3986692 Volvo.Penta Manifold

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 and/or event codes may cause poor performance. Refer to in the electronic service tool.
A. Use the electronic service tool to check for active or logged codes.
B. Use the electronic service tool to check the histogram information if the engine has been derated.
Note: If the histograms contain engine derates and no diagnostic codes are present, then the engine is operating normally.
Engine Derate or Diagnostic Codes
Result: A diagnostic code is present.
Repair: Troubleshoot the code and then reset the histogram.
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. Oil Pressure
Note: When the engine is started, the turbocharger protection strategy will lock the engine speed at low idle until the oil pressure builds or the engine has been running for 60 seconds. Wait to start lamp (if fitted) will flash when turbo protection strategy is active.
A. Ensure that the engine oil pressure is sufficient. Refer to Troubleshooting, Oil Pressure Is Low.
Oil pressure
Result: The oil pressure is not OK.
Repair: Make any necessary repairs. Refer to Troubleshooting, Oil Pressure Is Low.
Result: The oil pressure is OK.
Proceed to Test Step 4.
4. Electrical connectors
A. Turn the start switch to the ON position.
B. Use the electronic service tool to check the intake manifold pressure.
C. Run the engine until the speed is equal to the maximum no-load speed.
D. Use the electronic service tool to make sure that the throttle is set to reach the maximum no-load speed.
Electrical connections
Result: The intake manifold pressure is not zero 0.5 kPa (zero 0.070 psi).
Repair: Check the 5 VDC sensor supply for the intake manifold pressure. Refer to Troubleshooting, "Sensor Supply - Test".
Result: The throttle response is not as expected.
Repair: If the maximum no-load speed cannot be obtained, refer to Troubleshooting, "Switch Circuits - Test" 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 5.
5. Air Intake and Exhaust System
A. Check for an air filter restriction indicator, if equipped. Replace a plugged air filters. Refer to the Operation and Maintenance Manual.
B. Check the air inlet and exhaust system for restrictions and/or leaks.
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: There are no restrictions in the air inlet or exhaust system.
Proceed to Test Step 6.
6. Valve Lash
Note: The valve lash can affect the performance of the engine.
A. Check the valve lash.
Valve lash
Result: The valve lash is not correct.
Repair: Check the valve lash. Refer to Systems Operation, Testing, and Adjusting, "Engine Valve Lash - Inspect" for the correct procedure.
Result: The valve lash is correct.
For engines with a single turbocharger, proceed to Test Step 7.
For engines with twin turbochargers, proceed to Test Step 8.
7. Turbocharger
This Test Step is applicable to engines with a single 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 set 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: Replace the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove" and Disassembly and Assembly, "Turbocharger - Install".
If a turbocharger equipped with an electronic wastegate is replaced, use the electronic service tool to perform the "Turbocharger Wastegate Actuator Replacement Reset".
Use the electronic service tool to perform the "Air System Motor Valve Verification Test"
Result: The turbocharger is OK.
Proceed to Test Step 9.
8. Turbochargers
This Test Step is applicable to engines with twin turbochargers.
Note: The turbochargers that are installed on the engine are nonserviceable items. If any mechanical fault exists, then the faulty turbocharger must be replaced.
A. Ensure that the mounting bolts for the turbochargers are tight.
B. Check that the oil drains for the turbochargers are not blocked or restricted.
C. Check that the compressor housings for the turbochargers are free of dirt and debris. Make sure that the housings are not damaged.
D. Check that the turbine housings for the turbochargers are free of dirt and debris. Make sure that the housings are not damaged.
E. Check that the turbine blades rotate freely in the turbochargers.
F. For C4.4 TTA engines only Use the electronic service tool to perform the "Air System Motor Valve Verification Test".
G. Ensure that the wastegate on the high-pressure turbocharger is set correctly. Refer to Systems Operation, Testing, and Adjusting, "Turbocharger - Inspect". If the wastegate actuator is faulty, replace the high-pressure turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove" and Disassembly and Assembly, "Turbocharger