VOLVO TRUCKS INDIA

Update TFAR Query/Remarks:

VOLVO TRUCKS (VECV) - Technical Failure Analysis Report

Purpose of TFAR
 Approval
Approval / feedback
 Technical Goodwill
Type of TFAR
 Truck Chassis
Subject/Complaint
“Injection malfunction – contact workshop” message appears on the display
Report Number 691300-OR-2025-70880 Report Date 19-Aug-2025 Prepared By sujit
Dealer ID 691300-OR Dealer Name VSPC-Surat-On-road Trucks Support
Customer Name Nutan Rajumani Transport Pvt. Customer Contact Person Rahul Singh
Workshop/Site-Location Navapur, Maharashtra Customer Contact Number
Chassis Model with Axle Configuration FM(4)-B 420 4X2 BS6 Body CuM & Application On-road application
Chassis No 8-989570 Reg. Number MH 04 LY 4808 Date of Delivery 20-Apr-2024
Date of failure 13-Aug-2025 Repair Order No. 32961 Repair Date 14-Aug-2025
Failure Mileage kms 347874 Age in Months 16 Engine Hrs. 7141
Function Group 2371 Causal Part No. VO 24309482 Description INJECTOR
Defect Code Group 4 ELECTRICAL FAULTS Defect Code 43-CONTACT FAULT
Spare parts warranty No Spare parts invoice details Spare parts fitment date 0000-00-00
Driveline Warranty Yes GDR No

Repair Estimate Summary

Material Cost 194282.33 Labor Cost 0.00 Other Cost 0.00

Road Details

Type of road surface (Asphalt, Soil Gravel, Sharp stones etc. ASPHALT
Dust Condition (Heavy Slight, etc.,) SLIGHT
Approx. Gradient of the Road (required for engine and wheel Hub failures 0:0
Undulation on the Road( Heavy,Slight, Lot of pot holes, large Bumps, etc.) SLIGHT
Was the vehicle travelling Uphill or Downhill (required for engine and wheel hud failures NA

Load Details

Type of load carried OTHER Permitted Technical GCW 100 GCW during failure NA

Available information on the load types and GCW's handled by the vehicle earlier which could have caused the failure

NA

Aggregate details

Details of the concerned failed Aggregate ( Engine, Gearbox, Rear Axle, Diffeerential, Rear Axle, Diff. carrier, steering gear, Turbocharger, Superstructure Hydraulic parts etc.)
Aggregate -- Aggregate Part No. -- Aggregate Sr. No. --

Interview with the Driver ( Applicable for all driveline related failures)

Driver Name Gurudeep Singh Training details on the related variant Yes

Drivers description on the happening of the failure:

“Injection malfunction – contact workshop” message appears on the display.

Technical Explination of complaint (Dealer comment):

As per the driver complaint we checked and found the message in IC.
Further connected the tech tool and checked for any fault code related to the complaint and found- P020413 and P062B00 as inactive.

As per the GD suggestion we performed the checking procedure-
* DTC:- P020413:- Cylinder 4 injector"A" circuit open.
* Failure Event:-
1. Current too low
2.Fuel injectors activated.
3.Pin A14.A:78
4.Pin A14.A:94
* Observable Symptoms:-
Low power.
The engine misfires
Noise and Vibrations.

As per the instruction we removed the valve cover and checked-
* EMS connector we found ok.
* VCIR pins and connectors were found ok.
* Checked the 4th cylinder injector, found the harness connector and the injector connector was faulty. When checked the connector by hand found some play in it. Video attached for reference.
* Checked the continuity from EMS A connector to VCIR, found Ok.

Additionally we observed scoring marks on the ball stud of 2nd cylinder injector and injector ball seat area and scoring mark on 6th cylinder ball stud.
No scoring marks were found in 6th cylinder injectors.
We also found the injector wiring harness connector was damaged.

Suspecting that the internal contact failure in 4th injector was causing the poor connection between them and causing the problem.
VAS Ticket Id -WT0825008551

As per the repair history these two injectors were already been replaced. TFAR NO:- 693000-1-OR-2025-65158.

Fault codes registered in vehicle (Including Active and Inactive Faults)

Inactive- 1.P020413- Cylinder 4 injector"A" circuit open. 2.P062B00- Internal control module fuel injector control performance.
Is the causal part a recently modified one NA

If Yes, kindly provide more details about the modification:

NA
Is this a repeat failure Yes Is yes, provide relavant details 693000-1-OR-2025-65158
Relavant Argus No. If any -- Relavant DQR No. If any -- Relavant MQR No. If any --
Relavant QJ No. If any --

Affected Vehicle details

Chassis No Model Body No Date of Delivery Date of Failure Mileage Kms Engine hrs Parts Sl.no
-- -- -- -- -- -- -- --

Area(Photos Where required/Applicable)

Photo Area Description/Remarks
Message In IC
Causal Part with S/N:- S147412436
New part With S/N:- S120832428
2nd cylinder injector with S/N:- S150172438
Scoring marks found in the ball stufd of the 2nd cylinder injector
DTC found in tech tool
DTC
DTC details
VCIR wiring harness connector condition.
Scoring marks found on 6th cylinder injector rocker ball stud.

Probable Cause of Failure

Suspecting that the internal contact failure in 4th injector was causing the poor connection between them and causing the problem.

Corrective Action/Suggestions

Need to replace the below mentioned parts

Service and Repair History of the vehicle (Relevant to the failure)

S.No.
Job Card No.
Date
Mileage Kms
Engine Hrs.
 Job carried out Remarks
11878809-Jul-2025317129--3 lakh K.M service
29856027-Feb-2025207178--2 lakh K.M service
31675315-Oct-202497497--1 lakh K.M service

Repair Estimate

Material Cost

S.No. Part no Description Qty Unit Price Net Price GST % GST Amt. Net Price including GST Pay code Remarks
1VO 24309482INJECTOR272442.59144,885.182840,567.85185,453.0305
2VO 24476465WIRES14216.974,216.9718759.054,976.0205
3VO 21794321ADJUSTING SCREW3672.652,017.9518363.232,381.1805
4VO 1677396NUT3114.21342.631861.67404.3005
5 VO 980464CABLE TIE625.24151.441827.26178.7005
6VO 948211CABLE TIE1328.4369.201866.46435.6605
7VO 21344774FLANGE SCREW3128.09384.271869.17453.4405
Total 152,367.64 Total 194,282.33

Labour cost

S.No. Operation No Description Qty Unit Price Net Price GST % GST Amt. Net Price including GST Pay code Remarks
Total 0.00 Total 0.00

Other cost

S.No. Description Qty Unit Price Net Price GST % GST Amt. Net Price including GST Pay code Remarks
Total 0.00 Total 0.00
Total cost of Repair( Material, Labor and Other cost) 194,282.33

Any Local solution or suggestion from the Field team for Prevention/ Quick resolution of Complaint

NA

ANNEXURES (Select the annexure attached)

17012-3 VCADS Pro Error Codes Test Compulsory for all failures having fault codes
17034-3 Vehicle information test
28486-3 Sensor Values History Report Compulsory for all failures related with the engine
20007-3: Engine protection data
28407-3 Sensor Values, Monitoring
20005-3: Fuel consumption data
28108-8 Engine ECU, check Compulsary for all failures related with the engine ECU
PDF file of the Repair history of the vehicle in LDS– complete 1755583264_Service_History_1_2025081911300992593.pdf Optional
Scan or Fax copy of the Last BS or AS (as applicable) checksheet Compulsary
Completely filled checksheets and Protocols as given in Impact/FAG in YVD for the complaint Compulsary

Additional Attachments

S.No. Attatchemnt
11755583257_NRTPL_Injector_failure.docx
21755583257_WhatsApp_Video_2025-08-19_at_09.15.28.mp4
31755583257_WhatsApp_Video_2025-08-19_at_09.15.31.mp4
4
5
6

Oil & Fuel Sample Test Reports (Compulsory for all major engine related failures):

Sample Date Sent to ELF Mumbai


Dispatch Details of Failed Parts( Mandatory for critical failures/failures related to safety/failures related to performance)

Docket No -- Dispatch Date Courier Name -- Transporter Veh No. --

Present Status of the vehicle

Present Status Rectified & Running Reason Waiting for inputs from TS


Comments

S.No. Remarks By Date & Time TFAR Status
1H team,
Kindly find the attached repeat failure of the pumping injector. As this is the repeat failure hence requesting your inputs and consider the case under warranty.

Regards
Sujit		sujit2025-08-19 12:01:58TFAR RAISED
2Hi Team,
Requesting your inputs on this case and consider this case under warranty as this is the repeat failure.

Regards
Gaurav		gkumar92025-08-19 12:06:22TFAR FORWARDED
3Hello team,
Since the previous failure was closed under warrant. Repeat case cannot be considered under warranty so we have to take it in goodwill.

Br
Vinayak		vysandimani2025-08-20 11:19:57RETURNED
4Hi Sujit,

Kindly update as discussed.

Regards
Gaurav		gkumar92025-08-29 10:56:00RETURNED
5Hi Team,

updated.

Regards
Sujit		sujit2025-08-29 11:28:18TFAR RAISED
6Hi team,
As advised, updates were done.

Regards
Gaurav		gkumar92025-08-29 15:53:14TFAR FORWARDED
7Kindly consider this case under goodwill as per TFARsupadhyay22025-08-30 02:14:27TFAR FORWARDED
8Hello team,
This case will be referred to GW support of 80% on parts value i.e. INR 155425.9
We will revert once there is decision for this case.

Br
Vinayak		vysandimani2025-09-01 09:23:20RETURNED
9Hi, Please refer remarks from TS and do the needful.supadhyay22025-09-01 01:27:40RETURNED
10Hi Team,

As approve the case to close as per the TS remark.

Br,
Gaurav		gkumar92025-09-06 14:43:27TFAR FORWARDED
11ok approved supadhyay22025-09-13 04:37:12APPROVED
 
S.No. Remarks By Date & Time TFAR Status
1H team,
Kindly find the attached repeat failure of the pumping injector. As this is the repeat failure hence requesting your inputs and consider the case under warranty.

Regards
Sujit		sujit2025-08-19 12:01:58TFAR RAISED
2Hi Team,
Requesting your inputs on this case and consider this case under warranty as this is the repeat failure.

Regards
Gaurav		gkumar92025-08-19 12:06:22TFAR FORWARDED
3Hello team,
Since the previous failure was closed under warrant. Repeat case cannot be considered under warranty so we have to take it in goodwill.

Br
Vinayak		vysandimani2025-08-20 11:19:57RETURNED
4Hi Sujit,

Kindly update as discussed.

Regards
Gaurav		gkumar92025-08-29 10:56:00RETURNED
5Hi Team,

updated.

Regards
Sujit		sujit2025-08-29 11:28:18TFAR RAISED
6Hi team,
As advised, updates were done.

Regards
Gaurav		gkumar92025-08-29 15:53:14TFAR FORWARDED
7Kindly consider this case under goodwill as per TFARsupadhyay22025-08-30 02:14:27TFAR FORWARDED
8Hello team,
This case will be referred to GW support of 80% on parts value i.e. INR 155425.9
We will revert once there is decision for this case.

Br
Vinayak		vysandimani2025-09-01 09:23:20RETURNED
9Hi, Please refer remarks from TS and do the needful.supadhyay22025-09-01 01:27:40RETURNED
10Hi Team,

As approve the case to close as per the TS remark.

Br,
Gaurav		gkumar92025-09-06 14:43:27TFAR FORWARDED
11ok approved supadhyay22025-09-13 04:37:12APPROVED
Query/Reply


 
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