Volvo Symptom D12D US02 Service Manual
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Volvo Symptom D12D US02 Service Manual

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20
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Symptom
D12D US02 and D16D US 04
20045033

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Summary of Contents for Volvo Symptom D12D US02

  • Page 1 Service Manual Trucks Group Symptom D12D US02 and D16D US 04 20045033...
  • Page 3 Greensboro, NC USA Order number: 20045033 © 2006 Volvo Trucks North America, Inc., Greensboro, NC USA All rights reserved. No part of this publication may be reproduced, stored in retrieval system, or transmitted in any forms by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Volvo Trucks North America, Inc..

  • Page 5: Table Of Contents

    Contents Symptom, Fault Tracing ............... 3 Start and Stop Problems, Fault Tracing ..........4 Abnormal Smoke, Fault Tracing ............25 High Fuel Consumption, Fault Tracing ..........36 Contaminated Fluid ................41 Low Power Output, Fault Tracing ............47 Noise and Vibrations, Fault Tracing ............. 65 Uneven Operation, Fault Tracing ............

  • Page 7: Symptom, Fault Tracing

    Group 20 Symptom, Fault Tracing When fault tracing using symptoms, choose the symptom that best represents the condition of the vehicle. Fault tracing should be carried out according to the sequence described in the information for each symptom. This makes the job more effective by systematically excluding or documenting potential faults that can cause the particular symptom.

  • Page 8: Start And Stop Problems, Fault Tracing

    Group 20 Start and Stop Problems, Fault Tracing Symptom fault tracing “General Information” page 4 For specific symptoms, see: Depending on the vehicle configuration, conditions related to start and stop problems may be caused or • “Engine Does Not Start” page 5 influenced by specific faults or malfunctions in other •...
  • Page 9 Group 20 • “Engine Does Not Start” page 5 • “Engine Difficult to Start” page 5 • “Engine Starts But Will Not Continue to Run” page 5 • “Engine Unexpectedly Shuts Down During “Start and Stop Problems, Fault Tracing” page 4 Deceleration”...
  • Page 10 Group 20 Engine Unexpectedly Shuts Down During Deceleration • • Lack of communication with, or power to, the Engine “Step 1: Fault Code Readings” page 17 • ECU. “Step 2: Visual Inspection (System Checks)” page 18 • • Abnormal fuel supply pressure during deceleration or “Step 3: VCADS Pro Tests”...
  • Page 11 Group 20 Step 1: Fault Code Readings • MID 128, Engine ECU PID 94 Fuel supply pressure PPID 122 VCB compression brake status PPID 124 Exhaust pressure governor, EPG 1 PID 224 Electronic Immobilizer SID 1 -6 Unit injectors SID 21 Engine position (cam) SID 22 Engine speed sensor (flywheel)
  • Page 12 Group 20 Action: Refer to: Check that there is sufficient and good quality fuel in the tank(s). Check all fuel lines for leaks, damage and restrictions. Check fuel cut-off valves on fuel tank. Check EA and EB connectors and pins on EECU and that the 12-pin interface connector on the wiring harness box are properly connected and fault free.
  • Page 13 Group 20 Step 3: VCADS Pro Tests C2002640 Action: Refer to: Check fuel supply pressure (while cranking the engine with the starter motor). Fuel Supply Pressure Check Check vehicle information to verify that the engine software is available. Vehicle Information, Test Note: If no software numbers are available in MID 128, Engine ECU, the engine will not run.
  • Page 14 Group 20 Step 4: Component and Function Checks C2002641 Action: Refer to: Check supply voltage and ground signals at VECU on pins (PA12, PA13, PA14 and PB15) Impact or ID DVD: “MID 144 Fault Codes”, according to checks in VECU Fault Code Manual. Information type “Diagnostics”, group 3649.
  • Page 15 Group 20 Step 1: Fault Code Readings Freeze frames with information for specific fault codes can also assist in tracing causes of the symptom. Fault tracing using relevant service information must always be carried out for relevant fault codes. Components/functions of special interest: •...
  • Page 16 Group 20 Step 3: VCADS Pro Tests C2002640 Action: Refer to: Check preheater. Preheat, Test Check sensor values. Sensor Values Checks, Engine Not Running Check camshaft and flywheel signals at cranking speed. Flywheel and Camshaft Signal, Test Check the EPG function. Warm-Hold Function, Test Note: If the exhaust brake is applied, cylinder compression will be affected, which results in engine starting faults.
  • Page 17 Group 20 Step 4: Component and Function Checks C2002641 Action: Refer to: Check that the fuel quality is within specifications. Group 23: Fuel Quality, Checking Check for air in the fuel system. Group 23: Air in the Fuel System, Checking Check for carbon monoxide in the fuel.
  • Page 18 Group 20 Step 1: Fault Code Readings • MID 128, Engine ECU PID 94 Fuel supply pressure PID 100 Engine oil pressure (if extended engine protection is selected in the data set) PID 110 Coolant temperature (if extended engine protection is selected in the data set) PID 111 Coolant level (if extended engine...
  • Page 19 Group 20 Step 2: Visual Inspection (System Checks) T2020217 Action: Refer to: Check the fuel lines for damage, leakage, or restrictions. Also check that connections and seals are correctly installed. Check that EECU cable harness, including connectors and pins, is fault free and correctly connected.
  • Page 20 Group 20 Step 4: Component and Function Checks C2002641 Action: Refer to: Check that the fuel quality is within specifications. Group 23: Fuel Quality, Checking Check for carbon monoxide in the coolant. Group 26: Carbon Monoxide in the Coolant, Checking Check for carbon monoxide in the fuel.
  • Page 21 Group 20 Step 1: Fault Code Readings • MID 128, Engine ECU PID 94 Fuel supply pressure PID 100 Engine oil pressure (if extended engine protection is selected in the data set) PID 110 Coolant temperature (if extended engine protection is selected in the data set) PID 111 Coolant level (if extended engine...
  • Page 22 Group 20 Step 2: Visual Inspection (System Checks) T2020217 Action: Refer to: Check the fuel lines for damage, leakage, or restrictions. Also check that connections and seals are correctly installed. Check that the EECU cable harness (including connectors and pins) is fault free and correctly connected.
  • Page 23 Group 20 Step 4: Component and Function Checks C2002641 Action: Refer to: Check that the fuel quality is within specifications. Group 23: Fuel Quality, Checking Check for air in the fuel system. Fuel Supply Pressure, Fault Tracing (Checklist B) Impact or ID DVD: Information type "Diagnostics", Group 2309.
  • Page 24 Group 20 Step 1: Fault Code Readings Fault tracing using relevant service information must always be carried out for relevant fault codes. Components/functions of special interest: • MID 128, Engine ECU PID 91 Accelerator pedal SID 1–6 Unit injectors SID 21 Engine position, cam SID 22 Engine speed, flywheel...
  • Page 25 Group 20 Step 2: Visual Inspection (System Checks) T2020217 Action: Refer to: Check that the EECU cable harness (including connectors and pins) is fault free and correctly connected. Check the fuel lines for damage, leakage, or restrictions. Also check that connections and seals are correctly installed.
  • Page 26 Group 20 Step 4: Component and Function Checks C2002641 Action: Refer to: Check that the fuel quality is within specifications. Group 23: Fuel Quality, Checking Check power supply/ground and wiring harness for EECU, including the connectors and “Engine ECU, Fault Tracing” (Checklist M), terminal pins.
  • Page 27 Group 20 Step 2: Visual Inspection (System Checks) T2020217 Action: Refer to: Check that the engine ECU cable harness (including connectors and pins) is fault free and correctly connected. Check the condition of the starter switch contacts. Check all ground connections on the engine. “Step 3: VCADS Pro Tests”...
  • Page 28 Group 20 Step 4: Component and Function Checks C2002641 Action: Refer to: Check power supply/ground and wiring harness for EECU, including the connectors “Engine ECU, Fault Tracing” (Checklist M), and terminal pins. Check that all components are fault free and properly connected. (If Impact or ID DVD: Information type “Diagnostics”, terminals and connectors are faulty, the engine will not run.) group 2841.

  • Page 29: Abnormal Smoke, Fault Tracing

    Group 20 Abnormal Smoke, Fault Tracing Symptom fault tracing For specific symptoms, see: • “Black Smoke” page 26 Note: You must read and understand the precautions • “Blue Smoke” page 26 and guidelines in Service Information, group 20, • “White or Gray Smoke” page 26 "General Safety Practices, Engine"...

  • Page 30: Black Smoke

    Group 20 Fault Tracing Temporary faults can be difficult to trace since the fault but which does not have anything to do with the engine may not occur when the vehicle is brought in to be control system. checked. For specific symptoms, see: Fault tracing should be performed based on what the •...

  • Page 31: Step 1: Fault Code Readings

    Group 20 The larger the cooling surfaces used in the exhaust and components with no faults or malfunctions. The amount silencer system, the greater the amount of white smoke and sequence of checks depend on results from Basic when cold starting and at low outside temperatures. Checks (including active or inactive fault codes noted), White smoke may also be increased if the preheaters do vehicle conditions, vehicle service and repair history,...

  • Page 32: Step 2: Visual Inspection (System Checks)

    Group 20 Step 2: Visual Inspection (System Checks) T2020217 Action: Refer to: Check condition of the air filter. Check condition of the CAC hoses and pipes. “Step 3: VCADS Pro Tests” page 28 “Black Smoke” page 26 Step 3: VCADS Pro Tests C2002640 Action: Refer to:...

  • Page 33: Step 4: Component And Function Checks

    Group 20 Step 4: Component and Function Checks C2002641 Action: Refer to: Check that the fuel quality is within specifications. Group 23: Fuel Quality, Checking Check that the intake manifold pressure is according to specifications for the particular “Specifications” (Intake manifold pressure), horsepower variant at 100% engine load.

  • Page 34: Step 1: Fault Code Readings

    Group 20 Step 1: Fault Code Readings Freeze frames of information for specific fault codes may also be helpful for finding causes for the symptom. Fault tracing using relevant service information should always be carried out for relevant fault codes. Components/functions of special interest: •...

  • Page 35: Step 3: Vcads Pro Tests

    Group 20 Step 3: VCADS Pro Tests C2002640 Action: Refer to: Check sensor values. • “Sensor Values Check, (Engine Running)” • “Sensor Values Check, (Engine Not Running)” Check intake/exhaust system. Intake and Exhaust System, Check Check cylinder balancing. Cylinder balancing, Check Check cylinder compression.

  • Page 36: Step 4: Component And Function Checks

    Group 20 Step 4: Component and Function Checks C2002641 Action: Refer to: Check that the fuel quality is within specifications. Group 23: Fuel Quality, Checking Check that the charge air system (including turbocharger, plus exhaust and intake side) is “Intake and Exhaust System, Fault free from engine oil.
  • Page 37 Group 20 PPID 122 Compression brake, VEB SID 266 EGR valve 2 (D12D) PPID 124 Exhaust pressure governor, EPG 1 PPID 25 EGR Mass Flow (D16D) SID 70 Preheater element, 1 PID 172 Air Inlet Temperature (D16D) SID 71 Preheater element, 2 PID 354 Relative Humidity (D16D) SID 146...
  • Page 38 Group 20 Check start and warm-hold function. Warm-Hold Function, Test Check EGR function. EGR Function, test Check intake/exhaust system. Intake and Exhaust System, Check Check cylinder balancing Cylinder balancing, Check Check cylinder compression. Cylinder Compression, Test Check injector function. Injector Cut-Out, manual “Step 4: Component and Function Checks”...
  • Page 39 Group 20 Step 4: Component and Function Checks C2002641 Action: Refer to: Check that the fuel quality is within specifications Group 23: Fuel Quality, Checking Check for carbon monoxide in the coolant. "Low Compression, Fault Tracing" (Checklist G), Information type "Diagnostics" Group 2103. Check the charge air system for leaks, restrictions, or damage.

  • Page 40: High Fuel Consumption, Fault Tracing

    Group 20 High Fuel Consumption, Fault Tracing Symptom fault tracing certified in a procedure, ask your supervisor for training before you perform it. Depending on the vehicle configuration, conditions related “General Information” page 36 to high fuel consumption may be caused or influenced by specific faults or malfunctions in other vehicle For specific symptoms, see: components.
  • Page 41 Group 20 so, has the truck been serviced or repaired according related high fuel consumption. Check other vehicle to the instructions? components: • • All axles (complete combination) are parallel Some countries have stricter environmental regulations • No brakes are applied (or misaligned brakes) for diesel fuels than others.
  • Page 42 Group 20 Action: Refer to: Check for active or inactive fault codes related to symptoms. Instrument cluster or VCADS Pro Check inactive codes with high occurrences. VCADS Pro:“Fault Codes, Test Mode” “Step 2: Visual Inspection (System Checks)” page 38 “High Fuel Consumption, Fault Tracing” page 36 Step 2: Visual Inspection (System Checks) T2020217 Action:...
  • Page 43 Group 20 Check engine brake function. Engine Brake Function, Test Check calibration number ( K factor). K-factor, check “Step 4: Component and Function Checks” page 40 “High Fuel Consumption, Fault Tracing” page 36...
  • Page 44 Group 20 Step 4: Component and Function Checks C2002641 Action: Refer to: Check that the fuel quality is within specifications. Group 23: Fuel Quality, Checking Check charge air hoses and connections for damage, restrictions, or signs of engine Group 26: Charge Air Pipe, Checking oil inside the piping.

  • Page 45: Contaminated Fluid

    Group 20 Contaminated Fluid Symptom fault tracing certified in a procedure, ask your supervisor for training before you perform it. Depending on the vehicle configuration, conditions “General Information” page 41 related to contaminated fuel may be caused or influenced by specific faults or malfunctions in other vehicle For specific symptoms, see: components.
  • Page 46 Group 20 • and sequence of checks depend on results from Basic “Step 4: Component and Function Checks” page 44 Checks (including active or inactive fault codes noted), vehicle conditions, vehicle service and repair history, other symptoms, and information from the driver. •...
  • Page 47 Group 20 Step 1: Fault Code Readings fault-finding aid for the symptom. Freeze frames of information for specific fault codes may also be helpful for finding causes for the symptom. Fault tracing using relevant service information should always be carried out for relevant fault codes. Components/functions of special interest: •...
  • Page 48 Group 20 Step 3: VCADS Pro Tests The results of the following tests using the VCADS Pro tool may indicate which system or component is a possible cause of the symptom. These tests can also eliminate components or systems with no faults or malfunctions. Action: Refer to: None required.
  • Page 49 Group 20 Step 1: Fault Code Readings fault-finding aid for the symptom. Freeze frames of information for specific fault codes may also be helpful for finding causes for the symptom. Fault tracing using relevant service information should always be carried out for relevant fault codes. Components/functions of special interest: •...
  • Page 50 Group 20 Step 3: VCADS Pro Tests The results of the following tests using the VCADS Pro tool may indicate which system or component is a possible cause of the symptom. These tests can also eliminate components or systems with no faults or malfunctions. Action: Refer to: None required.

  • Page 51: Low Power Output, Fault Tracing

    Group 20 Low Power Output, Fault Tracing Symptom fault tracing “General Information” page 47 For specific symptoms, see: Depending on vehicle configuration, conditions related to low power output symptoms may be caused or influenced • “Sudden Loss of Power” page 49 by specific faults or malfunctions in other vehicle •...
  • Page 52 Group 20 One condition for achieving specified tractive power is to The direct result of this is a lower intake manifold have sufficient fuel supply pressure on the low pressure pressure, inferior response, and higher fuel consumption. side. For information on measuring fuel pressure, see An incorrectly rebuilt exhaust system with a lot of bends “Supply Pressure, Fault Tracing”...
  • Page 53 Group 20 Sudden Loss of Power Sudden power loss may be caused by: and sequence of checks depend on results from Basic Checks (including active or inactive fault codes noted), • Failure in a component or system causing a lack of fuel vehicle conditions, vehicle service and repair history, or air, or intake/exhaust restrictions.
  • Page 54 Group 20 Engine Does Not Reach Rated Speed • Difficulty reaching rated engine speed may be caused by: “Step 1: Fault Code Readings” page 59 • “Step 2: Visual Inspection (System Checks)” page 59 • Problems in the fuel or intake system. •...
  • Page 55 Group 20 Step 1: Fault Code Readings PID 94 Fuel supply pressure PID 100 Engine oil pressure PID 102 Intake manifold pressure PID 108 Atmospheric pressure PID 110 Coolant temperature PID 111 Coolant level PID 153 Crankcase pressure PID 175 Engine oil temperature PPID 122 Compression brake, VCB...
  • Page 56 Group 20 Step 2: Visual Inspection (System Checks) T2020217 Action: Refer to: Fuel lines are free of damage or leaks. Engine oil level is within specifications. Group 20: Specifications Engine oil level is not contaminated by coolant. Air intake and charge air systems are free from damage or restriction. Coolant level is within specifications.
  • Page 57 Group 20 Step 3: VCADS Pro Tests C2002640 Action: Refer to: Check sensor values. • “Sensor Values Check, (Engine Note: Loss of power can occur if one or more of the sensors show Running)” • abnormal values. “Sensor Values Check, (Engine Not Running)”...
  • Page 58 Group 20 Step 4: Component and Function Checks C2002641 Action: Refer to: Check for air in the fuel system. “Cylinder Balancing, Fault Tracing” (Checklist F), Information type “Diagnostics”, group 2111. Check that the fuel quality is within specifications. Group 23: Fuel Quality, Checking Check that there is no carbon monoxide in the fuel.
  • Page 59 Group 20 “Sudden Loss of Power” page 49 Step 1: Fault Code Readings • MID 128, Engine ECU PID 94 Fuel supply pressure PID 100 Engine oil pressure PID 102 Intake manifold pressure PID 108 Atmospheric pressure PID 110 Coolant temperature PID 111 Coolant level PID 175...
  • Page 60 Group 20 Step 2: Visual Inspection (System Checks) T2020217 Action Refer to: Fuel lines are free of damage or leaks. Check that there is sufficient fuel in the tanks. Check that the air cleaner is free of dirt or restrictions. “Step 3: VCADS Pro Tests”...
  • Page 61 Group 20 Step 4: Component and Function Checks C2002641 Action: Refer to: Check for air in the fuel system. “Cylinder Balancing, Fault Tracing” (Checklist F), Information type “Diagnostics”, group 2111. Check that the air vents are open in the fuel tank(s). Check that the fuel quality is within specifications.
  • Page 62 Group 20 Check the turbocharger compressor wheel for damage or signs of rubbing against Group 25: Turbocharger, Checking housing; also check end play. Check that the engine ECU receives the correct signals from the flywheel and camshaft “Cam and Flywheel Signals, Fault Tracing” sensors.
  • Page 63 Group 20 Step 1: Fault Code Readings Registered fault codes (whether active or inactive) can PID 102 Intake manifold pressure quickly point to faults; however, they also can be a PID 108 Atmospheric pressure fault-finding aid for the symptom. Freeze frames of PID 110 Coolant temperature information for specific fault codes may also be helpful for...
  • Page 64 Group 20 Action: Refer to: Check accelerator pedal and switches. Accelerator Pedal, Switches and Sensors, Check Check sensor values. ”Sensor Values Check, (Engine Running)” Check fuel supply pressure at low and high engine speeds. Fuel Supply Pressure, Check Check injector function. Injector Cut-Out, Manual Check intake/exhaust system.
  • Page 65 Group 20 Step 4: Component and Function Checks C2002641 Action: Refer to: Check that the fuel quality is within specifications. Group 23: Fuel Quality, Checking Check that the engine speed parameter is correctly defined. VCADS Pro: "Parameters programming" Check charge air hoses and connections for damage, restrictions, or signs of engine Group 26: Charge Air Pipe, Checking oil inside the piping.
  • Page 66 Group 20 “Step 2: Visual Inspection (System Checks)” page 62 “Low Power After Vehicle Repair” page 50 Step 2: Visual Inspection (System Checks) T2020217 Action: Refer to: Fuel lines are free of damage or leaks. Exhaust system is correct design and installed correctly with no modifications that can cause restrictions (excessive exhaust back pressure).
  • Page 67 Group 20 Step 3: VCADS Pro Tests C2002640 Action: Refer to: Check sensor values. VCADS Pro: • “Sensor Values Check, (Engine Running)” • “Sensor Values Check, (Engine Not Running)” Check fuel supply pressure at low and high engine speeds. Fuel Supply Pressure, Check Check start and warm-hold function.
  • Page 68 Group 20 Step 4: Component and Function Checks C2002641 Action: Refer to: Check that components (i.e. turbocharger, EECU, VECU, injectors, and EPG) have Group 20: Components, Checking correct part number; if EECU or VECU was replaced, verify that new unit was programmed correctly.

  • Page 69: Noise And Vibrations, Fault Tracing

    Group 20 Noise and Vibrations, Fault Tracing Symptom fault tracing “General Information” page 65 Depending on the vehicle configuration, conditions related to noise and vibration may be caused or influenced by specific faults or malfunctions in other vehicle • “Step 1: Fault Code Readings” page 68 components.
  • Page 70 Group 20 Noise Tracing the cause of abnormal sounds is often difficult, An open mind and the ability to see beyond the obvious is as the noise can be “transferred” to various parts of the oftentimes necessary to find the source of the problem. vehicle.
  • Page 71 Group 20 Problems while driving • It is more difficult to locate the source of the problem Does the problem only occur when driving using while driving, it is impossible to walk around the vehicle the accelerator pedal? (Is the problem a type of to listen and feel.

  • Page 72: General Information

    Group 20 Step 1: Fault Code Readings Active and inactive registered fault codes can point to faults but also be a fault finding aid for the symptom. Freeze frames of information for specific fault codes may also be helpful for finding causes for the symptom. Fault tracing using relevant service information should always be carried out for relevant fault codes.

  • Page 73: Step 3: Vcads Pro Tests

    Group 20 Step 3: VCADS Pro Tests The results of the following tests using the VCADS Pro tool may indicate which system or component is a possible cause of the symptom. These tests can also eliminate components or systems with no faults or malfunctions. Action: Refer to: Check sensor values.

  • Page 74: Step 4: Checks

    Group 20 Step 4: Checks Answering the questions in the checklist below, creates the basis to systematically continue the fault tracing. The continuation consists of following up the educated guesses and using a process of elimination to find the cause of the problem. This is difficult and time consuming work which requires wide knowledge and experience of the vehicles and engine control systems.

  • Page 75: Uneven Operation, Fault Tracing

    Group 20 Uneven Operation, Fault Tracing Symptom fault tracing For specific symptoms, see: • “Engine Runs Unevenly at Idle Speed” page 73 Depending on the vehicle configuration, conditions related • “Engine Speed Surges at Low or High Idle” page 73 to uneven running may be caused or influenced by specific •...
  • Page 76 Group 20 • Ignition Difficulties Damage to wiring. • The signal from the accelerator pedal sensor is At very low outside temperatures, misfiring when the interrupted. accelerator pedal is depressed could be due to one of • The intake manifold pressure sensor gives a defective the following: signal.
  • Page 77 Group 20 Engine Runs Unevenly at Idle Speed The following checks should be carried out in order until tests and fault codes, vehicle conditions, vehicle service the fault is found. These checks also can help eliminate and repair history, other symptoms, and information from components with no faults or malfunctions.
  • Page 78 Group 20 • “Step 3: VCADS Pro Tests” page 83 • “Step 4: Component and Function Checks” page 85 “Uneven Operation, Fault Tracing” page 71 Engine Speed Surges in Power Take-off or Cruise Control The following checks should be carried out in order until tests and fault codes, vehicle conditions, vehicle service the fault is found.
  • Page 79 Group 20 Step 2: Visual Inspection (System Checks) T2020217 Action: Refer to: None required. “Step 3: VCADS Pro Tests” page 75 “Engine Runs Unevenly at Idle Speed” page 73 Step 3: VCADS Pro Tests C2002640 Action: Refer to: Check that individual injectors are functioning correctly. Injector Cut-Out, manual Check cylinder balance.
  • Page 80 Group 20 Step 4: Component and Function Checks C2002641 Action Refer to: Check for air in the fuel system. Group 23: Air in the Fuel System, Checking Check that the fuel quality is within specifications. Group 23: Fuel Quality, Checking Check that there is no carbon monoxide in the fuel.
  • Page 81 Group 20 Step 1: Fault Code Readings Fault tracing using relevant service information should always be carried out for relevant fault codes. Components/functions of special interest: • MID 128 — Engine ECU PID 84 Vehicle speed PID 91 Accelerator pedal PID 94 Fuel supply pressure PID 102...
  • Page 82 Group 20 Step 3: VCADS Pro Tests C2002640 Action: Refer to: Check sensor values. ”Sensor Values Check, (Engine Running)” Check that individual injectors are functioning properly. Injector Cut-Out, manual Check cylinder balance. Cylinder balancing, Check Check cylinder compression. Cylinder Compression, Test Check fuel supply pressure at low and high engine speeds.
  • Page 83 Group 20 Step 4: Component and Function Checks C2002641 Action: Refer to: Check for air in the fuel system. Group 23: Air in the Fuel System, Checking Check that the fuel quality is within specifications. Group 23: Fuel Quality, Checking Check that the fuel supply pressure is within the specification from idle speed through to Group 23: Fuel pressure, checking full engine speed.
  • Page 84 Group 20 Step 1: Fault Code Readings Freeze frames of information for specific fault codes may also be helpful for finding causes for the symptom. Fault tracing using relevant service information should always be carried out for relevant fault codes. Components/functions of special interest: •...
  • Page 85 Group 20 Step 3: VCADS Pro Tests C2002640 Action: Refer to: Check that individual injectors are functioning properly. Injector Cut-Out, manual Check cylinder balance. Cylinder balancing, Check Check cylinder compression. Cylinder Compression, Test Check sensor values. ”Sensor Values Check, (Engine Running)” Check fuel supply pressure.
  • Page 86 Group 20 Step 4: Component and Function Checks C2002641 Action: Refer to: Check that there is no carbon monoxide in the fuel. “Low Compression, Fault Tracing” (Checklist G), Information type “Diagnostics”, group 2103. Check that the fuel quality is within specifications. Group 23: Fuel Quality, Checking Check that the fuel supply pressure is within the specification from idle speed through to “Supply Pressure, Fault Tracing”...
  • Page 87 Group 20 PPID 122 VCB compression brake status SID 22 Engine speed, flywheel PPID 124 Exhaust pressure governor SID 254 Engine ECU SID 1–6 Unit injectors SID 21 Engine position, cam Action: Refer to: Check for active or inactive fault codes related to symptoms. Instrument cluster or VCADS Pro Check inactive codes with high number of occurrences.
  • Page 88 Group 20 Check cylinder balance. Cylinder balancing, Check Check cylinder compression. Cylinder Compression, Test Check start and warm-hold function. Warm-Hold Function, Test “Step 4: Component and Function Checks” page 85 “Engine Speed Surges Under Load or in Normal Operating Range” page 73...
  • Page 89 Group 20 Step 4: Component and Function Checks C2002641 Action: Refer to: Check that there is no carbon monoxide in the fuel. “Low Compression, Fault Tracing” (Checklist G), Information type “Diagnostics”, group 2103. Check the fuel lines, seals, and connections. Check for leakage, damage, or restrictions. Group 23: Fuel lines, check Check that the fuel is the correct rated quality.
  • Page 90 Group 20 Step 1: Fault Code Readings Fault tracing using relevant service information should always be carried out for relevant fault codes. Components/functions of special interest: • MID 128, Engine ECU PID 94 Fuel supply pressure PID 102 Intake manifold pressure PID 110 Coolant temperature PPID 122...
  • Page 91 Group 20 Step 2: Visual Inspection (System Checks) T2020217 Action: Refer to: Check that there is sufficient fuel in the tank(s). “Step 3: VCADS Pro Tests” page 87 “Engine Speed Surges in Power Take-off or Cruise Control” page 74 Step 3: VCADS Pro Tests C2002640 Action: Refer to:...
  • Page 92 Group 20 Step 4: Component and Function Checks C2002641 Action: Refer to: Check that there is no carbon monoxide in the fuel. Group 23: Carbon Monoxide (CO) in the fuel system, check Check for air in the fuel system. Group 23: Air in the Fuel System, Checking Check the fuel lines, seals, and connections.

  • Page 93: Engine Brake Complaints

    Group 20 Engine Brake Complaints Symptom fault tracing For specific symptoms, see: • “Engine Brake Does Not Function” page 90 Note: You must read and understand the precautions • “Poor Engine Brake Performance” page 90 and guidelines in Service Information, group 20, "General Safety Practices, Engine"...
  • Page 94 Group 20 Fault Tracing Temporary faults can be difficult to trace since the fault Begin by determining if anything has recently happened may not occur when the vehicle is brought in to be to the vehicle that could point to the electrical system, checked.
  • Page 95 Group 20 SID 231 SAE J1939 control link PPID 70 Pedal switches supply PPID 124 Exhaust pressure Governor, EPG 1 PPID 71 Cruise control and engine brake SID 231 SAE J1939 Control Link switches supply PSID 201 SAE J1939 Data Link Interruption SID 230 Idle validation switch 1 •...
  • Page 96 Group 20 “Step 4: Component and Function Checks” page 93 “Engine Brake Does Not Function” page 90 92“Step4:ComponentandFunctionChecks”page93“EngineBrakeDoesNotFunction”page90...
  • Page 97 Group 20 Step 4: Component and Function Checks C2002641 Action Refer to: Check that the oil temperature sensor is functioning properly. Group 28: Oil temperature sensor, checking Check that the intake manifold pressure sensor is functioning properly. Group 28: Intake manifold pressure, checking Check power supply and ground for engine ECU.
  • Page 98 Group 20 Step 1: Fault Code Readings • MID 128, Engine ECU PID 84 Vehicle speed PID 91 Accelerator pedal PID 102 Intake manifold pressure PPID 124 Exhaust pressure governor PID 175 Engine oil temperature PPID 122 Compression brake, VCB SID 146 EGR valve 1 SID 231...
  • Page 99 Group 20 Step 3: VCADS Pro Tests C2002640 Action: Refer to: Check engine brake function. Engine Brake Function, Test Check sensor values. ”Sensor Values Check, (Engine Running)” Check start and warm-hold function. Warm-Hold Function, Test Check EGR function. EGR Function, test Check cylinder compression.
  • Page 100 Group 20 Step 4: Component and Function Checks C2002641 Action: Refer to: Check that the oil temperature sensor is functioning properly. Group 28: Oil temperature sensor, checking Check that the intake manifold pressure sensor is functioning properly. Group 28: Intake manifold pressure, checking (sensor removed) Check power supply to engine ECU “Engine ECU, Fault Tracing”...
  • Page 102 Volvo Trucks North America, Inc. P.O. Box 26115, Greensboro, NC 27402-6115 Volvo Trucks Canada, Ltd. 5600A Cancross Court, Mississauga, Ontario L5R 3E9 http://www.volvotrucks.volvo.com PV776-20045033 (1000) 3.2006 © Volvo Trucks North America, Inc., 2006...

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