9563A 1 Mercruiser CARBURETOR ASSEMBLY

Table 1
Diagnostic Trouble Codes for Engine Overcrank Occurrence
J1939 Code CDL Code Code Description
(code descriptions may vary) Comments
1664-31 E225 (3) Engine Automatic Start Failed The code is logged.
The fuel is shut off. Engine cranking is prevented. Probable Causes
Diagnostic codes
Starting aids
Load
Battery
Charging circuit
Starter
Fuel supplyRecommended Actions
Note: The procedures have been listed in order of probability. Complete the procedures in order.
Table 2
Troubleshooting Test Steps Values Results
1. Check for Associated Diagnostic Trouble Codes
A. Establish communication between the electronic service tool and the ECM. Refer to Troubleshooting, "Electronic Service Tools", if necessary.
B. Download the "Warranty Report" from the engine ECM before performing any troubleshooting or clearing diagnostic trouble codes.
Troubleshoot any diagnostic codes that are present before continuing with this procedure.
Diagnostic codes
Result: No diagnostic trouble codes are active or logged.
Proceed to Test Step 2.
Result: Codes are active or logged.
Repair: Troubleshoot the codes before continuing with this procedure.
Refer to Troubleshooting, "Diagnostic Trouble Codes" in order to troubleshoot the diagnostic codes.
2. Starting Aids
A. If cold ambient conditions exist, check the operation of the starting aids.
B. Verify that the starting aids are operating correctly.
Starting aids
Result: The starting aids are operating correctly.
Proceed to Test Step 3.
Result: The starting aids are not operating correctly.
Repair: Refer to the appropriate circuit test in order to troubleshoot the starting aid.
3. Excessive Loads
A. Check for an excessive load on the engine.
B. If necessary, disengage the driven equipment and test the engine.
Excessive load
Result: There are excessive loads on the engine.
Repair: Reduce the load on the engine. Return the unit to service.
Result: The are not excessive loads on the engine.
Proceed to Test Step 4.
4. Battery
A. Check if the battery is able to hold a charge. Refer to Systems Operation/Testing and Adjusting, "Battery - Test" for the correct procedure.
Battery
Result: The battery will no longer hold a charge.
Repair: Replace the battery. Refer to the machine Disassembly and Assembly manual for the correct procedure.
Result: The battery holds a charge.
Proceed to Test Step 5.
5. Switched Battery Circuit
A. Inspect the battery cables, wiring, and connections in the charging circuit.
B. Check if a switched battery circuit drained the battery by being left in the ON position.
C. Charge the battery. Verify that the battery is able to maintain a charge.
Battery circuit
Result: The battery circuit is OK.
Proceed to Test Step 6.
Result: The battery circuit is not OK.
Repair: Clean all connections and tighten all connections. Replace any faulty parts, if necessary.
6. Alternator
A. Inspect the condition of the alternator. Refer to Troubleshooting, "Alternator Problem" for the correct procedure.
Alternator
Result: The condition of the alternator is OK.
Proceed to Test Step 7.
Result: The condition of the alternator is not OK.
Repair: Replace or repair the alternator.
7. Starter Engagement
A. Attempt to start the engine while you observe the status of the relay for the starting motor on the electronic service tool.
Starter engagement
Result: The relay for the starting motor indicates that the engine should crank but no cranking occurs.
Repair: Troubleshoot the starting circuit.
Result: The relay for the starting motor indicates that the engine should crank and cranking occurs.
Proceed to Test Step 8.
8. Crank Cycle
Note: A maximum of one crank cycle per overcrank is recommended.
A. Make sure that the engine can be cranked for a sufficient amount of time.
Crank Cycle
Result: The engine cannot be cranked for a sufficient amount of time.
Repair: Use the electronic service tool to check the "Cycle Crank Time" and the "Overcrank Time" parameters. The purge cycle is part of the total crank cycle. Reprogram the parameters, if necessary.
Proceed to Test Step 9.
9. Inspection of the Fuel Supply
A. Visually check the fuel level in the fuel tank. Do not rely on the fuel gauge only.
B. Ensure that the fuel supply valve (if equipped) is in the full OPEN position.
C. Check the fuel quality.
Make sure that the fuel meets the specification given in the Operation and Maintenance Manual, "Fluid Recommendations".
D. Inspect the fuel system.
Refer to Systems Operation, Testing, and Adjusting, "Fuel System" for additional information.
Cold weather adversely affects the characteristics of the fuel. Refer to the engine Operation and Maintenance Manual, "Cold Weather Operation" for further information.
Fuel level
Result: The fuel level is not OK.
Repair: Fill the tank.
If the engine has run out of fuel, purge the air from the fuel system. Refer to Systems Operation, Testing, and Adjusting, "Fuel System - Prime".
Result: The fuel level is OK.
If the fault is still present, contact the Dealer Solutions Network (DSN).