859526 Volvo.Penta Oil cooler

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Harness
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Deutsch Sealing Plug
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Deutsch Contact TerminalsTest Step 1. Check the Locking of the DT Connector (Deutsch) and Check the Lock Ring of the HD Style Connector (Deutsch).
Ensure that the connector is properly locked. Also ensure that the two halves of the connector can not be pulled apart.
Verify that the latch tab of the connector is properly latched.Expected Result:The connector will securely lock. The connector and the locking mechanism are without cracks or without breaks.Results:
OK - The connector will lock securely. The connector and the locking mechanism are without cracks or without breaks. The connector is okay. Proceed to Test Step 2.
Not OK - The connector will not securely lock or the connector and the locking mechanism have cracks or breaks. The connector needs repair.Repair: Repair the connector or replace the connector, as required. Refer to Special Instruction, SEHS9615, "Servicing DT Connectors". Refer to Special Instruction, SEHS9065, "Use of CE/VE Connector Tools".Verify that the repair eliminates the problem.STOPTest Step 2. Check the Allen Head Screw on the Connector for the Electronic Control Module (ECM).
Ensure that the allen head screw is properly tightened. Be careful not to overtighten the screw and break the screw.
Do not exceed 2.25 N m (20 lb in) of torque on the allen head screw.Expected Result:The ECM connector is secure and the allen head screw is properly torqued.Results:
OK - The ECM connector is secure and the allen head screw is properly torqued. Proceed to Test Step 3.
Not OK - The ECM connector or allen head screw need repair.Repair: Repair the connector or replace the connector, as required. Refer to Special Instruction, SEHS9615, "Servicing DT Connectors". Refer to Special Instruction, SEHS9065, "Use of CE/VE Connector Tools".Verify that the repair eliminates the problem.STOPTest Step 3. Perform a Pull Test on each Wire Terminal Connection.
Each terminal and each connector should easily withstand 45 N (10 lb) of pull and each wire should remain in the connector body. This test checks whether the wire was properly crimped in the terminal and whether the terminal was properly inserted into the connector.
The "DT" connectors use an orange wedge to lock the terminals in place. Ensure that the orange wedge is not missing and that the orange wedge is installed properly on the "DT" connectors.Note: Terminals should always be crimped onto the wires through the use of a crimp tool. Do not solder terminals. Use the 1U-5804 Crimp Tool .Expected Result:Each terminal and each connector easily withstands 45 N (10 lb) of pull and each wire remains in the connector body.Results:
OK - The connector and the terminals withstand the pull test. Proceed to Test Step 4.
Not OK - The connectors and/or the terminals fail the pull test. The connectors and/or terminals need repair.Repair: Repair the terminals and/or replace the terminals, as required. Refer to Special Instruction, SEHS9615, "Servicing DT Connectors". Refer to Special Instruction, SEHS9065, "Use of CE/VE Connector Tools".Verify that the repair eliminates the problem.STOPTest Step 4. Monitor the Caterpillar Electronic Technician (ET) while the Wiring and the Connectors are Being Pulled.
If there is an active diagnostic code that pertains to the circuit, perform the following test:Monitor the active diagnostic code screen on the Cat ET while all the harnesses and the connectors that connect to the component with the active diagnostic code are pulled. If the harness is being pulled and the active diagnostic code disappears, there is a problem in the wiring or the connector.
If there are no active diagnostic codes that pertain to the circuit, perform the following test:Monitor the status screen on Cat ET for the suspect component while the harnesses are being pulled. If the harness is being pulled and the reading changes erratically, there is a problem in the wiring or the connector.
If there are no active diagnostic codes and the operator is complaining about speed burps or power cutouts, perform the following test:Run the engine. Listen for speed burps or power cutouts while the wiring or the connectors are pulled. If the harness is being pulled and the engine has a speed burp or a power cutout, there could be a problem in the wiring or in the connector.Expected Result:The problem appears to be external to the harnesses and to the connectors. Pulling on the harness and the connectors has no effect on the active diagnostic code, on the component status, or on the engine performance.Results:
OK - There was no change in the active diagnostic code, in the component status, or in the engine performance. Proceed to Test Step 5.
Not OK - There was a change in the active diagnostic code, in the component status, or in the engine performance.Repair: Repair the terminals and/or replace the terminals, as required. Refer to Special Instruction, SEHS9615, "Servicing DT Connectors". Refer to Special Instruction, SEHS9065, "Use of CE/VE Connector Tools".Verify that the repair eliminates the problem.STOPTest Step 5. Check the Wires for Nicks in the Insulation or Abrasion.
Carefully inspect each wire for signs of abrasion, nicks, or cuts.The following areas are locations that should be checked:
Exposed insulation
Points of rubbing wire against the engine
Points of rubbing wire against a sharp point
Check all of the hold down clamp