3801257 Volvo.Penta Cylinder head

The following background information is related to this procedure:NRS ValveThe NRS valve is used to control the amount of exhaust gas which is recirculated into the intake manifold.The amount of exhaust gas that is required is calculated by the software that is contained in the ECM. The NRS valve is controlled by a PWM signal from the ECM.Intake Throttle ValveThe intake throttle valve is used to increase the exhaust gas temperature to aid the Diesel Particulate Filter (DPF) regeneration process.
Illustration 1 g06551455
Schematic diagram for the motorized valves
Not all connectors are shown. Refer to the electrical schematic for the machine.
Illustration 2 g03616849
Typical view of the pin locations on the J2 connector for the motorized valves.
(8) Intake throttle valve position sensor 5 VDC supply
(9) NRS valve position sensor 5 VDC supply
(24) NRS valve position sensor ground
(34) Intake throttle valve return
(35) NRS valve return
(37) Intake throttle valve position sensor ground
(39) NRS valve position sensor signal
(49) Intake throttle valve PWM signal
(50) NRS valve PWM signal
(53) Engine intake throttle valve position sensor signal
Table 2
Troubleshooting Test Steps Values Results
1. Inspect Electrical Connectors and Wiring
A. Thoroughly inspect connectors for the motorized valves. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
B. Thoroughly inspect the P2/J2 ECM connector. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
C. Perform a 30 N (6.7 lb) pull test on each of the wires that are associated with the motorized valves.
Damaged wire or connector
Result: A damaged wire or damaged connector was found.
Repair the damaged wire or the damaged connector.
Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault.
Result: All connectors, pins, and sockets are correctly connected and/or inserted and the harness is free of corrosion, of abrasion or of pinch points.
Proceed to Test Step 2.
2. Check for Diagnostic Codes
A. Turn the keyswitch to the OFF position.
B. Connect the electronic service tool to the diagnostic connector.
C. Turn the keyswitch to the ON position.
D. Monitor the electronic service tool for active diagnostic codes and/or logged diagnostic codes.
Diagnostic codes
Result: An XXXX-7 diagnostic code is active or recently logged for one or more of the motorized valves
Note: Troubleshoot any -5 or -6 codes for motorized valves before troubleshooting -7 codes.
Proceed to Test Step 3.
Result: An XXXX-5 diagnostic code is active or recently logged for one or more of the motorized valves.
Proceed to Test Step 4.
Result: An XXXX-6 diagnostic code is active or recently logged for one or more of the motorized valves.
Proceed to Test Step 6.
3. Measure the Sensor Supply Voltage at the Valve Connector
A. Turn the keyswitch to the OFF position.
B. Disconnect the suspect valve from the engine harness.
C. Turn the keyswitch to the ON position.
D. Measure the voltage at the harness connector for the valve from the 5 VDC supply terminal of the position sensor to the sensor ground terminal.
4.9 v to 5.1 V
Result: The measured voltage is within the expected range.
Install a replacement for the suspect valve. Refer to Disassembly and Assembly for more information.
Note: If the NRS valve is replaced, use the electronic service tool to perform the "EGR Valve Learn Reset".
Use the electronic service tool to clear all logged diagnostic codes and then verify that the repair eliminates the fault.
Result: The measured voltage is not within the expected range.
The fault is in the wiring between the suspect valve and the ECM P2 connector.
Check all the wiring between the suspect valve and the P2 connector. Refer to the Electrical Schematic for the engine.
Replace the suspect wiring.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
4. Create a Short Circuit at the Valve Connector
A. Turn the keyswitch to the OFF position.
B. Disconnect the connector for the suspect valve.
C. Fabricate a jumper wire that is 150 mm (6 inch) long.
D. Install the jumper between the PWM signal and return pins on the connector for the suspect valve to create a short circuit.
E. Turn the keyswitch to the ON position. Check for active diagnostic codes on the electronic service tool.
F. Remove the jumper wire.
Diagnostic codes
Result: An XXXX-6 is active with the jumper installed.
Reconnect the valve. Start the engine.
Check for active diagnostic codes on the electronic service tool. Wait at least 30 seconds in order for the codes to be displayed.
If the XXXX-5 diagnostic code returns, then replace the valve. Refer to Disassembly and Assembly for the correct procedure.
Note: If the NRS valve is replaced, use the electronic service tool to perform the "EGR Valve Learn Reset".
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: An XXXX-5 diagnostic code is still active with the jumper installed.
Proceed to Test Step 5.
5. Create a Short Circuit at the ECM Connector
A. Turn the keyswitch to the OFF