977909 Volvo.Penta Shim

Illustration 1 g00750858
Schematic
Illustration 2 g00933439
P2 ECM connector
Test Step 1. Inspect Electrical Connectors and Wiring
Turn the keyswitch to the OFF/RESET position.
Thoroughly inspect the J3/P3 machine connector and the J2/P2 ECM connector. Thoroughly inspect the connectors for each analog sensor. Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connector and the sensor connectors that are associated with the active diagnostic code.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the J3/P3 machine connector (allen head screw) for the proper torque of 2.25 0.25 N m (20 2 lb in).
Check the harness and wiring for abrasions and for pinch points from the sensors back to the ECM. Expected Result:All connectors, pins, and sockets are completely coupled and/or inserted. The harness and wiring are free of corrosion, of abrasion, and of pinch points.Results:
OK - The harness and wiring are OK. Proceed to Test Step 5.
Not OK - There is a problem in the connectors and/or wiring.Repair: Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.Verify that the repair eliminates the problem.STOPTest Step 2. Check the Supply Voltage at the Sensor Connector
Turn the keyswitch to the OFF/RESET position.
Disconnect all of the analog sensors at the sensor connector:
Turn the keyswitch to the ON position.
Measure the voltage between terminal A (5 V analog supply) and terminal B (sensor return) at the sensor connectors.
Turn the keyswitch to the OFF/RESET position.
Reconnect all sensors. Expected Result:The voltage is 5.0 0.2 VDC.Results:
OK - The voltage is correct. Proceed to Test Step 3.
Not OK - The voltage is incorrect.Repair: Perform the diagnostic functional test Troubleshooting, "Analog Sensor Supply Circuit - Test".STOPTest Step 3. Check for Active Diagnostic Codes
Connect Caterpillar Electronic Technician (ET) to the service tool connector.
Turn the keyswitch to the ON position.
Monitor the active diagnostic code screen on Cat ET. Check and record any active diagnostic codes. Note: Wait at least 15 seconds in order for the diagnostic codes to become active.
Determine if the problem is related to an open circuit diagnostic code 03 or a short circuit diagnostic code 04. Expected Result:No diagnostic codes are active.Results:
OK - No diagnostic codes are active.Repair: The problem may have been related to a faulty connection in the harness. Carefully reinspect the connectors and wiring. Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - A short circuit diagnostic code (04) is active at this time. Proceed to Test Step 4.
Not OK - An open circuit diagnostic code (03) is active at this time. Proceed to Test Step 5.Test Step 4. Disconnect the Suspect Sensor in Order to Create an Open Circuit
Turn the keyswitch to the OFF/RESET position.
Disconnect the sensor connector of the sensor with the short circuit diagnostic code (04).
Turn the keyswitch to the ON position. Wait at least 15 seconds for activation of the diagnostic codes.
Access the "Active Diagnostic Code" screen on Cat ET. Check for an active open circuit diagnostic code (03).
Turn the keyswitch to the OFF/RESET position. Expected Result:An open circuit diagnostic code 03 is now active for the disconnected sensor.Results:
OK - A short circuit diagnostic code (04) was active before disconnecting the sensor. An open circuit diagnostic code (03) became active after disconnecting the sensor.Repair: Temporarily connect a new sensor to the harness, but do not install the new sensor in the engine. Verify that there are no active diagnostic codes for the sensor. If there are no active diagnostic codes for the sensor, permanently install the new sensor. Clear any logged diagnostic codes.STOP
Not OK - There is a short circuit between the sensor harness connector and the ECM. Leave the sensor disconnected. Proceed to Test Step 8.Test Step 5. Check the Pull-up Voltage at the Sensor Connector
Turn the keyswitch to the ON position.
Measure the voltage between terminal C (signal) and terminal B (sensor return) at the sensor connector.
Turn the keyswitch to the OFF/RESET position. Expected Result:The voltage is 8 2 VDC.Results:
OK - The voltage is correct. The signal wire to the ECM from the sensor connector is okay.Repair: The open circuit is in the sensor or the wire between the sensor and the sensor connector. Replace the sensor. Do not install the sensor in the engine. Verify that no diagnostic codes are active for the suspect sensor before permanently installing the sensor.STOP
Not OK - The voltage is incorrect. Proceed to Test Step 6.Test Step 6. Verify that the Circuit is not Shorted to a Voltage Source
Turn the keyswitch to the OFF/RESET position.
Disconnect ECM connectors P2 and ECM connector P1.
Disconnect the connector for the sensor.
Measure the resistance between the terminal for the sensor signal wire at the ECM and every terminal on ECM connector P1 and ECM connector P2.
Turn the keyswitch to the OFF/RESET position.
Reconnect ECM connector P2 and ECM connector P1. Expected Result:The resistance is greater than 20,000 Ohms.Results:
OK - The resistance is greater than 20,000 Ohms. Proceed to Test Step 7.
Not OK - The resistance is less than 20,000 Ohms.Repair: The resistance measurement indicates a low resistance between two or more wires. Repair the connectors or wiring and/or replace the connectors or wiring.STOPTest Step 7. Create a Short at the Suspe