38657A 1 Mercury SHIM ASSEMBLY

Probable Causes
Multiple failed starts with an ether wiring fault.Multiple failed starts in cold climate conditions with any of the following faults:
Diagnostic codes
Visible faults
Air intake and exhaust system faults
Speed/timing sensor faults
Low-pressure fuel system faults
High-pressure fuel system faults
Low compression (cylinder pressure)Recommended Actions
Note: The procedures have been listed in order of probability. Complete the procedures in order.
Table 2
Troubleshooting Test Steps Values Results
1. Download Information Using the Electronic Service Tool
A. Use the electronic service tool to download the "Warranty Report" and the "Product Status Report" (PSR) with histograms before performing any troubleshooting or clearing any diagnostic codes.
Note: The downloaded information will be required by the Dealer Solutions Network (DSN).
Downloaded information
Result: The information was successfully saved.
Proceed to Test Step 2.
Result: The electronic service tool information was not successfully saved.
Contact the Dealer Solutions Network (DSN)
2. Create an Electronic Service Tool Snapshot
A. Select "Snapshot Viewer" on the electronic service tool, using menus: Information -> Snapshot -> Viewer
B. Select the first diagnostic code and click "View Graph".
Select the following parameter and then click OK
1) Engine Speed
C. Select Save to "File to save" a Snapshot File (*.xml). This file will contain all the data in the snapshot and not only the data shown on the graph.
D. Repeat procedure for all diagnostic codes that contains stored snapshot engine data.
Note: The downloaded information will be required by the DSN if troubleshooting assistance is required.
Snapshot saved
Result: The electronic service tool snapshot was successfully saved.
Proceed to Test Step 3.
Result: The electronic service tool snapshot was not successfully saved.
Contact the DSN for guidance.
3. Check for Active or Logged Diagnostic Codes
Note: The ether canister must be removed prior to performing this procedure
A. Verify that the keyswitch is in the OFF position.
B. Remove the ether canister.
C. Connect the electronic service tool to the diagnostic connector.
D. Turn the keyswitch to the ON position.
E. Check for the active or logged diagnostic codes that relate to the ether injection system.
Diagnostic codes
Result: A 626-6 code is present.
Proceed to Troubleshooting, Ether Starting Aid - test to resolve the code. When the code is cleared, proceed to Test Step 4.
No diagnostic codes are present.
Proceed to Test Step 4.
4. Crank Engine Until Diagnostic Code Clears
A. Crank the engine until the diagnostic code clears
Note: If cranking time exceeds 30s, stop cranking and allow starter motor to cool before cranking again.
Note: Do not power-cycle ECM between cranks as this action will reset any clearing timers.
Note: If mechanical cranking interlock is active on keyswitch mechanism, a rapid key-cycle from IGNITION to OFFto IGNITION will not result in the ECM being power cycled.
B. Once diagnostic code clears, fuel injection will be re-enabled. Engine must be started and run for 5 minutes to prevent reactivation after a complete engine power down.
Fault cleared
Result: Diagnostic code clears and engine starts.
Note: Allow engine to run for 5 minutes to allow the system to purge and prevent reactivation occurring.
Ether injection will then be re-enabled after a key-cycle.
Result: Diagnostic code clears but engine does not start.
Warning: Ensure that ether canister has been removed. Active diagnostic code must have been cleared through engine cranking prior to next step as mitigation against ether accumulated in the exhaust system combusting.
Uninstall Ether in the service tool configuration screen:
A. Connect to the electronic service tool.
B. Select the "Service" tab.
C. Select the "Configuration" tab to view the configuration parameters.
D. Expand "Engine Configuration Parameters" heading.
E. Set "Ether Solenoid Configuration" to "Not Installed". See illustration 1
Proceed to Troubleshooting, Engine Cranks but Does Not Start.
Illustration 1 g06442579
Ether Solenoid Configuration window
Table 3
Troubleshooting Test Steps Values Results
5. Verify the Repair
A. Once engine has successfully started and run, reinstall Ether in the service tool configuration screen:
1: Connect to the electronic service tool.
2. Select the "Service" tab.
3. Select the "Configuration" tab to view the configuration parameters.
4. Expand "Engine Configuration Parameters" heading.
5. Set "Ether Solenoid Configuration" to "Continuous Flow Solenoid". See illustration 1.
6. Power cycle the engine ECM
B. Activate the Ether Injection Override
C. Verify that the plunger moved up when the override was active.
Repair verified
Result: The plunger moved up when the override was active.
Install the ether bottle and return the unit to service.
Result: The plunger did not move when the override was active.
Proceed to Troubleshooting, Ether Starting Aid -Test.