863903T Mercruiser HEAT EXCHANGER

Illustration 1 g01201894
Schematic for the ether injection system (typical configuration)
Test Step 1. Inspect the Electrical Connectors and the Wiring
Remove electrical power from the Electronic Control Module (ECM). Turn the battery isolator switch to the OFF position.
Illustration 2 g01186024
Location of the J1/P1 ECM connector (typical left side engine view)
Thoroughly inspect the ECM connector J1/P1. Inspect all of the other connectors that are in the circuit. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Illustration 3 g01241629
Terminal locations at the P1 ECM connector for the ether injection system
(P1-21) Ether starting aid
(P1-22) Auto/manual switch
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the circuit.
Check the allen head screw for each of the ECM connectors for the proper torque. Refer to the diagnostic functional Troubleshooting, "Electrical Connectors - Inspect" for correct torque values.
Check the harness and the wiring for abrasion and for pinch points. 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 wiring appear to be OK. Proceed to Test Step 2.
Not OK - There is a problem with the electrical 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.STOPTest Step 2. Check the Ether Canisters for Fluid
Turn the battery isolator switch to the OFF position.
Remove the ether canister from the ether solenoid. Determine if the canister contains any ether. Expected Result:The ether canister is not empty.Results:
OK - The ether canister is not empty. Remove the ether canister from the ether solenoid for the remainder of this test. Proceed to Test Step 3.
Not OK - The ether canister is empty.Repair: Replace the empty ether canister with a full ether canister. Retry the system.STOPTest Step 3. Check the Voltage from the Ether Start Relay
Turn the battery isolator switch to the OFF position.
Connect Caterpillar Electronic Technician (ET) to the service tool connector.
Disconnect the wire from terminal 87 of