5220200KZ Mercruiser END MODEL, +STERN DRIVE BRVII (2.00:1 Ratio)

Illustration 1 g01177679
Schematic for the digital supply circuit
Test Step 1. Inspect the Electrical Connectors and the Wiring
Turn the keyswitch to the OFF position.
Illustration 2 g01167488
Left side engine view (typical example)
(1) J1/P1 ECM Connectors
Illustration 3 g01146383
Left side engine view (typical example)
(2) J61 customer connector
Thoroughly inspect connectors (1) and (2). Inspect the connectors for each sensor that is associated with the digital supply. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Illustration 4 g01235961
Terminal locations at the P1 ECM connector
(P1-4) +8 VDC (digital sensor supply)
(P1-5) Sensor return
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the digital sensor supply.
Check the torque of the allen head screws for the ECM connectors and the customer connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
Check the harness and wiring for abrasions and for pinch points from the throttle position sensor to the ECM. Expected Result:All of the connectors, pins, and sockets are completely coupled and/or inserted, and the harness and wiring are free of corrosion, of abrasion and of pinch points.Results:
OK - The connectors and the wiring appear to be OK. Proceed to Test Step 2.
Not OK - There is a problem with a connector and/or the wiring.Repair: Repair the connector and/or the wiring. Replace parts, if necessary. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled. Verify that the problem is resolved.STOPTest Step 2. Check for Active Diagnostic Codes
Connect the Caterpillar Electronic Technician (ET) to the service tool connector. Refer to Troubleshooting, "Electronic Service Tools".
Turn the keyswitch to the ON position.
Observe the active diagnostic code screen on Cat ET. Wait at least 15 seconds so that any codes may become active. Look for these codes:
41-03
41-04 Expected Result:One of the above diagnostic codes is active.Results:
Active 41-03 code - A 41-03 diagnostic code is active. Proceed to Test Step 3.
Active 41-04 code - A 41-04 diagnostic code is active. Proceed to Test Step 4.
No active codes - None of the above codes 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. Refer to Troubleshooting, "Electrical Connectors - Inspect".STOPTest Step 3. Check the Voltage on the +8 V Supply Wire
Turn the keyswitch to the OFF position.
Disconnect the harness connectors for all of the sensors that are associated with the digital supply.
Turn the keyswitch to the ON position.
Illustration 5 g01159881
Sensor connector
(Terminal A) Supply
(Terminal B) Sensor return
(Terminal C) Signal
Measure the voltage between terminals A and B at the harness connector for each of the sensors that are associated with the digital supply. Expected Result:The voltage measurement is 8.0 0.4 VDC.Results:
OK - The voltage measurement is 8.0 0.4 VDC.Repair: Connect the connectors for the throttle position sensor. Clear all diagnostic codes. Check for active diagnostic codes. If the problem is intermittent, refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - The voltage measurement is not 8.0 0.4 VDC. There is a problem with the wiring or with the ECM. Proceed to Test Step 5.Test Step 4. Isolate the Digital Supply and Check for Active Diagnostic Codes
Disconnect the connectors of all of the sensors that are associated with the digital supply.
Wait for 15 seconds after you disconnect the sensor. Check Cat ET for the active 41-04 diagnostic code. Expected Result:The 41-04 diagnostic code deactivates when the sensors are disconnected.Results:
OK - The 41-04 diagnostic code deactivates when the sensors are disconnected.Repair: The problem is in one of the sensor circuits. Refer to the appropriate Troubleshooting procedure to troubleshoot the sensor circuit.STOP
Not OK - The 41-04 diagnostic code remains after the sensors are disconnected. Leave the sensors disconnected. Proceed to Test Step 5.Test Step 5. Check the +8 V Supply Wire for a Short Circuit
Turn the keyswitch to the OFF position.
Disconnect the J1/P1 and J2/P2 connectors.
Verify that the throttle position sensor is disconnected. Note: Wiggle the harness during the following measurements in order to reveal an intermittent condition.
Measure the resistance between P1-4 (+8 V supply) and the remaining terminals on the P1 and P2 connectors.
Measure the resistance between P1-4 (+8 VDC supply) and the engine ground. Expected Result:Each check of the resistance indicates an open circuit.Results:
OK - Each check of the resistance indicates an open circuit. Proceed to Test Step 6.
Not OK - At least one check of the resistance does not indicate an open circuit. A +8 V supply wire has a problem. There may be a problem with a connector.Repair: Repair the wire and/or the connector, when possible. Replace parts, if necessary. Verify that the problem is resolved.STOPTest Step 6. Check the +8 V Supply and the Sensor Return for an Open Circuit
Install a jumper wire between terminals P1-4 (+8 V supply) and P1-5 (sensor return). Note: Wiggle the harness during the following measurement in order to reveal any intermittent short condition.
Measure the resistance between terminals A and B at the harness connector of each of the sensors that are associated with the digital supply.
Remove the jumper wire. Expected Result:The resistance measurements are less than ten Ohms for each circuit.Results:
OK - The resistance measurement