2057 Mercruiser PLATE, BAFFLE-CHOKE HOUSING

"Intake Valve Actuator Solenoid Test"This test is available on the Cat® Electronic Technician (ET). The test helps diagnose problems with the circuits for the solenoids. The following conditions must be met before the test will function:
Engine speed must be zero.
Vehicle speed must be zero.
The transmission gearshift lever must be in neutral.
Illustration 1 g06351225Recommended Actions
Table 2
Troubleshooting Test Steps Values Results
1. Inspect the Electrical Connectors and the Wiring
A. Check the engine harness between the P2 connector and the connectors near the grommets. Look for the following problems:
- Moisture
- Loose connectors or damaged connectors
- Damage that is caused by excessive heat
- Damage that is caused by chafing
- Improper routing of wiring
- Damaged insulation
B. Inspect the connectors near the grommets. The connectors must be clean and dry.
C. Perform a 45 N (10 lb) pull test on each of the wires in the connectors. This test verifies that the wire is properly crimped to the terminal and that the terminal is properly inserted into the connector.
Electrical Connectors and Wiring
Result: The wiring is OK. There is a code present.
For a -5 code, proceed to Step 2.
For a -6 code, proceed to Test Step 4.
Result: The wiring is not OK.
Repair: Repair the wiring problem. Replace parts, if necessary. Perform the "Intake Valve Actuator Solenoid Test".
Return the unit to service.
2. Short the External Wiring Harness
A. Connect a jumper wire to the engine harness connector. Connect the jumper wire between the appropriate terminals for the supply and for the return of the suspect actuator.
The jumper will replace the actuator and the valve cover wiring harness with a short circuit.
B. Perform the "Intake Valve Actuator Solenoid Test". Determine the test result for the suspect cylinder.
Short
Result: The test result indicated "Not Active: Device Open" for the suspect cylinder. The ECM did not detect the jumper wire. There is an open circuit in the wiring between the valve cover connector and the P2 connector. There may be a problem inside a connector.
Repair: Repair the wiring problem. Replace parts, if necessary. Connect all the electrical connectors. Perform the "Intake Valve Actuator Solenoid Test". Verify that all the cylinders pass the test.
Result: The test result indicated "Not Active: Device Short" for the suspect cylinder. The ECM detected the jumper wire. The external engine wiring harness is OK.
Proceed to Test Step 3.
3. Inspect Wiring Under the Valve Cover
A. Remove the valve cover. Look for these problems:
- Loose connectors or damaged connectors
- Damage that is caused by excessive heat
- Damage that is caused by chafing
- Improper routing of wiring
- Damaged insulation
Damage to wires or connectors
Result: There is a problem with the wiring.
Repair: Repair any wiring problems. Replace parts, if necessary.
1. Connect all the electrical connectors.
2. Perform the "Intake Valve Actuator Solenoid Test".
Result: The suspect cylinder passed the test. the problem is resolved.
Return the engine to service.
Result: The suspect cylinder failed the test.
Repair: Replace the appropriate actuator housing. Verify that all actuators pass the "Intake Valve Actuator Solenoid Test" after the new housing is installed.
Return the engine to service.
4. Create an Open in the External Wiring Harness
A. Disconnect the appropriate connector near the grommets. This will replace the actuator and the valve cover wiring harness with an open circuit.
B. Perform the "Intake Valve Actuator Solenoid Test". Determine the test result for the suspect cylinder.
Open Circuit
Result: The test result indicated "Not Active: Device Short" for the suspect cylinder. The ECM did not detect the open circuit. There is a short circuit in the wiring between the valve cover connector and the P2 connector. There may be a problem inside a connector.
Repair: Repair the wiring. Replace parts, if necessary.
1. Connect all the electrical connectors and perform a "Intake Valve Actuator Solenoid Test". Verify that all the cylinders pass the test.
Result: The test result indicated "Not Active: Device Open" for the suspect cylinder. The ECM detected the open circuit. The external engine wiring harness is OK.
Proceed to Test Step 5.
5. Inspect Wiring Under the Valve Cover
A. Remove the valve cover. Look for these problems:
- Loose connectors or damaged connectors
- Damage that is caused by excessive heat
- Damage that is caused by chafing
- Improper routing of wiring
- Damaged insulation
Damage to wires or connectors
Result: There is a problem with the wiring.
Repair: Repair any wiring problems. Replace parts, if necessary.
1. Connect all the electrical connectors.
2. Perform the "Intake Valve Actuator Solenoid Test".