Workshop Manual System

Group 2 & 3
After-Treatment System
TAD580-3VE, TAD880-4VE, TAD1180-3VE
TAD1381-5VE, TWD1683VE/GE
 Table of Content

General Information
00-0 General ............................................................................................. 2

Specifications
03-2 Specifications, Engine .................................................................... 9
03-25 Inlet and Exhaust System ......................................................... 9

Safety and Other Instructions

05-1 Safety Instructions ........................................................................ 11

Special tools
08-2 Special Service Tools ................................................................... 16

Inlet and Exhaust System

25-8 Emission After-Treatment ............................................................ 17

General, Complete Vehicle Software

30-0 General ........................................................................................... 43
30-2 Fault Tracing ................................................................................. 44
Fault Codes ........................................................................................ 44
Measurements .................................................................................. 126
VODIA Log Parameters ................................................................... 131
VODIA Tests ..................................................................................... 132
Index ......................................................................................................... 135
References to Service Bulletins ............................................................ 137

47712292 02-2020 © AB VOLVO PENTA 1

00-0 General
About this Workshop manual
General information Certified engines
This Service Manual contains technical data, When carrying out service and repair on
descriptions and maintenance and repair instructions emission-certified engines, it is important to be
for standard model Volvo Penta products. A list of aware of the following:
these products may be found in the section
Specifications. Certification means that an engine type has been
inspected and approved by the relevant authority.
The product designation and the serial number and The engine manufacturer guarantees that all engines
specification is indicated on the engine decal or type of the same type are manufactured to correspond to
plate. This information must be included in all the certified engine.
correspondence regarding the product. This places special demands on service and repair
work, namely:
The service manual is produced primarily for the use
of Volvo Penta workshops and their qualified • Maintenance and service intervals
personnel. It is assumed that any person using the recommended by Volvo Penta must be
Service Manual has a fundamental knowledge of the complied with.
product and is able to carry out mechanical and • Only spare parts approved by Volvo Penta may
electrical work to trade standard. be used.
Volvo Penta continually develops its products; we • Service on injection pumps, pump settings and
therefore reserve the right to make changes. All injectors must always be carried out by an
information in this manual is based on product data authorized Volvo Penta workshop.
which was available up to the date on which the
• The engine must not be converted or modified,
manual was printed. New working methods and
except with accessories and service kits which
significant changes introduced to the product after
Volvo Penta has approved for the engine.
this date are communicated in the form of Service
bulletins. • No changes to the exhaust pipe and engine air
inlet duct installations may be made.
Spare Parts
• No warranty seals (where present on the
Spare parts for the electrical and fuel systems are product) may be broken by unauthorized
subject to various national safety standards. Volvo persons.
Penta Original Spare Parts meet these standards. No
damage of any kind caused by the use of spare parts The general instructions in the Operator's Manual
not approved by Volvo Penta will be compensated by concerning operation, service and maintenance
any warranty undertaking. apply.

IMPORTANT!
Neglected or poorly-performed care/service and the
use of spare parts not approved by Volvo Penta, will
mean that AB Volvo Penta no longer guarantees that
the engine conforms to the certified model.

Volvo Penta accepts no responsibility for damage or

costs arising as a result of failure to follow the above
mentioned standards.

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 00-0 General

Repair instructions
Introduction Our Mutual Responsibility
The working methods described in this manual are Each product comprises a large number of interacting
based on a workshop scenario where the product is systems and components. A deviation from the
mounted in a workholding fixture. Maintenance work technical specification may dramatically increase the
is often carried out in situ, in which case - if nothing environmental impact of an otherwise reliable
else is indicated - using the same working methods system. It is therefore critical that the stated wear
as the workshop. tolerances be adhered to, that systems which can be
adjusted be correctly set up and that only Volvo Penta
Warning symbols that occur in the service manual. Original Parts are used. The intervals in the care and
For significance, refer to Safety Information. maintenance schedule must be followed.
Some systems, e.g. fuel systems, often require
DANGER! special expertise and test equipment. A number of
components are factory-sealed, for among other
WARNING! things environmental reasons. Warranty-sealed
components may not be worked on without
CAUTION! authorization to perform such work.
IMPORTANT!, NOTE! Remember that most chemical products, incorrectly
are by no means comprehensive since not everything used, are harmful to the environment. Volvo Penta
can be foreseen as service work is carried out in the recommends the use of biodegradable degreasers
most varied of circumstances. We call attention to whenever components are cleaned, unless otherwise
risks that may occur due to incorrect handling during specified in the Service Manual. When working
work in a well-equipped workshop using working outdoors, take especial care to ensure that oils and
methods and tools tried and tested by us. wash residues etc. are correctly properly for
destruction.
The service manual describes work operations
carried out with the aid of Volvo Penta Special Tools,
Tightening torque
where such have been developed. Volvo Penta
Special Tools are designed to ensure the safest and Tightening torques for vital fasteners that must be
most rational working methods possible. It is applied using a torque wrench are indicated in the
therefore the responsibility of anyone using tools or Service Manual, chapter Tightening torques and in
working methods other than those we recommend to the Manual's work descriptions. All torque indications
ensure that no risk of personal injury or mechanical apply to clean threads, bolt heads and mating faces.
damage is present, or that malfunction can result. Indicated torque data apply to lightly-oiled or dry
threads. If lubricants, locking fluids or sealants are
In some cases, special safety regulations and user required for fasteners, the correct type will be
instructions may be in force for the tools and indicated in the job description.
chemicals mentioned in the Service Manual. These
rules must always be observed, so there are no Torque, angle tightening
special instructions about this in the workshop
manual. When torque/angle tightening, the fastener is
tightened to a specified torque, and tightening then
By following these basic recommendations and using continues through a pre-determined angle.
common sense it is possible to avoid most of the risks
involved in the work. A clean workplace and a clean Example: For 90° angle tightening, the fastener is
product will eliminate many risks of personal injury turned an additional 1/4 turn in one sequence, after
and malfunction. the specified tightening torque has been achieved.

Above all, when working on fuel systems, hydraulic

systems, lubrication systems, turbochargers, inlet
systems, bearings and seals, it is of the utmost
importance that dirt and foreign objects are kept
away, as malfunctions or shortened service intervals
may otherwise result.

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00-0 General

Lock nuts Anaerobic agents.

These agents cure in the absence of air. These
Removed lock nuts may not be re-used; they must be preparations are used when two solid components,
replaced by new ones, as locking properties are e.g. two cast components, are fitted together without
impaired or lost with re-use. a gasket. Common uses are also to lock and seal
In the case of lock nuts with plastic inserts, the plugs, stud threads, taps, oil pressure monitors etc.
tightening torque indicated must be reduced if the nut
has the same nut height as a standard, all-metal Hardened anaerobic preparations are vitreous and
hexagonal nut. for this reason, the preparations are colored to make
Reduce the torque by 25% for bolt sizes of 8 mm or them visible. Hardened anaerobic preparations are
larger. highly resistant to solvents, and old compound
In the case of lock nuts with plastic inserts with a high cannot be removed. On re-assembly, it is important
nut-height (where the all-metal thread is as high as a to carefully degrease and wipe dry components first,
standard hexagonal nut), the indicated torque before applying new sealant in accordance with the
applies. instructions.

Strength Classes Safety regulations for fluorocarbon

Nuts and bolts are grouped into different strength rubber
classes. Their classification is shown by a marking on Fluorocarbon rubber is a common material in seal
the bolt head. Markings of a higher number indicate rings for shafts, and in O-rings, for example.
stronger material. For example, a bolt marked 10-9 is
stronger than one marked 8-8. When fluorocarbon rubber is exposed to high
temperatures (above 300°C/572°F), hydrofluoric acid
For this reason, it is important that when bolted joints can form. This is highly corrosive. Contact with the
are removed they are returned to their original skin can result in severe chemical burns. Splashes in
locations on re-assembly. When replacing bolts, your eyes can result in corrosive wounds. If you
check the applicable Spare parts catalog to ensure breathe in the fumes, your lungs can be permanently
the correct bolt is used. damaged.

Sealing compounds etc. WARNING!

To ensure service work is correctly carried out, it is Seals must never be cut with a torch, or be burnt
important that the correct type of sealants and locking afterwards in an uncontrolled manner. Risk for
fluids are used on joints where such are required. poisonous gases.

In each service manual section concerned, the WARNING!

sealants used in product manufacture are indicated. Always use chloroprene rubber gloves (gloves for
The same sealants, or sealants with equivalent chemicals handling) and goggles. Handle the
properties, must be used for maintenance work. removed seal in the same way as corrosive acid. All
A service technician should have a basic knowledge residue, including ash, can be highly corrosive. Never
of how sealing compounds are handled, and are able use compressed air to blow clean.
to assess the condition of existing seals. Put the remains in a plastic container, seal it and
apply a warning label. Wash the gloves under running
Make sure that mating surfaces are dry and free from water before removing them.
oil, grease, paint and anti-corrosion agent before
applying sealant or locking fluid. Always follow the The following seals are most probably made from
manufacturer's instructions regarding applicable fluorocarbon rubber:
temperatures, hardening times and such.
Seal rings for the crankshaft, camshaft, idler shafts.
Two basic types of compound are used:
O-rings, regardless of where they are installed. O-
RTV preparations (Room Temperature rings for cylinder liner sealing are almost always
Vulcanizing). made of fluorocarbon rubber.
Used most often together with gaskets, e.g. sealing
gasket joints, or are brushed on gaskets. RTV Please note that seals which have not been
sealants are completely visible when the part has exposed to high temperature can be handled
been removed. Old RTV sealant must be removed normally.
before the component is sealed again. Use
denatured alcohol.

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 00-0 General

EATS Warnings and Inducements

If excessive NOx levels are reached, the engine will
lose power after a given period. High NOx levels may
result from faults, low AdBlue®/DEF level in the tank
or poor AdBlue®/DEF quality.

A warning will be displayed on the instrument panel by

means of a lamp (constant or flashing light) depending
on when the fault occurred and how long it has
persisted.

Following torque limitation, the engine can be restored

to full output using equipment from a Volvo Penta
workshop. The following pages describe by means of
text and illustrations various courses of events that
govern engine torque limitation in both Europe and the
USA.

There may be variations and different occurrence

between Europe and USA. This chapter is not
completely exhaustive.

NOTICE! Diagnostics can be carried out at any time

during the events described on the following pages and
if faults detected are remedied, the engine recover full
toque and engine speed.

NOTICE! Not applicable for D13 IMO III.

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00-0 General

EATS Inducements

EU
NOTICE! In some cases the Vodia operation ”Erase
All” DTCs needs to be performed after a repair/service
to be able to exit inducement mode.

Low tank level

1 When the level in the DEF/AUS tank falls to 15 %, a warning lamp lights up.
2 When the tank level has dropped to around 6 % the warning lamp will flash. Engine torque will drop to 75 %.
Ramp-down takes around 1 minute.
3 The engine will ramp down to 50 % torque 7 minutes after the tank level reaches 6 % and rpm will be limited
to 60 %, i.e. around 1600 rpm. Ramp-down takes around 3 minutes.
4 If the engine is re-started when the tank level is below 6 % the engine will only run at 50 % torque and rpm
will be limited to 60 %, i.e. around 1600 rpm.
5 For the engine to revert to full power the tank level must be above 12 %. The tank level must be above 21 %
for the system to extinguish the warning lamp and cancel the fault message.

Dosing and AdBlue/DEF quality

1 2
5
A 30 min

100% 3
10 h
75 %
10 h 4

50 %

0%
0h B
P0018676

A Engine rpm and torque

B Time axis

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 00-0 General

1 A fault is detected and the warning lamp lights up.

2 If the fault is not remedied within 10 hours engine power will drop to 75 %. Ramp-down takes around 1
minute. The warning lamp flashes.
3 After a further 10 hours the engine will drop to 50 % torque and rpm will be limited to 60 %, i.e. around 1600
rpm. Ramp-down takes around 1 minute.
4 Upon re-start the engine will run at max 50 % torque and rpm will be limited to 60 %, i.e. around 1600 rpm.
Service tools will be required to reset the system.
5 Depending on the installation, it is possible after the first 20 hours to manually override the system actions
and run the engine at full power for 3 x 30 minutes. After 30 minutes the engine drops to 50 % power. Each
30-minute period requires a manual activation.
6 If an additional fault recurs within 40 hours after the first fault was remedied, available running time will be
reduced to 120 minutes from the moment the fault is detected.

AdBlue high temperature and component fault

1 2 30 min 6 5
A
100% 3
36 h
75 %
4
64 h
50 %

0%
0h B
P0018677

A Engine rpm and torque

B Time axis

1 A fault is detected and the warning lamp lights up.

2 If the fault is not remedied within 36 hours engine power will drop to 75 %. Ramp-down time is approx 1
minute. The warning lamp flashes.
3 After a further 64 hours the engine will drop to 50 % torque and rpm will be limited to 60 %, i.e. around 1600
rpm.
4 Upon re-start the engine will run at max 50 % torque and rpm will be limited to 60 %, i.e. around 1600 rpm.
5 When the fault is remedied the engine will revert to full power.
6 Depending on the installation, it is possible after the first 100 hours to manually override the system actions
and run the engine at full power for 3 x 30 minutes. After 30 minutes the engine drops to 50 % power. Each
30-minute period requires a new manual activation.
7 If a fault recurs within 40 hours, available running time will be reduced to 300 minutes from the moment the
fault is detected.

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00-0 General

EATS Inducements

EPA/CARB

NOTICE! In some cases the Vodia operation ”Erase

All” DTCs needs to be performed after a repair/service
to be able to exit inducement mode.

Low tank level

1 When the level in the DEF tank falls to 15%, a warning lamp lights up.
2 When the tank level has dropped to around 6% the warning lamp will flash. Engine torque will drop to 75%.
Ramp-down takes around 1 minute.
3 The engine will drop to idle with a 50% torque reduction 7 minutes after the tank level reaches 6%. Ramp-
down takes around 3 minutes.
4 If the engine is started when the tank level falls below 6%, the engine will only run at idle.
5 For the engine to revert to full power the tank level must be above 12%. The tank level must be above 21%
for the system to extinguish the warning lamp and cancel the fault message.

AdBlue/DEF high temperature, quality and component faults

1 10 min
2 5
A 6
100% 3

75 % 4

50 %

0%
0h 3.5 h 27 B
P0018675 min

A Engine rpm and torque

B Time axis

1 A fault is detected and the warning lamp lights up.

2 If the fault is not remedied after 3.5 hours engine torque will drop to 75%. Ramp-down takes around 1 minute.
The warning lamp flashes.
3 After 27 minutes the engine will drop to idle with a 50% torque reduction. Ramp-down takes around 3
minutes.
4 Following re-start, the engine will run at idle with a 50% torque reduction. DEF quality problems will require
service tools to reset the system.
5 When component faults are remedied the engine will revert to full power.
6 Depending on the installation, it is possible after the first 3.5 hours, but before 4 hours, to manually override
the system actions and run the engine at full power for 2 x 10 minutes. After 10 minutes the engine drops
to 75% power. Each 10-minute period requires a manual activation.
7 If an additional fault recurs within 40 hours after the first fault was remedied, available running time will be
reduced to 30 minutes from the moment the fault is detected.

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 03-2 Specifications, Engine

03-2 Specifications, Engine

Inlet and Exhaust System

Technical Data

TAD580-3VE, TAD880-4VE, TAD1180-3VE

P0030615

POS Designation Tightening torque, Nm Notes

1 V-band clamp, connection pipe 20
2 LV-band clamp 12
3 Installation clamp 22
4 V-band clamp, DPF Stage 1: 10 Use new V-band clamps
Stage 2: 23 Tighten the clamps
alternately
5 Bolt 10
6 NOx sensor 50
7 Bolts, injector (D): 8
8 Exhaust temperature sensor DPF 45
9 Pipe connection, DPF differential pressure sensor 30 DP pipes
10 Bolts, differential pressure sensor 10 DP sensor.

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03-2 Specifications, Engine

Technical Data

TAD1381-5VE

P0030604

POS Designation Tightening torque, Nm Notes

1 V-band clamp, mixer cover, small Stage 1: 10 Use new V-band clamps
Stage 2: 24 Tighten clamps 1 and 2
alternately
2 V-band clamp, mixer cover, large Stage 1: 10 Use new V-band clamps
Stage 2: 20 Tighten clamps 1 and 2
alternately
3 Installation clamp 48
4 LV-band clamp 12
5 Bolt 10
6 NOx sensor 50
7 Bolt, injector (dosage valve) 8
8 Exhaust temperature sensor 45
9 Pipe connection, differential pressure sensor 30
10 Bolts, differential pressure sensor 10 DP pipes
11 Plug 30 DP sensor.

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 05-1 Safety Instructions

05-1 Safety Instructions

Safety Information
This workshop manual contains repair instructions,
descriptions and technical data for products or product
drawings from Volvo Penta. Check that you have the
correct workshop manual.

Read the safety information below and the section About this Workshop manual and Repair instructions
carefully before beginning any work with repairs or service.

!
In the workshop manual and on the product, this symbol is used to call your attention to the fact that this is safety
information. Always read such information very carefully.
Warning texts in the manual have the following order of priority:

DANGER!
Indicates a hazardous situation, which, if not avoided, result in death or serious injury.

WARNING!
Indicates a hazardous situation, which, if not avoided, could result in death or serious personal injury.

CAUTION!
Indicates a hazardous situation, which, if not avoided, could result in minor or moderate personal injury.

IMPORTANT!
Is used to make you aware of something that may cause minor damage or a minor malfunction to the product or
property.

NOTICE! Is used to make you aware of important information that will facilitate the work or operation in progress.

This symbol is used on certain functions to indicate the following:

This operation requires prior theoretical and/or instructor led training before attempting.Contact your local training
organization for further information.

This symbol informs you that supplemental information needs to be read. And where necessary information can
be found.

This symbol is used when a VODIA computer is needed, either for troubleshooting, testing or programming.

A compilation of safety precautions that must be taken and risks which you must be aware of is presented
in the following pages.

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05-1 Safety Instructions

Immobilize the engine by turning off the power Avoid opening the coolant filling cap when the
! supply with the main switch(es) and lock it ! engine is hot. Steam or hot coolant may spray
(them) in the off position before starting work. out and the system can lose pressure. Open the
Place a warning notice at the main switch. filler cap slowly, and release the pressure in the
cooling system if the filler cap or valve has to be
opened, or if a plug or coolant hose has to be
removed while the engine is hot.

As a general rule, all service operations must be Hot oil can cause burn injuries. Avoid exposing
! carried out with the motor stopped. However, ! your skin to hot oil. Make sure that the
some work, such as adjustments, will require lubrication system is not under pressure before
the engine to be running. Approaching a any work is begun. Never start or run an engine
running engine is a safety risk. Remember that without the oil filler cap in place. Hot oil under
loose clothing and long hair can fasten in pressure can spray out.
rotating parts and cause serious personal
injury.

Be aware of hot surfaces (exhaust pipes, Never start the engine without the air filter in
! turbocharger, charge air pipe, starting heaters, ! place. The rotating compressor turbine in the
etc.) and hot liquids in supply lines and hoses turbocharger can cause severe injury. Foreign
on an engine that is running or has just stopped. objects entering the intake ducts can also cause
A careless movement or a dropped tool may, in mechanical damage. Install all protective
the worst case, result in personal injury when covers before starting the engine.
working in the vicinity of a running engine.

Make sure that all warning and information Only start the engine if the surrounding
! decals on the product are always visible. ! ventilation is satisfactory. When operating in a
Replace decals that have been damaged or confined space, exhaust fumes and crankcase
painted over. gases must be led away from the engine
compartment or workshop area.

Avoid getting oil on the skin! Protracted or The majority of chemicals, e.g. engine and
! repeated exposure to oil can cause skin to ! transmission oils, glycol, gasoline, and diesel
become dry. Irritation, dryness, eczema and oil, together with chemicals for workshop use
other skin problems may then result. Used oil is such as degreasing agents, paints and
more dangerous than fresh oil from a health solvents, are health hazards. Carefully read the
aspect. Use protective gloves and avoid oil- instructions on the product packaging! Always
soaked clothes and rags. Wash regularly, follow the safety directions for a product, e.g.
especially before eating. Use suitable with regard to use of protective mask, glasses,
protective creams to counteract skin dryness gloves, etc. Make sure that other personnel are
and to aid dirt removal. not exposed to substances that are health
hazards. Ensure good ventilation. Handle used
and leftover chemicals in the prescribed
manner.

Turn off the engine and disconnect the power at Only make connection adjustments with the
! the main switch(es) before starting work on the ! engine switched off.
electrical system.

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 05-1 Safety Instructions

Always wear protective goggles if there is a risk Never start the engine with the valve cover
! of splinters, sparks and splashes from acid or ! removed. There is a risk of personal injury.
other chemicals. Your eyes are extremely
sensitive, injury to them could result in
blindness!

Never use start gas or similar products as a Stop the engine before working on the cooling
! starting aid. They may cause an explosion in the ! system.
inlet manifold. Danger of personal injury. Marine engines: Close the seacock/cooling
water inlet valve before starting work on the
cooling system.

All fuels, and many chemicals, are flammable. Make sure that rags soaked in oil or fuel and
! Never allow open flames or electrical sparks in ! used fuel and oil filters are stored safely. Oil-
the their vicinity. Gasoline, certain solvents and soaked rags may ignite spontaneously in
hydrogen from batteries are extremely certain conditions. Used fuel and oil filters are
flammable and explosive in the right environmentally hazardous waste and must be
concentration in air. No smoking! Ensure the taken to an approved waste management
work area is well ventilated and take the facility for correct handling, as must any used
necessary safety precautions before welding or lubricating oil, contaminated fuel, paint residue,
grinding work is begun. Always ensure that solvents, degreasers and wash residue.
there are fire extinguishers close at hand in the
work area.

Batteries must never be exposed to open Never work alone when dismantling heavy
! flames or electrical sparks. Never smoke in the ! components, even when using lifting equipment
vicinity of the batteries. During charging they such as lifting devices with lockable blocks. Two
generate hydrogen gas, which is explosive people are usually required when using a lifting
when mixed with air. This gas mixture is easily device; one to operate the lifting device and the
ignited and highly explosive. A spark, which can other to make sure the components do not
be caused by incorrect battery connection, is collide with objects and suffer damage during
enough to cause the battery to explode and the hoist.
cause serious damage.

Do not touch the connections during a starting

attempt. Spark hazard! Do not lean over
batteries.

Never mistake the positive (+) for the negative Use the loops on the engine when lifting it.
! (-) battery pole when installing batteries. ! Always check that the hoisting equipment is in
Incorrect pole connections can result in serious good condition and has the capacity to lift the
damage to electrical equipment. Refer to the engine (engine weight including gearbox and
wiring diagram. any auxiliary equipment installed). The engine
Always wear protective goggles when charging must be lifted with a properly adjusted lifting
or handling the batteries. The battery electrolyte boom to ensure safe handling and avoid
contains sulfuric acid which is highly corrosive. damage to components fitted to the top of the
Rinse immediately with plenty of water and engine. All chains or wires must run parallel to
soap if battery electrolyte comes into contact each other and be as perpendicular to the
with unprotected skin. If you get battery acid in engine as possible. If the engine has equipment
your eyes, flush at once with a generous fitted that alters its center of gravity, special
amount of water, and get medical assistance at lifting devices may be required to achieve the
once. correct balance for safe handling. Never carry
out any work on an engine that is only
suspended by lifting equipment.

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05-1 Safety Instructions

The components in the electrical and fuel Take extreme care when searching for fuel
! systems on Volvo Penta products are designed ! system leaks and testing fuel injector nozzles.
and manufactured to minimize the risk of fire Wear safety goggles. The jet from a nozzle is
and explosion. The engine must not be under very high pressure and has great
operated in areas where there are explosive penetration power. Fuel can penetrate deep
materials or gases. into body tissue and cause severe injury. There
is a risk of blood poisoning (septicemia).

Only use fuels and lubricating oils as Never use a high-pressure washer to clean the
! recommended by Volvo Penta. Refer to the ! engine.
operator's manual for the product concerned. Pay attention to the following when using a high-
Using fuels that are of a lower grade may pressure washer on components other than the
damage the engine, the injection pump and the actual engine: Never aim the water jet at seals,
injectors. In the case of diesel engines, low- rubber hoses or electrical components.
quality fuel may cause the control rod to stick
and the engine to overrev with the risk of engine
damage and personal injury as a result. Low-
quality fuel and oils may lead to higher service,
maintenance and repair costs.

Under no circumstances may fuel pipes be bent When overhauling an engine, perform leakage
! or straightened. Cracks may occur. Damaged ! and functional checks as necessary.
pipes must be replaced.

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 05-1 Safety Instructions

Requirements for work with after-

treatment system (EATS)

The following information must be observed for work performed on engines equipped with an after-treatment
system.
All work must be carried out in well-ventilated premises that meet health, safety and other national or international
requirements.

AdBlue/Diesel Exhaust IMPORTANT:

Fluid (DEF): • Always wait at least 2 minutes after ignition has been interrupted before
beginning work.
• AdBlue/DEF and urea solutions cause corrosion damage.
Avoid removing or loosening AdBlue/DEF hoses or electrical lines unless
the work requires this.
Always clean the AdBlue/DEF system before carrying out any from of work.
Use lukewarm water when cleaning.
• Always plug AdBlue/DEF and urea hoses in order to avoid dirt in the
AdBlue/DEF and urea system, and any crystallization of AdBlue/DEF.
• Tools that have come into contact with AdBlue/DEF or urea solution must
be cleaned.
Protective gloves must be discarded after use.
Remove contaminated clothing.

SCR catalyzer: WARNING!

• Use nitrile gloves and goggles.
• Keep in mind that SCR can contain residue of AdBlue/DEF.
• Never cut off, cut or machine an SCR. There is a risk of exposure to harmful
gases.
• If the casing is damaged, a protective mask must be used.

Particulate filter: WARNING!

• Always allow the components to cool to room temperature before starting
work.
• Use nitrile gloves goggles and protective filter mask.
• Handle the particulate filter with care.
Never try to cut off, cut or machine a particulate filter.
There is a risk of exposure to very harmful substances.
• Always follow the instructions that apply for the transport of particulate filter.

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08-2 Special Service Tools

08-2 Special Service Tools

The following special tools are used when working on
the engine. The tools can be ordered from AB Volvo
Penta by specifying the number indicated.

p0005125
P0008793
9990014 Break-out cable 9998699 Break-out box 88890074 Multimeter

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 25-8 Emission After-Treatment

25-8 Emission After-Treatment

Repair instructions
NOTICE! Because the illustrations in the maintenance
literature are used for different engine variants, certain
details may vary compared to the actual model
concerned. The essential information in the
illustrations is always correct, however.

IMPORTANT!
AdBlue/DEF and urea solutions cause corrosion
damage. Do not remove AdBlue/DEF hoses, urea
hoses or electrical wiring during normal service or
when moving a component. Tools that have come into
contact with AdBlue/DEF or urea solution must be
cleaned.

CAUTION!
Gloves must be changed. Take off contaminated
clothes.

WARNING!
In the case of any contact with eyes or skin the affected
area must be thoroughly rinsed with lukewarm water.
If you inhale any fumes, make sure you breathe fresh
air.

NOTICE! Always plug AdBlue/DEF and urea hoses in

order to avoid dirt in the AdBlue/DEF system, and any
crystallization of AdBlue/DEF.

NOTICE! Clean the AdBlue/DEF system before any

type of work is done to avoid dirt.

IMPORTANT!
Fluids other than AdBlue/DEF (such as diesel) and that
are not approved by Volvo, will cause a breakdown of
the exhaust aftertreatment system.

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25-8 Emission After-Treatment

Electrically Heated AdBlue/DEF

Hose, Change

See Requirements for work with after-treatment

system (EATS), page 15.

1 NOTICE! Wait at least 2 minutes after engine

stop so that the automatic drainage function is
depressurized before beginning to remove
components.
2 Remove the hose.
3 Install a new hose.

P0025276

4 Run the Urea pressure build up test.

Check that there are no leaks.

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 25-8 Emission After-Treatment

AdBlue/DEF Tank, Change

See Requirements for work with after-treatment

system (EATS), page 15.

Tools:
1 NOTICE! Wait at least 2 minutes after engine
stop to give the automatic drainage function time
to complete operations. Make sure the system is
depressurized before beginning to remove
components.
2 Unscrew the hexagonal cover (1).
Remove the drain screw (2) and empty the tank.
3 Remove the tank fittings; refer to Combined Tank
Unit, AdBlue/DEF Tank, Change, page 34.

P0019366

4 Hold the tank securely and remove the bolts.

P0025278

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25-8 Emission After-Treatment

5 Lift the tank module and pull it carefully out of the

locating pins on the bracket.

P0019369

6 Remove the bolts.

P0019370

7 Remove the bolts.

P0019372

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 25-8 Emission After-Treatment

8 Remove the bolts and hose holder.

P0019373

9 Carefully pry the tank sides (1) apart and then pull
out the tank (2). Be aware that the venting hose
is attached.
10 Install the new tank in reverse order.

P0019374

11 Run the Urea pressure build up test.

Check that there are no leaks.

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25-8 Emission After-Treatment

AdBlue/DEF Tank, Cleaning

See Requirements for work with after-treatment

system (EATS), page 15.

AdBlue/DEF contamination
If a fluid other than AdBlue/DEF is used in the system, or if the AdBlue/DEF tank is contaminated with other
material, the AdBlue/DEF system must be assessed, cleaned and tested to ensure it is functioning correctly.
This information provides general guidelines for the inspections that must be carried out and the actions that
must be taken if the AdBlue/DEF tank is contaminated.
The technician is expected to be acquainted with the SCR system and be able to judge of components can be
cleaned or must be replaced.

Inspection
Action: Checking for diesel or oil in the AdBlue/DEF solution, page 36.

Cleaning / replacement
If the tank has been contaminated by diesel, biodiesel, oil/grease, solvents or alkaline cleaning agents, the
tank fittings must be replaced and all hoses thoroughly cleaned with warm water.

Contamination < 20% Contamination > 20%

Change Change
• Pump unit • Pump unit
• Dosing unit • Dosing unit
• Tank fittings • Tank fittings
• All filters • AdBlue/DEF tank

Clean • All AdBlue/DEF hoses

• Use hot water to clean the AdBlue/DEF tank and • All filters
all AdBlue/DEF hoses.

NOTICE! Operations with contaminated AdBlue/DEF over extended periods can damage the SCR silencer. High
emissions following a complete cleaning as described above indicate a replacement of the SCR silencer may be
necessary.

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 25-8 Emission After-Treatment

1 Remove the tank module and tank fittings; refer

to steps 1–5 AdBlue/DEF Tank,
Change, page 19.
2 Flush through the tank fitting with warm water.
Replace the tank fitting filter.

P0019379

3 Remove the filler filter.

Place the cover and the unit in warm water for at
least 2 minutes.

P0019380

4 Flush the tank with hot water for at least 10

minutes.
5 Install in reverse order with a new filler filter and
breather filter.

NOTICE! Fit the drain screw.

P0019381

6 Run the Urea pressure build up test.

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25-8 Emission After-Treatment

Check that there are no leaks.

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 25-8 Emission After-Treatment

Exhaust Temperature Sensor,

Change
1 Disconnect the battery negative terminal.
2 Remove the cable ties.
3 Disconnect the connector.
4 Disconnect and remove the temperature sensor.
5 Screw in a new temperature sensor.
6 Connect the connector. Attach new cable ties.
7 Reconnect the battery negative terminal.
8 Start the engine. Check operation and inspect for
leaks.
9 Delete any fault codes.
P0019383

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25-8 Emission After-Treatment

Dosing unit, change

See Requirements for work with after-treatment

system (EATS), page 15.

1 NOTICE! Wait at least 2 minutes after engine

stop to give the automatic drainage function time
to complete operations. Make sure the system is
depressurized before beginning to remove
components.
2 Disconnect the connector.

P0025288

3 Remove the hoses.

P0025276

4 Remove the dosing valve.

5 Clean the contact surfaces.
6 Install the dosage valve.
Tightening torque: 8 Nm

P0025289

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 25-8 Emission After-Treatment

7 Run the Urea pressure build up test.

Check that there are no leaks.
8 Run the Urea adaption Reset operation.

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25-8 Emission After-Treatment

AdBlue/DEF-Pump Filter, Change

See Requirements for work with after-treatment

system (EATS), page 15.

1 NOTICE! Wait at least 2 minutes after engine

stop to give the automatic drainage function time
to complete operations. Make sure the system is
depressurized before beginning to remove
components.
2 Unscrew the filter cover.

P0019389

3 Remove the rubber gasket.

Pull out the filter. Use the puller (supplied with the
filter kit).

P0019390

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 25-8 Emission After-Treatment

4 Install as illustrated.
Filter cover:
Tightening torque: 20 Nm.

P0019391

5 Run the Urea pressure build up test.

Check that there are no leaks.

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25-8 Emission After-Treatment

Solenoid Valve, AdBlue/DEF Tank,

Change

See Requirements for work with after-treatment

system (EATS), page 15.

Tools:
1158957 Pliers
1 Pinch off the coolant hoses.
Remove the hoses.

A
p0013271

2 NOTICE! When installing the valve. Check valve

installation direction. Arrow toward tank.

P0025292

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 25-8 Emission After-Treatment

Pump Unit, Change

See Requirements for work with after-treatment

system (EATS), page 15.

1 NOTICE! Wait at least 2 minutes after engine

stop to give the automatic drainage function time
to complete operations. Make sure the system is
depressurized before beginning to remove
components.
2 Disconnect the connector.

P0025290

3 Remove the hoses.

P0019394

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25-8 Emission After-Treatment

4 Remove the pump.

5 Install the new pump in reverse order.

P0025291

6 Run the Urea pressure build up test.

Check that there are no leaks.
7 Run the Urea adaption Reset operation.

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 25-8 Emission After-Treatment

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25-8 Emission After-Treatment

Combined Tank Unit, AdBlue/DEF

Tank, Change

See Requirements for work with after-treatment

system (EATS), page 15.

Tools:
1158957 Pliers

1158957 1 NOTICE! Wait at least 2 minutes after engine

stop to give the automatic drainage function time
to complete operations. Make sure the system is
depressurized before beginning to remove
components.

p0013226
P0013226

2 Pinch off the coolant hoses (B).

3 Remove the hoses. Seal the connectors (A) in a
plastic bag.

P0019367

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 25-8 Emission After-Treatment

4 Remove the hose clamp.

Lift out the tank fitting.
5 Install the new tank fitting in reverse order.

P0025293

6 Run the Urea pressure build up test.

Check that there are no leaks.

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25-8 Emission After-Treatment

Checking for diesel or oil in the

AdBlue/DEF solution

See Requirements for work with after-treatment

system (EATS), page 15.

1 Remove the inset in the tank inlet for better visibility

and access to the liquid

P0019380

2 Dip half the indicator paper in the AdBlue solution

in the tank.
3 Attach the indicator paper to a suitable rod so that
it can reach the surface.

Evaluation
• If there is diesel or oil in the liquid, that part of the
paper that is dipped will become dark-blue in color.
• A so small a portion of diesel as 0.5% can be
detected
• The largest part of the diesel will remain on the
P0020548 surface in the AdBlue/DEF solution , but traces of
diesel can be found in the entire tank.
• The system is very sensitive to an incorrect AdBlue/
DEF solution.

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 25-8 Emission After-Treatment

Checking urea concentration in the

fluid
Tools:
88890105 Refractometer

NOTICE! Rinse the test equipment carefully with

distilled water before use.

1 Remove the insertion in the tank inlet for better

visibility and access to the fluid.
2 Draw in a small amount of the liquid from the
surface using the pipette.
Use a clean hose as extension to the pipette if tank
level is low.

P0019380

3 Apply a drop on the viewer of the instrument

(88890105 Refractometer).

Evaluation
• The level must be exactly on the line for correct
concentration.
• The system is very sensitive for incorrect urea
solution.
• If no level is shown in the instrument it may indicate
chemical residue, such as pure water or diesel.

P0020549

Particulate Filter Insert, Replace

TAD580-3VE, TAD880-4VE, TAD1180-3VE

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25-8 Emission After-Treatment

First read the instructions Requirements for work with

after-treatment system (EATS), page 15.

Removal
IMPORTANT:

Protect the dosage valve with a plastic bag.

1 Undo / remove:
• disconnect the inlet and outlet pipes (A)
• remove the harness connectors from the
NOx sensors (B)
• DP pipes (C)
• dosage valve with all hoses (D). Move aside
and secure.

P0030599

2 NOTICE! Handle the filter carefully.

NOTICE! The DOC/DPF filter unit weighs 32 kg.

Secure the unit for removal.

3 Undo and open the installation straps.
Remove the unit and move it to a workbench.

P0030602

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 25-8 Emission After-Treatment

4 Remove:

NOTICE! Note the orientation of the end covers

(A, C).

• V band clamp (E)

• gasket (D)
• inlet cover (A), DOC
• outlet end cover (C)
5 Inspect the DOC and remove any soot.
The removed DPF (B) must be placed in the
protective bag supplied.

P0030601

Installation
6 NOTICE! Use new components.

Transfer the end covers to the new DPF.

Grease the V-band clamps with graphite paste.
Lightly tighten the clamps.
7 Install the unit and tighten the installation straps
lightly.
Adapt the end cover positions.
8 Tighten the clamps.
Tightening torque, V-band clamps (E):
Stage 1: 10 Nm
Stage 2: 23 Nm
Tightening torque for installation straps (F): 22
Nm

P0030600

9
10 Install and fasten:
• inlet pipe (A) 12 Nm
• harness connector (B), Nox sensors
• DP pipe (C), 30 Nm
• attachment bolts, injector (D), 8 Nm
• V-band clamp (E), mixing pipe, 20 Nm

P0030603

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25-8 Emission After-Treatment

11 Run VODIA operation “DPF Reset”.

P0024905

Particulate Filter Insert, Replace

TAD1381-5VE

First read the instructions Requirements for work with

after-treatment system (EATS), page 15.

Removal
1 Disconnect the harness connector to:
• dosage valve
• exhaust temperature sensor
2 Remove the hoses.
3 Disconnect the pipe to the differential pressure
sensor.

P0030597

4 NOTICE! A minimum of 150 mm clearance

behind the cover is necessary to allow removal of
the cover and the DPF insert.

Remove the clamps and discard them.

Remove the mixer cover.

P0030598

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 25-8 Emission After-Treatment

5 NOTICE! Handle the filter carefully.

Pull out the DPF.

Remove and discard the seals.
6 Inspect the filter holder and remove any soot.
The removed DPF must be placed in the
protective bag supplied.

P0030596

Installation
7 NOTICE! Use new components.

Install the DPF.

8 NOTICE! Use new components.

Install the mixer cover.

Grease the V-band clamps with graphite paste.
9 Tighten the clamps alternately.
Stage 1: 10 Nm
Stage 2: Clamp, mixer cover, small 24 Nm
Stage 2: Clamp, mixer cover, large 20 Nm

P0030595

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25-8 Emission After-Treatment

10 Install the hoses.

11 Connect the pipe to the differential pressure
sensor.
Tightening torque 30 Nm
12 Connect the harness connector to:
• dosage valve
• exhaust temperature sensor

P0030597

13 Run VODIA operation “DPF Reset”.

P0024905

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 30-0 General

30-0 General
DTC interpretation
Type of DTC:
• P = Powertrain
• U = Network

The last two digits of the DTC states the failure type.

The most common failure types are:

00 No Sub Type Information

01 General Electrical Failure
11 Circuit Short To Ground
12 Circuit Short To Battery
13 Circuit Open
16 Circuit Voltage Below Threshold
17 Circuit Voltage Above Threshold
64 Signal Plausibility Failure
86 Signal Invalid
88 Bus Off

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30-2 Fault Tracing

30-2 Fault Tracing

Fault Codes
Erase DTC
IMPORTANT!
To erase any DTC the "Erase DTC" operation in Vodia
needs to be performed after the fault been repaired.
When the "Erase DTC" operation been performed the
system needs to be shut down in a proper way with
ignition off.
If the EATS system needs to be drained the ACM
performs an afterrun, then it can take up to 2 minutes
before the system has shut down properly. Only if the
system has been properly shut down the DTC will be
erased. If not erased properly an engine derate could
still be active.

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 30-2 Fault Tracing

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30-2 Fault Tracing

P054401
Exhaust Gas Temperature Sensor Bank 1 Sensor 1
SPN [FMI]: 3241 [12]
Failure type: General Electrical Failure
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 13 second
DTC Monitor Test Conditions: System powered on
Symptom: Engine derate
Regeneration not possible
Failure Event: Voltage on A:42 above 2.260742V
and
Voltage on A:42 below 4.852295V
OR
Voltage on A:42 above 0.147705V
and
Voltage on A:42 below 0.677490V
Possible Root Cause: • Sensor, exhaust temp, upstream catalyst/internal electronic failure
Corrective Action: 1 Check harness.
2 Check connectors.
3 Check sensor.
Connector information: A:42

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 30-2 Fault Tracing

P054411
Exhaust Gas Temperature Sensor Bank 1 Sensor 1
SPN [FMI]: 3241 [4]
Failure type: Circuit Short To Ground
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 13 second
DTC Monitor Test Conditions: System powered on
Symptom: Engine derate
Regeneration not possible
Failure Event: Voltage on A:42 below 0.147705V
Possible Root Cause: • Cable harness/Short circuit to low
• Sensor, exhaust temp, upstream catalyst/Short circuit to low
Corrective Action: 1 Check harness.
2 Check connectors.
3 Check sensor.
Connector information: A:42

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30-2 Fault Tracing

P054415
Exhaust Gas Temperature Sensor Bank 1 Sensor 1
SPN [FMI]: 3241 [5]
Failure type: Circuit Short To Battery or Open
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 13 second
DTC Monitor Test Conditions: System powered on
Symptom: Engine derate
Regeneration not possible
Failure Event: Voltage on A:42 above 4.852295V
Possible Root Cause: • Cable harness/open circuit
• Sensor, exhaust temp, upstream catalyst/open circuit
Corrective Action: 1 Check harness.
2 Check connectors.
3 Check sensor.
Connector information: A:42

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 30-2 Fault Tracing

P065711
Actuator Supply Voltage “A”
SPN [FMI]: 3597 [4]
Failure type: Circuit Short To Ground
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 5.5 second
DTC Monitor Test Conditions: Engine running
Symptom: No urea injected
Engine derate
Failure Event: Measured voltage is below 1.5V
OR
Measured current above 15A
Possible Root Cause: • Cable harness/Short circuit to low
• AdBlue Dosage Pump/Short circuit to low
• Solenoid valve, AdBlue tank heating/Short circuit to low
• Solenoid valve, AdBlue pump reverting/Short circuit to low
Corrective Action: 1 Check harness
2 Check tank heating valve, reverting valve and reductant pump
Connector information: A:62

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30-2 Fault Tracing

P065712
Actuator Supply Voltage “A”
SPN [FMI]: 3597 [3]
Failure type: Circuit Short To Battery
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 5.5 second
DTC Monitor Test Conditions: System powered on
Symptom: No urea injected
Engine derate
Failure Event: Measured voltage is above 1.25V
Possible Root Cause: • Cable harness/Short circuit to high
• AdBlue Dosage Pump/Short circuit to high
• Solenoid valve, AdBlue tank heating/Short circuit to high
• Solenoid valve, AdBlue pump reverting/Short circuit to high
Corrective Action: 1 Check harness
2 Check tank heating valve, reverting valve and reductant pump
3 Ignition off/on
Connector information: A:62

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 30-2 Fault Tracing

P066601
Control Module Internal Temperature Sensor "A"
SPN [FMI]: 1136 [12]
Failure type: General Electrical Failure
Lamp Status: –
DTC Monitor Detection Time: 13 second
DTC Monitor Test Conditions: System powered on
Symptom: None
Failure Event: Voltage on PCB:ECU internal above 2.874756V
and
Voltage on PCB:ECU internal below 4.852295V
OR
Voltage on PCB:ECU internal above 0.147705V
and
Voltage on PCB:ECU internal below 1.237793V
Possible Root Cause: • Control unit, EMS (Engine Management System)/internal electronic
failure
Corrective Action: 1 Ignition off/on
2 If the problem persists - replace the ACM
Connector information: PCB:ECU internal

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30-2 Fault Tracing

P066611
Control Module Internal Temperature Sensor "A"
SPN [FMI]: 1136 [4]
Failure type: Circuit Short To Ground
Lamp Status: –
DTC Monitor Detection Time: 13 second
DTC Monitor Test Conditions: System powered on
Symptom: None
Failure Event: Voltage on PCB:ECU internal below 0.147705V
Possible Root Cause: • Control unit, EMS (Engine Management System)/internal electronic
failure
Corrective Action: 1 Ignition off/on
2 If the problem persists - replace the ACM
Connector information: PCB:ECU internal

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 30-2 Fault Tracing

P066613
Control Module Internal Temperature Sensor "A"
SPN [FMI]: 1136 [5]
Failure type: Circuit Open
Lamp Status: –
DTC Monitor Detection Time: 13 second
DTC Monitor Test Conditions: System powered on
Symptom: None
Failure Event: Voltage on PCB:ECU internal above 4.852295V
Possible Root Cause: • Control unit, EMS (Engine Management System)/internal electronic
failure
Corrective Action: 1 Ignition off/on
2 If the problem persists - replace the ACM
Connector information: PCB:ECU internal

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30-2 Fault Tracing

P06B016
Sensor Power Supply “A”
SPN [FMI]: 3509 [4]
Failure type: Circuit Voltage Below Threshold
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 5.5 second
DTC Monitor Test Conditions: System powered on
Symptom: Diesel particulate filter regeneration request may be delayed
Failure Event: Voltage on A:50 below 4.5V
Possible Root Cause: • Cable harness/Short circuit to low
• Control unit, ACM (Aftertreatment Control Module)/Internal electrical fault
Corrective Action: 1 Check attached sensors
2 Check harness
3 Check connectors.
Connector information: A:50

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 30-2 Fault Tracing

P06B017
Sensor Power Supply “A”
SPN [FMI]: 3509 [3]
Failure type: Circuit Voltage Above Threshold
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 5.5 second
DTC Monitor Test Conditions: System powered on
Symptom: Diesel particulate filter regeneration request may be delayed
Failure Event: Voltage on A:50 above 5.5V
Possible Root Cause: • Cable harness/Short circuit to high
• Control unit, ACM (Aftertreatment Control Module)/Internal electrical fault
Corrective Action: 1 Check attached sensors
2 Check harness
3 Check connectors.
Connector information: A:50

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30-2 Fault Tracing

P06B316
Sensor Power Supply "B"
SPN [FMI]: 3510 [4]
Failure type: Circuit Voltage Below Threshold
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 5.5 second
DTC Monitor Test Conditions: System powered on
Symptom: None
Failure Event: Voltage on A:51 below 4.5V
Possible Root Cause: • Cable harness/Short circuit to low
• Control unit, ACM (Aftertreatment Control Module)/Internal electrical fault
Corrective Action: 1 Check attached sensors
2 Check harness
3 Check connectors.
Connector information: A:51

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 30-2 Fault Tracing

P06B317
Sensor Power Supply "B"
SPN [FMI]: 3510 [3]
Failure type: Circuit Voltage Above Threshold
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 5.5 second
DTC Monitor Test Conditions: System powered on
Symptom: None
Failure Event: Voltage on A:51 above 5.5V
Possible Root Cause: • Cable harness/Short circuit to high
• Control unit, ACM (Aftertreatment Control Module)/Internal electrical fault
Corrective Action: 1 Check attached sensors
2 Check harness
3 Check connectors.
Connector information: A:51

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30-2 Fault Tracing

P10AD11
Reductant Pump “A” Control Low Side
SPN [FMI]: 4375 [1]
Failure type: Circuit Short To Ground
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 6 second
DTC Monitor Test Conditions: Actuator must be inactive, i.e. duty must be 0.0%
Symptom: Engine derate
Failure Event: Measured voltage is below 1.5V
OR
Measured current above 15A
Possible Root Cause: • Cable harness/Short circuit to low
• Motor, AdBlue Dosage Pump/Short circuit to low
Corrective Action: 1 Check harness
2 Check connectors.
3 Check urea pump
Connector information: A:8

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 30-2 Fault Tracing

P10AD12
Reductant Pump “A” Control Low Side
SPN [FMI]: 4375 [0]
Failure type: Circuit Short To Battery
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 5.1 second
DTC Monitor Test Conditions: Actuator must be fully active, i.e. duty must be 100%
Symptom: Engine derate
Failure Event: Measured voltage is above 1.25V
Possible Root Cause: • Cable harness/Short circuit to high
• Motor, AdBlue Dosage Pump/Short circuit to high
Corrective Action: 1 Check harness
2 Check connectors.
3 Check urea pump
Connector information: A:8

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30-2 Fault Tracing

P10AD13
Reductant Pump “A” Control Low Side
SPN [FMI]: 4375 [12]
Failure type: Circuit Open
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 5.1 second
DTC Monitor Test Conditions: Actuator must be inactive, i.e. duty must be 0.0%
Symptom: Engine derate
Failure Event: Measured voltage is below 1.5V
OR
Measured voltage is above 3.75V
OR
Measured current below 60μA
Possible Root Cause: • Cable harness/open circuit
• Motor, AdBlue Dosage Pump/open circuit
Corrective Action: 1 Check harness
2 Check connectors.
3 Check urea pump
Connector information: A:8

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 30-2 Fault Tracing

P10CE97
Reductant Return No Flow Detected
SPN [FMI]: 5485 [14]
Failure type: Component or System Operation Obstructed or Blocked
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: –
DTC Monitor Test Conditions: Urea Pressure above 500 kPa
Symptom: No urea injected
Engine derate
Failure Event: Urea Pressure above 1100 kPa
Possible Root Cause: • Return pipe/clogged blocked
• Hose/clogged/blocked
• Hose/Deformed
Corrective Action: 1 Check for blocked reductant return line
2 Check urea pump
Connector information: Not applicable

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30-2 Fault Tracing

P202D7A
Aftertreatment Reagent Pressure Leakage
SPN [FMI]: 4374 [0]
Failure type: Fluid Leak or Seal Failure
Lamp Status: Yellow alarm statusRed alarm status
DTC Monitor Detection Time: –
DTC Monitor Test Conditions: Urea Pressure above 500 kPa
Symptom: Engine derate
Failure Event: Pump duty cycle above 60% + Offset dependent on Reductant Tank
Temperature
Possible Root Cause: • Motor, AdBlue Dosage Pump/Internal leakage
• Motor, AdBlue Dosage Pump/internal electronic failure
• Hose/External leakage
• Motor, AdBlue Dosage Pump/Clogged filter
Corrective Action: 1 Check for leakage on the pressure line
2 Check reductant pump unit
Connector information: Not applicable

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 30-2 Fault Tracing

P203101
Exhaust Gas Temperature Sensor Bank 1 Sensor 2
SPN [FMI]: 3249 [12]
Failure type: General Electrical Failure
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 13 second
DTC Monitor Test Conditions: System powered on
Symptom: Engine derate
Failure Event: Voltage on A:34 above 2.260742V
and
Voltage on A:34 below 4.852295V
OR
Voltage on A:34 above 0.147705V
and
Voltage on A:34 below 0.677490V
Possible Root Cause: • Sensor, exhaust temp, downstream catalyst/internal electronic failure
Corrective Action: 1 Check harness
2 Check connectors.
3 Check sensor.
Connector information: A:34

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P203111
Exhaust Gas Temperature Sensor Bank 1 Sensor 2
SPN [FMI]: 3249 [4]
Failure type: Circuit Short To Ground
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 13 second
DTC Monitor Test Conditions: System powered on
Symptom: Engine derate
Failure Event: Voltage on A:34 below 0.147705V
Possible Root Cause: • Cable harness/Short circuit to low
• Sensor, exhaust temp, downstream catalyst/Short circuit to low
Corrective Action: 1 Check harness
2 Check connectors.
3 Check sensor.
Connector information: A:34

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P203115
Exhaust Gas Temperature Sensor Bank 1 Sensor 2
SPN [FMI]: 3249 [5]
Failure type: Circuit Short To Battery or Open
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 13 second
DTC Monitor Test Conditions: System powered on
Symptom: Engine derate
Failure Event: Voltage on A:34 above 4.852295V
Possible Root Cause: • Cable harness/open circuit
• Sensor, exhaust temp, downstream catalyst/open circuit
Corrective Action: 1 Check harness
2 Check connectors.
3 Check sensor.
Connector information: A:34

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P203A11
Reductant Level Sensor “A”
SPN [FMI]: 3532 [4]
Failure type: Circuit Short To Ground
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 0.02 second
DTC Monitor Test Conditions: System powered on
Symptom: Engine derate
Failure Event: Reductant level sensor has reported the fault: internal short circuit low
Possible Root Cause: • Sensor, reductant quality, temperature and level/internal electronic
failure
Corrective Action: 1 Replace the reductant level sensor if the problem persists
Connector information: Not applicable

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P203A13
Reductant Level Sensor “A”
SPN [FMI]: 3532 [5]
Failure type: Circuit Open
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 0.02 second
DTC Monitor Test Conditions: System powered on
Symptom: Engine derate
Failure Event: Reductant level sensor has reported the fault: internal open circuit
Possible Root Cause: • Sensor, reductant quality, temperature and level/internal electronic
failure
Corrective Action: 1 Replace the reductant level sensor if the problem persists
Connector information: –

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P203A96
Reductant Level Sensor “A”
SPN [FMI]: 3532 [12]
Failure type: Component Internal Failure
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 0.02 second
DTC Monitor Test Conditions: System powered on
Symptom: Engine derate
Failure Event: Reductant level sensor has reported the fault: internal electronic fault
Possible Root Cause: • Sensor, reductant quality, temperature and level/internal electronic
failure
Corrective Action: 1 Replace the reductant level sensor if the problem persists
Connector information: –

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P204201
Reductant Temperature Sensor
SPN [FMI]: 4337 [12]
Failure type: General Electrical Failure
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 10 second
DTC Monitor Test Conditions: ACM software in temperature measurement mode
Symptom: None
Failure Event: Bad quality for pump temperature signal reported by Bosch pump
Possible Root Cause: • Pump unit, Urea dosage/open circuit
• Pump unit, Urea dosage/internal electronic failure
Corrective Action: 1 Replace the reductant pump if the problem persists
Connector information: –

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P204264
Reductant Temperature Sensor
SPN [FMI]: 4337 [2]
Failure type: Signal Plausibility Failure
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 0.5 second
DTC Monitor Test Conditions: Ignition on
Engine not started
Symptom: None
Failure Event: Difference during Precrank between Urea Quality Temperature and Urea
Pump Temperature above 40°C
Possible Root Cause: • Temperature sensor/internal electronic failure
Corrective Action: 1 Check reductant quality sensor
2 Check reductant pump
Connector information: –

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P204711
Reductant Injection Valve Control Bank 1 Unit 1
SPN [FMI]: 5394 [4]
Failure type: Circuit Short To Ground
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 6 second
DTC Monitor Test Conditions: Actuator must be active
Symptom: No urea injected
Engine derate
Failure Event: Measured voltage on low-side is below 1.5V
OR
Measured current in high-side is above 5.5A
Possible Root Cause: • Cable harness/Short circuit to low
• Solenoid valve, AdBlue dosing unit/Short circuit to low
Corrective Action: 1 Check harness
2 Check connectors.
3 Check dosage valve
Connector information: A:40, A:44

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P204712
Reductant Injection Valve Control Bank 1 Unit 1
SPN [FMI]: 5394 [3]
Failure type: Circuit Short To Battery
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 6 second
DTC Monitor Test Conditions: Actuator must be active
Symptom: No urea injected
Engine derate
Failure Event: Measured voltage on low-side is above 1.25V
Possible Root Cause: • Cable harness/Short circuit to high
• Solenoid valve, AdBlue dosing unit/Short circuit to high
Corrective Action: 1 Check harness
2 Check connectors.
3 Check dosage valve
Connector information: A:40, A:44

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P204713
Reductant Injection Valve Control Bank 1 Unit 1
SPN [FMI]: 5394 [5]
Failure type: Circuit Open
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 6 second
DTC Monitor Test Conditions: Actuator must be active
Symptom: No urea injected
Engine derate
Failure Event: Measured current is below 60 μA
OR
Measured voltage on low-side is above 1.25V
Possible Root Cause: • Cable harness/open circuit
• Cable harness/Short circuit to high
• Solenoid valve, AdBlue dosing unit/open circuit
• Solenoid valve, AdBlue dosing unit/Short circuit to high
Corrective Action: 1 Check harness
2 Check connectors.
3 Check dosage valve
Connector information: A:40, A:44

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P204A01
Reductant Pressure Sensor
SPN [FMI]: 4334 [12]
Failure type: General Electrical Failure
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 7 second
DTC Monitor Test Conditions: System powered on
Symptom: Engine derate
Failure Event: Voltage on A:30 above 4.637451V
and
Voltage on A:30 below 4.852295V
OR
Voltage on A:30 above 0.147705V
and
Voltage on A:30 below 0.362549V
Possible Root Cause: • Sensor, Urea Pressure/internal electronic failure
Corrective Action: 1 Check harness
2 Check connectors.
3 Check sensor.
Connector information: A:30

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P204A11
Reductant Pressure Sensor
SPN [FMI]: 4334 [4]
Failure type: Circuit Short To Ground
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 7 second
DTC Monitor Test Conditions: System powered on
Symptom: Engine derate
Failure Event: Voltage on A:30 below 0.147705V
Possible Root Cause: • Cable harness/Short circuit to low
• Sensor, Urea Pressure/Short circuit to low
Corrective Action: 1 Check harness
2 Check connectors.
3 Check sensor.
Connector information: A:30

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P204A13
Reductant Pressure Sensor
SPN [FMI]: 4334 [5]
Failure type: Circuit Open
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 7 second
DTC Monitor Test Conditions: System powered on
Symptom: Engine derate
Failure Event: Voltage on A:30 above 4.852295V
Possible Root Cause: • Cable harness/open circuit
• Sensor, Urea Pressure/open circuit
Corrective Action: 1 Check harness
2 Check connectors.
3 Check sensor.
Connector information: A:30

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P204A64
Reductant Pressure Sensor
SPN [FMI]: 4334 [2]
Failure type: Signal Plausibility Failure
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 180 second
DTC Monitor Test Conditions: Engine running and Urea not frozen and below 68 °C temperature
Symptom: None
Failure Event: Urea Pressure below 100
Possible Root Cause: • Sensor, Urea Pressure/plausability failure
• Pump unit, Urea dosage/clogged/blocked
Corrective Action: 1 Check reductant pump unit
Connector information: A:30

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P204F93
SCR System Performance Dosing Failure
SPN [FMI]: 3361 [12]
Failure type: No Operation
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 1 second
DTC Monitor Test Conditions: System powered on
Symptom: Engine derate
Failure Event: Fault code in ACM causing stopped dosing
Possible Root Cause: • Control unit, ACM (Aftertreatment Control Module)/internal electronic
failure
Corrective Action: 1 Check fault codes in ACM
2 Turn ignition off/on
Connector information: –

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P205A12
Reductant Tank Temperature Sensor
SPN [FMI]: 3519 [3]
Failure type: Circuit Short To Battery
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 0.02 second
DTC Monitor Test Conditions: System powered on
Symptom: Engine derate
Failure Event: Reductant temperature sensor has reported the fault: internal short circuit high
Possible Root Cause: • Sensor, reductant quality, temperature and level/internal electronic
failure
Corrective Action: 1 Replace sensor
Connector information: –

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P205A13
Reductant Tank Temperature Sensor
SPN [FMI]: 3519 [5]
Failure type: Circuit Open
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 0.02 second
DTC Monitor Test Conditions: System powered on
Symptom: Engine derate
Failure Event: Reductant temperature sensor has reported the fault: internal open circuit
Possible Root Cause: • Sensor, reductant quality, temperature and level/internal electronic
failure
Corrective Action: 1 Replace sensor
Connector information: –

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P206A13
Reductant Quality
SPN [FMI]: 3520 [5]
Failure type: Circuit Open
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 0.02 second
DTC Monitor Test Conditions: System powered on
Symptom: Engine derate
Failure Event: Reductant quality sensor has reported the fault: internal open circuit
Possible Root Cause: • Sensor, reductant quality, temperature and level/internal electronic
failure
Corrective Action: 1 Replace the reductant quality sensor if the problem persists
Connector information: –

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P206A96
Reductant Quality
SPN [FMI]: 3520 [12]
Failure type: Component Internal Failure
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 0.02 second
DTC Monitor Test Conditions: System powered on
Symptom: Engine derate
Failure Event: Reductant quality sensor has reported the fault: internal electronic fault
Possible Root Cause: • Sensor, reductant quality, temperature and level/internal electronic
failure
Corrective Action: 1 Replace the reductant quality sensor if the problem persists
Connector information: –

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P208A11
Reductant Pump “A” Control
SPN [FMI]: 4375 [4]
Failure type: Circuit Short To Ground
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 6 second
DTC Monitor Test Conditions: Actuator must be active
Symptom: No urea injected
Engine derate
Failure Event: Measured voltage is below 2.5V
Possible Root Cause: • Cable harness/Short circuit to low
• Motor, AdBlue Dosage Pump/Short circuit to low
Corrective Action: 1 Check harness
2 Check connectors.
3 Check sensor.
Connector information: A:7

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P208A12
Reductant Pump “A” Control
SPN [FMI]: 4375 [3]
Failure type: Circuit Short To Battery
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 6 second
DTC Monitor Test Conditions: Actuator must be active
Symptom: No urea injected
Engine derate
Failure Event: Measured voltage is above 3.75V
Possible Root Cause: • Cable harness/Short circuit to high
• Motor, AdBlue Dosage Pump/Short circuit to high
Corrective Action: 1 Check harness
2 Check connectors.
3 Check sensor.
Connector information: A:7

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P208A13
Reductant Pump “A” Control
SPN [FMI]: 4375 [5]
Failure type: Circuit Open
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 6 second
DTC Monitor Test Conditions: Actuator must be active
Symptom: No urea injected
Engine derate
Failure Event: Measured voltage is between 2.5V and 3.75V
Possible Root Cause: • Cable harness/open circuit
• Motor, AdBlue Dosage Pump/open circuit
Corrective Action: 1 Check harness
2 Check connectors.
3 Check sensor.
Connector information: A:7

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P208A92
Reductant Pump “A” Control
SPN [FMI]: 4374 [1]
Failure type: Performance or Incorrect Operation
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: –
DTC Monitor Test Conditions: Engine running and urea not frozen
Symptom: None
Failure Event: Error state indicates that pump speed error has occurred which prohibits the
system from running
and
Error state is confirmed when the pump has failed to run after 5 times within
300 s
Possible Root Cause: • Motor, AdBlue Dosage Pump/internal electronic failure
Corrective Action: 1 Check reductant pump unit
Connector information: –

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P20A007
Reductant Purge Control Valve
SPN [FMI]: 4376 [7]
Failure type: Mechanical Failures
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 0.02 second
DTC Monitor Test Conditions: Run the engine
Turn the engine off
Turn ignition off
Wait for at least 60 s
Symptom: Remaining urea in the urea lines after system shutdown. The urea system
(pump/urea hoses) may be damaged in cold climate.
Failure Event: Turn key on
and
A reverting valve fault was set in previous driving cycle
Possible Root Cause: • Solenoid valve, reductant pump reverting valve/clogged/blocked
Corrective Action: 1 Check reductant pump unit, reverting valve stuck
Connector information: –

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P20A011
Reductant Purge Control Valve
SPN [FMI]: 4376 [4]
Failure type: Circuit Short To Ground
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 6 second
DTC Monitor Test Conditions: Actuator must be inactive, i.e. duty must be 0.0%
Symptom: No pressure build up
No urea injected
Engine derate
Failure Event: Measured voltage is below 1.5V
OR
Measured current above 15A
Possible Root Cause: • Cable harness/Short circuit to low
• Motor, AdBlue Dosage Pump/Short circuit to low
Corrective Action: 1 Check harness
2 Check connectors.
3 Replace reverting valve
Connector information: A:12

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P20A012
Reductant Purge Control Valve
SPN [FMI]: 4376 [3]
Failure type: Circuit Short To Battery
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 6 second
DTC Monitor Test Conditions: Actuator must be fully active, i.e. duty must be 100%
Symptom: Remaining urea in the urea lines after system shutdown. The urea system
(pump/urea hoses) may be damaged in cold climate.
Failure Event: Measured voltage is above 1.25V
Possible Root Cause: • Cable harness/Short circuit to high
• Motor, AdBlue Dosage Pump/Short circuit to high
Corrective Action: 1 Check harness
2 Check connectors.
3 Replace reverting valve
Connector information: A:12

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P20A013
Reductant Purge Control Valve
SPN [FMI]: 4376 [5]
Failure type: Circuit Open
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 10 second
DTC Monitor Test Conditions: Actuator must be inactive, i.e. duty must be 0.0%
Symptom: Remaining urea in the urea lines after system shutdown. The urea system
(pump/urea hoses) may be damaged in cold climate.
Failure Event: Measured voltage is below 1.5V
OR
Measured voltage is above 3.75V
OR
Measured current below 60μA
Possible Root Cause: • Cable harness/open circuit
• Motor, AdBlue Dosage Pump/open circuit
Corrective Action: 1 Check harness
2 Check connectors.
3 Replace reverting valve
Connector information: A:12

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P20B111
Reductant Heater Coolant Control Valve Control
SPN [FMI]: 3363 [4]
Failure type: Circuit Short To Ground
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 6 second
DTC Monitor Test Conditions: Actuator must be inactive, i.e. duty must be 0.0%
Symptom: Reduced urea thawing performance
Possible Engine derate in cold climate
Failure Event: Measured voltage is below 1.5V
OR
Measured current above 15A
Possible Root Cause: • Cable harness/Short circuit to low
• Solenoid valve, AdBlue tank heating/Short circuit to low
Corrective Action: 1 Check harness
2 Check connectors.
3 Check tank heating valve
Connector information: A:4

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P20B112
Reductant Heater Coolant Control Valve Control
SPN [FMI]: 3363 [3]
Failure type: Circuit Short To Battery
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 6 second
DTC Monitor Test Conditions: Actuator must be fully active, i.e. duty must be 100%
Symptom: Reduced urea thawing performance
Possible Engine derate in cold climate
Failure Event: Measured voltage is above 1.25V
Possible Root Cause: • Cable harness/Short circuit to high
• Solenoid valve, AdBlue tank heating/Short circuit to high
Corrective Action: 1 Check harness
2 Check connectors.
3 Check tank heating valve
Connector information: A:4

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P20B113
Reductant Heater Coolant Control Valve Control
SPN [FMI]: 3363 [5]
Failure type: Circuit Open
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 10 second
DTC Monitor Test Conditions: Actuator must be inactive, i.e. duty must be 0.0%
Symptom: Reduced urea thawing performance
Possible Engine derate in cold climate
Failure Event: Measured voltage is below 1.5V
OR
Measured voltage is above 3.75V
OR
Measured current below 60μA
Possible Root Cause: • Cable harness/open circuit
• Solenoid valve, AdBlue tank heating/open circuit
Corrective Action: 1 Check harness
2 Check connectors.
3 Check tank heating valve
Connector information: A:4

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P20B197
Reductant Heater Coolant Control Valve Control
SPN [FMI]: 3363 [7]
Failure type: Component or System Operation Obstructed or Blocked
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: –
DTC Monitor Test Conditions: Urea frozen and Engine running
Symptom: None
Failure Event: Urea frozen
and
Engine running
and
Reductant Tank Temperature shall increase by at least 5 °C during evaluation
time (900 s)
and
Reductant Temperature shall increase by at least 5 °C during evaluation time
(900 s)
Possible Root Cause: • Sensor, AdBlue level and temperature/internal electronic failure
• Solenoid valve, AdBlue tank heating/clogged/blocked temperature
sensor/internal electronic failure
Corrective Action: 1 Check tank heating valve
2 Check pump temperature sensor
3 Check Reductant level and temperature sensor
Connector information: –

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P20B911
Reductant Heater “A” Control
SPN [FMI]: 4354 [4]
Failure type: Circuit Short To Ground
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 6 second
DTC Monitor Test Conditions: Actuator must be inactive, i.e. duty must be 0.0%
Symptom: Reduced urea thawing performance
Possible Engine derate in cold climate
Failure Event: Measured voltage is below 1.5V
OR
Measured current above 15A
Possible Root Cause: • Cable harness/Short circuit to low
• Heater internal short circuit to low
Corrective Action: 1 Check harness
2 Check connectors.
3 Replace hose (pump to dosing valve)
Connector information: A:32

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P20B912
Reductant Heater “A” Control
SPN [FMI]: 4354 [3]
Failure type: Circuit Short To Battery
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 6 second
DTC Monitor Test Conditions: Actuator must be active, i.e. duty must be above 0.0%
Symptom: Reduced urea thawing performance
Possible Engine derate in cold climate
Failure Event: Measured voltage is above 1.25V
Possible Root Cause: • Cable harness/Short circuit to high
• Heater internal short circuit to high
Corrective Action: 1 Check harness
2 Check connectors.
3 Replace hose (pump to dosing valve)
Connector information: A:32

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P20B913
Reductant Heater “A” Control
SPN [FMI]: 4354 [5]
Failure type: Circuit Open
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 6 second
DTC Monitor Test Conditions: Actuator must be inactive, i.e. duty must be 0.0%
Symptom: Reduced urea thawing performance
Possible Engine derate in cold climate
Failure Event: Measured voltage is below 1.5V
OR
Measured voltage is above 3.75V
OR
Measured current below 60μA
Possible Root Cause: • Cable harness/open circuit
• Heater internal open circuit
Corrective Action: 1 Check harness
2 Check connectors.
3 Replace hose (pump to dosing valve)
Connector information: A:32

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P20B992
Reductant Heater “A” Control
SPN [FMI]: 4366 [14]
Failure type: Performance or Incorrect Operation
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: –
DTC Monitor Test Conditions: Performance or Incorrect Operation
Symptom: Reduced urea thawing performance
Possible Engine derate in cold climate
Failure Event: Defrosting has been active for more than 7200 s
OR
Maximum number of tries to start the pump (1000) has been reached
Possible Root Cause: • Heater, AdBlue hose, /internal electronic failure
• Solenoid valve, AdBlue tank heating/clogged/blocked
Corrective Action: 1 Check urea hose heaters
2 Check tank heating valve
3 Check coolant flow level
Connector information: –

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P20BD11
Reductant Heater “B” Control
SPN [FMI]: 4355 [4]
Failure type: Circuit Short To Ground
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 6 second
DTC Monitor Test Conditions: Actuator must be inactive, i.e. duty must be 0.0%
Symptom: Reduced urea thawing performance
Possible Engine derate in cold climate
Failure Event: Measured voltage is below 1.5V
OR
Measured current above 15A
Possible Root Cause: • Cable harness/Short circuit to low
• Heater internal short circuit to low
Corrective Action: 1 Check harness
2 Check connectors.
3 Replace hose (tank suction line to pump)
Connector information: A:28

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P20BD12
Reductant Heater “B” Control
SPN [FMI]: 4355 [3]
Failure type: Circuit Short To Battery
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 6 second
DTC Monitor Test Conditions: Actuator must be active, i.e. duty must be above 0.0%
Symptom: Reduced urea thawing performance
Possible Engine derate in cold climate
Failure Event: Measured voltage is above 1.25V
Possible Root Cause: • Cable harness/Short circuit to high
• Heater internal short circuit to high
Corrective Action: 1 Check harness
2 Check connectors.
3 Replace hose (tank suction line to pump)
Connector information: A:28

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P20BD13
Reductant Heater “B” Control
SPN [FMI]: 4355 [5]
Failure type: Circuit Open
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 6 second
DTC Monitor Test Conditions: Actuator must be inactive, i.e. duty must be 0.0%
Symptom: Reduced urea thawing performance
Possible Engine derate in cold climate
Failure Event: Measured voltage is below 1.5V
OR
Measured voltage is above 3.75V
OR
Measured current below 60μA
Possible Root Cause: • Cable harness/open circuit
• Heater internal open circuit
Corrective Action: 1 Check harness
2 Check connectors.
3 Replace hose (tank suction line to pump)
Connector information: A:28

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P20C111
Reductant Heater “C” Control
SPN [FMI]: 4356 [4]
Failure type: Circuit Short To Ground
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 6 second
DTC Monitor Test Conditions: Actuator must be inactive, i.e. duty must be 0.0%
Symptom: Reduced urea thawing performance
Possible Engine derate in cold climate
Failure Event: Measured voltage is below 1.5V
OR
Measured current above 15A
Possible Root Cause: • Cable harness/Short circuit to low
• Heater internal short circuit to low
Corrective Action: 1 Check harness
2 Check connectors.
3 Replace hose (return flow to urea tank)
Connector information: A:24

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P20C112
Reductant Heater “C” Control
SPN [FMI]: 4356 [3]
Failure type: Circuit Short To Battery
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 6 second
DTC Monitor Test Conditions: Actuator must be active, i.e. duty must be above 0.0%
Symptom: Reduced urea thawing performance
Possible Engine derate in cold climate
Failure Event: Measured voltage is above 1.25V
Possible Root Cause: • Cable harness/Short circuit to high
• Heater internal short circuit to high
Corrective Action: 1 Check harness
2 Check connectors.
3 Replace hose (return flow to urea tank)
Connector information: A:24

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P20C113
Reductant Heater “C” Control
SPN [FMI]: 4356 [5]
Failure type: Circuit Open
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 6 second
DTC Monitor Test Conditions: Actuator must be inactive, i.e. duty must be 0.0%
Symptom: Reduced urea thawing performance
Possible Engine derate in cold climate
Failure Event: Measured voltage is below 1.5V
OR
Measured voltage is above 3.75V
OR
Measured current below 60μA
Possible Root Cause: • Cable harness/open circuit
• Heater internal open circuit
Corrective Action: 1 Check harness
2 Check connectors.
3 Replace hose (return flow to urea tank)
Connector information: A:24

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P20E892
Reductant Pressure Too Low
SPN [FMI]: 5392 [31]
Failure type: Performance or Incorrect Operation
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 0.02 second
DTC Monitor Test Conditions: Engine running and Urea not frozen and below 68 °C temperature and Ambient
air temperature above 0 °C and No severe errors that prevent the system from
running are active.
Symptom: Engine derate
Failure Event: Urea Pressure below 650 kPa
Possible Root Cause: • Motor, AdBlue Dosage Pump/clogged/blocked
• Motor, AdBlue Dosage Pump/Internal leakage
• Motor, AdBlue Dosage Pump/internal electronic failure
• Hose/External leakage
Corrective Action: 1 Check urea pump unit
2 Check empty reductant tank
3 Check leakage in suction line
Connector information: –

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P21CAA1
Reductant Control Module Supply Voltage
SPN [FMI]: 4375 [14]
Failure type: System Voltage
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: –
DTC Monitor Test Conditions: Control Module supply voltage inside permissible range (12 - 32 V)
Symptom: Reduced system performance
Failure Event: Control Module supply voltage outside permissible range (12-32 V)
Possible Root Cause: • Control unit, ACM (Aftertreatment Control Module)/damaged connector
• Alternator/internal electronic failure
Corrective Action: 1 Check harness
2 Check ACM connector
3 Check alternator function and connections
Connector information: –

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P242A01
Exhaust Gas Temperature Sensor Bank 1 Sensor 3
SPN [FMI]: 3245 [12]
Failure type: General Electrical Failure
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 13 second
DTC Monitor Test Conditions: System powered on
Symptom: Engine derate
Failure Event: Voltage on A:39 above 2.260742V
and
Voltage on A:39 below 4.852295V
OR
Voltage on A:39 above 0.147705V
and
Voltage on A:39 below 0.677490V
Possible Root Cause: • Sensor, exhaust temp, downstream DPF/internal electronic failure
Corrective Action: 1 Check harness
2 Check connectors.
3 Check sensor.
Connector information: A:39

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P242A11
Exhaust Gas Temperature Sensor Bank 1 Sensor 3
SPN [FMI]: 3245 [4]
Failure type: Circuit Short To Ground
Lamp Status: Yellow alarm statusRed alarm status
DTC Monitor Detection Time: 13 second
DTC Monitor Test Conditions: System powered on
Symptom: Engine derate
Failure Event: Voltage on A:39 below 0.147705V
Possible Root Cause: • Cable harness/Short circuit to low
• Sensor, exhaust temp, downstream DPF/Short circuit to low
Corrective Action: 1 Check harness
2 Check connectors.
3 Check sensor.
Connector information: A:39

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P242A15
Exhaust Gas Temperature Sensor Bank 1 Sensor 3
SPN [FMI]: 3245 [5]
Failure type: Circuit Short To Battery or Open
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 13 second
DTC Monitor Test Conditions: System powered on
Symptom: Engine derate
Failure Event: Voltage on A:39 above 4.852295V
Possible Root Cause: • Cable harness/open circuit
• Sensor, exhaust temp, downstream DPF/open circuit
Corrective Action: 1 Check harness
2 Check connectors.
3 Check sensor.
Connector information: A:39

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P245211
Particulate Filter Pressure Sensor "A"
SPN [FMI]: 3251 [4]
Failure type: Circuit Short To Ground
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 7 second
DTC Monitor Test Conditions: System powered on
Symptom: Diesel particulate filter regeneration request may be delayed
Failure Event: Voltage on A:26 below 0.118408V
Possible Root Cause: • Cable harness/Short circuit to low
• Sensor, DPF pressure (Diesel particulate filters)/Short circuit to low
Corrective Action: 1 Check harness
2 Check connectors.
3 Check sensor.
Connector information: A:26

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P245213
Particulate Filter Pressure Sensor "A"
SPN [FMI]: 3251 [5]
Failure type: Circuit Open
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 7 second
DTC Monitor Test Conditions: System powered on
Symptom: Diesel particulate filter regeneration request may be delayed
Failure Event: Voltage on A:26 above 4.881592V
Possible Root Cause: • Cable harness/open circuit
• Sensor, DPF pressure (Diesel particulate filters)/open circuit
Corrective Action: 1 Check harness
2 Check connectors.
3 Check sensor.
Connector information: A:26

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P24FF00
Reductant Temperature Too High
SPN [FMI]: 3031 [0]
Failure type: No Sub Type Information
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: –
DTC Monitor Test Conditions: Urea Pressure above 500 kPa and Reductant Tank Temperature below 70 °C
Symptom: Engine derate
Failure Event: Reductant Tank Temperature above 70 °C
Possible Root Cause: • Solenoid valve, AdBlue tank heating/clogged/blocked
• Sensor, AdBlue level and temperature/internal electronic failure
Corrective Action: 1 Check reductant tank heating valve
2 Check reductant tank temperature sensor
Connector information: –

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P266911
Actuator Supply Voltage “B”
SPN [FMI]: 3598 [4]
Failure type: Circuit Short To Ground
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 5.5 second
DTC Monitor Test Conditions: Engine running
Symptom: Reduced urea thawing performance
Possible Engine derate in cold climate
Failure Event: Measured voltage is below 1.5V
OR
Measured current above 15A
Possible Root Cause: • Cable harness/Short circuit to low
• Heater(s), AdBlue hose/Short circuit to low
Corrective Action: 1 Check harness
2 Check hose heaters
Connector information: A:59

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P266912
Actuator Supply Voltage “B”
SPN [FMI]: 3598 [3]
Failure type: Circuit Short To Battery
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 5.5 second
DTC Monitor Test Conditions: System powered on
Symptom: Reduced urea thawing performance
Possible Engine derate in cold climate
Failure Event: Measured voltage is above 1.25V
Possible Root Cause: • Cable harness/Short circuit to high
• Heater(s), AdBlue hose/Short circuit to high
Corrective Action: 1 Check harness
2 Check hose heaters
Connector information: A:59

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P26E711
Actuator Supply Voltage “D”
SPN [FMI]: 5016 [4]
Failure type: Circuit Short To Ground
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 6 second
DTC Monitor Test Conditions: Supply must be fully active, i.e. duty must be 100%
Symptom: Nox-sensors will not be functional
Reductant quality/temp sensor will not be functional
Failure Event: Measured current is above 18A
Possible Root Cause: • Cable harness/Short circuit to low
Corrective Action: 1 Check harness
2 Check connectors.
3 Check for short circuits in any connected actuator
Connector information: A:49(ACM2)

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U000188
CAN Communication Backbone 2 Net
SPN [FMI]: 1231 [2]
Failure type: Bus Off
Lamp Status: –
DTC Monitor Detection Time: 5.05 second
DTC Monitor Test Conditions: System powered on
Symptom: Not possible to communicate with Vodia
Failure Event: It has not been possible to send frames on BB2 Communication Bus
and
It has not been possible to receive frames on BB2 Communication Bus
Possible Root Cause: • Link, open circuit
• Link, short circuit
• ECU(s), internal electronic failure
Corrective Action: 1 Check harness
2 Check connectors.
Connector information: A:6, A:2

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U001088
CAN Communication Backbone 1 Net
SPN [FMI]: 639 [2]
Failure type: Bus Off
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 5.05 second
DTC Monitor Test Conditions: System powered on
Symptom: Not possible to communicate with HMI
Failure Event: It has not been possible to send frames on BB1 Communication Bus
and
It has not been possible to receive frames on BB1 Communication Bus
Possible Root Cause: • Link, open circuit
• Link, short circuit
• ECU(s), internal electronic failure
Corrective Action: 1 Check harness
2 Check connectors.
Connector information: A:14, A:10

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U008088
Vehicle communication engine subnet
SPN [FMI]: 1668 [2]
Failure type: Bus Off
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 5.05 second
DTC Monitor Test Conditions: System powered on
Symptom: No urea injected
Engine derate
Failure Event: It has not been possible to send frames on Engine Subnet
and
It has not been possible to receive frames on Engine Subnet
Possible Root Cause: • Cable harness/shorted high
• Cable harness/shorted low
Corrective Action: 1 Check harness
2 Check connectors.
Connector information: A:5, A:1

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U02A200
Lost Communication with Reductant Quality Module
SPN [FMI]: 3360 [9]
Failure type: No Sub Type Information
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 14 second
DTC Monitor Test Conditions: System powered on
Symptom: Engine derate
Failure Event: Lost communication with Reductant Quality Sensor on Engine Subnet
Possible Root Cause: • Cable harness/open circuit
• Reductant Quality Sensor/damaged connector
• Reductant Quality Sensor/internal electronic failure
Corrective Action: 1 Check harness
2 Check connectors.
3 Check sensor.
Connector information: A:5, A:1

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U05A300
Invalid Data Received From Reductant Quality Module
SPN [FMI]: 3521 [14]
Failure type: No Sub Type Information
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: –
DTC Monitor Test Conditions: System powered on
Symptom: Engine derate
Failure Event: Reductant concentration below 10%
OR
Urea Quality Sensor is detecting air
Possible Root Cause: • Reductant Quality Sensor/Incorrect fluid
Corrective Action: 1 Check reductant tank contents
2 Check reagent concentration
3 Check if sensor was removed from reductant tank
Connector information: –

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U114600
Lost Communication With ECM on Engine Subnet
SPN [FMI]: 520413 [9]
Failure type: No Sub Type Information
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 14 second
DTC Monitor Test Conditions: System powered on
Symptom: No urea injected
Engine derate
Failure Event: Lost Communication With ECM on Engine Subnet
Possible Root Cause: • Cable harness/open circuit
• Control unit, EMS (Engine Management System)/damaged connector
• Control unit, EMS (Engine Management System)/internal electronic
failure
• Control unit, EMS (Engine Management System)/open circuit
Corrective Action: 1 Check harness
2 Check connectors.
3 Check Engine Control Unit
Connector information: A:5, A:1

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U1FFF68
Factory Mode Active
SPN [FMI]: 628 [14]
Failure type: Event Information
Lamp Status: Yellow alarm status
DTC Monitor Detection Time: 0.5 second
DTC Monitor Test Conditions: New key cycle
Symptom: Exhaust aftertreatment system may not be functional
Failure Event: The factory mode is active through P1HCF
Possible Root Cause: • Flywheel not correctly mounted
Corrective Action: 1 Factory Mode was not turned off by P1HCF
Connector information: –

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U300041
Electronic Control Unit
SPN [FMI]: 636 [7]
Failure type: General Checksum Failure
Lamp Status: –
DTC Monitor Detection Time: 0 second
DTC Monitor Test Conditions: New key cycle
Symptom: No urea injected
Engine derate
Failure Event: Program memory corruption
Possible Root Cause: • ECU software/hardware issue
Corrective Action: 1 Reload ACM software
2 Replace ACM
Connector information: –

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U300044
Electronic Control Unit
SPN [FMI]: 636 [7]
Failure type: Data Memory Failure
Lamp Status: –
DTC Monitor Detection Time: 0 second
DTC Monitor Test Conditions: New key cycle
Symptom: No urea injected
Engine derate
Failure Event: RAM corruption
Possible Root Cause: • ECU software/hardware issue
Corrective Action: 1 Reload ACM software
2 Replace ACM
Connector information: –

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U300045
Electronic Control Unit
SPN [FMI]: 636 [7]
Failure type: Program Memory Failure
Lamp Status: –
DTC Monitor Detection Time: 0 second
DTC Monitor Test Conditions: New key cycle
Symptom: No urea injected
Engine derate
Failure Event: Program memory corruption Software memory checksum error
Possible Root Cause: • ECU software/hardware issue
Corrective Action: 1 Reload ACM software
2 Replace ACM
Connector information: –

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U300049
Electronic Control Unit
SPN [FMI]: 636 [7]
Failure type: Internal Electronic Failure
Lamp Status: –
DTC Monitor Detection Time: 0 second
DTC Monitor Test Conditions: New key cycle
Symptom: No urea injected
Engine derate
Failure Event: ECU internal error
Possible Root Cause: • ECU Hardware issue
Corrective Action: 1 Reload ACM software
2 Replace ACM
Connector information: –

Measurements

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 Component ACM # Measure box # Conn. pin # Signal type Ignition on Engine running Note
AdBlue/DEF level/temp B54 54 4 (-) GND 54-58 = 0 V 54-58 = 0 V -
(not valid if QLT sensor) B18 18 3 Temp. output 54-18 = 0-5 V 54-18 = 0-5 V U is depended of temp Rtemp, see table 1.
B51 51 1 (+) Supply 54-51 = 5 V 54-51 = 5 V -
B46 46 2 Level output 54-46 = 0.5-4.5 V 54-46 = 0.5-4.5 V U is depended of level Ulevel, see table 2.
Dosage valve(1) B40 40 2 Low side switch 4-44 = 0 V 4-44 = Pulsed output Low side switch is grounded at injection.
Coil resistance:
1-2 = 1.3 Ω (+/- 0.3 Ω) at 23 °C (73.4 °F)
B44 44 1 High-side switch 44-58 = Vbat 4-44 = Vbat During dosing
AdBlue/DEF pump pressure B51 51 2 (+) Supply 51-54 = 5 V 51-54 = 5 V -
B30 30 3 Pressure output 30-54 = 0.8 V 30-54 = 2.2 V* *At constant system pressure of 500 kPa (72.5 psi).

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B54 54 4 (-) GND - - -
Reverting valve in pump unit B12 12 12 Valve signal 12-62 = 0 V - In running conditions
Coil resistance:
1-2 = 21 Ω (+/- 3 Ω) at 23 °C (73.4 °F)
B62 62 11 (+) Supply 12-62 = Vbat - In afterrun conditions
Tank heating valve B4 4 4 Valve signal 4-62 = 0 V - Valve closed
Coil resistance:
1-2 = 46 Ω (+/- 1 Ω) at 23 °C (73.4 °F)
B62 62 1 (+) Supply - 4-62 = Vbat Valve closed

1. Measuring direct over the dosing valve, 40-44, might cause interference.
If so an indirect measuring can be done between the dosing valve low side switch and ground, 40-58 (gnd).

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30-2 Fault Tracing
128
Component ACM # Measure box # Conn. pin # Signal type Ignition on Engine running Note
Heater A(1) B32 32 2 PWM output 32-59 = fluctuating voltage - PWM powerstage of max 3 A at 28.5 V.
B59 59 1 Supply - - -
30-2 Fault Tracing

Heater B(1) B28 28 2 PWM output 28-59 = fluctuating voltage - PWM powerstage of max 3 A at 28.5 V.
B59 59 1 Supply - - -
Heater C(1) B24 24 2 PWM output 24-59 = fluctuating voltage - PWM powerstage of max 3 A at 28.5 V.
B59 59 1 Supply - - -
NOx sensor B5 5 1 CAN H 5-58 = 2.7 V* 5-58 = 2.7 V* *Approximate mean value.
B1 1 2 CAN L 1-58 = 2.3 V* 1-58 = 2.3 V* *Approximate mean value.
- - 3 (-) GND - - -
B49 49 4 (+) Supply 49-58 = Vbat 49-58 = Vbat -
Pump motor B8 8 8 (-) GND 8-58 = 0 V - -
B62 62 9 (+) Supply 8-62 = Vbat - -
B7 7 10 PWM output - - B7 is the pump motor control signal.

1. Measuring direct over the heating PWM output, 24/28/32-59, might cause interference.
If so an indirect measuring can be done between the heating PWM output and ground, 24/28/32-58 (gnd).

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Table 1: AdBlue/DEF temperature (25/45/70 L) Table 2: AdBlue/DEF level (25 L)

Temperature Nominal value Level (mm) Nominal value
-40 °C (-40 °F) R ≈ 156.1 kΩ > 322 U ≈ 4.6 V
-30 °C (-22 °F) R ≈ 82.3 kΩ 322 U ≈ 4.28 V
-20 °C (-4 °F) R ≈ 45.3 kΩ 306 U ≈ 4.05 V
-10 °C (+14 °F) R ≈ 25.9 kΩ 290 U ≈ 3.82 V
0 °C (+32 °F) R ≈ 15.3 kΩ 274 U ≈ 3.59 V
+10 °C (+50 °F) R ≈ 9.3 kΩ 258 U ≈ 3.36 V
+25 °C (+77 °F) R ≈ 4.7 kΩ 242 U ≈ 3.14 V
+30 °C (+86 °F) R ≈ 3.8 kΩ 226 U ≈ 2.92 V
+40 °C (+104 °F) R ≈ 2.5 kΩ 210 U ≈ 2.70 V
+40 °C (+122 °F) R ≈ 1.7 kΩ 194 U ≈ 2.48 V
+60 °C (+140 °F) R ≈ 1.2 kΩ 178 U ≈ 2.26 V
+70 °C (+158 °F) R ≈ 0.8 kΩ 162 U ≈ 2.06 V
+80 °C (+176 °F) R ≈ 0.6 kΩ 146 U ≈ 1.62 V
+90 °C (+194 °F) R ≈ 0.6 kΩ 130 U ≈ 1.60 V
118 U ≈ 1.38 V
106 U ≈ 1.16 V
94 U ≈ 0.94 V
82 U ≈ 0.72 V
70 U ≈ 0.5 V

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Table 2: AdBlue/DEF level (45 L) Table 2: AdBlue/DEF level (70 L)

Level (mm) Nominal value Level (mm) Nominal value
> 390 U ≈ 4.5 V > 494 U ≈ 4.5 V
390 U ≈ 4.31 V 494 U ≈ 4.35 V
374 U ≈ 4.12 V 478 U ≈ 4.20 V
358 U ≈ 3.93 V 462 U ≈ 4.06 V
342 U ≈ 3.74 V 446 U ≈ 3.91 V
326 U ≈ 3.54 V 430 U ≈ 3.76 V
310 U ≈ 3.35 V 414 U ≈ 3.61 V
294 U ≈ 3.16 V 398 U ≈ 3.47 V
278 U ≈ 2.97 V 382 U ≈ 3.32 V
262 U ≈ 2.78 V 366 U ≈ 3.17 V
246 U ≈ 2.59 V 350 U ≈ 3.02 V
230 U ≈ 2.40 V 334 U ≈ 2.87 V
214 U ≈ 2.21 V 318 U ≈ 2.73 V
198 U ≈ 2.02 V 302 U ≈ 2.58 V
182 U ≈ 1.82 V 286 U ≈ 2.43 V
166 U ≈ 1.63 V 270 U ≈ 2.28 V
150 U ≈ 1.44 V 254 U ≈ 2.13 V
134 U ≈ 1.25 V 238 U ≈ 1.99 V
118 U ≈ 1.06 V 222 U ≈ 1.84 V
106 U ≈ 0.92 V 206 U ≈ 1.69 V
94 U ≈ 0.78 V 190 U ≈ 1.54 V
82 U ≈ 0.64 V 174 U ≈ 1.40 V
70 U ≈ 0.50 V 158 U ≈ 1.25 V
142 U ≈ 1.10 V
130 U ≈ 1.00 V
118 U ≈ 0.90 V
106 U ≈ 0.80 V
94 U ≈ 0.70 V
82 U ≈ 0.60 V
70 U ≈ 0.50 V

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VODIA Log Parameters

Parameter name Error value
Urea tank temperature Depends on surrounding temperature and -50
heating function.
Control module voltage Normal supply voltage ~Vbat 65.535
Urea pressure Normal working pressure 32767.5
~900kPa
Urea tank level 0-100 % 255
Reagent Dosage System Status
- Aftertreatment catalyst reagent dosage 0-100 (Urea dosing valve duty cycle 102
valve percentage)
- Aftertreatment catalyst reagent tank 0 Off (Closed) 2
heating valve 1 On (Open when heating activated)
2 Error
3 Not available
- Aftertreatment catalyst reagent 0 Off (Closed during normal operation) 2
direction valve (flow direction) 1 On (Open during afterrun)
2 Error
3 Not available
- Aftertreatment catalyst reagent dosage 0 Wait for start (System waits to start) 3
status 1 Running (Normal operation)
2 Orifice test (System in self test)
3 Error (Error state)
4 Shut down (System is inactive)
5 Pressure build-up (System is building up
the pressure)
6 Defreeze (Defrosting the system)
7 Wait for afterrun (System waits for
afterrun)
8 Afterrun (System performs afterrun)
10 Post afterrun (System is inactive)
15 Not available
Aftertreatment Reagent Hose Heater 1 0-100 % 102
Aftertreatment Reagent Hose Heater 2 0-100 % 102

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VODIA Tests
IMPORTANT!
This operation requires prior theoretical and/or
instructor led training before attempting.
Contact your local training organization for further
information.

Urea Pressure Build Up Test

NOTICE! The engine and the EATS system must have a normal status with no active fault codes to run the tests
without interference.
1 The test checks that the correct urea pump pressure can be reached. Target pressure during the test is 650
kPa (6.5 bar).

Normally the pressure will be reached within a minute and the test will respond with “OK”. If the test has not
responded within two minutes press the “Stop” button in the test.
The test will not stop immediately since it must complete its current run cycle which can take up to 120 seconds
to complete. If the pressure couldn’t be reached, check that there is no leakage or restrictions in the system.
Be sure that the pump filter is ok and that the strainer in the inlet connector at the pump is clean. Check the function
of the non return valve in the backflow connector on the pump. If the system needs to be cleaned, please refer
to the workshop manual (group 21-26).
Re-run the test after any action.

Urea Dosing Test

NOTICE! The urea pressure build up test must be performed before the dosing test is performed to verify the
pump functionality.
To prevent serious damage of the catalyst the dosing valve must be removed before starting this test.
The engine and the EATS system must have a normal status with no active DTC’s to run the tests without
interference.

A complete dosing valve test consists of three separate tests that all must be carried out.
Precondition: A measuring glass (ml) shall be used to collect the urea solution.
1 Spray test
The test will spray a small dose. Verifying dosing valve function.
2 Dosing test 1 - Small volume test
This test determines if the correct amount of urea solution is dosed.
The dosed amount of urea is measured in milliliters (ml) by collecting the dosed urea solution in a measuring
glass.
3 Dosing test 2 - Big volume test
This test determines if the correct amount of urea solution is dosed.
The dosed amount of urea is measured in milliliters (ml) by collecting the dosed urea solution in a measuring
glass.

If measured volumes are lower than expected, check that there is no leakage or restrictions in the system.
Be sure that the pump filter is OK and that the strainer in the inlet connector at the pump is clean.
If the system needs to be cleaned, please refer to the workshop manual (group 21-26).
Re-run the test after any action. Check that the correct dosing valve is installed.

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Urea Hose Electrical Heating

Activation
NOTICE! The engine and the EATS system must have a normal status with no active fault codes to run the tests
without interference.

Normal running conditions:

Heating function activated: Ambient temperature (air filter sensor ) < +5 °C (41 °F).
Heating function deactivated: Tank temperature > +15 °C (59 °F).

1 The test is a activation of the electrically heated urea hoses. Touch the urea hoses by hand to verify a
temperature increase. Can take several minutes for the hoses to get warm.

If the hoses does not get warm:

1 Check all cables and connectors between the heated hoses and the ACM.
2 Check that the ACM activates the heater output by measuring the outputs.

Urea Heating Valve Diagnostic Test

NOTICE! The engine and the EATS system must have a normal status with no active faultcodes to run the tests
without interference.

Normal running conditions:

Valve open: Tank temperature < +10 °C (50 °F).
Valve closed: Tank temperature > +15 °C (59 °F).

1 The test is performed with the engine running. The test opens the tank heating valve and let engine coolant
warm the tank. Check, by touching the hoses by hand, that engine coolant heats up the hoses that runs
between the valve and the tank. As soon as you can verify that the valve is functioning, by feeling the hose
warming up, the test can be stopped.

If the hoses does not get warm:

1 Check that the valve and all hoses are correctly installed.

Urea forced blowout

NOTICE! The engine and the EATS system must have a normal status with no active fault codes to run the tests
without interference.

The operation, forced blowout, makes sure that the system is completely drained from urea solution. Normally
the system drains itself after ignition off by performing an after-run sequence.

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Dosing system

1. Urea/DEF tank temperature, quality and level sensor with filter.

2. Pump inlet connector strainer
3. 4/2 way directional valve (reverting valve).
4. Membrane pump.
5. Pump filter.
6. Pump pressure sensor.
7. Pump backflow outlet connector with non return valve.
8. Pump outlet connector.
9. Dosing valve.
10. Tank filler filter.
Index
A P204713................................................................... 73
About this Workshop manual..................................... 2 P204A01................................................................... 74
AdBlue/DEF Tank, Change...................................... 19 P204A11................................................................... 75
AdBlue/DEF Tank, Cleaning.................................... 22 P204A13................................................................... 76
AdBlue/DEF-Pump Filter, Change........................... 28 P204A64................................................................... 77
P204F93................................................................... 78
C P205A12................................................................... 79
Checking for diesel or oil in the AdBlue/DEF solution 36 P205A13................................................................... 80
Checking urea concentration in the fluid.................. 37 P206A13................................................................... 81
Combined Tank Unit, AdBlue/DEF Tank, Change... 34 P206A96................................................................... 82
D P208A11................................................................... 83
Dosing unit, change.................................................. 26 P208A12................................................................... 84
DTC interpretation.................................................... 43 P208A13................................................................... 85
P208A92................................................................... 86
E
P20A007................................................................... 87
EATS Inducements................................................ 6, 8
P20A011................................................................... 88
EATS Warnings and Inducements............................. 5
P20A012................................................................... 89
Electrically Heated AdBlue/DEF Hose, Change....... 18
P20A013................................................................... 90
Emission After-Treatment......................................... 17
P20B111................................................................... 91
Erase DTC................................................................ 44
P20B112................................................................... 92
Exhaust Temperature Sensor, Change.................... 25
P20B113................................................................... 93
F P20B197................................................................... 94
Fault Codes.............................................................. 44 P20B911................................................................... 95
Fault Tracing............................................................ 44 P20B912................................................................... 96
G P20B913................................................................... 97
General................................................................. 2, 43 P20B992................................................................... 98
P20BD11.................................................................. 99
I
P20BD12................................................................ 100
Inlet and Exhaust System..................................... 9, 17
P20BD13................................................................ 101
M P20C111................................................................ 102
Measurements........................................................ 126 P20C112................................................................ 103
P P20C113................................................................ 104
P054401................................................................... 46 P20E892................................................................. 105
P054411................................................................... 47 P21CAA1................................................................ 106
P054415................................................................... 48 P242A01................................................................. 107
P065711................................................................... 49 P242A11................................................................. 108
P065712................................................................... 50 P242A15................................................................. 109
P066601................................................................... 51 P245211................................................................. 110
P066611................................................................... 52 P245213................................................................. 111
P066613................................................................... 53 P24FF00................................................................. 112
P06B016................................................................... 54 P266911................................................................. 113
P06B017................................................................... 55 P266912................................................................. 114
P06B316................................................................... 56 P26E711................................................................. 115
P06B317................................................................... 57 Particulate Filter Insert, Replace........................ 37, 40
P10AD11.................................................................. 58 Pump Unit, Change.................................................. 31
P10AD12.................................................................. 59 R
P10AD13.................................................................. 60 Repair instructions................................................ 3, 17
P10CE97.................................................................. 61 Requirements for work with after-treatment
P202D7A.................................................................. 62 system (EATS)......................................................... 15
P203101................................................................... 63
S
P203111................................................................... 64
Safety Information.................................................... 11
P203115................................................................... 65
Safety Instructions.................................................... 11
P203A11................................................................... 66
Solenoid Valve, AdBlue/DEF Tank, Change............ 30
P203A13................................................................... 67
Special Service Tools............................................... 16
P203A96................................................................... 68
Specifications, Engine ............................................... 9
P204201................................................................... 69
P204264................................................................... 70 T
P204711................................................................... 71 Technical Data..................................................... 9, 10
P204712................................................................... 72

47712292 02-2020 © AB VOLVO PENTA 135

U
U000188................................................................. 116
U001088................................................................. 117
U008088................................................................. 118
U02A200................................................................ 119
U05A300................................................................ 120
U114600................................................................. 121
U1FFF68................................................................ 122
U300041................................................................. 123
U300044................................................................. 124
U300045................................................................. 125
U300049................................................................. 126
Urea Dosing Test................................................... 132
Urea forced blowout............................................... 133
Urea Heating Valve Diagnostic Test...................... 133
Urea Hose Electrical Heating Activation................. 133
Urea Pressure Build Up Test.................................. 132
V
VODIA Log Parameters.......................................... 131
VODIA Tests.......................................................... 132

136
 References to Service Bulletins

Group No. Date Refers to

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47712292 English