Fault codes

Reading fault codes via the diagnostic Reading fault codes via ”Easy Link” in-
lamp on the instrument panel, CIU strument (only with CIU)
When the system has discovered a malfunction, the When the system has discovered a malfunction, the
diagnostic lamp starts to flash. If the diagnostic but- diagnostic lamp starts to flash and the fault code will
ton is depressed and then released, a fault code is show in the display of the tachometer.
flashed out.
1. Press the diagnostic button, the fault code will
The fault code consists of two groups of flashes, sepa-
show in the display of the tachometer.
rated by a pause of two seconds. A fault code is ob-
tained by counting the number of flashes in each group. 2. Look up the fault code in the “Fault Code” chapter
and take the recommended measures.
Example: pause = Fault code 2.4
3. When the fault has been attended to, the fault
The fault code is stored and can be read as long as the
code disappears from the display and the diagnos-
malfunction remains. You can find information about
tic lamp goes out.
cause, reaction and actions in the “Fault Code” chapter.
Read the fault code as follows:
1. Press the diagnostic button.
2. Release the diagnostic button and make a note of
the fault that is flashed out.
3. Repeat items 1-2. A new fault code is flashed out Erasing fault codes
if more are stored. Repeat until the first fault code Fault codes must be erased by means of the VODIA
is repeated. tool.
4. Look up the fault code in the “Fault Code” chapter
and take the recommended measures.
NOTE! When the first fault code is repeated, all fault
codes have been read out.
If the diagnostic button is pressed after the fault has
been mended and the fault codes have been erased,
code 1.1 “No fault” will be displayed.

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 Fault codes

EDC III fault codes

WARNING! Read through the safety advice for care and maintenance work in the ”Safety information” chap-
ter before you start work.

NOTE! Reading the fault codes below, such as Code 2.1, PID 97 means that 2.1 is the flashing code indicated by
the diagnostic lamp. PID 97 is read with the VODIA diagnostic tool. With the use of DCU or DU the fault mes-
sage will be shown as text in the display.

NOTE! Please refer to ”Wiring schedule CIU and DCU” for references to the sleeves in the electrical connectors
on the engine control unit.

Code 1.1 No faults Code 2.4, SID22 / SPN 637

Flywheel speed sensor
There are no active faults.
Cause:
Code 2.1, PID / SPN 97. Water in fuel
• No signal.
Cause:
• Abnormal frequency.
• Water in fuel.
• “Intermittent” signal from the sensor.
Reaction:
• Fault in sensor.
• None.
Reaction:
Remedy:
• Engine is very difficult to start and runs roughly
• Empty the primary fuel filter. when it starts.
Code 2.2, PID / SPN 111. Coolant level Remedy:
Cause: • Check that the sensor connector is correctly in-
stalled.
• Low coolant level.
• Check that the engine speed sensor cable is not
Reaction:
damaged.
• Engine control module reduces engine power (un- Check that the engine speed sensor is correctly
less the protection has been shut off with the •
installed in the flywheelhousing.
VODIA diagnostic tool).
• Check engine speed sensor function.
• Engine stopped.
Code 2.5, SID21 / SPN 636
Remedy:
Camshaft drive speed sensor
• Check the coolant level.
Cause:
• Check coolant level monitor function.
• No signal.
Code 2.3, PID / SPN 111. Coolant level sensor • Abnormal frequency.
Cause: • Fault in sensor.
• Short circuit to positive (+). Reaction:
• Fault in sensor. • Engine takes longer to start than normal. Engine
Reaction: runs normally when running.
Remedy:
• None.
Remedy: • Check that the engine speed sensor connector is
correctly installed.
• Check that the coolant level sensor cable is not
• Check that the engine speed sensor cable is not
damaged.
damaged.
• Check coolant level sensor function. Check that the engine speed sensor is correctly
•
installed in the upper timing gear cover.
• Check engine speed sensor function.

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Fault codes

Code 2.8, PPID 132 / SPN 608 Code 3.2, PID / SPN 105
Speed potentiometer connected to CIU Boost temperature sensor
Cause: Cause:
• Shorted to plus (+) or minus (-). • Short circuit to positive (+) or earth (ground) (–).
• Fault in sensor. • Open circuit.
Reaction: Reaction:
• Engine goes to idle. • None.
• If you release the accelerator first, and the press Remedy:
it down again, the engine can be forced to run us- • Check that the boost temperature sensor connec-
ing the idle contact. tor is correctly installed.
Remedy: • Check that the boost temperature sensor cable is
• Check that the potentiometer has been connected not damaged.
correctly. • Check that the boost temperature sensor is cor-
• Check that the cable harness to the potentiometer rectly installed.
has not been damaged. • Check boost temperature sensor function.
• Check the potentiometer function. Code 3.3, PID / SPN 110
Coolant temperature sensor
Code 2.9, PID / SPN 97
Indicator for water in fuel Cause:
Cause: • Short circuit to positive (+) or earth (ground) (–).
• Short circuit • Open circuit.
• Open circuit. Reaction:
• Fault in indicator. • Preheating is also activated when the engine is hot.
Reaction: Remedy:
• None. • Check that the coolant temperature sensor con-
nector is correctly installed.
Remedy:
• Check that the coolant temperature sensor cable
• Check the indicator cables for breaks and short is not damaged.
circuits.
• Check that the coolant temperature sensor is cor-
• Check indicator function. Change indicator as nec- rectly installed.
essary
• Check coolant temperature sensor function.
Code 3.1, PID / SPN 100. Oil pressure sensor
Code 3.4, PID / SPN 106/102,
Cause: Boost pressure sensor
• Short circuit to positive (+) or earth (ground) (–).
Cause:
• Open circuit.
• Short circuit to positive (+) or earth (ground) (–).
Reaction:
• Open circuit.
• None.
Reaction:
Remedy:
• Engine smokes more than normally during accel-
• Check that the oil pressure sensor cable is not eration/load increase.
damaged.
Remedy:
• Check that the oil pressure sensor is correctly
• Check that the boost pressure sensor connector
connected.
is correctly installed.
• Check that the boost pressure sensor cable is not
damaged.
• Check that the boost pressure sensor is correctly
installed.
• Check boost pressure sensor function.

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 Fault codes

Code 3.5, PID / SPN 106/102. Boost pressure Code 3.8, PID / SPN 94. Fuel pressure
Cause: Cause:
• Boost pressure too high • Low supply pressure.
Reaction: Reaction:
• Engine control module reduces engine power (un- • None.
less the protection has been shut off with the Remedy:
VODIA diagnostic tool).
• Check if it is possible to build up pressure with
Remedy: the hand pump.
• Check turbocharger compressor function. • Check the fuel filter.
• Check boost pressure sensor function. • Check the fuel pre-filter.
• Check fuel volume/injector.
Code 3.9, PID / SPN 158. Battery voltage
Code 3.6, PID / SPN 94. Fuel pressure sensor Cause:
Cause: • Faulty alternator.
• Short circuit to positive (+) or earth (ground) (–). • Faulty battery, battery cables.
• Open circuit. Reaction:
Reaction: • None.
• None. Remedy:
Remedy: • Check the supply voltage from the control unit.
• Check that the fuel pressure sensor connector is
Code 4.1 PPID 260. Oil pressure alarm lamp,
correctly installed.
Connected to Stand-Alone Interface
• Check that the fuel pressure sensor cable is not
damaged. Reason:

• Check that the fuel pressure sensor is correctly • Short circuit to negative (-).
installed.
• Short circuit to positive (+).
• Check fuel pressure sensor function.
• Open circuit.
Code 3.7, PID / SPN 175. Oil temperature sensor Reaction:
Cause: • Alarm lamp gives constant light.
• Shorted to plus (+) or minus (-). • Alarm lamp does not work. If there is an open
• Break. circuit on start-up, the diagnosis is de-activated.
Reaction: Action:
• None. • Check that the alarm lamp cable is not damaged.
Remedy: • Check that the alarm lamp is intact and correctly
Check that the cable harness to the oil tempera- installed.
•
ture sensor has not been damaged.
• Check that the oil temperature sensor has been
connected correctly.

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Fault codes

Code 4.2 PPID 7. Coolant temperature alarm Code 4.5 PPID 261. Electrical fault, Coolant
lamp, Connected to Stand-Alone Interface temperature alarm lamp, Connected to Stand-
Alone Interface (TAD1240-1242VE)
Reason:
Reason:
• Short circuit to negative (-).
• Short circuit to negative (-).
• Short circuit to positive (+).
• Short circuit to positive (+).
• Open circuit.
• Open circuit.
Reaction:
Reaction:
• Alarm lamp gives constant light.
• Alarm lamp gives constant light.
• Alarm lamp does not work. If there is an open
• Alarm lamp does not work. If there is an open
circuit on start-up, the diagnosis is de-activated.
circuit on start-up, the diagnosis is de-activated.
Action:
Action:
• Check that the alarm lamp cable is not damaged.
• Check that the alarm lamp cable is not damaged.
• Check that the alarm lamp is intact and correctly
• Check that the alarm lamp is intact and correctly
installed.
installed.
Code 4.6, PPID 3 / SPN 677
Code 4.3 PPID 263 Operation indication lamp Start output / Start motor relay
(TAD1240-42GE)
Reason: Cause:
• Shorted to plus (+) or minus (-).
• Short circuit to negative (-).
• Activated for too long.
• Short circuit to positive (+).
Reaction:
• Open circuit.
• The engine cannot be started.
Reaction:
• The engine starts immediately when ignition is tur-
• Alarm lamp gives constant light. ned on.
• Alarm lamp does not work. If there is an open Remedy:
circuit on start-up, the diagnosis is de-activated.
• Check that connections to the ignition key have
Action: not been damaged.
• Check that the alarm lamp cable is not damaged.
• Check that the cable harness to the ignition key
• Check that the alarm lamp is intact and correctly has not been damaged.
installed. Code 4.8, PPID 6/ SPN 520195. Stop input
Code 4.4 PPID 264. Overspeed alarm lamp, Cause:
Connected to Stand-Alone Interface
(TAD1240-42GE) • Short circuit to negative (-).

Reason: • Open circuit.

Reaction:
• Short circuit to negative (-).
• Engine can only be stopped with the auxiliary
• Short circuit to positive (+). stop.
• Open circuit. Remedy:
Reaction: • Check that the starter switch connections are not
• Alarm lamp gives constant light. damaged.

• Alarm lamp does not work. If there is an open

circuit on start-up, the diagnosis is de-activated.
Action:
• Check that the alarm lamp cable is not damaged.
• Check that the alarm lamp is intact and correctly
installed.

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 Fault codes

Code 5.2, PPID 4 / SPN 520194. Starter input CIU Code 5.8, PID / SPN 175. Oil temperature
Cause: Cause:
• Shorted to minus (-). • Oil temperature is too high
• Activated for too long. Reaction:
Reaction: • Warning indication.
• The engine cannot be started. • The engine control module limits engine output
(unless protection has been turned off with the
• The engine starts immediately when ignition is tur-
diagnosis tool VODIA).
ned on.
Remedy: Remedy:

Check that connections to the ignition key have • Check the oil level.
•
not been damaged. • Check the oil temperature.
• Check that the cable harness to the ignition key • Check the oil temperature sensor function.
has not been damaged.
Code 6.1, PID / SPN 110. Coolant temperature
Code 5.3, PPID 6/ SPN 970. Stop input CIU
Cause:
Cause:
• Coolant temperature is too high.
• Short circuit to negative (-).
Reaction:
• Open circuit.
• Engine control module reduces engine power (un-
• Activated for too long time. less the protection has been shut off with the
Reaction: VODIA diagnostic tool).
• Engine can only be stopped with the auxiliary stop Remedy:
(AUX STOP) on engine. • Check the coolant level.
• Engine stops. A fault code is displayed for 40 • Check the intercooler (cleanliness).
seconds and the engine can not be started during
this time. When a fault code is active, the engine • Check if there is air in the cooling system.
can be started but not stopped. • Check the pressure cap on the expansion tank.
Remedy: • Check coolant temperature sensor function.
• Check that the starter switch connections are not • Check thermostat function.
damaged.
Code 6.2, PID / SPN 105. Boost temperature
• Check that the ignition switch cable is not
damaged. Cause:
• Boost temperature is too high.
Code 5.4, PID 45/ SPN 626. Preheating relay
(TAD1240-42VE) Reaction:

Cause: • Engine control module reduces engine power (un-

less the protection has been shut off with the
• Short circuit to positive (+) or earth (ground) (–). VODIA diagnostic tool).
• Open circuit. Remedy:
Reaction: • Check the coolant level.
• Preheating can not be activated. • Check the intercooler (cleanliness).
• Preheating is constantly connected. • Check boost temperature sensor function.
Remedy: • Check the function of the thermostat.
• Check that the relay input cable is not damaged.
• Check relay function.

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Fault codes

Code 6.4, PPID 231 / SPN 639, Data link (CAN), Code 6.9, PID / SPN 158, Battery voltage, CIU
CIU
Cause:
Cause:
• Short circuit to negative (-).
• Faulty data link (CAN), CIU.
• Faulty alternator.
Reaction:
• Faulty battery, battery cables.
• Instruments and warning lamps stop working.
Reaction:
Remedy:
• Problems in engine starting.
• Check that the 8-pin connector is not damaged.
Remedy:
• Check that the cables between the CIU and the
engine management unit are not damaged. • Check the supply voltage from the control unit.

Code 6.5, PPID 231 / SPN 639, 2017 / PSID 201 • Check the battery.
Data link (CAN) • Check the alternator.
Cause: • Check the 8-pin contact.
• Internal fault in control module. Code 7.1, SID 1 / SPN 651
Reaction: Injector, cylinder #1
• Engine not operating: engine can not be started. Cause:
Engine operating: engine idles and can only be • Electrical fault.
stopped with the auxiliary stop (AUX-stop).
• Faulty compression or injector.
Remedy:
Reaction:
• Check that the 8-pin connector is not damaged.
• Engine runs on 5 cylinders.
• Check that the cables between the CIU and the
engine management unit are not damaged. • Abnormal sound.
• Check that sleeves 11 and 12 in the connector on • Reduced performance.
the CIU are not damaged. Remedy:
Code 6.6, PID / SPN 100, Oil pressure • Check that the injector cables are not damaged.
Cause: • Check that the injector connections are not dam-
aged.
• Oil pressure is too low.
• Check fuel supply pressure.
Reaction:
• Check the valve clearance.
• Engine control module reduces engine power (un-
less the protection has been shut off with the • Do a compression test and check cylinder #1.
VODIA diagnostic tool).
Remedy:
• Check oil level.
• Check that the air filters are not blocked.
• Check system pressure valves and safety valves
in the oil system.
• Check oil pressure sensor function.

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 Fault codes

Code 7.2, SID 2 / SPN 652 Code 7.4, SID 4 / SPN 654
Injector, cylinder #2 Injector, cylinder #4

Cause: Cause:
• Electrical fault. • Electrical fault.
• Faulty compression or injector. • Faulty compression or injector.
Reaction: Reaction:
• Engine runs on 5 cylinders. • Engine runs on 5 cylinders.
• Abnormal sound. • Abnormal sound.
• Reduced performance. • Reduced performance.
Remedy: Remedy:
• Check that the injector cables are not damaged. • Check that the injector cables are not damaged.
• Check that the injector connections are not dam- • Check that the injector connections are not dam-
aged. aged.
• Check fuel supply pressure. • Check fuel supply pressure.
• Check the valve clearance. • Check the valve clearance.
• Do a compression test and check cylinder #2. • Do a compression test and check cylinder #4.

Code 7.3, SID 3 / SPN 653 Code 7.5, SID 5 / SPN 655
Injector, cylinder #3 Injector, cylinder #5
Cause:
Cause:
• Electrical fault.
• Electrical fault.
• Faulty compression or injector.
• Faulty compression or injector.
Reaction:
Reaction:
• Engine runs on 5 cylinders.
• Engine runs on 5 cylinders.
• Abnormal sound.
• Abnormal sound.
• Reduced performance.
• Reduced performance.
Remedy:
Remedy:
• Check that the injector cables are not damaged.
• Check that the injector cables are not damaged.
• Check that the injector connections are not dam-
• Check that the injector connections are not dam-
aged.
aged.
• Check fuel supply pressure.
• Check fuel supply pressure.
• Check the valve clearance.
• Check the valve clearance.
• Do a compression test and check cylinder #5.
• Do a compression test and check cylinder #3.

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Fault codes

Code 7.6, SID 6 / SPN 656 Code 9.3, 232 / SPN 620/1079
Injector, cylinder #6 Power supply to sensor
Cause: Cause:
• Electrical fault. • Shortcut.
• Faulty compression or injector. • Fault in sensor.
Reaction: Reaction:
• Engine runs on 5 cylinders. • Faulty values in oil pressure and boost pressure
sensors.
• Abnormal sound.
• Fault code for oil pressure- and boost pressure
• Reduced performance.
sensor.
Remedy:
• Low engine output.
• Check that the injector cables are not damaged.
• The instrument shows zero oil pressure and boost
• Check that the injector connections are not dam- pressure.
aged.
Remedy:
• Check fuel supply pressure.
• Check that the cable harness to oil pressure and
• Check the valve clearance. boost pressure sensor has not been damaged.
• Do a compression test and check cylinder #6.
• Check oil pressure and boost pressure sensors.
Code 8.3, SID 42 / SPN 679. Injection pressure,
regulator Code 9.8, SID 253 / SPN 630
Data set memory EEPROM, CIU
Cause:
Cause:
• Fault in cable harness.
• Internal fault in control module
• Fault in actuator.
• Programming faulty.
Reaction:
Reaction:
• Engine control module reduces engine power.
• Engine does not start.
Remedy:
Remedy:
• Contact an autorized Volvo Penta workshop.
• Re-program the control module. If the fault re-
Code 9.2, SID 250 / SPN 608 mains, change the control module.
Faulty data link (J1587)
Code 9.8, SID 254 / SPN 629
Cause: Fault in control unit, CIU
• Faulty data link. Cause:
Reaction: • Faulty EEPROM, CIU.
• None. • Faulty flash memory, CIU.
Remedy: • Fault in control module, CIU
• Check that the 8-pin connector is not damaged. Reaction:
• Check that the cables between the CIU/DCU and • CIU returns to factory setting.
the engine management unit are not damaged.
• Engine goes to idle.
• Engine can not be started.
Remedy:
• Re- program the unit
• Change CIU unit.

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 Fault codes

Code 9.9, SID 240 / SPN 639. Memory fault Code 9.9, SID 254 / SPN 629
Control module
Cause:
Cause:
• Memory fault in engine management system.
• Internal fault in control module.
Reaction:
Reaction:
• Engine might not start.
• Engine misfires.
Remedy:
• Engine does not start.
• Re-program the unit.
Remedy:
Code 9.9, SID 253 / SPN 630 • Change engine control unit.
Data set memory EEPROM
Cause:
• Internal fault in control module
• Programming faulty.
Reaction:
• Engine does not start.
Remedy:
• Re-program the control module. If the fault re-
mains, change the control module.

75