Volvo TSI User manual

Foreword
The descriptions and service procedures contained in this manual are based on de-
signs and methods studies carried out up to June 2001.
The products are under continuous development. Vehicles and components produced
after the above date may therefore have different specifications and repair methods.
When this is believed to have a significant bearing on this manual, supplementary ser-
vice bulletins will be issued to cover the changes.
The new edition of this manual will update the changes.
In service procedures where the title incorporates an operation number,this is arefer-
ence to an S.R.T. (Standard Repair Time).
Service procedures which do not include an operation number in the title are for gen-
eral information and no reference is made to an S.R.T.
The following levels of observations, cautions and warnings are used in this Service
Documentation:
Note: Indicates a procedure, practice, or condition that must be followed in order to
have the vehicle or component function in the manner intended.
Caution: Indicates an unsafe practice where damage to the product could occur.
Warning: Indicates an unsafe practice where personal injury or severe damage to the
product could occur.
Danger: Indicates an unsafe practice where serious personal injury or death could oc-
cur.
Volvo Trucks North America, Inc.
Greensboro, NC USA
Order number: PV776-144528
©2001 VolvoTrucks North America, Inc., Greensboro,NC USA
All rights reserved. No part of this publication may be reproduced, stored in
retrieval system, or transmitted in any forms by any means, electronic, me-
chanical, photocopying, recording or otherwise, without the prior written
permission of VolvoTrucks North America, Inc.

Contents
General .................................................................................................... 7
Vehicle Management System ................................................................ 7
Engine Control System Glossary........................................................ 8
Specifications ....................................................................................... 10
Description of Signals .......................................................................... 10
EECU (D7C) and Breakout BoxConnected in Series Between
EECU and Wiring Harness ............................................................... 10
EECU,D7C,with Breakout BoxConnected to Wiring Harness Only 13
EECU (D12B and D12C), Breakout BoxConnected in Series Be-
tween EECU and Wiring Harness ..................................................... 16
EECU (D12B and D12C), Breakout BoxConnected to Wiring
Harness Only ..................................................................................... 19
Pinouts ................................................................................................. 22
Engine Electronic Control Unit (EECU) ............................................ 22
Pinouts ................................................................................................. 26
Vehicle Electronic Control Unit(VECU) ............................................. 26
Schematic ............................................................................................ 28
D12B .................................................................................................. 28
Schematic ............................................................................................ 29
D12C ................................................................................................. 29
Schematic ............................................................................................ 30
D7C ................................................................................................... 30
Schematic ............................................................................................ 31
VECU ................................................................................................. 31
Tools ...................................................................................................... 33
Special Tools ....................................................................................... 33
Other Special Equipment .................................................................... 35
Design and Function ........................................................................... 37
Vehicle Management System .............................................................. 37
Strategy ............................................................................................. 37
Conventional Control Systems .......................................................... 37
Data Link System .............................................................................. 38
Data Links,Design and Function ...................................................... 39
Diagnostic Connector ........................................................................ 47
Communication Equipment ............................................................... 48
Instrument Cluster ............................................................................. 49
Vehicle Electronic Control Unit (VECU) ............................................ 50
Engine Electronic Control Unit .......................................................... 51
ABS BrakeSystem ECU ................................................................... 63
SRS Airbag ECU ............................................................................... 64
Transmission ECU ............................................................................. 65
Breakout Boxes and Harnesses ........................................................ 66
VECU Overview................................................................................ 67
VECU Functions ................................................................................ 68
Sensor Locations ............................................................................... 73
Control Unit Locations ....................................................................... 77
Fuses and Relays .............................................................................. 81
Troubleshooting ................................................................................... 85
Fault Code Troubleshooting ................................................................... 85
Message and Parameter Descriptions ................................................ 85
FMI Table ............................................................................................. 87
Reading/Clearing Fault Codes .......................................................... 88 1

Fault Tracing Strategy ....................................................................... 88
MID 128 EECU ...................................................................................... 92
MID 128 Fault Code Table .................................................................. 92
MID 128 PID 45 Preheater Status ...................................................... 96
Fault Codes ....................................................................................... 96
MID 128 PID 45 Preheater Status,Check.......................................... 97
MID 128 PID 49 ABS Control Status .................................................. 98
Fault Codes ....................................................................................... 98
MID 128 PID 49 ABS Control Status,Check...................................... 99
MID 128 PID 84 Road Speed ........................................................... 100
Fault Codes ..................................................................................... 100
MID 128 PID 84 Road Speed, Check............................................... 101
MID 128 PID 85 Cruise Control Status ............................................. 102
Fault Codes ..................................................................................... 102
MID 128 PID 85 Cruise Control Status,Check................................ 103
MID 128 PID 91 Accelerator Pedal Position ..................................... 104
Fault Codes ..................................................................................... 104
MID 128 PID 91 Accelerator Pedal Position, Check......................... 105
MID 128 PID 94 Fuel DeliveryPressure ........................................... 106
D7C and D12C ................................................................................ 106
Fault Codes ..................................................................................... 106
MID 128 PID 94 Fuel DeliveryPressure,Check.............................. 107
D7C and D12C ................................................................................ 107
MID 128 PID 100 Engine Oil Pressure ............................................. 110
Fault Codes ..................................................................................... 110
MID 128 PID 100 Engine Oil Pressure,Check................................. 111
MID 128 PID 102 Boost Pressure ..................................................... 114
Fault Codes ..................................................................................... 114
MID 128 PID 102 Boost Pressure,Check........................................ 115
MID 128 PID 105 Boost Air Temperature ......................................... 118
Fault Codes ..................................................................................... 118
MID 128 PID 105 Boost Air Temperature,Check............................. 119
MID 128 PID 107 Air Filter Differential Pressure .............................. 122
Fault Codes ..................................................................................... 122
MID 128 PID 107 Air Filter Differential Pressure,Check.................. 124
MID 128 PID 108 Atmospheric Pressure .......................................... 125
Fault Codes ..................................................................................... 125
MID 128 PID 110 Engine Coolant Temperature ............................... 126
Fault Codes ..................................................................................... 126
MID 128 PID 110 Engine Coolant Temperature,Check................... 127
MID 128 PID 111 Coolant Level ....................................................... 129
Fault Codes ..................................................................................... 129
MID 128 PID 111 Coolant Level, Check........................................... 130
MID 128 PID 158 BatteryVoltage ..................................................... 131
Fault Codes ..................................................................................... 131
MID 128 PID 158 BatteryVoltage,Check........................................ 132
MID 128 PID 172 Air Inlet Temperature ............................................ 133
Fault Codes ..................................................................................... 133
MID 128 PID 172 Air Inlet Temperature,Check............................... 134
MID 128 PID 174 Fuel Temperature ................................................. 136
D7C and D12C ................................................................................ 136
Fault Codes ..................................................................................... 136
MID 128 PID 174 Fuel Temperature,Check..................................... 137
D7C and D12C ................................................................................ 137
MID 128 PID 175 Engine Oil Temperature ....................................... 140
2

Fault Codes ..................................................................................... 140
MID 128 PID 175 Engine Oil Temperature,Check........................... 141
MID 128 PID 228 Road Speed Sensor Calibration .......................... 144
Fault Codes ..................................................................................... 144
MID 128 PID 228 Road Speed Sensor Calibration, Check.............. 145
MID 128 PPID 86 Engine BrakeTorque Percent .............................. 146
Fault Codes ..................................................................................... 146
MID 128 PPID 86 Engine BrakeTorque Percent, Check................. 147
MID 128 PPID 119 High Coolant Temperature ................................. 148
Fault Codes ..................................................................................... 148
MID 128 PPID 119 High Coolant Temperature,Check.................... 149
MID 128 PPID 122 VCB Engine Compression Brake...................... 151
D12B and D12C .............................................................................. 151
Fault Codes ..................................................................................... 151
MID 128 PPID 122 VCB Engine Compression Brake,Check.......... 152
D12B and D12C .............................................................................. 152
MID 128 PPID 123 EPG 2................................................................ 153
D12B and D12C .............................................................................. 153
Fault Codes ..................................................................................... 153
MID 128 PPID 123 EPG 2, Check.................................................... 154
D12B and D12C .............................................................................. 154
MID 128 PPID 124 EPG 1................................................................ 155
Fault Codes ..................................................................................... 155
MID 128 PPID 124 EPG 1, Check.................................................... 156
MID 128 SID 1/2/3/4/5/6 Injector ..................................................... 157
D12B and D12C .............................................................................. 157
Fault Codes ..................................................................................... 157
MID 128 SID 1/2/3/4/5/6 Injector,Check.......................................... 159
D12B and D12C .............................................................................. 159
MID 128 SID 17 Fuel Shutoff Valve.................................................. 161
Fault Codes ..................................................................................... 161
MID 128 SID 17 Fuel Shutoff Valve,Check...................................... 162
D7C only .......................................................................................... 162
MID 128 SID 20 Timing Sleeve......................................................... 163
D7C only .......................................................................................... 163
Fault Codes ..................................................................................... 163
MID 128 SID 20 Timing Sleeve, Check............................................ 165
D7C only .......................................................................................... 165
MID 128 SID 21 Engine Position Timing Sensor .............................. 166
D12B and D12C .............................................................................. 166
Fault Codes ..................................................................................... 166
MID 128 SID 21 Engine Position Timing Sensor,Check.................. 167
D12B and D12C .............................................................................. 167
MID 128 SID 21 Needle Lift Sensor ................................................. 168
Fault Codes ..................................................................................... 168
MID 128 SID 21 Needle Lift Sensor,Check..................................... 169
D7C only .......................................................................................... 169
MID 128 SID 22 Engine Speed Sensor ............................................ 170
Fault Codes ..................................................................................... 170
MID 128 SID 22 Engine Speed Sensor,Check................................ 171
MID 128 SID 23 RackActuator ......................................................... 172
D7C only .......................................................................................... 172
Fault Codes ..................................................................................... 172
MID 128 SID 23 RackActuator,Check............................................. 174
D7C only .......................................................................................... 174
3

MID 128 SID 24 RackPosition Sensor ............................................. 175
D7C only .......................................................................................... 175
Fault Codes ..................................................................................... 175
MID 128 SID 24 RackPosition Sensor,Check................................. 176
D7C only .......................................................................................... 176
MID 128 SID 33 Fan Control ............................................................. 177
Fault Codes ..................................................................................... 177
MID 128 SID 33 Fan Control, Check................................................ 178
MID 128 SID 64 Redundant Engine Speed Sensor ......................... 179
D7C only .......................................................................................... 179
Fault Codes ..................................................................................... 179
MID 128 SID 64 Redundant Engine Speed Sensor,Check............. 180
D7C only .......................................................................................... 180
MID 128 SID 70 Preheater Element 1.............................................. 181
Fault Codes ..................................................................................... 181
MID 128 SID 70 Preheater Element 1, Check.................................. 182
MID 128 SID 71 Preheater Element 2.............................................. 183
D12B only ........................................................................................ 183
Fault Codes ..................................................................................... 183
MID 128 SID 71 Preheater Element 2, Check.................................. 184
D12B ................................................................................................ 184
MID 128 SID 230 Idle Validation Switch 1........................................ 185
Fault Codes ..................................................................................... 185
MID 128 SID 230 Idle Validation Switch 1, Check............................ 186
MID 128 SID 231 SAE J1939 Control Link ....................................... 187
Fault Codes ..................................................................................... 187
MID 128 SID 232 5Volt DC Supply .................................................. 189
Fault Codes ..................................................................................... 189
MID 128 SID 232 5Volt DC Supply,Check...................................... 190
MID 128 SID 240 Program Memory................................................. 191
Fault Codes ..................................................................................... 191
MID 128 SID 250 SAE J1587/1708 Information Link ....................... 192
Fault Codes ..................................................................................... 192
MID 128 SID 253 Data Set MemoryEEPROM ................................ 193
Fault Codes ..................................................................................... 193
MID 128 SID 254 Engine Electronic Control Unit (EECU) ............... 194
Fault Codes ..................................................................................... 194
MID 144 VECU .................................................................................... 196
MID 144 Fault Code Table ................................................................ 196
MID 144 PID 29 Second Accelerator Pedal Position Sensor ........... 198
Fault Codes ..................................................................................... 198
MID 144 PID 29 Second Accelerator Pedal Position Sensor,Check199
MID 144 PID 84 Road Speed ........................................................... 201
Fault Codes ..................................................................................... 201
MID 144 PID 84 Road Speed, Check............................................... 202
MID 144 PID 91 Accelerator Pedal Position ..................................... 204
Fault Codes ..................................................................................... 204
MID 144 PID 91 Accelerator Pedal Position, Check......................... 205
MID 144 PID 152 VECU,Number of Resets .................................... 207
Fault Codes ..................................................................................... 207
MID 144 PPID 69 Idle Validation Switch ........................................... 208
Fault Codes ..................................................................................... 208
MID 144 PPID 69 Idle Validation Switch, Check.............................. 209
MID 144 PPID 70 Pedal Switches,Supply ....................................... 211
Fault Codes ..................................................................................... 211
4

MID 144 PPID 70 Pedal Switches,Supply,Check........................... 212
MID 144 PPID 71 Cruise Control and Engine Brake,Supply Switch 215
Fault Codes ..................................................................................... 215
MID 144 PPID 71 Cruise Control and Engine Brake,Supply
Switch, Check.................................................................................... 216
MID 144 PPID 72 Accelerator Pedal, Supply Sensors ..................... 220
Fault Codess ................................................................................... 220
MID 144 PPID 72 Accelerator Pedal, Supply Sensors,Check......... 221
MID 144 PPID 73 Second Accelerator Pedal, Supply Sensors ........ 223
Fault Codes ..................................................................................... 223
MID 144 PPID 73 Second Accelerator Pedal, Supply Sensors,
Check................................................................................................. 224
MID 144 PPID 75 Range Inhibitor,Solenoid ValveStatus ............... 226
Fault Codes ..................................................................................... 226
MID 144 PPID 75 Range Inhibitor,Solenoid ValveStatus,Check... 227
MID 144 SID 230 Idle Validation Switch 1........................................ 229
Fault Codes ..................................................................................... 229
MID 144 SID 230 Idle Validation Switch 1, Check............................ 230
MID 144 SID 231 SAE J1939 Control Link ....................................... 232
Fault Codes ..................................................................................... 232
MID 144 SID 231 SAE J1939 Control Link, Check.......................... 233
MID 144 SID 240 Program Memory................................................. 234
Fault Codes ..................................................................................... 234
MID 144 SID 243 Cruise Control Set Switch .................................... 235
Fault Codes ..................................................................................... 235
MID 144 SID 243 Cruise Control Set Switch, Check....................... 236
MID 144 SID 250 SAE J1587/1708 Information Link ....................... 238
Fault Codes ..................................................................................... 238
MID 144 SID 250 SAE J1587/1708 Information Link, Check........... 239
MID 144 SID 253 Data Set MemoryEEPROM ................................ 240
Fault Codes ..................................................................................... 240
MID 144 PSID 3Idle Validation Switch 3......................................... 241
Fault Codes ..................................................................................... 241
MID 144 PSID 3Idle Validation Switch 3, Check............................. 242
Service Procedures ........................................................................... 245
Engine ECU,Replacement ................................................................ 245
Feedback
Operation Numbers
5

6

Group 28 General
General
Vehicle Management System
W2002520
This information covers the Vehicle Management System, which includes VECTRO II
electronics, the vehicle ECU, and other control systems used in the vehicle.
7

Group 28 General
Engine Control System Glossary
ATA
American Trucking Association
ATDC (After Top Dead Center)
The 180

of crankshaft rotation after the piston reaches
top center (normal direction of rotation).
AC (Alternating Current)
An electrical current that alternates level and direction.
BTDC (Before Top Dead Center)
The 180

of crankshaft rotation before the piston reaches
top center (normal direction of rotation).
INFO lamp
Light that warns the operator of an active diagnostic fault
code; also referred to as the diagnostic lamp.
Data link
An electrical connection for communication with other
microprocessor-based devices (such as powertrain con-
trol, trip recorders and maintenance systems) that are
compatible with the ATA and SAE standard.
Diagnostic fault code
These codes indicate an electronic system malfunction,
indicating a problem with the D12 electrical systems.
Diagnostic flash code
Codes flashed out in a series via the INFO lamp to indi-
cate an active fault code.
DC (Direct Current)
An electrical current that flows in one direction only.
EEPROM (Electrical Erasable Programmable Read
Only Memory)
The contents of this type of memory may be electroni-
cally erased and new information programmed into the
device.
EECU (Engine Electronic Control Unit)
The computer that controls the power supplied to the en-
gine electronics, monitors and governs engine functions.
EUI (Electronic Unit Injector)
An injector pump which is mechanically activated and
electronically controlled. It combines metering and inject-
ing in a single unit.
Engine brake disable system
During the time ABS (anti-lock braking system) is active,
the engine brake is disabled.
FMI (Failure Mode Identifier)
Numbers and names used to identify how a system or
part failed.
FMI Description
0 Data valid but above normal operating range
1Data valid but below normal operating range
2Data erratic, intermittent, or incorrect
3Voltage above normal
4Voltage below normal
5Current below normal or open circuit
6Current above normal or short circuit
7Mechanical system not responding properly
8Abnormal frequency, pulse rate or period
9Abnormal update
10 Abnormal rate of change
11 Failure mode not identifiable
12 Defective device or component
13 Uncalibrated device or component
14/15 Reserved for future assignment
Hz (Hertz)
Measure of frequency in cycles per second.
MID
Message Identification Description
Open circuit
Condition where an electrical wire or connector is bro-
ken, preventing signal or supply voltage from reaching its
intended destination.
Parameter
A programmable value that affects the characteristics or
behavior of the engine and/or vehicle.
8