6211541 Volvo.Penta Thermostat

Table 1
Diagnostic Codes Table    
Code    Conditions which Generate this Code    System Response    
190-2 Engine Speed Sensor erratic, intermittent, or incorrect     The signal from the engine speed/timing sensor has been lost.
The code is logged only if the engine has been running for three seconds.     The code is logged.
If a valid signal is not received from the engine speed/timing sensor the engine will shut down.    
190-3 Engine Speed Sensor voltage above normal     The supply voltage for the engine speed/timing sensor is above normal.    
190-8 Engine Speed Sensor abnormal frequency, pulse width, or period     The signal from the engine speed/timing sensor has been incorrect for at least five seconds.    The Electronic Control Module (ECM) supplies 12.5 1.0 VDC to terminal A on the connector for the engine speed/timing sensor. The engine speed/timing sensor generates a pulse signal to the ECM as each tooth passes the sensor. The ECM counts the pulses in order to determine the engine rpm. The ECM memorizes the pattern of the pulses. The ECM compares that pattern to a standard pattern in order to determine the crankshaft position. The ECM uses this information to determine the position of the piston in the No. 1 cylinder. The ECM then triggers each unit injector to fire in the correct firing order and at the correct time. The actual timing and duration of each injection is determined by the ECM. The ECM uses engine rpm and engine load to determine the timing and duration of injection. The loss of the timing signal from the engine speed/timing sensor generates an alert on Caterpillar Electronic Technician (ET). The loss of the timing signal from the engine speed/timing sensor triggers the termination of the signals to the fuel injectors by the ECM.Note: When the timing gear is installed backward, the ECM generates a diagnostic code of CID-FMI 190-8. If this code is active, the ECM will not fire the injectors.
Illustration 1 g01455593
Typical schematic
Illustration 2 g01455596
P2 ECM connector (P2-29) Digital return (P2-1) +V timing (P2-37) Engine speed/timing signalTest Step 1. Inspect Electrical Connectors and Wiring
Turn the keyswitch to the OFF position.
Remove electrical power from the ECM.
Illustration 3 g01139425
ECM (1) J1/P1 connectors (2) J2/P2 connectors
Thoroughly inspect the J2/P2 ECM connector. Inspect all of the connectors that are associated with the circuit.Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
Perform a 45 N (10 lb) pull test on each of the wires in the ECM connectors that are associated with the circuit.
Check the ECM connector (allen head screw) for the proper torque. Refer to Troubleshooting, "Electrical Connectors - Inspect" for details.
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, and of pinch points.Results:
OK - The harness and wiring are OK. Proceed to Test Step 2.
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 for Diagnostic Codes
Connect Cat ET to the service tool connector. Refer to Troubleshooting, "Electronic Service Tools".
Restore electrical power to the ECM.
Turn the keyswitch to the ON position. Start the engine.
Check for active diagnostic codes on Cat ET.Look for the following codes:
190-2
190-3
190-8Expected Result:None of the above diagnostic codes are active.Results:
OK - None of the above codes are active, but there is a problem that has been associated with the engine speed/timing sensors. Proceed to Test Step 3.
OK - None of the above codes are active.Repair: There may be an intermittent problem in the circuit. If an intermittent problem is suspected, refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - One or more of the above codes are active. Proceed to Test Step 3.Test Step 3. Inspect the Condition of the Engine Speed/Timing Sensor
Turn the keyswitch to the OFF position.
Remove the engine speed/timing sensor.
Inspect the sensor tip for damage.
Inspect the plastic sliphead for damage.
Check the tension on the sliphead by gently prying the sliphead out of the sensor body. Extend the sliphead 3 to 4 mm (0.12 to 0.16 inch). Push the sliphead back into the sensor body from the extended position. Movement of the sliphead will require a small amount of force. The amount of tension that is on the sliphead must not allow movement of the sliphead during engine operation.
If the sensor is not damaged, pull the sliphead from the sensor body to the fully extended position and reinstall the sensor.Note: Be sure to extend the sliphead before installing the engine speed/timing sensor. Ensure that the timing gear is in a position that will not allow the sliphead to protrude into one of the slots of the timing gear during installation. If the sliphead protrudes into one of the slots of the timing gear, the sliphead will be damaged as the timing gear begins to rotate.Expected Result:The sensor is not damaged. An adequate amount of tension is felt on the sliphead and the movement is smooth.Results:
OK - The engine speed/timing sensor and the sliphead are undamaged. The tension on the sliphead is normal.Repair: Reinstall the engine speed/timing sensor. Ensure that the timing gear is positioned correctly prior to installing the sensor. Proceed to Test Step 4.
Not OK - The engine speed/timing sensor or the sliphead is damaged.Repair: Replace the engine speed/timing sensor.STOPTest Step 4. Check the Engine Speed on Cat ET
Turn the keyswitch to the ON position. Crank the engine.
Observe the engine speed on Cat ET while the engine is cranking.Expected Result:Cat ET displays a steady engine speed between 100 and 250 rpm while the engine is cranking and the engine starts.Results:
OK - The engine speed/timing sensor is operating normally at this time.Repair: If you are troubleshooting an intermittent problem, refer to Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - Cat ET displays zero engine