KC-2165
Service Bulletin Details
Public Details for: KC-2165
Def pump troubleshooting guide - us10+obd13 and newer emissions
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Models from 9999
Models from 2023
2023 VOLVO VN |
Models from 2021
2021 VOLVO VAH |
2021 VOLVO VHD |
2021 VOLVO VN |
2021 VOLVO VNL |
2021 VOLVO VNM |
2021 VOLVO VNR |
2021 VOLVO VNX |
Models from 2020
2020 VOLVO VAH |
2020 VOLVO VHD |
2020 VOLVO VN |
2020 VOLVO VNL |
2020 VOLVO VNM |
2020 VOLVO VNR |
2020 VOLVO VNX |
Models from 2019
2019 VOLVO VAH |
2019 VOLVO VHD |
2019 VOLVO VN |
2019 VOLVO VNL |
2019 VOLVO VNM |
2019 VOLVO VNR |
2019 VOLVO VNX |
Models from 2018
2018 VOLVO VAH |
2018 VOLVO VHD |
2018 VOLVO VN |
2018 VOLVO VNL |
2018 VOLVO VNM |
2018 VOLVO VNR |
2018 VOLVO VNX |
Models from 2017
2017 VOLVO VAH |
2017 VOLVO VHD |
2017 VOLVO VN |
2017 VOLVO VNL |
2017 VOLVO VNM |
2017 VOLVO VNR |
2017 VOLVO VNX |
Models from 2016
2016 VOLVO 780 |
2016 VOLVO VAH |
2016 VOLVO VHD |
2016 VOLVO VN |
2016 VOLVO VNL |
2016 VOLVO VNM |
2016 VOLVO VNX |
2016 VOLVO VT |
Models from 2015
2015 VOLVO VAH |
2015 VOLVO VHD |
2015 VOLVO VN |
2015 VOLVO VNL |
2015 VOLVO VNM |
2015 VOLVO VNX |
2015 VOLVO VT |
Models from 2014
2014 VOLVO VAH |
2014 VOLVO VHD |
2014 VOLVO VN |
2014 VOLVO VNL |
2014 VOLVO VNM |
2014 VOLVO VNX |
2014 VOLVO VT |
Models from 2013
2013 VOLVO VAH |
2013 VOLVO VHD |
2013 VOLVO VN |
2013 VOLVO VNL |
2013 VOLVO VNM |
2013 VOLVO VNX |
2013 VOLVO VT |
2013 VOLVO WHEB |
Models from 2012
2012 VOLVO VAH |
2012 VOLVO VHD |
2012 VOLVO VN |
2012 VOLVO VNL |
2012 VOLVO VNM |
2012 VOLVO VT |
Models from 2011
2011 VOLVO 780 |
2011 VOLVO VAH |
2011 VOLVO VH |
2011 VOLVO VHD |
2011 VOLVO VN |
2011 VOLVO VNL |
2011 VOLVO VNM |
2011 VOLVO VT |
Models from 2010
2010 VOLVO VAH |
2010 VOLVO VH |
2010 VOLVO VHD |
2010 VOLVO VN |
2010 VOLVO VNL |
2010 VOLVO VNM |
2010 VOLVO VT |
Models from 2009
2009 VOLVO VAH |
2009 VOLVO VH |
2009 VOLVO VHD |
2009 VOLVO VN |
2009 VOLVO VNL |
2009 VOLVO VNM |
2009 VOLVO VT |
Models from 2008
2008 VOLVO VAH |
2008 VOLVO VH |
2008 VOLVO VHD |
2008 VOLVO VN |
2008 VOLVO VNL |
2008 VOLVO VNM |
2008 VOLVO VT |
Models from 2007
2007 VOLVO VAH |
2007 VOLVO VH |
2007 VOLVO VHD |
2007 VOLVO VN |
2007 VOLVO VNL |
2007 VOLVO VNM |
2007 VOLVO VT |
Models from 2006
2006 VOLVO VH |
2006 VOLVO VHD |
2006 VOLVO VN |
2006 VOLVO VNL |
2006 VOLVO VNM |
2006 VOLVO VT |
Models from 2005
2005 VOLVO 660 |
2005 VOLVO VH |
2005 VOLVO VHD |
2005 VOLVO VHD84B |
2005 VOLVO VN |
2005 VOLVO VNL |
2005 VOLVO VNM |
2005 VOLVO VT |
Models from 2004
2004 VOLVO 780 |
2004 VOLVO VH |
2004 VOLVO VHD |
2004 VOLVO VHD84B |
2004 VOLVO VN |
2004 VOLVO VNL |
2004 VOLVO VNL430 |
2004 VOLVO VNL64T |
2004 VOLVO VNM |
2004 VOLVO VT |
2004 VOLVO WX |
2004 VOLVO WXLL |
Models from 2003
2003 VOLVO FM |
2003 VOLVO VH |
2003 VOLVO VHD |
2003 VOLVO VHD84B |
2003 VOLVO VN |
2003 VOLVO VNL |
2003 VOLVO VNM |
2003 VOLVO VT |
2003 VOLVO WX |
2003 VOLVO WXLL |
Models from 2002
Models from 2001
Models from 2000
Models from 1999
Models from 1998
Models from 1997
Models from 1996
Models from 1995
Models from 1994
Models from 1993
Models from 1992
Models from 1991
Models from 1990
Models from 1989
Models from 1988
Models from 1987
1987 VOLVO F7 SERIES |
1987 VOLVO FE6 |
1987 VOLVO FE7 |
1987 VOLVO N10 |
1987 VOLVO N12 |
1987 VOLVO VOLVO TRUCK |
Models from 1986
1986 VOLVO B10M |
1986 VOLVO F7 SERIES |
1986 VOLVO FE6 |
1986 VOLVO FE7 |
1986 VOLVO N10 |
1986 VOLVO N12 |
1986 VOLVO VOLVO TRUCK |
Models from 1985
Models from 1984
Models from 1983
Models from 1982
Models from 1981
1981 VOLVO 614 |
1981 VOLVO F6 SERIES |
1981 VOLVO F611 |
1981 VOLVO F613 |
1981 VOLVO VOLVO TRUCK |
Models from 1980
1980 VOLVO 614 |
1980 VOLVO F SERIES |
1980 VOLVO F611 |
1980 VOLVO F613 |
1980 VOLVO F716 |
1980 VOLVO VOLVO TRUCK |
1980 VOLVO VOLVO WHITE |
Models from 1979
1979 VOLVO 614 |
1979 VOLVO F SERIES |
1979 VOLVO F611 |
1979 VOLVO F613 |
1979 VOLVO F716 |
1979 VOLVO VOLVO TRUCK |
1979 VOLVO VOLVO WHITE |
Models from 1978
1978 VOLVO 614 |
1978 VOLVO F611 |
1978 VOLVO F613 |
1978 VOLVO F86 |
1978 VOLVO VOLVO TRUCK |
1978 VOLVO VOLVO WHITE |
Models from 1977
1977 VOLVO 614 |
1977 VOLVO F611 |
1977 VOLVO F613 |
1977 VOLVO F86 |
1977 VOLVO VOLVO TRUCK |
Models from 1976
1976 VOLVO F86 |
Models from 1975
1975 VOLVO F86 |
Models from 1974
1974 VOLVO F86 |
6/30/22, 11:06 AM Article DEF Pump Troubleshooting Guide - US10+OBD13 And Newer Emissions Component Overview The Diesel Exhaust Fluid (DEF) Pump's function is to build and regulate the DEF systems pressure that is supplied to the dosing valve. The DEF Pump is a multi-unit component that consists of: Mechanical pump Reverting valve Pressure sensor Main filter Fluid connectors (2 coolant & 3 DEF) Electrical connector The DEF Pump is controlled by the After-Treatment Control Module (ACM). On every key cycle, the sensors and actuators in the DEF dosing system perform a self-check for proper operation. When the truck is turned off, the ACM uses a temperature based delayed reverting/draining strategy to pump the DEF back into the tank. ; Live UI https://volvo-trkna-prod1.pegacloud.net/prweb/PRAuth/app/VolvoKM_/iNPUIKpeinqPJi2G0hH930k43USdE1gb*/!TABTHREAD5?pyActivity=%40base… 1/10 6/30/22, 11:06 AM Article The primary failure mode of the DEF Pump is: Leak - externally leaking fluid Internal Failure - which will generate a specific DTC Diagnose and Repair NOTE: a large amount of DEF Pumps returned through warranty have been tested and determined to have No Fault Found. It is extremely important to not replace the DEF Pump unnecessarily but to determine the root cause of the failure. Leaking DEF ; Live UI N t ll l k t th DEF i l t f th https://volvo-trkna-prod1.pegacloud.net/prweb/PRAuth/app/VolvoKM_/iNPUIKpeinqPJi2G0hH930k43USdE1gb*/!TABTHREAD5?pyActivity=%40base… 2/10 6/30/22, 11:06 AM Article Not all leaks at the DEF pump require replacement of the pump assembly. It is imperative to determine the location of the leak. 1. Clean the suspected area using a suitable solvent. 2. Run PTT Option 2589-08-03-05 Subtest A to pressurize the system. 3. Inspect the affected area to determine the location of the leak using the table below. Location of Leak Fluid Connectors Filter Assembly Electrical Connector Pump splitting Direction Repair or Replace fitting and/or hose Replace Filter Assembly Replace Filter Assembly Replace Filter Assembly Internal Failure of the Pump All internal pump failures will generate a specific Diagnostic Trouble Code (DTC) Perform a DTC Readout using Premium Tech Tool. Review the tables below to determine which category the Fault Code currently being diagnosed falls under. Proceed according to the directions for the appropriate section. Under Pressure Faults DTC Description P20E8-92 Reductant Pressure Too Low, Incorrect Operation P202D-00 Aftertreatment Reagent Pressure Leakage P20BA-00 Reductant Heater A control Performance Directions: 1. Inspect def tank for frozen fluid, debris, or low level. 2. Disconnect the supple line at the DEF Pump. ; Live UI https://volvo-trkna-prod1.pegacloud.net/prweb/PRAuth/app/VolvoKM_/iNPUIKpeinqPJi2G0hH930k43USdE1gb*/!TABTHREAD5?pyActivity=%40base… 3/10 6/30/22, 11:06 AM Article 3. Connect a clear 3/8" (inner diameter) hose to the fitting and place the other end of the hose into the DEF Tank. • Note: This will require removal of DEF Tank Filer Neck Insert (Impact 2589-03-02-42). 4. Run Pressure Build Up Operation in PTT 2589-08-03-05 Selection A. Ensure the DEF Pump is running (audible noise) and allow to run for at least 5 minutes. 5. Evaluate results: • If the system is not able to build pressure: Replace the inlet fitting (which contains a screen, which could be blocked). Re-run evaluate. If the pump is still not able to build pressure, Replace the DEF Pump in accordance with Impact operation 2581-03-02-01 . ; Live UI https://volvo-trkna-prod1.pegacloud.net/prweb/PRAuth/app/VolvoKM_/iNPUIKpeinqPJi2G0hH930k43USdE1gb*/!TABTHREAD5?pyActivity=%40base… 4/10 6/30/22, 11:06 AM Article • If the system is able to build pressure: The pump in not the issue. Further diagnosis is needed for the supply side of the system. Inspect the below components and repair as necessary: - DEF Tank Vent - make sure the vent is clean and free of debris. ○ NOTE: Do NOT blow air through the line, as this will likely introduce debris into the DEF Tank. - Lines Blockage from DEF Tank to Pump. ; Live UI - Blocked/damaged Tank Screen or pickup tube. https://volvo-trkna-prod1.pegacloud.net/prweb/PRAuth/app/VolvoKM_/iNPUIKpeinqPJi2G0hH930k43USdE1gb*/!TABTHREAD5?pyActivity=%40base… 5/10 6/30/22, 11:06 AM Article Over Pressure Faults - only diagnose active DTCs. Description DTC P208B-00 P10CE-97 Reductant Pump "A" Control Performance/Stuck Off P20A1-07 Aftertreatment Reagent Direction Valve Mechanical Problem Reductant Return No Flow Detected Directions: 1. Inspect def tank for frozen fluid or debris. 2. Replace return line fitting (this fitting contains a return orifice). 3. Run Pressure Build Up Operation in PTT 2589-08-03-05 Selection A. ; Live UI 4 E l t th lt https://volvo-trkna-prod1.pegacloud.net/prweb/PRAuth/app/VolvoKM_/iNPUIKpeinqPJi2G0hH930k43USdE1gb*/!TABTHREAD5?pyActivity=%40base… 6/10 6/30/22, 11:06 AM Article 4. Evaluate the results • If the DEF Pump builds pressure and does not shut down for 5 minutes: Clear the faults and release the vehicle. • If the DEF Pump over pressures and stops running (DTC will log again): a. Check return line (from DEF Pump to DEF Tank) for blockage and replace as necessary. b. Re-run the evaluation. If the pump continues to overpressure, replace the pump in accordance with Impact operation 2581-03-02-01. Electrical Faults - only diagnose active or confirmed DTCs DTC P20A0-13 P10AD-13 P204A-13 P208A-13 P208C-00 P20A2-00 P204C-00 P10AF-00 P204B-64 P10AE-00 P208D-00 P20A3-00 Description Reductant Purge Control Valve, Open Circuit Reductant Pump "A" Control Low Side, Open Circuit Reductant Pressure Sensor, Open Circuit Reductant Pump "A" Control, Open Circuit Aftertreatment Reagent Pump Control Short Circuit Low Aftertreatment Reagent Direction Valve Short Circuit Low Aftertreatment Reagent Pressure Sensor Circuit Low Reductant Pump "A" Control Low Side Circuit High Aftertreatment Reagent Pump Orifice Blocked Reductant Pump "A" Control Low Side Circuit Low Aftertreatment Reagent Pump Control Short Circuit High Aftertreatment Reagent Direction Valve Short Circuit High Directions: all of the above codes will cause the DEF Pump to discontinue operation until code is corrected. Inspect electrical circuits using PTT Diagnostics to identify the electrical issue. NOTE: For trucks operating in a dirty or harsh environment and experiencing repeat DEF Pump Failures see Technical Service Bulletin (TSB) Aftertreatment Diesel Exhaust Fluid (DEF) Tank Vent Filter, New Installation. ; Live UI https://volvo-trkna-prod1.pegacloud.net/prweb/PRAuth/app/VolvoKM_/iNPUIKpeinqPJi2G0hH930k43USdE1gb*/!TABTHREAD5?pyActivity=%40base… 7/10 6/30/22, 11:06 AM Article Rules for Replacement Warranty will only cover replacement of the DEF Pump if: Leak is identified as unrepairable (leaks at fittings or main filter are repairable), these pumps may require parts returned for analysis. Fault codes in the Yellow sections above is active or confirmed. In addition, if the DEF Pump is being replaced. Maintenance records will be required showing the cleaning of the DEF Tank and Filter Change have been properly maintained and are not the root cause of the failure. Refer to Service At a Glance (SAG) found in the Trucks Dealer Portal under the Information tab - Service - Service literature for replacement and cleaning intervals of the DEF Tank & Filters. Standard Diagnostic Time 1.0 hrs Diagnostic Trouble Codes With DEF/Urea in the Description Direction/Repair: DO NOT REPLACE the DEF Pump for these codes. Diagnostics should be performed using PTT Diagnostics and the comment Live UI in the table below. ; section https://volvo-trkna-prod1.pegacloud.net/prweb/PRAuth/app/VolvoKM_/iNPUIKpeinqPJi2G0hH930k43USdE1gb*/!TABTHREAD5?pyActivity=%40base… 8/10 6/30/22, 11:06 AM Article DTC Description Probable Source P2042- Reductant Temperature Temperature - Check wiring 01 Sensor, Electrical Failure harness CBR-2015 P21CA- Reductant Control Module 00 Check ACM Power Supply CBR- Supply Voltage 2040 Review the applicable video link below. MACK VOLVO ; DEF PUMP DEF PUMP Tags p2042-01 p20a3-00 def pump def tank def filter p204b-64 p10af-00 p204c-00 p20a2-00 p208c-00 p208a-13 p10ce-97 p20a1-07 p20e8-92 p202d-00 p20ba-00 p204a-13 p20a0-13 p208b-00 unlocking uptime Live UI p10ad-13 p208d-00 p10ae-00 p21ca-00 https://volvo-trkna-prod1.pegacloud.net/prweb/PRAuth/app/VolvoKM_/iNPUIKpeinqPJi2G0hH930k43USdE1gb*/!TABTHREAD5?pyActivity=%40base… 9/10 6/30/22, 11:06 AM mack Article volvo Related links and attachments KC-2165 2581-03-02-01 KC-2165 2589-03-02-42 KC-2165 2589-08-03-05 IMG 1 Feedback Give feedback to help improve the content of this article KC-2165 2589-08-03-05 IMG 2 KC-2165 2589-08-03-05 IMG 3 ; Live UI https://volvo-trkna-prod1.pegacloud.net/prweb/PRAuth/app/VolvoKM_/iNPUIKpeinqPJi2G0hH930k43USdE1gb*/!TABTHREAD5?pyActivity=%40bas… 10/10