18654A 1 Mercruiser BELLOWS ASSEMBLY, EXHAUST

Table 1
Diagnostic Trouble Code for the Water-in-Fuel Sensor
J1939 Code Code Description Comments
97-3 Water In Fuel Indicator : Voltage Above Normal The ECM detects the following conditions:
An open circuit in the Water-In-Fuel (WIF) sensor circuit or a faulty WIF sensor that is not sending the self check ground pulse on power up.
The warning lamp will stay on when the "indicator lamp self check" has been completed. The ECM will disable the function to detect water in fuel while the code is active. Water-in-Fuel Sensor OperationThe WIF sensor is a normally open sensor. During normal operation, there will be no signal sent from the WIF sensor to the ECM. If water is detected in the fuel, the sensor will send a signal to the ECM. If the signal remains constant for 5 seconds, a 97-15 diagnostic code will become active. If the signal remains constant for 30 minutes, a 97-16 diagnostic will become active. These diagnostic codes can also be caused by a short in the WIF sensor circuit.
Illustration 1 g06459729
Schematic diagram for the WIF sensor
Note: All connectors may not be shown. Refer to the Electrical Schematic for the application for details of any connectors between the WIF sensor connector and the ECM connectors.
Table 2
Troubleshooting Test Steps Values Results
1. Inspect Electrical Connectors and Wiring
A. Turn the keyswitch to the OFF position.
B. Thoroughly inspect the connector for the WIF sensor and any interface connectors between the WIF sensor and the ECM connectors. Refer to Troubleshooting, "Electrical Connectors - Inspect".
C. Perform a 30 N (6.7 lb) pull test on each of the wires in the WIF sensor connector and any interface connectors that are associated with the WIF sensor.
D. Check the harness for abrasions, for pinch points, and for corrosion.
Note: Do not disconnect the ECM connector at this stage. The ECM can only be disconnected and reconnected 10 times before damage to the harness connector may occur.
Loose connection or damaged wire
Result: There is a fault in a connector or the wiring.
Repair: Repair any faulty connectors or replace the wiring harness. Ensure that all the seals are properly in place and ensure that the connectors are correctly coupled.
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 coupled and/or inserted. The harness is free of corrosion, abrasion, and pinch points.
Proceed to Test Step 2.
2. Check For Active 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. If the engine will start, then run the engine.
D. Wait for at least 1 minute.
E. Monitor the active diagnostic code screen on the electronic service tool. Check and record any active diagnostic codes.
Diagnostic codes
Result: There are no active diagnostic codes for the WIF sensor.
There may be an intermittent fault.
Repair: Refer to Troubleshooting, "Electrical Connectors - Inspect" to identify intermittent faults.
Result: A 97-15 or 97-16 diagnostic code is active.
Refer to Troubleshooting, "Fuel Contains Water" before continuing with this procedure.
Proceed to Test Step 3.
Result: A 97-3 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 WIF sensor connector.
C. Turn the keyswitch to the ON position.
D. Measure the voltage between the sensor supply and sensor return terminals on the harness connector for the WIF sensor.
E. Turn the keyswitch to the OFF position.
Between 11 V and 13 V for a 12 V system.
Result: The voltage is not within the expected range. The fault is in the sensor supply wire or the return wire .
Repair: Repair the faulty sensor connector or replace the faulty harness.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: The voltage is within the expected range.
Reconnect the WIF sensor to the harness. Proceed to Test Step 4.
4. Check that the Diagnostic Code is Still Active
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. Wait for at least 1 minute.
D. Monitor the active diagnostic code screen on the electronic service tool. Check and record any active diagnostic codes.
Diagnostic code
Result: A 97-3 diagnostic code is active.
Proceed to Test Step 5.
Result: A 97-15 diagnostic code is active.
Proceed to Test Step 8.
Result: No diagnostic code is active.
Return the unit to service.
5. Create a Short Circuit at the Sensor Connector
A.Turn the keyswitch to the ON position. Wait for at least 1 minute.
B. Disconnect the WIF sensor from the harness.
C. Fabricate a jumper wire that is 150 mm (6 inch) long.
D. Use the jumper to connect the sensor signal terminal to the sensor return terminal on the harness connector for the WIF sensor.
E. Monitor the active diagnostic code screen on the electronic service tool. Check and record any active diagnostic codes.
Open circuit
Result: A 97-3 diagnostic code was active before installing the jumper. A 97-15 code was active with the jumper installed. There is an open circuit in the WIF sensor.
Repair: Install a replacement sensor. Refer to Disassembly and Assembly, "Water Separator and Fuel Filter (Primary) - Remove and Install" for the correct procedure.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: There is still an active 97-3 diagnostic code with the jumper installed. The sensor is OK.
Proceed to Test Step 6.
6. Check the Wiring Between the WIF Sensor and the Interface Connector (if equipped) for an Open Circuit
Note: This step is only applicable if an interface connector is installed between the WIF sensor and the ECM. Refer to the Electrical Schematic for the application for more information. Proceed to Test Step 7 if no interface connector is installed.
A. Turn the keyswitch to the OFF position.
B. Disconnect the connector for the WIF sensor. Disconnect the interface connector between the WIF sensor and the ECM.
C. Use a suitable multimeter to measure the resistance between the sensor signal terminal on the WIF sensor harness connector