21256263 Volvo.Penta Air shutter

Table 1
Event Code
Description Default Conditions which Generate this Code System Response
E035 Loss of Coolant Flow Warning The coolant flow switch opens. The code is active and the code is logged. The coolant flow switch is a reed switch that is used to detect the flow of coolant in the engine's cooling system.
Illustration 1 g01249790
Coolant flow switch
(1) Flow switch assembly
(2) Paddle The coolant flow switch is a normally open switch. The contacts of flow switch assembly (1) close as coolant flow from the engine flows across paddle (2) of the switch. The Electronic Control Module (ECM) monitors the status of the coolant flow switch during engine operation. If the ECM detects a loss of coolant flow in the engine during operation, a signal will be sent in order to alert the operator of the condition.The status of the "Engine Coolant Flow" can be monitored using Caterpillar Electronic Technician (ET) in order to determine the state of the coolant flow switch.
Illustration 2 g01521393
Right side view
(3) Coolant flow switch
Illustration 3 g01521414
Schematic
Test Step 1. Check the Coolant Level
Check the coolant level. Refer to the Operation and Maintenance Manual for information on checking the coolant level. Expected Result:The coolant level is OK.Results:
OK - The coolant level is OK. Proceed to Test Step 2.
Not OK - The coolant level is low.Repair: Determine the reason for a low coolant level.Refer to Systems Operation/Testing and Adjusting for information on testing the cooling system.Verify that the repair eliminates the problem.STOPTest Step 2. Inspect Electrical Connectors and Wiring
Turn the keyswitch to the OFF position.
Illustration 4 g01569775
Engine view (typical example)
Thoroughly inspect the J1/P1 and J2/P2 ECM connectors. Inspect the connector for the coolant flow switch. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Illustration 5 g01521430
P1 ECM connector
(P1-30) Coolant flow
Illustration 6 g01521432
P2 ECM connector
(P2-54) Digital return
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector and the sensor connectors that are associated with the active diagnostic code.
Check the ECM connectors (allen head screw) for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Check the harness and wiring for abrasions and for pinch points from the sensors back to the ECM. Expected Result:All connectors, pins, and sockets are completely inserted and coupled. The harness and wiring are free of corrosion, of abrasion, and of pinch points. All connections and grounds are tight and free of corrosion.Results:
OK - The harness and wiring are OK. Proceed to Test Step 3.
Not OK - There is a problem in the connectors and/or wiring.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.Verify that the repair eliminates the problem.STOPTest Step 3. Use Cat ET to Monitor the Switch Status
Connect Cat ET to the service tool connector.
Turn the keyswitch to the ON position.
Observe the status for "Engine Coolant Flow" on Cat ET.
Start the engine.
Observe the status for "Engine Coolant Flow" on Cat ET.
Turn the keyswitch to the OFF position. Expected Result:Cat ET indicates "No Flow" while the engine is not running. Cat ET indicates "Flow" while the engine is running.Results:
OK - Cat ET indicates "No Flow" while the engine is not running. Cat ET indicates "Flow" while the engine is running.Repair: The switch is operating correctly at this time. There may be an intermittent problem with the switch or the switch circuit. If an intermittent problem is suspected, refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - Cat ET does not indicate "No Flow" while the engine is not running. Cat ET does not indicate "Flow" while the engine is running. Cat ET does not indicate the correct status for the coolant flow switch. Proceed to Test Step 4.Test Step 4. Create a Short at the Connector for the Coolant Flow Switch
Disconnect the connector for the coolant flow switch.
Fabricate a jumper wire that is long enough to create a short at the harness connector for the coolant flow switch. Crimp connector pins to each end of the jumper wire.
Install the jumper wire to the terminals of the harness connector of the coolant level switch.
Turn the keyswitch to the ON position.
Observe the status of "Engine Coolant Flow" on Cat ET.
Turn the keyswitch to the OFF position. Restore the wiring to the original configuration. Expected Result:The status indicates "Flow" with the jumper wire in place.Results:
OK - The status indicates "Flow" with the jumper wire in place. Proceed to Test Step 5.
Not OK - The status indicates "No Flow" with the jumper wire in place. There is a problem in the harness between the ECM and the connector for the coolant flow switch. There may be a problem with the ECM. Proceed to Test Step 6.Test Step 5. Check the Coolant Flow Switch
Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap, stop the engine and wait until the cooling system components are cool. Loosen the cooling system pressure