Jump to content

Recommended Posts

I have discuss I have alarm problems before. The obvious manual "fixes" do not work. After starting the engines and running for 3-4 minutes on warm up an steady beeping alarm sounds. all oil levels checked and are good, temp is fine. oil pressure is fine. Seems to be being generating from the starboard engine. Sensors are seemingly ok, No error codes on the merc code scan. Mechanic thinks it a fuel vapor alarm but no leaks detected. when engine is shut off, alarm continues, If I shut all battery power off alarm seems to reset. Any ideas?

Link to post
Share on other sites

Sorry...I know you said all oil levels were fine. Does this include the Lower Unit fluid level. I ask because I had this happen on my first Sea Ray that had a merc. I would turn the engine off and leave it on acc and the alarm would still sound......for my problem it was the lower unit fluid was low. just trying. Hope you find the cure.

Link to post
Share on other sites

wow. I am sure some more folks on here with more knowlege will come along and try and help. strange mystery........maybe its haunted :haha-7383::oregonian_winesmiley: I hope that you find the problem. I am sure it is bugging you to crazy....

Link to post
Share on other sites

I can't find any Merc critical (constant) alarm that is programmed to continue annunciation after switched power has been removed. I’ve attached conditions that can generate the initial condition, but there must be an issue with the ECM’s alarm triac or a corrupt program that prevents the alarm condition from dropping out when pilot power is removed. The ECM does have base voltage applied even if the battery switch is in the off position, in order to maintain memory, as does your marine stereo system. I would disconnect the battery cables directly from the batteries over night to force a cold re-boot. This may get the ECM back to base program and working properly, allowing you to begin the process of finding what condition is generating the alarm in the first place.

I had a float failure on the drive oil bottle where the float actually sunk, and set an alarm when the bottle was full. As your Tech has not found an active alarm on the ECM histogram, you may have to catch your fault condition in the act as it sounds like one of those PITA intermittent deals. Alarm conditions per attachment below. I have also included some previous words of wisdomn from our "Boat Wisperer" north of the boarder.

W

1. IAC - idle air control valve. Your model should be the same as an '02 Ford Windstar. Will need gasket # 27-863112 for this job. Items # 15 & 16 in the link below.

http://www.marinepar.../884717/8093-85

2. Water pressure sensor - found on the power steering cooler. Job is to monitor the water pressure generated by the impeller. When the sensor fails, the ECM wonders if the impeller hasn't completely failed, but notices the engine isn't getting hot. Located by the distributor - will probably have a white body. Item # 17 in the link below.

http://www.marinepar...884717/8093-280

3. Faulty gear oil reservoir, or low gear oil level. If the reservoir is full, a test can be done where a new reservoir is attached to the wires, and the new empty reservoir turned upside down. If the beeping stops, the original reservoir is faulty. Items # 3 or 11 in the link below.

http://www.marinepar.../884717/8093-30

4. Loose wires - usually on the starter motor. EFI communicates by voltage, and if there are loose wires, the ECM can't talk properly to it's sensors for information. Also check the wires on the alternator.

5. Wrong grade/weight of engine oil. i.e. 10w30 instead of 25w40, etc. If 10w30 oil is used, once the engine is warmed up and under heavy load, one should be able to see the oil pressure fluctuating wildly above 3500 RPM which is causing the ECM to trigger the alarm.

Engine Guardian System

General Description

Engine Guardian is the focal point of the self-diagnostic strategy on these engines. It helps

protect the engine from possible damage that could result from several faulty conditions.

The system monitors the sensors incorporated on the engine and if a malfunction is

discovered, a fault description is stored in thePCMand available power is normally reduced.

By ensuring that engine output is at a low enough level, the engine is better protected from

thermally induced failures.

For example, if an open or short is found in any sensor, available power will be reduced to

90% of total, the AudioWarning System Alarmwill sound 2 beeps perminute (2 Bp/min) and

the Smartcraft gauges will display a warning lamp. In a seawater pump pressure low

condition, the maximum rpm will vary with the pressure and temperature of the engine and

could be limited to idle in extreme cases of overheating, a constant beep will sound and

Smartcraft gauges will display a warning lamp.

IMPORTANT: Engine Guardian cannot guarantee that engine damage will not occur

when adverse operating conditions are encountered. Engine Guardian is designed

to warn the operator of an adverse condition and to reduce power by limiting rpm in

an attempt to reduce possible engine damage. The boat operator is ultimately

responsible for proper engine operation.

SERVICE MANUAL NUMBER 36 GENERAL INFORMATION

90-864573 FEBRUARY 2002 Page 1A-25

Warning Chart

The engine warning system incorporates an audio alarm and, if installed, Smartcraft

Gauges System. When the key switch is turned to the ON position, the audio alarm will

momentarily activate to test thewarning system. The alarm should sound once if the system

is operable. This table is a guick guide, showingwhat warning output will accompany a fault.

Fault Smartcraft Gauges Audio Alarm Available Power Description

ECT CKT HI Yes 2 Bp/min 90% Open

ECT CKT LO Yes 2 Bp/min 90% Short

ECT Coolant Overheat Yes Constant 6 - 100 % Overheat condition

EST 1 Open 1 Yes 2 Bp/min 100% Coil harness wire open

EST 1 Short 1 Yes 2 Bp/min 100% Coil harness wire short

Fuel Injector 1-7-4-6 Open Yes 2 Bp/min 100% Fuel injector wire open

Fuel Injector 3-5-2-8 Open Yes 2 Bp/min 100% Fuel injector wire open

Guardian Strategy Yes Constant 0% - 100% Protection Strategy

IAC Output LO/HI 2 Yes 2 Bp/min 90% Open

Knock Sensor 1 Lo Yes 2 Bp/min 90% Open

Knock Sensor 1 Hi Yes 2 Bp/min 90% Short

Low Drive Lube Strategy Yes Constant 100% Low oil in sterndrive

Low Oil Pressure Strategy Yes Constant 0 - 100% Low oil pressure strategy

NOTE: If any 5v sensor becomes shorted to ground the engine will not start. If the engine is operating when the short occurs the engine may stop operating and will not start.

NOTE: 1 GM EFI ignition system failure open or shorted, driver will flag EST 1 fault.

NOTE: 2 TPS must see 5% throttle then back to 0% to flag IAC fault.

NOTE: 3 2-wire sensor open will read sensor Hi on scan tool.

NOTE: 4VDC PWR Low - if shorted or no voltage engine will not start; if VDC PWR voltage falls velow 22 volts will set sensor faults.

NOTE: 5 Shift Switch - will activate code when engine rpm are above 3500 rpm and 40%

load.

GENERAL INFORMATION SERVICE MANUAL NUMBER 36

Page 1A-26 90-864573 FEBRUARY 2002

Warning Chart (continued)

Fault Smartcraft Gauges Audio Alarm Available Power Description

Main Power Relay Output Yes No N/A Engine will not start

Main Power Relay Backfeed Yes No N/A Engine will not start

MAP Sensor 1 Input High Yes 2 Bp/min 90% High voltage or short

MAP Sensor 1 Input Low Yes 2 Bp/min 90% Open, no visual on

SC1000 Oil PSI CKT Hi Yes 2 Bp/min 90% Open, defaults to 50.7 psi

Oil PSI CKT Lo Yes 2 Bp/min 90% Short, defaults to 50.7 psi

Overspeed Yes Constant rpm limit Engine over rpm limit

Pitot CKT Hi No 100% Short or high voltage

Pitot CKT Lo No 100% Open

Sea Pump PSI Lo Yes Constant 6-100%

GuardStrat Sea Pump CKT Hi Yes 2 Bp/min 90% Open - 0 psi reading

Sea Pump CKT Lo Yes 2 Bp/min 90% Voltage high or short

Sea Water Temp No N/A Defaults to --31 degreesC

Fuel Level #1 No N/A Only if turned on

STB EMCT CKT Hi N/A N/A N/A N/A

STB EMCT CKT Lo N/A N/A N/A N/A

STB EMCT CKT Overheat N/A N/A N/A N/A

NOTE: If any 5v sensor becomes shorted to ground the engine will not start. If the engine

is operating when the short occurs the engine may stop operating and will not start.

NOTE: 1 GM EFI ignition system failure open or shorted, driver will flag EST 1 fault.

NOTE: 2 TPS must see 5% throttle then back to 0% to flag IAC fault.

NOTE: 3 2-wire sensor open will read sensor Hi on scan tool.

NOTE: 4VDC PWR Low - if shorted or no voltage engine will not start; if VDC PWR voltage

falls velow 22 volts will set sensor faults.

NOTE: 5 Shift Switch - will activate code when engine rpm are above 3500 rpm and 40%

load.

SERVICE MANUAL NUMBER 36 GENERAL INFORMATION

90-864573 FEBRUARY 2002 Page 1A-27

Warning Chart (continued)

Fault Smartcraft Gauges Audio Alarm Available Power Description

Steer CKT Hi No 100% Short or high voltage

Steer CKT Lo No 100% Open

TPS1 CKT or Range Hi Yes 2 Bp/min 90% Short or high voltage

TPS1 CKT or Range Lo Yes 2 Bp/min 90% Open or low voltage

Trim CKT or Range Hi Yes No 100% Open or high voltage

Trim CKT or Range Lo Yes No 100% Short

5 VDC PWR Low 4 Yes 2 Bp/min 90% Short or low -

engine may not start

MAT Sensor Hi Yes 2 Bp/min 90% Open -default to --32

degrees F

MAT Sensor Lo Yes 2 Bp/min 90% Short -default to --32

degrees F

Shift Switch 5 Yes 2 Bp/min 90% Open Circuit

NOTE: If any 5v sensor becomes shorted to ground the engine will not start. If the engine is operating when the short occurs the engine may stop operating and will not start.

NOTE: 1 GM EFI ignition system failure open or shorted, driver will flag EST 1 fault.

NOTE: 2 TPS must see 5% throttle then back to 0% to flag IAC fault.

NOTE: 3 2-wire sensor open will read sensor Hi on scan tool.

NOTE: 4VDC PWR Low - if shorted or no voltage engine will not start; if VDC PWR voltage

falls velow 22 volts will set sensor faults.

NOTE: 5 Shift Switch - will activate code when engine rpm are above 3500 rpm and 40%

load.

GENERAL INFORMATION SERVICE MANUAL NUMBER 36

Page 1A-28 90-864573 FEBRUARY 2002

General Reference Charts

Manifold Vacuum / Pressure

Manifold

Vacuum Absolute Pressure

Manifold

Vacuum Absolute Pressure

psi psi kPa psi psi kPa

0 14.7 101.3 7 1/4 7.45 51.4

1/4 14.45 99.6 7 1/2 7.2 49.6

1/2 14.2 97.9 7 3/4 6.95 47.9

3/4 13.95 96.2 8 6.7 46.2

1 13.7 94.4 8 1/4 6.45 44.5

1 1/4 13.45 92.7 8 1/2 6.2 42.7

1 1/2 13.2 91.0 8 3/4 5.95 41.0

1 3/4 12.95 89.3 9 5.7 39.3

2 12.7 87.5 9 1/4 5.45 37.6

2 1/4 12.45 85.8 9 1/2 5.2 35.8

2 1/2 12.2 84.1 9 3/4 4.95 34.1

2 3/4 11.95 82.4 10 4.7 32.4

3 11.7 80.6 10 1/4 4.45 30.7

3 1/4 11.45 78.9 10 1/2 4.2 29.0

3 1/2 11.2 77.2 10 3/4 3.95 27.2

3 3/4 10.95 75.5 11 3.7 25.5

4 10.7 73.8 11 1/4 3.45 23.8

4 1/4 10.45 72.0 11 1/2 3.2 22.1

4 1/2 10.2 70.3 11 3/4 2.95 20.3

4 3/4 9.95 68.6 12 2.7 18.6

5 9.7 66.9 12 1/4 2.45 16.9

5 1/4 9.45 65.1 12 1/2 2.2 15.2

5 1/2 9.2 63.4 12 3/4 1.95 13.4

5 3/4 8.95 61.7 13 1.7 11.7

6 8.7 60.0 13 1/4 1.45 10.0

6 1/4 8.45 58.2 13 1/2 1.2 8.3

6 1/2 8.2 56.5 13 3/4 0.95 6.5

6 3/4 7.95 54.8 14 0.7 4.8

7 7.7 53.1 14 1/4 0.45 3.1

14 1/2 0.2 1.4

SERVICE MANUAL NUMBER 36 GENERAL INFORMATION

90-864573 FEBRUARY 2002 Page 1A-29

Vacuum Gauge vs MAP Sensor

This graph is correct at sea level only.

GENERAL INFORMATION SERVICE MANUAL NUMBER 36

Page 1A-30 90-864573 FEBRUARY 2002

Centigrade to Fahrenheit Conversion

Centigrade Fahrenheit Centigrade Fahrenheit

--55 --67 85 185

--50 --58 90 194

--45 --49 95 203

--40 --40 100 212

--35 --31 105 221

--30 --22 110 230

--25 --13 115 239

--20 --4 120 248

--15 5 125 257

--10 14 130 266

--5 23 135 275

0 32 140 284

5 41 145 293

10 50 150 302

15 59 155 311

20 68 160 320

25 77 165 329

30 86 170 338

35 95 175 347

40 104 180 356

45 113 185 365

50 122 190 374

55 131 195 383

60 140 200 392

65 149 205 401

70 158 210 410

75 167 215 419

80 176 220 428

Link to post
Share on other sites

I can't find any Merc critical (constant) alarm that is programmed to continue annunciation after switched power has been removed. I’ve attached conditions that can generate the initial condition, but there must be an issue with the ECM’s alarm triac or a corrupt program that prevents the alarm condition from dropping out when pilot power is removed. The ECM does have base voltage applied even if the battery switch is in the off position, in order to maintain memory, as does your marine stereo system. I would disconnect the battery cables directly from the batteries over night to force a cold re-boot. This may get the ECM back to base program and working properly, allowing you to begin the process of finding what condition is generating the alarm in the first place.

I had a float failure on the drive oil bottle where the float actually sunk, and set an alarm when the bottle was full. As your Tech has not found an active alarm on the ECM histogram, you may have to catch your fault condition in the act as it sounds like one of those PITA intermittent deals. Alarm conditions per attachment below. I have also included some previous words of wisdomn from our "Boat Wisperer" north of the boarder.

W

1. IAC - idle air control valve. Your model should be the same as an '02 Ford Windstar. Will need gasket # 27-863112 for this job. Items # 15 & 16 in the link below.

http://www.marinepar.../884717/8093-85

2. Water pressure sensor - found on the power steering cooler. Job is to monitor the water pressure generated by the impeller. When the sensor fails, the ECM wonders if the impeller hasn't completely failed, but notices the engine isn't getting hot. Located by the distributor - will probably have a white body. Item # 17 in the link below.

http://www.marinepar...884717/8093-280

3. Faulty gear oil reservoir, or low gear oil level. If the reservoir is full, a test can be done where a new reservoir is attached to the wires, and the new empty reservoir turned upside down. If the beeping stops, the original reservoir is faulty. Items # 3 or 11 in the link below.

http://www.marinepar.../884717/8093-30

4. Loose wires - usually on the starter motor. EFI communicates by voltage, and if there are loose wires, the ECM can't talk properly to it's sensors for information. Also check the wires on the alternator.

5. Wrong grade/weight of engine oil. i.e. 10w30 instead of 25w40, etc. If 10w30 oil is used, once the engine is warmed up and under heavy load, one should be able to see the oil pressure fluctuating wildly above 3500 RPM which is causing the ECM to trigger the alarm.

Engine Guardian System

General Description

Engine Guardian is the focal point of the self-diagnostic strategy on these engines. It helps

protect the engine from possible damage that could result from several faulty conditions.

The system monitors the sensors incorporated on the engine and if a malfunction is

discovered, a fault description is stored in thePCMand available power is normally reduced.

By ensuring that engine output is at a low enough level, the engine is better protected from

thermally induced failures.

For example, if an open or short is found in any sensor, available power will be reduced to

90% of total, the AudioWarning System Alarmwill sound 2 beeps perminute (2 Bp/min) and

the Smartcraft gauges will display a warning lamp. In a seawater pump pressure low

condition, the maximum rpm will vary with the pressure and temperature of the engine and

could be limited to idle in extreme cases of overheating, a constant beep will sound and

Smartcraft gauges will display a warning lamp.

IMPORTANT: Engine Guardian cannot guarantee that engine damage will not occur

when adverse operating conditions are encountered. Engine Guardian is designed

to warn the operator of an adverse condition and to reduce power by limiting rpm in

an attempt to reduce possible engine damage. The boat operator is ultimately

responsible for proper engine operation.

SERVICE MANUAL NUMBER 36 GENERAL INFORMATION

90-864573 FEBRUARY 2002 Page 1A-25

Warning Chart

The engine warning system incorporates an audio alarm and, if installed, Smartcraft

Gauges System. When the key switch is turned to the ON position, the audio alarm will

momentarily activate to test thewarning system. The alarm should sound once if the system

is operable. This table is a guick guide, showingwhat warning output will accompany a fault.

Fault Smartcraft Gauges Audio Alarm Available Power Description

ECT CKT HI Yes 2 Bp/min 90% Open

ECT CKT LO Yes 2 Bp/min 90% Short

ECT Coolant Overheat Yes Constant 6 - 100 % Overheat condition

EST 1 Open 1 Yes 2 Bp/min 100% Coil harness wire open

EST 1 Short 1 Yes 2 Bp/min 100% Coil harness wire short

Fuel Injector 1-7-4-6 Open Yes 2 Bp/min 100% Fuel injector wire open

Fuel Injector 3-5-2-8 Open Yes 2 Bp/min 100% Fuel injector wire open

Guardian Strategy Yes Constant 0% - 100% Protection Strategy

IAC Output LO/HI 2 Yes 2 Bp/min 90% Open

Knock Sensor 1 Lo Yes 2 Bp/min 90% Open

Knock Sensor 1 Hi Yes 2 Bp/min 90% Short

Low Drive Lube Strategy Yes Constant 100% Low oil in sterndrive

Low Oil Pressure Strategy Yes Constant 0 - 100% Low oil pressure strategy

NOTE: If any 5v sensor becomes shorted to ground the engine will not start. If the engine is operating when the short occurs the engine may stop operating and will not start.

NOTE: 1 GM EFI ignition system failure open or shorted, driver will flag EST 1 fault.

NOTE: 2 TPS must see 5% throttle then back to 0% to flag IAC fault.

NOTE: 3 2-wire sensor open will read sensor Hi on scan tool.

NOTE: 4VDC PWR Low - if shorted or no voltage engine will not start; if VDC PWR voltage falls velow 22 volts will set sensor faults.

NOTE: 5 Shift Switch - will activate code when engine rpm are above 3500 rpm and 40%

load.

GENERAL INFORMATION SERVICE MANUAL NUMBER 36

Page 1A-26 90-864573 FEBRUARY 2002

Warning Chart (continued)

Fault Smartcraft Gauges Audio Alarm Available Power Description

Main Power Relay Output Yes No N/A Engine will not start

Main Power Relay Backfeed Yes No N/A Engine will not start

MAP Sensor 1 Input High Yes 2 Bp/min 90% High voltage or short

MAP Sensor 1 Input Low Yes 2 Bp/min 90% Open, no visual on

SC1000 Oil PSI CKT Hi Yes 2 Bp/min 90% Open, defaults to 50.7 psi

Oil PSI CKT Lo Yes 2 Bp/min 90% Short, defaults to 50.7 psi

Overspeed Yes Constant rpm limit Engine over rpm limit

Pitot CKT Hi No 100% Short or high voltage

Pitot CKT Lo No 100% Open

Sea Pump PSI Lo Yes Constant 6-100%

GuardStrat Sea Pump CKT Hi Yes 2 Bp/min 90% Open - 0 psi reading

Sea Pump CKT Lo Yes 2 Bp/min 90% Voltage high or short

Sea Water Temp No N/A Defaults to --31 degreesC

Fuel Level #1 No N/A Only if turned on

STB EMCT CKT Hi N/A N/A N/A N/A

STB EMCT CKT Lo N/A N/A N/A N/A

STB EMCT CKT Overheat N/A N/A N/A N/A

NOTE: If any 5v sensor becomes shorted to ground the engine will not start. If the engine

is operating when the short occurs the engine may stop operating and will not start.

NOTE: 1 GM EFI ignition system failure open or shorted, driver will flag EST 1 fault.

NOTE: 2 TPS must see 5% throttle then back to 0% to flag IAC fault.

NOTE: 3 2-wire sensor open will read sensor Hi on scan tool.

NOTE: 4VDC PWR Low - if shorted or no voltage engine will not start; if VDC PWR voltage

falls velow 22 volts will set sensor faults.

NOTE: 5 Shift Switch - will activate code when engine rpm are above 3500 rpm and 40%

load.

SERVICE MANUAL NUMBER 36 GENERAL INFORMATION

90-864573 FEBRUARY 2002 Page 1A-27

Warning Chart (continued)

Fault Smartcraft Gauges Audio Alarm Available Power Description

Steer CKT Hi No 100% Short or high voltage

Steer CKT Lo No 100% Open

TPS1 CKT or Range Hi Yes 2 Bp/min 90% Short or high voltage

TPS1 CKT or Range Lo Yes 2 Bp/min 90% Open or low voltage

Trim CKT or Range Hi Yes No 100% Open or high voltage

Trim CKT or Range Lo Yes No 100% Short

5 VDC PWR Low 4 Yes 2 Bp/min 90% Short or low -

engine may not start

MAT Sensor Hi Yes 2 Bp/min 90% Open -default to --32

degrees F

MAT Sensor Lo Yes 2 Bp/min 90% Short -default to --32

degrees F

Shift Switch 5 Yes 2 Bp/min 90% Open Circuit

NOTE: If any 5v sensor becomes shorted to ground the engine will not start. If the engine is operating when the short occurs the engine may stop operating and will not start.

NOTE: 1 GM EFI ignition system failure open or shorted, driver will flag EST 1 fault.

NOTE: 2 TPS must see 5% throttle then back to 0% to flag IAC fault.

NOTE: 3 2-wire sensor open will read sensor Hi on scan tool.

NOTE: 4VDC PWR Low - if shorted or no voltage engine will not start; if VDC PWR voltage

falls velow 22 volts will set sensor faults.

NOTE: 5 Shift Switch - will activate code when engine rpm are above 3500 rpm and 40%

load.

GENERAL INFORMATION SERVICE MANUAL NUMBER 36

Page 1A-28 90-864573 FEBRUARY 2002

General Reference Charts

Manifold Vacuum / Pressure

Manifold

Vacuum Absolute Pressure

Manifold

Vacuum Absolute Pressure

psi psi kPa psi psi kPa

0 14.7 101.3 7 1/4 7.45 51.4

1/4 14.45 99.6 7 1/2 7.2 49.6

1/2 14.2 97.9 7 3/4 6.95 47.9

3/4 13.95 96.2 8 6.7 46.2

1 13.7 94.4 8 1/4 6.45 44.5

1 1/4 13.45 92.7 8 1/2 6.2 42.7

1 1/2 13.2 91.0 8 3/4 5.95 41.0

1 3/4 12.95 89.3 9 5.7 39.3

2 12.7 87.5 9 1/4 5.45 37.6

2 1/4 12.45 85.8 9 1/2 5.2 35.8

2 1/2 12.2 84.1 9 3/4 4.95 34.1

2 3/4 11.95 82.4 10 4.7 32.4

3 11.7 80.6 10 1/4 4.45 30.7

3 1/4 11.45 78.9 10 1/2 4.2 29.0

3 1/2 11.2 77.2 10 3/4 3.95 27.2

3 3/4 10.95 75.5 11 3.7 25.5

4 10.7 73.8 11 1/4 3.45 23.8

4 1/4 10.45 72.0 11 1/2 3.2 22.1

4 1/2 10.2 70.3 11 3/4 2.95 20.3

4 3/4 9.95 68.6 12 2.7 18.6

5 9.7 66.9 12 1/4 2.45 16.9

5 1/4 9.45 65.1 12 1/2 2.2 15.2

5 1/2 9.2 63.4 12 3/4 1.95 13.4

5 3/4 8.95 61.7 13 1.7 11.7

6 8.7 60.0 13 1/4 1.45 10.0

6 1/4 8.45 58.2 13 1/2 1.2 8.3

6 1/2 8.2 56.5 13 3/4 0.95 6.5

6 3/4 7.95 54.8 14 0.7 4.8

7 7.7 53.1 14 1/4 0.45 3.1

14 1/2 0.2 1.4

SERVICE MANUAL NUMBER 36 GENERAL INFORMATION

90-864573 FEBRUARY 2002 Page 1A-29

Vacuum Gauge vs MAP Sensor

This graph is correct at sea level only.

GENERAL INFORMATION SERVICE MANUAL NUMBER 36

Page 1A-30 90-864573 FEBRUARY 2002

Centigrade to Fahrenheit Conversion

Centigrade Fahrenheit Centigrade Fahrenheit

--55 --67 85 185

--50 --58 90 194

--45 --49 95 203

--40 --40 100 212

--35 --31 105 221

--30 --22 110 230

--25 --13 115 239

--20 --4 120 248

--15 5 125 257

--10 14 130 266

--5 23 135 275

0 32 140 284

5 41 145 293

10 50 150 302

15 59 155 311

20 68 160 320

25 77 165 329

30 86 170 338

35 95 175 347

40 104 180 356

45 113 185 365

50 122 190 374

55 131 195 383

60 140 200 392

65 149 205 401

70 158 210 410

75 167 215 419

80 176 220 428

Link to post
Share on other sites

I can't find any Merc critical (constant) alarm that is programmed to continue annunciation after switched power has been removed. I’ve attached conditions that can generate the initial condition, but there must be an issue with the ECM’s alarm triac or a corrupt program that prevents the alarm condition from dropping out when pilot power is removed. The ECM does have base voltage applied even if the battery switch is in the off position, in order to maintain memory, as does your marine stereo system. I would disconnect the battery cables directly from the batteries over night to force a cold re-boot. This may get the ECM back to base program and working properly, allowing you to begin the process of finding what condition is generating the alarm in the first place.

I had a float failure on the drive oil bottle where the float actually sunk, and set an alarm when the bottle was full. As your Tech has not found an active alarm on the ECM histogram, you may have to catch your fault condition in the act as it sounds like one of those PITA intermittent deals. Alarm conditions per attachment below. I have also included some previous words of wisdom from our "Boat Whisperer" north of the boarder.

W

1. IAC - idle air control valve. Your model should be the same as an '02 Ford Windstar. Will need gasket # 27-863112 for this job. Items # 15 & 16 in the link below.

http://www.marinepar.../884717/8093-85

2. Water pressure sensor - found on the power steering cooler. Job is to monitor the water pressure generated by the impeller. When the sensor fails, the ECM wonders if the impeller hasn't completely failed, but notices the engine isn't getting hot. Located by the distributor - will probably have a white body. Item # 17 in the link below.

http://www.marinepar...884717/8093-280

3. Faulty gear oil reservoir, or low gear oil level. If the reservoir is full, a test can be done where a new reservoir is attached to the wires, and the new empty reservoir turned upside down. If the beeping stops, the original reservoir is faulty. Items # 3 or 11 in the link below.

http://www.marinepar.../884717/8093-30

4. Loose wires - usually on the starter motor. EFI communicates by voltage, and if there are loose wires, the ECM can't talk properly to it's sensors for information. Also check the wires on the alternator.

5. Wrong grade/weight of engine oil. i.e. 10w30 instead of 25w40, etc. If 10w30 oil is used, once the engine is warmed up and under heavy load, one should be able to see the oil pressure fluctuating wildly above 3500 RPM which is causing the ECM to trigger the alarm.

Engine Guardian System

General Description

Engine Guardian is the focal point of the self-diagnostic strategy on these engines. It helps

protect the engine from possible damage that could result from several faulty conditions.

The system monitors the sensors incorporated on the engine and if a malfunction is

discovered, a fault description is stored in thePCMand available power is normally reduced.

By ensuring that engine output is at a low enough level, the engine is better protected from

thermally induced failures.

For example, if an open or short is found in any sensor, available power will be reduced to

90% of total, the AudioWarning System Alarmwill sound 2 beeps perminute (2 Bp/min) and

the Smartcraft gauges will display a warning lamp. In a seawater pump pressure low

condition, the maximum rpm will vary with the pressure and temperature of the engine and

could be limited to idle in extreme cases of overheating, a constant beep will sound and

Smartcraft gauges will display a warning lamp.

IMPORTANT: Engine Guardian cannot guarantee that engine damage will not occur

when adverse operating conditions are encountered. Engine Guardian is designed

to warn the operator of an adverse condition and to reduce power by limiting rpm in

an attempt to reduce possible engine damage. The boat operator is ultimately

responsible for proper engine operation.

SERVICE MANUAL NUMBER 36 GENERAL INFORMATION

90-864573 FEBRUARY 2002 Page 1A-25

Warning Chart

The engine warning system incorporates an audio alarm and, if installed, Smartcraft

Gauges System. When the key switch is turned to the ON position, the audio alarm will

momentarily activate to test thewarning system. The alarm should sound once if the system

is operable. This table is a guick guide, showingwhat warning output will accompany a fault.

Fault Smartcraft Gauges Audio Alarm Available Power Description

ECT CKT HI Yes 2 Bp/min 90% Open

ECT CKT LO Yes 2 Bp/min 90% Short

ECT Coolant Overheat Yes Constant 6 - 100 % Overheat condition

EST 1 Open 1 Yes 2 Bp/min 100% Coil harness wire open

EST 1 Short 1 Yes 2 Bp/min 100% Coil harness wire short

Fuel Injector 1-7-4-6 Open Yes 2 Bp/min 100% Fuel injector wire open

Fuel Injector 3-5-2-8 Open Yes 2 Bp/min 100% Fuel injector wire open

Guardian Strategy Yes Constant 0% - 100% Protection Strategy

IAC Output LO/HI 2 Yes 2 Bp/min 90% Open

Knock Sensor 1 Lo Yes 2 Bp/min 90% Open

Knock Sensor 1 Hi Yes 2 Bp/min 90% Short

Low Drive Lube Strategy Yes Constant 100% Low oil in sterndrive

Low Oil Pressure Strategy Yes Constant 0 - 100% Low oil pressure strategy

NOTE: If any 5v sensor becomes shorted to ground the engine will not start. If the engine is operating when the short occurs the engine may stop operating and will not start.

NOTE: 1 GM EFI ignition system failure open or shorted, driver will flag EST 1 fault.

NOTE: 2 TPS must see 5% throttle then back to 0% to flag IAC fault.

NOTE: 3 2-wire sensor open will read sensor Hi on scan tool.

NOTE: 4VDC PWR Low - if shorted or no voltage engine will not start; if VDC PWR voltage falls velow 22 volts will set sensor faults.

NOTE: 5 Shift Switch - will activate code when engine rpm are above 3500 rpm and 40%

load.

GENERAL INFORMATION SERVICE MANUAL NUMBER 36

Page 1A-26 90-864573 FEBRUARY 2002

Warning Chart (continued)

Fault Smartcraft Gauges Audio Alarm Available Power Description

Main Power Relay Output Yes No N/A Engine will not start

Main Power Relay Backfeed Yes No N/A Engine will not start

MAP Sensor 1 Input High Yes 2 Bp/min 90% High voltage or short

MAP Sensor 1 Input Low Yes 2 Bp/min 90% Open, no visual on

SC1000 Oil PSI CKT Hi Yes 2 Bp/min 90% Open, defaults to 50.7 psi

Oil PSI CKT Lo Yes 2 Bp/min 90% Short, defaults to 50.7 psi

Overspeed Yes Constant rpm limit Engine over rpm limit

Pitot CKT Hi No 100% Short or high voltage

Pitot CKT Lo No 100% Open

Sea Pump PSI Lo Yes Constant 6-100%

GuardStrat Sea Pump CKT Hi Yes 2 Bp/min 90% Open - 0 psi reading

Sea Pump CKT Lo Yes 2 Bp/min 90% Voltage high or short

Sea Water Temp No N/A Defaults to --31 degreesC

Fuel Level #1 No N/A Only if turned on

STB EMCT CKT Hi N/A N/A N/A N/A

STB EMCT CKT Lo N/A N/A N/A N/A

STB EMCT CKT Overheat N/A N/A N/A N/A

NOTE: If any 5v sensor becomes shorted to ground the engine will not start. If the engine

is operating when the short occurs the engine may stop operating and will not start.

NOTE: 1 GM EFI ignition system failure open or shorted, driver will flag EST 1 fault.

NOTE: 2 TPS must see 5% throttle then back to 0% to flag IAC fault.

NOTE: 3 2-wire sensor open will read sensor Hi on scan tool.

NOTE: 4VDC PWR Low - if shorted or no voltage engine will not start; if VDC PWR voltage

falls velow 22 volts will set sensor faults.

NOTE: 5 Shift Switch - will activate code when engine rpm are above 3500 rpm and 40%

load.

SERVICE MANUAL NUMBER 36 GENERAL INFORMATION

90-864573 FEBRUARY 2002 Page 1A-27

Warning Chart (continued)

Fault Smartcraft Gauges Audio Alarm Available Power Description

Steer CKT Hi No 100% Short or high voltage

Steer CKT Lo No 100% Open

TPS1 CKT or Range Hi Yes 2 Bp/min 90% Short or high voltage

TPS1 CKT or Range Lo Yes 2 Bp/min 90% Open or low voltage

Trim CKT or Range Hi Yes No 100% Open or high voltage

Trim CKT or Range Lo Yes No 100% Short

5 VDC PWR Low 4 Yes 2 Bp/min 90% Short or low -

engine may not start

MAT Sensor Hi Yes 2 Bp/min 90% Open -default to --32

degrees F

MAT Sensor Lo Yes 2 Bp/min 90% Short -default to --32

degrees F

Shift Switch 5 Yes 2 Bp/min 90% Open Circuit

NOTE: If any 5v sensor becomes shorted to ground the engine will not start. If the engine is operating when the short occurs the engine may stop operating and will not start.

NOTE: 1 GM EFI ignition system failure open or shorted, driver will flag EST 1 fault.

NOTE: 2 TPS must see 5% throttle then back to 0% to flag IAC fault.

NOTE: 3 2-wire sensor open will read sensor Hi on scan tool.

NOTE: 4VDC PWR Low - if shorted or no voltage engine will not start; if VDC PWR voltage

falls velow 22 volts will set sensor faults.

NOTE: 5 Shift Switch - will activate code when engine rpm are above 3500 rpm and 40%

load.

GENERAL INFORMATION SERVICE MANUAL NUMBER 36

Page 1A-28 90-864573 FEBRUARY 2002

General Reference Charts

Manifold Vacuum / Pressure

Manifold

Vacuum Absolute Pressure

Manifold

Vacuum Absolute Pressure

psi psi kPa psi psi kPa

0 14.7 101.3 7 1/4 7.45 51.4

1/4 14.45 99.6 7 1/2 7.2 49.6

1/2 14.2 97.9 7 3/4 6.95 47.9

3/4 13.95 96.2 8 6.7 46.2

1 13.7 94.4 8 1/4 6.45 44.5

1 1/4 13.45 92.7 8 1/2 6.2 42.7

1 1/2 13.2 91.0 8 3/4 5.95 41.0

1 3/4 12.95 89.3 9 5.7 39.3

2 12.7 87.5 9 1/4 5.45 37.6

2 1/4 12.45 85.8 9 1/2 5.2 35.8

2 1/2 12.2 84.1 9 3/4 4.95 34.1

2 3/4 11.95 82.4 10 4.7 32.4

3 11.7 80.6 10 1/4 4.45 30.7

3 1/4 11.45 78.9 10 1/2 4.2 29.0

3 1/2 11.2 77.2 10 3/4 3.95 27.2

3 3/4 10.95 75.5 11 3.7 25.5

4 10.7 73.8 11 1/4 3.45 23.8

4 1/4 10.45 72.0 11 1/2 3.2 22.1

4 1/2 10.2 70.3 11 3/4 2.95 20.3

4 3/4 9.95 68.6 12 2.7 18.6

5 9.7 66.9 12 1/4 2.45 16.9

5 1/4 9.45 65.1 12 1/2 2.2 15.2

5 1/2 9.2 63.4 12 3/4 1.95 13.4

5 3/4 8.95 61.7 13 1.7 11.7

6 8.7 60.0 13 1/4 1.45 10.0

6 1/4 8.45 58.2 13 1/2 1.2 8.3

6 1/2 8.2 56.5 13 3/4 0.95 6.5

6 3/4 7.95 54.8 14 0.7 4.8

7 7.7 53.1 14 1/4 0.45 3.1

14 1/2 0.2 1.4

SERVICE MANUAL NUMBER 36 GENERAL INFORMATION

90-864573 FEBRUARY 2002 Page 1A-29

Vacuum Gauge vs MAP Sensor

This graph is correct at sea level only.

GENERAL INFORMATION SERVICE MANUAL NUMBER 36

Page 1A-30 90-864573 FEBRUARY 2002

Centigrade to Fahrenheit Conversion

Centigrade Fahrenheit Centigrade Fahrenheit

--55 --67 85 185

--50 --58 90 194

--45 --49 95 203

--40 --40 100 212

--35 --31 105 221

--30 --22 110 230

--25 --13 115 239

--20 --4 120 248

--15 5 125 257

--10 14 130 266

--5 23 135 275

0 32 140 284

5 41 145 293

10 50 150 302

15 59 155 311

20 68 160 320

25 77 165 329

30 86 170 338

35 95 175 347

40 104 180 356

45 113 185 365

50 122 190 374

55 131 195 383

60 140 200 392

65 149 205 401

70 158 210 410

75 167 215 419

80 176 2

Link to post
Share on other sites

I take it the alarm keeps going after both key switches are turned to the 'off' position, and the audio alarm is a rather piercing constant 'beeeeeeeep' or chirping 'beep' pause for a few seconds than a 'beep', repeat? If so, as Wingnut stated, the ECM shouldn't do that, even on a DTS set-up.

I'm thinking the fuel fume detector, or perhaps the house battery is low, and being the culprit.

Check on your dash for a Xintex Fireboy display, and when the alarm sounds, push the mute button. If this shuts the alarm up, then the sensor in the bilge may faulty, or perhaps a manifold to head exhaust gasket is starting to leak exhaust fumes.

If the mute button on the Xintrex display does not shut the alarm up, then check the high water alarm if your boat is equipped. (float switch mounted up by the stringers for the engines to warn of high water - Chaparral started putting them in cuddy cabin and cruiser models the last few years)

Lastly, check the condition of the house battery. I think if the house battery level is low, the battery charger may not want to charge it up properly, and the alarm may come on stating the house battery from where it draws its power is low. If this is the case, putting a trickle charger on the house battery or replacing the house battery may cure the alarm issue.

FBY-M1.jpg

Link to post
Share on other sites

+1 to Shepherd's reply on battery...

I had a similar experience with the alarm.

Turns out the battery was toast and caused the problem.

It was very tricky since it had enough power to crank and start the engine, but the alarm came on after 10-12 seconds and stayed on until I shut down.

Replacing the battery cleared up the problem.

:oregonian_winesmiley:

Link to post
Share on other sites

Join the conversation

You can post now and register later. If you have an account, sign in now to post with your account.

Guest
Reply to this topic...

×   Pasted as rich text.   Paste as plain text instead

  Only 75 emoji are allowed.

×   Your link has been automatically embedded.   Display as a link instead

×   Your previous content has been restored.   Clear editor

×   You cannot paste images directly. Upload or insert images from URL.

Loading...
×
×
  • Create New...