22092535 Charge air cooler Volvo.Penta
D6-280A-A; D6-280A-B; D6-280A-C, D6-300A-F; D6-300D-F; D6-300I-F
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Number on catalog scheme: 1
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Volvo Penta entire parts catalog list:
- Charge Air Cooler SN-A501445 » 22092535
Information:
Recommended Actions
Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.
Note: The procedures have been listed in order of probability. Complete the procedures in order.Note: If the problem only occurs under certain conditions, test the engine under those conditions. Examples of certain conditions are high engine speed, full load, and engine operating temperature. Troubleshooting the symptoms under other conditions can give misleading results.
Table 1
Troubleshooting Test Steps Values Results
1. Diagnostic Codes
Note: Certain diagnostic codes may cause poor performance.
A. Use the electronic service tool to check for active or logged diagnostic codes.
Engine Derate or Diagnostic Codes
Result: A diagnostic code is present.
Repair: Troubleshoot the diagnostic code. Refer to Troubleshooting, "Diagnostic Trouble Codes".
Result: A diagnostic code is not present.
Proceed to Test Step 2.
2. Parameters in the Electronic Control Module (ECM)
A. Use the electronic service tool to verify that the correct parameters are being used. Refer to Troubleshooting, "Configuration Parameters" for additional information.
Parameters
Result: The parameters are not correct.
Repair: Input the correct parameters. Refer to Troubleshooting, "Configuration Parameters" for additional information.
Result: The parameters are correct.
Proceed to Test Step 3.
3. Throttle Position Sensor/Throttle Switches
A. Turn the start switch to the ON position.
B. Run the engine until the speed is equal to the maximum no-load speed.
C. Use the electronic service tool to make sure that the throttle is set to reach the maximum no-load speed.
Electrical connections
Result: The throttle response is not as expected.
Repair: If the maximum no-load speed cannot be obtained refer to Troubleshooting, "Switch Circuits - Test (Throttle Switch)" and Troubleshooting, "Mode Selection - Test".
If the engine speed is erratic refer to Troubleshooting, "Speed Control - Test".
Result: All responses are normal.
Proceed to Test Step 4.
4. Air Intake and Exhaust System
A. Observe the engine warning lamp. Check for an air filter restriction indicator, if equipped. Replace plugged air filters. Refer to the Operation and Maintenance Manual.
B. Check the air inlet and exhaust system for restrictions and/or leaks. Refer to Systems Operation/Testing and Adjusting, "Air Inlet and Exhaust System - Inspect".
Restrictions
Result: There are restrictions in the air inlet or exhaust system.
Repair: Make the necessary repairs, Refer to Systems Operation/Testing and Adjusting, "Air Inlet and Exhaust System - Inspect" for additional information.
Result: The exhaust system is restricted with white deposits.
Repair: Refer to Troubleshooting, "Exhaust System Contains DEF Deposits"
Result: There are no restrictions in the air inlet or exhaust system.
Proceed to Test Step 5.
5. Valve Lash
Note: The valve lash can affect the performance of the engine.
A. Check the valve lash. Refer to Systems Operation, Testing and Adjusting, "Engine Valve Lash - Inspect".
Valve lash
Result: The valve lash is not correct.
Repair: Make any necessary repairs. Refer to Systems Operation, Testing and Adjusting, "Engine Valve Lash - Inspect".
Result: The valve lash is correct.
Proceed to Test Step 6.
7. Turbocharger
Note: The turbocharger that is installed on the engine is a nonserviceable item. If any mechanical fault exists, then the faulty turbocharger must be replaced.
A. Ensure that the mounting bolts for the turbocharger are tight.
B. Check that the oil drain for the turbocharger is not blocked or restricted.
C. Check that the compressor housing for the turbocharger is free of dirt and debris. Make sure that the housing is not damaged.
D. Check that the turbine housing for the turbocharger is free of dirt and debris. Make sure that the housing is not damaged.
E. Check that the turbine blades rotate freely in the turbocharger.
F. Ensure that the wastegate on the turbocharger is adjusted correctly. Refer to Systems Operation, Testing, and Adjusting, "Turbocharger - Inspect". If the wastegate actuator is faulty, replace the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove" and Disassembly and Assembly, "Turbocharger - Install".
Turbocharger
Result: There is a fault on the turbocharger.
Repair: Repair the turbocharger or replace the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove" and Disassembly and Assembly, "Turbocharger - Install".
Result: The turbocharger is OK.
Proceed to Test Step 8.
8. Fuel Supply
A. Visually check the fuel level in the fuel tank. Do not rely on the fuel gauge only.
B. Ensure that the vent in the fuel cap is not filled with debris.
C. Ensure that the fuel supply valve (if equipped) is in the full OPEN position.
D. If the temperature is below 0 °C (32 °F), check for solidified fuel (wax).
E. Check the primary filter/water separator for water in the fuel.
F. Check for fuel supply lines that are restricted.
G. Check that the low-pressure fuel lines are tight and secured properly.
H. Replace the primary and secondary fuel filters.
I. Check the diesel fuel for contamination. Refer to Systems Operation, Testing, and Adjusting, "Fuel Quality - Test".
J. Check for air in the fuel system. Refer to Systems Operation, Testing, and Adjusting, "Air in Fuel - Test".
K. Ensure that the fuel system has been primed. Refer to Systems Operation, Testing, and Adjusting, "Fuel System - Prime".
Fuel system
Result: The fuel supply is not OK.
Repair: Repair the fuel system or replace the fuel system components, as necessary.
Result: The fuel supply is OK.
Proceed to Test Step 9.
9. Low Compression (Cylinder Pressure)
A. Perform a compression test. Refer to Systems Operation, Testing, and Adjusting, "Compression - Test ".
Cylinder compression
Result: The results of the compression test are outside the specifications.
Repair: Investigate the cause and rectify any faults.
Note: Possible causes of low compression are shown in the following list:
Loose glow plugs
Faulty piston
Faulty piston rings
Worn cylinder bores
Worn valves
Faulty cylinder head gasket
Damaged cylinder head
Result: The results of the compression test are OK.
Proceed to Test Step 10.
10. Electronic Unit Injectors
A. Use the electronic service tool to check for active diagnostic codes that relate to the electronic unit injectors.
Diagnostic codes
Result: There are active diagnostic codes relating to the fuel injectors.
Repair: Troubleshoot the active diagnostic codes.
Refer to Troubleshooting, "Diagnostic Trouble Codes".
Result: All injectors are OK.
Proceed to Test Step 11.
11. Individual Malfunctioning Cylinders
A. With the engine speed at a fast idle, use the electronic service tool to perform the manual "Cylinder Cut Out Test".
As each cylinder is cut out, listen for a change in the sound from the engine. When a cylinder is cut out, there should be a noticeable change in the sound of
Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.
Note: The procedures have been listed in order of probability. Complete the procedures in order.Note: If the problem only occurs under certain conditions, test the engine under those conditions. Examples of certain conditions are high engine speed, full load, and engine operating temperature. Troubleshooting the symptoms under other conditions can give misleading results.
Table 1
Troubleshooting Test Steps Values Results
1. Diagnostic Codes
Note: Certain diagnostic codes may cause poor performance.
A. Use the electronic service tool to check for active or logged diagnostic codes.
Engine Derate or Diagnostic Codes
Result: A diagnostic code is present.
Repair: Troubleshoot the diagnostic code. Refer to Troubleshooting, "Diagnostic Trouble Codes".
Result: A diagnostic code is not present.
Proceed to Test Step 2.
2. Parameters in the Electronic Control Module (ECM)
A. Use the electronic service tool to verify that the correct parameters are being used. Refer to Troubleshooting, "Configuration Parameters" for additional information.
Parameters
Result: The parameters are not correct.
Repair: Input the correct parameters. Refer to Troubleshooting, "Configuration Parameters" for additional information.
Result: The parameters are correct.
Proceed to Test Step 3.
3. Throttle Position Sensor/Throttle Switches
A. Turn the start switch to the ON position.
B. Run the engine until the speed is equal to the maximum no-load speed.
C. Use the electronic service tool to make sure that the throttle is set to reach the maximum no-load speed.
Electrical connections
Result: The throttle response is not as expected.
Repair: If the maximum no-load speed cannot be obtained refer to Troubleshooting, "Switch Circuits - Test (Throttle Switch)" and Troubleshooting, "Mode Selection - Test".
If the engine speed is erratic refer to Troubleshooting, "Speed Control - Test".
Result: All responses are normal.
Proceed to Test Step 4.
4. Air Intake and Exhaust System
A. Observe the engine warning lamp. Check for an air filter restriction indicator, if equipped. Replace plugged air filters. Refer to the Operation and Maintenance Manual.
B. Check the air inlet and exhaust system for restrictions and/or leaks. Refer to Systems Operation/Testing and Adjusting, "Air Inlet and Exhaust System - Inspect".
Restrictions
Result: There are restrictions in the air inlet or exhaust system.
Repair: Make the necessary repairs, Refer to Systems Operation/Testing and Adjusting, "Air Inlet and Exhaust System - Inspect" for additional information.
Result: The exhaust system is restricted with white deposits.
Repair: Refer to Troubleshooting, "Exhaust System Contains DEF Deposits"
Result: There are no restrictions in the air inlet or exhaust system.
Proceed to Test Step 5.
5. Valve Lash
Note: The valve lash can affect the performance of the engine.
A. Check the valve lash. Refer to Systems Operation, Testing and Adjusting, "Engine Valve Lash - Inspect".
Valve lash
Result: The valve lash is not correct.
Repair: Make any necessary repairs. Refer to Systems Operation, Testing and Adjusting, "Engine Valve Lash - Inspect".
Result: The valve lash is correct.
Proceed to Test Step 6.
7. Turbocharger
Note: The turbocharger that is installed on the engine is a nonserviceable item. If any mechanical fault exists, then the faulty turbocharger must be replaced.
A. Ensure that the mounting bolts for the turbocharger are tight.
B. Check that the oil drain for the turbocharger is not blocked or restricted.
C. Check that the compressor housing for the turbocharger is free of dirt and debris. Make sure that the housing is not damaged.
D. Check that the turbine housing for the turbocharger is free of dirt and debris. Make sure that the housing is not damaged.
E. Check that the turbine blades rotate freely in the turbocharger.
F. Ensure that the wastegate on the turbocharger is adjusted correctly. Refer to Systems Operation, Testing, and Adjusting, "Turbocharger - Inspect". If the wastegate actuator is faulty, replace the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove" and Disassembly and Assembly, "Turbocharger - Install".
Turbocharger
Result: There is a fault on the turbocharger.
Repair: Repair the turbocharger or replace the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove" and Disassembly and Assembly, "Turbocharger - Install".
Result: The turbocharger is OK.
Proceed to Test Step 8.
8. Fuel Supply
A. Visually check the fuel level in the fuel tank. Do not rely on the fuel gauge only.
B. Ensure that the vent in the fuel cap is not filled with debris.
C. Ensure that the fuel supply valve (if equipped) is in the full OPEN position.
D. If the temperature is below 0 °C (32 °F), check for solidified fuel (wax).
E. Check the primary filter/water separator for water in the fuel.
F. Check for fuel supply lines that are restricted.
G. Check that the low-pressure fuel lines are tight and secured properly.
H. Replace the primary and secondary fuel filters.
I. Check the diesel fuel for contamination. Refer to Systems Operation, Testing, and Adjusting, "Fuel Quality - Test".
J. Check for air in the fuel system. Refer to Systems Operation, Testing, and Adjusting, "Air in Fuel - Test".
K. Ensure that the fuel system has been primed. Refer to Systems Operation, Testing, and Adjusting, "Fuel System - Prime".
Fuel system
Result: The fuel supply is not OK.
Repair: Repair the fuel system or replace the fuel system components, as necessary.
Result: The fuel supply is OK.
Proceed to Test Step 9.
9. Low Compression (Cylinder Pressure)
A. Perform a compression test. Refer to Systems Operation, Testing, and Adjusting, "Compression - Test ".
Cylinder compression
Result: The results of the compression test are outside the specifications.
Repair: Investigate the cause and rectify any faults.
Note: Possible causes of low compression are shown in the following list:
Loose glow plugs
Faulty piston
Faulty piston rings
Worn cylinder bores
Worn valves
Faulty cylinder head gasket
Damaged cylinder head
Result: The results of the compression test are OK.
Proceed to Test Step 10.
10. Electronic Unit Injectors
A. Use the electronic service tool to check for active diagnostic codes that relate to the electronic unit injectors.
Diagnostic codes
Result: There are active diagnostic codes relating to the fuel injectors.
Repair: Troubleshoot the active diagnostic codes.
Refer to Troubleshooting, "Diagnostic Trouble Codes".
Result: All injectors are OK.
Proceed to Test Step 11.
11. Individual Malfunctioning Cylinders
A. With the engine speed at a fast idle, use the electronic service tool to perform the manual "Cylinder Cut Out Test".
As each cylinder is cut out, listen for a change in the sound from the engine. When a cylinder is cut out, there should be a noticeable change in the sound of
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