Engine Measurements-Checking Volvo Diesel Engine

May. 21, 2018

Checking signal cable, inlet manifold pressure sensor

Tools:

885675 Break-out cable

88890074 Multimeter

1 NOTICE! Cut the current with the main switch.

2 Disconnect the connector from the sensor.

3 Connect break-out cable 885675 to the cable harness connector to the engine control unit.

4 Use multimeter 88890074 to do resistance measurement against the engine control unit.

Measurement points	Nominal value
4–1	R ≈ 80 – 120 k Ω

NOTICE! Measurement is done to eliminate short circuiting or breaks in the cable to the engine control unit.

Checking air inlet pressure sensor

Tools:

885675 Break-out cable

88890074 Multimeter

1 NOTICE! Turn ignition off.

2 Disconnect the connector from the sensor.

3 Connect break-out cable 885675 between the sensor and the engine control unit.

4 Use multimeter 88890074 for voltage measurement.

5 Turn ignition on.

Measurement points

Nominal value

1–4

U ≈ 1,1 V (at normal

atmospheric pressure)

Checking supply cable, coolant level switch

Tools:

885675 Break-out cable

88890074 Multimeter

1 NOTICE! Turn ignition off.

2 Disconnect the connector from the switch.

3 If grey switch: Connect break-out cable 885675 to the cable harness connector to the engine control unit.

4 Use multimeter 88890074 for voltage measurement.

5 NOTICE! Turn ignition on.

Measurement points	Nominal value
1–2	U ≈ Battery voltage x 0.8

Checking negative cable, coolant level switch

Tools:

885675 Break-out cable

88890074 Multimeter

1 NOTICE! Cut the current with the main switch.

2 Disconnect the connector from the switch.

3 If grey switch: Connect break-out cable 885675 to the cable harness connector to the engine control unit.

4 Use multimeter 88890074 to do resistance measurement against the engine control unit.

Measurement points	Nominal value
2 – Battery negative	R≈ 0 Ω

Checking coolant level switch

Tools:

885675 Break-out cable

88890074 Multimeter

NOTICE! The coolant level switch can be removed without having to drain the coolant.

Checking black coolant switch

1 Undo the connector and remove the switch from the expansion tank.

2 Use multimeter 88890074 to do resistance measurement against the switch.

Measurement points	Nominal value
Blue – Black	R ≈ ∞ Ω

3 Move a magnet along the switch and observe the resistance value. The resistance should drop to approx. 0 Ohm.

Measurement points	Nominal value
Blue – Black	R ≈ 0 Ω

Checking grey coolant switch

1 Undo the connector and remove the level switch from the expansion tank.

2 Connect break-out cable 885675 to the switch.

3 Use multimeter 88890074 to do resistance measurement against the switch.

Measurement points-Move a magnet along the

switch and observe the resistance value

Nominal value

1 – 2

R ≈ 0 Ω

4 Move a magnet along the switch and observe the resistance value. The resistance should be ∞ Ohm.

Measurement points	Nominal value
1 – 2	R ≈ ∞ Ω

Checking starter motor relay coil

Tools:

88890074 Multimeter

1 Cut the current with the main switch.

2 Remove one of the wires to the starter motor relay.

3 Use multimeter 88890074 to measure the resistance in the coil.

Measurement points	Nominal value
Relay connectors	R ≈ 9-15 Ω

Checking starter motor relay voltage supply

Tools:

88890074 Multimeter

1 Turn ignition off.

2 Connect multimeter 88890074 to do voltage measurement over the starter motor relay.

3 Turn ignition on.

Measurement points	Nominal value
Relay connectors	V ≈ 0 V

4 Push start button.

Measurement points	Nominal value
Relay connectors	V ≈ Battery Voltage

Checking the wiring

Between EMS2 and IEGR

If any of the measurements shows an abnormal value,

check the wiring to and from the engine interface.

1 Cut the current with the main switch.

2 Remove the connector to the IEGR solenoid.

3 Remove connector B from the EMS2.

4 Connect the B connector to break-out cable 9990014 with break-out box 9998699.

5 Use multimeter 88890074 to do resistance measurement.

Measurement points	Nominal value
30 (IEGR signal) - 2 (IEGR connector)	R ≈ 0 Ω
57, 60 (relay +) - 1 (IEGR connector)	R ≈ 0 Ω

Checking IEGR coil

Tools:

88890074 Multimeter

1 Cut the current with the main switch.

2 Remove the connector from the IEGR solenoid.

3 Use multimeter 88890074 to do resistance measurement.

Measurement points	Nominal value
1-2	R ≈ 28-42 Ω

Checking IEGR solenoid

1 NOTICE! Cut the current with the main switch.

2 Remove the IEGR solenoid. Please see workshop manual Group 21-26 for reference how to remove the IEGR solenoid.

3 One part of the solenoid is spring loaded. Press gently down that part with a screwdriver and hold.

4 Connect a 24 V power supply to the IEGR electrical connection. The solenoid should now make a click when altering its position.

Checking the injectors

Tools:

88890074 Multimeter

NOTICE! If any of the measurements shows an abnormal value, check the wiring to and from the engine interface.

1 Cut the current with the main switch.

2 Remove both wires that are connected to the injector that is to be measured.

3 Remove connector A from the EMS2.

4 Use multimeter 88890074 to do resistance measurement between connector A from the EMS 2 to the loosened wires from the injector. See circuit description which pin in the connector A to measure from.

Checking camshaft sensor wiring

Tools:

885675 Break-out cable

88890074 Multimeter

1 NOTICE! Cut the current with the main switch.

2 Remove the connector from the sensor. Connect break-out cable 885675 to the connector.

3 Remove connector A from the EMS2.

4 Use multimeter 88890074 to do a resistance measurement from the sensor connector to connector A to verify that neither of the wires are broken or short circuited.

Measurement points	Nominal value
1 (sensor conn.) – 46 (conn. A)	R ≈ 0 Ω
2 (sensor conn.) – 45 (conn. A)	R ≈ 0 Ω
1 (sensor conn.) – 2 (sensor conn.)	R ≈ ∞ Ω

IMPORTANT!

Be very careful when measuring inside the connector, to ensure that no pin is damaged.

Checking camshaft sensor

Tools:

885675 Break-out cable

88890074 Multimeter

1 NOTICE! Cut the current with the main switch.

2 Undo the connector from the sensor and remove the sensor from the cylinder head.

Check that the sensor does not have any external damage, or any swarf which has got stuck on it.

3 Connect break-out cable 885675 to sensor.

NOTICE! Do not connect the other end of the adapter cable to the engine cable harness, since

this can cause a measurement error.

4 Use multimeter 88890074 for resistance measurement.

Measurement points	Nominal value
1–2	R ≈ 3,5 kΩ at 20 °C (68 °F)

NOTICE! The measurement must exclude short circuit or open circuit to the engine control unit.

5 Use multimeter 88890074 for a AC voltage measurement.

Move a metal object rapidly back and forwards not more than 1 mm in front of the sensor. Check that the multimeter gives a reading.

6 Install the sensor

Checking crankshaft sensor wiring

Tools:

885675 Break-out cable

88890074 Multimeter

1 NOTICE! Cut the current with the main switch.

2 Remove the connector from the sensor. Connect break-out cable 885675 to the connector.

3 Remove connector A from the EMS2.

4 Use multimeter 88890074 to do a resistance measurement from the sensor connector to connector A to verify that neither of the wires are broken or short circuited.

Measurement points	Nominal value
1 (sensor conn.) – 38 (conn. A)	R ≈ 0 Ω
2 (sensor conn.) – 37 (conn. A)	R ≈ 0 Ω
1 (sensor conn.) – 2 (sensor conn.)	R ≈ ∞ Ω