Fault Condition: Code PID 158 will set with an FMI 3 if the voltage rises above 19 volts (12 volt system) or above 36 volts (24 volt system). FMI 4 will set when the battery voltage falls below 9 volts (12 volt system) or below 17 volts (24 volt system). Damage to the modules and its components may occur with high battery voltages.
Possible repairs:
1) Verify that code PID 158 is set. If code PID 158 is not set, wiggle the harness and connectors to try to set the code. 2) Check the Failure Mode Identifier (FMI) using a diagnostic computer. If the FMI is 3 (voltage too high), check the vehicles charging system. The generator may be overcharging the batteries. Perform vehicle charging system testing and diagnosis. If the FMI is 4 (voltage too low), check the vehicle’s charging system and external charger if equipped. Perform vehicle charging system testing and diagnosis.
Volvo All Engines (2004 Emissions) Fault Code: PID 105 FMI 5 Boost Air Pressure / Temperature Sensor
Volvo All Engines (2004 Emissions) Fault Code: PID 105 FMI 4 Boost Air Pressure / Temperature Sensor
Volvo All Engines (2004 Emissions) Fault Code: PID 102 FMI 5 Boost Air Pressure / Temperature Sensor
Volvo All Engines (2004 Emissions) Fault Code: PID 102 FMI 3 Boost Air Pressure / Temperature Sensor
Volvo All Engines (2004 Emissions) Fault Code: PID 102 FMI 2 Boost Air Pressure / Temperature Sensor
Fault Condition: Code PID 158 will set with an FMI 3 if the voltage rises above 19 volts (12 volt system) or above 36 volts (24 volt system). FMI 4 will set when the battery voltage falls below 9 volts (12 volt system) or below 17 volts (24 volt system). Damage to the modules and its components may occur with high battery voltages.
Possible repairs:
1) Verify that code PID 158 is set. If code PID 158 is not set, wiggle the harness and connectors to try to set the code. 2) Check the Failure Mode Identifier (FMI) using a diagnostic computer. If the FMI is 3 (voltage too high), check the vehicles charging system. The generator may be overcharging the batteries. Perform vehicle charging system testing and diagnosis. If the FMI is 4 (voltage too low), check the vehicle’s charging system and external charger if equipped. Perform vehicle charging system testing and diagnosis.
Volvo All Engines (2004 Emissions) Fault Code: PID 158 FMI 3 Battery Voltage
Volvo All Engines (2004 Emissions) Fault Code: PID 105 FMI 5 Boost Air Pressure / Temperature Sensor
Volvo All Engines (2004 Emissions) Fault Code: PID 105 FMI 4 Boost Air Pressure / Temperature Sensor
Volvo All Engines (2004 Emissions) Fault Code: PID 102 FMI 5 Boost Air Pressure / Temperature Sensor
Volvo All Engines (2004 Emissions) Fault Code: PID 102 FMI 3 Boost Air Pressure / Temperature Sensor
Volvo All Engines (2004 Emissions) Fault Code: PID 102 FMI 2 Boost Air Pressure / Temperature Sensor
Fault Condition: The Ambient Air Temperature Status code will set when a fault is detected in the Ambient Air Temperature Sensor, the J1507/J1708 Data Lines or the Instrument Cluster Module (ICM).
Possible repairs:
1) Verify that code PID 171 is set. If code PID 171 is not set, wiggle the harness and connectors to try to set the code. Visually inspect the connectors and wires for poor connections. 2) Is code MID 140 PID 171 set? If code MID 140 PID 171 is set, repair the code(s) MID 140 PID 171 first then retest the system. If only MID 128 PID 171 is set, a software problem in the Vehicle Electronic Control Unit (VECU) or data bus problems may exist. Reflashing the Vehicle Electronic Control Unit (VECU) or repairing the data lines may correct the problem, call MACK Reliability Engineering.
Fault Condition: The Electronic Malfunction Lamp (EML) will turn on and PID 172 will set when the Engine Management System (EMS) Module senses that the Intake Air Temperature Sensor signal voltage is less than 0.5 volts or greater than 4.9 volts for 1 second. If the Intake Air Temperature Sensor voltage returns to between 0.5 volts and 4.9 volts for more than 1 second, the fault will become inactive.
Possible repairs:
Turn the ignition key OFF first.
1) Disconnect the Intake Air Temperature and Humidity (IATH) Sensor connector. Measure the resistance between pins 3 and 4 of the Intake Air Temperature and Humidity (IATH) Sensor with the ambient air temperature between 32° and 104°F (0° and 40°C) If the measured resistance is NOT between 30029 and 5575 ohms, replace the sensor. 2) Disconnect the Intake Air Temperature and Humidity (IATH) Sensor connector. If continuity exists on any pin, replace the Intake Air Temperature and Humidity (IATH) Sensor. 3) Disconnect the Intake Air Temperature and Humidity (IATH) Sensor harness connector. Measure the resistance between pins 3 and 4 of the Intake Air Temperature and Humidity (IATH) Sensor with the ambient air temperature between 32° and 104°F (0° and 40°C). If the measured resistance is NOT between 30029 and 5575 ohms, replace the Intake Air Temperature and Humidity (IATH) Sensor. 4) Connect the Intake Air Temperature and Humidity (IATH) Sensor harness connector. Connect connectors to the Engine Management System (EMS) Module. Turn the ignition key ON. If PID 172 is still active, check the Engine Management System (EMS) Module and connector A for dirt, loose or shorted pins, or any other repairable damage. If no problems are evident or are not repairable, replace the Engine Management System (EMS) Module and retest the system. If PID 172 is NOT active, the diagnostic procedures have corrected the problem. Check all connectors to ensure proper connections. 5) Disconnect the Intake Air Temperature and Humidity (IATH) Sensor harness connector. Disconnect Engine Management System (EMS) Module harness connectors A and B. Check for continuity between Engine Management System (EMS) Module harness connector A pin 43 and all other pins on Engine Management System (EMS) Module connectors A and B. If continuity exists, the signal line is shorted to one of the other Engine Management System (EMS) Module circuits. Locate and repair the short circuit to voltage, then replace the sensor. If there is NO continuity, the signal line is shorted to voltage somewhere else in the harness. Locate and repair the short circuit to voltage, then replace the sensor. 6) Connect the Intake Air Temperature and Humidity (IATH) Sensor harness connector. Connect connector A to the Engine Management System (EMS) Module. Turn the ignition key ON. If PID 172 is still active, check the Engine Management System (EMS) Module and connectors A, and B for dirt, loose or shorted pins, or any other repairable damage. If no problems are evident or are not repairable, replace the Engine Management System (EMS) Module and retest the system. If PID 172 is NOT active, the diagnostic procedures have corrected the problem. Check all connectors to ensure proper connections.
Volvo All Engines (2004 Emissions) Fault Code: SID 1 FMI 12 Injector Unit #1
Volvo All Engines (2004 Emissions) Fault Code: SID 1 FMI 3 Injector Unit #1
Volvo All Engines (2004 Emissions) Fault Code: SID 1 FMI 5 Injector Unit #1
Volvo All Engines (2004 Emissions) Fault Code: SID 1 FMI 7 Injector Unit #1
Fault Condition: The Electronic Malfunction Lamp (EML) will turn on and PID 172 will set when the Engine Management System (EMS) Module senses that the Intake Air Temperature Sensor signal voltage is less than 0.5 volts or greater than 4.9 volts for 1 second. If the Intake Air Temperature Sensor voltage returns to between 0.5 volts and 4.9 volts for more than 1 second, the fault will become inactive.
Possible repairs:
Turn the ignition key OFF first.
1) Disconnect the Intake Air Temperature and Humidity (IATH) Sensor connector. Measure the resistance between pins 3 and 4 of the Intake Air Temperature and Humidity (IATH) Sensor with the ambient air temperature between 32° and 104°F (0° and 40°C) If the measured resistance is NOT between 30029 and 5575 ohms, replace the sensor. 2) Disconnect the Intake Air Temperature and Humidity (IATH) Sensor connector. If continuity exists on any pin, replace the Intake Air Temperature and Humidity (IATH) Sensor. 3) Disconnect the Intake Air Temperature and Humidity (IATH) Sensor harness connector. Measure the resistance between pins 3 and 4 of the Intake Air Temperature and Humidity (IATH) Sensor with the ambient air temperature between 32° and 104°F (0° and 40°C). If the measured resistance is NOT between 30029 and 5575 ohms, replace the Intake Air Temperature and Humidity (IATH) Sensor. 4) Connect the Intake Air Temperature and Humidity (IATH) Sensor harness connector. Connect connectors to the Engine Management System (EMS) Module. Turn the ignition key ON. If PID 172 is still active, check the Engine Management System (EMS) Module and connector A for dirt, loose or shorted pins, or any other repairable damage. If no problems are evident or are not repairable, replace the Engine Management System (EMS) Module and retest the system. If PID 172 is NOT active, the diagnostic procedures have corrected the problem. Check all connectors to ensure proper connections. 5) Disconnect the Intake Air Temperature and Humidity (IATH) Sensor harness connector. Disconnect Engine Management System (EMS) Module harness connectors A and B. Check for continuity between Engine Management System (EMS) Module harness connector A pin 43 and all other pins on Engine Management System (EMS) Module connectors A and B. If continuity exists, the signal line is shorted to one of the other Engine Management System (EMS) Module circuits. Locate and repair the short circuit to voltage, then replace the sensor. If there is NO continuity, the signal line is shorted to voltage somewhere else in the harness. Locate and repair the short circuit to voltage, then replace the sensor. 6) Connect the Intake Air Temperature and Humidity (IATH) Sensor harness connector. Connect connector A to the Engine Management System (EMS) Module. Turn the ignition key ON. If PID 172 is still active, check the Engine Management System (EMS) Module and connectors A, and B for dirt, loose or shorted pins, or any other repairable damage. If no problems are evident or are not repairable, replace the Engine Management System (EMS) Module and retest the system. If PID 172 is NOT active, the diagnostic procedures have corrected the problem. Check all connectors to ensure proper connections.
Volvo All Engines (2004 Emissions) Fault Code: PID 354 FMI 3 Intake Air and Humidity Sensor
Volvo All Engines (2004 Emissions) Fault Code: PID 172 FMI 4 Intake Air and Humidity Sensor
Volvo All Engines (2004 Emissions) Fault Code: SID 1 FMI 12 Injector Unit #1
Volvo All Engines (2004 Emissions) Fault Code: SID 1 FMI 3 Injector Unit #1
Volvo All Engines (2004 Emissions) Fault Code: SID 1 FMI 5 Injector Unit #1
Volvo All Engines (2004 Emissions) Fault Code: SID 1 FMI 7 Injector Unit #1
Fault Condition: The Electronic Malfunction Lamp (EML) will turn on and PID 175 will set if the engine oil temperature signal voltage is less than .17 volts or greater than 4.92 volts. If the EMS Module senses that the engine oil temperature signal is critically above range, FMI code 0 will be set. If the engine oil temperature reaches 259°F (126°C), the engine power will be reduced by 15%. If the engine oil temperature reaches 262°F (128°C), the engine will be shutdown. Yellow or red warning lamp identification and buzzer warning will accompany the extreme engine oil temperature conditions. If the reference voltage signal is shorted to ground FMI 4 will be set. If the reference voltage circuit is shorted to battery voltage or has an open circuit, FMI 5 will be set. If the ground circuit of the sensor has an open, FMI 5 will also be set.
Possible repairs:
Turn the ignition key OFF first.
1) Disconnect the Engine Oil Level/Temperature Sensor connector. Check for continuity between pin 1 of the Engine Oil Temperature/Level Sensor and a good ground. Check for continuity between pin 2 of the Engine Oil Temperature/Level Sensor and a good ground. Check for continuity between pin 3 of the Engine Oil Temperature/Level Sensor and a good ground. Check for continuity between pin 4 of the Engine Oil Temperature/Level Sensor and a good ground. If continuity exists between any of the pins and ground, replace the Engine Oil Level/Temperature Sensor. 2) Disconnect the Engine Oil Level/Temperature Sensor connector. Measure the resistance across the pins 3 and 4 of the Engine Oil Temperature/Level Sensor. If the resistance of the sensor is NOT as specified, replace the replace the Engine Oil Level/Temperature Sensor. 3) Disconnect the Engine Oil Level/Temperature Sensor harness connector. Turn the ignition key ON. Measure voltage between Engine Oil Level/Temperature Sensor harness connector pin 3 and a good ground. If the measured voltage is more than 4.5 volts, verify the diagnostic code, the FMI and retest. If FMI 4 is still active, replace the Engine Management System (EMS) Module and retest the system. 4) Disconnect the Engine Oil Level/Temperature Sensor harness connector. Disconnect the EMS Module harness connector A. Measure continuity between Engine Oil Level/Temperature Sensor harness connector pin 3 and a good ground. If continuity exists, repair the short to ground between in the signal line voltage circuit. If there is NO continuity, check the pins or the EMS Module for dirt, loose pins or deformed contacts. Replace the EMS Module if the pins of the module are not damaged. Retest the system. 5) Disconnect the Engine Oil Level/Temperature Sensor harness connector. Disconnect the EMS Module harness connector A. Turn the ignition key ON. Measure voltage between Engine Oil Level/Temperature Sensor harness connector pin 3 and a good ground. If the there is voltage present, repair the short to voltage on the signal line. 6) Disconnect the Engine Oil Level/Temperature Sensor connector. Disconnect connector A from the EMS Module. Check for continuity between connector A pin 11 and/or 31 of the EMS Module harness connector and pin 3 of the Engine Oil Level/Temperature Sensor harness connector. If there is NO continuity, locate and repair the open in the circuit between the Engine Oil Level/Temperature Sensor and the EMS Module. 7) Visually inspect the EMS Module harness connectors A and B for dirt, loose pins or deformed contacts. If a repairable open is found or any of the pins feel loose, repair the EMS Module harness connector. If an open is not found and the EMS Module harness connector has a good contact, verify the diagnostic code, the FMI and retest. If FMI 5 is still active, replace the Engine Management System (EMS) Module and retest the system.
Volvo All Engines (2004 Emissions) Fault Code: PID 175 FMI 4 Engine Oil Temperature / Temperature Sensor
Volvo All Engines (2004 Emissions) Fault Code: PID 175 FMI 5 Engine Oil Temperature / Temperature Sensor
Fault Condition: The Electronic Malfunction Lamp (EML) will turn on and PID 175 will set if the engine oil temperature signal voltage is less than .17 volts or greater than 4.92 volts. If the EMS Module senses that the engine oil temperature signal is critically above range, FMI code 0 will be set. If the engine oil temperature reaches 259°F (126°C), the engine power will be reduced by 15%. If the engine oil temperature reaches 262°F (128°C), the engine will be shutdown. Yellow or red warning lamp identification and buzzer warning will accompany the extreme engine oil temperature conditions. If the reference voltage signal is shorted to ground FMI 4 will be set. If the reference voltage circuit is shorted to battery voltage or has an open circuit, FMI 5 will be set. If the ground circuit of the sensor has an open, FMI 5 will also be set.
Possible repairs:
Turn the ignition key OFF first.
1) Disconnect the Engine Oil Level/Temperature Sensor connector. Check for continuity between pin 1 of the Engine Oil Temperature/Level Sensor and a good ground. Check for continuity between pin 2 of the Engine Oil Temperature/Level Sensor and a good ground. Check for continuity between pin 3 of the Engine Oil Temperature/Level Sensor and a good ground. Check for continuity between pin 4 of the Engine Oil Temperature/Level Sensor and a good ground. If continuity exists between any of the pins and ground, replace the Engine Oil Level/Temperature Sensor. 2) Disconnect the Engine Oil Level/Temperature Sensor connector. Measure the resistance across the pins 3 and 4 of the Engine Oil Temperature/Level Sensor. If the resistance of the sensor is NOT as specified, replace the replace the Engine Oil Level/Temperature Sensor. 3) Disconnect the Engine Oil Level/Temperature Sensor harness connector. Turn the ignition key ON. Measure voltage between Engine Oil Level/Temperature Sensor harness connector pin 3 and a good ground. If the measured voltage is more than 4.5 volts, verify the diagnostic code, the FMI and retest. If FMI 4 is still active, replace the Engine Management System (EMS) Module and retest the system. 4) Disconnect the Engine Oil Level/Temperature Sensor harness connector. Disconnect the EMS Module harness connector A. Measure continuity between Engine Oil Level/Temperature Sensor harness connector pin 3 and a good ground. If continuity exists, repair the short to ground between in the signal line voltage circuit. If there is NO continuity, check the pins or the EMS Module for dirt, loose pins or deformed contacts. Replace the EMS Module if the pins of the module are not damaged. Retest the system. 5) Disconnect the Engine Oil Level/Temperature Sensor harness connector. Disconnect the EMS Module harness connector A. Turn the ignition key ON. Measure voltage between Engine Oil Level/Temperature Sensor harness connector pin 3 and a good ground. If the there is voltage present, repair the short to voltage on the signal line. 6) Disconnect the Engine Oil Level/Temperature Sensor connector. Disconnect connector A from the EMS Module. Check for continuity between connector A pin 11 and/or 31 of the EMS Module harness connector and pin 3 of the Engine Oil Level/Temperature Sensor harness connector. If there is NO continuity, locate and repair the open in the circuit between the Engine Oil Level/Temperature Sensor and the EMS Module. 7) Visually inspect the EMS Module harness connectors A and B for dirt, loose pins or deformed contacts. If a repairable open is found or any of the pins feel loose, repair the EMS Module harness connector. If an open is not found and the EMS Module harness connector has a good contact, verify the diagnostic code, the FMI and retest. If FMI 5 is still active, replace the Engine Management System (EMS) Module and retest the system.
Volvo All Engines (2004 Emissions) Fault Code: PID 175 FMI 5 Engine Oil Temperature / Temperature Sensor
Fault Condition: The Electronic Malfunction Lamp (EML) will turn on and PID 175 will set if the engine oil temperature signal voltage is less than .17 volts or greater than 4.92 volts. If the EMS Module senses that the engine oil temperature signal is critically above range, FMI code 0 will be set. If the engine oil temperature reaches 259°F (126°C), the engine power will be reduced by 15%. If the engine oil temperature reaches 262°F (128°C), the engine will be shutdown. Yellow or red warning lamp identification and buzzer warning will accompany the extreme engine oil temperature conditions. If the reference voltage signal is shorted to ground FMI 4 will be set. If the reference voltage circuit is shorted to battery voltage or has an open circuit, FMI 5 will be set. If the ground circuit of the sensor has an open, FMI 5 will also be set.
Possible repairs:
Turn the ignition key OFF first.
1) Disconnect the Engine Oil Level/Temperature Sensor connector. Check for continuity between pin 1 of the Engine Oil Temperature/Level Sensor and a good ground. Check for continuity between pin 2 of the Engine Oil Temperature/Level Sensor and a good ground. Check for continuity between pin 3 of the Engine Oil Temperature/Level Sensor and a good ground. Check for continuity between pin 4 of the Engine Oil Temperature/Level Sensor and a good ground. If continuity exists between any of the pins and ground, replace the Engine Oil Level/Temperature Sensor. 2) Disconnect the Engine Oil Level/Temperature Sensor connector. Measure the resistance across the pins 3 and 4 of the Engine Oil Temperature/Level Sensor. If the resistance of the sensor is NOT as specified, replace the replace the Engine Oil Level/Temperature Sensor. 3) Disconnect the Engine Oil Level/Temperature Sensor harness connector. Turn the ignition key ON. Measure voltage between Engine Oil Level/Temperature Sensor harness connector pin 3 and a good ground. If the measured voltage is more than 4.5 volts, verify the diagnostic code, the FMI and retest. If FMI 4 is still active, replace the Engine Management System (EMS) Module and retest the system. 4) Disconnect the Engine Oil Level/Temperature Sensor harness connector. Disconnect the EMS Module harness connector A. Measure continuity between Engine Oil Level/Temperature Sensor harness connector pin 3 and a good ground. If continuity exists, repair the short to ground between in the signal line voltage circuit. If there is NO continuity, check the pins or the EMS Module for dirt, loose pins or deformed contacts. Replace the EMS Module if the pins of the module are not damaged. Retest the system. 5) Disconnect the Engine Oil Level/Temperature Sensor harness connector. Disconnect the EMS Module harness connector A. Turn the ignition key ON. Measure voltage between Engine Oil Level/Temperature Sensor harness connector pin 3 and a good ground. If the there is voltage present, repair the short to voltage on the signal line. 6) Disconnect the Engine Oil Level/Temperature Sensor connector. Disconnect connector A from the EMS Module. Check for continuity between connector A pin 11 and/or 31 of the EMS Module harness connector and pin 3 of the Engine Oil Level/Temperature Sensor harness connector. If there is NO continuity, locate and repair the open in the circuit between the Engine Oil Level/Temperature Sensor and the EMS Module. 7) Visually inspect the EMS Module harness connectors A and B for dirt, loose pins or deformed contacts. If a repairable open is found or any of the pins feel loose, repair the EMS Module harness connector. If an open is not found and the EMS Module harness connector has a good contact, verify the diagnostic code, the FMI and retest. If FMI 5 is still active, replace the Engine Management System (EMS) Module and retest the system.
Fault Condition: The J1587 and J1939 serial data lines are used as the standard communication link for on-board vehicle instrumentation, off-board service diagnostics and fleet management. The Transmission Oil Temperature Sensor sends a signal to the Instrument Cluster Module (ICM) which relays a signal to the Engine Management System (EMS) Module via the data lines.
Possible repairs:
1) Verify that code PID 177 is set. If code PID 177 is not set, wiggle the harness and connectors to try to set the code. Visually inspect the VECU connectors and wires for poor connections. 2) Turn the ignition key OFF and connect a diagnostic computer. Turn the ignition key ON. Use the diagnostic computer to attempt to communicate with the Instrument Cluster Module (ICM). If communication can be made with the Instrument Cluster Module (ICM), the fault may be intermittent. Wiggle the harness and connectors to try to set the code. If fault in the harness is found, repair or replace the harness. If there is NO communication with the Instrument Cluster Module (ICM) via the diagnostic tool, go to the Trouble Shooting Procedure for the Data Lines.
Volvo All Engines (2004 Emissions) Fault Code: PID 245 FMI 9 Total Vehicle Distance
Volvo All Engines (2004 Emissions) Fault Code: PID 251 FMI 9 Time Data Failure
Fault Condition: The J1587 and J1939 serial data lines are used as the standard communication link for on-board vehicle instrumentation, off-board service diagnostics and fleet management. The Transmission Oil Temperature Sensor sends a signal to the Instrument Cluster Module (ICM) which relays a signal to the Engine Management System (EMS) Module via the data lines.
Possible repairs:
1) Verify that code PID 177 is set. If code PID 177 is not set, wiggle the harness and connectors to try to set the code. Visually inspect the VECU connectors and wires for poor connections. 2) Turn the ignition key OFF and connect a diagnostic computer. Turn the ignition key ON. Use the diagnostic computer to attempt to communicate with the Instrument Cluster Module (ICM). If communication can be made with the Instrument Cluster Module (ICM), the fault may be intermittent. Wiggle the harness and connectors to try to set the code. If fault in the harness is found, repair or replace the harness. If there is NO communication with the Instrument Cluster Module (ICM) via the diagnostic tool, go to the Trouble Shooting Procedure for the Data Lines.
Volvo All Engines (2004 Emissions) Fault Code: PID 177 FMI 0 Transmission Oil Temperature
Volvo All Engines (2004 Emissions) Fault Code: PID 245 FMI 9 Total Vehicle Distance
Volvo All Engines (2004 Emissions) Fault Code: PID 251 FMI 9 Time Data Failure
