Académique Documents
Professionnel Documents
Culture Documents
4l dit appendix
TABLE OF CONTENTS
Torque Charts....................................................... 82-87
Wiring Diagram.................................................... 88-89
Diagnostic Codes............................................... 90-101
81
STANDARD
METRIC
Figure C
Figure C
114 lbf/in
13 Nm
114 lbf/in
13 Nm
23 lbf/ft
31 Nm
33 lbf/ft
45 Nm
50 lbf/ft
68 Nm
30 lbf/ft
41 Nm
23 lbf/ft
31 Nm
23 lbf/ft
31 Nm
114 lbf/in
13 Nm
18 lbf/ft
25 Nm
23 lbf/ft
31 Nm
180 lbf/in
20 Nm
114 lbf/in
13 Nm
Figure A
Figure A
32 lbf/ft
44 Nm
31 lbf/in
3.5 Nm
28 lbf/ft
38 Nm
23 lbf/ft
31 Nm
23 lbf/ft
31 Nm
Figure K
Figure K
23 lbf/ft
31 Nm
23 lbf/ft
31 Nm
23 lbf/ft
31 Nm
88 lbf/in
10 Nm
88 lbf/in
10 Nm
88 lbf/in
10 Nm
159 lbf/in
18 Nm
124 lbf/in
14 Nm
159 lbf/in
18 Nm
20 lbf/ft
27 Nm
80 lbf/in
9 Nm
180 lbf/in
20 Nm
180 lbf/in
20 Nm
159 lbf/in
18 Nm
88 lbf/in
10 Nm
88 lbf/in
10 Nm
Figure F
Figure F
23 lbf/ft
31 Nm
18 lbf/ft
24 Nm
Figure B
Figure B
23 lbf/ft
31 Nm
114 lbf/in
13 Nm
20 lbf/ft
27 Nm
28 lbf/ft
38 Nm
Fuel fitting banjo bolt with steel washer w/viton insert (M12)
18 lbf/ft
25 Nm
35 lbf/ft
47 Nm
28 lbf/ft
38 Nm
28 lbf/ft
38 Nm
20 lbf/ft
27 Nm
Figure L
Figure L
23 lbf/ft
31 Nm
82
STANDARD
METRIC
Glow plug
124 lbf/in
14 Nm
114 lbf/in
13 Nm
23 lbf/ft
31 Nm
Figure G, I
Figure G, I
Figure H
Figure H
114 lbf/in
13 Nm
57 lbf/ft
78 Nm
45 lbf/ft
62 Nm
144 lbf/in
30 Nm
106 lbf/in
12 Nm
124 lbf/in
14 Nm
Figure D
Figure D
45 lbf/ft
62 Nm
23 lbf/ft
31 Nm
89 lbf/in
10 Nm
18 lbf/ft
25 Nm
16 lbf/ft
22 Nm
Oil filter stand pipe bolt (M5 thread forming) W/new oil cooler
61 lbf/in
7 Nm
Oil filter stand pipe bolt (M5 thread forming) reusing existing oil cooler
30 lbf/in
3 Nm
114 lbf/in
13 Nm
114 lbf/in
13 Nm
32 lbf/ft
44 Nm
114 lbf/in
13 Nm
16 lbf/ft
22 Nm
26 lbf/ft
35 Nm
114 lbf/in
13 Nm
Figure J
Figure J
45 lbf/ft
62 Nm
23 lbf/ft
31 Nm
114 lbf/in
13 Nm
168 lbf/in
19 Nm
44lbf/in
5 Nm
45 lbf/ft
62 Nm
148 lbf/ft
201 Nm
79 lbf/in
9 Nm
96 lbf/in
11 Nm
28 lbf/ft
38 Nm
35 lbf/ft
47 Nm
114 lbf/in
13 Nm
114 lbf/in
13 Nm
80 lbf/in
9 Nm
Figure E
Figure E
Wrench
Size (mm)
8
10
13
15
21
83
84
85
86
If #8 intake pushrod shows cam lift, this is the #4 firing position. Torque only fulcrum plates #3,4,5,6 per steps 4-6.
Step 4: Partially run down both M10 bolts until they just contact the fulcrum plate.
Step 5: Fully run down and torque inboard (upper) bolt to 45 lb/ft (62 Nm).
Step 6: Fully run down and torque outboard (lower) bolt to 45 lb/ft (62 Nm).
Step 7: Rotate crankshafft 360 degrees to position it at the alternate cylinder TDC (dowel pin at 10:30 position).
Step 8: Identify remaining group of fulcrum plates per step 3, and torque per steps 4-6.
87
88
89
diagnostic codes
O - Self Test - Key On Engine Off
R - Key On Engine Running
C - Continuous Operation
REGEN - Test Follows a REGEN CYCLE
SHUT DOWN - Test Follows Key Off
KO - Test Operates at Key On
1PC - Once Per Cycle
DTC
P1111
How Set
O R C
X
P000E
Code Description
Brief Description
Software Parameters
Required to Set Code
System Pass
Service Instructions /
Part Replaced
PCM, connection to service tool
P0A09
DC/DC Converter
Fault Circuit Low
Low: < 42 V
High: >96 V
PCM
P0A10
DC/DC Converter
Fault Circuit High
Low: < 42 V
High: >96 V
PCM
Short to ground: 0 V
> 3A
Short to plus: 12 V
MAP - Barometric
Pressure Correlation
KO
MAP/EBP Correlation
P008C
P008D
P008E
Fuel Rail/System
Pressure - Too Low
This error will be set if the fuel pressure in the rail is too
low and the controller cannot regulate it to the setpoint.
20 % overposition of the
PCV or VCV [% PWM]
5% deviation of the fuel rail pressure
to the fuel rail pressure setpoint.
Fuel Rail/System
Pressure - Too High
This error will be set if the fuel pressure in the rail is too
high and the controller cannot regulate it to the setpoint.
20 % overposition of
the PCV [% PWM]
3% deviation of the fuel rail pressure
to the fuel rail pressure setpoint
P0001
P0003
P0004
P0069
P006B
X
P008F
X
KO
P0087
P0088
P0090
P0091
Short to ground: 0 V
> 3A
P0092
Short to plus: 12 V
90
diagnostic codes
DTC
How Set
O R C
Code Description
Software Parameters
Required to Set Code
Brief Description
Service Instructions /
Part Replaced
5 deg C
ECT has to change from 40 deg C
to 80 deg C to equal 1 drive cycle.
10 drive cycles required
P0096
P0097
P0098
P0101
P0102
P0103
P0104
P0106
Manifold Absolute
Pressure/BARO Sensor
Range/Performance
P0107
P0108
P0112
This error occurs if the input signal from the intake air
temperature sensor falls below a minimum calibrateable
threshold for a predetermined period of time.
P0113
This error occurs if the input signal from the intake air
temperature sensor rises above a maximum calibrateable
threshold for a predetermined period of time.
P0114
P0117
This error is set when the ECT sensor signal is lower than
the minimum threshold for a predetermined period of time.
P0118
This error sets when the ECT sensor signal is higher than a
maximum threshold for a predetermined period of time.
N/A
P0128
P0148
P0149
P0168
P0181
P0182
PCM
91
diagnostic codes
O - Self Test - Key On Engine Off
R - Key On Engine Running
C - Continuous Operation
REGEN - Test Follows a REGEN CYCLE
SHUT DOWN - Test Follows Key Off
KO - Test Operates at Key On
1PC - Once Per Cycle
DTC
How Set
O R C
Code Description
Brief Description
Software Parameters
Required to Set Code
Service Instructions /
Part Replaced
P0183
P0191
checktime is 0.4 s
maximum sensor voltage signal
minus minimum voltage signal
must be greater than 0.01 V
High: >4.80 V
EOT dependant
20minutes of engine running and EOT
has not changed more than 5 deg C
P0192
P0193
P0194
P0196
P0197
P0198
P02CC
P02CD
P02CE
P02CF
P02D0
P02D1
P02D2
P02D3
P02D4
P02D5
P02D6
P02D7
92
Injector
Injector
Injector
Injector
Injector
Injector
diagnostic codes
DTC
How Set
O R C
Code Description
Brief Description
Software Parameters
Required to Set Code
Service Instructions /
Part Replaced
P02D8
P02D9
P02DA
P02DB
P0201
P0202
P0203
P0204
P0205
P0206
P0207
P0208
Injector/Injection Timing
Control Circuit
PCM
4000 rpm
P0216
Injector
Injector
P0219
P0231
P0232
P0234
Turbocharger/Supercharger
Overboost Condition
P0263
Cylinder 1 Contribution/Balance
P0266
Cylinder 2 Contribution/Balance
P0269
Cylinder 3 Contribution/Balance
P0272
Cylinder 4 Contribution/Balance
P0275
Cylinder 5 Contribution/Balance
P0278
Cylinder 6 Contribution/Balance
P0281
Cylinder 7 Contribution/Balance
P0284
Cylinder 8 Contribution/Balance
P0297
P0298
This error occurs when the time required for EOT to cool
down to 110 deg. C is greater than the specified value.
P0300
93
diagnostic codes
O - Self Test - Key On Engine Off
R - Key On Engine Running
C - Continuous Operation
REGEN - Test Follows a REGEN CYCLE
SHUT DOWN - Test Follows Key Off
KO - Test Operates at Key On
1PC - Once Per Cycle
DTC
How Set
O R C
Code Description
Brief Description
Software Parameters
Required to Set Code
Service Instructions /
Part Replaced
P0301
P0302
P0303
P0304
P0305
P0306
P0307
P0308
P0336
P0337
P0341
P0342
Glow Plug/Heater
Indicator Circuit
P0381
P040B
P040C
P040D
P0401
94
diagnostic codes
DTC
How Set
O R C
Code Description
Brief Description
Software Parameters
Required to Set Code
Service Instructions /
Part Replaced
P0402
P0403
P0404
P0405
This error occurs when the EGR position voltage is below the
specified voltage for a predetermined amount of time. This
error can indicate either a short to ground or an open circuit.
P0406
P041B
P041C
P041D
P0420
REGEN
P042E
P042F
P0472
P0473
P0480
P0488
P0494
P0495
P0500
P0503
95
diagnostic codes
O - Self Test - Key On Engine Off
R - Key On Engine Running
C - Continuous Operation
REGEN - Test Follows a REGEN CYCLE
SHUT DOWN - Test Follows Key Off
KO - Test Operates at Key On
1PC - Once Per Cycle
DTC
How Set
O R C
Code Description
Brief Description
P0528
P0529
P0544
1
P
C
P0545
P0546
System Voltage
P0560
P0563
P0565
P0566
P0567
P0568
P0569
P0571
Software Parameters
Required to Set Code
Service Instructions /
Part Replaced
P0578
This error occurs if the voltage received by the PCM for the
cruise control circuit is above the calibrated threshold.
P0579
ECU
P060C
P060D
PCM
1
P
C
Powertrain Control
Module Program Error
1
P
C
P060B
P0600
P0602
P0603
96
PCM
diagnostic codes
DTC
How Set
O R C
Code Description
Brief Description
Software Parameters
Required to Set Code
Service Instructions /
Part Replaced
P0604
PCM
P0605
P061B
PCM
P061C
P062D
This error occurs when the sum of the voltage signals for
the main injection of all injectors on bank 1 or if the fuel
injector driver circuit for bank 1 fails to initialize properly.
max = 229 V
min = 93 V
P062E
This error occurs when the sum of the voltage signals for
the main injection of all injectors on bank 2 or if the fuel
injector driver circuit for bank 2 fails to initialize properly.
max = 229 V
min = 93 V
P0620
P0625
P0626
P0627
P0628
P0629
P0642
Sensor Reference
Voltage A Circuit Low
Wiring, PCM
P0643
Sensor Reference
Voltage A Circuit High
High: >5.25 V
Wiring, PCM
P065B
P0652
Sensor Reference
Voltage B Circuit Low
P0653
Sensor Reference
Voltage B Circuit High
High: >5.25 V
P0670
P0671
P0672
P0673
P0674
P0675
97
diagnostic codes
O - Self Test - Key On Engine Off
R - Key On Engine Running
C - Continuous Operation
REGEN - Test Follows a REGEN CYCLE
SHUT DOWN - Test Follows Key Off
KO - Test Operates at Key On
1PC - Once Per Cycle
DTC
P0676
P0677
How Set
O R C
X
Code Description
Brief Description
P0684
P0691
P0692
P1000
RESET
Service Instructions /
Part Replaced
P0678
Software Parameters
Required to Set Code
P0703
P1102
P1103
P115A
P117B
This error occurs when the KOER self test is attempted but the
engine has not reached an operating temperature of 60 C.
P117F
P1184
P120F
P127A
P132A
Turbocharger Boost
Control A Electrical
P132B
Turbocharger/Supercharger
Boost Control A Performance
P132C
P1335
P1336
NA
Wiring to FUP sensor,
FUP sensor, low pressure
fuel system
NA
Turbocharger/Supercharger
Boost Control A Voltage
1.3v >2.5sec
Crankshaft/Camshaft Sensor
Range/Performance
98
diagnostic codes
DTC
P138D
How Set
O R C
X
Code Description
Brief Description
Software Parameters
Required to Set Code
150 deg C
Service Instructions /
Part Replaced
P1397
NA
P1408
NA
P1501
NA
P1531
>10%
NA
P1536
P1551
max = 210 V
min = 62 V
P1552
max = 210 V
min = 62 V
P1553
max = 210 V
min = 62 V
P1554
max = 210 V
min = 62 V
P1555
max = 210 V
min = 62 V
P1556
max = 210 V
min = 62 V
P1557
max = 210 V
min = 62 V
P1558
max = 210 V
min = 62 V
P1586
P1639
This error occurs when the VID block data are not
programmed or programmed incorrectly.
P1703
< 500RPM
NA
>1600 RPM
NA
CAN ECM/Turbocharger
Boost Control & Actuator
Circuit Malfunction
P1725
P1726
P179A
P2002
REGEN
P2031
1
P
T
P2032
P2033
99
diagnostic codes
O - Self Test - Key On Engine Off
R - Key On Engine Running
C - Continuous Operation
REGEN - Test Follows a REGEN CYCLE
SHUT DOWN - Test Follows Key Off
KO - Test Operates at Key On
1PC - Once Per Cycle
DTC
How Set
O R C
Code Description
Brief Description
Software Parameters
Required to Set Code
Service Instructions /
Part Replaced
P2080
1
P
C
P2081
P2084
P2085
P2122
P2123
P2127
P2128
P2138
>20 deg C
8 minutes
P2199
P2228
Barometric Pressure
Circuit Low Input
This error occurs when the voltage signal from the barometric
pressure circuit falls below a minimum threshold.
PCM
P2229
Barometric Pressure
Circuit High Input
This error occurs when the voltage signal from the barometric
pressure circuit rises above a maximum threshold.
High: >4.36 V
PCM
P2230
Barometric Pressure
Circuit Intermittent
P2262
Turbocharger/Supercharger
Boost Pressure Not
Detected - Mechanical
PCM
This error occurs if the MAP sensor readings are below a
calibrated value for a predetermined amount of time.
System error
P2263
Turbocharger/Supercharger
Boost System Performance
P2269
P2289
SHUTDOWN
P2291
P242A
1PC
P242B
100
diagnostic codes
DTC
How Set
O R C
Code Description
Brief Description
P242C
P242D
P242E
P242F
REGEN
P244A
REGEN
Exhaust Temperature
too low for Particulate
Filter Regeneration
Exhaust Temperature
too high for Particulate
Filter Regeneration
P244C
P244D
REGEN
X
P2453
X
KO
P2454
P2455
P2456
P2458
P2459
P2457
P2545
P2563
P2610
Torque Management
Request Input Signal A
Range/Performance
Software Parameters
Required to Set Code
This error occurs when the engine off timer does not
correlate to the PCMs internal timer (compared while
the engine is running), if the engine off time does not
correspond with the measured ECT temperature variation
between the last engine stop and the next engine
start, or when the engine off timer is defective.
Service Instructions /
Part Replaced
U0073
Control Module
Communication Bus A Off
U0101
101
System error
Printed in U.S.A.
FCS-14853-MISC