Ignition and Engine Control Systems - General Diagnostics and Tests Volvo S80 II

CONNECTING THE BREAKOUT BOX (B6304T2, B6304T4; 2008-2012)

Special tools

see 9512902

see 9511428

see 9511499

HINT: The breakout box is designed to facilitate the reading of control module input and output signals when the control module is connected as well as the resistance of cables and components when the control module is disconnected. Using the breakout box reduces the risk of unintentionally short-circuited cables or damaged connector pins.

CONTROL MODULE DISCONNECTION

1. Wait 3 minutes after turning off the ignition before unplugging the connectors from the engine control module (ECM). The system relay must have released the voltage before the control module is removed from the vehicle. If the engine cooling fan runs after the ignition has been turned off, wait until it has stopped. Then wait an additional 3 minutes.
2. Release the engine control module (ECM) as per: see «PLENUM CHAMBER»(ref-499211-S42128832212012090500000)

ADAPTER CONNECTION

1. Check that no connector pins or sleeves are damaged.
2. Check that the male and female terminals on the engine control module (ECM) are undamaged and secure (cannot be pressed in). Check that the cables to the female terminals are secured to the terminal pins.
3. Carefully install the vehicle wiring harness on see «9512902»(ref-460875-S37351866312012033000000). Lock the connectors in position by pressing in the catches fully.

BREAKOUT BOX AND ENGINE CONTROL MODULE (ECM) CONNECTION

1. Connect breakout box see «9511428»(ref-460875-S19859279082012033000000) to the adapter via wiring harness see «9511499»(ref-460875-S42703648442012033000000).
2. Carefully install the adapter on the engine control module (ECM). Lock the adapter in position by pressing in the catches fully.

REMOVING THE ADAPTER AND CONNECTOR

1. Wait 3 minutes after turning off the ignition. The main relay must have released the voltage before the control module is removed from the vehicle. If the engine cooling fan runs after the ignition has been turned off, wait until it has stopped and then wait an additional 3 minutes. NOTE: Do not touch engine control module (ECM) connecting pins with your fingers. Engine control module (ECM) components can be damaged by static electricity.
2. Carefully detach the engine control module (ECM) from the adapter wiring harness. NOTE: Do not touch engine control module (ECM) connecting pins with your fingers. Engine control module (ECM) components can be damaged by static electricity.
3. Carefully detach the adapter from the vehicle wiring harness.

CONTROL MODULE CONNECTION

1. Check that no pins or sockets are damaged on the connector.
2. Plug in the engine control module (ECM) connector.
3. Refit the plastic covers, etc as per: see «PLENUM CHAMBER»(ref-499211-S42128832212012090500000)

CONNECTING THE BREAKOUT BOX (B6324S, B6324S5; 2007-2012)

Special tools

see 9512902

see 9511428

see 9511499

HINT: The breakout box is designed to facilitate the reading of control module input and output signals when the control module is connected as well as the resistance of cables and components when the control module is disconnected. Using the breakout box reduces the risk of unintentionally short-circuited cables or damaged connector pins.

1. Wait 3 minutes after turning off the ignition before unplugging the connectors from the engine control module (ECM). The system relay must have released the voltage before the control module is removed from the vehicle. If the engine cooling fan runs after the ignition has been turned off, wait until it has stopped. Then wait an additional 3 minutes.
2. Release the engine control module (ECM) as per: see «PLENUM CHAMBER»(ref-499211-S42128832212012090500000)

1. Check that no connector pins or sleeves are damaged.
2. Check that the male and female terminals on the engine control module (ECM) are undamaged and secure (cannot be pressed in). Check that the cables to the female terminals are secured to the terminal pins.
3. Carefully install the vehicle wiring harness on see «9512902»(ref-460875-S37351866312012033000000). Lock the connectors in position by pressing in the catches fully.

1. Connect breakout box see «9511428»(ref-460875-S19859279082012033000000) to the adapter via wiring harness see «9511499»(ref-460875-S42703648442012033000000).
2. Carefully install the adapter on the engine control module (ECM). Lock the adapter in position by pressing in the catches fully.

1. Wait 3 minutes after turning off the ignition. The main relay must have released the voltage before the control module is removed from the vehicle. If the engine cooling fan runs after the ignition has been turned off, wait until it has stopped and then wait an additional 3 minutes. NOTE: Do not touch engine control module (ECM) connecting pins with your fingers. Engine control module (ECM) components can be damaged by static electricity.
2. Carefully detach the engine control module (ECM) from the adapter wiring harness. NOTE: Do not touch engine control module (ECM) connecting pins with your fingers. Engine control module (ECM) components can be damaged by static electricity.
3. Carefully detach the adapter from the vehicle wiring harness.

1. Check that no pins or sockets are damaged on the connector.
2. Plug in the engine control module (ECM) connector.
3. Refit the plastic covers, etc as per: see «PLENUM CHAMBER»(ref-499211-S42128832212012090500000)

CONNECTING THE BREAKOUT BOX (B6324S2, B6324S4; 2010-2012)

Special tools

see 9512902

see 9511428

see 9511499

HINT: The breakout box is designed to facilitate the reading of control module input and output signals when the control module is connected as well as the resistance of cables and components when the control module is disconnected. Using the breakout box reduces the risk of unintentionally short-circuited cables or damaged connector pins.

1. Wait 3 minutes after turning off the ignition before unplugging the connectors from the engine control module (ECM). The system relay must have released the voltage before the control module is removed from the vehicle. If the engine cooling fan runs after the ignition has been turned off, wait until it has stopped. Then wait an additional 3 minutes.
2. Release the engine control module (ECM) as per: see «PLENUM CHAMBER»(ref-499211-S42128832212012090500000)

1. Check that no connector pins or sleeves are damaged.
2. Check that the male and female terminals on the engine control module (ECM) are undamaged and secure (cannot be pressed in). Check that the cables to the female terminals are secured to the terminal pins.
3. Carefully install the vehicle wiring harness on see «9512902»(ref-460875-S37351866312012033000000). Lock the connectors in position by pressing in the catches fully.

1. Connect breakout box see «9511428»(ref-460875-S19859279082012033000000) to the adapter via wiring harness see «9511499»(ref-460875-S42703648442012033000000).
2. Carefully install the adapter on the engine control module (ECM). Lock the adapter in position by pressing in the catches fully.

1. Wait 3 minutes after turning off the ignition. The main relay must have released the voltage before the control module is removed from the vehicle. If the engine cooling fan runs after the ignition has been turned off, wait until it has stopped and then wait an additional 3 minutes. NOTE: Do not touch engine control module (ECM) connecting pins with your fingers. Engine control module (ECM) components can be damaged by static electricity.
2. Carefully detach the engine control module (ECM) from the adapter wiring harness. NOTE: Do not touch engine control module (ECM) connecting pins with your fingers. Engine control module (ECM) components can be damaged by static electricity.
3. Carefully detach the adapter from the vehicle wiring harness.

1. Check that no pins or sockets are damaged on the connector.
2. Plug in the engine control module (ECM) connector.
3. Refit the plastic covers, etc as per: see «PLENUM CHAMBER»(ref-499211-S42128832212012090500000)

CONNECTING THE BREAKOUT BOX (B8444S; 2007-2010)

Special tools

see 9512902

see 9511428

see 9511499

HINT: The breakout box is designed to facilitate the reading of control module input and output signals when the control module is connected as well as the resistance of cables and components when the control module is disconnected. Using the breakout box reduces the risk of unintentionally short-circuited cables or damaged connector pins.

1. Wait 3 minutes after turning off the ignition before unplugging the connectors from the engine control module (ECM). The system relay must have released the voltage before the control module is removed from the vehicle. If the engine cooling fan runs after the ignition has been turned off, wait until it has stopped. Then wait an additional 3 minutes.
2. Release the engine control module (ECM) as per: see «PLENUM CHAMBER»(ref-499211-S42128832212012090500000)

1. Check that no connector pins or sleeves are damaged.
2. Check that the male and female terminals on the engine control module (ECM) are undamaged and secure (cannot be pressed in). Check that the cables to the female terminals are secured to the terminal pins.
3. Carefully install the vehicle wiring harness on see «9512902»(ref-460875-S37351866312012033000000). Lock the connectors in position by pressing in the catches fully.

1. Connect breakout box see «9511428»(ref-460875-S19859279082012033000000) to the adapter via wiring harness see «9511499»(ref-460875-S42703648442012033000000).
2. Carefully install the adapter on the engine control module (ECM). Lock the adapter in position by pressing in the catches fully.

1. Wait 3 minutes after turning off the ignition. The main relay must have released the voltage before the control module is removed from the vehicle. If the engine cooling fan runs after the ignition has been turned off, wait until it has stopped and then wait an additional 3 minutes. NOTE: Do not touch engine control module (ECM) connecting pins with your fingers. Engine control module (ECM) components can be damaged by static electricity.
2. Carefully detach the engine control module (ECM) from the adapter wiring harness. NOTE: Do not touch engine control module (ECM) connecting pins with your fingers. Engine control module (ECM) components can be damaged by static electricity.
3. Carefully detach the adapter from the vehicle wiring harness.

1. Check that no pins or sockets are damaged on the connector.
2. Plug in the engine control module (ECM) connector.
3. Refit the plastic covers, etc as per: see «PLENUM CHAMBER»(ref-499211-S42128832212012090500000)

POWER SUPPLY ENGINE CONTROL MODULE (ECM)

The engine control module (ECM) is supplied power via four voltage inputs on the control module.

With the ignition on, power is supplied to all voltage inputs and the engine control module (ECM) is in active mode.

1. Power input 1, terminal #B16 (#C16) is supplied with power via a fuse from the battery. This power input is used to power the memory in the Engine control module (ECM). In the event of an open-circuit, the engine control module (ECM) will be reset and adaptation values and diagnostic trouble codes (DTCs) and other information in the memory will disappear.
2. Voltage input 2, #B15 (#C15) is supplied via fuse in ignition position II. This power input is used to activate the engine control module (ECM). When power input 2 is powered, the system relay will be activated and power inputs 3 and 4 will be powered. The engine control module (ECM) will not be activated if there is an open-circuit.
3. Power input 3, terminal #B3 (#C3) is supplied with power via a fuse from the system relay. The system relay is activated by the engine control module (ECM). This power input governs the supply of power to the Engine control module (ECM).
4. Power input 4, terminal #B5 (#C5) is supplied with power via a fuse from the system relay. The system relay is activated by the engine control module (ECM). This power input governs the supply of power to the Engine control module (ECM).

Checking the power supply

Check the power supply cable from the battery to the Engine control module (ECM) terminal #B16 (#C16). Check for an open-circuit. Check for loose connections. Check for contact resistance. Check for oxidation. Check the fuse. The voltage must be approximately battery voltage.

Check the power supply cable to the Engine control module (ECM) #B15 (#C15). Check for an open circuit, loose connections, contact resistance, and oxidation. Check the fuse. The voltage must be approximately battery voltage.

Check the power supply from the system relay to engine control module (ECM) terminals #B3 (#C3) and #B5 (#C5). Check for an open-circuit. Check for loose connections. Check for contact resistance. Check for oxidation. Check the fuse. The voltage must be approximately battery voltage when the ignition is on.

Ground terminal engine control module (ECM)

Then engine control module (ECM) has three ground inputs. All ground inputs from the control module are connected via three separate ground leads to the same ground terminal in the car body.

1. Ground input 1, #B2 (#C2) is power ground and is connected to the ground terminal in the body.
2. Ground input terminal 2, #B4 (#C4), is power ground and is connected to the ground terminal in the car body.
3. Ground input terminal 3, #B6 (#C6), is power ground and is connected to the ground terminal in the car body.

Checking the ground terminal

Check the ground lead between engine control module (ECM) ground terminals #B2 (#C2), #B4 (#C4) and #B6 (#C6). Check for an open-circuit. Check for loose connections. Check for contact resistance. Check for oxidation. With the ignition on, the drop in voltage between the ground connection for the control module and the ground terminal must not be greater than 0.5 V.

Remedy as necessary.

Other information

1. see «CONNECTING THE BREAKOUT BOX»(/volvo/s80/ii-2006-2010/remont/engine-control-systems/#ignition-and-engine-control-systems-general-diagnostics-and-tests__connecting-the-breakout-box-b6304t2-b6304t4)
2. see «SIGNAL SPECIFICATION»(ref-499212-S24477611452012090500000)
3. see «CHECKING WIRING AND TERMINALS»(/volvo/s80/ii-2006-2010/remont/body-electrical/#intermittent-fault-tracing-wiring-and-terminals-general-diagnostics-and-tests)

The engine control module (ECM) is supplied power via four voltage inputs on the control module.

With the ignition on, power is supplied to all voltage inputs and the engine control module (ECM) is in active mode.

1. Power input 1, terminal #B16 (#C16) is supplied with power via a fuse from the battery. This power input is used to power the memory in the Engine control module (ECM). In the event of an open-circuit, the engine control module (ECM) will be reset and adaptation values and diagnostic trouble codes (DTCs) and other information in the memory will disappear.
2. Voltage input 2, #B15 (#C15) is supplied via fuse in ignition position II. This power input is used to activate the engine control module (ECM). When power input 2 is powered, the system relay will be activated and power inputs 3 and 4 will be powered. The engine control module (ECM) will not be activated if there is an open-circuit.
3. Power input 3, terminal #B3 (#C3) is supplied with power via a fuse from the system relay. The system relay is activated by the engine control module (ECM). This power input governs the supply of power to the Engine control module (ECM).
4. Power input 4, terminal #B5 (#C5) is supplied with power via a fuse from the system relay. The system relay is activated by the engine control module (ECM). This power input governs the supply of power to the Engine control module (ECM).

Checking the power supply

Check the power supply cable from the battery to the Engine control module (ECM) terminal #B16 (#C16). Check for an open-circuit. Check for loose connections. Check for contact resistance. Check for oxidation. Check the fuse. The voltage must be approximately battery voltage.

Check the power supply cable to the Engine control module (ECM) #B15 (#C15). Check for an open circuit, loose connections, contact resistance, and oxidation. Check the fuse. The voltage must be approximately battery voltage.

Check the power supply from the system relay to engine control module (ECM) terminals #B3 (#C3) and #B5 (#C5). Check for an open-circuit. Check for loose connections. Check for contact resistance. Check for oxidation. Check the fuse. The voltage must be approximately battery voltage when the ignition is on.

Ground terminal engine control module (ECM)

Then engine control module (ECM) has three ground inputs. All ground inputs from the control module are connected via three separate ground leads to the same ground terminal in the car body.

1. Ground input 1, #B2 (#C2) is power ground and is connected to the ground terminal in the body.
2. Ground input terminal 2, #B4 (#C4), is power ground and is connected to the ground terminal in the car body.
3. Ground input terminal 3, #B6 (#C6), is power ground and is connected to the ground terminal in the car body.

Checking the ground terminal

Check the ground lead between engine control module (ECM) ground terminals #B2 (#C2), #B4 (#C4) and #B6 (#C6). Check for an open-circuit. Check for loose connections. Check for contact resistance. Check for oxidation. With the ignition on, the drop in voltage between the ground connection for the control module and the ground terminal must not be greater than 0.5 V.

Remedy as necessary.

Other information

1. see «CONNECTING THE BREAKOUT BOX»(/volvo/s80/ii-2006-2010/remont/engine-control-systems/#ignition-and-engine-control-systems-general-diagnostics-and-tests__connecting-the-breakout-box-b6324s-b6324s5)
2. see «SIGNAL SPECIFICATION»(ref-499212-S26471256792012090500000)
3. see «CHECKING WIRING AND TERMINALS»(/volvo/s80/ii-2006-2010/remont/body-electrical/#intermittent-fault-tracing-wiring-and-terminals-general-diagnostics-and-tests)

The engine control module (ECM) is supplied power via four voltage inputs on the control module.

With the ignition on, power is supplied to all voltage inputs and the engine control module (ECM) is in active mode.

1. Power input 1, terminal #B16 (#C16) is supplied with power via a fuse from the battery. This power input is used to power the memory in the Engine control module (ECM). In the event of an open-circuit, the engine control module (ECM) will be reset and adaptation values and diagnostic trouble codes (DTCs) and other information in the memory will disappear.
2. Power input 2, terminal #B15 (#C15) is supplied with power via a fuse from the start control module (SCU), ignition position II. This power input is used to activate the engine control module (ECM). When power input 2 is powered, the system relay will be activated and power inputs 3 and 4 will be powered. The engine control module (ECM) will not be activated if there is an open-circuit.
3. Power input 3, terminal #B3 (#C3) is supplied with power via a fuse from the system relay. The system relay is activated by the engine control module (ECM). This power input governs the supply of power to the Engine control module (ECM).
4. Power input 4, terminal #B5 (#C5) is supplied with power via a fuse from the system relay. The system relay is activated by the engine control module (ECM). This power input governs the supply of power to the Engine control module (ECM).

Checking the power supply

Check the power supply cable from the battery to the Engine control module (ECM) terminal #B16 (#C16). Check for an open-circuit. Check for loose connections. Check for contact resistance. Check for oxidation. Check the fuse. The voltage must be approximately battery voltage.

Check the power supply cable from the start control module (SCU) to engine control module (ECM) terminal #B15 (#C15). Check for an open-circuit. Check for loose connections. Check for contact resistance. Check for oxidation. Check the fuse. The voltage must be approximately battery voltage.

Check the power supply from the system relay to engine control module (ECM) terminals #B3 (#C3) and #B5 (#C5). Check for an open-circuit. Check for loose connections. Check for contact resistance. Check for oxidation. Check the fuse. The voltage must be approximately battery voltage when the ignition is on.

Ground terminal engine control module (ECM)

Then engine control module (ECM) has three ground inputs. All ground inputs from the control module are connected via three separate ground leads to the same ground terminal in the car body.

1. Ground input 1, #B2 (#C2) is power ground and is connected to the ground terminal in the body.
2. Ground input terminal 2, #B4 (#C4), is power ground and is connected to the ground terminal in the car body.
3. Ground input terminal 3, #B6 (#C6), is power ground and is connected to the ground terminal in the car body.

Checking the ground terminal

Check the ground lead between engine control module (ECM) ground terminals #B2 (#C2), #B4 (#C4) and #B6 (#C6). Check for an open-circuit. Check for loose connections. Check for contact resistance. Check for oxidation. With the ignition on, the drop in voltage between the ground connection for the control module and the ground terminal must not be greater than 0.5 V.

Remedy as necessary.

Other information

1. see «CONNECTING THE BREAKOUT BOX»(/volvo/s80/ii-2006-2010/remont/engine-control-systems/#ignition-and-engine-control-systems-general-diagnostics-and-tests__connecting-the-breakout-box-b6324s2-b6324s4)
2. see «SIGNAL SPECIFICATION»(ref-499212-S09345396342012090500000)
3. see «CHECKING WIRING AND TERMINALS»(/volvo/s80/ii-2006-2010/remont/body-electrical/#intermittent-fault-tracing-wiring-and-terminals-general-diagnostics-and-tests)

The engine control module (ECM) is powered via five power inputs on the control module.

With the ignition on, power is supplied to all voltage inputs and the engine control module (ECM) is in active mode.

1. Power input 1, terminal #B54 (#C54) is constantly supplied with power from the battery. This power input is used to power the memory in the Engine control module (ECM). In the event of an open-circuit, the engine control module (ECM) will be reset and adaptation values and diagnostic trouble codes (DTCs) and other information in the memory will disappear.
2. Power input 2, terminal #B27 (#C27) is temporarily supplied with power from the central electronic module (CEM) when the key is inserted in the ignition switch. This power input is used to prepare the engine for start-up, e. g. temporarily activates the system relay and the fuel pump. The engine control module (ECM) will not be activated if there is an open-circuit.
3. Power input 3, terminal #B30 (#C30) is supplied with power from the ignition switch via the central electronic module (CEM) with the ignition on. This power input is used to activate the system relay. The engine control module (ECM) will not be activated if there is an open-circuit.
4. Power input 4, terminal #B4 (#C4) is supplied with power from the system relay. The system relay is activated by the Engine control module (ECM) with the ignition on. This power input governs the supply of power to the Engine control module (ECM). The engine control module (ECM) will not be activated if there is an open-circuit.
5. Power input 5, terminal #B6 (#C6) is supplied with power from the system relay. The system relay is activated by the Engine control module (ECM) with the ignition on. This power input governs the supply of power to the throttle unit. In the event of an open-circuit, the engine control module (ECM) will be activated but the throttle unit will not be activated.

Checking the power supply

Check the power supply cable from the battery to the Engine control module (ECM) terminal #B54 (#C54). Check for an open-circuit. Check for loose connections. Check for contact resistance. Check for oxidation. The voltage must be approximately battery voltage.

Check the power supply cable from the Central electronic module (CEM) to the Engine control module (ECM) terminal #B30 (#C30). Check for an open-circuit. Check for loose connections. Check for contact resistance. Check for oxidation. The voltage must be battery voltage when the key is in the ignition switch.

Check the power supply from the system relay to the Engine control module (ECM) terminal #B30 (#C30), #B4 (#C4) and #B6 (#C6). Check for an open-circuit. Check for loose connections. Check for contact resistance. Check for oxidation. The voltage must be approximately battery voltage when the ignition is on.

Ground terminal engine control module (ECM)

The Engine control module (ECM) has four ground inputs that are all internally connected in the control module.

1. Ground input 1, #B1 (#C1) is power ground and is connected to the ground terminal in the body.
2. Ground input 2, #B2 (#C2) is power ground and is connected to the ground terminal in the body.
3. Ground input 3, #B3 (#C3) is power ground and is connected to the ground terminal in the body.
4. Ground input 4, #B5 (#C5) is power ground and is connected to the ground terminal in the body.

Checking the ground terminal

Check the ground cable between the Engine control module (ECM) terminal #B1 (#C1), #B2 (#C2), #B3 (#C3), #B5 (#C5) and the ground terminal. Check for an open-circuit. Check for loose connections. Check for contact resistance. Check for oxidation. With the ignition on, the drop in voltage between the ground connection for the control module and the ground terminal must not be greater than 0.5 V.

Remedy as necessary.

Other information

1. see «CONNECTING THE BREAKOUT BOX»(/volvo/s80/ii-2006-2010/remont/engine-control-systems/#ignition-and-engine-control-systems-general-diagnostics-and-tests__connecting-the-breakout-box-b8444s-2007-2010)
2. see «SIGNAL SPECIFICATION»(ref-499212-S39947262732012090500000)
3. see «CHECKING WIRING AND TERMINALS»(/volvo/s80/ii-2006-2010/remont/body-electrical/#intermittent-fault-tracing-wiring-and-terminals-general-diagnostics-and-tests)

MEASURING THE ETHANOL CONTENT

The method works for gasoline-ethanol fuel.

Note. First read the safety instructions for handling fuel.

Drain the fuel carefully from the vehicle.

Note. The fuel should be drained from the fuel distribution pipe and not from the fuel filling pipe/tank.

Scheme 1

Mix equal parts of fuel and water in a graduated, transparent container. Let stand for at least 5 minutes. The ethanol dissolves in the water and the mixture separates into layers. Gasoline is the lightest and ends up at the top.

Read off the number of graduation steps of gasoline and compare to the number of graduation steps of fuel that has been added. Best accuracy is achieved with a long-narrow measuring glass. Suitable design of version measuring glass is total volume of 500 ml with markings for every 5 ml, or total volume of 1, 000 ml with markings for every 10 ml.

Example: Mix 500 ml fuel with approx. equal parts water. After the ethanol has dissolved we can assume that the measured amount of gasoline is 120 ml.

Gasoline content is then calculated to: 120 ml/500 ml = 0.24 = 24%

This, ethanol content is: 100%-24% = 76%

HINT: When the ethanol dissolves in the water the fluids' total volume is reduced. To facilitate read-off you can fill the container with more water. Note that this does not affect the calculations above, since this takes place in relation to the amount of added fuel.

See also:
• CHECKING WIRING AND TERMINALS
• CONNECTING THE BREAKOUT BOX
• CONNECTING THE BREAKOUT BOX
• CONNECTING THE BREAKOUT BOX
• CONNECTING THE BREAKOUT BOX