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Discussion Starter · #1 ·
I have been working with me mechanic and Volvo Mobile Tech for months trying to get this issue resolved.

SUM Module fails calibration due to "Right rear sensor voltage to high" and "Left rear sensor voltage to low". When we read the voltage feedback the right sensor returns 3.5V and the left sensor returns 1.5V.

Does any one know what the correct voltage feedback is supposed to be?

We can raise and lower the body on the car and the voltage feedback changes. Raising cause the right to go down and the left to go up, but we never found a position that did not return the same error.

No one at my Volvo dealership knows what the correct reading should be, and they want to replace both sensors. Does this sound correct?
 

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Re: (SilverSurf"R")

Quote, originally posted by SilverSurf"R" »
This all started when the EVOLVE springs were installed!!!!

Well there's your problem. But seriously, try jacking up the rear of the car 1/2 to 1 inch before trying the SUM calibration.
 

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Re: SUM Calibration issues.....STILL (SilverSurf"R")

I believe the sensors range from 0-5v so sounds like they are reading in the correct range. Question is, are they the correct voltages. I'm trying to recall my factory training class in which we discussed 4C and I looked through my Course Books briefly but I can't locate the exact manual in which I remember taking level sensor readings. IIRC in VIDA there are signal description charts on Operating conditions. I don't currently have access to VIDA or I'd look it up for you. I know there are two level sensors in the rear and one in the RF. When the Springs were installed were the level sensors moved or otherwise possible switched? Or maybe the harness or connectors swapped? Lowering springs don't normally cause issues but as someone said, try and calibrate SUM with ride height @ stock (have tech put on lift).

If I remember I will try and look up in the R course manual any level sensor specs, if they are even there. That manual is at work and I won't get access until Mon. But VIDA does contain the spec ranges, it just takes a little know how to locate. Volvo Search in VIDA sux and you have to talk to it like you are a first grader. If I find something later, I will post. Gotta go cook dinner. Having Tacos! http://********************/smile/emthup.gif
 

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Discussion Starter · #5 ·
Re: (PhilUp)

To be perfectly clear, we tried raising the car as suggested in numerous previous posts. This did not work. We always received the same error as mentioned above. We tried this about 6 different heights from 1 to 4 inches up from resting position. We noted the feedback from the sensors and the right dropped about 1V and the left increased about 1 volt from resting height to the highest chassis level.
 

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Re: SUM Calibration issues.....STILL (SilverSurf"R")

Quote, originally posted by SilverSurf"R" »

Does any one know what the correct voltage feedback is supposed to be?
The value should be approximately 2.5 volts with the car stationary

SilverSurf"R" We can raise and lower the body on the car and the voltage feedback changes. Raising cause the right to go down and the left to go up said:
If you are raising ONE side of the vehicle, and thusly making the other side go down, than this is the correct behavior. If you are suggesting that the rear of the car is being raised as a unit, than you should see both values change about the same amount, in the same direction. (Can a real tech validate this, since I have not validated this on my own car)

You want to have the position sensors at their midpoint of travel when the car is at rest in it's normal static position.
 

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Discussion Starter · #8 ·
Re: SUM Calibration issues.....STILL (rogersampson)

You are correct, if you believe the HELP files in the VID. I read these with the TECH and that is what they say..normal is about 2.5V.

AT REST - R = 3.5V, L = 1.5V

Whole car up about 4 inches, wheels on the ground R = 2.5V, L = 2.5V.
We never tried lifting one side and not the other.

Even at this height we got the same error code. Right Voltage to High, Left Voltage to Low.

My Tech is trying to Find another 04 R locally he can verify the readings and try to run the SUM calibration.

So I can surmise that the Help files in the VID are incorrect, or my Techs PC has a software glitch. But the problem is, no one seems to know what is correct.
 

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Re: SUM Calibration issues.....STILL (SilverSurf"R")

I'm wondering if your tech knocked a sensor out of location while they were doing the install? You should have equal readings when the car is stationary and level.

If you've got 2v difference, something is wrong with the sensors.

Make sure they are in the right location or try new ones.
 

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Re: SUM Calibration issues.....STILL (SilverSurf"R")

I think 2.5V is a logical, nominal value, since the range is 0-5V, so I do not suspect that the value is incorrect.

It is interesting to note , that when they were both at their normal values of 2.5V, that the error code remained. It is also interesting that when at rest, each one is off by 1.0V, in opposite directions. Are both encoders at mid range when at rest?

When the spings were installed, could the encoder have been remounted in such a fashion that the linkage is turning it the wrong direction?

And just to be sure, the tech is looking at the Rear Position Sensor values, not the rear accelerometer value, actually as I recall there is only one of these in the rear.
 

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Discussion Starter · #11 ·
Re: SUM Calibration issues.....STILL (SilverSurf"R")

If the suspension was at the midpoint, I would expect the feedback to be the same at 2.5, but with the car at rest the suspension is closer to the top of travel than the bottom.

I have spent some time under my car today and tried to depict what the sensors look like in this crude picture.

From all my years as an automation engineer the sensors look like simple potentiometers. And I can understand from the orientation why the voltages move in opposite directions as we saw with the VID on Friday. My car is a very early production model, 9/03 production date, and although this is not ideal for control I can under how it can happen from years in a prototype to production environment. Situations like this would be corrected in later production models and the software revised.
So, I hope my Tech can find an early 04 to compare this to so we can determine what the proper operation and corrective action would be.

She sure looks nicer lowered, but I am beginning to wonder if it is worth the hassle.
 

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Re: SUM Calibration issues.....STILL (SilverSurf"R")

Nice drawing


The only thing I would tell you is that in almost 18 years being a tech is that if the problem occurred after an Aftermarket part installation, then the problem either lies with the part or something went wrong during installation. Because you didn't have the issue with the stock springs.

Now, 1. Are you getting error messages or are you just unable to do a SUM calibration?

2. Was a SUM Upgrade done to your vehicle? Being an early '04 a SUM update is most definitely available. I would recommend the SUM Upgrade and go from there. After the SUM upgrade, the tech will then need to do the SUM Calibration. http://********************/smile/emthup.gif
 

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Re: SUM Calibration issues.....STILL (SilverSurf"R")

I found some old notes I had taken from earlier posts, and I now believe it is correct for one side to increase, as the other decreases, with the suspension being loaded or unloaded, as a unit. i.e not a case of one side raised and the other lowered. So with the new lower spings the system now thinks it is in a compression mode, and one sensor has increased by 1V and the other has decreased by 1V. I suspect this is normal. I do not know what range SUM calibration has, but it needs to establish this as the new static state, and in effect, calibrate it such that the sensors are at 2.5V. Of course you need to confirm there is sufficient travel up and down for the sensors. Worst case it could be done by lengthening or shortening the mechanical linkage to the the height sensors.
 

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Re: SUM Calibration issues.....STILL (SilverSurf"R")

Well, I found a Training Manual that discusses the Active Bi-Xenon Headlamps and that it uses the level sensor on the LR of Non AWD cars.

The sensors range is .5v-4.5v. A fully loaded car will have a value of .5v
Without current access to VIDA, I can't tell how the other side is supposed to read. I'll post back if I find any other info on level sensors.
 

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Re: SUM Calibration issues.....STILL (Oceans60R)

Checked the Course Code 0819 for the R.

Only thing it really mentions:

-The sensors are fed 5v from the SUM. The output signal from the sensors is approximately 2.5v when the car is stationary

-When vertical movements are detected, the signal will fluctuate around these values. The greater the movement, the greater the deviations.

-The SUM software contains diagnostic software for the position sensors.

Calibration
When a suspension module, shock absorber, or position sensor (rear) is replaced, adaptive data in the SUM has to be calibrated using VADIS

There's obviously more to it than that but without having VIDA and your vehicle to go over this step by step, diagnosing here on a message board will be very difficult. There are a few differences in the CAN starting with MY05 so having a '04 to compare to would be optimal, that is if the tech can't look up specs or diagnostic procedures in VIDA.

Have you tried a system reboot (aka disconnecting battery cables from battery and shorting them together for 10 minutes)? and then try the SUM Calibration. If the car is hooked up to VIDA, the Network reboot can be done under Vehicle Communication so no need to short cables.

If I find something else I will let you know.
 

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Re: (SilverSurf"R")

Should go and get the eibach spring and the HAVE ME INSTALL THEM!!! hehehehe ill hook it up. you wont get as sweet deal as Xman03 did but you get a good deal
 

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Re: SUM Calibration issues.....STILL (Oceans60R)

After looking at a wiring diagram it appears that your right rear level sensor is possibly installed upside down. Should read .5v fully loaded or compressed and 4.5v unload. Your RR is reading opposite. So I would check that sensor and verify its installed correctly. Maybe it was removed or something during installation.
 

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Re: SUM Calibration issues.....STILL (Oceans60R)

dissconect the rear sencer conectors and reconect them, then calbrate
I had a little issue when i frist SLAMED her (lowerd for you non-knowing)

BTW IDGAF! (I Dont give A Fu#$CK) about my spelling!
 

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Re: SUM Calibration issues.....STILL (Oceans60R)

Quote, originally posted by Oceans60R »
After looking at a wiring diagram it appears that your right rear level sensor is possibly installed upside down. Should read .5v fully loaded or compressed and 4.5v unload. Your RR is reading opposite. So I would check that sensor and verify its installed correctly. Maybe it was removed or something during installation.

I think we have a winner!
 
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