Page vi
90-864573 FEBRUARY 2002
SECTION 1A - GENERAL INFORMATION
How To Use This Guide
1A-2
. . . . . . . . . . . . . .
Abbreviations
1A-3
. . . . . . . . . . . . . . . . . . . . . . .
Special Tools
1A-4
. . . . . . . . . . . . . . . . . . . . . . .
Precautions
1A-10
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Service Precautions
1A-12
. . . . . . . . . . . . . . .
General Specifications
1A-14
. . . . . . . . . . . . . . .
4.3 liter (262 cid)
1A-14
. . . . . . . . . . . . . . . . .
5.0 liter (305 cid)
1A-14
. . . . . . . . . . . . . . . . .
5.7 liter (350 cid)
1A-15
. . . . . . . . . . . . . . . . .
6.2 liter (377 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
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Electronic Control Module
(ECM) and Sensors
1A-20
. . . . . . . . . . . . . . . . .
General Description
1A-20
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Computers and Voltage Signals
1A-20
. . . .
Analog Signals
1A-20
. . . . . . . . . . . . . . . . . . .
Digital Signals
1A-22
. . . . . . . . . . . . . . . . . . . .
Engine Control Module (ECM)
1A-23
. . . . . .
Engine Guardian System
1A-24
. . . . . . . . . . . . .
General Description
1A-24
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Warning Chart
1A-25
. . . . . . . . . . . . . . . . . . . .
General Reference Charts
1A-28
. . . . . . . . . . . .
Manifold Vacuum / Pressure
1A-28
. . . . . . .
Vacuum Gauge vs MAP Sensor
1A-29
. . . .
Centigrade to Fahrenheit Conversion 1A-30
SECTION 2A - TROUBLESHOOTING
Troubleshooting
Without A Diagnostic Tool
2A-2
. . . . . . . . . . . .
Troubleshooting
With A Diagnostic Tool
2A-3
. . . . . . . . . . . . . .
Troubleshooting 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
2A-9
. . . . . . . . . . . . .
Fuel Pressure Gauge Setup
2A-11
. . . . . . . .
Symptom Charts
2A-12
. . . . . . . . . . . . . . . . . . . .
Chart A-1 Engine Cranks Over
But Will Not Start
2A-12
. . . . . . . . . . . . . . . . .
Chart A-2 Main Power Relay Test
2A-13
. . .
Chart A-3 Fuel System Electrical Test 2A-14
Chart A-4 Fuel System Diagnosis
2A-15
. . .
Chart A-5 Ignition System Test
2A-17
. . . . .
Chart A-6 Hard Start Symptom
2A-19
. . . . .
Chart A-7 Engine Surges Symptom
2A-22
.
Chart A-8 Lack Of Power, Sluggish
or Spongy Symptom
2A-24
. . . . . . . . . . . . . .
Chart A-9 Detonation /
Spark Knock Symptom
2A-26
. . . . . . . . . . .
Chart A-10 Hesitation, Sag
or Stumble Symptom
2A-29
. . . . . . . . . . . . .
Chart A-11 Cuts Out
or Misses Symptom
2A-31
. . . . . . . . . . . . . .
Chart A-12 Rough, Unstable or
Incorrect Idle and Stalling Symptom
2A-33
Chart A-13 Poor Fuel
Economy Symptom
2A-35
. . . . . . . . . . . . . .
Chart A-14 Dieseling or
Run-On Symptom
2A-37
. . . . . . . . . . . . . . . .
Chart A-15 Backfire Symptom
2A-38
. . . . . .
Symptom Quick Reference Chart
2A-40
. . . . . .
Engine Fault Quick Reference Chart
2A-43
. . .
Injector Balance Test
2A-47
. . . . . . . . . . . . . . . .
Test Procedure
2A-47
. . . . . . . . . . . . . . . . . . .
Test Example
2A-49
. . . . . . . . . . . . . . . . . . . .
Mercury MerCruiser
Scan Tool Flowchart
2A-50
. . . . . . . . . . . . . .
Digital Diagnostic Terminal Flowchart 2A-51