No spark on a 480 Turbo

[volvo ov lov]

I have a 480 Turbo that's been in storage for a while and the time has come to get it to go. It turns over but there's no spark at the plugs. The Haynes manual describes how to check the ignition system but it also says taking it to a dealer so they can plug into the diagnostic socket would be quicker! I think a mobile engine diagnosis service may exist in my area (I'm in Cornwall) but I'd like to do what I can first and expand my understanding of this car.

[glasgowjim]

The hynes book of lies

Wowser a plug in diagnostic socket

Sorry but the HBOL is a standing joke in 480 circles.


There is NO plug in diagnostic socket .

But there is a read it yourself diagnostic box with a flashing led and all the codes etc are on the fourm here so you can do it yourself. Its not hard.

Do a search on diagnostic codes.

on second thoughts I have done it for you.....

[glasgowjim]

Fault Codes Retrieval

1. Open the diagnostic system's box cover and place the test cable mounted on the side of the box into an appropriate socket.
2. Turn the ignition ON to key position II without starting the engine. Wait about ten seconds.
3. Press the button once and hold it for more than one but less than three seconds.
4. The LED lamp will flash in successive series of three digits followed by a three-second pause. If there are no fault codes stored, it will flash 1-1-1 indicating the system being tested is operating correctly.
5. Count the successive flashes and record the fault code.
6. Press the button again, as described above.
7. Record the fault code. If it is the same as the previous one, then no additional codes are stored. Repeat until all the codes stored are retrieved (often a maximum of three).
8. Turn the ignition OFF and remove the test cable from a socket.

Erasing Fault Codes

1. Repeat step 1 and read all the fault codes again. Do not turn the ignition OFF after read-out.
2. Press and hold the button for more than five seconds, then release it.
3. When the LED lights, press the button again for more than five seconds and release it. When the LED goes off, the memory is cleared.
4. Test that memory is cleared by performing step 1. Code 1-1-1 should be returned.
Note: erasing fault codes on the ABS socket will cause the ABS control to be lit. It will turn off after a test-drive with speed of more than 40 km/h.

Sockets Description

1 – alarm and remote locking system,
2 – fuel system,
3 – ABS,
6 – cruise control,
7 – SRS (airbag).

Hints

Before assuming a fault in any of the systems tested, try to erase fault codes as described above. In my case, open circuit in ABS wiring has initially been signalled with codes 122, 152, 312 and 322. After erasing and performing a test-drive, only code 312 was signalled.

At first, read the codes when the engine is completely cold. Then, go for a longer test-drive and read them all again while the engine is still hot. Some codes (especially these related to lambda-sensor) tend to appear only while the vehicle is driven and short time afterwards.
 
Socket 1 — Alarm and remote locking system
Code:
1-1-1 No error code set
1-1-3 Transmitter to receiver: weak signal
1-1-4 Control Module (CM) faulty
2-1-1 Relay contacts, fuse or ground terminal (locking)
2-1-2 Relay contacts, fuse or ground terminal (unlocking)
2-2-1 Fuse or ground terminal (locking)
2-2-2 Fuse or ground terminal (unlocking)
2-2-3 Codes 2-2-1 and 2-2-2 combined
3-1-2 Siren: internal fault
3-2-1 Siren: power supply
4-1-2 Ultrasonic system: internal fault
4-1-3 Ultrasonic system: one or more sensors faulty
5-1-1 Key switch ground on (> 10 seconds)
5-1-2 Key switch ground off (> 10 seconds)
5-1-3 Locking door with ignition on
5-1-4 Unlocking door with ignition on
5-2-1 Central locking system switch (> 10 seconds locked)
5-2-2 Ultrasonic switch (> 20 seconds locked)
5-3-1 Interior lights, shorting to earth

 
Socket 2 — fuel system
Code:
1-1-1 No error code set
1-1-2 Malfunction in Electronic Control Module
1-1-3 Open circuit in injector wiring
1-2-1 Air pressure sensor: no signal correspondence
1-2-2 Air temperature sensor: no signal or signal faulty
1-2-3 Coolant temperature sensor: no signal or signal faulty
1-3-2 Incorrect battery voltage
1-4-3 Knock sensor: no signal or signal faulty
2-1-2 Oxygen sensor: no signal or signal faulty
2-1-4 Flywheel sensor: signal faulty
2-2-2 System relay coil: no voltage
2-2-3 Idle speed regulating valve: no signal or signal faulty
2-3-1 Adaptive Lambda closed loop control system lean or rich in part–load range
2-3-2 Adaptive Lambda closed loop control system lean or rich at idling speed
2-4-4 Knock sensor: no signal or signal faulty
3-1-1 Speedometer signal: no signal correspondence
3-1-3 Charcoal absorption canister valve: signal faulty
3-4-2 A/C relay signal: signal faulty
3-4-3 Main relay coil: no voltage
4-1-1 Throttle valve sensor: signal faulty

 
Socket 3 — ABS
Code: (40 km/h = 25 mph)
1-1-1 No error code set
1-2-1 Left side front wheel sensor: faulty signal at speed less than 40 km/h
1-2-2 Right side front wheel sensor: faulty signal at speed less than 40 km/h
1-2-3 Left side rear wheel sensor: faulty signal at speed less than 40 km/h
1-2-4 Right side rear wheel sensor: faulty signal at speed less than 40 km/h
1-2-5 Signal faulty from at least one sensor for a long period
1-3-5 Control Module (CM) faulty
1-4-1 Faulty pedal sensor: shorted to ground or supply
1-4-2 Faulty stop (brake) lamp switch: open circuit
1-4-3 Control Module (CM) faulty
1-4-4 Brake discs overheated
1-5-1 Left side front wheel sensor: open circuit or short-circuit to battery voltage
1-5-2 Right side front wheel sensor: open circuit or short-circuit to battery voltage
1-5-5 Rear axle sensor: open curcuit or short-circuit to battery voltage
2-1-1 Left side front wheel sensor: no signal or moving off
2-1-2 Right side front wheel sensor: no signal or moving off
2-1-3 Left side rear wheel sensor: no signal or moving off
2-1-4 Right side rear wheel sensor: no signal or moving off
2-1-5 Valve relay: open circuit or short-circuit
2-2-1 Left side front wheel sensor: ABS operation signal missing
2-2-2 Right side front wheel sensor: ABS operation signal missing
2-2-3 Left side rear wheel sensor: ABS operation signal missing
2-2-4 Right side rear wheel sensor: ABS operation signal missing
2-3-1 Left side front wheel sensor: signal missing
2-3-2 Right side front wheel sensor: signal missing
2-3-5 Rear axle sensor: signal missing
3-1-1 Left side front wheel sensor: open circuit or short-circuit
3-1-2 Right side front wheel sensor: open circuit or short-circuit
3-1-3 Left side rear wheel sensor: open circuit or short-circuit
3-1-4 Right side rear wheel sensor: open circuit or short-circuit
3-2-1 Left side front wheel sensor: irregular interference at speeds over 40 km/h
3-2-2 Right side front wheel sensor: irregular interference at speeds over 40 km/h
3-2-3 Left side rear wheel sensor: irregular interference at speeds over 40 km/h
3-2-4 Right side rear wheel sensor: irregular interference at speeds over 40 km/h
4-1-1 Left side front wheel inlet valve: open circuit or short-circuit
4-1-2 Left front return valve: open circuit or short-circuit
4-1-3 Right side front wheel inlet valve: open circuit or short-circuit
4-1-4 Right front return valve: open circuit or short-circuit
4-1-5 Rear valve: open circuit or short-circuit
4-2-1 Rear wheel circuit inlet valve: open circuit or short-circuit
4-2-2 Rear wheel circuit return valve: open circuit or short-circuit
4-2-3 Traction Control System (TRACS) valve: open circuit or short-circuit
4-2-4 Pressure switch for TRACS: faulty or short-circuit
4-4-1 Control Module (CM) faulty
4-4-2 Pump pressure low
4-4-3 Pump motor/relay: electrical or mechanical fault
4-4-4 No power supply to valves in hydraulic unit




Socket 6 — cruise control
Code: (40 km/h = 25 mph)
1-1-1 No error code set; speed was higher than 40 km/h
1-1-2 Vehicle Speed Sensor: abnormal signal received
1-2-2 Vehicle speed: 40 km/h not exceeded or no signal
2-1-1 Fault in supply voltage or Control Module
2-1-2 Circuit to vacuum pump or regulator: signal faulty

Important: cruise control diagnostics must be done immediately after the test drive. Do not turn the engine off! Codes will not be saved in memory if you do.
 
Socket 7 — SRS (airbag)
Code:
1-1-1 No error code set
1-1-2 Internal fault in the sensor unit
1-2-7 SRS warning lamp: open circuit or short-circuit
2-1-1 Steering wheel module: short-circuit in wiring
2-1-2 Steering wheel module: open circuit in wiring
2-1-3 Steering wheel module: short-circuit to the ground
2-1-4 Steering wheel module: short-circuit to +12V
2-2-1 Passenger module: short-circuit in wiring
2-2-2 Passenger module: open circuit in wiring
2-2-3 Passenger module: short-circuit to the ground
2-2-4 Passenger module: short-circuit to +12V
2-3-1 Left seat belt tensioner: short-circuit in wiring
2-3-2 Left seat belt tensioner: open circuit in wiring
2-3-3 Left seat belt tensioner: short-circuit to the ground
2-3-4 Left seat belt tensioner: short-circuit to +12V
2-4-1 Right seat belt tensioner: short-circuit in wiring
2-4-2 Right seat belt tensioner: open circuit in wiring
2-4-3 Right seat belt tensioner: short-circuit to the ground
2-4-4 Right seat belt tensioner: short-circuit to +12V
(no code) SRS warning lamp in the instrument panel does not light
(no code) Fault in diagnostic output



Thanks to: http://www.am.torun.pl/~ja/volvo/diagno ... stem.shtml

[volvo ov lov]

Thanks Jim.

Sorry if this info is widely known within 480 circles but i did have a scout around on the forum and couldn't see it.

This little lot should be the manwell. I'll have a go provided I can find diagnostic box.

Is there anything else that the Haynes manual lies about? Please tell me now to "manage my expectations."

[glasgowjim]

Go to the volvo 480 club europe home page and select downloads and you will find a diagram of the diagnostic box .

FYI its on the nearside front wing in the engine bay behind the battery as you stand at the front of the car it is a black plastic box about 6 x 4 x 6 cm .

PS dont worry we all had to start sometime.

[volvo ov lov]

Checked the fault codes today and socket 5 is the only one with any wiring to it.

Code result for socket 5 is 1-1-1 so no error code but the list i downloaded doesn't cover socket 5 so i don't know what is okay!

When I connect the battery, the side lights come on (front and rear) no matter what position the switch is in so there's obviously an issue there. I have to disconnect the battery when I'm not investigating the non starting.

I am wondering now if there should be other functions covered by the diagnostic socket.

[travelman]

Have you tried cleaning both ends of the earth from the engine to the coil. I had the problem of no spark-dead as a Dodo.I tried all the usual suggestions without success.So took off the earth and found there was some build up of corrosion around the fixings,even though it looked ok visually.I wire brushed it all,reconnected,and the engine fired up first turn.No problems since.
As your car has stood some time it may have a similar problem.It is probably worth checking other earths as well as these 480s are so electrically tempremental.

[volvo ov lov]

Yes I've cleaned up the earth leads from the distributor to the coil and also the one from the battery.

[heavend]

I had a 480 in the garage last week that wouldn't start after an extended period sitting.
The distributor cap was faulty - the central contact which is supposed to be spring loaded had seized in the up position.

I'm assuming you're using a timing light to confirm no spark?