832932 1 Mercury SEAL

Illustration 1 g00743757
Schematic for the air shutoff system
The connection of any electrical equipment and the disconnection of any electrical equipment may cause an explosion hazard which may result in injury or death. Do not connect any electrical equipment or disconnect any electrical equipment in an explosive atmosphere.
Test Step 1. Inspect the Electrical Connectors and the Wiring
Turn the keyswitch to the OFF position.
Verify that the air shutoff valves are set to the Open position.
Thoroughly inspect the J1/P1 ECM connector and the P61 customer connector. Refer to Troubleshooting, "Electrical Connectors - Inspect".
Illustration 2 g01102047
P1 terminals that are associated with the air shutoff system (P1-11) Air shutoff solenoid (P1-54) Overspeed verify switch (P1-67) Solenoid common
Illustration 3 g01123348
J61/P61 terminals that are associated with the air shutoff system (4) Air shutoff solenoid (5) Solenoid common (40) Overspeed verify switch
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the circuit for the air shutoff system.
Check the allen head screw on the ECM connectors and the customer connector for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
Check the harness and the wiring for abrasion and for pinch points from the air shutoff solenoid to the ECM.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 are not OK.Repair: Repair the wiring and/or the connectors. Replace parts, if necessary. Ensure that all of the seals are properly connected. Verify that the problem is resolved.STOPTest Step 2. Test for Voltage from the Normally Open Contacts of the Air Shutoff Relay
Turn the keyswitch to the OFF position.
Remove the wire from the normally open contacts of the air shutoff relay that goes to the air shutoff solenoid.
Connect a 8T-0500 Continuity Test Light between the normally open contact of the air shutoff relay and engine ground.
Start the engine.
Activate the overspeed verify switch.
Monitor the test light while you increase the engine speed past 75 percent of the programmed overspeed setpoint.
Turn the keyswitch to the OFF position.
Disconnect the test light's leads. Connect the wire to the normally open contact.Expected Result:The test light illuminated when the engine speed increased past 75 percent of the programmed overspeed setpoint.Results:
OK - The test light illuminated. The air shutoff relay is operating correctly. Proceed to Test Step 3.
Not OK - The test light did not illuminate. Proceed to Test Step 4.Test Step 3. Test for Voltage at the Air Shutoff Solenoid
Turn the keyswitch to the OFF position.
Disconnect the wires that are connected to the coil of the air shutoff solenoid.
Connect a 8T-0500 Continuity Test Light between the wire from the normally open contact of the air shutoff relay and engine ground.
Start the engine.
Activate the overspeed verify switch.
Monitor the test light while you increase the engine speed past 75 percent of the programmed overspeed setpoint.Expected Result:The test light illuminated when the engine speed increased past 75 percent of the programmed overspeed setpoint.Results:
OK - The test light illuminated. The voltage is present at the air shutoff solenoid.Repair: Verify the continuity of the wire from the air shutoff solenoid to the negative battery before proceeding. Replace the air shutoff solenoid. Verify that the problem is resolved.STOP
Not OK - The test light did not illuminate. System voltage was not present at the air shutoff solenoid. There is a problem in the wiring between the air shutoff solenoid and the air shutoff relay. There may be a problem with a connector.Repair: Repair the wiring and/or the connector. Replace parts, if necessary. Verify that the problem is resolved.STOPTest Step 4. Test for Voltage at the Coil of the Air Shutoff Relay
Turn the keyswitch to the OFF position.
Disconnect the wire that carries the drive signal from the ECM to the air shutoff relay. Disconnect the wire at the coil of the air shutoff relay.
Connect the 8T-0500 Continuity Test Light between the end of the wire and engine ground.
Start the engine.
Activate the overspeed verify switch.
Monitor the test light while you increase the engine speed past 75 percent of the programmed overspeed setpoint.Expected Result:The test light illuminated when the engine speed increased past 75 percent of the programmed overspeed setpoint.Results:
OK - The test light illuminated. Verify the continuity of the wire from the coil of the air shutoff relay to the ECM connector P1-67 before proceeding. Proceed to Test Step 6.
Not OK - The test light did not illuminate. The voltage from the ECM was not present at the coil of the air shutoff relay. Proceed to Test Step 5.Test Step 5. Short the Overspeed Verify Switch at the ECM
Turn the keyswitch to the OFF position.
Disconnect ECM connector P1.
Remove terminal P1-54 (overspeed verify switch).
Insert one end of a wire jumper into the socket for P1-54 (overspeed verify swtich). Connect the other end of the wire jumper to engine ground.
Remove terminal P1-11 (air shutoff solenoid).
Insert one end of the wire jumper into the socket for P1-11 (air shutoff solenoid).
Connect one lead of a 8T-0500 Continuity Test Light to the other end of the jumper wire in P1-11 (air shutoff solenoid).
Connect the other lead of the test light to negative battery.
Start the engine.
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