3583827 Volvo.Penta Thermostat

Illustration 1 g00751022
Schematic for ether injection system
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. Verify the Status of the Ether Injection SystemVerify that the ether injection system has been programmed to ON.Results:
OK - The ether injection system has been programmed to ON. Proceed to Test Step 2.
Not OK - The ether injection system has not been programmed to ON. Program the ether injection system to ON. Verify that all of the conditions are met in order for the ether injection system to function properly. Proceed to Test Step 2.Test Step 2. Inspect Electrical Connectors and Wiring
Turn the keyswitch to the OFF/RESET position.
Thoroughly inspect ECM connector J1/P1, customer connector J61/P61, and all other connectors in the wiring harness. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Inspect the following components for damage, for corrosion, and for incorrect attachment:
Battery posts
Alternator
Breaker
Engine ground
Chassis groundExpected Result:All connectors, pins, and sockets are completely inserted and coupled. The harness and wiring are free of corrosion, of abrasion, and of pinch points. All connections and grounds are tight and free of corrosion.Results:
OK - The harness and wiring are OK. Proceed to Test Step 3.
Not OK - There is a problem with the harness and/or wiring.Repair: Repair the circuit.Verify that the repair eliminates the problem.STOPTest Step 3. Check the Switch Circuit at the J61/P61 Customer Connector
Table 1
Pin Locations for Switch    
Name of Switch     J61 Connection     J1 Connection    
Starting Aid Override Switch     38     22    
Illustration 2 g00762294
Disconnect the J61 Customer Connector.
Connect one end of the voltage test lamp to J61-38 and connect the other end of the voltage test lamp to P61-38. Refer to illustration 2 for details.
Turn the keyswitch to the ON position.
Operate the starting aid override switch and observe the voltage test lamp.Expected Result:The voltage test lamp should turn on when the switch is closed. The voltage test lamp should turn off when the switch is opened.Results:
OK - The voltage test lamp turned on when the switch was closed. The voltage test lamp turned off when the switch was opened. The switch is operating correctly. Proceed to Test Step 4.
Not OK - The voltage test lamp failed to function according to the expected results.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 4. Check the Switch Circuit at the J1/P1 ECM Connector
Reconnect the J61 Customer Connector.
Disconnect the J1 ECM Connector.
Connect one end of the voltage test lamp to J1-22 and connect the other end of the voltage test lamp to P61-22. Refer to illustration 2 for details.
Turn the keyswitch to the ON position. The engine should be OFF.
Operate the starting aid override switch and observe the voltage test lamp.Expected Result:The voltage test lamp should turn on when the switch is closed. The voltage test lamp should turn off when the switch is opened.Results:
OK - The voltage test lamp turned on when the switch was closed. The voltage test lamp turned off when the switch was opened. The switch is operating correctly. Proceed to Test Step 5.
Not OK - The voltage test lamp failed to function according to the expected results. There is a problem in the wiring.Repair: Repair the wiring and/or replace the wiring. Verify that the repair eliminates the problem.STOPTest Step 5. Test the Ether Start Relay
Turn the keyswitch to the OFF/RESET position.
Connect the test lamp between the terminals of the ether start relay.
Turn the keyswitch to the ON position.
Activate the starting aid override switch.Expected Result:The test lamp should turn on for three seconds.Results:
OK - The test lamp turned on for three seconds. Proceed to Test Step 6.
Not OK - The test lamp did not turn on for three seconds. Proceed to Test Step 7.Test Step 6. Test the Voltage at the Ether Valve
Turn the keyswitch to the OFF/RESET position.
Disconnect the wires from the ether valve.
Connect the voltage test lamp between the wires that were removed from the ether valve.
Turn the keyswitch to the ON position and start the engine.
Activate the starting aid override switch.Expected Result:The voltage test lamp should turn on for three seconds.Results:
OK - The voltage test lamp turned on for three seconds.Repair: Temporarily install a new ether valve. Verify that the problem no longer exists. Reinstall the old ether valve. If the problem reoccurs, replace the old ether valve.Verify that the repair eliminates the problem.STOP
Not OK - The voltage test lamp did not turn on for three seconds. There is a problem in the wiring between the ether valve and the ether start relay.Repair: Repair