3803276 Volvo.Penta Injector

Illustration 1 g00782538
Typical schematic
Test Step 1. Check for Connector Damage.
Turn the circuit breaker for the battery to the OFF position.
Turn the keyswitch to the OFF position.
Disconnect the main power.
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 2.25 0.25 N m (20 2 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:All connectors, pins, and sockets are completely coupled and/or inserted. The harness and wiring should not have corrosion, abrasion or pinch points.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.STOPTest Step 2. Check for an "ACTIVE" Diagnostic Code.
Connect the Cat ET to the cab service tool connector J42. Start the Cat ET.
Turn the circuit breaker for the battery to the ON position.
Turn the keyswitch to the ON position.
Observe the Logged Diagnostic Codes on the Cat ET. Expected Result:The Cat ET should indicate a CID-FMI 190 or 342 diagnostic code.Results:
OK - The Cat ET indicates a CID-FMI 190-02, CID-FMI 190-03 or a CID-FMI 190-08 diagnostic code. The Cat ET indicates a CID-FMI 342-02, CID-FMI 342-03, or a CID-FMI 342-08 diagnostic code. Proceed to Test Step 5.
OK - The Cat ET indicates a CID-FMI 190-07 or 342-07 diagnostic code. Proceed to Test Step 3.Test Step 3. Check the Engine Speed/Timing Sensor.
Be sure to extend the sliphead before installing the Speed/Timing Sensor and also check that the Timing Gear is in a position that will not allow the sliphead of the Speed/Timing Sensor to protrude into the slot of the Timing Gear before the sensor is installed (visually inspect with a flashlight). Turn the crankshaft to rotate the Timing Gear, if necessary, to position the gear in a place that will not allow the sliphead to protrude into a slot. If the sensor sliphead does protrude into one of the slots, the sliphead will be broken off as the gear begins to rotate.
Turn the keyswitch to the OFF position.
Disconnect the sensor and remove the sensor.
Inspect the plastic sliphead for damage.
Check the tension. Gently extend the sliphead 3.5 mm (0.14 inch). Return the sliphead to the original position.
Extend the sliphead and reinstall the sensor. Expected Result:The sliphead should take at least 22 N (5 lb) of force in order to push in the sliphead from the extended position.Results:
OK - The Engine Speed/Timing sensor and the sliphead are undamaged. The tension on the sliphead is normal. Reinstall the sensor. Proceed to Test Step 4.
Not OK - The Engine Speed/Timing sensor or the sliphead is damaged, or the sliphead has insufficient tension.Repair: Replace the sensor. Calibrate the sensor. Perform the calibration procedure Troubleshooting, "Engine Speed/Timing Sensor - Calibrate".STOPTest Step 4. Check the Engine Speed.
Turn the keyswitch to the OFF position.
Connect the Cat ET.
Start the engine.
Observe the engine speed on the display screen of the Cat ET. Expected Result:The Cat ET should display a steady reading between 100 and 250 rpm. The engine should start.Results:
OK - The Engine Speed/Timing sensor is operating correctly at this time.Repair: There may be an intermittent problem. If the problem is intermittent, perform the diagnostic functional test Troubleshooting, "Inspecting Electrical Connectors".STOP
ENGINE DOES NOT START - An Engine speed appears on the display screen of the Cat ET. The engine does not start.Repair: Refer to the diagnostic procedure Troubleshooting, "Engine Cranks but Will Not Start".STOP
NO ENGINE SPEED SIGNAL - The engine will not start and no engine speed signal appears on the display screen on the Cat ET. Proceed to Test Step 5.Test Step 5. Check the Supply Voltage at the Connector for the Engine Speed/Timing Sensor.
Turn the keyswitch to the ON position.
Measure the voltage between P20-A and P20-B at the sensor connector if the problem is with the Rear engine's Primary Engine Speed/Timing sensor or the Front engine's Primary Engine Speed/Timing sensor.
Measure the voltage between P44-A and P44-B at the sensor connector if the problem is with the Rear engine's Secondary Engine Speed/Timing sensor or the Front engine's Secondary Engine Speed/Timing sensor.
Turn the keyswitch to the OFF position. Expected Result:The voltage should be 12 .5 VDC.Results:
OK - The voltage is 12 .5 VDC for all Engine Speed/Timing sensors. Proceed to Test Step 6.
Not OK - Rear or Front Engine Primary Engine Speed/Timing sensor - The voltage is not 12 .5 VDC. Proceed to Test Step 7.
Not OK - Rear or Front Engine Secondary Speed/Timing sensor - The voltage is not 12 .5 VDC. Proceed to Test Step 8.Test Step 6. Check the Isolated Signal at the Sensor Connector.
Remove pin-C from the connector for the Engine Speed/Timing sensor.
Turn the keyswitch to the ON position.
Measure the voltage between the wire that was removed from pin-C and pin-B of the connector for the Engine Speed/Timing sensor. Perform this step before you crank the engine. Perform this step while you are cranking the engine.
Turn the keyswitch to the OFF position.
Reinstall the wire into pin-C of the connector for the Engine Speed/Timing sensor. Expected Result:With the keyswitch in the ON position, the voltage should be less than 3.0 or the voltage should be greater than 10.0 VDC before you crank the engine. The voltage should be 2.0 to 7.0 V