P-501 P-501

TEST STEP RESULT DIAGNOSIS/ACTION

Step 4: Monitor An Electronic Service Tool While
Tugging On Wiring And Connectors
« If there is an Active Diagnostic Code pertaining to the OK = The reading on the Electronic
circuit, monitor the Service Tool Active Code screen Service Tool status screen
while tugging on all harnesses and connectors that does not change. Proceed to
connect to the component with the Active code. If the next step.
Active code disappears while tugging, there is a problem NOT OK = The reading on the Electronic
in the wiring or in the connector. Service Tool status screen
If there is no Active diagnostic code, use the Service Tool changes. Repair as required.
display Status screen to monitor the component status STOP.
while tugging on the harnesses. If the reading changes
erratically while tugging, there is a problem in the wiring
or connector.
If there are no Active Codes, run the engine while
listening and watching the Electronic Service Tool status
screen for the problem to reoccur while turning on the
wiring and connectors. If the problem return, there is a
problem in the wiring or connector.
The reading on the Electronic Service Tool status
screen should not change.

Step 5: Check Wires For Insulation Nicks Or Abrasions

« Carefully inspect each wire for signs of abrasion, nicks, or OK = The wires are free of abrasion,
cuts, Likely locations to check are anywhere the nicks and cuts and the
insulation is exposed, points where the wire rubs against harness clamp is properly
the engine or a sharp point. installed. Proceed to next
* Check all harness hold down clamps to verify the harness step.
is properly clamped and the clamp is not compressing the NOT OK = The wires are not free of
harness. Pull the harness sleeves away to check for abrasion, nicks and cuts or the
flattened wires where the clamp holds the harness. harness clamp is improperly
The wire should be free of abrasion, nicks and cuts and installed. Repair as required.
the harness clamp is properly installed. STOP.

3408 & 3412 High Performance Marine Engines 5-5 Troubleshooting

P-501 P-501

TEST STEP RESULT DIAGNOSIS/ACTION

Step 6: Check Connectors For Moisture Or Corrosion
» Ensure the connector seals and white sealing plugs are in OK = All connectors/seals are
place. If any of the seals or plugs are missing, replace the completely mated/inserted,
seal, plug or necessary connector. and the harness/wiring is free
* Check all wiring harnessers to verify the harness does of corrosion, abrasion or pinch
not make a sharp bend out of a connector. This will points. Proceed to next step.
deform the connector seal and create a moisture entry NOT OK = Ensure all seals are properly in
path. place and connectors are
* Thoroughly inspect ECM connector J14/P14 for evidence completely mated. Verify the
of moisture entry. Pull a few wires from each connector repair eliminates the problem.
and inspect the crimp area for corrosion. Run the engine for several
NOTE: It is normal to see some minor seal abrasion on the minutes and check again for
ECM connector seals. Minor seal abrasion will not cause moisture. If moisture
moisture entry. reappears, it is wicking into the
connector. Even if the
If moisture or corrosion is evident in the connector, the moisture entry path is
source of the moisture entry must be found and repaired repaired, it may be necessary
or the problem will reoccur. Simply drying the connector to replace the wires that have
will not fix the problem. Likely moisture entry paths are moisture wicking through them
missing or improperly installed seals, nicks in exposed as the wires may have
insulation, or unmated connectors. Moisture can also moisture trapped inside the
travel or “wick” from one connector through the inside of insulation. STOP.
a wire to the ECM Connector. If moisture is found in the
ECM connector, thoroughly check all connectors and
wires on the harness that connects to the ECM.
NOTE: The ECM is not the source of the moisture. Do not
replace the ECM if moisture is found in either ECM
connector. If corrosion is evident on pins, sockets or the
connector itself, use only denatured alcohol to
clean/remove the corrosion with a cotton swab or a soft
brush. Do not use any cleaners that contain 1, 1, 1,
trichloro-ethelyene because it may damage the connector.
All connectors/seals should be completely
mated/inserted, and the harness/wiring should be free
of corrosion, abrasion or pinch points.

Step 7: Inspect Connector Terminals

« Verify that terminals are not damaged. OK = Proceed to next step.
» Verify proper alignment and location of terminals in the NOT OK = STOP.
connector.
The terminals should be undamaged and properly
aligned.

3408 & 3412 High Performance Marine Engines 5-6 Troubleshooting

P-501 P-501

TEST STEP RESULT DIAGNOSIS/ACTION

Step 8: Check Individual Pin Retention By The Socket

* This is especially important for intermittent problems. OK = | STOP.
Using a new pin, insert the pin into each socket (one at a NOT OK = | Repair as required. STOP.
time) to check for a good grip on the pin by the socket.
Repeat for each pin on the mating side of the connector,
using a new socket for the test. The terminal contact (pin
or socket) should stay connected if held with the
connector hanging from the connector.

Deutsch Pin Contact Deutsch Socket

Terminal Contact Terminal

The contact should hang properly from the connector.

3408 & 3412 High Performance Marine Engines 57 Troubleshooting

P-504 P-504

P-504: THROTTLE POSITION SENSOR

System Operation

The Throttle Position Sensor is used to provide a Figure P-504.1: Throttle Position Sensor Diagram
throttle signal to the ECM. Sensor output is a constant
frequency signal with a pulse width that varies with
throttle position. This output signal is referred to as
either Duty Cycle or a Pulse Width Modulated (PWM)
signal and is expressed as a percentage between 0
and 100 percent.
Use this procedure to troubleshoot an ACTIVE 91-08
Invalid Throttle Signal (32) or a 91-10 Throttle Sensor
Rate Of Change (28). The ECM may not respond to the
Throttle Position Sensor if there is an ACTIVE 253-02
Check Customer or System Parameters (52).
The sensor will produce a Duty Cycle of 5 to 10 percent
at Low Idle and 90 to 95 percent at Full Throttle. The s
percent duty cycle is translated in the ECM into throttle
position of 0 to 100 percent as seen on the Display NOTE: The ECM may not respond to the Throttle
Status screen. The sensor is powered by a 12 VDC or Position Sensor if there is an Active 253-02 Check
24 VDC switched battery connection to pin-A. Customer or System Parameters (56) Diagnostic Code.

Figure P-504.2: Throttle Position Sensor Schematic

Port TPS Terminal Strip Port Engine J31 Port Engine ECM
T2 3 Customer Connector Connector J14/P14
Signal | C £l 8 €| Primary Throttle
-Battery| B T 2 37€{ Secondary Throttle
“Battery] Aj— 1 17€] Synch Input 1
2. - 36€] Synch Input 2
Synchronization Switch reSalllelhollle€
Skl s tBattToThotle §
'
' -
3 T
1
' 2 N

;fs"gz O H STBD Engine J31 STBD Engine ECM

= ! 1 Customer Connector Connector J14/P14
v t
PR [ ' K[ 8 <{Synch Input 1
Som To 2 37€{Synch Input 2
E;g:\ta c .—H1
*e Sl 17 Primary Throttie
-Battery Torminal Stip 8 36<€{ Secondary Throttle
Batiery| A
+Batte 7¢}<Batt
- To Thottle
| P +Batt To Thottle

3408 & 3412 High Performance Marine Engines 5-8 Troubleshooting

P-504 P-504

Figure P-504.3: Throttle Position Sensor Pin Connector

J14/P14 ECM Connector (Rear View)

Diagnostic Codes

CID-FMI | Conditions which generate this code: Systems Response: Troubleshooting

91-08 | Invalid Throttle Signal The fault is active and logged | Proceed with
Throttle Signal Frequency is less than 150 Hz | and the throttle position is set | P-504: Throttle
or greater than 1000 Hz. to 0 percent. The desired Position Sensor.
engine speed is set to low idle
speed.
91-10 | Throttle Sensor Rate Of Change The fault is active and logged. | Proceed with
Throttle Signal Frequency is changing at an P-504: Throttle
abnormal rate. Position Sensor.

Functional Test

TEST STEP RESULT DIAGNOSIS/ACTION

Step 1: Check Electrical Connectors And Wiring

* Thoroughly inspect J14/P14 ECM Connector, J31/P31 OK = | All connectors, pins, sockets
Customer Connector and the J35/P35 Throttle Position are completely mated and the
Sensor Connector. hamess is free of corrosion,
* Check the harness and wiring for abrasion and pinch abrasion or pinched points.
points from the sensor back to the ECM. Proceed to next step.
« Refer to P-501: Inspecting Electrical Connectors for NOT OK = | All connectors, pins, sockets
additional information. are not completely mated and
the harness is not free of
All connectors/pins/sockets should be completely
mated/inserted, and the harness/wiring should be free
corrosion, abrasion or
pinched points. Repair as
of corrosion, abrasion or pinch points.
required. STOP.

3408 & 3412 High Performance Marine Engines 5-9 Troubleshooting

P-504 P-504

TEST STEP RESULT DIAGNOSIS/ACTION

Step 2: Check System And Customer Parameters

* Ensure all System and Customer Parameters are OK = | If the Desired Engine Speed
programmed. changes when the throttles are
« To begin this procedure remove pin-1 and pin-2 from the moved refer to P-343: Engine
PORT and STBD, J31 Customer Connectors, this will Synchronization Not
ensure that the ECM's will respond to the appropriate Functioning Properly. STOP.
throttle signal. NOT OK = | The Desired Engine Speed
The Desired Engine Speed should change when the does not change when the
throttles are moved. throttles are moved. Proceed
to next step.

Step 3: Check Throttle Position Sensor Supply Voltage

At The Sensor Connector Sensor Side
* Turn keyswitch to the ON position, engine OFF. OK = | The Throttle Position Sensoris
« Insert Signal Reading Probes and measure the voltage at receiving the correct voltage.
J35 (Sensor side) pin-A (+Battery) with reference to pin-B Proceed to next step.
(Battery). NOT OK = | The sensor is not receiving
The voltage should be between 11.0 and 13.5 VDC for a correct voltage. Proceed to
12 VDC operating system and 22 VDC to 27 VDC for a Step 5.
24 VDC operating system.

Step 4: Check Throttle Position Sensor Duty Cycle At

The Sensor Connector Sensor Side
¢ Remove the signal wire from pin-C of the Throttle OK = | The Duty Cycle is between 5
Position Sensor connector J35. Set the 9U-7330 Digital and 10 percent at the low idle
Multimeter to VDC. Press the Hz button twice so the position and between 90 and
percent symbol is displayed. 95 percent at Full Throttle.
« Place the positive probe of the Multimeter on pin-C of the Proceed to Step 6.
Throttle Position Sensor connector J35/P35 (Sensor NOT OK = | Temporarily replace the
side) and the other probe on pin-B of the Throttle Position sensor. Verify that sensor
Sensor connector J35/P35 (Sensor side). Monitor the replacement solves the
Duty Cycle output of the Throttle Position Sensor on the problem before permanently
Multimeter while moving the throttle from low idle to Full replacing the sensor. STOP.
Throttle.
The Duty Cycle should be between 5 and 10 percent at
the low idle position and between 90 and 95 percent at
Full Throttle.
NOTE: The Electronic Service Tool Throttle Position
reading from the Display Status screen will NOT be the
same as the reading from the Digital Multimeter.

3408 & 3412 High Performance Marine Engines 5-10 Troubleshooting

P-504 P-504

TEST STEP RESULT DIAGNOSIS/ACTION

Step 5: Disconnect Throttle Position Sensor While

Monitoring Active Diagnostic Codes
* Access the Electronic Service Tool Active Diagnostic OK = | Replace the Throttle Position
Code screen. Monitor the Active Diagnostic Code screen Sensor. Ensure the
while disconnecting and reconnecting the Throttle Diagnostic Code is cleared,
Position Sensor. and the problem is resolved.
The Diagnostic Code is still Active after the sensor is STOP.
disconnected. NOT OK = | Ensure the Throttle Position
Sensor is reconnected.
Replace the ECM. Refer to
Section 2: ECM
Replacement Procedure.
STOP.

Step 6: Check Throttle Sensor Duty Cycle At ECM

* Turn keyswitch OFF. OK = | Check to ensure the ECM is
+ Remove the signal wire from pin-C of the Throttle receiving proper battery
Position Sensor connector J35/P35 (Sensor side). Set voltage. Check to ensure the
the 9U-7330 Digital Multimeter to VDC. Press the Hz ECM is receiving proper
button twice so the percent symbol is displayed. battery voltage. Refer to
. . Section 3: P-346: Electrical
* Place one probe of the Multimeter on pin-C of the Throttle
- Power Supply to The ECM.
Position Sensor and the other probe on the -Battery STOP.
terminal of the Throttle Position Sensor. Monitor the Duty B 3
Cycle output of the Throttle Position Sensor on the NOT OK = | There is a problem with the
Multimeter while moving the throttle from low idle to Full throttle sensor signal wire in
Throttle. the wiring harness. Proceed
The Duty Cycle should be between 5 and 10 percent at to next step.
the low idle position and between 90 and 95 percent at
Full Throttle.
Step 7: Route Supply Bypass Wires To The Throttle
Position Sensor
* Turn keyswitch OFF. OK = | The problem is in the wiring
* Remove wire from P14 pin-8 (Throttle Position) and P35 hamess. Repair as required.
Socket-C (Throttle Position). STOP.
* Route new wiring from the ECM to the Throttle Position NOT OK = | Replace the Sensor. STOP.
Sensor.
* Turn keyswitch to the ON position, engine OFF.
* Check the Throttle Sensor Duty Cycle with an Electronic
Service Tool while moving the throttle assembly over the
full range.
The Duty Cycle should be between 5 and 10 percent at
the low idle position and between 90 and 95 percent at
Full Throttle.

3408 & 3412 High Performance Marine Engines 5-11 Troubleshooting

P-513 P-513

P-513: ECM/PERSONALITY MODULE

System Operation

The Electronic Control Module (ECM) is the computer Figure P-513.1: ECM/Personality Module Diagram
which controls the engine. The Personality Module is
the software which defines how the computer (ECM) a0
behaves.
Personality Module
The Personality Module consists of:

B
The software (instructions) for the ECM to perform its
function. Updating the Personality Module to a different
version may cause some engine features to behave
J
Personality Module
differently. Access Cover
Performance maps that define fuel rate and timing for Electronic Service Tool

various operating conditions to achieve optimum

Programable Microprocessor
engine performance and fuel consumption. These
Parameters
features are programmed into the personality Module Logged
at the factory. Diagnostics

The ECM consists of: Input Power | - loutput

Circuit Circuit (Circuit
A microprocessor to perform the computing
necessary to execute the ECM's functions such as
governing, injection timing control, system diagnostics Pl
Sensor Sensor Battery
and data link communication. The microprocessors and Supply Voltage
receive instruction from the software stored in the Switch Voltage
Signals
Personality Module.
Permanent memory to store programmable parameters
(refer to Section 2:) and diagnostic codes.
Input Circuits to filter electrical noise from sensor
signals and to protect the ECM's internal circuits from
potentially damaging voltage levels.
Output Circuits to provide the high currents necessary
to energize injector solenoids, lamps and relays.
Power Circuits to provide high voltage for the injector
solenoids and clean stable electrical power for internal
circuits and external sensor.

3408 & 3412 High Performance Marine Engines 512 Troubleshooting

P-513 P-513

Diagnostic Codes

CID-FMI | Conditions which generate this code: Systems Response: Troubleshooting

252-12 | Personality Module Fault The engine will not start. Verify the
The ECM has detected a personality module | Clearing this diagnostic code | Personality
fault. requires resetting the Module installed
Personality Module Code matches the
(interlock) to zero with Factory | engine. If it does,
Passwords. obtain the
required Factory
Passwords and
reset the
Personality
Module Code.
Proceed with
P-513:
ECM/Personality
Module.
253-02 | Check Customer or Systems Parameters The electronic system Proceed with
Indicates a Customer or System Parameter response depends upon the P-513:
has not been programmed, or the Personality cause of the diagnostic code. ECM/Personality
Module Code of the installed Personality -If the Personality Module Module.
Module does not match the Personality Module Code of the installed
in the ECM. Personality Module does not
match the Personality module
in the ECM, the engine is
limited to low idle.
-If the Rating number (#) has
not been selected and is the
cause, the ECM will limit the
engine 119 kW (160 hp)/
-On initial power-up of a new
ECM the following parameters
must be programed to avoid
this diagnostic code. Full Load
Setting (FLS), Full Torque
Setting (FTS), Rating #,
Engine Serial Number. The
CID-FMI may be viewed on
display modules or an
Electronic Service Tool.

3408 & 3412 High Performance Marine Engines 5-13 Troubleshooting

P-513 P-513

CID-FMI | Conditions which generate this code: Systems Response: Troubleshooting

254-12 | ECM Fault The CID-FMI may be viewed | Proceed with
The ECM has detected an internal fault with its | O display modules or an P-513:
memory, microprocessor or power supplies. Electronic Service Tool. It is ECM/Personality
logged in memory. Module.
Engine power and
performance may be affected.
Any normal ECM function may
be affected such as governing,
injection timing control, system
diagnostics and data link
communication.

Functional Test

TEST STEP RESULT DIAGNOSIS/ACTION

Step 1: Check Electrical Connectors And Wiring
* Turn keyswitch OFF. OK = | All connectors/pins/sockets
« Check ECM Connectors J14/P14 for damage or incorrect are completely
attachment. Refer to the Electrical System Schematic for mated/inserted, and the
additional information. harness/wiring is free of
corrosion, abrasion or pinch
All connectors/pins/sockets should be completely points. Proceed to next step
mated/inserted, and the harness/wiring should be free
of corrosion, abrasion or pinch points. NOT OK = | All connectors/pins/sockets
are not completely
mated/inserted, and the
hamess/wiring is not free of
corrosion, abrasion or pinch
points. Repair as required.
STOP.

Step 2: Check ECM Personality Module Part Number

With An Electronic Service Tool
« Connect an Electronic Service Tool at the Service Tool OK = | The correct Personality
Connector. Module is installed, Proceed
« Turn keyswitch to the ON position, engine OFF. to next step.
« Access the Read Customer Specified Parameters NOT OK = | The correct Personality
screen. Refer to Programming Parameters for additional Module is not installed,
information. Replace the Personality
The correct Personality Module should be installed.
Module. STOP.

3408 & 3412 High Performance Marine Engines 5-14 Troubleshooting

P-513 P-513

TEST STEP RESULT DIAGNOSIS/ACTION

Step 3: Check ECM Personality Module

* Turn keyswitch OFF. OK = | The Personality Module is free
* Remove Personality Module access cover and remove of damage and corrosion and
Personality Module. is firmly seated into the
" . Personality Module socket.
. Llsr;r);ci;:\e Personality Module for physical damage and Proceed to next step.

* Inspect the Personality module socket inside the ECM for NOT OK = ;I'he P'ecl;sonality Mgdule is not
physical damage or corrosion. ree of damage and corrosion
. 3 and is not firmly seated into
* Reinstall the Personality Module. the Personality Module socket.
NOTE: Ensure the Personality Module is completely seated Repair as required. STOP.
into the socket and the access cover O-Ring is in place
when reinstalling the cover.
The Personality Module should be free of damage and
corrosion and be firmly seated into the Personality
Module socket.
Step 4: Use An Electronic Service Tool To Review
Parameters And Data
* Turn keyswitch to the ON position, Engine OFF. OK = | The ECM is OK. STOP.
* Check the Active and Logged Diagnostic Event Codes. NOT OK = | Customer Parameters are
* Review the Customer Parameters. scrambled. Try to reprogram
the suspect parameter(s), the
The Customer Parameters should not be scrambled or
ECM should maintain the new
displaying values not possible.
parameters. If not Replace the
ECM. Refer to Section 2:
ECM Replacement
Procedure. STOP.

3408 & 3412 High Performance Marine Engines 5-15 Troubleshooting

P-514 P-514

P-514: ENGINE SPEED SENSOR

System Operation

The ECM Primary Engine Speed Sensor determines Figure P-514.1: Engine Speed Sensor Diagram
engine speed by magnetically detecting the teeth on
the flywheel starter ring gear. The ECM will not try to
start the engine (either energize the shutoff solenoid or
move the BTM) until it senses an engine speed signal. A~ -0
The engine speed is determined by the frequency, not J14/P14
the voltage, of the engine speed sensor output signal.
The output frequency should be between 0 and 5 kHz.
The sensor is supplied with 8 VDC from the ECM. =
The Engine uses two speed sensors: one is the J31/P31
Primary Engine Speed Sensor PI0I10
PRIMARY Engine Speed Sensor and the other is the
BACKUP Engine Speed Sensor. If the Primary Engine
Speed Sensor signal is not present, the Backup Engine BackUp Engine Speed Sensor
Speed Sensor signal will be used and the operator will
be warned about the Primary Engine Speed Sensor
failure.
NOTE: When troubleshooting the Primary Engine
Speed Sensor disconnect the Backup Engine Speed
Sensor from the system at P16/J16.

Figure P-514.2: Engine Speed Sensor Schematic

ECM
P14/J14
P10/J10
Primary Engine Speed C| 18€| Primary Engine Speed
Sensor Common B * 35« Sensor Common
+8VDC Al 10« +8 VDC
284 Backup Engine Speed

P16/J16
Backup Engine Speed —p1
Sensor Common 2

Figure P-514.3: Engine Speed Sensor Pin Connector

J14/P14 ECM Connector (Rear View)

3408 & 3412 High Performance Marine Engines 5-16 Troubleshooting

P-514 P-514

Diagnostic Codes

CID-FMI | Conditions which generate this code: Systems Response: Troubleshooting

64-02 | Loss of Secondary Speed/Timing Signal The CID-FMI may be viewed Proceed with
The Secondary Speed/Timing signal to the on the display modules or an P-514: Engine
ECM was lost, without a ramp-down in engine Electronic Service Tool. It is Speed Sensor.
rpm and the ring gear pattern returns within logged in memory except as
one second of being lost. This fault is logged noted.
only if the engine has been running for three
seconds.
64-08 | Secondary Engine Speed Out Of Range The fault is active and logged. Proceed with
The ECM detects and engine speed greater The shutdown solenoid will de- P-514: Engine
than 3000 rpm, due to noise or other energize until the engine Speed Sensor.
conditions. speed is below 2410 rpm.

190-02 | Loss Of Engine RPM Signal The CID-FMI may be viewed Proceed with
The primary engine rpm signal is lost, without a on a display module or an P-514: Engine
ramp-down in engine rpm and the ring gear Electronic Service Tool. It is Speed Sensor.
pattern returns within one second of being lost. logged in memory except as
This fault is logged only if the engine has been noted.
running for three seconds and is not cranking.
190-08 | Engine Speed Out Of Range The fault is active and logged. Proceed with
The ECM detects and engine speed greater The shutdown solenoid will de- P-514: Engine
than 3000 rpm, due to noise or other energize until the engine Speed Sensor.
conditions. speed is below 2410 rpm.

190-10 | Engine Speed Rate Of Change The fault is active and logged. Proceed with
The ECM detects the engine speed is P-514: Engine
changing at an abnormal rate. Speed Sensor.

Functional Test

TEST STEP RESULT DIAGNOSIS/ACTION

Step 1: Inspect Electrical Connectors And Wiring
* Turn keyswitch to the OFF position. OK = All connectors/pins/sockets
* Check ECM Connector P14/J14, Backup Speed Sensor are completely mated/inserted
Connector P16/J16, Primary Speed Sensor Connector and the hamess/wiring is free
P10/J10 and associated wiring for damage, abrasion, of corrosion, abrasion or pinch
corrosion or incorrect attachment. points. Proceed to next step.

« Refer to P-501: Inspecting Electrical Connectors for NOT OK = All connectors/pins/sockets

details. are not completely
mated/inserted and the
All connectors/pins/sockets should be completely
harness/wiring is not free of
mated/inserted and the harness/wiring should be free
corrosion, abrasion or pinch
of corrosion, abrasion or pinch points.
points. Repair as required.
STOP.

3408 & 3412 High Performance Marine Engines 5-17 Troubleshooting

P-514 P-514

TEST STEP RESULT DIAGNOSIS/ACTION

Step 2: Check For Logged Diagnostic Codes
* Connect an Electronic Service Tool. OK = | The Electronic Service Tool
« Tumn keyswitch to the ON position, Engine OFF. 2”;&0132)95 a 1693-[())22 1%3%3
. . " . - ora - or -08.
ézcdeesss a status screen displaying Logged Diagnostic Proceed to next step.

The Electronic Service Tool should indicate a 190-02, NOT OK = ZQSSE;?)‘:';:(;:L‘;‘S::’:C:OTSZ‘JI

190-0: -1 4- 4-08.
8, 190-10 or a 64-02 or 6 190-08, 190-10 or a 64-02e or
64-08. STOP.

Step 3: Check Engine RPM With An Electronic Service

Tool While Cranking The Engine
* Turn keyswitch OFF. OK = | The problem is not active at
NOTE: If troubleshooting the Primary Speed Sensor this time or is not with the
Disconnect the Backup Speed Sensor. If Troubleshooting Engine Speed Sensor. STOP.
the Backup Speed Sensor disconnect the Primary Speed NOT OK =5 | The Electronic Service Tool
Sensor. does not indicate an engine
« Connect an Electronic Service Tool directly to the ECM rpm greater than 0 rpm while
and to a separate battery. cranking and the engine does
+ Turn keyswitch to the ON position, Engine OFF. not start. Proceed to next
step.
" . .
« Access a status screen displaying engine RPM.
* While cranking the engine observe the engine rpm
displayed on the Electronic Service Tool.
Engine RPM while cranking should show a steady
reading between 100 and 500 rpm.

Step 4: Check Engine Speed Signal Resistance To

Case
* Turn keyswitch OFF. OK = | The resistance is in range.
« Disconnect the suspect Speed Sensor connector Proceed to next step.
P10/J10 (Primary Speed Sensor) or P16/J16 Backup NOT OK = | The resistance is out of range.
Speed Sensor). Proceed to Step 6.
* Turn keyswitch to the ON position, engine OFF.
« Use a 9U7330 Digital Multimeter to measure the
resistance at the Hamess side of the sensor connector,
J10 pin-A for the Primary Engine Speed Sensor, and J16
pin-B for the Backup Engine Speed Sensor to the case of
the transducer module.
The resistance should be greater than 250k ohms.

3408 & 3412 High Performance Marine Engines 5-18 Troubleshooting

P-514 P-514

TEST STEP RESULT DIAGNOSIS/ACTION

Step 5: Check Engine Speed Signal With An Electronic
Service Tool
* Turn keyswitch OFF. OK => | The engine RPM shows a
« Disconnect the known good sensor and reconnect the steady reading between 100
suspect sensor. and 500 rpm. The sensor is
« Connect an Electronic Service Tool to the J13 Service operating correctly. STOP.
Tool Connector. NOT OK = | The engine RPM does not
. . e ” " how a steady reading
« Crank the engine and monitor the “Engine RPM” reading S!
on the Display Status Screen. between 100 and 500 rpm.
. . . Proceed to Step 7.
Engine RPM while cranking should show a steady
reading between 100 and 500 rpm.

Step 6: Check For Proper Installation

* Turn keyswitch OFF. OK = | Replace the Sensor. STOP.
Disconnect J10/P10 (or J16/P16) and remove the
Primary (or Backup Speed Sensor).
Inspect the sensor and ensure the sensor makes contact
with the flywheel.
Ensure the electronic sensor is backed out 195 + 15
DEG.
Ensure the locknut has been tightened to a torque of 13.5
+1.0Nm (1209 b in).
See Figure P-514.4.
The sensor should show no signs of damage.

Figure P-514.4: Speed Sensor Sliphead

-
Speed/Timing
Wheel

3408 & 3412 High Performance Marine Engines 5-19 Troubleshooting

P-514 P-514

TEST STEP RESULT DIAGNOSIS/ACTION

Step 7: Check Engine Speed Signal At The ECM
* Set the 9U-7730 Digital Multimeter to VDC and press the OK = The suspect Engine Speed
Hz button. Sensor signal is reaching the
* Using signal reading probes place the positive probe at ECM. Replace the ECM.
the ECM Connector J14/P14 pin-18 (Engine Speed) and Refer to Section 2: ECM
the other probe on J14/P14 pin-1 (-Battery). Replacement Procedure.
STOP.
* Crank the engine and observe the frequency of the
suspect Engine Speed Sensor signal. BACKUP = The Backup Engine Speed
Signal is not reaching the
The frequency displayed should be between 150 and
ECM. Proceed to next step.
1000 Hz and remain steady while cranking the engine.
PRIMARY = The Primary Engine Speed
Signal is not reaching the
ECM. Proceed to Step 9.

Step 8: Check Backup Engine Speed Sensor Operation

* Remove the signal wire at pin-2 of the Backup Engine OK = The frequency displayed on
Speed Sensor Connector P16/J16. the 9U-7330 Digital
* Set the 9U-7730 Digital Multimeter to VDC and press the Multimeter is between 150 and
Hz button. 1000 Hz and remain steady
while cranking the engine. The
* Using signal reading probes place the positive probe at
Backup Engine Speed Sensor
pin-2 of P16/J16 and the other probe at the transducer
is operating correctly. The
case.
signal is not getting through
* Crank the engine and observe the frequency of the the transducer module to the
Backup Engine Speed Sensor signal. ECM. Recheck sensor
The frequency displayed should be between 150 and connector and wiring for
1000 Hz and remain steady while cranking the engine. damage, corrosion, or
incorrect attachment. If no
damage is found then replace
the transducer module. Verify
the repair eliminates the
problem. STOP.
NOT OK = The Backup Engine Speed
Sensor is not generating a
signal. Replace the Sensor,
verify that the repair eliminates
the problem. STOP.

Step 9: Check Sensor Supply Voltage At The Primary

Engine Speed Sensor
* Use a 9U-7330 Digital Multimeter and measure the OK = The voltage is 8 VDC + .4
voltage at the Primary Engine Speed Sensor Connector VDC. Proceed to next step.
P10/J10 pin-A to pin-B. NOTOK = The voltage is not 8 VDC = .4
The voltage should be 8 VDC = .4 VDC. VDC. Refer to P-522: Digital
Sensor Supply. STOP.

3408 & 3412 High Performance Marine Engines 520 Troubleshooting

P-514 P-514

TEST STEP RESULT DIAGNOSIS/ACTION

Step 10: Check Engine Speed Sensor Operation

* Remove the signal wire at pin-C of the Primary Engine OK = | The frequency displayed on
Speed Sensor Connector P10/J10. the 9U-7330 Digital
« Set the 9U-7730 Digital Multimeter to VDC and press the Multimeter is between 150 and
Hz button. 109|0 Hz al?_d remain s?eady
* Using signal reading probes place the positive probe at gg:ficragn";ge‘hg Z?d'"e‘ The
pin-C of P10/J10 and the other probe at the transducer s Ty =ngine =p "
case. ensor is operatlng c_orrect ly.
. The signal is not getting
Crank the engine and observe the frequency of the through the transducer module
Primary Engine Speed Sensor signal. to the ECM. Recheck sensor
The frequency displayed on the 9U-7330 Digital connector and wiring for
Multimeter should be between 150 and 1000 Hz and damage, corrosion, or
remain steady while cranking the engine. incorrect attachment. If no
damage is found then replace
the transducer module. Verify
the repair eliminates the
problem. STOP.
NOT OK = | The Primary Engine Speed
Sensor is not generating a
signal. Replace the Sensor,
verify that the repair eliminates
the problem. STOP.

3408 & 3412 High Performance Marine Engines 5-21 Troubleshooting

P-515 P-515

P-515: RACK POSITION SENSOR

System Operation

The Rack Position Sensor is magnetically attached to Figure P-515.1: Rack Position Sensor Diagram
the fuel rack. The sensor is supplied with +8 VDC for
operation and uses +5 VDC for reference. The signal
output of 0.3 VDC to 5.25 VDC is read by the ECM as
rack position of 0 to 17.5 mm (0 to 0.69 in). A~ @
J14/P14

o
Rack BTM
P6/J6

Rack ack Position

Position S Sensor P

b—mmp—01
Figure P-515.2: Rack Position Sensor Schematic
P14/J14 EcM
Rack Position Sensor J1P1
+8 VDC Al 10€{+8 VDC
Sensor Common B 35€ Sensor Common
+5VDC C| 30« +5VDC
Rack Position D 40« Rack Position
23€{Rack BTM
22 <] Solenoid Common

Rack Solenoid

P6/J6
A
B
HclH

3408 & 3412 High Performance Marine Engines 5-22 Troubleshooting

P-515 P-515

Figure P-515.3: Rack Solenoid Pin Connector

J14/P14 ECM Connector (Rear View)

3 % 33 3435 ,35
—
37 38 39 40

Diagnostic Codes

CID-FMI | Conditions which generate this code: Systems Response: Troubleshooting

24-03 | Rack Sensor Open Circuit The fault logged. The ECM Proceed with
Rack Sensor voltage equals +5 VDC and uses engine speed to govern | P-515: Rack
desired rack is less than 16.0 mm (0.63 in) and | the engine (the rack sensor | Position Sensor.
there are no sensor supply voltage faults. signal is ignored), and the rack
limit is set to 13.5 mm
(0.53in).
24-04 | Rack Sensor Short Circuit The fault logged. The ECM Proceed with
Rack Sensor voltage is less than 0.3 VDC and | uses engine speed to govem | P-515: Rack
no sensor supply voltage faults are present. the engine (the rack sensor Position Sensor.
signal is ignored), and the rack
limit is set to 13.5 mm
(0.53in).
24-07 |Rack System Fault The fault logged. The ECM Proceed with
The mechanical system of the rack position uses engine speed to govern | P-515: Rack
sensor is not responding correctly. the engine (the rack sensor Position Sensor.
signal is ignored), and the rack
limit is set to 13.56 mm
(0.53in).
24-10 | Rack Sensor Rate of Change The fault logged. The ECM Proceed with
Rack position sensor is changing at an uses engine speed to govern P-515: Rack
abnormal rate. the engine (the rack sensor Position Sensor.
signal is ignored), and the rack
limit is set to 13.56 mm
(0.53 in).

3408 & 3412 High Performance Marine Engines 5-23 Troubleshooting

P-515 P-515

Functional Test

TEST STEP RESULT DIAGNOSIS/ACTION

Step 1: Check For Connector Damage

* Turn keyswitch to the OFF position. OK = | All connectors/pins/sockets
« Check ECM Connector P14/J14, Rack Position Sensor are completely mated/inserted
Connector P11/J11, Rack Solenoid (BTM) Connector and the hamess/wiring is free
P6/J6 and associated wiring for damage, abrasion, of corrosion, abrasion or pinch
corrosion or incorrect attachment. Refer to P-501: points. Proceed to next step.
Inspecting Electrical Connectors for details. NOT OK = | All connectors/pins/sockets
All connectors/pins/sockets should be completely are not completely
mated/inserted and the harness/wiring should be free mated/inserted and the
of corrosion, abrasion or pinch points. harness/wiring is not free of
corrosion, abrasion or pinch
points.
Step 2: Verify Calibration of the Sensor
+ Verify that the Rack Position Sensor is calibrated. OK = Th.e Rack Position Sensor s
) . calibrated. Proceed to next
* Refer to Section 3: P-378 Rack Position Sensor step.
Calibration Procedure.
NOT OK = | The Rack Position Sensor
could not be calibrated.
Replace the Rack Position
. " Sensor, Verify that the repair
The Rack Position Sensor should be calibrated. eliminates the problem. STOP.

Step 3: Check Rack Position Reading ON Electronic

Service Tool
* Remove the Rack Solenoid (BTM). OK = | The Rack Solenoid is reading
« Turn keyswitch to the ON position, engine OFF. 2)2 mm (0.07 in) in the Fuel
* Move the rack back and forth by hand and observe the position anq increases to
“Rack Pos” reading on the Electronic Service Tool 17.5 mm (0.601in) in the Fuel
display screen On position. The Rack
splay ) solenoid is operating
NOTE: The manual shutoff lever may have to be rotated correctly. STOP.
clockwise to free up the rack. NOT OK = | The Rack Solenoid is not
The Rack Solenoid reading should be 1.8 mm (0.07 in) reading 1.8 mm (0.07 in) in the
in the Fuel Off position and increase to 17.5 mm Fuel Off position or 17.5 mm
(0.60 in) in the Fuel On position. (0.60 in) in the Fuel On
position. Proceed to next
step.

3408 & 3412 High Performance Marine Engines 524 Troubleshooting

P-515 P-515

TEST STEP RESULT DIAGNOSIS/ACTION

Step 4: Check Supply Voltages At The Rack Position
Sensor
* Disconnect the Rack Position Sensor connector P11. OK = | The voltage should measures
« Measure the voltage at the Rack position sensor 8 0.4 VDC at pin-A and pin-B
connector J11/P11 from pin-A to pin-B. and 5 +0.25 VDC at pin-C to
. . pin-B. Proceed to next step.
* Measure the voltage from pin-C to pin-B.
" NOT OK = | The voltage was less than
The voltage should measure 8 + 0.4 VDC at
piB an D o025 VDo ot pineG1o pineB. P pin-A to
5VDC | 4.75 VDC or greater than 5.25
- ) VDC. Refer to P-521: Analog
Sensor Supply. STOP.
NOT OK = | The voltage was less than 7.6
8VDC VDC or greater than 8.4 VDC.
Refer to P-522: Digital
Sensor Supply. STOP.
Step 5: Check Resistance Through The Engine Harness
« Disconnect the Rack Position Sensor from the engine OK = | The resistance is less than 10
harness. Ohms. Proceed to next step.
* Measure the resistance between NOT OK = | The resistance is greater than
« pin-A at P11 and pin-10 of P14 10 Ohm. There is an Open
L . 4 circuit in the engine harness,
° p!n Bat P11 and pl.n 35 of P1 repair as required. STOP.
* pin-C at P11 and pin-30 of P14
* pin-D at P11 and pin-40 of P14
The resistance should be less than 10 Ohms. Wiggle
the harness to reveal an intermittent open condition.

Step 6: Check For Shorts In The Engine Harness

« Disconnect the Rack Position Sensor from the engine OK = | The resistance is greater than
harness. 20k Ohms. Proceed to next
Measure the resistance at P11 between step.
* pin-A and pin-D NOT OK = | The resistance is less than
20k Ohms. There is an short
* pin-B and pin-D
circuit in the engine harness,
* pin-C and pin-D repair as required. STOP.
* Wiggle the harness to reveal an intermittent short
condition.
The resistance should be greater than 20k Ohms.

3408 & 3412 High Performance Marine Engines 5-25 Troubleshooting

P-515 P-515

TEST STEP RESULT DIAGNOSIS/ACTION

Step 7: Check Rack Signal At The ECM
* Measure the voltage from pin-40 to pin-35 at the ECM OK = The voltage is greater than 4.4
Connector J14/P14 while moving the rack back and forth VDC in the Fuel Off position,
by hand. less than 1.8 mm (0.07 in) and
The voltage should be greater than 4.4 VDC in the Fuel smoothly decreases to less
Off position, less than 1.8 mm (0.07 in) and smoothly than 0.65 VDC in the Fuel On
decrease to less than 0.65 VDC in the Fuel On position, position, 16.5 mm (0.65 in).
16.5 mm (0.65 in). Replace the ECM.
Refer to Section 2: ECM
Replacement Procedure.
STOP.
NOT OK = The voltage is less than 4.4
VDC in the Fuel Off position,
less than 1.8 mm (0.07 in) and
does not smoothly decreases
to less than 0.65 VDC in the
Fuel On position, 16.5 mm
(0.65 in). Replace the Rack
Position Sensor. Verify the
repair eliminates the problem.
STOP.

3408 & 3412 High Performance Marine Engines 5-26 Troubleshooting

P-521 P-521

P-521: ANALOG SENSOR SUPPLY

System Operation

The Analog Sensor Supply is used to provide power to Figure P-521.1: Analog Sensor Supply Diagram
all analog sensors. The Analog Sensors are: Boost
Pressure, Oil Pressure, Rack Position and the
Transmission Oil Pressure Sensors. The ECM supplies
5.0 +0.2 VDC from pin-30 (+V Analog) to the sensor
@A‘\@
connector pin-A except for the Rack Position Sensor
J14/P14
which is supplied on pin-C. The sensor connector
return line, pin-B connects to pin-35 (Sensor Common).
The Analog Sensor Supply is output short circuit
protected, meaning a short to +Battery or the Battery
Bus Bar, will not damage the circuit inside the ECM. U
Boost Pressure Sensor P8Is

Oil Pressure Sensor

Rack Position Sensor

P11

Transmission Ol Pressure

3408 & 3412 High Performance Marine Engines 5-27 Troubleshooting

P-521 P-521

Figure P-521.2: Analog Sensor Supply Schematic

ECM
Boost Pressure Sensor P14/J14
P8/J8
Boost Pressure 25« Boost Pressure
Sensor Common B 35« Sensor Common
+5vDC—KA| + 30€] +5VDC
27 €] Oil Pressure
Qil Pressure Sensor oy
114 Transmission Oil Pressure
Oil Pressure C] 40€| +8 VDC
Sensor Common 10€{ Rack Position
+5VDC 'd

Transmission Oil Pressure

J33/P33
Transmission Oil Pressure
Sensor Common Bl
+5VDC -+

Rack Position Sensor P

+8 VDC A
Sensor Common Blere
+5VDC :tc
Rack Position Dj

Diagnostic Codes

CID-FMI Conditions which generate this code: Systems Response: Troubleshooting

241-00 +5 VDC Open Circuit All sensors powered by the Proceed with
The supply voltage for all Analog sensors is supply are set to default P-521: Analog
higher than it should be. values. All Diagnostic Codes Sensor Supply.
for sensors Powered by the
supply are disabled while this
diagnostic code is Active. An
Active Diagnostic code may
not cause any noticeable
effect on engine response, or it
may cause white smoke on
startup or low power.

3408 & 3412 High Performance Marine Engines 5-28 Troubleshooting

P-521 P-521

CID-FMI | Conditions which generate this code: Systems Response: Troubleshooting

241-01 | +5 VDC Short Circuit All sensors powered by the Proceed with
The supply voltage for all Analog sensors is supply are set to default P-521: Analog
lower than it should be. values. All Diagnostic Codes | Sensor Supply.
for sensors Powered by the
supply are disabled while this
diagnostic code is Active. An
Active Diagnostic code may
not cause any noticeable
effect on engine response, or it
may cause white smoke on
start-up or low power.

Functional Test

TEST STEP RESULT DIAGNOSIS/ACTION

Step 1: Inspecting Electrical Connectors And Wiring
¢ Turn keyswitch OFF. OK = | All connectors, pins, sockets
« Check ECM Connectors J14/P14 and the Analog Sensor are completely mated and the
Connectors for damage or incorrect attachment. Refer to harness is free of corrosion,
the Electrical System Schematic for additional abrasion or pinched points.
information. Proceed to next step.
* Refer to P-501: Inspecting Electrical Connectors for NOT OK = [ All connectors, pins, sockets
additional information. are not completely mated and
All connectors, pins, sockets should be completely the harnessgs not free of
mated and the harness should be free of corrosion, ;?r:(r:‘:zgr;oain:sasg:p::r as
abrasion or pinched points. required. STOP.

Step 2: Check Harness For Shorts

« Disconnect ECM Connectors J14/P14, and all Analog OK = | Resistance is more than 20k
Sensors. Ohms for each measurement.
« Set the multimeter on the 20k Ohm scale and measure Proceed to next step.
the resistance between P14 socket-30 (+V Analog) and NOT OK => | Resistance is less than 20k
P14 socket-35 (Analog Sensor Common). Ohms for each measurement.
« Measure the resistance between P14 socket-30 (+V There is a short circuit in the
Analog) and the -Battery Bus Bar. harness or connectors. Repair
* Measure the resistance between P14 socket-30 (+V or replace the hamess. STOP.
Analog) and +Battery.
« Measure the resistance between P14 socket-30 (+V
Analog) and P14 socket-35 (Analog Sensor Common).
* Wiggle the harness to reveal an intermittent condition.
See Figure P-521.3.
Resistance should be more than 20k Ohms for each
measurement.

3408 & 3412 High Performance Marine Engines 5-29 Troubleshooting

P-521 P-521

Figure P-521.3: Analog Sensor Supply Pin Connector (Front View)

ECM Connector 4mevew)

40 39 38 37_36 -34 33 382 31

TEST STEP RESULT DIAGNOSIS/ACTION

Step 3: Analog Sensor Supply Test At ECM
* Reconnect ECM Connector J14/P14. OK = | The Analog Supply circuit is
* Turn keyswitch to the ON position, engine OFF. producing the correct voltage.
* Use the Signal Reading Probe to measure the Analog Proceed to next step.
Sensor Supply voltage between pin-30 (+ V Analog) and NOT OK = | The Analog Supply circuit is
pin-35 (Analog Sensor Common). not producing the correct
voltage. Be sure the ECM is
See Figure P-521.4.
receiving the correct voltage
The voltage should measure 5.0 = 0.5 VDC from the battery. Refer to
Section 3: P-346 Electrical
Power Supply to the ECM.
STOP.

Figure P-521.4: Analog Sensor Supply Pin Connector

ECM Connector P1¢/J14 (Rear View)

TEST STEP RESULT DIAGNOSIS/ACTION

Step 4: Analog Sensor Supply Voltage Test At Sensors

* Measure the Analog Sensor Supply voltage between pin OK = | The voltage is in range.
or socket-A (+5 VDC) and pin or socket-B (Sensor Proceed to next step.
Common) on all analog sensors. For the Rack Position NOT OK = | The voltage is not in range.
Sensor, measure the voltage on pin-C to pin-B There is an open circuit in the
* Wiggle the harness to reveal an intermittent or open harness or connectors. Repair
condition. as required. Refer to Electrical
The voltage should measure 5.0 + 0.5 VDC. System Schematic. Verify
repair by checking Analog
Sensor Supply wires. STOP.

3408 & 3412 High Performance Marine Engines 5-30 Troubleshooting

P-521 P-521

TEST STEP RESULT DIAGNOSIS/ACTION

Step 5: Check Analog Sensors For Shorts

* Connect all analog sensors except for the Rack Position OK = | The Analog Sensor Supply
Sensor, one sensor at a time, while checking the Analog and harness are OK. Refer to
Sensor Supply voltage between pin-A (+5 VDC) and P-501: Inspecting Electrical
pin-B (Sensor Common) of each analog sensor Connectors if troubleshooting
connector after each connection is made. an intermittent problem.
NOTE: The voltage should measure 5.0 = 0.5 VDC. STOP.
* Connect the Rack Position Sensor. NOT OK = | The Analog Sensor Supply
« Clear all of the Active Diagnostic Codes from the yolyage is within the ?‘a‘ed
Electronic Service Tool limits before connecting a
B . sensor and is outside of the
* Tum the keyswitch OFF. limits after the sensor is
* Wait 15 seconds and turn the keyswitch to the ON connected, the sensor is
position, engine OFF. faulty. Replace the sensor.
* Check to see if the diagnostic code returned after the Verify that the sensor
Rack Position Sensor was reconnected. replacement solves the
« Tum keyswitch OFF. problem before permanently
installing the new sensor.
The voltage should measure 5.0 = 0.5 VDC and there STOP.
should be no Active Diagnostic Codes after the Rack
- f RACK = | The Analog Sensor Supply
Position Sensor is reconnected. y
POSITION voltage is within the stated
limits and no Diagnostic
Codes are Active before
connecting the Rack Position
Sensor, and a Diagnostic
Code appears after
reconnecting the Rack
Position Sensor. Replace the
Rack Position Sensor. STOP.

3408 & 3412 High Performance Marine Engines 5-31 Troubleshooting

P-522 P-522

P-522: DIGITAL SENSOR SUPPLY

System Operation

The Digital Sensor Supply is used to provide power to Figure P-522.1: Digital Sensor Supply Diagram
all digital sensors. The Digital Sensors are: Primary
Engine Speed, Coolant Level, Coolant Temperature
and the Transmission Oil Temperature Sensor.
The ECM supplies 8.0 + 0.2 VDC from pin-10 (+8 VDC)
to sensor connector pin-A. The sensor connector return J14/P14
line, pin-B connects to pin-35 (Digital Return).
The Digital Sensor Supply is output short circuit
protected, meaning a short to +Battery or -Battery will
not damage the circuit inside the ECM.

Primary Engine Speed Sensor P10/J10

o———=1-lI]
Coolant Level Sensor

Coolant Temperature Sensor P12

il
Transmission Temperature Sensor a4 /pay
= (I

Rack Position Sensor

I I J11/P11

3408 & 3412 High Performance Marine Engines 5-32 Troubleshooting

P-522 P-522

Figure P-522.2: Digital Sensor Supply Schematic

P14/014 Ecm
JTIP7
Coolant Level C 26| Coolant Level
Sensor Common B> 35<] Sensor Common
+8 VDC Al 2 g 10€] +8 VDC
18+ Engine Speed Sensor
J10/P10 20« Coolant Temperature
Engine Speed Sensor ~ 2 | 11<] Transmission Oil Pressure
Sensor Common B9 30 +5 vDC
+8VDC A 40<{ Rack Position

J12/P12
Coolant Temperature
Sensor Common B{>r¢
+8 VDC A T

P34/J34
Transmission Temperature A
Sensor Common B| >
+8 VDC |—p ¢

Jpit
+8VDC
Sensor Common B
+5VDC Ci
Rack Position D

Diagnostic Codes

CID-FMI | Conditions which generate this code: Systems Response: Troubleshooting

241-02 | +8 VDC Open Circuit The fault is current and active. | Proceed with
The supply voltage for all Digital sensors is P-522: Digital
below the normal range. Sensor Supply.
241-03 |+8 VDC Short Circuit The fault is current and Proceed with
The supply voltage for all Digital sensors is less | logged- P-522: Digital
than 6.4 or greater than 9.6 VDC. Sensor Supply.

3408 & 3412 High Performance Marine Engines 5-33 Troubleshooting

P-522 P-522

Functional Test

TEST STEP RESULT DIAGNOSIS/ACTION

Step 1: Inspecting Electrical Connectors And Wiring

* Turn keyswitch OFF. OK = | All connectors, pins, sockets
* Check ECM Connectors J14/P14 and the Digital Sensor are completely mated and the
Connectors for damage or incorrect attachment. Refer to harness is free of corrosion,
the Electrical System Schematic for additional abrasion or pinched points.
information. Proceed to next step.
« Refer to P-501: Inspecting Electrical Connectors for NOT OK = | All connectors, pins, sockets
additional information. are not completely mated and
All connectors, pins, sockets should be completely the “a_”‘essés not free of
mated and the harness should be free of corrosion, gfi;fijgr;oain{:sgjgpgirr as
abrasion or pinched points. required. STOP.

Step 2: Check Harness For Shorts

* Disconnect ECM Connectors J14/P14, and all Digital OK = | Resistance is more than 20k
Sensors. Ohms for each measurement.
« Set the multimeter on the 20k Ohm scale and measure Proceed to next step.
the resistance between P14 socket-10 (+8 VDC) and P14 NOT OK = | Resistance is less than 20k
socket-35 (Digital Sensor Common). Ohms for each measurement.
Measure the resistance between P14 socket-10 (+8 There is a short circuit in the
VDC) and -Battery. harness or connectors. Repair
or replace the harness. STOP.
Measure the resistance between P14 socket-10 (+8
VDC) and +Battery.
Measure the resistance between P14 socket-10 (+8
VDC) and P14 socket-35 (Digital Sensor Common).
See Figure P-522.3.
Resistance should be more than 20k Ohms for each
measurement.

Figure P-522.3: Digital Sensor Supply Pin Connector (Front View)

ECM Connector (FrontView)

" (elojelo)e)
40 39 38 3736

3408 & 3412 High Performance Marine Engines 5-34 Troubleshooting

P-522 P-522

TEST STEP RESULT DIAGNOSIS/ACTION

Step 3: Digital Sensor Supply Test At ECM

* Reconnect ECM Connector J14/P14. OK = | The Digital Supply circuit is
« Turn keyswitch to the ON position, engine OFF. producing the correct voltage.
« Use the Signal Reading Probe to measure the Digital Proceed to next step.
Sensor Supply voltage between pin-10 (+ V Digital) and NOT OK = | The Digital Supply circuit is not
pin-35 (Digital Sensor Common). producing the correct voltage.
Be sure the ECM is receiving
See Figure P-522.4.
the correct voltage from the
The voltage should measure 8.0 + 0.5 VDC. battery. Refer to Section 3:
P-346 Electrical Power
Supply to the ECM. STOP.

Figure P-522.4: Digital Sensor Supply Pin Connector

J14/P14 ECM Connector (Rear View)
—

TEST STEP RESULT DIAGNOSIS/ACTION

Step 4: Digital Sensor Supply Voltage Test At Sensors
* Measure the Digital Sensor Supply voltage between pin OK= | The voltage is in range.
or socket-A (+8 VDC Supply) and pin or socket-B (Digital Proceed to next step.
Return) on the harness side of all digital sensor NOT OK = | The voltage is not in range.
connectors. Ensure that you are measuring on the There is an open circuit in the
harness side of the connector since the sensors are harness or connectors. Repair
disconnected. as required. Refer to Electrical
* For the Rack Position Sensor, measure the voltage on System Schematic. Verify
pin-A to pin-B. repair by checking Digital
* Wiggle the harness to reveal an intermittent or open Sensor Supply wires. STOP.
condition.
The voltage should measure 8.0 = 0.5 VDC.

3408 & 3412 High Performance Marine Engines 5-35 Troubleshooting

P-522 P-522

TEST STEP RESULT DIAGNOSIS/ACTION

Step 5: Check Digital Sensors For Shorts
* Connect all digital sensors one sensor at a time, while OK = The Digital Sensor Supply and
checking the Digital Sensor Supply voltage between pin harness are OK. Refer to
or socket-A (+8 VDC Supply) and pin or socket-B (Digital P-501: Inspecting Electrical
Return) of each digital sensor connector after each Connectors if troubleshooting
connection is made. an intermittent problem.
* For the Rack Position Sensor, measure the voltage on STOP.
pin-A to pin-B. NOT OK = The Digital Sensor Supply
* Turn keyswitch OFF. voltage is within the stated
limits before connecting a
The voltage should measure 8.0 + 0.5 VDC.
sensor and is outside of the
limits after the sensor is
connected, the sensor is
faulty. Replace the sensor.
Verify that the sensor
replacement solves the
problem before permanently
installing the new sensor.
STOP.

3408 & 3412 High Performance Marine Engines 5-36 Troubleshooting

P-542 P-542

P-542: RACK SOLENOID

System Operation

The Rack BTM (Brushless Torque Motor) is used to Figure P-542.1: Rack Solenoid Diagram
move the engine fuel rack. The Rack Solenoid is spring
actuated to the Fuel OFF position and will move into
the Fuel ON range when a voltage is applied.
A X0
J14/P14

d
Rack BTM

Rack Position Sensor

Figure P-542.2: Rack Solenoid Schematic

P14/J14 ECM
Rack Position Sensor JP1
+8VDC A 10€{+8 VDC
Sensor Common B 35« Sensor Common
+5VDC—K C 30€+5 VDC
Rack Position— D] 40 €| Rack Position
23€{Rack BTM
22« Solenoid Common

Rack Solenoid

P6/J6
A
B

3408 & 3412 High Performance Marine Engines 5-37 Troubleshooting

P-542 P-542

Figure P-542.3: Rack Solenoid Pin Connector

J14/P14 ECM Connector (Rear View)

—

Diagnostic Codes

CID-FMI | Conditions Which Generate This Code: |Systems Response: Troubleshooting

23-02 Excessive Engine Power The fault is active and logged. | Proceed with
Actual Rack is greater than Desired Rack, | Factory passwords
are P-542: Rack
the ECM has detected excessive power | equired to clear this code. Solenoid.
being generated.
23-05 Rack BTM Open Circuit The fault is active and logged. | Proceed with
Actual Rack is not following Desired Rack | The ECM uses engine speed | P-542: Rack
closely enough and there are no sensor |t govern the engine (the rack | Solenoid.
supply voltage faults and the Rack sensor signal is ignored), and
Solenoid (BTM) position is less than the rack limitis set to 13.5 mm
desired. (0.53in).

23-06 Rack BTM Short Circuit The fault is active and logged. | Proceed with
Actual Rack is not following Desired Rack | The ECM uses engine speed = | P-542: Rack
closely enough and there are no sensor | to govern the engine (the rack | Solenoid.
supply voltage faults and the Rack sensor signal is ignored), and
Solenoid (BTM) position is greater than the rack limitis set to 13.5 mm
desired. (0.53in).

Functional Test

TEST STEP RESULT DIAGNOSIS/ACTION

Step 1: Check For Connector Damage

* Turn keyswitch to the OFF position. OK = | All connectors/pins/sockets
« Check ECM Connector P14/J14 , Rack Position are completely mated/inserted
Sensor Connector P11/J11, Rack Solenoid (BTM) and the harness/wiring is free
Connector P6/J6 and associated wiring for damage, of corrosion, abrasion or pinch
abrasion, corrosion or incorrect attachment. Refer to points. Proceed to next step.
P-501: Inspecting Electrical Connectors for details. NOT OK = | All connectors/pins/sockets
All connectors/pins/sockets should be completely are not completely
mated/inserted and the harness/wiring should be mated/inserted and the
free of corrosion, abrasion or pinch points. hamess/wiring is not free of
corrosion, abrasion or pinch
points. STOP.

3408 & 3412 High Performance Marine Engines 5-38 Troubleshooting

P-542 P-542

TEST STEP RESULT DIAGNOSIS/ACTION

Step 2: Remove And Inspect The Rack BTM

* Tum keyswitch OFF. OK = | The Rack Solenoid (BTM) arm
« Remove the Rack BTM. is not loose, or shows signs of
* Inspect the Rack BTM arm for damage, and for signs E;Z%Er;oi“fio?ifi:r:efi asit
of binding in the rack servo sleeve. . pring
. is moved. Proceed to next
The Rack Solenoid (BTM) arm should not be loose, step.
or show signs of binding, and should encounter .
resistance from the spring as it is moved. NOT OK = The Rack Solenoid (,BTM) arm
is loose, or shows signs of
binding, and does not
encounter resistance from the
spring as it is moved. Replace
the BTM. STOP.

Step 3: Sweep Test

* Connect an Electronic Service Tool to the J7 Service OK = | The BTM arm should begins to
Tool Connector. sweep smoothly clockwise.
« Turn keyswitch to the ON position, engine OFF. Once it moves slightly past the
. dot on the Rack solenoid face
« Activate the rack sweep test. y :
X plate, it pauses briefly and
* Deactivate the sweep test. then sweeps back to the OFF
The BTM arm should begin to sweep smoothly stop. The BTM is operating
clockwise. Once it moves slightly past the dot on correctly. STOP.
the Rack solenoid face plate, it should pause briefly NOT OK = | The BTM arm does not begin
and then sweep back to the OFF stop. to sweep smoothly clockwise
or it moves slightly past the dot
on the Rack solenoid face
plate does not pause briefly
and then sweeps back to the
OFF stop. Proceed to next
step.

Step 4: Check Rack Solenoid Resistance

* Using Signal Reading Probes measure the OK = | The resistance is between 1
resistance from pin-A to pin-B at P6. and 2 Ohms. Proceed to next
The resistance should be between 1 and 2 Ohms. step.
NOT OK = | The resistance is greater
than 2 Ohms. The BTM has an
open circuit. Replace the BTM.
STOP.

3408 & 3412 High Performance Marine Engines 5-39 Troubleshooting

P-542 P-542

TEST STEP RESULT DIAGNOSIS/ACTION

Step 5: Check Voltage To Rack Solenoid During

Sweep Test
* Tum keyswitch to the ON position, engine OFF. OK = | The Voltage begin at 0 VDC
« Activate the Rack Sweep Test. and increases t0 3.6 + 0.3
« Using Signal Reading Probes measure the voltage xgg aFr;: tlr;iz ;i:ecr;?:fles to0
during the sweep test at J6 between pin-A and pin-B. STOi’ P )

+ Deactivate the sweep le.st. . NOT OK = | The Voltage does not begin at
The Voltage should begin at 0 VDC and increase to 0 VDC and increase to 3.6
3.6 + 0.3 VDC and then decrease to 0 VDC. + 0.3 VDC and then decrease
to 0 VDC. Proceed to next
step.
Step 6: Check Voltage At The ECM During Sweep
Test
* Activate the rack Sweep Test. OK = | The Voltage begins at 0 VDC
« Using Signal Reading Probes measure the voltage at and increases t0 3.6 + 0.3
the ECM Connector J14/P14 at pin-22 and pin-23. VDC and then decreases to 0
The Voltage should begin at 0 VDC and increase to :{zg;};fiifim'?#’zymg
3.6 = 0.3 VDC and then decrease to 0 VDC. o ge. |
problem is in the wiring
between the ECM and the
BTM. Repair as required.
STOP.
NOT OK = | The Voltage does not begin at
0 VDC and increase to 3.6
+ 0.3 VDC and then decrease
to 0 VDC. If the voltage
increases to 12 + 12 VDC and
remains constant there is an
open circuit between the ECM
and the BTM. Repair as
required. STOP.

3408 & 3412 High Performance Marine Engines 5-40 Troubleshooting

P-552 P-552

P-552: SHUTOFF SOLENOID

System Operation

The Shutoff Solenoid provides a secondary means for Figure P-552.1: Shutoff Solenoid Diagram
the ECM to shut down the engine. When the solenoid
receives a voltage, the solenoids plunger is pulled in to
allow the engine to run. When the solenoid loses the ECM
voltage, the plunger releases and the engine shuts
down.
If an overspeed condition is detected by the Overspeed
switch, the relay in the overspeed switch box will open
causing the shutoff solenoid to release and the engine
to shut down.
With the engine running, the voltage at the shutdown
solenoid connector should be between 1.5 and 2.5
VDC (from pin-A to pin-B).
Shut-Off Solenoid

Figure P-552.2: Shutoff Solenoid Schematic

Engine
Speed
Switch
=T T T
1. 2 3 456 7 8 9 101112 1314
22 @ 2ka 2\ 22\2 2 2@ @

J32/P32

56— 57 E

Shutoff Solenoid Js/PS J14/P14 ECM

Al 33<€{Shutoff
Shutoff Solenoid 8 22 <{Solenoid Ground
+=Hcl h—

3408 & 3412 High Performance Marine Engines 5-41 Troubleshooting

P-552 P-552

Figure P-552.3: Shutoff Solenoid Pin Connector

J14/P14 ECM Connector (Rear View)

Diagnostic Codes

CID-FMI | Conditions Which Generate This Code: |Systems Response: Troubleshooting

17-05 Shutoff Solenoid Open The fault is active and logged. | Proceed with
The Shutoff solenoid voltage is less than | the shutoff solenoid is de- P-522: Shutoff
0.75 VDC, the engine speed is greater energized. Once the fault Solenoid.
than 500 rpm for ten seconds and there | réturns to normal the shutoff
are no sensor supply voltage faults. solenoid is reenergized.
17-06 Shutoff Solenoid Short The fault is active and logged. | Proceed with
The Shutoff solenoid voltage is greater the shutoff solenoid is de- P-522: Shutoff
than 2.5 VDC, the engine speed is greater | €nergized. Once the fault Solenoid.
than 500 rpm for ten seconds and there | returns to normal the shutoff
are no sensor supply voltage faults. solenoid is reenergized.

Functional Test

TEST STEP RESULT DIAGNOSIS/ACTION

Step 1: Inspecting Electrical Connectors And

Wiring
* Turn keyswitch OFF. OK = | All connectors, pins, sockets
« Check ECM Connectors J14/P14 and the shutoff are completely mated and the
Solenoid Connector for damage or incorrect hamess is free of corrosion,
attachment. Referto the Electrical System Schematic abrasion or pinched points.
for additional information. Proceed to next step.
« Refer to P-501: Inspecting Electrical Connectors for NOT OK = | All connectors, pins, sockets
additional information. are not completely mated and
All connectors, pins, sockets should be completely the hafnesst;s npt free of
mated and the harness should be free of corrosion, ;?r:";‘;se'grg:i‘m':s::pgir’ as
abrasion or pinched points. required. STOP.

Step 2: Override The Shutoff Solenoid Operation

Rotate the manual shutoff lever in the clockwise OK = | The engine starts and
direction to override the shutoff solenoid. continues to run after the
Start the engine and release the manual shutoff lever manual shutoff lever is
once the engine has started. released. Proceed to next
The engine should have started and continued to step. '
run after the manual shutoff lever is released. NOT OK => | The engine does not start after
the manual shutoff lever is
released. Proceed to Step 4.

3408 & 3412 High Performance Marine Engines 5-42 Troubleshooting

P-552 P-552

TEST STEP RESULT DIAGNOSIS/ACTION

Step 3: Verify That The Shutoff Solenoid Can Shut

Down The Engine
* Turn the keyswitch to the ON position, engine ON. OK = | The engine shuts down when
« Disconnect the shutoff solenoid connector J5/P5. the solenoid is disconnected.
The engine should shut down when the solenoid is Proceed to next step.
disconnected. NOT OK = | The engine does not shut
down when the solenoid is
disconnected. Ensure the
solenoid plunger is not sticking
and that the linkage in not
binding. STOP.

Step 4: Measure The Operating Voltage At The

Shutoff Solenoid
* Rotate the manual shutoff lever in the clockwise OK = [ The voltage rises to over 4
direction. VDC when cranking and as
« Using signal reading probes measure the voltage the engine starts, stabilize
from pin-A and pin-B of J5/P5 during cranking. between 1.5 and 2.5 VDC
The voltage should rise to over 4 VDC when ‘gm;f?vseoEcfiz?:'ofl;;nn
cranking and as the engine starts, then stabilize roperly. STOP P 9
between 1.5 and 2.5 VDC within five seconds. properly. .
NOT OK = | The voltage does not rise to
over 4 VDC when cranking
and as the engine starts, does
not stabilize between 1.5 and
2.5 VDC within five seconds. If
the voltage is less than 1.5
VDC the solenoid is shorted.
Replace the solenoid and
remeasure, if the voltage is still
to low proceed to next step.
Proceed to next step.

Step 5: Check Resistance Of Solenoid Coil

+ Disconnect the Shutoff Solenoid. OK = | The resistance is between 1
« Using Signal Reading Probes measure the and 2 Ohms. Proceed to next
resistance from pin-A to pin-B of J5/P5. step.
The resistance should measure between 1 and 2 NOT OK = | The resistance is not between
Ohms. 1 and 2 Ohms. Replace the
Shutoff Solenoid and verify
that the repair eliminates the
problem. STOP.

3408 & 3412 High Performance Marine Engines 5-43 Troubleshooting

P-552 P-552

TEST STEP RESULT DIAGNOSIS/ACTION

Step 6: Check For Solenoid Short To Case
* Clear or remove paint from a portion of the solenoid OK = | The resistance measures
case so that a solid electrical connection can be greater than 20 Megohms.
made to the case. Proceed to next step.
* Set the multimeter to the 20 Megohm scale. NOT OK = | The resistance measures less
« Measure the resistance between pin-a of J5/P5 and than 20 Megohms. Replace
the solenoid case. the Shutoff Solenoid and verify
The resistance should measure greater than 20 that the repair eliminates the
Megohms. problem. STOP.

Step 7: Check Resistance Of Speed Switch

Connector
* Connect a 7X1710 Problem Cable Group at Speed OK = | The resistance is between 0
Switch Connector P32, and 0.25 Ohms. Proceed to
« Using an ohmmeter, measure the resistance from next step.
pin-7 to pin-9. NOT OK = | The resistance is not between
The resistance should be between 0 and 0.25 0 and 0.25 Ohms. Proceed to
Ohms. Step 9.

Step 8: Check Solenoid Voltage From ECM

* Reconnect the Shutoff Solenoid connector J5/P5. OK = | The voltage is between 1.5
* Using Signal Reading Probes measure the voltage and 2.5 VDC. The ECM is
between pin-22 (Solenoid Common) and pin-33 supplying the correct voltage.
(Shutoff Solenoid) while the engine is running. LNSPSCY lh: ngr\gnha??:s
etween the and the
The voltage should be between 1.5 and 2.5 VDC. Shutoff Solenoid for damage
or a broken connection. Repair
as required. STOP.
NOT OK = | The voltage is not between 1.5
and 2.5 VDC. The ECM is not
supplying the correct voltage.
Refer to Section 3: P-346
Electrical Power Supply to
the ECM. STOP.

Step 9: Check Overspeed Relay

« Connect a 7X1710 Problem Cable Group at terminals OK = | The resistance is between 0
87A and 30 of the relay. and 0.25 Ohms. Replace the
« Using an Ohmmeter, measure the resistance form shorted wire. Verify that the
terminals 87A and 30. repair eliminates the problem.
NOTE: If an overspeed condition is detected by the STOP.
overspeed switch, the relay in the overspeed switch NOT OK = | The resistance is not between
box will open causing the Shutoff Solenoid to release 0 and 0.25 Ohms. Replace the
and the engine to shut down. Shutoff Solenoid and verify
that the repair eliminates the
The resistance should be between 0 and 0.25
problem. STOP.
Ohms.

3408 & 3412 High Performance Marine Engines Troubleshooting

P-591 P-591

P-591: ENGINE SENSOR OPEN/SHORT

System Operation

Use this procedure to troubleshoot the system when Figure P-591.1: Engine Sensor Open/Short Diagram
there is an Active or Logged Open or Short circuit
—X 0
diagnostic code associated with the Boost Pressure,
Oil Pressure, Coolant Level, Coolant Temperature, J14P1a
Transmission Oil Pressure and the Transmission Oil
Temperature Sensor.
The troubleshooting procedure for the Open and Short
circuit diagnostic codes is identical except when Paug
measuring voltage between an +8 Volt or +5 Volt PIISS Ol Pressure Sensor
sensor. Each of these sensors is provided supply
voltage from the ECM Connector P14/J14 pin-10 (+5
VDC) to the sensor connector pin-A or from P14/J14
pin-10
(+8 VDC) to the sensor connector pin-A. The Sensor
Common connection for each of these sensors is also
shared, provided from the ECM with Connector
P14/J14 pin-10 (Sensor Common) to each sensor
connector pin-B.

3408 & 3412 High Performance Marine Engines 5-45 Troubleshooting

P-591 P-591

Figure P-591.2: Engine Sensor Open/Short Schematic

ECM
Boost Pressure Sensor Pa/ls P14/
1 4

Boost Pressure 25 <] Boost Pressure

Sensor Common 8| 35 <| Sensor Common
+5VDC 30 €| +5 VDC
< | 27 <] oil Pressure
L Pressure Sanos"o:,,essure oS 11 <| Transmission Oil Pressure
Sensor Common 26 <{ Coolant Level
+5VDC 20 <| Coolant Temperature
o 2 < Transmission Oil Pressure
Transmission Oil Pressure 10 <| + 8 VDC
Sensor 433/P33 —<_| 40 <] Rack Position
Transmission Oil Pressure ]
Sensor Common =
+5VDC Al
Coolant Level Sensor 7IP7
Coolant Level
Sensor Common =
+8 VDC|—P A

Coolant Temperature Sensor ;11,5

Coolant Temperature
Sensor Common 8|S
+8 VDC A

Transmission Oil Temperature

Sensor P34/J34
Transmission Temperature Al
Sensor Common B[ >
+8 VDC cf
Rack Position Sensor 1P
+8 VDC
Sensor Common B|
+5VDC c
Rack Position :;D

Figure P-591.3: Engine Sensor Open/Short Pin Connector

J14/P14 ECM Connector (Rear View)
-

3408 & 3412 High Performance Marine Engines 5-46 Troubleshooting

P-591 P-591

Diagnostic Codes

CID-FMI | Conditions which generate this code: Systems Response: Troubleshooting

100-03 | Oil Pressure Sensor Open Circuit The Electronic Service Tool Proceed with
The oil pressure signal voltage is above will indicate approximately 603 | P-591: Engine
acceptable range. kPa (87 psi) while the Sensor
diagnostic code is active. The | Open/Short.
Check Engine Lamp will not
come ON unless this
diagnostic code has bee
continuously Active for one
hour. This diagnostic code
does not affect engine
response.
100-04 | Oil Pressure Sensor Short Circuit The Electronic Service Tool Proceed with
The oil pressure signal voltage is below the will indicate approximately 603 | P-591: Engine
acceptable range. kPa (87 psi) while the Sensor
diagnostic code is active. The | Open/Short.
Check Engine Lamp will not
come ON unless this
diagnostic code has bee
continuously Active for one
hour. This diagnostic code
does not affect engine
response.
102-03 |Boost Pressure Sensor Open Circuit The Electronic Service Tool Proceed with
The boost pressure signal voltage is above will indicate approximately 0 | P-591: Engine
acceptable range. kPa (0 psi) while the Sensor
diagnostic code is active. The | Open/Short.
engine may experience low
power when the diagnostic
code is Active.
102-04 | Boost Pressure Sensor Short Circuit The Electronic Service Tool Proceed with
The boost pressure signal voltage is below will indicate approximately 0 | P-591: Engine
acceptable range. kPa (0 psi) while the Sensor
diagnostic code is active. The | Open/Short.
engine may experience low
power when the diagnostic
code is Active.
110-03 | Coolant Temperature Sensor Open Circuit | The Electronic Service Tool Proceed with
The coolant temperature signal voltage is will indicate approximately P-591: Engine
above acceptable range. 90°C (194°F) while the Sensor
diagnostic code is active. On | Open/Short.
rare occasions the engine may
emit white smoke on start up
because Cold Mode is not
active.

3408 & 3412 High Performance Marine Engines 5-47 Troubleshooting

P-591 P-591

CID-FMI | Conditions which generate this code: Systems Response: Troubleshooting

110-04 | Coolant Temperature Sensor Short Circuit | The Electronic Service Tool Proceed with
The coolant temperature signal voltage is will indicate approximately P-591: Engine
below acceptable range. 90°C (194°F) while the Sensor
diagnostic code is active. On | Open/Short.
rare occasions the engine may
emit white smoke on start up
because Cold Mode is not
active.
127-03 | Transmission Oil Pressure Short Circuit The Electronic Service Tool Proceed with
The Transmission Oil Pressure signal voltage | Will indicate approximately 603 | P-591: Engine
is above acceptable range. kPa (87 psi) while the Sensor
diagnostic code is active. The | Open/Short.
Check Engine Lamp will not
come ON unless this
diagnostic code has bee
continuously Active for one
hour. This diagnostic code
does not affect engine
response.
127-04 | Transmission Oil Pressure Open Circuit The Electronic Service Tool Proceed with
The Transmission Oil Pressure signal voltage | Will indicate approximately 603 | P-591: Engine
is below the acceptable range. kPa (87 psi) while the Sensor
diagnostic code is active. The | Open/Short.
Check Engine Lamp will not
come ON unless this
diagnostic code has bee
continuously Active for one
hour. This diagnostic code
does not affect engine
response.
177-03 | Transmission Oil Temperature Open The fault is logged and the Proceed with
The Transmission Oil Temperature sensor coolant temperature is setto | P-591: Engine
voltage i greater than or equal to 4.7 VDC and | (0°C 32°F). Sensor
there are no sensor supply voltage faults. Open/Short.
177-04 | Transmission Oil Temperature Short The fault is logged and the Proceed with
The Transmission Oil Temperature Sensor coolant temperature is setto | P-591: Engine
voltage is less than 0.3 VDC and there are no | (0"C 32°F). Sensor
sensor supply voltage faults. Open/Short.

3408 & 3412 High Performance Marine Engines 5-48 Troubleshooting

P-591 P-591

Functional Test

TEST STEP RESULT DIAGNOSIS/ACTION

Step 1: Check Electrical Connectors And Wiring

« Check ECM Connector (J14/P14), Customer Connector OK = | All connectors, pins, sockets
(J31/P31), Sensor Connectors and the Service Tool are completely mated and the
Connectors (J13) for damage or incorrect attachment. harness is free of corrosion,
Refer to the Electrical System Schematic for additional abrasion or pinched points.
information. Proceed to next step.
« Refer to P-501: Inspecting Electrical Connectors for NOT OK = | All connectors, pins, sockets
additional information. are not completely mated and
All connectors, pins, sockets should be completely the harness is not free of
mated and the harness should be free of corrosion, corrosion, abrasion or
abrasion or pinched points. pinched points. Repair as
required. STOP.

3408 & 3412 High Performance Marine Engines 5-49 Troubleshooting

P-591 P-591

TEST STEP RESULT DIAGNOSIS/ACTION

Step 2: Connect An Electronic Service Tool And Note
All Active Diagnostic Codes
« Connect Electronic Service Tool to the Data Link OK = | The Diagnostic Code is
Connector. ACTIVE. Proceed to Step 9.
« Connect Electronic Service Tool to the Data Link NOT OK = | The Diagnostic Code is
Connector. Logged. Proceed to next
Tumn the keyswitch to the ON position, engine OFF. step.
Wait at least 15 seconds for Codes to become Active.
24-03 or 24-04 = A 24-03 Rack Sensor Open
Check to see if one of the following diagnostic codes is Diagnostic
Active. Circuit or a 24-04 Rack Sensor
Code Short Circuit is present. Refer
* 100-03 Oil Pressure Sensor Open Circuit to P-515: Rack Position
* 100-04 Oil Pressure Sensor Short Circuit Sensor. STOP.
* 102-03 Boost Pressure Sensor Open Circuit
* 102-04 Boost Pressure Sensor Short Circuit
¢ 110-03 Coolant Temperature Sensor Open Circuit
* 110-04 Coolant Temperature Sensor Short Circuit
* 127-03 Transmission Oil Pressure Open Circuit
¢ 127-04 Transmission Oil Pressure Short Circuit
* 177-03 Transmission Oil Temperature Open Circuit
* 177-04 Transmission Oil Temperature Short Circuit
NOTE: Code 241-00 +5 VDC Open Circuit or 241-01 +5
VDC Short Circuit
* (+5 V Sensor Supply Codes) should not be Active. Refer
to P-521: Analog sensor Supply for more detail. Code
241-02 +8 VDC Open Circuit or 241-03 +8 VDC Supply
Short Circuit (+8 VDC Supply Codes) should not be
Active. Refer to P-522: Digital Sensor Supply for more
details.
One of the Diagnostic Codes should be Active.
100-03 Oil Pressure Sensor Open Circuit
100-04 Oil Pressure Sensor Short Circuit
102-03 Boost Pressure Sensor Open Circuit
102-04 Boost Pressure Sensor Short Circuit
110-03 Coolant Temp. Sensor Open Circuit
110-04 Coolant Temp. Sensor Short Circuit
127-03 Transmission Oil Pressure Open Circuit
127-04 Transmission Oil Pressure Short Circuit
177-03 Transmission Oil Temperature Open Circuit
177-04 Transmission Oil Temperature Short Circuit

3408 & 3412 High Performance Marine Engines 5-50 Troubleshooting

P-591 P-591

TEST STEP RESULT DIAGNOSIS/ACTION

Step 3: Determine Sensor Type
* Determine if the Logged Diagnostic Code is for a OK = | The Sensor is identified as a
Pressure Sensor. Pressure Sensor with a
The Logged Diagnostic Code should indicate a Logged Diagnostic Code.
Pressure Sensor. Proceed to next step.
NOT OK = | The Sensor is identified as a
Temperature Sensor with a
Logged Diagnostic Code.
Proceed to Step 11.

Step 4: Check Electronic Service Tool Display With

Engine OFF
« Install an Electronic Service Tool at the Data Link OK = | The display is functioning
connector. properly. Proceed to next
* Turn keyswitch to the ON position, engine OFF. step.
* Observe the “Pressure” reading on the Electronic Service NOT OK => | The sensor is reading
Tool display status screen. pressure when none should
exist. Proceed to Step 7.
The display should show 0 kPa (0 psi) for pressure
when the engine is not running.

3408 & 3412 High Performance Marine Engines 5-51 Troubleshooting

P-591 P-591

TEST STEP RESULT DIAGNOSIS/ACTION

Step 5: Compare Pressure Reading On An Electronic
Service Tool To Actual Pressure
* Turn keyswitch OFF. OK = The sensor is operating
Disconnect and remove the Sensor. correctly. Proceed to next
step.
Reconnect the Pressure Sensor outside of the engine
port. NOT OK = The ECM is not reading a
correct signal from the sensor.
Connect the Vacuum Pump Test Unit to the Pressure
Sensor. There may be a problem in the
hamess. Proceed to Step 9.
Use the 1U5470 Engine Pressure Test Group to connect
the Vacuum Pump Test Unit to vacuum port of the VACUUM = Check for leaks in the hose or
8T0839 Differential Pressure Gauge. Refer to LEAK test kit. If none are found there
SEHS8907. is an internal leak in the
Pressure Sensor. Replace the
Install Electronic Service Tool and Communication
sensor. STOP.
Adapter Tool to the Service Tool Connector J13.
Turn keyswitch to the ON position, engine OFF.
Observe the pressure display on the Electronic Service
Tool Display Status screen. The screen should be
displaying the barometric pressure in kPa for your
location.
Use the Vacuum Pump to pull 10 kPa (1.5 psi) of vacuum
.

on the 8T0839 Differential Pressure Gauge.

Compare the readings on the Electronic Service Tool and
the pressure test kit.
NOTE: The pressure gauge reading should remain
constant until vacuum is released.
* Compare the readings on the Electronic Service Tool and
the pressure test kit.
The Electronic Service Tool reading should remain
constant and display a 10 = 2 kPa (1.5 + 0.3 psi) drop in
pressure.
Step 6: Check Sensor Installation
Verify sensor installation in the correct engine port and OK = The sensor is installed
sensor connection to the correct harness connector. correctly. Proceed to next
The sensor should be installed in the correct engine step.
port and should be connected to the correct harness NOT OK = Correctly install the sensor.
connector. STOP.

3408 & 3412 High Performance Marine Engines 5-52 Troubleshooting

P-591 P-591

TEST STEP RESULT DIAGNOSIS/ACTION

Step 7: Check Actual Pressure

* For the Boost Pressure Sensor install the 1U5470 Engine OK = | The pressure is in range.
Pressure Group on a T fitting with the Boost Pressure Proceed to next step.
Sensor. NOT OK = | The pressure is outside
For Engine Oil Pressure Install the 1U5470 Engine normal limits, is erratic, or
Pressure Group on a T fitting with the Oil Pressure leakage is present. The
Sensor. problem is NOT in the
For Transmission Oil Pressure Install the 5P14718 Probe Electronic control System.
and 8T0855 Gauge to measure Transmission Oil Refer to Systems Operation,
Pressure. Testing and Adjusting Manual
for help to identify and repair
Start the engine and run at low idle. If measuring
the problem. STOP.
Transmission Oil Pressure engage the transmission.
Move the throttle to High Idle and observe the pressure
readings.
If after five seconds the fuel pressure does not exceed 10
kPa (5 psi) shut OFF the engine.
Push the throttle to the high idle position and check for
fuel leakage.
Repair any leaks.
Compare the gauge reading with the electronic Service
tool Display Status screen and record.
At Low Idle, Engine Oil Pressure should be greater than
186 kPa (27 psi) and remain steady. At High Idle Engine
Oil Pressure should be greater than 265 kPa (39 psi)
and remain steady.
The readings for Boost Pressure should agree within
+ 40 kPa (6 psi) and be steady.
The Transmission Oil Pressure should exceed 1378
kPa (200 psi) within 10 seconds.

3408 & 3412 High Performance Marine Engines 5-53 Troubleshooting

P-591 P-591

TEST STEP RESULT DIAGNOSIS/ACTION

Step 8: Check Resistance Through Harness

* Disconnect ECM Connector J14/P14 and the suspect OK = | Harness resistance is within
sensor. acceptable limits. Proceed to
« Use a suitable piece of wire to short the Sensor next step.
Connector pin-A and pin-C together. NOT OK = | There is an open circuit or
« Set the multimeter on the 200 Ohm scale and measure excessive resistance in the
the resistance between the ECM Connector P14 pin-10 hames; or conceders. Repair
(for Analog Sensors) or pin-10 (for Digital Sensors). as required. STOP.
* Use a suitable piece of wire to short the suspect sensor
connector pin-B (Sensor Common) and pin-C (Signal)
together.
* Measure the resistance between the ECM Connector
P14 pin-10 (Sensor Common) and the suspect sensor
signal wire at the ECM.
* When finished remove the wire short.
See Figure P-591.4.
The resistance should measure less than 10 Ohms
through the harness.

Figure P-591.4: Sensor Connector View

Jack (J) Temperature Sensor Connector Plug (P)

Jack (J) Pressure Sensor Connector P|Ug (P)

Jumper Wire —— \J
Q\

3408 & 3412 High Performance Marine Engines 5-54 Troubleshooting