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Service and Diagnostic Manual

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4. 9 199 2011 Marine Engines Manual 9 2 Table of Contents Engine Cranks But Does Not Run Run Crank Relay Diagnosis Supercharger Intercooler Relay eee Boost Control System Diagnosis Fuel Pump Electrical Circuit Diagnosis Fuel System Diagnosis with Returnless Fuel System Fuel System Diagnosis without Returnless Fuel System Fuel Injector Diagnosis Alcohol Contaminants in Fuel Diagnosis Distributor Ignition DI System eet ste ee eden Electronic Ignition System Diagnosis Slow Mode Switch Diagnosis Repair Instructions Engine Control Module Replacement Engine Coolant Temperature Sensor Replacement Manifold Air Temperature Sensor Replacement Manifold Absolute Pressure Sensor Replacement without Supercharger Barometric Pressure Sensor Replacement Supercharger Air Inlet Pressure Sensor Replacement Charge Air Bypass Regulator Solenoid Valve Replacement Supercharger Bypass Valve Actuator Replacement Engine Oi
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6. Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 65561 FMI 0 SPN 65561 FMI 1 SPN 65561 FMI 3 SPN 65561 FMI 4 SPN 65561 FMI 5 SPN 65562 FMI 0 SPN 65562 FMI 1 SPN 65562 FMI 3 SPN 65562 FMI 4 SPN 65562 FMI 5 SPN 65563 FMI 0 SPN 65563 FMI 1 SPN 65563 FMI 3 SPN 65563 FMI 4 SPN 65563 FMI 5 SPN 65564 FMI 0 SPN 65564 FMI 1 SPN 65564 FMI 3 SPN 65564 FMI 4 SPN 65564 FMI 5 Oxygen Sensor Bank A Sensor 1 Data Valid But Above Normal Oxygen Sensor Bank A Sensor 1 Data Valid But Below Normal Oxygen Sensor Bank A Sensor 1 Voltage Above Normal or Shorted High Oxygen Sensor Bank A Sensor 1 Voltage Below Normal or Shorted Low Oxygen Sensor Bank A Sensor 1 Current Below Normal or Open Circuit Oxygen Sensor Bank A Sensor 2 Data Valid But Above Normal Oxygen Sensor Bank A Sensor 2 Data Valid But Below Normal Oxygen Sensor Bank A Sensor 2 Voltage Above Normal or Shorted High Oxygen Sensor Bank A Sensor 2 Voltage Below Normal or Shorted Low Oxygen Sensor Bank A Sensor 2 Current Below Normal or Open Circuit Oxygen Sensor Bank B Sensor 1 Data Valid But Above Normal Oxygen Sensor Bank B Sensor 1 Data Valid But Below Normal Oxygen Sensor Bank B Sensor 1 Voltage Above Normal or Shorted High Oxygen Sensor Bank B Sensor 1 Voltage Below Normal or Shorted Low Oxygen Sensor Bank B Sensor 1 Current Below Normal or Open Circuit Oxygen Sensor Bank B Sensor 2 Data Valid But Above
7. Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification 1 Ignition ON observe the SPN information with a scan tool SPNs 65620 65621 65622 or 65623 should not set 2 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing Note Additional SPNs will set when disconnecting the components 1 Ignition OFF disconnect the harness connector at all appropriate sensors for the applicable SPN Refer to Diagnostic Aids 2 Ignition ON test for greater than 4 4 V between one of the 5 volt reference circuits and ground If less than the specified range test for a short to ground on all the 5 volt reference circuits for each component associated with the appropriate 5 volt reference circuit If all circuits test normal replace the control module 3 Connect each component associated with the 5 volt reference circuit one at a time while monitoring th
8. Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Special Tools J 34730 1A Fuel Pressure Gauge Circuit System Verification 1 Ignition ON observe the SPN information with a scan tool Verify that SPN 65620 65621 65622 or 65623 is not set If either SPN is set refer to SPN 65620 65623 on page 9 149 2 Engine idling observe the scan tool FP Sensor parameter The reading should be between 379 427 kPa 55 62 psi 3 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Ignition OFF disconnect the harness connector at the FP sensor 2 Ignition OFF test for less than 5 between the low reference circuit terminal and ground greater than the specified range test the low reference circuit for an open high resistance If the circuit tests normal replace the ECM 3 Ignition ON test for 4 8 5 2 V between the 5 volt reference circuit terminal and ground If less than the specified range test the 5 volt reference circuit for a short to ground or open high resistance If the circuit tests normal replace the ECM
9. k K Service 89046636 f Ne Description 2 Way F Metri Pack 150 Tangless Series Sealed BK B Terminal Part Information Terminal Tray 12176636 19 Core Insulation Crimp C 1 Release Tool Test Probe 12094429 J 35616 2A GY 1273820 Fuel Injector 4 Circuit So Pin wie color ERN AQ quU Ignition Voltage Fueliector 4 Control Fuel Injector 5 4 3 5 0 5 7L Description 2 Way F Metri Pack 150 Tangless Series Sealed BK Terminal Part Information Terminal Tray 12176636 19 Core Insulation Crimp C 1 Release Tool Test Probe 12094429 J 35616 2A GY Fuel Injector 3 Circuit Wire Color No Function 1273820 Connector Part Information OEM 15355226 Service 89046636 Description 2 Way F Metri Pack 150 Tangless Series Sealed BK 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 43 Fuel Injector 7 4 3 5 0 5 7L Terminal Part Information Terminal Tray 12176636 19 Core Insulation Crimp C 1 Release Tool Test Probe 12094429 J 35616 2A GY Fuel Injector 5 Circuit Wire Color No Function Fuel Injector 6 4 3 5 0 5 7L 1273820 Connector Part Information OEM 15355226 k K Service 89046636 f Ne Description 2 Way F Metri Pack 150 Tangless Series Sealed BK B Terminal Part Information Terminal Tray 12176636 19 Core Insulation Crimp C 1 Release Tool Test Probe 12094429 J 35
10. page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification 1 Ignition ON observe the SPN information with a scan tool SPN 65623 4 should not be set Refer to SPN 65620 65623 on page 9 149 if the SPN is set 2 Engine operating observe the SPN information with a scan tool SPN 51 should not set 3 Ignition ON engine OFF slowly depress the accelerator pedal from the rest position to wide open throttle and observe the scan tool TP Sensor voltage parameter The voltage should increase from less than 1 volt with the throttle closed to greater than 4 volts at WOT with no drop outs or jumps in voltage 4 Operate the vehicle within the Conditions for Running the DTC to verify the DTC does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Ignition OFF disconnect the harness connector at the TP sensor 2 Ignition OFF for 30 S test for less than 5 Q between the low reference circuit terminal 3 and ground If greater than the specified range test the low reference circuit for an open high resistance If the circuit tests normal replace the ECM 3 Ignition ON test for 4 8 5 2 volts between the 5 volt reference circuit terminal 2 and ground If less than the spe
11. 537308 Note Be sure to use the correct part number when ordering replacement fuel injectors 1 The fuel injector assembly 1 is stamped with a par number identification 2 537311 1 Remove the fuel rail Refer to Fuel Injection Fuel Hail Assembly Replacement 3 0L on page 9 230 or Fuel Injection Fuel Rail Assembly Replacement 4 3L 5 0L and 5 7L on page 9 231 or Fuel Injection Fuel Rail Assembly Replacement 6 0L and 6 2L on page 9 234 or Fuel Injection Fuel Rail Assembly Replacement 2 4L on page 9 235 2 Remove the fuel injector retaining clip 1 Remove the fuel injector 3 from the fuel rail 4 Remove and discard the fuel injector lower O ring 4 5 Remove and discard the fuel injector upper O ring 2 537311 2 Lubricate the NEW injector O rings with clean engine oil Install the fuel injector upper O ring 2 Install the fuel injector lower O ring 4 Install the fuel injector 3 to the fuel rail Install the fuel injector retaining clip 1 Install the fuel rail Refer to Fuel Injection Fuel Rail Assembly Replacement 3 0L on page 9 230 or Fuel Injection Fuel Rail Assembly Replacement 4 31 5 0L and 5 7L on page 9 231 or Fuel Injection Fuel Rail Assembly Replacement 6 0L and 6 2L on page 9 234 or Fuel Injection Fuel Rail Assembly Replacement 2 4L on page 9 235 Co 2011 Marine Engines Manual Ignition Coil Replacement 3 0L Removal Procedure
12. A severe discoloration caused by excessive temperatures An internal rattle caused by damaged catalyst substrate Restrictions Ifa condition is found replace the catalytic converter 3 Verify the following conditions do not exist with the exhaust system Leaks Physical damage Loose or missing hardware Water intrusion or terminal corrosion within the HO2S harness connectors Properly torqued HO2S If a condition is found repair the exhaust system 4 Verify the following conditions do not exist with the HO2S 2 A grounded wiring harness Damage If acondition is found replace the HO2S 2 5 If no physical condition is detected perform the following 5 1 Operate the engine at 2 000 RPM for 5 minutes under a load 5 2 Allow the engine to return to a stabilized idle 5 3 Verify that the HO2S 2 is not as active as the HO2S 1 If the HO2S 2 is as active as the HO2S 1 then replace the catalytic converter Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure 2011 Marine Engines Manual SPN 65690 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides
13. Diagnostic Procedure Instructions on page 6 5 provide an overview of each diagnostic category Diagnostic Fault Information Ground DLC 1 Scan Tool Does Not Power Up Circuit System Description The data link connector DLC is a 6 cavity connector The connector provides the following Scan tool power battery positive voltage at terminal A Scan tool power ground at terminal Controller area network CAN HI communication circuit at terminal C CAN LO communication circuit at terminal 0 Diagnostic Aids The scan tool will power up with the ignition OFF The ECM will not communicate unless the ignition is ON If the battery positive voltage ground circuits and connections of the DLC are functioning properly the malfunction must be due to the scan tool Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Description and Operation Data Link Communications Description and Operation on page 11 5 2011 Marine Engines Manual Short to Ground Battery Positive Voltage DLC ___ __ Open High Short to Signal Resistance Voltage Performance Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Con
14. EEPROM The electronically erasable programmable read only memory EEPROM is a permanent memory that is physically part of the engine control module ECM The EEPROM contains program and calibration information that the ECM needs in order to control the powertrain operation Special equipment as well as the correct program and calibration for the vehicle are required in order to reprogram the ECM 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 279 ECM Default Actions When a malfunction occurs within the engine control system the engine control module ECM maintains control of the system with Default Actions Default Actions are calculated values and or calibrated default values that are stored within the ECM A certain level of engine performance is possible when a malfunction occurs dependant on the Default Actions taken The ECM Default Actions prevent a complete loss of engine performance ECM Output Controls The scan tool can control certain solenoids valves motors and relays The Output Controls can be found under the Special Functions selection of the scan tool Some Output Controls may be disabled by the engine control module ECM during certain types of vehicle operation Data Link Connector DLC The data link connector DLC provides the technician a means of accessing serial data for aid in diagnosis This connector allows the technician to use a scan tool in order to monitor
15. Refer to Fuel Pressure Gauge Installation and Removal on page 9 229 5 Operate the vehicle within the conditions of the customers concern while monitoring fuel related parameters with a scan tool The scan tool parameters should not indicate a lean condition If the scan tool parameters indicate a lean condition test for a restricted fuel feed pipe restricted fuel filter or poor connections at the harness connectors and ground circuits of the fuel pump If all test normal replace the fuel pump 6 If the fuel system components test normal refer to Symptoms Engine Controls on page 9 199 Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Fuel Injection Fuel Rail Assembly Replacement 3 0L on page 9 230 or Fuel Injection Fuel Rail Assembly Replacement 4 3L 5 0L and 5 7L on page 9 231 or Fuel Injection Fuel Rail Assembly Replacement 6 0L and 6 2L on page 9 234 or Fuel Injection Fuel Rail Assembly Replacement 2 4L on page 9 235 Fuel Injector Replacement Except 2 4L on page 9 238 or Fuel Injector Replacement 2 4L on page 9 240 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 211 Fuel Injector Diagnosis Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis page 6 4 for an overview of th
16. The cam reference angle is learned The SPN runs continuously once the above conditions are met 65570 65571 65572 65573 FMI 4 and 5 SPN 630 65580 15 not set e The ignition is ON or the engine is operating The ignition voltage is between 10 16 volts The SPNs run continuously once the above conditions are met 65570 65571 65572 65573 FMI 7 Before the ECM can report that SPN 65570 2 65571 2 65572 2 or 65573 2 failed SPNs 65570 4 65570 5 65571 4 65571 5 65572 4 65572 5 65573 4 65573 5 65723 65724 65725 or 65726 must run and pass SPN 630 or 65580 is not set The ignition is ON The cam reference angle is learned The cam phaser cleaning pulse is not enabled The SPN 65570 7 runs continuously once the above conditions are met Conditions for Setting the SPN 65570 65571 65572 and 65573 FMI 2 The ECM detects a deviation in the relationship between a camshaft and the crankshaft 65570 65571 65572 and 65573 FMI 4 and 5 The ECM detects that the commanded state of the driver and the actual state of the control circuit do not match for greater than 5 seconds 65570 65571 65572 and 65573 FMI 7 The ECM detects that the actual cam angle is 40 of the desired cam angle as measured in degrees of crank rotation 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 133 Action Taken When the DTC Sets e SPNs 65570 65571 65572 and 65573 are type
17. The engine is not operating in reduced power mode or fuel cut off mode SPN 3563 0 runs continuously when the above conditions are met 3563 1 Before the ECM can report that SPN 3563 1 failed SPNs 3563 3 3563 4 65601 65602 and 65610 must run and pass SPN 630 65580 65620 65621 65622 or 65623 is not set The throttle angle is greater than 75 percent OR The engine speed less than 150 RPM SPN 3563 1 runs continuously when the above conditions are met 2011 Marine Engines Manual 3563 2 Before the ECM can report that SPN 3563 2 failed SPNs 106 108 3563 0 3563 1 3563 3 and 3563 4 must run and pass SPN 630 65580 65620 65621 65622 or 65623 is not set The ignition is ON The engine speed is less than 150 RPM The MAP and BARO sensor correlation is within 5 kPa SPN 3563 2 runs continuously when the above conditions are met 3563 3 and 3563 4 SPN 630 65580 65620 65621 65622 or 65623 is not set The ignition is ON This SPNs 3563 3 and 3563 4 run continuously when the above conditions are met Conditions for Setting the SPN 3563 0 The ECM detects that the SCIP sensor signal is greater than 95 kPa for greater than 2 seconds 3563 1 The ECM detects that the SCIP sensor signal is less than 30 kPa for greater than 250 mS 3563 2 The ECM detects the SCIP sensor signal is not within 15 kPa of the MAP and BARO sensors for greater than 156 mS 356
18. greater than the specified range test the 5 volt reference circuit for a short to voltage If the circuit tests normal replace the ECM 4 Verify the scan tool FP sensor pressure parameter is 0 kPa 0 psi greater than the specified range test the signal circuit for a short to voltage If the circuit tests normal replace the ECM 5 Install a 3 A fused jumper wire between the signal circuit terminal and the 5 volt reference circuit terminal Verify the scan tool FP sensor parameter is greater than 655 kPa 95 psi If less than the specified range test the signal circuit for a short to ground or an open high resistance If the circuit tests normal replace the ECM 6 If all circuits test normal refer to Fuel System Diagnosis with Returnless Fuel System on page 9 208 or Fuel System Diagnosis without Returnless Fuel System on page 9 210 If the fuel System tests normal replace the FP sensor Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Engine Control Module Replacement on page 9 217 for engine control module replacement setup and programming 2011 Marine Engines Manual SPN 98 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnosti
19. 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 273 1670622 1658245 Warning Refer to Camshaft Position Actuator 2 Tighten the CMP actuator solenoid valve Removal and Installation Warning on page 0 4 2 1 Tighten the CMP actuator solenoid valve a 3 Remove the CMP actuator solenoid valve 234 first pass to 65 N m 48 Ib ft 4 Discard the solenoid valve 2 2 Tighten the CMP actuator solenoid valve a final pass an additional 90 degrees using Installation Procedure the J 45059 1658136 1670622 1 Install a NEW CMP actuator solenoid valve 234 With the CMP actuator properly positioned onto the camshaft the CMP actuator solenoid valve can be threaded completely into the camshaft using light hand pressure Tighten by hand until snug Remove the J 42386 A 1 Install the CMP actuator magnet Refer to Camshaft Position Actuator Magnet Replacement on page 9 271 A Ow 2011 Marine Engines Manual 9 274 Engine Controls and Fuel Marine Camshaft Position Actuator Installation Procedure Solenoid Valve Replacement 2 4L Removal Procedure 1 Disconnect the intake 3 or exhaust 2 camshaft position actuator solenoid valve electrical connector as required 1578482 1 Lubricate the solenoid valve O ring seals with clean engine oil Caution Refer to Fastener Caution on page 0 5 2 Install the intake 2 CMP actuator solenoid valve and bolt as required 1578482 Tighten 2
20. 6 12 Vehicle Diagnostic Information Diagnostic Trouble Code DTC List cont d FW DTC Descriptor Diagnostic Procedure Note If multiple powertrain SPNs are stored diagnose the SPNs in the following order 1 Component level SPNs such as sensor SPNs solenoid SPNs and relay SPNs 2 System level SPNs such as misfire SPNs and fuel trim SPNs Manifold Air Temperature MAT Sensor SPN 105 3 0L 4 3L 5 0L 5 7L on page 9 79 Circuit Voltage Data Valid But Above or Normal Range Least Severe Level SPN 105 2 4L 6 0L 6 2L on page 9 81 SPN 106 3 0L 4 3L 5 0L 5 7L on page 9 83 or SPN 106 2 4L 6 0L 6 2L on page 9 86 SPN 106 3 0L 4 3L 5 0L 5 7L on page 9 83 or SPN 106 2 4L 6 0L 6 2L on page 9 86 SPN 106 3 0L 4 3L 5 0L 5 7L on page 9 83 2 MAP Sensor Data Erratic Intermittent or r Incorrect SPN 106 2 4L 6 0L 6 2L on page 9 86 105 MAP Sensor Data Valid But Above Normal MAP Sensor Data Valid But Below Normal SPN 106 3 0L 4 3L 5 0L 5 7L on page 9 83 or SPN 106 2 4L 6 0L 6 2L on page 9 86 SPN 106 3 0L 4 3L 5 0L 5 7L on page 9 83 or SPN 106 2 4L 6 0L 6 2L on page 9 86 BARO Sensor Voltage Data Erratic E Intermittent or Incorrect SPN page 9 89 BARO Sensor Voltage Above Normal or Shorted High SPN 108 on page 9 89 BARO Sensor Voltage Below Normal or 1 Shorted Low SPN 108 on page 9 89 108 10 BARO Sensor Voltage Abnormal Rate of SPN 108 on page 9 89 Chan
21. Circuit System Description The controller area network CAN HI and CAN LO circuits transmit information between the engine control module ECM and the scan tool Some vehicles are equipped with multiple engines that require a control module for each engine Information is transmitted between the ECMs via the CAN communication circuits The data link connector DLC is a 6 cavity connector The connector provides the following Scan tool power battery positive voltage at terminal A Scan tool ground circuit at terminal Controller area network CAN HI communication circuit at terminal C CAN LO communication circuit at terminal 0 Conditions for Running the SPN SPN 630 65580 is not set The ignition is ON or the engine is operating The ignition voltage is between 9 16 volts SPNs 65558 and 65559 run continuously when the above conditions are met Conditions for Setting the SPN The ECM does not receive a valid message from 1 or more of the controllers on the CAN communication circuit The ECM detects the CAN communication circuit is shorted to a voltage or ground Action Taken When the SPN Sets SPNs 65558 and 65559 are Type B SPNs Conditions for Clearing the SPN SPNs 65558 and 65559 are Type B SPNs Diagnostic Aids The scan tool will power up with the ignition OFF The ECM will not communicate unless the ignition is ON It may be necessary to disconne
22. Conditions for Running the SPNs The ignition is ON or the engine is operating The ignition voltage is greater than 10 volts SPNs 630 65580 65582 run continuously once the above conditions are met Conditions for Setting the SPNs The ECM detects an internal failure or incomplete programming for greater than 14 seconds Action Taken When the SPN Sets SPN 630 65580 and 65581 are type A SPNs SPN 65582 is a type B SPN The will disable engine operation or command the TAC system to operate in a Reduced Engine Power mode Conditions for Clearing the SPNs SPN 630 65580 and 65581 are type A SPNs SPN 65582 is a type B SPN Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 2011 Marine Engines Manual Description and Operation Engine Control Module Description on page 9 279 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Testing 1 Ignition ON clear the SPN information with a scan tool
23. Mark the distributor housing to engine block position with a grease pencil 2211673 Remove the distributor hold down bolt 5 and hold down 4 Remove the distributor and gasket 3 4376 As the distributor is being removed from the engine the rotor will move in a counter clockwise direction Place a second mark 2 on the base of the distributor housing in order to ensure proper rotor alignment during the distributor installation 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 249 Installation Procedure 1 Note If installing a new distributor assembly transfer the two marks from the original housing to the new distributor housing in the same location 1 Install a new gasket on the distributor 4373 4 While the distributor is being installed observe the rotor moving in a clockwise direction 5 With the distributor fully seated verify the rotor segment is aligned with the mark on the distributor base in location 1 gt Ifthe rotor segment is not aligned with the 2 Align the distributor rotor with mark made at number 1 mark the driven gear teeth and the location 2 camshaft have meshed one or more teeth out of alignment In order to correct this condition remove the distributor and reinstall it Caution Refer to Component Fastener Tightening Caution on page 0 5 6 Install the distributor hold down bolt Tighten Tighten the distributor clamp bolt to 27 N m 2
24. Remove the fuel rail attaching bolts 511 512 ground strap 557 Lift evenly on both sides of the fuel rail and remove the fuel rail assembly Remove the injector lower O ring seal from the spray tip end of each injector Discard the O ring seals Installation Procedure Engine Controls and Fuel Marine 9 235 3 Install the fuel rail assembly to the intake manifold 4 Apply a 0 5 mm 0 020 in band of GM P N 12345382 Canadian P N 10953489 threadlock or equivalent to the threads of the fuel rail bolts Caution Refer to Fastener Caution on page 0 5 5 Install the fuel rail attaching bolts 511 512 ground strap 557 Tighten Tighten the fuel rail attaching bolts to 10 N m 89 Ib in Connect the injector electrical connectors Install each connector on the proper injector in order to ensure correct sequential injector firing order Rotate the injectors as required in order to avoid stretching the wire harness Connect the electrical harness to the fuel rail brackets Connect the fuel feed hose to the fuel rail fuel pipe Connect the negative battery cable Inspect for leaks 10 1 Ignition ON for 2 seconds 10 2 Ignition OFF for 10 seconds 10 3 Ignition ON 10 4 Inspect for fuel leaks Fuel Injection Fuel Rail Assembly Replacement 2 4L Removal Procedure 2011 1408856 Lubricate the new lower injector O ring seals with clean engine
25. Restricted or plugged fuel filter Restricted or plugged strainer Stuck or binding fuel level float Inspect the harness connectors and the ground circuits of the fuel pump for poor connections If greater than the specified range replace the fuel pump 2011 Marine Engines Manual Note The fuel pressure may vary slightly when the fuel pump stops operating After the fuel pump stops operating the fuel pressure should stabilize and remain constant 2 Verify the fuel pressure does not decrease greater than 34 kPa 5 psi in 1 minute If greater than the specified range perform the following procedure 2 1 Ignition OFF relieve the fuel pressure Refer to Fuel Pressure Relief on page 9 230 2 2 Install the J 37287 between the fuel feed pipe and the fuel rail 2 3 Open the valve on the J 37287 2 4 Ignition ON command the fuel pump relay ON with a scan tool and bleed the air from the fuel pressure gauge 2 5 Close the valve on the J 37287 2 6 Verify the fuel pressure does not decrease greater than 34 kPa 5 psi in 1 minute If the fuel pressure drops locate and replace the leaking fuel injector 2 7 If the fuel system test normal replace the fuel pump 3 Relieve the fuel pressure to 69 kPa 10 psi Verify the fuel pressure does not decrease greater than 14 kPa 2 psi in 5 minutes If greater than the specified range replace the fuel pump 4 Remove the J 37287 and J 34730
26. SPNs e The ECM will operate the engine in reduced power mode indicator may display Reduced Engine Power Conditions for Clearing the SPN SPN 65604 65605 and 65613 are type A SPNs Diagnostic Aids If a shared 5 volt reference circuit is shorted to ground or shorted to a voltage other 5 volt reference circuits may be affected 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 145 Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification 1 Ignition ON observe the SPN information with a scan tool Verify SPN 65620 or 65621 is not set If either SPN is set refer to SPN 65620 65623 on page 9 149 2 Observe the PP Sensor percentage parameters with a scan tool Verify the scan tool PP sensors parameters are at 0 percent 3 Observe both PP Sensor percentage parameters while pressing the accelerator pedal from a closed pedal
27. eoueJejou MO 9529459 urenieMod 2 4 pue oued 1ueuinagsut sin soneuieuos 2011 Marine Engines Manual 28 Engine Controls and Fuel 9 9 vvvC w03 Josusg ensseJd feng uou 1919S feng N22 L YDUMS 12 pue 1osues 5 1 05 jeng soneueuos 2011 Marine Engines Manual 29 9 Controls Fuel Mar Eng 7970955 1 7 eng Jojoelu lang 10joefu Snoaser snoasey Aejoy AGL 1041409 4 0 jeng soneueuos Marine Engines Manual 2011 9 30 Engine Controls and Fuel Marine Visual Identification Engine Control Module Connector End Views Engine Control Module ECM X1 784851 Connector Part Information Harness Engine OEM 13510837 Service 88988373 Description 56 Way 123 Series BK Terminal Part Information Pins 2 10 12 14 16 24 26 28 30 34 38 40 50 52 Ter
28. the normal flow is to proceed to the next step If the result is NOT achieved the repair arrow bullet gt will identify what actions need to take place Intrusive diagnostics are performed to locate the system fault System harness connections are disconnected from the module or component to test individual circuit functions The module or component will be used to assist in verifying the circuit function When a test does not pass the repair steps gt will indicate what circuit faults to test For example short to voltage short to ground or open high resistance When testing for individual circuit faults the technician is expected to include terminal inspections such as connection surfaces and terminal tension at both the harness and component module Additionally a technician can use the links in Electrical Information Reference Testing for Intermittent Conditions and Poor Connections on page 11 13 or Circuit Testing on page 11 6 The control modules and components will also be diagnosed during these test steps A retest of a control module or component should always be performed before replacement For example re connect all components and modules and retest the system to verify the condition still exists before replacing modules or components 2011 Marine Engines Manual Vehicle Diagnostic Information 6 7 Component Testing The diagnostic format does not force a technician to any of the 3 diagnostic categorie
29. 4 3 5 0 5 7L on page 9 262 or Camshaft Position Sensor Heplacement with CMP Actuator on page 9 268 or Camshaft Position Sensor Replacement without CMP Actuator on page 9 269 or Camshaft Position Sensor Replacement 2 4L Intake on page 9 270 or Camshaft Position Sensor Replacement 2 4L Exhaust on page 9 270 Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 9 160 Engine Controls and Fuel Marine SPN 65723 65724 65725 or 65726 2 4 6 0 6 2L Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 65723 FMI 2 SPN 65723 FMI 7 SPN 65723 FMI 8 SPN 65724 FMI 2 SPN 65724 FMI 7 SPN 65724 8 CMP CMP CMP CMP CMP CMP Camshaft Position Camshaft Position Camshaft Position Camshaft Position Camshaft Position Camshaft Position 2 5 HS 5 o Diagnostic Fault Information Sensor Circuit Data Erratic Intermittent or Incorrect Sensor Mechanical System Not Responding or Out of Adjustment Sensor Signal Abnormal Frequency or Pulse Width Sensor Circuit Data Erratic Intermittent or Incorrect Sensor Mechanical System Not Responding or Out of Adjustment Sensor
30. Fuel Injector 4 2 4 6 0 6 2L 1527729 Connector Part Information OEM 12602480 Service 88988313 Description 2 Way F GT 150 Series Sealed GY 9 40 Engine Controls and Fuel Marine Fuel Injector 6 6 0 6 2L Terminal Part Information Terminal Tray 12191819 8 Core Insulation Crimp E 1 Release Tool Test Probe 15315247 J 35616 2A GY Fuel Injector 4 2 4 6 0 6 2L Circuit Wire Color No Function Fuel Injector 5 6 0 6 2L 1527729 Connector Part Information OEM 12602480 Service 88988313 Description 2 Way F GT 150 Series Sealed GY Terminal Part Information Terminal Tray 12191819 8 Core Insulation Crimp E 1 Release Tool Test Probe 15315247 J 35616 2A GY Fuel Injector 6 6 0 6 2L 527729 Eure E Wire Col Connector Part Information OEM 12602480 Voltage Service 88988313 B Fuel Injector 6 Control Description 2 Way F GT 150 Series Sealed GY Terminal Part Information Fuel Injector 7 6 0 6 2L Terminal Tray 12191819 8 Core Insulation Crimp E 1 Release Tool Test Probe 15315247 J 35616 2A GY Fuel Injector 5 6 0 6 2L Circuit Wire Color No Function 1527729 Connector Part Information OEM 12602480 Service 88988313 Description 2 Way F GT 150 Series Sealed GY 2011 Marine Engines Manual Engine Controls Fuel Marine 9 41 Fuel Injector 1 4 3 5 0 5 7L Termina
31. General Information 1 9 Abbreviations and Meanings cont d Degrees Distributor Ignition Driver Information Center Diagnostic Distributor DK Dark DLC DMM Digital Multimeter DTC DC Data Link Connector DOHC Dual Overhead Camshafts DR DRVR Driver DIC Diagnostic Trouble Code C ECL Engine Coolant Level Electrical Center Engine Control Engine Control Module Electronic ECM Control Module ECS ECT Emission Control System Engine Coolant Temperature Electrically Erasable Programmable EEPROM Read Only Memory E Electronic Ignition E M English Metric EMF EM Eng Engine EOP EOT EPA Environmental Protection Agency Electromotive Force Electromagnetic Interference Engine Oil Pressure Engine Oil Temperature EPROM Vue Programmable Read Only ESD ESN EST Electronic Spark Timing E STOP Electrostatic Discharge Electronic Serial Number Emergency Stop Electronic Throttle Control Electronic ETC Temperature Control Electronic Timing Control Exh Exhaust FED Federal All United States except California Degrees Fahrenheit Fan Control FEDS Fuel Enable Data Stream Fuel Injection n P Fuel Pump 1 10 General Information Abbreviations and Meanings cont d Abbreviation Gauge Gags CS E General Motors General Motors Service Parts Operations Gallons Per Hour Gallons per Minute GVWR Gross Vehicle Weight Ratin
32. Open the Harness A wiring harness may be wrapped in tape or enclosed in a plastic conduit If it is conduit encased simply open the conduit and pull out the desired wire If the harness is wrapped in tape use a seam splitter 1 to open the harness This prevents damage to the insulation of the wire inside the harness Seam splitters are readily available from sewing supply stores When using a seam splitter use the blade with the pointed end 2 to start a small split in the tape away from any wires Use the blade with the rounded end 3 to slit the tape as far as necessary Be careful to avoid cutting into any wire insulation 1683714 Step 2 Cut the Wire Leave as much wire on the harness as possible More can be cut off later to adjust the location of the splice if necessary Note Ensure that each splice is at least 40 mm away from other splices harness branches and connectors This helps prevent moisture from bridging adjacent splices and causing damage Do not nick or cut any copper strands as this could limit the current carrying capabilities of the wire 11 18 Wiring Systems Step 3 Select the Correct Size and Type of Wire The wire must be of a size equal to or greater than the original except for fusible links The wire insulation must have the same or higher temperature rating Note XLPE insulated wire may be used to replace PVC but PVC must not be used to replace XLPE XLPE insulatio
33. are driven to opposite extremes from a rest or idle level The idle level which is approximately 2 5 volts is considered recessive transmitted data and is interpreted as a logic 1 Driving the lines to their extremes adds one volt to the high speed CAN serial data bus and subtracts one volt from the high speed CAN serial data bus wire This state is interpreted as a logic O 11 6 Wiring Systems Wiring Systems Diagnostic Information and Procedures General Electrical Diagnosis Basic Knowledge Required Without a basic knowledge of electricity it will be difficult to use the diagnostic procedures contained in the service manual You should understand the basic theory of electricity and know the meaning of potential voltage current amperes and resistance ohms You should also be able to read and understand a wiring diagram as well as understand what happens in a circuit with an open or a shorted wire Checking Aftermarket Accessories Inspect for aftermarket accessories non OEM as the first step in diagnosing electrical concerns Inquire with the customer if the condition occurs when an accessory is in use Possible causes of vehicle conditions related to aftermarket accessories include Power and ground circuits connected to terminals other than the battery Accessory wiring spliced into the ECM wiring harness Antenna location Transceiver wiring located too close to control modul
34. 1 ml 0 034 oz graduation marks fill the cylinder with fuel to the 90 ml 3 04 oz mark 2 Add 10 ml 0 34 oz of water in order to bring the total fluid volume to 100 ml 3 38 oz and install a stopper 3 Shake the cylinder vigorously for 10 15 seconds 4 Carefully loosen the stopper in order to release the pressure 5 Install the stopper and shake the cylinder vigorously again for 10 15 seconds 6 Place the cylinder on a level surface for approximately 5 minutes in order to allow adequate liquid separation If alcohol is present in the fuel the volume of the lower layer which would now contain both alcohol and water will be greater than 10 ml 0 34 oz For example if the volume of the lower layer is increased to 15 ml 0 51 oz this indicates at least 5 percent alcohol in the fuel The actual amount of alcohol may be somewhat greater because this procedure does not extract all of the alcohol from the fuel 9 214 Engine Controls and Fuel Marine Particulate Contaminants in Fuel Testing Procedure 1 Using an approved fuel container draw approximately 0 5 liter 0 53 qt of fuel 2 Place the container on a level surface for approximately 5 minutes in order to allow settling of the particulate contamination Particulate contamination will show up in various shapes and colors Sand will typically be identified by a white or light brown crystals Rubber will appear as black and irregular particles 3 Obse
35. Follow the instructions below in order to splice copper wire using crimp and seal splice sleeves 1 Open the harness If the harness is taped remove the tape To avoid wiring insulation damage use a sewing ripper in order to cut open the harness If the harness has a black plastic conduit pull out the desired wire 2 Cut the wire Cut as little wire off the harness as possible Ensure that each splice is at least 40 mm 1 5 in away from other splices harness branches and connectors This helps prevent moisture from bridging adjacent splices and causing damage 8796 3 Select the proper size and type of wire The wire must be of equal or greater size than the original The wire s insulation must have the same higher temperature rating 4 Use general purpose insulation for areas that are not subject to high temperatures 2011 Marine Engines Manual Wiring Systems 11 21 Note Use cross linked polyethylene wire to replace PVC but do not replace cross linked polyethylene with PVC Cross linked polyethylene wire is not fuel resistant Do not use to replace wire where there is the possibility of fuel contact Use a cross linked polyethylene insulated wire for areas where high temperatures are expected 4 Strip the insulation Select the correct size opening in the wire stripper or work down from the largest size Strip approximately 7 5 mm 5
36. If not within the specified range replace the relay 4 Install a 20 A fused jumper wire between relay terminal 85 and Install a jumper wire between relay terminal 86 and ground Test for less than 2 between terminals 30 and 87 If greater than the specified range replace the relay Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Replacement Fuse Block on page 11 28 or Relay Replacement Harness on page 11 29 Engine Control Module Replacement on page 9 217 for engine control module replacement setup and programming 2011 Marine Engines Manual SPN 66026 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors Engine Controls and Fuel Marine 9 191 SPN 66026 FMI 7 Shift Interrupt Switch Mechanical System Not Responding or Out of Adjustment Circuit System Description The shift interrupt switch is used to reduce the torque applied to the lower unit while shifting in and out of gear This makes it easier to shift and reduces gear noise The engine control module ECM supplies B to the shift interrupt switch sign
37. Remove the exhaust 1 camshaft position CMP Tighten the bolt to 10 N m 89 lb in actuator solenoid valve bolt and valve as required 3 Install the exhaust 1 CMP actuator solenoid 3 Remove the intake 2 CMP actuator solenoid valve and bolt as required valve bolt and valve as required Tighten 4 Inspect the solenoid valve O ring seals from Tighten the bolt to 10 89 Ib in damage replace as necessary 2 BY 4 21 m gu 8 Superis C LEA dec Re g S P OSs ba Ne ef E S AACA N S n X X NC KF p A OR TOU i 51 1647538 4 Connect the intake 3 or exhaust 2 camshaft position actuator solenoid valve electrical connector as required 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 275 Camshaft Position Actuator Magnet Cleaning and Inspection 1721006 3 Holding the CMP magnet with the pintle facing downward measure the pintle extended 1721004 position a Record the dimension Note Do not energize the camshaft position CMP 4 Subtract the retracted dimension from the magnet using a 12 volt power supply extended dimension to determine pintle travel A properly moving pintle will travel 1 Inspect the CMP magnet for the following 3 0 5 5 mm 0 12 0 22 in conditions damaged electrical connector 5 f the pintle of the CMP magnet is binding or does m not move
38. Terminal Tray 33467 0003 23 Core Insulation Crimp H H Release Tool Test Probe J 381 25 21 3 J 35616 64B L BU Crankshaft Position CKP Sensor 2 4L Circuit Wire Color No i SvotReterence 1 sensor signal Crankshaft Position CKP Sensor 3 0 4 3 5 0 5 7L 516611 Connector Part Information OEM 12059595 Service 88986451 Description 3 Way F Metri Pack 150 Series Sealed BK Terminal Part Information Terminal Tray 12048074 2 Core Insulation Crimp E 1 Release Tool Test Probe 12094429 J 35616 2A GY Crankshaft Position CKP Sensor 3 0 4 3 5 0 5 7L Circuit Wire Color No Ta 8 lt Sensor 2011 Marine Engines Manual Crankshaft Position Sensor 6 0 6 2L 516611 Connector Part Information OEM 12059595 Service 88986451 Description 3 Way F Metri Pack 150 Series Sealed BK Terminal Part Information Terminal Tray 12048074 2 Core Insulation Crimp E 1 Release Tool Test Probe 12094429 J 35616 2A GY Crankshaft Position CKP Sensor 6 0 6 2L Wire Color No Function Sensor Signal 8 lowReterence c SVoitReterence Engine Coolant Temperature ECT Sensor 1538760 Connector Part Information OEM 15449028 Service 88987993 Description 2 Way F 150 GT Seri
39. The DTC lamp should illuminate If the DTC lamp does not illuminate test the appropriate DTC lamp control circuit for a short to voltage or an open high resistance If the circuit test normal replace the IPC Bulb 5 f all the circuit connections test normal replace the ECM Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 9 174 Engine Controls and Fuel Marine SPN 66010 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptor SPN 66010 FMI 3 Slow Mode Lamp Voltage Above Normal or Shorted High SPN 66010 FMI5 Slow Mode Lamp Current Below Normal or Open Circuit Diagnostic Fault Information Short to Open High Short to Signal Circuit a Resistance me en Slow Mode Lamp Voltage Supply sd 660105 Slow Mode Lamp Control Se 66010 3 es The fuse that supplies voltage to the IPC Bulb opens Circuit System Description The slow mode lamp is located on the instrument panel cluster IPC Ignition voltage is supplied to the slow mod
40. XSi tow sionat 8 1 aS 1 ig Signal 684948 Connector Part Information OEM 15354716 Service 15306397 Description 4 Way F GT 150 Series Sealed BK 2011 Marine Engines Manual Knock Sensor KS 2 1232999 Connector Part Information OEM 15374222 Service 88953268 Description 2 Way F GT 150 Sealed WH Terminal Part Information Terminal Tray 12191819 8 Core Insulation Crimp E A Release Tool Test Probe 15315247 J 35616 2A GY Knock Sensor KS 2 Circuit Wire Color No Function es 2 tow signal KS2 High Signal Manifold Air Temperature MAT Sensor 6 0 6 2L 1538760 Connector Part Information OEM 15449028 Service 88987993 Description 2 Way 150 GT Series Sealed 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 51 Terminal Part Information Terminal Tray 15326267 19 Core Insulation Crimp E 4 Release Tool Test Probe 15315247 J 35616 2A GY Manifold Air Temperature MAT Sensor 6 0 6 2L Circuit Wire Color No War Sensor Sina 8 raw Reference Manifold Absolute Pressure MAP Sensor 2 4 6 0 6 2L 1331443 Connector Part Information Harness Type Engine OEM Connector 15365614 Service Connector 88988583 Description 3 Way F Kompakt 2 8 Series Sealed BK Terminal Part Information Terminated Lead Pending Release Tool J 38125 561 Diagnostic Test Prob
41. a plugged fuel filter or a restricted fuel pipe The system will become rich if a fuel injector is supplying too much fuel Review the Freeze Frame Failure Records with a scan tool Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 9 126 Engine Controls and Fuel Marine Circuit System Verification 65565 1 or 65566 1 1 Ignition ON observe the SPN information with a Fuel contamination Refer to Alcohol scan tool SPN 106 65601 65602 65561 65564 65567 or 65568 should not be set If any of the above SPNs are set refer to Diagnostic Trouble Code DTC List on page 6 11 Engine operating observe the SPN information with a scan tool SPN 65565 or 65566 should not set Observe the scan tool O2A1 BLM Cell Value and O2B1 BLM Cell Value Verify both parameters are between 0 75 and 1 25 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does
42. and are stored in the electrically erasable programmable read only memory EEPROM The system begins Closed Loop operation after reaching these values In Closed Loop the ECM calculates the air fuel ratio injector ON time based upon the signal from various sensors but mainly from the HO2S This allows the air fuel ratio to stay very close to 14 7 1 Acceleration Mode When the driver pushes on the accelerator pedal air flow into the cylinders increases rapidly To prevent possible hesitation the ECM increases the pulse width to the injectors to provide extra fuel during acceleration This is also known as power enrichment The ECM determines the amount of fuel required based upon the TP the ECT the MAP and the engine speed Deceleration Mode When the driver releases the throttle air flow into the engine is reduced The ECM monitors the corresponding changes in the TP and the MAP The ECM shuts OFF fuel completely if the deceleration is very rapid The fuel shuts OFF in order to prevent damage to the catalytic converters Battery Voltage Correction Mode When the battery voltage is low the ECM compensates for the weak spark delivered by the ignition system in the following ways Increasing the amount of fuel delivered Increasing the idle RPM Increasing the ignition dwell time Fuel Cutoff Mode The ECM cuts OFF fuel from the fuel injectors when the following conditions are met in order to protect the
43. be set If the SPN is set change the engine oil and oil filter per the OEM specific instructions Note Some applications may not be equipped with a pedal position sensor PPS Follow the OEM specific instructions to reset the oil life monitor when a PPS is not present 2 Reset the Oil Life monitor as follows 2 1 Ignition ON engine OFF 2 2 Press the accelerator pedal or actuate the throttle lever from the closed throttle position to the wide open throttle WOT position 3 times within 15 S 3 The Oil Life monitor is reset when the OEM specified lamp is OFF Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure 9 118 Engine Controls and Fuel Marine SPN 65558 or 65559 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 65558 11 CAN 2 Bus Hardware Fault Root Cause Unknown SPN 65559 11 1 Bus Hardware Fault Root Cause Unknown Diagnostic Fault Information Short to Open High Short to Signal Circuit Ground Resistance Voltage Performance CAN HI Grou ee ee CAN LO Circuit 1 Scan Tool Does Communicate
44. liep 5 lt lt I CEDENS d A ia C ex er e AS ORI QS A N CP GIS zA 9 J N N gt amp A the J 41712 1 Tighten 1 If installing the old sensor coat the threads with sealant GM P N 12346004 Canadian P N 10953480 or equivalent Caution Refer to Fastener Caution on page 0 5 2 Install the oil pressure sensor switch with 1656451 Tighten the engine oil pressure sensor to 2 Disconnect the electrical connector for the oil 35 N m 26 lb ft pressure sensor switch 2 lt ARS BIA AR WV MALES lt THIS WEDS RE r p 2 may 1658870 1656451 1658870 3 Reconnect the oil pressure sensor switch electrical 3 Remove the oil pressure sensor switch with the connector 2 J 41712 1 2011 Marine Engines Manual 9 226 Engine Controls and Fuel Marine Heated Oxygen Sensor Replacement Caution Replacement components must be the correct part number for the application Components requiring the use of the thread locking compound Removal Procedure lubricants corrosion inhibitors or sealants are Caution Refer to Heated Oxygen and Oxygen identified in the service procedure Some replacement Sensor Caution on page 0 6 components may come with these coatings already applied Do not use these coatings on components
45. live circuit the ohmmeter will be damaged Components or circuits MUST be disconnected from the power source when being tested 2011 Marine Engines Manual Wiring Systems 11 9 Resistance Testing Resistance measurements must be made with the circuit power OFF otherwise damage to the meter or the circuit may result To make the resistance test 1 Remove the power from the circuit and select ohm Q on the DMM 2 Plug the black test probe into the COM input jack and the red test probe into the Q input jack 3 Touch the probe tips across the component or the part of the circuit to be tested 4 Observe the reading being sure to note the unit of measurement Note 1 0000 1k OQ 1 000 000 0 1M Q Continuity Testing A continuity test is a quick test that distinguishes between an open and a closed circuit A digital multimeter with a continuity beeper allows you to complete many continuity tests easily and quickly as the meter beeps when it detects a closed circuit The level of resistance required to trigger the beeper varies from model to model of meter Continuity tests determine Good or blown fuses Open or shorted conductors Operation of switches Circuit paths Note Circuits which include any solid state control modules such as the Engine Control Module ECM should be tested only with a 10 Megohm or higher impedance digital multimeter Diodes and solid state components in a c
46. load or circuit It has a high internal resistance and takes only a small amount of current The meter will display the voltage difference between the points where the meter leads are attached If the voltmeter is connected in series the meter s high internal resistance will reduce the circuit current resulting in an incorrect reading Testing for correct supply voltage is usually the first thing measured in a circuit If there is no voltage present or if the supply voltage is too high or too low the voltage problem should be corrected before further testing 2011 Marine Engines Manual Note Voltage readings should always be taken in parallel i e across the load To make the reading 1 Select VOLTS DC 2 Plug the black test probe into the COM input jack and the red test probe into the V input jack 3 Touch the probe tips to the circuit across the load power source 4 View the reading being sure to note the unit of measurement Resistance Measurement With the resistance mode selected the digital multimeter will operate as an ohmmeter 1683682 The ohmmeter can be connected without regard to polarity unless there is a diode in the circuit Always remember however that an ohmmeter must NEVER be connected to a live circuit which could blow a fuse in the meter or damage the meter The ohmmeter has its own battery which provides the necessary voltage for testing If an ohmmeter is connected into a
47. replace the relay Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Replacement Fuse Block on page 11 28 or Relay Replacement Harness on page 11 29 Engine Control Module Replacement on page 9 217 for engine control module replacement setup and programming 9 184 Engine Controls and Fuel Marine SPN 66018 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptor SPN 66018 FMI 3 Tachometer Voltage Above Normal or Shorted High SPN 66018 FMI5 Tachometer Current Below Normal or Open Circuit Diagnostic Fault Information Short to Open High Short to Signal Circuit Ground Resistance Voltage Performance Tachometer Driver Circuit 66018 5 66018 5 66018 4 Tachometer Pull up Circuit 66018 5 66018 5 66018 4 Circuit System Description The engine control module ECM creates the tachometer signal by pulsing the engine speed signal circuit to ground at a rate of 2 pulses per engine revolution The instrument panel cluster IPC converts the 2 pulses per engine revolution signal to a tachometer position indicating the engine speed
48. replace the Camshaft Position Actuator Magnet 3 Test for infinite resistance between each terminal of the magnet and the magnet housing If not the specified value replace the Camshaft Position Actuator Magnet 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 131 Dynamic Test 1 Remove the Camshaft Position Actuator Magnet Note The Camshaft Position Actuator Magnet pintle should be facing downward for this test Do not allow electrical current to flow through the Camshaft Position Actuator Magnet for greater than 1 2 s 2 Install a 20 A fused jumper wire between the control circuit terminal 2 and 12 V Momentarily install a jumper wire between the low reference terminal 1 and ground The pintle should extent gt If the function does not perform as specified replace the Camshaft Position Actuator Magnet Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Camshaft Position Actuator Magnet Replacement on page 9 271 Camshaft Position Actuator Solenoid Valve Replacement 6 0 6 2L on page 9 272 or Camshaft Position Actuator Solenoid Valve Replacement 2 4L on page 9 274 Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 9 132 Engine Controls and Fuel Marine SPN 65570 65571 65572 or 65573 2 4L Diagnostic Instructions Perform the Powertrain On Board
49. reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Ignition OFF disconnect the harness connector at the CMP sensor 2 Test for less than 5 between the low reference circuit terminal A and ground If greater than the specified range test the low reference circuit for an open high resistance If the circuit tests normal replace the ECM 3 Ignition ON test for 4 8 5 2 V between the 5 volt reference circuit terminal C and ground If less than the specified range test the 5 volt reference circuit for a short to ground or an open high resistance If the circuit tests normal replace the ECM If greater than the specified range test the 5 volt reference circuit for a short to voltage If the circuit tests normal replace the ECM 4 Ignition ON test for 4 8 5 2 V between the signal circuit terminal B and ground If less than the specified range test the signal circuit for a short to ground or an open high resistance If the circuit tests normal replace the ECM If greater than the specified range test the signal circuit for a short to voltage If the circuit tests normal replace the ECM 5 If all circuits test normal replace the CMP sensor Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Camshaft Position Sensor Replacement
50. 0 4 3 5 0 5 7L Coil Terminal 2 4 6 0 6 2L 5 Ignition ON verify the voltage is less than 0 050 V greater than the specified range test the circuit for a short to voltage 6 Engine cranking or operating verify the voltage is greater than 100 mV If less than the specified range test the ignition control circuit for a short to ground or an open high resistance If the circuit tests normal replace the ECM 7 If all circuits test normal replace the ignition coil or IC module Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Ignition Coil Replacement 3 0L page 9 241 or Ignition Coil Replacement 6 0L and 6 2L on page 9 242 or Ignition Coil Replacement 4 3L 5 0L and 5 7L on page 9 243 or Ignition Coil Replacement 2 4L on page 9 244 Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 2011 Marine Engines Manual 65550 65551 65552 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptor SPN 65551 FMI 1 Knock Sensor KS SPN 65551 FMI 3 Knock Sensor KS SPN 6
51. 0 5 actuator magnet 3 Install the CMP sensor bolt 3 Remove the CMP actuator magnet bolts 751 Tighten and magnet 752 Tighten the bolt to 10 N m 89 lb in 4 Remove and discard the CMP actuator magnet gasket 753 v gt T AEC 1 72 1639712 4 Connect the exhaust CMP sensor electrical connector 1 2011 Marine Engines Manual 9 272 Engine Controls Fuel Marine Installation Procedure 1658168 Note The gasket surface should be free of oil or other foreign material during assembly 1 Install a NEW CMP actuator magnet gasket 753 onto the CMP actuator magnet 2 Install the CMP actuator magnet 752 to the front cover Caution Refer to Fastener Caution on page 0 5 3 Install the CMP actuator magnet bolts 751 and tighten to 12 N m 106 Ib in 4 Connect the engine harness electrical connector to the CMP actuator magnet 5 Install the water pump Camshaft Position Actuator Solenoid Valve Replacement 6 0 6 2L Special Tools J 42386 A Flywheel Holding Tool J 45059 Angle Meter Removal Procedure 1658136 Caution Refer to Fastener Caution on page 0 5 1 Install the J 42386 A 1 and bolts Use 1 M10 1 5 x 120 mm and 1 M10 1 5 x 45 mm bolt for proper tool operation Tighten the J 42386 A bolts to 50 N m 37 Ib ft 2 Remove the camshaft position CMP actuator magnet Refer to Camshaft Position Actuator Magnet Replacement on page 9 271
52. 0 or 174 1 The ECM detects that the FT is greater or less than a calibrated value of the expected value determined by the control module 174 3 The ECM detects that the FT sensor voltage is greater than a calibrated value 174 4 The ECM detects that the FT sensor voltage is less than a calibrated value Action Taken When the SPN Sets SPN 174 is a Type B SPN Conditions for Clearing the SPN SPN 174 is a Type B SPN Diagnostic Aids Test the FT sensor at various temperature levels in order to evaluate the possibility of a skewed sensor A skewed sensor can result in a driveability condition If the vehicle has set overnight the FT sensor ECT sensor and the MAT sensor values should display within 3 5 F 2011 Marine Engines Manual Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification 1 Engine running observe the SPN informatio
53. 1 Disconnect the negative battery terminal 2 Disconnect the harness connectors at the ignition coil module 3 Remove the ignition coil wire to the distributor 2211676 4 Remove the bolts 5 holding the bracket and the ignition coil module assembly to the engine 5 Remove the bracket and the ignition coil module assembly 6 Remove the two rivets that connect the ignition coil to the ignition coil bracket by drilling them out 7 Remove the ignition coil from the bracket 8 Remove the two bolts 3 that connect the ignition coil module 2 and heat sink 1 to the ignition coil bracket 9 Remove the ignition coil module and heat sink 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 241 Installation Procedure 2211676 Caution Refer to Component Fastener Tightening Caution on page 0 5 1 Install the ignition control module and heat sink to the ignition coil bracket Tighten Tighten the bolts to 2 N m 18 lb in Note A replacement ignition coil kit comes with 2 screws in order to attach the ignition coil to the bracket 2 Install the ignition coil to the bracket with the 2 screws 3 Install the ignition coil and the bracket to the engine with bolts Tighten Tighten the bolts to 25 N m 18 lb ft Note Verify the coil wire does not contact any metal objects Rubbing will cause a short after time of use 4 Install the ignition coil wire 5 Install the harness con
54. 1 must run and pass SPN 106 630 65580 65620 65621 65622 or 65623 is not set The engine speed is less than a predetermined value The MAP signal is less than a predetermined value 2011 Marine Engines Manual 51 3 and 51 4 SPN 630 65580 65620 65621 65622 or 65623 is not set The ignition is ON or the engine is operating The SPN runs continuously when the conditions above are met Conditions for Setting the SPN 51 0 The ECM detects that the TP sensor voltage is greater than a calibrated value for greater than 1 second 51 3 The ECM detects that the TP sensor voltage is greater than 4 49 volts 51 4 The ECM detects that the TP sensor voltage is less than 0 29 volt Action Taken When the SPN Sets SPN 51 is a Type B SPN 9 68 Engine Controls and Fuel Marine Conditions for Clearing the SPN SPN 51 is a Type B SPN Diagnostic Aids If a shared 5 volt reference circuit is shorted to ground or shorted to a voltage other 5 volt reference circuits may be affected Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs
55. 176 Engine Controls and Fuel Marine SPN 66011 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptor SPN 66011 FMI 3 Speed Based Output Voltage Above Normal or Shorted High SPN 66011 FMI5 Speed Based Output Current Below Normal or Open Circuit Diagnostic Fault Information Short to Open High Short to Signal Circuit a Resistance me Voltage 660115 a 1 5 1 5 66011 3 The fuse that supplies voltage to the device opens Circuit System Description This SPN diagnosis the control circuit of an OEM specified speed based component Ignition voltage is supplied to the component through a fuse The engine control module ECM turns the component ON or OFF by grounding and ungrounding the control circuit based on engine or vehicle speed The ECM controls the component by grounding the control circuit with a solid state device called a driver The driver is equipped with a feedback circuit that is pulled up to voltage The ECM can determine if the control circuit is open shorted to ground or shorted to a voltage by monitoring the feedback voltage Conditions for Running the SPN
56. 2 Installation Procedure 2 The alignment will not be exact 1 Rotate the number 1 cylinder to Top Dead e If the driven gear is installed incorrectly the Center TDC of the compression stroke dimple will be approximately 180 degrees opposite of the rotor segment when it is installed in the distributor 301395 2 Align white paint mark on the bottom stem of the distributor and the pre drilled indent hole in the 34997 bottom of the gear 3 4 With a long screw driver align the oil pump drive Caution The ignition system distributor driven gear shaft to the drive tab of the distributor and rotor may be installed in multiple positions 5 Guide the distributor into the engine In order to avoid mistakes mark the distributor on the Ensure that the spark plug towers are following components in order to ensure the same perpendicular to the centerline of the engine mounting position upon reassembly The distributor driven gear The distributor shaft The rotor holes 2011 Marine Engines Manual 9 254 Engine Controls and Fuel Marine 6 4350 Once the distributor is fully seated the rotor segment should be aligned with the pointer cast into the distributor base This pointer may have 6 cast into it indicating that the distributor is to be used ona 6 cylinder engine or a 8 cast into it indicating that the distributor is to be used on a 8 cylinder engine If the rotor segment does not co
57. 2 System level SPNs such as misfire SPNs and fuel trim SPNs System Voltage Data Valid But Below Normal Range Least Severe Level SPN 627 page 9 98 Cal Memory Out of Calibration SPN 630 65580 65581 or 65582 on page 9 99 SPN 636 3 0L 4 3L 5 0L 5 7L page 9 100 636 2 Crankshaft Position Sensor Data Erratic Gi Intermittent or Incorrect SPN 636 6 0L 6 2L on page 9 102 7 SPN 636 3 0L 4 3L 5 0L 5 7L on page 9 100 636 Crankshaft Position Sensor Abnormal or Frequency or Pulse Width SPN 636 6 0L 6 2L on page 9 102 651 3 Fuel Injector 1 Voltage Above Normal SPN 651 652 653 654 655 656 657 or 658 on Shorted High page 9 104 651 5 Fuel Injector 1 Current Below Normal SPN 651 652 653 654 655 656 657 658 on Open Circuit page 9 104 652 3 Fuel Injector 2 Short Voltage Above SPN 651 652 653 654 655 656 657 or 658 on Normal or Shorted High page 9 104 652 5 Fuel Injector 2 Current Below Normal SPN 651 652 653 654 655 656 657 or 658 on Open Circuit page 9 104 653 3 Fuel Injector Voltage Above Normal SPN 651 652 653 654 655 656 657 or 658 on Shorted High page 9 104 653 5 Fuel Injector 3 Current Below Normal or SPN 651 652 653 654 655 656 657 or 658 on Open Circuit page 9 104 654 3 Fuel Injector 4 Voltage Above Normal SPN 651 652 653 654 655 656 657 or 658 on Shorted High page 9 104 654 5 Fuel Injector 4 Current Below Norma
58. 20 kPa for greater than 2 seconds 106 3 The ECM detects that the MAP sensor voltage is greater than 4 8 V 106 4 The ECM detects that the MAP sensor voltage is less than 0 25 V Action Taken When the SPN Sets SPN 106 is a Type B SPN The BARO will not be updated The ECM operates with a default MAP reading which varies based on throttle angle Conditions for Clearing the SPN SPN 106 is a Type B SPN Diagnostic Aids If a shared 5 volt reference circuit is shorted to ground or shorted to a voltage other 5 volt reference circuits may be affected Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Special Tool Required J 23738 A Vacuum Pump Circuit System Verification 1 Ignition ON observe the SPN information with a scan tool Verify that SPN 65622 is not set If SPN 65622 is set refer to SPN 65620 65623 on page 9 149 for further diagnosis 2 Turn all accessories OF
59. 2L Circuit Wire Color No jtowRe erene ___ _ ____ Jionition Vottage 2011 Marine Engines Manual Ignition Coil 5 6 0 6 2L 1581641 Connector Part Information OEM 15439568 Service 88987184 Description 4 Way GT 150 Series Sealed Terminal Part Information Terminal Tray 15326267 19 Core Insulation Crimp Pins A D E 1 Core Insulation Crimp Pins B C E 4 Release Tool Test Probe 15315247 J 35616 2A GY Ignition Coil 5 6 0 6 2L Circuit Pm wrecoior Function _ ew 8 ewReeeme pe csoma o Ignition Coil 6 6 0 6 2L 1581641 Connector Part Information OEM 15439568 Service 88987184 Description 4 Way F GT 150 Series Sealed BK 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 49 Terminal Part Information Terminal Tray 15326267 19 Core Insulation Crimp Pins A D E 1 Core Insulation Crimp Pins B C E 4 Release Tool Test Probe 15315247 J 35616 2A GY Ignition Coil 6 6 0 6 2L Circuit Wire Color No Loe eI IC 6 Control Ignition Voltage Low Reference 1581641 Connector Part Information OEM 15439568 Service 88987184 Description 4 Way F GT 150 Series Sealed BK Terminal Part Information Terminal Tray 15326267 19 Core Insulation Crimp Pins A D E 1 Core Insulation Crimp
60. 3 5 0 5 7L Sensor 6 0 6 2L Circuit Circuit Wire Color No Function Wire Color No twRetrme Engine Oil Pressure Voh Reference Sensor Signal C 3 Engine Oil Pressure 5 Volt Reference Sensor Signal 1527729 Connector Part Information OEM 12602480 Service 88988313 Description 2 Way F GT 150 Series Sealed GY 2011 Marine Engines Manual Terminal Part Information Terminal Tray 12191819 8 Core Insulation Crimp E 1 Release Tool Test Probe 15315247 J 35616 2A GY Fuel Injector 1 2 4 6 0 6 2L Circuit Wire Color No Function Fuel Injector 2 2 4 6 0 6 2L 1527729 Connector Part Information OEM 12602480 Service 88988313 Description 2 Way F GT 150 Series Sealed GY Terminal Part Information Terminal Tray 12191819 8 Core Insulation Crimp E 1 Release Tool Test Probe 15315247 J 35616 2A GY Fuel Injector 2 2 4 6 0 6 2L Circuit Wire Color No Function 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 39 Fuel Injector 3 2 4 6 0 6 2L 1527729 Connector Part Information OEM 12602480 Service 88988313 Description 2 Way F GT 150 Series Sealed GY Terminal Part Information Terminal Tray 12191819 8 Core Insulation Crimp E 1 Release Tool Test Probe 15315247 J 35616 2A GY Fuel Injector 3 2 4 6 0 6 2L Circuit Wire Color No 8 Fuel injector 3 Control
61. 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification 1 Engine operating observe the SPN information with a scan tool SPN 65551 or 65552 should not set 2 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Ignition OFF disconnect the harness connector at the appropriate KS 2 Ignition ON test for 1 2 V between the low signal circuit terminal A and ground lf less than the specified range test the low signal circuit for a short to ground or an open high resistance If the circuit tests normal replace the ECM lf greater than the specified range test the low signal circuit for a short to voltage or for a wire to wire short between the KS circuits If the circuit tests normal replace the ECM 3 Test for 3 4 V between the high signal circuit terminal B and ground If less than the specified range test the high signal circuit for a short to ground or an open high resistan
62. 38 96 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provide an overview of each diagnostic category SPN Descriptor Engine Controls and Fuel Marine 9 65 SPN 38 FMI 3 Fuel Level Sensor 2 Circuit Voltage Above Normal or Shorted High SPN 38 FMI 4 Fuel Level Sensor 2 Circuit Voltage Below Normal or Shorted Low SPN 96 FMI 3 Fuel Level Sensor 1 Circuit Voltage Above Normal or Shorted High SPN 96 FMI 4 Fuel Level Sensor 1 Circuit Voltage Below Normal or Shorted Low Diagnostic Fault Information Short to Open High Short to Signal Circuit Ground Resistance Voltage Performance Fuel Level Sensor 1 Low Reference Circuit _ 9 9 Fuel Level Sensor 1 Signal Circuit 963 Fuel Level Sensor 2 Low Reference Circuit _ 383 Fuel Level Sensor 2 Signal Circuit Circuit System Description The fuel level sensor changes resistance in response to the fuel level The engine control module ECM monitors the signal circuit of the fuel level sensor in order to determine the fuel level When the fuel tank is full the sensor resistance is low and the ECM detects a low signal voltage When the fuel tank is empty the sensor resistance is high
63. 4 8 5 2 V between the 5 volt reference circuit terminal A 1 and ground If less than the specified range test the 5 volt reference circuit for a short to ground or an open high resistance If the circuit tests normal replace the ECM greater than the specified range test the 5 volt reference circuit for a short to voltage If the circuit tests normal replace the ECM 4 Test for 4 8 5 2 V between the signal circuit terminal C 3 and ground If less than the specified range test the signal circuit for a short to ground or an open high resistance If the circuit tests normal replace the ECM greater than the specified range test the signal circuit for a short to voltage If the circuit tests normal replace the ECM 5 If all circuits test normal test or replace the sensor Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Crankshaft Position Sensor Replacement 3 0L on page 9 256 or Crankshaft Position Sensor Replacement 4 3 5 0 5 7L on page 9 257 or Crankshaft Position Sensor Replacement 6 0 6 2L on page 9 258 or Crankshaft Position Sensor Replacement 2 4L on page 9 261 Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 9 102 Engine Controls and Fuel Marine SPN 636 6 0L 6 2L Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Chec
64. 5 between the ground circuit terminal 86 and ground gt If greater than the specified range repair the ground circuit for an open high resistance 3 Connect a test lamp between the relay coil control circuit terminal 85 and ground 4 Cycle the ignition ON and OFF The test lamp should turn ON and OFF when changing between the commanded states If the test lamp is always ON test the control circuit for a short to voltage If the circuit tests normal replace the ignition switch If the test lamp is always OFF test the control circuit for a short to ground or an open high resistance If the circuit tests normal replace the ignition switch 5 Test for between the relay switch voltage circuit terminal 30 and ground gt lf less than the specified range repair the relay switch voltage circuit for an open high resistance 6 Install a 20 A fused jumper wire between the relay Switch voltage circuit terminal 30 and the relay switch supply circuit terminal 87 Attempt to start the engine The engine should start and idle If the engine does not start and idle test the run crank relay signal circuit for a short to ground or an open high resistance If the circuit tests normal replace the ECM 7 f all circuits test normal test or replace the run crank relay Component Testing 1 Ignition OFF disconnect the run crank relay with the J 43244 2 Test for 70 110 between terminals 85 and 86 If not
65. 6 45 0 0929 0 8361 Volume 16 387 0 16 387 0 0164 0 9464 3 7854 0 764 o I 3 0 4536 907 18 0 907 tonne t 1 9 807 0 2780 4 448 Acceleration 0 3048 0 0254 Torque 0 11298 1 3558 newtons N 2 3 v o o c o o o 0 745 inches of 2 0 2488 kPa Ib sq in 6 895 Energy Work 1056 0 1 3558 3 600 000 0 2011 Marine Engines Manual J J one Ws General Information 1 3 US English Metric Conversion cont d _ Fass I e J o l oa sam Decimal and Metric Equivalents 1 4 General Information Decimal and Metric Equivalents cont d Arrows and Symbols This service manual uses various symbols in order to describe different service operations 9 16 14 2875 37 64 14 68437 19 32 15 08125 39 64 15 47812 5 8 15 875 41 64 16 27187 21 32 16 66875 43 64 17 06562 11 16 17 4625 45 64 17 85937 23 32 18 25625 47 64 18 65312 3 4 19 05 49 64 19 44687 1 Front of Vehicle 2 View Detail 3 Ambient Air Mixed with Another Gas or Motion or Direction 196216 4 5 View Angle 6 Dimension 1 2 7 Ambient Clean Air Flow or Cool Air Flow 8 Lubrication Point Oil or Fluid 9 Task Related 10 Sectioning 1 3 11 Gas Other Than Ambient Air or Hot Air Flow 12 Lubrication Point Grease or Jelly 13 Multidirectional
66. A Sensor 2 Not Available 47 _ 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 33 Engine Controls Connector End Views Barometric Pressure BARO Sensor 1331443 Connector Part Information Harness Type Engine OEM Connector 15365614 Service Connector 88988583 Description 3 Way F Kompakt 2 8 Series Sealed BK Terminal Part Information Terminated Lead Pending Release Tool J 38125 561 Diagnostic Test Probe J 35616 35 VT Terminal Tray 1928498056 8 Core Insulation Crimp E 1 Barometric Pressure BARO Sensor Circuit Wire Color No __ _ _ 5 Reference ____ 2 Jew Reference s Sensor Sona 9 34 Engine Controls and Fuel Marine Camshaft Actuator Solenoid 6 0 6 2L 1673477 Connector Part Information OEM 15472554 Service 88988610 Description 2 Way F 0 64 Series Sealed Terminal Part Information Terminal Tray 1393364 2 7 Core Insulation Crimp K K Release Tool Test Probe 15315247 J 35616 64B L BU Camshaft Actuator Solenoid 6 0 6 2L Circuit Wire Color No Function 1 Camshaft Actuator Solenoid Control 2 towReferene Camshaft Actuator Solenoid Exhaust 2 4L 646406 Connector Part Information OEM 15336004 Service 15306187 Description 2 Way F GT 150 Series Sealed BK Terminal Part Information Terminal Tray 15326267 19 Core Insulation Crimp E 4 Release Tool Test Probe 15
67. A fused jumper between the signal circuit terminal and the low reference circuit terminal Verify the appropriate scan tool Fuel Level Volts parameter is less than 0 10 V If greater than the specified range test the signal circuit for a short to voltage or an open high resistance If the circuit tests normal replace the ECM If all circuits test normal test or replace the fuel level sensor Component Testing 1 2 3 4 Ignition OFF disconnect the harness connector at the appropriate fuel level sensor Remove the fuel level sensor Connect a DMM between the terminals of the fuel level sensor While sweeping the fuel level sensor through its full range of motion test for a minimum value less than 41 O and a maximum value greater than 119 O If not within the specified range replace the fuel level sensor Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Engine Control Module Replacement on page 9 217 for engine control module replacement setup and programming 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 67 SPN 51 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5
68. B DTCs phasers not enabled Conditions for Clearing the DTC SPNs 65570 65571 65572 and 65573 are type B DTCs Diagnostic Aids The engine oil condition has a major impact the camshaft actuator system A low oil level condition may set this SPN The engine may require an oil change Inquire with the customer when the last oil change was performed You may also monitor the scan tool Engine Oil Life parameter Advise the customer an oil change may be required Inspect the engine for any recent engine mechanical repairs An incorrectly installed camshaft camshaft actuator or timing chain may cause SPN 65570 2 65570 7 65571 2 65571 7 65572 2 65572 7 65573 2 or 65573 7 to set Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views page 9 33 Electrical Information Reference Circuit Testing 11 6 e Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 9 134 Engine Controls and Fuel Marine Circuit System Verification Note If a crankshaft or camshaft position sensor
69. Connector End Views on page 9 33 for connector identification Note Testing for steps 2 4 is performed on the ECM side of the jumper harness connector 2 Ignition OFF for 1 minute test for less than 5 between the low reference circuit terminal E and ground If greater than the specified value test the low reference circuit for an open high resistance If the circuit tests normal replace the ECM 3 Ignition ON engine OFF verify that a test lamp does not illuminate between the control circuit terminal D and ground If the test lamp illuminates test the control circuit for a short to voltage If the circuit tests normal replace the ECM 4 Connect the DMM black lead to the control circuit terminal D Connect the DMM red lead to Set the DMM on the diode setting 5 Engine operating 2 000 2 500 RPM pulse the CMP actuator solenoid ON with a scan tool The DMM should transition from OL when commanded OFF to less than 1 V when commanded ON If the circuit voltage does not correspond to the specified values test the control circuit for an open high resistance or a short to ground If the circuit tests normal replace the ECM Note Testing for steps 5 and 6 is performed on the engine side of the jumper harness connector 6 Ignition OFF test for infinite resistance between the control circuit terminal D and ground If not the specified value repair the control circuit for a short to ground
70. Control Solenoid Mechanical System Not Responding or Out of Adjustment Circuit Description Supercharger SC boost pressure is regulated to prevent engine damage When the engine is operating under high boost conditions the engine control module ECM limits boost pressure to a calibrated value The ECM disables boost under the following conditions When an electronic throttle control ETC fault is detected When an intercooler pump failure is detected When the ECM detects an over temperature condition The ECM controls boost pressure by pulse width modulation PWM of the boost control solenoid The boost control solenoid is a normally open valve Under most conditions the ECM commands the boost control solenoid to operate at a 99 100 percent duty cycle This keeps the boost control solenoid valve closed and allows only inlet vacuum from the supercharger plenum to the bypass valve actuator to control the position of the bypass valve At idle engine vacuum is applied to the upper side of the bypass valve actuator counteracting spring tension to hold the bypass valve open When the engine load is increased the engine vacuum is decreased causing the spring in the bypass valve actuator to overcome the diminishing applied vacuum closing the bypass valve and allowing the boost pressure to increase When reduced boost pressure is desired the ECM commands the boost control solenoid to operate at a 0 98 percent duty c
71. Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 65570 FMI 2 SPN 65570 FMI 4 SPN 65570 FMI 5 SPN 65570 FMI 7 SPN 65571 FMI 2 SPN 65571 FMI 4 SPN 65571 5 SPN 65571 FMI 7 SPN 65572 FMI 2 SPN 65572 FMI 4 SPN 65572 5 SPN 65572 FMI 7 SPN 65573 FMI 2 SPN 65573 FMI 4 SPN 65573 FMI 5 SPN 65573 FMI 7 Cam Phaser W Data Erratic Intermittent or Incorrect Cam Phaser W Voltage Below Normal or Shorted Low Cam Phaser W Short High or Open Cam Phaser W Accuracy Mechanical System Not Responding or Out of Adjustment Cam Phaser X Data Erratic Intermittent or Incorrect Cam Phaser X Voltage Below Normal or Shorted Low Cam Phaser X Short High or Open Cam Phaser X Accuracy Mechanical System Not Responding or Out of Adjustment Cam Phaser Y Data Erratic Intermittent or Incorrect Cam Phaser Y Voltage Below Normal or Shorted Low Cam Phaser Y Short High or Open Cam Phaser Y Accuracy Mechanical System Not Responding or Out of Adjustment Cam Phaser Z Data Erratic Intermittent or Incorrect Cam Phaser Z Voltage Below Normal or Shorted Low Cam Phaser Z Short High or Open Cam Phaser Z Accuracy Mechanical System Not Responding or Out of Adjustment Diagnostic Fault Inf
72. Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Manifold Absolute Pressure Sensor Replacement without Supercharger on page 9 220 Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 2011 Marine Engines Manual 9 86 Engine Controls and Fuel Marine SPN 106 2 4L 6 0L 6 2L Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 106 FMI 0 Manifold Absolute Pressure MAP Sensor Circuit Voltage Data Valid But Above Normal SPN 106 FMI 1 Manifold Absolute Pressure MAP Sensor Circuit Voltage Data Valid But Below Normal SPN 106 FMI 2 Manifold Absolute Pressure MAP Sensor Circuit Voltage Data Erratic Intermittent or Incorrect SPN 106 FMI 3 Manifold Absolute Pressure MAP Sensor Circuit Voltage Above Normal or Shorted High SPN 106 FMI 4 Manifold Absolute Pressure MAP Sensor Circuit Voltage Below Normal or Shorted Low Diagnostic Fault Information Short to Open High Short to Signal Circuit Ground Resistance Voltage Performance 106 3 65604 2 5 Volt Reference 65622 4 106 4 65613 2 106 0 106 1 MAP Sensor Signal 106 4 106 4 106 3
73. Failure Records data 9 194 Engine Controls and Fuel Marine Circuit System Testing 1 Ignition OFF disconnect the intercooler coolant pump relay with the J 43244 Ignition ON verify a test lamp illuminates between the relay coil ignition voltage circuit terminal 85 and ground If the test lamp does not illuminate test the relay coil ignition voltage circuit for a short to ground or an open high resistance Ignition ON command the intercooler pump relay ON and OFF with a scan tool The test lamp turn ON and OFF as commanded If the test lamp is always ON test the relay coil control circuit for a short to ground If the circuit tests normal replace the ECM If the test lamp is always OFF test the relay coil control circuit for a short to voltage or an open high resistance If the circuit tests normal replace the ECM Connect a 20 A fused jumper wire between the relay switch circuit terminal 30 and the relay switch ignition voltage circuit terminal 87 The intercooler pump should operate If the intercooler pump does not operate refer to Supercharger Intercooler Relay Diagnosis on page 9 204 If all circuits test normal test or replace the intercooler pump relay Component Testing 1 2 Ignition OFF disconnect the intercooler pump relay with the J 43244 Test for 70 110 between terminals 85 and 86 If not within the specified range replace the relay T
74. If the test lamp is not illuminated test the appropriate voltage circuit for a short to ground or an open high resistance Connect a test lamp between the relay coil control circuit terminal 86 and ground Cycle the ignition ON and OFF The test lamp should turn ON and OFF when changing between the commanded states If the test lamp is always ON test the control circuit for a short to voltage If the circuit tests normal replace the ECM If the test lamp is always OFF test the control circuit for a short to ground or an open high resistance If the circuit tests normal replace the ECM Install a 20 A fused jumper wire between the relay Switch voltage circuit terminal 30 and the relay controlled output circuit terminal 87 Ignition ON the supercharger intercooler coolant pump should operate If the supercharger intercooler coolant pump does not operate test for the following The relay controlled output circuit for a short to ground or an open high resistance The supercharger intercooler coolant pump ground circuit for an open high resistance If the circuits test normal replace the supercharger intercooler coolant pump If all circuits test normal test or replace the supercharger intercooler coolant pump relay Component Testing 1 Ignition OFF disconnect the supercharger intercooler coolant pump relay with the J 43244 2 Test for 70 110 Q between terminals 85 and 86 If not
75. Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification Note If you were sent here from Engine Cranks but Does Not Run proceed to Circuit System Testing 1 Attempt to start the engine observe the SPN information with a scan tool SPN 65723 2 and 65723 8 should not set 2 Engine speed greater 1 000 RPM observe the SPN information with a scan tool SPN 65723 7 should not set If SPN 65723 7 is set perform the camshaft retard offset procedure Refer to Camshaft Retard Offset Adjustment 3 0L and 4 3L on page 9 255 or Camshaft Retard Offset Adjustment 5 0L and 5 7L on page 9 255 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 159 3 Move related harnesses connectors of the CMP sensor and verify the engine does not stumble stall or change engine speed 4 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not
76. Injector Replacement Except 2 4L on page 9 238 or Fuel Injector Replacement 2 4L on page 9 240 2 With the fuel injectors positioned downward lower the fuel injectors into the cylinder head ports 3 Carefully push the fuel injectors into the cylinder head ports Caution Refer to Fastener Caution on page 0 5 4 Install the fuel rail bolts Tighten Tighten the bolts to 10 N m 89 lb in 1625417 8 Connect the fuel feed line quick connect fitting to the fuel rail 9 Connect the negative battery cable 10 Inspect for fuel leaks using the following procedure 10 1 Turn ON the ignition with the engine OFF for 2 seconds 10 2 Turn OFF the ignition for 10 seconds 10 3 Turn ON the ignition 10 4 Inspect for fuel leaks 1623764 5 Connect the fuel injector harness electrical connector 2 2011 Marine Engines Manual 9 238 Engine Controls and Fuel Marine Fuel Pressure Regulator Replacement Special Tools J 34730 1A Fuel Pressure Gauge Warning Refer to Actions to Take When Working with Fuel Warning on page 0 3 Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury After you relieve the fuel system pressure a small amount of fuel may be released when servicing the fuel lines the fuel injection pump or the connections In order to reduce the risk of personal injury cover the fuel system co
77. Marine Engines Manual 9 232 Engine Controls and Fuel Marine 785740 7 Remove the secondary retainers 4 from the fuel feed and fuel return pipes 2 3 740874 8 Disconnect the fuel feed pipe 2 and the fuel return pipe 3 from the fuel rail assembly 1 738694 9 Remove the fasteners 1 from the fuel rail assembly Notice Mask off the intake ports Accidental entry of foreign objects can cause severe engine damage 10 Remove the fuel rail assembly 2 from the intake manifold 3 Installation Procedure 1 Inspect the fuel injector O ring seals for damage and replace if necessary 2 Lubricate the fuel injector O rings with clean engine oil before installation 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 233 785740 6 Install the secondary retainers 4 to the fuel feed and fuel return pipes 2 3 738694 3 Install the fuel rail assembly 2 to the intake manifold 3 Caution Refer to Fastener Caution on 0 5 4 Install the fasteners 1 to the fuel rail assembly Tighten Tighten the fasteners to 10 N m 88 lb in 735711 7 Connect the electrical connectors 2 to the fuel injectors 740874 5 Connect the fuel feed pipe 2 and the fuel return pipe 3 to the fuel rail assembly 1 2011 Marine Engines Manual 9 234 10 11 12 13 Connect the electrical connector to the throttle bod
78. Normal Oxygen Sensor Bank B Sensor 2 Data Valid But Below Normal Oxygen Sensor Bank 2 Sensor 2 Voltage Above Normal or Shorted High Oxygen Sensor Bank B Sensor 2 Voltage Below Normal or Shorted Low Oxygen Sensor Bank B Sensor 2 Current Below Normal or Open Circuit Typical Scan Tool Data Short to Ground Open __ Short to Voltage HO2S 1 and 2 Operating Conditions Engine operating in Closed Loop Parameter Normal Range Fluctuates above and below 200 800 mV HO2S 1 and 2 Signal 947 mV 1 245 mV owners orm 2011 Marine Engines Manual Circuit Description The heated oxygen sensor HO2S is used for fuel control and catalyst monitoring The HO2S compares the oxygen content of the surrounding air with the oxygen content of the exhaust stream The HO2S samples the oxygen content of the exhaust stream as it passes the sensor When the engine is started the control module operates in an Open Loop mode ignoring the HO2S signal voltage while calculating the air to fuel ratio The control module supplies the HO2S with a reference or bias voltage of about 1 900 mV When the engine is operating the exhaust stream warms the HO2S which affects the resistance of the sensing element During normal operation the temperature of the exhaust stream fluctuates according to oxygen content of the stream which causes the bias voltage to increase or decrease in a range of 0 1 000 mV Once sufficient HO2S voltage fluctuation is obs
79. ON refer to Fuel Pump Electrical Circuit Diagnosis on page 9 207 7 Ignition OFF disconnect the harness connector at a fuel injector 8 Connect a J 34730 405 between the control circuit and the ignition 1 voltage circuit Engine cranking the injector test lamp should flash gt If the injector test lamp does not flash refer to SPN 651 652 653 654 655 656 657 or 658 on page 9 104 9 Ignition OFF install the J 34730 1A Refer to Fuel Pressure Gauge Installation and Removal on page 9 229 Note The fuel pump may need to be commanded few times in order to obtain the highest possible fuel pressure Do NOT start the engine this test 10 Ignition ON command the fuel pump ON with a scan tool The fuel pressure should be between 380 427 kPa 55 62 psi gt If not within the specified range refer to Fuel System Diagnosis with Returnless Fuel System on page 9 208 or Fuel System Diagnosis without Returnless Fuel System on page 9 210 2011 Marine Engines Manual 11 Verify the following conditions do not exist Collapsed air intake duct to the throttle body Restricted air filter element Spark plugs for being gas or coolant fouled A skewed manifold absolute pressure MAP sensor Refer to SPN 106 3 0L 4 3L 5 0L 5 7L on page 9 83 or SPN 106 2 4L 6 0L 6 2L on page 9 86 A skewed engine coolant temperature ECT sensor Refer to SPN 110 on page 9 91 Exhaust system restr
80. Observe the scan tool SPN information Verify that SPN 630 13 does not fail this ignition cycle If the SPN fails this ignition cycle reprogram the ECM Refer to Engine Control Module Programming and Setup on page 6 3 If SPN 630 13 resets replace the ECM 2 Observe the SPN information with a scan tool Verify that SPNs 65580 12 65581 12 or 65582 2 do not fail this ignition cycle If any of the SPNs set this ignition cycle replace the ECM Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 9 100 Engine Controls and Fuel Marine SPN 636 3 0L 4 3L 5 0L 5 7L Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 636 FMI 2 Crankshaft Position CKP Sensor Circuit Data Erratic Intermittent or Incorrect SPN 636 FMI 8 Crankshaft Position Sensor Signal Abnormal Frequency or Pulse Width Diagnostic Fault Information Short to Open High Short to Signal Circuit Ground Resistance Voltage Performance 5 Volt Reference Circuit 65621 4 63
81. Oxygen Sensor Bank B Sensor 2 Heater Current Below Normal or Open Circuit Oxygen Sensor Bank B Sensor 2 Heater Abnormal Frequency or Pulse Width 65561 1 655610 66019 5 66019 3 66019 8 65563 1 66020 5 65563 1 655630 66020 5 66020 3 66020 8 65562 1 66021 5 655620 66021 3 560219 65562 65564 0 66022 3 66022 8 65564 1 66022 5 65564 1 66022 5 Engine cranks but does not run and the fuse the ignition circuit opens Circuit Description The heated oxygen sensors HO2S are used for fuel control and post catalyst monitoring Each HO2S compares the oxygen content of the surrounding air with the oxygen content in the exhaust stream The HO2S must reach operating temperature to provide an accurate voltage signal A heating element inside the HO2S minimizes the time required for the sensor to reach operating temperature Voltage is provided to the heater by the ignition voltage circuit through a fuse Ground is provided to the heater on the heater control circuit by a solid state device called a low side driver The driver is pulled up to a voltage within the controller which enables the ECM to determine if the control circuit is open shorted to ground or shorted to a voltage by monitoring the feed back voltage 2011 Marine Engines Manual Conditions for Running the SPN 66019 66020 66021 66022 FMI and 5 SPN 110 630 or 65580 is not set The ignition is ON or the engine is operat
82. Pins B C E 4 Release Tool Test Probe 15315247 J 35616 2A GY Ignition Coil 7 6 0 6 2L Circuit Wire Color No Gone jtowRe erene __ _ j rn onVotage 9 50 Engine Controls and Fuel Marine Ignition Coil 8 6 0 6 2L Terminal Part Information Terminal Tray 15326267 19 Core Insulation Crimp Pins A 0 Core Insulation Crimp Pins B C E 4 Release Tool Test Probe 15315247 J 35616 2A GY Ignition Control Module Distributor Ignition wWonVotse ic Timing eg 1581641 Ignition Coil Control Connector Part Information OEM 15439568 Service 88987184 Description 4 Way GT 150 Series Sealed BK Terminal Part Information Terminal Tray 15326267 19 Core Insulation Crimp Pins A D E 1 Core Insulation Crimp Pins B C 4 Release Tool Test Probe 15315247 J 35616 2A GY Ignition Coil 8 6 0 6 2L EE FN Wire Color No Function ean Dp ignition Connector Part Information u OEM 15374222 Ignition Control Module Service 88953268 Distributor Ignition Description 2 Way F GT 150 Sealed WH Terminal Part Information Terminal Tray 12191819 8 Core Insulation Crimp 2 A Release Tool Test Probe 15315247 J 35616 2A GY 1232999 Knock Sensor KS 1 Circuit Wire Color No LA
83. Position Position Actuator Solenoid Camshaft Position Actuator Control Camshaft Position Sensor Engine Load Engine Coolant Temperature Sensor Engine Oil Pressure Sensor The camshaft position CMP actuator system is used for a variety of engine performance enhancements These enhancements include lower emission output a wider engine torque range improved gas mileage and improved engine idle stability The park position for the CMP actuator and camshaft is 7 crankshaft degrees BTDC The engine control module ECM can only command the CMP actuator to retard the valve timing from the park position or return the valve timing back to the park position The total range of valve timing authority is 52 degrees of crankshaft rotation The control range is from the park position of 7 degrees crankshaft BTDC to 45 degrees crankshaft after top dead center ATDC CMP Actuator System Operation The camshaft position CMP actuator system is controlled by the engine control module ECM The ECM sends a pulse width modulated 12 volt signal to a CMP actuator solenoid in order to control the amount of engine oil flow to a camshaft actuator passage There are 2 different passages for oil to flow through a passage for cam advance and a passage for cam retard The camshaft actuator is attached to the 2011 Marine Engines Manual Actuator ECM 1916848 front of the camshaft and is hydraulically operated i
84. Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors Engine Controls and Fuel Marine 9 129 SPN 65570 FMI 2 Cam Phaser W Data Erratic Intermittent or Incorrect SPN 65570 FMI 4 Phaser W Voltage Below Normal or Shorted Low SPN 65570 5 Cam Phaser W Short High or Open SPN 65570 7 Cam Phaser W Accuracy Mechanical System Not Responding or Out of Adjustment Diagnostic Fault Information Circuit Cam Phaser Control Low Reference Ground ___ 65575 Open High Resistance Short to Voltage Signal Performance Internal or sensor damage may occur if the circuit is shorted to B Circuit System Description The camshaft position CMP actuator system enables the engine control module ECM to change the timing of the camshaft while the engine is operating The ECM controls the Camshaft Position Actuator Magnet duty cycle by controlling the amount of ON time The magnet controls the amount of engine oil flow to the CMP actuator by extending a pintle within the solenoid The pintle acts against a spool valve in the CMP actuator mechanism which is attached to the front of the camshaft As the spool valve is moved oil is dire
85. Programming System Speed Signal SOFT FT SQN RP SRi ST SW SYN TAC TACH 1 12 General Information Abbreviations and Meanings cont d Abbreviation Meaning Throttle Position Terminal Positive Assurance TPS Throttle Position Sensor TP TPA TPS TSC TT TV WC Three Way Oxidation Converter Catalytic Universal Asynchronous Receiver Transmitter V Abbreviations and Meanings cont d Abbreviation Meaning VAC Wi WHT WO WOT wis Y 2011 Marine Engines Manual Table of Contents 6 1 Section 6 Diagnostic Overview Starting Point and Programming Programming and Setup 6 3 Repair Instructions 6 3 Engine Control Module Programming ze me 6 3 Vehicle Diagnostic Information 6 4 Diagnostic Information and Procedures 6 4 Strategy Based Diagnosis 6 4 Diagnostic Procedure Instructions 6 5 Non Scan Diagnosis of Driveability Concerns No DTCs Set 6 7 Engine Control Module ECM Self Diagnosis 6 8 2011 Marine Engines Manual On Board Diagnostic System Check 6 8 Malfunction Indicator Lamp MIL 6 8 Reading Suspect Parameter Numbers 6 8 Clearing Suspect Parameter Numbers 6 8 Suspect Parameter Number SPN
86. Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification 1 Engine operating observe the appropriate scan tool HO2S voltage parameter The reading should fluctuate above and below 351 654 mV 2 Observe the SPN information with a scan tool Verify SPN 65567 or 65568 is not set 3 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Ignition OFF disconnect the harness connector at the appropriate HO2S 2 Test for less than 5 between the low reference circuit terminal A and ground If greater than the specified range test the low reference circuit for a short to voltage or an open high resistance If the circuit tests normal replace the ECM 3 Ignition ON verify the HO2S scan tool voltage parameter is between 900 1 000 mV If less than the specified range test the signal circuit for a short to ground If the circuit tests normal replace the ECM If greater than the specified range test the sign
87. Replacement on page 9 217 for ECM replacement setup and programming Symptoms Engine Controls Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category Symptoms Description Symptoms covers conditions that are not covered by DTCs Certain conditions can cause multiple symptoms These conditions are listed together under Symptoms Testing Conditions that may only cause specific symptoms are listed separately under Additional Symptoms Testing Perform the Symptoms Testing before using the Additional Symptoms Testing 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 199 Symptoms Definition Backfire Fuel ignites in the intake manifold or in the exhaust system making a loud popping noise Cuts Out Misses A steady pulsation or jerking that follows engine speed which is usually more pronounced as the engine load increases This condition is not normally felt above 1 500 RPM or 48 km h 30 mph The exhaust has a steady spitting sound at idle or at low speed Detonation Spark Knock A mild to severe ping which usually occurs worse while under acceleration The engine makes sharp metallic knocks that change with throttle opening D
88. SPN is set the Cam Phaser Cleaning test may not function 1 Ignition ON observe the scan tool SPN information Verify that none of the following SPNs are set SPN 98 100 636 65615 65616 65618 65723 or 65724 65725 or 65726 If any of the SPNs are set refer to Diagnostic Trouble Code DTC List on page 6 11 for further diagnosis 2 Engine idling observe the scan tool SPN information SPN 65570 2 65570 7 65571 2 65571 7 65572 2 65572 7 65573 2 65573 7 should not set Note It may be necessary to perform the procedure a few times in order to clean the cam phaser actuator If any of the SPNs are set perform the Cam Phaser Cleaning procedure with a scan tool Verify SPN 65570 2 65570 7 65571 2 65571 7 65572 2 65572 7 65573 2 or 65573 7 does not reset 3 Engine idling observe the scan tool SPN information SPN 65570 4 65570 5 65571 4 65571 5 65572 4 65572 5 65573 4 or 65573 5 should not be set 4 Operate the vehicle within the Conditions for Running the DTC to verify the DTC does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data om Testing lgnition OFF disconnect the harness connector at the appropriate Camshaft Position Actuator Solenoid Valve 2 Test for less than 5 between the low reference circuit terminal B and ground If greater than the specified value test the low reference circuit for an ope
89. SPNs 66013 and 66014 are Type B SPNs Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Special Tools J 43244 Relay Puller Pliers Circuit System Verification Note If you were sent here from Engine Cranks But Does Not Run proceed to Circuit System Testing 1 Ignition ON observe the SPN information with a scan tool SPN 66013 or 66014 should not set 2 Cycle the ignition from OFF to ON You should hear and feel an audible click from the powertrain relay Repeat as necessary in order to verify powertrain relay operation 3 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data 2011 Marine Engines Manual Circuit System Testing 1 Ignition OFF disconnect the powertrain relay with the J 43244 2 Ignit
90. Vehicle Diagnostic Information 6 9 The following applies to fuel trim SPNs f the control module detects a fuel trim condition during 2 consecutive trips the control module illuminates the MIL f the control module detects a fuel trim condition during 2 non consecultive trips the stored conditions are compared with the current conditions The control module illuminates the MIL when the following conditions occur The engine load is within a certain percentage of the previous test that failed The engine speed is within a certain percentage of the previous test that failed The engine coolant temperature is in the same range of the previous test that failed Action Taken When the SPN Sets Type E The control module illuminates the MIL on the third consecutive ignition cycle that the diagnostic runs and fails The control module records the operating conditions at the time the diagnostic fails The first time the diagnostic fails the control module stores this information in the Failure Records If the diagnostic reports a failure on the third consecutive ignition cycle the control module records the operating conditions at the time of the failure The control module writes the operating conditions to the Freeze Frame and updates the Failure Records Conditions for Clearing the MIL SPN Type A B or Type E The control module turns OFF the MIL after 3 consecutive ignition cycles that the di
91. Verification on page 6 22 after completing the diagnostic procedure Camshaft Position Sensor Replacement 4 3 5 0 5 7L on page 9 262 or Camshaft Position Sensor Heplacement with CMP Actuator on page 9 268 or Camshaft Position Sensor Replacement without CMP Actuator on page 9 269 or Camshaft Position Sensor Replacement 2 4L Intake on page 9 270 or Camshaft Position Sensor Replacement 2 4L Exhaust on page 9 270 Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 9 162 Engine Controls and Fuel Marine SPN 66002 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptor SPN 66002 FMI 4 Starter Relay High Side Driver Voltage Below Normal or Shorted Low SPN 66002 FMI5 Starter Relay High Side Driver Current Below Normal or Open Circuit Circuit System Description The Starter Relay is controlled by the engine control module ECM depending upon input from the ignition switch When the ignition switch is rotated to the crank position a voltage is applied to the neutral start switch With the neutral switch in the closed position the ECM will receive a crank signal The ECM will then supply
92. Voltage Above Normal or Shorted High Buzzer Driver Current Below Normal or Open Circuit Diagnostic Fault Information Short to Open High Short to Signal Circuit a Resistance me Buzzer Voltage Supply 66007 5 Buzzer Control 66007 3 5 The fuse that supplies voltage to the IPC Bulb opens Circuit System Description The Buzzer is located on the driver information center DIC Ignition voltage is supplied directly to the Buzzer The engine control module ECM turns the Buzzer ON by grounding the control circuit Conditions for Running the SPN SPN 630 or 65580 is not set The ignition is ON or the engine is operating The ignition voltage is greater than 9 volts The Buzzer has been commanded ON and OFF at least once during the ignition cycle The SPNs run continuously once the above conditions are met Conditions for Setting the SPN The ECM detects that the commanded state of the driver and the actual state of the control circuit do not match for greater than 5 seconds Action Taken When the SPN Sets SPN 66007 is a Type C SPN Conditions for Clearing the SPN SPN 66007 is a Type C SPN Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views page 9 33 Electrical Information Reference Circuit Testing on page
93. a voltage to the control circuit of the crank relay When this occurs battery voltage is supplied through the switch side of the crank relay to the S terminal of the starter solenoid The starter relay control circuit is equipped with a feedback circuit that is pulled up to 2 5 volts within the ECM The ECM can determine if the control circuit is open shorted to ground or shorted to a voltage by monitoring the feedback voltage Conditions for Running the SPN SPN 630 or 65580 is not set The ignition is ON or the engine is operating The ignition voltage is greater 9 volts The relay has been commanded ON and OFF at least once during the ignition cycle SPN 66002 runs continuously once the above conditions are met Conditions for Setting the SPN The ECM detects that the commanded state of the driver and the actual state of the control circuit do not match for greater than 2 seconds Action Taken When the SPN Sets SPN 66002 is a Type C SPN Conditions for Clearing the SPN SPN 66002 is a Type C SPN Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on pag
94. a charging system concern All charging system concerns must be repaired before programming a control module Battery voltage is greater than 12 volts but less than 16 volts The battery must be fully charged before programming the control module Turn OFF or disable any system that may put a load on the vehicles battery such as the following components Engine electrical loads turned OFF radio etc 2011 Marine Engines Manual Programming and Setup 6 3 The ignition switch must be in the proper position Turn ON the ignition with the engine OFF DO NOT change the position of the ignition switch during the programming procedure unless instructed to do so Make certain all tool connections are secure including the following components and circuits The connection at the data link connector DLC The voltage supply circuits DO NOT disturb the tool harnesses while programming If an interruption occurs during the programming procedure programming failure or control module damage may occur DO NOT turn OFF the ignition if the programming procedure is interrupted or unsuccessful Ensure that all control module and DLC connections are secure and the operating software is up to date Attempt to reprogram the control module If the control module cannot be programmed replace the control module 6 4 Vehicle Diagnostic Information Vehicle Diagnostic Information Diagnostic Information an
95. actual state of the control circuit do not match for greater than 5 seconds Action Taken When the SPN Sets SPN 1765 is a Type B SPN Conditions for Clearing the SPN SPN 1765 is a Type B SPN 2011 Marine Engines Manual Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification 1 Ignition ON command the fuel solenoid valve ON and OFF with a scan tool An audible click should be heard when changing between the commanded states 2 Observe the SPN information with a scan tool SPN 1765 3 1765 5 should not set Engine Controls and Fuel Marine 9 109 Circuit System Testing 1 Ignition OFF disconnect the harness connector at the fuel solenoid valve Ignition ON verify a test lamp illuminates between the ignition voltage supply circuit terminal and ground If the test lamp does not illuminate test the ignition circuit for
96. and Fuel Marine Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Special Tools Required J 26792 Spark Tester Circuit System Verification 1 Engine idling verify there is no abnormal engine noise If there is an abnormal engine noise refer to Engine Mechanical for further diagnosis 2 Observe the scan tool SPN information Verify that SPN 636 651 658 65541 65548 65723 7 65724 7 is not set If any of the SPNs are set refer to Diagnostic Trouble Code DTC List on page 6 11 for further diagnosis Note A misfire may occur only when the engine is under a load An engine load may be necessary to verify the condition 3 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Verify the following conditions do not exist Vacuum hose splits kinks and incorrect connections Engine vacuum leaks Crankcase ventilation system for vacuum leaks Fuel pressure that is too low or too high Refer to
97. and free of any foreign material which could impede proper terminal contact Damaged connector body Exposure of terminals to moisture and dirt causing improper terminal orientation with the component or mating connector Improperly formed or damaged terminals Check all connector terminals in problem circuits in order to ensure good contact tension Use a corresponding mating terminal to check for proper tension Refer to Checking Terminal Contact in this section for the specific procedure Poor terminal to wire connection Some conditions which fall under this description are poor crimps poor solder joints crimping over wire insulation rather than the wire itself corrosion in the wire to terminal contact area etc Wire insulation which is rubbed through This causes an intermittent short as the bare area touches other wiring or parts of the vehicle Wiring broken inside the insulation This condition could cause a continuity check to show a good circuit but if only one or two strands of a multi strand type wire are intact resistance could be far too high To avoid any of the above problems when making wiring or terminal repairs always follow the instructions for wiring and terminal repair detailed in Wiring Repairs and Connector Repairs Checking Terminal Contact When diagnosing an electrical system that utilizes Metri Pack 150 280 480 630 series terminals refer to the J 38125 A Terminal Repair Kit or the
98. and the ECM detects a high signal voltage The ECM uses the signal circuit of the fuel level sensor in order to calculate the percentage of remaining fuel in the tank Conditions for Running the SPN SPN 630 65580 65620 or 65621 is not set The ignition is ON for a predetermined time SPNs 38 and 96 run continuously when the conditions above exist Conditions for Setting the SPN 38 3 and 96 3 The ECM detects the fuel sensor voltage is greater than 2 9 volts The above condition is present for greater than 30 seconds 38 4 and 96 4 The ECM detects the fuel sensor voltage is less than 0 39 volts The above condition is present for greater than 30 seconds 2011 Marine Engines Manual Action Taken When the SPN Sets 5 38 and 96 are type C SPNs The fuel gauge defaults to empty if equipped The low fuel indicator illuminates if equipped Conditions for Clearing the SPN SPNs 38 and 96 are type C SPNs Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Description and Operation Fuel System Description on page 9 284 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs
99. approach Diagnostic Procedure Instructions on page 6 5 provide an overview of each diagnostic category SPN Descriptor SPN 84 FMI 1 Vehicle Speed Sensor VSS SPN 84 FMI 2 Vehicle Speed Sensor VSS SPN 84 FMI 3 Vehicle Speed Sensor VSS SPN 84 FMI 4 Vehicle Speed Sensor VSS lt lt lt Circuit System Description The vessel speed is provided to the engine control module ECM by the vehicle speed sensor VSS The sensor is a paddle wheel permanent magnet generator that is usually located through hull or attached to the transom of the vessel The VSS produces a signal whenever the vessel is moving The number of pulses increases with the speed of the vessel The ECM converts this signal into miles per hour MPH which can be monitored with a scan tool The vehicle speed information is used by the ECM for governing the vessels speed during cruise control operation Conditions for Running the SPN 84 1 Before the ECM can report that SPN 84 1 failed SPN 84 3 and 84 4 must run and pass SPN 106 630 65580 65620 65621 65622 or 65623 is not set The engine is operating for greater than a calibrated time The engine speed is greater than a calibrated value The MAP signal is less than a calibrated value The SPN runs continuously when the conditions above exist 2011 Marine Engines Manual The pedal position is less than a calibrated value Engine Controls and Fuel Marine 9 69 Data
100. between relay CRANK verify a test lamp illuminates when terminal 85 and 12 volts Install a jumper wire the ignition is cycled to CRANK between relay terminal 86 and ground If the test lamp does not illuminate test the 5 Test for less than 2 Q between terminals 30 relay control circuit for a short to ground or and 87 an open high resistance If the circuit tests normal replace the ECM If the test lamp is always ON test the relay coil control circuit for a short to voltage If greater than the specified range replace the starter relay If the circuit tests normal replace the ECM Repair Instructions 5 If all circuits test normal test or replace the Perform the Diagnostic Repair Verification on starter relay page 6 22 after completing the diagnostic procedure Engine Control Module Replacement page 9 217 Component Testing for ECM replacement setup and programming 1 Ignition OFF disconnect the starter relay with the J 43244 2 Test for 70 110 Q between terminals 85 and 86 gt If not within the specified range replace the starter relay 2011 Marine Engines Manual 9 164 Engine Controls and Fuel Marine SPN 66003 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on pa
101. cavity until it rests on the cavity shoulder 2011 Marine Engines Manual Wiring Systems 11 27 Note Never use force to remove a terminal from a Repairing Connector Terminals connector Tools Required J 38125 Terminal Repair Kit Use the following repair procedures in order to repair the following Push to Seat terminals Pull to Seat terminals Weather Pack terminals Some terminals do not require all of the steps shown Skip the steps that do not apply for your immediate terminal repair The J 38125 contains further information 1 Cut off the terminal between the core and the insulation crimp Minimize any wire loss For Weather Pack terminals remove the seal 2 Apply the correct seal per gauge size of the wire For Weather Pack terminals slide the seal back along the wire in order to enable insulation removal 3 Remove the insulation 5 Gently pull on the lead 2 to remove the m terminal through the back of the connector 4 For Weather terminals only align the seal with the end of the cable insulation 5 Position the strip in the terminal 1683762 6 Inspect the terminal and connector for damage 7 Repair or replace parts as necessary Refer to Parts Information for availability of For Weather Pack terminals position the strip terminal pigtail or connector body assemblies that and seal in the terminal are serviced separately 6 Hand crimp the core wings 8 Use
102. circuit The ICM also has a ground circuit and shares an ignition 1 voltage supply with the ignition coil The coil driver in the ICM controls current through the ignition coil based on signal pulses from the ECM There is no back up or by pass function in the ICM Secondary Ignition Components High Voltage Switch Distributor The high voltage switch HVS or distributor contains the Camshaft Position CMP Sensor cap rotor and shaft The HVS is splined by a helical gear to the camshaft and rotates providing a spark to each spark plug wire When servicing the HVS it is critical to ensure proper cap sealing to the Distributor body and correct installation to the camshaft If the HVS is installed a tooth off in relation to the camshaft a DTC may set or a misfire will occur Ignition Wires The spark plug wires are a carbon impregnated cord conductor encased in a silicone rubber jacket Silicone wiring will withstand very high temperature and is an excellent insulator for the higher voltages The silicone spark plug boots provide a tight seal on the spark plug Engine Control Module ECM The ECM controls all ignition system functions and constantly corrects the basic spark timing The ECM monitors information from various sensor inputs that include the following The throttle position TP sensor The engine coolant temperature ECT sensor The manifold air temperature MAT sensor The vehicle speed sensor VSS The transmi
103. circuit connections test normal replace the ECM 6 If all the circuit connections test normal test or replace the speed based component Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 9 178 Engine Controls and Fuel Marine SPN 66012 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptor SPN 66012 FMI 3 Trans UpShift Output Voltage Above Normal or Shorted High SPN 66012 FMI 5 Trans UpShift Output Current Below Normal or Open Circuit Diagnostic Fault Information Short to Open High Short to Signal Circuit a Resistance me een Trans Upshift Output Voltage Supply 66012 5 _ Trans Upshift Output Control 66012 3 The fuse that supplies voltage to the device opens Circuit System Description Ignition voltage is supplied to the transmission shift lock out solenoid through a fuse The engine control module ECM turns the solenoid ON or OFF by grounding and ungrounding the control circuit based on engine speed and load The ECM controls the s
104. circuit fuse is open test all components connected to the ignition voltage circuit and replace as necessary Note Set the DMM to the DC 4 volt scale for this test 5 Connect a DMM between the ignition control circuit terminal B and ground 6 Ignition ON verify the voltage is less than 0 050 V If greater than the specified range test the circuit for a short to voltage 7 Engine cranking verify the voltage is greater than 100 mV If less than the specified range test the ignition control circuit for a short to ground or an open high resistance If the circuit tests normal replace the ECM 8 Ignition OFF connect the ICM harness connector Disconnect the harness connector at the ignition coil 2011 Marine Engines Manual 9 Ignition ON that a test lamp illuminates between the ignition voltage circuit terminal A and ground gt If less than the specified range repair the ignition voltage circuit for an open high resistance 10 Connect a test lamp between the coil driver circuit terminal C and B 11 Engine cranking the test lamp should blink If the test lamp remains ON all the time test the ignition control circuit for a short to ground If the circuit tests normal replace the ICM If the test lamp remains OFF all the time test the ignition control circuit for a short to voltage or an open high resistance If the circuit tests normal replace the ICM 12 Ignition OFF connect
105. circuit is shorted to ground or shorted to a voltage other 5 volt reference circuits may be affected Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing 11 6 e Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification 1 Ignition ON observe the SPN information with a scan tool Verify SPNs 65615 65620 65621 65622 or 65623 is not set lf any of the listed SPNs set refer to SPN 65615 65616 or 65618 on page 9 147 or SPN 65620 65623 on page 9 149 2 Observe both TP Sensor percentage parameters while pressing the accelerator pedal from a closed throttle to WOT Both TP Sensor percentage parameters should change 3 Rapidly depress the accelerator pedal from the rest position to the WOT position and release pedal Repeat the procedure several times SPNs 65601 65602 or 65610 should not set 4 Slowly depress the accelerator pedal to WOT and then slowly return the pedal to closed throttle Repeat
106. damage or external leaks before proceeding Verify that adequate fuel is in the fuel tank before proceeding Verify that the low pressure fuel pump is operating if equipped A low pressure pump that is not functioning will cause low fuel pressure The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure 1 Ignition ON command the fuel pump relay ON with a scan tool You should hear the fuel pump turn ON and OFF f the fuel pump does not turn ON refer to Fuel Pump Electrical Circuit Diagnosis on page 9 207 2 Ignition OFF install the J 34730 1A Refer to Fuel Pressure Gauge Installation and Removal on page 9 229 3 Ignition ON command the fuel pump relay ON with a scan tool Verify the fuel pressure is between 380 427 kPa 55 62 psi and remains steady for 5 minutes Circuit System Testing Note The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure DO NOT start the engine 1 Ignition ON command the fuel pump relay ON with a scan tool and observe the fuel pressure gauge while the fuel pump is operating Verify the fuel pressure is between 380 427 kPa 55 62 psi Note It may be necessary to remove the fuel tank If less than the specified range test inspect and repair the items listed below If all items test normal replace the fuel pump Restricted fuel feed pipe
107. dependent upon the proper operation or performance of the System or component under repair Damage to fasteners basic tools or special tools The leakage of coolant lubricant or other vital fluids NOTE or IMPORTANT Defined NOTE and IMPORTANT statements emphasize a necessary characteristic of a diagnostic or repair procedure NOTE or IMPORTANT statements are designed to do the following Clarify a procedure Present additional information for accomplishing a procedure Give insight into the reason or reasons for performing a procedure in the manner recommended Present information that will help to accomplish a procedure in a more effective manner Present information that gives the technician the benefit of past experience in accomplishing a procedure with greater ease Actions to Take When Working with Fuel Warning Warning Fuel Vapors can collect while servicing fuel system components in enclosed areas such as the vessels cabin or engine compartment To reduce the risk of fire and increased exposure to vapors Use forced air ventilation such as a fan set outside of the vessels engine compartment Plug or cap any fuel system openings in order to reduce fuel vapor formation Clean up any spilled fuel immediately Avoid sparks and any source of ignition Use signs to alert others in the work area that fuel system work is in process Batteries Produce Explosive Gases Warning Warning Batteries produce explosive gase
108. e ECM detects the is warmer than The ignition is ON or the engine is operating 170 331 F The SPNs run continuously when the above 175 15 enable condition is met for greater than 2 s The ECM detects the EOT is warmer than a calibrated temperature for greater than 3 seconds 2011 Marine Engines Manual Action Taken When the SPN Sets SPN 175 3 and 175 4 are Type SPNs SPN 175 15 is a type SPN Conditions for Clearing the MIL SPN SPN 175 3 and 175 4 are Type SPNs SPN 175 15 is a type SPN Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification 1 Engine operating observe the SPN information with a scan tool SPN 175 3 175 4 or 175 15 should not set 2 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the condition
109. electric fuel pump operation through a fuel pump relay Fuel Filter The fuel filter is contained in the fuel sender assembly inside the fuel tank The paper filter element of the fuel filter traps particles in the fuel that may damage the fuel injection system The fuel filter housing is made to withstand maximum fuel system pressure exposure to fuel additives and changes in temperature Nylon Fuel Pipes Warning Refer to Fuel Pipe Fitting Warning on page 0 4 Nylon pipes are constructed to withstand maximum fuel system pressure exposure to fuel additives and changes in temperature There are 3 sizes of nylon pipes used 9 5 mm 3 8 in ID for the fuel supply 7 6 mm 5 16 in ID for the fuel return and 12 7 mm 1 2 in ID for the vent Heat resistant rubber hose or corrugated plastic conduit protects the sections of the pipes that are exposed to chafing to high temperatures or to vibration Nylon fuel pipes are somewhat flexible and can be formed around gradual turns under the vehicle However if nylon fuel pipes are forced into sharp bends the pipes kink and restrict the fuel flow Also once exposed to fuel nylon pipes may become stiffer and are more likely to kink if bent too far Take special care when working on a vehicle with nylon fuel pipes 2011 Marine Engines Manual Quick Connect Fittings Quick connect fittings provide a simplified means of installing and connecting fuel system components The fittings c
110. engine speed 4 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Ignition OFF disconnect the harness connector at the CMP sensor 2 Test for less than 5 between the low reference circuit terminal B and ground If greater than the specified range test the low reference circuit for an open high resistance If the circuit tests normal replace the ECM 3 Ignition ON test for 4 8 5 2 V between the 5 volt reference circuit terminal A and ground If less than the specified range test the 5 volt reference circuit for a short to ground or an open high resistance If the circuit tests normal replace the ECM If greater than the specified range test the 5 volt reference circuit for a short to voltage If the circuit tests normal replace the ECM 4 Ignition ON test for 4 8 5 2 V between the signal circuit terminal C and ground If less than the specified range test the signal circuit for a short to ground or an open high resistance If the circuit tests normal replace the ECM greater than the specified range test the signal circuit for a short to voltage If the circuit tests normal replace the ECM 5 If all circuits test normal replace the CMP sensor Repair Instructions Perform the Diagnostic Repair
111. if the circuit is shorted to B 2011 Marine Engines Manual Circuit System Description The pedal position sensor assembly contains 2 pedal position PP sensors The PP sensors provide a signal voltage that changes relative to the pedal angle The engine control module ECM supplies each PP sensor with a 5 volt reference circuit a low reference circuit and signal circuits Both of the PP sensors have positive functionality The PP sensor 1 signal voltage increases from approximately 1 0 volt at idle to greater than 4 volts at wide open throttle WOT While the PP sensor 2 signal voltage increases from approximately 0 5 volts at idle to greater than 2 volts at WOT Conditions for Running the SPN SPN 630 65580 65620 65621 65622 or 65623 is not set The ignition is ON or the engine is operating The ignition voltage is greater than 10 volts SPNs 65604 65605 and 65613 run continuously when the conditions above are met Conditions for Setting the SPN 65604 2 The ECM detects that the PP sensor 2 voltage is less than 0 5 V or greater than 4 5 V for greater than 247 mS 65605 2 The ECM detects that the PP sensor 1 voltage is less than 0 5 V or greater than 4 5 V for greater than 247 mS 65613 2 The ECM detects that the PP sensor 1 and PP sensor 2 values disagree by greater than 8 for greater than 247 mS Action Taken When the SPN Sets SPN 65604 65605 and 65613 type
112. information SPN 66025 should not be set 3 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Ignition OFF disconnect the fuel pump relay 2 with the J 43244 2 Test for less than 5 between the ground circuit terminal 86 and ground If greater than the specified range repair the ground circuit for an open high resistance 3 Connect a test lamp between the relay coil control circuit terminal 85 and ground 4 Ignition ON command the fuel pump relay 2 ON and OFF with a scan tool The test lamp should turn ON and OFF when changing between the commanded states If the test lamp is always ON test the control circuit for a short to voltage If the circuit tests normal replace the ECM If the test lamp is always OFF test the control circuit for a short to ground or an open high resistance If the circuit tests normal replace the ECM 5 f all circuits test normal test or replace the fuel pump relay 2 Component Testing 1 Ignition OFF disconnect the fuel pump relay 2 with the J 43244 2 Test for 70 110 Q between terminals 85 and 86 If not within the specified range replace the relay 3 Test for infinite resistance between the following terminals 30 and 86 30 and 87 30 and 85 85 and 87
113. lamp should illuminate and turn OFF as commanded If the test lamp is always OFF test the control circuit for an open high resistance If the circuit connections test normal replace the ECM 5 Test for 3 0 4 0 V between the control circuit terminal and ground If not within the specified range test the control circuit for a short to voltage If the circuit connections test normal replace the ECM 6 If all the circuit connections test normal test or replace the trans shift solenoid Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 9 180 Engine Controls and Fuel Marine SPN 66013 or 66014 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptor SPN 66013 FMI 3 SPN 66013 FMI 5 SPN 66014 FMI 4 Circuit System Description The Powertrain PT Relay or MEFI relay is controlled by the engine control module ECM depending upon input from the ignition switch Battery positive voltage is supplied to the relay coil and switch When the ignition switch is
114. less than 5 between the ground circuit terminal 86 and ground If greater than the specified range test the ground circuit for an open high resistance 3 Connect a test lamp between the relay coil control circuit terminal 85 and ground 4 Ignition ON command the fuel pump ON and OFF with a scan tool The test lamp should turn ON and OFF when changing between the commanded states If the test lamp is always ON test the control circuit for a short to voltage If the circuit tests normal replace the ECM If the test lamp is always OFF test the control circuit for a short to ground or an open high resistance If the circuit tests normal replace the ECM 5 f all circuits test normal test or replace the fuel pump relay 1 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 183 Component Testing 1 Ignition OFF disconnect the fuel pump relay 1 with the J 43244 2 Test for 70 110 Q between terminals 85 and 86 If not within the specified range replace the fuel pump relay 1 3 Test for infinite resistance between the following terminals 30 and 86 30 and 87 30 and 85 85 and 87 If not within the specified range replace the fuel pump relay 1 4 Install a 20 A fused jumper wire between relay terminal 85 and 12 volts Install a jumper wire between relay terminal 86 and ground Test for less than 2 between terminals 30 and 87 greater than the specified range
115. measures the pressure after the throttle body but before the supercharger Pressure in this area is affected by engine speed throttle opening air temperature and barometric pressure BARO A diaphragm within the SCIP sensor is displaced by the pressure changes that occur from the varying load and operating conditions of the engine The engine control module ECM supplies a regulated 5 volts to the sensor on a 5 volt reference circuit and a ground on a low reference circuit The SCIP sensor provides a signal to the ECM on the SCIP sensor signal circuit relative to pressure changes The ECM converts the signal voltage input to a pressure value Under normal operation the highest pressure that can exist in the supercharge intake manifold is equal to BARO This occurs when the vehicle is operated at wide open throttle WOT or when the ignition is ON while the engine is OFF The lowest manifold pressures occur when the vehicle is idling or decelerating The SCIP can range from 20 30 kPa when pressures are low to as much as BARO when pressures are high The ECM monitors the SCIP sensor signal for pressure outside of the normal range Conditions for Running the SPN 3563 0 Before the ECM can report that SPN 3563 0 failed SPNs 3563 3 3563 4 65601 65602 and 65610 must run and pass SPN 630 65580 65620 65621 65622 or 65623 is not set The throttle angle is less than 25 percent The engine speed is greater than 800 RPM
116. mileage The mileage at which the ECM indicates an oil change is necessary can vary considerably depending on operating conditions The oil life monitor must be reset every time the oil is changed for the oil life system to work properly When the ECM determines the oil life has diminished the ECM will illuminate and or flash an original equipment manufacturer OEM specified lamp to indicate an oil change is necessary The ECM may send oil life data via a CAN message to a monitored sub system that may display an oil life value and or a message to indicate an oil change is necessary Conditions for Running the DTC The engine is operating Conditions for Setting the DTC 65555 1 The detects that the remaining oil life is less than 6 percent 65555 18 The ECM detects that the remaining oil life is less than 20 percent Action Taken When the DTC Sets SPN 65555 is Type A SPN An OEM specified lamp illuminates or flashes OR A OEM specified sub system displays a Change Oil Soon or a Change Oil Now message 2011 Marine Engines Manual Conditions for Clearing the DTC SPN 65555 is a Type A SPN Reference Information SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification 1 Ignition ON observe the SPN information with a scan tool SPN 65555 1 or 65555 18 should not
117. misfiring as the water is applied Weak spark using the J 26792 Spark Tester Refer to Distributor Ignition DI System Diagnosis on page 9 214 or Electronic Ignition System Diagnosis on page 9 215 Items that can cause an engine to run lean or rich Refer to SPN 65565 or 65566 on page 9 125 The crankshaft position CKP sensor for the correct resistance The sensor resistance may be out of range after a hot soak The resistance should be between 460 620 The engine for the following mechanical failures Excessive oil in the combustion chamber or leaking valve seals Incorrect cylinder compression Sticking or leaking valves Worn camshaft lobes Incorrect valve timing Worn rocker arms Broken valve springs Excessive carbon buildup in the combustion chambers Clean the chambers with top engine cleaner Follow the instructions on the can Incorrect engine parts Vacuum hoses for splits or kinks Verify that the routing and connections are correct Knock sensor KS system for excessive spark retard activity Refer to SPN 65550 65551 or 65552 on page 9 115 The exhaust system components for the following Physical damage or possible internal failure The three way catalytic converters for a restriction Electromagnetic interference EMI on the reference circuit can cause a misfire condition You can usually detect EMI with a scan tool by monitori
118. not set The ignition is ON or the engine is operating The ignition voltage is greater than 9 volts The ECM has commanded the fuel pump relay ON and OFF at least once during the ignition cycle SPN 66025 runs continuously once the above conditions are met Conditions for Setting the SPN The ECM detects that the commanded state of the driver and the actual state of the control circuit do not match for greater than 2 seconds Action Taken When the SPN Sets SPN 66025 is a Type B SPN 2011 Marine Engines Manual Conditions for Clearing the SPN SPN 66025 is a Type B SPN Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Special Tools J 43244 Relay Puller Pliers 9 190 Engine Controls and Fuel Marine Circuit System Verification 1 Ignition ON command the fuel pump relay 2 ON and OFF with a scan tool You should hear and feel an audible click 2 Observe the scan tool SPN
119. number or an equivalent part Do not use a replacement part of lesser quality The service procedures we recommend and describe in this service manual are effective methods of performing service and repair Some of the procedures require the use of tools that are designed for specific purposes Accordingly any person who intends to use a replacement part a service procedure or a tool that is not recommended by General Motors must first establish that there is no jeopardy to personal safety or the safe operation of the vehicle This manual contains various Dangers Warnings and Cautions that you must observe carefully in order to reduce the risk of personal injury during service or repair Improper service or repair may damage the vehicle or render the vehicle unsafe These Dangers Warnings and Cautions are not exhaustive General Motors can not possibly warn of all the potentially hazardous consequences of your failure to follow these instructions This manual covers service procedures to vehicles that are equipped with a Supplemental Inflatable Restraint Refer to the Warnings in Dangers Warnings and Cautions in Supplemental Inflatable Restraint Refer to Supplemental Inflatable Restraint component and wiring location views in Supplemental Inflatable Restraint before performing a service on or around Supplemental Inflatable Restraint components or wiring Failure to follow these Dangers Wa
120. of burrs before installing the CKP sensor When installing the CKP sensor ensure the sensor is fully seated and held stationary in the front cover before torquing the hold down bolt A sensor which is not seated may cause erratic operation and false codes to set 2 Install the CKP sensor into the timing cover Caution Refer to Fastener Caution on page 0 5 3 Install the sensor hold down bolt Tighten Tighten the hold down bolt to 8 71 Ib in 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 257 10937 11485 11485 9 258 Engine Controls and Fuel Marine 4 Install the CKP sensor harness connector 5 Connect the negative battery cable 10937 Crankshaft Position Sensor Replacement 6 0 6 2L Removal Procedure Warning Refer to Battery Disconnect Warning on page 0 4 1 Disconnect the negative battery cable 2 Remove the starter 211621 3 Disconnect the crankshaft position CKP sensor electrical connector 56592 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 259 4 Remove the sensor retaining bolt 5 Remove the CKP sensor 55322 Installation Procedure 1 Install the CKP sensor Caution Refer to Fastener Caution on page 0 5 2 Install the CKP sensor retaining bolt Tighten Tighten the CKP sensor to 25 N m 18 lb ft 55322 2011 Marine Engines Manual 9 260 Engine Controls and Fuel Marine 3 Con
121. on the meter Danger Do not leave the test leads plugged into the current input jacks and then attempt a voltage measurement This causes a direct short across the source voltage through the low value resistor inside the digital multimeter and if the meter is not adequately protected can cause injury to the operator Caution Do not leave the test leads plugged into the current input jacks and then attempt a voltage measurement This causes a direct short across the source voltage through the low value resistor inside the digital multimeter and if the meter is not adequately protected can cause extreme damage to the meter and or the circuit To take a current reading 1 Remove the power from the circuit cut or open the circuit and select A 2 Plug the black test probe into the COM input jack and the red test probe into the 10 A input jack 3 Touch the probe tips across the cut or open circuit as shown in the following illustration 4 View the reading being sure to note the unit of measurement Note If the test leads are reversed a sign shows on the meter display Troubleshooting with a Test Lamp Tools Required J 35616 200 12 Volt Un powered Test Lamp Caution Refer to Test Probe Caution on page 0 6 A test lamp can simply and quickly test a low impedance circuit for voltage The J 35616 200 is Micro Pack compatible and comprised of a 12 volt light bulb with an attached pair of leads To properly oper
122. or Shorted High page 9 186 Oxygen Sensor Bank A Sensor 2 Heater SPN 66019 66020 66021 or 66022 on Current Below Normal or Open Circuit page 9 186 2011 Marine Engines Manual Powertrain Relay Contact Voltage Below Shared Low SPN 66013 or 66014 on page 9 180 NM Vehicle Diagnostic Information 6 21 Diagnostic Trouble Code DTC List cont d DTC Descriptor Diagnostic Procedure Note If multiple powertrain SPNs are stored diagnose the SPNs in the following order 1 Component level SPNs such as sensor SPNs solenoid SPNs and relay SPNs 2 System level SPNs such as misfire SPNs and fuel trim SPNs 66021 Oxygen Sensor Bank A Sensor 2 Heater SPN 66019 66020 66021 or 66022 on Abnormal Frequency or Pulse Width page 9 186 66022 Oxygen Sensor Bank B Sensor 2 Heater SPN 66019 66020 66021 or 66022 on Voltage Above Normal or Shorted High page 9 186 66022 Oxygen Sensor Bank B Sensor 2 Heater SPN 66019 66020 66021 or 66022 on Current Below Normal or Open Circuit page 9 186 66022 Oxygen Sensor Bank B Sensor 2 Heater SPN 66019 66020 66021 or 66022 on Abnormal Frequency or Pulse Width page 9 186 Fuel Pump Relay 2 Voltage Below 66025 r Shorted Low SPN 66025 on page 9 189 Fuel Pump Relay 2 Current Below 66025 Normal or Open Circuit SPN 66025 on page 9 189 Shift Interrupt Mechanical System Not 66026 Responding or Out of Adjustment SPN 66026 on page 9 191 Inter
123. provides an overview of each diagnostic category SPN Descriptors SPN 65601 FMI 2 Throttle Position TP Sensor 2 Data Erratic Intermittent or Incorrect SPN 65602 FMI 2 Throttle Position TP Sensor 1 Data Erratic Intermittent or Incorrect SPN 65610 FMI 2 Throttle Position TP Sensor 1 and 2 Data Erratic Intermittent or Incorrect Diagnostic Fault Information Short to High Short to Signal Circuit Ground Resistance Voltage Performance 65601 2 65601 2 65602 2 5 Volt Reference 65623 4 65610 2 65602 2 65605 2 65610 2 65610 2 65613 2 65602 2 65602 2 TP Sensor 1 Signal 65623 4 65610 2 65610 2 65610 2 65610 2 65601 2 65601 2 TP TP Sensor 2 Signal 2 TP Sensor 2 Signal 65623 4 65610 2 65610 2 65610 2 65610 2 65601 2 Low Reference 65610 2 65602 2 65610 2 65610 2 Typical Scan Tool Data TP Sensor 1 and 2 Short to Ground Open Voltage Operating Conditions The ignition is ON and the engine is OFF Parameter Normal Range TP Sensor 1 1 5 volts TP sensor 2 3 5 volts 5 Volt Reference TP 1 0 volts TP 2 TP 1 0 volts TP 2 0 06 5 0 volts Sensor 2 Signal 4 9 volts 4 9 volts 4 9 volts 4 9 volts Circuit System Description The TP sensors have opposite functionality The throttle body assembly contains 2 throttle Ds Sensor 1 signal voltage Lo position TP sensors The TP sensors are mounted to approximately 1 5 volts at idle to above vots the throttle b
124. reuse a terminal or lead assembly refer to Wiring Repairs on page 11 16 2 Ensure that the cable seal is kept on the terminal side of the splice 3 Insert the lead from the back until it catches 4 Install the TPA CPA and or the secondary locks 11 26 Wiring Systems Pull to Seat Connectors Terminal Removal If the terminal is visibly damaged or is suspected of having a faulty connection the terminal should be replaced Follow the steps below in order to repair pull to seat connectors 904718 1 Remove the connector position assurance CPA device and or the secondary lock 2 Disconnect the connector from the component or separate the connectors for in line connectors 3 Remove the terminal position assurance TPA device 4 Insert the proper pick or removal tool into the front of the connector body Note On connectors with more than one terminal the service loop may not be large enough to remove the terminal and crimp on a new one If the terminal wire does not have a large enough service loop for removal cut the wire 5 cm 2 in behind the connector before removal 5 Grasp the wire at the back of the connector body and gently push the terminal 1 out the front of the connector body 3 Terminal Repair 1 If the wire needed to be cut in order to remove the terminal gently push a small length of the same size wire through the back of the connector cavity until there is enough wire exposed in
125. sideways on each boot in order the inspect the seating Reinstall any loose boot 1707122 5 Connect the ignition coil wiring harness electrical connector 1 to the ignition coil 6 Install the intake manifold sight shield 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 243 Ignition Coil Replacement 4 3L 5 0L and 5 7L Removal Procedure 1 Disconnect the negative battery terminal 2 Disconnect the electrical connectors 3 Remove the ignition coil wire to the distributor 31466 4 Remove the studs holding the bracket and the ignition coil to the intake manifold 5 Remove the bracket and the ignition coil 6 Remove the two rivets that connect the ignition coil to the ignition coil bracket by drilling and them out 7 Remove the ignition coil from the bracket 9 244 Engine Controls and Fuel Marine Installation Procedure Ignition Coil Replacement 2 4L Note A replacement ignition coil kit comes with 2 screws in order to attach the ignition coil to the Removal Procedure bracket 1 Disconnect the ignition coil electrical 1 Install the ignition coil to the bracket with the connector s 3 2 screws Caution Refer to Component Fastener Tightening Caution on page 0 5 1578474 2 Remove the ignition coil bolt s 3 Remove the ignition coil s 31466 2 Install the ignition coil and the bracket to the d intake manifold with studs nstallation Proc
126. solenoid valve the fuel solenoid valve 2 Test for less than 5 between the low reference Repair Instructions circuit terminal and ground Perform the Diagnostic Repair Verification on If greater than the specified range test the low page 6 22 after completing the diagnostic procedure reference circuit for an open high resistance Engine Control Module Replacement on page 9 217 If the circuit tests normal replace the ECM for ECM replacement setup and programming 2011 Marine Engines Manual 9 108 Engine Controls and Fuel Marine SPN 1765 Low Side Driver Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptor SPN 1765 FMI 3 SPN 1765 5 Fuel Valve Low Side Driver Voltage Above Normal or Shorted High Fuel Valve Low Side Driver Current Below Normal or Open Circuit Diagnostic Fault Information Short to Open High Short to Signal Circuit a Resistance me een Fuel Solenoid Valve Voltage Supply 17655 Fuel Solenoid Valve Voltage Control The fuse that supplies voltage to the device opens Circuit System Description 1765 5 The fuel solenoid valve allows the engine control SPN 630 65580 6562
127. specified range replace the relay 3 Test for infinite resistance between the following terminals 30 and 86 30 and 87 30 and 85 85 and 87 If not the specified value replace the relay 4 Install a 20A fused jumper wire between relay terminal 85 and 12 volts Install a jumper wire between relay terminal 86 and ground Test for less than 2 between terminals 30 and 87 greater than the specified range replace the relay Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Replacement Fuse Block on page 11 28 or Replacement Harness on page 11 29 Engine Control Module Programming and Setup on page 6 3 for engine control module replacement setup and programming Fuel System Diagnosis with Returnless Fuel System Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category Circuit System Description When the ignition switch is turned ON the engine control module ECM supplies power to the fuel pump s by energizing the fuel pump relay The fuel pump remains ON as long as the engine is cranking or running and the ECM receives
128. system to operate in a reduced engine power mode Conditions for Clearing the SPN SPN 65620 65621 65622 and 65623 are Type A SPNs Diagnostic Aids If a shared 5 volt reference circuit is shorted to ground or shorted to a voltage other 5 volt reference circuits may be affected 2011 Marine Engines Manual 65620 4 The 5 volt reference A circuit provides 5 volts to the following sensors The barometric pressure BARO sensor The camshaft position CMP sensor s The engine oil pressure EOP sensor The variable governor control sensor 65621 4 The 5 volt reference B circuit provides 5 volts to the following sensors The crankshaft position CKP sensor The supercharger inlet pressure SCIP sensor The vehicle speed VSS sensor The general warning sensor 1 The general warning sensor 2 65622 4 The 5 volt reference C circuit provides 5 volts to the following sensors The manifold absolute pressure MAP sensor The accelerator pedal position APP sensor 2 65623 4 The 5 volt reference D circuit provides 5 volts to the following sensors The throttle position TP sensor 1 The throttle position TP sensor 2 The accelerator pedal position APP sensor 1 9 150 Engine Controls and Fuel Marine Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30
129. the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Ignition OFF disconnect the harness connector at the ignition control module ICM or the appropriate ignition coil 2 Test for less than 5 between the ground circuit terminal listed below and ground ICM Terminal C 3 0 4 3 5 0 5 7L Coil Terminals and B 2 2 4 6 0 6 2L gt If greater than the specified range repair the ground circuit for an open high resistance 2 4 6 0 6 2L If the EST return circuit terminal B 2 is greater than the specified range test for an open high resistance if the circuit tests normal replace the ECM 3 Ignition ON verify that a test lamp illuminates between the ignition voltage circuit terminal listed below and ground ICM Terminal 3 0 4 3 5 0 5 7L Coil Terminal D 4 2 4 6 0 6 2L gt If the test lamp does not illuminate test the ignition voltage circuit for a short to ground or an open high resistance If the circuit tests normal and the ignition voltage circuit fuse is open test all components connected to the ignition voltage circuit and replace as necessary Note Set the DMM to the DC 4 volt scale for this test 4 Connect a DMM between the appropriate ignition control circuit terminal listed below and ground ICM Terminal B 3
130. the ECM If greater than the specified range test the appropriate 5 volt reference circuit for a short to voltage If the circuit tests normal replace the ECM Observe the scan tool PP sensor 1 and PP sensor 2 voltage parameters Both parameters should display less than 1 volt If greater than the specified range test the appropriate signal circuit listed below for a short to voltage If the circuit tests normal replace the ECM PP sensor 1 signal circuit terminal PP sensor 2 signal circuit terminal 5 Connect a 3 fused jumper wire between PP sensor 1 signal circuit terminal B and the 5 volt reference circuit terminal A Verify the scan tool PP sensor 1 voltage parameter is greater than 4 89 V If less than the specified range test the signal circuit for a short to ground or an open high resistance If the circuit tests normal replace the ECM 6 Connect a fused jumper wire between PP sensor 2 signal circuit terminal E and the 5 volt reference circuit terminal F Verify the scan tool PP sensor 2 voltage parameter is greater than 4 89 V If less than the specified range test the signal circuit for an open high resistance or for a short to ground If the circuit tests normal replace the ECM 7 f all circuits test normal test or replace the pedal position sensor Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic proced
131. the ECM commands the battery saver mode During the battery saver mode the TAC module removes the voltage from the motor control circuits which removes the current draw used to maintain the idle position and allows the throttle to return to the spring loaded default position Reduced Engine Power Mode When the ECM detects a condition with the TAC system the ECM may enter a reduced engine power mode Reduced engine power may cause one or more of the following conditions Acceleration limiting The ECM will continue to use the accelerator pedal for throttle control however the vehicle acceleration is limited Limited throttle mode The will continue to use the accelerator pedal for throttle control however the maximum throttle opening is limited Throttle default mode The ECM will turn off the throttle actuator motor and the throttle will return to the spring loaded default position Forced idle mode The will perform the following actions Limit engine speed to idle by positioning the throttle position or by controlling the fuel and spark if the throttle is turned off Ignore the accelerator pedal input Engine shutdown mode The will disable fuel and de energize the throttle actuator 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 281 Camshaft Actuator System Description Camshaft Position CMP Actuator System Crankshaft Position Sensor Camshaft Camshaft
132. the J 34730 1A for one minute The fuel pressure should not decrease more than 34 kPa 5 psi If the fuel pressure decreases greater than 34 kPa 5 psi refer to Fuel System Diagnosis with Returnless Fuel System on page 9 208 or Fuel System Diagnosis without Returnless Fuel System on page 9 210 U If the fuel system tests OK perform the Fuel Injector Balance Test with Special Tool or the Fuel Injector Balance Test with Scan Tool Fuel Injector Balance Test with Special Tool 1 Install a J 34730 refer to Fuel System Diagnosis with Returnless Fuel System on page 9 208 or Fuel System Diagnosis without Returnless Fuel System on page 9 210 2 Set the amperage supply selector switch on the fuel injector tester to the Balance Test 0 5 2 5 amp position 3 Connect the J 39021 to a fuel injector with a J 44602 4 Command the fuel pump relay ON and then OFF three times with a scan tool On the last command as the fuel pressure begins to slowly degrade and stabilize select a fuel pressure within 34 kPa 5 psi of the maximum pump pressure Record this fuel pressure This is the starting pressure at which you will pulse each injector Caution Refer to Fuel Injector Balance Test Caution on page 0 5 5 Command the fuel pump relay ON and energize the fuel injector by depressing the Push to Start Test button on the J 39021 at the previously selected pressure Note The fuel pressure may rise after the fuel inject
133. the Weather Pack pick 1 to reform the 7 Hand crimp the insulation wings male lock tang 2 or the female lock tang 3 For Weather Pack terminals hand crimp the 9 Re seat the terminal in the connector body insulation wings around the seal and the cable 8 Solder all of the hand crimp terminals excepting Micro Pack 100 World terminals Soldering Micro Pack 100 World terminals may damage the terminal 1683763 10 Close the secondary lock and reinstall the connector to the component or mating connector 2011 Marine Engines Manual 11 28 Wiring Systems Repair Instructions Relay Replacement Fuse Block Notice Use J43244 to pull the relay straight out from the electrical center terminals The use of pliers or Tools Required a flat bladed tool could damage the electrical center J 43244 Relay Puller Pliers 4 Remove the relay 2 from the electrical center Removal Procedure Installation Procedure 1 Remove the electrical center cover 2 Locate the relay Note Always note the orientation of the relay Ensure that the electrical center is secure as not to put added stress on the wires or terminals 786629 1 Install the relay 2 in the same position as removed 2 Install the electrical center cover 786629 3 Using the J 43244 1 position the tool on opposing corners of the relay 2 2011 Marine Engines Manual Relay Replacement Harness Removal Procedure 1 Locate the re
134. the engine is running and the fuel pump relay is Fuel Pump 1 Relay Override commanded OFF the engine will stall This output can also be monitored on the scan tool data parameter Fuel Pump Relay Command The system remains in the commanded state until cancelled by the scan tool or the ECM 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 63 Engine Control Module ECM Scan Tool Output Controls cont d Description This function controls the fuel pump 2 relay When commanded ON OFF the ECM turns the fuel pump relay ON OFF If the engine is running and the fuel pump relay is Fuel Pump 2 Relay Override commanded OFF the engine will stall This output can also be monitored on the scan tool data parameter Fuel Pump Relay Command The system remains in the commanded state until cancelled by the scan tool or the ECM This function controls the respective fuel control circuit if used The normal commanded Fuel Select Output 1 or 2 state is None When commanded ON the ECM will command the control circuit ON and OFF This function controls the idle speed override from the base idle speed The scan tool initiates the test when the following conditions are met Idle Speed Override The transmission is in neutral The engine speed is less than 1 000 RPM The engine speed will remain in the commanded state until cancelled by the scan tool This function activates the intercooler coolant pump relay The normal comm
135. the ignition coil harness connector Disconnect the ignition coil wire from the distributor cap Connect the J 26792 between the boot of the coil wire and ground 13 Engine cranking the spark tester should spark gt If the spark tester does not spark test the coil wire for an open high resistance If the coil wire tests normal replace the ignition coil 14 Ignition OFF remove the distributor cap 15 Engine cranking verify the distributor rotor is rotating If the distributor rotor does not rotate repair the engine mechanical condition 16 If all circuits test normal inspect and replace the distributor cap and rotor Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Ignition Coil Replacement 3 0L on page 9 241 or Ignition Coil Replacement 6 0L and 6 2L on page 9 242 or Ignition Coil Replacement 4 3L 5 0L and 5 7L on page 9 243 or Ignition Coil Replacement 2 4L on page 9 244 Spark Plug Wire Inspection on page 9 245 Engine Control Module Programming and Setup on page 6 3 for ECM replacement setup and programming Electronic Ignition System Diagnosis Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis page 6 4 for an overview of the diagnostic approach Diagnostic Procedure In
136. the procedure several times SPNs 65601 65602 or 65610 should not set 5 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data 2011 Marine Engines Manual Circuit System Testing 1 2 Ignition OFF disconnect the harness connector at the throttle body assembly Ignition OFF test for less than 5 Q between the low reference circuit terminal C and ground If greater than the specified range test the low reference circuit for a short to voltage or an open high resistance If the circuit tests normal replace the ECM lgnition ON test for 4 8 5 2 V between the 5 volt reference circuit terminal E and ground lf less than the specified range test the 5 volt reference circuit for an open high resistance If the circuit tests normal replace the ECM If greater than the specified range test the 5 volt reference circuit for a short to voltage If the circuit tests normal replace the ECM Verify the following scan tool parameters TP sensor 1 0 0 V TP sensor 2 4 9 V lf less than the specified range test the appropriate signal circuit for a short to ground If the circuit tests normal replace the ECM If greater than the specified range test the appropriate signal circuit for a short to voltage If the circuit tests normal replace th
137. the test lamp does not illuminate gt If the test lamp illuminates test the control circuit for a short to ground If the circuit tests normal replace the ECM Note The heater control circuit is pulled up to a voltage within the controller 3 4 volts measured on this circuit is normal 4 5 Command the heater control circuit for the appropriate HO2S with a scan tool Verify the test lamp illuminates and turns OFF as commanded If the test lamp is always OFF test the control circuit for a short to voltage or an open high resistance If the circuit tests normal replace the ECM If all circuits test normal test or replace the HO2S Component Testing 1 Ignition OFF disconnect the harness connector at the HO2S Test for 4 8 between the ignition voltage circuit terminal D and the control circuit terminal C If not within the specified range replace the HO2S Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Heated Oxygen Sensor Heplacement on page 9 226 Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 189 SPN 66025 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Dia
138. to WOT Both PP Sensor percentage parameters should change 4 Rapidly depress the accelerator pedal from the rest position to the WOT position and release pedal Repeat the procedure several times SPNs 65604 65605 or 65613 should not set 5 Slowly depress the accelerator pedal to WOT and then slowly return the pedal to closed pedal Repeat the procedure several times SPN 65604 65605 or 65613 should not set 6 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data 9 146 Engine Controls and Fuel Marine Circuit System Testing 1 2 Ignition OFF disconnect the harness connector at the pedal position sensor assembly Test for less than 5 between the following low reference circuit terminals and ground PP sensor 1 terminal PP sensor 2 terminal If greater than the specified range test the appropriate low reference circuit for a short to voltage or an open high resistance If the circuit tests normal replace the ECM Ignition ON test for 4 8 5 2 V between the appropriate 5 volt reference circuit terminal and ground PP sensor 1 terminal PP sensor 2 terminal If less than the specified range test the appropriate 5 volt reference circuit for a short to ground or open high resistance If the circuit tests normal replace
139. tools Fastener should be hand tightened fully seated and not stripped Fuel Injector Balance Test Caution Caution Do Not repeat any portion of this test before running the engine in order to prevent the engine from flooding Fuel Pressure Caution Caution Do not allow the fuel pressure to exceed the specified value because damage to the fuel pressure regulator or the fuel pressure gauge may result Fuel Rail Caution Caution Use care when servicing the fuel system components especially the fuel injector electrical connectors the fuel injector tips and the injector O rings Plug the inlet and the outlet ports of the fuel rail in order to prevent contamination Do not use compressed air to clean the fuel rail assembly as this may damage the fuel rail components Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to the fuel rail assembly Handling Electrostatic Discharge Sensitive Parts Caution Caution Electrostatic discharge ESD can damage many solid state electrical components ESD susceptible components may or may not be labeled with the ESD symbol Handle all electrical components carefully Use the following precautions in order to avoid ESD damage Touch a metal ground point in order to remove your body s static charge before servicing any electronic component especially after sliding across the vehicle seat Do not touch exposed terminals Terminals may connect to cir
140. within the specified range replace the relay 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 205 3 Test for infinite resistance between the following terminals 30 and 86 30 and 87 30 and 85 85 and 87 If not within the specified range replace the relay 4 Install a 20 A fused jumper wire between relay terminal 85 and Install a jumper wire between relay terminal 86 and ground Test for less than 2 between terminals 30 and 87 greater than the specified range replace the relay Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Relay Replacement Fuse Block on page 11 28 or Replacement Harness page 11 29 Engine Control Module Programming and Setup on page 6 3 for engine control module replacement setup and programming Boost Control System Diagnosis Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category Circuit Description Supercharger boost pressure is regulated under certain conditions to prevent engine and drive train damage The ECM controls boost pressure by a pulse width modulated ground
141. 0 65621 65622 or 65623 is module ECM to control the amount of gaseous fuel not set entering the throttle body while the engine is cranking or operating The fuel solenoid valve is pulse width modulated PWM The ECM controls the fuel solenoid valve duty cycle by controlling the amount of solenoid valve ON time The fuel solenoid valve increases or decreases the amount of gaseous fuel entering the engine based on inputs to the ECM from the HO2S TPS and MAP sensors Ignition voltage is supplied directly to the fuel solenoid valve through a fuse The ECM controls the solenoid by grounding the control circuit with a solid state device called a driver The driver is equipped with a feedback circuit that is pulled up to a voltage The ECM can determine if the control circuit is open shorted to ground or shorted to a voltage by monitoring the feedback voltage Conditions for Running the SPN 1765 3 SPN 630 65580 65620 65621 65622 or 65623 is not set The ignition is ON or the engine is operating The ignition voltage is between 10 16 volts The fuel valve is commanded ON SPN 1765 runs continuously once the above conditions are met The ignition is ON or the engine is operating The ignition voltage is between 10 16 volts The fuel valve is commanded OFF SPN 1765 runs continuously once the above conditions are met Conditions for Setting the SPN The ECM detects that the commanded state of the driver and the
142. 0 0 when an SPN sets 3 Ignition ON rapidly move the accelerator from the closed throttle position to the wide open throttle WOT position and return to the closed throttle Repeat the procedure several times 4 Slowly move the accelerator to WOT and then slowly return to closed throttle Repeat the procedure several times 5 Observe the information with a scan tool Verify SPN 65615 65616 or 65618 is not set 6 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing Warning Turn OFF the ignition before inserting fingers into the throttle bore Unexpected movement of the throttle blade could cause personal injury 1 Ignition OFF inspect the throttle body for the following conditions A throttle blade that is not in the rest position A throttle valve that is binding open or closed A throttle valve that opens or closes without spring pressure If any condition is found replace the throttle body assembly Note Disconnecting the throttle body harness connector may cause additional SPNs to set 2 Ignition OFF disconnect the harness connector at the throttle body assembly 3 Connect a test lamp between the ETC Motor Control Closed circuit terminal A and ground 4 Ignition ON verify that the test lamp flashes onc
143. 0 kPa for greater than 2 seconds 106 1 The ECM detects that the MAP sensor signal is less than 20 kPa for greater than 2 seconds 106 2 The ECM detects that the MAP sensor does not correlate with the BARO sensor and the SCIP sensor at ignition ON for greater than 2 seconds 106 3 The ECM detects that the MAP sensor voltage is greater than 4 8 V for greater than 4 seconds 106 4 The ECM detects that the MAP sensor voltage is less than 0 25 V for greater than 4 seconds 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 87 Action Taken When the SPN Sets 106 is a Type B SPN The ECM operates with a default MAP reading which varies based on throttle angle Super charger boost is disabled Camshaft actuator not enabled Conditions for Clearing the SPN SPN 106 is a Type B SPN Diagnostic Aids If a shared 5 volt reference circuit is shorted to ground or shorted to a voltage other 5 volt reference circuits may be affected Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Numb
144. 0 lb ft 4376 2211673 3 Guide the distributor into the engine 2211673 Install the distributor cap 2011 Marine Engines Manual 9 250 Engine Controls and Fuel Marine 7 Install new distributor cap screws 6 Tighten Tighten the screws to 2 4 N m 21 Ib in T 8 Install the harness connector to the distributor 9 Install the spark plug wires to the distributor cap Perform the Cam Retard Offset procedure Refer to Camshaft Retard Offset Adjustment 8 0L and 4 3L on page 9 255 or Camshaft Retard Offset Adjustment 5 0L and 5 7L on page 9 255 Installation Procedure 2 1 Rotate the engine to number 1 cylinder Top Dead Center TDC of the compression stroke 2 Align the rotor segment with the number 1 tower on the distributor cap 3 With a long screw driver align the oil pump drive shaft to the drive tab of the distributor Notice The ignition system distributor driven gear and rotor may be installed in multiple positions In order to avoid mistakes mark the distributor on the following components in order to ensure the same mounting position upon reassembly The distributor driven gear The distributor shaft The rotor holes Installing the driven gear 180 degrees out of alignment or locating the rotor in the wrong holes will cause a no start condition Premature engine wear or damage may result 4 Rotate the rotor segment approximately 30 degrees counter clockwise 22
145. 0 on 9 141 65604 PPS 2 Data Erratic Intermittent or SPN 65604 65605 or 65613 on page 9 144 Misfire Cylinder 6 Mechanical System SPN 65590 65591 65592 65593 65594 65595 Not Responding or Out of Adjustment 65596 65597 65598 or 65599 on page 9 139 65605 1 Data Erratic Intermittent or SPN 65604 65605 or 65613 on page 9 144 65592 Misfire Cylinder 2 Mechanical System SPN 65590 65591 65592 65593 65594 65595 Not Responding or Out of Adjustment 65596 65597 65598 or 65599 on page 9 139 ETC TPS 1 2 Data Erratic Intermittent 65610 or Incorrect SPN 65601 65602 or 65610 on page 9 141 ETC PPS 1 2 Data Erratic Intermittent 65613 or Inc rrect SPN 65604 65605 or 65613 on page 9 144 2011 Marine Engines Manual 7 2 2 2 2 3 5 3 5 7 7 7 74 7 7 7 7 7 7 2 2 2 2 2 2 6 18 Vehicle Diagnostic Information Diagnostic Trouble Code DTC List cont d SN FM DTC Descriptor Diagnostic Procedure Note If multiple powertrain SPNs are stored diagnose the SPNs in the following order 1 Component level SPNs such as sensor SPNs solenoid SPNs and relay SPNs 2 System level SPNs such as misfire SPNs and fuel trim SPNs 65702 General Warning 2 Not Available SPN 65701 or 65702 on page 9 155 65710 Emergency Stop Warning Not Available SPN 65710 on page 9 157 SPN 65723 65724 65725 or 65726 3 0 4 3 5 0 5 7L on page 9 158 65723 2 6
146. 008 4 sas reset ge ee tede 9 164 SPN 105 3 0L 4 3L 5 0L 5 7L 9 79 SPIN 66004 9 166 SPN 105 2 4L 6 0L 6 2L 9 81 SPIN 66005 1 2 9 168 SPN 106 3 0L 4 3L 5 0L 5 7L 9 83 OPN 66007 9 170 SPN 106 2 4L 6 01 6 2L 9 86 SPN 66006 66008 6609 9 172 SPIN 108 seers 9 89 SPIN 66010 9 174 9 91 SPN BOOT 9 176 SPN 9 94 SPN 66012 9 178 SPN 175 RR 9 96 SPN 66013 or 66014 9 180 m PCT 9 98 SPN 66017 b bitum 9 182 SPN 630 65580 65581 or 65582 9 99 OPN 66018 ere ree 9 184 SPN 636 3 0L 4 3L 5 0L 5 7L 9 100 SPN 66019 66020 66021 or 66022 9 186 SPN 636 6 0L 6 2L 9 102 OPN O60 Mea ise nente 9 189 SPN 651 652 653 654 655 656 SPN 66026 diets xii e oed 9 191 657 Or 658 9 104 SPN C6080 9 193 SPN 1765 High Side Driver 9 106 SPN 6803b tete ie 9 195 SPN 1765 Low Side Driver 9 108 SPN 66040 66043 9 198 SPN 3563 9 110 Symptoms Engine Controls
147. 1 signal voltage at closed throttle is approximately 1 5 volts and increases to greater than 4 volts as the throttle plate is opened The TP sensor 2 signal voltage at closed throttle is approximately 3 5 volts and decreases to less than 1 volt as the throttle plate is opened Engine Control Module The engine control module ECM is the control center for the throttle actuator control TAC system The ECM determines the drivers intent and then calculates the appropriate throttle response The ECM achieves throttle positioning by providing a pulse width modulated voltage to the TAC motor Modes of Operation Normal Mode During the operation of the throttle actuator control TAC system several modes or functions are considered normal The following modes may be entered during normal operation Minimum pedal value At key up the engine control module ECM updates the learned minimum pedal value Minimum throttle position TP values At key up the ECM updates the learned minimum TP value In order to learn the minimum TP value the throttle blade is moved to the closed position break the throttle is not able to reach a predetermined minimum throttle position the ice break mode is entered During the ice break mode the ECM commands the maximum pulse width several times to the throttle actuator motor in the closing direction Battery saver a predetermined time without engine RPM
148. 106 0 106 1 Low Reference __ 105 3 106 0 106 1 Internal ECM damage may occur if the circuit is shorted to B Typical Scan Tool Data MAP Sensor Short to Ground Open Short to Voltage Operating Conditions Engine operating in Closed Loop Parameter Normal Range 30 48 kPa MAP Sensor Signal 4 9 volts LwReeeme mws Internal ECM damage may occur if the circuit is shorted to B Circuit System Description Conditions for Running the SPN The manifold absolute pressure MAP sensor 106 0 responds to pressure changes in the intake manifold The pressure changes occur based on the engine load Before the ECM can report that SPN 106 0 or The engine control module ECM supplies 5 volts 106 1 failed SPNs 100 3 100 4 65604 to the MAP sensor on the 5 volt reference circuit 65605 65610 65613 65615 65616 and 65618 The ECM provides a ground on the low reference must run and pass circuit The MAP sensor provides a signal to the ECM on the MAP sensor signal circuit which is relative to the pressure changes in the manifold The ECM detects low signal voltage at a low MAP such as during an idle or a deceleration The ECM detects a high signal voltage at a high MAP such as the ignition is ON with the engine OFF or at a wide open throttle WOT The MAP sensor is also used to determine the barometric pressure BARO This occurs when the ignition switch The SPN runs continuously once th
149. 106 3 65604 2 5 Volt Reference 65622 4 106 4 65613 2 106 0 106 1 MAP Sensor Signal 106 4 106 4 106 3 106 0 106 1 Low Reference 1053 1063 106 0 106 1 Internal ECM damage may occur if the circuit is shorted to B Typical Scan Tool Data MAP Sensor Short to Ground Open Short to Voltage Operating Conditions Engine operating in Closed Loop Parameter Normal Range 30 48 kPa Internal ECM damage may occur if the circuit is shorted to B Circuit System Description in the manifold The ECM detects a low signal voltage The manifold absolute pressure MAP sensor responds to pressure changes in the intake manifold The pressure changes occur based on the engine load The engine control module ECM supplies 5 volts to the MAP sensor on the 5 volt reference circuit The ECM provides a ground on the low reference circuit that is shared with the manifold air temperature MAT sensor which is a part of the MAP sensor The MAP sensor provides a signal to the ECM on the MAP sensor signal circuit which is relative to the pressure changes 2011 Marine Engines Manual at a low MAP such as during an idle or a deceleration The ECM detects a high signal voltage at a high MAP such as the ignition is ON with the engine OFF or ata wide open throttle WOT On some engine applications the MAP sensor is also used to determine the barometric pressure BARO This occurs when the igniti
150. 11 Power and Signal Distribution Data Communications 11 3 Testing for Intermittent Conditions and Diagnostic Information and Procedures 11 3 Poor Connections 11 13 Scan Tool Does Not Power 11 3 Inducing Intermittent Fault Conditions 11 14 Scan Tool Does Not Communicate with Testing for Electrical Intermittents 11 15 Device 11 4 Circuit Protection Fuses 11 15 Description and Operation 11 5 Circuit Protection Circuit Breakers 11 16 Data Link Communications Description Circuit Protection Fusible Links 11 16 and Operation 11 5 Wiring Repairs 11 16 Wiring Systems 11 6 Flat Wire Repairs 11 17 Diagnostic Information and Procedures 11 6 Heated Oxygen Sensor Wiring Repairs 11 17 General Electrical Diagnosis 11 6 Splicing Copper Wire Using Splice Checking Aftermarket Accessories 11 6 Clips uS 11 17 Circuit TES NG 11 6 S E R Wire Using Splice t4 Using Connector Test Adapters 11 6 ss m cee E Probing Electrical Connectors 11 6 a M eset Shielded
151. 11 Marine Engines Manual Engine Controls and Fuel Marine 9 105 Circuit System Testing 1 Ignition OFF disconnect the harness connector at the appropriate fuel injector 2 Ignition ON verify that a test lamp illuminates between the ignition voltage circuit terminal A 1 and ground gt If the test lamp does not illuminate repair the ignition voltage circuit for a short to ground or an open high resistance Replace the fuse if necessary 3 Ignition OFF connect the J 34730 405 between the control circuit terminal B 2 and the ignition voltage circuit terminal A 1 of the appropriate fuel injector 4 Engine idling the test lamp should flash lf the test lamp is always ON test the control circuit for a short to ground If the circuit tests normal replace the engine control module ECM If the test lamp is always OFF test the control circuit for a short to voltage or an open high resistance If the circuit tests normal replace the ECM 5 If all circuits test normal test or replace the fuel injector Component Testing Refer to Fuel Injector Diagnosis on page 9 211 for component testing Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Fuel Injector Replacement Except 2 4L on page 9 238 or Fuel Injector Replacement 2 4L on page 9 240 Engine Control Module Replacement on page 9 217 for engine control module replacement se
152. 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 2011 Marine Engines Manual Circuit System Verification 1 Ignition ON command the buzzer ON and OFF with a scan tool The buzzer should turn ON and OFF 2 Observe the SPN information with a scan tool SPN 66007 should not set 3 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Ignition ON verify that no other indicators are inoperative If any other indicators are inoperative repair the ignition supply voltage circuit 2 Ignition OFF disconnect the ECM harness connector X1 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 171 3 Ignition ON the buzzer should not sound If the buzzer sounds test the buzzer control circuit for a short to ground 4 Ignition ON connect a 3 A fused jumper wire between the buzzer control circuit terminal 1 54 and ground The buzzer should sound gt If the buzzer does not sound test the buzzer control circuit for a short to voltage or an open high resist
153. 11673 5 Guide the distributor into the engine 10 11 12 While the distributor is being installed observe the rotor moving in a clockwise direction With the distributor fully seated the rotor segment should be aligned with the number 1 tower on the distributor cap lf the rotor segment does not come within a few degrees of the tower the gear mesh between the distributor and the camshaft may be off one tooth or more Repeat the procedure again in order to achieve proper alignment Caution Refer to Component Fastener Tightening Caution on page 0 5 8 Install the distributor hold down and hold down bolt Tighten Tighten the distributor clamp bolt to 27 N m 20 Ib ft 2211673 Install the distributor cap Tighten Tighten the screws to 2 4 N m 21 Ib in Install the harness connector to the distributor Install the spark plug wires to the distributor cap Perform the Cam Retard Offset Procedure Refer to Camshaft Retard Offset Adjustment 3 0L and 4 3L on page 9 255 or Camshaft Retard Offset Adjustment 5 0L and 5 7L on page 9 255 2011 Marine Engines Manual Engine Controls Fuel Marine 9 251 Distributor Replacement 4 3L 5 0L 5 8L Removal Procedure Note There are two procedures available to install the distributor Use Installation Procedure 1 when the crankshaft has not been rotated from the original position Use Installation Procedure 2 when any of the following
154. 16 in of insulation from each wire to be spliced 1 5 Select the proper splice sleeve 2 and the required crimp nest tool refer to the Crimp and Seal Splice Table 6 Place the nest tool in the J 38125 crimp tool 7 Place the splice sleeve in the crimp tool nest so that the crimp falls at point 1 on the splice 8 Close the hand crimper handles slightly in order to hold the splice sleeve firmly in the proper crimp tool nest 9 Insert the wires into the splice sleeve until the wire hits the barrel stop The splice sleeve has a stop in the middle of the barrel in order to prevent the wire from passing through the splice 3 10 Close the handles of the J 38125 until the crimper handles open when released The crimper handles will not open until the proper amount of pressure is applied to the splice sleeve 11 Shrink the insulation around the splice Using the heat torch apply heat to the crimped area of the barrel Gradually move the heat barrel to the open end of the tubing The tubing will shrink completely as the heat is moved along the insulation A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved 11 22 Wiring Systems Splicing Twisted or Shielded Cable Step 3 Reassemble the Cable 1 Re wrap the conductors with the mylar tape taking care not to wrap the drain wire 1 in the tape Note Apply the mylar tape with the aluminum side inward to en
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156. 2011 Marine Engines Manual 7 Test for 5 0 9 0 between the control circuit terminal D and the low reference circuit terminal E gt lf less than the specified range test for a short between the control circuit and the low reference circuit If the circuits connections test normal test or replace the Camshaft Position Actuator Magnet If greater than the specified range test the control circuit and the low reference for an open high resistance If the circuits connections test normal test or replace the Camshaft Position Actuator Magnet 8 Remove the Camshaft Position Actuator Magnet Perform the Camshaft Position Actuator Magnet Cleaning and Inspection on page 9 275 The Camshaft Position Actuator Magnet should pass the inspection If the inspection fails replace the Camshaft Position Actuator Magnet 9 Perform the Camshaft Position Actuator Solenoid Valve Inspection on page 9 276 The Camshaft Position Actuator Solenoid Valve should pass the inspection If the inspection fails replace the Camshaft Position Actuator Solenoid Valve 10 If all circuits and components test normal replace the mechanical Camshaft Position Actuator Component Testing Static Test 1 Ignition OFF remove the Camshaft Position Actuator Magnet 2 Test for 5 0 9 0 between the solenoid control terminal 2 and the low reference terminal 1 at the Camshaft Position Actuator Magnet gt If not within the specified range
157. 22 or 65623 voltage A FP sensor fault code may cause an engine is not set speed reduction to occur on vessels with certain engine TREE applications The ignition is ON or engine is operating The fuel pump is commanded ON The desired fuel pressure is stable within 5 kPa 0 7 PSI SPN 94 runs continuously when the above conditions are met for greater than 10 seconds 2011 Marine Engines Manual 9 72 Engine Controls and Fuel Marine Conditions for Setting the SPN 94 3 The ECM detects that the FP sensor voltage is greater than 4 8 volts for greater than 1 3 seconds 94 4 The ECM detects that the FP sensor voltage is less than 0 25 volt for greater than 1 3 seconds 94 15 17 The ECM detects that the actual fuel pressure is 40 kPa 6 PSI of the desired fuel pressure for greater than 10 seconds Action Taken When the SPN Sets SPN 94 is a Type B SPN Conditions for Clearing the SPN SPN 94 is a Type B SPN Diagnostic Aids If a shared 5 volt reference circuit is shorted to ground or shorted to a voltage other 5 volt reference circuits may be affected Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22
158. 23 is not set e The ignition is ON or the engine is operating SPN 65616 runs continuously when the above conditions are met 65618 7 Before the ECM can report that SPN 65618 7 failed SPNs 65601 65602 and 65610 must run and pass SPN 630 65580 65620 65621 65622 or 65623 is not set The ignition is ON or the engine is operating SPN 65618 runs continuously when the above conditions are met 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 147 Electronic Throttle Control ETC Actuation Fault Mechanical System Not Responding or Out Electronic Throttle Control ETC Process Fault Bad Intelligent Device or Component Electronic Throttle Control ETC Return Fault Mechanical System Not Responding or Out of Conditions for Setting the SPN 65615 7 The difference between the commanded and the actual throttle position is greater than 10 percent for greater than 276 mS 65616 12 The predicted throttle position calculations in the main processor differ from the motor control processor 65618 7 The ECM detects that the throttle blade did not return to the default position during power up Action Taken When the SPN Sets SPN 65615 65616 and 65618 are SPNs The ECM commands the TAC system 10 operate in a Reduced Engine Power mode Conditions for Clearing the SPN SPN 65615 65616 and 65618 Type A SPNs Diagnostic Aids Inspect for a condition in which the t
159. 3 should not be set 5 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data 9 112 Engine Controls and Fuel Marine Circuit System Testing 5 Verify the scan tool SC Inlet Pressure Sensor parameter is less than 20 kPa 1 Inspect the SCIP sensor system for the following If the greater than the specified parameter conditions test the signal circuit terminal 3 for a short Any damage to the SCIP sensor housing to voltage If the circuit tests normal replace A loose or improperly installed SCIP sensor the ECM 6 Install a 3 A fused jumper wire between the 5 volt If a condition is found repair as necessary reference circuit terminal 1 and the signal circuit 2 Ignition OFF disconnect the harness connector at terminal 3 Verify the scan tool SC Inlet Pressure the SCIP sensor Sensor parameter is greater than 100 kPa gt If less than the specified parameter test the signal circuit for a short to ground open high resistance If the circuit tests normal 3 Test for less than 5 between the low reference circuit terminal 2 and ground If greater than the specified range test the low replace the ECM reference circuit for an open high resistance 7 If all circuits test normal test or replace the SCIP If the circuit tests normal replace the ECM se
160. 3 3 The ECM detects that the SCIP sensor voltage is greater than 4 8 volts for greater than 625 mS 3563 4 The ECM detects that the SCIP sensor voltage is less than 0 2 volt for greater than 625 mS Action Taken When the SPN Sets SPN 3563 is Type B SPN 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 111 Conditions for Clearing the MIL SPN SPN 3563 is Type B SPN Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 for scan tool information Special Tools J 23738 A Mityvac Circuit System Verification 1 Ignition ON observe SPN information with a scan tool Verify that SPN 65620 65621 or 65622 is not set If any SPN is set refer to SPN 65620 65623 on page 9 149 2 Observe the scan tool SCIP Sensor parameter The reading should be within 5 kPa of the BARO parameter Refer to Altitude Versus Barometric Pressure on page 9 3 3 Engine idling observe the scan tool SCIP sensor parameter The reading should closely match the MAP sensor parameter value 4 Observe the scan tool SPN information SPN 356
161. 315247 J 35616 2A GY Camshaft Actuator Solenoid Exhaust 2 4L Circuit Wire Color No Low Reference A Camshaft Actuator Solenoid Control Camshaft Actuator Solenoid Intake 2 4L 646403 Connector Part Information OEM 15335987 Service 15306430 Description 2 Way F GT 150 Series Sealed BK Terminal Part Information Terminal Tray 15326267 19 Core Insulation Crimp E 4 Release Tool Test Probe 15315247 J 35616 2A GY Camshaft Actuator Solenoid Intake 2 4L Circuit Wire Color No A Camshaft Actuator Solenoid Control towReterence 2011 Marine Engines Manual Camshaft Position Sensor Exhaust 2 4L 646415 Connector Part Information OEM 15326808 Service 15306388 Description 3 Way F GT 150 Series Sealed BK Terminal Part Information Terminal Tray 12191819 8 Core Insulation Crimp E A Release Tool Test Probe 15315247 J 35616 2A GY Camshaft Position CMP Sensor Exhaust 2 4L 353 Wire Color No Function SvotReterence ___ 8 towReterence c Sensor Signal _ Camshaft Position Sensor Intake 2 4L 646415 Connector Part Information OEM 15326808 Service 15306388 Description 3 Way F GT 150 Series Sealed BK 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 35 Terminal Part Information Terminal Tray 12191819 8 Core Insul
162. 42 5 _ 655425 Ignition 3 Control Circuit 655434 655495 655495 Ignition Coil 4 Control Circuit 655444 655445 655445 Ignition Coil 5 Control Circuit 655454 65555 655455 Ignition Coil 6 Control Circuit 655464 65565 655465 Ignition Coil 7 Control Circuit 655474 655475 655475 Ignition Coil 8 Control Circuit 65584 655845 65585 1 The Engine Cranks but Does Not Run and or the fuse opens that supplies voltage to the bank specific ignition coils 2 The Engine Cranks but Does Not Run Circuit System Description Ignition voltage is supplied to the ignition coil module The engine control module ECM provides a ground for the ignition coil IC control circuits When the ECM removes the ground path of the ignition primary coil the magnetic field produced by the coil collapses The collapsing magnetic field produces a voltage in the secondary coil which ignites the spark plugs The sequencing and timing are controlled by the ECM Conditions for Running the SPN SPN 630 or 65580 is not set The ignition voltage is equal to or greater than 9 volts The engine is cranking or operating e The SPNs 65541 65548 run continuously once the above condition is met 2011 Marine Engines Manual 9 114 Engine Controls and Fuel Marine Conditions for Setting the SPN The ECM detects that the commanded state of the driver and the ac
163. 5 volt reference circuit for a short to ground or open high resistance If the circuit tests normal replace the ECM If greater than the specified range test the 5 volt reference circuit for a short to voltage If the circuit tests normal replace the ECM 4 Verify the scan tool Oil Pressure Sensor Voltage parameter is less than 0 10 V If greater than the specified range test the signal circuit for a short to voltage If the circuit tests normal replace the ECM 5 Connect a 3 fused jumper wire between the signal circuit terminal C and the 5 volt reference circuit terminal B Verify the scan tool Oil Pressure Sensor Voltage parameter is greater than 4 9 V gt If less than the specified range test the signal circuit for a short to ground or for an open high resistance If the circuit tests normal replace the ECM 6 Ignition OFF install a mechanical engine oil pressure gauge 7 Engine idling verify the oil pressure is within 41 414 kPa 6 60 psi If not within the specified range repair the engine mechanical condition 8 If all circuits test normal replace the EOP sensor Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Engine Oil Pressure Sensor Replacement on page 9 225 Engine Control Module Replacement on page 9 217 for engine control module replacement setup and programming 2011 Marine Engines Manual Engine C
164. 50 mV and below 450 mV This parameter displays the oxygen sensor Varies rich lean and lean rich switches A switch is when the oxygen sensor voltage goes above 450 mV and below 450 mV A change made to the fuel delivery will be indicated by the Fuel Multiplier and the BLM O2 B1 Cross Counts Per Second Cell Value The BLM Cell Values change rapidly in response to the 2 signal voltages These changes fine tune the engine fueling The Fuel Multiplier values change in response to the trends in the BLM Cell Values The Fuel Multiplier makes O2 A1 or B1 Fuel Closed Loop ON 0 90 1 10 coarse adjustments to the fueling in order to re center and restore control to the BLM Cell Value The scan tool will display a value less than 1 00 when the engine is running too rich and fuel is being subtracted from the combustion event The scan tool will display a value greater than 1 00 if the engine is running too lean and fuel is being added to the combustion event This parameter displays the amperage of the O2 AT or B1 Heater 0 5 5 Amps HO2S heater commanded the control Current module This parameter displays the amperage of the HO2S heater commanded by the control O2 A2 or B2 Heater Catalyst Monitoring 0 5 Amps module The control module will not Current Enabled p command any current until the conditions for running the catalyst monitoring have been met This parameter displays the oxygen content of the exhaust stream at the res
165. 508 5 Remove and discard the throttle body gasket 509 Installation Procedure 1 Install a NEW throttle body gasket to the intake manifold Align the tab of the gasket with the notch in the manifold Caution Refer to Fastener Caution on page 0 5 2 Install the throttle body 508 bolts 538 and nuts 507 Tighten Tighten the bolts nuts to 10 N m 89 lb in Note Verify that the engine wiring harness electrical connector seal for the electronic throttle control is properly installed and not damaged 3 Connect the engine wiring harness electrical connector to the electronic throttle control 4 Install the air cleaner outlet duct 5 Connect a scan tool in order to test for proper throttle opening and throttle closing range 6 Operate the accelerator pedal and monitor the throttle angles The accelerator pedal should operate freely without binding between a closed throttle and a wide open throttle WOT 7 Verify that the vehicle meets the following conditions The vehicle is not in a reduced engine power mode The ignition is ON The engine is OFF 8 Start the engine 9 Inspect for coolant leaks 2011 Marine Engines Manual Fuel Pressure Gauge Installation and Removal Installation Procedure Tools Required J 34730 Fuel Pressure Gauge J 34730 FF Fuel Pressure Gauge Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fi
166. 5551 FMI 4 Knock Sensor KS SPN 65551 FMI5 Knock Sensor KS SPN 65552 FMI 1 Knock Sensor KS SPN 65552 FMI 3 Knock Sensor KS SPN 65552 FMI 4 Knock Sensor KS SPN 65552 FMI5 Knock Sensor KS lt gt lt gt lt gt lt gt lt Circuit System Description The knock sensor KS enables the engine control module ECM to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation The KS produces an AC voltage signal that varies depending on the vibration level during engine operation The ECM adjusts the spark timing based on the amplitude and the frequency of the KS signal The ECM receives the KS signal through a signal circuit The ECM supples a ground circuit to the KS through a low reference circuit The ECM also supplies a shielded ground circuit to the KS The ECM learns the normal KS noise level at idle and uses the normal noise level as a base to predict the normal values for the rest of the engine speed range The ECM monitors the KS signal for detonation levels that exceed the predicted value of the normal noise channel Conditions for Running the SPN 65551 or 65552 FMI 1 Before the ECM can report that SPN 65551 1 or 65552 1 failed SPN 65551 3 65551 4 65552 3 and 65552 4 must run and pass SPN 630 or 65580 is not set The engine coolant temperature is warmer than 50 122 F The Fuel Detonation Control Mode is
167. 5723 7 SPN 65723 65724 65725 or 65726 2 4 6 0 6 2L on page 9 160 SPN 65723 65724 65725 or 65726 3 0 4 3 5 0 5 7L on page 9 158 65723 Cam Sensor W Abnormal Frequency or Pulse Width er SPN 65723 65724 65725 or 65726 2 4 6 0 6 2L on page 9 160 Cam Sensor W Data Erratic Intermittent or Incorrect SPN 65723 65724 65725 or 65726 3 0 4 3 5 0 5 7L on page 9 158 Cam Sensor W Mechanical System Not o on page 9 160 Responding or Out of Adjustment SPN 65723 65724 65725 65726 2 4 6 0 6 2L 9 160 SPN 65723 65724 65725 65726 3 0 4 3 5 0 5 71 page 9 158 SPN 65723 65724 65725 65726 2 4 6 0 6 2L 9 160 Cam Sensor X Data Erratic Intermittent or Incorrect or SPN 65723 65724 65725 or 65726 2 4 6 0 6 2L SPN 65723 65724 65725 or 65726 3 0 4 3 5 0 5 7L page 9 158 65724 65724 Cam Sensor X Mechanical System Not Responding or Out of Adjustment 2011 Marine Engines Manual Vehicle Diagnostic Information 6 19 Diagnostic Trouble Code DTC List cont d 060 Diagnostic Procedure Note If multiple powertrain SPNs are stored diagnose the SPNs in the following order 1 Component level SPNs such as sensor SPNs solenoid SPNs and relay SPNs 2 System level SPNs such as misfire SPNs and fuel trim SPNs SPN 65723 65724 65725 or 65726 3 0 4 3 5 0 5 7L on page 9 158 Cam Sensor X Abnormal Frequency or P
168. 58 are Type B SPNs Conditions for Clearing the SPN SPN 651 652 653 654 655 656 657 and 658 are Type B SPNs Diagnostic Aids If the ECM detects a short to ground the ECM enters hydro lock protection mode The engine will stop and engine cranking will be disabled if the vessel is equipped with smart start 2011 Marine Engines Manual Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Diagnostic Starting Point Engine Controls on page 9 54 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Special Tools Required J 34730 405 Injector Test Lamp Circuit System Verification 1 Engine operating observe the SPN information with a scan tool SPNs 651 652 653 654 655 656 657 or 658 should not set 2 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data 20
169. 6 8 636 8 Sensor Signal 636 8 636 8 636 8 636 2 Low Reference _ J see Circuit System Description The crankshaft position sensor circuits consist of an engine control module ECM supplied 5 V circuit low reference circuit and an output signal circuit The crankshaft position sensor is an internally magnetic biased digital output integrated circuit sensing device The sensor detects magnetic flux changes between the peaks and valleys of a 58 tooth reluctor wheel on the crankshaft Each tooth on the reluctor wheel is spaced at 60 tooth spacing with 2 missing teeth for the reference gap The crankshaft position sensor produces an ON OFF DC voltage of varying frequency with 58 output pulses per crankshaft revolution The frequency of the crankshaft position sensor output depends on the velocity of the crankshaft The crankshaft position sensor sends a digital signal which represents an image of the crankshaft reluctor wheel to the ECM as each tooth on the wheel rotates past the crankshaft position sensor The ECM uses each crankshaft position signal pulse to determine crankshaft speed and decodes the crankshaft reluctor wheel reference gap to identify crankshaft position This information is then used to sequence the ignition timing and fuel injection events for the engine The ECM also uses crankshaft position sensor output information to determine the crankshaft relative position to the cams
170. 616 2A GY 1273820 Fuel Injector 7 Circuit OEM 15355226 He lonition Voltage B Fuel injector 7 Control Fuel Injector 8 4 3 5 0 5 7L Description 2 Way F Metri Pack 150 Tangless Series Sealed BK Terminal Part Information Terminal Tray 12176636 19 Core Insulation Crimp C 1 Release Tool Test Probe 12094429 J 35616 2A GY Fuel Injector 6 Circuit Wire Color No Function 1273820 Connector Part Information OEM 15355226 Service 89046636 Description 2 Way F Metri Pack 150 Tangless Series Sealed BK 2011 Marine Engines Manual 9 44 Engine Controls and Fuel Marine Heated Oxygen Sensor HO2S Bank A Sensor 2 Terminal Part Information Terminal Tray 12176636 19 Core Insulation Crimp C 1 Release Tool Test Probe 12094429 J 35616 2A GY Fuel Injector 8 Circuit Wire Color No Function Heated Oxygen Sensor HO2S Bank A Sensor 1 456551 Connector Part Information OEM 12160482 Service 88988598 Description 4 Way F Metri Pack 150 Series Sealed BK Terminal Part Information Terminal Tray 12048074 2 Core Insulation Crimp E 1 Release Tool Test Probe 12094429 J 35616 2A GY Heated Oxygen Sensor HO2S Bank A 280761 2 Circuit Connector Part Information Wire Color No Service 15305801 Bank A Sensor 2 Description 4 Way M Metri Pack 150 Series Sealed BK HO2S High Signal Bank A Sensor 2 Terminal Part Inform
171. 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 110 FMI 3 Engine Coolant Temperature ECT Sensor Circuit Voltage Above Normal or Shorted High SPN 110 4 Engine Coolant Temperature ECT Sensor Circuit Voltage Below Normal or Shorted Low SPN 110 FMI 15 Engine Coolant Temperature ECT Sensor Circuit Voltage Data Valid But Above Normal Range Least Severe Level SPN 110 FMI 16 Engine Coolant Temperature ECT Sensor Circuit Voltage Data Valid But Above Normal Range Moderate Severe Level Diagnostic Fault Information Short to Open High Short to Signal Circuit Ground Resistance Voltage Performance ECT Sensor Signal 110 4 110 3 110 3 110 15 Low Reference ______ COT 110 3 Internal ECM or sensor damage may occur if the circuit is shorted to B Typical Scan Tool Data ECT Sensor ___________ Open Short to Voltage Operating Conditions Engine operating in Closed Loop Parameter Normal Range Varies with ambient temperature ECT Sensor Signal 151 C 304 F 40 40 F 40 40 F FlowReterence 40 4097 Internal sensor damage may occur if the circuit is shorted to Circuit System Description Conditions for Runni
172. 65585 2 redi d ree d 9 135 Visual Identification 9 30 SPN 65586 65587 9 137 Engine Control Module Connector End SPN 65590 65591 65592 65593 MI 9 30 65594 65595 65596 65597 65598 Engine Controls Connector End Views 9 33 oM IE 9 139 Diagnostic Information and Procedures 9 54 SPN 65601 65602 or 65610 9 141 Diagnostic Starting Point Engine SPN 65604 65605 or 65613 9 144 MER 9 54 SPN 65615 65616 65618 9 147 Engine Control Module Scan Tool SPN 65620 65623 9 149 INFORMATION ettet rede tens 9 54 SPN 65675 0r 65676 9 151 Powertrain On Board Diagnostic OBD SPN 65690 iicet 9 153 System een i nas 9 64 SPN 65701 or 65702 9 155 5 88 0 90 iiie 9 65 SPN 65710 ovis 9 157 Coo EODEM 9 67 SPN 65723 65724 65725 or 65726 SPN 84 sic stie p e 9 69 9 0 4 3 5 0 5 9 158 E 9 71 65723 65724 65725 65726 SPN 98 ERU 9 73 2 4 6 0 6 2 teet 9 160 SPN 100 3 0L 4 3L 5 0L 5 7L 9 75 SPN 166002 5 9 162 SPN 100 6 0L 6 2L 9 77 SPN 66
173. 65623 is not set If either SPN is set refer to SPN 65620 65623 on page 9 149 2 Move the fuel select input switch between the fuel select 1 and 2 positions Verify SPN 65585 2 does not set 3 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data 9 136 Engine Controls and Fuel Marine Circuit System Testing 1 2 Ignition OFF disconnect the harness connector at the fuel select input sensor Ignition OFF test for less than 5 Q between the low reference circuit terminal and ground gt If greater than the specified range test the low reference circuit for an open high resistance If the circuit tests normal replace the ECM Ignition ON test for 4 8 5 2 V between the 5 volt reference circuit terminal and ground If less than the specified range test the 5 volt reference circuit for a short to ground or open high resistance If the circuit tests normal replace the ECM If greater than the specified range test the 5 volt reference circuit for a short to voltage If the circuit tests normal replace the ECM 4 Test for 0 050 1 volt between the signal circuit terminal and ground If greater than the specified range test the signal circuit for a short to voltage If the circuit tests normal replace the ECM If less than the specified rang
174. ARO sensor parameter with a scan tool The BARO parameter should be within the range specified in the Altitude vs Barometric Pressure table Refer to Altitude Versus Barometric Pressure on page 9 3 4 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Ignition OFF disconnect the harness connector at the BARO sensor 2 Ignition OFF test for less than 5 between the low reference circuit terminal 2 and ground If greater than the specified range test the low reference circuit for an open high resistance If the circuit tests normal replace the ECM 3 Ignition ON test for 4 8 5 2 V between the 5 volt reference circuit terminal 1 and ground If less than the specified range test the 5 volt reference circuit for an open high resistance or a short to ground If the circuit tests normal replace the ECM If greater than the specified range test the 5 volt reference circuit for a short to voltage If the circuit tests normal replace the ECM 4 Observe the scan tool BARO Pressure parameter Verify the parameter is at 0 1 kPa 0 0 inHg If greater than the specified range test the signal circuit for a short to voltage If the circuit tests normal replace the ECM 5 Ignition OFF connect a 3 A fused jumper wire between the signal c
175. Arrow 2011 Marine Engines Manual Basic Knowledge and Tools Required To use this manual most effectively a general understanding of basic electrical circuits and circuit testing tools is required You should be familiar with wiring diagrams the meaning of voltage ohms amps and the basic theories of electricity You should also understand what happens if a circuit becomes open shorted to ground or shorted to voltage To perform system diagnostics several special tools and equipment are required Please become acquainted with the tools and their use before attempting to diagnose the system Special tools that are required for system service are illustrated in this section Visual Physical Checks Visual Physical Inspection A careful visual and physical inspection must be performed as part of any diagnostic procedure This can often lead to repairing the condition without further diagnosis Inspect all vacuum hoses for correct routing pinches cracks or disconnects Inspect all wires in the engine compartment for proper connections pinched wires or contact with sharp edges or hot manifolds The visual physical inspection is very important It must be done carefully and thoroughly 2011 Marine Engines Manual General Information 1 5 Electrostatic Discharge Damage Electronic components used in control systems are often designed to carry very low voltage and are very susceptible to damage caused by electrostatic
176. Below Normal or SPN 65541 65542 65543 65544 65545 65546 Shorted Low 65547 or 65548 on page 9 113 65543 5 EST 3 Current Below Normal or Open SPN 65541 65542 65543 65544 65545 65546 Circuit 65547 or 65548 on page 9 113 65544 4 EST 4 Voltage Below Normal or SPN 65541 65542 65543 65544 65545 65546 Shorted Low 65547 or 65548 on page 9 113 65544 5 EST 4 Current Below Normal or Open SPN 65541 65542 65543 65544 65545 65546 Circuit 65547 or 65548 on page 9 113 65545 4 EST 5 Voltage Below Normal SPN 65541 65542 65543 65544 65545 65546 Shorted Low 65547 or 65548 on page 9 113 65545 5 EST 5 Current Below Normal or Open SPN 65541 65542 65543 65544 65545 65546 Circuit 65547 or 65548 on page 9 113 65546 4 EST 6 Voltage Below Normal or SPN 65541 65542 65543 65544 65545 65546 Shorted Low 65547 or 65548 on page 9 113 65546 EST 6 Current Below Normal Open SPN 65541 65542 65543 65544 65545 65546 Circuit 65547 or 65548 on page 9 113 EST 7 Voltage Below Normal or SPN 65541 65542 65543 65544 65545 65546 Shorted Low 65547 or 65548 on page 9 113 EST 7 Current Below Normal or Open SPN 65541 65542 65543 65544 65545 65546 Circuit 65547 or 65548 on page 9 113 EST 8 Voltage Below Normal or SPN 65541 65542 65543 65544 65545 65546 Shorted Low 65547 or 65548 on page 9 113 EST 8 Current Below Normal or Open SPN 65541 65542 65543 65544 65545 65546 Circuit 65547 or 65548 on page 9 113 K
177. Cable pt Troublesh ti ith Di it eee ux ees 11 8 Connector Position Assurance Locks 1 24 Troubleshooting with a Test Lamp 11 10 Terminal Position Assurance Locks 11 24 Using Fused Jumper Wires 11 10 Rodi e a ead us Measuring Voltage 14710 saat te E M en Voltage Drop Weather Pack Connectors 11 26 Meas rina Fr 11 11 Repairing Connector Terminals 11 27 dii Repair Instructions 11 28 Testing for Continuity 11 12 Relay Replacement Fuse Block 11 28 Testing for Short to Ground 11 12 Relay Replacement Harness 11 29 Testing for a Short to Voltage 11 13 Special Tools and Equipment 11 30 2011 Marine Engines Manual 11 2 Table of Contents BLANK 2011 Marine Engines Manual Data Communications Data Communications 11 3 Diagnostic Information and Procedures Scan Tool Does Not Power Up Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis page 6 4 for an overview of the diagnostic approach
178. Cause SPN 65558 or 65559 9 118 Unknown 65559 1 Bus Hardware Fault Root Cause SPN 65558 or 65559 on page 9 118 65560 9 CAN Bus Governor Command Lost SPN 65560 on page 9 120 65561 Oxygen Sensor Bank A Sensor 1 Data SPN 65561 65562 65563 or 65564 on Valid But Above Normal page 9 122 65561 1 Oxygen Sensor Bank A Sensor 1 Data SPN 65561 65562 65563 65564 Valid But Below Normal page 9 122 65561 3 Oxygen Sensor Bank A Sensor 1 SPN 65561 65562 65563 or 65564 on Voltage Above Normal or Shorted High page 9 122 65561 4 1 65561 65562 65563 65564 Voltage Below Normal or Shorted 9 122 65561 5 Oxygen Sensor Bank A Sensor 1 SPN 65561 65562 65563 or 65564 on Current Below Normal or Open Circuit page 9 122 65562 Oxygen Sensor Bank A Sensor 2 Data SPN 65561 65562 65563 or 65564 on Valid But Above Normal page 9 122 65562 1 Oxygen Sensor Bank A Sensor 2 Data SPN 65561 65562 65563 or 65564 on Valid But Below Normal page 9 122 65562 3 Oxygen Sensor Bank A Sensor 2 SPN 65561 65562 65563 or 65564 on Voltage Above Normal or Shorted High page 9 122 65562 4 Oxygen Sensor Bank A Sensor 2 SPN 65561 65562 65563 or 65564 on Voltage Below Normal or Shorted Low page 9 122 65562 5 Oxygen Sensor Bank A Sensor 2 SPN 65561 65562 65563 or 65564 on Current Below Normal or Open Circuit page 9 122 65563 Oxygen Se
179. Control Module Scan Tool Information on page 9 54 2011 Marine Engines Manual Circuit System Verification 1 Ignition ON command the transmission shift lock out solenoid ON and OFF with a scan tool The solenoid should turn ON and OFF as commanded Observe the SPN information with a scan tool SPN 66012 3 or 66012 5 should not set Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 2 Ignition OFF disconnect the harness connector at the trans shift solenoid Ignition ON verify a test lamp illuminates between the ignition voltage supply circuit terminal and ground If the test lamp does not illuminate test the ignition circuit for a short to ground or an open high resistance If the circuit tests normal and the ignition circuit fuse is open test all the components connected to the ignition circuit and replace as necessary Connect a test lamp between the control circuit terminal and B The test lamp should not illuminate If the test lamp is always ON test the control circuit for a short to ground If the circuit connections test normal replace the ECM 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 179 4 Command the trans shift solenoid ON and OFF with a scan tool The test
180. Control Module Scan Tool Information on page 9 54 Circuit System Verification 1 Engine running for 1 minute observe the SPN information with a scan tool SPNs 105 3 105 4 105 15 should not set 2 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Ignition OFF disconnect the harness connector at the MAP MAT sensor 2 Test for less than 5 O between the low reference circuit terminal 1 and ground If greater than the specified range test the low reference circuit for an open high resistance If the circuit tests normal replace the ECM 3 Ignition ON verify the scan tool MAT sensor parameter is at 40 40 F lf warmer than the specified range test the signal circuit terminal 2 for a short to ground If the circuit tests normal replace the ECM Note If the fuse in the jumper wire opens the signal circuit is shorted to a voltage and the sensor may be damaged 4 Connect a 3 A fused jumper wire between the signal circuit terminal A and ground Verify the scan tool MAT sensor parameter is warmer than 129C 264 F colder than the specified range test the signal circuit for a short to voltage or an open high resistance If the circuit tests normal replace the ECM 5 f all circuits test normal test or re
181. Description 3 Way F Kompakt 2 8 Series Sealed BK 2011 Marine Engines Manual 9 54 Engine Controls and Fuel Marine Diagnostic Information and Procedures Diagnostic Starting Point Engine Engine Control Module Scan Tool Controls Information Begin the system diagnosis with the Powertrain On The Engine Control Module Scan Tool Data List Board Diagnostic OBD System Check on page 9 64 contains all engine related parameters that are The Powertrain On Board Diagnostic OBD System available on the scan tool This is a master list arranged in alphabetical order Use the Engine Scan Tool Data List only after the following is determined The Powertrain On Board Diagnostic Check will provide the following information The identification of the control modules which command the system The ability of the control modules to communicate System Check on page 9 64 is completed through the serial data circuit No suspect parameter numbers SPNs The identification of any stored diagnostic trouble On board diagnostics are functioning properly codes DTCs and the code status The scan tool values from a properly running engine The use of the Powertrain On Board Diagnostic OBD may be used for comparison with the engine you are diagnosing The Engine Scan Tool Data List represents values that would be seen on a normally running engine Note A scan tool that displays faulty data should not be used The sc
182. ECM If not within the specified range repair the 7 Install a 3A fused jumper wire between the signal restriction in the vacuum supply to the circuit terminal 3 and the 5 volt reference circuit MAP sensor terminal 1 Verify the scan tool MAP sensor 3 Ignition OFF connect the vacuum hose to the parameter 15 greater than 4 8 MAP sensor or install the MAP sensor to the gt If less than the specified range test the signal intake manifold Disconnect the harness connector circuit for a short to ground or an open high at the MAP sensor resistance If the circuit tests normal replace 4 Ignition OFF test for less than 5 Q between the the ECM low reference circuit terminal 2 and ground 8 If all circuits test normal test or replace the MAP If greater than the specified range test the low Sensor reference circuit for an open high resistance If the circuit tests normal replace the ECM Component Testing 5 Ignition ON test for 4 8 5 2 V between the 5 volt The ignition ON engine OFF MAP sensor scan tool reference circuit terminal 1 and ground value should decrease within 4 kPa by the amount gt If less than the specified range test the 5 volt of vacuum applied with the J 23738 A For example reference circuit for a short to ground or at 92 kPa the MAP sensor scan tool reading should be open high resistance If the circuit tests normal between 71 79 kPa with 5 in Hg 17 kPa of vacuum replace the ECM applied to the
183. ECM replacement setup and programming 2011 Marine Engines Manual SPN 65585 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptor SPN 65685 FMI 2 Diagnostic Fault Information Engine Controls and Fuel Marine 9 135 Fuel Select Input Data Erratic Intermittent or Incorrect Short to Open High Short to Signal Circuit Ground Resistance Voltage 5 Volt Reference 65621 4 65685 2 65685 2 Fuel Select Input Signal 65621 4 65685 2 65685 2 LowReferene 6568 2 d ___ Circuit System Description The fuel select input FSI sensor changes voltage based on the position of the sensor switch The fuel select input sensor is a three wire sensor comprising of the signal circuit the low reference circuit and the 5 volt reference circuit The engine control module ECM supplies 5 volts to the sensor via the 5 volt reference circuit and provides ground via the FSI low reference circuit The ECM monitors the voltage signal of the FSI sensor to determine which fuel type to use for engine operation The FSI sensor voltage is within the normal operating range at approximately 1 or 4 volts Condit
184. Engine OFF verify communication with all of the control modules on the vehicle If the scan tool does not communicate with one or more of the expected control modules refer to Scan Tool Does Not Communicate with CAN Device on page 11 4 4 Verify that SPN 65558 or 65559 is not set If either SPN is set refer to SPN 65558 or 65559 on page 9 118 5 Attempt to start the engine Verify that the engine cranks If the engine does not crank refer to SPN 66002 on page 9 162 if equipped If the vehicle is not equipped with an ECM controlled starter relay repair the starting System 6 Attempt to start the engine Verify the engine starts and idles If the engine does not start and idle refer to Engine Cranks But Does Not Run on page 9 201 Note Do not clear any SPNs unless instructed to do so by a diagnostic procedure 7 Use the appropriate scan tool selections to obtain any SPNs from each of the vehicle control modules Verify there are no SPNs reported from any module If any SPNs are present refer to Diagnostic Trouble Code DTC List on page 6 11 and diagnose any current SPNs in the following order 7 1 Any of the following 630 65580 65581 or 65582 7 2 SPN 627 7 3 Component level SPNs 7 4 System level SPNs 7 5 Any remaining SPNs f none of the previous tests or inspections addresses the concern refer to Symptoms Engine Controls on page 9 199 2011 Marine Engines Manual SPN
185. F Note In extreme cold weather conditions ice may form in the vacuum source to the MAP sensor and may set a SPN Inspect the MAP sensor and the vacuum source for ice moisture or other restrictions 3 Engine operating observe the scan tool MAP Sensor parameter The reading should be between 31 68 kPa 9 20 in Hg 4 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data 2011 Marine Engines Manual Circuit System Testing 1 Ignition OFF disconnect the vacuum hose at the MAP MAT sensor or remove the MAP MAT sensor from the intake manifold Connect the J 23738 A to the vacuum source 2 Engine operating verify that 31 68 kPa 9 20 in Hg of vacuum is available to the MAP MAT sensor gt If not within the specified range repair the restriction in the vacuum supply to the Engine Controls and Fuel Marine 9 85 6 Verify the scan tool MAP sensor voltage parameter is less than 0 25 V If greater than the specified range test the signal circuit terminal 4 for a short to voltage If the circuit tests normal replace the ECM 7 Install a 3 A fused jumper wire between the signal circuit terminal 4 and the 5 volt reference circuit terminal 3 Verify the scan tool MAP sensor parameter is greater than 4 8 V If less than the specified range test the sig
186. FF This function activates the shift interlock solenoid if equipped The normal commanded Trans Shift Override state is NONE When commanded ON the control module turns the solenoid ON for approximately 2 seconds Oil Life Monitor Reset Power Balance Test 2011 Marine Engines Manual 9 64 Engine Controls and Fuel Marine Powertrain On Board Diagnostic OBD System Check 1 Verify that none of the following preliminary inspections tests reveal the cause of the vehicle concern before beginning diagnosis Ensure that the battery is fully charged Ensure that the battery cables are clean and tight Inspect for any open fuses Refer to Engine Controls Schematics on page 9 6 Ensure that the grounds are clean tight and in the correct location Inspect the easily accessible systems or the visible system components for obvious damage or conditions that could cause the concern This would include checking to ensure that all connections connectors are fully seated and secured Inspect for aftermarket devices that could affect the operation of the system Refer to Checking Aftermarket Accessories on page 11 6 Search for applicable service bulletins gt Ifthe preceding inspections tests resolve the concern go to Diagnostic Repair Verification on page 6 22 2 Install a scan tool Verify that the scan tool powers up gt If the scan tool does not power up refer to Scan Tool Does Not Power Up on page 11 3 3 Ignition ON
187. Fix After isolating the root cause make the repairs and validate for the correct operation by performing the Diagnostic Repair Verification Verifying that the DTC or symptom has been corrected may involve testing the vehicle Diagnostic Procedure Instructions The following is an overview of instructions for all 16 categories which may be included in a diagnostic procedure Diagnostic Instructions A link to the Powertrain On Board Diagnostic OBD System Check on page 9 64 is provided here This procedure should be performed prior to performing other diagnostic procedures as this prevents misdiagnosis where there are integrated system dependencies A link to the Strategy Based Diagnosis on page 6 4 is provided here This provides an overview on how a technician should diagnose a vehicle A link to the Diagnostic Procedure Instructions on page 6 5 is provided here This information is an overview of instructions for all 16 categories which may be included in a diagnostic procedure DTC Descriptor Describes what DTCs are diagnosed in this procedure The DTC number with Symptom Description when applicable and descriptor are written out Diagnostic Fault Information The diagnostic Fault Information table identifies each circuit that makes up an electrical subsystem and the associated circuit faults DTCs and symptoms are listed in the table for all circuit fault modes This information can be used to diagnose an elect
188. Fuel System Diagnosis with Returnless Fuel System on page 9 208 or Fuel System Diagnosis without Returnless Fuel System on page 9 210 Contaminated fuel Refer to Alcohol Contaminants in Fuel Diagnosis on page 9 213 If you find any of the above conditions repair as necessary 2 Ignition OFF disconnect the spark plug wire from the misfiring cylinder 3 Install the J 26792 to the boot of a spark plug wire and ground Note An erratic or weak spark is considered a no spark condition 4 Attempt to start the engine and observe the J 26792 The spark tester should spark lf there is no spark test the spark plug wire for the correct resistance Refer to Spark Plug Wire Inspection on page 9 245 Replace the spark plug wire if necessary If the spark plug wire tests normal refer to Distributor Ignition DI System Diagnosis on page 9 214 or Electronic Ignition System Diagnosis on page 9 215 for diagnosis of the ignition coil 5 Ignition OFF remove the spark plug from the misfiring cylinder Verify the following conditions do not exist A spark plug that is Gas coolant or oil fouled Refer to Spark Plug Inspection on page 9 245 Cracked worn incorrectly gapped spark plug lf there is a condition with the spark plug replace the spark plug 6 Exchange the suspected spark plug with another cylinder that is operating correctly 7 Clear the SPN information with a scan tool Operate the vehicle within the C
189. GM X 30A or equivalent if necessary Follow the package instructions Do not soak fuel rails in liquid cleaning solvent Caution Use care when servicing the fuel system components especially the fuel injector electrical connectors the fuel injector tips and the injector O rings Plug the inlet and the outlet ports of the fuel rail in order to prevent contamination Do not use compressed air to clean the fuel rail assembly as this may damage the fuel rail components Do not immerse the fuel rail assembly in a solvent bath in order to prevent damage to the fuel rail assembly 3 Disconnect the fuel feed hose from the fuel rail 2211680 4 Disconnect the electrical connectors from the fuel injectors Identify the connectors to their corresponding injectors to ensure correct sequential injector firing order after reassembly 5 Remove the fuel rail attaching bolts 1 6 Lift evenly on both sides of the fuel rail and remove the fuel rail assembly 7 Remove the injector lower O ring seal 3 from the spray tip end of each injector 8 Discard the O ring seals 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 231 Installation Procedure Fuel Injection Fuel Rail Assembly Replacement 4 3L 5 0L and 5 7L Removal Procedure Caution Refer to Fuel Rail Caution on page 0 5 1 Relieve the fuel system pressure Refer to Fuel Pressure Relief on page 9 230 2 Remove the air cleaner outlet re
190. Ground Voltage ne 5 Volt Reference Circuit 65620 4 100 17 CMP Sensor Signal 65723 8 65723 8 5 65723 2 65723 8 65723 7 Tow Reference O 68 Circuit System Description The 4X camshaft position sensor circuits consist of an engine control module supplied 5 V reference circuit low reference circuit and an output signal circuit The camshaft position sensor is an internally magnetic biased digital output integrated circuit sensing device The sensor detects magnetic flux changes between the peaks and valleys of a 4 tooth reluctor wheel attached to the camshaft As each reluctor wheel tooth rotates past the camshaft position sensor the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse The sensor returns a digital ON OFF DC voltage pulse of varying frequency with 2 narrow and 2 wide output pulses per camshaft revolution that represent an image of the camshaft reluctor wheel The frequency of the camshaft position sensor output depends on the velocity of the camshaft The ECM decodes the narrow and wide tooth pattern to identify camshaft position This information is then used to sequence the ignition timing and fuel injection events for the engine The ECM also uses camshaft position sensor output information to determine the camshaft relative position to the crankshaft to control the camshaft position actuator if equipped and for limp home ope
191. Indmar MARINE ENGINES Service and Diagnostic Manual For Electronic Fuel Injection Systems with MEFI 6 Controllers Indmar Products Company Inc 5400 Old Millington Road Millington TN 38053 5 Preface 0 0 Dangers Warnings and Cautions 0 3 General Information 1 3 General Information 1 3 Diagnostic Overview Starting Point and Programming 6 3 Programming and Setup Vehicle Diagnostic Information 2011 Marine Engines Manual Engine mee ener eee eee Engine Controls and Fuel Marine Power and Signal Distribution Data Communications Wiring Systems 2011 DANGER Danger In order to reduce the chance of death personal injury and or property damage carefully observe the instructions that follow The service manuals of General Motors are intended for use by professional qualified technicians Attempting repairs or service without the appropriate training tools and equipment could cause death or injury to you or others This could also damage the vehicle or cause the vehicle to operate improperly Proper vehicle service and repair are important to the safety of the service technician and to the safe reliable operation of all motor vehicles If you need to replace a part use the same part
192. J 38125 4 Instruction Manual for terminal identification it is important to check terminal contact between a connector and component or between in line connectors before replacing a suspect component When diagnosing an electrical system that utilizes Metri Pak Frequently a diagnostic chart leads to a step that reads Check for poor connection Mating terminals must be inspected to assure good terminal contact A poor connection between the male and female terminal at a connector may be the result of contamination or deformation Contamination is caused by the connector halves being improperly connected a missing or damaged connector seal or damage to the connector itself exposing the terminals to moisture and dirt Contamination usually in underhood or underbody connectors leads to terminal corrosion causing an open circuit or intermittently open circuit 11 14 Wiring Systems Deformation is caused by probing the mating side of a connector terminal without the proper adapter improperly joining the connector halves or repeatedly separating and joining the connector halves Deformation usually to the female terminal contact tang can result in poor terminal contact causing an open or intermittently open circuit Follow the procedure below to check terminal contact 1 Separate the connector halves Refer to the J 38125 A Terminal Repair Kit or the J 38125 4 instruction manual 2 Inspect the connector halves for co
193. Jo uoniuD 1041405 uous soneuieuos uo uoniubi 4901 8 SNJ L NH L HMd 1 1 1 1 1 1 2011 Marine Engines Manual 15 9 Engine Controls and Fuel 6rerrre Wod L __ a J pesn 10N 109 uoniub wa shg uous 101nquisiq ex 21 NO T 1 9inpow lonu uous 50305 25 2011 Marine Engines Manual Josueg Josues 470 uonisod BIg 0155 615 57 SM Marine dure uooS JesseA Jezzng YOUMS NOLLINOI 16 Engine Controls and Fuel 3 S 0 S E t 0 s1osueg pue jeusxue1 sjouo 9 2011 Marine Engines Manual 17 9 Engine Controls and Fuel vSsevvvo Josue 5 jonuo due uoos 12 9 0 9 40 6 pue yeysweg yeusxue1 Josue uonisod yeyuswey IH NOLLINOI yeysweg
194. N 66040 66041 66042 and 66043 are Type C SPNs Conditions for Clearing the SPN SPN 66040 66041 66042 and 66043 are Type C SPNs Reference Information Schematic Reference Engine Controls Schematics on page 9 6 OEM Output Driver 1 Voltage Above Normal or Shorted High OEM Output Driver 1 Current Below Normal or Open Circuit OEM Output Driver 2 Voltage Above Normal or Shorted High OEM Output Driver 2 Current Below Normal or Open Circuit OEM Output Driver 3 Voltage Above Normal or Shorted High OEM Output Driver 3 Current Below Normal or Open Circuit OEM Output Driver 4 Voltage Above Normal or Shorted High OEM Output Driver 4 Current Below Normal or Open Circuit Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification 1 Ignition ON command the OEM device ON and OFF with a scan tool The OEM device should turn ON and OFF 2 Observe the SPN information with a scan tool SPN 66040 66041 66042 or 66043 should not set 3 Ope
195. N Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 107 Circuit System Verification 3 Ignition ON connect a test lamp between the control circuit terminal and ground The test 1 Ignition ON command the fuel solenoid valve ON lamp should not illuminate and OFF with a scan tool An audible click should be heard when changing between the commanded bg control circuit for a short to voltage states 2 If the circuit connections test normal 2 Observe the SPN information with a scan tool replace the ECM SPN 1765 4 or 1765 5 should not set If the test lamp is always ON test the 4 Command the fuel solenoid valve ON and OFF 3 Operate the vehicle within the Conditions for with a scan tool The test lamp should illuminate Running the SPN to verify the SPN does not and turn OFF as commanded reset You may also operate the vehicle within the If the test lamp is always OFF test the control conditions that you observed from the Freeze ircuit f high resi h Frame F ailure Records data circuit for an open high resistance or a short to ground If the circuit connections test normal replace the ECM Circuit System Testing 5 all the circuit connections test normal test or 1 Ignition OFF disconnect the harness connector at replace the fuel
196. NN nition conr 01 2 Fuel Injector 1 Control s Fuel Injector 8 Control Fre injector Conto 5 Fuel injector 2 Control 6 Fuel injector 6 Contro Fuel injector como 8 Fuel injector Control 9 Fuel injectors Contr Wed ENNENNENE 7 AN Solenoid Control 3 Notused 15 15 Motor Control Open 16 ETC IAC Motor Control Close Lr dB O4 19 Electronic Spark Timing EST Return 2 Crank Sensor Low Reference 25 _ Not Used 27 Oil Temperature Sensor Low Reference Ignition 1 Voltage Camshaft Actuator Solenoid Low Reference Se 31 Switch Signal Exhaust Gas 32 Recirculation EGR Solenoid Valve or Fuel Valve High Control 3s 35 s oit Reference S otReferencet 9 32 Engine Controls and Fuel Marine Engine Control Module ECM X2 cont d Pin Wire Circuit Function TP Sensor 1 and 2 Low 44 Reference 4 wtued 46 Fuel Temperature Sensor Signal Heated Oxygen Sensor HO2S Signal Low Sank Sensor 1 HO2S Signal Low Bank B Sensor 1 Knock Sensor KS 1 Signal Low 5 kS2Signal
197. Normal or Shorted Low SPN 105 FMI 15 Manifold Air Temperature MAT Sensor Circuit Voltage Data Valid But Above Normal Range Least Severe Level Diagnostic Fault Information Short to Open High Short to Signal Circuit Ground Resistance Voltage Performance MAT Sensor Signal 105 4 105 3 105 3 105 15 MAP MAT Low Reference 105 3 __ 105 15 Internal or sensor damage may occur if the circuit is shorted to B Typical Scan Tool Data MAT Sensor ShottoGrund Open Short to Voltage Operating Conditions Engine operating in Closed Loop Parameter Normal Range Varies with ambient temperature 130 C 266 F 40 C 40 F 40 C 40 F lwReeeme 0050 409 Circuit Description The manifold air temperature MAT sensor is a variable resistor that measures the temperature of the air entering the engine The MAT sensor has a signal circuit and a low reference circuit The engine control module ECM supplies 5 volts to the MAT signal circuit and a ground for the MAT low reference circuit The following table illustrates the difference between temperature resistance and voltage MAT Signal MAT MAT Resistance Voltage Conditions for Running the SPN SPN 110 630 65580 65620 65621 65622 or 65623 is not set The engine is operating for greater than 10 seconds The SPN 105 runs continuously once the above conditions are met 2011 Marine Engines Manual Condit
198. PN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification Note The engine oil level and the oil pressure are critical to the correct operation of the camshaft position CMP actuator system Verify that the engine has the correct oil level and the correct oil pressure before continuing with this diagnostic 1 Ignition ON observe the scan tool SPN information Verify that none of the following 5 are set SPN 98 100 636 65615 65616 65618 or 65723 If any of the SPNs are set refer to Diagnostic Trouble Code DTC List on page 6 11 2 Engine idling observe the scan tool SPN information SPN 65570 2 or 65570 7 should not set Note may be necessary to perform the procedure few times in order to clean the cam phaser actuator If either SPN is set perform the cam phaser actuator cleaning procedure with a scan tool Verify SPNs 65570 2 or 65570 7 do not reset 3 Engine idling observe the scan tool SPN information SPN 65570 4 or 65570 5 should not be set 4 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Ignition OFF disconnect the Camshaft Position Sensor and Actuator Magnet jumper harness connector Refer to Engine Controls
199. PN 1765 Low Side Driver on page 9 108 2011 Marine Engines Manual 6 14 Vehicle Diagnostic Information Diagnostic Trouble Code DTC List cont d DTC Descriptor Diagnostic Procedure Note If multiple powertrain SPNs are stored diagnose the SPNs in the following order 1 Component level SPNs such as sensor SPNs solenoid SPNs and relay SPNs 2 System level SPNs such as misfire SPNs and fuel trim SPNs Supercharger Inlet Pressure Sensor 7388 Voltage Data Valid but Above Normal SPN 3563 on page 9 110 Supercharger Inlet Pressure Sensor 3563 Data Valid but Below Normal SPN 3563 on page 9 110 Supercharger Inlet Pressure Sensor _ 3563 Data Erratic Intermittent or Incorrect SPN 3563 on page 9 110 Supercharger Inlet Pressure Sensor Voltage Above Normal or Shorted High SPN 3563 on page 9 110 Supercharger Inlet Pressure Sensor os Voltage Below Normal or Shorted Low SPN 3563 on page 9 110 65541 4 EST 1 Voltage Below Normal or SPN 65541 65542 65543 65544 65545 65546 Shorted Low 65547 or 65548 on page 9 113 65541 5 EST 1 Current Below Normal Open SPN 65541 65542 65543 65544 65545 65546 Circuit 65547 or 65548 on page 9 113 65542 4 EST 2 Voltage Below Normal SPN 65541 65542 65543 65544 65545 65546 Shorted Low 65547 or 65548 on page 9 113 65542 5 EST 2 Current Below Normal or Open SPN 65541 65542 65543 65544 65545 65546 Circuit 65547 or 65548 on page 9 113 65543 4 EST 3 Voltage
200. RTV sealant The sensors may have a white powdery coating and result in a high but false signal voltage which gives a rich exhaust indication The ECM reduces the amount of fuel delivered to the engine causing a driveability condition 2011 Marine Engines Manual Hard Start Test the engine coolant temperature ECT sensor Compare the ECT sensor value to the manifold air temperature MAT sensor value on a cold engine The ECT and MAT sensor values should be within 3 C 5 F If the ECT sensor is out of range with the MAT sensor test the resistance of the ECT sensor Refer to Temperature Versus Resistance on page 9 3 for resistance specifications Replace the ECT sensor if the resistance is not within specification Refer to Engine Coolant Temperature Sensor Replacement on page 9 218 the sensor is within the specification test the ECT circuits for a high resistance Test the fuel pump relay operation The fuel pump should turn ON for 2 seconds when the ignition is turned ON Refer to Fuel Pump Electrical Circuit Diagnosis on page 9 207 Hesitation Sag Stumble Test the manifold absolute pressure MAP sensor Refer to SPN 106 3 01 4 3L 5 0L 5 7L on page 9 83 or SPN 106 2 4L 6 0L 6 2L on page 9 86 Test the generator Repair the charging system if the generator output voltage is less than 10 V or greater than 16 V Poor Fuel Economy Heavy loads being carried or towed Acceleration rate to
201. SPN 174 FMI3 Fuel Temperature FT Sensor Circuit Voltage Above Normal or Shorted High SPN 174 FMI 4 Fuel Temperature FT Sensor Circuit Voltage Below Normal or Shorted Low Diagnostic Fault Information Short to Circuit Ground Open High Short to Signal Resistance Voltage Performance FT Sensor Signal Low Reference 174 4 174 3 174 3 174 1 ___ 174 3 174 0 Internal ECM or sensor damage may occur if the circuit is shorted to B Circuit System Description The fuel temperature FT sensor is a variable resistor that measures the temperature of the fuel The engine control module ECM supplies 5 volts to the FT signal circuit and supplies a ground to the low reference circuit The following table illustrates the difference between temperature resistance and voltage FT Signal FT FT Resistance Voltage Low Low Conditions for Running the SPN 174 FMI 0 or 1 SPN 630 65580 65620 65621 65622 or 65623 is not set Before the ECM can report that SPN 174 0 or 174 1 failed SPN 110 174 3 and 174 4 must run and pass The engine is operating for greater than 10 seconds The SPNs run continuously when the above condition is met 174 FMI 3 or 4 SPN 630 65580 65620 65621 65622 or 65623 is not set The ignition is ON or the engine is operating for greater than 10 seconds The SPNs run continuously when the above condition is met Conditions for Setting the SPN 174
202. Select Normal from the Display Mode on the CH 48027 9 Press Enter on the scan tool to bring you back to the Select Injector screen 10 Repeat steps 3 through 9 for each fuel injector U Perform the Pressure Drop Calculation Pressure Drop Calculation 1 Subtract the minimum pressure from the starting pressure for one fuel injector The result is the pressure drop value 2 Obtain a pressure drop value for each fuel injector 3 Add all of the individual pressure drop values except for the injector suspected of being faulty This is the total pressure drop 4 Divide the total pressure drop by the number of fuel injectors that were added together This is the average pressure drop The difference between any individual pressure drop and the average pressure drop should not be more than 20 kPa 3 psi gt If the difference between any individual pressure drop and the average pressure drop is more than 20 kPa 3 psi replace the fuel injector Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Fuel Injector Replacement Except 2 4L on page 9 238 or Fuel Injector Replacement 2 4L on page 9 240 Alcohol Contaminants in Fuel Diagnosis Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis page 6 4 for an overview
203. Signal s low Reference 40 Powertrain Relay Coil Control ee High CAN Serial Data Bus Not edem IATIMAT Sensor Signal Exhaust Gas 46 Temperature EGT Sensor Bank B 47 49 Available 5 _ TAH Pull Up 8 Contra 53 Speed Based Output 2011 Marine Engines Manual Engine Control Module ECM 1 cont d Pim Wire Circuit Function Buzzer s Not Used 56 Governor Status Lamp Control Engine Control Module ECM X2 1590596 Connector Part Information Harness Engine OEM 15466079 Service 88988931 Description 73 Way MX123 Series Sealed Terminal Part Information Pins 11 24 29 40 43 44 60 63 65 Terminal Tray 33467 0003 23 Core Insulation Crimp H H Release Tool Test Probe J 38125 213 J 35616 64B L BU Pins 3 5 11 18 20 25 27 29 31 33 39 43 45 47 53 56 Terminal Tray 33467 0005 23 Core Insulation Crimp Pins 1 9 15 20 25 28 33 36 41 47 50 52 56 61 67 70 72 J J Core Insulation Crimp Pins 49 50 69 70 Release Tool Test Probe J 38125 213 J 35616 64B L BU Pins 73 Terminal Tray 7116 4152 02 9 Core Insulation Crimp A 5 Release Tool Test Probe J 38125 11A J 35616 35 VT 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 31 Engine Control Module ECM X2 eS
204. Signal Abnormal Frequency or Pulse Width Short to Open High Short to Signal Circuit Ground Resistance Voltage Performance 5 Volt Reference Circuit 65620 4 65723 8 65724 8 CMP Sensor Signal Circuit System Description The 4X camshaft position sensor circuits consist of an engine control module ECM supplied 5 V reference circuit low reference circuit and an output signal circuit The camshaft position sensor is an internally magnetic biased digital output integrated circuit sensing device The sensor detects magnetic flux changes between the peaks and valleys of a 4 tooth reluctor wheel attached to the camshaft As each reluctor wheel tooth rotates past the camshaft position sensor the resulting change in the magnetic field is used by the sensor electronics to produce a digital output pulse The sensor returns a digital ON OFF DC voltage pulse of varying frequency with 2 narrow and 2 wide output pulses per camshaft revolution that represent an image of the camshaft reluctor wheel The frequency of the camshaft position sensor output depends on the velocity of the camshaft The ECM decodes the narrow and wide tooth pattern to identify camshaft position This information is then used to sequence the ignition timing and fuel injection events for the engine The ECM also uses camshaft position sensor output information to determine the camshaft relative position to the crankshaft to control the camshaft position actuator if equipp
205. Terminal D If less than the specified range repair the appropriate circuit for an open If the circuit tests normal replace the ECM If greater than the specified range test the appropriate circuit for a short to voltage If the circuit tests normal replace the ECM 6 If all circuits test normal refer to the scan tool user guide Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the repair Engine Control Module Programming and Setup on page 6 3 for engine control module replacement setup and programming Description and Operation Data Link Communications Description and Operation The communication among control modules and scan tool is performed through the Controller area network CAN high speed serial data circuit The data link connector DLC is a 6 cavity connector The connector provides the following Scan tool power battery positive voltage at terminal A Scan tool power ground at terminal B CAN HI communication circuit at terminal C CAN LO communication circuit at terminal D The serial data is transmitted on two twisted wires The twisted pair is terminated with a 120 ohms resistor The resistor is located in the engine control module ECM The resistor is used to reduce noise on the High Speed CAN bus during normal vehicle operation The high speed CAN is a differential bus The high speed CAN serial data bus and high speed CAN serial data
206. Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs page 11 16 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification 1 Ignition ON observe the SPN information with a scan tool Verify SPN 65620 65621 65622 or 65623 is not set gt If an SPN is set refer to SPN 65620 65623 on page 9 149 for further diagnosis 2 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Ignition OFF disconnect the harness connector at the VSS 2 Test for less than 5 Q between the low reference circuit terminal and ground If greater than the specified range test the low reference circuit for an open high resistance If the circuit tests normal replace the ECM 3 Ignition ON test for 4 8 5 2 V between the 5 volt reference circuit terminal and ground If less than the specified range test the 5 volt reference circuit for a short to ground or an open high resistance If the circuit tests normal replace the ECM greater than the specified range test the 5 volt reference circuit for a short to voltage If the circuit tests normal replace the ECM 4 Ignition ON test for 4 8 5 2 V between the signal circuit terminal and ground If less than t
207. The engine speed is sent to the IPC over a discreet wire from the ECM Conditions for Running the SPN SPN 630 or 65580 is not set The ignition voltage is greater than 9 volts The component has been commanded ON and OFF at least once during the ignition cycle SPN 66018 runs continuously once the above conditions are met Conditions for Setting the SPN The ECM detects that the commanded state of the driver and the actual state of the control circuit do not match for greater than 5 seconds Action Taken When the SPN Sets SPN 66018 is Type C SPN Conditions for Clearing the SPN SPN 66018 is Type C SPN Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 2011 Marine Engines Manual Circuit System Verification 1 Engine idling the tachometer should display engine speed 2 Engine operating observe the scan tool SPN information SPN 66018 should not be set 3 Opera
208. Type 5 RS 6 9 Failure Mode Indicator FMI Definitions 6 10 Diagnostic Trouble Code DTC List 6 11 Data Link Connector Scan Tools 6 22 Scan Tool Use with Intermittents 6 22 Diagnostic Repair Verification 6 2 Table of Contents BLANK 2011 Marine Engines Manual Programming and Setup Repair Instructions Engine Control Module Programming and Setup For step by step programming instructions please refer to the manufacturers guidelines Review the information below to ensure proper programming protocol Important NOT program a control module unless you are directed by a service procedure or you are directed by the manufacturers service bulletin Programming a control module at any other time will not permanently correct a customers concern It is essential that the Scan Tool is equipped with the latest software before performing service programming Due to the time requirements of programming a controller it is recommended that an external power source be used to maintain system voltage Stable battery voltage is critical during programming Any fluctuation spiking over voltage or loss of voltage will interrupt programming SPNs may set during programming Clear DTCs after programming is complete Ensure the following conditions are met before programming a control module Vehicle system voltage There is not
209. Valid but Below Normal Data Erratic Intermittent or Incorrect Voltage Above Normal or Shorted High Voltage Below Normal or Shorted Low 84 2 SPN 630 65580 65620 65621 65622 65623 is not set The engine is operating for greater than a calibrated time The SPN runs continuously when the conditions above exist 84 3 and 84 4 SPN 630 65580 65620 65621 65622 or 65623 is not set The engine is operating for greater than a predetermined time The pedal position is less than a predetermined value The SPNs run continuously when the conditions above are met Conditions for Setting the SPN 84 1 The ECM detects that the VSS signal is greater than a calculated value 84 2 The ECM detects the VSS signal is erratic for greater than pre determined time 84 3 and 84 4 The ECM detects a short to ground an open or a short to voltage in the VSS circuits or sensor Action Taken When the SPN Sets SPN 84 is a Type C SPN The cruise control system will be disabled Conditions for Clearing the SPN SPN 84 is a Type C SPN 9 70 Engine Controls and Fuel Marine Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22
210. Varies present The scan tool will display a 0 if a Last DTC fault has occurred The scan tool will display a higher count if a number of warm up cycles have occurred without a fault This parameter displays the commanded Warning Buzzer Output OFF state of the warning buzzer control circuit by the control module Engine Control Module ECM Scan Tool Output Controls Output Control Boost Override This function controls the boost solenoid from the none to ON or OFF This function controls the buzzer The normal commanded state is None When commanded ON the ECM will command the buzzer ON and OFF This function controls the camshaft actuator solenoid The normal commanded state is NONE The system will command the camshaft solenoid valve ON to 90 percent for approximately 2 seconds This causes the camshaft actuator to travel to the maximum advance or retard position approximately 40 degrees camshaft depending on the actual Cam Phaser Cleaning engine speed The scan tool initiates the test when the following conditions are met The vehicle speed is 0 km h 0 mph The engine speed is between 2 000 2 500 RPM The transmission is in neutral This function controls the check gauges lamp The normal commanded state is None Check Gauges Lamp Override When commanded ON the ECM will blink the check gauges lamp ON and OFF This function controls the fuel pump relay When commanded ON OFF the ECM turns the fuel pump relay ON OFF If
211. a EOP Sensor Short to Ground Open Shortto Voltage Operating Conditions Engine idling at Normal Operating Temperature Parameter Normal Range 41 414 kPa 6 60 psi 5 Volt Reference 0 kPa 0 psi 0 kPa 0 psi 0 kPa 0 psi EOP Sensor Signal 0 kPa 0 psi 0 kPa 0 psi 910 kPa 132 psi C 15 77088 Internal ECM damage may occur if the circuit is shorted to B Circuit System Description The engine oil pressure EOP sensor changes voltage based on the engine oil pressure The EOP sensor is a 3 wire sensor comprising of the signal circuit the low reference circuit and the 5 volt reference circuit The engine control module ECM supplies 5 volts to the EOP sensor via the 5 volt reference circuit and provides ground via the EOP low reference circuit The ECM monitors the signal circuit of the EOP sensor to determine the EOP sensor voltage is within the normal operating range of approximately 1 4 volts When the engine oil pressure is high the EOP sensor voltage is high and the ECM senses a high signal voltage When the engine oil pressure is low the EOP sensor voltage is low and the ECM senses a low signal voltage An EOP fault code will cause RPM reduction to occur on some engine applications 2011 Marine Engines Manual Conditions for Running the SPN 100 3 and 100 4 SPNs 630 65580 65620 65621 65622 or 65623 is not set The ignition is ON or engine is operating The SPNs run
212. a for aid in diagnosis This connector allows the technician to use a scan tool in order to monitor the various serial data parameters and to display diagnostic trouble code DTC information The DTCs are displayed on the scan tool as a SPN The SPN s stored in the ECM memory can be retrieved through a hand held diagnostic scanner plugged into the DLC or through a PC based software program that is designed to interface with the ECM Clearing Suspect Parameter Numbers 1 Install scan tool or use PC based software 2 Engine idling observe the scan tool diagnostic trouble code DTC information 3 Select clear DTC function 4 Clear DTC s Important When clearing DTCs with the scan tool the ignition must be cycled OFF or the will not clear 5 Ignition OFF for 20 seconds 6 Engine idling observe the scan tool DTC information Verify no DTCs reset If any DTCs reset refer to Powertrain On Board Diagnostic OBD System Check on page 9 64 for further diagnosis 2011 Marine Engines Manual Suspect Parameter Number SPN Type Definitions Emissions Related SPNs Action Taken When the SPN Sets The control module illuminates the malfunction indicator lamp MIL when the diagnostic runs and fails The control module records the operating conditions at the time the diagnostic fails The control module stores this information in the Freeze Frame Failure Records Action Taken W
213. a short to ground or an open high resistance If the circuit tests normal and the ignition circuit fuse is open test all the components connected to the ignition circuit and replace as necessary Connect a test lamp between the control circuit terminal and The test lamp should not illuminate If the test lamp is always ON test the control circuit for a short to ground If the circuit connections test normal replace the ECM Command the fuel solenoid valve ON and OFF with a scan tool The test lamp should illuminate and turn OFF as commanded If the test lamp is always OFF test the control circuit for an open high resistance If the circuit connections test normal replace the ECM Test for 3 0 4 0 V between the control circuit terminal and ground If not within the specified range test the control circuit for a short to voltage If the circuit connections test normal replace the ECM If all the circuit connections test normal test or replace the fuel solenoid valve Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data 2011 Marine Engines Manual Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Engine Control Module Replacement on page 9 217 for ECM replacem
214. ace the ECM 5 all circuits test normal test or replace the ECT sensor 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 93 Component Testing 1 Ignition OFF disconnect the harness connector at the ECT sensor Note A thermometer can be used to test the sensor off the vehicle 2 Test the ECT sensor by varying the sensor temperature while monitoring the sensor resistance Compare the readings with the Temperature Versus Resistance on page 9 3 table and verify that the resistance is within 5 percent of the specification If not within the specified range replace the ECT sensor Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Engine Coolant Temperature Sensor Replacement on page 9 218 Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 9 94 Engine Controls and Fuel Marine SPN 174 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 174 FMI 0 Fuel Temperature FT Sensor Data Valid but Above Normal SPN 174 FMI 1 Fuel Temperature FT Sensor Data Valid but Below Normal
215. age indicates only the throttle opening necessary to maintain the desired idle speed and is not a function of the throttle plates total travel from closed to wide open This parameter displays YES if the vehicle is Intercooler Output Active YES equipped with an intercooler and the engine is operating This parameter displays YES when the a Bus ico control module is compensating for an engine detonation spark knock 2011 Marine Engines Manual 9 58 Engine Controls and Fuel Marine Engine Control Module Scan Tool Data cont d System State Expected Value Injector Bank A Injector Bank B E Knock Present in Last Second Load Anticipate 1 or 2 Input Load Anticipate 1 or 2 Enable Load Anticipate 1 or 2 This parameter displays the average pulse width modulation in milliseconds of the fuel injectors on cylinder bank A This parameter displays the average pulse width modulation in milliseconds of the fuel injectors on cylinder bank B This parameter displays YES when the control module detects a spark knock condition This parameter displays in degrees the amount of timing compensation the control module is commanding to compensate for spark knock This parameter displays YES if an OEM system or component has been installed that places an additional load on the engine when activated This parameter displays YES if an OEM installed system or component has been activated This
216. agnostic runs and does not fail A current SPN Last Test Failed clears when the diagnostic runs and passes A history SPN clears after 40 consecutive warm up cycles if no failures are reported by this or any other emission related diagnostic Clear the MIL and the SPN with a scan tool 6 10 Vehicle Diagnostic Information Non Emissions Related SPNs Action Taken When the SPN Sets Type The control module stores the SPN information into memory when the diagnostic runs and fails The Service Vessel Soon SVS lamp if equipped will illuminate The control module records the operating conditions at the time the diagnostic fails The control module stores this information in the Failure Records Action Taken When the SPN Sets Type C1 The control module stores the SPN information into memory when the diagnostic runs and fails The DTC 1 lamp if equipped will illuminate The control module records the operating conditions at the time the diagnostic fails The control module stores this information in the Failure Records Action Taken When the SPN Sets Type C2 The control module stores the SPN information into memory when the diagnostic runs and fails The DTC 2 lamp if equipped will illuminate The control module records the operating conditions at the time the diagnostic fails The control module stores this information in the Failure Records Action Taken When the SPN Sets T
217. al circuit When the throttle control is in the neutral position the ECM detects a high signal voltage When the throttle control is shifted out of neutral the contacts on the shift interrupt switch close and the ECM detects a low shift interrupt signal The ECM will momentarily reduced the engine RPM when the signal circuit is grounded Conditions for Running the SPN SPN 630 or 65580 is not set The ignition is ON or the engine is operating The pedal position is less than 5 percent SPN 66026 runs continuously when the above conditions are met Conditions for Setting the SPN The ECM detects the shift interrupt switch signal circuit is open shorted to ground or shorted to a voltage for greater than a calibrated amount of time Action Taken When the SPN Sets SPN 66026 is Type C SPN Conditions for Clearing the MIL SPN SPN 66026 is Type C SPN 2011 Marine Engines Manual Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 for scan tool information Circuit System Verification 1 Ignition ON observe th
218. al circuit for a short to voltage If the circuit tests normal replace the ECM 4 Install a 3 A fused jumper wire between the signal circuit terminal B and the low reference circuit terminal A Ignition ON verify the scan tool HO2S voltage parameter is less than 48 mV greater than the specified range test the signal circuit for an open high resistance If the circuit tests normal replace the ECM 5 Verify none of the following conditions exist The HO2S is loose Lean or rich fuel injectors Refer to Fuel Injector Diagnosis on page 9 21 1 Water intrusion in the HO2S harness connector Low or high fuel system pressure Refer to Fuel System Diagnosis with Returnless Fuel System on page 9 208 or Fuel System Diagnosis without Returnless Fuel System on page 9 210 Fuel that is contaminated Refer to Alcohol Contaminants in Fuel Diagnosis on page 9 213 Exhaust leaks near the HO2S Engine vacuum leaks If you find any of the above conditions repair as necessary 6 If all circuits test normal test or replace the applicable HO2S Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Heated Oxygen Sensor Heplacement on page 9 226 Engine Control Module Replacement on page 9 217 for engine control module replacement setup and programming 2011 Marine Engines Manual SPN 65570 6 0 6 2L Diagnostic Instructions Perform the
219. ale connector will swell and may prevent proper reconnection if not lubricated Fuel Storage Warning Warning Do not drain the fuel into an open container Never store the fuel in an open container due to the possibility of a fire or an explosion Fuel System Pressure Warning Warning Do not open the fuel system while the engine is running Allow the fuel system pressure to drop before opening the system The fuel system is under very high pressure Failure to comply could result in personal injury Gasoline Gasoline Vapors Warning Warning Gasoline or gasoline vapors are highly flammable A fire could occur if an ignition source is present Never drain or store gasoline or diesel fuel in an open container due to the possibility of fire or explosion Have a dry chemical Class B fire extinguisher nearby On Vehicle Fire Extinguisher Warning Warning Place a dry chemical Class B fire extinguisher nearby before performing any on vehicle service procedures Failure to follow these precautions may result in personal injury Relieving Fuel Pressure Warning Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury After you relieve the fuel system pressure a small amount of fuel may be released when servicing the fuel lines the fuel injection pump or the connections In order to reduce the risk of personal injury cover the fue
220. alfunction indicator lamp MIL are operating correctly There are no suspect parameter numbers SPNs stored The scan tool data is within the normal operating range Bulletins are not available for the current symptom The ECM grounds are clean tight and in the correct locations The air filter element is not restricted 9 200 Engine Controls and Fuel Marine Symptoms Testing Backfire Cuts Out Misses Detonation Spark Knock Dieseling Run On Hard Start Hesitation Sag Stumble Lack of Power Sluggishness Sponginess Poor Fuel Economy Rough Unstable or Incorrect Idle and Stalling or Surges Chuggles 1 Test for the following conditions The fuel system for the following Correct fuel pressure Refer to Fuel System Diagnosis with Returnless Fuel System on page 9 208 or Fuel System Diagnosis without Returnless Fuel System on page 9 210 Fuel injectors that are leaking or improper operation Refer to Fuel Injector Diagnosis on page 9 211 Contaminated or a poor fuel quality condition Refer to Alcohol Contaminants in Fuel Diagnosis on page 9 213 The ignition system for the following Spark plugs for incorrect heat range or an abnormal condition Refer to Spark Plug Inspection on page 9 245 Wet down the secondary ignition system with water from a spray bottle Wetting down the secondary ignition system may help locate damaged or deteriorated components Look listen for arcing or
221. ally magnetic biased digital output integrated circuit sensing device The sensor detects magnetic flux changes of the teeth and slots of the reluctor wheel on the crankshaft The CKP sensor produces an ON OFF DC voltage of varying frequency The CKP sensor sends a digital signal to the ECM as each tooth on the reluctor wheel rotates past the CKP sensor The ECM uses each CKP signal pulse to determine crankshaft speed and position This information is then used to determine the optimum ignition and injection points of the engine The ECM also uses CKP sensor output information to determine the camshaft relative position to the crankshaft to control camshaft phasing and to detect cylinder misfire 9 288 Engine Controls and Fuel Marine Camshaft Position CMP Sensor The sensor detects magnetic flux changes between the four narrow and wide tooth slots on the reluctor wheel The CMP sensor provides a digital ON OFF DC voltage of varying frequency per each camshaft revolution The ECM will recognize the narrow and wide tooth patterns to identify camshaft position or which cylinder is in compression and which is in exhaust The information is then used to determine the correct time and sequence for fuel injection and ignition spark events The CMP sensor information is used by the ECM to determine the position of the valve train relative to the crankshaft Ignition Coil and ICM The ICM is connected to the ECM by an ignition control IC
222. an overview of each diagnostic category SPN Descriptors SPN 65690 FMI 3 SPN 65690 FMI 4 Circuit System Description The variable governor control switch is used on vessels equipped with cruise control to adjust the cruise speed The ECM supplies the variable governor control switch with a 5 volt reference circuit and a low reference circuit The variable governor control switch supplies a signal voltage to the ECM that varies dependent upon switch rotation As The variable governed control switch is rotated the signal voltage increases or decreases depending on the cruise control speed that is desired The ECM controls the cruise speed with the throttle actuator control TAC system Conditions for Running the SPN SPN 630 65580 65620 65621 65622 or 65623 is not set The ignition is ON or the engine is operating SPN 65690 runs continuously when the conditions above are met for greater than 5 seconds Conditions for Setting the SPN 65690 3 The ECM detects the variable governor control signal voltage is greater than a calibrated value for greater than 5 seconds 65690 4 The ECM detects the variable governor control signal voltage is less than a calibrated value for greater than 5 seconds Action Taken When the SPN Sets SPN 65690 is a Type C SPN 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 153 Variable Governor Control Voltage Above Normal or Shorted High Variable G
223. an tool concern should be reported to the manufacturer Use of a faulty scan tool can result in misdiagnosis and unnecessary parts replacement Only the parameters listed below are referenced in this service manual for use in diagnosis System Check will identify the correct procedure for diagnosing the system and where the procedure is located Engine Control Module Scan Tool Data Expected Value Base Operating Conditions Engine Idling Normal Operating Temperature Neutral Closed Loop A DTC has set this ignition cycle This parameter displays if a DTC has set during this ignition cycle This parameter displays amount of boost 0 0 kPa being supplied by the supercharger as calculated by the control module This parameter displays the amount and speed of the air flow entering the engine as Air Flow Varies determined by the control module based on inputs from the TP and MAP sensors Actual Boost This parameter displays the barometric ik _ pressure The control module uses the 65 104 kPa 8 16 psi barometric pressure sensor input for fuel control to compensate for altitude differences This parameter displays B when the B control module detects a voltage at the ignition 1 input terminal This parameter displays the boost control 0 0 solenoid time or duty cycle being commanded by the control module This parameter displays YES when the Boost System Present YES NO control module de
224. ance The following guidelines should be used when servicing the heated oxygen sensor Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors These materials may get into the sensor causing poor performance Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed This could provide a path for foreign materials to enter the sensor and cause performance problems Ensure the sensor or vehicle lead wires are not bent sharply or kinked Sharp bends or kinks could block the reference air path through the lead wire Do not remove or defeat the oxygen sensor ground wire where applicable Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor Removal of the ground wire will cause poor engine performance Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion The engine harness may be repaired using Packard s Crimp and Splice Seals Terminal Repair Kit Under no circumstances should repairs be soldered since this could result in the air reference being obstructed Ignition OFF When Disconnecting Battery Caution Caution Always turn the ignition OFF when connecting or disconnecting battery cables battery chargers or jumper cables Failing to do so may damage the Powertrain Control Module PCM or other electronic com
225. ance If the circuit test normal replace the buzzer 5 f all the circuit connections test normal replace the ECM Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 9 172 Engine Controls and Fuel Marine SPN 66006 66008 or 6609 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptor SPN 66006 FMI 3 SPN 66006 FMI 5 SPN 66008 FMI 3 SPN 66008 FMI 5 SPN 66009 FMI 3 SPN 66009 FMI 5 Diagnostic Fault Information Circuit DTC 1 Lamp Voltage Supply DTC 2 Lamp Voltage Supply DTC 3 Lamp Voltage Supply DTC 1 Lamp Control DTC 2 Lamp Control DTC 3 Lamp Control DTC Lamp 3 Voltage Above Normal or Shorted High DTC Lamp 3 Current Below Normal or Open Circuit DTC Lamp 1 Voltage Above Normal or Shorted High DTC Lamp 1 Current Below Normal or Open Circuit DTC Lamp 2 Voltage Above Normal or Shorted High DTC Lamp 2 Current Below Normal or Open Circuit Short to Ground Short to Open High i Voltage Resistance 66008 5 Signal Performance P
226. ance Voltage Performance EOT Sensor Signal 175 4 175 3 175 3 175 15 __ _____ ___ EOT Low Reference __ 175 3 Internal or sensor damage may occur if the circuit is shorted to B Typical Scan Tool Data EOT Sensor Short to Ground Open _ Short to Voltage Operating Conditions Engine operating in Closed Loop Parameter Normal Range Varies with ambient temperature EOT Sensor Signal 152 C 305 40 40 F 40 40 F towers eo eo Internal ECM or sensor damage may occur if the circuit is shorted to B Circuit System Description 175 15 Before the ECM can report that 175 15 failed SPNs 175 3 and 175 4 must run and pass SPN 630 65580 65620 or 65621 is not set The engine run time is greater than a calibrated value SPN 175 15 runs continuously when the above conditions are met The engine oil temperature EOT sensor is a variable resistor that measures the temperature of the engine oil The engine control module ECM supplies 5 V on the EOT signal circuit and a ground to the low reference circuit Monitoring the engine oil temperature is necessary for optimal control of the cam actuators The oil temperature is monitored from the dual function oil level Conditions for Setting the SPNs switch and temperature sensor located in the oil pan 175 3 I The ECM detects the is colder than Conditions for Running the SPNs 35 C 31 F 175 3 and 175 4 ot
227. and ground at each relay connector If the test lamp does not illuminate test the ignition circuit for a short to ground or an open high resistance If the circuit tests normal and the ignition circuit fuse is open test all the components connected to the ignition circuit and replace as necessary 3 Connect a test lamp between a fuel control relay control circuit terminal 85 and The test lamp should not illuminate Ifthe test lamp is always ON test the control circuit for a short to ground If the circuit connections test normal replace the ECM Note Perform this test at terminal 85 of each relay if applicable 4 Command the appropriate fuel select output ON and OFF with a scan tool The test lamp should illuminate and turn OFF as commanded If the test lamp is always OFF test the control circuit for an open high resistance If the circuit connections test normal replace the ECM 5 Test for 3 0 4 0 V between the control circuit terminal and ground If not within the specified range test the control circuit for a short to voltage If the circuit connections test normal replace the ECM 6 If all the circuit connections test normal test or replace the fuel solenoid valve Component Testing 1 Ignition OFF disconnect the dual fuel control relay with the J 43244 2 Test for 70 110 between terminals 85 and 86 If not within the specified range replace the fuel pump relay 1 3 Test for
228. and idle If the engine does not start and idle perform the following 3 1 Ignition OFF disconnect the ECM harness connectors 3 2 Ignition ON verify that is available at the ECM ignition voltage circuit terminal X1 19 If less than the specified range refer to Run Crank Diagnosis on page 9 203 further diagnosis 3 3 Test for at the Battery voltage circuit terminal X1 20 gt If less than the specified range repair the circuit for a short to ground or an open high resistance 3 4 Test for less than 5 ohms between the ground circuit terminal X2 73 and ground If greater than the specified range repair the circuit for an open high resistance 3 5 If all circuits test normal replace the ECM 4 Ignition OFF verify a test lamp does not illuminate between the following data link connector CAN circuit terminals and CAN HI Terminal C CAN LO Terminal D If the test lamp illuminates disconnect each module connected to the CAN circuit one at a time while observing the test lamp If the test lamp does not illuminate when a module is disconnected replace the module If the test lamp remains illuminated repair the appropriate circuit for a short to ground 2011 Marine Engines Manual Data Communications 11 5 5 Ignition ON test for 2 7 volts between the following data link connector CAN circuit terminals and ground CANHI Terminal C CAN LO
229. anded state Intercooler Cooler Override is NONE When commanded ON the ECM turns the relay ON for approximately 2 seconds This function controls the malfunction indicator lamp MIL The normal commanded state MIL Lamp Override is None When commanded ON the ECM will blink the malfunction indicator lamp MIL ON and OFF O2 Heater Test This function commands the selected O2 heater control circuit ON and OFF This output control contains the engine oil remaining life determined from an algorithm based upon the effective engine revolutions and the hours of operation since the last oil change This output control may be used to reset the engine oil remaining life to 100 after an oil change or to any other value when replacing a control module This function will disable a fuel injector for a cylinder one at a time The engine speed can be monitored and used for comparing each cylinders RPM decrease Reset Block Learn Values Activates the reset of Fuel Multiplier data in all BLM Cell 1 05 This function controls the troll lamp lamp The normal commanded state is None Slow Mode Lamp Override When commanded ON the ECM will blink the troll lamp ON and OFF Speed Based Output Override This function allows the scan tool to override the speed based system for testing This function controls the service vehicle soon SVS lamp The normal commanded state SVS Lamp Override is None When commanded ON the ECM will blink the oil level lamp ON and O
230. ange the distributor is properly adjusted If not within the specified range remove the distributor in order to adjust the rotor Refer to Installation Procedure 2 in Distributor Replacement 3 0L on page 9 248 or Distributor Replacement 4 3L 5 0L 5 8L on page 9 251 Camshaft Retard Offset Adjustment 5 0L and 5 7L Test Procedure The ignition timing is not adjustable The distributor may need to adjusted in order to prevent ignition crossfire To insure proper alignment of the distributor perform the following Note The scan tool Cam Angle reading will not be accurate below 1 200 RPM 1 Engine idling at operating temperature Observe the scan tool Cam Angle parameter 2 Increase the engine speed to 1 200 RPM Verify the scan tool Cam Angle parameter is within 685 725 degrees If within the specified value the distributor is properly adjusted If not within the specified value adjust the distributor 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 255 Adjustment Procedure 18446 1 Ignition OFF slightly loosen the distributor hold down bolt Note The Cam Angle reading will not be accurate below 1 200 RPM 2 Engine operating raise the engine speed to 1 200 RPM Observe the scan tool Cam Angle parameter If the Cam Angle parameter is less than 685 degrees rotate the distributor in a counterclockwise direction to adjust If the Cam Angle parameter is greater t
231. are met 66035 7 Before the can report that SPN 66035 7 failed SPNs 66035 3 and 66035 5 must run and pass SPN 106 108 630 3563 or 65580 is not set The ignition is ON or the engine is operating The ignition voltage is greater than 9 volts The desired boost is stable within 5 percent SPN 66035 7 runs continuously when the above conditions are met 9 196 Engine Controls and Fuel Marine Conditions for Setting the SPN 66035 0 The ECM detects the SC boost exceeds 75 kPa for greater than 2 seconds 66035 3 and 66035 5 The ECM detects that the commanded state of the driver and the actual state of the control circuit do not match for greater than 5 seconds 66035 7 The Actual SC boost is 99 6 percent less than the desired boost for greater than 2 seconds OR The SC boost is 30 percent greater than the desired boost for greater than 2 seconds Action Taken When the SPN Sets SPN 66035 is a Type B SPN Conditions for Clearing the MIL SPN SPN 66035 is a Type B SPN Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Description and Operation Supercharger Description and Operation on page 9 282 Electrical Information Reference Circuit Testing on page 11 6 Connector Hepairs on page 11 22 Testing for Intermitt
232. arged The engine cranking speed is acceptable There is adequate fuel in the fuel tank 1 Engine cranking for 15 seconds observe the scan tool SPN information Verify that SPN 110 627 630 636 651 658 65541 65548 65580 65581 65615 65616 65620 65621 65622 65623 66013 66014 or 66017 is not set If any DTCs are set refer to Diagnostic Trouble Code DTC List on page 6 11 2 Engine cranking observe the scan tool Engine Speed parameter The scan tool should indicate an engine speed greater than 0 RPM If the engine speed is 0 RPM refer to SPN 636 3 0L 4 3L 5 0L 5 7L on page 9 100 or SPN 636 6 0L 6 2L on page 9 102 for further diagnosis 3 Cycle the ignition from OFF to ON You should hear and feel an audible click from the powertrain relay Repeat as necessary in order to verify powertrain relay operation gt If the powertrain relay does not click refer to SPN 66013 or 66014 on page 9 180 for further diagnosis 4 Connect a J 26792 to the boot of a spark plug wire of a cylinder and ground Note An erratic or weak spark is considered a no spark condition 5 Engine cranking verify the spark tester sparks lf there is no spark refer to Distributor Ignition DI System Diagnosis on page 9 214 or Electronic Ignition System Diagnosis on page 9 215 6 Ignition ON command the fuel pump ON with a scan tool You should hear the fuel pump turn ON If the fuel pump does not turn
233. at Inspect the harness connectors and the ground circuits of the fuel pump for poor connections If greater than the specified range replace the fuel pump Note The fuel pressure may vary slightly when the fuel pump stops operating After the fuel pump stops operating the fuel pressure should stabilize and remain constant 2 Verify the fuel pressure does not decrease greater Special Tools e J 34730 1A Fuel Pressure Gauge e J 37287 Fuel Line Shut Off Adapters Circuit System Verification Note Inspect the fuel system for damage or external leaks before proceeding Verify that adequate fuel is in the fuel tank before proceeding Verify that the low pressure fuel pump is operating if equipped A low pressure pump that is not functioning will cause low fuel pressure The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure 1 Ignition ON command the fuel pump relay ON with a scan tool You should hear the fuel pump turn ON and OFF If the fuel pump does not turn ON refer to Fuel Pump Electrical Circuit Diagnosis on page 9 207 2 Ignition OFF install the J 34730 1A Refer to Fuel Pressure Gauge Installation and Removal on page 9 229 3 Ignition ON command the fuel pump relay ON with a scan tool Verify the fuel pressure is between 380 427 kPa 55 62 psi and remains steady for 5 minutes Circuit System Testing Note T
234. ate this tool use the following procedure 1 Attach one lead to ground 2 Touch the other lead to various points along the circuit where voltage should be present 3 When the bulb illuminates there is voltage at the point being tested Using Fused Jumper Wires Tools Required J 36169 A Fused Jumper Wire Note A fused jumper may not protect solid state components from being damaged Do not use a fuse with a higher rating than the fuse that protects the circuit being tested The J 36169 A includes small clamp connectors that provide adaptation to most connectors without damage This fused jumper wire is supplied with a 20 A fuse which may not be suitable for some circuits Measuring Voltage To perform a voltage test 1 Connect one lead of a test light to a good ground If using a voltmeter ensure the voltmeter s negative COM lead is connected to ground battery negative 2 Switch the meter to V and connect the other lead of the test light or voltmeter to a selected test point on a connector or terminal 3 If the test light illuminates there is voltage present If using a voltmeter note the voltage reading It should be within one volt of the measured battery voltage unless otherwise specified in the system diagnosis 2011 Marine Engines Manual Wiring Systems 11 11 1683686 Legend 1 Power From Battery 2 Fuse 3 Switch 4 Relay Coil 5 Meter 6 Voltage Test Point 7 Voltage T
235. ation Crimp E A Release Tool Test Probe 15315247 J 35616 2A GY Camshaft Position CMP Sensor Intake 2 4L rn Wire Color No svetmeeewe ___ sensor Signal Camshaft Position CMP Sensor W 3 0 4 3 5 0 5 7L 684807 Connector Part Information OEM 12110293 Service 12117025 Description 3 Way F Metri Pack 150 Series Sealed BK Terminal Part Information Terminal Tray 12048074 2 Core Insulation Crimp E 1 Release Tool Test Probe 12094429 J 35616 2A GY Camshaft Position CMP Sensor W 3 0 4 3 5 0 5 7L Circuit Wire Color No SvotReterence e Om Sensor c tow Reterence 9 36 Engine Controls and Fuel Marine Camshaft Position CMP Sensor W 6 0 6 2L 684807 Connector Part Information OEM 12110293 Service 12117025 Description 3 Way F Metri Pack 150 Series Sealed BK Terminal Part Information Terminal Tray 12048074 2 Core Insulation Crimp E 1 Release Tool Test Probe 12094429 J 35616 2A GY Camshaft Position CMP Sensor W 6 0 6 2L mee S rune Wire Color No Function svotReerme towReeeme ____ CMP Sensor Signal Crankshaft Position Sensor 2 4L 1664596 Connector Part Information OEM 31403 3710 Service 88988337 Description 3 Way Mixed 64 Series Sealed Terminal Part Information
236. ation HO2S Heater Low Terminal Tray 12045773 2 Control Bank Core Insulation Crimp Sensor 2 Release Tool Test Probe 12094429 J 35616 3 GY I ignition 1 Voltage Heated Oxygen Sensor HO2S Bank Sensor 1 Circuit Wire Color No Function A HO2S Low Signal Bank A Sensor 1 HO2S High Signal Bank A Sensor 1 HO2S Heater Low Control Bank Sensor 1 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 45 Heated Oxygen Sensor HO2S Bank B Sensor 2 Heated Oxygen Sensor HO2S Bank B Sensor 1 280761 Connector Part Information OEM 12160825 Service 15305801 Description 4 Way Metri Pack 150 Series Terminal Part Information Terminal Tray 12045773 2 Core Insulation Crimp E 1 Release Tool Test Probe 12094429 J 35616 3 GY Heated Oxygen Sensor HO2S Bank B Sensor 1 Circuit Wire Color No Function A HO2S Low Signal Bank B Sensor 1 HO2S High Signal Bank B Sensor 1 HO2S Heater Low Control Bank Sensor 1 456551 Connector Part Information OEM 12160825 Service 15305801 Description 4 Way M Metri Pack 150 Series BK Terminal Part Information Terminal Tray 12045773 2 Core Insulation Crimp E 1 Release Tool Test Probe 12094429 J 35616 3 GY Heated Oxygen Sensor HO2S Bank B Sensor 2 Circuit Wire Color No A HO2S Low Signal Bank B Sensor 2 HO2S High Signal Bank B Sensor 2 HO2S Heat
237. aution on page 0 5 1699536 3 Tighten the KS mounting bolt 2 Disconnect the harness connector 4 at the Tighten knock sensor KS Tighten the KS mounting bolt to 25 N m 18 lb ft 3 Remove the mounting bolt 739 from the KS 718 1699536 4 Reconnect the harness connector 4 at the KS 5 Connect the negative battery cable 1402136 4 Remove the KS 718 from the engine block 2011 Marine Engines Manual 9 278 Engine Controls and Fuel Marine Knock Sensor Replacement 2 4L Installation Procedure Note Rotate the pigtail 90 degrees from vertical Removal Procedure before securing the fastener 1622787 1578476 1 Disconnect the knock sensor KS electrical 1 Install the KS connector 6 Caution Refer to Fastener Caution on page 0 5 2 Install the KS bolt Tighten Tighten the bolt to 25 N m 18 lb ft 1578476 2 Remove the KS bolt 3 Remove the KS 1622787 3 Connect the KS electrical connector 6 2011 Marine Engines Manual Description and Operation Engine Control Module Description The engine control module ECM interacts with many emission related components and systems The ECM also monitors emission related components and systems for deterioration The on board diagnostics monitor the system performance and a suspect parameter number SPN sets if the system performance degrades The malfunction indicator lamp MIL operation and SPN storage are dictated b
238. ays YES if the control detects that the oil temperature was greater Oil Temperature Flag than a calibrated value during the ignition cycle This parameter displays YES when the engine Paired Firing Mode OFF RPM is synchronized by the control module on a twin engine vehicle This parameter displays the pedal Position Pedal Position 096 angle as calculated by the control module using the signals from the PP sensors 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 61 Engine Control Module Scan Tool Data cont d System State Expected Value This parameter displays the actual voltage of Position Sensor 1 PP 1 0 7 1 2 Volts the PP 1 sensor signal circuit as measured by the control module This parameter displays the actual voltage of 2 PP 2 0 3 0 6 Volts the PP 2 sensor signal circuit as measured dis by the control module This parameter displays the control modules Powertrain Relay Output ON commanded state of the powertrain relay control circuit This parameter will display OPEN or CLOSE H Bridge Varies depending which direction the control module is commanding the throttle plate Rediiired fuel This parameter displays the desired fuel FI E Rate Varies pressure as determined by the control module if applicable E Varies with engine This parameter display the engine revolution Rev Limit Threshold application limit calibration in RPM XR AE This parameter displa
239. ays from a fuse block always inspect the component electrical terminals for corrosion and the mating electrical terminals for correct tension 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 193 Intercooler Relay Voltage Above Normal or Shorted High Intercooler Relay Voltage Below Normal or Shorted Low Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 for scan tool information Special Tools J 43244 Relay Puller Pliers Circuit System Verification 1 Ignition ON command the intercooler coolant pump relay ON and OFF several times with a scan tool Listen and feel for the intercooler coolant pump relay to click with each command 2 Observe the SPN information with a scan tool SPN 66030 should not set 3 Operate the vehicle within the Conditions for Running the SPN You may also operate the vehicle within the conditions that you observed from the Freeze Frame
240. between the BARO signal and the MAP or SCIP signals 108 3 The ECM detects the BARO sensor voltage is greater than 4 9 volts for greater than 5 seconds 108 4 The ECM detects the BARO sensor voltage is less than 0 20 volt for greater than 5 seconds 108 10 The ECM detects the BARO signal 10 kPa of the expected value for greater than 5 seconds Action Taken When the SPN Sets SPN 108 is Type B SPN Conditions for Clearing the MIL SPN SPN 108 is Type B SPN Reference Information Schematic Reference Engine Controls Schematics on page 9 6 9 90 Engine Controls and Fuel Marine Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 for scan tool information Special Tools J 23738 A Mityvac Circuit System Verification 1 Ignition ON observe the SPN information with a scan tool Verify that SPNs 65620 65621 65622 or 65623 is not set If an SPN is set refer to SPN 65620 65623 on page 9 149 2 Compare the scan tool BARO sensor pressure parameter MAP sensor pressure parameter and the SCIP sensor pressure parameter All three parameter readings should be within 3 kPa 3 Observe the B
241. c Information Diagnostic Trouble Code DTC List cont d FM DTC Descriptor Diagnostic Procedure Note If multiple powertrain SPNs are stored diagnose the SPNs in the following order 1 Component level SPNs such as sensor SPNs solenoid SPNs and relay SPNs 2 System level SPNs such as misfire SPNs and fuel trim SPNs oe Fuel Pump Relay 1 Voltage Below 2 Normal or Shorted Low SPN 66017 on page 9 182 Fuel Pump Relay 1 Current Below Normal or Open Circuit SPN 66017 on page 9 182 Tachometer Voltage Above Normal or Shorted High SPN 66018 on page 9 184 Tachometer Current Below Normal or Open Circuit SPN 66018 on page 9 184 Oxygen Sensor Bank A Sensor 1 Heater SPN 66019 66020 66021 or 66022 on Voltage Above Normal or Shorted High page 9 186 Oxygen Sensor Bank A Sensor 1 Heater SPN 66019 66020 66021 or 66022 on Current Below Normal or Open Circuit page 9 186 Oxygen Sensor Bank A Sensor 1 Heater SPN 66019 66020 66021 or 66022 on Abnormal Frequency or Pulse Width page 9 186 Oxygen Sensor Bank B Sensor 1 Heater SPN 66019 66020 66021 or 66022 on Shorted High page 9 186 Oxygen Sensor Bank B Sensor 1 Heater SPN 66019 66020 66021 or 66022 on Shorted Low or Open page 9 186 Oxygen Sensor Bank B Sensor 1 Heater SPN 66019 66020 66021 66022 on Abnormal Frequency or Pulse Width page 9 186 Oxygen Sensor Bank A Sensor 2 Heater SPN 66019 66020 66021 or 66022 on Voltage Above Normal
242. c Procedure Instructions on page 6 5 provide an overview of each diagnostic category SPN Descriptor Engine Controls and Fuel Marine 9 73 SPN 98 FMI17 Oil Level Switch Signal Data Valid But Below Normal Range Least Severe Level Circuit System Description The oil level switch is a normally open switch that is closed when the oil is at the proper level The engine control module ECM monitors the signal circuit of the oil level switch in order to determine the if there is a low oil level condition When the oil is full the switch contacts are closed and the ECM detects a low signal voltage When the oil level is low the switch contacts open and the ECM detects a high signal voltage Conditions for Running the SPN SPN 630 or 65580 15 not set The ignition is ON The ECM determines that the oil has had time to drain back into the oil pan The SPN runs at ignition ON depending on coolant temperature Conditions for Setting the SPN The ECM detects a low oil level condition for greater than 30 seconds Action Taken When the SPN Sets SPN 98 is a type C SPN Conditions for Clearing the SPN SPN 98 is a type C SPN 2011 Marine Engines Manual Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Description and Operation Data Lin
243. ce If the circuit tests normal replace the ECM If greater than the specified range test the signal circuit for a short to voltage If the circuit tests normal replace the ECM 4 f all circuits test normal replace the KS sensor Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Knock Sensor Replacement Except 2 4L on page 9 277 or Knock Sensor Replacement 2 4L on page 9 278 Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 2011 Marine Engines Manual SPN 65555 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 Powertrain On Board Diagnostic OBD System Check prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category DTC Descriptor Engine Controls and Fuel Marine 9 117 SPN 65555 1 Oil Life Monitor Data Valid But Below Normal SPN 65555 18 Oil Life Monitor Data Valid But Below Normal Range Moderate Severe Level Circuit System Description The engine control module ECM monitors the condition or life of the engine oil and indicates when to change the engine oil and filter This is based on engine revolutions and engine temperature and not on
244. cified range test the 5 volt reference circuit for a short to ground or open high resistance If the circuit tests normal replace the ECM greater than the specified range test the 5 volt reference circuit for a short to voltage If the circuit tests normal replace the ECM 4 Verify the scan tool TP Sensor voltage parameter is less than 0 10 volt If greater than the specified range test the signal circuit for a short to voltage If the circuit tests normal replace the ECM 5 Install a 3 A fused jumper wire between the signal circuit terminal 3 and the 5 volt reference circuit terminal 2 Verify the scan tool TP sensor voltage parameter is greater than 4 80 volts If less than the specified range test the signal circuit for a short to ground or an open high resistance If the circuit tests normal replace the ECM 6 If all circuits test normal test or replace the TP sensor Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Throttle Position Sensor Replacement Non ETC on page 9 227 Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 2011 Marine Engines Manual SPN 84 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic
245. components are removed The intake manifold The cylinder head The camshaft The timing chain or sprockets The complete engine 1 Ignition OFF 2 Disconnect the spark plug wires from the distributor cap 4373 3 Disconnect the harness connector from the 6 Mark the position of the rotor in relation to the distributor distributor housing 1 with a grease pencil 7 Mark the distributor housing to intake manifold position with a grease pencil 301393 4 Remove the distributor cap screws and discard 5 Remove the distributor cap from the distributor 34397 housing 8 Remove the distributor hold down bolt 9 Remove the distributor 2011 Marine Engines Manual 9 252 Engine Controls and Fuel Marine 4376 4373 10 As the distributor is being removed from the 2 While the distributor is being installed observe engine the rotor will move in a counter clockwise the rotor moving in a clockwise direction about direction about 42 degrees 42 degrees 11 Place a second mark 2 on the base of the 3 With the distributor completely seated verify the distributor housing in order to ensure proper rotor segment is aligned with the mark on the rotor alignment during the distributor installation distributor base in location 1 If the rotor segment is not aligned with the Installation Procedure 1 number 1 mark the driven gear teeth and T the camshaft have meshed one or more teeth Note If installing a new distributo
246. conditions are met for greater than 5 seconds Conditions for Setting the SPN The ECM detects the general warning sensor voltage is less than or greater than a calibrated value for greater than 5 seconds Action Taken When the SPN Sets SPN 65701 and 65702 are Type C SPNs Conditions for Clearing the SPN SPN 65701 and 65702 are Type C SPNs 2011 Marine Engines Manual Diagnostic Aids If a shared 5 volt reference circuit is shorted to ground or shorted to a voltage other 5 volt reference circuits may be affected Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 9 156 Engine Controls and Fuel Marine Circuit System Verification 1 Ignition ON observe the SPN information with a scan tool Verify that SPN 65620 65621 65622 or 65623 is not set If either SPN is set refer to SPN 65620 65623 on page 9 149 Operate the vehicle within the Conditions for Ru
247. continuously when the above conditions are met for greater than 10 seconds 100 17 SPNs 100 3 100 4 630 65580 65620 or 65621 65622 or 65623 is not set The engine speed is equal to or greater than 500 RPM The SPN runs continuously when the above conditions are met for greater than 10 seconds 9 76 Engine Controls and Fuel Marine Conditions for Setting the SPN 100 3 The ECM detects that the EOP sensor voltage is greater than 4 49 volts for greater than 3 seconds 100 4 The ECM detects that the EOP sensor voltage is less than 0 39 volts for greater than 3 seconds 100 17 The ECM detects that the engine oil pressure is less than a calibrated range based on engine speed for greater than 5 seconds Action Taken When the SPN Sets SPN 100 3 and 100 4 are SPNs SPN 100 17 is a Type C SPN Cam phaser not enabled Conditions for Clearing the SPN SPN 100 3 and 100 4 are SPNs e SPN 100 17 is a Type SPN Diagnostic Aids If a shared 5 volt reference circuit is shorted to ground or shorted to a voltage other 5 volt reference circuits may be affected Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Conn
248. control module OFF commanded state of the check gauges control circuit This parameter displays YES when the ees Idle YES throttle actuator control TAC motor is being used to control the idle speed This parameter displays the resistance of the Coolant Sensor Varies engine coolant sensor based on input to the Resistance control module from the engine coolant temperature ECT sensor This parameter displays a defaulted coolant temperature value being used by the control Ed uera module when the ECM has detected a P condition with the engine coolant temperature ECT sensor E This parameter displays the temperature of i M Raw ws epa the engine coolant based on the input to the E control module from the ECT sensor This parameter displays YES when the Crank Request Input control module detects a voltage at the crank request input terminal This parameter displays the state of the Cruise Cruise Control ON ON cruise control ON OFF switch input to the control module m This p the state of de cruise control decrease increase switch input Resume Accelerate Decrease Increase ON to the control module E Switch set to Increase ___ T o This parameter displays the state of the Cruise Set Coast Cruise cruise control decrease increase switch input Decrease Increase ON to the control module switch set to Decrease This parameter displays the torque being elias RPM Rated Var
249. control module ECM When the ignition Switch is rotated to the crank position a voltage is applied to the neutral start switch With the neutral switch in the closed position the ECM will receive a crank signal If the vessel is equipped with ECM starter control the ECM will then supply 12 volts or a ground to the control circuit of the starter control relay dependent upon option When this occurs battery voltage is supplied through the switch of the crank relay to S terminal of the starter solenoid Reference Information Schematic Reference Engine Controls Schematics on page 9 6 2011 Marine Engines Manual Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Special Tools Required J 43244 Relay Puller Pliers 9 204 Engine Controls and Fuel Marine Circuit System Verification Cycle the ignition from OFF to ON You should hear and feel an audible click from the run crank relay Repeat as necessary in order to verify run crank relay operation Circuit System Testing 1 Ignition OFF disconnect the run crank relay with the J 43244 2 Test for less than
250. cooler Relay Voltage Above Normal 66030 or Shorted High SPN 66030 on page 9 193 Intercooler Relay Current Below Normal 66030 or Open Circuit SPN 66030 on page 9 193 Supercharger Boost Control Solenoid 60095 Data Valid but Above Normal SPN 66035 on page 9 195 66035 Supercharger Boost Control Solenoid Current Below Normal or Open Circuit SFN 66039 0M page 9 195 Supercharger Boost Control Solenoid Mechanical System Not Responding SPN 66035 on page 9 195 Out of Adjustment OEM Output Driver 1 Voltage Above Normal or Shorted High SPN 66040 66043 on page 9 198 OEM Output Driver 1 Current Below Normal or Open Circuit SPN 66040 66043 on page 9 198 OEM Output Driver 2 Voltage Above Normal or Shorted High SPN 66040 66043 on page 9 198 OEM Output Driver 2 Current Below Normal or Open Circuit SPN 66040 66043 on page 9 198 OEM Output Driver 3 Voltage Above Normal or Shorted High SPN 66040 66043 on page 9 198 OEM Output Driver 3 Current Below Normal or Open Circuit SPN 66040 66043 on page 9 198 OEM Output Driver 4 Voltage Above Normal or Shorted High SPN 66040 66043 on page 9 198 OEM Output Driver 4 Current Below Normal or Open Circuit SPN 66040 66043 on page 9 198 MON zi 2011 Marine Engines Manual 6 22 Vehicle Diagnostic Information Data Link Connector Scan Tools The engine control module ECM communicates information through the data link connector DLC This data is transmitted at a high frequency which req
251. crankshaft reference pulses If there are no reference pulses the ECM turns the fuel pump OFF 2 seconds after the ignition switch is turned ON or 2 seconds after the engine stops running The fuel pump supplies fuel through a fuel filter through the fuel feed pipes to the fuel rail assembly The fuel pump provides fuel at a pressure above the pressure needed by the fuel injectors The fuel pressure regulator located in the modular fuel pump and sender assembly keeps the fuel available to the fuel injectors at a regulated pressure 2011 Marine Engines Manual When the fuel pressure rises above the pressure regulator calibration the pressure is relieved with excess fuel returned to the fuel tank Reference Information Description and Operation Fuel System Description on page 9 284 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs 11 16 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Engine Controls and Fuel Marine 9 209 Note It may be necessary to remove the fuel tank If less than the specified range test inspect and repair the items listed below If all items test normal replace the fuel pump Restricted fuel feed pipe Restricted or plugged fuel filter Restricted or plugged strainer Stuck or binding fuel level flo
252. cription and Operation 9 279 Engine Control Module Description 9 279 Throttle Actuator Control TAC System B T Tory o i o o 9 279 Camshaft Actuator System Description 9 281 Supercharger Description and Operation 9 282 Fuel System Description 9 284 Electronic Ignition System Description 9 286 Distributor Ignition DI System Description 9 287 Special Tools and Equipment 9 289 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 3 Engine Controls and Fuel Marine Specifications Temperature Versus Resistance ms Temperature vs Resistance Values Approximate 302 284 100 700 Altitude Versus Barometric Pressure Altitude Versus Barometric Pressure Barometric cont d Pressure Altitude Altitude Measured in Measured in Measured in Kilopascals Meters m Feet ft kPa Determine your altitude by contacting a local weather station or by using another reference source 4 267 14 000 56 64 Pressure Altitude Altitude Measured in Measured in Measured in Kilopascals Meters m Feet ft kPa 1 829 6 000 77 85 1 524 5 000 80 88 f 993 2011 Marine Engines Manual 9 4 Engine Controls and Fuel Marine Ignition System Specifications 2 4L Application Merc Engish Spark Plug Torque 15 Ib ft S
253. ct each module connected to the CAN communication circuits in order to isolate the condition On vehicles equipped with multiple engine controllers the scan tool can only communicate with one ECM at atime Attempt to establish communication with each ECM Communication with only one ECM can be caused by the following An open CAN communication circuit between the splice and the ECM An that is not powered up Test the B ignition feed and ground circuits for an open high resistance or short to ground 2011 Marine Engines Manual Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views page 9 33 Description and Operation Data Link Communications Description and Operation on page 11 5 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification Note If the vehicle is equipped with multiple engines the scan tool can only communicate with one ECM at a time Attempt to establish communication with each ECM The scan
254. cted to the CMP actuator which rotates the camshaft The ECM can only command the camshaft position actuator to retard the valve timing from the camshaft park position or advance the valve timing back to the park position The total range of valve timing command is 26 degree as measured at the camshaft or 52 degree as measured at the crankshaft The ECM controls the Camshaft Position Actuator Magnet by suppling a 12 V pulse width modulated PWM signal The ECM supplies a ground to the low reference circuit Conditions for Running the SPN 65570 2 Before the ECM can report that SPN 65570 2 failed SPNs 65570 3 65570 4 and 65723 must run and pass SPN 630 or 65580 is not set The ignition is ON The cam reference angle is learned SPN 65570 2 runs continuously once the above conditions are met 2011 Marine Engines Manual 65570 4 65570 5 The ignition is ON or the engine is operating The ignition voltage is between 10 16 volts e SPNs 65570 4 and 65570 5 run continuously once the above conditions are met 65570 7 Before the ECM can report that SPN 65570 7 failed SPNs 65570 2 65570 3 65570 4 and 65723 must run and pass SPN 630 or 65580 is not set The ignition is ON The cam reference angle is learned The cam phaser cleaning pulse is not enabled The SPN 65570 7 runs continuously once the above conditions are met Conditions for Setting the SPN 65570 2 The ECM detects a deviatio
255. cuit tests normal replace the ECM 6 If all circuits test normal replace the general warning sensor Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Engine Control Module Replacement on page 9 217 for engine control module replacement setup and programming 2011 Marine Engines Manual SPN 65710 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors Engine Controls and Fuel Marine 9 157 SPN 65710 FMI 31 Emergency Stop Warning Not Available Circuit System Description The engine control module ECM applies a voltage to the emergency stop switch circuit The ECM monitors the status of the emergency stop switch circuit When the emergency stop switch is removed the ECM detects a high signal voltage and will limit the engine speed output or stop the engine Conditions for Running the SPN SPN 630 or 65580 is not set The engine is operating SPN 65710 runs continuously when the above condition is met for greater than 5 seconds Conditions for Setting the SPN The ECM detects the emergency stop voltage is greater than a calibrated
256. cuits susceptible the ESD damage Do not allow tools to contact exposed terminals when servicing connectors Do not remove components from their protective packaging until required to do so Avoid the following actions unless required by the diagnostic procedure Jumpering or grounding of the components or connectors Connecting test equipment probes to components or connectors Connect the ground lead first when using test probes Ground the protective packaging of any component before opening Do not rest solid state components on metal workbenches or on top of TVs radios or other electrical devices 0 6 Dangers Warnings and Cautions Heated Oxygen and Oxygen Sensor Caution Caution Do not remove the pigtail from either the heated oxygen sensor HO2S or the oxygen sensor 025 Removing the pigtail the connector will affect sensor operation Handle the oxygen sensor carefully Do not drop the HO2S Keep the in line electrical connector and the louvered end free of grease dirt or other contaminants Do not use cleaning solvents of any type Do not repair the wiring connector or terminals Replace the oxygen sensor if the pigtail wiring connector or terminal is damaged This external clean air reference is obtained by way of the oxygen sensor signal and heater wires Any attempt to repair the wires connectors or terminals could result in the obstruction of the air reference and degraded sensor perform
257. customer concern was correctly identified All electrical circuits are protected against excessive loads which might occur because of shorts or overloads in the wiring system A fuse or circuit breaker provides such protection Fuses The fuse is the most common method of an automotive wiring circuit protection Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit A short circuit or any other type of overload condition may cause a fuse to open refer to Circuit Protection Fuses on page 11 15 for additional information Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity If there is a short circuit or any other type of overload condition in the circuit the excessive current will open the circuit between the circuit breaker terminals refer to Circuit Protection Circuit Breakers on page 11 16 for additional information Typical Electrical Repairs An open circuit is an incomplete circuit Power cannot reach the load or the ground If a circuit is open active components do not energize A short circuit is an unwanted connection between one part of the circuit and either the ground or another part of the circuit A short circuit may cause a fuse to blow a circuit breaker to open or a component to fail or become inoperative A shor
258. d If necessary adjust the stop collars on the cutting tool and tap to the required depth 2 Drill out the damaged threads Clean out any chips 3 Lubricate the tap with light engine oil Tap the hole Clean the threads 4963 4 Thread the thread insert onto the mandrel of the installer Engage the tang of the insert onto the end of the mandrel Important The insert should be flush to one turn below the surface 5 Lubricate the insert with light engine oil except when installing in aluminum and install the insert 6 If the tang of the insert does not break off when backing out the installer break the tang off with a drift Abbreviations and Meanings Abbreviation Weaning Ampere s Alternating Current Analog to Digital Air Fuel Ratio AM FM Amplitude Modulation Frequency Modulation Accelerator Pedal A A A A A A A A Accelerator Pedal Position ATDC After Top Dead Center AUTO American Wire Gauge Battery Positive Voltage BARO BATT Battery American Petroleum Institute A CL D F NT P VG WG A A 2011 Marine Engines Manual Abbreviations and Meanings cont d Abbreviation Meaning BP BakPresue CAFE Calibration Camshaft CARE CAL CAM CAN CCP CL CLS MP 5 CS CTP YL COAX COMM CONN CSF CUFT CUN 2011 Marine Engines Manual
259. d Fuel Marine Camshaft Position Sensor Replacement 2 4L Intake Removal Procedure 1 Disconnect the intake camshaft position CMP sensor electrical connector 2 1578483 2 Remove the CMP sensor bolt 3 Remove the CMP sensor Installation Procedure 1578483 Note Inspect the CMP sensor for damage Replace as necessary 1 Lubricate the CMP sensor O ring seal with clean engine oil 2 Install the CMP sensor Caution Refer to Fastener Caution on page 0 5 3 Install the CMP sensor bolt Tighten Tighten the bolt to 10 N m 89 lb in an di S 6 e 1639712 4 Connect the intake CMP sensor electrical connector 2 Camshaft Position Sensor Replacement 2 4L Exhaust Removal Procedure 1 Disconnect the exhaust camshaft position CMP sensor electrical connector 1 1578483 2 Remove the CMP sensor bolt Intake CMP shown exhaust CMP similar 3 Remove the CMP sensor 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 271 Installation Procedure Camshaft Position Actuator Magnet Replacement Removal Procedure 1578483 Note Inspect the CMP sensor for damage replace as necessary 1 Lubricate the CMP sensor O ring seal with clean 1658168 engine oil 1 Remove the water pump 2 se Intake CMP shown 2 Disconnect the engine harness electrical exnaus connector from the camshaft position Caution Refer to Fastener Caution on page
260. d Fuel Marine 9 247 Installation Procedure 14824 1 Inspect the spark plug gap Adjust the gap as needed Refer to gnition System Specifications 2 4L on page 9 4 or Ignition System Specifications 3 0L on page 9 4 or Ignition System Specifications 4 3L 5 0L or 5 7L on page 9 4 or Ignition System Specifications 6 0L or 6 2L on page 9 4 2 Hand start the spark plug in the corresponding cylinder Caution Refer to Fastener Caution on page 0 5 3 Tighten the spark plug to 15 11 Ib ft 4 Install the spark plug wire to the spark plug 5 Inspect the spark plug wire for proper installation 5 1 Push sideways on each boot in order to inspect the seating 5 2 Reinstall any loose boot 9 248 Engine Controls and Fuel Marine Distributor Replacement 3 0L Removal Procedure Note There are two procedures available to install the distributor Use Installation Procedure 1 when the crankshaft has not been rotated from the original position Use Installation Procedure 2 when any of the following components are removed The camshaft The complete engine 1 Ignition OFF 2211673 2 Disconnect the spark plug wires 1 from the distributor cap 3 Disconnect the harness connector from the distributor 4 Remove the distributor cap from the distributor housing 4373 5 Mark the position of the rotor in relation to the distributor housing 1 with a grease pencil 6 7 8 10
261. d Procedures Strategy Based Diagnosis Diagnosis boxes is numbered you are not required to complete every box in order to successfully diagnose The goal of Strategy Based Diagnosis is to provide a customer concern The first step of your diagnostic guidance when you create a plan of action for process should always be Understand and Verify each specific diagnostic situation Following a similar the Customers Concern The final step of your plan for each diagnostic situation you will achieve diagnostic process should be Repair and verify the maximum efficiency when you diagnose and repair Fix Refer to the following chart for the correct Strategy vehicles Although each of the Strategy Based Based Diagnosis Understand and Verify the Customer s Concern e Customer Misunderstanding of System Explain operation to Vehicle Operating as Designed customer or refer to owners or service manual Preliminary Checks Visual and Operational Perform Powertrain Diagnostic System Check Check for Bulletins Recalls and Preliminary Information Current DTC Symptom No No Published Intermittent DTC Diagnostics History DTC Follow DTC Follow Analyze and See Diagnostic Diagnostics Symptom Develop Detail Diagnostics Diagnostics Below Re Examine Isolate the Root Cause the Concern Yes 2002024 1 Understand and Verify the Customers Concern In order to verify the concern the technician The first part of this step is to obtain as much should be fam
262. d View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification Note The rear heated oxygen sensor HO2S must be in closed loop for the rear HO2S diagnostics to run A load condition is necessary to obtain closed loop 1 Engine operating observe the scan tool heated oxygen sensor voltage parameters The parameter should fluctuate above and below the range of 200 800 mV 2 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Ignition OFF disconnect the harness connector at the appropriate HO2S 2 Ignition OFF test for less than 5 Q of between the low reference circuit terminal A and ground If greater than the specified range test the low reference circuit for a short to voltage or an open high resistance If the circuit tests normal replace the ECM 3 Ignition ON
263. d and improper diagnosis Note The proper adapter for probing the terminals for fuses relays or diodes in an electrical center is J 35616 35 Using any other tool or adapter may damage the terminal being tested 2011 Marine Engines Manual Wiring Systems 11 7 Refer to the following table as a guide in selecting the correct test adapter for front probing connectors 150 Male Probe Adapter gray 150 Female Probe Adapter gray 280 Male Probe Adapter purple 280 Female Probe Adapter purple 100W Male round Probe Adapter brown 100W Female round Probe Adapter brown Weather Pack Male Probe Adapter orange Weather Pack Female Probe Adapter orange 100W Male round Probe Adapter green 100W Female round Probe Adapter green 130 Male Probe Adapter blue 130 Female Probe Adapter blue 150 Male Probe Adapter green 100 Male Probe Adapter It green 100 Female Probe Adapter It green 220 Male Probe Adapter black 220 Female Probe Adapter black 950 Female Probe Adapter red 950 Male Probe Adapter red 500 Male Probe Adapter orange 500 Female Probe Adapter orange 160 180 Male Probe Adapter yellow 160 180 Female Probe Adapter yellow 280 Male Probe Adapter violet 480 Male Probe Adapter dk blue 480 Female Probe Adapter dk blue 630 Male Probe Adapter red 630 Female Probe Adapter red 800 Male Probe Adapter yellow 800 Female Probe Adapter yellow 280 Male round P
264. d to determine the optimum ignition and injection points of the engine The ECM also uses CKP sensor output information to determine the camshaft relative position to the crankshaft to control camshaft phasing and to detect cylinder misfire Camshaft Position CMP Sensor The sensor detects magnetic flux changes between the four narrow and wide tooth slots on the reluctor wheel The CMP sensor provides a digital ON OFF DC voltage of varying frequency per each camshaft revolution The ECM will recognize the narrow and wide tooth patterns to identify camshaft position or which cylinder is in compression and which is in exhaust The information is then used to determine the correct time and sequence for fuel injection and ignition spark events The CMP sensor information is used by the ECM to determine the position of the valve train relative to the crankshaft Knock Sensor KS The knock sensor KS system enables the control module to control the ignition timing for the best possible performance while protecting the engine from potentially damaging levels of detonation also known as spark knock The KS system uses one or 2 flat response 2 wire sensors The sensor uses piezo electric crystal technology that produces an AC voltage signal of varying amplitude and frequency based on the engine vibration or noise level The amplitude and frequency are dependant upon the level of knock that the KS detects The control module receives th
265. d while the engine is idling The ECM then adds and removes fuel while monitoring the HO2S 2 When the catalyst is functioning properly the HO2S 2 response to the extra fuel is slow compared to the response of the HO2S 1 which is located before the TWC When the HO2S 2 response is near that of the 2 1 the oxygen storage capability and efficiency of the catalyst may be degraded below an acceptable threshold Conditions for Running the SPN Before the ECM can report that SPN 65675 or 65676 has failed SPN 65561 65562 65563 65564 65567 65568 and 66019 66022 must run and pass SPN 51 94 105 106 110 630 636 651 658 65541 65548 65561 65568 65565 65566 65580 65590 65599 65601 65602 65610 65620 65621 65622 65623 or 65723 65726 is not set 2011 Marine Engines Manual The engine has been operating for greater than a calibrated time The long term fuel trim is learned The engine coolant temperature ECT is between a calibrated value The manifold air temperature MAT is between a calibrated value The engine is operating in Closed Loop The engine MAP and RPM is steady within a calibrated value The vessel is operating under a load SPNs 65675 and 65676 attempts one test per ignition cycle when the conditions above have been met Conditions for Setting the SPN The ECM determines that the efficiency of the catalyst has degraded below a calibrated threshold Action Taken When t
266. dd all of the fuel injector resistance values to obtain a total resistance value Divide the total resistance value by the number of fuel injectors to obtain an average resistance value Subtract the lowest individual fuel injector resistance value from the average resistance value Compute the difference between the highest individual fuel injector resistance value and the average resistance value Replace the fuel injector that displays the greatest difference above or below the average Fuel Injector Balance Test Fuel Pressure Test Note DO NOT perform this test if the engine coolant temperature ECT is above 94 201 F Irregular fuel pressure readings may result due to hot soak fuel boiling Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic 1 Install a J 34730 refer to Fuel Pressure Gauge Installation and Removal on page 9 229 2 Ignition ON engine OFF Note The fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure DO NOT start the engine 3 Command the fuel pump relay ON with a scan tool 4 Observe the fuel pressure gauge with the fuel pump commanded ON The fuel pressure should be 380 427 kPa 55 62 psi lf less than the specified range refer to Fuel System Diagnosis with Returnless Fuel System on page 9 208 or Fuel System Diagnosis without Returnless Fuel System on page 9 210 5 Monitor
267. discharge It is possible for less than 100 volts of static electricity to cause damage to some electronic components By comparison it takes as much as 4 000 volts for a person to feel the zap of a static discharge There are several ways a person can become statically charged The most common methods of charging are by friction and by induction An example of charging by friction is a person sliding across a seat in which a charge of as much as 25 000 volts can build up Charging by induction occurs when a person with well insulated shoes stands near a highly charged object and momentarily touches ground Charges of the same polarity are drained off leaving the person highly charged with the opposite polarity Static charges of either type can cause damage Therefore it is important to use care when handling and testing electronic components Engine Wiring When it is necessary to move any of the wiring whether to lift wires away from their harnesses or move harnesses to reach some component take care that all wiring is replaced in its original position and all harnesses are routed correctly If clips or retainers break replace them Electrical problems can result from wiring or harnesses becoming loose and moving from their original positions or from being rerouted 1 6 General Information Fasteners M6 X 1 0 4T Low Carbon Steel 7T High Carbon Steel 7T Alloy Steel M8 X 1 25 4T Low Carbon Steel 7T High Carbon Steel 7T Al
268. displayed on the gauge If less than the specified range repair the boost source hose or the intake manifold port for a restriction or blockage 3 Ignition OFF connect the boost source hose to the boost solenoid 4 Disconnect the boost signal hose from the bottom port of the bypass valve actuator 5 Connect the J 23738 A to the boost signal hose 6 Engine idling verify that less than 1 inch Hg is displayed on the gauge If greater than the specified range replace the boost control solenoid Note SPNs will set when disconnecting components 7 Ignition OFF disconnect the harness connector at the boost control solenoid 8 Engine idling verify greater than 15 inch Hg is displayed on the gauge gt If less than the specified range test the boost signal hose for a restriction or blockage If the boost signal hose tests normal replace the boost control solenoid 9 Disconnect the inlet vacuum signal hose from the top of the bypass valve actuator and connect the J 23738 A to the inlet vacuum signal hose 10 Engine running observe the gauge on the J 23738 A The gauge should display greater than 15 inch Hg If less than the specified range repair the inlet vacuum signal hose or the intake manifold port for a restriction or blockage Component Testing 1 Ignition OFF disconnect the inlet vacuum signal hose from the top of the bypass valve actuator 2 Connect the J 23738 A to the inlet vacuum signal
269. dition s that must be present in order to fail the diagnostic and when to set the DTC Action Taken When the DTC Sets Actions Taken When the DTC sets identifies the default actions taken when a control module sets a DTC Conditions for Clearing the DTC Conditions for Clearing the DTC identifies the conditions that must be met in order to clear the DTC Diagnostic Aids Diagnostic Aids are suggestions which explain other methods to diagnose the condition It also provides unique information about the system used to assist the technician in finding and repairing a vehicle condition 40 C 40 F 40 C 40 F 40 C 40 F 40 C 40 F Reference Information Reference Information includes links providing additional information for the diagnostic procedure For example Schematic Reference Connector End View Reference Description and Operation Electrical Information Reference DTC Type Reference Scan Tool Reference Special Tools Required Circuit System Verification The diagnostic format does not force a technician to any of the 3 diagnostic categories Circuit System Verification Circuit System Testing and Component Testing However performing the Circuit System Verification category first aids in determining if a vehicle condition is current This category also serves to route the technician to another diagnostic procedure which should be performed first for example a DTC with a higher pr
270. does not display OFF test the signal circuit for a short to voltage or an open high resistance If the circuit tests normal replace the ECM 4 f all circuits test normal replace the oil level Switch Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Engine Control Module Replacement on page 9 217 for engine control module replacement setup and programming 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 75 SPN 100 3 0L 4 3L 5 0L 5 7L Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 100 FMI 3 Engine Oil Pressure EOP Sensor Circuit Voltage Above Normal or Shorted High SPN 100 FMI 4 Engine Oil Pressure EOP Sensor Circuit Voltage Below Normal or Shorted Low SPN 100 FMI 17 Engine Oil Pressure EOP Sensor Data Valid But Below Normal Range Least Severe Level Diagnostic Fault Information Short to Open High Short to Signal Circuit Ground Resistance Voltage ne 5 Volt Reference 65620 4 100 4 100 4 EOP Sensor Signal 100 4 100 4 100 3 17 owBeeeme To 1 Typical Scan Tool Dat
271. e J 35616 35 VT Terminal Tray 1928498056 8 Core Insulation Crimp E 1 Manifold Absolute Pressure MAP Sensor 2 4 6 0 6 2L Circuit Wire Color No ___ j5VetReerene Wa Sensor iat 9 52 Engine Controls and Fuel Marine Manifold Absolute Pressure Pedal Position Sensor Sensor Manifold Air Temperature MAP MAT Sensor 3 0 4 3 5 0 5 7L 886053 Connector Part Information OEM 15326830 1381341 Connector Part Information Service 88953153 Harness Type Engine Description 6 F 150 Series Sealed OEM Connector 10763258 Terminal Part Information Service Connector 88988320 Terminal Tray 12191819 8 Description 4 Way F Kompakt 280 Series Sealed BK Core Insulation Crimp Terminal Part Information Release Tool Test Probe 15315247 J 35616 2A GY Terminated Lead Pending uu Release Tool J 38125 561 Pedal Position Sensor Terminal Tray 1928498056 8 5 Volt Reference Core Insulation Crimp E 1 Pedal Position Sensor 1 _ Manifold Absolute Pressure 6 Jew Reference Sensor Manifold Air Temperature MAP MAT Sensor 3 0 4 3 5 0 5 7L Circuit Wire Color No Function La Low Reference Pedal Position Sensor 2 Signal Pedal Position Sensor 2 Signal Reference 2 War sensor Sonat L9 va Reference Sensor 2011 Marin
272. e correct size for the connector terminal Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity Using a larger terminal test adapter will damage the terminal Refer to the J 35616 GM Approved Terminal Test Kit label on the inside of the J 35616 GM Approved Terminal Test Kit for the correct adapter along with the connector end view for terminal size Probing Electrical Connectors Special Tools EL 35616 Terminal Test Probe Kit For equivalent regional tools refer to Special Tools on page 11 30 Danger This procedure should not be performed on high voltage circuits Performing this procedure on high voltage circuits may result in serious injury or death Note Always be sure to reinstall the connector position assurance CPA and terminal position assurance TPA when reconnecting connectors or replacing terminals Front Probe Disconnect the connector and probe the terminals from the mating side front of the connector Caution Refer to Test Probe Caution on page 0 6 Note When probing female 0 64 terminals it is important to use the correct adapter There have been some revisions to the test adapter for 0 64 terminals The proper adapter for 0 64 terminals is the J 35616 64B which has a gold terminal and a black wire between the base and tip Failure to use the proper test adapter may result in damage to the terminal being teste
273. e test the signal circuit for an open high resistance or a short to ground 5 If all circuits test normal replace the FSI sensor Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Engine Control Module Replacement on page 9 217 for engine control module replacement setup and programming 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 137 SPN 65586 or 65587 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptor SPN 65586 FMI 3 Fuel Select Output 1 Voltage Above Normal or Shorted High SPN 65586 FMI 5 Fuel Select Output 1 Current Below Normal or Open Circuit SPN 65587 FMI 3 Fuel Select Output 2 Voltage Above Normal or Shorted High SPN 65587 FMI 5 Fuel Select Output 2 Current Below Normal or Open Circuit Diagnostic Fault Information Short to Open High Short to Signal Circuit Ground Resistance Voltage Performance Fuel Select Output Control 65586 5 65586 5 65586 3 65587 5 65587 5 65587 3 The fuse that supplies voltage to the device opens Circuit System Description 65586 and 65587 FMI 5 The fuel select
274. e then remains illuminated If the test lamp is always OFF test the circuit for a short to ground or an open high resistance If the circuit tests normal replace the ECM If the test lamp illuminates without flashing test the circuit for a short to voltage 5 Ignition ON verify that a test lamp illuminates between the ETC Motor Control Open circuit terminal B and ground If the test lamp is always OFF test the circuit for a short to ground or an open high resistance If the circuit tests normal replace the ECM 6 Ignition OFF disconnect the ECM harness connector X2 7 Ignition ON test the ETC Motor Control Open circuit terminal B for a short to voltage or a short to the ETC Motor Control Closed circuit terminal A If a condition exists repair the circuit as necessary 8 If all the circuits and connections test normal replace the throttle body assembly Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Throttle Body Assembly Replacement on page 9 228 Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 2011 Marine Engines Manual SPN 65620 65623 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis page 6 4 for an overview of the diagnostic approach Diag
275. e 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Special Tools J 43244 Relay Puller Pliers Circuit System Verification 1 Ignition ON observe the SPN information with a scan tool SPN 66002 4 or 66002 5 should not set 2 Cycle the ignition from RUN to CRANK The engine should crank or you should hear and feel an audible click from the starter relay Repeat as necessary in order to verify starter relay operation 3 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 163 Circuit System Testing 3 Test for infinite resistance between the following 1 Ignition OFF disconnect the starter relay with the terminals J 43244 30 and 86 2 Test for less than 5 between the ground circuit 30 and 87 terminal 86 and ground 30 and 85 If greater than the specified range repair the 85 and 87 ground circuit for an open high resistance 7 3 Connect a test lamp between the starter relay If not the specified value replace the control circuit terminal 85 and ground starter relay 4 Ignition ON cycle the ignition from RUN to 4 Install a 20 A fused jumper wire
276. e 94 17 FP Sensor Signal 94 15 94 17 Low Reference s Typical Scan Tool Data Fuel Pressure Sensor Short to Ground Open Short to Voltage Operating Conditions Engine idling at Normal Operating Temperature Parameter Normal Range 379 427 kPa 55 62 psi 5 Volt Reference 0 kPa 0 psi 0 kPa 0 psi 689 kPa 100 psi FP Sensor Signal 0 kPa 0 psi 689 kPa 100 psi 689 kPa 100 psi 1717 Internal ECM damage may occur if the circuit is shorted to B Circuit System Description Conditions for Running the SPN The fuel pressure FP sensor changes resistance 94 3 and 94 4 based on fuel system pressure The engine control module ECM monitors the signal circuit from the FP SPN 630 65580 65620 65621 65622 or 65623 sensor The ECM supplies 5 volts to the FP sensor on is not set the 5 volt reference circuit The ECM also provides a The engine is operating for greater than ground on the low reference circuit The FP sensor 9 P 9 9 1 provides a signal to the ECM on the FP sensor signal circuit which is relative to the pressure changes in the SPN 94 runs continuously when the above fuel system pressure When the fuel pressure is high conditions are met the sensor resistance is high and the ECM senses a high voltage When the fuel pressure is low the sensor 94 15 and 94 17 voltage is low and the ECM senses a low signal SPN 630 65580 65620 65621 656
277. e B SPNs Cam phaser not enabled Boost not enabled The engine operates based on a default filtered coolant temp SPN 110 15 is a type C SPN Conditions for Clearing the MIL SPN SPN 11 3 and 110 4 are Type B SPNs SPN 110 15 is a type C SPN Diagnostic Aids After starting the engine the ECT sensor temperature should rise steadily then stabilize after the thermostat opens Test the ECT sensor at various temperature levels in order to evaluate the possibility of a skewed sensor A skewed sensor can result in a driveability condition If the vehicle has set overnight the ECT sensor and the MAT IAT sensor values should display within 3 C 5 F Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification 1 Ignition ON observe the SPN information with a scan tool SPNs 110 3 110 4 should not set 2 Engine operating observ
278. e ECM 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 143 5 Connect a 3 A fused jumper wire between TP sensor 1 signal circuit terminal F and the 5 volt reference circuit terminal E Verify the scan tool TP sensor 1 voltage parameter is greater than 4 5 V If less than the specified range test the signal circuit for a short to ground or an open high resistance If the circuit tests normal replace the ECM Connect a 3 A fused jumper wire between TP sensor 2 signal circuit terminal D and ground Verify the scan tool TP sensor 2 voltage parameter is less than 0 5 V greater than the specified range test the signal circuit for an open high resistance If the circuit tests normal replace the ECM 7 f all circuits test normal test or replace the throttle body assembly Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Throttle Body Assembly Replacement on page 9 228 Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 9 144 Engine Controls and Fuel Marine SPN 65604 65605 or 65613 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5
279. e Engines Manual Engine Controls and Fuel Marine 9 53 Supercharger Bypass Valve Solenoid Terminal Part Information Terminated Lead Pending Release Tool J 38125 561 Diagnostic Test Probe J 35616 35 VT Terminal Tray 1928498056 8 Core Insulation Crimp E 1 Supercharger Inlet Pressure SCIP Sensor Circuit Wire Color No __ _ _ jS5VotRefeene 3 SCIP Sensor Signal Connector Part Information OEM 184006 2 Throttle Body Service 88988501 Description 2 Way M Asm Key D C3 Sealed GY Terminal Part Information Terminal Tray See Terminal Repair Kit Core Insulation Crimp See Terminal Repair Kit Release Tool Test Probe See Terminal Repair Kit Supercharger Bypass Valve Solenoid Circuit Wire Color No Function 2 Supercharger Vacuum 1664617 Bypass Valve Control Connector Part Information OEM 15355297 Service 88988106 Description 6 Way F GT 150 Series Sealed BK Supercharger Inlet Pressure SCIP Sensor Terminal Part Information Terminal Tray 12191819 8 Core Insulation Crimp E A Release Tool Test Probe 15315247 J 35616 2A GY Throttle Body Circuit Wire Color No A _ TAC Motor B TAC Motor Open a TP Senso Signal Connector Part Information 5 Volt Reference Harness Type Engine F TP Sensor 1 Signal OEM Connector 15365614 1331443 Service Connector 88988583
280. e KS signal through the signal circuit The KS ground is supplied by the control module through the low reference circuit The control module learns a minimum noise level or background noise at idle from the KS and uses calibrated values for the rest of the RPM range The control module uses the minimum noise level to calculate a noise channel A normal KS signal will ride within the noise channel As engine speed and load change the noise channel upper and lower parameters will change to accommodate the normal KS signal keeping the signal within the channel In order to determine which cylinders are knocking the control module only uses KS signal information when each cylinder is near top dead center TDC of the firing stroke If knock is present the signal will range outside of the noise channel 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 287 If the control module has determined that knock is present it will retard the ignition timing to attempt to eliminate the knock The control module will always try to work back to a zero compensation level or no spark retard An abnormal KS signal will stay outside of the noise channel or will not be present KS diagnostics are calibrated to detect faults with the KS circuitry inside the control module the KS wiring or the KS voltage output Some diagnostics are also calibrated to detect constant noise from an outside influence such as a loose damaged component
281. e SPN 630 or 65580 is not set e The ignition is ON or the engine is operating The ignition voltage is between 10 16 volts The component has been commanded ON and OFF during the ignition cycle SPN 66011 runs continuously once the above conditions are met Conditions for Setting the SPN The ECM detects that the commanded state of the driver and the actual state of the control circuit do not match for greater than 5 seconds Action Taken When the SPN Sets SPN 66011 is a Type C SPN Conditions for Clearing the SPN SPN 66011 is a Type C SPN Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 2011 Marine Engines Manual Circuit System Verification 1 Ignition ON command the speed based component ON and OFF with a scan tool The component should turn ON and OFF Observe the SPN information with a scan tool SPN 66011 3 or 66011 5 should not set Operate the ve
282. e TP sensor attaching screws 1 3 Remove the TP sensor 2 and seal 3 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 227 Installation Procedure 13315 1 With the throttle valve in the normal closed idle position install the TP sensor 2 and the seal 3 on the throttle body assembly Caution Refer to Fastener Caution on page 0 5 Note Install the new TP sensor attaching screws when replacing the TP sensor 2 Install 2 TP sensor screws 1 Tighten Tighten the screws to 3 N m 27 16 in 3 Connect the TP sensor electric connection 9 228 Engine Controls and Fuel Marine 1401966 1401966 Throttle Body Assembly Replacement Removal Procedure Caution Handle the electronic throttle control components carefully Use cleanliness in order to prevent damage Do not drop the electronic throttle control components Do not roughly handle the electronic throttle control components Do not immerse the electronic throttle control components in cleaning solvents of any type Caution DO NOT for any reason insert a screwdriver or other small hand tools into the throttle body to hold open the throttle plate as the wedge inside the throttle body could be damaged 1 Remove the air cleaner outlet duct 2 Disconnect the engine wiring harness electrical connector from the electronic throttle control 3 Remove the throttle body nuts 507 and bolts 538 4 Remove the throttle body
283. e above is turned ON with the engine OFF The BARO reading conditions are met may also be updated whenever the throttle position TP sensor is greater than 28 percent SPN 105 110 630 65580 65621 or 65622 is not set The engine speed is greater than 800 RPM The ECM is not commanding reduced power or fuel cut off The throttle angle is less than 30 percent 2011 Marine Engines Manual 106 1 Before the ECM can report that SPN 106 0 or 106 1 failed SPNs 100 3 100 4 65604 65605 65610 65613 65615 65616 and 65618 must run and pass SPN 105 110 630 65580 65621 or 65622 is not set The engine speed is less than 150 RPM OR The throttle angle is greater than 75 percent The ECM is not commanding reduced power or fuel cut off The SPN runs continuously once the above conditions are met 106 2 Before the ECM can report that SPN 106 2 failed SPNs 106 0 106 1 106 3 106 4 and 3563 must run and pass SPN 105 110 630 65580 65621 or 65622 is not set The ignition is ON The engine speed is 0 RPM The ECM detects the BARO sensor and SCIP sensor The SPN runs at ignition ON once the above conditions are met 106 3 and 106 4 SPN 105 110 630 65580 65621 or 65622 is not set The ignition is ON The SPNs run continuously when the above conditions are met Conditions for Setting the SPN 106 0 The ECM detects that the MAP sensor signal is greater than 9
284. e appropriate scan tool 5 volt reference parameter The voltage should not change greater than 0 5 volt If less than the specified range when component is connected replace the component 4 f all circuits test normal replace the ECM Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Throttle Body Assembly Replacement on page 9 228 Manifold Absolute Pressure Sensor Heplacement without Supercharger on page 9 220 Barometric Pressure Sensor Heplacement on page 9 221 Crankshaft Position Sensor Replacement 3 0L on page 9 256 or Crankshaft Position Sensor Replacement 4 3 5 0 5 7L on page 9 257 or Crankshaft Position Sensor Replacement 6 0 6 2L on page 9 258 or Crankshaft Position Sensor Replacement 2 4L on page 9 261 Camshaft Position Sensor Replacement 4 3 5 0 5 7L on page 9 262 or Camshaft Position Sensor Replacement with CMP Actuator on page 9 268 or Camshaft Position Sensor Replacement without CMP Actuator on page 9 269 or Camshaft Position Sensor Replacement 2 4L Intake on page 9 270 or Camshaft Position Sensor Replacement 2 4L Exhaust on page 9 270 Engine Oil Pressure Sensor Replacement on page 9 225 Supercharger Air Inlet Pressure Sensor Replacement on page 9 222 Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 2011 Marine Engines Manual SPN 65675 65676 Diagno
285. e diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category Circuit System Description The control module enables the appropriate fuel injector pulse for each cylinder The ignition voltage is supplied directly to the fuel injectors The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver A fuel injector coil winding resistance that is too high or too low will affect the engine driveability A fuel injector control circuit DTC may not set but a misfire may be apparent The fuel injector coil windings are affected by temperature The resistance of the fuel injector coil windings will increase as the temperature of the fuel injector increases When performing the fuel injector balance test the scan tool is first used to energize the fuel pump relay The fuel injector tester or the scan tool is then used to pulse each injector for a precise amount of time allowing a measured amount of the fuel to be injected This causes a drop in the system fuel pressure that can be recorded and used to compare each injector Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Description and Operation Data Link Communications Description and Operatio
286. e lamp through a fuse The engine control module ECM turns the slow mode lamp ON by grounding the control circuit Conditions for Running the SPN SPN 630 65580 is not set The ignition is ON or the engine is operating The ignition voltage is greater than 9 volts The Slow Mode lamp has been commanded and OFF at least once during the ignition cycle SPN 66010 runs continuously once the above conditions are met Conditions for Setting the SPN The ECM detects that the commanded state of the driver and the actual state of the control circuit do not match for greater than 5 seconds Action Taken When the SPN Sets SPN 66010 is a Type C SPN Conditions for Clearing the SPN SPN 66010 is a Type C SPN Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 2011 Marine Engines Manual Circuit System Verification 1 Ignition ON command the Slow Mode lamp ON and OFF w
287. e nozzle one that provides hot or cold air This type of tool is capable of producing air stream temperatures down to 18 0 from one end and 71 C 160 F from the other This is ideally suited for localized cooling needs Once the vehicle component or harness has been sufficiently cooled manipulate the harness or components in an effort to duplicate the concern 2011 Marine Engines Manual Testing for Electrical Intermittents Special Tools J 39200 Digital Multimeter Perform the following procedures while wiggling the harness from side to side Continue this at convenient points about 6 inches apart while watching the test equipment Testing for Short to Ground on page 11 12 Testing for Continuity on page 11 12 Testing for a Short to Voltage on page 11 13 If the fault is not identified perform the procedure below using the MIN MAX feature on the J 39200 DMM This feature allows you to manipulate the circuit without having to watch the J 39200 The J 39200 will generate an audible tone when a change is detected Note The J 39200 should be used in order to perform the following procedure since the J 39200 can monitor current resistance or voltage while recording the minimum MIN and maximum MAX values measured 1 Connect the J 39200 to both sides of a suspected connector still connected or from one end of a suspected circuit to the other Refer to Troubleshooting with a Digital Multi
288. e plastic combs used in the control module connectors The TPA keeps the terminal securely seated in the connector body Do not remove the TPA from the connector body unless you remove a terminal for replacement 2011 Marine Engines Manual Push to Seat Connectors Terminal Removal Follow the steps below in order to repair push to seat connectors 0E E S2 8802 1 Remove the terminal position assurance TPA device the connector position assurance CPA device and or the secondary lock 2 Separate the connector halves 1 1 T 8 3 Use the proper pick or removal tool 1 in order to release the terminal 4 Gently pull the cable and the terminal 2 out of the back of the connector 8803 2011 Marine Engines Manual Wiring Systems 11 25 8804 5 Re form the locking device if you are going to reuse the terminal 1 6 To repair the terminal refer to Terminal Repair Terminal Repair Slip the cable seal away from the terminal Cut the wire as close to the terminal as possible Slip a new cable seal onto the wire Strip 5 mm 3 16 in of insulation from the wire Crimp a new terminal to the wire Solder the crimp with rosin core solder Slide the cable seal toward the terminal Crimp the cable seal and the insulation If the connector is outside of the passenger compartment apply grease to the connector Reinstalling Terminal 1 In order to
289. e service manual schematics will help you to see system power ground input and output circuits You can also identify splices and other areas where multiple circuits are tied together Look at component locations to see if components connectors or harnesses may be exposed to extreme temperature moisture or corrosives salt battery acid oil or other fluids Utilize the wiring diagrams system description 6 4 Intermittent History DTC An intermittent condition is one that does not occur continuously may be difficult to duplicate and will only occur when certain conditions are met Generally an intermittent is caused by faulty electrical connections and wiring malfunctioning components electromagnetic radio frequency interference driving conditions or aftermarket equipment The following approaches tools may prove to be beneficial in locating and repairing an intermittent condition or history DTC Combining technicians knowledge with the available service information Follow the suggestions on Testing for Intermittent Conditions and Poor Connections on page 11 13 Use the available scan tool or digital multi meter 2011 Marine Engines Manual Vehicle Diagnostic Information 6 5 7 Re examine the Concern If a technician cannot successfully find or isolate the concern a re evaluation is necessary Re verify the concern The concern could be an intermittent or normal condition 8 Repair and Verify
290. e shift interrupt switch parameter with a scan tool while shifting in and out of gear The parameter should display OFF in neutral and ON in gear 2 Observe the SPN information with a scan tool SPN 66026 should not set 3 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data 9 192 Engine Controls and Fuel Marine Circuit System Testing Note Verify the shift interrupt switch is properly adjusted before proceeding with this diagnostic procedure 1 2 Ignition OFF disconnect the harness connector at the shift interrupt switch Test for less than 5 Q between the ground circuit terminal 2 and ground If greater than the specified range test the ground circuit for an open high resistance Ignition ON test for greater than 10 V between the shift interrupt switch signal circuit terminal 1 and ground If less than the specified range test the signal circuit for an open high resistance or a short to ground If the circuit tests normal replace the ECM Ignition OFF install a 3 A fused jumper wire between the between the shift interrupt switch signal circuit terminal 1 and ground Ignition ON observe the scan tool shift interrupt switch parameter The parameter should display ON If the parameter does not display ON test the signal c
291. e the scan tool SPN information Verify that SPN 110 15 or 110 16 is not set If SPN 110 15 or 110 16 is set inspect for an engine overheating condition If a condition is found repair the cooling system as necessary 3 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data 2011 Marine Engines Manual Circuit System Testing 1 Ignition OFF disconnect the harness connector at the ECT sensor 2 Test for less than 5 between the low reference circuit terminal A and ground If greater than the specified range test the low reference circuit for an open high resistance If the circuit tests normal replace the ECM 3 Ignition ON verify the scan tool ECT sensor parameter is at 40 40 F If warmer than the specified range test the signal circuit for a short to ground If the circuit tests normal replace the ECM Note If the fuse in the jumper wire opens the signal circuit is shorted to a voltage and the sensor may be damaged 4 Install a 3 A fused jumper wire between the signal circuit terminal B and the low reference circuit terminal A Verify the ECT sensor parameter is warmer than 150 C 303 F lf less than the specified range test the signal circuit for a short to voltage or an open high resistance If the circuit tests normal repl
292. e voltage signal Fuel Temp Sensor Volts 0 5 Volts received by the control module from the fuel temperature sensor This parameter displays the commanded pou OFF state of the control module general warning amp AER lamp 1 control circuit This parameter displays the commanded aded OFF state of the control module general warning Sipe lamp 2 control circuit This parameter displays the status of the Gov Mode Input MONT ON cruise control system as determined by the control module This parameter displays the governed vehicle Governed Cruise MPH RPM switch Varies speed limit in miles per hour that is set by Vehicle Speed set to MPH ihe throttle control This parameter displays whether or not the This parameter displays the governed vehicle Governor RPM Speed switch Varies speed limit in engine RPM that is set by the throttle control This parameter displays the commanded Governor Status Lamp OFF state of the control module governor status lamp control circuit History Data Has Been This parameter displays YES if the control Corrupted module detects an ECM reset This parameter displays YES when the IAC in Control of RPM YES control module is regulating the engine speed with the ETC motor This parameter displays a percentage in a range of 0 100 percent relative to the position of throttle plate when the engine is considered to be at idle pedal position PP IAC Position 40 50 is 0 percent The percent
293. eal with clean engine oil before installing the sensor 1 Install the MAP sensor 2 Install the MAP sensor retainer 3 Connect the engine harness wiring electrical connector to the MAP sensor 1697060 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 221 Barometric Pressure Sensor Replacement HLS eee a 2164114 Barometric Pressure Sensor Replacement Callout Component Name Barometric Pressure Sensor Bolt Caution Refer to Component Fastener Tightening Caution on page 0 5 Tighten 10 N m 89 Ib in Barometric Pressure Sensor Procedure Disconnect the Baro sensor harness connector Tip Always install the NEW O ring provided with the BARO sensor 2011 Marine Engines Manual 9 222 Engine Controls Fuel Marine Supercharger Air Inlet Pressure Sensor Replacement D KON Li ee H UT ER gt SS 2157401 Supercharger Air Inlet Pressure Sensor Replacement Component Name Super Charger Inlet Pressure Sensor Bolt Caution Refer to Component Fastener Tightening Caution on page 0 5 Tighten 10 N m 89 Ib in Super Charger Inlet Pressure Sensor Procedure Disconnect the super charger pressure sensor harness connector Tip Always install the NEW O ring provided with the super charger pressure sensor 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 223 Charge Air Bypass Regulator Solenoid Valve Re
294. eater than the specified range repair the ground circuit for an open high resistance 3 Test for less than 2 Q between the EST return circuit terminal B 2 and ground If greater than the specified range test the EST return circuit for an open high resistance If the circuit tests normal replace the ECM 4 Ignition ON load test for B between the ignition voltage circuit terminal D 4 and ground gt Ifless than the specified range test the ignition voltage circuit for a short to ground or an open high resistance If the circuit tests normal and the ignition voltage circuit fuse is open test all components connected to the ignition voltage circuit and replace as necessary 5 If all circuits test normal replace the ignition coil 9 216 Engine Controls and Fuel Marine Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Ignition Coil Replacement 3 0L on page 9 241 or Ignition Coil Replacement 6 0L and 6 2L on page 9 242 or Ignition Coil Replacement 4 3L 5 0L and 5 7L on page 9 243 or Ignition Coil Replacement 2 4L on page 9 244 Engine Control Module Programming and Setup on page 6 3 for ECM replacement setup and programming Slow Mode Switch Diagnosis Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagn
295. ectly during installation 2011 Marine Engines Manual Spark Plug Visual Inspection Normal operation Brown to grayish tan with small amounts of white powdery deposits are normal combustion by products from fuels with additives Carbon fouled Dry fluffy black carbon or soot caused by the following conditions Rich fuel mixtures Leaking fuel injectors Excessive fuel pressure Restricted air filter element Incorrect combustion Reduced ignition system voltage output Weak coils Worn ignition wires Incorrect spark plug gap Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off Deposit fouling Oil coolant or additives that include substances such as silicone very white coating reduces the spark intensity Most powdery deposits will not effect spark intensity unless they form into a glazing over the electrode Spark Plug Replacement Removal Procedure 1 Remove the spark plug wire from the spark plug 1 1 Twist the spark plug wire boot a 1 2 turn 1 2 Pull only on the boot in order to remove the wire from the spark plug 14824 2 Brush or using compressed air blow away any dirt from around the spark plug 3 Remove the spark plug If removing more than one plug place each plug in a tray marked with the corresponding cylinder number 2011 Marine Engines Manual Engine Controls an
296. ector End Views page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification 1 Ignition ON test for 11 15 V between the terminals of each battery If not within the specified range charge and test the battery replace if necessary 2 Engine idling the battery voltage tested in step 1 should increase If the battery voltage does not increase repair the charging system condition 3 Observe the scan tool Battery Voltage parameter Compare the scan tool voltage parameter to the battery voltage displayed on the DMM The scan tool parameter and the DMM should display within 1 volt of each other 4 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Ignition OFF Disconnect the ECM harness connectors X1 and X2 Test for less than 1 O between the ground circuit terminal X2 73 and ground greater than the specified range test the ground circuit for an open high resistance 2 Load te
297. ector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification 1 Ignition ON observe the SPN information with a scan tool Verify that SPN 65620 65621 65622 or 65623 is not set If either SPN is set refer to SPN 65620 65623 on page 9 149 2 Engine operating observe the SPN information with a scan tool Verify SPN 100 3 100 4 or 100 17 is not set 3 Engine idling observe the scan tool EOP Sensor parameter The reading should be between 41 414 kPa 6 60 psi 4 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Ignition OFF disconnect the harness connector at the EOP sensor 2 Ignition OFF test for less than 5 between the low reference circuit terminal A and ground If greater than the specified range test the low reference circuit for an open high resistance If the circuit tests normal replace the ECM 3 Ignition ON test for 4 8 5 2 V between the 5 volt reference circuit terminal B and ground If less than the specified range test the
298. ed and for limp home operation 65723 8 65724 8 636 2 65723 2 65723 7 65724 2 65724 7 Conditions for Running the SPN 65723 2 65723 8 65724 2 and 65724 8 SPN 630 65580 65620 65621 65622 or 65623 is not set The engine is cranking or running SPN 65723 runs continuously once the above conditions are met 65723 7 and 65724 7 SPN 630 65580 65620 65621 65622 65623 is not set The engine speed is greater than 1 000 RPM SPN 65723 7 runs continuously once the above conditions are met Conditions for Setting the SPN 65723 2 and 65714 2 The ECM detects an incorrect number of CMP reference pulses for greater than 49 engine revolutions 65723 7 and 65724 7 The ECM detects the CMP sensor signal is out of range compared to the CKP sensor signal for greater than 49 engine revolutions 65723 8 65724 8 65723 8 65724 8 65723 8 65724 8 2011 Marine Engines Manual 65723 8 and 65724 8 The ECM does not detect a signal from the CMP sensor for greater than 49 engine revolutions Action Taken When the SPN Sets SPN 65723 and 65724 are Type B SPNs Closed Loop not enabled Cam phaser not enabled Conditions for Clearing the SPN SPN 65723 and 65724 are Type B SPNs Diagnostic Aids The following conditions may also set the SPNs Physical damage to the CMP sensor the reluctor wheel Excessive play or looseness of the CMP se
299. ed Oxygen and Oxygen Sensor tette Ignition OFF When Disconnecting Battery Caution J 35616 A Connector Test Adapter Kit M EE Test Lamp to Test Continuity Caution Test Probe Caution Three Way Catalytic Converter Damage ern 0 2 Table of Contents BLANK 2011 Marine Engines Manual Dangers Warnings and Cautions 0 3 Dangers Warnings and Cautions Definition of Danger Warning Caution and Note The diagnosis and repair procedures in a GM Service Manual contain both general and specific Dangers Warnings Cautions Notes or Importants GM is dedicated to the presentation of service information that helps the technician to diagnose and repair the systems necessary for the proper operation of the vehicle however certain procedures may present a hazard to the technician if they are not followed in the recommended manner Dangers Warnings Cautions and Notes or Importants are elements designed to prevent these hazards however not all hazards can be foreseen This information is placed at strategic locations within the service manual This information is designed to prevent the following from occurring Serious bodily injury or death to the technician Damage to the vehicle Unnecessary vehicle repairs Unnecessary component replacement Improper repair or replacement of vehicle com
300. edure Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 9 168 Engine Controls and Fuel Marine SPN 66005 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptor SPN 66005 FMI 3 Governor Status Lamp GSL Voltage Above Normal or Shorted High SPN 66005 FMI5 Governor Status Lamp GSL Current Below Normal or Open Circuit Diagnostic Fault Information Short to Open High Short to Signal Circuit a Resistance me en GSL Voltage Supply 66005 5 GSL Control aE 66005 3 The fuse that supplies voltage to the IPC Bulb opens Circuit System Description The Governor Status Lamp GSL is located on the instrument panel cluster IPC Ignition voltage is supplied to the GSL through a fuse The engine control module ECM turns the GSL ON by grounding the control circuit There should be a steady GSL with the ignition ON and the engine OFF Conditions for Running the SPN SPN 630 65580 is not set The ignition is ON or the engine is operating The ignition voltage is greater than 9 volts The GSL has been commanded ON and OFF at least once during t
301. edure Tighten Tighten the studs to 11 N m 97 Ib in Note Verify the coil wire does not contact any metal objects Rubbing will make a ground or short after time of use 1578474 1 Install the ignition coil s Caution Refer to Fastener Caution on page 0 5 2 Install the ignition coil bolt s Tighten Tighten the 5 to 10 N m 89 Ib in 3 Install the ignition coil wire 4 Install the electrical connectors 5 Install the negative battery terminal 2011 Marine Engines Manual 1628020 3 Connect the ignition coil electrical connector s 3 Spark Plug Wire Inspection Spark plug wire integrity is vital for proper engine operation A thorough inspection is necessary to accurately identify conditions that may affect engine operation Inspect for the following conditions 1 Correct routing of the spark plug wires Incorrect routing may cause cross firing 2 Any signs of cracks or splits in the wires 3 Inspect each boot for any of the following conditions Tearing Piercing Arcing Carbon tracking Corroded terminal If corrosion carbon tracking or arcing are indicated on a spark plug wire boot or terminal replace the wire and the component connected to the wire Spark Plug Wire Replacement Removal Procedure 1 Disconnect the spark plug wire at each spark plug Twist each spark plug 1 2 turn Pull only on the boot in order to remove the wire from eac
302. elated to a specific cylinder combustion event This parameter will display YES if the control module has not learned the minimum throttle position This parameter displays the number of the current failure mode indicator if an SPN is set This parameter displays if the control module 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 59 Engine Control Module Scan Tool Data cont d System State Expected Value This parameter displays the block learn memory BLM or fuel trim cell number as calculated by the control module based on O2 A1 or B1 BLM 0s engine speed and load inputs The scan tool Cell 1 0 will display a lower number as conditions are nearer to idle and a higher value as conditions approach maximum engine speed and maximum load This parameter displays the short term correction to fuel delivery for bank 1 or bank 2 in response to the amount of time the oxygen sensor voltage spends above or 02 A1 or B1 BLM below the 450 mV threshold The scan tool Cell Value Closed Loop ON 0 90 1 10 Varies will display a value of 1 00 which is equal to stoich 14 7 1 if no adjustments are required The scan tool will display a value greater than 1 00 if fuel has to be added anda value less than 1 00 if fuel has to be subtracted This parameter displays the oxygen sensor 02 A1 Cross Counts Manes rich lean and lean rich switches A switch is Per Second when the oxygen sensor voltage goes above 4
303. elow Normal SPN 65570 65571 65572 or 65573 2 4L 65571 4 Shorted Low page 9 132 SPN 65570 65571 65572 or 65573 2 41 on 65571 Cam Phaser X Short High or Open page 9 132 Cam Phaser X Accuracy Mechanical 65571 7 System Not Responding or Out of m 63371 63912 OF 69973 2 4L ON Adjustment pag Cam Phaser Y Data Erratic Intermittent SPN 65570 65571 65572 or 65573 2 4L on 65572 2 or Incorrect page 9 132 Cam Phaser Y Voltage Below Normal SPN 65570 65571 65572 65573 2 4L on 65572 4 Shorted Low page 9 132 SPN 65570 65571 65572 or 65573 2 4L on 65572 Cam Phaser Y Short High or Open page 9 132 Cam Phaser Y Accuracy Mechanical 65572 7 System Not Responding or Out of as 2 65571 65572 65573 2 4L Adjustment pag Cam Phaser Z Data Erratic Intermittent SPN 65570 65571 65572 or 65573 2 4L on 65673 2 or Incorrect page 9 132 Cam Phaser Z Voltage Below Normal or SPN 65570 65571 65572 or 65573 2 4L on 65673 4 Shorted Low page 9 132 2011 Marine Engines Manual 4 5 1 1 10 10 2 4 65570 Vehicle Diagnostic Information 6 17 Diagnostic Trouble Code DTC List cont d DTC Descriptor Diagnostic Procedure Note If multiple powertrain SPNs are stored diagnose the SPNs in the following order 1 Component level SPNs such as sensor SPNs solenoid SPNs and relay SPNs 2 System level SPNs such as misfire SPNs and fuel trim SPNs Adju
304. enabled The is not performing the KS intrusive open test 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 115 Bank 1 Data Valid but Below Normal Bank 1 Voltage Above Normal or Shorted High Bank 1 Voltage Below Normal or Shorted Low Bank 1 Current Below Normal or Open Circuit Bank 2 Data Valid but Below Normal Bank 2 Voltage Above Normal or Shorted High Bank 2 Voltage Below Normal or Shorted Low Bank 2 Current Below Normal or Open Circuit The engine speed is less than 2 000 RPM for greater than 5 seconds to establish base line knock activity The engine speed is greater than 3 500 RPM for greater than 5 seconds to obtain a test sample The SPN runs once every 250 cylinder events when the conditions above are met 65551 and 65552 FMI 3 and 4 SPN 630 or 65580 is not set The ignition is ON or the engine is operating The SPNs run continuously once the conditions above are met 65551 and 65552 FMI 5 Before the ECM can report that SPN 65551 5 or 65552 5 failed SPN 65551 3 65551 4 65552 3 and 65552 4 must run and pass SPN 630 or 65580 is not set The engine coolant temperature is warmer than 50 122 F The Fuel Detonation Control Mode is enabled The engine speed is greater than 1 500 RPM The engine speed is steady within 500 RPM for greater than 10 seconds The MAP signal is steady within 20 kPa for greater than 10 seconds Knock retard activity is less than 0 5 degre
305. ency stop switch ground circuit for an open high resistance 3 Ignition ON test for greater than 4 V between the emergency stop switch signal circuit terminal A and ground lf less than the specified range test the emergency stop switch signal circuit for a short to ground or an open high resistance If the circuit tests normal replace the ECM 4 f all circuits test normal replace the emergency stop switch Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 9 158 Engine Controls and Fuel Marine SPN 65723 65724 65725 or 65726 3 0 4 3 5 0 5 7L Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 65723 FMI 2 Camshaft Position CMP SPN 65723 FMI 7 Camshaft Position CMP SPN 65723 FMI 8 Camshaft Position CMP Diagnostic Fault Information Sensor Circuit Data Erratic Intermittent or Incorrect Sensor Mechanical System Not Responding or Out of Adjustment Sensor Signal Abnormal Frequency or Pulse Width Short to Open High Short to Signal Circuit
306. ends on the velocity of the crankshaft The crankshaft position sensor sends a digital signal which represents an image of the crankshaft reluctor wheel to the ECM as each tooth on the wheel rotates past the crankshaft position sensor The ECM uses each crankshaft position signal pulse to determine crankshaft speed and decodes the crankshaft reluctor wheel reference gap to identify crankshaft position This information is then used to sequence the ignition timing and fuel injection events for the engine The ECM also uses crankshaft position sensor output information to determine the crankshaft relative position to the camshaft to detect cylinder misfire and to control the camshaft position actuator if equipped Conditions for Running the SPNs SPNs 630 65580 65620 65621 65622 or 65623 is not set The engine is cranking or operating SPN 636 runs continuously once the above conditions are met Conditions for Setting the SPN 636 2 The ECM detects an incorrect number of CKP reference pulses for greater than 125 mS 636 8 The ECM does not detect a signal from the CKP sensor for greater than 125 mS Action Taken When the SPN Sets SPN 636 is Type A SPN The engine will crank but not start Conditions for Clearing the SPN SPN 636 is a Type A SPN Diagnostic Aids The following conditions could also set the SPNs Physical damage to the CKP sensor or the reluctor wheel Excessive play or loosen
307. ensor Bank B Sensor 2 SPN 65561 65562 65563 or 65564 on Current Below Normal or Open Circuit page 9 122 m Bank A Data Valid But Above SPN 65565 or 65566 on page 9 125 um Bank A Data Valid But Below SPN 65565 or 65566 on page 9 125 n Bank B Data Valid But Above SPN 65565 or 65566 on page 9 125 Bank Data Valid But Below 65565 65566 on 9 125 Oxygen Sensor Bank A Sensor 1 Abnormal Frequency or Pulse Width SPN 65567 or 65568 on page 9 127 Oxygen Sensor Bank A Sensor 1 Abnormal Rate of Change SPN 65567 or 65568 on page 9 127 Oxygen Sensor Bank B Sensor 1 Abnormal Frequency or Pulse Width SPN 65567 or 65568 on page 9 127 Oxygen Sensor Bank B Sensor 1 Abnormal Rate of Change SPN 65567 or 65568 on page 9 127 SPN 65570 6 0 6 21 page 9 129 or SPN Phaser W Data Erratic Intermittent 65570 65571 65572 or 65573 2 4L on page 9 132 SPN 65570 6 0 6 2L on page 9 129 or SPN Phaser W Voltage Below Normal 65570 65571 65572 or 65573 2 4L on page 9 132 SPN 65570 6 0 6 2L on page 9 129 or SPN 5 Cam Phaser W Short High or Open 65570 65571 65572 or 65573 2 4L on page 9 132 Cam Phaser W Accuracy Mechanical SPN 65570 6 0 6 2L on page 9 129 or SPN 65570 7 System Not Responding or Out of 65570 65571 65572 or 65573 2 4L on Adjustment page 9 132 Cam Phaser X Data Erratic Intermittent SPN 65570 65571 65572 or 65573 2 4L on 65571 2 or Incorrect page 9 132 Cam Phaser X Voltage B
308. ent setup and programming 9 110 Engine Controls and Fuel Marine SPN 3563 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 3563 FMI 0 SPN 3563 FMI 1 SPN 3563 FMI 2 SPN 3563 FMI 3 SPN 3563 FMI 4 Supercharger Inlet Pressure SCIP Diagnostic Fault Information Supercharger Inlet Pressure SCIP Supercharger Inlet Pressure SCIP Sensor Circuit Data Valid but Above Normal Supercharger Inlet Pressure SCIP Sensor Circuit Data Valid but Below Normal Sensor Circuit Data Erratic Intermittent or Incorrect ensor Circuit Voltage Above Normal or Shorted High Supercharger Inlet Pressure SCIP Sensor Circuit Voltage Below Normal or Shorted Low SC Inlet Pressure Sensor Short to High Short to Signal Circuit Ground Resistance Voltage Performance 636 8 5 Volt Reference 65621 4 3563 4 3563 4 3563 2 3563 3 SC Inlet Pressure Sensor Signal Inlet Pressure Sensor SC Inlet Pressure Sensor Signal 3504 3563 4 3563 4 3563 3 3563 0 3563 2 sees ose 35653 356592 Engine cranks but does not run Circuit Description The supercharger inlet pressure SCIP sensor
309. ent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 for scan tool information Circuit System Verification 1 Ignition ON compare the scan tool BARO sensor pressure parameter MAP sensor pressure parameter and the SCIP sensor pressure parameter All three parameter readings should be within 5 kPa of each other If greater than the specified range refer to Altitude Versus Barometric Pressure on page 9 3 and Diagnostic Trouble Code DTC List on page 6 11 for diagnosis of an out of range sensor 2 Engine operating verify the intercooler pump is operating If the intercooler pump is not operating refer to Supercharger Intercooler Relay Diagnosis on page 9 204 3 Verify proper operation of the boost control system Refer to Boost Control System Diagnosis on page 9 205 4 Observe the SPN information with a scan tool SPN 66035 should not set 5 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data 2011 Marine Engines Manual Circuit System Testing 1 Ignition OFF disconnect the harness connector at the SCB solenoid 2 Ignition ON verify that a test lamp illuminates bet
310. epair the wires connectors or terminals could result in the obstruction of the air reference and degrade oxygen sensor performance The following guidelines should be used when servicing the heated oxygen sensor Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors These materials may get into the sensor causing poor performance Also the sensor pigtail and harness wires must not be damaged in such a way that the wires inside are exposed This could provide a path for foreign materials to enter the sensor and cause performance problems Neither the sensor nor vehicle lead wires should be bent sharply or kinked Sharp bends kinks etc could block the reference air path through the lead wire Do not remove or defeat the oxygen sensor ground wire where applicable Vehicles that utilize the ground wire sensor may rely on this ground as the only ground contact to the sensor Removal of the ground wire will also cause poor engine performance To prevent damage due to water intrusion be sure that the peripheral seal remains intact on the vehicle harness connector 2011 Marine Engines Manual Wiring Systems 11 17 Splicing Copper Wire Using Splice Clips Splice clips are included in Terminal Repair Kit J 38125 A The splice clip is a general purpose wire repair device It may not be acceptable for applications having special requirements such as moisture sealing Step 1
311. er SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Special Tool Required J 23738 A Vacuum Pump Circuit System Verification 1 Ignition ON observe the SPN information with a scan tool Verify that SPN 65621 or 65622 is not set If SPN 65621 or 65622 is set refer to SPN 65620 65623 on page 9 149 for further diagnosis 2 Turn all accessories OFF 3 Engine operating observe the scan tool MAP Sensor parameter The reading should be between 31 68 kPa 9 20 in Hg 4 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data 9 88 Engine Controls and Fuel Marine Circuit System Testing gt If greater than the specified range test the i lichen OFF 5 volt reference circuit for a short to voltage ee If the circuit tests normal replace the MAP sensor or remove the MAP sensor from the intake manifold Connect the J 23738 A to the 6 Verify the scan tool MAP sensor pressure vacuum source parameter is less than 0 25 V 2 Engine operating verify that 31 68 kPa If greater than the specified range test the 9 20 in Hg of vacuum is available to the MAP signal circuit terminal 3 for a short to voltage sensor If the circuit tests normal replace the
312. er Low Control Bank Sensor 2 I ignition 1 Voltage 2011 Marine Engines Manual D ignitioni Voltage 9 46 Engine Controls and Fuel Marine Ignition Coil Distributor Ignition Terminal Part Information Terminal Tray 15326267 19 Core Insulation Crimp E 1 Release Tool Test Probe 12094430 J 35616 2A GY Ignition Coil 1 2 4L Circuit Wire Color No eons _____ 2 tow Reference L3 4 Connector Part Information Ignition Coil 2 2 4L OEM 12146121 Service 88987992 Description 3 Way F Metri Pack 150 Series BN 68743 Terminal Part Information Terminal Tray See Terminal Repair Kit Core Insulation Crimp See Terminal Repair Kit Core Insulation Crimp See Terminal Repair Kit Release Tool Test Probe See Terminal Repair Kit Ignition Coil Distributor Ignition Circuit Wire Color No Function A Ignition 1 Voltage LOW 9 9 Connector Part Information B it OEM 7283 3392 30 Ignition Control Service 88988338 Description 4 Way F GT 150 Series Sealed BK 1590069 Ignition Coil 1 2 4L Terminal Part Information Terminal Tray 15326267 19 Core Insulation Crimp E 1 Release Tool Test Probe 12094430 J 35616 2A GY Ignition Coil 21 2 4L Circuit Wire Color No quemeweee 1590069 Connector Part In
313. erate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 103 Circuit System Testing 1 Ignition OFF disconnect the harness connector at the CKP sensor 2 Test for less than 5 between the low reference circuit terminal B and ground If greater than the specified range test the low reference circuit for an open high resistance If the circuit tests normal replace the ECM 3 Ignition ON test for 4 8 5 2 V between the 5 volt reference circuit terminal C and ground If less than the specified range test the 5 volt reference circuit for a short to ground or an open high resistance If the circuit tests normal replace the ECM greater than the specified range test the 5 volt reference circuit for a short to voltage If the circuit tests normal replace the ECM 4 Test for 4 8 5 2 V between the signal circuit terminal A and ground If less than the specified range test the signal circuit for a short to ground or an open high resistance If the circuit tests normal replace the ECM greater than the specified range test the signal circuit for a short to voltage If the circuit tests normal replace the ECM 5 If all circuits test normal test or replace the sensor Repa
314. erican Operations General Motors LLC Milford Michigan 48380 2011 GENERAL MOTORS LLC ALL RIGHTS RESERVED The information cutoff date is 01 03 11 LITHO IN U S A No part of this manual may be reproduced stored in any retrieval system or transmitted in any form or by any means including but not limited to electronic mechanical photocopying and recording without the prior written permission of General Motors LLC This applies to all text illustrations and tables 2011 Marine Engines Manual Error and Suggestion Reporting If you find an error in a GM Service manual or if you have a suggestion about a GM service manual we want to hear from you When calling be prepared with the following information Your name The name of your dealership The phone number of your dealership The model year and the vehicle line The publication part number if present The vehicle identification number of the vehicle on which you are working The service category and page number s Any applicable electronic information element identification numbers descriptive explanation of your concern The GM service manual phone personnel will respond to your concerns in the following ways By delivering your concern to the author of the manual By eliciting a response from the author By supplying you with an answer to your concerns For paper manual users The GM service manual phone personnel will also explain how to send in examples or marked
315. erved by the control module Closed Loop is entered The control module uses the HO2S signal voltage to determine and vary the delivered air to fuel ratio based in part on the oxygen content of the exhaust An HO2S voltage that increases toward 1 000 mV indicates a rich fuel mixture An HO2S voltage that decreases toward 0 mV indicates a lean fuel mixture The heating elements inside each HO2S heats the sensor to bring the sensor up to operating conditions faster This allows the system to enter Closed Loop earlier and the control module to calculate the air to fuel ratio sooner which reduces fuel consumption and improves the vessels exhaust emissions performance Conditions for Running the SPN 65561 65563 SPN 94 106 630 or 65580 is not set The ignition voltage is greater than 10 volts The engine is operating for greater than 60 seconds The engine coolant temperature is warmer than 60 C 140 F The engine is operating in Closed Loop for greater than 50 seconds SPNs 65561 and 65563 run continuously when the above conditions are met 65562 65564 SPN 94 106 630 or 65580 is not set The ignition voltage is greater than 10 volts 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 123 The engine is operating for greater than 60 seconds The engine coolant temperature is warmer than 60 140 F The engine is operating in Closed Loop for greater than 50 seconds The enable condit
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317. es since the last test The SPN runs once every 300 seconds when the conditions above are met 9 116 Engine Controls and Fuel Marine Conditions for Setting the SPN 65551 or 65552 FMI 1 The ECM detects that the knock sensor activity did not increase with the engine speed for greater than 2 seconds 65551 or 65552 FMI The ECM detects that the KS voltage is greater than 2 5 volts for greater than 2 seconds 65551 or 65552 FMI 4 The ECM detects that the KS voltage is less than 0 29 volt for greater than 2 seconds 65551 or 65552 FMI 5 The ECM detects that an open KS circuit for greater than 2 seconds Action Taken When the SPN Sets SPN 65551 and 65552 are Type B SPNs Conditions for Clearing the SPN SPN 65551 and 65552 are Type B SPNs Diagnostic Aids The following conditions may also set the SPNs Inspect the KS for physical damage A KS that is dropped or damaged may cause an SPN to set Inspect the KS for proper installation A KS that is loose or over torqued may cause an SPN to set The KS should be free of thread sealant The KS mounting surface should be free of burrs casting flash and foreign material The KS must be clear of hoses brackets and engine electrical wiring Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views page 9
318. es Sealed BK 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 37 Terminal Part Information Terminal Tray 15326267 19 Core Insulation Crimp E 4 Release Tool Test Probe 15315247 J 35616 2A GY Engine Coolant Temperature ECT Sensor Circuit Wire Color No A jtewRe eeme sTSemeSina Engine Oil Level Switch 635009 Connector Part Information OEM 12052641 Service 12102747 Description 2 Way F Metri Pack 150 Series Sealed BK Terminal Part Information Terminal Tray 12048074 2 Core Insulation Crimp E 1 Release Tool Test Probe 12094429 J 35616 2A GY Engine Oil Level Switch Circuit Wire Color No Engine Oil Level Switch Signal _____ 9 38 Engine Controls and Fuel Marine Engine Oil Pressure EOP Engine Oil Pressure EOP Sensor 3 0 4 3 5 0 5 7L Sensor 6 0 6 2L 1519475 2212053 Connector Part Information Connector Part Information OEM 15477863 OEM 15477863 Service 88988301 Service 88988301 Description 3 Way F GT 150 Series Sealed BK Description 3 Way F GT 150 Series Sealed BK Terminal Part Information Terminal Part Information Terminal Tray 15326267 19 Terminal Tray 15326267 19 Core Insulation Crimp E 4 Core Insulation Crimp E 4 Release Tool Test Probe 15315247 J 35616 2A GY Release Tool Test Probe 15315247 J 35616 2A GY Engine Oil Pressure EOP Engine Oil Pressure EOP Sensor 4
319. es or wiring Poor shielding or poor connectors on antenna cable Circuit Testing The Circuit Testing section contains the following diagnostic testing information Using this information along with the diagnostic procedures will identify the cause of the electrical malfunction Using Connector Test Adapters on page 11 6 Probing Electrical Connectors on page 11 6 Troubleshooting with a Digital Multimeter on page 11 8 Troubleshooting with a Test Lamp on page 11 10 Using Fused Jumper Wires on page 11 10 Measuring Voltage on page 11 10 Measuring Voltage Drop on page 11 11 Measuring Frequency on 11 11 Testing for Continuity on page 11 12 Testing for Short to Ground on page 11 12 Testing for a Short to Voltage on page 11 13 Testing for Intermittent Conditions and Poor Connections on page 11 13 Inducing Intermittent Fault Conditions on page 11 14 Testing for Electrical Intermittents on page 11 15 Using Connector Test Adapters Caution Do not insert test equipment probes DVOM etc into any connector or fuse block terminal The diameter of the test probes will deform most terminals A deformed terminal will cause a poor connection which will result in a system failure Always use the J 35616 GM Approved Terminal Test Kit in order to front probe terminals Do not use paper clips or other substitutes to probe terminals When using the J 35616 GM Approved Terminal Test Kit ensure the terminal test adapter choice is th
320. ess of the CKP sensor or the reluctor wheel Improper installation of the CKP sensor or the reluctor wheel Foreign material passing between the CKP sensor and the reluctor wheel Excessive air gap between the CKP sensor and the reluctor wheel An intermittent condition with the CMP sensor or circuits 2011 Marine Engines Manual Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification Note If you were sent here from Engine Cranks but Does Not Run proceed to Circuit System Testing 1 Attempt to start the engine observe the SPN information with a scan tool SPNs 636 2 or 636 8 should not set 2 Engine cranking observe the scan tool Engine Speed parameter The scan tool should indicate an engine speed greater than 0 RPM 3 Move related harnesses connectors of the CKP sensor and verify the engine does not stumble stall or change engine speed 4 Op
321. essage from a OEM specific controller on the CAN communication circuit for greater than 10 seconds Action Taken When the SPN Sets SPN 65560 is a Type SPN The ECM may command the throttle actuator control TAC system to operate in reduced power Conditions for Clearing the SPN SPN 65560 is a Type C SPN Diagnostic Aids The scan tool will power up with the ignition OFF The ECM will not communicate unless the ignition is ON Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Description and Operation Data Link Communications Description and Operation on page 11 5 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs page 11 16 2011 Marine Engines Manual SPN Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification 1 Ignition ON observe the SPN information with a scan tool Verify that SPN 65658 11 65559 11 is not set is set refer to SPN 65558 or 65559 page 9 178 for further diagnosis 2 Ignition ON observe the SPN info
322. est Point Measuring Voltage Drop This test checks for voltage being lost along a wire or through a connection or switch 1 Switch the voltmeter to V and connect the positive lead to the end of the wire or to one side of the connection or switch which is closest to the battery 2 Connect the negative lead to the other end of the wire or other side of the connection or switch 3 Operate the circuit 4 The voltmeter will show the difference in voltage between the two points A difference or drop of more than 1 volt indicates a problem 2011 Marine Engines Manual 1683689 Legend Power From Battery Fuse 3 Switch Relay Coil Meter Fi Pes Measuring Frequency Caution Refer to Test Probe Caution on page 0 6 The following procedure determines the frequency of a signal Note Connecting the DMM to the circuit before pressing the Hz button will allow the DMM to autorange to an appropriate range 1 Apply power to the circuit 2 Set the rotary dial of the DMM to the V AC position 3 Connect the positive lead of the DMM to the circuit to be tested 4 Connect the negative lead of the DMM to a good ground 5 Press the Hz button on the DMM 6 The DMM will display the frequency measured 11 12 Wiring Systems Testing for Continuity To test for continuity 1 Disconnect the battery ground lead 2 Connect one lead of a self powered test light or ohmmeter to one end of the part of the circuit 1
323. est for infinite resistance between the following terminals 30 and 86 30 and 87 30 and 85 85 and 87 If not the specified value replace the relay 4 Install a 10 A fused jumper wire between relay terminal 85 and Install a jumper wire between relay terminal 86 and ground 6 Test for less than 2 between terminals 30 and 87 If greater than the specified range replace the relay Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the repair Relay Replacement Fuse Block on page 11 28 or Helay Replacement Harness on page 11 29 Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 2011 Marine Engines Manual SPN 66035 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptor Engine Controls and Fuel Marine 9 195 SPN 66035 0 Supercharger Boost Control Solenoid Data Valid but Above Normal SPN 66035 3 Supercharger Boost Control Solenoid Data Valid but Below Normal SPN 66035 5 Supercharger Boost Control Solenoid Current Below Normal or Open Circuit SPN 66035 7 Supercharger Boost
324. for Clearing the SPN SPNs 65586 and 65587 are Type B SPNs 2011 Marine Engines Manual 9 138 Engine Controls and Fuel Marine Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification 1 Ignition ON command the appropriate fuel select output ON and OFF with a scan tool An audible click should be heard when changing between the commanded states 2 Observe the SPN information with a scan tool SPN 65586 3 65586 5 65587 3 or 65587 5 should not set 3 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing Note 1 Ignition OFF disconnect all of the fuel control relays 2 Ignition ON verify a test lamp illuminates between the ignition voltage supply circuit terminal 86
325. formation Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 2011 Marine Engines Manual Circuit System Verification 1 Ignition ON command the MIL ON and OFF with a scan tool The MIL should turn ON and OFF 2 Observe the SPN information with a scan tool SPN 66003 should not set 3 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Ignition ON verify that no other indicators are inoperative If any other indicators are inoperative repair the ignition supply voltage circuit 2 Ignition OFF disconnect the ECM harness connector X1 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 165 3 Ignition ON the MIL should not illuminate If the MIL illuminates repair the MIL control circuit for a short to
326. formation OEM 7283 3392 30 Service 88988338 Description 4 Way F GT 150 Series Sealed BK 2011 Marine Engines Manual Ignition Coil 3 2 4L 1590069 Connector Part Information OEM 7283 3392 30 Service 88988338 Description 4 Way F GT 150 Series Sealed BK Terminal Part Information Terminal Tray 15326267 19 Core Insulation Crimp E 1 Release Tool Test Probe 12094430 J 35616 2A GY Ignition Coil 3 2 4L ETE ET _ Wire Color No Function 1 eon 7 2 twRewexe 4 lgtonVotage Ignition Coil 4 2 4L 1590069 Connector Part Information OEM 7283 3392 30 Service 88988338 Description 4 Way F GT 150 Series Sealed BK 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 47 Terminal Part Information Terminal Tray 15326267 19 Core Insulation Crimp E 1 Release Tool Test Probe 12094430 J 35616 2A GY Ignition Coil 4 2 4L Circuit Wire Color No eons 2 4 Ignition Coil 1 6 0 6 2L 1581641 Connector Part Information OEM 15439568 Service 88987184 Description 4 Way F GT 150 Series Sealed BK Terminal Part Information Terminal Tray 15326267 19 Core Insulation Crimp Pins A D E 1 Core Insulation Crimp Pins B C E 4 Release Tool Test Probe 15315247 J 35616 2A GY Ignition Coil 1 6 0 6 2L Circu
327. ft position CMP sensor in order to determine when an engine misfire is occurring By monitoring variations in the crankshaft rotation speed for each cylinder the ECM is able to detect individual misfire events A misfire rate that is high enough can cause 3 way catalytic converter damage The malfunction indicator lamp MIL will flash ON and OFF when the conditions for catalytic converter damage are present Conditions for Running the SPN SPN 94 105 106 110 630 636 65570 65571 or 65580 is not set The engine is operating for greater than 10 seconds Engine speed is between 1 500 6 000 RPM The ignition voltage is between 8 18 volts The engine coolant temperature ECT is between 108 221 F 42 105 The ECM is not in fuel cut off or fuel cut off DFCO mode The throttle angle is greater than 10 percent and steady within 5 percent The manifold absolute pressure is greater than 35 kPa SPNs 65590 65599 run continuously when the above conditions are met 2011 Marine Engines Manual Misfire Mechanical System Not Responding or Out of Adjustment Misfire Cylinder 1 Mechanical System Not Responding or Out of Adjustment Misfire Cylinder 2 Mechanical System Not Responding or Out of Adjustment Misfire Cylinder 3 Mechanical System Not Responding or Out of Adjustment Misfire Cylinder 4 Mechanical System Not Responding or Out of Adjustment Misfire Cylinder 5 Mechanical System N
328. g Hydrogen I Ham H Hydrocarbons h H GM SPO G GA GAL GAS CW GEN GL GM GND GOV GPH GPM GRN GRY HCMPR HI ALT HO2S H H H H H 20 C ex Hg P PS PV TD TR HZ IAC IAT IC ICM IGN IN INJ Abbreviations and Meanings cont d Abbreviation Meaning _ ISO International Standards Organization ISS Input Speed Shaft Input Shaft Speed K Keep Alive Memory AM i KG Kilogram KHZ KS KV Kw L Pona Pound LB FT Pound Feet Torque V M V M M L4 LB LCD LED LM LR LT LT LT M AF AP AT AX IL IN ML M PH MS MV NC NEG 2011 Marine Engines Manual Abbreviations and Meanings cont d Abbreviation NOx NPTC Catalytic 025 OC ODM OE OEM OHC Q OL OPT ORC ORN OSS OZ PROV PIS PS 2011 Marine Engines Manual PC PCB PCM PCS PFI P N PNK PNP POS POT PPL PPM PPS General Information 1 11 Abbreviations and Meanings cont d Abbreviation Meaning ao ar Random Access Memory Non permanent memory device memory contents are lost when power is removed RH Right Hand Read Only Memory Permanent ROM memory device memory contents are retained when power is removed RT E 5 SAE 5 sca si SLV SOL 502 SP SP SPN SPO SPS Service
329. g with clean engine oil before installing 2211668 Installation Procedure 1 Lubricate the CKP sensor O ring with clean engine oil Note Verify the crankshaft position sensor mounting surfaces are clean and free of burrs before installing the CKP sensor When installing the CKP sensor ensure the sensor is fully seated and held stationary in the engine block before torquing the hold down bolt A sensor which is not seated may cause erratic operation and false codes to set 2 Install the CKP sensor into the engine block Caution Refer to Fastener Caution on page 0 5 3 Install the sensor hold down bolt Tighten Tighten the hold down bolt to 10 N m 88 Ib in Install the CKP sensor harness connector 5 Connect the negative battery cable 2211668 4 2011 Marine Engines Manual Crankshaft Position Sensor Replacement 4 3 5 0 5 7L Removal Procedure Warning Refer to Battery Disconnect Warning on page 0 4 1 Disconnect the negative battery cable 2 Remove the CKP sensor harness connector 3 Remove the sensor hold down bolt Remove the sensor from the timing cover 5 Inspect the sensor O ring for wear cracks or leakage 6 Replace if necessary Lube the new O ring with clean engine oil before installing A Installation Procedure 1 Lube the CKP sensor O ring with clean engine oil Note Verify the crankshaft position CKP sensor mounting surfaces are clean and free
330. g 4 Install the retaining clip onto the fuel injector from the fuel rail assembly 5 Install the fuel rail assembly Refer to Fuel Injection Fuel Rail Assembly Replacement 3 0L Installation Procedure on page 9 230 or Fuel Injection Fuel Rail Assembly Replacement 4 3L 5 0L and 5 7L on inj ri Is f 1 Inspect the fuel injector O ring seals for damage 9 231 or Fuel Injection Fuel Rail Assembly if ane rr dh Replacement 6 0L and 6 2L on page 9 234 2 Lubricate the fuel injector O rings with clean or Fuel Injection Fuel Rail Assembly Replacement engine oil 2 4L on page 9 235 6 Connect the negative battery cable 7 Inspect for fuel leaks using the following procedure 7 1 Ignition ON for 2 seconds 7 2 Ignition OFF for 10 seconds 7 3 Ignition ON 7 4 Inspect for fuel leaks 738607 3 Install the fuel injector to the fuel rail assembly 2011 Marine Engines Manual 9 240 Engine Controls and Fuel Marine Fuel Injector Replacement 2 4L Installation Procedure Removal Procedure Caution Use care in removing the fuel injectors in order to prevent damage to the fuel injector electrical connector pins or the fuel injector nozzles Do not immerse the fuel injector in any type of cleaner The fuel injector is an electrical component and may be damaged by this cleaning method 2 Note If the fuel injectors are found the be leaking the engine oil may be contaminated with fuel
331. ge Engine Coolant Temperature Sensor 1 Voltage Above Normal or Shorted High SPN 110 9 91 Engine Coolant Temperature Sensor i Voltage Below Normal or Shorted Low SPN 110 on page 9 91 Engine Coolant Temperature Sensor 110 15 Data Valid But Above Normal SPN 110 on page 9 91 Range Least Severe Level Engine Coolant Temperature ECT Sensor Circuit Voltage Data Valid But i Tig Above Normal Range Moderate SPN 1100n page 3 91 Severe Level Fuel Temperature Sensor Voltage Above Normal Shorted High Fuel Temperature Sensor Voltage Below Engine Oil Temperature Sensor 175 3 Circuit Voltage Above Normal or SPN 175 on page 9 96 Shorted High Engine Oil Temperature EOT Sensor 175 4 Circuit Voltage Below Normal or SPN 175 on page 9 96 Shorted Low Engine Oil Temperature EOT Sensor 175 15 Circuit Voltage Data Valid But Above SPN 175 on page 9 96 Normal Range Least Severe Level System Voltage Data Valid But Above Normal Range Least Severe Level SPN 627 on page 9 98 2011 Marine Engines Manual MAP Sensor Voltage Above Normal or Shorted High MAP Sensor Voltage Below Normal or 106 Shorted Low 1 1 08 08 08 Vehicle Diagnostic Information 6 13 Diagnostic Trouble Code DTC List cont d FW 060 Diagnostic Procedure Note If multiple powertrain SPNs are stored diagnose the SPNs in the following order 1 Component level SPNs such as sensor SPNs solenoid SPNs and relay SPNs
332. ge 6 5 provides an overview of each diagnostic category SPN Descriptor SPN 66003 FMI 3 SPN 66003 FMI 5 Malfunction Indicator Lamp MIL Driver Voltage Above Normal or Shorted High Malfunction Indicator Lamp MIL Driver Current Below Normal or Open Circuit Diagnostic Fault Information Short to Open High Short to Signal Circuit a Resistance me en Voltage Supply 66003 5 MIL Control 66003 3 The fuse that supplies voltage to the IPC Bulb opens Circuit System Description The malfunction indicator lamp MIL is located on the instrument panel cluster IPC Ignition voltage is supplied to the MIL through a fuse The engine control module ECM turns the MIL ON by grounding the MIL control circuit There should be a steady MIL with the ignition ON and the engine OFF Conditions for Running the SPN SPN 630 or 65580 is not set The ignition is ON or the engine is operating The ignition voltage is greater than 9 volts The MIL has been commanded ON and OFF at least once during the ignition cycle SPN 66003 runs continuously once the above conditions are met Conditions for Setting the SPN The ECM detects that the commanded state of the driver and the actual state of the control circuit do not match for greater than 5 seconds Action Taken When the SPN Sets SPN 66003 is a Type B SPN Conditions for Clearing the SPN SPN 66003 is a Type B SPN Reference In
333. gers Warnings and Cautions 0 3 Definition of Danger Warning Caution lenior 0 3 Actions to Take When Working with Fuel Warning iiec neca 0 3 Batteries Produce Explosive Gases VEM 0 3 Battery Disconnect Warning 0 4 Camshaft Position Actuator Removal and Installation Warning 0 4 Exhaust Service Warning 0 4 Fuel Pipe Fitting Warning 0 4 Fuel Storage Warning 0 4 Fuel System Pressure Warning 0 4 Gasoline Gasoline Vapors Warning 0 4 On Vehicle Fire Extinguisher Warning 0 4 Relieving Fuel Pressure Warning 0 4 Shop Towel Fuel Leak Warning 0 4 Clean Spark Plug Recess Caution 0 5 Component Fastener Tightening 0 5 2011 Marine Engines Manual Cover and Plug Openings Caution Electrical Wiring Routing Caution Excessive Force and Oxygen Sensor Fastener Caution Fuel Injector Balance Test Caution Fuel Pressure Caution Fuel Rail Caution Handling Electrostatic Discharge Sensitive Parts Caution Heat
334. gnal Fuel Level 2 Volts 0 5 Volts received by the control module from the fuel level sensor 2 This parameter displays the pressure of the Fuel Pressure 380 427 kPa 55 62 psi fuel system based on input to the control module from the Fuel Pressure sensor This parameter displays YES if the control aun Sensor YES NO module detects the presence of a fuel pressure sensor 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 57 Engine Control Module Scan Tool Data cont d System State Expected Value This parameter displays the voltage signal d Pressure Sensor 0 5 Volts received by the control module from the fuel This parameter displays the commanded Pump Relay Output YES state of the control module fuel pump relay ee control circuit This parameter displays the commanded Relay state of the control module fuel pump relay control circuit This parameter displays YES when the Fe Output 1 engine is being operated by an alternate fuel source if equipped This parameter displays YES when the fae Select Output 2 engine is being operated by an alternate fuel source if equipped This parameter displays YES if the control module detects the presence of fuel temperature sensor Fuel Temperature Coarse Fine This parameter displays the type of scale the Sensor Resolution fuel temperature is being displayed on This parameter displays th
335. gnosis page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 66025 FMI 4 SPN 66025 FMI 5 Fuel Pump Relay 2 Voltage Below Normal or Shorted Low Fuel Pump Relay 2 Current Below Normal or Open Circuit Diagnostic Fault Information Short to Open High Short to Signal Circuit Ground Resistance Voltage en Battery Voltage Relay Switch m Fuel Pump Supply Voltage Fuel Pump Relay Control sas O Fuel Pump Ground 1 The fuel pump fuse opens and the engine cranks but does not run 2 The engine cranks but does not run 3 The fuel pump operates continuously and the battery will discharge Circuit System Description The engine control module ECM provides ignition voltage to the coil side of the fuel pump relay 2 whenever the engine is cranking or running The control module enables the fuel pump relay as long as the engine is cranking or running and ignition system reference pulses are received If no ignition system reference pulses are received the control module turns OFF the fuel pump The fuel pump relay control circuit is equipped with a feedback circuit that is pulled up to a voltage within the ECM The ECM can determine if the control circuit is open shorted to ground or shorted to a voltage by monitoring the feedback voltage Conditions for Running the SPN SPN 630 or 65580 is
336. ground 4 Ignition ON connect a 3 A fused jumper wire between the MIL control circuit terminal X1 52 and ground The MIL should illuminate If the MIL does not illuminate test the MIL control circuit for a short to voltage or an open high resistance If the circuit test normal replace the IPC Bulb 5 f all of the circuits connections test normal replace the ECM Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 9 166 Engine Controls and Fuel Marine SPN 66004 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptor SPN 66004 FMI 3 Service Vehicle Soon Lamp SVS Voltage Above Normal or Shorted High SPN 66004 FMI 5 Service Vehicle Soon Lamp SVS Current Below Normal or Open Circuit Diagnostic Fault Information Short to Open High Short to Signal Circuit a Resistance me en SVS Voltage Supply 660045 SVS Control a 66004 3 The fuse that supplies voltage to the IPC Bulb opens Circuit System Description The Service Veh
337. h spark plug 2 Disconnect the spark plug wire from the ignition coil Twist each spark plug boot 1 2 turn Pull only on the boot in order to remove the wires from the ignition coil 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 245 Installation Procedure 1 Install the spark plug wires at the ignition coil 2 Install the spark plug wire to each spark plug 3 Inspect the wires for proper installation Push sideways on each boot in order to inspect the seating Reinstall any loose boot Spark Plug Inspection Spark Plug Usage Ensure that the correct spark plug is installed An incorrect spark plug causes driveability conditions Ensure that the spark plug has the correct heat range An incorrect heat range causes the following conditions Spark plug fouling Colder plug Pre ignition causing spark plug and or engine damage Hotter plug Spark Plug Inspection 622530 1 Inspect the terminal post 1 for damage Inspect for a bent or broken terminal post 1 Test for a loose terminal post 1 by twisting and pulling the post The terminal post 1 should NOT move 9 246 Engine Controls and Fuel Marine 622529 2 Inspect the insulator 2 for flashover or carbon tracking soot This is caused by the electrical charge traveling across the insulator 2 between the terminal post 1 and ground Inspect for the following conditions Inspect the
338. haft to detect cylinder misfire and to control the camshaft position actuator if equipped Conditions for Running the SPNs SPNs 630 65580 65620 65621 65622 or 65623 is not set The engine is cranking or operating The SPN 636 runs continuously once the above conditions are met Conditions for Setting the SPN 636 2 The ECM detects an incorrect number of CKP reference pulses for greater than 125 mS 636 8 The ECM does not detect a signal from the CKP sensor for greater than 125 mS Action Taken When the SPN Sets SPN 636 is a Type A SPN The engine will crank but not start Conditions for Clearing the SPN SPN 636 is a Type A SPN Diagnostic Aids The following conditions may also set SPN 636 Physical damage to the CKP sensor or the reluctor wheel Excessive play or looseness of the CKP sensor or the reluctor wheel Improper installation of the CKP sensor or the reluctor wheel Foreign material passing between the CKP sensor and the reluctor wheel Excessive air gap between the CKP sensor and the reluctor wheel An intermittent condition with the CMP sensor or circuits 2011 Marine Engines Manual Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 C
339. han 725 degrees rotate the distributor in a clockwise direction to adjust 3 Repeat step 2 until 705 degrees is obtained 4 Ignition OFF Caution Use the correct fastener in the correct location Replacement fasteners must be the correct part number for that application Do not use paints lubricants or corrosion inhibitors on fasteners or fastener joint surfaces unless specified These coatings affect fastener torque and joint clamping force and may damage the fastener Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems When using fasteners that are threaded directly into plastic use extreme care not to strip the mating plastic part s Use hand tools only and do not use any kind of impact or power tools Fastener should be hand tightened fully seated and not stripped 5 Tighten the distributor hold down bolt Tighten Tighten the bolt to 27 N m 20 lb ft 9 256 Engine Controls and Fuel Marine Crankshaft Position Sensor Replacement 3 0L Removal Procedure Warning Refer to Battery Disconnect Warning on page 0 4 1 Disconnect the negative battery cable 2 Remove the crankshaft position sensor CKP sensor harness connector 3 Remove the CKP sensor hold down bolt 3 4 Remove the CKP sensor 2 from the engine block 5 Inspect the sensor O ring 1 for wear cracks or leakage 6 Replace if necessary Lubricate the new O rin
340. he ECT sensor 3 Remove the ECT sensor Installation Procedure Caution Refer to Component Fastener Tightening Caution on page 0 5 1 If installing the old sensor coat the threads with sealant GM P N 12346004 Canadian P N 10953480 or equivalent Caution Refer to Fastener Caution on page 0 5 2 Install the ECT sensor Tighten Tighten the sensor to 20 N m 15 Ib ft 3 Connect the engine wiring harness electrical connector to the ECT sensor 4 Refill the cooling Manifold Air Temperature Sensor Replacement Removal Procedure 1 Disconnect the negative battery cable 2 Disconnect the manifold air temperature MAT sensor harness connector 2011 Marine Engines Manual 3 Remove the MAT sensor from the air cleaner outlet duct by pulling the sensor upward Installation Procedure 1 Install the MAT sensor in the air cleaner outlet duct 2 Connect the MAT sensor harness connector 3 Connect the negative battery cable 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 219 2004821 2004821 2004809 9 220 Engine Controls and Fuel Marine Manifold Absolute Pressure Sensor Replacement without Supercharger Removal Procedure 1 Disconnect the engine wiring harness electrical connector from the manifold absolute pressure MAP sensor 2 Remove the MAP sensor retainer 3 Remove the MAP sensor 1697060 Installation Procedure Note Lightly coat the MAP sensor s
341. he SPN Sets SPN 65675 and 65676 are Type B SPNs Conditions for Clearing the SPN SPN 65675 and 65676 are Type B SPNs Diagnostic Aids Inspect for the following conditions which may cause a catalytic converter to degrade An engine misfire High engine oil or high coolant consumption Retarded spark timing A weak or poor spark A lean fuel mixture A damaged oxygen sensor or wiring harness 9 152 Engine Controls and Fuel Marine Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Testing 1 Engine operating observe the scan tool SPN information Verify there are no HO2S or misfire SPNs set If any of the SPNs are set refer to Diagnostic Trouble Code DTC List on page 6 11 to diagnosis the applicable SPN before proceeding with this diagnostic procedure 2 Verify the following conditions do not exist with the catalytic converter Dents
342. he assembly The Pedal Position sensors 1 and 2 are potentiometer type sensors each with 3 circuits A 5 volt reference circuit A low reference circuit A signal circuit The pedal position sensors are used to determine the throttle angle The engine control module ECM provides each pedal position sensor a 5 volt reference circuit and a low reference circuit The pedal position sensors provide the ECM with signal voltage proportional to the throttle movement The pedal position sensor 1 signal voltage at rest position is less than 1 volt and increases to above 4 volts as the pedal is actuated The APP sensor 2 signal voltage at rest position is greater than 4 volts and decreases to less than 1 volt as the throttle is actuated Throttle Body Assembly The throttle assembly contains the following components The throttle blade The throttle actuator motor The throttle position TP sensor 1 and 2 The throttle body functions similar to a conventional throttle body with the following exceptions An electric motor opens and closes the throttle valve The throttle blade is spring loaded in both directions and the default position is slightly open There are 2 individual TP sensors within the throttle body assembly The TP sensors are used to determine the throttle plate angle The TP sensors provide the engine control module ECM with a signal voltage proportional to throttle plate movement The TP sensor
343. he fuel pump relay may need to be commanded ON a few times in order to obtain the highest possible fuel pressure DO NOT start the engine 1 Ignition ON command the fuel pump relay ON with a scan tool and observe the fuel pressure gauge while the fuel pump is operating Verify the fuel pressure is between 380 427 kPa 55 62 psi 2011 Marine Engines Manual than 34 kPa 5 psi in 1 minute If greater than the specified range perform the following procedure 2 1 Ignition OFF relieve the fuel pressure Refer to Fuel Pressure Relief on page 9 230 2 2 Install the J 37287 between the fuel feed pipe and the fuel rail 2 3 Open the valve on the J 37287 2 4 Ignition ON command the fuel pump relay ON with a scan tool and bleed the air from the fuel pressure gauge 2 5 Close the valve on the J 37287 2 6 Verify the fuel pressure does not decrease greater than 34 kPa 5 psi in 1 minute If the fuel pressure drops locate and replace the leaking fuel injector 2 7 f the fuel system test normal replace the fuel pump Relieve the fuel pressure to 69 kPa 10 psi Verify the fuel pressure does not decrease greater than 14 kPa 2 psi in 5 minutes If greater than the specified range replace the fuel pump Remove the 37287 and 34730 Refer to Fuel Pressure Gauge Installation and Hemoval on page 9 229 Operate the vehicle within the conditions of the customers concern while monit
344. he ignition cycle SPN 66005 runs continuously once the above conditions are met Conditions for Setting the SPN The ECM detects that the commanded state of the driver and the actual state of the control circuit do not match for greater than 5 seconds Action Taken When the SPN Sets SPN 66005 is a Type C SPN Conditions for Clearing the SPN SPN 66005 is a Type C SPN Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 2011 Marine Engines Manual Circuit System Verification 1 Ignition ON command the GSL ON and OFF with a scan tool The GSL should turn ON and OFF 2 Observe the SPN information with a scan tool SPN 66005 should not set 3 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Ignitio
345. he specified range test the signal circuit for a short to ground or an open high resistance If the circuit tests normal replace the ECM greater than the specified range test the signal circuit for a short to voltage If the circuit tests normal replace the ECM 5 If all circuits test normal replace the VSS Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Vehicle Speed Sensor Replacement Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 2011 Marine Engines Manual Engine Controls Fuel Marine 9 71 SPN 94 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 94 FMI 3 Fuel Pressure Sensor Voltage Above Normal or Shorted High SPN 94 4 Fuel Pressure Sensor Voltage Below Normal or Shorted Low SPN 94 FMI 15 Fuel Pressure Data Valid But Above Normal Range Least Severe Level SPN 94 17 Fuel Pressure Data Valid But Below Normal Range Least Severe Level Diagnostic Fault Information Short to Open High Short to Signal Circuit Ground Resistance Voltage Performance 5 Volt Referenc
346. hen the SPN Sets Type B The control module illuminates the MIL on the second consecutive ignition cycle that the diagnostic runs and fails The control module records the operating conditions at the time the diagnostic fails The first time the diagnostic fails the control module stores this information in the Failure Records If the diagnostic reports a failure on the second consecutive ignition cycle the control module records the operating conditions at the time of the failure The control module writes the operating conditions to the Freeze Frame and updates the Failure Records The following applies to misfire SPNs f the control module detects a low level or an emission level misfire condition during 2 consecutive trips the control module illuminates the MIL f the control module detects a high level or catalyst damaging misfire the control module flashes the MIL at a rate of once per second f the control module detects a misfire during 2 non consecutive trips the stored conditions are compared with the current conditions The control module illuminates the MIL when the following conditions occur The engine load is within a certain percentage of the previous test that failed The engine speed is within a certain percentage of the previous test that failed The engine coolant temperature is in the same range of the previous test that failed 2011 Marine Engines Manual
347. hicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 2 Ignition OFF disconnect the harness connector to the speed based component Ignition ON verify a test lamp illuminates between the ignition voltage supply circuit terminal and ground gt If the test lamp does not illuminate test the ignition circuit for a short to ground or an open high resistance If the circuit tests normal and the ignition circuit fuse is open test all the components connected to the ignition circuit and replace as necessary Connect a test lamp between the control circuit terminal and The test lamp should not illuminate Ifthe test lamp is always ON test the control circuit for a short to ground If the circuit connections test normal replace the ECM 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 177 4 Command the speed based component ON and OFF with a scan tool The test lamp should illuminate and turn OFF as commanded If the test lamp is always OFF test the control circuit for an open high resistance If the circuit connections test normal replace the ECM 5 Test for 3 0 4 0 V between the control circuit terminal and ground If not within the specified range test the control circuit for a short to voltage If the
348. hrottle valve may have been held open For example ice may have formed in the throttle bore causing the throttle valve not to close A high resistance condition on the throttle position and throttle actuator control circuits could cause a DTC to set A low battery condition may cause a DTC to set 9 148 Engine Controls and Fuel Marine Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification 1 Ignition ON observe the SPN information with a scan tool Verify SPN 65601 65602 65604 65605 65610 or 65613 is not set gt If any of the SPNs are set refer to SPN 65601 65602 or 65610 on page 9 141 or SPN 65604 65605 or 65613 on page 9 144 for further diagnosis 2 Clear the with a scan tool Ignition OFF and all vehicle systems OFF Note If there is a condition with the throttle body the ETC or Governor Motor PWM parameter will display
349. iagnostic procedure Engine Control Module Replacement on page 9 217 for engine control module replacement setup and programming 2011 Marine Engines Manual SPN 65701 65702 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors Engine Controls and Fuel Marine 9 155 SPN 65701 FMI 31 General Warning Sensor 1 Not Available SPN 65702 FMI 31 General Warning Sensor 2 Not Available Circuit System Description The general warning sensor changes resistance based on position The engine control module ECM monitors the signal circuit from the general warning sensor The ECM supplies 5 volts to the general warning sensor on the 5 volt reference circuit The ECM also provides a ground on the low reference circuit The general warning sensor provides a signal to the ECM on the signal circuit which is relative to changes in position The component that the general warning sensor monitors may vary between manufacturers Conditions for Running the SPN SPN 630 65580 65620 65621 65622 65623 is not set The ignition is ON or the engine is operating The SPNs 65701 and 65702 run continuously when the above
350. ic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 66019 FMI 3 SPN 66019 FMI 5 SPN 66019 FMI 8 SPN 66020 FMI 3 SPN 66020 FMI 5 SPN 66020 FMI 8 SPN 66021 FMI 3 SPN 66021 FMI 5 SPN 66021 FMI 8 SPN 66022 FMI 3 SPN 66022 FMI 5 SPN 66022 FMI 8 Diagnostic Fault Information Short to Open High Short to Signal Circuit Ground Resistance Voltage Performance HO2S A Sensor 1 Heater Control 66019 5 25 Sensor 1 Ignition Voltage 25 Sensor 1 Heater Control 66020 5 25 Sensor 2 Ignition Voltage 1 HO2S A Sensor 2 Heater Control 66021 5 66021 5 HO2S B Sensor 2 Ignition Voltage HO2S B Sensor 2 Heater Control 66022 5 Oxygen Sensor Bank A Sensor 1 Heater Voltage Above Normal or Shorted High Oxygen Sensor Bank A Sensor 1 Heater Current Below Normal or Open Circuit Oxygen Sensor Bank A Sensor 1 Heater Abnormal Frequency or Pulse Width Oxygen Sensor Bank B Sensor 1 Heater Voltage Above Normal or Shorted High Oxygen Sensor Bank B Sensor 1 Heater Current Below Normal or Open Circuit Oxygen Sensor Bank B Sensor 1 Heater Abnormal Frequency or Pulse Width Oxygen Sensor Bank A Sensor 2 Heater Voltage Above Normal or Shorted High Oxygen Sensor Bank A Sensor 2 Heater Current Below Normal or Open Circuit Oxygen Sensor Bank A Sensor 2 Heater Abnormal Frequency or Pulse Width Oxygen Sensor Bank B Sensor 2 Heater Voltage Above Normal or Shorted High
351. icle Soon SVS Lamp is located on the instrument panel cluster IPC Ignition voltage is supplied to the SVS lamp through a fuse The engine control module ECM turns the SVS lamp ON by grounding the control circuit There should be a steady SVS lamp with the ignition ON and the engine OFF Conditions for Running the SPN SPN 630 or 65580 is not set The ignition is ON or the engine is operating The ignition voltage is greater than 9 volts The SVS lamp has been commanded ON and OFF at least once during the ignition cycle SPN 66004 runs continuously once the above conditions are met Conditions for Setting the SPN The ECM detects that the commanded state of the driver and the actual state of the control circuit do not match for greater than 5 seconds Action Taken When the SPN Sets SPN 66004 is a Type C SPN Conditions for Clearing the SPN SPN 66004 is a Type C SPN Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Co
352. icted Run Crank Relay Diagnosis Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category Diagnostic Fault Information Circuit Ground Resistance Voltage Performance Battery Voltage Relay Switch __ 1 _ _ _2 _ _ Battery Voltage Relay Col __ 1 2 4 _ _ __ oum oo mm __ NE Run Crank Relay Signal 1 Engine Controls and Fuel Marine 9 203 Fuel contamination Refer to Alcohol Contaminants in Fuel Diagnosis on page 9 213 Engine mechanical condition for example worn valve train components or low compression Ifyou find any of the above conditions repair as necessary Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Run Crank Ground 1 The fuse opens and the scan tool does communicate with the ECM 2 The scan tool does communicate with the ECM Circuit System Description The Run Crank Relay is controlled by the ignition switch When the ignition switch in the run or crank position ignition voltage is supplied to the relay coil which allows voltage through the relay switch contacts to the engine
353. ies delivered by the engine based on q engine speed This parameter displays the desired EGR Desired EGR Position 0 position as commanded by the control module This parameter displays the desired engine Desired Idle Speed 500 700 RPM idle speed as commanded by the control module This parameter displays the desired throttle Desired Throttle Position 7 0 11 0 position as commanded by the control module 2011 Marine Engines Manual 9 56 Engine Controls and Fuel Marine Engine Control Module Scan Tool Data cont d System State Expected Value This parameter displays YES if the control YES NO module detects the presence of a low oil pressure switch This parameter displays the position of the fuel select switch as determined by the Dual Fuel Mode Fuel 1 or Fuel 2 operator on vehicles equipped with dual fuel capability ECM Hardware 1 0 Varias This parameter displays the ECM hardware Version version installed in the vehicle ECM Embedded This parameter displays the ECM software Software Release Varies release that is programmed in the control Number module ECM Embedded This parameter displays the ECM software Software Revision Varies revision that is programmed in the control Number module This parameter displays the status of the Emergency Stop Input OFF emergency stop input terminal to the control module This parameter displays the engine Engine Displacement 5 7 6 0L displacement programmed in the control modu
354. ieseling Run On Fuel ignites in the intake manifold or in the exhaust system making a loud popping noise Hard Start Engine cranks OK but does not start for a long time The vehicle does eventually run or may start but immediately stalls Hesitation Sag Stumble Momentary lack of response as the accelerator is pushed down This condition can occur at any vehicle speed This condition is usually more pronounced when first trying to make the vehicle move as from a stop This condition may cause the engine to stall in severe conditions Lack of Power Sluggishness or Sponginess The engine delivers less than expected power Little or no increase in speed when the accelerator pedal is pushed down part way Poor Fuel Economy Fuel economy is noticeably lower than expected Also the fuel economy is noticeably lower than it was on this vehicle at one time Poor Fuel Fill Quality Difficulty when refueling the vehicle Rough Unstable or Incorrect Idle and Stalling engine runs unevenly at idle If severe the engine or the vehicle may shake Engine idle may vary in speed Either condition may be severe enough to stall the engine Surges Chuggles Engine power variation under steady throttle or cruise Feels like the vehicle speeds up and slows down with no change in the accelerator pedal position Symptoms Verification Verify all of the following conditions are true The engine control module ECM and the m
355. il pressure The engine control module ECM monitors the signal circuit from the EOP sensor The ECM supplies 5 volts to the EOP sensor on the 5 volt reference circuit The ECM also provides a ground on the low reference circuit The EOP sensor provides a signal to the ECM on the EOP sensor signal circuit which is relative to the pressure changes in the engine oil pressure When the oil pressure is high the sensor resistance is high and the ECM senses a high voltage When the oil pressure is low the sensor voltage is low and the ECM senses a low signal voltage An EOP fault code may cause an engine speed reduction to occur on vessels with certain engine applications 2011 Marine Engines Manual Conditions for Running the SPN 100 3 and 100 4 SPNs 630 65580 65620 65621 65622 or 65623 is not set The ignition is ON or engine is operating The SPNs run continuously when the above conditions are met for greater than 10 seconds 100 17 SPNs 100 3 100 4 630 65580 65620 or 65621 65622 or 65623 is not set The engine speed is equal to or greater than 500 RPM The SPN runs continuously when the above conditions are met for greater than 10 seconds 9 78 Engine Controls and Fuel Marine Conditions for Setting the SPN 100 3 The ECM detects that the EOP sensor voltage is greater than 4 49 volts for greater than 3 seconds 100 4 The ECM detects that the EOP sensor voltage is le
356. iliar with the normal operation of the information as possible from the customer system and refer to the owner or service manual Are there aftermarket accessories on the vehicle for any information needed When does the condition occur Where does the condition occur How long does the condition last How often does the condition occur 2011 Marine Engines Manual 2 Vehicle Operating as Designed This condition exists when the vehicle is found to operate normally The condition described by the customer may be normal Explain your findings and the operation of the system to the customer 3 Preliminary Checks Conduct a thorough visual inspection Review the service history Detect unusual sounds or odors Gather diagnostic trouble code DTC information in order to achieve an effective repair 4 The Powertrain On Board Diagnostic OBD System Check on page 9 64 verifies the proper operation of the system This will lead the technician in an organized approach to diagnostics 5 Check Bulletins or Recalls 6 Diagnostic categories 6 1 Current DTC Follow the designated DTC diagnostic in order to make an effective repair Refer to DTC List 6 2 Symptom No DTC Select the appropriate symptom diagnostic Follow the diagnostic steps or suggestions in order to complete the repair Refer to Symptoms Engine Controls on page 9 199 6 3 No Published Diagnostics Analyze the Concern Develop a plan for the diagnostics Th
357. infinite resistance between the following terminals 30 and 86 30 and 87 30 and 85 85 and 87 If not within the specified range replace the fuel pump relay 1 4 Install a 20 A fused jumper wire between relay terminal 85 and 12 volts Install a jumper wire between relay terminal 86 and ground Test for less than 2 O between terminals 30 and 87 greater than the specified range replace the relay Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 139 SPN 65590 65591 65592 65593 65594 65595 65596 65597 65598 or 65599 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 65590 FMI 7 SPN 65591 FMI 7 SPN 65592 FMI 7 SPN 65593 FMI 7 SPN 65594 FMI 7 SPN 65595 FMI 7 SPN 65596 FMI 7 SPN 65597 FMI 7 SPN 65598 FMI 7 SPN 65599 FMI 7 Circuit System Description The engine control module ECM uses information from the crankshaft position CKP sensor and the camsha
358. ing The ignition voltage is greater than 9 volts The heater control circuit has been commanded ON and OFF at least once during the ignition cycle The SPNs run continuously when the above conditions are met 66019 66020 66021 66022 FMI 8 SPN 110 630 or 65580 is not set The ignition voltage is greater than 10 volts The engine is operating The ECM is not commanding decel fuel cut off DFCO The calculated airflow is greater than 10 grams second 36 kg hour The SPN runs continuously when the above conditions are met Conditions for Setting the SPN 66019 66020 66021 66022 FMI 3 and 5 The ECM detects that the commanded state of the driver and the actual state of the control circuit do not match for greater than 5 seconds 66019 and 66020 FMI 8 The ECM detects that the heater control duty cycle is greater than 90 percent for greater than 160 seconds 66021 and 66022 FMI 8 The ECM detects that the heater control duty cycle is greater than 0 percent Action Taken When the SPN Sets SPN 66019 66020 66021 and 66022 are Type B SPNs 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 187 Conditions for Clearing the SPN SPN 66019 66020 66021 and 66022 are Type B SPNs Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Contr
359. ion ON verify a test lamp illuminates between the relay coil ignition circuit terminal 86 and ground If the test lamp does not illuminate test the relay coil ignition circuit for a short to ground or an open high resistance 3 Ignition OFF connect a test lamp between the relay coil control circuit terminal 85 and the relay coil ignition circuit terminal 86 If the test lamp is always ON test the relay coil control circuit for a short to ground If the circuit tests normal replace the ECM 4 Ignition ON the test lamp should illuminate If the test lamp is always OFF test the relay coil control circuit for a short to voltage or an open high resistance If the circuit tests normal replace the ECM 5 Connect a 20 A fused jumper wire between the relay switch circuit terminal 30 and the relay switch ignition voltage circuit terminal 87 6 Attempt to start the engine The engine should start lf the engine does not start test the relay Switched ignition voltage circuit between the MEFI relay and the ECM for a short to ground or for an open high resistance If the circuit tests normal replace the ECM 7 f all circuits test normal test or replace the powertrain MEFI relay 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 181 Component Testing 1 Ignition OFF disconnect the powertrain relay with the J 43244 2 Test for 70 110 Q between terminals 85 and 86 If no
360. ions for Running the SPN SPNs 630 65580 65620 65621 65622 or 65623 is not set The ignition is ON or engine is operating The SPNs run continuously when the above conditions are met Conditions for Setting the SPN The ECM detects that the FSI signal is greater or less than 0 25 1 5 volts OR The ECM detects that the FSI signal is greater or less than 3 5 4 5 volts Action Taken When the DTC Sets SPN 65585 2 is a Type B SPN Conditions for Clearing the DTC SPN 65585 2 is a Type B SPN Diagnostic Aids If a shared 5 volt reference circuit is shorted to ground or shorted to a voltage other 5 volt reference circuits may be affected 2011 Marine Engines Manual Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 for scan tool information Circuit System Verification 1 Ignition ON observe the SPN information with a scan tool Verify that SPN 65620 65621 65622 or
361. ions for Setting the SPN 105 3 The ECM detects that the MAT is colder than 38 36 F 105 4 The ECM detects that MAT sensor is warmer than 129 C 264 F 105 15 The ECM detects that the manifold air temperature is within the range of the MAT sensor but warmer than a predicted value Action Taken When the SPN Sets SPN 105 is a Type B SPN Conditions for Clearing the SPN SPN 105 is a Type B SPN Diagnostic Aids If the vehicle has set overnight the MAT sensor and the ECT sensor values should display within 3 C 5 F 9 82 Engine Controls and Fuel Marine Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification 1 Engine running for 1 minute observe the SPN information with a scan tool SPNs 105 3 105 4 or 105 15 should not set 2 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not re
362. ions for catalyst monitoring have been met The is not performing an intrusive catalyst test SPNs 65562 and 65564 run continuously when the above conditions are met Conditions for Setting the SPN 65561 0 65562 0 65563 0 and 65564 0 The engine control module ECM detects that the HO2S voltage is greater than 800 mV during Decel Fuel Cut Off 65561 1 65562 1 65563 1 and 65564 1 The ECM detects that HO2S voltage is less than 302 mV during Power Enrichment 65561 3 65562 3 65563 3 65564 3 The engine control module ECM detects that the HO2S voltage is greater than 1 240 mV 65561 4 65562 4 65563 4 and 65564 4 The engine control module ECM detects that the HO2S voltage is less than 48 mV for greater than 30 seconds 65561 5 65562 5 65563 5 and 65564 5 The ECM detects that the HO2S signal circuit is open for greater than 30 seconds Action Taken when the SPN Sets SPN 65561 65562 65563 and 65564 are Type B SPNs The ECM commands open loop fuel control Conditions for Clearing the SPN SPN 65561 65562 65563 and 65564 are Type B SPNs Diagnostic Aids This ECM uses a bias voltage on the high signal circuit of the HO2S The voltage measured between the high and low signal HO2S terminals is approximately 1 900 mV 9 124 Engine Controls and Fuel Marine Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector En
363. iority 2011 Marine Engines Manual Circuit System Verification is a non intrusive procedure outlining how to verify that a system or a portion of a system is functioning correctly During the verification process the vehicle is kept intact and tested as a complete system This verification is used to assist the technician in determining whether a condition is current or intermittent When a condition is determined to be intermittent a technician can use the link in Electrical Information Reference Testing for Intermittent Conditions and Poor Connections on page 11 13 The technician should be able to identify if the fault is occurring on the input circuit signal or on the output circuit control when applicable The technician will need to decide from the verification results if the system is working correctly or if further diagnosis needs to be performed in either Circuit System Testing and or Component Testing Circuit System Testing The diagnostic format does not force a technician to any of the 3 diagnostic categories Circuit System Verification Circuit System Testing and Component Testing However beginning with the Circuit System Verification category aids in determining if a vehicle condition is current Circuit System Testing is a step by step positive flow testing sequence which allows the technician to perform each test step in sequence until a fault is detected If the result of a test step is achieved
364. ir Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Crankshaft Position Sensor Replacement 3 0L on page 9 256 or Crankshaft Position Sensor Replacement 4 3 5 0 5 7L on page 9 257 or Crankshaft Position Sensor Replacement 6 0 6 2L on page 9 258 or Crankshaft Position Sensor Replacement 2 4L on page 9 261 Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 9 104 Engine Controls and Fuel Marine SPN 651 652 653 654 655 656 657 or 658 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 651 3 Fuel Injector 1 Voltage Above Normal or Shorted High SPN 651 FMI5 Fuel Injector 1 Current Below Normal or Open Circuit SPN 652 FMI 3 Fuel Injector 2 Voltage Above Normal or Shorted High SPN 652 FMI5 Fuel Injector 2 Current Below Normal or Open Circuit SPN 653 FMI 3 Fuel Injector Voltage Above Normal or Shorted High SPN 653 FMI5 Fuel Injector 3 Current Below Normal or Open Circuit SPN 654 FMI 3 Fuel Injector 4 Voltage Above Normal or Shorted High SPN 654 FMI 5 Fuel Injector 4 Current Below Normal or Open Ci
365. ircuit Protection Fuses 8786 The fuse is the most common method of an automotive wiring circuit protection Whenever there is an excessive amount of current flowing through a circuit the fusible element will melt and create an open or incomplete circuit Fuses are an one time protection device and must be replaced each time the circuit is overloaded To determine if a fuse is open remove the suspected fuse and examine the element in the fuse for an open break If not broken also check for continuity using a DMM or a continuity tester If the element is open or continuity is suspect replace the fuse with one of equal current rating Fuse Types Current Rating Amperes Auto Fuses Mini Fuses Gray Violet Ta Brown Blue Yellow White or Natural Green 8e ___ 11 16 Wiring Systems Circuit Protection Circuit Breakers A circuit breaker is a protective device that is designed to open the circuit when a current load is in excess of the rated breaker capacity If there is a short or other type of overload condition in the circuit the excessive current will open the circuit between the circuit breaker terminals Two types of circuit breakers are used Circuit Breaker This type opens when excessive current passes through it for a period of time It closes again after a few seconds and if the cause of the high current is still present it will open again The circuit breaker will continue to cycle open a
366. ircuit can cause an ohmmeter to give a false reading To find out if a component is affecting a measurement take a reading once reverse the leads and take a second reading If the readings differ the solid state component is affecting the measurement Diode Testing A diode is like an electronic switch It can be turned ON if the voltage is above a certain level generally about 0 6 V for a silicon diode and allows current to flow in one direction Some meters have a special mode called diode test In this mode the readings across the diode should be 0 6 V to 0 7 V in one direction and indicate an open circuit in the other This indicates a good diode If both readings are open circuit the diode is open If both readings indicate continuity the diode is shorted 11 10 Wiring Systems Current Measurement With the AMPS DC mode selected the digital multimeter will operate as an ammeter 1683685 An ammeter is an instrument that measures current flow in a circuit For this reason ammeters MUST be connected in series The ammeter must also be connected into the circuit according to polarity Current measurements are different from other measurements made with a digital multimeter Current measurements are made in series unlike voltage or resistance measurements which are made in parallel The entire current being measured flows through the meter Also the tests probes must be plugged into a different set of input jacks
367. ircuit for a short to voltage If the circuit tests normal replace the ECM If all circuits test normal test or replace the shift interrupt switch Component Testing 1 2 Ignition OFF disconnect the harness connector at the shift interrupt switch Measure the resistance between the shift interrupt switch signal circuit terminal 1 and the shift interrupt switch ground circuit terminal 2 The DMM should display OL If less than the specified value replace the shift interrupt switch Test for less than 5 while depressing the shift interrupt switch If greater than the specified range replace the shift interrupt switch Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 2011 Marine Engines Manual SPN 66030 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptor SPN 66030 FMI 3 SPN 66030 FMI 5 Circuit Description The supercharger intercooler relay is a normally open relay The relay switch is held in the open position by spring te
368. ircuit terminal 3 and the 5 volt reference circuit terminal 1 Note The SPN should set when the circuits are connected together with a jumper wire 6 Ignition ON observe the scan tool BARO Pressure parameter Verify the parameter is at 122 6 kPa 36 2 inHg lf less than the specified range test the sensor signal circuit for an open high resistance or a short to ground 7 If all circuits test normal test or replace the BARO sensor Component Testing The ignition ON engine OFF BARO sensor scan tool value should decrease within 4 kPa by the amount of vacuum applied with the J 23738 A For example at 92 kPa the BARO sensor scan tool reading should be between 71 79 kPa with 5 in Hg 17 kPa of vacuum applied to the sensor SPN 108 Ignition ON Engine OFF BARO BARO Sensor Parameter With 5 BARO Sensor Parameter With 10 Sensor Parameter Inches of Vacuum Applied Inches of Vacuum Applied 69 77 52 60 59 67 42 50 49 57 32 40 39 47 22 30 Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Barometric Pressure Sensor Replacement on page 9 221 Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 2011 Marine Engines Manual Engine Controls Fuel Marine 9 91 SPN 110 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9
369. iring Push To Seat And Pull To Seat Connectors The following steps will enable repair of Push to Seat or Pull to Seat type connectors The steps are illustrated with typical connectors A specific connector may differ but the repair steps are similar Some connectors do not require all the steps shown To repair a connector 1 Lift up the connector body retaining tangs 1 and pull mating connector bodies 2 apart or disconnect the connector from the component Note The anti backout combs must be removed prior to terminal removal and must be replaced when the terminal is repaired and re seated 1683755 Legend 1 Connector Body 2 Terminal 3 Locking Tang 4 Insertion Direction Pull to Seat Connectors Pull to Seat connectors refer to the following illustration have the terminal inserted in the front of the connector body when assembled Use the proper pick s or tool s that apply to the appropriate terminal and connector 1683757 2 Remove any anti backout combs that may be fitted to the connector Anti backout combs are designed to keep the terminal from backing out of the connector 1683756 Legend 1 Connector Body 2 Terminal 2011 Marine Engines Manual 11 24 Wiring Systems Note A secondary lock aids in terminal retention and is usually moulded as part of the connector body 1683758 3 If fitted open any connector secondary locks 1 4 Grasp the lead and push the termi
370. isconnect the harness connector at the FT sensor Note A thermometer can be used to test the sensor off the vehicle 2 Test the FT sensor by varying the sensor temperature while monitoring the sensor resistance Compare the readings with the Temperature Versus Resistance on page 9 3 table and verify that the resistance is within 5 percent of the specification gt If not within the specified range replace the FT sensor Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 9 96 Engine Controls and Fuel Marine SPN 175 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 175 FMI 3 Engine Oil Temperature EOT Sensor Circuit Voltage Above Normal or Shorted High SPN 175 FMI 4 Engine Oil Temperature EOT Sensor Circuit Voltage Below Normal or Shorted Low SPN 175 FMI15 Engine Oil Temperature EOT Sensor Circuit Voltage Data Valid But Above Normal Range Least Severe Level Diagnostic Fault Information Short to Open High Short to Signal Circuit Ground Resist
371. it Wire Color No lowReference ___ ____ 9 48 Engine Controls and Fuel Marine Ignition Coil 2 6 0 6 2L 1581641 Connector Part Information OEM 15439568 Service 88987184 Description 4 Way GT 150 Series Sealed Terminal Part Information Terminal Tray 15326267 19 Core Insulation Crimp Pins A D E 1 Core Insulation Crimp Pins B C E 4 Release Tool Test Probe 15315247 J 35616 2A GY Ignition Coil 2 6 0 6 2L Circuit Pm wrecoior Function _ eon 8 towReterence _ o Ignition Coil 3 6 0 6 2L 1581641 Connector Part Information OEM 15439568 Service 88987184 Description 4 Way F GT 150 Series Sealed BK Circuit Wire Color No Loe eI Terminal Part Information Terminal Tray 15326267 19 Core Insulation Crimp Pins A D E 1 Core Insulation Crimp Pins B C E 4 Release Tool Test Probe 15315247 J 35616 2A GY Ignition Coil 3 6 0 6 2L IC 3 Control Ignition Voltage Low Reference 1581641 Connector Part Information OEM 15439568 Service 88987184 Description 4 Way F GT 150 Series Sealed BK Terminal Part Information Terminal Tray 15326267 19 Core Insulation Crimp Pins A D E 1 Core Insulation Crimp Pins B C E 4 Release Tool Test Probe 15315247 J 35616 2A GY Ignition Coil 4 6 0 6
372. ith a scan tool The Slow Mode lamp should turn ON and OFF 2 Observe the SPN information with a scan tool SPN 66010 should not set 3 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Ignition ON verify that no other indicators are inoperative If any other indicators are inoperative repair the ignition supply voltage circuit 2 Ignition OFF disconnect the ECM harness connector 3 Ignition ON the slow mode lamp should not illuminate If the slow mode lamp illuminates repair the slow mode lamp control circuit for a short to ground 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 175 4 Ignition ON connect 3 A fused jumper wire between the slow mode lamp control circuit terminal X3 12 and ground The slow mode lamp should illuminate lf the slow mode lamp does not illuminate test the slow mode lamp control circuit for a short to voltage or an open high resistance If the circuit test normal replace the IPC Bulb 5 f all the circuit connections test normal replace the ECM Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 9
373. itions and Poor Connections on page 11 13 Wiring Repairs page 11 16 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Special Tools J 26792 Spark Tester Circuit System Verification Note Do not perform this diagnostic procedure if you were not sent here from a misfire DTC or the Engine Cranks but Does Not Run diagnostic It may be necessary to perform step 1 on a few of the spark plug wires 1 Ignition OFF connect the J 26792 to the boot of a spark plug wire of a cylinder and ground Note An erratic or weak spark is considered a no spark condition 2 Engine cranking the spark tester should spark Circuit System Testing 1 Ignition OFF inspect the spark plug wires and coil wire for the following Mis routed wires Cracks in the insulation connection at the spark plugs and distributor cap If a condition is found repair as necessary 2 Disconnect the harness connector at the ICM 3 Test for less than 5 O between the ground circuit terminal C and ground If greater than the specified range repair the ground circuit for an open high resistance 4 Ignition ON verify that a test lamp illuminates between the ignition voltage circuit terminal A and ground If the test lamp does not illuminate test the ignition voltage circuit for a short to ground or an open high resistance If the circuit tests normal and the ignition voltage
374. itions test normal test the engine for a mechanical condition Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Fuel Injector Replacement Except 2 4L on page 9 238 or Fuel Injector Replacement 2 4L on page 9 240 2011 Marine Engines Manual SPN 65567 65568 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors Engine Controls and Fuel Marine 9 127 SPN 65567 FMI 8 Oxygen Sensor Bank 1 Sensor 1 Abnormal Frequency or Pulse Width SPN 65567 10 Oxygen Sensor Bank 1 Sensor 1 Abnormal Rate of Change SPN 65568 FMI 8 Oxygen Sensor Bank 2 Sensor 1 Abnormal Frequency or Pulse Width SPN 65568 FMI 10 Oxygen Sensor Bank 2 Sensor 1 Abnormal Rate of Change Typical Scan Tool Data HO2S 1 and 2 ShetteGrund Open _ Short to Voltage Operating Conditions Engine operating in Closed Loop Parameter Normal Range Fluctuates above and below 350 500 mV Sensor Signal 947 mV 1 245 mV Low Reference ooo oo 9m Circuit Description The heated oxygen sensor HO2S is used for fuel control and catalyst monitoring The HO2S compares
375. ive 10 Emission EVAP Canister Purge Solenoid or Fuel Valve Control _ NeUsed 12 Slow Mode Lamp Control Not Used 14 10 Lamp Control 15 Supercharger Boost Solenoid Valve Control 16 HO2S Heater Control Bank B Sensor 2 2011 Marine Engines Manual Engine Control Module cont d Pin Wire Circuit ___ Function 7 Dep p e Signal 19 _ _______ 20 21 lowReference 23 25 ______ 26 27 lowReference 28 5 VoltReferencet 29 MAP Sensor Low Reference 30 ETC Sensor Low Reference 31 EGT Sensor A Low Reference 32 HO2S Heater Control Bank A Sensor 2 33 Cruise Set Decrease Signal a Used 36 5 Volt Reference General Warning 2 37 5 Volt Reference General Warning 1 38 42 Not Used 43 501 Reference 1 Fuel Level Sensor 2 44 Variable Governor Signal Cruise Control ON OFF Signal 47 Cruise Increase Signal Not Used emen NT a i __ a __ General Warning ES Sensor 2 Signal Fuel Tank Pressure Sensor Signal Fuel Level Sensor Signal Primary HO2S Signal High Bank B Sensor 2 HO2S Signal Low Bank B Sensor 2 HO2S Signal High Bank A Sensor 2 HO2S Signal Low Bank
376. k Communications Description and Operation on page 11 5 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 9 74 Engine Controls and Fuel Marine Circuit System Verification 1 2 Ignition OFF verify the engine crankcase is filled to the correct level with engine oil Ignition ON observe the scan tool Low Oil Level Input parameter The parameter should display OFF Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 2 Ignition OFF disconnect the harness connector at the oil level switch Ignition OFF test for less than 5 Q between the ground circuit terminal B and ground If greater than the specified range repair the ground circuit for a short to voltage or an open high resistance 3 Ignition ON install a 3 A fused jumper wire between the signal circuit terminal A and the ground circuit terminal B Observe the scan tool Oil Level parameter The parameter should display OFF If the parameter
377. k on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 636 FMI 2 Crankshaft Position CKP Sensor Circuit Data Erratic Intermittent or Incorrect SPN 636 FMI 8 Crankshaft Position Sensor Signal Abnormal Frequency or Pulse Width Diagnostic Fault Information Short to Open High Short to Signal Circuit Ground Resistance Voltage Performance 5 Volt Reference Circuit 65621 4 636 8 3563 2 Mose Sensor Signal 636 8 636 8 636 8 636 2 owReeeme _____________ J se Circuit System Description The crankshaft position sensor circuits consist of an engine control module ECM supplied 5 V circuit low reference circuit and an output signal circuit The crankshaft position sensor is an internally magnetic biased digital output integrated circuit sensing device The sensor detects magnetic flux changes between the peaks and valleys of a 58 tooth reluctor wheel on the crankshaft Each tooth on the reluctor wheel is spaced at 60 tooth spacing with 2 missing teeth for the reference gap The crankshaft position sensor produces an ON OFF DC voltage of varying frequency with 58 output pulses per crankshaft revolution The frequency of the crankshaft position sensor output dep
378. l SPN 651 652 653 654 655 656 657 or 658 on Open Circuit page 9 104 655 3 Fuel Injector 5 Voltage Above Normal SPN 651 652 653 654 655 656 657 or 658 on Shorted High page 9 104 655 5 Fuel Injector 5 Current Below Normal SPN 651 652 653 654 655 656 657 or 658 on Open Circuit page 9 104 656 3 Fuel Injector 6 Voltage Above Normal SPN 651 652 653 654 655 656 657 or 658 on Shorted High page 9 104 656 5 Fuel Injector 6 Current Below Normal or SPN 651 652 653 654 655 656 657 or 658 on Open Circuit page 9 104 657 3 Fuel Injector 7 Voltage Above Normal SPN 651 652 653 654 655 656 657 or 658 on Shorted High page 9 104 657 5 Fuel Injector 7 Current Below Normal or SPN 651 652 653 654 655 656 657 or 658 on Open Circuit page 9 104 658 3 Fuel Injector 8 Voltage Above Normal SPN 651 652 653 654 655 656 657 658 on Shorted High page 9 104 658 5 Fuel Injector 8 Current Below Normal or SPN 651 652 653 654 655 656 657 or 658 on Open Circuit page 9 104 SPN 1765 High Side Driver on page 9 106 1765 3 Fuel Valve Voltage Above Normal or or Shorted High SPN 1765 Low Side Driver on page 9 108 SPN 1765 High Side Driver on page 9 106 1765 4 Fuel Valve Voltage Below Normal oi Shorted Low SPN 1765 Low Side Driver page 9 108 SPN 1765 High Side Driver on page 9 106 1765 5 Fuel Valve Current Below Normal or BE Open Circuit S
379. l Vehicle Diagnostic Information 6 11 Diagnostic Trouble Code DTC List This master DTC list includes all applicable DTCs in alphanumeric order with descriptors Diagnostic Trouble Code DTC List Fw DiCDesciptr Diagnostic Procedure Note If multiple powertrain SPNs are stored diagnose the SPNs in the following order 1 Component level SPNs such as sensor SPNs solenoid SPNs and relay SPNs 2 System level SPNs such as misfire SPNs and fuel trim SPNs _ o epa van eeaeee Nema Reve Rolna Se ah epe up Rc Oil Level Data Valid But Below Normal Range Least Severe Level SPN 98 on page 9 73 SPN 100 3 0L 4 3L 5 0L 5 7L on page 9 75 or SPN 100 6 0L 6 2L on page 9 77 SPN 100 3 0L 4 3L 5 0L 5 7L on page 9 75 4 Oil Pressure Sensor Voltage Below Normal Shorted Low SPN 100 6 0L 6 2L on page 9 77 Oil Pressure Sensor Voltage Above Normal or Shorted High Oil Pressure Sensor Data Valid But SPN 100 3 0L 4 3L 5 0L 5 7L on page 9 75 Below Normal Range Least or Severe Level SPN 100 6 0L 6 2L on page 9 77 SPN 105 3 0L 4 3L 5 0L 5 7L on page 9 79 or SPN 105 2 4L 6 0L 6 2L on page 9 81 SPN 105 3 0L 4 3L 5 0L 5 7L on page 9 79 or SPN 105 2 4L 6 0L 6 2L on page 9 81 Manifold Air Temperature Sensor Voltage Above Normal or Shorted High Manifold Air Temperature Sensor Voltage Below Normal or Shorted Low ELM 2011 Marine Engines Manual
380. l Marine 9 229 180378 180378 9 230 Engine Controls and Fuel Marine Fuel Pressure Relief Special Tools J 34730 1A Fuel Pressure Gauge Warning Refer to Actions to Take When Working with Fuel Warning on page 0 3 Warning Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury After you relieve the fuel system pressure a small amount of fuel may be released when servicing the fuel lines the fuel injection pump or the connections In order to reduce the risk of personal injury cover the fuel system components with a shop towel before disconnection This will catch any fuel that may leak out Place the towel in an approved container when the disconnection is complete 180378 1 Disconnect the negative battery cable 2 Install the J 34730 1A Refer to Fuel Pressure Gauge Installation and Removal on page 9 229 3 Open the valve on the J 34730 1A in order to bleed the system pressure The fuel connections are now safe for servicing 4 Drain any fuel remaining in the gauge into an approved container 5 Once the system pressure is completely relieved remove the J 34730 Fuel Injection Fuel Rail Assembly Replacement 3 0L Removal Procedure 1 Relieve the fuel system pressure Refer to the Fuel Pressure Relief on page 9 230 2 Before removal clean the fuel rail assembly with a spray type engine cleaner
381. l Part Information Terminal Tray 12191819 8 Core Insulation Crimp E 1 Release Tool Test Probe 15315247 J 35616 2A GY Fuel Injector 7 6 0 6 2L Circuit Wire Color No Function Fuel Injector 8 6 0 6 2L 1278820 Connector Part Information OEM 15355226 Service 89046636 Description 2 Way F Metri Pack 150 Tangless Series Sealed BK Terminal Part Information Terminal Tray 12176636 19 Core Insulation Crimp C 1 Release Tool Test Probe 12094429 J 35616 2A GY 1527729 Fuel Injector 1 12602480 Ignition Voltage Service 88988313 La 3 B B injector 1 Control Description 2 Way F GT 150 Series Sealed GY TAMINA PAN moron Fuel Injector 2 4 3 5 0 5 7L Terminal Tray 12191819 8 Core Insulation Crimp Release Tool Test Probe 15315247 J 35616 2A GY Fuel Injector 8 6 0 6 2L Circuit Wire Color No Function 1273820 Connector Part Information OEM 15355226 Service 89046636 Description 2 Way F Metri Pack 150 Tangless Series Sealed BK 2011 Marine Engines Manual 9 42 Engine Controls and Fuel Marine Fuel Injector 4 4 3 5 0 5 7L Terminal Part Information Terminal Tray 12176636 19 Core Insulation Crimp C 1 Release Tool Test Probe 12094429 J 35616 2A GY Fuel Injector 2 Circuit Wire Color No Function Fuel Injector 3 4 3 5 0 5 7L 1273820 Connector Part Information OEM 15355226
382. l Pressure Sensor Replacement Heated Oxygen Sensor Replacement Throttle Position Sensor Replacement NOM ETO ase Throttle Body Assembly Replacement Fuel Pressure Gauge Installation and REMOVAL Fuel Pressure Relief Fuel Injection Fuel Rail Assembly Replacement 3 01 Fuel Injection Fuel Rail Assembly Replacement 4 3L 5 0L and 5 7L Fuel Injection Fuel Rail Assembly Replacement 6 0L and 6 2L Fuel Injection Fuel Rail Assembly Replacement 2 4L Fuel Pressure Regulator Replacement Fuel Injector Replacement EXGOpU 2 41 esra Fuel Injector Replacement 2 4L Ignition Coil Replacement 3 0L Ignition Coil Replacement 6 02 sand 6 2L e eue Ignition Coil Replacement 4 3L 5 0L and 5 7L 9 243 Ignition Coil Replacement 2 4L 9 244 Spark Plug Wire Inspection 9 245 Spark Plug Wire Replacement 9 245 Spark Plug Inspection 9 245 Spark Plug Replacement 9 247 Distributor Replacement 3 0L 9 248 Distributor Replacement 43 5 02 58 9 251 Camshaft Reta
383. l system components with a shop towel before disconnection This will catch any fuel that may leak out Place the towel in an approved container when the disconnection is complete Shop Towel Fuel Leak Warning Warning Wrap a shop towel around the fuel pressure connection in order to reduce the risk of fire and personal injury The towel will absorb any fuel leakage that occurs during the connection 2011 Marine Engines Manual of the fuel pressure gauge Place the towel approved container when the connection of the fuel pressure gauge is complete Clean Spark Plug Recess Caution Notice Clean the spark plug recess area before removing the spark plug Failure to do so could result in engine damage because of dirt or foreign material entering the cylinder head or by the contamination of the cylinder head threads The contaminated threads may prevent the proper seating of the new plug Use a thread chaser to clean the threads of any contamination Component Fastener Tightening Caution Caution Replacement components must be the correct part number for the application Components requiring the use of the thread locking compound lubricants corrosion inhibitors or sealants are identified in the service procedure Some replacement components may come with these coatings already applied Do not use these coatings on components unless specified These coatings can affect the final torque which may affect the operation
384. lay 2 Remove any fasteners which hold the relay in place 791846 3 Remove any connector position assurance CPA devices or secondary locks Note Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape 4 Separate the relay 1 from the wire harness connector 2 2011 Marine Engines Manual Wiring Systems 11 29 Installation Procedure 791846 1 Connect the relay 1 to the wire harness connector 2 2 Install any connector position assurance CPA devices or secondary locks 3 Install the relay using any fasteners or tape that originally held the relay in place 11 30 Wiring Systems Special Tools and Equipment WMiustration Tool Number Description __ _____ Tool Number Description J 35616 GM Approved Terminal Test Kit J 38125 Terminal Repair Kit J 35616 200 42675 Test Light Probe Kit Flat Wire Probe Adapter J 36169 A J 43244 Fused Jumper Wire lt Relay Puller Pliers 2011 Marine Engines Manual SMP0503 12 Preliminary
385. le This parameter displays the total hours the Cranking Greater than 60 RPM This parameter displays the speed of the Engine Spe d engine crankshaft rotation from information g Engine tating Idling Approximately 600 RPM received from the crankshaft position CKP sensor This parameter displays the avalaolg ae This parameter displays the duty cycle on a uds Valve Varies time of the ETC motor while the engine is idle mode This parameter displays the over all duty ome 8 0 30 0 96 cycle on time of the ETC motor regardless of pedal position This parameter displays whether or not the ETC System Present YES vehicle is equipped with Electronic Throttle Control This parameter displays in liters or gallons Fuel Flow Rate Varies per hour the fuel consumption as calculated by the control module This parameter displays the amount of fuel Fuel Level 0 100 remaining in percent of range as calculated by the control module This parameter displays the amount of fuel Fuel Level 1 Percent 0 100 in the fuel tank 1 in percent of range as calculated by the control module This parameter displays the amount of fuel Fuel Level 2 Percent 0 100 in the fuel tank 2 in percent of range as calculated by the control module This parameter displays the voltage signal Fuel Level 1 Volts 0 5 Volts received by the control module from the fuel level sensor 1 This parameter displays the voltage si
386. lity and fuel economy The engine control module ECM is the control center of this system The ECM performs continuous self diagnosis on numerous engine and vehicle functions The ECM constantly monitors the information from various sensors and other inputs and controls the systems that affect vehicle performance and emissions The ECM also performs the diagnostic tests on various parts of the system The ECM can recognize operational problems and alert the driver via the malfunction indicator lamp MIL or a buzzer When the ECM detects a malfunction the ECM stores a diagnostic trouble code DTC The problem area is identified by the particular DTC that is set The DTCs are identified by two sets of numbers The first set of numbers is called the Suspect Parameter Number SPN This number identifies the system that has a condition The second set of numbers is called the Failure Mode Indicator FMI This number identifies the condition that is occurring at the location An example of this numbering strategy is as follows SPN 66003 FMI 3 SPN 66003 is the Malfunction Indicator Lamp MIL Control Circuit FMI 3 indicates that the circuit is Shorted to a Voltage Refer to Failure Mode Indicator FMI Definitions on page 6 10 for further FMI information On Board Diagnostic System Check After performing the visual physical inspection the Powertrain On Board Diagnostic OBD System Check is the starting point for all diagnostic
387. lowed to time out or be disabled simply opening the driver door should disable RAP before disconnecting power Disconnecting power to the OnStar module in any way while the ignition is On or with RAP activated may cause activation of the OnStar Back Up Battery BUB system and will discharge and permanently damage the back up battery Once the Back Up Battery is activated it will stay on until it has completely discharged The BUB is not rechargeable and once activated the BUB must be replaced Camshaft Position Actuator Removal and Installation Warning Warning Do not push or pull on the reluctor wheel of the camshaft position CMP actuator during removal or installation The reluctor wheel is retained to the front of the CMP actuator by 3 roll pins Pushing or pulling on the wheel may dislodge the wheel from the front of the actuator The actuator return spring is under tension and may rotate the dislodged reluctor wheel causing personal injury Exhaust Service Warning Warning In order to avoid being burned do not service the exhaust system while it is still hot Service the system when it is cool Fuel Pipe Fitting Warning Warning Always apply a few drops of clean engine oil to the male pipe ends before connecting the fuel pipe fittings in order to reduce the risk of fire and personal injury This will ensure proper reconnection and prevent a possible fuel leak During normal operation the O rings located in the fem
388. loy Steel M10 X 1 25 4T Low Carbon Steel 7T High Carbon Steel 7T Alloy Steel M10 X 1 5 4T Low Carbon Steel 7T High Carbon Steel 7T Alloy Steel M12 X 1 25 4T Low Carbon Steel 7T High Carbon Steel 7T Alloy Steel M12 X 1 75 4T Low Carbon Steel 7T High Carbon Steel 7T Alloy Steel Fasteners Application 1245744 Specification 4 1 8 1 36 72 10 in 5 4 9 5 N m 48 84 Ib in 8 1 17 6 72 156 Ib in 12 2 23 0 N m 108 204 Ib in 16 30 N m 12 22 Ib ft 20 34 N m 15 25 Ib ft 0 27 46 N m 20 34 Ib ft 37 62 N m 27 46 Ib ft 19 34 N m 14 25 Ib ft 27 45 N m 20 33 Ib ft 37 60 N m 27 44 Ib ft 49 73 N m 36 54 Ib ft 61 91 45 67 ft 76 114 56 84 Ib ft 45 69 N m 33 51 Ib ft 57 84 N m 42 62 Ib ft 72 107 N m 53 79 Ib ft 2011 Marine Engines Manual General Information 1 7 Fasteners cont d Specification Application Metric 2011 Marine Engines Manual 1 8 General Information Thread Inserts Repair Procedure Tools Required General purpose thread repair kits These kits are available commercially Caution Wear safety glasses in order to avoid eye damage Important Refer to the thread repair kit manufacturer s instructions regarding the size of the drill and tap to use Avoid any buildup of chips Back out the tap every few turns and remove the chips 4962 1 Determine the size the pitch and the depth of the damaged threa
389. ls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Description and Operation Data Link Communications Description and Operation on page 11 5 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification Note If the vehicle is equipped with multiple engines the scan tool can only communicate with one ECM at a time Attempt to establish communication with each ECM The scan tool should display ECM information for each engine Ignition ON attempt to establish communication with the ECM The scan tool should display ECM information 2011 Marine Engines Manual Circuit System Testing 1 Ignition OFF test for less than 2 ohms between the DLC ground circuit terminal B and ground If greater than the specified range repair the ground circuit for an open high resistance 2 Ignition ON verify a test lamp illuminates between the DLC battery voltage circuit terminal A and ground If the test lamp does not illuminate repair the voltage supply circuit for a short to ground or an open high resistance 3 Attempt to start the engine The engine should start
390. ltage eee Battery Voltage Relay Switch Fuel Pump Supply Voltage Fuel Pump Relay 1 Control E Fuel Pump Ground Lom po 1 The fuel pump fuse opens and the engine cranks but does not run 2 The engine cranks but does not run 3 The fuel pump operates continuously and the battery will discharge Circuit System Description The engine control module ECM provides ignition voltage to the coil side of the fuel pump relay whenever the engine is cranking or running The control module enables the fuel pump relay as long as the engine is cranking or running and ignition system reference pulses are received If no ignition system reference pulses are received the control module turns OFF the fuel pump The fuel pump relay control circuit is equipped with a feedback circuit that is pulled up to a voltage within the ECM The ECM can determine if the control circuit is open shorted to ground or shorted to a voltage by monitoring the feedback voltage Conditions for Running the SPN SPN 630 or 65580 is not set The ignition is ON or the engine is operating The ignition voltage is greater than 9 volts The ECM has commanded the fuel pump relay ON and OFF at least once during the ignition cycle SPN 66017 runs continuously once the above conditions are met Conditions for Setting the SPN The ECM detects that the commanded state of the driver and the actual state of the control circuit do n
391. me within a few degrees of the pointer the gear mesh between the distributor and the camshaft may be off one tooth or more Repeat the procedure again in order to achieve proper alignment Caution Refer to Component Fastener Tightening Caution on page 0 5 7 Install the distributor hold down bolt Tighten Tighten the distributor clamp bolt to 27 20 Ib ft 10 11 12 301393 Install the distributor cap Install new distributor cap screws Tighten Tighten the screws to 2 4 N m 21 Ib in Install the harness connector to the distributor Install the spark plug wires to the distributor cap Perform the Cam Retard Offset Procedure Refer to Camshaft Retard Offset Adjustment 3 0L and 4 3L on page 9 255 or Camshaft Retard Offset Adjustment 5 0L and 5 7L on page 9 255 2011 Marine Engines Manual Camshaft Retard Offset Adjustment 3 0L and 4 3L The distributor and ignition timing are not adjustable The distributor will need to be removed in order to reposition the rotor in order to prevent ignition crossfire To verify proper alignment of the distributor perform the following Note The scan tool Cam Angle reading will not be accurate below 1 200 RPM 1 Engine idling at operating temperature Observe the scan tool Cam Angle parameter 2 Increase the engine speed to 1 200 RPM Verify the scan tool Cam Angle parameter is within 700 740 degrees gt If within the specified r
392. meter on page 11 8 for information on connecting the J 39200 to the circuit 2 Set the rotary dial of the J 39200 to the V AC or V DC position 3 Press the range button of the J 39200 in order to select the desired voltage range 4 Press the MIN MAX button of the J 39200 The J 39200 displays 100 ms RECORD and emits an audible tone beep Note The 100 ms RECORD mode is the length of time an input must stay at a new value in order to record the full change 5 Simulate the condition that is potentially causing the intermittent connection either by wiggling the connections or the wiring test driving or performing other operations Refer to Inducing Intermittent Fault Conditions on page 11 14 6 Listen for the audible Min Max Alert which indicates that a new minimum or maximum value has been recorded 7 Press the MIN MAX button once in order to display the MAX value and note the value 8 Press the MIN MAX button again in order to display the MIN value and note the value 9 Determine the difference between the MIN and MAX values If the variation between the recorded MIN and MAX voltage values is 1 V or greater an intermittent open or high resistance condition exists Repair the condition as necessary If the variation between the recorded MIN and MAX voltage values is less than 1 V an intermittent open or high resistance condition does not exist 2011 Marine Engines Manual Wiring Systems 11 15 C
393. minal Tray 33467 0003 23 Core Insulation Crimp H H Release Tool Test Probe J 381 25 21 3 J 35616 64B L BU Pins 3 5 11 18 20 25 27 29 31 33 39 43 45 47 53 56 Terminal Tray 33467 0005 23 Core Insulation Crimp Pins 3 5 11 18 20 25 27 29 31 33 39 43 45 47 56 J J Core Insulation Crimp Pins 53 K K Release Tool Test Probe J 381 25 21 3 J 35616 64B L BU Engine Control Module ECM X1 Pin Wire Circuit Function High Speed CAN Serial Data Bus 2 Pedal Position Sensor 2 Signal Sensor Signa Slave Engine Select 8wemoMede toad Anticipate Vehicle Speed Sensor Signal Engine Control Module ECM X1 cont d Pin Wie Circuit Function 8 swmesoma Supercharger Inlet Pressure Sensor Signal 10 Pedal Position Sensor 1 Signal 11 Sensor Signal Variable Governor Signal Variable Governor Low Reference 14 Fuel Pump Relay Control Secondary 15 High Speed CAN Serial Data Bus 2 _ Not Available 18 Mode 1 Voltage 20 Battery Positive Voltage 21 Vehicle Speed Sensor 5 Volt Reference 22 25 5 Volt Reference 2 27 High Side Driver Fuel Pump Relay Control Primary High Speed ii Serial Data Bus Emergency Stop Signa 34 Shift Interrupt Switch
394. mponents with a shop towel before disconnection This will catch any fuel that may leak out Place the towel in an approved container when the disconnection is complete 180378 1 Disconnect the negative battery cable 2 Install the J 34730 1A Refer to Fuel Pressure Gauge Installation and Removal on page 9 229 3 Open the valve on the J 34730 1A in order to bleed the system pressure The fuel connections are now safe for servicing 4 Drain any fuel remaining in the gauge into an approved container 5 Once the system pressure is completely relieved remove the J 34730 Fuel Injector Replacement Except 2 4L Removal Procedure 1 Relieve the fuel system pressure Refer to Fuel Pressure Relief on page 9 230 2 Disconnect the negative battery cable Note Mask off the intake ports Accidental entry of foreign objects can cause severe engine damage 3 Remove the fuel rail assembly Refer to Fuel Injection Fuel Rail Assembly Replacement 3 0L on page 9 230 or Fuel Injection Fuel Rail Assembly Replacement 4 3L 5 0L and 5 7L on page 9 231 or Fuel Injection Fuel Rail Assembly Replacement 6 0L and 6 2L on page 9 234 or Fuel Injection Fuel Rail Assembly Replacement 2 4L on page 9 235 77 738617 4 Remove the retaining clip from the fuel injector 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 239 Z 738607 738617 5 Remove the fuel injector and the injector O rin
395. municate Circuit System Description The controller area network CAN HI and CAN LO circuits transmit information between the engine control module ECM and the scan tool Some vehicles are equipped with multiple engines that require a control module for each engine Information is transmitted between each ECM via the CAN communication circuits The data link connector DLC is a 6 cavity connector The connector provides the following Scan tool power battery positive voltage at terminal A Scan tool power ground at terminal Controller area network CAN HI communication circuit at terminal C CAN LO communication circuit at terminal 0 Diagnostic Aids The scan tool will power up with the ignition OFF The ECM will not communicate unless the ignition is ON It may be necessary to disconnect each module connected to the CAN communication circuits in order to isolate the condition On vehicles equipped with multiple engine controllers the scan tool can only communicate with one ECM at a time Attempt to establish communication with each ECM Communication with only one ECM can be caused by the following An open CAN communication circuit between the splice and the ECM An ECM that is not powered up Test the B ignition feed and ground circuits for an open or short to ground C KNEES EEUU NE Signal Performance Reference Information Schematic Reference Engine Contro
396. n on page 11 5 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs page 11 16 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Special Tools CH 48027 Digital Fuel Pressure Gauge e J 34730 1A Fuel Pressure Gauge e J 39021 Fuel Injector Coil and Balance Tester 44602 Injector Test Adapter 9 212 Engine Controls and Fuel Marine Component Testing Fuel Injector Coil Test Verify the resistance of each fuel injector with one of the following methods If the engine coolant temperature ECT sensor is between 10 32 50 90 F the resistance of each fuel injector should be 11 14 Q If the injectors test OK perform the Fuel Injector Balance Test Fuel Pressure Test gt If not within the specified range replace the fuel injector f the ECT sensor is not between 10 32 50 90 F measure and record the resistance of each fuel injector with a DMM Subtract the lowest resistance value from the highest resistance value The difference between the lowest value and the highest value should be equal to or less than 3 O Ifthe difference is equal to or less than 3 refer to Fuel Injector Balance Test Fuel Pressure Test for further diagnosis of the fuel injectors Ifthe difference is greater than 3 a
397. n order to change the angle of the camshaft relative to crankshaft position CKP Incorrect engine oil pressure EOP viscosity temperature engine oil level or aftermarket engine oil additives can have an adverse affect on camshaft phaser performance CMP Actuator Solenoid Circuit Diagnostics The engine control module ECM monitors the control circuit of the camshaft position CMP actuator solenoid for electrical faults The control module has the ability to determine if a control circuit is open shorted high or shorted low CMP Actuator System Performance Diagnostic The engine control module ECM monitors the performance of the camshaft position CMP actuator system by monitoring the calibrated desired position and the actual position of the camshaft through the 4X signal of the CMP sensor 9 282 Engine Controls and Fuel Marine Supercharger Description and Operation Supercharger Description The marine supercharger is a positive displacement pump that consists of 2 counter rotating rotors an inlet port and an outlet port and an air bypass valve that is built into a housing The rotors are designed with 3 lobes and a helical twist An air bypass valve is built into the housing The rotors in the supercharger are designed to run at a minimal clearance not in contact with each other or the housing and are timed to each other by a pair of precision spur gears which are pressed onto the rotor shafts The front end
398. n page 6 22 after completing the diagnostic procedure Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 9 198 Engine Controls and Fuel Marine SPN 66040 66043 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptor SPN 66040 FMI 3 SPN 66040 5 SPN 66041 FMI 3 SPN 66041 FMI 5 SPN 66042 FMI 3 SPN 66042 FMI 5 SPN 66043 FMI 3 SPN 66043 FMI 5 Circuit System Description Ignition voltage is supplied to the OEM device through a fuse The engine control module ECM turns the OEM device ON by grounding the OEM output control circuit Conditions for Running the SPN SPN 630 65580 not set The ignition is ON or the engine is operating The ignition voltage is greater than 9 volts The ECM has commanded the OEM output ON and OFF at least once during the ignition cycle The SPNs 66040 66043 run continuously once the above conditions are met Conditions for Setting the SPN The ECM detects that the commanded state of the driver and the actual state of the control circuit do not match for greater than 5 seconds Action Taken When the SPN Sets SP
399. n with a scan tool Verify SPN 100 3 100 4 or 100 17 is not set 3 Engine idling observe the scan tool EOP Sensor parameter The reading should be between 41 414 kPa 6 60 psi 4 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Ignition OFF disconnect the harness connector at the EOP sensor 2 Ignition OFF test for less than 5 between the low reference circuit terminal 3 and ground If greater than the specified range test the low reference circuit for an open high resistance If the circuit tests normal replace the ECM 3 Ignition ON test for 4 8 5 2 V between the 5 volt reference circuit terminal 2 and ground If less than the specified range test the 5 volt reference circuit for a short to ground or open high resistance If the circuit tests normal replace the ECM greater than the specified range test the 5 volt reference circuit for a short to voltage If the circuit tests normal replace the ECM 4 Verify the scan tool Oil Pressure Sensor Voltage parameter is less than 0 10 V If greater than the specified range test the signal circuit for a short to voltage If the circuit tests normal replace the ECM 5 Connect a 3 A fused jumper wire between the signal circuit terminal 1 and the 5 vol
400. n ON verify that no other indicators are inoperative If any other indicators are inoperative repair the ignition supply voltage circuit 2 Ignition OFF disconnect the ECM harness connector X1 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 169 3 Ignition ON the GSL should not illuminate gt If the GSL illuminates repair the GSL control circuit for a short to ground 4 Ignition ON connect a 3 A fused jumper wire between the GSL control circuit terminal X1 56 and ground The GSL should illuminate If the GSL does not illuminate test the GSL control circuit for a short to voltage or an open high resistance If the circuit test normal replace the IPC Bulb 5 f all the circuit connections test normal replace the ECM Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 9 170 Engine Controls and Fuel Marine SPN 66007 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptor SPN 66007 FMI 3 SPN 66007 FMI 5 Buzzer Driver Short
401. n a new section of wire The two stripped sections of wire to be joined should be of equal length 1683718 Gripper Jaws Gripper Casting Stripped Wire 4 Cutter Casting Insulation Guide Blades 2011 Marine Engines Manual Wiring Systems 11 19 Step 5 Crimping the Joint 1 Select the correct sized clip 2 Unlock the crimping tool 3 Slightly close the clip using the nose of the crimping tool as shown in the following illustration 1683723 6 Centre the splice clip 2 under the stripped wires and hold in place as shown Ensure that the wires extend beyond the clip in each direction 1683721 Ensure no insulation is caught under the clip Legend Strands of wire are not cut or loose 1 Nose 7 Fully open the crimping tool and rest one handle 2 Former on a firm flat surface 3 Small Anvil 4 Lock 5 Former 6 Large Anvil 7 Clip 4 Select the correct crimper anvil 5 Overlap the two stripped wire ends 1 and hold them between the thumb and forefinger as shown in the following illustration 1683724 8 Centre the back of the splice clip on the proper anvil 2 and close the crimping tool to the point where the former touches the wings of the clip 1 9 Verify the clip and wires are still in the correct position before closing the crimping tool with steady pressure 2011 Marine Engines Manual 11 20 Wiring Systems Ensure there are none of the faul
402. n high resistance If the circuit tests normal replace the ECM 3 Ignition ON Engine OFF verify that a test lamp does not illuminate between the control circuit terminal A and ground If the test lamp illuminates test the control circuit for a short to voltage If the circuit tests normal replace the ECM 4 Test for B between the control circuit terminal A and ground with a DMM If less than the specified range test the control circuit for a short to ground or for an open high resistance 5 Connect the DMM black lead to the control circuit terminal A Connect the DMM red lead to Set the DMM on the diode setting 6 Engine operating 2 000 2 500 RPM pulse the CMP actuator solenoid ON with a scan tool The DMM should transition from OL when commanded OFF to less than 1 V when commanded ON If the circuit voltage does not correspond to the specified values replace the ECM 10 Ignition OFF remove the Camshaft Position Actuator Solenoid Valve Verify the following conditions do not exist with the Camshaft Position Actuator Solenoid Valve Torn restricted mis positioned or missing screens at the CMP actuator solenoid Engine oil leak between the oil sealing lands of the CMP actuator solenoid Inspect the lands of the CMP actuator solenoid for nicks Oil seepage at the CMP actuator solenoid connector If a condition is found replace Camshaft Position Actuator Solenoid Valve Igni
403. n in the relationship between a camshaft and the crankshaft 65570 4 and 65570 5 The ECM detects that the commanded state of the driver and the actual state of the control circuit do not match for greater than 5 seconds 65570 7 The ECM detects the difference between the desired camshaft position angle and the actual camshaft position angle 9 130 Engine Controls and Fuel Marine Action Taken When the SPN Sets SPN 65570 is a SPN Cam phaser not enabled Conditions for Clearing the SPN SPN 65570 is a Type B SPN Diagnostic Aids The engine oil condition has a major impact on the camshaft actuator system A low oil level condition may set this SPN The engine may require an oil change Inquire with the customer when the last oil change was performed Inspect the engine for any recent engine mechanical repairs An incorrectly installed camshaft camshaft actuator or timing chain may cause SPN 65570 2 or 65570 7 to set Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number S
404. n is not fuel resistant so XLPE covered wire must not be used where there is the possibility of fuel contact General purpose insulation PVC is used in areas not subject to high temperatures Cross linked polyethylene XLPE insulation wire is used where high temperatures are expected Step 4 Strip the Insulation Find the wire size using a wire gauge AWG A wire stripper labelled in AWG sizes is needed for stripping away the insulation If the wire size is not known start with the largest stripper hole and work down until a clean strip of insulation is removed without nicking or cutting the wire Set the stripper guide to a 7 5 mm long strip AWG The splice should be at least 40 mm away from any other splices or outlets 1683716 Metric 022 0 35 05 08 10 20 30 50 80 130 190 320 500 3 35 4 1 5 1 5 gt 1 Use the following procedure when using a wire stripper Hold both handles in the right hand with gripper jaws to the left Hold the wire in the left hand and press the end of the wire against the guide and up into the correct notch of the upper blade Close left handle first to grip the wire firmly before cutting the insulation If the stripper castings stick open after stripping the wire pull the handles outward to snap the tool closed Check the stripped wire for nicks or cut strands If the wire is damaged repeat the procedure o
405. n with scan tool SPN 174 3 or 174 4 should not set 2 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Ignition OFF disconnect the harness connector at the FT sensor 2 Test for less than 5 between the low reference circuit terminal A and ground gt If greater than the specified range test the low reference circuit for an open high resistance If the circuit tests normal replace the ECM 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 95 3 Ignition ON verify the scan tool FT sensor voltage parameter is greater than 4 5 V If less than the specified range test the signal circuit for a short to ground If the circuit tests normal replace the ECM Note If the fuse in the jumper wire opens the signal circuit is shorted to a voltage and the sensor may be damaged 4 Install a 3 A fused jumper wire between the signal circuit terminal B and the low reference circuit terminal A Verify the FT sensor voltage parameter is less than 0 5 V gt If greater than the specified range test the signal circuit for a short to voltage or an open high resistance If the circuit tests normal replace the ECM 5 If all circuits test normal test or replace the FT sensor Component Testing 1 Ignition OFF d
406. nal MAP MAT sensor 3 Ignition OFF connect the vacuum hose to the resistance If the circuit tests normal replace MAP MAT sensor or install the MAP MAT the ECM sensor to the intake manifold Disconnect the harness connector at the MAP sensor 8 If all circuits test normal test or replace the 4 Ignition OFF test for less than 5 Q between the Sensor low reference circuit terminal 1 and ground gt If greater than the specified range test the low reference circuit for an open high resistance If the circuit tests normal replace the ECM 5 Ignition ON test for 4 8 5 2 V between the 5 volt reference circuit terminal 3 and ground If less than the specified range test the 5 volt reference circuit for a short to ground or open high resistance If the circuit tests normal replace the ECM If greater than the specified range test the 5 volt reference circuit for a short to voltage If the circuit tests normal replace the ECM SPN 106 3 0L 4 3L 5 0L 5 7L Sensor parameter of vacuum applied 10 inches of vacuum applied circuit for a short to ground or an open high Component Testing The ignition ON engine OFF MAP sensor scan tool value should decrease within 4 kPa by the amount of vacuum applied with the J 23738 A For example at 92 kPa the MAP sensor scan tool reading should be between 71 79 kPa with 5 in Hg 17 kPa of vacuum applied to the sensor Repair Instructions Perform the
407. nal 1 to the forward most position in the connector body 2 Hold the lead at this position 5 Locate the terminal lock tang 3 in the connector canal 6 Insert the proper size pick 4 refer to Terminal Repair Kit J 38125 A straight into the connector canal at the mating end of the connector 7 Depress the locking tang to unseat the terminal 8 For push to seat connectors gently pull on the leas to remove the terminal through the back of the connector Note Never use force to remove a terminal from a connector 9 For pull to seat connectors gently push on the lead to remove the terminal through the front of the connector 10 Inspect terminal and connector for damage 11 Repair or replace parts as necessary Refer to Parts Information for availability of terminal pigtail or connector body assemblies that are serviced separately 12 Reform lock tang 1 using a wide pick 2 and re seat terminal in connector body 1683760 13 Reinstall any anti backout combs and join the connector bodies Connector Position Assurance Locks The Connector Position Assurance CPA is a small plastic insert that fits through the locking tabs of electrical harness connectors The CPA ensures that the connector halves cannot vibrate apart You must have the in place in order to ensure good contact between the mating terminals Terminal Position Assurance Locks The terminal position assurance TPA insert resembles th
408. nd closed until the condition causing the high current is removed Positive Temperature Coefficient PTC Circuit Breaker This type greatly increases its resistance when excessive current passes through it The excessive current heats the PTC device as the device heats its resistance increases Eventually the resistance gets so high that the circuit is effectively open Unlike the ordinary circuit breaker the PTC unit will not reset until the circuit is opened by removing the voltage from its terminals Once the voltage is removed the circuit breaker will re close within a second or 2 Circuit Protection Fusible Links Fusible link is wire designed to melt and break continuity when excessive current is applied It is often located between or near the battery and starter or electrical center Use a continuity tester or a DMM at each end of the wire containing the fusible link in order to determine if it is broken If broken it must be replaced with fusible link of the same gauge size Repairing a Fusible Link Note Fusible links cut longer than 225 mm approximately 9 in will not provide sufficient overload protection Refer to Splicing Copper Wire Using Splice Clips in Wiring Repairs on page 11 16 Wiring Repairs Circuit Protection Note After you make any electrical repair always test the circuit by operating the devices in the circuit This confirms not only that the repair is correct but also that the cause of the
409. ne should operate at a reduced RPM Circuit System Testing 1 Ignition OFF disconnect the slow mode switch harness connector 2 Test for less than 5 between the slow mode switch ground circuit and ground gt If greater than the specified range repair the slow mode switch ground circuit for an open high resistance 3 Ignition ON test for greater than 4 V between the slow mode switch signal circuit and ground gt If less than the specified range test the slow mode switch signal circuit for a short to ground or an open high resistance If the circuit tests normal replace the ECM 4 f all circuits test normal replace the slow mode switch Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Engine Control Module Programming and Setup on page 6 3 for ECM replacement setup and programming 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 217 Repair Instructions Engine Control Module Replacement Removal Procedure Note Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module in order to prevent internal control module damage Control module damage may result when the metal case contacts battery voltage DO NOT contact the control module metal case with battery voltage when servicing a control module using battery booste
410. nect the CKP sensor electrical connector 56592 4 Install the starter 211621 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 261 Crankshaft Position Sensor Installation Procedure Replacement 2 4L Removal Procedure 1578475 1 Lubricate the CKP sensor O ring seal with clean engine oil 2 Install the CKP sensor 1 Remove the starter motor assembly Caution Refer to Fastener Caution on page 0 5 2 Disconnect the crankshaft position CKP sensor 3 Install the CKP sensor bolt electrical connector 4 Tighten Tighten the sensor bolt to 10 N m 89 lb in 1622787 1578475 3 Remove the CKP sensor bolt 1622787 4 Remove the CKP sensor 4 Connect the CKP sensor electrical connector 4 5 Install the starter motor assembly 2011 Marine Engines Manual 9 262 Engine Controls and Fuel Marine Camshaft Position Sensor Replacement 4 3 5 0 5 7L Removal Procedure 1 Disconnect the spark plug wires and ignition coil wire from the distributor Refer to Spark Plug Wire Replacement on page 9 245 302854 2 Disconnect the camshaft position CMP sensor harness connector from the distributor 302829 3 Remove the distributor cap screws 157984 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 263 4 Remove the distributor cap 157986 5 Remove the rotor screws 4354 6 Remove the rotor 156748 2011 Marine Engines Ma
411. nected wiggling the wires may uncover a faulty input to the control module The snapshot option would be appropriate here You may need to load the vehicle in order to duplicate the concern This may require the use of weights floorjacks jackstands frame machines etc In these cases you are attempting to duplicate the concern by manipulating the suspension or frame This method is useful in finding harnesses that are too short and their connectors pull apart enough to cause a poor connection A DMM set to Peak Min Max mode and connected to the suspect circuit while testing can yield desirable results Refer to Testing for Electrical Intermittents on page 11 15 Certainly using the senses of sight smell and hearing while manipulating the circuit can provide good results as well There may be instances where circuit manipulation alone will not meet the required criteria for the fault condition to appear In such cases it may be necessary to expose the suspect circuit to other conditions while manipulating the harness Such conditions would include high moisture conditions along with exceptionally high or low temperatures The following discusses how to expose the circuit to these kinds of conditions Salt Water Spray Some compounds possess the ability to conduct electricity when dissolved in water such as ordinary salt By mixing table salt with water in sufficient quantities you can enhance the conductive properties of water
412. nections on page 11 13 Wiring Repairs 11 16 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification Ignition ON connect a scan tool to the diagnostic connector The scan tool should power up Circuit System Testing 1 Test for less than 2 ohms between the DLC ground circuit terminal B and ground If greater than the specified range repair the ground circuit for an open high resistance 2 Ignition ON verify a test lamp illuminates between the DLC battery voltage circuit terminal A and ground gt If the test lamp does not illuminate repair the voltage supply circuit for a short to ground or an open high resistance 3 If all circuits test normal refer to the scan tool user guide Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the repair 11 4 Data Communications Scan Tool Does Not Communicate with CAN Device Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category Diagnostic Fault Information Short to Open High Short to Circuit Ground Resistance Voltage CAN HI Circuit CAN LO Circuit 1 Scan Tool Does Com
413. nectors at the ignition coil module 6 Install the negative battery terminal 9 242 Engine Controls and Fuel Marine Ignition Coil Replacement 6 0L and 6 2L Removal Procedure 1707122 1 Remove the intake manifold sight shield if equipped 2 Disconnect the ignition coil wiring harness electrical connector 1 from the ignition coil 1707124 3 Remove the spark plug wire from the ignition coil Twist the spark plug wire boot a 1 2 turn Pull only on the boot in order to remove the wire from the ignition coil 4 Remove the ignition coil bolts 5 Remove the ignition coil from the bracket left side shown right side similar 6 There are 2 different manufacturers for the ignition coils and coil brackets They are as follows 260177 The Melco 1 ignition coil is a square design 8 The Delphi 2 ignition coil is a round design 10 design 260077 The Melco ignition coil bracket 1 is a square The Delphi ignition coil bracket 2 is a round design 2011 Marine Engines Manual Installation Procedure 1707124 1 Position the ignition coil to the ignition coil bracket left side shown right side similar Caution Refer to Fastener Caution on page 0 5 2 Install the ignition coil bolts Tighten Tighten the bolts to 10 N m 89 lb in 3 Install the spark plug wire to the ignition coil 4 Inspect the spark plug wire for proper installation Push
414. ng as calculated by the control module using information from the two TP sensors This parameter displays the actual voltage on 0 95 1 25 Volts the TP sensor 1 signal circuit as measured by the control module i This parameter displays the actual voltage on Hus p 3 75 4 25 Volts the TP sensor 2 signal circuit as measured 9 by the control module Throttle Position 7 11 96 Throttle Position Sensor 1 Voltage This parameter displays the total amount of Total Fuel Used Varies Gal Ltr fuel consumed over the life of the engine Varies This parameter displays the total number of hours that the engine has been operating Total Hours 2011 Marine Engines Manual 9 62 Engine Controls and Fuel Marine Engine Control Module Scan Tool Data cont d System State Expected Value This parameter displays the total number of Total Operating Time Varies crankshaft revolutions since the very first engine start up This parameter displays if the control module This parameter displays if the control module This parameter displays if troll mode This parameter displays the state of the troll Variable Governor Input 0 5 Volts This parameter displays signal voltage of an Voltage OEM installed speed or RPM control system This parameter displays the vehicle speed Vehicle Speed Fo 0 mph kph signal to the control module This parameter indicates the number of warm up cycles that have occurred without a fault Warm Up Cycles Since
415. ng the SPNs The engine coolant temperature ECT sensor is a 110 3 and 110 4 variable resistor that measures the temperature of the engine coolant The engine control module ECM SPN 630 65580 65620 65621 65622 or 65623 supplies 5 volts to the ECT signal circuit and supplies is not set a ground to the low reference circuit The ignition is ON or the engine is operating The following table illustrates the difference between temperature resistance and voltage SPN 110 3 and 110 4 run continuously when the above conditions are met Per ECT Signal 110 15 and 110 16 ECT ECT Hasistalies Voltage Before the ECM can report that 110 15 110 16 failed SPNs 110 3 and 110 4 must run and pass SPN 630 65580 65620 65621 65622 or 65623 is not set The engine is operating for greater than 10 seconds SPN 110 15 runs continuously when the above conditions are met 2011 Marine Engines Manual 9 92 Engine Controls and Fuel Marine Conditions for Setting the SPNs 110 3 The ECM detects that the ECT is warmer than 302 F 150 C for greater than 1 second 110 4 The ECM detects that the is colder than 23 31 C for greater than 1 second 110 15 The ECM detects the ECT is warmer than 220 F 104 C for greater than 1 second 110 16 The ECM detects the ECT is warmer than 239 F 11590 for greater than 1 second Action Taken When the SPN Sets SPN 11 3 and 110 4 are Typ
416. ng the engine speed parameter A sudden increase in the engine speed parameter with little change in actual engine speed indicates that EMI is present Inspect the high voltage components near the ignition control circuit if a condition exists Inspect the positive crankcase ventilation PCV System and all connections for leaks or restrictions The engine cooling system for the following conditions The thermostat is the correct heat range Proper engine coolant level The supercharger intercooler pump operation Refer to Supercharger Intercooler Relay Diagnosis on page 9 204 The supercharger boost control system for proper operation Refer to Boost Control System Diagnosis on page 9 205 2 f the above conditions do not address the symptom refer to the additional symptoms tests Additional Symptoms Tests Detonation Spark Knock Test the engine for an overheating condition Lack of Power Hesitation or Cut Out Test for the correct operation of the ignition system Refer to Distributor Ignition DI System Diagnosis on page 9 214 or Electronic Ignition System Diagnosis on page 9 215 Rough Unstable or Incorrect Idle and Stalling Inspect the engine mounts Surges Chuggles Test the heated oxygen sensors HO2S The HO2S should respond quickly to a change in throttle position If the HO2S do not respond to different throttle positions inspect for contamination from fuel silicon or the incorrect use of
417. nient circuit breaker Solder a lead to each terminal of the turn signal flasher and each lead with a terminal from an old fuse If this unit is inserted in the junction block in place of a fuse it may operate too fast to produce good compass needle deflection To slow it down insert a rheostat in series with the flasher By cutting in additional resistance the flashing rate of the unit may be slowed down to produce good compass needle deflection Testing for a Short to Voltage Caution Refer to Test Probe Caution on page 0 6 The following procedure tests for a short to voltage in a circuit 1 Set rotary dial of the DMM to the V DC position 2 Connect the positive lead of the DMM to one end of the circuit to be tested 3 Connect the negative lead of the DMM to a good ground 4 Turn ON the ignition and operate all accessories 5 f the voltage measured is greater than 1 V there is a short to voltage in the circuit Testing for Intermittent Conditions and Poor Connections Intermittent and Poor Connections Most intermittents are caused by faulty electrical connections or wiring Occasionally a sticking relay or solenoid can also cause an intermittent failure 2011 Marine Engines Manual Wiring Systems 11 13 Some items to check are Poor mating of connector halves or terminals not fully seated in the connector body backed out Dirt or corrosion on the terminals The terminals must be clean
418. nning the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 2 Ignition OFF disconnect the harness connector at the general warning sensor Ignition OFF test for less than 5 Q between the low reference circuit terminal and ground If greater than the specified range test the low reference circuit for an open high resistance If the circuit tests normal replace the ECM Ignition ON test for 4 8 5 2 V between the 5 volt reference circuit terminal and ground If less than the specified range test the 5 volt reference circuit for a short to ground or open high resistance If the circuit tests normal replace the ECM gt If greater than the specified range test the 5 volt reference circuit for a short to voltage If the circuit tests normal replace the ECM 4 Test for less than 0 5 V between the signal circuit terminal and ground gt If greater than the specified range test the signal circuit for a short to voltage If the circuit tests normal replace the ECM 5 Install a 3 A fused jumper wire between the signal circuit terminal and the 5 volt reference circuit terminal Verify the scan tool general warning sensor voltage parameter is greater than 4 8 V If less than the specified range test the signal circuit for a short to ground or an open high resistance If the cir
419. nock Sensor KS Bank 1 Data Valid but Below Normal SPN 65550 65551 or 65552 on page 9 115 Knock Sensor KS Bank 1 Voltage Above Normal or Shorted High SPN 65550 65551 or 65552 on page 9 115 Knock Sensor KS Bank 1 Voltage Below Normal or Shorted Low SPN 65550 65551 or 65552 on page 9 115 Knock Sensor KS Bank 1 Current Below Normal or Open Circuit SPN 65550 65551 or 65552 on page 9 115 Knock Sensor KS Bank 2 Data Valid but Below Normal SPN 65550 65551 or 65552 on page 9 115 2011 Marine Engines Manual Vehicle Diagnostic Information 6 15 Diagnostic Trouble Code DTC List cont d ______ Diagnostic Procedure Note If multiple powertrain SPNs are stored diagnose the SPNs in the following order 1 Component level SPNs such as sensor SPNs solenoid SPNs and relay SPNs 2 System level SPNs such as misfire SPNs and fuel trim SPNs Knock Sensor KS Bank 2 Voltage _ 65552 Above Normal or Shorted High SPN 65550 65551 or 65552 on page 9 115 Knock Sensor KS Bank 2 Voltage 65552 Below Notmalior Shorted Low SPN 65550 65551 or 65552 on page 9 115 Knock Sensor KS Bank 2 Current 65552 Below Normal or Open Circuit SPN 65550 65551 or 65552 on page 9 115 65555 1 Change Oil Now Data Valid but Below SPN 65555 on page 9 117 Normal Change Oil Soon Data Valid but Above 29039 Normal Range Least Severe Level SPN 65555 on page 9 117 65558 11 CAN 2 Bus Hardware Fault Root
420. nor control sensor Ignition OFF test for less than 5 Q between the low reference circuit terminal C and ground If greater than the specified range test the low reference circuit for an open high resistance If the circuit tests normal replace the ECM Ignition ON test for 4 8 5 2 V between the 5 volt reference circuit terminal A and ground If less than the specified range test the 5 volt reference circuit for a short to ground or open high resistance If the circuit tests normal replace the ECM gt If greater than the specified range test the 5 volt reference circuit for a short to voltage If the circuit tests normal replace the ECM 4 Verify the scan tool variable governor control sensor voltage parameter is less than 0 5 V greater than the specified range test the signal circuit terminal B for a short to voltage If the circuit tests normal replace the ECM 5 Install a 3 A fused jumper wire between the signal circuit terminal B and the 5 volt reference circuit terminal A Verify the scan tool variable governor control sensor voltage parameter is greater than 4 8 V If less than the specified range test the signal circuit for a short to ground or an open high resistance If the circuit tests normal replace the ECM 6 If all circuits test normal replace the variable governor control sensor Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the d
421. nostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors Engine Controls and Fuel Marine 9 149 SPN 65620 FMI 4 5 Volt Reference A Circuit Voltage Below Normal or Shorted Low SPN 65621 FMI 4 5 Volt Reference B Circuit Voltage Below Normal or Shorted Low SPN 65622 FMI 4 5 Volt Reference C Circuit Voltage Below Normal or Shorted Low SPN 65523 FMI 4 5 Volt Reference D Circuit Voltage Below Normal or Shorted Low Circuit System Description The engine control module ECM uses two internal 5 volt reference circuits Each internal reference circuit provides a bussed 5 volts via the external circuits that supply several sensors on each 5 V buss A short to ground or short to voltage on one of the external 5 V reference circuits may affect the other components connected to the same internal 5 V reference buss The ECM monitors the 5 volt reference circuits for conditions that pull the 5 V buss above or below a predetermined voltage Conditions for Running the SPN e SPNs 630 or 65580 are not set The ignition is ON or the engine is running 5 65620 65621 65622 and 65623 run continuously when the above condition is met Conditions for Setting the SPN The control module detects less than 4 5 volts on a 5 volt reference circuit for greater than 5 mS Action Taken When the SPN Sets SPN 65620 65621 65622 and 65623 are Type A SPNs The ECM commands the TAC
422. not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Verify none of the following conditions exist 65565 0 or 65566 0 Splits kinks or improper connections at the vacuum hoses Vacuum leaks at the intake manifold throttle body and injector O rings Leaking crankcase ventilation system Fuel contamination Refer to Alcohol Contaminants in Fuel Diagnosis on page 9 213 The fuel system is operating lean Refer to Fuel System Diagnosis with Returnless Fuel System on page 9 208 or Fuel System Diagnosis without Returnless Fuel System on page 9 210 The fuel injectors are operating lean Refer to Fuel Injector Diagnosis on page 9 211 Contaminants in Fuel Diagnosis on page 9 213 The fuel system is operating rich Refer to Fuel System Diagnosis with Returnless Fuel System page 9 208 or Fuel System Diagnosis without Returnless Fuel System on page 9 210 The fuel injectors are operating rich Refer to Fuel Injector Diagnosis on page 9 21 1 The air intake duct for being collapsed or restricted or a restricted air filter Leaking fuel pressure regulator Inspect for evidence of fuel in the vacuum line Refer to Fuel System Diagnosis with Returnless Fuel System on page 9 208 or Fuel System Diagnosis without Returnless Fuel System on page 9 210 Excessive fuel in the crankcase 2 If all cond
423. nsion Ignition voltage is supplied directly to the relay coil Battery voltage is supplied to the switch side of the relay The engine control module ECM provides ground to the control circuit of the relay with a low side driver When the ECM commands the relay ON the relay contacts will close allowing current to flow from the battery to the supercharger intercooler pump The fuel pump relay control circuit is equipped with a feedback circuit that is pulled up to 2 5 volts within the ECM The ECM can determine if the control circuit is open shorted to ground or shorted to a voltage by monitoring the feedback voltage Conditions for Running the SPN SPN 630 or 65580 is not set The ignition is ON or the engine is operating The ignition voltage is greater than 9 volts The ECM has commanded the intercooler relay ON and OFF at least once during the ignition cycle SPN 66030 run continuously when the above condition is met Conditions for Setting the SPN The ECM detects that the commanded state of the driver and the actual state of the control circuit do not match for greater than 5 seconds Action Taken When the SPN Sets SPN 66030 is a Type B SPN Conditions for Clearing the MIL SPN SPN 66030 is a Type B SPN Diagnostic Aids A resistance on the intercooler pump control circuit or the relay coil ignition voltage circuit may cause this SPN to set When disconnecting electrical connectors or removing fuses and rel
424. nsor 4 Ignition ON test for 4 8 5 2 V between the 5 volt reference circuit terminal 1 and ground Component Testing The ignition ON engine OFF SCIP sensor scan tool If less than the specified range test the 5 volt value should decrease within 4 kPa by the amount reference circuit for a short to ground or an of vacuum applied with the J 23738 A For example at open high resistance If the circuit tests normal 92 kPa the SCIP sensor scan tool reading should be replace the ECM between 71 79 kPa with 5 in Hg 17 kPa of vacuum applied to the sensor SPN 3563 Ignition ON Engine OFF SCIP SCIP Sensor Parameter With 5 SCIP Sensor Parameter With 10 Sensor Parameter Inches of Vacuum Applied Inches of Vacuum Applied ______ 6977 52 60 59 87 42 50 19 57 32 40 20 47 22 30 Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Supercharger Air Inlet Pressure Sensor Replacement on page 9 222 Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 113 SPN 65541 65542 65543 65544 65545 65546 65547 or 65548 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of
425. nsor or the reluctor wheel A distributor that is installed improperly Improper installation of the CMP sensor or the reluctor wheel Foreign material passing between the CMP sensor and the reluctor wheel Excessive air gap between the CMP sensor and the reluctor wheel Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification Note If you were sent here from Engine Cranks but Does Not Run proceed to Circuit System Testing 1 Attempt to start the engine observe the SPN information with a scan tool SPN 65723 2 65723 8 65724 2 or 65724 8 should not set 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 161 2 Engine speed greater 1 000 RPM observe the SPN information with a scan tool SPN 65723 7 or 65724 7 should not set 3 Move related harnesses connectors of the CMP sensor and verify the engine does not stumble stall or change
426. nsor Bank B Sensor 1 Data SPN 65561 65562 65563 or 65564 on Valid But Above Normal page 9 122 65563 1 Oxygen Sensor Bank B Sensor 1 Data SPN 65561 65562 65563 or 65564 on Valid But Below Normal page 9 122 65563 3 Oxygen Sensor Bank B Sensor 1 SPN 65561 65562 65563 or 65564 on Voltage Above Normal or Shorted High page 9 122 65563 4 Oxygen Sensor Bank Sensor 1 SPN 65561 65562 65563 or 65564 on Voltage Below Normal or Shorted page 9 122 65563 5 Oxygen Sensor Bank B Sensor 1 SPN 65561 65562 65563 or 65564 on Current Below Normal or Open Circuit page 9 122 65564 Oxygen Sensor Bank B Sensor 2 Data SPN 65561 65562 65563 or 65564 on Valid But Above Normal page 9 122 65564 1 Oxygen Sensor Bank B Sensor 2 Data SPN 65561 65562 65563 or 65564 on Valid But Below Normal page 9 122 65564 3 Oxygen Sensor Bank B Sensor 2 SPN 65561 65562 65563 or 65564 on Voltage Above Normal or Shorted High page 9 122 2011 Marine Engines Manual 6 16 Vehicle Diagnostic Information Diagnostic Trouble Code DTC List cont d DTC Descriptor Diagnostic Procedure Note If multiple powertrain SPNs are stored diagnose the SPNs in the following order 1 Component level SPNs such as sensor SPNs solenoid SPNs and relay SPNs 2 System level SPNs such as misfire SPNs and fuel trim SPNs Oxygen Sensor Bank B Sensor 2 SPN 65561 65562 65563 or 65564 on Voltage Below Normal or Shorted Low page 9 122 Oxygen S
427. ntamination Contamination will result in a white or green build up within the connector body or between terminals causing high terminal resistance intermittent contact or an open circuit An underhood or connector that shows signs of contamination should be replaced in its entirety terminals seals and connector 3 Using an equivalent male terminal from the J 38125 A Terminal Repair Kit check the retention force is significantly different between the two female terminals replace the female terminal in question refer to the J 38125 A Terminal Repair Kit If visual physical check does not reveal the cause of the problem you may have the vehicle with a DMM connected to the suspected circuit An abnormal voltage reading when the problem occurs indicates the problem may be in that circuit Inducing Intermittent Fault Conditions In order to duplicate the customer s concern it may be necessary to manipulate the wiring harness if the malfunction appears to be vibration related Manipulation of a circuit can consist of a wide variety of actions including Wiggling the harness Disconnecting a connector and reconnecting Stressing the mechanical connection of a connector Pulling on the harness or wire in order to identify a separation break inside the insulation Relocating a harness or wires All these actions should be performed with some goal in mind For instance with a scan tool con
428. nternal condition Reference Information Schematic Reference Engine Controls Schematics on page 9 6 2011 Marine Engines Manual Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs page 11 16 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Special Tools Required J 43244 Relay Puller Pliers 9 208 Engine Controls and Fuel Marine Circuit System Verification 1 Cycle the ignition ON you should hear and feel a click from the fuel pump relay when you turn the ignition ON 2 Ignition ON command the fuel pump relay ON and OFF with a scan tool You should hear and feel a click when you command the fuel pump relay ON and OFF Circuit System Testing 1 Ignition OFF the fuel pump should not be running If the fuel pump runs continuously test the relay switch supply circuit terminal 87 for a short to voltage If the circuit tests normal replace the fuel pump relay 2 Ignition OFF remove the fuel pump relay with the J 43244 3 Test for less than 5 Q between the relay coil ground circuit terminal 86 and ground If greater than the specified range repair the relay coil ground circuit for an
429. ntrol Module Scan Tool Information on page 9 54 2011 Marine Engines Manual Circuit System Verification 1 Ignition ON command the SVS lamp ON and OFF with a scan tool The SVS lamp should turn ON and OFF Observe the SPN information with a scan tool SPN 66004 should not set Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 2 Ignition ON verify that no other indicators are inoperative If any other indicators are inoperative repair the ignition supply voltage circuit Ignition OFF disconnect the ECM harness connector X3 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 167 3 Ignition ON the SVS lamp should not illuminate If the SVS illuminates test the SVS control circuit for a short to ground 4 Ignition ON connect a 3 A fused jumper wire between the SVS lamp control circuit terminal 8 and ground The SVS should illuminate If the SVS lamp does not illuminate test the SVS control circuit for a short to voltage or an open high resistance If the circuit test normal replace the IPC Bulb 5 If all the circuit connections test normal replace the ECM Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic proc
430. nual 9 264 Engine Controls and Fuel Marine 7 Align the square slot in the reluctor wheel with the CMP sensor 156754 8 Remove the CMP screws 4341 9 Remove the CMP sensor 301398 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 265 Installation Procedure Note Do not use the old cap CMP sensor and rotor screws Use the replacement screws that have been coated with a thread locking compound 1 Insert the CMP sensor through the reluctor wheel slot Caution Use the correct fastener in the correct location Replacement fasteners must be the correct part number for that application Do not use paints lubricants or corrosion inhibitors on fasteners or fastener joint surfaces unless specified These coatings affect fastener torque and joint clamping force and may damage the fastener Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems When using fasteners that are threaded directly into plastic use extreme care not to strip the mating plastic part s Use hand tools only and do not use any kind of impact or power tools Fastener should be hand tightened fully seated and not stripped 2 Install new CMP mounting screws Tighten Tighten the bolts to 2 2 N m 19 Ib in 3 Install the rotor onto the reluctor wheel 2011 Marine Engines Manual 301398 4341 156748 9 266 Engine Contr
431. ny of the following conditions Insufficient fuel can cause a no start condition Thoroughly inspect the fuel delivery system for sufficient fuel volume to the fuel injectors Inspect the fuel supply components for partial blockage or restrictions Fuel injectors with partially blocked and restricted nozzles or a malfunctioning solenoid can cause a no start condition Refer to Fuel Injector Diagnosis on page 9 211 There may be fuel spray at the fuel injectors and the indicated fuel pressure may be correct yet there may not be enough fuel to start the engine If the fuel injectors and the injector circuit are OK and fuel spray is detected the fuel injector ON time may be inadequate If the engine control module ECM receives incorrect inputs from the various information sensors the fuel delivered by the fuel injectors may be inadequate to start the engine Check all the engine data parameters with a scan tool and compare the values indicated with the expected values Check the crankshaft position CKP sensor engine reference signal with a scan tool Observe the Engine Speed parameter while cranking the engine The scan tool should indicate a steady 200 300 RPM while cranking If erratic values such as sudden spikes in the engine speed are displayed the engine reference signal is not stable enough for the engine to start and run properly Inspect the engine for good secure electrical grounds If the engine almost start
432. o monitor the short term and long term fuel trim values The long term fuel trim diagnostic is based on an average of several of the long term speed load learn cells The ECM selects the cells based on the engine speed and engine load If the ECM detects an excessive lean or rich condition the ECM will set a fuel trim diagnostic trouble code DTC Electronic Ignition System Description Electronic Ignition El System Operation The electronic ignition El system produces and controls the high energy secondary spark This spark ignites the compressed air fuel mixture at precisely the correct time providing optimal performance fuel economy and control of exhaust emissions The engine control module ECM primarily collects information from the crankshaft position CKP and camshaft position CMP sensors to control the sequence dwell and timing of the spark 2011 Marine Engines Manual Crankshaft Position Sensor The crankshaft position CKP sensor is an internally magnetic biased digital output integrated circuit sensing device The sensor detects magnetic flux changes of the teeth and slots of the reluctor wheel on the crankshaft The CKP sensor produces an ON OFF DC voltage of varying frequency The CKP sensor sends a digital signal to the ECM as each tooth on the reluctor wheel rotates past the CKP sensor The ECM uses each CKP signal pulse to determine crankshaft speed and position This information is then use
433. o much or too often Inspect for foreign material accumulation in the throttle bore and for carbon deposits on the throttle plate and shaft Also inspect for throttle body tampering Poor Fuel Fill Quality Test for the following conditions that are applicable to the current symptom Difficult to fill Restricted fill lines Restricted vent lines High fuel temperature A condition with the internal components of the fuel tank assembly Fuel Odor A leak in the fuel supply or return lines Refer to Fuel System Diagnosis with Returnless Fuel System on page 9 208 or Fuel System Diagnosis without Returnless Fuel System on page 9 210 condition with the internal components of the fuel tank assembly 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 201 Engine Cranks But Does Not Run Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category Circuit System Description This Engine Cranks but Does Not Run diagnostic is an organized approach to identify a condition which causes the engine to crank but not start This diagnostic directs the technician to the appropriate system diagnosis Diagnostic Aids Inspect for a
434. ody assembly and are not serviceable at wide open throttle WOT TP sensor 2 signal The TP sensors provide a signal voltage that changes voltage decreases from approximately 3 5 volts relative to throttle blade angle The engine control at idle to below 1 volt at WOT module ECM supplies the TP sensors with a common 5 volt reference circuit a common low reference circuit and 2 independent signal circuits 2011 Marine Engines Manual 9 142 Engine Controls and Fuel Marine Conditions for Running the SPN SPN 630 65580 65620 65621 65622 or 65623 is not set The ignition is ON or the engine is running SPNs 65601 65602 and 65610 run continuously when the conditions above are met Conditions for Setting the SPN 65601 2 The ECM detects that the TP sensor 2 voltage is less than 0 25 V or greater than 4 75 V for greater than 247 mS 65602 2 The ECM detects that the TP sensor 1 voltage is less than 0 25 V or greater than 4 75 V for greater than 247 mS 65610 2 The ECM detects that the actual TP sensor 1 and TP sensor 2 values disagree by greater than 5 for greater than 247 mS Action Taken When the SPN Sets SPN 65601 65602 and 65610 type A SPNs e The ECM will operate the engine in reduced power mode indicator may display Reduced Engine Power Conditions for Clearing the SPN SPN 65601 65602 and 65610 are type A SPNs Diagnostic Aids If a shared 5 volt reference
435. of the component Use the correct torque specification when installing components in order to avoid damage Cover and Plug Openings Caution Caution Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages Electrical Wiring Routing Caution Caution Note the correct routing of the electrical wiring Failure to reinstall the wiring properly could result in damage to the wiring Excessive Force and Oxygen Sensor Caution Caution The oxygen sensor may be difficult to remove when the engine temperature is below 48 C 120 F Excessive force may damage threads in the exhaust manifold or the exhaust pipe Fastener Caution Caution Use the correct fastener in the correct location Replacement fasteners must be the correct part number for that application Do not use paints lubricants or corrosion inhibitors on fasteners or fastener joint surfaces unless specified These coatings affect fastener torque and joint clamping force and may damage the fastener Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems When using fasteners that are threaded 2011 Marine Engines Manual Dangers Warnings and Cautions 0 5 directly into plastic use extreme care not to strip the mating plastic part s Use hand tools only and do not use any kind of impact or power
436. of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provide an overview of each diagnostic category 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 213 Test Description Water contamination in the fuel system may cause driveability conditions such as hesitation stalling no start or misfires in one or more cylinders Water may collect near a single fuel injector at the lowest point in the fuel injection system and cause a misfire in that cylinder If the fuel system is contaminated with water inspect the fuel system components for rust or deterioration Alcohol concentrations of 10 percent or greater in fuel can be detrimental to fuel system components Alcohol contamination may cause fuel system corrosion deterioration of rubber components and subsequent fuel filter restriction Some types of alcohol are more detrimental to fuel system components than others Ethanol is commonly used in gasoline but in concentrations of no more than 10 percent Some fuels such as E85 contain a very high percentage of ethanol Fuel with more than 10 percent ethanol may cause driveability conditions such as hesitation lack of power stalling or no start System Verification The fuel sample should be drawn from the bottom of the tank so that any water present in the tank will be detected The sample should be bright and clear System Testing 1 Using a 100 ml 3 38 oz specified cylinder with
437. oil Install the new O ring seals on the spray tip end of each injector Marine Engines Manual 1625417 Relieve the fuel system pressure Refer to Fuel Pressure Relief on page 9 230 Disconnect the fuel feed line quick connect fitting from the fuel rail 9 236 Engine Controls and Fuel Marine 1623764 1578472 3 Disconnect the fuel injector harness electrical 6 Remove the fuel rail studs connector 2 Note Use when removing the fuel rail assembly sensor electrical connector electrical connector terminals and spray tips 7 Pull the fuel rail back and upward in order to release the fuel injectors from the cylinder head ports 8 Remove the fuel rail 9 Remove the fuel injectors if necessary Refer to Fuel Injector Replacement Except 2 4L on page 9 238 or Fuel Injector Replacement 2 4L on page 9 240 1623549 5 Remove the fuel injector harness electrical connector clips 4 and 5 from the intake manifold 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 237 Installation Procedure 6 Connect the MAP sensor electrical connector Note Install new lower O rings when reusing fuel injectors Lubricate the injector tip O rings prior to installing the injectors into the intake manifold 1623549 7 Install the fuel injector harness electrical connector clips 4 and 5 to the intake manifold 1578472 1 Install the fuel injectors if necessary Refer to Fuel
438. olenoid by grounding the control circuit with a solid state device called a driver The driver is equipped with a feedback circuit that is pulled up to voltage The ECM can determine if the control circuit is open shorted to ground or shorted to a voltage by monitoring the feedback voltage Conditions for Running the SPN SPN 630 or 65580 is not set The ignition is ON or the engine is operating The ignition voltage is between 10 16 volts The component has been commanded ON and OFF during the ignition cycle SPN 66012 runs continuously once the above conditions are met Conditions for Setting the SPN The ECM detects that the commanded state of the driver and the actual state of the control circuit do not match for greater than 5 seconds Action Taken When the SPN Sets SPN 66012 is a Type C SPN Conditions for Clearing the SPN SPN 66012 is a Type C SPN Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine
439. ols Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification 1 Engine idling at normal operating temperature observe the SPN information with a scan tool SPN 66019 66020 66021 or 66022 should not set 2 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data 9 188 Engine Controls and Fuel Marine Circuit System Testing 1 2 Ignition OFF disconnect the harness connector at the appropriate HO2S Ignition ON verify that a test lamp illuminates between the ignition voltage circuit terminal D and ground If the test lamp does not illuminate test the ignition voltage circuit for a short to ground open high resistance If the circuit tests normal and the ignition voltage circuit fuse is open test all components connected to the ignition voltage circuit and replace as necessary Ignition ON connect a test lamp between the heater control circuit terminal C and B Verify
440. ols and Fuel Marine 4 Install new rotor screws Tighten Tighten the screws to 1 9 17 Ib in 4354 5 Install the distributor cap 157986 6 Install new distributor cap screws Tighten Tighten the screws to 2 4 N m 21 6 in 157984 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 267 7 Connect the CMP sensor harness connector 302829 8 Connect the spark plug wires and ignition coil wire Refer to Spark Plug Wire Replacement on page 9 245 302854 2011 Marine Engines Manual 9 268 Engine Controls and Fuel Marine Camshaft Position Sensor Replacement with CMP Actuator 2491396 Camshaft Position Sensor Replacement with CMP Actuator Callout Component Name Camshaft Position Sensor Fastener Qty 3 Caution Refer to Fastener Caution on page 0 5 1 Tighten 12 106 Ib in Camshaft Position Sensor 2 Procedure Disconnect the electrical connectors 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 269 Camshaft Position Sensor Replacement without CMP Actuator SX 2491402 Camshaft Position Sensor Replacement without CMP Actuator Component Name Camshaft Position Sensor Fastener Qty 2 Caution Refer to Fastener Caution on page 0 5 1 Tighten 12 106 Ib in Camshaft Position Sensor 2 Procedure Disconnect the electrical connectors 2011 Marine Engines Manual 9 270 Engine Controls an
441. on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 9 66 Engine Controls and Fuel Marine Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification 1 Ignition ON observe the SPN information with a scan tool SPN 38 or 96 should not be set 2 Observe the scan tool Fuel Level 1 or 2 Percent parameter The parameter should be between 4 percent and 98 percent 3 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Ignition OFF disconnect the harness connector at the appropriate fuel level sensor 2 Ignition OFF test for less than 5 Q between the low reference circuit terminal and ground If greater than the specified range test the low reference circuit for a short to voltage or an open high resistance If the circuit tests normal replace the ECM 3 Ignition ON verify that the appropriate scan tool Fuel Level Volts parameter is greater than 4 97 V lf less than the specified range test the signal circuit for a short to ground If the circuit tests normal replace the ECM Note If the fuse in the jumper wire opens the signal circuit is shorted to a voltage and the fuel level sensor may be damaged 4 Install a 3
442. on switch is turned ON with the engine OFF The BARO reading may also be updated whenever the throttle position TP sensor is greater than 28 percent 9 84 Engine Controls and Fuel Marine Conditions for Running the SPN 106 0 Before the ECM can report that SPN 106 0 or 106 1 failed SPNs 100 3 100 4 65604 65605 65610 65613 65615 65616 and 65618 must run and pass SPN 105 110 630 65580 65621 or 65622 is not set The engine speed is greater than 800 RPM The throttle angle is less than 30 percent The ECM is not commanding reduced power or fuel cut off The SPN runs continuously once the above conditions are met 106 1 Before the ECM can report that SPN 106 0 or 106 1 failed SPNs 100 3 100 4 65604 65605 65610 65613 65615 65616 and 65618 must run and pass SPN 105 110 630 65580 65621 or 65622 is not set The engine speed is less than 150 RPM OR The throttle angle is greater than 75 percent The ECM is not commanding reduced power or fuel cut off The SPN runs continuously once the above conditions are met 106 3 and 106 4 SPN 105 110 630 65580 65621 or 65622 is not set The ignition is ON The SPN runs continuously when the above conditions are met Conditions for Setting the SPN 106 0 The ECM detects that the MAP sensor signal is greater than 90 kPa for greater than 2 seconds 106 1 The ECM detects that the MAP sensor signal is less than
443. onditions for Running the SPN Observe the scan tool SPN information The misfire should not follow the spark plug exchange If the misfire follows the spark plug replace the spark plug 8 If all conditions test normal test or inspect for the following A lean or rich fuel injector Refer to Fuel Injector Diagnosis on page 9 211 An engine mechanical condition Refer to Engine Mechanical Repair Instructions Spark Plug Wire Replacement on page 9 245 Spark Plug Replacement on page 9 247 Repair Verification 1 If the customer concern was a flashing MIL operate the vehicle within the Conditions for Running SPN 65675 or 65676 Refer to SPN 65675 or 65676 on page 9 151 Clear the SPNs with a scan tool Turn OFF the ignition for 30 seconds Start the engine Operate the vehicle within the Conditions for Running the SPN You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records 6 If the SPN fails this ignition a misfire still exists W 2011 Engine Controls and Fuel Marine 9 141 SPN 65601 65602 or 65610 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5
444. onnector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification Note If you were sent here from Engine Cranks but Does Not Run proceed to Circuit System Testing 1 Attempt to start the engine observe the SPN information with a scan tool SPN 636 2 or 636 8 should not set 2 Engine cranking observe the scan tool Engine Speed parameter The scan tool should indicate an engine speed greater than 0 RPM 3 Move related harnesses connectors of the CKP sensor and verify the engine does not stumble stall or change engine speed 4 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 101 Circuit System Testing 1 Ignition OFF disconnect the harness connector at the CKP sensor 2 Test for less than 5 between the low reference circuit terminal B 2 and ground If greater than the specified range test the low reference circuit for an open high resistance If the circuit tests normal replace the ECM 3 Ignition ON test for
445. onsist of a unique female connector and a compatible male pipe end O rings located inside the female connector provide the fuel seal Integral locking tabs inside the female connector hold the fittings together Fuel Pipe O Rings O rings seal the threaded connections in the fuel system Fuel system O ring seals are made of special material Service the O ring seals with the correct service part Fuel Rail Assembly 1542826 The fuel rail assembly attaches to the engine intake manifold The fuel rail assembly performs the following functions Positions the injectors 3 in the intake manifold Distributes fuel evenly to the injectors 2 Fuel rail feed pipe 1 Fuel Injectors The fuel injector assembly is a solenoid device controlled by the engine control module ECM that meters pressurized fuel to a single engine cylinder The ECM energizes the injector solenoid to open a normally closed ball valve This allows the fuel to flow into the top of the injector past the ball valve and through a director plate at the injector outlet The director plate has machined holes that control the fuel flow generating a spray of finely atomized fuel at 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 285 the injector tip Fuel from the injector tip is directed at the intake valve causing the fuel to become further atomized and vaporized before entering the combustion chamber This fine atomization improve
446. ontrols and Fuel Marine SPN 627 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptor SPN 627 FMI 15 System Voltage Data Valid But Above Normal Range Least Severe Level SPN 627 FMI 17 System Voltage Data Valid But Below Normal Range Least Severe Level Circuit System Description The engine control module ECM monitors the ignition voltage to ensure that the voltage stays within the proper range Damage to components and incorrect data may occur when the voltage is out of range Conditions for Running the SPN e SPNs 630 or 65580 are not set The ignition is ON or the engine is operating The ignition voltage is between 10 16 volts Conditions for Setting the SPN 627 15 The ECM detects the ignition voltage is greater than 16 volts 627 17 The ECM detects the ignition voltage is less than 10 volts Action Taken When the SPN Sets SPN 627 is a Type C SPN Conditions for Clearing the SPN SPN 627 is a Type C SPN Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Conn
447. ontrols and Fuel Marine 9 77 SPN 100 6 0L 6 2L Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 100 FMI 3 Engine Oil Pressure EOP Sensor Circuit Voltage Above Normal or Shorted High SPN 100 FMI 4 Engine Oil Pressure EOP Sensor Circuit Voltage Below Normal or Shorted Low SPN 100 FMI 17 Engine Oil Pressure EOP Sensor Data Valid But Below Normal Range Least Severe Level Diagnostic Fault Information Short to Open High Short to Signal Circuit Ground Resistance Voltage ne 5 Volt Reference 65620 4 100 4 100 4 EOP Sensor Signal 100 4 100 4 100 3 17 owBeeeme To 1 Typical Scan Tool Data EOP Sensor Short to Ground Open Shortto Voltage Operating Conditions Engine idling at Normal Operating Temperature Parameter Normal Range 41 414 kPa 6 60 psi 5 Volt Reference 0 kPa 0 psi 0 kPa 0 psi 0 kPa 0 psi EOP Sensor Signal 0 kPa 0 psi 0 kPa 0 psi 910 kPa 132 psi C 15 77088 Internal ECM damage may occur if the circuit is shorted to B Circuit System Description The engine oil pressure EOP sensor changes resistance based on engine o
448. oolant pump 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 283 Boost Control System Operation Bypass Valve Closed S E Engine Supercharger 1 Control Vacuum Bypass Module Valve Control 1 ECM 1671645 Legend 1 By pass Valve Actuator 7 By pass Valve normally closed 2 Boost Signal 8 Throttle Body 3 Boost Control Solenoid 9 Air Cleaner 4 Boost Vacuum Source 10 MAF Sensor 5 Supercharger 11 Inlet Vacuum Signal 6 Intake Plenum 2011 Marine Engines Manual 9 284 Engine Controls and Fuel Marine Operation The ECM controls boost pressure by using the boost control solenoid The boost control solenoid is normally an open valve Under most conditions the ECM commands the boost control solenoid to operate at 99 100 percent duty cycle This keeps the solenoid valve closed and allows only inlet vacuum to control the position of the bypass valve At idle engine vacuum is applied to the upper side of the bypass valve actuator counteracting spring tension to hold the bypass valve open As engine load is increased engine vacuum is decreased causing the spring in the bypass valve actuator to overcome the applied vacuum closing the bypass valve and allowing the boost pressure to increase When reduced boost pressure is desired the ECM decreases the boost control solenoid duty cycle This opens the solenoid valve and allows boost pressure to enter the bypa
449. open high resistance 4 Ignition ON verify a test lamp illuminates between the relay switch B voltage circuit terminal 30 and ground gt If the test lamp does not illuminate repair the relay switch B voltage circuit for a short to ground or an open high resistance 5 Install a 15A fused jumper wire between the relay switch B voltage circuit terminal 30 and the relay switch supply circuit terminal 87 The fuel pump should turn ON If the fuel pump does not turn ON test for the following conditions An open high resistance in the relay switch supply circuit An open high resistance in the fuel pump ground circuit If the above circuits test normal replace the fuel pump 6 Ignition OFF connect a test lamp between the relay coil control circuit terminal 85 and ground 7 lgnition ON The test lamp should turn ON for approximately 3 seconds and then OFF If the test lamp is always ON test the relay coil control circuit for a short to voltage If the circuit tests normal replace the ECM If the test lamp is always OFF test the relay coil control circuit for a short to ground or an open high resistance If circuit tests normal replace the ECM 8 If all circuits test normal test or replace the fuel pump relay Component Testing 1 Ignition OFF remove the fuel pump relay from the electrical center with the J 43244 2 Test for 70 110 between terminals 85 and 86 If not within the
450. or stops pulsing Record the fuel pressure value immediately after the fuel injector stops pulsing DO NOT record the higher fuel pressure value 6 After the injector stops pulsing record the minimum pressure displayed on the J 34730 1A 7 Repeat steps 5 and 6 for each fuel injector U Perform the Pressure Drop Calculation Fuel Injector Balance Test with Scan Tool and CH 48027 5 Note Before proceeding with this test review the User Manual CH 48027 5 for Safety Information and Instructions 1 Command the fuel pump relay ON and then OFF three times with a scan tool On the last command as the fuel pressure begins to slowly degrade and stabilize select a fuel pressure within 34 kPa 5 psi of the maximum pump pressure Record this fuel pressure This is the starting pressure at which you will pulse each injector 2 Select the Fuel Injector Balance Test function within the Control Functions menu of a scan tool 3 Select an injector to be tested 4 Press Enter to prime the fuel system 2011 Marine Engines Manual 5 Energize the fuel injector by depressing the Pulse Injector button on the scan tool at the previously selected pressure 6 After the injector stops pulsing select Min from the Display Mode on the CH 48027 and record the minimum pressure Note New test results will not be recorded if the Min Max results are not cleared after each injector is tested 7 Clear the Min Max results on the CH 48027 8
451. or excessive engine mechanical noise Ignition Coils Each ignition coil has an ignition 1 voltage feed and a ground circuit The engine control module ECM supplies a low reference and an ignition control IC circuit Each ignition coil contains a solid state driver module The ECM will command the IC circuit ON which allows the current to flow through the primary coil windings When the ECM commands the IC circuit OFF this will interrupt current flow through the primary coil windings The magnetic field created by the primary coil windings will collapse across the secondary coil windings which induces a high voltage across the spark plug electrodes Distributor Ignition DI System Description The distributor ignition DI system is responsible for producing and controlling a high energy secondary spark This spark is used to ignite the compressed air fuel mixture at precisely the correct time This provides optimal performance fuel economy and control of exhaust emissions This ignition system consists of a single ignition coil and ignition control module ICM Spark energy is delivered via a distributor cap rotor and secondary spark plug wires The driver module within the ICM is commanded to operate the coil by the engine control module ECM that has complete control over spark timing The DI System consists of the following components Crankshaft Position CKP Sensor The crankshaft position CKP sensor is an intern
452. or is stuck within the normal operating range the condition may go undetected by the ECM and could result in a driveability concern A basic understanding of sensor operation is necessary in order to diagnose a sensor that is stuck in range An example of a sensor that is stuck in range would be if the coolant sensor is reading 10 C 50 F but the actual coolant temperature is 66 C 150 F This condition would cause the ECM to deliver more fuel than is actually required by the engine This would result in an overly rich condition and cause the engine to run rough This condition would not set a diagnostic trouble code DTC because the ECT value is within the normal operating range To help identify a sensor that is stuck in range operate the engine under various conditions while observing the appropriate scan tool parameter The parameter value should vary as engine temperature engine speed or load is varied 6 8 Vehicle Diagnostic Information Resistance on a low reference circuit or signal circuit may also cause a sensor value to be incorrect If this condition is suspected disconnecting the sensor and testing the circuits may isolate the condition Refer to the appropriate Circuit System Testing procedure for the applicable sensor to assist in testing the circuit Engine Control Module ECM Self Diagnosis The marine engine has electronic controls to reduce exhaust emissions while maintaining excellent driveabi
453. order to crimp on a new terminal If the wire was not cut cut the existing wire as close to the old terminal as possible 2 Strip 5 mm 3 16 in of insulation from the wire 3 Crimp a new terminal to the wire 4 Solder the crimp with rosin core solder Terminal Installation 1 Align the terminal and pull the wire from the back of the connector in order to seat the terminal 2 If necessary cut the new wire to proper length and splice with existing circuit Refer to Splicing Copper Wire Using Splice Sleeves in Wiring Repairs on page 11 16 3 If the connector is outside of the passenger compartment apply dielectric grease to the connector 4 Install the TPA CPA and or the secondary locks Weather Pack Connectors Weather Pack Connectors To remove Weather Pack terminals 1 Lift up the connector body retaining tangs and pull the mating connector bodies apart or disconnect the connector from the component Note Anti backout combs are designed to keep the terminal from backing out of the connector The anti backout combs must be removed before terminal removal and must be replaced when the terminal is repaired and re seated 1683758 2 f fitted open secondary lock 1 or remove the anti backout comb 3 Grasp the lead and push the terminal to the forward most position Hold the lead at this position 4 Insert the Weather Pack terminal removal tool 1 into the front mating end of the connector
454. oring fuel related parameters with a scan tool The scan tool parameters should not indicate a lean condition lf the scan tool parameters indicate a lean condition test for a restricted fuel feed pipe restricted fuel filter or poor connections at the harness connectors and ground circuits of the fuel pump If all test normal replace the fuel pump If the fuel system components test normal refer to Symptoms Engine Controls on page 9 199 9 210 Engine Controls and Fuel Marine Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Fuel Injection Fuel Rail Assembly Replacement 3 0L on page 9 230 or Fuel Injection Fuel Rail Assembly Replacement 4 3L 5 0L and 5 7L on page 9 231 or Fuel Injection Fuel Rail Assembly Replacement 6 0L and 6 2L on page 9 234 or Fuel Injection Fuel Rail Assembly Replacement 2 4L on page 9 235 Fuel Injector Replacement Except 2 4L on page 9 238 or Fuel Injector Replacement 2 4L on page 9 240 Fuel System Diagnosis without Returnless Fuel System Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category Circuit System Descri
455. ormation Short to Open High Short to Signal Circuit Ground Resistance Voltage Performance 65570 4 65570 5 65570 5 Cam Phaser Control 65571 4 65571 5 65571 5 Low Reference 65571 5 Internal or sensor damage may occur if the circuit is shorted to B Circuit System Description The camshaft position actuator system enables the Engine Control Module ECM to change the timing of the camshafts while the engine is operating The Camshaft Position Actuator Solenoid Valve signal from the ECM is pulse width modulated PWM The ECM controls the Camshaft Position Actuator Solenoid Valve duty cycle by controlling the amount of solenoid valve ON time The Camshaft Position Actuator Solenoid Valve controls the advance or the retard of each camshaft The Camshaft Position Actuator Solenoid Valve controls the oil flow that applies the pressure to advance or retard the camshafts The ECM controls the Camshaft Position Actuator Solenoid Valve by suppling a 12 V pulse width modulated PWM signal The ECM supplies a ground to the low reference circuit 2011 Marine Engines Manual Conditions for Running the SPN 65570 65571 65572 65573 FMI 2 Before the ECM can report that SPN 65570 2 65571 2 65572 2 or 65573 2 failed SPNs 65570 4 65570 5 65571 4 65571 5 65572 4 65572 5 65573 4 65573 5 65723 65724 65725 or 65726 must run and pass SPN 630 65580 15 not set e The ignition is ON
456. ort to Circuit Ground Fuel Pump Relay Ignition 1 Voltage 2 Fuel Pump Motor Supply Voltage Fuel Pump Relay Control 66017 4 66017 5 Fuel Pump Relay Ground Fuel Pump Ground Engine Controls and Fuel Marine 9 207 Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the repair Charge Air Bypass Regulator Solenoid Valve Replacement on page 9 223 Supercharger Bypass Valve Actuator Replacement on page 9 224 Open High Short to Signal Resistance Voltage Performance ___ ___ 3 J ____ 9 a a SEE _ 1 The fuel pump fuse opens and the engine cranks but does not run 2 The engine cranks but does not run 3 The fuel pump operates continuously and the battery will discharge Circuit System Description When the ignition switch is turned ON the engine control module ECM energizes the fuel pump relay which powers the fuel pump ON The fuel pump remains ON as long as the engine is cranking or running and the ECM receives ignition reference pulses If there are no ignition reference pulses the ECM shuts the fuel pump OFF within 2 seconds after the ignition was switched to the ON position or if the engine stops Diagnostic Aids The following conditions may cause the fuel pump fuse to open The fuse is faulty There 15 an intermittent short to ground in the supply voltage circuit of the fuel pump The fuel pump has an intermittent i
457. osis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category Circuit System Description The slow mode switch allows the operator to change the throttle control percentage in order to maintain a more accurate control of the engine speed at low vehicle speeds The engine control module ECM applies a voltage to the slow mode circuit The ECM monitors the status of the slow mode circuit When the slow mode switch is depressed the ECM detects a low signal voltage and will limit the engine speed output Normal throttle control will return when the slow mode switch is OFF and the throttle has been placed in neutral Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs page 11 16 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification Note Verify the throttle is in neutral for this procedure Engine idling depress the slow mode switch With the throttle control in neutral raise the engine speed The engi
458. ot match for greater than 2 seconds Action Taken When the SPN Sets SPN 66017 is a Type B SPN Conditions for Clearing the SPN SPN 66017 is a Type B SPN Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Special Tools J 43244 Relay Puller Pliers 2011 Marine Engines Manual Circuit System Verification 1 Cycle the ignition from OFF to ON You should hear and feel an audible click from the fuel pump relay Repeat as necessary in order to verify fuel pump relay operation 2 Ignition ON command the fuel pump relay ON and OFF with a scan tool Verify SPN 66017 is not set 3 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Ignition OFF disconnect the fuel pump relay 1 with the J 43244 2 Test for
459. ot Responding or Out of Adjustment Misfire Cylinder 6 Mechanical System Not Responding or Out of Adjustment Misfire Cylinder 7 Mechanical System Not Responding or Out of Adjustment Misfire Cylinder 8 Mechanical System Not Responding or Out of Adjustment Misfire Random Mechanical System Not Responding or Out of Adjustment Conditions for Setting the SPN The ECM detects a crankshaft rotation speed variation indicating a misfire rate sufficient to cause emissions levels to exceed a predetermined value The ECM detects a crankshaft rotation speed variation indicating a misfire rate sufficient to cause catalyst damage MIL flashing Action Taken When the SPN Sets SPN 65590 65591 65592 65593 65594 65595 65956 65597 65598 and 65599 are Type A MIL flashing or Type B SPNs Conditions for Clearing the SPN SPN 65590 65591 65592 65593 65594 65595 65956 65597 65598 and 65599 are Type A MIL flashing or Type B SPNs Diagnostic Aids On an engine equipped with a distributor ignition system a misfire SPN may be caused by a cam sensor or distributor that is out of adjustment A misfire SPN may be caused by an excessive vibration from sources other than the engine Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 9 140 Engine Controls
460. ottle and the supercharger inlet Spring force from the actuator holds the valve in a normally closed position to create boost and vacuum pulls the valve open when the throttle closes to decrease boost A solenoid valve is attached to the supercharger housing This three way valve controlled by the engine control module ECM determines whether pressure from the manifold is routed to the bypass actuator or closed off This valve allows pressure from the manifold to open the bypass valve and lower boost pressure during specific driving conditions The open bypass valve reduces the pumping effort of the supercharger thereby increasing the fuel efficiency in light load operations Intercooler The supercharger has an intercooler Cooling the supercharger boost air enhances the effectiveness of the supercharger The intercooler uses conventional coolant in a separate sealed system from the engine cooling system The intercooler system has a radiator a back fill port at the rear of the supercharger attaching hoses and a coolant pump The coolant pump is supplied power through the coolant pump relay The coolant pump relay operation is controlled by the Ignition voltage is supplied to the coolant pump relay coil and the coolant pump relay switch The ECM controls the coolant pump relay with a low side driver When the ECM commands the coolant pump relay ON the relay contacts close supplying power to the supercharger intercooler c
461. output 1 or 2 circuit is used to enable a SPN 630 or 65580 15 not set relay or series of relays which are wired in parallel The ignition is ON or th La ti The duel fuel relay s allow the engine to be operated LR PUE MA with an alternate fuel system Ignition voltage is The ignition voltage is between 10 16 volts supplied to the relay s through a fuse The engine The fuel select output is commanded OFF control module ECM turns the relay s ON by grounding the control circuit when the ECM receives the appropriate fuel select input The ECM controls the solenoid by grounding the control circuit with a solid state device known low side driver The driver is Conditions for Setting the SPN equipped with a feedback circuit that is pulled up to The d nat E IS tects that the commanded state of the voltage The ECM can determine if the control circuit 18 bus is open shorted to ground or shorted to a voltage by circuit do not monitoring the feedback voltage The SPNs run continuously once the above conditions are met Conditions for Running the SPN Action Taken When the SPN Sets 65586 and 65587 3 SPNs 65586 and 65587 are Type B SPNs SPN 630 or 65580 is not set The ignition is ON or the engine is operating The ignition voltage is between 10 16 volts The fuel select output is commanded ON The SPNs run continuously once the above conditions are met Conditions
462. overnor Control Voltage Below Normal or Shorted Low Conditions for Clearing the SPN SPN 65690 is a Type C SPN Diagnostic Aids If a shared 5 volt reference circuit is shorted to ground or shorted to a voltage other 5 volt reference circuits may be affected Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 9 154 Engine Controls and Fuel Marine Circuit System Verification 1 Ignition ON observe the SPN information with a scan tool Verify that SPN 65620 65621 65622 or 65623 is not set If either SPN is set refer to SPN 65620 65623 on page 9 149 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 2 Ignition OFF disconnect the harness connector at the variable gover
463. ow Low 2011 Marine Engines Manual Conditions for Running the SPN SPN 110 630 65580 65620 65621 65622 or 65623 is not set The engine is operating for greater than 10 seconds The SPN 105 runs continuously once the above conditions are met Conditions for Setting the SPN 105 3 The ECM detects that the MAT sensor parameter is colder than 38 C 36 105 4 The ECM detects that the MAT sensor is warmer than 129 C 264 F 105 15 The ECM detects that the manifold air temperature is within the range of the MAT sensor but warmer than a predicted value 9 80 Engine Controls and Fuel Marine Action Taken When the SPN Sets SPN 105 is a Type B SPN Conditions for Clearing the SPN SPN 105 is a Type B SPN Diagnostic Aids If the vehicle has set overnight the MAT sensor and the ECT sensor values should display within 3 C 5 F Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine
464. p po 6009 5 Pe 66006 5 66008 5 66008 5 66009 5 66009 5 66006 5 66006 5 The fuse that supplies voltage to the IPC Bulb opens Circuit System Description The DTC 1 2 and 3 lamps are located in the instrument panel cluster IPC Ignition voltage is supplied to the DTC lamps through a fuse The engine control module ECM turns the DTC lamps ON by grounding a dedicated control circuit for each lamp Conditions for Running the SPN SPN 630 or 65580 is not set The ignition is ON or the engine is operating The ignition voltage is greater ha 9 volts The DTC lamp has been commanded ON and OFF at least once during the ignition cycle SPNs 66006 66008 and 66009 run continuously once the above conditions are met Conditions for Setting the SPN The ECM detects that the commanded state of the driver and the actual state of the control circuit do not match for greater than 5 seconds Action Taken When the SPN Sets SPNs 66006 66008 and 66009 are Type C SPNs Conditions for Clearing the SPN SPNs 66006 66008 and 66009 are SPNs Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Condition
465. parameter displays the percentage of load compensation needed to offset the engine drag caused by the activation of an OEM installed system or component This parameter displays the status of the low Low Oil Level Lamp This parameter displays the control module commanded state of the low oil level lamp control circuit Manifold Absolute LAE This parameter displays the pressure from This parameter displays the signal voltage MAP Sensor Voltage pF 0 5 Volts from the MAP sensor to the control module 39 to 140 C 38 to 284 ETE Min Position Learn Pending Manifold Air Temperature MAT Sensor Resistance MAT Sensor Voltage Max Knock Retard Cylinder This parameter displays the temperature of the air entering the air induction system based on input to the control module from the MAT sensor This parameter displays whether or not the vehicle is equipped with a manifold air temperature MAT sensor This parameter displays the resistance of the manifold air temperature MAT sensor based on input to the control module from the MAT sensor This parameter displays the voltage of the manifold air temperature MAT sensor based on input to the control module from the MAT sensor This parameter displays the number of a cylinder if a knock condition has been detected related to that cylinders combustion event The scan tool will display 0 if there is no knock condition detected r
466. park Plug Gap AC Spark Plug P N 41 103 Ignition System Specifications 3 0L Application Merc Engin O Spark Plug Torque 22 Ib ft Spark Plug Gap 2 050 in GM P N 19158043 AC Spark Plug P N 41 950 Spark Plug Type Ignition System Specifications 4 3L 5 0L or 5 7L Application Merc _ 1 6 5 4 3 2 4 3L 1 8 4 3 6 5 7 2 5 0 5 7L Spark Plug Wire Resistance 1 200 1 500 ohms per ft Spark Plug Torque Spark Plug Type GM P N 12607234 P 2 AC Spark Plug P N 41 993 Ignition System Specifications 6 0L or 6 2L Metric English Firing Order 1 8 7 2 6 5 4 3 Spark Plug Wire Resistance 397 1 337 ohms Firing Order Spark Plug Torque 11 Ib ft Spark Plug Gap 0 040 n Spark Plug Type GM P N 12571164 i bid AC Spark Plug P N 41 985 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 5 Fastener Tightening Specifications Application Camshaft Position CMP Actuator Magnet Bolts Camshaft Position CMP Sensor Wire Harness Bolt Engine Coolant Temperature ECT Sensor Schematic and Routing Diagrams 2011 Marine Engines Manual 6 Engine Controls and Fuel 9 32 4442 eead L S20H MNVYO NNY 4 1 1 l V Oc 2 esnd 14 m
467. pective O2 O2 A1 A2 B1 or B2 22 to 22 Percent sensor A negative value indicates rich exhaust and a positive value indicates lean exhaust Multiplier Percent 2011 Marine Engines Manual 9 60 Engine Controls and Fuel Marine Engine Control Module Scan Tool Data cont d System State Expected Value This parameter displays the state of the fuel control system as commanded by the control module ON indicates that the control module is controlling the fuel delivery based on the pee ON oxygen sensors input signal OFF indicates p Open Loop operation The control module ignores the oxygen sensor input signal in Open Loop and bases the amount of fuel to be delivered on other sensor inputs O2 Sensor A1 A2 B1 YES This parameter displays whether or not the or B2 Present vehicle is equipped with an oxygen sensor O2 Sensor A1 or YES This parameter displays that the HO2S 1 is B1 Ready at operating temperature This parameter displays the oxygen sensor O2 Sensor A1 or B1 rich lean and lean rich status A switch is Rich Lean Closed Loop ON Varies when the oxygen sensor voltage goes above 450 mV and below 450 mV This parameter displays the voltage output O2 A1 A2 B1 or 100 900 mV from the HO2S to the control module A lower B2 Volts voltage indicates a lean exhaust while a higher voltage indicates a rich exhaust This parameter displays ON when the control module is calibrated to allow the ECM learn the octane
468. place the MAP MAT sensor Component Testing 1 Ignition OFF disconnect the harness connector at the MAP MAT sensor Note A thermometer can be used to test the sensor off the vehicle 2 Test the MAT sensor by varying the sensor temperature while monitoring the sensor resistance Compare the readings with the Temperature Versus Resistance on page 9 3 table and verify that the resistance is within 5 percent of the specification If not within the specified range replace the MAP MAT sensor Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Manifold Absolute Pressure Sensor Replacement without Supercharger on page 9 220 Engine Control Module Replacement on page 9 217 for engine control module replacement setup and programming 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 81 SPN 105 2 4L 6 0L 6 2L Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 105 FMI 3 Manifold Air Temperature MAT Sensor Circuit Voltage Above Normal or Shorted High SPN 105 4 Manifold Air Temperature MAT Sensor Circuit Voltage Below
469. placement A M dade Ss NN PSC SS 0257 SA 7 2164115 Charge Air Bypass Regulator Solenoid Valve Replacement Component Name Charge Air Bypass Regulator Solenoid Fastener Caution Refer to Component Fastener Tightening Caution on page 0 5 Tighten 10 N m 89 Ib in Charge Air Bypass Regulator Solenoid Procedure Disconnect the harness connector Disconnect the vacuum tubes from the charge air bypass regulator solenoid 2011 Marine Engines Manual 9 224 Engine Controls and Fuel Marine Supercharger Bypass Valve Actuator Replacement a Ws Ju 2159710 Supercharger Bypass Valve Actuator Replacement Callout Component Name Supercharger Air Bypass Regulator Actuator Fastener Caution Refer to Component Fastener Tightening Caution on page 0 5 Tighten 10 N m 89 Ib in Supercharger Air Bypass Regulator Actuator Procedure 1 Disconnect the Vacuum Tube from the supercharger 2 Disconnect the vacuum tubes from the supercharger air bypass regulator actuator 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 225 Engine Oil Pressure Sensor Installation Procedure Replacement Special Tools J 41712 Oil Pressure Sensor Socket Removal Procedure 1 Clean area around the oil sensor switch before removing it 3 2 LIP L FR BNN ORS S EN gt gt gt X amp s LU 2 Y
470. ponents Any warning or caution that appears in this service category is referenced from the individual service categories DANGER Defined When encountering a DANGER you will be asked to take a necessary action or not to take a prohibited action If a DANGER is not heeded the following consequences may occur Serious bodily injury or death to the technician Serious bodily injury or death to other technicians in the workplace area WARNING Defined When encountering a WARNING you will be asked to take a necessary action or not to take a prohibited action If a WARNING is not heeded the following consequences may occur Serious bodily injury to the technician Serious bodily injury to other technicians in the workplace area Serious bodily injury to the driver and or passenger s of the vehicle if the vehicle has been improperly repaired CAUTION Defined CAUTIONS call special attention to a necessary action or to a prohibited action If a CAUTION is not heeded the following consequences may occur Damage to the vehicle Unnecessary vehicle repairs Unnecessary component replacement operation or performance of the system or component under repair 2011 Marine Engines Manual Damage to any systems or components which are dependent upon the proper operation of the system or component under repair Improper operation or performance of any systems or components which are
471. ponents J 35616 A Connector Test Adapter Kit Caution Caution Use the connector test adapter kit J 35616 A for any test that requires probing the following items The ECM harness connectors The electrical center fuse relay cavities The component terminals The component harness connector Using this kit will prevent damage caused by the improper probing of connector terminals Test Lamp to Test Continuity Caution Caution Do not use a test lamp in order to test the continuity of the low reference circuit Damage to the Engine Control Module ECM will result Test Probe Caution Caution Do not insert test equipment probes DVOM etc into any connector or fuse block terminal The diameter of the test probes will deform most terminals A deformed terminal will cause a poor connection which will result in a system failure Always use the J 35616 GM Approved Terminal Test Kit in order to front probe terminals Do not use paper clips or other substitutes to probe terminals When using the J 35616 GM Approved Terminal Test Kit ensure the terminal test adapter choice is the correct size for the connector terminal Do not visually choose the terminal test adapter because some connector terminal cavities may appear larger than the actual terminal in the cavity Using a larger terminal test adapter will damage the terminal Refer to the J 35616 GM Approved Terminal Test Kit label on the inside of the J 35616 GM A
472. port at the bypass valve actuator Slowly apply 15 inch Hg of vacuum while observing the bypass valve actuator The bypass valve actuator and cable should retract gt If the bypass valve actuator and cable do not retract inspect the bypass valve and bypass valve actuator linkage for binding sticking or damage If the bypass valve cable and linkage operate normally replace the bypass valve actuator 3 Connect the inlet vacuum signal hose to the top of the bypass valve actuator 4 Disconnect the boost signal hose from the bottom of the bypass valve actuator 5 Connect the J 23738 A to the boost signal port on the bypass valve actuator 2011 Marine Engines Manual 6 Engine idling slowly apply 20 inch Hg of vacuum while observing the bypass valve actuator The bypass valve actuator should extend If the bypass valve actuator does not extend inspect the bypass valve and linkage for binding sticking or damage If the bypass valve and linkage operate normally replace the bypass valve actuator Fuel Pump Electrical Circuit Diagnosis Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category Diagnostic Fault Information Sh
473. powertrain from damage and improve driveability The ignition is OFF This prevents engine run on The ignition is ON but there is no ignition reference signal This prevents flooding or backfiring The engine speed is too high above red line During rapid deceleration in order to prevent damage to the catalytic converters Fuel Trim The engine control module ECM controls the air fuel metering system in order to provide the best possible combination of driveability fuel economy and emission control The ECM monitors the heated oxygen sensor HO2S signal voltage while in Closed Loop and regulates the fuel delivery by adjusting the pulse width of the fuel injectors based on this signal The ideal fuel trim values are around 0 percent for both short term and long term fuel trim A positive fuel trim value indicates the ECM is adding fuel in order to compensate for a lean condition by increasing the pulse width A negative fuel trim value indicates that the ECM is reducing the amount of fuel in order to compensate for a rich condition by decreasing the pulse width A change made to the fuel delivery changes the short term and long term fuel trim values The short term fuel trim values change rapidly in response to the HO2S signal voltage These changes fine tune the engine fueling The long term fuel trim makes coarse adjustments to the fueling in order to re center and restore control to short term fuel trim A scan tool can be used t
474. pproved Terminal Test Kit for the correct adapter along with the connector end view for terminal size Three Way Catalytic Converter Damage Caution Caution In order to avoid damaging the replacement three way catalytic converter correct the engine misfire or mechanical fault before replacing the three way catalytic converter 2011 Marine Engines Manual Table of Contents 1 1 Section 1 General Information General Information 1 3 Introduction 1 3 US English Metric Conversion 1 3 Decimal and Metric Equivalents 1 3 Arrows and Symbols 1 4 Basic Knowledge and Tools Required 1 5 2011 Marine Engines Manual Visual Physical Checks 1 5 Electrostatic Discharge Damage 1 5 Engine Wiring nite t 1 5 eM Em 1 6 Thread Inserts orte teretes 1 8 Abbreviations and Meanings 1 8 1 2 Table of Contents BLANK 2011 Marine Engines Manual General Information Introduction US English Metric Conversion Multiply Divide by In order to calculate English measurement divide by the number in the center column In order to calculate metric measurement multiply by the number in the center column Length 25 4 0 3048 0 9144 1 609 3 3 x 3 645 2
475. procedures Refer to Powertrain On Board Diagnostic OBD System Check on page 9 64 Malfunction Indicator Lamp MIL The malfunction indicator lamp MIL is located in the instrument panel cluster The MIL indicates that an emissions related fault has occurred and vehicle service is required The following is a list of the modes of operation for the MIL The MIL illuminates when the ignition is turned ON with the engine OFF This is a bulb test to ensure the MIL is able to illuminate The MIL turns OFF after the engine is started if a diagnostic fault is not present The MIL remains illuminated after the engine is started if the control module detects a fault A diagnostic trouble code is stored any time the control module illuminates the MIL due to an emissions related fault The MIL turns OFF after three consecutive ignition cycles in which a Test Passed has been reported for the diagnostic test that originally caused the MIL to illuminate The MIL flashes if the control module detects a misfire condition which could damage the catalytic converter When the MIL is illuminated and the engine stalls the MIL will remain illuminated as long as the ignition is ON When the MIL is not illuminated and the engine stalls the MIL will not illuminate until the ignition is cycled OFF and then ON Reading Suspect Parameter Numbers The data link connector DLC provides the technician a means of accessing serial dat
476. provides an overview of each diagnostic category DTC Descriptors SPN 51 FMI 0 Throttle Position TP Sensor Circuit Voltage Data Valid but Above Normal SPN 51 3 Throttle Position TP Sensor Circuit Voltage Above Normal or Shorted High SPN 51 FMI 4 Throttle Position TP Sensor Circuit Voltage Below Normal or Shorted Low Diagnostic Fault Information Short to Open High Short to Signal Circuit Ground Resistance Voltage 5 Volt Reference 65623 4 51 3 65605 2 TP Sensor Signal flow Reference SOS OY Typical Scan Tool Data TP Sensor 1 and 2 Short to Ground Open Short to Voltage Operating Conditions The ignition is ON and the engine is OFF Parameter Normal Range TP Sensor 0 5 volts 5 Volt Reference 0 00 V 0 00 V 3 75 V TP Sensor Signal 0 00 V 0 00 V 5 02 V 0 00 V Circuit System Description The throttle body assembly contains a throttle position TP sensor The TP sensor is mounted externally on the throttle body assembly The TP sensor is a potentiometer which provides a signal voltage that changes relative to the throttle blade angle The engine control module ECM supplies the TP sensor with a 5 volt reference circuit a low reference circuit and a signal circuit The TP sensor signal voltage increases from less than 1 volt at idle to greater than 4 volts at wide open throttle WOT Conditions for Running the SPN Before the ECM can report that SPN 51 0 failed SPN 106 0 and 106
477. provides an overview of each diagnostic category SPN Descriptors SPN 65604 FMI 2 Pedal Position PP Sensor 2 Data Erratic Intermittent or Incorrect SPN 65605 FMI 2 Pedal Position PP Sensor 1 Data Erratic Intermittent or Incorrect SPN 65613 FMI 2 Pedal Position PP Sensor 1 and 2 Data Erratic Intermittent or Incorrect Diagnostic Fault Information Short to High Short to Signal Circuit Ground Resistance Voltage Performance 65601 2 65602 2 PP Sensor 1 5 Volt Reference 65623 4 65613 2 65605 2 65605 2 65613 2 65610 2 65613 2 65605 2 65605 2 Sensor 1 Signal 65623 4 65613 2 65613 2 65613 2 65613 2 65605 2 999 Short to High Short to Signal Circuit Ground Resistance Voltage Performance 106 2 65604 2 106 3 PP Sensor 2 5 Volt Reference 65622 4 65613 2 65613 2 65604 2 65613 2 65613 2 65604 2 65604 2 PP Sensor 2 Signal 65622 4 65613 2 65613 2 65613 2 65613 2 PP Sensor 2 Low Reference 656182 6502 656132 Typical Scan Tool Data PP Sensor 1 and 2 ShorttoGround_ Open Short to Voltage Operating Conditions The ignition is ON and the engine is OFF Parameter Normal Range PP Sensor 1 1 0 volts PP sensor 2 0 49 volts PP 1 5 Volt Reference 0 00 volts 0 00 volts 1 92 volts PP Sensor 1 Signal 0 00 volts 0 00 volts 4 98 volts TPP tow PP Sensor 2 Signa Internal ECM or sensor damage may occur
478. ption When the ignition switch is turned ON the engine control module ECM supplies power to the fuel pump s by energizing the fuel pump relay The fuel pump remains ON as long as the engine is cranking or running and the ECM receives crankshaft reference pulses If there are no reference pulses the ECM turns the fuel pump OFF 2 seconds after the ignition switch is turned ON or 2 seconds after the engine stops running The fuel pump supplies fuel through a fuel filter through the fuel feed pipes to the fuel rail assembly The fuel pump provides fuel at a pressure above the pressure needed by the fuel injectors The fuel pressure regulator located in the modular fuel pump and sender assembly keeps the fuel available to the fuel injectors at a regulated pressure When the fuel pressure rises above the pressure regulator calibration the pressure is relieved with excess fuel returned to the fuel tank Reference Information Description and Operation Fuel System Description on page 9 284 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Special Tools e J 34730 Fuel Pressure Gauge 37287 Fuel Line Shut Off Adapters Circuit System Verification Note Inspect the fuel system for
479. r Circuit Voltage Above Normal or Shorted High Manifold Air Temperature MAT Sensor Circuit Voltage Below Normal or Shorted Low Manifold Air Temperature MAT Sensor Circuit Voltage Data Valid But Above Normal Short to Open High Short to Signal Circuit Ground Resistance Voltage Performance MAT Sensor Signal 105 4 105 3 105 3 105 15 MAP MAT Low Reference __ 1058 1063 105 15 Internal or sensor damage may occur if the circuit is shorted to B Typical Scan Tool Data MAT Sensor ShottoGrund Open Short to Voltage Operating Conditions Engine operating in Closed Loop Parameter Normal Range Varies with ambient temperature 130 266 F MAT Sensor Signal MAP MAT Low Reference O Internal or sensor damage may occur if the circuit is shorted to 40 C 40 F 40 C 40 F 40 C 40 F 40 C 40 F Circuit Description The manifold air temperature MAT sensor is a part of the manifold absolute pressure MAP sensor The MAT is a variable resistor that measures the temperature of the air entering the engine The MAT sensor has a signal circuit and shares a low reference circuit with the MAP sensor The engine control module ECM supplies 5 volts to the MAT signal circuit and a ground for the MAP MAT low reference circuit The following table illustrates the difference between temperature resistance and voltage MAT Signal MAT MAT Resistance Voltage L
480. r Heplacement on page 9 226 Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 2011 Marine Engines Manual SPN 65565 65566 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 65565 FMI 0 SPN 65565 FMI 1 SPN 65566 FMI 0 SPN 65566 FMI 1 Circuit Description The engine control module ECM controls a Closed Loop air fuel metering system in order to provide the best possible combination of driveability fuel economy and emission control The ECM monitors the heated oxygen sensor HO2S signal voltage and adjusts the fuel delivery based on the signal voltage while in Closed Loop A change made to the fuel delivery changes the long and short term fuel trim values The short term fuel trim or O2 Fuel Multiplier values change rapidly in response to the HO2S signal voltages These changes fine tune the engine fueling The long term fuel trim or O2 BLM Cell Values change in response to trends in the O2 Fuel Multiplier The O2 BLM Cell Value makes coarse adjustments to fueling in order to re center and restore control to the O2 Fuel Multiplier The ideal O2 BLM Cell Values are aro
481. r Running the SPN 1765 4 SPN 630 65580 65620 65621 65622 or 65623 is not set The ignition is ON or the engine is operating The ignition voltage is between 10 16 volts The fuel valve is commanded ON SPN 1765 runs continuously once the above conditions are met 1765 5 SPN 630 65580 65620 65621 65622 or 65623 is not set The ignition is ON or the engine is operating The ignition voltage is between 10 16 volts The fuel valve is commanded OFF SPN 1765 runs continuously once the above conditions are met Fuel Valve High Side Driver Voltage below normal or shorted low Fuel Valve High Side Driver Current Below Normal or Open Circuit Signal Performance Open High Short to Resistance Voltage Conditions for Setting the SPN The ECM detects that the commanded state of the driver and the actual state of the control circuit do not match for greater than 5 seconds Action Taken When the SPN Sets SPN 1765 is a Type B SPN Conditions for Clearing the SPN SPN 1765 is a Type B SPN Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SP
482. r assembly transfer out of alignment In order to correct this the two marks from the original housing to the new Dn dde condition remove the distributor and distributor housing in the same location reinstall it Caution Refer to Component Fastener Tightening Caution on page 0 5 4 Install the distributor hold down bolt Tighten Tighten the distributor clamp bolt to 27 N m 20 Ib ft 4376 1 Align the distributor rotor with mark made at location 2 301393 Install the distributor cap 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 253 5 Install new distributor cap screws Installing the driven gear 180 degrees out of alignment or locating the rotor in the wrong holes will cause a Tighten no start condition Premature engine wear or damage Tighten the screws to 2 4 N m 21 Ib in may result d s 6 Install the harness connectar to Caution Installing the driven gear 180 degrees out 7 Install the spark plug wires to the distributor cap of alignment or locating the distributor rotor in 8 Perform the Cam Retard Offset Procedure the wrong holes may cause a no start condition Refer to Camshaft Retard Offset Adjustment Premature engine wear and damage may result 3 0L and 4 3L on page 9 255 or Camshaft Retard 3 With the gear in this position the rotor segment Offset Adjustment 5 0L and 5 7L on page 9 255 should be positioned as shown for a V6 engine 1 or V8 engine
483. r cables or when charging the vehicle battery In order to prevent any possible electrostatic discharge damage to the control module do no touch the connector pins or the soldered components on the circuit board 1838648 Remove any debris from around the control module connector surfaces before servicing the control module Inspect the control module connector gaskets when diagnosing or replacing the control module Ensure that the gaskets are installed correctly The gaskets prevent contaminant intrusion into the control module 1 Ignition OFF 2 Disconnect the negative battery cable 3 Disconnect the engine wiring harness electrical connectors 1 and 2 from the ECM Installation Procedure 1 Connect the engine wiring harness electrical connectors 1 and 2 to the ECM 2 Connect the negative battery cable 3 If a NEW ECM was installed the ECM may need to be programmed Refer to Engine Control Module Programming and Setup on page 6 3 1838648 2011 Marine Engines Manual 9 218 Engine Controls and Fuel Marine 855737 855737 2004809 Engine Coolant Temperature Sensor Replacement Removal Procedure 1 Drain the cooling system to a level below the engine cooling temperature ECT sensor Note Use care when handling the coolant sensor Damage to the coolant sensor will affect the operation of the fuel control system 2 Disconnect the engine wiring harness electrical connector from t
484. r flickers or the ohmmeter changes or registers there is a short to ground in the wiring near that point 1683692 Legend 1 Power From Battery With Fuse Removed 2 Starting Test Point 3 Switch 4 Disconnected Load 5 Meter Set To Ohms 6 Short To Ground 2011 Marine Engines Manual Using A Short Finder A short finder is a device used for locating hidden shorts These create a magnetic field in the shorted circuit and allow you to read its location through body trim or sheet metal Using A Compass An ordinary magnetic compass may be used to locate grounded circuits It makes use of the fact that a wire carrying current creates a magnetic field In circuits that are protected by a circuit breaker a short or ground can be quickly located by use of an ordinary magnetic compass Turn the circuit breaker on and off and start following the wiring with the compass the compass will kick each time the circuit breaker closes As the compass passes the point of the short or ground the compass will stop kicking Thus the compass can pinpoint the problem without removing trim cover plates or tape If the circuit is fused the problem can be found in the same manner by substituting a circuit breaker for the fuse Using A Circuit Breaker By using a circuit breaker as a substitute for a fuse other tools can be more effectively used to find troubles A turn signal flasher makes a conve
485. rate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data 2011 Marine Engines Manual Circuit System Testing 1 Ignition OFF disconnect the harness connector at the OEM device 2 Ignition ON verify a test lamp illuminates between the ignition voltage circuit terminal and ground gt If the test lamp does not illuminate test the ignition voltage circuit for a short to ground an open high resistance If the circuit tests normal and the ignition voltage circuit fuse is open test all components connected to the ignition voltage circuit and replace as necessary 3 Ignition OFF connect a test lamp between the control circuit terminal and B 4 Ignition ON command the OEM device ON and OFF with a scan tool The test lamp should turn ON and OFF with each command Ifthe test lamp is ON all of the time test the control circuit for a short to ground If the circuit test normal replace the ECM If the test lamp is OFF all of the time test the control circuit for a short to voltage or an open high resistance If the circuit test normal replace the ECM 5 If all circuits test normal test or replace the OEM device Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Engine Control Module
486. rating of the fuel being consumed This feature when enabled increases the Octane Adapt Enable ignition timing advance curve to raise the performance of an engine operating on higher octane fuels Used primarily in racing applications This parameter displays a range of 0 100 percent and indicates amount of Octane Rating Adapt 0 0 an increase in the ignition timing advance curve based on the learned octane rating This parameter displays YES when the control Update in module is in the process of learning the octane rogress ratin 9 These parameters display YES if an input is OEM Input 1 4 Active YES NO supplied to the control module on the respective OEM circuit These parameters display YES if the control module is using the respective output control OEM Output 1 4 Active YES NO circuit to operate an OEM component or system This parameter displays the oil pressure Oil Pressure 41 414 kPa 6 60 psi based on input to the control module from the engine oil pressure sensor This parameter displays the oil pressure ecd Sensor 0 5 Volts sensor voltage based on input to the control 9 module from the engine oil pressure sensor This parameter displays the resistance of the Oil Sensor Resistance Varies oil pressure sensor based on input to the control module from the sensor This parameter displays the temperature of Oil Temperature Varies the engine oil as determined by the control module This parameter displ
487. ration Conditions for Running the SPN 65723 2 and 65723 8 e SPN 630 65580 65620 or 65621 65622 or 65623 is not set The engine is cranking or running SPN 65723 runs continuously once the above conditions are met 65723 7 SPN 630 65580 65620 65621 65622 65623 is not set The engine speed is greater than 1 000 RPM SPN 65723 7 runs continuously once the above conditions are met Conditions for Setting the SPN 65723 2 The ECM detects an incorrect number of CMP reference pulses for greater than 49 engine revolutions 65723 7 The ECM detects the CMP sensor signal is out of range compared to the CKP sensor signal for greater than 49 engine revolutions 65723 8 The ECM does not detect a signal from the CMP sensor for greater than 49 engine revolutions Action Taken When the SPN Sets SPN 65723 is a Type B SPN Closed Loop not enabled Conditions for Clearing the SPN SPN 65723 is a Type B SPN 2011 Marine Engines Manual Diagnostic Aids The following conditions may also set the SPNs Physical damage to the CMP sensor or the reluctor wheel Excessive play or looseness of the CMP sensor or the reluctor wheel A distributor that is installed improperly Improper installation of the CMP sensor or the reluctor wheel Foreign material passing between the CMP sensor and the reluctor wheel Excessive air gap between the CMP sensor and the reluctor wheel Reference
488. rcuit SPN 655 FMI 3 Fuel Injector 5 Voltage Above Normal or Shorted High SPN 655 FMI5 Fuel Injector 5 Current Below Normal or Open Circuit SPN 656 FMI 3 Fuel Injector 6 Voltage Above Normal or Shorted High SPN 656 FMI5 Fuel Injector 6 Current Below Normal or Open Circuit SPN 657 FMI 3 Fuel Injector 7 Voltage Above Normal or Shorted High SPN 657 5 Fuel Injector 7 Current Below Normal or Open Circuit SPN 658 FMI 3 Fuel Injector 8 Voltage Above Normal or Shorted High SPN 658 FMI5 Fuel Injector 8 Current Below Normal or Open Circuit Circuit System Description The engine control module ECM enables the appropriate fuel injector pulse for each cylinder Ignition voltage is supplied to the fuel injectors The ECM controls each fuel injector by grounding the control circuit via a solid state device called a driver The ECM monitors the status of each driver Conditions for Running the SPN SPN 630 or 65580 is not set The ignition voltage is equal to or greater than 9 volts The SPNs 651 658 runs continuously once the above conditions are met for greater than 6 seconds Conditions for Setting the SPN The ECM detects that the commanded state of the driver and the actual state of the control circuit do not match for greater than 5 seconds Action Taken When the SPN Sets SPN 651 652 653 654 655 656 657 and 658 are Type B SPNs Closed loop not enabled SPN 651 652 653 654 655 656 657 and 6
489. rd Offset Adjustment 3 OL arid 9 255 Camshaft Retard Offset Adjustment GoL 5 oiean R 9 255 Crankshaft Position Sensor Replacement 3 0L 9 256 Crankshaft Position Sensor Replacement 4 3 5 0 5 7L 9 257 Crankshaft Position Sensor Replacement 6 0 6 2L 9 258 Crankshaft Position Sensor Replacement 2 4L 9 261 Camshaft Position Sensor Replacement 4 3 5 0 5 7I reet teet tke 9 262 Camshaft Position Sensor Replacement with CMP Actuator 9 268 Camshaft Position Sensor Replacement without CMP Actuator 9 269 Camshaft Position Sensor Replacement 2 41 ioo iiri 9 270 Camshaft Position Sensor Replacement 2 41 Exhaust tms 9 270 Camshaft Position Actuator Magnet Replacement 9 271 Camshaft Position Actuator Solenoid Valve Replacement 6 0 6 2L 9 272 Camshaft Position Actuator Solenoid Valve Replacement 2 4L 9 274 Camshaft Position Actuator Magnet Cleaning and Inspection 9 275 Camshaft Position Actuator Solenoid Valve Inspection 9 276 Knock Sensor Replacement Except 2 4L see 9 277 Knock Sensor Replacement 2 4L 9 278 Des
490. re and personal injury The towel will absorb any fuel leakage that occurs during the connection of the fuel pressure gauge Place the towel in an approved container when the connection of the fuel pressure gauge is complete Warning Fuel Vapors can collect while servicing fuel system components in enclosed areas such as the vessels cabin or engine compartment To reduce the risk of fire and increased exposure to vapors Use forced air ventilation such as a fan set outside of the vessels engine compartment Plug or cap any fuel system openings in order to reduce fuel vapor formation Clean up any spilled fuel immediately Avoid sparks and any source of ignition Use signs to alert others in the work area that fuel system work is in process 1 Remove the fuel rail pressure fitting cap 2 Connect the J 34730 1A or the J 34730 FF to the fuel pressure valve Wrap a shop towel around the fitting while connecting the gauge in order to avoid spillage 3 Install the bleed hose on the J 34730 the J 34730 FF into an approved container Removal Procedure 1 Remove the bleed hose on the J 34730 or the J 34730 FF from the approved container 2 Remove the shop towel from around the fitting and discard into an approved container 3 Disconnect the J 34730 1A or the J 34730 FF from the fuel pressure valve 4 Install the fuel rail pressure fitting cap 2011 Marine Engines Manual Engine Controls and Fue
491. rease the air to fuel ratio The ECM holds this injector rate as long as the throttle stays wide open and the engine speed is below a predetermined RPM If the throttle is not held wide open the ECM returns to the starting mode Run Mode without Heated Oxygen Sensors HO2S On vehicles that are not equipped with heated oxygen sensors 25 the run mode is called Open Loop When the engine is first started and the engine speed is above a predetermined RPM the system begins Open Loop operation The ECM calculates the air fuel ratio based on inputs from the ECT MAP and TP sensors 9 286 Engine Controls and Fuel Marine Run Mode with Heated Oxygen Sensors HO2S On vehicles that are equipped with heated oxygen sensors HO2S the run mode has 2 conditions called Open Loop and Closed Loop When the engine is first started and the engine speed is above a predetermined RPM the system begins Open Loop operation The ECM ignores the signal from the heated oxygen sensors HO2S The ECM calculates the air fuel ratio based on inputs from the ECT MAP and TP sensors The system stays in Open Loop until meeting the following conditions Both front HO2S have varying voltage output showing that both HO2S are hot enough to operate properly The ECT sensor is above a specified temperature A specific amount of time has elapsed after starting the engine Specific values for the above conditions exist for each different engine
492. rence 65620 4 108 4 108 4 108 3 108 10 BARO Sensor Signal 108 4 108 4 108 4 108 3 108 10 Referense 08 3 108 10 Circuit System Description The engine control module ECM supplies 5 volts to the BARO sensor on a 5 volt reference circuit and provides a ground on a low reference circuit The BARO sensor provides a voltage signal to the ECM on a signal circuit relative to the changes in atmospheric pressure Conditions for Running the SPN 108 2 Before the ECM can report that SPN 108 2 failed SPNs 106 108 3 108 4 108 10 and 3563 must run and pass SPN 630 65580 65620 65621 65622 or 65623 is not set The engine speed is less than 150 RPM The ignition is ON The MAP and SCIP sensor correlation is within 5 kPa SPN 108 2 runs continuously when the conditions above exist 108 3 and 108 4 SPN 630 65580 65620 65621 65622 65623 is not set The ignition is ON or the engine is operating SPNs 108 3 and 108 4 run continuously when the above conditions are met 108 10 Before the ECM can report that SPN 108 10 failed SPNs 108 3 and 108 4 must run and pass SPN 630 65580 65620 65621 65622 or 65623 is not set 2011 Marine Engines Manual The ignition is ON or the engine is operating SPN 108 10 runs continuously when the above conditions are met Conditions for Setting the SPN 108 2 The ECM detects a differance of greater than 15 kPa
493. resistance reading to zero each time a resistance range is selected or changed 4 f you are not sure of the reading you expect to get always select the highest scale then reduce to allow an effective reading 5 When measuring current ensure the meter can handle the load and that the test leads are in the correct jacks 6 Treat the instrument with the respect it deserves Note Voltage readings are taken in parallel i e over the load Current readings are taken in series i e break the circuit and use meter leads to complete the open circuit Resistance Disconnect all external power which includes the discharging of capacitors in electronic components Selection Of Multimeters The best type of multimeter is one which has Internal protection so that it cannot be damaged if for example voltage is put through when the meter is set on ohms The fuse protects the meter and is the only thing that has to be replaced One that you can use to carry out a diode check facility which also provides an audible signal An audible signal when carrying out continuity checks A data hold facility so when a reading is taken that reading will remain on the display after the leads are removed A multimeter today also has to have a high impedance factor The common analogue type multimeter may be inadequate and may actually damage sensitive electronic circuitry Analogue meters due to their low internal resistance input impedance dra
494. rical fault or as a quick visual aid showing how the different symptoms and DTCs apply for the subsystem being diagnosed 6 6 Vehicle Diagnostic Information Even though all the DTCs and symptoms are shown in this table it does not mean they will all be diagnosed in the same procedure An example table from an engine coolant temperature ECT procedure Circuit ECT Sensor Signal Low Reference Short to Ground 110 4 110 3 110 3 110 15 __ Jp Wes pn Open High Resistance Short to Signal Voltage Performance Internal or sensor damage may occur if the circuit is shorted to B Typical Scan Tool Data The Typical Scan Tool Data table identifies a scan tool data parameter and its value in reference to potential circuit faults An example table from an ECT procedure ECT Sensor Short to Ground ShorttoVoltage Operating Conditions Engine operating in Closed Loop Parameter Normal Range Varies with ambient temperature 152 C 305 ECT Sensor Signal o Internal ECM or sensor damage may occur if the circuit is shorted to B Circuit System Description Circuit System Description identifies how circuit system normally functions Conditions for Running the DTC Conditions for Running the DTC identifies what conditions must be present to allow the diagnostic to run Conditions for Setting the DTC Conditions for Setting the DTC identifies the con
495. rmation with a scan tool SPN 65560 9 should not set 3 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 121 Circuit System Testing 1 Ignition OFF disconnect the harness connector at the OEM specific control module 2 Ignition ON test for 2 3 V between the following CAN circuit terminals and ground CAN HI Terminal CAN LO Terminal If less than the specified range test the appropriate circuit for an open If the circuit tests normal replace the ECM greater than the specified range test the appropriate circuit for a short to voltage If the circuit tests normal replace the ECM 3 If all circuits test normal replace the vehicle specific control module Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the repair Engine Control Module Programming and Setup on page 6 3 for engine control module replacement setup and programming 9 122 Engine Controls and Fuel Marine SPN 65561 65562 65563 or 65564 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach
496. rnings and Cautions could cause air bag deployment personal injury or otherwise unnecessary Supplemental Inflatable Restraint repairs In order to help avoid accidental air bag deployment and personal injury whenever you service a vehicle that requires repair of the Supplemental Inflatable Restraint and another vehicle system we recommend that you first repair the Supplemental Inflatable Restraint then go on to the other system 2011 Marine Engines Manual 2011 Marine Electronic Fuel Injection EFI Service Manual This manual provides information on the diagnosis the service procedures the adjustments and the specifications for the marine engines Because the marine engines cover a broad range of uses some of the instructions figures or references contained within this manual may not pertain to every customer or engine application This information is furnished to ensure completeness and is to be followed only where appropriate The technicians who understand the material in this manual better serve the vehicle owners When this manual refers to a brand name a part number or a specific tool you may use an equivalent product in place of the recommended item All information illustrations and specifications in this manual are based on the latest product information available at the time of publication approval General Motors LLC reserves the right to make changes at any time without notice Published by North Am
497. robe Adapter tan 280 Female round Probe Adapter tan 0 64 Male Probe Adapter It blue 0 64 Female Probe Adapter It blue 150 Male round Probe Adapter yellow 150 Female round Probe Adapter yellow Backprobe Backprobing can be a source of damage to connector terminals Use care in order to avoid Note deforming the terminal either by forcing the test probe too far into the cavity or by using too Backprobe connector terminals only when large of a test probe specifically required in diagnostic procedures After backerebi er backprobing any connector inspect for Do not backprobe a sealed Weather Pack terminal damage If terminal damage is suspected connector less than a 280 series Metri Pack test for proper terminal contact connector a Micro Pack connector or a flat wire connector Do not disconnect the connector and probe the terminals from the harness side back of the connector 2011 Marine Engines Manual 11 8 Wiring Systems Troubleshooting with a Digital Multimeter One of the most useful diagnostic tools is the digital multimeter These basic operating procedures for a multimeter may vary with the make of meter and the manufacturer s operating instructions should be read and understood before using the multimeter Use Of A Multimeter 1 Always turn meter OFF when not in use 2 Ensure the meter face reads zero 3 If applicable touch the leads together then adjust the
498. rol Module Replacement on page 9 217 for engine control module replacement setup and programming 9 120 Engine Controls and Fuel Marine SPN 65560 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 65560 FMI9 CAN Bus Governor Command Abnormal Update Rate Circuit System Description The controller area network CAN HI and CAN LO circuits transmit information between the engine control module ECM vessel specific control modules such as a helm control module and the scan tool Some vehicles are equipped with multiple engines that require a control module for each engine Information is transmitted between the ECMs via the CAN communication circuits The ECM monitors the CAN communication circuits for messages from control modules that are connected to the CAN Communication circuits Conditions for Running the SPN SPN 630 or 65580 is not set The ignition is ON or the engine is operating for greater than 6 seconds The ECM is not operating in CAN bus override mode SPN 65560 runs continuously when the above conditions are met Conditions for Setting the SPN The ECM does not receive a valid m
499. rve the fuel sample If any physical contaminants or water are present clean the fuel system Distributor Ignition DI System Diagnosis Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category Circuit System Description The distributor ignition DI system uses the crankshaft position CKP sensor in order to provide a timing input to the engine control module ECM Ignition control IC spark timing for each cylinder is based on this input The ECM provides the ignition timing signal to the ignition control module ICM to control the ignition coil Each timing pulse detected by the ICM allows it to energize the ignition coil A large secondary ignition voltage is induced in the secondary coil by the primary coil This high voltage is switched to the correct spark plug by the distributor Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Cond
500. s Batteries contain corrosive acid Batteries supply levels of electrical current high enough to cause burns Therefore in order to reduce the risk of personal injury while working near a battery observe the following guidelines Always shield your eyes Avoid leaning over the battery whenever possible 0 4 Dangers Warnings and Cautions Do not expose the battery to open flames or sparks Do not allow battery acid to contact the eyes the skin Flush any contacted areas with water immediately and thoroughly Get medical help Battery Disconnect Warning Warning Unless directed otherwise the ignition and start switch must be in the OFF or LOCK position and all electrical loads must be OFF before servicing any electrical component Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal Failure to follow these precautions may result in personal injury and or damage to the vehicle or its components For Vehicles equipped with OnStar with Back Up Battery The Back Up Battery is a redundant power supply to allow limited OnStar functionality in the event of a main vehicle battery power disruption to the OnStar module Do not disconnect the main vehicle battery or remove the OnStar fuse with the ignition key in any position other than OFF Retained accessory power RAP should be al
501. s Circuit System Verification Circuit System Testing and Component Testing However beginning with the Circuit System Verification category aids in determining if a vehicle condition is current Component Testing can offer static and or dynamic component tests These tests can be used to if a component is operating correctly to avoid unnecessary replacement Testing modules in this category will not be offered In most cases the module is used to verify the harness circuits in the Circuit System Testing category and a retest of the module should always be performed before replacement Repair Instructions Repair Instructions provides a link to Diagnostic Repair Verification on page 6 22 This link describes how to verify the vehicle is repaired All links to Repair or Replacement procedures are located here Repair Verification Repair Verification describes how to verify the vehicle is repaired when additional instructions are needed beyond what is in Diagnostic Repair Verification Non Scan Diagnosis of Driveability Concerns No DTCs Set If a driveability condition still exists after following the Powertrain OBD system check and reviewing the Symptoms tables a sensor that is stuck in range may be the cause In the case of a sensor or circuit malfunction the ECM will replace sensed values with calibrated default values This feature allows limited engine performance until the condition is repaired If a sens
502. s and Poor Connections on page 11 13 Wiring Repairs page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 2011 Marine Engines Manual Circuit System Verification 1 Ignition ON command the appropriate DTC lamp ON and OFF with a scan tool The DTC lamp should turn ON and OFF as commanded 2 Observe the SPN information with a scan tool SPN 66006 66008 or 66009 should not set 3 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Ignition ON verify that no other indicators are inoperative If any other indicators are inoperative repair the ignition supply voltage circuit 2 Ignition OFF disconnect the ECM harness connectors 3 Ignition ON the DTC lamps should not illuminate DTC lamp illuminates test the appropriate DTC lamp control circuit for a short to ground 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 173 4 Ignition ON connect a 3 A fused jumper wire between ground and a DTC lamp control circuit terminal listed below DTC 1 lamp control circuit terminal X1 51 DTC 2 lamp control circuit terminal X3 9 lamp control circuit terminal X3 14
503. s and then stalls check for an open in the ground circuits of the CKP sensor and the camshaft position CMP sensor 9 202 Engine Controls and Fuel Marine Water or foreign material in the fuel can cause a no start or engine will not stay running condition During freezing weather water can freeze inside the fuel system Extreme weather conditions can cause contaminated fuel to prevent the vehicle from starting A vehicle that starts and runs after being brought to the repair shop for a no start condition may have an ignition system that is susceptible to moisture Spray water on the ignition system components and the wiring in order to check for an engine starting or will not stay running concern Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs page 11 16 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Special Tools e J 34730 1A Fuel Pressure Gauge J 26792 Spark Tester e J 34730 405 Injector Test Lamp Circuit System Verification Note This diagnostic assumes the following The battery is completely ch
504. s fuel economy and emissions Fuel Pressure Regulator The type of fuel system return or returnless will vary depending on year and engine Returnless fuel systems are not regulated at the fuel rail Fuel pressure regulation is controlled at the module outlet filter therefore the type of fuel system can be determined by the number of fuel lines to the fuel rail The fuel pressure regulator controls the fuel pressure that is delivered to the fuel injectors Fuel Metering Modes of Operation The engine control module ECM monitors voltages from several sensors in order to determine how much fuel to give the engine The ECM controls the amount of fuel delivered to the engine by changing the fuel injector pulse width The fuel is delivered under one of several modes Starting Mode When the ignition is first turned ON the ECM energizes the fuel pump relay for 2 seconds This allows the fuel pump to build pressure in the fuel System The ECM calculates the air fuel ratio based on inputs from the engine coolant temperature ECT manifold absolute pressure MAP and throttle position TP sensors The system stays in starting mode until the engine speed reaches a predetermined RPM Clear Flood Mode If the engine floods clear the engine by pressing the accelerator pedal down to the floor and then crank the engine When the TP sensor is at wide open throttle WOT the ECM reduces the fuel injector pulse width in order to inc
505. s of the rotors are held in position by deep groove ball bearings while the rear ends of the rotors are supported by sealed roller bearings The gears and ball bearings are lubricated by a synthetic oil The oil reservoir is self contained in the supercharger isolated from the engine oil sealed for the life of the unit and is not serviceable The cover on the supercharger contains the input shaft which is supported by 2 deep groove ball bearings and is coupled to the rotor drive gears The pulley is pressed onto the input shaft and is not serviceable The bearings are lubricated by the synthetic oil contained in the same reservoir Operation The supercharger is designed to increase the air pressure and density in the intake manifold When this air is mixed with the correct amount of fuel the result is more power from the engine This excess air creates a boost pressure in the intake manifold Because the supercharger is a positive displacement pump and is directly driven from the engine drive belt system boost pressure is available at all driving conditions When boost is not required such as during idle or light throttle cruising the excess air is routed through the bypass passage between the intake manifold and the supercharger inlet This bypass circuit is regulated by a bypass valve which is similar to a throttle plate The bypass valve is controlled by a vacuum actuator which is connected to the vacuum signal between the thr
506. s that you observed from the Freeze Frame Failure Records data 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 97 Circuit System Testing 1 Ignition OFF disconnect the harness connector at the EOT sensor 2 Test for less than 5 between the low reference circuit terminal and ground If greater than the specified range test the low reference circuit for an open high resistance If the circuit tests normal replace the ECM 3 Ignition ON test for 4 8 5 2 V between the 5 V reference circuit terminal and ground lf less than the specified range test the circuit for a short to ground or an open high resistance If the circuit tests normal replace the ECM greater than the specified range test the circuit for a short to voltage If the circuit tests normal replace the ECM 4 f all circuits test normal replace the engine oil level and temperature sensor Component Testing 1 Connect a DMM between the signal and low reference circuit terminals 2 Verify the engine oil level and temperature sensor resistance is between 400 500 Q at 21 70 F lf the resistance is outside the specified range replace the engine oil level and temperature sensor Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 9 98 Engine C
507. s under which the customer concern occurred to verify the repair If the customer concern reoccurs return to Symptoms Engine Controls on page 9 199 and perform the appropriate symptom diagnostic E 2011 Marine Engines Manual Table of Contents 9 1 Section 9 Engine Engine Controls and Fuel Marine 9 3 SPN 65541 65542 65543 65544 Specifications 9 3 65545 65546 65547 65548 9 113 Temperature Versus Resistance 9 3 SPN 65550 65551 65552 9 115 Altitude Versus Barometric Pressure 9 3 SPN 65555 9 117 Ignition System Specifications 2 4L 9 4 SPN 65558 or 65559 iiem en 9 118 Ignition System Specifications 3 0L 9 4 OPN 65560 9 120 Ignition System Specifications SPN 65561 65562 65563 or 65564 9 122 4 3L 5 01 5 7L 9 4 SPN 65565 or 65566 9 125 Ignition System Specifications SPN 65567 65568 ceu 9 127 COL 01 6 2 9 4 SPN 65570 6 0 6 2L 9 129 Fastener Tightening Specifications 9 5 SPN 65570 65571 65572 Schematic and Routing Diagrams 9 5 65579 2 4L acceder etre erae 9 132 Engine Controls Schematics 9 6 SBPN
508. se The engine control module ECM supplies the ground path to the relay coil control circuit with a low side driver When the engine is operating the ECM commands the relay ON which allows B through the relay switch contacts to the supercharger intercooler pump Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 2011 Marine Engines Manual Special Tools Required J 43244 Relay Puller Pliers Circuit System Verification 1 Cycle the ignition from OFF to ON You should hear and feel an audible click from the supercharger intercooler coolant pump relay Repeat as necessary in order to verify supercharger intercooler relay operation Cycle the ignition from OFF to ON You should hear and feel the supercharger intercooler coolant pump operate Circuit System Testing 1 2 Ignition OFF disconnect the supercharger intercooler coolant pump relay with the J 43244 Ignition ON verify a test lamp illuminates between the voltage supply circuit terminals 30 and 85
509. sensor SPN 106 2 4L 6 0L 6 2L Ignition ON engine OFF MAP MAP Sensor parameter with 5 inches MAP Sensor parameter with Sensor parameter of vacuum applied 10 inches of vacuum applied 100 kPa 79 87 kPa 62 70 kPa 95 kPa 74 82 kPa 57 65 kPa Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Manifold Absolute Pressure Sensor Replacement without Supercharger on page 9 220 Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 89 SPN 108 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 108 FMI 2 Barometric Pressure BARO Sensor Voltage Data Erratic Intermittent or Incorrect SPN 108 FMI 3 Barometric Pressure BARO Sensor Voltage Above Normal or Shorted High SPN 108 FMI 4 Barometric Pressure BARO Sensor Voltage Below Normal or Shorted Low SPN 108 FMI 10 Barometric Pressure BARO Sensor Abnormal Rate of Change Diagnostic Fault Information Short to High Short to Signal Circuit Ground Resistance Voltage Performance 5 Volt Refe
510. set You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Ignition OFF disconnect the harness connector at the MAT sensor 2 Test for less than 5 between the low reference circuit terminal B and ground If greater than the specified range test the low reference circuit for an open high resistance If the circuit tests normal replace the ECM 3 Ignition ON verify the scan tool MAT sensor parameter is at 40 40 F lf warmer than the specified range test the signal circuit terminal A for a short to ground If the circuit tests normal replace the ECM Note If the fuse in the jumper wire opens the signal circuit is shorted to a voltage and the sensor may be damaged 4 Connect a 3 A fused jumper wire between the signal circuit terminal A and ground Verify the scan tool MAT sensor parameter is warmer than 129C 264 F colder than the specified range test the signal circuit for a short to voltage or an open high resistance If the circuit tests normal replace the ECM 5 f all circuits test normal test or replace the MAT sensor Component Testing 1 Ignition OFF disconnect the harness connector at the MAT sensor Note A thermometer can be used to test the sensor off the vehicle 2 Test the MAT sensor by varying the sensor temperature while monitoring the sensor resistance Compare the readings wi
511. signal to the boost control solenoid The boost control solenoid is a normally open valve Under most conditions the ECM commands the boost control solenoid to 99 100 percent This keeps the boost control solenoid valve closed and allows only inlet vacuum from the supercharger plenum to the bypass valve actuator to control the position of the bypass valve At idle engine vacuum is applied to the upper side of the bypass valve actuator counteracting spring tension to hold the bypass valve open When the engine load increases the engine vacuum decreases allowing the spring in the bypass valve actuator to overcome the applied vacuum This closes the bypass valve and allows the boost pressure to increase When reduced boost pressure is desired the ECM decreases the boost control solenoid duty cycle This opens the boost control solenoid and allows boost pressure to enter the bypass valve actuator at the lower side to counteract the spring tension When the bypass valve opens excess boost pressure is re circulated back into the supercharger inlet 9 206 Engine Controls and Fuel Marine Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views page 9 33 Description and Operation Supercharger Description and Operation on page 9 282 Electrical Information Reference Circuit Te
512. so that any circuit which may be sensitive to moisture will more readily fail when liberally sprayed with this mixture Mixing 0 35L 12 oz of water with approximately 1 tablespoon of salt will yield a salt solution of 5 percent Fill a normal spray bottle with this mixture This mixture is sufficient to enhance the water s own conductivity This may cause the circuit to fail more easily when sprayed Once the mixture is completed spray the suspect area liberally with the solution Then while monitoring either a scan tool or DMM manipulate the harness as discussed previously High Temperature Conditions Tools Required J 25070 Heat Gun If the complaint tends to be heat related you can simulate the condition using the J 25070 Using the heat gun you can heat up the suspected area or component Manipulate the harnesses under high temperature conditions while monitoring the scan tool or DMM to locate the fault condition The high temperature condition may be achieved simply by test driving the vehicle at normal operating temperature If a heat gun is unavailable consider this option to enhance your diagnosis This option does not allow for the same control however Low Temperature Conditions Depending on the nature of the fault condition placing a fan in front of the vehicle while the vehicle is in the shade can have the desired effect If this is unsuccessful use local cooling treatments such as ice or a venturi typ
513. sonator 3 Remove the accelerator controls cable 4 Remove the radiator inlet hose 2211680 1 Lubricate the new lower injector O ring seals with clean engine oil 2 Install the new O ring seals on the spray tip end of each injector 3 Install the fuel rail assembly to the cylinder head 4 Apply a 0 5 mm 0 020 in band of GM P N 12345382 Canadian P N 10953489 threadlock or equivalent to the threads of the fuel rail bolts Caution Refer to Fastener Caution on page 0 5 12885 5 Install the fuel rail attaching bolts 5 Disconnect the electrical connector from the ins throttle body assembly Tighten Tighten the fuel rail attaching bolts to 10 N m 89 lb in 6 Connect the injector electrical connectors Install each connector on the proper injector in order to ensure correct sequential injector firing order Rotate the injectors as required in order to avoid stretching the wire harness 7 Connect the fuel feed hose to the fuel rail fuel pipe 8 Connect the negative battery cable 9 Inspect for leaks 9 1 Turn ON the ignition for 2 seconds 9 2 Turn OFF the ignition for 10 seconds 9 3 Turn ON the ignition 9 4 Inspect for fuel leaks 735711 6 Disconnect the electrical connectors 2 from the fuel injectors using the following procedure 6 1 Pull upwards on the CPA retainer 6 2 Pinch the connector to unlock 6 3 Disconnect the connector from the fuel injector 2011
514. spark plug boot for damage Inspect the spark plug recess area of the cylinder head for moisture such as oil coolant or water A spark plug boot that is saturated causes arcing to ground 622528 3 Inspect the insulator 2 for cracks All or part of the electrical charge may arc through the crack instead of the electrodes 3 4 622527 4 Inspect 3 for evidence of improper arcing Measure the gap between the center electrode 4 and the side electrode 3 terminals An excessively wide electrode gap can prevent correct spark plug operation Inspect for the correct spark plug torque Insufficient torque can prevent correct spark plug operation An over torqued spark plug causes the insulator 2 to crack Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode 4 Inspect for a broken or worn side electrode 3 Inspect for a broken worn or loose center electrode 4 by shaking the spark plug A rattling sound indicates internal damage A loose center electrode 4 reduces the spark intensity Inspect for bridged electrodes 3 4 Deposits on the electrodes 3 4 reduce or eliminates the gap Inspect for worn or missing platinum pads on the electrodes 3 4 if equipped Inspect for excessive fouling 5 Inspect the spark plug recess area of the cylinder head for debris Dirty or damaged threads can cause the spark plug not to seat corr
515. ss than 0 39 volts for greater than 3 seconds 100 17 The ECM detects that the engine oil pressure is less than a calibrated range based on engine speed for greater than 5 seconds Action Taken When the SPN Sets SPN 100 3 and 100 4 are SPNs SPN 100 17 is a Type C SPN Cam phaser not enabled Conditions for Clearing the SPN SPN 100 3 and 100 4 are SPNs e SPN 100 17 is a Type C SPN Diagnostic Aids If a shared 5 volt reference circuit is shorted to ground or shorted to a voltage other 5 volt reference circuits may be affected Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification 1 Ignition ON observe the SPN information with a scan tool Verify that SPN 65620 65621 65622 or 65623 is not set If an SPN is set refer to SPN 65620 65623 page 9 149 2 Engine operating observe the SPN informatio
516. ss valve actuator at the lower side to counteract the spring tension opening the bypass valve and re circulating excess boost pressure back into the supercharger inlet Results of Incorrect Operation The following conditions will result in reduced engine power especially during a wide open throttle WOT operation An open boost control solenoid control circuit An open control solenoid ignition 1 voltage circuit An open control solenoid control circuit A boost control solenoid valve that is stuck open The following conditions will result in full boost to be commanded at all times These conditions can also result in over boost conditions during high engine load situations A boost control solenoid control circuit shorted to ground A boost control solenoid valve is stuck closed A restriction in the boost source or signal vacuum hoses A restriction in the exhaust system may cause over boost condition and reduced fuel economy A restriction in the vacuum signal hose to the bypass valve actuator or stuck closed bypass valve will cause a noisy idle and reduced fuel economy Fuel System Description Fuel System Overview Low Pressure Fuel Pump The low pressure fuel pump supplies low pressure high volume fuel flow to the high pressure fuel pump The low pressure fuel pressure pump maintains a constant flow of fuel to the high pressure fuel pump in order to prevent long cranking
517. ssion gear position or range information sensors The engine knock sensors KS Modes of Operation There is one normal mode of operation with the spark under ECM control If the CKP pulses are lost the engine will not run The loss of a CMP signal may result in a longer crank time since the ECM cannot determine which stroke the pistons are on Diagnostic trouble codes are available to accurately diagnose the ignition System with a scan tool 2011 Marine Engines Manual Special Tools and Equipment WMustration ____ Number Description 26792 Spark Tester J 34730 1A Fuel Pressure Gauge CH 48027 5 Digital Pressure Gauge J 35616 GM Approved Terminal Test Kit J 35616 200 Test Light Probe Kit 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 289 Illustration Tool Number Description J 37088 A Fuel Line Disconnect Tool Set J 37287 Fuel Line Shut Off Adapters J 39021 Fuel Injector Coil Balance Tester J 43244 Relay Puller Pliers J 44602 Injector Test Adapter 9 290 Engine Controls and Fuel Marine illustration Tool Number Description illustration Tool Number Description 47814 Supercharger Bypass valve Actuator Setting Tool J 44603 Injector Test Lamp J 41712 EN 47748 Oil Pressure Switch Socket Supercharger Lifting Fixture J 23738 A Mityvac Vacuum Pump 2011 Marine Engines Manual Table of Contents 11 1 Section
518. st for battery voltage between the battery positive voltage circuit terminal X1 20 and ground If not within the specified range test the battery positive voltage circuit for a short to ground or an open high resistance 3 If all circuits test normal replace the ECM Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 2011 Marine Engines Manual SPN 630 65580 65581 65582 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 630 FMI 13 Cal Memory Out of Calibration Engine Controls and Fuel Marine 9 99 SPN 65580 12 CPU Bad Intelligent Device or Component SPN 65581 12 MHC Failure Bad Intelligent Device or Component SPN 65582 FMI 2 NV RAM Failure Data Erratic Intermittent or Incorrect Circuit System Description This diagnostic applies to the integrity of the engine control module s ECM internal microprocessor and the throttle actuator control TAC system This diagnostic also addresses is Not Programmed conditions
519. stic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptor Engine Controls and Fuel Marine 9 151 SPN 65675 FMI 11 Catalytic Converter A Efficiency Root Cause Unknown SPN 65676 FMI 11 Catalytic Converter B Efficiency Root Cause Unknown Circuit System Description A 3 way catalytic converter TWC controls emissions of hydrocarbons HC carbon monoxide CO and oxides of nitrogen NOx The catalyst within the converter promotes a chemical reaction which oxidizes the HC and the CO that are present in the exhaust gas This process converts the HC and the CO into water vapor and carbon dioxide CO2 and reduces the NOx converting the NOx into nitrogen The catalytic converter also stores oxygen The engine control module ECM monitors this process by using a heated oxygen sensor HO2S that is in the exhaust stream after the TWC The HO2S 2 produces an output signal that the ECM uses to calculate the oxygen storage capacity of the catalyst This indicates the ability of the catalyst to convert the exhaust emissions efficiently The ECM monitors the efficiency of the catalyst by allowing the catalyst to heat then wait for a stabilization perio
520. sting on 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs page 11 16 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 for scan tool information Special Tools J 23738 A Mityvac Circuit System Verification 1 Ignition OFF inspect the supercharger vacuum lines for any of the following conditions Cracking Loose fit Improper connections Improper routing Restrictions 2 Inspect the following components for damage and for improper connections improper adjustments and improper installation The bypass valve actuator The boost control solenoid The bypass valve lever The bypass valve cable 3 Verify that the supercharger coolant pump coolant level is full 4 Ignition ON command the supercharger coolant pump ON with a scan tool Listen for the supercharger coolant pump to turn ON for 2 seconds and then OFF gt If the supercharger coolant pump does not turn ON and OFF refer to Supercharger Intercooler Relay Diagnosis on page 9 204 5 Verify there are no vacuum leaks at the supercharger manifold gaskets and supercharger intake plenum Circuit System Testing 1 Ignition OFF disconnect the boost source hose from the boost control solenoid Connect the J 23738 A to the boost source hose 2 Engine idling verify that greater than 15 inch Hg is
521. stment page 9 132 Misfire Mechanical System Not SPN 65590 65591 65592 65593 65594 65595 Responding or Out of Adjustment 65596 65597 65598 or 65599 on page 9 139 Misfire Cylinder 1 Mechanical System SPN 65590 65591 65592 65593 65594 65595 Not Responding or Out of Adjustment 65596 65597 65598 or 65599 on page 9 139 Misfire Cylinder 3 Mechanical System SPN 65590 65591 65592 65593 65594 65595 Not Responding or Out of Adjustment 65596 65597 65598 or 65599 on page 9 139 Misfire Cylinder 4 Mechanical System SPN 65590 65591 65592 65593 65594 65595 Not Responding or Out of Adjustment 65596 65597 65598 or 65599 on page 9 139 Misfire Cylinder 5 Mechanical System SPN 65590 65591 65592 65593 65594 65595 Not Responding or Out of Adjustment 65596 65597 65598 or 65599 on page 9 139 Misfire Cylinder 7 Mechanical System SPN 65590 65591 65592 65593 65594 65595 Not Responding or Out of Adjustment 65596 65597 65598 or 65599 on page 9 139 Misfire Cylinder 8 Mechanical System SPN 65590 65591 65592 65593 65594 65595 Not Responding or Out of Adjustment 65596 65597 65598 or 65599 on page 9 139 Misfire Random Mechanical System Not SPN 65590 65591 65592 65593 65594 65595 Responding or Out of Adjustment 65596 65597 65598 or 65599 on page 9 139 ae TPS 2 Data Erratic Intermittent or SPN 65601 65602 or 65610 on page 9 141 ncorrect TPS 1 Data Erratic Intermittent SPN 65601 65602 or 6561
522. structions on page 6 5 provides an overview of each diagnostic category 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 215 Circuit System Description Ignition 1 voltage is supplied to the ignition coil The engine control module ECM provides a ground for the ignition coil IC control circuits When the ECM removes the ground path of the ignition primary coil the magnetic field produced by the coil collapses The collapsing magnetic field produces a voltage in the secondary coil which ignites the spark plugs The sequencing and timing are controlled by the ECM Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs page 11 16 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Testing Note Do not perform this diagnostic procedure if you were not sent here from a misfire DTC or the Engine Cranks but Does Not Run diagnostic 1 Ignition OFF disconnect the harness connector at the ignition coil 2 Test for less than 2 between the ground circuit terminal A 1 and ground gt If gr
523. sure good electrical connection 2 Follow the instructions for splicing copper wire Twisted or shielded cable is used to protect wiring from electrical noise Two conductor cable is used between the radio and the Delco Bose speaker amplifier units and other applications where low level sensitive signals must be carried Step 1 Strip the Cable and splice the drain wire 1 Remove the outer jacket 1 Use care not to cut 3 Wrap the drain wire around the conductors and into the drain wire 2 of the mylar tape 3 tape with mylar tape 1 1 3 2 1683739 1683742 2 Unwrap the mylar tape Do not remove the tape Step 4 Tape the Joint because it will be used to re wrap the conductors Tape over the entire cable using a winding motion after the splice has been made while applying the tape Step 2 Prepare the Splice 1 Straighten the conductors and stagger the splices by 65 mm TEDO 1683740 1683745 Connector Repairs The following general terminal removal procedures can be used on most types of connectors The removal 2 Follow the instructions for splicing copper wire procedures are divided into three general groups Push to Seat Pull to Seat and Weather Pack 2011 Marine Engines Manual Wiring Systems 11 23 Push to Seat Connectors 3 Locking Tang Push to Seat connectors are those which have the 4 Insertion Direction terminal inserted in the rear of the connector body when assembled Repa
524. t emissions performance 2011 Marine Engines Manual Conditions for Running the SPN Before the ECM can report that SPN 65567 or 65568 failed SPNs 106 110 and 65561 65562 65563 and 65564 must run and pass SPN 94 105 630 651 658 65541 65548 65580 or 65590 655989 is not set The engine is operating for greater than 60 seconds The coolant temperature is warmer than a 60 140 F The engine speed is between 2 000 4 500 RPM The MAP is between 35 80 kPa The engine is operating in Closed Loop The is not performing an intrusive catalyst test SPNs 65567 and 65568 run continuously once the above conditions are met for greater than 20 seconds Conditions for Setting the SPN The engine control module ECM detects that the HO2S rich to lean average response time is greater than 309 mS The engine control module ECM detects that the HO2S lean to rich average response time is greater than a 281 mS Either condition exists for greater than 20 seconds Action Taken when the SPN Sets SPNs 65567 and 65568 are Type B SPNs 9 128 Engine Controls and Fuel Marine Conditions for Clearing the SPN SPNs 65567 and 65568 are Type B SPNs Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information
525. t circuit may be caused by damaged wire insulation If the damage is minor locate the problem and tape over the wire If the damage is more extensive replace the faulty segment of the wire Refer to the following list of instructions to repair copper wire and shielded cables Flat Wire Repairs on page 11 17 Heated Oxygen Sensor Wiring Repairs on page 11 17 Splicing Copper Wire Using Splice Clips on page 11 17 Splicing Copper Wire Using Splice Sleeves on page 11 21 Splicing Twisted or Shielded Cable on page 11 22 Wire Size Conversion Table 2011 Marine Engines Manual Splice Sleeve Crimp Tool Nest Wire Gauge Color Color AWG Metric 22 26 0 2 0 35 Green Salmon M 0 35 0 8 Flat Wire Repairs Caution The flat wire within the flex wiring harness is not serviceable If an open or short exists within the flex wiring harness the complete harness must be replaced Heated Oxygen Sensor Wiring Repairs Caution Do not solder repairs under any circumstances as this could result in the air reference being obstructed If the heated oxygen sensor pigtail wiring connector or terminal is damaged the entire oxygen sensor assembly must be replaced Do not attempt to repair the wiring connector or terminals In order for the sensor to function properly it must have a clean air reference This clean air reference is obtained by way of the oxygen sensor signal and heater wires Any attempt to r
526. t not set a DTC Comparing the sensor s readings with those of a known good identical vehicle may uncover the condition Proper use of the scan tool will save time in diagnosis and prevent the replacement of good parts It is important for the technician to understand the system that is being diagnosed as well as an understanding of the scan tool operation and limitations The technician should read the tool manufacturer s operating manual to become familiar with the tool s operation Diagnostic Repair Verification 1 Install any components or connectors that have been removed or replaced during diagnosis 2 Perform any adjustment programming or setup procedures that are required when a component or module is removed or replaced 3 Clear the SPNs Turn OFF the ignition for 60 seconds If the repair was related to a SPN duplicate the Conditions for Running the SPN and use the Freeze Frame Failure Records if applicable in order to verify the SPN does not reset If the SPN resets or another SPN is present refer to the Diagnostic Trouble Code List on page 6 11 and perform the appropriate diagnostic procedure 6 Observe the Expanded Diagnostic Readiness Data to verify the SPN has run and passed If the SPN has run and passed the SPN will not appear in the list If a SPN diagnostic has not run or runs and fails the SPN will remain in the list 7 If the repair was symptom related duplicate the condition
527. t reference circuit terminal 2 Verify the scan tool Oil Pressure Sensor Voltage parameter is greater than 4 9 V If less than the specified range test the signal circuit for a short to ground or for an open high resistance If the circuit tests normal replace the ECM 6 Ignition OFF install a mechanical engine oil pressure gauge 7 Engine idling verify the oil pressure is within 41 414 kPa 6 60 psi If not within the specified range repair the engine mechanical condition 8 If all circuits test normal replace the EOP sensor Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Engine Oil Pressure Sensor Replacement page 9 225 Engine Control Module Replacement on page 9 217 for engine control module replacement setup and programming 2011 Marine Engines Manual SPN 105 3 0L 4 3L 5 0L 5 7L Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 105 FMI 3 SPN 105 FMI 4 SPN 105 FMI 15 Range Least Severe Level Diagnostic Fault Information Engine Controls and Fuel Marine 9 79 Manifold Air Temperature MAT Senso
528. t within the specified range replace the powertrain relay 3 Test for infinite resistance between the following terminals 30 and 86 30 and 87 30 and 85 85 and 87 If not the specified value replace the relay 4 Install a 20 A fused jumper wire between relay terminal 85 and Install a jumper wire between relay terminal 86 and ground Test for less than 2 between terminals 30 and 87 If greater than the specified range replace the powertrain relay Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Relay Replacement Fuse Block on page 11 28 or Replacement Harness on page 11 29 Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 9 182 Engine Controls and Fuel Marine SPN 66017 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 66017 FMI 4 SPN 66017 FMI 5 Diagnostic Fault Information Fuel Pump Relay 1 Voltage Below Normal or Shorted Low Fuel Pump Relay 1 Current Below Normal or Open Circuit Short to Open High Short to Signal Circuit Ground Resistance Vo
529. te the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Ignition OFF disconnect the harness connector at the tachometer 2 Ignition ON test for greater than 11 V from the tachometer circuit gt If less than the specified range test the tachometer driver circuit and tachometer pull up circuit for an open or a short to ground If the circuits test normal replace the ECM 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 185 3 Engine idling test for 4 7 V from the tachometer circuit If greater than the specified range test the tachometer driver circuit and tachometer pull up circuit for a short to voltage If the circuit tests normal replace the ECM 4 f all circuits test normal replace the tachometer Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 9 186 Engine Controls and Fuel Marine SPN 66019 66020 66021 or 66022 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis page 6 4 for an overview of the diagnost
530. tects the presence of certain boost system components This parameters displays the actual amount CAM Angle in camshaft degrees of camshaft actuation as measured by the control module This parameters displays the actual amount CAM W Angle in camshaft degrees of camshaft actuation as measured by the control module This parameters displays the CAM Phaser CAM W Phaser 0 0 duty cycle as commanded by the control Duty Cycle module 2011 Marine Engines Manual BARO Pressure Varies with altitude Battery Voltage Engine Controls and Fuel Marine 9 55 Engine Control Module Scan Tool Data cont d System State Expected Value This parameters displays the CAM Phaser CAM W Phaser Varies reference angle as determined by the control Ref Angle module based on inputs from the CMP and CKP sensors This parameters displays the actual amount CAM X Angle in camshaft degrees of camshaft actuation as measured by the control module This parameters displays the CAM Phaser PME ee 0 0 duty cycle as commanded by the control y Sy module This parameters displays the CAM Phaser CAM X Phaser Varies reference angle as determined by the control Ref Angle module based on inputs from the CMP and CKP sensors This parameter displays YES when the Power control module is operating in reduced power mode Check Engine Lamp OFF This parameter displays the control module Output commanded state of the MIL control circuit This parameter displays the
531. th the Temperature Versus Resistance on page 9 3 table and verify that the resistance is within 5 percent of the specification If not within the specified range replace the MAT sensor Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Manifold Air Temperature Sensor Replacement on page 9 218 Engine Control Module Replacement on page 9 217 for engine control module replacement setup and programming 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 83 SPN 106 3 0L 4 3L 5 0L 5 7L Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 106 FMI 0 Manifold Absolute Pressure MAP Sensor Circuit Voltage Data Valid But Above Normal SPN 106 FMI 1 Manifold Absolute Pressure MAP Sensor Circuit Voltage Data Valid But Below Normal SPN 106 FMI 3 Manifold Absolute Pressure MAP Sensor Circuit Voltage Above Normal or Shorted High SPN 106 FMI 4 Manifold Absolute Pressure MAP Sensor Circuit Voltage Below Normal or Shorted Low Diagnostic Fault Information Short to Open High Short to Signal Circuit Ground Resistance Voltage Performance
532. the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 65541 FMI 4 SPN 65541 FMI 5 SPN 65542 FMI 4 SPN 65542 FMI 5 SPN 65543 FMI 4 SPN 65543 FMI 5 SPN 65544 FMI 4 SPN 65544 FMI 5 SPN 65545 FMI 4 SPN 65545 FMI 5 SPN 65546 FMI 4 SPN 65546 FMI 5 SPN 65547 FMI 4 SPN 65547 FMI 5 SPN 65548 FMI 4 SPN 65548 FMI 5 Ignition Coil 1 Voltage Below Normal or Shorted Low Ignition Coil 1 Current Below Normal or Open Circuit Ignition Coil 2 Voltage Below Normal or Shorted Low Ignition Coil 2 Current Below Normal or Open Circuit Ignition Coil 3 Voltage Below Normal or Shorted Low Ignition Coil 3 Current Below Normal or Open Circuit Ignition Coil 4 Voltage Below Normal or Shorted Low Ignition Coil 4 Current Below Normal or Open Circuit Ignition Coil 5 Voltage Below Normal or Shorted Low Ignition Coil 5 Current Below Normal or Open Circuit Ignition Coil 6 Voltage Below Normal or Shorted Low Ignition Coil 6 Current Below Normal or Open Circuit Ignition Coil 7 Voltage Below Normal or Shorted Low Ignition Coil 7 Current Below Normal or Open Circuit Ignition Coil 8 Voltage Below Normal or Shorted Low Ignition Coil 8 Current Below Normal or Open Circuit Diagnostic Fault Information Circuit ELE me Ignition Voltage O eee em Ignition Coil 2 Control Circuit 655424 655
533. the oxygen content of the surrounding air with the oxygen content of the exhaust stream The HO2S samples the oxygen content of the exhaust stream as it passes the sensor When the engine is started the control module operates in an Open Loop mode ignoring the HO2S signal voltage while calculating the air to fuel ratio The control module supplies the HO2S with a reference or bias voltage of about 450 mV When the engine is operating the exhaust stream warms the HO2S which affects the resistance of the sensing element During normal operation the temperature of the exhaust stream fluctuates according to oxygen content of the stream which causes the bias voltage to increase or decrease in a range of 0 1 000 mV Once sufficient HO2S voltage fluctuation is observed by the control module Closed Loop is entered The control module uses the HO2S signal voltage to determine and vary the delivered air to fuel ratio based in part on the oxygen content of the exhaust An HO2S voltage that increases above bias voltage toward 1 000 mV indicates a rich fuel mixture An HO2S voltage that decreases below the bias voltage toward 0 mV indicates a lean fuel mixture The heating elements inside each HO2S heats the sensor to bring the sensor up to operating conditions faster This allows the system to enter Closed Loop earlier and the control module to calculate the air to fuel ratio sooner which reduces fuel consumption and improves the vessels exhaus
534. the various serial data parameters and to display SPN information Malfunction Indicator Lamp MIL The malfunction indicator lamp MIL is located on the instrument panel cluster IPC The MIL is controlled by the engine control module ECM and illuminates when the ECM detects a condition that affects the vehicle emissions ECM Service Precautions The engine control module ECM is designed to withstand the normal current draws that are associated with vehicle operation Care must be used in order to avoid overloading any circuits during testing Do not ground or apply voltage to any ECM circuits unless a diagnostic procedure instructs you to do so Circuits should only be tested with a DMM Throttle Actuator Control TAC System Description Purpose The throttle actuator control TAC system delivers improved throttle response and greater reliability and eliminates the need for mechanical cable The TAC system performs the following functions Pedal position sensing Throttle positioning to meet driver and engine demands Throttle position sensing Internal diagnostics Cruise control functions Manage TAC electrical power consumption 9 280 Engine Controls and Fuel Marine The TAC system includes the following components The pedal position sensors The throttle body assembly The engine control module ECM Pedal Position Sensor The pedal position sensor contains 2 individual sensors within t
535. times High Pressure Fuel Pump The fuel pump supplies high pressure fuel through the fuel filter and the fuel feed pipe to the fuel injection system The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system The fuel pressure regulator maintains the correct fuel pressure to the fuel injection system The fuel pump and sender assembly contains a reverse flow check valve The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking times Fuel Level Sensor The fuel level sensor consists of a float a wire float arm and a ceramic resistor cord The position of the float arm indicates the fuel level The fuel level sensor contains a variable resistor which changes resistance in correspondence to the amount of fuel in the fuel tank The engine control module ECM sends the fuel level information via the class 2 circuit to the instrument panel I P cluster This information is used for the fuel gauge and the low fuel warning indicator if applicable The ECM also monitors the fuel level input for various diagnostics Fuel Pump The fuel pump is an electric high pressure pump Fuel is pumped to the fuel rail at a specified flow and pressure The fuel pump delivers a constant flow of fuel to the engine during low fuel conditions and aggressive vehicle maneuvers The engine control module ECM controls the
536. tion OFF swap the appropriate Camshaft Position Actuator Solenoid Valve with a Camshaft Position Actuator Solenoid Valve that is operating correctly Engine operating perform the Cam Phaser Cleaning procedure with a scan tool Verify SPN 65570 2 65570 7 65571 2 65571 7 65572 2 65572 7 65573 2 65573 7 does not reset If an SPN resets replace the mechanical camshaft position actuator If all circuits connections test normal test or replace the appropriate Camshaft Position Actuator Solenoid Valve Component Testing 1 Ignition OFF disconnect the harness connector at the appropriate Camshaft Position Actuator Solenoid Valve Test for 8 15 between the control terminal A and the low reference circuit terminal B of the Camshaft Position Actuator Solenoid Valve gt If not within the specified range replace the Camshaft Position Actuator Solenoid Valve Test for infinite resistance between each terminal and the Camshaft Position Actuator Solenoid Valve housing If not the specified value replace the Camshaft Position Actuator Solenoid Valve Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Camshaft Position Actuator Solenoid Valve Replacement 6 0 6 2L on page 9 272 or Camshaft Position Actuator Solenoid Valve Replacement 2 4L on page 9 274 Engine Control Module Replacement on page 9 217 for
537. tool should display ECM information for each engine 1 Ignition ON attempt to establish communication with the ECM The scan tool should display ECM information 2 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 119 Circuit System Testing 1 Ignition OFF verify a test lamp does not illuminate between the following CAN circuit terminals and CAN Terminal CAN LO Terminal D If the test lamp illuminates disconnect each module connected to the CAN circuit one at a time while observing the test lamp If the test lamp does not illuminate when a module is disconnected replace the module If the test lamp remains illuminated repair the appropriate circuit for a short to ground 2 Ignition ON test for 2 3 V between the following CAN circuit terminals and ground CANHI Terminal C CAN LO Terminal D lf less than the specified range repair the appropriate circuit for an open If the circuit tests normal replace the ECM If greater than the specified range test the appropriate circuit for a short to voltage If the circuit tests normal replace the ECM Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the repair Engine Cont
538. tow _ 51 towRefeene 1 SJ sos 0 1 0 9 Poss 5 CKP Sensor Signal _ 57 59 Sensor Signal _ Oil Pressure Sensor Signal _ ____ EGR Solenoid Valve 64 Position or Fuel Level Sensor Signal Engine Oil Temperature Sensor Signal HO2S Signal High Bank A Sensor 1 HO2S Signal High Bank B Sensor 1 m 92See Ho mn o Bank A Sensor 1 73 Engine Control Module 1590596 Connector Part Information Harness Engine OEM 15482787 Service 88988372 Description 73 Way F 64 2 8 Series Sealed BK Terminal Part Information Pins 27 43 44 55 63 64 Terminal Tray 33467 0003 23 Core Insulation Crimp H H Release Tool Test Probe J 38125 213 J 35616 64B L BU Pins 10 16 17 28 30 32 45 46 48 49 65 68 Terminal Tray 33467 0005 23 Core Insulation Crimp J J Release Tool Test Probe J 381 25 21 3 J 35616 64B L BU Engine Control Module ECM X3 Pin Wire Circuit Function 1 1 boad Anticipate Signal 2 gt 2 Crank Request Signal 3 6 _ Nouse 7 Intercooler Relay Control Service Vessel Soon Lamp Control __ DTC 2 Lamp Control Evaporat
539. ts shown in the following illustration 1683725 10 Crimp the splice clip a second and third time once at each end 1 Do not let the crimping tool extend beyond the edge of the clip when doing so Step 6 Solder Apply 50 50 resin core solder to the hole in the back of the clip as shown in the following illustration 1683729 Legend 1 Poor Solder Application With Bad Solder Fillets 2 Excessive Burning Which Cannot Be Covered With 50 mm Splice Tape 3 Insulation Clamped Under The Clip 4 Sharp Solder Spikes 5 Wires Not Fully Inserted Into The Clip 6 Tape Width Less Than 50 mm aT gt Step 7 Tape the Splice Centre and roll a 50 mm x 50 mm piece of tape around the splice joint 1683727 If the wire is not in conduit or another harness covering tape it again using a winding motion entirely overlapping the first piece Legend 1 Example Of Properly Rolled Tape 2 Tape Again Needed 3 Example Of Bad Flagged Taping 2011 Marine Engines Manual Splicing Copper Wire Using Splice Sleeves Tools Required J 38125 Terminal Repair Kit Note Use only GM splice sleeves other splice sleeves may not protect the splice from moisture or provide a good electrical connection Use crimp and seal splice sleeves to form a one to one splice on all types of insulation except tefzel and coaxial to form a one to one splice Use tefzel and coaxial where there is special requirements such as moisture sealing
540. tual state of the control circuit do not match for greater than 500 mS Action Taken When the SPN Sets SPN 65541 65542 65543 65544 65545 65546 65547 and 65548 are Type B SPNs Closed loop not enabled The injector to the corresponding EST fault is disabled Conditions for Clearing the SPN SPN 65541 65542 65543 65544 65545 65546 65547 and 65548 are Type B SPNs Diagnostic Aids The SPN must be cleared after the condition is repaired to enable the injector s Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 Description and Operation Electronic Ignition System Description on page 9 286 Distributor Ignition DI System Description on page 9 287 SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification 1 Engine running or cranking observe the scan tool SPN information SPN 65541 65542 65543 65544 65545 65546 65547 or 65548 should not set 2 Operate the vehicle within
541. tup and programming 9 106 Engine Controls and Fuel Marine SPN 1765 High Side Driver Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptor SPN 1765 FMI 4 SPN 1765 5 Diagnostic Fault Information Short to Ground 1765 4 1765 5 1765 5 _ eo C jl Circuit Fuel Solenoid Valve Control Fuel Solenoid Valve Low Reference Internal ECM or sensor damage may occur if the circuit is shorted to B Circuit System Description The fuel solenoid valve allows the engine control module ECM to control the amount of gaseous fuel entering the throttle body while the engine is cranking or operating The fuel solenoid valve signal from the ECM is pulse width modulated PWM The ECM controls the fuel solenoid valve duty cycle by controlling the amount of solenoid valve ON time The fuel solenoid valve increases or decreases the amount of gaseous fuel entering the engine based on inputs to the ECM from the HO2S TPS and MAP sensors The ECM controls the fuel solenoid valve by suppling a 12 V pulse width modulated PWM signal The ECM supplies a ground to the low reference circuit Conditions fo
542. turned to the ON position the ECM will provide ground on the control circuit of the relay with a low side driver This will allow voltage through the relay switch contacts to the MEFI components The ECM monitors the voltage level on the control circuit of the relay Conditions for Running the SPN 66013 3 and 66013 5 SPN 630 and 65580 are not set The relay has been commanded ON and OFF at least once during the ignition cycle The ignition voltage is greater than 9 volts SPN 66013 runs continuously once the above conditions are met 66014 4 SPN 630 and 65580 are not set The ignition is ON or the engine is operating SPN 66014 runs continuously once the above conditions are met for greater than 1 second Conditions for Setting the SPN 66013 3 and 66013 5 The ECM detects that the commanded state of the driver and the actual state of the control circuit do not match for greater than 5 seconds 66014 4 The ECM detects greater than 3 volts on the relay output circuit when the relay has been commanded OFF OR The ECM detects 5 volts or less on the PT relay output circuit when the relay has been commanded ON Action Taken When the SPN Sets SPNs 66013 and 66014 are Type B SPNs Powertrain Relay Voltage Above Normal or Shorted High Powertrain Relay Current Below Normal or Open Circuit Powertrain Relay Contact Voltage Below Normal or Shorted Low Conditions for Clearing the SPN
543. uires a scan tool or PC based scan program in order to read With an understanding of the data that the scan tool displays and knowledge of the circuits involved the scan tool can be very useful in diagnosing a condition A scan tool does not make the use of diagnostic procedures unnecessary nor does it indicate exactly where the problem is occurring in a particular circuit Diagnostic procedures contain information that can only be obtained with a scan tool or PC based scan program Scan Tool Use with Intermittents The scan tool provides the ability to perform a wiggle test on wiring harnesses or components under various conditions while observing the scan tool display The scan tool parameters can be observed while operating the vehicle under the conditions for running a diagnostic trouble code DTC or when there is an engine driveability condition If the condition appears to be related to certain parameters that can be verified with the scan tool they should be observed while operating the vehicle If there does not seem to be any correlation between the condition and any specific circuit the scan tool can be observed on each position for a period of time to verify if there is any change in the parameters that indicates an intermittent operation The scan tool can also be used to compare the operating parameters of a poorly operating engine with those of a known good engine For example a sensor may shift in value bu
544. ulse Width 65723 65724 65725 65726 2 4 6 0 6 21 9 160 SPN 65723 65724 65725 65726 3 0 4 3 5 0 5 71 9 158 65723 65724 65725 65726 2 4 6 0 6 21 9 160 SPN 65723 65724 65725 65726 3 0 4 3 5 0 5 71 9 158 65723 65724 65725 65726 2 4 6 0 6 21 9 160 SPN 65723 65724 65725 65726 3 0 4 3 5 0 5 71 page 9 158 65724 Cam Sensor Data Erratic Intermittent or Incorrect Cam Sensor Y Mechanical System Not Responding or Out of Adjustment Cam Sensor Y Abnormal Frequency or Pulse Width o SPN 65723 65724 65725 or 65726 2 4 6 0 6 2L on page 9 160 SPN 65723 65724 65725 or 65726 3 0 4 3 5 0 5 7L on page 9 158 or SPN 65723 65724 65725 or 65726 2 4 6 0 6 2L on page 9 160 Cam Sensor Z Data Erratic Intermittent or Incorrect SPN 65723 65724 65725 or 65726 3 0 4 3 5 0 5 7L on page 9 158 Cam Sensor Z Abnormal Frequency or Pulse Width or SPN 65723 65724 65725 or 65726 2 4 6 0 6 2L 65726 2011 Marine Engines Manual on page 9 160 SPN 66002 on page 9 162 Concent imn Voltage Above Normal SPN 65723 65724 65725 or 65726 3 0 4 3 5 0 5 7L page 9 158 65726 7 Cam Sensor Z Mechanical System Not Sr Responding or Out of Adjustment SPN 65723 65724 65725 or 65726 2 4 6 0 6 2L on page 9 160 6 20 Vehicle Diagnosti
545. und 1 00 A value greater than 1 00 indicates that the ECM is adding fuel in order to compensate for a lean condition A value less than 1 00 indicates that the ECM is reducing the amount of fuel in order to compensate for a rich condition The BLM Cell ID numbers are based on the engine speed and load Conditions for Running the SPN SPN 94 105 106 630 651 658 65541 65548 65580 or 65591 65599 is not set The engine is operating in Closed Loop The ECT is warmer than 140 F 60 The engine speed in less than 4 100 RPM SPNs 65565 and 65566 run continuously when the above conditions are met Conditions for Setting the SPN 65565 0 and 65566 0 The O2 BLM Cell value is greater than 1 24 for greater than 1 second 65565 1 and 65566 1 The O2 BLM Cell value is less than 0 74 for greater than 1 second 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 125 Fuel Trim Bank 1 Data Valid But Above Normal Fuel Trim Bank 1 Data Valid But Below Normal Fuel Trim Bank 2 Data Valid But Above Normal Fuel Trim Bank 2 Data Valid But Below Normal Action Taken When the SPN Sets SPNs 65565 and 65566 are B SPNs Conditions for Clearing the SPN SPNs 65565 and 65566 are Type B SPNs Diagnostic Aids The system will become lean if a fuel injector is not supplying enough fuel A lean condition could be present during high fuel demand due to a fuel pump that does not deliver enough fuel
546. under test 3 Switch the meter to ohm and connect the other 2 lead to the other end of the circuit 4 f the self powered test light illuminates there is 3 continuity If you are using an ohmmeter low or 4 no resistance means good continuity 1683688 Legend 1 Meter Switched to Ohms 2 Switch Terminal Testing for Short to Ground Using A Test Light Or Voltmeter To test for a short to ground using a test light or a voltmeter 1 Remove the blown fuse and disconnect the load 2 Ensure that fuse block is powered and connect a test light or voltmeter across the fuse terminals 3 Beginning near the fuse block wiggle the harness from side to side Continue this at convenient points about 150 mm apart while watching the test light or voltmeter 4 f the test light illuminates or the voltmeter registers there is a short to ground in the wiring near that point Using A Self Powered Test Light Or Ohmmeter To test for a short to ground using a self powered test light or an ohmmeter Remove the blown fuse and disconnect the battery and load Connect one lead of a self powered test light or ohmmeter to the fuse terminal on the load side Connect the other lead to a known good ground Beginning near the fuse block wiggle the harness from side to side Continue this at convenient points about 150 mm apart while watching the self powered test light or ohmmeter If the self powered test light illuminates o
547. unless specified These coatings can affect the final torque which may affect the operation of the component Use the correct torque specification when installing components in order to avoid damage 1 If reinstalling the old sensor coat the threads with anti seize compound GM P N 12377953 or equivalent 1 Remove the connector position assurance CPA retainer 313264 2 Disconnect the HO2S harness connector from the engine wiring harness connector Caution Refer to Excessive Force and Oxygen Sensor Caution on page 0 5 3 Remove the HO2S 313264 2 Install the HO2S Installation Procedure Tighten Note A special anti seize compound is used on the Tighten the sensor to 42 N m 31 Ib ft HO2S threads The compound consists of liquid 3 Connect the HO2S harness connector to the graphite and glass beads The graphite tends to burn engine wiring harness connector away but the glass beads remain making the sensor 4 Install the CPA retainer easier to remove New or service replacement sensors already have the compound applied to the threads If the sensor is removed from an exhaust component and if for any reason the sensor is to be reinstalled the threads must have anti seize compound applied before the reinstallation 2011 Marine Engines Manual Throttle Position Sensor Replacement Non ETC Removal Procedure 13315 1 Disconnect the throttle position TP sensor electric connection 2 Remove th
548. up pages For Electronic Manual users Be prepared to provide any applicable identification numbers pertaining to the electronic information in question The GM service manual comment telephone numbers do not provide technical assistance For technical assistance contact your regular technical assistance source United States and Canada General Motors Dealer Employees Please call the following number with your comments 1 800 828 6860 You may call Monday through Friday 8 a m 8 p m Eastern Time In order to send fax use the following number 248 265 9327 Canada French Speaking General Motors Dealer Employees Please call the following number with your comments 1 800 503 3222 You may call Monday through Friday 8 a m 5 p m Eastern Time In order to send a fax use the following number 248 265 9327 International English Speaking General Motors Dealer Employees Please call the following number with your comments 248 265 0840 You may call Monday through Friday 8 a m 8 p m Eastern Time In order to send a fax use the following number 248 265 9327 United States and Canadian Vehicle Owner Operator Vehicle owners or operators are encouraged to address their comments and concerns to the applicable Customer Assistance Center The phone number and address of the Customer Assistance Center are in the Owner s Manual 2011 Marine Engines Manual Table of Contents 0 1 Section 0 Dangers Warnings and Cautions Dan
549. ure Engine Control Module Replacement on page 9 217 for ECM replacement setup and programming 2011 Marine Engines Manual SPN 65615 65616 or 65618 Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category SPN Descriptors SPN 65615 FMI 7 of Adjustment SPN 65616 FMI 12 SPN 65618 FMI 7 Adjustment Circuit System Description The engine control module ECM controls the throttle valve by applying a varying voltage to the control circuits of the throttle actuator control TAC motor The ECM monitors the duty cycle that is required to actuate the throttle valve The ECM monitors the throttle position TP sensors 1 and 2 to determine the actual throttle valve position Conditions for Running the SPN 65615 7 Before the ECM can report that SPN 65615 7 failed SPNs 65601 65602 65610 and 65618 7 must run and pass SPN 630 65580 65620 65621 65622 or 65623 is not set The ignition is ON or the engine is operating The minimum throttle position is learned The ignition voltage is greater than 9 volts SPN 65615 runs continuously when the above conditions are met 65616 12 e SPN 630 65580 65620 65621 65622 or 656
550. value for greater than 5 seconds Action Taken When the SPN Sets SPN 65710 is a Type C SPN Conditions for Clearing the SPN SPN 65710 is a Type C SPN Reference Information Schematic Reference Engine Controls Schematics on page 9 6 Connector End View Reference Engine Control Module Connector End Views on page 9 30 Engine Controls Connector End Views on page 9 33 Electrical Information Reference Circuit Testing on page 11 6 Connector Repairs on page 11 22 Testing for Intermittent Conditions and Poor Connections on page 11 13 Wiring Repairs on page 11 16 2011 Marine Engines Manual SPN Type Reference Suspect Parameter Number SPN Type Definitions on page 6 9 Scan Tool Reference Engine Control Module Scan Tool Information on page 9 54 Circuit System Verification 1 Ignition ON observe the scan tool emergency stop parameter The parameter should display ON 2 Observe the scan tool SPN information SPN 65710 should not be set 3 Operate the vehicle within the Conditions for Running the SPN to verify the SPN does not reset You may also operate the vehicle within the conditions that you observed from the Freeze Frame Failure Records data Circuit System Testing 1 Ignition OFF disconnect the emergency stop switch harness connector 2 Test for less than 5 between the emergency stop switch ground circuit terminal B and ground greater than the specified range test the emerg
551. verify the HO2S scan tool voltage parameter is between 900 1 000 mV If less than the specified range test the signal circuit for a short to ground If the circuit tests normal replace the ECM If greater than the specified range test the signal circuit for a short to voltage If the circuit tests normal replace the ECM 4 Install a 3 A fused jumper wire between the signal circuit terminal B and the low reference circuit terminal A Ignition ON verify the scan tool HO2S voltage parameter is less than 48 mV greater than the specified range test the signal circuit for an open high resistance If the circuit tests normal replace the ECM 5 Verify none of the following conditions exist Lean or rich fuel injectors Refer to Fuel Injector Diagnosis on page 9 21 1 Water intrusion in the HO2S harness connector Low or high fuel system pressure Refer to Fuel System Diagnosis with Returnless Fuel System on page 9 208 or Fuel System Diagnosis without Returnless Fuel System on page 9 210 Fuel that is contaminated Refer to Alcohol Contaminants in Fuel Diagnosis on page 9 213 Exhaust leaks near the HO2S Engine vacuum leaks If you find any of the above conditions repair as necessary 6 If all circuits test normal test or replace the appropriate HO2S Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Heated Oxygen Senso
552. w too much power from the device they are testing for use on computers Many analogue meters use 9 volts to power the resistance test which is enough to destroy sensitive digital components Digital multimeters have an input impedance of about 10 Megohms which is much higher than analogue multimeters The high impedance means that the meter will draw very little power from the device under test This means the meter will provide a more accurate measurement and will not damage delicate electronic components The multimeter used should also be able to test temperature and high amperages This allows the one tool to do a vast amount of work in the area of diagnosis Auto diagnosis is the art of the mechanical trade To be able to fault find the fault and have the vehicle back to the owner operator with minimum delay is what leads to repeat business for the workshop To do this you must be able to refer to available literature apply basic theories and use the correct test equipment Voltage Measurement With the Volts DC mode selected the digital multimeter will operate as a voltmeter 1683680 When using a voltmeter the circuit power must be ON and the voltmeter must be connected with the correct polarity This means the red lead should be on the positive side of the load or circuit and the black lead should be on the negative side of the load or circuit The voltmeter must be connected in parallel with the
553. ween the ignition voltage supply circuit terminal 1 and ground If the test lamp does not illuminate test the ignition circuit for a short to ground or an open high resistance If the circuit tests normal and the ignition voltage circuit fuse is open test all components connected to the ignition voltage circuit and replace as necessary 3 Test for 2 6 4 6 V between the control circuit terminal 2 and ground If less than the specified range test the control circuit for a short to ground or an open high resistance If the circuit tests normal replace the ECM If greater than the specified range test the control circuit for a short to voltage If the circuit tests normal replace the ECM 4 Connect a test lamp between the ignition voltage supply circuit terminal 1 and the control circuit terminal 2 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 197 5 Command the SCB solenoid on with a scan tool Verify the test lamp should illuminates If the test lamp does not illuminate replace the ECM 6 If all circuits test normal test or replace the SCB solenoid Component Testing 1 Ignition OFF disconnect the harness connector at the SCB solenoid 2 Test for 30 55 between the control terminal and the voltage supply terminal of the SCB solenoid lf the resistance is not within the specified range replace the SCB solenoid Repair Instructions Perform the Diagnostic Repair Verification o
554. within the proper range of travel An accumulation of dirt or debris in the replace the CMP magnet as an assembly recessed area around the pintle A build up of burnt engine oil on the shaft of the pintle which may cause the pintle to stick and not move freely within the proper range of travel 2 Holding the CMP magnet with the pintle facing upward measure the pintle retracted position a Record the dimension 2011 Marine Engines Manual 9 276 Engine Controls and Fuel Marine Camshaft Position Actuator Solenoid Valve Inspection Note Do not use the camshaft position CMP actuator solenoid valve again Install a NEW valve during assembly The inspection procedure below is provided for on vehicle diagnostic purposes only 1 With the CMP magnet removed inspect for a sticking valve spool or broken valve spool spring 2 Depress the valve spool into the housing The valve should move freely with no binding or sticking and minimal resistance inward When released the valve spring should return the spool to the proper extended position 1 of 6 08 6 12 mm 0 239 0 241 in 1714950 2011 Marine Engines Manual Engine Controls and Fuel Marine 9 277 Knock Sensor Replacement Installation Procedure Except 2 4L Removal Procedure 1 Disconnect the negative battery cable 1402136 1 Position the KS 718 on the engine block 2 Install the mounting bolt 739 for the KS Caution Refer to Fastener C
555. within the specified range replace the relay 3 Test for infinite resistance between the following terminals 30 and 86 30 and 87 30 and 85 85 and 87 If not within the specified range replace the relay 4 Install a 20 A fused jumper wire between relay terminal 85 and 12 volts Install a jumper wire between relay terminal 86 and ground Test for less than 2 between terminals 30 and 87 greater than the specified range replace the relay Repair Instructions Perform the Diagnostic Repair Verification on page 6 22 after completing the diagnostic procedure Relay Replacement Fuse Block on page 11 28 or Relay Replacement Harness on page 11 29 Engine Control Module Programming and Setup on page 6 3 for engine control module replacement setup and programming Supercharger Intercooler Relay Diagnosis Diagnostic Instructions Perform the Powertrain On Board Diagnostic OBD System Check on page 9 64 prior to using this diagnostic procedure Review Strategy Based Diagnosis on page 6 4 for an overview of the diagnostic approach Diagnostic Procedure Instructions on page 6 5 provides an overview of each diagnostic category Circuit System Description The supercharger intercooler relay is a normally open relay Ignition voltage is supplied to the relay coil when the ignition is ON or the engine is operating and is supplied directly to the switch side contact through a fu
556. y assembly Connect the vacuum hose to the fuel pressure regulator Install the radiator inlet hose Install the air cleaner outlet resonator Connect the negative battery cable Inspect for fuel leaks using the following procedure 13 1 Ignition ON for 2 seconds 13 2 Ignition OFF for 10 seconds 13 3 Ignition ON 13 4 Inspect for fuel leaks Engine Controls and Fuel Marine 12885 Fuel Injection Fuel Rail Assembly Replacement 6 0L and 6 2L Removal Procedure 1408855 Note Observe the location of the fuel rail ground strap 557 1 Relieve the fuel system pressure Refer to the Fuel Pressure Relief on page 9 230 2 Before removal clean the fuel rail assembly with a spray type engine cleaner GM X 30A or equivalent if necessary Follow the package instructions Do not soak fuel rails in liquid cleaning solvent Caution Refer to Fuel Rail Caution on page 0 5 Caution Cap the fittings and plug the holes when servicing the fuel system in order to prevent dirt and other contaminants from entering the open pipes and passages 3 Disconnect the fuel feed hose from the fuel rail 2011 Marine Engines Manual 8 9 1408856 Disconnect the electrical connectors from the fuel injectors Identify the connectors to their corresponding injectors to ensure correct sequential injector firing order after reassembly Disconnect the electrical harness from the fuel rail brackets
557. y the SPN type SPNs are ranked as A or E Types A B and E SPNs are emissions related Type C SPNs are non emissions related The is the control center of the engine controls system The ECM controls the following components The fuel injection system The ignition system The emission control systems The on board diagnostics The throttle control TAC system The ECM constantly monitors the information from various sensors and other inputs and controls the systems that affect the vehicle performance and emissions The ECM also performs diagnostic tests on various parts of the system The ECM can recognize operational problems and alert the driver via the MIL When the ECM detects a malfunction the ECM stores a SPN The condition area is identified by the particular SPN that is set This aids the technician in making repairs ECM Function The engine control module ECM can supply 5 volts 12 volts or ground to various sensors or switches Voltage is supplied through pull up resistors to the regulated power supplies within the ECM In some cases an ordinary shop voltmeter will not give an accurate reading due to low input resistance A DMM with at least 10 megaohms input impedance is required in order to ensure accurate voltage readings The ECM controls the output circuits by controlling the ground or the power feed circuit through the transistors or a device called an output driver module
558. ycle This opens the solenoid valve and allows boost pressure to enter the bypass valve actuator at the lower side to counteract the spring tension opening the bypass valve and recirculating excess boost pressure back into the supercharger inlet The ECM controls the valve by grounding the control circuit with a solid state device called a driver The driver is equipped with a feedback circuit that is pulled up to a voltage The ECM can determine if the control circuit is open shorted to ground or shorted to a voltage by monitoring the feedback voltage 2011 Marine Engines Manual Conditions for Running the SPN 66035 0 Before the ECM can report that SPN 66035 0 failed SPNs 66035 3 and 66035 5 must run and pass SPN 106 108 630 3563 or 65580 is not set The ignition is ON or the engine is operating The ignition voltage is greater than 9 volts SPN 66035 0 runs continuously when the above conditions are met 66035 3 SPN 630 65580 is set The ignition is ON or the engine is operating The ignition voltage is greater than 9 volts The boost control solenoid is commanded ON SPN 66035 3 runs continuously when the above conditions are met 66035 5 SPN 630 65580 is not set The ignition is ON the engine is operating The ignition voltage is greater than 9 volts The boost control solenoid is commanded OFF e SPN 66035 5 runs continuously when the above conditions
559. ype The control module stores the SPN information into memory when the diagnostic runs and fails The DTC 3 lamp if equipped will illuminate The control module records the operating conditions at the time the diagnostic fails The control module stores this information in the Failure Records Conditions for Clearing the SPN Type C A current SPN Last Test Failed clears when the diagnostic runs and passes A history SPN clears after 40 consecutive warm up cycles if no failures are reported by this or any other non emission related diagnostic Clear the SPN with a scan tool Failure Mode Indicator FMI Definitions The are identified by two sets of numbers The first set of numbers is called the Suspect Parameter Number SPN This number identifies the System that has a condition The second set of numbers is called the Failure Mode Indicator FMI The following is a list of the possible FMIs that may be displayed Failure Mode Indicator FMI Definitions FMI out of adjustment FMIS FMIS FMI 10 FMIT FMI 15 Data valid but above normal range Least Severe Level FMI 16 Data valid but above normal range Moderate Severe Level FMI 17 Data valid but below normal range Least Severe Level FMI 18 Data valid but below normal range Moderate Severe Level FMI 19 Received network data error FMI 20 30 Reserved for SAE assignment FMI31 Not available 2011 Marine Engines Manua
560. ys YES if the engine ao Within Last speed was limited by the rev limit threshold within the last second This parameter displays YES if the control ee Output module detects OEM installed cruise control system has been switched ON This parameter displays the shift interrupt Shift Interrupt Input switch circuit status to the control module This parameter displays the amount of spark advance the control module is commanding on the ignition control circuits The control module determines the desired advance This parameter displays the control modules Starter Relay Output OFF commanded state of the starter relay control circuit Supercharger Inlet Thi is parameter displays YES if the control Sensor YES NO module detects a SCIP sensor signal This parameter indicates the pressure at the supercharger inlet as calculated by the control module based on the signal from the supercharger inlet pressure SCIP sensor The scan tool will display a higher value wide open throttle and a lower value at idle Spark Advance 20 to 40 Degrees Supercharger Inlet Varies Pressure Sensor This parameter indicates the voltage signal received by the control module from the Supercharger Inlet 0 5 Volts SCIP sensor The scan tool displays a low Pressure Sensor Volts voltage at idle and a high voltage at wide open throttle Barometric pressure and altitude can effect these values This parameter displays the percent of throttle openi

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