40003 30 Mercury SCREW, (M6 x 25), ANODE

Illustration 1 g01331479
Schematic of the throttle position sensor (31 Pin MIC)
Illustration 2 g01331476
Schematic of the throttle position sensor (70 Pin MIC)
Illustration 3 g01625191
ECM pin locations (16) Throttle Position (17) +8 Volt DC Supply (44) Sensor CommonTest Step 1. Check for Connector Damage
Turn the keyswitch to the OFF position.
Check the connectors and wiring for the following faults: damage, abrasion, corrosion and incorrect attachment.
Refer to Troubleshooting, "Electrical Connectors - Inspect".
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the pedal mounted throttle position sensor:
P1:16
P1:17
P1:44
Check the ECM connector (Allen Head Screw) for the proper torque of 6.0 N m (55 lb in).Expected Result:The connectors and wiring should be free of the following faults: damage, abrasion, corrosion and incorrect attachment.Results:
OK - Proceed to Test Step 2.
Not OK - Repair: Repair the connectors or wiring and/or replace the connectors or wiring.Ensure that the repair has eliminated the fault.STOPTest Step 2. Check for active Diagnostic Codes
Turn the keyswitch to the ON position.
Use the electronic service tool to check for diagnostic codes.Expected Result:RESULT 1 The electronic service tool displays the following active diagnostic codes:
91-08 Throttle Position Sensor abnormal frequency, pulse width, or period
774-08 Secondary Throttle Position Sensor abnormal frequency, pulse width, or periodRESULT 2 The electronic service tool displays the following active diagnostic codes:
41-03 8 Volt DC Supply voltage above normal
41-04 8 Volt DC Supply voltage below normalRESULT 3 The electronic service tool displays no active diagnostic codes.Results:
Result 1 - Proceed to Test Step 3.
Result 2 - Proceed to Test Step 5.
Result 3 - Proceed to Test Step 3.Test Step 3. Check the Throttle Position with the Electronic Service Tool
Connect the electronic service tool to the J60 diagnostic connector.
Turn the keyswitch to the ON position. Do not start the engine.
Observe the throttle position reading on the electronic service tool.
Depress the throttle and release the throttle.Expected Result:Calibrated PositionThe output should be "0 percent" when the pedal is released. The output should increase to "100 percent" when the throttle pedal is fully depressed.Raw PositionThe output should be between "20 percent" and "27 percent" at the low idle position. The output should be between "80 percent"and "87 percent " at the high idle position.Results:
OK - The throttle position sensor is operating correctly. Proceed to Test Step 5.
Not OK - The ECM is not receiving a correct signal from the sensor. There may be a problem in the harness. Proceed to Test Step 4.Test Step 4. Check the Voltage at the Throttle Position Sensor.
Illustration 4 g01331475
Typical example of the throttle position sensor
Turn the keyswitch to the OFF position.
Install a Breakout T with 3 terminals for this test procedure. Refer to Illustration 1 or illustration 2.
Turn the keyswitch to the ON position.
Measure the voltage between terminal A and terminal B.Expected Result:Supply voltage should be between 7.6 Volts DC and 8.4 Volts DC.Results:
OK - The supply voltage is reaching the sensor. Proceed to Test Step 5.
Not OK - Proceed to Test Step 6.Test Step 5. Disconnect the Throttle Position Sensor and Check for Active Diagnostic Codes
Turn the keyswitch to the ON position. Use the electronic service tool to check for active diagnostic codes.
Ensure that one of the following diagnostic codes are active:
41-03 8 Volt DC Supply voltage above normal
41-04 8 Volt DC Supply voltage below normal
While the throttle position sensor is connected and disconnected, monitor the electronic service tool screen. Check and record active diagnostic codes.Expected Result:Diagnostic codes are active after disconnecting the throttle sensor.Diagnostic codes are not active after disconnecting the throttle sensor.Results:
OK - Diagnostic codes are not active after disconnecting the throttle position sensor. Reconnect the throttle sensor and proceed to test step 7.
Not OK - Diagnostic codes are active after disconnecting the throttle position sensor.Repair: Temporarily install another throttle position sensor. Use the electronic service tool in order to check if the diagnostic codes are still active. Replace the throttle position sensor if both of the following conditions occur:
The fault is corrected with the new throttle position sensor.
The fault returns after the old throttle position sensor has been reconnected.STOPTest Step 6. Check the Throttle Selection Status with the Electronic Service Tool
Check the status of the throttle selection switch (if equipped). The throttle selection status can be observed on the status display screen of the electronic service tool.Expected Result:If the throttle selection switch status is shown in the OFF position, then the Throttle 1 has control of the engine speed.If the throttle selection switch status is shown in the ON position then the Throttle 2 has control of the engine speed. The throttle could be overridden by instructions via the SAE J1939 (CAN) or the set speed control.Results:
OK - The throttle position sensor is operating correctly.Repair: There may be an intermittent fault. Refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - The wrong throttle is selected. Change to the other throttle. There may be a fault with the input from the selector switch. Proceed to Step 7.Test Step 7. Disconnect the Supply Terminals of the Throttle Position Sensor at the ECM.