P/N 7788884-0

4-1996

Workshop Manual
"NC" Models

MF! Diagnostic (7.4 Gi/GSi, 8.2 GSi)-

VOLVO

PENTA
 A~ Safety Warning

This WorkshopManual will alert you to certain procedures that

must be done very carefully. If you ignore this information,
you could...

Injure yourself or peoplearoundyou

injure the boat operator, boat passengers,or
people around the boat
Damagethe Volvo Penta product or its systems

Understandthe following symbols before proceeding:

Alerts you to the possibility of dangerand

/~ Safety Warning identifies informationthat will help pre-
ventinjuries.
Identifies informationthat will help pre-
vent damageto machinery.
Appearsnext to information that controls
correct assemblyand operation of the
product.

This WorkshopManualis written for qualified, factory trained

service technicians familiar with the use of Volvo Penta special
tools.

This WorkshopManual tells you how to correctly maintain and

service Volvo Penta products and systems. Whencorrectly
serviced, the Volvo Penta product will be reliable and safe to
operate.

WhenVolvo Penta special tools are called for, use them.

Wherementioned, the tools are required to perform the service
procedure.

if you use service procedures or service tools that are not

recommendedin this manual, YOUALONEmust decided if
your actions might injure people or damagethe Volvo Penta
product.
 Contents

General Information ....................................

ECMand Sensors .......................................

Fuel System ..... , .....................................

Spark Management.....................................

Symptoms...............................................

Diagnoses ..............................................

On-Board Service .......................................

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 7788883-2TB!Diagnostic(4.3 Gi, 5.7 Gi/GSi) -

Containstroubleshootingproceduresfor all TBI GMmodelsand re-
lated components.

PIN 7788884-0MFi Diagnostic(7.4 Gi/GSi, 8.2 GSi) -

includes step by step troubleshooting procedures for all MFI GM
related componentsand wiring.

PIN 7788885-7SP-DPDrive Unit and TransomShield

Includesinformation on Transom Shield, UpperGearUnit, LowerGear
Unit service; Drive Unit removalandinstallation; Propellers;andTrim/
Tilt hydraulicoperationandservicing procedures.

. PIN 7788886-5 Engine Components

Includes information on Engineservice andtroubleshooting; Engine
removalandinstallation; Stee~ngsystems;Throttle andShift Control
systems; and Cooling systems.

PIN 7788887-3Electrical & Ignition System

Includes service and troubleshootinginformation on Crankingsys-
tems;Chargingsystems;Trim/Tilt electrical systems;ignition systems;
and Engineand Instrumentwiring diagrams.

PIN 7788888-1Fuel System

Includesserviceandtroubleshootinginformationon all carburetor,MFI
and TBI fuel systemsand related components.

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

3.0 GSSX NPS 3868181 3868268/SX-LIMITEO

TRIM 36881591SX-CTI1.85:1 3868176/SX-C

3.0 GSSX 3868182 3868288/SX-LIMITED

TRiM 3868159/SX-CTll.85:1 3868176/SX-C

4.3 GL SX 3868184 3868176/SX..C 3868160/SX-C/1.66:1 3868159/SX-C/1.85:1/H.A.

3 GS SX 3868186 3868176/SX-C 3868160/SX..CI1.68:1 36881591SX-C/1.85:11H.A.

5.0 FL SX 3868189 3868176/SX-C 3688160/SX-C/1.66:1 38681591SX-C/I.85:l/H.A.

5.0 F| SX 3868193 38681761SX-C 3868161/SX-C/1.60:1 3868160/SX-C/1.68:11

H.A.

6.8 FL SX 3868190 3868176/SX-C 3868162/SX-C/1.51:1 3868160/SX-,CI1.68:t/

H.A.

5.8 F1 SX 3868194 3868176/SX,.C 3868162./SX-CI1.51:1 3688160/SX-C/1.68:1t

H.A.

5.8 FSI SX 3868195 3868176/SX-C 3688208/SX-C/1.43:1 3868162/$X-C/1.51

:IIH.A.

HA.= highaltitudeapplications

DuoProp
Engine ModelNr. TransomShield Drive Unit Options

4.3 GI DP 3868320 3868299JDP-S 3868008/DP-C1/2.30:1

4.3 GSDP 3868321 3868299/DP-S 3868008/DP-C1/2.30:1

5.0 FL DP 3868322 386829g/DP-S 3868002/DP-C111.95:1 3868(X)8/DP-C1/2.30:1/HA.

5.0 Fi DP 3868323 3868299/DP-S 3868GO2/DP-CI/1.95:1 3868008/DP-C1/2.30:l/H

J~.

5.7 G| DP 3868325 3868299/DP-S 3868002/OP-C1/1.95:1 3868008/DP-C1/2.30:ltH.A.

5.8 FL DP 3868324 3868299/DP-S 3868002/DP-Cl/1.95:1 3868068/DP-C1/2.30:1/HA.

5.8 F| DP* 3868326 3868299/DP-S 3868002K)P,.C111.95:1 386800&~)P-C

I/2.30:1/H J~

5.8 FSi DP 3868327 3868299/DP-S 3868002/DP-Cl/1.95:1 3868022JDP-D1/1.78:1

7.4 GL DP 3868328 3868299/DP-S 3868022/DP-.DlI1.78:1 3688002/DP-C

1/1.95:1/HA.

7.4 Gi DP 3868335 3868299/DP-S 3868022/DP-.DII1.78:1 NA.

= exportonly HA. : high a~deapplications NA.= Not Available

Engine Model Number TransomShield Drive Unit

7.4 GSi DPX-CA 3868198 3868289/DPX~ 6868020/DPX-C/1.5g:1

7.4 GSi DPX-CB 3868198 3688289/DPX~ 3868021/OPX-C

I1.68:1

7.4 GSi DPX-CC 3868198 3868289/DPX~ 3868023/DPX-C

11.78:1

8.2 GL DPX-CA 3868133 3688289/DPX-C 3868020/DPX-.C

11.59:1

8.2 GL DPX-CB 3868133 3868289K~X-C 3868021/DPX..C

11.68:1

8.2 GL DPX-CC 3868133 3868289/DPX-C 6868023/DPX-C/1.78:1

 This Volvo Penta MFI WorkshopManual
Covers The Following Volvo Penta "NC" Models

SX
TM

Engine ModelNr. TransomShield DriveUnit Options

3.0 GSSX NPS 3868181 3868432/SX-LIMITED
TRIM 3868396/SX-CTI1.85:1 3868397/1.97/SXC
386404/TSK
3.0 GSSX 3868182 3868432/SX-LIMITED
TRIM 3868396/SX-CT/1.85:1 3868397/1.97/SXC
3864(~#TSK
4.3 GL SX 3868184 3868404/SXJDP 3868395/SX/1.66 3868465/SXJ1.85

4,3 GSSX 3868186 3688404/SX/DP 3868395/SX/1.66 3868465/SX/1.85

5,0 FL SX 3868414 3868404/SX/DP 3868395/SX/1.66

5.0 R SX 3868416 3~/SX/DP 3868394/SYJ1.60 3868395/SX/1.66

5,7 Gi SX 3868429 3868404/SX/DP 3868393/SX/1.51 N.Ao

5.8 FL SX 3868415 3868404/SX/DP 3868393/SX/1.51 N~.

5.8 FSI SX 3868418 3~8404/SX/DP 3868393/SX/1.51 N.A.

H.A.= highattitude applications

DuoProp
Engine ModelNr. TransomShield DriveUnit .Options

4.3 GL DP 3868184 3868404/SYJDP 3868163/DP/2.30 N.A.

4.3 GSDP 3868186 3868404/SX/DP 3868163/DP/2.30 N.A.

4.3 Gi DP 3868185 3868404/SX/DP 3868163/DP/2.30 N.A.

5.0 FL DP 3868414 38S~O~SX/DP 386816/DPI1.95 N.A.

5.0 F! DP 3868416 3688404/SX/DP 386816,~/DP/1.95 N.A.

5.7 Gi DP 3868429 3868164/DP/1.95 HA

5.8 FL DP 3868415 :~04~P N.A.

5.8 FSi DP 3868415 386816#JDPI1.95 3868165~DP/1.78

7.4 GL DP 3868196 3~4tN~P 3868022/DP-DI/I.78:1 N.A.

7.4 Gi DP 3868450 38~41N/SX~P 3868166K)P/I.68 N.A.

* = for exportonly H~a~

= highaltitude applications N.A.= NotAvailable

Engine Model Nr. TransomShield Drive Unit

7.4 GSt DPX-CA 3868198 3868289/DPX 3868020/DPX

!1.59:1

7.4 GSi DPX-CB 3868198 3868289tDPX 3868021/DPX

11.68:1

7.4 GSl DPX-CC 3868198 3868289/DPX 3688023/[PX

11.78:1

8.2 GL DPX-CA 3868133 3868289/DPX 3868020/DPX

il.59:1

8.2 GL DPX-CB 3868133 3868289K)PX 3868021/DPX

11.68:1

8.2 GL DPX-CC 3868133 3868289K)PX 3868023tDPX

11.78:1
 Section I

General Information

Table of Contents

Basic Knowledge and Tools Required .................. 1-2

Code / Scan Tools ................................. 1-3
Diagnosis of Driveability Concerns(With No DTCs Set) ... 1-6
Diagnostic information ............................. 1-2
Diagnostic Trouble Codes (DTCs) ..................... 1-2
ECMClearing ........... ........................ 1-5
How They Are Set ............................... 1-3
Manually Clearing ......... o ..................... 1-6
Reading ....................................... 1-4
DLC Connector ................................... 1-3
ECMSelf-Diagnostics .............................. 1-3
Electrostatic Discharge Damage...................... 1-2
Metri-Pack Series 150 Terminals ...................... 1-7
On-Board Diagnostic (OBD) ..... ; ................... 1-3
Service Mode .................................... 1-4
Service Tools Needed .............................. 1-9
Visual / Physical inspection ......... : ............... 1-3
Weather-Pack Terminals ........... ................. 1-7
Wiring Connector Service ......................... .. 1-6
Wiring Harness Service ............................ 1-8

Z~ Safety Warning

To reduce the chanceof personal injury and / or
property damage, the following cautions must
be carefully observed.
Proper service and repair are important to the
safety of the service technician and safe, reliable
operation of all Electronic Fuel Injection (EFI)
equipped engine If part replacement is neces-
sary, the part must be replaced with one of the
samepart numberor with an equivalent part. Do
not use a replacement part of lesser quality.
The service procedures recommendedand de-
scribed in this service manual are effective
methodsof performing service and repair. Some
of these procedures require the use of tools
specially designed for the purpose.
Accordingly, anyone who intends to use a re-
placement part, service procedure or tool, which
is not recommendedby the manufacturer, must
first determine that neither his safety nor the
safe operation of the engine will be jeopardized
by the replacement part, service procedure or
tool selected.
Its important to note that this manualcontains
Various "Safety Warnings" and "Notes" that
must be carefully observed in order to reduce
the risk of personal injury during service or
repair, or the possibility that improperservice or
repair may damagethe engine or render it un-
safe. Its also important to understandthat these
"Safety Warnings" and "Notes" are not exhaus-
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
understanding of basic electrical circuits and
circuit testing tools is required. Youshould un-
derstand the meaning of voltage, ohms, and
amps; the basic theories of electricity; what
happens to an open, shorted or grounded wire;
and be able to follow wiring diagrams.
To perform system diagnostics, several special
tools and equipment are required. Becomeac-
quainted with the tools and their use before
attempting to diagnose the system. Special tools
which are required for systemservice are illus-
trated at the end of this section.
Electrostatic Discharge Damage
Electronic componentsused in control systems
are often designed to carry very low voltages,
and are very susceptible to damagecaused by
electrostatic discharge. Its possib|e for less than
100 volts of static electricity to causedamage to
someelectronic components. By comparison, it
takes as muchas 4,000 volts for a person to feel
the zap of a static discharge.
There are several ways for a person to become
statically charged. The most commonmethods
of charging are by friction and induction An
exampleof charging by friction is a person slid-
ing across a seat, in which a charge of as muchas
25,000 volts can build up.
Charging by induction occurs when a person
with well-insulated shoes stands near a highly
charged object and momentarily touches
ground. Chargesof the samepolarity are drained
off, leaving the person highly charged with the
opposite polarity. Static charges of either type
can cause damage;therefore, its important to
use care when handling and testing electronic
components.
The diagnostic charts and function checks in this
manualare designed to locate a faulty circuit or
component through logic based on the process
of elimination. The charts are prepared with the
assumption that the system functioned correctly
at the time of assembly and that there are no
rnultiple failures.
Engine control circuits contain manyspecial de-
sign features not found in standard marine wir-
ing. Electrical contacts are protected against en-
vironmental effects and proper splicing methods
must be used when necessary. The proper oper-
ation of low amperageinput / output circuits
depends upon good continuity between circuit
connectors.
Its important before component replacement
and / or during normal troubleshooting proce-
dures that a visual inspection of any question-
able mating connector be performed. Mating
surfaces should be properly formed, clean, and
makegood contact. Sometypical causes of con-
nector problems are listed below.
e Improperly formed contacts and / or connec-
tor housing
Damagedcontacts or housing due to im-
proper engagement
Corrosion, sealer or other contaminants on
the contact mating surfaces
|ncomplete mating of the connector halves
during initial assembly or during subsequent
troubleshooting procedures
Tendency for connectors to comeapart due
to vibration and / or temperature cycling
e Terminals not fully seated in the connector
bodies
inadequate terminal crimps to the wire
DLC Connector Ifa sensor
is withinits workingor acceptable
parameters,
the ECMwill notdetecta problem. When a sensorvolt-
agesignalfalls outof this -window",
or anopenor short
TheECMcan communicate a variety of information occursin the wiring to the sensor,the ECM wouldnot
throughthe DataLink Connector
(DLC)at the front receivethe=window"voltagefor that sensor.
the engine.Storedinformationcanbe acquiredusing
a scan tool or a MarineDiagnostic Trouble Code Whenthe ECM doesnotreceivethe "window" voltagefor
(MDTC)tool. Stepcharts in the Diagnoses section a programmedlengthof time,a DTCwitl bestored.The
incorporateprocedures usingthe MDTC tool. CheckEngine
light (if soequipped)
will beilluminatedand
a knowndefaultvaluewill replacethe sensed valueto
ThemarineDLCis a 10-pin connector;, restoreengine.performance.
an automotiveDLCis a 12-pin connector.Make
sure the scanor codetool is an appropriateonefor Visual / PhysicalInspection
madneuse.
A careful visual andphysical inspection mustbe
Code/ Scan Tools performedas part of any diagnostic procedure.
This can often lead to fixing a problemwithout
A variety of devicesattachto the DLCto aid techni- further stops. Inspectall vacuum hosesfor correct
routing, pinches, cuts, or disconnects Besureto in-
cian diagnostics.Theyrangefrominexpensive blink- spect hoses that are difficult to see. Inspectall the
ing lights (codetools) to sophisticated
LCD/ LEDmad-- wires in the enginecompartment for properconnec-
outs (scantools). Choose onethat hasbeendesigned
for marineapplications, andbest suits your needs tions, burnedor chafedspots,pinchedwires, or con=
tact with sharpedgesor hot manifolds.Thisvisual /
andbudget.Thetext in this manual hasbeenwritten physicalinspectionis veryimportant.It mustbe done
in termsof using a MarineDignostic trouble Code carefully andthoroughly.
(MDTC)tool. If using a scan tool, follow the
manufacturers instructions.
On-BoardDiagnostic (OBD) System
ECMSelf-Diagnosis Check

TheECM performsa continualserf-diagnosison cer-
tain control functions.Thisdiagnosticcapability is
complemented by the diagnostic procedurescon-
tained in this manualTheECMslanguagefor com-
municatingthe sourceof a malfunctionis a systemof
diagnostic codes.Thecodesare two digit numbers
that canrangefrom12 to 51. When a malfunctionis
detectedby the ECM,a codeis set.
HowDiagnostic Trouble Codes
(DTCs) Are Set
TheECM is programmedto receive calibrated volt-
agesignalsfromthe sensors.Thevoltagesignal from
a sensormayrangefromaslow as 0.1 volt to as high
as 4.9 volts. Thesensorvoltagesignal is calibrated
for engineapplication. This wouldbe the sensors
working parameteror 9Nindow."TheECMandsen-
sors will be discussedfurther in the ECM andSen-
sor section.
After the visual / physicalinspection,the OBD sys-
temcheckis thestarting point for all diagnosticpro-
cedures.Referto the Diagnoses section.
Thecorrect procedureto diagnosea problemis to
follow twobasicsteps"
1. Arethe on-board diaonostics working.?. This is
determinedby performingthe OBDsystemche",J<.
Sincethis is the startingpointfor thediagnosticpro.
cedures,alwaysbeginhere. If the on-board diagnos-
tics arent working,the OBD systemcheckwill lead
to a diagnosticchartin the Diagnoses sectionto cor-
rect the problem.If the on-boarddiagnostics
are work-
ing correctly,thenextstepis:
2. ,~stored? If a DTCis stored, go di-
rectly to the numbered DTCchart in the Diagnoses
section.Thiswill determine
if thefault is still present.

~ 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
its switchin the "OFF = position, andthe keyin the
"ON"position andthe enginenot running, the MDTC
tool light will come"ON".When the engineis started~
the light will turn "OFF.If the light remains=ON",
the self-diagnostic systemhas detecteda problem.
if the problemgoesaway,the light will go out in
mostcasesafter 10 seconds,but a codewill re-
mainstored in the ECM.
Whenthe light remains"ON"while the engine is
running, or whena malfunction is suspecteddue
to a ddveability problem,an MFIDiagnosticCircuit
Checkmust be performed.Thesechecks will ex-
pose malfunctions which maynot be detected if
other diagnosticsare performedprematurely.
"[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.
IntermittentLight
In the caseof an =intermittent" problem,the MDTC
tool bulbwill light for 10 seconds
andthengo out.
However,the corresponding codewill be stored in
the memory.of the ECM.Whenunexpectedcodes
appearduring the codereading process, one can
assume that these codeswereset by art intermit-
tent malfunctionandcould be helpful in diagnos-
ing the system.
An intermittent DTC,if cleared, mayor maynot
reset, if its an intermittentfailure, consultthe Di-
agnostic Aids on the pagefacing the diagnostic
codechart corresponding to the intermittent DTC.
Symptoms also coversthe topic of =intermittents".
A physical inspectionof the applicablesub-system
mostoften will resolvethe problem.
Manually Clearing DTCs
I. Turnignition switchto the =OFF"
position.
2. Install MarineDiagmosticTroubleCode(MDTC)
tool with pushswitch in the =OFF"
position.
3. Turnignition "ON",enginenot running.
4. PushMDTC
tool switch to =ON"position.
5. To clear DTCs,disengage
the remotecontrols
shift function, then SLOWLY
movethe throttle from
0%(idle) to 100%(VVOT)then back to
6. PushMDTC
tool switch to "OFF"position.
Turnignition =ON",enginenot running. PushMDTC
tool switchto =ON"
position andverify DTC12 only.
RemoveMDTCtool.
When clearing DTCs,the battery mustbe
fully chargedandcrankingspeedmustbe at least
200RPM.Theability to clear DTCsis directly de-
pendenton the battery beingfully chargedandable
to crank engine with adequatecranking RPM.
ECMClearing of DTCs
TheECM will automaticallyclear DTCsif they have
not re-occurredwithin 25 "power-ups".One=power-
up" is definedas anytimethe engine,either crank-
ing or running, enters RunModeby exceeding300
RPMfor 16 secondsor more.
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-
ant sensorincorrectly reads50. This wouldcause
the ECMto deliver morefuel thanwasactual!yneeded
andresult in anoverlyrich, roughrunningcondition.
This condition wouldnot havecauseda DTCto set
as the ECMinterprets this as within its "range".
Beforemakinga connectorrepair, be certain of the
type of connector.Some connectorslook similar but
are serviceddifferently. Replacementconnectors and
terminalsarelisted in the PartsCatalog.

Toidentify a sensorwhichis out of range,unplugit

while iunningthe engine.After approximately 2 min-
utes,the diagnostic DTCfor that sensor
will set, illu-
minate the CheckEngine or Marine Diagnostic
TroubleCodetool light, andreplacethe sensed value
witha defaultvalue.If at that pointa noticeable per-
formanceimprovement is observed,the DTCchart
for that particular sensorshouldbe followedto cor-
rect the problem.
Be sure to clear eachDTCafterdisconnectingand
reconnectingeachsensor.Failure to do so mayre-
suit in a mis-diagnosis
of thedriveability concern.
 DRC64J
Metri-Pack- Series 150 Terminals
SomeECMharness connectors contain terminals
called Metri-Pack. Theseare used at someof the
sensors and the distributor connectors. Metri-
Pack connectors require tools J 35689, BT-8518
or an equivalent to service them.
[~ SomeMetri-Pack terminals are called "pull-
to-seat". To removethe terminal, slide the seal (~)
backon the wire. Insert a flat tool thru the backof
the connector ~) to release the locking tang ,
and push the wire out through the front of the
connector. To install a terminal, the wire is first
inserted through the one piece seal then out the
front of the connector. The terminal is crimped
on the wire, and the terminal pulled back into the
connectorto seat it in place.
Weather-PackTerminals
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~,~
DR54G4 M
~ To remove the terminal, pivot the con-
nector retaining hinge (~) out of the way. Insert
the specified removaltool (~) thru the front of the
connector, and pushthe terminal and seal (~) out
of the connector. To install a terminal, the wire is
first inserted through the seal. Thewire and seal
are crimped to the.terminal ~). The terminal is
then pushed back into the connector to seat and
seal it in place. Makecertain that the connectors
are property seated and all of the sealing rings
are in place whenclosing the retaining hinge.
[~] The retaining hinge (~) provides a secondary
locking feature for the connector. It improvesthe
connectorsreliability by retaining the terminals if
the small terminal lock tangs are not positioned
properly.
Weather-Pack connectors cannot be replaced
with standard connectors. Instructions are
provided with Weather-Packconnector and ter-
minal packages.
1-7
 01~57S
Wiring HarnessService
Whensignal wires are spliced into a harness, use
the same gauge wire with high temperature
insulation only. With the low current and voltage
levels found in the system, its important that the
best possible bond be madeat all wire splices by
soldering the splices.
Twisted / Shielded Cable Repair
Step 1. Remove
outer jacket (~).
Step 2. Unwrap aluminum / mylar tape and
ground (uninsulated) wire. Do not remove mylar
tape (~), or ground wire
Step 3. Untwist conductors. Strip insulation (~)
necessary.
Step 4. Splice wires using splice clips and rosin
core solder. Wrapeachsplice to insulate.
Step 5. Wrap with mylar (~ and ground wire .
Step 6. Tape (~) over whole bundle to secure
before.
1-8
Twisted Lead Wire Repair
Step 1. Locate damagedwire. Removeinsulation
@as required. Ifshrink tube is to be used as an
insulator, cut and slide shrink tube over damaged
wire.
Step 2. Splice wire together using splice clip (~)
and rosin core solder.
Step 3. Cover splice with electrical tape to insu-
late from other wires.
Step 4. Retwist as before and cover with electri-
cal tape (~ to hold in place.
Use care when probing a connector or
replacing connector terminals. Its possible to
short between opposite terminals, if this hap-
pens, certain components can be damaged. Al-
ways use jumper wires with the corresponding
mating terminals between connectors fop circuit
checking. NEVER probe through connector seals,
wire insulation, secondaryignition wires, boots,
nipples or covers. Microscopic damageor holes
mayresutt in eventual water intrusion, corrosion,
and componentor circuit failure.
Service Tools Needed

For diagnosis the system requires a CodeTool (CT) (TA-06075),

inductive pick-up timing light, fuel pressure test gauge, tachome-
ter, test light, ohmmeter, digital voltmeter with 10 megohms
impedance (J29125-A, J34029-A or equivalent), vacuum gauge
and jumper wires. A test light or voltmeter must be used when
specified in the procedures. For more complete information on
the operation of these tools, consult the tool manufacturers
instructions.
[~ High Impedance Multi-Meter (Digital Volt-Ohmmeter
DVOM)
A digital voltmeter with a 10 megohmsinput impedanceis used
because this type of meter will not load down the circuit and
result in faulty readings. Somecircuits require accurate voltage
readings because they have very high resistance.

!~] VacuumPumpWith Gauge (20 in. Hg. Minimum)

Use the gauge to monitor engine manifold vacuum, and the hand
pumpto check vacuumcontrolled devices.

EEl UnpoweredTest Light DR5574

Usedfor checking wiring for complete circuits, shorts to ground,

or voltage.

DE] Tachometer
Must have inductive signal pick-up.

[~ Metri-Pack Terminal Remover

Usedfor removing 150 series Metri-Pack "pull-to-seat" terminals
from connectors. Refer to Wiring HarnessService in this section
fo=r removal procedure. M

DR4CB3

D~c.q67
 DR,me1

E~ Weather Pack Terminal Remover

Usedfor removingterminals from WeatherPackconnectors.Refer to
WiringHarnessServicein this sectionfor removalprocedure.

[~ Timing Light

Must haveinductive signal pickup

~] Marine Diagnostic Trouble Code (MDTC) Tool
DR44~

It will flash a DTC

whena problem
is detected.

E~ Fuel Pressure Gauge

A
Usedfor checkingfuel pumppressureand comparinginjector pressure ! J
dropfor equalfuel distribution.
I !

El Injector Hamoss Test Light

A speciallydesigned
light usedto visually indicateinjector electrical DRcsrP
impulses from the ECM.

[~ injector Tester (optional)

Separatelyenergizeseachinjector to compare
for equatimpulsesover a
constanttimeinterval.

[~ This function included in the VP2000 scan tool

[-~ VP 2000 Scan Tool (optiorai) m

Universalhandheld diagnostictool thats usedto determineMFIandTB!

systemproblems,it wiUdisplaysvarious engineoperatingparameters, /

1-10
 Section 2

Engine Control Module

(ECM) and Sensors
Table of Contents

Analog Signals ................................... 2-2

Three Wire Sensors .............................. 2-2
Two Wire Sensors ............................... 2-2
Check Engine Light ................................ 2-g
Computers and Voltage Signals ...................... 2-2
Digital Signals ................................... 2-3
Pulse Counters ................................. 2-3
Switch Types ................................... 2-3
ECMInputs and Sensor Description .................... 2-5
Discrete Switch Inputs ...................... ..... 2-9
Engine Coolant Temperature Sensor (ECT) ............ 2-6
ignition Control Reference (IC) ..................... 2-9
Intake Air Temperature Sensor (IAT) ................... 2-8
Knock Sensor (KS) ............................... 2-7
Knock Sensor (KS) Module ........................ 2-7
Manifold Absolute Pressure (MAP) Sensor ............ 2-6
Throttle Position Sensor (TP} ....................... 2-8
Engine Control Module (ECM) ............... . ....... 2-4
ECM Function. ................................. 2-4
Memory ........................... - ...... ..... 2-4
EEPROM..................................... 2-4
RAM ......................................... 2-4
ROM...................... .................. 2-4
General Description ............................... 2-2
RPMLimiter ..................................... 2-9
S.LOoW. ". ...................................... 2-9
Speed Density System .......................... ;.. 2-5

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

~--" SIGNAL ~Pt~

_1_ GROUNO

General Description Analog Signals

VolvoPentasMulti-PointFuel Injection (MFI)sys- Ananalogsignal is continuously

variable. Thismeans
temis equippedwith a computer that. providesthe that the signal canbe anyvoltagewithin a certair
operatorwith state-of-the-artcontrolof fuel andspark range.
delivery. Computers use voltageto sendandreceive
informationas describedbelow. Ananalogsignal usually gives informationabout
condition that changescontinuouslyOvera certair
Computers and Voltage Signals range.For example,temperature is usually providec
~
by an analogsignal. Thereare twogeneraltypeso
sensorsthat producean analogsignal; the 3-wireanc
Voltageis electrical pressure.Voltagedoesnot flow the 2-wiresensor.
throughcircuits; instead, voltagecausescurrent.
Currentdoesthereal workin electrical circuits. Its Threewire Sensors
current,the flowof electricallycharged
particles,that
energizessolenoids,closesrelays andlights lamps. I~ All ~wire sensorshavea referencevoltage,
groundanda variable "wiper." Thelead comingof~
Besidescausingcurrents in circuits, vo~gecan be the =wiper"will be the signal to the EngineContro
usedas a signal. Voltagesignals cansendinforma- Module(ECM).As the wiper position changes,th~
tion by changinglevels, changingwaveform (shape), signal voUtagereturnedto the computer also changes
or changingthe speedat whichthe signal switches
from onelevel to another. Computers use voltage TwoWireSensors
signals to communicatewith oneanother.Thediffer-
ent sectionsinside computers also use voltagesig-
nalsto talk to eachother. [~ This sensoris basically a variable resistor ir
serieswith a fixed known resistorwithinthe computer
Thereare twokinds of voltages~nais, analogand By knowing the values of the input voltageandth~
digital. Bothof theseare usedin computersystems. voltage drop across the known resistor, the valueo
its importantto understandthe differencebetween the variableresistor can be determined. Thevariable
themandthe different waystheyre used. resistors that are commonly used are called ther
mistors.A therrnistorsresistance varieswith tempera
ture.
 V DiGiTAL
BINARY
SIGNAL
0
L
T
A
nnno
Digital Signals
I~ Digital signals are also variable, but not
continuously. They can only be represented by
distinct voltages within a range. For example,1V,
2V or 3V would be allowed, but 1.27 V or 2.65 V
would not. Digital signals are especially useful
when the information can only refer to two
conditions - "YES" and "NO," "ON" and "OFF,"
or "HIGH" and "LOW." This would be called a
digital binary signal. A digitalbinary signal is
limited to two voltage levels. One level is a
positive voltage, the other is no voltage (zero
volts). A digital binary signal is a square wave.
The computeruses digital signals in a code that
contains only ones and zeros. The high voltage of
the digital signal represents a one (1), and
voltage represents a zero (0). Eachzero and each
one is called a bit of information, or just a "bit."
Eight bits together are called a word. A word,
therefore, contains some combination of eight
binary code bits: eight ones, eight zeros, five
ones and three zeros, and so on.
Binary code is used inside a computer, and
between a computer and any electronic device
that understands the code. By stringing together
thousands of bits, computers can communicate
and store an infinite variety of information.
c~n~
To a computer that understands binary,
11001011 might mean that it should turn an
output device "ON" at a slow speed. Although
the computeruses 8-bit digital codes internally
and when talking to another computer, each bit
can have a meaning.
Switch Types
Switched inputs (also knownas discretes) to the
computer can cause one bit to change, resulting
in information being communicatedto the com-
puter. Switched inputs can comein two types;
they are "pull-up" and "pull-down".
With a "pull-up" type switch, the ECMwill sense
a voltage whenthe switch is CLOSED. In the case
of the "pull-down," the ECM"sees" the voltage
when the switch is OPEN.
Pulse Counters
For a computer to determine frequency informa-
tion from a switched input, the computer must
measurethe time between voltage pulses. As a
numberof pulses are recorded in a set amountof
time, the computercan calculate the frequency.
The meaning of the frequency number can have
any number of meanings to the computer.
2-3

An exampleof a pulse counter type of input is the
distributor reference pulse input. The computer
can count a train of pulses, a given numberof
pulses per engine revolution, in this way, the
computer can determine the RPMof the engine.
Engine Control Module (ECM)
[~ The Engine Control Module {ECM) is the
control center of the fuel injection system, it
constantly monitors information from various
sensors, and controls the systems that affect
engine performance.
E~ The ECMalso performs a diagnostic func-
tion check of the system./t can recognize opera-
tional problems and store a Diagnostic Trouble
Code(s) (DTC) which identifies the problem area
to aid the technician in makingrepairs.
ECMFunction
The ECMsupplies 5 or 12 volts to power various
sensors or switches. This is done through resis-
tances in the ECMwhich are so high in value that
a test light will not light whenconnectedto the
circuit, in somecases, even an ordinary shop
voltmeter will not give an accurate reading be-
causeits resistance is too tow. Therefore, the use
of a 10 megohmsor greater input impedance
digital voltmeter is required to assure accurate
voltage readings.
2-4
5 VOLTS
XXXXXXXXXXXXXXXX DEFAULT XXXXXXXXXXXXXXXX
4.9V
t
TYPICAL SENSOR RANGE
"WINDOW"
0.iV
XXXXXXXXXXXXX,Y~XX DEFAULT XXXXXXXXXXXXXXXX
0 VOLTS
Memory
There are three types of memorystorage within
the ECM: ROM, RAM and EEPROM.
ROM
Read Only Memory (ROM) is a permanent mem-
ory that is physically soldered to the circuit
boards within the ECM. The ROMcontains the
overall control programs. Oncethe ROMis pro-
grammed, it cannot be changed. ROMmemoryis
non-erasable, and does not need power to be
retained.
RAM
Random Access Memory (RAM) is the micro-
processor "scratch pad." The processor can
write into, or read from, this memoryas needed.
This memoryis erasable and needs a constant
supply of voltage to be retained. During normal
engine operation, acquired DTCs are stored in
RAM memory.
EEPROM
Electronic Erasable Programmable Read Onty
Memory(EEPROM) is the portion of the ECMthat
contains the different engine calibration informa-
tion that is specific to each application. Upon
engine shut-off, DTCs are stored to the EEPROM
from RAM. DTCs will remain in the EEPROM
even if B+ voltage is subsequently lost (i.e.
battery removed,master switch turned off, etc.).
~o~.~