883608T52 Mercruiser GEAR HOUSING ASSEMBLY, Complete

Illustration 1 g01657033Test Step 1. INSPECT ELECTRICAL CONNECTORS AND WIRING
Turn the keyswitch to the OFF position.
Illustration 2 g01167488
Engine view (typical example)
(1) J1/P1 ECM connectors
Thoroughly inspect the J1/P1 and thoroughly inspect the J2/P2 ECM connectors. Thoroughly inspect any connectors that are associated with the prelubrication system. Refer to Troubleshooting, "Electrical Connectors - Inspect".
Illustration 3 g01657113
P1 ECM connector
(P1-10) Prelube relay
Check the torque of the allen head screws for the ECM connectors.
Illustration 4 g01149844
Terminal locations of the prelube relay
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the analog sensors.
Check the harness and wiring for abrasion and for pinch points from the analog sensors to the ECM. 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 connectors and wiring appear to be OK. Proceed to Test Step 2.
Not OK - The connectors and/or wiring are not OK.Repair: Perform the necessary repairs and/or replace parts, if necessary. Refer to Troubleshooting, "Electrical Connectors - Inspect".STOPTest Step 2. VERIFY OPERATION OF THE PRELUBRICATION OIL PUMP
Turn the keyswitch to the ON position. The engine should not be running.
Proceed to the "Diagnostic Override Screen" in Cat ET.
Activate the prelubrication system. Expected Result:The prelubrication oil pump activates.Results:
OK - The prelubrication oil pump activates. The prelubrication system is functioning properly.Repair: If an intermittent problem is suspected, refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - The prelubrication oil pump does not activate. Proceed to Test Step 3.Test Step 3. CHECK THE POWER SUPPLY TO THE PRELUBRICATION RELAY
Measure the voltage between terminal 30 (+Battery) of the prelubrication relay and chassis ground. Expected Result:The voltage is 24.0 8.0 VDC.Results:
OK - The supply voltage is 24.0 8.0 VDC. Proceed to Test Step 4.
Not OK - The supply voltage is not 24.0 8.0 VDC. There is a problem in the wiring between the prelubrication relay and the +Battery.Repair: Repair the circuit.Verify that the repair eliminates the problem.STOPTest Step 4. CHECK THE OUTPUT VOLTAGE OF THE PRELUBRICATION RELAY
Proceed to the "Diagnostic Override Screen" in Cat ET.
Activate the prelubrication system.
Measure the voltage between terminal 85 (+Battery) of the prelubrication relay and chassis ground. Expected Result:The voltage is 24.0 8.0 VDC.Results:
OK - The output voltage is 24.0 8.0 VDC. Proceed to Test Step 10.
Not OK - The output voltage is not 24.0 8.0 VDC. Proceed to Test Step 5.Test Step 5. CHECK THE RESISTANCE OF THE PRELUBRICATION RELAY
Turn the keyswitch to the OFF position.
Measure the resistance across terminal 86 (signal input) and terminal 85 (ground terminal) of the prelubrication relay. Expected Result:The resistance is between 250 Ohms and 500 Ohms.Results:
OK - The resistance is between 250 Ohms and 500 Ohms. Proceed to Test Step 6.
Not OK - The resistance is not between 250 Ohms and 500 Ohms. The relay is faulty.Repair: Replace the relay.Verify that the repair eliminates the problem.STOPTest Step 6. CHECK THE SIGNAL VOLTAGE TO THE PRELUBRICATION RELAY
Turn the keyswitch to the ON position. The engine should not be running.
Proceed to the "Diagnostic Override Screen" in Cat ET.
Activate the prelubrication system.
Measure the voltage between terminal 86 (signal voltage) of the prelubrication relay and chassis ground. Expected Result:The voltage is 24.0 8.0 VDC.Results:
OK - The signal voltage is 24.0 8.0 VDC. Proceed to Test Step 10.
Not OK - The signal voltage is not 24.0 8.0 VDC. Proceed to Test Step 7.Test Step 7. CHECK THE GROUND CIRCUIT FOR THE PRELUBRICATION RELAY
Turn the keyswitch to the OFF position.
Measure the resistance between terminal 85 of the prelubrication relay and chassis ground. Expected Result:The resistance does not indicate an open circuit.Results:
OK - The resistance does not indicate an open circuit. Proceed to Test Step 8.
Not OK - The resistance indicates an open circuit. The ground for the relay for the prelubrication pump is faulty.Repair: Repair the circuit.Verify that the repair eliminates the problem.STOPTest Step 8. CHECK THE HARNESS TO THE ECM
Turn the keyswitch to the OFF position.
Disconnect the J1/P1 ECM connector.
Remove the wire from terminal P1-10 (prelubrication relay signal).
Reconnect the J1/P1 ECM connector.
Disconnect the connector for the prelubrication relay.
Use a suitable piece of wire to short terminal 86 (signal voltage ) and terminal 85 (return) on the connector for the prelubrication relay.
Measure the resistance between the end of the wire from terminal P1-10 (prelubrication relay signal) and chassis ground. Expected Result:The resistance does not indicate an open circuit.Results:
OK - The resistance does not indicate an open circuit. Proceed to Test Step 9.
Not OK - There is a open circuit in the wiring harness between the prelubrication relay and the ECM.Repair: Repair the circuit.Verify that the repair eliminates the problem.STOPTest Step 9. CHECK THE ECM
Turn the keyswitch to the OFF position.
Disconnect the J1/P1 ECM connector.
Install a jumper wire into terminal P1-10 (prelubrication relay signal).
Reconnect the J1/P1 ECM connector.
Return the wiring at the prelubrication relay to the original configuration.
Turn the keyswitch to the ON position. The engine should not be running.
Proceed to the "Diagnostic Override Screen" in Cat ET.
Activate the prelubrication system.
Measure the voltage between the jumper wire from terminal P1-10 (prelubrication relay signal) and chassis gro