Mercury V6 175 Diagnostic Manual

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V6 175 / 200 / 225

V8 200 / 225 / 250 / 300

FourStroke

Outboard

DI AGN O S T I C

MAN U AL

S t ar t i n g s er i al n u m b e r 2 B 5 2 9 4 8 2

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Troubleshooting

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Summary of Contents for Mercury V6 175

Page 1 V6 175 / 200 / 225 V8 200 / 225 / 250 / 300 FourStroke Outboard DI AGN O S T I C MAN U AL S t ar t i n g s er i al n u m b e r 2 B 5 2 9 4 8 2...
Page 3 NOTE: Indicates information that helps in the understanding of a particular step or action. This manual has been written and published by the Mercury Marine Service Department to aid our dealers’ mechanics and company service personnel when servicing the products described herein. It is assumed that these personnel are familiar with marine product servicing procedures.
Page 4 Cleanliness and Care of Product A Mercury Marine power product is a combination of many machined, honed, polished, and lapped surfaces with tight tolerances. When any product component is serviced, care and cleanliness are important. Proper cleaning and protection of machined surfaces and friction areas is an implied part of the repair procedure.
Page 5 D - Advanced Midsection (AMS) Power Trim 7 - Fuel System A - Fuel System B - Troubleshooting and Diagnostics 8 - Color Diagrams A - SmartCraft Circuit Diagrams B - Engine Harness Diagrams Page iii © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 7 General Service Precautions When Working on EFI Section 3 ‑ General Troubleshooting and CDS G3..1A-2 Systems................1A-3 Section 4 ‑ Fault Codes..........1A-3 Section 5 ‑ Sensors, Actuators, Relays, and Accessories.............1A-3 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 1A-1...
Page 8 Mercury 175 V6, 175 V6 Pro XS, 200 V6, 200 V6 SeaPro, 225 V6 2018 and Newer Mercury 200 V8 Pro XS, 225 V8 Pro XS, 225 V8 SeaPro, 250 V8, 250 V8 Pro XS, 250 V8 SeaPro, 2018 and Newer...
Page 9 Always disconnect the negative terminal first when removing a battery, and connect it last when installing a battery to prevent arcing. • Never start the engine without the battery being solidly connected. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 1A-3...
Page 10 Do not allow spark plugs or wires to arc in the engine bay. • Always relieve fuel system pressure prior to opening the fuel system. Safety glasses should be worn when working on the fuel system. Page 1A-4 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 11: Table Of Contents
Speed/Density Theory............1B-2 Propulsion Control Module (PCM)........1B-4 Stoichiometry, Equivalency Ratio, and Emissions Control Description..............1B-4 ..................1B-2 Engine Guardian System........... 1B-5 Oxygen (O2) Sensor............1B-3 Important Terms..............1B-5 Open‑Loop and Closed‑Loop Operation......1B-3 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 1B-1...
Page 12: Overview
14.14:1 and higher To allow for these differences, Mercury uses the equivalency ratio. This is defined as the ratio of the ideal air/fuel ratio to the actual air/fuel ratio: ideal/actual = equivalency ratio. An equivalency ratio of 1.00 means that the combustion is stoichiometric. A ratio of 1.03 means the blend is 3% rich.
Page 13: Oxygen (O2) Sensor
The PCM 112 stays in closed‑loop control throughout the power ranges, except for brief moments when the engine starts or transitions from power settings. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 1B-3...
Page 14: Advanced Range Optimization
Block water pressure sensor • Camshaft position sensor • Crankshaft position sensor • Engine coolant temperature (ECT) sensor • ESTOP or lanyard switch position • Exhaust gas temperature (EGT) sensor Page 1B-4 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 15: Engine Guardian System
When the system is unable to enter closed‑loop operation, it will revert to this table for values to be used in determining the appropriate air/fuel ratio in accordance with the Speed/Density Theory. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 1B-5...
Page 17 Oxides of Nitrogen – NOx...........1C-2 Manufacturer's Certification Label........1C-3 Controlling Emissions..........1C-2 Service Replacement EPA Decal........1C-4 Stoichiometric Ratio (14.7:1) Air/Fuel Ratio....1C-2 Removal..............1C-4 Emissions Information............1C-2 Installation..............1C-4 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 1C-1...
Page 18 The U.S. EPA regulates potentially harmful emissions. Engines manufactured by Mercury Marine reduce the emissions of certain pollutants, and potentially harmful gases in the exhaust to conform with levels legislated by the U.S. EPA. Standards are set primarily with regard to three types of emissions: hydrocarbons (HC), carbon monoxide (CO), and oxides of nitrogen (NOx).
Page 19 EPA Emission Regulations All 1998 and newer outboards manufactured by Mercury Marine are certified to the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new outboard motors. This certification is contingent on certain adjustments being set to factory standards.
Page 20 Service Replacement EPA Decal IMPORTANT: By federal law, it is required that all 1998 and newer Mercury Marine outboards have a visible and legible emission certification decal. If this decal is missing or damaged, contact Mercury Marine Service for a replacement.
Page 21 Section 1D - Glossary, Reference Charts, and Conversions Table of Contents Glossary................1D-2 Altitude and Barometric Pressure.......1D-6 Abbreviations..............1D-4 Vacuum Gauge versus MAP Sensor......1D-7 General Reference Charts..........1D-5 Centigrade to Fahrenheit Conversion......1D-8 Manifold Vacuum and Pressure......... 1D-5 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 1D-1...
Page 22: Glossary
(yellow and brown wires). Previously referred to as CAN 2. Cold cranking amps, a rating method for batteries tested at –17.7 °C (0 °F). CDS G3 Mercury's latest computer diagnostic system. Powers up the DTS/SmartCraft system. Two‑wire harness that connects directly to the engine Clean Power cranking battery.
Page 23 1. Forward gear position. Mercury's latest computer diagnostic system. Also known as CDS G3. Intake air temperature sensor, alternately known as a manifold air temperature (MAT) sensor. An engineering term describing the percentage of fuel being added or subtracted from the base ITerm fueling number.
Page 24: Abbreviations
Universal Exhaust Gas Oxygen Electronic Throttle Control Micro Chi (DTS command module) Ground Volt Idle Air Control Wide‑Open Throttle Intake Air Temperature XDRP Sensor Power (transducer power) In. Hg Inches of Mercury Page 1D-4 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 25: General Reference Charts
1.95 13.4 5‑1/2 63.4 11.7 5‑3/4 8.95 61.7 13‑1/4 1.45 10.0 60.0 13‑1/2 6‑1/4 8.45 58.2 13‑3/4 0.95 6‑1/2 56.5 6‑3/4 7.95 54.8 14‑1/4 0.45 53.1 14‑1/2 7‑1/4 7.45 51.4 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 1D-5...
Page 26: Altitude And Barometric Pressure
0.651 4.49 80,000 15.2 24,408 –62 –52 0.8273 0.406 0.406 90,000 17.1 27,459 –57 –59 0.52 13.2 0.255 0.255 1.76 100,000 18.9 30,510 –51 –46 0.329 8.36 0.162 0.162 1.12 Page 1D-6 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 27: Vacuum Gauge Versus Map Sensor
Handheld Vacuum Gauge (in. Hg) 17123 This graph is correct at sea level only MAP sensor (volt) MAP sensor (kPa absolute) MAP sensor (in. Hg absolute) MAP sensor (psi) Handheld vacuum gauge (in. Hg) 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 1D-7...
Page 28: Centigrade To Fahrenheit Conversion
Glossary, Reference Charts, and Conversions Centigrade to Fahrenheit Conversion Centigrade Fahrenheit Centigrade Fahrenheit –55 –67 –50 –58 –45 –49 –40 –40 –35 –31 –30 –22 –25 –13 –20 –4 –15 –10 –5 Page 1D-8 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 29 Load Balancing............2A-4 Propulsion Control Module (PCM) Overview....2A-2 PCM 112 Pinouts............... 2A-5 Important PCM Notes..........2A-3 Connector A..............2A-5 Test Equipment............2A-3 Connector B..............2A-7 Software and Adaptive Speed Control......2A-4 Connector C..............2A-9 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 2A-1...
Page 30: Important Information
The inputs to the PCM can be monitored and tested by using the computer diagnostic system (CDS G3). CDS G3 Interface Kit 8M0138392 The PCM controls the following functions and components: • Electronic shift control • Electronic throttle control • Main power relay Page 2A-2 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 31: Important Pcm Notes
In diagnosing Mercury PCM 112 engines, the following test equipment will prove to be invaluable: • The Mercury CDS G3 System. CDS G3 is designed to work specifically with Mercury engines. It includes live data monitoring, active tests, and calibrations for many Mercury engines. Often, a calibration update can resolve an issue.
Page 32: Software And Adaptive Speed Control
Spark is added to weak cylinders, and subtracted from strong cylinders to achieve a balanced load. Page 2A-4 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 33: Pcm 112 Pinouts
AG1 MP Alert Blue/red – Fires cylinders 2 Directly drives the ignition coil by grounding the circuit AH1 Ignition coil driver—number 4 Green/yellow and 3 on V8; not internally. used on V6. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 2A-5...
Page 34 – Fires cylinders 1 and 6 on V8. Fires Directly drives the ignition coil by grounding the circuit AH4 Ignition coil driver—number 1 Green/brown cylinders 1 and 4 on internally. Page 2A-6 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 35 – commands. These circuits require both high and low sides to operate. This is the low (negative) side. Throttle demand sensor Not used on DTS Gray/green – position 1 engines 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 2A-7...
Page 36 Oil pressure analog gauge Blue/yellow – – driver BM3 Not used – – – BA4 Not used – – – BB4 Not used – – – BC4 Not used – – – Page 2A-8 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 37 B3A B3B B3C B3D B3E B3F B3G B3H B3J B3K A3A A3B A3C A3D A3E A3F B4A B4B B4C B4D B4E B4F B4G B4H B4J A4A A4B A4C A4D A4E A4F A4G 57211 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 2A-9...
Page 38 CA4 Continuous battery Red/black – the engine battery and is protected with a 5 A fuse. Do not connect to a battery switch. CB4 Block water pressure White/green – – Page 2A-10 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 39 (MPR) and through the PCM 112. The PCM controls CG4 Driver power 2 Red/blue – the MPR through pin AA2. This power is used for high current actuators. CH4 Shift actuator A (+) Red/purple – – 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 2A-11...
Page 41 Comprehensive Component Diagnostics....2B-2 PCM Operation, Faults, and Data Fields....2B-2 Closed‑Loop Control Status........2B-2 Faults................2B-2 O2 Control State Diagnostic Aids........2B-3 System Diagnostics Overview........... 2B-2 Recommended Course of Action........2B-3 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 2B-1...
Page 42 Mercury fault codes are explained in Section 4A. Not every engine issue triggers a fault; however, the Live Data feature in CDS G3 can provide important clues to the engine's operation.
Page 43 (low oil pressure, high engine coolant temperature, Go to step 8. Go to the next step. etc.). Check for and resolve any primary faults. Did you find and resolve any primary faults? 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 2B-3...
Page 44 Clear all faults, and after Freeze Frame data is Contact Mercury Product Put the engine back into recorded, clear the Freeze Frame buffer. Water test Support. service. the boat. Does the fault reoccur? Page 2B-4 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 45 General Troubleshooting and CDS G3 Section 3A - General Troubleshooting Table of Contents Audio Warning System............3A-2 Nonconfigured Alarm..........3A-2 Caution............... 3A-2 Testing the Audio Warning System......3A-2 Critical.................3A-2 Troubleshooting MFD Faults..........3A-2 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 3A-1...
Page 46 NOTE: Text shown in the first, third, and fourth columns is verbatim from the MFD. NOTE: The Mercury universal fault code (UFC) is also visible to the boat operator on the MFD or on certain SmartCraft gauges. The UFC contains two parts: 1) a three or four digit fault code and 2) a one or two digit failure code. These two codes are listed in the following table in the two columns under the UFC heading.
Page 47 It correlates the MFD fault to the Mercury universal fault codes (UFC) and CDS G3 Freeze Frame names for propulsion control module (PCM) faults. In some cases, there is a one‑to‑one correspondence between the MFD fault and a PCM fault, although this is not always true.
Page 55 If CDS G3 Does Not Communicate with the System Fault Codes.............. 3B-14 ................3B-3 Addressing Faults............. 3B-14 CDS G3 Operation and Screen Descriptions.....3B-4 Diagnosing Intermittent Problems......3B-15 Home Screen..............3B-4 Visual/Physical Check..........3B-15 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 3B-1...
Page 56: Troubleshooting With The Computer Diagnostic System (Cds G3)
About CDS G3 CDS G3 is a standalone program that provides diagnostic support for select Mercury engines and engine control systems. CDS G3 also supports all configuration functions necessary for preparing these systems for delivery. CDS G3 provides a clean, easy‑to‑navigate interface.
Page 57: Connection To The Junction Box Or Diagnostic Port
Is the SmartCraft diagnostic interface’s PWR LED illuminated continuously? This indicates the cable is recognized by the computer and is communicating with the computer. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 3B-3...
Page 58: Cds G3 Operation And Screen Descriptions
Unplug the diagnostic interface at both ends, wait a few minutes, and plug it in again. Try rebooting your computer after all the connections have been made. If none of these resolve the issue, contact Mercury Product Support. CDS G3 Operation and Screen Descriptions...
Page 59: Selecting An Ebom
Print Full Report, accessible through the File menu or by pressing F12, will print a full report, which includes freeze frame data, faults, and run history, along with the ability to include dealership information and your customer’s information. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 3B-5...
Page 60: Reflash Screen
(for example; date, category, service bulletin, etc.). Click the Show Filtered button and the diagnostic tool will automatically filter the correct reflash package. Refer to Section 3F ‑ CDS G3—Module Reflash for more information. Page 3B-6 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 61: Diagnostics Screen
The Configuration screen provides options for configuring the helm, CAN pads, and electronic compass, as well as resetting the theft deterrent system, or importing a vessel personality. Each option walks the operator through the necessary procedures, and is not covered in this manual. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 3B-7...
Page 62: Module Data Screen
Clear All Modules Faults button—Clears existing faults. Used to clear the buffer. Faults that are still active will reappear after a few moments. Rescan This Boat button—Refreshes the list of modules on the boat. Status—Displays the status of each listed module. Page 3B-8 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 63 Module being referenced, the starboard engine in this example Data value Plain‑text description Engine tab Vessel tab Meters tab Graph tab Record and Pause buttons Check boxes to select data on graph and meters tab 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 3B-9...
Page 64 Data bar Upper limit set bar Maximum value and reset icon Limits tab Data item being measured Unit of measure Play/pause button (record and pause buttons when displaying live data) Page 3B-10 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 65 The Fault screen lists the active faults for the selected module. The faults for PCM 112 are listed in Section 4A ‑ Fault Codes. 67655 Fault screen. To clear the faults, select the gear icon in the upper right corner. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 3B-11...
Page 66 It also displays the total engine run time at the bottom of the screen. The data on this screen cannot be cleared or reset with the CDS G3 tool. 67534 Run History screen Page 3B-12 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 67: Cds G3 And Diagnostic Fault Resolution
CDS G3 is a powerful tool. Take some time to become acquainted with its operation, features, and capabilities. It will not diagnose all problems, but will provide clues as to what is happening with a Mercury engine. Talk to the customer to get as much information as possible about the complaint. There's a reason the boat was brought in.
Page 68: Fault Codes
A sensor showing a reading outside of its normal range, but not shorted or open, has a Range High or Range Low fault. This means the circuit is operating correctly, but the engine is outside of its operating range, such as engine coolant overheating. Page 3B-14 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 69: Diagnosing Intermittent Problems
Ensure that the safety lanyard is correctly installed and that the customer understands the correct starting procedure. Verify that the battery is fully charged and is of sufficient capacity for the engine being tested. If necessary, substitute a known good battery. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 3B-15...
Page 70 If there is damage at the external connections, you will have to inspect several of the internal splices to verify that the damage is not also present at these locations. Page 3B-16 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 71 CDS G3—Live Data General Troubleshooting and CDS G3 Section 3C - CDS G3—Live Data Table of Contents Live Data Screen............... 3C-2 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 3C-1...
Page 72 The following table explains the line entries on the Live Data screen. Note that some entries appear on the Engine (Eng.) tab, and some on the Vessel (Ves.) tab. The information in the Name, Description, and Value columns correspond directly to what is displayed in CDS G3. Page 3C-2 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 79 CDS G3—PCM 112 Freeze Frame Data General Troubleshooting and CDS G3 Section 3D - CDS G3—PCM 112 Freeze Frame Data Table of Contents Freeze Frame Screen............3D-2 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 3D-1...
Page 80 Crank ‑ Engine is cranking The engine function at the time the fault occurred. Run ‑ Engine is running Engine speed in RPM at the time the fault Engspeed occurred. Page 3D-2 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 81 Measured in AD counts, this is the engine oil level between 0 (0%) and 1024 (100%) at the time of Oillevelpercent 0–1024 ADC the fault. (Not all engines are equipped with an oil level sensor.) 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 3D-3...
Page 83 CDS G3—Diagnostics Screen General Troubleshooting and CDS G3 Section 3E - CDS G3—Diagnostics Screen Table of Contents Diagnostic Screen..............3E-2 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 3E-1...
Page 84 RPM drop occurs or not. Activates the fuel pump relay for diagnostic Fuel Pump Output purposes. Activates the warning horn to confirm its Horn Output functionality. Page 3E-2 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 85 Advanced Sound Activates the Advanced Sound Control valve With the engine running, a change in the exhaust Control open or closed. noise should be very apparent. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 3E-3...
Page 87 CDS G3—Module Reflash General Troubleshooting and CDS G3 Section 3F - CDS G3—Module Reflash Table of Contents Reflash Procedure............. 3F-2 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 3F-1...
Page 88 Reflash Procedure Mercury Marine will occasionally make changes or enhancements to its engine calibrations. The CDS G3 tool has the ability to reflash PCMs and other vessel control modules when necessary. Always make sure to keep the CDS G3 tool updated, as this will ensure that you have the latest available calibration files from Mercury.
Page 89 Read and follow the warning messages on the following screen before clicking Begin Reflash. 67662 Once the reflash has completed, click the Next button at the bottom of the screen. Complete status Next button 67663 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 3F-3...
Page 90 (RWOT) for at least five seconds. After turning the key back on, click the finish button. Green check mark Key‑off RWOT reminder Finish button 67664 Page 3F-4 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 91 Fault Codes Fault Codes Section 4A - Fault Codes Table of Contents Mercury UFC List............... 4A-3 I ..................4A-23 CDS G3 Freeze Frame Faults........... 4A-8 IAT_RangeHigh............4A-23 A ..................4A-8 IAT_RangeLow............4A-23 AEV_OutputFault............4A-8 INJ1_OutputFault............4A-24 AuthTimeout............... 4A-8 INJ2_OutputFault............4A-24 B ..................4A-9 INJ3_OutputFault............4A-24 BaroRange..............4A-9...
Page 92 Watchdog_Active............4A-46 SysVolt_RangeLow............ 4A-41 WaterInFuel_RangeLow..........4A-46 T ..................4A-41 X ..................4A-47 TPS1_ETC_NoAdapt..........4A-41 XDRPa_RangeHigh........... 4A-47 TPS1_RangeHigh............4A-42 XDRPa_RangeLow............ 4A-47 TPS1_RangeLow............4A-42 XDRPb_RangeHigh........... 4A-47 TPS2_ETC_NoAdapt..........4A-42 XDRPb_RangeLow............ 4A-47 TPS2_RangeHigh............4A-42 XDRPc_RangeHigh............4A-48 TPS2_RangeLow............4A-43 XDRPc_RangeLow.............4A-48 Page 4A-2 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 93: Mercury Ufc List
The following table lists every fault currently (as of this writing) enabled on Mercury V6 and V8 4‑stroke outboard engines. Not all faults will apply to every model. The faults are presented in the order of their Mercury universal fault code (UFC). The columns contain the following information: •...
Page 94 The signal received is valid but is higher than the XDRPc_RangeHigh expected range. Sensor supply voltage C The signal received is valid but is lower than the XDRPc_RangeLow expected range. Page 4A-4 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 95 The input circuit for the sensor is above the valid DemandSensor2_RangeHigh limit. 1062 Mechanical demand sensor B The input circuit for the sensor is below the valid DemandSensor2_RangeLow limit. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 4A-5...
Page 96 Electronic shift control loss of The device, calculation or process detected a 3032 ESCLossOfControl control fault. Electronic shift control reverse The device, calculation or process detected a 3033 ESC_NoAdapt_Reverse adapt fault. Page 4A-6 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 97 Security locked A particular state or condition exists. Security_Locked 4503 Security setup A particular state or condition exists. Security_Setup 4602 Fault blocker system voltage A particular state or condition exists. SysVolt_FaultBlocker 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 4A-7...
Page 98: Cds G3 Freeze Frame Faults
CDS G3 Freeze Frame Faults The following pages list all of the faults that could be displayed in the CDS G3 Freeze Frame window for Mercury V6/V8 4‑stroke outboards. The faults are sequenced alphabetically. Where applicable, the following details are provided for each fault: •...
Page 99: Barorange
Check the sensor for metallic debris. • Check the sensor target for damage. • Replace the sensor. Crosscheck_Failed Fault Type: Horn: Guardian: UFC: Transmission to Helm: Freeze Frame Priority: Nonsticky Critical 4014‑6 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 4A-9...
Page 100: Demandsensor1_Rangehigh
Defective sensor Summary of Fault Correction Possibilities • Check the wiring. • Replace the sensor. DemandSensor2_RangeHigh Fault Type: Horn: Guardian: UFC: Transmission to Helm: Freeze Frame Priority: Sticky Caution 100% 1062‑24 Page 4A-10 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 101: Demandsensor2_Rangelow
4001‑6 Explanation This fault indicates that a command module is not equal to the PCM in the cross‑check of demand value. Possible Causes • Incorrect positions used when configuring levers 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 4A-11...
Page 102: Dmdsense1_Noadapt
A21 and across command module harness pins 8 and 9) or CAN X (brown and yellow wires; should measure 58–60 ohms across bottom PCM engine harness pins A31 and A32 and across command module harness pins 6 and 7). Page 4A-12 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 103: Dual_Demandsen_Fault
The shift position sensors do not appear to be working properly. Possible Causes • Shift actuator wiring problem • Failed shift actuator Summary of Fault Correction Possibilities • Inspect the wiring to the shift actuator. • Replace the shift actuator. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 4A-13...
Page 104: Dual_Tps_Faults
• Wiring problem • Defective sensor Summary of Fault Correction Possibilities • Inspect the wiring to the sensor. • Check the sensor. • Check the exhaust sprayer outlets for obstructions. Page 4A-14 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 105: Egt_Rangelow
Worn linkage between shift shaft and shift actuator • Worn gearcase components • Faulty shift actuator Summary of Fault Correction Possibilities • Correct the wiring problem. • Replace the worn shift linkage components. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 4A-15...
Page 106: Esc_Noadapt_Forward
PCM is constantly trying to adjust the ESC because it is falling out of the adapted position. If the ESC tries to continuously adjust, the PCM will time out the circuit. This fault is most prevalent under high torque use. Possible Causes • Wiring problem Page 4A-16 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 107: Est1_Outputfault
DTS (if equipped) calibration has not been correctly completed • Failed command module Summary of Fault Correction Possibilities • Deactivate the lanyard or troubleshoot the circuit (locate and correct the short). 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 4A-17...
Page 108: Etc_Loss_Of_Control
Critical 3014‑6 Explanation The electronic throttle control (ETC) does not appear to be working properly. Possible Causes • Obstruction in the throttle body assembly • Wiring problem • Defective ETC Page 4A-18 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 109: Etc_Tpsdisagree
The fuel pump does not appear to be working properly. The PCM detected a problem when trying to send a signal to the fuel pump relay. Possible Causes • Fuel pump relay wiring problem • Failed fuel pump relay 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 4A-19...
Page 110: Guardian_Active
Engine Guardian is active due to low oil pressure. Power will be limited to prevent engine damage. Possible Causes • Low engine oil • Sensor wiring problem • Defective sensor Page 4A-20 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 111: Guardian_Oil_Temp_Derate
• Damaged water pump impeller Summary of Fault Correction Possibilities • Flush the cooling system. • Inspect the thermostat. • Inspect the cooling system. • Inspect the water pump impeller. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 4A-21...
Page 112: Guardian_Overspeed
Engine Guardian is active due to high or low battery voltage. Power will be limited to prevent engine damage. Possible Causes • Failed alternator • Failed fusible link Summary of Fault Correction Possibilities • Replace the alternator. • Replace the fusible link. Page 4A-22 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 113: Horn_Outputfault
The intake air temperature (IAT) sensor does not appear to be working properly; the PCM received a signal that is below the valid limit. Possible Causes • Wiring problem • Defective sensor Summary of Fault Correction Possibilities • Correct the sensor wiring problem. • Replace the sensor. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 4A-23...
Page 114 • Shift demand sensor wiring problem • Failed shift demand sensor Summary of Fault Correction Possibilities • Correct the shift demand sensor wiring problem. • Replace the shift demand sensor. Page 4A-24 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 115: Map_Angle_Rangehigh
The manifold absolute pressure (MAP) sensor does not appear to be working properly; the PCM received a signal that is above the valid limit. Possible Causes • Sensor out of range • Wiring problem 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 4A-25...
Page 116: Map_Time_Rangelow
Correct the MAP sensor or ETC wiring problem. • Inspect the cold air intake assembly for obstructions. • Inspect the intake manifold for air leaks. • Replace the MAP sensor or throttle body assembly. Page 4A-26 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 117: Mapr_Tps2Rationality
Possible Causes • Engine is not in gear • Shift demand sensor failed Summary of Fault Correction Possibilities • Shift the engine into gear. • Inspect the shift demand sensor. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 4A-27...
Page 118: O2Control_Itermhighport
Engine temperature too high to read oil level • Engine trimmed too high to read oil level Summary of Fault Correction Possibilities • Allow the engine to cool down. • Trim the engine down. Page 4A-28 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 119: Oillevel_Critically_Low
The engine oil level sensor does not appear to be working properly. Possible Causes • Wiring problem • Defective sensor Summary of Fault Correction Possibilities • Inspect the wiring to the sensor, and repair as necessary. • Replace the sensor. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 4A-29...
Page 120: Oillevel_Sensor_Invalid
The oil pressure sensor does not appear to be working properly; the PCM received a signal that is above the valid limit. Possible Causes • Wiring problem • Defective sensor Summary of Fault Correction Possibilities • Inspect the wiring to the sensor, and repair as necessary. • Replace the sensor. Page 4A-30 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 121: Oilpress_Rangelow
Inspect the wiring to the sensor, and repair as necessary. • Replace the sensor. R ..RxDoc1_SOH Fault Type: Horn: Guardian: UFC: Transmission to Helm: Freeze Frame Priority: Sticky Critical 100% 4004‑6 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 4A-31...
Page 122: Rxdoc2_Soh
Resistance across the command module pins 8 and 9 should show approximately 37.1K ohms. Summary of Fault Correction Possibilities • Repair the open or short on CAN P (blue and white wires). • Replace the terminator resistor. • Replace the command module. Page 4A-32 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 123: Rxdoc7_Soh
6 and 7 should measure 58–60 ohms. Resistance across pins A31 and A32 at the PCM should show approximately 37.1K ohms. Resistance across the command module pins 6 and 7 should show approximately 37.1K ohms. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 4A-33...
Page 124: Rxdoc11_Soh
Security_Locked Fault Type: Horn: Guardian: UFC: Transmission to Helm: Freeze Frame Priority: Nonsticky None 4502‑23 Explanation The security device is locked. Possible Causes • Device fob incorrect • Wiring problem Page 4A-34 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 125: Security_Setup
The shift demand sensor does not appear to be working properly. Possible Causes • Wiring problem • Defective sensor Summary of Fault Correction Possibilities • Correct the wiring problem. • Replace the sensor. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 4A-35...
Page 126: Shiftdmdsensor1_Rangehigh
Summary of Fault Correction Possibilities • Correct the wiring problem. • Replace the sensor. ShiftDmdSensor2_RangeLow Fault Type: Horn: Guardian: UFC: Transmission to Helm: Freeze Frame Priority: Sticky Caution 100% 1064‑25 Page 4A-36 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 127: Shiftpos_Rangehigh
The primary shift position encoder in the shift actuator does not appear to be working properly; the PCM received a signal that is below the valid limit. Power is limited to prevent engine damage. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 4A-37...
Page 128: Shiftpos2_Rangelow
The command module is not equal to the PCM in cross‑check of shift position. Possible Causes • Incorrect DTS system configuration • Faulty command module or PCM • Wiring problem Page 4A-38 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 129: Spi_Crosscheckdata_Soh
The engine coolant temperature (ECT) sensor does not appear to be working properly; the PCM received a signal that is above the valid limit. Possible Causes • Wiring problem • Defective sensor 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 4A-39...
Page 130: Stbdect_Rangelow
• Battery switch is not turned on • Overcharging or undercharging due to faulty alternator Summary of Fault Correction Possibilities • Turn the battery switch on. • Replace the alternator. Page 4A-40 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 131: Sysvolt_Rangehigh
Low system voltage to ETC • Defective throttle position sensor Summary of Fault Correction Possibilities • Inspect the wiring for problems, and correct as necessary. • Replace the throttle body assembly 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 4A-41...
Page 132: Tps1_Rangehigh
• Replace the throttle body assembly. TPS2_RangeHigh Fault Type: Horn: Guardian: UFC: Transmission to Helm: Freeze Frame Priority: Sticky Caution 100% 302‑24 Explanation The TPS 2 sensor circuit is open. Page 4A-42 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 133: Tps2_Rangelow
The trim up relay does not appear to be working properly; the PCM detected a problem when trying to send a signal to the trim up relay. Possible Causes • Wiring problem • Failed trim up relay 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 4A-43...
Page 134: Trimpos_Rangehigh
The oxygen (O2) sensor does not appear to be working properly; the PCM received a signal that is valid, but is lower than expected. The O2 sensor is not heating up. Possible Causes • O2 sensor fuse failed • Wiring problem • O2 sensor failed Page 4A-44 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 135: Uego1_Sensor_Open
The oxygen (O2) sensor does not appear to be working properly; the output circuit from the PCM to the O2 sensor is open or has too much resistance. Possible Causes • O2 sensor fuse failed • Wiring problem 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 4A-45...
Page 136: Uego1_Sensor_Short
The PCM received a signal from the water‑in‑fuel filter that is below the valid limit. Possible Causes • Wiring problem • Defective sensor • Contaminated fuel Summary of Fault Correction Possibilities • Inspect the wiring for problems, repair as needed. • Replace the sensor. Page 4A-46 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 137: Xdrpa_Rangehigh
Inspect the Sensor Power B circuitry for opens and shorts. For the circuit diagram, refer to Section 5A ‑ Sensors. XDRPb_RangeLow Fault Type: Horn: Guardian: UFC: Transmission to Helm: Freeze Frame Priority: Nonsticky Critical 100% 602‑5 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 4A-47...
Page 138: Xdrpc_Rangehigh
If the fault does not disappear, reconnect the sensor and continue with the next sensor. • If the fault does disappear, test that sensor for a short, and replace as required. Page 4A-48 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 139 EGT Sensor Test............5A-19 Trim Position Sensor............5A-43 EGT Sensor Removal..........5A-21 Water‑in‑Fuel (WIF) Sensor..........5A-43 EGT Sensor Installation..........5A-22 WIF Sensor Test............5A-44 Intake Air Temperature (IAT) Sensor.......5A-22 WIF Sensor Removal and Installation...... 5A-45 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5A-1...
Page 140: Sensor Tests
(PCM) is not the source of the fault. Replacing the PCM might appear to fix an issue, but the very act of disconnecting and reconnecting components can reposition a connector with a broken wire (intermittent connection) or even clean corrosion from a connector that is the actual cause of a fault. Page 5A-2 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 141: Three-Wire Sensor Power Supply And Ground Circuit Test
Ground Lead • If the ground lead opens, the signal lead will indicate 5 volts. • If the ground lead shorts to the power lead, the PCM will indicate 0 volts. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5A-3...
Page 142: Wire Color Code Abbreviations
Wire Color Abbreviations Black Blue Brown GRY or GRA Gray Green ORN or ORG Orange Pink PPL or PUR Purple White Yellow LT or LIT Light DK or DRK Dark Page 5A-4 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 144: Sensor Power A - Dts
TAN/PPL TAN/LT BLU BLK/ORN WHT/YEL RED/WHT 100C LT BLU TAN/LT BLU BLK/ORN PPL/YEL BLU/RED BLK/RED BLK/ORN PPL/YEL WHT/GRN S101 WHT/GRN RED/PPL 100B 100A 1 2 3 4 5 6 67571 Page 5A-6 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 145: Circuit Description
PCM sensor ground A (XDRG1) connects all ten sensors to ground through the PCM (pin E1 of connector C). The black and orange ground circuit incorporates three splices (100A, 100B, and 100C). 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5A-7...
Page 146: Sensor Power A - Mechanical
BLK/ORN PPL/YEL BLU/RED 100A 100C BLK/RED 101B 101A WHT/GRN 100B RED/PPL A B C D E F A B C D E F 1 2 3 4 5 6 67572 Page 5A-8 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 147: Circuit Description
PCM sensor ground B (XDRG2) connects both identified sensors to ground through the PCM (pin E2 of connector C). The black and pink ground circuit incorporates a single splice (116). 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5A-9...
Page 148: Sensor Power
The block water pressure sensor measures the pressure of the coolant that the water pump supplies to the cylinder block. The sensor converts the measured pressure to a voltage that is read by the PCM. Page 5A-10 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 149: Block Water Pressure Sensor Tests
Perform a continuity check of the sensor wiring in the engine harness, between the sensor connector and the PCM. Note that there are splices in both the power and ground circuits. NOTE: Sensor power splice numbers vary between DTS and mechanical models. DMT 2004 Digital Multimeter 91‑892647A01 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5A-11...
Page 150: Block Water Pressure Sensor Removal
If the camshaft position sensor fails, the PCM will control the fuel injection in a batch fire strategy. The engine may not start as quickly as normal. The PCM will generate and store a fault code, if the camshaft position sensor fails. Page 5A-12 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 151: Camshaft Position Sensor Tests
Perform a continuity check of the sensor wiring between the sensor connector and the PCM. Note that there are splices in both the power and ground circuits. NOTE: Sensor power splice numbers vary between DTS and mechanical models. DMT 2004 Digital Multimeter 91‑892647A01 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5A-13...
Page 152: Camshaft Position Sensor Removal
Place the bracket over the sensor, and secure both items with an M6 x 20 screw. Tighten the screw to the specified torque. Description lb‑in. lb‑ft M6 x 20 screw 70.8 – Connect the engine harness to the sensor. Page 5A-14 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 153: Crankshaft Position Sensor (Cps)
Connect the sensor harness to the engine harness, disconnect connector A from the PCM, and measure the resistance across pins C4 and D4 of the connector. Resistance must be within specification. If not, repair the wiring between the PCM and the sensor. DMT 2004 Digital Multimeter 91‑892647A01 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5A-15...
Page 154: Crankshaft Position Sensor Removal
M5 x 13 hex washer head screw 44.3 – Connect the sensor harness to the engine harness. Install the alternator, alternator belt, and oil fill bracket. Refer to the appropriate service manual. Page 5A-16 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 155: Engine Coolant Temperature (Ect) Sensor
Immerse the tip of the sensor in a controlled temperature medium. If the readings do not match those in the table, replace the sensor and retest. Pin A—ground (–) Cylinder block temperature sensor Pin B—engine coolant temperature signal (+) 16973 DMT 2004 Digital Multimeter 91‑892647A01 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5A-17...
Page 156: Ect Sensor Removal
Engine coolant temperature signal 53172 ECT Sensor Removal Cut the cable tie that secures the sensor harness connector to the engine harness. Disconnect the sensor harness from the engine harness. Page 5A-18 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 157: Ect Sensor Installation
Monitor the exhaust gas temperature (data item EGT) on the CDS G3 Live Data screen. With the engine cold and not running, exhaust gas temperature should be approximately the same as the ambient air temperature. After the engine is started, the temperature sensor should indicate a rise in temperature. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5A-19...
Page 158 PCM connector sockets CE1 and BE1. If the two resistance values match, then the wiring is good. DMT 2004 Digital Multimeter 91‑892647A01 Page 5A-20 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 159: Egt Sensor Removal
On V8 models, pull the top aft until the pins are clear of the grommets, and then lift up. V8 models Pull aft Lift up 63580 • On V6 models, pull the panel aft. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5A-21...
Page 160: Egt Sensor Installation
The PCM receives the data from the IAT, and adjusts the fuel injection duration needed to run the engine at optimum efficiency. When intake air is cold, the sensor resistance is high. As the air temperature rises, resistance lowers. Outside air temperature directly affects the engine intake air temperature. Page 5A-22 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 161: Iat Sensor Test
Immerse the sensor into a temperature controlled medium. If the readings do not match those in the table, replace the sensor and retest. Pin A (signal) Pin B (ground) IAT sensor 17003 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5A-23...
Page 162: Iat Sensor Removal
Black/orange Sensor ground A (–) 65666 IAT Sensor Removal Remove the starboard air intake runner. Refer to the appropriate service manual. Disconnect the engine harness connector from the IAT sensor. Page 5A-24 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 163: Iat Sensor Installation
IMPORTANT: The intake runner fasteners must be tightened to the specified torque in the specified order. Refer to the appropriate service manual. Install the starboard air intake runner. Refer to the appropriate service manual. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5A-25...
Page 164: Manifold Absolute Pressure (Map) Sensor
At 21 °C (70 °F) Pin A Pin B Auto 4.28 kΩ ± 30% Pin A Pin C Auto 1.93 kΩ ± 30% Pin B Pin C Auto 6.48 kΩ ± 30% Page 5A-26 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 165: Map Sensor Removal
The oil level sensor is immersed into the oil sump. It acts as an electronic dipstick, sensing the level of the oil in the sump. When the oil level is low, the propulsion control module (PCM) sets a fault and notifies the boat operator to check the oil level. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5A-27...
Page 166: Oil Level Sensor Test
Perform a continuity check of the sensor wiring between the sensor connector and the PCM. Note that there are splices in both the power and ground circuits. DMT 2004 Digital Multimeter 91‑892647A01 Page 5A-28 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 167: Oil Level Sensor Removal
Insert the oil level sensor into the engine, and tighten it to the specified torque. Description lb‑in. lb‑ft Oil level sensor – Use two screws to attach the relay bracket to the engine. Tighten the screws to the specified torque. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5A-29...
Page 168: Oil Pressure Sensor
Visually inspect the pins of the oil pressure sensor and the wires coming from the engine harness connector. Look for broken, bent, or corroded pins at the oil pressure sensor and loose, broken, or corroded wires at the engine harness connector. Page 5A-30 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 169: Oil Pressure Sensor Removal
Oil Pressure Sensor Removal Disconnect the engine harness from the sensor. Remove the sensor from the engine. Oil pressure sensor connector on the engine harness Oil pressure sensor Oil filter 67418 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5A-31...
Page 170: Oil Pressure Sensor Installation
Immerse the tip of the sensor in a controlled temperature medium. If the readings do not match those in the table, replace the sensor and retest. Pin A—ground (–) Oil temperature sensor Pin B—oil temperature signal (+) 16973 Page 5A-32 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 171: Oil Temperature Sensor Removal
Oil Temperature Sensor Installation Ensure that the O‑ring is in good condition and is installed on the sensor. Install the oil temperature sensor into the engine. Tighten the sensor to the specified torque. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5A-33...
Page 172: Oxygen (O2) Sensor
Perform a continuity check of the relevant circuitry in the engine harness. Note that the sensor receives fused 12‑volt power via the main power relay. DMT 2004 Digital Multimeter 91‑892647A01 Page 5A-34 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 173: O2 Sensor Removal
Cut the cable tie that secures the O2 sensor harness to the crankshaft position sensor (CPS) leg of the engine harness. Disconnect the O2 sensor harness from the engine harness. Use an appropriate oxygen sensor socket to remove the O2 sensor from the exhaust manifold. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5A-35...
Page 174: O2 Sensor Installation
Check the resistance of the pitot pressure sensor between pins A, B, and C. Pin A Pin B Pin C Pitot pressure sensor 17006 DMT 2004 Digital Multimeter 91‑892647A01 Page 5A-36 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 175: Pitot Pressure Sensor Removal
Cut the cable tie to remove the sensor from the engine. Remove the sensor adapter from the pitot pressure sensor. Items removed for clarity Cable tie Sensor connector Sensor adapter Flush hose Pitot tube 67576 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5A-37...
Page 176: Pitot Pressure Sensor Installation
Visually inspect the sensor pins and the wires coming from the engine harness connector. Look for broken, bent, or corroded pins at the sensor and loose, broken, or corroded wires at the engine harness connector. Page 5A-38 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 177: Shift Demand Sensor Removal
Cut the cable tie that secures the shift demand sensor harness to the engine harness. Disconnect the shift demand sensor harness from the engine harness. Shift demand sensor connection Cable ties (2) Throttle demand sensor connection 67446 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5A-39...
Page 178: Shift Demand Sensor Installation
The sensors can be swapped for diagnostic purposes. Exercise special care to ensure that the sensor connections to the engine harness are correct, prior to attempting to run the engine. Page 5A-40 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 179: Throttle Demand Sensor Testing
Perform a continuity check of the sensor wiring in the engine harness, between the sensor connector and the PCM. Note that there are splices in both the power and ground circuits. DMT 2004 Digital Multimeter 91‑892647A01 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5A-41...
Page 180: Throttle Demand Sensor Removal
Cut the cable tie that secures the throttle demand sensor harness to the engine harness. Disconnect the throttle demand sensor harness from the engine harness. Shift demand sensor connection Cable ties (2) Throttle demand sensor connection 67446 Page 5A-42 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 181: Throttle Demand Sensor Installation
PCM. When water is present, the PCM generates an error history and activates a warning horn to inform the operator. If SmartCraft gauges are installed, the display will flash a visual warning to the operator. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5A-43...
Page 182: Wif Sensor Test
If the sensor is serviceable, perform a continuity check on the sensor harness between the sensor connector and the PCM. Check for shorts to ground. Note that there is a splice in the ground circuit. DMT 2004 Digital Multimeter 91‑892647A01 Page 5A-44 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 183: Wif Sensor Removal And Installation
IMPORTANT: The engine mounted water‑separating fuel filter WIF sensor is not replaceable as an individual component. It must be replaced as part of the fuel filter assembly. Refer to the appropriate service manual. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5A-45...
Page 185 Overview..............5B-2 Shift Actuator..............5B-8 Troubleshooting the ETC..........5B-2 Shift Actuator Harness Connector Pin Out....5B-8 Fuel Pump Relay............... 5B-4 Shift Control..............5B-9 Main Power Relay (MPR)..........5B-5 Shift Actuator Troubleshooting........5B-9 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5B-1...
Page 186: Electronic Throttle Control (Etc)
IMPORTANT: The ETC is integral to the throttle body assembly, and cannot be serviced separately. If the ETC fails, the entire throttle body assembly must be replaced. Refer to the appropriate service manual for throttle body assembly replacement procedures. Page 5B-2 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 187 Disconnect the PCM from the engine harness. The connectors must be removed in sequence: A, B, and then C. Refer to the appropriate service manual for details. Test the engine harness for continuity between each of the ETC connector pins and the PCM connectors: 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5B-3...
Page 188: Fuel Pump Relay
ON for five seconds. After the initial five seconds, the fuel pumps will not be active until engine RPM is recognized by the PCM. Fuel pump relay Starter relay 65378 Page 5B-4 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 189: Main Power Relay (Mpr)
To remove and install the starboard intake runner, refer to the appropriate outboard service manual. Starboard side of powerhead, intake runner removed MPR socket on the engine harness 67396 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5B-5...
Page 190: Start Relay
The relay closes and sends power to the starter solenoid to crank the engine. Once the PCM determines that the engine has started, it removes the ground from the start relay and the starter motor stops cranking. Page 5B-6 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 191 Fused (20 A) 12 V power (+) – Black/blue Start relay control Yellow/red Starter solenoid power (+) – 59637 Yellow/purple MPR control signal Red/white Switched 12 V power (+) – 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5B-7...
Page 192: Shift Actuator
DC motor (+) Green Sensor output 1 (shift position 1) Orange Sensor +5V power Black DC motor (–) White Sensor ground (–) 59335 Yellow Sensor output 2 (shift position 2) Page 5B-8 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 193: Shift Control
PCM connectors. The shift actuator does not have any internal serviceable components. PCM Shift Actuator Circuit Test Refer to the following illustration for the PCM shift actuator circuit test. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5B-9...
Page 195 If the 5.0 volt reference voltage is present at sensor power A, but either position sensor feedback voltage is outside of the range for the specified shift position, replace the shift actuator. The shift position sensors are not individually serviceable components. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5B-11...
Page 197 Advanced Sound Control...........5C-2 Analog Gauges (DTS only)..........5C-7 Troubleshooting............5C-2 Boat Harness..............5C-8 Moving Propeller (MP) Alert..........5C-4 Diagnostics (RS48) ............5C-9 Power Steering..............5C-4 Battery Isolator Troubleshooting........5C-9 Troubleshooting an Inoperable Power Steering Pump ................5C-5 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5C-1...
Page 198: Advanced Sound Control
PCM. If no issues are discovered, replace the advanced sound control actuator and retest. Page 5C-2 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 199 – Green ASC diagnostic 65662 Red/white Switched 12 V power (+) – Yellow/purple Main power relay (MPR) control signal Hot stud ring terminal – 12 V battery power (+) – 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5C-3...
Page 200: Moving Propeller (Mp) Alert
The pump should only operate while the engine is running. Refer to the troubleshooting procedure below if the pump is not operating. WHT/BLU WHT/BLU 102B 104B 65459 PCM connector A Power steering connector PCM connector C Chassis ground (–) Page 5C-4 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 201: Troubleshooting An Inoperable Power Steering Pump
DMT Meter Leads Black Circuit voltage = Purple Engine/battery ground Battery voltage Power steering driver module ‑ engine starts and runs Blue/white Engine/battery ground Battery voltage 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5C-5...
Page 202 See the instruction sheet supplied with the power steering module primer kit. Power Steering Module Primer Kit 91‑895040K01 Page 5C-6 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 203: Analog Gauges (Dts Only)
Oil pressure analog gauge Brown Coolant temperature analog gauge Orange/green Trim position analog gauge 65767 IMPORTANT: Refer to CDS G3 for the tachometer, oil pressure, coolant temperature, and trim position output values. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 5C-7...
Page 204: Boat Harness
Wire Color Function Black/green Sensor ground (–) Purple/black Sensor power (+) Brown Fuel level 2 signal Gray/blue Paddle wheel signal Tan/orange Sea temperature signal 53175 Pink/black Fuel level 1 signal Page 5C-8 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 205: Diagnostics (Rs48)
Accessories Diagnostics (RS48) This connector is labeled as "Diagnostics RS48," however Mercury's CDS G3 diagnostic tool always connects to the 10‑pin SmartCraft connection. This connector is used instead for the connection of a depth transducer. The PCM communicates with the transducer and then broadcasts the information onto the SmartCraft network for display at the helm. CDS G3 will also display the depth data under the Vessel tab of the Live Data display for troubleshooting purposes.
Page 206 If not, check the voltage on the input stud. The input stud voltage should be 14.5 V ± 0.5V. If voltage is not making it "through" the isolator, replace the isolator. Page 5C-10 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 207 Spark Plug Wires............... 6A-7 Ignition Coil Tests ‑ Digital Multimeter......6A-3 Spark Plug Wire Resistance ‑ V6 Models....6A-8 Ignition Coil Wiring Diagram ‑ V6........6A-4 Spark Plug Wire Resistance ‑ V8 Models....6A-8 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 6A-1...
Page 208: Ignition Specifications - V6 Models
Not adjustable; PCM controlled Special Tools CDS G3 Interface Kit 8M0138392 CDS G3 License Key, Interface, Adapter, and Harness 66165 Spark Gap Tester 91‑850439T 1 Provides a visual indication of spark/coil efficiency. 7513 Page 6A-2 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 209: Ignition Coils
Turn off the ignition key and change the meter to ohms. Measure the resistance between pin E of the coil harness and each of the other pins. The resistance should be approximately that of the primary coil (0.3–0.5 ohms). 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 6A-3...
Page 210: Ignition Coil Wiring Diagram - V6
Ignition Coil Wiring Diagram ‑ V6 A B C D E F 30858687 109B 105B 105A RED/WHT RED/YEL A B C D E A B C D E GRN/RED GRN/BLK GRN/PPL 65451 Page 6A-4 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 211: Wire Color Code Abbreviations
Wire Color Abbreviations Black Blue Brown GRY or GRA Gray Green ORN or ORG Orange Pink PPL or PUR Purple White Yellow LT or LIT Light DK or DRK Dark 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 6A-5...
Page 212: Ignition Coil Wiring Diagram - V8
Ignition Coil Wiring Diagram ‑ V8 A B C D E F H1 A2 30858687 109B 105B 105A RED/WHT RED/YEL A B C D E A B C D E GRN/RED GRN/BLK GRN/PPL GRN/YEL 65452 Page 6A-6 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 213: Ignition Coil Resistance Test
Always ensure that you use the correct wire to connect a given spark plug to its corresponding ignition coil. After installing each spark plug wire, ensure that the terminal has engaged by lightly tugging on each connection. Spark plug end Ignition coil end 66596 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 6A-7...
Page 214: Spark Plug Wire Resistance - V6 Models
NOTE: The length of each spark plug wire is measured between the coil terminal (center of the coil boot) and the plug boot (center of the plug boot). Each stated length is plus or minus 0.6 cm (0.25 in.). Page 6A-8 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 215 Starting System Components and Connections ‑ Fuses................. 6B-4 Mechanical............6B-11 Charging System............... 6B-5 Starting System Electrical Checks......6B-12 Charging System Components........6B-5 Key Switch Test (Four Position)....... 6B-13 Alternator Description..........6B-5 Key Switch Test (Three Position)......6B-14 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 6B-1...
Page 216: Charging And Starting Specifications
With the key switch in the "START" position, measure the voltage across the battery posts, not the cable clamps. Record the voltage reading. If the voltage is less than 10 VDC, replace the battery. Page 6B-2 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 217: Replacement Parts
Replacement Parts WARNING Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with federal and international standards to minimize risk of fire or explosion. Do not use replacement electrical or fuel system components that do not comply with these standards. When servicing the electrical and fuel systems, properly install and tighten all components.
Page 218: Fuses
Driver power—20 amp (start relay, fuel pump relay, PCM drivers) TVM power—15 amp (not used on all models) Spare fuses (3) Good fuse Open fuse 64390 Page 6B-4 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 219: Charging System
An excitation circuit supplies a small amount of current to the rotor field to initially start the electromagnetic field. Once the alternator begins to produce output, field current is supplied solely by the rectifier diodes. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 6B-5...
Page 220: Alternator
Verify the output lead attaching nut is tightened to the specified torque. Alternator output lead/fusible link, to hot stud Alternator connection to engine harness (excitation and sense leads) 66511 Page 6B-6 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 221: Charging System Circuitry Tests
Connect the positive (+) DMT lead to the alternator output post. Connect the negative (–) DMT lead to the ground post on the alternator. Alternator output post Alternator ground post 66370 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 6B-7...
Page 222 Unplug the engine harness connector from the alternator. Connect the positive (+) DMT lead to the purple pin (pin C) and the negative (–) DMT lead to the alternator ground post. Page 6B-8 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 223 The DMT should indicate battery voltage. If battery voltage is not present, check the purple lead for a loose or dirty connection or damaged wiring. Excitation circuit purple lead Alternator ground post 66377 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 6B-9...
Page 224: Starting System
NOTE: RED* indicates a black cable with red sleeves at the ring terminals. Chassis ground stud 14‑pin data harness (engine to helm) To helm components; refer to DTS Diagnostic Manual 8M0057654 Clean power harness with 5‑amp fuse Engine starting battery Shift actuator Page 6B-10 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 225: Starting System Components And Connections - Mechanical
Neutral start switch (typically integral to the remote control) Ignition key switch (typical) 14‑pin data harness (engine to helm) Clean power harness with 5‑amp fuse Engine starting battery Shift actuator 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 6B-11...
Page 226: Starting System Electrical Checks
Measure the resistance of the relay's coil, between terminal 86 and terminal 85. Replace the relay, if the coil's resistance is not within specification. 67575 Four-pin relay pin identification Start Relay Coil resistance (terminal 86 to terminal 85) 80–100 Ω Page 6B-12 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 227: Key Switch Test (Four Position)
Pin B ‑ Black Pin C ‑ Purple/white Pin D ‑ Purple Pin E ‑ Black/yellow Pin F ‑ Yellow/red 3887 Key Position Continuity should be indicated at the following points: 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 6B-13...
Page 228: Key Switch Test (Three Position)
Pin E Continuity Pin A Pin F Continuity Pin A Pin C, D Pin A Pin F Continuity Pin F Pin C, D Start Continuity Pin A Pin C, D Continuity Page 6B-14 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 229 Troubleshooting the Down and Up Circuits (All 2004A..............6C-14 Circuits Inoperative)..........6C-9 Trim Switches and Sensor ‑ DTS........6C-15 Trim Circuit................ 6C-9 Trim Switches and Sensor ‑ Mechanical......6C-16 Trim Up Circuit............6C-10 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 6C-1...
Page 230: Electrical System Troubleshooting
Power Trim Electrical Circuit IMPORTANT: Numerical callouts shown in the circuit diagrams are test points. Refer to Troubleshooting the Down Circuit or Troubleshooting the Up Circuit. Page 6C-2 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 232 LT BLU/WHT LT BLU/WHT GRN/WHT GRN/WHT GRN/WHT RED/BLK BLK/GRN GRN/WHT RED/BLK LT BLU/WHT PPL/BLK BLK/GRN PPL/BLK RED/BLK S112 GRN/WHT LT BLU/WHT S107 RED/BLK S115 GRN/WHT RED/BLK S114 LT BLU/WHT 64670 Page 6C-4 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 233 Clean power connector Down relay 14‑pin connector –12 volts ground IMPORTANT: Numerical callouts shown in the circuit diagrams are test points. Refer to Troubleshooting the Down Circuit or Troubleshooting the Up Circuit. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 6C-5...
Page 234 Relay Components as Viewed Separated M4 C2 A1 A3 H4 GRN/WHT LT BLU/WHT LT BLU/WHT GRN/WHT LT BLU/WHT GRN/WHT GRN/WHT BLK/GRN LT BLU/WHT PPL/BLK BLK/GRN PPL/BLK GRN/WHT LT BLU/WHT S109B 64671 Page 6C-6 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 235: Troubleshooting The Down Circuit
Point 3 (female bullet connector) and • Go to Step 6. battery voltage at black lead to ground. No battery voltage measured: Point 3. Depress the down trim button. • Relay is defective. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 6C-7...
Page 236: Troubleshooting The Up Circuit
Step 6: Check the • Pump motor is defective. black lead to ground. down relay. Relay is faulty (no battery voltage measured): Depress the down trim button. • Replace relay. Page 6C-8 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 237: Troubleshooting The Down And Up Circuits (All Circuits Inoperative)
Trim Circuit When the trim relays are de‑energized, contacts 30 and 87a of both relays complete the circuit to the trim motor leads. Both trim motor leads are to ground. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 6C-9...
Page 238: Trim Up Circuit
LT BLU/WHT (–) (–) 67464 GRN/WHT Trim up circuit Trim relay contacts Trim up relay 12 volts (+) To trim motor (+) Trim down relay To trim motor (–) From PCM Page 6C-10 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 239: Trim Down Circuit
The trim motor relay system, used on permanent magnet trim systems, connects each of the two wires from the trim motor to either ground or positive to allow the motor to run in both directions. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 6C-11...
Page 240: Trim Position Sensor Troubleshooting
Monitor the trim position sensor analog‑to‑digital counts (ADC) with CDS G3. Verify wiring harness integrity with a DMT 2004 digital multimeter or equivalent. CDS G3 Interface Kit 8M0138392 DMT 2004 Digital Multimeter 91‑892647A01 Page 6C-12 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 241 PCM harness may be faulty. harness side): a. PCM C, pin E3 to black/green wire. b. PCM B, pin C2 to yellow wire. c. PCM C, pin E4 to purple/black wire. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 6C-13...
Page 242: Trim Position Sensor Location
Check the resistance of the trim position sensor circuit harness and PCM. DMT 2004 Digital Multimeter 91‑892647A01 Meter Test Leads Meter Scale Reading Black Yellow Black/green Ohms 210 kΩ ± 20% Page 6C-14 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 243: Trim Switches And Sensor - Dts
Sensor ground C (–) Yellow Trim position sensor signal 65697 Purple/black Sensor power C (+) 12 V battery power (+) – Green/white Trim down (from switch) Light blue/white Trim up (from switch) 65695 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 6C-15...
Page 244: Trim Switches And Sensor - Mechanical
Trim down (from switch) Light blue/white Trim up (from switch) 65695 Clean power harness Black Clean power ground (–) – *Clean power is in input to the PCM at pin CA4, not shown. Page 6C-16 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 245 Trim Position Sensor Location........6D-12 Troubleshooting the Down and Up Circuits (All Testing the Trim Position Sensor with DMT 2004A..6D-12 Circuits Inoperative)..........6D-7 Trim Switches and Sensor ‑ DTS........6D-13 Trim Circuit................ 6D-7 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 6D-1...
Page 246: Electrical System Troubleshooting
Power Trim Electrical Circuit IMPORTANT: Numerical callouts shown in the circuit diagrams are test points. Refer to Troubleshooting the Down Circuit or Troubleshooting the Up Circuit. Page 6D-2 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 248 Relay Components as Viewed Separated M4 C2 A1 A3 H4 GRN/WHT LT BLU/WHT LT BLU/WHT GRN/WHT LT BLU/WHT GRN/WHT GRN/WHT BLK/GRN LT BLU/WHT PPL/BLK BLK/GRN PPL/BLK GRN/WHT LT BLU/WHT S109B 64671 Page 6D-4 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 249: Troubleshooting The Down Circuit
Point 3 (female bullet connector) and • Go to Step 6. battery voltage at black lead to ground. No battery voltage measured: Point 3. Depress the down trim button. • Relay is defective. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 6D-5...
Page 250: Troubleshooting The Up Circuit
Step 6: Check the • Pump motor is defective. black lead to ground. down relay. Relay is faulty (no battery voltage measured): Depress the down trim button. • Replace relay. Page 6D-6 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 251: Troubleshooting The Down And Up Circuits (All Circuits Inoperative)
Trim Circuit When the trim relays are de‑energized, contacts 30 and 87a of both relays complete the circuit to the trim motor leads. Both trim motor leads are to ground. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 6D-7...
Page 252: Trim Up Circuit
LT BLU/WHT (–) (–) 67464 GRN/WHT Trim up circuit Trim relay contacts Trim up relay 12 volts (+) To trim motor (+) Trim down relay To trim motor (–) From PCM Page 6D-8 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 253: Trim Down Circuit
The trim motor relay system, used on permanent magnet trim systems, connects each of the two wires from the trim motor to either ground or positive to allow the motor to run in both directions. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 6D-9...
Page 254: Trim Position Sensor Troubleshooting
Monitor the trim position sensor analog‑to‑digital counts (ADC) with the CDS G3. Verify wiring harness integrity with a DMT 2004 digital multimeter or equivalent. CDS G3 Interface Kit 8M0138392 DMT 2004 Digital Multimeter 91‑892647A01 Page 6D-10 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 255 PCM harness may be faulty. harness side): a. PCM C, pin E3 to black/green wire. b. PCM B, pin C2 to yellow wire. c. PCM C, pin E4 to purple/black wire. 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 6D-11...
Page 256: Trim Position Sensor Location
Check the resistance of the trim position sensor circuit harness and PCM. DMT 2004 Digital Multimeter 91‑892647A01 Meter Test Leads Meter Scale Reading Black Yellow Black/green Ohms 210 kΩ ± 20% Page 6D-12 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 257 Sensor ground C (–) Yellow Trim position sensor signal 65697 Purple/black Sensor power C (+) 12 V battery power (+) – Green/white Trim down (from switch) Light blue/white Trim up (from switch) 65695 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 6D-13...
Page 259 Fuel Supply Module (FSM) Description...... 7A-7 Fuel System..............7A-2 Fuel Pressure Regulator..........7A-8 Fuel Injector..............7A-2 Fuel Lift Pump.............7A-8 In‑line Fuel Filter............7A-3 High‑Pressure Fuel Pump.......... 7A-9 V6 Fuel Flow Diagram..........7A-4 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 7A-1...
Page 260: Fuel System Specifications
There are two separate streams of fuel aimed at the intake valves, for better atomization of the fuel. The fuel injector is not serviceable. Page 7A-2 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 261: In-Line Fuel Filter
In the event of fuel contamination, the filter element can be cleaned by backflushing the element with a locally available fuel system cleaner. Replacement is not required unless the in‑line fuel filter is damaged, punctured, or otherwise unsuitable for use. 55858 In-line fuel filter 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 7A-3...
Page 262: V6 Fuel Flow Diagram
Fuel System V6 Fuel Flow Diagram 66084 Page 7A-4 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 263 Siphon tube Manifold reference quick‑connect 20 - Fuel cooler 10 - Port rail hose quick‑connect 21 - Fuel lift pump 11 - Port rail hose 22 - Recirculation check valve 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 7A-5...
Page 264: V8 Fuel Flow Diagram
Fuel System V8 Fuel Flow Diagram 66099 Page 7A-6 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 265: Fuel Supply Module (Fsm)
High‑pressure fuel out port Fuel cooler water out port to the water pump indicator Fuel lift pump (from vessel) Fuel cooler water in port from strainer Fuel cooler fuel tube 47841 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 7A-7...
Page 266: Fuel Pressure Regulator
FSM to pass through the fuel lift pump, preventing the pump from overheating. The FSM is a volume displacement module, which replaces the fuel inside the FSM automatically without the installation of a float switch or needle and seat. 47837 Page 7A-8 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 267: High-Pressure Fuel Pump
The fuel pressure dumped by the fuel pressure regulator passes through a fuel cooler. Passing the excessive fuel through the fuel cooler prevents the high‑pressure fuel pump from overheating. 47839 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 7A-9...
Page 269 Antisiphon Valves............7B-2 Fuel Injector Resistance Test........7B-4 Fuel Supply Module (FSM)......... 7B-2 Wire Color Code Abbreviations........7B-5 Fuel Lift Pump ............7B-2 Fuel Injector Circuits........... 7B-6 High‑Pressure Fuel Pump.......... 7B-3 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 7B-1...
Page 270: Fuel Component Troubleshooting And Diagnostics
NOTE: This test should be completed during engine idle or light load operation. If no fuel demand exists and the FSM is filled, the lift pump will not pull fuel to create a vacuum. At engine idle, inlet vacuum may build slowly. Page 7B-2 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 271: High-Pressure Fuel Pump
There is no logic in the engine control module to know if the high‑pressure fuel pump is functioning or not. No fault will be set if the high‑pressure fuel pump fails. Connect a fuel pressure gauge to the fuel rail Schrader valve. Fuel Pressure Gauge Kit 91‑881833A03 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 7B-3...
Page 272: Fuel Pressure Calculations, Engine Running
The fuel injector is not polarity sensitive. Removed from fuel rail for clarity Fuel injector pins Fuel Injector Resistance at 21 °C (71 °F) 12.5 ± 0.6 Ω Page 7B-4 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 273: Wire Color Code Abbreviations
Wire Color Abbreviations Black Blue Brown GRY or GRA Gray Green ORN or ORG Orange Pink PPL or PUR Purple White Yellow LT or LIT Light DK or DRK Dark 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 7B-5...
Page 274 F4 G4 RED/ORN PNK/BRN RED/ORN PNK/RED RED/ORN PNK/ORN 108A 108B RED/ORN PNK/YEL RED/ORN PNK/BLU RED/ORN 104B RED/PNK YEL/BLK 106B RED/BLU RED/PNK 109A 109B RED/WHT 105B RED/WHT 105A RED/ORN RED/WHT RED/BLU 65385 Page 7B-6 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 275 Fuel pump 12 V power (+) – 59637 Hot stud ring terminal 12 V battery power (+) – Yellow/purple Main power relay (MPR) control signal Red/white Switched 12 V power (+) – 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 7B-7...
Page 276 RED/ORN PNK/ORN 108A 108B RED/ORN PNK/YEL RED/ORN PNK/BLU RED/ORN RED/ORN PNK/WHT RED/ORN PNK/LT GRN 104B RED/PNK YEL/BLK 106B RED/BLU RED/PNK 109A 109B RED/WHT 105B RED/WHT 105A RED/ORN RED/WHT RED/BLU 65384 Page 7B-8 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 277 Fuel pump 12 V power (+) – 59637 Hot stud ring terminal – 12 V battery power (+) – Yellow/purple Main power relay (MPR) control signal Red/white Switched 12 V power (+) – 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 7B-9...
Page 279 Table of Contents 14‑Pin Data Harness ‑ DTS..........8A-2 CAN Circuits ‑ DTS............8A-6 Wire Color Code Abbreviations..........8A-3 CAN Circuits ‑ Mechanical..........8A-8 14‑Pin Data Harness ‑ Mechanical........8A-4 Clean Power..............8A-9 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 8A-1...
Page 280: 14-Pin Data Harness - Dts
S104B 65436 PCM connector A PCM connector B PCM connector C CAN P and H terminator CAN X terminator 14‑pin connector Hot stud Engine fuses ‑ 15‑amp fuse Chassis ground Page 8A-2 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 281: Wire Color Code Abbreviations
Wire Color Abbreviations Black Blue Brown GRY or GRA Gray Green ORN or ORG Orange Pink PPL or PUR Purple White Yellow LT or LIT Light DK or DRK Dark 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 8A-3...
Page 282: 14-Pin Data Harness - Mechanical
A B C D E F G H J K L M N P S115 S114 TAN/LT BLU S123 S122 BLU/YEL 102B YEL/RED S107 LT BLU/WHT ORN/GRN S112 GRN/WHT 65437 Page 8A-4 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 283 CAN P low Light blue/white Trim up command Green/white Trim down command Orange/green Trim position analog gauge 53467 Tan/light blue Horn Gray Tachometer signal Yellow/red Start/stop signal Brown Coolant temperature analog gauge 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 8A-5...
Page 284: Can Circuits - Dts
F G H J K A B C D E F G H J K A B C D E F G H J K L M N P S123 S122 102A 102B 65443 Page 8A-6 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 285 12 V wake circuit (+) Green/orange CAN H low – Not used 57554 White CAN P high Blue CAN P low Yellow CAN X high Brown CAN X low 53172 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 8A-7...
Page 286: Can Circuits - Mechanical
Purple 12 V wake circuit (+) Not used – Not used – 57554 White CAN P high Blue CAN P low Yellow CAN X high Brown CAN X low 53172 Page 8A-8 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 287 Clean power connector 14‑pin connector Trim harness connector Cowl trim switch connector PCM connector C Connector Wire Color Function Red/black 12 V clean power (+) Black Clean power ground (–) – 65743 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 8A-9...
Page 289 Color Diagrams Section 8B - Engine Harness Diagrams Table of Contents 4.6L V8 DTS Wiring Diagram..........8B-4 3.4L V6 DTS Wiring Diagram..........8B-6 4.6L V8 Non‑DTS Wiring Diagram........8B-5 3.4L V6 Non‑DTS Wiring Diagram........8B-7 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 8B-1...
Page 292: 4.6L V8 Dts Wiring Diagram
Engine coolant temperature (ECT) sensor 23 - Alternator 48 - PCM ground (–) 24 - Electronic throttle control (ETC) 49 - PCM connector C 25 - Engine fuses 50 - PCM connector B Page 8B-4 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 293 4.6L V8 DTS Wiring Diagram A B C D E F G H J K A1B1 C1 D1 E1 F1 G1 H1 A2 B2 C2 D2 E2 F2 G2 H2 A3 B3 C3 D3 E3 H3 A4 B4 C4 D4 E4 F4 G4 A B C 1 2 3 4 5 6...
Page 294 4.6L V8 Non-DTS Wiring Diagram A B C D E F G H J K A1B1 C1 D1 E1 F1 G1 H1 A2 B2 C2 D2 E2 F2 G2 H2 A3 B3 C3 D3 E3 H3 A4 B4 C4 D4 E4 F4 G4 A B C 1 2 3 4 5 6...
Page 295: 4.6L V8 Non-Dts Wiring Diagram
49 - Throttle demand sensor 24 - Electronic throttle control (ETC) 50 - PCM connector C 25 - Engine fuses 51 - PCM connector B 26 - Oil level sensor 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 8B-5...
Page 296: 3.4L V6 Dts Wiring Diagram
Cowl trim switch 43 - Analog gauge harness 44 - Exhaust coolant temperature (ECT) sensor 45 - PCM ground (–) 46 - PCM connector C 47 - PCM connector B Page 8B-6 © 2018 Mercury Marine 90-8M0146617 eng JULY 2018...
Page 297 3.4L V6 DTS Wiring Diagram A B C D E F G H J K A1B1 C1 D1 E1 F1 G1 H1 A2 B2 C2 D2 E2 F2 G2 H2 A3 B3 C3 D3 E3 H3 A4 B4 C4 D4 E4 F4 G4 A B C 1 2 3 4 5 6...
Page 298 3.4L V6 Non-DTS Wiring Diagram A B C D E F G H J K A1B1 C1 D1 E1 F1 G1 H1 A2 B2 C2 D2 E2 F2 G2 H2 A3 B3 C3 D3 E3 H3 A4 B4 C4 D4 E4 F4 G4 A B C 1 2 3 4 5 6...
Page 299: 3.4L V6 Non-Dts Wiring Diagram
46 - Throttle demand sensor 22 - Electronic throttle control (ETC) 47 - PCM connector C 23 - Engine fuses 48 - PCM connector B 24 - Oil level sensor 90-8M0146617 eng JULY 2018 © 2018 Mercury Marine Page 8B-7...
Page 302 Parc Industriel de Petit-Rechain 41-71 Bessemer Drive P.O. Box 1939 B-4800 Verviers, Belgium Dandenong South, Victoria 3175 Australia Fond du Lac, WI 54936-1939 USA © Mercury Marine. All rights reserved. 90-8M0146617 JULY 2018 Printed in U.S.A.

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V6 200 V6 225 V8 200 V8 225 V8 250 V8 300

Mercury V6 175 Diagnostic Manual

Important Information 1

Important Information 1

Section 2A - Pcm 112 Important Information and Pinouts a

General Troubleshooting and Cds G3 3

Fault Codes

Sensors, Actuators, Relays, and Accessories

Sensors, Actuators, Relays, and Accessories

Sensors, Actuators, Relays, and Accessories

Electrical Systems

Electrical Systems

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

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