866560 Volvo.Penta Injection pump

Illustration 1 g01119633
Schematic
Illustration 2 g01024457
P2 ECM connector
(P2-15) Boost pressure sensor
(P2-17) Sensor common
(P2-28) Engine oil pressure sensor
(P2-40) Fuel pressure sensor
(P2-57) Atmospheric pressure sensor
(P2-72) +5 V Supply
Illustration 3 g01119636
C13 Sensor locations
(1) Atmospheric pressure sensor
(2) Fuel pressure sensor
(3) Engine oil pressure sensor
(4) Boost pressure sensor
Illustration 4 g01252438
C15 and C18 Sensor locations
(5) Boost pressure sensor
(6) Fuel pressure sensor
(7) Atmospheric pressure sensor
(8) Engine oil pressure sensor
Illustration 5 g01094844
Sensor connector
Test Step 1. Inspect Electrical Connectors and Wiring
Turn OFF the power to 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 for 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 or 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 Caterpillar Electronic Technician (ET) to the service tool connector.
Restore electrical power to the ECM.
Monitor the active diagnostic code screen on Cat ET. Check and record any active diagnostic codes. Look for the following diagnostic codes:
262-3
262-4 Note: Wait at least 30 seconds in order for the diagnostic codes to become active.Expected Result:No diagnostic codes are active.Results:
OK - No diagnostic code is active.Repair: The problem is no longer present. If the problem is intermittent, refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - Either the 262-3 or 262-4 diagnostic code is active at this time. Proceed to Test Step 3.Test Step 3. Disconnect the 5 Volt Sensors while you Monitor the Active Diagnostic Codes
Monitor the active diagnostic code screen on Cat ET while you disconnect each 5 Volt sensor at the sensor connector. Check for an active 262-3 code or an active 262-4 code. Note: Wait at least 30 seconds in order for the diagnostic codes to become active.
Disconnect the following sensors one at a time:
Boost pressure sensor
Engine oil pressure sensor
Fuel pressure sensor
Atmospheric pressure sensor
Remove electrical power from the ECM. Expected Result:The diagnostic code deactivates when a particular sensor is disconnected.Results:
OK - The 262-3 or 262-4 diagnostic code deactivates when a particular sensor is disconnected.Repair: Connect the suspect sensor. If the code returns, replace the sensor. Connect all of the connectors. Verify that the problem is resolved.STOP
Not OK - The 262-3 or 262-4 diagnostic code remains active after all of the sensors are disconnected. Leave the sensors disconnected. The sensors are not the cause of the diagnostic code. Proceed to Test Step 4.Test Step 4. Check the 5 Volt Supply Voltages at the ECM
Disconnect the J2/P2 ECM connector.
Fabricate two jumper wires that are long enough to be used to measure the supply voltage at the ECM connectors. Crimp connector sockets to one end of each jumper wire.
Remove the wires from terminal locations P2-72 (5 V sensor supply) and P2-17 (sensor return). Install a jumper wire into each of these terminal locations.
Connect the J2/P2 ECM connector.
Restore electrical power to the engine ECM.
Measure the voltage between the jumper wire in P2-72 (5 V sensor supply) and the jumper wire in P2-17 (sensor return).
Remove electrical power from the ECM. Expected Result:The voltage measurement is 5.0 0.2 VDC.Results:
OK - The voltage measurement is 5.0 0.2 VDC. The ECM is operating correctly.Repair: The supply wire is shorted to another wire in the harness or the supply wire is shorted to engine ground. Repair the supply wire.STOP
Not OK - The voltage measurement is not 5.0 0.2 VDC.Repair: Replace the ECM. Refer to Troubleshooting, "Replacing the ECM".STOP