5F36810HH Mercruiser STERNDRIVE UNIT, Complete

Illustration 1 g01331653
Schematic for engine temperature sensors
Illustration 2 g01625522
Pin locations on the P1 connector
(15) Engine coolant temperature
(32) Intake manifold air temperature
(34) Sensor common
Illustration 3 g01331652
Pin locations on the temperature sensors
(1) Temperature signal
(2) Sensor common Test Step 1. Verify All Active Diagnostic Codes
Connect the electronic service tool to the diagnostic connector.
Turn the keyswitch to the ON position. Note: Wait at least 15 seconds for activation of the diagnostic codes.
Use the electronic service tool in order to verify if any of the following diagnostic codes are active:
105-03 Inlet Manifold Temperature Sensor voltage above normal
105-04 Inlet Manifold Temperature Sensor voltage below normal
110-03 Engine Coolant Temperature Sensor voltage above normal
110-04 Engine Coolant Temperature Sensor voltage below normalExpected Result:One or more of the preceding diagnostic codes are active.Results:
Yes - Proceed to Test Step 2.
No - Repair: The fault is intermittent. Perform a "Wiggle Test". Refer toTroubleshooting, "Electrical Connectors - Inspect".STOPTest Step 2. Inspect Electrical Connectors And Wiring
Thoroughly inspect ECM engine harness connector J1/P1 and the suspect sensor connector. Refer to Troubleshooting, "Electrical Connectors - Inspect".
Perform a 45 N (10 lb) pull test on each of the wires in the sensor connector and the ECM connector that are associated with the active diagnostic code. Refer to Illustration 2.
Verify that the latch tab of the connector is properly latched. Verify that the latch tab of the connector has returned to the fully latching position.
Check the ECM connector (Allen head screw) 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 sensor to the ECM. Expected Result:All connectors, pins, and sockets should be completely coupled and/or inserted. The harness and wiring should be free of corrosion, abrasion, and pinch points.Results:
OK - Proceed to Test Step 3.
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.Clear all inactive diagnostic codes and verify that the repair has eliminated the fault. Proceed to test step 3 if the fault has not been eliminated.Test Step 3. Verify That The Diagnostic Code Is Still Active
Turn the keyswitch to the ON position. Note: Wait at least 15 seconds for activation of the diagnostic codes.
Access the "Active Diagnostic Code" screen on the electronic service tool and check for active diagnostic codes.
Determine if the fault is related to an open circuit diagnostic code or a short circuit diagnostic code. Expected Result:A Voltage Below Normal diagnostic code or an Voltage Above Normal diagnostic code is active.Results:
OK - SHORT Circuit - A Voltage Below Normal diagnostic code is active at this time. Proceed to Test Step 4.
OK - OPEN Circuit - An Voltage Above Normal diagnostic code is active at this time. Proceed to Test Step 5.
Not OK - A Voltage Below Normal diagnostic code is not active. An Voltage Above Normal diagnostic code is not active. An intermittent fault may exist.Repair: Use the electronic service tool to perform a "Wiggle Test". Refer to Troubleshooting, "Electrical Connectors - Inspect".If faults are indicated then go to the appropriate procedure.STOPTest Step 4. Disconnect The Sensor In Order To Create An Open Circuit.
Turn the keyswitch to the OFF position.
Disconnect the sensor connector of the sensor with the "voltage below normal" diagnostic code.
Turn the keyswitch to the ON position. Note: Wait at least 15 seconds for activation of the diagnostic codes.
Access the "Active Diagnostic Code" screen of the electronic service tool. Check for an active "voltage above normal" diagnostic code. Expected Result:An "voltage above normal" diagnostic code for the disconnected sensor is now active.Results:
OK - A "voltage below normal" diagnostic code was active before disconnecting the sensor. A "voltage above normal" diagnostic code became active after disconnecting the sensor.Repair: Refer to Troubleshooting, "Electrical Connectors - Inspect".Connect the sensor and verify that the fault returns.Temporarily connect a new sensor to the connector on the engine harness.Verify that the fault has been eliminated.If the fault has been eliminated, install the new sensor.Clear all inactive diagnostic codes.STOP
Not OK - There is a short circuit between the sensor harness connector and the ECM. Leave the sensor disconnected. Proceed to Test Step 6.Test Step 5. Create A Short Circuit Between The Signal And The Common Terminals At The Sensor Harness Connector
Disconnect the suspect sensor connector P100 for the coolant temperature sensor or disconnect P103 for the inlet manifold air temperature sensor.
Turn the keyswitch to the ON position. Note: Wait at least 10 seconds for the activation of any diagnostic fault codes.
Fabricate a jumper wire 150 mm (6 inch) long. Crimp a terminal to both ends of the wire.
Monitor the "Active Diagnostic Code" screen on the electronic service tool before installing the jumper wire and after installing the jumper wire.
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