853291 Volvo.Penta Ds unit

Illustration 1 g00934448
12 or 16 Cylinder EngineTest Step 1. Check for Connector Damage.
Turn the keyswitch to the OFF position.
Thoroughly inspect the ECM connectors J1/P1 and machine connector 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 2.25 0.25 N m (20 2 lb in).
Check the machine 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 are 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 Cat ET to the service tool connector J31. Start the Cat ET.
Turn the keyswitch to the ON position. The engine should be off.
Observe the diagnostic codes on Cat ET.Expected Result:A CID-FMI 1-05 to 16-05 or 1-06 to 16-06 is not logged.Results:
OK - A CID-FMI 1-05 to 16-05 or 1-06 to 16-06 is not logged. Logged diagnostic codes are not present. Proceed to Test Step 3.
Not OK - A CID-FMI 1-05 to 16-05 or 1-06 to 16-06 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.
Verify that the ECM connector J1/P1 and the injector connectors J3/P3 through J18/P18 are properly connected.
Start Cat ET.
Turn the keyswitch to the ON position.
Start the engine.
Apply a load to the engine.
Use the diagnostic test on Cat ET to initiate the cylinder cutout test.
Check for a difference in the sound, feel, or 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 a bad cylinder.
Disable the override. Repeat the above steps for each cylinder (solenoid).Expected Result:The amount of change is similar for all of the good cylinders. The amount of change is minimal for a weak cylinder or for a cylinder that does not fire.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. 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.
Check the adjustment of the fuel injector and of the engine valve lash setting. Refer to the Testing and Adjusting manual for further information.Expected Result:The engine valve lash setting is correct. The injectors are 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 manual for further information. 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 Injector 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.
Disconnect ECM connector J1/P1 and the injector connectors J3/P3 through J18/P18.
Measure the resistance at the ECM connector P1 between the power output for the individual solenoid and the solenoid return. For the twelve or the sixteen cylinder engine, refer to Illustration 1.Expected Result:The resistance is 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 either the 3512B engine or the 3516B engine, measure the resistance between the following sockets at ECM connector P1 and the engine ground: P1-1, P1-14, P1-15, P1-16, P1-17, P1-26, P1-27, P1-28, P1-29, P1-30, P1-31, P1-40, P1-41, P1-42, P1-43, P1-44, P1-45, P1-54, P1-55, P1-56, P1-58, P1-59, P1-68 and P1-69.Expected Result:The resistance is 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: Repair the connectors or wiring and/or replace the connectors or wiring. Stop.Test Step 7. Check for an Open Circuit in the Harness.
Use a suitable piece of wire to short socket 1 to socket 2 at each injector connector.
Measure the resistance at the ECM connector P1 between the power output for the individual solenoid and the solenoid return. For the twelve or the sixteen cylinder engine, refer to Illustration 1.Expected Result:The resi