Volvo D4 260 Ignition Issue

[GusC@AK]

I have a new D4-260 (as a port re-power). Worked fine at beginning of season, then suddenly had intermittent ignition issue which has become permanent. I turn the key to the "on" position, and get no power to the helm- no EVC display lights, no voltage at battery gauge, no engine hours display. Just blank.
1. I have 13.8 V at the battery and starter.
2. I am able to get it to crank by jump starting to battery (but won't turn over).
3. Replaced my relay.
4. Replaced my key switch at the helm.
5. Swapped out the EVC in the engine room with a known-to-work EVC.
6. Checked all my grounds and connections from battery to starter/solenoid.

Out of ideas! Any suggestions?

 

[frenzy]

Not sure if it’s the same issue that I just posted last Monday. I had no power to the ignition switch. Have a look at the post
No Power Volvo Penta KAD 300

 

[spannerman]

Sounds like tge DC-DC converter has failed, its a small black box at the back of the motor on the port side behind the intercooler. This takes power from the starter terminal and gIves a stabilised voltage to the ECU.

 

[GusC@AK]

Thanks for the replies. I will test this. One detail I failed to mention- when I turn on the main power to the engine I hear the injectors waking up and ticking... does this fit your theory too?

 

[Andyroonot]

Thanks for the replies. I will test this. One detail I failed to mention- when I turn on the main power to the engine I hear the injectors waking up and ticking... does this fit your theory too?

They will only ‘tick’ if the engine ECU has been switched on, and that only happens if the ignition is on and the signal (voltage) is being sent from the PCU.
DC-DC converter has two outputs, one to the engine ECU & the other to the EVC system.
What EVC generation? Do you have the engine serial number? What is the stbd side doing?
It might be that the key is doing its job but the HCU isn’t showing anything on the displays?

 

[GusC@AK]

They will only ‘tick’ if the engine ECU has been switched on, and that only happens if the ignition is on and the signal (voltage) is being sent from the PCU.
DC-DC converter has two outputs, one to the engine ECU & the other to the EVC system.
What EVC generation? Do you have the engine serial number? What is the stbd side doing?
It might be that the key is doing its job but the HCU isn’t showing anything on the displays?

The engine is a 2019 D4-260I-E (I don't have the serial number with me), connected to an early gen EVC (2008 model). Strbd work fine, but its a original install D4 (2008) connected to same get EVC.

 

[Andyroonot]

The engine is a 2019 D4-260I-E (I don't have the serial number with me), connected to an early gen EVC (2008 model). Strbd work fine, but its a original install D4 (2008) connected to same get EVC.

Was all the software on the old EVC system changed to match the new engine? Or alternatively, was the new engine ECU software downgraded to match the original EVC system?
Serial numbers of the old and new engine would be useful if you could get them, and the stbd engines number
Where are you based?

 

[GusC@AK]

Thanks for the reply! I'll check to see if software was upgraded asap. Serial numbers will have to wait until I go to the harbor in a few days. I'm in Alaska.

 

[GusC@AK]

Was all the software on the old EVC system changed to match the new engine? Or alternatively, was the new engine ECU software downgraded to match the original EVC system?
Serial numbers of the old and new engine would be useful if you could get them, and the stbd engines number
Where are you based?

I got the old serial numbers: the old engine was a D4-260I-B BT
S/N: 2004008202
The new (problematic) engine is a D4-260A-F
S/N: A1063135
The EVC S/N is 061200048907

The EVC was not touched when the new engine was installed. The engine’s software was downgraded to match the EVC. We ran the engine for 300 hours with no issues until now.

 

[Andyroonot]

I got the old serial numbers: the old engine was a D4-260I-B BT
S/N: 2004008202
The new (problematic) engine is a D4-260A-F
S/N: A1063135
The EVC S/N is 061200048907

The EVC was not touched when the new engine was installed. The engine’s software was downgraded to match the EVC. We ran the engine for 300 hours with no issues until now.

I’ll have a proper look at the software tomorrow, but it all needs to match to work properly
Just to confirm, does the new engine connect at the helm station to the original Helm Control Unit (HCU) under the dashboard?

 

[GusC@AK]

I’ll have a proper look at the software tomorrow, but it all needs to match to work properly
Just to confirm, does the new engine connect at the helm station to the original Helm Control Unit (HCU) under the dashboard?

Thanks for your help. I finally traced the issue to an intermittent failing HCU. Ordered a new one (with new matching software). Issue resolved!

 

[Paul@fal]

I have a new D4-260 (as a port re-power). Worked fine at beginning of season, then suddenly had intermittent ignition issue which has become permanent. I turn the key to the "on" position, and get no power to the helm- no EVC display lights, no voltage at battery gauge, no engine hours display. Just blank.
1. I have 13.8 V at the battery and starter.
2. I am able to get it to crank by jump starting to battery (but won't turn over).
3. Replaced my relay.
4. Replaced my key switch at the helm.
5. Swapped out the EVC in the engine room with a known-to-work EVC.
6. Checked all my grounds and connections from battery to starter/solenoid.

Out of ideas! Any suggestions?

I have a new D4-260 (as a port re-power). Worked fine at beginning of season, then suddenly had intermittent ignition issue which has become permanent. I turn the key to the "on" position, and get no power to the helm- no EVC display lights, no voltage at battery gauge, no engine hours display. Just blank.
1. I have 13.8 V at the battery and starter.
2. I am able to get it to crank by jump starting to battery (but won't turn over).
3. Replaced my relay.
4. Replaced my key switch at the helm.
5. Swapped out the EVC in the engine room with a known-to-work EVC.
6. Checked all my grounds and connections from battery to starter/solenoid.

Out of ideas! Any suggestions?

Hi Gus
I've got the same problem with my volvo penta ignition how did you find out it was the HCU giving the problem?
Cheers Paul

 

[GusC@AK]

Hi Gus
I've got the same problem with my volvo penta ignition how did you find out it was the HCU giving the problem?
Cheers Paul

It was pretty easy. I took the good HCU from the working starboard engine and installed it on the port engine. It fired right up. Do you have access to an operable HCU to try?

 

[Paul@fal]

Thanks for getting back to me
No i haven't ,it's a single engine boat
Do you if it would show up as a problem if the engine was pluged in to a laptop?

 

[GusC@AK]

Thanks for getting back to me
No i haven't ,it's a single engine boat
Do you if it would show up as a problem if the engine was pluged in to a laptop?

Possibly, if using Volvo VODA software?

 

[Shetland28]

Sounds like tge DC-DC converter has failed, its a small black box at the back of the motor on the port side behind the intercooler. This takes power from the starter terminal and gIves a stabilised voltage to the ECU.

Hi
Is the same converter fitted to 4.3 petrol engines.
I've got an issue with the gear shift not responding, and a Vodio has been connected by a dealer to find the fault, but what he can't make sense of is the voltage dropping from 12.8 to 1 volt .