Mercruiser Scantool
Mercruiser Scantool
Mercruiser Scantool
USERS GUIDE
Version 6 Software
Limitation of Liability
Neither Rinda Technologies, Inc. nor its authorized dealer shall be liable for any defect, indirect, incidental,
special, or consequential damages, whether in an action in contract or tort (including negligence and strict
liability), such as, but not limited to, loss of anticipated profits or benefits resulting from the use of this scan
tool and its software or any breach of any warranty, even if Rinda Technologies or its authorized dealer has
been advised of the possibility of such damages. In no event will Rinda Technologies, Inc. or its authorized
dealers liability exceed the price paid for the product.
The information presented in this manual is believed to be accurate. Responsibility for errors, omission of
information, or consequences resulting from the use of this information cannot be assumed by Rinda
Technologies, Inc. Rinda Technologies, Inc. retains all rights to make changes to specifications at any time
without notice.
Safety Precautions . . . . . . . . . . . . . . . . . . . . . 2
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Scan Tool Key Functions . . . . . . . . . . . . . . . . . . 4
Setup & Operation. . . . . . . . . . . . . . . . . . . . . . 5
Function Flowchart . . . . . . . . . . . . . . . . . . . . . 6
Support Information. . . . . . . . . . . . . . . . . . . . . 62
Scan Tool Adapters . . . . . . . . . . . . . . . . . . . . . 63
Page 1
Safety Precautions
Before attempting to use the MerCruiser Scan Tool please
read and observe the following safety precautions:
Always refer to and follow the engine and boat manufacturers safety
and service procedures to prevent personal injury and equipment
damage.
Never connect or disconnect the scan tool with the vehicles ignition
turned ON or while the engine is running.
Always stay clear of any moving or movable engine components
when connecting and using the scan tool.
When working near marine batteries never use any device that is
capable of producing a spark, high temperature or open flame.
Marine 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.
Always test and service a running engine in a well ventilated area.
Always wear approved eye protection.
IMPORTANT
This scan tool is a sensitive electronic instrument. Handle the tool
with extreme care.
DO NOT subject the scan tool to excessive water spray or expose it
to rain. The scan tool is water resistant but not water proof.
DO NOT leave the scan tool in direct sunlight for extended periods of
time or subject it to extreme temperatures (hot or cold).
ALWAYS store the scan tool in its protective carrying case (# 94015)
when not in use. If you do not have a carrying case, store the scanner
in its original packaging.
Page 2
Overview
What is the MerCruiser Scan Tool?
In addition to the MerCruiser Scan Tools diagnostic functions, the tool also
contains a programmable fuel injector tester that is compatible with most
multi-port marine fuel injectors.
The MerCruiser Scan Tool automatically tailors its menu choices and
available functions based upon the type of ECM it detects on the engine. A
flowchart of the basic menu choices is detailed on the Function Flowchart
pages. Some functions and features may vary between similar ECM types.
This variation is due to the way that a particular ECM is programmed at the
factory. Some ECMs may have certain features enabled or disabled which
will cause the MerCruiser scan tool to automatically adjust its menu and data
display choices.
To Begin:
1. Review the Key Functions, Setup and Operation, as well as the Function
Flowchart information.
2. Proceed to the section pertaining to the specific system type being diagnosed.
Page 3
Scan Tool Key Functions
KEY FUNCTIONS
Page 4
Setup and Operation
Setup
The setup function is accessible while in any of the scan tools menus or while in the
data scanning mode. Pressing the SETUP key causes the scanner to suspend its
current mode of operation and enter a special setup menu. The setup menu contains
items that allow you to tailor various functions of the scan tool.
These functions are as follows:
English/Metric Causes data related to pressure, temperature and velocity to be
Mode displayed in English or Metric units.
GPH Scaling Affects the display of GM MEFI 1 & 2 fuel flow readings. Use
Scale Factory #1 for most engines. Use Scale Factor #2 when
working on older MerCruiser engines.
MAP Scaling Use 2 ATM setting only when working on supercharged engines.
Screen Adjust Allows the scanners display contrast to be adjusted. Please note
that the displays readability is affected by both ambient lighting
conditions and temperature. Use the screen adjustment feature as
necessary to produce a suitable amount of contrast for your
viewing purposes.
Press the NO key to exit the Setup mode.
Operation
The s and t keys are used to access all menu choices throughout the operation of
the scan tool.
The YES key is used to select or activate the currently displayed menu item.
The HELP key provides information on current menu choices or items.
After the scan tool displays its initial opening messages, use the s and t keys to
access one of the following operating modes, then press the YES key to select it.
Marine EFI
Merc D-Tronic
Thunderbolt V
Mercury Outboard
Injector Test
Support Information
Page 5
Function Flowchart
Connect Tool
Start Here
Page 6
Function Flowchart
Page 7
Function Flowchart
Page 8
Function Flowchart
Page 9
Function Flowchart
Page 10
Engines Supported by the Scan Tool
All marine engines equipped with GM MEFI (MEFI 1 thru MEFI 5d)
Volvo Penta engines equipped with EGC EFI
Pleasurecraft / Crusader engines with ECM-07 & ECM-08 EFI
Indmar engine models equipped with GCP EFI
MerCruiser engines equipped with PCM-555 and ECM-555 EFI
MerCruiser engines equipped with Visteon EFI (PCM-09)
OBD-M compliant sterndrive / inboard gasoline marine engines.
MerCruiser engines with Thunderbolt V Ignition
MerCruiser 2.8L and 4.2L D-Tronic Diesel Engines
MerCruiser 7.3L D-Tronic Diesel Engines
Mercury 2 & 4 stroke outboards (see outboard supplement for details)
Page 11
GM Marine EFI
Page 12
GM Marine EFI
1) Locate the engines 10 pin marine diagnostic connector (DLC). The location of
this connector is specified in the engine manufacturers service manual. Please be
aware that the connector may have a protective cap attached to it. Shown below
are photos depicting common locations of the GM diagnostic connector.
Page 13
GM Marine EFI
2) With the engines ignition switch in the OFF position, plug the scan tools
communication cable into the diagnostic connector. Scan tool adapter #94005 is
required for this application.
3) Once the tool is connected, turn the ignition switch ON and start the engine if
necessary. If the engine will not start, simply leave the ignition switch ON and
proceed.
4) After the scan tool displays its initial opening messages, use the s and t keys to
select the Marine EFI operating mode, then press the YES key to select it.
Page 14
GM Marine EFI
1) Locate the engines 6 pin CAN diagnostic connector. This connector may also be
referred to as the OBD-M connector (On-Board Diagnostics-Marine). The
location of this connector is specified in the engine manufacturers service
manual. Please note that the connector may have a protective cap attached to it.
2) With the engines ignition switch in the OFF position, plug the scan tools
communication cable into the diagnostic connector. Scan tool adapter #94027
(CAN Adapter) is required for this application as shown in Figure 3 above.
3) Once the tool is connected, turn the ignition switch ON and start the engine if
necessary. If the engine will not start, simply leave the ignition switch ON and
proceed.
4) After the scan tool displays its initial opening messages, use the s and t keys to
select the Marine EFI operating mode, then press the YES key to select it.
Page 15
GM Marine EFI
Obtaining Data
After selecting the Marine EFI function the scan tool will attempt to communicate
with the engines fuel injection computer and automatically identify it. After an
identification is made, you will be presented with several menu choices. To obtain
diagnostic data and system trouble codes, select the ECM Data function. This
menu choice causes the scanner to begin reading information from the ECM module.
The scanner will prompt for your input as follows:
1) After choosing the ECM data function, the scanner may prompt you to choose a
data list(MEFI-1 thru MEFI-4 systems only). Select Data List #1 or Data List #0.
Data List #1 contains diagnostic service information and will usually be of
primary interest to you.
Data List #0 contains a smaller number of information items and is intended for
electronic instrumentation purposes.
2) The scanner will now attempt to communicate with the engines computer and
automatically determine what version of ECM is installed on the engine.
3) Next, the scanner will provide you with the number of Operating Hours the
engine has logged. Once displayed, the scanner will interrogate the ECM and
obtain any stored Fault Codes. If any codes are detected, they will be displayed
along with their descriptions. Options will be displayed allowing you to Review
as well as Erase the stored codes.
4) The tool will now enter its Scanner mode and allow you to select and display a
wide variety of engine sensor and operating information. The displayed data is
updated several times per second. Use the s and t keys to scroll through the
available information. Use the HELP key to access information on the currently
displayed engine parameter. Use the NO key to exit the Scanner mode and
return to the main menu.
Page 16
GM Marine EFI
Code Description
MEFI-2
Code Description
Page 17
GM Marine EFI
Code Description
Page 18
GM Marine EFI
Mefi-5 ECM modules introduce a new system of fault codes that differs
significantly from prior generations of MEFI modules. The new system breaks
faults down into two parts, a Suspect Parameter Number (SPN) and a Fault
Mode Identifier (FMI). This method of fault code delivery conforms to the
OBD-M emissions standards being phased in for sterndrive and inboard
gasoline marine engines.
SPN (Suspect Parameter Number): This number provides a general
description of the engine component, sub-system or process that is suspected of
having an operational error.
FMI (Fault Mode Identifier): This number reflects the type or method of
failure associated with the SPN described above. In other words it describes
how the engine component, sub-system or process has failed.
On the scan tool's display screen the Suspect Parameter Number is preceded by
the letters SPN and the Fault Mode Identifier is preceded by the letters FM as
shown below:
The scan tool will display text descriptions of all SPN and FMI values,
scrolling the descriptions across the lower line of the scan tool's display screen.
Due to the large number of SPN values a listing of all possible faults cannot be
included in this manual. Please refer to the scan tool's display screen for all
SPN and FMI descriptions.
Note: In some cases additional information, such as the number of
fault occurrences will be shown after the scan tool displays the SPN
and FMI text descriptions.
Page 19
GM Marine EFI
Service Mode Function (MEFI-1 thru MEFI-4 ECMs Only)
The Service Mode function is primarily used to set an engines base spark timing.
This function normally applies to engines equipped with a mechanical distributor and
is typically not used on engines with Distributorless Ignition Systems (DIS) unless
otherwise specified. Upon selecting the Service Mode menu option, the currently
active mode will be displayed and you will have the choice of selecting either the
Normal or Service Modes. Simply select the desired mode then continue on to
perform other scanner functions if necessary. The Service mode will stay activated
until changed by entering the Service Mode function again and selecting a different
mode or by disconnecting the scan tool.
Special note for twin engine systems:
In order for the service Mode to function properly on twin engine systems, you
must have the scan tool attached to the Diagnostic Connector on the engine
being serviced.
Page 20
GM Marine EFI
Reset BLM Values (MEFI-5 only)
This function applies to MEFI-5 based engine that are equipped with oxygen sensors.
During engine operation the ECM learns and stores modifications to it's factory preset
fuel delivery values. This allows the ECM to adapt itself to the unique operating
conditions it is subjected to in a particular engine application. The Reset BLM
function allows a service technician to clear the ECM's learned values and reset the
system back to factory default conditions.
Note: Always consult the engine manufacturer's service literature prior to
performing this function. Under normal circumstances resetting the BLM
values should not need to be performed unless specified by the engine
manufacturer.
Page 21
GM Marine EFI
Page 22
GM Marine EFI
ECM Pin #
General Warning #1 Output J1-21
Buzzer Output J1-26
RPM Controlled Output J1-8
Oil Level Lamp J1-25
Check Gauges Lamp J1-7
Check Engine Lamp J1-9
General Warning #2 Output J1-22
Fuel Pump Output J1-23
IAC Motor Reset
ECM Pin #
General Warning #1 Output J1-22
Buzzer Output J1-8
RPM Controlled Output J1-7
Oil Level Lamp J1-18
Check Gauges Lamp J1-9
Check Engine Lamp J1-27
General Warning #2 Output J1-23
Fuel Pump Output J1-6
IAC Motor Reset
Page 23
GM Marine EFI
ECM Pin #
Malfunction Indicator Lamp J1-12
Check Gauges Lamp J1-41
Oil Level Lamp J3-8
Warning Horn Output J1-54
General Warning #1 Output J1-51
General Warning #2 Output J1-52
RPM Controlled Output J1-53
Troll Lamp J3-16
Trans Shift Output J3-13
Governor Lamp J1-55
Fuel Pump Output J1-13
Page 24
Volvo Penta EGC
This section describes scan tool functions related to marine engines equipped with
Volvo Penta EGC (Electronic Gas Control) fuel injection systems. This system was
introduced on Volvo Penta gasoline marine engines for the 2006 model year.
1) Locate the engines diagnostic connector (DLC). The exact location of this
connector is specified in the engine manufacturers service manual and may vary
depending upon the engine type. Please be aware that the connector may have a
protective cap attached to it.
2) With the engines ignition switch in the OFF position, plug the scan tools
communication cable into the diagnostic connector. For 2006 & 2007 EGC
systems use adapter #94024, for 2008 and newer systems use adapter #94027.
Page 25
Volvo Penta EGC
3) Once the tool is connected, turn the ignition switch ON and start the engine if
necessary. If the engine will not start, leave the ignition switch ON and proceed.
4) After the scan tool displays its initial opening messages, use the s and t keys to
display the MARINE EFI operating mode from the main menu, then press the
YES key to select it.
1) After selecting the ECM Data function the scanner will communicate with the
engines EGC control module and automatically provide you with the number of
Operating Hours the engine has logged.
2) Once the engine operating hours have been displayed the scanner will prompt you
to scan for trouble codes. Selecting YES will cause the scanner to interrogate the
EGCs trouble code memory. If any codes are present, their descriptions will be
displayed. After the trouble code description is displayed you will be prompted to
view optional information associated with each code. This information includes
whether the code was set during the current ignition cycle and the number of
engine restarts since the code was set.
3) After trouble codes are displayed the scan tool will provide an option to Erase the
stored codes.
Page 26
Volvo Penta EGC
Page 27
Volvo Penta EGC
ECM Tests
The ECM TESTS option provides access to a variety of EGC functional tests.
IMPORTANT: Before performing any ECM or engine test refer to
the engine manufacturer's service literature for safety precau-
tions and proper engine test procedures.
1) After selecting the ECM TESTS option from the scanners main EGC system
menu you will be presented with a sub-menu containing the following choices:
2) Use the s and t keys to select the desired menu item then press YES.
To abort the Spark Kill test at any time, press and hold the
scanners NO key.
Page 28
Volvo Penta EGC
Spark Fire Test
This test allows individual spark outputs to be fired.
WARNING: Engine backfire and external flame can occur during
this test. As a safety precaution, purge fuel vapors from the
engine before proceeding. Do not remove the flame arrestor if
the engine is equipped with one.
IMPORTANT: Before performing this test disconnect the
engines Crank Position Sensor.
This test must be performed with Key-On and Engine Off.
Upon selecting this test you will be prompted to select the spark output to fire. Spark
outputs follow cylinder number order. Use the s and t keys to select the desired
spark output and then press the FIRE key to start the test. The test will run for
approximately 10 seconds. Use an inductive pickup KV tester to verify the spark
outputs operation.
To abort the Spark Fire test at any time, press and hold the
scanners NO key.
Page 29
Volvo Penta EGC
Relay Test
This test allows the EGC modules relay outputs to be activated. The test must be
performed with Key ON / Engine OFF. Upon selecting this test you will be
prompted to select either the Ignition Relay output or All Relays (including the Fuel
Pump relay). Pressing the FIRE key will activate the selected relay(s) for
approximately two seconds.
Compression Test
The Compression Test is a special test mode that the EGC system provides to allow a
technician to safely perform a cylinder compression check.
WARNING: This test commands the EGC module to disable all
spark and fuel injector outputs. The test must be properly exited
from the scan tool in order to re-enable normal spark and fuel
operation. Do not perform 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 scan tool is disconnected from the engine during the
Compression Test the engine will remain in a disabled state.
You must reconnect the scan tool, re-enter the Compression
Test mode and then properly exit the test.
Page 30
Volvo Penta EGC
Drive by Wire Test
This test is available only when connected to engines equipped with Electronic
Throttle Control (ETC). The test allows a technician to check the functionality of the
ETC system by commanding the engine throttle blade to track helm throttle control
lever movements.
This test must be performed with Key ON / Engine OFF. Upon selecting this test
you will be prompted to move the helm throttle lever and observe movements of the
engine throttle blade. The scan tool will also display the commanded Throttle
Control Position percentage as well as the commanded Throttle Position
percentage (percentage of throttle blade movement).
To stop the Drive by Wire test at any time, press and hold the
scanners NO key.
When the O2 sensor test is complete the scan tool will scroll messages across its
screen displaying the results of the pre-catalyst and post-catalyst oxygen sensors. A
message will also be displayed instructing the technician to scan for ECM fault codes
to obtain additional information on any O2 sensor problem that was detected during
the test.
Page 31
PCM / Crusader ECM-07 & ECM-08
Pleasurecraft Engine Group, manufacturer of both PCM and Crusader brand engines
introduced their ECM-07 engine control system on 2007 model year engines.
Engines produced prior to the 2007 model year used GM-Delphi MEFI control
modules which are described starting on page 12 of this manual.
ECM-07 equipped engines require use of the #94026 GCP scan tool adapter for
diagnostic communication (see photo below). Please note that 2007 year engines are
also equipped with a CAN connector which is compatible with the #94027 CAN
adapter, however diagnostics are NOT supported via the CAN connector on
ECM-07 equipped engines. You must use the #94026 GCP adapter.
In 2008 Pleasurecraft Engine Group introduced the ECM-08 module which fully
supports CAN communication for engine diagnostics. ECM-08 based systems
require use of the #94027 scan tool CAN network adapter for all diagnosis and
troubleshooting functions. Be sure to correctly identify the model year of the engine
you are working on and select the correct adapter as shown in the photos below.
PCM / Crusader GCP (ECM-07) Adapter Scan Tool CAN Network Adapter
# 94026 # 94027
Diagnostic functions for ECM-07 and ECM-08 modules are identical to those
described in the Volvo Penta EGC section of this manual. Please refer to pages 25
through 31 for a comprehensive description of the available functions.
Page 32
Indmar models with GCP ECM
In 2008 Indmar Engine Co. began installing GCP engine control modules (type 1
shown above) on engines used in tournament ski applications. Prior model years of
Indmar engines used GM-Delphi MEFI control modules which are described starting
on page 12 of this manual.
The type 1 GCP module was a direct retrofit for the GM-Delphi MEFI-5 modules used
on Indmar's production engines in the 2006 thru 2009 model years.. As of the date of
this publication, Indmar is planning to phase in the type 2 GCP module on future
production engines.
The MerCruiser scan tool fully supports both the type 1 and type 2 modules with an
extensive set of diagnostic functions. Both type 1 and type 2 modules require use of
the #94027 scan tool CAN network adapter (shown above) for diagnostic
communication.
Diagnostic functions for both the type 1 and type 2 GCP modules are identical to those
described in the Volvo Penta EGC section of this manual. Please refer to pages 25
through 31 for a comprehensive description of the available functions.
Page 33
OBD-M compliant ECMs
The MerCruiser scan tool supports marine sterndrive and inboard engines that comply
with the 2008 California mandated OBD-M diagnostic specification. The scan tool
displays both live data and fault codes when connected to OBD-M compliant systems.
1) Locate the engines 6 pin OBD-M diagnostic connector. The location of this
connector is specified in the engine manufacturers service manual. Please note
that the connector may have a protective cap attached to it.
2) With the engines ignition switch in the OFF position, plug the scan tools
communication cable into the diagnostic connector. Scan tool adapter #94027
(CAN Network Adapter) is required for this application as shown below.
3) Once the tool is connected, turn the ignition switch ON and start the engine if
necessary. If the engine will not start, simply leave the ignition switch ON and
proceed.
4) After the scan tool displays its initial opening messages, use the s and t keys to
select the Marine EFI operating mode, then press the YES key to select it.
5) After selecting the Marine EFI function the scan tool will attempt to
communicate with the engines ECM and automatically identify it. To obtain
general diagnostic data and system trouble codes, select the ECM Data
function. This menu choice causes the scanner to begin reading information from
the ECM module. Follow the prompts on the scan tool display screen.
Page 34
MerCruiser PCM-555 EFI
This section describes MerCruiser Scan Tool functions related to marine engines
equipped with MerCruiser PCM-555 / (ECM-555) fuel injection systems. PCM-555
fuel injection systems were first introduced on a limited number of MerCruiser
engines in October of 2000.
1) Locate the engines 4 pin diagnostic connector (DLC) as shown in the photo
above. The exact location of this connector is specified in the engine
manufacturers service manual and may vary depending upon the engine type.
Please be aware that the connector may have a protective cap attached to it.
2) With the engines ignition switch in the OFF position, plug the scan tools
communication cable into the diagnostic connector. Scan tool adapter #94006 is
required for this application.
3) Once the tool is connected, turn the ignition switch ON and start the engine if
necessary. If the engine will not start, simply leave the ignition switch ON and
proceed.
Page 35
MerCruiser PCM-555 EFI
4) After the scan tool displays its initial opening messages, use the s and t keys to
display the MARINE EFI operating mode from the main menu, then press the
YES key to select it.
Obtaining Data
After selecting the MARINE EFI function the scan tool will attempt to
communicate with the engines fuel injection computer and automatically identify it.
After an identification is made you will be presented with several menu choices. To
obtain diagnostic data and system trouble codes, select the PCM Data function.
This menu choice causes the scanner to begin reading information from the PCM
module. The scanner will prompt for your input as follows:
1) After selecting the PCM Data function the scanner will communicate with the
engines PCM-555 control module and automatically provide you with the
number of Operating Hours the engine has logged.
2) Once the engine operating hours have been displayed the scanner will prompt you
to display any currently stored system faults. Selecting YES will cause the
scanner to interrogate the PCMs Fault Memory. If any faults are present,
their descriptions will be displayed.
The PCM-555 engine control module stores faults concurrently in two different
areas of its internal memory. One area, called the Fault Memory, only stores
faults that have been detected during the engines current Ignition-On cycle.
These faults will not be retained after the ignition switch is turned OFF.
The second fault storage area is referred to as the Freeze Frame Memory. The
Freeze Frame Memory retains the last 10 faults that the PCM has detected
regardless of when they occurred and even if ignition power has been turned
OFF. The Freeze Frame Memory also contains a snapshot of several critical
engine parameters, such as the engines speed and temperature, for each fault that
is stored. This information is helpful in making an accurate diagnosis and also
useful for understanding why the fault occurred. See Fault History for
additional details.
3) After the scanner displays a fault description it will give you the option to access
the faults associated Freeze Frame engine data. This data represents a
snapshot of various engine parameters at the time the fault was detected. Use the
s and t keys to recall and scroll through the faults Freeze Frame data. After
viewing the Freeze Frame data, press the NO key to return to the Fault Memory
access mode.
Note: While displaying Freeze Frame data a ff: will appear on the left side
of the second line of the scanners display.
Page 36
MerCruiser PCM-555 EFI
4) When all faults from the PCMs Fault Memory have been displayed, the scanner
will provide you with the option of reviewing the faults or erasing them. The
erase function will clear the PCMs Fault Memory to eradicate the faults that
were stored during the present Ignition ON cycle. The faults and associated
snapshot engine data stored in the PCMs Freeze Frame Memory will not be
erased.
5) After the scanner has exited its fault access mode the tool will enter its Scanner
mode. This mode allows you to select and display a wide variety of engine sensor
and operating information. The displayed data is updated several times per
second. Use the s and t keys to scroll through the available data. Use the
HELP key to access information on the currently displayed engine parameter.
Use the NO key to exit the Scanner mode and return to the main menu.
Fault History
The PCM-555 control module contains a non-volatile memory that is used to retain
fault and operating history information. This information is retained in the PCM even
if power is removed from the system and allows historical operating information to be
recalled. This information is designed to aid a technician in diagnosing intermittent
and past events. To view Fault History information, perform the following steps:
1) After selecting the Fault History function from the scanners PCM-555 menu
you will be presented with a sub-menu containing the following choices:
2) Select the Read Fault Hist menu item then press YES. The scanner will now
interrogate the PCMs Freeze Frame Memory to determine if any faults have
occurred in the past. If any faults are found, their descriptions will be displayed.
3) After the scanner displays a fault description it will give you the option to access
the faults associated Freeze Frame engine data. This data represents a snapshot
of various engine parameters at the time the fault was detected. Use the s and
t keys to recall and scroll through the faults Freeze Frame data. After viewing
the Freeze Frame data press NO to return to the Fault History access mode.
Note: While displaying Freeze Frame data a ff: will appear on the left side
of the second line of the scanners display.
4) When all faults from the PCMs Freeze Frame Memory have been displayed the
scanner will provide you with the option of reviewing the faults or erasing them.
The erase function will clear the PCMs Freeze Frame Memory to eradicate
the PCMs fault history data . The faults and associated snapshot engine data
stored in the PCMs Freeze Frame Memory (including Fault Seconds,
described in the next paragraph) will be completely erased.
Page 37
MerCruiser PCM-555 EFI
Fault Seconds
When critical faults occur and remain active the PCM-555 keeps track of how many
seconds the fault has persisted during engine operation. The type and number of
critical faults this function keeps track of is pre-selected by the engine manufacturer.
All PCM-555 faults do not have an associated Fault Second counter assigned to
them, only a select number of fault types are kept track of. To view Fault Seconds
information perform the following steps:
1) After selecting the Fault History function from the scanners PCM-555 menu
you will be presented with a sub-menu containing the following choices:
2) Select the Read Fault Sec menu item then press YES. The scanner will now
read the PCMs Fault Second Memory and display the number of seconds
each critical fault has persisted. Use the s and t keys to recall and scroll
through the Fault Second data. After viewing the Fault Second data, press the
NO key to return to the Fault History access mode.
Note: The Fault Second information is erased when the Fault Historys
Freeze Frame Memory is cleared. See the prior section describing Fault
History for details.
RPM History
PCM-555 control modules have the ability to record the number of hours an engine
has been operated within a predetermined set of RPM ranges. These ranges are set at
the factory and allow a service technician to view a profile of how a particular engine
has been operated. To view RPM History information perform the following
steps:
1) After selecting the RPM History function from the scanners PCM-555 menu
you will be presented with a sub-menu containing the following choices:
2) Select the Read RPM History menu item then press YES. The scanner will
now read the PCMs RPM History Memory and display the number of hours
the engine has operated in 9 sets of RPM ranges. Use the s and t keys to scroll
through the RPM History data. After viewing the RPM History data press the NO
key to return to the RPM History menu.
Page 38
MerCruiser PCM-555 EFI
1) After selecting the PCM System Info function from the main PCM-555 menu
the scanner will begin to display the first line of System Info text from the PCMs
memory. Use the following keys to navigate through the multiple lines of System
Info text information:
Keys to control System Info display:
Use the s key to repeat the line of information currently scrolling across the
scanners display screen.
Use the t key to skip to the next available line of system information.
Use the PAUSE key to momentarily pause the scrolling display.
Use the NO key to abort the System Info function and return to the main PCM-555
scanner menu.
2) After the scanner displays the last line of system information it will automatically
return to the main PCM-555 menu.
Page 39
MerCruiser PCM-555 EFI
PCM Functions
The PCM Functions menu option allows a technician to access a variety of PCM
functional tests and settings. To access the PCM Functions menu perform the
following steps:
1) After selecting the PCM Functions option from the scanners PCM-555
menu you will be presented with a sub-menu containing the following choices:
2) Use the s and t keys to select the desired menu item then press YES.
1) Review the warnings stated above and be sure the engine is not running when
attempting to conduct this test. The Auto Self Test should be run with Key-On
and Engine Off.
Page 40
MerCruiser PCM-555 EFI
2) After selecting the Auto Self Test function from the PCM Functions menu the
scanner will begin to display several warning messages. Review these messages
and be certain their instructions are followed.
3) When the warning messages have been displayed, you may begin the Auto Self
Test by pressing the YES key. This action will initiate a series of engine actuator
and sensor tests. The entire testing process may take several minutes to complete.
While the Auto Self Test is in progress the scanners display will indicate the type
of test being performed.
To Abort the Auto Self Test at any time, press and hold the
scanners NO key.
4) When the Auto Self Test has completed, the scanner will automatically
interrogate the PCMs fault code memory and report any errors that have
occurred. A successful self test will report no errors.
Fuel Injectors
Fuel Pump Relay
Ignition Coils
Warning Horn
Tach Output
The sections presented on the following pages will provide specific details on each
output test.
Page 41
MerCruiser PCM-555 EFI
1) Review the warnings stated above and be sure the engine is not running when
attempting to perform this test.
2) After selecting the Fuel Injector function from the PCM Output Test menu the
scanner will begin to display several warning messages. Review these messages
and be certain their instructions are followed.
3) When the warning messages have been displayed, you may select the fuel
injector you wish to test by using the s and t keys. To begin firing the
selected injector press the FIRE key. This action will being actuating the fuel
injector at a speed equivalent to 1600 rpm for a period of approximately 10
seconds.
To abort the Fuel Injector test at any time, press and hold the
scanners NO key.
4) After the test is complete you may return to step #3 to test another injector or press
the NO key to return to the scanners Output Test menu.
1) Review the advisory message stated above and be sure the engine is not running
when attempting to perform this test.
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MerCruiser PCM-555 EFI
2) After selecting the Fuel Pump Relay test from the PCM Output Test menu
the scanner will prompt you to begin the test. To initiate the test press the FIRE
key. The fuel pump relay will be activated for approximately one second.
3) You may press the FIRE key again to repeat the test or press the NO key to return
to the Output Test menu.
1) Review the warnings stated above and be sure the engine is not running when
attempting to perform this test.
2) After selecting the Ignition Coil function from the PCM Output Test menu the
scanner will begin to display several warning messages. Review these messages
and be certain their instructions are followed.
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MerCruiser PCM-555 EFI
3) When the warning messages have been displayed, you may select the ignition coil
you wish to test by using the s and t keys. To begin firing the selected coil
press the FIRE key. This action will begin firing the ignition coil at a speed
equivalent to 1600 rpm for a period of approximately 10 seconds.
To abort the Ignition Coil test at any time, press and hold the
scanners NO key.
4) After the test is complete you may return to step #3 to test another ignition coil or
press the NO key to return to the scanners Output Test menu.
1) Review the advisory message stated above and be sure the engine is not running
when attempting to perform this test.
2) After selecting the Warning Horn test from the PCM Output Test menu the
scanner will prompt you to begin the test To initiate the test press the FIRE key.
The warning horn will be activated for approximately one second.
3) You may press the FIRE key again to repeat the test or press the NO key to return
to the Output Test menu.
1) Review the advisory message stated above and be sure the engine is not running
when attempting to perform this test.
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MerCruiser PCM-555 EFI
2) After selecting the Tach Output test from the PCM Output Test menu the
scanner will prompt you to begin the test. To initiate the test press the FIRE key.
The tachometer output will begin sending a signal equivalent to 3000 rpm to an
externally attached (usually dashboard mounted) tachometer gauge. The tach
signal will be active for approximately 10 seconds.
3) You may press the FIRE key again to repeat the test or press the NO key to return
to the Output Test menu.
1) Review the warnings stated above prior to conducting this test. For best results
the engine should be idling at normal operating temperature.
2) After selecting the IAC Test function from the PCM Functions menu the
scanner will begin to display one or more advisory messages. Review these
messages and be certain their instructions are followed.
3) When the advisory messages have been displayed, you may begin the test by
pressing the YES key. While the test is in progress the scanner will display the
current engine RPM as well as the IAC valves position. Use the s and t keys
to change the IACs position in 10% increments. The IAC position range is from
-100% to +100%. While changing the IAC position you should hear a noticeable
change in engine speed.
4) To exit the IAC test, press the NO key. You will be returned to the scanners PCM
Function menu.
Page 45
MerCruiser PCM-555 EFI
STARBOARD
PORT
STARBRD 2 INSIDE
PORT 2 INSIDE
Perform the following steps to read and change the Engine Location.
1) Review the advisory message stated above prior to performing this function.
2) After selecting the Set Engine Loc function from the PCM Functions menu
the scanner will automatically read and display the current Engine Location
setting. After displaying the setting you may choose to proceed to alter the
location setting by pressing the YES key. Use the s and t keys to scroll
through the available location settings.
3) When you have selected the correct Engine Location Setting, press the YES key
to make the new setting permanent. The scanner will program the new location
setting into the PCMs memory and you will be returned to the scanners PCM
Function menu.
Note: The new Engine Location setting will not become active until the
ignition has been cycled OFF and then back ON.
Page 46
MerCruiser PCM-555 EFI
1) Review the warnings stated above prior to conducting this test. For best results
the engine should be running at approx. 1500 rpm and under a moderate load.
2) After selecting the Induced Misfire function from the PCM Functions menu
the scanner will begin to display one or more advisory messages. Review these
messages and be certain their instructions are followed.
3) When the advisory messages have been displayed, you may select the cylinder
you wish to disable by using the s and t keys. To begin the test press the
FIRE key. This action will command the PCM to disable the fuel injector on the
selected cylinder for approximately 10 seconds. During this time you should hear
a noticeable decrease in engine speed. This decrease indicates that the selected
cylinder was contributing power to the system.
If a decrease in engine speed is not heard during the course of this test it may
indicate a problem with one or more cylinder components including the fuel
injector, ignition coil, spark plug, or other component. Refer to the engine
manufacturers troubleshooting procedures to isolate the problem component.
To Abort the Induced Misfire Test at any time, press and hold
the scanners NO key.
4) After the test is complete you may return to step #3 to test another cylinder or press
the NO key to return to the scanners PCM Function menu.
1) Review the advisory message stated above prior to performing this function.
2) After selecting the Set Trim Limit function from the PCM Functions menu the
scanner will display the current Trim Limit setting.
Page 47
MerCruiser PCM-555 EFI
3) After displaying the current setting you may choose to alter the setpoint by
pressing the YES key. Use the s and t keys to change the setpoint in 1%
increments. The Trim Limit Setpoint range is from 0% to 100%. You may press
the NO key at any time to abort the Trim Limit setpoint procedure.
4) To make the currently displayed setpoint permanent press the YES key. The
scanner will program the new setpoint into the PCMs memory and you will be
returned to the scanners PCM Function menu.
Page 48
MerCruiser PCM-09 (Visteon) EFI
MerCruiser introduced the PCM-09 ECM module on their 2009 model year engine's
equipped with catalytic converters. These engines are initially intended for the
California market and are designed to meet OBD-M emission requirements.
The PCM-09 module is an entirely new ECM type for MerCruiser and bears little
resemblance both physically and functionally to the PCM-555 / ECM-555 modules
used on their non-catalyst engines.
Page 49
MerCruiser Thunderbolt V Ignition
Thunderbolt V
Figure 3
1st and 2nd Generation
Thunderbolt V Module Figure 4
3rd Generation
Thunderbolt V Module
This section describes a procedure which allows marine service technicians to obtain
engine operating hour information. This information is not useful for diagnosing
ignition performance related problems. If you are trying to diagnose ignition system
problems, please refer to an appropriate MerCruiser factory service manual for
ignition system diagnostic procedures.
The MerCruiser Thunderbolt V ignition module is a microprocessor based electronic
ignition controller. The module incorporates a variety of performance related
features and is designed to provide optimum spark advance throughout the engines
operating range. Three versions of the Thunderbolt V module are currently in
existence. Two of the three versions are capable of providing historical engine
operating information to the MerCruiser scan tool.
The 1st generation Thunderbolt V module was originally introduced during the 1994
model year. Although this generation module provided precise spark control for the
engine, it was superseded in 1996 and again in 1998 by second and third generation
models which contained data logging capabilities. These newer Thunderbolt V
modules are equipped with the ability to record engine operating hour information
throughout the life of the engine. The 3rd generation Thunderbolt V module,
introduced in 1998, has a redesigned outer case and improved diagnostic terminal
connections. MerCruiser has eliminated the modules recessed diagnostic terminal
connections. All connections to the module are now integrated into two
weather-proof electrical connectors at the modules base.
Page 50
MerCruiser Thunderbolt V Ignition
Identifying the Thunderbolt V Version
Before using your MerCruiser scan tool to extract information from the Thunderbolt
V module you will first need to determine which version of the Thunderbolt V is
installed on the engine you are servicing.
The 1st and 2nd generation Thunderbolt V modules are mounted on a bracket that is
attached to the engines distributor as shown in figure 3. On some MerCruiser
engines a Knock Sensor (KS) module is also mounted on the same bracket. The 3rd
generation Thunderbolt V modules are mounted on the engines exhaust elbow and
may also have a Knock Sensor module mounted above it (see Fig. 4).
Be careful not to confuse the Thunderbolt V module with the Knock
Sensor module that may be mounted adjacent to it.
White outline
New Data
around text
Connector
Referring to Figures 5 and 6, you will notice that both the 1st and 2nd generation
Thunderbolt V modules are physically identical. The telltale indicator that identifies
the 2nd generation module is the white box that surrounds the printed information
on the modules cover. Thunderbolt V modules displaying this white outline around
their printed text are the 2nd generation modules which are capable of providing
engine operating data to the MerCruiser scan tool. Modules that do not display this
white outline will NOT communicate with the scan tool.
The 3rd generation Thunderbolt V module exhibiting a redesigned outer case is
shown in Fig. 7. All 3rd generation Thunderbolt V modules are capable of providing
data to the MerCruiser scan tool.
Page 51
MerCruiser Thunderbolt V Ignition
Figure 9
2nd generation Thunderbolt V Data
Terminals
Page 52
MerCruiser Thunderbolt V Ignition
Please note that reversing the YELLOW and VIOLET leads will cause the scan
tool to fail to communicate with the module. No damage will occur to the scan
tool or the module, the scan tool will simply display an error message stating it
cannot communicate properly.
4)
Connect the BLACK test lead to a good engine ground location. The lower mounting
stud for the Thunderbolt V module, as shown in Figure 11, is a suitable location for
this lead.
Page 53
MerCruiser Thunderbolt V Ignition
5) With the engines ignition switch still in the OFF position, connect the RED
test lead to a +12 volt ignition power source. The engines circuit breaker
terminal, as shown in Figure 12, is a good connection for +12v power.
1. Before connecting the scan tool cables to the Thunderbolt V module, be sure the
engines ignition switch is in the OFF position.
2. Locate the 3rd generation Thunderbolt V module mounted on the exhaust elbow .
Unplug the engine wiring harness from the modules four pin data connector.
Plug the square connector of the Thunderbolt V adapter into this connector (see
Figure 13 on the next page).
3. Connect the adapters BLACK test lead to a good ground location.
4. With the engines switch still in the OFF position, connect adapters RED test
lead to a +12 volt ignition power source. The engine circuit breaker terminal is a
good location for +12 volt power (as shown in Figure 12).
Page 54
MerCruiser Thunderbolt V Ignition
Figure 13
Location of 3rd generation Thunderbolt V module
Obtaining Data
The Thunderbolt V module is capable of providing engine operating history
information to the MerCruiser scan tool. In order for the module to communicate this
information to the scan tool, the Engine must be OFF. After checking that you have
properly connected the scan tool to the module, proceed though the following steps to
extract the modules data.
1) After observing standard safety precautions and ensuring that the scan tool is
correctly connected to the module, place the engines ignition switch in the ON
position. DO NOT START THE ENGINE.
2) Choose the"Thunderbolt V" option from the scan tools main menu.
3) The scan tool will now automatically attempt to retrieve data from the
Thunderbolt V module.
If data is not received within 10 seconds the scan tool will report that a
communication error has occurred. In this situation, turn the engines ignition
switch to the OFF position and recheck the scan tool connections to the
Thunderbolt V module. Also, be sure you have correctly identified the module as
described in Identifying the Thunderbolt V Version.
4) After the scan tool has successfully retrieved the Thunderbolt Vs data, the
information will be displayed for your review.
Please note the scan tool does not continually retrieve information from the module.
Unlike the live monitoring functions the scan tool performs on EFI systems, the
Thunderbolt Vs information is not continuously updated while you are viewing it.
Also note that the information is not retained when the scan tool is powered off.
Page 55
MerCruiser Thunderbolt V Ignition
Thunderbolt V Data
Scan Tool Display Description
Number of hours ignition has been
KEY-ON / ENG OFF ON with engine OFF
Number of hours engine has operated
UNDER 1000 RPM
under 1000 RPM
Number of hours engine has operated
1000-1999 RPM
between 1000 and 1999 RPM
Number of hours engine has operated
2000-2999 RPM between 2000 RPM and 2999 RPM
Number of hours engine has operated
3000-3999 RPM between 3000 and 3999 RPM
Number of hours engine has operated
4000-4999 RPM between 4000 and 4999 RPM
Number of hours engine has operated
TIME AT REV LIMIT
at its Rev (rpm) limiter
TOTAL RUN TIME Total number of hours engine has run
Figure 11 Thunderbolt V Data
Page 56
MerCruiser Thunderbolt V Ignition
Disconnecting from the Thunderbolt V Modules
Use the following procedure to disconnect the scan tool from all Thunderbolt V
modules.
2) Remove the RED power lead from the +12v power connection.
3) Remove the BLACK ground lead from the engines ground connection.
6) On 3rd generation modules, replace the four pin engine harness connector.
Page 57
MerCruiser 2.8L / 4.2L D-Tronic Diesel
The MerCruiser scan tool fully supports the D-Tronic fuel injection system found on
1997-Up 2.8L and 4.2L MerCruiser diesel engines. The D-Tronic system is equipped
with a connector which is located on upper rear corner of the engines electrical box as
shown below. The electrical box is located near the rear of the engine on the left side.
#94014
Figure 16
2.8L / 4.2L D-Tronic Adapter
Figure 17
Data Connector Location
Obtaining Data
Select the Merc D-Tronic option from the scan tools main menu to begin reading
the D-Tronic systems data. Follow the prompts to read fault codes and live data.
Page 58
MerCruiser 7.3L D-Tronic Diesel
The MerCruiser scan tool fully supports the D-Tronic fuel injection system found on
1997-Up 7.3L MerCruiser diesel engines. The 7.3L D-Tronic system is equipped
with a diagnostic data connector which is located on upper rear corner of the engines
electrical box as shown below. The electrical box is located near the rear of the engine
on the left side.
Figure 18 Figure 19
7.3L D-Tronic Adapter 7.3L D-Tronic Engine
#94021
Data Connector
Connection of the MerCruiser scan tool to the 7.3L D-Tronic system requires the use
of adapter #94021 (see Figure 18 above) along with a MerCruiser scan tool that has
been updated with Version 3 or newer software
Be sure the Engines Ignition Switch is in the OFF position before connecting the
scan tool to the D-Tronic data connector.
1) Locate the D-Tronic data connector as shown in Figure 19. Remove the data
connectors protective cover.
2) Connect the 94021 adapter to the data connector.
3) Connect the scan tool to the adapters round DIN connector.
4) Standing clear of all engine components, turn the engines ignition switch ON.
You may also start and run the engine if necessary.
Obtaining Data
Select the Merc Diesel EDI option from the scan tools main menu to begin reading
the D-Tronic systems data. Follow the scan tools prompts to read fault codes and
live data.
Page 59
Injector Test Mode
When entering the fuel injector test mode, be sure to follow all pertinent fuel system
safety precautions provided by the engine and injector manufacturers. Refer to the
engine manufacturers service manuals for fuel system safety and injector test
information.
Injector
Test
1) Select the type of injector test required. The following two test modes are
available:
Single Pulse Mode Cycles the injector ON/OFF one time. When in this
mode, you may use the s and t keys to select an
ON time between 1 and 1000 milliseconds. Holding
either the s or t key down for more than ten
counts causes the ON time to change in 10 ms
increments.
The Multi-Pulse modes overall ON time may be adjusted between 100 and 600
milliseconds by entering the Time Adjust menu option.
Page 60
Injector Test Mode
400 ms 20 Cycles
500 ms
50 Cycles
600 ms
Page 61
Support Mode
The Support menu option provides factory and scan tool manufacturer contact
information.
Support
Info
Marine
Mercury OB
Scan Tool
Page 62
Sterndrive / Inboard Adapters
#94005 #94006
GM MEFI-1 thru MEFI-4 Adapter PCM-555 / ECM-555 Adapter
#94014 #94020
2.8L / 4.2L D-Tronic Diesel Adapter Thunderbolt V Adapter
#94021 #94024
7.3L D-Tronic Diesel Adapter Volvo Penta EGC Adapter
Page 63
Sterndrive / Inboard Adapters
#94026 #94027
PCM / Crusader ECM-07 Adapter CAN Network Adapter
Page 64
Notes:
Page 65
Notes:
Page 66
Notes:
Page 67
Rinda Technologies Inc.
4563 N. Elston Ave.
Chicago, IL 60630 USA
Tel: (773) 736-6633 Fax: (773) 736-2950
www.rinda.com