20412266 Volvo.Penta Plug

Operator Information
* What happened, and when?* Under what conditions?Was the engine rpm (speed) high or low?Was the engine under load?* Are there any customer or dealer installed systems that could cause this symptom?* What else occurred?* When the did the symptoms begin (and what else happened at that time)?LOGGED Diagnostic Codes
* Do they correlate to probable causes?* Did they occur at the same time as the symptoms?* Are some codes Logged repeatedly?Other Symptoms
* Are they related to this symptom?* Do they have common probable causes?Finally, test each probable cause using the tests suggested by the procedure. Be sure to check connectors, especially on intermittent problems! Refer to Section 5, P-501: Inspecting Electrical Connectors for details.Operator Questionnaire
Ask the operator to answer the following question before attempting to repair an intermittent problem, or a problem with symptoms but no diagnostic codes. Use this and the response guidelines to these questions on the next page. Questionnaire Response
P-301: Engine Will Not Crank
This is NOT an electronic system problem. Refer to the Systems Operation, Testing & Adjusting Manual for additional information on the following tests. Probable root causes:* Battery Cables/Batteries* Starting motor solenoid or circuit problem (in system wiring)* Starting motor/flywheel ring gear* Engine accessory* Hydraulic cylinder lock* Internal engine problem Perform the following tests in order:1. Check shutdown switch, battery posts and battery/starter cables for loose connections and corrosion. Remove and clean cables and connections if corroded. Load test batteries. Refer to Special Instruction, SEHS9249, Use of 4C4911 Battery Load Tester. If necessary, charge the batteries. Refer to Special Instruction, SEHS7633, Battery Test Procedure.2. Test starting motor solenoid operation. Check system wiring to starting motor solenoid.3. Test starting motor operation. Refer to Systems Operation, Testing & Adjusting Manual. Inspect starting motor pinion and ring gear for damage.4. Ensure free movement of driveline. Refer to the Systems Operation, Testing & Adjusting Manual. Check transmission neutral gear indicator for proper operation and adjustment, repair or replace as required.5. Verify timing pin was not left in the flywheel housing after setting valve lash. Use the 9S9082 Engine Turning Tool and attempt to manually turn the engine. If unable to turn the engine, remove and inspect engine accessories that can lock up the engine (air compressor, oil pump, etc). Repair or replace as necessary. Refer to the System Operation Testing & Adjusting Manual.6. Remove injectors and check for fluid in the cylinders.7. Disassemble engine to inspect for internal components that may be seized, broken, bent, out of alignment, etc. Refer to the Disassembly & Assembly Manual.8. 3176C/3196 EnginesEnsure the Engine Shutdown Switch is not engaged. Measure the resistance between pin 1 and pin 2 at the Engine Shutdown Switch. The resistance should be less than 2 ohms. If the resistance is greater than 2 ohms replace the switch.9. 3406E EngineEnsure the Engine Shutdown Switch is not engaged. Measure the resistance between pin 3 and pin 4 at the Engine Shutdown Switch (located on the control panel). The resistance should be less than 2 ohms. If the resistance is greater than 2 ohms replace the switch.P-302: Engine Cranks But Will Not Start
Probable root causes:* Starting aids/fuel gel (cold temperature operation)* Engine Shutdown Switch setting* Vessel/Engine wiring* Personality Module or ECM* Engine Speed/Timing signal; injection timing, incorrect Engine Speed/Timing wheel orientation assembly, Engine Speed/Timing Sensor calibration error after replacement.* Electrical connections to the unit injector solenoids* Fuel supply* Combustion problem Perform the following tests in order:1. If cold ambient conditions exist, check operation of starting aids. Check cylinder block jacket water heater for malfunction and replace if required. Check for presence of congealed fuel (wax).2. Ensure the Engine Shutdown Switch is not engaged. Connect an Electronic Service Tool and verify Shutdown Switch position status. If the Electronic Service Tool does not show the current switch position, refer to P-343: Engine Synchronize Switch Not Functioning Properly.3. Remove Pin 36 at the J3 Customer Connector.4. For the 3176C and 3196 Marine Engines remove pin B from P-107. For the 3406E Marine Engine remove pin 2 from P-110. Restart the Engine. If the Engine starts there is a problem in the customer supplied wiring. Ensure the engine shutdown Switch is in the RUN position.5. If Electronic Service Tool does not operate, Refer to P-307: Electronic Service Tool Will Not Communicate With ECM. If a shutdown occurs, the keyswitch must be turned to the OFF position, then to the ON position before the engine will start. Aftermarket engine protection devices usually interrupt power to the ECM and prevent communications with the Electronic Service Tool. Check for correct installation and operation of aftermarket engine protection devices. Aftermarket devices may need to be bypassed to continue.6. Check for correct installation of the ECM connectors J1/P1 and J2/P2, Engine Speed/Timing Sensor connector J20/P20, J44/P44 and Unit Injector connectors J91/P91. Refer to P-501: Inspecting Electrical Connectors. If the problem occurs only after the engine is warmed up, the circuit breakers may be exceeding the trip point because of overheating. Check the circuit breakers on the vessel, reset if required.7. Turn Keyswitch ON, engine OFF. Use signal reading probes and measure the voltage between J1 pin 4 and J1 pin 5. The voltage should be 12 2 VDC and 24 2 VDC. If the voltage is out of range, refer to P-346: Electrical Power Supply to the ECM.8. Verify there is not an Active 25302 Diagnostic Code. If the diagnostic code is present, refer to P-513: ECM Personality Module.9. Observe the engine rpm on an Electronic Service Tool Status screen while cranking the engine. If the Electronic Service Tool displays 0 rpm while cranking the engine, there is a problem in the Engine Speed/Timing Sensor circuit. Refer to P-514: Engine Speed/Timing. If engine rpm is present (50 rpm or greater while cranking) the Engine Speed/Timing circuitry appears to be operating correctly. If engine speed is present but the engine does not fire, check