3583499 Volvo.Penta Fitting

Illustration 1 g01205844
Schematic
Illustration 2 g01093760
Typical location of the engine's 5 volt sensors (1) Fuel pressure sensor (2) Injection actuation pressure sensor (3) Intake air (boost) pressure sensor (4) Engine oil pressure sensor (5) Connector for the transmission oil pressure sensor (6) Connector for the Transmission oil temperature sensor
Illustration 3 g01093307
SchematicP2 Connector (P2-2) 5 V sensor supply (P2-3) Sensor common (P2-41) 5 V sensor supply (P2-42) Sensor commonTest Step 1. Inspect Electrical Connectors and Wiring
Remove the electrical power from the ECM.
Thoroughly inspect the J1/P1 ECM connector and the J2/P2 ECM connector. Inspect all of the connectors that are associated with the circuit.Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connectors that are associated with the circuit.
Check the ECM connector (allen head screw) for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Check the harness and wiring for abrasion and pinch points from the sensors back 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 harness and connectors appear to be OK. Proceed to Test Step 2.
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.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.
Restore the electrical power to the ECM.
Monitor the active diagnostic code screen on the electronic service tool. Check and record any active diagnostic codes.Note: Wait at least 30 seconds in order for the diagnostic codes to become active.Expected Result:One of the following diagnostic codes is active:
262-03
262-04 Results:
OK - A 262-03 diagnostic code is active. Proceed to Test Step 4.
OK - A 262-04 diagnostic code is active. Proceed to Test Step 3.
Not OK - No diagnostic code is active.Repair: The problem is no longer present. If the problem is intermittent, refer to Troubleshooting, "Electrical Connectors - Inspect".STOPTest Step 3. Disconnect the +5 V Sensors while you Monitor the Active Diagnostic Codes
Monitor the active diagnostic code screen on the electronic service tool. Check and record any active diagnostic codes.Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
Disconnect the following sensors at the sensor connector:
Intake air (boost) pressure sensor
Engine oil pressure sensor
Fuel pressure sensor
Transmission oil pressure sensor
Transmission oil temperature sensor
Wait for 30 seconds after each sensor is disconnected. Check for an active diagnostic code on the electronic service tool.Expected Result:The 262-04 diagnostic code deactivates.Results:
OK - The 262-04 diagnostic code deactivates. The diagnostic code is not active after a specific sensor is disconnected.Repair: Reconnect the sensor that is suspected of causing the problem. If the problem returns after the reconnection of the sensor, disconnect the sensor. If the problem disappears after the disconnection of the sensor, replace the sensor. Reconnect all wires to the original configuration. Clear all diagnostic codes. Verify that the repair eliminates the problem.STOP
Not OK - The 262-04 diagnostic code stays active. Leave the sensors disconnected. Proceed to Test Step 4.Test Step 4. Check the +5 V Supply Wire for a Short to Engine Ground or a Short to another Wire in the Harness
Remove the electrical power from the ECM.
Disconnect the J2/P2 ECM connector.
Leave the sensors disconnected at the sensor connectors.Note: Wiggle the harness during the following measurements in order to reveal any intermittent short condition.
Measure the resistance from the ECM connector P2-2 (+5 V Supply) to every terminal on ECM connector P2 and ECM connector P1. Measure the resistance from the ECM connector P2-2 to the ECM ground strap.
Measure the resistance from the ECM connector P2-41 (+5 V Supply) to every terminal on ECM connector P2 and ECM connector P1. Measure the resistance from the ECM connector P2-41 to the ECM ground strap.Expected Result:Each resistance measurement is more than 20,000 Ohms.Results:
OK - The resistance check does not indicate a short in the engine harness or a short to engine ground. Proceed to Test Step 5.
Not OK - A resistance measurement is less than 20,000 Ohms. The +5 V supply wire is shorted in the engine harness or the +5 V supply wire is shorted to engine ground.Repair: Repair the wire or replace the wire. Clear all logged diagnostic codes. Reconnect all wires to the original configuration. Verify that the repair eliminates the problem.STOPTest Step 5. Check the +5 V Supply and the Sensor Common for an Open Circuit
Install a wire jumper between terminal P2-2 (+5 V Supply) and terminal P2-3 (Sensor Common).
Install a wire jumper between terminal P2-41 (+5 V Supply) and terminal P2-42 (Sensor Common).Note: Wiggle the harness during the following measurements in order to reveal any intermittent short condition.
Record the resistance at each analog sensor connector between terminal A and terminal B.
Remove the wire jumpers.Expected Result:The resistance is less than 5 Ohms for each measurement.Results:
OK - The resistance check does not indicate an open circuit in the engine harness. Proceed to Test Step 6.
Not OK - A resistance measurement is greater than 5 Ohms. The +5 V supply wire or the sensor common has excessive resistance.Repair: Repair the wires or replace the wires. Clear all logged diagnostic codes. Reconnect all wires to the original configuration. Verify that the repair eliminates the problem.STOPTest Step 6. Check the +5 V Supply at the ECM
Remove the wire 997-OR from ECM connector P2-2 (+5 V Supply). Install a wire jumper with socket terminals on both ends into P2-2.
Remove the wire 993-BR from ECM connector P2-3 (Sensor Common). Install a wire jumper with socket