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Six Cylinder Engines 1996-2005 2.0L and 2.5 L Engines Using CDM Modules

NO SPARK ON ANY CYLINDER:

  • 1.

    Inspect the spark plug wires, boots and spark plugs. Check for chafing on the wiring and harnesses.

  • 2.

    Clean and inspect CDM ground wire connection to engine ground

  • 3.

    Disconnect the Black/Yellow stop wires from the harness and RPM Limiter. Retest. If the engine’s ignition now has spark, the stop circuit has a fault-check the key switch, harness and shift switch. If there is still no spark, disconnect the CDM’s one at a time and see if you get spark back on the other cylinders. A shorted stop circuit in one CDM will prevent ALL cylinders from sparking.

  • 4.

    Disconnect the yellow wires from the rectifier and retest. If the engine has spark, replace the rectifier.

  • 5.

    Check the cranking RPM. A cranking speed less than 250-RPM will not allow the system to fire properly.

  • 6.

    Check the stator resistance and DVA output as given below:

WIRE

Read To

OEM RESISTANCE

CDI RESISTANCE

DVA

White/Green

Green/White

500-700

500-600

180V or more

CDM Pin #

A

C

700-1300 Ohms

CDM Pin #

D

A

DIODE*

CDM Pin #

A

D

DIODE*

CDM Pin #

D

B

DIODE*

CDM Pin #

B

D

DIODE*

CDM Pin #

A

B

DIODE*

CDM Pin #

B

A

DIODE*

High Tension Lead

A

700-1300 Ohms

Note: Diode readings are to be read one way, then reverse the leads and read again. You should get a low reading in one direction and a higher reading in the other.

Reading

Black Meter Lead

7.

Check the resistance of each of the CDM’s as follows: Red Meter Lead

NO SPARK OR INTERMITTENT SPARK ON ONE OR TWO CYLINDERS:

1. 2. 3.

4.

Inspect the spark plug wires, boots and spark plugs. Check for chafing on the wiring and harnesses Clean and inspect CDM ground wire connection to engine ground. If the cylinders are only misfiring above an idle, connect an inductive RPM meter to all cylinders and try to isolate the problem cylinders. Using a set of piercing probes, check the trigger Resistance and DVA output as given below:

1100-1400

850-1050

4V or more

1100-1400

850-1050

4V or more

1100-1400

850-1050

4V or more

Wire Color

Check to Wire Color

Purple wire

Blue

White wire

Red

Brown wire

Yellow

OEM Resistance CDI Resistance DVA Reading

High Speed Miss:

  • 1.

    Connect an inductive RPM meter to all cylinders and try to isolate the problem. A high variance in RPM on one cylinder usually indicates a problem in the CDM module.

  • 2.

    Perform a high-speed shutdown and read the spark plugs. Check for water. A crack in the block can cause a miss at high speed when the water pressure gets high, but a normal shutdown will mask the problem.

  • 3.

    Remove the flywheel and check the triggering and charge coil flywheel magnets for cracks or broken magnets.

  • 4.

    Index the flywheel and check the timing on ALL cylinders. On carbureted models, the control module rev limi function starts to retard timing in sequence (2, 3, 4, 5, 6, 1) at 5800-6000 RPM. The control module will retard the timing each cylinder up to 30 degrees (starting with #2) and then stop firing that cylinder if the RPM is still above the limit. It will continue to retard, then shut down each cylinder until the engine drops below the limit.

NO SPARK OR INTERMITTENT SPARK ON #1, #2 and #3 OR #4, #5 and #6 CYLINDERS:

  • 1.

    Check the cranking RPM. A cranking speed less than 250-RPM will not allow the system to fire properly.

  • 2.

    Disconnect the CDM’s one at a time and see if you get spark back on the problem cylinders.

  • 3.

    Check the stator resistance and DVA output as given below:

WIRE White/Green White/Green White/Green Green/White Green/White

Read To Green/White Engine Gnd Engine Gnd Engine Gnd Engine Gnd

OEM 500-700 ohms Open Open Open Open

CDI 500-600 ohms Open Open Open Open

DVA 180V or more connected 180V or more connected Less than 2 V disconnected 180V or more connected Less than 2 V disconnected

59

Mercury/Force CDM Troubleshooting

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