Beruflich Dokumente
Kultur Dokumente
4-1996
Workshop Manual
"NC" Models
VOLVO
PENTA
A~ Safety Warning
Spark Management.....................................
Symptoms...............................................
Diagnoses ..............................................
Glossary .................................................
Diagrams ...............................................
Safety ...................................................
This WorkshopManualis one of a set of nine that covers Volvo
Pentasterndrive models.All nine bookscan be orderedas a set
from Volvo Penta Parts. Order PIN 7788880-8.
IndividualWorkshop Manuals
coveringthesemodels are also avail-
able. Orderthe following part numbers
from Volvo PentaParts.
PIN 7788881-6SX, DP-SDrive Unit and Transom
Shield
Includes information on TransomShield, UpperGearUnit and Lower
GearUnit service; Drive Unit removalandinstallation; Propellers;and
Trim/13mthydraulicoperation.
PIN 7788882-4
MFiDiagnostic(5.0 Fi, 5.8 Fi/FSi) - Ford
Includesstep by step troubleshootingprocedures
for all MF!Fordre~
lated components and wiring.
PIN 77888899DPXoLower
Unit and)(actTM Steering System
Includesspecific information for repair and overhaulof the DPXLower
unit and XactTMsteering systemsnot coveredin the SPandDPWorkshop
manual.
This Volvo Penta MFI WorkshopManual
Covers The Following Volvo Penta "HU" Models
SX"
Engine ModelNr. TransomShield DriveUnit Options
HA.= highaltitudeapplications
DuoProp
Engine ModelNr. TransomShield Drive Unit Options
SX
TM
DuoProp
Engine ModelNr. TransomShield DriveUnit .Options
General Information
Table of Contents
Z~ Safety Warning
To reduce the chanceof personal injury and / or Accordingly, anyone who intends to use a re-
property damage, the following cautions must placement part, service procedure or tool, which
be carefully observed. is not recommendedby the manufacturer, must
first determine that neither his safety nor the
Proper service and repair are important to the safe operation of the engine will be jeopardized
safety of the service technician and safe, reliable by the replacement part, service procedure or
operation of all Electronic Fuel Injection (EFI) tool selected.
equipped engine If part replacement is neces-
sary, the part must be replaced with one of the Its important to note that this manualcontains
samepart numberor with an equivalent part. Do Various "Safety Warnings" and "Notes" that
not use a replacement part of lesser quality. must be carefully observed in order to reduce
the risk of personal injury during service or
The service procedures recommendedand de- repair, or the possibility that improperservice or
scribed in this service manual are effective repair may damagethe engine or render it un-
methodsof performing service and repair. Some safe. Its also important to understandthat these
of these procedures require the use of tools "Safety Warnings" and "Notes" are not exhaus-
specially designed for the purpose. tive, becauseits impossible to warn of all the
possible hazardous consequences that might
result from failure to follow these Instructions.
Basic Knowledge/ Tools Required __ Diagnostic Information
To use this manual most effectively, a general The diagnostic charts and function checks in this
understanding of basic electrical circuits and manualare designed to locate a faulty circuit or
circuit testing tools is required. Youshould un- component through logic based on the process
derstand the meaning of voltage, ohms, and of elimination. The charts are prepared with the
amps; the basic theories of electricity; what assumption that the system functioned correctly
happens to an open, shorted or grounded wire; at the time of assembly and that there are no
and be able to follow wiring diagrams. rnultiple failures.
To perform system diagnostics, several special Engine control circuits contain manyspecial de-
tools and equipment are required. Becomeac- sign features not found in standard marine wir-
quainted with the tools and their use before ing. Electrical contacts are protected against en-
attempting to diagnose the system. Special tools vironmental effects and proper splicing methods
which are required for systemservice are illus- must be used when necessary. The proper oper-
trated at the end of this section. ation of low amperageinput / output circuits
depends upon good continuity between circuit
Electrostatic Discharge Damage connectors.
TheECM performsa continualserf-diagnosison cer- After the visual / physicalinspection,the OBD sys-
tain control functions.Thisdiagnosticcapability is temcheckis thestarting point for all diagnosticpro-
complemented by the diagnostic procedurescon- cedures.Referto the Diagnoses section.
tained in this manualTheECMslanguagefor com-
municatingthe sourceof a malfunctionis a systemof Thecorrect procedureto diagnosea problemis to
diagnostic codes.Thecodesare two digit numbers follow twobasicsteps"
that canrangefrom12 to 51. When a malfunctionis
detectedby the ECM,a codeis set. 1. Arethe on-board diaonostics working.?. This is
determinedby performingthe OBDsystemche",J<.
Sincethis is the startingpointfor thediagnosticpro.
HowDiagnostic Trouble Codes cedures,alwaysbeginhere. If the on-board diagnos-
(DTCs) Are Set tics arent working,the OBD systemcheckwill lead
to a diagnosticchartin the Diagnoses sectionto cor-
TheECM is programmedto receive calibrated volt- rect the problem.If the on-boarddiagnostics
are work-
agesignalsfromthe sensors.Thevoltagesignal from ing correctly,thenextstepis:
a sensormayrangefromaslow as 0.1 volt to as high 2. ,~stored? If a DTCis stored, go di-
as 4.9 volts. Thesensorvoltagesignal is calibrated rectly to the numbered DTCchart in the Diagnoses
for engineapplication. This wouldbe the sensors section.Thiswill determine
if thefault is still present.
working parameteror 9Nindow."TheECMandsen-
sors will be discussedfurther in the ECM andSen-
sor section.
~ 1-3
Service Mode Theignition andMDTC tool switchesmustbe in the
"OFF"position whenconnectingthe MDTC tool to
the DLC.Thenturn the ignition switch, to the "ON"
Whenthe MDTC tool is connectedto the DLC,and positionwiththe engine not running.At this point, the
the MDTC tool switchis in the "ON"position, the sys- MDTC tool light should be on. PushtheMDTC tool
temwill enter whatis called ServiceMode.in this switchto the =ON"positionandthe light shouldflash
modethe ECM will: DTC12 threetimesconsecutively (i.e. fla.sh pause
flash-flash - pause,then it wouldrepeattwomore
1. Displaya DTCi2 by flashing the MDTC toot light times). DTC12 indicates that the ECMsd!agnostic
(indicatingthe system is operatingcorrectly). systemis operating,if DTC12is not indicated,a prob-
lemis presentwithinthe diagnosticsystem itself, and
2. Display any stored DTCsby flashing the MDTC shouldbe addressed by consultingthe appropriate
tool light. EachDTC will beflashedthreetimes,then diagnosticschart in the Diagnoses section.
DTC12 will be flashedagain.
Followingthe output of DTC12, the MDTC tool light
3. Holdignition timing at a fixed timingdegreepro- will indicatea DTC threetimesif a DTC
is present,or
grammedinto the ECM. This will allow basetiming to it will simplycontinueto outputDTC 12. if morethan
beadjustedondistributor ignition engines. oneDTChas beenstored in the ECMsmemory,the
4. Movethe IACvalveto its fully extended position, DTCS will be displayedfromthe numericallylowest
to the highest, with eachDTCbeingdispiayedthree
blockingthe idleair passage.Thisis importantto re-
member, as an attemptto run the boat while in Ser- times.
vice Modewill mostlikely result in an abnormally
low MaiPdnction
indicatorLamp
(MIL)
idmespeed.
Thislight is part of the MarineDignosticTroubleCode
Reading Diagnostic Trouble Codes (MDTC) tool 3851088-9 andhas the following func-
(DTC} tions:
it informsthe operatorthat a problem
hasoc
Theprovision for communicating with the ECM isthe curredandthat the boatshouldbe takenin for
DataLink Connector (DLC).Its part of the MFIen- serviceas soonas reasonablypossible.
ginewiring harness,andis a 10-pinconnector,its
usedin the assembly plar~t to checkengineopera- . it displaysDTCsstoredby the ECM
whichhelp
tion beforeit leavesthe plant. TheDTCsstored in the techniciandiagnosesystemproblems.
the ECMsmemory can be readeither througha scan
tool (a hand-helddiagnosticscannerpluggedinto the
DLC),or by countingthe numberof flashes of the
MDTC tool whenin Service Mode.
Whenthe MDTC tool is attached to the DLCwith Manually Clearing DTCs
its switchin the "OFF = position, andthe keyin the
"ON"position andthe enginenot running, the MDTC
tool light will come"ON".When the engineis started~ I. Turnignition switchto the =OFF"
position.
the light will turn "OFF.If the light remains=ON",
the self-diagnostic systemhas detecteda problem. 2. Install MarineDiagmosticTroubleCode(MDTC)
if the problemgoesaway,the light will go out in tool with pushswitch in the =OFF"
position.
mostcasesafter 10 seconds,but a codewill re- 3. Turnignition "ON",enginenot running.
mainstored in the ECM.
Whenthe light remains"ON"while the engine is 4. PushMDTC
tool switch to =ON"position.
running, or whena malfunction is suspecteddue 5. To clear DTCs,disengage
the remotecontrols
to a ddveability problem,an MFIDiagnosticCircuit shift function, then SLOWLY
movethe throttle from
Checkmust be performed.Thesechecks will ex- 0%(idle) to 100%(VVOT)then back to
pose malfunctions which maynot be detected if
other diagnosticsare performedprematurely. 6. PushMDTC
tool switch to "OFF"position.
"[O retrieve a DTC,turn the key to the =ON"posi- 7. "rumignition =OFF"for 20 seconds.
tion with the enginenot running. Pushthe MDTC
tool switchto the "ON"positionandthe light should 8. Start engineandlet it run for 20 seconds.
flash a Code12 three times, and then any other
Code(s)that are stored in the ECMmemory. 9. Turnignition "OFF"for 20 seconds.
Turnignition =ON",enginenot running. PushMDTC
IntermittentLight tool switchto =ON"
position andverify DTC12 only.
RemoveMDTCtool.
In the caseof an =intermittent" problem,the MDTC
tool bulbwill light for 10 seconds
andthengo out. When clearing DTCs,the battery mustbe
However,the corresponding codewill be stored in fully chargedandcrankingspeedmustbe at least
the memory.of the ECM.Whenunexpectedcodes 200RPM.Theability to clear DTCsis directly de-
appearduring the codereading process, one can pendenton the battery beingfully chargedandable
assume that these codeswereset by art intermit- to crank engine with adequatecranking RPM.
tent malfunctionandcould be helpful in diagnos-
ing the system. ECMClearing of DTCs
An intermittent DTC,if cleared, mayor maynot
reset, if its an intermittentfailure, consultthe Di- TheECM will automaticallyclear DTCsif they have
agnostic Aids on the pagefacing the diagnostic not re-occurredwithin 25 "power-ups".One=power-
codechart corresponding to the intermittent DTC. up" is definedas anytimethe engine,either crank-
Symptoms also coversthe topic of =intermittents". ing or running, enters RunModeby exceeding300
A physical inspectionof the applicablesub-system RPMfor 16 secondsor more.
mostoften will resolvethe problem.
Diagnosisof Driveability Concerns Wiring ConnectorService
(With No DTCsSet)
Mostconnectorsin the enginecompartment are pro-
still existsafter followingthe tected againstmoistureanddirt whichcouldcreate
if a driveabilityconcern
diagnosticcircuit checkandreviewingthe Symptoms oxidationarid depositson the terminals.Thisprotec-
section, an out-of-rangesensormaybe suspected. tion is importantbecause of the.verylow voltageand
Becauseof the uniquedesign of the MFIsystem, current levels found in the electronics system.The
failsafes havebeenincorporatedinto the ECM.A connectors have a lock which securesthe maleand
sensedvalueis replacedwith a default valuein the female terminals together. A secondarylock holds
caseof a sensormalfunctionor sensorwidngprob- the seal andterrninal into the connector.
lem.Withthis feature,limited engineperformance is
restoreduntil the engineis repaired.A basicunder- When diagnosing,opencircuits are often d~icult to
standingof sensoroperationis necessary to be able locate bysight because oxidationor terminalmisalign-
to diagnosean out-of-rangesensor. merit are hidden by the connectors.-Merelywiggling
a connectoron a sensoror in the widngharnessmay
if a sensoris outof range,butstill withintheoperat- locate the opencircuit condition.Thisshouldalways
ing Window"of the ECM,the problemwill go unde- be consideredwhen.an opencircuit or failed sensor
tected by the ECM andmayresult in a ddveability is indicated.Intermittent problemsmayalso becaused
concern. by oxidized or loose connections.
ExarnDl~ coolanttemperature is 150, but the cool- Beforemakinga connectorrepair, be certain of the
ant sensorincorrectly reads50. This wouldcause type of connector.Some connectorslook similar but
the ECMto deliver morefuel thanwasactual!yneeded are serviceddifferently. Replacementconnectors and
andresult in anoverlyrich, roughrunningcondition. terminalsarelisted in the PartsCatalog.
This condition wouldnot havecauseda DTCto set
as the ECMinterprets this as within its "range".
Metri-Pack- Series 150 Terminals ~ To remove the terminal, pivot the con-
nector retaining hinge (~) out of the way. Insert
SomeECMharness connectors contain terminals the specified removaltool (~) thru the front of the
called Metri-Pack. Theseare used at someof the connector, and pushthe terminal and seal (~) out
sensors and the distributor connectors. Metri- of the connector. To install a terminal, the wire is
Pack connectors require tools J 35689, BT-8518 first inserted through the seal. Thewire and seal
or an equivalent to service them. are crimped to the.terminal ~). The terminal is
then pushed back into the connector to seat and
[~ SomeMetri-Pack terminals are called "pull- seal it in place. Makecertain that the connectors
to-seat". To removethe terminal, slide the seal (~) are property seated and all of the sealing rings
backon the wire. Insert a flat tool thru the backof are in place whenclosing the retaining hinge.
the connector ~) to release the locking tang ,
and push the wire out through the front of the [~] The retaining hinge (~) provides a secondary
connector. To install a terminal, the wire is first locking feature for the connector. It improvesthe
inserted through the one piece seal then out the connectorsreliability by retaining the terminals if
front of the connector. The terminal is crimped the small terminal lock tangs are not positioned
on the wire, and the terminal pulled back into the properly.
connectorto seat it in place.
Weather-Pack connectors cannot be replaced
Weather-PackTerminals with standard connectors. Instructions are
provided with Weather-Packconnector and ter-
minal packages.
DE] some Weather-Pack terminals are called
"push-to-seat", Weather-Packconnectors require
tools J 28742, BT-8234-A or an equivalent to
service them. These tools are used to removepin
and sleeve terminals. If terminal removal is at-
temptedwithout using the special tool required,
there is a good chance that the terminal will be
bent or deformed. Unlike standard blade type
terminals, these terminals cannot be straight-
ened once they are bent.
~mo~,~ 1-7
01~57S
Whensignal wires are spliced into a harness, use Step 1. Locate damagedwire. Removeinsulation
the same gauge wire with high temperature @as required. Ifshrink tube is to be used as an
insulation only. With the low current and voltage insulator, cut and slide shrink tube over damaged
levels found in the system, its important that the wire.
best possible bond be madeat all wire splices by
soldering the splices. Step 2. Splice wire together using splice clip (~)
and rosin core solder.
Twisted / Shielded Cable Repair
Step 3. Cover splice with electrical tape to insu-
Step 1. Remove
outer jacket (~). late from other wires.
Step 2. Unwrap aluminum / mylar tape and Step 4. Retwist as before and cover with electri-
ground (uninsulated) wire. Do not remove mylar cal tape (~ to hold in place.
tape (~), or ground wire
Use care when probing a connector or
Step 3. Untwist conductors. Strip insulation (~) replacing connector terminals. Its possible to
necessary. short between opposite terminals, if this hap-
pens, certain components can be damaged. Al-
Step 4. Splice wires using splice clips and rosin ways use jumper wires with the corresponding
core solder. Wrapeachsplice to insulate. mating terminals between connectors fop circuit
checking. NEVER probe through connector seals,
Step 5. Wrap with mylar (~ and ground wire . wire insulation, secondaryignition wires, boots,
nipples or covers. Microscopic damageor holes
Step 6. Tape (~) over whole bundle to secure mayresutt in eventual water intrusion, corrosion,
before. and componentor circuit failure.
1-8
Service Tools Needed
DE] Tachometer
Must have inductive signal pick-up.
DR4CB3
D~c.q67
DR,me1
[~ Timing Light
A speciallydesigned
light usedto visually indicateinjector electrical DRcsrP
impulses from the ECM.
Separatelyenergizeseachinjector to compare
for equatimpulsesover a
constanttimeinterval.
1-10
Section 2
Safety Warning
Before working on any part of the electricel system, read the
section called Safety at the end of this manual.
ECM
TYPICAL
SENSOR
VOLTAGE OUT
_1_ GROUNO
nnno
The computeruses digital signals in a code that With a "pull-up" type switch, the ECMwill sense
contains only ones and zeros. The high voltage of a voltage whenthe switch is CLOSED. In the case
the digital signal represents a one (1), and of the "pull-down," the ECM"sees" the voltage
voltage represents a zero (0). Eachzero and each when the switch is OPEN.
one is called a bit of information, or just a "bit."
Eight bits together are called a word. A word, Pulse Counters
therefore, contains some combination of eight
binary code bits: eight ones, eight zeros, five For a computer to determine frequency informa-
ones and three zeros, and so on. tion from a switched input, the computer must
measurethe time between voltage pulses. As a
Binary code is used inside a computer, and numberof pulses are recorded in a set amountof
between a computer and any electronic device time, the computercan calculate the frequency.
that understands the code. By stringing together The meaning of the frequency number can have
thousands of bits, computers can communicate any number of meanings to the computer.
and store an infinite variety of information.
c~n~ 2-3
5 VOLTS
t
TYPICAL SENSOR RANGE
"WINDOW"
0.iV
0 VOLTS
2-4 ~o~.~