Service Bulletin
Volvo Trucks North America, Inc.
Greensboro, NC USA Trucks
Date Group No. Page
This Service Bulletin replaces SB 233–17, “Electric
Fuel Pump, Fault Tracing” (11.2002), publication no. 12.2003 233 17 1(10)
PV776–TSP170590.
Electric Fuel Pump
Fault Tracing
Checklist S
D12D
Electric Fuel Pump, Fault Tracing
Checklist S
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
• “Electric Fuel Pump, Fault Tracing” page 5
Note: Information is subject to change without notice.
Illustrations are used for reference only and may differ slightly from the actual engine
version. However, key components addressed in this information are represented as
accurately as possible.
PV776-20 000184 USA14500
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2003 233 17 2(10)
General Guide to Fault Tracing
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.
To use this checklist:
1 • Complete basic data gathering
• Read fault codes
• Check vehicle parameters
2 Use the recommendations in appropriate symptom information, plus the
information gathered above to provide a foundation for continued fault tracing
using this checklist.
One fault often affects other systems. Therefore, it is important to confirm or
eliminate suspected causes of faults at an early stage, using tests in VCADS
Pro.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2003 233 17 3(10)
System Overview
W2004345
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.
Fuel System, Bleeding
The fuel system can be bled automatically. The driver If the engine is started during fuel system bleeding,
activates fuel system bleeding by pressing the dashboard bleeding stops and the warning indicator goes out.
switch (1). If all preconditions are met, the VECU (2)
transmits the request via J1939 Control Data Link to For more information about the fuel system, refer to
the EECU (3), which activates the electric fuel pump Service Information, group 23. For information on fault
(4). System bleeding takes approximately 5 minutes, as tracing the fuel system, refer to “Fault Tracing, Checklist
all air in the system is pumped back into the fuel tank. B, Fuel Pressure.”
During bleeding, the instrument cluster (5) displays a
warning. When bleeding is complete, the warning is no
longer displayed.
The following preconditions must be met for fuel system
bleeding to start:
• Engine OFF
• Ignition key in ON position
• Vehicle stationary
• Parking brake applied
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2003 233 17 4(10)
Electric Fuel Pump, Fault Tracing
See also:
• “General Guide to Fault Tracing” page 2
The numbers in brackets refer to the schematic diagram;
see “System Overview” page 3.
Before beginning fault tracing, all system-related fault
codes must be resolved using the appropriate checks.
Vehicle Chassis No. Mileage Customer
Yes No
1 Are there any fault codes active? (refer to diagnostic information group 28 in
IMPACT or IMPACT DVD)
2 Fuel system bleeding / fuel pump, test
Check the electric fuel pump system using the PC tool (VCADS Pro).
Does the electric pump operate when activated by VCADS Pro?
Does the fuel pressure display in VCADS Pro indicate any fuel pressure?
Do the results from the tests indicate any faults?
Test object Applicable checks
Switch, status 3
Bleeding, status 4
Bleeding, active 4
3 “Switch, Fuel Pump, Check ” page 5
Is the switch fuse okay?
Is the switch (5) free of faults?
Are the switch terminals free of faults?
Does the VECU receive the signal from the switch?
4 “Fuel Pump, Check” page 6
Is the fuel pump fuse okay?
Is the electric fuel pump free of faults?
Are the electric fuel pump connections fault free?
Notes:
Completed by: Dealer: Date:
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2003 233 17 5(10)
Electric Fuel Pump, Fault Tracing
Switch, Fuel Pump, Check
If fault code is present, refer to Fault Code Information,
group 28. Possible fault code:
• MID 128 SID 78 (fuel priming pump)
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.
9813194, 9998699, 85104407
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4
Turn ignition key to the ON position. Using multimeter
J-39200, measure the voltage pin PA4 and PA12.
Measurement point Expected value
PA4 (switch signal) - PA12 0V
(ECU ground) (switch not pressed)
B+
(switch pressed)
J-39200
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.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2003 233 17 6(10)
6
If fault is not found, continue fault tracing according to
next step in the checklist. See “Electric Fuel Pump,
Fault Tracing” page 4.
Fuel Pump, Check
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: 9990014, 9998567, 9998699
Other special equipment: J-39200
1
Turn the ignition key to the OFF position.
2
Connect PC tool to diagnostic connector (if not already
connected) and select “Fuel system bleeding, test”
in VCADS Pro.
3
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 doesn’t 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.
4
Disconnect the connector for the electric fuel pump.
Connect adapter 9998567 to the wiring harness and
connector on the pump housing.
9998567
5
Turn the ignition key to the ON position. Using multimeter
J-39200, measure voltage between pin 5 in the 7–pin
breakout box and ground.
Measurement point Expected value
5 (control) — ground ≈ 8 V (inactive)
• If less than 8 volts is read from the multimeter,
continue with step 6.
• If expected value is read, go to step 9.
Volvo Trucks North America, Inc. Date Group No. Page
Service Bulletin 12.2003 233 17 7(10)
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.
Measurement point Expected value
1 (supply) - ground B+
Note: If value from step 7 is correct (B+), go to step 9.
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 12.2003 233 17 8(10)
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:
• The switch for bleeding; or
• The connection between the pump and the
and EECU.
• The 1939 data link (check for fault codes SID 231
or PSID 201
In either case, continue with step
11.
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
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Service Bulletin 12.2003 233 17 9(10)
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 7–pin
adapter 9998567 and socket A3 in breakout box 9998699.
Measurement point Expected value
5 - A3 ≈0
If an open circuit or other unexpected values are
obtained, there is probably a fault in the connection
between the pump and the EECU.
9998699, 9990014 , 9998567
14
Remove the cover for the fuel pump harness. Check the
supply and control wires between the 7–pin connector
and the pump. Pin 1 is supply and pin 5 is control/ground.
15
Connect 7–pin 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.
Measurement point Expected value
1-5 >10
1 - ground open circuit
5 - ground open circuit
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Service Bulletin 12.2003 233 17 10(10)
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.
