42763 Mercruiser GASKET SET, INTAKE MANIFOLD

Table 1
Diagnostic Trouble Codes for Ether Injection
J1939 Code CDL Code Code Description
(code descriptions may vary) Comments
626-5 2417-5 Ether Injection Control Solenoid : Current Below Normal The Electronic Control Module (ECM) detects a low current condition in the output from the ECM to the solenoid for ether injection.
The code is latched. The code is logged.
Ether injection is disabled.
626-6 2417-6 Ether Injection Control Solenoid : Current Above Normal The ECM detects a high current condition in the output from the ECM to the solenoid for ether injection.
The code is latched. The code is logged.
Ether injection is disabled. The ether injection system will improve cold weather starting of the engine. The engine Electronic Control Module (ECM) controls the ether injection system. The ether injection system is disabled if there is an active engine shutdown.Activation of the ether starting aid is based from a map using the coolant temperature, intake manifold temperature, and atmospheric pressure. Refer to Illustration 1.
Illustration 1 g02445796The following conditions must be met for the ether injection system to be enabled:
Ether injection is set to "Enabled" in the electronic service tool
Engine coolant temperature is less than the "Start Aid Selection Temperature - Coolant". Refer to Illustration 1.
Intake manifold temperature is less than the "Start Aid Selection Temperature - IMAT."
Coolant temperature and intake manifold air temperature are within 11° C of each other.
Note: Continuous cranking with Ether that does not achieve an engine start will result in the Ether being locked out if the maximum allowed volume of Ether has been exceeded (10 x 15 second cranks).
To re-enable Ether injection, a successful start must be achieved, the engine run at low idle speed for at least 5 seconds and a minimum SCR inlet temperature of 160°C achieved for at least 5 seconds.
Illustration 2 g01696575
Ether starting aid group (typical example)
(1) Ether injection solenoid
Illustration 3 g01155187
Terminal locations at the harness connector for the ether solenoid
(1) Ether enable solenoid
(2) Return for ether injection solenoid
Illustration 4 g03712340
Schematic for the ether injection system
Not all connectors are shown. Refer to the appropriate electrical schematic.
Complete the procedure in the order in which the steps are listed.
Table 2
Troubleshooting Test Steps Values Results
1. Inspect Electrical Connectors and Wiring
A. Remove the electrical power from the ECM.
B. Thoroughly inspect the ECM connector J1/P1. Inspect all 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 correct torque of 6 N m (53 lb in).
E. Check the harness and the wiring for abrasion and for pinch points.
Loose connection or damaged wire
Result: The harness and wiring are OK.
Proceed to Test Step 2.
Result: There is a fault in a connector or the wiring.
Repair: Repair any faulty connectors or replace the wiring harness. Ensure that all the seals are properly in place and ensure that the connectors are correctly coupled.
Proceed to Test Step 4.
2. Check the Wiring Between the ECM and the Ether Injection Solenoid
The ether canister must be removed prior to performing this procedure.
A. Verify that the keyswitch is in the OFF position.
B. Remove the ether canister.
C. Disconnect the engine harness connector for the ether injection solenoid.
D. Connect a digital voltmeter across the two terminals on the engine harness connector for the ether injection solenoid.
E. Turn the keyswitch to the ON position.
F. Measure the voltage across the terminals while the keyswitch is turned ON.
10 VDC
Result: The voltage measured 0 VDC.
Repair: There is a problem in an electrical component between the ECM and the harness connector for the ether injection solenoid. The problem may be inside an electrical connector. Make the necessary repairs.
Proceed to Test Step 3.
Result: The voltage measured greater than 10 VDC.
The electrical components between the ECM and the harness connector for the ether injection solenoid are OK.
Proceed to Test Step 3.
3. Measure the Resistance of the Ether Injection Solenoid
A. Verify that the ether injection solenoid is not connected to the engine harness.
B. Measure the resistance of the coil inside the ether injection solenoid.
20 Ω
Result: The measured resistance was approximately 20 Ω.
Proceed to Test Step 4.
Result: The measured resistance was not approximately 20 Ω.
Repair: Replace the ether injection solenoid.
Proceed to Test Step 4.
Illustration 5 g03152796
Ether injection solenoid activation pin
Table 3
Troubleshooting Test Steps Values Results
4. Verify the Repair
A. Activate the Ether Injection Override.
B. Verify that the plunger moved up when the override was active.
Plunger movement
Result: The plunger moved up when the override was active.
Install the