21456469 Volvo.Penta Insert

Illustration 1 g00602826
Test Step 1. Check for Connector Damage
Turn the circuit breaker for the battery to the OFF position.
Turn the ECS to the OFF/RESET position.
Disconnect the main power.
Thoroughly inspect the ECM connectors J1/P1 and J2/P2. Inspect all of the other connectors. Perform the diagnostic functional testTroubleshooting, "Inspecting Electrical Connectors".
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 pinch points.Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted, and the harness and wiring should be free of 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. Stop.Test Step 2. Check for a CID-FMI.
Connect the Caterpillar Electronic Technician (ET).
Turn the circuit breaker for the battery to the ON position.
Turn the ECS to the STOP position.
Observe Logged Diagnostic Codes on the Cat ET.Expected Result:The Cat ET should indicate a CID-FMI 190-03 or 342-03.Results:
OK - The Cat ET indicates a CID-FMI 190-03 or 342-03. Proceed to test step 3.
Not OK - The Cat ET does not indicate a CID-FMI 190-03 or 342-03. Proceed to test step 4.Test Step 3. Check for Shorts in Wiring Harness
Turn the ECS to the OFF/RESET position.
Disconnect J1/P1 from the Primary ECM. Disconnect J1/P1 from the Secondary ECM. Disconnect the Primary Engine Speed/Timing Sensor J20/P20. Disconnect the Secondary Engine Speed/Timing Sensor J44/P44.
To test the Primary Engine Speed/Timing Sensor, measure the resistance at the Primary ECM connector P1:Measure the resistance between P1-38 and P1-29.Measure the resistance between P1-38 and P1-30.Measure the resistance between P1-38 and P1-32.Measure the resistance between P1-32 and P1-29.Measure the resistance between P1-32 and P1-30.Measure the resistance between P1-32 and P1-39.Measure the resistance between J20-A and engine ground.Measure the resistance between J20-B and engine ground.Measure the resistance between J20-C and engine ground.
To test the Secondary Engine Speed/Timing Sensor, measure the resistance at the Secondary ECM connector P1:Measure the resistance between P1-39 and P1-29.Measure the resistance between P1-39 and P1-32.Measure the resistance between P1-32 and P1-29.Measure the resistance between P1-32 and P1-38.Measure the resistance between J44-A and engine ground.Measure the resistance between J44-B and engine ground.Measure the resistance between J44-C and engine ground.Expected Result:The resistance should be greater than 20,000 Ohm.Results:
OK - The resistance is greater than 20,000 Ohm. 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. Stop.Test Step 4. 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 ECS to the OFF/RESET 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.Note: If you are troubleshooting the Primary Engine Speed/Timing Sensor, disconnect the secondary sensor for the remainder of the test. If you are troubleshooting the Secondary Engine Speed/Timing Sensor, disconnect the primary sensor for the remainder of the test.Expected Result:The sliphead should take at least 22 N (5 lb)of force 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 6.
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". Stop.Test Step 5. Check the Resistance through the Harness.
Turn the ECS to the OFF/RESET position.
Disconnect J1/P1 from the Primary ECM. Disconnect J1/P1 from the Secondary ECM. Disconnect the Primary Engine Speed/Timing Sensor J20/P20. Disconnect the Secondary Engine Speed/Timing Sensor J44/P44.
For the Primary Engine Speed/Timing Sensor, perform the following steps.
Use a suitable piece of wire to short J20-A and J20-B together.
Measure the resistance between P1-32 and P1-29. Wiggle the harness during the measurement in order to reveal an intermittent condition.
Use a suitable piece of wire to short J20-A and J20-C.
Measure the resistance between P1-32 and P1-38. Wiggle the harness during the measurement in order to reveal an intermittent condition.
For the Secondary Engine Speed/Timing Sensor, perform the following steps.
Use a suitable piece of wire to short J44-A and J44-B.
Measure the resistance between P1-32 and P1-29. Wiggle the harness during the measurement in order to reveal an intermittent condition.
Use a suitable piece of wire to short J44-A and J44-C together.
Measure the resistance between P1-32 and P1-39. Wiggle the harness during the measurement in order to reveal an intermittent condition.
Measure the resistance between Primary ECM connector P1-38 and Secondary ECM connector P1-38. Wiggle the harness during the measurement in order to reveal an intermittent condition.
Measure the resistance between Primary ECM connector P1-39 and Secondary ECM connector P1-39. Wiggle the harness during the measurement in order to reveal an intermittent condition.Expected Result:The resistance should be less than 10 Ohms through the wires.Results:
OK - The resistance is less than 10 Ohms through the wires. Proceed to test step 11.
Not OK - The resistance is greater than 10 Ohms through the wires. There is an open