828553 Mercury GASKET-CYLINDER BLOCK (INC. W/ REF #1)

Illustration 1 g00996821
Schematic for the electrical power supplyTest Step 1. Inspect the Electrical Connectors and Wiring
Set the engine control to the OFF/RESET mode. Switch the 16 amp circuit breaker OFF.Note: For the following steps, refer to Troubleshooting, "Inspecting Electrical Connectors".
Illustration 2 g00995686
Terminal box for the master ECM (1) J1/P1 connectors for the master ECM (2) J16/P16 connectors for the fuel metering valve (3) J23 connector for the service tool (4) 16 amp circuit breaker (5) 6 amp circuit breaker (6) J5/P5 connectors for the ITSM (7) J8/P8 connectors for the harness to the slave ECM (8) J9/P9 connectors for the customer
Disconnect the J1/P1 connectors (1). Inspect the J1 connector and the P1 connector for damage, corrosion, and moisture. Reconnect the J1/P1 connectors.
Illustration 3 g00995687
Terminal box for the slave ECM (9) J3/P3 connectors for the slave ECM (10) J20/P20 connectors for the harness to the master ECM
Disconnect the J3/P3 connectors (9). Inspect the J3 connector and the P3 connector for damage, corrosion, and moisture. Reconnect the J3/P3 connectors.
Thoroughly inspect the following connections:
Electrical connections to each of the circuit breakers
Connectors for the 24 VDC power supply
Connectors for the engine control switch
Check the torque of the Allen head screw for the ECM connectors. The proper torque is 6 1 N m (55 9 lb in).
Illustration 4 g00995688
ECM connectors P1 and P3 (52) Unswitched +battery (53) Unswitched +battery (55) Unswitched +battery (57) Unswitched +battery (63) -Battery (65) -Battery (67) -Battery (69) -Battery (70) Switched +battery
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the electrical power supply:
Unswitched +battery terminals 52, 53, 55, and 57
−Battery terminals 63, 65, 67, and 69
Switched +battery terminal 70
Check the harness and wiring for abrasion and pinch points from the power supply to the master ECM and from the engine control switch to the master ECM.
Check the harness and wiring for abrasion and pinch points from the master ECM to the slave ECM.Expected Result:The connectors, pins, and sockets are connected properly. The connectors and the wiring do not have corrosion, abrasion, or pinch points.Results:
OK - The components are in good condition with proper connections. Proceed to Test Step 2.
Not OK - The components are not in good condition and/or at least one connection is improper.Repair: Perform the necessary repairs and/or replace parts, if necessary. Ensure that all of the seals are properly installed. Make sure that the connectors are properly fastened. Verify that the repair has eliminated the problem.STOPTest Step 2. Check the Voltage at the Power Supply, at the Master ECM, and at the Slave ECM
Make sure that the engine will not crank during this procedure. For an engine with an electric starting motor, make sure that the battery cables are disconnected from the motor. For an engine with an air starting motor, make sure that the pressurized air supply is OFF. Make sure that the air is purged from the system.Note: If a power supply is used instead of batteries, the minimum voltage for the power supply is 22 VDC at 16 amperes. Troubleshoot the power supply if the voltage is less than 22 VDC or more than 29 VDC.
Measure the voltage at the terminals for the power supply. Record the measurement.
Illustration 5 g00995689
Harness side of master ECM P1 connector (P1-52) Unswitched +battery (P1-63) -Battery
Insert two 7X-1710 Multimeter Probes into the harness side of the P1 connector. Insert the first probe into terminal 52. Insert the second probe into terminal 63. Connect a multimeter to the probes.
Switch the 16 amp circuit breaker ON.
Measure the power supply voltage at the P1 connector. During the measurement, wiggle the harness in order to check for an intermittent problem. Be sure to wiggle the harness near each of the connections. Record the measurement.
Switch the 16 amp circuit breaker OFF. Remove the probes from connector P1.
Illustration 6 g00903016
Harness side of the P3 connector for the slave ECM (P3-52) Unswitched +battery (P3-63) -Battery
Insert two 7X-1710 Multimeter Probes into the harness sid