IMPACT 4.07.

71 26/06/2020

Printed by:Htun Htun Win

Service

Chassis ID Path
A 563867 200/Diagnostics//Abnormal smoke, fault tracing. Symptom fault tracing

Model Identity
FM12 75541600

Publish date ID/Operation

21/02/2006

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.07.71 26/06/2020

Abnormal smoke, fault tracing

Symptom fault tracing

When fault tracing, select the symptom that best matches the fault on the vehicle. Fault tracing should be carried out as
described in the information for each symptom. This makes fault tracing more efficient by systematically eliminating or
documenting faults which may be the symptom cause.

Contents

General information
Black smoke
Blue smoke
White or grey smoke

General information

Note: Before fault tracing is started, chock the wheels and release the parking brake.

Note: During fault tracing, the engine should be run at the operating temperature as well as at the temperature where
the symptom occurs.

The colour of the exhaust smoke can, in many cases, reveal which engine system the fault may be in.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.07.71 26/06/2020

Try to first determine if the smoke problem is caused by poor fuel quality or whether the fuel filled does not meet
specifications.
The unit injector is an important component in the combustion process. Due to this, it can often be suspected as
the cause of smoky exhaust. Before a unit injector is replaced, the systems and components outside the
combustion chamber should be excluded as a direct cause of the fault.

Fault tracing

Temporary faults can be difficult to trace as the fault may not occur when the vehicle is checked. Fault tracing should
be carried out based on the driver's understanding of the fault(s). The information that the driver has provided together
the factual data collected should form the basis for how the problem is to be resolved.
Whenever possible, try to recreate the problem in an environment and situation similar to that described by the driver.
Begin by determining if anything has recently happened to the vehicle that could affect the electrical system, but which
is not related to the engine control system.

Black smoke

There should be no black smoke from a fault free and well maintained engine. Black smoke indicates poor combustion
and is caused by excess fuel or shortage of air.
Black smoke that is caused by a fault in a unit injector and where the fault gives abnormally high levels of fuel
starvation, can be considered to be a surplus of fuel supplied (incomplete combustion).
A harsh throttle in the exhaust pressure governor prevents the engine's exhaust exchange. In this case the cause of
black smoke is a lack of air.

Step 1: Fault code readings

Active and inactive fault codes registered can point to faults, but can also be useful in searching for the symptom
cause. Freeze frames with information for specific fault codes, can also be useful when searching for symptom causes.

Fault tracing, using relevant service information, must always be carried out for relevant fault codes.
Components/functions of special interest:
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.07.71 26/06/2020

MID 128, Engine control unit

PID 107 Pressure drop, air filter

PPID 122 Engine compression brake, VCB

PPID 123 Exhaust pressure governor, EPG 2 (D12C)

PPID 124 Exhaust pressure governor, EPG 1

SID 1-6 Unit injectors

Step 2: Visual check

Check engine oil level.

Check that the air filter is not blocked or damaged.
Check that the crank house ventilation is not damaged or blocked.
Check that the installed components, for example the turbocharger, engine ECU, unit injectors, exhaust
pressure governor, have the correct part numbers.

Step 3: Tests

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.07.71 26/06/2020

The results of the following tests, carried out using VCADS Pro, can show which systems or which components may be
the cause of the symptom. These tests can also eliminate components or systems with no faults or malfunctions.

Cylinder balancing, test

Shutting off injectors, manually
Cylinder compression, test
Inlet and exhaust system, test
Start and temperature control, function check
Note. Check that the temperature control function operates correctly. Abnormal smoke generation can occur if
the temperature control function is activated incorrectly.
Auxiliary brake, test (D9A, D12D, D16C)
Note. Check that the exhaust brake functions correctly. Abnormal smoke generation can occur if the exhaust
brake is activated incorrectly.
Exhaust brake, test (D12C)
Note. Check that the exhaust brake functions correctly. Abnormal smoke generation can occur if the exhaust
brake is activated incorrectly.
Sensor value check, engine running
Sensor value check, stationary engine
Note. Abnormal smoke generation can occur if any or several sensors display abnormal values.

Step 4: Component and function checks

The following checks should be carried out in the specified order until the fault is found. These checks also can help
eliminate components with no faults or malfunctions. The number of tests and the sequence depends on the following:
the results from tests and fault codes; the vehicle's condition; the vehicle's service and repair history; other symptoms
and information from the driver.

Fuel quality, check

Check that the fuel quality is good (not mixed with water or other additives).
Exhaust pipe, check
Check that there is no damage, blockages or non-approved changes to the exhaust manifold or exhaust pipe.
See group 25: Charge air, fault detection (Checklist A)
Air pressure indicator, check
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.07.71 26/06/2020

Check that the pressure drop indicator functions as it should.

See group 25: Charge air, fault detection (Checklist A)
Inlet manifold, check
Check that the inlet manifold is clean internally and undamaged.
See group 25: Charge air, fault detection (Checklist A)
Charge air pipe, check
Check the charge air pipe for visible cracks and external damage and that it is clean internally.
See group 25: Charge air, fault detection (Checklist A)
Charge air cooler, check
Check that the charge air cooler does not leak and that all hoses and connections are not damaged or blocked.
See group 25: Charge air, fault detection (Checklist A)
Engine management system, check
Check that the engine ECU earth connections and supply cables are fault free and correctly tightened.
See group 25: Engine control system, check (Checklist M)
Exhaust pressure governor, throttle
Check that the exhaust pressure governor throttle is not blocked and that it is not stuck in the closed or half
closed position.
See group 25: Exhaust pressure governor, fault detection (Checklist E)
Exhaust pressure governor, check
Check the exhaust pressure governor function, input signals, power supply and air supply.
See group 25: Exhaust pressure governor, fault detection (Checklist E)
Control valve VCB, check
Check the condition of the VCB's control valve.
See group 25: Exhaust brake fault detection (Checklist O)
Valves and unit injectors, check
Check that the valves and unit injectors are correctly adjusted.
See group 25: Valves and unit injectors, adjustment
Camshaft settings
Check that the camshaft is correctly set.
See group 21: Camshaft and flywheel signals, fault detection (Checklist H)
Rocker arm shaft, oil pressure, check
Check that the oil pressure in the rocker arm shaft is within the specification value.
See group 25: Exhaust brake fault detection (Checklist O)

Blue smoke

Blue smoke often is due to mechanical problems that are related to fuel or engine oil. Electrical problems can also
cause blue smoke when, for example, sensors give incorrect values to the engine's control unit. Blue smoke may be
unburnt fuel or oil. Blue smoke often has a characteristic smell of fuel or oil.
Blue smoke can be caused by:

Poor fuel quality.

Poor combustion due to irregular fuel injection.
Low compression.
Some of the temperature sensors (for example ambient air temperature or coolant temperature) give incorrect
values, i.e. the sensors indicate higher temperatures than the actual temperature. As long as the sensor values
are within the sensors' normal operating range, no error code for an unreasonable sensor value is set.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.07.71 26/06/2020

The start and temperature control function for the exhaust pressure governor does not function (for cold start).
Preheating is out of operation (for cold start).

Step 1: Fault code readings

Active and inactive fault codes registered can point to faults, but can also be useful in searching for the symptom
cause. Freeze frames with information for specific fault codes, can also be useful when searching for symptom causes.

Fault tracing, using relevant service information, must always be carried out for relevant fault codes.
Components/functions of special interest:

MID 128, Engine control unit

PID 94 Feed pressure

PID 100 Engine oil pressure

PID 110 Coolant temperature:

PID 172 Air temperature, inlet

PID 175 Engine oil temperature

PPID 123 Exhaust pressure governor, EPG 2 (D12C)

PPID 123 Buffer air TC (only D12D500)

PPID 124 Exhaust pressure governor, EPG 1

Step 2: Visual check

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.07.71 26/06/2020

Check engine oil level

Check that the crank house ventilation is not damaged or blocked.
Check that there is no damage, blockages or non-approved changes to the exhaust manifold or exhaust pipe.
Check that the installed components, for example the turbocharger, engine ECU, unit injectors, exhaust
pressure governor, have the correct part numbers.

Step 3: Tests

The results of the following tests, carried out using VCADS Pro, can show which systems or which components
probably cause the symptom. These tests can also eliminate components or systems with no faults or malfunctions.

Sensor value check, engine running

Sensor value check, stationary engine
Inlet and exhaust system, test
Cylinder compression, test
Cylinder balancing, test
Shutting off injectors, manually

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.07.71 26/06/2020

Step 4: Component and function checks

The following checks should be carried out in the specified order until the fault is found. These checks also can help
eliminate components with no faults or malfunctions. The number of tests and the sequence depends on the following:
the results from tests and fault codes; the vehicle's condition; the vehicle's service and repair history; other symptoms
and information from the driver.

Fuel quality, check

Check that the fuel quality is good (not mixed with water or other additives).
Air pressure indicator, check
Check that the pressure drop indicator functions as it should.
See group 25: Charge air, fault detection (Checklist A)
Engine management system, check
Check that the engine ECU earth connections and supply cables are fault free and correctly tightened.
See group 25: Engine control system, check (Checklist M)
Inlet manifold, check
Check that the inlet manifold is clean internally and undamaged.
See group 25: Charge air, fault detection (Checklist A)
Charge air pipe, check
Check the charge air pipe for visible cracks and external damage and that it is clean internally.
See group 25: Charge air, fault detection (Checklist A)
Charge air cooler, check
Check that the charge air cooler does not leak and that all hoses and connections are not damaged or blocked.
See group 25: Charge air, fault detection (Checklist A)
Exhaust pressure governor, throttle
Check that the exhaust pressure governor throttle is not blocked and that it is not stuck in the closed or half
closed position.
See group 25: Exhaust pressure governor, fault detection (Checklist E)
Exhaust pressure governor, check
Check the exhaust pressure governor function, input signals, power supply and air supply.
See group 25: Exhaust pressure governor, fault detection (Checklist E)
Control valve VCB, check
Check the condition of the VCB's control valve.
See group 25: Exhaust brake fault detection (Checklist O)
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.07.71 26/06/2020

Valves and unit injectors, check

Check that the valves and unit injectors are correctly adjusted.
See group 25: Valves and unit injectors, adjusting
Camshaft settings
Check that the camshaft is correctly set.
See group 21: Camshaft and flywheel signals, fault detection (Checklist H)
Rocker arm shaft, oil pressure, check
Check that the oil pressure in the rocker arm shaft is within the specification value.
See group 25: Exhaust brake fault detection (Checklist O)

White or grey smoke

White smoke

White odourless smoke when starting and/or during driving during cold weather is completely normal and does not
indicate a fault. The white smoke is a result of completely normal small amounts of water in air that evaporates during
combustion and condenses when it comes into contact with the cold air. Note that larger cooling areas in the exhaust
and silencer system means greater amounts of white smoke generated in cold starts and at low ambient temperatures.

In extreme cases, coolant can get into the engine via an intake or exhaust port and produce white smoke. In such
cases, this is indicated by loss of coolant. If it is not possible to start due to the start and temperature control function
and the preheater does not function, this results in an increased generation of white smoke.

Grey smoke

Grey smoke is a mixture of black smoke and steam and often occurs during cold weather. Therefore, where grey
smoke is generated, the fault detection procedures for black smoke can be used, see Black smoke.

Step 1: Fault code readings

Active and inactive fault codes which are registered, can point to faults but can also be useful in searching for the
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.07.71 26/06/2020

symptom cause. Freeze frames with information for specific fault codes, can also be useful when searching for
symptom causes.

Fault tracing, using relevant service information, must always be carried out for relevant fault codes.
Components/functions of special interest:

MID 128, Engine control unit

PID 45 Starting heater status relay

PID 107 Pressure drop, air filter

PID 111 Coolant level:

PPID 122 Engine compression brake, VEB

PPID 123 Exhaust pressure governor, EPG 2 (D12C)

PPID 124 Exhaust pressure governor, EPG 1

SID 70 Starting heater 1

Step 2: Visual check

Check engine oil level

Check the coolant level

Step 3: Tests

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.07.71 26/06/2020

The results of the following tests, carried out using VCADS Pro, can show which systems or which components
probably cause the symptom. These tests can also eliminate components or systems with no faults or malfunctions.

Preheat, check
Start and temperature control, function check
Note. Check that the temperature control function operates correctly. Abnormal smoke generation can occur if
the temperature control function is activated incorrectly.
Auxiliary brake, test (D9A, D12D, D16C)
Note. Check that the exhaust brake functions correctly. Abnormal smoke generation can occur if the exhaust
brake is activated incorrectly.
Exhaust brake, test (D12C)
Note. Check that the exhaust brake functions correctly. Abnormal smoke generation can occur if the exhaust
brake is activated incorrectly.
Inlet and exhaust system, test
Cylinder compression, test
Cylinder balancing, test
Sensor value check, engine running
Note. Abnormal smoke generation can occur if any or several sensors display abnormal values.
Sensor value check, stationary engine
Note. Abnormal smoke generation can occur if any or several sensors display abnormal values.
Shutting off injectors, manually

Step 4: Component and function checks

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.07.71 26/06/2020

The following checks should be carried out in the specified order until the fault is found. These checks also can help
eliminate components with no faults or malfunctions. The number of tests and the sequence depends on the following:
the results from tests and fault codes; the vehicle's condition; the vehicle's service and repair history; other symptoms
and information from the driver.

Fuel quality, check

Check that the fuel quality is good (not mixed with water or other additives).
Carbon monoxide in the coolant, check
Check that the coolant is free of carbon monoxide.
See group 23: Poor compression, fault detection (Checklist G)
Charge air cooler, check
Check that the charge air cooler does not leak and that all hoses and connections are not damaged or blocked.
See group 25: Charge air, fault detection (Checklist A)
Exhaust pressure governor, throttle
Check that the exhaust pressure governor throttle is not blocked and that it is not stuck in the closed or half
closed position.
See group 25: Exhaust pressure governor, fault detection (Checklist E)
Exhaust pressure governor, check
Check the exhaust pressure governor function, input signals, power supply and air supply.
See group 25: Exhaust pressure governor, fault detection (Checklist E)
Control valve VCB, check
Check the condition of the VCB's control valve.
See group 25: Exhaust brake, fault detection (Checklist O)
Rocker arm shaft, oil pressure, check
Check that the oil pressure in the rocker arm shaft is within the specification value.
See group 25: Exhaust brake, fault detection (Checklist O)

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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