Mercury MerCruiser #33 PCM 555 Diagnostic Service Manual + Wiring Diagrams [, ENG, 10.6 MB]

Page i Notice to Users of This Manual Throughout this publication, dangers, warnings, cautions, and notices (accompanied by the International HAZARD Symbol ! ) are used to alert the mechanic to special instructions concerning a particular service or operation that may be hazardous if performed incorrectly or carelessly. These safety alerts follow ANSI standard Z535.6‑2006 for product safety information in product manuals, instructions, and other collateral materials. Observe them carefully! These safety alerts alone cannot eliminate the hazards that they signal. Strict compliance to these special instructions when performing the service, plus common sense operation, are major accident prevention measures. ! DANGER Indicates a hazardous situation which, if not avoided, will result in death or serious injury. ! WARNING Indicates a hazardous situation which, if not avoided, could result in death or serious injury. ! CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE Indicates a situation which, if not avoided, could result in engine or major component failure. IMPORTANT: Identifies information essential to the successful completion of the task. NOTE: Indicates information that helps in the understanding of a particular step or action. This manual has been written and published by the Service Department of Mercury Marine to aid our dealers’ mechanics and company service personnel when servicing the products described herein. We reserve the right to make changes to this manual without prior notification. © 2007, Mercury Marine Mercury, Mercury Marine, MerCruiser, Mercury MerCruiser, Mercury Racing, Mercury Precision Parts, Mercury Propellers, Mariner, Quicksilver, #1 On The Water, Alpha, Bravo, Pro Max, OptiMax, Sport‑Jet, K‑Planes, MerCathode, RideGuide, SmartCraft, Zero Effort, M with Waves logo, Mercury with Waves logo, and SmartCraft logo are all registered trademarks of Brunswick Corporation. Mercury Product Protection logo is a registered service mark of Brunswick Corporation. It is assumed that these personnel are familiar with marine product servicing procedures. Furthermore, it is assumed that they have been trained in the recommended service procedures of Mercury Marine Power Products, including the use of mechanics’ common hand tools and the special Mercury Marine or recommended tools from other suppliers. We could not possibly know of and advise the marine trade of all conceivable procedures and of the possible hazards and/or results of each method. Therefore, anyone who uses a service procedure and/or tool, which is not recommended by the manufacturer, first must completely satisfy himself that neither his nor the products safety will be endangered.

Page ii All information, illustrations, and specifications contained in this manual are based on the latest product information available at the time of publication. As required, revisions to this manual will be sent to all dealers contracted by us to sell and/or service these products. Refer to dealer service bulletins, operation maintenance and warranty manuals, and installation manuals for other pertinent information concerning the products described in this manual. Precautions It should be kept in mind, while working on the product, that the electrical and ignition systems are capable of violent and damaging short circuits or severe electrical shocks. When performing any work where electrical terminals could possibly be grounded or touched by the mechanic, the battery cables should be disconnected at the battery. Any time the intake or exhaust openings are exposed during service they should be covered to protect against accidental entrance of foreign material into the cylinders which could cause extensive internal damage when the engine is started. During any maintenance procedure, replacement fasteners must have the same measurements and strength as those removed. Numbers on the heads of the metric bolts and on the surfaces of metric nuts indicate their strength. American bolts use radial lines for this purpose, while most American nuts do not have strength markings. Mismatched or incorrect fasteners can result in damage or malfunction, or possibly personal injury. Therefore, fasteners removed should be saved for reuse in the same locations whenever possible. Where the fasteners are not satisfactory for reuse, care should be taken to select a replacement that matches the original. Replacement Parts Use of parts other than the recommended service replacement parts will void the warranty on those parts that are damaged as a result. ! WARNING Avoid fire or explosion hazard. Electrical, ignition, and fuel system components on Mercury Marine products comply with U.S. Coast Guard rules to minimize risk of fire or explosion. Do not use replacement electrical or fuel system components that do not comply with these rules. When servicing the electrical and fuel systems, properly install and tighten all components. Cleanliness and Care of Product A Mercury Marine Power Product is a combination of many machined, honed, polished, and lapped surfaces with tolerances measured in the ten thousands of an inch/mm. When any product component is serviced, care and cleanliness are important. It should be understood that proper cleaning and protection of machined surfaces and friction areas is a part of the repair procedure. This is considered standard shop practice even if not specifically stated. Whenever components are removed for service, they should be retained in order. At the time of installation, they should be installed in the same locations and with the same mating surfaces as when removed. Personnel should not work on or under an engine that is suspended. Engines should be attached to work stands, or lowered to ground as soon as possible.

Page iii Manual Outline 1 - General Information A - General Information 2 - Troubleshooting A - Troubleshooting 3 - Diagrams A - Diagrams—Mechanical B - Diagrams—Integrated C - Diagrams—14 Pin D - Diagrams—DTS 5.0, 5.7, and 6.2 General Information 1 Troubleshooting 2 Diagrams 3

Page iv

General Information 90-863757002 SEPTEMBER 2007 Page 1A-1 1 A General Information Section 1A - General Information Table of Contents How To Use This Guide...................................1A-2 ECM and PCM Abbreviations..........................1A-2 Precautions....................................................1A-10 Service Precautions ...............................1A-11 General Information.......................................1A-12 Electrostatic Discharge Damage............1A-12 Wiring Harness Service..........................1A-12 Wire Repair.............................................1A-13 Wiring Connector Service.......................1A-13 Intermittent Problems..............................1A-14 PCM 555 Ignition System..............................1A-15 PCM 555 Controller................................1A-15 Main Power Relay (MPR).......................1A-15 Fuse........................................................1A-15 Crankshaft Position (CPS) Sensor.........1A-15 Crankshaft Reluctor Wheel.....................1A-16 Camshaft Position (CMP) Sensor...........1A-16 Camshaft Reluctor Wheel.......................1A-16 Ignition Coil Harness...............................1A-16 Ignition Coils ..........................................1A-17 PCM 555 Ignition System Operation......1A-17 PCM 555 Diagnostics....................................1A-17 Abbreviated Procedure:..........................1A-18 Visual and Physical Check:....................1A-19 Clearing Codes:......................................1A-21 DTS Faults..............................................1A-21 Propulsion Control Module (PCM) and Sensors .......................................................................1A-22 General Description................................1A-22 Computers and Voltage Signals.............1A-22 Analog Signals........................................1A-22 Digital Signals.........................................1A-24 Propulsion Control Module (PCM)..........1A-25 Engine Guardian System...............................1A-25 General Description................................1A-25 Audio Warning System..................................1A-25 All Serial Numbers 0M000000 and Above ................................................................1A-26 All Serial Numbers 0M000000 and Above ................................................................1A-26 All Digital Throttle and Shift (DTS) Sterndrive and Inboard Engines...............................1A-27 Setting the Trim Limit on 496 Mechanical Engines (with 3‑wire SmartCraft sender).....................1A-27 Setting Trailer and Trim Position on MerCruiser DTS Engines..........................................................1A-29 General Reference Charts.............................1A-43 Manifold Vacuum and Pressure..............1A-43 Vacuum Gauge versus MAP Sensor......1A-44 Centigrade to Fahrenheit Conversion.....1A-45

General Information Page 1A-2 90-863757002 SEPTEMBER 2007 How To Use This Guide This diagnostic guide is separated into three sections: General Information, Troubleshooting, and Wiring Diagrams. General Information covers: • General wiring information • Engine Guardian description • Warning chart Troubleshooting covers: • Basic scan tool information • Symptom trouble chart • Fault chart • CDS Wiring diagrams covers: • Engine electrical harness • Circuit diagrams • 14‑pin harness Troubleshooting covers possible electrical and mechanical causes for engine faults on the scan tool. In wiring diagrams, the single circuit diagrams cover each sensor and subset of the electrical system of the engine. These two sections help the technician pinpoint problems occurring in the electrical system. ECM and PCM Abbreviations NOTE: Throughout this manual the Computer Diagnostic System is often abbreviated as CDS. Abbreviation Description 5 VDC PWR LO 5‑volt ECM internal power supply low 5 VDC PWR 2 LO 5‑volt ECM power supply low to SmartCraft Sensors (Not available on all models) ACT Air compressor temperature (F or C) sensor ACT INPUT HI Air compressor temperature sensor input is high ACT INPUT LO Air compressor temperature sensor input is low ACT TMP Sec Time spent in air compressor overheat ACTIVE Active fault state of sensors, switches, injectors, etc. AT Intake manifold air temperature (F or C) sensor AT I NPUT HI Air temperature (engine) sensor input is high AT INPUT LO Air temperature (engine) sensor input is low AIR COM TMP Air compressor temperature sensor (F or C) AIRFLOW HI Incoming airflow to engine is higher than expected AIR TEMP CKTHI Air temperature (engine) sensor circuit is high AIR TEMP CKT LO Air temperature (engine) sensor circuit is low AIR TMP Intake manifold air temperature (F or C) sensor AVAILABLE PWR % A normally functioning system will allow engine to make 100% power. B+ Battery positive BARO Barometric pressure

General Information 90-863757002 SEPTEMBER 2007 Page 1A-3 Abbreviation Description BARO PSI Barometric pressure (psi or kPa) BAT Battery positive terminal, battery or system voltage BATT VOLT HIGH Battery voltage is above the allowable limit BATT VOLT LOW Battery voltage is below the allowable limit BLK PSI MIN Block pressure minimum specification BLK TEMP CKT HI Engine block temperature sensor circuit is high BLK TEMP CKT LO Engine block temperature sensor circuit is low BLOCK PRESS LOW Engine block pressure below acceptable limit BLOCK PSI Inlet water pressure to block (PSI or kPa) BLOCK PSI Sec time spent with low water pressure to block BLOCK PSI Inlet water pressure (PSI or kPa) BLOCK OVRHEAT Engine block is overheating BPSI INPUT HI Block pressure sensor input is high BPSI INPUT LO Block pressure sensor input is low BREAK‑IN Engine break‑in routine BREAKIN ACTIVE Engine break‑in routine is active BREAK‑IN LEFT Time remaining in engine break‑in routine BREAKIN STR Break‑in strategy BUFFER An area used to temporarily store data BUS +12 CAN Bus 12‑volt supply for SmartCraft CALIB ID Calibration ID of ECM CAN Controller area network CAN ERR1 CAN wiring problem. Check ALL pins and terminators CAN ERR2 CAN wiring problem. Check ALL pins and terminators CAN ERR3 CAN wiring problem. Check ALL pins and terminators CAN ERR4 CAN wiring problem. Check ALL pins and terminators CAN ERR5 CAN wiring problem. Check ALL pins and terminators CAN ERR6 CAN wiring problem. Check ALL pins and terminators CAN ERR7 CAN wiring problem. Check ALL pins and terminators CAN ERR8 CAN wiring problem. Check ALL pins and terminators CAN ERR9 CAN wiring problem. Check ALL pins and terminators CAN ERR10 CAN wiring problem. Check ALL pins and terminators CHI Customer helm interface (SC5000) CKT Circuit CODE Calibration ID of ECM COOL TMP PRT Coolant temp port (F or C) sensor COOL TMP STB Coolant temp starboard (F or C) sensor COMP Air compressor temperature sensor COMP OVERHEAT Air compressor temperature is above the allowable limit COMP TEMP CKT HI Air compressor temperature sensor circuit is high COMP TEMP CKT LO Air compressor temperature sensor circuit is low COMP TMP Air compressor temperature (F or C) COMPRESS OVRHT Air compressor temperature is above the allowable limit

General Information Page 1A-4 90-863757002 SEPTEMBER 2007 Abbreviation Description CONN Connector CTP INPUT HI Coolant temperature port sensor input is high CTP INPUT LO Coolant temperature port sensor input is low CTP TMP Sec time spent in overheat on the port bank CTS INPUT HI Coolant temperature starboard sensor input is high CTS INPUT LO Coolant temperature starboard sensor input is low CTS TMP Sec time spent in overheat on the starboard bank CYL Cylinder DDT Digital diagnostic terminal DEC Refers to a decreasing potentiometer reading in the electronic remote control. A decreasing potentiometer reads from high to low volts through its total travel range. DEG Degrees DEMAND % TPI% or TPS% ; On DTS models, this is ERC demand % DEMAND DIFF Faulty potentiometers in ERC DIAG Diagnostic DINJ1 ‑‑ DINJ6 OPEN Direct injector 1‑6 circuit is open DINJ1 ‑‑ DINJ6 SHORT Direct injector 1‑6 circuit is short DIST Distributor DLC Data link connector DRIVE LUBE LO Low drive lube reservoir DRIVER POWER LO Insufficient battery voltage or wiring problem DTC Diagnostic trouble code DTS Digital throttle and shift DUAL CAN ERR Wiring problem between CAN 1 and CAN 2 DVOM Digital volt ohm meter ECM 555 Electronic control module with a power PC 555 microcomputer ECM ID ECM Hardware revision level ECM MEMORY ERR ECM memory has been corrupted ECM_TRIG1‑8 OPEN ECM spark trigger signal circuit 1‑8 is open ECM_TRIG1‑8 SHORT ECM spark trigger signal circuit 1‑8 is short ECT Engine coolant temperature (F or C) sensor EEPROM Electronic erasable programmable read only memory EMI Electromagnetic interference ENG Engine ENGINE ID Engine identification ENGINE RPM Revolutions per minute of engine ERC Electronic remote control handle at the helm ESC Electronic shift control (actuator) ESC CONTROL LOST ESC cannot maintain in‑gear position ESC ‑ NS POS DIFF ESC determination of its position and neutral switch position don’t agree ESC ‑ ERC POS DIFF ESC position (actuator's determination of its position) and commanded position do not agree. ESC TIMEOUT ESC actuator has not physically moved with respect to the ERC lever (demand) position.

General Information 90-863757002 SEPTEMBER 2007 Page 1A-5 Abbreviation Description EST Electronic spark timing EST 1‑8 Electronic spark trigger signal to the ignition coil driver circuit EST 1‑8 OPEN Electronic spark trigger signal circuit 1‑8 is open EST 1‑8 SHORT Electronic spark trigger signal circuit 1‑8 is short ETC CONTROL Loss of electronic throttle control circuit ETC STICKING Electronic throttle control sticking or binding ETC IDLE RANGE ETC Is outside of its expected idle range ETC MOTOR OPEN Electronic throttle control motor is open (Not available on all models) ETC MOTOR SHORT Electronic throttle control motor is shorted (Not available on all models) FINJ 1 ‑ FINJ 8 OPEN Fuel injector circuit 1‑8 is open FINJ 1 ‑ FINJ 8 SHORT Fuel injector circuit 1‑8 is shorted FPC TOTAL Fuel per cycle per cylinder. Total fuel amount currently being used by engine. FREEZE FRAME A snapshot of captured engine data stored in ECM history FUEL LEVEL Boat tank fuel sender data FUEL LVL CKT HI Fuel level sensor circuit high (same as FUEL LVL IN HI) FUEL LVL CKT LO Fuel level sensor circuit low (same as FUEL LVL IN LO) FUEL LVL CKT2 HI Fuel level sensor circuit #2 high (same as FUEL LVL IN HI) FUEL LVL CKT2 LO Fuel level sensor circuit #2 low (same as FUEL LVL IN LO) FUEL LVL IN HI Fuel level sensor input is high FUEL LVL IN LO Fuel level sensor input is low FUEL PRES CKT LO Fuel pressure sensor circuit is low (not available on all models) FUEL PRES CKT HI Fuel pressure sensor circuit is high (not available on all models) FUEL PSI CKT HI Fuel pressure sensor circuit (same as Fuel Pres Input Hi) FUEL PSI CKT LO Fuel pressure sensor circuit low (same as Fuel Pres Input Lo) FUEL PUMP CKT Fuel pump circuit or relay fault FUEL PUMP RLY Fuel pump relay GEAR POS DIFF ESC Position sensor doesn’t agree with the shift switch GND Ground GUARDIAN Engine Guardian strategy is active GRD LIMIT Sec time spent in engine guardian H20 IN FUEL Water‑in‑fuel filter H2O PRES CKT HI Engine water pressure sensor circuit is high H2O PRES CKT LO Engine water pressure sensor circuit is low HALL SENSOR Hall effect (encoder/crank position) sensor HALL SNSR STR Hall effect (encoder/crank position) sensor strategy is active HEAD OVRHT Cylinder head is overheating HEAD TEMP CKT HI Cylinder head temperature sensor circuit is high HEAD TEMP CKT LO Cylinder head temperature sensor circuit is low HEI High energy ignition HELM ADC CHECK Command module reliability check or CAN bus problem HIRES Indicates a high‑resolution potentiometer which has voltage readings that move from high to low to high through its entire range. HORN Horn driver (internal to ECM for non DTS models)

Mercury MerCruiser #33 PCM 555 Diagnostic Service Manual + Wiring Diagrams [, ENG, 10.6 MB]

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