3827870 Volvo.Penta Charge air cooler

Illustration 1 g00599630
Test Step 1. Check for Connector Damage.
Turn the keyswitch to the OFF position.
Turn the circuit breaker for the battery to the OFF position.
Thoroughly inspect the ECM connectors J1/P1 and J2/P2. 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 for pinch points.Expected Result:The connectors and wiring should be free of the following problems: damage, corrosion, abrasion and incorrect attachment.Results:
OK - The connectors and wiring are okay. Proceed to test step 2.
Not OK - The connectors and/or wiring are not okay.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Stop.Test Step 2. Check for "ACTIVE" Diagnostic Codes.
Connect the Cat ET to the service tool connector. Start the Cat ET.
Turn the circuit breaker for the battery to the ON position.
Turn the keyswitch to the ON position. The engine should be off.
Observe the diagnostic codes on the Cat ET.Expected Result:A CID-FMI 1-05 to 8-05 or 1-06 to 8-06 should not be logged.Results:
OK - A CID-FMI 1-05 to 8-05 or 1-06 to 8-06 is not logged. Logged diagnostic codes are not present. Proceed to test step 3.
Not OK - A CID-FMI 1-05 to 8-05 or 1-06 to 8-06 is logged. There are logged diagnostic codes. Proceed to test step 5.Test Step 3. Perform the Cylinder Cutout Test.
Engine power is reduced when a properly functioning cylinder is cut out. Make sure that you will not damage auxiliary or driven equipment if the engine power is suddenly reduced.
Turn the keyswitch to the OFF position.
Turn the circuit breaker for the battery to the OFF position.
Verify that the ECM connector J2/P2 and the injector connectors J4/P4 through J11/P11 are properly connected.
Start the Cat ET.
Turn the circuit breaker for the battery to the ON position.
Turn the keyswitch to the ON position.
Start the engine.
Apply a load to the engine.
Use the diagnostic test on the Cat ET to initiate the cylinder cutout test.
Check for a difference in the sound, in the feel, or in the power of the engine as each cylinder is cut out. The amount of change should be similar for all of the good cylinders. The amount of change should be minimal for a weak cylinder or for a bad cylinder.
Disable the override. Repeat the above steps for each cylinder (solenoid).Expected Result:The amount of change should be similar for all of the good cylinders. The amount of change should be minimal for a weak cylinder or for a bad cylinder.Results:
OK - There was a noticeable change in engine performance during the cylinder cutout test.Repair: The change in engine performance indicates that each cylinder is operating correctly. There may be an intermittent problem. If the problem is intermittent, perform the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors". Stop.
Not OK - There was no noticeable change in engine performance during the cylinder cutout test for a specific cylinder. Proceed to test step 4.Test Step 4. Check the Adjustment of the Fuel Injector and of the Engine Valve Lash Setting.
Turn the keyswitch to the OFF position.
Turn the circuit breaker for the battery to the OFF position.
Check the adjustment of the fuel injector and of the engine valve lash setting for the suspect cylinder. Refer to the Testing and Adjusting, "Fuel Injector Adjustment".Expected Result:The engine valve lash setting should be correct. The injectors should be okay.Results:
OK - The engine valve lash setting is correct. The injectors are okay.Repair: Recheck the system for any diagnostic codes. Stop.
Not OK - The engine valve lash setting is not correct. The injectors are not okay. A problem is found with the injector.Repair: Adjust the engine valve lash. Refer to the Testing and Adjusting, "Valve Lash and Valve Bridge Adjustment". Repair the injector. If the problem is still present, replace the injector. If the new injector has a 4 Digit code that is different from the old injector, change the code in the ECM. Stop.Test Step 5. Check the Resistance of the Harness from the Solenoid to the ECM Connector.
This engine uses high voltage to control the fuel injectors.Disconnect electronic fuel injector enable circuit connector to prevent personal injury.Do not come in contact with the fuel injector terminals while the engine is running.
Turn the keyswitch to the OFF position.
Turn the circuit breaker for the battery to the OFF position.
Disconnect ECM connector J2/P2 and the injector connectors J4/P4 through J11/P11.
Measure the resistance at the ECM connector P2 between the following pins:
P2-16 and P2-5
P2-32 and P2-5
P2-26 and P2-17
P2-38 and P2-17
P2-37 and P2-27
P2-30 and P2-27
P2-31 and P2-39
P2-36 and P2-39Expected Result:The resistance should be greater than 20,000 Ohms.Results:
OK - The resistance was greater than 20,000 Ohms. Proceed to test step 6.
Not OK - The resistance was less than 20,000 Ohms.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Stop.Test Step 6. Check for a Short Circuit from the Harness to the Engine Ground.
This engine uses high voltage to control the fuel injectors.Disconnect electronic fuel injector enable circuit connector to prevent personal injury.Do not come in contact with the fuel injector terminals while the engine is running.
For the 3508B, measure the resistance between the following sockets at ECM connector P2 and the engine ground: P2-5, P2-16, P2-17, P2-26, P2-27, P2-30, P2-31, P2-32, P2-36, P2-37, P2-38 and P2-39.Expected Result:The resistance should be greater than 20,000 Ohms.Results:
OK - The resistance is greater than 20,000 Ohms. Proceed to test step 7.
Not OK - The resistance is less than 20,000 Ohms.Repair: