Home

Fuel System

1. 28207 Meter Test Leads Meter Scale Reading Q su mx DMT 2004 Digital Multimeter 91 892647A01 90 883064R03 NOVEMBER 2010 Page 3B 35 Diagnostics and Troubleshooting Notes Page 3B 36 90 883064R03 NOVEMBER 2010
2. Available GuardianLatchedPwrLim Power GuardianState VVarning Horn HornOutputState Status 1 0 Off Intake Air Temperature IAT IAT Sensor in AT ADC Counts Idle Air Control IAC Valve IdleAir IdleControlState 90 883064R03 NOVEMBER 2010 Fuel pump current flowing through ECM Allows a technician to monitor the condition of the fuel pump over time Current draw changes can be an early indication of electrical mechanical or fuel supply problems Fuel consumption listed by an individual cylinder Displayed where each oylinder value is shown Lists four possible choices of Guardian Helps determine the component or System that is activating Guardian Similar to Guardian due to on original CDS tool Maximum Power allowed by the Guardian System at any given time When 100 the engine can produce full power without any Guardian restrictions Displays whether Guardian is active or inactive Guardian will only display active when operator demand exceeds GuardianLatchedPwrLim available power Displays when the ECM expects the horn to be audible Displays the temperature of the air in the intake manifold Intake air temp and manifold air temp are terms that are often used interchangeably Displays the IAT sensor value in analog to digital conversion ADC counts Counts range between 0 low and 1023 high Very low readings 0 10 indicate a circuit low fault Very h
3. unilE W93 in euu id esneo IM spunoJD eouejsiseJ 1461 pue uee o eq jsnuJ eJewpueu eu punoub o pej euuoo eJe 02 pue 99 suid wou Buruoo spee xoe q eu pepunojJ s N23 eu EDO SI pue N23 90 uBnouu smoly 1ue uno Mewnd Ueaujs y uo pe el dsip si uoneuJoJul UPIM esing pej eo s usdo s J0joefu y euun u B5u 9u weeds ejep y uo peKejdsip si snjejs ujou Burusem eu L weajs ejep y uo peKe dsip SI oBejoA siu Jewod JeAup eu 0 BENOA Mo esneo ueo VZg uid pue og uid U M Q sjoejuoo p uunq uy ejeJ V UleeJjs ejep y uo pe ejdsip SI oDeyoA siu amod jeAup eui O eDeyoA Mo esneo ueo Vg uid pue o uid ueejeq sjoejuoo peuunq uy e 1 v uado si ueuw 1seuBiu pue p soro s mo u ueuw S MO 3q eDeyo EUB S Sd L weas ejep y uo p eldsip s BENOA uoyws Avy weas y uo p eldsip si uoneuuoJul ujpi esing UJpIM asjnd pej eo s u do si 10 2 fu y euun jo u Bu 9u weas y uo pe el dsip si uoneuJoJul esing UJpiM asjnd pej eo s usdo si 10 2 fu y euun jo u Bu 9u S ON 9IAJ 9S si ueyeq U9UM A Zi lue suoo 102 eui eBueuosip O uid si suado pue 109 uoniufi eg v eDueuo 0 99 uid spuno46 W93 8950 0 Jojoefur q ni ay p u do u yM 1ojo ul f n i eu li 0 sg uid spuno1i6 423 BuiuJeM
4. A 1 Ajeyeuurxoudde SI jIn2JiIo y p solo u uAA A 8 Aj eyeuurxoudde IM N0119 Mojle 4oe q y uedo ueuM weas ejep uo peKejdsip eBeyoA Jewod Josues N 51 Buisn sjosues 2 40 punoJ8 e sepi oud Zy Uld S1osu s 9JIM pue IIE OLA S A S 48 u Jo je eq sAemje pinoys 1ewod 1osueg EULOU uey 12M0 Jo pemeys eq IIIA sjeuBis siosu s JIA pue Z 112 ewou uey Jewo Jo JeuBiu si eDeyo Josues J W93 esneo spunou6 eouejsiseJ 1uBn pue uea eq snu eJeMpJeu eu punoJ oj pejoeuuoo 02 pue 89 suid wouy Buiuioo SPE xoe q AjueA si W93 24 eEonuo SI INO3 eu smol jueuno eouis 102 y eBueuosip o uid siy suado pue i09 uoniui 1 v eDueuo 0 e uid spuno46 W93 W93 esneo Iim spunou6 eouejsiseJ 1461 pue uea eq snuu eJeMpJeu eu punoJ oj pejoeuuoo aue 02 pue 89 suid wouy Buiuoo spee xoe q 9y AjueA pepunojJ si W93 24 leono SI 1 WO eu yno swoj 1ueuno Hewnd souls 102 y eBueuosip o uid siy suado pue i02 uoniui v eDueuo 0 Ze uid spuno46 W93 SO9I op U M Q uoneoiunuJuloo OU ul jnsoJ II pz uid do Z uid yno 1 uli Bunious Jo Buiuedo s oSi A p ye19ueus pue 001 9 INO3 40 AemyBiy ejeq So9I op U M Q uorneoiunuJuloo OU ul 1 5 III pz uid 10 Z uid yno
5. ECM is trying to achieve Use the data BaseldleRPM engine to idle at when at operating item IdleCtrlSetpointRPM for the actual RPM temperature and running normal idle speed the ECM is trying to achieve when the engine is running Use the G3 tool to change the engine location STBD Outer default PORT Outer STBD Inner or PORT Inner Available Displays how much available power ActiveFaultPwrLim power due to remains after all active faults have active faults reduced it from 100 Displays the current engine location programmed into the ECM CurrentEngineLocation 90 883064R03 NOVEMBER 2010 Page 3B 15 Diagnostics and Troubleshootin Data Item Name Description Significance Service Information from G3 sensor Battery Voltage DRVP from Main Power Relay Engine Coolant EC Temperature ECT Operator Demand from TPS How much power is requested from the engine Shows if the ECM is receiving the voltage it needs to control all of the actuators The voltage should be within 0 5V of actual battery voltage The ECM measures this voltage at pins 57 and 58 Temperature of the Engine Coolant EFI engines will not run correctly unless they reach operating temperature Running too cold will cause rich mixtures like a stuck choke The engine will idle very poorly until the problem is resolved Always verify proper ECT temperature when diagnosing an engine 52 on ECM This voltage tells the ECM to wake
6. If the switch is open VVhen the engine is off the svvitch is or the sensor lead is open the voltage at closed when oil pressure is present 205 pin 11 will be near 5V high and the oil the svvitch is open pressure is good Displays the percent of maximum power the engine is producing The Engine Power PctMaxPower Output lower the number the less horsepower p produced The higher the number the more power produced RPM Engine Speed How fast the engine s crankshaft is rotating in revolutions per minute Ignition timing in degrees before top Timing that is after top dead center dead center ATDC will appear as negative values Total Engine TotalEngRunTime Operating Hours ar An estimate of the total fuel consumed TotalFuel Total Fuel during this run event Consumption Throttle plate position in percent When moving the throttle slowly from idle to The TPS reads low numbers when the Throttle vvide open throttle the data must throttle plate is closed and high numbers TPS1 Position Sens r increase steadily with the throttle when the throttle plate is opened The movement If the data freezes dips or TPS and MAP sensor mirror each other is erratic the TPS sensor is suspect Displays the TPS sensor value in analog to digital conversion counts Counts range between 0 low and TPS Sensor in 1023 high Counts can be converted 1 Counts to voltag
7. Noaeul o p9joeuuoo si paujxyuid oAneBDou 101oefu ey z Jewod ureui WOJ S OA s AI 95891 EU U ANISOd i1o 5 ui j nj soya ful JO epis eAneBeu siOnuo2 J AHD Z Jojoefui f n i peJ yud NO3 24 q pejoguoo s uwoJq yuid eAneBeu Jojoefu nos Aey l ureui WOJ S OA Asayeq se ieo9J jeur eAnisod 10j2efur on 4 40 0 8 ful JO epis eAneBeu sjo1zuo9 J AHD L3 Jojoefui jon 4 uJq xud snol uoiueduio uonduoseq LO eo oo LO eo LO N LO LO N N 90 883064 NOVEMBER 2010 Page 3 8 Diagnostics and Troubleshootin eJIM eBneb AAP U e uA Beuluu eje eJIM eBneb Aneay e uA JeuruJoe eje eBneb AAP U e uA EU U eje S ON 9IA19S W93 Jeuiuue Aq yeq AneB u Hel puno 6 WO3 uloq ale 02 pue 89 suld ow euiBue punog 69 uid spunoJ6 N23 1 69 uid W93 01 51004 00 y u ym suni duund jan jeuiuuo oAneBeu aU ueoJs y duund jen J ejoJ duund f n uo pa elA eq UBD W93 Jewod ureui S OA vq p eunssaJud JeAug eujuluJM p inse ul As neq s AI 85 1 611 meup uano duund jan ny sod dwnd jen4 puno4B W93 Jeuiuue Auayeq eAneDeu puno WO3 Uloq 9Je 02 pue 89 Uld euiBue punog uoneuuoJu syno uoiueduio uonduos q Page 3B 9 90 883
8. One of the many causes of an overheat condition can be a damaged or plugged thermostat If the engine has a thermostat that allows the engine to reach temperatures between 71 77 C 160 170 F the Guardian system may activate due to engine load as part of the calibration not covered in the above chart In these scenarios the fault will be recorded as a RPM Limit fault Gen Ill EFI System Troubleshooting Guide Lanyard stop switch is in the OFF position Set lanyard stop switch to RUN Weak battery or bad starter motor Battery voltage drops below 8 Three beeps every Check condition of battery starter solenoid terminals and volts while cranking four minutes for low cables Charge replace battery Inspect condition of ECM cuts out below 6 battery voltage starter motor volts fuel pump requires 8 volts Replace fuse located in the port fuse holder Inspect engine wiring harness and electrical components Blown fuse Fuse 2 Fuel injectors IAC fuel pump Fuse 3 Main power relay accessory Fuse 4 Ignition coils Listen for relay to click when key switch is turned to ON 81 99 ohms Between pin 8 yel ppl of the ECM connector and red blu wire of fuse 3 fuse removed Main power relay Intermittent beeps Or Engine cranks but will Between pin 85 and pin 86 of relay not start or Test suppression diode Refer to Section 2B Suppression Diode Tests 300 350 ohms Between pin 29 and pin 1
9. time of the fault Lists the total engine run time vvhen the fault occurred For example if the buffer data is 11 8 hours and total engine run time is 13 2 hours the fault occurred 1 4 engine run hours ago Recent faults deserve more attention than faults from long ago Fault number a specific number tied to a specific fault name Lists the available povver at the time the fault occurred Lists the intake manifold air temperature at the time the fault occurred Lists the IAC valve position at the time of the fault Lists the manifold absolute pressure at the time of the fault Lists the oil pressure status at the time of fault 0 0 kPa indicates the oil pressure svvitch vvas closed 87 0 kPa indicates the oil pressure svvitch vvas open Temperatures belovv normal operating temperature are usually the result of debris holding the thermostat open A cold running engine will run rich and can eventually dilute the engine oil with gasoline EFI engines must reach an operating temperature to run properly Possible engine states are dead stall crank run and unknown This helps you understand the operating mode the engine was in at the time of the fault Normal values are stall crank or run A fault that stored a couple of times a long time ago and occurred again is usually something to not spend time on In these cases record the buffer data on the work order in case it shows up again then clear the fault buf
10. MAP sensor wiring harness to MAP TPS p connector and engine ground key switch to RUN Fuel 2 aL vS None See fuel pressure test Flywheel misaligned Remove flywheel and inspect flywheel key and keyway Engine idles Engine coolant fast after warm up temperature ECT 900 1100 RPM sensor Three beeps every See sensor resistance chart four minutes 10 0 13 5 ohms Between fuel injector pin 1 and pin 2 or Three beeps every Between removed fuse 2 red blu wire and the ECM four minutes connector Pin 49 pnk brn fuel injector 1 Pin 50 pnk red fuel injector 2 Pin 65 pnk org fuel injector 3 ui Three beeps every rr TP 1 See ignition coil resistance chart Section 2A Ignition Fuel injector running quality Fuel pressure at VST fitting None See fuel pressure test Fuel filter plugged Replace fuel filter Improper spark plugs Use recommended resistor spark plugs Flywheel timing tooth N Check tooth pattern for partially missing or damaged one pattern teeth Fouled spark plug Replace spark plug 1 The ECM will only monitor the EST connection to the ignition coil use resistance tests and or spark gap test to confirm an ignition coil failure 90 883064R03 NOVEMBER 2010 Page 3B 31 Diagnostics and Troubleshootin 300 350 ohms Between pin 14 red and pin 13 wht of the ECM connector or Between pin 1 red and pin 2 wht of CPS connector Manifold absolute S
11. accurate results Converting the counts allows you to measure the voltage in the circuit when checking for circuit problems such as shorts opens and high resistance Displays the MAP sensor value in analog to digital conversion ADC counts Counts range between 0 low and 1023 high Very low readings 0 10 normally indicate a circuit low fault Very high readings 1015 1023 normally indicate a circuit high fault If MAP status is the default then the engine is not using the MAP sensor data to run This is usually because of a MAP circuit high or circuit low fault Displays all faults that have occurred in this key cycle Continuously scrolls through all faults one per second If a fault is present here but not in the ActiveFaultMarquee then the fault is not active Displays dashes when there are no faults If the fault is present in this list and in ActiveFaultMarquee then the fault is active The dedicated fault page is the best place to view inactive faults 90 883064R03 NOVEMBER 2010 Diagnostics and Troubleshootin Data Item Name Description Significance Service Information from G3 The monitors the voltage at pin 11 Oil pressure is normal or low The b f the svvitch is closed or the sensor lead sensor is a pressure switch that is is shorted to ground the voltage at pin 11 either open or closed to engine ground 255 OilPressSvv N A r will be near 0 low
12. circuit pin 71 red black circuit ground Possible defective pump open circuit Check wiring for low or no 12 V to the fuel pump or high resistance on the fuel pump driver circuit pin 71 red black circuit Battery to fuel pump Pin 69 fuel pump driver Pins 68 and 70 ECM ground Check sensor power circuit for short to battery voltage or other higher voltage source Pin 34 sensor power Pin 42 sensor ground Check for shorted sensor by unplugging one sensor at a time while watching sensor power on data stream When voltage goes up you have located the problem sensor Pin 34 sensor power Pin 42 sensor ground Check sensor and circuits for open sensor ground short between sensor power and sensor signal and short between sensor signal and other voltage source Pin 22 MAP signal Pin 34 sensor power Pin 42 sensor ground Check sensor and circuits for open sensor power open sensor signal or short between sensor signal and sensor ground Pin 22 MAP signal Pin 34 sensor power Pin 42 sensor ground The voltage entering the ECM is too high usually above 16 volts This can be caused by a defective voltage regulator can also be caused by a circuit with higher voltage shorting to this circuit Pins 57 and 58 driver power Pins 68 and 70 ECM ground Pin 11 sensor signal Pin 68 and 70 ECM ground Check oil level Check oil pressure with a mechanical gauge Guardian No
13. sind Buisn uid spunoJB W93 uoneuuoJu 10sues Zp pue 49mod losu s PE Uld Josuas Zy Uld Josuas Zy Uld Syinouio WO pejejosi ase pue suoiueduJoo ale Y pue gj SUld Syinouio 1 U10 uuouj pejejosi ase pue suoiueduJoo ale Y pue gj suld Jeujo v uo g uid W03 pue pue auo uo sjjoA o pey euuoo SI 1102 jonuo2 Aejay punoio e 1 JOMOd UIEW WO S JOA S n 1 eAnisod OY 912110 uolueduloo jeuBis dY eunsseud ejnjosqe pjojiueyy 3ndu H 1q uey ue jeuBis 193 eunjeueduue juejooo euifu3 3ndu jeuBis LWW enjeueduue Jte pjopue yndu jeuBis SqO 10sues uonisod yeusyueJo 1ndu 7 jeuBis 10sues uonisod yeusyueJo 1ndu jeuBis eunsseJd ro 1104 Ud sjojuoo yeu uid JeAup Mdiy Jamod ule JeAug uoneunByjuoo Jull yoke JO jno jeubis yor Bojeuy JOAUP A PA OVI Ionuoo 41e p 10102 uonduos q peoueApy uoneoynuep Uld INO3 111 U99 143 07 90 883064R03 NOVEMBER 2010 Page 3B 6 Diagnostics and Troubleshootin siosu s 9JIM pue Z Je JO JInoJio A S pejeoipeg uni o euibue eui MO E JOU JIM N23 punos6 o p MHOUS ueuM UNL uedo eq ysnw n119 MOL JO uiu p m ys aq IM siosu s V HBS jou JIM euiBue uedo 11
14. switch lead setting See Oil Pressure Switch Test in Section 4B Cylinder Block Crankcase Check for short between pin 11 It blu of the ECM connector and open connector of oil pressure switch Crankshaft position sensor Three beeps every See ECT sensor resistance chart four minutes Fuel injector Three beeps every Idle air control 1AC f r minutes Three beeps every See sensor resistance chart four minutes Engine runs rich Page 3B 32 90 883064R03 NOVEMBER 2010 Diagnostics and Troubleshootin Engine Guardian System is activated Power limit will vary withlevelofoverheat Stop engine and check water intake Engine overheat Continuous for obstruction Advancing throttle above idle may provide additional cooling Speed reduction Engine RPM limited Battery voltage Continuous horn Less than 10 V or above 75 power more than 16 V setting Engine Guardian System is activated Engine power is limited to 75 of maximum Engine coolant Continuous horn Engine Guardian System is activated Engine power is temperature ECT above 50 power limited to 50 of maximum Engine overheat protection sensor failure setting is compromised IMPORTANT In all instances check wiring harness integrity especially ground connections in boat and on engine Component Resistance Tests Engine Coolant Temperature ECT Sensor and Manifold Air Temperature MAT Sensor The ECT and MAT sensors are thermistor
15. 064R03 NOVEMBER 2010 Diagnostics and Troubleshooting Troubleshooting without a CDS G3 Troubleshooting without the CDS G3 tool is not recommended The CDS G3 tool is required to access the necessary faults data active tests and historic data that is available from the ECM Checking only the resistance on some of the sensors is not a recommended method for diagnosis Typical failures usually do not involve the ECM Most likely at fault are the connectors set up and mechanical wear The engine may not run or may not run above idle with the wrong spark plugs installed Swap ignition coils to see if the problem follows the coil or stays with the particular cylinder Any sensor or connection can be disconnected and reconnected while the engine is operating without damaging the ECM Disconnecting the crankshaft position sensor will stop the engine IMPORTANT Any sensor that is disconnected while the engine is running will be recorded as a fault in the ECM Fault Hours e Ifall cylinders exhibit similar symptoms the problem is with a sensor or harness input to the ECM f problem is speed related or intermittent it is probably connector or contact related Inspect connectors for corrosion loose Wires or loose pins Secure connector seating If dielectric compound was used to protect the wire connections the dielectric compound must be removed Inspect the harness for obvious damage pinched wires chaffing Check fuel pump c
16. 1 uli Bunious Jo Buiuedo s oSi A p ye19uetuus pue 001 O NO4 40 AemyBiy ejeq UOIjeoIunuJUJOO OU SJOjSIS9J ON ejeoiunuJUJOO 0 SJ0jsIseJ NYO seuinbey UOIjeoIunuJUJOO OU SJOjSIS9J ON ejeoiunuJuJOO o SJO SISOJ Jojeuruue NVO seuinbey S ON 9IA19S uoneuuoJu BdIAIES 49mod JOSUaS pg Uld Jeo s uun uuos g z A S punoJ6 Josuas 4 AS jaA jdd SHOSU S O INO4 wouy Je od JOSUaS 1 NVO uld ol uBnouu do s ASu B1 uug 1ndu Josuas Zy Uld Josuas Zy Uld IN93 pejoeuuoo s ayeb u 102 e 1 JOMOd UIEW S JOA S n JEUILWI9 eAnisod 1102 IN93 0 pejoeuuoo s u 1B AneB u 102 ej8a4 JOMOd urew WO S JOA S A L euru eAnisod 109 JOAUP Z 100 153 JeAug JOAUP Lif 109 1S3 noo uoneoiunuuuuoo 1 ue uo suoiueduioo 9Je yz uid pue z Uld d NYO 1 8 uolesjunwwoyg INDIIO uoHeo UNWIWOS pejelosl U d NYO ue uo SuOlUEdUlO2 1 uolesjunwwoyg 9Je yz uid pue z uld uojueduo uonduoseq May be switchable with the CDS G3 90 883064R03 NOVEMBER 2010 1 Page 3B 7 Diagnostics and Troubleshootin eJIM BneB AAP U e uA JeuruJoe 26127
17. 3 wht of the Crankshaft position NOTE No RPM pi 57 wht sensor CPS reading at or tachometer Between pin 1 red and pin 2 wht of CPS connector Listen for pump Fuel pump should run two seconds after key switch is turned to RUN position 32 41 ohms Between pin 69 blk blu and pin 57 or 58 red blu or Between pins of fuel pump connector Flywheel misaligned Remove flywheel and inspect flywheel key keyway See ECT sensor resistance chart Three beeps every Advancing the remote control fast idle feature or four minutes advancing the tiller handle throttle grip halfvvay may assist starting None Electric fuel pump ntermittent beeps Engine coolant temperature ECT sensor Page 3B 30 90 883064R03 NOVEMBER 2010 Diagnostics and Troubleshootin Remote control to engine wiring harness Clean and inspect male and female connections connection is poor Air in fuel system lines Crank and start engine several times Mani p ote SIX beeps at key up See MAP sensor resistance chart pressure MAP sensor or failure Throttle position sensor Six beeps at key up Typical TPI range with CDS TPS or failure Idle 0 39 1 0 volts WOT 3 66 4 80 volts Engine cranks starts 20 24 ohms and stalls Between pin 3 wht org and pin 57 or 58 red blu of the Idle air control IAC 12777 ECM connector or Between pin A and pin B of IAC ECM reference voltage intermittent sana 5 V between ppl yel pin of
18. A S IM niq 11 11n2ur v uedo ueuM eJnssaJd ou p solo eJnssaeJd poof u do U91JIMS 9 euiBue sepi oud YyoUMS HO u uA eoueijsisaJ uBiu uedo ue pue UO u ym v9 pue og 5414 ejaJ u m q eouejsisaJ MOJ yN p soj e epi oJd 1snuJ e aJ u AjpoeJ1oo BubuioMw eq jou Aew sor yeu V uonoun AUr YOR 199 94 lqesiq no v v JeuBis pue 1 AAOd Jejeuouoe1 9JIM EUOIUSAUOD J uonounj XUr 195 y 9 qeue 1snuu no p sn aue sjonpoud yeuguews J weeds ejep uo pe eldsip 51 jueoJed esing S ON N S 30 40 EFI Gen Ill ECM Pin Identification Advanced Josues eJnsseJd eeJu 40 SIUJJ9U 9JIM OM JOJSIUU9U OML yi pue L suid yBnosu N23 pue Josues U M Q SAL Ajuo eBeyoA punos6 WO 51 SI 3In2JI yi pue L suid yBnosu N23 pue Josues U M Q SAL Ajuo eBeyoA punos6 WO p9JeJOSI SI PNUD Josues eJnsseJd euo HO suun eui p u do uauM UO sulun y pepunoJ6 l o3 8 y 104 eui sjouoo g utd N23 p lqesip SI uonounj iney p Ag ndino si eunBijuoo O UI 1S9 au HET 199 esf Buiu do BAJEA OV BU JoJjuoo 01 WM d uone npouu
19. Diagnostics and Troubleshooting Fuel System Section 3B Diagnostics and Troubleshooting Table of Contents Fuel System Specifications Fuel ystefii easy VVire Color Code Abbreviations Pressure Regulator Test Electric Fuel Pump 30 40 EFI Gen Ill ECM Pin Identification Anti Siphon 30 40 EFI Gen 11 ECM Pin Identification Advanced Mechanical Fuel Pump Test Vacuum Troubleshooting without a CDS G3 Mechanical Fuel Pump Test Pressure Troubleshooting with the CDS G3 Fuel Pump Pressure Troubleshooting Accessing ECM Information Guardian Protection 5 Engine Information Displayed by CDS G3 Overheat Temperature Parametters R U cpm DC DE 30 40 EFI FourStroke einen Freeze Frame Buffer CDS G3 Display Information 3B 12 Gen III EFI System Troubleshooting Guide Default Sensor 3B 14 Component Resistance Tests Data Count to Voltage Table 3B 14 Engine Coolant Temperature ECT Sensor and Data Ste T 3B 15 Manifold Air Temperature MAT Sensor 3B 33 Fault Conditions een 3B 19 FUGI ECION m 3B 34 Ba
20. d be replaced a When troubleshooting Active Faults faults displayed under the Fault Status screen the circuit in question is an active failure Look for an open circuit or short circuit in the two or three wires involved with the sensor in question The sensor itself has actually failed or the connections at the ECU have failed b When troubleshooting intermittent faults faults displayed under the Fault History screen the circuit in question is not an active failure at the moment You are looking for an intermittent connection or an intermittent short circuit that is not present currently Check the circuits for opens and shorts and wiggle the wires and connectors during all tests in an attempt to locate the poor connection Carefully look for subtle problems such as corroded connections and internal wiring harness splices and for connectors with a loose fit between the male and female pins NOTE An excellent way to find an intermittent problem is to use the data monitor function in the CDS G3 tool While observing the data from the suspect circuit wiggle the wires and connectors while the key is on or while the engine is running When you locate the bad connection the data reading will fluctuate 2 If the fault is an abnormal operating condition repair the system as needed For example if the engine coolant temperature is too hot check the water pickups for obstructions or replace the water pump impeller as needed Active Test Table T
21. e 0 counts 0 V 1023 counts The ECM reads the TPS signal at pin 53 5 V Values in between can be calculated by multiplying the ADC value by 0 0048828 Normal reading 4 98 5 02 V 4 90 5 10 V 5 0 vdc power for operating all sensors is the maximum acceptable range When Power 1 When this voltage is incorrect all the voltage is too low it is usually caused XDRPa Sensor Power sensor data can be out of calibration by the sensor or sensor harness short If 5 vdc VVhenever you have multiple sensor the voltage is high it has shorted to faults verify this voltage is correct battery voltage Sensor povver comes from ECM pin 34 Fault Conditions Most faults can be detected without the engine running or key on engine off However some faults require the presence of engine RPM and cannot be detected key on engine off Examples of this type of fault are EST cylinders 1 3 shorted circuit or fuel injector faults Some faults are only detected in the key on engine off mode An example of this type of fault would be EST cylinders 1 3 open circuit In addition some faults are programmed to ignore certain engine speeds For example a low block pressure sensor fault sea pump pressure on a MerCruiser is typically not enabled until enough RPM has been achieved to develop a reasonable amount of water pressure Therefore this fault will not be set at idle The total time the engine has been Total engine run time cannot be erased
22. eed and or load The regulator vent line is not connected to manifold vacuum Fuel pressure should be stable from idle to full throttle If fuel pressure drops at higher speed and higher engine loads check the boat s fuel system for restrictions with an accurate vacuum gauge and clear hose at the water separating fuel filter s inlet As the engine is run from idle to wide open throttle and back to idle the clear hose must not show any air bubbles and the vacuum gauge must not read higher than 2 in hg If the supply system tests OK but the fuel pressure is low at high speeds and loads replace any fuel filters and test If rail pressure remains low the electric fuel pump is suspected as defective Check any and all vacuum lines for splits kinks and proper connections Check for any air leaks in the induction system such as throttle body and intake manifold gaskets If the normal IAC percentage for the engine is known then any air leak will result in a lower IAC percent than normal IAC should read 30 50 Unplug and inspect the ECM connector Ensure there are no ECM pins bent over and that all of the correct pins are present Refer to the service manual charts for the pins used and not used Look for signs of tampering corrosion damage to the pin locking mechanisms melted insulation and any other evidence of shorts or other damage Unplug and inspect as many of the sensors and actuators as you can reasonably access Look for signs of tampe
23. engine is overheating Fault codes can be displayed active or historic 90 883064R03 NOVEMBER 2010 Page 3B 11 Diagnostics and Troubleshooting Anactive fault is a fault that is present right now It is occurring at this instant Active faults affect how the engine is running right now Active faults will activate the Guardian program which will reduce engine power based on the severity of the problem Refer to Guardian Protection System Anoccurred fault is a fault that was active during this key switch cycle but is not active now Occurred faults do not affect how the engine is running They are valuable for diagnosing intermittent faults faults that come and go but do not stay active permanently Without the intermittent historic fault we would not know that a problem occurred in the past The View Fault displays active and inactive faults the code number description and the source of the faults When the status column shows YES they are active When the status shows NO they are inactive historic which also means intermittent a fault that comes and goes but does not stay active permanently Freeze Frame Buffer CDS G3 Display Information Freeze Frames are captures of selected data stream items at the time a fault occurs A Buffer can be created for each fault that is enabled on a particular calibration When a fault becomes active the ECM will store the data items in the first buffer using the values the instant
24. fer Old buffers are relevant when the customer complaint is about something that happened a long time ago Review the buffer data and inspect the relevant circuit and components Currently CDS G3 displays the fault number in freeze frame buffers but does not display the fault number in active inactive faults Guardian will reduce available power the most for severe problems low oil pressure and engine overheat Mild problems sensor circuit high will result in a small reduction in available power Intake air temperature data is used to calibrate the air fuel mixture It cannot cause drastic changes to the air fuel mixture Do not blame major engine issues on this sensor The IAC valve will open on deceleration to prevent stalling Low numbers or even 0 at idle indicate air leaks into the intake manifold Higher than normal numbers can indicate tampering with the throttle body Similar to Baro the MAP sensor modify the fuel curve richer or leaner The MAP reading will change with throttle RPM and load changes Higher than normal MAP readings cause rich mixtures Lovver than normal reading cause lean mixtures The oil pressure svvitch opens at a predefined pressure f the svvitch is closed shorted to ground then oil pressure is not high enough for safe engine operation f the switch is open no continuity to ground then oil pressure is high enough for safe engine operation Lists the engine RPM at the time t
25. he CDS G3 can send commands to the ECM to perform special functions These functions called Active Tests are useful for verifying proper function of various actuators and systems in addition to diagnosing problems with engine performance The following table lists the active tests available CDS G3 Active Tests Additional Information Set engine location Change the electronic address stored in the ECM Used in preparing the engine for delivery Set the tachometer output to operate a SmartCraft AGI or other SmartCraft gauges Used in preparing Set tachometer link the engine for delivery or adding nevv accessories to the boat Cylinder misfire Drop cylinders on a running engine to compare power output of each cylinder Assists with diagnosing a poorly running engine or an engine with low power Fuel pump output Operate the fuel pump to verify function current draw and assist in diagnosis of the fuel pump IAC output Operate the IAC valve to verify function and assist in diagnosis of idle control problems Horn output Operate the warning horn to verify function and assist in diagnosis of horn malfunctions Visual Physical Inspection 1 Verify that the battery is fully charged and is of sufficient capacity for the engine being tested If necessary substitute a known good battery Page 3B 20 90 883064R03 NOVEMBER 2010 Diagnostics and Troubleshooting 2 10 11 12 13 14 15 Check the battery cable connect
26. he fault No additional information occurred Page 3B 13 Diagnostics and Troubleshooting Buffer Data Item Service Description Service Information FF RunFPC Data FF SeaPumpPress Data FF SysVolt Data FF TPS Data FF XDRPa Data Default Sensor Information Lists the fuel per cylinder per cycle value at the time the fault occurred Lists the water pressure inside the engine block Lists the system voltage at the time the fault occurred Lists the throttle position at the time the fault occurred Lists the sensor power voltage at the time the fault occurred This value should be 5V Indication of fuel flow through injectors Higher numbers indicate richer mixtures lower numbers indicate lean mixtures Not applicable on this engine No sensor installed Will always read 0 0 kPa regardless of the actual water pump pressure System voltage starts at the battery and flows to the MPR and fuses When the MPR is turned on battery voltage flows from the MPR and into the ECM on pins 57 and 58 System voltage is used to control actuators IAC valve fuel injectors fuel pumps and ignition coils TPS data can be used to determine operator demand TPS and MAP data mirror each other in most operating conditions High TPS high MAP Low TPS low MAP This is only true when the engine is running Ideally this reads 4 98 5 02V 4 90 5 10V is the maximum acceptable range When it is unacceptable it is usually
27. hot Diagnose the cooling system Volts Battery voltage is too low or high Diagnose the charging system Active Fault A circuit high or circuit low sensor failure has occurred Check fault status Oil Pressure 4 stroke mechanical oil pump pressure is low Fuel System Pressure Regulator Test Electric Fuel Pump 1 Installthe fuel pressure gauge onto the Schrader valve located on the VST Page 3B 24 90 883064R03 NOVEMBER 2010 Diagnostics and Troubleshootin 2 a Start the engine The fuel pressure should be within specification Schrader valve b To Schrader valve c Fuel pressure gauge d Pressure relief button e Drain hose Fuel Pump Pressure At all speeds 290 303 kPa 42 44 psi Fuel Pressure Gauge Kit 91 881833A03 Dual Fuel Air Pressure Gauge Kit 91 881834A 1 Anti Siphon Valves While anti siphon valves may be helpful from a safety standpoint they clog with debris they may be too small or they may have too heavy a spring The pressure drop across these valves can and often does create operational problems and or powerhead damage by restricting fuel to the fuel lift pump and subsequently the high pressure fuel pump Some symptoms of restricted lean fuel flow which could be caused by use of an anti siphon valve are Severe fuel rail pressure fluctuation Loss of fuel pump pressure High speed surging Outboard cuts out or hesitates upon acceleration Outboard runs rough Outboard qu
28. icky activated The engine will not start ESTOP circuit for short to ground Pin 42 sensor ground as long as it is on 90 883064R03 NOVEMBER 2010 Page 3B 21 Diagnostics and Troubleshootin Fault Text Service Information Circuit information Crankshaft position sensor signal is erratic This engine does not use a camshaft sensor EncoderFault CrankCamtrigger Non Sticky Non Sticky Non Sticky Non Sticky Non Sticky MAPInputHigh Sticky MAPInputLow Sticky Non Sticky Non Oil pressure is too low Guardian Sticky enabled Fuel pump is drawing too much current The pump could be locked up or its windings shorted FuelPumpCurrent High Fuel pump is not drawing enough current The impeller may not be turning with the pump or there may be excessive resistance in the pump armature and pump circuits FuelPumpCurrent Low XDRPalnputHigh Sensor power 1 voltage too high XDRPalnputLow Sensor power 1 voltage too low MAP circuit high MAP circuit low DRVPInputHigh Driver system voltage too high Guardian_ OilPressure Check sensor for proper mounting Check white and red circuits for intermittent shorts and opens Check for damage to the flywheel encoder ring Pins 13 and 14 crankshaft position sensor Most likely a defective pump short Battery to fuel pump Check for 12 V pump positive circuit Pin 69 fuel pump driver shorted to the fuel pump driver Pins 68 and 70 ECM
29. igh readings 1015 1023 indicate a circuit high fault Displays the pulse width modulation PWM signal sent from the IAC driver Signals range from 0 valve closed proportionally to 10096 valve open Displays one of the six possible modes of idle control operation that is active Excessive current can result from shorted armature windings or excessive internal friction within the pump Current draw below normal can result from high resistance in the armature or fuel pump circuits aerated fuel fuel vapor or pump cavitation from wear or damage Displays one ofthe following None Volts ECT Oil Pressure or Active Fault Example If GuardianLatchedPwrLim available power is 6596 None is displayed until the operator exceeds 6596 demand A demand 65 or greater Guardian limits engine output to 65 power and will display Volts ECT Oil Pressure or Active Fault The engine will run normal below 65 and the data will display None Guardian will reduce available power significantly for severe problems low oil pressure and engine overheat Mild problems sensor circuit high will result in a small reduction in available power Guardian limits engine power when problems are detected It reduces power by adjusting fuel injection and ignition timing It can stop cylinders from firing when necessary Horn should be audible whenever the data value is 1 Intake air temp data is used to calibrate the air fuel mixture I
30. ions Ensure they are clean and tight If present discard wing nuts and replace with corrosion resistant hex nuts Ensure the cable connections are tight at the starter solenoid and the ground stud Verify the ground stud is not loose in the engine block even if the nut is tight If there is any doubt about the mechanical condition of the engine perform a cylinder leak down test Ensure the safety lanyard is correctly installed and that the customer understands the correct starting procedure Unplug and inspect the main harness 14 pin connector between the engine and boat harnesses If there is any doubt about the boat harness substitute a shop harness and key switch assembly and rerun the boat If the problem disappears the problem is in the boat harness not the engine harness A test harness is available from Mercury Parts and Accessories as part number Check for adequate fuel pressure at the fuel rail test port at the VST If there is no fuel pressure check that the fuel pump is actually operating The pump must run for at least two seconds each time the key is turned to the on position If the fuel pump and the warning horn are not operating as the key is turned on verify the ECM is powering up The low pressure supply pump is a mechanical pump on this engine The pump is driven by a lobe on a camshaft It must maintain the fuel level in the VST for the high pressure electric pump The rail fuel pressure does not vary with engine sp
31. it information Check for proper propeller pitch Guardian Engine overspeed Guardian damaged propeller or other causes Overspeed Sticky enabled of ventilation Possible slipping propeller hub Check for open sensor open IATInputHigh Non IAT circuit high sensor signal or open sensor Pin 20 IAT signal Sticky Pin 42 sensor ground ground circuit Not applicable IATInputLow Non_ IAT circuit low Check for shorted sensor or sensor Pin 20 IAT Signal Sticky signal circuit shorted to ground Pin 42 sensor ground Check for proper CAN P 3 RxDoc2 SOH Non CAN COMM fault type 2 termination Check CAN P circuits Pin 23 and 24 CAN Sticky circuits for opens and shorts Check horn and tan blue circuit for Battery to horn HORN Output Warning horn problem check open and short circuits Check horn Pin 63 horn driver Fault Sticky circuit for battery voltage at purple lead Pins 68 and 70 ECM when key is on ground Non Sticky indicates the fault will go inactive as soon as the problem is corrected Sticky indicates the fault will remain active until the problem is corrected and the key switch is cycled Cycle key often when diagnosing faults CDS G3 Text Guardian Cause CDS G3 Text for Data Stream item Guardian Cause Probable Cause Guardian is not currently active No faults or operator demand is less than None GuardianLatchedPwrLim ECT engine coolant temperature Hot ECT is
32. its and cannot be restarted Outboard will not start Vapor lock Since any type of anti siphon device must be located between the outboard fuel inlet and fuel tank outlet a simple method of checking if such a device or bad fuel is a problem source is to operate the outboard with a separate fuel supply which is known to be good such as a remote fuel tank If after using a separate fuel supply it is found that the anti siphon valve is the cause of the problem there are two solutions to the problem either 1 replace the anti siphon valve with one that has a lighter spring tension or 2 replace it with a solenoid operated fuel shut off valve Mechanical Fuel Pump Test Vacuum Fuel system vacuum be checked by using a short piece of extra fuel hose vacuum gauge and a T fitting 1 2 Conduct the test with water to the engine cooling system using one of the following methods a n a test tank b With the boat outboard lower unit in water Disconnect the fuel hose from the inlet fitting of the mechanical fuel pump 90 883064R03 NOVEMBER 2010 Page 3B 25 Diagnostics and Troubleshooting Connect an extra fuel hose onto the outlet fitting of the pump Install a T fitting into the extra hose making the connection as close to the pump as possible Connect a vacuum gauge and the fuel inlet hose onto the T fitting Start the engine and run at 1000 RPM normal fuel system vacuum lift should be to specifications NOTE The syste
33. ix beeps at key up ses MAP sensoPresi tanc chart pressure MAP sensor or failure Throttle position sensor Six beeps at key up Typical TPI range with CDS TPS or failure Idle 0 39 1 0 volts VVOT 3 66 4 80 volts Engine coolant temperature ECT sensor Manifold air temperature Six beeps at key up See MAT sensor resistance chart MAT sensor or failure 10 0 13 5 ohms Between fuel iniector pin 1 and pin 2 Poor idle quality Or Three beeps every Between removed fuse 2 red blu vvire and the ECM four minutes connector Pin 49 pnk brn fuel iniector 1 Pin 50 pnk red fuel iniector 2 Pin 65 pnk org fuel injector 3 Ignition coil EST 1 See ignition coil resistance chart Section 2A Ignition 20 24 ohms Between pin 3 wht org and pins 57 or 58 red blu of the ECM connector or Between pin A and pin B of IAC Fuel una See fuel pressure test Fouled spark plug Replace spark plug Fuel pressure regulator 42 44 psi 290 303 kPa at VST fitting Engine coolant temperature ECT sensor Thermostat stuck open Remove and inspect Section 4A Cylinder Check engine oil level and add oil as needed Remove oil pressure switch and install oil pressure gauge warm engine oil pressure should be Speed reduction Low oil pressure or Continuous horn Above 2 9 psi 20 0 kPa at idle Engine RPM limited tol grounded oil pressure above 1096 power 30 40 psi 207 278 kPa at 3000 RPM 2000
34. k oil level Add oil if necessary Continuous beep Battery voltage less than 10 V or more than Engine Guardian Protection System is activated Engine 16V power is limited to 7596 of maximum Engine Guardian Protection System is activated Engine Coolant sensor failure ECT power is limited to 5096 of maximum Engine overheat protection is compromised Exceeding 6200 RPM cuts spark injection on cylinders 2 Engine speed limiter and 3 to reduce engine speed Exceeding 6350 RPM cuts spark injection on all cylinders to reduce engine speed Overheat Temperature Parameters 30 40 EFI FourStroke When troubleshooting these models of engines questions often arise as to what the actual engine overheat parameters are for Guardian Please see the table below as a reference point for this information Engine Temperature Percent of Available Power GuardianLatchedPwrLim Below 77 C 170 F 10096 90 883064R03 NOVEMBER 2010 Page 3B 29 Diagnostics and Troubleshooting NOTE These models of engines are able to run at idle speed with temperatures up to 90 C 194 F before any Guardian or horn is activated Keep in mind that the operator must attempt to operate the engine above the available power limit to activate the Guardian system the engine is operating at one of the above temperatures but below the available power limit no reduction in speed or warning horn will be noticed GuardianLatchedPwrLim available power IMPORTANT
35. l 5 V Page 3B 14 90 883064R03 NOVEMBER 2010 Diagnostics and Troubleshooting 0 0 x 64 kx Data stream value x 0 0048828 equivalent DC voltage Data Stream Data Item Name Description Significance Service Information from G3 Continuously scrolls through all active faults approximately one per second Displays dashes when there are no faults Convenient to see if active faults are present without switching to the fault page ActiveFaultMarquee Most technicians use the data item GuardianLatchedPwrLim to determine the total amount of power available to the operator Air per Cylinder APC per Cycle Similar to FPCA caleulation ol alr Compare to previously recorded values APC passing through the cylinders A technician should understand what the typical Baro value is at his location Displays the current barometric Compensate your shop value for pressure Baro on an EFI engine is extremely high or low barometric Barometric absolute often called raw Raw data pressures due to extreme weather Pressure must be used to calculate fuel delivery conditions When Baro readings are at different altitudes Baro data incorrect and higher than actual due to determines the fuel delivery at start up sensor or circuit problems the engine will run rich When incorrect and lower than actual the engine will run lean This may not be the actual idle speed the Default Idle This is the idle RPM the ECM wants the
36. lve Fuel system pressure belovv specification Restriction vvithin primer bulb Pinched collapsed fuel hose Dirty plugged vvater separating fuel filter Fuel filter bowl loose Fuel filter gasket cut worn Loose fuel pump screws Fuel pump gaskets worn or leaking Fuel pump check valves seals leaking Leaky fuel pump diaphragm Worn broken fuel pump springs Leaky fuel pump seals Fuel vaporization Guardian Protection System Refer to Anti Siphon Valves preceding Fill tank with fuel Clean replace fuel pickup screen Replace fuel pickup tube Check tighten all connections Inspect replace fuel hoses Rebuild replace primer bulb Inspect replace fuel hoses Clean replace water separating fuel filter Tighten fuel filter bowl Replace gasket Tighten screws to specification Rebuild replace fuel pump Rebuild replace fuel pump The Guardian Protection System monitors critical engine functions and will reduce engine power accordingly in an attempt to keep the engine running within safe operating parameters 1 Air bubbles may also be visible as fuel passes through the clear fuel test hose installed between the mechanical fuel pump outlet fitting and the VST Page 3B 28 90 883064R03 NOVEMBER 2010 Diagnostics and Troubleshooting IMPORTANT The Guardian Protection System cannot guarantee that powerhead damage will not occur when adverse operating conditions are encountered The Guardian Protection Sy
37. m vacuum test is normally performed at 1000 RPM As engine RPM is increased there will be a slight increase in vacuum this increase should not exceed normal readings oa o pop Mechanical Fuel Pump Vacuum Lift Vacuum at 1000 RPM 25 50 mm Hg 1 2 in Hg 7 Too isolate the mechanical fuel pump from the rest of the fuel system a Pinch off restrict the fuel supply hose between the vacuum gauge and the fuel tank b The mechanical fuel pump vacuum lift should be to specifications f the vacuum reading for the pump is below specifications the pump needs rebuilding a Fuel supply hose from fuel tank b T fitting c Extra hose to inlet fitting of the mechanical fuel pump d Vacuum gauge 28177 Mechanical Fuel Pump Vacuum Lift Minimum vacuum at 1000 RPM with fuel line pinched 102 mm Hg 4 in Hg minimum If the fuel pressure reading is not within specifications refer to Fuel Pump Pressure Troubleshooting table Stop the engine remove the gauge and reconnect the fuel line to the inlet fitting of the fuel pump NOTE The fuel pump is designed to lift fuel vertically approximately 152 cm 60 in if there are no other restrictions in the system using a fuel hose that is 8 mm 5 16 in minimum diameter As restrictions are added such as filters fittings valves etc the amount of fuel pump lift decreases Fuel Pump Vacuum Troubleshooting Dirty plugged water separating fuel Fuel system vacuum lift ab
38. n Engine coolant is too hot Check cooling system for possible Pin 21 ECT signal Overheat Sticky Guardian enabled malfunction Pin 42 sensor ground Oil pressure is too low Non OilPress Low Sticky Non BaroRange Sticky Baro Value out of expected range Pin 11 sensor signal Pin 68 and 70 ECM ground Pin 22 MAP signal Pin 34 sensor power Pin 42 sensor ground Check oil level Check oil pressure with a mechanical gauge Baro pressure is absolute pressure It is not compensated for altitude Non Engine coolant temperature too Check 7 system for possible Pin 21 ECT signal VS sticky Pin 42 sensor ground EST1 OutputFault Non EST 1 primary circuit open or Sticky shorted Page 3B 22 Check ignition coil primary circuit for Battery to ignition coil opens and shorts Check circuit Pin 32 EST 1 between ignition coil and ECM for Pin 68 and 70 ECM opens and shorts ground 90 883064R03 NOVEMBER 2010 Diagnostics and Troubleshootin Fault Text Service Information Circuit information EST 2 primary circuit open or EST2 OutpufFault Sticky shorted _ EST 3 primary circuit open or Sticky shorted EST3_OutputFault Check ignition coil primary circuit for Battery to ignition coil opens and shorts Check circuit Pin 33 EST 2 between ignition coil and ECM for Pin 68 and 70 ECM opens and shorts ground Check ignition coil primary circuit for Battery to ig
39. nation Harness 84 8M0045065 E E Contains termination resistors to allow communication when G3 is connected to 43351 the engine s diagnostic connector Tests the fuel pump pressure can be used to relieve fuel pressure Page 3B 2 90 883064R03 NOVEMBER 2010 Diagnostics and Troubleshooting Dual Fuel Air Pressure Gauge Kit 91 881834A 1 Tests fuel and air pressure the dual gauges allow the viewing of both pressures simultaneously Measures RPM on spark ignition SI engines ohms amperes AC and DC voltages records maximums and minimums simultaneously and accurately reads in high RFI environments Wire Color Abbreviations 4 Oil pressure signal gry CPS signal 1 May be switchable with the CDS G3 90 883064R03 NOVEMBER 2010 Page 3B 3 Diagnostics and Troubleshooting Gen III ECM Empty Intake air temperature IAT signal Engine coolant temperature ECT signal Manifold absolute pressure MAP signal CAN 1 signal for SmartCraft gauges and CDS G3 tool CAN 1 signal for SmartCraft gauges and CDS G3 tool Empty N N Empty N Empty Not for service Not for service Empty EST coil 1 driver controls smart coil EST coil 2 driver Sensor power power 1 5 V from ECM to sensors Emergency stop through 14 pin main engine harness Sensor ground 5 V sometimes called filtered ground Fuel injector 1 driver controls negative side of injector Fuel injector 2 driver control
40. ne Debris in the cooling system can hold the thermostat open causing the engine to run cold If this voltage is more than 1 V below actual battery voltage check the circuit to the helm key switch and back to engine for high resistance loose connections corrosion or other causes for voltage drop More critical when used in the freeze frame buffer Displayed to allow familiarization with the data ESTOP starts at ECM pin 41 Black yellow circuit goes to the 14 pin main harness connector and any lanyard safety switches on the engine or at the helm Defective lanyard and ignition switches can cause high speed misfires when they intermittently short this circuit to ground If counts are higher than 150 when ESTOP is on or lower than 850 when ESTOP is off the black yellow ESTOP circuit has a problem Check the ignition and lanyard switches for excessive resistance corrosion or damage Check the black yellow circuit between the ECM and the ignition switch for shorts to ground or any other circuit that could provide a ground path On remote control boats check the ESTOP circuit to the helm This legacy item is used through many generations of engines New ECMs are Switching to pulse width as a measurement of fuel flow through the injector 90 883064R03 NOVEMBER 2010 Diagnostics and Troubleshootin Data Item Name Description Significance Service Information from G3 FuelPumpCurrent FuelRate GuardianCause
41. nition coil opens and shorts Check circuit Pin 66 EST 3 between ignition coil and ECM for Pins 68 and 70 ECM opens and shorts ground Guardian_Active_ Non_ Guardian is active due to an active Sticky 75777 77 Battery voltage problem Sticky Guardian enabled Non Sticky Non Sticky Non Sticky Non Idle air control valve is open or Sticky shorted Non MAP and TPS are not reading as Sticky expected Non Sticky Non TSP1 RangeLow Sticky Non TPS AdaptMech Sticky Non ECTInputHigh Sticky Guardian Voltage INJ1_OutputF ault Injector 1 circuit is open or shorted INJ2_OutputFault Injector 2 circuit is open or shorted INJ3 OutputFault Injector 3 circuit is open or shorted LIAC OutputFault MAPR_ TPS1Rationality TPS1_RangeHigh TPS circuit high TPS circuit low TPS cannot adapt ECT circuit high Pin 52 key switch Pins 57 and 58 driver Check for low or high voltage on pin power 52 57 58 and 67 Pin 67 battery Pins 68 and 70 ECM ground Battery to fuel injector Pin 49 injector 1 driver Pins 68 and 70 ECM ground Check injector and circuit between ECM and injector for opens and shorts Battery to fuel injector Pin 50 injector 2 driver Pins 68 and 70 ECM ground Check injector and circuit between ECM and injector for opens and shorts Battery to fuel injector Pin 65 injector 3 Driver Pins 68 and 70 ECM ground Check inject
42. o raise the idle speed The most common reason for elevated idle speed is a cold engine or a throttle body not returning to its idle stop the ECM considers the throttle open the ECM does not control engine idle speed The time required for the injector to react to the electric signal Displayed where each cylinder s value is shown Time the injector should be mechanically open Adding the MPW to the EPW equals the total time the electrical signal is on Displayed where each oylinder s value is shown Longer MPW values result in more fuel injected rich mixture Shorter MPW values results in less fuel lean mixture A calculation of the engine work load The data is not relevant unless the engine is running Calculated mass air flow MAF When determining if the MAP sensor is delivering accurate data do not compare a standard vacuum gauge reading to the MAP sensor Vacuum gauges are referenced against the current atmospheric pressure about 14 7 psi while a MAP sensor is referenced against a nearly perfect vacuum Displays the intake manifold pressure MAP data must follow throttle RPM and load changes MAP readings have a large effect on air fuel ratios Counts can be related and converted to voltage Sensor circuits are 0 5 V circuits 0 counts 0 V and 1023 counts 5 V The data is proportional Counts can be multiplied by 0 0048828 to convert it to volts Do not round the multiplier it will not produce
43. onnections and fuel pump pressure Secure grounds and all connections involving ring terminals Coat grounds and ring terminals with Liquid Neoprene Troubleshooting with the CDS G3 Accessing ECM Information 1 Connect the USB cable end into one of the computer USB ports IMPORTANT Always connect to the same USB port when acquiring data 43969 2 Connect the SmartCraft Diagnostic Interface 9 pin connector to the CAN P CAN H adapter harness 9 pin connector a 9 pin connector Page 3B 10 90 883064R03 NOVEMBER 2010 Diagnostics and Troubleshooting 3 Remove the CAN P termination resistor from the engine harness 4 Connect the CAN P CAN H adapter harness to the CAN P CAN H termination harness 84 8M0045065 5 Connect the CAN P CAN H termination harness to the CAN P engine harness SmartCraft diagnostic port MPORTANT The G3 CAN P CAN H termination harness 84 8M0045065 contains the correct termination resistor for the CDS G3 SmartCraft Diagnostic Interface to communicate vvith the ECM 6 Key up the engine 7 Open the G3 softvvare program NOTE The following lights on the G3 interface should be lit Pwr e Bus e Bus l disregard any activity on these engines a SmartCraft diagnostic port b ECM The ECM is designed that if a sensor fails the ECM will compensate so the engine continues to run efficiently as possible However the air fuel mixture will not be as accurate without all of the sensors pro
44. or running cleared 90 883064R03 NOVEMBER 2010 Page 3B 19 Diagnostics and Troubleshooting Basic Diagnostic Outline G3 Diagnostics 1 Verify the customer complaint Try to duplicate the symptom 2 Connect the G3 system and read all fault information Document all the fault information 3 Diagnose the active faults Use the Data Stream and Active Tests to assist with the diagnostics of the faults 4 Diagnose Inactive Faults next Use Freeze Frame Buffer data to assist with diagnostics of these faults 5 Clear faults as they are diagnosed and test the engine to see if any faults return Faults rarely indicate a defective ECM Assume the ECM is working correctly until complete and thorough troubleshooting procedures prove that it is defective 6 Again diagnose faults that have reoccurred 7 When all faults have been diagnosed and do not reoccur check to see if the original customer complaint still exists 8 If customer complaint still exists repeat the diagnosis of the symptom 9 9 Perform the Visual Physical Inspection It process will help diagnose symptoms that do not produce faults Faults 1 If the fault is a CUT HI or CUT LO refer to the appropriate wiring diagram and check each of the leads between the suspect sensor and the PCM ECM for open and short circuits The short circuit does not have to be to ground it could be to any other wire in the harness If all of the leads test good then the sensor shoul
45. or and circuit between ECM and injector for opens and shorts Battery to IAC valve Pin 3 IAC Driver Pins 68 and 70 ECM ground Check IAC valve and circuit between ECM and IAC valve for opens and shorts For any given MAP signal the TPS is not reading as expected Check MAP and TPS circuits for high resistance Check if MAP and TPS data appear correct Pin 22 MAP signal Pin 53 TPS signal Pin 34 sensor power Pin 42 sensor ground Check sensor and circuits for open sensor ground short between sensor power and sensor signal and short between sensor signal and other voltage source Pin 53 TPS signal Pin 34 sensor power Pin 42 sensor ground Check sensor and circuits for open sensor power open sensor signal or short between sensor signal and sensor ground Pin 53 TPS signal Pin 34 sensor power Pin 42 sensor ground Check linkage for anything preventing throttle from fully closing Throttle must be closed when engine is started Pin 53 TPS signal Pin 34 sensor power Pin 42 sensor ground Check for open sensor open sensor signal or open sensor ground circuit Pin 21 ECT signal Pin 42 sensor ground Non_ Check for shorted sensor or sensor Pin 21 ECT signal ST Inputt w Sticky EO Circuit low signal circuit shorted to ground Pin 42 sensor ground 90 883064R03 NOVEMBER 2010 Page 3B 23 Diagnostics and Troubleshootin Fault Text Service Information Circu
46. ove filter Clean replace water separating fuel filter Restriction in fuel line thru hull m Clean replace fitting fitting Restriction in fuel tank switching valve Clean replace valve Restriction within primer bulb Rebuild replace primer bulb Page 3B 26 90 883064R03 NOVEMBER 2010 Diagnostics and Troubleshooting Fuel Pump Vacuum Troubleshooting Fill tank with fuel Hole cut in pickup tube of fuel tank Replace fuel pickup tube Check tighten all connections Inspect replace fuel hoses Torque screws to specification i i Fuel pump gaskets worn or leaking Rebuild replace fuel pump Fuel System vacuum lift below Rebuild replace fuel pump specification Check for plugged fuel pump water cooling circuit Mechanical Fuel Pump Test Pressure Fuel system pressure troubleshooting can be performed by using a piece of clear fuel hose 10 cm 4 in long a pressure gauge and a T fitting 1 Conduct the test with water to the engine cooling system using one of the following methods n a test tank With the boat outboard lower unit in water Disconnect the fuel hose from the outlet fitting of the mechanical fuel pump Connect the clear fuel hose onto the outlet fitting of the pump Install the T fitting onto the clear fuel hose Connect the pressure gauge and fuel outlet hose to VST onto the T fitting Start the engine and run at 1000 RPM normal fuel system pressure should be to specifications Normal Mechanical F
47. pulled down by a shorted sensor or sensor harness If it is too high it has shorted to battery voltage Sensors cannot display accurate data when sensor power is unacceptable Default sensor values are preprogrammed amounts used by the PCM to calculate fuel and ignition values when the sensor in question has exceeded its preprogrammed diagnostic limits Default sensor values are typically used when the sensor has a circuit high or circuit low fault For example all 2 wire sensors operate the same When you unplug the sensor a circuit high fault occurs and when you short the two wires together a circuit low fault occurs Most temperature sensors default to 0 C 32 F This can be verified by unplugging the sensor in question and watching the data stream value with the CDS Most pressure sensors default to a preprogrammed number also The MAP sensor is an exception A failed MAP sensor will display a value that is near the actual value but diagnosed with displayed fault codes Refer to Fault Information Data Count to Voltage Table Some data on the CDS G3 screen is presented as analog to digital conversion ADC counts ADC is a method of changing the sensor signal into display information for diagnosis In diagnosing circuits that use data counts it is helpful to convert the counts into volts to allow the use of a multimeter on that circuit The display range for data counts is 0 1023 Zero counts equal zero volts and 1023 counts equa
48. ring corrosion damage to the pin locking mechanisms melted insulation and any other evidence of shorts or other damage Based on the results of this inspection further inspection of the harness may be necessary There are many internal splices in the harness that may be damaged or defective If there is damage on the external connections you will have to inspect several of the internal splices to verify that the damage is not also present at these locations 30 40 EFI Fault Information NOTE Not all faults may be enabled on any specific engine Each calibration can have its own fault setup Fault Text Service Information Circuit information The PCM estimates the amount of Mass airflow is too high Check for 7 6L T MAF too High Sticky proper ECM calibration number p Not applicable Driver system Non Voltage too Low Sticky fault it active Usually the result of the wrong calibration or engine modifications and or modified components The voltage entering the ECM at pins 57 and 58 is too low This is usually caused by a defective Pins 57 and 58 driver alternator excessive accessory power load or high resistance in the MPR Pins 68 and 70 ECM the fuse and or the entire circuit ground The fault sets when the voltage is approximately 11 V or lovver Driver system voltage too low Emergency stop circuit is Non Check lanyard stop svvitch Check 1 Pin 41 ESTOP ESTOF St
49. s a resistor that changes value based on temperature Low temperature produces a high resistance High temperature causes low resistance 1 Place the temperature sensor in a container filled with water 2 Place a thermometer in the water and slowly heat the water 3 Measure the resistance when the specified temperature is reached If the reading is out of specification replace the sensor a Temperature sensor 000000000 28198 DMT 2004 Digital Multimeter 91 892647A01 5 vv kk 40 336 000 90 883064R03 NOVEMBER 2010 Page 3B 33 Diagnostics and Troubleshootin Fuel Injector 28204 a Pin A b Pin B DMT 2004 Digital Multimeter 91 892647A01 Meter Test Leads Meter Scale Reading 0 Black i Q DMT 2004 Digital Multimeter 91 892647A01 Meter Test Leads Meter Scale Reading Q lr Terminal 85 Terminal 86 81 91 Manifold Absolute Pressure MAP Sensor m5 nun 28206 a Pin A blk org b Pin B yel c Pin C pur yel Page 3B 34 90 883064R03 NOVEMBER 2010 Diagnostics and Troubleshooting DMT 2004 Digital Multimeter 91 892647A01 Meter Test Leads Meter Scale Reading 0 ro Bak T Crankshaft Position Sensor CPS
50. s negative side of injector Wake up key switch Throttle position sensor TPS signal Driver power 12 V from MPR into the ECM Driver power 12 V from MPR into the ECM Empiy Page 3B 4 90 883064R03 NOVEMBER 2010 N o co NII o NP Ol O Diagnostics and Troubleshooting Pin Gen III ECM Color Code Empiy Empiy VVarning horn driver controls negative side of horn tan It blu 64 _ Empy Empty Fuel injector 3 driver controls negative side of injector 90 883064R03 NOVEMBER 2010 Page 3B 5 Diagnostics and Troubleshootin 1991109 s GVW v p ds joexe y je 3d x AHood uni o ulB5u y esneo III siu enjeA 15 e je y9ns ueo Ss10sues dv A JUSWSAOW emojJui uy eBueuo sHulpee dVIN AH A pasoo SI U UM S AO 51 eUBIS eunsseud oujeujoJeq BuipeaJ u uA 1s uBiu si jeuBiS JOY U UA AO pue pjoo ueuM uBiu si eBeyo jeus Josues JOY U UA AO pue pjoo u uA uBiu SI eBeyjo jeus josues peeds pue uonisod yeusyxueJo sesn W93 eu 84615 eDeyoA OV ue eonpoJd pue Josues ayy Aq ssed seue Hulu au sejejoJ I uA JJ eui sv peeds pue uonisod yeysyueso euruuejep o s sn W93 eui jeus eBeyo OV ue eonpoud pue Josues ayy Aq ssed seue Bull eu sejejoJ f UMAI eu sv A 0 01 eSOJ9 JO A 0 pea IM 11 0 10 eu pesojo ueuM A G 0 9SOJO JO
51. s will cause the opposite taken once per run cycle when the key is Barometric pressures will change with the turned on weather barometric sensor displays absolute pressure which means it is a raw reading that has not been compensated Spark advance is ignition timing and is listed Lists the spark advance at the time ofthe in degrees before top dead center BTDC fault Negative numbers indicate degrees after top dead center FF_BaseSparkAdv_Data Battery voltage anywhere on the engine should always be within one volt of the voltage at the battery terminals The battery should not drop below 11 0V during normal operation except while starting the engine Low voltages at the ECM can indicate problems with loose or corroded connections excessive accessory loads defective charging system and or battery The voltage that determines this fault is measured at Pin 67 and or pin 52 Lists the battery voltage at the time of the FF BattVolt Data fault Page 3B 12 90 883064R03 NOVEMBER 2010 Diagnostics and Troubleshooting Buffer Data Item FF_ECT_Data FF_EngineState_Data FF_EngRunTime_Data FF Faultindex Data FF GuardianLatchedPwrLim Data FF IAT Data FF IdleAir Data FF MAP Data FF OilPress Data FF RPM Data 90 883064R03 NOVEMBER 2010 Service Description Service Information Lists the engine temperature at the time of the fault Displays the engine operating mode at the
52. sic Diagnostic Outline 3B 20 Main Power Relay 3B 34 30 40 EFI Fault Information 3B 21 Manifold Absolute Pressure MAP Sensor 3B 34 CDS G3 Text Guardian Cause 3B 24 Crankshaft Position Sensor CPS 3B 35 90 883064R03 NOVEMBER 2010 Page 3B 1 Diagnostics and Troubleshooting Fuel System Specifications Fuel System Specifications Mechanical vvater cooled plunger Fuel lift pump type diaphragm Fuel pump pressure maximum 20 41 kPa 3 6 psi Plunger stroke 5 9 mm 0 232 in Fuel tank capacity Accessory Fuel iniection system Sequential Fuel iniector resistance 10 13 5 ohms Electric fuel pump Engine running after five minutes 295 kPa 43 psi Minimum pressure at 1000 RPM with pinched fuel 20 7 kPa 3 psi outlet line i p Mechanical fuel pump Minimum vacuum at 1000 RPM with fuel inlet line 102 mm Hg 4 in Hg pinched Vapor separator float height float needle seated 36 5 39 5 mm 1 437 1 555 in Idle RPM neutral warm 750 25 RPM Idle RPM forward gear warm 750 25 RPM Lubricant Sealant Adhesives Liquid Neoprene Grounds and ring terminals 92 257113 Special Tools CDS G3 Diagnostic Interface Tool With 8 0046124 Harness Provides diagnostic support for the Computer Diagnostic System CDS G3 Termi
53. stem is designed to 1 warn the boat operator that the engine is operating under adverse conditions and 2 reduce power by limiting maximum RPM in an attempt to avoid or reduce the possibility of engine damage The boat operator is ultimately responsible for proper engine operation Warning Horn Guardian System Operation Six beeps on key up or during a running failure Failure detected with MAP IAT TPS or Flash Check Sum ECM Engine should run well however service will be required Failure detected with Battery voltage EST Open detected at key up Short detected with engine running Engine will start hard run rough and or stall Utilizing the Fuel iniector Detected while cranking neutral fast idle feature may assist starting Service is required Three beeps every four minutes running Coolant sensor ECT IAC Failure detected with Fuel pump May start momentarily Intermittent beeps Main Power Relay MPR No start ECM reference voltage to MAP TPS Starts but stalls under load Engine may or may not start If engine starts it easily stalls Service is required Engine Guardian Protection System is activated Power limit will vary with level of overheat Stop engine and check water intake for obstruction Advancing throttle above idle may provide additional cooling Engine overheat Guardian Protection System is activated Engine power is Low oil pressure limited to 10 of maximum Stop engine and chec
54. t cannot cause drastic changes to the air fuel mixture Major engine issues are not related to this sensor Counts can be related and converted to voltage Sensor circuits are 0 5 volt circuits 0 counts 0 V and 1023 counts 5 V The data is proportional Counts can be multiplied by 0 0048828 to convert itto volts Do notround the multiplier it will not produce accurate results Converting the counts allows you to measure the voltage in the circuit when checking for circuit problems such as shorts opens and high resistance PWM is a measurement of the time a signal is on or off 096 indicates the valve is off closed 10096 indicates the valve is open Possible modes are Crank Flare Inc Idle Entry Base Idle no offset Base idle with offset and off idle Page 3B 17 Diagnostics and Troubleshootin Data Item Name Description Significance Service Information from G3 Desired Idle RPM T LoadPercent P IdleCtriSetpointRPM Calculated Engine Load Calculated Engine Air Flow Manifold Absolute Pressure MAP M MA MAP Sensor in Counts MAP_ADC MAPIsDefaulted MAP Data Status Live 0 Default 1 OccurredFaultMarquee Page 3B 18 typically a range between 0 5 When This is the idle speed the ECM wants to achieve Idle speed is ECM controlled when the TPS is closed Helps diagnose idle problems If desired idle speed is higher than base idle something is causing the ECM t
55. the fault became active Buffer Data Item Service Description Service Information FF Faultindex Lists the fa ltname Refer to the fault listing for more fault information The number of times the fault has occurred is important Lovv number of occurrences could be someone tampering vvith the system One or tvvo occurrences over a long time are not cause for concem A single occurrence 30 minutes ago needs to be checked out High numbers can indicate an intermittent problem Look for loose and corroded connections Check both battery cable connections at the battery and engine Check for corrosion on connectors and terminal studs FF ActualGear Data Lists the gear position at the time of the fault Not applicable on ne engine No Sensor switch installed Will always read In gear Lists the air per cylinder per cycle calculation FF APC Data at the time of the fault Compare to previously saved data Lists the number of times the fault has FF Occurance Cnt Data occurred This count starts at where 0 1 122 3 2 and so on The barometric reading is a reference pressure reading that relates to the altitude the ECM was at when the fault was stored Lists the barometric pressure reading taken Higher than normal readings will cause the at the start of the run cycle during which this 55 engine to be richer than normal Lovver than FF Baro Data fault occurred The barometric reading is normal reading
56. uel System Pressure Pressure at 1000 RPM 13 8 kPa 2 psi 7 To isolate the mechanical fuel pump from the rest of the fuel system a Pinch off restrict the fuel hose between the T fitting and the VST b The mechanical fuel pump pressure should be to specifications f pressure reading for the pump is below specifications the pump needs rebuilding oa gt N 8 Ifthe fuel pressure reading is below specifications refer to Fuel Pump Pressure Troubleshooting table Stop the engine remove the gauge and clear hoses Reconnect the fuel line to the outlet fitting of the fuel pump a Fuelhose to VST b Clear hose from mechanical fuel pump outlet to T fitting 28182 90 883064R03 NOVEMBER 2010 Page 3B 27 Diagnostics and Troubleshootin Mechanical Fuel Pump Pressure Pressure at 1000 RPM with pinched fuel line 20 7 kPa 3 psi Fuel Pressure Gauge Kit 91 881833A03 Dual Fuel Air Pressure Gauge Kit Fuel Pump Pressure Troubleshooting 91 881834A 1 Mechanical Fuel Pump Pressure Troubleshooting Cause Restricted anti siphon valve Low fuel level in fuel tank Plugged fuel tank pickup screen Hole cut in pickup tube of fuel tank1 Loose fuel line connection Hole cut in fuel line Fuel line primer bulb check valves not opening Fuel hose line internal diameter too small Restriction in fuel line thru hull fitting Restriction in fuel tank svvitching va
57. up and turn itself on Battery Voltage Voltage from the ignition switch to pin ECUP from Ignition Switch EngineState ESTOP ESTOP ADC Counts FPC Total Page 3B 16 Emergency Stop ESTOP EStop Circuit in Fuel per Cylinder per Cycle FPC Displays the current operating mode of the engine Dead Stall Crank Run Unknown Typical modes are Stall Crank or Run Tells whether the emergency stop program is active 0 no 1 yes When ESTOP circuit black yellow is shorted to ground the engine stops and will not start Displays the ESTOP circuit analog to digital conversion in ADC counts Counts range between 0 low and 1023 high ESTOP is off when counts are high and on when counts are low The ESTOP circuit should never indicate near the middle of the ADC range Counts above 100 or below 900 are an indication of trouble in the ESTOP circuit A calculation of fuel flow through the injectors Useful when compared to known good values Large numbers rich fuel mixtures smaller numbers lean mixtures Important when working with the Guardian program If voltage is low and battery voltage is correct at battery terminals test the main power relay and engine fuses Check battery cables for loose corroded or high resistance connections Verify ECM grounds to the negative battery cable Test the red blue between the ECM the MPR and fuse block The cooling system uses raw water to cool the engi
58. viding input Under most conditions a sensor failure results in an air fuel mixture that is richer than normal Because of this disconnecting a sensor for troubleshooting purposes will produce noticeably different effects on the running quality depending on which sensor is disconnected The CDS G3 system was developed specifically to help technicians diagnose and repair Mercury Marine engines and systems The CDS G3 will monitor sensors and ECM data values including the status of switches 8M0046124 84 8M0045065 Engine Information Displayed by CDS G3 The Module Data screen will display the following information for each module it finds on the CAN Bus Status online or offline Electronic Address city ID e CAN bus on P or H Calibration ID Informational Messages Faults A Fault indicates the ECU has either sensed the circuit in question has reported a sensor value outside of its acceptable parameters or a sensor value has gone outside its normal range For example A circuit with an open or short would give a fault that is CUT HI or CUT LO This indicates the sensor has failed with an open or short circuit or one of the leads between the sensor and the PCM ECM is open or shorted A sensor showing a reading outside of its normal range but not shorted or open would give a fault identifying an abnormal operating condition such as ECT Coolant Overheat which indicates the ECT circuit is operating correctly and the
59. y uid siu spuno4B 423 SI u9uM juesaud Auo oDejoA n s Keja Jemod ureui WOJ A ZL SI MdiN u9uM juesaud Auo abeyo n l Keja J mod ureui A ZL Josues uollisod l 1U uo N23 34 WIN 0 yous 9 WO A ZL S SOTO Jojoefui q ni ay p u do uauM 1oJo ul l n Z OY li 0 6g uid spuno46 W93 S SOI 1ojoefur Jen ay p u do uauM 1oJo ul t ni Vik 94 li O 6y uid spuno46 W93 uoneuuoju 8913S W93 Auayeg 1ndui eBeyoA Idd p i INO4 94 0 2 si nouo u16 eAneBeu J109 JOmod urew wos wo us6 S JOA S AI9291 IEU UL eAnisod 109 NO4 94 0 pejoeuuoo s UJO yUd io lul 17 7 uJo yud JO epis eAneBeu soJjuoo 4 S4 J AHD Jojoefui JEN JeAug Asayeq se ieo9J jeur ANISOd 10joefur on U91IMS ae uoy Jo epis eAnebDeu uonlubi woy SyoA Iq uer SIO u02 ujou ButuJeM niq p AZI Wo3 eui OU Yd Woy Jewod niqypeu A ZL W03 eui OU Hd Woy ISAOd jeu amp is 541 Josues uoinisod epoJu ndu JOAUP 109 1553 ssousey euiBue y ul p olids gg uid pue JG Uld sseuJeu euibue y ul s u 5o peoids gg uid pue 4G Uld Josues Zp uid pue 49mod JOsUas pg Uld JUM NIG YOUMS W903 EE Key dn exew 1ndui eDejoA

Fuel System

Contents

Download Pdf Manuals

Related Search

Related Contents