90350 1 Mercury STUD, DRIVE SHAFT HOUSING (LONG)

P-201: Inspecting Electrical Connectors
Many of the Operational Procedures and Diagnostic Code Procedures in this troubleshooting guide will direct you to check a specific electrical connector. Use the following steps to help determine if the connector is the cause of the problem. If a problem is found in the electrical connector, repair the connector and continue the test procedure.1. Check connector lock ring.Make sure the connector was locked correctly and the lock ring is capable of locking the connector together.2. Perform 10 pound pull test on each pin/wire.Each pin and connector should easily withstand 10 pounds of pull and remain in the connector body. This test checks whether the wire was correctly crimped in the pin and whether the pin was correctly inserted into the connector. Repair as needed.Any time a wire is removed from a connector for testing purposes, repeat the 10 pound pull test on the wire after re-inserting it into the connector, to be sure it was properly installed. Pins should ALWAYS be crimped onto the wires; NEVER soldered. Use 1U5804 Crimping Tool (part of 4C3406 Connector Repair Kit).3. Visually inspect wiring.Look for worn or abraded wires. Check for pinched or damaged harnesses.4. Visually inspect connectors.Verify that pins and sockets are not corroded or damaged. Verify correct alignment and location of pins in the connector.5. Check individual pin, socket and connections.This is especially important for intermittent problems. Using a new pin, insert the pin into each socket one at a time to check for a good grip on the pin by the socket. Repeat for each pin on the mating side of the connector, using a new socket for the test.P-210: Electrical Power Supply Test
The Electronic Control Module (ECM) of the 3176 System, receives electrical power (battery voltage) through wiring supplied by the vehicle manufacturer. In typical applications, the 3176 System receives power whenever the key is turned on.Some vehicles may be equipped with an engine protection shutdown system (such as a Kysor or Vigil shutdown system). An idle time shutdown system (external to the 3176 System) may also be used. These devices interrupt electrical power to the ECM, to shut the engine down. Some of these devices will not supply power to the ECM until the engine is cranked, until oil pressure comes up to acceptable limits, or until an override button is pressed. Keep in mind that these devices may be the cause of loss of (or intermittent) power to the ECM.This procedure tests whether correct voltage is being supplied by the vehicle wiring. Detailed tests to identify specific failures in the vehicle wiring are the responsibility of the vehicle manufacturer.Note that the ECAP or DDT is supplied with electrical power through connections in the 3176 Engine Wiring Harness. Therefore, if the ECAP or DDT has power, the ECM probably does also.For intermittent problems that could be caused by vehicle wiring (such as intermittent shutdowns), temporarily bypassing the vehicle wiring may be an effective means of determining if the problem is in the engine or the vehicle wiring. If symptoms are not present when the vehicle wiring is bypassed, then the engine and engine wiring are probably not defective, and vehicle wiring is probably causing the fault. A means of bypassing vehicle wiring is explained later in this procedure. Step 1. Check Electrical Connectors And WiringCheck Power/Data Link Connector (J8/P8), battery connection and grounds to J8/P8, being sure to:* Visually and physically check ground connections for looseness or corrosion, particularly the connections at the battery posts, the starter posts and the cylinder head grounding stud. If a problem is found, disconnect, clean, and reconnect the connector* Perform 10 pound pull test on each pin or wire.* Inspect wiring for pinch points or abrasion.* Inspect connectors for damage or corrosion. Refer to P-201: Inspecting Electrical Connectors for details.Step 2. Check Battery Voltage Coming To ECMA. Connect 9-Pin Breakout 'T' at Power/Data Link Connector (J8/P8).B. Turn key ON (engine off).C. Measure the voltage between + Battery (Pin A) and - Battery (Pin B). The battery voltage should be between 11.5 and 13.5 volts DC. OK: The ECM is currently receiving the correct voltage. If intermittent problems with battery voltage may be occurring, consider temporarily bypassing vehicle wiring as shown in Step 3. Otherwise, Stop. NOT OK: The ECM is NOT receiving the correct voltage. If voltage is less than 2 volts DC, check for loose connections in vehicle wiring leading to Power/Data Link Connector (J8/P8) (see Step 1). If voltage is between 2 and 11.5 volts DC, load test batteries. Refer to Operating Manual, Form No. SEHS9249, Use Of The 4C4911 Battery Load Tester and Special Instruction, Form No. SEHS7633, Battery Test Procedure.Step 3. Bypass Vehicle Wiring For Testing This bypass is for TEST PURPOSES ONLY. It may be left on the vehicle temporarily to test whether intermittent problems are due to interruptions in battery power to the ECM. Since this will also bypass any engine protection devices, obtain approval from the owner before releasing a truck with this bypass installed. The bypass switch is installed in parallel with the ignition switch. Either one will turn power ON, and both must be OFF to turn power OFF and shutdown the engine.A. Build a bypass circuit as shown in the illustration, using #14 AWG wire. B. Connect the battery end of the bypass DIRECTLY to the (+) Battery post.C. Remove Pin A (+ Battery) from P8 (Power/Data Link Connector - vehicle side).D. Insert the other end of the bypass into P8, Pin A (as shown).E. After the engine has started, then connect the wire that was originally in P8, Pin A to the wire spliced into the bypass, as shown above. This supplies voltage to the Throttle Position Sensor, Vehicle Speed Buffer and Diagnostic Lamp.Tape all temporary connections tightly to keep them clean, to prevent shorting to ground and to prevent loosening during vehicle operation.F. Turn the ignition key OFF. This will isolate the 3176 System from the original vehicle power circuit.G. Install the temporary switch in