TROUBLESHOOTING AND DIAGNOSTICS

ELECTRONIC FUEL INJECTION

Section 3B - Troubleshooting and Diagnostics

Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . 3B-1 Troubleshooting Without the Digital
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B-2 Diagnostic Terminal . . . . . . . . . . . . . . . . . . 3B-11
EFI System Diagnostic Procedures . . . . . . . .
Pressure Regulator Test . . . . . . . . . . . . . . .
3B-4
3B-4
Guardian Protection System . . . . . . . . . . . 3B-11
EFI System Troubleshooting Guide . . . . . . . . 3B-13
3
Mechanical Fuel Pump Test . . . . . . . . . . . . . . 3B-5 Component Resistance Tests . . . . . . . . . . . . . 3B-17 B
Checking for Restricted Fuel Flow Engine Coolant Temperature (ECT) Sensor
Caused by Anti-Siphon Valves . . . . . . . . . 3B-5 Manifold Air Temperature (MAT) Sensor . 3B-17
Vacuum (Lift) Test . . . . . . . . . . . . . . . . . . . . 3B-5 Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . 3B-18
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . 3B-8 Main Power Relay . . . . . . . . . . . . . . . . . . . . 3B-18
EFI System Troubleshooting . . . . . . . . . . . . . . 3B-10 Manifold Absolute Pressure
Using the Digital Diagnostical (MAP) Sensor . . . . . . . . . . . . . . . . . . . . . . . 3B-19
Terminal (DDT) . . . . . . . . . . . . . . . . . . . . . . 3B-10 Crank Position Sensor (CPS) . . . . . . . . . . 3B-19

Fuel Pump Type Mechanical Water Cooled

(Plunger/Diaphragm)
FUEL
Fuel Pump:
SYSTEM
Pressure 3-6 psi
Fuel Tank Capacity Accessory
Fuel Injector System Batch (1 & 4) - (2 & 3)
Idle rpm (Out Of Gear) 725 ± 25 rpm
Idle rpm (In Forward Gear) 725 ± 25 rpm
FUEL INJECTION
Wide Open Throttle rpm (WOT)
Range 5500–6000
Fuel Pump Pressure - Electric 42-44 psi (290-303 kPa)

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TROUBLESHOOTING AND DIAGNOSTICS

Special Tools
1. Fuel Pressure Gauge 91-16850A7 or Fuel Pressure Gauge 91-852087A3.

91-16850A7

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

3. Cartridge 91-880118--2

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 TROUBLESHOOTING AND DIAGNOSTICS

4. Digital Diagnostic Tester 91-823686A2

5. DDT Reference Manual 90-881204--2

6. DDT Cable 10’ (3.05m) Extension 84-825003A1

7. DDT Test Harness 84-822560A5

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TROUBLESHOOTING AND DIAGNOSTICS

EFI System Diagnostic Procedures

Pressure Regulator Test
1. Install the fuel pressure gauge onto the pressure check valve (located on the VST).
2. Start the engine. Fuel pressure should be within specification.

b
91-16850A7

58821

a - Fuel Pressure Gauge

b - Pressure Relief Button
c - Drain Hose

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 TROUBLESHOOTING AND DIAGNOSTICS

Mechanical Fuel Pump Test

Checking for Restricted Fuel Flow Caused by Anti-Siphon Valves
While anti-siphon valves may be helpful from a safety stand-point, they clog with debris,
they may be too small, or they may have too heavy a spring. Summarizing, the pressure
drop across these valves can, and often does, create operational problems and/or powerhead
damage by restricting fuel to the fuel pump and VST. Some symptoms of restricted (lean)
fuel flow, which could be caused by use of an anti-siphon valve, are:
1 - Loss of fuel pump pressure
2 - Loss of power
3 - High speed surging
4 - Preignition/detonation (piston dome erosion)
5 - Outboard cuts out or hesitates upon acceleration
6 - Outboard runs rough
7 - Outboard quits and cannot be restarted
8 - Outboard will not start
9 - Vapor lock
Since any type of anti-siphon device must be located between the outboard fuel inlet and
fuel tank outlet, a simple method of checking [if such a device (or bad fuel) is a problem
source] is to operate the outboard with a separate fuel supply which is known to be good,
such as a remote fuel tank.
If, after using a separate fuel supply, it is found that the anti-siphon valve is the cause of
the problem, there are 2 solutions to the problem; either 1) replace the anti-siphon valve
with one that has lighter spring tension or 2) replace it with a solenoid-operated fuel shut
off valve.
Vacuum (Lift) Test
Fuel system vacuum can be checked using a short piece of extra fuel hose, vacuum
gauge, and a “TEE” fitting.
1. Conduct test with water to the engine cooling system using one of the following methods:
• In a test tank.
• With boat/outboard lower unit in water
2. Disconnect fuel hose from inlet fitting of mechanical fuel pump.
3. Connect extra fuel hose onto the inlet fitting of pump.
4. Install “TEE” fitting into extra hose making connection as close to pump as possible.
5. Connect vacuum gauge and fuel inlet hose onto “TEE” fitting.
6. Start engine and run at 1000 RPM, normal fuel system vacuum (lift) should be to speci-
fications.
NOTE: The system vacuum test is normally performed at 1000 RPM. As engine RPM is
increased there will be a slight increase in vacuum; this increase should not exceed normal
readings.

Normal Fuel System Vacuum (Lift) @ 1000 RPM

1 – 2 in. Hg (25 – 50 mm Hg)

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TROUBLESHOOTING AND DIAGNOSTICS

7. To isolate the mechanical fuel pump from the rest of the fuel system:
a. Pinch off/restrict the fuel supply hose between the vacuum gauge and the fuel tank.
b. The mechanical fuel pump vacuum (lift) should be to specifications.
c. If vacuum reading for the pump is below specifications, the pump needs rebuilding.

Mechanical Fuel Pump Vacuum (Lift) @ 1000 RPM

4 in. Hg (101.6 mm Hg)

8. If vacuum reading is not within specifications, refer to “Vacuum (Lift) Troubleshooting”

table.
9. Stop engine, remove gauge, and reconnect fuel line to inlet fitting of fuel pump.
The fuel pump is designed to lift fuel (vertically) about 60 in. (1524 mm) if there are no other
restrictions in the system using a fuel hose that is 5/16 in. (7.9 mm) minimum diameter.
As restrictions are added, such as filters, fittings, valves etc., the amount of fuel pump lift
decreases.

d
a
b
57859
a - Extra Hose - To Inlet Fitting of Mechanical Fuel Pump
b - “TEE”-fitting
c - Vacuum Gauge
d - Fuel Supply Hose - From Fuel Tank

Page 3B-6 90-883065 APRIL 2001

 TROUBLESHOOTING AND DIAGNOSTICS

Vacuum (Lift) Troubleshooting

Condition Cause Correction
Fuel system vacuum (lift) above Restricted anti-siphon valve Refer to “Checking for Restricted
specification Fuel Flow caused by Anti-Siphon
Valves” preceding
Plugged fuel tank pick-up screen Clean/replace fuel pick-up
screen
Pinched/collapsed fuel hose Inspect/replace fuel hose(s)
Dirty/plugged water separating Clean/replace water separating
fuel filter fuel filter
Restriction in fuel line thru-hull Clean/replace fitting
fitting
Restriction in fuel tank switching Clean/replace valve
valve
Restriction within primer bulb Rebuild/replace primer bulb
Fuel system vacuum (lift) below Low fuel level in fuel tank Fill tank with fuel
specifications
ifi ti Hole/cut in pick-up tube of fuel Replace fuel pick-up tube
tank
Loose fuel line connection Check/tighten all connections
Hole/cut is fuel line Inspect/replace fuel hose(s)
Loose fuel pump screws Torque screws to specification
Fuel pump gasket(s) worn or Rebuild/replace fuel pump
leaking
Fuel pump check valves/seals Rebuild/replace fuel pump
leaking
Leaky fuel pump diaphragm Rebuild/replace fuel pump
Worn/broken fuel pump springs Rebuild/replace fuel pump
Leaky fuel pump seals Rebuild/replace fuel pump
Fuel filter bowl loose Tighten fuel filter bowl
Fuel filter gasket cut/worn Replace gasket
Fuel vaporization Check for plugged fuel pump wa-
ter cooling circuit

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TROUBLESHOOTING AND DIAGNOSTICS

Pressure Test
Fuel system pressure/trouble shooting can be performed using piece of clear fuel hose 4
in. (10 cm) long, a pressure gauge, and a “TEE” fitting.
1. Conduct test with water to the engine cooling system using one of the following methods:
• In a test tank
• With boat/outboard lower unit in water
2. Disconnect fuel hose from outlet fitting of mechanical fuel pump.
3. Connect clear fuel hose onto the inlet fitting of pump.
4. Install “TEE” fitting onto clear fuel hose.
5. Connect pressure gauge and fuel outlet hose (to VST) onto “TEE” fitting.
6. Start engine and run at 1000 RPM, normal fuel system pressure should be to specifica-
tions.

Normal Fuel System Pressure @ 1000 RPM

Pressure should exceed 2 psi (13.7 kPa)

7. To isolate the mechanical fuel pump from the rest of the fuel system:
a. Pinch off/restrict the fuel hose between the “TEE” fitting and the VST.
b. The mechanical fuel pump pressure should be to specifications.
c. If pressure reading for the pump is below specifications, the pump needs rebuild-
ing.

Mechanical Fuel Pump Pressure @ 1000 RPM

Pressure should exceed 3 psi (20.7 kPa)

8. If fuel pressure reading is below specifications, refer to “Fuel Pressure Troubleshoot-

ing” table.
9. Stop engine, remove gauge/clear hoses and reconnect fuel line to outlet fitting of fuel
pump.

b a

a - Clear Hose - From Mechanical Fuel Pump Outlet to “Tee” Fitting

b - “TEE”-fitting
c - Fuel Pressure Gauge
d - Fuel Hose - To VST

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 TROUBLESHOOTING AND DIAGNOSTICS

Fuel Pressure Troubleshooting

Condition Cause Correction
Fuel system pressure below Restricted anti-siphon valve Refer to “Checking for Restricted
specification Fuel Flow caused by Anti-Siphon
Valves” preceding
Low fuel level in fuel tank * Fill tank with fuel
Plugged fuel tank pick-up screen Clean/replace fuel pick-up
screen
Hole/cut in pick-up tube of fuel Replace fuel pick-up tube
tank *
Loose fuel line connection * Check/tighten all connections
Hole/cut in fuel line * Inspect/replace fuel hose(s)
Fuel line primer bulb check Replace fuel line primer bulb
valves not opening
Fuel hose/line internal diameter Use 5/16 in. (8mm) fuel hose
too small
Restriction in fuel line thru-hull Clean/replace fitting
fitting
Restriction in fuel tank switching Clean/replace valve
valve
Restriction within primer bulb Rebuild/replace primer bulb
Pinched/collapsed fuel hose Inspect/replace fuel hose(s)
Dirty/plugged water separating Clean/replace water separating
fuel filter fuel filter
Fuel filter bowl loose * Tighten fuel filter bowl
Fuel filter gasket cut/worn * Replace gasket
Loose fuel pump screws * Torque screws to specification
Fuel pump gasket(s) worn or Rebuild/replace fuel pump
leaking *
Fuel pump check valves/seals Rebuild/replace fuel pump
leaking
Leaky fuel pump diaphragm * Rebuild/replace fuel pump
Worn/broken fuel pump springs Rebuild/replace fuel pump
Leaky fuel pump seals Rebuild/replace fuel pump
Fuel vaporization Check for plugged fuel pump
water cooling circuit

NOTE: * Air bubbles may also be visible as fuel passes through the clear fuel (test) hose
installed between the mechanical fuel pump outlet fitting and the VST.

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TROUBLESHOOTING AND DIAGNOSTICS

EFI System Troubleshooting

The ECM is designed such that if a sensor fails the ECM will compensate so that the engine
does not go into an over-rich condition. Because of this, disconnecting a sensor for trouble-
shooting purposes may have no noticeable effect.
Using the Digital Diagnostical Terminal (DDT)
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.

a c
d
b

a - Digital Diagnostic Terminal (91-823686A2)

b - Software Cartridge (91-880118--2)
c - DDT Reference Manual (90-881204--2)
d - DDT Cable 10ft. (3.05m) Extension (84-825003A1)
e - Adaptor 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.

Page 3B-10 90-883065 APRIL 2001

 IGNITION

DDT Functions – 4-Stroke EFI Models

Software Version 1.2 (P/N 91-880118-2) 02MY EFI xx HP 995cc
ECM #859613-X Any fault will turn on fault light. Refer to
CODE
SPARK PLUG Fault Status to identify fault
CHAMPION RA8HC
GAP 0.040 (1 mm)
FIRING ORDER FAULT LIGHTS FAULT LIGHTS
SmartCraft Monitor 1-3-4-2
BATV 12.6 - 15.0
1 – Mercury Marine
IGNITION TIMING:
2 – Tool Setup IDLE ECM CONTROL IGNITION 1 5 SWITCHES
1500 - 1800 14° BTDC
6000 RPM 28° BTDC INJECTOR 2 6 MISCELLANEOUS
STATOR
0.2 - 0.3 ohm PUMP 3 7 RPM LIMIT
THIS ENGINE IS A CPS 300 - 500 ohm
IGN SEC 3 - 7 K ohm SENSORS
xx MY EFI xxx HP xxxcc 4 8 BREAK–IN
FINJ 10.0 - 13.5 ohm
PRESS 1 to CONTINUE PWR RLY 81 - 99 ohm
IAC 24 - 30 ohm
MAT/ECT
10 K ohm @ 77F/25C
RPM LIMIT 6200
ENGINE RPM
PROP RPM 5500 - 6000
Select Function: Select Auto Test: BATTERY VOLTS
TYPICAL TPS RANGE
1 - AUTO SELF TEST PWR 1 VOLTS
1 – STATIC TEST MAP PSI TPI 0.39 - 1.00v IDLE
TRIGGER ERR 3.66 - 4.80v WOT
2 - MANUAL TEST AVAILABLE PWR % MAP 3.5 - 15 psi
IAC PWM % 24 - 103 kPa
SPARK ANG _TDC FUEL 42 - 44 psi
ECT °F 290 - 303 kPa
TPS 1 VOLTS 1 FUSE - BUS +12 V
TPS % 2 FUSE - INJ/IAC/PMP
MAT °F 3 FUSE - MAIN RELAY
4 FUSE - IGN COIL
OVERTEMP/LOW OIL
PRESSURE LIMITS Fault Status List
ARE CONTROLLED BY
ENGINE GUARDIAN
Select Function: MAT INPUT HI or LO Manifold Air Temperatrure (engine) sensor input is high or low
1 - DATA MONITOR
2 - FAULT STATUS BATT VOLT HI or LOW Battery voltage is high or low
3 - SYSTEM INFO
4 - HISTORY ECT INPUT HI or LO Engine Coolant Temperature sensor input is high or low
5 - SPECIAL FUNCTIONS EST 1 thru 4 SHORT or OPEN Electronic spark trigger signal (1 thru 4) is short or open circuit
FREEZE FRAME BUFFERS FINJ 1 thru 4 SHORT or OPEN Fuel injector (1 thru 4) is short or open circuit
Select Function: Select Fault Hist: 0 thru 9
1 - FAULT HISTORY 1 – FREEZE FRAME Note: Select Desired Buffer GUARDIAN Guardian system activated
2 - RUN HISTORY
2 – FAULT SECONDS
3 - CLEAR FAULT HIST MAP INPUT HI or LO MAP sensor input high or low
4 - CLEAR RUN HIST
FREEZE FRAME BUFFERS MPRLY BACKFEED Main Power Relay is Receiving a Current Back feed

Selected Buffer: x - xxxxx MPRLY OUTPUT Main Power Relay Output

BARO PSI
FAULT SECONDS BATT VOLTS OVERSPEED Overspeed is activated
BATT VOLT HIGH BLOCK PSI
Select Function: BOAT SPEED COOL TMP OVRHT Engine overheat
BATT VOLT LOW
1 - OIL PUMP PRIME BLOCK PSI LOW AIR TMP °F
2 - CYLINDER MISFIRE COMP OVERHEAT COOL TMP °F TPS1 CKT HI or LO TPS #1 sensor input is high or low
3 - OUTPUT LOAD TEST ETC MOTOR OPEN DEMAND %
RUN TIME HR. TPS1 NO ADAPT ECM is unable to adapt to the current position of the TPS
4 - RESET BREAK-IN OIL ETC MOTOR SHORT ENGINE RPM
RPM 0 – 799
5 - CHANGE FUEL OFFSET FUEL PSI IN HI ENGINE STATE
RPM 800 – 1499 TPS1 RANGE HI or LO TPS #1 is above or below the allowable range
6 - ENGINE LOCATION FUEL PSI IN LO FPC TOTAL
RPM 1500 – 1999
7 - TRIM LIMIT GUARDIAN FREQ COUNTER
RPM 2000 – 2999 WARNING HORN Warning horn fault
KNOCK SENS1 FUEL LEVEL %
RPM 3000 – 3999
KNOCK SENS2 SHIFT
RPM 4000 – 4499
Select Load Test: OIL PSI STR LAKE/SEA TMP °F
RPM 4500– 4999
1 - IGNITION OIL REMOTE STR LOAD%
RPM 5000 – 5999
2 - FUEL INJECTOR OIL RESERVE STR MPRLY REQ
RPM 6000 +
3 - DIRECT INJECTOR MAP INPUT HI MAP PSI
BREAK-IN LEFT
4 - OIL PUMP MAP INPUT LO OIL LEVEL %
RPM LIMIT Sec
5 - FUEL PUMP MAP IDLE CHECK PORT TAB POS
GRD LIMIT Sec
6 - HORN OIL PUMP AVAILABLE PWR %
CTS TMP Sec
7 - MISCELLANEOUS OVERSPEED RUN TIME
1 - IDLE AIR CONTROL PORT OVERHEAT STAR TAB POS
8 - TACHOMETER STAR OVERHEAT TPI %
9 - RELAYS WARNING HORN TRIM POSITION
1 - MAIN POWER RELAY H2O IN FUEL
2 - FUEL PUMP RELAY

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 TROUBLESHOOTING AND DIAGNOSTICS

Troubleshooting Without Digital Diagnostic Terminal

Troubleshooting without the DDT is limited to checking resistance on some of the sensors.
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 cylin-
der.
NOTE: ECMs are capable of performing a cylinder misfire test to isolate problem cylinders.
Once a suspect cylinder is located, an output load test on the ignition coil or fuel injector
can be performed using 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.

Guardian Protection System

The guardian protection system monitors critical engine functions and will reduce engine
power accordingly in an attempt to keep the engine running within safe operating parameters.
IMPORTANT: The Guardian System cannot guarantee that powerhead damage will
not occur when adverse operating conditions are encountered. The Guardian Sys-
tem is designed to (1) warn the boat operator that the engine is operating under ad-
verse conditions and (2) reduce power by limiting maximum rpm in an attempt to
avoid or reduce the possibility of engine damage. The boat operator is ultimately
responsible for proper engine operation.

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TROUBLESHOOTING AND DIAGNOSTICS

Warning Horn/Guardian System Operation

Sound Condition Description
One Beep on key up Normal System Test
Six Beeps on key up, Failure detected with Engine should run well however,
or during a running failure. MAP, MAT *, TPS, or Flash Check service will be required.
Sum (ECM)
Three Beeps every 4 Minutes. Failure detected with: Engine will start hard, run rough
• Battery Voltage * and/or stall. Utilizing the neutral
• EST *- Open detected at key fast idle feature may assist start-
up. Short detected with engine ing. Service is required.
running
• Fuel Injector - Detected while
cranking/running *
• Coolant Sensor *
• IAC **
Intermittent Beeps Failure detected with: Engine may or may not start. If en-
• Fuel Pump - May start gine starts it easily stalls. Service
momentarily ** is required.
• Main Power Relay - No start **
• ECM Reference Voltage to
MAP/TPS - Starts but stalls
under load
Continuous Engine Overheat Engine Guardian System is acti-
vated. Power limit will vary with
level of overheat. Stop engine and
check water intake for obstruction.
Advancing throttle above idle may
provide additional cooling.
Low Oil Pressure Guardian System is activated. En-
gine power is limited to 10% of
maximum. Stop engine and check
oil level. Add oil if necessary.
Battery Voltage Engine Guardian System is acti-
Less Than 10v or More Than 16v vated. Engine power is limited to
75% of maximum.
Coolant Sensor Failure Engine Guardian System is acti-
vated. Engine power is limited to
50% of maximum. Engine over-
heat protection is compromised.
Engine Speed Limiter Exceeding 6200 rpm cuts spark/in-
jection on cylinders #2 and #3 to
reduce engine speed.
Exceeding 6350 rpm cuts spark/in-
jection on all cylinders to reduce
engine speed.

* Horn Beeps once on key up, plus failure code.

** Sticky Fault requires key off to reset.

Page 3B-14 90-883065 APRIL 2001

 TROUBLESHOOTING AND DIAGNOSTICS

EFI System Troubleshooting Guide

IMPORTANT: In all instances check wiring harness integrity (especially ground connections) in boat and
on engine.
Condition Cause/Fault Warning Check
Mode
Engine cranks Lanyard stop switch is in the None Set lanyard stop switch to “RUN”
but will not
ot sta
startt “OFF” position
Weak battery or bad starter 3 Beeps Check condition of battery/starter sole-
motor. Battery voltage drops every 4 noid terminals and cables. Charge/re-
below 8 volts while cranking minutes for place battery. Inspect condition of starter
(ECM cuts out below 6 volts) low battery motor.
(Fuel pump requires 8 volts). voltage.
Blown Fuse None Replace fuse. Inspect engine wiring har-
ness and electrical components.
Fuse #2 - Fuel Injectors/IAC/Fuel Pump
Fuse #3 - Main Power Relay/Accessory
Fuse #4 - Ignition Coils
Main Power Relay Intermittent Listen for relay to “click” when key switch
Beeps is turned to “ON”
81 - 99 ohms
Between pin #22 (YEL/PUR) of port ECM
connector and (RED/BLU) wire of fuse #3
(fuse removed)
- or -
Between pin #85 and pin #86 of relay
Crank Position Sensor None 300 – 350 ohms
(CPS) Note: Between pin #5 (RED) and pin #6 (WHT)
No rpm of starboard ECM connector.
reading at - or -
tachometer
Between pin #1 (RED) and pin #2 (WHT)
of CPS connector.
Electric fuel pump Intermittent Listen for pump. Fuel pump should run 2
Beeps seconds after key switch is turned to
“RUN” position.
32 - 41 ohms
Between pin #19 (BLK/BLU) and pin # 23
(RED/BLU)
- or -
Between pins of fuel pump connector.
Flywheel misaligned None Remove flywheel and inspect flywheel
key/key way
Engine Coolant Temperature 3 Beeps See ECT sensor resistance chart -
(ECT) sensor every 4 Section 3B “ELECTRONIC FUEL
minutes INJECTION”.
Advancing the remote control fast idle
feature or advancing the tiller handle
throttle grip half way may assist starting.

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TROUBLESHOOTING AND DIAGNOSTICS

IMPORTANT: In all instances check wiring harness integrity (especially ground connections) in boat and
on engine.
Condition Cause/Fault Warning Check
Mode
Engine cranks, Remote control to engine None Clean and inspect male and female
starts and stalls wiring harness connection is connections.
poor
Air in fuel system/lines None Crank and start engine several times.
Manifold Absolute Pressure 6 Beeps at See MAP sensor resistance chart -
(MAP) sensor key up or Section 3B “ELECTRONIC FUEL
failure INJECTION”.
Throttle Position Sensor 6 Beeps at Typical TPI range with DDT:
(TPS) key up or Idle 0.39-1.0 volts, WOT 3.66-4.80 volts.
failure
Idle Air Control (IAC) 3 Beeps 20 - 24 ohms
every 4 Between pin #20 (WHT/ORG) and pin
minutes #23 (RED/BLU) of starboard ECM con-
nector.
- or -
Between pin A and pin B of IAC.
ECM reference voltage to Intermittent 5 volts
MAP/TPS Beeps Between PUR/YEL pin of MAP sensor
wiring harness connector and engine
ground (key switch to “RUN”).
Fuel pressure at VST fitting None See fuel pressure test - Section 3B
“ELECTRONIC FUEL INJECTION”.
Flywheel misaligned None Remove flywheel and inspect flywheel key
and key way
Engine Idles Engine Coolant Temperature 3 Beeps See ECT sensor resistance chart -
Fast after warm- (ECT) sensor every 4 Section 3B “ELECTRONIC FUEL
up minutes INJECTION”.
(900-1100rpm)
Poor off idle or Fuel injector 3 Beeps 10.0 - 13.5 ohms
WOT running every 4 Between fuel injector pin #1 and pin #2.
quality minutes
- or -
Between (removed) fuse #2 (RED/BLU)
wire and port ECM connector:
Pin #17 (PNK/BRN) Fuel Injector #1
Pin #2 (PNK/RED) Fuel Injector #2
Pin #1 (PNK/ORG) Fuel Injector #3
Pin #18 (PNK/YEL) Fuel Injector #4
Ignition coil (EST) *** 3 Beeps See ignition coil resistance chart -
every 4 Section 2A “IGNITION”
minutes
Fuel pressure at VST fitting None See fuel pressure test - Section 3B
“ELECTRONIC FUEL INJECTION”.
Fuel filter plugged None Replace fuel filter
Improper spark plugs None Use recommended resistive spark plugs
Loose grounds None Check all ground connections.
Flywheel timing tooth pattern None Check tooth pattern for partially missing
or damaged teeth
Fouled spark plug(s) None Replace spark plug(s).

Page 3B-16 90-883065 APRIL 2001

 TROUBLESHOOTING AND DIAGNOSTICS

IMPORTANT: In all instances check wiring harness integrity (especially ground connections) in boat and
on engine.
Condition Cause/Fault Warning Check
Mode
Poor idle quality Crank Position Sensor None 300 - 350 ohms
(CPS) Between pin #5 (RED) and pin #6 (WHT)
of starboard ECM connector.
- or -
Between pin #1 (RED) and pin #2 (WHT)
of CPS connector.
Manifold Absolute Pressure 6 Beeps at See MAP sensor resistance chart -
(MAP) sensor key up or Section 3B “ELECTRONIC FUEL
failure INJECTION”.
Throttle Position Sensor 6 Beeps at Typical TPI range with DDT:
(TPS) key up or Idle 0.39-1.0 volts, WOT 3.66-4.80 volts.
failure
Engine Coolant Temperature 3 Beeps See ECT sensor resistance chart -
(ECT) sensor every 4 Section 3B “ELECTRONIC FUEL
minutes INJECTION”.

Manifold Air Temperature 6 Beeps at See MAT sensor resistance chart –-

(MAT) sensor key up or Section 3B “ELECTRONIC FUEL
failure INJECTION”.
Fuel injector 3 Beeps 10.0 - 13.5 ohms
every 4 Between fuel injector pin #1 and pin #2.
minutes
- or -
Between (removed) fuse #2 (RED/BLU)
wire and port ECM connector:
Pin #17 (PNK/BRN) Fuel Injector #1
Pin #2 (PNK/RED) Fuel Injector #2
Pin #1 (PNK/ORG) Fuel Injector #3
Pin #18 (PNK/YEL) Fuel Injector #4
Ignition coil (EST) *** 3 Beeps See ignition coil resistance chart -
every 4 Section 2A “IGNITION”
minutes
Idle Air Control (IAC) 3 Beeps 20 - 24 ohms
every 4 Between pin #20 (WHT/ORG) and pin
minutes #23 (RED/BLU) of starboard ECM con-
nector.
- or -
Between pin A and pin B of IAC.
Fuel pressure at VST fitting. None See fuel pressure test - Section 3B
“ELECTRONIC FUEL INJECTION”.
Loose grounds None Check all ground connections.
Fouled spark plug(s) None Replace spark plug(s).
*** The ECM will only monitor the EST connection to the ignition coil, use resistance tests and/or spark gap
test to confirm an ignition coil failure.

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TROUBLESHOOTING AND DIAGNOSTICS

IMPORTANT: In all instances check wiring harness integrity (especially ground connections) in boat and
on engine.
Condition Cause/Fault Warning Check
Mode
Engine runs rich Fuel pressure regulator None 42 - 44 psi (290 – 303 kPa) at VST fitting
- Section 3B “ELECTRONIC FUEL
INJECTION”
Engine Coolant Temperature 3 Beeps See ECT sensor resistance chart -
(ECT) Sensor every 4 Section 3B Electronic Fuel Injection
minutes
Thermostat stuck open None Remove and inspect thermostat.
Section 4A “CYLINDER HEAD”
Speed Reduction Low oil pressure or GUARDIAN Check engine oil level and add oil as
Engine RPM grounded oil pressure switch Continuous needed.
Limited to 2000 lead Horn Above Remove oil pressure switch and install oil
10% Power pressure gauge, (warm engine) oil pres-
Setting sure should be:
Above 2.9 psi (20.0 kPa) at idle
30-40 psi. (207-278 kPa) at 3000 rpm.
See Oil Pressure Switch test -
Section 4B “Cylinder Block/Crankcase”.
Check for short between pin #7 (BLU) of
starboard ECM connector and open
connector of oil pressure switch.
Speed Reduction Engine Overheat GUARDIAN Engine Guardian System is activated.
Engine RPM Continuous Power limit will vary with level of overheat.
Limited Stop engine and check water intake for
obstruction.
Advancing throttle above idle may provide
additional cooling.
Battery Voltage GUARDIAN Engine Guardian System is activated.
Less Than 10v or More Continuous Engine power is limited to 75% of maxi-
Than 16v Horn Above mum.
75% Power
Setting
Engine Coolant Temperature GUARDIAN Engine Guardian System is activated.
(ECT) Sensor Failure Continuous Engine power is limited to 50% of maxi-
Horn Above mum. Engine overheat protection is com-
50% Power promised
Setting

Page 3B-18 90-883065 APRIL 2001

 TROUBLESHOOTING AND DIAGNOSTICS

Component Resistance Tests

NOTE: Refer to section 1C General Information (powerhead reference views) for location
of sensors.
NOTE: If using DMT 2000 turn the selector switch to Ω Allow the meter to auto-range.

Engine Coolant Temperature (ECT) Sensor

Manifold Air Temperature (MAT) Sensor
1. Place the engine coolant temperature sensor in a container filled with water.
2. Place a thermometer in the water and slowly heat the water.
3. Measure the resistance when the specified temperature is reached. If the reading is
out of specification, replace the sensor.

a - Engine Coolant Temperature(ECT) Sensor

270
255
240
Test Water Temperature ( F)

225
210
195
Temperature Sensor
180
165
150
135
120
105
90
75
60
45
30
15
0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32

Resistance (k
)

90-883065 APRIL 2001 Page 3B-19

TROUBLESHOOTING AND DIAGNOSTICS

Fuel Injector

b a

METER TEST LEADS METER SCALE READING

(ANALOG) (

RED BLACK
PIN A PIN B RX1 10 - 13
13.5
5

Main Power Relay

85 86

METER TEST LEADS METER SCALE READING

(ANALOG) (

RED BLACK
PIN 85 PIN 86 RX1 81 - 91

Page 3B-20 90-883065 APRIL 2001

 TROUBLESHOOTING AND DIAGNOSTICS

Manifold Absolute Pressure (MAP) Sensor

b

c a

a - Black/Orange
b - Yellow
c - Purple/Yellow
METER TEST LEADS METER SCALE READING
(ANALOG) (

RED BLACK
PIN A PIN B
95 - 105 K
PIN A PIN C RX1K 3.9 - 4.3 K
PIN B PIN C 95 - 105 K

Crank Position Sensor

METER TEST LEADS METER SCALE READING

(ANALOG) (

RED BLACK
RED WHT RX1 300 - 350

90-883065 APRIL 2001 Page 3B-21