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DPF temp sensor DTC fault - even after replacing sensor + ECU

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo XC90s. The XC90 proved to be very popular, and very good for Volvo's sales numbers, since its introduction in model year 2003 (North America).
hjns
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DPF temp sensor DTC fault - even after replacing sensor + ECU

Post by hjns » Mon Aug 01, 2016 7:25 pm

Hi all,

This is my first post to this forum. For full transparency, I have posted the same question on Swedespeed.
I would appreciate any help with the following problem:

In December 2015, I purchased a 2005 XC90 AWD with the D5 185ps motor. At that time, it had run around 110k km. After a month of driving (around 1k km), the engine light went on, and the motor went into limp mode. I went to my local Volvo specialist. He hooked his Vida unit on, and it told him that there was an issue with the signal from the DPF temperature sensor.

The garage replaced the temp sensor, and cleaned the DPF (300 Euro). However, when replacing the temp sensor, the garage found that the old temp sensor was not connected as usual to the wire going to the ECU, but soldered with like 10 intermittent pieces of wire, all soldered together. That was the first sign something was really wrong.

After 50km driving, engine light went on again. I went back to the garage, Vida showed same error, and they replaced the temp sensor under warranty (0 Euro).

After another 100km of driving, engine light came on again, back in the garage, Vida showed same error, and they completely replaced the wire from the DPF temp sensor to the ECU (another 300 Euro). The old wire consisted of another 5 wires soldered in series....

After another 75km of driving, engine light came on again. This time, the garage replaced the complete ECU (1500 Euro).

At this time, (and after reading up a lot on this forum), I had purchased a Chinese version of Vida with a Dice unit myself. I went on a holiday, from Switzerland, to the south of France, to the Netherlands, and back to Switzerland (around 2000 km). The engine light came on many many times. Many times, I looked with Vida, and then I erased the same fault again (DPF temp sensor fault). However, many other times, I just continued driving. Then the engine would move into limp mode after a variable amount of time. Many times the engine would then come out of limp mode, allowing me to drive normally. It is completely unpredictable when the engine light comes on, or then when the engine goes into limp mode, or when it comes out of limp mode again.

Using Vida, I recorded some data, to see if I could identify the source of the DPF temp sensor error. Unfortunately, one can only graph 5 parameters at the same time.

I noticed that the Battery Voltage remained around 13.6V, even when accelerating hard. When the DPF sensor error happened, no extremely low value of Battery Voltage was observed. I conclude that it is not likely to be a low voltage.

Similarly, the alternator provided approximately 40A continuously. Seems good enough for me to charge the Battery while driving.

DPF sensor temperature consistently showed more than 300 oC when the error happened. One time, I observed a DPF temp of 600 oC. I don't know if this is within the normal range.

I actually don't know what to do, anymore :confused:. Can anyone recommend me what to measure with Vida that would help diagnosing the issue, or who to contact for further information?

Or is there anything I can do with the DPF sensor that would remove these errors from happening?

Many thanks!

KR, Henk

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Re: DPF temp sensor DTC fault - even after replacing sensor + ECU

Post by doublebug » Tue Aug 02, 2016 3:15 am

What is the error code?
If you have questions about Volvo firmware ask me. I may know an answer :)

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Re: DPF temp sensor DTC fault - even after replacing sensor + ECU

Post by hjns » Tue Aug 02, 2016 1:31 pm

Hi there,

Thanks for the quick response. The errors are:

ECM-2B10 Particulate filter temperature sensor - Faulty signal
ECM-2B00 Exhaust temperature - Faulty signal


I am not sure if the following is useful to further investigate....

ECM-2B10 Particulate filter temperature sensor - Faulty signal - Details
SI 01 DTC Test is running No
SI 02 DTC Test completed at least once during current operation cycle No
SI 03 Sporadic fault found last time the DTC Test was completed during current operation cycle No
SI 04 Sporadic fault found at least once during current operation cycle No
SI 05 Warning indicator requested Yes
SI 06 DTC Test inhibited No
SI 08 Fault Detection Counter, current value 255
SI 09 Fault Detection Counter, maximum value during current operation cycle 255

Frozen values
Engine load 59.38 %
Engine coolant temperature 88.13 °C
Boost pressure 1575.38 hPa
Engine Speed 2236.12 r/min
Vehicle Speed 26 km/h
Intake air temperature 41.65 °C
Air mass 228.44 kg/h
Fuel pressure 1134276.92 hPa
EGR valve 78.13 %
Atmospheric pressure 945.23 hPa
Battery voltage 14.11 V
Throttle valve position 0 %
Ambient Temperature 22.06 °C
Accelerator pedal sensor - PWM signal 21.96 %
Accelerator pedal (AP) sensor, analog signal 23.14 %
Intake throttle, desired position 325.14 %
Engine running status ECM Engine running
Torque from engine 162.75 Nm
Previous engine state NOT TRANSLATED
Ignition key position Engine running
Engine oil temperature 103.24 °C
Fuel temperature 55.27 °C
Brake light switch Not activated
Injection quantity 28.50 mg/cyc


ECM-2B00 Exhaust temperature - Faulty signal - Details
SI 01 DTC Test is running No
SI 02 DTC Test completed at least once during current operation cycle No
SI 03 Sporadic fault found last time the DTC Test was completed during current operation cycle No
SI 04 Sporadic fault found at least once during current operation cycle No
SI 05 Warning indicator requested No
SI 06 DTC Test inhibited No
SI 08 Fault Detection Counter, current value 255
SI 09 Fault Detection Counter, maximum value during current operation cycle 255

Frozen values
Engine load 96.88 %
Engine coolant temperature 90.94 °C
Boost pressure 1654.15 hPa
Engine Speed 3271.79 r/min
Vehicle Speed 102 km/h
Intake air temperature 45.17 °C
Air mass 385.98 kg/h
Fuel pressure 1016123.08 hPa
EGR valve 100 %
Atmospheric pressure 945.23 hPa
Battery voltage 14.03 V
Throttle valve position 0 %
Ambient Temperature 25.75 °C
Accelerator pedal sensor - PWM signal 76.47 %
Accelerator pedal (AP) sensor, analog signal 80.39 %
Intake throttle, desired position 325.14 %
Engine running status ECM Engine running
Torque from engine 109.80 Nm
Previous engine state NOT TRANSLATED
Ignition key position Engine running
Engine oil temperature 106.93 °C
Fuel temperature 51.58 °C
Brake light switch Not activated
Injection quantity 18.83 mg/cyc

Kind regards,
Henk

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Re: DPF temp sensor DTC fault - even after replacing sensor + ECU

Post by Roger_850T » Tue Aug 02, 2016 6:07 pm

Can you track the error in VIDA and see if it gives you any useful information? I don't have a D5, so I cannot comment on the specific issue, however for codes I have seen on my car, I can often follow them to the description of operation and/or the troubleshooting section and see what will set the trouble codes.

Looking at your captures, it looks like it never even completes a cycle, so it just appears that the sensor is dead to the ECU.

Getting rid of all those solder joints is probably a good thing! Looks like this problem was around for a while for the prior owner.
'05 XC90 V8 140k
'95 854T 310k
'02 V70 159k
'03 S80 111k (crashed)
'93 945T 217k (gone to be parted out)
'87 245 300k+ sold, still going
'84 264 Diesel, RIP at 160k
'78 242 manual everything.
'73 P1800ES, fun until the rust set in...

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Re: DPF temp sensor DTC fault - even after replacing sensor + ECU

Post by doublebug » Wed Aug 03, 2016 1:50 am

hjns wrote: ECM-2B10 Particulate filter temperature sensor - Faulty signal
ECM-2B00 Exhaust temperature - Faulty signal
There are 2 sensors
ECM-2B00 that is for upstream sensor (before particle filter)
ECM-2B10 that is for downstream sensor (after particle filter)

One of them are faulty so you need to monitor signals from both sensors.
Maybe you'll notice some strange temperatures.

At a time of DPF regeneration down stream sensor can show up to 600 °C
at that time upstream sensor will show something 200-300 °C
If you have questions about Volvo firmware ask me. I may know an answer :)

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Re: DPF temp sensor DTC fault - even after replacing sensor + ECU

Post by hjns » Wed Aug 03, 2016 9:44 am

Roger_850T wrote:Can you track the error in VIDA and see if it gives you any useful information? I don't have a D5, so I cannot comment on the specific issue, however for codes I have seen on my car, I can often follow them to the description of operation and/or the troubleshooting section and see what will set the trouble codes.

Looking at your captures, it looks like it never even completes a cycle, so it just appears that the sensor is dead to the ECU.

Getting rid of all those solder joints is probably a good thing! Looks like this problem was around for a while for the prior owner.
Hi Roger,

Thanks for your response. Yes, the garage and I tracked the error. The information provided mentioned broken sensor, connector issues and wire issues. As mentioned, the garage replaced the sensors twice, to no avail. In addition, they replaced the wires from the sensors to the ECU. That did not help. Finally, they replaced the complete ECU. And still the issue exists.

Tomorrow morning I will make another tour with Vida graphs and try to record a video.

KR, Henk

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Re: DPF temp sensor DTC fault - even after replacing sensor + ECU

Post by hjns » Wed Aug 03, 2016 9:45 am

doublebug wrote: There are 2 sensors
ECM-2B00 that is for upstream sensor (before particle filter)
ECM-2B10 that is for downstream sensor (after particle filter)

One of them are faulty so you need to monitor signals from both sensors.
Maybe you'll notice some strange temperatures.

At a time of DPF regeneration down stream sensor can show up to 600 °C
at that time upstream sensor will show something 200-300 °C
I will try to make a video tomorrow, showing the outputs of these sensors and some more...
Thanks again for sharing your thoughts.

KR, Henk

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Re: DPF temp sensor DTC fault - even after replacing sensor + ECU

Post by hjns » Thu Aug 04, 2016 2:49 am

Quick update:

No video, because the screen-capture program crashed. However, the 2B00 reported a steadily increasing Temp from 200 oC to 350oC, and the 2B10 went up to 450oC. While driving ~80km/h, the CEL came up again. I stopped, and Vida showed both same errors again. Again, nothing special with the actual temps reported from these sensors. In addition, I also monitored the DPF pressure sensor, and it showed variable pressures between 5 and 30, which I understand is completely normal. I also looked at the EGF valve position, and this nicely correlated with whatever I did with my right foot on the pedal.

As reported, I had the ECU replaced. Is there any other module that could interfere with these sensors?

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Re: DPF temp sensor DTC fault - even after replacing sensor + ECU

Post by doublebug » Thu Aug 04, 2016 3:38 am

I will try to get some logging on my D5. It is the same as yours but has Polestar 210 hp software installed.
If you have questions about Volvo firmware ask me. I may know an answer :)

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Re: DPF temp sensor DTC fault - even after replacing sensor + ECU

Post by doublebug » Sat Aug 06, 2016 12:43 pm

If you have questions about Volvo firmware ask me. I may know an answer :)

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