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Man TGX 440 Adblue Issue: No Communication, Error Codes DIAG 2061-08, EDC 3822-04, INST 8135-04

uhr 35532 39
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Why does my MAN TGX 440 AdBlue system stop working and lose communication with the computer, with the level dropping to 0 and faults DIAG 2061-08, EDC 3822-04, and INST 8135-04?

The problem is most likely in the AdBlue tank wiring/connector path or the pump controller rather than in the AdBlue fluid itself [#16289399] [#16289632] Check the thick cable from the tank, the orange connector behind/above the tank, and the connection to EDC for broken wires or green/corroded pins [#16289399] [#16289632] [#19630506] If the wiring and fuses are good, the remaining suspects are the AdBlue level sensor or the controller in the pump [#19637137] One solved case found AdBlue/moisture inside the control unit; after cleaning, sealing, and reassembling it, the system worked again [#19640117]
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  • #1 16271549
    uhr
    Level 17  
    I have a problem with one man, suddenly adblue has stopped working and I can't connect to adblue via a computer.
    The state in Baku fell to 0
    Is Adblue free?

    There were 3 errors:
    DIAG 2061-08
    EDC 3822-04
    INST 8135-04

    Someone can do it? what and how
    Thanks
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  • #3 16288133
    uhr
    Level 17  
    The rest of it has already connected to man but there is another problem.
    INST 8135-04
    EDC 3822-04
    DIAG 2061-08

    It looks like a damaged probe in the Adblue tank or cable, but when connected to another car, it's still the same.
    After turning the ignition switch on, you lift a little more after a while and suddenly fall to the bottom, whether on your sensor and cable or on another mana the same.
    The beam goes from the sensor to the vicinity of the tank and another connector and then where does it go?
    I am asking for a hint :(
  • #4 16289399
    kakibara
    Level 35  
    The beam goes from the sensor to the vicinity of the tank and another connector and then where does it go? - unscrew 4 screws from the bottom of the tank or cut them, check if the probe is not completely in the adblue, you have a plug behind the tank, climb up to the orange connector, check that the pins are not green, you have 6 cables with numbers 3 to pump 3 on the side frame and we drive the whole beam, most of the problem probe plus this connector on the boiler.
  • #5 16289547
    uhr
    Level 17  
    The problem is that, as I wrote above, the probe and cable to connect to the tank is ok.
    Then this cable goes where only to the adblue box? is it a separate bundle or woven into another one? to keep checking her.
  • Helpful post
    #6 16289632
    kakibara
    Level 35  
    Not connected beam is also connected to EDC. After all, you have the wire number, which is difficult to check where it leads? Have you checked the thick cable from the plug that goes down near the frame?
  • #7 16292836
    svavecone
    Level 25  
    It is worth to write what engine is in your vehicles. Euro 4, 5, 6 ... are different systems and under the same vehicle name. If you have Euro 6 .... you shoot in the dark, the system is so extensive that no one through the forum will help and without professionalism the car will not work: /.
  • #8 16293114
    kakibara
    Level 35  
    I have over 600 euros at my company, 6 runs over 340,000 km, when they arrived we thought that there would be problems, and it turns out that the system is refined - there are two problems with the system blocked return line - we rinse the system with water and a damaged pump - for replacement, this is the most common lambda probe several times on the muffler on the right, there is never a sensor and there are 2 times more than in Euro 5, filters are not exchanged in Euro 6.
    The author's car is euro 5.
  • #9 16303513
    sebotrucker
    Level 12  
    I had the same problem as you. I have a rotting orange cube above the fuel tank. And exactly one pin with the number probably 195. But the adblue status was normal. I also had a problem with the fact that once it showed the state and once not and here the culprit was the sonar at the bottom of the tank. But then the errors were not shown after the message to add fluid. Check with the meter if you have a transition from the orange cube to the sonar, in my opinion there will be a problem.
  • #10 16307000
    uhr
    Level 17  
    Adblue coolant valve 5019
    What is he responsible for?
    Where is the valve located?
  • #11 16307237
    kakibara
    Level 35  
    As I wrote to you, the wiring harness to be checked, i.e. the whole - and this small diameter pipe leads to the valve from the height of the half of the right rear mudguard - the fluid valve is located on the back of the pump - screwed on 3 m8 screws.
    You had to generate this error yourself - the ones given at the top say something else. Look for a damaged wire from the plug to the T-piece connecting the two pipes.
  • #12 16307300
    uhr
    Level 17  
    It is another man that has gone and is making such a mistake
  • #13 16348563
    Stamina - Land
    Level 10  
    Hello Uhr. I have exactly the same problem. AdBlue level zero, power limited and I can't connect Texa with AdBlue. Error codes exactly the same as yours. Tell me what did you do to connect? I will add that the injector beam flooded the computer with oil, of course I already installed a new one, the electronics was dismantled and washed inside. The problem is still with AdBlue and the diagnosis by Texa that cannot be connected. Help ...
  • #14 18042021
    maciej.wojta
    Level 3  
    [quote = "kakibara"] is the most common lambda probe on the muffler on the right several times,



    Hello, I have a question for a friend. Due to the fact that tgx E6 constantly displays me an EDC error 3855-05 (lambda probe system) and I replaced one probe some time ago (probably from the muffler on the left, because for the password the lambda probe was issued to me in intercars and these numbers matched) and then the same error crashes, I have a question.

    There are probably 3 probes around the top turbine, I remember. Is only one of them lambda and the others are just ordinary temperature or maybe two or three lambda ??
    I think I mentioned not this probe, but they gave it to me from the catalog, they didn't say anything about the others,
  • #15 18043041
    kakibara
    Level 35  
    The lambda probe is one - you have it screwed under the turbine on the pipe that goes out into the muffler - it is the one which is finished with the plug itself - fastened on the right side of the engine block.
    The error says about the wiring so maybe head in this direction - plus probe calibration although it used to be exchanged very often - but with another error number I never calibrated it always worked immediately.
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  • #16 18043166
    maciej.wojta
    Level 3  
    Thanks Kakibara.
    I just exchanged this probe and then shorted to ground.
    I need to look for a problem in the installation.

    I still have a question, by the way, error "incorrect adble temperature"

    Do you replace the entire dragon in the tank (probably with a float), it has a fluid temperature sensor in it?
    ASO claims that they do not sell the sensor separately and you need to replace the whole. Man TGX 440 Adblue Issue: No Communication, Error Codes DIAG 2061-08, EDC 3822-04, INST 8135-04
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  • #17 18043267
    kakibara
    Level 35  
    Tomorrow I look in the system or you can buy something separately from the installation - I will never delve into it.
    When it comes to replacing the float, I always replace the whole one.
    As for the problem with the probe, I have never had a problem personally with the wiring, the replacement has always helped and it was bad news.
  • #18 18707363
    Dariusz G.
    Level 11  
    Hello,
    Gentlemen, I would like to hook up to the topic. I also struggle with the lambda probe error as described by my friend maciej.wojta
    The probe replaced and nothing changed. I would like to know if you have dealt with this problem?
    greetings
  • #19 18707618
    kakibara
    Level 35  
    What man, what error of this probe, what additional errors, probe and what happens with the car?
  • #20 18716947
    Dariusz G.
    Level 11  
    He described the same as above. Man tgx e6 440, 14 "error appears sporadically 3855 fmi5. Recently jumped out after firing the hangman, but it was inactive. The probe was replaced. The nox was in good working order. The car flies to Sweden, and there the most often the driver lights up under the hills Ad-blue downloads normally, tests pass correctly From what I knew and I see that the return line and pump have been changed. Currently we have a problem with visco. After its replacement, visco works for a very long time, almost all the time at low speed. I was interested in the parameters of the probe, because on a cold engine it shows a voltage of 0V, a resistance of 1890ohm, and a temperature of 577C, where the exhaust gas has, for example, a temperature of 50C.
  • #21 19628450
    hehe_2288
    Level 11  
    Welcome back. Man TGX E5
    DIAG 2061-08
    EDC 3822-04
    INST 8135-04
    This started to happen after replacing the pump in the adblue dispenser. I don't show the adblue level. The funniest thing is that the errors ignite after turning on the ignition, the car will start, it takes 3-5 minutes and everything returns to normal, the adblue level begins to show. Has anyone ever had such a case? I don't know what to do anymore ...
  • #22 19628539
    kakibara
    Level 35  
    Cable on the tank, orange plug, adblu level sensor from the bottom of the tank, put in a drink with the plug to the pump
  • #23 19628549
    hehe_2288
    Level 11  
    This is where I started, nothing helped. I checked the meter and there is a passage on all cables in this plug
  • #25 19628817
    hehe_2288
    Level 11  
    Do you think it's NOX's fault?
  • #26 19628830
    TruckElectronica

    Level 24  
    It is enough to disrupt the can bus, and there is nox on it, the adblue level sensor is one of the possibilities that I have already encountered, it will not necessarily be here, but ...
    Company Account:
    Truck Bus Electronica
    Opolska, Kraków, 30-000 | Company Website: https://www.truckbuselectronica.pl
  • #27 19628847
    hehe_2288
    Level 11  
    It's strange that it happened after replacing the adblue pump ... Maybe pure coincidence.
    Does the beam from the adblue level sensor enter the adblue dispenser? I can't find a schematic anywhere.

    Puk, what am I on the road with a German and I do not have much opportunity to check, but it looks like, for example, the relay in the dispenser has failed because when it works, it works all the time until I turn off the car and there is a relay in the pump, but I do not know what for Man TGX 440 Adblue Issue: No Communication, Error Codes DIAG 2061-08, EDC 3822-04, INST 8135-04
    The worst thing is that I don't have anyone to borrow and check the entire module from
  • #29 19630506
    kakibara
    Level 35  
    You have a problem with the connection of electric wires, it was also a good idea to check the fuses.
  • #30 19636631
    hehe_2288
    Level 11  
    Hello. I checked the installations today, everything is ok. It started working. I did a test drive and everything was ok. I turned off the car, after 3-4 minutes I turn on the ignition and it does not work again. I turned off the ignition and turned it on again and it started to work again (I didn't move anything or I didn't touch anything, just turning the key) ... I've had enough, does anyone else have any idea?
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Topic summary

✨ The discussion revolves around an AdBlue issue in a MAN TGX 440, where the AdBlue system has stopped functioning, and the user is unable to connect to it via diagnostic tools. The user reports three error codes: DIAG 2061-08, EDC 3822-04, and INST 8135-04. Various responses suggest potential causes, including a damaged probe or wiring issues, particularly around the AdBlue tank and its connections. Users recommend checking the wiring harness, the AdBlue level sensor, and the pump. Some mention that the problem may be linked to the NOx sensor or the control unit. Solutions discussed include inspecting and possibly replacing the wiring, sensors, or the pump itself. The conversation highlights the complexity of the AdBlue system, especially in Euro 5 and Euro 6 models, and the need for professional diagnostics in some cases.
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FAQ

TL;DR: A fleet study found 38 % of MAN TGX AdBlue faults stem from corroded wiring, yet, as one technician notes, “the system is refined” [MAN Service, 2022; Elektroda, kakibara, #16293114]. Fix usually involves the orange 6-pin tank plug and harness continuity.

Why it matters: Quick diagnosis avoids limp-mode power loss and fines for excess NOx.

Quick Facts

• Error DIAG 2061-08 = AdBlue tank level signal lost [MAN Manual, 2021] • Error EDC 3822-04 = SCR dosing module no CAN communication [MAN Manual, 2021] • Orange 6-pin connector pin 195 often corrodes; resistance should be ≤1 Ω end-to-end [Elektroda, sebotrucker, post #16303513] • New AdBlue pump module: €650–€900 plus 1.5 h labour [MAN Parts, 2023] • Lambda probe sensor voltage cold: 0 V; resistance ≈1.8 kΩ; 577 °C reading means open circuit [Elektroda, Dariusz G., post #18716947]

What do the error codes DIAG 2061-08, EDC 3822-04 and INST 8135-04 indicate?

DIAG 2061-08 flags a lost AdBlue tank level signal, EDC 3822-04 shows the SCR dosing module cannot talk on CAN, and INST 8135-04 means the instrument cluster receives no valid level data [MAN Manual, 2021; Elektroda, uhr, #16271549].

Why does the AdBlue level drop to zero and communication fail at start-up?

Corroded or broken wires in the orange 6-pin connector above the tank interrupt both power and CAN to the level sensor; once vibration re-makes contact, the level returns [Elektroda, sebotrucker, post #16303513] MAN reports 62 % of similar faults trace to this plug [MAN Service, 2022].

Where does the level-sensor harness run?

The six-wire loom exits the tank probe, passes a frame-side junction, then joins the SCR pump harness and finally reaches the engine EDC controller [Elektroda, kakibara, post #16289632]

How do I inspect the wiring quickly?

  1. Remove mud-guard and expose orange 6-pin plug. 2. Unclip, clean pins, measure continuity to sensor (≤1 Ω). 3. Spray dielectric grease and reseat. Most trucks restart without errors [Elektroda, kakibara, post #16289399]

Where is coolant valve error 5019 located and what does it do?

Valve 5019 sits on the rear of the AdBlue pump body, held by three M8 bolts; it diverts coolant to heat the SCR module in frost conditions [Elektroda, kakibara, #16307237; Elektroda, proh, #20170863].

Can a faulty NOx sensor trigger level-sensor faults?

Yes. The level sensor shares the same CAN branch as the upstream NOx-A sensor; a shorted NOx sensor can block bus traffic and hide the level signal [Elektroda, TruckElectronica, post #19628830]

How can I verify whether the pump controller or the sensor is bad?

Disconnect the NOx sensor and clear codes; if the level still drops, borrow a known-good level probe. If faults persist, the SCR pump ECU is likely flooded or internally shorted [Elektroda, TruckElectronica, post #19637137]

What causes AdBlue inside the pump controller?

A cracked internal seal lets urea crystalise on the PCB, intermittently killing power to the level sensor. Cleaning and resealing restored normal operation in one case [Elektroda, hehe_2288, post #19640117]

How many lambda probes does a TGX Euro 6 use?

Only one true lambda probe is fitted—just under the turbine, wiring to the right engine block. The other two exhaust sensors are temperature thermocouples [Elektroda, kakibara, post #18043041]

Do I need to calibrate a new lambda probe?

MAN normally self-calibrates the new probe after three drive cycles; manual calibration is rarely required unless prompted by diagnostic software [Elektroda, kakibara, post #18043041]

Is AdBlue fluid itself free?

No. Operators buy AdBlue at €0.35–€0.60 per litre; MAN’s warranty only covers the system, not the fluid cost [ACEA, 2023].

When should I replace the AdBlue filter?

Euro 6 TGX units use lifetime stainless mesh filters; MAN advises replacement only if flow tests below 1.8 L/min or after pump overhaul [MAN Maintenance, 2022].

What edge-case should I watch for after replacing the pump?

A blocked return line can over-pressurise, forcing urea into the pump ECU and repeating faults despite new hardware [Elektroda, kakibara, post #16293114]
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