18080 Mercruiser SOLENOID SWITHCH (3-5/8" LONG)

The following background information is related to this procedure:Fuel Control Valve for the High-Pressure Fuel PumpThe high-pressure fuel pump is equipped with a fuel control valve. The fuel control valve precisely controls the amount of fuel that enters the high-pressure fuel pump.The amount of fuel that is required is calculated by the software that is contained in the ECM. The solenoid in the fuel control valve is controlled by a PWM signal from the ECM.
Illustration 1 g06371362
Schematic diagram for the fuel control valve
Table 2
Troubleshooting Test Steps Values Results
1. Inspect Electrical Connectors and Wiring
A. Thoroughly inspect the connector for the fuel control valve. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
B. Thoroughly inspect the engine interface connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
C. Check the harness for corrosion, abrasion, and pinch points from the fuel control valve to the ECM.
Note: Do not disconnect the ECM connector at this stage. The ECM can only be disconnected and reconnected 10 times before damage to the harness connector may occur.
Loose connection or damaged wire
Result: There is a fault in a connector or the wiring.
Repair: Repair any faulty connectors or replace the wiring harness. Ensure that all the seals are properly in place and ensure that the connectors are correctly coupled.
Use the electronic service tool to clear all logged diagnostic codes.
Use the electronic service tool to verify that the repair eliminates the fault.
Result: All connectors, pins, and sockets are correctly coupled and/or inserted. The harness is free of corrosion, abrasion, and pinch points.
Proceed to Test Step 2.
2. Check for Active Diagnostic Codes
A. Turn the keyswitch to the OFF position.
B. Connect the electronic service tool to the diagnostic connector.
C. Turn the keyswitch to the ON position.
E. Verify if any of the diagnostic codes that are listed in Table 1 are active.
F. Turn the keyswitch to the OFF position.
Diagnostic codes
Result: A 1076-5 diagnostic code is active.
Proceed to Test Step 3.
Result: A 1076–6 diagnostic code is active.
Proceed to Test Step 6.
Result: No diagnostic codes are active. There may be an intermittent fault.
Repair: Use the electronic service tool to perform a Wiggle Test.
If no faults are found, return the unit to service.
If the Wiggle Test identifies a fault, investigate the cause.
3. Create a Short Circuit at the Harness Connector for the Fuel Control Valve
A. Turn the keyswitch to the OFF position.
B. Disconnect the connector for the fuel control valve.
C. Fabricate a jumper wire that is 150 mm (6 inch) long.
D. Install the wire between the terminal 1 and terminal 2 on the harness connector for the fuel control valve to create a short circuit.
E. Turn the keyswitch to the ON position.
F. Check for active diagnostic codes.
G. Remove the jumper wire from the connector for the fuel control valve.
Short circuit
Result: A 1076–5 diagnostic code was active before installing the jumper. A 1076–6 diagnostic code is active when the jumper is installed - There is a fault in the fuel control valve.
Repair: Install a replacement fuel control valve. Refer to Disassembly and Assembly, Flow Control Valve - Remove and Install.
Use the electronic service tool to check that the repair eliminates the fault.
Result: A 1076–5 diagnostic code is still active with the jumper installed.
Remove the jumper. Reconnect all connectors. Proceed to Test Step 4.
4. Create a Short Circuit at the Engine Interface Connector
A. Turn the keyswitch to the OFF position.
B. Disconnect the engine interface connector.
C. Fabricate a jumper wire that is 150 mm (6 inch) long.
D. Install the wire between terminal 39 and terminal 40 on the engine interface connector (ECM side).
E. Turn the keyswitch to the ON position.
F. Use the electronic service tool to check for an active 1076 diagnostic code.
Note: Diagnostic codes for all the engine sensors will be active with the engine interface connector disconnected. Disregard the other active diagnostic codes. Only look for an active 1076 code.
Short circuit
Result: A 1076–5 diagnostic code was active before installing the jumper. A 1076–6 diagnostic code is active when the jumper is installed - There is a fault in the engine wiring harness.
Repair: Repair the faulty wiring or replace the faulty wiring.
Use the electronic service tool to check that the repair eliminates the fault.
Result: A 1076–5 diagnostic code is still active with the jumper installed.
Remove the jumper. Reconnect all connectors. Proceed to Test Step 5.
5. Check the Wiring to the ECM for an Open Circuit
A. Turn the keyswitch to the OFF position.
B. Disconnect the P2 connector. Disconnect the connector for the fuel control valve.
C. Inspect the P2/J2 connectors for damage or corrosion. Refer to Troubleshooting, Electrical Connectors - Inspect for more information.
D. Perform a 30 N (6.7 lb) pull test on P2:72 and P2:94.
E. Use a suitable multimeter to measure the resistance between terminal 1 on the harness connector for the fuel control valve and P2:94.
Use a suitable multimeter to measure the resistance between terminal 2 on the harness connector for the fuel control valve and P2:72.
Less than 2 Ohms
Result: At least one of the measured resistances is greater than 2 Ohms. The fault is in the wiring connected to the ECM connector.
Repair: Repair the faulty wiring or replace the faulty wiring.
Result: The resistance is less than 2 Ohms.
Contact the Dealer Solutions Network (DSN).
6. Create an Open Circuit at the Fuel Control Valve
A. Turn the keyswitch to the OFF position.
B. Disconnect the connector for the fuel control valve.
C. Turn the keyswitch to the ON position.
D. Check for active diagnostic codes.
Open circuit
Result: A 1076–6 diagnostic code was active before disconnecting the fuel control valve. A 1076–5 diagnostic code is active with the fuel control valve disconnected. The fault is in the fuel control valve.
Repair: Install a replacement fuel control valve. Refer to Disassembly and Assembly, Flow Control Valve - Remove and Install.
Use the electronic service tool to check that the repair eliminates the fault.
Result: A 1076–6 diagnostic code is still active with the fuel control valve disconnected.
Proceed to Test Step 7.
7. Create an Open Circuit at the Engine Interface Connector
A. Turn the keyswitch to the OFF position.
B. Disconnect the engine interface connector.
C. Turn the keyswitch to the ON