Section 7B1

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Workshop Manual
EFI Diagnostic

C
2(0)

4.3GXi-A/B /C/D, 4.3OSi-A/B/C/D

5.0GXi-A/B /C/D, 5.0OSi-A/B/C/D
5.7Gi-A/B/C/D, 5.7GXi-A/ B/C/D/E, 5.7OSi-A/B/C, 5.7OSXi-A/ B/C
8.1Gi-B/C/D, 8.1GXi-A/B /C, DPX375-B, DPX420-B

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Service Manual
Corrections
----------------The Next 4 pages
contain changes to this
service manual

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Service Bulletin
Volvo Penta of the Americas
1300 Volvo Penta Drive
Chesapeake, Virginia 23320-9810
USA

Group

Number

04-2

40

Version

01

EFI Diagnositc Workshop Manual

Models
7742218

Distribution: M

Date: 11-2003

Binder: C

Page: 1(4)

Volvo Penta has identified various values that were incorrectly published in the original workshop manual. This
document is intended as a notice to be used to replace information in the original publication.Original text is
boldface italics.
provided along with the corrections, which are denoted using

Page 39: Second sentence When engine RPM reaches a predetermined value (for this example 400 RPM),
the ECM considers the engine running and applies five volts ton the BYPASS line to the IC module
more than 400 RPMs), the ECM
Should read When engine RPM reaches a predetermined value (
considers the engine running and applies five volts to the BYPASS line to the IC module.
Page 42: Engine Control Module (ECM) Step 2: Remove the J-1 (A) and J-2 (B) connectors from the ECM
(C).
J-2 (A) and J-1 (B) connectors from the ECM (C).

Change to read Remove the

Page 149: DTC 14 - Engine Coolant Temperature (ECT) Sensor Circuit - High Temperature Indicated
DTC 15 - Engine Coolant Temperature (ECT) Sensor Circuit - High Temperature Indicated
Page 160: Under paragraph Diagnostic Aids
If engine starts and stalls, it may set a false DTC 41.
If engine starts and stalls, it may set a false DTC

42.

Page 250: B and C terminals on the IAC connector are switched.

BN/Y

J1-30

GN/SB

J1-15

J1-31

P/BL

BL/Y

J1-16

4306

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Volvo Penta of the Americas

Service Bulletin

Group

Number

Version

04-2

40

01

Page
2(4)

Manifold
Absolute
Pressure
(MAP)
Sensor

GR
SB/OR

Page 274: MAP diagram. The light green wire comes from
pin B to J2-6. Make pin B
J2-8.

SB/OR

Lt GN
SB/OR
J2-2

J2-8

J2-3

Engine
Control
Module
(ECM)

P/W

P/W

P/W

Fuel

Fuel

Fuel

Fuel

Injector
Cylinder #1

Injector
Cylinder #4

Injector
Cylinder #6

Injector
Cylinder #7

A
A

A
BL/SB

A
G

Y/SB

SB

R/SB
J1-11

Page 312: J2-26 should be

P/W

T/OR

Fuel
Injector
Driver A

J2-11.

P/W

P/W

P/W

P/W

Fuel
Injector

Fuel
Injector

Fuel
Injector

Fuel
Injector

Cylinder #2

Cylinder #3

Cylinder #5

Cylinder #8

A
H

A
F

P/SB

SB/W

GN/SB

BL/W
J1-26

Page 314: J2-11 should be

J2-26.

Fuel
Injector
Driver B

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Engine
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Volvo Penta of the Americas

Service Bulletin

Group

Number

Version

04-2

40

01

3(4)

Fuel

Fuel

Fuel

Fuel

Injector
Cylinder #1

Injector
Cylinder #4

Injector
Cylinder #6

Injector
Cylinder #7

A
A

Page 416: J2-26 should be

Page

J2-11.

A
G

T/OR
J1-11
Fuel
Injector
Driver A

P/W

P/W

P/W

P/W

B
Fuel

Fuel

Fuel

Injector
Cylinder #2

Injector
Cylinder #3

Injector
Cylinder #5

Injector
Cylinder #8

A
H

A
D

SB/W

GN/SB

BL/W

J2-26.

J1-26

Fuel
Injector
Driver B

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A
F

P/SB

Page 418: J2-11 should be

Fuel

Engine
Control
Module
(ECM)

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Volvo Penta of the Americas

Service Bulletin

Wiring Diagrams:

Group

Number

Version

04-2

40

01

Page
4(4)

A Red/Blue R/BL wire should connect pin 30 of the Start relay to the adjacent fuse of the following
schematics.

4.3GXi-B
4.3GXi-C/D
5.0GXi-B, 5.7Gi-B, GXi-C
8.1Gi-B, GXi-A
8.1Gi-C/D, GXiB-C
DPX375-B, DPX420-B

Y/R
R/PU
86
30

1
5

87
85

PU

86
30

P/W

R/PU

19

1
5

87
85

R/W

86
30

2
0

87
85

SB/Y

6
SB

20

20

R/PU

Wiring Diagrams: Replace the existing Engine Schematic 4.3GXi-A, 4.3OSi-A/B, 5.0GXi-A, 5.0OSi-A/B, 5.7Gi-A,
5.7OSi-A, 5.7GXi-B, 5.7OSXi-A with the attached wiring schematic.

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Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Throttle Body Injection (TBI)
TBI Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
TBI On Board Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
TBI Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
TBI Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
TBI Non-Scan Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
TBI Scan Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Port Fuel Injection (PFI)

PFI Operation - 8.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
PFI On Board Repair 8.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
PFI Symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
PFI Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
PFI Scan Diagnostics 8.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
PFI Operation - 4.3, 5.0, 5.7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
PFI On Board Repair 4.3, 5.0, 5.7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
PFI Scan Diagnostics - 4.3, 5.0, 5.7 . . . . . . . . . . . . . . . . . . . . . . . . . . . 371

Wiring Diagrams
4.3GXi-A, 5.0GXi-A, 5.7Gi-A, 5.7GXi-A/B . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
4.3GXi-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
4.3GXi-C/D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
5.0GXi-B, 5.7Gi-B, 5.7GXi-C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
5.0GXi-C/D5.7Gi-C/D, 5.7GXi-D/E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443
8.1Gi-B, 8.1GXi-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445
8.1Gi-C/D, 8.1GXi-B/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
DPX375, DPX420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
Fues Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S1

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General Information
Contents
Circuit Protection .......................................................................................................................... 3
Circuit Protectors and Locations ................................................................................................ 3
Battery and Cables ........................................................................................................................ 4
Special Tools Required: Battery Hydrometer ............................................................................. 4
Battery Requirements ................................................................................................................... 4
Battery Maintenance ..................................................................................................................... 4
Cable Requirements ..................................................................................................................... 4
Tuning The Engine ........................................................................................................................ 5
Gasoline Requirements ................................................................................................................ 5
Gasoline Containing Alcohol ....................................................................................................... 5
Storage ........................................................................................................................................... 6
Prepare a storage mixture ............................................................................................................ 6
Electric fuel pumps and fuel cells ............................................................................................... 6
Stuck Pumps ................................................................................................................................. 7
Noisy Pumps ................................................................................................................................. 7
Periodic Maintenance Chart ......................................................................................................... 8
Abbreviations ................................................................................................................................ 9
Aftermarket (Add-On) Electrical And Vacuum Equipment ...................................................... 10
Visual/Physical Inspection ......................................................................................................... 10
Basic Knowledge and Tools Required ...................................................................................... 10
Electrostatic Discharge Damage ............................................................................................... 10
Engine Wiring .............................................................................................................................. 10
Engine Control Module (ECM) Self-Diagnostics ...................................................................... 10
Malfunction Indicator Lamp (MIL) ............................................................................................. 11
Intermittent Malfunction Indicator Lamp (MIL)......................................................................... 11
Reading Diagnostic Trouble Codes (DTCs) ............................................................................ 11
Service Mode ............................................................................................................................... 12
Normal Mode ............................................................................................................................... 12
On-Board Diagnostic (OBD) System Check ............................................................................. 12
DLC Scan Tools ........................................................................................................................... 12
Scan Tool Use With Intermittents .............................................................................................. 12
How Diagnostic Trouble Codes (DTC) Are Set ......................................................................... 13
Clearing Diagnostic Trouble Codes (Non-Scan) ...................................................................... 13
Clearing Diagnostic Trouble Codes (Scan) .............................................................................. 14
Non-Scan Diagnosis Of Drivability Concerns (No DTCs Set) ................................................ 14
Service Precautions .................................................................................................................... 15
Special Tools and Equipment .................................................................................................... 16
Special Tools and Equipment (cont.) ........................................................................................ 17
Wiring Harness Service .............................................................................................................. 18
Wiring Connector Service .......................................................................................................... 19
Metri-Pack Series 150 Terminals ............................................................................................... 19
Weather-Pack Connectors ......................................................................................................... 20
Micro-Pack 100/W Series Connectors ....................................................................................... 21

VPA 7742218 03-2003

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Document Outline

7742218_cover.pdf
 Page 1
Section 2A.pdf
 Contents


General Description
Sensors and Voltage Signals
 Engine Control Module (ECM)
 ECM Function
 Memory
 Speed Density System
 ECM Inputs / Sensor Descriptions
 Engine Coolant Temperature (ECT) Sensor
 Manifold Absolute Pressure (MAP) Sensor
 Knock Sensor (KS) System
 ENGINE PROTECTION MODE
 Fuel System
 Modes Of Operation
 Fuel Supply Components
 Fuel Pump Electrical Circuit
 Fuel Injectors
 Pressure Regulator Assembly
 Fuel System Operation
 Ignition System
 Ignition Coil
 Ignition Control (IC) Module
 Pole Piece and Coil Assembly
 Engine Control Module (ECM)
 Ignition Timing
Section 3A.pdf
 Contents



General Information
Engine Control Module (ECM)
 Engine Coolant Temperature (ECT) Sensor
 Manifold Absolute Pressure (MAP) Sensor
 Throttle Position (TP) Sensor
 Idle Air Control (IAC) Valve
 Knock Sensor (KS)
 Fuel System Component Replacement
 Fuel Control Service
 Fuel Pressure Relief Procedure
 Throttle Body Injector (TBI) Unit
 Fuel Meter Cover Assembly
 Fuel Injector
 Fuel Cell
 Circuit Breaker
 Relay Replacement
 Relay Ohmmeter Tests
 Troubleshooting Electric Pump(s)
 Pressure Testing Fuel System
 Troubleshooting Boat Fuel System
 Vacuum Testing Fuel System
 Engine Fuel System Troubleshooting
 Engine Will Start When Primed - Will Not Continue to Run
 Engine Hard Starting, Cold
 Engine Hard Starting, Hot
 Engine Runs Rough, Low Speed
 Engine Runs Rough, High Speed
 Engine Dies (On Initial Acceleration) or Has Acceleration Flat Spot
 Engine Will Not Run at Recommended RPM
 Ignition System Description
 Ignition Coil Test
 Pickup Coil Test
 Ignition Module Test
 Inductor
 Distributor
 Setting Initial Timing
 Setting Timing
 Ignition Coil Replacement
 Ignition and Pickup Coils
 Specifications
 Ignition System Problems
 Torque Specifications
Section 4A.pdf
 Contents
 Important Preliminary Checks
 Hard Start Symptom
 Surges Symptom
 Hesitation, Sag, or Stumble Symptom
 Detonation / Spark Knock Symptom



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Lack of Power, Sluggish, or Spongy Symptom

Cuts Out, Misses Symptom
 Rough, Unstable or Incorrect Idle and Stalling Symptom
 Backfire (intake) Symptom
 Backfire (exhaust) Symptom
 Dieseling, Run-On Symptom
 Poor Fuel Economy Symptom
 ECM J1 Connector and Symptoms Identification
 ECM J1 Connector and Symptoms Identification (cont.)
 ECM J2 Connector and Symptoms Identification
Section 6A.pdf
 Contents
Section 7A.pdf
 Contents
 DTC 14 - Engine Coolant Temperature (ECT) Sensor Low Temperature Indicated
 DTC 15 - Engine Coolant Temperature (ECT) Sensor - High Temperature Indicated
 DTC 21 - Throttle Position (TP) Sensor - Signal Voltage High
 DTC 22 - Throttle Position (TP) Sensor - Signal Voltage Low
 DTC 33 - Manifold Absolute Pressure (MAP) Sensor - Signal Voltage High
 DTC 34 - Manifold Absolute Pressure (MAP) Sensor - Signal Voltage Low
 DTC 41 - Ignition Control (IC) - Open IC Circuit
 DTC 42 - Ignition Control (IC) - Grounded IC Circuit, Open or Grounded Bypass
 DTC 44 - Knock Sensor (KS) - System Inactive
 DTC 51 - ECM Calibration Memory Failure
 Engine Protection Mode Circuit
Wiring Diagrams
 4.3GXi-A_5.0GXi-A_5.7Gi-A_5.7GXi-B
 4.3GXi-B
 4.3GXi-C/D
 50GXi-B_57Gi-B_57GXi-C
 50GXi-C/D_57Gi-C/D_57GXi-D/E
 81Gi-B, 81GXi-A
 81Gi-C/D, 81GXi-B/C
 DPX375-B_DPX420-B.pdf
Safety
 Part A
 Part B
Section Covers 1.pdf
 General Information



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