815471A 3 Mercruiser CABLE ASSEMBLY

Troubleshooting Index
1. Engine Will Not Turn When Start Switch Is On.2. Engine Will Not Start.3. Misfiring Or Running Rough.4. Stall At Low rpm.5. Sudden Changes In Engine rpm.6. Not Enough Power.7. Too Much Vibration.8. Loud Combustion Noise.9. Valve Train Noise (Clicking).10. Oil In Cooling System.11. Mechanical Noise (Knock) In Engine.12. Fuel Consumption Too High.13. Loud Noise From Valves Or Valve Drive Components.14. Little Movement Of Rocker Arm And Too Much Valve Clearance.15. Valve Rotocoil Or Spring Lock Is Free.16. Oil At The Exhaust.17. Little Or No Valve Clearance.18. Engine Has Early Wear.19. Coolant In Lubrication Oil.20. Too Much Black Or Gray Smoke.21. Too Much White Or Blue Smoke.22. Engine Has Low Oil Pressure.23. Engine Uses Too Much Lubrication Oil.24. Engine Coolant Is Too Hot.25. Starter Motor Does Not Turn.26. Alternator Gives No Charge.27. Alternator Charge Rate Is Low Or Not Regular.28. Alternator Charge Is Too High.29. Alternator Has Noise.30. Exhaust Temperature Is Too High.Problem 1. Engine Crankshaft Will Not Turn When Start Switch Is On
Probable Cause:1. Battery Has Low OutputMake Reference To Problem 25.2. Wires Or Switches Have DefectMake Reference To Problem 25.3. Starter Motor Solenoid Has A DefectMake Reference To Problem 25.4. Starter Motor Has A DefectMake Reference To Problem 25.5. Inside Problem Prevents Engine Crankshaft From TurningIf the crankshaft can not be turned after the driven equipment is disconnected, remove the fuel nozzles and check for fluid in the cylinders when the crankshaft is turned. If fluid in the cylinders is not the problem, the engine must be disassembled to check for other inside problems. Some of these inside problems are bearing seizure, piston seizure and wrong pistons installed in the engine.Problem 2. Engine Will Not Start
Probable Cause:1. Starter Motor Turns Too SlowMake Reference To Problem 26.2. Dirty Fuel FilterInstall new fuel filter.3. Dirty Or Broken Fuel LinesClean or install new fuel lines as necessary.4. Fuel Transfer PumpAt starting rpm, the minimum fuel pressure from fuel transfer pump must be 35 kPa (5 psi). If fuel pressure is less that 35 kPa (5 psi), change the fuel filter element. Look for air in the fuel system. Check and clean, if necessary, the screen at the fuel inlet in the fuel transfer pump. If fuel pressure is still low, install a new fuel transfer pump.5. No Fuel To CylindersPut fuel in fuel tank. "Prime" (remove the air and/or low quality fuel) the fuel system.6. Bad Quality FuelRemove the fuel from the fuel tank. Install a new fuel filter element. Put a good grade of clean fuel in the fuel tank.7. Wrong Fuel Injection TimingMake adjustment to timing.Problem 3. Misfiring Or Running Rough
Probable Cause:1. Fuel Pressure Is LowMake sure there is enough fuel in the fuel tank. Look for leaks or bad bends in the fuel line between fuel tank and fuel transfer pump. Look for air in the fuel system. Check fuel pressure. The outlet pressure of the fuel transfer pump at full load speed is 205 to 345 kPa (30 to 50 psi). If fuel pressure is lower than 140 kPa (20 psi), install a new fuel filter element. Check and clean, If necessary, the screen at the fuel inlet in the fuel transfer pump. If fuel pressure is still low, install a new fuel transfer pump.For New Scroll Fuel System, inspect the check valves in the fuel transfer pump for dirt and debris. Check for a weak or broken pumping spring.2. Air In The Fuel SystemFind the air leak in the fuel system and correct it. If air is in the fuel system, it will probably get in on the suction side of fuel transfer pump.3. Leak Or Break In Fuel Line Between Injection Pump And Injection ValveInstall a new fuel line.4. Wrong Valve ClearanceMake adjustment according to the subject, Valve Clearance Setting.5. Defect In Fuel Injection Valve(s) or Injection Pump(s)Run engine at rpm that misfires the most or runs the roughest. Then loosen a fuel line nut on the injection valve for each cylinder, one at at time. Find the cylinder where a loosened fuel line nut does not change the way the engine runs. Test the injection pump and injection valve for that cylinder. Install new parts where needed6. Wrong Fuel Injection TimingMake adjustment to timing.7. Bent Or Broken Push Rod.Replacement of push rod is necessary.8. Fuel Has "Cloud Point" Higher Than Atmospheric Temperature ("Cloud Point" = Temperature Which Makes Wax For in Fuel).Drain the fuel tank lines, and fuel injection pump housing. Change the fuel filter. Fill the tank with fuel which has the correct "correct point" and remove the air from the system with the priming pump.Problem 4. Stall At Low rpm
Probable Cause:1. Fuel Pressure Is LowMake sure there is enough fuel in the fuel tank. Look for leaks or bad bends in the fuel line between fuel tank and fuel transfer pump. Look for air in the fuel system. Check fuel pressure. The outlet pressure of the fuel transfer pump at full load speed is 205 to 345 kPa (30 to 50 psi). If fuel pressure is lower than 140 kPa (20 psi), install a new fuel filter element. Check and clean, if necessary, the screen at the fuel inlet in the fuel transfer pump. If fuel pressure is still low, install a new fuel transfer pump.For New Scroll Fuel System, inspect the check valves in the fuel transfer pump for dirt and debris. Check for a weak or broken pumping spring.2. Idle rpm Too LowMake adjustment to governor so idle rpm is the same as given in the FUEL SETTING AND RELATED INFORMATION FICHE.3. Defect In Fuel Injection Valve(s)Install a new fuel injection nozzle.4. Engine AccessoriesCheck engine accessories for damage and correct adjustment. If necessary, disconnect the accessories and test the engine.5. Defect In Fuel Injection Pump(s)Install new parts if needed.Problem 5. Sudden Changes in Engine Speed (rpm)
Probable Cause:1. Failure Of Governor Or Fuel Injection PumpLook for damaged or broken springs, linkage or other parts. Remove the governor. Check for free travel of the fuel rack. Be sure fuel