808009A11 Mercruiser SWITCH ASSEMBLY, Gear Indicator

Illustration 1 g01190307
Schematic of the ether injection system
Breathing ether vapors or repeated contact of ether with skin can cause personal injury. Personal injury may occur from failure to adhere to the following procedures.Use ether only in well ventilated areas.Do not smoke while changing ether cylinders.Use ether with care to avoid fires.Do not store replacement ether cylinders in living areas or in the operator's compartment.Do not store ether cylinders in direct sunlight or at temperatures above 49 °C (120 °F).Discard cylinders in a safe place. Do not puncture or burn cylinders.Keep ether cylinders out of the reach of unauthorized personnel.To avoid possible injury, be sure the brakes are applied and all controls are in Hold or Neutral when starting the engine.
Test Step 1. Inspect the Electrical Connectors and the Wiring
Turn the keyswitch to the OFF position.
Illustration 2 g01142796
Engine components for the ether injection system (1) J1/P1 ECM connectors (2) Ether injection solenoid
Thoroughly inspect connectors (1). Inspect the J504/P504 connectors for solenoid (2). Refer to Troubleshooting, "Electrical Connectors - Inspect".
Illustration 3 g01142845
P1 terminals for the ether injection system (P1-18) Return (P1-20) Ether injection solenoid
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the ether injection system.
Check the torque of the allen head screws for the ECM connectors. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
Check the harness and the wiring for abrasion and for pinch points from the ether injection solenoid to the ECM.Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted, and the harness and wiring are free of corrosion, of abrasion or of pinch points.Results:
OK - The connectors and the wiring are OK. Proceed to Test Step 2.
Not OK - The connectors and/or the wiring are not OK.Repair: Repair the connectors and/or the wiring. Replace parts, if necessary.Verify that the problem is resolved.STOPTest Step 2. Check for Active Diagnostic CodesNote: Remove the ether canister before you perform this procedure.
Connect Caterpillar Electronic Technician (ET) to the service tool connector. Refer to Troubleshooting, "Electronic Service Tools".
Turn the keyswitch to the ON position.
Proceed to the "Diagnostic Overrides" screen on Cat ET.
Activate the ether injection system. The system will activate for ten seconds.
Monitor the active diagnostic code screen on Cat ET. Wait at least 15 seconds in order for any diagnostic codes to become active. Look for these codes:
2417-05
2417-06Expected Result:No diagnostic codes are active.Results:
No active codes - Neither diagnostic code is active.Repair: The problem may have been caused by a poor electrical connection. Carefully reinspect the connectors and the wiring. Refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Active 2417-06 code - A 2417-06 code is active. Proceed to Test Step 3.
Active 2417-05 code - A 2417-05 code is active. Proceed to Test Step 4.Test Step 3. Create an Open at the Harness Connector for the Ether Injection Solenoid
Turn the keyswitch to the OFF position.
Disconnect the P504 connector from the ether injection solenoid.
Turn the keyswitch to the ON position.
Proceed to the "Diagnostic Overrides" screen on Cat ET.
Activate the ether injection system. The system will activate for ten seconds.
Monitor the "Active Diagnostic Codes" screen on Cat ET. Wait at least 15 seconds in order for any diagnostic codes to become active. Look for an active 2417-05 code.
Turn the keyswitch to the OFF position.Expected Result:A 2417-05 code is now active.Results:
OK - A 2417-06 code was active before the connector was disconnected. A 2417-05 code became active after the connector was disconnected.Repair: Temporarily connect a new ether solenoid to the harness, but do not install the new ether solenoid. Verify that there are no active codes for the ether injection system.If there are no active codes for the ether injection system, permanently install the new solenoid. Clear any logged diagnostic codes.STOP
Not OK - A 2417-06 code was active before the connector was disconnected. The 2417-06 code remained active after the connector was disconnected. Do not connect the P504 connector to the ether injection solenoid. Proceed to Test Step 5.Test Step 4. Create a Short at the Connector for the Ether Injection Solenoid
Turn the keyswitch to the OFF position.
Disconnect the P504 connector from the ether injection solenoid.
Install a jumper wire between terminals 1 and 2 of the P504 harness connector.
Turn the keyswitch to the ON position.
Proceed to the "Diagnostic Overrides" screen on Cat ET.
Activate the ether injection system. The system will activate for ten seconds.
Monitor the "Active Diagnostic Codes" screen on Cat ET. Wait at least 15 seconds for any diagnostic codes to become active. Look for an active 2417-06 code.
Turn the keyswitch to the OFF position. Remove the jumper wire from the connector.Expected Result:A 2417-05 code was active before the jumper wire was installed. A 2417-06 code became active after the jumper wire was installed.Results:
OK - A 2417-05 code was active before the jumper wire was installed. A 2417-06 code became active after the jumper wire was installed. The engine harness and the ECM are OK.Repair: Temporarily connect a new ether injection solenoid to the harness, but do not install the new solenoid. Verify that there are no active diagnostic codes for the solenoid. If there are no active diagnostic codes for the solenoid, permanently install the new solenoid. Clear any logged diagnostic codes.STOP
Not OK - A 2417-05 code was active before the jumper wire was installed. The 2417-05 code remained after the jumper wire was installed. Proceed to Test Step 5.Test Step 5. Check the Operation of the ECM
Create an open at the ECM.
Remove the terminal from P1-18.
Turn the