6645225 Volvo.Penta Repair kit

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. Thoroughly inspect the terminal connections on the P2/J2 ECM connector and the solenoids. Refer to Troubleshooting, "Electrical Connectors - Inspect".
B. Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector and the solenoid connectors that are associated with the active diagnostic code.
C. Check the screw for the ECM connector for the correct torque of 6 N m (53 lb in).
D. Check the harness for corrosion, abrasion, and pinch points from the solenoids to the ECM.
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.
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 coupled and/or inserted. The harness is free of corrosion, abrasion, and pinch points.
Proceed to Test Step 2.
2. Check for Active Diagnostic Codes
A. Turn the keyswitch to the OFF position.
B. Connect the electronic service tool to the diagnostic connector.
C. Turn the keyswitch to the ON position. Wait at least 20 seconds for activation of the diagnostic codes.
D. Verify if any of the diagnostic codes that are listed in Table 1 are active.
E. Turn the keyswitch to the OFF position.
Diagnostic codes
Result: An XXXX-5 diagnostic code is active.
Proceed to Test Step 3.
Result: An XXXX-6 diagnostic is active.
Proceed to Test Step 5.
3. Create a Short Circuit at the Harness Connector for the Solenoid
A. Turn the keyswitch to the OFF position.
B. Disconnect the connector for the suspect solenoid.
C. Fabricate a jumper wire that is 150 mm (6 inch) long.
D. Install the wire between the two pins on the harness connector for the suspect solenoid in order to create a short circuit.
E. Turn the keyswitch to the ON position. Wait for 10 seconds. Check for active diagnostic codes on the electronic service tool.
F. Remove the jumper wire from the connector for the solenoid valve.
Open circuit
Result: An XXXX-5 diagnostic code was active before installing the jumper. An XXXX-6 diagnostic code is active when the jumper is installed. There is a fault in the solenoid.
Repair: Temporarily connect a replacement for the suspect valve to the harness.
Turn the keyswitch to the ON position. Use the electronic service tool in order to check for active diagnostic codes. Wait at least 30 seconds in order for the codes to be displayed.
If the fault is eliminated, reconnect the suspect valve. If the fault returns, permanently install the replacement valve. Refer to Disassembly and Assembly for the correct procedure.
Result: An XXXX-5 diagnostic code is still active with the jumper installed.
Proceed to Test Step 4.
4. Check the Wiring for an Open Circuit
A. Turn the keyswitch to the OFF position.
B. Disconnect the P2 connector and the connector for the suspect valve.
C. Check the resistance between the signal terminal on P2 and the signal terminal on the valve connector.
D. Check the resistance between the return terminal on P2 and the return terminal on the valve connector.
E. Reconnect the connectors.
Less than two Ohms
Result: One of the measured resistances is greater than two Ohms. There is a fault in the engine wiring harness
Repair: Repair the engine wiring harness or replace the engine wiring harness.
Use the electronic service tool to clear all logged diagnostic codes and verify that the repair eliminates the fault.
Result: All measured resistances are less than two Ohms.
Contact the Dealer Solutions Network (DSN).
5. Create an Open Circuit at the Solenoid
A. Turn the keyswitch to the OFF position.
B. Disconnect the connector for the suspect solenoid valve.
C. Turn the keyswitch to the ON position. Wait for 10 seconds. Check for active diagnostic codes on the electronic service tool.
Short circuit
Result: An XXXX-6 diagnostic code was active before disconnecting the valve. An XXXX-5 diagnostic code is active with the valve disconnected.
Repair: Temporarily connect a replacement for the suspect valve to the harness.
Turn the keyswitch to the ON position. Use the electronic service tool in order to check for active diagnostic codes. Wait at least 30 seconds in order for the codes to be displayed.
If the fault is eliminated, reconnect the suspect valve. If the fault returns, permanently install the replacement valve. Refer to Disassembly and Assembly for the correct procedure.
Result: An XXXX-6 diagnostic code is still active with the valve disconnected.
Proceed to Test Step 6.
6. Check the Wiring for a Short Circuit
A. Turn the keyswitch to the OFF position.
B. Disconnect the P2 connector and the connector for the suspect valve.
C. Check the resistance between the suspect signal terminal on P2 all other terminals on P2.
D. Check the resistance between the suspect return terminal on P2 and all other terminals on P2.
E. Reconnect the connectors.
Greater than 100 Ohms
Result: At least one of the resistance measurements is less than 100 Ohms. The fault is in the engine harness.
Repair: Repair the faulty harness or replace the faulty harness. Use the electronic service tool to verify that the repair eliminates the fault.
Result: All resistance measurements are greater than 100 Ohms.
Contact the Dealer Solutions Network (DSN).
If the procedure did not correct the issue, contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the Dealer Solutions Network (DSN).