3801277 Volvo.Penta Injection pump

Recommended Actions
Diagnostic Codes and Event Codes
Certain diagnostic codes and/or event codes may prevent the engine from starting. Connect the Caterpillar Electronic Technician (ET) and check for active codes and/or logged codes. Troubleshoot any codes that are present before continuing with this procedure.Fuel Level
Visually check the fuel level. Do not rely on the fuel gauge only. If necessary, add fuel.Oil Level
Check the engine oil level. If necessary, add oil.Note: Engine oil supplies the injection actuation pressure circuit. Proper engine oil level is necessary for fuel injection.Remote Shutdown Switch
Make sure that the remote shutdown switch is run position. Use Cat ET to verify the status of the shutdown switch. If a problem with the remote shutdown switch is suspected, check the electrical circuit for the switch.Electrical Connectors
Check for correct installation of the following connectors:
J1/P1 ECM connector
J2/P2 ECM connector
J20/P20 Engine speed/timing sensor connector
J44/P44 Engine speed/timing sensor connector
Unit injector connectorsRefer to Troubleshooting, "Electrical Connectors - Inspect".Circuit Breakers
Check the circuit breakers. if a circuit breaker is tripped, reset the circuit breaker.Flash File
Verify that the correct flash file is installed in the ECM.Note: If a new ECM has been installed, the ECM will need to be programmed before the engine will run. Also, the ECM will not communicate with Cat ET if the ECM has not been programmed.Engine Speed/Timing
Crank the engine and observe the engine speed on the status screen in Cat ET. If Cat ET indicates 0 rpm, troubleshoot the circuit for the engine speed/timing sensor.
Ensure that the timing reference gear is installed correctly. The engine will not start if the gear was installed backward. Check for proper orientation between the crankshaft and camshaft drive gears. Correct the orientation and/or replace the drive gear, if necessary. Refer to the engine's Disassembly and Assembly manual.Injection Actuation Pressure
The following criteria must be meet for injection to be enabled. If this criteria is not met, then there should be error for "Injection Disabled".
Engine speed in the range of 100 to 250 rpm
The ECM determining correct timing between the primary speed sensors and the HEUI fuel pump drive train
Minimum injection actuation pressure of 6205 kPa (900 psi)
Desired and Actual Injection Actuation Pressure (IAP) within 1379 kPa (200 psi)
Check the engine oil level. if necessary, add oil. Verify that the pressure for the lube oil system is accurate.Note: Engine oil supplies the injection actuation pressure circuit. proper engine oil level is necessary for fuel injection.
Crank the engine while you observe the injection actuation pressure on the Cat ET status screen. if the injection actuation pressure is at least 5000 200 kPa (725 29 psi), the problem is not in the injection actuation pressure control system.
Check the seals on the injection actuation pressure control valve. if the seals are faulty, replace the seals and repeat Step 1.
Check the wiring harness to the injection actuation pressure control valve for opens and/or shorts.
Measure the coil resistance on the injection actuation pressure control valve. If the coil resistance is not between 5.0 Ohms and 15.0 Ohms, replace the injection actuation pressure control valve.
If the injection actuation pressure during cranking is less than 5000 200 kPa (725 29 psi), the high pressure oil supply circuit may have a leak.
Unplug the injection actuation pressure control valve and the unit injector connectors.
This engine uses high voltage to control the fuel injectors.Disconnect electronic fuel injector enable circuit connector to prevent personal injury.Do not come in contact with the fuel injector terminals while the engine is running.
Disable the unit injectors with Cat ET and/or the engine shutdown switch.
Remove the valve mechanism cover.
Crank the engine while checking the drain holes in the unit injector adapter and the jumper block seals for leaks.
Excessive leakage will result in a large stream of oil flow from the drain hole of the affected unit injector's adapter. The splashing of engine oil will be visible at the bottom of the oil shield for the jumper block's adapter. IF an excessively leaking unit injector is diagnosed, replace only the excessively leaking unit injector. Leaking jumper block seals can also create this problem. This can be diagnosed with the technique that is described above. Replace leaking seals.
If the problem persists, there may be a problem with the pump compensator displacement control. Correct this problem with the compensator's kit. Adjust the load for the spool spring by turning the retaining screw. Unplug the injection actuation pressure control valve and adjust the screw in order to obtain a pressure of 5000 200 kPa (725 29 psi) during engine cranking.
If the injection actuation pressure remains low after installing a new kit for the compensator, install a longer plug for the compensator. The longer compensator plug that is marked with a "D" is part of the plug kit. If the injection actuation pressure is above the specified range, select the shorter compensator plug from the plug kit that is marked with a "B".
If the pressure cannot be obtained, replace the pump or rebuild the pump.Unit Injectors
Perform the Injector Solenoid Test with Cat ET in order to determine if all of the injector solenoids are being energized by the ECM. Troubleshoot the electrical circuit for the injectors.Fuel Supply
Check the fuel lines for the following problems: restrictions, collapsed lines and pinched lines. If problems are found with the fuel lines, repair the lines and/or replace the lines.
Check the fuel tank for foreign objects which may block the fuel supply.
Check for air in the low pressure fuel supply system if any of the following procedures have been performed:
Replacement of the fuel filters
Service on the low pressure fuel supply circuit
Replacement of unit injectorsNote: A sight glass in the low pressure supply line is helpful in diagnosing air in the fuel. Refer to Testing and Adjusting for more information.
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.
Purge air from the low pressure fuel supply circuit. Refer to Operation and Maintenance Manual, "Fuel System - Prime" for the correct procedure.
Check fuel quality. In