3803150 Volvo.Penta Aquamatic drive, exc

Illustration 1 g00807128
Location of components
Illustration 2 g00806931
Schematic for the injectorsTest Step 1. Inspect Electrical Connectors And Wiring.
Illustration 3 g00807133
Pin locations for ECM
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
Turn the ignition key switch to the OFF position. A strong electrical shock hazard is present if the ignition key is not turned OFF.
Thoroughly inspect the ECM engine harness connector J2/P2 and the solenoid connector for the injector J300/P300. Refer to Troubleshooting, "Inspecting Electrical Connectors" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector and the solenoid connector for the injector J300/P300 that are associated with injector solenoids.Refer to Illustration 3.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the solenoid connector for the injector J300/P300 in order to ensure the proper mating of the connector.
Check the harness and wiring for abrasion and pinch points from the injectors to the ECM.Expected Result:All connectors, pins and sockets should be completely coupled and/or inserted and the harness and wiring should be free of corrosion, abrasion or pinch points.Results:
OK - Proceed to Test Step 2.
Not OK - Repair: Perform the following 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. Stop.Test Step 2. Check For Logged Diagnostic Codes Regarding Injector Solenoids.
Connect an Electronic Service Tool to the cab data link connector.
Turn the ignition key switch to the ON position.
Monitor the "Logged Diagnostic Code" screen of the Electronic Service Tool.Expected Result:One or more of the listed codes have been logged:
CID 0001-FMI 11, SPN 651-FMI 11, Flash Code 72 Cylinder #1 fault
CID 0002-FMI 11, SPN 652-FMI 11, Flash Code 72 Cylinder #2 fault
CID 0003-FMI 11, SPN 653-FMI 11, Flash Code 73 Cylinder #3 fault
CID 0004-FMI 11, SPN 654-FMI 11, Flash Code 73 Cylinder #4 fault
CID 0005-FMI 11, SPN 655-FMI 11, Flash Code 74 Cylinder #5 fault
CID 0006-FMI 11, SPN 656-FMI 11, Flash Code 74 Cylinder #6 faultResults:
Yes - Proceed to Test Step 4.
No - Proceed to Test Step 3.Test Step 3. Check The Variation Of The Injectors From Cylinder To Cylinder.
Connect an Electronic Service Tool to the cab data link connector.
Start the engine.
Allow the engine to warm up to normal operating temperature 77 °C (171 °F).
After the engine is warmed to operating temperature, access the "Cylinder Cutout Test" by accessing the following display screens in order:
"Diagnostics"
"Diagnostic Tests"
"Cylinder Cutout Test"
Enable the cooling fan, if the fan is not controlled by the ECM. If the ECM controls the cooling fan, the cooling fan will start automatically when the test begins.
Shut off all parasitic loads such as the air conditioning and the air compressors which could affect the results of the test.
Cut out each cylinder and watch the "Fuel Position" of all of the other cylinders.
Verify that cutting out a specific cylinder causes only a slight change to the Fuel Position of the other cylinders in comparison to the change to the Fuel Position that occurs when other cylinders are cut out. If a cylinder is cut out and only a slight change occurs to the Fuel Position of the other cylinders, a mechanical problem with the injector or a mechanical problem with the cylinder may exist.
After the test is finished, use the Electronic Service Tool to check for active diagnostic codes or for logged diagnostic codes that are new.Expected Result:An active diagnostic code for a cylinder fault results from running the Cylinder Cutout Test.Results:
Yes - Proceed to Test Step 4.
No - Perform the following repair:Repair: If a cylinder is cut out and only a slight change occurs to the Fuel Position of the other cylinders, a mechanical problem with the injector or a mechanical problem with the cylinder may exist. If the engine is misfiring or if the engine has low power, refer to Troubleshooting, "Engine Misfires, Runs Rough or Is Unstable" and Troubleshooting, "Low Power/Poor or No Response to Throttle". If a diagnostic code for a cylinder fault results from running the Cylinder Cutout test, proceed to Test Step 4.Test Step 4. Use The Injector Solenoid Test To Test The Injector Solenoids.
Start the engine.
Allow the engine to warm up to 77 °C (171 °F) which is the normal operating temperature.
Turn the ignition key switch to the OFF position.
Connect an Electronic Service Tool at the cab data link connector.
Turn the ignition key switch to the ON position.
After the engine is warmed to operating temperature, access the "Injector Solenoid Test" by accessing the following display screens in order:
"Diagnostics"
"Diagnostic Tests"
"Injector Solenoid Test"
Activate the test.Note: Do not confuse the Injector Solenoid Test with the Cylinder Cutout Test. The Cylinder Cutout Test is used to shut off fuel to a specific cylinder while the engine is running. The Injector Solenoid Test is used in order to actuate the injector solenoids. This allows the click of the injector solenoids to be heard when the engine is not running in order to determine that the circuit is functioning properly.