40003 77 Mercury SCREW, (M10 x 30), MANIFOLD

Illustration 1 g01625542
The schematic for the engine speed/timing sensor
Illustration 2 g01625543
Pin locations on the P1 ECM connector
(41) Engine speed/timing sensor +
(49) Engine speed/timing sensor -
(59) Engine position Test Step 1. Inspect the Electrical Connectors and the Harness
Turn the keyswitch to the OFF position.
Inspect the following electrical connectors for these conditions: damage, abrasions, corrosion and incorrect attachment. Refer to Troubleshooting, "Electrical Connectors - Inspect".
P1/J1 ECM connector
P401/J401 Connector for the engine speed/timing sensor
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector and the sensor connectors that are associated with the active diagnostic code.
Check the ECM connector (Allen head screw) for the correct torque of 6.0 N m (55 lb in).
Check the harness and wiring for abrasions and for pinch points from the sensors to the ECM.
Check that the engine speed/timing sensor is correctly installed and that the sensor is fully seated against the cylinder block.
Perform a "Wiggle Test" by using the electronic service tool in order to identify intermittent connections. Refer to Troubleshooting, "Electrical Connectors - Inspect". Expected Result:All connectors, pins, and sockets should be completely coupled and inserted. The harness should be free of corrosion, abrasion, and pinch points.Results:
OK - Proceed to Test Step 2.
Not OK - Repair: Repair the connectors or the harness and/or replace the connectors or the harness. Ensure that all of the seals are correctly installed and ensure that the connectors are completely coupled.Use the electronic service tool to clear all logged diagnostic codes.Verify that the repair eliminates the fault.STOPTest Step 2. Measure the Sensor Resistance Through the Wiring Harness
Turn the keyswitch to the OFF position.
Remove the P1 ECM connector.
Use a multimeter to measure the resistance of the sensor from P1:41 to P1:49.
Wiggle the cables that are associated with the engine speed/timing sensor while the resistance is measured in order to check for an intermittent open or short circuit. Refer to Illustration 1.
The resistance between the terminals should be from 75 to 230 ohms. Expected Result:The resistance value is between 75 ohms and 230 ohms.Results:
OK - Neither a short circuit nor an open circuit is indicated. Proceed to Test Step 4.
Not OK - The resistance is not within the acceptable range when the circuit resistance is measured through the engine harness. Proceed to Test Step 3.Test Step 3. Measure the Resistance of the Sensor
Turn the keyswitch to the OFF position.
Check the harness and the wiring for abrasion and pinch points from the sensor to the ECM.
Disconnect P401 engine speed/timing sensor connector.
Thoroughly inspect the J401/P401 engine speed/timing sensor connector. Refer to Troubleshooting, "Electrical Connectors - Inspect".
The resistance between the terminals should be from 75 to 230 ohms. Expected Result:The resistance value is between 75 ohms and 230 ohms.Results:
OK - The sensor resistance is within tolerance.Repair: There is a fault in the cable between the P1 ECM connector and the P401 connector. Proceed to Test Step 5.
Not OK - The sensor resistance is out of the nominal range. Proceed to Test Step 4.Test Step 4. Check the Installation of the Engine Speed/Timing Sensors
Illustration 3 g01332035
Speed/timing sensor
(1) Engine speed/timing sensor -
(2) Engine speed/timing sensor +
(3) O ring seal
Turn the keyswitch to the OFF position.
Refer to Troubleshooting, "Electrical Connectors - Inspect".
For correct operation, ensure that the metal plate of the engine speed/timing sensor is installed flat against the cylinder block.
Check that "O" ring (3) has been installed correctly on the sensor and that the "O" ring is not damaged. Expected Result:Check that the electrical connectors and the cables are correctly installed.Results:
OK - The electrical connectors and the cables are correctly installed. Proceed to Test Step 5.
Not OK - Repair: In order to correctly install the engine speed/timing sensor, complete all of the following tasks:
Lubricate the "O" ring with clean engine lubricating oil.
Ensure that the sensor has a seal inside the connector body. If a seal is damaged or missing, replace the seal.
Ensure that the sensor is fully seated into the engine before tightening the bracket bolt.
Ensure that the connector is latched on both sides.
Ensure that the harness is correctly secured, and ensure that the harness is attached to the harness clip.Use the electronic service tool to clear all logged diagnostic codes.Verify that the repair has eliminated the fault.STOPTest Step 5. Measure the Resistance of the Cables Between the Fuel Injection Pump and the ECM
Turn the keyswitch to the OFF position.
Disconnect the P1 ECM connector and the P40 fuel injection pump connector.
Measure the resistance from P1:59 to P40:8.
The resistance should be less than 2 ohms. Expected Result:The readings agree with the values that are listed above.Results:
OK - The ECM does not operate correctly.Repair: Perform the following repairs on the suspect ECM.
Temporarily install a test ECM. Note: The test ECM should be programmed with the correct software. All parameters should be set to the same value as the suspect ECM.
If the fault is eliminated with the test ECM, reconnect the suspect ECM.
If the fault returns with the suspect ECM, then the suspect ECM is faulty. Replace the suspect ECM. STOP
Not OK - The readings are higher than 2 ohms. Proceed to Test Step 6.Test Step 6. Check the Continuity of the Cables From the ECM to the Fuel Injection Pump
Turn the keyswitch to the OFF position.
Disconnect the J1/P1 ECM connector and the J40/P40 fuel injection pump connector.
Perform a continuity test between P40:8 and the following terminals:
P40:1
P40:2
P40:5
P40:6
P40:7Expected Result:The continuity check is positive.Results:
OK - There is a fault with the cables between the fuel injection pump and/or the ECM.Repair: Replace the cable.Use the electronic service tool to clear all logged diagnostic codes.Verify that the repair eliminates the fault.STOP
Not OK - The ECM is suspect.Repair: Perform the following procedure:.
Temporarily install a test ECM. Note: The test ECM should be programmed with the correct software. All parameters should be set to the same value as the suspect ECM.
If the faul