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Course 2 Reference Material.indd - For Dealers

1. YEL RED YEL RED 7 8 12ga 12 al Starter Y Relay ToECM t Control TRANSMISSION INEUTRAL ISAFETY SWITCH To EXC STARTER s YELLOW 12 ga Alternator To ECM paca Ignition L gt Pl JR LE 5 8 Pin GROUND ENGINE BLOCK 01 With the Key ON and boat s O System nav and panel lights ON all test Relay points should read within 3 vdc Eos nad al of the battery voltage vsw Fuse Not Used zx 5A Purple To ECM TP 11 Ignition 71 ru A Rel Fuse Block P Fuse Block Y To ECM EOM Fuse 204 20A Feed Pin A 7 Fuse Block 4 4 Fuse Block IGN 1 5780 192 STUD 20 m BELLHOUSING T Battery Feed Pins Fuel TP 9 TP 1 0 Pump Relay Fuel Control Cell 5 To Injectors Low Pressure Not Used 1 Module O2 Sensors Fuel Pump To Ele Pnk Yel White Pnk Yel 7 uel Pumps FROM ECM Ground FUEL PUMP BLACK 109a vc pin RELAY 125 C CONTROL To Ignition ALL STBD To ECM Control GROUNDS Ground Pins Module Ee sow GROUND STUD Bel OLSIN GROUND STUD BELLHOUSING 5 0 57LONLY BELLHOUSING ECM GROUND ONLY 98 Figure 5 6 System Power Test Points L599003 13 89 MAIN ELECTRICAL SYSTEM 5 Starter Circuit
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3. STARBOARD GROUND STUD BELLHOUSING Figure 4 6 Main Power Fuel Pumps Power Feed L599003 13 75 FUEL SYSTEM 4 Fuel Pressure is Out of RANGE When we took our first look at the engine and turned the ignition to ON our first observation was to listen and feel for the fuel pumps to run and we ve discussed the procedure that covers the condition when they do not The second observation we needed to make was fuel pressure Was the pressure near the WOT specification while the pumps ran Refer to Figure 4 7 the Fuel Pressure Out Of Range Troubleshooting Tree Looking at the Troubleshooting Tree you will observe that this test sequence will require you to use an auxiliary fuel tank The use of an auxiliary fuel tank allows you to isolate the boat s fuel system from the engine The use of the auxiliary tank is a quick and extremely useful way to determine the source of a problem when fuel contamination or restriction is suspected Some of the more common symptoms are rough running the engine cuts out stalls loses power at high speed or fuel pressure problems NOTE When using an auxiliary fuel source to test an engine with a FCC that returns fuel to the boat s fuel tank the return fuel from the FCC must be redirected into the auxiliary fuel source Important Caution must be taken when using the auxiliary fuel tank The tank must be properly strapped down The lines an
4. pue suqep 104 buisnou j edsu 5 e ej day YSJ4 JO gal 5507 JURJOOD DM4 AY 01 Jajay y SI 1 2 002 AUBA 193eM 45944 pauinbai se 151005 30U 91220 01 paJeJju ue esf SUOn211 91 10J 1nd3no J91eAA 2942 SSVd Figure 3 6 Engine Over Temperature With Codes Troubleshooting Tree L599003 13 48 ENGINE MANAGEMENT SYSTEM 3 Exhaust Manifold Water Temperature EMWT 1 and or 2 Higher than Expected Stage 1 Stage 2 Set Refer to Figure 3 7 and 3 8 Exhaust Manifold Water Temperature EMWT Higher than Expected Stage 1 Stage 2 indicates that the ECM has detected an exhaust water over temperature condition The EMWT sensors provide the over temperature reading to the ECM There is an EMWT sensor in each exhaust manifold EMWT 1 refers to the ODD cylinder Left side of the engine and EMWT 2 refers to the EVEN cylinder Right side of the engine These trouble codes will be set and Power Derate Mode may be enabled when either EMWT sensor detects a temperature in excess of 220 Stage 1 and 225 F Stage 2 You would perform the EMWT Over Temperature Troubleshooting Tree Figure 3 8 which will be discussed in more detail in the Cooling System section of this course These trouble codes illuminate the Check Gauges Lamp CGL
5. Bu ees yeus uonezueluM JO uonejduio2 eJnsu3 ol IInd Figure 6 7 XR550 Partial Fresh Water Cooling L599003 13 115 COOLING SYSTEM 6 PCM DRIVABILITY CHECKLIST ENGINE SERIAL NUMBER Date Technician s Name Dealership Name Owner Operator Name Person Reporting the problem if different from owner operator Service Writer or Person that took the problem report 1 PROBLEM OR SYMPTOM Who first observed the symptom Technician s Contact Phone When did the symptom first occur Any recent change or service work prior to symptom occurring replaced belts or impeller major engine or boat repairs recently refueled etc correct the current symptom If yes what work was done Accessories Added Recently Special conditions if any required to duplicate the symptom Has someone other than yourself tried to ls the symptom currently present Use an additional sheet of paper if more space is required for symptoms or descriptions 2 CHECK FOR SERVICE UPDATES ENGINE SERIAL NUMBER HULL NUMBER ENGINE None Apply __ Performed ENGINE MODEL NUMBER ENGINE HOURS BOAT None Apply Performed 3 VISUAL INSPECTION Inspection Evidence of an over heat Engine Harness connectors connected properly Physical Damage wiring connectors assemblies and Remove Spark Plugs e inspect for fluids Corrosion
6. Go to First Step on the Next Page Using Diacom display ECM engine data Ignition ON engine OFF Observe the MIL driver status on the Diacom display Is the MIL status ON or flashing Using Diacom display ECM engine data Start the engine Select the Codes tab on the Diacom display Refer to Drivability Checklist Go to DP A1 Is there any DTC s stored Compare ECM data values displayed on the scan tool to known good data values Are the display values normal or close to the typical values Ignition ON engine OFF Observe the fuel pressure gauge while the fuel pumps are running Is fuel pressure near or at the specified pressure on the Master Specification sheet pumps run 2 4 seconds then turn OFF Diagnose Fuel Pump Circuit Isolate the engine from the boat harness using remote key switch 0091 Ignition ON engine OFF Select the Codes tab on the Diacom display Make a note of existing code s and clear the DTC s Ignition OFF Start the engine and run for at least 2 minutes gt Diagnose Fuel Pump Out of Range Did any noted DTC s return Yes Go to applicable DTC Procedure Refer to Boat Diagnostics
7. ejenbs o b Figure 6 2 CES EX343 CES Raw Water Cooling L599003 13 110 COOLING SYSTEM 6 ueg eAugA p epouy ouiz Bn gd esoH 1948M e SOH lelul JelooD IO UOISSILUSUEJ p puBi s Aew sesou y edeus Jo pue jenjoe eu sesodund uoneasni 10 si siu eloN leadenbs o b 1 1 uo e esoH 4989 4 yeys UueJ6eld SMO 530 sAleleD 17 6 Figure 6 3 EX343 CES CWS Full Fresh Water Cooling L599003 13 111 COOLING SYSTEM 6 uo Buipuedep Aew sesou y edeus 10 pue eu uo 6nld 191000 IIO uorssiuusue1 7 sasodind 10 S siu aloN 9 A s6nld SI9UJOD 1sneux3 esoH JO 6nld splohuelN 15neux3 p epouy oulz 6nld ure1q leeH e esoH MNO e lt lt
8. Total Trouble Codes Calibration Checksum CC2C HEX Engine Hours 15 6 hrs Engine Running Time 10 82 Min Starts Without Malfunction 65 Battery Voltage 14 30 VDC Starts Without Warning 17 x 50 1 DEG Enqine Speed 1234 RPM 1250 RPM Throttle Position 9 Battery Voltage 0 94 VDC IAC Position 148 3 Coolant Temperature 160 F 29 0 Hq MAP Sensor Voltage 2 69 VDC 19 5 Hq Spark Advance 14 0 DEG 0 0 DEG MAT Sensor Present On 115 F Injector Bank A Pulse Width 4 2 ms Injector Bank B Pulse Width 4 2 ms RPM Reduction Control Off Disable Injector Bank Off Malfunction Indicator Lamp Off Fuel Pump Output On Gen Warning 1 Input Off Gen Warninq 1 Lamp Output Off Gen Warning 2 Input Off Gen Warninq 2 Lamp Output Off Check Gauges Lamp Warning Buzzer Output Off Tm 0 1 hrs 2 7 hrs 0 4 hrs 0 0 hrs 871 GM DELCO MEFI 4 MODE 1 MASTER Current Packet Index 0 15 22 00 130 Refer to Figure 5 12 The final check on the charge circuit is the Run Test This will verify the operation of the alternator and its ability to maintain the battery at full charge Connect your Diacom scan tool to the engine and with the key ON link to the ECM On the Diacom ECM Data display locate the Battery Voltage label This is the current battery voltage reading Start the engine and bring the engine to a fast idle between 1200 and 1500 RPM Using your DMM verify the charge voltage
9. m PREMIER DEALER WORLDWIDE PCM E TRAIN PROGRAM Course 2 Reference Material TABLE OF CONTENTS INTRODUCTION Welcome 3 Stop Pause Play Training Session 3 Bookmarking Your Training Session 4 Section Checkpoints 5 Safety Precautions 6 Notes 7 REFERENCE MATERIAL PCM Drivability Checklist Section 2 9 Engine Management System Section 3 29 Fuel System Section 4 65 Main Electrical System Section 5 81 Cooling System Section 6 107 Catanium Clean Exhaust System CES Section 7 131 NOTE All other publications can be quickly referenced downloaded or printed conveniently from your PCM Premier Dealer Website Use your assigned Dealer ID and Password to access this information L599003 13 2 WELCOME Congratulations on your new PCM Electronic Training E Train Program purchase We hope you ll enjoy the new look and convenience of PCM s E Train program training online from the comfort and convenience of your dealership or personal computer The PCM E Train Program is a series of electronic courses designed to prepare PCM dealers and Service Technicians to do business with PCM pre deliver maintain diagnose and repair PCM marine engines At Pleasurecraft we believe that well trained dealers who supply genuine PCM engines parts and service are absolutely essential to our company s success in fully satisfying our customers PCM s primary focus is first and always the safety and dependability of our pr
10. Refer to DTC Procedure for the Circuit that is Out of Range L599003 13 37 ENGINE MANAGEMENT SYSTEM 3 OBD System Check Continued Ignition OFF Refer to the Fuse Block Pinout Diagram Using a DMM verify there is B voltage on both sides of the 15A Diagnostic Fuse Was Yes No Ignition OFF Check for faulty connections or faulty scan tool NOTE See Diagnostic Aids You must verify that your Diacom is properly installed the correct and current software level and functions on a known good engine before proceeding with the tests present at the fuse Disconnect ECM connector Check CAN BUS and wires for open short to ground or short to voltage Check the OBDM connector circuit for open Check the OBDM connector ground circuit for open or short to voltage Was a problem found Yes Repair faulty connections or replace ECM Repeat OBD System Check Ignition OFF Verify the Diagnostic Connector 15A fuse If a problem is found replace the fuse and repeat previous step If the fuse blows again check the OBDM Connector wiring for a short to ground going to terminal No Was a Repeat OBD System Check L599003 13 38 problem found Repeat OBD System Check ENGINE MANAGEMENT SYSTEM 3 15A IGNITION A DIA
11. oe VERIFY THE PROBLEM the engine start and continue to go to 3 go to 1 run below below 1 Key ON Engine OFF KOEO YES NO Fuet Press Both Fuel Pumps run 2 4 Fuel Pressure near wot specification _ d d when pumps run 2 Key ON Engine Running KOER YES NO Fuel Press Engine cranks Fuel Pressure near wot specification eng gine cranking Engine Starts and continues geld is Water Test 3 WATER TEST YES NO FuelPress Cc b 1 Fuel Pressure ide Fuel Pressure under load WOT 4A Revised or additional symptom found Evidence of or Excessive Water in the Bilge Fluid levels checked Leaking Fluids Firing order correct Correct size propellers installed Underwater gear is undamaged Accessories added If yes check items Check Accessories Added Heater Shower Hot Water Tank Flush Kit Multi Function Display Synchronizer L After Market Stereo Equipment After Market Depth Fish Finder L After Market Navigational Equipment such as GPS Radar Sonar Auto pilot systems Radio Equipment L Lights Other please list Figure 6 8 PCM Drivability Checklist L599003 13 116 COOLING SYSTEM 6 PCM DRIVABILITY CHECKLIST 5 PERFORM THE OBD SYSTEM CHECK CODE S PRESENT DIAGNOSTIC PROCEDURE U
12. Oxygen Sensor Test Clear Misfire Data Pleasurecraft Crusader GCP ETC 4G Engine Data Trouble Code s Found Not Linked to ECM DIACOM TESTS Your Diacom software package is much more than just a scan tool to read engine parameters and codes Diacom through its Tests screen provides you with control over various ECM functions Utilizing these functions can allow you to test and or control circuits to determine the source of a problem more efficiently On your Diacom screen you will see a tab for Tests Left click on this tab to reveal the test screen These tests can be used to assist in diagnosis clear ECM data or run through an automated test cycle Some of the more commonly used tests are Relay Tests Clear Fuel Adaption Oxygen Sensor Test Injector Kill Test Compression Test Mode and Clear Misfire Data The following is a brief description of these Diacom tests and how they may be used For more information on these tests you should refer to your Diacom Help menu NOTE The contents and appearance of the Test Screen will vary from system to system due to the fact that different ECMs have different capabilities L599003 13 55 8 47 12 096 e e e 9 ENGINE MANAGEMENT SYSTEM 3 _ ___ __ 2 eT m RO fle Tools Opbons Help ECM Data Graph Codes ECM Output Tests Tests Injector Kill Test l System into Injector Fire Te
13. 9 8 28 6L Sex T v rubis jeu is 105495 Josueg JosueS 22105095 100W 193 ainssald IIO dl dL 041002 i as RS Figure 3 7 Power Derate Mode EMWT Circuits L599003 13 50 TROUBLESHOOTIN ENGINE MANAGEMENT SYSTEM 3 G AN EXHAUST MANIFOLD WATER TEMPERATURE HIGHER THAN EXPECTED STAGE 1 STAGE 2 CONDITION Trouble Code SPN 441 FMI 15 DTC 1415 EMWT 1 Higher than Expected Stage 1 SPN 441 FMI 0 DTC 1417 EMWT 1 Higher than Expected Stage 2 SPN 442 FMI 15 DTC 1416 EMWT 2 Higher than Expected Stage 1 SPN 442 FMI 0 DTC 1418 EMWT 2 Higher than Expected Stage 2 Check Check Service Updates Check ECM for trouble codes Perform Diagnostic Procedure For Engine Coolant Temperature ECT Overheat Raw Water Systems Full Fresh Water Systems Thermostatically Controlled Exhaust Cooling Parial Systems for restrictions in hoses Perform Exhaust Cooling fittings and exhaust System Thermostat Inspection components Cleaning Perform Corrective Action Check Clear ECM of codes Verifiy corrective action has corrected the problem Figure 3 8 Exhaust Coolant Over Temperature With Codes Troubleshooting Tree L599003 13 51 ENGINE MANAGEMENT SYSTEM 3 Low Oil Pressure Telltale Set Refer to Figures 3 9 and 3 10 The Low Oil Pressure trouble codes indicates the ECM has
14. Fuel Pump ECM Relay Fuse a 20A Feed Pin 28 A A Fuse Block 4 Fuse Block IGN 1 Pink Fuse ene 20A Fuse 1 Battery Feed Pins ECM operation is dependant upon maintaining proper ground locations The port ground stud is for ECM grounds only Battery ground and all accessory grounds Not Used To Elec Pnk Yel Ground BLACK 1 2 2 125 C uel Pumps should be located at the starboard ground stud PEG To Ignition ALL STBD Control To ECM GROUNDS Ground Pins Module CENTER PORT GROUND STUD STARBOARD GROUND STUD BELLHOUSING ECM GROUND ONLY GROUND STUD BELLHOUSING BELLHOUSING 5 0 5 7L ONLY i Figure 5 5 System Power Ground Locations L599003 13 88 100A 70A e p 2 TP 4ex ALTERNATOR To STBD GRD STUD BELLHOUSING TP 1 BATTERY BLACK 6 ga MAIN ELECTRICAL SYSTEM 5 To STBD GRD STUD BELLHOUSING RED WHITE PURPLE WHITE From 5 Harness Fuse Block Panel Fuse 40A RED WHITE 10ga 1 259 c 2 Pin 8 Pin Boat Harness Battery 1 Q Pin Fuse Block Starter Relay Fuse Starter
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16. faulty ignition coil faulty distributor cap engine mechanical issue wiring connections Diagnostic Trouble Suspect Parameter Code DTC Number SPN ailure Mode Identifier FMI Abnormal vibrations to the crankshaft can also be induced by such things as bent propshaft or bent prop Refer to the Diagnostic Procedure for a particular fault in the diagnostic manual for some diagnostic aids for diagnosing these faults Fault Description DTC 420 3050 Catalyst inactive on gasoline Bank 1 DTC 430 3051 Catalyst inactive on gasoline Bank 2 The trouble codes above are associated with the efficiency of the catalyst substrate As described earlier the Post O2 sensors are monitoring the integrity of the catalyst substrate If the Post O2 sensor feedback reaches a level in which the catalyst substrate is no longer reducing emissions to the level it was designed at these trouble codes would set This is a very uncommon failure due to the extreme engineering specifications that the catalyst substrates are built to As described earlier the catalyst substrates are constructed of stainless steel not ceramic and are very robust The diagnostics for either of these codes is simply replace the inefficient catalyst substrate and verify repair L599003 13 136 NOTES L599003 13 137
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18. GRD STUD ol BELLHOUSING 0 RED WHITE 10ga 1259 Red ANNE i Purple A Fuse Block Sener Starter Relay Fuse BATTERY les YEL RED YEL RED 7 8 Pin 12 12 ga Key Switch START Position Key Switch ON Position o Starter uy Relay To ECM c Control TRANSMISSION INEUTRAL Dii ers ent Bares 12 STARTER S LO rc Me Alternator To L Control jud PURPLE 5 8 Pin GROUND ENGINE BLOCK E Fuse Block A vsw Fuse E LET S To ECM Ignition F Block A Relay Fuse Blo Control Pin De Fuse20A ES i Feed Pin re eA eA Fuse 4 Fuse Bh IGN 1 780 Pink Fuse GRD STUD Black 20A B BELLHOUSING Taian A i i Battery Feed Pins Fuel Pump Relay Fuel Control 8 Cell Not Used Y To Coils To Injectors Light Low Pressure Pnk Yel Bite Module O2 Sensors Pump To Elec Pnk Yel White Pnk Yel uel Pumps Ground BLACK 10ga 2 Q Pin ST Ignition A BD To ECM Control GROUNDS Ground Pins Module 2 PORT CENTER f GROUND STUD GROUND STUD BELLHOUSING BELLHOUSING GROUND ONLY M
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20. NOTE The 5 0 5 7L engines utilize the center bolt on the bell housing as a ground for the Ignition Coil Module Assembly This should be the only ground at this location System Power KEY ON 3 Refer to Figure 5 6 After checking battery voltage and battery cable connections Turn the ignition ON and apply a load to the battery by turning ON the Navigation Lights and boat Courtesy Lamps Verify that system power is not less than the battery voltage by more than 0 3 vdc at the test points shown The test points are at junctions connectors and fuses that are either routing points for system power or after major splices in the engine harness As you take measurements at each of these points inspect for tightness of the connectors and inspect for corrosion You should clean or repair connections as necessary Turn the lights and ignition switch OFF when you have completed the test Example Battery Voltage is 13 0 vdc all test points should read 12 7 13 0 vdc A reading outside of this range may indicate a bad splice connection or broken wire which should be repaired before proceeding with any other troubleshooting NOTE Test points are labeled on Figure 5 6 for easy reference If battery voltage is not available at TP 2 starter battery terminal Ensure that the boat s Battery Switch if equipped is in the correct position before troubleshooting or replacing the cable Once you have verified that the proper voltage and gr
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22. 6A 9 a simialr boat w same Same engine package 6A 10 Perform the Diacom Refer to the Power Balance Test Diagnostic Manual 6A 11 Perform the harness Isolate and repair wiring Wiggle Test or connector problems 6A 12 Pre Delivery Diacom Isolate and repair circuits recording outside of normal parameters Figure 2 4 PCM Drivability Checklist No Codes L599003 13 20 Normal operation PCM DRIVABILITY CHECKLIST 2 7 Verify your repair action has corrected the problem Once you have completed a repair action clear any codes from the ECM If codes return after repairs are made or you had multiple codes listed in the ECM s memory return to Step 6 Isolate and Repair the Problem and perform the procedure and repair action for the remaining code s Steps 6 and 7 will have to be performed for each stored code until the system is repaired and tests normally Always retest to verify the engine is operating normally The original problem may have been caused by another system or event ensure that you have corrected both the cause and the original problem When you verify your repair action be sure to test With the boat in the water and 1 Run the boat a minimum of two 2 minutes to verify that no codes reset and then 2 Run the boat long enough to verify your repair has corrected the problem L599003 13 21 PCM DRIVABILITY CHECKLIST 2 SYSTEM POWER CHECK Key OFF Verify that the battery is the correct size r
23. The owner may or may not report the condition based on the soot fuel burn and or his temperature reading at the instrument panel IMPORTANT Some additional causes for over fueling of the engine include an engine coolant temperature ECT sensor that has shifted in value a manifold absolute pressure MAP sensor that has shifted in value system voltage out of range or a fuel system pressure out of range condition Typically the aforementioned conditions will not set a code in the ECM Be sure to complete the PCM Drivability Checklist verifying system power fuel system operation and verifying system parameters by comparing a DIACOM recording of a known good engine against the DIACOM recording of the suspect engine When troubleshooting all cooling system problems it is important to determine if added accessories are installed properly This is particularly important on an engine that is operating in an Under Temperature Condition Properly completing the PCM Drivability Checklist Visual Inspection Step 3 will ensure that these accessories are not overlooked NOTE For illustrative purposes each test presumes the problem has not been resolved Therefore you proceed to the next step In actual troubleshooting if any step corrects the problem there would be no reason to proceed further Under temperature readings on the instrument panel may be the result of high system voltage Be sure to perform the System Power check as part of St
24. When equipped the CGL is RED In many models these trouble codes are reported through a digital dash display L599003 13 49 ENGINE MANAGEMENT SYSTEM 3 v pais uod Aoa Josues punoiD Josues z LMW3 105095 IMNE LL 02 lg dau qau 3 NVL pais INV L uod V 205095 V JOSUaS oL wma Yu WOL LMA sais lt dua if 201504 815 OL lt duel WH 5 ATI IAME 2 uod OL plolue plolue WHO g g E THM 20 01 LHM ZO 8Jd 815 OL 9 uuo lHWI8 josues ieseug WVO OL 6LLS 618 IHME IHME THM Zu 4d WL ule pays uuoo uuo5 V uou 1HM rTg Josueg 2 OL Josuas 199 8 105095 V eunjejedue 2 ejnsseJg why juejoo uuo IO 105095 42101 IHW I8 Josueg V g 9 1VI 01 Ma ule uuo Josue uuoo e Mei E adisi 106495 YURI OL uuoD Josueg LHM WHO LHM uuo ma 10896 A Jeseud 01 Apog emoJu jeublg eufis Jojenjoy 10sues 1JosueS 2205095 5 208095 dL uonisog epo4du p dl dl JoloN 100 9 WHO uuo 3 v 8 Josueg dOL OL ma ma Ngo NH9 8215 11 INVL LHM
25. troubleshooting a starter problem A known good fully charged battery is essential for proper testing A weak or failing battery will give false test results Refer Figure 5 8 When you perform the Visual Inspection Step 3 of the PCM Drivability Checklist include in that inspection All Starter wiring connections are tight and free of corrosion The Starter has no physical and or water damage The exhaust flaps are present and there are no exhaust restrictions The spark plugs show no evidence of fluid in the cylinders The shift lever in the boat is in the Neutral position NOTE Starters used are permanent magnet starters and the magnet can be broken if the housing is pounded on Also Marine Starter means that the starter is spark arrested and safe to use in the bilge of the boat It does not mean that the starter will operate under water Part of the Visual Inspection Figure 5 1 will be to remove all eight spark plugs and inspect them for evidence of fluids This check is done to eliminate a possible mechanical problem for a slow or no crank condition Caution When you have a reported slow or no cranking condition Do Not attempt to crank the engine until you have performed a physical check of each spark plug for fluids in a cylinder If water coolant or fuel is in the cylinders hydrostatically locking the engine you can do major engine damage by attempting to crank the engine The owner operator may have
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27. water is circulated through the tubes of the Heat Exchanger This allows the heat to be removed from the antifreeze which is circulating around the tubes The raw water and heat are discharged through the exhaust system A Fresh Water Cooling System may be configured in several different setups All Fresh Water Cooling systems circulate antifreeze through The engine block and cylinder heads The heat exchanger Refer to Figure 6 14 A Partial Fresh Water Cooling System may also include an exhaust system coolant thermostat This allows the raw or sea water in the exhaust system to be thermostatically controlled This greatly reduces the possibility of condensation within the exhaust system The exhaust system thermostat filter must be inspected and cleaned as necessary at the 25 Hour Engine Inspection The filter should then be inspected and cleaned every 50 hours or once a year If the boat is operating in an area with high levels of sea grass this inspection should be done more frequent Important Any boat that has an engine equipped with an exhaust system coolant thermostat MUST have a sea water strainer installed The sea water strainer must be an approved component from PCM or your boat manufacturer Many sea water strainers available severely restrict the overall system raw water flow If you need to install a strainer consult PCM or your boat manufacturer for the proper part and installation Important The
28. 13 95 MAIN ELECTRICAL SYSTEM 5 Starter Circuit Testing NOTE Always perform the system power check before troubleshooting a starter problem A known good fully charged battery is absolutely essential for proper testing A weak or failing battery will give false test results No Crank Condition The No Crank condition is the more common starter problem Testing will determine if the problem is in the boat or engine wiring the relay or safety interlock or the starter itself Refer to Figure 5 10 the Starter Circuit No Crank Troubleshooting Tree The first test to perform is at the starter Using a remote starter switch connected between the Starter BAT and S terminals we can verify right away if the problem is the starter or in the control circuit NOTE Connecting a remote starter switch at the starter is not only useful for testing the starter but for any other test that requires the engine to crank without starting such as a compression check If the engine cranks when the remote starter switch is engaged you know the starter is good and the problem lies in the control circuit If the engine does not crank you have found the problem replace the starter NOTE For illustrative purposes each test presumes the problem has not been resolved Therefore you proceed to the next step In actual troubleshooting if any step corrects the problem there would be no reason to proceed further Refer to Figure 5 10 The
29. 15 In many cases the problem of coolant loss can be resolved by locating the leak and tightening a hose clamp and or properly filling the system As was mentioned previously when you performed Step 3 of the Drivability Checklist you should be keenly aware of accessory devices added into the fresh water cooling system The addition of an accessory device such as a heater or recent service to change the coolant may have left the coolant level low When the coolant was added the level may have initially appeared to be full After running the system may have purged some air and became too low to cool properly It is extremely important to get the air out of the system whenever the system is serviced NOTE For illustrative purposes each test presumes the problem has not been resolved Therefore you proceed to the next step In actual troubleshooting if any step corrects the problem there would be no reason to proceed further All current production Fresh Water Cooling Systems utilize a degas bottle The cap on the degas bottle is a pressurized cap Make sure the engine is cool before removing the cap to add coolant When you begin service on a coolant loss problem start with a cold engine For a partial fresh water cooled engine you will fill the system cold Run the engine with the cap off so you can verify circulation of the coolant in the Degas bottle Top off the system and reinstall the cap Observe that the coolant cont
30. 16 PCM DRIVABILITY CHECKLIST 2 STEP 4 VERIFY THE PROBLEM IMPORTANT FOR REPORTED MAIN ELECTRICAL SYSTEM PROBLEMS SUCH AS STARTER OR CHARGE YES SYSTEM PROBLEMS STOP START THE ENGINE PERFORM MAIN ELECTRICAL SYSTEM Does the engine start and run TROUBLESHOOTING FIRST NO START 4 1 Key ON Engine OFF NO Refer to the KOEO Do Both Fuel Pumps Run 2 4 Seconds Pump s Do Not Run then turn off Troubleshooting Tree YES Is fuel pressure within NO Refer to the Fuel specification while fuel pumps run Pressure Out Of Range Troubleshooting Tree YES 4 2 Key ON Engine Running Does the engine crank over for 5 seconds if the NO Refer to the Starter Circuit Troubleshooting Tree engine does not start YES Does fuel pressure rise near specification while engine cranks and fuel pumps run 2 4 seconds Perform the OBD after the engine stops cranking if engine System Check does not start Does the engine start and continue NO Perform the OBD to run System Check WATER TEST Verify the Owner reported problem Is fuel pressure within specification NO REIS Tto Heel under load W O T YES STEP 5 OBD SYSTEM CHECK Pressure Out Of Range Troubleshooting Tree lt lt m m Figure 2 3 Verify the Problem L599003 13 17 PCM DRIVABILITY CHECKLIST 2 5 Perform the On Board Diagnostic OBD System Check The On Board Diagnostic OBD System Check is an organized approach to i
31. 7 in the Reference Material Begin troubleshooting cooling system problems in the same manner you begin all of your troubleshooting exercises by completing the PCM Drivability Checklist Once the Checklist is completed if the complaint has not been resolved begin your Cooling System troubleshooting tests with the Raw Water Pump Volume Test Troubleshooting an Over Temperature Condition Refer to Figure 6 13 Trouble Tree Over Temp Condition and the PCM Drivability Checklist Figure 6 8 When you receive an over temperature complaint follow the PCM Drivability Checklist When you get to Step 3 The Visual Inspection you are not only looking for evidence that an overheat condition occurred but for conditions that may have caused the overheat One condition could be recently installed accessory items like a heater shower or flush kit Other conditions such as loose or missing hose clamps or a blocked sea strainer are easily identified and corrected Continue with the Drivability Checklist until the overheat condition is completely resolved When you get to Step 4 of the PCM Drivability 2 Figure 6 9 Raw Water Pump Volume Test Checklist Verify the Problem you will want to begin your troubleshooting of the over temperature condition by following the Over Temperature Troubleshooting Tree The first step to perform will be the Raw Water Pump Volume Test The Raw Water Pump Volume Test Refer to Figure 6 9 The Raw
32. OBD System Check SPN 100 FMI 1 DTC 524 Oil Pressure Sensor Low Pressure Verify Engine Oil Level NOTE An engine over filled with oil can aerate Add or remove oil as and cause low oil pressure resulting in engine required to bring oil to the damage Full level on the dipstick Verify oil pressure at idle with a mechanical oil pressure gauge at the engine LESS THAN NORMAL 10 PSI PRESSURE Refer to Engine Mechanical Verify oil pressure under load Manual and troubleshoot above 4000 RPM with a and repair mechanical oil pressure gauge at the engine Verify Repair NORMAL PRESSURE Disconnect Oil Pressure Sensor Ignition ON engine OFF Using a DMM measure voltage between connector pins B and A 5 vdc Not Present 5 vdc Present Troubleshoot and repair 5 volt Troubleshoot and repair and or ground circuits between signal circuit between OP OP sensor and ECM sensor and ECM Verify Repair veri Pepai Replace Oil Replace ECM Pressure Switch Verify Repair Verify Repair Figure 3 10 Low Oil Pressure With Codes Troubleshooting Tree L599003 13 54 DIAC ine gt Tools Options Utilities ECM Data Graph Codes Tests ECM Output Tests Injector Kill Test ENGINE MANAGEMENT SYSTEM 3 System Info Relay Tests Injector Fire Test Compression Test Mode Idle Speed Test Drive By Wire Test Clear Fuel Adaption
33. Pins Fuel Pump Relay Fuel Control Cell Not Used Light To Coils To Injectors Low Pressure loc Module O2 Sensors Fuel Pump To Elec Pnk Yel White Pnk Yel uel Pumps FROM ECM i8 roun FUEL PUMP BLACK 9 2 2 Pin RELAY 125 C CONTROL PEG __ To Ignition To ECM Control Ground Pins Module CENTER GROUND STUD GROUND STUD S RDUND STU BELLHOUSING BEDS BELLHOUSING ECM GROUND ONLY 5 0 5 7 ONLY Figure 5 7 Starter Circuit Wiring Diagram L599003 13 91 MAIN ELECTRICAL SYSTEM 5 Starter Circuit Refer to Figure 5 8 The Starter Circuit Troubleshooting Tree lists the steps for troubleshooting starter problems starting with 1 A visual inspection 2 Verify there is no engine mechanical issue Result of the spark plug inspection 3 Check the ECM for a Fuel Injector code or Engine Overheat code 4 Verify System Power The most difficult part about troubleshooting a starter problem will be NOT turning the key to the START position before the Starter Circuit Troubleshooting Tree instructs you Caution When you have a reported slow or no cranking condition Do Not attempt to crank the engine until you have performed a physical check of each spark plug for fluids in a cylinder If water coolant or fuel is in the cylinders hydrostatically locking the engine you may do major engine damage by attempting to crank the engine Always perform the System Power Check before
34. Premier Dealer Website All the Latest j rone Sor enome Publications NO DISTRIBUTOR FIRING ORDER FIRING ORDER FIRING ORDER 1 8 4 3 6 5 7 2 1 2 7 5 6 3 4 8 1 8 7 2 6 5 4 3 Figure 5 1 PCM Drivability Checklist L599003 13 83 MAIN ELECTRICAL SYSTEM 5 Main Electrical System Engine reliability performance and safety depend upon an electrical system that is functioning at peek efficiency Marine engines are constructed from electrical components that meet strict safety and performance standards These standards must be maintained to ensure that the performance and safety features engineered into PCM engines are not compromised This section covers the Main Electrical System The primary functions of the Main Electrical System are to provide an uninterrupted source of constant power to all electrical sub systems and to crank the engine for starting NOTE The discussion that follows is for current production engines Older models may have different configurations and illustrations The following may not apply to these older models Refer to Figure 5 2 The Main Electrical System consists of three sub systems 1 System Power The 12 volt Battery and its associated components and cables 2 Starter Circuit The Starter and its associated components and wiring 3 Charge Circuit The Alternator and its associated components and wiring It is necessary that
35. Retard 5 0 5 71 only 10 Performance verified against ____ similar boat w same engine and Rotor 5 0 5 7L only IB 8 Perform a Compression Check on all 8 cylinders Record below 7 VERIFY REPAIR HAS CORRECTED THE PROBLEM Check for and clear all codes from the ECM memory Water test the boat Run the engine for a minimum of two 2 minutes then verify that no codes have returned Continue with your water test long enough to verify that the problem has been corrected CAM Retard 02 thru 06 43 47 degrees 07 SN 485993 0 4 degrees CES and SN 4859944 15 2 degrees 11 Perform the Diacom Power Balance Check under load 1600 1800rpm 12 Perform the harness Wiggle Test 13 Diacom recording Pre Delivery test FRONT COMPRESSION PRESSURE 5 0 5 7L 130 215 psi 6 0L 130 215 psi 6 2L 130 215 psi Lowest pressure should be within 7096 of highest pressure Minimum cylinder pressure 100 psi FLYWHEEL END OF ENGINE ALL V 8 MODELS FLYWHEEL END OF ENGINE ALL V 8 MODELS 5 0 5 7 Liter 5 7 Liter 6 0 6 2 Liter LH ROTATION RH ROTATION LH ROTATION IGNITION WIRE RESISTANCE CHECK FRONT ERON PRONT Less than 10 000 ohms ft REFERENCES Master Engine Specification Sheets L510030 GCP 4G Diagnostic Service Manual L510015 5 0 5 7L Engine Mechanical Service Manual L510016 6 0L Engine Mechanical Service Manual PCM
36. S esoH 1eju 18 009 D SUOIne207 AP ouiz ureJq J91eM 45914 Bs ees yeus 112 Figure 6 4 ZR409 CES ZR450 CES Partial Fresh Water Cooling L599003 13 COOLING SYSTEM 6 ureJq 10 lelul J9 002 UOISSIUISUE 9 sjeuj02 1sneux3 G p epouy 5ulz 6nld 1e9H PRNO dung JeleN uleJd 10 lelul 19 009 IO D SUOI 8207 uonejeisui uo Buipuedep Aea Aew sesou ay edeus 1o pue Huno eu AIuo sesodind uoneusni 10 s siu eloN ureug JeleN 7 AAAA SAD 0StSMO SAD 605 0 Figure 6 5 28409 CES CWS 28450 CES CWS 3 4 Fresh Water Cooling L599003 13 113 COOLING SYSTEM 6 6nld Jedle 18 009 9 9 6nld 10 esoH JelooD uoissiusue t epouy oulz 6nld
37. There are seven basic steps to this approach These seven basic steps are the basis for the POM Drivability Checklist 1 Obtain a detailed description of the problem Check for Service Updates Perform a detailed visual inspection Verify the problem Perform the On Board Diagnostics 2 Isolate and Repair the problem 7 Verify the problem has been corrected You probably use most of these steps every day when you analyze a problem Using the Drivability Checklist will help you to remember to do all the steps for every problem NOTE Not all problems reported as engine problems may actually be problems with the engine Using the PCM Drivability Checklist will help you distinguish between boat and engine problems The Drivability Checklist is a guide designed to give you list of items and procedures often overlooked when troubleshooting a problem Remember that the objective is to repair the reported problem The PCM Drivability Checklist is especially useful for troubleshooting those more difficult problems when it is unclear where the problem may lie Even for easily identified problems such as an overheat condition the checklist can keep you from overlooking or spending an unreasonable amount of time on conditions known to PCM Known problems will have Service Updates issued to address problems such as the overheat example cited above Service Updates are designed to quickly resolve and p
38. a technician servicing PCM engines maintain the reliability performance and safety built into our engines by 1 Repairing electrical system components in a manner consistent with our design standards 2 Replacing defective components with original equipment parts that meet all of our applicable marine safety and manufacturer design criteria Warning PCM electrical components are certified to meet Coast Guard requirements for ignition or explosion protection DO NOT use electrical components that do not meet the Coast Guard requirements Symptoms of a malfunctioning Main Electrical System may not always be easily isolated to the Main Electrical System itself Many of the symptoms reported could be interpreted as Engine Management or Fuel System problems while others can be directly associated with the Main Electrical System As shown in the procedures so far verifying that you have sufficient power is one of the very first steps to perform In all cases whether performing the On Board Diagnostic System Check or troubleshooting the Fuel System having the correct voltage and current available is essential for proper operation We will begin troubleshooting Main Electrical System problems in the same manner we begin all of our troubleshooting exercises by completing the PCM Drivability Checklist Figure 5 1 Before you can complete Step 4 and beyond of the PCM Drivability Checklist you must resolve all system power and star
39. already damaged the engine by continuing to attempt to crank an engine that has fluid in a cylinder s By doing this inspection before you attempt to crank the engine you may find water coolant or fuel in a cylinder before it is pumped out as the engine starts and runs You would troubleshoot and repair the cause of the fluid in the cylinders then verify the starter is operating properly If fluid is found in the engine cylinder s use your Diacom scan tool to check the ECM for a Fuel Injector Fault code or Engine Over Temperature code If present you may have found the starting issue One or more cylinders may be filled with fuel from a defective injector circuit or one or more cylinders may be filled with water from the engine dieseling after an overheat condition occurred Perform the Diagnostic Procedure for the trouble code present first Return to the Starter Circuit Troubleshooting Tree and continue testing to ensure there are no other engine mechanical issues and the starter issue is resolved If no codes are present and there is evidence of fluid in the cylinders there are two paths for troubleshooting 1 If itis fuel troubleshoot the injector circuit for that cylinder and repair the wiring or replace the injector 2 If water or coolant is present determine the source of the water or coolant by pressure testing the exhaust manifolds and elbows Determine whether it is a failed exhaust component or does the engine
40. and pitch change recognition when a cylinder is shut off The Diacom Power Balance Test will be discussed in detail in the PCM Engine Management System Section under Diacom Tests Step 6A 11 Perform the engine harness Wiggle Test With the engine running start at the boat engine harness connectors and wiggle the harness Move forward along the starboard side wiggling the harness at sensor injector and coil connections Then repeat for the port side of the harness A change in engine operation indicates a wiring defect in the area where the wires were wiggled Repair wiring or connections as required Warning Take ALL Safety Precautions into consideration since you will be working around a HOT running engine with moving components Step 6A 12 The final test will be a Diacom recording based on the Pre Delivery test run Compare this Diacom file to the Pre Delivery recording of this engine if available or to another new engine of the same model Look for data that is out of range versus new engine data Troubleshoot and repair circuits that read out of range File this test and all relative information in the customer s service and or sales file NOTE Keep your Diacom recording so that it may be emailed to the factory service representative if you are unable to resolve the problem Completing the steps on your PCM Drivability Checklist through step 6A will locate most symptomatic problems Be sure to record all your findings as y
41. another fuel system example CAUTION Refer to the Diagnostic Manual for handling and testing instructions for the ECM before you troubleshoot any harness problem Never disconnect or connect the ECM connectors while power is applied The ECM may be damaged L599003 13 72 FUEL SYSTEM 4 edad WUBA IN23 e ej daj poob SYNI J 159194 pue uid 041002 onj IN23 pue 58 1920s e oJ gt suid 1032auuo2 peej lelledq IN23 edad Aya u1oq HUA lanj e ejday 032euuo IN23 pnldun KHA janj e ejdoJ poob Jol2euuoD edad Aya 394205 ssousey pue jan S3 UaaMjaq suon euuo Aejay pue pue Aja sseuJeu ispuo ss 10 eleuluunlllly6l 1593 seoq SJA ON Sdwind jany 58 pue og 1461 1591 1 2BuUUuoD SJA Zuni janz 78 v 0935 ol og 1620s 53 ye Jalleq HHUA OE uid esnj uid 19305 Aejas janj Aya 53291018 asnj 993 PND 993 ebeyjo lelledq
42. be able to finish the course at a later time even from a different computer if needed To properly end your session and bookmark your location you must 1 Click the STOP button on the lower left corner of the screen 2 Click on CLOSE in order to properly close the session 3 SIGN OUT Your training session has been bookmarked and can be resumed at a later time Home Catalog My Gradebook fa Home Take Course View Chalkboard Course 2 Chapters Notes PCM Electronic Training Course 213 Troubleshooting Service and Repair of PCM Marine Engine Systems Congratulations on your new PCM Electronic Training PCM m d r n e n gi n B 5 E Train Program software purchase We hope you ll enjoy the new look and convenience of PCM E Train program training online from the comfort and convenience of gt D EALER your dealership or personal computer The PCM E Train Program is a series of electronic courses designed to WORLDWIDE prepare PCM dealers and Service Technicians to do business with PCM pre deliver maintain diagnose and repair PCM marine engines At Pleasurecraft we believe that well trained dealers who stock service parts are absolutely essential to our company s success in fully satisfying our customers PCM s primary focus is first and always the safety and dependability of our products As a result PCM inboards command the highest degree of customer satisfaction in the industry PCM s goal is
43. be down a few psi from specification In this case the system would want to run a little lean The ECM learns that and adjusts the values for the adaptive learn The problem is that it just populated the table based on a lean system Therefore once the filter is replaced and fuel pressure is back to specification this function would Clear the Adaptive Learn tables and allow the ECM to relearn a normal system again L599003 13 57 ENGINE MANAGEMENT SYSTEM 3 DIE I zT Graph coges J Tests system nto 1 ECM Output Tests Warning Please read the messages below rm low D Perform this test with engine idling in NEUTRAL Relay Tests Idle Speed Test Engine speed will be increased to 1200 RPM during this test Clear Fuel Adaption Oxygen Sensor Test Cancel Pleasurecraft Crusader GCP ETC 4G Engine Data 8 47 12 096 Oxygen Sensor Test When selected this commands the ECM to enter into an Automated Test Mode The Engine Management System controls fuel delivery based on Oxygen Sensor feedback The system also monitors the efficiency of the catalyst system by monitoring Oxygen sensors prior to the catalyst substrate pre O2 sensors and Oxygen sensors after the catalyst substrate post O2 sensors This test allows for the technician to run diagnostics on ALL four oxygen sensors The test requires the engine to be idling in
44. designed to be controlled by the boat s mechanical and electrical controls Problems in these areas may cause conditions that may be mistaken for engine defects Often it is necessary to determine if the boats electrical system is the cause of a reported engine problem It will be necessary to separate the engine electrical system from the boats electrical system before testing begins Some common symptoms that may indicate the need for this procedure are 1 Intermittent crank or starts Nocrank or no start The engine cuts off and on during operation Low voltage or dead battery a RO Im Perceived under or over charge conditions Refer to Figure 5 3 Isolating the engine harness from the boat harness is easily done by disconnecting the boat harness at the engine boat harness 8 pin and 2 pin connectors Once you have disconnected the boat harness connectors verify that you have Battery voltage at Pin 1 of the engine s 2 pin connector Troubleshoot System Power if voltage is not present You can then use a remote key switch P N RT0091 at the engine side of the two connectors to simulate Key and START functions that would normally take place through the boat harness and the ignition switch At the engine s 8 pin and 2 pin connectors connect the remote key switch If the engine operates normally with the boat harness disconnected you know the problem lies somewhere within the boat wiring or b
45. eeH 9 SesoH dung ure1q Jo esoH lelul 19 009 IO D SUOIJ8207 uonejeisui uo Buipuedep Aven sesou y edeus 10 pue jenjoe uo sesodind 10 Si siu 910N epouy oulz ulesq JeleN 5 A Bud 2 ees yeus ime 9 d od J8e9H JeleN 18 19 002 Figure 6 6 5550 3 4 Fresh Water Cooling L599003 13 114 COOLING SYSTEM 6 s6nld splollueN D 18 005 9 6 6nld ure1q JO esoH 18 009 UOISSIUISUEJ apouy oulz 6nld SesoH dung o ueq 10 esoH lelul JelooD D 9 Suolleoo1 uonejejsui uo Buipuedep Aven Aew sesou Jo edeus 10 pue Bunnoau eu AIuo sasodind 1 S siu eloN JeleN JeleN d 9 19 002 19 002491U oulz ulesq 489H
46. following operations He she must be fully familiar with all the safety and operational warnings provided by the boat manufacturer for the craft being tested 6 Prior to starting the engine carefully follow the boat manufacturer s starting procedures including operation of the blower etc to ensure safe operation 7 Fuel and oil are the most dangerous items onboard any boat A small oil or fuel line leak may cause a fire or explosion It is imperative that all fuel and oil lines be checked for leaks and corrected prior to delivery to our customer 8 Over or under filling or using oils not recommended by PCM may cause engine or transmission damage which will not be covered under the PCM warranty 9 When working near batteries never use any device that is capable of producing a spark high temperature or open flame Batteries contain sulfuric acid and produce highly explosive gasses that may ignite To prevent serious injury always observe this precaution along with the safety precautions provided by the engine boat and battery manufacturers 10 Always test and service a running engine in a well ventilated area 11 Always wear approved eye protection It is important that you recognize the potential danger to yourself others around you and or property that may be damaged if an accident should occur It is impossible for PCM to foresee all the potential for accidents that are present at the numerous locations and under varying circum
47. for this procedure are 1 Intermittent crank or starts 2 No crank or no start 3 The engine cuts off and on during operation 4 Low voltage or dead battery 5 Perceived under or over charge conditions Isolating the engine harness from the boat harness is easily done by disconnecting the boat harness at the engine boat harness 8 pin and 2 pin connectors Once you have disconnected the boat harness connectors verify that you have Battery voltage at Pin 1 of the engine s 2 pin connector Troubleshoot System Power if voltage is not present You can then use a remote key switch P N RT0091 at the engine side of the two connectors to simulate Ignition ON and START functions that would normally take place through the boat harness and the ignition switch At the engine s 8 pin and 2 pin connectors connect the remote key switch NOTE The remote key switch test harness P N RT0091 can be purchased from the PCM Parts Department Battery voltage is present at pin 1 and a remote key switch is connected to the 2 pin and 8 pin connector If the engine cranks you know the issue is on the boat side of the circuit such as wiring a connection or the ignition switch If you still have a no crank condition you know that the problem lies on the engine side of the circuit such as an EOM wiring or the starter relay L599003 13 96 You have determined from the previous test that the problems lies somewhere in the engine
48. ignition fuel 8 47 12 096 bad cylinder a compression check of the cylinder will isolate this problem and mechanical problems to a specific cylinder of the Best results are obtained when this test is performed with engine This test is part of Step 6A of the PCM Drivability the engine under load in gear running between 1600 Checklist that has been previously discussed You can 1800 RPM RPM changes are more easily seen and use this test as a starting point when troubleshooting heard when the engine is under load ignition problems fuel system problems and various Warning Please follow all engine and boat symptomatic problems such as a misfire conditions 068 rmanufacturer s safety precautions and stay clear of all of power and rough running moving engine components while running this test The Injector Kill Test allows you to turn OFF the injector driver output to a selected cylinder which in turn will greatly aid you in determining if that particular cylinder is functioning properly When you shut OFF an injector to a properly operating cylinder the engine RPM or pitch will change indicating that the cylinder was indeed shut off Typically you will see a 150 200 RPM drop when a cylinder is shut off If there is no change in RPM you may have a cylinder malfunction Cylinder malfunctions can be fuel spark or mechanical in nature Some of the more common causes for a cylinder not firing are bad spark plug foule
49. is only a partial listing of the safety warnings that apply when working on the boat or the PCM product It is required of all technicians performing service on the boat or the PCM product that all manuals be reviewed for the proper procedures and safety precautions these include but are not limited to the boat manufacturer s Owner s Manual and the PCM Owner s Operation and Maintenance Manual NOTE This is only a partial listing of the safety warnings that apply when working on a boat or PCM product All applicable boat and engine manuals should be consulted before beginning work Before attempting to perform any procedure operation or action on the boat or PCM product please read and observe all safety precautions 1 Always refer to and follow the engine manufacturer s safety and service procedures to prevent personal injury and damage to the equipment 2 Always refer to and follow the boat manufacturer s safety and service procedures to prevent personal injury and damage to the equipment 3 Always refer to and follow all test equipment manufacturer s safety and service procedures to prevent personal injury and damage to the equipment 4 The technician should review all owner s manuals boat manufacturer and PCM to become fully aware of all safety and operational warnings before performing any procedure on the boat or engine e The boat operator must be qualified and aware of his or her surroundings in order to safely perform the
50. need diagnosed for a problem such as a failed head gasket Once you have corrected a fluid condition in the cylinder s be sure to perform a compression check of all 8 cylinders to check for indications of other engine damage This test is not all conclusive but may reveal internal engine damage that could cause major engine damage Return to the Starter Circuit Troubleshooting Tree at Verify System Power and verify starter operation Refer Figure 5 8 If the spark plugs are dry Verify System Power You must have a known good source of system power to complete the Starter Circuit testing L599003 13 92 MAIN ELECTRICAL SYSTEM 5 STARTER CIRCUIT TROUBLESHOOTING TREE Reported symptom is a Slow or No Crank condition From Step 3 of the PCM Drivability Checklist When you perform the Visual Inspection 2 Er exhaust system Correct conditions withthe to include physical damage missing exhaust system Continue with exhaust flaps and exhaust restrictions Starter Circuit trouble Remove all 8 spark plugs and inspect for verify starter opration evidence of fluid in the cylinders Ensure the shift lever is in Neutral position Was fluid found in cylinders and or on the spark plugs Verify System Power Wet Check for Diagnostic No Codes Trouble Codes Codes Present Perform Diagnostic Procedure for the Code s present Water Coolant Present Pressure check exhaust Perform diagnos
51. of tests we can quickly isolate this problem The first test will be to verify an unrestricted supply of fuel Without a sufficient supply of fuel proper fuel pressure cannot be achieved Without a sufficient supply of fuel the high pressure fuel pump cannot make or maintain pressure This requires testing of the fuel delivery to the high pressure fuel pump located inside the FCC Disconnect the fuel return line from the FCC to the fuel tank and plug Attach an adequate length approved fuel line to the return fitting on the FCC This is where you will measure the amount of fuel required during the low pressure fuel pump volume test The Low Pressure Fuel Pump should output at least 16 to 20 ounces of fuel in 10 seconds Be sure you use an approved container to capture the fuel output and have a graduated measure to verify the quantity of fuel A one quart glass measuring cup is very useful for this Not only can you accurately measure the fuel but you can also see if you have contamination in the fuel Low Pressure Fuel Pump Volume Test 1 Disconnect the return to tank fuel line from the FCC 2 Connect a piece of fuel line between the FCC return output and an approved empty container 3 Remove the Fuel Pump Relay 4 Jumper relay socket Pin 30 to Pin 87 for 10 seconds then disconnect jumper 5 Verify 16 20 oz of fuel in the container 6 Return system to normal configuration If the result of the test is low output v
52. of your Reference Material which will be discussed in more detail in the Cooling System section of this course These trouble codes illuminate the Check Gauges Lamp CGL When equipped the CGL is RED In many models these trouble codes are reported through a digital dash display L599003 13 46 ENGINE MANAGEMENT SYSTEM 3 pais jeubis Josueg punog JOSUaS ii INWL pays V Josueg p due LHM e 19M ma plolueW 8 ijsneux3 6118 IHAMW Ta8 pqs TEMAS 4L WL JOSUBS 40101 uuoo woy 8 Josueg YURID OL Apog emoJu ru is jeubis Joyenjoy Josuag 205095 2 105 05 41 uonisog dL dL ma 11 ma 11 8 9 GY pubis W23 L40sueg 105 elnpo 1 dL dL 104009 2 1504 815 OL HM nna 81S OL 1 uuo2 Josues 01 punoJt C JOON V 9 NHO INVL LHM ANd 8 28 JoloIN JoloN 10505 souejele Hed N93 hen In pel vr 1 iiis uod V JOSU8S MANG gt due 5 IHME plolueW IHNW T8 LHM IHME 6 IHME IHME HM g Josuas 103 Ba L WL juejooD UuoD Josues LHM Josueg uuo 208
53. return to tank fuel line from the FCC Connect a piece of fuel line between the FCC return output and an approved empty container Remove the Fuel Pump Relay Jumper relay socket Pin 30 to Pin 87 for 10 seconds then disconnect jumper Verify 16 20 oz of fuel in the container Return system to normal configuration FAIL Connect an auxiliary fuel tank to the input of the LPFP Repeat fuel pump volume test Fuel volume to spec PASS FAIL Troubleshoot and repair Replace LPFP fuel restriction on supply Verify repair inlet side of the LPFP Verify repair Inspect and repair FCC internal high pressure hose fittings and connections If good Replace HP fuel pump Verify repair Replace Fuel Pressure Regulator Verify repair Troubleshoot fuel rail for leaking injector s and repair Verify repair Figure 2 10 Fuel System Fuel Pressure Out Of Range L599003 13 27 NOTES L599003 13 28 A E N B PREMIER DEALER WORLDWIDE Section 3 Engine Management System ENGINE MANAGEMENT SYSTEM 3 Engine Management System Overview The ECM Engine Control Module is the brain of the Engine Management System The ECM is responsible for maintaining the proper spark and fuel delivery for all operating conditions of the engine To provide optimum drivability and emissions the ECM monitors various input or sensor signals in order to calculate ignition control and fuel deli
54. stops cranking If the fuel pumps do not run for 2 4 seconds after the engine stops cranking the ECM did not turn the pumps on Perform the On Board Diagnostic System Check to troubleshoot this problem NOTE Turning the key to the START position resets the ECM which will enable the fuel pumps for 2 4 seconds for prime If the engine is failing to start be sure to crank the engine for a minimum of 5 seconds You are checking to see if the ECM is receiving the Crankshaft Position Sensor CKP signal which enables the fuel and ignition circuits It is the CKP signal that causes the pumps to run for 2 4 seconds after you stop cranking the engine For troubleshooting utilize the Diacom scan tool to observe Battery Voltage Engine Speed and Fuel Pump Output status while the engine cranks Your action of turning the key ON then to the START position has allowed you to verify more of the operational capability of the three engine systems Electrical Fuel and Engine Management The additional circuit and component functions verified are 1 Main Electrical System All of the Starter Circuits to include the starter relay transmission neutral safety switch starter the associated power and grounds the boat s ignition and safety lanyard circuits and the Battery meets the minimum system voltage requirements 2 Engine Management System IF the fuel pumps run for 2 4 seconds after the engine stops cranking the Cran
55. switch to the ECM Repair as necessary Verify relay socket pin 86 ranks path to 8 pin connector pin 5 Repair as necessary 2 Starter Relay erify Repair Verify Repair No Crank Verify and repair wire between relay socket pin 87 5 terminal of the Starter Verify repair kkkkkk IMPORTANT kkkkkk When you have completed your troubleshooting and repair of the starter be sure to Reinstall the System Relay then verify the engine starts and runs Figure 5 10 Starter Circuit No Crank Troubleshooting Tree L599003 13 98 Charge Circuit The most common problems associated with the Charge Circuit are 1 A dead battery 2 An over under charge voltage reading on the instrument panel These problems may be the result of 1 An improperly tensioned drive belt Failing battery Failing alternator An excessive current drain on the battery or a Inm Defective gauges and wiring Refer to Figure 5 11 The charge path is from the BAT connection on the Alternator through the 100 Amp Fuse to the Starter BAT connection From the Starter BAT connection to the Battery Positive connection Ground is from the Alternator GND stud to the Starboard ground stud on the engine back to the Battery Negative connection MAIN ELECTRICAL SYSTEM 5 L599003 13 99 MAIN ELECTRICAL SYSTEM 5 2 Pin BLACK 6 ga E 8 Pin 100A 70A g BELLHOUSING Boat Harness yee E me
56. systems Place the ignition switch in the Key ON Engine OFF KOEO position Ensure the boat s safety lanyard is properly connected You should listen feel and observe that the following actions take place 1 Both fuel pumps run for 2 4 seconds Listen for each pump and place your hand on each pump to verify that it is indeed running Diacom can be used to cycle the fuel pumps as necessary NOTE You can unplug the low pressure fuel pump mounted to outside of electrical connector and cycle the ignition to listen and feel whether the high pressure fuel pump located inside FCC runs 2 Observe the Fuel Pressure Gauge fuel pressure should rise to the proper specification while the fuel pumps run You have learned a lot about the engine systems when you turned the ignition ON The simple action of turning the key to the ON position has allowed you to check three engine systems simultaneously Electrical Fuel and Engine Management If the actions described in the previous frame occur then you have verified the Boat s Ignition Switch Boat s Safety Lanyard circuit Low and High Pressure Fuel pumps Relays System and Fuel Pump Fuse Block fuses and 100A Fuse A ECM powered up and functioned to turn on the fuel pumps N Battery voltage is at least 9 6 vdc and 8 Power and ground circuits and related components are functioning L599003 13 15 PCM DRIVABILITY CHECKLIS
57. that all engine manufacturers have the same identification numbers for each emission failure Failures are now identified by a Suspect Parameter Number SPN and Failure Mode Indicator FMI Both of these numbers are required in order to identify the exact failure detected NOTE Diacom only displays the FMI and SPN numbers Be sure to have both these numbers for each fault displayed Diacom does not report the DTC number OBD System Check During a previous discussion on the PCM Drivability Checklist it was noted the reported problem may be found and corrected during any step of the checklist During Step 4 refer to Figure 3 1 you checked for both system power and starting capabilities of the engine You did this when you turned the key to the ON and then START positions If the actions described did not occur you would have begun troubleshooting and repair of the Main Electrical System Engine Mechanical System or the Fuel System If we completed Step 4 then we have determined the basic engine condition to be normal at this point in our testing Step 5 of the Drivability Checklist OBD System Check is the first diagnostic procedure you will perform for any remaining drivability issue with the engine Important Starting issues are not the same as starter issues If the engine has a cranking problem diagnose that problem first through the Main Electrical system troubleshooting If the engine cranks normally 150 200 rpm but wi
58. the CAN BUS circuit that could be affecting communications L599003 13 36 ENGINE MANAGEMENT SYSTEM 3 OBD System Check Important Do not perform this diagnostic if there is not a drivability concern unless another procedure directs you to that diagnostic Before you proceed with diagnosis search for applicable service updates Before you proceed with diagnosis perform a visual inspection of the engine for damaged wiring connections assemblies or added accessories If there is a condition with the Main Electrical System such as a starter or charging system problem repair that first Ensure the battery has a full charge Ensure the battery cables are clean and tight Ensure the ECM grounds are clean tight and in the correct location Unless a diagnostic procedure instructs you DO NOT clear the DTC s Attempt to start the engine Does the If a flooded engine is engine start No suspected go to wide open and continue to throttle and attempt to restart run the engine Does the engine start and continue to run Yes Ignition ON engine OFF Ignition ON engine OFF Install Diacom Diagnostic Scan Tool DST Attempt to connect and display ECM Engine Data Connect a fuel pressure gauge to fuel rail Do both fuel Does the scan tool connect and display ECM data
59. the cause of the overheat and cleared the ECM of codes these codes should not return L599003 13 122 COOLING SYSTEM 6 Aja 159 Mey jeaday Sapo JO W23 Jea D pue Mel o2e day Ji Jo jees Buisnoy 32adsu peuinbai se obe x o q 10 suon u1seJ syeay 104 JeleN 12edsu pauinbau se 1 pue Hulsnoy 1215 1 69504 suuqep Je9 5 10 su1ed 3ndino pue lndul 32adsu 10 Jajjaduy 941 2adsul 1 55 gt se 423 10 Aejdsip AInej 10 72945 se seday jeoq au pue W53 SUOI DBUUOD HULIM yay 6oleuV jusA pue Sopoo JO N23 123 e ejdey Aja SAG NYD j yeog Alnej ade da J sebne6 Ny JeUlo JO uoneJedo 1294102 Aya Sng NYD 01 UlU1IM e dsip yeog pue
60. thermostat housing MUST be assembled and tightened as shown in the vertical position Failure to do so may cause the thermostat to improperly seat and result in a leak A 3 4 Fresh Water Cooling System circulates antifreeze through The engine block and cylinder heads The heat exchanger The exhaust manifolds A Full Fresh Water Cooling System circulates antifreeze through The engine block and cylinder heads The heat exchanger The exhaust manifolds The exhaust corners NOTE Refer to the PCM Owner s Operation and Maintenance manual to properly identify the cooling System you are working on This is important to properly identify the raw water draining locations The raw water pump impeller should be serviced every 50 hours or once a year whichever occurs first See Maintenance Schedule Locations A are access holes in order to loosen the raw water pump attaching bolts The bolts are secured in the pump by O rings and will not fall out during removal Torque the raw water pump housing attaching bolts to 8 5 9 1105 11 5 12 when re installing the impeller NOTE PCM Impeller Kit Part Number is RP061022 for all current modular engine mounted raw water pumps L599003 13 108 COOLING SYSTEM 6 9 1 JelooD UOISSIUISUEJ p jsneux3 eunssaoJd oAISS
61. to continue to maintain a network of knowledgeable dealers who can provide parts service and warranty on the PCM product line The PCM E Train is one tool used to elevate the standards of PCM service technicians who were already providing a superior uncompromising commitment to customer satisfaction to a level not seen before Thank you for choosing to be part of the PCM Premier Dealer Worldwide Team 1 STOP DOBLE _ 2 Close L599003 13 4 SECTION CHECKPOINTS At the end of each section or chapter a Checkpoint dialogue box will appear The Checkpoint requires you to click OK to proceed to the next section You must click OK within one minute or the session will time out If you allow the session to time out this way when you log back in you must start the course over from the beginning BE SURE to stop the session and properly close out so a bookmark is established and you can resume where you left off Brian Emenheiser 0 items Checkpoint Proceed To The Next Section fh Home Take Course View Chalkboard Course 2 Chapters Notes 00 00 Introduction Section 04 25 04 25 Parts and Warranty Procedures Sec marine engines Proceed To The Next Section OK L599003 13 9 SAFETY PRECAUTIONS PCM s primary focus is first and always the safety and dependability of our products As a result PCM inboards command the highest degree of customer satisfaction in the industry The following
62. wiring and circuits the next check is for starter control voltage at the Starter relay socket 1 2 Remove the Starter Relay from its socket Install a remote key switch to the 2 pin and 8 pin connector Turn the Key to the START position While the engine is cranking measure battery voltage between socket pins 85 ground TP 6 and 86 B TP 5 a If the voltage is not present troubleshoot the power and ground paths Verify continuity 0 ohms between relay socket pin 85 TP 6 and the ECM Starter Relay control pin TP 9 You have already verified the operation of the Transmission Neutral Safety Switch Repair ground circuit as required b Verify ignition voltage from relay socket pin 86 TP 5 back to pin 5 of the 8 Pin boat engine harness connector Look for a break in the MAIN ELECTRICAL SYSTEM 5 wire or bad connection between pin 86 and the switch TP 4 or between the switch TP 3 and pin 7 of the 8 Pin boat engine harness connector Repair power circuit as required need to determine if the relay is defective or the wire between socket pin 87 TP 8 to the starter S terminal is defective Verify that battery voltage is present at pin 30 TP 7 o the relay socket a If not troubleshoot and repair the break in the If the control voltage is present at the relay socket you f wire between pin 30 and the main power circuit connection If voltage is present jumper pin
63. 095 9 WL Josues dol OL OL L1 Wa uuo9 Josueg qaad yuen oL 4d WL uod uuoD uoniub 01 WOL OL WIOL cO 84d uod OL W uuo 2108095 OL 208095 eJnsseJg IO 9 M uuo Josueg md 8215 61 64 99U9J9J9H jeubis S Josueg eunsseJg O Figure 3 5 Power Derate Mode ECT Circuit L599003 13 47 ENGINE MANAGEMENT SYSTEM 3 AUBA Aja Mey 9 Sapo Jo W23 1 Bulsnoy pue Mel o2e day 5 Ji e ejdaj 10 ees buisnou 32edsu peuinbaa se edas obex o q 10 suonou1seJ eal 104 u1ed 55 gt se lndlno IN23 10 AInej 10 72945 pauinbau se Aejdsip jeoq au pue IN23 yay 5 6oleuV Kjlj9A pue SapoD JO DJ 123 e ejday Apa UJe qoJd lin24D SAG NYD 19u10 Aejdsip yeog Knez yo Jj se6neb Ny Jo uonejedo 12894105 JUBA Sng NYD uonej
64. 0A BELLHOUSING 0 pi ER 2 1 RED WHITE 10ga 125 m 8 e e _ c m zt Fuse Block Bae Starter BATTERY YEL RED vEL mED 7 amp Pin 12 ga 12 ga o al Starter y Relay To ECM Control TRANSMISSION INEUTRAL DM To EXC YELLOW 12 STARTER s LOW 12 ga Alternator To ECM iani 1 Control gnition HEUS p gt a PURPLE 5 8 Pin 14ga GROUND ENGINE BLOCK Da Fuse Block A VSW Y Fuse Not Used _ 5A Purple By LI 7 To ECM Ignition ru A Relay Fuse Block Fuse Block Control Pin 1 Y Fuel Pump o EM EOM Relay Fuse Ignition Fuse 20A 20A Feed Pin B i BI 4 Fuse Block IGN 1 To STBD Pink Fuse ENS GRD STUD Black 20 B BELLHOUSING To ECM Battery Feed Pins Fuel Pump Relay Fuel Control Cell N To Coils To Injectors Low Pressure ot Used m Module O2 Sensors Fuel Pump To Elec _ Pnk Yel White Pnk Yel uel Pumps FROM ECM Ground FUEL PUMP BLACK 109a pin RELAY 125 C CONTROL To Ignition ALL STBD To ECM Control GROUNDS Ground Pins Module CENTER GROUND STUD GROUND STUD GROUND STUD BELLHOUSING BELHOUSING BELLHOUSING ECM GROUND ONLY 5 0 5 7L ONLY Figure 5 2 Main Electrical System Wiring Diagram L599003 13 85 MAIN ELECTRICAL SYSTEM 5 Isolating the Electrical System The engine is
65. 2 For raw and fresh water systems the next action will be to replace the thermostat and retest Whenever you replace a thermostat ensure that the housing and thermostat seat are free of debris and scale Ensure that the new thermostat is orientated and seated properly For freshwater systems inspect the heat exchanger fresh water passages for scale and build up and debris If the heat exchanger cannot freely pass raw water the engine will overheat If you have performed the aforementioned actions and the engine still overheats inspect and test the circulating pump Typically a circulating pump failure will be characterized by a wobbly serpentine pulley and leakage around the pump shaft or housing Refer to Figure 6 13 PASS path After you have completed the mechanical inspections and tests for an overheat problem you may find that you have a perceived overheat condition Connect the Diacom scan tool and begin by checking for stored trouble codes The Engine Temperature Higher than Expected Stage 1 and or Stage 2 trouble codes may be stored indicating the Engine Coolant Temperature ECT sensor detected a high temperature condition in the engine EMWT 1 and or EMWT 2 Temperature Higher than Expected Stage 1 and or Stage 2 trouble codes may be stored indicating the exhaust manifold water temperature sensor s if equipped detected a high temperature condition in the exhaust manifold cooling system Once you have corrected
66. 2 Using the PCM Drivability Checklist will help you to remember to do all the steps for every problem The PCM Drivability Checklist The following seven checks are the basis for the PCM Drivability Checklist Figure 2 2 The seven steps of the Basic Troubleshooting Approach can be applied to every problem that you encounter 1 Obtain a clear concise description of the problem Whenever possible interview the owner operator and understand any conditions leading up to and during the problem occurring Understanding if recent service has been performed or a recent abnormal event has happened can greatly aid you in your troubleshooting effort Often an owner operator provides only information about the symptom that is currently present Find out if any recent work was performed on the engine such as a broken belt or failed raw water pump impeller Has someone already tried to correct the current problem Have any new accessories been added lately Did the problem occur shortly after the last time he refueled Did the problem occur after a recent repair such as a hull repair where the underwater gear was replaced As you can see there are numerous questions that could be asked based on the symptom and the owner operator s responses Some of the more important questions to ask are detailed on the PCM Drivability Checklist Figure 2 2 Step 1 Based on the symptom you receive from the owner operator you may
67. 3 13 24 PCM DRIVABILITY CHECKLIST 2 STARTER CIRCUIT TROUBLESHOOTING TREE NO CRANK CONDITION No Crank Connect a Remote Starter Switch between the Starter s Battery and S terminals Momentarily engage the switch No Crank Cranks Verify Transmission Neutral Verify repair Safety Switch operation Adjust shift linkage or Replace Transmission Neutral Safety Switch as necessary Disconnect the 2 pin Boat Harness connector NO Troublesh otand loss Is battery voltage present at pin 1 of the Gk sustento dt de iq connector y P P Momentarily jumper engine 2 pin connector pin 1 to 8 pin connector pin 7 Does the engine crank YES Remove Starter Relay Repair boat wiring Jumper engine 2 pin connector Verify repair pin 1 to 8 pin connector pin 5 Is battery voltage present between relay socket pins 85 and 86 4 YES Verify battery voltage is present at pin 30 of the starter relay socket Troubleshoot and repair power to pin 30 as required Verify repair Momentarily jumper relay socket pin 30 to 87 Verify relay socket pin 85 path to ground The ground path goes through the neutral safety switch to the ECM Repair as necessary Verify relay socket pin 86 Conk path to 8 pin connector pin 5 Repair as necessary Starter Relay erify Repair Verify Repair No Crank Verify and repair wire between relay socket pin 87 S ter
68. 30 TP 7 to pin 87 TP 8 of the relay socket If the engine cranks replace the starter relay a If the engine does not crank repair the wire between pin 87 of the relay socket and the S terminal of the starter L599003 13 97 MAIN ELECTRICAL SYSTEM 5 STARTER CIRCUIT TROUBLESHOOTING TREE NO CRANK CONDITION No Crank Connect a Remote Starter Switch between the Starter s Battery 5 terminals Momentarily engage the switch No Crank Cranks Replace Starter Verify Transmission Neutral Verify repair Safety Switch operation Adjust shift linkage or Replace Transmission Neutral Safety Switch as necessary Disconnect the 2 pin Boat Harness connector NO Troubleshoot and repair loss Is battery voltage present at pin 1 of the AED of system power at 1 connector YES Momentarily jumper engine 2 pin connector pin 1 to 8 pin connector 7 Does the engine crank YES Remove Starter Relay Repair boat wiring Jumper engine 2 pin connector Verify repair 1 to 8 pin connector 5 Is battery voltage present between relay socket pins 85 and 86 4 YES Verify battery voltage is present at pin 30 of the starter relay socket Troubleshoot and repair power to pin 30 as required Verify repair Momentarily jumper relay socket pin 30 to 87 Verify relay socket pin 85 path to ground The ground path goes through the neutral safety
69. 54 3227 EGO2 open lazy DTC 160 3266 EGO4 open lazy The trouble codes above are associated with the four oxygen sensors These failures probably indicate a failure in the sensor wiring or ECM circuits Refer to the Diagnostic Procedure in the diagnostic manual for the organized approach to correcting the present fault s EGO 1 Left side odd cylinder side Pre O2 Sensor EGO 3 Left side odd cylinder side Post O2 Sensor EGO 2 Right side even cylinder side Pre O2 Sensor EGO 4 Right side even cylinder side Post O2 Sensor Diagnostic Trouble Suspect Parameter Failure Mode Code DTC Number SPN Identifier FMI Fault Description DTC 1411 DTC 1412 DTC 1413 07011414 The trouble codes above associated with the two Exhaust Manifold Water Temperature EMWT sensors These failures probably indicate a failure in the sensor wiring or ECM circuits Refer to the Diagnostic Procedure in the diagnostic manual for the organized approach to correcting the present fault s EMWT 1 Left side odd cylinder side EMWT 2 Right side even cylinder side Diagnostic Trouble Suspect Parameter ailure Mode Code OTC DTe 1415 EMWT2 higher than expected stage 2 The trouble codes above are associated with the two Failures setting these trouble codes may consist of but Exhaust Manifold Water Temperature EMWT sensors not limited to cooling system problem raw water flow These failures indicate that the
70. 70 FUEL SYSTEM 4 STEP 4 VERIFY THE PROBLEM IMPORTANT FOR REPORTED MAIN ELECTRICAL SYSTEM PROBLEMS SUCH AS STARTER OR CHARGE YES SYSTEM PROBLEMS STOP START THE ENGINE PERFORM MAIN ELECTRICAL SYSTEM Does the engine start and run TROUBLESHOOTING FIRST NO START 4 1 Key ON Engine OFF NO Refer to the KOEO Do Both Fuel Pumps Run 2 4 Seconds Pump s Do Not Run then turn off Troubleshooting Tree YES Is fuel pressure within NO 22 ification while fuel specification while fuel pumps run Troubleshooting Tree YES 4 2 Key ON Engine Running Does the engine crank over for 5 seconds if the NO Refer to the Starter Circuit Troubleshooting Tree engine does not start YES Does fuel pressure rise near specification while engine cranks and fuel pumps run 2 4 seconds Perform the OBD System Check after the engine stops cranking if engine does not start Does the engine start and continue NO Perform the OBD to run System Check YES WATER TEST m o Verify the Owner reported problem Ref heF Is fuel pressure within specification NO rue under load W O T YES STEP 5 OBD SYSTEM CHECK Pressure Out Of Range Troubleshooting Tree Figure 4 3 Verify the Problem L599003 13 71 FUEL SYSTEM 4 requirement The ECM can be damaged if the non KOEO Pump s Do Not Run Refer to Figure 4 4 Key On Engine Off Troubleshooting Tree We need to deter
71. Clamp Meter clamp the meter on the positive battery cable connected to the starter Set the meter for DC Amperage reading Turn the key to START Observe meter reading Are readings within range listed Typical 5 0 5 7L 150 250 A Typical 6 0 8 1L 210 325 A YES duras 5tarter Normal Verify repair Operation Check both cables NO Negative Battery Cable Check Positive Battery Cable Check Connect DMM to the battery Connect the DMM lead to the post Connect DMM to the battery post Connect the starboard engine block ground DMM lead to the Starter stud Turn the Key switch to battery terminal Turn the START and observe your DMM for key to START and observe the a reading less than 2 vdc DMM reading is less than 6 vdc YES YES Normal Normal NO Troubleshoot positive cable back to the battery Ensure that devices such as a Battery Switch are connected and functioning properly Verify the positive cable is the same Replace negative battery cable with one of the correct gauge and length gauge from the starter to the battery Replace undersized cable with the correct size Repair or replace postive cable with one of the correct gauge and length Verify Repair kkkkkk IMPORTANT kkkkkk When you have completed your troubleshooting and repair of the starter be sure to Reinstall the System Relay then verify the engine starts and runs Figure 2 7 Starter Circuit Slow Crank L59900
72. Crusader GCP ETC 4G Engine Data 8 47 12 096 Clear Misfire Data When selected this commands the ECM to erase all Misfire data stored in the ECM The ECM constantly monitors various inputs to determine if a cylinder is misfiring The ECM stores data every time a cylinder misfires This data is stored for each cylinder This data can be retrieved through the System Info tab using your Diacom Misfires can be damaging to the catalyst system if ignored There are two levels of misfire trouble codes associated with the engine management system There is Cylinder Misfire trouble codes for each cylinder and there is Catalyst Damaging Misfire trouble codes for each cylinder Abnormal vibrations to the crankshaft can also be induced by such things as bent propshaft or bent prop This function would only be used after a repair is made An example would be if an engine was diagnosed to have a bad spark plug wire on cylinder 3 In this case the ECM has detected and accumulated misfire data on cylinder 3 Once the spark plug wire is replaced and the problem is corrected this function would reset the ECM misfire data back to 0 Caution Reseiting misfire data before a repair of a misfire condition can cause the system to NOT detect an actual misfire under certain operating conditions L599003 13 61 ENGINE MANAGEMENT SYSTEM 3 BASIC TROUBLESHOOTING APPROACH Obtain a clear concise description of the problem Check for applicab
73. E ALTERNATOR PURPLE WHITE From 5 2 5 Harness Fuse Block Panel To STBD a Fuse GRD STUD D 40A T BELLHOUSING mm attery 9 c 1 Q Pin Red e Purpl PUR Fuse Block Starter Starter Relay Fuse BATTERY vEL RED 7 8 12 ga al Y To ECM Control Not Used Ly TRANSMISSION NEUTRAL To EXC STA RT E R S YE LLOW 12 ge Alternator To ECM Control Ignition L dum N Bl JIRPLE 5 8 14ga GROUND ENGINE BLOCK Fuse Blockl A VSW Fuse 5A B JN To ECM Ignition Al Relay Fuse Blacki Control Pin Y ECM Fuel Pump To ECM Relay Fuse Ignition 20 20 B eH Feed Pin Fuse Block Fuse Block IGN 1 STBD Fuse 182 STUD 20 By B BELLHOUSING To ECM Battery Feed Pins Fuel Pump Relay Fuel Control To Inject Cell Not Used Light o n i n ors Low Pressure Blue Module 2 Sensors Fuel Pump To Elec Pnk Yel White G m m Pnk Yel uel Pumps FROM ECM Ground FUEL PUMP BLACK 10948 9 pin RELAY 125 C CONTROL To Ignition ALL STBD To ECM Control GROUNDS Ground Pins Module eti STUD G
74. ECM has detected problem restricted exhaust cooling system thermostat temperatures higher than expected There are two etc Refer to the Diagnostic Procedure in the diagnostic different levels of temperature Stage 1 puts the system manual for the organized approach to correcting the into Power Derate and allows up to 35 maximum present fault s throttle Stage 2 puts the system into Power Derate and EMWT 1 Left side odd cylinder side allows only An Blevated idie spssd EMWT 2 Right side even cylinder side DTC 1416 OTC 1417 DTC 1418 L599003 13 135 CATANIUM CLEAN EMISSION SYSTEM CES 7 ailure Mode Identifier FMI Diagnostic Trouble Suspect Parameter Code DTC Number SPN Fault Description DTC 301 1323 Cylinder 1 emissions catalyst damaging misfire DTC 302 1324 Cylinder 2 emissions catalyst damaging misfire DTC 303 1325 Cylinder 3 emissions catalyst damaging misfire DTC 308 1330 Cylinder 8 emissions catalyst damaging misfire The trouble codes above are associated with engine misfire The engine management system is constantly monitoring the crankshaft position sensor for engine misfire Depending on the level of misfire it can be damaging to the catalyst substrate These trouble codes are set when the level reaches a potential catalyst damaging condition Some conditions that can cause misfire detection but not limited to are faulty injector faulty spark plug wire faulty spark plug
75. EM 3 DTC 0117 ECT Sensor Circuit Low Voltage SPN 110 FMI 4 ECT Signal A a AAA B 20 5Vrtn1 Thermistor ECT Sensor lt g O e Engine Coolant Temperature Sensor e Check Condition Engine Running Fault Condition sensor voltage less than 0 050 volts Corrective Action s Sound audible warning or illuminate secondary warning lamp disable adaptive learn fueling correction during active fault or any combination thereof as defined in calibration Recommend a power derate 1 2 to reduce the possibility of engine damage due to the inability to sense temperature Non emissions related fault The Engine Coolant Temperature sensor is a thermistor temperature sensitive resistor located in the engine coolant This is used for engine airflow calculation ignition timing control to enable certain features and for engine protection The ECM provides a voltage divider circuit so when the sensor reading is cool the sensor reads higher voltage and lower when warm This fault will set if the signal voltage is less than 0 050 volts The ECM will use a default value for the ECT sensor in the event of this fault Ignition ON Engine OFF Key OFF Disconnect ECT sensor electrical connector Key ON Engine OFF Does DST display ECT Sensor Volts 0 5 volts Intermittent Problem Does DST d
76. Engine OFF ves NO Fuel Press Fuel Pressure near wot specification when pumps run 2 Key ON Engine Running KOER VES NO Fuet Press Check Accessories Added Heater Shower Hot Water Tank Flush Kit Multi Function Display Synchronizer L After Market Stereo Equipment L After Market Depth Fish Finder L After Market Navigational Equipment Engine mmu uem E engine cranking Engine Starts and continuestorun goto 3 WeaterTest 3 WATER TEST YES NO FuelPress Verify reported symptom Fuel Pressure idle Fuel Pressure under load WOT such as GPS Radar Sonar Auto pilot systems Radio Equipment L Lights L Other please list 4A Revised or additional symptom found Figure 3 1 PCM Drivability Checklist L599003 13 33 ENGINE MANAGEMENT SYSTEM 3 PCM DRIVABILITY CHECKLIST 5 PERFORM THE OBD SYSTEM CHECK CODE S PRESENT DIAGNOSTIC PROCEDURE USED Continue to Step 6 6 ISOLATE AND REPAIR THE PROBLEM Were you able to isolate and repair the problem If YES continue to Step 7 If NO complete the Drivability Checklist for No Codes step 6A below If the problem is still not resolved then call for factory technical assistance 6A NO CODES ENGINE RUNS DRIVABILITY SYMPTOM STILL PRESENT Inspection or Check Inspecti
77. G COM Figure 3 2 FUSE BLOCK PIN OUT DIAGRAM When you successfully complete the OBD System Check you will have accomplished one of the following actions 1 Identified and corrected the problem by performing one or more of the diagnostic procedures which supports the completion of the OBD System Check 2 Identified and corrected the problem by performing the Diagnostic Procedure for a stored Diagnostic Trouble Code DTC 3 Completed the OBD System Check with no DTCs present and the drivability symptom still present Items 1 and 2 above would require you to execute the additional diagnostic procedures you were directed to by the OBD System Check Item 3 requires you to complete the checks and inspections previously discussed as part of Step 6 of the PCM Drivability Checklist Refer to Figure 3 1 the PCM Drivability Checklist Step 6A and Figure 3 3 Drivability Checklist No Codes Troubleshooting Tree Clearing Diagnostic Trouble Codes procedure is located in Section 5 Diagnostic manual One of the most important items to note is that the ignition must be cycled OFF or the code may not be cleared from the ECM s memory It is important to note the conditions under which the ECM will or will not set a code Occasionally during troubleshooting you may wish to verify that a device or circuit will or will not set its code Disabling or disconnecting the circuit and turning the ignition ON is not enough to set a code The
78. Inspect engine oil for coolant Inspect spark plugs for evidence of coolant A coolant leak into the combustion chamber usually is evidenced by a lack of carbon build up on the piston and or a white or gummy residue deposit on the spark plug Add a small amount of marker dye to the engine coolant Run the engine under load Evidence of dye in the raw water expelled through the exhaust would indicate a defective Heat Exchanger Pressure test the heat exchanger engine exhaust manifolds and elbows and perform a compression check prior to replacing the Heat Exchanger Verify Repair Engine Running Pressure Cap Installed 1 Verify coolant circulation in Degas Bottle 2 Allow engine to achieve normal operating temperature 3 Verify that coolant level rises and falls slightly as engine achieves and maintains operating temperature Normal Operation Pressure test exhaust manifolds and elbows Replace defective parts as necessary then retest If no defects are found Refer to the Engine Mechanical Service manual for diagnosis of an internal engine failure Figure 6 15 Troubleshooting Tree Fresh Water Coolant Loss L599003 13 126 Troubleshooting an Under Temperature Condition Refer to Figure 6 16 An under temperature condition will cause over fueling of the engine under both cold and warm running conditions The owner may or may not notice the build up of black soot on the transom and excessive fuel burn
79. Master Engine Specification Sheets L510030 GCP 4G Diagnostic Service Manual NO 2 v DISTRIBUTOR L510015 5 0 5 7L Engine Mechanical Service Manual SR 7 1510016 6 01 Engine Mechanical Service Manual PCM Premier Dealer Website All the Latest Sena ALL V 8 MODELS Publications FIRING ORDER FIRING ORDER FIRING ORDER 1 8 4 3 6 5 7 2 1 2 7 5 6 3 4 8 1 8 7 2 6 5 4 3 Figure 4 2 PCM Drivability Checklist L599003 13 69 FUEL SYSTEM 4 Refer to Figure 4 2 Step 4 of the Checklist was to Verify the Problem During that step you performed a number of steps leading up to verifying the reported symptom Figure 4 3 is a Troubleshooting Tree for these steps As you can see two of the tests and observations that you perform are directly related to the Fuel System When the ignition is in the ON position first 2 4 seconds or you cycle the pumps ON using Diacom there are a number of possible outcomes that could occur The best outcome is that both fuel pumps run and the fuel pressure rises near the WOT specification The other possibilities are one or both pumps do not run or the pumps run and fuel pressure is not to specification As you can see from Figure 4 3 if the pumps do not run you would use the KOEO Fuel Pumps Do Not Run Troubleshooting Tree Figure 4 4 or the Fuel Pressure Out Of Range Troubleshooting Tree Figure 4 7 L599003 13
80. NOTE Starter problems are those associated with cranking the engine Starting problems are those associated with making the engine run Starter problems should be addressed before performing any other troubleshooting procedures The most common problems associated with the Starter Circuit will be 1 Ano crank 2 Slow crank condition Typically these conditions may be the result of 1 A defective ignition switch or control Afailing battery Afailing starter Afaulty starter relay a amp misadjusted or failed Transmission Neutral Safety Switch 6 An engine mechanical problem Refer to Figure 5 7 The starter circuit path is from the battery positive connection to the Starter BAT connection through the 100A fuse to the 20A Starter Relay Maxi fuse From the Maxi Fuse to pin 30 of the Starter Relay Power from Pin 1 of the 2 Pin connector is routed through the boat harness to the Ignition Key Switch When the Key Switch is in the START Position power is routed back through the boat harness to pin 7 of the engine boat harness 8 Pin connector to ECM Starter Circuit pin which energizes the relay Ground for the Starter Relay is relay pin 85 through the neutral safety Switch to the ECM Starter Relay Control circuit pin When the Starter Relay closes power from pin 30 is routed through the relay to pin 87 then to the Starter Solenoid S contact causing the Starter to engage and crank th
81. Operator Name Person Reporting the problem if different from owner operator Service Writer or Person that took the problem report 1 PROBLEM OR SYMPTOM Who first observed the symptom When did the symptom first occur Any recent change or service work prior to symptom occurring replaced belts or impeller major engine or boat repairs recently refueled etc Has someone other than yourself tried to correct the current symptom If yes what work was done Accessories Added Recently Is the symptom currently present Special conditions if any required to duplicate the symptom Use an additional sheet of paper if more space is required for symptoms or descriptions 2 CHECK FOR SERVICE UPDATES ENGINE SERIAL NUMBER ENGINE MODEL NUMBER ENGINE HOURS HULL NUMBER ENGINE None Apply __ Performed BOAT None Apply Performed 3 VISUAL INSPECTION Inspection Evidence of an over heat Evidence of or Excessive Water Engine Harness connectors in the Bilge connected properly Fluid levels checked Physical Damage wiring connectors Leaking Fluids assemblies and Remove Spark Plugs Firing order correct and inspect for fluids Correct size propellers installed __ Corrosion Underwater gear is undamaged Hull clean and free of excessive growth Accessories added If yes check items 4 VERIFY THE PROBLEM Does the engine start and continue to go to 3 go to 1 Key ON
82. ROUND STUD GERTHGUSINC GROUND STUD BELLHOUSING 5 0 5 7L ONLY BELLHOUSING ECM GROUND ONLY iud Figure 5 11 Charge Circuit Wiring Diagram L599003 13 100 Charge Circuit Testing NOTE Always perform the system power check before troubleshooting a charge circuit problem a weak or failing battery can give false test results Refer to Figure 5 12 The Charge Circuit Troubleshooting Tree The first two steps of the Charge Circuit Troubleshooting Tree will be to Verify System Power then perform a Visual Inspection which includes checking the drive belt for the proper adjustment When you perform your visual inspection make sure all connections are tight and free of corrosion Look for conditions that may cause an Alternator failure such as a coolant leak above or near the alternator allowing fluids into the Alternator Inspect the Alternator for physical damage Pay close attention to the alternator wiring for scorched melted or discolored wiring at the alternator If you have damaged wiring the next test to perform will be to check the alternator for evidence of an internal short This must be done to prevent damaging the wires again NOTE For illustrative purposes each test presumes the problem has not been resolved Therefore you proceed to the next step In actual troubleshooting if any step corrects the problem there would be no reason to proceed further If there is no visible damage to the alternator wires
83. Review Steps 1 thru 5 WATER TEST 2 Inspect fuel for contamination 9 Verify CAM Retard 5 0 5 7L only 3 Electrically isolate engine from boat and Rotor 5 0 5 7L onl 11 Perform the Diacom Power Balance Check under load 1600 1800rpm 12 Perform the harness Wiggle Test 8 Perform a Compression Check 13 Diacom recording Pre Delivery test on all 8 cylinders Record below 7 VERIFY REPAIR HAS CORRECTED THE PROBLEM Check for and clear all codes from the ECM memory Water test the boat Run the engine for a minimum of two 2 minutes then verify that no codes have returned Continue with your water test long enough to verify that the problem has been corrected CAM Retard 02 thru 06 43 47 degrees 07 SN 485993 0 4 degrees CES and SN 485994 15 2 degrees ination i i e 10 Performance verified against 4 Powertrain is aligned similar boat w same engine ESO _____ BEES COMPRESSION PRESSURE 5 0 5 7L 130 215 psi 6 0L 130 215 psi 6 2L 130 215 psi Lowest pressure should be within 7096 of highest pressure Minimum cylinder pressure 100 psi FLYWHEEL END OF ENGINE ALL V 8 MODELS FLYWHEEL END OF ENGINE ALL V 8 MODELS 5 0 5 7 Liter 5 7 Liter 6 0 6 2 Liter LH ROTATION RH ROTATION LH ROTATION IGNITION WIRE RESISTANCE CHECK ERUNT PRONT Less than 10 000 ohms ft REFERENCES
84. SED Continue to Step 6 6 ISOLATE AND REPAIR THE PROBLEM Were you able to isolate and repair the problem If YES continue to Step 7 If NO complete the Drivability Checklist for No Codes step 6A below If the problem is still not resolved then call for factory technical assistance 6A NO CODES ENGINE RUNS DRIVABILITY SYMPTOM STILL PRESENT Inspection or Check YES NO warERTEST 9 Verify CAM Retard 5 0 5 7L only 10 Performance verified against similar boat wsame engine MN and Rotor 5 0 5 7L onl a o 6 Check amp record Ignition wire resistance package if available 11 Perform the Diacom Power Balance Check under load 1600 1800rpm 12 Perform the harness Wiggle Test 13 Diacom recording Pre Delivery test 3 Electrically isolate engine from boat 8 Perform a Compression Check on all 8 cylinders Record below 7 VERIFY REPAIR HAS CORRECTED THE PROBLEM Check for and clear all codes from the ECM memory Water test the boat Run the engine for a minimum of two 2 minutes then verify that no codes have returned Continue with your water test long enough to verify that the problem has been corrected CAM Retard 02 thru 06 43 47 degrees 07 SN 485993 0 4 degrees CES and SN 485994 15 2 degrees FRONT COMPRESSION PRESSURE 5 0 5 7L 130 215 psi 6 0L 130 215 psi 6 2L 130 215 psi Lowest pressure s
85. STEM CES 7 Exhaust Manifold Water Temperature EMWT Sensors PCM s Catanium CES incorporates two Exhaust Manifold Water Temperature EMWT sensors one located in each exhaust manifold EMWT 1 refers to the sensor located on the left side of the engine odd cylinder side and EMWT 2 refers to the sensor located on the right side of the engine even cylinder side Each sensor is a two wire thermistor that changes resistance with temperature High and low voltage faults and over temperature trouble codes are associated with each sensor If either of these sensors report a temperature higher than expected a trouble code will set and the engine will enter into Power Derate mode Diagnostic Trouble Codes Associated with Catanium CES Each of the components used on the Catanium CES for PLEASURECRAFT ENGINE GROUP controlling emissions or for monitoring components have crusZier diagnostic trouble codes associated with them These trouble codes are diagnosed the same way as any other engine management fault Performing the OBD System GCP 4G Check will determine if any of these faults are present Diagnostic If any of these faults are present you are directed to the z diagnostic manual to follow the Diagnostic Procedure 5 associated with the trouble code s that is present Below is a break
86. T 2 NOTE ECM will not power up if the battery voltage is less than 9 6 vdc NOTE If the actions described do not occur the shift lever is in neutral Verify the battery voltage system power and ground connections starting at the battery If the previously mentioned actions do not take place you can see on Figure 2 3 that you would move to a new branch of the troubleshooting tree Here you will be troubleshooting the fuel pumps for a no run condition or fuel pressure for an abnormal condition Each step or action you take will help resolve the problem that is present If the pumps run and the fuel pressure rises the next step is the Key ON Engine Running KOER test Key ON Engine Running KOER Test Do Not turn the key to OFF between the Key ON Engine OFF test and this test Place the ignition switch in the START position to crank or roll over the engine You should observe the following actions Warning Most engines utilize an auto crank feature This feature allows the engine to crank up to 5 seconds or until the engine starts 1 The engine cranks or rolls over for at least 5 seconds 2 The Fuel Pressure Gauge reading should rise to the same level observed during the Key On Engine Off test Fuel pressure rising is your indication that the fuel pumps are running 3 The engine starts and continues to run 4 f the engine does not start the fuel pumps should run for 2 4 seconds after engine
87. Tank Flush Kit L Multi Function Display Synchronizer Stereo Equipment Depth Fish Finder L After Market Navigational Equipment Ee NN the engine start and continue to go to 3 go to 1 run below below KeyONEngmeOFF KOEO YES NO Fuel Press Both Fuel Pumps run 2 4 seconds uw Fuel Pressure near wot specification when pumps run 2 Key ON Engine Running KOER YES NO FusPress _ Engine cranks Fuel Pressure near wot specification d engine cranking Engine Starts and continues geto Water Tesi 3 WATER TEST YES NO FuelPress i RR TR Fuel Pressure J Fuel Pressure under load WOT d E such as GPS Radar Sonar Auto pilot systems Radio Equipment L Lights L Other please list 4A Revised or additional symptom found Figure 4 2 PCM Drivability Checklist L599003 13 68 FUEL SYSTEM 4 PCM DRIVABILITY CHECKLIST 5 PERFORM THE OBD SYSTEM CHECK CODE S PRESENT DIAGNOSTIC PROCEDURE USED Continue to Step 6 6 ISOLATE AND REPAIR THE PROBLEM Were you able to isolate and repair the problem If YES continue to Step 7 If NO complete the Drivability Checklist for No Codes step 6A below If the problem is still not resolved then call for factory technical assistance 6A NO CODES ENGINE RUNS DRIVABILITY SYMPTOM STILL PRESENT 1
88. Technician s Name Technician s Contact Phone Owner Operator Name Person Reporting the problem if different from owner operator Service Writer or Person that took the problem report 1 PROBLEM OR SYMPTOM Who first observed the symptom When did the symptom first occur Any recent change or service work prior to symptom occurring replaced belts or impeller major engine or boat repairs recently refueled etc Has someone other than yourself tried to correct the current symptom If yes what work was done Accessories Added Recently Is the symptom currently present Special conditions if any required to duplicate the symptom Use an additional sheet of paper if more space is required for symptoms or descriptions 2 CHECK FOR SERVICE UPDATES ENGINE SERIAL NUMBER ENGINE MODEL NUMBER ENGINE HOURS HULL NUMBER ENGINE None Apply Performed BOAT None Apply Performed 3 VISUAL INSPECTION Inspection Evidence of an over heat Evidence of or Excessive Water Engine Harness connectors in the Bilge connected properly Fluid levels checked Physical Damage wiring connectors Leaking Fluids assemblies and Remove Spark Plugs on Firing order correct and inspect for fluids Correct size propellers installed Corrosion 22 Underwater gear is undamaged FutdbsmaniTerg eoe VERIFY THE PROBLEM Check Accessories Added IHeater L Shower Water
89. Water Pump Volume Test is the most important test you can use to troubleshoot Cooling System problems This procedure is used on both raw water and fresh water systems If you do not have a sufficient supply of raw water the engine cannot cool properly The raw water pump volume test must be accomplished with the boat in the water Use a container that will hold a minimum of 5 gallons of water 1 Disconnect the hose connected to the output of the Raw Water Pump and connect a hose of sufficient length to reach your 5 gallon minimum container 2 With the boat in the water not on a trailer start the engine and bring the engine RPMs quickly up to 3000 Hold 3000 RPM for 15 seconds then slowly return to idle and shut off the engine Important The output hose must be directed into the bilge or over the side of the boat when the engine is started DO NOT put the hose into the 5 gallon container until you have brought the engine up to 3000 RPM This MUST be done quickly as the engine is not getting cooling water at this time 3 At the 15 second point in the test verify you have at least 5 gallons of water in the container Note Make sure the hose stays in the container during the test The output of hose will be under sufficient pressure to blow the hose out of the container Important Most cooling systems require much more water flow than this static test creates When the boat is underway there is water being forced into
90. already know where to begin your troubleshooting Many symptoms provide you that quick and easy insight to the problem Some examples would be 1 Over or Under Temperature problems Troubleshoot the Cooling System 2 Various electrical issues such as no or slow cranking dead battery low or high voltage reading at the dash etc Troubleshoot the Main Electrical System 3 Malfunction Indicator Lamp MIL or Check Gauges Lamp CGL is illuminated on the dash troubleshoot the engine management system NOTE The MIL or CGL normally lights when the ECM stores a trouble code Some boat manufacturers utilize a digital dash display to indicate these faults Check your boat owners manual for each application Remember to closely follow the PCM Drivability Checklist so a problem or cause of a problem is not overlooked 2 Check for applicable Service Updates Before you begin work on an engine always check for Service Updates that may apply to the engine being serviced Service Updates must be performed prior to proceeding with any troubleshooting procedure Record your engine serial number model number and engine hours on the PCM Drivability Checklist This information is necessary to locate applicable Service Updates With very little time and effort the reported symptom may be identified as an issue that a Service Update corrects Always check for Service Updates before proceeding Go to your PCM Premier Dealer websi
91. an Exhaust System CES 47 6 p i t Ne CN Ww 4 E _ _ x 4 X 4 44 6 E a 2 X 7 v gt JA M NX p EA 1 A 3 p e 557 NA JS CATANIUM CLEAN EMISSION SYSTEM CES 7 Catanium Clean Emission System CES Overview PCM s Catanium Clean Emission System is available to reduce emissions without diminishing performance Catanium CES is patented catalyst technology which uses precious metals to create clean emissions and greatly reduce dangerous carbon monoxide gases PCM s Catanium CES is simply an emission reduction system added to an already sophisticated engine management system PCM s CES consists of additional emission s components such as catalyst substrates pre oxygen sensors post oxygen sensors and Exhaust Manifold Water Temperature EMWT sensors PCM s CES exhaust components are comprised of five castings Right and left exhaust manifolds each contain a catalyst substrate The right and left exhaust corners and the exhaust crossover tie the two exhaust manifolds together allowing for one exhaust outlet This design greatly reduces backpressure associated with a catalyst system and does not compromise any performance from a non catalyst application Right Exhaust Right Exhaust Corner Manifold Exhaust Crossover Left Exhau
92. and sensors Section 3 describes how the fuel metering System operates and provides a description and service instructions for the different fuel systems on the engines Section 4 provides a description and service instructions for the two Ignition Systems used on the engines Section 5 is the Diagnostic section and provides you with the procedures schematic diagrams and definitions for troubleshooting an engine management problem Section 5 contains your primary diagnostic information definitions diagnostic procedures and wiring diagrams While all the information contained in the manual is important Section 5 will be your most widely used section of the manual You should thoroughly familiarize yourself with the information contained in this section Section 6 provides a description and service instructions for the Positive Crankcase Ventilation PCV System Section 7 provides you with symptom diagnostics using the PCM Drivability Checklist for various malfunctions that do not generate a trouble code Diagnostic Trouble Codes DTC Suspect Parameter Number SPN and Failure Mode Indicator FMI Diagnostic Trouble Codes DTC will be set and stored in the ECM whenever the ECM detects an engine management failure These failures when active are reported to the operator through either lamps buzzers or through a warning on the digital display DTC s have been commonized through Federal Regulations This means
93. ard Diagnostic OBD System Check Circuit Description The on board diagnostic system check must be the starting point for any drivability complaint diagnosis Before using this procedure you should perform a careful visual physical check of the ECM and engine grounds for being clean and tight The on board diagnostic system check is an organized approach to identifying a problem created by an electronic engine control system malfunction Diagnostic Aids An intermittent may be caused by a poor connection rubbed through wire insulation or a wire broken inside the insulation Check for the following items e Inspect the ECM harness and connectors for improper mating broken locks improperly formed or damaged terminals poor terminal to wire connection and damaged harness e Conditions of the starting system that require repair before proceeding are no crank or slow crank conditions Always verify battery condition and connections prior to troubleshooting starter issues Crank with no start and hard start conditions are addressed by this procedure The Malfunction Indicator Lamp data display should be ON steady with the ignition ON engine OFF If it is a steady OFF DP A 1 should be used to isolate the malfunction If the MIL is slowly blinking this indicates a diagnostic trouble code is stored e Verify your Diacom Installation and cables on a known good engine b Verify that no auxiliary devices are plugged into
94. at harness from the engine boat harness 2 pin connector and retest This will complete the isolation of the current draw to either the engine or the boat If your reading is less than 130 dc amps you know you have problem in the boat and would troubleshoot the boat systems for a device that is drawing power from the engine boat harness 2 Pin connector pin 1 If the reading is still greater than 130 dc amps you have a defective alternator Replace the alternator and verify your repair Refer to the Charge Circuit Troubleshooting Tree path for a current reading of less than 130 dc amps The next check of the charge system will be to verify that the alternator has the required inputs to function properly Verify that you have reconnected the battery cable properly after the previous test was completed This test is a KEY ON Check You will verify that battery voltage is present at the alternator Battery Sense and Exciter inputs The Exciter input is only available when the ignition switch is in the ON position This voltage enables the alternator regulator circuit If battery voltage is not present troubleshoot and repair the connector or wire that is defective 3 When troubleshooting a loss of voltage on the Exciter input refer to Figure 5 11 L599003 13 101 MAIN ELECTRICAL SYSTEM 5 DIACOM e x File Tools Options Help ECM Data 155
95. at the alternator Battery terminal and at the battery s positive post NOTE When you measure the Alternator voltage at the battery ensure that the DMM test lead has a good connection on the battery s terminal post not the battery cable clamp A lower than expected reading may be the result of corrosion between the battery cable clamp and the battery post or a defective connection between the cable clamp and the battery cable Inspect the cable to clamp bond and clean the clamp and battery post mating surfaces reconnect and retest if a lower than expected reading is seen Your Diacom displayed voltage and the Alternator battery terminal reading should be within 3 vdc of the measured voltage at the battery s positive terminal and within the normal output range of the alternator which is 12 5 14 0 vdc for normal charge or 14 0 15 2 vdc for normal high charge operation Voltage readings above or below the specified ranges would require the replacement of the alternator Upon completion of the Run Test you have verified the charge system for the engine If you have a discrepancy between your readings and the boat s instrument panel for a perceived over or under charging condition refer to the boat s service and repair manual for troubleshooting L599003 13 102 MAIN ELECTRICAL SYSTEM 5 Jede Aja JoleuellV o2e day 991 ol 132euuo2ai e e dai 10 31045 993 Jo
96. ating and fully charged Battery charge needs to be verified using a load tester Inspect clean and repair as required battery terminals and connections Inspect clean and repair as required engine ground connections Key ON and boat lights ON Verify voltage is not less than 3 vdc of battery voltage at each system power test point Refer to Main System Power Test Points Diagram Continue to Starter Circuit Charge Circuit or return to the diagnostic procedure that requested a System Power Check Replace Battery with a known good battery of the correct size and rating NOTE Ground locations are critical for proper engine operation Refer to the Main System Power Grounds Diagram for device and ground locations Ensure only the ECM is grounded at the Port ground stud Inspect clean and repair connections or wiring that are not within specification Figure 2 5 System Power Troubleshooting Tree L599003 13 22 PCM DRIVABILITY CHECKLIST 2 STARTER CIRCUIT TROUBLESHOOTING TREE Reported symptom is a Slow or No Crank condition From Step 3 of the PCM Drivability Checklist When you perform the Visual Inspection include the Starter Circuit exhaust system Cotrart conditions with the to include physical damage missing exhaust system Continue with exhaust bs en Starter Circuit trouble treeand Remove all 8 pun pgs an verify starter opration evidence of fluid in the cylinders En
97. ating condition If the overheating condition has not been corrected you will continue your troubleshooting of the cooling system by performing the tests for the PASS path from the Raw Water Pump Volume Check L599003 13 119 COOLING SYSTEM 6 Refer to Figure 6 13 PASS path If the Raw Water Pump Volume test results in at least 5 gallons of water you know the problem lies somewhere after the Raw Water Pump You would then check for defects or restrictions in the output path to include 1 Transmission cooler only engines equipped with both an engine oil and transmission cooler refer to Figure 6 4 in Reference Material for an example 2 Hoses 3 The engine thermostat and its housing A The exhaust cooling thermostat screen if equipped 5 Exhaust hoses 6 Muffler 7 The heat exchanger 8 The engine block You are looking for any possible restrictions or debris that could block the flow of raw water These are all examples of engine side of the pump problems An infrared thermometer is useful for verifying the operating temperature at the thermostat housing temperature sensor and other points along the engine block Temperature readings from your infrared thermometer can aid you in locating hot spots determining where to focus your troubleshooting efforts Refer to Figure 6 11 An often over looked component of the output path is the exhaust manifolds elbows and hoses With a severe ove
98. begin testing of the charge path by checking for any unusual current drain on the battery A constant drain on the battery may be the cause of repeated low or dead battery issues and failure of the alternator This test is done with the key OFF The current drain check is accomplished using the DMM set to the DC Amperage mode Connect the DMM between the negative battery cable clamp and the battery s negative terminal Normal readings will be 130 dc amps or less It is normal to have a small draw on the battery due to various devices on the boat and engine which have keep alive circuits Some examples of these devices are 1 the ECM 2 automatic bilge pumps 3 stereo equipment NOTE When taking current readings allow sufficient time for devices to cycle on and resume their keep alive state Initial readings may be above the 130 dc amp specification while the device s warms up Typically this cycle will take 1 2 minutes Refer to Figure 5 12 Refer to the Charge Circuit Troubleshooting Tree path for readings greater than 130 dc amps You will need to disconnect devices connected directly to the battery s positive post one at a time As a device is disconnected verify the current draw If the current draw drops upon removal of a device you now know the source of the drain on the battery When only MAIN ELECTRICAL SYSTEM 5 the starter is connected to the positive terminal of the battery disconnect the bo
99. bleshooting Service and Repair of PCM Marine Engine Systems P Up eee PCM marine engings E Train Program software purchase We hope you ll enjoy the new look and convenience of PCM s E Train program training online from the comfort and convenience of PREMIER DEALER your dealership or personal computer The PCM E Train Program is a series of electronic courses designed to WORLDWIDE prepare PCM dealers and Service Technicians to do business with pre deliver maintain diagnose and repair PCM marine engines At Pleasurecraft we believe that well trained dealers who stock service parts are absolutely essential to our company s success in fully satisfying our customers PCM s primary focus is first and always the safety and dependability of our products As a result PCM inboards command the highest degree of customer satisfaction in the industry PCM s goal is to continue to maintain a network of knowledgeable dealers who can provide parts service and warranty on the PCM product line The PCM E Train is one tool used to elevate the standards of PCM service technicians who were already providing a superior uncompromising commitment to customer satisfaction to a level not seen before Thank you for choosing to be part of the PCM Premier Dealer Worldwide Team E m ims L599003 13 3 BOOKMARKING YOUR TRAINING SESSION If for any reason you need to end your session before completing the training course you will
100. crossfire Refer to the Master Specifications for each model year engine for the correct setting 6 0 6 2L engines use the Electronic Ignition system This System uses eight individual ignition control IC circuits and coils When starting the 6 0 6 2L engines the ECM fires two coils for each IC signal until 1 cylinder can be located by the ECM The 6 0 6 2L engines use DISTRIBUTOR 8 ASSEMBLY COIL IGNITION CONTROL MODULE COIL IGNITION CONTROL MODULE CRANK POSITION POSITION SENSOR SENSOR CKP CMP POSITION SENSOR CKP TYPICAL FOR 5 0 5 7L TYPICAL FOR 6 0L 6 21 18 SIMILAR Camshaft CMP sensor to identify the compression stroke of TDC position of 1 cylinder allowing the ECM to fire individual cylinders in the firing order sequence The failure of critical system components and or circuits monitored by the ECM will generate and store Diagnostic Trouble Codes DTCs and illuminate the Malfunction Indicator Lamp MIL or Check Gauges Lamp CGL on the dash panel of boats Refer to Section 4 of the Diagnostic Manual for a detailed description of the ignition components used The MIL or CGL will stay illuminated when the engine is running as long as the failure is present If the problem is intermittent or has been repaired the MIL or CGL will stay illuminated for up to 3 ignition cycles after the problem is corrected L599003 13 30 ENGINE MANAGEMENT SYSTEM 3 NOTE When the DTC s a
101. d fittings must be secure and away from heat and moving components Refer to Figure 4 7 the Fuel Pressure Out Of Range Troubleshooting Tree You can see there are two distinct paths for fuel pressure problems Pressure could be above the required specification or below Fuel pressures above specification are uncommon occurrences Symptoms of excessive fuel pressure may be similar to those associated with other engine problems such as a cold running engine or under temperature condition The following is a partial list of symptoms Excessive fuel consumption Heavy black soot deposit on the transom Hard starts especially on a warm or hot engine Erratic idle speed problems that may include stalling warm or cold Fouled spark plugs engine missing or backfires Owner reports great top end performance but cannot get through an idle zone without stalling Typically the most common cause of a high fuel pressure condition will be a restriction in the return to tank fuel line such as an anti syphon valve installed at the tank instead of a straight through fitting Less common will be a restriction in the fuel rail or a failed fuel pressure regulator Using an auxiliary fuel tank will quickly isolate this problem The more common condition is fuel pressure below specification Refer to Figure 4 7 the Below Specification path It would appear that pressure below specification is a complex problem to isolate By making a couple
102. d or broken bad spark plug wire broken or too high in resistance bad distributor cap and rotor 5 0 5 7L only or a coil ignition module faulty wiring between a coil module and ECM fuel injector failing to fire or leaking bad injector or faulty wiring between the injector and ECM L599003 13 59 ENGINE MANAGEMENT SYSTEM 3 n DIACOM M i EN ECM Data i Graph Codes ECM Output Tests Warning Please read the messages below WARNING This test disables spark and all injectors This test should be performed with Key On and Engine Off Tests Injector Kill Test Injector Fire Test Compression Test Mode Drive By Wire Test Clear Misfire Data System Info Cancel Pleasurecraft Crusader GCP ETC 4G Engine Data 8 47 12 096 Compression Test Mode The Compression Test is a special test mode that the ECM provides to allow a technician to safely perform a cylinder compression check The Compression Test Mode is not really a test in itself itis simply a mode or state the engine management system enters to allow a technician to manually perform a compression check without the possibility of the engine firing or starting Warning This test commands the ECM to disable all spark and fuel injector outputs The test must be properly exited from within Diacom in order to re enable normal spark and fuel operation Do not perfor
103. dentifying a problem created by an electronic engine control system malfunction This check verifies the following 1 The ECM power and ground circuits 2 The ECM can communicate with the scan tool 3 The ECM will allow the engine to start and continue to run 4 The ECM has or has not stored Diagnostic Trouble Codes DTC If DTC s are present the OBD System Check will direct you to the next procedure you need to perform Details of the OBD System Check will be covered in the Engine Management section of this course The OBD System Check will direct you to additional diagnostic procedures based on the results of each step 6 Isolate and Repair the Problem Utilize your resources Obtain the Diagnostic manual for the problem you have encountered Follow the procedures exactly as they are written Do Not skip any steps If you have reached a point in your testing where you have 1 Checked all the components in a system 2 Properly completed the PCM Drivability Checklist procedures through Step 5 3 Completed Step 5 and did not find codes or found and corrected code related problems but the symptom is still present 4 An engine that starts and runs but still exhibits a symptom and 5 Not resolved the problem You need to STOP and refer Figure 2 2 of the PCM Drivability Checklist Step 6A Step 6A is designed to check for a variety of problems known to affect drivability Refer to Figure 2 4 The Drivability Checklist No C
104. detected a low oil pressure condition The oil pressure sensor provides the oil pressure information to the ECM This trouble code will be set and Power Derate Mode may be enabled when the oil pressure sensor detects an oil pressure less than 5 psi at idle or less than 24 psi at 4000 RPM The diagnostics are linear between idle and 4000 RPM This means if the engine was at 2000 RPM the diagnostic limit would be less than 16 psi Using a sensor instead of a switch allows for much better protection throughout the RPM range You would perform the Low Oil Pressure Troubleshooting Tree Figure 3 10 This trouble code illuminates the Check Gauges Lamp CGL When equipped the CGL is RED In many models these trouble codes are reported through a digital dash display This is a good example of a problem reported through the Engine Management System that may be the result of another engine system failure In this case the Engine Lubrication System By following the Diagnostic Procedures provided for this trouble code you will be able to distinguish between the system being monitored and a possible engine management system failure L599003 13 52 ENGINE MANAGEMENT SYSTEM 3 euiBu3 g pais uod jeu is aoa JosueS punoiy JOSU8S 2 Josue L ________ 1 H 95 wd WOL NVL pais INVL uod uod v JosueSs v Josues SENS
105. down of the trouble codes associated Mat with the Catanium CES and a description of what they Serial Number 4704 mean Some of the trouble codes identify a particular while others identify a system not operating CVSS 1510030 Diagnostic Trouble Suspect Parameter allure Mode entier FM orons s o Obseepgeoiebamigh Dus ms eset gasoline bare a7 o Adaptive learn gasoline bank high reia 42e o Adaptve learn gasoline bank2 high DTC 175 4239 Adaptive learn gasoline bank2 low The trouble codes above are associated with the overall The issues that can set these faults more than likely engine management system These trouble codes identify has nothing to do with the Catanium CES components extremely rich or extremely lean conditions As you can Things like low fuel pressure high fuel pressure exhaust see they are identified as Bank 1 and Bank 2 Bank 1 restrictions leaking or stuck injector other sensor failures refers to the left side odd cylinder side of the engine and etc can cause these trouble codes to set Refer to the Bank 2 refers to the right side even cylinder side of the Diagnostic Procedure for a particular fault in the diagnostic engine manual for some diagnostic aids for diagnosing these faults L599003 13 134 CATANIUM CLEAN EMISSION SYSTEM CES 7 DTC 134 3217 EGO open lazy DTC 140 3256 open lazy DTC 1
106. e Instrument panel reading Operate engine while observing Coolant Temperature on Diacom ECT temperature display Verify displayed reading is within 5 within 10 degrees temperature with an Infrared degrees of the of each other Thermometer at the ECT sensor Infrared intak ifold Normal Operation Panel reading is PALIDIN ohne Wiens Thermometer significantly lower than Diacom value Raw Water or Fresh Water Replace thermostat Inspect housing for debris and proper seating of the thermostat CAN BUS Gauges Verify correct operation of other CAN gauges If OK replace Replace ECT Fresh Water Verify there is no air in the system coolant level should be full With the engine running coolant should circulate through the degas bottle and coolant level in the bottle will rise Analog Gauges Check and fall as the engine wiring connections maintains temperature between ECM Temperature Gauge Driver and the boat display Repair as required Clear ECM of codes and Verify Repair faulty boat display If other gauges inoperative repair CAN BUS circuit problem Verify Repair Check for faulty boat display or ECM output driver Repair as necessary Verify Repair Figure 6 16 Troubleshooting Tree Under Temperature L599003 13 128 NOTES 1599003 13 129 NOTES L599003 13 130 5 PREMIER DEALER WORLDWIDE Section 7 Catanium Cle
107. e engine The Starter ground path is through the Starter s case to the engine block through the starter mounting surface at the bell housing The engine block is grounded through the negative battery cable back to the Battery negative terminal or post L599003 13 90 MAIN ELECTRICAL SYSTEM 5 BLACK 6 ga 100A 70A ALTERNATOR To STBD d GRD STUD D BELLHOUSING 0 2 8 Boat Harness To STBD GRD STUD BATTERY YELLOW 12 ga STARTER s RED WHITE BELLHOUSING 8 PURPLE WHITE From 5 B 8 Pin Boat Harness Fuse Block Panel Fuse 40A UA s an 10ga 125 Red E V I urple Fuse Block Relay Fuse YEL RED vEL RED 7 8 Pin 12ga 12 ga Starter Y Relay To ECM Control P 6 To EXC LW TP 7 Ignition Control GROUND ENGINE BLOCK 5 8 Pin Fuse Not Used 5A Red Purple By d _ To ECM Igniti Fuse Block EY Fuse Block Al Relay Y use DIOC Control Pin ToECM Fuel Pump 9 oa EGM Relay Fuse Ignition Fuse 20A 20A Feed Pin B m mu F Block m Fuse Block IGN 1 To STBD Fuse ane GRD STUD 20A BELLHOUSING To ECM p Battery Feed
108. e harness connections and power to the pumps When you jumper pin 30 to pin 87 of the Fuel Pump Relay Socket both fuel pumps should run 1 Pumps Do Not Run Verify battery voltage is present at both fuel pump connectors Battery Voltage Not Present Diagnose and repair harness or connection problem between relay sockets and fuel pump s Battery Voltage Present Verify good ground circuit and repair as necessary If OK check connections and replace fuel pump s 2 Both Pumps Run Verify battery voltage is present at both fuel pump connectors Battery Voltage Not Present Diagnose and repair harness or connection problem between relay sockets and fuel pump s Battery Voltage Present Verify good ground circuit and repair as necessary If OK check connections and replace fuel pump s Connect your test lamp between fuel pump relay socket pins 30 and 85 Cycle the fuel pumps either with your Diacom or the ignition switch The test lamp should illuminate for 2 4 seconds then go out 1 Lamp Illuminates Replace the Fuel Pump Relay 2 Lamp Did Not Illuminate Troubleshoot and repair the wiring between the ECM and the relay socket If the wiring checks out good replace the ECM Using the Troubleshooting Tree and the main power diagram we have taken a logical step by step approach to solving this problem Similar approaches can be used to solve most any problem you encounter with the engine Let s look at
109. eck ECM for trouble codes Trouble Code SPN 110 15 DTC 116 ECT Higher than Expected Stage 1 Perform Diagnostic Procedure SPN 110 FMI 0 DTC 217 For Engine Coolant ECT Higher than Expected Stage 2 Temperature ECT Overheat SPN 441 FMI 15 DTC 1415 EMWT 1 Higher than Expected Stage 1 SPN 441 0 DTC 1417 EMWT 1 Higher than Expected Stage 2 Perform Diagnostic Procedure For Exhaust Manifold Water SPN 442 FMI 15 DTC 1416 Temperature EMWT Overheat EMWT 2 Higher than Expected Stage 1 SPN 442 FMI 0 DTC 1418 EMWT 2 Higher than Expected Stage 2 Perform Diagnostic Procedure For Low Oil Pressure SPN 100 FMI 1 DTC 524 Oil Pressure Sensor Low Pressure Check Clear ECM of codes Verifiy corrective action has corrected the problem Figure 3 4 Power Reduction Mode Troubleshooting Tree L599003 13 45 ENGINE MANAGEMENT SYSTEM 3 Engine Coolant Temperature ECT Higher than Expected Stage 1 Stage 2 Set Refer to Figure 3 5 and 3 6 Engine Coolant Temperature ECT Higher than Expected Stage 1 Stage 2 indicates that the ECM has detected an engine over temperature condition The ECT sensor provides the over temperature reading to the ECM These trouble codes will be set and Power Derate Mode may be enabled when the ECT detects a coolant temperature in excess of 200 F Stage 1 and 205 F Stage 2 You would perform the Over Temperature Troubleshooting Tree Figure 3 6
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111. engine must be running to set most codes Run times vary on when the ECM will recognize a fault and set a code In general the engine should run for at least two minutes at the specified criteria in order to set the code you are trying to induce or to verify a successful circuit repair Clearing Diagnostic Trouble Codes 1 Install scan tool 2 Start engine 3 Link Diacom to the ECM 4 Select Codes tab on the Diacom display 5 Select Erase Trouble Codes IMPORTANT If the code s do not clear when you select Erase Trouble Codes then the code s is currently active This indicates that the fault is still present in the system you must trouble shoot the code s and correct the problem before the code can be cleared 6 Turn ignition OFF for at least 5 seconds 7 Turn ignition ON and read DTC s If DTC s are still present check Notice below and repeat procedure following from step 2 It is important to note the conditions under which the ECM will or will not set a code Occasionally during troubleshooting you may wish to verify that a device or circuit will or will not set its code Disabling or disconnecting the circuit and turning the ignition ON is not enough to set a code The engine must be running to set most codes Run times vary on when the ECM will recognize a fault and set a code In general the engine should run for at least two minutes at the specified criteria in order to set the code you a
112. ep 5 OBD System Check on the PCM Drivability Checklist If codes were found during Step 5 of the PCM Drivability Checklist perform the diagnostic and repair procedure in the diagnostic manual then verify your repair In most cases a code will not be present You will have to determine the source of the problem by using Diacom information from the PCM Drivability Checklist and the Troubleshooting Trees Check for real or perceived problems using Diacom and or an infrared thermometer The Under Temperature Condition Troubleshooting Tree uses the same troubleshooting path as the over temperature condition we discussed previously Use Diacom to display the Coolant Temperature value from the ECT and verify the reading using an infrared thermometer If the engine temperature is within normal parameters the system should be operating normally If so there may be a defective Temperature Gauge or an engine or boat wiring problem COOLING SYSTEM 6 If the Diacom displayed value shows the engine to be running cold typically this is the result of a defective thermostat Verify that you do not have an ECT sensor shifted in value Then replace the thermostat Before you replace the thermostat on a fresh water system be sure to inspect the thermostat installation to verify the thermostat is seated properly Fresh water systems that have the thermostat located in the heat exchanger can experience an under temperature condition if the the
113. er Check Let s take a detailed look at the System Power Check System Power KEY OFF 1 Verify that the battery is the correct size and rating for the boat and most importantly fully charged Verify that the battery is the correct size and rating for the boat and most importantly fully charged To verify the charge on a battery you will need a battery load tester To load test a battery you must 1 Disconnect both the negative and positive leads of the battery 2 Connect your load tester and then load the battery per your load tester instructions 3 Under load verify the battery voltage to be a minimum of 9 7 vdc 4 If the battery check confirms the battery is good inspect and clean your battery terminals and connectors then reconnect the battery IMPORTANT The ECM may reset if voltage drops below 9 6 vdc This can cause false codes and inaccurate display readings to occur Always begin your troubleshooting procedures with a known good battery MAIN ELECTRICAL SYSTEM 5 2 Refer to Figure 5 5 Inspect the engine power and ground locations Clean and repair these connections as necessary Proper ground connections are very important for engine operation The flywheel housing s port ground stud should have only the ECM grounds from the main engine harness attached The flywheel housing s starboard ground stud should be used for the battery all other main engine harness grounds and all accessory grounds
114. ers exhaust hoses and elbows and heat exchanger if equipped These components work together to keep the engine running at the desired operating temperature The ability of the raw water pump to supply cooling water is essential to the proper operation of the Cooling System Blockages either before or after the pump can greatly reduce the efficiency of the system or cause the engine temperature to exceed normal readings There are basically two classifications of cooling systems used on a marine engine Both systems require an endless supply of cool lake sea water being constantly supplied to the engine for cooling A Raw Water Cooling System has no antifreeze or coolant in the system This means there is no reason for a heat exchanger Raw or sea water is pulled from the lake by the raw water pump This sea water is circulated through the engine and expelled through the exhaust manifolds A thermostat controls the sea water temperature in the engine to around 160 170 F The Fresh Water Cooling System functions very much like your automobile The engine block and cylinder heads at minimal are filled with an antifreeze solution fresh water This antifreeze solution is constantly circulated around the engine in a closed system The antifreeze is cooled by circulating through the tubes of a Heat Exchanger The Heat Exchanger functions like a radiator Instead of air blowing across the tubes an endless supply of raw sea
115. fective out of date Diacom interface cable While some of these examples are definitely engine management system problems most are outside conditions or other system failures that appear through the engine management system 2 There is a stored Diagnostic Trouble Code DTC This may be the result of 1 a failed electronic circuit 2 low system voltage or any other condition which could cause an interruption in system power such as a defective ignition switch or corroded or loose power and ground connections improper shut down of the engine such as using the battery switch instead of the ignition switch 4 a defective engine or boat harness or b a improperly connected device 3 There are no stored DTC s Any abnormal condition from system power to an engine mechanical problem can affect the performance and drivability of the engine The fact is none of these results clearly indicate an engine management system problem This is why just checking for codes is an insufficient check Stay on track by using the PCM Drivability Checklist and perform Steps 1 4 completely prior to Step 5 the OBD System Check Finding or not finding a trouble code and jumping to a conclusion could waste valuable time in your troubleshooting effort L599003 13 32 ENGINE MANAGEMENT SYSTEM 3 PCM DRIVABILITY CHECKLIST ENGINE SERIAL NUMBER Date Dealership Name Technician s Name Technician s Contact Phone Owner
116. han 10 000 ohms ft REFERENCES Master Engine Specification Sheets L510030 GCP 4G Diagnostic Service Manual L510015 5 0 5 7L Engine Mechanical Service Manual L510016 6 0L Engine Mechanical Service Manual NO DISTRIBUTOR PCM Premier Dealer Website the Latest n ALL V 8 MODELS Publications FIRING ORDER FIRING ORDER FIRING ORDER 1 8 4 3 6 5 7 2 1 2 7 5 6 3 4 8 1 8 7 2 6 5 4 3 Figure 3 1 PCM Drivability Checklist L599003 13 34 ENGINE MANAGEMENT SYSTEM 3 OBD SYSTEM CHECK Step 5 of the PCM Drivability Checklist The OBD System Check procedure provides 5 areas of testing as follows Checks the ECM s ability to transmit data Malfunction Indicator Lamp circuit Tests the ability of the engine management system to allow the engine to start and run and or set trouble codes Checks for trouble codes and then directs you to the next diagnostic procedure Diagnostic troubleshooting steps As you can see from the descriptions you have accomplished much of the OBD System Check when you connected the scan tool and checked for trouble codes Be sure to do the complete OBD System Check for any engine management or drivability concerns Remember that skipping steps may cause you to skip over the cause of a problem It is not practical to cover every Diagnostic Procedure in the diagnostic manual The layout of the On Board D
117. he fuse element open This may have been caused by a temporary surge and replacing the fuse corrects the problem or the problem may be more serious To determine if the device the fuse protects or the wiring caused the fuse to blow you can disconnect the device replace the fuse and then reapply power and perform a wiggle test on the wiring Be sure to wiggle the entire harness when checking to see if there is a short in the wiring If during the wiggle test the fuse blows you have a wiring problem at the point in the harness you were affecting when the fuse blew If the fuse does not blow then the device it is protecting may need to be replaced Refer to Figure 4 4 and 4 5 KOEO Pumps Do Not Run Troubleshooting Tree and Main Power diagram If the fuses are good we will perform step 3 of the Troubleshooting Tree Step 3 requires the use of a non powered test lamp CAUTION Before you perform this step you should verify that your test lamp meets the requirement for circuit testing Refer to the Diagnostic Manual for this powered test lamp does not meet this requirement Using your test lamp connected to a know good ground test for power at the Fuel Pump Relay socket Looking at the main power diagram you can see that we are testing each device and harness connection on the way to the fuel pumps If step 3 checks are good continue to step 4 and verify the harness connections and power to the pumps Step 4 will verify th
118. he meter reading as the engine cranks Typical values will be in the range of 150 250 dc Amps for a 5 0 5 7L engine and 210 325 dc Amps for a 6 0 6 2L engine An excessively high current draw could indicate a failing starter It is possible that you could still have a slow crank condition after replacing the starter due to defective or undersized battery cables If this occurs you would test each cable and repair or replace the cables as required The positive cable may have multiple connection points between the battery and the starter because of the addition of Battery Switches Power Panels or Isolators Ensure that the same gauge cable is used throughout and each connection or device is good between the battery and the starter Next disable the fuel and spark by removing the System Relay Turn the ignition to the START position There are three paths that may be followed based on the result of this test 1 If the engine cranks normally perform a compression test The result of that test could locate an engine mechanical problem or indicate normal engine condition 2 f the engine cranks slowly we will go to Figure 5 9 the Starter Circuit Slow Crank Trouble Tree 3 If the engine is a no crank we will go to Figure 5 10 the Starter Circuit No Crank Trouble Tree L599003 13 94 MAIN ELECTRICAL SYSTEM 5 STARTER CIRCUIT TROUBLESHOOTING TREE SLOW CRANK CONDITION Slow Crank Using a Clamp Meter clam
119. hould be within 7096 of highest pressure Minimum cylinder pressure 100 psi FLYWHEEL END OF ENGINE ALL V 8 MODELS FLYWHEEL END OF ENGINE ALL V 8 MODELS 5 0 5 7 Liter 6 0 6 2 Liter LH ROTATION LH ROTATION IGNITION WIRE RESISTANCE CHECK FRONT FRONT FRONT Less than 10 000 ohms ft REFERENCES Master Engine Specification Sheets L510030 GCP 4G Diagnostic Service Manual L510015 5 0 5 7L Engine Mechanical Service Manual NO DISTRIBUTOR L510016 6 0L Engine Mechanical Service Manual PCM Premier Dealer Website All the Latest T mei cae ALL V 8 MODELS Publications FIRING ORDER FIRING ORDER FIRING ORDER 1 8 4 3 6 5 7 2 1 2 7 5 6 3 4 8 1 8 7 2 6 5 4 3 Figure 6 8 PCM Drivability Checklist L599003 13 117 COOLING SYSTEM 6 The most common problem associated with all cooling systems is an overheat condition An overheat condition is usually caused by a raw water pump volume failure or a defective thermostat Other problems may be perceived conditions where the owner operator reports an under over temperature condition based on the temperature gauge or warning devices An additional cause for overheating found only in fresh water systems is a loss of engine coolant Cooling flow diagrams are located in the PCM Owner s Operation and Maintenance Manual which comes with each engine and are Figures 6 1 through 6
120. iagnostic System Check is representative of each of the diagnostic procedures you will find in Section 5 of the Diagnostic Manual Each diagnostic procedure incorporates the following a schematic or drawing of the circuit under test a Circuit Description Diagnostic Aids Test Description and Diagnostic Procedure The schematic and circuit description provided are a snap shot of the circuit being tested Diagnostic Aids are inspections and tests in addition to the diagnostic procedure that may help you better isolate the problem Test Descriptions define or clarify Diagnostic Procedure steps It is good shop practice to always Review the schematic Read the Circuit Description Read the Diagnostic Aids and Read the Test Descriptions that relate to the steps of the Diagnostic Procedure being performed prior to actually performing any of the tests NOTE Not all diagnostic procedures or steps in a diagnostic procedure have Test Descriptions Refer to the beginning of the OBD System Check diagnostic procedure You will always begin each diagnostic procedure at the top You may or may not perform every step in a procedure The action performed compared to the result will dictate your next step in the procedure Diagnostic procedures may specify actions test set ups and or a test procedure to perform as part of a single step Step 1 specifies a number of preliminary actions you must perform befo
121. ill covering these items Multiple electrical issues may remain Most common is a failed starter High water may short out the battery and other electrical devices As mentioned above you may have water in the engine oil or transmission The results of a good visual inspection will help you determine where you will concentrate your troubleshooting efforts 4 Verify the problem At this point you must verify the problem or symptom you are trying to repair In order to verify the problem you will need to connect your Diacom scan tool and Fuel Pressure gauge to the engine You should also have your Digital Multi Meter DMM available Always verify for yourself that the problem you are about to troubleshoot is the same problem reported to you in Step 1 of the PCM Drivability Checklist Verifying the problem may require you to water test the boat and trying to recreate the conditions under which the failure occurred Refer to Figure 2 2 Step 4 Step 4 is a series of checks leading up to verifying the reported problem Remember that the PCM Drivability Checklist is to be used to help you locate a problem Refer to the Troubleshooting Tree for Step 4 of PCM Drivability Checklist Figure 2 3 This diagram will take you through a step by step approach to troubleshoot and repair the problem Refer to Figure 2 3 This diagram is a troubleshooting tree for Step 4 of PCM Drivability Checklist As you can see from Figure 2 3 if an action pe
122. ine management failures is made even easier using the PCM Drivability Checklist Diagnostic Trouble Codes DTC have assigned numbers associated with each code DTC 117 is ECT Sensor Circuit Low Voltage The DTC s also have both a Failure Mode Indicator FMI and Suspect Parameter Number SPN Each DTC has both a FMI and SPN in order to identify the exact circuit failure NOTE Diacom only displays the FMI and SPN numbers Be sure to have both these numbers for each fault displayed NOTE If you need training on connecting Diacom or checking for trouble codes refer to www rinda com training for some short How To videos to assist you Failures which do not set trouble codes must be resolved using the symptoms that are present Some symptoms are easily recognized such as the engine overheated Other symptoms can be vague because one person s description of hesitation may be another person s stumble Basically you are dealing with conditions where the engine boat package is no longer performing as it once did This may be relayed to you as a loss of rpm at wide open throttle or the boat doesn t feel as strong as it once did The Drivability Checklist is based on seven basic steps Performing these steps in the order provided will help you to isolate identify and repair problems more effectively Refer to Figure 2 1 Successful problem diagnosis requires the following approach to be applied to all reported problems
123. inues to circulate as the engine reaches normal operating temperature You should observe a slight rise in the coolant level in the degas bottle when the engine reaches operating temperature For 3 4 and full fresh water cooled engines you will fill the system completely when the engine is cold and NOT RUNNING There are specific air bleed locations to allow the coolant to completely fill the system and purge the air without running Consult the Full Fresh Water Coolant Fill Procedure on the PCM Premier Dealer website After you have completed the coolant fill procedure you should shut the engine off and let it completely cool off This may require you to come back to the engine the next day On the cold engine verify that the coolant level is between the Min and Max level on the degas bottle If it is the system is operating normally If it is not repeat the coolant fill procedure and recheck the coolant level The low coolant level may be the result of 1 Not getting the system full when an accessory device was added 2 Service performed such as a thermostat replacement 3 An overheat condition 4 Air trapped in the system during a service interval COOLING SYSTEM 6 If you have performed the coolant fill procedure as specified and return to the cold engine to find the coolant level has fallen outside of the specified range You then have to look to the engine for the cause of the coolant consumption Perform the fo
124. isplay ECT Sensor Volts 4 5 volts Replace faulty ECT sensor Carefully inspect wiring for chaffed or damaged areas Inspect the connectors for being loose or damaged Inspect terminals for damage or not Using a DMM check for seating properly in the ECT sensor signal circuit Yes Repair faulty ECT signal circuit connector shorted to ground as necessary Was a problem found No Replace faulty ECM L599003 13 41 ENGINE MANAGEMENT SYSTEM 3 DRIVABILITY CHECKLIST NO CODES 6A 1 Review the results of Steps Inspect or correct recent 1 5 service work performed 6A 2 Inspect fuel for contamination Correct fuel fuel system water correct fuel type ect as necessary 6A 3 Verify powertrain Correct alignment alignment as required Remove and Inspect the Replace 4 Distributor Cap and Rotor 5 0 5 7L Only y 6A 5 Ignition Wire Resistance check Replace spark plug Record results wires as necessary Remove and Inspect each spark Replace spark plugs 6A 6 plug for damage or abnormal as necessary condition Refer to the Engine 6A 7 Perform a Compression Check on all 8 cylinders and record WATER TEST Verify 3 6A 8 Cam Retard 5 0 5 7L only Adjust as required Mechanical Service Manual Performance verified against 6A 9 a simialr boat w same Same Normal operation engine package 6A 10 Perfor
125. k Sensor signal is presumed to be present at the ECM enabling the ignition circuits and Fuel System Typically at this point the engine will be running NOTE If the actions described do not occur verify the shift lever is in neutral Verify the battery voltage system power and ground connections starting at the battery At this point in our test process typically we know the engine will start and run Complete Step 4 of the PCM Drivability Checklist by water testing the boat During the Water Test you will be verifying two things 1 The reported problem from Step 1 is or is not present 2 The fuel pressure under load at Wide Open Throttle WOT remains at the proper specification Remember it is absolutely essential to verify fuel pressure under load at wide open throttle This is the only reading that verifies the integrity of the fuel system Refer to Figure 2 3 You can see that if an action failed we continue to another branch on the trouble tree If the engine cranks normally but still fails to start continue to Step 5 the On Board Diagnostic OBD System Check of the PCM Drivability Checklist The OBD System Check will guide you to the appropriate diagnostic procedure for no start and hard start conditions NOTE Normal starter cranking RPM is 150 200 RPM This can be observed on the Diacom display If normal cranking RPM is not achieved troubleshoot the starter for a slow crank condition L599003 13
126. le Service Updates Perform a visual inspection of the engine for obvious faults Verify the Problem Perform the On Board Diagnostic OBD System Check Isolate and Repair the Problem Check Clear Trouble Codes from ECM Verify the Problem has been Corrected Figure 3 14 Basic Troubleshooting Approach Tree L599003 13 62 NOTES L599003 13 63 NOTES L599003 13 64 gt E 7 2 PREMIER DEALER WORLDWIDE Section 4 Fuel System FUEL SYSTEM 4 Fuel System With the ever increasing sophistication of the engine s systems the fuel system has had major changes over the years The Fuel System is comprised of two distinct sub systems the Fuel Supply and the Fuel Metering Systems 1 Fuel Supply System Fuel Tank Fuel Filters Fuel Pumps Fuel Lines 2 Fuel Metering System Fuel Rail Fuel Injectors Fuel Pressure Regulator The operation of the Fuel System and the precise delivery of fuel to the engine are controlled by the ECM Refer to Figure 4 1 Fuel System Diagrams As you can see in the diagrams the pressure regulator is located on the fuel rail on 5 0L and 5 7L applications The pressure regulator is located in the Fuel Control Cell FCC on 6 0L and 6 2L applications Remember to always verify fuel pressure during a lake test at wide open throttle under load This is the most accurate reading you can take on the fuel system If the fuel pressure is correct under load at wide o
127. ll not start then you would perform Step 5 of the PCM Drivability Checklist the OBD System Check While it may seem that almost all problems encountered with the engine are Engine Management System problems in reality very few actually are This perception exists because we are conditioned to begin troubleshooting by connecting the scan tool and checking the ECM for trouble codes What needs to be realized this is more a check to eliminate the engine management system from the troubleshooting effort When you check the ECM for stored codes there are basically three results that may occur L599003 13 31 ENGINE MANAGEMENT SYSTEM 3 1 The Diacom scan tool cannot communicate The OBD System Check is followed by multiple Diagnostic with the ECM Procedures These diagnostic procedures all support and ensure the successful completion of the OBD System Check All the engine management and drivability 1 a system power failure troubleshooting procedures will require the successful 2 a blown fuse completion of the OBD System Check before proceeding 3 to the next Diagnostic Procedure If your OBD System Check fails you will be referenced to one or more of these 4 a defective ECM Diagnostic Procedures S 6 This may be the result of a faulty System Relay 5 a damaged engine harness 6 an accessory device connected improperly into the CAN BUS data circuits 8 Diacom improperly installed or 9 a de
128. llowing inspections on a cold engine Running the engine before testing can temporarily remove the evidence of moisture causing you to miss the source of the problem and perform unnecessary troubleshooting steps 1 Inspect the engine oil for evidence of coolant 2 Inspect each cylinder and spark plug for evidence of coolant Carefully inspect the spark plugs for a white or gummy carbon like residue on them This residue will be present if coolant or salt water is present in the cylinder 3 Look for coolant standing on the pistons or a lack of carbon build up on the pistons Whenever evidence of coolant or moisture is present in any cylinder and before performing expensive engine work always pressure test the exhaust manifolds and elbows for evidence of a failure NOTE Whenever evidence of coolant or moisture is present in any cylinder and before performing expensive engine work always pressure test the exhaust manifolds and elbows for evidence of a failure The next check for a coolant leak will be at the heat exchanger Add a small amount of marker dye to the engine coolant You will need to water test the boat Perform the following checks and or inspections 1 Verify that the engine has reached normal operating temperature 2 Operate the boat under load do not idle in the slip operate under load at approximately half throttle 3 Inspect all hoses and connections on the engine for coolant leaks correct a
129. lyst substrate The Pre O2 sensors provide feedback to the ECM allowing the ECM to constantly fine tune the calibrated fuel delivery to maintain stochiometric air fuel ratio This system is referred to as Closed Loop fuel control Post Oxygen O2 sensors are placed in the exhaust stream after the catalyst substrate The primary function of the Post O2 sensors is to monitor the exhaust gases and provide feedback to the ECM With this information the ECM can determine how efficient the catalyst substrate is reducing emissions In the event that the catalyst substrate becomes inefficient the Post O2 sensor reports this information to the ECM and the ECM will then turn ON a warning and set a trouble code Catalyst Substrates PCM s Catanium CES utilizes two catalyst substrates one located in each exhaust manifold The catalyst substrates are stainless steel cans that are coated with a certain recipe of precious metals It is the precious metals interacting with the exhaust gases that cause a chemical reaction resulting in the reduction of emission gases such as hydrocarbons carbon monoxide and nitrogen oxides Catalyst substrates require to be at extremely high temperatures in order to be effective Catalyst substrate temperatures can reach in excess of 1500 F Engine misfires can be damaging to the catalyst substrates Engine Misfire is monitored on all Catanium CES applications L599003 13 133 CATANIUM CLEAN EMISSION SY
130. m the Diacom Refer to the Power Balance Test Diagnostic Manual 6A 11 Perform the harness Isolate and repair wiring Wiggle Test or connector problems 6A 12 Pre Delivery Diacom Isolate and repair circuits recording outside of normal parameters Figure 3 3 PCM Drivability Checklist No Codes Troubleshooting Tree L599003 13 42 ENGINE MANAGEMENT SYSTEM 3 Check Gauges Lamp CGL Trouble Codes Most of the trouble codes that the ECM stores for conditions detrimental to the engine and or transmission turn on a RED Check Gauges Lamp if equipped The AMBER Malfunction Indicator Lamp is triggered for emission related faults If the boat contains a Digital Display in the dash in most cases neither lamp is used All faults are displayed through the digital display The ECM may enter into Power Derate Mode should one of the following conditions occur an engine overheats Cooling System failure low engine oil pressure Engine Mechanical failure and exhaust cooling system overheats indicated by an Exhaust Manifold Water Temperature sensors located in each manifold on CES equipped engines Power Derate Mode is a reduced performance mode that will allow an owner operator sufficient performance to Seek service and repairs Power Derate Mode limits the engine RPM at two different stages When the cooling temperature or oil pressure indicates a reading exceeding the Stage 1 value the ECM limits the throttle body to 3596 maximu
131. m this test at sea The Compression Test should only be performed dockside or at a service facility since the engine will be disabled until the test is properly exited If the Diacom s communication cable is disconnected from the engine during the Compression Test the engine will remain in a disabled state You must reconnect Diacom re enter the Compression Test mode and then properly exit the test When the Compression Test is active spark and fuel delivery functions will be disabled on the engine When you have completed your compression test procedures simply click the Stop Test button L599003 13 60 ENGINE MANAGEMENT SYSTEM 3 n bine a uar ur um O na z ECM Data Graph Codes Tests System Into ECM Output Tests Warning Please read the messages below Misfire adaptive memory should be reset AFTER the repair of any failed engine or drive component that could have induced an abnormal vibration into the crankshaft Injector Fire Test Examples of this are bent props tight or worn U joints a bent shaft a damaged drive coupling Kill Test Compression Test Mode Drive By Wire Test CAUTION resetting misfire adaptive memories BEFORE repair of a misfire condition could cause the system to NOT detect an actual misfire under certain operating conditions Clear Misfire Data Do you want to continue OK Cancel Pleasurecraft
132. m throttle If the problem continues to get worse and reaches a reading exceeding Stage 2 values the ECM limits the throttle body to an elevated idle speed Warning The ECM never intentionally shuts the engine down If the engine has low oil pressure or an over temp condition the operator has to make the decision to shut the engine down or get to a safe location The following are good examples of problems reported through the Engine Management System that may be the result of another engine system failure In these cases the Engine Cooling System the Exhaust Cooling System or the Engine Lubrication System may be the cause By following the Diagnostic Procedures provided for each of the trouble codes you will be able to distinguish the root cause of the reported failure Your task is to determine if the condition was caused by A mechanical condition fluid levels under or over filled conditions Fluid restrictions or lack of flow Once the cause has been determined apply the procedure located in the service manual that applies to the problem L599003 13 43 ENGINE MANAGEMENT SYSTEM 3 g pais uod reus jeu is aoa Josueg punoJ5 Josues 03002 ERE MM aad pe agy m 3 WL NYL INYL uod uod uoo V JosuaS V JosuaS THAV IB uous E v uuo jus pre
133. minal of the Starter Verify repair kkkkkk IMPORTANT kkkkkk When you have completed your troubleshooting and repair of the starter be sure to Reinstall the System Relay then verify the engine starts and runs Figure 2 8 Starter Circuit No Crank L599003 13 25 PCM DRIVABILITY CHECKLIST 2 Aja WD e e da1 poop SYND J 159192 pue uid 041002 Aejal lanj IN23 pue sg 205 WUBA suid Jol2euuoD peej Jelleq IND3 ureda Xelsd u1oq ae elled HUA O3OM lanj aoelday IN23 pnldun edal Ajo janj poob ssouJeu pue Apa 1920s suon euuo Aejay jan4 pue pue Jan sseuJeu ispuo2es p Z JO e3euiunj 1461 1591 lanj 245 58 pue og uid J4ol2euuoo jan 1461 1591 122000 ye elledq HUA unu janj oq 8 uid pue asnj ol o 385205 uid 19205 jan edad Aja 53291010 esnj ay YNDI Y ebeyjoA Kjexeq 51 u uoys pue smojq
134. mine the cause of the fuel pump failure The cause of this condition could be electrical such as 1 An open or shorted wiring circuit 2 Afaulty relay 3 A bad fuel pump 4 A blown fuse 5 A control problem with the ECM Looking at the Troubleshooting Tree you will see that the first step to perform is the On Board Diagnostic OBD System Check Perform this check to determine if the problem is located in the Fuel System or Engine Management System If you find a Fuel Pump Relay Circuit Open High or Short to Ground diagnostic trouble code you will diagnose the Engine Management System problem first If there are no trouble codes you will need to take a logical approach to isolating why the fuel pump or pumps do not run Refer to the No Code path Figure 4 4 The second check is for battery voltage at the Fuel Pump Relay and ECM fuses Looking at the main power diagram we have picked a starting point for troubleshooting roughly in the middle of the circuit When the key switch is in the ON position you can see that the fuses should have power across them By taking a voltage reading between a known good ground and each fuse you can then make a decision as to the direction of your troubleshooting path Refer to Figure 4 6 If voltage is not present across the fuses the fuel pumps cannot run If you find a fuse blown typically the device or the wiring it protects has shorted causing too much current flow and melts t
135. n all 8 cylinders Record below 7 VERIFY REPAIR HAS CORRECTED THE PROBLEM Check for and clear all codes from the ECM memory Water test the boat Run the engine for a minimum of two 2 minutes then verify that no codes have returned Continue with your water test long enough to verify that the problem has been corrected CAM Retard 02 thru 06 43 47 degrees 07 SN 485993 0 4 degrees CES and SN 4859944 15 2 degrees FRONT COMPRESSION PRESSURE 5 0 5 7L 130 215 psi 6 0L 130 215 psi 6 2L 130 215 psi Lowest pressure should be within 70 of highest pressure Minimum cylinder pressure 100 psi FLYWHEEL END OF ENGINE ALL V 8 MODELS FLYWHEEL END OF ENGINE ALL V 8 MODELS 5 0 5 7 Liter 5 7 Liter 6 0 6 2 Liter LH ROTATION RH ROTATION LH ROTATION FRON IGNITION WIRE RESISTANCE CHECK FRONT FRONT Less than 10 000 ohms ft REFERENCES Master Engine Specification Sheets L510030 GCP 4G Diagnostic Service Manual L510015 5 0 5 7L Engine Mechanical Service Manual NO DISTRIBUTOR L510016 6 0L Engine Mechanical Service Manual PCM Premier Dealer Website All the Latest Madii ALL V 8 MODELS Publications FIRING ORDER FIRING ORDER FIRING ORDER 1 8 4 3 6 5 7 2 1 2 7 5 6 3 4 8 1 8 7 2 6 5 4 3 Figure 2 2 Drivability Checklist L599003 13 13 PCM DRIVABILITY CHECKLIST
136. n can prevent you from coming to an erroneous result and spending unnecessary time troubleshooting a problem NOTE A Note directing you to read the Test Descriptions is not always located in the test step Always read Test Descriptions prior to performing the diagnostic procedure L599003 13 35 ENGINE MANAGEMENT SYSTEM 3 Engine Control Module ECM Aud ECM Ground Ground Ground Stud 8 Pin Boat check Gauges Harness Lamp CGL Circuit Connector L Battery Battery Fuse 20A STARTER RELAY Max Fuse20A Diagnostic Connector Fuse OBDM Diagnostic Connector Malfunction Indicator 1 Lamp MIL 15A From 102 Ignition To CAM Phaser Sensor Conn Term D To Port Pre O2 Term C To Port Post O2 FUEL PUMP RELAY Fuse 20A Ignition Relay Not Used To PANEL Maxi Fuse 40A To 100a Alt Connector Term D To Ignition Coil Connector stbd Term H Bank 2 To Ignition Coil Connector port Term H Bank 1 Nu 127 ex 1 To STB Post O2 Term C To STB Pre O2 Term C gt STB Fuel Injector Connectors 2 4 6 8 Port Fuel Injector 57 80 14 15 CAN CAN BUS BUS Malfunction Indicator Lamp MIL Circuit Check Gauges Lamp CGL Circuit PNK DK GRN Connectors Term C 1 3 5 7 Ignition Relay On Bo
137. neutral The test will automatically increase the RPM to about 1200 RPM All four oxygen sensors are checked for the ability to report a lean air fuel mixture a rich air fuel mixture or heater circuit control The test usually takes several minutes This function can be used to help diagnose a faulty oxygen sensor circuit or to validate a repair to any of the four oxygen sensors or circuits L599003 13 58 ENGINE MANAGEMENT SYSTEM 3 Jorg J hbes Helg ECM Data Graph Codes ECM Output Tests Warning Please read the messages below Perform cylinder deactivation test under moderate load between 1000 and 2000 RPM To START test Engine should P Tests System Into 1 Injector Kill Test be idling under 1000 RPM and in NEUTRAL When test is started the throttle control mode will be changed which will change the RPM of the engine Click OFF to deactivate cylinder To STOP test put in NEUTRAL and idling under 1000 RPM WARNING ENGINE RPM WILL SURGE WHEN TEST IS STOPPED OR STARTED USE CAUTION WHEN STARTING OR STOPPING THE TEST Please follow all engine and boat manufacturer s safety precautions and stay clear of all moving engine components while running this test OK Cancel Injector Fire Test Compression Test Mode Drive By Wire Test Clear Misfire Data Pleasurecraft Crusader GCP ETC 4G Engine Data Injector Kill Test This is an extremely useful test for isolating
138. next series of steps verify the operation of the starter control circuit Begin at the Transmission Neutral Safety Switch Disconnect the wire from one side of the Transmission Neutral Safety Switch Use your DMM to verify continuity O ohms when the Transmission Neutral Safety Switch is closed and the transmission is in neutral When the transmission is shifted into gear the switch should read open infinite ohms or OL out of limit on the meter Use your DMM to verify that the switch is opening and closing properly as the transmission is shifted into and out of gear Be sure to check adjustment for both forward and reverse Adjust the shift cable as necessary to ensure the switch is closed when the transmission is in neutral and open when the transmission is in gear Reconnect the wire removed to perform this test and proceed to the next test Isolating the engine electrical system from the boat Refer to Figure 5 3 for isolating the engine from the boat The engine is designed to be controlled by the boat s mechanical and electrical controls Problems in these areas may cause conditions that may be mistaken for engine defects BATTERY TERMINAL Often it is necessary to determine if the boats electrical system is the cause of a reported engine problem It will be necessary to separate the engine electrical system from the boats electrical system before testing begins Some common symptoms that may indicate the need
139. ng type size reach or heat range of the spark plug installed improper gap fouling or physical damage Step 6A 7 With all eight spark plugs removed perform a compression check on all 8 cylinders Record the results of the compression check in the space provided on the PCM Drivability Checklist Re install the spark plugs and ensure the ignition wires are all connected and routed properly L599003 13 18 PCM DRIVABILITY CHECKLIST 2 Step 6A 8 5 0L 5 7L Engines Only Using your Diacom scan tool with the engine running at idle verify CAM Retard is within specifications Adjust as required to set to the proper specification Refer to Steps 9 12 The final series of checks will be made with the boat in the water Step 6A 9 Whenever practical if another boat of similar size with the same engine package is available use it to verify and compare engine parameters for performance issues Step 6A 10 Perform a Power Balance Test on the engine The Power Balance Test is accessed using your Diacom scan tool For best results perform this test with the engine under load running between 1600 1800 RPMs This test can isolate a coil ignition module circuit and or fuel injector circuit problem to a specific cylinder This will help determine what cylinder s to focus your diagnostic efforts on NOTE The Diacom Power Balance Test should be performed with the engine under load This provides for easier viewing
140. ns listed such as discolored paint from excessive heat fluid leaks fluid levels etc Most of the inspections listed are items easily seen as faults When you have a performance issue be sure to include in your inspection a check of the ignition wires and spark plugs to include 1 Proper routing 2 Correct firing order and 3 Inspect spark plugs for broken or cracked insulators Be alert as you perform the visual inspection You may repair the reported problem by reconnecting a wiring connector or cleaning the corrosion away from the power and ground terminals of the battery Samples of some observations that would need attention before attempting to run the engine are L599003 13 14 PCM DRIVABILITY CHECKLIST 2 1 Melted skinned or burnt wiring You will need to repair the wiring The condition of the wiring may have been caused by a Cooling System failure or a Main Electrical System failure 2 Oil level excessively high on the dipstick This may indicate a foreign liquid in the oil or an over fill condition exists Investigate and correct a high oil level condition before proceeding Symptoms of too much oil in the crankcase include a loss of power a loss of top end rpm a possible low oil pressure reading and the engine may be going into Power Derate Mode 3 Evidence of excessive water in the bilge A rust water line on the starter engine block is usually a good indication if the water is not st
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142. oat accessory devices You would then troubleshoot and repair that problem If the problem is still present in the engine you can now focus your troubleshooting on the engine NOTE The remote key switch test harness P N RT0091 can be purchased from the PCM Parts Department Figure 5 2 Remote Key Switch P N RT0091 System Power Refer to Figure 5 3 You should have the following tools available when troubleshooting the Main Electrical System 1 Diacom scan tool 2 DMM 3 Battery Load Tester Your starting point for any Main Electrical System problem and most other troubleshooting problems will be the Battery Low or no voltage at the ECM Starter and other devices will cause multiple faults and symptoms to occur Remember voltage below 9 6 vdc at the ECM will cause the ECM to not power up shut off or reset during cranking This may cause an interruption in fuel and or spark control and cause starting or drivability issues In other words low voltage equals a loss of 1 fuel 2 air 3 spark Figure 5 3 Tools L599003 13 86 System Power Previously we discussed the OBD System Check Part of the first step in that procedure was to ensure that 1 The Battery is good of the proper size and fully charged 2 The Battery cables are clean tight properly connected and in the correct locations 3 Excessive resistance is not present in the cable circuits These steps are the basis for the System Pow
143. odes Troubleshooting Tree for Step 6A of the PCM Drivability Checklist Figure 2 2 This troubleshooting tree follows the items listed under Step 6A on the PCM Drivability Checklist Step 6A 1 is to review the data collected as you performed the first 5 steps of the checklist 1 Review the symptom information the owner operator provided when you questioned him her on recent events or service Recheck the engine model and serial number Recheck the Service Updates Review your visual inspection Recheck for accessories added Review Step 4 Verify The Problem Mo c Run another check for diagnostic trouble codes If a problem is found correct that problem before proceeding If you skipped any portion of the first 5 steps go back and perform those checks or inspections After you verify that all steps 1 5 have been properly completed and the results properly analyzed proceed to Step 6A 2 Step 6A 2 An extremely important test is to verify the quality of the fuel in the boat Sample the gasoline for water diesel fuel and or other contaminants This can be done by draining the FCC fuel bowl into an approved container for inspection If you suspect fuel system contamination connect your auxiliary fuel tank to the engine drain the FCC and retest the boat If performance returns to normal you know you have a fuel quality and or fuel availability problem This test analyzes two problems fuel q
144. oducts As a result PCM inboards command the highest degree of customer satisfaction in the industry PCM s goal is to create a network of knowledgeable dealers who can provide parts service and warranty on the PCM product line The PCM E Train is one tool used to elevate the standards of PCM service technicians who were already providing a superior uncompromising commitment to customer satisfaction to a level not seen before Thank you for choosing to be part of the PCM Premier Dealer Worldwide Team STOP PAUSE PLAY TRAINING SESSION There are video controls at the lower left hand corner of the screen These controls work the same as any other video controls You can stop pause and play the training session at your pace The training session will run continuously through each section or chapter pausing for several seconds in between screens You can use the controls to stop or pause the screen if you need more time to make some notes Once the Stop Pause button is clicked on the control changes to a Play button so you can resume the training session when you are done taking your notes The only time the training session stops or pauses automatically is at the end of each section or chapter See the following Section Checkpoints for further information so your training session does not timeout on you Catalog Gradebook Manage Courses instructor Gradeboo Administration View Chalkboard PCM Electronic Training Course 213 Trou
145. olume from the Low Pressure Fuel Pump the Low Pressure Fuel Pump volume test will have to be repeated using your auxiliary fuel tank The auxiliary fuel tank is used to isolate the engine s fuel system from the boat Restrictions in the fuel line anti siphon valve in line fuel filter or in the fuel pick up tube are some of the most common causes for the volume output of the Low Pressure Fuel Pump to be low Determining if the problem is on the boat side or engine side may be accomplished by connecting the auxiliary fuel tank Remove the fuel line connection at the input to the Low Pressure Fuel Pump Connect the auxiliary fuel tank directly to the Low Pressure Fuel Pump input and repeat the Low Pressure Fuel Pump output volume test If the Low Pressure Fuel Pump again fails the volume test the fuel inlet or outlet is restricted or the pump is defective Determine and resolve the problem and verify the repair L599003 13 76 FUEL SYSTEM 4 Refer to Figure 4 7 Once the Low Pressure Fuel Pump output volume has been verified to be correct the next check is an inspection of the high pressure pump and its output path The result of that inspection will determine if we have a pump problem or a metering problem such as the pressure regulator or defective fuel injector s Inspect the FCC internal fittings and hoses for leaks and repair as required If no problem is found you will need to replace the high pressure pump If the p
146. on or Check Review Steps 1 thru 5 WATER TEST 2 Inspect fuel for contamination 9 Verify CAM Retard 5 0 5 7L only ination i 10 Performance verified against 4 Powertrain is aligned similar boat w same engine 1 3 Electrically isolate engine from boat and Rotor 5 0 5 7L onl 11 Perform the Diacom Power Balance Check under load 1600 1800rpm 2 Perform the harness Wiggle Test 8 Perform a Compression Check 13 Diacom recording Pre Delivery test on all 8 cylinders Record below 7 VERIFY REPAIR HAS CORRECTED THE PROBLEM Check for and clear all codes from the ECM memory Water test the boat Run the engine for a minimum of two 2 minutes then verify that no codes have returned Continue with your water test long enough to verify that the problem has been corrected CAM Retard 02 thru 06 43 47 degrees 07 SN 485993 0 4 degrees CES and SN 4859944 15 2 degrees FRONT COMPRESSION PRESSURE 5 0 5 7L 130 215 psi 6 0L 130 215 psi 6 2L 130 215 psi Lowest pressure should be within 70 of highest pressure Minimum cylinder pressure 100 psi FLYWHEEL END OF ENGINE ALL V 8 MODELS FLYWHEEL END OF ENGINE ALL V 8 MODELS 5 0 5 7 Liter 5 7 Liter 6 0 6 2 Liter LH ROTATION RH ROTATION LH ROTATION FRONT IGNITION WIRE RESISTANCE CHECK FRONT FRONT Less t
147. ou perform the PCM Drivability Checklist If you have completed the PCM Drivability Checklist through Step 6A and have not found and resolved the problem STOP and call the PCM Technical Service Department for assistance PCM Warranty and Service Department 803 345 0050 Have your completed PCM Drivability Checklist and Diacom recording readily available when you call the PCM Technical Service Department for assistance You may be requested to fax or e mail a copy of the checklist to the Technical Service Department during your discussion with the factory service representative L599003 13 19 PCM DRIVABILITY CHECKLIST 2 DRIVABILITY CHECKLIST NO CODES 6A 1 Review the results of Steps Inspect or correct recent 1 5 service work performed 6A 2 Inspect fuel for contamination Correct fuel fuel system water correct fuel type ect as necessary 6A 3 Verify powertrain Correct alignment alignment as required Remove and Inspect the 4 Distributor Cap and Rotor 5 0 5 7L Only Replace Cap and Rotor as necessary 6A 5 Ignition Wire Resistance check Replace spark plug Record results wires as necessary Remove and Inspect each spark 6A 6 plug for damage or abnormal condition 6A 7 Perform a Compression Check ilicis o on all 8 cylinders and record Manual WATER TEST Verify Cam Retard 5 0 5 7L only Replace spark plugs as necessary 6A 8 Adjust as required Performance verified against
148. ounds are available for System Power you would return to the test procedure that requested a System Power check If the problem you are troubleshooting is a starter problem or a charge system problem you would return to the Starter or Charge Circuit Troubleshooting Tree and complete the troubleshooting Always resolve system power starter or charging problems before you perform the On Board Diagnostic System Check or any other Engine Management System troubleshooting procedure L599003 13 87 MAIN ELECTRICAL SYSTEM 5 ALTERNATOR To STBD GRD STUD BELLHOUSING BATTERY 2 8 Pin Boat Harness STBD GRD STUD BELLHOUSING BLACK 6 ga 100A 70A R ITE ED WH PUFPLE VVHITE 5 E 8 Boat Harness Fuse Block Panel Fuse 40A Battery 1 Q Pin L Purple 4 Fuse Block starter Starter 7 8 Pin Relay Fuse 20 YEL RED BAT STARTER s GROUND ENGINE BLOCK Fuse Block ECM Fuse 20A To STBD GRD STUD BELLHOUSING Fuel Low Pressure Fuel Pump 1 2ga 71 12 Starter m Y Relay To ECM c Control To EXC Alternator Ignition gt PURPLE 5 8 Pin m 14ga um vw Fuse Block A VSW Fuse 5A Le PON To ECM zt 24 Ignition 7A 11 Aj Fuse Block pede Pin Y
149. p the meter on the positive battery cable connected to the starter Set the meter for DC Amperage reading Turn the key to START Observe meter reading Are readings within range listed Typical 5 0 5 7L 150 250 A Typical 6 0 8 1L 210 325 A YES Replace Starter Normal Verify repair Operation Check both cables NO Negative Battery Cable Check Positive Battery Cable Check Connect DMM to the battery Connect the DMM 4 lead to the post Connect DMM to the battery post Connect the starboard engine block ground DMM lead to the Starter stud Turn the Key switch to battery terminal Turn the START and observe your DMM for key to START and observe the a reading less than 2 vdc DMM reading is less than 6 vdc YES YES Normal Normal NO Troubleshoot positive cable back to the battery Ensure that devices such as a Battery Switch are connected and functioning properly Verify the positive cable is the same gauge from the starter to the battery Replace undersized cable with the correct size Repair or replace postive cable with one of the correct gauge and length Replace negative battery cable with one of the correct gauge and length Verify Repair kkkkkk IMPORTANT kkkkkk When you have completed your troubleshooting and repair of the starter be sure to Reinstall the System Relay then verify the engine starts and runs Figure 5 9 Starter Circuit Slow Crank Troubleshooting Tree L599003
150. pen throttle your fuel system is functioning correctly When troubleshooting a fuel system problem your primary tool will be a Fuel Pressure Gauge You should also have available 1 Diacom 2 DMM 3 Auxiliary fuel tank 4 A graduated container Previously we discussed the actions that occur when the ignition switch is placed in the ON position Step 4 of the POM Drivability Checklist Figure 4 2 While observing the fuel pressure rising to the required specification on the fuel pressure gauge we were to listen to and feel both fuel pumps to verify that they were running Once the ignition is in the position you can use your Diacom Tests screen to select and cycle the fuel pumps Using this test allows you to remain next to the engine and cycle the fuel pumps whenever a test procedure calls for individually testing each fuel pump and or priming the fuel system NOTE Diacom Relay test enables both fuel pumps If testing an individual pump the electrical connector for the other pump can be disconnected during testing L599003 13 66 FUEL SYSTEM 4 PRESSURE REGULATOR Fuel Control Cell Fuel System FUEL FILTER FUEL SYSTEMS TYPICAL Fuel Control Cell Fuel System Returnless Fuel Rail 777 D ri M4054P 2 12 04 Figure 4 1 Typical Fuel System Configurations L599003 13 67 FUEL SYSTEM 4 PCM DRIVABILITY CHECKLIST ENGINE SERIAL NUMBER Date Dealership Name
151. r Remove the Fuel Pump Relay Jumper relay socket Pin 30 to Pin 87 for 10 seconds then disconnect jumper Verify 16 20 oz of fuel in the container Return system to normal configuration FAIL Connect an auxiliary fuel tank to the input of the LPFP Repeat fuel pump volume test Fuel volume to spec PASS PASS FAIL Troubleshoot and repair Replace LPFP fuel restriction on supply Verify repair inlet side of the LPFP Verify repair Inspect and repair FCC internal high pressure hose fittings and connections If good Replace HP fuel pump Verify repair Replace Fuel Pressure Regulator Verify repair Troubleshoot fuel rail for leaking injector s and repair Verify repair Above Specification Connect an auxiliary fuel tank between the LPFP inlet and FCC return Cycle the fuel pumps Verify At Specification Troubleshoot and repair restriction in fuel return line from FCC to the fuel tank Verify repair Above Specification Replace Fuel Pressure Regulator Verify repair Figure 4 7 KOEO Fuel Pressure Out Of Range Troubleshooting Tree L599003 13 NOTES L599003 13 01 13 79 NOTES L599003 13 80 N B PREMIER DEALER WORLDWIDE Section 5 Main Electrical System MAIN ELECTRICAL SYSTEM 5 PCM DRIVABILITY CHECKLIST ENGINE SERIAL NUMBER Date Dealership Name Technician s Name Technician s Contact Phone Owner Operato
152. r Name Person Reporting the problem if different from owner operator Service Writer or Person that took the problem report 1 PROBLEM OR SYMPTOM Who first observed the symptom When did the symptom first occur Any recent change or service work prior to symptom occurring replaced belts or impeller major engine or boat repairs recently refueled etc Has someone other than yourself tried to correct the current symptom If yes what work was done Accessories Added Recently Is the symptom currently present Special conditions if any required to duplicate the symptom Use an additional sheet of paper if more space is required for symptoms or descriptions 2 CHECK FOR SERVICE UPDATES ENGINE SERIAL NUMBER ENGINE MODEL NUMBER ENGINE HOURS HULL NUMBER ENGINE None Apply Performed BOAT None Apply __ Performed 3 VISUAL INSPECTION Inspection Evidence of an over heat Evidence of or Excessive Water Engine Harness connectors in the Bilge connected properly Fluid levels checked Physical Damage wiring connectors Leaking Fluids assemblies and Remove Spark Plugs mem Firing order correct and inspect for fluids Correct size propellers installed EE Corrosion Underwater gear is undamaged E es snacks oe VERIFY THE PROBLEM Check Accessories Added Heater Shower Water Tank Flush Kit Multi Function Display Synchronizer LlAf
153. rally when an impeller fails small pieces of the impeller will be flushed out of the system and expelled with the water exiting the exhaust Larger pieces may enter the hose attached to the inlet and outlet side of the raw water pump and can cause problems if they are not retrieved All engines will require inspection of the inlet side of the pump to determine if a restriction exists Remove any restrictive material that is found COOLING SYSTEM Figure 6 10 Failed Raw Water Pump Impeller On raw water systems further inspection of the outlet hose and the thermostat housing is required On fresh water systems inspect the outlet hose the transmission cooler if equipped and the raw water section of the heat exchanger On fresh water partial systems equipped with an exhaust coolant system thermostat the thermostat screen assembly requires inspection cleaning For raw or fresh water systems ensure the restrictive material is located and removed Refer to Figures 6 1 through 6 7 water flow diagrams for specific differences in the raw water cooling flow path Refer to Figure 6 13 FAIL path Once you have completed your inspections of the input and output paths replace the Raw Water Pump impeller Clear the ECM of codes and perform the Raw Water Pump Volume Test again Verify that you have corrected the raw water supply problem Return the engine to its normal configuration and verify you have corrected the overhe
154. ransmitted to the dash directly from the ECM via CAN BUS In this case the engine temperature on Diacom and on the digital display should be the same L599003 13 124 ale Pls le le s GM DELCO 40 MODE 1 MASTER Camew 474 arise COOLING SYSTEM 6 Outlet Housing Part Number RA026009 IMPORTANT Thermostat housing MUST be assembled and tightened as shown in the vertical position Filter Failure to do so may cause the thermostat to improperly seat and result ina Inlet leak Housing This filter must be inspected and cleaned as necessary at your 25 Hour Engine Inspection The filter should then be inspected and cleaned every 50 hours or once a year Figure 6 14 6 0L CES Exhaust System Thermostat L599003 13 125 COOLING SYSTEM 6 TROUBLESHOOTING A FWC COOLANT LOSS CONDITION Inspect for visible coolant leaks Verify Coolant level is correct Engine Running Pressure Cap Removed 1 Verify coolant circulation in Degas Bottle 2 Add coolant as necessary to maintain MAX level in Degas Bottle 3 Verify engine achieves normal operating temperature and the thermostat has opened Degas System Add coolant to the MAX level on the Degas Bottle Engine OFF Completely cooled off Verify coolant level to be YES between MIN and MAX on the Repeat cold fill if coolant level is low for the NO first check Degas Bottle
155. re cleared using the Diacom scan tool and the fault is not present the MIL or CGL will immediately go out with the engine running NOTE The Malfunction Indicator Lamp MIL is AMBER in color and the Check Gauges Lamp CGL is RED in color Over temperature and oil pressure faults illuminate the CGL all other faults illuminate the MIL Many manufacturers use digital displays for instrumentation Faults are indicated through these displays and DO NOT use separate lamps The DTCs are accessed using Diacom when you check the ECM for stored codes Diagnostic Manual One of your most important tools for troubleshooting an Engine Management System problem will be the Diagnostic Manual Take some time and familiarize yourself with the location and information that is contained in each of the sections The manual is divided into several sections Section 1 is General Information on the system special tools an abbreviation definition table and service instructions for engine harness and connector problems Section 1 not only lists the special tools required when working on an engine management system but also specifies requirements for common tools you may already be using Atest light used for troubleshooting must pass the test requirements specified in Section 1 A Digital Multi Meter must have a minimum input impedance of 10 mega ohms Section 2 provides a description and service instructions for the Engine Control Module ECM
156. re the actual test As part of Step 1 the OBD System Check incorporates three steps we discussed as part of the PCM Drivability Checklist Figure 3 1 These include 1 Review of Service Updates 2 a Visual Inspection 3 Condition of the Starter and System Power When you follow the PCM Drivability Checklist these checks will have been accomplished before you begin this procedure When you complete an action or test sequence in a diagnostic procedure the procedure will ask you a YES NO question about the result The OBD System Check Step 1 asks Does the scan tool display ECM Data The answer determines the correct path to proceed to in the procedure Some steps are diagnostic checks for communications problems of the ECM One step of this procedure is an example of how the Test Descriptions can aid you in your troubleshooting In this case there is a Note referring you to the Test Descriptions The Test Description for this provides you with conditions that can affect the transmission of CAN BUS data to the scan tool One is a faulty scan tool the other is an suspect auxiliary device s possibly wired into the CAN BUS circuit Both are conditions that can affect the outcome of your test Even though some diagnostic steps do not have Test Descriptions you should always read the Test Description information available for the step you are performing prior to executing a diagnostic procedure Test Description informatio
157. re trying to induce or to verify a successful circuit repair NOTICE When clearing DTC s the ignition must be cycled to the OFF position or the DTC s will not clear L599003 13 39 ENGINE MANAGEMENT SYSTEM 3 Malfunction Indicator Lamp MIL Trouble Codes The majority of the trouble codes that the ECM stores are for emission related conditions The AMBER Malfunction Indicator Lamp MIL is triggered for emission related faults If the boat contains a Digital Display in the dash in most cases the MIL is not used All faults are displayed through the digital display Remember that DTC s have been commonized through Federal Regulations This means that all engine manufacturers have the same identification numbers for each emission failure Failures are now identified by a Suspect Parameter Number SPN and Failure Mode Indicator FMI Both of these numbers are required in order to identify the exact failure detected NOTE Diacom ONLY reports the SPN and FMI numbers The scan tool does not report the DTC number The trouble codes help isolate the problem area to things such as circuit short to ground circuit open circuit short to voltage or Bank 1 or 2 problem These trouble codes also define sensor identification when multiple sensors are used such as knock sensors O2 sensors or exhaust manifold water temperature sensors These trouble codes are diagnosed using the same logic previously stated as part of the PCM Dri
158. ressure is still low replace the fuel pressure regulator The last step would be to troubleshoot and replace the faulty fuel injectors It is important to note that if you have an injector or injectors stuck open causing a low fuel pressure problem you will have multiple symptoms related to over fueling of the engine Some of the more common symptoms of over fueling are hard to start possibly slow to crank rough running at low RPM evidence of heavy black soot on the transom and raw fuel in the exhaust The Diacom Power Balance Test can be used to isolate this problem to the specific cylinder s being over fueled IMPORTANT Some additional causes for over fueling of the engine include an engine coolant temperature ECT sensor that has shifted in value a manifold absolute pressure MAP sensor that has shifted in value system voltage out of range or a cooling system under temperature condition Typically the aforementioned conditions will not set a code in the ECM Be sure to complete the PCM Drivability Checklist verifying system power cooling system operation and verifying system parameters by comparing a DIACOM recording of a known good engine against the DIACOM recording of the suspect engine The Fuel pressure troubleshooting procedures discussed have approached the pressure problem from the stand point that the fuel pressure is out of tolerance under all conditions Always verify fuel pressure is correct under load at
159. ressure near wot specification engine cranking Engine Starts and continues to run go td 3 Water Test 3 WATER TEST YES NO FuelPress Verify reported symptom Fuel Pressure idle Fuel Pressure underload wor such as GPS Radar Sonar Auto pilot systems Radio Equipment L Lights Other please list 4A Revised or additional symptom found Figure 2 2 Drivability Checklist L599003 13 12 PCM DRIVABILITY CHECKLIST 2 PCM DRIVABILITY CHECKLIST 5 PERFORM THE OBD SYSTEM CHECK CODE S PRESENT DIAGNOSTIC PROCEDURE USED Continue to Step 6 6 ISOLATE AND REPAIR THE PROBLEM Were you able to isolate and repair the problem If YES continue to Step 7 If NO complete the Drivability Checklist for No Codes step 6A below If the problem is still not resolved then call for factory technical assistance 6A NO CODES ENGINE RUNS DRIVABILITY SYMPTOM STILL PRESENT Inspection or Check 7 YES NO waer restr 9 Verify CAM Retard 5 0 5 7L only 10 Performance verified against ____ similar boat wsame engine and Rotor 5 0 5 7L only 11 Perform the Diacom Power Balance m Check under load 1600 1800rpm 12 Perform the harness Wiggle Test i 13 Diacom recording Pre Delivery test 7 Remove and Inspect each spark plug 8 Perform a Compression Check o
160. revent a reoccurrence of the problem In most cases performing the PCM Drivability Checklist will help you identify the problem so that you can repair it In those instances where you are unable to locate the problem the data you have collected on the completed POM Drivability Checklist will allow you to work with your POM Technical Service representative to more quickly isolate and resolve the problem L599003 13 10 PCM DRIVABILITY CHECKLIST 2 BASIC TROUBLESHOOTING APPROACH Obtain a clear concise description of the problem Check for applicable Service Updates Perform a visual inspection of the engine for obvious faults Verify the Problem Perform the On Board Diagnostic OBD System Check Isolate and Repair the Problem Check Clear Trouble Codes from ECM Verify the Problem has been Corrected Figure 2 1 Basic Troubleshooting Approach Tree L599003 13 11 PCM DRIVABILITY CHECKLIST 2 PCM DRIVABILITY CHECKLIST ENGINE SERIAL NUMBER Date Dealership Name Technician s Name Technician s Contact Phone Owner Operator Name Person Reporting the problem if different from owner operator Service Writer or Person that took the problem report 1 PROBLEM OR SYMPTOM Who first observed the symptom When did the symptom first occur Any recent change or service work prior to symptom occurring replaced belts or impeller major engine or boat repairs recently refueled etc Has someone other than yo
161. rformed fails you may have a new branch to follow to troubleshoot and repair the problem NOTE For illustrative purposes each test presumes the problem has not been resolved Therefore you proceed to the next step In actual troubleshooting if any step corrects the problem there would be no reason to proceed further You would verify your repair Step 7 of the PCM Drivability Checklist We want to perform some basic checks before we go for a water test and verify the problem You are going to need your senses sight hearing and touch as much as you will need your tools A Digital Multi Meter DMM Diacom and Fuel Pressure Gauge will be used while performing these checks This will be your first look at the various engine Systems with a focus on troubleshooting the problem Within a few minutes of testing you may know the direction of your troubleshooting efforts Try to start the engine If the engine starts and continues to run you would go to the Water Test and verify 1 The reported problem and 2 The fuel pressure at wide open throttle If we have a no crank condition we would troubleshoot the Main Electrical System and the Starter circuit For any other conditions long crank hard start stalling etc we want to continue with our testing and perform the Key On Engine Off KOEO test Key On Engine Off KOEO Test This test may be used to determine the condition of the engine s Electrical Fuel and Engine Management
162. rheat condition the exhaust hoses may be damaged by the heat and the exhaust manifold and elbow gaskets may need to be replaced Remember that without the cooling water going through the exhaust system exhaust temperatures can easily exceed 1200 degrees and burn out gaskets and melt blister and collapse the inner liner of the exhaust hose creating an exhaust restriction Always inspect the exhaust system after an overheat condition has occurred Failed gaskets can let coolant fresh or raw water flow back into the engine causing severe damage Collapsed or severely blistered exhaust hoses can create excessive back pressure resulting in loss of power and performance and in severe cases cause water to back up into the engine causing major engine damage Inspect Exhaust Hose Exhaust Manifold Water Temperature EMWT Sensor Figure 6 11 Exhaust System Inspection Points Refer to Figure 6 13 PASS path For Fresh Water Cooling Systems For Fresh Water Cooling systems 1 Verify coolant level 2 Verify that coolant can be seen circulating through the degas bottle 3 Verify the coolant level rises and falls slightly as the engine maintains operating temperature Fresh water systems may suffer a coolant loss as a result of an overheat condition or a low coolant level may have been the cause of the overheat condition L599003 13 120 Troubleshooting a Fresh Water Coolant Loss Refer to Figure 6
163. rmostat comes off seat in the housing Whenever you replace the thermostat especially in a fresh water system heat exchanger ensure that the thermostat housing fits tight against the thermostat before you tighten the clamps If the thermostat is not held in place securely coolant will bypass the thermostat and the engine will run cold 1 On Gen Warning 1 Lamp Output on Gen Warning 2 Lamp Output TENT Trouble Code s Found GM DELCO 48 MODE 1 MASTER gt Current Packet index 0 10 16 13 060 Real Under Temp Condition le x ECM Data Li Graph Y Codes Y Tests Calibration Checksum Engine Runsing Time TGF7 MEX 1245 Min 2 Le le 5 le GM DELCO MODE 1 MASTER Current Packet Index 474 10 12 15 700 Perceived Under Temp Condition L599003 13 127 COOLING SYSTEM 6 TROUBLESHOOTING AN UNDER TEMPERATURE CONDITION Verify System voltage is within specifications From Step 5 of the PCM Drivability Checklist Connect Diacom Check ECM for codes No Codes Present Codes Present Perform diagnostic procedure Bring engine to operating for DTC s present as outlined in Diagnostic Manual temperature while observing the Diacom Coolant Temperature displayed value Normal Temperature Verify Repair 160 10 or 170 10 Low Temperature Under 150 degrees Compare Diacom value to th
164. roubleshooting Tree Over Temperature Condition L599003 13 123 COOLING SYSTEM 6 Refer to Figure 6 13 PASS path With the Diacom scan tool connected operate the engine Observe the ECT Sensor value on the Diacom screen Using an infrared thermometer verify the Diacom displayed temperature with the infrared temperature readings at the ECT and at the Thermostat housing The ECT s displayed temperature and thermometer readings should be within 5 degrees of each other An ECT that has shifted in value can cause a perceived overheat condition to occur placing the engine into Power Derate Mode and set the Engine Temperature Higher than Expected code If the readings are not close to each other replace the ECT then verify your repair If the infrared thermometer readings and the Diacom Coolant Temperature display readings are within 5 degrees of each other compare these readings to the boat s temperature display reading The boat s engine temperature gauge typically receives engine temperature from the ECM If your temperature readings and the boat s temperature gauge readings are within 10 degrees of each other the system is operating normally If not troubleshoot the Temperature Gauge and its wiring If that does not resolve the problem refer to the boat or instrument manufacturers troubleshooting procedures NOTE Many applications today display the engine temperature on a digital display at the dash This information is t
165. rter Relay Fuse Starter GROUND ENGINE BLOCK VSW Fuse 5A Ignition Rela Fuse Block Fuse Block Y ECM Fuel Pump To ECM Relay Fuse lgnition Fuse 20A 20A 1 Feed Pin EN Fuse Block 4 Fuse Block STBD Fuse 12 Fuse HOD 20A _ By 20a Battery Feed Pins Fuel Pump Relay Fuel Control Cell To Coils To Injectors Module O2 Sensors Low Pressure Pnk Yel M Fuel Pump Ground 1 BLACK Oga 2 Q Pin To Ignition ALL STBD To ECM Control GROUNDS Ground Pins Module PORT GROUND STUD BELLHOUSING NE ECM GROUND ONLY DO YEL RED YEL RED 7 8 Pin 12ga 1 12 ga Key Switch START Position Key Switch ON Position Starter Relay To ECM Control TRANSMISSION NEUTRAL ISAFETY SWITCH To EXC Alternator To ECM Control onion PURPLE 5 8 e Fuse Block Figure 4 5 Main Power Fuse Check L599003 13 74 FUEL SYSTEM 4 2 BLACK 6 ga Meo 8 Pin GRD STUD Boat Harness 100A REDANHITE BELLHOUSING ALTERNATOR PURPLE WHITE FromPin 5 aepin Boat Harness Fuse Block Panel To STBD Fuse 40A Battery
166. s gt 20 4904 uod 01 e ng e plolueN plolueW Ya HM TM icis 1 ZO 8Jd uod OL zoe 18 OL LHM 8 Wa uuoo LHMW gt 18 josuas jeseug WNVO OL 6115 6118 IHME IHME on IHME 2 na WL pais uuoo uuo v g uoniub OL LHW gt 18 JOSU8S pecia 10sueg 103 108095 2 why WH jue oo2 uuoD 105095 401 OL 205095 v g 2 AVI OL Wa uuo Josue ubu uuoo e Mua m 10895 YURI OL LIHME Josueg LHM Va WHS LHM NVL uuoD ma JOSU8S 11 NVO OL Apog emouu puis punog Jopenjoy 10sueS 1 5 96 2106496 108495 eoueiejed dL OMIL dl dl JOD 100W 9 3 10595 92101 nig Bin NHO 11 8215 E NVL LHM Nd 9 88 28 es Sy re ee eus 7 guasg X ius ipsus INO3 n S di 8 103 einssaJd IIO e npojwN Jo4uoo ie ea eg NN Figure 3 3 Sensor and Power Derate Circuits L599003 13 44 ENGINE MANAGEMENT SYSTEM 3 TROUBLESHOOTING A POWER DERATE CONDITION Check Service Updates Verify Power Derate Mode Verify System voltage is within specifications Perform OBD System Check Ch
167. s necessary 4 Be vigilant in your observation of the water being expelled through the exhaust If dye is present in the expelled water you may have a defective heat exchanger exhaust component or an internal engine problem L599003 13 121 COOLING SYSTEM 6 NOTE Checks performed prior to this test will typically find a defective exhaust component or engine problem At this point the heat exchanger is the most likely defective component However before you replace the heat exchanger always pressure check the heat exchanger exhaust manifolds and elbows to verify no leaks exist Perform a compression check to confirm no internal engine problem d Make a note of any other code that may be present You will have to return to the OBD System Check after you have corrected the cause of the over temperature condition and perform any remaining diagnostic procedures IMPORTANT High temperature readings at the instrument panel may be caused by low system voltage Be sure to perform a system power check and verify the Ensure the thermostat seat is clean voltage and wiring at the instrument panel You may have of debris and she thermostat to refer to the boat OEM service manual or the Instrument is in its seat before tighting bolts OEM s service manual for detailed troubleshooting instructions Figure 6 12 Thermostat Assembly Refer to Figure 6 13 PASS path and Figure 6 1
168. st Relay Tests Compression Test Mode JB Relay Tests 41 Drive By Wire Test Ignition relay is now ON To turn all relays on you must first turn off the ignition relay Please note may take a tow seconds for the relays to tum OFFI Turn Relays ON Turn Ignition Relay OFF Exit Clear Misfire Data Pleasurecraft Crusader GCP ETC 4G Engine Data Relay Tests When selected this commands the ECM to activate the driver output for the Ignition Relay or All Relays This command is very useful for troubleshooting engine management and or fuel system problems Once the ignition switch is in the ON position this command can be used to turn on the System Relay for electrical diagnosis When the ignition is ON engine OFF the ECM turns the Ignition Relay ON for about 5 seconds If the engine is not started the ECM turns OFF the Ignition Relay If you were diagnosing the 12 volt circuit supplied to injectors ignition coils O2 sensors or throttle body you would turn on the Ignition Relay through Diacom This would allow you to take the voltage measurements required without constantly cycling the ignition ON and OFF If you need to turn ON the fuel pumps for priming and or troubleshooting purposes you would select Turn ALL Relays ON L599003 13 56 8 47 12 096 ENGINE MANAGEMENT SYSTEM 3 LED lll QS file Tools Opt ECM Data Graph Codes Te
169. st Corner Left Exhaust Manifold Figure 7 1 CES Exhaust Components L599003 13 132 CATANIUM CLEAN EMISSION SYSTEM CES 7 Catalyst Substrate Isolating Mesh Catalyst Substrate Pre O2 Sensor Right Side EGO2 Right Side EGO 4 Pre O2 Sensor Post O2 Sensor Left Side Left Side EGO 1 Figure 7 2 CES Catalyst and Sensor Components Let s take a closer look at what makes this system different than a non catalyst We have discussed the additional components involved now let s take a closer look at what these components do and how to diagnose them Pre and Post Oxygen Sensors Traditional non catalyst engines had an engine management system that electronically controlled fuel delivery This fuel delivery method is known as Open Loop fuel control This means that the ECM based fuel delivery strictly on a calibrated value at any given RPM and load There is no feedback to the ECM validating the air fuel ratio that was delivered Although this method works fine for making power and good drivability it does not control emissions very well A catalyst system requires the air fuel ratio being delivered to the cylinders to be around 14 7 1 stochiometric air fuel ratio This air fuel ratio is required in order for the catalyst substrate to perform efficient emission reduction Pre Oxygen O2 sensors are placed in the exhaust stream prior to the cata
170. stances existing at those locations Therefore IT IS YOUR RESPONSIBILITY to determine if you are able to proceed safely in performing repairs at your location L599003 13 6 NOTES L599003 13 7 NOTES L599003 13 8 E o S PREMIER DEALER WORLDWIDE Section 2 PCM Drivability Checklist PCM DRIVABILITY CHECKLIST 2 Basic Troubleshooting Approach In this section we will look at a basic troubleshooting approach and some service techniques for isolating various engine systems from the boat systems Proper engine operation depends on numerous systems and components functioning together This of course makes any one system dependant upon the proper operation of all the other systems When troubleshooting an electronic engine management system it is necessary that the Engine Mechanical Components the Engine Fuel System Components the Engine Cooling System Components and the Main Engine Electrical System Components are all functioning as designed prior to troubleshooting the engine management system The PCM Drivability Checklist is designed to help you ensure those requirements are met Most engine management circuit failures cause stored diagnostic trouble codes which have a diagnostic and repair procedure designed to resolve the problem causing the code These codes identify specific failures and will be resolved using the diagnostic manual Isolating analyzing and resolving eng
171. sts 1 System Info ECM Output Tests Warning Please read the messages below This command will erase all learned fuel adaptation data stored in the ECM Relay Tests Idle Speed Test Clear Fuel Adaption Oxygen Sensor Test Do you want to continue Oeoooo OK Cancel Pleasurecraft Crusader GCP ETC 4G Engine Data 8 47 12 096 Clear Fuel Adaption When selected this commands the ECM to erase all Learned Fuel Adaption data stored in the ECM The Engine Management System controls fuel in a Closed Loop fueling state most of the time This means the ECM is taking feedback information from the Oxygen Sensors and adjusting the fuel delivery to constantly maintain a near stochiometric air fuel ratio This is done in order for the catalyst to be most affective Open Loop fueling is when the engine is cold during transients accelerations decelerations and near wide open throttle loads Under normal conditions the ECM learns each application and populates a table based on engine speed and load The adaptive learn allows the ECM to fine tune the fuel delivery based on variables such as backpressure By fine tuning and populating the adaptive learn tables the engine management system can precisely control the fuel delivery for optimal emission reduction This function would only be used after a repair is made An example would be if a system has a restricted fuel filter causing fuel pressure to
172. sure the shift lever is in Neutral position Was fluid found in cylinders Dry and or on the spark plugs Verity system Power Wet Check for Diagnostic No Codes Trouble Codes Codes Present Perform Diagnostic Procedure for the Code s present Water Coolant Present Pressure check exhaust Perform diagnostics for manifolds and elbows for system running rich or leaks possible fuel injector stuck open Fuel Present Replace faulty exhaust manifold or elbow if good Troubleshoot and repair Disable fuel and spark by engine mechanical removing the System Relay Key Switch to START position Once the condition that allowed fluid into the cylinders is repaired Disable fuel and spark by Normal Slow Crank No Crank removing the System Relay Perform a compression check on Perform a compression all 8 cylinders to verify no other check on all 8 cylinders Re Install spark plugs Re Install spark plugs engine damage is present Return Fail Pass to Verify System Power step on the Starter Circuit Trouble Tree Re Install spark plugs GoTo Go T No Crank and verify starter operation Slow Crank Trouble Tree Trouble Tree Normal Troubleshoot and repair Operation engine mechanical Re Install System Relay problem Figure 2 6 Starter Circuit Troubleshooting Tree L599003 13 23 PCM DRIVABILITY CHECKLIST 2 STARTER CIRCUIT TROUBLESHOOTING TREE SLOW CRANK CONDITION Slow Crank Using a
173. te to search applicable Service Updates 3 Perform a visual inspection of the engine for obvious faults One of the most important yet least performed functions when troubleshooting is a detailed visual inspection Always visually and physically inspect the engine wiring harness for damage caused by misrouting chaffing pinched wires or excessive heat Check suspect connections for any that may be loose or broken Inspect terminals for corrosion or being properly seated into connector Pay close attention to the power and ground connections for corrosion and or accessory devices added in Improperly added accessories can adversely affect engine operation Inspect the engine and its assemblies for signs of damage or failure Visually inspect for signs of arcing fluid leaks excessive water in the bilge cracked or damaged assemblies and signs of excessive heat such as melted or deformed parts and discolored paint When you perform a visual inspection you are looking for obvious conditions that could cause the reported symptom If an overheat is reported you look for discolored paint and other heat related damage When you have a performance issue reported include the often overlooked inspections of the boat for conditions that may affect performance such as hull damage or growth damaged underwater gear and if the correct propeller is installed Referring to the PCM Drivability Checklist you can see there are a number of inspectio
174. ter Market Stereo Equipment L After Market Depth Fish Finder L After Market Navigational Equipment ECHE DE the engine start and continue to 10 3 go to 1 run below below KeyONEngimeOFF KOEO YES NO Fuet Press Both Fuel Pumps run 2 4 seconds Fuel Pressure near wot specification when pumps run 2 Key ONEngine Running KOER YES NO Fuel Press Engine Fuel Pressure near wot specification engine cranking Engine Starts and continues torun geld Water Test 3 WATER TEST YES NO Fuel Press Fuel Pressure S Po oo y Fuel Pressure under load WOT such as GPS Radar Sonar Auto pilot Systems Radio Equipment L Lights Other please list 4A Revised or additional symptom found Figure 5 1 PCM Drivability Checklist L599003 13 82 MAIN ELECTRICAL SYSTEM 5 PCM DRIVABILITY CHECKLIST 5 PERFORM THE OBD SYSTEM CHECK CODE S PRESENT DIAGNOSTIC PROCEDURE USED Continue to Step 6 6 ISOLATE AND REPAIR THE PROBLEM Were you able to isolate and repair the problem If YES continue to Step 7 If NO complete the Drivability Checklist for No Codes step 6A below If the problem is still not resolved then call for factory technical assistance 6A NO CODES ENGINE RUNS DRIVABILITY SYMPTOM STILL PRESENT Inspection or Check 7 YES NO waer mestr 9 Verify CAM
175. ter issues Low or no power may not only keep you from starting the engine but may cause the ECM to set false codes cause improper operation of the engine s ignition and fuel systems and may cause erroneous instrument readings We will use the following procedures to troubleshoot the Main Electrical System This partial list contains some of the more common complaints associated with the Main Electrical System 1 A dead battery 2 Over or under voltage displayed on the volt gauge 3 4 The engine cranks but will not start 5 6 7 The engine cuts off and on or stalls during operation Slow cranking or no crank of the engine The engine stops and will not restart The engine stops but will restart The malfunction indicator light MIL and or warning buzzer lights sounds during cranking No DTC codes are stored in the ECM s memory 9 Scan Tool does not recognize the ECM 10 Any similar complaint that may be caused by the loss of a power feed circuit L599003 13 84 MAIN ELECTRICAL SYSTEM 5 2 Pin BLACK 6 ga rece 8 Pin Boat Harness 100A 70A 0 RED WHITE BELLHOUSING ALTERNATOR PURPLE WHITE FromPin s lt 8 pinBoat Harness Fuse Block Panel To STBD Fuse GRD STUD el 4
176. the system due to ram affect This flow can only be measured with an inline water flow meter while the boat is underway L599003 13 118 Refer to Figure 6 13 the FAIL path If the Raw Water Pump Volume test results in less than 5 gallons of water you know the problem lies somewhere between the hull inlet and the Raw Water Pump outlet You would then check for a failed or fatigued impeller caused by 1 Arestriction in the Water Pump Inlet fitting 2 Aleaking Raw Water Pump bearing housing seal 3 Apinched or defective Raw Water Pump housing gasket Amissing or leaking sea strainer gasket Ablocked sea strainer Adefective hose Leaking hose connections OO gt Blockage in an oil and or transmission cooler refer to the water flow diagrams 6 1 through 6 6 in Reference Material for the different configurations 9 A blocked intake grate The previously mentioned examples are problems that could cause an insufficient amount of water to flow through the Raw Water Pump Additional problem areas include 1 Loose hose clamps 2 Failing hoses 3 Heaters improperly installed leaking or blocked 4 Flush kits improperly installed or with failing check valves Showers improperly installed or leaking Aseacock partially or completely closed A failed raw water pump bearing seal Starting and or running the engine without a raw water supply Refer to Figure 6 10 Gene
177. tics for manifolds and elbows for system running rich or leaks possible fuel injector stuck open Fuel Present Replace faulty exhaust manifold or elbow if good Troubleshoot and repair Disable fuel and spark by engine mechanical removing the System Relay Key Switch to START position Once the condition that allowed fluid into the cylinders is repaired Disable fuel and spark by removing the System Relay Perform a compression check on Perform a compression engine damage is present Return Fail UN to Verify System Power step on the Starter Circuit Trouble Tree Re Install spark plugs Go To Go To Normal Slow Crank No Crank and verify starter operation slow Caii Mo Gran Trouble Tree Trouble Tree Normal Troubleshoot and repair Operation engine mechanical Re Install System Relay problem Figure 5 8 Starter Circuit Troubleshooting Tree L599003 13 93 MAIN ELECTRICAL SYSTEM 5 15A Starter Circuit Testing IGNITION NOTE Always perform the system power check before DIAG COM troubleshooting a starter problem A known good fully charged battery is absolutely essential for proper testing A weak or failing battery will give false test results Slow Crank Condition Refer to figure 5 9 For a slow crank condition use a Clamp Meter to check the current draw of the starter Clamp the meter on the positive battery cable connected to the starter and turn the ignition to the START position Observe t
178. uality and fuel availability at the same time Be careful not to misinterpret the results Important Caution must be taken when using the remote fuel tank The tank must be properly strapped down The lines and fittings must be secure and away from heat and moving components Remember that proper fuel pressure verifies the components of the fuel system not the quality of the fuel Always inspect for fuel quality and utilize your auxiliary fuel tank to confirm your findings Step 3 Improper powertrain alignment may affect boat and engine performance The powertrain cannot be properly aligned if there is damage to the strut or shaft When you performed the Visual Inspection Step 3 of the PCM Drivability Checklist you should have inspected the boat for damage that may cause a loss of engine or boat performance If you did not perform those inspections do so before performing this step Steps 6A 4 6A 8 are a series of inspections involving the ignition circuits Step 6A 4 On 5 0 5 7L engines only remove the distributor cap and inspect the cap and rotor for abnormal conditions Step 6A 5 Check and record the resistance of each spark plug wire Ignition wire resistance should not be greater than 10 000 ohms per foot Record the results in the space provided on the PCM Drivability Checklist Figure 2 2 Leave the plug wires disconnected Step 6A 6 Remove each spark plug and inspect for abnormal conditions such as wro
179. urself tried to correct the current symptom If yes what work was done Accessories Added Recently Is the symptom currently present Special conditions if any required to duplicate the symptom Use an additional sheet of paper if more space is required for symptoms or descriptions 2 CHECK FOR SERVICE UPDATES ENGINE SERIAL NUMBER ENGINE MODEL NUMBER ENGINE HOURS HULL NUMBER ENGINE None Apply Performed BOAT None Apply Performed 3 VISUAL INSPECTION inspection YES Evidence of an over heat Evidence of or Excessive Water in the Bilge Fluid levels checked Engine Harness connectors EN connected properly Physical Damage wiring connectors assemblies and Remove Spark Plugs and inspect for fluids Corrosion Hull clean and free of excessive growth ENS 4 VERIFY THE PROBLEM ee Se Does the engine start and continue to 3 to 1 run below below 1 Key ON Engine OFF KOEO YES NO Fuet Press Both Fuel Pumps run 2 4 seconds Fuel Pressure near wot specification when pumps run 2 Key ON Engine Running KOER YES NO FuelPress Leaking Fuis m E Check Accessories Added Heater Shower Water Tank Flush Kit Ll Multi Function Display Synchronizer L After Market Stereo Equipment After Market Depth Fish Finder L After Market Navigational Equipment Engine cranks Fuel P
180. vability Checklist Each trouble code has a corresponding Diagnostic Procedure The Diagnostic Procedure will help determine if the condition was caused by 1 A defective sensor or switch 2 Afaulty circuit or wiring 3 A mechanical condition Once the cause has been determined apply the procedures located in the service manual or troubleshooting tree that apply to the problem The following gives an example for the Engine Coolant Temperature ECT sensor Low Voltage As you can see the DTC is 0117 however the important identification numbers that Diacom would display are SPN 110 FMI 4 Using the Engine Coolant Temperature ECT sensor Low Voltage as an example you can see the DTC is 0117 however the important identification numbers that Diacom would display are SPN 110 FMI 4 The facing page for each Diagnostic Procedure contains information that describes the fault condition to set this code This information can be very useful when you are trying to recreate the problem or verify a repair many cases the ECM will use a default value when a circuit failure has been detected In this case the ECM uses a default value of 165 F Normally on this failure the ECM would see a value from the ECT around 300 F With that temperature the ECM would not deliver near enough fuel to keep the engine running properly The default value is what Diacom is displaying in this situation L599003 13 40 ENGINE MANAGEMENT SYST
181. very The following devices provide these inputs to the ECM ECT the Engine Coolant Temperature sensor IAT the Intake Air Temperature sensor TP the Throttle Position sensor KS the Knock Sensor s MAP the Manifold Absolute Pressure sensor TCP the Throttle Control Position sensor HO2 the Heated Oxygen sensors CKP the crankshaft sensor and CMP the camshaft sensor S ENGINE MANIFOLD AIR INTAKE AIR KNOCK COOLANT PRESSURE MAP TEMPERATURE IAT SENSOR KS TEMPERATURE OR SENSOR SENSOR ECT 5 THROTTLE CONTROL POSITION TCP SENSOR CAM POSITION gt SENSOR CMP THROTTLE POSITION SENSOR TP CRANK P O THROTTLE BODY POSITION SENSOR Pea MILI Refer to Section 2 of the Diagnostic Manual for a detailed description of the sensors and ECM To control spark and ignition timing the ECM controls one of two ignition systems Both systems utilize a crankshaft sensor CKP to create Ignition Control IC signals The ECM uses these inputs to trigger the ignition coil s and fuel injector circuits 5 0 5 7L engines use the Distributor Ignition system This System uses a Distributor to route spark to each cylinder from a single ignition control IC circuit and coil The 5 0 5 7L engines use a Camshaft CMP sensor to generate a signal named CAM Retard The CAM Retard specification in degrees ensures proper rotor to cap positioning to prevent ignition
182. wide open throttle If the pressure drops or varies at wide open throttle use your auxiliary fuel tank to determine if the problem is in the engine s fuel system or the boat s supply components Always water test the boat Verify fuel pressure is correct under load at wide open throttle If the pressure drops or varies at wide open throttle use your auxiliary fuel tank to determine if the problem is in the engine s fuel system or the boat s supply components IMPORTANT When you connect the auxiliary fuel tank to the FCC fuel system always drain the FCC of any old fuel before you begin the test The FCC holds sufficient fuel to perform a water test and you would not get to the fresh fuel in the auxiliary tank thus invalidating your test If the engine operates normally with the auxiliary fuel tank you know that the problem lies somewhere in the boat s fuel system such as contaminated fuel fuel line restrictions or fuel tank problems If the problem persists you know the problem lies in the engines fuel system and you would inspect for leaks failing low pressure pump or failing high pressure pump L599003 13 71 FUEL SYSTEM 4 KEY ON ENGINE OFF FUEL PRESSURE OUT OF RANGE PUMPS RUN Below Specification Verify LPFP output volume Low Pressure Fuel Pump Volume Test Disconnect the return to tank fuel line from the FCC Connect a piece of fuel line between the FCC return output and an approved empty containe

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