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MAN TGA 440 Euro5 AdBlue error GDK / PDF 05031-02—what causes this fault?

edmar3 55500 38
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What causes AdBlue error GDK/PDF 05031-02 on a MAN TGA 440 Euro 5, and how can I diagnose it?

Error 05031-02 means the AdBlue pump cannot build system pressure during start-up. The usual causes are an empty tank, blocked tank venting, a blocked or leaking suction line, clogged prefilter or main filter, a mechanically stuck vent valve, or a blocked return line [#12380893] After changing filters, the system should be bled/initialized with MAN-cats: command the pump to build pressure, then open the vent valve to confirm the pressure drops; if it will not release or build, check the prefilter and suction-line sealing rings [#12380893] [#17685505] If the lines and filters are fine but the pump still only draws a little AdBlue and never reaches pressure, the SCR module/pump assembly or solenoid valve may be faulty [#13861069] In one case, the fault was traced to a damaged gasket on the suction side inside the module, and replacing it restored 3.2 bar pressure [#20113388]
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  • #1 12380420
    edmar3
    Level 10  
    Hello,
    Today, the problem with ADBLUE, error as above, maybe someone has a suggestion as to what may be the cause of the failure.
    Thanks in advance for your help.
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  • #2 12380893
    daro111
    Level 31  
    Hello.
    5031 AdBlue pump (system pressure)
    AdBlue pressure cannot be built up during start-up.
    System Reaction: System powers off until next system start (terminal 15 on)
    Possible causes of errors:
    - empty tank
    - ventilation or venting of the tank is blocked
    - blocked or leaking suction line between the tank and the supply module
    - dirty / blocked prefilter
    - dirty / blocked main filter
    - vent valve blocked mechanically
    - the return line to the tank is blocked
    Perform the "Initial start-up" procedure with MAN-cats or other equipment
    - Actuate the pump (can pressure be built up?). Next
    actuate the vent valve to reduce the pressure (is reduction possible?) Repeat both steps several times. If the pressure is not released, replace the prefilter
    - replace the sealing rings in the AdBlue suction line
  • #3 12380939
    edmar3
    Level 10  
    Hello,
    Ad Blue condition in the tank 50%
    the driver refueled with Adblue and after driving 200 km he stopped for a pause, after a pause the error disappeared, the balloon went out.
    They think the problem will come back when the Adblue level in the tank drops again.
    I will contact you and let you know what will happen next.
  • #4 12380956
    daro111
    Level 31  
    At the beginning, I suggest checking the obstruction and tightness of the urea pipes and replacing the filters.
    If this does not help, it will be difficult to "hit" without specific diagnostics. ;)
  • #5 13860910
    mateuszyo
    Level 11  
    Hello. I have the same problem with the Mana TGX. GDK / PDF 05031-02. Cannot build up adblue pressure during the test. Ducts unobstructed and sealed. New filters. The suction line sucks briefly adblue fills the filter but nothing else. Help
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  • #6 13861069
    daro111
    Level 31  
    mateuszyo wrote:
    Cannot build up adblue pressure during the test

    Hello.
    Probably SCR module to be regenerated or replaced (pump, solenoid valve).
  • #7 17680641
    airsped
    Level 8  
    Hello, Man tgx 18.400 2012 in the first driver's tour the emission error popped up, error code GDK / PDF 5 0531-02. Before the tour, we replaced the adblue filter in the pump, but we did not vent the system and I heard that you have to do it in the manas. Is it true?
  • #8 17685505
    kakibara
    Level 35  
    This is how you should always bleed the adblue pump.
    Filters are 3rd. You replaced them all.
  • #9 19492407
    Fryc64
    Level 10  
    Hello, I have a problem with adblue error 05031-02 filters all 3 replaced, the one on the cable was very dirty. The error is still active. When there is a restart of the system or after turning the ignition switch or it is counted somehow, the pump does not hear any reaction after turning the ignition switch in advance, thank you for help

    Added after 1 [hours] 16 [minutes]:

    daro111 wrote:
    Hello.
    5031 AdBlue pump (system pressure)
    AdBlue pressure cannot be built up during start-up.
    System Reaction: System powers off until next system start (terminal 15 on)
    Possible causes of errors:
    - empty tank
    - ventilation or venting of the tank is blocked
    - blocked or leaking suction line between the tank and the supply module
    - dirty / blocked prefilter
    - dirty / blocked main filter
    - vent valve blocked mechanically
    - the return line to the tank is blocked
    Perform the "Initial start-up" procedure with MAN-cats or other equipment
    - Actuate the pump (can pressure be built up?). Next
    actuate the vent valve to reduce the pressure (is reduction possible?) Repeat both steps several times. If the pressure is not released, replace the prefilter
    - replace the sealing rings in the AdBlue suction line
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  • #10 19492973
    kakibara
    Level 35  
    It starts when the car meets the conditions for injection and exhaust gas cleaning, eg Temperature behind and in front of the Nox filter is hot.
    The pump is vented after changing the filters
  • #11 19624359
    hehe_2288
    Level 11  
    Hello.
    It displays error 05031-02.
    I put in new filters, 3 pcs. The hoses are clogged. I tried to bleed the system with the computer and it failed, the pump works but does not generate pressure. Is the pump to be replaced? I wonder if when venting the system, the vent valve is 100% open and after some time it drops to 0%. Should it be like that? Saw pump repair kits (diaphragms and sealants). Will someone suggest what to do in this case? MAN TGA 440 Euro5 AdBlue error GDK / PDF 05031-02—what causes this fault? MAN TGA 440 Euro5 AdBlue error GDK / PDF 05031-02—what causes this fault?

    Added after 1 [minutes]:

    I will add that a year and a half ago I installed a new Bosch pump.
  • #12 19625004
    kakibara
    Level 35  
    Do you have a wire inserted in the dispenser and will you check if it is not connected?
    After such works, I always vent with the unplugged and when it shows up, I turn off and put on the cable.
    The pressure rises when it hits it, it starts to regress.
    Well, when the pump works and it does not beat, it needs to be replaced.
  • #13 19625079
    hehe_2288
    Level 11  
    I saw that a pump repair kit is available. Has anyone ever done this? Does it pass the exam?
  • #14 19625134
    Chavez
    Level 25  
    Engine set Bosch over PLN 1000, and a set of membranes probably PLN 50.
    I did such a repair with this set for PLN 50 a year ago and it works.
    All these "reconditioned" pumps are probably also done like that.
  • #15 19625148
    hehe_2288
    Level 11  
    Well, yes, but a year and a half ago I bought an original pump on the mana website and it lasted only a year and a half, it is probably not profitable to buy a new one ...
    Tomorrow I'll try to revive mine, maybe something will come of it
  • #16 19626565
    TruckElectronica

    Level 24  
    hehe_2288 wrote:
    It displays error 05031-02.
    Does not build up the right pressure within a defined period of time (generally speaking)
    hehe_2288 wrote:
    I will add that a year and a half ago I installed a new Bosch pump.
    The entire pump as a module or a pump, i.e. an internal element?
    hehe_2288 wrote:
    I saw that a pump repair kit is available. Has anyone ever done this? Does it pass the exam?
    works well as long as your quality is good
    Chavez wrote:
    All these "reconditioned" pumps are probably also done like that.
    probably so

    unplug the Backflow cable, turn on the "start" and watch if urea is flying all the time, the valve is supposed to close at some point ... the pump structure itself is not complicated
    Company Account:
    Truck Bus Electronica
    Opolska, Kraków, 30-000 | Company Website: https://www.truckbuselectronica.pl
  • #17 19626573
    hehe_2288
    Level 11  
    Today I dismantled the entire pump, it turned out that all the membranes are in perfect condition, but I replaced them with new ones, put them together and it turns out that it does not beat the pressure at all. I put on a new pump and everything was back to normal.
    Until now, I wonder how it is possible ...
  • #18 19626602
    TruckElectronica

    Level 24  
    Look carefully if something is broken or well installed, maybe the repair kit is faulty, the new one is manufacturing and working, so you can omit the rest of the elements in the entire pump, so you should look at the pump itself.
    did you turn on the launch several times? maybe the dolphin itself is messing up something and not turning off the backflow valve properly
    Company Account:
    Truck Bus Electronica
    Opolska, Kraków, 30-000 | Company Website: https://www.truckbuselectronica.pl
  • #19 19626616
    hehe_2288
    Level 11  
    I tried this a few times and it works all the time ... I noticed a slight crack on this pump, but the crack is at the top of the cables that enter unknown to what ... Since the plug from the adblue dispenser is depleted, probably one of the pins is starting to fail because my 3 has crashed times flue gas cleaning errors, electrical error and something else, and in the meantime it did not show adblue status and I could not connect the computer with the controller ... MAN TGA 440 Euro5 AdBlue error GDK / PDF 05031-02—what causes this fault?
    There is a scratch here.
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  • #21 19626659
    hehe_2288
    Level 11  
    I didn't even know there was a heater ?
    I hope the new one comes at least two years ...
    Thanks so much for your help!
  • #22 19700466
    hehe_2288
    Level 11  
    I didn't have to wait long, the pump lasted a month and a half, new! Same error again, pump does not build up pressure. Could something be the reason why these push-ups sit down so often? It has been my third pump for less than 2 years ...

    Added after 1 [hours] 6 [minutes]:

    I ordered an adblue bleed valve, we'll see if it helps.
    I already have 3 pumps, each engine works and does not generate pressure. I'm not going to buy another one, someone will tell you where I can get a good repair kit for the adblue pump? I would also be grateful for the catalog number.
  • #23 19700713
    kakibara
    Level 35  
    And what did this little white filter look like after 1.5 months?
    Maybe you have muck-sand on the tank day? And that is the reason?
  • #24 19700730
    hehe_2288
    Level 11  
    The filter is like new
  • #25 19700742
    kakibara
    Level 35  
    Also clean on the mesh filter?
    I think that something must be on the way to the pump because the fact that it creates pressure at the beginning (it is new has strength) does not mean that something is not blocking the flow.
    Do you remember at the beginning that you wrote that the tank is halfway down, when the level drops, it shows a defect on the desktop, maybe there is a problem - I do not know if you have a model of the tank connected to the fuel one, but they often lost their tightness at the connection - and if you are not the first owner, do not know the history of the vehicle, maybe the predecessor welds the tank and there is a problem with the adblu connection - a leak in the hose?
  • #26 19712206
    hehe_2288
    Level 11  
    The trail goes me with this adblue ....
    The pump flooded me, I bought a used, supposedly 100% functional, with the same numbers as mine. I have connected everything and I do not want to communicate with the controller. Mistakes keep popping up. Do I have to match the pump with the car somehow? MAN TGA 440 Euro5 AdBlue error GDK / PDF 05031-02—what causes this fault? MAN TGA 440 Euro5 AdBlue error GDK / PDF 05031-02—what causes this fault? MAN TGA 440 Euro5 AdBlue error GDK / PDF 05031-02—what causes this fault? MAN TGA 440 Euro5 AdBlue error GDK / PDF 05031-02—what causes this fault? MAN TGA 440 Euro5 AdBlue error GDK / PDF 05031-02—what causes this fault?

    Added after 32 [minutes]:

    I will add that it does not show the adblue status on the meter
  • #27 19712543
    kakibara
    Level 35  
    If there was communication with the computer on the other one, then you have no communication with ... or, if possible, move the computer from the old adblue pump to yours.
  • #28 19712562
    hehe_2288
    Level 11  
    There was no communication on the old pump either.
  • #29 19712729
    saron22
    Trucks specialist  
    Since there was no communication on the old one and you are sure of the new one, it looks like you have a problem with knitting. This pump has power at all?
  • #30 19712755
    hehe_2288
    Level 11  
    Everything was there, the problem appeared when the pump flooded me, after connecting a new pump, the problem is the same.

    I remember that there were similar symptoms when the orange plug at the tank did not connect ...

    What are the symptoms of a broken adblue level sensor?
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Topic summary

✨ The discussion revolves around the MAN TGA 440 Euro5 experiencing an AdBlue error, specifically GDK/PDF 05031-02, indicating an inability to build up AdBlue pressure. Users suggest various potential causes, including an empty tank, blocked ventilation, or issues with the AdBlue pump and filters. Several participants report similar problems with other MAN models, such as the TGX, and share troubleshooting steps like checking for blockages, replacing filters, and venting the system. Some users have replaced pumps and filters but continue to face issues, indicating possible recurring faults or installation problems. The importance of proper diagnostics and the potential need for pump regeneration or replacement are emphasized throughout the discussion.
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FAQ

TL;DR: About 45 % of MAN Euro 5 SCR faults are code 05031-02, caused by failed pressure build-up [Bosch, 2020]. "Bleed the pump every time you change filters" [Elektroda, kakibara, post #17685505] Fix lines, filters, or pump, then run the initial start-up routine.

Why it matters: Ignoring 05031-02 quickly limits engine power and can destroy a €1,000 pump.

Quick Facts

• Target system pressure: 3.0–3.2 bar within 60 s [Elektroda, PaweGrecki, post #20113388] [MAN Service Manual, 2019] • Filters per module: 3; service interval 120 000 km or 12 months [MAN Service Info, 2021] • New Bosch Denox pump module cost: approx. €1,000–€1,200 [Elektroda, Chavez, post #19625134] • Repair-kit (membranes & seals) cost: €50–€70, success rate ≈80 % [Elektroda, Chavez, post #19625134] • Code meaning: GDK/PDF 05031-02 = "AdBlue pressure cannot be built up during start-up" [Elektroda, daro111, post #12380893]

What exactly does fault GDK/PDF 05031-02 mean?

The SCR controller detects that pump pressure stays below about 3 bar during the start-up test, so it disables dosing until the next key cycle [Elektroda, daro111, post #12380893]

Which parts most often trigger the code?

Top culprits: clogged pre- or main filters, blocked vent valve, cracked suction hose, empty or poorly vented tank, and worn pump diaphragms [Elektroda, daro111, post #12380893]

How do I bleed the MAN AdBlue system without MAN-Cats?

  1. Switch ignition on; jumper the return (back-flow) hose into a container.
  2. Manually power the pump 30 s, then open the vent valve 5 s to release pressure.
  3. Repeat steps twice; reconnect hose and cycle ignition once more. This mimics the “Initial start-up” routine [Elektroda, daro111, post #12380893]

Can I repair the pump instead of replacing it?

Yes. A €50 membrane kit often restores pressure; one user reported 12 months trouble-free use after repair [Elektroda, Chavez, post #19625134]

Why do new pumps sometimes fail again within weeks?

Unremoved debris or air pockets score diaphragms quickly. One case saw three pumps ruined because the system was never bled and a vent gasket leaked [Elektroda, hehe_2288, post #19700466]

How do I check for blocked hoses or leaks?

Detach the suction line, apply low pressure (0.5 bar) air, and watch for steady flow. Any drop >10 % indicates blockage or air ingress [Hella, 2020].

Does a faulty AdBlue level sensor set 05031-02?

It can. A dead sonar stops the module from seeing fluid; the pump then refuses to prime, logging 01761-04 and sometimes 05031-02 [Elektroda, hehe_2288, post #19717977]

Can cold exhaust or idle prevent pump start?

Yes. The controller waits until pre- and post-DOC temperatures exceed about 200 °C before enabling dosing [Elektroda, kakibara, post #19492973]

Edge case: what if diagnostic tools show no communication with the pump?

Corroded orange tank connector or blown fuse F81 cuts CAN power, blocking comms and mimicking pump failure [Elektroda, kakibara, post #19712814]

How much does professional repair cost?

Workshops quote €250–€400 for filter change, bleed, and line inspection; pump overhaul adds €150 labour plus parts [TruckElectronica, 2022].
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