Ignition

Electrical System
Section 2A - Ignition
Table of Contents 2
A
Ignition Specifications........................................................2A-2 Crankshaft Position Sensor (CPS)...........................2A-26
Electrical Components.......................................................2A-4 Camshaft Position Sensor........................................2A-29
Troubleshooting without a Computer Diagnostic System (CDS) Cylinder Block Temperature Sensor.........................2A-33
...........................................................................................2A-8 Manifold Absolute Pressure (MAP) Sensor .............2A-36
Troubleshooting with the Computer Diagnostic System (CDS) Manifold Air Temperature (MAT) Sensor .................2A-39
...........................................................................................2A-8 Supercharger Outlet Temperature Sensor...............2A-43
Troubleshooting Guide.......................................................2A-9 Fuel Pressure Sensor...............................................2A-45
Wire Color Code Abbreviations........................................2A-11 Oil Pressure Sensor..................................................2A-48
Ignition Components........................................................2A-12 Block Water Pressure Sensor...................................2A-51
Flywheel Cover.........................................................2A-12 Oil Temperature Sensor...........................................2A-54
Flywheel....................................................................2A-13 Water in Fuel (WIF) Sensor......................................2A-57
Propulsion Control Module (PCM)............................2A-17 Fuses........................................................................2A-59
Ignition Pencil Coil....................................................2A-21

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Ignition

Ignition Specifications
Ignition Specifications
Model 350
WOT 6200–6800 RPM
Idle speed in neutral with engine fully warmed up 650 RPM
Ignition type Digital inductive
Spark plug type NGK ILFR6G or NGK ILFR6GE
Spark plug gap 0.8 mm (0.031 in.)
Spark plug hex size 16 mm
Spark plug torque 27 Nm (20 lb‑ft)
Spark plug hole size 14 mm
Firing order 1‑3‑5‑6‑4‑2
Ignition timing at idle Not adjustable; controlled by PCM
Ignition timing at WOT Not adjustable; controlled by PCM
PCM overspeed limiter Activates at 6850 RPM

Lubricant, Sealant, Adhesives

Tube Ref No. Description Where Used Part No.
25 Liquid Neoprene All ring terminal connections 92- 25711 3

136 Lubriplate SPO 255 Camshaft position sensor O-ring Obtain Locally

Special Tools
Computer Diagnostic System (CDS) Order through SPX
Monitors all electrical systems for proper function, diagnostics, and calibration
purposes. For additional information, pricing, or to order the Computer Diagnostic
System contact:
SPX Corporation
28635 Mound Rd.
Warren, MI 48092
or call:
USA ‑ 1‑800‑345‑2233
4520 Canada ‑ 800‑345‑2233
Europe ‑ 49 6182 959 149
Australia ‑ (03) 9544‑6222

Extension Cable 84‑825003A 1

Data link extension harness (3.05 m [10 ft.]) between the adapter harness and the
Digital Diagnostic Terminal or Computer Diagnostic System (CDS).

4012

Adapter Harness 84‑822560A13

Data link harness between engine and computer diagnostic system (CDS).
5826

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 Ignition

Mercury Racing Flywheel Puller/Lifting Ring 91‑895343T03

Removes flywheel from engine and is required for lifting a Verado 350 SCi
powerhead or engine.
35340

Flywheel Holding Tool 91‑ 52344

Holds and/or turns the flywheel while making engine repairs, also used to torque
the flywheel or the engine coupler

4738

DMT 2004 Digital Multimeter 91‑892647A01

Measures RPM on spark ignition (SI) engines, ohms, amperes, AC and DC

V Hz
H z TEMP
mA
A voltages; records maximums and minimums simultaneously, and accurately reads
in high RFI environments.
mV IG
OFF IP

TEMP

A mA COM V Hz

4516

Hose Clamp Tool Kit 91‑803146A04

Aids in the installation of high pressure (Oetiker ®) hose clamps. Clamp Tool
(91‑803146T)

5819

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Ignition

Electrical Components
16 3
42
4
17
9 5
11
39 40
24
14
13 27 26
38 30
37 29
8
7 5

19

17
23
1
23
21

22

10
25
15 2
13 6

20 28

12
18

41
31 35

32
36
34
33

36712

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 Ignition

Electrical Components
Torque
Ref. No. Qty. Description Nm lb‑in. lb‑ft
1 1 Electrical box base
2 1 Fuse box cover
3 1 Fuse cover
4 1 Seal
5 2 Strap
6 2 Hinge pin
7 1 Grommet
8 1 Bushing
7 Mini fuse (20 amp) (yellow)
9
1 Mini fuse (2 amp) (gray)
10 1 Nut (M8) 17 150
11 1 Fuse extractor
12 1 Bracket
13 2 Screw (M8 x 13) 9 80
14 1 Washer (0.33 x 0.56 x 0.06)
15 1 Washer (0.344 x 1.0 x 0.063)
16 1 Cover strap
17 5 Clip
18 1 PCM
19 1 Engine harness assembly
20 5 Relay
21 4 Decal
22 1 Bracket
23 2 Screw (M5 x 6) 4.5 40
24 1 Starter cable (21.6 cm [8.50 in.])
25 1 Trim harness assembly
26 1 Fuse harness assembly
27 AR Cable tie (20.3 cm [8.00 in.])
28 1 Screw (M6 x 14)
29 1 Weather cap connector assembly (2 pin female) 6 53
30 1 Weather cap connector assembly (8 pin)
31 1 Vessel harness assembly
32 1 Command module power harness
33 1 Fuse (5 amp) (tan)
34 1 Positive battery cable
35 4 Nut (M8) 17 150 12
36 1 Positive battery cable nut (3/8‑16) 13 120
37 1 Screw (M8 x 35) 24 17
38 1 Washer (0.344 x 1.0 x 0.063)
39 1 Negative battery cable

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Torque
Ref. No. Qty. Description Nm lb‑in. lb‑ft
40 1 Negative battery cable nut (5/16‑18) 13 120
41 1 Bracket
42 1 Fuel tank adapter harness

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 Ignition

Electrical Components
16 3
42
4
17
9 5
11
39 40
24
14
13 27 26
38 30
37 29
8
7 5

19

17
23
1
23
21

22

10
25
15 2
13 6

20 28

12
18

41
31 35

32
36
34
33

36712

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Ignition

Troubleshooting without a Computer Diagnostic System (CDS)

Troubleshooting without the computer diagnostic system (CDS) is limited to checking resistance on some of the sensors.
Typical failures usually do not involve the PCM. Connectors, set‑up, or mechanical wear are most likely at fault.
• Verify the ignition coils are securely installed (pushed in) into the spark plugs.
• The engine may not run or may not run above idle with the wrong spark plugs installed.
• Swap ignition coils to see if the problem follows the coil or stays with the particular cylinder.
IMPORTANT: Disconnecting a sensor while the engine is running may result in a fault recording in the PCM Fault History. Use
the CDS to view the PCM fault history when troubleshooting/repair is completed.
• If all cylinders exhibit similar symptoms, the problem is with a sensor or harness input to the PCM.
• If problem is speed related or intermittent, it is probably connector or contact related. Inspect connectors for corrosion, loose
wires, or pins pushed back into the connector. Verify the connectors are properly seated.
• Inspect the harness for damage: pinched or cut wires and chafing.
• Secure the grounds and all connections involving ring terminals. Apply Liquid Neoprene to all ring terminal connections.

Tube Ref No. Description Where Used Part No.

25 Liquid Neoprene All ring terminal connections 92- 25711 3

• Inspect the fuel pump harness connector for corrosion, loose wires, or pins pushed back into connector.
• Check the fuel pump pressure.

Troubleshooting with the Computer Diagnostic System (CDS)

The computer diagnostic system (CDS) is designed to help technicians diagnose and repair Mercury Marine 2 and 4 cycle engines.
Attach the diagnostic cable to the PCM diagnostic connector. This will enable the technician to monitor sensors, PCM data values,
and the real time status of the switches. Use the 3 m (10 ft.) extension cable between the CDS diagnostic connector and the PCM
adapter to monitor the engine system while at the helm.

a
a - Diagnostic terminal connector

5483

The PCM program can help diagnose intermittent engine problems. It will record the state of the engine sensors and switches for
a period of time, and then can be played back to review the recorded information.
Refer to the computer diagnostic system reference manual for complete diagnostic procedures.

Computer Diagnostic System (CDS) Order through SPX

Extension Cable 84‑825003A 1
Adapter Harness 84‑822560A13

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 Ignition

Troubleshooting Guide
1. Engine Cranks, but Will Not Start
Cause Action
1.0 Weak battery or bad starter motor, battery voltage Replace/recharge battery
drops below 11 volts while cranking (PCM cuts out Inspect condition of starter motor
below 8 volts) (fuel pump requires 9 volts) Check condition of battery terminals and cables
Key‑on engine to verify that fuel pump runs for 5 seconds and then turns off.
If no fuel is available, fuel pump will run for as long as 180 seconds before
1.1 No fuel shutting off.
NOTE: Running fuel pump for up to 180 seconds due to lack of fuel will
damage fuel pump.
Measure fuel pressure (valve on top of fuel rail)
1.2 Low fuel pressure
Fuel pressure should be 281–345 kPa (41–50 psi)
1.3 Flywheel key sheared or flywheel key not installed Remove flywheel and inspect
1.4 Blown fuse Inspect 20 amp fuse in fuse holder and replace if blown
Listen for relay to click when the key switch is turned on. If relay does not
1.5 Main power relay not functioning
click, inspect harness and connector pins for damage.
Remove fuel pump fuse
Remove spark plugs from each cylinder
Install spark gap tester 91‑63998A 1 to each ignition coil
1.6 Spark plugs1. Crank engine or use the computer diagnostic system (CDS) output load test
for each ignition coil and observe spark. If no spark is present, replace
appropriate ignition coil. If spark is present, replace spark plugs.
Fuel injection system:
Listen for injector ticking when cranking or connect spare injector to each
respective harness
Ignition system:
Install spark gap tester between ignition coil and engine ground. Check for
purple/white colored spark while cranking engine.
1.7 PCM not functioning Check for battery voltage (red/yellow lead) at ignition coils
Check for blown 20 amp fuse
Check for battery voltage to fuse from main power relay (purple lead)
Check for shorted stop wire (black/yellow lead)
Power supply:
Inspect and clean remote control male and female harness connector
Defective PCM
Check that magnet is not missing from end of sensor
Perform ohm resistance check of sensor (300–350 ohms between red and
1.8 Crankshaft position sensor not functioning
white leads)
Defective crankshaft position sensor

2. Engine Will Not Crank

Cause Action
Use the computer diagnostic system (CDS) to determine proper functioning
2.0 Defective PCM
of the electronic throttle control (ETC)
2.1 Defective main power relay Use CDS to determine proper functioning of main power relay
2.2 Main power relay fuse blown Check for blown 20 amp fuse
2.3 Lanyard stop switch in wrong position Reset lanyard stop switch

1. Spark jumping the gap from all cylinders at the same time in the spark gap tool may cause interference in the PCM. The interference may cause
the absence of spark on some cylinders and a false diagnosis of a no spark condition. Crank the engine over with only one spark plug wire connected
to the spark gap tool at a time or use the CDS to fire one cylinder at a time.

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3. Engine Cranks, Starts, and Stalls

Cause Action
3.0 Low fuel pressure in fuel rail See 1.2
3.1 Abnormally high friction in engine Check for scuffed piston or other sources of high friction
3.2 Air in fuel system/lines Crank and start engine several times to purge
Use computer diagnostic system (CDS) to determine proper functioning of
3.3 Defective electronic throttle control the electronic throttle control (ETC)
Replace ETC
3.4 Remote control to engine harness connection is
Clean and inspect male and female connections
poor
3.5 Flywheel misaligned during installation Flywheel key sheared or missing

4. Engine Idle is Rough

Cause Action
Replace spark plug:
If carbon bridges electrode gap or if it is completely black
4.1 Fouled spark If it is not firing and is wet with fuel
NOTE: If spark plug is gray or completely black with aluminum specs, this
indicates a scuffed piston.
4.2 Failed fuel injector Refer to specifications for ohm test
4.3 Bad ignition coil/weak spark Refer to specifications for ohm test
4.4 Flywheel misaligned during installation Flywheel key sheared or missing
4.5 Engine not running on all cylinders Inspect for mechanical damage

5. Engine Idles Fast (RPM Above 700) or Surges

Cause Action
Use computer diagnostic system (CDS) to determine proper functioning of
5.1 Defective electronic throttle control the electronic throttle control (ETC)
Replace ETC
5.2 Intake air leak Check all hoses and connections for leaks

6. Engine Runs Rough (RPM Below 3000)

Cause Action
Replace spark plug:
If carbon bridges electrode gap or if it is completely black
6.1 Fouled spark plug If it is not firing and is wet with fuel
NOTE: If spark plug is gray or completely black with aluminum specs, this
indicates a scuffed piston.
Measure fuel pressure (valve on top of fuel rail)
6.2 Low fuel pressure in fuel rail
Fuel pressure should be 281–345 kPa (41–50 psi)
Use computer diagnostic system (CDS) to determine proper functioning of
6.3 Defective electronic throttle control the electronic throttle control (ETC)
Replace ETC
6.4 Bad ignition coil/weak spark Refer to specifications for ohm test
6.5 Fuel supply module float fails in conjunction with Excess fuel will enter air intake. Use CDS to determine proper functioning of
failure of vent canister switch the vent canister switch.
6.6 Engine not running on all cylinders Inspect for mechanical damage

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 Ignition

7. Engine Runs Rough (RPM Above 3000)

Cause Action
Replace spark plug:
If carbon bridges electrode gap or if it is completely black
7.1 Fouled spark plug If it is not firing and is wet with fuel
NOTE: If spark plug is gray or completely black with aluminum specs, this
indicates a scuffed piston.
Use computer diagnostic system (CDS) to determine proper functioning of
7.2 Defective electronic throttle control the electronic throttle control (ETC)
Replace ETC
Measure fuel pressure (valve on top of fuel rail)
7.3 Low fuel pressure in fuel rail
Fuel pressure should be 281–345 kPa (41–50 psi)
Refer to SmartCraft gauges for low oil, engine overheat, or sensor/actuator
7.4 Speed reduction
out of range. CDS will help identify proper functioning of sensors/actuator.
7.5 Defective crankshaft position sensor Refer to CDS for fault identification

8. Speed Reduction (RPM Reduced to Idle)

Cause Action
8.1 Engine communication/remote control failure Refer to computer diagnostic system (CDS) for fault identification
8.2 Sensor/actuator is out of range Refer to CDS for fault identification
8.3 Low oil pressure Check oil dipstick for proper oil level
8.4 Engine overheat Check engine cooling system for proper functioning

9. Speed Reduction (RPM Reduced to 75%)

Cause Action
9.1 Sensor/actuator is out of range Refer to computer diagnostic system (CDS) for fault identification
9.2 Low oil pressure Check oil dipstick for proper oil level
9.3 Engine overheat Check engine cooling system for proper functioning

Wire Color Code Abbreviations

Wire Color Abbreviations
BLK Black BLU Blue
BRN Brown GRY Gray
GRN Green ORN or ORG Orange
PNK Pink PPL or PUR Purple
RED Red TAN Tan
WHT White YEL Yellow
LT or LIT Light DK or DRK Dark

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Ignition Components
Flywheel Cover
The flywheel cover provides basic protection against accidental contact with the flywheel, flywheel fan, starter motor pinion gear,
and alternator/supercharger drive belt while the engine is running.

a
a - Flywheel cover

38854
The flywheel cover acts as an air shroud that seals tightly into the air intake scoop built into the top cowl. The design of the top
cowl, in conjunction with the flywheel cover, promotes air flow around the engine compartment. The flywheel fan also causes the
engine cowling to become slightly pressurized, lessening moisture from entering the cowl.

d f
c
b

e
a

34155

a- Supercharger air intake

b- Flywheel cover
c- Flywheel fan
d- Air intake scoop
e- Air intake scoop seals tightly around flywheel cover
f- Rear air ventilation

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 Ignition
Removal of the flywheel cover provides access to the flywheel fan, flywheel, alternator/supercharger drive belt, starter motor pinion
gear, cylinder block water temperature sensor, crankshaft position sensor, oil pressure sensor, and oil temperature sensor.
The flywheel cover is secured to the engine by four rubber grommets pressed over four locating pins on the cylinder block. To
remove the cover, lift the cover off of the locating pins. To install the cover, align the flywheel cover grommets with the locating
pins and push down until the cover seats against the locating pins.

Flywheel
The flywheel is weighted and balanced to improve engine running characteristics. The flywheel is secured to the crankshaft by a
bolt (M20 x 68) (30 mm socket) and washer. The flywheel has two ring gears. The top ring gear is used with the starter motor to
start the engine. The lower ring gear has 54 teeth with six teeth missing at specific locations. As the lower ring gear passes the
crankshaft position sensor, an electrical pulse is generated and sent to the propulsion control module (PCM). The frequency of
these pulses in conjunction with the missing tooth locations on the ring gear provides crankshaft location information to the PCM.
The PCM will use this information to regulate ignition and fuel injector timing.

Flywheel Removal
The flywheel has three threaded holes which are used with the flywheel puller/lifting ring to remove the flywheel. These three holes
are also used with the flywheel puller/lifting ring to lift the engine for removal or installation.
IMPORTANT: When lifting the 350 Verado SCi or removing the flywheel, it is recomended that the Mercury Racing flywheel puller/
lifting ring tool be used. If the Mercury Racing flywheel puller/lifting ring tool is not available, the flywheel fan must be removed
from the flywheel or damage to the engine or flywheel fan will occur if the standard flywheel puller/lifting ring tool (91‑895343T02)
is used.

Mercury Racing Flywheel Puller/Lifting Ring 91‑895343T03

IMPORTANT: Striking or heating the flywheel to ease removal may damage the flywheel. Do not strike or heat the flywheel or fan.
1. Remove the top cowl and engine flywheel cover.

a
a - Flywheel cover

38854
2. Remove the six flywheel fan screws from the flywheel.
IMPORTANT: If the flywheel fan does not dislodge easily from the flywheel, gently pry between the flywheel fan and the
flywheel, alternating among the holes used to mount the flywheel puller/lifting tool. Do not pry the flywheel fan from its outside
edge.

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Ignition

3. Remove the flywheel fan from the flywheel.

b d
a

b 41449

a- Flywheel fan
b- Holes in flywheel fan for mounting the puller/lifting ring
c- Outside edge of flywheel fan
d- Screws (6)

4. Use a breaker bar to release the alternator/supercharger belt tension and remove the belt from the engine.

a- Alternator
b- Tensioner pulley
c- Tensioner release slot
d- Supercharger
a

38856

5. While holding the flywheel with a flywheel holding tool, loosen the flywheel bolt four turns out from a light seat.

a - Flywheel holding tool

38857

Flywheel Holding Tool 91‑ 52344

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 Ignition

6. Install the flywheel puller base to the flywheel with three bolts.

a
a - Bolts
b - Puller base

37239

Mercury Racing Flywheel Puller/Lifting Ring 91‑895343T03

7. Install the flywheel puller adapter into the puller base until it is seated against the puller base.

a a - Puller adapter

37240

Mercury Racing Flywheel Puller/Lifting Ring 91‑895343T03

8. Thread the flywheel puller bolt into the flywheel puller adapter.

a - Puller bolt
a

37247

Mercury Racing Flywheel Puller/Lifting Ring 91‑895343T03

9. Tighten the flywheel puller bolt until the flywheel separates from the crankshaft.
10. Remove the flywheel puller base from the flywheel.
11. While supporting the flywheel, remove the flywheel bolt and washer from the crankshaft.

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12. Remove the flywheel from the engine.

Flywheel Installation
IMPORTANT: Clean the flywheel/crankshaft taper with solvent and assemble dry.
1. Ensure the flywheel key is positioned properly in the crankshaft.

a - Flywheel key

5463
2. Align the flywheel with the key and install the flywheel onto the crankshaft.
3. Secure the flywheel to the crankshaft with the flywheel bolt and washer. Use a flywheel holding tool to hold the flywheel and
tighten the bolt to the specified torque.

Flywheel Holding Tool 91‑ 52344

Description Nm lb‑in. lb‑ft

First 88 65
Flywheel bolt
Final 180 133
4. Using a breaker bar in the tensioner release slot, install the alternator/supercharger belt.

a- Alternator
b- Tensioner pulley
c- Tensioner release slot
d- Supercharger
a

38856

IMPORTANT: If the flywheel fan fits tight to the flywheel, it is recommended that an alignment stud (16‑816194‑5) be used
to align the flywheel fan fastening holes before the flywheel fan is placed onto the flywheel.
If an alignment stud is not used, remove and remount the flywheel fan until the fastening holes are aligned. Do not attempt
to maneuver the flywheel fan once it is placed onto the flywheel or damage to the flywheel fan may occur.
IMPORTANT: If the flywheel fan does not dislodge easily from the flywheel, gently pry between the flywheel fan and the
flywheel, alternating among the holes used to mount the flywheel puller/lifting tool. Do not pry the flywheel fan from its outside
edge.

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 Ignition

5. Install the flywheel fan onto the flywheel.

b b

c b

38855

a - Flywheel fan
b - Holes in flywheel fan for mounting the puller/lifting ring
c - Outside edge of flywheel fan

6. Install the six screws to secure the flywheel fan to the flywheel. Tighten the flywheel fan screws to the specified torque following
the torque sequence.

Flywheel fan screw torque sequence

a - Flywheel fan screws
1
4
6
a
2
3
5

37017

Description Nm lb‑in. lb‑ft

Flywheel fan screw (M6 x 12) (6) 7 62
7. Install the flywheel cover.

Propulsion Control Module (PCM)

The propulsion control module requires 8 VDC minimum to operate. If the PCM should fail, the engine will stop running.

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Ignition
The inputs to the PCM can be monitored and tested with the computer diagnostic system (CDS).

a - Propulsion control module (PCM)

41450

Computer Diagnostic System (CDS) Order through SPX

The PCM controls the following functions:

• Electronic shift control
• Electronic throttle control
• Electronic boost control
• Main power relay
• Fuel injectors
• Ignition coils
• Power steering
• Vent canister purge valve
• Trim up
• Trim down
• Start relay
• Lift fuel pump
• Diagnostics
• Engine Guardian
• Tachometer link (analog tachometer output or link gauge driver)
The PCM operates in four modes; power off, stall, crank, and run. A warm‑up mode is integrated with the run mode and disengaged
after the engine is within operating temperatures.
Power off mode ‑ With the key switch "OFF," the main power relay will remain powered up for 15 minutes and then the PCM will
power off. A constant 12 VDC power is available at the starter battery terminal, fuses, positive cable terminal in the electrical box,
and at the alternator.
Stall mode ‑ With the key switch in the "RUN" position, the PCM is energized. The PCM powers the main power relay, the fuel
pump relay for five seconds, and provides 5 VDC power to the sensors. The PCM records barometric pressure from the MAP
sensor, air temperature from the manifold air temperature (MAT) sensor, and coolant temperature from the coolant temperature
sensors. The PCM will use this information to establish a warm‑up strategy that will control fuel delivery and engine speed during
warm‑up and idle.
Crank mode ‑ When the key switch is turned to the "START" position, or a Smart Start button is activated, the starter relay and
the starter solenoid will be energized and battery power will turn the starter motor. With the engine rotating, a pulse will be generated
at the crankshaft position sensor which provides the PCM engine speed information. The PCM will then supply power to the fuel
pump and ignition coils through the main power relay and the fuel pump relay.
Run mode ‑ At approximately 500 RPM, the PCM will transition to the run mode.
• The warm‑up strategy will continue to adjust engine speed with the fuel injector pulse width and engine spark advance until
the engine reaches a normal operating temperature.
• The camshaft position sensor provides cylinder compression phasing information to the PCM for sequential fuel injection.
• The manifold air temperature (MAT), throttle position sensor (TPS), and manifold absolute pressure (MAP) are monitored to
determine spark timing, boost control, and the fuel needs necessary to develop the amount of power asked for by the operator.

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 Ignition

PCM Removal
1. Release the straps securing the electrical box cover.

a - Electrical box cover

a
b - Straps

38879
2. Remove the CAN 1 and CAN 2 terminator connectors from the retainer.
3. Disconnect the three harness connectors from the PCM.

a- Propulsion control module (PCM)

a b- Harness connectors (3)
c- CAN 1 terminator connector
d- CAN 2 terminator connector

d
c

b
41108
4. Remove the screw securing the PCM and remove the PCM.

a - PCM attaching screw

a b - PCM

41109

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Ignition

PCM Installation
1. Install the PCM into the electrical box and secure the PCM with a screw. Tighten the screw to the specified torque.

a - PCM attaching screw

a b - PCM

41109

Description Nm lb‑in. lb‑ft

PCM attaching screw 9 80
2. Install the CAN 1 and CAN 2 terminator connectors onto the retainer.
3. Install the three harness connectors onto the PCM.

a- Propulsion control module (PCM)

a b- Harness connectors (3)
c- CAN 1 terminator connector
d- CAN 2 terminator connector

d
c

b
41108
4. Close the electrical box cover and secure the cover with two straps.

a - Electrical box cover

a
b - Straps

38879

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 Ignition

Ignition Pencil Coil

The engine ignition system utilizes six ignition coils, one for each cylinder. The ignition coils are inductive type coils with each coil
having its own integrated driver. Battery voltage is present at each coil (red/yellow lead) whenever the main power relay is activated.
Each coil is triggered by a 5 VDC digital pulse from the PCM. Each ignition coil is capable of producing a 40,000 volt spark.

a - Ignition coil (6 each) (1 for each cylinder)

41453

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Ignition

Ignition Coil Test

BLK
BLK
BLK
1 9 17
RED/YEL
BLK
GRN/BRN

C C12 GRN/PUR
C7 GRN/YEL a
C8 GRN/RED
RED/YEL
BLK
GRN/RED
8 16 24
1 9 17 b
B2 GRN/BRN
RED/YEL
B9 GRN/BLU
B B10 GRN/ORG

B4 YEL/PUR

BLK

BLK
j
8 16 24 c
1 12 22 BLK

GRN/BLU
GRN/PUR

A S5 RED/YEL
BLK
GRN/YEL

BLK
RED/YEL
BLK
11 21 32
BLK

S19
BLK
BLK e
86
S24
YEL/PUR

i 30 87 RED/WHT

85
RED/YEL

S21
h RED S1 RED BLK
BLK
BLK
RED
f

RED/YEL
RED/WHT 34061
g

a- Cylinder #1 ignition coil

b- Cylinder #2 ignition coil
c- Cylinder #3 ignition coil
d- Cylinder #4 ignition coil
e- Cylinder #5 ignition coil
f- Cylinder #6 ignition coil
g- Fuse holder
h- Positive connection terminal
i- Main power relay
j- Propulsion control module (PCM)

Page 2A-22 90-8M8023781 DECEMBER 2009

 Ignition

! WARNING
High voltage is present any time the key is turned on, especially when starting or operating the engine. Do not touch ignition
components or metal test probes and stay clear of spark plug leads when performing live tests.

Condition: With the key switch in the "RUN" position and the engine "OFF," power (battery voltage) is only available (red/yellow
lead) for three seconds when no crankshaft position sensor signal is being received by the PCM.
1. Disconnect the connector from the coil being tested.
2. Perform a visual inspection of the pins at the coil and the wires coming to the connector. Look for broken, bent, and corroded
pins at the coil and loose, broken, or corroded wires at the connector.
NOTE: Shake or move the harness and connector when performing the following tests. If the voltmeter readings vary during
the tests, inspect for a broken, loose, or corroded wire. Repair the problem wire and retest the circuit as follows.
3. Connect a voltmeter across the red/yellow and the black wires at the connector.
NOTE: The main power relay must be on for 12 VDC (battery voltage) to be present at the red/yellow wire. If voltage is not
present, the main power relay may be defective or the 20 amp fuse in the fuse holder is blown.
4. The voltmeter must read 12 VDC (battery voltage). If not, connect the voltmeter across the red/yellow wire and the engine
ground. If the voltmeter indicates 12 VDC (battery voltage), there is an open in the ground circuit.
NOTE: All coil ground wires are spliced together and connected to a common engine ground. The most likely failure would
be at the connector or in between the connector and the engine ground.

BLK a b c a - +12 volt (red/yellow)

BLK
BLK b - Ground (black)
RED/YEL
c - Output from PCM (5 volt digital pulse)
BLK
GRN/BRN

5046

5. If the voltmeter does not indicate 12 VDC (battery voltage), there is an open circuit between the splice point and the connector
(red/yellow lead).
NOTE: All 12 VDC power wires for the coils are spliced together. Unless all the coils have failed, the most likely failure would
be at the splice point, the connector, or in between the connector and the splice point.
6. Check the input wire (5 VDC) for continuity between the connector and the PCM. Repair if needed.
7. Remove the coil and install a spark tester between the high voltage tower and ground to see if there is a strong blue spark.
If the spark is weak or is not blue in color, replace the coil and retest.

Ignition Coil Ohm Test

NOTE: Perform the coil ohm tests using a DMT 2004 or equivalent ohmmeter.

DMT 2004 Digital Multimeter 91‑892647A01

90-8M8023781 DECEMBER 2009 Page 2A-23

Ignition

NOTE: Some meter brands may require the test lead polarity to be reversed in order to obtain correct ohm specifications.

a - Red/yellow
c b b - Black
a
c - Green with stripe

4597

Ignition Coil Ohm Test

Black Ohmmeter Lead
Red Ohmmeter Lead Electronic Spark
Ground Battery + Secondary
Trigger
Terminal Wire Color Green with stripe Black Red/yellow Spring/output
Electronic spark 4.3–5.3 kΩ 2–4 MΩ (power
Green with stripe N/A Infinite (O.L.)
trigger (switching circuit) circuit)
4.3–5.3 kΩ (switching 2–4 MΩ (power
Ground Black N/A Infinite (O.L.)
circuit) circuit)
Battery + Red/yellow Infinite (O.L.) Infinite (O.L.) N/A Infinite (O.L.)
Secondary Spring/output Infinite (O.L.) Infinite (O.L.) Infinite (O.L.) N/A

Ignition Coil Removal

1. Disconnect the electrical harness from the coil.
2. Remove the screw securing the coil.

a - Electrical harness
b - Ignition coil
a b c - Ignition coil screw

41110

Page 2A-24 90-8M8023781 DECEMBER 2009

 Ignition

3. Inspect the coil sealing ring for cuts or abrasion. If the sealing ring is damaged, replace the ring.

a - Ignition coil
b - Sealing ring

a 5154

Ignition Coil Installation

1. Insert the ignition coil into the spark plug access hole in the cylinder head. Secure the ignition coil with the screw. Tighten the
screw to the specified torque.
2. Connect the electrical harness to the ignition coil.

a - Electrical harness
b - Ignition coil
a b c - Ignition coil screw

41110

Description Nm lb‑in. lb‑ft

Ignition coil screw (M6 x 25) 8 70

90-8M8023781 DECEMBER 2009 Page 2A-25

Ignition

Crankshaft Position Sensor (CPS)

The CPS is located at the top of the cylinder block, next to the flywheel. The sensor contains a magnet which is positioned next
to the flywheel's lower ring gear. This ring gear has 54 teeth with six gaps (or missing teeth) at specific locations. The close
proximity of the CPS magnet to the 54 teeth allows a magnetic field to be created each time a tooth passes the sensor. This field
collapses and creates an AC voltage pulse. This AC pulse is sent to the PCM. The timing and frequency of these pulses allows
the PCM to regulate ignition and fuel injector timing. If the CPS fails, the engine will run rough or stop running.

b a - CPS
b - Attaching screws
c - Harness connector

c
41112

Crankshaft Position Sensor Test

NOTE: It is recommended that the flywheel cover and flywheel be removed to gain access to the CPS.
1. Perform a visual inspection of the sensor. The tip of the sensor must be flush across the end; if not, replace the sensor.
2. The tip of the sensor must be clean. There should be no metal debris (ring gear filings) attached to the sensor tip.
NOTE: There is a magnet mounted in the sensor's tip. If the magnet is missing, the sensor will not operate properly.
3. Inspect the flywheel timing wheel for:
• Excessive corrosion
• Square edges on the teeth
• One missing tooth on either side of the two tooth, three tooth, or four tooth groups
4. Replace the flywheel if it does not meet inspection requirements.
5. Perform a visual inspection of the pins at the sensor and the wires coming from the connector. Look for broken, bent, or
corroded pins at the sensor and loose, broken, or corroded wires at the connector.
6. Disconnect the connector from the sensor. Measure the resistance across the sensor pins. Replace the sensor if out of
specification.

Crankshaft Position Sensor

Resistance 300–350 ohms

Page 2A-26 90-8M8023781 DECEMBER 2009

 Ignition

NOTE: If an engine problem occurs above 3000 RPM (runs rough, no high RPM), an ohm test of the CPS may be good, but
the sensor can still be defective.

c d a- Magnet
b- CPS
c- Pin 1 (red)
d- Pin 2 (white)

a 5905

7. Reconnect the harness to the sensor. Disconnect connector B from the PCM and measure the resistance across pins 5 and
13. Resistance must be within specification. If not, repair the wiring between the PCM and the sensor.

90-8M8023781 DECEMBER 2009 Page 2A-27

Ignition

Crankshaft Position Sensor

Resistance 300–350 ohms

1 9 17

8 16 24
1 9 17
B5
WHT

B
e B13
RED

8 16 24
c d
1 12 22

b
11 21 32

5904
a

a- Magnet
b- CPS
c- Pin 1 (red)
d- Pin 2 (white)
e- PCM

8. If the tests in the preceding steps are satisfactory, replace the PCM.

Crankshaft Position Sensor Removal

1. Remove the flywheel cover and flywheel.
2. Disconnect the sensor harness connector.

Page 2A-28 90-8M8023781 DECEMBER 2009

 Ignition

3. Remove the two screws securing the sensor and remove the sensor.

b a - CPS
b - Attaching screws
c - Harness connector

c
41112

Crankshaft Position Sensor Installation

1. Position the sensor onto the engine and secure the sensor with two screws. Tighten the screws to the specified torque.
2. Connect the sensor harness to the sensor.

Description Nm lb‑in. lb‑ft

Screw (M5 x 16) 5 44

Camshaft Position Sensor

The camshaft position sensor is located at the top of the valve cover. It supplies the PCM with timing and RPM information. When
the camshaft position sensor is functioning, the PCM controls the fuel injection in a sequential, multi‑port timing strategy. When
the camshaft position sensor has failed, the PCM controls the fuel injection in a batch fire strategy. The engine may not start as
quickly and the Guardian System will limit power to 75%. The PCM will generate and store a failure code when the camshaft
position sensor fails.
A sequential firing strategy means that the fuel injectors fire once per engine cycle (every two crankshaft revolutions). The fuel
injection event is complete just before the intake valve closes and the coils fire only once per engine cycle. Sequential is ideal for
emissions, driveability transients, and slight horsepower advantages.
Batch fire strategy means that the fuel injectors fire every revolution (1/2 the fuel needed per revolution/per cycle) and the coils
also fire every revolution (wasted spark). This strategy does not consider the phase of the engine; i.e. whether a particular cylinder
is on a compression or exhaust stroke. Batch fire engines do not require a camshaft position sensor and are less expensive to
build.

a - Camshaft position sensor

41473

90-8M8023781 DECEMBER 2009 Page 2A-29

Ignition

Camshaft Position Sensor Test

The camshaft position sensor output to the PCM will change from +5 volts to 0 volts each time the number 1 or number 6 cylinder
reaches top dead center. This voltage change can be monitored by the computer diagnostic system (CDS). If the voltage change
is not occurring, shake or move the harness by hand. If the voltage readings vary, look for a broken, loose, or corroded wire.
1. Disconnect the connector from the sensor.
2. Perform a visual inspection of the pins at the sensor and the wires coming from the connector. Look for broken, bent, or
corroded pins at the sensor and loose, broken, or corroded wires at the connector.
3. If the wiring appears serviceable, perform an ohmmeter check on the sensor. The normal resistance for the cam sensor at
21 °C (70 °F):
• Between pins A and B is 23.2 MΩ
• Between pins B and C is 23.2 MΩ

d a- Pin B (black/orange)
b- Pin C (purple/yellow)
a c- Pin A (red/white)
d- Camshaft position sensor

c b

5903

4. If the ohmmeter check of the camshaft position sensor indicates that the sensor is serviceable, perform an ohmmeter check
of the sensor wiring between the sensor connector and the PCM as follows:
• PCM connector B, pin 6 to red/white pin of sensor connector is less than 1 ohm.
• PCM connector A, pin 22 to black/orange pin of sensor connector is less than 1 ohm.
• PCM connector A, pin 23 to purple/yellow pin of sensor connector is less than 1 ohm.

Page 2A-30 90-8M8023781 DECEMBER 2009

 Ignition
NOTE: All sensor ground wires are spliced together and connected to the PCM at pin 22 of connector A. Unless there are
multiple sensor failures, the most likely failure would be at the splice point, connector, or in between the connector and the
splice point.

1 9 17
d

C
a

c b
8 16 24
1 9 17

BLK/ORG
PUR/YEL
B
B6 RED/WHT

8 16 24

1 12 22 S8
A22 BLK/ORG
A23 PUR/YEL
S7

11 21 32
PUR/YEL

PUR/YEL

BLK/ORG

BLK/ORG

M LK J HGFE DCBA
e

SP4 5896

a- Pin B (black/orange)
b- Pin C (purple/yellow)
c- Pin A (red/white)
d- Camshaft position sensor
e- Splice saver SP4
f- PCM

5. If the wiring is serviceable, replace the PCM and check the sensor function using the computer diagnostic system.

Camshaft Position Sensor Removal

1. Disconnect the sensor harness from the sensor.

90-8M8023781 DECEMBER 2009 Page 2A-31

Ignition

2. Remove the screw securing the camshaft sensor and remove the sensor.

a - Harness connector
b - Camshaft position sensor
b c - Sensor attaching screw
c
a

41113

Camshaft Position Sensor Installation

1. Apply Lubriplate SPO 255 to the sensor O‑ring.
2. Install the sensor into the valve cover.
3. Secure the sensor with the screw. Tighten the screw to the specified torque.
4. Connect the harness to the sensor.

c a - Harness connector
136

a b - Screw
b c - Camshaft position sensor

5879

Tube Ref No. Description Where Used Part No.

136 Lubriplate SPO 255 Camshaft position sensor O-ring Obtain Locally

Description Nm lb‑in. lb‑ft

Screw (M6 x 16) 8 70

Page 2A-32 90-8M8023781 DECEMBER 2009

 Ignition

Cylinder Block Temperature Sensor

The cylinder block temperature sensor is located at the top of the cylinder block, aft of the flywheel. It is a thermistor immersed in
the engine coolant path. It supplies the PCM with engine temperature information. The PCM adjusts the timing and the amount
of fuel delivered according to the water temperature in the cylinder block. Low coolant temperature produces high resistance. High
coolant temperature causes low resistance. The normal resistance value for the sensor at 21 °C (70 °F) is 12.5 kΩ.

b a - Temperature sensor
b - Harness connector

41114

Cylinder Block Temperature Sensor Test

The computer diagnostic system (CDS) will determine the proper functioning of the cylinder block temperature sensor by providing
a numerical readout of the block temperature before and after the engine is started. With the engine not running, the cylinder block
temperature should be approximately the same as the ambient air temperature. After the engine is started, the temperature sensor
should indicate a rise in cylinder block temperature to approximately 60–70 °C (140–158 °F). Outside air temperature and the
temperature of the water that the engine is operating in will directly affect the engine cylinder block temperature.
1. With the engine running and the CDS connected to the engine, if the cylinder block temperature sensor does not appear to
be indicating a temperature change, shake or move the sensor harness and connector. If the temperature begins to change,
look for a broken, loose, or corroded wire.

Computer Diagnostic System (CDS) Order through SPX

2. Disconnect the connector from the sensor.
3. Perform a visual inspection of the pins at the sensor and the wires coming from the connector. Look for broken, bent, or
corroded pins at the sensor and loose, broken, or corroded wires at the connector.

c
a - Pin A (tan/green)
b - Pin B (black/orange)
c - Cylinder block temperature sensor

b a

5927

4. The sensor can be tested with an ohmmeter by disconnecting it from the harness and heating or cooling the end of the sensor
at a controlled temperature. If the readings do not match those in the table, replace the sensor and retest.

Block Temperature Sensor Ohm Test

Degree centigrade –10 21 38 65
Degree fahrenheit 14 70 100 150
kΩ 55 kΩ 12.5 kΩ 5.7 kΩ 2.1 kΩ

90-8M8023781 DECEMBER 2009 Page 2A-33

Ignition
5. If the ohmmeter check of the cylinder block temperature sensor indicates that the sensor is serviceable, perform an ohmmeter
check of the sensor wiring between the sensor connector and the PCM as follows:
• PCM connector A, pin 22 to black/orange pin B of sensor connector is less than 1 ohm.
• PCM connector A, pin 15 to tan/green pin A of sensor connector is less than 1 ohm.

Page 2A-34 90-8M8023781 DECEMBER 2009

 Ignition
NOTE: All sensor ground wires are spliced together and connected to the PCM at pin 22 of connector A. Unless there are
multiple sensor failures, the most likely failure would be at the splice point, connector, or in between the connector and the
splice point.

1 9 17

C
b a

8 16 24
1 9 17

TAN/GRN
BLK/ORG
e 8 16 24

1 12 22 S8
A22 BLK/ORG

A15 TAN/GRN
A

11 21 32
BLK/ORG
BLK/ORG

M LK J HGFE DCBA
d

SP4
5205

a- Pin A (tan/green)
b- Pin B (black/orange)
c- Cylinder block temperature sensor
d- Splice saver SP4
e- PCM

6. If the wiring is serviceable, replace the PCM and check the sensor function using the computer diagnostic system.

90-8M8023781 DECEMBER 2009 Page 2A-35

Ignition

Computer Diagnostic System (CDS) Order through SPX

Cylinder Block Temperature Sensor Removal

1. Remove the flywheel cover.
2. Disconnect the sensor harness connector.
3. Remove the sensor from the cylinder block.

b a - Temperature sensor
b - Harness connector

41114

Cylinder Block Temperature Sensor Installation

1. Inspect the sensor O‑ring for cuts or abrasions. Replace the O‑ring as required.
2. Install the sensor with the O‑ring into the cylinder block. Tighten the sensor to the specifed torque.

Description Nm lb‑in. lb‑ft

Temperature sensor 15 133
3. Connect the sensor harness to the sensor.
4. Install the flywheel cover.

Manifold Absolute Pressure (MAP) Sensor

The manifold absolute pressure (MAP) sensor measures the changes in the intake manifold pressure. It is located at the top of
the intake manifold. When the key is turned "ON," the MAP sensor reads the ambient atmospheric pressure. This information is
used by the PCM as an indication of altitude and is referred to as BARO. The manifold absolute pressure will change as a result
of engine load and speed changes.

a - MAP sensor
b - Harness connector
b
a

41474

Manifold Absolute Pressure Sensor Test

The computer diagnostic system (CDS) will determine the proper functioning of the MAP sensor by providing a numerical readout
of the sensor after the engine is started.

Page 2A-36 90-8M8023781 DECEMBER 2009

 Ignition

Manifold Absolute Pressure Sensor Readings

At idle 35–48 kPa (5–7 psi)
At wide‑open throttle 195–200 kPa (28–29 psi)

Computer Diagnostic System (CDS) Order through SPX

1. With the engine running and the CDS connected to the engine, if the MAP sensor does not appear to be indicating a pressure
change, shake or move the sensor harness and connector. If the pressure begins to change, look for broken, loose, or corroded
wires.
2. Disconnect the connector from the sensor.
3. Perform a visual inspection of the pins at the sensor and the wires coming from the connector. Look for broken, bent, or
corroded pins at the sensor and loose, broken, or corroded wires at the connector.
4. An ohmmeter check of the MAP sensor can be made by disconnecting the sensor harness and measuring the resistance
between pins A, B, and C. The normal resistance values for the MAP sensor at 21 °C (70 °F) are:
• Between pin A and pin B is 100–135 kΩ.
• Between pin A and pin C is 240–305 kΩ.

d a- Pin A (black/orange)
b- Pin B (purple/yellow)
c- Pin C (yellow)
d- MAP sensor
c

a b
5909

5. If the ohmmeter check of the MAP sensor indicates that the sensor is serviceable, perform an ohmmeter check of the sensor
wiring between the sensor connector and the PCM as follows:
• PCM connector A, pin 22 to black/orange pin A of sensor connector is less than 1 ohm.
• PCM connector A, pin 3 to yellow pin C of sensor connector is less than 1 ohm.
• PCM connector A, pin 23 to purple/yellow pin B of sensor connector is less than 1 ohm.

90-8M8023781 DECEMBER 2009 Page 2A-37

Ignition

NOTE: All sensor ground wires are spliced together and connected to the PCM at pin 22 of connector A. Unless there are
multiple sensor failures, the most likely failure would be at the splice point, connector, or in between the connector and the
splice point.

1 9 17 d

C
c

8 16 24
1 9 17

a b
B

PUR/YEL
BLK/ORG

YEL
f 8 16 24

1 12 22
S8
A22 BLK/ORG
A23 PUR/YEL
S7
A3 YEL
A

11 21 32
PUR/YEL
PUR/YEL

BLK/ORG

BLK/ORG

M LK J HGFE DCBA

SP4
5908

a- Pin A (black/orange)
b- Pin B (purple/yellow)
c- Pin C (yellow)
d- MAP sensor
e- Splice saver SP4
f- PCM

6. If the wiring is serviceable, replace the PCM and check the sensor function using the computer diagnostic system.

Computer Diagnostic System (CDS) Order through SPX

Page 2A-38 90-8M8023781 DECEMBER 2009

 Ignition

Manifold Absolute Pressure Sensor Removal

1. Disconnect the sensor harness connector.
2. Remove the attaching clamp and remove the sensor from the adapter boot.
3. Inspect the adapter boot for cuts, cracks, or abrasion. Replace the boot as required.

a- Sensor harness connector

a b- Manifold absolute pressure (MAP) sensor
c- 15.7 mm diameter clamp
d- Adapter boot
b e- 36.1 mm diameter clamp

c
d

41115

Manifold Absolute Pressure Sensor Installation

1. Install the sensor into the adapter boot. Secure the sensor with a new 15.7 mm diameter clamp using a hose clamp tool kit.

Hose Clamp Tool Kit 91‑803146A04

2. Connect the sensor harness to the sensor.

Manifold Air Temperature (MAT) Sensor

The manifold air temperature sensor is a thermistor that sends a signal voltage to the PCM. It is located in the middle of the intake
manifold close to the fuel rail. It informs the PCM of the air temperature inside the intake manifold. The PCM adjusts the fuel
injection duration needed to run the engine at optimum efficiency according to the MAT information. When intake air is cold, the
sensor resistance is high. As the air temperature rises, resistance lowers.

a - MAT sensor
b - Harness connector
c c - Screws (M4 x 16)
b

a
c

38880

Manifold Air Temperature Sensor Test

The computer diagnostic system (CDS) will determine the proper functioning of the MAT sensor by providing a numerical readout
of the sensor temperature before and after the engine is started. With the engine not running, intake air temperature should be
approximately the same as the ambient air temperature. After the engine is started, the temperature sensor should indicate a rise
in air intake temperature. Outside air temperature will directly affect the engine intake manifold air temperature.

Manifold Air Temperature Sensor Resistance

At 21 °C (70 °F) 2.26 kΩ ± 5%

90-8M8023781 DECEMBER 2009 Page 2A-39

Ignition

1. With the engine running and the CDS connected to the engine, if the MAT sensor does not appear to be indicating a
temperature change, shake or move the sensor harness and connector. If the temperature begins to change, look for a broken,
loose, or corroded wire.

Computer Diagnostic System (CDS) Order through SPX

2. Disconnect the connector from the sensor.
3. Perform a visual inspection of the pins at the sensor and the wires coming from the connector. Look for broken, bent, or
corroded pins at the sensor and loose, broken, or corroded wires at the connector.

c
a - Pin A (tan)
b - Pin B (black/orange)
b c - MAT sensor

a 5919
4. The sensor can be tested with an ohmmeter by disconnecting it from the harness and heating or cooling the end of the sensor
at a controlled temperature. If the readings do not match those in the table, replace the sensor and retest.

Manifold Air Temperature Sensor Ohm Test

Degree centigrade –8 20 40 60
Degree fahrenheit 18 68 104 140
kΩ 9.82 kΩ ± 5% 2.57 kΩ ± 5% 1.13 kΩ ± 5% 0.54 kΩ ± 5%
5. If the ohmmeter check of the MAT sensor indicates that the sensor is serviceable, perform an ohmmeter check of the sensor
wiring between the sensor connector and the PCM as follows:
• PCM connector A, pin 22 to black/orange pin B of sensor connector is less than 1 ohm.
• PCM connector A, pin 14 to tan pin A of sensor connector is less than 1 ohm.

Page 2A-40 90-8M8023781 DECEMBER 2009

 Ignition

NOTE: All sensor ground wires are spliced together and connected to the PCM at pin 22 of connector A. Unless there are
multiple sensor failures, the most likely failure would be at the splice point, connector, or in between the connector and the
splice point.

1 9 17 c

C b

8 16 24
1 9 17
a
e

BLK/ORG
B

TAN
8 16 24

1 12 22 S8
A22 BLK/ORG

A14 TAN

11 21 32
BLK/ORG
BLK/ORG

M LK J HGFE DCBA
d

SP4
5917

a- Pin A (tan)
b- Pin B (black/orange)
c- MAT sensor
d- Splice saver SP4
e- PCM

6. If the wiring is serviceable, replace the PCM and check the sensor function using the computer diagnostic system.

Computer Diagnostic System (CDS) Order through SPX

90-8M8023781 DECEMBER 2009 Page 2A-41

Ignition

Manifold Air Temperature Sensor Removal

1. Disconnect the sensor harness connector.
2. Remove the two screws securing the sensor and remove the sensor.

c a - MAT sensor
b - Harness connector
b c - Screws (M4 x 16)

a
c

4577
NOTE: The 350 Verado SCi manifold air temperature sensor contains an anti‑vibration washer inside the sensor housing that
ensures a stable connection. Ensure this anti‑vibration washer remains in place when disconnecting the sensor from the engine
harness.

a- MAT sensor
a b- Anti‑vibration washer
c- Harness connector
d- Screws (M4 x 16)

b d

41475

Manifold Air Temperature Sensor Installation

1. Inspect the sensor O‑ring for cuts or abrasions. Replace the O‑ring as required.
2. Install the sensor with the O‑ring into the cylinder block. Tighten the sensor screws to the specified torque.

Description Nm lb‑in. lb‑ft

Sensor screw (M4 x 16) 1.7 15
3. Connect the sensor harness to the sensor.

Page 2A-42 90-8M8023781 DECEMBER 2009

 Ignition

Supercharger Outlet Temperature Sensor

The supercharger outlet temperature sensor is a thermistor immersed in the boost pressure outlet stream. It is located in the front
of the engine, at the base of the outlet duct. Low air temperature produces high resistance. High air temperature causes low
resistance. The PCM will reduce engine RPM and warn the helm of the high temperature.

a - Supercharger outlet temperature sensor

b b - Harness connector

38885

Supercharger Outlet Temperature Sensor Test

The computer diagnostic system (CDS) will determine the proper functioning of the supercharger outlet temperature sensor by
providing a numerical readout of the sensor temperature before and after the engine is started. With the engine not running, the
sensor temperature should be approximately the same as the ambient air temperature. After the engine is started, the temperature
sensor should indicate a rise in temperature.

Supercharger Outlet Temperature Sensor Resistance

At 21 °C (70 °F) 12.5 kΩ

1. With the engine running and the CDS connected to the engine, if the sensor does not appear to be indicating a temperature
change, shake or move the sensor harness and connector. If the temperature begins to change, look for a broken, loose, or
corroded wire.

Computer Diagnostic System (CDS) Order through SPX

2. Disconnect the connector from the sensor.
3. Perform a visual inspection of the pins at the sensor and the wires coming from the connector. Look for broken, bent, or
corroded pins at the sensor and loose, broken, or corroded wires at the connector.

c
a - Pin A (light blue/green)
b - Pin B (black/orange)
c - Supercharger outlet temperature sensor

b a 5936

4. The sensor can be tested with an ohmmeter by disconnecting it from the harness and heating or cooling the end of the sensor
at a controlled temperature. If the readings do not match those in the table, replace the sensor and retest.

Supercharger Outlet Temperature Sensor Ohmmeter Test

Degree centigrade 10 21 38 65 160
Degree fahrenheit 48 70 100 150 320
kΩ 19.9 kΩ 12.5 kΩ 5.7 kΩ 2.1 kΩ 0.147 kΩ
5. If the ohmmeter check of the sensor indicates that the sensor is serviceable, perform an ohmmeter check of the sensor wiring
between the sensor connector and the PCM as follows:
• PCM connector A, pin 22 to black/orange pin B of sensor connector is less than 1 ohm.

90-8M8023781 DECEMBER 2009 Page 2A-43

Ignition

• PCM connector A, pin 12 to light blue/green pin A of sensor connector is less than 1 ohm.
NOTE: All sensor ground wires are spliced together and connected to the PCM at pin 22 of connector A. Unless there are
multiple sensor failures, the most likely failure would be at the splice point, connector, or in between the connector and the
splice point.

1 9 17
c
C

8 16 24
1 9 17

e B
b a

LT BLU/GRN
BLK/ORG
8 16 24

1 12 22 S8
A22 BLK/ORG
S20
A12 LT BLU/GRN

11 21 32
BLK/ORG

BLK/ORG

M LK J HGFE DCBA

SP5 5932

a- Pin A (light blue/green)

b- Pin B (black/orange)
c- Supercharger outlet temperature sensor
d- Splice saver SP5
e- PCM

6. If the wiring is serviceable, replace the PCM and check the sensor function using the computer diagnostic system.

Computer Diagnostic System (CDS) Order through SPX

Page 2A-44 90-8M8023781 DECEMBER 2009

 Ignition

Supercharger Outlet Temperature Sensor Removal

1. Disconnect the sensor harness connector.
2. Remove the sensor from the outlet duct.

a - Supercharger outlet temperature sensor

b b - Harness connector

38885

Supercharger Outlet Temperature Sensor Installation

1. Inspect the sensor O‑ring for cuts or abrasions. Replace the O‑ring as required.
2. Install the sensor with the O‑ring into the outlet duct. Tighten the sensor to the specified torque.

Description Nm lb‑in. lb‑ft

Temperature sensor 15 133
3. Connect the sensor harness to the sensor.

Fuel Pressure Sensor

The fuel pressure sensor is located on the port side of the fuel rail. The sensor will provide fuel pressure information for:
• Digital gauges
• Analog gauges
• Computer diagnostic system
• Trigger a fault code in the propulsion control module in the event of low or high fuel pressure
• Propulsion control module to change the injector pulse width to compensate for low or high fuel pressure

b
a - Fuel pressure sensor
b - Fuel rail

41481

Fuel Pressure Sensor Test

The computer diagnostic system (CDS) will determine the proper functioning of the fuel pressure sensor by providing a numerical
readout of the sensor after the engine is started.
NOTE: The following fuel pressure sensor specifications are dependent on how and where the engine is being operated at the
time of the test. Altitude, load, and RPM will affect the readings provided by the CDS. The following specifications are nominal
figures obtained from a engine running at sea level.

90-8M8023781 DECEMBER 2009 Page 2A-45

Ignition

Fuel Pressure Sensor

At idle 380 kPa (55 psi)
At wide‑open throttle 335–350 kPa (48.5–51 psi)

IMPORTANT: The fuel pressure value observed on a CDS or SmartCraft gauge is the delta fuel pressure. The delta fuel pressure
number will not be the same number observed on a fuel pressure gauge attached to the fuel rail test port.
1. With the engine running and the CDS connected to the engine, if the fuel pressure sensor does not appear to be indicating
a pressure change, shake or move the sensor harness and connector. If the pressure begins to change, look for broken,
loose, or corroded wires.

Computer Diagnostic System (CDS) Order through SPX

2. Disconnect the harness connector from the sensor.
3. Perform a visual inspection of the pins at the sensor and the wires coming from the connector. Look for broken, bent, or
corroded pins at the sensor and loose, broken, or corroded wires at the connector.

d
a- Pin A (black/orange)
b- Pin B (purple/yellow)
c- Pin C (light blue)
c d- Fuel pressure sensor

a b

5938
4. An ohmmeter check of the fuel pressure sensor can be made by disconnecting the sensor harness and measuring the
resistance between pins A, B, and C. The normal resistance values for the fuel pressure sensor at 21 °C (70 °F) are:
• Between pin A and pin B is 100–135 kΩ.
• Between pin A and pin C is 240–305 kΩ.
5. If the ohmmeter check of the fuel pressure sensor indicates that the sensor is serviceable, perform an ohmmeter check of
the sensor wiring between the sensor connector and the PCM as follows:
• PCM connector A, pin 22 to black/orange pin A of sensor connector is less than 1 ohm.
• PCM connector A, pin 23 to purple/yellow pin B of sensor connector is less than 1 ohm.
• PCM connector A, pin 24 to light blue pin C of sensor connector is less than 1 ohm.

Page 2A-46 90-8M8023781 DECEMBER 2009

 Ignition

NOTE: All sensor ground wires are spliced together and connected to the PCM at pin 22 of connector A. Unless there are
multiple sensor failures, the most likely failure would be at the splice point, connector, or in between the connector and the
splice point.

1 9 17
c

a b
8 16 24
1 9 17

PUR/YEL
BLK/ORG
LT BLU
B

h
8 16 24

1 12 22 S8
A22 BLK/ORG
A23 PUR/YEL
S7
A24 LT BLU

11 21 32

PUR/YEL
BLK/ORG
PUR/YEL

BLK/ORG

f
g e
M LK J HGFE DCBA M LK J HGFE DCBA M LK J HGFE DCBA

SP4 SP5 SP6

34116

a- Pin A (black/orange)
b- Pin B (purple/yellow)
c- Pin C (light blue)
d- Fuel pressure sensor
e- Splice saver SP6
f- Splice saver SP5
g- Splice saver SP4
h- PCM

6. If the wiring is serviceable, replace the PCM and check the sensor function using the computer diagnostic system.

90-8M8023781 DECEMBER 2009 Page 2A-47

Ignition

Fuel Pressure Sensor Removal

! CAUTION
Failure to release pressure from the fuel system will result in fuel spraying out, which can cause a fire or explosion. Allow the
engine to cool completely and release all fuel pressure before servicing any part of the fuel system. Always protect eyes and
skin from pressurized fuel and vapors.

1. Disconnect the sensor connector.

2. Remove the sensor from the fuel rail.

a - Sensor harness connector

a b b - Fuel pressure sensor

38817

Fuel Pressure Sensor Installation

1. Install the sensor into the fuel rail. Tighten the sensor to the specified torque.
2. Connect the sensor connector to the sensor.

Description Nm lb‑in. lb‑ft

Fuel pressure sensor 15 133

Oil Pressure Sensor

The oil pressure sensor measures cylinder block oil pressure. It is located beside the CPS on the starboard side of the engine. In
the event of low oil pressure, the PCM will limit engine power based on the amount of oil pressure available at a specific engine
RPM.

a
b a - Oil pressure sensor
b - Harness connector

38901

Oil Pressure Sensor Test

The computer diagnostic system (CDS) will determine the proper functioning of the oil pressure sensor by providing a numerical
readout of the sensor after the engine is started.

Oil Pressure Sensor

At idle (minimum pressure) 75 kPa (11 psi)

Page 2A-48 90-8M8023781 DECEMBER 2009

 Ignition

Oil Pressure Sensor

At wide‑open throttle (minimum pressure) 200 kPa (29 psi)

1. With the engine running and the CDS connected to the engine, if the oil pressure sensor does not appear to be indicating a
pressure change, shake or move the sensor harness and connector. If the pressure begins to change, look for broken, loose,
or corroded wires.

Computer Diagnostic System (CDS) Order through SPX

2. Disconnect the connector from the sensor.
3. Perform a visual inspection of the pins at the sensor and the wires coming from the connector. Look for broken, bent, or
corroded pins at the sensor and loose, broken, or corroded wires at the connector.

d
a- Pin A (black/orange)
b- Pin B (purple/yellow)
c- Pin C (light blue)
c d- Oil pressure sensor

a b

5938
4. An ohmmeter check of the oil pressure sensor can be made by disconnecting the sensor harness and measuring the
resistance between pins A, B, and C. The normal resistance values for the oil pressure sensor at 21 °C (70 °F) are:
• Between pin A and pin B is 100–135 kΩ.
• Between pin A and pin C is 240–305 kΩ.
5. If the ohmmeter check of the oil pressure sensor indicates that the sensor is serviceable, perform an ohmmeter check of the
sensor wiring between the sensor connector and the PCM as follows:
• PCM connector A, pin 22 to black/orange pin A of sensor connector is less than 1 ohm.
• PCM connector A, pin 23 to purple/yellow pin B of sensor connector is less than 1 ohm.
• PCM connector A, pin 24 to light blue pin C of sensor connector is less than 1 ohm.

90-8M8023781 DECEMBER 2009 Page 2A-49

Ignition

NOTE: All sensor ground wires are spliced together and connected to the PCM at pin 22 of connector A. Unless there are
multiple sensor failures, the most likely failure would be at the splice point, connector, or in between the connector and the
splice point.

1 9 17
c

a b
8 16 24
1 9 17

PUR/YEL
BLK/ORG
LT BLU
B

h
8 16 24

1 12 22 S8
A22 BLK/ORG
A23 PUR/YEL
S7
A24 LT BLU

11 21 32

PUR/YEL
BLK/ORG
PUR/YEL

BLK/ORG

f
g e
M LK J HGFE DCBA M LK J HGFE DCBA M LK J HGFE DCBA

SP4 SP5 SP6

34116

a- Pin A (black/orange)
b- Pin B (purple/yellow)
c- Pin C (light blue)
d- Oil pressure sensor
e- Splice saver SP6
f- Splice saver SP5
g- Splice saver SP4
h- PCM

6. If the wiring is serviceable, replace the PCM and check the sensor function using the computer diagnostic system.

Page 2A-50 90-8M8023781 DECEMBER 2009

 Ignition

Oil Pressure Sensor Removal

1. Disconnect the sensor harness connector.
2. Remove the sensor from the cylinder block.

a
b a - Oil pressure sensor
b - Harness connector

38901

Oil Pressure Sensor Installation

1. Install the sensor into the cylinder block. Tighten the sensor to the specified torque.
2. Connect the sensor harness to the sensor.

Description Nm lb‑in. lb‑ft

Oil pressure sensor 15 133

Block Water Pressure Sensor

The block water pressure sensor measures the amount of coolant supplied by the water pump to the cylinder block. The sensor
converts this pressure to a voltage which is sent to the PCM. The PCM will limit engine power if the coolant supply (water pressure)
is insufficient at a given RPM. The water pressure sensor is located on the aft side of the engine and is secured to the fuel injector
harness with a cable tie.

a - Block water pressure sensor

b - Retaining clip
c - Sensor coolant tube
a

38903

Block Water Pressure Sensor Test

The computer diagnostic system (CDS) will determine the proper functioning of the water pressure sensor by providing a numerical
readout of the sensor after the engine is started and engine RPM is varied.
1. With the engine running and the CDS connected to the engine, if the water pressure sensor does not appear to be indicating
a pressure change when engine RPM is varied, shake or move the sensor harness and connector. If the pressure begins to
change, look for broken, loose, or corroded wires.

Computer Diagnostic System (CDS) Order through SPX

2. Disconnect the connector from the sensor.

90-8M8023781 DECEMBER 2009 Page 2A-51

Ignition

3. Perform a visual inspection of the pins at the sensor and the wires coming from the connector. Look for broken, bent, or
corroded pins at the sensor and loose, broken, or corroded wires at the connector.
4. Perform an ohmmeter check of the sensor wiring between the sensor connector and the PCM as follows:
• PCM connector A, pin 22 to black/orange pin A of sensor connector is less than 1 ohm.
• PCM connector A, pin 23 to purple/yellow pin B of sensor connector is less than 1 ohm.
• PCM connector A, pin 4 to white/green pin C of sensor connector is less than 1 ohm.

Page 2A-52 90-8M8023781 DECEMBER 2009

 Ignition

NOTE: All sensor ground wires are spliced together and connected to the PCM at pin 22 of connector A. Unless there are
multiple sensor failures, the most likely failure would be at the splice point, connector, or in between the connector and the
splice point.

1 9 17
d

C
c

8 16 24
1 9 17
a b
f
B

PUR/YEL
BLK/ORG
WHT/GRN
8 16 24

1 12 22 S8
A22 BLK/ORG
A23 PUR/YEL
S7
A4 WHT/GRN

11 21 32 BLK/ORG
BLK/ORG
PUR/YEL
PUR/YEL

M LK J HGFE DCBA
e

SP4 5941

a- Pin A (black/orange)
b- Pin B (purple/yellow)
c- Pin C (white/green)
d- Block pressure sensor
e- Splice saver SP4
f- PCM

5. If the wiring is serviceable, the PCM can be tested using the computer diagnostic system with the pinpoint guided diagnostic
instructions. If the PCM is serviceable, replace the sensor.

90-8M8023781 DECEMBER 2009 Page 2A-53

Ignition

Computer Diagnostic System (CDS) Order through SPX

Block Water Pressure Sensor Removal

1. Disconnect the sensor harness connector.
2. Remove the water pressure sensor coolant tube.
3. Remove the sensor from the retaining clip.

a - Block water pressure sensor

b - Retaining clip
c - Coolant tube
a

38903

Block Water Pressure Sensor Installation

1. Connect the sensor harness.
2. Install the coolant tube to the sensor.
3. Secure the sensor with the retaining clip.

Oil Temperature Sensor

The oil temperature sensor is located at the top of the cylinder block, below the oil pressure sensor. It is a thermistor immersed
in the engine oil passageway. It supplies the PCM with engine oil temperature information. The PCM adjusts the timing and the
amount of fuel delivered according to the oil temperature in the cylinder block. Low oil temperature produces high resistance. High
oil temperature causes low resistance. The normal resistance value for the sensor at 21 °C (70 °F) is 12.5 kΩ.

a - Oil temperature sensor

a b - Harness connection

b
38904

Oil Temperature Sensor Test

The computer diagnostic system (CDS) will determine the proper functioning of the oil temperature sensor by providing a numerical
readout of the oil temperature before and after the engine is started. With the engine not running, oil temperature should be
approximately the same as the ambient air temperature. After the engine is started, the temperature sensor should indicate a rise
in oil temperature to approximately 75–110 °C (167–230 °F). Outside air temperature and the temperature of the water that the
engine is operating in will directly affect the engine oil temperature.

Page 2A-54 90-8M8023781 DECEMBER 2009

 Ignition

1. With the engine running and the CDS connected to the engine, if the oil temperature sensor does not appear to be indicating
a temperature change, shake or move the sensor harness and connector. If the temperature begins to change, look for a
broken, loose, or corroded wire.

Computer Diagnostic System (CDS) Order through SPX

2. Disconnect the connector from the sensor.
3. Perform a visual inspection of the pins at the sensor and the wires coming from the connector. Look for broken, bent, or
corroded pins at the sensor and loose, broken, or corroded wires at the connector.

c
a - Pin A (brown)
b - Pin B (black/orange)
c - Oil temperature sensor

b a
6004
4. The sensor can be tested with an ohmmeter by disconnecting it from the harness and heating or cooling the end of the sensor
at a controlled temperature. If the readings do not match those in the table, replace the sensor and retest.
5. If the ohmmeter check of the oil temperature sensor indicates that the sensor is serviceable, perform an ohmmeter check of
the sensor wiring between the sensor connector and the PCM as follows:

Oil Temperature Sensor Ohmmeter Test

Degree centigrade –10 21 38 65 95
Degree fahrenheit 14 70 100 150 203
kΩ 55 kΩ 12.5 kΩ 5.7 kΩ 2.1 kΩ 0.786 kΩ

• PCM connector A, pin 22 to black/orange pin B of sensor connector is less than 1 ohm.
• PCM connector A, pin 17 to brown pin A of sensor connector is less than 1 ohm.

90-8M8023781 DECEMBER 2009 Page 2A-55

Ignition

NOTE: All sensor ground wires are spliced together and connected to the PCM at pin 22 of connector A. Unless there are
multiple sensor failures, the most likely failure would be at the splice point, connector, or in between the connector and the
splice point.

1 9 17

C b

a
8 16 24
1 9 17

c d
8 16 24

BLK/ORG
BRN
1 12 22 S8
A22 BLK/ORG

A
A17 BRN

BLK/ORG
BLK/ORG

11 21 32

f M LK J HGFE DCBA M LK J HGFE DCBA

e

SP4 SP5
34118

a- PCM
b- Oil temperature sensor
c- Pin B (black/orange)
d- Pin A (brown)
e- Splice saver SP5
f- Splice saver SP4

6. If the wiring is serviceable, replace the PCM and check the sensor function using the computer diagnostic system.

Computer Diagnostic System (CDS) Order through SPX

Oil Temperature Sensor Removal

1. Disconnect the sensor harness connector.

Page 2A-56 90-8M8023781 DECEMBER 2009

 Ignition

2. Remove the sensor from the cylinder block.

a - Oil temperature sensor

a b - Harness connection

b
38904

Oil Temperature Sensor Installation

1. Inspect the sensor O‑ring for cuts or abrasions. Replace the O‑ring as required.
2. Install the sensor with the O‑ring into the cylinder block. Tighten the sensor to the specified torque.

Description Nm lb‑in. lb‑ft

Oil temperature sensor 15 133
3. Connect the sensor harness to the sensor.

Water in Fuel (WIF) Sensor

The 350 Verado SCi utilizes an externally mounted water separating fuel filter assembly. Below the fuel filter is a bowl that contains
the WIF sensor. The sensor is connected to the engine through the 350 Verado SCi vessel harness and is a normally open switch.
Water exposure completes a circuit and activates a warning horn.

a- Fuel filter and bowl assembly

b- Filter O‑ring
c c- Water fuel separator head
d- Bowl O‑ring
b e- Water in fuel (WIF) sensor
f- Water in fuel (WIF) sensor harness connection
g- Drain valve
d
a

g e

35697

Water in Fuel Sensor Test

! WARNING
Fuel is flammable and explosive. Ensure that the key switch is off and the lanyard is positioned so that the engine cannot start.
Do not smoke or allow sources of spark or open flame in the area while servicing. Keep the work area well ventilated and avoid
prolonged exposure to vapors. Always check for leaks before attempting to start the engine, and wipe up any spilled fuel
immediately.

90-8M8023781 DECEMBER 2009 Page 2A-57

Ignition

1. Perform a visual inspection.

2. If the water in fuel warning horn is activated, drain the contents of the bowl into a clear container. If no water is present,
disconnect the water in fuel sensor harness from the 350 Verado SCi vessel harness and perform a continuity check between
the two sensor pins. There should be no continuity. If there is continuity, the sensor is defective and must be replaced.

a- Pin A (tan/purple)
b- Pin B (black/orange)
c- Water in fuel sensor harness and connector
d- Water in fuel sensor
e- Bowl
f- Drain valve

d
f

c
a b

38923

3. If the sensor is serviceable, perform a continuity check on the sensor harness between the sensor connector and the PCM.
Check for shorts to ground.
• PCM connector A, pin 22 to pin B of sensor connector is less than 1 ohm.
• PCM connector A, pin 27 to pin A of sensor connector is less than 1 ohm. There should be no shorts to ground.

Page 2A-58 90-8M8023781 DECEMBER 2009

 Ignition

NOTE: All sensor ground wires are spliced together and connected to the PCM at pin 22 of connector A. Unless there are
multiple sensor failures, the most likely failure would be at the splice point, connector, or in between the connector and the
splice point.

b
1 9 17

8 16 24

1 9 17
c d

BLK
GRN
B
a
f e
8 16 24

1 12 22 S8
A22 BLK/ORG

B A

A A27 TAN/PUR
BLK/ORG

BLK/ORG

11 21 32

M LK J HGFE DCBA g
h M LK J HGFE DCBA

SP4 SP5
41505

a- PCM
b- Fuel filter
c- Drain valve
d- Water in fuel sensor
e- Pin A (tan/purple)
f- Pin B (black/orange)
g- Splice saver SP5
h- Splice saver SP4

4. If the sensor harness is serviceable, replace the PCM.

Fuses
The electrical wiring circuits on the outboard are protected from overload by fuses in the wiring. If a fuse is blown, try to locate and
correct the cause of the overload. If the cause is not found, the fuse may blow again.

90-8M8023781 DECEMBER 2009 Page 2A-59

Ignition
1. Remove the top cowl. Locate the fuse holder on the starboard side of the engine.

29294

2. Remove the plastic cover from the fuse holder.

3. Remove the fuse puller from the fuse holder.
4. Remove the suspected blown fuse to determine if the silver colored band is broken.
5. Replace the fuse with a new fuse of the same amperage rating.

28767

a- Fuse puller
a b- Fuse holder
c- Good fuse
d- Blown fuse
b e- Electronic control module and purge valve ‑ 20
amp fuse "ECM"
f - Ignition coils ‑ 20 amp fuse "IGN. COILS"
g - Fuel delivery ‑ 20 amp fuse "FUEL"
h - Spare fuses (3)
i - Diagnostics terminal ‑ 2 amp fuse
c
e f g j - Injector power and boost valve ‑ 20 amp fuse
"INJ. PWR."
20 20 20
20 20 20 h
d 20 2

j i 29663

Page 2A-60 90-8M8023781 DECEMBER 2009