operating manual

engine diagnostics

=

operating manual

® STATS MANUAL - V2.5 MARCH 2014

one

system

=

multiple operations

multiple

engine coverage

MERCURY/MERCRUISER ®

YAMAHA ®

SUZUKI ®

HONDA ®

VOLVO ®

YANMAR ® DIESEL

KAWASAKI ®

BRP ® (JOHNSON/EVINRUDE)

BRP ® (SE ADOO/JETLEV)

MEFI ® 1, 2, 3, 4, 5 & 6

HYDROSPACE/BENELLI/WEBER

(any combination or single engine systems) multiple

diagnostics

DIAGNOSES:

Ø IGNITION SYSTEM

Ø ELECTRONICS

Ø FUEL SYSTEM

ECM HISTORY

READ/CLEAR CODES

TOUCH CONSOLE USER INTERFACE multiple

benefits

LESS DOWNTIME

✓

MAXIMIZE PERFORMANCE

✓

INCREASE PROFIT

PLUG AND PLAY

✓

✓

INTUITIVE

✓

BACK TO CONTENTS contents

1. Operating Manual

A1 Warranty

A2

B1

Precautions

Introduction

B2

B3

B4

B5

General Operation

Functionality

Software Updates

Save/Print Data

C Specification

D iQ (Info Quest)

2. Yamaha

3. Mercury/Mercruiser

4. MEFI

5. Kawasaki

6. BRP (Johnson/Evinrude)

7. BRP – SeaDoo/Jetlev

8. Suzuki

9. Honda

10. Volvo

11. Yanmar Diesel

12. Hydrospace/Benelli/Weber

VERSION: 2.5 MARCH 2014

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A1

OPERATING MANUAL

Unlocking Technology

STATS (Sierra Touch And Test System)

Software Warranty Terms and Conditions

Due to any possible anomalies in software programming beyond SeaStar Solutions (Sierra) or any of its suppliers, SeaStar Solutions (Sierra) will not be held liable. Customer assumes any and all damages, including, but not limited to, lost revenue, time, profit or incidental and consequential damages resulting from any possible anomalies in the software. Sierra does not and cannot warrant that the software is free of errors or that the operator will be able to use the system without issues or interruption. Sierra endeavors to provide the most accurate software available; however, in the event software anomalies are found, Sierra will actively pursue said anomalies for correction and advise the customer of the corrective action once any software anomaly has been remedied. Customer/user of the STATS software is strongly recommended to contact Sierra Technical Support upon finding any software anomaly. However, before contacting Technical Support, insure the correct cables and dongle are being used as well as making sure the STATS software is current. The above exclusion related to software programming will not affect other portions of the “Sierra Warranty”. Please see website www.sierramarine.com for warranty information or back cover on catalog.

Software License Agreement

The Software contained on the STATS equipment is owned by Sierra International/Advanced

Diagnostics.

The customer has no title of ownership of the software, other than the ownership of the physical media that the software is intended to work on.

The Copyright of software is owned by Sierra International/Advanced Diagnostics and any customer responsible for software infringement or violation of this agreement will be held responsible for infringement of the copyright laws.

Sierra International/Advanced Diagnostics retains the right to erase software from any tester/customer that has been found to infringe these laws.


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OPERATING MANUAL

A Precautions

1. The hand held diagnostic tool is an electronic piece of equipment, and although designed for

hostile environments it should not be exposed to excessive sunlight, high temperatures or

immersed in liquids.

2. Return unit to carrying case when not in use.

3. Observe normal health and safety precautions when using this equipment.

4. Keep clear of all moving objects when near engine compartment.

5. When connecting to vehicle connectors, probe from the back.

6. Ignition circuits generate high voltages, extra precautions and care should be observed when

diagnosing these systems.

7. Incorrect connections may damage sensitive electronic devices fitted to the vehicle.

8. Switch off the vehicle ignition when making or breaking connections.

9. Keep the unit away from spark plugs and coil leads to avoid measurement errors.

10. DO NOT disconnect any wiring harnesses or electronic component while ignition is ON.

11. DO NOT disconnect battery while engine is running.

12. Before any work is carried out, consult the vehicle manufacturer’s recommended procedures

and warranty specs to ensure any work is carried out in accordance with their instructions.


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Sierra STATS - INTRODUCTION

Product Description

The Sierra STATS has been developed to offer diagnostics for marine engines and recreational vehicles.

The Sierra STATS can be used as a hand-held portable diagnostic system, and is equipped with 64MB of RAM which is used for the application data, and 512MB of Flash for the protocol handling system. In addition to this it has a USB interface connection for fast downloads.

Designed with simplicity in mind Sierra STATS integrates simple color coded dongles that configures the tester, thus reducing the quantity of cables/adaptors required.

The unit is capable of reading/clearing fault codes, displaying live data, programming safety keys, component actuation, service resetting along with other functions that any particular system may allow.

POWER CONNECTION Powered via the diagnostic socket or through the system wiring through a 25 way D-Type cable system. If no power is available through the vehicle diagnostic socket then the adapter cable will have the vehicle battery connections or adaptor required.

VEHICLE CONNECTION The unit is supplied with a range of cables to cover various manufacturers. The smaller adaptor cables use the ADC300 Master Cable, which connects to the tester. These adaptor cables can then be connected depending on which system is being tested.

LCD BACKLIGHT The LCD BACKLIGHT is automatically switched on when the unit has power. This cannot be switched off or adjusted. If the unit is not used for a period of time the LCD backlight will automatically switch off, and as soon as any key is pressed it will switch back on again.

PASSWORD OPERATED To stop unauthorized access the unit is fitted with a password system. If the password is entered incorrectly three times the tester will be erased. For any problems with password operation or software updates, contact Sierra Tech Support at (800) 648-3976.

--------

SOFTWARE Sierra STATS has the ability to store both a Standard version and Beta version of software. The required software is selected each time the tester is used.


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Sierra STATS - GENERAL OPERATION


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Password Operation

To stop unauthorized access the unit is protected by a unique password, which must be entered each time the tester is switched on.

Additionally this password will also be required for a number of other services such as updating software etc.

WARNING

If the password is entered incorrectly 3 times the unit will

‘lock’ and the Sierra STATS will require unlocking.

If this occurs then please contact Sierra at

1-800-648-3976 (ext. 3)

The process for unlocking will take up to 48 hours dependant on the time zone

ENSURE THE SCREEN IS CALIBRATED

Engine Connections & Dongles

The unit is supplied with a range of cables to connect to various manufacturers diagnostic sockets. The smaller adaptor cables use the ADC300 Master Cable (Fig 7), which connects to the STATS. These adaptor cables can then be connected depending on which system is being tested.

The unit is also supplied with a range of dongles (Fig 6) that configure the tester for the particular system being tested. The tester screen will advise if the incorrect dongle is fitted when the tester attempts to communicate with the vehicle.

NOTE: Refer to the appropriate vehicle manufacturer section or Sierra IQ for which cable and dongle to use.

FIG 5

FIG 6

FIG 7 ADC300 + adaptor cable


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Initial Operation

1. Connect the appropriate dongle and diagnostic cable for the vehicle being connected to.

2. Press & Hold the Power button until the green LED illuminates / the tester emits a beep.

3. The Main Menu selection screen will appear.

SEE IMPORTANT NOTE BELOW

4. If required the contrast can be adjusted using the

‘+ or -’ buttons.

NOTE: The contrast can be adjusted on any screen.

IMPORTANT

If the Sierra STATS is being loaded from a blank state then the screen calibration process must be completed initially. If the unit is blank and any part of the screen is touched the unit will enter the calibration process.


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Main Menu

F1

To select a function either press the

Function buttons (F1 to F5) or touch the appropriate icon.

F3

F5

Battery Voltage

This displays the battery voltage of the engine/vessel it is connected to. Ensure the battery voltage is sufficient before proceeding. Note the voltage is displayed inside the icon and is not a selectable function.

Calibration

This function is selected to calibrate the touch screen.

Once selected a ‘+’ will appear on the screen. The user must touch and hold the center of this cross either with a finger or pointer (not sharp and careful not to damage screen). When the ‘+’ has been selected, another ‘+’ will appear in a different area of the screen, which must be touched & held centrally again.

Repeat this for all the ‘+’ that appear on the screen.

Once complete the screen will indicate that calibration was successful and then revert to the main menu.

10

Engine Selection

This function is selected to proceed to the Engine

Selection menu.


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STATS

Enter the 6 Digit security code using the screen keypad.

The numbers will appear as they are typed. Confirm that the correct security code has been entered by clicking the

‘check’ icon.

WARNING




1-800-648-3976 (ext. 3)



Using the arrows, select the required manufacturer and then press ENTER.

NOTE: For further information and operation refer to the specific application manual.

STATS


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Sierra STATS - FUNCTIONALITY

The functionality of the software will vary depending upon the engine.

Typical functions are as follows :

FAULT CODES

LIVE DATA

ACTUATOR

OPERATION

SPECIAL

FUNCTIONS

READING FAULT CODES

Lists fault codes that are stored on the vehicle.

Some manufacturers offer Freeze Frame data by pressing ENTER on fault code screen.

NOTE : Fault codes can be either current, historic or intermittent.

Possible causes of failure may also be on some manufacturers by pressing the right arrow key.

CLEARING FAULT CODES

Allows fault codes to be cleared.

Allows values of certain components to be displayed in real time (ie battery voltage, throttle pot voltage, injector opening).

Recording Live Data is available on tester to view back to aid in diagnosing intermittent concerns. Use the F5 Function Key to access the Live Data Recording menu.

Allows actuators to be operated via the tester to check they are working e.g. Injectors, Relays,

Ignition Coils.

A variety of functions that are available, dependant upon the system (ie all systems do not have the same options available).

Service data such as Hour info can be found under Special Functions.

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Sierra STATS - FUNCTIONALITY

Sierra STATS - APPLICATIONS ICON DEFINITIONS

APPLICATION LIVE DATA ACTUATOR TESTING

YEAR RANGE

SPECIAL FUNCTIONS

Sp.

Func.

REMOTE PROGRAMMING

FAULT CODES

KEY PROGRAMMING

START

CABLES

DONGLE

OFF

ON RECORD PLAY

SAVE

DECREMENT

LIVE DATA RECORD

BACK

UP DOWN

INCREMENT

FAULT CODE CLEAR


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Sierra STATS - SOFTWARE UPDATE

Introduction

Sierra is constantly improving the existing software and developing new software. To ensure you get all software updates it is recommended that you connect to the Sierra website and download the latest software on a regular basis ie every 2 weeks.

Sierra STATS has the ability to store both a Standard version and Beta version of software. The required software is selected each time the tester is used.

Each time you have downloaded new software, re-calibrate the touch screen.

Downloading Software

The following procedure will guide you through the necessary steps to download the software.

Step 1 - Software Loader a. Visit our website at www.sierrastats.com

b. Select the Software Loader/warranty registration link and download to your computer.

Note: You will need to either download the 32 bit version or 64bit version dependant upon your PC.

c. Follow the on-screen instructions in the dialog boxes that appear.

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Sierra STATS - SOFTWARE UPDATE d. At this stage your PC may display a warning about the installation not being verified. Select allow/continue...


15 e. Once you click finish, the Software Loader will launch automatically (providing the check box is ticked)

®

STATS

BACK TO CONTENTS b4


Updating Your Tester

A. Connect the power cable 18-ADC152 to the STATS.

B. Connect the USB cable 18-ADC153 between PC and STATS.

C. Turn the tester on and leave with the main menu being displayed. No communication from tester will result if this step is not followed. Ensure STATS loader has been installed prior to installing tester to PC USB port.

D. The first time the tester is connected to the PC, the PC will detect new hardware and install the driver. Leave the PC to fully install the driver before proceeding.

Note: ·

It is important that you always have the latest version of download

·

The version number can be found in the title bar of the Sierra

·

The STATS Loader will prompt you to download when a new version is available. Loader will not be usable until latest version is

installed.

E. Open the Sierra STATS Loader program from your desktop by double clicking the icon on your desktop.

F. The Loader program will open.

The Loader program version number will appear in the top right-hand corner of the program.

·

If you don’t have the latest loader program installed on your PC, a

message advising you will appear and then take you through the

process of automatically updating to the latest version.

NOTE: There is no need to uninstall the old loader program first.

·

If you are able to connect to the internet.

If you have a connection problem indicated after this test, you will

need to check your firewall/anti-virus program settings with

someone that understands how to configure the settings.

G. Click ‘GO’ icon (green arrow).


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H. Enter the tester 6 digit passcode

I. The DEVICE INFO screen will be displayed. The other options are listed down the left hand side of the dialog box. The options are:

Device Info - Details information regarding your tester.

It also indicates the version of software you currently have loaded on your tester and the version available on the website for download.

Load Device - Enables you to update your tester.

Software Lookup - Lists the software that ‘YOU HAVE’ and ‘DON’T HAVE’ loaded on your tester

Upload Data - Loads saved data from STATS console to

PC to view/save/or print.


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J. SOFTWARE LOOKUP

Two tabs listing the software that ‘YOU HAVE’ and ‘DON’T

HAVE’ for standard and beta software.

i) Software modules that are not currently equipped on your console are available for purchase in the form of a software upgrade kit. Contact your distributor to purchase.

K. LOAD DEVICE

Enables you to update your tester

Tick the appropriate check boxes (or both) depending on what software you wish to update (ie Standard or Beta) i) When either Standard or Beta is selected it will be downloaded

& previous software versions on the tester are over written.

ii) If the unit has no software loaded, then Standard software must always be loaded onto the tester prior to loading Beta or both at the same time.

iii) Please note that BETA software is the latest software that we are working on and is not fully tested, however it allows customers to use the latest software at their own risk.

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L. Once at least one check box has been ticked, the GO button will become active.


M. Click GO, the tester will now be updated.

Notes: i) If there is a newer version of operating software (OS) for the tester, the loader will indicate.

ii) Do not disconnect the tester during the update procedure.

iii) The red USB LED on the tester flashes during data transfer.

N. Click OK when completed. The tester has now been fully updated and can now be disconnected.

After Downloading new software, re-calibrate your screen

WARNING




1-800-648-3976 (ext. 3)



®

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Sierra STATS - SAVE/PRINT DATA

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Data is stored on a drop-down tree on the left side of the window—click to view

Each separate session is started when you power up the tester and select a manufacturer.

As a guide, a maximum of approx 20 sessions can be recorded, dependant upon how much data is in each individual session.


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SPECIFICATION

DESCRIPTION

OPERATING SUPPLY

USER INTERFACE

DISPLAY

COMMUNICATION

PROTOCOLS

PC INTERFACE

REVERSE POLARITY PROTECTION

SIZE (INCHES)

WEIGHT

MEMORY

STORAGE

TEMPERATURE

OPERATING

TEMPERATURE

CURRENT

CONSUMPTION

SPECIFICATION

Sierra STATS

12 - 27 VOLTS DC

KEYPAD & TOUCHSCREEN

128x64 Dot Matrix Back Lit LCD TFT

J1850

ISO9141

SCP

5 VOLTS

CCD & VPW

ISO 11898-2 HIGH SPEED CAN

ISO 11992 CAN

NMEA 2000

J1939

USB

YES

10.43 X 8.66 X 1.96

2lb 4.33oz

512KB RAM

64MB FLASH

32°F to 122°F

41°F TO 104°F

200mA

360mA (Back Lit)

24




Sierra IQ

Sierra InfoQuest (iQ) is an informational database for marine engines and serves as a supplement to the STATS printed instruction manual. Sierra iQ also displays all of the applications that Sierra STATS is currently able to connect to.

Sierra iQ allows the user to view all the basic information on the engine (Year Range, HP, etc.). It also allows the user to see what software, cables, and hardware are required to connect the STATS diagnostic tool to an engine.

In order to gain full access, users will need to log in with the email address registered to the users STATS console while using the serial number of the STATS console as the password. To gain Public access that displays application and cable information only, users will click ‘Sign In’ and then ‘Sign In as Guest’ in the sign in dialog box.

The web-based version is free of charge at www.sierra-iq.com

. For iOS and Android users, a mobile version is available for a one-time purchase of $0.99 in the App Store for iPhone/iPad and

Google Play for all Android devices.


25

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26




Pictures and descriptions of where to find the Data Link Connector (DLC) are available on most models when properly logged in with Username and Password and provides the user with tips and hints about the engine to aid in diagnostics.

Sierra iQ is also equipped with a feedback function that allows users to add information to each engine (ie. pictures, helpful diagnostic info, diagnostic socket locations, ect.) allowing STATS users to support each other as well.


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2 YAMAHA

YAMAHA OPERATING MANUAL

Contents

C

D

A

B

E

APPLICATIONS

DIAGNOSTIC SOCKET

GENERAL OPERATION

FAULT CODES

SPECIAL FUNCTIONS

28



2 yamaha-

A

Yamaha Jet Ski’s

APPLICATIONS

GS1800, XLT1200,

XA1200AC-C

FX All Models

GP 1300

VX All Models

VX Deluxe

FZ-R, FZ-S

2009

2002 → UP

2003 → 2008

2005 → UP

2004 → UP

2003 → UP

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

Yamaha Jet Ski’s Remote Control Programming

Sp.

Func.

✓

✓

✓

✓

✓

✓

ADC300 + ADC403

ADC300 + ADC403

ADC300 + ADC403

ADC300 + ADC403

ADC300 + ADC403

ADC300 + ADC403

A

A

A

A

A

A

FX All Models

VX All Models

VX Deluxe

FZR, FZS

2002

2005

2004

2003

→

→

→

→

UP

UP

UP

UP

✓

✓

✓

✓

ADC300 + ADC418 +

ADC450

ADC300 + ADC418 +

ADC450

ADC300 + ADC418 +

ADC450

ADC300 + ADC418 +

ADC450

*Remote Programming available on those craft equipped with YCOP controller

Yamaha Outboards

A

A

A

A

4 Stroke EFI: F275

4 Stroke EFI: F115, 150, 200,

225HP

4 Stroke EFI: F40, 50, 60, 90,

250, 300

HPDI: 150, 175, 200, 225,

250, 300HP

2008 → UP

2000 → UP

2008 → UP

1998 → UP

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

Sp.

Func.

✓

✓

✓

✓

ADC300 + ADC403

ADC300 + ADC403

ADC300 + ADC403

ADC300 + ADC403

A

A

A

A


29

®


2 yamahab


Yamaha Diagnostic Socket

SIDE VIEW FRONT VIEW

30




2 yamahac


Yamaha

ECU IDENTIFICATION

Displays basic engine information such as HP, Serial number, etc. ECU IDENTIFICATION is available to be saved and stored to be viewed later on a PC to build a custom made diagnostic printout.

READ FAULT CODES

Displays a list of diagnostic trouble codes currently active on the engine. Each fault code needs to be investigated and corrected. Additional testing steps for the failure will also be displayed on the next screen by pressing the RIGHT ARROW key. Once the faults have been corrected, then the CLEAR FAULT CODES function should be used to clear the engines fault code memory. All FAULT CODES are available to be saved and stored to be viewed later on a PC to build a custom made diagnostic printout.

CLEAR FAULT CODES

This functions allows any fault codes that have been fixed to be cleared. After the fault codes have successfully been cleared, if any are still displayed, this indicates that the faults have not been corrected and further investigation is required.

LIVE DATA

This function displays a list of LIVE DATA parameters and values from the engine ECU. This data list is what is available from the engine ECU, and each value will change as the engine components are operated. Please refer to vehicle manufacturers data for correct values and correct operating limits. All LIVE DATA is available to be saved and stored to be viewed later on a PC to build a custom made diagnostic printout.

STATIC TESTS (KEY ON ENGINE OFF)

This option allows you to :

1. Activate any fuel injector

2. Activate any ignition coil

3. Command the fuel pump ON

DYNAMIC TESTS (KEY ON ENGINE RUNNING)

These tests are useful if there is a problem when the engine is running. These options can also be used to help identify the cause of the problem. This option allows you to:

1. Command off individual cylinders to isolate a running concern (Power Balance).

2. Command off fuel pump

3. Test Alarm Functions

ENGINE HOURS

This function displays the engine running hours and will break down hours via specific engine RPM ranges and the overall hours the engine has been used. All ENGINE HOURS are available to be saved and stored to be viewed later on a PC to build a custom made diagnostic printout.

*NOTE: Some functions may not be supported on all engines. STATS will auto-detect what tests and functions are available.

VERSION: 2.5 MARCH 2014 ®

31


2 yamahad

FAULT CODES

Yamaha

DTC # Description

1 NORMAL OPERATION

12 INCORRECT CHARGE COIL INPUT SIGNAL

13

14

15

17

18

19

22

23

24

25

26

27

28

29

FUEL PRESSURE (FP) SENSOR SIGNAL INCORRECT

INJECTOR OPERATIONAL SIGNAL INCORRECT OR

NOT FOUND

WATER IN FUEL FILTER

NEUTRAL SWITCH SIGNAL OUT OF SPEC

AIR PRESSURE (AP) SENSOR OUT OF SPEC

Symptom

ENGINE OPERATES NORMALLY

PULSER COIL IRREGULAR SIGNAL

AIR TEMPERATURE (AT) SENSOR OUT OF SPEC

CAM POSITION SENSOR (CMP) IRREGULAR

SIGNAL (EX)

MIL DISPLAYED

ENGINE STOPS

ENGINE WILL NOT RESTART

CRANKSHAFT POSITION SENSOR (CPS)

INCORRECT SIGNAL

ENGINE TEMPERATURE (ECT) SENSOR OUT OF

SPEC

KNOCK SENSOR (KS) IRREGULAR SIGNAL

THROTTLE POSITION SENSOR (TPS) OUT OF SPEC

BATTERY VOLTAGE BELOW SPECIFIED VOLTAGE

MIL DISPLAYED

ENGINE AT HIGH IDLE

DEGRADED ACCELERATION PERFORMANCE

DECLINING MAX ENGINE SPEED

DIFFERENCE IN IDLE SPEEDS

ENGINE SPEEDS DO NOT SYNC

MIL DISPLAYED

ENGINE AT HIGH IDLE



MIL DISPLAYED

ENGINE AT HIGH IDLE


BATTERY VOLTAGE AND BATTERY ALERT DISPLAYED


ENGINE WILL NOT RESTART DEPENDING ON BATTERY CONDITION

ATMOSPHERIC PRESSURE (AP) SENSOR

MIL DISPLAYED

ENGINE AT HIGH IDLE


MIL DISPLAYED

ENGINE AT HIGH IDLE





WATER IN FUEL DISPLAYED

ALERT BUZZER ACTIVATED WHILE SHIFT IS IN NEUTRAL

MIL DISPLAYED

ENGINE MAY NOT START

MIL DISPLAYED

ENGINE AT HIGH IDLE




31

32

33

TACHOMETER PULSE OUTPUT NOT FOUND

SHIFT CUTOFF CONTROL DURING OPERATION

IGNITION TIMING SLIGHT CORRECTION DURING

COLD START


32


2 yamahad

FAULT CODES

Yamaha

37

39

40

41

42

43

44

45

46

47

48


35

FUEL INJECTION PWM SLIGHT CORRECTION BY

KNOCK CONTROL

36

IGNITION TIMING SLIGHT CORRECTION BY

KNOCK CONTROL

49

59

68

69

Symptom

"INTAKE AIR PASSAGE (AIR LEAK)

IDLE SPEED CONTROL SIGNAL OUT OF SPEC

OIL PRESSURE (OP) SENSOR OUT OF SPEC

MIL DISPLAYED

ENGINE AT HIGH IDLE

IMPOSSIBLE TO SHIFT-IN WHEN RPM IS >1500 RPM




MIL DISPLAYED

ENGINE AT HIGH IDLE



SHIFT POSITION (SP) SENSOR

INTAKE PRESSURE (IP) SENSOR

OVERHEAT CONTROL / OIL EMPTY CONTROL

BUZZER ACTIVATED

ENGINE STOP LANYARD SWITCH SIGNAL OUT OF

SPEC

SHIFT CUT SWITCH SIGNAL OUT OF SPEC

THERMOSWITCH SIGNAL OUT OF SPEC

SLANT DETECTION SWITCH SIGNAL OUT OF SPEC

DATA TRANSMISSION INCORRECT

OVERCOOLING IRREGULAR SIGNAL

ECM MEMORY DATA SIGNAL

VARIABLE CAMSHAFT TIMING STARBOARD VALVE

PULLEY ABNORMAL ADVANCE

VARIABLE CAMSHAFT TIMING PORT VALVE PULLEY

ABNORMAL ADVANCE

MIL DISPLAYED

ENGINE STALLS (WHEN RUNNING)

BUZZER COMES ON

MIL DISPLAYED

SHIFTING TO NEUTRAL IS DIFFICULT

MIL DISPLAYED

MIL DISPLAYED


71

72

73

CAM POSITION (CMP) SENSOR (S BANK IN)

IRREGULAR SIGNAL

CAM POSITION (CMP) SENSOR (P BANK IN)

IRREGULAR SIGNAL

OIL CONTROL VALVE (OCV) (S BANK) IRREGULAR

LOAD CURRENT VALUE

MIL DISPLAYED

ENGINE AT HIGH IDLE





MIL DISPLAYED

ENGINE AT HIGH IDLE





MIL DISPLAYED






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2 yamahad

FAULT CODES

Yamaha

DTC #

74

85

86

112

113

114

115

116

117

118

119

Description

OIL CONTROL VALVE (OCV) (P BANK) IRREGULAR

LOAD CURRENT VALUE

Symptom

MIL DISPLAYED





ION DETECTION MODULE

IMMOBILIZER COMMUNICATION ERROR

ETV (ELECTRONIC THROTTLE VALVE) SYSTEM

(ENGINE ECM INTERNAL CIRCUIT MALFUNCTION)


(THROTTLE VALVE MALFUNCTION)











MIL DISPLAYED


MIL DISPLAYED

ENGINE AT HIGH IDLE

THROTTLE INOPERATIVE

ENGINE SPEED IS SET AT 1500 RPM



MIL DISPLAYED

ENGINE AT HIGH IDLE







ENGINE WILL NOT START

MIL DISPLAYED

ENGINE AT HIGH IDLE





MIL DISPLAYED

ENGINE AT HIGH IDLE





MIL DISPLAYED

ENGINE AT HIGH IDLE





MIL DISPLAYED

ENGINE AT HIGH IDLE





MIL DISPLAYED

ENGINE AT HIGH IDLE






34


2 yamahad

FAULT CODES

Yamaha

DTC #

121

122

123

124

125

126

127

128

129

131

Description














ACCELERATOR POSITION SENSOR (APS)

MALFUNCTION

Symptom

MIL DISPLAYED

ENGINE AT HIGH IDLE





MIL DISPLAYED

ENGINE AT HIGH IDLE





MIL DISPLAYED

ENGINE AT HIGH IDLE





MIL DISPLAYED

ENGINE AT HIGH IDLE





MIL DISPLAYED

ENGINE AT HIGH IDLE





MIL DISPLAYED

ENGINE AT HIGH IDLE





DIFFERENCE IN MAX ENGINE SPEEDS

MIL DISPLAYED

ENGINE AT HIGH IDLE





MIL DISPLAYED

ENGINE AT HIGH IDLE





MIL DISPLAYED


DECLINING MAX ENGINE SPEEDS



ENGINE WILL NOT OPERATE


35

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2 yamahad

FAULT CODES

Yamaha

DTC #

132

133

134

135

136

137

138

139

140

141

142

143

Description


MALFUNCTION


MALFUNCTION


MALFUNCTION


MALFUNCTION









Symptom


ENGINE WILL NOT OPERATE


ENGINE MAY NOT OPERATE

MAX ENGINE SPEED DECREASES

DEGRADED ACCERATION PERFORMANCE


ENGINE MAY NOT OPERATE





MIL DISPLAYED

ENGINE AT HIGH IDLE





MIL DISPLAYED

ENGINE AT HIGH IDLE





MIL DISPLAYED

ENGINE AT HIGH IDLE





MIL DISPLAYED

ENGINE AT HIGH IDLE












MIL DISPLAYED

ENGINE AT HIGH IDLE





MIL DISPLAYED




MIL DISPLAYED

ENGINE AT HIGH IDLE






36


2 yamahad

FAULT CODES

Yamaha


144



145



146 SPS OUT OF SPEC

147 SPS OUT OF SPEC

148 SPS CENTER OUTBOARD ENGINE OUT OF SPEC

149 SPS CENTER OUTBOARD ENGINE OUT OF SPEC

150 SPS OUT OF SPEC

153 SPS OUT OF SPEC

154 SPS OUT OF SPEC

155 SPS OUT OF SPEC

Symptom

MIL DISPLAYED

ENGINE AT HIGH IDLE





ENGINE AT HIGH IDLE



MIL DISPLAYED

ENGINE OPERATES NORMALLY UNLESS STOPPED

ENGINE WILL NOT CRANK OR RESTART

ALERT INDICATOR ON


MIL DISPLAYED

ENGINE OPERATES NORMALLY UNLESS STOPPED

ENGINE WILL NOT CRANK OR RESTART

ALERT INDICATOR ON


MIL DISPLAYED

NORMAL OPERATION POSSIBLE

SHIFT ACTUATOR INOPERATIVE (WHEN CODE 146/147 AND 148/149 TRIGGERED

SIMULTANEOUSLY)

ALERT INDICATOR ON


MIL DISPLAYED

NORMAL OPERATION POSSIBLE

SHIFT ACTUATOR INOPERATIVE (WHEN CODE 146/147 AND 148/149 TRIGGERED

SIMULTANEOUSLY)

ALERT INDICATOR ON


MIL DISPLAYED

ENGINE AT HIGH IDLE

ENGINE WILL NOT RESTART (IN SHIFT IN POSITION)

SHIFT ACTUATOR INOPERATIVE

ALERT INDICATOR ON


MIL DISPLAYED

ENGINE AT HIGH IDLE

ENGINE WILL NOT RESTART (IN SHIFT IN POSITION)


ALERT INDICATOR ON


MIL DISPLAYED


SHIFT DOES NOT DISENGAGE FROM SHIFT IN POSITION

ALERT INDICATOR ON

MIL DISPLAYED

ENGINE WILL NOT RESTART ( IN A SHIFT IN POSITION)

GEAR SHIFT INOPERATIVE

ALERT INDICATOR ON



37

®


2 yamahad

FAULT CODES

Yamaha

DTC #

156

157

160

REMOTE CONTROL SYSTEM MAIN STATION LPS

IRREGULAR SIGNAL

161

162

163

164

165

Description

ENGINE R/C COMMUNICATION ERROR

ENGINE R/C COMMUNICATION ERROR


IRREGULAR SIGNAL


IRREGULAR SIGNAL


IRREGULAR SIGNAL


IRREGULAR SIGNAL (DIGITAL ELECTRONIC CON-

TROL ECM INTERNAL CIRCUIT MALFUNCTION)


IRREGULAR SIGNAL

Symptom

MIL DISPLAYED

ALERT INDICATOR ON



FULLY CLOSED THROTTLE

SHIFT ACTUATOR ROD RETURNS TO THE NEUTRAL POSITION

LAN GAUGE INOPERATIVE

DTC 156 AND 157 DETECTED SIMULTANEOUSLY

UNABLE TO SWITCH ACTIVE STATION (DUAL ENGINE DTC 186)

MIL DISPLAYED

ALERT INDICATOR ON



FULLY CLOSED THROTTLE

SHIFT ACTUATOR ROD RETURNS TO THE NEUTRAL POSITION

LAN GAUGE INOPERATIVE

DTC 156 AND 157 DETECTED SIMULTANEOUSLY

UNABLE TO SWITCH ACTIVE STATION (DUAL ENGINE DTC 186)

MIL DISPLAYED

ALERT INDICATOR ON


LOCKED AT IDLE SPEED

SHIFT ACTUATOR ROD RETURN TO NEUTRAL POSITION

WHEN EITHER DTC 160/161 AND 162/163 TRIGGERED SIMULTANEOUSLY

MIL DISPLAYED

ALERT INDICATOR ON





MIL DISPLAYED

ALERT INDICATOR ON





MIL DISPLAYED

ALERT INDICATOR ON





MIL DISPLAYED


SHIFT ACTUATOR ROD RETURNS TO NEUTRAL POSITION

SHIFT ACTUATOR CAN BE OPERATED MANUALLY

ALERT INDICATOR IS ON

MIL DISPLAYED



ALERT INDICATOR IS ON




38


2 yamahad

FAULT CODES

Yamaha

DTC #

166

167

168

169

170

171

172

173

174

175

176

177

Description

REMOTE CONTROL SYSTEM MAIN STATION CENTER

OUTBOARD ENGINE LPS IRREGULAR SIGNAL








IRREGULAR SIGNAL

REMOTE CONTROL SYSTEM SUB STATION LPS

IRREGULAR SIGNAL


IRREGULAR SIGNAL


IRREGULAR SIGNAL


IRREGULAR SIGNAL


IRREGULAR SIGNAL (DIGITAL ELECTRONIC

CONTROL ECM INTERNAL CIRCUIT MALFUNCTION)

REMOTE CONTROL SYSTEM SUB STATION CENTER




Symptom

MIL DISPLAYED


ALERT INDICATOR ON

WHEN EITHER DTC 166/167 AND 168/169 TRIGGER SIMULTANEOUSLY

MIL DISPLAYED


ALERT INDICATOR ON


MIL DISPLAYED


ALERT INDICATOR ON


MIL DISPLAYED


ALERT INDICATOR ON


MIL DISPLAYED



ALERT INDICATOR ON

MIL DISPLAYED


ALERT INDICATOR ON



MIL DISPLAYED


ALERT INDICATOR ON



MIL DISPLAYED


ALERT INDICATOR ON



MIL DISPLAYED


ALERT INDICATOR ON



MIL DISPLAYED



ALERT INDICATOR ON

MIL DISPLAYED



ALERT INDICATOR ON

MIL DISPLAYED



ALERT INDICATOR ON

ENGINES DO NOT SYNC



39

®


2 yamahad

FAULT CODES

Yamaha

DTC #

178

179

180

181

183

184

185

186

187

Description









REMOTE CONTROL SYSTEM LPS IRREGULAR

SIGNAL (DIGITAL ELECTRONIC CONTROL ECM

INTERNAL CIRCUIT MALFUNCTION)





IRREGULAR SIGNAL




LEVER PICKUP ABNORMAL

Symptom

MIL DISPLAYED



ALERT INDICATOR ON

ENGINES DO NOT SYNC


MIL DISPLAYED



ALERT INDICATOR ON

ENGINES DO NOT SYNC


MIL DISPLAYED



ALERT INDICATOR ON

ENGINES DO NOT SYNC


MIL DISPLAYED




ALERT INDICATOR ON

MIL DISPLAYED

STATION SELECTION INOPERATIVE

ALERT INDICATOR ON

MIL DISPLAYED

STATION SELECTION INOPERATIVE

ALERT INDICATOR ON

SUB STATION DIGITAL ELECTRONIC CONTROL INOPERATIVE

UNABLE TO CHANGE TO SUB STATION DIGITAL ELECTRONIC CONTROL



ALERT INDICATOR ON

MIL DISPLAYED


ALERT INDICATOR ON

* 3-DIGIT CODES ARE USED FOR DIGITAL ELECTRONIC CONTROL (DEC) SYSTEM DIAGNOSIS

40



2 yamaha-

E


Yamaha

Outboard

Diagnostics


41

®


2 yamaha-

E


Yamaha

Jet Ski

Diagnostics

42



2 yamaha-

E


Yamaha

Jet Ski Remote

Programming


43

®


3 mercury/Mercruiser

MERCURY/MERCRUISER OPERATING MANUAL

Contents

C

D

A

B

E

APPLICATIONS



FAULT CODES


44



3 mercury/Mercruisera

APPLICATIONS

Mercury/Mercruiser

Mercury

Optimax I3, 1.5L, 75, 90,

115HP

Optimax- DFI

2002 → 2012

1997 → 2001

Optimax V6 115, 135, 150,

175, 200, 225, 250, 2.5L,

3.0L

2001 → 2012

✓

V6 EFI and Sport Jet 2002 → 2009

2.5L EFI, 150, 175, 200,

225HP

Mercury Racing

2002 → 2009

225X, 250XS, 300X, 300XS 2001 → 2009

2.5L (280) EFI

Mercury Fuel ECM 824003

1998 → 2005

V-150 EFI 1993 → 2001

V-175 EFI 1991 → 2001

V-200 EFI 1989 → 2001

✓

Mercuy 4 Stroke EFI

40, 50, 60, 75, 90, 115 HP 2002 → 2009

✓

Mercury Verado

I-4 135, 150, 175, 200HP

I-6 200, 225, 250, 275, 300

2001 → 2009

2001 → 2009

I-6 350 2001 → 2009

Mercury MFG by Yamaha

30, 40, 50, 60, 75, 90,

115HP EFI

2001 → 2006

See Yamaha Section For Additional Information

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

Sp.

Func.

✓ ADC300 + ADC410 +

ADC450 or ADC407

ADC300 + ADC410 +


ADC300 + ADC410 +


ADC300 + ADC410 +


ADC300 + ADC410 +


ADC300 + ADC410 +

ADC450

ADC300 + ADC410 +

ADC450

ADC300 + ADC410 +

ADC450

ADC300 + ADC410 +

ADC450

ADC300 + ADC410 +

ADC450

ADC300 + ADC410 +


ADC300 + ADC407

ADC300 + ADC407

ADC300 + ADC407

ADC300 + ADC407

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A


45

®


3 mercury/Mercruisera

APPLICATIONS

Mercury/Mercruiser (cont.)

Sp.

Func.

Mercruiser

4.3L MPI, 5.0MPI, 350 MAG

MPI, MX 6.2MPI, Black

Scorpion

496 MAG, 496 HO MAG,

8.1L, 8.1L HO

GM MEFI-1 thru MEFI-3

Mercruiser Racing

1075 SCi, 414 EFI, 600 Sci,

8.1 SHO

HP500 GM MEFI Equipped

2003 → 2009

2001 → 2009

1992 → 2000

2001 → 2009

1998 → 2009

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

ADC300 + ADC407

ADC300 + ADC407

ADC300 + ADC424

ADC300 + ADC407

ADC300 + ADC424

A

A

A

A

A

46



3 mercury/Mercruiserb


Mercury/Mercruiser Diagnostic Socket

2-PIN

FRONT VIEW SIDE VIEW

4-PIN

SIDE VIEW


FRONT VIEW

47

®


3 mercury/Mercruiser-

C


MERCURY/MERCRUISER ENGINES


Displays basic engine information such as HP, Model Year, etc. ECU IDENTIFICATION is available to be saved and stored to be viewed later on a PC to build a custom made diagnostic printout.


Displays a list of diagnostic trouble codes currently active on the engine. Each fault code needs to be investigated and corrected. Freeze Frame data also be displayed on the next screen by pressing the RIGHT ARROW key. Once the faults have been corrected, then the CLEAR FAULT CODES function should be used to clear the engines fault code memory. All

FAULT CODES and FREEZE FRAME DATA are available to be saved and stored to be viewed later on a PC to build a custom made diagnostic printout.



LIVE DATA


STATIC TESTS (KEY ON ENGINE OFF )



2. Activate any Direct Injector


4. Activate Fuel Pump

5 Test Alarm Functions

6. Test Oil Pump






4. Actuate Digital Throttle and Shift System

5. Set Base Timing (MERCRUISER EQUIPPED WITH MEFI CONTROLLER ONLY – NOT SUPPORTED ON 555 PROCESSORS)


1. Prime Oil Pump

2. Reset Oil Break-In Period

ENGINE HOURS

This function displays the engine running hours and will break down hours via specific engine RPM ranges (resettable) and the overall hours the engine has been used (Not Resettable). All ENGINE HOURS are available to be saved and stored to be viewed later on a PC to build a custom made diagnostic printout.



48



D

Fault

Codes

Mercury/Mercruiser

Code # Fault Text

1

2

3

4

5

6

BATTERY VOLTAGE

HIGH

BATTERY VOLTAGE

LOW

SEA PUMP PRESSURE

IS LOW

O/B ONLY BLOCK

WATER PRESSURE IS

LOW

AIR COMPRESSOR

OVERHEAT

ETC LOSS OF

CONTROL

ETC STICKING

Code Description

BATTERY VOLTAGE IS ABOVE

ALLOWABLE LIMIT. THE FURTHER LIMIT

IS EXCEEDED, THE MORE GUARDIAN

REDUCES POWER.

BATTERY VOLTAGE IS BELOW

ALLOWABLE LIMIT. THE FURTHER LIMIT

IS EXCEEDED, THE MORE GUARDIAN

REDUCES POWER.

Possible Causes

1. Check alternator for overcharging.

2. Check regulator and sense circuit

for malfunction.

3. Wiring Problem.

4. Check for incorrectly installed 24

or 36V systems.

Battery voltage is below normal limit. Turn off unnecessary loads, increase engine RPM and check battery connections.

Check for:

1. Loose belts.

2. Defective Battery.

3. Excessive amp drain from

Accessories such as a radio system.

WATER PRESSURE IN ENGINE BLOCK

LOW. GUARDIAN IS ACTIVE.

GUARDIAN ACTIVE

VARIABLE POWER LIMIT DEPENDS ON

BLOCK PRESSURE, COOLANT

TEMPERATURE, AND RPM.

Water pressure in the cooling system is low.

Check for:

1. Plugged water inlet.

2. Faulty water pump/impeller.

3. Faulty Temp Sensor/Wiring.

COMPRESSOR IS OVERHEATING.

FEEDBACK FROM ETC INDICATES

ACTUAL THROTTLE BLADE POSITION

DOES NOT MATCH ERC POSITION

THROTTLE BLADE NOT RESPONDING

TO ETC

BLADE IS STUCK OR OBSTRUCTED

Check for:

1. Other overheat related faults.


3. Faulty Water Pump/Impeller

4. Faulty Temp Sensor/Wiring.

Throttle position control is not working properly.

The throttle plate may move, but will not move as commanded by the PCM.

Check for:

1. ETC motor Circuit A or B shorts/opens.

2. ETC termination continuity

3. Faulty ETC assembly

Throttle position control is not working properly.

The PCM does not see a movement in the TPS signal after commanding the ETC to move.

Check for:

1. Obstructions causing the throttle

plate to be sticking.

2. ETC motor circuit A or B shorts/

opens.

3. ETC termination continuity/

condition.

4. TPS 1 or TPS 2 circuit short/open.

7

8

FUEL PRESSURE

SENSOR CIRCUIT HIGH

FUEL PRESSURE

SENSOR CIRCUIT LOW

9

10

11

GUARDIAN STRATEGY

KNOCK SENSOR 1

KNOCK SENSOR 2

GUARDIAN IS TRYING TO PROTECT

ENGINE BY REDUCING POWER

Engine Guardian is active. Power will be limited to prevent engine damage.

Additional Faults will be set with this code.

KNOCK SENSOR IS EXPECTED TO

SENSE A MINIMUM AMOUNT OF

VIBRATION. TOO LITTLE OF A SIGNAL

WILL CAUSE THIS FAULT. TOO MUCH

AND THE KNOCK CONTROL BECOMES

ACTIVE

KNOCK SENSOR IS EXPECTED TO

SENSE A MINIMUM AMOUNT OF

VIBRATION. TOO LITTLE OF A SIGNAL

WILL CAUSE THIS FAULT. TOO MUCH

AND THE KNOCK CONTROL BECOMES

ACTIVE

Check for:

1. Faulty Knock Sensor

2. Loose or broken Wiring

3. Incorrect Knock Sensor Mounting

Check for:

1. Faulty Knock Sensor


3. Incorrect Knock Sensor Mounting

Type

CONSTANT BEEP

CONSTANT BEEP

CONSTANT BEEP

CONSTANT BEEP

CONSTANT BEEP

CONSTANT BEEP

VARYING HORN

VARYING HORN

Application

VARIES

VARIES

VARIES

5%

5%

VARIES

90%

90%


49



D

Fault

Codes

Mercury/Mercruiser

Code #

12

13

14

15

16

17

18

19

20

21

22

Fault Text

OIL PRESSURE LOW

OIL LEVEL (REMOTE)

IS LOW

OIL LEVEL (ENGINE)

IS LOW

MAP SENSOR CIRCUIT

HIGH

MAP SENSOR CIRCUIT

LOW

MAP SENSOR IDLE

FAULT

OIL PUMP OUTPUT

MAXIMUM RPM

EXCEEDED

PORT HEAD OVERHEAT

I/B ECT OVERHEAT

O/B STARBOARD HEAD

OVERHEAT

WARNING HORN

OUTPUT


OIL PRESSURE LOW

GUARDIAN IS ACTIVE


RPM

OIL LEVEL IN THE 2-STROKE REMOTE

OIL TANK IS LOW

OIL LEVEL IN THE 2-STROKE ON BOARD

OIL TANK IS LOW

MAP CIRCUIT SHORTED

(INDICATING 5V TO PCM)

AIRFLOW CALCULATION IS NO

LONGER VALID

POWER LIMIT IS ACTIVE

FUELING LEVEL IS A STRAIGHT LOOKUP

BASED ON DEMAND AND RPM

MAP CIRCUIT SHORTED


AIRFLOW CALCULATION IS NO

LONGER VALID

POWER LIMIT IS ACTIVE

FUELING LEVEL IS A STRAIGHT LOOKUP

BASED ON DEMAND AND RPM

Possible Causes

Engine oil pressure is low.

Stop Engine and Check:

1. Oil Level (High/Low)

2. Oil Condition (Aerated, Milky, Diluted)

3. Worn Mechanical Engine Components

(Bearings, etc.)

4. Clogged oil pump pickup screen

5. Faulty Oil Pressure Sensor (Not shorted open)

Check for:

1. Low Oil in the Remote Oil Tank

2. Faulty Oil Level Sensor


Check for:

1. Low Oil in the On-Board Oil Tank



Manifold absolute pressure sensor is not working properly. This fault will result in reduction of engine performance.

MAP sensor is indicating a near 5V signal

Check for:

1. MAP sensor internal short/open

2. MAP sensor circuit short/open

3. Faulty PCM

Manifold absolute pressure sensor is not working properly. This fault will result in reduction of engine performance.

MAP sensor is indicating a near 0V signal

Check for:

1. MAP sensor internal short/open

2. MAP sensor circuit short/open

3. Faulty PCM

THE ENGINE IS EXPECTED TO PULL

SOME VACUUM ON THE INLET AT

IDLE. IF THERE IS NO DIFFERENCE IN

PSI DROP FROM KEY ON TO RUNNING,

THE MAP SENSOR MAY BE BAD OR

AIRFLOW DISRUPTED IN THE INTAKE

SYSTEM. ENGINE IS RECEIVING TOO

MUCH AIR AT IDLE.

Check for:

1. Faulty MAP Sensor

2. Throttle Bore Missing or Oversized

3. Vacuum Leak in Manifold

OIL PUMP IS NOT WORKING PROPERLY

Check for:


2. Internal Short or Open in Oil Pump

RECOMMENDED RPM RANGE

EXCEEDED

FIRST, HORN SOUNDS

SECOND, CYLINDERS STOP FIRING

THIRD, MORE CYLINDERS STOP FIRING

TYPICALLY NEXT FAULT IS OVERSPEED1

WHICH CAUSES POWER LIMIT

Excessive engine speed.

Check for:

1. Improper trim angle

2. Improper propeller.

OVERHEAT ON THE PORT BANK

Check for:

1. Plugged Water Inlet

2. Faulty or Weak SeaWater Pump

3. Faulty Thermostat

4. Blockage in Engine

5. Temperature Sensor is Out of Specification

1. WATER TEMPERATURE IN HEAD HIGH

GUARDIAN IS ACTIVE


BLOCK PRESSURE, COOLANT

TEMPERATURE, AND RPM

2. ENGINE COOLANT SENSOR

EXCEEDS A SPECIFIED LIMIT

3. STARBOARD CYLINDER HEAD

EXCEEDS A SPECIFIED LIMIT (OUTBOARD)

Engine Coolant Temp is High.

Check for:


2. Faulty water pump/Impeller.

3. Faulty thermostat

4. Engine lugging (Check for correct prop

application)

5. Faulty sensor/wiring

WARNING HORN IN BOAT NOT

OPERATING. NO AUDIBLE ALARM WILL

BE HEARD IN EVENT OF ENGINE

MALFUNCTION.

Warning horn in boat is not operating. There will be no audible alarm in case of engine malfunction.

Check:

1. tan/blue lead for opens/shorts.

2. Faulty horn

Type

CONSTANT BEEP

VARYING HORN

VARYING HORN

NONE

CONSTANT BEEP

CONSTANT BEEP

NONE

Application

VARIES

90%

90%

100%

100%

VARIES

100%


50

Fault

Codes



D

Fault

Codes

Mercury/Mercruiser

Code #

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

Fault Text

WATER IN FUEL

DIRECT INJECTOR 1

OPEN CIRCUIT

DIRECT INJECTOR 1

SHORTED CIRCUIT

DIRECT INJECTOR 2

OPEN CIRCUIT

DIRECT INJECTOR 2

SHORTED CIRCUIT

DIRECT INJECTOR 3

OPEN CIRCUIT

DIRECT INJECTOR 3

SHORTED CIRCUIT

DIRECT INJECTOR 4

OPEN CIRCUIT

DIRECT INJECTOR 4

SHORTED CIRCUIT

DIRECT INJECTOR 5

OPEN CIRCUIT

DIRECT INJECTOR 5

SHORTED CIRCUIT

DIRECT INJECTOR 6

OPEN CIRCUIT

DIRECT INJECTOR 6

SHORTED CIRCUIT

SEA PUMP PRESSURE

CIRCUIT HIGH

O/B ONLY BLOCK

WATER PRESSURE

CIRCUIT IS HIGH

SEA PUMP PRESSURE

CIRCUIT LOW

O/B ONLY BLOCK

WATER PRESSURE

CIRCUIT IS LOW

BREAKIN STRATEGY

ACTIVE

MANIFOLD AIR

TEMPERATURE CIRCUIT

HIGH


WATER IN FUEL SYSTEM

DIRECT INJECTOR 1 OPEN CIRCUIT

DIRECT INJECTOR 1 SHORT CIRCUIT











BLOCK PRESSURE SENSOR CIRCUIT

SHORTED

BLOCK PRESSURE SENSOR CIRCUIT

OPEN

ENGINE IS IN BREAK-IN MODE. THIS

WILL INCREASE OIL CONSUMPTION.

AIR TEMPERATURE SENSOR CIRCUIT

OPEN (INDICATING 5V TO PCM)

AIRFLOW CALCULATION IS USING THE

DEFAULT TEMPERATURE

Possible Causes

Check for:

1. Water in the fuel system

2. Shorted Water Sensor

Check for:

1. Open Circuit in Wiring

2. Open Circuit in Injector

Check for:

1. Short Circuit in Wiring

2. Short Circuit in Injector

Check for:



Check for:



Check for:



Check for:



Check for:



Check for:



Check for:



Check for:



Check for:



Check for:



Water pressure sensor is not working properly.

Sea Pump Pressure Sensor indicating a near 5V signal.

Check for:

1. Faulty Sea Pump Pressure Sensor

2. Shorted/Open Sensor Wiring

3. Faulty PCM

Water pressure sensor is not working properly.

Sea Pump Pressure Sensor indicating a near 0V signal.

Check for:

1. Faulty Sea Pump Pressure Sensor

2. Shorted/Open Sensor Wiring

3. Faulty PCM

ECM has been reset to activate the Engine Break-in

Cycle.

Engine air temperature sensor is not working properly.

Intake Manifold Air Temp Sensor indicating a near

5V signal.

Check for:

1. Open in Engine Air Temp Sensor circuit in wiring.

2. Faulty PCM

3. Internally Shorted/Open Engine Air Temp Sensor

Type

NONE

NONE

NONE

NONE

NONE

NONE

NONE

NONE

NONE

NONE

NONE

NONE

VARYING HORN

VARYING HORN

VARYING HORN

Application

100%

100%

100%

100%

100%

100%

100%

100%

100%

100%

100%

100%

90%

90%

90%


51



D

Fault

Codes

Mercury/Mercruiser

Code #

40

41

42

43

44

45

46

47

48

49

Fault Text

AIR COMPRESSOR

TEMP CIRCUIT HIGH

AIR COMPRESSOR

TEMP CIRCUIT LOW

EST 1 OPEN CIRCUIT

EST 1 SHORTED

CIRCUIT

EST 2 OPEN CIRCUIT

EST 2 SHORTED

CIRCUIT

EST 3 OPEN CIRCUIT

EST 3 SHORTED

CIRCUIT

EST 4 OPEN CIRCUIT


MANIFOLD AIR

TEMPERATURE CIRCUIT

LOW

AIR TEMPERATURE SENSOR CIRCUIT

SHORTED (INDICATING 0V TO PCM)

AIRFLOW CALCULATION IS USING THE

DEFAULT TEMPERATURE

AIR COMPRESSOR TEMPERATURE SEN-

SOR IS NOT WORKING PROPERLY.

AIR COMPRESSOR TEMPERATURE SEN-

SOR IS NOT WORKING PROPERLY.

IGNITION FAULT

SIGNAL FROM ECM TO IGNITION

DRIVER MODULE OPEN

DETECTABLE ONLY WITH KEY ON AND

ENGINE OFF

IGNITION FAULT


DRIVER MODULE SHORTED

DETECTABLE ONLY WITH ENGINE

RUNNING

IGNITION FAULT


DRIVER MODULE OPEN

IGNITION FAULT




RUNNING

IGNITION FAULT


DRIVER MODULE OPEN


ENGINE OFF

IGNITION FAULT




RUNNING

IGNITION FAULT


DRIVER MODULE OPEN


ENGINE OFF

Possible Causes

Engine air temperature sensor is not working properly.

Intake Manifold Air Temp Sensor indicating a near

0V signal.

Check for:

1. Short in Sensor circuit wiring to Sensor Ground or Engine Ground

2. Faulty PCM

3. Internally Shorted/Open Sensor

Check for:

1. Short/Open in Wiring

2. Short/Open in Temperature Sensor

3. Faulty PCM

Check for:


2. Short/Open in Temperature Sensor

3. Faulty PCM

Ignition coil is not working properly.

Low Voltage Trigger Lead indicating a near 0V or

5V Signal.

Check for:

1. Shorted/Open Trigger Lead

2. Faulty Ignition Coil

3. Faulty PCM

NOTE: When engine is rotating, signal flucuates from 0-5V

Check for:



NOTE: Fault may trigger during OVERSPEED as the

Ignition Trigger is being turned OFF.



5V Signal.

Check for:



3. Faulty PCM


Check for:







5V Signal.

Check for:



3. Faulty PCM


Check for:







5V Signal.

Check for:



3. Faulty PCM


Type

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

Application

90%

100%

100%

100%

100%

100%

100%

100%


52

Fault

Codes



D

Fault

Codes

Mercury/Mercruiser

Code # Fault Text

50

51

52

53

54

55

56

57

58

59

60

EST 4 SHORTED

CIRCUIT

EST 5 OPEN CIRCUIT

EST 5 SHORTED

CIRCUIT

EST 6 OPEN CIRCUIT

EST 6 SHORTED

CIRCUIT

EST 7 OPEN CIRCUIT

EST 7 SHORTED

CIRCUIT

EST 8 OPEN CIRCUIT

EST 8 SHORTED

CIRCUIT

FUEL INJECTOR 1

OPEN CIRCUIT

FUEL INJECTOR 1

SHORTED CIRCUIT


IGNITION FAULT




RUNNING

IGNITION FAULT


DRIVER MODULE OPEN


ENGINE OFF

IGNITION FAULT




RUNNING

IGNITION FAULT


DRIVER MODULE OPEN


ENGINE OFF

IGNITION FAULT




RUNNING

IGNITION FAULT


DRIVER MODULE OPEN


ENGINE OFF

IGNITION FAULT




RUNNING

IGNITION FAULT


DRIVER MODULE OPEN


ENGINE OFF

IGNITION FAULT




RUNNING

INSUFFICIENT CURRENT DRAW ON

FUEL INJECTOR CIRCUIT

CURRENT DRAW OF FUEL INJECTOR

HAS EXCEEDED LIMIT

Possible Causes

Check for:







5V Signal.

Check for:



3. Faulty PCM


Check for:







5V Signal.

Check for:



3. Faulty PCM


Check for:







5V Signal.

Check for:



3. Faulty PCM


Check for:







5V Signal.

Check for:



3. Faulty PCM


Check for:





Check for:

1. Open Fuel Injector Circuit

2. Faulty Fuel Injector

Check for:

1. Shorted Fuel Injector Circuit


Type

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

Application

100%

100%

100%

100%

100%

90%

100%

100%

100%

100%

100%


53



D

Fault

Codes

Mercury/Mercruiser

Code #

61

62

63

64

65

66

67

68

69

70

71

72

73

74

75

76

77

Fault Text

FUEL INJECTOR 2

OPEN CIRCUIT

FUEL INJECTOR 2

SHORTED CIRCUIT

FUEL INJECTOR 3

OPEN CIRCUIT

FUEL INJECTOR 3

SHORTED CIRCUIT

FUEL INJECTOR 4

OPEN CIRCUIT

FUEL INJECTOR 4

SHORTED CIRCUIT

FUEL INJECTOR 5

OPEN CIRCUIT

FUEL INJECTOR 5

SHORTED CIRCUIT

FUEL INJECTOR 6

OPEN CIRCUIT

FUEL INJECTOR 6

SHORTED CIRCUIT

FUEL INJECTOR 7

OPEN CIRCUIT

FUEL INJECTOR 7

SHORTED CIRCUIT

FUEL INJECTOR 8

OPEN CIRCUIT

FUEL INJECTOR 8

SHORTED CIRCUIT

FUEL LEVEL 1 CIRCUIT

HIGH


LOW

CAMSHAFT SENSOR

FAULT





HAS EXCEEDED LIMIT




HAS EXCEEDED LIMIT




HAS EXCEEDED LIMIT




HAS EXCEEDED LIMIT




HAS EXCEEDED LIMIT




HAS EXCEEDED LIMIT




HAS EXCEEDED LIMIT

FUEL LEVEL SENSOR CIRCUIT OPEN

(PRIMARY FUEL TANK)

FUEL LEVEL SENSOR CIRCUIT SHORTED

(PRIMARY FUEL TANK)

CAM POSITION SENSOR CIRCUIT IS

FAULTY, MISSING, OR INCORRECTLY

PHASED TO CKP SENSOR

FUEL AND IGNITION STRATEGIES WILL

BE MODIFIED

Possible Causes

Check for:



Check for:



Check for:



Check for:



Check for:



Check for:



Check for:



Check for:



Check for:



Check for:



Check for:



Check for:



Check for:



Check for:



Fuel level sensor is not working properly.

Check for:

1. Open/Short Circuit in Fuel Level Sensor 1 wiring

2. Faulty Fuel Level 1 Sensor

3. Faulty PCM

Fuel level sensor is not working properly.

Check for:

1. Open/Short Circuit in Fuel Level Sensor 1 wiring

2. Faulty Fuel Level 1 Sensor

3. Faulty PCM

Engine crank/cam encoder is not working properly.

Camshaft Position Sensor signal is missing, erratic, or incorrectly phased to the Crankshaft Position

Sensor.

Check for:

1. 0-5V signal changes on cam signal lead during

cranking as cam gear vane passes sensor.

2. Metal shavings sticking to sensor magnet.

3. Loose/Damaged wiring or connections

4. Open/Short sensor or sensor wiring.

5. Faulty PCM

Type

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

NONE

VARYING HORN

Application

100%

100%

100%

100%

100%

100%

100%

100%

100%

100%

100%

100%

100%

100%

100%

100%

90%


54

Fault

Codes



D

Fault

Codes

Mercury/Mercruiser

Code #

80

81

82

83

84

85

89

90

91

92

93

94

95

96

97

98

99

100

Fault Text

MAIN POWER RELAY

OUTPUT

MAIN POWER RELAY

BACKFEED

OIL LEVEL SENSOR

CIRCUIT HIGH

OIL LEVEL SENSOR

CIRCUIT LOW

OIL PRESSURE CIRCUIT

HIGH

OIL PRESSURE CIRCUIT

HIGH

OIL TEMPERATURE

CIRCUIT HIGH

OIL TEMPERATURE

CIRCUIT LOW

OIL TEMPERATURE

OVERHEAT

PADDLE WHEEL SEN-

SOR FAULT

PITOT PRESSURE CIR-

CUIT HIGH

PITOT PRESSURE CIR-

CUIT LOW

PORT HEAD TEMP

CIRCUIT HIGH

PORT HEAD TEMP

CIRCUIT LOW

PORT TAB CIRCUIT

HIGH

PORT TAB CIRCUIT

LOW

PORT TAB DOWN

SOLENOID OUTPUT

PORT TAB UP

SOLENOID OUTPUT


KEY SWITCH +12V AND DRDIVER

POWER DO NOT AGREE WITHIN

CALIBRATED LIMITS

UNINTENDED VOLTAGE SUPPLIED TO

ECU. FAULT DECLARED IF VOLTAGE

REGULATOR IN ECU IS OFF, BUT ECU

SENSES VOLTAGE ON DRIVER POWER

OIL LEVEL SENSOR IN THE OIL TANK IS

NOT WORKING PROPERLY. CHECK OIL

LEVEL BEFORE CONTINUING ENGINE

OPERATION.

OIL LEVEL SENSOR IN THE OIL TANK IS

NOT WORKING PROPERLY. CHECK OIL

LEVEL BEFORE CONTINUING ENGINE

OPERATION.

OIL PRESSURE SENSOR CIRCUIT

SHORTED (INDICATING 5V TO PCM)

OIL PRESSURE SENSOR CIRCUIT OPEN


OIL TEMPERATURE SENSOR CIRCUIT

OPEN

OIL TEMPERATURE SENSOR CIRCUIT

SHORTED

ENGINE OIL IS OVERHEATING. REDUCE

THROTTLE. STOP ENGINE AND CHECK

OIL LEVEL.

PADDLE WHEEL IS NOT WORKING

PROPERLY.

Possible Causes

Check for:

1. Low Battery Voltage

2. Open Coil on the Main Power Relay

Check for:

Faulty Sensor

Wiring for Shorts/Opens

Check for:

1. Low Oil Level



Check for:

1. Low Oil Level



Engine oil pressure sensor is not working properly.

Oil Pressure Sensor indicating nearly 5V signal.

Check for:

1. Internally open/shorted Oil Pressure Sensor

2. Open/Shorted Oil Pressure Sensor wiring

3. Faulty PCM

Engine oil pressure sensor is not working properly.

Oil Pressure Sensor indicating nearly 0V signal.

Check for:

1. Internally open/shorted Oil Pressure Sensor

2. Open/Shorted Oil Pressure Sensor wiring

3. Faulty PCM

Check for:

1. Opens in Wiring

2. Internal Open in Temperature Sensor

Check for:

1. Shorts in Wiring

2. Internal Short in Temperature Sensor

Check for:

1. Low Oil Level

2. Insufficient Water (Coolant) Flow

PITOT PRESSURE SENSOR CIRCUIT

SHORTED

PITOT PRESSURE SENSOR CIRCUIT

OPEN

Pitot sensor is not working properly.

Check for:

1. Internally open/shorted Pitot Pressure Sensor

2. Open/Shorted Pitot Pressure Sensor wiring

3. Faulty PCM

Pitot sensor is not working properly.

Check for:

1. Internally open/shorted Pitot Pressure Sensor

2. Open/Shorted Pitot Pressure Sensor wiring

3. Faulty PCM

COOLANT TEMPERATURE SENSOR IS

NOT WORKING PROPERLY.

COOLANT TEMPERATURE SENSOR IS

NOT WORKING PROPERLY.

TRIM TAB SENSOR IS NOT WORKING

PROPERLY.


PROPERLY.

TAB DOWN CONTROLLER IS NOT

WORKING PROPERLY.

TAB UP CONTROLLER IS NOT WORK-

ING PROPERLY.

Type

NONE

NONE

VARYING HORN

VARYING HORN

NONE

NONE

NONE

NONE

Application

100%

100%

90%

90%

100%

100%

100%

100%


55



D

Fault

Codes

Mercury/Mercruiser

Code #

101

102

103

104

105

106

107

108

109

110

111

Fault Text

CAN CIRCUIT FAULT 1

CAN CIRCUIT FAULT 2

CAN CIRCUIT FAULT 3

LAKE/SEA TEMP

CIRCUIT HIGH

LAKE/SEA TEMP

CIRCUIT LOW

SHIFT ACTUATOR

DRIVER OVERTEMP

SHIFT ACTUATOR

SENSOR CIRCUIT HIGH

SHIFT ACTUATOR

SENSOR CIRCUIT LOW

SHIFT ACTUATOR NO

ADAPT

SHIFT POSITION

SWITCH FAULT

ECT CIRCUIT HIGH

O/B ONLY STARBOARD

HEAD TEMP CIRCUIT

IS HIGH


1. CAN COMMUNICATION FAULT 1

2. PCM AND COMMAND MODULE

CANNOT COMMUNICATE OVER CAN

X CIRCUIT

1. CAN COMMUNICATION FAULT

2. TROLL CONTROL DATA MISSING

CAN COMMUNICATION FAULT 3

CANNOT COMMUNICATE OVER CAN

P CIRCUIT

BOAT MOUNTED WATER TEMPERATURE

SENSOR CIRCUIT OPEN

BOAT MOUNTED WATER TEMPERATURE

SENSOR CIRCUIT SHORTED

SHIFT ACTUATOR DRIVER (WITHIN

PCM) TEMPERATURE HIGH

SHIFT POSITION SENSOR CIRCUIT

HIGH (INDICATING 5V TO PCM)

SHIFT POSITION SENSOR CIRCUIT LOW

ACTUATOR STALLED BUT NOT WITHIN

A VALID RANGE

SWITCH INDICATES NEUTRAL AT HIGH

SPEED AND HIGH LOADS

ESC SENSOR DOES NOT AGREE

ENGINE COOLANT TEMPERATURE

SENSOR CIRCUIT OPEN

Possible Causes

PCM and Command Module are not communicating properly over the CAN X Circuit.

Check for:

1. Correct termination

2. Command Module and PCM are using

compatible calibrations

3. Open/Short in yellow/brown leads of main CANBus.

4. Faulty PCM or Command Module

NOTE: Substitute known good 14-pin CAN harness and recheck for faults.

Troll Control Data is missing

Check for:

1. PCM and Command Module software

mismatch.

2. Open/Short in CAN 3 System

PCM and Command Module are not communicating properly over the CAN P Circuit.

Check for:

1. Correct termination

2. Command Module and PCM are using

compatible calibrations

3. Open/Short in blue/white leads of main CANBus.

4. Faulty PCM or Command Module

NOTE: Substitute known good 14-pin CAN harness and recheck for faults.

Check for:

1. Open/Short in Wiring

2. Open/Short in Temperature Sensor

Check for:


2. Open/Short in Temperature Sensor

Check for:


2. Faulty Shift Actuator

3. Binding Linkage

Check for:


2. Open/Short in Shift Position Sensor

3. Faulty PCM

Shift actuator is not working properly.

ESC Sensor indicating a near 0V signal.

Check for:

1. Internally shorted/open ESC sensor

2. Open/Shorted ESC Sensor wiring

3. Faulty PCM

NOTE: If sensor is faulty, you must replace the entire ESC.

Check for:

1. Linkage for Wear and Binding

2. Faulty Shift Actuator

Shift switch is not working properly.

Switch indicates either near 0V or 5V depending on the switch position.

Fault is set if ESC Sensor signal disagrees with the switch signal.

Switch plunger should be depressed when the ESC is in neutral.

Check for:

1. Misadjusted switch

2. Sticking switch

3. Open/Shorted Switch

4. Open/Shorted Switch wiring

Coolant temperature sensor is not working properly.

ECT signal indicating a near 5V signal.

Check for:

1. Internally Open/Shorted Sensor (Check

Resistance Value)

2. Open/Shorted Sensor wiring

3. Faulty PCM

Type

CONSTANT BEEP

VARYING HORN

VARYING HORN

NONE

NONE

CONSTANT BEEP

VARYING HORN

VARYING HORN

NONE

CONSTANT BEEP

VARYING HORN

Application

90%

90%

90%

100%

100%

100%

90%

90%

100%

5%

90%


56

Fault

Codes



D

Fault

Codes

Mercury/Mercruiser

Code #

112

113

114

115

116

117

118

119

120

121

122

123

124

125

126

Fault Text

ECT CIRCUIT LOW

O/B ONLY STARBOARD

HEAD TEMP CIRCUIT

IS LOW

STARBOARD TAB

CIRCUIT HIGH

STARBOARD TAB

CIRCUIT LOW

STARBOARD TAB

DOWN SOLENOID

OUTPUT

STARBOARD TAB UP

SOLENOID OUTPUT

START SOLENOID

OUTPUT

STEERING POSITION

CIRCUIT HIGH

STEERING POSITION

CIRCUIT LOW

TPS 1 CIRCUIT HIGH

TPS 1 CIRCUIT LOW

TPS 1 RANGE HIGH

TPS 1 RANGE LOW

TPS 1 NO ADAPT

TPS 2 CIRCUIT HIGH

TPS 2 CIRCUIT LOW




Possible Causes

Coolant temperature sensor is not working properly.

ECT signal indicating a near 0V signal.

Check for:

1. Internally Open/Shorted Sensor (Check

Resistance Value)

2. Open/Shorted Sensor wiring

3. Faulty PCM


PROPERLY.


PROPERLY.

TAB DOWN CONTROLLER IS NOT

WORKING PROPERLY.

TAB UP CONTROLLER IS NOT

WORKING PROPERLY.

OPEN CIRCUIT TO OR INSUFFICIENT

CURRENT DRAW ON START RELAY.

STEERING SENSOR CIRCUIT SHORTED

STEERING SENSOR CIRCUIT OPEN

TPI SENSOR CIRCUIT SHORTED

TPI SENSOR CIRCUIT OPEN

TPI ABOVE THE NORMAL EXPECTED

RANGE

TPI BELOW THE NORMAL EXPECTED

RANGE

TPS 1 SENSOR FAILED TO ADAPT;

OUTSIDE NORMAL OPERATING RANGE

THROTTLE PLATE NOT IN IDLE

POSITION WHEN EXITING CRANK ON

WAY TO RUN

TPI SENSOR CIRCUIT IS SHORTED

TPI SENSOR CIRCUIT IS OPEN

Engine may not start. The starter solenoid is not working properly.

Possible open/short circuit in relay control circuit.

Check for:

1. Yellow/Black lead between PCM and Starter

Relay for short/open circuit.

2. Relay windings (pins 85 & 86) for open/short

circuit.

3. Battery voltage to relay control circuit (pin 85 or 86

battery voltage should be found on one of these).

Steering angle sensor is not working properly.

Check for:

1. Internally Open/Shorted Sensor

2. Open/Shorted Sensor Wiring

3. Faulty PCM

Steering angle sensor is not working properly.

Check for:



3. Faulty PCM

Check for:


2. Open/Short in Throttle Position Sensor

3. Faulty PCM

Check for:


2. Open/Short in Throttle Position Sensor

3. Faulty PCM

Check for:

1. Faulty Sensors inside of ETC

Check for:


Throttle positioning sensor was reading outside window specified for adaptation to occur as key was turned on.

Throttle plate is not in idle position at key up.

Check for:

1. Misadjusted throttle body stop screw.

Throttle positioning sensor is not working properly.

Check for:



3. Faulty PCM


Check for:



3. Faulty PCM

Type

NONE

NONE

NONE

NONE

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

Application

100%

100%

100%

100%

90%

90%

90%

90%

100%

90%

90%


57



D

Fault

Codes

Mercury/Mercruiser

Code #

127

128

129

130

131

132

133

134

135

136

137

138

148

149

150

Fault Text

TPS 2 RANGE HIGH

TPS 2 RANGE LOW

TPS 2 NO ADAPT

TRIM SENSOR CIRCUIT

HIGH

TRIM SENSOR CIRCUIT

LOW

CRANK POSITION SEN-

SOR FAULT

POWER 1 VOLTS

(5VDC) LOW

ABUSIVE OVERSPEED-

STAGE 1

ABUSIVE OVERSPEED-

STAGE 2

BOOST BYPASS VALVE

CIRCUIT HIGH

BOOST BYPASS VALVE

CIRCUIT LOW

ECM MEMORY FAULT

ESC AND NEUTRAL

SWITCH POSITION

FAULT

ETC IDLE RANGE

FAULT

MULTIPLE CAN

COMM. FAULTS


TPI ABOVE THE NORMAL EXPECTED

RANGE

TPI BELOW THE NORMAL EXPECTED

RANGE

TPS 2 SENSOR FAILED TO ADAPT

DURING ENGINE SHUT DOWN

TRIM SENSOR CIRCUIT SHORTED

TRIM SENSOR CIRCUIT OPEN

VARIABLE RELUCTANCE SENSOR

(CRANK POSITION SENSOR)

ALL ENGINE SENSORS (+5V) POWER

SUPPLY LOW

LEVEL 1 OF OVERSPEED EXCEEDED

LEVEL 2 OF OVERSPEED EXCEEDED

Possible Causes

Check for:


Check for:



TPS 2 did not indicate the throttle plate moved to the specified closed position during the engine shut down process.

Trim position sensor is not working properly.

Check for:



3. Faulty PCM

Trim position sensor is not working properly.

Check for:



3. Faulty PCM

Check for:

1. Faulty Crankshaft Position Sensor

2. Noise on Crankshaft Position Sensor Circuit

3. Open/Shorts in Wiring

NOTE: Engine will not run with this fault.

Check for:

1. Excessive Current Draw on the +5V DC Circuit

2. Circuit or Sensor Shorted to Ground

Check for:

1. Undersized Propeller

2. Excessive Trim Up

3. Excessive Vent in Prop

4. Excessive Throttle in Neutral Position

5. Broken Drive

Excessive engine speed in Neutral

Neutral RPM limit set at 3500 RPM

Check for:

1. Undersized Propeller

2. Excessive Trim Up

3. Excessive Vent in Prop

4. Excessive Throttle in Neutral Position

5. Broken Drive

BOOST BYPASS VALVE IS NOT

WORKING PROPERLY.

BOOST BYPASS VALVE IS NOT

WORKING PROPERLY.

ECM MEMORY IS CORRUPTED

ESC SENSORS AND NEUTRAL SWITCH

POSITION DO NOT AGREE

ETC OUT OF RANGE FOR IDLE

POSITION

COMMUNICATION BETWEEN SYSTEM

VIEW AND PCM HAS BEEN LOST

DISCREPANCY BETWEEN CAN 1 (X)

AND CAN 2 (P)

Check for:

1. Faulty ECM

Shift Controller is not working properly.

Check for:

1. Faulty Harness Connection to Neutral Switch

2. Faulty Neutral Switch

3. Neutral Switch for Correct Open/Close

Operation; If Neutral Switch Operates as

Designed, Check ESC Sensor Circuit

Check for:


2. Debris in ETC

3. Faulty ETC

4. Air leak in Induction System

There is no communication between the

Command Module and PCM.

Check for:

1. Open/Short in CAN 1 (X) and CAN 2 (P)

2. Lost Terminator Connection

Type

VARYING HORN

VARYING HORN

VARYING HORN

NONE

NONE

VARYING HORN

VARYING HORN

CONSTANT BEEP

CONSTANT BEEP

CONSTANT BEEP

CONSTANT BEEP

CONSTANT BEEP

CONSTANT BEEP

Application

90%

90%

100%

100%

100%

90%

100%

100%

5%

5%

5%

100%

5%


58

Fault

Codes



D

Fault

Codes

Mercury/Mercruiser

Code #

151

152

153

154

155

156

157

158

159

160

163

173

174

175

176

Fault Text

FUEL PUMP RELAY

CIRCUIT

IAC OUTPUT

DRIVE LUBE BOTTLE

LOW

(MAF) MASS AIR FLOW

TOO HIGH

SECONDARY MAP

SENSOR CIRCUIT HIGH

SECONDARY MAP

SENSOR CIRCUIT LOW

SECONDARY MAP

SENSOR IDLE FAULT

PORT EMCT CIRCUIT

HIGH

PORT EMCT CIRCUIT

LOW

PORT EMCT OVERHEAT

CAN COMM. FAULT

TYPE 5


OPEN CIRCUIT IN FUEL PUMP

RELAY CIRCUIT

IAC MOTOR OPEN CIRCUIT. IF ENGINE

DOES NOT START, TRY SLIGHTLY OPEN-

ING THROTTLE VALVE TO START.

DRIVE LUBE SWITCH ACTIVATED.

CONTINUED OPERATION MAY CAUSE

DAMAGE.

Possible Causes

Fuel pump is not working properly.

Check for:

1. Faulty Fuel Pump Relay

2. Open/Short Relay Control Circuit (pins 85 & 86)

3. Battery voltage on either pin 85 or 86 of relay circuit

Check for:


2. Connector Problem

3. Faulty IAC Motor

Check for:

1. Low Drive Lube

2. Drive Lube Leak

3. Faulty Low Gear Lube Switch or Float

4. Transmission Temperature High


MASS AIR FLOW CALCULATION IS

ABOVE LIMIT.

SECONDARY MANIFOLD PRESSURE

SENSOR IS NOT WORKING PROPERLY.

SECONDARY MANIFOLD PRESSURE


ENGINE IS RECEIVING TOO MUCH AIR

AT IDLE.

PORT EXHAUST MANIFOLD COOLANT

SENSOR CIRCUIT OPEN

PORT EXHAUST MANIFOLD COOLANT


PORT EXHAUST MANIFOLD

OVERHEATING

Check for:

1. Manifold Vacuum Leak

Port exhaust manifold coolant temperature sensor is not working properly.

Check for:

1. Internally open/shorted EMCT Sensor

2. Open/Shorted EMCT Sensor Wiring

3. Faulty PCM

Port exhaust manifold coolant temperature sensor is not working properly.

Check for:



3. Faulty PCM

Port exhaust manifold temperature is too High

Verify the temperature reading from the EMCT

Sensor

Check for:

1. Faulty or worn water pump

2. Clogged cooler or strainer.

3. Manifold for restriction (sediment or corrosion)

THERE IS A COMMUNICATION

PROBLEM WITH THE SMARTCRAFT

CONTROL SYSTEM

Check for:

1. Open/Short in CAN system

FUEL PRESSURE DELTA

HIGH

FUEL PRESSURE IS HIGH

FUEL PRESSURE DELTA

LOW

FUEL PRESSURE IS LOW

Check for:

1. Proper amount of fuel in fuel tank.

2. Extreme fuel leak

3. Fuel lines disconnected.

4. Faulty Fuel Pump

KNOCK SYSTEM FAULT

ENGINE KNOCK SYSTEM IS NOT

FUNCTIONING. AVOID RUNNING

ENGINE AT MAX RPM

ESC/ERC POSITION

DIFFERENCE

ESC ACTUATORS ACTUAL POSITION

AND COMMANDED POSITION DO

NOT AGREE

A shift fault has occurred.

ERC shift position and actual gear position do not agree.

The remote control is in one gear while the PCM thinks the engine is in a different gear.

Check for:

1. Worn Linkage

2. Faulty ESC

3. Faulty ERC

Type

VARYING HORN

VARYING HORN

CONSTANT BEEP

VARYING HORN

VARYING HORN

CONSTANT BEEP

CONSTANT BEEP

CONSTANT BEEP

Application

90%

90%

100%

90%

90%

VARIES

3%

5%


59



D

Fault

Codes

Mercury/Mercruiser

Code #

177

178

179

180

181

182

183

184

185

186

187

188

189

190

Fault Text

STARBOARD EMCT

CIRCUIT HIGH

STARBOARD EMCT

CIRCUIT LOW

STARBOARD EMCT

OVERHEAT

MAP/TPI DIFFERENCE

FAULT

TPI SENSORS (ALL)

TPS 1 DIFFERENCE

FAULT

TPS 2 DIFFERENCE

FAULT

TRIM DOWN RELAY

OUTPUT

TRIM UP RELAY

OUTPUT

CAN COMM. FAULT

TYPE 7

CAN COMM. FAULT

TYPE 8

PRIMARY DEMAND TO

REDUNDANT DIFF

DEMAND CROSS

CHECK DIFFERENCE

SHIFT CROSS CHECK

DIFFERENCE


STARBOARD EXHAUST MANIFOLD

COOLANT TEMPERATURE CIRCUIT

OPEN


COOLANT TEMPERATURE CIRCUIT

SHORTED


OVERHEATING

BOTH TPI ‘S ARE FUNCTIONING BUT

MAP SENSOR CALCULATIONS DONT

AGREE

MAP DOES NOT AGREE WITH EITHER

TPI. POWER OFF THE ETC

MAP SENSOR RANGE EQUAL TO TPI2,

BUT TPI1 DOES NOT AGREE

MAP SENSOR RANGE EQUAL TO TPI1,

BUT TPI2 DOES NOT AGREE

FAULTY TRIM DOWN CIRCUIT

FAULTY TRIM UP CIRCUIT

TRIM CONTROL DATA MISSING

Possible Causes

Starboard exhaust manifold coolant temperature sensor is not working properly.

Check for:



3. Faulty PCM

Starboard exhaust manifold coolant temperature sensor is not working properly.

Check for:



3. Faulty PCM

Starboard exhaust manifold temperature is too High

Verify the temperature reading from the EMCT

Sensor

Check for:

1. Faulty or worn water pump

2. Clogged cooler or strainer.

3. Manifold for restriction (sediment or corrosion)

Check for:

1. MAP Sensor out of operating range

2. Faulty MAP Sensor

3. Abnormal Airflow in Intake Manifold

Check for:

1. Open/Short in ETC Wiring

2. Open/Short in Sensors

Check for:



Check for:



Engine may not trim up. The trim up relay is not working properly.

Check for:

1. Faulty trim relay

2. Open/Shorted Trim Relay Circuit

NOTE: Try switching the UP/Down Relays to see if problem moves to other circuit.

Engine may not trim up. The trim up relay is not working properly.

Check for:

1. Faulty trim relay

2. Open/Shorted Trim Relay Circuit

NOTE: Try switching the UP/Down Relays to see if problem moves to other circuit.

Trim Control Data Missing.

Check:

1. CANBus wiring

THERE IS A COMMUNICATION

PROBLEM WITH THE SMARTCRAFT

CONTROL SYSTEM

CROSS CHECK FAILURE-- CAN1 NOT

EQUAL TO CAN2

COMMAND MODULE NOT EQUAL

TO PCM CROSS CHECK OF DEMAND

VALUE

COMMAND MODULE NOT EQUAL TO

PCM CROSS CHECK OF SHIFT POSI-

TION

Check for:

1. Open/Short in CAN System

Check for:

1. Faulty Pots in ERC

Check for:

1. Incorrect Positions used when Configuring

Levers at Command Module

2. Faulty Command Module

3. Faulty ECM

NOTE: Refer to DTS Manual for Further Information

Check for:

1. Incorrect Positions used when Configuring

Levers at Command Module


3. Faulty ECM

NOTE: Refer to DTS Manual for Further Information

Type

VARYING HORN

VARYING HORN

CONSTANT BEEP

CONSTANT BEEP

CONSTANT BEEP

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

CONSTANT BEEP

CONSTANT BEEP

CONSTANT BEEP

Application

90%

90%

VARIES

5%

5%

90%

90%

100%

100%

100%

100%

5%

5%

5%


60

Fault

Codes



D

Fault

Codes

Mercury/Mercruiser

Code #

191

192

193

194

195

196

197

198

199

200

201

202

203

204

205

206

207

Fault Text


HIGH


LOW

SHIFT ANTICIPATE

SWITCH FAULT

ESC TIMEOUT FAULT

THERMOSTAT FAULT

TRANSMISSION

OVERHEAT

SUPERCHARGER TEMP

CIRCUIT HIGH

SUPERCHARGER TEMP

CIRCUIT LOW

SUPERCHARGER

OVERHEAT

BOOST BYPASS VALVE

FAULT

HEAD TEMP CIRCUIT

HIGH

HEAD TEMP CIRCUIT

LOW

HEAD TEMP OVERHEAT

BLOCK TEMP CIRCUIT

HIGH

BLOCK TEMP CIRCUIT

LOW

BLOCK TEMP

OVERHEAT

LIFT PUMP TIMEOUT


SECONDARY BOAT MOUNTED FUEL

TANK SENSOR CIRCUIT OPEN

SECONDARY BOAT MOUNTED FUEL

TANK SENSOR CIRCUIT SHORTED

SHIFT ANTICIPATE (INTERRUPT)

SWITCH ACTIVE AT INCORRECT TIME

SHIFT ACTUATOR CANNOT REACH DE-

SIRED POSITION OR SHIFT ACTUATOR

ARTICULATES BACK AND FORTH WHEN

IT SHOULD BE STEADY

THERMOSTAT FAULT

TRANMISSION TEMPERATURE IS HIGH.

TURN ENGINE OFF AND ALLOW TO

COOL.

Possible Causes

Level sender for tank 2 is not working properly.

Check for:

1. Internally open/shorted Fuel Level Sensor

2. Open/Shorted Fuel Level Sensor Wiring

3. Faulty PCM

Level sender for tank 2 is not working properly.

Check for:

1. Internally open/shorted Fuel Level Sensor

2. Open/Shorted Fuel Level Sensor Wiring

3. Faulty PCM


Alpha shift system problem keeps the shift anticipate switch on.

Switch stays on because the clutch dog has not disengaged.

Fault caused by incorrect shift adjustments or binding in the shift system which keeps the load lever engaged.


Actuator is taking too long to complete shift.

Check for:

1. Correct ESC and shift linkage.

2. Binding from the ESC down into the gearcase.

Check Cooling system components

Transmission is overheating.

Key engine off and allow to cool.

Restart engine.

Check for:

1. Correct fluid level in Transmission Cooler

2. Incorrect shift adjustments

3. Clutch slippage caused by low internal pressures

4. Engine modifications greatly increasing engine

HP and torque

SUPERCHARGER OUTPUT

TEMPERATURE SENSOR IS NOT

WORKING PROPERLY.

SUPERCHARGER OUTPUT

TEMPERATURE SENSOR IS NOT

WORKING PROPERLY.

SUPERCHARGER IS OVERHEATING.

DECREASE THROTTLE AND ALLOW TO

COOL.

BOOST BYPASS VALVE IS NOT WORK-

ING PROPERLY.

ENGINE TEMPERATURE SENSOR IS NOT

WORKING PROPERLY.

ENGINE TEMPERATURE SENSOR IS NOT

WORKING PROPERLY.

ENGINE IS OVERHEATING.

Check for:

1. Cooling Problem

2. Faulty or Worn Water Pump

3. Obstructed inlets or passages

BLOCK TEMPERATURE SENSOR IS NOT

WORKING PROPERLY.

BLOCK TEMPERATURE SENSOR IS NOT

WORKING PROPERLY.

ENGINE IS OVERHEATING.

Check for:

1. Cooling Problem

2. Faulty or Worn Water Pump

3. Obstructed inlets or passages

FUEL LIFT PUMP IS NOT WORKING

PROPERLY.

Type

NONE

NONE

CONSTANT BEEP

VARYING HORN

CONSTANT BEEP

Application

100%

100%

ENGINE DIES

90%

100%


61



D

Fault

Codes

Mercury/Mercruiser

Code #

208

209

210

211

212

213

214

215

216

217

218

219

220

221

222

223

224

Fault Text

LIFT PUMP OUTPUT

ENGINE VOLTAGE

LOW

OVERSPEED IN

NEUTRAL

OVERSPEED IN

REVERSE

SMARTSTART

ABORTED

FUEL IN VENT

CANISTER

BOOST DIAG. CIRCUIT

HIGH AT KEY UP

CAN COMM. FAULT

TYPE 9

CAN COMM. FAULT

TYPE 10

POWER 2 (5VDC) LOW

HELM ADC CHECK

ESC LOSS OF

CONTROL

VENT FLOAT SWITCH

HIGH

LIFT PUMP FLOAT

SWITCH HIGH

LIFT PUMP FLOW LOW

OIL JET PRESSURE LOW

OIL JET CIRCUIT HIGH



PROPERLY.

Possible Causes

SUPPLIES POWER TO ALL DRIVERS +12V

ALLOWABLE OVERSPEED LIMIT IN

NEUTRAL HAS BEEN EXCEEDED

ALLOWABLE OVERSPEED LIMIT IN

REVERSE HAS BEEN EXCEEDED

DTS ENGINE FAILED TO SEE FLYWHEEEL

ROTATION WHEN COMMANDED

TO START. NO RPM DETECTED. NO

STARTER ENGAGEMENT.

FUEL HAS OVERFLOWED INTO THE

VENT SYSTEM.

Check for:

1. Faulty Battery

2. Low Battery


Check for:

1. Faulty Shift Switch

Check for:

1. Faulty Shift Switch

Attempted start was not successful.

If engine cranks but does not start, check for:

1. RPM signal from the crankshaft position sensor

2. Faulty Crankshaft position sensor

3. Open/Shorted Crankshaft Position Sensor wiring

Check for:

1. Fuel Leak

NOTE: Fault may have been caused by multiple restart attempts.

BOOST BYPASS VALVE IS NOT WORK-

ING PROPERLY.

CROSSCHECK DATA MISSING

DUAL ENGINE SYNCHRONIZATION

DATA MISSING

SUPPLIES POWER TO ALL SMARTCRAFT

SENSORS 5V

COMMAND MODULE RELIABILITY

CHECK OR CAN BUS PROBLEM

PCM CANNOT TELL IF ESC IS

RESPONDING TO PCM COMMANDS

FUEL HAS OVERFLOWED INTO THE

VENT SYSTEM.

Crosscheck data missing.

Check:

1. CAN X Wiring

Dual Engine synchronization data missing.

Software compatibility issue between modules.

NOTE: Fault should only trigger on dual engine applications only.

Sensor (Boat/SmartCraft) power supply voltage is low.

Check for:

1. Low Battery Voltage

2. Open/Short Circuit from PCM to sensor circuits

3. Faulty PCM

The Command Moudle Failed a test calculation.

The PCM sends a message to the command module asking to make a calculation. The

Command Module sends a message back and the

PCM compares the message to the correct Answer.

Fault will trigger is the PCM does not recieve the correct message.

Check for:

1. Mismatched software


Return handle to neutral and key engine off. Restart and shift engine.

PCM cannot determine if the ESC is responding to

PCM commands.

Position sensor is not confirming PCM commands.

Check for:

1. Faulty Potentiometers in Shift Actuator

2. Faulty Wiring in Shift Actuator

Check for:

1. Fuel Leak

NOTE: Fault may have been caused by multiple restart attempts.

LIFT PUMP FLOAT SWITCH IS NOT

WORKING PROPERLY


PROPERLY.

PISTON COOLING OIL JET PRESSURE

IS LOW



Type

N/A

CONSTANT BEEP

CONSTANT BEEP

VARYING HORN

VARYING HORN

VARYING HORN

VARYING HORN

CONSTANT BEEP

VARYING HORN

Application

N/A

100%

100%

100%

100%

100%

100%

5%

5%


62

Fault

Codes



D

Fault

Codes

Mercury/Mercruiser

Code #

225

226

227

228

229

230

231

232

233

234

235

236

237

238

239

Fault Text

OIL JET CIRCUIT LOW




Possible Causes

CAN COMM. FAULT

TYPE 11

CAN BUS Communication problem on the CAN system

HYDRAULIC SHIFT

PRESSURE SENSOR A

HYDRAULIC SHIFT

PRESSURE SENSOR A

HYDRAULIC SHIFT

PRESSURE SENSOR A

HYDRAULIC SHIFT

PRESSURE SENSOR B

HYDRAULIC SHIFT

PRESSURE SENSOR B

HYDRAULIC SHIFT

PRESSURE SENSOR B

HYDRAULIC SHIFT

SYSTEM FAULT

HYDRAULIC SHIFT

SYSTEM PRESSURE

TOO HIGH

HYDRAULIC SHIFT

SYSTEM POSITION

FAULT

EMERGENCY STOP

ACTIVATED

EXCESSIVE KNOCK

DETECTED

OVERSPEED IN TRAILER

MODE

UNDERWATER IMPACT

PRESSURE SENSOR A OPEN

PCM CANNOT DETERMINE STATE OF

TRANSMISSION

PRESSURE SENSOR A SHORTED


TRANSMISSION

TRANSMISSION PRESSURE HIGHER OR

LOWER THAN EXPECTED AT SPECIFIC

RPM

PRESSURE SENSOR B OPEN


TRANSMISSION

PRESSURE SENSOR B SHORTED


TRANSMISSION

PRESSURE SENSOR B CANNOT

DETERMINE STATE OF TRANSMISSION

BOTH PRESSURE SENSOR INDICATE

TRANSMISSION IS IN-GEAR

Shift pressure sensor is not working properly.

Check for:

1. Internally open/shorted Transmission Pressure

Sensor

2. Open/Shorted Transmission Pressure Sensor

Wiring

3. Faulty PCM


Check for:


Sensor


Wiring

3. Faulty PCM


Transmission pressure is higher or lower than expected at specific RPM when fault was triggered.


Check for:


Sensor


Wiring

3. Faulty PCM


Check for:


Sensor


Wiring

3. Faulty PCM


Transmission pressure is higher or lower than expected at specific RPM when fault was triggered.

Shift system is not working properly.

PCM cannot determine gear position.

Check:

1. Transmission pressure sensors

PRESSURE SENSORS INDICATE THAT

THE TRANSMISSION FLUID PRESSURE IS

TOO HIGH

Shift pressure is high.

PRESSURE SENSORS INDICATE THAT

THE SOLENOID THAT IS BEING

ACTIVATED IS INCORRECT

EMERGENCY STOP PERFORMED

Shift fault has occurred. Return the handle to neutral and retry shift command.

ERC Control Handle is in one gear, while the PCM senses the engine is in a different gear (from transmission pressure sensor readings).

Emergency stop has been activated.

Check:

1. Emergency Stop Lanyard has not been removed

2. Black/Yellow wire for shorts to ground (Helm

to Engine)

Engine power is limited due to knock system.

Reduce throttle demand.

EXCESSIVE KNOCK DETECTED -

ENGINE POWER LIMITED

ENGINE RPM IS ABOVE SPECIFIED

LIMITS IN TRAILER POSITION.

UNDERWATER IMPACT HAS OC-

CURRED. INSPECT ENGINE FOR

DAMAGE.

Type

CONSTANT BEEP

NONE

NONE

CONSTANT BEEP

NONE

NONE

CONSTANT BEEP

CONSTANT BEEP

CONSTANT BEEP

CONSTANT BEEP

VARYING HORN

Application

5%

100%

100%

100%

100%

100%

100%

100%

5%

5%

100%


63



D

Fault

Codes

Mercury/Mercruiser

Code #

240

241

242

243

244

245

246

247

248

249

Fault Text

LOW BATTERY

MANIFOLD AIR TEMP

OVERHEAT

FUEL VENT PURGE

VALVE

CENTER TAB CIRCUIT

HIGH

CENTER TAB CIRCUIT

LOW

SHIFT SWITCH 2 FAULT

BOOST LIMIT DUE TO

SC TEMP

BOOST LIMIT DUE TO

KNOCK

THROTTLE LIMIT DUE

TO SC BOOST

THROTTLE LIMIT DUE

TO KNOCK


BATTERY VOLTAGE IS BELOW

ALLOWABLE LIMIT.

TURN OFF UNCESSESSARY LOADS AND

INCREASE RPM.

CHARGE AIR TEMPERATURE IS ABOVE

SPECIFIED LIMITS. REDUCE THROTTLE

DEMAND.

FUEL PURGE VALVE IS NOT WORKING

PROPERLY.


PROPERLY.


PROPERLY.

SHIFT SWITCH IS NOT WORKING

PROPERLY.

ENGINE POWER IS LIMITED DUE TO

SUPERCHARGER OVERHEAT

ENGINE POWER IS LIMITED DUE TO

KNOCK SYSTEM

THROTTLE BLADE IS LIMITED DUE TO

SUPERCHARGER BOOST VALVE

THROTTLE BLADE IS LIMITED DUE TO

KNOCK SYSTEM

Possible Causes Type Application

64


Fault

Codes



E

SPECIAL

FUNCTIONS

Mercury

Outboards


65

®


4 MEFI

MEFI OPERATING MANUAL

Contents

C

D

A

B

E

APPLICATIONS



FAULT CODES


66



4 mefia

MEFI

APPLICATIONS

Crusader


Equipped

Flagship Marine

GM MEFI-1 thru MEFI-4 equipped

1992 → 2006

1992 → 2006

GM MEFI-5, MEFI-6 Equipped 2006 → UP

GM RamJet Crate Engines

GM MEFI-1 thru MEFI-4 equipped

2000 → UP

Indmar

GM MEFI-1 thru MEFI-4 1992 → 2007

GM MEFI 5, MEFI-6 Equipped

Kodiak Marine


2007 → UP

1992 → 2008

2008 → UP GM MEFI-5

Panther Air Boats

GM MEFI-1 thru MEFI-4 2000 → 2007

2008 → UP GM MEFI-5

PleasureCraft Marine


Equipped

Volvo Penta


Equipped

1992 → 2006

1992 → 2005

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

Sp.

Func.

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

ADC300 + ADC424

ADC300 + ADC424

ADC300 + ADC425

ADC300 + ADC424

ADC300 + ADC424

ADC300 + ADC425

ADC300 + ADC424

ADC300 + ADC425

ADC300 + ADC424

ADC300 + ADC425

ADC300 + ADC424

ADC300 + ADC424

A

A

A

A

A

A

A

A

A

A

A

A


67

®


4 mefi-

B

MEFI Diagnostic Socket

MEFI I-IV


SIDE VIEW

MEFI V & VI

FRONT VIEW


68



4 mefi-

C


MEFI I-IV


Displays basic engine information such as Size, Model, etc. ECU IDENTIFICATION is available to be saved and stored to be viewed later on a PC to build a custom made diagnostic printout.


Displays a list of diagnostic trouble codes currently active on the engine. Each fault code needs to be investigated and corrected. Once the faults have been corrected, then the CLEAR FAULT CODES function should be used to clear the engines fault code memory. All FAULT CODES and FREEZE FRAME DATA are available to be saved and stored to be viewed later on a PC to build a custom made diagnostic printout.



LIVE DATA








1. Command off individual cylinders to isolate a running concern (Power Balance, MEFI IV CONTROLLER ONLY).




1. Set Base Timing

ENGINE HOURS

This function displays the overall engine running hours. All ENGINE HOURS are available to be saved and stored to be viewed later on a PC to build a custom made diagnostic printout.



69

®


4 mefi-

C


MEFI V-VI


Displays basic engine information such as Size Engine, Type of MEFI controller, etc. ECU IDENTIFICATION is available to be saved and stored to be viewed later on a PC to build a custom made diagnostic printout.


Displays a list of diagnostic trouble codes currently active and history on the engine. Each current fault code needs to be investigated and corrected. History codes will clear after 40 continuous warm up cycles. Freeze Frame data will also be displayed on the next screen by pressing the ENTER key. Once the faults have been corrected, then the CLEAR FAULT CODES function should be used to clear the engines fault code memory. All FAULT CODES and FREEZE FRAME DATA are available to be saved and stored to be viewed later on a PC to build a custom made diagnostic printout.



NOTE: When clearing DTCs with the scan tool, the ignition must be cycled OFF or the DTCs will not clear.

LIVE DATA

This function displays a list of LIVE DATA parameters and values from the engine ECU. This data list is what is available from the engine ECU, and each value will change as the engine components are operated. Please refer to vehicle manufacturers data for correct values and correct operating limits. Due to the large amount of parameters available on MEFI V and VI controllers, several

Live Data displays are available for view to narrow down the parameters viewed, such as EGR data. This will only show parameters pertaining to the EGR system. All LIVE DATA is available to be saved and stored to be viewed later on a PC to build a custom made diagnostic printout.


This option allows you to:

1. Trans Shift Override Function

2. Command fuel pump ON

3. Test Alarm Functions (Lamps, Buzzers)



1. Command off individual fuel injectors to isolate a running concern (Power Balance).


3. Test Alarm Functions (Lamps, Buzzers)

4. Idle Speed Override Test (Raise/Lower Idle RPM)

5. Perform O2 Heater Test

6. Perform Boost Override Function

ENGINE HOURS




70


4 mefi-

D

FAULT CODES

MEFI I DIAGNOSTIC TROUBLE CODE LIST

41

42

43

23

24

33

44

45

51

CODE NUMBER DTC DESCRIPTION

12 SYSTEM NORMAL

13

14

21

OXYGEN SENSOR CIRCUIT

COOLANT TEMPERATURE SENSOR

THROTTLE POSITION SENSOR

MANIFOLD AIR TEMPERATURE SENSOR

SPEED SENSOR CIRCUIT

MAP SENSOR

TRIM SENSOR

IC OR BYPASS CIRCUIT

KNOCK SENSOR

OXYGEN SENSOR

OXYGEN SENSOR

ECM CALIBRATION MEMORY CHECKSUM

FAILURE DESCRIPTION

NO FAULT DETECTED

MALFUNCTION

MALFUNCTION

MALFUNCTION

MALFUNCTION

MALFUNCTION

MALFUNCTION

MALFUNCTION

MALFUNCTION

CONTINUOUS KNOCK DETECTED

LEAN

RICH

FAULT

MEFI II DIAGNOSTIC TROUBLE CODE LIST

42

43

44

51

52

33

34

41

23

24

25

15

21

22


13 COOLANT TEMPERATURE SENSOR (ECT)

14 COOLANT TEMPERATURE SENSOR (ECT)

COOLANT TEMPERATURE SENSOR (ECT)

THROTTLE POSITION SENSOR (TPS)


MANIFOLD TEMPERATURE SENSOR (IAT)



MANIFOLD PRESSURE SENSOR (MAP)


EST SYSTEM (IGNITION CONTROL)

EST SYSTEM (IGNITION CONTROL)

KNOCK SENSOR

KNOCK SENSOR


INTERNAL EEPROM


VOLTAGE HIGH

VOLTAGE LOW

VOLTAGE HIGH

VOLTAGE HIGH

VOLTAGE LOW

VOLTAGE HIGH

MALFUNCTION

VOLTAGE LOW

VOLTAGE HIGH

VOLTAGE LOW

OPEN CIRCUIT

SHORT CIRCUIT


NO KNOCK DETECTED

FAILURE

FAILURE


71

®


4 mefi-

D

FAULT CODES

MEFI III DIAGNOSTIC TROUBLE CODE LIST

61

62

65

45

51

54

55

42

43

44

33

34

41

25

31

32

22

23

24


13 OXYGEN SENSOR CIRCUIT

14

15

21

COOLANT SENSOR (ECT)







GOVERNOR NOT TRACKING

EGR VALVE NOT TRACKING



IGNITION CONTROL

IGNITION CONTROL

KNOCK SENSOR

KNOCK SENSOR

COIL DRIVER


OXYGEN SENSOR

OXYGEN SENSOR

FUEL PRESSURE SENSOR


EEPROM


MALFUNCTION

VOLTAGE LOW

VOLTAGE HIGH

VOLTAGE HIGH

VOLTAGE LOW

LOW TEMPERATURE DETECTED

MALFUNCTION

HIGH TEMPERATURE DETECTED

NULL

NULL

SIGNAL VOLTAGE HIGH

SIGNAL VOLTAGE LOW

OPEN CIRCUIT

SHORT CIRCUIT

NULL

NULL

FAULT

FAULT

LEAN

RICH

VOLTAGE HIGH

VOLTAGE LOW

FAILURE

72



4 mefi-

D

FAULT CODES

MEFI IV DIAGNOSTIC TROUBLE CODE LIST

81

81

81

81

81

54

54

55

55

61

44

51

52

34

41

42

43

44

31

32

33

81

81

81

81

62

63

64

81

81


13

13

14

15

21

21

22

23

24

25

OXYGEN SENSOR 1

OXYGEN SENSOR 2






MANIFOLD TEMPERATURE SENSOR (IAT) LOW

TEMPERATURE INDICATED

SPEED SENSOR

MANIFOLD TEMPERATURE SENSOR (IAT) HIGH

TEMPERATURE INDICATED

GOVERNOR

EGR VALVE



IGNITION CONTROL

IGNITION CONTROL

KNOCK SENSOR

KNOCK 1

KNOCK 2


ECM EEPROM

OXYGEN SENSOR 1

OXYGEN SENSOR 2

OXYGEN SENSOR 1

OXYGEN SENSOR 2



FUEL TEMPERATURE SENSOR

FUEL TEMPERATURE SENSOR

CRANK SIGNAL

CRANK SYNC

CAM SIGNAL

THROTTLE ACTUATOR CONTROL TAC

FUEL PUMP

PUMP

INJECTOR A

INJECTOR A

INJECTOR B

INJECTOR B

RECIRCULATION J1 32


INACTIVE

INACTIVE

VOLTAGE HIGH

VOLTAGE LOW

VOLTAGE HIGH

SKEWED HIGH

VOLTAGE LOW

VOLTAGE HIGH

MALFUNCTION

VOLTAGE LOW

NOT TRACKING

NOT TRACKING

VOLTAGE HIGH

VOLTAGE LOW

OPEN CIRCUIT

SHORT CIRCUIT


NO KNOCK DETECTED

NO KNOCK DETECTED

FAILURE

FAILURE

LEAN

LEAN

RICH

RICH

VOLTAGE HIGH

VOLTAGE LOW

HIGH

LOW

FAULT

FAULT

FAULT

MALFUNCTION

OPEN

LOW OPEN

HIGH

LOW OPEN

HIGH

LOW OPEN

NULL


73

®


4 mefi-

D

FAULT CODES

MEFI IV DIAGNOSTIC TROUBLE CODE LIST (cont.)

41

41

41

41

41

41

41

41

81

81

81

81

81

81

81

81

41

41

41

41

41

41

41

41

81

81

81

81

81

81

81

81

81

81

81

81

81


81 5 VOLT REFERENCE

81 DEPSPWR RANGE

CAN COMMUNICATION BUS

OIL CAT

OIL CAT

TAC FAULT

TAC FAULT

TAC FAULT

TAC FAULT

TAC FAULT

TAC FAULT

TAC FAULT

TAC FAULT

TAC FAULT

TAC FAULT

TAC FAULT

TAC FAULT

TAC FAULT

TAC FAULT

TAC FAULT

TAC FAULT

TAC FAULT

TAC FAULT

EST FAULT

EST FAULT

EST FAULT

EST FAULT

EST FAULT

EST FAULT

EST FAULT

EST FAULT

ENGINE OVER TEMPERATURE

LOW OIL PRESSURE

LOW SYSTEM VOLTAGE

LOW OIL LEVEL

GENERAL WARNING 1

GENERAL WARNING 2

LOW FUEL PRESSURE

ENGINE SHUTDOWN


MALFUNCTION

NULL

FAULT

HIGH

LOW

TPS2 RANGE

TPS1 RANGE

PPS3 RANGE

PPS2 RANGE

PPS1 RANGE

BAD CHECKSUM

NO TAC REPLY

BUS CONTENTION

SERIAL COMMUNICATION FAULT

TPS12 CORR

PPS23 CORR

PPS13 CORR

PPS12 CORR

LMTD AUTHORITY

ACUATION FAULT

PROCESS FAULT

NOT TRACKING

THROTTLE RETURN FAULT

EST H FAULT

EST G FAULT

EST F FAULT

EST E FAULT

EST D FAULT

EST C FAULT

EST B FAULT

EST A FAULT

TELLTALE SET

TELLTALE SET

TELLTALE SET

TELLTALE SET

TELLTALE SET

TELLTALE SET

TELLTALE SET

TELLTALE SET


74


4 mefi-

D

MEFI V-VI DIAGNOSTIC TROUBLE CODE LIST

113

620

627

628

629

630

636

168

174

175

515

FMI

5

6

7

3

4

0

1

2

8

9

10

11

12

13

15

16

17

18

19

SPN

102

105

106

108

110

94

96

98

100

0

29

38

51

84

91

CODE DESCRIPTION

Data Valid But Above Normal

Data Valid But Below Normal

Data Erratic, Intermittent or Incorrect

Voltage Above Normal or Shorted High

Voltage Below Normal or Shorted Low

Current Below Normal or Open Circuit

Shorted

Mechanical System Not Responding or Out of Adjustment

Abnormal Frequency or Pulse Width

Command Lost

Abnormal Rate of Change

Root Cause Unknown

Bad Intelligent Device or Component

Out of Calibration

Valid but Above Normal Range- Least Severe Level

Valid but Above Normal Range- Moderate Severe Level

Valid but Below Normal Range- Least Severe Level

Valid but Below Normal Range- Moderate Severe Level

Message Receipt Lost


INVALID FAULT CODE

FPP2 FAULT

FUEL LEVEL SENSOR 2 FAULT

(TPS) THROTTLE POSITION SENSOR FAULT

SPEED SENSOR FAULT

FPP1 FAULT

FUEL PRESSURE SENSOR FAULT

FUEL LEVEL SENSOR 1 FAULT

OIL LEVEL SENSOR FAULT

OIL PRESSURE SENSOR FAULT

TIP/TOP FAULT

(MAT) MANIFOLD AIR TEMPERATURE SENSOR FAULT

(MAP) MANIFOLD PRESSURE SENSOR FAULT

(BARO) BAROMETRIC SENSOR FAULT

(ECT) COOLANT TEMPERATURE SENSOR FAULT

GOVERNOR INTEGRAL FACTOR FAULT

VBAT FAULT

FUEL TEMPERATURE SENSOR FAULT

(EOT) ENGINE OIL TEMPERATURE SENSOR FAULT

RPM FAULT

5 VOLT SENSOR REFERENCE VOLTAGE FAULT

CHARGING SYSTEM VOLTAGE FAULT

MICROPROCESSOR FAILURE

MICROPROCESSOR FAILURE

CALIBRATION FAULT

(CPS) CRANKSHAFT POSITION SENSOR FAULT

FAULT CODES


75

®


4 mefi-

D

FAULT CODES

MEFI V-VI DIAGNOSTIC TROUBLE CODE LIST (cont.)

SPN

710

723

731

920

1079

1080

1110

658

695

701

702

703

639

645

651

652

653

654

655

656

657

1325

1326

1327

1328

1329

1330

1347

1348

1485

1192

1213

1268

1269

1270

1271

1272

1273

1274

1275

1321

1323

1324

1765

3050

3051

3217


CAN-J1939 TX/RX FAULT

TACH OUTPUT FAULT

CYLINDER 1 INJECTOR FAULT








J1939 TSC 1 FAULT

AUX ANALOG PULL-UP 1



AUX ANALOG PULL-DOWN 1

(CMP) CAMSHAFT POSITION SENSOR FAULT

(KS) KNOCK SENSOR 1 FAULT

BUZZER FAULT

SENSOR SUPPLY VOLTAGE 1 FAULT

SENSOR SUPPLY VOLTAGE 2 FAULT

J1939 SHUTDOWN REQUEST

WGP FAULT

(MIL) MALFUNCTION INDICATOR LAMP) FAULT

SPARK COIL 1 FAULT

SPARK COIL 2 FAULT

SPARK COIL 3 FAULT

SPARK COIL 4 FAULT

SPARK COIL 5 FAULT

SPARK COIL 6 FAULT

SPARK COIL 7 FAULT

SPARK COIL 8 FAULT

START RELAY FAULT

CYLINDER 1 MISFIRE

CYLINDER 2 MISFIRE

CYLINDER 3 MISFIRE

CYLINDER 4 MISFIRE

CYLINDER 5 MISFIRE

CYLINDER 6 MISFIRE

CYLINDER 7 MISFIRE

CYLINDER 8 MISFIRE

FUEL PUMP HIGH SIDE FAULT

FUEL PUMP RELAY CONTROL FAULT

POWER RELAY FAULT

FUEL VALVE FAULT

CATALYST INACTIVE BANK 1

CATALYST INACTIVE BANK 2

EG01 FAULT


76


4 mefi-

D

FAULT CODES


SPN

3227

65545

65546

65547

65548

65550

65551

65552

65555

65559

65561

65562

65563

3256

3266

3563

3673

4236

4237

4238

4239

65538

65541

65542

65543

65544

65564

65565

65566

65567

65568

65570

65571

65572

65573

65580

65581

65582

65585

65586

65587

65590

65591

65592

95593

95594


EG02 FAULT

EG03 FAULT

EG04 FAULT

SUPERCHARGER INLET PRESSURE SENSOR

(TPS) THROTTLE POSITION SENSOR 2 FAULT

CLOSED LOOP BANK 1

ADAPTIVE LEARN BANK 1

CLOSED LOOP BANK 2

ADAPTIVE LEARN BANK 2

EGR NOT TRACKING

CYLINDER 1 (EST) ELECTRONIC SPARK TIMING FAULT








(KS) KNOCK CIRCUIT FAULT

(KS) KNOCK SENSOR BANK 1 FAULT

(KS) KNOCK SENSOR BANK 2 FAULT

CHANGE OIL SOON

CAN BUS HARDWARE FAULT

OXYGEN SENSOR BANK A SENSOR 1 FAULT


OXYGEN SENSOR BANK B SENSOR 1 FAULT


FUEL TRIM BANK A

FUEL TRIM BANK B



CAM PHASER W FAULT

CAM PHASER X FAULT

CAM PHASER Y FAULT

CAM PHASER Z FAULT

ECM/CPU

MHC FAILURE

ECM NON VOLATILE RAM FAILURE

FUEL SELECT INPUT

FUEL SELECT OUTPUT 1

FUEL SELECT OUTPUT 2

CYLINDER MISFIRE FAULT

MISFIRE CYLINDER 1

MISFIRE CYLINDER 2

MISFIRE CYLINDER 3

MISFIRE CYLINDER 4


77

®


4 mefi-

D

FAULT CODES

SPN

95595

65596

65597

65598

65599

65601

65602

65604

65605

66003

66004

66005

66006

66007

66008

66009

66010

66011

66012

65676

65677

65678

65690

65701

65702

65710

65723

65724

65725

65726

66001

66002

65610

65613

65615

65616

65618

65620

65621

65622

65623

65671

65672

65675



MISFIRE CYLINDER 5

MISFIRE CYLINDER 6

MISFIRE CYLINDER 7

MISFIRE CYLINDER 8

RANDOM MISFIRE

(ETC) ELECTRONIC THROTTLE CONTROL (TPS) THROTTLE POSITION SENSOR 2

RANGE FAULT

(ETC)ELECTRONIC THROTTLE CONTROL (TPS) THROTTLE POSITION SENSOR 1 RANGE

FAULT

(ETC) ELECTRONIC THROTTLE CONTROL (PPS) PEDAL POSITION SENSOR 2 RANGE

FAULT

(ETC) ELECTRONIC THROTTLE CONTROL (PPS) PEDAL POSITION SENSOR 1 RANGE

FAULT

(ETC) ELECTRONIC THROTTLE CONTROL TPS 1 VERSUS TPS 2 CORRELATION FAULT

(ETC) ELECTRONIC THROTTLE CONTROL PPS 1 VERSUS PPS 2 CORRELATION FAULT

(ETC) ELECTRONIC THROTTLE CONTROL ACTUATION FAULT

(ETC) ELECTRONIC THROTTLE CONTROL PROCESS FAULT

(ETC) ELECTRONIC THROTTLE CONTROL RETURN FAULT

5 VOLT REFERENCE A CIRCUIT FAULT

5 VOLT REFERENCE B CIRCUIT FAULT

5 VOLT REFERENCE C CIRCUIT FAULT

5 VOLT REFERENCE D CIRCUIT FAULT

CATALYTIC CONVERTER A TEMPERATURE SENSOR FAULT

CATALYTIC CONVERTER B TEMPERATURE SENSOR FAULT

CATALYTIC CONVERTER A EFFICIENCY

CATALYTIC CONVERTER B EFFICIENCY

CATALYTIC CONVERTER A EXOTHERM FAULT

CATALYTIC CONVERTER B EXOTHERM FAULT

VARIABLE GOVERNOR FAULT

GENERAL WARNING 1 CONDITION HAS OCCURRED SEE ENGINE SERVICE MANUAL

GENERAL WARNING 2 CONDITION HAS OCCURRED SEE ENGINE SERVICE MANUAL

EMERGENCY STOP WARNING

CAM SENSOR W FAULT

CAM SENSOR X FAULT

CAM SENSOR Y FAULT

CAM SENSOR Z FAULT

STARTER RELAY LOW SIDE DRIVER FAULT

STARTER RELAY HIGH SIDE DRIVER FAULT

MALFUNCTION INDICATOR LAMP DRIVER FAULT

SERVICE VEHICLE SOON LAMP DRIVER FAULT

GOVERNOR STATUS LAMP FAULT

LOW OIL LEVEL LAMP FAULT

WARNING BUZZER FAULT

GENERAL WARNING 1 LAMP FAULT

GENERAL WARNING 2 LAMP FAULT

SLOW MODE LAMP FAULT

SPEED BASED OUTPUT FAULT

TRANSMISSION UP SHIFT OUTPUT FAULT


78


4 mefi-

D

FAULT CODES


SPN

65598

65599

65620

65621

65560

65567

65568

65673

65674

65489

65509

65501

66030

66035

520197

520199

65572

65573

65591

65592

65593

65594

65595

65596

65597

66035

66040

66041

66042

66043

65565

65566

65570

65571

66013

66014

66015

66016

66017

66018

66019

66020

66021

66022

66025

66026

66030


POWERTRAIN RELAY FAULT

POWERTRAIN RELAY CONTACT FAULT

CANISTER PURGE FAULT

LINEAR EGR FAULT

FUEL PUMP RELAY 1 FAULT

TACHOMETER OUTPUT FAULT

OXYGEN SENSOR BANK A SENSOR 1 HEATER FAULT

OXYGEN SENSOR BANK B SENSOR 1 HEATER FAULT

OXYGEN SENSOR BANK A SENSOR 2 HEATER FAULT

OXYGEN SENSOR BANK B SENSOR 2 HEATER FAULT

FUEL PUMP RELAY 2 FAULT

SHIFT INTERRUPT FAULT

INTERCOOLER RELAY FAULT

SUPERCHARGER BOOST CONTROL SOLENOID FAULT

OEM OUTPUT DRIVER 1

OEM OUTPUT DRIVER 2

OEM OUTPUT DRIVER 3

OEM OUTPUT DRIVER 4

OXYGEN SENSOR A FUEL TRIM FAULT

OXYGEN SENSOR B FUEL TRIM FAULT

CAM PHASER W FAULT

CAM PHASER X FAULT

CAM PHASER Y FAULT

CAM PHASER Z FAULT

CYLINDER 1 MISFIRE

CYLINDER 2 MISFIRE

CYLINDER 3 MISFIRE

CYLINDER 4 MISFIRE

CYLINDER 5 MISFIRE

CYLINDER 6 MISFIRE

CYLINDER 7 MISFIRE

CYLINDER 8 MISFIRE

RANDOM CYLINDER MISFIRE

5 VOLT SENSOR POWER SUPPLY A FAULT

5 VOLT SENSOR POWER SUPPLY B FAULT

CANBUS GOV CMD

OXYGEN SENSOR BANK A SENSOR 1 RESPONSE

OXYGEN SENSOR BANK B SENSOR 1 RESPONSE

CATALYTIC CONVERTER A TEMPERATURE WARNING

CATALYTIC CONVERTER B TEMPERATURE WARNING

BOOST CONTROL DATA

NGINE SUPER CHARGER INLET PRESSURE SCIP SENSOR DATA

FUEL CONSUMPTION

INTER COOLER RELAY CIRCUIT

BOOST CONTROL CIRCUIT

(KS) KNOCK SENSOR 2 FAULT

FPP1/FPP2 CORRELLATION FAULT (LOSS OF REDUNDANCY)


79

®


4 mefi-

D

FAULT CODES

MEFI Warning Horn Operation

HORN OUTPUT

2 SECOND BEEP

POSSIBLE CAUSES CORRECTIVE ACTION

NORMAL TEST HORN OPERATION NONE

SOLID HORN

OIL PSI / ENGINE TEMP / DRIVE

LUBE LEVEL / TRANSMISSION

TEMP ON MIE MODELS

STOP ENGINE TO CHECK RE-

LATED PROBLEMS. CONNECT

STATS.

BEEP ALTERNATES ON

FOR 1 SECOND, OFF

3 SECONDS WITH

SOFT ALARM BELOW

3000 RPM AND SOLID

HORN ABOVE 3000

RPM

OIL PSI / ENGINE TEMP / DRIVE

LUBE LEVEL / TRANSMISSION

TEMP ON MIE MODELS / SENSOR

FAULT

STOP ENGINE TO CHECK RE-

LATED PROBLEMS. CONNECT

STATS.

5 SECOND BEEP

5 SECOND BEEP

LOW BATTERY

LOW FUEL PRESSURE (V6 AND V8

SMALL BLOCK)

INCREASE ENGINE RPM. IF

ALARM CONTINUES, INSPECT

BATTERY AND CHARGING

CIRCUITS.

CHECK FOR OBSTRUCTIONS

AND POSSIBLE CAUSES OF

LOW FUEL PRESSURE

AVAILABLE POWER %

NONE

POSSIBLE REDUCTION FROM

2800 RPM TO 1200 RPM BY

ECM DISABLING 4 INJECTORS.

INSPECT AND REPAIR.

POSSIBLE REDUCTION

DEPENDING ON ALARM.

INSPECT AND REPAIR.

ENGINE MAY CUT OUT OR

STOP RUNNING.

ENGINE MAY CUT OUT OR

STOP RUNNING.

80



4 mefi-

E

MEFI

Diagnostics



81

®


4 mefi-

E

MEFI

Diagnostics


82



5 kawasaki

KAWASAKI OPERATING MANUAL

Contents

C

D

A

B

APPLICATIONS





83

®


5 kawasakia

APPLICATIONS

Kawasaki PWC Diagnostics

STX 1100 DI (FITCH)

ULTRA 130 DI (FITCH)

STX (4 STROKE)

STX-12F (4 STROKE)

STX-15F (4 STROKE)

ULTRA LX (4 STROKE)

ULTRA 250 X (4 STROKE)

ULTRA 260LX (4 STROKE)


2000 → 2003

2001 → 2004

2009 → 2010

2003 → 2008

2004 → 2010

2007 → 2010

2007 → 2008

2009 → 2010

2009 → 2010

✓

✓

✓

✓

✓

✓

✓

✓

✓

Kawasaki PWC Diagnostics

✓

✓

✓

✓

✓

✓

✓

✓

✓

Sp.

Func.

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

ADC300 + ADC416 +

ADC450

ADC300 + ADC416 +

ADC450

ADC300 + ADC416 +

ADC414

ADC300 + ADC416 +

ADC414

ADC300 + ADC416 +

ADC414

ADC300 + ADC416 +

ADC414

ADC300 + ADC416 +

ADC414

ADC300 + ADC416 +

ADC414

ADC300 + ADC416 +

ADC414

A

A

A

A

A

A

A

A

A

ULTRA LX (4 STROKE)


ULTRA 260LX (4 STROKE)


2007 → 2010

2007 → 2008

2009 → 2010

2009 → 2010

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

Sp.

Func.

✓

✓

✓

✓

ADC300 + ADC419

ADC300 + ADC419

ADC300 + ADC419

ADC300 + ADC419

A

A

A

A

84



5 kawasakib


Kawasaki Diagnostic Socket



85

®


5 kawasakic


Kawasaki


Displays basic engine information such as Size, Model, Year, etc. ECU IDENTIFICATION is available to be saved and stored to be viewed later on a PC to build a custom made diagnostic printout.


Displays a list of diagnostic trouble codes currently active on the engine. Each fault code needs to be investigated and corrected. Once the faults have been corrected, then the CLEAR FAULT CODES function should be used to clear the engines fault code memory. All FAULT CODES and FREEZE FRAME DATA are available to be saved and stored to be viewed later on a PC to build a custom made diagnostic printout.


Not Available—ECU detects when faults have been corrected and automatically clears them.

LIVE DATA


ACTUATOR TESTS





KEY PROGRAMMING

This function allows Kawasaki Slo-Key and Fas-Key to be programmed to 4-Stroke LS and LX Models


86



5 kawasaki-

D


Kawasaki Jet Ski (DI Fitch)

Outboards


87

®


6

BRP (Johnson/Evinrude)

BRP (JOHNSON/EVINRUDE) OPERATING MANUAL

Contents

C

D

A

B

E

APPLICATIONS


GENERAL OPERATIONS

FAULT CODES


88



6

BRP (Johnson/Evinrude)a

APPLICATIONS

BRP (Johnson/Evinrude)

Johnson Ficht

Air Cooled ECU 1997 → 1998

Water Cooled EMM

Evinrude

1999 → 2007

E-Tec Water Cooled EMM 2004 → UP

Johnson 4-Stroke MFG by Suzuki

40, 50, 60, 70, 90, 115, 140,

200, 225HP

1996 → 2006

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

Sp.

Func.

✓

✓

✓

✓

ADC300 + ADC423 +

ADC450

ADC300 + ADC423 +

ADC450

ADC300 + ADC423 +

ADC450

ADC300 + ADC421

A

A

A

A


89

®


6

BRP (Johnson/Evinrude)b


BRP (Johnson/Evinrude) Diagnostic Socket


90



6

BRP (Johnson/Evinrude)c


BRP (JOHNSON-EVINRUDE)


Displays basic engine information such as HP, Model Number, etc. ECU IDENTIFICATION is available to be saved and stored to be viewed later on a PC to build a custom made diagnostic printout.


Displays a list of diagnostic trouble codes currently active on the engine. Each fault code needs to be investigated and corrected. Additional testing steps are also displayed on the next screen by pressing the RIGHT ARROW key.

Once the faults have been corrected, then the CLEAR FAULT CODES function should be used to clear the engines fault code memory. Occurred and History Fault Codes are also available for view however, may not be erasable from the ECM’s fault code memory. All FAULT CODES are available to be saved and stored to be viewed later on a PC to build a custom made diagnostic printout.


This functions allows any active fault codes that have been fixed to be cleared. After the fault codes have successfully been cleared, if any are still displayed, this indicates that the faults have not been corrected and further investigation is required.

LIVE DATA





2. Activate any Direct Injector




6. Test Oil Pump






4. Test Injector fuel mixtures (ADJUST LEAN/RICH)


1. Prime Oil Pump

2. Reset Oil Break-In Period

3. Winterization Mode

4. Change Oil Type Used

5. Fix Ignition Timing

ENGINE HOURS

This function displays the engine running hours and will break down hours via specific engine RPM ranges, temperature ranges and the overall hours the engine has been used. All ENGINE HOURS are available to be saved and stored to be viewed later on a

PC to build a custom made diagnostic printout.



91

®


6

BRP (Johnson/Evinrude)-

D

17

18

19

20

21

22

FAULT CODES

BRP (Johnson-Evinrude)

5

6

7

2

3

4

CODE NUMBER EMM CIRCUIT/SENSOR

1 Cylinder 1 Excessive Knock

Cylinder 2 Excessive Knock



8

9

10

11

12



Knock Sensor Detected Port

Knock Sensor Detected Starboard

Not Defined

Not Defined

Throttle Position Sensor (TPS) out of idle range

Throttle Position Sensor (TPS) circuit fault

13 TPS below range

23

24

25

26

27

28

29

14

15

16

SYSTEM CHECK WARNING LIGHT ACTIVATION EMM LED ACTIVATION

CHECK ENGINE (IDLE ONLY)

CHECK ENGINE

TPS above range CHECK ENGINE

ROM (EMM program)

Crankshaft Position Sensor

(CPS) Intermittent loss of SYNC

55 V circuit BELOW range (40V

Ficht)

55 V circuit ABOVE range (40V

Ficht)

Start-in-gear

Not Defined

Winterization activated

Engine temperature switch closed

EMM Temperature Sensor

CKT malfunction

EMM Temperature BELOW range

CHECK ENGINE

CHECK ENGINE

ALL LIGHTS FLASHING

WATER TEMP/HOT

EMM Temperature ABOVE range

12 V circuit BELOW range

12 V circuit ABOVE range

WATER TEMP/HOT

LOW BATTERY

LOW BATTERY

Shift switch malfunction

Shift assist CKT malfunction

EMM temperature OVER range WATER TEMP/HOT (FLASHING)

LED 3: OFF (CRANKING) / ON

(RUNNING)


(RUNNING)


(RUNNING)

"LED 2: OFF (CRANKING)

LED 3: ON (RUNNING)"

LED 1: ON (RUNNING)

LED 1: ON (RUNNING)

LED 3: OFF (CRANKING)

LED 1-4: FLASHING


(RUNNING)


(RUNNING)

LED 4: ON (RUNNING)

LED 1: ON (RUNNING)

LED 1: ON (RUNNING)

LED 3: ON (RUNNING)

LED 4: FLASHING


92


6


D

FAULT CODES

54

55

56

57

50

51

52

53


30 Not Defined

31

32

SYSTEM CHECK WARNING LIGHT ACTIVATION

Engine temperature OVER range WATER TEMP/HOT (FLASHING)

Oil pressure switch, CONSTANT

EMM LED ACTIVATION

LED 4: FLASHING

SENSOR FAULT (LED 3)

33

34

35

36

Critical LOW oil detected

"NO OIL

(FLASHING)"

Oil injection pump circuit OPEN NO OIL

No oil pressure (1997-2000 DI) NO OIL

Cylinder Oiler Solenoid Not

Connected

NO OIL

LED 4: FLASHING

LED 4: ON (RUNNING)

LED 4: ON (RUNNING)

37 Water in fuel CHECK ENGINE


(RUNNING)

38

39

40

41

42

Oil pressure feedback NOT detected

Oil pressure prime failure

Engine Temperature ABOVE range (port) - lowspeed

Engine Temperature Sensor

(port/inline) circuit fault

NO OIL

NO OIL

WATER TEMP/ HOT

LED 4: ON (RUNNING)

LED 4: ON (RUNNING)


(RUNNING)


(RUNNING)

43

44

45

46

Engine Temperature BELOW range (port/ inline)

Engine Temperature ABOVE range (port/ inline)

Barometric Pressure (BP) Sensor circuit fault

Barometric Pressure (BP) Sensor

BELOW range

Barometric Pressure (BP) Sensor

ABOVE range

WATER TEMP/HOT LED 4: ON (RUNNING)

47

48

49

Air Temperature (AT) circuit


(RUNNING)


(RUNNING)


(RUNNING)

58


BELOW range


ABOVE range

Not Defined

Fuel injector circuit #1 OPEN






High RPM with low TPS setting CHECK ENGINE (FLASHING)

Operating temperature not reached (Port/ inline)

LED 2: ON (RUNNING)

LED 2: ON (RUNNING)

LED 2: ON (RUNNING)

LED 2: ON (RUNNING)

LED 2: ON (RUNNING)

LED 2: ON (RUNNING)

LED 3: FLASHING


(RUNNING)


93

®


6


D

FAULT CODES


59

60

Operating temperature not reached (Starboard)

Not Defined

61

62

63

64

65

66

67

68

69

70

71

72

73

74

75

76

Fuel injector circuit #1 SHORT-

ED


ED


ED


ED


ED


ED

Engine temperature sensor

(Starboard) Circuit Fault

Engine temperature BELOW range (Starboard)

Engine temperature ABOVE range (Starboard)

Engine temperature ABOVE range (Starboard) Low Speed

Oil pressure circuit sensor fault detected

Oil pressure BELOW expected range

Oil pressure ABOVE expected range

Water pressure sensor circuit fault detected

Water pressure BELOW expected range

Water pressure ABOVE expected range



(RUNNING)

WATER TEMP/ HOT

WATER TEMP/ HOT

CANBUS OPTION

CANBUS OPTION

LED 2: ON (RUNNING)

LED 2: ON (RUNNING)

LED 2: ON (RUNNING)

LED 2: ON (RUNNING)

LED 2: ON (RUNNING)

LED 2: ON (RUNNING)


(RUNNING)


(RUNNING)

LED 4: ON (RUNNING)

LED 4: ON (RUNNING)

LED 3: ON (RUNNING)

LED 3: ON (RUNNING)

LED 3: ON (RUNNING)

LED 3: ON (RUNNING)

LED 3: ON (RUNNING)

LED 3: ON (RUNNING)

77

78

79

80

81

82

S.A.C. overcurrent fault

Analog 5V circuit overload detected

Starter solenoid circuit OPEN

Not Defined

Ignition primary circuit #1

OPEN


OPEN

CHECK ENGINE

LED 1: OFF (KEY ON) / ON

(RUNNING)


(RUNNING)

LED 3: OFF (KEY ON)

INJECTOR/IGNITION FAULT

(LED 2)


(LED 2)


94


6


D

FAULT CODES

90

91

92

98

99

100

101

93

94

95

96

97


83


OPEN

84

85

86


OPEN


OPEN


OPEN

87 Exhaust pressure circuit fault

88

89

102

103

104

105

106

107

108

109

Exhaust pressure BELOW expected range

Exhaust pressure ABOVE expected range

Water injection solenoid

SHORTED

Fuel pump circuit OPEN

Exhaust valve solenoid OPEN

(115-130HP)

Water injection solenoid (40-

60HP)

Fuel pump circuit SHORTED

Not Defined

Not Defined

Intermittent switched B+ detected

Air Valve Open Circuit

Air Valve Short Circuit

Not Defined

Ignition timing circuit #1

SHORTED


SHORTED


SHORTED


SHORTED


SHORTED


SHORTED

ICON Control Head Hardware

Failure

ICON System Fail-Safe Mode

ICON control Head Hardware

Failure



(LED 2)


(LED 2)


(LED 2)


(LED 2)


(RUNNING)


(RUNNING)


(RUNNING)

LED 2: ON (RUNNING)

LED 2: ON (RUNNING)

LED 2: ON (RUNNING)

LED 2: ON (RUNNING)

LED 2: ON (RUNNING)

LED 3: ON (RUNNING)

LED 2: ON (RUNNING)

LED 2: ON (RUNNING)

LED 2: ON (RUNNING)

LED 2: ON (RUNNING)

LED 2: ON (RUNNING)

LED 2: ON (RUNNING)


95

®


6


D

FAULT CODES


110

ICON Trim Switch Module

Communication Fault

111

112

113

Oil level sender circuit fault detected

Oil level sender voltage BELOW expected range

Oil level sender voltage ABOVE expected range

114

115

116

117

118

119

120

Critical LOW oil detected

Not Defined

Not Defined

Oil Level Sensor Open Circuit

121

122

123 - 143

144

145 - 147

148

149

150

151

152

153 - 256

EMM Major Overheat

Engine Major Overheat

Reserved

Excessive Knock on MAG 1

Reserved

Excessive Knock on PTO 2

ICON Throttle Actuator Sensor

Fault

ICON Throttle Actuator Motion

Fault

ICON Shift Actuator Sensor

Fault

ICON Shift Actuator Motion

Fault

Reserved


CANBUS OPTION

CANBUS OPTION

CANBUS OPTION

NO OIL

LED 3: ON (RUNNING)

LED 3: ON (RUNNING)

LED 3: ON (RUNNING)

LED 4 ON (RUNNING)

96



6


E


BRP

(Johnson/Evinrude)

Outboards


97

®


6


E


BRP

(Johnson/Evinrude)

Outboards

98



7

brp (seadoo/JETLEV)

BRP (SEADOO/JETLEV) OPERATING MANUAL

Contents

E

F

G

C

D

A

B

APPLICATIONS



FAULT CODES


GLOSSARY

SEADOO TROUBLESHOOTING


99

®


7

BRP/Seadoo/JETLEVa

APPLICATIONS

BRP (SEADOO/JETLEV) PWC Diagnostics

GTI-RENTAL

GTX DI (947 DI)

RX DI (947 DI)

LRV DI (947 DI)

XP DI (947 DI)

GTX 4 TEC (4 TEC)

GTX WAKE (4 TEC)

GTX LTD SUPERCHARGED

(4 TEC)

GTX 155 (4 TEC)

RXP (4 TEC)

RXP-X (4 TEC)

RXT (4 TEC)

RXT-X (4-TEC)

GTI (4 TEC)

GTI RENTAL (4 TEC)

GTI SE (4 TEC)

WAKE 155 (4 TEC)

WAKE 215 (4 TEC)

WAKE PRO 215 (4 TEC)

2006

2000 → 2003

2000 → 2003

2003

2003 → 2004

2003 → 2006

2003 → UP

2003 → 2007

2007 → UP

2004 → UP

2008 → UP

2005 → UP

2008 → UP

2007 → UP

2007 → UP

2007 → UP

2008 → UP

2008

2009

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

Sp.

Func.

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

ADC300 + ADC404

ADC300 + ADC404

+ADC450

ADC300 + ADC404

+ADC450

ADC300 + ADC404

+ADC450

ADC300 + ADC404

+ADC450

ADC300 + ADC404

ADC300 + ADC404

ADC300 + ADC404

ADC300 + ADC404

ADC300 + ADC404

ADC300 + ADC404

ADC300 + ADC404

ADC300 + ADC404

ADC300 + ADC404

ADC300 + ADC404

ADC300 + ADC404

ADC300 + ADC404

ADC300 + ADC404

ADC300 + ADC404

C

C

B

C

C

B

B

B

B

B

B

B

B

B

B

B

B

B

B

100



7

BRP/Seadoo/JETLEVa

APPLICATIONS

BRP (SEADOO/JETLEV) PWC Key Programming

GTX DI (947 DI)

RX DI (947 DI)

LRV DI (947 DI)

XP DI (947 DI)

GTI-RENTAL

GTX 4 TEC (4 TEC)

GTX WAKE (4 TEC)

GTX LTD SUPERCHARGED

(4 TEC)

GTX 155 (4 TEC)

RXP (4 TEC)

RXP-X (4 TEC)

RXT (4 TEC)

RXT-X (4-TEC)

GTI (4 TEC)

GTI RENTAL (4 TEC)

GTI SE (4 TEC)

WAKE 155 (4 TEC)

WAKE 215 (4 TEC)

WAKE PRO 215 (4 TEC)

GS (DESS CARB)

GSX (DESS CARB)

GSX LTD (DESS CARB)

2000 → 2003

2000 → 2003

2003

2003 → 2004

2006

2003 → 2006

2003 → UP

2003 → 2007

2007 → UP

2004 → UP

2008 → UP

2005 → UP

2008 → UP

2007 → UP

2007 → UP

2007 → UP

2008 → UP

2008

2009

1997 → 2001

1997 → 1999

1997 → 1999

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

D

D

B

B

B

B

B

B

B

B

B

B

B

B

B

B

B

C

C

C

C

D

ADC300 + ADC404

+ADC450 + ADC402

ADC300 + ADC404

+ADC450 + ADC402

ADC300 + ADC404

+ADC450 + ADC402

ADC300 + ADC404

+ADC450 + ADC402

ADC300 + ADC404 +

ADC402

ADC300 + ADC404 +

ADC402

ADC300 + ADC404 +

ADC402

ADC300 + ADC404 +

ADC402

ADC300 + ADC404 +

ADC402

ADC300 + ADC404 +

ADC402

ADC300 + ADC404 +

ADC402

ADC300 + ADC404 +

ADC402

ADC300 + ADC404 +

ADC402

ADC300 + ADC404 +

ADC402

ADC300 + ADC404 +

ADC402

ADC300 + ADC404 +

ADC402

ADC300 + ADC404 +

ADC402

ADC300 + ADC404 +

ADC402

ADC300 + ADC404 +

ADC402

ADC300 + ADC404

+ADC450 + ADC408 or

ADC422

ADC300 + ADC404

+ADC450 + ADC408 or

ADC422

ADC300 + ADC404

+ADC450 + ADC408 or

ADC422


101

®


7

BRP (Seadoo/JETLEV)a

APPLICATIONS

BRP (SEADOO/JETLEV) PWC Key Programming (cont.)

GTI (DESS CARB)

GTS (DESS CARB)

GTX (DESS CARB)

GTX LTD (DESS CARB)

HX (DESS CARB)

SPX (DESS CARB)

XP (DESS CARB)

XP LTD (DESS CARB)

RX (DESS CARB)

LRV (DESS CARB)

GTX (DESS RFI)

GSX (DESS RFI)

GTI (DESS RFI)

GTI-LE (DESS RFI)

3D RFI

1997

1997

1997

1997

→ 2005

→ 2001

→ 2002

→ 2002

1997

1997

1997

1997

2000

2000

1998

1999

2004

2003

2004

→ 1999

→ 2001

→ 2001

→ 2002

→ 2001

→ 2002

→ 2000

→ 2006

→ 2006

→ 2005

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

ADC300 + ADC404

+ADC450 + ADC408 or

ADC422

ADC300 + ADC404

+ADC450 + ADC408 or

ADC422

ADC300 + ADC404

+ADC450 + ADC408 or

ADC422

ADC300 + ADC404

+ADC450 + ADC408 or

ADC422

ADC300 + ADC404

+ADC450 + ADC408 or

ADC422

ADC300 + ADC404

+ADC450 + ADC408 or

ADC422

ADC300 + ADC404

+ADC450 + ADC408 or

ADC422

ADC300 + ADC404

+ADC450 + ADC408 or

ADC422

ADC300 + ADC404

+ADC450 + ADC408 or

ADC422

ADC300 + ADC404

+ADC450 + ADC408 or

ADC422

ADC300 + ADC404

+ADC450 + ADC408 or

ADC422

ADC300 + ADC404

+ADC450 + ADC408 or

ADC422

ADC300 + ADC404

+ADC450 + ADC408 or

ADC422

ADC300 + ADC404

+ADC450 + ADC408 or

ADC422

ADC300 + ADC404

+ADC450 + ADC408 or

ADC422

D

D

D

D

D

D

D

D

D

D

D

D

D

D

D

*Dependant on the system, either the ADC408 or ADC422 will be required to program or clear keys from the Sea-Doo. One cable will allow communication, the other will not. Use the cable that allowed communication to the MPEM module to program and erase keys.

102



7

BRP (Seadoo/JETLEV)-

B


BRP (Seadoo/Jetlev) Diagnostic Socket



103

®


7


C


BRP (SEADOO/JETLEV)




Displays a list of diagnostic trouble codes currently active on the engine. Each fault code needs to be investigated and corrected. Once the faults have been corrected, then the CLEAR FAULT CODES function should be used to clear the engines fault code memory. All FAULT CODES and FREEZE FRAME DATA are available to be saved and stored to be viewed later on a




LIVE DATA

This function displays a list of LIVE DATA parameters and values from the engine ECU. This data list is what is available from the engine

ECU, and each value will change as the engine components are operated. Please refer to vehicle manufacturers data for correct values and correct operating limits. All LIVE DATA is available to be saved and stored to be viewed later on a PC to build a custom made diagnostic printout.

ACTUATOR TESTS





4. Activate Buzzer

5. Activate Blow By Valve

6. Activate Bilge Pump

7. Activate CPI Valve


1. Reset Throttle Position

2. Key Programming (See Below)

3. Reset Service Data Including Engine Maintenance Light and Supercharger Light

KEY PROGRAMMING

This function allows Sea-Doo DESS keys to be programmed/erased to MPEM module. STATS programs both Normal and Learner keys.

Up to 8 keys can be on a craft at any given time. STATS also has the ability to check DESS keys to ensure they are able to be read by the MPEM module when connected.

ENGINE HOURS




104


7


D

P1103

P1300

P1400

P1401

P1500

P1501

P0222

P0230

P0325

P0335

P0351

P0352

P0353

P0460

P0475

P0562

P0563

P0606

P1100

P1101

P1102

P0105

P0106

P0110

P0116

P0120

P0122

P0123

P0201

P0202

P0217

P0220

FAULT CODES

BRP (SEADOO/JETLEV) DTC-DI

FAULT DETECTED

FAULT DETECTED KEY ON EN-

GINE RUNNING

Yes

MAPS (Manifold Air Pressure Sensor) Sensor Out of Range Yes

MATS (Manifold Air Temperature

Sensor)

WTS

Sensor Out of Range

Sensor Out of Range

Yes

Yes

TPS, PTO

Sensor Supply (TPS, MAG and

MAPS)

Sensor Out of Range

Sensor 5V Supply

Failure

Yes

Yes

P1600

P1601

Fuel Injector, MAG

Fuel Injector, PTO

Open or Short Circuit Yes


WTS (Water Temperature Sensor)

TPS, MAG

Sensor Supply (TPS, PTO)

Overheat Warning Yes

Sensor Out of Range Yes

Sensor 5V Supply

Failure

Yes

Open or Short Circuit Yes, Short Circuit Fuel Pump

Knock Sensor

Encoder (CPS)

Ignition Coil, Primary Winding,

MAG

Knock Sensor Failure Yes, over 4500 RPM

Wrong Pattern Sensed Yes


Ignition Coil, Primary Winding, PTO Open or Short Circuit Yes

Fuel Level Sensor

RAVE Solenoid

Battery Voltage

Battery Voltage

ECU

Direct Injector, MAG

Direct Injector, PTO

Sensor Out of Range Yes

Open or Short Circuit Yes, Open and Short Circuit

Battery Voltage Low Yes

Battery Voltage High Yes

Internal ECU faults Yes



TPS, PTO

TPS, MAG

Throttle Position

Adaptation Failure

Throttle Position

Adaptation Failure

Yes

Yes

Starting System Solenoid (Winding) Open or Short Circuit Yes, Open and Short Circuit

EGT (Exhaust Gas Temperature)

EGT (Exhaust Gas Temperature)

Battery Voltage

Sensor Out of Range

Overheat Warning

Battery Voltage Very

High

Yes

Yes

Yes

Battery Voltage

ECU

Diagnostic Cap

Battery Voltage Very

Low

TDC and ECU not

Initialized

Diagnostic cap is not installed on wiring harness

Yes

Yes

Yes

FAULT DETECTED KEY ON

ENGINE OFF

No

No

No

No

No

Yes

No

No

No

No

Yes

Yes, Open Circuit

No

No

No

No

No

Yes, Open Circuit

Yes

Yes

Yes

No

No

No

No

Yes, Open Circuit

No

No

Yes

Yes

Yes

Yes


105

®


7


D

FAULT CODES

BRP (SEADOO/JETLEV) 4-TEC

FAULT CODE

P0106

P0107

P0108

P0111

P0112

P0113

P0116

P0117

P0118

P0122

P0123

P0231

P0232

P0236

P0261

P0262

P0264

P0265

P0267

P0268

P0326

P0336

P0337

DIAGNOSED COMPONENT/

SENSOR/ CIRCUIT

FAULT DETECTED

MAPS (Manifold Air Pressure

Sensor)

MAPS (MANIFOLD AIR PRESSURE

SENSOR

MANIFOLD BAROMETRIC

PRESSURE SENSOR

Sensor Out of Range

SHORTED TO GROUND

SHORTED TO POWER OR

OPEN CIRCUIT

INTAKE MANIFOLD

TEMPERATURE SENSOR

FUNCTIONAL PROBLEM

INTAKE MANIFOLD

TEMPERATURE SENSOR

INTAKE MANIFOLD

TEMPERATURE SENSOR

SHORTED TO GROUND

SHORTED TO POWER OR

OPEN CIRCUIT

ENGINE TEMPERATURE SENSOR FUNCTIONAL PROBLEM

ENGINE TEMPERATURE SENSOR SHORTED TO GROUND

ENGINE TEMPERATURE SENSOR

SHORTED TO POWER OR

OPEN CIRCUIT


(TPS)


(TPS)

OUT OF RANGE OR

SHORTED TO GROUND

SHORT TO POWER OR

OPEN CIRCUIT

FUEL PUMP

FUEL PUMP

SHORTED TO GROUND

OR OPEN CIRCUIT

SHORTED TO POWER

INJECTOR #1

INJECTOR #1

INJECTOR #2

INJECTOR #2

SHORT TO GROUND OR

OPEN CIRCUIT

SHORT TO POWER

SHORT TO GROUND OR

OPEN CIRCUIT

SHORT TO POWER

INJECTOR #3

INJECTOR #3

KNOCK SENSOR

SHORT TO GROUND OR

OPEN CIRCUIT

SHORT TO POWER

OUT OF RANGE

CRANKSHAFT POSITION SENSOR WRONG RPM DETECTED

CRANKSHAFT/CAMSHAFT

POSITION SENSOR CORRELATION

NO CPS SIGNAL DE-

TECTED/ CMP SIGNAL

DETECTED

P0339

P0344 CAM PHASE SENSOR

P0351

P0352

IGNITION COIL #1

IGNITION COIL #2

SIGNAL MISSING

OPEN CIRCUIT OR

SHORTED TO GROUND

OR POWER

OPEN CIRCUIT OR

SHORTED TO GROUND

OR POWER

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

YES

NO

YES

NO

NO

NO

NO

NO

NO

FAULT DETECTED

KEY ON ENGINE OFF

No

NO

FAULT DETECTED

KEY ON ENGINE

RUNNING

Yes

YES

LIMP HOME

MODE

NO

NO

No

NO

YES

YES

NO

NO

YES

YES

YES

YES

YES

YES

YES

NO

YES

NO

NO

NO

NO

NO

NO/YES (3500

RPM)

NO

NO

NO

YES

YES

YES

YES

YES

YES

YES

NO

YES

YES

YES

NO

NO

NO

NO

NO

NO

NO

NO

NO

5000 RPM

5000 RPM


106


7


D

P1102

P1104

P1148

P1200

P1201

P1202

P1203

P1502

P0353

P0461

P0462

P0463

P0505

P0513

P0520

P0536

P0544

P0545

P0546

P0562

P0563

P0600

FAULT CODES

BRP (SEADOO/JETLEV) 4-TEC (cont.)

FAULT CODE


SENSOR/ CIRCUIT

IGNITION COIL #3

FUEL LEVEL SENSOR

FUEL LEVEL SENSOR

FUEL LEVEL SENSOR

DLA OUTPUT STAGE CUTOFF

MEMORY DIFFERENCE

DESS

OIL PRESSURE SWITCH

FAULT DETECTED

OPEN CIRCUIT OR

SHORTED TO GROUND

OR POWER

OUT OF RANGE

SHORTED TO GROUND

SHORTED TO POWER OR

OPEN CIRCUIT

OPEN CIRCUIT OR

SHORTED TO POWER

INCORRECT KEY

FUNCTIONAL PROBLEM

NO

YES

YES

YES

YES

YES

YES

FAULT DETECTED


FAULT DETECTED

KEY ON ENGINE

RUNNING

LIMP HOME

MODE

YES

YES

YES

YES

NO

5000 RPM

NO

NO

NO

NO

YES 2500 RPM

P0601

P0602

P0604

P0605

P0608

EXHAUST GAS TEMPERATURE

SENSOR


SENSOR


SENSOR

BATTERY VOLTAGE

BATTERY VOLTAGE

CAM COMMUNICATION

TPS

ECU NOT CODED

RAM FAULTY

EEPROM FAULTY

SENSOR 5V POWER SUPPLY

FUNCTIONAL PROBLEM NO

SHORTED TO GROUND

SHORTED TO POWER OR

OPEN CIRCUIT

TOO LOW

TOO HIGH

PROBLEM DETECTED BY

EMS

LEARNS UNLIKELY OR

CHECKSUM FAULT / MOD-

ULE CALL MONITORING

YES/NO

YES/NO

NO

NO

YES

YES

YES

YES

YES

YES

YES

NO

NO

NO

NO

NO

NO

NO

P0616

P0617

STARTER RELAY

STARTER RELAY


(TPS)


(TPS)

FUEL INJECTOR 1, 2, OR 3

BLOW BY VALVE

BLOW BY VALVE

OIL TANK PRESSURE SWITCH

UNUSED

TOPS

SHORTED TO GROUND

OR SHORTED TO POWER

SHORTED TO GROUND

OR OPEN CIRCUIT

SHORTED TO POWER

ADAPTATION FAILURE

ADAPTATION CANCELLED

SAFETY FUEL CUTOFF

DETECTED

SHORTED TO GROUND

OR OPEN CIRCUIT

SHORTED TO POWER

IMPLAUSIBLE OR BLOW BY

VALVE STILL CLOSED

Y/N

NO

NO

YES

NO (FAULT DETECTED

WHILE CRANKING)

YES"

Y/N (SOMETIMES

WHEN PRESSING

START/STOP SWITCH)

YES

YES

NO

YES

NO

NO

FUNCTIONAL PROBLEM YES

NO

NO

5000 RPM

NO

NO

5000 RPM


107

®


7


D

FAULT CODES

BRP (SEADOO/JETLEV) 4-TEC (cont.)

P1676

P1678

P1679

P1680

P1681

P1682

P1683

P1690

P1514

P1517

P1590

P1591

P1592

P1593

P1607

P1611

P1655

P1656

P1660

P1661

P1670

P1675

P1691

P1692

P1693

FAULT CODE

P1509

P1510

P1511

P1513


SENSOR/ CIRCUIT

FAULT DETECTED

LAKE TEMPERATURE SENSOR



EXTERIOR TEMPERATURE SEN-

SOR

EXTERIOR TEMPERATURE

SENSOR

COMPASS

VTS POSITION SENSOR

VTS POSITION SENSOR

VTS POSITION SENSOR

VTS

MPEM

P+ TEST OF ISC

DESS

DESS

BILGE PUMP

BILGE PUMP

BUZZER

SPARE OUTPUT 1

SPARE OUTPUT 1

SPARE OUTPUT 2

OUT OF RANGE

LOW VOLTAGE

HIGH VOLTAGE

LOW VOLTAGE

HIGH VOLTAGE

OUT OF RANGE

OUT OF RANGE

LOW VOLTAGE

HIGH VOLTAGE

MALFUNCTION

FAULT

OUTPUT SIGNAL FAILED

SHORTED TO POWER

SHORTED TO GROUND

SHORTED TO GROUND

OR OPEN CIRCUIT

SHORTED TO POWER

SHORT TO POWER

SHORTED TO GROUND

OR OPEN CIRCUIT

SHORTED TO POWER

SHORTED TO GROUND

OR OPEN CIRCUIT

SPARE OUTPUT 2

COMMUNICATION PROBLEM



COM RAM

VTS CONTROL UP CIRCUIT

SHORTED TO POWER

DETECTED BY MPEM

INSTRUMENT CLUSTER

MESSAGE MISSING

EMS MESSAGE MISSING

FAULT

OPEN CIRCUIT OR

SHORTED TO GROUND

VTS CONTROL UP CIRCUIT

VTS CONTROL DOWN CIRCUIT

SHORTED TO POWER

OPEN CIRCUIT OR

SHORTED TO GROUND

VTS CONTROL DOWN CIRCUIT SHORTED TO POWER

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

FAULT DETECTED


YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

NO

NO

NO

YES

YES

YES

FAULT DETECTED

KEY ON ENGINE

RUNNING

YES

YES

YES

YES

LIMP HOME

MODE

NO

NO

NO

NO

YES

YES

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

YES

YES

YES

YES

NO

NO

NO

NO


108


7


D

P0336

P0112

P0113

P0107

P0108

P0262

P0261

P1200

P0265

P0264

P1201

P0230

P0478

P0477

P0479

P0604

P0605

P1600

P1601

P1602

P0562

P0563

P0117

P0118

P0116

P0122

P0123

P0219

P0335

FAULT CODES

BRP (SEADOO/JETLEV) RFI

FAULT CODE DIAGNOSED COMPONENT/ SENSOR/ CIRCUIT

NO FAULT DETECTED

ELECTRONIC CONTROL UNIT INTERNAL MEMORY

ELECTRONIC CONTROL UNIT INTERNAL MEMORY

ELECTRONIC CONTROL UNIT EEPROM

EEPROM DATA SETTING

EEPROM DATA SETTING

SUPPLY VOLTAGE TO ECU

SUPPLY VOLTAGE TO ECU

ENGINE WATER TEMPERATURE SENSOR (WTS)








AIR INTAKE TEMPERATURE SENSOR (ATS)

AIR INTAKE TEMPERATURE SENSOR (ATS)

AIR PRESSURE SENSOR (APS)

AIR PRESSURE SENSOR (APS)

INJECTOR 1

INJECTOR 1

INJECTOR 1

INJECTOR 2

INJECTOR 2

INJECTOR 2

FUEL PUMP

RAVE VACUUM SOLENOID



FAULT DETECTED

INTERNAL DEFECT

NOT PLAUSIBLE (EEPROM DEFECT)

NOT PROGRAMMED

OUT OF RANGE (1 OF 3 BYTES)

OUT OF RANGE (ALL 3 BYTES DIFFERENT)

TOO LOW

TOO HIGH

CIRCUIT SHORTED TO GROUND

SIGNAL INTERRUPTION OR SHORT CIRCUIT TO BATTERY

NON PLAUSIBLE SIGNAL


CIRCUIT SHORTED TO BATTERY

SIGNAL EXCEEDING RPM LIMITS

NO SIGNAL DETECTED (FAULT CODE ACTIVE WHEN

ENGINE IS NOT RUNNING AND IGNITION IS ON)

SYNCHRONIZATION ERROR (SENSOR/ RELUCTOR

WHEEL)





SHORT CIRCUIT TO BATTERY

SHORT CIRCUIT TO GROUND

INTERRUPTION OR OPEN CIRCUIT









109

®


7


E

SPECIAL

FUNCTIONS

BRP

(SEADOO/

JETLEV)

Jet Ski (4 Tec)

110



7


E

SPECIAL

FUNCTIONS

BRP

(SEADOO/

JETLEV) (4 Tec)

Key Prog


111

®


7


E

SPECIAL

FUNCTIONS

BRP

(SEADOO/

JETLEV)

Jet Ski (4 Tec)

112



7


E


BRP (SEADOO/JETLEV) Jet Ski (4 Tec)


113

®


7


F

GLOSSARY

ECU

EMS

EPA

HP

LED

MAG

PFD

PSI

PTO

RAVE

RFI

RPM

MPEM

MPH

MPI

OPT

P/N

STD

TDC

TPS

VDC

VCK

VTS

WTS

ACRONYM

ADC

AC

AP

ATS

B.U.D.S

CDI

CPS

CSI

DC

DESS

DI

E.I.N

ECM

DEFINITION

Analog to Digital Conversion

Alternate Current

Air Pressure Sensor

Air Temperature Sensor

Bombardier Utility and Diagnostic Software

Capacitor Discharge Ignition

Crankshaft Position Indicator

Cooling System Indicator

Direct Current

Digital Electronic Security System

Direct Injected

Engine Identification Number

Electronic Control Module

Electric Control Unit

Engine Management System

Environmental Protection Agency (USA)

Horse Power

Light Emitting Diode

Magneto

Multi-Purpose Electronic Module

Mile Per Hour

Multi Protocol Interface

Optional

Part Number

Personal Flotation Device

Pounds Per Square Inch

Power Take Off

Rotax Adjustable Variable Exhaust

Rotax Fuel Injection

Revolutions Per Minute

Standard

Top Dead Centre

Throttle Position Sensor

Volts Direct Current

Vehicle Communication Kit

Variable Trim System

Water Temperature sensor


114


7


G

BRP (SEADOO/JETLEV) TROUBLESHOOTING

BRP (SEADOO/JETLEV) SELF DIAGNOSTIC MODE

CODE NUMBER DIAGNOSED COMPONENT/ SENSOR/ CIRCUIT FAULT DETECTED

DI

2 Short beeps while installing safety lanyard on

DESS post

Confirms safety lanyard signal operation.

Safety lanyard is recognized by the ECM.

Good contact between safety lanyard and DESS post.

Engine can be started.

1 long beep while installing safety lanyard on

DESS post

Bad DESS system connection.

Wrong safety lanyard.

Defective safety lanyard.

Dried salt water or dirt in safety lanyard cap.

Defective DESS post.

Improper operation of ECM or defective wiring harness."

Reinstall safety lanyard cap correctly over DESS post.

Use a safety lanyard that has been programmed for the watercraft. If it does not work, check safety lanyard condition with STATS. Replace safety lanyard if reported defective.

Use another programmed safety lanyard.

Clean safety lanyard cap to remove salt water.

Refer to Engine Management section of Sea-Doo shop manual.

1 short beep followed by 1 long beep

4 short beeps every 3 seconds interval for 4 hours

4-TEC


DESS post

ECM has been set to onboard diagnosis mode.

Safety lanyard has been left on DESS post without starting engine or after engine was stopped.




Remove and reinstall safety lanyard.

To prevent battery discharge, remove safety lanyard from DESS post.



DESS post






Improper operation of ECM or defective wiring harness.






2 very short beeps every 3 seconds interval for 4 hours

Safety lanyard has been left on DESS post without starting engine or after engine was stopped.

To prevent battery discharge, remove safety lanyard from DESS post.

2 Second beep every minute interval

High pressure in oil separator tank.

Low fuel level.

Fuel tank level sensor or circuit malfunction.

Refer to Lubrication System Section of Sea-Doo shop manual.

Refer to Instruments and Accessories Section of Sea-

Doo shop manual.

Refer to Instruments and Accessories Section of Sea-

Doo shop manual.

2 Second beep every 15 minute interval

Engine coolant temperature sensor or circuit malfunction.

Exhaust temperature sensor or circuit malfunction.

Engine oil pressure sensor or circuit malfunction.

Low pressure in oil separator tank (engine oil leak)

TOPS valve solenoid or circuit malfunction.

EMS ECU failure.

Bilge pump circuit low or high voltage (if equipped)

Starter solenoid circuit malfunction.

Communication link fault detected by MPEM

EMS ECU communication link message missing

(detected by MPEM)

Refer to Engine Management Section of Sea-Doo shop manual.

Refer to Cooling System Section of Sea-Doo shop manual.


115

®


7


G

BRP (SEADOO/JETLEV) TROUBLESHOOTING

BRP (SEADOO/JETLEV) SELF DIAGNOSTIC MODE (cont.)

CODE NUMBER DIAGNOSED COMPONENT/ SENSOR/ CIRCUIT FAULT DETECTED

(DESS) RFI (Basic Diagnostic)


DESS post






DESS post






Improper operation of ECM or defective wiring harness.

4 long beeps while installing safety lanyard on

DESS post

The MPEM cannot communicate with the BOSCH

ECU (787 RFI)

Low Battery

8 short beeps Defective MPEM memory

Continuous Beep Engine overheating.






Check fuse on relay located in fron electrical box or on the MPEM.

Check connectors between MPEM and ECU module.

Check battery connections and battery condition.

Recharge or replace battery.

Replace MPEM.

Refer to Troubleshooting Chart 03-01 in Sea-Doo shop manual.

Restricted jet pump water intake

Cooling system restriction.

Grounded temperature sensor or sensor wire.

Advanced Self-

Diagnostic

No beep

To initialize diagnostic mode: Press start/stop button 5 times. A short and long beep must be heard. Install safety lanyard to DESS post. Press start/stop button again.

Engine starts.

1 long and 1 short beep

No safety lanyard has ever been programmed in watercraft MPEM.

Everything is correct.

Use STATS and program a safety lanyard. This code can occur only when you receive a new MPEM from the factory and no key has ever been programmed.

2 short beeps

3 short beeps

"MPEM can not read the digital code of the safety lanyard cap or the magnet is defective.

Mixed wires at safety lanyard switch connectors or bad connection."

Wiring harness of DESS switch is grounded or there is a short circuit.

Check safety lanyard cap condition with the STATS.

Replace safety lanyard if reported defective.

Check switch wiring harness.

Check wiring harness and safety lanyard switch.

116



8 sUZUKI

SUZUKI OPERATING MANUAL

Contents

C

D

A

B

E

APPLICATIONS



FAULT CODES



117

®


8

SUZUKI-

A

APPLICATIONS

SUZUKI 4-STROKE

DF40, DF50

DF40, DF50

DF60, DF70

DF60, DF70

DF80

DF90

DF90

DF100

DF115

DF115

DF140

DF140

DF150, DF175

DF150, DF175

DF200, DF225, DF250

DF200, DF225, DF250

DF300

DF300

1999 → 2007

2008 → 2012

1998 → 2007

2008 → 2012

2009 → 2012

2001 → 2007

2008 → 2012

2009 → 2012

2001 → 2007

2008 → 2012

2002 → 2007

2008 → 2012

2006 → 2007

2008 → 2012

2004 → 2007

2008 → 2012

2007

2008 → 2012

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

Sp.

Func.

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

ADC300 + ADC421

ADC300 + ADC420

ADC300 + ADC421

ADC300 + ADC420

ADC300 + ADC420

ADC300 + ADC421

ADC300 + ADC420

ADC300 + ADC420

ADC300 + ADC421

ADC300 + ADC420

ADC300 + ADC421

ADC300 + ADC420

ADC300 + ADC421

ADC300 + ADC420

ADC300 + ADC421

ADC300 + ADC420

ADC300 + ADC421

ADC300 + ADC420

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

118



8

SUZUKI-

B

Suzuki Diagnostic Socket

4-PIN


SIDE VIEW

8-PIN

FRONT VIEW

SIDE VIEW


FRONT VIEW

119

®


8

SUZUKI-

C


SUZUKI 4-STROKE


Displays basic engine information such as HP, Model Number, etc. ECU IDENTIFICATION is available to be saved and stored to be viewed later on a PC to build a custom made diagnostic printout.


Displays a list of diagnostic trouble codes currently active on the engine. Each fault code needs to be investigated and corrected. Once the faults have been corrected, then the CLEAR FAULT CODES function should be used to clear the engines fault code memory. All FAULT CODES are available to be saved and stored to be viewed later on a PC to build a custom made diagnostic printout.


Not Available—ECU detects when faults have been corrected and automatically clears them.

LIVE DATA














ENGINE HOURS



120


22

23

23

24

24

25

26

16

21

22

DTC #

11

12

14

15

31

32

32

33

34

35

37


8

SUZUKI-

D

FAULT CODES

DESCRIPTION

RECTIFIER AND REGULATOR (OVERCHARGING)

SPS (SHIFT POSITION SENSOR)

CYLINDER TEMPERATURE SENSOR

EXHAUST MANIFOLD TEMPERATURE SENSOR (STBD

OR INLINE)

EXHAUST MANIFOLD TEMPERATURE SENSOR

(PORT)

TPS (THROTTLE POSITION SENSOR)

AIR INTAKE SYSTEM

CTP SWITCH

IAT (INTAKE AIR TEMPERATURE) SENSOR

IAT (IDLE AIR TEMPERATURE) SENSOR

CMP (CAMSHAFT POSITION SENSOR)

CMP (CAMSHAFT POSITION) SENSOR

CMP (CAMSHAFT POSITION SENSOR) (VVT) (STBD)

CMP (CAMSHAFT POSITION SENSOR) (VVT) (PORT)

IAC VALVE/ BYPASS AIR SCREW ADJUSTMENT

MAP (MANIFOLD ABSOLUTE PRESSURE) SENSOR 2

(PRESSURE DETECT PASSAGE)(150HP AND UP)

MAP (MANIFOLD ABSOLUTE PRESSURE) SENSOR 2

(INLINE ENGINES: SENSOR HOSE)

NEUTRAL SWITCH

MAP SENSOR 1

SPEED SENSOR

TRIM SENSOR

SYMPTOMS

RECEIVING 16V SIGNAL OR HIGHER

NO SIGNAL

NO SIGNAL

RECEIVING AN OUT OF RANGE SIGNAL

NO SIGNAL


NO SIGNAL


NO SIGNAL

ENGINE OPERATES AT ABNORMALLY HIGH SPEED (2500

RPM OR HIGHER) AS ECM RECEIVES TPS FULLY CLOSED

MESSAGE

RECEIVING ON SIGNAL WHEN ENGINE SPEED IS 2500

RPM OR HIGH AND INTAKE MANIFOLD PSI IS 300MM

HG OR HIGHER

NO SIGNAL


NO SIGNAL


4 PULSES NOT RECEIVED BY ECM PER 2 CRANKSHAFT

REVOLUTIONS

NO INPUT PULSES FROM CMP SENSOR WHILE HAVING

544 INPUT PULSES FROM CKP SENSOR (16 CRANKSHAFT

REVOLUTIONS)


REVOLUTIONS


REVOLUTIONS

IAC VALVE OPERATES AT 90% DURY OR HIGH WHEN CTP

SWITCH IS ON

AC VALVE OPERATES AT 10% DUTY OR LOWER WHEN

CTP SWITCH IS ON

RECEIVING UNCHANGING SIGNAL REGARDLESS ENGINE

SPEED CHANGE

RECEIVING UNCHANGING SIGNAL REGARDLESS ENGINE

SPEED CHANGE

WITH NEUTRAL SWITCH INDICATING IN GEAR, ECM

RECIEVES NEUTRAL MESSAGE FROM SWITCH

NO SIGNAL (WITH ENGINE RUNNING)

RECEIVING AN OUT OF RANGE SIGNAL (WITH ENGINE

RUNNING)




121

®

75

81

82

83


8

SUZUKI-

D

FAULT CODES

72

73

74

52

61

62

71

DTC #

42

42

43

51

DESCRIPTION

CKP (CRANKSHAFT POSITION SENSOR)

CKP (CRANKSHAFT POSITION) SENSOR (INLINE

ENGINES)

FUEL INJECTOR (OPEN CIRCUIT)

VVT (VARIABLE VALVE TIMING) ADVANCE (STBD)

VVT (VARIABLE VALVE TIMING) ADVANCE (PORT)

OCV (OIL CONTROL VALVE) (STBD)

OCV (OIL CONTROL VALVE) (PORT)

ETV ECM

ETV MOTOR

ETV VALVE

SUB BCM

DBW SYSTEM

ESA ECM

ESA MOTOR

ESA

SYMPTOMS

34 PULSES NOT RECEIVED BY ECM PER CRANKSHAFT

REVOLUTION

NO INPUT PULSES FROM CKP SENSOR WHILE HAVING 3

INPUT PULSES FROM CMP SENSOR

NO SIGNAL

LARGE DIFFERENTIAL BETWEEN TARGET ADVANCE

ANGLE AND ACTUAL ADVANCE ANGLE

LARGE DIFFERENTIAL BETWEEN TARGET ADVANCE

ANGLE AND ACTUAL ADVANCE ANGLE

OCV NOT OPERATING

OCV NOT OPERATING

ECM ELECTRONIC THROTTLE CONTROL CIRCUIT

FAILURE

THROTTLE VALVE ACTUATOR MOTOR OPERATION

FAILURE OR ITS POWER SUPPLY SYSTEM (THROTTLE

RELAY, ETC) FAILURE

THROTTLE VALVE OPERATION FAILURE

SUB BCM COMMUNICATION ERROR

LOW SUB BCM SOURCE VOLTAGE

SUB BCM FAILURE"

CAN COMMUNICATION ERROR BETWEEN BCM AND

ECM

LPS ERROR (ECM RECEIVED AN INPUT SIGNAL FROM

EACH SENSOR OUT OF RANGE AS TOTAL OF MAIN

SENSOR AND SUB SENSOR OUTPUT VOLTAGE

LOW BCM SOURCE VOLTAGE

BCM FAILURE

ECM FAILURE

ECM ELECTRONIC SHIFT CONTROL CIRCUIT FAILURE

ELECTRONIC SHIFT MOTOR FAILURE

MOTOR CONNECTOR OPEN

MOTOR POWER SUPPLY LINE OPEN

RESPONSE FAILURE

ECM HAS DETECTED TARGET LPS OUTPUT VOLTAGE

SIGNAL, BUT NO CHANGE OCCURS IN INPUT SIGNAL

VOLTAGE FROM SHIFT POSITION SENSOR

122



8

SUZUKI-

E

Suzuki 4-Stroke

Diagnostics



123

®


8

SUZUKI-

E

Suzuki 4-Stroke

Diagnostics


124



9 HONDA

HONDA OPERATING MANUAL

Contents

C

D

A

B

E

APPLICATIONS



FAULT CODES



125

®


9

HONDA-

A

APPLICATIONS

Honda

Sp.

Func.

BF40D

BF50D

BF60A

BF75D

BF90D

BF115A*

2008 → UP

2008 → UP

2009 → UP

2007 → UP

2007 → UP

2005 → UP

✓

✓

✓

✓

✓

✓

*2005-2008 Models-- Information is limited, but available

✓

✓

✓

✓

✓

✓

BF115D

BF135A

BF150A

BF200A*

2010 → UP

2005 → UP

2005 → UP

2002 → UP

✓

✓

✓

✓

*2002 Models-- Information is limited, but available

✓

✓

✓

✓

BF225A* 2002 → UP

✓

*2002 Models-- Information is limited, but available

BF200AK1

BF225AK1

BF250A

2009 → UP

2009 → UP

2012 → UP

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

ADC300 + ADC427

ADC300 + ADC427

ADC300 + ADC427

ADC300 + ADC427

ADC300 + ADC427

ADC300 + ADC427

ADC300 + ADC427

ADC300 + ADC427

ADC300 + ADC427

ADC300 + ADC427

ADC300 + ADC427

ADC300 + ADC427

ADC300 + ADC427

ADC300 + ADC427

A

A

A

A

A

A

A

A

A

A

A

A

A

A

*Engines equipped with 2-Pin diagnostic plug are not designed to work with computer diagnostics. Plug must be grounded together to perform flash diagnostics on the gauge. See Fault code list for flash code descriptions.

126



9

HONDA-

B


Honda Diagnostic Socket



127

®


9

HONDA-

C


HONDA


Displays basic engine information such as HP, Serial number, etc. ECU IDENTIFICATION is available to be saved and stored to be viewed later on a PC to build a custom made diagnostic printout.


4- pin DLC: Displays a list of diagnostic trouble codes currently active on the engine. Each fault code needs to be investigated and corrected. Freeze Frame data and Possible Causes for the failure will also be displayed on the next screen by pressing the RIGHT ARROW key. Once the faults have been corrected, then the CLEAR FAULT CODES function should be used to clear the engines fault code memory. All FAULT CODES and FREEZE FRAME DATA are available to be saved and stored to be viewed later on a


2- pin DLC: Pins must be shorted together to perform Flash Diagnostics. See Fault Code Section for Flash Code Descriptions. NOTE:

This type of connection is not supported by STATS, manual code read only.


4-pin DLC: This functions allows any fault codes that have been fixed to be cleared. After the fault codes have successfully been cleared, if any are still displayed, this indicates that the faults have not been corrected and further investigation is required.

2- pin DLC: Procedure must be performed within 20 seconds. 1. Turn ignition switch OFF. 2. Short DLC connector together. 3.

Turn ignition switch ON. With emergency stop lanyard in place, press emergency stop switch for 1 second and release. Repeat total of 5 times. At this time, buzzer should sound and MIL should illuminate steady. 5. Turn ignition switch OFF and disconnect short from DLC connector.

LIVE DATA







3. Command the fuel pump ON

4. Test Alarm Functions (lights, buzzers)

5. Test Tachometer at different RPM ranges

6. Test select solenoids such as VTEC solenoid



1. Command off individual cylinders to isolate a running concern (Power Balance) (injector & ignition coil).


3. Test Alarm Functions (lights, buzzers)

ENGINE HOURS




128


9

HONDA-

D

FAULT CODES

DTC #

0 or does not communicate

"(-)

0-2

0-5

0-8"

0 or does not communicate

"(-)

0-2

0-5

0-8"

DTC 1-4

DTC 3-1

DTC 3-2

DTC 4-1

DTC 4-2

DTC 6-1

DTC 6-2

DTC 7-1

DTC 7-2

MIL FLASH

DOES NOT FLASH

OR BLINK

DOES NOT FLASH

OR BLINK

MIL STEADY

MIL STEADY

1

3

3

4

4

6

6

7

7

MIL

MIL OFF/ No Blinking

MIL OFF/ No Blinking

MIL ON

MIL ON

MIL ON

MIL ON

MIL ON

MIL ON

MIL ON

MIL ON

MIL ON

MIL ON

MIL ON

DESCRIPTION

ECM

ECM

ECM

ECM

HO2S (Heated

Oxygen Sensor) is

Faulty

MAP (Manifold

Absolute Pressure)

Sensor Voltage Low

MAP (Manifold

Absolute Pressure)

Sensor Voltage High

CKP (Crankshaft

Position)(TDC 1)

Sensor No Pulse

CKP (Crankshaft

Position)(TDC 1)

Sensor Pulse

Abnormal

ECT (Engine Coolant

Temperature) Sensor

1 Voltage Low

ECT (Engine Coolant

Temperature) Sensor

1 Voltage High

TPS (Thottle Position

Sensor) Voltage Low

TPS (Thottle Position

Sensor) Voltage

High

PROBABLE CAUSES

Indicator Light

Loose connector

MIL Circuit open

ECM ground circuit open or poor grounding

ECM

MIL Circuit Open

Burned out MIL

ECM Ground Circuit Open or Poor Ground

ECM"

SCS Service Check Connector Activated

DLC Circuit Short

MIL Ciruit Short

Sensor Power Circuit Short

ECM Power Circuit Open

ECM

ECM Power Circuit Open

DLC Wire Circuit Shorted

MIL Circuit Shorted

Sensor Power Circuit Shorted

ECM

HO2S Circuit Open or Shorted

HO2S

Fuel Supply

ECM

Loose connector

MAP Sensor Circuit Shorted (PB)

MAP Sensor Open Circuit (VCC1)

MAP Sensor

ECM

Loose Connector

MAP Sensor Open Circuit (PB)

MAP Sensor Open Circuit (VCC1)

MAP Sensor Open Circuit (SG1)

MAP Sensor

ECM

Loose Connector

CKP Sensor Circuit Open or Shorted (CRK)

CKP Sensor Circuit Open (IGP2)

CKP Sensor Circuit Open (LG1)

CKP Sensor

ECM

Loose Connector

CKP Sensor

CKP Sensor is not properly installed

ECM

Loose Connector

ECT Sensor 1 Circuit Shorted (TE)

ECT Sensor 1

ECM

Loose Connector

ECT Sensor 1 Circuit Open (TE)

ECT Sensor 1 Circuit Open (SG2)

ECT Sensor 1

ECM

Loose Connector

TPS Sensor Circuit Shorted or Open (THL)

TPS Sensor Circuit Open (VCC2)

TPS Sensor

ECM

Loose Connector

TPS Sensor Circuit Open (SG2)

TPS Sensor

ECM


129

®


9

HONDA-

D

FAULT CODES

DTC #

DTC 8-1

DTC 8-2

DTC 10-1

DTC 10-2

DTC 13-1

DTC 13-2

DTC 14-1

DTC 21-1

DTC 22-1

DTC 22-2

DTC 23-1

DTC 41-2

DTC 41-3

8

10

13

13

14

23

41

MIL FLASH

8

10

21

41

MIL

MIL ON

MIL ON

MIL ON

MIL ON

MIL ON

MIL ON

MIL ON

MIL ON

MIL ON

MIL ON

MIL ON

MIL ON

MIL ON

DESCRIPTION

CMP (Camshaft

Position)(Pulser Coil)

Sensor No Pulse

CMP (Camshaft

Position)(Pulser Coil)

Sensor Abnormal

Pulse

IAT (Intake Air

Temperature) Sensor

Voltage Low

IAT (Intake Air

Temperature) Sensor

Voltage High

Barometric (BARO)

Sensor Voltage Low

Barometric (BARO)

Sensor Voltage High

IAC (Idle Air

Control) Valve

Abnormal Current

VTEC Solenoid Valve

Abnormal Signal

EOP (Engine Oil

Pressure) Sensor

Voltage Low

EOP (Engine Oil

Pressure) Sensor

Voltage High

Knock Sensor

Abnormal Detection

PROBABLE CAUSES

Loose Connector

CMP Sensor Circuit Shorted or Open (TDC)

CMP Sensor Circuit Open (IGP2)

CMP Sensor Circuit Open (LG1)

CMP Sensor

ECM

Loose Connector

CMP Sensor

CMP Sensor Installed Incorrectly

ECM

Loose Connector

IAT Sensor Circuit Shorted (TA)

IAT Sensor

ECM

Loose Connector

IAT Sensor Circuit Open (TA)

IAT Sensor Circuit Open (SG2)

IAT Sensor

ECM

BARO Sensor Circuit Open

BARO Sensor Circuit Shorted

BARO Sensor

ECM

BARO Sensor Circuit Open

BARO Sensor

ECM

Loose Connector

IAC Valve Circuit Shorted (EACVP)

IAC Valve Circuit Shorted (EACVM)

IAC Valve

ECM

Loose Connector

VTEC Solenoid Valve Circuit Open or Shorted (VTS)

VTEC Solenoid Valve

ECM

Loose Connector

EOP Sensor Circuit Shorted (POIL)

EOP Sensor Circuit Open (VCC2)

EOP Sensor

ECM

Loose Connector

EOP Sensor Circuit Open (POIL)

EOP Sensor Circuit Open (VCC2)

EOP Sensor Circuit Open (SG2)

EOP Sensor

ECM

Loose Connector

Knock Sensor Circuit Shorted or Open (KS)

Knock Sensor

ECM

HO2S (Heated

Oxygen Sensor)

Heater Abnormal

Current

HO2S Heater Circuit Shorted or Open

HO2S Heater

ECM

A/F (Air Flow) Sensor

Heater Abnormal

Current (High or

Low)

Loose connector

A/F Sensor Heater Circuit Shorted or Open (LAFR)

A/F Sensor Heater Circuit Open (AFHT+)

A/F Sensor Heater Circuit Shorted or Open (AFHT)

A/F Sensor Heater

A/F Sensor Heater Relay

ECM


130

DTC 41-4

DTC 48-5

DTC 48-6

DTC 48-7

DTC 58-1

DTC 58-2

DTC #


9

HONDA-

D

FAULT CODES

MIL FLASH MIL

DTC 58-1

DTC 58-2

DTC 140-1

DTC 140-2

DTC 141-1

DTC 141-2

DTC 142-1

41

48

48

48

58

24 OR 25

24 OR 25

24 OR 25

24 OR 25

26

MIL ON

MIL ON

MIL ON

MIL ON

MIL ON

MIL ON

MIL ON

MIL ON

MIL ON

MIL ON

MIL ON

MIL ON

MIL ON

DESCRIPTION

A/F (Air Flow) Sensor

Heater Abnormal

Current

A/F Sensor Open

Circuit (AFV/AFC)

A/F Sensor Short

Circuit (AFV)

A/F Sensor Short

Circuit (AFC)

Pulser Coil Current

Abnormal

Pulser Coil Current

Abnormal

CMP (Camshaft

Position)(TDC 2)

Sensor 2 No Pulse

(BF40,50 ONLY --

Pulser Coil Current

Abnormal)

CMP (Camshaft

Position)(TDC 2)

Sensor 2 Abnormal

Pulse (BF40,50

ONLY -- Pulser Coil

Current Abnormal)

ECT (Engine Coolant

Temperature)(Overheat

1) Sensor 2 Voltage

Low

ECT (Engine Coolant


1) Sensor 2 Voltage

High

ECT (Engine Coolant


2) Sensor 3 Voltage Low

ECT (Engine Coolant


2) Sensor 3 Voltage

High

EOP (Engine Oil

Pressure) Switch

Abnormal

PROBABLE CAUSES

Loose Connector

A/F Sensor Heater Circuit Shorted (AFHT) and (AFC)

A/F Sensor Heater Circuit Shorted (AFHT) and (AFV)

A/F Sensor Heater Circuit Shorted (AFHT+) and (AFC)

A/F Sensor Heater Circuit Shorted (AFHT+) and (AFV)

A/F Sensor Heater Circuit Shorted or Open (LAFR)

A/F Sensor Heater Circuit Shorted or Open (AFHT+)

A/F Sensor Heater Circuit Shorted or Open (AFHT)

A/F Sensor Heater

A/F Sensor Relay

ECM

Loose Connector

A/F Sensor Circuit Open (AFV)

A/F Sensor Circuit Open (AFC)

ECM

Loose Connector

A/F Sensor Circuit Shorted (AFV)

ECM

Loose Connector

A/F Sensor Circuit Shorted (AFC)

ECM

Pulser Coil Circuit Shorted or Open

Pulser Coil

ECM

Pulser Coil

Pulser Rotor

ECM

CMP 2 Sensor Circuit Shorted

CMP 2 Sensor

ECM

(BF40, 50 ONLY

Pulser Coil Circuit Shorted or Open

Pulser Coil

ECM)

CMP 2 Sensor

ECM

(BF40, 50 ONLY

Pulser Coil

Pulser Rotor

ECM)

Loose Connector

ECT Sensor 2 Short Circuit

ECT Sensor 2

ECM

Loose Connector

ECT Sensor 2 Circuit Open (TOH1)


ECT2 Sensor 2

ECM

Loose Connector

ECT Sensor 3 Short Circuit (TOH2)

ECT Sensor 3

ECM

Loose Connector



ECT Sensor 3

ECM

EOP Switch Circuit Shorted or Open

EOP Switch

ECM


131

®


9

HONDA-

D

FAULT CODES

DTC #

DTC 143-1

MIL FLASH

27

MIL

MIL ON

DTC 143-2 27 MIL ON

Multiple Codes Present

DTC 7, 13 7, 13

DTC 6, 7, 10, 13,

48, 140, 141, 143

DTC 1, 3, 13, 7,

10, 24, 25

6, 7, 10, 13, 48,

140, 141, 143

1, 3, 13, 7, 10, 24,

25

MIL ON

MIL ON

MIL ON

DESCRIPTION

ECT (Engine Coolant

Temperature) Sensor

4 Voltage Low

ECT (Engine Coolant

Temperature) Sensor

4 Voltage High

PROBABLE CAUSES

Loose Connector

ECT Sensor 4 Circuit Shorted (TOH3)

ECT Sensor 4

ECM

Loose Connector



ECT Sensor 4

ECM

See Above For Code

Descriptions

See Above For Code

Descriptions

See Above For Code

Descriptions

Power Source for Sensor Open Circuit (VCC) Line (B/W)

Sensor Ground Circuit Open (SG) Line

Sensor Ground Circuit Open (SG) Line (G/R)

132



9

HONDAe


Honda

Outboard

Diagnostics


133

®


9

HONDAe


Honda

Outboard

Diagnostics

(continued)

DIAGNOSTICS DIAGNOSTICS DIAGNOSTICS

134



10 VOLVO DIESEL

VOLVO DIESEL OPERATING MANUAL

Contents

C

D

A

B

E

APPLICATIONS



FAULT CODES



135

®


10

VOLVO DIESEL-

A

Volvo Diesel

APPLICATIONS

Sp.

Func.

D3-220

D4-180

D4-210

D4-225

D4-260

D4-300

D6-280

D6-310

D6-330

D6-350

D6-370

D6-435

Volvo Penta Gasoline


Equipped

Volvo Penta Diesel

D3-110

D3-130

D3-140

D3-150

D3-160

D3-170

D3-190

D3-200

1992 → 2005

2004 → 2010

2005 → 2010

2009 → 2010

2009 → 2010

2004 → 2009

2009 → 2010

2005 → 2010

2009 → 2010

2009 → 2010

2005 → 2010

2003 → 2006

2005 → 2010

2004 → 2010

2007 → 2010

2004 → 2010

2004 → 2010

2007 → 2010

2004 → 2007

2004 → 2010

2006 → 2010

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

ADC300 + ADC424

ADC300 + ADC415

ADC300 + ADC415

ADC300 + ADC415

ADC300 + ADC415

ADC300 + ADC415

ADC300 + ADC415

ADC300 + ADC415

ADC300 + ADC415

ADC300 + ADC415

ADC300 + ADC415

ADC300 + ADC415

ADC300 + ADC415

ADC300 + ADC415

ADC300 + ADC415

ADC300 + ADC415

ADC300 + ADC415

ADC300 + ADC415

ADC300 + ADC415

ADC300 + ADC415

ADC300 + ADC415

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

A

136



10

VOLVO DIESEL-

B

Volvo Diesel Diagnostic Socket




137

®


10

VOLVO DIESEL-

C


VOLVO DIESEL (D3, D4, D6) ENGINES




Displays a list of diagnostic trouble codes currently active on the engine. Each fault code needs to be investigated and corrected. Once the faults have been corrected, then the CLEAR FAULT CODES function should be used to clear the engines fault code memory. All

FAULT CODES are available to be saved and stored to be viewed later on a PC to build a custom made diagnostic printout.


This function allows any fault codes that have been fixed to be cleared. After the fault codes have successfully been cleared, if any are still displayed, this indicates that the faults have not been corrected and further investigation is required.

LIVE DATA




Engine and Helm Configuration


138



10

VOLVO DIESEL-

D

Volvo Diesel - MID 128 SID FAULTS

DTC #

29

30

31

32

25

26

27

28

19

20

21

22

15

16

17

18

11

12

13

14

8

9

10

6

7

4

5

1

2

3

49

50

57

41

42

47

48

37

38

39

40

34

35

36

DESCRIPTION

INJECTOR 1

INJECTOR 2

INJECTOR 3

INJECTOR 4

INJECTOR 5

INJECTOR 6

INJECTOR 7

INJECTOR 8

INJECTOR 9

INJECTOR 10

INJECTOR 11

INJECTOR 12

INJECTOR 13

INJECTOR 14

INJECTOR 15

INJECTOR 16

FUEL SHUTOFF VALVE

FUEL CONTROL VALVE

THROTTLE BYPASS VALVE

TIMING ACTUATOR

ENGINE POSITION SENSOR

TIMING SENSOR

EXTERNAL ENGINE PROTECTION INPUT

AUXILIARY OUTPUT DEVICE DRIVER 1

VARIABLE GEOMETRY TURBOCHARGER ACTUATOR 1

VARIABLE GEOMETRY TURBOCHARGER ACTUATOR 2

EXTERNAL FUEL COMMAND INPUT

EXTERNAL SPEED COMMAND INPUT

TACHOMETER SIGNAL OUTPUT

TURBOCHARGER 1 WASTEGATE DRIVE

EXHAUST BACK PRESSURE SENSOR

EXHAUST BACK PRESSURE REGULATOR SOLENOID

GLOW PLUG LAMP

ELECTRONIC DRIVE UNIT POWER RELAY

GLOW PLUG RELAY

ENGINE STARTER MOTOR RELAY

AUXILIARY OUTPUT DEVICE DRIVER 2

ECM 8 VOLTS DC SUPPLY

INJECTION CONTROL PRESSURE REGULATOR

INJECTOR 17

INJECTOR 18

INJECTOR 19

INJECTOR 20

AUXILIARY PWM DRIVER 1

FAULT CODES


139

®


10

VOLVO DIESEL-

D

Volvo Diesel - MID 128 SID FAULTS (cont.)

DTC #

85

86

87

88

81

82

83

84

76

78

79

80

72

73

74

75

68

69

70

71

65

66

67

61

62

63

64

58

59

60

96

97

98

99

100

101

102

92

93

94

95

89

90

91

DESCRIPTION




VARIABLE SWIRL SYSTEM VALVE

PRESTROKE SENSOR

PRESTROKE ACTUATOR

ENGINE SPEED SENSOR 2

HEATED OXYGEN SENSOR

IGNITION CONTROL MODE SIGNAL

IGNITION CONTROL TIMING SIGNAL

SECONDARY TURBO INLET PRESSURE

AFTER COOLER OIL COOLER COOLANT TEMPERATURE

INLET AIR HEATER DRIVER 1

INLET AIR HEATER DRIVER 2

INJECTOR CYLINDER 21




KNOCK SENSOR

FUEL SUPPLY PUMP ACTUATOR

ENGINE COMPRESSION BRAKE OUTPUT 1


ENGINE EXHAUST BRAKE OUTPUT


FUEL CONTROL VALVE 2

TIMING ACTUATOR 2

ENGINE OIL BURN VALVE

ENGINE OIL REPLACEMENT VALVE

IDLE SHUTDOWN VEHICLE ACCESSORIES RELAY DRIVER

TURBOCHARGER 2 WASTEGATE DRIVE

AIR COMPRESSOR ACTUATOR CIRCUIT

ENGINE CYLINDER 1 KNOCK SENSOR













FAULT CODES


140


10

VOLVO DIESEL-

D

Volvo Diesel - MID 128 SID FAULTS (cont.)

DTC #

132

133

134

135

128

129

130

131

123

124

126

127

118

119

120

121

122

114

115

116

117

110

111

112

113

103

104

105

106

107

108

109

144

146

147

218

231

140

141

142

143

136

137

138

139

DESCRIPTION












MULTIPLE UNIT SYNCHRONIZATION SWITCH

ENGINE OIL CHANGE INTERVAL

ENGINE WAS SHUT DOWN HOT

ENGINE HAS BEEN SHUT DOWN FROM DATA LINK INFORMATION

INJECTOR NEEDLE LIFT SENSOR 1

INJECTOR NEEDLE LIFT SENSOR 2

COOLANT SYSTEM THERMOSTAT

ENGINE AUTOMATIC START ALARM

ENGINE AUTOMATIC START LAMP

ENGINE AUTOMATIC START SAFETY INTERLOCK CIRCUIT

ENGINE AUTOMATIC START FAILED ENGINE

FUEL PUMP PRESSURIZING ASSEMBLY 1

FUEL PUMP PRESSURIZING ASSEMBLY 2

STARTER SOLENOID LOCKOUT RELAY DRIVER CIRCUIT

CYLINDER 1 EXHAUST GAS PORT TEMPERATURE
















EXHAUST GAS RE CIRCULATION EGR VALVE MECHANISM

VARIABLE NOZZLE TURBOCHARGER VNT MECHANISM

MAIN RELAY

J1939 ENGINE BUS


141

FAULT CODES

®


10

VOLVO DIESEL-

D

Volvo Diesel - MID 140 SID FAULTS

2

2

2

2

2

1

1

1

1

1

1

8

9

4

5

2

3

7

DTC #

1

DESCRIPTION

LEFT FUEL LEVEL SENSOR

RIGHT FUEL LEVEL SENSOR

FUEL FEED RATE SENSOR

FUEL RETURN RATE SENSOR

TACHOMETER GAUGE COIL

TURBOCHARGER AIR PRESSURE GAUGE COIL

FUEL PRESSURE GAUGE COIL

FUEL LEVEL GAUGE COIL

SECOND FUEL LEVEL GAUGE COIL

ENGINE OIL PRESSURE GAUGE COIL

ENGINE OIL TEMPERATURE GAUGE COIL

ENGINE COOLANT TEMPERATURE GAUGE COIL

PYROMETER GAUGE COIL

VOLTMETER GAUGE COIL

PRIMARY AIR PRESSURE GAUGE COIL

SECONDARY AIR PRESSURE GAUGE COIL

AMMETER GAUGE COIL

AIR APPLICATION GAUGE COIL

AIR RESTRICTION GAUGE COIL

FAULT CODES

142



10

VOLVO DIESEL-

D

Volvo Diesel - MID 128 PID FAULTS

DTC #

101

102

103

104

96

97

98

93

94

95

99

100

90

91

92

81

82

89

67

71

72

64

65

66

73

80

51

62

63

44

47

48

30

38

40

42

43

27

28

29

20

21

22

5

6

15

16

17

18

19

DESCRIPTION

UNDERRANGE WARNING CONDITION

OVERRANGE WARNING CONDITION

FUEL SUPPLY PUMP INLET PRESSURE

SUCTION SIDE FUEL FILTER DIFFERENTIAL PRESSURE

ENGINE OIL LEVEL REMOTE RESERVOIR

EXTENDED RANGE FUEL PRESSURE

EXTENDED RANGE ENGINE OIL PRESSURE

EXTENDED RANGE ENGINE COOLANT PRESSURE

ENGINE ECU TEMPERATURE

EXTENDED ENGINE CRANKCASE BLOW BY PRESSURE

PERCENT EXHAUST GAS RECIRCULATION VALVE 1 POSITION

PERCENT ACCELERATOR POSITION 3

PERCENT ACCELERATOR POSITION 2

CRANKCASE BLOW BY PRESSURE

SECOND FUEL LEVEL RIGHT SIDE

ENGINE RETARDER SWITCHES STATUS

PRESSURE SWITCH STATUS

IGNITION SWITCH STATUS

ATTENTION WARNING INDICATOR LAMPS STATUS

RETARDER STATUS

EXTENDED RANGE BAROMETRIC PRESSURE

THROTTLE POSITION

RETARDER INHIBIT STATUS

TRANSMISSION ACTUATOR STATUS 1

DIRECTION SWITCH STATUS

SERVICE BRAKE SWITCH STATUS

VEHICLE ENABLING COMPONENT STATUS

SHIFT REQUEST SWITCH STATUS

IDLE SHUTDOWN TIMER STATUS

BLOWER BYPASS VALUE POSITION

AUXILIARY WATER PUMP PRESSURE

WASHER FLUID LEVEL

PARTICULATE TRAP INLET PRESSURE

AIR START PRESSURE

POWER TAKEOFF STATUS

PTO OIL TEMPERATURE

PERCENT ACCELERATOR PEDAL POSITION

PERCENT ENGINE LOAD

OUTPUT TORQUE

FUEL DELIVERY PRESSURE

FUEL FILTER DIFFERENTIAL PRESSURE

FUEL LEVEL

WATER IN FUEL INDICATOR

ENGINE OIL LEVEL

ENGINE OIL FILTER DIFFERENTIAL PRESSURE

ENGINE OIL PRESSURE

CRANKCASE PRESSURE

BOOST PRESSURE

TURBO SPEED

TURBO OIL PRESSURE

FAULT CODES


143

®


10

VOLVO DIESEL-

D

Volvo Diesel - MID 128 PID FAULTS (cont.)

DTC #

167

168

169

171

172

159

160

161

162

163

164

165

166

153

154

155

156

157

158

133

135

136

137

138

150

151

152

127

128

129

130

131

132

121

122

124

125

126

112

113

114

115

119

120

105

106

107

108

109

110

111

DESCRIPTION

INTAKE MANIFOLD TEMPERATURE

AIR INLET PRESSURE

AIR FILTER DIFFERENTIAL PRESSURE

BAROMETRIC PRESSURE

COOLANT PRESSURE


COOLANT LEVEL

COOLANT FILTER DIFFERENTIAL PRESSURE

GOVERNOR DROOP

NET BATTERY CURRENT

ALTERNATOR CURRENT

HYDRAULIC RETARDER PRESSURE

HYDRAULIC RETARDER OIL TEMPERATURE

ENGINE RETARDER STATUS

ENGINE RETARDER PERCENT

TRANSMISSION OIL LEVEL

TRANSMISSION OIL LEVEL HIGH LOW

TRANSMISSION FILTER DIFFERENTIAL PRESSURE

TRANSMISSION OIL PRESSURE

COMPONENT SPECIFIC REQUEST

INJECTOR METERING RAIL 2 PRESSURE

POWER SPECIFIC FUEL ECONOMY

EXHAUST BACK PRESSURE

MASS AIR FLOW

AVERAGE FUEL RATE

EXTENDED RANGE FUEL DELIVERY PRESSURE ABSOLUTE

AUXILIARY VACUUM PRESSURE READING

AUXILIARY GAGE PRESSURE READING 1

AUXILIARY ABSOLUTE PRESSURE READING

PTO ENGAGEMENT CONTROL STATUS

ATC CONTROL STATUS

NUMBER OF ECU RESETS

CRANKCASE PRESSURE

AUXILIARY INPUT AND OUTPUT STATUS 2

AUXILIARY INPUT AND OUTPUT STATUS 1

INJECTOR TIMING RAIL PRESSURE

INJECTOR METERING RAIL PRESSURE

BATTERY POTENTIAL VOLTAGE SWITCHED

GAS SUPPLY PRESSURE

MAIN SHAFT SPEED

INPUT SHAFT SPEED

TRANSMISSION RANGE SELECTED

TRANSMISSION RANGE ATTAINED

INJECTION CONTROL PRESSURE

COMPASS BEARING

RATED ENGINE POWER

ALTERNATOR POTENTIAL VOLTAGE

BATTERY POTENTIAL VOLTAGE

CARGO AMBIENT TEMPERATURE

AMBIENT AIR TEMPERATURE

AIR INLET TEMPERATURE

FAULT CODES


144


10

VOLVO DIESEL-

D

Volvo Diesel - MID 128 PID FAULTS (cont.)

DTC #

250

251

252

253

244

245

246

247

248

249

234

235

236

237

238

239

240

243

222

223

224

228

232

233

196

197

198

214

217

218

220

221

190

191

192

193

194

195

182

183

184

185

186

187

188

189

173

174

175

176

177

DESCRIPTION


FUEL TEMPERATURE

ENGINE OIL TEMPERATURE

TURBO OIL TEMPERATURE

TRANSMISSION 1 OIL TEMPERATURE

TRIP FUEL

FUEL RATE INSTANTANEOUS

INSTANTANEOUS FUEL ECONOMY

AVERAGE FUEL ECONOMY

POWER TAKEOFF SPEED

POWER TAKEOFF SET SPEED

IDLE ENGINE SPEED

RATED ENGINE SPEED

ENGINE SPEED

TRANSMISSION OUTPUT SHAFT SPEED

MULTISECTION PARAMETER

TRANSMITTER SYSTEM DIAGNOSTIC TABLE

TRANSMITTER SYSTEM DIAGNOSTIC CODE

DIAGNOSTIC DATA REQUEST CLEAR COUNT

DIAGNOSTIC DATA COUNT CLEAR RESPONSE

CONNECTION MANAGEMENT

CONNECTION MODE DATA TRANSFER

VEHICLE WHEEL SPEEDS

FUEL TANK NOZZLE IDENTIFICATION

STATE LINE CROSSING

ENGINE TORQUE HISTORY

ANTI THEFT REQUEST

ANTI THEFT STATUS

AUXILIARY A D COUNTS

IMMOBILIZER SECURITY CODE

SPEED SENSOR CALIBRATION

DGPS DIFFERENTIAL CORRECTION

UNIT NUMBER POWER UNIT

SOFTWARE IDENTIFICATION

TOTAL IDLE HOURS

TOTAL IDLE FUEL USED

VEHICLE IDENTIFICATION NUMBER

VELOCITY VECTOR

VEHICLE POSITION

CHANGE REFERENCE NUMBER

COMPONENT IDENTIFICATION

TRIP DISTANCE

TOTAL VEHICLE DISTANCE

TOTAL VEHICLE HOURS

TOTAL ENGINE HOURS

TOTAL PTO HOURS

TOTAL ENGINE REVOLUTIONS

TOTAL FUEL USED

CLOCK

DATE

ELAPSED TIME


145

FAULT CODES

®


10

VOLVO DIESEL-

D

Volvo Diesel - MID 187 PPID FAULTS

DTC #

393

398

399

401

402

DESCRIPTION

POWER SUPPLY DATA BUS

GEAR SHIFT ACTUATOR POSITION IN RELATION TO POTENTIOMETER POWER

SUPPLY

POWER SUPPLY FAULT POTENTIOMETER IN GEAR SHIFT ACTUATOR

POWER TRIM POSITION RELATIVE TO POT SUPPLY

POWER TRIM POTENTIOMETER SUPPLY

Volvo Diesel - MID 187 PSID FAULTS

DTC #

226

232

401

402

24

26

30

31

200

20

21

22

23

13

14

15

17

DESCRIPTION

INVALID COMBINATION EXTERNAL COMPONANTS,

DETECTION FAULT EXTENAL COMPONANTS,

INCOMPATABLE HARDWARE EVC,

CONFIGURATION FAULT DATA BUS NETWORK,

PRIMARY SOLENOID VALVE HIGH SIDE SWITCH,

PRIMARY SOLENOID VALVE LOW SIDE SWITCH,

SECONDARY SOLENOID VALVE HIGH SIDE SWITCH,

SECONDARY SOLENOID VALVE LOW SIDE SWITCH,

MOTOR DIRECTION 1 HIGH SIDE SWITCH,

MOTOR DIRECTION 2 HIGH SIDE SWITCH,

POWER TRIM MOTOR DIRECTION UP,

POWER TRIM MOTOR DIRECTION DOWN,

NO DATA ON THE ENGINE BUS,

COMMUNICATION FAULT ON DATA BUS PASSIVE ACTIVE HELM STATION,

COMMUNICATION WARNING DATA BUS,


POWER TRIM POTENTIOMETER SUPPLY,


DTC #

10

11

30

31

200

401

402

DESCRIPTION

INCOMPATABLE ENGINE TYPE, NULL

CRANK SWITCH KEY SWITCH, NULL

POWER TRIM MOTOR DIRECTION UP, NULL

POWER TRIM MOTOR DIRECTION DOWN, NULL

J1939 ENGINE BUS, NULL


POWER TRIM POTENTIOMETER SUPPLY, NULL

FAULT CODES


146


10

VOLVO DIESEL-

D

Volvo Diesel - MID 140 PPID FAULTS

DTC #

289

290

397

398

410

401

402

DESCRIPTION

POWER TRIM SWITCH, NULL

POWER TRIM SIGNAL OR SUPPLY, NULL

MAIN PANEL, NULL

DISPLAY, NULL

DEPTH ALARM, NULL


POWER TRIM POTENTIOMETER SUPPLY, NULL


DTC #

56

70

71

216

50

51

53

54

55

DESCRIPTION

FUEL PRESSURE MONITORING MPROP, NULL

REDUNDANT SHUT OFF PATH, NULL

MONITORING THE PRESSURE RELIEF VALVE, NULL

BOOSTER VOLTAGE HIGH BANK 1, NULL

BOOSTER VOLTAGE HIGH BANK 2, NULL

SYSTEM STARTUP TEST FOR SHUTOFF PATH, NULL

FUEL PRESSURE MONITORING 1, NULL

FUEL PRESSURE MONITORING 2, NULL

SAE J1939 DATA LINK, NULL

FAULT CODES


147

®


10

VOLVO DIESELe

Volvo

Outboard

Diagnostics


148



11 YANMAR DIESEL

YANMAR DIESEL OPERATING MANUAL

Contents

C

D

A

B

E

APPLICATIONS



FAULT CODES



149

®


11

YANMAR DIESEL-

A

Yanmar Diesel

Sp.

Func.

Stern Drive

4BY2

6BY2

ALL

ALL

✓

✓

✓

✓

✓

✓

ADC300 + ADC417

ADC300 + ADC417

APPLICATIONS

A

A

150



11

YANMAR DIESEL-

B


Yanmar Diesel Diagnostic Socket



151

®


11

YANMAR DIESEL-

C


YANMAR DIESEL (BY) ENGINES







LIVE DATA




Freeze Frame Data


152



11

YANMAR DIESEL-

D

FAULT CODES

P0137

P0138

P0139

P0140

P0141

P0142

P0143

P0144

P0126

P0128

P0130

P0131

P0132

P0133

P0134

P0135

P0136

Yanmar Diesel - OBDII MARINE CODES

DTC #

P0113

P0114

P0115

P0116

P0117

P0118

P0119

P0120

P0121

P0122

P0123

P0124

P0125

P0107

P0108

P0109

P0109

P0110

P0111

P0112

P0100

P0101

P0102

P0103

P0104

P0105

P0106

DESCRIPTION

Mass or Volume Air Flow Circuit Malfunction

Mass or Volume Air Flow Circuit Range/Performance Problem

Mass or Volume Air Flow Circuit Low Input

Mass or Volume Air Flow Circuit High Input

Mass or Volume Air Flow Circuit Intermittent

Manifold Absolute Pressure/Barometric Pressure Circuit Malfunction

Manifold Absolute Pressure/Barometric Pressure Circuit Range/Performance Problem

Manifold Absolute Pressure/Barometric Pressure Circuit Low Input

Manifold Absolute Pressure/Barometric Pressure Circuit High Input

Manifold Absolute Pressure/Barometric Pressure Circuit Intermittent

Intake Air Temperature Circuit Malfunction

IAT Circuit Malfunction

Intake Air Temperature Circuit Range/Performance Problem

Intake Air Temperature Circuit Low Input

Intake Air Temperature Circuit High Input

Intake Air Temperature Circuit Intermittent

Engine Coolant Temperature Circuit Malfunction

Engine Coolant Temperature Circuit Range/Performance Problem

Engine Coolant Temperature Circuit Low Input

Engine Coolant Temperature Circuit High Input

Engine Coolant Temperature Circuit Intermittent

Throttle Position Sensor/Switch A Circuit Malfunction

Throttle Position Sensor/Switch A Circuit Range/Performance Problem

Throttle Position Sensor/Switch A Circuit Low Input

Throttle Position Sensor/Switch A Circuit High Input

Throttle Position Sensor/Switch A Circuit Intermittent

Insufficient Coolant Temperature for Closed Loop Fuel Control;

ECT Excessive Time to Closed Loop Fuel Control

Insufficient Coolant Temperature for Stable Operation

Coolant Thermostat Malfunction

O2 Sensor Circuit Malfunction (Bank 1 Sensor 1)

O2 Sensor Circuit Low Voltage (Bank 1 Sensor 1)

O2 Sensor Circuit High Voltage (Bank 1 Sensor 1)

O2 Sensor Circuit Slow Response (Bank 1 Sensor 1)

O2 Sensor Circuit No Activity Detected (Bank 1 Sensor 1)

O2 Sensor Heater Circuit Malfunction (Bank 1 Sensor 1)











153

®


11

YANMAR DIESEL-

D

Yanmar Diesel - OBDII MARINE CODES (cont.)

DTC #

P0172

P0173

P0174

P0175

P0176

P0177

P0178

P0179

P0163

P0164

P0165

P0166

P0167

P0170

P0171

P0155

P0156

P0157

P0158

P0159

P0160

P0161

P0162

P0145

P0146

P0147

P0150

P0151

P0152

P0153

P0154

P0180

P0181

P0182

P0183

P0184

P0185

P0186

P0187

P0188

P0189

P0190

P0191

P0192

DESCRIPTION






















Fuel Trim Malfunction (Bank 1)

Fuel Trim System Lean (Bank 1)

Fuel Trim too Rich (Bank 1)

Fuel Trim Malfunction (Bank 2)

Fuel Trim too Lean (Bank 2)

Fuel Trim too Rich (Bank 2)

Fuel Composition Sensor Circuit Malfunction

Fuel Composition Sensor Circuit Range/Performance

Fuel Composition Sensor Circuit Low Input

Fuel Composition Sensor Circuit High Input

Fuel Temperature Sensor A Circuit Malfunction

Fuel Temperature Sensor A Circuit Range/Performance

Fuel Temperature Sensor A Circuit Low Input

Fuel Temperature Sensor A Circuit High Input

Fuel Temperature Sensor A Circuit Intermittent

Fuel Temperature Sensor B Circuit Malfunction

Fuel Temperature Sensor B Circuit Range/Performance

Fuel Temperature Sensor B Circuit Low Input

Fuel Temperature Sensor B Circuit High Input

Fuel Temperature Sensor B Circuit Intermittent

Fuel Rail Pressure Sensor Circuit Malfunction

Fuel Rail Pressure Sensor Circuit Range/Performance

Fuel Rail Pressure Sensor Circuit Low Input

FAULT CODES


154


11

YANMAR DIESEL-

D


DTC #

P0216

P0217

P0218

P0219

P0220

P0221

P0222

P0223

P0208

P0209

P0210

P0211

P0212

P0213

P0214

P0215

P0201

P0202

P0203

P0204

P0205

P0206

P0207

P0193

P0194

P0195

P0196

P0197

P0198

P0199

P0200

P0231

P0232

P0233

P0234

P0235

P0236

P0237

P0224

P0225

P0226

P0227

P0228

P0229

P0230

DESCRIPTION

Fuel Rail Pressure Sensor Circuit High Input

Fuel Rail Pressure Sensor Circuit Intermittent

Engine Oil Temperature Sensor Malfunction

Engine Oil Temperature Sensor Range/Performance

Engine Oil Temperature Sensor Low

Engine Oil Temperature Sensor High

Engine Oil Temperature Sensor Intermittent

Injector Circuit Malfunction

Injector Circuit Malfunction – Cylinder 1












Cold Start Injector 1 Malfunction

Cold Start Injector 2 Malfunction

Engine Shutoff Solenoid Malfunction

Injection Timing Control Circuit Malfunction

Engine Overtemp Condition

Transmission Over Temperature Condition

Engine Overspeed Condition

Throttle/Petal Position Sensor/Switch B Circuit Malfunction

Throttle/Petal Position Sensor/Switch B Circuit Range/Performance Problem

Throttle/Petal Position Sensor/Switch B Circuit Low Input

Throttle/Petal Position Sensor/Switch B Circuit High Input

Throttle/Petal Position Sensor/Switch B Circuit Intermittent

Throttle/Petal Position Sensor/Switch C Circuit Malfunction

Throttle/Petal Position Sensor/Switch C Circuit Range/Performance Problem

Throttle/Petal Position Sensor/Switch C Circuit Low Input

Throttle/Petal Position Sensor/Switch C Circuit High Input

Throttle/Petal Position Sensor/Switch C Circuit Intermittent

Fuel Pump Primary Circuit Malfunction

Fuel Pump Secondary Circuit Low

Fuel Pump Secondary Circuit High

Fuel Pump Secondary Circuit Intermittent

Engine Overboost Condition

Turbocharger Boost Sensor A Circuit Malfunction

Turbocharger Boost Sensor A Circuit Range/Performance

Turbocharger Boost Sensor A Circuit Low


155

FAULT CODES

®


11

YANMAR DIESEL-

D


DTC #

P0261

P0262

P0263

P0264

P0265

P0266

P0267

P0268

P0254

P0255

P0256

P0257

P0258

P0259

P0260

P0246

P0247

P0248

P0249

P0250

P0251

P0252

P0253

P0238

P0239

P0240

P0241

P0242

P0243

P0244

P0245

P0269

P0270

P0271

P0272

P0273

P0274

P0275

P0276

P0277

P0278

P0279

P0280

P0281

DESCRIPTION

Turbocharger Boost Sensor A Circuit High

Turbocharger Boost Sensor B Malfunction

Turbocharger Boost Sensor B Circuit Range/Performance

Turbocharger Boost Sensor B Circuit Low

Turbocharger Boost Sensor B Circuit High

Turbocharger Wastegate Solenoid A Malfunction

Turbocharger Wastegate Solenoid A Range/Performance

Turbocharger Wastegate Solenoid A Low

Turbocharger Wastegate Solenoid A High

Turbocharger Wastegate Solenoid B Malfunction

Turbocharger Wastegate Solenoid B Range/Performance

Turbocharger Wastegate Solenoid B Low

Turbocharger Wastegate Solenoid B High

Injection Pump Fuel Metering Control "A" Malfunction (Cam/Rotor/Injector)

Injection Pump Fuel Metering Control "A" Range/Performance (Cam/Rotor/Injector)

Injection Pump Fuel Metering Control "A" Low (Cam/Rotor/Injector)

Injection Pump Fuel Metering Control "A" High (Cam/Rotor/Injector)

Injection Pump Fuel Metering Control "A" Intermittent (Cam/Rotor/Injector)

Injection Pump Fuel Metering Control "B" Malfunction (Cam/Rotor/Injector)

Injection Pump Fuel Metering Control "B" Range/Performance (Cam/Rotor/Injector)

Injection Pump Fuel Metering Control "B" Low (Cam/Rotor/Injector)

Injection Pump Fuel Metering Control "B" High (Cam/Rotor/Injector)

Injection Pump Fuel Metering Control "B" Intermittent (Cam/Rotor/Injector)

Cylinder 1 Injector Circuit Low

Cylinder 1 Injector Circuit High

Cylinder 1 Contribution/Balance Fault



















FAULT CODES


156


11

YANMAR DIESEL-

D


DTC #

P0308

P0309

P0310

P0311

P0312

P0320

P0321

P0322

P0300

P0301

P0302

P0303

P0304

P0305

P0306

P0307

P0290

P0291

P0292

P0293

P0294

P0295

P0296

P0282

P0283

P0284

P0285

P0286

P0287

P0288

P0289

P0331

P0332

P0333

P0334

P0335

P0336

P0337

P0323

P0325

P0326

P0327

P0328

P0329

P0330

DESCRIPTION















Cylinder 12 Contribution/Range Fault

Random/Multiple Cylinder Misfire Detected

Cylinder 1 Misfire Detected












Ignition/Distributor Engine Speed Input Circuit Malfunction

Ignition/Distributor Engine Speed Input Circuit Range/Performance

Ignition/Distributor Engine Speed Input Circuit No Signal

Ignition/Distributor Engine Speed Input Circuit Intermittent

Knock Sensor 1 Circuit Malfunction (Bank 1 or Single Sensor)

Knock Sensor 1 Circuit Range/Performance (Bank 1 or Single Sensor)

Knock Sensor 1 Circuit Low Input (Bank 1 or Single Sensor)

Knock Sensor 1 Circuit High Input (Bank 1 or Single Sensor)

Knock Sensor 1 Circuit Intermittent (Bank 1 or Single Sensor)

Knock Sensor 2 Circuit Malfunction (Bank 2)

Knock Sensor 2 Circuit Range/Performance (Bank 2)

Knock Sensor 2 Circuit Low Input (Bank 2)

Knock Sensor 2 Circuit High Input (Bank 2)

Knock Sensor 2 Circuit Intermittent (Bank 2)

Crankshaft Position Sensor A Circuit Malfunction

Crankshaft Position Sensor A Circuit Range/Performance

Crankshaft Position Sensor A Circuit Low Input


157

FAULT CODES

®


11

YANMAR DIESEL-

D


DTC #

P0373

P0374

P0375

P0376

P0377

P0378

P0379

P0380

P0359

P0360

P0361

P0362

P0370

P0371

P0372

P0351

P0352

P0353

P0354

P0355

P0356

P0357

P0358

P0338

P0339

P0340

P0341

P0342

P0343

P0344

P0350

P0381

P0382

P0385

P0386

P0387

P0388

P0389

P0400

P0401

P0402

P0403

P0404

P0405

DESCRIPTION

Crankshaft Position Sensor A Circuit High Input

Crankshaft Position Sensor A Circuit Intermittent

Camshaft Position Sensor Circuit Malfunction

Camshaft Position Sensor Circuit Range/Performance

Camshaft Position Sensor Circuit Low Input

Camshaft Position Sensor Circuit High Input

Camshaft Position Sensor Circuit Intermittent

Ignition Coil Primary/Secondary Circuit Malfunction

Ignition Coil A Primary/Secondary Circuit Malfunction

Ignition Coil B Primary/Secondary Circuit Malfunction

Ignition Coil C Primary/Secondary Circuit Malfunction

Ignition Coil D Primary/Secondary Circuit Malfunction

Ignition Coil E Primary/Secondary Circuit Malfunction

Ignition Coil F Primary/Secondary Circuit Malfunction

Ignition Coil G Primary/Secondary Circuit Malfunction

Ignition Coil H Primary/Secondary Circuit Malfunction

Ignition Coil I Primary/Secondary Circuit Malfunction

Ignition Coil J Primary/Secondary Circuit Malfunction

Ignition Coil K Primary/Secondary Circuit Malfunction

Ignition Coil L Primary/Secondary Circuit Malfunction

Timing Reference High Resolution Signal A Malfunction

Timing Reference High Resolution Signal A Too Many Pulses

Timing Reference High Resolution Signal A Too Few Pulses

Timing Reference High Resolution Signal A Intermittent/Erratic Pulses

Timing Reference High Resolution Signal A No Pulses

Timing Reference High Resolution Signal B Malfunction

Timing Reference High Resolution Signal B Too Many Pulses

Timing Reference High Resolution Signal B Too Few Pulses

Timing Reference High Resolution Signal B Intermittent/Erratic Pulses

Timing Reference High Resolution Signal B No Pulses

Glow Plug/Heater Circuit "A" Malfunction

Glow Plug/Heater Indicator Circuit Malfunction

Exhaust Gas Recirculation Flow Malfunction

Crankshaft Position Sensor B Circuit Malfunction

Crankshaft Position Sensor B Circuit Range/Performance

Crankshaft Position Sensor B Circuit Low Input

Crankshaft Position Sensor B Circuit High Input

Crankshaft Position Sensor B Circuit Intermittent

Exhaust Gas Recirculation Flow Malfunction

Exhaust Gas Recirculation Flow Insufficient Detected

Exhaust Gas Recirculation Flow Excessive Detected

Exhaust Gas Recirculation Circuit Malfunction

Exhaust Gas Recirculation Circuit Range/Performance

Exhaust Gas Recirculation Sensor A Circuit Low

FAULT CODES


158


11

YANMAR DIESEL-

D


DTC #

P0432

P0433

P0434

P0436

P0437

P0438

P0440

P0441

P0422

P0423

P0424

P0426

P0427

P0428

P0430

P0431

P0415

P0416

P0417

P0418

P0419

P0420

P0421

P0406

P0407

P0408

P0410

P0411

P0412

P0413

P0414

P0449

P0450

P0451

P0452

P0453

P0454

P0455

P0442

P0443

P0444

P0445

P0446

P0447

P0448

DESCRIPTION

Exhaust Gas Recirculation Sensor A Circuit High

Exhaust Gas Recirculation Sensor B Circuit Low

Exhaust Gas Recirculation Sensor B Circuit High

Secondary Air Injection System Malfunction

Secondary Air Injection System Incorrect Flow Detected

Secondary Air Injection System Switching Valve A Circuit Malfunction

Secondary Air Injection System Switching Valve A Circuit Open

Secondary Air Injection System Switching Valve A Circuit Shorted

Secondary Air Injection System Switching Valve B Circuit Malfunction

Secondary Air Injection System Switching Valve B Circuit Open

Secondary Air Injection System Switching Valve B Circuit Shorted

Secondary Air Injection System Relay "A" Circuit Malfunction

Secondary Air Injection System Relay "B" Circuit Malfunction

Catalyst System Efficiency Below Threshold (Bank 1)

Warm Up Catalyst Efficiency Below Threshold (Bank 1)

Main Catalyst Efficiency Below Threshold (Bank 1)

Heated Catalyst Efficiency Below Threshold (Bank 1)

Heated Catalyst Temperature Below Threshold (Bank 1)

Catalyst Temperature Sensor Range/Performance (Bank 1)

Catalyst Temperature Sensor Low Input (Bank 1)

Catalyst Temperature Sensor High Input (Bank 1)

Catalyst System Efficiency Below Threshold (Bank 2)

Warm Up Catalyst Efficiency Below Threshold (Bank 2)

Main Catalyst Efficiency Below Threshold (Bank 2)

Heated Catalyst Efficiency Below Threshold (Bank 2)

Heated Catalyst Temperature Below Threshold (Bank 2)

Catalyst Temperature Sensor Range/Performance (Bank 2)

Catalyst Temperature Sensor Low Input (Bank 2)

Catalyst Temperature Sensor High Input (Bank 2)

Evaporative Emission Control System Malfunction

Evaporative Emission Control System Incorrect Purge Flow

Evaporative Emission Control System Leak Detected (small leak)

Evaporative Emission Control System Purge Control Valve Circuit Malfunction

Evaporative Emission Control System Purge Control Valve Circuit Open

Evaporative Emission Control System Purge Control Valve Circuit Shorted

Evaporative Emission Control System Vent Control Circuit Malfunction

Evaporative Emission Control System Vent Control Circuit Open

Evaporative Emission Control System Vent Control Circuit Shorted

Evaporative Emission Control System Vent Valve/Solenoid Circuit Malfunction

Evaporative Emission Control System Pressure Sensor Malfunction

Evaporative Emission Control System Pressure Sensor Range/Performance

Evaporative Emission Control System Pressure Sensor Low Input

Evaporative Emission Control System Pressure Sensor High Input

Evaporative Emission Control System Pressure Sensor Intermittent

Evaporative Emission Control System Leak Detected (gross leak)


159

FAULT CODES

®


11

YANMAR DIESEL-

D


DTC #

P0601

P0602

P0603

P0604

P0605

P0606

P0620

P0621

P0521

P0522

P0523

P0560

P0561

P0562

P0563

P0600

P0622

P0650

P0654

P0655

P1100

P0478

P0479

P0505

P0506

P0507

P0510

P0520

P0470

P0471

P0472

P0473

P0474

P0475

P0476

P0477

DESCRIPTION

Exhaust Pressure Sensor Malfunction

Exhaust Pressure Sensor Range/Performance

Exhaust Pressure Sensor Low

Exhaust Pressure Sensor High

Exhaust Pressure Sensor Intermittent

Exhaust Pressure Control Valve Malfunction

Exhaust Pressure Control Valve Range/Performance

Exhaust Pressure Control Valve Low

Exhaust Pressure Control Valve High

Exhaust Pressure Control Valve Intermittent

Idle Control System Malfunction

Idle Control System RPM Lower Than Expected

Idle Control System RPM Higher Than Expected

Closed Throttle Position Switch Malfunction

Engine Oil Pressure Sensor/Switch Circuit Malfunction

Engine Oil Pressure Sensor/Switch Circuit Range/Performance

Engine Oil Pressure Sensor/Switch Circuit Low Voltage

Engine Oil Pressure Sensor/Switch Circuit High Voltage

System Voltage Malfunction

System Voltage Unstable

System Voltage Low

System Voltage High

Serial Communication Link Malfunction

Control Module Read Only Memory(ROM)

Control Module Programming Error

Internal Control Module Keep Alive Memory (KAM) Error

Internal Control Module Random Access Memory (RAM) Error

Internal Control Module Read Only Memory (ROM) Error

PCM Processor Fault

Generator Control Circuit Malfunction

Generator Lamp "L" Control Circuit Malfunction

Generator Field "F" Control Circuit Malfunction

Malfunction Indicator Lamp (MIL) Control Circuit Malfunction

Engine RPM Output Circuit Malfunction

Engine Hot Lamp Output Control Circuit Malfucntion

MAF Sensor Intermittent/ Check of all OBDII Systems Not Complete

FAULT CODES


160


11

YANMAR DIESELe



161

®


12

HYDROSPACE/BENELLI/WEBER

HYDROSPACE/BENELLI/WEBER OPERATING MANUAL

Contents

C

D

A

B

E

APPLICATIONS



FAULT CODES


162



12

HYDROSPACE/BENELLI/WEBER -

A

APPLICATIONS

Hydrospace/Benelli/Weber

Sp.

Func.

Hydrospace/Benelli

S4 Pro Edition

S4 110HP

Weber

S4 Jet Boat

2005 → UP

2005 → UP

2005 → UP

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

✓

ADC300 + ADC411

ADC300 + ADC411

ADC300 + ADC411

A

A

A


163

®


12


B


Hydrospace/Benelli/Weber Diagnostic Socket


164



12


C


HYDROSPACE/BENELLI/WEBER PWC







LIVE DATA



ENGINE HOURS

This function displays the engine running hours and will break down hours via specific engine RPM ranges (resettable) and the overall hours the engine has been used (Not Resettable). All ENGINE HOURS are available to be saved and stored to be viewed later on a PC to build a custom made diagnostic printout.



165

®


12


D

FAULT CODES

563

562

1202

1202

1202

1202

563

563

563

563

563

563

118

119

115

115

115

563

FAULT #

122

1213

105

115

1352

1352

1352

1352

1351

1351

1351

1601

1202

1202

1202

1202

1202

1352

1352

FAULT DESCRIPTION

(TPS) Throttle Position Sensor

(TPS) Throttle Position Sensor

(BARO) Atmospheric Pressure Sensor

(MAP) Manifold Absolute Pressure Sensor

(ECT) Engine Temp Sensor

(ECT) Engine Temp Sensor




Battery Voltage

Battery Voltage

Battery Voltage

Battery Voltage

Battery Voltage

Battery Voltage

Battery Voltage

Battery Voltage

Battery Voltage

Fuel Injector 2

Fuel Injector 2

Fuel Injector 2

Fuel Injector 2

Fuel Injector 1

Fuel Injector 1

Fuel Injector 1

Fuel Injector 1

Fuel Injector 1 Fuel Injector 2

Ignition Coil 2

Ignition Coil 2

Ignition Coil 2

Ignition Coil 2

Ignition Coil 2

Ignition Coil 2

Ignition Coil 1

Ignition Coil 1

Ignition Coil 1

ECR Relay

FAILURE TYPE

Open Short Circuit

Open Short Circuit

Open Short Circuit

Open Short Circuit

Signal Too High

Signal Too High

Signal Too High

Signal Too High

Signal Too High

Signal Too High

Signal Too High

Signal Too High

Signal Too Low

Open Short Gnd

Open Short Gnd

Open Short Gnd

Open Short Gnd

Open Short Gnd

Open Short Gnd

Open Short Gnd

Open Short Gnd

Open Short Gnd

Open Short to Battery




Open Short Gnd





Open Short Gnd


166


12


D

FAULT CODES

1501

1501

1501

1602

1601

FAULT #

1601

1501

1501

1501

FAULT DESCRIPTION

ECR Relay

(IAT) Air Temperature Sensor






ECR Relay

ECR Relay

FAILURE TYPE

Open Short Gnd

Short Circuit

Short Circuit

Short Circuit

Short Circuit

Short Circuit

Short Circuit




167

®


12


E


Hydrospace/Benelli/Weber

Outboard Diagnostics

168


COMPLETE KITS

STATS Basic Kit (No software)

Mercury/Mercruiser®/MEFI®, BRP®, Yamaha®, Suzuki® Diagnostic System

Mercury/Mercruiser®/MEFI®, BRP®, Yamaha® Diagnostic System

Mercury/Mercruiser®/MEFI®, BRP®, Suzuki® Diagnostic System

Mercury/Mercruiser®/MEFI®, Yamaha® Diagnostic System

Mercury/Mercruiser®/MEFI® Diagnostic System

BRP® Diagnostic System

Yamaha® Diagnostic System

Suzuki® Diagnostic System

SeaDoo®/Yamaha®/Kawasaki® Diagnostic System

SeaDoo®, Yamaha® PWC, Kawasaki®, Hydrospace®/Benelli®/Weber® Full PWC Package

Mercury/Mercruiser®/MEFI® 1-6, BRP® Outboard, Yamaha® Outboard, Suzuki® Outboard, Volvo®, Yanmar®, Honda®

Volvo® D3 D4 D6 Package

Mercury/Mercruiser®/MEFI®1-6, BRP®, Yamaha®, Suzuki®, Honda®, Yamaha® PWC, Kawasaki® PWC, SeaDoo®, Hydrospace®/Benelli®/Weber®, Volvo® D3 D4 D6,

Yanmar® Diagnostic System Plus

Honda® Diagnostic System

Mercury/Mercruiser®/MEFI®, BRP®, Yamaha®, Honda®, Suzuki® Diagnostic System

SOFTWARE ADD-ON KITS

Mercury/Mercruiser®/MEFI® 1-4 Engine Add On Software Kit

BRP® Engine Add On Software Kit

Yamaha® Outboard Engine Add On Software Kit

Suzuki® Engine Add On Software Kit

Yamaha® PWC Engine Add On Software Kit

Kawasaki® Engine Add On Software Kit

Sea Doo® Engine Add On Software Kit

Hydrospace®/Benelli®/Weber® Add On Software Kit

Volvo® D3 D4 D6 Add On Software Kit

Yanmar® Add On Software Kit

MEFI® 5-6 Add On Software Kit

Honda® Add On Software Kit

REPLACEMENT PRODUCTS

CARRYING CASES

STATS Carry Case

STATS Tester Neoprene Case

STATS Dongle Case

STATS Yamaha® Neoprene Carry Case

STATS Mercury/Mercruiser®/MEFI® Carry Case

STATS BRP®/Seadoo® Neoprene Carry Case

STATS Kawasaki® Neoprene Carry Case

STATS Suzuki® Neoprene Carry Case

STATS Volvo® Neoprene Carry Case

STATS MEFI® Neoprene Carry Case

STATS Honda® Neoprene Carry Case

STATS Generic® Neoprene Carry Case

DONGLES

Dongle A Universal

Dongle B Seadoo® 4 Tech Engines

Dongle C Seadoo® DI Engines

Dongle D BRP® DESS (2 Stroke)

CABLES

Power Cable (AC)

Power Cable (12V)

USB Cable

Master Cable

BRP® Safety Key Programming Cable

Yamaha® Diagnostic Cable

BRP® Diagnostics Cable

Kawasaki® T-In Power Cable

Mercury® Diagnostic Cable

BRP® T-In Power Cable

Mercury® Outboard Cable

Kawasaki® Power Cable (4-Stroke)

Kawasaki® Ficht DI Cable

Yamaha® Remote Programming Cable

Kawasaki® Key Programming Cable

Suzuki® 4 Pin Diagnostic Cable

Suzuki® 8 Pin Diagnostic Cable

BRP® DESS Diagnostic Cable

Johnson Evinrude® Diagnostic Cable

Mercruiser®/MEFI® Diagnostic Cable

MEFI® 5-6 Diagnostic Cable

Honda® Diagnostic Cable

CONSOLE

STATS Tester (Console)

18-ADA501

18-ADA502

18-ADA503

18-ADA504

18-ADA505

18-ADA506

18-ADA507

18-ADA508

18-ADA509

18-ADA510

18-ADA511

18-ADA512

18-ADC400

18-ADC401

18-ADC409

18-ADC412

PART NO.

18-SD100

18-SD102

18-SD103

18-SD104

18-SD105

18-SD106

18-SD107

18-SD108

18-SD109

18-SD110

18-SD118

18-SD119

18-SD120

18-SD202

18-SD408

18-SD409

PART NO.

18-SD111

18-SD112

18-SD113

18-SD114

18-SD115

18-SD116

18-SD117

18-SD405

18-SD406

18-SD407

18-SD413

18-SD414

PART NO.

18-ADC152

18-ADC450

18-ADC153

18-ADC300

18-ADC402

18-ADC403

18-ADC404

18-ADC406

18-ADC407

18-ADC408

18-ADC410

18-ADC414

18-ADC416

18-ADC418

18-ADC419

18-ADC420

18-ADC421

18-ADC422

18-ADC423

18-ADC424

18-ADC425

18-ADC427

18-ADA500

The OnBoard Rewards Program is an internet based listing of dealers that install, stock and service SeaStar Solutions products.

We want to recognize dealers for the work they do on behalf of our brand. Our goal is to make it fun, easy - and rewarding - for a dealer to build a good relationship with SeaStar Solutions and with our products.

Sign up today, go to: www.seastarsolutions.com

STATS Complete Kit www.sierrastats.com

®

©2013 SeaStar Solutions All Rights Reserved.

Document: NA - STATS - 2013

Printed in the USA.

18 -SD102 COMPLETE KIT INCLUDES:

• Hand Held STATS Console

• STATS Console Neoprene Case

• STATS Dongle Case

• Software for Mercury/Mercruiser ® , Yamaha ® , Suzuki ® , BRP ® and

MEFI ® 1,2,3,& 4

• Diagnostic Cables for Mercury/Mercruiser ® , Yamaha ® , Suzuki ® ,

BRP ® and MEFI ® 1,2,3,& 4

• Power Supply Cable

• USB and Master Cable

• Dongle A (universal)

• Neoprene Branded Cables/Console Cases

• Branded STATS Carrying Case

• Printed Instruction Manual (also available electronically)

operating manual

engine diagnostics

operating manual

system

multiple operations

engine coverage

diagnostics

benefits

✓

✓

✓

✓

✓

The Software contained on the STATS equipment is owned by Sierra International/Advanced

Diagnostics.

The customer has no title of ownership of the software, other than the ownership of the physical media that the software is intended to work on.

The Copyright of software is owned by Sierra International/Advanced Diagnostics and any customer responsible for software infringement or violation of this agreement will be held responsible for infringement of the copyright laws.

Sierra International/Advanced Diagnostics retains the right to erase software from any tester/customer that has been found to infringe these laws.

1. The hand held diagnostic tool is an electronic piece of equipment, and although designed for

hostile environments it should not be exposed to excessive sunlight, high temperatures or

immersed in liquids.

2. Return unit to carrying case when not in use.

3. Observe normal health and safety precautions when using this equipment.

4. Keep clear of all moving objects when near engine compartment.

5. When connecting to vehicle connectors, probe from the back.

6. Ignition circuits generate high voltages, extra precautions and care should be observed when

diagnosing these systems.

7. Incorrect connections may damage sensitive electronic devices fitted to the vehicle.

8. Switch off the vehicle ignition when making or breaking connections.

9. Keep the unit away from spark plugs and coil leads to avoid measurement errors.

10. DO NOT disconnect any wiring harnesses or electronic component while ignition is ON.

11. DO NOT disconnect battery while engine is running.

12. Before any work is carried out, consult the vehicle manufacturer’s recommended procedures

and warranty specs to ensure any work is carried out in accordance with their instructions.

APPLICATION LIVE DATA ACTUATOR TESTING

YEAR RANGE

SPECIAL FUNCTIONS

REMOTE PROGRAMMING

FAULT CODES

KEY PROGRAMMING

START

CABLES

DONGLE

OFF

ON RECORD PLAY

SAVE

DECREMENT

LIVE DATA RECORD

BACK

UP DOWN

INCREMENT

FAULT CODE CLEAR

YAMAHA OPERATING MANUAL

MERCURY/MERCRUISER OPERATING MANUAL

2-PIN

4-PIN

MEFI OPERATING MANUAL

MEFI I-IV

MEFI V & VI

KAWASAKI OPERATING MANUAL

BRP (Johnson/Evinrude)

BRP (JOHNSON/EVINRUDE) OPERATING MANUAL

brp (seadoo/JETLEV)

BRP (SEADOO/JETLEV) OPERATING MANUAL

DI

4-TEC

(DESS) RFI (Basic Diagnostic)

SUZUKI OPERATING MANUAL

4-PIN

8-PIN

HONDA OPERATING MANUAL

VOLVO DIESEL OPERATING MANUAL

YANMAR DIESEL OPERATING MANUAL

HYDROSPACE/BENELLI/WEBER

HYDROSPACE/BENELLI/WEBER OPERATING MANUAL

Hydrospace/Benelli

Weber

STATS Complete Kit www.sierrastats.com

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