Ignition won't work on PCM ZR6

[Hexa73]

Hi

I have a problem, probably electronic, since a few weeks on my 2008 SANTE 230 equipped with a PCM ZR6 390 (1000 hrs)... After a long period at rest (1 month), I go to take the boat out and the engine doesn't start anymore, as if there wasn't gas or ignition. So I checked the fuel pump, the fuses, the pump and ignition relays and it was not coming from there, so that leaves the ignition and the sensors connected to the ECM.

The starter turns the engine as it should but the engine doens't firing. The MIL flashes slowly.

On the last trip with the boat there was no problem though, it ran for about 2 hours.

A mechanic equipped with a code reader came to make the diagnosis. The code indicates defect camshaft sensor / crankshaft sensor. It seems quite logical since the ignition is in security because no or bad signal from the CAM and/or CRANK sensors.

So I changed the crank sensor, without success, then the cam sensor, without success too. The connectors are good, no rust, wires ok.

From my point of view, I still have to check the harness but I have doubts that the problem comes from that. The harness goes under the exchanger on this version of the PCM ZR6 and is not very exposed.

Do you have any other leads? I am in France and there are not many people who know about this kind of boat

Thanks for your help!

[Schwiiing]

Is your Kill switch plastic tab seated correctly?

[Hexa73]

Is your Kill switch plastic tab seated correctly?

Yes it was the first thing I checked (to also check the noise of fuel pumps)

[Hexa73]

I didn't reset the codes after changing the 2 sensors (cam and crank), is this necessary ? the mechanic told me that it wasn't necessary but ...

[scottb7]

Have you verified spark by pulling a plug and grounding against the block? If no spark then does that engine have rotor and distribtor? My 2008 210 did. If you have spark to the plugs then you know it not an ignition or kill switch issues, as I think that is what the lanyard kills.

[Hexa73]

Have you verified spark by pulling a plug and grounding against the block? If no spark then does that engine have rotor and distribtor? My 2008 210 did. If you have spark to the plugs then you know it not an ignition or kill switch issues, as I think that is what the lanyard kills.

My 230 don't have a distributor, only the 5.7L engine has one on 2008 models(to my knowledge).

I don't try to ground a spark plug against the block but I'll try anyway. I also need to check the camshaft sensor harness / connector (12v input and 5v signal) but it is hidden behind the heat exchanger and the harness is very short ... Crank sensor harness looks good.

[Hexa73]

I did a few more tests after changing the CKP and CMP sensors. I tested all the grounds (on the pins of the ECM, and on the engine), 2 battery feed wires on ECM ok, ignition switched voltage on ECM ok. I took the voltage and the continuity of the grounds of the CKP and CMP sensors directly on the female connector of the ECM and the values are ok (I crank the motor to check the variation of the voltages on the + 5V and the 5V signal which oscillates between 0V and 5V depending on the rotation of the motor). Let me think thé harness is ok. And the engine still not start No sparks and no fuel (fuel pump works)

Could ECM replacement be a solution in your opinion? I'm out of ideas ... Im in France and no one know what to do...

[scottb7]

I posted a ton of info in this post in a few attachments. I know it may be different model, but probably most of it is pretty appliciable.

I think in quite a few spots there were diagnostic flow charts.

ECM Econtrol HD GCP pinout diagram - PlanetNautique Forums

[Hexa73]

I read again the GCP 4G Diag manual. The fact that the fuel pumps run for 2-3 seconds after I stop cranking the engine tells me that the crank sensor is doing its job. The diag manual also says that a crank sensor failure will cause the engine to stop immediately and then it will not restart, this isn't my case as the engine was running fine until I put the boat in port and turned off the engine.

So I will change the cam sensor again and if it still doesn't work, I will have to change the ECM.

For your information, I have already done the diagnosis for DTC 0337 (page 219 of the doc) and I've come to the conclusion that I need to change the ECM.

Thanks for your help Scott

[endgame]

The kill switch has gotten me more times then not. Last time I had another issue and then when that was fixed I found the kill switch died. Take the 2 leads on the kill switch and short them then try to start that will confirm or deny it’s the kill switch

[Hexa73]

I've already check the kill switch.

Yesterday I change the cam sensor and no difference... But I notice something weird, during I cranked engine, the tachometer show around 1000 RPM. I already change the crank sensor few weeks ago but I never noticed that the tachometer showed such high RPMs at cranking.

Another observation, the tachometer needle is not at 0 but remains at around 250 rpm when key on engine off and no cranking. Same when all electronics are off (battery switch off).

Bad (new) crank sensor maybe ? Or reluctor wheel bent (engine have 1000 hrs) ? I checked the routing of the crank sensor harness to be sure it is not too close to the spark plug wires or the + 12v starter motor, seems ok.

[Hexa73]

Can someone tell me how much their rpm gauge tour goes up during cranking?

I am suspicious that my tachometer is showing around 1000 rpm when the manual says normal engine cranking speed is 150-200rpm ... after many more tests my boat still won't start I'll try to check for electric noise problem in the harness (bad alternator?) or something like that. A test with oscillospe would also be helpful but not easy to find someone tondo this.

[Hexa73]

Can someone tell me how much their rpm gauge tour goes up during cranking?

I am suspicious that my tachometer is showing around 1000 rpm when the manual says normal engine cranking speed is 150-200rpm ... after many more tests my boat still won't start I'll try to check for electric noise problem in the harness (bad alternator?) or something like that. A test with oscillospe would also be helpful but not easy to find someone tondo this.

Nobody ?