238958 Volvo.Penta Sealing plug

Probable Causes
Diagnostic codes
ECM parameters
Throttle signal from the throttle position sensor
Air intake and exhaust system
Fuel supply
Low compression (cylinder pressure)
Electronic unit injectors
Individual malfunctioning cylindersRecommended Actions
Diagnostic Codes
Use one of the following methods to check for active diagnostic codes:
The electronic service tool
The display on the control panel
Flash CodesElectronic Service Tool
Connect the electronic service tool to the diagnostic connector.
Check for active diagnostic codes on the electronic service tool.
Investigate any active codes before continuing with this procedure. Refer to Troubleshooting, "Troubleshooting with a Diagnostic Code". Display on the Control PanelNote: The following procedure is only applicable if the application is equipped with a display on the control panel.
Check the display on the control panel for active diagnostic codes.
Troubleshoot any active codes before continuing with this procedure. Refer to Troubleshooting, "Troubleshooting with a Diagnostic Code". Flash CodesNote: The following procedure is only applicable if the machine is equipped with the appropriate warning lamps.
Check the warning lamps on the control panel for flash codes. Flash codes are explained in Troubleshooting, "Flash Codes".
If any flash codes are displayed, troubleshoot the codes before continuing with this procedure. Refer to Troubleshooting, "Troubleshooting with a Diagnostic Code". ECM Parameters
Ensure that the fault is not an incorrect or missing programmed parameter.
Ensure that the correct mode was selected by using the electronic service tool.
Use the electronic service tool to verify the correct engine rating for the engine.
Use the electronic service tool to verify the maximum engine speed limit.
Use the electronic service tool to verify the following parameters at maximum speed: the boost pressure, the smoke limit, the torque limit and the amount of fuel that is delivered.
Use the electronic service tool to reset the parameters to the OEM specifications.
Ensure that the repairs have eliminated the fault.
If the repairs have not eliminated the fault, proceed to "Throttle Signal for the Throttle Position Sensor". Throttle Signal for the Throttle Position Sensor
Use the electronic service tool and observe the signal for the throttle position sensor. Make sure that the throttle reaches the 100% raw position and the calibrated position.
If the signal is erratic, refer to Troubleshooting, "Analog Throttle Position Sensor Circuit - Test" or refer to Troubleshooting, "Digital Throttle Position Sensor Circuit - Test".
If the engine has a throttle switch, refer to Troubleshooting, "Throttle Switch Circuit - Test".
If the fault has not been eliminated, proceed to "Air Intake and Exhaust System". Air Intake and Exhaust System
Check the air filter restriction indicator, if equipped.
Ensure that the air filter is clean and serviceable.
Check the air intake and the exhaust system for the following defects:
Blockages
Restrictions
Damage to the air intake and exhaust lines and hoses
Make all necessary repairs to the engine.
Ensure that the repairs have eliminated the fault.
If the fault has not been eliminated, proceed to "Fuel Supply". Fuel Supply
Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.
Contact with high-pressure fuel may cause personal injury or death. Wait 10 minutes after the engine has stopped to allow fuel pressure to purge before any service or repair is performed on the engine fuel lines.
Check for leaks from the high-pressure fuel lines. If the high-pressure fuel lines have a leak, the high-pressure fuel lines must be replaced. Refer to Disassembly and Assembly, "Fuel injection lines - Remove" and Disassembly and Assembly, "Fuel injection lines - Install".
Visually check the fuel tank for fuel. The fuel gauge may be faulty.
If equipped, ensure that the fuel supply valve is in the full OPEN position.
If the temperature is below 0 °C (32 °F), check for solidified fuel (wax).
Visually inspect the fuel supply lines for restrictions.
Check that the low-pressure fuel lines are tight and secured properly.
Replace the in-line fuel strainer that is installed upstream of the Electric Fuel Lift Pump (EFLP).
Remove the fuel filters. Inspect the fuel filters for contamination. Install new fuel filters. Refer to the Operation and Maintenance Manual, "Fuel System Filter- Replace and Fuel System Primary Filter (Water Separator) Element - Replace". Determine the cause of the contamination.
Check the diesel fuel for contamination. Refer to Systems Operation, Testing, and Adjusting, "Fuel Quality - Test".
Check for air in the low-pressure fuel system and check the pressure in the low-pressure fuel system. Refer to Systems Operation, Testing, and Adjusting, "Air in Fuel - Test". Note: Before performing the following fuel system tests, the engine must be run for a minimum of 30 minutes.Note: When performing the following fuel system tests, the Electric Fuel Lift Pump (EFLP) will only operate for 2 minutes unless the engine is running. If necessary, cycle the keyswitch in order to reactivate the pump.
Illustration 1 g02873776
(1) Return line pressure relief valve
(2) Secondary fuel filter base
(3) Transfer pump inlet regulator (TPIR)
(4) Transfer pump inlet regulator return port Transfer Pump Inlet Regulator (TPIR) Flow Test
Refer to Illustration 1.Perform the following procedure:
Make sure the keyswitch is in the OFF position.
Disconnect the TPIR return line from the drain port on the TPIR. Install a suitable blanking cap on the open port in the TPIR return line.
Connect a temporary drain line to the drain port on the TPIR.
Place the end of the temporary drain line into a suitable calibrated container.
With the keyswitch in the ON position but the engine not running, use a suitable multimeter to measure the input voltage to the EFLP. Record the reading.
With the keyswitch in the ON position but the engine not running, measure the fuel flow from the temporary drain line. For a 12 VDC system, refer to Illustration 2 for the minimum acceptable flow rate. For a 24 VDC system, refer to Illustration 3 for the minimum acceptable flow rate.
Illustration 2 g02355128
Minimum TPIR flow rate for a 12 VDC system