV Supply) and P2:35 (IAPCV Return).
Disconnect the J46/P46 IAPCV connector.
Measure the resistance between P46:1 (IAPCV Supply) and P46:2 (IAPCV Return).Expected Result:The resistance is less than 10 Ohms.Results:
OK - Proceed to Test Step 6.
Not OK - There is an open circuit in the wiring harness between the IAPCV and the ECM.Repair: Repair the circuit.Verify that the repair eliminates the problem.STOPTest Step 6. Perform the "Injection Actuation Pressure Test"
Reconnect all connectors.
Connect Cat ET to the data link connector.
Start the engine.
Select the "Injection Actuation Pressure Test" under the "Diagnostics" menu in Cat ET.
Increase the desired injection actuation pressure to 21,500 kPa. Observe the actual injection actuation pressure reading.
Decrease the desired injection actuation pressure to 8,000 kPa. Observe the actual injection actuation pressure reading.Expected Result:Actual injection actuation pressure is within 2000 kPa of the desired injection actuation pressure.Results:
OK - The injection actuation pressure circuit is working properly.Repair: Refer to Troubleshooting, "Electrical Connectors - Inspect" if the problem is intermittent.Verify that the repair eliminates the problem.STOP
Not OK - Proceed to Test Step 7.Test Step 7. Temporarily Install a New IAPCV
Remove the IAPCV.
Temporarily install a new IAPCV.
Reconnect all connectors.
Connect Cat ET to the data link connector.
Start the engine.
Select the "Injection Actuation Pressure Test" under the "Diagnostics" menu in Cat ET.
Increase the desired injection actuation pressure to 21,500 kPa. Observe the actual injection actuation pressure reading.
Decrease the desired injection actuation pressure to 8,000 kPa. Observe the actual injection actuation pressure reading.Expected Result:Actual injection actuation pressure is within 2000 kPa of the desired injection actuation pressure.Results:
OK - The IAPCV was faulty.Repair: Permanently install the new IAPCV.Verify that the repair eliminates the problem.STOP
Not OK - Proceed to Test Step 8.Test Step 8. Check the ECM
Turn the keyswitch to the OFF position and install a 7X-1715 Adapter Cable (40-PIN BREAKOUT) at the J2/P2 ECM connector.
Turn the keyswitch to the ON position.
Connect Cat ET to the data link connector.
Access the "Injection Actuation Pressure Driver Test" in the "Special Test" screen that is under the "Diagnostics" menu.
Connect a circuit test light to P2:29 (IAPCV Supply) and P2:35 (IAPCV Return).
Start the "Injection Actuation Pressure Driver Test". Observe the circuit test light.Expected Result:The circuit test light illuminates when the test is active.Note: The presence of the circuit test light may cause a 42-05 Injection Actuation Valve open circuit or a 42-06 Injection Actuation Valve short to ground to become active.Results:
OK - There may be a mechanical problem with the high pressure oil system.Repair: Repair the problem. Refer to the appropriate topic in the "Troubleshooting Without A Diagnostic Code" section in this manual.Verify that the repair eliminates the problem.STOP
Not OK - The ECM is not controlling the IAPCV correctly.Repair: Verify your results.Replace the ECM. Refer to Troubleshooting, "Replacing the ECM" before replacing the ECM.Verify that the repair eliminates the problem.STOP