Installation manual

90-898305
7-8
OptiMax Service Tips
1998/99 135/150, 2.5 LITRE
1998/99 200/225, 3.0 LITRE
The following Troubleshooting/Service tips have been accumulated over the
past several months. These are not necessarily the only solution to the
problem.
Shift Slide:
3.0 LITRE
There have been reports of the shift slide P/N 853968--1 being installed
upside down, in the roller guide, this could result in hard shifting. The ribbed
side of the slide should face down.
Main Power Relay
2.5 & 3.0 LITRE
On occasions dealers have diagnosed an electrical problem, to no output from
the main power relay. The relay has been found to be good, there is battery
voltage on both the PURPLE and RED leads, going to the relay, but the ECM
is not allowing it to turn on. The YELLOW/PURPLE wire is a ground circuit in
the ECM that allows the main power relay to close. If there is a fault in the kill
circuit (BLACK/YELLOW) wire the ECM will not allow the main power relay to
turn on. See DDT main power relay load test, page 128 of DDT Reference
Manual.
Temperature Readings:
3.0 LITRE
The 3.0L power head has rubber water deflectors/dams in the water passages
between the cylinders (see cooling system section 4B). If these
deflectors/dams are not installed, the cylinder temperature will read 30 to 40
degrees higher on that bank of cylinders. Remove cylinder head and install
water deflectors P/N 824857--2.
Fuel Supply Hose Restricted:
2.5 & 3.0 LITRE
Fuel restriction problems have been seen in two locations on Optimax
product.
Where the fuel hose passes through the bottom cowl clamp, on both 2.5 and
3.0 Litre.
On the 3.0 Litre product, if excess fuel hose gets pushed into the bottom cowl,
the pulse pump inlet fuel hose may kink at the lower formed 90 degree bend.
This may not occur when the engine is first put into operation, it may occur
some time later when the fuel hose becomes soft from heat and fuel.
Notes
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