5829A 8 Mercury GEAR HOUSING ASSEMBLY

Illustration 1 g00920740
Test Step 1. Check for Connector Damage
Turn the circuit breaker for the ECM to the OFF position.
Turn the keyswitch to the OFF 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 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 for pinch points.Expected Result:The connectors and wiring should be free of the following problems: damage, corrosion, abrasion and incorrect attachment.Results:
OK - The connectors and wiring are okay. Proceed to test step 2.
Not OK - The connectors and/or wiring need repair.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Stop.Test Step 2. Check the Voltage at the Battery Post.
Measure the voltage at the battery posts.Expected Result:The voltage should be 24 3 VDC.Results:
OK - The voltage is 24 3 VDC. Proceed to test step 3.
Not OK - The voltage is not 24 3 VDC.Repair: There is a problem with the batteries or the charging system. Refer to Testing and Adjusting, "Charging System". Stop.Test Step 3. Check the Voltage to the ECM.
Remove ECM connector J1/P1.
Turn the circuit breaker for the ECM to the ON position.
Turn the keyswitch to the ON position. The engine should be off.
Measure the voltage between P1-4 and P1-11 at the ECM connector P1.
Measure the voltage between P1-6 and P1-5 at the ECM connector P1.Expected Result:The voltage should be 1 VDC from the voltage at the battery terminals.Results:
OK - The voltage should be 1 VDC from the voltage at the battery terminals. The voltage at the ECM is okay. Proceed to test step 4.
Not OK - The voltage should be 1 VDC from the voltage at the battery terminals. The voltage is not correct at the ECM.Repair: There is an open circuit or excessive resistance in the wiring or connections between the batteries and the ECM. Verify that the circuit breaker for the ECM is not tripped. Verify that the connection for the engine ground is clean and tight. Repair the connectors or wiring and/or replace the connectors or wiring. Stop.Test Step 4. Check the Voltage at the Input for the Keyswitch at the ECM.
Measure the voltage between wire 308-YL from ECM connector P1-23 and wire 229-BK from ECM connector P1-11.
Turn the keyswitch to the OFF position. The engine should be