21757269 Volvo.Penta Cap

Illustration 1 g00820920
Test Step 1. Check for "ACTIVE" Diagnostic Codes.
Start the Cat ET.
Turn the engine control to the ON position.
Monitor the active diagnostic codes on the Cat ET.Expected Result:Any of the following diagnostic codes are active:
CID-FMI 190-02 Loss of Engine Speed signal
CID-FMI 190-03 Engine Speed open/short to +batt
CID-FMI 190-07 Primary Speed Sensor misinstalled
CID-FMI 342-02 Loss of Secondary Engine Speed signal
CID-FMI 342-07 Secondary Speed Sensor misinstalled
CID-FMI 342-03 Secondary Engine Speed open/short to +battResults:
OK - Either a CID-FMI 190-03 Engine Speed open/short to +batt diagnostic code or a CID-FMI 342-03 Secondary Engine Speed open/short to +batt diagnostic code is active. Proceed to test step 2.
OK - A CID-FMI 190-07 Primary Speed Sensor misinstalled diagnostic code or a CID-FMI 342-07 Secondary Speed Sensor misinstalled diagnostic code is active.Repair: Switch the Primary Engine Speed/Timing Sensor and the Secondary Engine Speed/Timing Sensor. Verify that the problem is no longer present.STOP
OK - A CID-FMI 190-02 Loss of Engine Speed signal diagnostic code or a CID-FMI 342-02 Loss of Secondary Engine Speed signal diagnostic code is present. Proceed to test step 5.Test Step 2. Check the Electrical Connectors and the Wiring.
Turn the engine control to the OFF position.
Thoroughly inspect the ECM connector J1/P1. Inspect all of the other connectors. Refer to the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the circuit.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the customer connector (allen head screw) for the proper torque of 2.25 0.25 N m (20 2 lb in).
Check the harness and the wiring for abrasion and pinch points.Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted, and the harness and wiring should be free of corrosion, abrasion or pinch points.Results:
OK - The wiring and connectors are okay. Proceed to test step 3.
Not OK - The wiring and/or connectors are not okay.Repair: Repair the wiring and connectors or replace the wiring or the connectors. Ensure that all of the seals are properly connected. Verify that the repair eliminates the problem.STOPTest Step 3. Check for a Short Circuit in the Wiring Harness.
Disconnect J1/P1 from the ECM. Disconnect the Primary Engine Speed/Timing Sensor J20/P20. Disconnect the Secondary Engine Speed/Timing Sensor J44/P44.
Measure the resistance between P1-38 and P1-29.
Measure the resistance between P1-38 and P1-32.
Measure the resistance between P1-32 and P1-29.
Measure the resistance between P1-39 and P1-29.
Measure the resistance between P1-39 and P1-32.
Measure the resistance between J20-A and the engine ground.
Measure the resistance between J20-B and the engine ground.
Measure the resistance between J20-C and the engine ground.
Measure the resistance between J44-A and the engine ground.
Measure the resistance between J44-B and the engine ground.
Measure the resistance between J44-C and the engine ground.Expected Result:The resistance should be greater than 20,000 Ohms for each measurement.Results:
OK - The resistance is greater than 20,000 Ohms. Proceed to test step 4.
Not OK - The resistance is less than 20,000 Ohms. There is a short circuit in the harness or connectors.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 4. Check for an Open Circuit in the Wiring Harness.
Use a suitable piece of wire to short J44-A and J44-B together.
Measure the resistance between P1-32 and P1-29.
Use a suitable piece of wire to short J44-B and J44-C together.
Measure the resistance between P1-29 and P1-39.
Use a suitable piece of wire to short J44-C and J44-A together.
Measure the resistance between P1-39 and P1-32.
Use a suitable piece of wire to short J20-A and J20-B.
Measure the resistance between P1-32 and P1-29.
Use a suitable piece of wire to short J20-B and J20-C.
Measure the resistance between P1-29 and P1-38.
Use a suitable piece of wire to short J20-C and J20-A.
Measure the resistance between P1-38 and P1-32.
Remove all shorts and reconnect J1/P1, J44/P44, and J20/P20.Expected Result:The resistance should be less than 10 Ohms through the wires.Results:
OK - The resistance is less than 10 Ohms. The harness resistance is within acceptable limits. Proceed to test step 6.
Not OK - The resistance is greater than 10 Ohms. There is an open circuit or excessive resistance in the harness or connectors.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 5. Check the Engine Speed/Timing Sensor.
Be sure to extend the sliphead before installing the Engine Speed/Timing Sensor. Also check that the Timing Gear is in a position that will not allow the sliphead of the Engine Speed/Timing Sensor to protrude into one of the slots of the Timing Gear. This is done visually with a flashlight prior to the installation of the Engine Speed/Timing Sensor. Turn the crankshaft to rotate the Timing Gear, if necessary, to position the gear in a place that will not allow the sliphead to protrude into a slot. If the sensor sliphead does protrude into one of the slots, the sliphead will be broken off as the gear begins to rotate.
Remove the suspect Engine Speed/Timing Sensor.
Inspect the plastic sliphead for damage.
Check the tension. Gently extend the sliphead 3.5 mm (0.14 inch). Return the sliphead to the original position.
Extend the sliphead.
Install the Engine Speed/Timing Sensor.Expected Result:The sliphead should take at least 22 N (5 lb) of force to push in the sliphead from the extended position.Results:
OK - The Engine Speed/Timing Sensor and the sliphead are undamaged. The tension on the sliphead is normal. Reinstall the sensor. Proceed to test step 6.
Not OK - The Engine Speed/Timing Sensor or the sliphead is damaged, or