828151A 1 Mercury RELAY ASSEMBLY

Illustration 1 g01057701
Illustration 2 g01151217
Pin locations on ECM connector (P1-48) Unswitched +Battery (P1-52) Unswitched +Battery (P1-53) Unswitched +Battery (P1-55) Unswitched +Battery (P1-63) −Battery (P1-65) −Battery (P1-67) −Battery (P1-69) −Battery (P1-70) KeyswitchTest Step 1. Inspect Electrical Connectors and Wiring
Thoroughly inspect the J1/P1 ECM connector, the battery connections and the connections to the keyswitch. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the following connections:
P1-48
P1-52
P1-53
P1-55
P1-63
P1-65
P1-67
P1-69
P1-70
Check the ECM connector (allen head screw) for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Check the harness and wiring for abrasion and for pinch points from the battery to the ECM, and from the keyswitch to the ECM.Expected Result:Ensure that all connectors, pins and sockets are completely coupled and/or inserted. Ensure that the harness and wiring are free of corrosion, of abrasion, and of pinch points.Results:
OK, Troubleshooting a 43-02 Code - Proceed to Test Step 2.
OK, Troubleshooting a 168-02 Code - Proceed to Test Step 3.
Not OK - There is a problem with the connectors or with the wiring.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.STOPTest Step 2. Use Cat ET to Check the Status of the Keyswitch
Turn the keyswitch to the OFF position.
Connect Cat ET to the data link connector and access the status screen that shows the status of the keyswitch.
Monitor the status of the keyswitch while the keyswitch is being cycled slowly from the ON position to the OFF position.Note: Cat ET may indicate that a new ECM has been detected. This condition is normal, due to a powerdown of the ECM with the keyswitch in the OFF position.Note: Cycling the keyswitch several times may cause additional 43-02 faults to be logged. This is normal. Clear any logged faults.Expected Result:The status of the keyswitch changes from "ON" with the keyswitch in the ON position to "OFF" with the keyswitch in the OFF position.Results:
OK - The input for the keyswitch is functioning properly at this time.Repair: If an intermittent connection is suspected, refer to Troubleshooting, "Electrical Connectors - Inspect". Excessive cycling of the keyswitch can cause this fault to be logged. This is normal. Clear any logged faults.STOP
Not OK - The status of the keyswitch did not change. Proceed to Test Step 3.Test Step 3. Check the Battery Voltage at the ECMPerform Steps A, B, C, D and E if the 168-02 ECM Battery Power Intermittent (51) is active or logged:
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Pin locations on breakout T (48) Unswitched +Battery (52) Unswitched +Battery (53) Unswitched +Battery (55) Unswitched +Battery (63) −Battery (65) −Battery (67) −Battery (69) −Battery (70) Keyswitch
Disconnect the P1 ECM connector and insert a breakout T.Refer to Illustration 3 for the breakout T.
Measure the voltage between terminal 48 unswitched +Battery and terminal 63 -Battery.
Measure the voltage from terminal 52unswitched +Battery and terminal 65 -Battery.
Measure the voltage between terminal 53 unswitched +Battery and terminal 67 -Battery.
Measure the voltage between terminal 55 unswitched +Battery and terminal 69 -Battery.Refer to Illustration 3 for the breakout T.Perform Steps F, G, H, and I if 43-02 Key Switch Fault (71) is active or logged:
Disconnect P1 ECM connector and insert a breakout T.
Turn the keyswitch to the ON position.
Measure the voltage between P1-70 keyswitch and the following terminals:
P1-63
P1-65
P1-67
P1-69Expected Result:For 12 volt systems, the measured voltage is a constant 11.0 to 13.5 VDC with no suspected intermittent problems at this time.For 24 volt systems, the measured voltage is a constant 22.0 to 27.0 VDC with no suspected intermittent problems at this time.Results:
OK - The ECM is receiving the correct voltage. Repair: If an intermittent condition is suspected, refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - Battery voltage out of range Proceed to Test Step 4.
Not OK - Intermittent voltage or no voltage Proceed to Test Step 5.
Not OK - Voltage for key switch out of rangeRepair: Trace the wiring for the keyswitch from the ECM through the keyswitch circuit to the batteries. Find the problem and repair the prob