20849979 Volvo.Penta Insert, exhaust

Illustration 1 g00833062
Typical schematic
Illustration 2 g01072835
P1 ECM connector (P1-24) Low oil level (P1-29) Digital returnTest Step 1. Inspect Electrical Connectors and Wiring
Turn the keyswitch to the OFF position.
Thoroughly inspect the ECM connectors J1/P1. Inspect the connector for the low oil level switch. Refer to 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:All connectors, pins, and sockets are completely coupled and/or inserted. The harness and wiring are free of corrosion, of abrasion, and of pinch points.Results:
OK - The harness and wiring are OK. Proceed to Test Step 2.
Not OK - There is a problem in 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 the Level of the Engine Oil
Check the engine oil level.
Ensure that the correct engine oil dipstick is installed.
Check for external oil leaks.Expected Result:The engine oil is at the correct level.Results:
OK - The engine oil level is correct. Proceed to Test Step 3.
Not OK - The engine oil level is not correct.Repair: If necessary, add oil to the engine.STOPTest Step 3. Check the Engine Oil Level on the Caterpillar Electronic Technician (ET)
Connect Cat ET to the service tool connector.
Turn the keyswitch to the ON position. The engine should be off.
Observe the "Engine Oil Level" reading on Cat ET.Expected Result:The "Engine Oil Level" reads "OK".Results:
OK - The "Engine Oil Level" does read "OK".Repair: The switch signal is correct.STOP
Not OK - The "Engine Oil Level" does not read "OK". The switch signal is not correct. Proceed to Test Step 4.Test Step 4. Short the Wires at the Low Oil Level Switch
Disconnect connector J112/P112 of the low oil level switch.
Use a wire to short P112-1 to P112-2.
Turn the keyswitch to the ON position. The engine should be off.
Observe the status of the "Engine Oil Level" on Cat ET.
Remove the wire short.
Observe the status of the "Engine Oil Level" on Cat ET.
Turn the keyswitch to the OFF position.Expected Result:Cat ET indicates "OK" when the wire short is installed. The Cat ET indicates "LOW" when the wire short is removed.Results:
OK - Cat ET indicates "OK", when the wire short is in place. Cat ET indicates "LOW", when the wire short is removed. Cat ET recognized the input from the switch.Repair: Temporarily replace the switch. Verify that the new switch solves the problem before you permanently install the new switch.STOP
Not OK - Cat ET does not indicate "OK", when the wire short is in place. Cat ET does not indicate "LOW", when the wire short is removed. Cat ET does not recognize the input from the switch. Proceed to Test Step 5.Test Step 5. Check for Shorts in the Wiring Harness
Disconnect ECM connector J1/P1.
Measure the resistance between P1-24 and every terminal on ECM connector P1.
Measure the resistance between P1-24 and the engine ground.Expected Result:The resistance is greater than 20,000 Ohms.Results:
OK - The resistance is greater than 20,000 Ohms. Proceed to Test Step 6.
Not OK - The resistance is less than 20,000 Ohms. There is a short in the wiring harness.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 6. Check for an Open in Wiring Harness
Use a wire to short P112-1 to P112-2.
Measure the resistance between P1-24 and P1-29 at the ECM connector.Expected Result:The resistance is less than 5 Ohms.Results:
OK - The resistance is less than 5 Ohms. Proceed to Test Step 7.
Not OK - The resistance is greater than 5 Ohms. There is an open circuit or excessive resistance in the wiring harness.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 7. Short the Input Wires of the Low Oil Level Switch at the ECM Connector
Disconnect ECM connector P1.
Remove the wire from P1-24 (low oil level). Install a wire jumper with a socket on one end into P1-24.
Remove the wire from P1-29 (digital return). Install a wire jumper with a socket on one end into P1-29.
Connect a wire jumper between the wire jumpers in P1-24 and P1-29.
Reconnect all connectors.
Turn the keyswitch to the ON position. The engine should be off.Note: Additional diagnostic codes will be generated because the digital return will no longer be connected to the other sensors and switches. Ignore the codes and clear the codes when you complete this test.
Observe the status of the "Engine Oil Level" on Cat ET.
Turn the keyswitch to the OFF position.
Disconnect ECM connector J1/P1 and remove the wire short.
Reconnect all connectors.
Turn the keyswitch to the ON position. The engine should be off.
Observe the status of the "Engine Oil Level" on Cat ET.
Turn the keyswitch to the OFF position.
Disconnect ECM connector J1/P1 and remove the wire short.
Reconnect all connectors.Expected Result:Cat ET indicates "OK" when the wire short is installed. Cat ET indicates "LOW" when the wire short is removed.Results:
OK - Cat ET indicates "OK", when the wire short is installed. Cat ET indicates "LOW", when the wire short is removed. The harness is faulty.Repair: Repair the connectors or wiring and/or replace the connectors or wiring.STOP
Not OK - Cat ET does not indicate "OK", when the wire short is in place. Cat ET does not indicate "LOW", when the wire short is removed. The ECM is not reading the switch position.Repair: Replace the ECM. Refer to Troubleshooting, "Replacing the ECM".STOP