864291 Volvo.Penta Manifold

Recommended Actions
Note: The procedures have been listed in order of probability. Complete the procedures in the order of the listed test steps.
Table 1
Troubleshooting Test Steps Values Results
1. Check for Active Codes and Logged Codes
A. Establish communication between Cat® Electronic Technician (ET) and the Electronic Control Module (ECM).
B. Monitor the diagnostic codes on Cat ET. Check for any active or logged codes.
Note: Wait at least 30 seconds in order for diagnostic codes to become active.
Codes
Result: A code is active or logged.
Repair: Troubleshoot any codes before continuing with this procedure.
Result: A code is not active or logged.
Proceed to Test Step 2.
2. Inspect the Electrical Connections
A. Check for the correct installation of the ECM J1/P1 and the J2/P2 connectors. Check for correct installation of the fuel injector connectors.
Connectors
Result: The electrical connectors are NOT OK.
Repair: Repair connectors that are suspect or replace connectors that are suspect. Perform the "Wiggle Test" on Cat ET.
Result: The electrical connectors are OK.
Proceed to Test Step 3.
3. Test the Fuel Injectors
A. Perform the "Run Up Test" on Cat ET in order to determine if all of the injector solenoids are being energized by the ECM.
Injector Solenoid Test or Fuel System Verification Test
Result: The test was successful.
Proceed to Test Step 4.
Result: The test was not successful.
Repair: Diagnose the problem and then repair the problem.
Reset all active codes and clear all logged codes.
If the problem is not resolved, proceed to Test Step 4.
4. Check the Fuel Quality
A. Refer to Operation and Maintenance Manual for information on the proper characteristics of the fuel for the engine. If necessary, obtain a fuel analysis in order to confirm that the correct fuel is being used for the engine. Refer to Systems Operation/Testing and Adjusting, "Fuel System Quality Test" for the proper procedure.
Fuel Quality
Result: The fuel quality is OK.
Proceed to Test Step 5.
Result: The fuel quality is NOT OK.
Repair: Replace the fuel.
If the problem is not resolved, proceed to Test Step 5.
5. Check for Proper Lubrication
A. Check for proper lubrication of the valve components. Check for sufficient lubrication between the injector tappets and the rocker arms.
B. Check for blocked oil passages. Oil passages must be clean. Clean any oil passages that are questionable. Refer to the Disassembly and Assembly for additional information.
C. Inspect the engine oil filters for ferrous material.
D. Obtain an S-O-S oil analysis. The analysis will contribute to a better understanding of oil contamination and the origin of the contamination.
Lubrication
Result: The oil passages are OK.
Proceed to Test Step 6.
Result: The oil passages are NOT OK.
Repair: Make the necessary repairs, Verify that the repair eliminated the problem.
If the problem is not resolved, proceed to Test Step 6.
6. Isolate the Source of the Noise
A. If the source of the noise is the engine accessory, remove the suspect engine accessory. Inspect the suspect engine accessory.
Engine Accessory
Result An engine accessory is NOT OK.
Repair: Repair the engine accessory and/or replace the engine accessory, if necessary.
Result The engine accessories are OK.
Proceed to Test Step 7.
7. Inspect the Valve Train Components
A. Check the valve lash. Refer to Troubleshooting, "Valve Lash Is Excessive".
B. Check for damage to valve train components. Remove the valve cover from the suspect cylinders. Check the following items for damage:
Camshaft
Valve rotocoil
Valve springs
Camshaft followers
Rocker shaft
Bridges
Pushrods
Injectors
Refer to the Disassembly and Assembly for additional information.
C. Check for valves that do not move freely. Remove the cylinder head and inspect the valves.
Refer to the Disassembly and Assembly for additional information.
Valve Train
Result: The valve train components are OK.
Proceed to Test Step 8.
Result: The valve train components are NOT OK.
Repair: Make the necessary repairs.
If the problem is not resolved, proceed to Test Step 8.
8. Inspect the Gear Train and Components of the Lower End
A. Inspect the gear train and lower end components.
Gear Train
Result: The gear train or lower end components are NOT OK.
Repair: Replace any damaged parts.
Result: The gear train or lower end components are OK.
Proceed to Test Step 9.
9. Inspect the Crankshaft
A. Inspect the crankshaft and the related components. Look for worn thrust plates and wear on the crankshaft.
B. Inspect the connecting rod bearings and the bearing surfaces on the crankshaft. Make sure that the bearings are in the correct position.
C. Check the counterweight bolts.
Crankshaft
Result: The crankshaft or the related components are NOT OK.
Repair: Repair or replace any damaged parts.
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).