Volvo Penta TAD1641GE troubleshooting: 30 fault codes and 46 symptom-cause-remedy entries from the manufacturer's own service documentation.
Volvo Penta TAD1641GE — full specs, parts & maintenance.
| Code | Meaning | Cause | Remedy |
|---|---|---|---|
| 1.1 | No faults — There are no active faults. | ||
| 2.1 | Water in fuel — Warning lamp lights up. | Water in fuel. | Empty the primary fuel filter. |
| 2.2 | Coolant level — Warning lamp lights up. VE engines: Engine control module reduces engine power (unless the protection has been shut off with the diagnostic tool VODIA). GE engines: Engine is shut off (unless the protection has been shut off with the diagnostic tool VODIA). | Low coolant level | Check the coolant level; Check coolant level monitor function. |
| 2.3 | Coolant level sensor | Short circuit to positive (+); Fault in sensor. | Check that the coolant level sensor cable is not damaged; Check coolant level sensor function; Check contact pressure in sockets 23 and 10 in the upper cable connector (A) on the engine management module. |
| 2.4 | Engine speed sensor, flywheel — Engine is very difficult to start and runs roughly when it starts. | No signal; Abnormal frequency; "Intermittent" signal from the sensor; Fault in sensor. | Check that the sensor connector is correctly installed; Check that the engine speed sensor cable is not damaged; Check that the engine speed sensor is correctly installed in the flywheel housing; Check engine speed sensor function; Check contact pressure in sockets 37 and 38 in the upper cable connector (A) on the engine management module. |
| 2.5 | Speed sensor, camshaft gear — Engine takes longer to start than normal. Engine runs normally when is running. | No signal; Abnormal frequency; Fault in sensor. | Check that the engine speed sensor connector is correctly installed; Check that the engine speed sensor cable is not damaged; Check that the engine speed sensor is correctly installed in the upper timing gear cover; Check engine speed sensor function; Check contact pressure in sockets 45 and 46 in the upper cable connector (A) on the engine management module. |
| 2.6 | Engine speed | Engine speed too high | Once the engine has stopped, search for the reason for high engine speed. |
| 2.8 | Engine speed potentiometer connected to the CIU — VE engines: Engine goes to idle. GE engines: Engine speed is maintained. If the accelerator is first released and then depressed, the engine can be emergency operated by means of the idling switch. | Short circuit to positive (+) or earth (ground) (-); Faulty potentiometer | Check that the potentiometer is correctly connected; Check that the potentiometer cable is not damaged; Check potentiometer function. |
| 2.9 | Indicator for water in fuel | Short circuit; Open circuit; Fault in indicator. | Check the indicator cables for breaks and short circuits; Check indicator function. Change indicator as necessary. |
| 3.1 | Oil pressure sensor | Short circuit to positive (+) or earth (ground) (-); Open circuit | Check that the oil pressure sensor cable is not damaged; Check that the oil pressure sensor is correctly connected; Check contact pressure in socket 11 in the lower cable connector (B) on the engine management module. |
| 3.2 | Charge air temperature sensor | Short circuit to positive (+) or earth (ground) (-); Open circuit. | Check that the charge air temperature sensor connector is correctly installed; Check that the charge air temperature sensor cable is not damaged; Check that the charge air temperature sensor is correctly installed; Check charge air temperature sensor function; Check contact pressure in socket 47 in the upper cable connector (A) on the engine management module. |
| 3.3 | Coolant temperature sensor — Pre-heating is also activated when the engine is hot. | Short circuit to positive (+) or earth (ground) (-); Open circuit. | Check that the coolant temperature sensor connector is correctly installed; Check that the coolant temperature sensor cable is not damaged; Check that the coolant temperature sensor is correctly installed; Check coolant temperature sensor function. |
| 3.4 | Charge pressure sensor — Engine smokes more than normally during acceleration/load increase. | Short circuit to positive (+) or earth (ground) (-); Avbrott. | Check that the charge pressure sensor connector is correctly installed; Check that the charge pressure sensor cable is not damaged; Check that the charge pressure sensor is correctly installed; Check charge pressure sensor function; Check contact pressure in socket 22 in the upper cable connector (A) on the engine management module. |
| 3.5 | Charge air pressure — VE engines: Engine control module reduces engine power (unless the protection has been shut off with the diagnostic tool VODIA). GE engines: Engine is shut off (unless the protection has been shut off with the diagnostic tool VODIA). | Charge pressure too high | Check turbocharger compressor function; Check charge pressure sensor function; Check fuel volume/unit injector. |
| 3.6 | Fuel pressure sensor | Short circuit to positive (+) or earth (ground) (-); Open circuit. | Check that the fuel pressure sensor connector is correctly installed; Check that the fuel pressure sensor cable is not damaged; Check that the fuel pressure sensor cable is correctly installed; Check fuel pressure sensor function; Check contact pressure in socket 16 in the lower cable connector (B) on the engine management module. |
| 6.2 | Charge air temperature — VE engines: Engine control module reduces engine power (unless the protection has been shut off with the diagnostic tool VODIA). GE engines: Engine is shut off (unless the protection has been shut off with the diagnostic tool VODIA). | Charge air temperature is too high. | Check the coolant level; Check the intercooler (cleanliness); Check charge air temperature sensor function; Check thermostat function. |
| 6.3 | Starter output, EMS 2 — Engine can not be started. The engine starts as soon as the ignition is switched on. | Short circuited to (+) or negative (-); Activated for too long time. | Check that the starter switch connections are not damaged; Check that the ignition switch cable is not damaged. |
| 6.4 | Data link (CAN), CIU — Instruments and warning lamps stop working. | Faulty data link (CAN), CIU. | Check that the 8-pin connector is not damaged; Check that the cables between the CIU and the engine management unit are not damaged; Check that sleeves 11 and 12 in the connector on the CIU are not damaged; Check contact pressure in sockets 51 and 55 in the lower cable connector (B) on the engine management module. |
| 6.5 | Data link (CAN), EMS 2 — Engine not operating: engine can not be started. Engine operating: engine idles and can only be stopped with the emergency stop. | Internal fault in control module. | Check that the 8-pin connector is not damaged; Check that the cables between the CIU and the engine management unit are not damaged; Check that sleeves 11 and 12 in the connector on the CIU are not damaged; Check contact pressure in sockets 51 and 55 in the lower cable connector (B) on the engine management module. |
| 6.6 | Oil pressure — Warning lamp lights up. VE engines: Engine control module reduces engine power (unless the protection has been shut off with the diagnostic tool VODIA). GE engines: Engine is shut off (unless the protection has been shut off with the diagnostic tool VODIA). | Oil pressure is too low. | Check oil level; Check that the air filters are not blocked; Check system pressure valves and safety valves in the oil system; Check oil pressure sensor function. |
| 6.7 | Piston cooling pressure — Engine stopped, applies to both GE and VE engines. The fault code is de-activated at engine speeds below 1000 rpm. | Piston cooling pressure is too low. | Check that the oil pressure in the engine exceeds 2 kPa (0.3 psi). |
| 6.8 | Piston cooling pressure sensor | Short circuited to (+) or negative (-); Open circuit. | Check that the piston cooling pressure sensor connector is correctly installed; Check that the piston cooling pressure sensor cable is not damaged; Check that the piston cooling pressure sensor is correctly installed; Check piston cooling pressure sensor function; Check contact pressure in sockets 10 and 14 in the lower cable connector (B) on the engine management module. |
| 6.9 | Battery voltage, CIU — Warning lamp lights up. Problems in engine starting. | Short circuit to negative (-); Faulty alternator; Faulty battery, battery cables. | Check the supply voltage from the control unit; Check that battery; Check the alternator. |
| 7.1 | Unit injector: cylinder #1 — Engine runs on 5 cylinders. Abnormal sound. Reduced performance. Cylinder balancing is stopped -> Less even running at lower speeds and low loading. | Electrical fault; Faulty compression or unit injector. | Check contact pressure in socket 24 in the upper cable connector (A) on the engine management module; Check that the unit injector cables are not damaged; Check that the unit injector connections are not damaged; Check fuel supply pressure; Check the valve clearance; Do a compression test and check cylinder #1. |
| 9.2 | Faulty data link (J1708/J1587) — Warning lamp lights up. | Faulty data link. | Check that the 8-pin connector is not damaged; Check that the cables between the CIU/DCU and the engine management unit are not damaged; Check that sleeves 22 and 37 in the connector on the CIU are not damaged; Check contact pressure in sockets 33 and 34 in the upper cable connector (A) on the engine management module. |
| 9.3 | Power supply to sensor — Faulty values in oil pressure and charge air pressure sensors. Fault code for oil pressure and charge air pressure sensors. Low engine power. Oil pressure and oil temperature instruments show 0. | Short circuit; Fault in oil pressure sensor and/or charge air pressure sensor. | Check that the oil pressure and charge air pressure sensors are not damaged; Check contact pressure in socket 7 in the upper cable connector (A) on the engine management module; Check the oil pressure sensor and charge air pressure sensor. |
| 9.8 | Fault in control module, CIU — CIU returns to factory setting. Engine goes to idle. Engine can not be started. | Faulty EEPROM, CIU; Faulty flash memory, CIU; Fault in control module, CIU. | Change CIU unit. |
| 9.9 | Memory fault in EMS — Engine might not start. | Memory fault in engine management system. | Change engine control unit. |
| 9.9 | Data set memory, EEPROM — Engine does not start. | Internal fault in control module; Faulty programming | Re-program the control module. If the fault remains, change the control module. |
| 9.9 | Control module, EMS — Engine misfires. Engine does not start. | Internal fault in control module. | Change engine control unit. |
| Symptom | Cause | Remedy |
|---|---|---|
| The diagnosis button lamp flashes. | Please refer to the "Diagnostic information" chapter. | |
| Starter motor does not rotate | Flat batteries | |
| Starter motor does not rotate | Poor contact/open circuit in cables | |
| Starter motor does not rotate | Main switch turned off | |
| Starter motor does not rotate | Main circuit breaker faulty | |
| Starter motor does not rotate | Faulty ignition lock | |
| Starter motor does not rotate | Faulty main relay | |
| Starter motor does not rotate | Faulty starter motor/solenoid | |
| Starter motor does not rotate | Break in "Pot+" cable to pedal | |
| Starter motor rotates slowly | Flat batteries | |
| Starter motor rotates slowly | Poor contact/open circuit in cables | |
| Starter motor rotates normally but engine does not start | Lack of fuel: fuel taps closed; fuel tank empty/wrong tank connected | |
| Starter motor rotates normally but engine does not start | Blocked fuel filter/pre-filter (because of contamination, or paraffin fraction separation in fuel at low temperature). | |
| Starter motor rotates normally but engine does not start | Air in the fuel system | |
| Starter motor rotates normally but engine does not start | Water/contamination in fuel | |
| Engine starts but stops again | Lack of fuel: fuel taps closed; fuel tank empty/wrong tank connected | |
| Engine starts but stops again | Blocked fuel filter/pre-filter (because of contamination, or paraffin fraction separation in fuel at low temperature). | |
| Engine starts but stops again | Air in the fuel system | |
| Engine starts but stops again | Water/contamination in fuel | |
| Engine starts but stops again | Faulty unit injector | |
| Engine does not reach correct operating speed at full throttle | Lack of fuel: fuel taps closed; fuel tank empty/wrong tank connected | |
| Engine does not reach correct operating speed at full throttle | Blocked fuel filter/pre-filter (because of contamination, or paraffin fraction separation in fuel at low temperature). | |
| Engine does not reach correct operating speed at full throttle | Air in the fuel system | |
| Engine does not reach correct operating speed at full throttle | Water/contamination in fuel | |
| Engine does not reach correct operating speed at full throttle | Faulty unit injector | |
| Engine does not reach correct operating speed at full throttle | Insufficient air supply to engine: blocked air filter; air leakage between turbocharger and engine inlet pipe; fouled compressor section in turbocharger; faulty turbocharger; poor engine bay ventilation | |
| Engine does not reach correct operating speed at full throttle | High back pressure in exhaust system | |
| Engine does not reach correct operating speed at full throttle | Water entry into engine | |
| Engine runs roughly | Blocked fuel filter/pre-filter (because of contamination, or paraffin fraction separation in fuel at low temperature). | |
| Engine runs roughly | Air in the fuel system | |
| High fuel consumption | Water/contamination in fuel | |
| High fuel consumption | Faulty unit injector | |
| High fuel consumption | Too low coolant temperature | |
| High fuel consumption | High back pressure in exhaust system | |
| Black exhaust smoke | Water/contamination in fuel | |
| Black exhaust smoke | Faulty unit injector | |
| Blue or white exhaust smoke | Too low coolant temperature | |
| Blue or white exhaust smoke | Too high oil level | |
| Too low lubrication oil pressure | Too low oil level | |
| Excessive coolant temperature | Coolant level too low | |
| Excessive coolant temperature | Air in the coolant system | |
| Excessive coolant temperature | Faulty circulation pump | |
| Excessive coolant temperature | Defective thermostat | |
| Too low coolant temperature | Defective thermostat | |
| No, or poor charge | Poor contact/open circuit in cables | |
| No, or poor charge | Alternator drive belt slips |
Fault codes and symptom→remedy steps extracted from this model’s service/owner documentation; verify against the official manual before servicing.
Documented causes: Flat batteries; Poor contact/open circuit in cables; Main switch turned off; Main circuit breaker faulty. See the table for the matching fixes.
Documented causes: Lack of fuel: fuel taps closed; fuel tank empty/wrong tank connected; Blocked fuel filter/pre-filter (because of contamination, or paraffin fraction separation in fuel at low temperature).; Air in the fuel system; Water/contamination in fuel. See the table for the matching fixes.
Documented causes: Lack of fuel: fuel taps closed; fuel tank empty/wrong tank connected; Blocked fuel filter/pre-filter (because of contamination, or paraffin fraction separation in fuel at low temperature).; Air in the fuel system; Water/contamination in fuel. See the table for the matching fixes.