978915 Volvo.Penta Shim

Illustration 1 g01090095
Schematic
Illustration 2 g00744372
ECM connector P2 (ECM side)
(5) Injector 1 & 2 Solenoid Return
(17) Injector 3 & 4 Solenoid Return
(27) Injector 5 & 6 Solenoid Return
(6) Solenoid 1 Power
(12) Solenoid 2 Power
(18) Solenoid 3 Power
(22) Solenoid 4 Power
(28) Solenoid 5 Power
(34) Solenoid 6 Power Test Step 1. Inspect Electrical Connectors and Wiring
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
Turn the keyswitch to the OFF/RESET position. A strong electrical shock hazard is present if the keyswitch is not turned to the OFF/RESET position.
Thoroughly inspect the J2/P2 ECM connector and the J91/P91 injector connector. 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 in the J91/P91 injector connector that are associated with injector solenoids. Refer to Illustration 2.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the J91/P91 injector connector in order to ensure the proper mating of the connector.
Check the harness and wiring for abrasions and for pinch points from the injectors 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 connectors and wiring are OK. Proceed to Test Step 2.
Not OK - There is a problem with 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 for Logged Diagnostic Codes
Connect the Caterpillar Electronic Technician (ET) to the service tool connector.
Turn the keyswitch to the ON position.
Monitor the "Logged Diagnostic Codes" screen on Cat ET. Expected Result:One or more of the following diagnostic codes has been logged:
1-05
2-05
3-05
4-05
5-05
6-05
1-06
2-06
3-06
4-06
5-06
6-06 Results:
OK - There are logged diagnostic codes for the injectors. Proceed to Test Step 4.
Not OK - There are no logged diagnostic codes for the injectors. Proceed to Test Step 3.Test Step 3. Check the Variation of the Injectors Between Each of the Cylinders
Start the engine.
Allow the engine to warm up to normal operating temperature (approximately 77 °C (171 °F)).
After the engine is warmed to operating temperature, access the "Cylinder Cutout Test" on Cat ET by accessing the following display screens in order:
"Diagnostics"
"Diagnostic Tests"
"Cylinder Cutout Test"
Enable the cooling fan, if the fan is not controlled by the ECM. If the ECM controls the cooling fan, the cooling fan will start automatically when the test begins.
Shut off all parasitic loads such as the air conditioning and the air compressors which could affect the results of the test.
Set the engine speed to 1200 20 rpm.
Select the start button at the bottom of the screen for the "Cylinder Cutout Test".
Select the "4 Cylinder Cutout Test" which is the default test.
Follow the instructions that are provided in the "Cylinder Cutout test". The cylinder cutout tests are interactive so the procedure is guided to the finish. Note: The "Manual Cylinder Cutout Test" is also available. Access the manual test by selecting the "Change" button on the screen for the "Cylinder Cutout Test". The "4 Cylinder Cutout Test" is the recommended starting procedure. The automated tests run twice collecting data. The two sets of data are analyzed and an "OK" or "NOT OK" result is displayed.Expected Result:All cylinders indicate "OK".Results:
OK - All cylinders indicate "OK".Repair: If the engine is misfiring or if the engine has low power, refer to the diagnostic procedure Troubleshooting, "Engine Misfires, Runs Rough or Is Unstable" and the diagnostic procedure Troubleshooting, "Low Power/Poor or No Response to Throttle".If a diagnostic code results from running the "Cylinder Cutout Test", proceed to Test Step 4.
Not OK - A problem was found with one of the cylinders. Proceed to Test Step 4.Test Step 4. Use the Injector Solenoid Test to Test the Injector Solenoids
Start the engine.
Allow the engine to warm up to normal operating temperature (approximately 77 °C (171 °F)).
Turn the keyswitch to the OFF/RESET position.
Turn the keyswitch to the ON position.
Access the "Injector Solenoid Test" on Cat ET by accessing the following display screens in order:
"Diagnostics"
"Diagnostic Tests"
"Injector Solenoid Test"
Activate the test. Note: The test is in the "Interactive Diagnostic Tests". Do not confuse the "Injector Solenoid Test" with the "Cylinder Cutout Test". The "Cylinder Cutout Test" is used to shut off fuel to a specific cylinder while the engine is running. The injector solenoid test is used in order to actuate the injector solenoids. This allows the click of the injector solenoids to be heard when the engine is not running in order to determine that the circuit is functioning properly.
As each solenoid is energized by the ECM an audible click can be heard at the valve cover. Listen for a click at each valve cover. A black square will appear over the cylinder number when the cylinder is being fired.
Perform the injector solenoid test at least two times. Expected Result:All cylinders indicate "OK".Results:
OK - There is not an electronic problem with the injectors at this time.Repair: If the "Cylinder Cutout Test" returned a "NOT OK" for any injector, refer to the diagnostic procedure Troubleshooting, "Engine Misfires, Runs Rough or Is Unstable".STOP
Not OK - No