5220165KZ Mercruiser END MODEL, +STERN DRIVE BRVII (1.65:1 Ratio)

Illustration 1 g01249601
Schematic for the engine pressure sensors
Test Step 1. INSPECT THE ELECTRICAL CONNECTORS AND THE WIRING
Remove electrical power from the engine ECM.
Illustration 2 g01249633
Locations of the engine pressure sensors
(1) Intake manifold pressure sensor
(2) Atmospheric pressure sensor
(3) Engine oil pressure sensor
(4) Fuel pressure sensor
(5) J2/P2 ECM connectors
(6) J1 ECM connector
Illustration 3 g01142856
Air filter assembly (typical example)
(7) Turbocharger inlet pressure sensor
Thoroughly inspect connectors (5) and (6). Also, thoroughly inspect the connectors for sensors (1), (2), (3), (4), and (7). Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Illustration 4 g01204484
Terminal locations at the P2 ECM connector
(P2-15) Intake manifold pressure
(P2-17) Sensor return
(P2-28) Engine oil pressure
(P2-40) Fuel pressure
(P2-57) Atmospheric pressure
(P2-72) Sensor supply
Illustration 5 g01249703
Terminal locations at the P1 ECM connector
(P1-2) Sensor supply (No. 2)
(P1-3) Sensor return (No. 2)
(P1-15) Turbocharger inlet pressure sensor
(P1-27) Fan drive pump pressure
Illustration 6 g01159881
Terminal locations at the sensor connector
(A) Sensor supply
(B) Sensor return
(C) Sensor signal
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connectors that are associated with the circuit.
Check the allen head screw for each of the ECM connectors and the machine connectors for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
Check the harness and wiring for abrasion and for pinch points from the sensors back to the ECM.Expected Result:All connectors, pins and sockets are completely coupled and/or inserted and the harness and wiring are free of corrosion, of abrasion or of pinch points.Results:
OK - The harness and connectors appear to be OK. Proceed to Test Step 2.
Not OK - There is a problem with the connectors and/or wiring.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals for each of the connectors are properly in place and ensure that the connectors are completely coupled. Verify that the repair eliminates the problem.STOPTest Step 2. CHECK FOR ACTIVE DIAGNOSTIC CODES
Connect Caterpillar Electronic Technician (ET) to the service tool connector.
Restore electrical power to the engine ECM.Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
Monitor the active diagnostic code screen on Cat ET. Check if one of the following codes becomes active:
262-03
262-04
2131-03
2131-04
Remove electrical power from the engine ECM.Expected Result:None of the diagnostic codes that are listed above are active.Results:
OK - None of the diagnostic codes that are listed above are active.Repair: If any of the above codes are logged and the engine is not running properly, refer to Troubleshooting, "Troubleshooting Without a Diagnostic Code".If the engine is running properly at this time, there may be an intermittent problem in a harness that is causing the codes to be logged. If an intermittent electrical problem is suspected, refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - One of the diagnostic codes that is listed above is active at this time. There is a problem in the circuit for the pressure sensor supply. Proceed to Test Step 3.Test Step 3. DISCONNECT THE PRESSURE SENSORS AND CHECK FOR ACTIVE DIAGNOSTIC CODES
Restore electrical power to the engine ECM.Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
Monitor the active diagnostic code screen on Cat ET. Check if one of the following codes becomes active:
262-03
262-04
2131-03
2131-04Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
Disconnect the following sensors one at a time:
Atmospheric pressure sensor
Engine oil pressure sensor
Fan drive pump pressure
Fuel pressure sensor
Intake manifold pressure sensor
Turbocharger inlet pressure sensor
Remove electrical power from the ECM.Expected Result:The active diagno