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Problems

Radio Suppression relay (white colour near front fender)

ALL VOLVO FUEL INJECTION MODELS – Intermittent poor/non start. Has vehicle got a radio suppression relay? (white color near front fender) If yes REPLACE! (radio suppression relay supplies injector 12volts – any problems here can cause injector mis-operation)

 

Vehicle occasionally breaks down on road or fails to start

VOLVO 740/760 TURBO MODELS with Bosch Motronic engine management ECU and LUXOR injection amplifier 1986-90. Motronic ECU part numbers 0261 200 022 and 026. Motronic ECU is located inside car – LUXOR is black painted cast alloy box mounted vertically immediately behind battery with large connector on top edge.

Symptoms

VEHICLE OCCASIONALLY BREAKS DOWN ON ROAD OR FAILS TO START (but sometimes starts after waiting). Problem is intermittent but GETTING WORSE. Breakdown services diagnose engine management ECU (Bosch Motronic) failure.

Diagnostic Checklist

1) Problem is more likely to be LUXOR injection amplifier ECU which is part of traction control system – standard fit to these cars whether traction control specified or not. Luxor ECU is black painted cast alloy box mounted vertically immediately behind battery with connector on top. Luxor ECU takes 5V level output signal from Motronic and amplifies this to drive injectors. WITH TRACTION CONTROL FITTED – If the ABS system detects drive wheel speed differential (brakes NOT applied), this ECU will switch off first 1 injector, then 3 injectors (if wheel speeds still different)

2) Liberally spray Luxor connector and pins with WD40 and road test before proceeding.

3) Diagnosis takes some time and involves using oscilloscope to monitor input (Luxor pin 16) pulse signal from Motronic and output pulse to each injector (Luxor pins 17/18/19/20). Failure is indicated by reduced AMPLITUDE of output injector pulse (which can be momentary and intermittent) – banging Luxor can help speed things up!

4) Sending Luxor ECU for reconditioning anyway may be best option!

Vehicle breaks down on road or fails to start in car park following short journey

VOLVO (CAT and NON CAT) 240/440/480/740/745/760/940 MODELS with Bosch Jetronic LH 2.2 and 2.4 fuel injection ECUs 1988 onwards. ECU part numbers 0280 000 5XX/56X/590/591/594/595/935/others.

Symptom
VEHICLE BREAKS DOWN ON ROAD OR FAILS TO START IN CAR PARK FOLLOWING SHORT JOURNEY. Breakdown services diagnose fuel injection ECU failure – loss of fuel pump relay control from ECU pin 20.

Diagnostic Checklist

1) ACCURATELY Identify fuel pump relay and remove. Connect jumper lead to provide 12 volt feed to fuel pump after ACCURATELY identifying relay socket pins. If you have ANY doubts about this test, call in auto electrician.

2) If car now starts and runs, take for road test to confirm OK (put on exhaust gas analyser first with catalyst equipped vehicles). IT IS NOT OK to use car with fixed feed to fuel pump.

3) If car now runs OK, ECU confirmed failed. Please complete the form found below to request a repair quotation.

4) If car doesn’t run with jumper lead fitted, there may be other causes of breakdown.

Vehicle suffers from poor idle speed control following work in engine compartment – especially tune up

VOLVO (CAT and NON CAT) 440/460/480/ MODELS fitted with FENIX (35 pin) (RENIX on Renault) engine management ECUs 1989 onwards.

Symptom

Vehicle suffers from poor idle speed control following work in engine compartment – especially tune up. Possible unrepairable damage to ECU idle control circuits due to crossing over idle control valve and throttle position switch connectors. These connectors can be undone whilst setting base idle speed or mixture.

This problem is most likely to occur on vehicles (both Volvo and Renault) with 1.7 litre engines.

On SOME cars these connectors are identical unkeyed 3 way connectors. The effect of crossing over is to apply earth directly to idle control IC within ECU – It is destroyed immediately ignition is turned on. This part is not commercially available so ECU cannot be repaired apart from robbing another ECU.

Diagnostic checklist
1) Confirm vehicle has 35 pin FENIX/RENIX system (BENDIX or SIEMENS stamped clearly on cast alloy ECU cover.
2) Confirm vehicle has idle control valve and throttle position switch with identical 3 way connectors in wiring to each component.3) Confirm wire colors match each side of connectors.
4) If wire colors don’t match, open ECU and look for obvious internal damage.
5) Even if wire colors match, open ECU and look for obvious internal damage (connectors could have been changed back).

ABS warning light REMAINS ON after switching on ignition

The ABS ECU fitted to Volvo 850 (with or without traction control) is now causing problems with vehicles failing annual or roadside safety tests because of ABS failure.

Symptoms

ABS warning light REMAINS ON after switching on ignition – most usually there is a history of the ABS light operating intermittently for some time. This means the ABS system has switched off and the automatic antilock function is NOT operating although the brakes remain effective.

ECU Identification Numbers:- TBA

Please see below for quotation request form.