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W2003793
This information covers fault tracing the electric fuel pump on the Volvo D12D engine.
Contents
General Guide to Fault Tracing page 2
System Overview page 3
Electric Fuel Pump, Fault Tracing page 4
You must read and understand the precautions and guidelines in Service Information,
group 20, "General Safety Practices, Engine" before performing any procedure. If
you are not properly trained and certified in a procedure, ask your supervisor for
training before you perform it.
System Overview
System Overview
When fault tracing, it is important to understand the function of the system
and to follow the fault tracing sequence in the checklist to avoid replacing
non-defective components.
W2004345
Engine OFF
Ignition key in ON position
Vehicle stationary
Parking brake applied
1
IMPACT or ID DVD: Info type Diagnostics, group 2309
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 4.2004 233 17 4(11)
1 Are there any fault codes active? (refer to diagnostic information group 28 in
Intelligent Diagnostics (ID) DVD)2
2 Fuel system bleeding / fuel pump, test
Check the electric fuel pump system using the PC tool (VCADS Pro).
Does the fuel pressure display in VCADS Pro indicate any fuel pressure?
Notes:
2
IMPACT or ID DVD: Info type Diagnostics, group 2841
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 4.2004 233 17 5(11)
Note: If fault codes SID 33, PPID 122, and PPID 124 are
also active, this might indicate that the common supply
wire from fuse F80 has opened or shorted.
Special tools: 9998699, 9813194, 85104407
Other special equipment: J-39200
1
Check fuse (F80 located in main fuse panel) for the
switch. If fuse is good, proceed with next step.
2
Turn the ignition key to the OFF position. Disconnect
the PA connector from the VECU.
3
Connect adapter 9813194 and breakout box 9998699
with overlay 85104407 between the wiring and the VECU.
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4
Turn ignition key to the ON position. Using multimeter
J-39200, measure the voltage between pins PA4 and
PA12.
J-39200
3
IMPACT or ID DVD: Info type Diagnostics, group 2841
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 4.2004 233 17 6(11)
5
If the expected value is not obtained, there is probably a
fault in:
switch; or
connections or wire between the switch and the fuse; or
connections or wire between the switch and the VECU.
6
If fault is not found, continue fault tracing according to
next step in the checklist. See Electric Fuel Pump,
Fault Tracing page 4.
2
Connect PC tool to diagnostic connector (if not already
connected) and select Fuel system bleeding, test in
VCADS Pro. Turn the ignition switch to the ON position.
3
Start the test and activate the Bleed fuel injection
system activation. Note the fuel pressure displayed in
the test. Fuel pressure display should indicate a low
pressure reading when pump is running and there is
sufficient fuel in system. If a fault occurs or pump doesnt
run, go to step 4.
If the pump runs when activated via VCADS Pro, but not
with the switch, check the switch and wiring. If the switch
and wiring is good, check the J1939 data link. Refer to
Service information group 371 Datalink Fault Tracing.5
4
IMPACT or ID DVD: Info type Diagnostics, group 2841
5
IMPACT or ID DVD: Info type Diagnostics, group 3711
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 4.2004 233 17 7(11)
4
Stop the test and turn the ignition switch to the OFF
position. Disconnect the connector for the electric fuel
pump. Connect adapter 9998567 to the wiring harness
and connector on the pump housing.
9998567
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5
Turn the ignition key to the ON position. Using multimeter
J-39200, measure voltage between pin 5 in the 7pin
breakout box and ground.
6
Turn the ignition key to the OFF position. Disconnect the
connector for the electric fuel pump.
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7
Turn the ignition key to the ON position. Using multimeter
J-39200, measure voltage between pin 1 in the adapter
breakout box and ground.
J-39200
8
If the voltage is less than B+, check the fuse for the fuel
pump (fuse EMS-B, fuse no. F80). If fuse is okay, check
voltage supply at 12-pin interface connector on the engine
wiring harness on terminal EM7 to determine if fault is
between fuse and engine wiring harness or between
12-pin connector and the fuel pump housing. If fuse is
open, check supply wire for short circuit to ground.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 4.2004 233 17 9(11)
9
Connect adapter 9998567 between the wiring and the
pump. With ignition switch in ON position listen for the
electric pump. Determine whether it operates when
socket 5 of the breakout box is properly grounded.
9998567
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10
If the pump does not operate, go to step 14.
If the pump operates (but still does not activate when the
switch is pressed) and all other conditions for the function
are met, there is probably a fault in:
11
Turn the Ignition key to the OFF position. Disconnect
adapter 9998567 from the pump. Only the adapter must
be connected to the wiring harness
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 4.2004 233 17 10(11)
12
Connect breakout box 9998699 and adapter 9990014
with the EECU wiring (EA connector/lower).
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13
Using multimeter J-39200, check the connection by
measuring the resistance between socket 5 in 7pin
adapter 9998567 and socket A3 in breakout box 9998699.
14
Remove the cover for the fuel pump harness. Check the
supply and control wires between the 7pin connector
and the pump. Pin 1 is supply and pin 5 is control/ground.
15
Connect 7pin adapter 9998567 to fuel pump connector
only. Using multimeter J-39200, measure resistance
between pins 1 and 5. Also check for short circuit
to ground.
16
If no faults are found with the wiring, apply B+ to the
black lead on the pump and ground to the white lead.
If the pump still does not operate, replace the electric
fuel pump.
17
After any repairs, activate the pump switch in the dash
panel to verify pump function.