3594614 Volvo.Penta Starter motor

Illustration 1 g00833841
(1) Intake manifold air temperature sensor (2) Intake manifold air temperature sensor connector (3) Air inlet heater relay (4) Air inlet heater switch connector (5) Customer connector (6) Service tool connector (7) ECM (8) P1 ECM connector (9) P2 ECM connector
Illustration 2 g00833831
Schematic for the air inlet heater relay
Illustration 3 g00767304
Terminal locations for the ECM
Illustration 4 g00767315
Chart for operation of the air inlet heaterTest Step 1. Inspect Electrical Connectors And Wiring
Thoroughly inspect the J501/P501 inlet air heater relay connector and inspect the J2/P2 ECM connector. Inspect the terminal connections on the air inlet heater relay and the air inlet heater. Refer to Troubleshooting, "Electrical Connectors-Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the connectors that are associated with the air inlet heater. Refer to illustration 2 for pin locations.
Check the ECM connector (allen head screw) for the proper torque of 6.0 N m (55 lb in).
Check the harness and wiring for abrasion 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 or of pinch points.Results:
OK - Proceed to Test Step 2.
Not OK - Repair: Perform the following 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. Stop.Test Step 2. The Powerup Test for the Air Inlet Heater
Turn the keyswitch to the OFF position.
Connect the Caterpillar Electronic Technician (Cat ET) to the J60 service tool connector.
Turn the keyswitch to the ON position.
Go to the "Air Inlet Heater Override" in the "Override Parameters" in the "Diagnostic Tests" under the "Diagnostics" menu on Cat ET.
Start the test and listen for a click from the air inlet heater relay.Note: The air inlet heater relay is located on the front left side of the engine.Note: Do not leave the "Air Inlet Heater Override" ON. Avoid unnecessary cycling of the air inlet heater in order to prevent the battery from discharging. The "Air Inlet Heater Override" has a one minute timer in order to disable the test when the time expires.Expected Result:Result 1 The relay is active.Result 2 The relay is active but the air inlet heater is suspected of having a problem.Result 3 The relay does not activate.Results:
RESULT 1 - The lamp and the relay are functioning normally. Stop.
RESULT 2 - Proceed to Test Step 3.
RESULT 3 - There is a problem with the relay circuit. Proceed to Test Step 4.Test Step 3. Check the Voltage at the Relay Contacts for the Air Inlet Heater
Illustration 5 g00767620
Connections for the test lamp
Turn the keyswitch to the OFF position.
Disconnect the wire from the relay terminal of the air inlet heater to the air inlet heater.
Fabricate two jumper wires with Deutsch sockets on one end and Deutsch pins on the other end. Strip a small amount of insulation from the middle of one jumper wire.
Disconnect J501/P501 and insert the jumper wires in the electrical connectors.
Connect a voltage test lamp from the disconnected relay terminal to the jumper wire that is connected to J501 and P501 terminals.
Turn the keyswitch to the ON position.
Go to the "Air Inlet Heater Override" on Cat ET.
Start the test and watch the voltage test lamp.Note: Do not leave the "Air Inlet Heater Override" On. Avoid unnecessary cycling of the air inlet heater in order to prevent the battery from discharging. The "Air Inlet Heater Override" has a one minute timer in order to disable the test when the time expires.Expected Result:The test lamp turned ON and the test lamp turned OFF with the "Air Inlet Heater Override".Results:
OK - The air inlet heater relay and the +Battery connection to the air inlet heater relay are OK. Leave the wire disconnected from the relay terminal. Proceed to Test Step 5.
Not OK - The test lamp does not turn ON. Reconnect the wire from the air inlet heater to the terminal on the air inlet heater relay. Proceed to Test Step 6.
NO - The test lamp turns ON. The test lamp stays in the ON position. Reconnect the wire from the air inlet heater to the terminal on the air inlet heater relay. Proceed to Test Step 6.Test Step 4. Check the Voltage at the Air Inlet Heater Relay
Illustration 6