876793 Volvo.Penta Repair kit

Illustration 1 g00822142
Schematic
Breathing ether vapors or repeated contact of ether with skin can cause personal injury. Personal injury may occur from failure to adhere to the following procedures.Use ether only in well ventilated areas.Do not smoke while changing ether cylinders.Use ether with care to avoid fires.Do not store replacement ether cylinders in living areas or in the operator's compartment.Do not store ether cylinders in direct sunlight or at temperatures above 49 °C (120 °F).Discard cylinders in a safe place. Do not puncture or burn cylinders.Keep ether cylinders out of the reach of unauthorized personnel.To avoid possible injury, be sure the brakes are applied and all controls are in Hold or Neutral when starting the engine.
Test Step 1. Inspect Electrical Connectors and Wiring
Turn the keyswitch to the OFF/RESET position.
Thoroughly inspect the J1/P1 ECM connector and all other connectors in the circuit. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.Expected Result:All connectors, pins, and sockets should be completely inserted and coupled. The harness and wiring should be free of corrosion, abrasion, and pinch points. All connections and grounds should be tight and free of corrosion.Results:
OK - Proceed to Test Step 2.
Not OK - Repair: Repair the circuit.Verify that the repair eliminates the problem.STOPTest Step 2. Check the Status of the Ether Switch on ET
Remove the ether canister from the ether solenoid.
Connect ET to the service tool connector.
Turn the keyswitch to the ON position.
Press the start aid switch to "MANUAL". Observe the status of "Ether Switch" on ET.Expected Result:When the start aid switch is pressed, ET should display the status of the switch as "On".When the start aid switch is not pressed, ET should display the status of the switch as "Off".Results:
OK - The start aid switch is operating correctly. Proceed to Test Step 6.
Not OK - The ECM is not seeing the signal from the start aid switch. Proceed to Test Step 8.Test Step 3. Short the Switch Wires
Turn the keyswitch to the ON position.
Disconnect the start aid switch.
Observe the status of "Ether Switch" on ET.Note: The status should be "Off".
Install a jumper wire between terminal 2 and terminal 3 in the plug for the start aid switch.
Observe the status of "Ether Switch" on ET.Note: The status should be "On".Expected Result:When the terminals are shorted, ET should display the status of the start aid switch as "On".When the terminals are not shorted, ET should display the status of the start aid switch as "Off".Results:
OK - The start aid switch is not operating correctly.Repair: Replace the start aid switch.Verify that the repair eliminates the problem.STOP
Not OK - The start aid switch is operating correctly. Proceed to Test Step 4.Test Step 4. Short the Switch Inputs at the ECM
Illustration 2 g00823121
P1 ECM connector (wire side)
Turn the keyswitch to the OFF/RESET position.
Remove the wires from P1:22 (Start Aid Switch) and P1:18 (Switch Return).
Turn the keyswitch to the ON position.
Observe the status of "Ether Switch" on ET.Note: The status should be "Off".
Install a jumper wire with Deutsch sockets on each end between P1:22 (Start Aid Switch) and P1:18 (Switch Return).
Turn the keyswitch to the ON position.
Observe the status of "Ether Switch" on ET.Note: The status should be "On".
Remove the jumper wire and reinstall the wires in the P1 connector.Expected Result:When the jumper wire is installed, ET should display the status of the switch as "On".When the jumper wire is not installed, ET should display the status of the start aid switch as "Off".Results:
OK - There is a problem in the wiring between the switch and the ECM.Repair: Repair the circuit.Verify that the repair eliminates the problem.STOP
Not OK - The ECM is not reading the switch input properly.Repair: Verify your results. Replace the ECM. Refer to Troubleshooting, "Replacing the ECM" before replacing the ECM.Verify that the repair eliminates the problem.STOPTest Step 5. Check for Correct Operation of the SolenoidNote: The ether canister must be removed prior to activating this test.
Turn the keyswitch to the ON position.
Proceed to the "Diagnostic Overrides" screen on ET.
Activate the ether injection system.Note: The diagnostic override will only activate the relay for 3 seconds.
Listen for an audible click as the start aid solenoid is activated. Listen for an audible click as the start aid solenoid is deactivated.Expected Result:A click should be heard when the solenoid is activated.Results:
OK - The ether injection system is operating correctly.STOP
Not OK - The solenoid is not being energized or the solenoid is bad. Proceed to Test Step 6.Test Step 6. Check the Resistance of the Solenoid
Disconnect the J504/P504 start aid solenoid connector.
Measure the resistance of the solenoid between J504:1 (Solenoid Power) and J504:2 (Solenoid Return).
Reconnect J504/P504 Start Aid Solenoid connector.Expected Result:Resistance should be less than 10 Ohms.Results:
OK - The resistance of the solenoid is OK. Proceed to Test Step 7.
Not OK - The resistance of the solenoid is out of specification.Repair: Replace the solenoid.Verify that the repair eliminates the problem.STOPTest Step 7. Check the Supply Voltage to the SolenoidNote: The ether canister must be removed prior to activating this test.
Disconnect the J504/P504 start aid solenoid connector.
Turn the keyswitch to the ON position.
Proceed to the "Diagnostic Overrides" screen on ET.
Activate the ether injection system.Note: The diagnostic override will only activate the relay for 3 seconds.
Measure the voltage between P504:1 (Solenoid Power) and P504:2 (Solenoid Return) when the ether injection system is activated.Expected Result:The supply voltage should be greater than 22.0 VDC.Results:
OK - The ECM is prope