857238 Volvo.Penta Piston

Probable Causes
Diagnostic codes
Cold mode
Starting aids (if applicable)
Water temperature regulators
Unit injectors
Flash file
Fuel supply
Component wear
Cooling system
Engine timingRecommended Actions
Table 1
Troubleshooting Test Steps Values Results
1. Diagnostic Codes
A. Establish communication between Cat Electronic Technician (Cat ET) and the ECM. Refer to Troubleshooting"Electronic Service Tools", if necessary.
Diagnostic Codes
Result: A diagnostic code is not active or logged.
Proceed to Test Step 2.
Result: A diagnostic code is active or logged.
Repair: Troubleshoot any codes before continuing with this procedure. Verify that the repair eliminated the problem.
2. Cold Mode
A. Use Cat ET to verify that the engine has exited cold mode. Cold mode operation may slow throttle response.
If the engine is operating in cold mode, an indicator will be displayed on the top of any of the status screen.
Cold Mode
Result: The engine is not operating in cold mode.
Proceed to Test Step 3.
Result: The engine has not exited from the cold mode.
Repair: This is normal operation. Return the engine to service.
3. Starting Aids
A. Ensure that the air inlet heater is operating correctly. Refer to the diagnostic functional test Troubleshooting"Air Inlet Heater Circuit - Test".
B. Ensure that the ether injection system is operating correctly. Refer to the diagnostic functional test Troubleshooting, "Ether Injection System - Test".
Starting Aid
Result: The air inlet heater and the ether injection system are operating correctly.
Proceed to Test Step 4.
Result: The air inlet heater and/or the ether injection system is not operating correctly.
Repair: Make the necessary repairs. Verify that the repair eliminated the problem.
4. Water Temperature Regulators
A. Check the water temperature regulators for correct operation. Refer to Testing and Adjusting.
Temperature Regulator
Result: The water temperature regulator is operating properly.
Proceed to Test Step 5.
Result: The water temperature regulator is not operating properly.
Repair: If necessary, replace the water temperature regulators.
Verify that the repair eliminated the problem.
5. Unit Injectors
A. Perform the "Cylinder Cutout Test" in order to identify any injector that might be misfiring.
Use similar conditions for the test that were experienced during operation. Refer to the diagnostic functional test Troubleshooting "Injector Solenoid Circuit -Test".
Fuel Injectors
Result: The test was successful.
Proceed to Test Step 6.
Result: The test was NOT successful.
Repair: Remove the suspect injector, and install a new electronic unit injector. Refer to Disassembly and Assembly.
Ensure that the repairs have determined the problem.
6. Flash File
A. Ensure that the correct flash file is properly installed on the ECM.
Flash File
Result: The correct flash file is properly installed on the ECM.
Proceed to Test Step 7.
Result: The incorrect flash file is installed on the ECM.
Repair: Download the correct flash file and install properly to the ECM.
Refer to programming parameters Troubleshooting, "Flash Programming".
7. Fuel Supply
A. Inspect the fuel system components.
B. Check for the correct fuel pressure.
C. Check the fuel quality.
Low cetane fuel can create white smoke. Replace the fuel with a higher cetane fuel. In temperatures below 0° C (32° F), check for solidified fuel (wax). Refer to Applied Failure Analysis, SEBD0717, "Diesel Fuels and Your Engine". If necessary, replace the fuel with a higher cetane fuel.
Fuel Supply
Result: The fuel system is operating properly.
Proceed to Test Step 8.
Result: The fuel system is not operating properly.
Repair: Make the necessary repairs. Verify that the repair eliminated the problem.
8. Component Wear
A. Check the engine for the following problems:
- Excessive Valve Wear
- Piston Wear
- Ring Wear
- Liner Wear
- Reduced Compression Pressure
Component Wear
Result: There is no excessive component wear found in the engine.
Proceed to Test Step 9.
Result: There is excessive component wear found in the engine.
Repair: Repair or replace the excessive component and return engine to service.
9. Cooling System
A. Check the engine for coolant leaks.
B. Check for coolant in the cylinder and for coolant in the exhaust system
Cooling System
Result: There were no coolant leaks found in the engine or coolant found in the cylinder or exhaust.
Proceed to Test Step 10.
Result: There is coolant leaks found in the engine and/or coolant found in the cylinder or exhaust.
Repair: Make the necessary repairs to the engine and return to service.
10. Engine Timing
A. Check the calibration of the engine speed/timing sensors. Refer to the Troubleshooting, "Engine Speed/Timing Sensor - Calibrate".
B. Verify that the crankshaft and camshaft drive gears are properly oriented. Refer to the engines Disassembly and Assembly manual.
Engine Timing
Result: The crankshaft/camshaft gears are aligned properly and the engine speed/timing sensor are calibrated correct.
STOP
Result: The crankshaft/camshaft gears are not aligned properly and/or the engine speed/timing sensor is not calibrated correct.
Repair: Realign the crankshaft/camshaft gears and/or properly calibrate the engine speed/timing sensor.