898101422 Mercruiser COUPLING KIT

Illustration 1 g00953087
SchematicTest Step 1. Inspect Electrical Connectors and Wiring
Turn the keyswitch to the OFF/RESET position.
Thoroughly inspect the J1/P1 ECM connector, the J3/P3 machine connector, and all other connectors in the wiring harness. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.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. All connections and grounds should be tight and free of corrosion.Results:
OK - Proceed to Test Step 2.
Not OK - Repair: Repair the circuit.Verify that the repair eliminates the problem. Stop.Test Step 2. Check for Shorts in the Harness from the ECM to the Digital Sensors
Illustration 2 g00953088
J1/P1 ECM connector
Disconnect ECM connector J1/P1 and all of the digital sensors.
Measure the resistance between P1:4 (Digital Sensor +8 VDC) and engine ground.
Measure the resistance between P1:4 (Digital Sensor +8 VDC) and P1:5 (Digital Return).Expected Result:The resistance should be greater than 20,000 Ohms for each measurement.Results:
OK - Proceed to Test Step 3.
Not OK - There is a short between the ECM and one of the sensors.Repair: Repair the circuit. Stop.Test Step 3. Check for Open Circuits in the Harness Between the ECM and the Digital Sensors
Turn the keyswitch to the OFF/RESET position and install a 140-2266 Adapter Cable (70 Pin Breakout T) at the J1/P1 ECM connector .
Use a suitable piece of wire to short P1:4 (Digital Sensor +8 VDC) and P1:5 (Digital Return) at the breakout.
Disconnect all of the digital sensors.
Measure the resistance between terminal A (+8 VDC) and terminal B (Digital Return) of the connector for each digital sensor.
Remove the wire short from the breakout.Expected Result:The resistance should be less than 10 Ohms for each measurement.Results:
OK - Proceed to Test Step 4.
Not OK - There is an open circuit in the wiring harness between the sensor and the ECM.Repair: Repair the circuit.Verify that the repair eliminates the problem. Stop.Test Step 4. Check the Digital Sensor Supply Voltage at the Sensor Connectors
Disconnect all of the digital sensors.
Turn the keyswitch to the ON position.
Measure the voltage across terminal A (+8 VDC) and terminal B (Digital Return) of the connector for each digital sensor.Expected Result:The digital sensor supply voltage should be 8.0 0.5 VDC.Results:
OK - The supply voltage is reaching the sensor. Proceed to Test Step 5.
Not OK - The supply voltage is not reaching the sensor. Proceed to Test Step 7.Test Step 5. Check the Digital Sensors for Internal Shorts
Illustration 3 g00953088
J1/P1 ECM connector
Disconnect all of the digital sensors.
Turn the keyswitch to the ON position.
Reconnect each of the digital sensors while you observe the voltage across P1:4 (Digital Sensor +8 VDC) and P1:5 (Digital Return) at the breakout.Expected Result:The supply voltage should be 8.0 0.5 VDC. The voltage should not drop when the sensors are connected.Results:
OK - None of the sensors are internally shorted.Repair: Refer to Troubleshooting, "Electrical Connectors - Inspect" if the problem is intermittent. Stop.
Not OK - The sensor that caused the voltage to drop may have an internal short. Proceed to Test Step 6.Test Step 6. Temporarily Install a New Sensor
Disconnect the suspect sensor and remove the suspect sensor.
Temporarily install a new sensor.
Turn the keyswitch to the ON position.
Observe the voltage across P1:4 (Digital Sensor +8 VDC) and P1:5 (Digital Return) at the breakout while you connect the new sensor.Expected Result:The supply voltage should be 8.0 0.5 VDC. The voltage should not drop when the sensor is connected.Results:
OK - The suspect sensor was faulty.Repair: Permanently install the new sensor. Stop.
Not OK - The sensor and the circuit appear to be OK at this time.Repair: Refer to Troubleshooting, "Electrical Connectors - Inspect" if the problem is intermittent. Stop.Test Step 7. Check the Digital Sensor Supply Voltage at the ECM
Disconnect all of the digital sensors.
Turn the keyswitch to the ON position.
Measure the voltage across P1:4 (Digital Sensor +8 VDC) and P1:5 (Digital Return) at the breakout.Expected Result:The supply voltage should be 8.0 0.5 VDC.Results:
OK - The ECM is supplying the correct voltage.Repair: Refer to Troubleshooting, "Electrical Connectors - Inspect" if the problem is intermittent. Stop.
Not OK - The ECM is not supplying the correct voltage.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.