Volvo Penta D3 190 limp mode / fault gremlins. Please help!

What happens if you leave one engine at idle, and try powering up the other in gear for a short period of time?
Then put that engine to idle and power up the other.
Do both engines reach the same RPM when only one is engaged?

The the new turbos that were fitted: were they genuine VP new parts, or refurbs?
 
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As far as I know there is a cable that connects the ecu of each engine together to allow for synchronisation etc.

Others may know what happens when you disconnect it, but if you did then you could see if they both still fault at the same time.

If they do then the only common thing is fuel such as a line collapsing under heavy draw.
 
jrudge said:
As far as I know there is a cable that connects the ecu of each engine together to allow for synchronisation etc.

Others may know what happens when you disconnect it, but if you did then you could see if they both still fault at the same time.

If they do then the only common thing is fuel such as a line collapsing under heavy draw.
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Would low fuel pressure throw a code though? Well it ought to .

This isn’t throwing codes that’s the main issue .Rudderless .
 
SC35 said:
What happens if you leave one engine at idle, and try powering up the other in gear for a short period of time?
Then put that engine to idle and power up the other.
Do both engines reach the same RPM when only one is engaged?

The the new turbos that were fitted: were they genuine VP new parts, or refurbs?
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When each engine is powered up in silo and the other in neutral they both still hit 2,000rpm and 50 psi and plateau.

New turbos are VP parts.
 
jrudge said:
As far as I know there is a cable that connects the ecu of each engine together to allow for synchronisation etc.

Others may know what happens when you disconnect it, but if you did then you could see if they both still fault at the same time.

If they do then the only common thing is fuel such as a line collapsing under heavy draw.
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We are doing this next Wednesday. Disconnecting the engines so they think they are singles. Plus doing stand alone fuel systems, intake and return all to totes.

I have a gut feel now that there is something like a overflow return valve blocked as in the past she has drawn from the port tank twice as quick as the starboard.
 
When you accelerate look at the fuel priming knob , is it sucked down ? If it is then it’s a fuel supply issue between the engine filter and the tank .
There are 2 models of engine filter , one has a supply tube down the middle , the other doesn’t , have you got the correct filter ? This problem seems very strange because I’d assume you have a Volvo dealer on the job and it’s not resolved so it’s got to be a comm problem as both engines are faulty .

As they have vodia have they updated the ecu , have you checked the engines have had any campaign upgrades installed ?
 
volvopaul said:
When you accelerate look at the fuel priming knob , is it sucked down ? If it is then it’s a fuel supply issue between the engine filter and the tank .
There are 2 models of engine filter , one has a supply tube down the middle , the other doesn’t , have you got the correct filter ? This problem seems very strange because I’d assume you have a Volvo dealer on the job and it’s not resolved so it’s got to be a comm problem as both engines are faulty .

As they have vodia have they updated the ecu , have you checked the engines have had any campaign upgrades installed ?
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It’s funny you say that. As this problem all started after a service and all fuel filters were changed.
 
volvopaul said:
When you accelerate look at the fuel priming knob , is it sucked down ? If it is then it’s a fuel supply issue between the engine filter and the tank .
There are 2 models of engine filter , one has a supply tube down the middle , the other doesn’t , have you got the correct filter ? This problem seems very strange because I’d assume you have a Volvo dealer on the job and it’s not resolved so it’s got to be a comm problem as both engines are faulty .

As they have vodia have they updated the ecu , have you checked the engines have had any campaign upgrades installed ?
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So looking at pre service photos (I’m not near the boat right now) it has the older D3 fuel filter (silver no writing), and post service it has the newer white ones with the branding and writing. Could that be enough to starve the engines and stick them into limp?
 
GooseGas said:
Sorry maybe not PSI. Just the boost reading goes up in tens. 10,20,30 up to 50 or 60 and stops. Normal operation it will hit 110-120.
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50 kPa is about 7.25 PSI
50 PSI and pipes would be flying around in the engine bay
 
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GooseGas said:
So looking at pre service photos (I’m not near the boat right now) it has the older D3 fuel filter (silver no writing), and post service it has the newer white ones with the branding and writing. Could that be enough to starve the engines and stick them into limp?
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Yes it could I’ve had problems with the incorrect filters fitted
 
GooseGas said:
Scratch that idea. Shot down to the boat. Correct filters fitted. Both new.

We will rule out fuel this week or find that it is fuel. One or the other.
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Also rule out anything with a , or throws a code .Get the VP code configuration book ( your hand books ? ) and re read the list .
Figure out what remains .

Is it possible for example for a VP tech to connect a running lap top ( vodia ?? ) while the fault happens ? .See any changes to parameters etc .
 
Portofino said:
Also rule out anything with a , or throws a code .Get the VP code configuration book ( your hand books ? ) and re read the list .
Figure out what remains .

Is it possible for example for a VP tech to connect a running lap top ( vodia ?? ) while the fault happens ? .See any changes to parameters etc .
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Wow - my problems sound exactly the same, and so far have spent over €30,000 euros with mechanics ( inv VOLVO MAIN AGENTS !!) and still my Starboard D3 190 will not rev over 1500rpm when under load, but reaches 3400 when in nuetral.

Nee turbo
New pressure valves
New everything it seems 🤷‍♂️🤷‍♂️

Volvo main distributer in asouthern Spain (Elias Blanco of Algecirias) has connected Vodia, run all updates, cleared log, and we do not get any fault codes.

Engine starts and runs smoothly.

Am at my wits end knowing what to do …. Any more suggestions
 
Must be pretty poorly designed and engineered for official VP techs with correct and updated fully subscribed lap tops to identify a fault in the absence of existing user fault codes .

Sorry to hear this .

It sounding all too typical , there’s a oversupply of VP woes on boat forums .


What I was thinking in the absence of real “ fault codes “ with the lap top connected they might be able ( said “ might “ before anyone bites my head off ! ) to see real time stuff .
Kinda bar charts and graphs , of every separate cylinder parameter , fuel load , pressure , injector opening times , waste gate openings , temps , air vols , water flow pressure etc etc + much more you name it .We know it’s not throwing a code .
Realise to see all this the engine needs to be littered with sensors and have suitable software to put it all on data screens to view .

All assuming the relevant ECU s that process available data can make sense of it to pass on to the vodia ( lap top ) .

Could you swop ECU s + harness .Or if single maybe the tech can borrow a set ?
 
We have used a mechanics Spare ECU and it made no difference…. Tomorrow I am renewing fuel lines from fuel/water Racor filter to the main fuel filter as I can see a small indentation on the outside from a possible crush… am wondering if its as simple as restricted fuel flow through pipe?? … but, why the hell would it not throw a fault code for lack of fuel. ??

Im also doing a visual on the Turbo boost pipe for any small split etc that only expands when boost is needed under load ?????

PS. The Volvo guy only did the fault trqving and clearing log etc whilst in berth…. Maybe i should get them back and see what the vodia system shows when trying to pull a load at sea ??
 
You could first partially compress fuel pipe bit by bit with a clamp , while running to see what happens.
If at the dock at 3200 rpm I would expect it to stutter , throw a code .If it defaults down to 1500 rpm ish as you tighten the clamp at least it tells you restricting fuel might be the culprit .

Have you tried a separate fuel supply ? Thinking your tank pick up can’t cope with full load demand at sea .But copes with no load @ the dock .

Can you see any fuel flow data , or could a vodia plugged in see any real time fuel flow .This will confirm or eliminate what you are thinking a restriction.

I can see fuel flow on my boat FWIW ( MAN s )
 
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