Mercury MerCruiser ECM 555, Service Manual

Page 1: ...Serial Number 0M300000 and Above www mercurymarine com au Frankston Road P O Box 80 Dandenong Victoria 3175 Australia www mercurymarine com W6250 Pioneer Road Fond du Lac WI 54936 1939 USA www marinep...

Page 2: ...described herein It is assumed that these personnel are familiar with marine product servicing procedures Furthermore it is assumed that they have been trained in the recommended service procedures of...

Page 3: ...d wide open throttle operation and therefore require heavy duty components Special marine engine parts have design and manufacturing specifications that are required to provide long life and dependabl...

Page 4: ...Alpha and Bravo 350 MAG MPI Alpha and Bravo 0M300000 and Above 350 MAG MPI Alpha and Bravo Horizon 0M300000 and Above MX 6 2 MPI MX 6 2 MPI Horizon Inboard and Tow Sports MIE Serial Number 350 MAG MP...

Page 5: ...Page iv 90 864573 FEBRUARY 2002 THIS PAGE IS INTENTIONALLY BLANK...

Page 6: ...1 2 3 5 8 General Information Troubleshooting Wiring Diagrams 90 864573 FEBRUARY 2002 Page v Service Manual Outline Section 1 General Information Section 2 Troubleshooting Section 3 Wiring Diagrams...

Page 7: ...ing Worksheet 2A 4 ECM Calibration Label 2A 4 Data Collection 2A 5 PCM 555 ECM 555 Scan Tool Worksheet 2A 5 Preliminary Checks 2A 8 Visual Physical Checklist 2A 8 On Board Diagnostic OBD System Chart...

Page 8: ...uits 3A 13 Ignition System 3A 14 CAN Fuel Level Paddle Wheel and Temperature Circuit 3A 15 Transom Harness 3A 16 Transom Connector Engine Side 3A 17 Transom Harness Transom Side 3A 18 Slave Solenoid C...

Page 9: ...Page viii 90 864573 FEBRUARY 2002 THIS PAGE IS INTENTIONALLY BLANK...

Page 10: ...77 cid 1A 15 General Information 1A 16 Electrostatic Discharge Damage 1A 16 Wiring Harness Service 1A 16 Wiring Connector Service 1A 17 Intermittents 1A 18 Electronic Control Module ECM and Sensors 1A...

Page 11: ...iption Warning chart Troubleshooting covers Basic scan tool information Symptom trouble chart Fault chart Wiring diagram covers Engine electrical harness Circuit diagrams Troubleshooting covers possib...

Page 12: ...mally Open CPS Crankshaft Position Sensor OBD On Board Diagnostic Test Cyl Cylinder PCM Propulsion Control Module DDT Digital Diagnostic Terminal RAM Random Access Memory Deg Degrees REF HI Reference...

Page 13: ...ent Components 91 854010 1 8 ft 2 4 m Inductive Pick Up 91 854011 1 Temperature Probe 91 854012 Ferrite Core 91 854013 1 Interface Module 91 854014 1 Hard Carrying Case 91 854015 1 User s Guide 91 802...

Page 14: ...ries An additional harness assembly may be required when using the DDT refer to the following 91 822560A13 Harness Assembly Diagnostic Tester 91 861540A1 Adaptor Harness 91 822560A7 Outboard Adapter H...

Page 15: ...s Adaptor Kit is included with the Fuel Pressure Gauge Kit 91 881833A2 Fuel Pressure Gauge Kit 91 881833A2 Description Use to test the fuel pump pressure includes 91 803135 Fuel Pressure Gauge Adaptor...

Page 16: ...214 Mercury MerCruiser DDT Cartridge Version 1 2 91 880118A2 Description Use on PCM 555 and ECM 555 models 78036 Scan Tool Kit Version 4 0 Note in Description Description Hand held Scan Tool updated f...

Page 17: ...L NUMBER 36 Page 1A 8 90 864573 FEBRUARY 2002 Special Tools continued Portable Timing Light 91 99379 Description Checks the ignition timing powered by 2 D cell batteries 73664 Spark Gap Tester 91 6399...

Page 18: ...4563 N Elston Ave Chicago IL 60630 Phone 773 736 6633 Fax 773 736 2950 Email Sales rinda com Mercury Marine W6250 Pioneer Road P O Box 1929 Fond Du Lac WI 54935 1939 Phone 920 929 5589 800 487 8736 w...

Page 19: ...from an electrical shock fire or explosion Always disconnect both battery cables from the battery before servicing the power package WARNING Be careful when cleaning flame arrestor and crankcase vent...

Page 20: ...flon to threads of brass fitting or plug Do NOT USE TEFLON TAPE Thread brass fitting or plug into fuel pump or fuel filter base until finger tight Tighten fitting or plug an additional 1 3 4 to 2 1 4...