0441257 EVINRUDE STOP, Throttle

Illustration 1 g00687331
Schematic
Illustration 2 g00893821
8 cylinder P2 ECM connector (5) Solenoid 1/3 Return (16) Solenoid 1 Power (17) Solenoid 2/4 Return (26) Solenoid 2 Power (27) Solenoid 5/7 Return (30) Solenoid 7 Power (31) Solenoid 6 Power (32) Solenoid 3 Power (36) Solenoid 8 Power (37) Solenoid 5 Power (38) Solenoid 4 Power (39) Solenoid 6/8 ReturnTest Step 1. Inspect Electrical Connectors And Wiring
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
Turn the keyswitch to the OFF/RESET position. A strong electrical shock hazard is present if the ignition key is not turned OFF.
Thoroughly inspect the J2/P2 ECM connector and the J52/P52 through J57/P57 unit injector connectors. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Check the harness and wiring for abrasion and pinch points from the injectors 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. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.Verify that the repair eliminates the problem. Stop.Test Step 2. Check for Logged Diagnostic Codes
Connect the Caterpillar Electronic Technician (Cat ET) to the service tool connector.
Turn the keyswitch to the ON position, while the engine is OFF.
Observe the diagnostic codes on Cat ET.Expected Result:The following diagnostic codes should not be logged:
1-05 Injector Cylinder 1 open circuit through 8-05 Injector Cylinder 8 open circuit
1-06 Injector Cylinder 1 short through8-06 Injector Cylinder 8 shortResults:
OK - None of the diagnostic codes are logged. Proceed to Test Step 3.
Not OK - One or more of the diagnostic codes are logged. Proceed to Test Step 4.Test Step 3. Perform the Injector Solenoid TestNote: This test will help the service technician verify that the ECM can fire the injector solenoids. DO NOT try to crank the engine during this test. The ECM will terminate the Injector Solenoid Test.
Turn the keyswitch to the ON position, while the engine is OFF.
Perform the Injector Solenoid Test on Cat ET.
As each solenoid is energized by the ECM an audible click can be heard at the valve mechanism cover. Listen for a click at each valve mechanism cover.Note: Repeat the Injector Solenoid Test a few times in order to verify that the ECM is energizing each solenoid.Expected Result:As each solenoid is energized by the ECM, an audible click of the solenoid should be heard. The solenoids will be energized one at a time in numerical order from 1 through 8. There will be a momentary delay between each one.Results:
OK - All of the solenoids were energized. Proceed to Test Step 9.
Not OK - One or more of the solenoids did not energize. Proceed to Test Step 4.Test Step 4. Check the Harness Resistance
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
Turn the keyswitch to the OFF/RESET position.
Disconnect the J2/P2 ECM connector.
Measure the resistance at the P2 ECM connector between the terminals for each solenoid.Refer to Illustration 2.Expected Result:The resistance should be less than 10 Ohms.Results:
OK - Proceed to Test Step 5.
Not OK - There is an open in the harness or there is an open in the injector solenoid. Proceed to Test Step 6.Test Step 5. Check the Harness for Shorts
Disconnect the J52/P52 through J57/P57 unit injector connectors.
Measure the resistance at the P2 ECM connector between the terminals for each solenoid.Refer to Illustration 2.Expected Result:The resistance should be greater than 20,000 Ohms.Results:
OK - There are no shorts in the harness or the connectors. Proceed to Test Step 7.
Not OK - There is a short in the harness or the connectors.Repair: Repair the circuit.Verify that the repair eliminates the problem. Stop.Test Step 6. Isolate the Open Circuit
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
Turn the keyswitch to the OFF/RESET position.
Disconnect the suspect injector at the valve cover base.
Measure the solenoid resistance of the suspect injector at the valve cover base (J52 through J57). Refer to Illustration 1.Expected Result:Resistance should be less than 3.6 Ohms.Results:
OK - There is an open circuit or excessive resistance in the harness or the connectors.Repair: Repair the circuit. Refer to Troubleshooting, "Electrical Connectors - Inspect".Verify that the repair eliminates the problem. Stop.
Not OK - There is an open circuit in the valve cover base harness or the injector solenoid. Proceed to Test Step 8.Test Step 7. Measure Solenoid Resistance at Valve Cover Base
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
Turn the keyswitch to the OFF/RESET position.
Ensure that the J2/P2 ECM connector and J52/P52 through J57/P57 unit injector connectors are disconnected.
Measure the solenoid resistance between terminals 1 and 2 and between terminals 3 and 4 at the J52 through J57 unit injector connectors. Record the measured resistance for each solenoid.Expected Result:Resistance should be between 0.6 and 3.6 Ohms for each solenoid.Results:
OK - Repair: