Cat TH255C Telehandler Engine Service Manual - PDF DOWNLOAD

Engine Service Manual

Model TH255C Engine 441-9208 & 441-9209 31200980 Original October 31, 2013

EFFECTIVITY PAGE October 31, 2013 - A - Original Issue Of Manual

31200980

TH255C

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EFFECTIVITY PAGE

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TH255C

31200980

FOREWORD Read and observe the information in this documentation. You will avoid accidents, retain the manufacturer's warranty and possess a fully functional and ready to operate engine.

This engine is built exclusively for purpose according to the scope of delivery - defined by the equipment manufacturer (use for the intended purpose). Any use above and beyond this is considered improper use. The manufacturer will not be liable for damages resulting from this. The user bears the sole risk.

Use for the intended purpose also includes observance of the operating, maintenance and repair instructions specified by the manufacturer. The engine may only be used, maintained and repaired by persons who are familiar with this and are aware of the risks involved.

Make sure that this documentation is available to everyone involved in the operation, maintenance and repair and that they have understood the contents.

Failure to observe this documentation may lead to malfunctions and engine damage as well as injury to persons for which the manufacturer will not accept any liability.

Prerequisite for proper maintenance and repair is the availability of all the necessary equipment, conventional and special tools and their perfect condition.

Engine parts such as springs, clamps, elastic retaining rings etc. pose an increased risk of injury when handled incorrectly.

The pertinent rules for the prevention of accidents and other generally recognized health and safety regulations must be observed.

Maximum economy, reliability and long life is only guaranteed when using original parts.

Repair of the engine must correspond to its use for the intended purpose. Only parts released by the manufacturer for the respective purpose may be used for conversion work. Unauthorized modifications to the engine exclude manufacturer liability for resulting damages. Failure to observe this will void the warranty.

The engines are developed for a wide range of applications. A wide range of variants ensures that the respective special requirements are met.

The engine is equipped according to the installation case, i.e. not all the parts and components described in this documentation are installed in your engine necessarily.

DISCLAIMER: Information provided within (excluding Section 1) is supplied directly from the component manufacturer. Due to continuous improvements, the component manufacturer reserves the right to make changes without prior notification.

31200980

TH255C

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FOREWORD

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TH255C

31200980

SECTION CONTENTS Section

Subject

Section 1 JLG Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1 1.2 1.3 1.4 1.5 1.6 1.7

Page

1-1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation & Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Do Not Operate Tags . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2 1-2 1-2 1-2 1-2 1-3 1-4

Section 2 Safety information / User information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

2.1 2.2 2.3 2.4

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation Manual And Service Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Explanation Of Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2 2-2 2-5 2-6

Section 3 Disassembly and Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20 3.21 3.22 3.23 3.24 3.25 3.26 3.27 3.28 TH255C

Oil Measuring Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V-belt Pulley Add-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V-belt Pulley Add-on Fastening Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Head Cover (Engine 441-9208) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Head Cover (Engine 441-9209) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heat Protection Plate (Engine 441-9208) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Injector (Engine 441-9208) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Injector (Engine 441-9209) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Supply Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Turbocharger Intake Nozzle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Charge Air Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Charge Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant Pump Fastening Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thermostat Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Gas Recirculation Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flutter Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Gas Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating Oil Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating Oil Return Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V-Belt Pulley (parts to generator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4 3-5 3-6 3-12 3-15 3-16 3-17 3-21 3-25 3-26 3-29 3-30 3-36 3-42 3-44 3-52 3-53 3-54 3-55 3-56 3-60 3-63 3-64 3-67 3-72 3-76 3-80 3-85 i

Section 3.29 3.30 3.31 3.32 3.33 3.34 3.35 3.36 3.37 3.38 3.39 3.40 3.41

Subject

Page

Generator Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cable Harness Fastening Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cable Harness Fastening Parts (Engine 441-9208) . . . . . . . . . . . . . . . . . . . . . . . . . . .

Impulse Transmitter (Crankshaft). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pressure Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connection Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start-aid Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Gas Treatment Inlet Module (Engine 441-9208) . . . . . . . . . . . . . . . . . . . . . . .

Holder (Engine 441-9208) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly Material Compensator Structure (Engine 441-9208). . . . . . . . . . . . . . . . . . .

3-86 3-87 3-91 3-94 3-95 3-96 3-99 3-100 3-101 3-104 3-107 3-109 3-110

Section 4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1

4.1

Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2

Section 5 Engine Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1

5.1 5.2

Power Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Equipment Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2 5-3

Section 6 Wire Sensor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1

6.1 6.2 6.3

Engine Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Sensor Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Signal Wire Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2 6-3 6-4

Section 7 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1

7.1

ii

Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-5

TH255C

Section 1 JLG Safety Practices

Contents PARAGRAPH 1.1 1.2 1.3 1.4 1.5 1.6

1.7

TH255C

TITLE

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation & Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Do Not Operate Tags. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6.1 Personal Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6.2 Equipment Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6.3 General Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.6.4 Operational Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAGE 1-2 1-2 1-2 1-2 1-2 1-3 1-3 1-3 1-3 1-4 1-4

1-1

JLG Safety Practices

1.1

INTRODUCTION

This service manual provides general directions for accomplishing service and repair procedures. Following the procedures in this manual will help assure safety and equipment reliability.

Read, understand and follow the information in this manual, and obey all locally approved safety practices, procedures, rules, codes, regulations and laws.

These instructions cannot cover all details or variations in the equipment, procedures, or processes described, nor provide directions for meeting every possible contingency during operation, maintenance, or testing. When additional information is desired consult the local Caterpillar Dealer.

Many factors contribute to unsafe conditions: carelessness, fatigue, overload, inattentiveness, unfamiliarity, even drugs and alcohol, among others. For optimal safety, encourage everyone to think, and to act, safely.

Appropriate service methods and proper repair procedures are essential for the safety of the individual doing the work, for the safety of the operator, and for the safe, reliable operation of the machine. All references to the right side, left side, front and rear are given from the operator’s seat looking in a forward direction.

before proceeding.

1.4

DO NOT OPERATE TAGS

Place Do Not Operate Tags on the ignition key switch and the steering wheel before attempting to perform any service or maintenance. Remove key and disconnect battery leads.

1.5

SAFETY INFORMATION

To avoid possible death or injury, carefully read, understand and comply with all safety messages.

In the event of an accident, know where to obtain medical assistance and how to use a first-aid kit and fire extinguisher/fire suppression system. Keep emergency telephone numbers (fire department, ambulance, rescue squad/paramedics, police department, etc.) nearby. If working alone, check with another person routinely to help assure personal safety.

Supplementary information is available from Caterpillar in the form of Service Bulletins, Service Campaigns, Service Training Schools, the manufacturer website, other literature and through updates to the manual itself.

1.2

DISCLAIMER

All information in this manual is based on the latest product information available at the time of publication.

The manufacturer reserves the right to make changes and improvements to its products, and to discontinue the manufacture of any product, at its discretion at any time without public notice or obligation.

1.3

OPERATION & MAINTENANCE MANUAL

The mechanic must not operate the machine until the Operation & Maintenance Manual has been read and understood, training has been accomplished and operation of the machine has been completed under the supervision of an experienced and qualified operator.

An Operation & Maintenance Manual is supplied with each machine and must be kept in the manual holder located in the cab. In the event that the Operation & Maintenance Manual is missing, consult the local Caterpillar Dealer 1-2

TH255C

JLG Safety Practices

1.6

SAFETY INSTRUCTIONS

Following are general safety statements to consider BEFORE performing maintenance procedures on the telehandler. Additional statements related to specific tasks and procedures are located throughout this manual and are listed prior to any work instructions to provide safety information before the potential of a hazard occurs.

For all safety messages, carefully read, understand and follow the instructions BEFORE proceeding.

1.6.1

Personal Hazards

PERSONAL SAFETY GEAR: Wear all the protective clothing and personal safety gear necessary to perform the job safely. This might include heavy gloves, safety glasses or goggles, filter mask or respirator, safety shoes or a hard hat.

LIFTING: NEVER lift a heavy object without the help of at least one assistant or a suitable sling and hoist.

1.6.2

Equipment Hazards

LIFTING OF EQUIPMENT: Before using any lifting equipment (chains, slings, brackets, hooks, etc.), verify that it is of the proper capacity, in good working order, and is properly attached.

NEVER stand or otherwise become positioned under a suspended load or under raised equipment. The load or equipment could fall or tip.

DO NOT use a hoist, jack or jack stands only to support equipment. Always support equipment with the proper capacity blocks or stands properly rated for the load.

1.6.3

General Hazards

SOLVENTS: Only use approved solvents that are known to be safe for use.

HOUSEKEEPING: Keep the work area and operator’s cab clean, and remove all hazards (debris, oil, tools, etc.).

FIRST AID: Immediately clean, dress and report all injuries (cuts, abrasions, burns, etc.), no matter how minor the injury may seem. Know the location of a First Aid Kit, and know how to use it.

CLEANLINESS: Wear eye protection and clean all components with a high-pressure or steam cleaner before attempting service.

When removing hydraulic components, plug hose ends and connections to prevent excess leakage and contamination. Place a suitable catch basin beneath the machine to capture fluid run-off.

It is good practice to avoid pressure-washing electrical/ electronic components. In the event pressure-washing the machine is needed, ensure machine is shut down before pressure-washing. Should pressure-washing be utilized to wash areas containing electrical/electronic components, it is recommended a maximum pressure of 750 psi (52 bar) at a minimum distance of 12 in (30.5 cm) away from these components. If electrical/electronic components are sprayed, spraying must not be direct and for brief time periods to avoid heavy saturation, Check and obey all Federal, State and/or Local regulations regarding waste storage, disposal and recycling.

HAND TOOLS: Always use the proper tool for the job; keep tools clean and in good working order, and use special service tools only as recommended.

TH255C

1-3

JLG Safety Practices 1.6.4

Operational Hazards

ENGINE: Stop the engine before performing any service unless specifically instructed otherwise.

VENTILATION: Avoid prolonged engine operation in enclosed areas without adequate ventilation.

SOFT SURFACES AND SLOPES: NEVER work on a machine that is parked on a soft surface or slope. The machine must be on a hard level surface, with the wheels blocked before performing any service.

FLUID PRESSURE: Before loosening any hydraulic or diesel fuel component, hose or tube, turn the engine OFF. Wear heavy, protective gloves and eye protection.

NEVER check for leaks using any part of your body; use a piece of cardboard or wood instead. If injured, seek medical attention immediately. Diesel fluid leaking under pressure can explode. Hydraulic fluid and diesel fuel leaking under pressure can penetrate the skin, cause infection, gangrene and other serious personal injury.

Refer to the engine manufacturers manual for specific details concerning the fuel system.

Relieve all pressure before disconnecting any component, part, line or hose. Slowly loosen parts and allow release of residual pressure before removing any part or component. Before starting the engine or applying pressure, use components, parts, hoses and pipes that are in good condition, connected properly and are tightened to the proper torque. Capture fluid in an appropriate container and dispose of in accordance with prevailing environmental regulations.

PRESSURE TESTING: When conducting any test, only use test equipment that is correctly calibrated and in good condition. Use the correct equipment in the proper manner, and make changes or repairs as indicated by the test procedure to achieve the desired result.

LEAVING MACHINE: Lower the forks or attachment to the ground before leaving the machine.

TIRES: Always keep tires inflated to the proper pressure to help prevent tipover. DO NOT over-inflate tires.

NEVER use mismatched tire types, sizes or ply ratings.

Always use matched sets according to machine specifications.

MAJOR COMPONENTS: Never alter, remove, or substitute any items such as counterweights, tires, batteries or other items that may reduce or affect the overall weight or stability of the machine.

BATTERY: DO NOT charge a frozen battery.

Charging a frozen battery may cause it to explode. Allow the battery to thaw before jump-starting or connecting a battery charger.

1.7

SAFETY DECALS

Check that all safety decals are present and readable on the machine. Refer to the Operation & Maintenance Manual supplied with machine for information.

COOLANT SYSTEM CAP: The cooling system is under pressure, and escaping coolant can cause severe burns and eye injury. To prevent personal injury, NEVER remove the coolant system cap while the cooling system is hot. Wear safety glasses. Turn the coolant system cap to allow pressure to escape before removing the cap completely. Failure to follow the safety practices could result in death or serious injury.

FLUID FLAMABILTITY: DO NOT service the fuel or hydraulic systems near an open flame, sparks or smoking materials.

Properly disconnect battery prior to servicing the fuel or hydraulic systems.

NEVER drain or store fluids in an open container. Engine fuel and hydraulic fluid are flammable and can cause a fire and/or explosion.

DO NOT mix gasoline or alcohol with diesel fuel. The mixture can cause an explosion.

1-4

TH255C

Section 2 Safety information / User information

Contents PARAGRAPH 2.1 2.2 2.3 2.4

TH255C

TITLE

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation Manual And Service Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Explanation Of Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAGE 2-2 2-2 2-5 2-6

2-1

Safety information / User information

2.1

GENERAL

The documentation of the service manual has been created based on the engine available at the time of going to press.

• Only briefed personnel may operate or maintain the engine. Unauthorised persons are prohibited access to the machine room.

• Wear close-fitting clothing and ear protectors in the machine room when the engine is in operation.

There may be deviations in the descriptions, illustrations and parts due to further developments.

• Only deploy trained personnel to do repairs and maintenance work.

The valid documentations published by Engine Manufacturer (for example Technical Circulars, Service Bulletins, etc.) must be observed.

• Do not work on the fuel system when the engine is running. The fuel system is under high pressure danger of death.

The maintenance work described in the operation manual & in the service manual must be carried out on schedule and completely. The maintenance personnel must have the necessary technical knowledge to perform the work.

Safety and protection devices which are removed during maintenance work must be replaced again afterwards.

• Go to the workshop immediately in case of leaks in the fuel system.

Caution The rules for the prevention of accidents and the safety regulations must be observed during maintenance work.

Reference is made in the service manual job cards to the regulations in Section 2.2, “Specifications.”. These must be read before working on the engine and must be strictly followed.

The maintenance intervals and the work to be performed are specified in the maintenance schedule of the operation manual. The job cards contain technical documentation on the execution of maintenance work.

2.2 2.2.1

SPECIFICATIONS Accident prevention and safety regulations

The legally prescribed rules for the prevention of accidents must be observed. These are available from professional associations or from dealers. These are dependent on the application site, operating mode & operating and auxiliary materials being used.

Special protection measures are specified depending on the work being carried out, and are identified in the job description.

Among other things it generally applies that: All information in this manual is based on the latest product information available at the time of publication.

The manufacturer reserves the right to make changes and improvements to its products, and to discontinue the manufacture of any product, at its discretion at any time without public notice or obligation.

1. For the Personnel:

2-2

2. for the engine room: • Ensure adequate ventilation (do not cover air shafts).

• Provide first aid kit and suitable fire extinguishers.

Check the filling and readiness for operation regularly.

• Only store inflammable materials in the machine room if they are essential for operation of the system.

• Smoking and naked flames are prohibited in the machine room.

3. for operation, maintenance and repairs on the engine: • The common rail systems used work with operating pressures up to approximately 2000 bar. In the case of potential faults, the pressure can even rise to significantly higher values before the pressure reducing valve opens.

• After shutting down the engine, wait at least 30 seconds before performing work on the fuel system.

Depending on the version of common rail system, the fuel pressure in the common rail system will still not have dissipated after 30 seconds. The fuel pressure can permanently be several 100 bar.

The fuel pressure here does not drop until the fuel system is opened and the fuel can escape.

• Only start the engine when all the protective devices have been fitted. Make sure no-one is standing in the danger area.

• Cleaning, maintenance and repair work may only be performed with the engine at a standstill and secured against starting.

• Fuel lines, injection lines or fuel high-pressure lines must never be disconnected when the engine is running.

• Danger of injury. The fuel jet can deeply penetrate the skin.

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Safety information / User information • Do not come close to the leakage area in the fuel high-pressure system with any body parts (for example hand).

• Always carry out an exact visual inspection of all high-pressure carrying components before tests on the running engine. Wear suitable protective clothing (for example goggles, gloves) for this. Leakages entail potential hazard sources for the workshop personnel.

• Even if no leakages can be discerned in the fuel high-pressure system, the workshop personnel should avoid the direct hazard zone or wear protective clothing (for example goggles, gloves) during tests when the engine is running and during the first test run.

• Always stay out of range of a fuel jet, as it could cause severe injury.

• Fuel lines, injection lines and high-pressure lines must not be deformed.

• Damaged fuel lines, injection lines and high-pressure lines must be replaced.

• Smoking is strictly prohibited when working on the fuel system.

• Do not work near to sparks and flames.

• Never disconnect an injector when the engine is running.

• Loosen screw connections slowly and not abruptly.

• Open screw connections on the fuel system with extreme caution.

• After all work on the fuel system, it must be bleeded - see the operation manual, “chapter 6 Fuel system”.

2.2.2

Cleanliness instructions and measures for working with common rail systems

The common rail systems used in engines comprise high-precision components subjected to extreme loads.

In view of the high-precision technology, ensure utmost cleanliness when working on the fuel system. a. Notes and measures to be observed before starting work on the fuel system.

4. Blowing (dry) with compressed air is only permissible with the fuel system closed.

5. When using a steam jet, first cover up the control unit, the cable plugs, all other electrical plug connections and the generator. Also, the steam jet may not be pointed directly at them.

6. Electrical plug connections must be plugged when spraying.

7. Remove loose parts (for example paint chips from assembly work) with an industrial vacuum cleaner or other suction device. Only suction may be used in assembly work on the open fuel system.

8. Only work on the fuel system in a clean environment (no dust, no grinding or welding). Avoid draughts (dust). Clean the workshop floor regularly. No brake or performance test benches may be kept or operated in the same room.

9. Air currents which kick up dust, such as those caused by brake repairs or the starting of engines, should be avoided.

10. For work such as removal and installation on defective hydraulic components on the Common Rail System. it is recommended to partition off a separate workshop area in the factory. This must be separate from other areas in which general vehicle repairs such as brake repairs are carried out.

11. No general machine tools may be operated in this room.

12. Regular cleaning of the workshop area is mandatory.

Draughts, ventilation systems and heating fans should be minimised.

13. Areas of the engine room from which particles of dirt could be loosened (for example the bottom part of the tipped driver cab) must be covered with fresh clean film.

14. Working materials and tools must be cleaned before work. Only use tools without damage to the chrome plating or tools which are not chrome-plated. b. Notes and measures to be observed during work on the fuel system or with the fuel system open.

1. Only work in clean overall.

1. The fuel system must be closed. Make a visual inspection for leaks/damage to the fuel system.

2. Only lint-free cleaning cloths may be used for work on the fuel system.

2. Clean the whole engine and engine room with the system closed before starting work on the fuel system.

3. Remove loose parts (for example paint chips from assembly work) with an industrial vacuum cleaner or other suction device. Only suction may be used in assembly work on the open fuel system.

3. The engine must be dry when you start working on the fuel system.

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2-3

Safety information / User information 4. Working materials and tools must be cleaned before work. Only use tools without damage to the chrome plating or tools which are not chrome-plated.

5. Do not use used cleaning fluid or test fluid for cleaning.

6. Compressed air must not be used for cleaning on the open fuel system.

d. Notes and measures for workbench and tools in the vehicle hall 1. A special workbench must be set up for work on removed components.

2. Clean the removal and installation tools regularly and keep them in a closed tool cabinet.

7. Work on removed components may only be performed at a suitably equipped workbench.

3. Remove loose parts (for example paint chips from assembly work) with an industrial vacuum cleaner or other suction device.

8. When removing and installing components, no materials which can leave behind particles or fibres (cardboard, wood, cloths) may be used.

4. Working materials and tools must be cleaned before work. Only use tools without damage to the chrome plating or tools which are not chrome-plated.

9. Removed parts may only be rubbed down with clean, lint-free cloths. No dirt particles may be rubbed into the components.

10. Openings on the components and on the engine must be closed immediately with suitable stoppers/caps.

11. The stoppers/caps may only be removed immediately before installing.

12. Store stoppers/caps free from dust and dirt in the original packaging and dispose of after using once.

13. Only remove new parts from the original packaging just before installation.

14. Removed components must be kept in new, sealable bags or if available in the packaging of the new parts.

15. Always use the original packaging of the new part to send back the removed components. c. Notes and measures for the vehicle workshop area 1. For work such as removal and installation on defective hydraulic components on the Common Rail System it is recommended to partition off a separate workshop area in the factory. This must be separate from other areas in which general vehicle repairs such as brake repairs are carried out.

2. The workshop floor is sealed or tiled.

3. No welding gear, grinders, general machine tools, brakes or performance test benches may be operated in this room.

4. Regular cleaning of the workshop area is mandatory.

Draughts, ventilation systems and heating fans should be minimised.

2.2.3

Additional information and measures for the handling of exhaust aftertreatment systems

1. Basically all the same regulations and instructions up to and including 2.2.2 must also be observed for work on exhaust after treatment systems.

2. Utmost cleanliness must be observed for all work. a. DPF (Diesel Particle Filter) 1. The filter regeneration must be deactivated or, in systems with a filter regeneration prompt, not activated before performing service work.

2. The duration of a full filter regeneration is 25 minutes on average. High exhaust temperatures occur in the exhaust system/on the end exhaust pipe independently of the actual load state of the engine (i.e. also during engine idling).

3. No foreign bodies may get into the exhaust line or the combustion chamber. If this happens, the engine must be "run free" without diesel particle filter.

4. Tensions and deformations of the shape of the V-belt clip must be avoided. The DPF module may only be transported using the transport sleeves.

5. V-belt clips and seals may not be reused (this also applies as soon as the screw connection has been loosened once). b. Ignition system 1. Caution! Dangerous high voltage.

The ignition system operates with ignition voltages up to 10000 Volts.

2. The ignition system must not be operated without a secondary load.

3. Store the components in a dry and clean area.

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Safety information / User information 4. It is not permitted to store the components temporarily or stack them without their transport packaging.

5. Components may only be stored and transported in the specified packaging.

6. Only remove new parts from the original packaging just before installation.

7. Incorrectly operated or damaged components or parts that have been dropped must not be installed.

8. Do not subject the components to any hard impacts or any other use of force.

9. Faulty earthing, cable and plug connections can lead to malfunctions. Electronic components can be destroyed.

10. Dirt and moisture on the primary and high voltage connections can cause malfunctions (leakage current, misfiring, high voltage sparks).

11. Check the protective caps of the ignition lines for dis-colouration, deformation and cracks before each usage. c. SCR (Selective Catalytic Reduction) 1. AdBlue® is a caustic medium which causes heavy corrosion damage when it comes into contact with electronic components or similar.

2. Leaks on the AdBlue® pipes, the tank, the supply module and the feeding unit must be fixed immediately to avoid leakage of AdBlue®.

10. The so-called lag time is application-dependent and may be up to 2 minutes in engines with an SCR system because the SCR pipes have to be pumped empty in this time.

2.2.4

Disposal regulations

The work described in the operation manual & service manual necessitates renewal of parts and operating materials among other things. The renewed parts/operating materials must be stored, transported and disposed of according to regulations. The owner himself is responsible for this.

Disposal includes recycling and the scrapping of parts/operating materials, although recycling has priority.

Details of disposal and their monitoring are governed by regional, national and international laws and directives which the system operator must observe on his own responsibility.

2.3

OPERATION MANUAL AND SERVICE MANUAL

The use of job cards (service manual) presupposes knowledge of the operating instructions content this applying in particular for the service specifications.

Repairs to the engine and components are described in the job cards (service manual), for the implementation of which more effort and correspondingly qualified experts are required.

3. Make sure the room is well ventilated.

4. Contact with the skin should be avoided. Wear latex gloves if possible.

5. Wash hands thoroughly before taking breaks and at the end of shifts.

6. If the substance comes into contact with eyes, rinse thoroughly with water.

7. If swallowed, rinse out mouth with a lot of water, drink plenty of water and seek medical advice.

8. If discomfort or illness continues, seek medical advice.

9. Product can pose danger of slipping if spilled. It is essential to remove spilled liquid. In so doing, ensure that the liquid does not enter the sewage system or ground/surface water. This means that the contamination should be physically removed and disposed of in suitable containers. Minimal amounts of remaining liquid may be rinsed away with a lot of water.

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2-5

Safety information / User information

2.4

EXPLANATION OF SYMBOLS Danger Of death or to health. Must be observed.

For example: The incorrect use or conversion of the turbocharger can lead to serious injury.

Caution!

Danger to the component/engine.

Non-compliance can lead to destruction of the component/engine.

Must be observed.

Note General notes on assembly, environmental protection etc. No potential danger for man or machine.

Tool Conventional and special tools required for the work.

Auxiliary materials Working materials required in addition to the tools for performing the work (e.g. greases, oils, adhesives, sealants.

References To important documents Reference Within the workflow or to assemblies in which further documents or job cards are provided.

Test and setting data The necessary values are indicated here with link to a table within the job card.

Tightening specifications The necessary values are indicated here with link to a table within the job card.

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Section 3 Disassembly and Assembly

Contents PARAGRAPH 3.1 3.2 3.3

3.4

3.5 3.6 3.7

3.8

3.9 3.10

3.11 3.12

3.13

3.14 3.15

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TITLE

Oil Measuring Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1.1 Oil Measuring Device Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankcase Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.1 Lubricating Oil Pan Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.2 Lubricating Oil Pan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3.3 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.1 Flywheel Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.2 Flywheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.3 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V-belt Pulley Add-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V-belt Pulley Add-on Fastening Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Head Cover (Engine 441-9208) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7.1 Cylinder Head Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7.2 Cylinder Head Cover Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7.3 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder Head Cover (Engine 441-9209) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8.1 Cylinder Head Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8.2 Cylinder Head Cover Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8.3 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heat Protection Plate (Engine 441-9208). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10.1 Lubricating Oil Cooler Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10.2 Lubricating Oil Cooler Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10.3 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Injector (Engine 441-9208) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.12.1 Injector Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.12.2 Injector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.12.3 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Injector (Engine 441-9209) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.13.1 Injector Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.13.2 Injector Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.13.3 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Supply Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.15.1 High-pressure Line Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAGE 3-4 3-4 3-5 3-6 3-6 3-9 3-11 3-12 3-12 3-13 3-14 3-15 3-16 3-17 3-17 3-19 3-20 3-21 3-21 3-23 3-24 3-25 3-26 3-26 3-27 3-28 3-29 3-30 3-30 3-32 3-35 3-36 3-36 3-38 3-41 3-42 3-44 3-44

3-1

Disassembly and Assembly

3.16 3.17 3.18 3.19

3.20

3.21

3.22 3.23

3.24

3.25

3.26

3.27

3.28 3.29 3.30

3-2

3.15.2 Injection Pipes Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.15.3 Rail Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.15.4 Pressure Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.15.5 Pressure Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.15.6 Pressure Limiting Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.15.7 Pressure Limiting Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.15.8 Mounting Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.15.9 Injection Pipes Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.15.10 High-pressure Line Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.15.11 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Turbocharger Intake Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Charge Air Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Charge Air Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant Pump Fastening Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.19.1 V-rib Belt Pulley Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.19.2 V-rib Belt Pulley Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thermostat Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.20.1 Thermostat Test In Removed State. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.20.2 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.21.1 Thermostat Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.21.2 Thermostat Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.21.3 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Gas Recirculation Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.23.1 Exhaust Line Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.23.2 Installing Exhaust Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.23.3 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flutter Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.24.1 Flutter Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.24.2 Flutter Valve Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.24.3 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Gas Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.25.1 Turbocharger Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.25.2 Turbocharger Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.25.3 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating Oil Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.26.1 Lubricating Oil Line Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.26.2 Lubricating Oil Line Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.26.3 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubricating Oil Return Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.27.1 Oil Return Line Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.27.2 Oil Return Line Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.27.3 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

V-Belt Pulley (parts to generator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.30.1 Generator Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.30.2 Generator Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.30.3 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-44 3-45 3-45 3-46 3-46 3-47 3-48 3-48 3-49 3-51 3-52 3-53 3-54 3-55 3-55 3-55 3-56 3-56 3-59 3-60 3-60 3-61 3-62 3-63 3-64 3-64 3-65 3-66 3-67 3-67 3-69 3-71 3-72 3-72 3-74 3-75 3-76 3-76 3-77 3-79 3-80 3-80 3-82 3-84 3-85 3-86 3-87 3-87 3-89 3-90 TH255C

Disassembly and Assembly 3.31

3.32 3.33 3.34

3.35 3.36 3.37

3.38

3.39 3.40 3.41

TH255C

Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.31.1 Starter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.31.2 Starter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.31.3 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cable Harness Fastening Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cable Harness Fastening Parts (Engine 441-9208) . . . . . . . . . . . . . . . . . . . . . . .

Impulse Transmitter (Crankshaft) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.34.1 Impulse Transmitter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.34.2 Impulse Transmitter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.34.3 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pressure Transmitter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connection Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.37.1 Connection Housing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.37.2 Connection Housing Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.37.3 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start-aid Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.38.1 Glow Plugs Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.38.2 Glow Plugs Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.38.3 Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Gas Treatment Inlet Module (Engine 441-9208). . . . . . . . . . . . . . . . . . .

Holder (Engine 441-9208) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Assembly Material Compensator Structure (Engine 441-9208) . . . . . . . . . . . . .

3-91 3-91 3-92 3-93 3-94 3-95 3-96 3-96 3-97 3-98 3-99 3-100 3-101 3-101 3-102 3-103 3-104 3-104 3-105 3-106 3-107 3-109 3-110

3-3

Disassembly and Assembly

3.1

OIL MEASURING DEVICE

3.1.1

Oil Measuring Device Removal

Standard tools Special tools: – Disassembly tool – Safety information / User information

1

Oil dipstick

2

O-ring

1. Remove O-rings with disassembly tool.

Use new round sealing rings.

3-4

TH255C

Disassembly and Assembly

3.2

CRANKCASE BREATHER Standard tools Special tools: – Pliers

449-2489

– Safety information / User information

1

Breather pipe

2

Rubber sleeve

3

Spring band clip

4

Pipe clip

5

Hexagon head screw, Torque to 6.5 Nm (4.8 ft-lb) Ensure that the installation location is free from faults.

TH255C

3-5

Disassembly and Assembly

3.3

LUBRICATING OIL PAN

3.3.1

Lubricating Oil Pan Removal

Standard tools

– Loctite® 5900TM

– Safety information / User information – Operation manual

Attention Make sure that no gasket residue falls into the crankcase.

Seal all openings.

Collect leaking operating substances in suitable vessels and dispose of according to regulations.

Emptying and filling the engine with operating media must be carried out according to the operating manual and the appropriate documentation of the vehicle/equipment manufacturer.

3-6

1

Lubricating oil pan

2

Sealing ring

3

Screw plug

4

Sealing ring

5

Screw plug

6

Torx screw

244

Loctite® 5900TM

TH255C

Disassembly and Assembly

1. Unscrew locking screw (1).

2. Remove sealing ring.

Attention

3. Drain lubricating oil, collect and dispose of according to regulations.

Area X: It is not permissible to drive in the separating tool in this area.

4. Unscrew all screws (1).

5. Drive in separating tool (1) to the stop (2).

TH255C

3-7

Disassembly and Assembly

Attention The tool can only be driven in the area of the crankcase.

Separation in the area of aluminium parts is not allowed.

Do not damage the sealing surfaces.

7. Lever out lubricating oil pan.

8. Remove lubricating oil pan.

6. Drive in second separating tool (1) to the stop (2).

Attention The tool can only be driven in the area of the crankcase.

Separation in the area of aluminium parts is not allowed.

Do not damage the sealing surfaces.

3-8

TH255C

Disassembly and Assembly 3.3.2

Lubricating Oil Pan Installation

1. Scrape off sealing compound with separating tool.

3. To align the lubricating oil pan, screw four pin bolts (1) diagonally opposed into the crankcase.

Attention

Wear protective glasses.

4. Clean sealing surfaces.

The sealing surfaces must be dry and free from grease and dirt.

2. Clean the sealing surface on the lubricating oil pan with a wire brush.

5. Apply Loctite® 5900TM to the joints (arrows).

The sealing surfaces must be dry and free from grease and dirt.

TH255C

3-9

Disassembly and Assembly

6. Apply Loctite® 5900TM evenly to the sealing surface.

11. Tighten the screws according to the tightening sequence.

20 Nm (15 ft-lb)

7. Align the lubricating oil pan in the appropriate installation position with the pin bolts.

8. Mount lubricating oil pan.

Attention Do not move the lubricating oil pan any more.

Observe the drying time for the Loctite® 5900TM.

12. Mount new sealing ring.

13. Tighten screw plug (1).

55 Nm (40 ft-lb) 14. Fill in lubricating oil according to operating manual.

9. Unscrew the pin bolts.

10. Fasten all screws (1).

3-10

TH255C

Disassembly and Assembly 3.3.3

Technical Data

Tightening specifications ID no.

Name

Screw type

Notes / Remark

Value

A02 030 Lubricating oil pan on crankcase

Observe tightening sequence.

20 Nm (15 ft-lb)

A02 031 Locking screw on lubricating oil pan

Replace sealing ring.

55 Nm (40 ft-lb)

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

TH255C

3-11

Disassembly and Assembly

3.4

FLYWHEEL

3.4.1

Flywheel Removal

Standard tools Special tools: – Guide pin (self-constructed) – Auxiliary screws – Rotation angle disc

M10 X 120 449-2484

1

Flywheel

2

Ring gear

3

Screw

1. Hold the crankshaft at the central screw.

2. Screw in auxiliary screws (1).

3. Unscrew screws (2).

4. Remove flywheel using auxiliary screws.

5. Visually inspect the components.

3-12

TH255C

Disassembly and Assembly 3.4.2

Flywheel Installation

3. Tighten screws alternately.

Stage 1: 30 Nm (22 ft-lb) 4. Tighten screws with rotation angle disc.

Stage 2: 60° Stage 3: 30° 5. Remove guide pin.

6. Unscrew auxiliary screws.

1. Insert self-made guide pin (arrow).

The bores in the flywheel must match the threaded bores in the crankshaft flange.

2. Mount flywheel using auxiliary screws.

Attention

Renew screws every time they are loosened.

TH255C

3-13

Disassembly and Assembly 3.4.3

Technical Data

Tightening specifications ID no.

Name

Screw type

Notes / Remark

Value

A05 001 Flywheel on crankshaft

Stage 1: Use new screws.

Oiled screws.

30 Nm (22 ft-lb)

A05 001 Flywheel on crankshaft

Stage 2:

60°

A05 001 Flywheel on crankshaft

Stage 3:

30°

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

3-14

TH255C

Disassembly and Assembly

3.5

V-BELT PULLEY ADD-ON Standard tools

– Safety information / User information

1

TH255C

V-belt pulley

3-15

Disassembly and Assembly

3.6

V-BELT PULLEY ADD-ON FASTENING PARTS Standard tools

– Safety information / User information

1

Hexagon head screw, Torque to 60 Nm (44 ft-lb)

1. Tighten the screws according to the tightening sequence.

3-16

TH255C

Disassembly and Assembly

3.7

CYLINDER HEAD COVER (ENGINE 441-9208)

3.7.1

Cylinder Head Cover Removal

Standard tools Special tools: – Disassembly tool – Safety information / User information

TH255C

1

Cylinder head cowling

2

Filler lock

3

Seal

4

Seal

5

Seal

6

Seal

3-17

Disassembly and Assembly

1. Removing the crankcase breather. See Section 3.2, “Crankcase Breather.”

2. Removing charge air manifold. See Section 3.17, “Charge Air Manifold.”

6. Remove seal (1) with disassembly tool.

7. Remove seal (2) with disassembly tool.

8. Remove seal (3) with disassembly tool.

3. Remove seal (1) with disassembly tool.

4. Unscrew screws (1).

5. Remove cylinder head cowling (2).

3-18

TH255C

Disassembly and Assembly 3.7.2

Cylinder Head Cover Installation

1. Insert new seal (1).

2. Insert new seal (2).

3. Insert new seal (3).

6. Tighten the screws according to the tightening sequence.

8.5 Nm (6.2 ft-lb)

4. Mount cylinder head cover (1).

7. Insert new seal (1).

5. Tighten screws (2).

8. Installing charge air manifold. See Section 3.17, “Charge Air Manifold.”

9. Install crankcase breather. See Section 3.2, “Crankcase Breather.”

TH255C

3-19

Disassembly and Assembly 3.7.3

Technical Data

Tightening specifications ID no.

Name

A08 004 Cylinder head cover on cylinder head

Screw type

Notes / Remark

Value

8.5 Nm (6.2 ft-lb)

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

3-20

TH255C

Disassembly and Assembly

3.8

CYLINDER HEAD COVER (ENGINE 441-9209)

3.8.1

Cylinder Head Cover Removal

Standard tools Special tools: – Disassembly tool – Safety information / User information

TH255C

1

Cylinder head cowling

2

Filler lock

3

Seal

4

Seal

5

Seal

6

Seal

3-21

Disassembly and Assembly

1. Removing the crankcase breather. See Section 3.2, “Crankcase Breather.”

2. Removing charge air manifold. See Section 3.17, “Charge Air Manifold.”

6. Remove seal (1) with disassembly tool.

7. Remove seal (2) with disassembly tool.

8. Remove seal (3) with disassembly tool.

3. Remove seal (1) with disassembly tool.

4. Unscrew screws (1).

5. Remove cylinder head cowling (2).

3-22

TH255C

Disassembly and Assembly 3.8.2

Cylinder Head Cover Installation

1. Insert new seal (1).

2. Insert new seal (2).

3. Insert new seal (3).

6. Tighten the screws according to the tightening sequence.

8.5 Nm (6.2 ft-lb)

4. Mount cylinder head cover (1).

7. Insert new seal (1).

5. Tighten screws (2).

8. Installing charge air manifold. See Section 3.17, “Charge Air Manifold.”

9. Install crankcase breather. See Section 3.2, “Crankcase Breather.”

TH255C

3-23

Disassembly and Assembly 3.8.3

Technical Data

Tightening specifications ID no.

Name

A08 004 Cylinder head cover on cylinder head

Screw type

Notes / Remark

Value

8.5 Nm (6.2 ft-lb)

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

3-24

TH255C

Disassembly and Assembly

3.9

HEAT PROTECTION PLATE (ENGINE 441-9208) Standard tools

– Safety information / User information

TH255C

1

Heat protection plate

2

Hexagon head screw, Torque to 20 Nm (15 ft-lb)

3-25

Disassembly and Assembly

3.10

LUBRICATING OIL COOLER

3.10.1

Lubricating Oil Cooler Removal

Standard tools

– Safety information / User information

Collect leaking operating substances in suitable vessels and dispose of according to regulations.

The appropriate operating manual should be observed for emptying and filling the engine.

1

Lubricating oil cooler

2

Seal

3

Hexagon head screw

1. Unscrew all screws (1).

2. Remove lubricating oil cooler (2).

3. Remove gasket (3).

Collect draining lubricating oil and dispose of properly.

4. Visually inspect the components.

3-26

TH255C

Disassembly and Assembly 3.10.2

Lubricating Oil Cooler Installation

1. Visually inspect the components.

2. Clean sealing surfaces.

3. Fasten new seal (1) on lubricant oil cooler housing with screws.

4. Turn in screws (arrows).

5. Mount lubricating oil cooler (1).

6. Tighten screws (2).

7. Tighten all screws (2) alternately.

20 Nm (15 ft-lb)

TH255C

3-27

Disassembly and Assembly 3.10.3

Technical Data

Tightening specifications ID no.

Name

A15 051 Lubricating oil cooler on crankcase

Screw type

Notes / Remark

Value

20 Nm (15 ft-lb)

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

3-28

TH255C

Disassembly and Assembly

3.11

LUBRICATING OIL FILTER Standard tools

– Loctite® 270TM

– Safety information / User information

1 137

TH255C

Threaded bush, Torque to 40 Nm (30 ft-lb) Loctite® 270TM

3-29

Disassembly and Assembly

3.12

INJECTOR (ENGINE 441-9208)

3.12.1

Injector Removal

Standard tools Special tools: – Diagnostic tool SerDia 2010 – Assembly pliers – Torx tool set – Plug – Lever tool – Disassembly tool

449-2493 449-2497

– Safety information / User information

Danger Do not carry out work on the fuel system when the engine is running.

The fuel system is under high pressure Danger of death.

The fuel pressure can continuously remain up to several 100 bar even after stopping the engine.

Here the fuel pressure is only reduced if the fuel system is opened and the fuel can escape outside.

Attention

1

Injector

2

Sealing disc

3

Clip

4

O-ring

5

Clamping claw

6

Torx screw

7

Sealing disc

Ensure utmost cleanliness for all work.

Remove any paint residue and dirt particles before disassembly.

Clean the area around the components concerned carefully. Blow wet parts dry with compressed air.

Observe the safety regulations and national specifications for handling fuels.

Close all connections immediately after opening with new, clean plugs/caps.

Do not remove plugs/caps until immediately before assembling.

Collect leaking operating substances in suitable vessels and dispose of according to regulations.

3-30

TH255C

Disassembly and Assembly 1600 Bar Injection System

Attention

Note assignment of the injector to the cylinder.

The injector is assigned by the relevant IMA code (1) to the corresponding cylinder.

The assignment is saved in the control unit.

Each time an injector is replaced/renewed, the correct assignment to the relevant cylinder must be made by transferring the new IMA code in the control unit.

Observe installed injection system.

The IMA codes of the different injection systems are basically different.

The injector calibration depends on the installed injection system.

The exact procedure can be taken from the listed documentation and must be observed.

1. Unlock cable plug and remove.

2. Disconnect the fuel line from the injector. See Section 3.15, “Fuel Pipes.”

Attention

Position (1): The injector must be renewed if the pipe connection is disconnected.

3. Hold pipe connection (1).

4. Remove injection line. See Section 3.15, “Fuel Pipes.”

5. Unscrew screw (2).

The following work procedure describes the removal and installation of an injector.

Proceed in the same way to remove further injectors.

TH255C

3-31

Disassembly and Assembly 9. Grip fixed sealing disc (1) using the assembly pliers (2) and pull off with slight turning movements.

10. Visually inspect the components.

6. Insert lever tool (1) in the clamping claw.

7. Loosen the injector by moving the lever tool (1) in the direction of the arrow.

8. Remove injector and clamping claw.

11. Remove the round sealing ring (1) carefully from the injector with the disassembly tool.

Attention

Do not damage the injector.

3.12.2

Injector Installation

Attention

Do not brush off the nozzle tip of the injector.

Do not damage nozzle head on the injector during disassembly of the sealing disc (1).

Number of sealing discs: See the spare parts documentation.

3-32

1. Mount new O-ring (1).

TH255C

Disassembly and Assembly

Attention

Do not damage the O-ring.

Attention 2. Mount new sealing disc (1) on injector.

Attention

Observe number of sealing discs.

See spare parts documentation.

Before installing the injector, combustion residue must be cleaned carefully from the bore on the cylinder head.

Suck off dirt particles.

Note assignment of the injector to the cylinder.

Ensure that the installation location is free from faults.

3. Insert injector carefully in the cylinder head.

4. Mount clamping shoe.

5. Insert screw (1).

Do not tighten the screw until after assembling the injection line.

6. Mount new injection pipe. See Section 3.15, “Fuel Pipes.”

Do not tighten union nuts.

TH255C

3-33

Disassembly and Assembly

Attention

Position (1): The injector must be renewed if the pipe connection is disconnected.

7. Tighten screw (2).

30 Nm (22 ft-lb) 8. Tighten union nuts of the injection line. See Section 3.15, “Fuel Pipes.”

9. Connect fuel line. See Section 3.15, “Fuel Pipes.”

Attention

Removed, missing and bent clips must be renewed.

The clip must spring back to the hold position automatically. Otherwise renew the clip.

10. Plug in and lock cable plug.

3-34

TH255C

Disassembly and Assembly 3.12.3

Technical Data

Tightening specifications ID no.

Name

Injector on cylinder head, clamping A19 001 claw

Screw type

Notes / Remark

Observe order of installation.

Install injector without tension.

Value

30 Nm (22 ft-lb)

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

TH255C

3-35

Disassembly and Assembly

3.13

INJECTOR (ENGINE 441-9209)

3.13.1

Injector Removal

Standard tools Special tools: – Diagnostic tool SerDia 2010 – Assembly pliers – Torx tool set – Plug – Lever tool – Disassembly tool

449-2493 449-2497

– Safety information / User information

Danger Do not carry out work on the fuel system when the engine is running.

The fuel system is under high pressure Danger of death.

The fuel pressure can continuously remain up to several 100 bar even after stopping the engine.

Here the fuel pressure is only reduced if the fuel system is opened and the fuel can escape outside.

1

Injector

2

Sealing disc

3

Clip

4

O-ring

5

Clamping claw

6

Torx screw

Attention Ensure utmost cleanliness for all work.

Remove any paint residue and dirt particles before disassembly.

Clean the area around the components concerned carefully. Blow wet parts dry with compressed air.

Observe the safety regulations and national specifications for handling fuels.

Close all connections immediately after opening with new, clean plugs/caps.

Do not remove plugs/caps until immediately before assembling.

Collect leaking operating substances in suitable vessels and dispose of according to regulations.

3-36

TH255C

Disassembly and Assembly 1600 Bar Injection System

Attention

Note assignment of the injector to the cylinder.

The injector is assigned by the relevant IMA code (1) to the corresponding cylinder.

The assignment is saved in the control unit.

Each time an injector is replaced/renewed, the correct assignment to the relevant cylinder must be made by transferring the new IMA code in the control unit.

Observe installed injection system.

The IMA codes of the different injection systems are basically different.

The injector calibration depends on the installed injection system.

The exact procedure can be taken from the listed documentation and must be observed.

1. Unlock cable plug and remove.

2. Disconnect the fuel line from the injector. See Section 3.15, “Fuel Pipes.”

Attention

Position (1): The injector must be renewed if the pipe connection is disconnected.

3. Hold pipe connection (1).

4. Remove injection line. See Section 3.15, “Fuel Pipes.”

5. Unscrew screw (2).

The following work procedure describes the removal and installation of an injector.

Proceed in the same way to remove further injectors.

TH255C

3-37

Disassembly and Assembly 10. Visually inspect the components.

6. Insert lever tool (1) in the clamping claw.

7. Loosen the injector by moving the lever tool (1) in the direction of the arrow.

11. Remove the round sealing ring (1) carefully from the injector with the disassembly tool.

Attention

8. Remove injector and clamping claw.

Do not damage the injector.

3.13.2

Injector Installation

Attention

Do not brush off the nozzle tip of the injector.

Do not damage nozzle head on the injector during disassembly of the sealing disc (1).

9. Grip fixed sealing disc (1) using the assembly pliers (2) and pull off with slight turning movements.

3-38

1. Mount new O-ring (1).

Attention

Do not damage the O-ring.

TH255C

Disassembly and Assembly

2. Mount new sealing disc (1) on injector.

Attention

Before installing the injector, combustion residue must be cleaned carefully from the bore on the cylinder head.

Suck off dirt particles.

Attention

Note assignment of the injector to the cylinder.

Ensure that the installation location is free from faults.

3. Insert injector carefully in the cylinder head.

4. Mount clamping shoe.

5. Insert screw (1).

Do not tighten the screw until after assembling the injection line.

6. Mount new injection pipe. See Section 3.15, “Fuel Pipes.”

Do not tighten union nuts.

TH255C

3-39

Disassembly and Assembly

Attention

Position (1): The injector must be renewed if the pipe connection is disconnected.

7. Tighten screw (2).

30 Nm (22 ft-lb) 8. Tighten union nuts of the injection line. See Section 3.15, “Fuel Pipes.”

9. Connect fuel line. See Section 3.15, “Fuel Pipes.”

Attention

Removed, missing and bent clips must be renewed.

The clip must spring back to the hold position automatically. Otherwise renew the clip.

10. Plug in and lock cable plug.

3-40

TH255C

Disassembly and Assembly 3.13.3

Technical Data

Tightening specifications ID no.

Name

Injector on cylinder head, clamping A19 001 claw

Screw type

Notes / Remark

Observe order of installation.

Install injector without tension.

Value

30 Nm (22 ft-lb)

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

TH255C

3-41

Disassembly and Assembly

3.14

FUEL SUPPLY PUMP Standard tools Special tools: – Plug

449-2493

– Safety information / User information

Danger Do not carry out work on the fuel system when the engine is running.

The fuel system is under high pressure Danger of death.

The fuel pressure can continuously remain up to several 100 bar even after stopping the engine.

Here the fuel pressure is only reduced if the fuel system is opened and the fuel can escape outside.

1

Supply pump

2

Clip Fastening Screws, 4 X M5-8.8

Attention

Ensure utmost cleanliness for all work.

Remove any paint residue and dirt particles before disassembly.

Clean the area around the components concerned carefully. Blow wet parts dry with compressed air.

Observe the safety regulations and national specifications for handling fuels.

Close all connections immediately after opening with new, clean plugs/caps.

Do not remove plugs/caps until immediately before assembling.

Collect leaking operating substances in suitable vessels and dispose of according to regulations.

3-42

7.5 Nm (5.5 ft-lb)

Attention

Ensure that the installation location is free from faults.

TH255C

Disassembly and Assembly

1

Nut Terminal +, Torque to 7.5 Nm (5.5 ft-lb)

2

Nut Terminal • , Torque to 7.5 Nm (5.5 ft-lb)

3

Connection Nozzle Fuel outlet

Attention

Ensure that the cables are connected properly.

TH255C

3-43

Disassembly and Assembly

3.15

FUEL PIPES

3.15.1

High-pressure Line Removal

Standard tools: – Wrench insert size 14 Special tools: – Long socket wrench insert – Plug 449-2493 – Key 449-2496 – Disassembly tool – Marker pen, waterproof, permanent – Multipurpose Grease

01016496

– Safety information / User information

1. Remove fuel return line.

Danger

2. Unscrew union nut (1) with special wrench.

Do not carry out work on the fuel system when the engine is running.

The fuel system is under high pressure Danger of death.

3. Unscrew union nuts (2) with special wrench.

The fuel pressure can continuously remain up to several 100 bar even after stopping the engine.

Here the fuel pressure is only reduced if the fuel system is opened and the fuel can escape outside.

4. Remove high-pressure line (3).

Collect draining fuel and dispose of according to regulations.

3.15.2

Injection Pipes Removal

Attention

Ensure utmost cleanliness for all work.

Remove any paint residue and dirt particles before disassembly.

Clean the area around the components concerned carefully. Blow wet parts dry with compressed air.

Observe the safety regulations and national specifications for handling fuels.

Close all connections immediately after opening with new, clean plugs/caps.

Do not remove plugs/caps until immediately before assembling.

Collect leaking operating substances in suitable vessels and dispose of according to regulations.

3-44

1. Unscrew lock nuts (1) with special wrench.

TH255C

Disassembly and Assembly 3.15.4

Pressure Sensor Removal

Attention

Position (3): The injector must be renewed if the pipe connection is disconnected.

2. Hold pipe connection of injector.

3. Unscrew lock nuts (2).

4. Remove injection lines.

Collect draining fuel and dispose of according to regulations.

3.15.3

Rail Removal

1. Unscrew the rail pressure sensor (1) with the socket wrench.

Collect draining fuel and dispose of according to regulations.

1. Unlock cable plug.

2. Pull out cable plug.

3. Unscrew screws (1).

4. Remove the rail (2).

5. Visually inspect the components.

Attention

Do not touch the pin contacts of the rail pressure sensor with your hands to avoid electrostatic discharging.

Ensure absolute cleanliness of the connector.

TH255C

3-45

Disassembly and Assembly 2. Visually check the thread and the sealing edge (arrows) of the rail pressure sensor.

3.15.5

Pressure Sensor Installation

Attention

Attention

No foreign bodies may get into the rail.

Ensure utmost cleanliness. Especially on the thread and the sealing surface of the rail.

See the spare parts documentation.

Rail pressure sensor and pressure limiting valve must be replaced as a pair.

Only tighten the rail pressure sensor with the hexagon.

3. Screw in rail pressure sensor (1).

4. Tighten rail pressure sensor (1) with the socket wrench insert.

70 Nm (51 ft-lb)

3.15.6

Pressure Limiting Valve Removal

1. Clean thread and sealing area of the rail.

2. Coat the thread and sealing edge of the rail pressure sensor lightly with assembly grease.

1. Unscrew pressure limiting valve (1).

3-46

TH255C

Disassembly and Assembly 3.15.7

Pressure Limiting Valve Installation

Collect draining fuel and dispose of according to regulations.

Attention

2. Visually check the thread and the sealing edge of the pressure limiting valve.

No foreign bodies may get into the rail.

Ensure utmost cleanliness. Especially on the thread and the sealing surface of the rail.

See the spare parts documentation.

Rail pressure sensor and pressure limiting valve must be replaced as a pair.

1. Mount new O-ring (1).

3. Remove the O-ring with the disassembly tool.

TH255C

3-47

Disassembly and Assembly 2. Lightly coat the thread and sealing edge of the pressure limiting valve with assembly grease.

3. Clean thread and sealing area of the rail.

4. Screw in pressure limiting valve (1).

5. Tighten pressure limiting valve.

3.15.9

Injection Pipes Installation

Attention

The injection lines must always be renewed after disassembly.

100 Nm (73 ft-lb)

3.15.8

Mounting Rail

Note assignment and installation position of the injection lines.

1. Mount new injection lines (1).

1. Mount rail (1).

2. Pre-assemble the rail (1) loosely with screws (2).

Do not tighten screws.

3-48

TH255C

Disassembly and Assembly

Attention

Pay attention to alignment of the injection pipes.

Lines must not be in the bores (1) of the union nuts.

Install injection lines without tension and without touching.

They must be a safe distance away from adjacent parts.

2. Align injection lines.

3. Tighten union nuts hand-tight.

3.15.10

High-pressure Line Installation

Attention

Pay attention to alignment of the high-pressure line.

Line may not touch in the bore (1) of the union nut.

Install high-pressure line without tension and contact.

They must be a safe distance away from adjacent parts.

2. Align high-pressure line.

3. Tighten union nuts hand-tight.

Attention

The high-pressure line must always be renewed after dismantling.

Ensure that the installation location is free from faults.

1. Mount new high-pressure line (1).

TH255C

3-49

Disassembly and Assembly 4. Tighten screws (1).

30 Nm (22 ft-lb)

9. Check the high-pressure line for perfect installation position.

10. Mount fuel return line.

11. Plug in and lock cable plug.

Ensure that the connection is perfect.

5. Tighten the union nuts in order.

Stage 1: 10 Nm (7 ft-lb)

6. Draw help markings (1).

7. Tighten union nut.

Stage 2 (2): 60°

+ 5°

8. Check injection lines for perfect installation position.

3-50

TH255C

Disassembly and Assembly 3.15.11

Technical Data

Tightening specifications ID no.

Name

Screw type

Notes / Remark

Value

Stage 1: Observe assembly instructions.

Use new line.

10 Nm (7 ft-lb)

Injection line on rail and injector, A21 003 high-pressure line on high-pressure pump and on rail

Stage 2:

60°

A21 038 Rail on cylinder head

Observe assembly specification.

30 Nm (22 ft-lb)

A21 039 Pressure limiting valve on rail

Lightly coat the thread and sealing edge with assembly grease.

100 Nm (73 ft-lb)

Lightly coat the thread and sealing edge with assembly grease.

70 Nm (51 ft-lb)

Injection line on rail and injector, A21 003 high-pressure line on high-pressure pump and on rail

A21 040 Pressure sensor on rail

Union nut

M18 X 1.5

+ 5°

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

TH255C

3-51

Disassembly and Assembly

3.16

EXHAUST TURBOCHARGER INTAKE NOZZLE Standard tools Special tools: – Pliers

449-2489

– Safety information / User information

1

Intake nozzle

2

Spring band clip

1. Position spring band clip with spring band pliers.

Ensure that the installation location is free from faults.

Note position of intake nozzle.

3-52

TH255C

Disassembly and Assembly

3.17

CHARGE AIR MANIFOLD Standard tools Special tools: – Disassembly tool – Safety information / User information

1

Charge air manifold

2

Hexagon head screw, Torque to 20 Nm (15 ft-lb)

1. Remove seal (1) with disassembly tool.

Use a new gasket.

TH255C

3-53

Disassembly and Assembly

3.18

CHARGE AIR LINE Standard tools Special tools: – Pliers

449-2489

– Safety information / User information

1

Charge air line

2

Spring band clip

3

Spring band clip Ensure that the installation location is free from faults.

Position the spring band clip facing upwards in an easy to reach position.

3-54

TH255C

Disassembly and Assembly

3.19

COOLANT PUMP FASTENING PARTS Standard tools

– Safety information / User information

1

Torx screw, Torque to 30 Nm (22 ft-lb)

3.19.1

V-rib Belt Pulley Removal

1. Loosen screws (1).

2. Remove V-rib belt.

3. Unscrew screws (1).

4. Remove V-rib belt pulley.

3.19.2

V-rib Belt Pulley Installation

1. Mount V-rib belt pulley.

2. Tighten screws (1).

3. Position V-rib belt.

4. Tighten screws (1).

The procedure is the same for removing/installing a V-belt pulley.

TH255C

3-55

Disassembly and Assembly

3.20

THERMOSTAT TEST

3.20.1

Thermostat Test In Removed State

Standard tools: – Thermometer

Danger Risk of injury.

Hot water and hot thermostat.

1

Thermostat

2

O-ring

3

Outlet nozzle

4

Hexagon head screw

1. Measure beginning of stroke, dimension (a).

2. Note measured value, dimension (a).

3-56

TH255C

Disassembly and Assembly

3. Heat up the thermostat in the water bath.

4. Determine beginning of opening.

In order to determine the exact begining of opening, the temperature should be measured as close as possible to the thermostat.

Do not touch the thermostat.

5. Measure water temperature.

Nominal value: 99°C 6. Measure end of stroke, dimension (b).

7. Note measured value, dimension (b).

The water should be continuously stirred for an even temperature distribution. The temperature rise should not take place faster than 1°C/min. Otherwise the begining of opening will be delayed accordingly.

Nominal value: 86°C

8. Determine stroke.

TH255C

3-57

Disassembly and Assembly

Calculation Example

Desired:

Stroke

Given:

-

Measured:

Beginning of stroke, dimension (a) End of stroke, dimension (b)

Calculation:

Dimension (b) - dimension (a)

Result:

= stroke

9. Compare result with set point value.

Nominal value: 9 mm

3-58

TH255C

Disassembly and Assembly 3.20.2

Technical Data

Testing and setting data ID no.

Name

P38 11

Thermostat, beginning of opening

P38 13

Thermostat, stroke

P38 14

Thermostat, stroke, test temperature

TH255C

Additional information

Value

86°C at 99 , minimum

9 mm 99°C

3-59

Disassembly and Assembly

3.21

THERMOSTAT

3.21.1

Thermostat Removal

Standard tools

– Operation manual

Collect leaking operating substances in suitable vessels and dispose of according to regulations.

Observe the appropriate operating instructions for emptying and filling the engine.

1

Thermostat

2

O-ring

3

Outlet nozzle

4

Hexagon head screw

1. Drain, collect and dispose of coolant according to regulations.

2. If present: Remove coolant hose from outlet nozzle.

3. Unscrew screws (1).

4. Remove outlet nozzle (2).

3-60

TH255C

Disassembly and Assembly

5. Remove round sealing ring (1).

3. Clean sealing surfaces.

6. Remove thermostat (2).

4. Insert new O-ring (1).

7. Visually inspect the components.

8. Check thermostat. See Section 3.20, “Thermostat Test.”

3.21.2

Thermostat Installation

5. Mount thermostat housing (1).

6. Tighten screws (2).

7. Tighten screws (2).

13 Nm (10 ft-lb) 1. Clean sealing surfaces.

2. Insert thermostat (1).

8. If present: Push coolant hose onto outlet nozzle and fasten.

9. Fill cooling system according to the operating manual.

TH255C

3-61

Disassembly and Assembly 3.21.3

Technical Data

Tightening specifications ID no.

Name

A38 002 Outlet nozzle on thermostat housing

Screw type

Notes / Remark

Value

13 Nm (10 ft-lb)

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

3-62

TH255C

Disassembly and Assembly

3.22

EXHAUST GAS RECIRCULATION LINE Standard tools

– Safety information / User information

1

Pipe

3

Seal

5

Hexagon head screw, Torque to 20 Nm (15 ft-lb) Use new gaskets.

Attention

Check seal.

Ensure that the installation location is free from faults.

Install without tension (without torsional stresses) and do not pre-compress.

TH255C

3-63

Disassembly and Assembly

3.23

EXHAUST PIPE

3.23.1

Exhaust Line Removal

Standard tools

– Henkel C5-A Anti-Seize

– Safety information / User information

1

Exhaust line

2

Torx screw

3

Seal

1. Remove turbocharger. See Section 3.25, “Exhaust Gas Turbocharger.”

2. Remove the exhaust return pipe. See Section 3.25, “Exhaust Gas Turbocharger.”

3. Unscrew all screws (1).

4. Remove exhaust line (2).

5. Remove gasket (3).

3-64

TH255C

Disassembly and Assembly 3.23.2

Installing Exhaust Line

1. Clean sealing surfaces.

2. Mount gasket (1).

3. Mount exhaust line (2).

Note installation position.

4. Coat new screws with mounting compound.

6. Tighten all screws according to the tightening sequence.

55 Nm (41 ft-lb) 7. Install the turbocharger. See Section 3.25, “Exhaust Gas Turbocharger.”

8. Install the exhaust gas return pipe. See Section 3.25, “Exhaust Gas Turbocharger.”

5. Fasten all screws (3).

TH255C

3-65

Disassembly and Assembly 3.23.3

Technical Data

Tightening specifications ID no.

Name

A41 001 Exhaust line on cylinder head

Screw type

Notes / Remark

Observe tightening order Use new screws

Value

55 Nm (41 ft-lb)

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

3-66

TH255C

Disassembly and Assembly

3.24

FLUTTER VALVE

3.24.1

Flutter Valve Removal

Standard tools

– Ultra 5 Moly

– Safety information / User information

TH255C

1

Pipe

2

Flutter valve

3

Seal

4

Seal

5

Hexagon head screw

6

Housing

7

Cover

8

Hexagon head screw

3-67

Disassembly and Assembly

1. Unscrew screws (1).

4. Unscrew screws (1).

2. Remove pipe (2).

5. Remove cover (2).

3. Remove gaskets (3).

6. Remove flutter valve (1).

1. Unscrew screws (1).

2. Remove housing (2).

3. Remove gasket (3).

3-68

TH255C

Disassembly and Assembly 3.24.2

Flutter Valve Installation

1. Clean components.

4. Mount cover (1).

2. Insert sealing ring with mounting compound.

5. Tighten screws (2).

Ensure that the installation location is free from faults.

20 Nm (15 ft-lb)

6. Mount gasket (1).

3. Install flutter valves (1).

7. Mount housing (2).

8. Tighten screws (3).

20 Nm (15 ft-lb)

TH255C

3-69

Disassembly and Assembly

9. Mount gasket (1).

10. Mount pipe (3).

Attention

Ensure that the installation location is free from faults.

Install without tension (without torsional stresses) and do not pre-compress.

12. Mount gasket (1).

13. Tighten screws (2).

20 Nm (15 ft-lb)

Attention

Check seal.

11. Tighten screws (2).

20 Nm (15 ft-lb)

3-70

TH255C

Disassembly and Assembly 3.24.3

Technical Data

Tightening specifications ID no.

Name

Screw type

Notes / Remark

Value

A41 080 Line on charge air manifold/housing

20 Nm (15 ft-lb)

A41 082 Cover on housing

20 Nm (15 ft-lb)

A41 083

Housing on cooler (exhaust gas recirculation)

20 Nm (15 ft-lb)

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

TH255C

3-71

Disassembly and Assembly

3.25

EXHAUST GAS TURBOCHARGER

3.25.1

Turbocharger Removal

Standard tools Special tools: – Fitting tool – Assembly tool

449-2487

– Henkel C5-A Anti-Seize

– Safety information / User information

3-72

1

Exhaust turbocharger

2

Seal

3

Stud

4

Hexagonal nut

6

Lubricating oil line

7

Hollow screw

8

Sealing ring

10

Hexagon head screw

11

Hexagon head screw

12

Seal

13

Return line

14

O-ring

15

Fastening flange

16

O-ring

TH255C

Disassembly and Assembly

1. Removing the crankcase breather. See Section 3.2, “Crankcase Breather.”

2. Remove intake nozzle. See Section 3.16, “Exhaust Turbocharger Intake Nozzle.”

9. Remove gasket (1).

10. Unscrew studs (2).

3. Remove the charge air pipe. See Section 3.18, “Charge Air Line.”

4. Remove exhaust manifold. See Section 3.17, “Charge Air Manifold.”

5. Remove the lubricating oil line. See Section 3.26, “Lubricating Oil Line.”

6. Remove lubricating oil return line. See Section 3.27, “Lubricating Oil Return Line.”

7. Unscrew nuts (1).

8. Remove turbocharger (2).

11. Mount disassembly tool (1) on pin screw.

12. Unscrew pin screw in direction of the arrow.

TH255C

3-73

Disassembly and Assembly 3.25.2

Turbocharger Installation

1. Insert new pin bolts with mounting compound.

6. Mount turbocharger (1). See

2. Screw assembly tool (1) onto pin screws in direction of the arrow.

7. Turn on new nuts (2).

8. Tighten nuts (2).

21 Nm (15 ft-lb) 9. Install exhaust manifold. See Section 3.17, “Charge Air Manifold.”

10. Install lubricating oil line. See Section 3.26, “Lubricating Oil Line.”

11. Install lubricating oil return line. See Section 3.27, “Lubricating Oil Return Line.”

12. Fit intake nozzle. See Section 3.16, “Exhaust Turbocharger Intake Nozzle.”

13. Install the charge air pipe. See Section 3.18, “Charge Air Line.”

14. Install crankcase breather. See Section 3.2, “Crankcase Breather.”

3. Clean sealing surfaces.

4. Tighten pin bolts (1).

12 Nm (9 ft-lb) 5. Mount gasket (2).

3-74

TH255C

Disassembly and Assembly 3.25.3

Technical Data

Tightening specifications ID no.

Name

Screw type

Notes / Remark

Value

A43 021 Pin screws on exhaust line

Use new pin screws.

Insert using Henkel C5-A Anti-Seize mounting compound.

12 Nm (9 ft-lb)

A43 020 Exhaust turbocharger on exhaust line

Use new nuts

21 Nm (15 ft-lb)

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

TH255C

3-75

Disassembly and Assembly

3.26

LUBRICATING OIL LINE

3.26.1

Lubricating Oil Line Removal

Standard tools

– Safety information / User information

Collect leaking operating substances in suitable vessels and dispose of according to regulations.

Observe the appropriate operating instructions for emptying and filling the engine.

3-76

1

Exhaust turbocharger

2

Seal

3

Stud

4

Hexagonal nut

6

Lubricating oil line

7

Hollow screw

8

Sealing ring

10

Hexagon head screw

11

Hexagon head screw

12

Seal

13

Return line

14

O-ring

15

Fastening flange

16

O-ring

TH255C

Disassembly and Assembly

1. Remove holder. See Section 3.40, “Holder (Engine 441-9208).”

2. Unscrew hollow screw (1).

6. Remove lubricating oil line (1) in direction of arrow.

3.26.2

Lubricating Oil Line Installation

3. Remove sealing rings (2).

1. Clean sealing surfaces.

4. Unscrew hollow screw (1).

2. Mount lubricating oil line (1) in direction of arrow.

5. Remove sealing rings (2).

TH255C

3-77

Disassembly and Assembly

3. Mount sealing rings (1).

4. Screw on hollow screw (2).

9. Tighten hollow screw (1).

20 Nm (15 ft-lb)

Attention

Install tension-free.

10. Mount holder. See Section 3.40, “Holder (Engine 441-9208).”

5. Clean sealing surfaces.

6. Mount lubrication oil line (1).

7. Mount sealing rings (2).

8. Tighten hollow screw (3).

18 Nm (13 ft-lb)

Attention

Install tension-free.

3-78

TH255C

Disassembly and Assembly 3.26.3

Technical Data

Tightening specifications ID no.

Name

A43 047

Lubricating oil pipe on exhaust turbocharger

A43 048 Lubricating oil line on crankcase

Screw type

Notes / Remark

Value

Hollow screw Use new sealing rings

18 Nm (13 ft-lb)

Hollow screw Use new sealing rings

18 Nm (13 ft-lb)

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

TH255C

3-79

Disassembly and Assembly

3.27

LUBRICATING OIL RETURN LINE

3.27.1

Oil Return Line Removal

Standard tools Special tools: – Disassembly tool – Ultra 5 Moly

– Safety information / User information

Collect leaking operating substances in suitable vessels and dispose of according to regulations.

Observe the appropriate operating instructions for emptying and filling the engine.

3-80

1

Exhaust turbocharger

2

Seal

3

Stud

4

Hexagonal nut

6

Lubricating oil line

7

Hollow screw

8

Sealing ring

10

Hexagon head screw

11

Hexagon head screw

12

Seal

13

Return line

14

O-ring

15

Fastening flange

16

O-ring

TH255C

Disassembly and Assembly

1. Unscrew screws (1).

5. Remove flange (1) in direction of arrow.

2. Remove gasket (2).

6. Remove round sealing ring (2) with disassembly tool.

7. Visually inspect the component.

3. Unscrew screw (1).

4. Pull out oil return line (2) in direction of arrow.

8. Remove the O-ring (1) with the disassembly tool.

9. Visually inspect the component.

TH255C

3-81

Disassembly and Assembly 3.27.2

Oil Return Line Installation

1. Clean sealing surfaces.

8. Clean sealing surfaces.

2. Lightly coat new round sealing ring with Ultra 5 Moly mounting compound.

9. Mount oil return pipe (1).

10. Insert oil return line (1) in direction of arrow.

3. Insert new O-ring (1).

11. Fasten screw (2).

4. Clean sealing surfaces.

5. Lightly coat new round sealing ring with Ultra 5 Moly mounting compound.

6. Insert new O-ring (1).

7. Insert flange (2) in direction of arrow.

12. Clean sealing surfaces.

13. Mount gasket (1).

14. Mount oil return pipe (2).

15. Tighten screws (3).

8.5 Nm (6.2 ft-lb)

3-82

TH255C

Disassembly and Assembly

16. Tighten screw (1).

8.5 Nm (6.2 ft-lb)

Attention

Install tension-free.

TH255C

3-83

Disassembly and Assembly 3.27.3

Technical Data

Tightening specifications ID no.

Name

A43 044

Oil return line on exhaust turbocharger

A43 046 Oil return line on crankcase

Screw type

Notes / Remark

Value

8.5 Nm (6.2 ft-lb) 8.5 Nm (6.2 ft-lb)

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

3-84

TH255C

Disassembly and Assembly

3.28

V-BELT PULLEY (PARTS TO GENERATOR) Standard tools

– Safety information / User information

TH255C

1

V-belt pulley

2

V-belt

3-85

Disassembly and Assembly

3.29

GENERATOR PARTS Standard tools

– Safety information / User information

1

Generator Terminal B+, Torque to 7.5 - 8 Nm (5.5 - 5.9 ft-lb Terminal L, Torque to 2.7 - 3.8 Nm (1.9 - 2.8 ft-lb)

2

Voltage regulator, Torque to 4 Nm (3 ft-lb)

3

Fan

4

Spacing washer

5

Washer

6

Hexagonal nut Position 6

Attention

Observe tightening torque for V-rib belt pulley with clamping cone.

1. Hexagonal nut 90 Nm (66 ft-lb) 2. Hexagonal nut in conjunction with clamping cone and V-rib belt pulley.

75 Nm (55 ft-lb)

3-86

TH255C

Disassembly and Assembly

3.30

GENERATOR

3.30.1

Generator Removal

Standard tools

– Safety information / User information – Operation manual

1

Holding plate

2

Hexagon head screw

3

Hexagon head screw

4

Clamping strap

5

Hexagonal nut

1. Disconnect the battery's negative terminal.

2. Remove plus cable.

3. Pull out cable plug (1).

TH255C

3-87

Disassembly and Assembly

4. Loosen screws (1).

11. Unscrew screw (1).

5. Hold nut (2).

12. Remove clamping strap (2).

6. Unscrew screw (3).

13. Unscrew screws (3).

7. Swing generator (4) in direction of arrow.

14. Remove holding plate (4).

8. Remove the V-belt, V-belt pulley.

9. Unscrew screw (1).

10. Remove generator (2).

3-88

TH255C

Disassembly and Assembly 3.30.2

Generator Installation

8. Mount and tighten V-belt.

1. Mount clamping latch (1).

2. Fasten screw (2).

3. Mount holding plate (3).

4. Tighten screws (4).

30 Nm (22 ft-lb)

9. Hold nut (1).

10. Tighten screws (2).

60 Nm (44 ft-lb) 11. Tighten screw (3).

30 Nm (22 ft-lb) 12. Check V-belt tension.

5. Mount generator (1).

6. Tighten screws (2).

13. Plug in the cable plug (1).

7. Screw on nut (3).

14. Fit plus cable.

15. Connect the battery's negative terminal.

TH255C

3-89

Disassembly and Assembly 3.30.3

Technical Data

Tightening specifications ID no.

Name

A44 010 Holding plate on coolant pump A44 015

Generator on holding plate/clamping latch

A44 019 Clamping latch on coolant pump

Screw type

Notes / Remark

Value

30 Nm (22 ft-lb) 60 Nm (44 ft-lb) 30 Nm (22 ft-lb)

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

3-90

TH255C

Disassembly and Assembly

3.31

STARTER

3.31.1

Starter Removal

Standard tools

– Safety information / User information

1

Starter

2

Hexagon head screw

1. Remove holder. See Section 3.40, “Holder (Engine 441-9208).”

2. Disconnect the battery's negative terminal.

3. Remove plus cable.

4. Pull out cable plug (1).

5. Remove cable ties.

TH255C

3-91

Disassembly and Assembly 3.31.2

Starter Installation

6. Unscrew screws (1).

1. Insert starter (1).

7. Remove starter (2).

2. Tighten screws (2).

8. Visually inspect the components.

25 Nm (18 ft-lb)

3. Mount cable plug (1) and lock.

4. Tighten cable ties.

5. Fit plus cable.

6. Connect the battery's negative terminal.

7. Mount holder. See Section 3.40, “Holder (Engine 441-9208).”

3-92

TH255C

Disassembly and Assembly 3.31.3

Technical Data

Tightening specifications ID no.

Name

A44 001 Starter on gear case

Screw type

Notes / Remark

Value

25 Nm (18 ft-lb)

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

TH255C

3-93

Disassembly and Assembly

3.32

CABLE HARNESS FASTENING PARTS Standard tools

– Safety information / User information

3-94

1

Holder

2

Holding plate

3

Holding plate

4

Hexagon head screw, Torque to 60 Nm (44 ft-lb)

5

Hexagon head screw, Torque to 30 Nm (22 ft-lb)

6

Hexagon head screw, Torque to 30 Nm (22 ft-lb)

7

Spacer

TH255C

Disassembly and Assembly

3.33

CABLE HARNESS FASTENING PARTS (ENGINE 441-9208) Standard tools

– Safety information / User information

TH255C

1

Cable harness

2

Holding plate

3

Adapter

4

Cylinder head screw, Torque to 6 Nm (4 ft-lb)

5

Mounting bracket

6

Holder

7

Connector

8

Connector

9

Connector

10

Connector

11

Connector

12

Connector

13

Connector

14

Holding tape

15

Retaining clip

16

Holder

17

Spacer

18

Holding tape

19

Holding tape

20

Holding tape

3-95

Disassembly and Assembly

3.34

IMPULSE TRANSMITTER (CRANKSHAFT)

3.34.1

Impulse Transmitter Removal

Standard tools

– Safety information / User information

Attention

Ensure utmost cleanliness for all work.

Remove any paint residue and dirt particles before disassembly.

Clean the area around the components concerned carefully. Blow wet parts dry with compressed air.

Observe the safety regulations and national specifications for handling fuels.

Close all connections immediately after opening with new, clean plugs/caps.

Do not remove plugs/caps until immediately before assembling.

Collect leaking operating substances in suitable vessels and dispose of according to regulations.

1

Impulse transmitter

2

Hexagon head screw

3

O-ring

1. Unlock cable plug and remove.

2. Unscrew screw (1).

3. Remove impulse transmitter (2).

3-96

TH255C

Disassembly and Assembly 3.34.2

Impulse Transmitter Installation

4. Remove round sealing ring (1).

1. Clean contact surfaces.

5. Visually inspect the component.

2. Mount new O-ring (1).

3. Insert impulse transmitter (1).

4. Insert screw (2).

5. Tighten screw (2).

8.5 Nm (6.2 ft-lb) 6. Plug on cable plug.

Ensure that the connection is perfect.

TH255C

3-97

Disassembly and Assembly 3.34.3

Technical Data

Tightening specifications ID no.

Name

A51 011

Speed sensor (crankshaft) on front cover

Screw type

Notes / Remark

Use new round sealing ring.

Value

8.5 Nm (6.2 ft-lb)

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

3-98

TH255C

Disassembly and Assembly

3.35

TEMPERATURE SENSOR Standard tools

– Safety information / User information

1

TH255C

Temperature sensor, Torque to 25 Nm (18 ft-lb)

3-99

Disassembly and Assembly

3.36

OIL PRESSURE TRANSMITTER Standard tools: – Long socket wrench insert – Safety information / User information

1

Pressure sensor, Torque to 25 Nm (18 ft-lb)

2

O-ring Use new round sealing ring.

3-100

TH255C

Disassembly and Assembly

3.37

CONNECTION HOUSING

3.37.1

Connection Housing Removal

Standard tools

– Safety information / User information

1

Connection housing

2

Clamping pin

3

Hexagon head screw

1. Remove flywheel. See Section 3.4, “Flywheel.”

2. Unscrew screws (1).

3. Remove connection housing (2).

4. Visually inspect the component.

TH255C

3-101

Disassembly and Assembly 3.37.2

Connection Housing Installation

4. Tighten screws (1).

1. Clean contact surfaces.

Ensure that the clamping pins (1) are present.

5. Tighten all screws (1) alternately.

70 Nm (52 ft-lb) 6. Install flywheel. See Section 3.4, “Flywheel.”

2. Position connection housing (1).

3. Centre the connection housing with the clamping pins.

3-102

TH255C

Disassembly and Assembly 3.37.3

Technical Data

Tightening specifications ID no.

Name

A52 080 Connection housing on crankcase

Screw type

Notes / Remark

Tighten alternately

Value

70 Nm (52 ft-lb)

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

TH255C

3-103

Disassembly and Assembly

3.38

START-AID GLOW PLUGS

3.38.1

Glow Plugs Removal

Standard tools Special tools: – Assembly tool

02992357

– Safety information / User information

Attention

Ensure utmost cleanliness for all work.

Remove any paint residue and dirt particles before disassembly.

Clean the area around the components concerned carefully. Blow wet parts dry with compressed air.

Observe the safety regulations and national specifications for handling fuels.

Close all connections immediately after opening with new, clean plugs/caps.

Do not remove plugs/caps until immediately before assembling.

Collect leaking operating substances in suitable vessels and dispose of according to regulations.

1

Glow plug

1. Pull out plug (1).

3-104

TH255C

Disassembly and Assembly

2. Unscrew heating plugs (1) with assembly tool.

3. Visually inspect the components.

3.38.2

Glow Plugs Installation

3. Insert plug (1).

Attention

Ensure that the connection is perfect.

Ensure that the installation location is free from faults.

1. Screw in glow plugs (1).

Attention

Ensure that the installation location is free from faults.

2. Tighten glow plug (1) with assembly tool.

21 Nm (15 ft-lb)

TH255C

3-105

Disassembly and Assembly 3.38.3

Technical Data

Tightening specification ID no.

Name

A63 032 Glow plug on cylinder head

Screw type

Notes / Remark

Value

21 Nm (15 ft-lb)

For the tightening procedure according to torque using a torque wrench, a maximum variation of the tightening torque of +/- 10% is permissible.

3-106

TH255C

Disassembly and Assembly

3.39

EXHAUST GAS TREATMENT INLET MODULE (ENGINE 441-9208) Standard tools: – Industrial vacuum cleaner – Lifting gear – Carrying straps – Henkel C5-A Anti-Seize – Cleaning fleece – Marker pen, waterproof, permanent – Safety information / User information

Attention

The installation situation is application and equipment dependent.

Externally damaged parts must be renewed.

The documentation of the vehicle manufacturer/equipment manufacturer must be observed for disassembly and installation.

Dismantling and assembly should only be done in the vertical position.

All the help markings must be transferred when renewing/changing a part.

V-belt clips must be replaced each time they are loosened.

The gaskets must be disposed of properly and always renewed.

Danger

Use a new gasket.

Hot components.

Danger of burns.

Let the engine/components cool down sufficiently (to at least ambient temperature).

Use new sealing rings.

Do not carry out work when the engine is running.

When using hoists (workshop crane) the safety regulations for handling hoists must be observed.

It is not permitted to stay under moving loads.

Place the components on a level and secure surface.

Secure the components against tipping over.

Wear a respirator with at least protection class FFP2, goggles and protective gloves as protection against fine dust and soot particles.

Extract soot from the end faces with an industrial vacuum cleaner.

Do not blow compressed air onto soot-covered areas.

TH255C

3-107

Disassembly and Assembly

3. Clean sealing surfaces.

1

Inlet module

2

V-belt clip, Torque to 10 Nm (7.3 ft-lb)

3

Seal

4

Cap, Torque to 15 Nm (11 ft-lb)

1. Mark installation position.

2. Apply help markings.

Use a new gasket.

4. Coat surfaces (arrows) with mounting compound.

Attention

Make sure it is applied evenly and without gaps.

V-belt clip must be replaced each time it is loosened.

5. Perform leak test.

Attention

Ensure that the installation location is free from faults.

Make sure that the inlet module, outlet module, particle filter, V-belt clips and fastening points are reassembled in the same installation position.

Do not scratch or damage surfaces.

All the help markings must be transferred when renewing/changing a part.

Note flow direction.

The arrow indicates the flow direction.

3-108

TH255C

Disassembly and Assembly

3.40

HOLDER (ENGINE 441-9208) Standard tools

– Safety information / User information

Danger Hot components!

Danger of burns / explosion!

Let the engine / components cool down sufficiently (to at least ambient temperature).

Attention

Note installation position.

The installation situation is application and equipment-dependent.

The documentation of the vehicle manufacturer/equipment manufacturer must be observed for disassembly and installation.

Make sure that the inlet module, outlet module, particle filter, V-belt clips and fastening points are reassembled in the same installation position.

Do not scratch or damage surfaces.

Externally damaged parts must be renewed.

All the help markings must be transferred when renewing/changing a part.

V-belt clips must be replaced each time they are loosened.

The gaskets must be disposed of properly and always renewed.

TH255C

1

Holder

1

Screw, Torque to 12 Nm (9 ft-lb)

2

Clamping band

3-109

Disassembly and Assembly

3.41

ASSEMBLY MATERIAL COMPENSATOR STRUCTURE (ENGINE 441-9208) Standard tools

– Safety information / User information

Danger Hot components!

Danger of burns / explosion!

Let the engine / components cool down sufficiently (to at least ambient temperature).

Attention

Note installation position.

The installation situation is application and equipment dependent.

The documentation of the vehicle manufacturer/equipment manufacturer must be observed for disassembly and installation.

Externally damaged parts must be renewed.

V-belt clips must be replaced each time they are loosened.

The gaskets must be disposed of properly and always renewed.

3-110

1

Clip, Torque to 12 Nm (9 ft-lb)

2

Seal Use new gaskets.

Use new V-belt clips.

Attention

Ensure that the installation location is free from faults.

Check seal.

TH255C

Section 4 Special Tools

Contents PARAGRAPH 4.1

TH255C

TITLE

Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.1 Pump (P/N 449-2474) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.2 Assembly Pliers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.3 Measuring Device (P/N 449-2482) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.4 Torx Tool Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.5 Rotation Angle Disc (P/N 449-2484) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.6 Check Designation (P/N 449-2485) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.7 Fitting Tool (P/N 449-2487) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.8 Check Designation (P/N 449-2488) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.9 Pliers (P/N 449-2489) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.10 Socket Wrench Insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.11 Plug (P/N 449-2493) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.12 Assembly Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.13 Key (P/N 449-2496) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.14 Lever Tool (P/N 449-2497) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.15 Disassembly Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1.16 Assembly Device (P/N 449-2500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAGE 4-2 4-2 4-2 4-2 4-2 4-3 4-3 4-3 4-3 4-4 4-4 4-4 4-4 4-5 4-5 4-5 4-5

4-1

Special Tools

4.1

TOOLS

4.1.3

Measuring Device (P/N 449-2482)

Special tools: These must be ordered like a normal spare part by specifying the order number.

4.1.1

Pump (P/N 449-2474)

• 150 to 600 N • Check V-belt tension

4.1.4

Torx Tool Set

• Checking cooling system for leak-tightness.

4.1.2

Assembly Pliers

• Contents of case • Double-ended ring spanner E6/E8 • Double-ended ring spanner E10/E12 • Socket wrench insert E8 and E10 (1/4 inch) • Socket wrench insert E10 and E12 (3/8 inch) • Removing valve shaft seals.

4-2

• Socket wrench insert E18 (1/2 inch)

TH255C

Special Tools 4.1.5

Rotation Angle Disc (P/N 449-2484)

• With magnet • Setting valve clearance

4.1.6

4.1.7

Fitting Tool (P/N 449-2487)

• Disassemble pin screw (M8).

4.1.8

Check Designation (P/N 449-2488)

Check Designation (P/N 449-2485)

• Removing and installing valves • Removing rotary shaft lip seal

TH255C

4-3

Special Tools 4.1.9

Pliers (P/N 449-2489)

4.1.11

Plug (P/N 449-2493)

• 320 mm

• One set of differently-sized stoppers and caps.

• Tighten spring clamp.

• Sealing openings on the fuel system.

4.1.10

Socket Wrench Insert

• Long

4.1.12

Assembly Tool

• Mount pin screw (M8).

• Installing and removing pressure sensors. (rail pressure, oil pressure, fuel pressure)

4-4

TH255C

Special Tools 4.1.13

Key (P/N 449-2496)

• Wrench size 17, • Removing and installing high-pressure lines.

4.1.14

4.1.15

Disassembly Tool

• Removing O-ring.

4.1.16

Assembly Device (P/N 449-2500)

Lever Tool (P/N 449-2497)

• Installing crankshaft sealing ring (flywheel side).

• Removing the injector.

TH255C

4-5

Special Tools

This Page Intentionally Left Blank

4-6

TH255C

Section 5 Engine Electrical Schematic

Contents PARAGRAPH 5.1 5.2

TH255C

TITLE

Power Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Equipment Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAGE 5-2 5-3

5-1

Engine Electrical Schematic

5.1

5-2

POWER HARNESS

TH255C

Engine Electrical Schematic

5.2

TH255C

EQUIPMENT HARNESS

5-3

Engine Electrical Schematic

This Page Intentionally Left Blank

5-4

TH255C

Section 6 Wire Sensor Troubleshooting

PARAGRAPH 6.1 6.2 6.3

TH255C

TITLE

Engine Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Sensor Circuit Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Signal Wire Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAGE 6-2 6-3 6-4

6-1

Wire Sensor Troubleshooting

6.1

ENGINE SENSOR TEST

All Engine Sensors used in the EMR4 systems requires 5000 millivolts and ground. By testing the voltage at the sensor connector with the power on, the following can be determined.

• A reading above 5000 millivolts indicates a short to battery voltage.

• A reading below 5000 millivolts indicates a short to ground or open.

• A reading of 5000 millivolts indicates the power and ground wires are OK.

6-2

TH255C

Wire Sensor Troubleshooting

6.2

ENGINE SENSOR CIRCUIT TEST

All Engine Sensor Circuits used in the EMR4 system uses a pull-up resistor. By testing the voltage at the sensor connector with the power on, the following can be determined.

• A reading of 5000 millivolts indicates a short to voltage.

• A reading below 4800 millivolts indicates a short to ground or open.

• A reading of 4970 volts indicates that the signal wire is OK.

TH255C

6-3

Wire Sensor Troubleshooting

6.3

SIGNAL WIRE TEST

To test for a broken signal wire from the sensor to the ECU, a jumper wire can be installed from the ground terminal at the sensor connector to the signal wire at the same connector.

• If the circuit high fault code goes passive and a circuit low fault is produced, the signal wire is intact.

• If the circuit high fault code stays active, the signal wire is broken.

6-4

TH255C

Section 7 Diagnostics

PARAGRAPH 7.1

TH255C

TITLE

Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.1 KWP Code 45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.2 KWP Code 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.3 KWP Code 47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.4 KWP Code 84 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.5 KWP Code 85 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.6 KWP Code 88 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.7 KWP Code 89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.8 KWP Code 96 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.9 KWP Code 97 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.10 KWP Code 98 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.11 KWP Code 99 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.12 KWP Code 101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.13 KWP Code 121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.14 KWP Code 122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.15 KWP Code 291 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.16 KWP Code 292 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.17 KWP Code 305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.18 KWP Code 360 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.19 KWP Code 361 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.20 KWP Code 376 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.21 KWP Code 377 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.22 KWP Code 378 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.23 KWP Code 387 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.24 KWP Code 388 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.25 KWP Code 389 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.26 KWP Code 390 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.27 KWP Code 391 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.28 KWP Code 419 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.29 KWP Code 420 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.30 KWP Code 421 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.31 KWP Code 422 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.32 KWP Code 423 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.33 KWP Code 464 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.34 KWP Code 465 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.35 KWP Code 472 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.36 KWP Code 473 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.37 KWP Code 474 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.38 KWP Code 559 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7.1.39 KWP Code 560 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAGE 7-5 7-5 7-6 7-7 7-8 7-9 7-10 7-11 7-12 7-13 7-14 7-15 7-16 7-17 7-18 7-19 7-20 7-21 7-22 7-23 7-24 7-25 7-26 7-27 7-28 7-29 7-30 7-31 7-32 7-33 7-34 7-35 7-36 7-37 7-38 7-39 7-40 7-41 7-42 7-43

7-1

Diagnostics 7.1.40 7.1.41 7.1.42 7.1.43 7.1.44 7.1.45 7.1.46 7.1.47 7.1.48 7.1.49 7.1.50 7.1.51 7.1.52 7.1.53 7.1.54 7.1.55 7.1.56 7.1.57 7.1.58 7.1.59 7.1.60 7.1.61 7.1.62 7.1.63 7.1.64 7.1.65 7.1.66 7.1.67 7.1.68 7.1.69 7.1.70 7.1.71 7.1.72 7.1.73 7.1.74 7.1.75 7.1.76 7.1.77 7.1.78 7.1.79 7.1.80 7.1.81 7.1.82 7.1.83 7.1.84 7.1.85 7.1.86 7.1.87 7.1.88 7.1.89 7-2

KWP Code 561 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 562 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 565 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 566 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 567 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 568 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 569 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 570 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 571 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 580 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 581 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 582 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 583 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 592 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 594 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 595 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 596 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 597 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 612 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 613 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 614 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 615 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 616 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 617 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 618 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 619 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 620 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 621 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 624 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 625 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 627 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 628 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 637 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 732 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 733 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 736 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 737 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 747 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 752 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 776 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 777 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 825 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 826 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 827 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 828 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 829 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 830 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 831 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 832 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-44 7-45 7-46 7-47 7-48 7-49 7-50 7-51 7-52 7-53 7-54 7-55 7-56 7-57 7-58 7-59 7-60 7-61 7-62 7-63 7-64 7-65 7-66 7-67 7-68 7-69 7-70 7-71 7-72 7-73 7-74 7-75 7-76 7-77 7-78 7-79 7-80 7-81 7-82 7-83 7-84 7-85 7-86 7-87 7-88 7-89 7-90 7-91 7-92 7-93 TH255C

Diagnostics 7.1.90 7.1.91 7.1.92 7.1.93 7.1.94 7.1.95 7.1.96 7.1.97 7.1.98 7.1.99 7.1.100 7.1.101 7.1.102 7.1.103 7.1.104 7.1.105 7.1.106 7.1.107 7.1.108 7.1.109 7.1.110 7.1.111 7.1.112 7.1.113 7.1.114 7.1.115 7.1.116 7.1.117 7.1.118 7.1.119 7.1.120 7.1.121 7.1.122 7.1.123 7.1.124 7.1.125 7.1.126 7.1.127 7.1.128 7.1.129 7.1.130 7.1.131 7.1.132 7.1.133 7.1.134 7.1.135 7.1.136 7.1.137 7.1.138 7.1.139 TH255C

KWP Code 833 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 834 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 835 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 836 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 837 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 856 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 857 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 858 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 859 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 861 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 862 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 864 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 876 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 877 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 878 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 935 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 940 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 946 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 947 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 948 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 956 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 957 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 958 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 959 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 960 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 961 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 973 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 974 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 975 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 976 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 980 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 994 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 995 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 996 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 997 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 1014 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 1015 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 1016 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 1022 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 1023 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 1024 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 1025 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 1157 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 1170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 1180 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 1181 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 1223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 1224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 1226 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 1227 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-94 7-95 7-96 7-97 7-98 7-99 7-100 7-101 7-102 7-103 7-104 7-105 7-106 7-107 7-108 7-109 7-110 7-111 7-112 7-113 7-114 7-115 7-116 7-117 7-118 7-119 7-120 7-121 7-122 7-123 7-124 7-125 7-126 7-127 7-128 7-129 7-130 7-131 7-132 7-133 7-134 7-135 7-136 7-137 7-138 7-139 7-140 7-141 7-142 7-143 7-3

Diagnostics 7.1.140 7.1.141 7.1.142 7.1.143 7.1.144 7.1.145 7.1.146 7.1.147

7-4

KWP Code 1228 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 1229 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 1230 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 1231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 1232 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 1505 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 1669 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

KWP Code 1679 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-144 7-145 7-146 7-147 7-148 7-149 7-150 7-151

TH255C

Diagnostics

7.1

FAULT CODES

KWP Codes are displayed on the Sertia 2010 software.

SPN Codes are displayed on the display in the cab.

7.1.1

KWP Code 45

KWP CODE 45

SPN CODE 168

ERROR PATH BattUSRCMax

SPN GROUP

Vehicle Electrical Power 1

SPN NAME

FMI-NO.

FMI-INFO

3

COMPONENT

Battery Potential / Power Input 1 Voltage above normal or shorted high Battery voltage

Short Description • Battery voltage: the voltage measured by ECU is out of the target range, system reaction is initiated.

• Sensor error battery voltage; signal range check high, Battery voltage above warning threshold, Short cut to battery.

System Reaction • Warning : Error lamp shows permanent light. entry in the ECU fault memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Alternator defective.

• Connecting cable damaged.

Possible Consequence • Error lamp on, for permanent overvoltage, the ECU can be damaged.

Actions for Repair • Check wiring, • Check alternator, • Check cables and repair or replace if necessary.

TH255C

7-5

Diagnostics 7.1.2

KWP Code 46

KWP CODE 46

SPN CODE 168

ERROR PATH BattUSRCMin

SPN GROUP

Vehicle Electrical Power 1

SPN NAME

FMI-NO.

FMI-INFO

4

COMPONENT

Battery Potential / Power Input 1 Voltage below normal or shorted low Battery voltage

Short Description • Battery voltage: the voltage measured by ECU is out of the target range, system reaction is initiated.

• Sensor error battery voltage; signal range check low, Battery voltage below warning threshold, Short cut to ground.

System Reaction • Warning : Error lamp shows permanent light. entry in the ECU fault memory.

• Measurement in case of error : Not available.

Power Reduction • No reduction.

Possible Reason for Error • Alternator defective, connecting cable damaged.

Possible Consequence • Error lamp on, Engine can be shut off due to missing electric power.

Actions for Repair • Check wiring.

• Check alternator.

• Check cables and repair or replace if necessary.

7-6

TH255C

Diagnostics 7.1.3

KWP Code 47

KWP CODE 47

SPN CODE 168

SPN GROUP

Vehicle Electrical Power 1

FMI-NO.

ERROR PATH BattUSysReacMax SPN NAME FMI-INFO

2

COMPONENT

Battery Potential / Power Input 1 Data erratic, intermittent or incorrect Battery voltage

Short Description • Battery voltage: the voltage measured by ECU is out of the target range, system reaction is initiated.

• Battery voltage; system reaction initiated, Battery voltage above warning threshold.

System Reaction • Warning : Error lamp shows permanent light. entry in the ECU fault memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Alternator regulator defective.

• Diode in regulator defective.

• Damage in power harness.

Possible Consequence • Diagnostic lamp on, for permanent overvoltage, the ECU can be damaged.

Actions for Repair • Check alternator and if necessary replace it.

• Check connections and if neccessary renew the cable for power supply.

TH255C

7-7

Diagnostics 7.1.4

KWP Code 84

KWP CODE

SPN CODE 639

84 SPN GROUP FMI-NO.

Stop Start Broadcast

ERROR PATH BusDiagBusOffNodeA SPN NAME

J1939 Network #1, Primary Vehicle Network (previously SAE J1939 Data Link)

FMI-INFO

Special Instructions

COMPONENT

CAN Bus Controller

14

Short Description • CAN bus 0: the ECU is not allowed to send messages, because the status "BusOff" is detected.

• CAN-Bus 0 "BusOff-Status", CAN BusOff error; CAN 0 (Customer CAN).

System Reaction • Warning : Limp home speed if applicated.

• Error lamp shows permanent light. entry in the ECU fault memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Cable break or short circuit.

• Off-state (CAN bus 0), CAN bus deactivated.

• Connection cable damaged, terminal resisitors defect.

Possible Consequence • Diagnostic lamp on (if analog lamp), no damage on parts.

Actions for Repair • Check wiring of CAN bus and if necessary repair it.

• Check connection cable and if necessary repair or replace it.

• Check resistance in CAN lines (60 Ohm).

7-8

TH255C

Diagnostics 7.1.5

KWP Code 85

KWP CODE

SPN CODE 1231

85 SPN GROUP FMI-NO.

ERROR PATH BusDiagBusOffNodeB

Stop Start Broadcast

SPN NAME

J1939 Network #2

FMI-INFO

Special Instructions

COMPONENT

CAN Bus Controller

14

Short Description • CAN bus 1: the ECU is not allowed to send messages, because the status "BusOff" is detected.

• CAN-Bus 1 "BusOff-Status", CAN BusOff error; CAN 1 (engine/diagnostic CAN).

System Reaction • Warning : Error lamp shows permanent light. entry in the ECU fault memory.

• Measurement in case of error: Not available

Power Reduction • No reduction.

Possible Reason for Error • Cable break or short circuit.

• Off-state (CAN bus 1), CAN bus deactivated.

• Connection cable damaged, terminal resistors defect.

Possible Consequence • Diagnostic lamp on, no damage on further parts.

Actions for Repair • Check wiring of CAN bus and if necessary repair it • Check connection cable and if necessary repair or replace it.

• Check resistance in CAN lines (60 Ohm).

TH255C

7-9

Diagnostics 7.1.6

KWP Code 88

KWP CODE 88

SPN CODE 102

SPN GROUP

Inlet/Exhaust Conditions 1

FMI-NO.

ERROR PATH CACDsPSysReacMax SPN NAME

Engine Intake Manifold #1 Pressure

FMI-INFO

Data erratic, intermittent, or incorrect

2

COMPONENT

Charge air pressure sensor

Short Description • Charge air pressure messured by sensor is above the warning threshold.

• Charged air pressure; system reaction initiated, Charge air pressure above warning threshold.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Charge air pressure control not okay.

• Waste gate system on turbo charger not okay.

• Sensor gives out wrong values.

• Charge air cooler clogged.

• Blocked charge air pipes.

Possible Consequence • Diagnostic lamp on, engine can be damaged.

Actions for Repair • Check waste gate system if necessary replace TC. • Check CAC if all channels are clean.

• Check charge air piping if necessary clean or repair it.

7-10

TH255C

Diagnostics 7.1.7

KWP Code 89

KWP CODE 89

SPN CODE 102

SPN GROUP

Inlet/Exhaust Conditions 1

FMI-NO.

ERROR PATH CACDsPSysReacMin SPN NAME

Engine Intake Manifold #1 Pressure

FMI-INFO

Data erratic, intermittent, or incorrect

2

COMPONENT

Charge air pressure sensor

Short Description • Charge air pressure messured by sensor is above the shut off threshold.

• Charged air pressure; system reaction initiated, Charge air pressure above shut off threshold.

System Reaction • Warning : Shut off demand.

• Blinking light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Charge air pressure control not okay.

• Waste gate system on turbo charger not okay.

• Sensor gives out wrong values.

• Charge air cooler clogged.

• Blocked charge air pipes.

Possible Consequence • Diagnostic lamp on, engine can be damaged.

Actions for Repair • Check waste gate system if necessary replace TC. • Check CAC if all channels are clean.

• Check charge air piping if necessary clean or repair it.

TH255C

7-11

Diagnostics 7.1.8

KWP Code 96

KWP CODE

SPN CODE 110

96 SPN GROUP FMI-NO.

Engine Temperature 1

ERROR PATH CEngDsTSRCMax SPN NAME FMI-INFO

3

COMPONENT

Engine Coolant Temperature Voltage above normal or shorted high Coolant temperature sensor

Short Description • Coolant temperature sensor: the voltage of the sensor measured by ECU is out of the target range.

• Sensor error coolant temperature; signal range check high, Short cut to battery or open load.

System Reaction • Ramp to default value engine on (100° C) engine off (0° C).

• Permanent light, entry into error memory.

• Measurement in case of error: engine on (100° C) engine off (0° C).

Power Reduction • No reduction.

Possible Reason for Error • Cable break or short circuit,sensor defective.

• Connection cable damaged.

Possible Consequence • Diagnostic lamp on, reduced control for example engine cold start.

Actions for Repair • Check wiring, sensor defect.

• Check sensor and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

7-12

TH255C

Diagnostics 7.1.9

KWP Code 97

KWP CODE

SPN CODE 110

97 SPN GROUP FMI-NO.

Engine Temperature 1 4

ERROR PATH CEngDsTSRCMin SPN NAME FMI-INFO COMPONENT

Engine Coolant Temperature Voltage below normal or shorted low Coolant temperature sensor

Short Description • Coolant temperature sensor: the voltage of the sensor measured by ECU is out of the target range.

• Sensor error coolant temperature; signal range check low, Short cut to ground.

System Reaction • Ramp to default value engine on (100° C) engine off (0° C).

• Permanent light, entry into error memory.

• Measurement in case of error: engine on (100° C) engine off (0° C).

Power Reduction • No reduction.

Possible Reason for Error • Cable break or short circuit.

• Sensor defective • Connection cable damaged.

Possible Consequence • Diagnostic lamp on, reduced control for example engine cold start.

Actions for Repair • Check wiring, sensor defect.

• Check sensor and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

TH255C

7-13

Diagnostics 7.1.10

KWP Code 98

KWP CODE

SPN CODE 110

98 SPN GROUP FMI-NO.

Engine Temperature 1

ERROR PATH CEngDsTSysReacMax SPN NAME FMI-INFO

0

COMPONENT

Engine Coolant Temperature Data valid but above normal operational range Coolant temperature sensor

Short Description • Coolant temperature: the coolant temperature calculated by ECU is above the target range; the ECU activates a system reaction.

• Coolant temperature; system reaction initiated, Coolant temperature above warning threshold.

System Reaction • Warning : Power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: 111°C-118°C /100%-70%.

Power Reduction • 111°C-118°C /100%-70%.

Possible Reason for Error • Radiator is clogged.

• Fan system does not work proper.

• Coolant level too low, thermostat does not open.

Possible Consequence • Diagnostic lamp on, engine can be damaged.

Actions for Repair • Clean radiator.

• Check fan drive.

• Check coolant level.

• Check cooling system in general.

• Check thermostat function.

7-14

TH255C

Diagnostics 7.1.11

KWP Code 99

KWP CODE

SPN CODE 110

99 SPN GROUP FMI-NO.

ERROR PATH CEngDsTSysReacMin

Engine Temperature 1

SPN NAME FMI-INFO

0

COMPONENT

Engine Coolant Temperature Data valid but above normal operational range Coolant temperature sensor

Short Description • Coolant temperature: the coolant temperature calculated by ECU is above the target range; the ECU activates a system reaction.

• Coolant temperature; system reaction initiated, Coolant temperature above shut off threshold.

System Reaction • Warning : Power reduction + engine shut off demand.

• Blinking light, entry into error memory.

• Measurement in case of error: 111°C-118°C /100%-70%.

Power Reduction • 118°C / 70%.

Possible Reason for Error • Radiator is clogged.

• Fan system does not work proper.

• Coolant level too low, thermostat does not open.

Possible Consequence • Diagnostic lamp on, engine can be damaged.

Actions for Repair • Clean radiator.

• Check fan drive.

• Check coolant level.

• Check cooling system in general.

• Check thermostat function.

TH255C

7-15

Diagnostics 7.1.12

KWP Code 101

KWP CODE

SPN CODE 111

101 SPN GROUP FMI-NO.

ERROR PATH ClntLvSysReac

Engine Fluid Level/ Pressure 1

SPN NAME FMI-INFO

1

COMPONENT

Engine Coolant Level Data valid but below normal operational range Coolant temperature sensor

Short Description • Coolant level: the coolant level calculated by ECU is underneath the allowed minimum.

• Coolant level too low, Coolant level too low.

System Reaction • Warning : Power reduction + engine shut off demand.

• Blinking light, entry into error memory.

• Measurement in case of error: actual value.

Power Reduction • Not available.

Possible Reason for Error • Coolant level too low.

• Leakage in cooling system.

• Sensor defective.

• Wiring damaged.

Possible Consequence • Diagnostic lamp on, engine can be damaged.

Actions for Repair • Check coolant level.

• Inspect cooling system for leakage and if necessary repair it.

• Check sensor and wiring.

7-16

TH255C

Diagnostics 7.1.13

KWP Code 121

KWP CODE

SPN CODE 1109

121 SPN GROUP FMI-NO.

ERROR PATH CoEngShOffDemIgr

Shutdown

SPN NAME FMI-INFO

2

COMPONENT

Engine Protection System Approaching Shutdown Data erratic, intermittent, or incorrect Supervisor Monitoring

Short Description • Request of engine shut off: the operator ignors the engine shut off request within an allowed period.

• Engine shut off demand ignored, Engine Shut Off demand has been ignored by the user.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: actual value.

Power Reduction • No reduction.

Possible Reason for Error • Shut-off request due to an critical system error has been ignored by operator.

Possible Consequence • Diagnostic lamp on.

Actions for Repair • Warranty relevant Additional error must be set: • Charge air temperature.

• Coolant temperature.

• Coolant level.

• Fuel pressure.

• Oil pressure.

• PRV open.

TH255C

7-17

Diagnostics 7.1.14

KWP Code 122

KWP CODE

SPN CODE 523698

122 SPN GROUP FMI-NO.

Not Available

ERROR PATH CoEngSpvsShOff SPN NAME FMI-INFO

11

COMPONENT

Manufacturer Assignable SPN Not Available Supervisor Monitoring

Short Description • Shut off request from supervisory monitoring function.

• Shut off request from supervisory monitoring function, Engine Shut Off due to supervisory function.

System Reaction • Engine Shut off.

• Blinking light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Critical system error is active.

Possible Consequence • Diagnostic lamp blinking.

Actions for Repair • Warranty relevant, Additional error must be set: • Charge air temperature.

• Coolant temperature.

• Coolant level.

• Fuel pressure.

• Oil pressure.

• PRV open.

7-18

TH255C

Diagnostics 7.1.15

KWP Code 291

KWP CODE

SPN CODE 523776

291 SPN GROUP FMI-NO.

Not Available

ERROR PATH ComTOTSC1TEAct SPN NAME

Manufacturer Assignable SPN

FMI-INFO

Not Available

COMPONENT

CAN message

9

Short Description • Missing message TSC1-TE. • Timeout Error of CAN-Receive-Frame TSC1TE active, Timeout Error (Missing CAN Bus message).

System Reaction • Warning: Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • CAN bus wrong cabled.

• Wiring is damaged.

• Receiver (sender of the message) work inaccurately, parametering inaccurate.

Possible Consequence • Diagnostic lamp on, Limp home speed activated.

Actions for Repair • Check CAN Bus wiring (Bus scheduling, polarity, short circuit, power interrupt).

• Test protocol of receiver.

• Check CAN functional range.

• Check actuator.

TH255C

7-19

Diagnostics 7.1.16

KWP Code 292

KWP CODE

SPN CODE 523777

292 SPN GROUP FMI-NO.

Not Available

ERROR PATH ComTOTSC1TEPas SPN NAME

Manufacturer Assignable SPN

FMI-INFO

Not Available

COMPONENT

CAN message

9

Short Description • Message TSC1-TE has been missing (passive).

• Passive Timeout Error of CAN-Receive-Frame TSC1TE; Setpoint, Passive timeout Error (Missing CAN Bus message).

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • CAN bus wrong cabled, wiring is damaged, receiver (sender of the message) work inaccurately, parametering inaccurate.

Possible Consequence • Diagnostic lamp on, Limp home speed activated.

Actions for Repair • Check CAN Bus wiring (Bus scheduling, polarity, short circuit, power interrupt).

• Test protocol of receiver.

• Check CAN functional range.

• Check actuator.

7-20

TH255C

Diagnostics 7.1.17

KWP Code 305

KWP CODE

SPN CODE 898

305 SPN GROUP FMI-NO.

Torque/Speed Control 1

ERROR PATH ComTSC1TETO SPN NAME FMI-INFO

9

COMPONENT

Engine Requested Speed/Speed Limit Abnormal update rated CAN message

Short Description • Missing message TSC1-TE. • Timeout Error of CAN-Receive-Frame TSC1TE; Setpoint, Timeout Error (Missing CAN Bus message)

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction

Possible Reason for Error • CAN bus wrong cabled.

• Wiring is damaged.

• Receiver (sender of the message) work inaccurately, parametering inaccurate

Possible Consequence • Diagnostic lamp on, Limp home speed activated

Actions for Repair • Check CAN Bus wiring (Bus sheduling, polarity, short circuit, power interrupt) • Test protocol of receiver • Check CAN functional range • Check actuator

TH255C

7-21

Diagnostics 7.1.18

KWP Code 360

KWP CODE

SPN CODE 523982

306 SPN GROUP FMI-NO.

Not Available

ERROR PATH DevLibBattUHi SPN NAME

Manufacturer Assignable SPN

FMI-INFO

Not Available

COMPONENT

Device Library

0

Short Description • Powerstage diagnosis disabled; high battery voltage • Powerstage diagnosis disabled; high battery voltage, Powerstage diagnostic can be deactivated due to too high battery voltage.

System Reaction • Warning : Permanent light, entry into error memory • Measurement in case of error: Not available

Power Reduction • No reduction

Possible Reason for Error • Alternator defective.

• Connecting cable damaged.

Possible Consequence • Diagnostic lamp on.

Actions for Repair • Check wiring.

• Check alternator.

• Check cables and repair or replace if necessary.

7-22

TH255C

Diagnostics 7.1.19

KWP Code 361

KWP CODE

SPN CODE 523982

361 SPN GROUP FMI-NO.

Not Available

ERROR PATH DevLibBattULo SPN NAME

Manufacturer Assignable SPN

FMI-INFO

Not Available

COMPONENT

Device Library

1

Short Description • Powerstage diagnosis disabled; low battery voltage.

• Powerstage diagnosis disabled; low battery voltage, Powerstage diagnostic can be deactivated due to too low battery voltage.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Alternator defective.

• Connecting cable damaged.

Possible Consequence • Diagnostic lamp on

Actions for Repair • Check wiring.

• Check alternator.

• Check cables and repair or replace if necessary.

TH255C

7-23

Diagnostics 7.1.20

KWP Code 376

KWP CODE

SPN CODE 630

376 SPN GROUP FMI-NO.

Not Available

ERROR PATH EEPEraseErr SPN NAME FMI-INFO

12

COMPONENT

Calibration Memory Bad intelligent device or component Hardware monitoring EEPROM

Short Description • Internal hardware monitoring: the ECU finds an error during the access to its EEPROM memory or works with an alternative value.

• Access error EEPROM, Section could not be erased.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Error during EEPROM memory access or EEPROM works with substitute value.

• Programming error.

• ECU defective.

Possible Consequence • Diagnostic lamp on.

Actions for Repair • If not programmed, EEPROM is defect.

• ECU is defect, reprogramm ECU and if necessary replace it.

7-24

TH255C

Diagnostics 7.1.21

KWP Code 377

KWP CODE

SPN CODE 630

377 SPN GROUP FMI-NO.

Not Available

ERROR PATH EEPRdErr SPN NAME FMI-INFO

12

COMPONENT

Calibration Memory Bad intelligent device or component Hardware monitoring EEPROM

Short Description • Internal hardware monitoring: the ECU finds an error during the access to its EEPROM memory or works with an alternative value.

• Access error EEPROM, Minimum 3 blocks could not be readed.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Error during EEPROM memory access or EEPROM works with substitute value.

• Programming error.

• ECU defective.

Possible Consequence • Diagnostic lamp on.

Actions for Repair • If not programmed, EEPROM is defect.

• ECU is defect, reprogramm ECU and if necessary replace it.

TH255C

7-25

Diagnostics 7.1.22

KWP Code 378

KWP CODE

SPN CODE 630

378 SPN GROUP FMI-NO.

Not Available

ERROR PATH EEPWrErr SPN NAME FMI-INFO

12

COMPONENT

Calibration Memory Bad intelligent device or component Hardware monitoring EEPROM

Short Description • Internal hardware monitoring: the ECU finds an error during the access to it's EEPROM memory or works with an alternative value.

• Access error EEPROM, Block could not be written for minimum 3 times.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Error during EEPROM memory access or EEPROM works with substitute value.

• Programming error.

• ECU defective.

Possible Consequence • Diagnostic lamp on.

Actions for Repair • If not programmed, EEPROM is defect.

• ECU is defect, reprogramm ECU and if necessary replace it.

7-26

TH255C

Diagnostics 7.1.23

KWP Code 387

KWP CODE

SPN CODE 523612

387 SPN GROUP FMI-NO.

ERROR PATH EngICO

Not Available

SPN NAME FMI-INFO

12

COMPONENT

Manufacturer Assignable SPN Bad intelligent device or component Engine Injection Cut Off

Short Description • Internal hardware monitoring: the CPU of the ECU is reset and the cause is logged internally; no item will be created in error memory.

• Internal software error ECU, Injector shut off demand for the ICO coordinator.

System Reaction • Warning : Blinking light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • A recovery occurred which is stored as protected.

Possible Consequence • Diagnostic lamp on.

Actions for Repair • Sequence error.

• Check error memory for other errors.

TH255C

7-27

Diagnostics 7.1.24

KWP Code 388

KWP CODE

SPN CODE 190

388 SPN GROUP FMI-NO.

Electronic Engine Controller 1

ERROR PATH EngPrtOvrSpd SPN NAME FMI-INFO

0

COMPONENT

Engine Speed Data valid but above normal operational range Engine protection

Short Description • Engine speed: The engine speed calculated by ECU is above the target range; the ECU activates a system reaction.

• Engine speed above warning threshold (FOC-Level 1).

• Overspeed monitoring (Engine speed was over MoFOvR_nSpdGovLim_C = 2750 rpm).

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Engine overspeed detected with system reaction, maximum engine speed exceeded.

Possible Consequence • Diagnostic lamp on.

Actions for Repair • Check powertrain settings regarding overspeed

7-28

TH255C

Diagnostics 7.1.25

KWP Code 389

KWP CODE

SPN CODE 190

389 SPN GROUP FMI-NO.

Electronic Engine Controller 1

ERROR PATH EngPrtSysReacFOC1 SPN NAME FMI-INFO

0

COMPONENT

Engine Speed Data valid but above normal operational range Engine protection

Short Description • Engine speed: the engine speed calculated by ECU is above the target range; the ECU activates a system reaction.

• Engine speed above warning threshold (FOC-Level 1).

• Overspeed monitoring during 1 level of FOC (Failure overrun condition), if engine speed was over EngPrt_nEnaFOCWarn_C = 2774rpm.

System Reaction • Warning : Blinking light, entry into error memory • Measurement in case of error: Not available

Power Reduction • No reduction.

Possible Reason for Error • Engine overspeed detected with system reaction, maximum engine speed exceeded.

Possible Consequence • Diagnostic lamp on.

Actions for Repair • Check powertrain settings regarding overspeed.

TH255C

7-29

Diagnostics 7.1.26

KWP Code 390

KWP CODE

SPN CODE 190

390 SPN GROUP FMI-NO.

Electronic Engine Controller 1

ERROR PATH EngPrtSysReacFOC2 SPN NAME FMI-INFO

11

COMPONENT

Engine Speed Failure mode not identifiable Engine protection

Short Description • Engine speed: the engine speed calculated by ECU is above the target range; the ECU activates a system reaction.

• Engine speed above warning threshold (FOC-Level 2).

• Overspeed monitoring during 2 level of FOC (Failure overrun condition). If engine speed was over EngPrt_nEnaFOCShOff_C = 2860rpm.

System Reaction • Warning : Blinking light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Engine overspeed detected with system reaction, maximum engine speed exceeded.

Possible Consequence • Diagnostic lamp on.

Actions for Repair • Check powertrain settings regarding overspeed.

7-30

TH255C

Diagnostics 7.1.27

KWP Code 391

KWP CODE

SPN CODE 190

391 SPN GROUP FMI-NO.

Electronic Engine Controller 1

ERROR PATH EngPrtSysReacORC SPN NAME FMI-INFO

14

COMPONENT

Engine Speed Special Instructions Engine protection

Short Description • Engine speed: the engine speed calculated by ECU is above the target range; the ECU activates a system reaction.

• Speed detection; out of range, signal disrupted, Overspeed monitoring during ORC (Override conditions) if engine speed was over EngPrt_nEnaORC_C = 2774rpm.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Engine overspeed detected with system reaction, maximum engine speed exceeded.

Possible Consequence • Diagnostic lamp on.

Actions for Repair • Check powertrain settings regarding overspeed.

TH255C

7-31

Diagnostics 7.1.28

KWP Code 419

KWP CODE

SPN CODE 190

419 SPN GROUP FMI-NO.

Electronic Engine Controller 1

ERROR PATH EpmCaSI1ErrSig SPN NAME FMI-INFO

8

COMPONENT

Engine Speed Abnormal frequency, pulse width or period Camshaft sensor

Short Description • Camshaft speed sensor: the ECU receives no signal and uses the signal from crankshaft speed sensor as alternative to calculate the engine speed.

• Speed detection; out of range, signal disrupted, Erratic signal.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Engine running only with crankshaft speed signal, transmitter defective.

• Cable connection damaged.

• Shielding of wiring broken.

Possible Consequence • Diagnostic lamp on, emission regulations are not kept.

Actions for Repair • Check wiring of camshaft sensor.

• Check camshaft sensor and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

7-32

TH255C

Diagnostics 7.1.29

KWP Code 420

KWP CODE

SPN CODE

420

190

SPN GROUP FMI-NO.

Electronic Engine Controller 1

ERROR PATH EpmCaSI1NoSig SPN NAME FMI-INFO

12

COMPONENT

Engine Speed Bad intelligent device or component Camshaft sensor

Short Description • Camshaft speed sensor: the ECU receives no signal and uses the signal from camshaft speed sensor as alternative to calculate the engine speed.

• Speed detection; out of range, signal disrupted, Missing signal.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Engine running only with camshaft speed signal, transmitter defective.

• Cable connection damaged.

• Shielding of wiring broken.

Possible Consequence • Diagnostic lamp on, emission regulations are not kept.

Actions for Repair • Check wiring of crankshaft sensor.

• Check crankshaft sensor and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

TH255C

7-33

Diagnostics 7.1.30

KWP Code 421

KWP CODE

SPN CODE

421

190

SPN GROUP FMI-NO.

Electronic Engine Controller 1

ERROR PATH EpmCaSI1OfsErr SPN NAME FMI-INFO

2

COMPONENT

Engine Speed Data erratic, intermittent, or incorrect Camshaft sensor

Short Description • ECU measures a deviation between camshaft and crankshaft angle to target.

• Offset angle between crank- and camshaft sensor is too large, Offset error between crankshaft and camshaft.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Increment wheel angle manipulated.

• Dirt between speed sensor and increment wheel.

• Sensor position manipulated.

• Wrong setting in dataset.

Possible Consequence • Diagnostic lamp on, emission regulations are not kept.

Actions for Repair • Check increment wheel position.

• Clean and adjust if necessary.

• Check sensor postition, reflash datset with SerDia 2010.

7-34

TH255C

Diagnostics 7.1.31

KWP Code 422

KWP CODE

SPN CODE

422

190

SPN GROUP FMI-NO.

Electronic Engine Controller 1

ERROR PATH EpmCrSErrSig SPN NAME FMI-INFO

8

COMPONENT

Engine Speed Abnormal frequency, pulse width or period Crankshaft sensor

Short Description • Sensor crankshaft speed; disturbed signal.

• Speed detection; out of range, signal disrupted, Missing signal.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Connecting cable damaged, sensor defective.

Possible Consequence • Diagnostic lamp on, emission regulations are not kept, engine can be damaged.

Actions for Repair • Check wiring.

• Check cables and repair or replace if necesary, • Check sensor and if necessary replace it.

TH255C

7-35

Diagnostics 7.1.32

KWP Code 423

KWP CODE

SPN CODE

423

190

SPN GROUP FMI-NO.

Electronic Engine Controller 1

ERROR PATH EpmCrSNoSig SPN NAME FMI-INFO

12

COMPONENT

Engine Speed Bad intelligent device or component Crankshaft sensor

Short Description • Crankshaft speed sensor: the ECU receives no signal and uses the signal from camshaft speed sensor as alternative to calculate the engine speed.

• Speed detection; out of range, signal disrupted, Missing signal.

System Reaction.

• Warning : Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Engine running only with cam-shaft speed signal, transmitter defective, connection cable damaged.

Possible Consequence • Diagnostic lamp on, emission regulations are not kept, engine can be damaged.

Actions for Repair • Check wiring of crankshaft sensor.

• Check crankshaft sensor and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

7-36

TH255C

Diagnostics 7.1.33

KWP Code 464

KWP CODE

SPN CODE

464

97

SPN GROUP FMI-NO.

Water in Fuel Indicator 3

ERROR PATH FlFWLvlSRCMax SPN NAME FMI-INFO COMPONENT

Water In Fuel Indicator Voltage above normal or shorted high Water level sensor / Fuel pre filter

Short Description • Fuel filter water level sensor: the voltage of sensor measured by ECU is out of the target range.

• Sensor error water in fuel; signal range check high, Short cut to battery or open load.

System Reaction • Default value (5000mV).

• Permanent light, entry into error memory.

• Measurement in case of error: 5000mV.

Power Reduction • No reduction

Possible Reason for Error • Cable break or short circuit, sensor defective, connection cable damaged.

Possible Consequence • Diagnostic lamp on.

Actions for Repair • Check wiring, if sensor is not working, • Check sensor and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

TH255C

7-37

Diagnostics 7.1.34

KWP Code 465

KWP CODE

SPN CODE

465

97

SPN GROUP FMI-NO.

Water in Fuel Indicator 4

ERROR PATH FlFWLvlSRCMin SPN NAME FMI-INFO COMPONENT

Water In Fuel Indicator Voltage below normal or shorted low Water level sensor / Fuel pre filter

Short Description • Fuel filter water level sensor: the voltage of sensor measured by ECU is out of the target range.

• Sensor error water in fuel; signal range check low, Short cut to ground.

System Reaction • Default value (5000mV).

• Permanent light, entry into error memory.

• Measurement in case of error: 5000mV.

Power Reduction • No reduction.

Possible Reason for Error • Cable break or short circuit, sensor defective, connection cable damaged.

Possible Consequence • Diagnostic lamp on.

Actions for Repair • Check wiring, if sensor is not working.

• Check sensor and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

7-38

TH255C

Diagnostics 7.1.35

KWP Code 472

KWP CODE

SPN CODE

472

94

SPN GROUP FMI-NO.

Engine Fluid Level/ Pressure 1 3

ERROR PATH FuelPSRCMax SPN NAME FMI-INFO COMPONENT

Engine Fuel Delivery Pressure Voltage above normal or shorted high Fuel low pressure sensor

Short Description • Low fuel pressure sensor: the voltage of sensor measured by ECU is out of the target range.

• Sensor error low fuel pressure; signal range check high, Short cut to battery or open load.

System Reaction • Ramp to default value (5000hPa).

• Permanent light, entry into error memory.

• Measurement in case of error: 5000hPa.

Power Reduction • No reduction.

Possible Reason for Error • Cable break or short circuit, sensor defective, connection cable damaged.

Possible Consequence • Diagnostic lamp on.

Actions for Repair • Check wiring, if sensor not working.

• Check sensor and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

TH255C

7-39

Diagnostics 7.1.36

KWP Code 473

KWP CODE

SPN CODE

473

94

SPN GROUP FMI-NO.

Engine Fluid Level/ Pressure 1 4

ERROR PATH FuelPSRCMin SPN NAME FMI-INFO COMPONENT

Engine Fuel Delivery Pressure Voltage below normal or shorted low Fuel low pressure sensor

Short Description • Low fuel pressure sensor: the voltage of sensor measured by ECU is out of the target range.

• Sensor error low fuel pressure; signal range check low, Short cut to ground.

System Reaction • Ramp to default value (5000hPa).

• Permanent light, entry into error memory.

• Measurement in case of error: 5000hPa.

Power Reduction • No reduction.

Possible Reason for Error • Cable break or short circuit.

• Sensor defective.

• Connection cable damaged.

Possible Consequence • Diagnostic lamp on.

Actions for Repair • Check wiring, if sensor not working.

• Check sensor and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

7-40

TH255C

Diagnostics 7.1.37

KWP Code 474

KWP CODE

SPN CODE

474

94

SPN GROUP FMI-NO.

ERROR PATH FuelPSysReacMax

Engine Fluid Level/ Pressure 1

SPN NAME FMI-INFO

1

COMPONENT

Engine Fuel Delivery Pressure Data valid but below normal operational range Fuel low pressure sensor

Short Description • Low fuel pressure: the low fuel pressure calculated

by ECU is underneath the target range; the ECU activates a system reaction.

• Low fuel pressure; system reaction initiated, Fuel pressure below warning threshold.

System Reaction • Warning : Power reduction + engine shut off demand.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 100%

Possible Reason for Error • Fuel tank is empty, fuel filter is blocked or dirty, fuel pump, relay or fuse is defective.

Possible Consequence • Diagnostic lamp on.

Actions for Repair • Check low fuel pressure system (fuel feed pump, relay , fuse, wiring, sensor) and if necessary repair or replace it.

TH255C

7-41

Diagnostics 7.1.38

KWP Code 559

KWP CODE

SPN CODE

559

523895

SPN GROUP FMI-NO.

Not Available

ERROR PATH IVAdjDiaIVAdj_0 SPN NAME FMI-INFO

13

COMPONENT

Manufacturer Assignable SPN Not Available Injector diagnosis

Short Description • Missing or wrong injector adjustment value programming (IMA) injector 1.

• Check of missing injector adjustment value programming (IMA) injector 1 (in firing order), Missing or wrong parametrisation of injector adjustment cyl. 1.

System Reaction • Warning : Errorlamp shows permanent light. Entry in error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Dataset not valid or does not match to installed injector.

Possible Consequence • Diagnostic lamp on, emission regulations are not kept, engine can be damaged.

Actions for Repair • Check dataset and flash correct injector adjustement value (IMA). Use SERDIA UseCase to check it.

7-42

TH255C

Diagnostics 7.1.39

KWP Code 560

KWP CODE

SPN CODE

560

523896

SPN GROUP FMI-NO.

Not Available

ERROR PATH IVAdjDiaIVAdj_1 SPN NAME FMI-INFO

13

COMPONENT

Manufacturer Assignable SPN Not Available Injector diagnosis

Short Description • Missing or wrong injector adjustment value programming (IMA) injector 3.

• Check of missing injector adjustment value programming (IMA) injector 2 (in firing order), Missing or wrong parametrisation of injector adjustment cyl. 3.

System Reaction • Warning : Errorlamp shows permanent light. Entry in error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Dataset not valid or does not match to installed injector.

Possible Consequence • Diagnostic lamp on, emission regulations are not kept, engine can be damaged.

Actions for Repair • Check dataset and flash correct injector adjustement value (IMA).

• Use SERDIA UseCase to check it.

TH255C

7-43

Diagnostics 7.1.40

KWP Code 561

KWP CODE

SPN CODE

561

523897

SPN GROUP FMI-NO.

ERROR PATH IVAdjDiaIVAdj_2

Not Available

SPN NAME FMI-INFO

13

COMPONENT

Manufacturer Assignable SPN Not Available Injector diagnosis

Short Description • Missing or wrong injector adjustment value programming (IMA) injector 4.

• Check of missing injector adjustment value programming (IMA) injector 3 (in firing order), Missing or wrong parametrisation of injector adjustment cyl. 4

System Reaction • Warning : Errorlamp shows permanent light.

Entry in error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Dataset not valid or does not match to installed injector.

Possible Consequence • Diagnostic lamp on, emission regulations are not kept, engine can be damaged.

Actions for Repair • Check dataset and flash correct injector adjustement value (IMA).

• Use SERDIA. • Use Case to check it..

7-44

TH255C

Diagnostics 7.1.41

KWP Code 562

KWP CODE

SPN CODE

562

523898

SPN GROUP FMI-NO.

ERROR PATH IVAdjDiaIVAdj_3

Not Available

SPN NAME FMI-INFO

13

COMPONENT

Manufacturer Assignable SPN Not Available Injector diagnosis

Short Description • Missing or wrong injector adjustment value programming (IMA) injector 2.

• Check of missing injector adjustment value programming (IMA) injector 4 (in firing order), Missing or wrong parametrisation of injector adjustment cyl. 2.

System Reaction • Warning : Errorlamp shows permanent light.

Entry in error memory.

• Measurement in case of error: Not available

Power Reduction • No reduction.

Possible Reason for Error • Dataset not valid or does not match to installed injector

Possible Consequence • Diagnostic lamp on, emission regulations are not kept, engine can be damaged

Actions for Repair • Check dataset and flash correct injector adjustement value (IMA).

• Use SERDIA. • UseCase to check it.

TH255C

7-45

Diagnostics 7.1.42

KWP Code 565

KWP CODE

SPN CODE

565

523350

SPN GROUP FMI-NO.

ERROR PATH IVDiaBnkShCir_0

Not Available

SPN NAME FMI-INFO

4

COMPONENT

Manufacturer Assignable SPN Voltage below normal or shorted low Injector diagnosis

Short Description • Injector cylinder bank 1: the current drop measured

by ECU is above the target range.

• Injector cylinder-bank 1; short circuit, Short circuit injection bank 1 (all injectors of this bank can be affected).

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Actual value.

Power Reduction • No reduction.

Possible Reason for Error • Short circuit (cylinder bank 1), injector defective, connection cable damaged.

Possible Consequence • Diagnostic lamp on, emission regulations are not kept, engine can be damaged.

Actions for Repair • Check wiring.

• Check injectors and if necessary replace them.

• Check connection cable and if necessary repair or replace it.

7-46

TH255C

Diagnostics 7.1.43

KWP Code 566

KWP CODE

SPN CODE

566

523352

SPN GROUP FMI-NO.

ERROR PATH IVDiaBnkShCir_1

Not Available

SPN NAME FMI-INFO

4

COMPONENT

Manufacturer Assignable SPN Voltage below normal or shorted low Injector bank diagnosis

Short Description • Injector cylinder bank 2: the current drop measured

by ECU is above the target range.

• Injector cylinder-bank 2; short circuit, Short circuit injection bank 2 (all injectors of this bank can be affected).

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: actual value.

Power Reduction • No reduction

Possible Reason for Error • Short circuit (cylinder bank 2), • Injector defective.

• Connection cable damaged.

Possible Consequence • Diagnostic lamp on, emission regulations are not kept, engine can be damaged.

Actions for Repair • Check wiring.

• Check injectors and if necessary replace them.

• Check connection cable and if necessary repair or replace it.

TH255C

7-47

Diagnostics 7.1.44

KWP Code 567

KWP CODE

SPN CODE

567

523354

SPN GROUP FMI-NO.

ERROR PATH IVDiaChp_0

Not Available

SPN NAME FMI-INFO

12

COMPONENT

Manufacturer Assignable SPN Bad intelligent device or component Injector chip diagnosis

Short Description • Internal hardware monitoring: the ECU detects an error of its injector high current output.

• Injector powerstage output defect, Chip in powerstage component defect.

System Reaction • Warning : Errorlamp shows blinking light.

Entry in error memory.

• Measurement in case of error: Actual value.

Power Reduction • No reduction.

Possible Reason for Error • High power stage Injector group A. • ECU defective.

Possible Consequence • Diagnostic lamp blinking.

• Emission regulations are not kept, engine can be damaged.

Actions for Repair • If error is not removable, change ECU.

7-48

TH255C

Diagnostics 7.1.45

KWP Code 568

KWP CODE

SPN CODE

568

651

SPN GROUP FMI-NO.

ERROR PATH IVDiaCylNoLd_0

Not Available

SPN NAME FMI-INFO

5

COMPONENT

Engine Injector #01 Current below normal or open circuit Injector diagnosis

Short Description • Injector cyl. 1: interruption of electrical connection.

• Injector 1 (in firing order); interruption of electric connection, Interruption of electronic connection Injector cyl. 1.

System Reaction • Warning : Errorlamp shows permanent light.

• Entry in error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Cable break (cylinder 1), • Injector defective.

• Connection cable damaged.

Possible Consequence • Diagnostic lamp on, emission regulations are not kept, engine can be damaged.

Actions for Repair • Check wiring.

• Check injector and if necessary replace them.

• Check connection cable and if necessary repair or replace it.

• Use SerDia Injector test for diagnosis.

TH255C

7-49

Diagnostics 7.1.46

KWP Code 569

KWP CODE

SPN CODE

569

652

SPN GROUP FMI-NO.

Not Available

ERROR PATH IVDiaCylNoLd_1 SPN NAME FMI-INFO

5

COMPONENT

Engine Injector #02 Current below normal or open circuit Injector diagnosis

Short Description • Injector cyl. 3: interruption of electrical connection.

• Injector 2 (in firing order); interruption of electric connection, Interruption of electronic connection Injector cyl. 3.

System Reaction • Warning : Errorlamp shows permanent light. Entry in error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Cable break (cylinder 3), injector defective, connection cable damaged.

Possible Consequence • Diagnostic lamp on, emission regulations are not kept, engine can be damaged.

Actions for Repair • Check wiring.

• Check injector and if necessary replace them.

• Check connection cable and if necessary repair or replace it.

• Use SerDia Injector test for diagnosis.

7-50

TH255C

Diagnostics 7.1.47

KWP Code 570

KWP CODE

SPN CODE

570

653

SPN GROUP FMI-NO.

Not Available

ERROR PATH IVDiaCylNoLd_2 SPN NAME FMI-INFO

5

COMPONENT

Engine Injector #03 Current below normal or open circuit Injector diagnosis

Short Description • Injector cyl. 4: interruption of electrical connection.

• Injector 3 (in firing order); interruption of electric connection, Interruption of electronic connection Injector cyl. 4.

System Reaction • Warning : Errorlamp shows permanent light. Entry in error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Cable break (cylinder 4).

• Injector defective.

• Connection cable damaged.

Possible Consequence • Diagnostic lamp on, emission regulations are not kept, engine can be damaged.

Actions for Repair • Check wiring.

• Check injector and if necessary replace them.

• Check connection cable and if necessary repair or replace it.

• Use SerDia Injector test for diagnosis.

TH255C

7-51

Diagnostics 7.1.48

KWP Code 571

KWP CODE

SPN CODE

571

654

SPN GROUP FMI-NO.

Not Available

ERROR PATH IVDiaCylNoLd_3 SPN NAME FMI-INFO

5

COMPONENT

Engine Injector #04 Current below normal or open circuit Injector diagnosis

Short Description • Injector cyl. 2: interruption of electrical connection.

• Injector 4 (in firing order); interruption of electric connection, Interruption of electronic connection Injector cyl. 2.

System Reaction • Warning : Errorlamp shows permanent light. Entry in error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Cable break (cylinder 2).

• Injector defective.

• Connection cable damaged.

Possible Consequence • Diagnostic lamp on, emission regulations are not kept, engine can be damaged.

Actions for Repair • Check wiring.

• Check injector and if necessary replace them.

• Check connection cable and if necessary repair or replace it.

• Use SerDia Injector test for diagnosis.

7-52

TH255C

Diagnostics 7.1.49

KWP Code 580

KWP CODE

SPN CODE

580

651

SPN GROUP FMI-NO.

ERROR PATH IVDiaCylShCir_0

Not Available

SPN NAME FMI-INFO

3

COMPONENT

Engine Injector #01 Voltage above normal or shorted high Injector diagnosis

Short Description • Injector cyl. 1: the current drop measured by ECU is above the target range.

• Injector 1 (in firing order); short circuit, Short circuit injector cylinder 1

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Actual value.

Power Reduction • No reduction.

Possible Reason for Error • Short circuit (cylinder 1), injector defective, connection cable damaged.

Possible Consequence • Diagnostic lamp on, emission regulations are not kept, engine can be damaged.

Actions for Repair • Check wiring and counter plugs.

• Check injectors and if necessary replace them.

• Check connection cable and if necessary repair or replace it.

• Use SerDia Injector test for diagnosis.

TH255C

7-53

Diagnostics 7.1.50

KWP Code 581

KWP CODE

SPN CODE

581

652

SPN GROUP FMI-NO.

ERROR PATH IVDiaCylShCir_1

Not Available

SPN NAME FMI-INFO

3

COMPONENT

Engine Injector #02 Voltage above normal or shorted high Injector diagnosis

Short Description • Injector cyl. 3: the current drop measured by ECU is above the target range.

• Injector 2 (in firing order); short circuit, Short circuit injector cylinder 3.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Actual value.

Power Reduction • No reduction

Possible Reason for Error • Short circuit (cylinder 3), injector defective.

• Connection cable damaged.

Possible Consequence • Diagnostic lamp on, emission regulations are not kept, engine can be damaged.

Actions for Repair • Check wiring and counter plugs.

• Check injectors and if necessary replace them.

• Check connection cable and if necessary repair or replace it.

• Use SerDia Injector test for diagnosis.

7-54

TH255C

Diagnostics 7.1.51

KWP Code 582

KWP CODE

SPN CODE

582

653

SPN GROUP FMI-NO.

ERROR PATH IVDiaCylShCir_2

Not Available

SPN NAME FMI-INFO

3

COMPONENT

Engine Injector #03 Voltage above normal or shorted high Injector diagnosis

Short Description • Injector cyl. 4: the current drop measured by ECU is above the target range.

• Injector 3 (in firing order); short circuit, Short circuit injector cylinder 4.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Actual value.

Power Reduction • No reduction.

Possible Reason for Error • Short circuit (cylinder 4), injector defective.

• Connection cable damaged.

Possible Consequence • Diagnostic lamp on.

• Emission regulations are not kept, engine can be damaged.

Actions for Repair • Check wiring and counter plugs.

• Check injectors and if necessary replace them.

• Check connection cable and if necessary repair or replace it.

• Use SerDia Injector test for diagnosis.

TH255C

7-55

Diagnostics 7.1.52

KWP Code 583

KWP CODE

SPN CODE

583

654

SPN GROUP FMI-NO.

ERROR PATH IVDiaCylShCir_3

Not Available

SPN NAME FMI-INFO

3

COMPONENT

Engine Injector #04 Voltage above normal or shorted high Injector diagnosis

Short Description • Injector cyl. 2: the current drop measured by ECU is above the target range.

• Injector 4 (in firing order); short circuit, Short

circuit injector cylinder 2.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Actual value.

Power Reduction • No reduction

Possible Reason for Error • Short circuit (cylinder 2).

• Injector defective.

• Connection cable damaged.

Possible Consequence • Diagnostic lamp on.

• Emission regulations are not kept, engine can be damaged.

Actions for Repair • Check wiring and counter plugs.

• Check injectors and if necessary replace them.

• Check connection cable and if necessary repair or replace it.

• Use SerDia Injector test for diagnosis.

7-56

TH255C

Diagnostics 7.1.53

KWP Code 592

KWP CODE

SPN CODE

592

523615

SPN GROUP FMI-NO.

Not Available

ERROR PATH MeUnOL SPN NAME FMI-INFO

5

COMPONENT

Manufacturer Assignable SPN Current below normal or open circuit Fuel high pressure metering Unit

Short Description • Fuel metering unit: the ECU detects no load or temperature excess of the ECU component for power supply of the valve.

• Metering unit (Fuel-System); open load, Open load.

System Reaction • Warning, Speed pending power reduction, pressure relief valve may open.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 75%.

Possible Reason for Error • Wiring error or ECU output is switched off because of over temperature.

• Fuel metering unit defective.

• Connection cable damaged.

Possible Consequence • Diagnostic lamp on, emission regulations are not kept, pressure release valve can be damaged.

Actions for Repair • Check wiring , if necessary check FCU. • Check fuel metering unit and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

TH255C

7-57

Diagnostics 7.1.54

KWP Code 594

KWP CODE

SPN CODE

594

523615

SPN GROUP FMI-NO.

ERROR PATH MeUnShCirHSBatt

Not Available

SPN NAME FMI-INFO

3

COMPONENT

Manufacturer Assignable SPN Voltage above normal or shorted high Fuel high pressure metering Unit

Short Description • Fuel metering unit: the current drain measured by ECU is above the target range.

• Metering unit (Fuel-System); short circuit to battery, HighSide-Shortcut to battery.

System Reaction • Warning, Speed pending power reduction, pressure relief valve may open.

• Permanent light, entry into error memory.

• Measurement in case of error: actual value.

Power Reduction • 75%

Possible Reason for Error • Short circuit to Ubatt.

• Fuel metering unit defective.

• Connection cable damaged.

Possible Consequence • Diagnostic lamp on, emission regulations are not kept, pressure release valve can be damaged.

Actions for Repair • Check wiring , if necessary check FCU. • Check fuel metering unit and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

7-58

TH255C

Diagnostics 7.1.55

KWP Code 595

KWP CODE

SPN CODE

595

523615

SPN GROUP FMI-NO.

ERROR PATH MeUnShCirHSGnd

Not Available

SPN NAME FMI-INFO

4

COMPONENT

Manufacturer Assignable SPN Voltage below normal or shorted low Fuel high pressure metering Unit

Short Description • Fuel metering unit: the current drain measured by ECU is above the target range.

• Metering unit (Fuel-System); short circuit to ground, HighSide-Shortcut to ground.

System Reaction • Warning : Speed pending power reduction, pressure relief valve may open.

• Permanent light, entry into error memory.

• Measurement in case of error: Actual value.

Power Reduction • 75%

Possible Reason for Error • Short circuit to ground.

• Fuel metering unit defective.

• Connection cable damaged.

Possible Consequence • Diagnostic lamp on, emission regulations are not kept, pressure release valve can be damaged.

Actions for Repair • Check wiring , if necessary check FCU. • Check fuel metering unit and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

TH255C

7-59

Diagnostics 7.1.56

KWP Code 596

KWP CODE

SPN CODE

596

523615

SPN GROUP FMI-NO.

ERROR PATH MeUnShCirLSBatt

Not Available

SPN NAME FMI-INFO

3

COMPONENT

Manufacturer Assignable SPN Voltage above normal or shorted high Fuel high pressure metering Unit

Short Description • Fuel metering unit: the current drain measured by ECU is above the target range.

• Metering unit (Fuel-System); short circuit to battery, LowSide-Shortcut to battery.

System Reaction • Warning : Speed pending power reduction, pressure relief valve may open.

• Permanent light, entry into error memory.

• Measurement in case of error: actual value.

Power Reduction • 75%

Possible Reason for Error • Short circuit to Ubatt.

• Fuel metering unit defective.

• connection cable damaged.

Possible Consequence • Diagnostic lamp on, emission regulations are not kept, pressure release valve can be damaged.

Actions for Repair • Check wiring , if necessary check FCU. • Check fuel metering unit and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

7-60

TH255C

Diagnostics 7.1.57

KWP Code 597

KWP CODE

SPN CODE

597

523615

SPN GROUP FMI-NO.

ERROR PATH MeUnShCirLSGnd

Not Available

SPN NAME FMI-INFO

4

COMPONENT

Manufacturer Assignable SPN Voltage below normal or shorted low Fuel high pressure metering Unit

Short Description • Fuel metering unit: the current drain measured by ECU is above the target range.

• Metering unit (Fuel-System); short circuit to ground, LowSide-Shortcut to ground.

System Reaction • Warning : Speed pending power reduction, pressure relief valve may open.

• Permanent light, entry into error memory.

• Measurement in case of error: Actual value.

Power Reduction • 75%

Possible Reason for Error • Short circuit to ground, fuel metering unit defective, connection cable damaged.

Possible Consequence • Diagnostic lamp on, emission regulations are not kept, pressure release valve can be damaged.

Actions for Repair • Check wiring , if necessary check FCU. • check fuel metering unit and if necessary replace it.

• check connection cable and if necessary repair or replace it.

TH255C

7-61

Diagnostics 7.1.58

KWP Code 612

KWP CODE

SPN CODE

612

523612

SPN GROUP FMI-NO.

Not Available

ERROR PATH MoCADCNTP SPN NAME FMI-INFO

12

COMPONENT

Manufacturer Assignable SPN Bad intelligent device or component ADC monitoring

Short Description • Internal hardware monitoring: the CPU of the ECU is reset and the cause is logged internally; no item will be created in error memory.

• ECU reported internal software error, Plausibility check (MoCADC_uNTP_mp is bigger than MoCADC_uNTPMax_C).

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Short circuit in wiring of analog signals to ECU (Analog Digital Converter). Defective ECU.

Possible Consequence • Diagnostic lamp on, no damage on further parts.

Actions for Repair • Check wiring.

• Check connected sensors actuators.

• If error is still active replace ECU.

7-62

TH255C

Diagnostics 7.1.59

KWP Code 613

KWP CODE

SPN CODE

613

523612

SPN GROUP FMI-NO.

Not Available

ERROR PATH MoCADCTst SPN NAME FMI-INFO

12

COMPONENT

Manufacturer Assignable SPN Bad intelligent device or component ADC monitoring

Short Description • Internal hardware monitoring: the CPU of the ECU is reset and the cause is logged internally; no item will be created in error memory.

• ECU reported internal software error, Analysis of test voltage (Value is out of the target -> ECU internal error).

System Reaction • Warning: Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Short circuit in wiring of analog signals to ECU (Analog Digital Converter). Defective ECU.

Possible Consequence • Diagnostic lamp on, no damage on further parts.

Actions for Repair • Check wiring.

• Check connected sensors actuators. If error is still active replace ECU.

TH255C

7-63

Diagnostics 7.1.60

KWP Code 614

KWP CODE

SPN CODE

614

523612

SPN GROUP FMI-NO.

Not Available

ERROR PATH MoCADCVltgRatio SPN NAME FMI-INFO

12

COMPONENT

Manufacturer Assignable SPN Bad intelligent device or component ADC monitoring

Short Description • Internal hardware monitoring: the CPU of the ECU is reset and the cause is logged internally; no item will be created in error memory.

• ECU reported internal software error, Analysis of the ratiometric correction (Value is out of the target -> ECU internal error).

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Short circuit in wiring of analog signals to ECU (Analog Digital Converter). Defective ECU.

Possible Consequence • Diagnostic lamp on, no damage on further parts.

Actions for Repair • Check wiring.

• Check connected sensors actuators. If error is still active replace ECU.

7-64

TH255C

Diagnostics 7.1.61

KWP Code 615

KWP CODE

SPN CODE

615

523612

SPN GROUP FMI-NO.

Not Available

ERROR PATH MoCComErrCnt SPN NAME

Manufacturer Assignable SPN

FMI-INFO

Bad intelligent device or component

COMPONENT

Communication monitoring module

12

Short Description • Internal hardware monitoring: the CPU of the ECU is reset and the cause is logged internally; no item will be created in error memory.

• ECU reported internal software error, Error report due to an error in the plausbility of FC and MM (ECU internal error).

System Reaction • Warning : Blinking light, entry into error memory • Measurement in case of error: Not available

Power Reduction • No reduction

Possible Reason for Error • ECU defective, Software erratic

Possible Consequence • Diagnostic lamp on, no damage on further parts.

Actions for Repair • Reflash ECU. If error is still active replace ECU.

TH255C

7-65

Diagnostics 7.1.62

KWP Code 616

KWP CODE

SPN CODE

616

523612

SPN GROUP FMI-NO.

ERROR PATH MoCComSPI

Not Available

SPN NAME

Manufacturer Assignable SPN

FMI-INFO

Bad intelligent device or component

COMPONENT

Communication monitoring module

12

Short Description • Internal hardware monitoring: the CPU of the ECU is reset and the cause is logged internally; no item will be created in error memory.

• ECU reported internal software error, Error report due to an interrupted SPI communication (ECU internal error)

System Reaction • Warning : Blinking light, entry into error memory • Measurement in case of error: Not available

Power Reduction • No reduction.

Possible Reason for Error • ROM memory in ECU defective.

Possible Consequence • Diagnostic lamp on, no damage on further parts.

Actions for Repair • Reflash ECU. If error is still activ replace ECU.

7-66

TH255C

Diagnostics 7.1.63

KWP Code 617

KWP CODE

SPN CODE

617

523612

SPN GROUP FMI-NO.

Not Available

ERROR PATH MoCROMErrXPg SPN NAME FMI-INFO

12

COMPONENT

Manufacturer Assignable SPN Bad intelligent device or component ROM memory

Short Description • Internal hardware monitoring: the CPU of the ECU is reset and the cause is logged internally; no item will be created in error memory.

• ECU reported internal software error, multiple error in complete ROM-test during postdrive detected (ECU internal error).

System Reaction • Warning : Not configured.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • ECU defective, Software erratic.

Possible Consequence • Diagnostic lamp on, no damage on further parts.

Actions for Repair • Reflash ECU. • If error is still active replace ECU.

TH255C

7-67

Diagnostics 7.1.64

KWP Code 618

KWP CODE

SPN CODE

618

523612

SPN GROUP

Not Available

ERROR PATH MoCSOPErrMMRespByte SPN NAME FMI-INFO

FMI-NO.

12 COMPONENT

Manufacturer Assignable SPN Bad intelligent device or component Test of redundant shut-off paths (ECU internal error)

Short Description • Internal hardware monitoring: the CPU of the ECU is reset and the cause is logged internally; no item will be created in error memory.

• ECU reported internal software error, Too less bytes received by monitoring memory from CPU as response (ECU internal error).

• Loss of synchronization sending bytes to the monitoring memory from CPU.

System Reaction • Warning : Speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 75%

Possible Reason for Error • ECU defective, Software erratic.

Possible Consequence • Diagnostic lamp on, no damage on further parts.

Actions for Repair • Reflash ECU. • If error is still active replace ECU.

7-68

TH255C

Diagnostics 7.1.65

KWP Code 619

KWP CODE

SPN CODE

619

523612

SPN GROUP

Not Available

ERROR PATH MoCSOPErrNoChk SPN NAME FMI-INFO

FMI-NO.

12 COMPONENT

Manufacturer Assignable SPN Bad intelligent device or component Test of redundant shut-off paths (ECU internal error)

Short Description • Internal hardware monitoring: the CPU of the ECU is reset and the cause is logged internally; no item will be created in error memory.

• ECU reported internal software error, Error during SOP test; uncertain cause (defective injector or shut-off path).

• DFC to set a torque limitation once an error is detected before MoCSOP's error reaction is set.

System Reaction • Warning, Speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 75%

Possible Reason for Error • ECU defective, Software erratic.

Possible Consequence • Diagnostic lamp on, no damage on further parts.

Actions for Repair • Reflash ECU. • If error is still active replace ECU.

TH255C

7-69

Diagnostics 7.1.66

KWP Code 620

KWP CODE

SPN CODE

620

523612

SPN GROUP

Not Available

ERROR PATH MoCSOPErrRespTime SPN NAME FMI-INFO

FMI-NO.

12 COMPONENT

Manufacturer Assignable SPN Bad intelligent device or component Test of redundant shut-off paths (ECU internal error)

Short Description • Internal hardware monitoring: the CPU of the ECU is reset and the cause is logged internally; no item will be created in error memory.

• ECU reported internal software error, Error trying to set MM Response time (ECU internal error).

System Reaction • Warning : Speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 75%

Possible Reason for Error • ECU defective.

• Software erratic.

Possible Consequence • Diagnostic lamp on, no damage on further parts.

Actions for Repair • Reflash ECU. • If error is still active replace ECU.

7-70

TH255C

Diagnostics 7.1.67

KWP Code 621

KWP CODE

SPN CODE

621

523612

SPN GROUP

Not Available

ERROR PATH MoCSOPErrSPI SPN NAME FMI-INFO

FMI-NO.

12 COMPONENT

Manufacturer Assignable SPN Bad intelligent device or component Test of redundant shut-off paths (ECU internal error)

Short Description • Internal hardware monitoring: the CPU of the ECU is reset and the cause is logged internally; no item will be created in error memory.

• ECU reported internal software error, Error detected in the internal ECU communication.

System Reaction • Warning : Speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 75%

Possible Reason for Error • ECU defective.

• Software erratic

Possible Consequence • Diagnostic lamp on, no damage on further parts

Actions for Repair • Reflash ECU. • If error is still active replace ECU.

TH255C

7-71

Diagnostics 7.1.68

KWP Code 623

KWP CODE

SPN CODE

623

523612

SPN GROUP

Not Available

ERROR PATH MoCSOPLoLi SPN NAME FMI-INFO

FMI-NO.

12 COMPONENT

Manufacturer Assignable SPN Bad intelligent device or component Test of redundant shut-off paths (ECU internal error)

Short Description • Internal hardware monitoring: the CPU of the ECU is reset and the cause is logged internally; no item will be created in error memory.

• ECU reported internal software error, Error in the check of the shut-off path test of the under voltage detection (ECU internal error). Diagnostic fault check to report the error in undervoltage monitoring.

System Reaction • Warning : Speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 75%

Possible Reason for Error • ECU defective.

• Software erratic.

Possible Consequence • Diagnostic lamp on, no damage on further parts.

Actions for Repair • Reflash ECU. • If error is still active replace ECU.

7-72

TH255C

Diagnostics 7.1.69

KWP Code 624

KWP CODE

SPN CODE

624

523612

SPN GROUP

Not Available

ERROR PATH MoCSOPMM SPN NAME FMI-INFO

FMI-NO.

12 COMPONENT

Manufacturer Assignable SPN Bad intelligent device or component Test of redundant shut-off paths (ECU internal error)

Short Description • Internal hardware monitoring: the CPU of the ECU is reset and the cause is logged internally; no item will be created in error memory.

• ECU reported internal software error, Error in the check of the shut-off path of the monitoring module (ECU internal error).

System Reaction • Warning : Speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 75%

Possible Reason for Error • ECU defective.

• Software erratic.

Possible Consequence • Diagnostic lamp on, no damage on further parts.

Actions for Repair • Reflash ECU. • If error is still active replace ECU.

TH255C

7-73

Diagnostics 7.1.70

KWP Code 625

KWP CODE

SPN CODE

625

523612

SPN GROUP

Not Available

ERROR PATH MoCSOPOSTimeOut SPN NAME FMI-INFO

FMI-NO.

12 COMPONENT

Manufacturer Assignable SPN Bad intelligent device or component Test of redundant shut-off paths (ECU internal error)

Short Description • Internal hardware monitoring: the CPU of the ECU is reset and the cause is logged internally; no item will be created in error memory.

• ECU reported internal software error, Time out error trying to set or cancelling the alarm task (ECU internal error). Failure setting the alarm task period.

System Reaction • Warning : Speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 75%

Possible Reason for Error • ECU defective.

• Software erratic.

Possible Consequence • Diagnostic lamp on, no damage on further parts.

Actions for Repair • Reflash ECU. • If error is still active replace ECU.

7-74

TH255C

Diagnostics 7.1.71

KWP Code 627

KWP CODE

SPN CODE

627

523612

SPN GROUP

Not Available

ERROR PATH MoCSOPOSTimeOut SPN NAME FMI-INFO

FMI-NO.

12 COMPONENT

Manufacturer Assignable SPN Bad intelligent device or component Test of redundant shut-off paths (ECU internal error)

Short Description • Internal hardware monitoring: the CPU of the ECU is reset and the cause is logged internally; no item will be created in error memory.

• ECU reported internal software error, Error in time monitoring of the shut-off path test (ECU internal error). Diagnostic fault check to report the timeout in the shut off path test.

System Reaction • Warning : Speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 75%

Possible Reason for Error • ECU defective.

• Software erratic.

Possible Consequence • Diagnostic lamp on, no damage on further parts

Actions for Repair • Reflash ECU. • If error is still active replace ECU.

TH255C

7-75

Diagnostics 7.1.72

KWP Code 628

KWP CODE

SPN CODE

628

523612

SPN GROUP

Not Available

ERROR PATH MoCSOPUpLi SPN NAME FMI-INFO

FMI-NO.

12 COMPONENT

Manufacturer Assignable SPN Bad intelligent device or component Test of redundant shut-off paths (ECU internal error)

Short Description • Internal hardware monitoring: the CPU of the ECU is reset and the cause is logged internally; no item will be created in error memory.

• ECU reported internal software error, Error in the check of the shut-off path test of the over voltage detection (ECU internal error). Diagnostic fault check to report the error in overvoltage monitoring.

System Reaction • Warning : Speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 75%

Possible Reason for Error • ECU defective.

• Software erratic.

Possible Consequence • Diagnostic lamp on, no damage on further parts.

Actions for Repair • Reflash ECU. • If error is still active replace ECU.

7-76

TH255C

Diagnostics 7.1.73

KWP Code 637

KWP CODE

SPN CODE

637

523612

SPN GROUP FMI-NO.

Not Available

ERROR PATH MoFOvR SPN NAME FMI-INFO

12

COMPONENT

Manufacturer Assignable SPN Bad intelligent device or component Monitoring Function Overrun

Short Description • Engine speed: the engine speed calculated by ECU is above the target range; the ECU activates a system reaction.

• ECU reported internal software error, Error in the plausibility of current energizing time with maximum permitted energizing time. Diagnostic fault check to report the error due to Over Run.

System Reaction • Warning : Errorlamp shows blinking light. Entry in error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Engine overspeed detected with system reaction.

• Maximum engine speed exceeded.

Possible Consequence • Diagnostic lamp on, no damage on further parts.

Actions for Repair • Check powertrain settings regarding overspeed.

TH255C

7-77

Diagnostics 7.1.74

KWP Code 732

KWP CODE

SPN CODE

732

100

SPN GROUP FMI-NO.

Engine Fluid Level/ Pressure 1

ERROR PATH OilPSwmpSRCMax SPN NAME FMI-INFO

3

COMPONENT

Engine Oil Pressure Voltage above normal or shorted high Engine oil pressure sensor

Short Description • Oil pressure sensor: the voltage of sensor measured

by ECU is out of the target range.

• Sensor error oil pressure; signal range check high, Short circuit to battery or open load.

System Reaction • Warning : Default value (4000hPa).

• Permanent light, entry into error memory.

• Measurement in case of error: 4000hPa.

Power Reduction • No reduction.

Possible Reason for Error • Cable break or short circuit.

• Sensor defective.

• Connection cable damaged.

• Wiring damaged.

Possible Consequence • Diagnostic lamp on, (no damage on engine).

Actions for Repair • Check wiring, if sensor not working.

• Check sensor and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

7-78

TH255C

Diagnostics 7.1.75

KWP Code 733

KWP CODE

SPN CODE

733

100

SPN GROUP FMI-NO.

Engine Fluid Level/ Pressure 1

ERROR PATH OilPSwmpSRCMin SPN NAME FMI-INFO

4

COMPONENT

Engine Oil Pressure Voltage below normal or shorted low Engine oil pressure sensor

Short Description • Oil pressure sensor: the voltage of sensor measured

by ECU is out of the target range.

• Sensor error oil pressure sensor; signal range check low, Short circuit to ground.

System Reaction • Warning : Default value (4000hPa).

• Permanent light, entry into error memory.

• Measurement in case of error: 4000hPa.

Power Reduction • No reduction.

Possible Reason for Error • Cable break or short circuit.

• Sensor defective.

• Connection cable damaged.

• Wiring damaged.

Possible Consequence • Diagnostic lamp on, (no damage on engine).

Actions for Repair • Check wiring, if sensor not working.

• Check sensor and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

TH255C

7-79

Diagnostics 7.1.76

KWP Code 736

KWP CODE

SPN CODE

736

100

SPN GROUP FMI-NO.

Engine Fluid Level/ Pressure 1

ERROR PATH OilPSwmpSysReacLoMax SPN NAME FMI-INFO

1

COMPONENT

Engine Oil Pressure Data valid but below normal operational range Engine oil pressure sensor

Short Description • Oil pressure is below the target range (warning threshold).

• Low oil pressure; system reaction initiated, Oilpressure too low (pressure below warning threshold).

System Reaction • Warning : Power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 80%

Possible Reason for Error • Low oil level.

• Oil pump defective.

• Oil leackage.

• Suction pipe inlet mash clogged.

Possible Consequence • Diagnostic lamp blinking.

• Oil lamp on, engine can be damaged.

Actions for Repair • Check oil level.

• Check engine for oil leckage, measure oil pressure external to evaluate sensor value.

• Clean suction pipe inlet mash in oil pump.

7-80

TH255C

Diagnostics 7.1.77

KWP Code 737

KWP CODE

SPN CODE

737

100

SPN GROUP FMI-NO.

ERROR PATH OilPSwmpSysReacLoMin

Engine Fluid Level/ Pressure 1

SPN NAME FMI-INFO

1

COMPONENT

Engine Oil Pressure Data valid but below normal operational range Engine oil pressure sensor

Short Description • Oil pressure is below the target range (shut off threshold).

• Low oil pressure; system reaction initiated, Oilpressure too low (pressure below shut off threshold).

System Reaction • Warning: Power reduction + engine shut off demand.

• Blinking light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 80%.

Possible Reason for Error • Low oil level.

• Oil pump defective.

• Oil leackage.

• Suction pipe inlet mash clogged.

Possible Consequence • Diagnostic lamp on.

• Oil lamp on, engine can be damaged.

Actions for Repair • Check oil level.

• Check engine for oil leckage, measure oil pressure external to evaluate sensor value.

• Clean suction pipe inlet mash in oil pump.

TH255C

7-81

Diagnostics 7.1.78

KWP Code 747

KWP CODE

SPN CODE

747

1237

SPN GROUP FMI-NO.

ERROR PATH OvrdSwtPlaus

Cruise Control/ Vehicle Speed

SPN NAME FMI-INFO

2

COMPONENT

Engine Shutdown Override Switch Data erratic, intermittent, or incorrect Override Monitoring

Short Description • Override switch switch: the ECU receives a permanent signal.

• Override switch; plausibility error, plausbility error "override switch > 250ms pressed".

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Actual value.

Power Reduction • No reduction.

Possible Reason for Error • Switch is blocked.

• Taster locked.

• Connection cable damaged.

Possible Consequence • Diagnostic lamp on, no damage on further parts.

Actions for Repair • Check wiring, if sensor is not working.

• Check switch and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

7-82

TH255C

Diagnostics 7.1.79

KWP Code 752

KWP CODE

SPN CODE

752

107

SPN GROUP

Inlet/Exhaust Conditions 1

FMI-NO.

ERROR PATH PAirFltDSysReac SPN NAME FMI-INFO

0

COMPONENT

Engine Air Filter 1 Differential Pressure Data valid but above normal operational range Air filter differential sensor

Short Description • Air filter differential pressure: The pressure difference of the intake air between the filter inlet and outlet calculated by ECU is above the target range and the ECU activates a system reaction.

• Air filter differential pressure; system reaction initiated, Pressure value above warning threshold.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Actual value.

Power Reduction • No reduction.

Possible Reason for Error • Pressure loss above target range with system reaction.

• Air filter clogged or defective.

• Sensor not working.

• Connection cable damaged.

Possible Consequence • Diagnostic lamp on, no damage on further parts.

Actions for Repair • Check airfilter and if necessary clean or renew it.

• Check wiring.

• Check sensor and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

TH255C

7-83

Diagnostics 7.1.80

KWP Code 776

KWP CODE

SPN CODE

776

102

SPN GROUP

Inlet/Exhaust Conditions 1

FMI-NO.

3

ERROR PATH PCACDsSRCMax SPN NAME FMI-INFO COMPONENT

Engine Intake Manifold #1 Pressure Voltage above normal or shorted high Charge air pressure sensor

Short Description • Charge air pressure sensor: The measured voltage of sensor by ECU is out of the target range.

• Sensor error charged air pressure; signal range check high, Short circuit to battery or open load.

System Reaction • Warning : Default value (1800hPa).

• Permanent light, entry into error memory.

• Measurement in case of error: 1800hPa.

Power Reduction • No reduction.

Possible Reason for Error • Cable break or short circuit.

• Sensor defective.

• Connection cable damaged.

Possible Consequence • Diagnostic lamp on.

• Emission regulations are not kept.

• High soot load in exhaust gas.

Actions for Repair • Check wiring, if charge air pressure/temperature sensor is not working.

• Check sensor and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

7-84

TH255C

Diagnostics 7.1.81

KWP Code 777

KWP CODE

SPN CODE

777

102

SPN GROUP

Inlet/Exhaust Conditions 1

FMI-NO.

4

ERROR PATH PCACDsSRCMin SPN NAME

Engine Intake Manifold #1 Pressure

FMI-INFO

Voltage below normal or shorted low

COMPONENT

Charge air pressure sensor

Short Description • Charge air pressure sensor: the measured voltage of sensor by ECU is out of the target range.

• Sensor error charged air pressure; signal range check low, Short circuit to ground.

System Reaction • Warning : Default value (1800hPa).

• Permanent light, entry into error memory.

• Measurement in case of error: 1800hPa.

Power Reduction • No reduction.

Possible Reason for Error • Cable break or short circuit.

• Sensor defective.

• Connection cable damaged.

Possible Consequence • Diagnostic lamp on. E • Emission regulations are not kept. H • High soot load in exhaust gas.

Actions for Repair • Check wiring, if charge air pressure/temperature sensor is not working.

• Check sensor and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

TH255C

7-85

Diagnostics 7.1.82

KWP Code 825

KWP CODE

SPN CODE

825

523009

SPN GROUP FMI-NO.

ERROR PATH PRVctOpnMax

Not Available

SPN NAME FMI-INFO

9

COMPONENT

Manufacturer Assignable SPN Abnormal update rated Pressure relief valve Rail.

Short Description • Rail pressure relief valve: is open more frequently than what the technical specification allows.

• Pressure Relief Valve (PRV) reached maximun allowed opening count, PRV needs to be exchanged.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Actual value.

Power Reduction • No reduction.

Possible Reason for Error • Rail pressure relief valve open more than 50 times.

• Rail pressure relief valve defective.

Possible Consequence • Diagnostic lamp on, PRV can be damaged (replace PRV).

Actions for Repair • Change rail pressure relief valve and remove the error through Serdia command.

7-86

TH255C

Diagnostics 7.1.83

KWP Code 826

KWP CODE

SPN CODE

826

523470

SPN GROUP FMI-NO.

ERROR PATH PRVFrOpnPresInc

Not Available

SPN NAME FMI-INFO

2

COMPONENT

Manufacturer Assignable SPN Data erratic, intermittent, or incorrect Pressure relief valve Rail

Short Description • Rail pressure relief valve will be forced to open.

• Pressure Relief Valve (PRV) forced to open, performed by pressure rising.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Actual value.

Power Reduction • No reduction

Possible Reason for Error • Rail pressure relief valve is forced to open by an increasing rail pressure. This error occurs due to an supervising error.

Possible Consequence • Diagnostic lamp on, emission regulations are not kept, PRV can be damaged

Actions for Repair • Check error memory for other additional errors and eleminate them first.

TH255C

7-87

Diagnostics 7.1.84

KWP Code 827

KWP CODE

SPN CODE

827

523470

SPN GROUP FMI-NO.

ERROR PATH PRVFrOpnPresShck

Not Available

SPN NAME FMI-INFO

2

COMPONENT

Manufacturer Assignable SPN Data erratic, intermittent, or incorrect Pressure relief valve Rail

Short Description • Rail pressure relief valve: is open, will be forced to open, the forced-open failed.

• Pressure Relief Valve (PRV) forced to open, is forced to open (pressure shock).

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Actual value.

Power Reduction • No reduction.

Possible Reason for Error • Rail pressure relief valve open or forced open abortive (interpretation of the rail pressure gradient).

• Operating voltage too low.

• Rail pressure sensor defective.

• Fuel metering unit defective.

• Rail pressure relief valve defective.

Possible Consequence • Diagnostic lamp on.

• Emission regulations are not kept, PRV can be damaged.

Actions for Repair • Check working voltage and if necessary correct it, • Check rail-pressure sensor and if necessary replace it, • Check FCU and if necessary replace it, • Check rail pressure relief valve and if necessary replace it

7-88

TH255C

Diagnostics 7.1.85

KWP Code 828

KWP CODE

SPN CODE

828

523470

SPN GROUP FMI-NO.

ERROR PATH PRVMonSysReacShOff

Not Available

SPN NAME FMI-INFO

12

COMPONENT

Manufacturer Assignable SPN Bad intelligent device or component Pressure relief valve Rail

Short Description • Rail pressure relief valve: is open.

• Pressure Relief Valve (PRV) forced to open; system reaction initiated, Fault path indicating shutoff condition in case of open PRV.

System Reaction • Warning : Speed pending power reduction and engine shut off demand.

• Permanent light, entry into error memory.

• Measurement in case of error: Actual value.

Power Reduction • No reduction

Possible Reason for Error • Rail pressure relief valve open.

Possible Consequence • Diagnostic lamp on • Emission regulations are not kept, PRV can be damaged.

Actions for Repair • Check PRV opening counter and if necessary replace it.

• Check rail-pressure sensor for plausibility and if necessary replace it.

• Check FCU and if necessary replace it.

TH255C

7-89

Diagnostics 7.1.86

KWP Code 829

KWP CODE

SPN CODE

829

523470

SPN GROUP FMI-NO.

ERROR PATH PRVMonSysReacWarn

Not Available

SPN NAME FMI-INFO

12

COMPONENT

Manufacturer Assignable SPN Bad intelligent device or component Pressure relief valve Rail

Short Description • Rail pressure relief valve: is open.

• Pressure Relief Valve (PRV) forced to open; System reaction initiated, Fault path indicating warning condition in case of open PRV.

System Reaction • Warning : Speed pending power reduction and engine shut off demand.

• Permanent light, entry into error memory.

• Measurement in case of error: Actual value.

Power Reduction • 75%

Possible Reason for Error • Rail pressure relief valve open.

Possible Consequence • Diagnostic lamp on.

• Emission regulations are not kept, PRV can be damaged.

Actions for Repair • Check PRV opening counter and if necessary replace PRV. • Check rail-pressure sensor for plausibility and if necessary replace it.

• Check FCU and if necessary replace it.

7-90

TH255C

Diagnostics 7.1.87

KWP Code 830

KWP CODE

SPN CODE

830

523470

SPN GROUP FMI-NO.

ERROR PATH PRVOpn

not available

SPN NAME FMI-INFO

14

COMPONENT

Manufacturer Assignable SPN Special Instructions Pressure relief valve Rail

Short Description • Rail pressure relief valve: is open • Pressure Relief Valve (PRV) is open, Pressure relief valve (PRV) in rail is open.

System Reaction • Warning : Power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: actual value.

Power Reduction • 75%

Possible Reason for Error • Rail pressure relief valve open

Possible Consequence • Diagnostic lamp on, emission regulations are not kept, PRV can be damaged.

Actions for Repair • Check PRV opening counter and if necessary replace it.

• Check rail-pressure sensor for plausibility and if necessary replace it.

• Check FCU and if necessary replace it.

TH255C

7-91

Diagnostics 7.1.88

KWP Code 831

KWP CODE

SPN CODE

831

523470

SPN GROUP FMI-NO.

Not Available

ERROR PATH PRVQBalChk SPN NAME FMI-INFO

11

COMPONENT

Manufacturer Assignable SPN Failure mode not identifiable Pressure relief valve Rail

Short Description • Rail pressure relief valve can not be opened due to the railpressure.

• Pressure Relief Valve (PRV) error; Rail pressure out of tolerance range, Railpressure out of tolerance range (PRV can not be opened by a pressure peak in this operating point).

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Rail pressure in abnormal range, FCU defective.

Possible Consequence • Diagnostic lamp on, emission regulations are not kept, PRV can be damaged.

Actions for Repair • Check railpressure.

• Check rail pressure sensor for plausibility.

• Check FCU.

7-92

TH255C

Diagnostics 7.1.89

KWP Code 832

KWP CODE

SPN CODE

832

523470

SPN GROUP FMI-NO.

Not Available

ERROR PATH PRVRPOutOfRng SPN NAME FMI-INFO

11

COMPONENT

Manufacturer Assignable SPN Failure mode not identifiable Pressure relief valve Rail

Short Description • Rail pressure is out of the expected average range.

• Rail pressure out of tolerance range.

• Averaged rail pressure is outside the expected tolerance range.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • PRV defective.

Possible Consequence • Diagnostic lamp on, emission regulations are not kept, PRV can be damaged.

Actions for Repair • Check PRV and replace if necessary.

TH255C

7-93

Diagnostics 7.1.90

KWP Code 833

KWP CODE

SPN CODE

833

523009

SPN GROUP FMI-NO.

ERROR PATH PRVtiOpnMax

Not Available

SPN NAME

Manufacturer Assignable SPN

FMI-INFO

Abnormal rate of change

COMPONENT

Pressure relief valve Rail

10

Short Description • Rail pressure relief valve: is open for a longer time than what the technical specification allows.

• Pressure relief valve (PRV) reached maximun allowed open time, PRV open longer than 300 minutes.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Actual value.

Power Reduction • No reduction.

Possible Reason for Error • Rail pressure relief valve was open for more than 300 minutes.

• Rail pressure relief valve defective.

Possible Consequence • Diagnostic lamp on.

• Emission regulations are not kept, PRV can be damaged.

Actions for Repair • Change rail pressure relief valve and remove the error through Serdia command.

7-94

TH255C

Diagnostics 7.1.91

KWP Code 834

KWP CODE

SPN CODE

834

523906

SPN GROUP FMI-NO.

Not Available

ERROR PATH PSPOL SPN NAME FMI-INFO

5

COMPONENT

Manufacturer Assignable SPN Not Available Fuel feed pump

Short Description • ECU detects open load on the electric fuel feed pump output.

• Electrical fuel pre-supply pump; open load, Cable break, open load.

System Reaction • Powerstage in ECU is switched off.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Cable break or loose contact in fuel feed pump wiring, relay defective.

Possible Consequence • Diagnostic lamp on.

• Engine shut off due to missing fuel pressure.

• Start function is locked. (no damage on further parts)

Actions for Repair • Check wiring of the fuel feed pump circuit including relay, if necessary repair or replace wiring.

TH255C

7-95

Diagnostics 7.1.92

KWP Code 835

KWP CODE

SPN CODE

835

523906

SPN GROUP FMI-NO.

Not Available

ERROR PATH PSPOvrTemp SPN NAME FMI-INFO

12

COMPONENT

Manufacturer Assignable SPN Not Available Fuel feed pump

Short Description • ECU detects too high temperature in powerstage of fuel pump circuit.

• Electrical fuel pre-supply pump; powerstage over temperature, Temperature is over limit.

System Reaction • Powerstage in ECU is switched off.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Relay defective.

• Wiring problem in fuel pump relay circuit.

Possible Consequence • Diagnostic lamp on. E • Engine shut off due to missing fuel pressure.

• Start function is locked (no damage on further parts).

Actions for Repair • Check fuel pump relay if necessary replace it.

• Check wiring of fuel feed pump circuit.

7-96

TH255C

Diagnostics 7.1.93

KWP Code 836

KWP CODE

SPN CODE

836

523906

SPN GROUP FMI-NO.

Not Available

ERROR PATH PSPSCB SPN NAME FMI-INFO

3

COMPONENT

Manufacturer Assignable SPN Not Available Fuel feed pump

Short Description • ECU detects short cut to battery in fuel feed pump circuit.

• Electrical fuel pre-supply pump; short circuit to battery, Short cut to battery.

System Reaction • Powerstage in ECU is switched off.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Cable break or loose contact in fuel feed pump wiring.

• Relay defective.

Possible Consequence • Diagnostic lamp on.

• Engine shut off due to missing fuel pressure.

• Start function is locked (no damage on further parts).

Actions for Repair • Check wiring of the fuel feed pump circuit including relay, if necessary repair or replace wiring.

TH255C

7-97

Diagnostics 7.1.94

KWP Code 837

KWP CODE

SPN CODE

837

523906

SPN GROUP FMI-NO.

Not Available

ERROR PATH PSPSCG SPN NAME FMI-INFO

4

COMPONENT

Manufacturer Assignable SPN Not Available Fuel feed pump

Short Description • ECU detects short cut to ground in fuel feed pump circuit.

• Electrical fuel pre-supply pump; short circuit to ground, Short cut to ground.

System Reaction • Powerstage in ECU is switched off.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Cable break or loose contact in fuel feed pump wiring.

• Relay defective.

Possible Consequence • Diagnostic lamp on.

• Engine shut off due to missing fuel pressurestart function is locked (no damage on further parts).

Actions for Repair • Check wiring of the fuel feed pump circuit including relay, if necessary repair or replace wiring.

7-98

TH255C

Diagnostics 7.1.95

KWP Code 856

KWP CODE

SPN CODE

856

523613

SPN GROUP FMI-NO.

ERROR PATH RailMeUn0

Not Available

SPN NAME FMI-INFO

0

COMPONENT

Manufacturer Assignable SPN Data valid but above normal operational range Rail pressure metering unit

Short Description • Rail pressure: the fuel pressure in rail calculated by ECU is below the target range which is dependant on the engine speed.

• Rail pressure disrupted, Positive governor deviation.

System Reaction • Warning : Speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: Actual value.

Power Reduction • 75 %

Possible Reason for Error • Leakage in high pressure system (external) • Leakage at rail pressure relief valve (internal) • Needle clamped in open position.

• Abrasion at high pressure pump.

• Too low primary pressure on low pressure side, sensor defective, fuel system distur.

Possible Consequence • Diagnostic lamp on, no damage on further parts.

Actions for Repair • Check for leakage.

• Check fuel-primary pressure.

• Change components.

• Check sensor and if necessary replace it.

• Check fuel system and if necessary repair it.

TH255C

7-99

Diagnostics 7.1.96

KWP Code 857

KWP CODE

SPN CODE

857

523613

SPN GROUP FMI-NO.

ERROR PATH RailMeUn1

Not Available

SPN NAME FMI-INFO

0

COMPONENT

Manufacturer Assignable SPN Data valid but above normal operational range Rail pressure metering unit

Short Description • Rail pressure: the fuel pressure in rail calculated by ECU is below the target range which is dependant on the engine speed.

• Rail pressure disrupted, maximum positive deviation of rail pressure exceeded concerning set flow of fuel.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Actual value.

Power Reduction • No reduction.

Possible Reason for Error • Leakage in high pressure system (external).

• Leakage at rail pressure relief valve (internal).

• Needle clampt in open position.

• Abrasion at high pressure pump.

• Too low primary pressure on low pressure side, sensor defective, fuel system disturb.

Possible Consequence • Diagnostic lamp on, no damage on further parts.

Actions for Repair • Check for leakage.

• Check fuel-primary pressure.

• Change components.

• Check sensor and if necessary replace it.

• Check fuel system and if necessary repair it.

7-100

TH255C

Diagnostics 7.1.97

KWP Code 858

KWP CODE

SPN CODE

858

523613

SPN GROUP FMI-NO.

ERROR PATH RailMeUn10

Not Available

SPN NAME FMI-INFO

0

COMPONENT

Manufacturer Assignable SPN Data valid but above normal operational range Rail pressure metering unit

Short Description • Rail pressure: the fuel pressure in rail calculated by ECU is above the target range which is dependant on the engine speed.

• Rail pressure disrupted, leakage is detected based on fuel quantity balance.

System Reaction • Warning : Speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: Actual value.

Power Reduction • 75%

Possible Reason for Error • Metering unit is not working properly • Fuel return line blocked.

• Injectors do not open.

Possible Consequence • Diagnostic lamp on, no damage on further parts.

Actions for Repair • Check backflow pressure.

• Check Injector function with SerDia. • Change components (metering unit, injector) if necessary.

TH255C

7-101

Diagnostics 7.1.98

KWP Code 859

KWP CODE

SPN CODE

859

523613

SPN GROUP FMI-NO.

ERROR PATH RailMeUn2

Not Available

SPN NAME FMI-INFO

0

COMPONENT

Manufacturer Assignable SPN Data valid but above normal operational range Rail pressure metering unit

Short Description • Rail pressure: the fuel pressure in rail calculated by ECU is above the target range which is dependant on the engine speed.

• Rail pressure disrupted, maximum negative rail pressure deviation with metering unit on lower limit is exceeded.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Actual value.

Power Reduction • No reduction.

Possible Reason for Error • Metering unit is not working properly.

• Fuel return line blocked.

• Injectors do not open.

Possible Consequence • Diagnostic lamp on, no damage on further parts.

Actions for Repair • Check backflow pressure.

• Check Injector function with SerDia. • Change components (metering unit, injector) if necessary.

7-102

TH255C

Diagnostics 7.1.99

KWP Code 861

KWP CODE

SPN CODE

861

523613

SPN GROUP FMI-NO.

Not Available

ERROR PATH RailMeUn3 SPN NAME FMI-INFO

1

COMPONENT

Manufacturer Assignable SPN Data valid but below normal operational range Rail pressure metering unit

Short Description • Rail pressure: the fuel pressure in rail calculated by ECU is below the target range which is dependant on the engine speed.

• Minimum rail pressure exceeded (RailMeUn3), minimum rail pressure exceeded.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Too low primary pressure on low pressure side.

• Sensor defective.

• Fuel system disturbed.

Possible Consequence • Diagnostic lamp on, no damage on further parts.

Actions for Repair • Check fuel level in tank and low pressure system.

TH255C

7-103

Diagnostics 7.1.100

KWP Code 862

KWP CODE

SPN CODE

862

523613

SPN GROUP FMI-NO.

ERROR PATH RailMeUn4

Not Available

SPN NAME FMI-INFO

0

COMPONENT

Manufacturer Assignable SPN Data valid but above normal operational range Rail pressure metering unit

Short Description • Rail pressure: the fuel pressure in rail calculated by ECU is above the target range which is dependant on the engine speed.

• Rail pressure disrupted, maximum rail pressure exceeded.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Actual value.

Power Reduction • No reduction

Possible Reason for Error • Metering unit is not working properly.

• Fuel return line blocked.

• Injectors do not open.

Possible Consequence • Diagnostic lamp on, no damage on further parts.

Actions for Repair • Check backflow pressure.

• Check pressure relief valve and metering unit.

• Change components if necessary.

7-104

TH255C

Diagnostics 7.1.101

KWP Code 864

KWP CODE

SPN CODE

864

523613

SPN GROUP FMI-NO.

Not Available

ERROR PATH RailMeUn7 SPN NAME FMI-INFO

2

COMPONENT

Manufacturer Assignable SPN Data erratic, intermittent, or incorrect Rail pressure metering unit

Short Description • Rail pressure: the fuel pressure in rail calculated by ECU is above the target range which is dependant on the engine speed.

• Setpoint of metering unit in overrun mode not plausible, setpoint of metering unit in overrun mode not plausible.

System Reaction • Warning : Speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 75%

Possible Reason for Error • Metering unit is not working properly.

Possible Consequence • Diagnostic lamp on, no damage on further parts

Actions for Repair • Check backflow pressure.

• Check metering unit.

• Change components if necessary.

TH255C

7-105

Diagnostics 7.1.102

KWP Code 876

KWP CODE

SPN CODE

876

523470

SPN GROUP FMI-NO.

Not Available

ERROR PATH RailPRV4 SPN NAME FMI-INFO

7

COMPONENT

Manufacturer Assignable SPN Mechanical system not responding properly Pressure relief valve Rail

Short Description • Rail pressure is out of the expected average range.

• Maximum rail pressure in limp home mode exceeded (PRV), Monitoring for maximum rail pressure in limp home mode with PRV.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Rail pressure relief valve does not open.

• Rail pressure relief valve defective.

Possible Consequence • Diagnostic lamp on, engine will be shut off, engine can be damaged.

Actions for Repair • Check rail pressure relief valve and replace if necessary.

7-106

TH255C

Diagnostics 7.1.103

KWP Code 877

KWP CODE

SPN CODE

877

157

SPN GROUP FMI-NO.

ERROR PATH RailPSRCMax

Engine Fluid Level/ Pressure 2

SPN NAME FMI-INFO

3

COMPONENT

Engine Injector Metering Rail 1 Pressure Voltage above normal or shorted high Rail pressure sensor

Short Description • Rail pressure sensor: the voltage of sensor measured by ECU is out of the target range.

• Sensor error rail pressure; signal range check high, Short cut to battery or open load.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Cable break or short circuit.

• Sensor defective.

• Connection cable damaged.

Possible Consequence • Diagnostic lamp on.

• Limp home speed activated.

• Engine shut off in about 5 minutes.

• Emission regulations are not kept.

Actions for Repair • Check wiring.

• Check rail pressure sensor and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

TH255C

7-107

Diagnostics 7.1.104

KWP Code 878

KWP CODE

SPN CODE

878

157

SPN GROUP FMI-NO.

ERROR PATH RailPSRCMin

Engine Fluid Level/ Pressure 2

SPN NAME FMI-INFO

4

COMPONENT

Engine Injector Metering Rail 1 Pressure Voltage below normal or shorted low Rail pressure sensor

Short Description • Rail pressure sensor: the voltage of sensor measured by ECU is out of the target range.

• Sensor error rail pressure; signal range check low, Short cut to ground.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Cable break or short circuit.

• Sensor defective.

• Connection cable damaged.

Possible Consequence • Diagnostic lamp on.

• Limp home speed activated.

• Engine shut off in about 5 minutes.

• Emission regulations are not kept.

Actions for Repair • Check wiring.

• Check rail pressure sensor and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

7-108

TH255C

Diagnostics 7.1.105

KWP Code 935

KWP CODE

SPN CODE

935

91

SPN GROUP FMI-NO.

ERROR PATH SRCHighAPP1

Electronic Engine Controller 2

SPN NAME FMI-INFO

3

COMPONENT

Accelerator Pedal Position 1 Voltage above normal or shorted high Accelerator pedal

Short Description • Analog accelerator pedal sensor 1 or double accelerator pedal sensor: the voltage measured by ECU is out of the target range or the calculated pedal position is implausible compared with the position of the second pedal.

• Sensor error accelerator pedal; signal range check high, Short cut to battery or open load.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Actual value.

Power Reduction • No reduction

Possible Reason for Error • Voltage outside target range.

• Signal implausible compared to signal of redundant pedal (analog pedal 1).

• Sensor defective.

• Connection cable damaged.

Possible Consequence • Diagnostic lamp on.

• Limp home speed is activated if applicated.

Actions for Repair • Check wiring.

• Check accelator pedal sensor and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

TH255C

7-109

Diagnostics 7.1.106

KWP Code 940

KWP CODE

SPN CODE

940

91

SPN GROUP FMI-NO.

ERROR PATH SRCLowAPP1

Electronic Engine Controller 2

SPN NAME FMI-INFO

4

COMPONENT

Accelerator Pedal Position 1 Voltage below normal or shorted low Accelerator pedal

Short Description • Analog accelerator pedal sensor 1 or double accelerator pedal sensor: the voltage measured by ECU is out of the target range or the calculated pedal position is implausible compared with the position of the second pedal.

• Sensor error accelerator pedal; signal is below the range, Short cut to ground.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Actual value.

Power Reduction • No reduction

Possible Reason for Error • Voltage outside target range.

• Signal implausible compared to signal of redundant pedal (analog pedal 1).

• Sensor defective.

• Connection cable damaged.

Possible Consequence • Diagnostic lamp on, limp home speed is activated if applicated.

Actions for Repair • Check wiring.

• Check accelator pedal sensor and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

7-110

TH255C

Diagnostics 7.1.107

KWP Code 946

KWP CODE

SPN CODE

946

1079

SPN GROUP FMI-NO.

Not Available

ERROR PATH SSpMon1 SPN NAME FMI-INFO

13

COMPONENT

Sensor Supply Voltage 1 (+5V DC) (obsolete) Out of Calibration Sensor voltage 1 monitoring

Short Description • Internal hardware monitoring: the ECU detects a deviation of the target range of the power supply voltage of sensor output 1.

• Sensor supply voltage monitor 1 error (ECU), Error in sensor voltage 1.

System Reaction • Warning : Error lamp shows permanent light. Entry in error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Wrong voltage of internal 5V reference source 1.

• Operating voltage too high or too low.

• Connection cable damaged.

• ECU defective.

Possible Consequence • Diagnostic lamp on.

• Analog connected actuators on ECU may not work.

Actions for Repair • Check wiring of external components.

• Check working voltage and if necessary correct it.

• Check connection cable and if necessary repair or replace it, if error is not removable, change ECU.

TH255C

7-111

Diagnostics 7.1.108

KWP Code 947

KWP CODE

SPN CODE

947

1080

SPN GROUP FMI-NO.

Not Available

ERROR PATH SSpMon2 SPN NAME FMI-INFO

13

COMPONENT

Sensor Supply Voltage 2 (+5V DC) (obsolete) Out of Calibration Sensor voltage 2 monitoring

Short Description • Internal hardware monitoring: the ECU detects a deviation of the target range of the power supply voltage of sensor output 2.

• Sensor supply voltage monitor 2 error (ECU), Error in sensor voltage 2.

System Reaction • Warning : Errorlamp shows permanent light. Entry in error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Wrong voltage of internal 5V reference source 2.

• Operating voltage too high or too low.

• Connection cable damaged.

• ECU defective.

Possible Consequence • Diagnostic lamp on.

• Analog connected actuators on ECU may not work.

Actions for Repair • Check wiring of external components.

• Check working voltage and if necessary correct it, • Check connection cable and if necessary repair or replace it, if error is not removable, change ECU.

7-112

TH255C

Diagnostics 7.1.109

KWP Code 948

KWP CODE

SPN CODE

948

523601

SPN GROUP FMI-NO.

ERROR PATH SSpMon3

Not Available

SPN NAME FMI-INFO

13

COMPONENT

Manufacturer Assignable SPN Out of Calibration Sensor voltage 3 monitoring

Short Description • Internal hardware monitoring: the ECU detects a deviation of the target range of the power supply voltage of sensor output 3.

• Sensor supply voltage monitor 3 error (ECU), Error in sensor voltage 3.

System Reaction • Warning : Error lamp shows permanent light. Entry in error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Wrong voltage of internal 5V reference source 3.

• Operating voltage too high or too low.

• Connection cable damaged, ECU defective.

Possible Consequence • Diagnostic lamp on.

• Analog connected actuators on ECU may not work.

Actions for Repair • Check wiring of external components.

• Check working voltage and if necessary correct it, • Check connection cable and if necessary repair or replace it, if error is not removable, change ECU.

TH255C

7-113

Diagnostics 7.1.110

KWP Code 956

KWP CODE

SPN CODE

956

677

SPN GROUP FMI-NO.

Not Available

ERROR PATH StrtHSSCB SPN NAME FMI-INFO

3

COMPONENT

Engine Starter Motor Relay Voltage above normal or shorted high Starter control

Short Description • Start relay (high side power stage): the current drop measured by ECU is above the target range.

• Starter relay; short circuit, Short cut HighSide-output to battery.

System Reaction • Powerstage is switched off.

• permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Start relay (high side): short circuit.

• Relay defective.

• Conncection cable defective.

Possible Consequence • Diagnostic lamp on

Actions for Repair • Check wiring and start relay and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

7-114

TH255C

Diagnostics 7.1.111

KWP Code 957

KWP CODE

SPN CODE

957

677

SPN GROUP FMI-NO.

Not Available

ERROR PATH StrtHSSCG SPN NAME FMI-INFO

4

COMPONENT

Engine Starter Motor Relay Voltage below normal or shorted low Starter control

Short Description • Start relay (high side power stage): the current drain measured by ECU is above the target range.

• Starter relay; short circuit, Short cut HighSide-output to ground.

System Reaction • Powerstage is switched off.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Start relay (high side): short circuit.

• Relay defective.

• Conncection cable defective.

Possible Consequence • Diagnostic lamp on.

Actions for Repair • Check wiring and start relay and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

TH255C

7-115

Diagnostics 7.1.112

KWP Code 958

KWP CODE

SPN CODE

958

677

SPN GROUP FMI-NO.

Not Available

ERROR PATH StrtLSOL SPN NAME FMI-INFO

5

COMPONENT

Engine Starter Motor Relay Current below normal or open circuit Starter control

Short Description • Start relay (low side power stage): the current drop measured by ECU is above the target range.

• Starter relay; no load error, Open circuit/ disconnection LowSide-Output.

System Reaction • Powerstage is switched off.

• Errorlamp shows permanent light. Entry in error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction

Possible Reason for Error • Start relay (low side): cable break or short circuit.

• Disabled by ECU. • Relay defective.

• Connection cable damaged.

Possible Consequence • Diagnostic lamp on.

Actions for Repair • Check wiring and start relay and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

7-116

TH255C

Diagnostics 7.1.113

KWP Code 959

KWP CODE

SPN CODE

959

677

SPN GROUP FMI-NO.

ERROR PATH StrtLSOvrTemp

Not Available

SPN NAME FMI-INFO

12

COMPONENT

Engine Starter Motor Relay Bad intelligent device or component Starter control

Short Description • Start relay (low side power stage): the current drop measured by ECU is above the target range.

• Starter relay; powerstage over temperature, Temperature over limit.

System Reaction • Powerstage is switched off.

• Errorlamp shows permanent light. Entry in error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Start relay (low side): short circuit.

• Relay defective.

• Conncection cable defective.

Possible Consequence • Diagnostic lamp on.

Actions for Repair • Check wiring and start relay and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

TH255C

7-117

Diagnostics 7.1.114

KWP Code 960

KWP CODE

SPN CODE

960

677

SPN GROUP FMI-NO.

Not Available

ERROR PATH StrtLSSCB SPN NAME FMI-INFO

3

COMPONENT

Engine Starter Motor Relay Voltage above normal or shorted high Starter control

Short Description • Start relay (high side power stage): the current drain measured by ECU is above the target range.

• Starter relay; short circuit, Short cut LowSide-Output to battery.

System Reaction • Powerstage is switched off.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Start relay (high side): short circuit, • Relay defective.

• Connection cable defective.

Possible Consequence • Diagnostic lamp on.

Actions for Repair • Check wiring and start relay and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

7-118

TH255C

Diagnostics 7.1.115

KWP Code 961

KWP CODE

SPN CODE

961

677

SPN GROUP FMI-NO.

Not Available

ERROR PATH StrtLSSCG SPN NAME FMI-INFO

4

COMPONENT

Engine Starter Motor Relay Voltage below normal or shorted low Starter control

Short Description • Start relay (high side power stage): the current drop measured by ECU is above the target range.

• Starter relay; short circuit, Short cut LowSide-Output to ground.

System Reaction • Powerstage is switched off.

• Error lamp shows permanent light. Entry in error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Start relay (high side): short circuit, • Relay defective.

• Conncection cable defective.

Possible Consequence • Diagnostic lamp on.

Actions for Repair • Check wiring and start relay and if necessary replace it.

• Check connection cable of terminal 50 and if necessary repair or replace it.

TH255C

7-119

Diagnostics 7.1.116

KWP Code 973

KWP CODE

SPN CODE

973

523612

SPN GROUP FMI-NO.

Not Available

ERROR PATH SWReset_0 SPN NAME FMI-INFO

14

COMPONENT

Manufacturer Assignable SPN Special Instructions Software reset 1

Short Description • Internal hardware monitoring: the CPU of the ECU is reset and the cause is logged internally; no item will be created in error memory.

• Softwarereset CPU, Visibility of Softwareresets in DSM.

System Reaction • Warning : Errorlamp shows blinking light. Entry in error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • A recovery occurred which is stored as protected.

Possible Consequence • Diagnostic lamp on.

Actions for Repair • If possible the software update has to be done.

Replace the ECU.

7-120

TH255C

Diagnostics 7.1.117

KWP Code 974

KWP CODE

SPN CODE

974

523612

SPN GROUP FMI-NO.

Not Available

ERROR PATH SWReset_1 SPN NAME FMI-INFO

14

COMPONENT

Manufacturer Assignable SPN Special Instructions Software reset 2

Short Description • Internal hardware monitoring: the CPU of the ECU is reset and the cause is logged internally; no item will be created in error memory.

• Softwarereset CPU, Visibility of Softwareresets in DSM.

System Reaction • Warning : Blinking light, entry into error memory.

• Measurement in case of error: Not available

Power Reduction • No reduction.

Possible Reason for Error • A recovery occurred which is stored as protected.

Possible Consequence • Diagnostic lamp on.

Actions for Repair • If possible the software update has to be done.

Replace the ECU.

TH255C

7-121

Diagnostics 7.1.118

KWP Code 975

KWP CODE

SPN CODE

975

523612

SPN GROUP FMI-NO.

Not Available

ERROR PATH SWReset_2 SPN NAME FMI-INFO

14

COMPONENT

Manufacturer Assignable SPN Special Instructions Software reset 3

Short Description • Internal hardware monitoring: the CPU of the ECU is reset and the cause is logged internally; no item will be created in error memory.

• Software reset CPU, Visibility of SoftwareResets in DSM.

System Reaction • Warning : Error lamp shows blinking light. Entry in error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • A recovery occurred which is stored as protected.

Possible Consequence • Diagnostic lamp on.

Actions for Repair • If possible the software update has to be done.

Replace the ECU.

7-122

TH255C

Diagnostics 7.1.119

KWP Code 976

KWP CODE

SPN CODE

976

91

SPN GROUP FMI-NO.

Electronic Engine Controller 2

ERROR PATH SyncAPP SPN NAME

Accelerator Pedal Position 1

FMI-INFO

Failure mode not identifiable

11

COMPONENT

Accelerator pedal synchronisation

Short Description • Plausibility error between APP1 and idle switch.

• Plausibility error between APP1 and APP2 or APP1 and idle switch, Measured voltage of accelearotor pedal 1 is out of plausible range.

System Reaction • Warning: Error lamp shows permanent light. Entry in error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Broken pedal axle which causes a stacked pedal sensor.

• Defect IVS which causes wrong sensor signal.

• Voltage outside of range.

• Signal implausible compared to signal of redundant pedal (analog pedal 1).

• Sensor defective.

• Connection cable damaged.

Possible Consequence • Diagnostic lamp on.

• Limp home speed is activated.

Actions for Repair • Check wiring.

• Check accelerator pedal and pedal sensor and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

TH255C

7-123

Diagnostics 7.1.120

KWP Code 980

KWP CODE

SPN CODE

980

523550

SPN GROUP FMI-NO.

ERROR PATH T50Err

Not Available

SPN NAME FMI-INFO

12

COMPONENT

Manufacturer Assignable SPN Bad intelligent device or component Terminal 50

Short Description • Terminal 50: ECU receives a permanent signal.

• T50 start switch active for too long, Startinformation to Starter (T50-switch) erratic/defect.

System Reaction • Warning: Prio 1, permanent light, entry into error memory.

• Measurement in case of error: actual value.

Power Reduction • No reduction.

Possible Reason for Error • Engine start switch stuck.

• Start switch clamped.

• Connection cable damaged.

Possible Consequence • Diagnostic lamp on.

• T50 switch can be damaged.

Actions for Repair • Check wiring, if sensor not working.

• Check start switch and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

7-124

TH255C

Diagnostics 7.1.121

KWP Code 994

KWP CODE

SPN CODE

994

105

SPN GROUP

Inlet/Exhaust Conditions 1

FMI-NO.

3

ERROR PATH TCACDsSRCMax SPN NAME

Engine Intake Manifold 1 Temperature

FMI-INFO

Voltage above normal or shorted high

COMPONENT

Charge air temperature sensor

Short Description • Charge air temperature sensor: the voltage of sensor measured by ECU is out of the target range.

• Sensor error charged air temperature; signal range check high, Short cut to battery or open load.

System Reaction • Ramp to default value (60° C).

• Errorlamp shows permanent light. Entry in error memory.

• Measurement in case of error: 60° C.

Power Reduction • No reduction.

Possible Reason for Error • Cable break or short circuit.

• Sensor defective.

• Connection cable damaged.

Possible Consequence • Diagnostic lamp on.

Actions for Repair • Check wiring.

• CAC-sensor not working, • Check sensor and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

TH255C

7-125

Diagnostics 7.1.122

KWP Code 995

KWP CODE

SPN CODE

995

105

SPN GROUP

Inlet/Exhaust Conditions 1

FMI-NO.

4

ERROR PATH TCACDsSRCMin SPN NAME FMI-INFO COMPONENT

Engine Intake Manifold 1 Temperature Voltage below normal or shorted low Charge air temperature sensor

Short Description • Charge air temperature sensor: the voltage of sensor measured by ECU is out of the target range.

• Sensor error charged air temperature; signal range check low, Short cut to ground.

System Reaction • Ramp to default value (60° C).

• Error lamp shows permanent light. Entry in error memory.

• Measurement in case of error: 60° C.

Power Reduction • No reduction.

Possible Reason for Error • Cable break or short circuit.

• Sensor defective.

• Connection cable / wiring damaged.

Possible Consequence • Diagnostic lamp on.

Actions for Repair • Check CAC-sensor and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

7-126

TH255C

Diagnostics 7.1.123

KWP Code 996

KWP CODE

SPN CODE

996

105

SPN GROUP

Inlet/Exhaust Conditions 1

FMI-NO.

ERROR PATH TCACDsSysReacMax SPN NAME FMI-INFO

0

COMPONENT

Engine Intake Manifold 1 Temperature Data valid but above normal operational range Charge air temperature sensor

Short Description • Charge air temperature downstream calculated by ECU is above the target range; the ECU activates a system reaction.

• Charged air cooler temperature; system reaction initiated, Charge air temperature (downstream) over warning threshold.

System Reaction • Warning : Power reduction and engine shut off demand.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 185°C-199°C /100% - 80%.

Possible Reason for Error • Charge air cooler is clogged.

• Fan system does not work proper.

• Blocked or dirty piping to CAC.

Possible Consequence • Diagnostic lamp on.

Actions for Repair • Check CAC system and clean it.

• Check fan functionality.

• Check cooling perfomance with temperature measurement.

TH255C

7-127

Diagnostics 7.1.124

KWP Code 997

KWP CODE

SPN CODE

997

105

SPN GROUP

Inlet/Exhaust Conditions 1

FMI-NO.

ERROR PATH TCACDsSysReacMin SPN NAME FMI-INFO

0

COMPONENT

Engine Intake Manifold 1 Temperature Data valid but above normal operational range Charge air temperature sensor

Short Description • Charge air temperature downstream calculated by ECU is above the shut down threshold; the ECU activates a system reaction.

• Charged air cooler temperature; system reaction initiated, Charge air temperature (downstream) over shut off threshold.

System Reaction • Warning : Power reduction and engine shut off demand.

• Error lamp shows blinking light. Entry in error memory.

• Measurement in case of error: Not available.

Power Reduction • 185°C-199°C /100% - 80%.

Possible Reason for Error • Charge air cooler is clogged.

• Fan system does not work proper.

• Blocked or dirty piping to CAC.

Possible Consequence • Diagnostic lamp blinking.

Actions for Repair • Check CAC system and clean it.

• Check fan functionality.

• Check cooling perfomance with temperature measurement.

7-128

TH255C

Diagnostics 7.1.125

KWP Code 1014

KWP CODE

SPN CODE

1014

51

SPN GROUP FMI-NO.

Fuel Economy (Liquid)

ERROR PATH ActrCustCrntMeasSRCMax SPN NAME FMI-INFO

6

COMPONENT

Engine Throttle Position Not Available H-Bride Output

Short Description • Actuator error EGR-Valve; signal range check high.

• Actuator error EGR-Valve: internal error, Short cut to battery or open load.

System Reaction • Warning : Speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 60%

Possible Reason for Error • Short circuit to Ubatt.

• Connecting cable is damaged.

Possible Consequence • Diagnostic lamp on.

• Emission regulations are not kept.

Actions for Repair • Check wiring and repair or replace if necessary.

• Check actuator with SERDIA test for EGR and if necessary replace it.

TH255C

7-129

Diagnostics 7.1.126

KWP Code 1015

KWP CODE

SPN CODE

1015

51

SPN GROUP FMI-NO.

Fuel Economy (Liquid)

ERROR PATH ActrCustCrntMeasSRCMin SPN NAME FMI-INFO

5

COMPONENT

Engine Throttle Position Not Available H-Bride Output

Short Description • Actuator error EGR-Valve; signal range check low.

• Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); internal error, Short cut to ground.

System Reaction • Warning : Speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 60%

Possible Reason for Error • Short circuit to ground or open load.

• Connecting cable is damaged.

• Counter plug is loose.

Possible Consequence • Diagnostic lamp on.

• Emission regulations are not kept.

Actions for Repair • Check wiring and repair or replace if necessary.

• Check actuator with SERDIA test for EGR and if necessary replace it.

7-130

TH255C

Diagnostics 7.1.127

KWP Code 1016

KWP CODE

SPN CODE

1016

51

SPN GROUP FMI-NO.

Fuel Economy (Liquid)

ERROR PATH ActrCustInvalidPosErr SPN NAME FMI-INFO

7

COMPONENT

Engine Throttle Position Not Available H-Bride Output

Short Description • Actuator position for EGR valve is not plausible, internal error, angular misalignement of the flap (deviation from setpoint > 7%).

• Actuator error EGR-Valve; internal error, Position error of throttle flap (deviation > 7%).

System Reaction • Warning : Speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 60%

Possible Reason for Error • incorrect calibration, failed control of ECU.

Possible Consequence • Diagnostic lamp on.

• Emission regulations are not kept.

Actions for Repair • Troubleshooting with SERDIA 2010 Use Case "EGR Diagnostic".

TH255C

7-131

Diagnostics 7.1.128

KWP Code 1022

KWP CODE

SPN CODE

1022

51

SPN GROUP FMI-NO.

Fuel Economy (Liquid)

ERROR PATH ActrCustSRCCrntMax SPN NAME FMI-INFO

6

COMPONENT

Engine Throttle Position Not Available H-Bride Output

Short Description • Actuator error EGR-Valve; signal range check high, measured current by ECU is over target.

• Actuator error EGR-Valve; internal error, Short cut to battery or open load.

System Reaction • Warning : Speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 60%.

Possible Reason for Error • Actuator defective.

• Connecting cable is damaged.

Possible Consequence • Diagnostic lamp on.

• Emission regulations are not kept.

Actions for Repair • Check wiring, • Check cabels and repair or replace if necessary.

• Check actuator with SERDIA 2010 test for EGR and if necessary replace it.

7-132

TH255C

Diagnostics 7.1.129

KWP Code 1023

KWP CODE

SPN CODE

1023

51

SPN GROUP FMI-NO.

Fuel Economy (Liquid)

ERROR PATH ActrCustSRCCrntMin SPN NAME FMI-INFO

5

COMPONENT

Engine Throttle Position Not Available H-Bride Output

Short Description • Actuator error EGR-Valve; signal range check low, measured current is below target.

• Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); internal error, Short cut to ground.

System Reaction • Warning: Speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 60%

Possible Reason for Error • Actuator defective.

• Connecting cable is damaged.

Possible Consequence • Diagnostic lamp on.

• Emission regulations are not kept.

Actions for Repair • Check wiring.

• Check cabels and repair or replace if necessary.

• Check actuator with SERDIA 2010 test for EGR and if necessary replace it.

TH255C

7-133

Diagnostics 7.1.130

KWP Code 1024

KWP CODE

SPN CODE

1024

51

SPN GROUP FMI-NO.

Fuel Economy (Liquid) 3

ERROR PATH ActrCustSRCMax SPN NAME FMI-INFO COMPONENT

Engine Throttle Position Not Available H-Bride Output

Short Description • Actuator of the external EGR valve: the ECU detects a short circuit to battery or open load.

• Actuator error EGR-Valve; internal error, Short cut to battery or open load.

System Reaction • Warning, Ramp to Not available (50%) and speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: 50%.

Power Reduction • 60%

Possible Reason for Error • Short circuit to Ubatt.

• Connection cable damaged.

Possible Consequence • Diagnostic lamp on.

• Emission regulations are not kept.

Actions for Repair • Check wiring, actuator defect.

• Check actuator and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

7-134

TH255C

Diagnostics 7.1.131

KWP Code 1025

KWP CODE

SPN CODE

1025

51

SPN GROUP FMI-NO.

Fuel Economy (Liquid) 4

ERROR PATH ActrCustSRCMin SPN NAME FMI-INFO COMPONENT

Engine Throttle Position Not Available H-Bride Output

Short Description • Actuator of the external EGR valve: the ECU detects a short circuit to ground.

• Actuator error EGR-Valve; internal error, Short cut to ground.

System Reaction • Warning, Ramp to Not available (50%) and speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: 50%.

Power Reduction • 60%

Possible Reason for Error • Short circuit to ground, connection cable damaged.

Possible Consequence • Diagnostic lamp on, emission regulations are not kept.

Actions for Repair • Check wiring, actuator defect.

• Check actuator and if necessary replace it.

• Check connection cable and if necessary repair or replace it.

TH255C

7-135

Diagnostics 7.1.132

KWP Code 1157

KWP CODE

SPN CODE

1157

97

SPN GROUP FMI-NO.

Water in Fuel Indicator

ERROR PATH WtLvlFlFWLvl SPN NAME FMI-INFO

12

COMPONENT

Water In Fuel Indicator Bad intelligent device or component Water seperator fuel filter

Short Description • Fuel filter water level sensor: the maximum level is exceeded.

• Water in fuel level prefilter; maximum value exceeded, Water level over limit (bad fuel quality).

System Reaction • Warning : Error lamp shows permanent light. Entry in error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Water level in fuel pre-filter.

Possible Consequence • Diagnostic lamp on.

Actions for Repair • Drain water out from pre-filter.

7-136

TH255C

Diagnostics 7.1.133

KWP Code 1170

KWP CODE

SPN CODE

1170

523612

SPN GROUP

Not Available

ERROR PATH MoCSOPPsvTstErr SPN NAME FMI-INFO

FMI-NO.

12 COMPONENT

Manufacturer Assignable SPN Bad intelligent device or component Test of redundant shut-off paths (ECU internal error)

Short Description • Internal hardware monitoring: the CPU of the ECU is reset and the cause is logged internally; no item will be created in error memory.

• ECU reported internal software error, Error during positive test (ECU internal error). Diagnostic fault check to report that the positive test failed.

System Reaction • Warning: Speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 75%

Possible Reason for Error • ECU defective.

• Software erratic.

Possible Consequence • Diagnostic lamp on, no damage on further parts.

Actions for Repair • Reflash ECU. • If error is still active replace ECU.

TH255C

7-137

Diagnostics 7.1.134

KWP Code 1180

KWP CODE

SPN CODE

1180

168

ERROR PATH BattUHi

SPN GROUP

Vehicle Electrical Power 1

SPN NAME

FMI-NO.

FMI-INFO

0

COMPONENT

Battery Potential / Power Input 1 Data valid but above normal operational range Battery voltage

Short Description • Battery voltage: The voltage measured by ECU is out of the target range.

• Physikal range check high for battery voltage, Batteryvoltage over limit.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Actual value.

Power Reduction • No reduction.

Possible Reason for Error • Alternator regulator defective.

• Wiring damaged.

Possible Consequence • Diagnostic lamp on for permanent overvoltage, the ECU can be damaged.

Actions for Repair • Check alternator regulatorof alternator and if necessary replace it.

• Check wiring and voltage of alternator.

7-138

TH255C

Diagnostics 7.1.135

KWP Code 1181

KWP CODE

SPN CODE

1181

168

ERROR PATH BattULo

SPN GROUP

Vehicle Electrical Power 1

SPN NAME

FMI-NO.

FMI-INFO

1

COMPONENT

Battery Potential / Power Input 1 Data valid but below normal operational range Battery voltage

Short Description • Battery voltage: the voltage measured by ECU is out of the target range.

• Physical range check low for battery voltage.

• Battery voltage below limit.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Actual value.

Power Reduction • No reduction

Possible Reason for Error • Alternator defective.

• Voltage below target range.

• battery defective.

• Too low power supply voltage.

• Too high contact resistance.

Possible Consequence • Diagnostic lamp on, ECU will reset, no damage to ECU.

Actions for Repair • Check alternator, wiring, contact resistance, safety fuses, too high load in energy system.

• Check battery and if necessary replace it.

• Check battery pole and if necessary clean it, • Check voltage of alternator.

TH255C

7-139

Diagnostics 7.1.136

KWP Code 1223

KWP CODE

SPN CODE

1223

51

SPN GROUP FMI-NO.

Fuel Economy (Liquid)

ERROR PATH ActrCustHBrgOL SPN NAME FMI-INFO

5

COMPONENT

Engine Throttle Position Not Available H-Bride Output

Short Description • Actuator EGR-Valve: Open load on ECU output is detected.

• Actuator error EGR-Valve (2.9;3.6) internal error, Open circuit to connected actuator.

System Reaction • Warning : Speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 60%

Possible Reason for Error • Disconnected actuator.

• Connection cable damaged.

• Broken wiring.

Possible Consequence • Diagnostic lamp on.

• Emission regulations are not kept.

Actions for Repair • Check wiring and if necessary repair or replace it.

• Check EGR valve function with SerDia 2010 use case.

7-140

TH255C

Diagnostics 7.1.137

KWP Code 1224

KWP CODE

SPN CODE

1224

51

SPN GROUP FMI-NO.

Fuel Economy (Liquid)

ERROR PATH ActrCustHBrgOvrCurr SPN NAME FMI-INFO

6

COMPONENT

Engine Throttle Position Not Available H-Bride Output

Short Description • Actuator EGR-valve: too high cuurent is going into the actuator. Output is switched off.

• Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); internal error, Overload.

System Reaction • Warning : Speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 60%

Possible Reason for Error • Broken wiring.

• Actuator defective.

Possible Consequence • Diagnostic lamp on.

• Emission regulations are not kept.

Actions for Repair • Check wiring and if necessary repair or replace it.

• Check EGR valve function with SerDia 2010 use case, if necessary replace actuator.

TH255C

7-141

Diagnostics 7.1.138

KWP Code 1226

KWP CODE

SPN CODE

1226

51

SPN GROUP FMI-NO.

Fuel Economy (Liquid)

ERROR PATH ActrCustHBrgSCB1 SPN NAME FMI-INFO

3

COMPONENT

Engine Throttle Position Not Available H-Bride Output

Short Description • Actuator EGR-valve: short cut to battery on ECU pin A19 is detected.

• Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); internal error, Short cut to battery.

System Reaction • Warning : Speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 60%

Possible Reason for Error • Short circuit or broken wiring on ECU pin A19.

• Actuator defective.

Possible Consequence • Diagnostic lamp on.

• Emission regulations are not kept.

Actions for Repair • Check wiring and if necessary repair or replace it.

• Check actuator with SerDia 2010 use case and replace if necessary.

7-142

TH255C

Diagnostics 7.1.139

KWP Code 1227

KWP CODE

SPN CODE

1227

51

SPN GROUP FMI-NO.

Fuel Economy (Liquid)

ERROR PATH ActrCustHBrgSCB2 SPN NAME FMI-INFO

3

COMPONENT

Engine Throttle Position Not Available H-Bride Output

Short Description • Actuator EGR-valve: short cut to battery on ECU pin A20 is detected.

• Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); internal error, Short cut to battery.

System Reaction • Warning : Speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 60%

Possible Reason for Error • Short circuit or broken wiring on ECU pin A20.

• Actuator defective.

Possible Consequence • Diagnostic lamp on.

• Emission regulations are not kept.

Actions for Repair • Check wiring and if necessary repair or replace it.

• Check actuator with SerDia 2010 use case and replace if necessary.

TH255C

7-143

Diagnostics 7.1.140

KWP Code 1228

KWP CODE

SPN CODE

1228

51

SPN GROUP FMI-NO.

Fuel Economy (Liquid)

ERROR PATH ActrCustHBrgSCG1 SPN NAME FMI-INFO

4

COMPONENT

Engine Throttle Position Not Available H-Bride Output

Short Description • Actuator EGR-valve: short cut to ground on ECU pin A19 is detected.

• Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); internal error, Short cut to ground.

System Reaction • Warning: Speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 60 %

Possible Reason for Error • Short circuit or broken wiring on ECU pin A19.

• Actuator defective.

Possible Consequence • Diagnostic lamp on.

• Emission regulations are not kept.

Actions for Repair • Check wiring and if necessary repair or replace it.

• Check actuator with SerDia 2010 use case and replace if necessary.

7-144

TH255C

Diagnostics 7.1.141

KWP Code 1229

KWP CODE

SPN CODE

1229

51

SPN GROUP FMI-NO.

Fuel Economy (Liquid)

ERROR PATH ActrCustHBrgSCG2 SPN NAME FMI-INFO

4

COMPONENT

Engine Throttle Position Not Available H-Bride Output

Short Description • Actuator EGR-valve: short cut to battery on ECU pin A20 is detected.

• Actuator error EGR-Valve (2.9;3.6); internal error, Short cut to ground.

System Reaction • Warning: Speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 60%

Possible Reason for Error • Short circuit or broken wiring on ECU pin A20.

• Actuator defective.

Possible Consequence • Diagnostic lamp on.

• Emission regulations are not kept.

Actions for Repair • Check wiring and if necessary repair or replace it.

• Check actuator with SerDia 2010 use case and replace if necessary.

TH255C

7-145

Diagnostics 7.1.142

KWP Code 1230

KWP CODE

SPN CODE

1230

51

SPN GROUP FMI-NO.

Fuel Economy (Liquid)

ERROR PATH ActrCustHBrgShCirOvrLd SPN NAME FMI-INFO

6

COMPONENT

Engine Throttle Position Not Available H-Bride Output

Short Description • Actuator error EGR-valve; Overload by short-circuit.

• Actuator error EGR-Valve (2.9;3.6); internal error, Short circuit, load over limit.

System Reaction • Warning : Speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 60%

Possible Reason for Error • Short circuit on H-bridge.

• Actuator defective.

• Connection cable damaged.

• ECU defective.

Possible Consequence • Diagnostic lamp on.

• Emission regulations are not kept.

Actions for Repair • Check actuator function with SerDia use case and replace if necessary.

• Check wiring, • If the error still occurs replace ECU.

7-146

TH255C

Diagnostics 7.1.143

KWP Code 1231

KWP CODE

SPN CODE

1231

51

SPN GROUP FMI-NO.

Fuel Economy (Liquid)

ERROR PATH ActrCustHBrgTempOvrCurr SPN NAME FMI-INFO

11

COMPONENT

Engine Throttle Position Not Available H-Bride Output

Short Description • Actuator EGR-valve: Temperature limit in powerstage of the actuator is reached due to high current.

• Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); internal error, Temperature over limit.

System Reaction • Warning : Speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 60 %

Possible Reason for Error • Actuator defective.

• EGR throttle flap stuck.

Possible Consequence • Diagnostic lamp on, emission regulations are not kept.

Actions for Repair • Check actuator function with SerDia 2010 use-case and repair or replace it if necessary.

TH255C

7-147

Diagnostics 7.1.144

KWP Code 1232

KWP CODE

SPN CODE

1232

51

SPN GROUP FMI-NO.

Fuel Economy (Liquid)

ERROR PATH ActrCustHBrgUndrVltg SPN NAME FMI-INFO

4

COMPONENT

Engine Throttle Position Not Available H-Bride Output

Short Description • Actuator EGR-valve: meassured voltage by ECU is under limit.

• Actuator error EGR-Valve (2.9;3.6) or Throttle-Valve (6.1,7.8); internal error, Current over limit.

System Reaction • Warning : Speed pending power reduction.

• Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • 60%

Possible Reason for Error • Actuator counter plug disconnected.

• Broken wiring, open load, loose contact.

Possible Consequence • Diagnostic lamp on.

• Emission regulations are not kept.

Actions for Repair • Check wiring and counter plugs in the actuator EGR circuit and if necessary repair or replace it.

7-148

TH255C

Diagnostics 7.1.145

KWP Code 1505

KWP CODE

SPN CODE

1505

524057

SPN GROUP FMI-NO.

Not Available

ERROR PATH PSPCtlPresBuildUp SPN NAME FMI-INFO

2

COMPONENT

Manufacturer Assignable SPN Not Available Fuel feed pump (Pre pressure control)

Short Description • Electric fuel pump; fuel pressure build up error.

• Electric fuel pump; fuel pressure build up error, Pressure build up error.

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • Leakage in fuel system.

• Fuel pump defective.

Possible Consequence • Diagnostic lamp on.

Actions for Repair • Check low fuel pressure system (fuel feed pump, relay , fuse, wiring, sensor) and if necessary repair or replace it.

TH255C

7-149

Diagnostics 7.1.146

KWP Code 1669

KWP CODE

SPN CODE

1669

524108

SPN GROUP FMI-NO.

Not Available

ERROR PATH ComEGRTVActrTO SPN NAME

Manufacturer Assignable SPN

FMI-INFO

Not Available

COMPONENT

CAN Message

9

Short Description • Missing CAN message of EGR throttle valve.

• Timeout error of CAN-Transmit-Frame ComEGRTVActr, Timeout Error (Missing CAN Bus message).

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • CAN bus wrong cabled.

• Wiring is damaged.

• Receiver (sender of the message) work inaccurately.

• Parametering inaccurate.

Possible Consequence • Diagnostic lamp on, emission regulations are not kept, engine can be damaged.

Actions for Repair • Check CAN Bus wiring (Bus sheduling, polarity, short circuit, power interrupt).

• Test protocol of receiver.

• Check CAN functional range.

• Check actuator.

7-150

TH255C

Diagnostics 7.1.147

KWP Code 1679

KWP CODE

SPN CODE

1679

524109

SPN GROUP FMI-NO.

Not Available

ERROR PATH ComRxEGRTVActrTO SPN NAME

Manufacturer Assignable SPN

FMI-INFO

Not Available

COMPONENT

CAN message

9

Short Description • Missing message of EGR throttle valve.

• Timeout error of CAN-Receive-Frame ComRxEGRTVActr, Timeout Error (Missing CAN Bus message).

System Reaction • Warning : Permanent light, entry into error memory.

• Measurement in case of error: Not available.

Power Reduction • No reduction.

Possible Reason for Error • CAN bus wrong cabled.

• Wiring is damaged.

• Receiver (sender of the message) work inaccurately.

• Parametering inaccurate.

Possible Consequence • Diagnostic lamp on.

• Emission regulations are not kept.

• Engine can be damaged.

Actions for Repair • Check CAN Bus wiring (Bus scheduling, polarity, short circuit, power interrupt).

• Test protocol of receiver.

• Check CAN functional range.

• Check actuator.

TH255C

7-151

Diagnostics

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TH255C

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