Mercury Marine MerCruiser Service Manual #36 ECM 555 Diagnostics

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This Workshop Service Repair manual PDF download for the ECM 555 Diagnostics Mercury Marine MerCruiser has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


APPLICABLE MODELS :

ECM 555 Diagnostics


TABLE OF CONTENTS :

1 - General Information
2 - Troubleshooting
3 - Wiring Diagrams


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 90-864573001
Total Pages : 121


All Official Mercury Marine Manuals for MerCruiser Sterndrives and Inboards include easy to follow, step-by-step illustrated procedures based on the complete dismantling, repair, and assembling of boat motors, from the simplest repair to complex procedures, this manuals give you everything you need to do the job with confidence.

This Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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90-864573001
Notice
Index
Notice to Users of This Manual
Precautions
Replacement Parts
Cleanliness and Care of Product
Manual Outline
Section 1A General Information
Section 1A - General Information
Table of Contents
How To Use This Guide
ECM and PCM Abbreviations
Precautions
Service Precautions
General Information
Electrostatic Discharge Damage
Wiring Harness Service
Wire Repair
Wiring Connector Service
Intermittent Problems
ECM 555 Ignition System
Electronic Control Module (ECM) and Sensors
General Description
Computers and Voltage Signals
Analog Signals
Digital Signals
Engine Control Module (ECM)
Engine Guardian System
General Description
General Reference Charts
Manifold Vacuum and Pressure
Vacuum Gauge vs MAP Sensor
Centigrade to Fahrenheit Conversion
Section 2A Troubleshooting
Section 2A - Troubleshooting
Table of Contents
ECM 555 Diagnostics
Abbreviated Procedure
Visual/Physical Check
Clearing Codes
Important Notes
DTS Faults
Troubleshooting Without a Diagnostic Tool
Troubleshooting With a Diagnostic Tool—CDS
CDS Connection to the Engine
CDS Power Up
ECM Troubleshooting Worksheet
ECM Calibration Label
Data Collection
PCM 555 and ECM 555 CDS Worksheet
Symptom Charts
Chart A-1 Engine Cranks Over but Will Not Start
Chart A-2 Main Power Relay Test
Chart A-3 Fuel System Electrical Test
Chart A-4 Fuel System Diagnosis
Chart A-5 Ignition System Test
Chart A-6 Hard Start Symptom
Chart A-7 Engine Surges Symptom
Chart A-8 Lack of Power, Sluggish, or Spongy Symptom
Chart A-9 Detonation or Spark Knock Symptom
Chart A-10 Hesitation, Sag, or Stumble Symptom
Chart A-11 Engine Misses Symptom
Chart A-12 Rough, Unstable, or Incorrect Idle and Stalling Symptom
Chart A-13 Poor Fuel Economy Symptom
Chart A-14 Dieseling or Run-On Symptom
Chart A-15 Backfire Symptom
Fuel Pressure Gauge Setup for ECM Engines
Installation
Test
Removal
Injector Balance Test
Test Procedure
Troubleshooting With a Vacuum Gauge
Vacuum Gauge Troubleshooting Guide
Engine Fault Quick Reference Chart
MerCruiser ECM/PCM Fault List
ECM/PCM Fault List Information
Fault Conditions
Sticky and Non-Sticky Faults
Default Sensor Values
MerCruiser ECM/PCM Fault List Table Columns
Fault #
CDS Fault Message
DDT Fault Status Message
Icon/Horn/Guardian Column
♠- System View Icon
♥- Warning Horn Signals
♦- Engine Guardian
Fault Explanation
Possible Root Cause
MerCruiser ECM/PCM Fault List Table
ECM Frequently Asked Questions
What is a circuit (CKT) high or low fault?
What is a STR (Strategy)?
What is a TPI/TPS High or Low Range fault?
Why do we use the loaded volts lead on some pinpoint tests?
How can I switch between the data screens and the service manual?
Why do some faults take longer to set than others?
What is a Main Power Relay (MPR) Output Fault?
What is wrong when I see a PWR1 or 5VDC Power Low fault?
Why does an EST or ECM Trigger Open not register as a fault when the engine is running?
What are MAP Diff or TPI Diff errors?
What is a MAP Idle Check or MAP Idle Err?
What do Overspeed Fault and Engine Guardian Fault indicate?
What is a Main Power Relay Request (MPRLY REQ) in the Freeze Frame buffer?
Why is the engine slowing down and how do I know if Engine Guardian is active?
I see the following faults: OIL LVL IN (CKT) HI, FUEL LVL IN (CKT) HI or SEA TEMP IN (CKT). Is there a problem and how can I eliminate these faults?
What is a good tool to use to diagnose boat wiring problems?
Why can I not get the active data screen to list any values?
What should I do if the CDS system locks up?
Why do I have to connect the ohm meter leads together at the start of the pinpoint tests?
Why do the pinpoint tests ask me if I have started the engine?
Why am I not able to get past the ohmmeter verification screen during the pinpoint tests?
Why am I not able to get the VOM meter to communicate with the CDS system?
I have multiple engines on the boat, but do not have the ability to view data from all the engines from a single connection with the CDS system. Why?
How does the cylinder misfire test work?
Why do I need to run the cylinder misfire test at a higher RPM or under load?
Why do I need to disconnect power to both fuel pumps?
How do I perform a fuel injector test on a MerCruiser ECM555 system?
How do I test a MerCruiser ECM555 system with one ignition coil?
How do I configure a digital throttle and shift helm station?
How do I calibrate the cursor or screen on my Panasonic touch-screen PCs?
What does IAT mean?
What does DTS mean?
Why is my laptop battery charge low after long-term storage?
How do I connect to a MEFI 4 engine system?
Why am I having trouble zeroing the ohms reading on my multimeter?
Why does the DMT 2004 voltmeter report high readings for the 5-volt reference signal?
What is the difference between a sticky and non-sticky fault?
What is Engine Guardian?
What does Fault Seconds information tell me?
How do I tell the difference between 2004, 2005, and 2006 and Newer DTS systems?
What does the Unit of Measurement Counts stand for?
How do I detect a COM port setting for my multimeter?
What is a trim delta test?
What is shadow mode?
Why do my Freeze Frame buffers and FPC (Fuel per Cylinder) data items display incorrectly?
Section 3A Wiring Diagrams
Section 3A - Wiring Diagrams–ECM with 10-Pin Harness
Table of Contents
Engine Harness Legend
Wire Splice Description
Wire Color Code Abbreviations
10-Pin ECM 555 Pinouts
EFI System Engine Wiring Harness Diagrams
10-Pin Engine Harness Starting System
Wake, Horn, and Tachometer Circuits
Fuses, IAC, and Relays
Manifold Air Pressure and Temperature, Crankshaft Position, and Throttle Position Sensors: V6 Engines
Manifold Air Pressure and Temperature, Crankshaft Position, Camshaft Position, and Throttle Position Sensors—V8 Engines
Engine Coolant Temperature, Seawater Pump, and Oil Pressure Sensors
Gear Indicator and Shift Interrupt—Sterndrive
Fuel Injector Control Circuits and Diagnostic Circuits–Batch-Fired Injector System
Fuel Injector Control Circuits and Diagnostic Circuits—Batch-Fired Injector System (V6 Sterndrive)
Fuel Injector Control Circuits and Diagnostic Circuits—Semi–Batch-Fired (V8)
Ignition System Without Cam Position Sensor
Ignition System With Cam Position Sensor
CAN, Fuel Level, Paddle Wheel, and Temperature Circuits—V6 Sterndrive
CAN, Fuel Level, Paddle Wheel, and Temperature Circuits—V8 Sterndrive and Inboard
Transom Harness Connector (to Engine)
Starter Solenoid Circuit
Alternator Output Circuit
Engine 12-Volt Ground Circuit—All engines
Single Circuit Diagrams
Seawater Pump Circuit
Diagnostics Circuit
Engine Coolant Temperature Circuit
IAC Circuit
TMAP Circuit
MAT circuit
MAP Circuit
Throttle Position Circuit
Oil Pressure Circuit
ECM Single Knock Sensor Signal—V6
ECM Dual Knock Sensor Signal—V8
Paddle Wheel Connector Circuit—All Engines
Fuel Level Circuit—V6 and V8 Sterndrive
Fuel Level Circuit—V8 Inboard
Fuel Pump Relay Circuit—All Engines
Control Area Network (CAN) Circuit—V6 and V8

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