64855 1 Mercury J-CLAMP

Illustration 1 g00749185
Test Step 1. Check the Electrical Connectors and the Wiring.
Prevent sparks near the batteries. Sparks could cause vapors to explode. Do not allow jumper cable ends to contact each other or the engine.
Turn the Battery switch for the ECM to the OFF position.
Turn the breaker at the battery to the OFF position.
Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors. Refer to 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 6.0 N m (55 lb in).
Check the customer 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 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, abrasion or pinch points.Results:
OK - The wiring and connectors are okay. Proceed to Test Step 2.
Not OK - Repair the wiring and connectors or replace the wiring or the connectors. Ensure that all of the seals are properly connected. Verify that the repair eliminates the problem.STOPTest Step 2. Check the Voltage Output to the Air Shutoff Solenoids.
Connect the ET to the service tool connector.
Connect a voltmeter between wire G971-BR on terminal 1 of the air shutoff relay and the engine ground.
Turn the breaker at the battery to the OFF position.
Turn the Battery switch for the ECM to the ON position.
Access the override on the Electronic Service Tool. Activate the override for the air shutoff.
Monitor the status of the Air Shutoff System on the ET.
Monitor the voltage on the voltmeter.
Disable the override for the air shutoff.Expected Result:The voltage should measure 24 3 VDC. The ET should indicate that the air shutoff system is "ON".Results:
OK - The voltage measures 24 3 VDC. The ET indicates that the air shutoff system is "ON". The air shutoff solenoid does not activate. Proceed to test step 5.
Not OK - The voltage does not measure 24 3 VDC. The ET indicates that the air shutoff system is "ON". Proceed to test step 3.
Intermittent Problem - Repair: Perform the following diagnostic procedure Troubleshooting, "Inspecting Electrical Connectors".STOPTest Step 3. Check the Voltage to the Coil of the Air Shutoff Relay.
Turn the Battery switch for the ECM to the OFF position.
Connect a voltmeter between terminal 3 and terminal 4 of the air shutoff relay.
Turn the Battery switch for the ECM to the ON position.
Access the override on the Electronic Service Tool. Activate the override for the air shutoff.
Monitor the voltage on the voltmeter.
Deactivate the override for the air shutoff.Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC. Proceed to test step 4.
Not - OK - The voltage does not measure 24 3 VDC. Proceed to test step 6.Test Step 4. Check the Voltage to the Contacts of the Air Shutoff Relay.
Measure the voltage between wire 150-OR on terminal 2 of the air shutoff relay and the engine ground.Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC.Repair: Replace the air shutoff relay. Test the system and verify that the problem is no longer present.STOP
Not OK - The voltage does not measure 24 3 VDC.Repair: Check the battery for the correct voltage. Check the wires, the connectors, and the breaker between the battery and the air shutoff relay for problems. Refer to Testing and Adjusting, "Electrical System".STOPTest Step 5. Check the Voltage at the Air Shutoff Solenoids.
Turn the Battery switch for the ECM to the OFF position.
Connect a voltmeter between the wire G971-BR and wire 229-BK of the air shutoff solenoids.
Turn the Battery switch for the ECM to the ON position.
Access the override on the Electronic Service Tool. Activate the override for the air shutoff.
Monitor the voltage on the voltmeter. Check the voltage at both of the air shutoff solenoids.
Deactivate the override for the air shutoff.Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC.Repair: Replace the air shutoff solenoid. Test the system and verify that the problem is no longer present.STOP
Not - OK - The voltage does not measure 24 3 VDC.Repair: The wiring between the air shutoff solenoid and the air shutoff relay needs repair or the wiring between the air shutoff solenoid and the battery needs repair. Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 6. Check the Output Voltage from the ECM.
Turn the Battery switch for the ECM to the OFF position.
Remove ECM connectors P1 and P2.
Remove wire G971-BR from ECM connector P2-19.
Remove wire 229-BK from ECM connector P1-05.
Install a 40-pin Breakout T at ECM connector P1 and at ECM connector P2.
Turn the Battery switch for the ECM to the ON position.
Access the override on the Electronic Service Tool. Activate the override for the air shutoff.Note: This test will cause a 446-05 CID-FMI to be logged. Be sure to delete this CID-FMI when this test is completed.
Monitor the voltage between ECM terminal P1-05 and ECM terminal P2-19.
Deactivate the override for the air shutoff.
Turn the Battery switch for the ECM to the OFF position. Remove the wires and the Breakout T. Reinstall all wires. Reconnect the ECM connectors.Expected Result:The voltage should measure 24 3 VDC.Results:
OK - The voltage measures 24 3 VDC. The wiring and/or the connectors between the ECM and the air shutoff relay need repair.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOP
Not - OK - The voltage does not measure 24 3 VDC.Repair: Replace the ECM. Refer to Troubleshooting, "Replacing the ECM".STOP