857074A 1 Mercury BOOT/TERMINAL KIT

The following background information is related to this procedure:Coolant Diverter ValveWhen the coolant diverter valve is activated, the engine coolant is diverted through the Diesel Exhaust Fluid (DEF) tank in order to maintain the correct DEF temperature for dosing.
Illustration 1 g03733188
Schematic diagram for the coolant diverter valve
Not all connectors are shown. Refer to the Electrical Schematic for the application.
Illustration 2 g03733196
View of the pin location on the P1 connector for the coolant diverter valve
(7) Coolant diverter valve return
Table 2
Troubleshooting Test Steps Values Results
1. Inspect Electrical Connectors and Wiring
A. Check the fuses.
B. Thoroughly inspect the P1/J1 ECM connector and thoroughly inspect the connector for the coolant diverter valve. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
C. Perform a 30 N (6.7 lb) pull test on each of the wires that are associated with the coolant diverter valve.
Damaged wire or connector
Result: A damaged wire or damaged connector was found. A fuse is blown.
Repair: Repair the damaged wire or the damaged connector. Replace any blown fuses
Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault.
Result: All connectors, pins, and sockets are correctly connected and/or inserted and the harness is free of corrosion, of abrasion or of pinch points.
Proceed to Test Step 2.
2. Check for Diagnostic Codes
A. Turn the keyswitch to the OFF position.
B. Connect the electronic service tool to the diagnostic connector.
C. Run the engine.
D. Monitor the electronic service tool for active diagnostic codes and/or logged diagnostic codes.
Diagnostic codes
Result: A 3363-5 diagnostic code is active or recently logged.
Proceed to Test Step 3.
Result: A 3363-6 diagnostic code is active or recently logged.
Proceed to Test Step 6.
3. Check the Power Supply to the Coolant Diverter Valve
A. Turn the keyswitch to the OFF position.
B. Disconnect the connector for the coolant diverter valve.
C. Turn the keyswitch to the ON position. Do not start the engine.
10 V to 14 V
Result: The measured voltage is not within the expected range.
Proceed to Test Step 4.
Result: The measured voltage is within the expected range.
Proceed to Test Step 5.
4. Check the Wiring Between the Coolant Diverter Valve and the SCR Relay
A. Turn the keyswitch to the OFF position.
B. Disconnect the connector for the coolant diverter valve. Disconnect the SCR relay.
C. Use a multimeter to measure the resistance between terminal 1 on the harness connector for the coolant diverter valve and terminal 87 on the harness connector for the SCR relay.
Less than 5 Ohms
Result: The measured resistance is greater than 5 Ohms.
Repair: Check the fuse. If the fuse is OK, the fault is in the wiring between the coolant diverter valve and the SCR relay.
Replace the faulty wiring.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: The measured resistance is less than 5 Ohms.
Repair: Test the circuit for the SCR relay. Refer to Troubleshooting, "Relay - Test (SCR Relay)".
5. Create a Short Circuit at the Coolant Diverter Valve Connector
A. Turn the keyswitch to the OFF position.
B. Disconnect the connector for the coolant diverter valve.
C. Fabricate a jumper wire that is 150 mm (6 inch) long. Install the jumper wire between terminal 1 and terminal 2 on the harness connector for the coolant diverter valve.
D. Run the engine. Check for active diagnostic codes on the electronic service tool. Wait at least 30 seconds for activation of the diagnostic codes.
E. Turn the keyswitch to the OFF position.
F. Remove the jumper wire.
Diagnostic codes
Result: A 3363-6 diagnostic code is active when the jumper is installed.
Repair: Install a replacement coolant diverter valve.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: A 3363-5 diagnostic code is still active with the jumper installed.
The fault is in the wiring between the coolant diverter valve and the ECM.
Repair: Replace the faulty wiring.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
6. Create an Open Circuit at the Solenoid
A. Turn the keyswitch to the OFF position.
B. Disconnect the connector for the coolant diverter valve.
C. Run the engine. Check for active diagnostic codes on the electronic service tool. Wait at least 30 seconds for activation of the diagnostic codes.
D. Turn the keyswitch to the OFF position.
Diagnostic codes
Result: A 3363-5 diagnostic code is active with the valve disconnected.
Repair: Install a replacement coolant diverter valve.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: A 3363-6 diagnostic code is still active with the valve disconnected.
The fault is in the wiring between the coolant diverter valve and the ECM.
Repair: Replace the faulty wiring.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
If the procedure does not correct the fault, contact the Dealer Solution Network (DSN).