837932 Volvo.Penta Intermediate section

The position sensor is an integral part of the fuel rack solenoid. If the following procedure indicates a fault with the position sensor, then the entire solenoid must be replaced.The following background information is related to this procedure:The ECM supplies 5 VDC to terminal "B" of the fuel rack solenoid position sensor connector. The sensor common from the ECM connector goes to terminal "A" of the fuel rack solenoid position sensor connector. The sensor supply is output short circuit protected. A short circuit to the battery will not damage the circuit inside the ECM. The signal voltage from terminal "C" of the fuel rack solenoid position sensor connector is supplied to P2:49 on the ECM connector.
Illustration 1 g03695146
Schematic for the fuel rack position sensor
Illustration 2 g03330798
Typical view of the pin locations on the P2 connector for the position sensors
(48) Fuel rack solenoid position sensor ground
(49) Fuel rack solenoid position sensor 5 VDC supply
(50) Fuel rack solenoid position sensor signal
Illustration 3 g03330886
View of the harness connector for the fuel rack solenoid position sensor
(A) Fuel rack position sensor ground
(B) Fuel rack position sensor 5 VDC supply
(C) Fuel rack solenoid position sensor signal
Table 2
Troubleshooting Test Steps Values Results
1. Verify All Active and Recently Logged Diagnostic Codes
A. Turn the keyswitch to the ON position. Wait at least 10 seconds for activation of the diagnostic codes.
B. Verify if any of the diagnostic codes that are listed in Table 1
Diagnostic codes
Result: None of the preceding diagnostic codes are active or recently logged.
The fault may be intermittent. Refer to Troubleshooting, "Electrical Connectors - Inspect" in order to identify intermittent faults.
Result: One or more of the preceding diagnostic codes are active or recently logged.
Proceed to Test Step 2.
2. Inspect Electrical Connectors and Wiring
A. Thoroughly inspect the terminal connections on the P2/J2 ECM connectors.
B. Thoroughly inspect the connector for the fuel rack solenoid position sensor.
C. Refer to Troubleshooting, "Electrical Connectors - Inspect".
D. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector that are associated with the fuel rack solenoid position sensor.
E. Check the harness for abrasions and for pinch points from the fuel rack solenoid position sensor back to the ECM.
Loose connection or damaged wire
Result: There is a fault in a connector or the wiring.
Repair the connectors or the harness and/or replace the connectors or the harness. Ensure that all of the seals are correctly in place and ensure that the connectors are correctly connected.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: All connectors, pins, and sockets are correctly connected and/or inserted and the harness is free of corrosion, of abrasion and of pinch points.
Proceed to Test Step 3.
3. Measure the Supply Voltage at the Sensor Connector
A. Turn the keyswitch to the OFF position.
B. Disconnect the fuel rack solenoid position sensor from the harness.
C. Turn the keyswitch to the ON position.
D. Measure the voltage between terminal A and terminal B on the harness connector for the sensor.
E. Reconnect the sensor to the harness.
4.9V to 5.1 V
Result: The measured voltage is not within the expected range.
Proceed to Test Step 4.
Result: The measured voltage is within the expected range.
Proceed to Test Step 5.
4. Measure the Supply Voltage at the ECM
A. Turn the keyswitch to the OFF position.
B. Disconnect the P2 connector from the ECM.
C. Turn the keyswitch to the ON position.
D. Use a suitable multimeter to measure the voltage between J2:48 and J2:50.
E. Turn the keyswitch to the OFF position.
F. Reconnect the P2 connector.
4.9 V to 5.1 V
Result: The voltage measurement is within the expected range.
The fault is in the 5 VDC supply wire or the ground wire between the sensor connector and the P2 connector.
Replace the faulty wiring.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: The voltage measurement is not within the expected range.
Proceed to Test Step 10.
5. Verify the Type of Active Diagnostic Code
A. Turn the keyswitch to the ON position. Wait at least 10 seconds for activation of the diagnostic codes.
B. Use the electronic service tool to check for active diagnostic codes. Record all active diagnostic codes.
Diagnostic codes
Result: A 733-4 diagnostic code is active at this time.
Proceed to Test Step 6.
Result: A 733-3 diagnostic code is active at this time.
Proceed to Test Step 8.
Result: A short circuit diagnostic code is not active. An open circuit diagnostic code is not active.
An intermittent fault may exist.
Refer to Troubleshooting, "Electrical Connectors - Inspect" in order to identify intermittent faults.
6. Create an Open Circuit at the Sensor Connector
A. Turn the keyswitch to the OFF position.
B. Disconnect the fuel rack solenoid position sensor connector.
C. Turn the keyswitch to the ON position. Wait for at least 10 seconds for activation of the diagnostic codes.
D. Use the electronic service tool to check the "Active Diagnostic Code" screen. Check for a 733-3 diagnostic code.
E. Turn the keyswitch to the OFF position.
Diagnostic codes
Result: A 733-3 diagnostic code is active with the sensor disconnected.
Reconnect the connector for the sensor.
Turn the keyswitch to the ON position. Use the electronic service tool to check for active diagnostic codes.
If the 733-4 diagnostic code returns, there is a short in the sensor.
Install a replacement fuel rack solenoid. Refer to Disassembly and Assembly, "Position Sensor (Governor Control) - Remove and Install" for the correct procedure.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: The 733-4 diagnostic code remains active with the sensor disconnected.
Reconnect the sensor. Proceed to Test Step 7.
7. Create an Open Circuit at the ECM Connector
A. Turn the keyswitch to the OFF position.