463903 Volvo.Penta Expansion plug

Table 1
Diagnostic Trouble Codes for Excessive Soot Load    
CDL Code and Description    Information that Relates to the Code    
E995-2 High DPF #1 Soot Loading - Level 2     The estimated soot load is high. The ECM shuts down the engine when this code becomes active for the first time. The engine can be started and operated. Engine power is gradually derated as the soot load increases.    
E995-3 High DPF #1 Soot Loading - Level 3     The estimated soot load is high. Engine operation is limited to 30 second intervals when the electronic service tool is not communicating with the ECM.    
E991-3 DPF Active Regeneration Inhibited Due to Permanent System Lockout - Level 3     The estimated soot load is high. The engine may not operate properly. Factory passwords are required in order to clear this code.    
Follow the troubleshooting procedure in order to determine the root cause of the problem.    Troubleshooting Procedure
Perform this test step only when an E991-3 code is displayed. The E991-3 code indicates that the engine has continued to run after repeated warnings and engine shutdowns.
Replace the DPF. Refer to Disassembly and Assembly, "Diesel Particulate Filter - Remove" and Disassembly and Assembly, "Diesel Particulate Filter - Install" for the correct procedure.
Connect the electronic service tool to the diagnostic connector. Check for diagnostic codes that relate to the Clean Emissions Module (CEM). Refer to Table 2. Troubleshoot any codes that are present before continuing with this procedure.
Table 2
Associated Codes    
CDL Code    Failure Mode Identifier (FMI)    
E993     2    
E1239     1    
E593     2    
E1025     2    
E1026     2    
E992     3    Troubleshoot the systems in the order that is listed above if there are diagnostic codes for more than one of the systems. Use the electronic service tool to perform a service regeneration after the successful completion of the diagnostic procedures.
If there are no associated codes, proceed to Test Step 3.
Illustration 1 g02456116
View of the CEM (1) Soot antennas (2) Diesel Particulate Filter (DPF) (3) Nozzle heater relay (4) DPF inlet pressure sensor (5) Diesel Oxidation Catalyst (DOC) (6) ARD combustion head
Illustration 2 g02232033
Measuring the current through the ARD nozzle heater (7) ARD combustion head (8) Metal part of heater wire (9) Insulated part of heater wire
Use the following procedure to check the ARD nozzle heater:
Verify that the engine is off.
Connect a suitable clamp-ammeter around the insulated part of the heater wire (9). Make sure that the jaws of the ammeter are away from the metal part of the heater wire (8) .
Establish communication between the electronic service tool and the ECM. Refer to Troubleshooting, "Electronic Service Tools" for the proper procedure.
Start the engine. Use the electronic service tool to activate the "ARD Nozzle Heater Test".
Check that the ammeter reads at least 3.5 Amps.
Disable the "ARD Nozzle Heater Test". Stop the engine. Remove the clamp-ammeter.
Disconnect the electronic service tool.
If the current flow is acceptable, proceed to Test Step 4.
If the current flow is not acceptable, refer to Troubleshooting, "ARD Nozzle Heater - Test".
Use the following procedure to test the ARD air system:
Use the electronic service tool to perform the ARD Air System Service Test.
If the ARD Air System Service Test is not successful, troubleshoot the ARD air supply and then proceed to Test Step 5.If the ARD Air System Service Test is successful, proceed to Test Step 5 .
Perform this Test Step if all of the following conditions are true:
The "DPF Disable" switch was not disabling the ARD.
The ARD fuel nozzle is operating correctly.
The results of the "ARD Combustion Air - Test" are acceptable.Proceed to Test Step 6 if a fault has been discovered and the fault has been rectified.
Perform the "Cylinder Cutout Test" on the electronic service tool. If there is a fault with injection, make the necessary repairs and proceed to Test Step 6. If there is not a fault with injection, continue with this procedure.
Remove the inlet section from the DPF. Inspect the inside of the inlet section and the front face of the DPF. Look for oil and for excessive soot.The presence of a small amount of soot is a normal condition. If the amount of soot is considered to be excessive, contact the technical communicator at the Caterpillar dealer. Continue with this procedure after guidance has been received from the technical communicator.If oil is found, inspect the outlet of the turbocharger. If oil is found, contact the technical communicator at the Caterpillar dealer. Continue with this procedure after guidance has been received from the technical communicator. Clean the oil from the inside of the inlet section of the DPF and the front face of the DPF. Assemble the DPF. Run the engine at 1400 rpm for 15 minutes. Then, proceed to Test Step 6.Note: Do not use the cab switch for a stationary regeneration. The service tests prov