802632T Mercruiser INJECTOR, Fuel

Illustration 1 g01276771
Schematic for crank without injectionTest Step 1. Inspect the Electrical Connectors and the Wiring
Turn the keyswitch to the OFF position.
Illustration 2 g01183529
Location of the P1 ECM connector (typical left side engine view)
Thoroughly inspect the J1/P1 ECM connector and the connectors for the crank without injection. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Illustration 3 g01181796
P1 terminal locations for the crank without injection (P1-5) Digital return (P1-35) Crank without injection (NC) (P1-44) Crank without injection (NO)
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector and in the connectors for the crank without injection.
Check the allen head screw for each of the ECM connectors for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Check the harness and wiring for abrasions and for pinch points from the connectors back to the ECM.Expected Result:All connectors, pins, and sockets are completely inserted and coupled. The harness and wiring are free of corrosion, of abrasion, and of pinch points.Results:
OK - The harness and wiring appear to be OK. Proceed to Test Step 2.
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 Status on Caterpillar Electronic Technician (ET)
Connect Cat ET to the service tool connector.
Turn the keyswitch to the ON position.
Observe the status for "Crank w/o Injection" on Cat ET.
Turn the keyswitch to the OFF position.
Remove connector HHH (engine run) and install connector JJJ (crank w/o injection input).
Turn the keyswitch to the ON position.
Observe the status for "Crank w/o Injection" on Cat ET.Expected Result:The status reads "Off" when connector HHH (engine run) is installed. The status reads "On" when connector JJJ (crank w/o injection input) is installed.Results:
OK - The status is correct.Repair: The feature is working properly. There may be an intermittent problem. Refer to Troubleshooting, "Electrical Connectors - Inspect"for a problem that is intermittent.STOP
Not OK - Cat ET did not show the correct status. There may be a problem with the circuit. Proceed to Test Step 3.Test Step 3. Check the Harness for Shorts
Turn the keyswitch to the OFF position.
Disconnect the J1/P1 ECM connector and the connectors for the crank without injection input.
Measure the resistance between the following terminals:
P1-35 crank w/o injection input (NC) and P1-5 digital return
P1-35 crank w/o injection input (NC) and P1-44 crank w/o injection input (NO)
P1-35 crank w/o injection input (NC) and chassis ground
P1-44 crank w/o injection input (NO) and chassis ground
P1-44 crank w/o injection input (NO) and P1-5 digital returnExpected Result:The resistance indicated an open circuit for each measurement.Results:
OK - An open circuit was indicated for each measurement. The harness is not shorted. Proceed to Test Step 4.
Not OK - An open circuit was not indicated for each measurement.Repair: There is a short circuit in the harness between the connector and the ECM. Repair the harness. Verify that the repair eliminates the problem.STOPTest Step 4. Check the Resistance through the Harness
Install connector HHH (engine run) at the connector for the crank without injection input.
Measure the resistance between P1-35 crank w/o injection input (NC) and P1-5 digital return.
Remove connector HHH (engine run) and install connector JJJ (crank without injection) at the connector for the crank without injection input.
Measure the resistance between P1-44 crank w/o injection input (NO) and P1-5 digital return.Expected Result:The measured resistance indicates a short circuit condition.Results:
OK - A short circuit condition was indicated during the measurement. A short circuit condition was indicated during the measurement. The resistance through the harness is OK. Proceed to Test Step 5.
Not OK - Excessive resistance was measured in the harness.Repair: There is an open circuit or excessive resistance in the harness. Repair the harness. Verify that the repair eliminates the problem.STOPTest Step 5. Short the Inputs at the ECM
Turn the keyswitch to the OFF position.
Disconnect the J1/P1 ECM connector.
Disconnect the connectors for the crank without injection input.
Fabricate a jumper wire that can be used to connect two terminals at the ECM connector. Crimp connector sockets to each end of the jumper wire.
Remove terminal P1-35 (crank w/o injection input (NC)) and terminal P1-5 (digital return) from the ECM connector. Install the jumper wire into these terminal locations.
Turn the keyswitch to the ON position.
Observe the status for "Crank w/o Injection" on Cat ET.
Turn the keyswitch to the OFF position.
Disconnect the J1/P1 ECM connector.
Remove the terminal of the jumper wire from P1-35 crank w/o injection input (NC) and install the original wiring.
Remove the wire from terminal P1-44 (crank w/o injection input (NO)). Install the jumper wire into the terminal location. Leave the other end of the jumper wire in P1-5 digital return.
Turn the keyswitch to the ON position.
Observe the status for "Crank w/o Injection" on Cat ET.
Turn the keyswitch to the OFF position.Expected Result:The correct status is "On" when the jumper wire is installed between P1-35 crank w/o injection input (NC). The correct status is "Off" when the wire short is installed in P1-44 crank w/o injection input (NO).Results:
OK - The status was correct.Repair: The ECM is functioning properly. The problem is in the wiring harness between the ECM connector and the connector for the crank without injection input. Repair the harness or replace the harness. Verify that the repair eliminates the problem.STOP
Not OK - The status was not correct.Repair: The correct inputs appear at the ECM, but the ECM is not responding properly. Replace the ECM. Refer to Troubleshooting, "Replacing the ECM" before replacing the ECM.STOP