Mercury Marine MerCruiser Service Manual #33 ECM 555 Diagnostics

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This Workshop Service Repair manual PDF download for the ECM 555 Diagnostics Mercury Marine MerCruiser has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

ECM 555 Diagnostics


TABLE OF CONTENTS :

1 - General Information
2 - Troubleshooting
3 - Diagrams


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 90-863757002
Total Pages : 271


All Official Mercury Marine Manuals for MerCruiser Sterndrives and Inboards include easy to follow, step-by-step illustrated procedures based on the complete dismantling, repair, and assembling of boat motors, from the simplest repair to complex procedures, this manuals give you everything you need to do the job with confidence.

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90-863757002
Notice to Users of This Manual
Precautions
Replacement Parts
Cleanliness and Care of Product
Manual Outline
90-863757002_1A
Section 1A - General Information
Table of Contents
How To Use This Guide
ECM and PCM Abbreviations
Precautions
Service Precautions
General Information
Electrostatic Discharge Damage
Wiring Harness Service
Wire Repair
Wiring Connector Service
Intermittent Problems
PCM 555 Ignition System
PCM 555 Controller
Main Power Relay (MPR)
Fuse
Crankshaft Position (CPS) Sensor
Crankshaft Reluctor Wheel
Camshaft Position (CMP) Sensor
Camshaft Reluctor Wheel
Ignition Coil Harness
Ignition Coils
PCM 555 Ignition System Operation
PCM 555 Diagnostics
Abbreviated Procedure:
Visual and Physical Check:
Clearing Codes:
DTS Faults
Propulsion Control Module (PCM) and Sensors
General Description
Computers and Voltage Signals
Analog Signals
Digital Signals
Propulsion Control Module (PCM)
Engine Guardian System
General Description
Audio Warning System
All Serial Numbers 0M000000 and Above
All Serial Numbers 0M000000 and Above
All Digital Throttle and Shift (DTS) Sterndrive and Inboard Engines
Setting the Trim Limit on 496 Mechanical Engines (with 3-wire SmartCraft sender)
Setting Trailer and Trim Position on MerCruiser DTS Engines
General Reference Charts
Manifold Vacuum and Pressure
Vacuum Gauge versus MAP Sensor
Centigrade to Fahrenheit Conversion
90-863757002_2A
Section 2A - Troubleshooting
Table of Contents
Troubleshooting Without a Diagnostic Tool
Troubleshooting with a Diagnostic Tool—CDS
Troubleshooting with the CDS Tool
DTS System Troubleshooting
CDS Connection to the Engine
CDS Power Up
Testing DTS Engine Components
Troubleshooting Worksheet for PCM
PCM Calibration Label
Data Collection
PCM 555/ECM 555 Scan Tool Worksheet
PCM 555/ECM 555 CDS Worksheet
Preliminary Checks
Symptom Charts
Chart A-1 Engine Cranks Over but Will Not Start
Chart A-2 Main Power Relay Test
Chart A-3 Fuel System Electrical Test
Chart A-4 Fuel System Diagnosis
Chart A-5 Ignition System Test
Chart A-6 Hard Start Symptom
Chart A-7 Engine Surges Symptom
Chart A-8 Lack of Power, Sluggish, or Spongy Symptom
Chart A-9 Detonation or Spark Knock Symptom
Chart A-10 Hesitation, Sag, or Stumble Symptom
Chart A-11 Engine Misses Symptom
Chart A-12 Rough, Unstable, or Incorrect Idle and Stalling Symptom
Chart A-13 Poor Fuel Economy Symptom
Chart A-14 Dieseling or Run-On Symptom
Chart A-15 Backfire Symptom
Fuel Pressure Gauge Setup for PCM Engines
Installation
Test
Removal
Injector Balance Test
Test Procedure
Troubleshooting With a Vacuum Gauge
Vacuum Gauge Troubleshooting Guide
Engine Fault Quick Reference Chart
MerCruiser PCM Fault List
MerCruiser ECM/PCM Fault List
ECM/PCM Fault List Information
Fault Conditions
Sticky and Non-Sticky Faults
Default Sensor Values
MerCruiser ECM/PCM Fault List Table Columns
Fault #
CDS Fault Message
DDT Fault Status Message
Icon/Horn/Guardian Column
♠- System View Icon
♥- Warning Horn Signals
♦- Engine Guardian
Fault Explanation
Possible Root Cause
MerCruiser ECM/PCM Fault List Table
PCM Frequently Asked Questions
What is a circuit (CKT) high or low fault?
What is a STR (Strategy)?
What is a TPI/TPS High or Low Range fault?
Why do we use the loaded volts lead on some pinpoint tests?
How can I switch between the data screens and the service manual?
Why do some faults take longer to set than others?
What is an (MPR) Main Power Relay Output Fault?
What’s wrong when I see a PWR1 or 5VDC Power Low fault?
Why does an EST or ECM Trigger Open not register as a fault when the engine is running?
What are MAP Diff or TPI Diff errors?
What is a MAP Idle Check or MAP Idle Err?
What do Overspeed Fault and Engine Guardian Fault indicate?
What is a MPRLY REQ (Main Power Relay Request) in the Freeze Frame buffer?
Why is the engine slowing down and how do I know if Engine Guardian is active?
I see the following faults: OIL LVL IN(ckt) HI, FUEL LVL IN(ckt) HI or SEA TEMP IN(ckt) HI. Is there a problem and how can I eliminate these faults?
What is a good tool to use to diagnose boat wiring problems?
Why can I not get the active data screen to list any values?
What should I do if the CDS system locks up?
Why do I have to connect the ohm meter leads together at the start of the pinpoint tests?
Why do the pinpoint tests ask me if I have started the engine?
Why am I not able to get past the Ohmmeter verification screen during the pinpoint tests?
Why am I not able to get the VOM meter to communicate with the CDS system?
I have multiple engines on the boat, but do not have the ability to view data from all the engines from a single connection with the CDS system. Why?
How does the cylinder-misfire test work?
Why do I need to run the cylinder misfire test at a higher RPM or under load?
Why do I need to disconnect power to both fuel pumps?
How do I perform a fuel injector test on a MerCruiser PCM 555 system?
How do I test a MerCruiser ECM 555 system with one ignition coil?
How do I configure a digital throttle and shift helm station?
How do I calibrate the cursor/screen on my Panasonic touch-screen PC's?
What does IAT and MAT stand for?
What does DTS stand for?
Why is my laptop battery charge low after long-term storage?
Why am I having trouble zeroing the ohms reading on my multimeter?
Why does the DMT 2004 voltmeter report high readings for the 5-volt reference signal?
What is the difference between a sticky and non-sticky fault?
What is Engine Guardian?
What does Fault Seconds information tell me?
How do I tell the difference between 2004, 2005, and 2006 and newer DTS systems?
What does the Unit of Measurement Counts stand for?
How do I detect a COM port setting for my multimeter?
What is a trim delta test?
What is shadow mode?
Why don’t my Freeze Frame buffers and FPC (Fuel per Cylinder) data items display correctly?
Why do MerCruiser engines with Hurth Electronically controlled transmissions have fewer active tests?
What is AutoSync?
DTS Command Module Faults
90-863757002_3A
Section 3A - Diagrams—Mechanical
Table of Contents
Sensor Locations on the 8.1 Liter (496 CID) Engine
Engine Harness
Wiring Color Legend
Wire Splice Description—Mechanical
PCM 555 Pin-out—Mechanical
Wiring Diagrams
Wire Harness Connector Socket Identification
5-Volt Sensor Circuit—Mechanical
Coil Harness Circuit
Fuel Injector Circuit (Engine Harness)
Fuel Injector Circuit (Injector Harness)
Ground Circuit
Ignition Circuit
Positive Current Flow
Start Circuit with Start Solenoid Relay
Typical Starting System Components—10-Pin Engine Harness
Single Circuit Diagrams
Control Area Network (CAN) Circuit
Crank Position Sensor (CPS) and Camshaft Position Sensor (CMP) Circuits
Diagnostics Circuit
Engine Coolant Temperature Sensor (ECT) Circuit
Exhaust Manifold Coolant Temperature Sensor (EMCT) Circuit
Fuel Level Sensor Circuit—Harness 84-865457A02
Fuel Pump Relay Circuit
Fuse Circuit
Gear Lube Monitor or Transmission Overtemp Circuit
Idle Air Control Valve (IAC) Circuit—Mechanical
Main Power Relay (MPR) Circuit—Serial Number OW000000 and Below
Manifold Absolute Pressure Sensor (MAP) Circuit
Manifold Air Temperature Sensor (MAT) Circuit
Odd and Even Knock Sensor Circuits
Oil Pressure Sensor Circuit
Paddle Wheel and Seawater Temperature Circuit
Throttle Position Sensor (TPS) Circuit—Harness 84-863084A1 and 84-862536A1
Transom Circuit (Transom Harness)—Sterndrive Mechanical
Trim Up Relay Circuit
Seawater Pump Circuit
Smart Transom Circuit (Engine Harness)
90-863757002_3B
Section 3B - Diagrams—Integrated
Table of Contents
Engine Harness
Wiring Color Legend
Wire Splice Description—Integrated
PCM 555 Pin-out—Integrated, Non-DTS
Wiring Diagrams
Typical Starting System Components
Positive Current Flow
5 Volt Sensor Circuit—Integrated
Coil Harness Circuit—496/8.1
Fuel Injector Circuit (Engine Harness)—Harness 84-865457A02 and 84-865457A05
Fuel Injector Circuit (Injector Harness)
Ignition Circuit
Start Circuit with Start Solenoid Relay
Start Relay Circuit—Mechanical
Single Circuit Diagrams
10 Pin Harness Circuit—84-865457A01 and 84-865457A02
10 Pin Harness Circuit—84-865457A05
14 Pin Harness Circuit—84-865457A05
Control Area Network (CAN) Circuit—Harness 84-865457A02
Control Area Network (CAN) Circuit—Harness 84-865457A05
Crank Position and Camshaft Position Circuits
Diagnostics Circuit
Engine Coolant Temperature Sensor (ECT) Circuit
Exhaust Manifold Coolant Temperature Sensor (EMCT) Circuits
Fuel Level Sensor Circuit—Harness 84-865457A02
Fuel Level Sensor Circuit—Harness 84-865457A05 and 84-865457A06
Fuel Pump Relay Circuit
Fuse Circuit—Harness 84-865457A02
Gear Lube Monitor and Transmission Over-Temperature Circuit
Gear Position Switch
Idle Air Control Valve (IAC) Circuit—Integrated
Main Power Relay Circuit—Serial Numbers OW000000 and Above
Manifold Absolute Pressure Sensor (MAP) Circuit
Manifold Air Temperature Sensor (MAT) Circuit
Odd And Even Knock Sensor Circuits
Oil Pressure Sensor Circuit
Seawater Pump Circuit
Smart Transom Circuit (Engine Harness)—Harness 84-865457A02
Smart Transom Circuit (Engine Harness)—Harness 84-865457A05
Throttle Position Sensor (TPS) Circuit
Transom Circuit (Transom Harness)
Trim Up Relay Circuit—84-865457A02
Trim Up Relay Circuit—84-865457A05
90-863757002_3C
Section 3C - Diagrams—14 Pin
Table of Contents
Sensor Locations—14 Pin
Engine Harness
Wiring Color Legend
Wire Splice Description—14 Pin
PCM 555 Pin-out—14 Pin, 496/8.1
Wiring Diagrams
5 Volt Sensor Circuit—PCM Power 1
Coil Harness Circuit—496/8.1
Fuel Injector Harness—496/8.1
Fuel Injector Circuit (Engine Harness)
Power 2 Circuit
Start Relay Circuit—Mechanical
Single Circuit Diagrams
14 Pin Harness Circuit—84-865457A06
Main Power Relay Circuit—Serial Numbers OW000000 and Above
Control Area Network (CAN) Circuit—Mechanical
Crank Position Sensor (CPS) and Camshaft Position Sensor (CMP) Circuits—Mechanical 496/8.1
Diagnostics Circuit
Electronic Shift Control (ESC) Circuit—Sterndrive DTS
Electronic Throttle Control (ETC)—Sterndrive and Inboard DTS
Engine Coolant Temperature Sensor (ECT) Circuit
Exhaust Manifold Coolant Temperature (EMCT) Sensor Circuits–496/8.1
Fuel Level Sensor Circuit—Harness 84-865457A05 and 84-865457A06
Fuel Level Sensor Circuit—Harness 84-865458A01
Fuel Level Sensor Circuit—Harnesses 84-865653A03 and 84-865653A04
Fuel Pump Relay Circuit
Fuse Circuit—DTS
Fuse Circuit—Mechanical
Gear Lube Monitor or Transmission Overtemp Circuit
Gear Position Switch
Idle Air Control Valve (IAC) Circuit—14 Pin
Manifold Absolute Pressure Sensor (MAP) Circuit—496/8.1
Manifold Air Temperature Sensor (MAT) Circuit—496/8.1
Odd and Even Knock Sensor Circuits—Harness 84-865458A01 and 84-865653A03
Odd and Even Knock Sensor Circuits—Harness 84-865457A06 and 84-865653A04
Oil Pressure Sensor Circuit
Seawater Pump Circuit
Smart Transom Circuit—DTS Sterndrive
Smart Transom Circuit—DTS Inboard
Smart Transom Circuit (Engine Harness)—Mechanical
Start Relay Circuit—DTS
Throttle Position Sensor (TPS) Circuit
Transom Circuit (Engine Harness)—84-865457A06
Transom Circuit (Transom Harness)—8.1, Inboard Mechanical
Transom Circuit (Transom Harness)—Inboard DTS
Transom Circuit (Transom Harness)—Sterndrive DTS
Transom Circuit (Transom Harness)—Sterndrive Mechanical
Trim Relay Circuit—DTS
Trim Up Relay Circuit—Mechanical
90-863757002_3D
Section 3D - Diagrams—DTS 5.0, 5.7, and 6.2
Table of Contents
Sensor Locations—DTS
Engine Harness
Wiring Color Legend
Wire Splice Description—DTS 5.0, 5.7, and 6.2
PCM 555 Pinout-DTS
Wiring Diagrams
Coil Harness Circuit—5.0, 5.7, 6.2
Fuel Injector Circuit (Engine Harness)—5.0, 5.7 and 6.2
Fuel Injector Circuit (Injector Harness)—5.0, 5.7, 6.2
Single Circuit Diagrams
Control Area Network (CAN) Circuit—DTS
Crank Position Sensor (CPS) and Camshaft Position Sensor (CMP) Circuits—Mechanical 5.0, 5.7, and 6.2
Electronic Shift Control (ESC) Circuit—Inboard
Electronic Throttle Control (ETC)—Sterndrive and Inboard DTS
Fuse Circuit—DTS
Smart Transom Circuit—DTS Inboard
Smart Transom Circuit—DTS Sterndrive
Start Relay Circuit—DTS
Temperature and Manifold Absolute Pressure Sensor (TMAP) Circuit—5.0, 5.7, and 6.2
Transom Circuit (Transom Harness)—Inboard DTS
Transom Circuit (Transom Harness)—Sterndrive DTS
Trim Relay Circuit—DTS

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