69342 Mercury WASHER, SWIVEL PIN - UPPER

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Schematic for the relay of the fuel pump
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Terminal locations for the ECM connector J1/P1Test Step 1. Inspect Electrical Connectors and Wiring
Turn the keyswitch to the OFF/RESET position.
Thoroughly inspect the J1/P1 ECM connector and all other connectors in the circuit. Refer to Troubleshooting, "Electrical Connectors-Inspect" for details.
Perform a 45 N (10 lb) pull test on the wire P1:19 (Fuel Pump Relay).
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the harness and wiring for abrasion and for pinch points from the sensors back to the ECM.Expected Result:All connectors, pins and sockets should be completely coupled and/or inserted and the harness and wiring should be free of corrosion, abrasion or pinch points.Results:
OK - The connectors and the wiring is good. Proceed to Test Step 2.
Not OK - There is a problem with the connectors and the wiring.Repair: Perform the following repair:Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.Verify that the repair eliminates the problem. Stop.Test Step 2. Check the Status of the Command Signal of the Relay for the Fuel Pump
Turn the keyswitch to the OFF/RESET position.
Connect the Caterpillar Electronic Technician (Cat ET) to the J63 service tool connector.
Turn the keyswitch to the ON position.
Go to the "Fuel Pump Relay Test" on Cat ET.
Start the test and listen for a click from the relay for the fuel pump.Note: Do not leave the "Fuel Pump Relay Test" ON. Avoid unnecessary cycling of the fuel pump in order to prevent the battery from discharging. The fuel pump has a 120 second timer in order to disable the test when the time expires.Expected Result:Result 1 The relay is active.Result 2 The relay is active but the fuel pump is suspected of having a problem.Result 3 The relay does not activate.Results:
RESULT 1 - The relay is functioning normally. Stop.
RESULT 2 - Proceed to Test Step 3.
RESULT 3 - There is a problem with the relay circuit. Proceed to Test Step 6.Test Step 3. Check the Voltage at the Relay Contacts for the Fuel Pump
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Connections for the test lamp
Turn the keyswitch to the OFF/RESET position.
Disconnect the wire from terminal 4 on the relay.
Fabricate two jumper wires with Deutsch sockets on one end and Deutsch pins on the other end. Strip a small amount of insulation from the middle of one jumper wire.
Disconnect the connector for the fuel pump and insert jumper wires into the connector.
Connect a voltage test lamp from the disconnected relay terminal to the jumper wire that is connected to the ground terminal.
Turn the keyswitch to the ON position.
Go to the "Fuel Pump Relay Test" on Cat ET.
Start the test and watch the voltage test lamp.Note: Do not leave the "Fuel Pump Relay Test" On. Avoid unnecessary cycling of the fuel pump in order to prevent the battery from discharging. The fuel pump has a 120 second timer in order to disable the test when the time expires.Expected Result:The test lamp turned on and the test lamp turned off with the "Fuel Pump Relay Test".Results:
OK - The relay for the fuel pump and the +battery connection to the relay for the fuel pump are OK. Leave the wire disconnected from the relay terminal. Proceed to Test Step 4.
Not OK - The test lamp does not turn on. Reconnect the wire from the fuel pump to the terminal on the relay for the fuel pump. Proceed to Test Step 9.
Not OK - The test lamp turns on. The test lamp remains on. Reconnect the wire from the fuel pump to the terminal on the relay for the fuel pump. Proceed to Test Step 9.Test Step 4. Check the Resistance of the Fuel Pump
Disconnect the connector for the fuel pump.
Measure the resistance of the fuel pump.
Reconnect the connector for the fuel pump.Expected Result:Resistance should be less than 10 Ohms.Results:
OK - The resistance of the fuel pump is OK. Proceed to Test Step 5.
Not OK - The resistance of the pump is out of specification.Repair: Replace the fuel pump.Verify that the repair eliminates the problem. Stop.Test Step 5. Check the Supply Voltage to the Fuel Pump
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Disconnect the fuel pump.
Turn the keyswitch to the ON position.
Proceed to the "Diagnostic Overrides" screen on Cat ET.
Activate the relay for the fuel pump.Note: The diagnostic override will only activate the relay for 120 seconds.
Use signal reading probes to measure the voltage across terminal 2 (Ground) and terminal 4 (Fuel Pump Power) of the relay.Expected Result:The supply voltage should be greater than 22.0 VDC.Results:
OK - The ECM is properly controlling the relay for the fuel pump, but the fuel pump is not working.Repair: Replace the fuel pump.Verify that the repair eliminates the problem. Stop.
Not OK - The fuel pump is not receiving the correct signal. Proceed to Test Step 6.Test Step 6. Check the Resistance of the Relay
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Relay Terminals
Turn the keyswitch to the OFF/RESET position.
Unplug the relay for the fuel pump.
Measure the resistance between terminal 5 (Fuel Pump Relay (Signal)) and terminal 2 (Ground) of the relay.Expected Result:The resistance should be between 250 Ohms and 500 Ohms.Results:
OK - The resistance is between 250 Ohms and 500 Ohms. Proceed to Test Step 7.
Not OK - The relay is faulty.Repair: Replace the relay.Verify that the repair eliminates the problem. Stop.Test Step 7. Check the Signal Voltage to the RelaySho