865653T04 Mercruiser HARNESS ASSEMBLY, Engine


865653T04 HARNESS ASSEMBLY, Engine Mercruiser 4S42028UT, 4S42028UU HARNESS
865653T04 HARNESS ASSEMBLY, Engine Mercruiser
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Number on catalog scheme: NS
 

Compatible models:

4S42028UT   4S42028UU   Mercruiser

Mercruiser entire parts catalog list:

4S42028UT 1998
4S42028UU 1998

Information:

Probable Causes
Diagnostic codes
Fuel supply
Transfer Pump Inlet Regulator (TPIR)
Electric Fuel Lift Pump (EFLP)
Return fuel lines
Throttle position sensor
CAN data link
High-pressure fuel pump
Low compression (cylinder pressure)
Electronic unit injectors
Individual malfunctioning cylinderRecommended Actions
Note: The procedures have been listed in order of probability. Complete the procedures in order.
Table 1
Troubleshooting Test Steps Values Results
1. Diagnostic Codes
A. Establish communication between the electronic service tool and the Electronic Control Module (ECM). Refer to Troubleshooting, "Electronic Service Tools", if necessary.
B. Download the Warranty Report and the Product Status Report with Histograms before performing any troubleshooting or clearing any diagnostic codes.
Note: The downloaded information will be required by the Dealer Solutions Network (DSN) if troubleshooting assistance is needed.
C. Use the electronic service tool to check for active or logged codes.
Codes
Result: There are active codes.
Repair: Troubleshoot any active codes before continuing with this procedure.
Result: There are no active codes.
Proceed to Test Step 2.
2. Fuel Supply
A. Visually check the fuel tank for fuel. The fuel gauge may be faulty.
B. Ensure that the vent in the fuel cap is not filled with debris.
C. Ensure that the fuel supply valve (if equipped) is in the full OPEN position.
D. Check the primary filter/water separator for water in the fuel.
E. Check for fuel supply lines that are restricted.
F. Check that the Electric Fuel Lift Pump (EFLP) is operating. If the EFLP is suspect, refer to Troubleshooting, "Relay - Test (Electric Fuel Lift Pump)".
G. Check for air in the fuel system. Refer to Systems Operation, Testing, and Adjusting, "Air in Fuel - Test".
H. Obtain a fuel analysis to confirm that the correct fuel is being used. Refer to Systems Operation/Testing and Adjusting, "Fuel Quality - Test" for the correct procedure.
Fuel supply
Result: There is air in the fuel system.
Repair: Prime the fuel system. Refer to Systems Operation, Testing, and Adjusting, "Fuel System - Prime".
Result: The fuel quality is not OK.
Repair: Replace the fuel. Replace the in line fuel filter that is upstream of the EFLP. Replace the primary and secondary fuel filters. Verify that the repair eliminated the fault.
Proceed to Test Step 13.
Result: The fuel quality is OK.
Proceed to Test Step 3.
Illustration 1 g03700009
Transfer Pump Inlet Regulator (TPIR) components on a C4.4 engine
(1) Transfer Pump Inlet Regulator (TPIR)
(2) TPIR return port
Illustration 2 g06100802
Transfer Pump Inlet Regulator (TPIR) components on a C6.6 engine
(1) Transfer Pump Inlet Regulator (TPIR)
(2) TPIR return port
Illustration 3 g02485896
Minimum TPIR flow rate in a 12 VDC system on a C4.4 engine
Illustration 4 g02485897
Minimum TPIR flow rate in a 24 VDC system on a C4.4 engine
Illustration 5 g02355128
Minimum TPIR flow rate in a 12 VDC system on a C6.6 engine
Illustration 6 g02355130
Minimum TPIR flow rate in a 24 VDC system on a C6.6 engine
Table 2
Troubleshooting Test Steps Values Results
3. Transfer Pump Inlet Regulator (TPIR) Flow Test
For a C4.4 engine, refer to Illustration 1. For a C6.6 engine, refer to Illustration 2.
A. Disconnect the TPIR return line from the drain port on the TPIR. Install a suitable blanking cap on the open port in the TPIR return line.
B. Connect a temporary drain line to the drain port on the TPIR.
C. Place the end of the temporary drain line into a suitable calibrated container.
D. With the isolator switch in the ON position but the engine not running, use a suitable multimeter to measure the input voltage to the EFLP. Record the reading.
E. With the isolator switch in the ON position but the engine not running, measure the fuel flow from the temporary drain line.
F. Refer to Illustration 3 through 6 for the minimum acceptable flow rate.
G. Remove the temporary drain line from the drain port on the TPIR. Connect the TPIR return line to the TPIR.
TPIR flow rate
Result: The fuel flow is greater than the minimum limit.
Proceed to Test Step 5.
Result: The fuel flow is less than the minimum limit.
Proceed to Test Step 4.
Illustration 7 g02527498
Minimum EFLP flow rate in a 12 VDC system


Parts harness Mercruiser:

865181T01
 
865181T01 HARNESS ASSEMBLY, Mercathode
40200002D, 40200002G, 40280002D, 40420002D, 40500006T, 40500010T, 40500010U, 40500120U, 4211025US, 4211025UU, 424106LTT, 424106LUS, 424106PUU, 4C72040TD, 4M11025US, 4S42028UT, 4S42028UU, 4S420P8UE
79147A09
 
79147A09 HARNESS ASSEMBLY, With Packard Connector
40200002D, 40200002G, 4S42028N1, 4S42028TS, 4S42028TT, 4S42028UT, 4S42028UU, 4S420P8UE, 5231100TP, 5232100TP, 5E31200TP, 5E31200TS, 5E31210TP, 5E31210TS, 5E31800TP, 5E31800TS, 5E31810TP, 5E31810TS, 5E31900TP, 5E31900TS, 5E31910TP, 5E31910TS, 5E32200T
865771A02
 
865771A02 HARNESS ASSEMBLY, Adaptor - Molded 3 Pin Male To Packard 3 Pin Male
40200002D, 40200002G, 4S42028N1, 4S42028TS, 4S42028TT, 4S42028UT, 4S42028UU, 4S420P8UE, 5231100TP, 5232100TP, 5E31200TP, 5E31200TS, 5E31210TP, 5E31210TS, 5E31800TP, 5E31800TS, 5E31810TP, 5E31810TS, 5E31900TP, 5E31900TS, 5E31910TP, 5E31910TS, 5E32200T
888416T04
 
888416T04 HARNESS ASSEMBLY, DTS
40500120U, 41510P1UE, 4S42028N1, 4S42028TS, 4S42028TT, 4S42028UT, 4S42028UU, 4S420P8UE
865677T01
 
865677T01 HARNESS ASSEMBLY, Transom
40500006T, 40500010T, 40500010U, 40500120U, 4S42028TS, 4S42028TT, 4S42028UT, 4S42028UU, 4S420P8UE
895013A02
 
895013A02 HARNESS ASSEMBLY
40500006T, 40500010T, 40500010U, 40500120U, 4M4102LTS, 4S42028TS, 4S42028TT, 4S42028UT, 4S42028UU, 4S420P8UE
865774T01
 
865774T01 HARNESS ASSEMBLY, Trim Pump
40500010T, 40500010U, 40500120U, 4S42028UT, 4S42028UU, 4S420P8UE
891886
 
891886 HARNESS ASSEMBLY, Ignition Coil Wiring
4S42028N1, 4S42028TS, 4S42028TT, 4S42028UT, 4S42028UU, 4S420P8UE
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