3883610 Volvo.Penta Drive, DPS-A

Illustration 1 g00779064
Schematic for ECM battery circuit
Illustration 2 g00640974
Terminal locations for ECMTest Step 1. Inspect Electrical Connectors and Wiring
Thoroughly inspect the J1/P1 ECM connector, the battery connections and the connections to the key switch. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the following connections:
J1/P1:52 & 53 (Unswitched +Battery)
J1/P1:65 & 67 (−Battery)
J1/P1:70 (Ignition Key Switch)
Check the allen head screws on the ECM connector for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Check the harness and wiring for abrasion and for pinch points from the battery to the ECM, and from the key switch to the ECM.Expected Result:All 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 connectors and wiring are OK but there may be a problem with the keyswitch. Proceed to Test Step 2.
OK - The connectors and wiring are OK but there may be a problem with the battery voltage. Proceed to Test Step 3.
Not OK - There is a problem with 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.STOPTest Step 2. Check the Status for the Ignition Key Switch
Turn the key switch to the OFF position.
Connect Cat ET to the data link connector and access the status screen that shows the status for "Ignition Key Switch".
Monitor the status for "Ignition Key Switch" while the key switch is being cycled slowly from the ON position to the OFF position.Note: Cat ET may indicate that a new ECM has been detected. This condition is normal, due to a powerdown of the ECM with the key switch in the OFF position.Note: Cycling the key switch several times may cause additional 43-02 faults to be logged. This is normal. Clear any logged faults.Expected Result:The status for "Ignition Key Switch" changes from "On" with the key switch in the ON position to "Off" with the key switch in the OFF position.Results:
OK - The key switch input is functioning properly at this time.Repair: If an intermittent connection is suspected, refer to Troubleshooting, "Electrical Connectors - Inspect". Excessive cycling of the key switch can cause this fault to be logged. This is normal. Clear any logged faults.STOP
Not OK - The key switch input is not functioning properly. Proceed to Test Step 3.Test Step 3. Check the Battery Voltage at the ECMPerform Steps A, B, and C if the following diagnostic code is active or logged:
168-02 ECM Battery Power Intermittent
Insert a 140-2266 Cable (Seventy-Pin Breakout) between the J1 and P1 ECM connector.
Measure the voltage between P1:52 (Unswitched +Battery) and P1:65 (-Battery).
Illustration 3 g00640981
ECM Breakout T-connector
Measure the voltage between P1:53 (Unswitched +Battery) and P1:67 (-Battery).Refer to Illustration 3.Perform Steps D, E, and F if the following diagnostic code is active or logged:
43-02 Key Switch Fault
Insert a 140-2266 Cable (Seventy-Pin Breakout) between the J1 and P1 ECM connector.
Turn the key switch to the ON position.
Measure the voltage between P1:70 (Ignition Key Switch) and P1:65 (-Battery).Refer to Illustration 3.Expected Result:For 12 Volt Systems, the measured voltage is a constant 11.0 to 13.5 VDC with no suspected intermittent problems at this time.For 24 Volt Systems, the measured voltage is a constant 22.0 to 27.0 VDC with no suspected intermittent problems at this time.Results:
OK - The ECM is receiving the correct voltage. Repair: If an intermittent condition is suspected, refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - The battery voltage is intermittent or there is no voltage. Proceed to Test Step 5.
- The voltage for the key switch is out of the acceptable range.Repair: Trace the wiring for the key switch from the ECM through the key switch circuit to the batteries. Find the problem and repair the problem. Check the circuit protection for the circuit and the wiring. Refer to the vehicle service manual for instructions on troubleshooting the circuit for the key switch.Verify that the repairs eliminate the problem.STOPTest Step 4. Check the Batteries
Measure no-load battery voltage at the battery posts.
Load test the batteries. Use the 4C-4911 Battery Load Tester. Refer to Special Instruction, SEHS9249, "Use of 4C-4911 Battery Load Tester for 6, 8 and 12 Volt Lead Acid Batteries" and Special Instruction, SEHS7633, "Battery Test Procedure".Expected Result:The batteries pass the load test. For 12 Volt systems, the measured voltage is at least 11.0. For 24 Volt systems, the measured voltage is at least 22.0.Results:
OK - The voltage is within the acceptable range.Repair: Refer to the vehicle service manual for i