3801439 Volvo.Penta Unit injector

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Schematic for the fuel level sensorTest Step 1. Inspect the Electrical Connectors and the Wiring
Remove the electrical power from the ECM.
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J1/P1 and J2/P2 ECM connectors (typical left side engine view) (1) J60 Customer connector (2) J2 ECM connector (3) J803 Fuel level connector
Thoroughly inspect the J2/P2 ECM connectors. Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors-Inspect".
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P2 terminals that are associated with the fuel level sensor (P2-38) Fuel level sensor signal (P2-93) Sensor return
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Fuel level sensor connector (1) Fuel level (2) Sensor return
Perform a 45 N (10 lb) pull test on each of the wires that are associated with the fuel level sensor.
Check the allen head screw on the ECM connectors for the proper torque. Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".
Check the harness and the wiring for abrasion and for pinch points from the fuel level sensor to the ECM.Expected Result:All connectors, pins and sockets are completely coupled and/or inserted and the harness and wiring are free of corrosion, of abrasion and of pinch points.Results:
OK - The connectors and the wiring appear to be OK. Proceed to Test Step 2.
Not OK - There is a problem in the connectors and/or the wiring.Repair: Repair the circuit. Verify that the repair eliminates the problem.STOPTest Step 2. Confirm the Fuel Level in the Tank
Visually check the fuel level in the tank.
Compare the fuel level in the tank to the indicator on the fuel level sensor.Expected Result:The fuel level in the tank agrees with the indicator on the fuel level sensor.Results:
OK - The fuel level in the tank agrees with the indicator on the fuel level sensor. Proceed to Test Step 3.
Not OK - The indicator on the fuel level sensor does not reflect the actual fuel level in the tank.Repair: Replace the fuel level sensor. Verify that the repair eliminates the problem.STOPTest Step 3. Check the Status of the Fuel Level
Remove the electrical power from the ECM.
Connect the Caterpillar Electronic Technician (ET) to the service tool connector.
Restore the electrical power to the ECM.
Observe the status of "Fuel Gauge" on Cat ET.Note: The "Fuel Gauge" on Cat ET represents the percentage of fuel level in the tank.
Remove the electrical power from the ECM.Expected Result:The status of "Fuel Gauge" displays the correct fuel level.Results:
OK - Cat ET displays the correct fuel level.Repair: The fuel level sensor appears to be operating correctly at this time. There may be an intermittent problem in the harness or in a connector. Refer to the diagnostic functional test Troubleshooting, "Electrical Connectors - Inspect".STOP
Not OK - Cat ET does not display the correct fuel level. Proceed to Test Step 4.Test Step 4. Check the Sensor's Resistance at the Sensor
Disconnect the fuel level sensor connector.Note: Be sure to wiggle the harness during the following measurement in order to reveal an intermittent condition.
Measure the sensor's resistance between 1 (fuel level) and 2 (sensor return).The correct resistance is 33 Ohms when the indicator is on "F". The correct resistance is 240 Ohms when the indicator is on "E".Expected Result:The resistance measurement is between 33 Ohms and 240 Ohms.Results:
OK - The resistance of the sensor is between 33 Ohms and 240 Ohms. Record the measurement. Connect the fuel level sensor connector. The sensor's resistance is OK. Proceed to Test Step 5.
Not OK - The resistance measurement is greater than 240 Ohms or the resistance measurement is less than 33 Ohms.Repair: Perform the following procedure:
Disconnect the fuel level sensor from the vessel's wiring. Verify that the fuel level sensor is operating correctly. Refer to the literature that is provided by the OEM for the sensor.
If the sensor is causing the high resistance, adjust the sensor, when possible. Replace the sensor, if necessary.STOPTest Step 5. Check the Sensor's Resistance at the ECM
Disconnect the J2/P2 connectors.Note: Be sure to wiggle the harness during the following measurement in order to reveal an intermittent condition.
Measure the resistance between P2-38 (fuel level sensor) and P2-93 (sensor return) at the ECM connector.Expected Result:The resistance measurement is approximately equal to the resistance that was measured at the sensor connector.Results:
OK - The resistance measurement is approximately equal to the resistance measurement that was recorded in the previous Test Step.Repair: The fuel level sensor and the wiring are OK. Perform the following procedure:
Connect the J2/P2 connectors.
Restore the electrical power to the ECM. Check for a diagnostic code for the fuel level sensor again. Wait at least 30 seconds in order for codes to become active.
If the diagnostic code does not recur, the problem is resolved. The original problem was probably caused by a poor electrical connection. Return the engine to service. STOP.
If the diagnostic code recurs, Replace the ECM. Refer to electronic troubleshooting Troubleshooting, "Replacing the ECM". Verify that the problem is resolved.STOP
Not OK - The resistance measurement is not approximately equal to the resistance that was measured at the sensor connector. There is a problem with the engine's wiring harness. There may be a problem with a connector.Repair: Repair the wiring, when possible. Replace parts, if necessary. Verify that the problem is resolved.STOP