889032 Mercruiser COVER, Water in Fuel

Probable Causes
Diagnostic codes
Event codes
Electrical connectors
Air inlet and exhaust restrictions
Circuit protection
Unstable fuel supplyRecommended Actions
Table 1
Troubleshooting Test Steps Values Results
1. Check for Diagnostic Codes
A. Establish communication between Cat® Electronic Technician (Cat ET) and the Electronic Control Module (ECM).
B. Certain event codes may derate engine power. Monitor the diagnostic codes on Cat ET. Check for active diagnostic codes and logged codes (intermittent problems).
Note: Wait at least 30 seconds in order for diagnostic codes to become active.
Codes
Result: A code is active or logged.
Repair: Troubleshoot any codes before continuing with this procedure.
Verify that the repair eliminated the problem.
Result: A code is not active or logged.
Proceed to Test Step 2.
2. Inspect Electrical Connectors and Wiring
A. Remove the electrical power from the ECM.
B. Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors for the circuit. Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".
C. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the circuit.
D. Check the ECM connector (allen head screw) for the proper torque. Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".
E. Check the harness and the wiring for abrasion and for pinch points.
Connectors and Wiring
Result: The harness and wiring are OK.
Proceed to Test Step 3.
Result: There is a problem in the connectors and/or wiring.
Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are coupled.
3. Check for a Restriction in the Inlet Air and Exhaust System
A. Check the air filter restriction indicator, if equipped. Clean plugged air filters or replace plugged air filters. Refer to the Operation and Maintenance Manual.
B. Check the air inlet and exhaust system for restrictions and/or leaks.
Restrictions
Result: There are no restrictions in the inlet air or exhaust system.
Proceed to Test Step 4.
Result: There are restrictions in the inlet air or exhaust system.
Repair: Repair or replace damaged inlet air or exhaust system components.
If the problem is not resolved, proceed to Test Step 4.
4. Circuit Protection
A. Inspect the wires and connectors to all circuit protection for the engine.
B. Check the device for circuit protection.
Circuit Protection
Result The circuit protection device is tripped.
Reset the circuit breakers if the circuit breakers are tripped. If necessary, replace fuses (if equipped). Prior to returning the engine to service, determine the condition that caused the circuit breaker to trip. Make the necessary repairs.
Result The circuit protection device is not tripped.
Proceed to Test Step 5.
5. Unstable Fuel Supply
If there is an immediate engine shutdown, troubleshoot the electrical connectors before proceeding with this procedure.
A. Inspect the fuel system. Refer to Systems Operation/Testing and Adjusting, "Fuel System - Inspect" for additional information.
Cold weather adversely affects the characteristics of the fuel. Refer to the engine Operation and Maintenance Manual for information on improving the characteristics of the fuel during cold-weather operation.
B. Check fuel quality. Check the fuel tank for debris or foreign objects which may block the fuel supply.
C. Check the filtered fuel pressure while the engine is being cranked.
Fuel
Result: The fuel quality is not OK.
Replace the fuel. Verify that the repair eliminated the problem.
If the procedure did not correct the issue, contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the Dealer Solutions Network (DSN).