840013 Volvo.Penta Instrument panel

Illustration 1 g03837117
Schematic for the main relay
Illustration 2 g03837131
Main relay
Complete the procedure in the order in which the steps are listed.
Table 2
Troubleshooting Test Steps Values Results
1. Inspect Electrical Connectors and Wiring
A. Inspect the terminals on the start relay. Refer to Troubleshooting, "Electrical Connector - Inspect" for details.
B. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connectors that are associated with the start relay.
C. Check the harness for abrasion and pinch points from the start relay back to the ECMs.
D. Check that neither of the two 30 Amp fuses on the main relay are blown.
Loose connection or damaged wire
Result: There is a fault in a connector or the wiring.
Repair: Repair any faulty connectors or replace the wiring harness. Ensure that all of the seals are properly in place and ensure that the connectors are correctly coupled.
Result: A 30 Amp fuse on the main relay is blown.
Repair: Replace the blown fuse.
Proceed to Test Step 2.
Result: All connectors, pins, and sockets are correctly coupled and/or inserted. The harness is free of corrosion, abrasion, and pinch points. The fuses are not blown.
Proceed to Test Step 2.
2. Check for Active Diagnostic Codes
A. Connect the electronic service tool to the diagnostic connector.
B. Turn the keyswitch to the ON position.
Note: Do not start the engine.
C. Use the electronic service tool to check for active diagnostic codes.
D. Turn the keyswitch to the OFF position.
Diagnostic codes
Result: No diagnostic code is active or recently logged.
Confirm that the fault is eliminated and then return the unit to service.
Result: Diagnostic code 1485-14 is active or recently logged.
Proceed to Test Step 3.
3. Check the Supply Voltage at the Main Relay Connector
A. Disconnect the two pin connector from the main relay.
B. Turn the battery isolator to the ON position.
C. Measure the voltage between Test Point 1 on the two pin connector and a suitable ground.
D. Turn the battery isolator to the OFF position.
At least 11 VDC
Result: The voltage is not within the expected range.
Repair: Repair or replace the supply wiring to the main relay.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: The voltage is within the expected range.
Proceed to Test Step 4.
4. Check the Control Wire from the Main Relay to the Engine ECM
A. Turn the battery isolator to the OFF position.
B. Disconnect the P1 connector from the engine ECM.
C. Disconnect the two pin connector from the main relay.
D. Measure the resistance between Test Point 2 on the 2 pin connector and P1:33 and P1:34.
E. Connect the two pin connector to the main relay.
F. Connect the P1 connector to the engine ECM.
Less than 2.0 Ohms
Result: The measured resistance is more than 2.0 Ohms.
Repair: Repair or replace the control wire from the main relay to the ECM.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: The measured resistance is less than 2.0 Ohms.
Proceed to Test Step 5.
5. Check the Main Relay Solenoid for an Open Circuit
A. Turn the battery isolator to the OFF position.
B. Disconnect the two pin connector from the main relay.
C. Measure the resistance between Test Points 1 and 2 on the main relay. Refer to Illustration 2.
D. Connect the two pin connector from the main relay.
80 to 100 Ohms
Result: The measured resistance is outside the range of 80 to 100 Ohms.
Repair: Install a replacement main relay.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: The measured resistance is within 81 to 133 Ohms.
Proceed to Test Step 6.
6. Check the Wiring for a Short Circuit
A. Turn the battery isolator to the OFF position.
B. Disconnect the two pin connector from the main relay.
C. Disconnect the P1 connector from the ECM.
D. Disconnect the power terminal from Test Point 4 on the main relay.
E. Measure the resistance between P1:33 and all other pins on the P1 connector. Refer to Illustration 1.
F. Measure the resistance between P1:34 and all other pins on the P1 connector. Refer to Illustration 1.
G. Measure the resistance between P1:5 and all other pins on the P1 connector. Refer to Illustration 1.
H. Measure the resistance between P1:6 and all other pins on the P1 connector. Refer to Illustration 1.
I. Connect the power terminal to Test Point 4 on the main relay.
J. Connect the P1 connector to the ECM.
K. Connect the two pin connector to the main relay.
More than 1k Ohms
Result: A measured resistance is less than 1k Ohms.
Repair: Repair or replace the wiring between the main relay and the ECM.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: All resistance measurements are more than 1k Ohms.
Contact the Dealer Solutions Network (DSN).