3594036 Volvo.Penta Bellows

Illustration 1 g01209646
Schematic
Illustration 2 g01093741
P2 ECM connector (P2-14) Transmission oil pressure sensor (P2-16) Fuel pressure sensor (P2-24) Engine oil pressure sensor (P2-25) Injection actuation pressure sensor (P2-40) Intake manifold (boost) pressure sensor
Illustration 3 g01094844
Sensor connector
Illustration 4 g01192882
Sensor locations (1) Fuel pressure sensor (2) Injection actuation pressure sensor (3) Intake manifold (boost) pressure sensor (4) Engine oil pressure sensor (5) Connector for the transmission oil pressure sensorTest Step 1. Inspect Electrical Connectors and Wiring
Remove the electrical power from the ECM.
Thoroughly inspect the J1/P1 ECM connector and the J2/P2 ECM connector. Thoroughly inspect the connectors for each analog sensor.Refer to diagnostic functional tests Troubleshooting, "Electrical Connectors - Inspect" for details.
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 connector (allen head screw) for the proper torque. Refer to diagnostic functional tests 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 coupled and/or inserted. The harness and wiring are free of corrosion, of abrasion, and of pinch points.Results:
OK - The harness and wiring are OK. Proceed to Test Step 5.
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 2. Check the Supply Voltage at the Sensor Connector
Disconnect all of the following analog sensors at the sensor connector:
Fuel pressure sensor
Engine oil pressure sensor
Intake manifold (boost) pressure sensor
Injection actuation pressure sensor
Transmission oil pressure
Restore the electrical power to the ECM.Note: The original diagnostic code may go away. An open circuit diagnostic code for the sensor supply may become active when all of the sensors are disconnected. Ignore the active codes at this time and continue with this test step.
Measure the voltage between terminal A (5 V analog supply) and terminal B (sensor return) at the sensor connectors.
Remove the electrical power from the ECM.
Reconnect all sensors.Expected Result:The voltage is 5.0 0.16 VDC.Results:
OK - The voltage is 5.0 0.16 VDC. The voltage is correct. Proceed to Test Step 3.
Not OK - The voltage is not 5.0 0.16 VDC. The voltage is incorrect.Repair: Refer to diagnostic functional tests Troubleshooting, "Analog Sensor Supply Circuit - Test".STOPTest Step 3. Check for Active Diagnostic Codes
Connect Caterpillar Electronic Technician (ET) to the service tool connector.
Restore the electrical power to the ECM.
Monitor the active diagnostic code screen on Cat ET. Check and record any active diagnostic codes.Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
Determine if the problem is related to an open circuit diagnostic code 03 or a short circuit diagnostic code 04.Expected Result:No diagnostic codes are active.Results:
OK - No diagnostic codes are active.Repair: The problem may have been related to a faulty connection in the harness. Carefully reinspect the connectors and wiring. Refer to diagnostic functional tests Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - A short circuit diagnostic code (04) is active at this time. Proceed to Test Step 4.
Not OK - An open circuit diagnostic code (03) is active at this time. Proceed to Test Step 5.Test Step 4. Disconnect the Suspect Sensor in Order to Create an Open Circuit
Remove the electrical power from the ECM.
Disconnect the sensor connector of the sensor with the short circuit diagnostic code (04).
Restore the electrical power to the ECM. Wait at least 30 seconds for activation of the diagnostic codes.
Access the "Active Diagnostic Code" screen on Cat ET. Check for an active open circuit diagnostic code (03).
Remove the electrical power from the ECM.Expected Result:An open circuit diagnostic code 03 is now active for the disconnected sensor.Results:
OK - A short circuit diagnostic code (04) was active before disconnecting the sensor. An open circuit diagnostic code (03) became active after disconnecting the sensor.Repair: Temporarily connect a new sensor to the harness, but do not install