802565 Mercruiser COVER, Rocker

The connection of any electrical equipment and the disconnection of any electrical equipment may cause an explosion hazard which may result in injury or death. Do not connect any electrical equipment or disconnect any electrical equipment in an explosive atmosphere.
Test Step 1. Check Connectors for Moisture and Corrosion
Illustration 1 g01131211
Leaky seal at the connector (typical example)
Inspect all wiring harnesses. Ensure that the routing of the wiring harness allows the wires to enter the face of each connector at a perpendicular angle. Otherwise, the wire will deform the seal bore. Refer to Illustration 1. This will create a path for the entrance of moisture. Verify that the seals for the wires are sealing correctly.
Illustration 2 g01131276
Diagram for the installation of a connector plug (typical example)
(1) Electronic Control Module (ECM) connector
(2) Correctly inserted plug
(3) Incorrectly inserted plug
Ensure that the sealing plugs are in place. If any of the plugs are missing, replace the plug. Ensure that the plugs are inserted correctly into the connector. Refer to Illustration 2.
Illustration 3 g00835079
Seal for a three-pin connector (typical example)
Illustration 4 g01131019
Seal for a three-pin connector (typical example)
Illustration 5 g01131165
Seal for ECM connector (typical example)
Disconnect the suspect connector and inspect the connector seal. Ensure that the seals are in good condition. If necessary, replace the connector.
Thoroughly inspect the connectors for evidence of moisture entry. Note: It is normal to see some minor seal abrasion on connector seals. Minor seal abrasion will not allow the entry of moisture.If moisture or corrosion is evident in the connector, the source of the moisture entry must be found and the source of the moisture entry must be repaired. If the source of the moisture entry is not repaired, the problem will recur. Simply drying the connector will not fix the problem. Check the following items for the possible moisture entry path:
Missing seals
Improperly installed seals
Nicks in exposed insulation
Improperly mated connectorsMoisture can also travel to a connector through the inside of a wire. If moisture is found in a connector, thoroughly check the connector's harness for damage. Also check other connectors that share the harness for moisture.Note: The ECM is a sealed unit. If moisture is found in an ECM connector, the ECM is not the source of the moisture. Do not replace the ECM.Expected Result:The harness wiring, connectors, and seals are in good condition. There is no evidence of moisture in the connectors.Results:
OK - The harness wiring, connectors, and seals are in good condition. Proceed to Test Step 2.
Not OK - A problem has been found with the harness or the connectors.Repair: Repair the connectors or the wiring, as required. Ensure that all of the seals are properly in place. Ensure that the connectors have been reattached.If corrosion is evident on the pins, sockets or the connector, use only denatured alcohol to remove the corrosion. Use a cotton swab or a soft brush to remove the corrosion.If moisture was found in the connectors, run the engine for several minutes and check again for moisture. If moisture reappears, the moisture is wicking into the connector. Even if the moisture entry path is repaired, it may be necessary to replace the wires.Verify that the repair eliminates the problem.STOPTest Step 2. Check the Wires for Damage to the Insulation
Carefully inspect each wire for signs of abrasion, of nicks, and of cuts. Inspect the wires for the following conditions:
Exposed insulation
Rubbing of a wire against the engine
Rubbing of a wire against a sharp point
Check all of the wiring harness fasteners in order to verify that the harness is properly secured. Also check all of the fasteners in order to verify that the harness is not compressed. Pull back the harness sleeves in order to check for a flattened portion of wire. A fastener that has been overtightened flattens the harness. This damages the wires that are inside the harness. Expected Result:The wires are free of abrasion, of nicks, and of cuts and the harness is properly clamped.Results:
OK - The harness is OK. Proceed to Test Step 3.
Not OK - There is damage to the harness.Repair: Repair the wires or replace the wires, as required. Verify that the repair eliminates the problem.STOPTest Step 3. Inspect the Connector Terminals
Visually inspect each terminal in the connector. Verify that the terminals are not damaged. Verify that the terminals are properly aligned in the connector and verify that the terminals are properly located in the connector. Expected Result:The terminals are properly aligned and the terminals appear undamaged.Results:
OK - The terminals are OK. Proceed to Test Step 4.
Not OK - The terminals of the connector are damaged.Repair: Repair the terminals and/or replace the terminals, as required.Verify that the repair eliminates the problem.STOPTest Step 4. Perform a Pull Test on Each Wire Terminal Connection