3850379 Volvo.Penta Gasket kit, intake manifold

Illustration 1 g01804053
Typical schematic of the circuit for the indicator lamps
Illustration 2 g01804073
Typical example of the pin locations on the P1 connector for the indicator lamps (1) Ground (GND) (2) Ground (GND) (3) Ground (GND) (9) Ground (GND) (10) Ground (GND) (7) Battery (+) (8) Battery (+) (15) Battery (+) (16) Battery (+) (40) Keyswitch (59) Warning lamp (60) Stop lamp (61) PTO lamp (62) Low oil pressure lamp (63) Cold start lampTest Step 1. Inspect Electrical Connectors and Wiring
Turn the keyswitch to the OFF position.
Thoroughly inspect the P1 connector and the lamp connections. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the P1 connector that are associated with the indicator lamps.
Check the screw for the P1 connector for the correct torque of 5.0 N m (44 lb in).
Check the harness for abrasions and for pinch points from the battery to the ECM.Results:
OK - Proceed to Test Step 2.
Not OK - 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 completely coupled.Verify that the repair eliminates the fault.STOPTest Step 2. Inspect the Lamp, the Fuse and the Power Supply
Disconnect the lamp from the harness. Inspect the lamp in order to determine if the lamp has failed.
Measure the resistance across the two terminals of the lamp. If the resistance is more than 2000 Ohms, the bulb has failed.
Check the battery by connecting a test lamp across the terminal of the battery.Expected Result:The lamp has less than 2000 Ohms and the power supply is OK.Results:
OK - The lamp appears to be operating correctly at this time. Proceed to Test Step 3.
Not OK - Repair: Replace the suspect component or repair the suspect component. Verify that the repairs have eliminated the fault.STOPTest Step 3. Measure the Input to the Lamp at the Lamp Socket
Turn the keyswitch to the ON position.
Use the electronic service tool to select the "override" function in order to switch individual lamps ON and OFF.Note: The "Override" function is contained in the "Diagnostics" menu of the electronic service tool.
Measure the voltage at the lamp socket.Expected Result:The voltage should be between 12.0 Volts DC and 24.0 Volts DC.Results:
OK - The voltage is between 12.0 Volts DC and 24.0 Volts DC.Repair: Replace the bulb.Verify that the repair eliminates the fault.If the fault persists, measure the resistance across the 2 terminals of the lamp. If the resistance is more than 2000 Ohms, the replacement bulb has failed. Replace the bulb and repeat the test. If the fault persists, proceed to Test Step 4.
Not OK - The voltage is not in the range that is expected. Proceed to Test Step 5.Test Step 4. Test the Individual Lamp Circuits
Disconnect the P1 connector.
Temporarily disconnect the wire from the P1 connector socket that is connected to the suspect lamp.
By using a jumper wire, connect the removed wire to the battery-.
Turn the keyswitch to the ON position and observe the lamp.Expected Result:The diagnostic lamp comes on while the jumper is connected. Also, the diagnostic lamp goes off when the jumper is removed.Results:
OK - The circuit for the diagnostic lamp is functioning correctly. Proceed to Test Step 5.
Not OK - The lamp did not turn ON. The lamp circuit is not functioning correctly. There is a fault in the harness between the lamp and the ECM.Repair: Repair the lamp circuit.Verify that the repair eliminated the fault.STOPTest Step 5. Check the Voltage at the ECM
Disconnect the P1 connector.
Temporarily disconnect the wire from the P1 connector that supplies the suspect lamp.
Fabricate the jumper wire with a suitable pin for the P1 connector.
Install one end of the jumper wire into the P1 connector socket that is connected to the suspect lamp. Connect a voltage test bulb between the battery+ and the jumper wire.
Reinstall the P1 connector to the ECM.
Turn the keyswitch to the ON position. Use the electronic service tool to select the override function in order to switch individual lamps ON and OFF.Note: The "Override" function is contained in the "Diagnostics" menu of the electronic service tool.Expected Result:The lamp should illuminate.Results:
OK - The ECM is operating correctly. There is a fault in the wiring or the lamp. Repair the wiring or the lamp, as required. Verify that the repair eliminates the fault.
STOP
Not OK - The ECM is faulty.Repair: Perform the following repair:
Make sure that the latest flash file for the application is installed in the ECM. Refer to Troubleshooting, "Flash Programming".
Contact the Technical Communicator.Note: This consultation can greatly reduce the repair time.
If the Technical Communicator recommends the use of a test ECM, install a test ECM. Refer to Troubleshooting, "Replacing the ECM".
Use the electronic service tool to recheck the system for active diagnostic codes.
If the fault is resolved with the test ECM, reconnect the suspect ECM.
If the fault returns with the suspect ECM, replace the ECM.
Use the electronic service tool in order to clear all logged diagnostic codes and then verify that the repair eliminates the fault.STOP