1622515 Volvo.Penta Level relay

Illustration 1 g03721809
Schematic diagram for the DEF tank header unit
Not all connectors are shown. Refer to the Electrical Schematic for the application.
Illustration 2 g03721884
View of the pin locations on the P1 connector for the DEF tank header unit.
(23) CAN 2 +
(45) CAN 2 -
Illustration 3 g03722336
View of the connector for the DEF tank header unit
(1) CAN C -
(2) CAN C +
(3) Ground
(4) Battery +
Table 2
Troubleshooting Test Steps Values Results
1. Inspect Electrical Connectors and Wiring
A. Check the fuses.
B. Inspect the P1/J1 ECM connectors.
C. Inspect the connector for the DEF tank header unit.
D. Perform a 30 N (6.7 lb) pull test on each of the wires in the ECM connector and the connector for the DEF tank header unit.
E. Check all of the wiring associated with the DEF tank header unit for abrasions and pinch points.
Damaged wire or connector
Result: A damaged wire or damaged connector was not found. The fuses are OK
Proceed to Test Step 2.
Result: A damaged wire or damaged connector was found. A fuse is blown.
Repair: Repair the damaged wire or the damaged connector. Replace any blown fuses.
Use the electronic service tool to clear all logged diagnostic codes. Verify that the repair eliminates the fault.
2. Check for Active or Recently Logged Diagnostic Codes
A. Connect the electronic service tool to the diagnostic connector. Refer to Troubleshooting, "Electronic Service Tools"
B. Look for active or logged diagnostic codes.
Diagnostic Trouble Codes
Result: One or more of the diagnostic codes listed in Table 1 is active.
Proceed to Test Step 3.
Result: There is an active diagnostic code relating to the CAN data link.
Repair: Refer to Troubleshooting, "CAN Data Link - Test" before returning to this procedure.
Result: One or more of the diagnostic codes listed in Table 1 is recently logged.
Repair: There may be an intermittent fault. Refer to Troubleshooting, "Electrical Connector - Inspect" in order to identify intermittent faults.
3. Check the Power Supply to the Auxiliary Main Relay
A. Turn the keyswitch to the OFF position.
B. Disconnect the auxiliary main relay.
C. Turn the keyswitch to the ON position.
D. Use a multimeter to measure the voltage between terminal 30 on the harness connector for the auxiliary main relay and a suitable ground.
E. Turn the keyswitch to the OFF position.
10 V to 14 V
Result: The measured voltage is not within the expected range.
There is a fault in the power supply wiring between the auxiliary main relay and battery (+).
Repair: 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 measured voltage is within the expected range.
Proceed to Test Step 4.
4. Check the Power Supply from the ECM Main Relay
A. Turn the keyswitch to the OFF position.
B. Disconnect the auxiliary main relay.
C. Use a multimeter to measure the voltage between terminal 86 on auxiliary main relay and a suitable ground.
10 V to 14 V
Result: The measured voltage is not within the expected range.
Proceed to Test Step 5.
Result: The measured voltage is within the expected range.
Proceed to Test Step 6.
5. Check the Wiring Between the Auxiliary Main Relay and the ECM Main Relay
A. Turn the keyswitch to the OFF position.
B. Disconnect the auxiliary main relay.
C. Disconnect the ECM main relay.
D. Use a multimeter to measure the resistance between terminal 86 on the harness connector for the auxiliary main relay and terminal 87 on the harness connector for the ECM main relay.
Less than 5 Ohms
Result: The measured resistance is greater than 5 Ohms.
The fault is in the wiring between the auxiliary main relay and the ECM main relay.
Repair: 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 measured resis