Ignition

Electrical
Section 2A - Ignition
Table of Contents 2
A
Ignition Specifications......................................2A-2 Camshaft Position Sensor......................2A-32
Special Tools - Ignition System........................2A-2 Cylinder Block Temperature Sensor.......2A-37
Electrical Components (200 through 275 HP In-line Cylinder Head Coolant Temperature Sensor
4-Stroke)..........................................................2A-6 ................................................................2A-41
Troubleshooting without Digital Diagnostic Terminal Manifold Absolute Pressure (MAP) Sensor
or Computor Diagnostic System......................2A-9 ................................................................2A-44
Troubleshooting with the Computer Diagnostic Manifold Intake Air Temperature (MAT) Sensor
Terminal (CDS) and Digital Diagnostic Terminal ................................................................2A-48
(DDT)...............................................................2A-9 Supercharger Outlet Temperature Sensor
Troubleshooting Guide...................................2A-11 ................................................................2A-52
Wire Color Code Abbreviations......................2A-13 Oil Pressure Sensor................................2A-56
Ignition Components......................................2A-13 Pitot Pressure Sensor.............................2A-59
Flywheel Cover.......................................2A-13 Block Water Pressure Sensor.................2A-63
Flywheel..................................................2A-14 Oil Temperature Sensor.........................2A-66
Propulsion Control Module (PCM)..........2A-19 Water in Fuel (WIF) Sensor....................2A-69
Ignition Pencil Coil..................................2A-24 Knock Sensor.........................................2A-72
Crankshaft Position Sensor (CPS).........2A-29 Fuses......................................................2A-75

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Ignition Specifications
Ignition Specifications
Full Throttle RPM (All Models) 5800 - 6400
Idle RPM (All Models) 550
Ignition Type Digital Inductive
Spark Plug Type NGK ILFR6G
Spark Plug Gap 0.8 mm (0.031 in.)
Spark Plug Hex Size 16 mm
Spark Plug Torque 27.5 Nm (19 lb. ft.)
Spark Plug Hole Size 14 mm
Firing Order 1-3-5-6-4-2
Ignition Timing @ Idle Not Adjustable; Controlled by PCM
Ignition Timing @ WOT Not Adjustable; Controlled by PCM
PCM Over Speed Limiter Activates @ 6500 RPM

Lubricant, Sealant, Adhesives

Tube Ref No. Description Where Used Part No.

136 Lubriplate SPO 255 Camshaft position sensor O-ring Obtain Locally

Special Tools - Ignition System

Digital Diagnostic Terminal (DDT) 91-823686A2

DIGITAL
Displays and stores real time sensor outputs. Performs self-test
procedures on select engine electrical systems
DIAGNOSTIC
TERMINAL

4011

DMT 2004 Digital Tachometer Multi-meter 91-892647A01

Measures RPM, ohms, amperes, AC and DC voltages; records

maximums and minimums simultaneously, and accurately
reads in high RFI environments.

4014

Software Cartridge 91-880118A20

Used with Digital Diagnostic Terminal 91-823686A2

SYSTEMS DIAGNOSTICS

4013

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Digital Diagnostic Terminal Reference

90-881204003
Manual

Technician Reference Manual

Lists procedures, specifications and sensor outputs that can be

monitored by using the Digital Diagnostic Terminal

Digital
Diagnostic
Terminal
Software Version 1.3

SmartCraft Systems
Printed in U.S.A. 90-881204003 603

6160

Adaptor Harness 84-822560A13

Data link harness between engine and Computer Diagnostic

System (CDS) or Digital Diagnostic Terminal (DDT)
5826

Extension Cable 3.05 mm (10 ft.) 84-825003A1

Data link extension harness between adaptor harness and

Digital Diagnostic Terminal

4012

Flywheel Puller/Lifting Ring 91-895343T01

Removes flywheel and used to install outboard on boat

4733

Flywheel Holding Tool 91-52344

Holds and/or turns the flywheel while making engine repairs,

also used to torque the flywheel or the engine coupler.

4738

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Ignition

Computer Diagnostic System Order through SPX

Monitors all electrical systems for proper function and
diagnostic purposes.
NOTE: For additional information, pricing or to order the
Computer Diagnostic System contact:
SPX Corporation
28635 Mound Rd.
Warren, MI 48092
or call:
4520
USA - 1-800-345-2233
Canada - 800-345-2233
Europe - 49 6182 959 149
Australia - (03) 9544-6222

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Notes:

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Ignition

Electrical Components (200 through 275 HP In-line 4-Stroke)

3
4 11 36
16
9 5
17
10
14
13
7
5 37
34
8
33

35
15 13

22
17 18
23
1 12 21

2
19 20

32

6
27

26
24

39 29

25

30
28
38
31
2462

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Electrical Components (200 through 275 HP In-line 4-Stroke)

Torque
Ref. No. Qty. Description Nm lb. in. lb. ft.
1 1 Base, Electrical box
2 1 Cover, Fuse box
3 1 Fuse cover
4 1 Seal
5 2 Strap
6 2 Hinge pin
7 1 Grommet
8 1 Bushing
9 7 Fuse, Mini (20 amp)
10 1 Nut, M8 17 150
11 1 Extractor, Fuse
12 1 Conduit
13 2 Screw, M8 x 13 9 80
14 1 Washer
15 1 Washer
16 1 Strap, Cover
17 5 Clip
18 1 PCM
19 1 Harness, Engine
20 4 Trim relay
21 4 Decal
22 1 Bracket
23 2 Screw, M5 x 6 4.5 40
24 1 Starter cable, 8-1/2 in.
25 1 Trim harness
26 1 Fuse harness
6 Cable tie, 8-1/2 in.
27
4 Cable tie, 8 in.
28 1 Battery cable, Negative (long)
29 1 CHI power harness
30 1 Fuse, 5 ampere
31 1 Harness, DBW boat adaptor
32 1 Nut 7.5 67
33 1 Screw, M8 x 35 24 17.5
34 1 Washer
35 1 Battery cable, Positive (long)
36 5 Nut, M8 17 150 12.5
37 1 Nut, 3/8-16, Battery cable - positive 13.5 120
38 1 Nut, 5/16-18, Battery cable - negative 13.5 120
39 1 Clip

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Electrical Components (200 through 275 HP In-line 4-Stroke)

3
4 11 36
16
9 5
17
10
14
13
7
5 37
34
8
33

35
15 13

22
17 18
23
1 12 21

2
19 20

32

6
27

26
24

39 29

25

30
28
38
31
2462

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Troubleshooting without Digital Diagnostic Terminal or Computor

Diagnostic System
Troubleshooting without the DDT or Computor Diagnostic System (CDS) is limited to
checking resistance on some of the sensors.
Typical failures usually do not involve the PCM. Connectors, set-up and mechanical wear
are most likely at fault.
• Verify iginition coils are securely installed (pushed in) into the spark plugs.
• 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.
IMPORTANT: Disconnecting a sensor while the engine is running may result in a fault
recording in the PCM Fault History. Use the DDT or CDS to view and clear the PCM fault
history when troubleshooting/repair is completed.
• If all cylinders exhibit similar symtoms, the problem is with a sensor or harness input
to the PCM.
• If problem is speed related or intermittant, it is probably connector or contact related.
Inspect connectors for corrosion, loose wires or pins pushed back into connector. Verify
connectors are properly seated.
• Inspect harness for damage: pinched or cut wires and chaffing.
• Secure grounds and all connections involving ring terminals (coat with Liquid
Neoprene).
• Inspect fuel pump harness connector for corrosion, loose wires or pins pushed back
into connector.
• Check fuel pump pressure.

Troubleshooting with the Computer Diagnostic Terminal (CDS) and

Digital Diagnostic Terminal (DDT)
The Computer Diagnostic Terminal (CDS) and Digital Diagnostic Terminal (DDT) are
designed to help technicians diagnose and repair Mercury Marine 2 and 4 cycle engines.

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Attach the diagnostic cable to the PCM diagnostic connector and plug in the software
cartridge. This will enable the technician to monitor sensors and PCM data values including
status switches.

5483

a - Diagnostic terminal connector (for CDS and DDT)

The PCM 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 Computer Diagnostic System or Digital Diagnostic Terminal reference manual
for complete diagnostic procedures.
Computer Diagnostic System (CDS) Order through SPX
Digital Diagnostic Terminal (DDT) 91-823686A2

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Troubleshooting Guide
1. Engine Cranks But Will Not Start
Cause Action
1.0 Weak battery or bad starter motor, battery voltage Replace/recharge battery
drops below 11 volts while cranking (PCM cuts out Inspect condition of starter motor
below 8 volts) (Fuel pump requires 9 volts) Check condition of battery terminals and cables
Key-on engine to verify that fuel pump runs for 5 seconds and then turns off.
If no fuel is available, fuel pump will run for as long as 180 seconds before
1.1 No fuel shutting off
NOTE: Running fuel pump for up to 180 seconds due to lack of fuel will
damage fuel pump.
Measure fuel pressure (valve on top of fuel rail)
1.2 Low fuel pressure
Fuel pressure should be 281 - 345 kPa (41 - 50 psi)
1.3 Flywheel key sheared or flywheel key not installed Remove flywheel and inspect
1.4 Blown fuse Inspect 20 ampere fuse in fuse holder and replace if blown
Listen for relay to click when the key switch is turned on. If relay does not
1.5 Main power relay not functioning
click, inspect harness and connector pins for damage
Remove fuel pump fuse (FUEL) fuse holder.
Remove spark plugs from each cylinder
Install Spark Gap Tester 91-63988A1 to each ignition coil.
1.6 Spark plugs1.
Crank engine or use DDT or CDS output load test for each ignition coil and
observe spark. If no spark is present, replace appropriate ignition coil. If spark
is present, replace spark plugs
Fuel injection system;
Listen for injector ticking when cranking or connect spare injector to each
respective harness
Ignition system:
Install spark gap tool between ignition coil and engine ground. Check for
purple/white colored spark while cranking engine
1.7 PCM not functioning Check for battery voltage (red/yellow lead) at ignition coils
Check for blown 20 ampere fuse
Check for battery voltage to fuse from main power relay (purple lead)
Check for shorted stop wire (black/yellow lead).
Power supply:
Inspect and clean remote control male and female harness connector
Defective PCM.
Check that magnet is not missing from end of sensor
Perform ohm resistance check of sensor - (300 to 350 ohms between red and
1.8 Crank position sensor not functioning
white leads)
Defective crank position sensor.

2. Engine Will Not Crank

Cause Action
Use Computer Diagnostic System (CDS) to determine proper functioning of
2.0 Defective PCM
ETC
Use Computer Diagnostic System (CDS) to determine proper functioning of
2.1 Defective main power relay
main power relay
2.2 Main power relay fuse blown Check for blown 20 ampere fuse
2.3 Lanyard stop switch in wrong position Reset lanyard stop switch

1. Spark jumping the gap from all 6 cylinders at the same time in the spark gap tool may cause interference in the PCM. The interference
may cause the absence of spark on some cylinders and a false diagnosis of a no spark condition. Crank the engine over with only
one spark plug wire connected to spark gap tool at a time or use the DDT or CDS to fire one cylinder at a time

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3. Engine Cranks, Starts and Stalls

Cause Action
3.0 Low fuel pressure in fuel rail See 1.3
3.1 Abnormally high friction in engine Check for scuffed piston or other sources of high friction
See 1.3
3.2 Air in fuel system/lines
Crank and start engine several times to purge
Use Computer Diagnostic System (CDS) to determine proper functioning of
3.3 Defective electronic throttle control ETC
Replace electronic throttle control
3.4 Remote control to engine harness connection is
Clean and inspect male and female connections
poor
3.5 Flywheel misaligned during installation Flywheel key sheared or missing

4. Engine Idle is Rough

Cause Action
Replace spark plug:
If carbon bridges electrode gap or if it is completely black
4.1 Fouled spark If it is not firing and is wet with fuel
NOTE: If spark plug is gray or completely black with aluminum specs, this
indicates a scuffed piston
4.2 Failed fuel injector Refer to specifications for ohm test
4.3 Bad ignition coil/weak spark Refer to specifications for ohm test
4.4 Flywheel misaligned during installation Flywheel key sheared or missing
4.5 Engine not running all cylinders Inspect for mechanical damage

5. Engine Idles Fast (RPM Above 700) or Surges

Cause Action
Use Computer Diagnostic System (CDS) to determine proper functioning of
5.1Defective electronic throttle control ETC
Replace electronic throttle control

6. Engine Runs Rough Below 3000 RPM

Cause Action
Replace spark plug:
If carbon bridges electrode gap or if it is completely black
6.1 Fouled spark plug If it is not firing and is wet with fuel
NOTE: If spark plug is gray or completely black with aluminum specs, this
indicates a scuffed piston
Measure fuel pressure (valve on top of fuel rail).
6.2 Low fuel pressure in fuel rail
Fuel pressure should be 281 - 345 kPa (41 - 50 psi)
Use Computer Diagnostic System (CDS) to determine proper functioning of
6.3 Defective electronic throttle control ETC.
Replace electronic throttle control
6.4 Bad ignition coil/weak spark Refer to specifications for ohm test
6.5 Fuel system module float fails in conjuction with Excess fuel will enter air intake. Use CDS system to determine proper function
failure of vent canister switch of vent canister switch
6.6 Engine not running on all cylinders Inspect for mechanical damage

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7. Engine Runs Rough Above 3000 RPM.

Cause Action
Replace spark plug:
7.1 Fouled spark plug If carbon bridges electrode gap or if it is completely black
If it is not firing and is wet with fuel
Use Computer Diagnostic System (CDS) to determine proper functioning of
7.2 Defective electronic throttle control ETC
Replace electronic throttle control
Measure fuel pressure (valve on top of fuel rail).
7.3 Low fuel pressure in fuel rail
Fuel pressure should be 281 - 345 kPa (41 - 50 psi)
Refer to Smartcraft gauges for low oil, engine overheat or sensor/actuator out
7.4 Speed reduction
of range. DDT or CDS will help identify proper functioning of sensors/actuator
7.5 Defective crank position sensor Refer DDT or CDS for fault identification

8. Speed Reduction (RPM Reduced to Idle)

Cause Action
8.1 Engine communication/remote control failure Refer CDS for fault identification
8.2 Sensor/actuator is out of range Refer DDT or CDS for fault identification
8.3 Low oil pressure Check oil dipstick for proper oil level
8.4 Engine overheat Check engine cooling system for proper functioning

9. Speed Reduction (RPM Reduced to 75%)

Cause Action
9.1 Sensor/actuator is out of range Refer DDT or CDS for fault identification
9.2 Low oil pressure Check oil dipstick for proper oil level
9.3 Engine overheat Check engine cooling system for proper functioning

Wire Color Code Abbreviations

Wire Color Abbreviations
BLK Black BLU Blue
BRN Brown GRY Gray
GRN Green ORN or ORG Orange
PNK Pink PPL or PUR Purple
RED Red TAN Tan
WHT White YEL Yellow
LT or LIT Light DK or DRK Dark

Ignition Components
Flywheel Cover
The purpose of the flywheel cover is to provide basic protection against accidental contact
with the flywheel, starter motor pinion gear and alternator/supercharger drive belt while the
engine is running.

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Removal of the flywheel cover provides access to the flywheel, alternator/supercharger

drive belt, starter motor pinion gear, cylinder block water temperature sensor, cylinder block
water pressure sensor, crankshaft position sensor, oil temperature sensor and oil pressure
sensor.

3837

a - Flywheel cover

The flywheel cover is secured to the engine by four rubber grommets pressed over four
locating pins on the cylinder block. To remove cover, lift cover off of locating pins. To
reinstall cover, align flywheel cover grommets with locating pins and push down until cover
seats against locating pins.
Flywheel
The flywheel is weighted and balanced to improve engine running characteristics. The
flywheel is secured to the crankshaft by a bolt (M20 x 68) (30 mm socket) and washer. The
flywheel has two ring gears. The top ring gear is used with the starter motor to start the
engine. The lower ring gear has 54 teeth with 6 teeth missing at specific locations. As the
lower ring gear passes the crankshaft position sensor, an electrical pulse is generated and
sent to the propulsion control module (PCM). The frequency of these pulses in conjunction
with the missing tooth locations on the ring gear provides crankshaft location information
to the PCM. The PCM will use this information to regulate ignition and fuel injector timing.
FLYWHEEL REMOVAL
The flywheel has three threaded holes which are used with Flywheel Puller/Lifting Ring to
remove the flywheel. These three holes can also be used with the Flywheel Puller/Lifting
Ring to remove or install the complete outboard on a boat.
Flywheel Puller/Lifting Ring 91-895343A01

! CAUTION
Do not use heat or strike the flywheel to aid in the flywheel removal process as the
flywheel may be damaged.

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 Ignition

1. Remove flywheel cover.

3837

a - Flywheel cover

2. Remove flywheel bolt cap from flywheel.

5407
a - Cap

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Ignition

3. Use a breaker bar to release alternator/supercharger belt tension and remove belt from
flywheel.

d
3736

a - Alternator c - Tensioner release slot

b - Tensioner pulley d - Supercharger

4. Hold the flywheel with Flywheel Holding Tool. Loosen the flywheel bolt four turns out
from a light seat.

5408

a - Flywheel Holding Tool

Flywheel Holding Tool 91-52344

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5. Install the flywheel puller base to the flywheel with three bolts.

5409
a - Puller base b - Bolts

Flywheel Puller/Lifting Ring 91-895343T01

6. Thread the flywheel puller adapter into the puller base until it bottoms out.

5410
a - Puller adapter

Flywheel Puller/Lifting Ring 91-895343T01

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7. Thread the flywheel puller bolt into the flywheel puller adapter.

5411
a - Puller bolt

Flywheel Puller/Lifting Ring 91-895343T01

8. Tighten the flywheel puller bolt until the flywheel becomes loose and remove flywheel.
FLYWHEEL INSTALLATION
IMPORTANT: Clean flywheel/crankshaft taper with solvent and assemble dry.
1. Install flywheel key in crankshaft.

5463
a - Flywheel key

2. Align flywheel with key and install flywheel onto crankshaft.

3. Secure flywheel with bolt and washer. Use Flywheel Holding Tool to hold flywheel and
torque bolt to specification.
Flywheel Puller/Lifting Ring 91-895343T01
Flywheel Holding Tool 91-52344

Description Nm lb. in. lb. ft.

First 60 44
Flywheel bolt
Final 120 133

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4. Using breaker bar in tensioner release slot, reinstall alternator/supercharger belt.

d
3736

a - Alternator c - Tensioner release slot

b - Tensioner pulley d - Supercharger

5. Install flywheel cover.

Propulsion Control Module (PCM)
The propulsion control module requires 8 VDC minimum to operate. If the PCM should fail,
the engine will stop running.
The inputs to the PCM can be monitored and tested by the Digital Diagnostic Terminal or
by using the Computer Diagnostic System available from the SPX Corporation in Warren,
Michigan.

4711

a - Propulsion control module (PCM)

Digital Diagnostic Terminal 91-823686A2

Computer Diagnostic System Order from SPX

The PCM controls the following functions:

• Electronic shift control
• Electronic throttle control
• Electronic boost control

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Ignition

• Main power relay

• Fuel injectors
• Ignition coils
• Power steering
• Vent canister purge valve
• Trim up
• Trim down
• Start relay
• Lift fuel pump
• Diagnostics
• Engine guardian
• Tachometer link (analog tachometer output or link gauge driver)
The PCM operates in four modes; Power Off, Stall, Crank and Run. The PCM also provides
for a smooth throttle response between varying throttle positions and engine loads. A
Warm-up Mode is integrated with the Run Mode and disengaged after the engine
accumulates a given amount of power.
Power Off Mode - With the key switch "OFF", PCM function does not exist. Power, 12 VDC,
is available from the battery at the starter battery terminal, fuses, positive cable terminal in
the electrical box and at the alternator.
Stall Mode - With the key switch in the "RUN" position, the PCM is energized and powers
the main power relay and the fuel pump relay for five seconds. It also provides 5 VDC
power to the sensors. The PCM records barometric pressure from the MAP sensor, intake
air temperature from the manifold intake air temperature (MAT) sensor and coolant
temperature from the coolant temperature sensors. The PCM will use this information to
establish a warm-up strategy that will control fuel delivery and engine speed during
warm-up and idle.
Crank Mode - When the key switch is turned to the "START" position, the start relay and
the starter solenoid will be energized and battery power will turn the starter motor. With the
engine rotating, a pulse will be generated at the crankshaft sensor which provides the PCM
engine speed information. The PCM will then supply power to the fuel pump and ignition
coils through the main power relay and the fuel pump relay.
Run Mode - At approximately 500 RPM, the PCM will transition to the Run Mode.
• The warm-up strategy will continue to adjust engine speed with the fuel injector pulse
width and engine spark advance until the engine accumulates a given amount of power.
• The camshaft position sensor provides cylinder compression phasing information to
the PCM for sequential fuel injection.
• The manifold air temperature (MAT), throttle position and manifold absolute pressure
(MAP) are monitored to determine proper spark timing, boost control and the fuel needs
necessary to develop the amount of power asked for by the operator.

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PCM REMOVAL
1. Release straps securing electrical box cover.

5520

a - Electrical box cover b - Straps

2. Remove terminator connector.

3. Disconnect three harness connectors.

5518

a - Terminator connector b - Harness connectors

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4. Remove screw securing PCM and remove PCM.

b
5519
a - PCM attaching screw b - PCM

PCM INSTALLATION
1. Install PCM into electrical box and secure PCM with screw. Torque screw to
specification.

b
5519
a - PCM attaching screw b - PCM

Description Nm lb. in. lb. ft.

PCM attaching screw (M8 x 13) 9 80

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 Ignition

2. Reinstall terminator connector and three harness connectors.

5518

a - Terminator connector b - Harness connectors

3. Close electrical box cover and secure cover with two straps.

5520

a - Cover b - Straps

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Ignition

Ignition Pencil Coil

The engine ignition system utilizes six ignition coils, one for each cylinder. The ignition coils
are inductive type coils with each coil having its own integrated driver. Battery voltage is
present at each coil (red/yellow lead) whenever the main power relay is activated. Each
coil is triggered by a 5 VDC digital pulse from the Propulsion Control Module (PCM). Each
ignition coil is capable of producing a 40,000 volt spark.

4710

a - Ignition coil (6 each) (1 for each cylinder)

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IGNITION COIL TEST

BLK
BLK
BLK
1 9 17
RED/YEL
BLK
GRN/BRN

C C12 GRN/PUR
C7 GRN/YEL
C8 GRN/RED
a
RED/YEL
BLK
GRN/RED
8 16 24
1 9 17
B2 GRN/BRN

B9 GRN/BLU RED/YEL
b
B B10 GRN/ORG

B4 YEL/PUR
j

BLK

BLK
8 16 24 c
1 12 22 BLK

GRN/BLU
GRN/PUR

RED/YEL
A BLK
GRN/YEL

BLK RED/YEL d
BLK
11 21 32
BLK

BLK
BLK

86
YEL/PUR

i 30 87 RED/WHT e
85
RED RED BLK
BLK
BLK
RED
f
RED/YEL

RED/YEL
RED/WHT
RED/YEL
h RED/YEL
RED/YEL
RED/YEL g
RED/YEL
RED/YEL 5045

a- Cylinder #1 ignition coil f- Cylinder #6 ignition coil

b- Cylinder #2 ignition coil g- Terminal junction
c- Cylinder #3 ignition coil h- Fuse holder
d- Cylinder #4 ignition coil i- Main power relay
e- Cylinder #5 ignition coil j- Propulsion control module (PCM)

! WARNING
To prevent electrical shock, do not touch any ignition or wiring components when starting
or running the engine.

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Ignition

Condition: With key switch in the "RUN" position and the engine "OFF", power (battery
voltage) is only available (red/yellow lead) for three seconds when no crank position sensor
signal is being received by the Propulsion Control Module (PCM).
1. Disconnect the connector from the coil being tested.
2. Perform a visual inspection of the pins at the coil and the wires coming to the connector.
Look for broken, bent, and corroded pins at the coil; and loose, broken, or corroded
wires at the connector.
NOTE: Shake or move the harness and connector when performing the following tests. If
the voltmeter readings vary during the tests, inspect for a broken, loose or corroded wire.
Repair the problem wire and retest the circuit as follows.
3. Connect a voltmeter across the red/yellow and the black wires at the connector.
NOTE: The main power relay must be on for 12 VDC (battery voltage) to be present at the
red/yellow wire. If voltage is not present, main power relay may be defective or 20 ampere
fuse in fuse holder is blown.
4. The voltmeter must read 12 VDC (battery voltage), if not, connect the voltmeter across
the red/yellow wire and the engine ground. If the voltmeter indicates 12 VDC (battery
voltage), there is an open in the ground circuit.
NOTE: All coil ground wires are spliced together and connected to a common engine
ground. The most likely failure would be at the connector or in between the connector and
the engine ground.

BLK a b c
BLK
BLK

RED/YEL
BLK
GRN/BRN

5046

a - + 12 volt (red/yellow) c - Output from PCM (5 volt digital

b - Ground (black) pulse)

5. If the voltmeter does not indicate 12 VDC (battery voltage), there is an open circuit
between the splice point and the connector (red/yellow lead).
NOTE: All 12 VDC power wires for the coils are spliced together. Unless all the coils have
failed, the most likely failure would be at the splice point, the connector or in between the
connector and the splice point.
6. Check the input wire (5 VDC) for continuity between the connector and the PCM. Repair
if needed.
7. Remove the coil and install a spark tester between the high voltage tower and ground
to see if there is a strong blue spark. If the spark is weak or is not blue in color, replace
the coil and retest.
IGNITION COIL OHM TEST
NOTE: Perform coil ohm tests using a DMT 2004 or equivalent ohm meter.
DMT 2004 91-892647A01

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 Ignition

NOTE: Some meter brands may require the test lead polarity to be reversed in order to
obtain correct ohm specifications.

c b
a

4597

a - Red/yellow c - Green/stripe
b - Black

Ignition Coil Ohm Test

Black Ohm Meter Lead
Red Ohm Meter Lead Electronic spark
Ground Battery + Secondary
trigger
Terminal Wire Color green with stripe black red/yellow spring/output
Electronic spark green with 4.3 - 5.3 kΩ 2 - 4 M ohms
n/a infinite (O.L.)
trigger stripe (switching circuit) (power circuit)
4.3 - 5.3 kΩ 2 - 4 M ohms
Ground black n/a infinite (O.L.)
(switching circuit) (power circuit)
Battery + red/yellow infinite (O.L.) infinite (O.L.) n/a infinite (O.L.)
Secondary spring/output infinite (O.L.) infinite (O.L.) infinite (O.L.) n/a

IGNITION COIL REMOVAL

1. Disconnect electrical harness from coil.

90-896580200 JULY 2004 Page 2A-27

Ignition

2. Remove screw securing coil.

b
a

5143
a - Electrical harness c - Screw
b - Ignition coil

3. Inspect coil sealing ring for cuts or abrasion. If sealing ring is damaged, replace ring.

a 5154

a - Ignition coil b - Sealing ring

IGNITION COIL INSTALLATION

1. Insert ignition coil into spark plug access hole in cylinder head. Secure ignition coil with
screw. Torque screw to specification.

Page 2A-28 90-896580200 JULY 2004

 Ignition

2. Reconnect electrical harness to ignition coil.

b
a

5143
a - Electrical harness c - Ignition coil screw
b - Ignition coil

Description Nm lb. in. lb. ft.

Ignition coil screw (M6 x 25) 8 70

Crankshaft Position Sensor (CPS)

The crankshaft position sensor is located at the top of the cylinder block next to the flywheel.
The sensor contains a magnet which is positioned next to the flywheel's lower ring gear.
This ring gear has 54 teeth with six gaps (or missing teeth) at specific locations. The close
proximity of the crank position sensor magnet to the 54 teeth allows a magnetic field to be
created each time a tooth passes the sensor. This field collapses and creates a AC voltage
pulse. This AC pulse is sent to the propulsion control module (PCM). The timing and
frequency of these pulses allows the PCM to regulate ignition and fuel injector timing. If
the crank position sensor fails, the engine will run rough or stop running.

c
5522

a - Crank position sensor c - Harness connector

b - Attaching screws

CRANKSHAFT POSITION SENSOR TEST

NOTE: It is recommended that the flywheel cover and flywheel be removed to gain access
to the crank position sensor.

90-896580200 JULY 2004 Page 2A-29

Ignition

1. Perform a visual inspection of the sensor. The tip of the sensor must be flush across
the end; if not, replace the sensor.
2. The tip of the sensor must be clean. There should be no metal debris (ring gear filings)
attached to the sensor tip.
NOTE: There is a magnet mounted in the sensor's tip. If the magnet is missing, the sensor
will not operate properly.
3. Inspect the flywheel timing wheel for:
• Excessive corrosion
• The teeth should have square edges
• There should only be one missing tooth on either side of the two tooth, three tooth
or four tooth groups.
4. Replace the flywheel if it does not meet inspection requirements.
5. Perform a visual inspection of the pins at the sensor and the wires coming from the
connector. Look for broken, bent or corroded pins at the sensor and loose, broken or
corroded wires at the connector.
6. Disconnect the connector from the sensor. Measure the resistance across the sensor
pins. Replace the sensor if out of specification.
Crankshaft Position Sensor
Resistance 300 - 350 ohms

NOTE: If engine problem occurs above 3000 RPM (runs rough, no high RPM), ohm test
of crank position sensor may be good but sensor can still be defective.

c d

a 5905

a - Magnet c - Pin 1 (red)

b - Crankshaft position sensor d - Pin 2 (white)

7. Reconnect the harness to the sensor. Disconnect the B connector from the PCM and
measure the resistance across pins 5 and 13. Resistance must be within specification.
If not, repair the wiring between the PCM and the sensor.

Page 2A-30 90-896580200 JULY 2004

 Ignition

Crankshaft Position Sensor

Resistance 300 - 350 ohms

1 9 17

8 16 24
1 9 17
B5
WHT

B
RED
e B13

8 16 24
c d
1 12 22

b
11 21 32

5904
a
a - Magnet d - Pin 2 (white)
b - Crankshaft position sensor e - PCM
c - Pin 1 (red)

8. If the tests in the preceeding steps are satisfactory, replace the PCM.
CRANKSHAFT POSITION SENSOR REMOVAL
1. Remove flywheel cover and flywheel.
2. Disconnect sensor harness connector.

90-896580200 JULY 2004 Page 2A-31

Ignition

3. Remove two screws securing sensor and remove sensor.

c
5522

a - Crank position sensor c - Harness connector

b - Attaching screws

CRANKSHAFT POSITION SENSOR INSTALLATION

1. Position sensor on engine and secure sensor with two screws. Torque screws to
specification.
2. Connect sensor harness to sensor.
Description Nm lb. in. lb. ft.
Screw (M5 x 16) 5 45

Camshaft Position Sensor

The camshaft position sensor is located at the top of the valve cover. It supplies the PCM
with timing and RPM information. When the camshaft position sensor is functioning, the
PCM controls the fuel injection in a sequential, multi-port timing strategy. When the
camshaft position sensor has failed, the PCM controls the fuel injection in a batch fire
strategy. The engine may not start as quickly and the Guardian System will limit power to
75%. The PCM will generate and store a failure code when the camshaft position sensor
fails.
A sequential firing strategy means that the fuel injectors fire once per engine cycle (every
two crankshaft revolutions). The fuel injection event is complete just before the intake valve
closes and the coils fire only once per engine cycle. Sequential is ideal for emissions,
driveability transients and slight horsepower advantages.

Page 2A-32 90-896580200 JULY 2004

 Ignition

Batch fire strategy means that the fuel injectors fire every revolution (1/2 the fuel needed
per revolution/per cycle) and the coils also fire every revolution (wasted spark). This
strategy does not consider the phase of the engine; i.e. whether a particular cylinder is on
a compression or exhaust stroke. Batch fire engines do not require a camshaft position
sensor and are less expensive to build.

5540
a - Camshaft position sensor

CAMSHAFT POSITION SENSOR TEST

The cam position sensor output to the PCM will change from +5 volts to 0 volts each time
the number 1 or number 6 cylinder reaches top dead center. This voltage change can be
monitored by the Computer Diagnostic System (CDS). If the voltage change is not
occurring, shake or move the harness by hand. If the voltage readings vary, look for a
broken, loose or corroded wire.
1. Disconnect the connector from the sensor.
2. Perform a visual inspection of the pins at the sensor and the wires coming from the
connector. Look for broken, bent, or corroded pins at the sensor and loose, broken, or
corroded wires at the connector.
3. If the wiring appears serviceable, perform an ohm check on the sensor. The normal
resistance for the cam sensor at 21° C (70° F) is:
• Between pins A and B is 23.2 mohms
• Between pins B and C is 23.2 mohms

c b

5903

a - Pin B (black/orange) c - Pin A (red/white)

b - Pin C (purple/yellow) d - Camshaft position sensor

90-896580200 JULY 2004 Page 2A-33

Ignition

4. If the ohm check of the camshaft position sensor indicates that the sensor is
serviceable, perform an ohm check of the sensor wiring between the sensor connector
and the PCM as follows:
• PCM connector B pin 6 to red/white pin of sensor connector is less than 1 ohm.
• PCM connector A pin 22 to black/orange pin of sensor connector is less than 1
ohm.
• PCM connector A pin 23 to purple/yellow pin of sensor connector is less than 1
ohm.

Page 2A-34 90-896580200 JULY 2004

 Ignition

NOTE: All sensor ground wires are spliced together and connect to the PCM at pin 22 of
the A connector. Unless there are multiple sensor failures, the most likely failure would be
at the splice point, connector, or in between the connector and the splice point.

d
1 9 17
a
C
c b

8 16 24
1 9 17

f
B B6
RED/WHT

8 16 24

1 12 22
A22
BLK/ORG
PUR/YEL
A23

PUR/YEL

11 21 32
BLK/ORG

M L K J HGF E D C B A

5896

a - Pin B (black/orange) d - Camshaft position sensor

b - Pin C (purple/yellow) e - Splice saver SP4
c - Pin A (red/white) f - PCM

5. If the wiring is serviceable, replace the PCM and recheck the sensor function using the
Computer Diagnostic System.

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Ignition

CAMSHAFT POSITION SENSOR REMOVAL

1. Disconnect sensor harness from sensor.
2. Remove screw securing camshaft sensor and remove sensor.

c
a
b

4569

a - Sensor harness c - Camshaft position sensor

b - Sensor attaching screw

CAMSHAFT POSITION SENSOR INSTALLATION

1. Apply Lubriplate SPO 255 to sensor O-ring.
2. Install sensor into valve cover.
3. Secure sensor with screw. Torque screw to specification.
4. Connect harness to sensor.

c
136

a
b

5879

a - Harness connector c - Camshaft position sensor

b - Screw

Tube Ref No. Description Where Used Part No.

136 Lubriplate SPO 255 Camshaft position sensor O-ring Obtain Locally

Description Nm lb. in. lb. ft.

Screw (M6 x 16) 8 70

Page 2A-36 90-896580200 JULY 2004

 Ignition

Cylinder Block Temperature Sensor

The cylinder block temperature sensor is located at the top of the cylinder block, aft of the
flywheel. It is a thermistor immersed in the engine coolant path. It supplies the PCM with
engine temperature information. The PCM adjusts the timing and the amount of fuel
delivered according to the water temperature in the cylinder block. Low coolant temperature
produces high resistance, while high temperature causes low resistance. The normal
resistance value for the sensor at 21° C (70° F) is 11.3 kΩ.

4574
a - Temperature sensor b - Sensor harness connector

CYLINDER BLOCK TEMPERATURE SENSOR TEST

The Computer Diagnostic System (CDS) and the Digital Diagnostic Terminal (DDT) will
both determine the proper functioning of the cylinder block temperature sensor by providing
a numerical readout of the block temperature before and after the engine is started. With
the engine not running, block temperature should be approximately the same as the
ambient air temperature. After the engine is started, the temperature sensor should indicate
a rise in block temperature to approximately 60° - 70° C (140° - 158° F). Outside air
temperature and the temperature of the water that the engine is operating in will directly
affect the engine block temperature.
1. With the engine running and the CDS or DDT connected to the engine, if the block
temperature sensor does not appear to be indicating a temperature change, shake or
move the sensor harness and connector. If the temperature begins to change, look for
a broken, loose or corroded wire.
Computer Diagnostic System (CDS) Order from SPX
Digital Diagnostic Terminal 91-823686A2
2. Disconnect the connector from the sensor.

90-896580200 JULY 2004 Page 2A-37

Ignition

3. Perform a visual inspection of the pins at the sensor and the wires coming from the
connector. Look for broken, bent or corroded pins at the sensor and loose, broken or
corroded wires at the connector.

b a

5927

a - Pin A (tan/green) c - Cylinder block temperature sensor

b - Pin B (black/orange)

4. The sensor can be tested with an ohmmeter by disconnecting it from the harness and
heating or cooling the end of the sensor at a controlled temperature. If the readings do
not match those in the table, replace the sensor and retest.
Block Temperature Sensor Ohm Test
Degree Centigrade -10 21 38 65
Degree Fahrenheit 14 70 100 150
KΩ 20 kΩ 11.3 kΩ 5.7 kΩ 2.1 kΩ
5. If the ohm check of the block temperature sensor indicates that the sensor is
serviceable, perform and ohm check of the sensor wiring between the sensor connector
and the PCM as follows:
• PCM connector A pin 22 to pin B of sensor connector is less than 1 ohm.
• PCM connector A pin 15 to pin A of sensor connector is less than 1 ohm.

Page 2A-38 90-896580200 JULY 2004

 Ignition

NOTE: All sensor ground wires are spliced together and connect to the PCM at pin 22 of
the A connector. Unless there are multiple sensor failures, the most likely failure would be
at the splice point, connector or in between the connector and the splice point.

1 9 17

C
b a

8 16 24
1 9 17

TAN/GRN
BLK/ORG
e 8 16 24

1 12 22
A22
BLK/ORG

A15
TAN/GRN
A

11 21 32
BLK/ORG

M L K J H G F E DC B A

SP4
5205

a - Pin A (tan/green) d - Splice saver SP4

b - Pin B (black/orange) e - PCM
c - Cylinder block temperature sensor

6. If the wiring is serviceable, replace the PCM and recheck the sensor function using the
Computer Diagnostic System or Digital Diagnostic Terminal.

90-896580200 JULY 2004 Page 2A-39

Ignition

Computer Diagnostic System (CDS) Order from SPX

Digital Diagnostic Terminal 91-823686A2

CYLINDER BLOCK TEMPERATURE SENSOR REMOVAL

1. Remove flywheel cover.
2. Disconnect sensor harness connector.
3. Remove sensor from cylinder block.

4574
a - Temperature sensor b - Harness connector

CYLINDER BLOCK TEMPERATURE SENSOR INSTALLATION

1. Inspect sensor O-ring for cuts or abrasions. Replace O-ring as required.
2. Install sensor with O-ring into cylinder block. Torque sensor to specification.
Description Nm lb. in. lb. ft.
Temperature sensor 15 133
3. Connect sensor harness to sensor.
4. Install flywheel cover.

Page 2A-40 90-896580200 JULY 2004

 Ignition

Cylinder Head Coolant Temperature Sensor

The head coolant temperature sensor is a thermistor immersed in the engine coolant
stream. It is located on the starboard side of the head near the top of the head. It supplies
the PCM with temperature information. The PCM adjusts the timing and the amount of fuel
delivered according to the water temperature in the head. Low coolant temperature
produces high resistance, while high temperature causes low resistance. The normal
resistance value for the sensor at 21° C (70° F) is 11.3 kΩ.

4575

a - Cylinder head temperature sensor b - Harness connector

CYLINDER HEAD COOLANT TEMPERATURE SENSOR TEST

The Computer Diagnostic System (CDS) and the Digital Diagnostic Terminal (DDT) will
both determine the proper functioning of the cylinder head temperature sensor by providing
a numerical readout of the head temperature before and after the engine is started. With
the engine not running, cylinder head temperature should be approximately the same as
the ambient air temperature. After the engine is started, the temperature sensor should
indicate a rise in head temperature to approximately 40° to 50° C (104° to 122° F). Outside
air temperature and the temperature of the water that the engine is operating in will directly
affect the engine block temperature.
1. With the engine running and the CDS or DDT connected to the engine, if the head
temperature sensor does not appear to be indicating a temperature change, shake or
move the sensor harness and connector. If the temperature begins to change, look for
a broken, loose or corroded wire.
Computer Diagnostic System (CDS) Order from SPX
Digital Diagnostic Terminal (DDT) 91-823686A2
2. Disconnect the connector from the sensor.
3. Perform a visual inspection of the pins at the sensor and the wires coming from the
connector. Look for broken, bent or corroded pins at the sensor and loose, broken or
corroded wires at the connector.

90-896580200 JULY 2004 Page 2A-41

Ignition

4. The sensor can be tested with an ohmmeter by disconnecting it from the harness and
heating or cooling the end of the sensor at a controlled temperature. If the readings do
not match those in the table, replace the sensor and retest.

b a

5907

a - Pin A (green) c - Cylinder head coolant temperature

b - Pin B (black/orange) sensor

Cylinder Head Temperature Sensor Ohm Test

Degree Centigrade -10 21 38 65 95
Degree Fahrenheit 14 70 100 150 203
KΩ 20 kΩ 11.3 kΩ 5.67 kΩ 2.05 kΩ 800 Ω
5. If the ohm check of the cylinder head coolant temperature sensor indicates that the
sensor is serviceable, perform and ohm check of the sensor wiring between the sensor
connector and the PCM as follows:
• PCM connector A pin 22 to pin B of sensor connector is is less than 1 ohm.
• PCM connector A pin 16 to pin A of sensor connector is less than 1 ohm.

Page 2A-42 90-896580200 JULY 2004

 Ignition

NOTE: All sensor ground wires are spliced together and connect to the PCM at pin 22 of
the A connector. Unless there are multiple sensor failures, the most likely failure would be
at the splice point, connector or in between the connector and the splice point.

1 9 17
c

8 16 24
1 9 17
b a

1 9 17
8 16 24
e d

8 16 24 A B C DEF GH J K LM

1 12 22
BLK/ORG
A22
BLK/ORG

A16 GRN

11 21 32
5906
a - Pin A (green) d - Splice saver SP5
b - Pin B (black/orange) e - PCM
c - Cylinder head temperature sensor

6. If the wiring is serviceable, replace the PCM and recheck the sensor function using the
Computer Diagnostic System or Digital Diagnostic Terminal.
Computer Diagnostic System (CDS) Order from SPX
Digital Diagnostic Terminal (DDT) 91-823686A2

CYLINDER HEAD COOLANT TEMPERATURE SENSOR REMOVAL

1. Disconnect sensor harness connector.

90-896580200 JULY 2004 Page 2A-43

Ignition

2. Remove sensor from cylinder block.

4575

a - Cylinder head temperature sensor b - Harness connector

CYLINDER HEAD COOLANT TEMPERATURE SENSOR INSTALLATION

1. Inspect sensor O-ring for cuts or abrasions. Replace O-ring as required.
2. Install sensor with O-ring into cylinder block. Torque sensor to specification.
Description Nm lb. in. lb. ft.
Temperature sensor 15 133
3. Connect sensor harness to sensor.
Manifold Absolute Pressure (MAP) Sensor
The manifold absolute pressure (MAP) sensor measures the changes in the intake
manifold pressure. It is located at the top of the intake manifold. When the key is turned
"ON" the MAP sensor reads the ambient atmospheric pressure. This information is used
by the PCM as an indication of altitude and is referred to as BARO. The manifold absolute
pressure will change as a result of engine load and speed changes.

4576

a - MAP sensor b - Harness connector

MANIFOLD ABSOLUTE PRESSURE SENSOR TEST

The Computer Diagnostic System (CDS) and the Digital Diagnostic Terminal (DDT) will
both determine the proper functioning of the MAP sensor by providing a numerical readout
of the sensor after the engine is started.

Page 2A-44 90-896580200 JULY 2004

 Ignition

Manifold Absolute Pressure Sensor Readings

@ idle 35 to 48 kPa (5 to 7 psi)
@ wide open throttle 195 to 200 kPa (28 to 29 psi)

1. With the engine running and the CDS or DDT connected to the engine, if the MAP
sensor does not appear to be indicating a pressure change, shake or move the sensor
harness and connector. If the pressure begins to change, look for broken, loose, or
corroded wires.
2. Disconnect the connector from the sensor.
3. Perform a visual inspection of the pins at the sensor, and the wires coming from the
connector. Look for broken, bent, or corroded pins at the sensor; and loose, broken, or
corroded wires at the connector.
4. An ohm check of the MAP sensor can be made by disconnecting the sensor harness
and measuring the resistance between pins A, B and C. The normal resistance values
for the MAP sensor at 21° C (70° F) are:
• Between pin A and pin B is 9.33 kΩ.
• Between pin A and pin C is 3.89 kΩ.

a b
5909

a - Pin A (black/orange) c - Pin C (yellow)

b - Pin B (purple/yellow) d - MAP sensor

5. If the ohm check of the MAP sensor indicates that the sensor is serviceable, perform
and ohm check of the sensor wiring between the sensor connector and the PCM as
follows:
• PCM connector A pin 22 to pin A of sensor connector is less than 1 ohm.
• PCM connector A pin 3 to pin C of sensor connector is less than 1 ohm.
• PCM connector A pin 23 to pin B of sensor connector is less than 1 ohm.

90-896580200 JULY 2004 Page 2A-45

Ignition

NOTE: All sensor ground wires are spliced together and connect to the PCM at pin 22 of
the A connector. Unless there are multiple sensor failures, the most likely failure would be
at the splice point, connector or in between the connector, and the splice point.

1 9 17 d

C
c

8 16 24
1 9 17
a
b
B

f
8 16 24

1 12 22
A22
BLK/ORG
PUR/YEL
A23

A
YEL
A3

PUR/YEL

11 21 32
BLK/ORG

M L K J H GF E D C B A

5908

a - Pin A (black/orange) d - MAP sensor

b - Pin B (purple/yellow) e - Splice saver SP4
c - Pin C (yellow) f - PCM

6. If the wiring is serviceable, replace the PCM and recheck the sensor function using the
Computer Diagnostic System or Digital Diagnostic Terminal.

Page 2A-46 90-896580200 JULY 2004

 Ignition

Computer Diagnostic System Order through SPX

Digital Diagnostic Terminal (DDT) 91-823686A2

MANIFOLD ABSOLUTE PRESSURE SENSOR REMOVAL

1. Disconnect sensor harness connector.
2. Remove attaching clamp and remove sensor from adaptor boot.
3. Inspect adaptor boot for cuts, cracks or abrasion. Replace boot as required.

b
a

5628
a - Clamp 15.7 diameter c - Clamp 36.1 diameter
b - Boot

MANIFOLD ABSOLUTE PRESSURE SENSOR INSTALLATION

1. Install sensor into adaptor boot. Secure sensor with new 15.7 diameter clamp.
2. Connect sensor harness to sensor.

90-896580200 JULY 2004 Page 2A-47

Ignition

Manifold Intake Air Temperature (MAT) Sensor

The manifold intake air temperature sensor is a thermistor that controls a signal voltage to
the PCM. It is located in the middle of the intake manifold close to the fuel rail. It informs
the PCM of the air temperature inside the intake manifold. The PCM adjusts the fuel
injection duration needed to run the engine at optimum efficiency according to the MAT
information. When intake air is cold, the sensor resistance is high. As the air temperature
rises, resistance lowers.

c
b

a
c

4577
a - MAT sensor c - Screws (M4 x 16)
b - Harness connector

MANIFOLD INTAKE AIR TEMPERATURE SENSOR TEST

The Computer Diagnostic System (CDS) and the Digital Diagnostic Terminal (DDT) will
both determine the proper functioning of the MAT sensor by providing a numerical readout
of the sensor temperature before and after the engine is started. With the engine not
running, intake air temperature should be approximately the same as the ambient air
temperature. After the engine is started, the temperature sensor should indicate a rise in
air intake temperature. Outside air temperature will directly affect the engine manifold air
intake temperature.
Manifold Intake Air Temperature Sensor Resistance
@ 21° C (70° F) 2.26 kΩ ± 5%

1. With the engine running and the CDS or DDT connected to the engine, if the MAT
sensor does not appear to be indicating a temperature change, shake or move the
sensor harness and connector. If the temperature begins to change, look for a broken,
loose or corroded wire.
Computer Diagnostic System Order through SPX
Digital Diagnostic Terminal (DDT) 91-823686A2
2. Disconnect the connector from the sensor.

Page 2A-48 90-896580200 JULY 2004

 Ignition

3. Perform a visual inspection of the pins at the sensor and the wires coming from the
connector. Look for broken, bent or corroded pins at the sensor and loose, broken or
corroded wires at the connector.

a 5919

a - Pin A (tan) c - MAT sensor

b - Pin B (black/orange)

4. The sensor can be tested with an ohmmeter by disconnecting it from the harness and
heating or cooling the end of the sensor at a controlled temperature. If the readings do
not match those in the table, replace the sensor and retest.
Manifold Air Intake Temperature Sensor Ohm Test
Degree Centigrade -8 20 40 60
Degree Fahrenheit 18 68 104 140
KΩ 9.82 kΩ ± 5% 2.57 kΩ ± 5% 1.13 kΩ ± 5% 0.54 kΩ ± 5%
5. If the ohm check of the MAT sensor indicates that the sensor is serviceable, perform
and ohm check of the sensor wiring between the sensor connector and the PCM as
follows:
• PCM connector A pin 22 to pin B of sensor connector is less than 1 ohm.
• PCM connector A pin 14 to pin A of sensor connector is less than 1 ohm.

90-896580200 JULY 2004 Page 2A-49

Ignition

NOTE: All sensor ground wires are spliced together and connect to the PCM at pin 22 of
the A connector. Unless there are multiple sensor failures, the most likely failure would be
at the splice point, connector or in between the connector, and the splice point.

1 9 17 c

C b

8 16 24
1 9 17
a
e
B

8 16 24

1 12 22
A22
BLK/ORG

A14
TAN

11 21 32
BLK/ORG

M L K J H GF E D C B A

5917

a - Pin A (tan) d - Splice saver SP4

b - Pin B (black/orange) e - PCM
c - MAT Sensor

6. If the wiring is serviceable, replace the PCM and recheck the sensor function using the
Computer Diagnostic System or Digital Diagnostic Terminal.

Page 2A-50 90-896580200 JULY 2004

 Ignition

Computer Diagnostic System Order through SPX

Digital Diagnostic Terminal (DDT) 91-823686A2

MANIFOLD INTAKE AIR TEMPERATURE SENSOR REMOVAL

1. Disconnect sensor harness connector.
2. Remove two screws securing sensor and remove sensor.

c
b

a
c

4577
a - MAT sensor c - Screws
b - Harness connector

MANIFOLD AIR TEMPERATURE SENSOR INSTALLATION

1. Inspect sensor O-ring for cuts or abrasions. Replace O-ring as required.
2. Install sensor with O-ring into cylinder block. Torque sensor screws to specification.
Description Nm lb. in. lb. ft.
Sensor Screw (M4 x 16) 1.7 15
3. Connect sensor harness to sensor.

90-896580200 JULY 2004 Page 2A-51

Ignition

Supercharger Outlet Temperature Sensor

The supercharger outlet temperature sensor is a thermistor immersed in the boost pressure
outlet stream. It is located in the front of the engine, at the base of return duct. Low air
temperature produces high resistance while high temperature causes low resistance. The
PCM will reduce engine RPM and warn the helm of the high temperature.

b
4579

a - Post supercharger temperature b - Harness connector

sensor

SUPERCHARGER OUTLET TEMPERATURE SENSOR TEST

The Computer Diagnostic System (CDS) and the Digital Diagnostic Terminal (DDT) will
both determine the proper functioning of the supercharger outlet temperature sensor by
providing a numerical readout of the sensor temperature before and after the engine is
started. With the engine not running, the sensor temperature should be approximately the
same as the ambient air temperature. After the engine is started, the temperature sensor
should indicate a rise in temperature.
Supercharger Outlet Temperature Sensor Resistance
@ 21° C (70° F) 11.3 kΩ

1. With the engine running and the CDS or DDT connected to the engine, if the sensor
does not appear to be indicating a temperature change, shake or move the sensor
harness and connector. If the temperature begins to change, look for a broken, loose
or corroded wire.
Digital Diagnostic Terminal (DDT) 91-823686A2
Computer Diagnostic System Order through SPX
2. Disconnect the connector from the sensor.

Page 2A-52 90-896580200 JULY 2004

 Ignition

3. Perform a visual inspection of the pins at the sensor and the wires coming from the
connector. Look for broken, bent, or corroded pins at the sensor; and loose, broken, or
corroded wires at the connector.

b a 5936

a - Pin A (light blue/green) c - Supercharger outlet temperature

b - Pin B (black/orange) sensor

4. The sensor can be tested with an ohmmeter by disconnecting it from the harness and
heating or cooling the end of the sensor at a controlled temperature. If the readings do
not match those in the table, replace the sensor and retest.
Supercharger Outlet Temperature Sensor Ohm Test
Degree Centigrade 10 21 38 65 160
Degree Fahrenheit 48 70 100 150 320
KΩ 17.63 kΩ 10.90 kΩ 5.05 kΩ 2.01 kΩ 174 Ω
5. If the ohm check of the sensor indicates that the sensor is serviceable, perform and
ohm check of the sensor wiring between the sensor connector and the PCM as follows:
• PCM connector A pin 22 to pin B of sensor connector is less than 1 ohm.
• PCM connector A pin 12 to pin A of sensor connector is less than 1 ohm.

90-896580200 JULY 2004 Page 2A-53

Ignition

NOTE: All sensor ground wires are spliced together and connect to the PCM at pin 22 of
the A connector. Unless there are multiple sensor failures, the most likely failure would be
at the splice point, connector or in between the connector, and the splice point.

1 9 17
c
C

8 16 24
1 9 17

e B
b a

8 16 24

1 12 22
A22
BLK/ORG

A12
LT BLU/GRN

BLK/ORG

11 21 32

M L K J H GF E D C B A

5932

a - Pin A (light blue/green) d - Splice saver SP5

b - Pin B (black/orange) e - PCM
c - Supercharger outlet temperature
sensor

6. If the wiring is serviceable, replace the PCM and recheck the sensor function using the
Computer Diagnostic System or Digital Diagnostic Terminal.

Page 2A-54 90-896580200 JULY 2004

 Ignition

Digital Diagnostic Terminal (DDT) 91-823686A2

Computer Diagnostic System Order through SPX

SUPERCHARGER OUTLET TEMPERATURE SENSOR REMOVAL

1. Disconnect sensor harness connector.
2. Remove sensor from cylinder block.

b
4579

a - Supercharger outlet temperature b - Harness connector

sensor

SUPERCHARGER OUTLET TEMPERATURE SENSOR INSTALLATION

1. Inspect sensor O-ring for cuts or abrasions. Replace O-ring as required.
2. Install sensor with O-ring into cylinder block. Torque sensor to specification.
Description Nm lb. in. lb. ft.
Temperature sensor 15 133
3. Connect sensor harness to sensor.

90-896580200 JULY 2004 Page 2A-55

Ignition

Oil Pressure Sensor

The oil pressure sensor measures cylinder block oil pressure. It is located below the crank
position sensor on the starboard side of the engine. In the event of low oil pressure, the
PCM will limit engine power based on the amount of oil pressure available at a specific
engine RPM.

b
a

5772

a - Oil pressure sensor b - Harness connector

OIL PRESSURE SENSOR TEST

The Computer Diagnostic System (CDS) and the Digital Diagnostic Terminal (DDT) will
both determine the proper functioning of the oil pressure sensor by providing a numerical
readout of the sensor after the engine is started.
Oil Pressure Sensor
@ idle 48 to 69 kPa (7 to 10 psi)
@ wide open throttle 448 to 655 kPa (65 to 95 psi)

1. With the engine running and the CDS or DDT connected to the engine, if the oil pressure
sensor does not appear to be indicating a pressure change, shake or move the sensor
harness and connector. If the pressure begins to change, look for a broken, loose, or
corroded wires.
Computer Diagnostic System Order through SPX
Digital Diagnostic Terminal (DDT) 91-823686A2
2. Disconnect the connector from the sensor.

Page 2A-56 90-896580200 JULY 2004

 Ignition

3. Perform a visual inspection of the pins at the sensor and the wires coming from the
connector. Look for broken, bent or corroded pins at the sensor and loose, broken or
corroded wires at the connector.

a b

5938

a - Pin A (black/orange) c - Pin C (light blue)

b - Pin B (purple/yellow) d - Oil pressure sensor

4. An ohm check of the oil pressure sensor can be made by disconnecting the sensor
harness and measuring the resistance between pins A, B and C. The normal resistance
values for the oil pressure sensor at 21° C (70° F) are:
• Between pin A and pin B is 9.33 kΩ.
• Between pin A and pin C is 3.89 kΩ.
5. If the ohm check of the oil pressure sensor indicates that the sensor is serviceable,
perform and ohm check of the sensor wiring between the sensor connector and the
PCM as follows:
• PCM connector A pin 22 to pin A of sensor connector is less than 1 ohm.
• PCM connector A pin 23 to pin B of sensor connector is less than 1 ohm.
• PCM connector A pin 24 to pin C of sensor connector is less than 1 ohm.

90-896580200 JULY 2004 Page 2A-57

Ignition

NOTE: All sensor ground wires are spliced together and connect to the PCM at pin 22 of
the A connector. Unless there are multiple sensor failures, the most likely failure would be
at the splice point, connector or in between the connector, and the splice point.

1 9 17
c
C

a b
8 16 24
1 9 17

g
B

8 16 24

1 12 22 A22
BLK/ORG
PUR/YEL
A23
LT BLU
A24
A

BLK/ORG

PUR/YEL
11 21 32

f e

5937

a- Pin A (black/orange) e - Splice saver SP6

b- Pin B (purple/yellow) f - Splice saver SP5
c- Pin C (light blue) g - PCM
d- Oil pressure sensor

6. If the wiring is serviceable, replace the PCM and recheck the sensor function using the
Computer Diagnostic System or Digital Diagnostic Terminal.

Page 2A-58 90-896580200 JULY 2004

 Ignition

OIL PRESSURE SENSOR REMOVAL

1. Disconnect sensor harness connector.
2. Remove sensor from cylinder block.

b
a

5772

a - Oil pressure sensor b - Harness connector

OIL PRESSURE SENSOR INSTALLATION

1. Install sensor into cylinder block. Torque sensor to specification.
2. Connect sensor harness to sensor.
Description Nm lb. in. lb. ft.
Oil pressure sensor 15 133

Pitot Pressure Sensor

The pitot pressure sensor measures the force of the water at the front of the gearcase. The
sensor converts this pressure to a voltage which is sent to the PCM. The PCM uses this
voltage signal to determine boat speed. The pitot pressure sensor is located beneath the
electronic boost control front tube on the port side of the engine.

a
c

4578
a - Pitot pressure sensor c - Sensor retainer
b - Harness connector d - Sensor water tube

90-896580200 JULY 2004 Page 2A-59

Ignition

PITOT PRESSURE SENSOR TEST

The Computer Diagnostic System (CDS) and the Digital Diagnostic Terminal (DDT) will
both determine the proper functioning of the pitot pressure sensor by providing a numerical
readout of the sensor after the engine is started and the boat is moving forward through
the water.
1. With the engine running and the boat moving forward and the CDS or DDT connected
to the engine, if the pitot pressure sensor does not appear to be indicating a speed
change, shake or move the sensor harness and connector. If the speed begins to
change, look for a broken, loose, or corroded wires.
Computer Diagnostic System Order through SPX
Digital Diagnostic Terminal (DDT) 91-823686A2
2. Disconnect the connector from the sensor.
3. Perform a visual inspection of the pins at the sensor and the wires coming from the
connector. Look for broken, bent or corroded pins at the sensor and loose, broken or
corroded wires at the connector.

a b
5940
a - Pin A (black/orange) c - Pin C (white/orange)
b - Pin B (purple/black) d - Pitot pressure sensor

4. An ohm check of the pitot pressure sensor can be made by disconnecting the sensor
harness and measuring the resistance between pins A, B and C. The normal resistance
values for the pitot sensor at 21° C (70° F) :
• Between pin A and pin B is 9.33 kΩ.
• Between pin A and pin C is 3.89 kΩ.
5. If the ohm check of the pitot pressure sensor indicates that the sensor is serviceable,
perform and ohm check of the sensor wiring between the sensor connector and the
PCM as follows:
• PCM connector A pin 22 to pin A of sensor connector is less than 1 ohm.
• PCM connector B pin 24 to pin B of sensor connector is less than 1 ohm.
• PCM connector A pin 5 to pin C of sensor connector is less than 1 ohm.

Page 2A-60 90-896580200 JULY 2004

 Ignition

NOTE: All sensor ground wires are spliced together and connect to the PCM at pin 22 of
the A connector. Unless there are multiple sensor failures, the most likely failure would be
at the splice point, connector or in between the connector, and the splice point.

d
1 9 17

C
c

8 16 24
1 9 17
a b
B
g B24
PUR/BLK

8 16 24

1 12 22
A22
BLK/ORG PUR/BLK

A WHT/ORG
A5

BLK/ORG

11 21 32 PUR/BLK

M L K J HG F E D C B A M L K J HGF E D C B A

f e

5939

a- Pin A (black/orange) e - Splice saver SP6

b- Pin B (purple/black) f - Splice saver SP5
c- Pin C (white/orange) g - PCM
d- Pitot pressure sensor

6. If the wiring is serviceable, replace the PCM and recheck the sensor function using the
Computer Diagnostic System or Digital Diagnostic Terminal.

90-896580200 JULY 2004 Page 2A-61

Ignition

Computer Diagnostic System Order through SPX

Digital Diagnostic Terminal (DDT) 91-823686A2

PITOT PRESSURE SENSOR REMOVAL

1. Disconnect sensor harness connector.
2. Disconnect sensor water tube.
3. Unlock sensor retainer and remove sensor.

a
c

4578
a - Pitot pressure sensor c - Sensor retainer
b - Harness connector d - Sensor water tube

PITOT PRESSURE SENSOR INSTALLATION

1. Secure sensor with retainer.
2. Connect sensor harness to sensor.
3. Reconnect sensor water tube.

Page 2A-62 90-896580200 JULY 2004

 Ignition

Block Water Pressure Sensor

The block water pressure sensor measures the amount of coolant being supplied by the
water pump to the cylinder block. The sensor converts this pressure to a voltage which is
sent to the PCM. The PCM will limit engine power if the coolant supply (water pressure) is
insufficient at a given RPM. The water pressure sensor is located on the aft side of the
engine and is secured to the fuel injector harness with a cable tie.

a
d
5850

a - Block water pressure sensor c - Harness connector

b - Cable tie d - Sensor coolant tube

BLOCK WATER PRESSURE SENSOR TEST

The Computer Diagnostic System (CDS) and the Digital Diagnostic Terminal (DDT) will
both determine the proper functioning of the water pressure sensor by providing a
numerical readout of the sensor after the engine is started and engine RPM is varied.
1. With the engine running and the CDS or DDT connected to the engine, if the water
pressure sensor does not appear to be indicating a pressure change when engine RPM
is varied, shake or move the sensor harness and connector. If the pressure begins to
change, look for a broken, loose or corroded wires.
Computer Diagnostic System (CDS) Order from SPX
Digital Diagnostic Terminal (DDT) 91-823686A2
2. Disconnect the connector from the sensor.
3. Perform a visual inspection of the pins at the sensor and the wires coming from the
connector. Look for broken, bent or corroded pins at the sensor and loose, broken or
corroded wires at the connector.
4. Perform an ohm check of the sensor wiring between the sensor connector and the PCM
as follows:
• PCM connector A pin 22 to pin A of sensor connector is less than 1 ohm.
• PCM connector A pin 23 to pin B of sensor connector is less than 1 ohm.
• PCM connector A pin 4 to pin C of sensor connector is less than 1 ohm.

90-896580200 JULY 2004 Page 2A-63

Ignition

NOTE: All sensor ground wires are spliced together and connect to the PCM at pin 22 of
the A connector. Unless there are multiple sensor failures, the most likely failure would be
at the splice point, connector, or in between the connector and the splice point.

1 9 17
d

C
c

8 16 24
1 9 17
a b
f
B

8 16 24

1 12 22
A22
BLK/ORG
PUR/YEL
A23

A
WHT/GRN
A4

PUR/YEL

11 21 32
BLK/ORG

M L K J H GF E D C B A

SP4 5941

a - Pin A (black/orange) d - Block pressure sensor

b - Pin B (purple/yellow) e - Splice saver SP4
c - Pin C (white/green) f - PCM

5. If the wiring is serviceable, the PCM can be tested using the Digital Diagnostic Terminal
or the Computer Diagnostic System with the pinpoint guided diagnostic instructions. If
the PCM is serviceable, replace the sensor.

Page 2A-64 90-896580200 JULY 2004

 Ignition

Computer Diagnostic System (CDS) Order from SPX

Digital Diagnostic Terminal (DDT) 91-823686A2

BLOCK WATER PRESSURE SENSOR REMOVAL

1. Disconnect sensor harness connector.
2. Remove the water pressure sensor coolant tube.
3. Cut the cable tie securing the sensor and remove the sensor.

a
d
5850

a - Block water pressure sensor c - Harness connector

b - Cable tie d - Coolant tube

BLOCK WATER PRESSURE SENSOR INSTALLATION

1. Connect sensor harness.
2. Install coolant tube to sensor.
3. Secure sensor to fuel injector wiring harness with cable tie.

90-896580200 JULY 2004 Page 2A-65

Ignition

Oil Temperature Sensor

The oil temperature sensor is located at the top of the cylinder block, below the oil pressure
sensor. It is a thermistor immersed in the engine oil passage way. It supplies the PCM with
engine oil temperature information. The PCM adjusts the timing and the amount of fuel
delivered according to the oil temperature in the cylinder block. Low oil temperature
produces high resistance, while high temperature causes low resistance. The normal
resistance value for the sensor at 21° C (70° F) is 11.3 kΩ.

b
5851

a - Oil temperature sensor b - Sensor harness connection (not

shown)

OIL TEMPERATURE SENSOR TEST

The Computer Diagnostic System (CDS) and the Digital Diagnostic Terminal (DDT) will
both determine the proper functioning of the oil temperature sensor by providing a
numerical readout of the oil temperature before and after the engine is started. With the
engine not running, oil temperature should be approximately the same as the ambient air
temperature. After the engine is started, the temperature sensor should indicate a rise in
oil temperature to approximately 75° to 110° C (167° to 230° F). Outside air temperature
and the temperature of the water that the engine is operating in will directly affect the engine
oil temperature.
1. With the engine running and the CDS or DDT connected to the engine, if the oil
temperature sensor does not appear to be indicating a temperature change, shake or
move the sensor harness and connector. If the temperature begins to change, look for
a broken, loose or corroded wire.
Computer Diagnostic System (CDS) Order from SPX
Digital Diagnostic Terminal (DDT) 91-823686A2
2. Disconnect the connector from the sensor.

Page 2A-66 90-896580200 JULY 2004

 Ignition

3. Perform a visual inspection of the pins at the sensor and the wires coming from the
connector. Look for broken, bent or corroded pins at the sensor and loose, broken or
corroded wires at the connector.

b a
6004
a - Pin A (brown) c - Oil temperature sensor
b - Pin B (black/orange)

4. The sensor can be tested with an ohmmeter by disconnecting it from the harness and
heating or cooling the end of the sensor at a controlled temperature. If the readings do
not match those in the table, replace the sensor and retest.
5. If the ohm check of the oil temperature sensor indicates that the sensor is serviceable,
perform and ohm check of the sensor wiring between the sensor connector and the
PCM as follows:
Oil Temperature Sensor Ohm Test
Degree Centigrade -10 21 38 65 95
Degree Fahrenheit 14 70 100 150 203
KΩ 20 kΩ 11.3 kΩ 5.67 kΩ 2.05 kΩ 800 Ω

• PCM connector A pin 22 to pin B of sensor connector is less than 1 ohm.

• PCM connector A pin 17 to pin A of sensor connector is less than 1 ohm.

90-896580200 JULY 2004 Page 2A-67

Ignition

NOTE: All sensor ground wires are spliced together and connect to the PCM at pin 22 of
the A connector. Unless there are multiple sensor failures, the most likely failure would be
at the splice point, connector, or in between the connector and the splice point.

1 9 17

C c

8 16 24
1 9 17

B
e
b a
8 16 24

BLK/ORG
BRN
1 12 22
A22
BLK/ORG

A A17
BRN

d
11 21 32 5989
SP5

a - Pin A (brown) d - Splice saver SP5

b - Pin B (black/orange) e - PCM
c - Oil temperature sensor

6. If the wiring is serviceable, replace the PCM and recheck the sensor function using the
Computer Diagnostic System or Digital Diagnostic Terminal.
Computer Diagnostic System (CDS) Order from SPX
Digital Diagnostic Terminal (DDT) 91-823686A2

OIL TEMPERATURE SENSOR REMOVAL

1. Disconnect sensor harness connector.

Page 2A-68 90-896580200 JULY 2004

 Ignition

2. Remove sensor from cylinder block.

b
5851

a - Oil temperature sensor b - Harness connection (not shown)

OIL TEMPERATURE SENSOR INSTALLATION

1. Inspect sensor O-ring for cuts or abrasions. Replace O-ring as required.
2. Install sensor with O-ring into cylinder block. Torque sensor to specification.
Description Nm lb. in. lb. ft.
Oil temperature sensor 15 133
3. Connect sensor harness to sensor.
Water in Fuel (WIF) Sensor
The water in fuel sensor is located in the lower portion of the engine fuel filter which is
mounted on the starboard side of the engine. The sensor is a normally open switch which
when exposed to water completes a circuit and activates a warning horn.

5892

a - Water in fuel sensor b - Fuel filter assembly

90-896580200 JULY 2004 Page 2A-69

Ignition

WATER IN FUEL SENSOR TEST

1. If the water in fuel warning horn activates, remove the fuel filter assembly from the
engine and pour the contents into a clear container. If no water is present, disconnect
the water in fuel sensor harness and perform a continuity check between the two sensor
pins. There should be no continuity. If there is continuity, the sensor is defective and
the fuel filter assembly must be replaced.

c b 5986

a - Pin A (tan/purple) c - Water in fuel sensor

b - Pin B (black/orange) d - Fuel filter

2. If the sensor is serviceable, perform a continuity check on the sensor harness between
the sensor connector and the PCM. Check for shorts to ground.
• PCM connector A pin 22 to pin B of sensor connector is less than 1 ohm.
• PCM connector A pin 27 to pin A of sensor connector is less than 1 ohm. There
should be no shorts to ground.

Page 2A-70 90-896580200 JULY 2004

 Ignition

All sensor ground wires are spliced together and connect to the PCM at pin 22 of the A
connector. Unless there are multiple sensor failures, the most likely failure would be at the
splice point, connector, or in between the connector and the splice point.

d
1 9 17

C
a
8 16 24
1 9 17

c b
B

BLK/ORG
TAN/PUR
f
8 16 24

1 12 22
A22
BLK/ORG

A A27
TAN/PUR

e
11 21 32 5981
SP5

a - Pin A (tan/purple) d - Fuel filter

b - Pin B (black/orange) e - Splice saver SP5
c - Water in fuel sensor f - PCM

If the sensor harness is serviceable, replace the PCM.

WATER IN FUEL SENSOR REMOVAL
NOTE: The water in fuel sensor is not replaceable as an individual component. It must be
replaced as part of the fuel filter assembly.
1. Disconnect sensor harness.
2. Remove two fuel hoses from fuel filter.

90-896580200 JULY 2004 Page 2A-71

Ignition

3. Slide fuel filter assembly up and out of the retaining bracket.

b
c

5895

a - Fuel hoses c - Retaining bracket

b - Harness connector

WATER IN FUEL SENSOR INSTALLATION

1. Slide fuel filter assembly into retaining bracket.
2. Reconnect fuel hoses.
3. Reconnect sensor harness.
Knock Sensor
There are two knock sensors located on the port side of the engine behind the charge
cooler/intake manifold. The knock sensors are piezoelectric transducers with a 1-2 mv per
G - force output signal. When detonation occurs in a cylinder, a vibration is generated in
the cylinder block which activates the knock sensors to produce their output signal to the
PCM. The PCM will reduce timing and/or increase fuel into the cylinders until the detonation
stops.

Page 2A-72 90-896580200 JULY 2004

 Ignition

IMPORTANT: The knock sensor harness connections must not be interchanged with one
another. The PCM is calibrated to receive detonation information from a specific location.
Switching harness connections between knock sensors may allow certain levels of
detonation to occur unimpeded by the PCM resulting in engine damage.

6010

a - Upper knock sensor (hidden d - Lower knock sensor connector

behind charge cooler/intake (white/black wire)
manifold) e - Charge cooler/intake manifold
b - Lower knock sensor (hidden
behind charge cooler/intake
manifold)
c - Upper knock sensor connector
(white/blue wire)

90-896580200 JULY 2004 Page 2A-73

Ignition

KNOCK SENSOR TEST

There is no practical field test for this device. Check connector for bent, broken, or corroded
pins. Perform continuity check between knock sensor connectors and PCM. Consult the
PCM fault codes. If the PCM indicates a fault, test the connector and wire connections.
• PCM connector A pin 29 to pin A (white/blue) of upper knock sensor connector is 20
kohms (+/- 10%).
• PCM connector A pin 19 to pin B (black/red) of upper knock sensor connector is less
than 1 ohm.
• PCM connector A pin 30 to pin E (white/black) of lower knock sensor is 20 kohms (+/-
10%).
• PCM connector A pin 20 to pin F (black/white) of lower knock sensor connector is less
than 1 ohm.

c g

d h
1 9 17

C b f

8 16 24
1 9 17 e
a

WHT/BLK
WHT/BLU

WHT/BLK
WHT/BLU

BLK/WHT
BLK/RED

B
i

8 16 24

1 12 22

A
A29
WHT/BLU
A19
BLK/RED
A30
WHT/BLK
A20
BLK/WHT
11 21 32
6011
a - Pin A (white/blue) (upper knock f - Pin B (black/white) (lower knock
sensor connector) sensor connector)
b - Pin B (black/red) (upper knock g - Lower knock sensor
sensor connector) h - Resistor (lower knock sensor)
c - Upper knock sensor i - PCM
d - Resistor (upper knock sensor)
e - Pin A (white/black) (lower knock
sensor connector)

Page 2A-74 90-896580200 JULY 2004

 Ignition

KNOCK SENSOR REMOVAL

1. Refer to Section 4 for charge cooler/intake manifold removal procedures.
2. Disconnect knock sensor harness connectors.
3. Remove screw and washer securing knock sensor and remove sensor.
KNOCK SENSOR INSTALLATION
1. Secure knock sensor with screw and washer. Torque screw to specification.
Description Nm lb. in. lb. ft.
Screw (M10 x 35) 20 15
2. Reconnect sensor harness to sensor.
3. Refer to Section 4 for installation procedures for charge cooler/intake manifold.
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. Remove top cowl. Locate fuse holder on starboard side of engine.

ob01516

2. Remove the plastic cover from the fuse holder.

3. Remove fuse puller from fuse holder.
4. Remove suspected blown fuse to determine if the silver colored band is broken.

90-896580200 JULY 2004 Page 2A-75

Ignition

5. Replace fuse with a new fuse of the same amperage rating.

ob01252

b
a c

20 20 20
20 20 20
d
20

e ob01259

a - Electronic Control Module and d - Spare fuses - 20 amp fuse

purge valve "ECM" - 20 amp fuse e - Injector power and boost valve "INJ.
b - Ignition coils "IGN. COILS" - 20 PWR." - 20 amp fuse
amp fuse
c - Fuel delivery "FUEL" - 20 amp
fuse

Page 2A-76 90-896580200 JULY 2004