93702 Mercruiser WASHER, (.250 External Star)

Illustration 1 g00903452
Note: The Engine Control Switch (ECS) is mounted within an instrument panel that is located on the right side of the engine. The ECS is locked into the AUTO position with a pin. The pin must be removed in order to perform this test. After performing this test, ensure that the ECS is placed in the AUTO position and that the locking pin has been reinstalled.Test Step 1. Check for Connector Damage.
Verify that the circuit breakers are not tripped.
Turn the circuit breaker for the battery to the OFF position.
Turn the ECS to the OFF/RESET position.
Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors. Refer to the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connectors that are associated with the circuit.
Check the ECM connectors (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the customer connectors (allen head screw) for the proper torque of 2.25 0.25 N m (20 2 lb in).
Check the harness and the wiring for abrasion and pinch points.Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted, and the harness and wiring should be free of corrosion, of abrasion or of pinch points.Results:
OK - The connectors and wiring are okay. Proceed to test step 2.
Not OK - The connectors and/or wiring are not okay.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Stop.Test Step 2. Check the CAT Data Link.
Turn the ECS to the OFF/RESET position.
Connect the Cat ET.
Turn the circuit breaker for the battery to the ON position.
Turn the ECS to the STOP position.
Check for any LOGGED diagnostic codes.
Start the engine and read the status information on the Cat ET.
Observe the engine oil pressure and the coolant temperature on the Electronic Monitoring System.Note: If some of the parameters, but not all of the parameters were displayed, the CAT Data Link is okay. Check the component that is associated with any missing parameter.Expected Result:The Cat ET should display the status information. The Electronic Monitoring System should display engine parameters.Results:
OK - The CAT Data Link is operating correctly at this time.Repair: If the problem is intermittent, perform the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors". Stop.
No Parameter Displayed - There is a problem with the CAT Data Link. Proceed to test step 3.
Service Tool Did Not Power ON - The Cat ET or the Communication Adapter did not power up. Proceed to test step 4.Test Step 3. Check Communication with the Cat ET and the Communication Adapter.
Turn the ECS to the OFF/RESET position.
Disconnect the service tool connector J60.
Connect the Cat ET.
Turn the ECS to the STOP position.
Read LOGGED diagnostic codes and status information on the Cat ET.Expected Result:Status information should appear on the Cat ET.Results:
OK - Status information appears on the Cat ET. Proceed to test step 7.
Not OK - Status information does not appear on the Cat ET. Proceed to test step 8.Test Step 4. Check Supply Voltage to the CAT Data Link.
Turn the ECS to the OFF/RESET position.
Ensure that all connectors are connected.
Turn the ECS to the STOP position.
Measure the voltage between pin A and pin B at service tool connector J60.Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC. Proceed to test step 7.
Not OK - The voltage does not measure 24 3 VDC. Verify that the wire 200-BK has continuity to the - Battery terminal. Proceed to test step 5.Test Step 5. Check the Voltage at the ECS.
Turn the ECS to the STOP position.
Measure the voltage between the wire 103-RD on Pin 3 of the ECS and the - Battery terminal.Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC.Repair: Repair the wire that is between the ECS and Pin A of the service tool connector. Stop.
Not OK - The voltage does not measure 24 3 VDC. Proceed to test step 6.Test Step 6. Check the Voltage to the ECS.
Turn the ECS to the STOP position.
Measure the voltage between the wire 110-RD on Pin 1 of the ECS and the - Battery terminal.Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC.Repair: Perform the diagnostic functional test Troubleshooting, "Engine Control Switch (ECS)". Stop.
Not OK - The voltage does not measure 24 3 VDC.Repair: Check the breakers and the wiring between the ECS and the Battery. Stop.Test Step 7. Check for Shorts in the Harness
Turn the ECS to the OFF/RESET position.
Disconnect ECM connector J1/P1 from the primary ECM and from the secondary ECM. Disconnect the service