7748500_014 Volvo.Penta Fitting

Table 1
Diagnostic Trouble Codes for the Starting Motor Relay    
CDL Code     Description     Notes    
444-5     Starter Motor Relay : Current Below Normal     The Electronic Control Module (ECM) detects the following conditions:
A low current condition (open circuit) in the circuit for the starting motor relay for one second.
The ECM has been powered for at least one second.    
444-6     Starter Motor Relay : Current Above Normal     The ECM detects the following conditions:
A high current condition (short circuit) in the circuit for the starting motor relay for at least one second.
The ECM has been powered for at least one second.    
Illustration 1 g03380658
Schematic of the circuit for the starting motor
Illustration 2 g02608541
View of the pin locations on the P1 connector for the starting motor relay (20) Starting motor relay control (64) Start signalThe following background information is related to this procedure:When the keyswitch is turned to the START position, a signal is sent to the transmission neutral switch. If the transmission is in the Neutral position, the signal continues to pin P1:64 on the engine ECM. Power is supplied from P1:20 to the starting motor relay.The starting motor relay supplies battery power to the relay solenoids in the starting motor. This internal relay provides high current battery voltage to the starting motor. Test Step 1. Inspect Electrical Connectors and Wiring
Check that the fuses are not blown.
Check the harness for abrasion and pinch points from the starting motor relay back to the ECM. Check the harness for abrasion and pinch points from the starting motor back to the battery.
Inspect the terminals on the starting motor relay and then inspect the harness connector for the relay. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Inspect the connections on the starting motor.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the starting motor relay.
Check the screw for the ECM connector for the correct torque of 6 N m (53 lb in).Results:
All connectors, pins, and sockets are correctly coupled and/or inserted. The harness is free of corrosion, abrasion, and pinch points. The fuses are not blown. - Proceed to Test Step 2.
There is a fault with the harness and connectors - Repair: Repair the connectors or the harness and/or replace the connectors or the harness. Ensure that all of the seals are correctly in place and ensure that the connectors are correctly connected. Replace blown fuses.
Turn the keyswitch to the ON position. Do not start the engine. Use the electronic service tool to check for active diagnostic codes.
Confirm that the fault has been eliminated.Note: If a fuse is replaced and the fault reoccurs, continue with this procedure.STOPTest Step 2. Check for Active Diagnostic Codes
Connect the electronic service tool to the diagnostic connector.
Start the engine.
Make a note of any active diagnostic codes.Results:
Diagnostic code 444-5 is active. - Proceed to Test step 3.
Diagnostic code 444-6 is active. - Proceed to Test Step 4.
An active diagnostic code was not displayed. - There may be a fault with the start signal from the keyswitch or the power circuit for the starting motor. The ECM does not monitor the status of these conditions. Proceed to Test Step 8.Test Step 3. Create a Short Circuit at the Starting Motor Relay
Turn the keyswitch to the OFF position.
Disconnect the connector for the starting motor relay.
Fabricate a jumper wire that is 150 mm (6 inch) long.
Use the jumper wire to connect pin 1 to pin 2 on the harness connector for the starting motor relay. Refer to Illustration 1.
Turn the keyswitch to the START position.
Use the electronic service tool to check for an active 677-6 diagnostic code.
Turn the keyswitch to the OFF position.
Remove the jumper.Results:
A 444-6 diagnostic code was active with the jumper installed. - Repair: Perform the following repair:
Install a replacement starting motor. Refer to Disassembly and Assembly, "Electric Starting Motor - Remove and Install".
Use the electronic service tool to check for an active 444-5 diagnostic code.
Confirm that the fault has been eliminated.STOP
A 444-5 diagnostic code is still active with the jumper installed. - Reconnect the starting motor relay and proceed to Test Step 5.Test Step 4. Create an Open Circuit at the Relay
Turn the keyswitch to the OFF position.
Disconnect the starting motor relay connector.
Turn the keyswitch to the START position.
Use the electronic service tool to check for an active 677-5 diagnostic code.
Turn the keyswitch to the OFF position.
Reconnect the starting motor relay connector.Results:
A 444-5 diagnostic code became active with the starting motor relay disconnected. - The wiring for the starting motor relay is OK.Repair: Perform the following repair:
Install a replacement starting motor. Refer to Disassembly and Assembly, "Electric Starting Motor - Remove and Install".
Use the electronic service tool to check for an active 444-5 diagnostic code.
Confirm that the fault has been eliminated.STOP
A 444-6 diagnostic code is still active with the starting motor relay disconnected. - The starting motor relay is OK. Proceed to Test Step 5.Test Step 5. Bypass the Engine Harness
Turn the keyswitch to the OFF position.
Disconnect the P1 connector.
Disconnect the starting motor relay connector.
Remove the wire from P1:20.
Remove the wire from socket 1 starting motor relay connector.
Fabricate a jumper wire that is long enough to reach from the ECM to the starting motor relay connector.
Insert one end of the jumper into P1:20. Insert the other end of the jumper into socket 1 on the starting motor relay connector.
Reconnect the P1 connector. Reconnect the starting motor relay connector.
Attempt to start the engine. Use the electronic service tool to check for an