89902 Mercruiser SOLENOID SWITCH ASSEMBLY

Note: Use this procedure only if the engine does not shut down completely.Probable Causes
Diagnostic codes
Electrical connectors
ECM connection
Intake manifold pressure
Fuel supplyRecommended Actions
Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.
Note: The procedures have been listed in order of probability. Complete the procedures in order.
Table 2
Troubleshooting Test Steps Values Results
1. Diagnostic Codes
A. Establish communication between the electronic service tool and the Electronic Control Module (ECM). Refer to Troubleshooting, "Electronic Service Tools", if necessary.
B. Download the Product Status Report before performing any troubleshooting or clearing any diagnostic codes.
Note: The downloaded information will be required by the DSN if troubleshooting assistance is needed.
C. Use the electronic service tool to check for active or logged codes.
Diagnostic codes
Result: There is an active or logged 3597-1 code.
Contact the Dealer Solutions Network (DSN).
Result: There are active or logged codes other than 3597-1.
Repair: Troubleshoot any codes before continuing with this procedure.
Result: There are no active or logged codes.
Proceed to Test Step 2.
2. Electrical Connectors
A. Check all electrical connectors for damage. Refer to Troubleshooting, "Electrical Connectors - Inspect".
Make sure that all the connector seals are in place and that the connectors have been correctly installed.
Electrical connectors
Result: An electrical connector is damaged.
Repair: Repair the electrical connector or replace the electrical connector.
Result: A connector seal is displaced or missing or an electrical connector is not correctly installed.
Repair: Repair the electrical connector or replace the electrical connector.
Result: All electrical connectors are OK.
Proceed to Test Step 3.
3. ECM Connection
A. Check that the P1/J1 and P2/J2 connectors are correctly installed.
Note: If a fault is suspected with the ECM power or ground connections, refer to Troubleshooting, "Electrical Power Supply - Test".
ECM connection
Result: An ECM connector is not correctly installed.
Repair: Repair the electrical connector or replace the electrical connector.
Result: Both ECM connectors are correctly installed.
Proceed to Test Step 4.
4. Intake Manifold Pressure
A. Use the electronic service tool to verify the intake manifold pressure.
Turn the start switch to the ON position.
The intake manifold pressure must read 0 0.5 kPa (0 0.07 psi).
Intake manifold
Result: The intake manifold pressure does not read 0 0.5 kPa (0 0.07 psi).
Repair: Refer to Troubleshooting, "Intake Manifold Air Pressure Is Low".
Result: The intake manifold pressure reads 0 0.5 kPa (0 0.07 psi).
Proceed to Test Step 5.
5. Fuel Supply
A. Visually check the fuel level in the fuel tank. Do not rely on the fuel gauge only.
B. Ensure that the vent in the fuel cap is not filled with debris.
C. Ensure that the fuel supply valve (if equipped) is in the full OPEN position.
D. If the temperature is below 0 °C (32 °F), check for solidified fuel (wax).
E. Check the filter/water separator for water in the fuel.
F. Check for fuel supply lines that are restricted.
G. Check that the low-pressure fuel lines are tight and secured properly.
H. Check that the Electric Fuel Lift Pump (EFLP) is operating correctly.
I. Replace the in-line fuel filter that is upstream of the primary fuel filter.
J. Replace the fuel filter.
K. Check the diesel fuel for contamination. Refer to Systems Operation, Testing, and Adjusting, "Fuel Quality - Test".
L. Check for air in the fuel system. Refer to Systems Operation, Testing, and Adjusting, "Air in Fuel - Test".
M. Ensure that the fuel system has been primed. Refer to Systems Operation, Testing, and Adjusting, "Fuel System - Prime".
Fuel system
Result: The fuel supply is not OK.
Repair: Repair the fuel system or replace the fuel system components, as necessary.
Result: The fuel supply is OK.
Contact the Dealer Solutions Network (DSN).