Ignition and Control Systems - General Diagnostics and Tests: Other Volvo XC90 I

CHECKING POWER SUPPLY AND GROUND TERMINAL, ENGINE CONTROL MODULE (ECM)

Checking the power supply

1. Check the fuse for power supply to engine control module (ECM) terminal #A17 (#A17). If the fuse is blown, check the circuit for a short-circuit to ground
2. Check the fuse for power supply to engine control module (ECM) terminal #B11 (#B21). If the fuse is blown, check the circuit for a short-circuit to ground
3. Check the power supply to engine control module (ECM) terminal #A17 (#A17). The voltage must be approximately battery voltage when the ignition is on. If the voltage is incorrect, check the cable between ignition switch terminal 30 and system relay terminal #3 and the cable between system relay terminal #5 and engine control module (ECM) terminal #A17 (#A17). Check for an open-circuit
4. Check the power supply to engine control module (ECM) terminal #B11 (#B21). The voltage must be approximately battery voltage when the ignition is on. If the voltage is incorrect, check the cable between ignition switch terminal 30 and engine control module (ECM) terminal #B11 (#B21). Check for an open-circuit.

Checking ground terminal

1. Check the ground leads between engine control module (ECM) terminals #A53 (#A53), #A54 (#A54), #A63 (#B3) and the common ground terminal in the body for the wiring. Check for an open-circuit
2. Check the ground terminal in the body for the engine control module (ECM). Check for contact resistance and oxidation.

Remedy as necessary

Other information

1. To connect the breakout box, see «CONNECTING THE BREAKOUT BOX»(ref-476691-S38062545372012060500000)
2. For information about signals on 5 cylinder engines, See «SIGNAL SPECIFICATION»(ref-476694-S29505181092012060500000)
3. For information about signals on 6 cylinder engines, see «SIGNAL SPECIFICATION»(ref-476694-S31890965202012060500000)
4. see «CHECKING WIRING AND TERMINALS»(ref-476689-S17655503092012060500000)

Scheme 1

see CHECKING POWER SUPPLY AND GROUND TERMINAL, ENGINE CONTROL MODULE (ECM)

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 intake 2, #B15 (#C15) is supplied power from the ignition switch via the central electronic module (CEM). 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.
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»(ref-476691-S30437390172012060500000)
2. see «SIGNAL SPECIFICATION»(ref-476694-S29505181092012060500000)
3. see «CHECKING WIRING AND TERMINALS»(ref-476689-S17655503092012060500000)

CHECKING THE VOLTAGE / GROUND TERMINAL

see CHECKING THE VOLTAGE / GROUND TERMINAL

CHECKING THE POWER SUPPLY AND GROUND TERMINALS

Power supply engine control module (ECM)

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»(ref-476691-S27857399862012060500000)
2. see «SIGNAL SPECIFICATION, ENGINE CONTROL MODULE (ECM)»(ref-476694-S30016655152012060500000)
3. see «CHECKING WIRING AND TERMINALS»(ref-476689-S17655503092012060500000)

CONNECTING THE BREAKOUT BOX

Special tools

see 9512902

see 9512974

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 switching off the ignition before disconnecting the connectors from the engine control module (ECM). The system relay must be voltage free before the control module can be removed from the vehicle. 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 3 minutes.
2. Remove the engine control module (ECM). see «ENGINE CONTROL MODULE (ECM)»(ref-476695-S30933262542012060500000)
3. Install the cover plate see «9512974»(ref-460875-S38344968982012040200000) over the hole after the engine control module (ECM).

Note. Ensure that the cover plate is properly sealed

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 CONNECTORS

1. Wait 3 minutes after the ignition has been switched off. The main relay must be voltage free before the control module can be removed from the vehicle. 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 3 minutes. NOTE: Do not touch the terminal pins of the engine control module (ECM) 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.
3. Carefully detach the adapter from the vehicle wiring harness.
4. Remove the cover plate.

CONTROL MODULE CONNECTION

1. Check that no pins or sockets are damaged on the connector.
2. Install the engine control module (ECM). see «ENGINE CONTROL MODULE (ECM)»(ref-476695-S30933262542012060500000)

see CONNECTING THE BREAKOUT BOX

Special tools

see 9512902

see 9512974

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 switching off the ignition before disconnecting the connectors from the engine control module (ECM). The system relay must be voltage free before the control module can be removed from the vehicle. 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 3 minutes.
2. Remove the engine control module (ECM). see «ENGINE CONTROL MODULE (ECM), REPLACING»(ref-476695-S24530329132012060500000)
3. Install cover plate see «9512974»(ref-460875-S38344968982012040200000) over the hole after the engine control module (ECM).

Note. Ensure that the cover plate is properly sealed

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 the ignition has been switched off. The main relay must be voltage free before the control module can be removed from the vehicle. 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 3 minutes. NOTE: Do not touch the terminal pins of the engine control module (ECM) 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.
3. Carefully detach the adapter from the vehicle wiring harness.
4. Remove the cover plate.

1. Check that no pins or sockets are damaged on the connector.
2. Install the engine control module (ECM). see «ENGINE CONTROL MODULE (ECM), REPLACING»(ref-476695-S24530329132012060500000)

Special tools

see 9511504

see 9511428

see 9511499

see 9995722

Scheme 2

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 see «9995722»(ref-460875-S03732819042012033000000) 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 3

1. Check that no pins or sockets are damaged on the connector
2. Gently press adapter see «9511504»(ref-460875-S18603087282012040200000) down into the grooves inside the control module box. Press to the limit position!
3. Insert tool see «9995722»(ref-460875-S03732819042012033000000) around the adapter
4. Move the upper section of the tool forwards as far as it will go. Pull the tool up.

Scheme 4

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 see «9511504»(ref-460875-S18603087282012040200000) to the control module connector (wiring side). Connect breakout box see «9511428»(ref-460875-S19859279082012033000000) to the adapter via wiring see «9511499»(ref-460875-S42703648442012033000000)
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 5

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 NOTE: Do not touch the control module terminal pins with your fingers. Static electricity may damage components in the control module.
2. Insert tool see «9995722»(ref-460875-S03732819042012033000000) around the adapter
3. Move the upper section of the tool backwards as far as it will go. Pull up the tool
4. Carefully pull up the adapter.

Scheme 6

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 see «9995722»(ref-460875-S03732819042012033000000) 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.

see CONNECTING THE BREAKOUT BOX

see CONNECTING THE BREAKOUT BOX

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 7

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 MEASURING THE ETHANOL CONTENT