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Page 1 of 12
Workshop Manual
EFI Diagnostic
C
2(0)
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Section 7B1
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Service Manual
Corrections
----------------The Next 4 pages
contain changes to this
service manual
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Section 7B1
Page 3 of 12
Service Bulletin
Volvo Penta of the Americas
1300 Volvo Penta Drive
Chesapeake, Virginia 23320-9810
USA
Group
Number
04-2
40
Version
01
Distribution: M
Date: 11-2003
Binder: C
Page: 1(4)
Volvo Penta has identified various values that were incorrectly published in the original workshop manual. This
document is intended as a notice to be used to replace information in the original publication.Original text is
boldface italics.
provided along with the corrections, which are denoted using
Page 39: Second sentence When engine RPM reaches a predetermined value (for this example 400 RPM),
the ECM considers the engine running and applies five volts ton the BYPASS line to the IC module
more than 400 RPMs), the ECM
Should read When engine RPM reaches a predetermined value (
considers the engine running and applies five volts to the BYPASS line to the IC module.
Page 42: Engine Control Module (ECM) Step 2: Remove the J-1 (A) and J-2 (B) connectors from the ECM
(C).
J-2 (A) and J-1 (B) connectors from the ECM (C).
Page 149: DTC 14 - Engine Coolant Temperature (ECT) Sensor Circuit - High Temperature Indicated
DTC 15 - Engine Coolant Temperature (ECT) Sensor Circuit - High Temperature Indicated
Page 160: Under paragraph Diagnostic Aids
If engine starts and stalls, it may set a false DTC 41.
If engine starts and stalls, it may set a false DTC
42.
BN/Y
J1-30
GN/SB
J1-15
J1-31
P/BL
BL/Y
J1-16
4306
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Section 7B1
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Group
Number
Version
04-2
40
01
Page
2(4)
Manifold
Absolute
Pressure
(MAP)
Sensor
GR
SB/OR
Page 274: MAP diagram. The light green wire comes from
pin B to J2-6. Make pin B
J2-8.
SB/OR
Lt GN
SB/OR
J2-2
J2-8
J2-3
Engine
Control
Module
(ECM)
P/W
P/W
P/W
Fuel
Fuel
Fuel
Fuel
Injector
Cylinder #1
Injector
Cylinder #4
Injector
Cylinder #6
Injector
Cylinder #7
A
A
A
BL/SB
A
G
Y/SB
SB
R/SB
J1-11
P/W
T/OR
Fuel
Injector
Driver A
J2-11.
P/W
P/W
P/W
P/W
Fuel
Injector
Fuel
Injector
Fuel
Injector
Fuel
Injector
Cylinder #2
Cylinder #3
Cylinder #5
Cylinder #8
A
H
A
F
P/SB
SB/W
GN/SB
BL/W
J1-26
J2-26.
Fuel
Injector
Driver B
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Engine
Control
Module
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Section 7B1
Page 5 of 12
Group
Number
Version
04-2
40
01
3(4)
Fuel
Fuel
Fuel
Fuel
Injector
Cylinder #1
Injector
Cylinder #4
Injector
Cylinder #6
Injector
Cylinder #7
A
A
Page
J2-11.
A
G
T/OR
J1-11
Fuel
Injector
Driver A
P/W
P/W
P/W
P/W
B
Fuel
Fuel
Fuel
Injector
Cylinder #2
Injector
Cylinder #3
Injector
Cylinder #5
Injector
Cylinder #8
A
H
A
D
SB/W
GN/SB
BL/W
J2-26.
J1-26
Fuel
Injector
Driver B
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A
F
P/SB
Fuel
Engine
Control
Module
(ECM)
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Section 7B1
Page 6 of 12
Wiring Diagrams:
Group
Number
Version
04-2
40
01
Page
4(4)
A Red/Blue R/BL wire should connect pin 30 of the Start relay to the adjacent fuse of the following
schematics.
4.3GXi-B
4.3GXi-C/D
5.0GXi-B, 5.7Gi-B, GXi-C
8.1Gi-B, GXi-A
8.1Gi-C/D, GXiB-C
DPX375-B, DPX420-B
Y/R
R/PU
86
30
1
5
87
85
PU
86
30
P/W
R/PU
19
1
5
87
85
R/W
86
30
2
0
87
85
SB/Y
6
SB
20
20
R/PU
Wiring Diagrams: Replace the existing Engine Schematic 4.3GXi-A, 4.3OSi-A/B, 5.0GXi-A, 5.0OSi-A/B, 5.7Gi-A,
5.7OSi-A, 5.7GXi-B, 5.7OSXi-A with the attached wiring schematic.
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Section 7B1
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Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Throttle Body Injection (TBI)
TBI Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
TBI On Board Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
TBI Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
TBI Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
TBI Non-Scan Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
TBI Scan Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Wiring Diagrams
4.3GXi-A, 5.0GXi-A, 5.7Gi-A, 5.7GXi-A/B . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
4.3GXi-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
4.3GXi-C/D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
5.0GXi-B, 5.7Gi-B, 5.7GXi-C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
5.0GXi-C/D5.7Gi-C/D, 5.7GXi-D/E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
8.1Gi-B, 8.1GXi-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
8.1Gi-C/D, 8.1GXi-B/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
DPX375, DPX420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
Fues Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S1
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General Information
Contents
Circuit Protection .......................................................................................................................... 3
Circuit Protectors and Locations ................................................................................................ 3
Battery and Cables ........................................................................................................................ 4
Special Tools Required: Battery Hydrometer ............................................................................. 4
Battery Requirements ................................................................................................................... 4
Battery Maintenance ..................................................................................................................... 4
Cable Requirements ..................................................................................................................... 4
Tuning The Engine ........................................................................................................................ 5
Gasoline Requirements ................................................................................................................ 5
Gasoline Containing Alcohol ....................................................................................................... 5
Storage ........................................................................................................................................... 6
Prepare a storage mixture ............................................................................................................ 6
Electric fuel pumps and fuel cells ............................................................................................... 6
Stuck Pumps ................................................................................................................................. 7
Noisy Pumps ................................................................................................................................. 7
Periodic Maintenance Chart ......................................................................................................... 8
Abbreviations ................................................................................................................................ 9
Aftermarket (Add-On) Electrical And Vacuum Equipment ...................................................... 10
Visual/Physical Inspection ......................................................................................................... 10
Basic Knowledge and Tools Required ...................................................................................... 10
Electrostatic Discharge Damage ............................................................................................... 10
Engine Wiring .............................................................................................................................. 10
Engine Control Module (ECM) Self-Diagnostics ...................................................................... 10
Malfunction Indicator Lamp (MIL) ............................................................................................. 11
Intermittent Malfunction Indicator Lamp (MIL)......................................................................... 11
Reading Diagnostic Trouble Codes (DTCs) ............................................................................ 11
Service Mode ............................................................................................................................... 12
Normal Mode ............................................................................................................................... 12
On-Board Diagnostic (OBD) System Check ............................................................................. 12
DLC Scan Tools ........................................................................................................................... 12
Scan Tool Use With Intermittents .............................................................................................. 12
How Diagnostic Trouble Codes (DTC) Are Set ......................................................................... 13
Clearing Diagnostic Trouble Codes (Non-Scan) ...................................................................... 13
Clearing Diagnostic Trouble Codes (Scan) .............................................................................. 14
Non-Scan Diagnosis Of Drivability Concerns (No DTCs Set) ................................................ 14
Service Precautions .................................................................................................................... 15
Special Tools and Equipment .................................................................................................... 16
Special Tools and Equipment (cont.) ........................................................................................ 17
Wiring Harness Service .............................................................................................................. 18
Wiring Connector Service .......................................................................................................... 19
Metri-Pack Series 150 Terminals ............................................................................................... 19
Weather-Pack Connectors ......................................................................................................... 20
Micro-Pack 100/W Series Connectors ....................................................................................... 21
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Document Outline
7742218_cover.pdf
Page 1
Section 2A.pdf
Contents
General Description
Sensors and Voltage Signals
Engine Control Module (ECM)
ECM Function
Memory
Speed Density System
ECM Inputs / Sensor Descriptions
Engine Coolant Temperature (ECT) Sensor
Manifold Absolute Pressure (MAP) Sensor
Knock Sensor (KS) System
ENGINE PROTECTION MODE
Fuel System
Modes Of Operation
Fuel Supply Components
Fuel Pump Electrical Circuit
Fuel Injectors
Pressure Regulator Assembly
Fuel System Operation
Ignition System
Ignition Coil
Ignition Control (IC) Module
Pole Piece and Coil Assembly
Engine Control Module (ECM)
Ignition Timing
Section 3A.pdf
Contents
General Information
Engine Control Module (ECM)
Engine Coolant Temperature (ECT) Sensor
Manifold Absolute Pressure (MAP) Sensor
Throttle Position (TP) Sensor
Idle Air Control (IAC) Valve
Knock Sensor (KS)
Fuel System Component Replacement
Fuel Control Service
Fuel Pressure Relief Procedure
Throttle Body Injector (TBI) Unit
Fuel Meter Cover Assembly
Fuel Injector
Fuel Cell
Circuit Breaker
Relay Replacement
Relay Ohmmeter Tests
Troubleshooting Electric Pump(s)
Pressure Testing Fuel System
Troubleshooting Boat Fuel System
Vacuum Testing Fuel System
Engine Fuel System Troubleshooting
Engine Will Start When Primed - Will Not Continue to Run
Engine Hard Starting, Cold
Engine Hard Starting, Hot
Engine Runs Rough, Low Speed
Engine Runs Rough, High Speed
Engine Dies (On Initial Acceleration) or Has Acceleration Flat Spot
Engine Will Not Run at Recommended RPM
Ignition System Description
Ignition Coil Test
Pickup Coil Test
Ignition Module Test
Inductor
Distributor
Setting Initial Timing
Setting Timing
Ignition Coil Replacement
Ignition and Pickup Coils
Specifications
Ignition System Problems
Torque Specifications
Section 4A.pdf
Contents
Important Preliminary Checks
Hard Start Symptom
Surges Symptom
Hesitation, Sag, or Stumble Symptom
Detonation / Spark Knock Symptom
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