Volvo Penta 5.0 GXI-E Fault Code 41

[manuel0307]

Hi from Germany,

I have a problem with my engine especially with the ignition system.

The engine and the ECM brings the fault code 41 with the following discription:
+ (41) EST A Fault
+ (41) EST has open circuit

The engine starts normal but when reaching the operating temperature it is no really misfiring but it stops (may be in Cylinder #1)

Because of the behavior I changed:
1.) crankshaft sensor
2.) camshaft sensor
3.) rotor
4.) ignition coil + ignition module
4.) distributor cap
5.) ignition cable (8+1)

How can I evaluate the open est circuit?

AND

Waht does the error on cylinder #1 means?

 

[alldodge]

Howdy

When the system is running in ignition module (Crank) mode, there is no voltage on the bypass line, and the IC module grounds the IC signal. The ECM expects to see the IC line grounded during this mode. If not, it sets DTC 41 and will not go into IC mode.

Check continuity between J1-10 and Pin-G on ignition module its a Green/White wire

 

[manuel0307]

Hi,

I will check it tomorrow morging. Unfortunately the sun has already set.

 

[manuel0307]

Hi,

sorry I need to ask again.

Should I check continuity between J1-10 and ICM G-Pin?

It seems that pin 10 is not occupied. I have not compared the picture to my connector in the boat.

 

[alldodge]

Guess your correct, I'm finding a DTC 41 for EST distributors but not for HVS distributors. There should be no DTC 41 even show up from what I'm finding

+ (41) EST A Fault
+ (41) EST has open circuit

Maybe muc can help

Have a motor serial number?

 

[manuel0307]

Hi,

first of all I have to say thank you for the answers. The SerialNumber of the engine is: 4012127750 (3869255). Back from boat I realized that I provided you the wrong picture from MEFI-4 adapter. The correct one should be J2. This adapter has two connections to the ICM:
1.) pink-white (Ignition Feed) (Pin 19)
2.) purple-white (Ignition Control / Ignition Control A) (Pin 31)
Both connections have continuity to the ICM plug. Is that correct?

I have read that the ICM switch the Signal from Bypass to EST when the engine is cranking (>400 RPM). The switch lives inside the ICM. Is it possible that this switch stands permantly in EST mode?

Does the error code 41 with "EST A Fault" mean that the ICM provides worng values to the ECM?

The strange behavior is, that the engine starts very well and runs great until it is reaching the operational temperatur. After that the engine has misfires in the lower RPM area.

 

[manuel0307]

Hi,

I have made a little scheme of the wiring and plugs on the ignition coil with the ICM. I hope it will help. I think the engine is a GM Model from 2000 to 2002.

 

[alldodge]

Morning, I don't have a wiring diagram for your motor. Have the GXI-F which uses the HVS distributor and there is no mention of DTC 41. Also have the GXI-E which list DTC 41 but uses the EST distributor

EST

HVS

 

[manuel0307]

Hi,

thanks for reply. I think the error does not depend on the distributor. The main difference between the 2 systems is that the ICM is integrated in the coil (HVS) or distributor (EST). The EST and BYPASS signal is controlled by the switch in the ICM. On the MEFI-4 J2 connector the 5v Reference signal is provided by pin 2. The error says that the IC-Control-connection (J2-31) needs to be grounded during crank (but it seems to be not). But how should I evaluate the error? How can I check that the ic-signal is not grounded? Is there a general ground problem or only for that connection?

 

[alldodge]

Your second pic is a good one, I didn't have it. Thanks for posting

 

[muc]

7742218 is the part number for the diagnostic manual for your engine. Also should have a copy of service bulletin 04-2-40 that that covers the corrections. The manual has very detailed instructions on how to troubleshoot your code. Just don’t make the mistake of going straight to the DTC 41. Start with Electronic Ignition System - General on page 372 and work through that first.

The DTC 41 is a valid code for your engine. Don’t get confused by the EST in the code description, it is probably due to the scan tool you’re using. Don’t worry about the A in the description, it is referring to what driver in the ECM is seeing a problem. Because you have a HVS style ignition, the only driver used is the A driver.

The ECM has total control of this ignition system, there is no bypass circuit or crank mode. That was just used with the EST system.

Follow the troubleshooting instructions in the manual manual and we will all hope it’s not the ECM. But I’m guessing based on what parts you have replaced and the symptoms,it will be. Let’s hope I’m wrong.

P.S. on this engine, never replace the cam sensor. If you think it might be a problem. Just disconnect it, only change will be the engine might have to crank for a couple of seconds longer before it starts.

 

[manuel0307]

Hi,

thanks for answering. Where can I find the manual (7742218)? I do not know the difference the models A, B, C, D and E but the manual with the given part number is for the models (A, B, C and D) but model E is not mentioned on the cover. Are you sure with the part number?

 

[muc]

https://www.volvopenta.com/marinelei...handbooks.html

Yes I'm sure. The link above might not work in the EU. But I would think that if you Google "Volvo Penta Owners Manual" from your IP, you will get a similar website to look up and buy the manual.

There aren't any real troubleshooting differences between the D and your E model. The E model was the last year that used the MEFI 4 ECM so Volvo didn't make a new manual for it. But the 5.0GXi-E is covered in this manual. If you buy the manual from a Volvo dealer I'm guessing they would be happy to print a copy of the service bulletin that has the corrections for that manual. As near as I can tell those corrections never made it into the print copy. But it has been years since I ordered one.

 

[manuel0307]

Hi,

thnaks for all the answers. I ordered the manual.

It reason of the fault code was the ignition coil with the ignition modul. It was new but it was not an original from Volvo Penta. I bought it from Recmar.

What is left? - The engine suddenly goes off! - In the lower rpm range the motor goes off without any warnings and fault codes in the ecm. It seems to be a bad cabel or plug. Hopefully I will find it soon.

 

[muc]

What is left? - The engine suddenly goes off! - In the lower rpm range the motor goes off without any warnings and fault codes in the ecm.

I missed this in your first post. I also didn’t know that you had used non Volvo Penta parts.
Is this a new symptom or is it what started the parts replacing?
If you would like help troubleshooting this we will need more information.
What does the engine do right before it shuts down? How fast does the shutdown happen? What are the gauges doing while this is happening? Do you get a warning horn? Does your warning horn work? Did you get the code before you replaced the coil?

The more information you can provide, the better we will be able to offer advice.

Unfortunately the manual will not provide a lot of direction for this symptom. That comes from experience and attending the Volvo classroom training.

 

[noot74]

Following this post as I’m having the same exact issue with my gxi-e

 

[noot74]

Just wanted to drop in and say my problem was solved. I also replaced so many components and was having this same issue. Replaced the grounding studs and connectors on the back of the block which were in bad shape. This did not solve it.
My J connector had some corrosion in it and for the female side we used a dremel and a small wire brush attachment to ream out each female portion after cleaning the male portions. Some marine dielectric grease and now the problem is solved.
4 marine shops that couldn’t solve the problem. $1000’s in parts. One additional mechanic who came to my house and that’s what solved it for me.

 

[Centella]

Hi Manuel

I am actually facing the same issue and engine behavior (EST A fault). it starts very well when cold and runs great until it is reaching the operational temperature, same as you.

Did you find out the reason behind ?

Please advise me, I must use full throttle to be able to start the engine when it is warm as there is no other way.

Thanks in advance,
David

Hi,

thnaks for all the answers. I ordered the manual.

It reason of the fault code was the ignition coil with the ignition modul. It was new but it was not an original from Volvo Penta. I bought it from Recmar.

What is left? - The engine suddenly goes off! - In the lower rpm range the motor goes off without any warnings and fault codes in the ecm. It seems to be a bad cabel or plug. Hopefully I will find it soon.

Hi,

first of all I have to say thank you for the answers. The SerialNumber of the engine is: 4012127750 (3869255). Back from boat I realized that I provided you the wrong picture from MEFI-4 adapter. The correct one should be J2. This adapter has two connections to the ICM:
1.) pink-white (Ignition Feed) (Pin 19)
2.) purple-white (Ignition Control / Ignition Control A) (Pin 31)
Both connections have continuity to the ICM plug. Is that correct?

I have read that the ICM switch the Signal from Bypass to EST when the engine is cranking (>400 RPM). The switch lives inside the ICM. Is it possible that this switch stands permantly in EST mode?

Does the error code 41 with "EST A Fault" mean that the ICM provides worng values to the ECM?

The strange behavior is, that the engine starts very well and runs great until it is reaching the operational temperatur. After that the engine has misfires in the lower RPM area.

 

[muc]

Hi Manuel

I am actually facing the same issue and engine behavior (EST A fault). it starts very well when cold and runs great until it is reaching the operational temperature, same as you.

Did you find out the reason behind ?

Please advise me, I must use full throttle to be able to start the engine when it is warm as there is no other way.

Thanks in advance,
David

Hi David,
It's best to start your own post. Tell us what engine you have (serial number is best) and what you have tested and what the engine is doing.

 

[jbcurt00]

Hi David,
It's best to start your own post. Tell us what engine you have (serial number is best) and what you have tested and what the engine is doing.

What Muc said..
@Centella

Closed