78467242 Volvo.Penta Exhaust manifold

Illustration 1 g02032893
(1) Connection points to check
Illustration 2 g06348034
(2) Gate Valve #1
(3) Gate Valve #2Required Tooling
The table below contains required tooling to complete this procedure.
Table 1
Quantity Part Number Part Name
1 215-2592 Wastegate Kit
1 061-7921 7/16"-20 JIC to 1/4" NPTF Fitting
1 006-6586 1/4"-18 NPTF to hose barb Fitting Recommended Actions
Table 2
Troubleshooting Test Steps Values Results
1. Inspect the Air Lines from the Exhaust Balance Valve Solenoid to the Exhaust Balance Valve Actuator
A. Inspect the air lines from the outlet of the exhaust balance valve solenoid to the inlet of the exhaust balance valve actuator. Inspect the lines for any signs of leakage.
Damaged Air Line
Result: A line is not damaged.
Proceed to Test Step 2.
Result: A line is damaged.
Repair: Repair the line or replace the line. Return the unit to service.
2. Inspect the Linkage to the Exhaust Balance Valve
A. Inspect the linkage to the exhaust balance valve from the canister to the housing. Also, inspect the connection point from the linkage to the valve. Inspect the linkage for the following issues:
- Bending
- Breakage
Damaged or Broken Linkage
Result: The linkage is not damaged.
Proceed to Test Step 3.
Result: The linkage is damaged.
Repair: Replace the turbocharger. Return the unit to service.
3. Test the Exhaust Balance Valve Solenoid to Make Sure that the Valve Is Not Stuck in the Closed Position
A. Disconnect the hose from the mixer.
B. Connect the 215-2592 Wastegate Kit and necessary adapters between the hose and the mixer. The other end of the hose must stay connected to the inlet of the balance valve solenoid.
C. Turn the keyswitch to OFF.
Note: Only apply 138 kPa (20 psi) air pressure to the exhaust balance valve.
D. With gate valve #1 in the open position, regulate the supply air pressure to 138 kPa (20 psi). Make sure gate valve #2 is closed. Once the pressure is stable, close gate valve #1.
E. Loosen the fitting for the line from the exhaust balance valve solenoid to the exhaust balance valve.
Valve Stuck Closed
Result: Air leaked out of the line from the exhaust balance valve solenoid after the fitting was loosened.
The solenoid is not stuck closed. Proceed to Test Step 4.
Result: Air did not leak out of the line from the exhaust balance valve solenoid after the fitting was loosened.
Repair: The exhaust balance valve solenoid is not operating properly. Replace the exhaust balance valve solenoid. Return the unit to service.
4. Test the Exhaust Balance Valve Solenoid to Make Sure that the Valve Is Not Stuck in the Open Position
A. Relieve any residual pressure in the system by using gate valve #2 on the wastegate test kit. Once the pressure is relieved, close the valve.
Note: Only apply 138 kPa (20 psi) air pressure to the exhaust balance valve.
B. With gate valve #1 in the open position, regulate the supply air pressure to 138 kPa (20 psi). Make sure gate valve #2 is closed. Once the pressure is stable, close the gate valve.
C. Turn the keyswitch to ON.
D. In Cat ET, navigate to the"Engine Exhaust Manifold Bank #1 Flow Balance Valve Solenoid Override" "Override Parameters" menu under the diagnostic tab. Override the exhaust balance valve to ON.
E. Loosen the line to the balance valve from the exhaust balance valve solenoid.
Valve Stuck Open
Result: Air did not leak out of the line from the exhaust balance valve solenoid after the line was loosened. The solenoid is operating properly.
Proceed to Test Step 5.
Result: Air leaked out of the line from the exhaust balance valve solenoid after the line was loosened.
Repair: The exhaust balance valve solenoid is not operating properly. Replace the exhaust balance valve solenoid. Return the unit to service.
5. Pressure Test the System for Leaks
A. Relieve any residual pressure in the system by using gate valve #2 on the wastegate test kit. Once the pressure is relieved, close the valve.
Note: Only apply 138 kPa (20 psi) air pressure to the exhaust balance valve.
B. With gate valve #1 in the open position, regulate the supply air pressure to 138 kPa (20 psi). Make sure gate valve #2 is closed. Once the pressure is stable, close gate valve (5).
C. Turn the keyswitch On to activate the exhaust balance valve solenoid.
Note: Air should now flow between gate valve #1 and the exhaust balance valve.
System Leaks
Result: The pressure on the gauge maintains approximately 138 kPa (20 psi). There are no leaks in the system.
Proceed to Test Step 6.
Result: The pressure on the gauge does not maintain 138 kPa (20 psi).
Repair: There is a leak in the system. Check all lines and connections and repair the leak. Return the unit to service.
6. Check the Spring for the Exhaust Balance Valve
A. Remove all air pressure from the exhaust balance valve actuator.
B. Try to move the linkage rod for the exhaust balance valve by hand.
Broken Spring
Result: The linkage would not move by hand.
Proceed to Test Step 7.
Result: The linkage will move by hand.
Repair: Replace the exhaust balance valve actuator. Return the unit to service.
7. Inspect the Exhaust Balance Valve
A. Relieve all pressure from the exhaust balance valve system.
B. Remove the cover from the exhaust balance valve chamber.
C. Ensure that the exhaust balance valve is not broken.
Damaged or Broken Valve
Result: The exhaust balance valve is broken.
Repair: Replace the turbocharger. Return the unit to service.
If the procedure did not correct the issue, contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the Dealer Solutions Network (DSN).