INJECTORS wont open please HELP

[|RS|]

Hello people, for starting i am really sorry for my english as i am portuguese, i will try to express my self as fine as possible. I am rRenato, i am 22 years old, i have my volvo about an year now, i bought it with the engine dead, but the previous owner said it workrd just fine. So i have a 440 turbo with only 59k km on the clock, the engine its as new ! I run perfectly, as i love the 480, and its in really good shape, i swaped the engine, and let the ecu and all the electrics, what happens now, its that the car wont start. I have this problem about an year now, i dont know what to do anymore, i run th whole experienced mechanics, and the dont have explanation to this, So what happens is that the ECU dont make the injectores opening, but if the mechanic do it manually, it works perfectly, i have more ECUs, but i am afraid some of them are damaged (i dont know, and these cars here are really rare here), i dont know. The 480 come with a purple on the centre, in front of the gear knob, and an orange on the passenger side. The previous owner said it works fine ? Is it the normal combination ? I tried two orange ones but it dont start anyway. If i manually give power to that fuse box(that square litl box, that its like a fuse, i dont know what you call there), that the pin number 13 of the ecu controls, and make the ground manually, and make the ijector works it starts perfectly ! Please people help me, i want my 480 turbo with live again

You guys are my 480 turbo last chance of survival or i will send it to the scrapyard,, i dont want because he is really good shape but i dont have anymore to do in it....

[glasgowjim]

Where in Portugal are you as we have a member Joao in Lisbon .

We do not need your address but are you close to Lisbon ?


Onde em Portugal está você porque nós temos um membro Joao em Lisboa.
Nós não precisamos seu endereço mas é você perto de Lisboa?

apologies for the poor translation

[grafi]

Ok, first:
Let me guess, the 440 has blue and green ecus. if yes, put both to the 480 and try.
If not, then I am going to the details. It will be very very long..

[|RS|]

Hello, thanks for the answers, unfortunately, i am from an island in portugl, so its impossible to get in touch with that member The 440 The centre ECU was orange, and the passenger side i didnt know in that time it has two ecus, so it went to junkyard with the ecu on it . Experience

My 480 has a purple in the midle and ornge in passenger side, is it normal ? I don know what to do anymore

[glasgowjim]

the second ecu is it a metal casing or black plastic ?

have been looking through old posts read this one http://volvo-480-europe.org/forum/viewt ... uk#p185148

and if you need more help pm bkf_uk as he should be able to help you.

[grafi]

There are 2 "boxes", the black plastic in the centre, and the metal on the passenger side.
The black controls ignition, boost, idle.
The metal controls, fuel and injection.

Depends on modellyear, there were various pairs:

plastik - metal:

purple - brown(or purple)
orange - orange
maroon - maroon
blue - green

Around 1991, there was a change in flywheel. (The cars with purple and orange are works with the old flywheel (pre '91), maroon works both, and blue works only with the new (after '92). The crank sensor was changed as well, read this: http://volvo-480-europe.org/forum/viewt ... 12&t=18009
Engines with old flywheel has black air intake, new ones has silver. (there some exeptions, but very few, from the modellyear of 1991)

When you try to run the car with the bad combination of ECUs, it cuts the fuel when you try to start.

There are some combinations wich can be working, for instance, my car has an engine from 1992, BUT with the 200mm clutch, the wire loom is from 1994
the black ECU is maroon, and the metal box is green.

So, first we should know, the engine from the 440 is from what modellyear, and also your 480 is what modellyear.

[|RS|]

Hello, my 480 its from 1988, and the 440 was from 1989. The 480 in the middle has a plastic purple, and in the side it has a orange metal one. The 440 in the middle was plastic orange, and in the side i dont know

I tried another ECus, TWO orange ones, and it dont start, but the plastic one could be damaged i dont know, i have to try nother ECU´s But in the island my 480 turbo its the lastest ones runing.... I only see one more in the road...

[grafi]

Hello, my 480 its from 1988, and the 440 was from 1989. The 480 in the middle has a plastic purple, and in the side it has a orange metal one. The 440 in the middle was plastic orange, and in the side i dont know

I tried another ECus, TWO orange ones, and it dont start, but the plastic one could be damaged i dont know, i have to try nother ECU´s But in the island my 480 turbo its the latest ones running.... I only see one more in the road...

Okay, so this means that your problem is not what I tought in the first place. It would have been too easy, as usual. (With two orange ECUs, it should work, if that would be the problem. What do you mean the plastic one could be damaged? )

So, if I understand right: You changed the engine - I guess together with the gearbox - plugged every wire and thats all. Were there any problems with the cables? Different connectors, or something? Did you change the flywheel sensor as well? Was it 2pin or 3? did you check the injector cables? the injectors? would be nice if you write down the progress a bit more detailed, and a few pictures about the engine, the ECUs would be nice. Just because I am a visual man.

And by the way, I have a lot of spare ECUs with different colors, all tested. I am sure Jim has as well.

[grafi]

One more idea:

Obviously the easiest way to rule out ECU problem, is to test your ECUs in another car. If you cant find anyone closer, you can send both ECU to me by post and I can try them with my friends '89 Turbo. Just a tought.

[Van]

[OT]Do you live on Madeira or Açores?

[|RS|]

Hello people, in first place, i wanna thank you all for the help, in the portuguese forum, i didnt have too much hel, unfortunately. I swap the, and let the gearbox of the 480 turbo, an m59 i think, anf the 440 was m57, i am not sure, it has been an year now. I tried too much things, i dont remember.

One thing i am sure i did not do right was swap the engine harness, i let the 480 engine harness, and it could be damaged, but the previous owner guarantee me that it works. I tried the 440 flyweel cable too. One thing i remember was different, was that litle harness that passes up the gearbox, the 440 was small head on the wires and the 480 a big one, those that goes to the fan. But i think its all correct, the electrician man saw the all car and said me that its the ecu´s or harness, OBVIOUSLY i now that lol. The injectores dont have voltage on the plug, but if i give some voltage to that reley that stays before the pin 13 of the metal ECU, it gives voltage to the injectores, but they dont make te pulses, the correct opening, if i make it manually it works perfectly.

I am from Madeira island

[|RS|]

Oh one more thing the electrician said to mee, was the FLYWEEL cabele was not giving information t the ECU, i dont know why

[|RS|]

Any more help ? :/

[glasgowjim]

[quote="|RS|"]Hello people, in first place, i wanna thank you all for the help, in the portuguese forum, i didnt have too much hel, unfortunately. I swap the, and let the gearbox of the 480 turbo, an m59 i think, anf the 440 was m57, i am not sure, it has


what do you mean by let ?

the best that I can do is photograph my sons 480 turbo so you can compare would that help ?

[Van]

I think he kept the original gear box.

[|RS|]

Yes, i kept my original Gearbox Any more ideas ? If you can take some pictures at the harness that passes closer to the gbox i will apreciate it !

[grafi]

well, if your electrician said that the flywheel cable doesnt give any sign to the ECU, than obviously the cable or the sensor has some problem.
The sensor itself is a quite simple thing, a magnet basically, with one function.
Question: you said, you kept the gearbox of the 480. did you replaced the clutch?

[|RS|]

Hello, my engine was 100% perfect, i just swaped to the 480, the flywheel cable its OK, i have two, i tried the two, and nothing. I did not replace the clutch but it was identical.

[glasgowjim]

Both the 480 and the 440 wont have a CAT and you have swopped over the ECUs with the engine then it must be a wiring problem. So check all earths and that the connectors are where they are supposed to be. The 480 loom had extra connectors for various things.

[|RS|]

I have some good NEWS ! I tried my ecus in a friend 440 turbo and they are perfect, and th car worked after. So it must be a bad conection....any ideas why the car wont give signal to the injectors ?