Ignition and Control Systems - General Diagnostics and Tests (Coupe): Other Volvo C70 I

Cleaning and greasing the camshaft position (CMP) sensor connector

1. Ignition off.
2. Disconnect the camshaft position (CMP) sensor. Check camshaft position (CMP) sensor connector for contact resistance and oxidation and remedy according to «Contact resistance and oxidation»(ref-408435-S11196285822011071200000) . Connect the camshaft position (CMP) sensor.

Cleaning and greasing the engine speed (RPM) sensor connector

1. Ignition off.
2. Disconnect the engine speed (RPM) sensor. Remedy engine speed (RPM) sensor connector for contact resistance and oxidation according to «Contact resistance and oxidation»(ref-408435-S11196285822011071200000) .

Continue when corrective action has been carried out.

1. Continue Refer to «Checking engine speed (RPM) sensor»(ref-408435-S38926044772011071200000)

Scheme 585

Scheme 586

Scheme 587

1. Ignition off.
2. Engine speed (RPM) sensor disconnected. Connect an ohmmeter between engine speed (RPM) sensor connector terminals 1 and 2.

The ohmmeter should read approximately 200-400 depending on engine coolant temperature (ECT).

1. OK OKAY: Troubleshooting has been completed.
2. NOT OK Refer to «Replacing engine speed (RPM) sensor»(ref-408435-S39871605272011071200000)

Replacing engine speed (RPM) sensor

1. Try a new engine speed (RPM) sensor.

Scheme 588

Scheme 589

1. Switch off ignition.
2. Disconnect Power stage connector. Check power stage connector for contact resistance and oxidation as per «Contact resistance and oxidation»(ref-408435-S11196285822011071200000) . Reconnect power stage.

Connecting the breakout box

Is the breakout box connected to the Motronic 4.4 connector?

1. YES FAULT NOT FOUND: Troubleshooting has been completed.
2. NO Refer to «Connecting breakout box to Motronic 4.4 connector B (gray)»(ref-408435-S36959255082011071200000)

Scheme 590

1. Ignition off.
2. Disconnect control module. NOTE: The engine control module (ECM) must not be removed from the car until the main relay has interrupted its power supply. This may take up to 150 seconds (cars with an immobilizer 245 seconds) after the ignition has been switched off. Connect adapter «9511351»(ref-403953-S10348238732011061000000) to engine control module (ECM) connector and connect breakout box «9813190»(ref-403953-S32930552542011061000000) to adapter.

1. Continue Refer to «Checking ground terminal #B28»(ref-408435-S00671233742011071200000)

Scheme 591

1. Ignition off.
2. Switch off all equipment that takes power from the battery (courtesy lighting, radio etc.).
3. Connect control module. Connect an ohmmeter between #28 (#B28) on the breakout box and battery negative terminal.

The ohmmeter should read approximately 0 ohms.

1. OK Refer to «Reading is OK»(ref-408435-S05072310982011071200000)
2. NOT OK Refer to «Checking for an open-circuit»(ref-408435-S13576339242011071200000)

Checking for an open-circuit

1. check ground terminals 31/32 and 31/33 on the engine and their cables for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000) and contact resistance and oxidation according to «Contact resistance and oxidation»(ref-408435-S11196285822011071200000) .

Reading is OK

1. Return to the fault-tracing procedure where it was interrupted.

1. Continue FAULT NOT FOUND: Troubleshooting has been completed.

Is the breakout box connected to the Motronic 4.4 connector?

1. YES FAULT NOT FOUND: Troubleshooting has been completed.
2. NO Refer to «Connecting breakout box to Motronic 4.4 connector A (black)»(ref-408435-S35120307742011071200000)

Connecting breakout box to Motronic 4.4 connector A (black)

1. Ignition off.
2. Disconnect control module. NOTE: The engine control module (ECM) must not be removed from the car until the main relay has interrupted its power supply. This may take up to 150 seconds (cars with an immobilizer 245 seconds) after the ignition has been switched off. Connect adapter «9511351»(ref-403953-S10348238732011061000000) to engine control module (ECM) connector and connect breakout box «9813190»(ref-403953-S32930552542011061000000) to adapter.

1. Continue Refer to «Checking ground terminals»(ref-408435-S19144375282011071200000)

Scheme 592

1. Ignition off.
2. Switch off all equipment that takes power from the battery (courtesy lighting, radio etc.). Connect an ohmmeter between battery negative terminal and: #13 (#A13) on the breakout box. #28 (#A28) on the breakout box. #42 (#A42) on the breakout box.

The ohmmeter should read approximately 0 ohms for all readings.

1. OK Refer to «Reading is OK»(ref-408435-S30214250642011071200000)
2. NOT OK Refer to «Checking for an open-circuit»(ref-408435-S35829223902011071200000)

1. Check ground terminals 31/32 and 31/33 at rear of engine and their cables for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000) and contact resistance and oxidation according to «Contact resistance and oxidation»(ref-408435-S11196285822011071200000) .
2. Check ground lead between engine and chassis for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000) and contact resistance and oxidation according to «Contact resistance and oxidation»(ref-408435-S11196285822011071200000) .

1. Return to the fault-tracing procedure where it was interrupted.

1. Continue FAULT NOT FOUND: Troubleshooting has been completed.

Scheme 593

Scheme 594

Scheme 595

1. Start the engine and idle it.
2. Air conditioning (A/C) switch on.
3. Blower fan on: Select Volvo Scan Tool (ST) to read off the status of the air conditioning (A/C) relay.

Is the A/C relay on?

1. YES Refer to «Checking the air conditioning (A/C) compressor signal»(ref-408435-S16912127542011071200000)
2. NO Refer to «Connecting breakout box (connector B)»(ref-408435-S06143901152011071200000)

Checking the air conditioning (A/C) compressor signal

1. Start the engine and idle it.
2. Air conditioning (A/C) switch on.
3. Blower fan on. Select Volvo Scan Tool (ST) to read off the status of the air conditioning (A/C) compressor while the compressor is running.

Is the compressor on?

1. YES Refer to «Cleaning idle air control (IAC) valve connector»(ref-408435-S11105012842011071200000)
2. NO Refer to «Connecting breakout box (connector B)»(ref-408435-S24496753862011071200000)

Cleaning idle air control (IAC) valve connector

1. Clean and grease engine control module (ECM) and idle air control (IAC) valve connectors. «Contact resistance and oxidation»(ref-408435-S11196285822011071200000) . Check whether the engine speed still dips

Do the fault symptoms persist?

1. YES Refer to «Replacing idle air control (IAC) valve»(ref-408435-S02217338842011071200000)
2. NO OKAY: Troubleshooting has been completed.

Replacing idle air control (IAC) valve

1. Try a new idle air control (IAC) valve.

Scheme 596

1. Ignition off.
2. Breakout box connected.
3. Connect control module.
4. Air conditioning (A/C) switch on.
5. Blower fan on.
6. Start engine. Connect a voltmeter between connectors #6 (#B6) and #28 (#B28) on the breakout box.

The voltmeter should read battery voltage when the compressor is running.

1. OK Refer to «Checking for contact resistance and oxidation»(ref-408435-S11489017102011071200000)
2. NOT OK Refer to «Checking for an open-circuit»(ref-408435-S08010868232011071200000)

Checking for contact resistance and oxidation

1. The cause of dipping has been contact resistance in the engine control module (ECM) connector. Clean and grease engine control module (ECM) connector according to «Contact resistance and oxidation»(ref-408435-S11196285822011071200000) .

Scheme 597

1. Check cable between #B6 and pressure switch (Pressostat) connector (7/53) terminal 2 for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000) .

Scheme 598

Checking air conditioning (A/C) relay signal cable

1. Ignition off.
2. Breakout box connected.
3. Connect control module.
4. Air conditioning (A/C) switch on.
5. Blower fan on.
6. Start engine. Connect a voltmeter between connectors #25 (#B25) and #28 (#B28) on the breakout box.

The voltmeter should read battery voltage when the compressor is running.

1. OK Refer to «Checking for contact resistance and oxidation»(ref-408435-S38307963812011071200000)
2. NOT OK Refer to «Checking for an open-circuit»(ref-408435-S01129150002011071200000)

1. The cause of dipping has been contact resistance in the engine control module (ECM) connector. Clean and grease engine control module (ECM) connector according to «Contact resistance and oxidation»(ref-408435-S11196285822011071200000) .

1. Check cable between #B25 and pressure switch (Pressostat) connector (7/53) terminal 1 for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000) .

Is the breakout box connected to the Motronic 4.4 connector?

1. YES Refer to «Checking air conditioning (A/C) compressor signal cable»(ref-408435-S02717672932011071200000)
2. NO Refer to «Connecting breakout box to Motronic 4.4 connector B (gray)»(ref-408435-S23229475312011071200000)

Connecting breakout box to Motronic 4.4 connector B (gray)

1. Ignition off.
2. Disconnect control module. NOTE: The engine control module (ECM) must not be removed from the car until the main relay has interrupted its power supply. This may take up to 150 seconds (cars with an immobilizer 245 seconds) after the ignition has been switched off. Connect adapter «9511351»(ref-403953-S10348238732011061000000) to engine control module (ECM) connector and connect breakout box «9813190»(ref-403953-S32930552542011061000000) to adapter.

1. Continue Refer to «Checking ground terminal #B28»(ref-408435-S27983516792011071200000)

Checking ground terminal #B28

1. Ignition off.
2. Switch off all equipment that takes power from the battery (courtesy lighting, radio etc.).
3. Connect control module. Connect an ohmmeter between #28 (#B28) on the breakout box and battery negative terminal.

The ohmmeter should read approximately 0 ohms.

1. OK Refer to «Reading is OK»(ref-408435-S31558803962011071200000)
2. NOT OK Refer to «Checking for an open-circuit»(ref-408435-S13948411532011071200000)

1. check ground terminals 31/32 and 31/33 on the engine and their cables for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000) and contact resistance and oxidation according to «Contact resistance and oxidation»(ref-408435-S11196285822011071200000) .

Continue when the fault has been remedied.

1. Continue Refer to «Checking air conditioning (A/C) compressor signal cable»(ref-408435-S02717672932011071200000)

1. Return to the fault-tracing procedure where it was interrupted.

1. Continue Refer to «Checking air conditioning (A/C) compressor signal cable»(ref-408435-S02717672932011071200000)

Is the breakout box connected to the Motronic 4.4 connector?

1. YES Refer to «Checking air conditioning (A/C) relay signal cable»(ref-408435-S28543399392011071200000)
2. NO Refer to «Connecting breakout box to Motronic 4.4 connector B (gray)»(ref-408435-S35669920102011071200000)

1. Ignition off.
2. Disconnect control module. NOTE: The engine control module (ECM) must not be removed from the car until the main relay has interrupted its power supply. This may take up to 150 seconds (cars with an immobilizer 245 seconds) after the ignition has been switched off. Connect adapter «9511351»(ref-403953-S10348238732011061000000) to engine control module (ECM) connector and connect breakout box «9813190»(ref-403953-S32930552542011061000000) to adapter.

1. Continue Refer to «Checking ground terminal #B28»(ref-408435-S28741380882011071200000)

1. Ignition off.
2. Switch off all equipment that takes power from the battery (courtesy lighting, radio etc.).
3. Connect control module. Connect an ohmmeter between #28 (#B28) on the breakout box and battery negative terminal.

The ohmmeter should read approximately 0 ohms.

1. OK Refer to «Reading is OK»(ref-408435-S02057301282011071200000)
2. NOT OK Refer to «Checking for an open-circuit»(ref-408435-S37611144332011071200000)

1. check ground terminals 31/32 and 31/33 on the engine and their cables for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000) and contact resistance and oxidation according to «Contact resistance and oxidation»(ref-408435-S11196285822011071200000) .

Continue when the fault has been remedied.

1. Continue Refer to «Checking air conditioning (A/C) relay signal cable»(ref-408435-S28543399392011071200000)

1. Return to the fault-tracing procedure where it was interrupted.

1. Continue Refer to «Checking air conditioning (A/C) relay signal cable»(ref-408435-S28543399392011071200000)

Scheme 599

1. Start engine.
2. Air conditioning (A/C) switch on.
3. Blower fan at low-speed.
4. Disconnect the Volvo Scan Tool (ST) from the VIDA station and use it in stand-alone mode. Make a note of the air conditioning (A/C) compressor and air conditioning (A/C) relay values on the Volvo Scan Tool (ST) Compare the values with the following fault-tracing chart below. Parameter Volvo Scan Tool (ST) displays Corrective action A/C COMP A/C RELAY OFF OFF Select 1. A/C COMP A/C RELAY OFF/ON Select 2. A/C COMP A/C RELAY ON ON Select 3. Connect the Volvo Scan Tool (ST) to the VIDA station before continuing fault-tracing.

Select a suitable alternative.

1. 1 Refer to «Checking fuse»(ref-408435-S29168130342011071200000)
2. 2 Refer to «Checking the power supply to the pressure switch (Pressostat)»(ref-408435-S02525210482011071200000)
3. 3 Refer to «Checking the power supply to the compressor»(ref-408435-S31262785632011071200000)

Checking fuse

1. Check that fuse 31 is intact.

Scheme 600

Is the fuse intact?

1. YES Refer to «Connecting breakout box (connector B)»(ref-408435-S11733940432011071200000)
2. NO Refer to «Checking for a short-circuit»(ref-408435-S21436064542011071200000)

Checking for a short-circuit

1. Check circuit for a short-circuit to ground according to «Short-circuit to ground, permanent faults»(ref-408435-S41115456742011071200000) .

Continue when the fault has been remedied.

1. Continue Refer to «Information»(ref-408435-S15418424322011071200000)

Checking the signal cable

1. Remove glove compartment.
2. Disconnect air conditioning (A/C) relay (2/22). Connect an ohmmeter between relay base terminal 4 and #40 (#B40) on the breakout box.

The ohmmeter should read approximately 0 ohms.

1. OK Refer to «Checking the power supply to relay base terminal 1»(ref-408435-S18377827902011071200000)
2. NOT OK Refer to «Checking for an open-circuit»(ref-408435-S41022713132011071200000)

1. Check cable between #B40 and relay base terminal 4 for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000) .

Continue when the fault has been remedied.

1. Continue Refer to «Information»(ref-408435-S15418424322011071200000)

Scheme 601

Scheme 602

1. Air conditioning (A/C) switch on.
2. Ignition on.
3. Air conditioning (A/C) relay disconnected. Connect a voltmeter between relay base terminal 1 and ground.

The voltmeter should read battery voltage.

1. OK Refer to «Checking the power supply to relay base terminal 2»(ref-408435-S33678952372011071200000)
2. NOT OK Refer to «Fault-tracing information»(ref-408435-S32893307162011071200000)

Fault-tracing information

1. 1. The car has ECC. Refer to «Checking for an open-circuit»(ref-408435-S24197796302011071200000)
2. 2. The car has MCC. Refer to «Checking the power supply from the air conditioning (A/C) switch»(ref-408435-S21239677632011071200000)

Select one of the above alternatives.

1. Check cable between fuse 31 and air conditioning (A/C) relay (2/22) terminal 1 for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000) .

Continue when the fault has been remedied.

1. Continue Refer to «Information»(ref-408435-S15418424322011071200000)

Scheme 603

1. Ignition off.
2. Remove heater controls.
3. Air conditioning (A/C) switch on.
4. Ignition on. Connect a voltmeter between air conditioning (A/C) (3/54) terminal 2 and ground.

The voltmeter should read battery voltage.

1. OK Refer to «Checking for an open-circuit»(ref-408435-S07894695382011071200000)
2. NOT OK Refer to «Checking the power supply to the air conditioning (A/C) switch»(ref-408435-S09142057532011071200000)

1. Check cable between air conditioning (A/C) switch terminal 2 and air conditioning (A/C) relay terminal 1 for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000) .

Continue when the fault has been repaired.

1. Continue Refer to «Information»(ref-408435-S15418424322011071200000)

Checking the power supply to the air conditioning (A/C) switch

1. Ignition on. Connect a voltmeter between air conditioning (A/C) switch terminal 1 and ground.

The voltmeter should read battery voltage.

1. OK Refer to «Fault-tracing information»(ref-408435-S20797107292011071200000)
2. NOT OK Refer to «Checking for an open-circuit»(ref-408435-S12603728382011071200000)

1. Try a new air conditioning (A/C) switch.

Continue when the fault has been remedied.

1. Continue Refer to «Information»(ref-408435-S15418424322011071200000)

1. Check cable between fuse 31 and air conditioning (A/C) switch terminal 1 for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000) .

Continue when the fault has been remedied.

1. Continue Refer to «Information»(ref-408435-S15418424322011071200000)

Checking the power supply to relay base terminal 2

1. Ignition on.
2. Blower fan at low-speed.
3. Air conditioning (A/C) relay disconnected. Connect a voltmeter between relay base terminal 2 and ground.

The voltmeter should read battery voltage.

1. OK Refer to «Checking air conditioning (A/C) relay»(ref-408435-S18279510422011071200000)
2. NOT OK Refer to «Fault-tracing information»(ref-408435-S30244960022011071200000)

1. 1. The car has ECC.
2. 2. The car has MCC.

Select one of the above alternatives.

1. Continue Refer to «Checking for an open-circuit»(ref-408435-S17674804842011071200000)
2. Continue Refer to «Checking the power supply from the blower fan switch»(ref-408435-S22079901732011071200000)

1. check cable between air conditioning (A/C) relay terminal 2 and ECC control module (4/30) #B11 for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000) .

Continue when the fault has been remedied.

1. Continue Refer to «Information»(ref-408435-S15418424322011071200000)

Scheme 604

1. Ignition off.
2. Connect air conditioning (A/C) relay.
3. Ignition on.
4. Air conditioning (A/C) switch on.
5. Blower fan at low-speed.
6. Start the engine and idle it. Connect a voltmeter between the underside of relay base (2/22) terminal 3 and ground.

The voltmeter should read battery voltage.

1. OK Refer to «Checking the power supply to the pressure switch (Pressostat)»(ref-408435-S02525210482011071200000)
2. NOT OK Refer to «Fault-tracing information»(ref-408435-S14519444462011071200000)

1. Try a new air conditioning (A/C) relay.

Continue when the fault has been remedied.

1. Continue Refer to «Information»(ref-408435-S15418424322011071200000)

Scheme 605

1. Ignition off.
2. Remove heater controls.
3. Blower fan at low-speed.
4. Ignition on. Connect a voltmeter between blower fan switch terminal B1 and ground.

The voltmeter should read battery voltage.

1. OK Refer to «Checking for an open-circuit»(ref-408435-S19525731222011071200000)
2. NOT OK Refer to «Checking the voltage supply to the blower fan switch»(ref-408435-S39342249652011071200000)

1. check cable between blower fan switch terminal B1 and air conditioning (A/C) relay terminal 2 for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000) .

Continue when the fault has been remedied.

1. Continue Refer to «Information»(ref-408435-S15418424322011071200000)

Checking the voltage supply to the blower fan switch

1. Ignition on. Connect a voltmeter between blower fan switch terminal A4 and ground.

The voltmeter should read battery voltage.

1. OK Refer to «Fault-tracing information»(ref-408435-S30078121342011071200000)
2. NOT OK Refer to «Checking for an open-circuit»(ref-408435-S38483962642011071200000)

1. Try a new blower fan switch.

Continue when the fault has been remedied.

1. Continue Refer to «Information»(ref-408435-S15418424322011071200000)

1. Check cable between fuse 31 and blower fan switch terminal A4 for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000) .

Continue when the fault has been remedied.

1. Continue Refer to «Information»(ref-408435-S15418424322011071200000)

Scheme 606

1. Ignition off.
2. Disconnect the pressure switch (Pressostat) (7/53) connector.
3. Blower fan at low-speed.
4. Air conditioning (A/C) switch on.
5. Start engine. Connect a voltmeter between pressure switch (Pressostat) terminal 1 and ground.

The voltmeter should read battery voltage.

1. OK Refer to «Checking the pressure switch (Pressostat) resistance»(ref-408435-S00621178102011071200000)
2. NOT OK Refer to «Checking for an open-circuit»(ref-408435-S33597986062011071200000)

1. Check cable between relay (2/22) terminal 3 and pressure switch (Pressostat) (7/53) terminal 1 for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000) .

Continue when the fault has been remedied.

1. Continue Refer to «Information»(ref-408435-S15418424322011071200000)

Checking the pressure switch (Pressostat) resistance

1. Ignition off.
2. Pressure switch (Pressostat) disconnected. Connect an ohmmeter across both pressure switch (Pressostat) terminals.

The ohmmeter should read approximately 0 ohms.

1. OK Refer to «Checking for an open-circuit»(ref-408435-S05412600902011071200000)
2. NOT OK Refer to «Fault-tracing information»(ref-408435-S04184568252011071200000)

1. check cable between pressure switch (Pressostat) (7/53) terminal 2 and compressor (8/3) connector for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000) .

Continue when the fault has been remedied.

1. Continue Refer to «Information»(ref-408435-S15418424322011071200000)

1. Check pressure in air conditioning (A/C) system, see the relevant service information.

Continue when the fault has been remedied.

1. Continue Refer to «Information»(ref-408435-S15418424322011071200000)

Checking the power supply to the compressor

1. Ignition off.
2. Disassemble the 1-pin compressor connector. Connect an ohmmeter between the cylinder block and the connector (compressor side). The ohmmeter reads approximately 0 ohms. Select 1. Refer to «Fault-tracing information»(ref-408435-S10011111122011071200000) The ohmmeter reads 2-5 ohms: Select 2. Refer to «Checking for an open-circuit»(ref-408435-S02283580572011071200000) The ohmmeter reads infinite resistance. Select 3. Refer to «Fault-tracing information»(ref-408435-S40739974652011071200000)

Select a suitable alternative above.

1. the compressor clutch is faulty, replace clutch.

Continue when the fault has been remedied.

1. Continue Refer to «Information»(ref-408435-S15418424322011071200000)

1. check cable between pressure switch (Pressostat) (7/53) terminal 2 and compressor connector for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000) .

Continue when the fault has been remedied.

1. Continue Refer to «Information»(ref-408435-S15418424322011071200000)

1. Defective thermoswitch or compressor clutch. Remedy as necessary.

Continue when the fault has been remedied.

1. Continue Refer to «Information»(ref-408435-S15418424322011071200000)

Is the breakout box connected to the Motronic 4.4 connector?

1. YES Refer to «Checking the signal cable»(ref-408435-S11756237662011071200000)
2. NO Refer to «Connecting breakout box to Motronic 4.4 connector B (gray)»(ref-408435-S26152987892011071200000)

1. Ignition off.
2. Disconnect control module. NOTE: The engine control module (ECM) must not be removed from the car until the main relay has interrupted its power supply. This may take up to 150 seconds (cars with an immobilizer 245 seconds) after the ignition has been switched off. Connect adapter «9511351»(ref-403953-S10348238732011061000000) to engine control module (ECM) connector and connect breakout box «9813190»(ref-403953-S32930552542011061000000) to adapter.

1. Continue Refer to «Checking ground terminal #B28»(ref-408435-S29363311802011071200000)

1. Ignition off.
2. Switch off all equipment that takes power from the battery (courtesy lighting, radio etc.).
3. Connect control module. Connect an ohmmeter between #28 (#B28) on the breakout box and battery negative terminal.

The ohmmeter should read approximately 0 ohms.

1. OK Refer to «Reading is OK»(ref-408435-S24953981172011071200000)
2. NOT OK Refer to «Checking for an open-circuit»(ref-408435-S27276853462011071200000)

1. check ground terminals 31/32 and 31/33 on the engine and their cables for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000) and contact resistance and oxidation according to «Contact resistance and oxidation»(ref-408435-S11196285822011071200000) .

Continue when the fault has been remedied.

1. Continue Refer to «Checking the signal cable»(ref-408435-S11756237662011071200000)

1. Return to the fault-tracing procedure where it was interrupted.

1. Continue Refer to «Checking the signal cable»(ref-408435-S11756237662011071200000)

Fault-tracing shows that the fault is no longer present. The diagnostic trouble code (DTC) was probably caused by an intermittent fault.

Fault-tracing for this diagnostic trouble code is not followed by a verification.

You can view the information again or exit fault-tracing for this diagnostic trouble code (DTC).

Checking cylinder for defective function

1. Start engine.
2. Disconnect injectors one at a time until the cylinder which is not firing is identified.

1. Continue Refer to «Checking the ignition system.»(ref-408435-S09733814112011071200000)

Scheme 607

1. Ignition off.
2. Remove the spark plugs from all cylinders. Keep them in order. Compare the spark plug from the poor cylinder with the rest of the spark plugs. Check if this spark plug shows signs of wear and if it is of a lighter color than the others. Alternative: The spark plug is OK. Refer to «Checking spark»(ref-408435-S13388944002011071200000) The spark plug is worn. Refer to «Replacing all spark plugs»(ref-408435-S25550236022011071200000) The spark plug is of a lighter color. Refer to «Replacing a fuel injector»(ref-408435-S20445943822011071200000)

Select alternative according to above.

Replacing all spark plugs

1. Replace all spark plugs in case one of them is worn.

Continue when the fault has been remedied.

1. Continue Refer to «Verify»(ref-408435-S19540821022011071200000)

Replacing a fuel injector

HINT: In case one of the spark plugs is of a lighter color than the others this indicates that the cylinder receives too little fuel.

Scheme 608

Continue when the fault has been remedied.

1. Continue Refer to «Verify»(ref-408435-S19540821022011071200000)

Checking spark

1. Install new spark plugs in all cylinders.
2. Start the engine.

Is the engine running normally?

1. YES OKAY: Troubleshooting has been completed.
2. NO Refer to «Checking ignition cables»(ref-408435-S38938107572011071200000)

Checking ignition cables

1. Ignition off.
2. Remove the ignition cable from the poor cylinder. Check that there is no loose connection between the ignition cable and the distributor cap or between the ignition cable and the spark plug. Measure resistance of the ignition cable. The resistance shall be 1.5 - 4.5 kohms depending on the length, at +20°C.

1. Continue Refer to «Checking distributor cap»(ref-408435-S05135341422011071200000)

Scheme 609

1. Ignition off.
2. Remove the distributor cap. Check the distributor cap for damage, cracks and flash-over. Clean or replace damaged components.

1. Continue Refer to «Verify»(ref-408435-S19540821022011071200000)

Verification

HINT: After repair it is necessary to check that the fault has been corrected.

HINT: Perform as described below

1. Ignition off.
2. Reconnect connectors, components etc.
3. Start engine.

Does engine run evenly?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-408435-S14347345002011071200000)

The fault should be diagnosed and remedied. Since this is not the case the fault-tracing process has failed.

Complete the fault-tracing for those fault or try again.

Scheme 610

Scheme 611

1. Ignition off.
2. Disconnect one spark plug cap.
3. Put a new spark plug into the cap.
4. Place the spark plug against the engine. Operate the starter motor and check for a spark at the plug.

Is there a spark?

1. YES Refer to «Checking spark plugs»(ref-408435-S18187708072011071200000)
2. NO Refer to «Checking engine speed (RPM) sensor signal»(ref-408435-S35326323652011071200000)

Scheme 612

1. Ignition off.
2. Disconnect the ignition discharge module (IDM).
3. Ignition on. Connect a voltmeter between ignition discharge module (IDM) connector terminal 3 and ground.

The voltmeter should read battery voltage.

1. OK Refer to «Checking the ignition discharge module (IDM) ground lead»(ref-408435-S32125228302011071200000)
2. NOT OK Refer to «Checking component»(ref-408435-S38574927822011071200000)

Checking component

1. Check fuse 4. Replace fuse if necessary.

Was the fuse intact?

1. YES Refer to «Verify»(ref-408435-S38831291812011071200000)
2. NO Refer to «Checking for an open-circuit»(ref-408435-S24038379012011071200000)

1. Check cable between ignition discharge module (IDM) terminal 3 and fuse 4 for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000) .

Continue when the fault has been remedied.

1. Continue Refer to «Verify»(ref-408435-S38831291812011071200000)

Checking the ignition discharge module (IDM) ground lead

1. Ignition off.
2. Wait approximately 150 seconds.
3. Ignition discharge module (IDM) disconnected. Connect an ohmmeter between ignition discharge module (IDM) connector terminal 1 and ground.

The ohmmeter should read approximately 0 ohms.

1. OK Refer to «Checking ignition discharge module (IDM) control signal»(ref-408435-S09588285912011071200000)
2. NOT OK Refer to «Checking ignition discharge module (IDM) ground terminal»(ref-408435-S41694204502011071200000)

Checking ignition discharge module (IDM) ground terminal

1. Ignition off.
2. Ignition discharge module (IDM) disconnected.
3. Check ignition discharge module (IDM) ground terminal (31/52) for contact resistance and oxidation and remedy according to «Contact resistance and oxidation»(ref-408435-S11196285822011071200000) . Connect an ohmmeter between ignition discharge module (IDM) connector terminal 1 and ground.

The ohmmeter should read approximately 0 ohms.

1. OK Refer to «Fault-tracing information»(ref-408435-S06363692172011071200000)
2. NOT OK Refer to «Checking for an open-circuit»(ref-408435-S00386481192011071200000)

1. The cause of the fault has been loose connections in the ignition discharge module (IDM) ground terminal.

1. Check cable between ignition discharge module (IDM) terminal 1 and ground terminal (31/52) for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000) .

Continue when the fault has been remedied.

1. Continue Refer to «Verify»(ref-408435-S38831291812011071200000)

Scheme 613

1. Ignition on.
2. Ignition discharge module (IDM) disconnected. Connect a multimeter between ignition discharge module (IDM) connector terminal 4 and ground. Operate starter motor.

Frequency should be 8 - 10 Hz when the engine is turned over by the starter motor.

1. OK Refer to «Checking ignition spark from the ignition coil»(ref-408435-S42359295892011071200000)
2. NOT OK Refer to «Checking signal cable voltage»(ref-408435-S10574738252011071200000)

Checking signal cable voltage

1. Ignition on.
2. Ignition discharge module (IDM) disconnected. Connect a voltmeter between ignition discharge module (IDM) connector terminal 4 and ground.

The voltmeter should read 0 - 1 V.

1. OK Refer to «Checking signal cable resistance to ground»(ref-408435-S12898955312011071200000)
2. NOT OK Refer to «Checking for a short-circuit»(ref-408435-S30978271412011071200000)

1. Check cable between ignition discharge module (IDM) terminal 4 and engine control module (ECM) #B11 for a short-circuit to supply voltage according to «Short-circuit to supply voltage. Permanent faults»(ref-408435-S39443934942011071200000) .

Scheme 614

Continue when the fault has been remedied.

1. Continue Refer to «Verify»(ref-408435-S38831291812011071200000)

Scheme 615

1. Ignition off.
2. Wait approximately 150 seconds.
3. Ignition discharge module (IDM) disconnected.
4. Disconnect control module. Connect an ohmmeter between ignition discharge module (IDM) connector terminal 4 and ground.

The ohmmeter should read infinite resistance.

1. OK Refer to «Checking for an open-circuit»(ref-408435-S31366708902011071200000)
2. NOT OK Refer to «Checking for a short-circuit»(ref-408435-S14756211522011071200000)

1. Check cable between ignition discharge module (IDM) terminal 4 and engine control module (ECM) #B11 for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000) .

Continue when the fault has been remedied.

1. Continue Refer to «Verify»(ref-408435-S38831291812011071200000)

1. Check cable between ignition discharge module (IDM) terminal 4 and engine control module (ECM) #B11 for a short-circuit to ground according to «Short-circuit to ground, permanent faults»(ref-408435-S41115456742011071200000) .

Scheme 616

Continue when the fault has been remedied.

1. Continue Refer to «Verify»(ref-408435-S38831291812011071200000)

Scheme 617

1. Ignition off.
2. Connect the ignition discharge module (IDM).
3. Ignition on.
4. Disconnect ignition coil ignition cable from the distributor cap.
5. Hold the end of the cable 3-5 mm from ground. Operate the starter motor and check for a spark.

Is there a spark?

1. YES Refer to «Checking rotor and distributor cap»(ref-408435-S06423412042011071200000)
2. NO Refer to «Replacing ignition coil/ignition discharge module (IDM)»(ref-408435-S33524869402011071200000)

Replacing ignition coil/ignition discharge module (IDM)

1. Try a new ignition coil/ignition discharge module (IDM).

Continue when the fault has been remedied.

1. Continue Refer to «Verify»(ref-408435-S38831291812011071200000)

Checking rotor and distributor cap

1. Reinstall the spark plug cap.
2. Connect ignition coil ignition cable to distributor cap. Try to start the engine.

Does the engine start?

1. YES Refer to «Checking for contact resistance and oxidation»(ref-408435-S26537672602011071200000)
2. NO Refer to «Checking for damage»(ref-408435-S20947764852011071200000)

1. The cause of the fault has been loose connections in the ignition discharge module (IDM) or engine control module (ECM) connector. Check connectors for contact resistance and oxidation and remedy in accordance with «Contact resistance and oxidation»(ref-408435-S11196285822011071200000) .

Checking for damage

1. Check the distributor cap, rotor and ignition cables for arcing damage, moisture or dirt. Replace if necessary.

Continue when the fault has been remedied.

1. Continue Refer to «Verify»(ref-408435-S38831291812011071200000)

Checking spark plugs

1. Ignition off.
2. Replace all spark plugs. NOTE: It is vital that the correct spark plugs are used, see parts catalogue for P/N. Check the spark gap of new plugs before they are fitted. Spark gap should be 0.7 - 0.8 mm.
3. Connect ignition cables to spark plugs. Try to start the engine.

Does the engine start?

1. YES Refer to «Fault-tracing information»(ref-408435-S10130372092011071200000)
2. NO Refer to «Information»(ref-408435-S23118449122011071200000)

The cause of the fault has been poor spark plugs.

Checking engine speed (RPM) sensor signal

1. Ignition on.
2. Operate starter motor. Read off engine speed (RPM).

Engine speed (RPM) should be 100-300 rpm when the engine is being turned by the starter motor.

1. OK Refer to «Checking ignition discharge module (IDM) power cable»(ref-408435-S15082504932011071200000)
2. NOT OK Refer to «Information»(ref-408435-S23118449122011071200000)

HINT: After carrying out the repair, check that the fault has been remedied.

HINT: Carry out the following

1. Ignition off.
2. Reconnect connectors, reinstall components.
3. Disconnect spark plug cap
4. Put a new spark plug into the cap.
5. Place the spark plug against the engine. Operate the starter motor and check for a spark at the plug.

Is there a spark?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-408435-S05136137992011071200000)

The fault should be diagnosed and remedied. Since this is not the case the fault-tracing process has failed.

Complete the fault-tracing for those fault or try again.

The previous test indicates that a repair must be made before continuing with fault-tracing. You cannot proceed with the fault-tracing tests at this point.

Scheme 618

1. Ignition off.
2. Remove all ignition cables. Check the distributor cap, rotor and ignition cables for of arcing damage, cracking and dirt. Measure the resistance in each ignition cable Resistance should be 1.81 - 5.46 kohms depending on length, at +20°C. Replace ignition cables that are damaged or that have incorrect resistance. Check that there are no loose connections between the ignition cables and distributor cap and between the ignition cables and spark plugs.

Continue when the fault has been repaired.

1. Continue Refer to «Checking distributor cap and rotor»(ref-408435-S05097450702011071200000)

Checking distributor cap and rotor

1. Remove the distributor cap. Check distributor cap and rotor for damage, cracking and arcing. Clean or if necessary replace components which may be damaged or faulty.

Scheme 619

1. Disconnect the Volvo Scan Tool (ST) from the VIDA station and use it in stand-alone mode.
2. Start engine. Test drive the car and watch the "KN IGN RET". If timing retardation due to knock constantly exceeds 10° while the car accelerates poorly or lacks power, it is probably because of this timing retardation.

Does ignition retardation constantly exceed 10°?

1. YES Refer to «Checking knocking»(ref-408435-S11681385012011071200000)
2. NO FAULT NOT FOUND: Troubleshooting has been completed.

Checking knocking

Abnormal knock may be due to any one of the following reasons (which are not listed in any particular fault-tracing order).

Oil contamination

If oil is sucked into the engine through the crankcase ventilation (due to a high oil level in the engine), combustion will be poor causing knocking.

Defective spark plugs/ignition cables

Can cause poor combustion causing knocking.

Defective distributor cap/rotor

Can cause poor combustion causing knocking.

Loose/defective knock sensors (KS)

Can transmit incorrect information about knocking to the engine control module (ECM).

Incorrect fuel

Can cause poor combustion causing knocking.

Extremely high engine coolant temperature (ECT)/intake air temperature (IAT)

Can cause poor combustion causing knocking.

Incorrectly adjusted camshafts

If the camshafts are not correctly set up the intake and exhaust times will be incorrect. Ignition advance will also be incorrect as the distributor is mounted at the rear of the camshaft. This can cause poor combustion causing knocking.

Mechanical knocking

Knocking may be due to worn mechanical components (for example excessive bearing play, excessive piston running clearance, valve rattle due to defective hydraulic lifters).

1. Ignition off. Replace all spark plugs. NOTE: It is vital that the correct spark plugs are used, see parts catalogue for P/N. Check the spark gap of new plugs before they are fitted. Spark gap should be 0.7 - 0.8 mm. Reconnect all ignition cables.

Checking signal from AW 50-42

1. Start the engine and idle it.
2. Disconnect the Volvo Scan Tool (ST) from the VIDA station and use it in stand-alone mode.
3. Move the gear selector to position N and note the gear position displayed by the Volvo Scan Tool (ST).
4. Move the gear selector to position D and note the gear position displayed by the Volvo Scan Tool (ST). Compare the values in the chart below to continue fault-tracing. Gear selector position Volvo Scan Tool (ST) displays Corrective action N P/N Select 1. D R/D/3/L N P/N Select 2. D P/N N R/D/3/L Select 3. D R/D/3/L Connect the Volvo Scan Tool (ST) to the VIDA station before continuing fault-tracing.

Select a suitable alternative.

1. 1 Refer to «Cleaning idle air control (IAC) valve connector»(ref-408435-S27929834762011071200000)
2. 2 Refer to «Connecting the breakout box»(ref-408435-S24227028162011071200000)
3. 3 Refer to «Connecting the breakout box»(ref-408435-S41069043972011071200000)

1. Clean and grease engine control module (ECM) and idle air control (IAC) valve connectors «Contact resistance and oxidation»(ref-408435-S11196285822011071200000) . Check whether the engine speed still dips

Do the fault symptoms persist?

1. YES Refer to «Replacing idle air control (IAC) valve»(ref-408435-S01193457822011071200000)
2. NO OKAY: Troubleshooting has been completed.

1. Try a new idle air control (IAC) valve.

Scheme 620

1. Breakout box connected.
2. Ignition on. Connect a voltmeter between #29 (#A29) and #44 (#A14) on the breakout box.

The value should be 7-9 V.

1. OK Refer to «Fault-tracing information»(ref-408435-S23556285342011071200000)
2. HIGH Refer to «Checking for a short-circuit to supply voltage»(ref-408435-S11138430702011071200000)
3. LOW Refer to «Checking for an open-circuit»(ref-408435-S38669479692011071200000)

1. Check signal from gear selector to transmission control module (TCM), see the relevant service information.

Checking for a short-circuit to supply voltage

1. Check cable between Motronic engine control module (ECM) #B24 and transmission control module (TCM) #B14 for a short-circuit to supply voltage according to «Short-circuit to supply voltage. Permanent faults»(ref-408435-S39443934942011071200000) .

1. Check cable between Motronic engine control module (ECM) #B24 and transmission control module (TCM) #B14 for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000) .

Checking signal cable, continuously in R/D/3/L

1. Breakout box connected.
2. Ignition on. Connect a voltmeter between #29 (#A29) and #44 (#A14) on the breakout box.

The value should be 7-9 V.

1. OK Refer to «Fault-tracing information»(ref-408435-S28370633982011071200000)
2. LOW Refer to «Checking for a short-circuit to ground»(ref-408435-S23750918252011071200000)

1. Check signal from gear selector to transmission control module (TCM), see the relevant service information.

Checking for a short-circuit to ground

1. Check cable between Motronic engine control module (ECM) #B24 and transmission control module (TCM) #B14 for a short-circuit to ground according to «Short-circuit to ground, permanent faults»(ref-408435-S41115456742011071200000) .

Special tools

See 9813190

See 9813195

Scheme 621

Is the breakout box connected to the control module?

1. YES Refer to «Checking signal cable, continuously in P or N»(ref-408435-S22266399122011071200000)
2. NO Refer to «Connecting the breakout box»(ref-408435-S30073425262011071200000)

Scheme 622

1. Ignition off.
2. Control module disconnected.
3. Turn of all equipment in the car that takes power from the battery (the interior lighting and radio etc.). Connect an ohmmeter between the battery negative terminal and: #20 (#A20) on the breakout box #29 (#A29) on the breakout box.

The ohmmeter should read approximately 0ohms for all readings

1. OK Refer to «Checking signal cable, continuously in P or N»(ref-408435-S22266399122011071200000)
2. NOT OK Refer to «Checking for an open-circuit, contact resistance and oxidation»(ref-408435-S21344039082011071200000)

Checking for an open-circuit, contact resistance and oxidation

Check ground terminals 31/32 and 31/33 and cables between ground terminals and control module #A20 and #A29 for an open-circuit according to Open-circuit, permanent faults , and contact resistance and oxidation according to Contact resistance and oxidation .

Check ground lead between battery and bodywork for an open-circuit according to Open-circuit, permanent faults , and contact resistance and oxidation according to Contact resistance and oxidation .

Scheme 623

Continue when the fault has been repaired.

1. Continue Refer to «Verification»(ref-408435-S03690751412011071200000)

Special tools

See 9813190

See 9813195

Scheme 624

1. For more help with connection see «Measuring instruments»(ref-438963-S00735558682011120700000) .
2. Ignition off
3. Disconnect the transmission control module (TCM).
4. Connect adapter «9813195»(ref-403953-S41148216722011061000000) to transmission control module (TCM) connector and connect breakout box «9813190»(ref-403953-S32930552542011061000000) to adapter. NOTE: Ensure that the adaptor is the right way round - with the breakout box cable harness outwards towards the fender.

1. Continue Refer to «Checking ground terminals»(ref-408435-S42513391892011071200000)

HINT: After carrying out the repair check that the fault has been remedied.

HINT: Carry out the following

1. Ignition off
2. Turn of all equipment in the car that takes power from the battery (the interior lighting and radio etc.).
3. Control module disconnected. Connect an ohmmeter between the battery negative terminal and: #20 (#A20) on the breakout box #29 (#A29) on the breakout box.

The ohmmeter should read approximately 0ohms for all readings

1. OK Refer to «Checking signal cable, continuously in P or N»(ref-408435-S22266399122011071200000)
2. NOT OK Refer to «Information»(ref-408435-S37804257822011071200000)

The fault should be diagnosed and remedied. Since this is not the case the fault-tracing process has failed.

Complete the fault-tracing for those fault or try again.

Special tools

See 9813190

See 9813195

Connecting the breakout box (Automatic transmission)

Is the breakout box connected to the control module?

1. YES Refer to «Checking signal cable, continuously in R/D/3/L»(ref-408435-S10471128672011071200000)
2. NO Refer to «Connecting the breakout box»(ref-408435-S01274110082011071200000)

Checking ground terminals

1. Ignition off.
2. Control module disconnected.
3. Turn of all equipment in the car that takes power from the battery (the interior lighting and radio etc.). Connect an ohmmeter between the battery negative terminal and: #20 (#A20) on the breakout box #29 (#A29) on the breakout box.

The ohmmeter should read approximately 0ohms for all readings

1. OK Refer to «Checking signal cable, continuously in R/D/3/L»(ref-408435-S10471128672011071200000)
2. NOT OK Refer to «Checking for an open-circuit, contact resistance and oxidation»(ref-408435-S36167938462011071200000)

Check ground terminals 31/32 and 31/33 and cables between ground terminals and control module #A20 and #A29 for an open-circuit according to Open-circuit, permanent faults , and contact resistance and oxidation according to Contact resistance and oxidation .

Check ground lead between battery and bodywork for an open-circuit according to Open-circuit, permanent faults , and contact resistance and oxidation according to Contact resistance and oxidation .

Continue when the fault has been repaired.

1. Continue Refer to «Verification»(ref-408435-S06488497282011071200000)

Special tools

See 9813190

See 9813195

1. For more help with connection see «Measuring instruments»(ref-438963-S00735558682011120700000) .
2. Ignition off
3. Disconnect the transmission control module (TCM).
4. Connect adapter «9813195»(ref-403953-S41148216722011061000000) to transmission control module (TCM) connector and connect breakout box «9813190»(ref-403953-S32930552542011061000000) to adapter. NOTE: Ensure that the adaptor is the right way round - with the breakout box cable harness outwards towards the fender.

1. Continue Refer to «Checking ground terminals»(ref-408435-S06802268482011071200000)

HINT: After carrying out the repair check that the fault has been remedied.

HINT: Carry out the following

1. Ignition off
2. Turn of all equipment in the car that takes power from the battery (the interior lighting and radio etc.).
3. Control module disconnected. Connect an ohmmeter between the battery negative terminal and: #20 (#A20) on the breakout box #29 (#A29) on the breakout box.

The ohmmeter should read approximately 0ohms for all readings

1. OK Refer to «Checking signal cable, continuously in R/D/3/L»(ref-408435-S10471128672011071200000)
2. NOT OK Refer to «Information»(ref-408435-S29751899762011071200000)

The fault should be diagnosed and remedied. Since this is not the case the fault-tracing process has failed.

Complete the fault-tracing for those fault or try again.

Is the breakout box connected to the Motronic 4.4 connector?

1. YES Refer to «Checking camshaft position (CMP) sensor signal»(ref-408435-S14429954992011071200000)
2. NO Refer to «Connecting breakout box to Motronic 4.4 connector A (black)»(ref-408435-S41435572812011071200000)

1. Ignition off.
2. Disconnect control module. NOTE: The engine control module (ECM) must not be removed from the car until the main relay has interrupted its power supply. This may take up to 150 seconds (cars with an immobilizer 245 seconds) after the ignition has been switched off. Connect adapter «9511351»(ref-403953-S10348238732011061000000) to engine control module (ECM) connector and connect breakout box «9813190»(ref-403953-S32930552542011061000000) to adapter.

1. Continue Refer to «Checking ground terminals»(ref-408435-S25912627642011071200000)

1. Ignition off.
2. Switch off all equipment that takes power from the battery (courtesy lighting, radio etc.). Connect an ohmmeter between battery negative terminal and: #13 (#A13) on the breakout box. #28 (#A28) on the breakout box. #42 (#A42) on the breakout box.

The ohmmeter should read approximately 0 ohms for all readings.

1. OK Refer to «Reading is OK»(ref-408435-S39529428022011071200000)
2. NOT OK Refer to «Checking for an open-circuit»(ref-408435-S25228196852011071200000)

1. Check ground terminals 31/32 and 31/33 at rear of engine and their cables for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000) and contact resistance and oxidation according to «Contact resistance and oxidation»(ref-408435-S11196285822011071200000) .
2. Check ground lead between engine and chassis for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000) and contact resistance and oxidation according to «Contact resistance and oxidation»(ref-408435-S11196285822011071200000) .

Continue when the fault has been remedied.

1. Continue Refer to «Checking camshaft position (CMP) sensor signal»(ref-408435-S14429954992011071200000)

1. Return to the fault-tracing procedure where it was interrupted.

1. Continue Refer to «Checking camshaft position (CMP) sensor signal»(ref-408435-S14429954992011071200000)

Checking camshaft position (CMP) sensor signal

1. Ignition off.
2. Connect control module.
3. Ignition on.
4. Connect a frequency meter between #21 (#A21) and #42 on the breakout box. Operate starter motor.

Frequency should be 1.5 - 2 Hz when the engine is turned over by the starter motor.

1. OK FAULT NOT FOUND: Troubleshooting has been completed.
2. NOT OK Refer to «Faulty signal. Permanent fault»(ref-408435-S11760398772011071200000)

Faulty signal. Permanent fault

EFI-314 Camshaft position (CMP) sensor, signal

Scheme 625

1. Ignition off.
2. Wait for approximately 150 seconds (cars with immobilizer 245 seconds).
3. Disconnect the camshaft position (CMP) sensor. Connect an ohmmeter between the camshaft position (CMP) sensor connector terminal 1 (engine control module (ECM) side) and ground.

The ohmmeter should read approximately 0 ohms.

1. OK Refer to «Checking power cable»(ref-408435-S22019474372011071200000)
2. NOT OK Refer to «Checking control module connector»(ref-408435-S02443214552011071200000)

Scheme 626

1. Ignition off.
2. Camshaft position (CMP) sensor disconnected.
3. Check control module connector for contact resistance and oxidation and remedy according to «Contact resistance and oxidation»(ref-408435-S11196285822011071200000)
4. Control module connected. Connect an ohmmeter between the camshaft position (CMP) sensor connector terminal 1 (engine control module (ECM) side) and ground.

The ohmmeter should read approximately 0 ohms.

1. OK Refer to «Fault-tracing information»(ref-408435-S21769328902011071200000)
2. NOT OK Refer to «Checking for an open-circuit»(ref-408435-S01265511162011071200000)

The cause of the diagnostic trouble code (DTC) has been loose connections in the control module connector.

1. Continue Refer to «Verification»(ref-408435-S05249568012011071200000)

1. Check cable between camshaft position (CMP) sensor terminal 1 and engine control module (ECM) #A18 for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000)

Continue when the fault has been remedied.

1. Continue Refer to «Verification»(ref-408435-S05249568012011071200000)

Checking power cable

1. Ignition on.
2. Camshaft position (CMP) sensor disconnected. Connect a voltmeter between camshaft position (CMP) sensor terminal 3 (engine control module (ECM) side) and ground.

The voltmeter should read battery voltage.

1. OK Refer to «Checking the signal cable»(ref-408435-S04011753952011071200000)
2. NOT OK Refer to «Checking control module connector»(ref-408435-S02476719952011071200000)

Checking control module connector

1. Ignition off.
2. Camshaft position (CMP) sensor disconnected.
3. Check control module connector for contact resistance and oxidation and remedy according to «Contact resistance and oxidation»(ref-408435-S11196285822011071200000)
4. Control module connected.
5. Ignition on. Connect a voltmeter between camshaft position (CMP) sensor terminal 3 (engine control module (ECM) side) and ground.

The voltmeter should read battery voltage.

1. OK Refer to «Fault-tracing information»(ref-408435-S20132304782011071200000)
2. NOT OK Refer to «Checking for an open-circuit»(ref-408435-S24836312612011071200000)

The cause of the diagnostic trouble code (DTC) has been loose connections in the control module connector.

1. Continue Refer to «Verification»(ref-408435-S05249568012011071200000)

1. Check cable between camshaft position (CMP) sensor terminal 3 and engine control module (ECM) #A36 for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000)

Continue when the fault has been remedied.

1. Continue Refer to «Verification»(ref-408435-S05249568012011071200000)

1. Ignition on.
2. Camshaft position (CMP) sensor disconnected. Connect a voltmeter between camshaft position (CMP) sensor terminal 2 (engine control module (ECM) side) and ground.

The voltmeter should read battery voltage.

1. OK Refer to «Checking signal cable voltage»(ref-408435-S02090345452011071200000)
2. NOT OK Refer to «Checking signal cable resistance to ground»(ref-408435-S13037678772011071200000)

Scheme 627

1. Ignition on.
2. Camshaft position (CMP) sensor disconnected. Connect an electrician's screwdriver between camshaft position (CMP) connector terminal 2 (engine control module (ECM) side) and ground.

Does the electrician's screwdriver light?

1. YES Refer to «Checking for a short-circuit»(ref-408435-S02500255532011071200000)
2. NO Refer to «Checking camshaft position (CMP) sensor»(ref-408435-S25797850882011071200000)

1. Check cable between the camshaft position (CMP) sensor terminal 2 and engine control module (ECM) #A21 for a short-circuit to supply voltage according to «Short-circuit to supply voltage. Permanent faults»(ref-408435-S39443934942011071200000) .

Continue when the fault has been remedied.

1. Continue Refer to «Checking camshaft position (CMP) sensor signal»(ref-408435-S01890412432011071200000)

Checking signal cable resistance to ground

1. Ignition off.
2. Wait for approximately 150 seconds (cars with immobilizer 245 seconds).
3. Camshaft position (CMP) sensor disconnected. Connect an ohmmeter between the camshaft position (CMP) sensor connector terminal 2 (engine control module (ECM) side) and ground.

Is resistance infinite?

1. YES Refer to «Checking control module connector»(ref-408435-S30129661882011071200000)
2. NO Refer to «Checking for a short-circuit»(ref-408435-S25239507182011071200000)

1. Check cable between the camshaft position (CMP) sensor terminal 2 and engine control module (ECM) #A21 for a short-circuit to ground according to «Short-circuit to ground, permanent faults»(ref-408435-S41115456742011071200000) .

Continue when the fault has been remedied.

1. Continue Refer to «Verification»(ref-408435-S05249568012011071200000)

1. Ignition off.
2. Camshaft position (CMP) sensor disconnected.
3. Check control module connector for contact resistance and oxidation and remedy according to «Contact resistance and oxidation»(ref-408435-S11196285822011071200000)
4. Control module connected. Connect an ohmmeter between the camshaft position (CMP) sensor connector terminal 2 (engine control module (ECM) side) and ground.

The ohmmeter should read 0.5 - 3.0 kohms.

1. OK Refer to «Fault-tracing information»(ref-408435-S18657967902011071200000)
2. NOT OK Refer to «Checking for an open-circuit»(ref-408435-S24961724882011071200000)

The cause of the diagnostic trouble code (DTC) has been loose connections in the control module connector.

1. Continue Refer to «Verification»(ref-408435-S05249568012011071200000)

1. Check cable between the camshaft position (CMP) sensor terminal 2 and engine control module (ECM) #A21 for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000)

Continue when the fault has been remedied.

1. Continue Refer to «Verification»(ref-408435-S05249568012011071200000)

Checking camshaft position (CMP) sensor

1. Connect the camshaft position (CMP) sensor. Try to start the engine.

Does the engine start?

1. YES Refer to «Checking for contact resistance and oxidation»(ref-408435-S37263641212011071200000)
2. NO Refer to «Replacing camshaft position (CMP) sensor»(ref-408435-S20752264292011071200000)

The cause of the diagnostic trouble code (DTC) has been loose connections in the camshaft position (CMP) sensor and/or engine control module (ECM) connectors.

1. Check connectors for contact resistance and oxidation and remedy in accordance with «Contact resistance and oxidation»(ref-408435-S11196285822011071200000)

Continue when the fault has been remedied.

1. Continue Refer to «Verification»(ref-408435-S05249568012011071200000)

Replacing camshaft position (CMP) sensor

1. Try a new camshaft position (CMP) sensor.

Scheme 628

Continue when the fault has been remedied.

1. Continue Refer to «Verification»(ref-408435-S05249568012011071200000)

1. The camshaft position (CMP) sensor may fail if there has been a short-circuit to supply voltage in the signal cable. Check camshaft position (CMP) sensor as follows.
2. Connect the camshaft position (CMP) sensor. Try to start the engine.

Does the engine start?

1. YES Refer to «Fault-tracing information»(ref-408435-S03545676542011071200000)
2. NO Refer to «Replacing camshaft position (CMP) sensor»(ref-408435-S39828240542011071200000)

Camshaft position (CMP) sensor OK.

1. Try a new camshaft position (CMP) sensor.

Continue when the fault has been remedied.

1. Continue Refer to «Verification»(ref-408435-S05249568012011071200000)

HINT: After carrying out the repair, check that the fault has been remedied as follows

1. Ignition off.
2. Reconnect connectors and reinstall components.
3. Try to start the engine.

Does the engine start?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-408435-S15573687872011071200000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

Checking engine coolant temperature (ECT)

1. Start the engine and idle it. Select Volvo Scan Tool (ST) to read off the engine coolant temperature (ECT).

Engine coolant temperature (ECT) should be approximately 80 - 105°C, at normal operating temperature.

1. OK FAULT NOT FOUND: Troubleshooting has been completed.
2. NOT OK Refer to «Checking engine coolant temperature (ECT) sensor signal»(ref-408435-S36834433772011071200000)

Checking engine coolant temperature (ECT) sensor signal

1. Connect multimeter «9996525»(ref-403953-S26944699622011061000000) with temperature box «9995281»(ref-403953-S37524634972011061000000) and temperature sensor «9995282»(ref-403953-S16512621202011061000000) .
2. Carefully remove the expansion tank cover. WARNING: Danger - coolant is hot.
3. Clamp the hose between the radiator and thermostat housing using a hose clip and disconnect the hose from the thermostat housing.
4. Insert sensor in thermostat housing and reinstall hose.
5. Remove hose clip.
6. Start engine and run up to operating temperature. The engine should be hot enough for the thermostat to open.
7. Select Volvo Scan Tool (ST) to read off the engine coolant temperature (ECT). Check that the engine coolant temperature (ECT) is within its permitted range.

Is the temperature within its permitted range?

1. YES Refer to «Checking cooling system»(ref-408435-S01003451742011071200000)
2. NO Refer to «Replacing engine coolant temperature (ECT) sensor»(ref-408435-S32182210192011071200000)

Checking cooling system

1. Check cooling system according to «Check or replacing cooling system»(ref-408449-S24353804352011071200000) .

Continue when the fault has been remedied.

1. Continue Refer to «Verify»(ref-408435-S31795134492011071200000)

Replacing engine coolant temperature (ECT) sensor

1. Replace engine coolant temperature (ECT) sensor.

Scheme 629

Continue when the fault has been remedied.

1. Continue Refer to «Verify»(ref-408435-S31795134492011071200000)

HINT: After repair, it is necessary to check that the fault has been corrected.

HINT: Perform as described below.

1. Ignition off.
2. Reconnect connectors, components etc.
3. Start engine and let it run at idling speed. Read engine coolant temperature and check for reasonableness.

Engine coolant temperature should exceed 80°C when engine is warm. Upper coolant hose should be hot.

1. OK VERIFIED: Troubleshooting has been completed.
2. NOT OK Refer to «Information»(ref-408435-S02629899862011071200000)

The fault should be diagnosed and remedied. Since this is not the case the fault-tracing process has failed.

Complete the fault-tracing for those fault or try again.

1. Ignition on.
2. Operate starter motor. Select Volvo Scan Tool (ST) to read off the engine speed (RPM).

Engine speed (RPM) should be 100-300 rpm when the engine is being turned by the starter motor.

1. OK FAULT NOT FOUND: Troubleshooting has been completed.
2. NOT OK Refer to «Signal missing. Permanent fault»(ref-408435-S07830112492011071200000)

Signal missing. Permanent fault

EFI-131 Engine speed (RPM) sensor, signal missing

Checking engine speed (RPM) sensor resistance

1. Ignition off.
2. Disconnect the engine speed (RPM) sensor. Connect a voltmeter between engine speed (RPM) sensor connector terminals 1 and 2 (engine control module (ECM) side).

The ohmmeter should read 200 - 500 ohms depending on engine speed (RPM) sensor temperature.

1. OK Refer to «Checking ground lead»(ref-408435-S29383306612011071200000)
2. NOT OK Refer to «Replacing engine speed (RPM) sensor»(ref-408435-S36909875652011071200000)

1. Try a new engine speed (RPM) sensor.

Continue when the fault has been remedied.

1. Continue Refer to «Verification»(ref-408435-S32883738412011071200000)

Checking ground lead

1. Ignition off.
2. Wait for approximately 150 seconds (cars with immobilizer 245 seconds).
3. Engine speed (RPM) sensor disconnected. Connect an ohmmeter between engine speed (RPM) sensor connector terminal 2 (engine control module (ECM) side) and ground.

The ohmmeter should read approximately 0 ohms.

1. OK Refer to «Checking signal cable resistance to ground»(ref-408435-S00951232182011071200000)
2. NOT OK Refer to «Checking engine control module (ECM) ground terminals»(ref-408435-S40787313122011071200000)

Checking engine control module (ECM) ground terminals

1. Ignition off.
2. Engine speed (RPM) sensor disconnected.
3. Check engine control module (ECM) connector and ground terminals 31/32 and 31/33 for contact resistance and oxidation and remedy according to «Contact resistance and oxidation»(ref-408435-S11196285822011071200000) .
4. Control module connected. Connect an ohmmeter between engine speed (RPM) sensor connector terminal 2 (engine control module (ECM) side) and ground.

The ohmmeter should read approximately 0 ohms.

1. OK Refer to «Checking signal cable resistance to ground»(ref-408435-S00951232182011071200000)
2. NOT OK Refer to «Checking for an open-circuit»(ref-408435-S42320472112011071200000)

1. Check cable between engine speed (RPM) sensor connector 2 and engine control module (ECM) #A6 for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000) .

Continue when the fault has been remedied.

1. Continue Refer to «Verification»(ref-408435-S32883738412011071200000)

1. Ignition off.
2. Engine speed (RPM) sensor disconnected. Connect an ohmmeter between engine speed (RPM) sensor connector terminals 1 and 2 (engine control module (ECM) side).

The ohmmeter should read 15 - 25 kohms.

1. OK Refer to «Checking for a short-circuit to supply voltage in signal cable»(ref-408435-S29768869172011071200000)
2. LOW Refer to «Checking for a short-circuit»(ref-408435-S33682446302011071200000)
3. HIGH Refer to «Checking control module connector»(ref-408435-S28399436112011071200000)

1. Check cable between engine speed (RPM) sensor terminal 1 and control module #A20 for a short-circuit to ground according to «Short-circuit to ground, permanent faults»(ref-408435-S41115456742011071200000) .

Continue when the fault has been remedied.

1. Continue Refer to «Verification»(ref-408435-S32883738412011071200000)

1. Ignition off.
2. Engine speed (RPM) sensor disconnected.
3. Check control module connector for contact resistance and oxidation and remedy according to «Contact resistance and oxidation»(ref-408435-S11196285822011071200000)
4. Control module connected. Connect an ohmmeter between engine speed (RPM) sensor connector terminals 1 and 2 (engine control module (ECM) side).

The ohmmeter should read 15 - 25 kohms.

1. OK Refer to «Fault-tracing information»(ref-408435-S41382895402011071200000)
2. NOT OK Refer to «Checking for an open-circuit»(ref-408435-S18009272882011071200000)

The cause of the diagnostic trouble code (DTC) has been loose connections in the control module connector.

1. Check cable between engine speed (RPM) sensor terminal 1 and engine control module (ECM) #A20 for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000) .

Continue when the fault has been remedied.

1. Continue Refer to «Verification»(ref-408435-S32883738412011071200000)

Checking for a short-circuit to supply voltage in signal cable

1. Ignition on.
2. Engine speed (RPM) sensor disconnected. Connect a voltmeter between engine speed (RPM) sensor connector terminal 1 and 2 (control module side).

The voltmeter should read 1 - 2 V.

1. OK Refer to «Checking the engine control module (ECM) connector»(ref-408435-S31309774842011071200000)
2. NOT OK Refer to «Checking for a short-circuit»(ref-408435-S25704064532011071200000)

1. Check cable between engine speed (RPM) sensor terminal 1 and engine control module (ECM) #A20 for a short-circuit to supply voltage according to «Short-circuit to supply voltage. Permanent faults»(ref-408435-S39443934942011071200000) .

Continue when the fault has been remedied.

1. Continue Refer to «Verification»(ref-408435-S32883738412011071200000)

Checking the engine control module (ECM) connector

1. Ignition off.
2. Check engine speed (RPM) sensor connector for contact resistance and oxidation and remedy according to «Contact resistance and oxidation»(ref-408435-S11196285822011071200000) . Try to start the engine.

Does the engine start?

1. YES Refer to «Checking for contact resistance and oxidation»(ref-408435-S25274642592011071200000)
2. NO Refer to «Checking for damage»(ref-408435-S21484392862011071200000)

The engine did not start because of loose connections in the engine speed (RPM) sensor and/or engine control module (ECM) connectors.

1. Check connectors for contact resistance and oxidation and remedy in accordance with «Contact resistance and oxidation»(ref-408435-S11196285822011071200000) .

Continue when the fault has been remedied.

1. Continue Refer to «Verification»(ref-408435-S32883738412011071200000)

1. Check carrier plate/flywheel for damage and scratches through the engine speed (RPM) sensor hole. If no faults are detected on the carrier plate/flywheel: Try a new engine speed (RPM) sensor.

Continue when the fault has been remedied.

1. Continue Refer to «Verification»(ref-408435-S32883738412011071200000)

HINT: After carrying out the repair, check that the fault has been remedied as follows

1. Ignition off.
2. Reconnect connectors and reinstall components.
3. Try to start the engine.

Does the engine start?

1. YES VERIFIED: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-408435-S22833940572011071200000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

Scheme 630

1. Ignition off.
2. Disconnect idle air control (IAC) valve. Connect an ohmmeter between idle air control (IAC) valve connector terminals 1 and 2. Read off value. Connect an ohmmeter between idle air control (IAC) valve connector terminals 2 and 3. Read off value.

The ohmmeter should read 9 - 14 ohms at 20°C (68°F) in both cases.

1. OK Refer to «Checking the idle air control (IAC) valve control slide»(ref-408435-S17626882132011071200000)
2. NOT OK Refer to «Replacing idle air control (IAC) valve»(ref-408435-S36809482862011071200000)

Scheme 631

1. Ignition off.
2. Remove idle air control (IAC) valve. CAUTION: Under no circumstances touch the control slide with a screwdriver or other tools as this could scratch and damage the control slide. Hold the valve by the connector and twist it quickly but carefully back and forth.

The control slide should switch.

1. OK Refer to «Cleaning and greasing connectors»(ref-408435-S19768088362011071200000)
2. NOT OK Refer to «Replacing idle air control (IAC) valve»(ref-408435-S36809482862011071200000)

Cleaning and greasing connectors

1. Clean and grease engine control module (ECM) and idle air control (IAC) valve connectors. «Contact resistance and oxidation»(ref-408435-S11196285822011071200000) .

1. Try a new idle air control (IAC) valve.

Scheme 632

Checking air intake

1. Check air intake in front of radiator, air duct, air cleaner (ACL) housing and filter insert for blockage (leaves, paper etc.).

Scheme 633

Is there any blockage?

1. YES Refer to «Fault-tracing information»(ref-408435-S28433147442011071200000)
2. NO Refer to «Checking mass air flow (MAF) sensor»(ref-408435-S21410810862011071200000)

1. Remedy as necessary.

Scheme 634

1. Ignition on.
2. Mass air flow (MAF) sensor connected. Connect a voltmeter between mass air flow (MAF) sensor connector terminals 2 and 4.

The voltmeter should read 0.1 - 0.2 V.

Troubleshooting has been completed.

Checking engine control module (ECM) power supply and ground terminal

Checking power supply

1. Check fuse 11 B/3. If the fuse is blown check the circuit after the fuse for a short-circuit to ground according to «Short-circuit to ground, permanent faults»(ref-408435-S41115456742011071200000)
2. Check fuse 11B/1. If the fuse is blown check the circuit after the fuse for a short-circuit to ground according to «Short-circuit to ground, permanent faults»(ref-408435-S41115456742011071200000) .
3. Check power supply to #A70. Voltage should be approximately battery voltage.
4. Check power supply to #B11. Voltage should be approximately battery voltage.

Checking ground terminal

1. Check ground lead between engine control module (ECM) #A53, #A54, #A63 and right side member ground terminal 31/71 for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000)
2. Check engine control module (ECM) ground terminal for contact resistance and oxidation according to «Contact resistance and oxidation»(ref-408435-S11196285822011071200000)

Remedy as necessary

Other information

1. Connecting the breakout box/accessing the control module, see «Connecting the breakout box»(ref-408435-S12899753102011071200000) .
2. Power supply to the engine control module (ECM) #A70 is from fuse 11 B/3 via the system relay.
3. Power supply to engine control module (ECM) #B11 is from fuse 11 B/1 via terminal 30+.
4. The engine control module (ECM) ground terminal is common to engine control module (ECM) terminals #A53, #A54 and #A63.
5. Location of components see «Component location, B52X4 T»(ref-408450-S30453749682011071200000) .
6. For information about signals, see «Signal specification»(ref-408451-S42269556162011071200000) .
7. For information about circuit see the relevant wiring diagram

Was a fault detected?

1. YES OKAY: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-408435-S41646912722011071200000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

Checking throttle unit power and ground terminal

Checking power supply

1. Check fuse 11 B/2. If the fuse is blown check circuit after the fuse for a short-circuit to ground according to «Short-circuit to ground, permanent faults»(ref-408435-S41115456742011071200000)
2. Check power supply to throttle unit #6. Voltage should be approximately battery voltage.

Checking ground terminal

1. Check ground lead between throttle unit #5 and engine ground terminal ETM 31/91 for an open-circuit according to «Open-circuit, permanent faults»(ref-408435-S07999989592011071200000)
2. Check throttle unit ground terminal for contact resistance and oxidation according to «Contact resistance and oxidation»(ref-408435-S11196285822011071200000)

Remedy as necessary

Other information

1. Power supply to the electronic throttle module #6 is from fuse 11 B/2 via the system relay.
2. Ground terminal electronic throttle module (ETM) 31/91 for the throttle unit is located on the front of the cylinder block above the starter motor
3. For information about signals, see «Signal specification»(ref-408451-S42269556162011071200000) .
4. For information about circuit see the relevant wiring diagram

Scheme 635

Was a fault detected?

1. YES OKAY: Troubleshooting has been completed.
2. NO Refer to «Information»(ref-408435-S39104140052011071200000)

The fault should have been detected and remedied. As this is not the case fault-tracing has failed.

Exit fault-tracing for this diagnostic trouble code (DTC) or make another attempt.

Open-circuit, intermittent faults

An open-circuit in a cable will be indicated by the loss of a function (or functions).

Chafed and broken leads are common causes of faults.

Checks

1. Disconnect the connectors at both ends of the cable.

Check the cables visually according to Inspect terminals visually .

Connect an ohmmeter between the ends of the cable.

The ohmmeter should read approximately 0ohms if there is no open-circuit in the cable.

Shake the cable lightly and pull on connectors during measurement to locate the damage.

If the reading is not correct. Replace the cable and / or continue according to Contact resistance and oxidation .

Always check the control module and control module box connectors to ensure that their pins and sockets are not bent or damaged, this may cause faults.

Check pins and terminals particularly carefully.

Short-circuit to ground, intermittent faults

A short-circuit between a live cable and ground is often indicated by the loss of a function or a fuse blowing when a current is passed through the cable.

Checks

1. Check the cables visually according to «Inspect terminals visually»(ref-408435-S34108999952011071200000) . Activate all switches and sensors in the circuit. Check whether the fuse blows
2. Disconnect the connectors in the circuit to ensure that they do not affect readings.

Connect an ohmmeter between cable and ground.

The ohmmeter should read infinite resistance if no components are connected.

Shake the cable lightly and pull on connectors during measurement to locate the damage.

If the reading is not correct, replace the cable and / or continue according to Contact resistance and oxidation .

Short-circuit to supply voltage, intermittent faults

A short-circuit between a cable and supply voltage is often indicated by the loss of a function or a fuse blowing when a current is passed through the cable.

Checks

1. Check the cables visually according to «Inspect terminals visually»(ref-408435-S34108999952011071200000) . Use a voltmeter to take readings at various points in the circuit while operating switches and sensors.

The voltmeter reading depends on the circuit being tested and the positions of switches and sensors. Use the wiring diagram to determine the correct voltage in the circuit.

Use an ohmmeter between the suspect cables to detect short-circuits between them.

The ohmmeter should read infinite resistance between cables not connected to each other in the circuit.

Shake the cable lightly and pull on connectors during measurement to locate the damage.

If the reading is not correct. Replace the cable and / or continue according to Contact resistance and oxidation .

Scheme 636

Loose connections in terminals may be caused by oxidation of the pins and sockets, or by a faulty connection of a cable to its cable terminal.

Loose connections produce the same faults as an intermittent open-circuit in a cable.

Checks

1. Inspect terminals visually according to «Inspect terminals visually»(ref-408435-S34108999952011071200000) . Continue according to «Contact resistance and oxidation»(ref-408435-S41703021522011071200000) .

Contact resistance and oxidation

In theory, the resistance across contacts, leads and terminals should be 0 ohms. However, there is always some resistance due to terminal oxidation.

If resistance is too great there will be function problems. The magnitude of the resistance before it causes a malfunction depends on the circuit load. A guideline would be a few ohms.

Cleaning female socket terminals and male pin terminals

Scheme 637

Note. Do not apply rust solvent spray or grease to the catalyst monitor sensor or instrument cluster connectors.

1. Ignition off
2. Disconnect the battery negative terminal
3. Use compressed air to clean the disconnected connector
4. Apply rust solvent spray 1161422 to the disconnected connectors
5. Blow clean using compressed air.

Greasing female terminals

Scheme 638

Note. Do not fill the protective cover with grease.

1. Press grease, P/N 1161417-9, into the terminals directly from the tube
2. Check that all the cavities in the connectors are filled
3. Use a loose male pin to ensure that contact in sockets is good. The pin should remain in position when pulled gently.

Scheme 639

Check terminals visually

Note. When checking the engine control module (ECM), do not remove the control module from the car before the main relay has interrupted the power supply. This may take up to 4 minutes after the ignition has been switched off and the engine cooling fan (FC) has stopped running.

Inspect the terminals visually when checking, or taking readings from, opened connectors.

Checks

1. Check for oxidation. This can cause poor connections in the terminals
2. Check for damage to pins and terminals. Check that they are properly inserted into the connector. Check that the cable is properly connected to the pin or terminal. Check pins and terminals particularly carefully
3. Use a separate male terminal to check the female terminal. Check that they are secure: Pull on the pin.

Open-circuit, permanent faults

An open-circuit in a cable is indicated by a loss of one or more functions.

Chafed and broken cables or terminals that have come loose are common causes of faults in electrical systems.

Checks

1. Disconnect the connectors at both ends of the cable.

Connect an ohmmeter between the ends of the cable.

The ohmmeter should read approximately 0 ohms if there is no open-circuit in the cable.

Always check the control module and control module box connectors to ensure that their pins and sockets are not bent or damaged, as this can cause faults.

Check pins and terminals particularly for this fault. See Check terminals visually .

Short-circuit to ground, permanent faults

A short-circuit between a live cable and ground is often indicated by the loss of a function or a fuse blowing when a current is passed through the cable.

Checks

1. Activate all switches and sensors in the circuit. Check whether the fuse blows
2. Disconnect the connectors in the circuit to ensure that they do not affect readings.

Use an ohmmeter to take a resistance reading between the cable and ground.

The ohmmeter should read infinite resistance if no components are connected.

Check pins and terminals particularly for this fault. See Check terminals visually .

Short-circuit to supply voltage. Permanent faults

A short-circuit between a cable and supply voltage is often indicated by the loss of a function or a fuse blowing when voltage is passed through the cable.

Checks

1. Use a voltmeter to take readings at various points in the circuit while operating switches and sensors.

Voltmeter readings will depend on which circuit is tested and the status of switches and sensors. Use the wiring diagram to determine the correct voltage in the circuit.

Use an ohmmeter between the suspect cables to detect short-circuits between them.

The ohmmeter should read infinite resistance between cables not connected to each other in the circuit.

Check pins and terminals particularly for this fault. See Check terminals visually .

In theory, the resistance across contacts, leads and terminals should be 0 ohms. However, there is always some resistance due to terminal oxidation.

If this resistance becomes too great the result will be a malfunction. The magnitude of the resistance before it causes a malfunction depends on the circuit load.

Checks

1. Check the cables visually according to «Check terminals visually»(ref-408435-S38557215912011071200000) .

Cleaning female socket terminals and male pin terminals

Note. Do not apply rust solvent spray or grease to the catalyst monitor sensor or instrument cluster connectors.

1. Ignition off
2. Disconnect the battery negative terminal
3. Use compressed air to clean the disconnected connector
4. Apply rust solvent spray 1161422 to the disconnected connectors
5. Blow clean using compressed air.

Greasing female terminals

Note. Note Do not fill the protective cover with grease.

1. Press grease, P/N 1161417-9, into the female sockets directly from tube
2. Check that all the terminal cavities are filled
3. Use a loose male pin to ensure that the connection in the sockets is good. The pin should remain in position when pulled gently.

Special tools

9511504

9511428

9511499

9995722

Scheme 640

1. Wait 2 minutes after the ignition has been switched off. The main relay must be voltage free before the control module is removed from the car. If the engine cooling fan (FC) runs on after the ignition has been switched off, wait until it stops and then wait for a further 2 minutes
2. Remove the cover over the control module box. Put the cover to one side. NOTE: Do not touch the control module terminal pins with your fingers. Static electricity may damage components in the control module.
3. Insert tool «9995722»(ref-403953-S10522720692011061000000) around the control module
4. Move the upper section of the tool backwards as far as it will go. Pull up the tool
5. Carefully pull up the control module.

Scheme 641

1. Check that no pins or sockets are damaged on the connector
2. Gently press adapter «9511504»(ref-403953-S20513889072011061000000) down into the grooves inside the control module box. Press to the limit position.
3. Insert tool «9995722»(ref-403953-S10522720692011061000000) around the adapter
4. Move the upper section of the tool forwards as far as it will go. Pull the tool up.

Scheme 642

1. Check the control module and control module connectors to ensure that the male and female terminals are undamaged and secure (cannot be pressed in). Check that the cables to the female terminals are secured to the terminal pins
2. Connect adapter «9511504»(ref-403953-S20513889072011061000000) to the control module connector (wiring side). Connect breakout box «9511428»(ref-403953-S35709646712011061000000) to the adapter via wiring «9511499»(ref-403953-S17823813432011061000000)
3. The breakout box is designed to facilitate reading off the control module input and output signals when the control module is connected; and the cable and component resistance when the control module is disconnected. The use of a breakout box reduces the risk of accidental short-circuits and damage to the connector pins.

Scheme 643

1. Wait 2 minutes after the ignition has been switched off. The main relay must be voltage free before removing the control module from the car. If the engine cooling fan (FC) runs on after the ignition has been switched off, wait until it stops and then wait for a further 2 minutes
2. NOTE: Do not touch the control module terminal pins with your fingers. Static electricity may damage components in the control module.
3. Insert tool «9995722»(ref-403953-S10522720692011061000000) around the adapter
4. Move the upper section of the tool backwards as far as it will go. Pull up the tool
5. Carefully pull up the adapter.

Scheme 644

1. Check that no pins or sockets are damaged on the connector
2. Gently press the control module down into the grooves inside the control module box. Press to the limit position.
3. Insert tool «9995722»(ref-403953-S10522720692011061000000) around the control module
4. Move the upper section of the tool forwards as far as it will go. Pull the tool up
5. Press the cover into place over the control modules
6. Check that the air ducts are correctly positioned.