3D-34 - FUEL SYSTEMS 90-824052R3 JUNE 2002
Injector Electrical Harness Test
Purpose: This test will determine if electrical or fuel
delivery problem exists during the fuel
delivery process by checking for open circuits
in injector harness.
1. With outboard in water, start and allow to warm
up. Raise engine speed to 2000-2500 RPM.
Remove spark plug leads one at a time and note
RPM change. Determine non-working (no RPM
change) cylinder. Stop engine.
2. Disconnect injector harness (4 pin connector).
IMPORTANT: Use digital ohmmeter when testing
injector harness.
3. Connect digital ohmmeter (dial set at 200 scale)
leads. POSITIVE lead from ohmmeter connects
to POSITIVE prong “2” (RED wire) of harness
connector. Connect NEGATIVE lead from
ohmmeter to the remaining wires of harness
connector as follows:
WHITE Lead = Injectors, Cylinders 1 and 2
DARK BLUE Lead = Injectors, Cylinders 3 and 4
YELLOW = Injectors, Cylinders 5 and 6
55194
(1) YELLOW
(2) RED
(3) DARK BLUE
(4) WHITE
Results: If readings are 1.1 ± .2 both injector circuits
are complete. Perform Injector Fuel Delivery
Test.
If readings are 2.2 ± .2 one injector does not have a
complete circuit. Perform induction manifold
disassembly and inspection following.
ECM Injector Driver Test
To verify that the ECM is operating the injector pairs,
connect test harness between manifold connector
and engine harness. Start engine.
Use DVA meter (91-99750). Set DVA to 200 scale.
Connect BLACK meter lead to engine ground and
RED test lead to each BLUE, WHITE or YELLOW
female bullet connector.
Normal voltage for a 2.4L – 2.5L engines will be 25
to 60 volts. Voltage will vary with RPM.
Injector Fuel Delivery Test
CAUTION
CAUTION: Switch boxes must be grounded to
engine block if removed for fuel delivery test to
prevent possible damage to ignition system.
Purpose: This test will determine if injector is
delivering fuel when signal is received.
NOTE: Pro Max and Super Magnum high
performance engines do not have bleed fittings in the
transfer ports of each cylinder and the following
method of the fuel delivery test is not applicable. It is
recommended that the Digital Diagnostic Terminal
91-823686A2 be utilized following the procedure
listed with its’ instruction manual.
1. Place outboard in water, start engine and allow to
warm up. Raise engine speed to 2000-2500
RPM. Remove spark plug leads one at a time and
note RPM change. Determine non-working
cylinder (no RPM change).
2. Using squirt bottle of fuel and hose, inject small
amount of fuel into cylinder bleed fitting (a) on
non-working cylinder.
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