8866G04 Mercruiser GEAR HOUSING ASSEMBLY, Complete (16/27) (Complete)

Table 1
Pin Connections
Sensor Pin Function P2 Pin Connection
1 Ground 19
2 Signal 17
Illustration 1 g02710265
Schematic for the wastegate regulator connector
Illustration 2 g01459431
Wastegate regulator connector
(1) Ground (GND)
(2) Signal (SIG)
Illustration 3 g01459727
Pin locations for the wastegate regulator on the P2 connector
(17) Wastegate pulse width modulation (PWM) signal
(19) Wastegate return
Illustration 4 g01661858
Wastegate regulator
(1) Wastegate regulatorTest Step 1. CHECK FOR DIAGNOSTIC CODES
Turn the keyswitch to the OFF position.
Connect the electronic service tool to the data link connector.
Turn the keyswitch to the ON position. Start the electronic service tool.
Monitor the electronic service tool for active diagnostic codes and/or logged diagnostic codes.Expected Result:One or more diagnostic codes are active or logged.Results:
Diagnostic codes 526-5, 526-6 are active and/or logged - Proceed to Test Step 2.
No Codes - The fault seems to be resolved.Repair: For intermittent faults, refer to Troubleshooting, "Electrical Connectors - Inspect".STOPTest Step 2. INSPECT ELECTRICAL CONNECTORS AND WIRING
Thoroughly inspect the P2/J2 ECM connector and the P511 wastegate regulator connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the wastegate solenoid.
Check the screw for the ECM connector for the correct torque of 5.0 N m (44 lb in).Expected Result:All connectors, pins, and sockets are coupled and/or inserted and the harness is free of corrosion, abrasion, and pinch points.Results:
OK - The harness is OK. Proceed to Test Step 3.
Not OK - There is a fault in the connectors and/or the harness.Repair: Repair the connectors or the harness and/or replace the connectors or the harness. Ensure that all the seals are correctly in place and ensure that the connectors are coupled.Use the electronic service tool to clear all logged diagnostic codes and then verify that the repair eliminates the fault.STOPTest Step 3. DETERMINE THE DIAGNOSTIC CODE THAT IS ACTIVE
Turn the keyswitch to the ON position. Access the "Diagnostics Tests" on the electronic service tool. Activate the "Turbo Wastegate Solenoid Test". Wait at least 30 seconds for the result to be displayed.
Determine if the fault is related to either of the following:
"Low current" (open circuit)
"High current" (short circuit)Expected Result:The electronic service tool displays no diagnostic codes.Results:
OK - There are no active codes.Repair: The original codes may have been caused by a loose connector. If this is an intermittent fault, refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - Diagnostic code 526-5 is active. Proceed to Test Step 4.
Not OK - Diagnostic code 526-6 is active. Proceed to Test Step 6.
Not OK - Diagnostic code 526-7 is active. Proceed to Test Step 4.Test Step 4. CREATE A SHORT CIRCUIT IN THE HARNESS AT THE SOLENOID
Turn the keyswitch to the OFF position.
Disconnect the P511 wastegate regulator connector.
Fabricate a jumper wire between P511:1 and P511:2 to create a short circuit.
Turn the keyswitch to the ON position. Access the "Diagnostics Tests" on the electronic service tool. Activate the "Turbo Wastegate Solenoid Test". Wait at least 30 seconds for the result to be displayed.
Check for active diagnostic codes on the electronic service tool.Expected Result:Diagnostic code 526-6 is now active.Results:
OK - Diagnostic code 526-6 is now active. There is a problem with the solenoid.Repair: Perform the following procedure:
Temporarily connect a replacement wastegate regulator.
Turn the keyswitch to the ON position. Access the "Diagnostics Tests" on the electronic service tool. Activate the "Turbo Wastegate Solenoid Test". Wait at least 30 seconds for the result to be displayed.
Diagnostic code 526-6 is no longer active.
If the fault is eliminated, reconnect the suspect wastegate regulator. If the fault returns, permanently install the replacement wastegate regulator.STOP
Not OK - The low current diagnostic code (open circuit) is still active. Proceed to Test Step 5.Test Step 5. CREATE A SHORT CIRCUIT AT THE ECM
Turn the keyswitch to the OFF position.
Temporarily remove the wires from P2:17 and P2:19.
Fabricate a jumper wire between P2:17 and P2:19 to create a short circuit.Note: P2/J2 must be connected during the next step.
Turn the keyswitch to the ON position. Access the "Special Tests" under the "Diagnostics" menu on the electronic service tool. Activate the "Turbo Wastegate Solenoid Output" on the electronic service tool. Wait at least 30 seconds for activation of the diagnostic codes.
Check for active diagnostic codes on the electronic service tool.Expected Result:Diagnostic code 526-6 is now active.Results:
OK - Diagnostic code 526-6 is now active. There is a fault in the harness between the ECM and the solenoid.Repair: Repair the harness or replace the harness.Use the electronic service tool to clear all logged diagnostic codes.STOP
Not OK - There is still an open circuit diagnostic code.Repair: Perform the following procedure:
Make sure that the latest flash file for the application is installed in the ECM. Refer to Troubleshooting, "Flash Programming".
Use the electronic service tool to check for active diagnostic codes.
If a diagnostic code is still active, contact the technical communicator at