Subsection XX (IGNITION SYSTEM)

IGNITION SYSTEM
SERVICE TOOLS
Description Part Number Page
D.E.S.S. POST REMOVER ............................................................ 529 035 943 ............................................. 8
ECM ADAPTER TOOL................................................................... 529 036 166 ......................................... 4, 7
FLUKE 115 MULTIMETER ............................................................ 529 035 868 ......................................... 4, 7

SERVICE PRODUCTS
Description Part Number Page
LOCTITE 767 (ANTISEIZE LUBRICANT) ....................................... 293 800 070 ............................................. 7

GENERAL
WARNING
Torque wrench tightening specifications
must be strictly adhered to.
Locking devices when removed (e.g.: locking
tabs, elastic stop nuts, self-locking fasteners,
cotter pins, etc.) must be replaced.

Hoses, cables or locking ties removed during a

procedure must be reinstalled as per factory stan-
dards. smr2014-032-001_a

1. Ignition coils
WARNING
Never check for engine ignition spark from When a ground signal is provided by the ECM to
an open coil and/or spark plug as spark may an ignition coil primary winding, a high voltage is
cause potential fuel vapors to ignite. Always induced in the coil secondary winding that is used
use an approved spark tester. to produce a spark at the spark plug electrode.
Cylinder 1 is located on the PTO side of the en-
SYSTEM DESCRIPTION gine. Each cylinder is identified by a number on
cylinder block housing.
The ignition system is a digital inductive type (IDI)
system.
Ignition system parameters such as ignition tim-
ing, spark duration, and firing order, as well as
many other engine related functions are con-
trolled by the engine management system (EMS)
in order to meet engine operational requirements.
The EMS can detect many abnormalities includ-
ing a short circuit in the primary winding of the
ignition coils as well as its associated circuits.
Three direct ignition coils receive power from the
fuse F3 through the relay.

smr2014-032-060_a

1. Cylinder identification numbers

smr2012-029 1
Subsection XX (IGNITION SYSTEM)

Ignition Timing The secondary winding of the ignition coils is not

Ignition timing is not adjustable. monitored by the ECM.
The ECM is programmed with data (ignition map- Other sensors in relation with the ignition system
pings) that it uses to establish optimum ignition are also monitored by the ECM.
timing under all engine operating conditions.
Ignition System Testing Sequence
It receives signals from a variety of sensors that
it compares with the ignition mappings and uses Check for fault codes using B.U.D.S. software as a
it to control the ignition spark timing, duration and first troubleshooting step. Refer to DIAGNOSTIC
firing order. SYSTEM AND FAULT CODES subsection.
The firing of each spark plug is independent of the Ensure fuse F3 and relay are powered and in good
others. condition.
If a fuse is burnt, test for a short circuit or faulty
Engine RPM Limiter component on that fuse circuit before replacing
The ECM will limit the maximum engine speed by the fuse.
cutting off ignition spark and fuel at a predeter- WARNING
mined engine RPM.
Due to the possibility of flammable vapors ac-
ENGINE SPEED LIMITER cumulating in the bilge, you should always
8300 RPM
SETTING test for a short circuit which may produce a
spark and ignite the vapors before replacing
Knock Sensor a burnt fuse.
A knock sensor is mounted on the cylinder block
below the exhaust manifold. It detects specific vi- Check ignition spark, refer to IGNITION COIL
brations that would typically be generated by en- QUICK TEST USING B.U.D.S. in this subsection.
gine detonation.
If detonation occurs, the knock sensor detects DIAGNOSTIC GUIDELINES
it and the ECM goes into a specific operating The following is provided to help in diagnosing the
mode whereby it temporarily retards the ignition probable cause of a problem. It is a guideline and
advance until detonation stops. should not be assumed to list all possible causes.
The ECM is able to identify in which cylinder the
knocking occurs and modifies the ignition advance ENGINE WILL NOT STOP WHEN
on that cylinder only. REMOVING KEY FROM ENGINE CUT-OFF
SWITCH
Refer to the ELECTRONIC FUEL INJECTION
(EFI) subsection for testing and replacement pro- 1. Defective engine cut-off switch
cedures. - Check engine cut-off switch. Replace if neces-
sary.
TROUBLESHOOTING ENGINE WILL NOT START (ENGINE
It is good practice to check for fault codes using TURNS OVER)
the B.U.D.S. as a first troubleshooting step. Refer 1. Fouled or defective spark plug
to DIAGNOSTIC AND FAULT CODES subsection.
- Check spark plug condition. Replace if necessary.
Refer to POWER DISTRIBUTION for fuses and re-
lay information. 2. Defective CPS
Always refer to the WIRING DIAGRAM when - Test CPS, refer to ELECTRONIC FUEL INJEC-
TION (EFI) subsection.
troubleshooting an electrical circuit.
3. Defective trigger wheel
IGNITION SYSTEM TESTING - Check. Refer to MAGNETO AND STARTER sub-
section.
The ECM controls the ignition system.
4. Defective ignition circuit
If a fault is detected by the ECM, the check engine - Check fuses, ignition coils, wiring and connec-
light will turn on. tors.
The ECM can detect a problem on the primary
winding or circuit of the ignition coils.
2 smr2012-029
 Subsection XX (IGNITION SYSTEM)

ENGINE HARD TO START PROCEDURES

1. Faulty, fouled or worn out spark plug
- Check spark plug condition. Replace if necessary. IGNITION COILS
2. Drowned engine WARNING
- Check engine temperature value using B.U.D.S. Never check for engine ignition spark from
monitoring page. If the temperature read is lower an open coil and/or spark plug in the engine
than the ambient temperature, CTS sensor may compartment as a spark may cause fuel va-
be defective or have a bad connection. There-
fore, the ECM would erroneously set the engine pors which may have accumulated in the
in cold start mode and it could flood the spark bilge to ignite.
plugs.
Ignition Coil Access
ENGINE MISFIRES, RUNS IRREGULARLY
1. Remove the central body.
1. Fouled, defective, worn spark plugs
Ignition coils are located on top of the valve cover.
- Check spark plug condition. Replace if necessary.
2. Damaged trigger wheel/loose CPS
- Check. Refer to MAGNETO AND STARTER sub-
section.
3. Defective ignition circuit
- Check fuses, ignition coils, wiring and connec-
tors.
4. Poor engine grounds
- Check ground condition, refer to POWER DISTRI-
BUTION AND GROUNDS subsection.

ENGINE CONTINUALLY BACKFIRES

1. Fouled, defective spark plugs smr2014-032-001_a

1. Ignition coils
- Check spark plug condition. Replace if necessary.
2. Damaged trigger wheel/defective or loose CPS Ignition Coil Test Using B.U.D.S.
- Check, refer to MAGNETO AND STARTER and 1. Connect to the latest applicable B.U.D.S. soft-
ELECTRONIC FUEL INJECTION (EFI) subsec- ware. Refer to COMMUNICATION TOOLS
tions.
AND B.U.D.S. subsection.
ENGINE DETONATION OR PINGING 2. Select the Activation and ECM tabs.
1. Faulty or disconnected knock sensor 3. Energize the ignition coil to be tested by clicking
- Check, refer to ELECTRONIC FUEL INJECTION
on the corresponding illustration.
(EFI) subsection.

ENGINE LACKS ACCELERATION OR

POWER
1. Weak spark
- Check spark plugs, coils, wiring and connections.

smr2012-029 3
Subsection XX (IGNITION SYSTEM)

smr2014-032-011_a
smr2014-032-010_a
IGNITION COIL INPUT VOLTAGE TEST
IGNITION COIL ACTIVATION
1. Activation tab
2. ECM tab If test succeeds, carry out an IGNITION COIL RE-
3. Click on the desired ignition coil SISTANCE TEST.
You should hear the spark occurring. If in doubt, If test fails, carry out an IGNITION COIL POWER
use a sealed vapor proof spark tester or an induc- CIRCUIT CONTINUITY TEST.
tive spark tester as available from tool suppliers,
to prevent a spark from occurring in the bilge. Ignition Coil Power Circuit Continuity
If there is no ignition at one or more coils, carry
Test
out a IGNITION COIL INPUT VOLTAGE TEST. 1. Use the FLUKE 115 MULTIMETER (P/N 529 035
868) and select .
If spark is weak, try a new spark plug. If spark is
still weak, try a new ignition coil. 2. Press the START button to activate the ECM.
NOTE: The voltage required to produce a spark in 3. Read resistance of the desired ignition coil cir-
the combustion chamber is higher when the en- cuit.
gine is running. IGNITION
IGNITION FUSE
COIL MEASUREMENT
Ignition Coil Input Voltage Test COIL
WIRE
BOX
Make sure fuse F3 and the relay are good before 1
testing. VT/BU
(rear)
Terminal
1. Disconnect the applicable ignition coil connec- 2 VT/GN A4
Close to 0
tor.
3 VT/OG
2. Remove tether cord from the engine cut-off
switch. If test fails at any ignition coil, test the following
3. Set the FLUKE 115 MULTIMETER (P/N 529 035 items separately and repair/replace wiring or ter-
868) to Vdc. minals from fuse box to the applicable ignition coil.
4. Press the START button to activate the ECM. Refer to WIRING DIAGRAM for details.
5. Measure voltage. – Wiring from fuse box to engine connector
– Wiring from engine connector to ignition coil.
TEST PROBES VOLTAGE
VIOLET/BLUE wire Ignition Coil Control Circuit Continuity
(ignition coil no. 1) Test
VIOLET/GREEN wire Battery Battery 1. Disconnect ECM connector "A". For connector
(ignition coil no. 2) ground voltage identification, refer to WIRING HARNESS AND
CONNECTOR subsection.
VIOLET/ORANGE wire
(ignition coil no. 3) 2. Connect ECM connector to the ECM ADAPTER
TOOL (P/N 529 036 166).

4 smr2012-029
 Subsection XX (IGNITION SYSTEM)

3. Using a multimeter, test the resistance in both

primary and secondary windings.

529036166

smr2014-032-012_a
3. Disconnect ignition coil connector.
PRIMARY WINDING
4. Test for continuity of circuit as per following ta-
ble. RESISTANCE @
CIRCUIT TERMINAL
20°C (68°F)
IGNITION
ECM Primary
COIL COIL RESISTANCE 1 and 2 0.85 - 1.15
ADAPTER winding
WIRE
Cylinder 1
BN/BK A-M4
(rear)
Close to 0
Cylinder 2 BN/OG A-M2 (continuity)
Cylinder 3 BN/YE A-M1

smr2014-032-013_a

SECONDARY WINDING

RESISTANCE @
CIRCUIT TERMINAL
20°C (68°F)
Secondary 1 and spark
9.5 - 13.5 k
winding plug terminal

If any test fails, replace ignition coil.

If test succeeds, carry out an IGNITION COIL
smr2014-032-011_b
CONTROL CIRCUIT CONTINUITY TEST.
IGNITION COIL CONTROL CIRCUIT TEST

If test fails, repair the connector or replace the en- Ignition Coil Removal
gine wiring harness. 1. Disconnect ignition coil connector.
2. Remove ignition coil retaining screw.
Ignition Coil Resistance Test
An ignition coil with a good resistance measure- NOTICE Do not pry on ignition coil with a
ment can still be faulty. Current leakage can occur tool.
at high voltage levels which is not detectable with
3. Remove ignition coil from spark plug by rotating
an ohmmeter. Replacing the ignition coil may be
coil side to side as you pull up.
necessary as a test.
1. Remove ignition coil. Refer to IGNITION COIL Ignition Coil Installation
REMOVAL in this subsection. Install the ignition coil on the spark plug.
2. Perform a visual inspection of the ignition coils. Align the retaining screw hole of the ignition coil
Check for corrosion, bent pins, loose or burnt with the threaded hole on the valve cover.
contacts, and cracked or torn insulator.
Push the ignition coil all the way down until it rests
on the valve cover.

smr2012-029 5
Subsection XX (IGNITION SYSTEM)

Install and tighten retaining screw.

IGNITION COIL RETAINING SCREW
9 N•m ± 1 N•m
Tightening torque
(80 lbf•in ± 9 lbf•in)

Connect ignition coil connector.

SPARK PLUGS
Spark Plug Removal
1. Remove ignition coil. Refer to IGNITION COIL smr2014-032-051_a

REMOVAL in this subsection. 1. Ignition coil

2. Spark plug

WARNING Troubleshooting a Fouled Spark Plug

Never remove an ignition coil from a spark
Fouling of the spark plug is indicated by irregular
plug without disconnecting it from the wiring
running or misfiring of the engine, decreased
harness. Flammable vapors may be present
engine speed due to misfiring, reduced perfor-
in the bilge. Should the tether cord be in-
mance, and increased fuel consumption.
stalled on the engine cut-off switch, a spark
could be generated at the spark plug end of Other possible causes are: use of an incorrect
the coil possibly resulting in an explosion. or bad fuel, defective ignition system, incorrect
spark plug gap, loss of compression, or lubricating
2. Using a spark plug socket, release the torque oil entering the combustion chamber.
applied to the spark plug. The plug face of a fouled spark plug has either a
wet or dry black carbon deposit. Such coatings
form a conductive connection between the center
electrode and the ground electrode.

Spark Plug Analysis

1 2

A00E0BA
A00E0AA 1 2 3
1. Approved socket
2. Improper socket TYPICAL
1. Overheated (light gray, white)
3. Clean the spark plug and cylinder head with 2. Normal (light brown, brown)
3. Fouled (black, wet or dry, dark deposits, gray, melted coating)
pressurized air.
4. Unscrew spark plug then use the ignition coil to The plug face reveals the condition of the engine,
take spark plug out of spark plug hole. operating condition, method of driving and fuel
mixture. For this reason it is advisable to inspect
the spark plug at prescribed intervals, examining
the plug face (i.e. the part of the plug projecting
into the combustion chamber).

6 smr2012-029
 Subsection XX (IGNITION SYSTEM)

Spark Plug Installation NOTICE Do not attempt to probe the steering

Prior to installation, ensure the contact surfaces of connector on the watercraft. Use the test con-
the cylinder head and spark plug are free of grime. nector on the diagnostic harness.
1. Using a wire feeler gauge, check electrode gap 3. Set multimeter to .
as specified in TECHNICAL SPECIFICATIONS. 4. Probe test connector on diagnostic harness to
2. Apply LOCTITE 767 (ANTISEIZE LUBRICANT) check continuity as follows.
(P/N 293 800 070) over the spark plug threads to
DIAGNOSTIC
prevent possible seizure. TETHER CORD
HARNESS
READING
3. Hand screw spark plug into cylinder head.
Removed Open circuit
Then, tighten the spark plug to specification Pin 6 and Pin 9
with an approved spark plug socket. Installed Close to 0
TIGHTENING TORQUE
If continuity test fails:
13 N•m ± 1 N•m – Check steering harness between steering con-
Spark plug
(115 lbf•in ± 9 lbf•in) nector and engine cut-off switch. Repair or re-
place.
4. Install ignition coil. Refer to IGNITION COIL IN-
– If harness is good, replace the engine cut-off
STALLATION in this subsection.
switch.
5. Complete the installation in the reverse order of
If all readings were as specified, carry out the
the removal.
CONTINUITY TEST OF VEHICLE HARNESS TO
ENGINE CUT-OFF SWITCH.
ENGINE CUT-OFF SWITCH
Continuity Test of Engine Cut-Off Continuity Test of Vehicle Harness to
Switch Engine Cut-Off Switch
REQUIRED TOOLS
REQUIRED TOOLS
Diagnostic harness (P/N 529 036 276)
Diagnostic harness (P/N 529 036 276)
FLUKE 115 MULTIMETER (P/N 529 035 868)
FLUKE 115 MULTIMETER (P/N 529 035 868)
ECM ADAPTER TOOL (P/N 529 036 166)
1. Disconnect the steering connector from the ve-
hicle harness. 1. Disconnect the diagnostic harness from the
steering connector and reconnect it to vehicle
connector.
2. Disconnect connector "B" from ECM.

smr2014-032-055_a

1. Steering connector

2. IMPORTANT: Connect the diagnostic harness smr2014-032-056_a

to the steering connector only, NOT to the ve-

3. Install the ECM ADAPTER TOOL (P/N 529 036 166)
hicle harness connector.
on ECM connector "B".
4. Probe test connector as follows.

smr2012-029 7
Subsection XX (IGNITION SYSTEM)

DIAGNOSTIC ECM
HARNESS ADAPTER READING
CONNECTOR TOOL
Pin 9 B-E4
Close to 0
Pin 6 B-F2

If any continuity test failed, check wiring harness

between steering connector and ECM connector.
If problem persists and all tests have been per-
formed, try a new ECM. Refer to ELECTRONIC
FUEL INJECTION (EFI) subsection.
5. Reconnect ECM "B" connector and steering har-
ness connector.
6. Reinstall removed components.

Engine Cut-Off Switch Replacement

REQUIRED TOOL
D.E.S.S. POST REMOVER (P/N 529 035 943)

529035943

8 smr2012-029