97861 Mercruiser INSULATOR

Test Step 1. Inspect Electrical Connectors and Wiring
Illustration 1 g01332012
Schematic for the mode switch (31 pin MIC)
Illustration 2 g01332011
Schematic for the mode switches (70 pin MIC)
Illustration 3 g01625533
ECM pin locations for the mode switches
(9) Mode switch No. 3 (if equipped)
(21) Mode switch No. 2 (if equipped)
(30) Mode switch No. 1
(37) Switch return
Illustration 4 g01625534
Pin locations for the mode switch (31 pin MIC)
(26) Mode switch No. 1
(28) Switch return
Illustration 5 g01332010
Pin locations for the mode switches (70 pin MIC)
(9) Mode switch No. 3
(21) Mode switch No. 2
(30) Mode switch No. 1
(37) Switch return
Turn the keyswitch OFF.
Thoroughly inspect J1/P1 ECM connector and the J20/P20 MIC. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the P1/J1 ECM connector and the P20/J20 MIC that are associated with the mode switch. Refer to illustration 1 or 2.
Check the Allen head screw on the J1/P1 ECM connector for the correct torque of 6.0 N m (55 lb in).
Check the harness and wiring for abrasions and for pinch points from the battery to the ECM. Results:
OK - Proceed to Test Step 2.
Not OK - Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are correctly installed and ensure that the connectors are completely coupled.Verify that the repair eliminates the fault. STOP
- If the fault has not been eliminated, proceed to Test Step 2.Test Step 2. Check the Mode Selector Switch
Turn the keyswitch to the OFF position.
Disconnect the harness connector from the mode selector switch.
Install a jumper wire between the suspect terminal on the mode selector switch and the terminal for the switch return.
Turn the keyswitch to the ON position.
Monitor the status screen on the electronic service tool.
Slowly disconnect the jumper wire and then reconnect the jumper wire on the suspect terminal on the mode selector switch. Expected Result:When the jumper wire is disconnected, the switch should be in the OPEN position.When the jumper wire is connected, the switch should be in the CLOSED position.Results:
OK - When the jumper wire is disconnected, the status of the switch changes from "CLOSED" to "OPEN".Repair: Replace the faulty mode selector switch.Use the electronic service tool to clear any logged diagnostic codes and verify that the fault has been eliminated.STOP
Not OK - When the jumper wire is disconnected, the status of the mode selector switch does not change. Proceed to Test Step 3.Test Step 3. Insert a Jumper at the Suspect Mode Switch
Turn the keyswitch to the OFF position. Disconnect the suspect mode switch.
Perform the following procedure to test the circuit of Mode Switch No. 1. Insert the jumper wire between P20:30 and P20:37.
If the installation has a 70 pin MIC, perform the following procedure to test the circuit of Mode Switch No. 2. Insert a jumper wire between P20:21 and P20:37 .
If the installation has a 70 pin MIC, perform the following procedure to test the circuit of Mode Switch No. 3. Insert a jumper wire between P20:9 and P20:37.
Turn the keyswitch to the ON position. Monitor the status screen on the electronic service tool. Slowly connect and disconnect each jumper wire. Expected Result:When the jumper wire is disconnected the switch should be in the OPEN position. When the jumper wire is connected the switch should be in the CLOSED position.Results:
OK - Repair: Verify that the jumper wire has been removed. The suspect mode switch is faulty. Replace the switch and verify that the repair has eliminated the fault.STOP
Not OK - Proceed to Test Step 4.Test Step 4. Measure the Resistance at the P20/J20 MIC
Turn the keyswitch to the OFF position.
Reconnect the suspect switch.
Disconnect the P20 connector from the J20 MIC.
Measure the resistance between P20:37 switch return and the following MIC pins:
P20:30 Switch No. 1
P20:21 Switch No. 2 (if equipped)
P20:9 Switch No. 3 (if equipped)Expected Result:The switch measures less than 10 ohms in the ON position. The switch measures more than 2000 ohms in the OFF position.Results:
OK - Proceed to Test Step 5.
Not OK - The fault is in the wires between the switch and the MIC.Repair: Repair the connector or replace the connector. Verify that the repair has eliminated the fault.Repeat Test Step 3 if the problem has not been eliminated.Test Step 5. Measure the Resistance of the Wire Harness at the ECM
Turn the keyswitch to the OFF position.
Disconnect the P1 connector from the ECM connector.
Measure the resistance between P1:37 switch return and the following ECM pins:
P1:30 Switch No. 1
P1:21 Switch No. 2 (if equipped)
P1:9 Switch No. 3 (if equipped)
Cycle the switch to the OFF position and to the ON position. Expected Result:The switch measures less than 10 ohms in the ON position. The switch measures more than 2000 ohms in the OFF position.Results:
OK - There is not a fault in the wire or the wire harness. Proceed to Test Step 6.
Not OK - The fault is in the wire harness between the MIC and the ECM connector.Repair: Repair the connector or replace the connector. Verify that the repair has eliminated the fault.Proceed to Test Step 6 if the fault has not been eliminated.Test Step 6. Test the ECM
Turn the keyswitch to the OFF position.
Disconnect the P1 connector from the J1 ECM connector. Connect a 70 pin Breakout T between the ECM connector J1 and ECM connector P1.
Measure the resistance between P1:37 switch r