Electrical: Section 2A - Ignition

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IGNITION

ELECTRICAL
Section 2A – Ignition
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-1 Direct Injectors . . . . . . . . . . . . . . . . . . . . . . . 2A-24
2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-2 Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . 2A-24 A
Electrical Components Model Year 2000 . . . 2A-4 Disconnecting Harness Connectors from
Electrical Components . . . . . . . . . . . . . . . . . . . . . 2A-6 Ignition Coils and/or Injectors . . . . . . . . . . 2A-25
Coil Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-8 Shift Interrupt Switch . . . . . . . . . . . . . . . . . . 2A-25
Solenoid Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 2A-26
Theory of Operation . . . . . . . . . . . . . . . . . . . . . 2A-13 Troubleshooting Without Digital
Ignition Component Description . . . . . . . . . . . 2A-14 Diagnostic Terminal . . . . . . . . . . . . . . . . . . . . . . 2A-26
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-14 Troubleshooting with the Digital
Electronic Control Module (ECM) . . . . . . . 2A-15 Diagnostic Terminal . . . . . . . . . . . . . . . . . . . . . . 2A-27
Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-16 Notes: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-28
Ignition Coils . . . . . . . . . . . . . . . . . . . . . . . . . 2A-16 DDT Functions – Version 4.0 and 4.1 . . . . . . 2A-29
Coil Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-17 DDT Functions – Version 1.0 . . . . . . . . . . . . . 2A-30
Crank Position Sensor . . . . . . . . . . . . . . . . 2A-18 DFI Troubleshooting Guide . . . . . . . . . . . . . . . 2A-31
Throttle Position Sensor (TPS) . . . . . . . . . 2A-18 Ignition Components Removal and
Throttle Position Sensor (TPS) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2A-35
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . 2A-19 Flywheel Cover . . . . . . . . . . . . . . . . . . . . . . 2A-35
Charging System Alternator . . . . . . . . . . . . 2A-20 Electronic Control Module (ECM) . . . . . . . . 2A-36
Temperature Sensor . . . . . . . . . . . . . . . . . . 2A-21 Ignition Module . . . . . . . . . . . . . . . . . . . . . . . . 2A-37
Manifold Absolute Pressure Crank Position Sensor . . . . . . . . . . . . . . . . . 2A-38
(MAP) Sensor . . . . . . . . . . . . . . . . . . . . . . . . 2A-23 Throttle Position Sensor (TPS) . . . . . . . . . . 2A-39
Air Temperature Sensor . . . . . . . . . . . . . . . 2A-23

Specifications
IGNITION Type Digital Inductive
SYSTEM Firing Order 1-2-3-4-5-6
Model Year 2000
Spark Plug Type CHAMPION QC12GMC
Spark Plug Gap 0.040 in. (1.0 mm)
Model Year 2001
Spark Plug Type NGK PZFR5F-11 (heavy duty)
Spark Plug Gap 0.043 in. (1.1 mm)
Maximum Timing Not Adjustable; Controlled by ECM
Idle Timing Not Adjustable; Controlled by ECM
Throttle Position Sensor
Model Year 2000
@ Idle 4.0 - 4.7 vdc
@ W.O.T 0.4 - 1.3 vdc
Model Year 2001
@ Idle 0.4 - 1.3 vdc
@ W.O.T 4.0 - 4.7 vdc
Crank Position Sensor
Air Gap 0.025 in. – 0.040 in.
(0.635 mm – 1.01 mm)

90-859769R1 DECEMBER 2000 Page 2A-1


IGNITION

Special Tools
1. Digital Diagnostic Terminal (DDT) 91-823686A2

2. Model Year 2000 – Software Cartridge 91-822608--5


Model Year 2001 – Software Cartridge 91-880118

3. Model Year 2000 – DDT Reference Manual 90-825159-3


Model Year 2001 – DDT Reference Manual 90-881204

4. Adaptor Harness 84-822560A5

Page 2A-2 90-859769R1 DECEMBER 2000


IGNITION

5. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1

6. Inductive Timing Light 91-99379

7. Spark Gap Tester 91-850439T

55117

90-859769R1 DECEMBER 2000 Page 2A-3


IGNITION

Electrical Components Model Year 2000


37 36
12 10
10 11 34
9 35 A = TO BLOCK
8 A
7 33 18
45
39
25
19
6 38
17 2324
22
40 21
38 20
1
2 TO
3 13 BLOCK
14 15 41

4 16 62 49
5 67
66
65
46 52
55 50
53
43
51 48
57 64
44 61 58
59 47
56 62 54
70 63 31
30
29
32
69

68 27

28

42

26

*NOTE: Coat all eyelet wiring terminals with #25 GACO N700.
*NOTE: Coat all multi-pin electrical connections (except power trim relay connections)
with #6DC-4.

Page 2A-4 90-859769R1 DECEMBER 2000


IGNITION

Electrical Components Model Year 2000


TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm
1 1 ELECTRICAL MOUNTING PLATE
2 6 IGNITION COIL
3 6 HI-TENSION CABLE
4 12 BOOT
5 6 SPARK PLUG 20 27
6 12 SCREW (M6 x 30)
7 1 SENSOR
8 1 FITTING
9 1 CLIP
10 2 STA-STRAP
11 1 FITTING
12 1 TUBING (15 IN.)
13 4 SCREW (.312-18 x 1-1/4 IN.) 235 19.5 26
14 4 WASHER
15 4 GROMMET
16 4 BUSHING
17 2 SCREW-engine harness ground (M6 x 14) 35 4
18 1 PITOT SENSOR ASSEMBLY
19 1 SENSOR – FUEL PRESSURE
20 1 FITTING – STRAIGHT DIGITAL
21 1 CLIP – CONDUIT
22 1 BRACKET – SPEEDO SENSOR
23 1 GROMMET
24 1 BUSHING
25 1 SCREW (M6 x 25)
26 1 TRIM HARNESS
27 3 RELAY
28 3 DECAL-Trim Relay
29 3 BRACKET
30 3 BUSHING
31 3 GROMMET
32 3 SCREW (M6 x 25) 35 4
1 ECU (200)
33
1 ECU (225)
34 3 SCREW (M6 x 25) 100 11.5
35 3 BUSHING
36 3 GROMMET
37 3 WASHER
38 2 SCREW (M6 x 14) 100 11.5
39 1 CLIP
40 1 CLIP

90-859769R1 DECEMBER 2000 Page 2A-5


IGNITION

Electrical Components
37 36
12 10
10 11 34
9 35 A = TO BLOCK
8 A
7 33 18
45
39
25
19
6 38
17 2324
22
40 21
38 20
1
2 TO
3 13 BLOCK
14 15 41

4 16 60 49
5 67
66
65
46 52
52 50
53
43 48
51
57 64
44 61 58 59 47
56 62 54
70 63 31
30
29
32
69
68 27

28

42

26

NOTE: COAT ALL EYELET WIRING TERMINALS WITH #25 GACO N700
NOTE: COAT ALL MULTI-PIN ELECTRICAL CONNECTIONS (EXCEPT POWER TRIM RELAY CONNEC-
TORS) WITH #6 DC-4
A = TO BLOCK

Page 2A-6 90-859769R1 DECEMBER 2000


IGNITION

Electrical Components
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm
41 1 ELECTRICAL PLATE ASSY
42 1 ENGINE HARNESS
43 5 FUSE
44 1 FUSE COVER
45 1 BRACKET
46 1 RELAY PLATE ASSEMBLY
47 1 RELAY PLATE
48 3 SCREW (M6 x 12) 100 11.5
49 1 BATTERY CABLE (NEGATIVE)
50 2 SCREW (M6 x 14) 35 4
51 1 STARTER SOLENOID
52 2 GROMMET
53 2 SCREW (M6 x 25) 35 4
54 1 CABLE (BLACK)
55 2 BUSHING
56 1 BATTERY CABLE (POSITIVE)
57 2 LOCKWASHER
58 2 NUT (5/16-18) 50 5.5
59 2 NUT (10-32) 8 0.9
60 1 SCREW (M8 x 20) 18 24.5
61 1 BOOT (RED)
62 1 CAP NUT
63 1 CABLE
64 2 INSULATOR BOOT (YELLOW)
65 1 CLIP
66 1 SCREW (M6 x 14)
67 1 CLIP
68 1 STA STRAP
69 1 NUT
70 1 PLUG (GRAY WIRE) (DIGITAL)

90-859769R1 DECEMBER 2000 Page 2A-7


IGNITION

Coil Plate Model Year 2001


17 18
20
16
15 19

18
1

11
13 12
22
14

10 9
8

10
80
21
80
2

11
12 2
22
13 7
14 80

10 9

4 80
6

80 30W 4 Cycle Engine Oil (92-97959) 58557

Page 2A-8 90-859769R1 DECEMBER 2000


IGNITION

Coil Plate Model Year 2001


TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm
1 1 COIL MOUNTING PLATE
2 6 IGNITION COIL
3 12 SCREW 60 7
4 6 HIGH TENSION CABLE
5 12 BOOT
6 6 SPARK PLUG 20 27
7 3 DUAL COIL DRIVER
8 2 CABLE
9 2 SCREW (M6 x 10) 60 7
10 4 WASHER
11 4 GROMMET
12 4 WASHER
13 4 BUSHING
14 4 SCREW (.312-18 x 1-1/4 IN.) 20 27
15 1 SENSOR
16 1 FITTING 40 4.5
17 1 CLIP
18 2 STA STRAP
19 1 TUBING (15 IN.)
20 1 FITTING
21 2 SCREW (M6 x 14)
22 2 WASHER

90-859769R1 DECEMBER 2000 Page 2A-9


IGNITION

Solenoid Plate Model Year 2001


32
A A = TO BLOCK 29
30
41
35 31 28
42 47
39
40
38 34
37
36 33

14 12 34
10 9
15 4 TO
6 BLOCK

46

45
13 17

34

16 2
9 24 27
11
25
10 23
4
5
43 8 3
4
23 24 26
22
6 20
7 44
19 21
18

*NOTE: Coat all eyelet wiring terminals with #25 GACO N700.
*NOTE: Coat all multi-pin electrical connections (except power trim relay connections)
with #6DC-4.

Page 2A-10 90-859769R1 DECEMBER 2000


IGNITION

Solenoid Plate Model Year 2001


TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm
1 1 SOLENOID PLATE
2 1 SOLENOID
3 2 GROMMET
4 5 SCREW (M6 x 25) 35 4
5 2 BUSHING
6 3 RELAY ASSEMBLY
7 3 DECAL
8 3 BRACKET
9 3 BUSHING
10 3 GROMMET
11 1 ENGINE HARNESS
12 5 FUSE (4 – 20 AMP) (1 – 15 AMP)
13 1 FUSE COVER
14 1 HARNESS (DIRECT INJECTOR)
15 1 HARNESS (FUEL INJECTOR)
16 1 HARNESS (TPS)
17 3 SCREW-(M6 x 12) 100 11.5
18 1 TRIM HARNESS
19 1 INSULATOR BOOT (RED)
20 1 INSULATOR BOOT (YELLOW)
21 1 CABLE (RED)
22 1 CAP NUT
23 2 NUT (5/16-18) 50 5.5
24 2 NUT (10-32) (BRASS) 8 0.9
25 2 LOCKWASHER
26 1 CLIP
27 1 CLIP
1 ECU (200)
28
1 ECU (225)
29 3 SCREW (M6 x 25) 100 11.5
30 3 BUSHING
31 3 GROMMET
32 3 WASHER
33 1 CLIP
34 5 SCREW (M6 x 14) 100 11.5
35 1 SENSOR – SPEEDOMETER WATER PRESSURE
36 1 FITTING 50 5.5
37 1 CLIP
38 1 BRACKET
39 1 GROMMET
40 1 BUSHING
41 1 SCREW (M6 x 25) 35 4
42 1 CLIP
43 2 STA–STRAP

90-859769R1 DECEMBER 2000 Page 2A-11


IGNITION

Solenoid Plate Model Year 2001


32
A A = TO BLOCK 29
30
41
35 31 28
42 47
39
40
38 34
37
36 33

14 12 34
10 9
15 4 TO
6 BLOCK

46

45
13 17

34

16 2
9 24 27
11
25
10 23
4
5
43 8 3
4
23 24 26
22
6 20
7 44
19 21
18

*NOTE: Coat all eyelet wiring terminals with #25 GACO N700.
*NOTE: Coat all multi-pin electrical connections (except power trim relay connections)
with #6DC-4.

Page 2A-12 90-859769R1 DECEMBER 2000


IGNITION

Solenoid Plate Model Year 2001


TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm
44 1 CABLE
45 1 SCREW (M8 x 20) 18 24.5
46 1 BATTERY CABLE (NEGATIVE)
47 1 BRACKET

Theory of Operation
When the ignition key is turned to the RUN position, battery voltage is applied to the main
relay through the PURPLE wire. When the Electronic Control Module (ECM) receives a
signal from the Crank Position Sensor, the main relay ground circuit is completed through
the ECM. The main relay is then closed and D.C. current from the battery or charging sys-
tem is transferred through the main relay 20 ampere fuse to the positive terminal of all 6
ignition coil primary windings. The negative terminal of the coil primary is connected to
engine ground through the ECM. When this circuit is closed, a magnetic field is allowed
to be built up in the ignition coil. The Crank Position Sensor senses the location of the 24
teeth (Model 2000) or 54 teeth (Model 2001) on the flywheel and supplies a trigger signal
to the ECM. When the ECM receives this signal, the ECM will then open the ground circuit
of the coil primary. The magnetic field in the ignition coil primary will then collapse cutting
across the coil secondary winding creating a high voltage charge (50,000 volts) that is
sent to the spark plug.

90-859769R1 DECEMBER 2000 Page 2A-13


IGNITION

Ignition Component Description


Fuses
The electrical wiring circuits on the outboard are protected from overload by fuses in the
wiring. If a fuse is blown, try to locate and correct the cause of the overload. If the cause
is not found, the fuse may blow again.
1. Open the fuse holder and look at the silver colored band inside the fuse. If band is
broken, replace the fuse. Replace fuse with a new fuse with the same rating.
2. The fuses and circuits are identified as follows:
a. Model Year 2000 – ECM Driver Power/Oil Pump Circuit – SFE 20 AMP Fuse
Model Year 2001 – Smart Craft Data Bus Circuit – SFE 15 AMP Fuse.
b. Accessories – SFE 20 AMP Fuse.
c. Ignition Coil Circuit – SFE 20 AMP Fuse.
d. Model Year 2000 – Electric Fuel Pump Circuit – SFE 20 AMP Fuse
Model Year 2001 – Electric Fuel Pump/ECM Driver Power/Oil Pump Circuit – SFE
20 AMP Fuse.

a b

Model 2000
d c
57777

57494

a b

Model 2001

d c
58459

58707

Page 2A-14 90-859769R1 DECEMBER 2000


IGNITION

Ignition Component Description


Electronic Control Module (ECM)
The ECM requires 8 VDC minimum to operate. If the ECM should fail, the engine will stop
running.
The inputs to the ECM can be monitored and tested by the Digital Diagnostic Terminal
91-823686A2 using adaptor harness 84-822560A5.
The ECM performs the following functions:
• Calculates the precise fuel and ignition timing requirements based on engine speed,
throttle position, manifold pressure and coolant temperature.
• Controls fuel injectors for each cylinder, direct injectors for each cylinder and ignition
for each cylinder.
• Controls all alarm horn and warning lamp functions.
• Supplies tachometer signal to gauge.
• Controls RPM limit function.
• Monitors shift interrupt switch.
• Records engine running information.

57779

90-859769R1 DECEMBER 2000 Page 2A-15


IGNITION

Flywheel
Model Year 2000 – 24 teeth under the flywheel ring gear
Model Year 2001 – 54 teeth under the flywheel ring gear
Provide engine rpm and crankshaft position information to the ECM through the crank
position sensor.

57799
Ignition Coils
Model Year 2000/2001 – Inductive type ignition coils are used on the DFI engines.
12 volt DC is supplied to the coils at all times from the boat battery. For a predetermined
length of time (dwell), the primary circuit of the coil is completed by closing the electrical
circuit within the coil driver. When the coil driver circuit opens, the primary field of the coil
collapses inducing high voltage in the secondary windings which produces up to 50000
volts at the spark plugs.

57785 58701

MODEL YEAR 2000 MODEL YEAR 2001


Ignition Coil Ohm Test

Connect meter leads between primary terminal (GRN/Striped)


0.38 - 0.78 
and (RED/YELLOW) terminal pin.
Connect meter leads between spark plug wire/high voltage
8.1 - 8.9 k 
tower and ground terminal pin.

Page 2A-16 90-859769R1 DECEMBER 2000


IGNITION

Coil Driver
Model Year 2001 only
The ECM sends a 5 VDC pulse to the coil driver mounted on each ignition coil. Which coil
driver receives this pulse is determined by the ECM receiving a signal from the crank posi-
tion sensor.
When the coil driver receives its ECM pulse (signal), it closes its circuit which allows the
primary side of the ignition coil to build up energy which it initially receives from the boat
battery.
When the ECM pulse (signal) to the coil driver drops below 1.3 volts, the coil driver opens
its circuit which causes the primary field of the ignition coil to collapse. This field collapse
induces a voltage buildup in the secondary winding of the ignition coil resulting in a poten-
tial voltage of up to 50000 volts at the spark plug.

58701
a - Coil Driver c - 2 Pin Connector
b - 4 Pin Connector
Coil Driver Ohm Test

GREEN/STRIPE

GREEN/STRIPE

RED/YELLOW GREEN/STRIPE
BLACK GREEN/STRIPE

58418

4 Pin Connector – Connect meter leads between RED/YEL


85 k  ± 10%
and BLACK male pins.
4 Pin Connector – Connect meter leads between BLACK male
10 k  ± 10%
pin and each GREEN STRIPED male pin.
Connect meter leads between BLACK male pin on 4 pin con- OPEN – No Conti-
nector and each GREEN STRIPED male pin on the 2 pin con- nuity
nector.

90-859769R1 DECEMBER 2000 Page 2A-17


IGNITION

Crank Position Sensor


Model Year 2000 – Senses 24 teeth located on flywheel under ring gear.
Model Year 2001 – Senses 54 teeth located on flywheel under ring gear.
Supplies the ECM with crank position information and engine speed. If sensor should fail,
the engine will stop running.

57796

Crank Position Sensor Specifications


Air Gap 0.025 in – 0.040 in
(0.635 mm – 1.01 mm)

Throttle Position Sensor (TPS)


The TPS transmits throttle angle information to the ECM which varies the injector pulse
width accordingly. Should the sensor fail, the dash mounted CHECK ENGINE light will
light and the warning horn will sound. RPM will be reduced by the ECM. TPS settings are
not adjustable. TPS settings can be monitored with the Digital Diagnostic Terminal
through the ECM. Voltage change should be smooth from idle to wide open throttle. If volt-
age change is erratic, TPS is defective.

57797

Model Year 2000 Throttle Position Sensor Specifications


Idle 4.0 – 4.7 VDC
Wide Open Throttle 0.4 – 1.3 VDC

Model Year 2001 Throttle Position Sensor Specifications


Idle 0.4 – 1.3 VDC
Wide Open Throttle 4.0 – 4.7 VDC

Page 2A-18 90-859769R1 DECEMBER 2000


IGNITION

Throttle Position Sensor (TPS) Troubleshooting


If the throttle position sensor(s) are out of the intended operating range when the engine
is started, the Electronic Control Module (ECM) will sense that the Throttle Position Sen-
sor (TPS) has failed. The warning horn will sound, check engine light will illuminate DDT
will indicate failed TPS and the engine will go into RPM reduction. When the engine is
started, the throttle arm on the engine must be against the throttle stop screw.
• Check throttle cable adjustment. The throttle stop screw on the throttle arm must be
against the throttle stop on the cylinder block when the engine is started. Pre-load the
throttle cable barrel 1 or 2 turns if necessary.
• Verify driver is not pushing on throttle (if foot throttle is used) or advancing the throttle
only on the control box.
• Check throttle cam to roller adjustment. If the roller is not down in the pocket/valley
area on the cam, there is a tendency for the roller to ride up or down on the cam which
causes the TPS link arm to push/pull on the TPS lever resulting changing values.
• Heat or pressure test the TPS.
HEAT TEST
With engine at idle, heat the TPS (with a hot air gun) below the electrical connection until
warm to the touch. Watch for any one or a combination of the following symptoms:
• RPM change
• Check engine light illumination
• Momentary warning horn signal
• TPS voltage value change (1/2 volt) on DDT
*NOTE: Excessive heat will damage TPS.
PRESSURE TEST
IMPORTANT: When testing TPS voltage, do not move the drive mechanism (rotor/
wiper).
1. Connect DDT and rotate the key to the “ON” position.
2. Set DDT to read TPS voltage; expand the screen to show Now/Min/Max.
*NOTE: Test accuracy is improved when TPS is at its lowest voltage reading; this may
be idle or WOT depending on model year.
3. Clear the minimum/maximum values on the DDT – press the “0” button.
4. Watch the DDT readings while pressing below the electrical connection point on the
TPS cover.

a
a - Press on cover below electrical connection
5. Voltage reading should change:
• Less than a couple of digits (i.e. 1.90 v to 1.92 v)
*NOTE: Version 5.0 cartridge gives 3 decimal point (millivolts) accuracy if below 1 volt.
• Less than 10 millivolts (i.e. 0.293 v to 0.285 v)
Replace any TPS that fails either test.

90-859769R1 DECEMBER 2000 Page 2A-19


IGNITION

Charging System Alternator


Battery charging system is contained within the belt driven alternator, including the regu-
lator. At cranking speeds, electrical power for the engine is provided by the boat battery
– minimum recommended size is 750 CCA, or 1,000 MCA, cold cranking amperes or 105
(Minimum) Ampere Hours. Above 550 RPM, all electrical power is provided by the alter-
nator. Should engine rpm drop below 550 RPM, the alternator is not capable of providing
sufficient output and the battery becomes the primary source of electrical power.
Alternator output (when hot) to the battery @ 2000 RPM is approximately 33 - 38 am-
peres.

57806

Page 2A-20 90-859769R1 DECEMBER 2000


IGNITION

Temperature Sensor
Three (3) temperature sensors are used to provide cylinder head temperature information
to the ECM. One sensor is mounted on each cylinder head and one in the air compressor
cylinder head. The ECM uses this information to increase injector pulse width for cold
starts and to retard timing in the event of an over-heat condition.

b
a a

57794
57795
MODEL 2000 PORT MODEL 2000 STARBOARD

e
c

MODEL 2001
a - Cylinder Temperature Sensor
b - Air Compressor Temperature Sensor
c - Cylinder Temperature Sensor (PORT
d - Air Compressor Temperature Sensor
e - Cylinder Temperature Sensor (STARBOARD)

90-859769R1 DECEMBER 2000 Page 2A-21


IGNITION

An ohms test of the temperature sensor would be as follows:


MODEL YEAR 2000 – Insert digital or analog ohmmeter test leads into both TAN/BLACK
sensor leads. With engine at temperature (F) indicated, ohm readings should be as indi-
cated ±10%. There should be no continuity between BLACK and each TAN/BLACK lead
and no continuity between each TAN/BLACK lead and ground.
MODEL YEAR 2001 – Disconnect temperature sensor harness and check continuity with
digital or analog ohmmeter test leads between both connector pins. With engine at tem-
perature (F) indicated, ohm readings should be as indicated ±10%. There should be no
continuity between each connector pin and ground.
MODEL YEAR 2000 MODEL YEAR 2001
F C OHMS F C OHMS
257 125 34 257 125 340
248 120 38 248 120 390
239 115 44 239 115 450
230 110 51 230 110 517
221 105 59 221 105 592
212 100 68 212 100 680
203 95 79 203 95 787
194 90 92 194 90 915
185 85 107 185 85 1070
176 80 126 176 80 1255
167 75 148 167 75 1480
158 70 175 158 70 1752
149 65 208 149 65 2083
140 60 248 140 60 2488
131 55 298 131 55 2986
122 50 360 122 50 3603
113 45 436 113 45 4370
104 40 532 104 40 5327
95 35 653 95 35 6530
86 30 805 86 30 8056
77 25 1000 77 25 10000
68 20 1250 68 20 12493
59 15 1573 59 15 15714
50 10 1993 50 10 19903
41 5 2546 41 5 25396
32 0 3277 32 0 32654
14 –10 5579 14 –10 55319
5 –15 7372 5 –15 72940

Page 2A-22 90-859769R1 DECEMBER 2000


IGNITION

Manifold Absolute Pressure (MAP) Sensor


The MAP sensor is mounted on top of the air plenum. The ECM regulates fuel flow, in part,
based on manifold absolute pressure.

57793

Air Temperature Sensor


The air temperature sensor is mounted on top of the air plenum. The ECM regulates fuel
flow, in part, based on manifold air temperature. As air temperature increases, the ECM
decreases fuel flow.

57793

90-859769R1 DECEMBER 2000 Page 2A-23


IGNITION

Direct Injectors
6 direct injectors (1 per cylinder) are used to inject a fuel/air mix into cylinders. Injectors
are mounted between fuel rails and cylinder heads.

57986 57985

Direct Injector Ohm Test (Injector Lead Disconnected)


Connect meter leads between each in-
1 - 1.6 
jector terminal pin.
Connect 1 meter lead to either injector No continuity
pin while touching the other meter lead to
the injector metal case.

Fuel Injectors
6 fuel injectors (1 per cylinder) are used to provide fuel from the fuel rail to the direct injec-
tors. The fuel injectors are mounted in the fuel rail.

57785

Fuel Injector Ohm Test (Injector Lead Disconnected)


Connect meter leads between each in-
1.7 - 1.9 
jector terminal pin.

Page 2A-24 90-859769R1 DECEMBER 2000


IGNITION

Disconnecting Harness Connectors from Ignition Coils and/or Injectors


a

54871

a - Wire Clip (push center down to remove)

Shift Interrupt Switch

57737
a - Shift Interrupt Switch

The shift interrupt switch is designed to reduce the torque load on the gear case compo-
nents to assist in shifting. The switch is monitored by the ECM which will interrupt the fuel
flow momentarily to 3 cylinders (#1, #2 and #4) when engine speed exceeds 600 rpm in
neutral.
The switch function can be monitored by the DDT. The DDT will display ON when out-
board is in neutral and OFF when in gear.
The switch is open (no continuity) when outboard is in gear and closed (continuity) when
outboard is in neutral.
If shift operation is difficult, shift interrupt switch function can be checked by the DDT or
an ohmmeter – for open or closed operation and for a continuity check of the switch har-
ness for shorts or open wiring.

90-859769R1 DECEMBER 2000 Page 2A-25


IGNITION

Troubleshooting
The ECM is designed such that if a sensor fails, the ECM will compensate so that the en-
gine does not go into an over-rich condition.
Disconnecting a sensor for troubleshooting purposes may have no noticeable effect.

Troubleshooting Without Digital Diagnostic Terminal


Troubleshooting without the DDT is limited to checking resistance on some of the sen-
sors.
Typical failures usually do not involve the ECM. Connectors, set-up, and mechanical wear
are most likely at fault.
• Verify spark plug wires are securely installed (pushed on) on the coil tower.
• The engine may not run or may not run above idle with the wrong spark plugs installed.
• Swap ignition coils to see if the problem follows the coil or stays with the particular
cylinder.
*NOTE: ECMs are capable of performing a cylinder misfire test to isolate problem cylin-
ders. Once a suspect cylinder is located, an output load test on the ignition coil, fuel injec-
tor and direct injector may be initiated through use of the DDT.
• Any sensor or connection can be disconnected and reconnected while the engine is
operating without damaging the ECM. Disconnecting the crank position sensor will
stop the engine.
IMPORTANT: Any sensor that is disconnected while the engine is running will be
recorded as a Fault in the ECM Fault History. Use the DDT to view and clear the fault
history when troubleshooting/repair is completed.
• If all cylinders exhibit similar symptoms, the problem is with a sensor or harness input
to the ECM.
• If problem is speed related or intermittent, it is probably connector or contact related.
Inspect connectors for corrosion, loose wires or loose pins. Secure connector seating;
use dielectric compound 92-823506-1.
• Inspect the harness for obvious damage: pinched wires, chaffing.
• Secure grounds and all connections involving ring terminals (coat with Liquid Neo-
prene 92-25711--3).
• Check fuel pump connections and fuel pump pressure.
• Check air compressor pressure.

Page 2A-26 90-859769R1 DECEMBER 2000


IGNITION

Troubleshooting with the Digital Diagnostic Terminal

a
c d
b

a - Digital Diagnostic Terminal (91-823686A2)


b - 2000 and Prior – Software Cartridge (91-822608--4 or --5 or --6)
2001 and Up – Software Cartridge (91-880118)
c - 2000 and Prior – DDT Reference Manual (90-825159-3)
2001 – DDT Reference Manual (90-881204)
d - Adapter Harness (84-822560A5)

The Quicksilver Digital Diagnostic Terminal (DDT) has been developed specifically to
help technicians diagnose and repair Mercury Marine 2 and 4 cycle engines.
Attach the diagnostic cable to the ECM diagnostic connector and plug in the software car-
tridge. You will be able to monitor sensors and ECM data values including status switches.
The ECM program can help diagnose intermittent engine problems. It will record the state
of the engine sensors and switches for a period of time and then can be played back to
review the recorded information.
Refer to the Digital Diagnostic Terminal Reference Manual for complete diagnostic proce-
dures.

90-859769R1 DECEMBER 2000 Page 2A-27


IGNITION

Notes:

Page 2A-28 90-859769R1 DECEMBER 2000


IGNITION

DDT Functions – Optimax Models Software Version 4.0 and 4.1


IGN ACTIVE HIST
IGN 1 PASS PASS
IGN 2 PASS PASS
1 5 IGN 3 PASS PASS
2 6 IGN 4 PASS PASS
IGN 5 PASS PASS
Select Auto Test: 3 7 IGN 6 PASS PASS
MARINE DIAGNOSTICS
1 1 - STATIC TEST Engine Not Running During Test
1 - Mariner/Mercury 4 8 INJECTOR ACTIVE HIST
2 - MerCruiser INJ 1 PASS PASS
3 - Injector Test 2 - RUNNING TEST Engine Running During Test
INJ 2 PASS PASS
4 - Tool Setup INJ 3 PASS PASS
Monitors Engine Functions
While Engine is Running INJ 4 PASS PASS
INJ 5 PASS PASS
SELECT ECM INJ 6 PASS PASS
1 - 3.0L Ignition ECM
2 - 3.0L Fuel ECM ENGINE RPM PUMP ACTIVE HIST
3 - 824003 Fuel ECM TPI 1 VOLTS OIL PMP PASS PASS
4 - 2.5L Hi Perf ECM TPI 2 VOLTS
5 BATTERY VOLTS SENSOR ACTIVE HIST
5 - DFI ECM Select Status:
PWR 1 VOLTS COOL STB PASS PASS
6 - 4 Stroke ECM 1 - IGNITION
PWR 2 VOLTS COOL PRT PASS PASS
2 - INJECTOR
COOL TMP STB °F MAP PASS PASS
3 - PUMP AIR TMP PASS PASS
COOL TMP PRT °F 4 - SENSORS TPI 1 PASS PASS
MAP PSI 5 - SWITCHES TPI 2 PASS PASS
Select Function: AIR TMP ° 6 - MISCELLANEOUS TRIG SIG PASS PASS
1 - AUTO SELF TEST TRIGGER ERR 7 - RPM LIMIT COMP TMP PASS PASS
TIME TO OIL 8 - BREAK-IN BLOCK PSI PASS PASS
2 - MANUAL TEST OIL INJ CNT
1 or 2
TPI % Text Book Data SWITCH ACTIVE HIST
AIR COM TMP °F (specs) SHIFT SW ON NA
BLOCK PSI Any fault in Select Status functions 1 thru 7 will turn
Select Function: on the matching panel light. H2O FUEL NO NO
1 - DATA MONITOR Illuminated panel light 8 Indicates engine is in Break-in. L OIL NO NO
2 - STATUS SWITCHES 98 DI
ECM # MISC. ACTIVE HIST
3 - SYSTEM INFO NOTE:Test data is lost when Key Switch is turned off.
CODE BATTERY PASS PASS
4 - HISTORY Any existing faults from Tests 1 thru 6 are transferred
IGN PRI .38-.78 ohm PWR RLY PASS PASS
5 - SPECIAL FUNCTIONS to Fault History.
SEC 8.1-8.9 Kohm PWR 1 V PASS PASS
DINJ 1.0-1.6 ohm PWR 2 V PASS PASS
FINJ 1.7-1.9 ohm HORN PASS PASS
Select Function: TPI1 3.7-4.9v IDLE LAMP PASS PASS
1 - OIL PUMP PRIME 0.3-1.8v WOT LIMIT ACTIVE HIST
2 - CYLINDER MISFIRE Select Fault Hist: TPI2 0.1-1.5v IDLE CTS LIM OFF ON
3 - OUTPUT LOAD TEST 1-IGNITION 3.2-4.9v WOT
ECM RUN TIME xx CTP LIM OFF OFF
4 - RESET BREAK-IN OIL 2-INJECTOR TPI1 LtBlu/Red IN
RPM 0000-0999 xx ACT LIM OFF OFF
3-PUMP TPI2 LtBlu/Wht OUT TP1 LIM OFF OFF
RPM 1000-1499 xx
4-SENSORS TGAP 0.025-.04in
Select Load Test: RPM 1500-2999 xx TP2 LIM OFF OFF
5-SWITCHES PWR RLY 81-99 ohm
1 - IGNITION Select Function: RPM 3000-3999 xx RPM LIM OFF OFF
6-MISCELLANEOUS CTS max 220F
2 - FUEL INJECTOR 1 - FAULT HISTORY RPM 4000-4999 xx OIL LIM OFF ON
2 - RUN HISTORY RPM 5000-5999 xx ACT max 150-220F BAT LIM OFF OFF
3 - DIRECT INJECTOR
3 - CLEAR FAULT HIST RPM 6000+ xx 30-8000 ohm 1K@77F BLK LIM OFF OFF
4 - OIL PUMP
4 - CLEAR RUN HIST BREAK IN Min xx AIR TMP .540-44 PWR LIM OFF OFF
5 - FUEL PUMP
OVER TMP Sec x BATV 12.6-15.0
6 - HORN
RPM LIMIT CNT x MAP 7-15 psi STATUS BREAK-IN ENGINE IS IN
7 - LAMPS
RPM LIMIT SEC x FUEL 88-90 psi BREAK-IN MODE. xxx MINUTES
8 - TACHOMETER
ACT TEMP SEC x AIR 77-81 psi TO COMPLETION.
9 - MAIN POWER RELAY or
BLOCK PSI Sec x
STATUS BREAK-IN ENGINE HAS
CTS TMP Sec x
COMPLETED A FACTORY SCHED-
CTP TMP Sec x
ULED BREAK-IN.
OIL PMP Sec x
90-859769R1 DECEMBER 2000 Page 2A-29
IGNITION

DDT Functions – Optimax Models Software Version 1.0


01MY DI
ECM #
CODE
Any fault will turn on fault light. Refer to
IGN PRI .38-.78 ohm Fault Status to identify fault
SEC 8.1-8.9 Kohm
DINJ 1.0-1.6 ohm
FINJ 1.7-1.9 ohm
TYPICAL TPI RANGE FAULT LIGHTS FAULT LIGHTS
SmartCraft Monitor
TPI 1 0.19-1.0v IDLE
1 – Mercury Marine 3.45-4.63v WOT
2 – Tool Setup TGAP 0.025-.04in IGNITION 1 5 SWITCHES
PWR RLY 81-99 ohm
RPM LIMIT 5850 INJECTOR 2
PROP RPM 5000-5750
6 MISCELLANEOUS
AIR COMPRESSOR
ENGINE RPM PUMP 3 7 RPM LIMIT
1Kohm @ 77F/25C
THIS ENGINE IS A TPI 1 VOLTS
BATTERY VOLTS AIRTEMP/COOLANT
xx MY xxx x.xL xxx 10 Kohm @ 77F/25C SENSORS 4 8 BREAK–IN
PWR 1 VOLTS
PRESS 1 to CONTINUE COOL TMP STB °F BATV 12.6-15.0
COOL TMP PRT °F MAP 7-15 psi
MAP PSI FUEL AIR +10 psi
AIR TMP °F AIR 77-82 psi
BLOCK PSI OIL PUMP COIL
OIL INJ CNT 1.8-2.0 ohms
Select Function: Select Auto Test: TPI % 1 FUSE-INJ/OIL PUMP
1 - AUTO SELF TEST
1 – STATIC TEST AIR COM TMP °F 2 FUSE-FUEL PUMP
OIl LEVEL 3 FUSE-ACCESSORY
2 - MANUAL TEST FUEL LEVEL
AVAILABLE PWR % 4 FUSE-IGNITION
SHIFT OVERTEMP/BLOCK
TRIM
PRESSURE LIMITS ARE
PITOT
PADDLE WHEEL CONTROLLED BY
LAKE/SEA TMP °F ENGINE GUARDIAN
SEE SERVICE MANUAL
FOR GUARDIAN INFO Fault Status List

ACT INPUT HI or LO Air compessor temperature sensor input is high or low


Select Function: AT INPUT HI or LO Air temperatrure (engine) sensor input is high or low
1 - DATA MONITOR
BATT VOLT HI or LOW Battery voltage is high or low
2 - FAULT STATUS
3 - SYSTEM INFO BLOCK PRESS LOW Block pressure is low
4 - HISTORY Block Pressure Sensor input is high or low
BPSI INPUT HI or LO
5 - SPECIAL FUNCTIONS
BREAK-IN Engine Break-In In Progess
COMP OVERHEAT Compressor overheat
Select Function: Select Fault Hist: CTP INPUT HI or LO Coolant temp port sensor input is high or low
1 - FAULT HISTORY 1 – FREEZE FRAME Coolant temp starboard sensor input is high or low
2 - RUN HISTORY CTS INPUT HI or LO
2 – FAULT SECONDS Direct injector (1 thru 6) is short or open circuit
3 - CLEAR FAULT HIST DINJ 1 thru 6 SHORT or OPEN
4 - CLEAR RUN HIST
FREEZE FRAME BUFFERS EST 1 thru 6 SHORT or OPEN Electronic spark trigger signal (1 thru 6) is short or open circuit
0-BREAK-IN Fuel injector (1 thru 6) is short or open circuit
FINJ 1 thru 6 SHORT or OPEN
BARO PSI
BATT VOLTS FUEL LVL IN HI or LO Fuel level sensor input is high or low
FAULT SECONDS BLOCK PSI GUARDIAN Guardian system activated
BATT VOLT HIGH BOAT SPEED Water in fuel
AIR TMP °F H2O IN FUEL
Select Function: BATT VOLT LOW
1 - OIL PUMP PRIME COOL TMP °F MAP INPUT HI or LO MAP sensor input high or low
BLOCK PRESS LOW
2 - CYLINDER MISFIRE DEMAND % MPRLY BACKFEED Main Power Relay is Receiving a Current Back feed
COMP OVERHEAT
3 - OUTPUT LOAD TEST RUN TIME HR. ETC MOTOR OPEN ENGINE RPM Main Power Relay Output
4 - RESET BREAK-IN OIL ENGINE STATE MPRLY OUTPUT
RPM 0 – 749 ETC MOTOR SHORT
5 - CHANGE FUEL OFFSET RPM 750 – 1499 FPC TOTAL OIL LVL IN HI or LO Oil level sensor input is high or low
FUEL P INPUT HI
6 - ENGINE LOCATION RPM 1500 – 2999 FUEL P INPUT LO FREQ COUNTER OIL PUMP Oil pump electrical failure
RPM 3000 – 3999 GUARDIAN FUEL LEVEL % OIL RESERVE STR Oil reserve strategy is active
RPM 4000 – 4499 KNOCK SENS1 SHIFT Overspeed is activated
LAKE/SEA TMP °F OVERSPEED
RPM 4500 – 4999 KNOCK SENS2
RPM 5000– 5499 LOAD% PITOT INPUT HI or LO Pilot Pressure Sensor input is high or low
OIL PSI STR
RPM 5500 – 6249 OIL REMOTE STR MPRLY REQ PORT OVERHEAT Port cylinder head overheat
Select Load Test: RPM 6250 + OIL RESERVE STR MAP PSI Sea or lake temperature sensor input is high or low
OIL LEVEL % SEA TMP IN HI or LO
1 - IGNITION BREAK-IN LEFT MAP INPUT HI
RPM LIMIT Sec PORT TAB POS STAR OVERHEAT Starboard cylinder head overheat
2 - FUEL INJECTOR MAP INPUT LO
3 - DIRECT INJECTOR GRD LIMIT Sec MAP IDLE CHECK AVAILABLE PWR % TPI1 INPUT HI or LO TPI #1 sensor input is high or low
4 - OIL PUMP ACT TEMP Sec OIL PUMP RUN TIME ECM is unable to adapt to the current position of the TPI
STAR TAB POS TPI1 NO ADAPT
5 - FUEL PUMP BLOCK PSI Sec OVERSPEED
CTS TMP Sec TPI % TPI1 RANGE HI or LO TPI #1 is above or below the allowable range
6 - HORN PORT OVERHEAT
7 - Reserve CTP TEMP Sec STAR OVERHEAT TRIM POSITION TRIM INPUT HI or LO Trim sensor input is high or low
8 - TACHOMETER LOW OIL Sec WARNING HORN COOL TMP STB °F
Warning horn fault
9 - MAIN POWER RELAY OIL PMP Sec H2O IN FUEL COOL TMP PRT °F WARNING HORN

Page 2A-30 90-859769R1 DECEMBER 2000


IGNITION

DFI Troubleshooting Guide


Symptom Cause Action
1. Engine cranks but won’t 1.0 Lanyard stop switch in wrong Reset lanyard stop switch.
start position.
1.1 Weak battery or bad starter Replace/charge battery.
motor, battery voltage drops Inspect condition of starter motor.
below 8 volts while cranking Check condition of battery termi-
(ECM cuts out below 8 volts) nals and cables.
(Fuel pump requires 9 Volts).
1.2 Low air pressure in rail (less Inspect air system for leaks.
than 70 psi at cranking Inspect air filter for plugging (air
pressure measured on port rail).
Inspect air compressor reed valves
if necessary.
1.3 No fuel Check that primer bulb is firm.
Key-on engine to verify that fuel
pump runs for 2 seconds and then
turn off. Measure fuel pressure
(valve on starboard rail). Fuel pres-
sure should be 10 ± 1 psi greater
than the air pressure.
1.4 Low fuel pressure Check fuel pressure from low pres-
sure electric fuel pump (6–10 psi).
Check for fuel leaks. If fuel pres-
sure leaks down faster than air
pressure, seals on fuel pump may
be leaking. Check air system pres-
sure, see 1.2.
1.5 Flywheel misaligned during Remove flywheel and inspect.
installation
1.6 Blown fuse Replace fuse. Inspect engine har-
ness and electrical components.
1.7 Main Power Relay not Listen for relay to “click” when the
functioning key switch is turned on.
1.8 Spark Plugs Remove fuel pump fuse.
Unplug all direct injector connec-
tors.
Remove spark plugs from each
cylinder.
Connect spark plug leads to Spark
Gap Tester 91-830230T.
Crank engine or use DDT output
load test for each ignition coil and
observe spark. If no spark is pres-
ent, replace appropriate ignition
coil. If spark is present, replace
spark plugs.

90-859769R1 DECEMBER 2000 Page 2A-31


IGNITION

DFI Troubleshooting Guide (continued)


Symptom Cause Action
1. Engine cranks but will not 1.9 ECM not functioning Injection System:
start (continued) Listen for injector “ticking” when
cranking or connect spare injector
to each respective harness. Tick-
ing should start after 2 cranking
revolutions.

Ignition System:
– Check for proper operation by
using Inductive Timing Light
91-99379.
– Check battery voltage
(RED/YEL Lead) @ ignition
coils.
– Check for blown fuse (C15).
– Check battery voltage to fuse
from main power relay
(PURPLE Lead).
– Check for shorted stop wire
(BLK/YEL).
1.9A Crank Position Sensor not – Check crank position sensor
functioning setting [0.015 in. – 0.040 in.
(0.38mm – 1.01mm)] from
flywheel or for defective crank
position sensor.
– Defective ECM.

Power Supply:
Clean and inspect remote control
male and female harness connec-
tors.
2. Engine cranks, starts and 2.0 Low air pressure in rail See 1.2
stalls
2.1 Low fuel pressure in rail See 1.2 and 1.3
2.2 Abnormally high friction in Check for scuffed piston or other
engine sources of high friction.
2.3 Air in fuel system/lines See 1.3 Crank and start engine
several times to purge.
2.4 TPS malfunction Check motion of throttle arm. Stop
nuts should contact block at idle
and WOT. Check TPS set-up. Must
connect DDT with adapter harness
(84-822560A5) to ECM.
2.5 Remote control to engine Clean and inspect male and fe-
harness connection is poor male connectors.
2.6 Flywheel misaligned during Remove flywheel and inspect.
installation

Page 2A-32 90-859769R1 DECEMBER 2000


IGNITION

DFI Troubleshooting Guide (continued)


Symptom Cause Action
3. Engine idle is rough 3.1 Low air pressure in rail (less See 1.2
than 79 ± 2 psi while running)
3.2 Fouled spark plug Replace spark plug:
–If carbon bridges electrode gap
or if it is completely black.
–If it is not firing and is wet with
fuel.
Note: If spark plug is grey or com-
pletely black with aluminum specs,
this indicates a scuffed piston.
3.3 Failed direct injector Refer to specifications for ohm
test.
3.4 Failed fuel injector Refer to specifications for ohm
test.
3.5 Bad coil/weak spark Refer to specifications for ohm
test.
3.6 Flywheel misaligned during Remove flywheel and inspect.
installation
4. Engine idles fast (rpm 4.1 Broken fuel pressure regulator Measure fuel pressure. Remove
>700) or surges or tracker diaphragm and inspect diaphragms (a special
tool is required for assembly).
4.2 Fuel leak Check for fuel entering induction
manifold or air compressor inlet.
Fuel pump diaphragm leaking and/
or Vapor Separator flooding over.
4.3 Tracker Valve spring missing Inspect tracker valve for proper as-
sembly.
4.4 Improper set-up Check throttle cable & cam roller
adjustment.
5. Engine runs rough below 5.1 Fouled spark plug See 3.2
3000 rpm
5.2 Low air pressure in rail See 1.2
5.3 Throttle misadjusted Check throttle cam setup on induc-
tion manifold. Inspect linkage and
roller.
If throttle plate stop screws have
been tampered with, contact Mer-
cury Marine Service Department
for correct adjustment procedures.
5.4 Bad coil/weak spark See 3.5
5.5 TPS malfunction See 2.4
6. Engine runs rough above 6.1 Fouled spark plug See 3.2
3000 rpm
6.2 Speed Reduction See 7

6.3 Low air pressure in rails See 1.2


6.4 TPS malfunction See 2.4

90-859769R1 DECEMBER 2000 Page 2A-33


IGNITION

DFI Troubleshooting Guide (continued)


Symptom Cause Action
7. Speed Reduction (RPM 7.1 Low battery voltage Check battery and/or alternator.
reduced or limited to 3000) ECM requires 8 volts minimum Check electrical connections.
Fuel Pump requires 9 volts
7.2 Overheat condition (engine Check water pump impeller/cooling
and/or air compressor) system.
7.3 Oil pump electrical failure Check electrical connection.
7.4 TPS failure Check electrical connections.
If TPS fails, rpm is reduced
approximately 20% and the
ECM refers to the MAP sensor
8. Engine RPM reduced to Refer to Guardian System Section
idle only 2D

9. Loss of spark on 1 cylin- 9.1 Loose wire or pin in connectors Check connectors.
der between ECM and coil primary.
9.2 Faulty ignition coil. Replace coil.
9.3 Faulty spark plug. Replace spark plug.
9.4 Faulty spark plug wire Replace spark plug wire.
Note: Due to the long spark dura-
tion of this ignition system, the
DDT may indicate the incorrect cyl-
inder as having an ignition fault.
Example: If the DDT indicates an
ignition fault on cylinder #4, the
problem may be on the prior cylin-
der in the firing order – I.E. cylinder
number #3.

Page 2A-34 90-859769R1 DECEMBER 2000


IGNITION

Ignition Components Removal and Installation


Flywheel Cover Removal and Installation
REMOVAL
Remove flywheel cover by lifting off.

57783

INSTALLATION
Install flywheel cover by inserting the front pin and air tube into the rubber grommets and
then pushing the cover down onto the rear pin and air intake tube for the air compressor.

a
b

57783

a - Front Pin and Air Tube


b - Air Intake Tube

90-859769R1 DECEMBER 2000 Page 2A-35


IGNITION

Electronic Control Module (ECM)


REMOVAL
1. Disconnect ECM harness connectors.
2. Remove 3 bolts securing ECM.
e
d e
f
g
h

c a

57789
a - Electronic Control Module
b - Screw [Torque to 100 lb in. (11.5 Nm)]
c - Bracket
d - Screw [Torque to 70 lb in. (8.0 Nm)]
e - Bushing
f - Grommet
g - Bracket
h - Screw [Torque to 100 lb. in. (11.5 Nm)]

INSTALLATION
1. Secure ECM to powerhead with 3 bolts.
2. Install rubber pad and bracket for the fuse holder.
3. Reconnect harness connectors.

Page 2A-36 90-859769R1 DECEMBER 2000


IGNITION

Ignition Module (Coil)


REMOVAL
1. Disconnect coil harness and spark plug lead.
2. Loosen the electrical mounting plate to gain access to the rear locknuts.
3. Remove module attaching bolts.

a
g b

p
f
h e
c d

i
j k

57785

k d
c
a e
l
o
c
f
q

h m

i j
58701
a - Electrical Mounting i - Spark Plug Boot
Plate j - Spark Plug
b - Screw [Torque to 35 lb. k - Bushing
in. (4.0 Nm)] l - Screw [Torque to 60 lb.
c - Washer in. (7 N m)]
d - Rubber Grommet m - Coil Driver (3)
e - Bolts (4) – Torque to n - Screw [Torque to 60 lb.
20 lb. ft. (27 N·m). in. (7 N m)]
f - Ignition Coils (6) o - Ground Strap
g - Screw [Torque to 80 lb. p - Model 2000
in. (9.0 Nm)] q - Model 2001
h - Spark Plug Lead

90-859769R1 DECEMBER 2000 Page 2A-37


IGNITION

INSTALLATION
1. Fasten coils to electrical mounting plate as shown.
2. Reinstall electrical mounting plate.
3. Reconnect spark plug lead and coil harness.
Crank Position Sensor
REMOVAL
1. Disconnect harness.
2. Remove bolt securing sensor to bracket.
e

a
b
c
d

57796 56069
a - Screw [Torque to 50 lb. c - Bracket
in. (5.5 Nm)] d - Guide Bracket
b - Crank Position Sensor e - Screw [Torque to 100 lb. in. (11.5 Nm)]

INSTALLATION
1. Fasten sensor to bracket with bolt.
2. Set air gap @ 0.025 in. – 0.040 in. (0.635 mm – 1.01 mm)
3. Reconnect sensor harness.

Page 2A-38 90-859769R1 DECEMBER 2000


IGNITION

Throttle Position Sensor (TPS)


REMOVAL
1. Disconnect wiring harness.
2. Remove screws securing sensor to bracket.

d c

a f e

g
h
h i

a - Bracket e - Throttle Link


b - Sensor f - TPS Lever
c - Screw (3) – Torque to g - Screw [Torque to 70 lb. in. (8.0 Nm)]
20 lb. in (2.5 Nm) h - Bushing (2)
d - TPS Cover i - Grommet
INSTALLATION
1. Fasten sensors to bracket as shown.
2. Reconnect wiring harness.

90-859769R1 DECEMBER 2000 Page 2A-39

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