Electrical Problem following manual tranny swap.

[BEJinFbk]

The big black cable from the battery needs to be attached to the block!
The starter pulls FAR more juice than any other device in the car.
That's what the big red and black cables from the battery are there for.
Connecting the big battery ground cable to a body part will MESS YOU UP!

Just to test, find a bolt as near the starter as possible and connect the ground cable there.
Put a meter on the Red and Black cables at the starter/block end with some long leads and
observe the voltage while cranking (or trying to). You MAY also have a toasted battery.
But DEFINETELY GROUND AT THE BLOCK! NOT THE FENDER!!!

[phils94850]

japedo... your fuel system relay ( i assume you mean fuel pump relay ) isnt on top of the fan shroud. Thats your cooling fan relay. Your fuel pump relay is under the fuses..

[Japedo]

BEJinFBK - If you read two posts above yours, I said that I made progress and that the car is cranking now. I didn't attach the ground for the battery to the body? I replaced the grounds at the back of the engine up top.

phils- There is actually another relay next to the coolant fan one, which has to do with the injectors somehow as well as the IAC.
your right though the fuel relay is up by the fuse panel.

Had to take a break from messing with the car today, no progress there.

[Ozark Lee]

japedo... your fuel system relay ( i assume you mean fuel pump relay ) isnt on top of the fan shroud. Thats your cooling fan relay. Your fuel pump relay is under the fuses..

The master fuel system relay is indeed on the fan shroud - just on the other side from the fan relay. That relay provides power to the injectors and the IAC valve.

...Lee

[BEJinFbk]

BEJinFBK - If you read two posts above yours, I said that I made progress and that the car is cranking now. I didn't attach the ground for the battery to the body? I replaced the grounds at the back of the engine up top.

phils- There is actually another relay next to the coolant fan one, which has to do with the injectors somehow as well as the IAC.
your right though the fuel relay is up by the fuse panel.

Had to take a break from messing with the car today, no progress there.

My Bad - I guess I just panicked when I read that the braided strap was still getting hot.
That's just a red flag to me that something somewhere is drawing way too much current.
( And I hate to see a Volvo Smoke! ) Keep posting, we'll keep trying to help.

[Japedo]

Ya, I hate to see a volvo smoke too. Although it is 16yrs old now, another 3 years and it will be legally old enough to smoke!

My plan to further diagnose this problem is to check voltage to the pins at the ECU. I should be able to confirm which component is not communicating with the ECU that way. BUt I am in the middle of a 24hr shift right now Have to save that testing for the morning.

I think I have a short somewhere in the fuel system. As I am not able to read codes from A2 socket. In the past 5 years I have never had trouble reading codes from the A2 socket, untill now. To bad because It would make this diagnosis a heck of a lot easier.

When I do attempt to read the A2 codes, and place the wire in the A2 socket, the Light illuminates dimmly and stays light dimmly. Pressing the button will make the LED light brighter, but upon releasing the button it goes back to being lite dimmly, and doesn't flash any codes. Anyone know what this might mean or indicate?

The tranny shifts so smooth and the clutch pedal feels great, if I can't figure this thing out by tuesday it's getting put on a trailer and heading to the dealer. With their testing equipment the could probably detect my electrical problem quickly.

Thanks to all for their advice and support.

Curtis

[ttermyna]

did you check the speed/timing sensor on top of the tranny? i had a similiar issue due to that.

[BEJinFbk]

If you do elect to go dealer, be sure they have some old timers that speak 850.
You may do better with a good Volvo indy wrencher.

[Japedo]

ttermyna-
I did check the rpm sensor, the one that goes into the bell housing. It tested fine on a resistance test. But when I checked the pin voltage for this at the ECU terminal, I got a reading of 0.0 Volts. But this is due to my main fuel system relay not getting the right signal. The main fuel relay supply's power to a ton of sensors under the hood.
The signal wire "brown/orange" is supposed to supply 0.2 volts of signal to the fuel system relay, and it is reading battery voltage when I test it. So I think I know my problem, just haven't been able to fix it.

BEJinFbK-
That is some good advice, there are a couple old timers at my local dealer. And a couple of younger guys with modde'd 850's. So with anyluck they can figure it out for me.
I borrowed by brother in laws 08 F150 today, and he works at united rentals so he hooked me up with a car hauler too.. So I loaded up the old girl and hauled her to the dealer "second time in almost 6 years"
THey didn't tell me I was an idiot for swapping the 5 speed in anyway, lol they just asked me how the work in progress was going.... Im hopeing it's a silly thing that I messed up and some how didn't notice. Hopefully reasonably cheap! I am glad to see it out of the yard after all the hours I spent working on it this year.... I just can't give up on it! lol

Thanks folks, you guys will be the first to know what's up!

Curtis

[Japedo]

Well, the dealer was supposed to look at my car either last thursday or friday. According to the guy in the service department when I dropped it off. But I didn't get a phone call and didn't bother calling them to inquire.
Im just assuming they didn't get to it and am hopeing they will get to it first thing monday morning "tomorrow"

Normally I wouldn't be as impatient to get a car back, but after just swapping the M56 tranny in I am looking forward to trying it out.