3858461 Volvo.Penta Gear

Illustration 1 g01046429
Ignition transformer and spark plug (1) Ground spring (2) 2-pin connector (3) Secondary spark plug terminal (4) Extension (5) O-ring seal (6) Spark plugThe secondary circuit of the transformer provides an initial 8,000 to 32,000 volts to the spark plug. This voltage ionizes the spark plug gap. This voltage is then reduced to about 1000 volts. The total duration of the spark is approximately 400 microseconds.The control module checks the secondary circuit for these faults:
The voltage in the secondary circuit is abnormally low.
The voltage in the secondary circuit is abnormally high.
The voltage in the secondary circuit has reached the maximum limit.
Excessive ignition system noiseAbnormal voltages in a secondary circuit will not directly shut down the engine. However, these conditions may lead to misfire which can cause lugging of the engine. Lugging of the engine can cause a shutdown.If there is excessive ignition system noise and the date of the EIS control module's software is earlier than October 1994, the control module will not shut down the engine. If there is excessive ignition system noise and the date of the EIS control module's software is October 1994 or later than October 1994, the control module will shut down the engine.Test Step 1. Check for Diagnostic Codes for the Secondary Circuits
Connect an electronic service tool to a service tool connector.
Attempt to start the engine. Use the service tool in order to determine if the following codes are activated:
401-00 Ignition Transformer Secondary #1 maintenance needed through 416-00 Ignition Transformer Secondary #16 maintenance needed
401-05 Ignition Transformer Secondary #1 open circuit through 416-05 Ignition Transformer Secondary #16 open circuit
401-06 Ignition Transformer Secondary #1 short to ground through 416-06 Ignition Transformer Secondary #16 short to ground
401-12 Ignition Transformer Secondary #1 noisy component through 416-12 Ignition Transformer Secondary #16 noisy componentNote: If a diagnostic code for the secondary circuit is not currently activated, attempt to repeat the condition that activated the code. Run the engine to full operating temperature.Expected Result:None of the above diagnostic codes are activated.Results:
No Code - The secondary ignition is working properly.STOP
Code - The secondary ignition is not working properly. Proceed to Test Step 2.Test Step 2. Inspect the Transformer
Ignition systems can cause electrical shocks. Avoid contacting the ignition system components and wiring.Do not attempt to remove the valve covers when the engine is operating. The transformers are grounded to the valve covers. Personal injury or death may result and the ignition system will be damaged if the valve covers are removed during engine operation. The engine will not operate without the valve covers.
Set the engine control to the OFF/RESET mode. Remove the electrical power from the engine.
Illustration 2 g00893893
(1) Valve cover (2) 2-pin connector
Remove valve cover (1) from the suspect cylinder.
Pulling on the wiring harness may break the wires. Do not pull on the wiring harness.
Disconnect connector (2). Remove the transformer from the engine.
Illustration 3 g01046474
(3) Screw (4) Ground spring (5) Spacer (6) Secondary terminal (7) Extension (8) O-ring seal
Inspect the body of the transformer and ground spring 4 for corrosion and/or damage. Verify that the screws (3) for the ground spring are secure.
Inspect the secondary terminal (6) for the spark plug inside the extension for corrosion and/or damage.
Inspect the O-ring seal (8) inside the extension for damage.
Check for a secure connection between the transformer and the spark plug.Note: Punch through is caused by misfire in the engine that does not generate a diagnostic code.
Check the extension near the spacer for signs of punch through (pin holes) and/or arcing.
The extension can be scratched and damaged with a wire brush. Do not use a wire brush on the extension.
Clean any deposits from the inside of the extension. Use a 6V-7093 Brush with isopropyl alcohol.Expected Result:The transformer is in good condition.Results:
OK - The transformer appears to be in good condition. Proceed to Test Step 3.
Not OK - An inspection found a problem with the transformer.Repair: Repair the transformer, when possible. Replace the transformer, if necessary. Be sure to use the correct transformer for the Electronic Ignition System.Verify that the original problem is resolved.STOPTest Step 3. Check the Resistance of the Transformer's Secondary Winding
Measure the resistance of the ignition transformer according to the engine's Testing and Adjusting manual.Expected Result:The resistance is within the specifications.Results:
OK - The resistance of the transformer's secondary winding is correct. Proceed to Test Step 4.
Not OK - The resistance of the transformer's secondary winding is not correct.Repair: Verify that the electrical power is removed from the engine. Replace the ignition transformer. Make sure that you use the correct transformer for the Electronic Ignition System.STOPTest Step 4. Check the Spark Plug
Perform the following procedures according to the instructions in the engine's Operation and Maintenance Manual.
Remove the spark plug from the cylinder head.
Inspect the spark plug.
Clean the spark plug.
Measure the resistance of the spark plug.Expected Result:The spark plug is in good condition.Results:
OK - The spark plug is in good condition. Proceed to Test Step 5.
Not OK - The spark plug is not in good condition.Repair: Discard the spark plug. Install a new spark plug according to the instructions in the engine's Operation and Maintenance Manual.Verify that the original problem is resolved.STOPTest Step 5. Operate the Engine
Install the spark plug according to the instructions in the engine's Operation and Maintenance Manual.
Install the transformer and the valve cover.
Clear any diagnostic codes.