3801287 Volvo.Penta Starter motor, exch

Illustration 1 g06346652Required Tooling
Table 2
Required Tooling for the Procedure
373-4609 Spark Tester
Illustration 2 g03766502
(1) 373-4609 Spark Tester
Illustration 3 g03766761Recommended Actions
Table 3
Troubleshooting Test Steps Values Results
1. Check for Codes
A. Connect Cat® Electronic Technician (ET) to the service tool connector.
B. Use the "Aftertreatment #1 Ignition Transformer Primary Override" on Cat ET to turn on the ARD ignition system. The ARD ignition system must operate for 20 seconds in order for a diagnostic trouble code to become active.
C. Determine the code that is present.
Codes
Result: A 2465-5 or 3484-5 code is present.
Proceed to Test Step 5.
Result: A 3180-5 or 4265-5 code is present.
Proceed to Test Step 2.
Result: A 2465-6 or 3484-6 code is present.
Proceed to Test Step 6.
2. Inspect the Ignition Wire
A. Visually inspect the ignition wire between the ignition coil and the ARD combustion head. Look for the following problems:
- Loose connections or damaged connectors
- Moisture on the connectors or the ignition wire
- Damage to the ignition wire that is caused by excessive heat
- Damage to the ignition wire that is caused by chafing
- Improper routing of the ignition wire
- Damaged insulation on the ignition wire
B. Push the boot on each end of the ignition wire. This tests whether the clip inside the boot is connected to the spark plug and to the ignition coil.
Ignition Wire
Result: The ignition wire is not damaged.
Proceed to Test Step 3.
Result: The ignition wire is damaged.
Repair: Replace the ignition wire.
Proceed to Test Step 8.
3. Check for Spark at the Coil Output, Using the Spark Indicator
A. Assemble the 373-4609 Spark Tester. Ensure that the alligator clip is secured to a good ground source.
B. Install the spark indicator as shown in illustration 2.
C. Use the "Aftertreatment #1 Ignition Transformer Primary Override" on Cat ET to turn on the ARD ignition system. Check for spark in the spark indicator.
Spark
Result: Spark is present in the indicator.
Proceed to Test Step 4.
Result: Spark is not present in the indicator.
Repair: Replace the ignition coil.
Proceed to Test Step 8.
4. Check for Spark to the Spark Plug
A. Assemble the 373-4609 Spark Tester.
B. Install the spark plug indicator between the spark plug and the end of the spark plug wire.
C. Use the "Aftertreatment #1 Ignition Transformer Primary Override" in Cat ET to turn on the ARD ignition system. Check for spark in the spark indicator.
Spark
Result: Spark is present in the indicator.
Repair: Replace the spark plug.
Proceed to Test Step 8.
Result: Spark is not present in the indicator.
Repair: Replace the ignition wire.
Proceed to Test Step 8.
5. Replace the Ignition Wire
A. Replace the ignition wire between the ignition coil and the ARD combustion head.
B. Use the "Aftertreatment #1 Ignition Transformer Primary Override" in Cat ET to turn on the ARD ignition system.
Ignition Wire
Result: The ignition wire was replaced and the 3484–5 or 2465–5 is no longer active.
Proceed to Test Step 8.
Result: The ignition wire was replaced and the 3484–5 or 2465–5 remains active.
Proceed to Test Step 6.
6. Check for Voltage at the Ignition Coil
A. Disconnect the connector from the ignition coil.
Not all connectors may be shown in the illustration above, refer to the electrical schematic.
B. Turn the keyswitch to "ON".
C. Establish communication between Cat ET and the ECM . Refer to Troubleshooting, "Electronic Service Tools", if necessary.
D. Use the "Aftertreatment #1 Ignition Transformer Primary Override" in Cat ET to turn on the ARD ignition system. Measure the voltage between terminal 1 and terminal 3 on the Clean Emissions Module (CEM) harness connector for the ignition coil.
E. Turn off the ARD ignition system by disabling the override.
Greater than 1.5 VDC .5 VDC
Result: The voltage between terminal 1 and terminal 3 is greater than 1.5 VDC .5 VDC.
Proceed to Test Step 7.
Result: The voltage between terminal 1 and terminal 3 is less than 1.5 VDC .5 VDC. The problem is in the wiring between the ECM and the ignition coil connector.
Repair: Repair the wiring or replace the wiring.
Proceed to Test Step 8.
7. Check the Ground for the Ignition Coil
A. Disconnect the connector from the ignition coil.
B. Turn the keyswitch to ON.
C. Establish communication between Cat ET and the ECM . Refer to Troubleshooting, "Electronic Service Tools", if necessary.
D. Use the "Aftertreatment #1 Ignition Transformer Primary Override" in Cat ET to turn on the ARD ignition system. Measure the voltage between terminal 1 an