3801368 Volvo.Penta Unit injector

Table 1
Associated Diagnostic Trouble Codes
Suspect Parameter Number
E198
E398
5580-17
5580-18
157-17 Probable Causes
Active codes and logged codes
Incorrect parameters
Accessory and/or parasitic loads
Incorrect flash file
Restriction in the air inlet and exhaust system
Proper operation of the turbocharger
Low-pressure fuel system
Fuel injectorsRecommended Actions
Table 2
Troubleshooting Test Steps Values Results
1. Check for Codes
A. Establish communication between Cat® Electronic Technician (ET) and the Electronic Control Module (ECM). Refer to Troubleshooting, "Electronic Service Tools", if necessary.
B. Download the "Warranty Report" from the engine ECM before performing any troubleshooting or clearing diagnostic trouble codes.
Codes
Result: There are no active codes.
Proceed to Test Step 2.
Result: There are active codes.
Repair: Troubleshoot any active codes before continuing with this procedure.
2. Check for Incorrect Parameters
A. Use Cat ET to verify that the correct engine parameters are being used. Refer to Troubleshooting, "Configuration Parameters" for additional information.
B. Verify that all the parameters for parasitic loads are correct.
Parameters
Result: The parameters are configured correctly.
Proceed to Test Step 3.
Result: The parameters are not configured correctly.
Repair: Correctly configure the parameters.
3. Check for Accessory and/or Parasitic Loads
A. Check all accessory equipment for problems that may create excessive load on the engine.
B. Check for any excess parasitic load on the engine.
Parasitic Loads
Result: There is not an excessive load on the engine.
Proceed to Test Step 4.
Result: There is an excessive load on the engine.
Repair: Diagnose the problem and then repair the problem.
4. Incorrect Flash File
A. Verify that the latest flash file is installed in the Electronic Control Module (ECM). Refer to Troubleshooting, "ECM Software - Install" for the proper procedure.
Flash File
Result: The latest flash file is installed in the ECM.
Proceed to Test Step 5.
Result: The latest flash file is not installed in the ECM.
Repair: Install the latest flash file. Verify that the repair eliminated the problem.
5. Restriction in the Air Inlet and Exhaust System
A. Check the air filter restriction indicator, if equipped. Clean plugged air filters or replace 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, Verify that the repair eliminated the problem.
Result: There are no restrictions in the air inlet or exhaust system.
Proceed to Test Step 6.
6. Check for Proper Operation of the Turbocharger
Turbocharger
Result: The turbocharger is operating properly.
Proceed to Test Step 7.
Result: The turbocharger is not operating properly.
Repair: Repair or replace the turbocharger. Verify that the repair eliminated the problem.
7. Inspect the Low-Pressure Fuel System
A. Visually check the fuel level in the fuel tank. Do not rely on the fuel gauge only.
B. Ensure that the fuel supply valve (if equipped) is in the full OPEN position.
C. Inspect the fuel system. Refer to Systems Operation/Testing and Adjusting, "Fuel System - Inspect" for additional information.
Cold weather adversely affects the characteristics of the fuel. Refer to the engines Operation and Maintenance Manual for information on improving the characteristics of the fuel during cold-weather operation.
D. Check fuel quality. Check the fuel tank for debris or foreign objects which may block the fuel supply.
E. Check the filtered fuel pressure while the engine is being cranked. Refer to Troubleshooting, "Fuel Pressure Is Low" for the proper testing procedure.
Fuel System
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 eliminates the problem.
8. Check the Fuel Injectors
Note: If service has been performed on the engine fuel system recently, verify that the injector trim files are correct. Use Cat ET to check that the injector trim files are correct for the injectors that are installed on the engine.
A. Use Cat ET to ensure that there are not any active diagnostic codes for the injector solenoids. Perform the "Cylinder Cutout Test" to check for a misfiring cylinder. Refer to Troubleshooting, "Injector Solenoid - Test" for information that is related to the test.
B. Use Cat ET to perform the "Fuel Rail Pressure Test" to check the mechanical condition of the fuel injectors. Refer to Troubleshooting, "Injector Solenoid - Test" for information that is related to the test.
"Fuel Rail Pressure Test"
Result: The test was successful.
Return the unit to service.
Result: The test was not successful.
Repair: Diagnose the problem and then repair the problem. Reset all active codes and clear all logged codes.
Verify that the repair eliminated the problem.
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 Solution Network (DSN).