854161 Mercruiser FUEL LINE-FUEL PUMP TO INJECTOR PUMP

Illustration 1 g01094971
Schematic
Illustration 2 g01093791
P2 ECM connector (P2-48) Top engine speed/timing + (P2-48) Top engine speed/timing − (P2-58) Bottom engine speed/timing + (P2-59) Bottom engine speed/timing −Test 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 speed/timing 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 circuit.
Check the allen head screw on each ECM connector and the customer connector for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
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 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 for Active Diagnostic Codes
Connect the Caterpillar Electronic Technician (ET) to the service tool connector.
Turn the keyswitch to the ON position.
Verify whether any of the following diagnostic codes are active or logged:
190-02
190-11
342-02
342-11
If the diagnostic code is logged but not active, run the engine until the engine is at normal operating temperature. The problem may only occur when the engine is at the normal operating temperature.
If the engine will not start, monitor the engine speed on Cat ET while the engine is being cranked. Cat ET may need to be powered from another battery while the engine is being cranked in order to ensure that Cat ET does not reset.Note: Upon initial cranking, the status for engine speed may indicate that the engine speed signal is abnormal. This message will be replaced with an engine speed once the ECM is able to calculate a speed from the signal.Expected Result:One or more of the diagnostic codes that are listed above are logged or active.Results:
Diagnostic Codes - There is a logged diagnostic code or an active diagnostic code for the engine speed/timing sensors. Proceed to Test Step 4.
No Diagnostic Codes - There are no diagnostic codes for the engine speed/timing sensors, but the engine is not running properly.Repair: Proceed to the appropriate topic in Troubleshooting, "Troubleshooting without a Diagnostic Code".STOP
No Engine rpm - Engine rpm is not indicated on Cat ET. Proceed to Test Step 3.Test Step 3. Check the Installation of the Sensors and the Brackets
Illustration 3 g00767308
Flange of the sensor and mounting bracket
The flange of the sensor should be flush against the engine in order to ensure proper operation.
Inspect the bracket in order to ensure that the installation allows the flange of the sensor to be flush against the engine.Verify that the bracket is not bent.Note: The bracket cannot be replaced separately.
Ensure that the O-ring has been installed on the sensor, and ensure that the O-ring is free of damage.
If either of the following diagnostic codes is active, there may be a problem with the assembly of the camshaft gear or the crankshaft gear:
190-11
342-11Expected Result:The sensors and the bracket are properly installed.Results:
OK - The sensors and the bracket are properly installed. Proceed to Test Step 4.
Not OK - The sensors and/or the bracket are not properly installed.Repair: Perform the following procedure in order to properly install the sensors and the bracket:
Loosen the bolt that holds the sensor mounting bracket to the engine.
Seat the sensor and tighten the bolt.If the sensor will not seat, repair the sensor or replace the sensor, as required.Note: The sensor must not be removed from the bracket.
Ensure that the sensor is properly oriented and that the harness is secured in the proper location.
Verify that the repair eliminates the problem.STOPTest Step 4. Measure the Sensor Resistance at the ECM Connector