Briggs & Stratton VANGUARD M490000 Mode d'emploi

M490000/M540000/M610000 Repair Manual

80021828 (Revision A)

BRIGGS&STRATTON, LLC

CUSTOMER EDUCATION

Milwaukee, WI 53201 USA

VANGUARDPOWER.COM

Vanguard® BIG BLOCK™and 810

EFI Diagnostic and Repair

M490000/M540000/M610000

REPAIR MANUAL

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Foreword

This manual was written to assist engine technicians and service personnel with the troubleshooting

and repair procedures for Briggs & Stratton® engines equipped with Electronic Fuel Injection (EFI). It

assumes that persons using this manual have been properly trained and are familiar with the service

procedures for these products, including the proper use of required tools and the application of

appropriate safety practices. Persons untrained or unfamiliar with these procedures or products should

not attempt to perform such work.

Proper repair is important to safe, reliable operation of all engines and engine-driven systems. The

troubleshooting and repair procedures described in this manual are appropriate for the Briggs & Stratton

engines described herein. Alternative methods or procedures may pose risks to both personal safety and

engine reliability and are not endorsed or recommended by Briggs & Stratton.

All information, illustrations, and specifications contained in this manual were based on the data available

at the time of publication. Briggs & Stratton, LLC reserves the right to change, alter, or otherwise improve

the product or the product manuals at any time without prior notice.

No part of this manual may be reproduced or transmitted in any form or by any means, electronic or

mechanical, including photocopying or recording by any information storage and retrieval system, without

prior written permission from Briggs & Stratton, LLC.

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This engine troubleshooting and repair manual includes the following EFI equipped engine models:

• MODEL 490000

• MODEL 540000

• MODEL 610000

NOTE: Some models have limited service parts. Review theIllustrated

Parts Listfor part availability before conducting any service work.

NOTE: The images in this document are representative and may differ according to model.

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SECTION 1 - DIAGNOSTIC INTRODUCTION 1

SECTION 2 - TROUBLESHOOTING DTCs 2

SECTION 3 - WIRE SCHEMATICS AND PIN-OUTS 3

SECTION 4 - SYMPTOMS 4

SECTION 5 - REMOVAL/INSTALLATION 5

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SECTION 1 - DIAGNOSTIC INTRODUCTION

DIAGNOSTIC INTRODUCTION ----------------------------------------------------------------------------------------------------------------- 4

On-Board Diagnostic (OBD) System Check -------------------------------------------------------------------------------------------- 4

Diagnostic Trouble Codes (DTCs) --------------------------------------------------------------------------------------------------------- 4

Malfunction Indicator Lamp (MIL) ---------------------------------------------------------------------------------------------------------- 4

Data Link Connector (DLC) ------------------------------------------------------------------------------------------------------------------4

Non-Scan Diagnostics -------------------------------------------------------------------------------------------------------------------------4

Scan Diagnostics ------------------------------------------------------------------------------------------------------------------------------- 4

Use MIL to Read DTCs ---------------------------------------------------------------------------------------------------------------------- 4

Use Tiny Scan Code Reader to Read/Clear DTCs ----------------------------------------------------------------------------------- 5

Use Diagnostic Tool to Read/Clear DTCs ----------------------------------------------------------------------------------------------- 5

Back Probe Connector Terminals ----------------------------------------------------------------------------------------------------------6

Avoid ECM Damage ---------------------------------------------------------------------------------------------------------------------------6

Special Tools ------------------------------------------------------------------------------------------------------------------------------------ 7

Product Improvements/Field Upgrades --------------------------------------------------------------------------------------------------- 8

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DIAGNOSTIC INTRODUCTION

On-Board Diagnostic (OBD) System Check

The basic steps of any diagnosis are as follows:

1. Observe the Malfunction Indicator Lamp (MIL) with

engine running. If MIL is illuminated, then current

Diagnostic Trouble Codes (DTCs) are present.

2. Read DTC(s) using MIL, Tiny Scan Code Reader,

orDiagnostic Toolsoftware.

3. To diagnose system problem(s), proceed to the

applicable Diagnostic Table(s) inSECTION 2 -

TROUBLESHOOTING DTCs.

4. Once the problem is located and corrected through

repair or replacement of faulty components, clear

DTC(s) using the Tiny Scan Code Reader or

theDiagnostic Toolsoftware.

NOTE:For information on the location or

replacement of specific components, seeSECTION 5

- REMOVAL/INSTALLATION.

5. Start and run engine to validate repairs. Observe MIL

to verify that no DTCs are set.

6. If no DTCs are set, but engine performance issues

exist, seeSECTION 4 - SYMPTOMS.

Diagnostic Trouble Codes (DTCs)

The ECM receives voltage signals from as many as five

sensors. Each sensor functions within an established

set of parameters, which can be viewed as its operating

“window.”

When a malfunction or fault condition occurs, a change

in the signal voltage alerts the ECM that the sensor is

functioning outside its operating “window,” a DTC is set

and stored in ECM memory, and the MIL is illuminated.

A default value temporarily replaces the erroneous sensor

value to restore engine performance until the problem is

corrected.

Malfunction Indicator Lamp (MIL)

As a bulb and diagnostic system check, the MIL

illuminates at Ignition ON, Engine OFF. When the engine

is started, the MIL is extinguished if no current fault

condition exists.

If the MIL remains illuminated, it is an indication that a

current DTC is stored. If the fault should correct itself, as

in an intermittent condition, the MIL is extinguished after

a ten second delay. The DTC remains stored in ECM

memory as a historic code until cleared by the technician.

The MIL does not indicate the existence of only historic

codes.

Data Link Connector (DLC)

The DLC provides for direct communication with the

ECM. By plugging the Tiny Scan Code Reader, or laptop

withDiagnostic Tool, into the 6-pin connector in the EFI

wire harness, the DTCs stored in ECM memory can be

read and cleared.

Non-Scan Diagnostics

In the Non-Scan diagnostic mode, either the MIL or

the Tiny Scan Code Reader is used to read DTCs. The

technician then refers to the applicable Diagnostic Table

to troubleshoot the problem. Those tables labeledNon-

Scan Diagnosticsmust be used, as the data stream

provided by the ECM is not available for analysis.

Scan Diagnostics

In the more sophisticated diagnostic mode, theDiagnostic

Toolsoftware can facilitate the diagnosis of system

problems through an expanded interface with the ECM.

Through the use of data displays and menu selections,

the technician has access to “live” data for analysis.

It is important to note that the software is not a stand-

alone diagnostic tool for resolving DTCs, but must be

used in conjunction with the Diagnostic Tables for the

most efficient and effective diagnosis. Those tables that

are applicable to users with access to theDiagnostic

Toolsoftware are labeled asScan Diagnostics.

Use MIL to Read DTCs

1. Verify that battery voltage is above 12v.

2. Turn Ignition key OFF for ten seconds.

3. Turn Ignition key ON-OFF-ON-OFF-ON (but do not

start the engine).

NOTE:No more than 2.5 seconds can elapse

between each ON and OFF cycle or the routine is

aborted.

4. When performed correctly, the MIL begins to flash the

first of four digits.

NOTE:While each DTC actually begins with the

letter “P,” only the numeric characters are flashed.

5. Count the number of flashes to obtain the first of four

digits. If the first digit is zero, it is represented as a

series of ten flashes.

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

6. Count the number of flashes after the first one second

pause to obtain the second digit of the DTC.

7. Count the number of flashes after the second one

second pause to obtain the third digit, and then count

the number of flashes after the third one second

pause to obtain the fourth digit.

8. Write down each digit as it is displayed.

9. If there is more than one DTC, the next DTC begins

to flash after a three second pause.

10. After all DTCs are reported, the number “61” is

flashed to indicate this condition to the technician.

The flashing sequence is then restarted and the

technician may choose to verify the DTCs written

down or exit the routine.

NOTE:If “61” is the first code flashed, then no active

DTCs are set.

Use Tiny Scan Code Reader to Read/Clear

DTCs

NOTE:Always follow steps 1-9 for an accurate report of

current DTCs. Failure to do so may generate a report that

includes historic codes.

1. Obtain Briggs & Stratton Tiny Scan Code Reader

(Part No. 19626).

2. Connect code reader to DLC.

3. Turn Ignition ON, Engine OFF.

NOTE:If the Tiny Scan Code Reader cannot connect

to the ECM, “no-C” is displayed, which stands for “no

communication.” If communication is established, the

tool displays the number of DTCs read. For example,

“dc-0” means that no DTCs were found, while “dc-4”

means that four DTCs are recorded.

4. Press the select button to cycle through the list of

DTCs.

5. Once the last DTC is displayed, “CLr?” appears.

Press and hold the select button until “Hold” changes

to “Done,” which indicates that all DTCs have been

“cleared” from ECM memory.

6. Turn Ignition OFF for a minimum of 20 seconds.

7. Turn Ignition ON, Engine OFF.

8. The tool displays the number of DTCs read.

9. Press the select button to cycle through the list of

DTCs. Write down each DTC as it is displayed.



Use Diagnostic Tool to Read/Clear DTCs

1. Obtain Briggs & Stratton Diagnostic Tool (Part No.

19636) with USB and Interface cables.

2. Connect one end of the USB cable to the Diagnostic

Tool and the other end to the USB port on the laptop.

3. Connect one end of the Interface cable to the

Diagnostic Tool and the other end to the DLC on the

EFI harness.

4. Turn Ignition ON, Engine OFF. The Diagnostic Tool

can take up to 30 seconds to connect to the engine.

5. See Figure3. Select theDashboardicon (A) in the

left sidebar to view theDealertab.

6. Observe the Current codes display (B).

NOTE:TheCHECK ENGINElight (C) is green if a

current fault code is present. To display a description

of the fault code, hover the cursor over the code.

NOTE:A Current codes display can also be viewed

under theTroubleshootingtab.

7. ClickClear(D) to erase both current and historic

DTCs.

NOTE:See the Briggs & Stratton EFI Diagnostic Tool

Software User Manual for more information.

8. Turn Ignition OFF.



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Back Probe Connector Terminals

NOTE:Do not insert probes into terminals on the mating

side of any connector. The diameter of the test probes

can damage terminals.

1. Obtain Briggs & Stratton Back Probe Wire Set (Part

No. 19625).

2. Carefully slide metal pin on probe between the rubber

seal and wire insulation on the back side (wire end) of

the connector.

3. Gently push the pin in until it stops. Stop pushing

when the pin “bottoms out,” or when the plastic

sheath is very close to the connector housing.



DO NOTforce the pin into the connector as terminal

and/or probe pin damage can occur. Probe travel

may be stopped by contact with insulation or core

crimps. Try again after removing and re-positioning

probe pin.

IMPORTANT:

• Use care to avoid deforming connector terminals,

either by forcing the probe too far into the cavity

or by using a probe that is too large. If terminal

damage is suspected, test for proper terminal

contact.

• A deformed terminal can cause a poor

connection resulting in intermittent problems or

even complete component failure. Do not use

paper clips or other substitute devices as they

also can damage terminals.

• Do not probe through connector seals, wire

insulation, secondary ignition wires, boots, etc.

Damage can occur that is not readily apparent

and tiny holes can result in water intrusion, which

leads to corrosion and eventual component

failure.

Avoid ECM Damage

CAUTION

A surge in voltage, current or both, is called a

voltage spike. Voltage spikes can cause major

damage to the ECM.

1. To avoid ECM failure due to accidentally induced

voltage spikes, always observe the following

precautions:

• Do not start engine if battery cable connections

are loose.

• Do not use a battery charger to start engine.

• Turn Ignition OFF before disconnecting and/or

connecting battery cables.

• When disconnecting battery, always disconnect

battery negative (-) cable first.

• When connecting battery, always connect battery

positive (+) cable first.

• When charging battery, turn Ignition OFF and

remove battery negative cable (black) from

battery negative (-) terminal.



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Ce manuel convient aux modèles suivants

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