5D30243KZ Mercruiser END MODEL, Stern Drive (2.43:1 Ratio)

Illustration 1 g01249899
Schematic for the crank without injection
Test Step 1. Inspect the Electrical Connectors and the Wiring
Turn the keyswitch to the OFF position.
Illustration 2 g01249923
Locations of the circuit components for the crank without injection
(1) Crank without injection plugs
(2) J1/P1 ECM connectors
Thoroughly inspect the connector for the crank without injection plugs (1). Also, thoroughly inspect connectors (2). Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Illustration 3 g01249918
Terminal locations at the P1 ECM connector for the crank without injection
(P1-35) Crank without injection input (NC)
(P1-44) Crank without injection input (NO)
Illustration 4 g01250093
Terminal locations at the connectors for the crank without injection
(Terminal A) Return (chassis ground)
(Terminal B) Crank without injection input (NC)
(Terminal C) Crank without injection input (NO)
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the circuit.
Check the allen head screw for each of the ECM connectors for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
Check that all connectors, pins, and sockets are completely inserted and coupled. The harness and wiring must be free of corrosion, of abrasion, and of pinch points. All connections and grounds must be tight and free of corrosion. Expected Result:All connectors, pins, and sockets are completely inserted and coupled. The harness and wiring are free of corrosion, of abrasion, and of pinch points. All connections and grounds are tight and free of corrosion.Results:
OK - The harness and wiring appear to be OK. Proceed to Test Step 2.
Not OK - There is a problem in the connectors and/or wiring.Repair: 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 completely coupled.Verify that the repair eliminates the problem.STOPTest Step 2. Check the Status on Cat ET
Check the connector for the crank without injection in order to ensure that the plug for HHH (engine run) is installed.
Connect Cat ET to the service tool connector.
Turn the keyswitch to the ON position.
Observe the status for "Crank w/o Injection" on Cat ET.
Turn the keyswitch to the OFF position.
Remove plug HHH (engine run) and install plug JJJ (crank w/o injection input).
Turn the keyswitch to the ON position.
Observe the status for "Crank w/o Injection" on Cat ET. Turn the keyswitch to the OFF position.Expected Result:The status reads "Off" when plug HHH (engine run) is installed. The status reads "On" when plug JJJ (crank w/o injection input) is installed.Results:
OK - The status of the "Crank w/o Injection" on Cat ET agrees with the results that are stated above.Repair: The feature is working properly. There may be an intermittent problem in a connector or in the wiring harness. If an intermittent problem is suspected, refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct troubleshooting procedures.STOP
Not OK - The status of the "Crank w/o Injection" on Cat ET does not agree with the results that are stated above. The ECM is not detecting the inputs correctly. Proceed to Test Step 3.Test Step 3. Check the Continuity at the Terminals of the Crank Without Injection Plugs
Disconnect the crank without injection plug from the connector.
Remove the crank without injection plugs from the connector.
Check that plug HHH is in good repair:
Check for continuity between terminals A and B. Continuity will exist between these terminals for a plug that is in good repair.
Check for continuity between terminals A and C. Also check for continuity between terminals B and C. An open circuit will exist between these terminals for a plug that is in good repair.
Check that plug JJJ is in good repair:
Check for continuity between terminals A and C. Continuity will exist between these terminals for a plug that is in good repair.
Check for continuity between terminals A and B. Also check for continuity between terminals B and C. An open circuit will exist between these terminals for a plug that is in good repair.Expected Result:All of the measurements indicate that the plugs are OK.Results:
OK - Both of the plugs are OK. The crank without injection plugs are not the cause of the problem. There is a problem in the wiring harness between the connector and the ECM. There may be a problem with the ECM. Proceed to Test Step 4.
Not OK - At least one of the measurements does not agree with the results that are given above.Repair: There is either a short circuit or an open circuit in one of the plugs. Replace the crank without injection plug that failed the test. Verify that the repair eliminates the problem.STOPTest Step 4. Check for the Correct Operation of the ECM
Disconnect the J1/P1 ECM connectors.
Fabricate two jumper wires that are long enough to create a short between the ECM connector and the engine ground stud. Crimp a connector socket to one end of each of the jumper wires.
Remove the wires from terminal locations P1-35 and P1-44 at the ECM connector. Install one of the jumper wires into each of these terminal locations.
Reconnect the J1/P1 ECM connector.
Connect the loose end of the jumper wire that is in terminal P1-35 to the engine ground stud.
Hold the loose end of the other jumper wire away from any ground source in order to create an open circuit condition for this ECM input.
Turn the keyswitch to the ON position.
Observe the status for "Crank w/o Injection" on Cat ET. The correct status for "Crank w/o Injection" in this configuration is "Off".
Turn the keyswitch to the OFF position.
Remove the loose end of the jumper wire that is in terminal P1-35 from the engine ground stud. Hold the loose end of this jumper wire away from any ground source in order to create an open circuit condition for this ECM input.
Connect the loose end of the jumper wire that is in terminal P1-44 to the engine ground stud.
Turn the keyswitch to the ON position.
Observe the status for "Crank w/o Injection" on Cat ET. The correct status for "Crank w/o Injection" in this configuration is "On".
Turn the keyswitch to the OFF position. Restore all wiring to