855543 Mercury BOOT

Illustration 1 g01011535
Test Step 1. Check for Connector Damage.
Turn the keyswitch to the OFF position.
Turn the breaker for the engine control to the OFF position.
Thoroughly inspect the ECM connector J1/P1 and the machine connector 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 connector that are associated with the circuit.
Check the ECM connector (allen head screw) for the proper torque of 2.25 0.25 N m (20 2 lb in).
Check the machine connector (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 for pinch points.Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted. The harness and wiring are 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 for "ACTIVE" Diagnostic Codes.
Connect Caterpillar Electronic Technician (ET) to the ECM through the J31 service tool connector.
Turn the keyswitch to the ON position. The engine should be off.
Wait for 15 seconds for the CID-FMI.
Determine the failure mode identifier (FMI). Determine if any diagnostic codes 03 or 04 are present for an engine sensor.Expected Result:A diagnostic code 03 or 04 is present for an engine sensor.Results:
FMI 03 - A diagnostic code for a sensor with a FMI of 03 is present. Proceed to Test Step 3.
FMI 04 - A diagnostic code for a sensor with a FMI of 04 is present. Proceed to Test Step 4.
262-03 or 262-04 Active Code - A diagnostic code of 262-03 or of 262-04 is present.Repair: Perform the diagnostic functional test Troubleshooting, "Analog Sensor Supply". Stop.
263-03 or 263-04 Active Code - A diagnostic code of 263-03 or 263-04 is present.Repair: Perform the diagnostic functional test Troubleshooting, "Digital Sensor Supply". Stop.Test Step 3. Check the Sensor Supply Voltage at the Sensor Connector if the Diagnostic Code FMI-03 is Present.
Turn the keyswitch to the OFF position.
Disconnect the suspect sensor. If more than one sensor has a diagnostic code, disconnect all of the analog sensors.Note: Disconnecting the sensor will generate an open circuit diagnostic code for any sensor that is disconnected. Troubleshoot the original diagnostic code. Reset the system. Delete the logged diagnostic codes when you are finished.
Turn the keyswitch to the ON position. The engine should be off.
Measure the voltage on the ECM side of the sensor connector between pin A and pin B for the suspect sensor.Expected Result:The supply voltage is 5.0 0.2 VDC for all analog sensors.Results:
OK - The voltage is 5.0 0.2 VDC for all analog sensors. Proceed to Test Step 5.
Not OK - The voltage is not 5.0 0.2 VDC for all analog sensors. Proceed to Test Step 7.Test Step 4. Check the Sensor Supply Voltage at the Sensor Connector if the Diagnostic Code FMI-04 is Present.
Turn the keyswitch to the OFF position.
Disconnect the suspect sensor.Note: Disconnecting the sensor will generate an open circuit diagnostic code for any sensor that is disconnected. Troubleshoot the original diagnostic code. Reset the system. Delete the logged diagnostic codes when you are finished.
Turn the keyswitch to the ON position. The engine should be off.
Measure the voltage on the ECM side of the sensor connector between pin A and pin B for the suspect sensor.Expected Result:The supply voltage is 5.0 0.2 VDC for all analog sensors.Results:
OK - The voltage is 5.0 0.2 VDC for all analog sensors. Proceed to Test Step 8.
Not OK - The voltage is not 5.0 0.2 VDC for all analog sensors. Proceed to Test Step 7.Test Step 5. Check for a Short to the +Battery.
Turn the keyswitch to the OFF position.
Disconnect the suspect sensor.Note: Disconnecting the sensor will generate an open circuit diagnostic code for any sensor that is disconnected. Troubleshoot the original diagnostic code. Reset the system. Delete the logged diagnostic codes when you are finished.
Turn the keyswitch to the ON position. The engine should be off.
Measure the voltage on the ECM side of the sensor connector between pin B and the engine ground.
Measure the voltage on the ECM side of the sensor connector between pin C and the engine ground.
Turn the keyswitch to the OFF position.Expected Result:The voltage measures 24 3 VDC when a short to the +Battery is present.Results:
OK - The voltage measures 24 3 VDC. A short to the +Battery is present. Proceed to Test Step 11.
Not OK - The voltage on pin B measures 0 VDC. The voltage on pin C may measure approximately 6.5 VDC. The voltage on pin C is a pull up voltage. The ECM provides the pull up voltage to the signal input when the ECM senses an open circuit in the incoming input signal. The sensor common and signal wire are not shorted to the +Battery. Proceed to Test Step 6.Test Step 6. Create a Short Circuit at the Sensor Connector.
Turn the keyswitch to the OFF position.
Remove the sensor's signal wire from the ECM side of the sensor connector.
Reconnect the suspect sensor.
Turn the keyswitch to the ON position. The engine should be off.
Wait for the CID-FMI 03.
Use a wire jumper to connect the sensor's signal wire to engine ground.
Check if the CID-FMI has changed from 03 to 04.
Turn the keyswitch to the OFF position.
Remove the wire jumper. Reinstall the sensor's signal wire into the sensor connector.Expected Result:The CID-FMI changes from 03 to 04.Results:
OK - The CID-FMI changed from 03 to 04. The circuit now indicates a short circuit diagnostic code. The short circuit was seen by the ECM. The wiring between the ECM and the sensor is good.Repair: Temporarily connect a new sensor. Verify that the new sensor solves the problem before you permanently install the new sensor. Calibrate the sensor. Perform the calibration procedure Troubleshooting, "Anolog Sensor