Content .. 65 66 67 68 ..

Snowmobile Ski Doo REV SERIES (2006 year). Instruction - part 67

Section 06 ENGINE MANAGEMENT (SDI)
Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT)

A32C9NA

ECM CONNECTOR

COMPONENT

CONTACT LOCATION

Fuel injector, MAG

external

4 (Engine Connector)

and A-15

(ECM connector)

Fuel injector, MAG

internal

3 (Engine Connector)

and A-14

(ECM connector)

Fuel injector, MAG

external

4 (Engine Connector)

and A-33

(ECM connector)

Fuel injector, MAG

internal

3 (Engine Connector)

and A-30

(ECM connector)

The resistance should be around 14.5

If resistance value is correct, check wiring of cor-
responding relay. If good, try a new ECM. Refer
to ECM REPLACEMENT procedures elsewhere in
this section.

If resistance value is incorrect, repair the wiring
harness/connectors or replace the wiring harness
between ECM connector and fuel injector.

Fuel Injector Replacement

Removal

Before removing the injectors, the fuel rail has to
be removed from the engine. Refer to REMOVAL
in FUEL RAIL REPLACEMENT for the procedure.

A32C9OA

FUEL RAIL ASS’Y
1. Fuel injector
2. Injector clip
3. O-ring

Then remove the injector clip. Now the fuel injec-
tor can be easily pulled out of the fuel rail.

Installation

For the installation, reverse the removal proce-
dure. Pay attention to the following details.

Insert injectors with your hand. Do not use any
tool.

Ensure clip and injector are properly in-

stalled.

Replace O-rings with new ones.

NOTE: A thin film of engine oil should be applied
to O-rings to ease insertion in rail.

Torque rail retaining nuts to 10 N•m (89 lbf•in).

Attach injector wires with locking tie as shown in
following photo.

A32CCSA

1. Locking ties



WARNING

Perform a fuel pressure test and ensure that
there is no leak. Refer to FUEL PUMP above.
Run engine and check for leaks.

264

mmr2005-081

Section 06 ENGINE MANAGEMENT (SDI)

Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT)

ELECTRONIC MANAGEMENT

ECM REPLACEMENT

General

Prior to replacing a suspected ECM, ensure that all
the recommendations in the general introduction
of this section have been followed.

IMPORTANT: When the ECM is replaced, the
tether cord cap(s) and the Closed Throttle must
be reprogrammed/reset. Refer to their specific
section for adjustment.

To allow transferring the previous recorded infor-
mation from the old ECM to the new one, use the
vehicle communication kit (VCK) with the B.U.D.S.
software. Use Replace ECM in the ECM menu.
Follow instructions provided by the help system.

NOTE: If the old ECM can still communicate, it
must be read inside B.U.D.S. prior to removing it
from the vehicle to carry vehicle information and
history to the new ECM.

ECM Replacement

Disconnect battery cables.



WARNING

Battery BLACK (-) cable must always be dis-
connected first and connected last.

Disconnect both connectors from ECM.

A33I0HA

1. ECM
2. Retaining screws

Unscrew all retaining screws and remove the en-
gine ECM from its support.

Install the new ECM to the support.

Reconnect ECM connectors to ECM, and then bat-
tery cables.

Transfer the data from the previous ECM to the
new one using B.U.D.S. then proceed with the
required resets and reprogram tether cord cap(s),
if you were unable to transfer the data.

NOTE: If data cannot be transferred, manually en-
ter information in Vehicle tab.

After performing the required resets, ensure to
clear all faults from the newly replaced ECM.

Start the engine and increase engine speed above
6000 RPM to be sure no fault appears.

ENGINE WIRING HARNESS

A32CCQA

1. ECM
2. CTS connector
3. EGTS connector
4. Fuel injector connector (cylinder MAG side)
5. Ignition coil connector
6. Fuel injector connector (cylinder PTO side)
7. TPS connector
8. ATS connector
9. Engine connector
10. APS connector
11. KS connector
12. CPS connector

Resistance Test

Check continuity of the circuits according to the
wiring diagram in the WIRING DIAGRAMS section
of this manual.

If wiring harness is good, check the respective
sensor/actuator as described in this section.

Otherwise, repair the connectors, replace the
wiring harness or the ECM as diagnosed.

mmr2005-081

265

Section 06 ENGINE MANAGEMENT (SDI)
Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT)

Removal

Remove air intake silencer.

Disconnect the wiring harness from all sensors/
actuators.

Disconnect the connector from the ECM.

Cut all locking tie which are holding the wiring har-
ness in position.

Remove complete wiring harness.

Installation

First connect the connector A to the ECM and the
engine connector to the vehicle wiring harness.

Reconnect the wiring harness to all sensors/actu-
ators and reinstall all locking tie that have been re-
moved.

Install all remaining parts, which have been re-
moved.

THROTTLE POSITION SENSOR
(TPS)

General

The throttle position sensor (TPS) is a potentiome-
ter that sends a signal to the ECM which is propor-
tional to the throttle shaft angle.

A32C9RA

THROTTLE POSITION SENSOR (TPS)

IMPORTANT: Prior to testing the TPS, ensure
that mechanical components/adjustments are
adequate according to THROTTLE BODY in AIR
INDUCTION SYSTEM above.

The ECM may generate several fault codes per-
taining to the TPS. Refer to SYSTEM FAULT
CODES in DIAGNOSTIC PROCEDURES section
for more information.

Wear Test

While engine is not running, activate throttle and
pay attention for smooth operation without physi-
cal stops of the cable.

Using the vehicle communication kit (VCK) with
the B.U.D.S. software, use the Throttle Opening
display under Monitoring.

Slowly and regularly depress the throttle. Ob-
serve the needle movement.

It must change

gradually and regularly as you move the throttle.
If the needle “sticks”, bounces, suddenly drops
or if any discrepancy between the throttle move-
ment and the needle movement is noticed, it
indicates a worn TPS that needs to be replaced.

Voltage Test

Check the voltage output from ECM to the throttle
position sensor.

A32C9SA

TPS

Disconnect plug connector from throttle position
sensor. To unlock connector, insert a small screw-
driver between the folded tab. To see the con-
nector pin-out and its pin numbers, temporarily re-
move the connector shield joining the harness.

Install the tether cord cap, turn OFF engine cut-out
switch and push START/RER button momentarily
to activate the ECM.

Connect a voltmeter between pin 1 and 2 in the
wiring harness.

Voltage should be 5 V.

266

mmr2005-081

Section 06 ENGINE MANAGEMENT (SDI)

Subsection 03 (COMPONENT INSPECTION, REPLACEMENT AND ADJUSTMENT)

Check the continuity between pin 3 on wiring har-
ness TPS connector and pin 24 on wiring harness
ECM connector.

If tests are good, replace the TPS.

If voltage tests are not good, continue to check
the resistance of the rest of the TPS circuit.

Resistance Test

Reconnect the TPS.

Disconnect the connector A from the ECM.

R1503motr191A

Using a multimeter, check resistance value as per
the following table.

ECM CONNECTOR

THROTTLE

IDLE

POSITION

WIDE OPEN

THROTTLE

POSITION

Resistance

A-24

A-25

2500

1000

A-25

A-39

1600-2400

A–24

A-39

1000

2500

NOTE: The resistance value should change
smoothly and proportionally to the throttle move-
ment. Otherwise, replace TPS.

If resistance values are correct, try a new ECM.
Refer to ECM REPLACEMENT procedures else-
where in this section.

If resistance values are incorrect, replace TPS.

Replacement

Remove the throttle body as described above.

Loosen two screws retaining the TPS.

Remove TPS.

A32C9RB

THROTTLE BODY
1. Throttle position sensor (TPS)
2. Screws

Install the new TPS.

Apply Loctite 243 on the TPS retaining screws,
then torque to 3 N•m (27 lbf•in).

Reinstall remaining removed parts.

Proceed with the Closed Throttle Reset. See be-
low.

Closed Throttle Reset

Ensure throttle body synchronization and throttle
cable are properly adjusted prior to performing this
setting.

NOTE: This operation performs a reset of the val-
ues in the ECM.

This reset is very important. The setting of the
TPS will determine the basic parameters for all
fuel mapping and several ECM calculations in idle
speed control of the engine.

NOTE: Reset must be done each time the throttle
position sensor (TPS) is loosened or removed or
throttle body or ECM is replaced.

CAUTION: An improperly set TPS may lead to
poor engine performance.

Use the vehicle communication kit (VCK) with the
B.U.D.S. software to perform this adjustment.

Unscrew idle speed screw until the throttle body
plate stop lever rest against its zero position stop-
per screw (capped screw). If necessary, loosen
the throttle cable. Open throttle approximately
one quarter then quickly release. Repeat 2 - 3
times to settle throttle plate.

mmr2005-081

267

Content .. 65 66 67 68 ..