3801618 Volvo.Penta Unit injector, exch

The Electronic Control Module (ECM) creates 5.0 0.2 VDC that is supplied to terminal A of the harness connectors for these sensors:
Injection actuation pressure sensor
Boost pressure sensor
Atmospheric pressure sensor
Fuel pressure sensor
Engine oil pressure sensor
Auxiliary pressure sensor (if equipped)A +5 V diagnostic code is probably caused by a short circuit to ground or a short circuit to another voltage source in the harness. The next likely cause is a problem with a sensor. The least likely cause is a problem with the ECM.
Illustration 1 g01119880
Schematic for the 5 volt supply
Probable Causes
Electrical connectors and wiring
Codes
Sensor
ECMRecommended Actions
Illustration 2 g01121143
Left side view
(1) Boost pressure sensor
(2) Atmospheric pressure sensor
(3) J2/P2 connectors
(4) J1/P1 connectors
(5) Engine oil pressure sensor
Illustration 3 g01121144
The location of the fuel pressure sensor depends on the engine configuration.
(6) Fuel pressure sensor
Table 2
Troubleshooting Test Steps Values Results
1. Inspect the Electrical Connectors and Wiring
A. Turn the keyswitch to OFF.
B. Inspect J1 connector (3) and J2 connector (4). Inspect all the connectors associated with the pressure sensors. Refer to Troubleshooting , Electrical Connectors - Inspect for the appropriate procedure.
C. Perform a 45 N (10 lb) pull test on each of the wires that are associated with the pressure sensor supply.
D. Check the allen head screw for the ECM connector and the customer connector for proper torque. Refer to Troubleshooting , Electrical Connectors - Inspect.
E. Check the harness and wiring for abrasions and pinch points from each sensor back to the ECM.
Electrical Connectors and Wiring
Result: The electrical connectors and wiring are in good condition.
Proceed to Test Step 2.
Result: There are electrical connectors and/or wiring damage present.
Repair: Repair and/or replace the connectors or wiring as needed. Ensure that all seals are in place and connectors are coupled completely.
If the problem is not resolved, proceed to Test Step 2.
2. Check for Codes
A. Connect Cat® Electronic Technician (ET) to the service tool.
B. Turn the keyswitch to ON.
C. Observe the "Active Diagnostic" screen in Cat ET. Wait at least for 30 seconds for any of the codes from Table 1 to become active.
Codes
Result: There is an active -03 code.
Proceed to Test Step 3.
Result: There is an active -04 code.
Proceed to Test Step 5.
Result: There is an active -10 code.
Proceed to Test Step 4.
Result: There are no active codes present.
If any of the codes in the table above are logged and the engine is not running properly, refer to Troubleshooting, Troubleshooting Without a Diagnostic Code.
If the engine is running properly currently, there may be an intermittent problem in the wiring harness. Refer to Troubleshooting , Electrical Connectors - Inspect.
3. Check the Voltage of the +5V Supply Wire
A. Turn the keyswitch to OFF.
B. Disconnect the harness connectors for the following sensors:
- Injection actuation pressure sensor
- Boost pressure sensor
- Atmospheric pressure sensor
- Fuel pressure sensor
- Engine oil pressure sensor
- Auxiliary pressure sensor (If equipped)
C. Turn the keyswitch to ON.
D. Measure the voltage between terminals A and B at each sensor connector on the engine harness.
Note: Wiggle the wiring harness during the measurement to reveal an intermittent condition.
Supply Voltage
Result: Each voltage measurement is 5.0 0.2 VDC.
Repair: Connect all the sensor connectors and clear all the codes. Check for active codes. If the problem is intermittent, refer to Troubleshooting , Electrical Connectors - Inspect.
Result: At least one voltage measurement was not 5.0 0.2 VDC. There is a problem with the wiring and/or ECM.
Proceed to Test Step 6.
4. Check the Voltage on the Supply Wire for the Suspect Sensor
A. Turn the keyswitch to OFF.
B. Disconnect the harness connector of the suspected sensor.
C. Turn the keyswitch to ON.
D. Measure the voltage between terminals A and B at each sensor connector on the engine harness.
Note: Wiggle the wiring harness during the measurement to reveal an intermittent condition.
Supply Voltage
Result: The voltage measurement is not 5.0 0.2 VDC. The 5 volt supply is not present at the harness connector. There is a problem with the wiring or with the ECM.
Proceed to Test Step 6.
Result: The voltage measurement is 5.0 0.2 VDC. The 5 volt supply is present at the harness connector for the suspect sensor, but there is an active -10 code.
Repair: Replace the suspected sensor.
If the problem is not resolved, proceed to Test Step 5.
5. Disconnect the 5V Pressure Sensor and Check for Active Codes
A. Disconnect the following sensor one at a time:
- Injection actuation pressure sensor
- Boost pressure sensor
- Atmospheric pressure sensor
- Fuel pressure sensor
- Engine oil pressure sensor
- Auxiliary pressure sensor (If equipped)
B. Wait for 30 seconds after disconnecting each sensor for the 262-04 code to deactivate.
Sensors
Result: The 262-04 code deactivates when a sensor is disconnected.
Repair: Connect the suspect sensor, if the code returns replace the sensor.
Connect all the connectors and verify that the problem is resolved. Return the unit to service.
Result: The 262-04 remains after all the sensors are disconnected.
Leave the sensors disconnected and proceed to Test Step 6.
6. Check for a Short in the +5V Supply Wire to Engine Ground or a Short Circuit
A. Turn the keyswitch to OFF.
B. Disconnect the J1/P1 and J2/P2 ECM connectors.
C. Verify that all the pressure sensors are disconnected.
D. Measure the resistance between the following pins:
- P2-72 and all other terminals on the P2 connector
- P-72 and engine ground
- P2-80 and all other terminals on the P2 connector
- P2-80 and engine ground