65478 Mercury LEVER, COWL LATCH

Illustration 1 g01199226
Typical exampleNote: If a remote START switch is installed, the remote START switch must be in the STOP position for this test. Test Step 1. Check for Connector Damage
Turn the ECS to the OFF/RESET position.
Turn the circuit breaker for the battery to the OFF position.
Verify that the circuit breakers are not tripped.
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 allen head screw on each ECM connector for the proper torque. Refer to Troubleshooting, "Inspecting Electrical Connectors" for the correct torque values.
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, and the harness and wiring are free of corrosion, of abrasion, and of pinch points.Results:
OK - The connectors and wiring are OK. 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.STOPTest Step 2. Check the Voltage to the ECM
Disconnect the ECM connector J1/P1.
Turn the circuit breaker for the battery to the ON position.
Turn the ECS to the STOP position.Note: Verify that wire D229 and wire 229 have continuity from the ECM to the −Battery terminal.
Measure the voltage at the ECM. Measure the voltage between P1-53 and P1-65. Measure the voltage between P1-52 and P1-63.
Measure the voltage between P1-70 and P1-65 at the ECM.Expected Result:The voltage is 24 3 VDC. The difference between the three voltage measurements should be less than 0.5 VDC.Results:
OK - The ECM is receiving the correct voltage. Proceed to Test Step 6.
Not OK - The voltage is not 24 3 VDC. The wiring or components between the battery and the ECM may be preventing the voltage from reaching the ECM. Proceed to Test Step 3.
Not OK - P1-70 - The voltage is not 24 3 VDC on the input for the keyswitch to the ECM. Proceed to Test Step 7.Test Step 3. Check the Battery Voltage
Turn the circuit breaker for the battery to the OFF position.
Turn the ECS to the OFF/RESET position.
Measure no-load battery voltage at the battery terminals. Refer to Testing and Adjusting, "Test Tools for the Electrical System" for the proper procedures to check the batteries.
Load test the batteries. Use the 4C-4911 Battery Load Tester. Refer to the Operating Manual, SEHS9249. Refer to Special Instruction, SEHS7633.Expected Result:The no-load voltage at the batteries is at least 23.5 VDC and the batteries pass the load test.Results:
OK - The battery voltage is OK and the battery passes the load test. Proceed to Test Step 4.
Not OK - The battery voltage is incorrect and/or the battery fails the load test.Repair: The batteries or the alternator are causing the problem. Recharge the batteries or replace the batteries. Verify that the original condition is resolved.STOPTest Step 4. Check the Voltage at Relay " R2A"
Reconnect the ECM connector J1/P1.
Turn the circuit breaker for the battery to the ON position.
Turn the ECS to the STOP position.
Measure the voltage from wire A150 on terminal 30 of relay "R2A" to the −Battery terminal.Expected Result:The voltage is 24 3 VDC.Results:
OK - The voltage is 24 3 VDC. Proceed to Test Step 5.
Not OK - The voltage is not 24 3 VDC.Repair: Verify that voltage is present at the breaker for the ECM. If voltage is present at the breaker for the ECM, repair the wire A150 between the breaker for the ECM and relay "R2A".If voltage is not present at the breaker for the ECM, check the wiring between the battery and the breaker for the ECM. Verify that the breaker for the ECM is not tripped and that the breaker for the ECM is operating correctly.STOPTest Step 5. Check the Voltage at Terminal 87A of Relay "R2A"
Measure the voltage from wire C150 at terminal 87A of relay "R2A" to the −Battery terminal.Expected Result:The voltage is 24 3 VDC.Results:
OK - The voltage is 24 3 VDC.Repair: The wiring between relay "R2A" and the ECM connector P1 is damaged. Check wire C150 and wire 150 between relay "R2A" and the ECM connector P1.STOP
Not OK - The voltage is not 24 3 VDC.Repair: Verify that relay "R2A" is not energized. Relay "R2A" will be energized under the following conditions: The local emergency stop is activated., The remote emergency stop is activated. and A short to the +Battery is present on the wire T120 that goes to the coil of relay "R2A". If the coil of relay "R2A" is not energized, the contact of relay "R2A" is damaged. Replace relay "R2A".STOPTest Step 6. Check the Voltage at the Sensor Power Supplies
Turn the ECS to the OFF/RESET position.
Disconnect the ECM connector P1/J1.Note: If you remove the sensor common from the ECM, an open circuit diagnostic code will be generated for all sensors that use the sensor common. Troubleshoot the original code. Delete the logged diagnostic codes when you are finished.
Check the analog supply voltage. Remove the wire 997 from P1-2. Remove the wire 993 from P1-3. Install wire jumpers into the sockets for the above wires.
Check the analog supply voltage. Remove the wire A997 from P1-18. Remove the wire A993 from P1-35. Install wire jumpers into the sockets for the above wires.
Check the digital supply voltage. Remove the wire 700 from P1-4. Remove the wire D998 from P1-5. Install wire jumpers into the sockets for the above wires.
Reconnect the ECM connector P1/J1.
Disconnect the ECM connector P2/J2.
Check the digital supply voltage. Remove the wire A700 from P2-56. Remove the wire F998 from P2-66. Install wire jumpers into the sockets for the above wires.
Reconnect the ECM connector P2/J2.
Turn the ECS to the STOP position.
Measure the analog voltage between the wire jumpers in the following pins:
P1-2 and P1-3
P1-18 and P1-35
Measure the digital voltage between the wire jumpers in the following pins:
P1-4 and P1-5
P2-56