Volvo

Fault Condition: When the Engine Management System (EMS) Module detects there is a short to voltage in the cooling fan control circuit. If there is an open circuit, FMI 5 will be set and the fan will operate continuously.

If a customer complains that the fan clutch does not disengage and code SID 33 has not been logged in the EMS Module, the problem may be due to a mechanical failure in the chassis air system.

Possible repairs:

Warning: The fan can engage without warning. Hands, arms and personal items can easily be entangled in the belts or fan blades. Keep arms, hair, clothing, jewelry, etc. clear from the fan and belts when the engine is running.

Turn the ignition key OFF first.

1) Disconnect connector from the Fan Clutch Solenoid connector and the Engine Management System (EMS) Module connector B. Measure the voltage between the Fan Clutch Solenoid harness connector pin 3 and a good ground. If voltage is present, the signal line circuit is shorted to voltage. Locate the short to voltage, repair the circuit and retest the system. If there is NO voltage present, replace the Fan Clutch Solenoid and retest the system. If the FMI 3 is still active after replacing the solenoid, verify the diagnostic code, the FMI and retest the system. If the FMI 3 is still active, replace the EMS Module and retest the system.
2) Disconnect connector from the Fan Clutch Solenoid. Turn the ignition key ON. Measure the voltage between Fan Clutch Solenoid connector pin 4 and a good ground. If 12 volts is not present, then there is an open or short in the voltage circuit to the solenoid. Locate and repair the open or short circuit.
3) Disconnect the connector from the Fan Clutch Solenoid. Check for continuity between the Fan Clutch Solenoid pins 3 and 4. If there is NO continuity, replace the Fan Clutch Solenoid and retest the system.
4) Disconnect connector from the Fan Clutch Solenoid connector and the Engine Management System (EMS) Module connector B. Check for continuity between the Fan Clutch Solenoid harness connector pin 3 and the
EMS Module harness connector B pin 49. If there is NO continuity, locate and repair the open in the circuit.
5) Disconnect EMS Module connector B. Visually inspect EMS Module connector B for dirt, loose pins or deformed contacts. If a repairable open is found or the terminal feels loose, repair the harness connector.
If the test lead is making good contact with the connector terminal, verify the diagnostic code, the FMI and retest the system. If the FMI 5 is still active, replace the EMS Module and retest the system.

Fault Condition: FMI 0 indicates the starter estimated temperature has exceeded the manufacture’s limit. The starter can not be re-engaged until a cool down time down has occurred.

Possible repairs:

Turn the ignition key OFF first.

1) Check the Failure Mode Identifier (FMI) using a diagnostic computer. If the FMI is 0 (valid high), the starter estimated temperature has exceeded the manufacture’s limit. The starter can not be re-engaged until a cool down time down has past.

Fault Condition: FMI 10 indicates the command to the starter has been sent, but the engine is not turning.

Possible repairs:

Turn the ignition key OFF first.

1) If the FMI is 10 (abnormal rate of change), the command to the starter has been sent, but the engine is not turning. Check and diagnose the mechanical operation of the starting system.

Fault Condition: FMI 14 indicates the PTO is engaged and locks out the starter motor operation.

Possible repairs:

Turn the ignition key OFF first.

1) If the FMI is 14 (programming failure), the PTO is engaged and locks out the starter motor operation.

Fault Condition: FMI 3 indicates there is a short circuit to voltage in the starter relay control circuit.

Possible repairs:

Turn the ignition key OFF first.

1) Disconnect the Vehicle Electronic Control Unit (VECU) connector B. Turn the ignition key ON. Measure the voltage between the VECU connector B pin 28 and a good ground. If voltage is present, the control line circuit is
shorted to voltage. Locate the short to voltage, repair the circuit and retest the system. If there is NO voltage present, verify the diagnostic code, the FMI and retest the system. If the FMI 3 is still active, replace the VECU and retest the system.

Fault Condition: FMI 4 indicates there is a short circuit to ground in the starter relay control circuit.

Possible repairs:

Turn the ignition key OFF first.

1) Disconnect the Vehicle Electronic Control Unit (VECU) connector B. Check for continuity between the Vehicle Electronic Control Unit (VECU) connector B pin 28 and a good ground. If continuity exists to ground, locate and
repair the short circuit to ground. If there is NO continuity, verify the diagnostic code, the FMI and retest the system. If the FMI 4 is still active, replace the VECU and retest the system.

Fault Condition: FMI 5 indicates there is an open circuit in the starter relay control circuit.

Possible repairs:

Turn the ignition key OFF first.

1) Disconnect the Vehicle Electronic Control Unit (VECU) connector B. With Eaton A/T, disconnect the 20 Starter Enable Relay. Without Eaton A/T, disconnect the 36 Start Cntrl 1 Relay. With Eaton A/T, check for continuity between the Vehicle Electronic Control Unit (VECU) connector B pin 28 and 20 Starter Enable Relay pin 30. Without Eaton A/T, check for continuity between the Vehicle (VECU) connector B pin 28 and 36 Start Cntrl 1 Relay pin 85. If there is NO continuity, repair the circuit between the VECU and the relay.
2) With Eaton A/T, disconnect the Starter Enable Relay and Starter CNTRL 1 Relay. Without Eaton A/T, disconnect the Start Cntrl 1 Relay. With Eaton A/T, check for continuity between the Starter Enable Relay pin 87 and the Starter CNTRL 1 Relay pin 85. With Eaton A/T, check for continuity between the Starter CNTRL 1 Relay pin 85 and a good ground. Without Eaton A/T, check for continuity between the Start Cntrl 1 Relay pin 87 and a
good ground. If there is NO continuity, repair the open in the circuit.
3) Disconnect the Vehicle Electronic Control Unit (VECU) connectors A, B and C. Visually inspect VECU connectors for dirt, loose pins or deformed contacts. If a repairable open is found or the terminal feels loose, repair the harness connector. If the test lead is making good contact with the connector terminal, verify the diagnostic code, the FMI and retest the system. If the FMI 5 is still active, replace the VECU and retest the system.

Fault Condition: FMI 7 indicates that starter engagement has been denied because the automated/automatic transmission is not in neutral.

Possible repairs:

Turn the ignition key OFF first.

1) If the FMI is 7 (mechanical system not responding), the starter engagement has been denied because the automated/automatic transmission is not in neutral.

Fault Condition: If the Engine Management System (EMS) Module detects a fault in the electrical circuit while attempting to operate the Fuel Injector Unit, the Electronic Malfunction Lamp (EML) will turn ON and code SID 4 will set.

Possible repairs:

Turn the ignition switch OFF first.

1) Disconnect the harness electrical connector from Fuel Injector Unit #4. Check for continuity between the pins 1 and 2 of the Fuel Injector Unit #4. If the resistance is NOT between 0.9-5.2 Ohms at 68°F (20°C) or 1.5-5.8 Ohms at 218°F (103°C), Fuel Injector #4 is faulty and must be replaced.
2) Disconnect the harness electrical connectors from Fuel Injector Unit #4. Check for continuity from pins 1 and 2 on Fuel Injector Unit #4 to a good ground. If continuity exists, the Fuel Injector Unit #4 is shorted to ground and must be replaced.
3) Disconnect connectors A and B from the Engine Management System (EMS) Module. Disconnect the harness connector from Fuel Injector Unit #4. Check for continuity between the Fuel Injector Unit #4 harness connector pin 1 and 2 and a good ground.
4) Disconnect connectors A and B from the (EMS) Module. Check for continuity between EMS Module harness connector A pin 62 and pin 1 of the Fuel Injector Unit #4. If there is NO continuity, repair the open in the circuit.
5) Disconnect connectors A and B from the (EMS) Module. Check for continuity between pin 2 of the the Fuel Injector Unit #4 and EMS Module harness connector A pin 20. If there is NO continuity, repair the open in the circuit.
6) Disconnect connectors A and B from the (EMS) Module. Turn the ignition key ON. Measure the voltage between EMS Module connector A pin 62 and a good ground. If voltage is present, the voltage supply circuit is shorted to voltage. Locate and repair the short circuit.
7) Disconnect (EMS) Module connectors A and B. Disconnect the harness connector from Fuel Injector Unit #4. Turn the ignition key ON. Measure the voltage between the EMS Module connector A pin 20 and a good ground. If voltage is present, the Fuel Injector Unit #4 control line is shorted to voltage. Locate and repair the short.
8) Disconnect connector A and B from the (EMS) Module. Disconnect the harness electrical connector from the Fuel Injector Unit #4. Check for continuity between EMS Module harness connector A pin 20 and/or 62 and all other pins on EMS Module connectors A and B. If continuity exists, the Fuel Injector Unit #4 circuit is shorted to one of the other EMS Module circuits. Locate and repair the short circuit.
9) Disconnect the harness electrical connector from Fuel Injector Unit #4. Check for continuity between the pins 3 and 4 of the Fuel Injector Unit #4. If the resistance is NOT between 0.9-5.2 Ohms at 68°F (20°C) or 1.5-5.8 Ohms at 218°F (103°C), Fuel Injector #4 is faulty and must be replaced.
10) Disconnect the harness electrical connectors from Fuel Injector Unit #4. Check for continuity from either pin on Fuel Injector Unit #4 to a good ground. If continuity exists, the Fuel Injector Unit #4 is shorted to ground and must be replaced.
11) Disconnect connectors A and B from the (EMS) Module. Disconnect the harness connector from Fuel Injector Unit #4. Check for continuity between the Fuel Injector Unit #4 harness connector pin 3 and pin 4 and a good ground. If continuity exists, the circuit is shorted to ground. Locate and repair the short circuit.
12) Disconnect connectors A and B from the (EMS) Module. Disconnect the harness connector from Fuel Injector Unit #4. Check for continuity between EMS Module harness connector A pin 59 and pin 3 of the Fuel Injector Unit #4. If there is NO continuity, repair the open in the circuit.
13) Disconnect connectors A and B from the (EMS) Module. Disconnect the harness connector from Fuel Injector Unit #4. Check for continuity between pin 4 of the the Fuel Injector Unit #4 and EMS Module harness connector A pin 24. If there is NO continuity, repair the open in the circuit.
14) Disconnect connectors A and B from the (EMS) Module. Turn the ignition key ON. Measure the voltage between EMS Module connector A pin 59 and a good ground. If voltage is present, the voltage supply circuit is shorted to voltage. Locate and repair the short circuit.
15) Disconnect (EMS) Module connectors A and B. Disconnect the harness connector from Fuel Injector Unit #4. Turn the ignition key ON. Measure the voltage between the EMS Module connector A pin 24 and a good ground. If voltage is present, the Fuel Injector Unit #4 control line is shorted to voltage. Locate and repair the short.
16) Disconnect connector A and B from the (EMS) Module. Disconnect the harness electrical connector from the Fuel Injector Unit #4. Check for continuity between EMS Module harness connector A pin24 and/or 59 and all other pins on EMS Module connectors A and B. If continuity exists, the Fuel Injector Unit #4 circuit is shorted to one of the other EMS Module circuits. Locate and repair the short circuit.
17) Disconnect connectors A and B from the EMS Module. Visually inspect EMS Module connectors A and B for dirt, loose pins or deformed contacts. If a pin feels loose or appears damaged, repair the connector.
18) Ensure that there is fuel in the fuel tank. Inspect the fuel lines between the tank and the transfer pump for sharp bends or kinks, and repair as needed. Check for air in the fuel system, and repair as needed. Check the fuel pressure at the secondary fuel filter outlet. If the fuel pressure is NOT within specifications, perform any required fuel system repairs. Remove Fuel Injector Unit #4 from the engine and inspect for surface rust between the O-rings. If rust is present, locate the source of the fuel contamination and replace any damaged components. If all of the mechanical fuel system components are in good working order, replace the EMS Module and retest the system.