859506 Volvo.Penta Injection pump

Illustration 1 g00665900
Test Step 1. Check for Connector Damage.
Turn the circuit breaker for the engine to the OFF position.
Turn the keyswitch to the OFF position.
Thoroughly inspect the ECM connectors J1/P1 and 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 6.0 N m (55 lb in).
Check the customer 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 should be 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 need repair.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Stop.Test Step 2. Check the Digital Sensor Supply Voltage at the Sensor Connector.
Disconnect all of the digital sensors at the sensor connectors.
Turn the circuit breaker for the engine to the ON position.
Turn the keyswitch to the ON position. The engine should be off.
Measure the digital sensor supply voltage between terminal-A and the digital return terminal-B of all the digital sensors.Expected Result:The supply voltage should be 8.0 0.4 VDC.Results:
OK - The supply voltage is 8.0 0.4 VDC. The supply voltage is present at all of the digital sensor connectors. Proceed to test step 6.
Not OK - The supply voltage is not 8.0 0.4 VDC. The supply voltage is not correct. Proceed to test step 3.Test Step 3. Check the Digital Supply Voltage at the ECM.
Remove the digital supply line on pin P1-35 of the ECM. Install a jumper into the socket for P1-35.
Remove the digital supply line on pin P1-29 of the ECM. Install a jumper into the socket for P1-29.
Reconnect the ECM connectors.
Turn the circuit breaker for the engine to the ON position.
Turn the keyswitch to the ON position. The engine should be off.
Measure the voltage between the digital supply P1-35 and the digital return P1-29.
Turn the keyswitch to the OFF position.
Turn the circuit breaker for the engine to the OFF position.
Remove the jumpers and replace all wires.Expected Result:The supply voltage should be 8.0 0.4 VDC.Results:
OK - The supply voltage is 8.0 0.4 VDC. The digital sensor supply is producing the correct voltage. Proceed to test step 4.
Not OK - The supply voltage is not 8.0 0.4 VDC. The digital sensor supply is not producing the correct voltage.Repair: Perform the diagnostic functional test Troubleshooting, "Electrical Power Supply". Stop.Test Step 4. Check for a Short Circuit in the Wiring Harness.
Disconnect ECM connector J1/P1, ECM connector J2/P2, and all of the digital sensors.
Measure the resistance between the digital supply wire 700-OR at the ECM connector P1-35 and the digital return wire 998-BR on the ECM connector P1-29.
Measure the resistance between the digital supply wire 700-OR at the ECM connector P1-35 and the engine ground.
Measure the resistance between the digital return wire 998-BR at the ECM connector P1-29 and the engine ground.Expected Result:The resistance should be greater than 20,000 Ohms for each measurement.Results:
OK - The resistance is greater than 20,000 Ohms. Proceed to test step 5.
Not OK - The resistance is less than 20,000 Ohms.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Verify repair by rechecking for shorts in the harness. Stop.Test Step 5. Check for an Open Circuit in the Wiring Harness.
Disconnect ECM connector J1/P1, ECM connector J2/P2, and all of the digital sensors.
Connect a wire jumper between the digital supply wire 700-OR at the ECM connector P1-35 and the digital return wire 998-BR on the ECM connector P1-29. Connect the wire jumper on the ECM side of connector P1.
Measure the resistance between the digital supply terminal-A (700-OR) and the digital return terminal-B (998-BR). Repeat this step at all of the digital sensor connectors.
Remove the wire jumper and reconnect all connectors.Expected Result:The resistance should measure less than 10 Ohms for each measurement.Results:
OK - The resistance measures less than 10 Ohms for each measurement. Proceed to test step 6.
Not OK - The resistance measures more than 10 Ohms for one of the measurements.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Verify the repair by rechecking for shorts in the harness. Stop.Test Step 6. Check the Digital Sensors for Short Circuits.
Connect one digital sensor at a time.
Check the digital sensor supply voltage between the digital supply terminal-A (700-OR) and the digital return terminal-B (998-BR). Repeat this step with all of the digital sensors.Note: The voltage should measure 8.0 0.4 VDC. If a sensor is internally shorted, the voltage will read 0.0 VDC.
Turn the keyswitch to the OFF position.Expected Result:The supply voltage should be 8.0 0.4 VDC.Results:
OK - The supply voltage is 8.0 0.4 VDC. The digital sensor supply and the harness are okay.Repair: The problem may be intermittent. Perform the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors". Stop.
Not OK - The supply voltage is not 8.0 0.4 VDC. The supply voltage is not correct. The sensor may be internally shorted.Repair: Temporarily connect a new sensor. Verify that the new sensor solves the problem before permanently installing the new sensor. Stop.