Volvo 960 3.0L (1992) Trouble Code Info

Model: 960 3.0L
Year: 1992
Engine identification: B6304F
System:   • Bosch Motronic  1.8  •  Bosch Motronic 4.3  •  Siemens Fenix  5.2

Data link connector (DLC)  locations

datalink960

General information

  • Refer to the front of this manual for general test conditions, terminology, detailed descriptions of wiring faults and a general trouble shooter for electrical and mechanical faults.
  • Trouble codes are displayed by the LED on the data link connector (DLC).
  • The ECM fault memory can also be checked and erased using diagnostic equipment connected to the data link connector (DLC).

Accessing

  • Ensure ignition switched OFF.
  • Open cover on black data link connector (DLC).
  • Insert selector cable in socket 2 [1] [1].
  • Switch ignition ON.
  • Depress test button for approximately 1 second [1] [2].
  • Count LED flashes [1] [3]. Note trouble code.
  • Each trouble code consists of three groups of flashes [2].
  • A 3 second pause separates each group [2] [A].
  • For example: Trouble code 223 displayed [2] -idle air control (lAC) valve.
  • Repeat switch operation [1] [2]. Note trouble codes. Compare with trouble code table.
  • Switch ignition OFF. Rectify faults as necessary.
960-1960-2

Erasing

  • Ensure ignition switched OFF.
  • Insert selector cable in socket 2 [1] [1].
  • Access trouble codes.

NOTE: Trouble codes must be displayed at least once before they can be erased.

  • Depress test button for approximately 5 seconds.
  • Release test button.
  • Wait for LED to illuminate.
  • Depress test button for approximately 5 seconds.
  • Release test button.
  • Depress test button for approximately 1 second.
  • Ensure trouble code 111 displayed.

Trouble code identification

Flash code Fault location Probable cause
111 No fault found
112 Engine control module (ECM) ECM
113 0 Early models: lnjector(s) Wiring, fuse, injector(s)
113 0 Late models: Injectors 1, 2 & 4 Wiring, fuse, injector(s)
113 fJ 1993: Short tenn fuel trim No vacuum to MAP sensor, H02S/signal   short to ground, MAP sensor/ground wire
113 fJ 1994 -+: Short tenn fuel trim – upper limit reached Wiring, H02S
115 0 Injectors 3, 5 & 6 Wiring, fuse, injector(s)
115 D Injector 1 Wiring, injector
121 Mass air flow (MAF) sensor/manifold absolute pressure (MAP) sensor Wiring, hose connection, MAF/MAP sensor
122 Intake air temperature (IAT) sensor Wiring, IAT sensor
123 Engine coolant temperature (ECT) sensor Wiring, ECT sensor
125 Injector 2 Wiring, injector
131 Engine speed (RPM) sensor – no signal Wiring, RPM sensor
132 Engine control module (ECM) – supply voltage low/high Battery, alternator
135 Injector 3 Wiring, injector
143 Knock sensor (KS) 1 Wiring, KS
145 Injector 4 Wiring, injector
152 Secondary air injection (AIR) solenoid Wiring, AIR solenoid
153 Heated oxygen sensor (H02S) 2 Wiring, heating inoperative, H02S
154 Exhaust gas recirculation (EGR) system – excessive flow detected Wiring, EGR valve, EGR control module, engine coolant thermostat
155 Injector 5 Wiring, injector
212 Heated oxygen sensor (H02S) 1 Wiring, heating inoperative, MAF sensor, H02S
214 Engine speed (RPM) sensor- intermittent signal Wiring, flywheel/drive plate damaged, air gap, RPM sensor
221 Long term fuel trim, part load – upper limit reached Intake/exhaust leak, fuel pressure low, injector(s) blocked, hose connection, wiring, MAF/MAP sensor, ECT sensor, H02S
222 Engine control relay Wiring, engine control relay
223 D Early models: Idle air control (lAC) valve Wiring, lAC valve
223 D Late models: Idle air control (lAC) valve – opening signal Wiring, lAC valve
225 NC refrigerant pressure sensor Wiring, NC refrigerant pressure sensor
231 Long term fuel trim, part load – lower limit reached Fuel pressure high, excessive fuel in engine oil, engine oil level high, injector(s) leaking, EVAP canister purge valve, hose connection, wiring, MAF/MAP sensor, ECT sensor, H02S
232 Long term fuel trim, idling Intake/exhaust leak, fuel pressure, excessive fuel in engine oil, injector(s), EVAP canister purge valve, wiring, MAF sensor, ECT sensor, H02S
233 Long term fuel trim, idle air adjustment Intake leak/blockage, throttle valve adjustment, wiring, lAC valve
235 Exhaust gas recirculation (EGR) solenoid Wiring, EGR solenoid
241 Exhaust gas recirculation (EGR) system – incorrect flow detected Hose leak/blockage, wiring, EGR valve, EGR   control module, engine coolant thermostat
243 Throttle position (TP) sensor Wiring, TP sensor
245 Idle air control (lAC) valve – closing signal Wiring, lAC valve
311 Vehicle speed sensor (VSS) Wiring, speedometer, VSS
314 Camshaft position (CMP) sensor Wiring, CMP sensor
315 Evaporative emission (EVAP) system EVAP canister, hose leak/blockage, EVAP   canister purge valve
322 Mass air flow (MAF) sensor – no filament burn- off signal Wiring, ECM
323 Malfunction indicator lamp (MIL) Wiring, MIL
325 Engine control module (ECM) – supply voltage, battery Battery discharged/disconnected, wiring, ECM disconnected
335 Transmission control module (TCM) – MIL ON   request Wiring
342 NC relay Wiring, NC relay
343 Fuel pump relay Wiring, fuel pump relay
411 Throttle position (TP) sensor Wiring, TP sensor
413 Exhaust gas recirculation temperature (EGRT)   sensor Wiring, EGRT sensor
414 Turbocharger (TC) boost pressure – control TC wastegate regulating valve hose leak/blockage, wiring, MAF sensor, TCM wire (TC boost reduction), TC wastegate regulating valve
416 Transmission control module (TCM) – TC boost reduction signal Wiring short to ground
432 Engine control module (ECM) – overheating Engine coolant blower motor, air supply blocked, module cooling fan
433 Knock sensor (KS) 2 Wiring, KS
435 Heated oxygen sensor (H02S) 1 – slow response Intake/exhaust leak, fuel pressure, compression, H02S
436 Heated oxygen sensor (H02S) 2- compensation Intake/exhaust leak, fuel pressure, compression, H02S 1/2
442 Secondary air injection (AIR) pump relay Wiring, AIR pump relay
443 Catalytic converter – efficiency Intake/exhaust leak, fuel pressure, compression, catalytic converter
444 Accelerator pedal position (APP) sensor Wiring, APP sensor
451 Cylinder 1 – misfire detected Spark plug, HT lead, distributor rotor/cap, moisture ingress, injector/wiring, air leak, compression, head gasket, low-tension wiring, repeated cold starts (flooding), puncture in front tire
452 Cylinder 2 – misfire detected Spark plug, HT lead, distributor rotor/cap, moisture ingress, injector/wiring, air leak, compression, head gasket, low-tension wiring, repeated cold starts (flooding), puncture in front tire
453 Cylinder 3 – misfire detected Spark plug, HT lead, distributor rotor/cap, moisture ingress, injector/wiring, air leak, compression, head gasket, low-tension wiring, repeated cold starts (flooding), puncture in front tire
454 Cylinder 4 – misfire detected Spark plug, HT lead, distributor rotor/cap, moisture ingress, injector/wiring, air leak, compression, head gasket, low-tension wiring, repeated cold starts (flooding), puncture in front tire
455 Cylinder 5 – misfire detected Spark plug, HT lead, distributor rotor/cap, moisture ingress, injector/wiring, air leak, compression, head gasket, low-tension wiring, repeated cold starts (flooding), puncture in front tire
511 Long term fuel trim, idling Intake/exhaust leak, fuel pressure, excessive fuel in engine oil, injector(s), EVAP canister purge valve, wiring, MAF sensor, ECT sensor, H02S
512 f) Short term fuel trim – lower limit reached H02S signal wire short to ground, EGR system leak, MAP sensor, H02S, MAP sensor ground wire open circuit/poor connection
512 0 Short term fuel trim Fuel pressure, wiring, MAF sensor
513 Engine control module (ECM) – overheating Engine coolant blower motor, air supply blocked, module cooling fan
514 Engine coolant blower motor, low speed Wiring, engine coolant blower motor relay
515 Engine coolant blower motor, high speed Wiring, engine coolant blower motor relay
521 Heated oxygen sensor (H02S) 1 – heater control Wiring, H02S
522 Heated oxygen sensor (H02S) 2 – heater control Wiring, H02S
523 Module cooling fan Wiring, module cooling fan
524 Transmission control. module (TCM) – torque reduction signal Wiring
531 ngine control module (ECM) – power stage – group A Wiring, injector(s), EVAP canister purge valve, ECM
532 Engine control module (ECM) – power stage – group B Wiring, lAC valve, TC wastegate regulating valve, engine coolant blower motor relay, ECM
533 Engine control module (ECM) – power stage – group C Wiring short to positive, EGR control module, engine coolant blower motor relay, TCM (load signal), instrument panel (ECT/RPM/fuel consumption signals), ECM
534 Engine control module (ECM) – power stage – group D Wiring short to positive, MIL, AIC relay, fuel pump, ignition amplifier, ECM
535 Turbocharger (TC) wastegate regulating valve Wiring, TC wastegate regulating valve
541 Evaporative emission (EVAP) canister purge valve Wiring, EVAP canister purge valve
542 Misfire detected, more than 1 cylinder Spark plug, HT lead, distributor rotor/cap, moisture ingress, injector/wiring, air leak, compression, head gasket, low-tension wiring, fuel pressure, fuel pump/wiring, fuel level low, incorrect/contaminated fuel, engine oil level high, repeated cold starts (flooding), puncture in front tire
543 Misfire detected, at least 1 cylinder Spark plug, HT lead, distributor rotor/cap, moisture ingress, injector/wiring, air leak, compression, head gasket, low-tension wiring, repeated cold starts (flooding), puncture in front tire
544 Misfire detected, more than 1 cylinder – TWC   damage Spark plug, HT lead, distributor rotor/cap, moisture ingress, injector/wiring, air leak, compression, head gasket, low-tension wiring, fuel pressure, fuel pump/wiring, fuel level low, incorrect/contaminated fuel, engine oil levelhigh, repeated cold starts (flooding), puncture in front tire
545 Misfire detected – at least 1 cylinder- TWC   damage Spark plug, HT lead, distributor rotor/cap, moisture ingress, injector/wiring, air leak, compression, head gasket, low-tension wiring, repeated cold starts (flooding), puncture in front tire
551 Cylinder 1, misfire detected – TWC damage Spark plug, HT lead, distributor rotor/cap, moisture ingress, injector/wiring, air leak, compression, head gasket, low-tension wiring, repeated cold starts (flooding), puncture in front tire
552 Cylinder 2, misfire detected – TWC damage Spark plug, HT lead, distributor rotor/cap, moisture ingress, injector/wiring, air leak, compression, head gasket, low-tension wiring, repeated cold starts (flooding), puncture in front tire
553 Cylinder 3, misfire detected – TWC damage Spark plug, HT lead, distributor rotor/cap, moisture ingress, injector/wiring, air leak, compression, head gasket, low-tension wiring, repeated cold starts (flooding), puncture in front tire
554 Cylinder 4, misfire detected – TWC damage Spark plug, HT lead, distributor rotor/cap, moisture ingress, injector/wiring, air leak, compression, head gasket, low-tension wiring, repeated cold starts (flooding), puncture in front tire
555 Cylinder 5, misfire detected – TWC damage Spark plug, HT lead, distributor rotor/cap, moisture ingress, injector/wiring, air leak, compression, head gasket, low-tension wiring, repeated cold starts (flooding), puncture in front tire