Content .. 48 49 50 51 ..

Snowmobile Ski Doo REV SERIES (2004 year). Manual - part 50

Section 05 2–TEC ENGINE MANAGEMENT
Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT)

A32C9MA

1. Fuel injectors

Disconnect wiring harness from the four fuel in-
jectors.

Cut tie raps and remove the wiring harness from
the fuel rail.

Unscrew rail retaining nuts.

Gently pull rail up by hand, working each side
slightly at a time.

Pull rail out with fuel injectors.

If necessary remove fuel injectors as described
below.

Installation

For installation, reverse the removal process but
pay attention to the following.

Replace O-rings with new ones.

A thin film of injection oil should be applied to
O-rings of fuel injectors to ease installation in cylin-
der.

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

Make sure that injector clips are well in place.

Add dielectric grease (P/N 293 550 004) to injector
electrical connector.

When installing fuel line connector to the fuel rail,
put some oil on the O-ring to ease installation.



WARNING

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

FUEL INJECTORS

Leakage Test

To perform a leakage test, the injectors and fuel
rail have to be removed from the engine. Refer to
REMOVAL in FUEL RAIL REPLACEMENT for the
procedure.

NOTE: Do not detach injectors from the fuel rail.

Reconnect the fuel line and the wiring harness.

Place each injector in a clean bowl.

Install the tether cord cap on the DESS post and
press the engine START/RER button to activate
the fuel pump.

Check for fuel leakage from the injector nozzle.
There should be less than 1 drop per minute. Per-
form the test for 2 minutes.

If not within specification, replace the fuel injec-
tor(s).

The leakage test is validated when performing the
FUEL DELIVERY SYSTEM DIAGNOSTIC FLOW
CHART elsewhere in this section.

Electrical Test

Tether cord cap must be on DESS post.

Using the vehicle communication kit (VCK) with
the B.U.D.S. software, energize the fuel injector
from the Activation section.

If the injector does not work, disconnect the plug
connector from the injector.

Install a temporary connector to the injector with
wires long enough to make the connection outside
the engine compartment and apply voltage (12 V)
to this test harness.

This will validate the injector mechanical and elec-
trical operation.

If it does not work, replace it.

Wake up ECM using START button and measure
voltage between pin 1 (of injector on harness side)
and battery ground.

If 12 V is read, disconnect connector A from the
ECM and check continuity of circuit as per follow-
ing table.

186

mmr2004-Rev

Section 05 2–TEC ENGINE MANAGEMENT

Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT)

CIRCUIT NUMBER

(ECM connector «DA»)

INJECTOR NUMBER

DA-15

1/1 (MAG external)

DA-33

2/1 (PTO external)

DA-14

1/2 (MAG internal)

DA-30

2/2 (PTO internal)

If it is good, check the resistance of the fuel injec-
tor circuit.

Resistance Test

Disconnect the injector from the wiring harness
and check the resistance of the injector itself.

The resistance should be around 14.5

If resistance value is incorrect, replace the injector.

Reconnect the injector and disconnect the con-
nector A from the ECM as well as the engine con-
nector.

Using a multimeter, check resistance value be-
tween terminals as shown in the table below.

A32C9IA

ENGINE CONNECTOR

A32C9NA

ECM CONNECTOR

COMPONENT

CONTACT LOCATION

Fuel injector 1 cylinder 1

4 (Engine Connector)

and A-15

(ECM connector)

Fuel injector 2 cylinder 2

3 (Engine Connector)

and A-14

(ECM connector)

Fuel injector 1 cylinder 1

4 (Engine Connector)

and A-33

(ECM connector)

Fuel injector 2 cylinder 2

3 (Engine Connector)

and A-30

(ECM connector)

The resistance should be around 14.5

If resistance value is correct, try a new ECM. Refer
to ECM REPLACEMENT procedures elsewhere in
this section.

NOTE: Check if wiring harness shows any signs
of scoring prior to replace the ECM.

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.

mmr2004-Rev

187

Section 05 2–TEC ENGINE MANAGEMENT
Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT)

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.

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

188

mmr2004-Rev

Section 05 2–TEC ENGINE MANAGEMENT

Subsection 02 (COMPONENT INSPECTION AND ADJUSTMENT)

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
5000 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

NOTE: Check if wiring harness shows any signs
of scoring.

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.

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.

mmr2004-Rev

189

Content .. 48 49 50 51 ..