8866A61 Mercruiser GEAR HOUSING ASSEMBLY, (15/19), Complete

Illustration 1 g01482153
Schematic of the ether injection system
Illustration 2 g01160725
Connector for the ether start valve
(Terminal 1) Ether solenoid
(Terminal 2) Solenoid return
Illustration 3 g01482318
Pin locations on the P1 connector (harness side)
(25) Ether solenoid return
(29) Ether injection signal
Breathing ether vapors or repeated contact of ether with skin can cause personal injury. Personal injury may occur from failure to adhere to the following procedures.Use ether only in well ventilated areas.Do not smoke while changing ether cylinders.Use ether with care to avoid fires.Do not store replacement ether cylinders in living areas or in the operator's compartment.Do not store ether cylinders in direct sunlight or at temperatures above 49 °C (120 °F).Discard cylinders in a safe place. Do not puncture or burn cylinders.Keep ether cylinders out of the reach of unauthorized personnel.
Test Step 1. Inspect the Electrical Connectors and the Wiring
Remove electrical power from the ECM.
Thoroughly inspect the ECM connectors. Inspect any other connectors that are associated with the circuit. Refer to Troubleshooting, "Electrical Connectors - Inspect".
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the ether injection system.
Check the torque of the allen head screws for the ECM connectors. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
Check the harness and the wiring for abrasion and for pinch points from the ether injection solenoid 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 and of pinch points.Results:
OK - The connectors and the wiring appear to be OK. Proceed to Test Step 2.
Not OK - The connectors and/or the wiring are not OK.Repair: Repair the connectors and/or the wiring. Replace parts, if necessary. If necessary, use the electronic service tool to perform a "Wiggle Test".Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault.STOPTest Step 2. Check for Active Diagnostic CodesNote: Remove the ether canister before you perform this procedure.
Connect the electronic service tool to the diagnostic connector. Refer to Troubleshooting, "Electronic Service Tools".
Restore electrical power to the engine ECM.
Proceed to the "Diagnostic Overrides" screen on the electronic service tool.
Activate the ether injection system. The system will activate for ten seconds.
Monitor the active diagnostic code screen on the electronic service tool. Check and record any active diagnostic codes. Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
Check for a 2417-5 diagnostic code or a 2417-6 diagnostic code. Expected Result:No diagnostic codes are active.Results:
No active codes - Neither diagnostic code is active.Repair: The fault may have been caused by a poor electrical connection. Carefully inspect the connectors and the wiring. Refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - A 2417-06 code is active at this time. Proceed to Test Step 3.
Not OK - A 2417-05 code is active at this time. Proceed to Test Step 4.Test Step 3. Create an Open at the Harness Connector for the Ether Injection Solenoid
Remove electrical power from the engine ECM.
Disconnect the connector for the solenoid.
Restore electrical power to the engine ECM.
Proceed to the "Diagnostic Overrides" screen on the electronic service tool.
Activate the ether injection system. The system will activate for ten seconds.
Monitor the active diagnostic code screen on the electronic service tool. Check for a 2417-05 code. Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
Remove electrical power from the engine ECM. Expected Result:A 2417-05 code is now active.Results:
OK - A 2417-06 code was active before the connector was disconnected. A 2417-05 code became active after the connector was disconnected.Repair: Temporarily connect a new solenoid to the harness, but do not install the new solenoid. Use the electronic service tool in order to verify that the repair eliminates the fault.If there are no active codes for the ether injection system, permanently install the new solenoid.Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault.STOP
Not OK - A 2417-06 code was active before the connector was disconnected. The 2417-06 code remained active after the connector was disconnected. Leave the connector for the solenoid disconnected. Proceed to Test Step 5.Test Step 4. Create a Short at the Connector for the Ether Injection Solenoid
Remove electrical power from the engine ECM.
Disconnect the connector for the solenoid.
Fabricate a jumper wire that can be used to create a short between terminal 1 and terminal 2 at the connector for the solenoid. Crimp connector pins to each end of the jumper wire.
Install the jumper wire between terminals 1 and 2 of the harness connector.
Restore electrical power to the engine ECM.
Proceed to the "Diagnostic Overrides" screen on the electronic service tool.
Activate the ether injection system. The system will activate for ten seconds.
Monitor the active diagnostic code screen on the electronic service tool. Check for a -06 code. Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
Remove electrical power from the engine ECM. Remove the jumper wire from the connector. Expected Result:A 2417-05 code is now active.Results:
OK - A 2417-05 code was active before the jumper wire was installed. A 2417-6 code became active after the jumper wire was installed.Repair: The engine harness and the ECM are OK. Temporarily connect a new solenoid to the harness, but do not install the new solenoid. Use the electronic service tool in order to verify that the repair eliminates the fault. If there are no active diagnostic codes for the solenoid, permanently install the new solenoid.Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault.STOP
Not OK - A 2417-05 code was active before the jumper wire was installed. The 2417-05 code remained active after the jumper wire was installed. Remove the jumper wire and connect the connector. Proceed to Test Step 5.Test Step 5. Check the Operation of the ECM
Remove electrical power from the engine ECM.
Check the operation of the ECM