862081A 2 Mercruiser HARNESS ASSEMBLY, Engine

Illustration 1 g01087948
Schematic for ECM with serial number suffix IF
Illustration 2 g01087832
Schematic for ECM with serial number suffix KD, KH, or IE
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Sensor locations (1) Injection actuation pressure sensor (2) Turbocharger outlet pressure sensor (3) Oil pressure sensor (4) Atmospheric pressure sensor (5) Turbocharger inlet pressure sensor
Illustration 4 g01087857
P1 ECM connector (P1-2) +5 V Analog sensor power (P1-3) Analog sensor common (P1-15) Turbocharger inlet pressure sensor (ECM suffix IF) (P1-17) Turbocharger inlet pressure sensor (ECM suffix KD, KH, IE)
Illustration 5 g01087858
P2 ECM connector (P2-2) +5 V Analog sensor power (P2-3) Analog sensor common (P2-14) Atmospheric pressure sensor (P2-24) Oil pressure sensor (P2-27) Injection actuation pressure sensor (P2-40) Turbocharger outlet pressure sensor (P2-41) +5 V Oil pressure sensor (P2-42) common
Illustration 6 g01094844
Terminals for pressure sensorsTest Step 1. Inspect Electrical Connectors and Wiring
Turn the keyswitch to the OFF position.
Thoroughly inspect the J1/P1 ECM connector and the J2/P2 ECM connector. Thoroughly inspect the connectors for each analog sensor.Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector and the sensor connectors that are associated with the active diagnostic code.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the J61/P61 customer connector (allen head screw) for the proper torque of 2.25 0.25 N m (20 2 lb in).
Check the harness and wiring for abrasions and for pinch points from the sensors back to the ECM.Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted. The harness and wiring are free of corrosion, of abrasion, and of pinch points.Results:
OK - The harness and wiring are OK. Proceed to Test Step 5.
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 Supply Voltage at the Sensor Connector
Turn the keyswitch to the OFF position.
Disconnect all of the following analog sensors at the sensor connector:
Engine oil pressure sensor
Injection actuation pressure sensor
Turbocharger outlet pressure sensor
Atmospheric pressure sensor
Right turbocharger inlet pressure sensor
Turn the keyswitch to the ON position.
Measure the voltage between terminal A (5 V analog supply) and terminal B (sensor return) at the sensor connectors.
Turn the keyswitch to the OFF position.
Reconnect all sensors.Expected Result:The voltage is 5.0 0.2 VDC.Results:
OK - The voltage is 5.0 0.2 VDC. The voltage is correct. Proceed to Test Step 3.
Not OK - The voltage is not 5.0 0.2 VDC. The voltage is incorrect.Repair: Perform the diagnostic functional test Troubleshooting, "5 Volt Engine Pressure Sensor Supply Circuit - Test".STOPTest Step 3. Check for Active Diagnostic Codes
Connect the electronic service tool to the service tool connector.
Turn the keyswitch to the ON position.
Monitor the active diagnostic code screen on the electronic service tool. Check and record any active diagnostic codes.Note: Wait at least 15 seconds in order for the diagnostic codes to become active.
Determine if the problem is related to an open circuit diagnostic code 03 or a short circuit d