Mercury V6 200 Manuals

Manuals and User Guides for Mercury V6 200. We have 1 Mercury V6 200 manual available for free PDF download: Diagnostic Manual

Mercury V6 200 Diagnostic Manual

Mercury V6 200 Diagnostic Manual (302 pages)

Brand: Mercury | Category: Outboard Motor | Size: 33.78 MB

Table of Contents

Important Information 1

11
- Table of Contents
  11
- Overview
  12
- Speed/Density Theory
  12
- Stoichiometry, Equivalency Ratio, and Emissions Control
  12
- Oxygen (O2) Sensor
  13
- Open-Loop and Closed-Loop Operation
  13
- Advanced Range Optimization
  14
- Propulsion Control Module (PCM)
  14
- Description
  14
- Engine Guardian System
  15
- Important Terms
  15
Important Information 1

21
- Glossary
  22
- Abbreviations
  24
- General Reference Charts
  25
- Manifold Vacuum and Pressure
  25
- Altitude and Barometric Pressure
  26
- Vacuum Gauge Versus MAP Sensor
  27
- Centigrade to Fahrenheit Conversion
  28
Section 2A - Pcm 112 Important Information and Pinouts a

29
- Important Information
  30
- Propulsion Control Module (PCM) Overview
  30
- Important PCM Notes
  31
- Test Equipment
  31
- Load Balancing
  32
- Software and Adaptive Speed Control
  32
- Connector
  33
- PCM 112 Pinouts
  33
General Troubleshooting and Cds G3 3

55
- About CDS G3
  56
- Connecting and Starting CDS G3
  56
- Connection to the Engine
  56
- Installing CDS G3
  56
- Troubleshooting with the Computer Diagnostic System (CDS G3)
  56
- Connection to the Junction Box or Diagnostic Port
  57
- If CDS G3 Does Not Communicate with the System
  57
- Starting CDS G3
  57
- CDS G3 Operation and Screen Descriptions
  58
- Home Screen
  58
- Print Screen/Print Report
  59
- Selecting an Ebom
  59
- Reflash Screen
  60
- Configuration Screen
  61
- Diagnostics Screen
  61
- Module Data Screen
  62
- CDS G3 and Diagnostic Fault Resolution
  67
- How to Begin
  67
- Addressing Faults
  68
- Fault Codes
  68
- Diagnosing Intermittent Problems
  69
- Visual/Physical Check
  69
Fault Codes

91
- Mercury UFC List
  93
- Aev_Outputfault
  98
- Authtimeout
  98
- CDS G3 Freeze Frame Faults
  98
- Barorange
  99
- Camshaft_Encoder_Fault
  99
- Crosscheck_Failed
  99
- Demandsensor1_Rangehigh
  100
- Demandsensor1_Rangelow
  100
- Demandsensor2_Rangehigh
  100
- Demandsensor2_Rangelow
  101
- Demandsensor_Diff
  101
- Demand_Xcheck_Diff
  101
- Dmdsense1_Noadapt
  102
- Dmdsense2_Noadapt
  102
- Dual_Can_Soh_Faults
  102
- Dual_Demandsen_Fault
  103
- Dual_Shiftdemandsen_Fault
  103
- Dual_Shiftpossen_Fault
  103
- Dual_Tps_Faults
  104
- Egt_Overtemp
  104
- Egt_Rangehigh
  104
- Egt_Rangelow
  105
- Esclossofcontrol
  105
- Esc_Desiredactualdiff
  105
- Esc_Noadapt_Forward
  106
- Esc_Noadapt_Reverse
  106
- Esc_Timeout
  106
- Est1_Outputfault
  107
- Est2_Outputfault
  107
- Est3_Outputfault
  107
- Est4_Outputfault
  107
- Estop_Active
  107
- Etc_Loss_Of_Control
  108
- Etc_Outputfault
  108
- Etc_Sticking
  108
- Encoderfaultcrankcamtrigger
  109
- Etc_Tpsdisagree
  109
- Fulp_Outputfault
  109
- Guardian_Active
  110
- Guardian_Egttemp
  110
- Guardian_Oilpressure
  110
- Guardian_Oil_Temp_Derate
  111
- Guardian_Overheat
  111
- Guardian_Overspeed
  112
- Guardian_Uxpowerlimit
  112
- Horn_Outputfault
  113
- Iat_Rangehigh
  113
- Iat_Rangelow
  113
- Map_Angle_Rangehigh
  115
- Map_Angle_Rangelow
  115
- Map_Time_Rangehigh
  115
- Mapr_Tps1Rationality
  116
- Map_Time_Rangelow
  116
- Mapr_Tps2Rationality
  117
- Microchi_Pwm_Adc
  117
- Neutral_Overspeed
  117
- O2Control_Itermhighport
  118
- O2Control_Itermlowport
  118
- Oillevelinvalid
  118
- Oillevel_Critically_Low
  119
- Oillevel_Rangehigh
  119
- Oillevel_Sensor_Faulted
  119
- Oillevel_Sensor_Invalid
  120
- Oilpress_Low
  120
- Oilpress_Rangehigh
  120
- Oilpress_Rangelow
  121
- Oiltemp_Rangehigh
  121
- Oiltemp_Rangelow
  121
- Rxdoc1_Soh
  121
- Rxdoc2_Soh
  122
- Rxdoc3_Soh
  122
- Rxdoc10_Soh
  123
- Rxdoc7_Soh
  123
- Rxdoc9_Soh
  123
- Rxdoc11_Soh
  124
- Security_Device_Missing
  124
- Security_Locked
  124
- Security_Setup
  125
- Shft_Outputfault
  125
- Shiftdemandsensor_Diff
  125
- Shiftdmdsensor1_Rangehigh
  126
- Shiftdmdsensor1_Rangelow
  126
- Shiftdmdsensor2_Rangehigh
  126
- Shiftdmdsensor2_Rangelow
  126
- Shiftpos2_Rangehigh
  127
- Shiftpos_Rangehigh
  127
- Shiftpos_Rangelow
  127
- Shiftpos2_Rangelow
  128
- Shiftpositionsensor_Diff
  128
- Shift_Xcheck_Diff
  128
- Spi_Crosscheckdata_Soh
  129
- Stbdect_Overtemp
  129
- Stbdect_Rangehigh
  129
- Stbdect_Rangelow
  130
- Strt_Outputfault
  130
- Sysvolt_Faultblocker
  130
- Sysvolt_Rangehigh
  131
- Sysvolt_Rangelow
  131
- Tps1_Etc_Noadapt
  131
- Tps1_Rangehigh
  132
- Tps1_Rangelow
  132
- Tps2_Etc_Noadapt
  132
- Tps2_Rangehigh
  132
- Tps2_Rangelow
  133
- Trmd_Outputfault
  133
- Trmu_Outputfault
  133
- Trimpos_Rangehigh
  134
- Trimpos_Rangelow
  134
- Uego1_Htrlwrlimit
  134
- Uego1_Sensor_Open
  135
- Uego1_Sensor_Short
  136
- Watchdog_Active
  136
- Waterinfuel_Rangelow
  136
- Xdrpa_Rangehigh
  137
- Xdrpa_Rangelow
  137
- Xdrpb_Rangehigh
  137
- Xdrpb_Rangelow
  137
- Xdrpc_Rangehigh
  138
- Xdrpc_Rangelow
  138
Sensors, Actuators, Relays, and Accessories

139
- General Sensor Troubleshooting
  140
- Sensor Tests
  140
- Swapping Sensors
  140
- Sensor Opens and Shorts
  141
- Sensor Signal Circuit Test
  141
- Three-Wire Sensor Opens and Shorts
  141
- Three-Wire Sensor Power Supply and Ground Circuit Test
  141
- Two-Wire Sensor Opens and Shorts
  141
- Wire Color Code Abbreviations
  142
- Sensor Power a - DTS
  144
- Circuit Description
  145
- Sensor Power a - Mechanical
  146
- Circuit Description
  147
- Sensor Power
  147
- Block Water Pressure Sensor
  148
- Circuit Description
  148
- Sensor Power
  148
- Block Water Pressure Sensor Tests
  149
- Block Water Pressure Sensor Installation
  150
- Block Water Pressure Sensor Removal
  150
- Camshaft Position Sensor
  150
- Camshaft Position Sensor Tests
  151
- Camshaft Position Sensor Installation
  152
- Camshaft Position Sensor Removal
  152
- CPS Test
  153
- Crankshaft Position Sensor (CPS)
  153
- Crankshaft Position Sensor Installation
  154
- Crankshaft Position Sensor Removal
  154
- ECT Sensor Test
  155
- Engine Coolant Temperature (ECT) Sensor
  155
- ECT Sensor Removal
  156
- ECT Sensor Installation
  157
- EGT Sensor Test
  157
- Exhaust Gas Temperature (EGT) Sensor
  157
- EGT Sensor Removal
  159
- EGT Sensor Installation
  160
- Intake Air Temperature (IAT) Sensor
  160
- IAT Sensor Test
  161
- IAT Sensor Removal
  162
- IAT Sensor Installation
  163
- Manifold Absolute Pressure (MAP) Sensor
  164
- MAP Sensor Test
  164
- MAP Sensor Installation
  165
- MAP Sensor Removal
  165
- Oil Level Sensor
  165
- Oil Level Sensor Test
  166
- Oil Level Sensor Installation
  167
- Oil Level Sensor Removal
  167
- Oil Pressure Sensor
  168
- Oil Pressure Sensor Test
  168
- Oil Pressure Sensor Removal
  169
- Oil Pressure Sensor Installation
  170
- Oil Temperature Sensor
  170
- Oil Temperature Sensor Test
  170
- Oil Temperature Sensor Installation
  171
- Oil Temperature Sensor Removal
  171
- O2 Sensor Test
  172
- Oxygen (O2) Sensor
  172
- O2 Sensor Removal
  173
- O2 Sensor Installation
  174
- Pitot Pressure Sensor
  174
- Pitot Pressure Sensor Test
  174
- Pitot Pressure Sensor Removal
  175
- Pitot Pressure Sensor Installation
  176
- Shift Demand Sensor
  176
- Shift Demand Sensor Testing
  176
- Shift Demand Sensor Removal
  177
- Shift Demand Sensor Installation
  178
- Throttle Demand Sensor
  178
- Throttle Demand Sensor Testing
  179
- Throttle Demand Sensor Removal
  180
- Throttle Demand Sensor Installation
  181
- Trim Position Sensor
  181
- Water-In-Fuel (WIF) Sensor
  181
- WIF Sensor Test
  182
- WIF Sensor Removal and Installation
  183
Sensors, Actuators, Relays, and Accessories

185
- Electronic Throttle Control (ETC)
  186
- Overview
  186
- Troubleshooting the ETC
  186
- Fuel Pump Relay
  188
- Main Power Relay (MPR)
  189
- Start Relay
  190
- Shift Actuator
  192
- Shift Actuator Harness Connector Pin out
  192
- Shift Actuator Troubleshooting
  193
- Shift Control
  193
Sensors, Actuators, Relays, and Accessories

197
- Advanced Sound Control
  198
- Troubleshooting
  198
- Moving Propeller (MP) Alert
  200
- Power Steering
  200
- Troubleshooting an Inoperable Power Steering Pump
  201
- Analog Gauges (DTS Only)
  203
- Boat Harness
  204
- Battery Isolator Troubleshooting
  205
- Diagnostics (RS48)
  205
Electrical Systems

207
- Ignition Specifications - V6 Models
  208
- Ignition Specifications - V8 Models
  208
- Ignition Coil Test - CDS G3
  209
- Ignition Coil Tests - Digital Multimeter
  209
- Ignition Coils
  209
- Ignition Coil Wiring Diagram - V6
  210
- Wire Color Code Abbreviations
  211
- Ignition Coil Wiring Diagram - V8
  212
- Ignition Coil Resistance Test
  213
- Spark Plug Wires
  213
- Spark Plug Wire Resistance - V6 Models
  214
- Spark Plug Wire Resistance - V8 Models
  214
Electrical Systems

215
- Battery
  216
- Battery Cable Test
  216
- Battery Specifications
  216
- Charging and Starting Specifications
  216
- Battery Precautions
  217
- Charging a Discharged Battery
  217
- Replacement Parts
  217
- Fuses
  218
- Alternator Description
  219
- Charging System
  219
- Charging System Components
  219
- Alternator
  220
- Charging System Inspection
  220
- Charging System Circuitry Tests
  221
- Starting System
  224
- Starting System Components and Connections - DTS
  224
- Starting System Components and Connections - Mechanical
  225
- Starting System Electrical Checks
  226
- Key Switch Test (Four Position)
  227
- Key Switch Test (Three Position)
  228
Electrical Systems

229
- Condition/Problem
  230
- Electrical System Troubleshooting
  230
- General Checks
  230
- Power Trim Electrical Circuit
  230
- Problem/Solution
  230
- Troubleshooting the down Circuit
  235
- Troubleshooting the up Circuit
  236
- Trim Circuit
  237
- Troubleshooting the down and up Circuits (All Circuits Inoperative)
  237
- Trim up Circuit
  238
- Power Trim Relay Test
  239
- Trim down Circuit
  239
- Trim Position Sensor
  240
- Trim Position Sensor Troubleshooting
  240
- Troubleshooting the Trim Position Circuit
  240
- Testing the Trim Position Sensor Circuit with DMT 2004A
  242
- Trim Position Sensor Location
  242
- Trim Switches and Sensor - DTS
  243
- Trim Switches and Sensor - Mechanical
  244
Electrical Systems

245
- Condition/Problem
  246
- Electrical System Troubleshooting
  246
- General Checks
  246
- Power Trim Electrical Circuit
  246
- Problem/Solution
  246
- Troubleshooting the down Circuit
  249
- Troubleshooting the up Circuit
  250
- Trim Circuit
  251
- Troubleshooting the down and up Circuits (All Circuits Inoperative)
  251
- Trim up Circuit
  252
- Power Trim Relay Test
  253
- Trim down Circuit
  253
- Trim Position Sensor
  254
- Trim Position Sensor Troubleshooting
  254
- Troubleshooting the Trim Position Circuit
  254
- Testing the Trim Position Sensor with DMT 2004A
  256
- Trim Position Sensor Location
  256
Fuel System

259
- Fuel Injector
  260
- Fuel System
  260
- Fuel System Overview
  260
- Fuel System Specifications
  260
- Theory of Operation
  260
- In-Line Fuel Filter
  261
- V6 Fuel Flow Diagram
  262
- V8 Fuel Flow Diagram
  264
- Fuel Supply Module (FSM)
  265
- Fuel Supply Module (FSM) Description
  265
- Fuel Lift Pump
  266
- Fuel Pressure Regulator
  266
- High-Pressure Fuel Pump
  267
Fuel System

269
- Antisiphon Valves
  270
- Fuel Component Troubleshooting and Diagnostics
  270
- Fuel Lift Pump
  270
- Fuel Supply Module (FSM)
  270
- High-Pressure Fuel Pump
  271
- Fuel Injector Resistance Test
  272
- Fuel Pressure Calculations, Engine Running
  272
- Wire Color Code Abbreviations
  273
- 14-Pin Data Harness - DTS
  280
- Wire Color Code Abbreviations
  281
- 14-Pin Data Harness - Mechanical
  282
- CAN Circuits - DTS
  284
- CAN Circuits - Mechanical
  286
- Clean Power
  286
- 4.6L V8 DTS Wiring Diagram
  292
- 4.6L V8 Non-DTS Wiring Diagram
  295
- 3.4L V6 DTS Wiring Diagram
  296
- 3.4L V6 Non-DTS Wiring Diagram
  299

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