993943 Volvo.Penta Cap plug

Illustration 1 g01173234
Test Step 1. Inspect the Electrical Connectors and the Wiring
Turn the keyswitch to the OFF position.
Thoroughly inspect the J2/P2 ECM connectors. Refer to Troubleshooting, "Electrical Connectors - Inspect".
Illustration 2 g01149851
P2 terminals that are associated with the 5 volt supply (P2-2) +5 VDC (P2-3) Return (P2-41) +5 VDC (P2-42) Return
Illustration 3 g01123211
Connectors for the sensors (A) Supply (B) Return (C) Signal
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the 5 volt supply.
Check the allen head screw on each ECM connector for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for the correct torque values.
Check the harness and the wiring for abrasion and for pinch points from each sensor back to the ECM.Expected Result:All of the connectors, pins and sockets are completely coupled and/or inserted and the harness and wiring are free of corrosion, of abrasion and of pinch points.Results:
OK - The harness and connectors appear to be OK. Proceed to Test Step 2.
Not OK - The connectors and/or wiring are not OK.Repair: Repair the wiring and/or the connectors. Replace parts, if necessary. 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 for Active Diagnostic Codes
Connect the Caterpillar Electronic Technician (ET) to the service tool connector. Refer to Troubleshooting, "Electronic Service Tools".
Turn the keyswitch to the ON position.
Use Cat ET to check for active diagnostic codes. Wait at least 15 seconds so that any codes may become active. Check for these codes:
262-03
262-04Expected Result:One of the above codes is active.Results:
Active -03 code - An -03 diagnostic code is active. Proceed to Test Step3.
Active -04 code - An -04 diagnostic code is active. Proceed to Test Step 4.
No active codes - None of the above codes are active.Repair: If any of the above codes are logged and the engine is not running properly, refer to Troubleshooting, "Troubleshooting Without a Diagnostic Code".If the engine is running properly at this time, there may be an intermittent problem in a harness that is causing the codes to be logged. Refer to Troubleshooting, "Electrical Connectors - Inspect".STOPTest Step 3. Check the Voltage on the +5 V Supply Wire
Turn the keyswitch to the OFF position.
Disconnect the harness connectors for the following sensors:
Engine oil pressure sensor J201/P201
Turbocharger outlet (boost) pressure sensorJ200/P200
Fuel pressure sensor J209/P209
Injection actuation pressure sensor J204/P204
Atmospheric pressure sensorJ203/P203
Turn the keyswitch to the ON position.Note: Be sure to wiggle the harness during the following measurements in order to reveal an intermittent condition.
Measure the voltage between terminals A and B at each sensor connector on the engine harness.Expected Result:Each voltage measurement is 5.0 0.2 VDC.Results:
OK - Each voltage measurement is 5.0 0.2 VDC. The problem appears to be resolved.Repair: Connect all of the sensor connectors. Clear all diagnostic codes. Check for active diagnostic codes. If the problem is intermittent, refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - At least one voltage measurement is not 5.0 0.2 VDC. There is a problem with the wiring or with the ECM. Proceed to Test Step 5.Test Step 4. Disconnect the +5 V Pressure Sensors and Check for Active Diagnostic Codes
Use Cat ET to check for an active 262-04 diagnostic code while you disconnect the harness connectors. Note: Wait at least 15 seconds after disconnecting the sensor connector so that any codes may become active.
Disconnect the following sensors one at a time:
Engine oil pressure sensor
Turbocharger outlet (boost) pressure sensor
Fuel pressure sensor
Injection actuation pressure sensor
Atmospheric pressure sensorExpected Result:The 262-04 diagnostic code deactivates when a particular sensor is disconnected.Results:
OK - The 262-04 diagnostic code deactivates when a particular sensor is disconnected.Repair: Connect the suspect sensor. If the code returns, replace the sensor.Connect all of the connectors. Verify that the problem is resolved.STOP
Not OK - The 262-04 diagnostic code remains after all of the sensors are disconnected. Leave the sensors disconnected. Proceed to Test Step 5.Test Step 5. Check the +5 V Supply Wire for a Short to Engine Ground or a Short Circuit
Turn the keyswitch to the OFF position.
Disconnect the J2/P2 ECM connector. Disconnect the J1/P1 ECM connector.
Verify that all of the pressure sensors are disconnected.Note: Wiggle the harness during the following measurements in order to reveal an intermittent condition.
Measure the resistance between terminals P2-2 (+5 V supply) and all of the other terminals on the P2 connector.
Measure the resistance between terminals P2-41 (+5 V supply) and all of the other terminals on the P2 connector.
Measure the resistance between terminal P2-2 (+5 V supply) and the engine ground.
Measure the resistance between terminal P2-41 (+5 V supply) and the engine ground.Expected Result:Each resistance measurement indicates an open circuit.Results:
OK - Each resistance measurement indicates an open circuit. Proceed to Test Step 6.
Not OK - At least one of the resistance measurements does not indicate an open circuit. A +5 V supply wire has a short circuit. There may be a problem with a connector.Repair: Repair the wire and/or the connector, when possible. Replace parts, if necessary. Verify that the problem is resolved.STOPTest Step 6. Check the +5 V Supply and the Sensor Common for an Open Circuit
Install a jumper wire between terminals P2-2 (+5 V supply) and P2-3 (return).
Install a jumper wire between terminals P2-41 (+5 V supply) and P2-42 (return).Note: Wiggle the harness during the following measurements in order to reveal any intermittent short condition.
Measure the resistance between terminals A and B at the harness connector for each pressure sensor.Expected Result:Each resistance measurement is less than ten Ohms.Results:
OK - Each measurement is less than ten Ohms. Proceed to Test Step 7.
Not OK - At least one resistance measurement is greater than ten Ohms. The +5 V supply wire or the return wire has excessive resistance. There may be a problem in a connector.Repair: Repair the wire and/or the connector, when possible. Replace parts, if necessary. Verify that the problem is resolved.STOPTest Step 7. Check the +5 V Supply at th