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DRAFTService InfTrucks

ormation

Group 593
Release01

Diagnostic Trouble Codes


3.8 Litter Engine

89130181
DRAFT
Malfunction ..............................................................................................................................1
P06B1 - Sensor Power Supply A Circuit Low ...............................................................................1
P06B2 - Sensor Power Supply A Circuit High...............................................................................2
P0105 - Manifold Absolute Pressure/Barometric Pressure Sensor...................................................4
P0108 - Manifold Absolute Pressure/Barometric Pressure Sensor Circuit High..................................6
P1116 - Manifold Absolute Pressure Moderately Too High..............................................................8
P1118 - Manifold Absolute Pressure Too High ............................................................................ 11
P2226 - Barometric Pressure Circuit......................................................................................... 14
P2229 - Barometric Pressure Circuit High ................................................................................. 15
P0110 - Intake Air Temperature Sensor 1 Bank 1........................................................................ 16
P0112 - Intake Air Temperature Sensor 1 Circuit Low Bank 1........................................................ 18
P1119 - Intake Manifold Temperature Moderately Too High .......................................................... 20
P111A - Intake Manifold Temperature Too High .......................................................................... 21
P0217 - Engine Coolant Over Temperature Condition ................................................................. 23
P111E - Engine Coolant Temperature Moderately High................................................................ 25
P0115 - Engine Coolant Temperature Sensor 1 .......................................................................... 27
P0117 - Engine Coolant Temperature Circuit Low ....................................................................... 29
P0201 - Cylinder 1 Injector A ................................................................................................... 31
P0262 - Injector 1 Short Circuit High......................................................................................... 33
P02CC - Cylinder 1 Fuel Injector Offset Learning at Min Limit ....................................................... 34
P02CD - Cylinder 1 Fuel Injector Offset Learning at Max Limit ...................................................... 36
P0261 - Cylinder 1 Injector Circuit Low...................................................................................... 37
P0202 - Cylinder 2 Injector A ................................................................................................... 39
P0265 - Injector 2 Short Circuit High......................................................................................... 41
P02CE - Cylinder 2 Fuel Injector Offset Learning At Min Limit....................................................... 42
P02CF - Cylinder 2 Fuel Injector Offset Learning at Max Limit....................................................... 44
P0264 - Cylinder 2 Injector Circuit Low...................................................................................... 45
P0203 - Cylinder 3 Injector A ................................................................................................... 47
P0268 - Injector 3 Short Circuit High......................................................................................... 49
P02D0 - Cylinder 3 Fuel Injector Offset Learning At Min Limit ....................................................... 50
P02D1 - Cylinder 3 Fuel Injector Offset Learning at Max Limit....................................................... 52
P0267 - Cylinder 3 Injector Circuit Low...................................................................................... 53
P0204 - Cylinder 4 Injector A ................................................................................................... 55
P0271 - Injector 4 Short Circuit High......................................................................................... 57
P02D2 - Cylinder 4 Fuel Injector Offset Learning At Min Limit ....................................................... 58
P02D3 - Cylinder 4 Fuel Injector Offset Learning at Max Limit....................................................... 60
P0270 - Cylinder 4 Injector Circuit Low...................................................................................... 61
P0335 - Crankshaft Position Sensor A ...................................................................................... 63
P0336 - Crankshaft Position Sensor A Circuit Range/Performance................................................ 65
P0339 - Crankshaft Position Sensor A Circuit Intermittent............................................................ 66
P0524 - Engine Oil Pressure Too Low....................................................................................... 67
P0520 - Engine Oil Pressure Sensor/Switch A ........................................................................... 70
P1093 - Engine Oil Pressure Moderately Low ............................................................................ 72
P0522 - Engine Oil Pressure Circuit Low................................................................................... 75
P0340 - Camshaft Position Sensor A Bank 1 or Single Sensor ..................................................... 76
P0341 - Camshaft Position Sensor A Circuit Range/Performance ................................................. 78
P0016 - Crankshaft Position - Camshaft Position Correlation........................................................ 79
P0615 - Starter Relay............................................................................................................. 81
P0616 - Starter Relay Circuit Low ............................................................................................ 82
P0617 - Starter Relay Circuit High............................................................................................ 83
P1176 - Starter Motor Deactivated - Over Temperature................................................................ 85
P1178 - Starter Motor Deactivated - Cogwheels of Starter Motor and Engine Stuck.......................... 86
P1179 - Starter Motor Deactivated - PTO Active ......................................................................... 88
P0666 - Control Module Internal Temperature Sensor A .............................................................. 89
P0668 - PCM/ECM/TCM Internal Temperature Sensor Circuit Low................................................ 90
P1104 - Factory Mode ............................................................................................................ 91
P1141 - Buffered Idle Validation Switch Wire - ECM Side ............................................................. 92
P0091 - Fuel Pressure Regulator Control Circuit Low .................................................................. 94
P0092 - Fuel Pressure Regulator Control Circuit High ................................................................. 96
P0090 - Fuel Pressure Regulator 1 Control................................................................................ 97
DRAFT
P0088 - Fuel Rail/System Pressure - Too High Bank 1 ................................................................ 99
P1147 - Fuel Rail/System Bank 1 Pressure - Moderately Too High .............................................. 101
P0087 - Fuel Rail/System Pressure - Too Low Bank 1 ............................................................... 103
P00C6 - Fuel Rail Pressure Too Low - Engine Cranking ............................................................ 104
P0192 - Engine Injection Control Pressure Circuit Low .............................................................. 106
P0190 - Fuel Rail Pressure Sensor Bank 1 .............................................................................. 107
P228E - Fuel Pressure Regulator 1 Exceeded Learning Limits - Too Low ..................................... 109
P228F - Fuel Pressure Regulator 1 Exceeded Learning Limits - Too High......................................111
P016E - Closed Loop Fuel Pressure Control At Limit - Pressure Too High .................................... 115
P016F - Closed Loop Fuel Pressure Control At Limit - Pressure Too Low ..................................... 117
U0010 - CAN Communication Backbone 1 Net ........................................................................ 118
U0001 - CAN Communication Backbone 2 Net ........................................................................ 121
U0155 - Lost Communication With Instrument Panel Cluster (IPC) Control Module ........................ 123
P1154 - Body Control Module A - Lost Communication With Instrument Panel Cluster (IPC) Control
Module .............................................................................................................................. 126
U0141 - Lost Communication With VMCU ............................................................................... 129
Group 593 P06B1 - Sensor Power Supply A Circuit Low

DRAFT
P06B1 - Sensor Power Supply A Circuit Low
Malfunction

Fault Condition for Fault Observable Symptoms Possible cause


type
P06B1
FTB 00
• The voltage at pin A14.J1:88 is • Low power. • Wiring harness.
less than 4.5 V. • Inlet manifold pressure gauge • Connector.
shows 0. • Sensor.

Voltage measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Voltage drop On 1– 3 B37:1– B37:3 U = 4.75 V – 9990216,
out check in 5.25 V 88890074
wiring harness

1
Group 593 Resistance measurement

DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Supply Voltage On 26 – 02 A14.J1:88 – U = 4.75 V – 9998699,
A14.J1:64 5.25 V 9990062,
88890227,
88890074

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short Circuit Off 26 – All pins on A14.J1:88 – R = Open 9998699,
the J1 A14.J1 Circuit 9990062,
connector 88890227,
88890074

P06B2 - Sensor Power Supply A Circuit High

2
Group 593 Voltage measurement

Fault
type
P06B2
Condition for Fault


DRAFT
The voltage at pin A14.J1:88 is
Observable Symptoms

• Incorrect values on inlet mani-


Possible cause

• Wiring harness.
FTB 00 more than 5.5 V. fold air pressure sensor. • Connector.
• Low power. • Sensor.
• Inlet manifold pressure gauge
shows 0.

Voltage measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short circuit to On 26 – 02 A14.J1:88 – U = 4.75 V – 9998699 ,
higher voltage A14.J1:64 5.25 V 9990062,
88890227,
88890074

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short circuit to Off 26 – 35 A14.J1:88 – R = Open 9998699,
battery voltage A14.J2:01 Circuit 9992699,
88890227,
88890074
Short circuit to Off 26 – All pins at A14.J1:88 – All R = Open 9998699,
battery voltage connectors J1 pins at connec- Circuit 9992699,
and J2 tors J1 and J2 88890227,
88890074

3
P0105 - Manifold Absolute Pressure/Barometric Pressure
Group 593

DRAFT
Sensor

P0105 - Manifold Absolute Pressure/Barometric Pressure Sensor

Fault Condition for Fault Observable Symptoms Possible cause


type
P0105
FTB13
• The voltage at pin A14.J1:93 is • Low power. • Wiring harness.
less than 0.16V. • The charge pressure gauge • Charge pressure and tempera-
shows 0 in the instrument. ture sensor.
• Connector.

Voltage measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Supply Voltage On 1– 3 B37:1– B37:3 U = 4.75 V – 9990216,
5.25 V 88890074
Signal Voltage On 1– 4 B37:1– B37:4 U = 0.8 V – 1.2 9990216,
V (Engine not 88890074
running)

4
Group 593 Resistance measurement

DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Supply Voltage On 02– 26 A14.J1:64– U = 4.75 V – 9998699,
A14.J1:88 5.25 V 9990062,
88890074,
88890227
Signal Voltage On 02– 31 A14.J1:64– U = 0.8 V – 1.2 9998699,
A14.J1:93 V (Engine not 9990062,
running) 88890074,
88890227

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short Circuit / Off 1– 02, 3 – 26, B37:1– A14. R = <10 Ω 9998699,
Open Circuit 4– 31 J1:64, B37:3– 9990062,
A14.J1:88 88890227,
B37:4– A14. 88890074
J1:93

5
P0108 - Manifold Absolute Pressure/Barometric Pressure
Group 593

DRAFT
Sensor Circuit High

P0108 - Manifold Absolute Pressure/Barometric Pressure Sensor


Circuit High

Fault Condition for Fault Observable Symptoms Possible cause


type
P0108
FTB00
• The voltage at pin A14:J1:93 is • Low power. • Wiring harness.
more than 4.94 V. • The charge pressure gauge • Charge pressure and tempera-
shows 0 in the instrument, if the ture sensor.
signal wire is short-circuited to • Connector.
5V or to battery voltage.
• The charge pressure gauge al-
ways displays pressure if there
is open circuit on the ground
wire.

Voltage measurement

6
Group 593 Resistance measurement

Measuring Key position


DRAFT
Measurement points
Breakout box Wiring
diagram
Reference
value
Measured
value
Other (Special
tool No.)

Supply Voltage On 1– 3 B37:1– B37:3 U = 4.75 V – 9990216,8889-


5.25 V 0074
Signal Voltage On 1– 4 B37:1– B37:4 U = 0.8 V – 1.2 9990216,8889-
V (Engine not 0074
running)

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Supply Voltage On 02– 26 A14.J1:64– U = 4.75 V – 9998699,
A14.J1:88 5.25 V 9990062,
88890074,
88890227
Signal Voltage On 02– 31 A14.J1:64– U = 0.8 V – 1.2 9998699,
A14.J1:93 V (Engine not 9990062,
running) 88890074,
88890227

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short Circuit / Off 1– 02, 3 – 26, B37:1– A14. R = <10 Ω 9998699,
Open Circuit 4– 31 J1:64, B37:3– 9990062,
A14.J1:88 88890227,
B37:4– A14. 88890074
J1:93

7
Group 593 P1116 - Manifold Absolute Pressure Moderately Too High

DRAFT
P1116 - Manifold Absolute Pressure Moderately Too High

Fault Condition for Fault Observable Symptoms Possible cause


type
P1116 • Charge pressure High. • Engine derate according to error • Charge pressure and tempera-
FTB 00 torque map. ture sensor.
• Actuator.
• By-pass shutter.

Voltage measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Supply Voltage On 1– 3 B37:1 – B37:3 U = 4.75 V – 9990216,8889-
check 5.25 V 0074
Signal Voltage On 4- 1 B37:4 – B37:1 U =0.5 V - 4.5 9990216,8889-
check V 0074

8
Group 593 Resistance measurement

Measuring Key position


DRAFT
Measurement points
Breakout box Wiring
diagram
Reference
value
Measured
value
Other (Special
tool No.)

Sensor signal On 4- 1 B37:4 – B37:1 U =0.500 V - 9990216,8889-


check in 0 kPa 4.50 V 0074,
(0 psi) pressure 9998538,
9990123
Sensor signal On 4- 1 B37:4 – B37:1 U =0.500 V - 9990216,8889-
check in 50 4.50 V 0074,
kPa (7.25 psi) 9998538,
pressure 9990123
Sensor signal On 4- 1 B37:4 – B37:1 U =0.500 V - 9990216,8889-
check in 100 4.50 V 0074,
kPa (14.5 psi) 9998538,
pressure 9990123
Sensor signal On 4- 1 B37:4 – B37:1 U =0.500 V - 9990216,8889-
check in 200 4.50 V 0074,
kPa (29 psi) 9998538,
pressure 9990123

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Supply Voltage On 3 – Engine B37:3 – Engine U = 4.75 V – 9990216,8889-
check ground point ground point 5.25 V 0074

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Supply Voltage On 26 – Engine A14.J1:88 – U = 4.75 V – 9998699,
check ground point Engine ground 5.25 V 9990062,
poit. 88890074,
88890227

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Ground wire Off 1– Engine B37:1– Engine R = 0Ω – 10 Ω 9990216,
check ground point ground point 88890074

9
Group 593 Overflow valve opening pressure, Check

Measuring Key position


DRAFT
Measurement points
Breakout box Wiring
diagram
Reference
value
Measured
value
Other (Special
tool No.)

Open circuit Off 2 – Engine A14.J1:64 – R = 0Ω – 10 Ω 9998699,


check ground point Engine ground 9990062,
point 88890074,
88890227
Open circuit Off 31 – 4 A14.J1:93 – R = 0Ω – 5 Ω 9998699,
check B37:4 9990062,
88890074,
88890227,
99900216
Short circuit Off 31 – All other A14.J1:93 – All R = Open 9998699,
between wires pins at connec- other pins at circuit 9990062,
tors J1 and J2 connectors J1 88890074,
and J2 88890227

Overflow valve opening pressure, Check


Special Tools:

9996662, 9999696, 9989876, 9998538.

Action:

• Check the zero setting of the dial indicator.


• Measure in the push rod's lengthwise direction to avoid an-
gular displacement in the measurement.
• Maximum pressure is {0}, otherwise the valve can be
damaged.
• Perform the test several times to ensure the measurement
result.
• Release the pressure completely between the measure-
ments to get a correct result.
• Increase the pressure to 210 kPa, Read the manometer
pressure, The push rod should move 1 mm - 2 mm.
Evaluation:

• If necessary screw the push rod inwards to increase pres-


sure or outwards to reduce pressure.
• Incorrectly set charge pressure can lead to both turbo-
charger and engine breakdown.

Visual check:
• Check that the air hoses are not damaged or pinched and
that they are free from folds.
• Check if the fault is in the actuator or at the by-pass
shutter.
• Check the By pass shutter for easy turning or functioning
by hand.
• Check the hoses and actuator for air leakage.

10
Group 593 P1118 - Manifold Absolute Pressure Too High

DRAFT
P1118 - Manifold Absolute Pressure Too High

Fault Condition for Fault Observable Symptoms Possible cause


type
P1118 • Charge pressure High. • Engine derate according to error • Charge pressure and tempera-
FTB 00 torque map. ture sensor.
• Actuator.
• By-pass shutter.

Voltage measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Supply Voltage On 1– 3 B37:1 – B37:3 U = 4.75 V – 9990216,8889-
check 5.25 V 0074
Signal Voltage On 4- 1 B37:4 – B37:1 U =0.5 V - 4.5 9990216,8889-
check V 0074

11
Group 593 Resistance measurement

Measuring Key position


DRAFT
Measurement points
Breakout box Wiring
diagram
Reference
value
Measured
value
Other (Special
tool No.)

Sensor signal On 4- 1 B37:4 – B37:1 U =0.500 V - 9990216,8889-


check in 0 kPa 4.50 V 0074,
(0 psi) pressure 9998538,
9990123
Sensor signal On 4- 1 B37:4 – B37:1 U =0.500 V - 9990216,8889-
check in 50 4.50 V 0074,
kPa (7.25 psi) 9998538,
pressure 9990123
Sensor signal On 4- 1 B37:4 – B37:1 U =0.500 V - 9990216,8889-
check in 100 4.50 V 0074,
kPa (14.5 psi) 9998538,
pressure 9990123
Sensor signal On 4- 1 B37:4 – B37:1 U =0.500 V - 9990216,8889-
check in 200 4.50 V 0074,
kPa (29 psi) 9998538,
pressure 9990123

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Supply Voltage On 3 – Engine B37:3 – Engine U = 4.75 V – 9990216,8889-
check ground point ground point 5.25 V 0074

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Supply Voltage On 26 – Engine A14.J1:88 – U = 4.75 V – 9998699,
check ground point Engine ground 5.25 V 9990062,
poit. 88890074,
88890227

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Ground wire Off 1– Engine B37:1– Engine R = 0Ω – 10 Ω 9990216,
check ground point ground point 88890074

12
Group 593 Overflow valve opening pressure, Check

Measuring Key position


DRAFT
Measurement points
Breakout box Wiring
diagram
Reference
value
Measured
value
Other (Special
tool No.)

Open circuit Off 2 – Engine A14.J1:64 – R = 0Ω – 10 Ω 9998699,


check ground point Engine ground 9990062,
point 88890074,
88890227
Open circuit Off 31 – 4 A14.J1:93 – R = 0Ω – 5 Ω 9998699,
check B37:4 9990062,
88890074,
88890227,
99900216
Short circuit Off 31 – All other A14.J1:93 – All R = Open 9998699,
between wires pins at connec- other pins at circuit 9990062,
tors J1 and J2 connectors J1 88890074,
and J2 88890227

Overflow valve opening pressure, Check


Special Tools:

9996662, 9999696, 9989876, 9998538.

Action:

• Check the zero setting of the dial indicator.


• Measure in the push rod's lengthwise direction to avoid an-
gular displacement in the measurement.
• Maximum pressure is {0}, otherwise the valve can be
damaged.
• Perform the test several times to ensure the measurement
result.
• Release the pressure completely between the measure-
ments to get a correct result.
• Increase the pressure to 210 kPa, Read the manometer
pressure, The push rod should move 1 mm - 2 mm.
Evaluation:

• If necessary screw the push rod inwards to increase pres-


sure or outwards to reduce pressure.
• Incorrectly set charge pressure can lead to both turbo-
charger and engine breakdown.

Visual check:
• Check that the air hoses are not damaged or pinched and
that they are free from folds.
• Check if the fault is in the actuator or at the by-pass
shutter.
• Check the By pass shutter for easy turning or functioning
by hand.
• Check the hoses and actuator for air leakage.

13
Group 593 P2226 - Barometric Pressure Circuit

P2226 - Barometric Pressure Circuit DRAFT

Fault Condition for Fault Observable Symptoms Possible cause


type
P2226
FTB13
• The atmospheric pressure from • Poor response at high altitudes. • Atmospheric pressure sensor.
the sensor is not rational.

Atmospheric pressure Sensor, check


• The sensor is located in the engine control unit (EECU)
and therefore cannot be checked.
• Check the sensor for blockage e.g. dirt, paint or stickers it
may send an incorrect value.
• If problem persists replace component.

14
Group 593 P2229 - Barometric Pressure Circuit High

P2229 - Barometric Pressure Circuit High DRAFT

Fault Condition for Fault Observable Symptoms Possible cause


type
P2229 • The atmospheric pressure from • Poor response at high altitudes. • Atmospheric pressure sensor.
FTB00 the sensor is not rational.

Atmospheric pressure Sensor, check


• The sensor is located in the engine control unit (EECU)
and therefore cannot be checked.
• Check the sensor for blockage e.g. dirt, paint or stickers it
may send an incorrect value.
• If problem persists replace component.

15
Group 593 P0110 - Intake Air Temperature Sensor 1 Bank 1

DRAFT
P0110 - Intake Air Temperature Sensor 1 Bank 1

Fault Condition for Fault Observable Symptoms Possible cause


type
P0110
FTB13
• The voltage at pin A14.J1:33 is • Engine is running but could be • Charge pressure and tempera-
more than 4.57 V. difficult to start in cold ture sensor.
conditions. • Wiring harness.

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short Circuit / Off 1– 02, 3 – 26, 2 B37:1– A14. R = <10 Ω 9998699,
Open Circuit – 33 J1:64, B37:3– 9990062,
A14.J1:88 88890227,
B37:2 – A14. 88890074
J1:33

16
Group 593 Reference Table

DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Component Off 1– 2 B37:1– B37:2 Reference 9990216,
resistance Table 88890074

Reference Table

17
P0112 - Intake Air Temperature Sensor 1 Circuit Low Bank
Group 593

DRAFT
1

P0112 - Intake Air Temperature Sensor 1 Circuit Low Bank 1

Fault Condition for Fault Observable Symptoms Possible cause


type
P0112
FTB00
• The voltage at pin A14.J1:33 is • High fuel consumption. • Charge pressure and tempera-
less than 0.02 V. • Engine is running but could be ture sensor.
difficult to start in cold • Short circuit to ground.
conditions. • Connector.
• Wiring harness.
• Engine control module (ECM).

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short Circuit / Off 1– 02, 3 – 26, 2 B37:1– A14. R = <10 Ω 9998699,
Open Circuit – 33 J1:64, B37:3– 9990062,
A14.J1:88 88890227,
B37:2 – A14. 88890074
J1:33
18
Group 593 Reference Table

DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Component Off 1– 2 B37:1– B37:2 Reference 9990216,8889-
resistance Table 0074

Reference Table

19
Group 593 P1119 - Intake Manifold Temperature Moderately Too High

DRAFT
P1119 - Intake Manifold Temperature Moderately Too High

Fault Condition for Fault Observable Symptoms Possible cause


type
P1119 • Charge air temperature too high. • Charge pressure and tempera-
FTB 00 ture sensor.
• Extreme driving conditions.
• Poor cooling.

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Open circuit Off 33 – 2 A14.J1:33 – R = 0 Ω – 10 Ω 9998699,
check B37:2 9990062,
88890227,
88890074,
9990216

20
Group 593 Visual checks:

DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Component Off 1– 2 B37:1– B37:2 R = 1kΩ - 10 9990216,8889-
resistance kΩ 0074

Visual checks:
• Check the charge air cooler for damage to tanks, cells and
connections.
• Check the charge air cooler, the radiator and the air condi-
tioning condenser for external clogging.
• Check that the charge air cooler is clean internally at the
hose connections (Oil in the charge air cooler indicates
leakage at the turbo).
• Check the turbo for damage to the compressor wheel.
P111A - Intake Manifold Temperature Too High

21
Group 593 Resistance measurement

Fault
type
P111A
Condition for Fault


DRAFT
Charge air temperature too high.
Observable Symptoms Possible cause

• Charge pressure and tempera-


FTB 00 ture sensor.
• Extreme driving conditions.
• Poor cooling.

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Open circuit Off 33 – 2 A14.J1:33 – R = 0 Ω – 10 Ω 9998699,
check B37:2 9990062,
88890227,
88890074,
9990216

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Component Off 1– 2 B37:1– B37:2 R = 1 kΩ - 10 9990216,8889-
resistance kΩ 0074

Visual checks:
• Check the charge air cooler for damage to tanks, cells and
connections.
• Check the charge air cooler, the radiator and the air condi-
tioning condenser for external clogging.
• Check that the charge air cooler is clean internally at the
hose connections (Oil in the charge air cooler indicates
leakage at the turbo).
• heck the turbo for damage to the compressor wheel.

22
Group 593 P0217 - Engine Coolant Over Temperature Condition

DRAFT
P0217 - Engine Coolant Over Temperature Condition

Fault Condition for Fault Observable Symptoms Possible cause


type
P0217 • Temperature too high.. • A buzzer sounds. • Engine fan.
FTB00
• High derate with potential en- • Fan belt.
gine shutdown. • Thermostat.
• Low coolant level.
• Clogged radiator.
• Clogged cooling system.
• Coolant pump drive belt.
• Coolant pump belt tensioner.
• Slipping impeller.
• Poor flow through in the cooling
system.
• Pressure cap, expansion tank.
• Engine coolant temperature
sensor.
• Engine control module (ECM).
• Temperature too high

23
Group 593 Resistance measurement

Resistance measurement
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Component Off 1– 2 B231:1– Reference 9990216,
resistance B231:2 Table 88890074
Component Off 1– 2 B123:1– 0Ω when the 9990008,
resistance B123:2 float is at the 88890074
lower end posi-
tion and infinite
when the float
is at the upper
end

Reference Table

Visual check:
• Check engine coolant level. • Check if the coolant is contaminated.
24
Group 593 P111E - Engine Coolant Temperature Moderately High



DRAFT
Check the Cylinder head gasket, cylinder liner, oil cooler
for leakage and do the pressure test of cylinder head.
Check the radiator and charge air cooler free from residue.
• Check the coolant thermostat and pump for proper
functioning.
• Check radiator and hoses for leakage.
P111E - Engine Coolant Temperature Moderately High

Fault Condition for Fault Observable Symptoms Possible cause


type
P111E
FTB00
• Temperature too high.. • A buzzer sounds. • Engine fan.
• Engine derate. • Fan belt.
• Thermostat.
• Low coolant level.
• Clogged radiator.
• Clogged cooling system.
• Coolant pump drive belt.
• Coolant pump belt tensioner.
• Slipping impeller.
• Poor flow through in the cooling
system.
• Pressure cap, expansion tank.
• Engine coolant temperature
sensor.
• Engine control module (ECM).
25
Group 593 Resistance measurement

Resistance measurement
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Component Off 1– 2 B231:1– Reference 9990216,
resistance B231:2 Table 88890074

Reference Table

Visual check:
• Check engine coolant level. • Check the coolant thermostat and pump for proper
• Check if the coolant is contaminated. functioning.

• Check the Cylinder head gasket, cylinder liner, oil cooler • Check radiator and hoses for leakage.
for leakage and do the pressure test of cylinder head.
• Check the radiator and charge air cooler free from residue.

26
Group 593 P0115 - Engine Coolant Temperature Sensor 1

DRAFT
P0115 - Engine Coolant Temperature Sensor 1

Fault Condition for Fault Observable Symptoms Possible cause


type
P0115 • The voltage at pin A14.J1:09 is • High fuel consumption. • Engine coolant temperature
FTB13 more than 4.92 V. • The coolant temperature gauge sensor.
shows 0. • Connector.
• Engine fan constantly engaged. • Wiring harness.
• Short circuit to battery voltage,
Signal wire.
• Open circuit, Ground wire.
• Engine control module (ECM).

Resistance measurement

27
Group 593 Reference Table

Measuring Key position


DRAFT
Measurement points
Breakout box Wiring
diagram
Reference
value
Measured
value
Other (Special
tool No.)

Short Circuit / Off 1– 09, 2– 39 B231:1– A14. R = <10 Ω 9998699,


Open Circuit J1:09, B231:2– 9990062,
A14.J1:39 9990216,
88890227

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Component Off 1– 2 B231:1– Reference 9990216,
resistance B231:2 Table 88890074

Reference Table

28
Group 593 P0117 - Engine Coolant Temperature Circuit Low

DRAFT
P0117 - Engine Coolant Temperature Circuit Low

Fault Condition for Fault Observable Symptoms Possible cause


type
P0117 • The voltage at pin A14.J1:09 is • High fuel consumption. • Engine coolant temperature
FTB 00 less than 0.17 V. • The coolant temperature gauge sensor.
shows 0. • Short circuit to ground, Signal
• Engine fan constantly engaged. wire.

• Less powerful engine since the • Connector.


fan takes power from the engine. • Wiring harness.
• Engine control module (ECM).

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short Circuit / Off 1– 09, 2– 39 B231:1– A14. R = <10 Ω 9998699,
Open Circuit J1:09, B231:2– 9990062,
A14.J1:39 9990216,
88890227
29
Group 593 Reference Table

DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Component Off 1– 2 B231:1– Reference 9990216,
resistance B231:2 Table 88890074

Reference Table

30
Group 593 P0201 - Cylinder 1 Injector A

P0201 - Cylinder 1 Injector A DRAFT

Fault Condition for Fault Observable Symptoms Possible cause


type
P0201 • Unit injector activated. • Low power. • Connector.
FTB13
• Open circuit. • Engine runs unevenly or • Wiring harness between engine
misfires. control unit and unit injector.
• Abnormal noise. • Injector.
• Engine is operating on only 3 • Engine control module (ECM).
cylinders.

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short Circuit to Off 49 – Engine A14.J1:49 – R = Open 9998699,
Ground ground point Engine ground circuit 88890074
point

31
Group 593 Resistance measurement

Measuring Key position


DRAFT
Measurement points
Breakout box Wiring
diagram
Reference
value
Measured
value
Other (Special
tool No.)

Short Circuit to Off 10 – Engine FI:10 – Engine R = Open 9990008,


Ground ground point ground point circuit 88890074
Open circuit Off Y122:B - Y122: Y122:B - Y122: R = <= 3 Ω 9990008,
check A A 88890074

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Resistance Off 49 – 50 A14.J1:49 – R = <=3 Ω 88890227,
check A14.J1:50 9998699, ,
88890074
Resistance Off FI:10 – FI:09 FI:10 – FI:09 R = <= 3 Ω 9990008,
check 88890074

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Resistance Off Y122:B – En- Y122:B – En- R = Open 88890074
check gine ground gine ground circuit
point point

32
Group 593 P0262 - Injector 1 Short Circuit High

P0262 - Injector 1 Short Circuit High DRAFT

Fault Condition for Fault Observable Symptoms Possible cause


type
P0262 • Unit injector activated. • Low power. • Connector.
FTB00
• Uneven operation. • Wiring harness.
• Abnormal noise. • Injector.
• Engine is operating on only 3 • Engine control module (ECM).
cylinders.

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short Circuit Off 49 – All pins at A14.J1:49 – All R = Open 9998699,
between wires connectors J1 pins at connec- circuit 88890227,
and J2 tors J1 and J2 88890074

33
P02CC - Cylinder 1 Fuel Injector Offset Learning at Min
Group 593

DRAFT
Limit

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short Circuit Off 49 – 50 A14.J1:49 – R = Open 9998699,
between wires A14.J1:50 circuit 88890227,
9990062,
88890074
Short Circuit Off 49 – 12 A14.J1:49 – R = Open 9998699,
between wires A14.J1:74 circuit 88890227,
9990062,
88890074
Short Circuit Off 49 – 01 A14.J1:49 – R = Open 9998699,
between wires A14.J1:01 circuit 88890227,
9990062,
88890074
Short Circuit Off 49 – 02 A14.J1:49 – R = Open 9998699,
between wires A14.J1:02 circuit 88890227,
9990062,
88890074

P02CC - Cylinder 1 Fuel Injector Offset Learning at Min Limit

34
Group 593 Visual Check:

Fault
type
P02CC
Condition for Fault

• Unit injector activated.


DRAFT Observable Symptoms

• Low power.
Possible causes

• Nozzle.
FTB00
• Cylinder balancing data too • Uneven operation. • Power Take Off (PTO).
high. • Abnormal noise. • Camshaft.
• Low compression.

Visual Check:
• Check the compression pressure on all cylinder.
• Check for leakage at the attachment point of the unit injec-
tor and fuel lines.
• Check if the cylinder head gasket is free from cracks and
damages.
• Check if the cylinder head and cylinder liner is free from
damage or cracks.
• Check if there are combustion gases entering the fuel sys-
tem by using carbon monoxide tester.
• Check that the fuel is of good quality and water separator
is free from residue.
• Visual check the Injector for any damage.
• Check the parameter code of Injectors.
• Adjust the valves (clearance) and Injectors for any fault.
• Check the Injector tip for damage and cracks.
• Check if there are exhaust gases entering the cooling sys-
tem by using carbon monoxide tester..
• Check that the fuel tank is free from rubbish and other
contaminants.
Leakage in the fuel system, Check
Action:

• Remove the supply line from the fuel tank.


• Connect 88800175 Kit on the supply line connection.
• Attach the pressure gauge to the fuel hose and connect
the pressure gauge to the pneumatic system in the
workshop.
• Check that the reduction valve on the pressure gauge and
the shut-off valve are open.
• Pressure test the fuel system..
• Build up the pressure to 200 kPa (29 psi).
• Apply soapy water to the lines and connections.

Evaluation:

• Leakage in fuel hoses and connections can cause air in


the fuel system.
• Air in the fuel can cause starting problems.

35
P02CD - Cylinder 1 Fuel Injector Offset Learning at Max
Group 593

DRAFT
Limit

P02CD - Cylinder 1 Fuel Injector Offset Learning at Max Limit

Fault Condition for Fault Observable Symptoms Possible cause


type
P02CD • Unit injector activated. • Low power. • Nozzle.
FTB00
• Cylinder balancing data too • Uneven operation. • Power Take Off (PTO).
high. • Abnormal noise. • Camshaft.
• Low compression.

Visual Check:
• Check the compression pressure on all cylinder. • Check the Injector tip for damage and cracks.
• Check for leakage at the attachment point of the unit injec- • Check if there are exhaust gases entering the cooling sys-
tor and fuel lines. tem by using carbon monoxide tester..
• Check if the cylinder head gasket is free from cracks and • Check that the fuel tank is free from rubbish and other
damages. contaminants.
• Check if the cylinder head and cylinder liner is free from
damage or cracks.
• Check if there are combustion gases entering the fuel sys-
tem by using carbon monoxide tester.
• Check that the fuel is of good quality and water separator
is free from residue.
• Visual check the Injector for any damage.
• Check the parameter code of Injectors.
•36 Adjust the valves (clearance) and Injectors for any fault.
Group 593 Leakage in the fuel system, Check

Leakage in the fuel system, Check


Action:


DRAFT
Remove the supply line from the fuel tank.
• Connect 88800175 Kit on the supply line connection.
• Attach the pressure gauge to the fuel hose and connect
the pressure gauge to the pneumatic system in the
workshop.
• Check that the reduction valve on the pressure gauge and
the shut-off valve are open.
• Pressure test the fuel system..
• Build up the pressure to 200 kPa (29 psi).
• Apply soapy water to the lines and connections.

Evaluation:

• Leakage in fuel hoses and connections can cause air in


the fuel system.
• Air in the fuel can cause starting problems.
P0261 - Cylinder 1 Injector Circuit Low

37
Group 593 Resistance measurement

Fault
type
P0261
Condition for Fault

• Unit injector activated.


DRAFT Observable Symptoms

• Low power.
Possible cause

• Connector.
FTB00
• Abnormal noise. • Wiring harness.
• Engine is operating on only 3 • Engine control module (ECM).
cylinders.

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short Circuit to Off 50 – Engine A14.J1:50 – R = Open 9998699,
Ground ground point Engine ground circuit 88890074
point
short circuit be- Off 50 – All pins at A14.J1:50 – All R = Open 88890227,
tween wires connectors J1 pins at connec- circuit 9998699, ,
and J2 tors J1 and J2 88890074
Short Circuit to Off 50 – Engine A14.J1:50 – R = Open 9998699,
Ground ground point Engine ground circuit 88890074
point (FI con-
nector
disconnected)

38
Group 593 P0202 - Cylinder 2 Injector A

P0202 - Cylinder 2 Injector A DRAFT

Fault Condition for Fault Observable Symptoms Possible cause


type
P0202 • Unit injector activated. • Low power. • Connector.
FTB13
• Engine runs unevenly or • Wiring harness between engine
misfires. control unit and unit injector.
• Abnormal noise. • Nozzle.
• Engine is operating on only 3 • Engine control module (ECM).
cylinders.

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short Circuit to Off 11 – Engine A14.J1:73 – R = Open 9998699,
Ground ground point Engine ground circuit 88890074
point

39
Group 593 Resistance measurement

Measuring Key position


DRAFT
Measurement points
Breakout box Wiring
diagram
Reference
value
Measured
value
Other (Special
tool No.)

Short Circuit to Off 1 – Engine FI:1 – Engine R = Open 9990008,


Ground ground point ground point circuit 88890074
Open circuit Off Y124:B - Y124: Y124:B - Y124: R = <= 3 Ω 9990008,
check A A 88890074

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Resistance Off 11 – 12 A14.J1:73 – R = <=3 Ω 88890227,
check A14.J1:74 9998699, ,
88890074
Resistance Off FI:1 – FI:2 FI:1 – FI:2 R = <= 3 Ω 9990008,
check 88890074

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Resistance Off Y124:B – En- Y124:B – En- R = Open 88890074
check gine ground gine ground circuit
point point

40
Group 593 P0265 - Injector 2 Short Circuit High

P0265 - Injector 2 Short Circuit High DRAFT

Fault Condition for Fault Observable Symptoms Possible cause


type
P0265 • Unit injector activated. • Low power. • Connector.
FTB00
• Uneven operation. • Wiring harness.
• Abnormal noise. • Injector.
• Engine is operating on only 3 • Engine control module (ECM).
cylinders.

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short Circuit Off 11 – All pins at A14.J1:73 – All R = Open 9998699,
between wires connectors J1 pins at connec- circuit 88890227,
and J2 tors J1 and J2 88890074

41
P02CE - Cylinder 2 Fuel Injector Offset Learning At Min
Group 593

DRAFT
Limit

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short Circuit Off 11 – 12 A14.J1:73 – R = Open 9998699,
between wires A14.J1:74 circuit 88890227,
9990062,
88890074
Short Circuit Off 11 – 50 A14.J1:73 – R = Open 9998699,
between wires A14.J1:50 circuit 88890227,
9990062,
88890074
Short Circuit Off 11 – 01 A14.J1:73 – R = Open 9998699,
between wires A14.J1:01 circuit 88890227,
9990062,
88890074
Short Circuit Off 11 – 02 A14.J1:73 – R = Open 9998699,
between wires A14.J1:02 circuit 88890227,
9990062,
88890074

P02CE - Cylinder 2 Fuel Injector Offset Learning At Min Limit

42
Group 593 Visual Check:

Fault
type
P02CE
Condition for Fault

• Unit injector activated.


DRAFT Observable Symptoms

• Low power.
Possible cause

• Nozzle.
FTB00
• Cylinder balancing data too • Uneven operation. • Power Take Off (PTO).
high. • Abnormal noise. • Camshaft.
• Low compression.

Visual Check:
• Check the compression pressure on all cylinder.
• Check for leakage at the attachment point of the unit injec-
tor and fuel lines.
• Check if the cylinder head gasket is free from cracks and
damages.
• Check if the cylinder head and cylinder liner is free from
damage or cracks.
• Check if there are combustion gases entering the fuel sys-
tem by using carbon monoxide tester.
• Check that the fuel is of good quality and water separator
is free from residue.
• Visual check the Injector for any damage.
• Check the parameter code of Injectors.
• Adjust the valves (clearance) and Injectors for any fault.
• Check the Injector tip for damage and cracks.
• Check if there are exhaust gases entering the cooling sys-
tem by using carbon monoxide tester..
• Check that the fuel tank is free from rubbish and other
contaminants.
Leakage in the fuel system, Check
Action:

• Remove the supply line from the fuel tank.


• Connect 88800175 Kit on the supply line connection.
• Attach the pressure gauge to the fuel hose and connect
the pressure gauge to the pneumatic system in the
workshop.
• Check that the reduction valve on the pressure gauge and
the shut-off valve are open.
• Pressure test the fuel system..
• Build up the pressure to 200 kPa (29 psi).
• Apply soapy water to the lines and connections.

Evaluation:

• Leakage in fuel hoses and connections can cause air in


the fuel system.
• Air in the fuel can cause starting problems.

43
P02CF - Cylinder 2 Fuel Injector Offset Learning at Max
Group 593

DRAFT
Limit

P02CF - Cylinder 2 Fuel Injector Offset Learning at Max Limit

Fault Condition for Fault Observable Symptoms Possible cause


type
P02CF • Unit injector activated. • Low power. • Nozzle.
FTB00
• Cylinder balancing data too • Uneven operation. • Power Take Off (PTO).
high. • Abnormal noise. • Camshaft.
• Low compression.

Visual Check:
• Check the compression pressure on all cylinder. • Check the Injector tip for damage and cracks.
• Check for leakage at the attachment point of the unit injec- • Check if there are exhaust gases entering the cooling sys-
tor and fuel lines. tem by using carbon monoxide tester..
• Check if the cylinder head gasket is free from cracks and • Check that the fuel tank is free from rubbish and other
damages. contaminants.
• Check if the cylinder head and cylinder liner is free from
damage or cracks.
• Check if there are combustion gases entering the fuel sys-
tem by using carbon monoxide tester.
• Check that the fuel is of good quality and water separator
is free from residue.
• Visual check the Injector for any damage.
• Check the parameter code of Injectors.
•44 Adjust the valves (clearance) and Injectors for any fault.
Group 593 Leakage in the fuel system, Check

Leakage in the fuel system, Check


Action:


DRAFT
Remove the supply line from the fuel tank.
• Connect 88800175 Kit on the supply line connection.
• Attach the pressure gauge to the fuel hose and connect
the pressure gauge to the pneumatic system in the
workshop.
• Check that the reduction valve on the pressure gauge and
the shut-off valve are open.
• Pressure test the fuel system..
• Build up the pressure to 200 kPa (29 psi).
• Apply soapy water to the lines and connections.

Evaluation:

• Leakage in fuel hoses and connections can cause air in


the fuel system.
• Air in the fuel can cause starting problems.
P0264 - Cylinder 2 Injector Circuit Low

45
Group 593 Resistance measurement

Fault
type
P0264
Condition for Fault

• Unit injector activated.


DRAFT Observable Symptoms

• Low power.
Possible cause

• Connector.
FTB00
• Abnormal noise. • Wiring harness.
• Engine is operating on only 3 • Engine control module (ECM).
cylinders.

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short Circuit to Off 12 – Engine A14.J1:74 – R = Open 9998699,
Ground ground point Engine ground circuit 88890074
point
short circuit be- Off 12 – All pins at A14.J1:74 – All R = Open 88890227,
tween wires connectors J1 pins at connec- circuit 9998699, ,
and J2 tors J1 and J2 88890074
Short Circuit to Off 12 – Engine A14.J1:74 – R = Open 9998699,
Ground ground point Engine ground circuit 88890074
point (FI con-
nector
disconnected)

46
Group 593 P0203 - Cylinder 3 Injector A

P0203 - Cylinder 3 Injector A DRAFT

Fault Condition for Fault Observable Symptoms Possible cause


type
P0203 • Unit injector activated. • Low power. • Connector.
FTB13
• Engine runs unevenly or • Wiring harness between engine
misfires. control unit and unit injector.
• Abnormal noise. • Injector.
• Engine is operating on only 3 • Engine control module (ECM).
cylinders.

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short Circuit to Off 25 – Engine A14.J1:25 – R = Open 9998699,
Ground ground point Engine ground circuit 88890074
point

47
Group 593 Resistance measurement

Measuring Key position


DRAFT
Measurement points
Breakout box Wiring
diagram
Reference
value
Measured
value
Other (Special
tool No.)

Short Circuit to Off 3 – Engine FI:3 – Engine R = Open 9990008,


Ground ground point ground point circuit 88890074
Open circuit Off Y126:B - Y126: Y126:B - Y126: R = <= 3 Ω 9990008,
check A A 88890074

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Resistance Off 25 – 01 A14.J1:25 – R = <=3 Ω 88890227,
check A14.J1:01 9998699, ,
88890074
Resistance Off FI:3 – FI:4 FI:3 – FI:4 R = <= 3 Ω 9990008,
check 88890074

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Resistance Off Y126:B – En- Y126:B – En- R = Open 88890074
check gine ground gine ground circuit
point point

48
Group 593 P0268 - Injector 3 Short Circuit High

P0268 - Injector 3 Short Circuit High DRAFT

Fault Condition for Fault Observable Symptoms Possible cause


type
P0268 • Unit injector activated. • Low power. • Connector.
FTB00
• Uneven operation. • Wiring harness.
• Abnormal noise. • Injector.
• Engine is operating on only 3 • Engine control module (ECM).
cylinders.

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short Circuit Off 25 – All pins at A14.J1:25 – All R = Open 9998699,
between wires connectors J1 pins at connec- circuit 88890227,
and J2 tors J1 and J2 88890074

49
P02D0 - Cylinder 3 Fuel Injector Offset Learning At Min
Group 593

DRAFT
Limit

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short Circuit Off 25 – 01 A14.J1:25 – R = Open 9998699,
between wires A14.J1:01 circuit 88890227,
9990062,
88890074
Short Circuit Off 25 – 50 A14.J1:25 – R = Open 9998699,
between wires A14.J1:50 circuit 88890227,
9990062,
88890074
Short Circuit Off 25 – 12 A14.J1:25 – R = Open 9998699,
between wires A14.J1:74 circuit 88890227,
9990062,
88890074
Short Circuit Off 25 – 02 A14.J1:25 – R = Open 9998699,
between wires A14.J1:02 circuit 88890227,
9990062,
88890074

P02D0 - Cylinder 3 Fuel Injector Offset Learning At Min Limit

50
Group 593 Visual Check:

Fault
type
P02D0
Condition for Fault

• Unit injector activated.


DRAFT Observable Symptoms

• Low power.
Possible cause

• Nozzle.
FTB00
• Cylinder balancing data too • Uneven operation. • Power Take Off (PTO).
high. • Abnormal noise. • Camshaft.
• Low compression.

Visual Check:
• Check the compression pressure on all cylinder.
• Check for leakage at the attachment point of the unit injec-
tor and fuel lines.
• Check if the cylinder head gasket is free from cracks and
damages.
• Check if the cylinder head and cylinder liner is free from
damage or cracks.
• Check if there are combustion gases entering the fuel sys-
tem by using carbon monoxide tester.
• Check that the fuel is of good quality and water separator
is free from residue.
• Visual check the Injector for any damage.
• Check the parameter code of Injectors.
• Adjust the valves (clearance) and Injectors for any fault.
• Check the Injector tip for damage and cracks.
• Check if there are exhaust gases entering the cooling sys-
tem by using carbon monoxide tester..
• Check that the fuel tank is free from rubbish and other
contaminants.
Leakage in the fuel system, Check
Action:

• Remove the supply line from the fuel tank.


• Connect 88800175 Kit on the supply line connection.
• Attach the pressure gauge to the fuel hose and connect
the pressure gauge to the pneumatic system in the
workshop.
• Check that the reduction valve on the pressure gauge and
the shut-off valve are open.
• Pressure test the fuel system..
• Build up the pressure to 200 kPa (29 psi).
• Apply soapy water to the lines and connections.

Evaluation:

• Leakage in fuel hoses and connections can cause air in


the fuel system.
• Air in the fuel can cause starting problems.

51
P02D1 - Cylinder 3 Fuel Injector Offset Learning at Max
Group 593

DRAFT
Limit

P02D1 - Cylinder 3 Fuel Injector Offset Learning at Max Limit

Fault Condition for Fault Observable Symptoms Possible cause


type
P02D1 • Unit injector activated. • Low power. • Nozzle.
FTB00
• Cylinder balancing data too • Uneven operation. • Power Take Off (PTO).
high. • Abnormal noise. • Camshaft.
• Low compression.

Visual Check:
• Check the compression pressure on all cylinder. • Check the Injector tip for damage and cracks.
• Check for leakage at the attachment point of the unit injec- • Check if there are exhaust gases entering the cooling sys-
tor and fuel lines. tem by using carbon monoxide tester..
• Check if the cylinder head gasket is free from cracks and • Check that the fuel tank is free from rubbish and other
damages. contaminants.
• Check if the cylinder head and cylinder liner is free from
damage or cracks.
• Check if there are combustion gases entering the fuel sys-
tem by using carbon monoxide tester.
• Check that the fuel is of good quality and water separator
is free from residue.
• Visual check the Injector for any damage.
• Check the parameter code of Injectors.
•52 Adjust the valves (clearance) and Injectors for any fault.
Group 593 Leakage in the fuel system, Check

Leakage in the fuel system, Check


Action:


DRAFT
Remove the supply line from the fuel tank.
• Connect 88800175 Kit on the supply line connection.
• Attach the pressure gauge to the fuel hose and connect
the pressure gauge to the pneumatic system in the
workshop.
• Check that the reduction valve on the pressure gauge and
the shut-off valve are open.
• Pressure test the fuel system..
• Build up the pressure to 200 kPa (29 psi).
• Apply soapy water to the lines and connections.

Evaluation:

• Leakage in fuel hoses and connections can cause air in


the fuel system.
• Air in the fuel can cause starting problems.
P0267 - Cylinder 3 Injector Circuit Low

53
Group 593 Resistance measurement

Fault
type
P0267
Condition for Fault

• Unit injector activated.


DRAFT Observable Symptoms

• Low power.
Possible cause

• Connector.
FTB00
• Abnormal noise. • Wiring harness.
• Engine is operating on only 3 • Engine control module (ECM).
cylinders.

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short Circuit to Off 01 – Engine A14.J1:01 – R = Open 9998699,
Ground ground point Engine ground circuit 88890074
point
short circuit be- Off 01 – All pins at A14.J1:01 – All R = Open 88890227,
tween wires connectors J1 pins at connec- circuit 9998699, ,
and J2 tors J1 and J2 88890074
Short Circuit to Off 01 – Engine A14.J1:01 – R = Open 9998699,
Ground ground point Engine ground circuit 88890074
point (FI con-
nector
disconnected)

54
Group 593 P0204 - Cylinder 4 Injector A

P0204 - Cylinder 4 Injector A DRAFT

Fault Condition for Fault Observable Symptoms Possible cause


type
P0204 • Unit injector activated. • Low power. • Connector.
FTB13
• Engine runs unevenly or • Wiring harness between engine
misfires. control unit and unit injector.
• Abnormal noise. • Injector.
• Engine is operating on only 3 • Engine control module (ECM).
cylinders.

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short Circuit to Off 26 – Engine A14.J1:26 – R = Open 9998699,
Ground ground point Engine ground circuit 88890074
point

55
Group 593 Resistance measurement

Measuring Key position


DRAFT
Measurement points
Breakout box Wiring
diagram
Reference
value
Measured
value
Other (Special
tool No.)

Short Circuit to Off 5 – Engine FI:5 – Engine R = Open 9990008,


Ground ground point ground point circuit 88890074
Open circuit Off Y127:B - Y127: Y127:B - Y127: R = <= 3 Ω 9990008,
check A A 88890074

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Resistance Off 26 – 02 A14.J1:26 – R = <=3 Ω 88890227,
check A14.J1:02 9998699, ,
88890074
Resistance Off FI:5 – FI:8 FI:5 – FI:8 R = <= 3 Ω 9990008,
check 88890074

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Resistance Off Y127:B – En- Y127:B – En- R = Open 88890074
check gine ground gine ground circuit
point point

56
Group 593 P0271 - Injector 4 Short Circuit High

P0271 - Injector 4 Short Circuit High DRAFT

Fault Condition for Fault Observable Symptoms Possible cause


type
P0271 • Unit injector activated. • Low power. • Connector.
FTB00
• Uneven operation. • Wiring harness.
• Abnormal noise. • Injector.
• Engine is operating on only 3 • Engine control module (ECM).
cylinders.

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short Circuit Off 26 – All pins at A14.J1:26 – All R = Open 9998699,
between wires connectors J1 pins at connec- circuit 88890227,
and J2 tors J1 and J2 88890074

57
P02D2 - Cylinder 4 Fuel Injector Offset Learning At Min
Group 593

DRAFT
Limit

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short Circuit Off 26 – 02 A14.J1:26 – R = Open 9998699,
between wires A14.J1:02 circuit 88890227,
9990062,
88890074
Short Circuit Off 26 – 50 A14.J1:26 – R = Open 9998699,
between wires A14.J1:50 circuit 88890227,
9990062,
88890074
Short Circuit Off 26 – 12 A14.J1:26 – R = Open 9998699,
between wires A14.J1:74 circuit 88890227,
9990062,
88890074
Short Circuit Off 26 – 01 A14.J1:26 – R = Open 9998699,
between wires A14.J1:01 circuit 88890227,
9990062,
88890074

P02D2 - Cylinder 4 Fuel Injector Offset Learning At Min Limit

58
Group 593 Visual Check:

Fault
type
P02D2
Condition for Fault

• Unit injector activated.


DRAFT Observable Symptoms

• Low power.
Possible cause

• Nozzle.
FTB00
• Cylinder balancing data too • Uneven operation. • Power Take Off (PTO).
high. • Abnormal noise. • Camshaft.
• Low compression.

Visual Check:
• Check the compression pressure on all cylinder.
• Check for leakage at the attachment point of the unit injec-
tor and fuel lines.
• Check if the cylinder head gasket is free from cracks and
damages.
• Check if the cylinder head and cylinder liner is free from
damage or cracks.
• Check if there are combustion gases entering the fuel sys-
tem by using carbon monoxide tester.
• Check that the fuel is of good quality and water separator
is free from residue.
• Visual check the Injector for any damage.
• Check the parameter code of Injectors.
• Adjust the valves (clearance) and Injectors for any fault.
• Check the Injector tip for damage and cracks.
• Check if there are exhaust gases entering the cooling sys-
tem by using carbon monoxide tester..
• Check that the fuel tank is free from rubbish and other
contaminants.
Leakage in the fuel system, Check
Action:

• Remove the supply line from the fuel tank.


• Connect 88800175 Kit on the supply line connection.
• Attach the pressure gauge to the fuel hose and connect
the pressure gauge to the pneumatic system in the
workshop.
• Check that the reduction valve on the pressure gauge and
the shut-off valve are open.
• Pressure test the fuel system..
• Build up the pressure to 200 kPa (29 psi).
• Apply soapy water to the lines and connections.

Evaluation:

• Leakage in fuel hoses and connections can cause air in


the fuel system.
• Air in the fuel can cause starting problems.

59
P02D3 - Cylinder 4 Fuel Injector Offset Learning at Max
Group 593

DRAFT
Limit

P02D3 - Cylinder 4 Fuel Injector Offset Learning at Max Limit

Fault Condition for Fault Observable Symptoms Possible cause


type
P02D3 • Unit injector activated. • Low power. • Nozzle.
FTB00
• Cylinder balancing data too • Uneven operation. • Power Take Off (PTO).
high. • Abnormal noise. • Camshaft.
• Low compression.

Visual Check:
• Check the compression pressure on all cylinder. • Check the Injector tip for damage and cracks.
• Check for leakage at the attachment point of the unit injec- • Check if there are exhaust gases entering the cooling sys-
tor and fuel lines. tem by using carbon monoxide tester..
• Check if the cylinder head gasket is free from cracks and • Check that the fuel tank is free from rubbish and other
damages. contaminants.
• Check if the cylinder head and cylinder liner is free from
damage or cracks.
• Check if there are combustion gases entering the fuel sys-
tem by using carbon monoxide tester.
• Check that the fuel is of good quality and water separator
is free from residue.
• Visual check the Injector for any damage.
• Check the parameter code of Injectors.
•60 Adjust the valves (clearance) and Injectors for any fault.
Group 593 Leakage in the fuel system, Check

Leakage in the fuel system, Check


Action:


DRAFT
Remove the supply line from the fuel tank.
• Connect 88800175 Kit on the supply line connection.
• Attach the pressure gauge to the fuel hose and connect
the pressure gauge to the pneumatic system in the
workshop.
• Check that the reduction valve on the pressure gauge and
the shut-off valve are open.
• Pressure test the fuel system..
• Build up the pressure to 200 kPa (29 psi).
• Apply soapy water to the lines and connections.

Evaluation:

• Leakage in fuel hoses and connections can cause air in


the fuel system.
• Air in the fuel can cause starting problems.
P0270 - Cylinder 4 Injector Circuit Low

61
Group 593 Resistance measurement

Fault
type
P0270
Condition for Fault

• Unit injector activated.


DRAFT Observable Symptoms

• Low power.
Possible cause

• Connector.
FTB00
• Abnormal noise. • Wiring harness.
• Engine is operating on only 3 • Engine control module (ECM).
cylinders.

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short Circuit to Off 02 – Engine A14.J1:02 – R = Open 9998699,
Ground ground point Engine ground circuit 88890074
point
short circuit be- Off 02 – All pins at A14.J1:02 – All R = Open 88890227,
tween wires connectors J1 pins at connec- circuit 9998699, ,
and J2 tors J1 and J2 88890074
Short Circuit to Off 02 – Engine A14.J1:02 – R = Open 9998699,
Ground ground point Engine ground circuit 88890074
point (FI con-
nector
disconnected)

62
Group 593 P0335 - Crankshaft Position Sensor A

P0335 - Crankshaft Position Sensor A DRAFT

Fault Condition for Fault Observable Symptoms Possible cause


type
P0335
FTB 31
• No signal. • Long start time. • Flywheel sensor.
• Uneven operation. • Wiring harness.
• Incorrectly installed sensor (in-
correct distance to tooth wheel).
• Engine control module (ECM).

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Open Circuit Off 58 – 59 A14.J1:58– R = 750 – 1000 9998699,
check A14.J1:59 Ω 9990062,
88890227,
88890074

63
Group 593 Visual check:

DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Component Off 1– 2 B04:1– B04:2 R = 750 – 1000 9990216,
resistance Ω 88890074

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short circuit to Off 58 – All pins at A14.J1:58 – All R = Open 9998699,
battery voltage connectors J1 pins at connec- Circuit 9990062,
and J2 tors J1 and J2 88890227,
88890074
Short circuit to Off 59 – All pins at A14.J1:59 – All R = Open 9998699,
battery voltage connectors J1 pins at connec- Circuit 9990062,
and J2 tors J1 and J2 88890227,
88890074

Visual check:
• Check the Tooth wheel for any damage or loose fitting.
• Check the camshaft intermediate gear for any damage or
loose fitting.
• Check the sensor for faulty connection.
• Check that the sensor is free from external damage.

64
P0336 - Crankshaft Position Sensor A Circuit Range/
Group 593

DRAFT
Performance

P0336 - Crankshaft Position Sensor A Circuit Range/Performance

Fault Condition for Fault Observable Symptoms Possible cause


type
P0336 • Incorrect engine speed sensor • Long start time. • Flywheel sensor.
FTB 38 signal. • Uneven operation. • Wiring harness.
• Loss of power. • Flywheel.
• Electrical interference in the en-
gine speed sensor signal.
• Incorrectly installed sensor (in-
correct distance to tooth wheel).

Visual check:
• Check the Tooth wheel for any damage or loose fitting.
• Check the sensor for proper signal.
• Check the camshaft intermediate gear for any damage or
loose fitting.
• Check the sensor for faulty connection.
• Check that the sensor is free from external damage.

65
Group 593 P0339 - Crankshaft Position Sensor A Circuit Intermittent

DRAFT
P0339 - Crankshaft Position Sensor A Circuit Intermittent

Fault Condition for Fault Observable Symptoms Possible cause


type
P0339
FTB 00
• Incorrect engine speed sensor • Long start time. • Flywheel sensor.
signal. • Uneven operation. • Wiring harness.
• Loss of power. • Flywheel.
• Electrical interference in the en-
gine speed sensor signal.

Visual check:
• Check the Tooth wheel for any damage or loose fitting.
• Check the sensor for proper signal.
• Check the camshaft intermediate gear for any damage or
loose fitting.
• Check the sensor for faulty connection.
• Check that the sensor is free from external damage.

66
Group 593 P0524 - Engine Oil Pressure Too Low

P0524 - Engine Oil Pressure Too Low DRAFT

Fault Condition for Fault Observable Symptoms Possible cause


type
P0524
FTB 00
• Oil pressure critically low. • A buzzer sounds. • Low engine oil level.
• Low power. • Contaminated oil, slow flowing
• Reduced engine output and en- or too thin.
gine switch-off if the vehicle • Reduction valve.
speed falls below 3 km/h (2 • Worn oil pump.
mph) when engine protection is
chosen in the data set. • Oil pressure sensor.

Voltage measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Signal voltage On 2–4 B118:2 – U = 0.01 V – 88890039,
from Oil pres- B118:4 0.03 V 88890074
sure sensor at
an oil pressure
of 0kPa (0psi)
67
Group 593 Oil Gallery pressure, Check

Measuring Key position


DRAFT
Measurement points
Breakout box Wiring
diagram
Reference
value
Measured
value
Other (Special
tool No.)

Supply Voltage On 1– 4 B118:1 – U = 4.75 V – 88890039,


check B118:4 5.25 V 88890074
Signal voltage On 2–4 B118:2 – U = 2 V – 2.4 V 88890039,
from Oil pres- B118:4 88890074,
sure sensor at 88800267,
an pressure of 9990123
300kPa
(43.5psi)

Oil Gallery pressure, Check


Special tool No.:

9996398, 9992873

Action:

• Disconnect Y111 (Piston cooling valve) connector.


• Check if the oil pressure is according to specifications by
performing ONE of the test procedures below .
Test Procedure 1:

• Remove the B118 (Oil pressure sensor) and connect the


pressure gauge.
• Warm up the engine until the engine oil temperature reach
90°C (194°F).
• Run the engine at all idle speeds that are specified in Im-
pact (600 rpm, 800 rpm, 1000 rpm).
• Check if the engine oil pressure and the piston cooling
pressure reach the minimum pressures according to speci-
fications (Engine oil pressure must be read from the
manometer).
• Check the values as per specification.

Test Procedure 2:

• Fix the B118 (Oil pressure sensor).


• Warm up the engine until the engine oil temperature reach
117°C (243°F).

68
Group 593 Visual check:



Perform a test drive.
DRAFT
Run the engine at full load at the engine speeds that are
specified in Impact (700 rpm, 1100 rpm, 1400 rpm).
• Check if the engine oil pressure and the piston cooling
pressure reach the minimum pressures according to
specifications.

Visual check:
• Check the oil for external leakage.
• Check the oil pan and suction strainer for plugged or re-
stricted and clogged.
• Check the oil lines for leakage and damage.
• Check the oil pump for clogged and damage or wear.

Found oil colour gray, check:


• Check radiator and hoses for leakage.
• Check the pressure drop of cooling system to find internal
leakage.
• If internal leakage found check the Cylinder head gasket,
cylinder liner, oil cooler for leakage and do the pressure
test of cylinder head.

Found oil too thin and smells like diesel fuel, check:
• Check that there is no fuel leakage into the engine oil from
the fuel system.
• Check for leakage at the attachment point of the unit
injector.
• Do the Pressure test of fuel system.

69
Group 593 P0520 - Engine Oil Pressure Sensor/Switch A

DRAFT
P0520 - Engine Oil Pressure Sensor/Switch A

Fault Condition for Fault Observable Symptoms Possible cause


type
P0520
FTB13
• The voltage at pin J1:96 is less • The oil pressure gauge shows 0 • Open circuit, Signal wire.
than 0.3 V. when the engine is running. • Open circuit, Supply wire.
• Engine wiring harness.
• Oil pressure sensor.
• Engine control module (ECM).

Voltage measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Supply Voltage On 1– 4 B118:1– U = 4.75 V – 88890039,
B118:4 5.25 V 88890074
Signal Voltage On 2– 4 B118:2– U = 0.4 V – 0.6 88890039,
B118:4 V (Engine not 88890074
running)

70
Group 593 Resistance measurement

DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Supply Voltage On 29 – 05 A14.J1:91 – U = 4.75 V – 9998699,
A14.J1:67 5.25 V 9990062,
88890074
Signal Voltage On 34 – 05 A14.J1:96 – U = 0.4 V – 0.6 9998699,
A14.J1:67 V (Engine not 9990062,
running) 88890074

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short Circuit / Off 1– 29, 2– 34, 4 B118:1– A14. R = <10 Ω 9998699,
Open Circuit –5 J1:91, B118:2– 9990062,
A14.J1:96, 88890039,
B118:4– A14. 88890074
J1:67

71
Group 593 P1093 - Engine Oil Pressure Moderately Low

P1093 - Engine Oil Pressure Moderately Low DRAFT

Fault Condition for Fault Observable Symptoms Possible cause


type
P1093
FTB 00
• Oil pressure critically low. • A buzzer sounds. • Low engine oil level.
• Low power. • Contaminated oil, slow flowing
• Reduced engine output and en- or too thin.
gine switch-off if the vehicle • Reduction valve.
speed falls below 3 km/h (2 • Worn oil pump.
mph) when engine protection is
chosen in the data set. • Oil pressure sensor.

Voltage measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Signal voltage On 2–4 B118:2 – U = 0.01 V – 88890039,
from Oil pres- B118:4 0.03 V 88890074
sure sensor at
an oil pressure
of 0kPa (0psi)
72
Group 593 Oil Gallery pressure, Check

Measuring Key position


DRAFT
Measurement points
Breakout box Wiring
diagram
Reference
value
Measured
value
Other (Special
tool No.)

Supply Voltage On 1– 4 B118:1 – U = 4.75 V – 88890039,


check B118:4 5.25 V 88890074
Signal voltage On 2– 4 B118:2– U = 2 V – 2.4 V 88890039,
from Oil pres- B118:4 88890074,
sure sensor at 88800267,
an pressure of 9990123
300kPa
(43.5psi)

Oil Gallery pressure, Check


Special tool No.:

9996398, 9992873

Action:

• Disconnect Y111 (Piston cooling valve) connector.


• Check if the oil pressure is according to specifications by
performing ONE of the test procedures below .
Test Procedure 1:

• Remove the B118 (Oil pressure sensor) and connect the


pressure gauge.
• Warm up the engine until the engine oil temperature reach
90°C (194°F).
• Run the engine at all idle speeds that are specified in Im-
pact (600 rpm, 800 rpm, 1000 rpm).
• Check if the engine oil pressure and the piston cooling
pressure reach the minimum pressures according to speci-
fications (Engine oil pressure must be read from the
manometer).
• Check the values as per specification.

Test Procedure 2:

• Fix the B118 (Oil pressure sensor).


• Warm up the engine until the engine oil temperature reach
117°C (243°F).

73
Group 593 Visual check:



Perform a test drive.
DRAFT
Run the engine at full load at the engine speeds that are
specified in Impact (700 rpm, 1100 rpm, 1400 rpm).
• Check if the engine oil pressure and the piston cooling
pressure reach the minimum pressures according to
specifications.

Visual check:
• Check the oil for external leakage.
• Check the oil pan and suction strainer for plugged or re-
stricted and clogged.
• Check the oil lines for leakage and damage.
• Check the oil pump for clogged and damage or wear.

Found oil colour gray, check:


• Check radiator and hoses for leakage.
• Check the pressure drop of cooling system to find internal
leakage by using pressure gauge.
• If internal leakage found check the Cylinder head gasket,
cylinder liner, oil cooler for leakage and do the pressure
test of cylinder head.

Found oil too thin and smells like diesel fuel, check:
• Check that there is no fuel leakage into the engine oil from
the fuel system.
• Check for leakage at the attachment point of the unit
injector.
• Do the Pressure test of fuel system.

74
Group 593 P0522 - Engine Oil Pressure Circuit Low

P0522 - Engine Oil Pressure Circuit Low DRAFT

Fault Condition for Fault Observable Symptoms Possible cause


type
P0522
FTB 00
• The voltage at pin J1:96 is less • The oil pressure gauge shows 0 • Short circuit to ground, Signal
than 0.3 V. when the engine is running. wire.
• Low power.

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short circuit to Off 2–4 B118:2 – R = Open 88890039,
ground, Signal B118:4 circuit 88890074
wire
Short circuit to Off 2 – Engine B118:2 – En- R = Open 88890039,
ground, Signal ground point gine ground circuit 88890074
wire point

75
P0340 - Camshaft Position Sensor A Bank 1 or Single
Group 593

DRAFT
Sensor

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Sensor signal On 2–4 B118:2 – U = 0.01 V - 88890039,
check B118:4 0.03 V 88890074

P0340 - Camshaft Position Sensor A Bank 1 or Single Sensor

Fault Condition for Fault Observable Symptoms Probable cause


type
P0340
FTB 31
• No camshaft speed sensor • Difficult to start at next start de- • Engine position timing sensor.
signal. spite that no fault code is set • Wiring harness.
when the engine is running.
• Connector.
• Loss of power.
• Tooth wheel.
• Engine control module(ECM).

Resistance measurement

76
Group 593 Visual check:

Measuring Key position


DRAFT
Measurement points
Breakout box Wiring
diagram
Reference
value
Measured
value
Other (Special
tool No.)

Short Circuit in Off 20 – 21 A14.J1:82 - R = 750 Ω - 9998699,


signal wire A14.J1:83 1000 Ω 9990062,
88890227,
88890074
Open Circuit Off 58 – 59 A14.J1:58 - R = 750 Ω - 9998699,
A14.J1:59 1000 Ω 9990062,
88890227,
88890074

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Component Off 1– 2 B05:1 - B05:2 R = 750 Ω - 9990216,
resistance 1000 Ω 88890074
Component Off 1– 2 B04:1 - B04:2 R = 750 Ω - 9990216,
resistance 1000 Ω 88890074

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short circuit to Off 20 – All pins at A14.J1:82 - All R = Open 9998699,
battery voltage connectors J1 pins at connec- circuit 9990062,
and J2 tors J1 and J2 88890227,
88890074
Short circuit to Off 21 – All pins at A14.J1:83 - All R = Open 9998699,
battery voltage connectors J1 pins at connec- circuit 9990062,
and J2 tors J1 and J2 88890227,
88890074

Visual check:
• Check the Tooth wheel for any damage or loose fitting.
• Check that the camshaft is correctly adjusted.
• Check the camshaft intermediate gear for any damage or
loose fitting.
• Check the sensors for faulty connection.
• Check that the sensors is free from external damage.
• Check the distance between the flywheel sensor and the
flywheel.
• Check the distance between the camshaft sensor and a
camshaft tooth wheel pin .

77
P0341 - Camshaft Position Sensor A Circuit Range/
Group 593

DRAFT
Performance

P0341 - Camshaft Position Sensor A Circuit Range/Performance

Fault Condition for Fault Observable Symptoms Probable cause


type
P0341 • Engine Control Module (ECM) • Difficult to start at next start de- • Engine position timing sensor.
FTB 38 detects extra pulses on the en-
gine speed sensor signal.
spite that no fault code is set
when the engine is running.
• Wiring harness.
• Tooth wheel.
• Loss of power.

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short Circuit in Off 20 – 21 A14.J1:82 - R = 750 Ω - 9998699,
signal wire A14.J1:83 1000 Ω 9990062,
88890227,
88890074
Open Circuit Off 58 – 59 A14.J1:58 - R = 750 Ω - 9998699,
A14.J1:59 1000 Ω 9990062,
88890227,
88890074
78
Group 593 Visual check:

DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Component Off 1– 2 B05:1 - B05:2 R = 750 Ω - 9990216,
resistance 1000 Ω 88890074
Component Off 1– 2 B04:1 - B04:2 R = 750 Ω - 9990216,
resistance 1000 Ω 88890074

Visual check:
• Check the Tooth wheel for any damage or loose fitting.
• Check that the camshaft is correctly adjusted.
• Check the camshaft intermediate gear for any damage or
loose fitting.
• Check the sensors for faulty connection.
• Check that the sensors is free from external damage.
• Check the distance between the flywheel sensor and the
flywheel.
• Check the distance between the camshaft sensor and a
camshaft tooth wheel pin.

P0016 - Crankshaft Position - Camshaft Position Correlation

79
Group 593 Resistance measurement

Fault
type
P0016
Condition for Fault


DRAFT
The cam shaft sensor signal is
Observable Symptoms

• High fuel consumption.


Probable cause

• Engine transmission.
FTB 76 dislocated compared to the fly
wheel sensor signal.

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short Circuit in Off 20 – 21 A14.J1:82 - R = 750 Ω - 9998699,
signal wire A14.J1:83 1000 Ω 9990062,
88890227,
88890074
Open Circuit Off 58 – 59 A14.J1:58 - R = 750 Ω - 9998699,
A14.J1:59 1000 Ω 9990062,
88890227,
88890074

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Component Off 1– 2 B05:1 - B05:2 R = 750 Ω - 9990216,
resistance 1000 Ω 88890074
Component Off 1– 2 B04:1 - B04:2 R = 750 Ω - 9990216,
resistance 1000 Ω 88890074

Visual check:
• Check the Tooth wheel for any damage or loose fitting.
• Check that the camshaft is correctly adjusted.
• Check the camshaft intermediate gear for any damage or
loose fitting.
• Check the sensors for faulty connection.
• Check that the sensors is free from external damage.
• Check the distance between the flywheel sensor and the
flywheel.
• Check the distance between the camshaft sensor and a
camshaft tooth wheel pin.

80
Group 593 P0615 - Starter Relay

P0615 - Starter Relay DRAFT

Fault Condition for Fault Observable Symptoms Probable cause


type
P0615 • None. • Starter motor does not run. • Starter motor relay (K01A).
FTB13
• Wiring harness between Engine
control module and Starter mo-
tor relay (K01A).
• Engine control module(ECM).

Voltage measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Voltage Supply On NA M04.K01A:86 – U = 20 V - 30 V 88890074
Engine ground

81
Group 593 Resistance measurement

Resistance measurement
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Open circuit Off M04.K01A:85 – M04.K01A:85 - R = 0 Ω – 10 Ω 9998699,
check 19 A14.J1:81 9990062,
88890227,
88890074
Open circuit Off M04.K01A:86 – M04.K01A:86 - R = 0 Ω – 10 Ω 9998699,
check 08 A14.J1:08 9990062,
88890227,
88890074

P0616 - Starter Relay Circuit Low

Fault Condition for Fault Observable Symptoms Probable cause


type
P0616
FTB00
• Short circuit to ground on A14. • Starter motor does not become • Wire between engine control
J1:81. activated. unit (EECU) and starter motor
• Engine does not start. relay.
• Starter motor relay (K01A).

82
Group 593 Resistance measurement

Resistance measurement
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Open circuit Off M04.K01A:85 – M04.K01A:85 – R=0Ω— 9998699,
check 19 A14.J1:81 10 Ω 9990062,
88890227,
88890074

P0617 - Starter Relay Circuit High

Fault Condition for Fault Observable Symptoms Probable cause


type
P0617
FTB00
• The fault code is set only after • Starter motor does not run. • Wiring harness between Engine
3s when the ignition key is in • Automatic dipped beam is not Management System and Start-
start position. turned off when the ignition key er motor relay (K01A).
• Output A14.J1:81 active. is in start position. • Starter motor relay (K01A).

83
Group 593 Voltage measurement

Voltage measurement
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Short circuit to On NA M04.K01A:85 – U = 20 V – 30 88890074
battery voltage Engine ground V

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short circuit to On NA M04.K01A:85 – U = 20 V – 30 88890074
battery voltage Engine ground V

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short circuit to Off NA M04:30 – M04. R = >= 1 k Ω 88890074
battery voltage K01A:86

84
Group 593 P1176 - Starter Motor Deactivated - Over Temperature

DRAFT
P1176 - Starter Motor Deactivated - Over Temperature

Fault Condition for Fault Observable Symptoms Probable cause


type
P1176
FTB 00
• The starter motor has been acti- • Not possible to activate the start- • Engine is difficult to start.
vated for too long time. er motor during a certain time. • Cold ambient temperature.
• Too many tries to start. • Text message on the display, • Low battery voltage.
Wait to start, and count down.

Visual check:
• Check the Air filter element for cleanliness. • Check if the overflow valve opens at the specified opening
• Check that the fuel is of good quality and water separator pressure (pressure = 300 kPa — 550 kPa).
is free from residue. • Check the fuel pump for proper functioning.
• Check that the fuel tank is free from rubbish and other
contaminants.
• Check fuel hoses and connections.
• Check the fuel supply pressure using an external pressure
sensor to eliminate a fault in the pressure sensor (Fuel
supply pressure at 600 rpm 300 kPa , Fuel supply pres-
sure at 1200 rpm 300 kPa).
• Check the fuel filter for clogged by Comparing the pres-
sure before the filter to the pressure after the filter, using
Special tools (9996398, 9992936, 968126).The pressure
may not decrease more than 40 kPa (5.8 psi) over the fuel
filter.
85
Group 593 Leakage in the fuel system, Check

Leakage in the fuel system, Check


Action:


DRAFT
Remove the supply line from the fuel tank.
• Connect 88800175 Kit on the supply line connection.
• Attach the pressure gauge to the fuel hose and connect
the pressure gauge to the pneumatic system in the
workshop.
• Check that the reduction valve on the pressure gauge and
the shut-off valve are open.
• Pressure test the fuel system.
• Build up the pressure to 200 kPa (29 psi).
• Apply soapy water to the lines and connections.

Evaluation:

• Leakage in fuel hoses and connections can cause air in


the fuel system.
• Air in the fuel can cause starting problems.
P1178 - Starter Motor Deactivated - Cogwheels of Starter Motor and
Engine Stuck

86
Group 593 Voltage measurement

Fault
type
P1178
Condition for Fault


DRAFT
Starter motor activated, no
Observable Symptoms

• Starter motor does not run.


Probable cause

• Batteries.
FTB 00 speed signal. • Starter motor solenoid.
• Open circuit electric cables.
• The starter pinion does not
mesh with the gear ring on the
fly wheel.
• Starter motor.

Voltage measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Supply Voltage On NA M04:30 – En- U = 20 V – 30 88890074
check gine ground V
Supply Voltage On NA X54:1 – Engine U = 20 V – 30 88890074
check ground V
Supply Voltage On NA M04.K01A:86 – U = 20 V – 30 88890074
check Engine ground V
Supply Voltage On NA M04.K01A:85 – U = 20 V – 30 88890074
check Engine ground V
Supply Voltage On NA M04.K01A:30 – U = 20 V – 30 88890074
check Engine ground V

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Open circuit Off M04.K01A:86 – M04.K01A:86 – R = 0 Ω – 10 Ω 88890074,
check 08 A14.J1:08 9998699,
88890227
Open circuit Off M04.K01A:85 – M04.K01A:85 – R = 0 Ω – 10 Ω 88890074,
check 19 A14.J1:81 9998699,
88890227
Open circuit Off NA M04.K01A:87 – R=0Ω–5Ω 88890074
check M04:50

Visual check:
• Check the Starter motor connection for fault free and prop-
erly installed.
• Check that the connectors are properly connected and
locked into position..
87
Group 593 P1179 - Starter Motor Deactivated - PTO Active

DRAFT
P1179 - Starter Motor Deactivated - PTO Active

Fault Condition for Fault Observable Symptoms Probable cause


type
P1179
FTB00
• Power take-off activated. • Not possible to activate the start- • Power take-off switch.
er motor.

Action:
• Put the power take-off switch in off position and try to start
again.

88
Group 593 P0666 - Control Module Internal Temperature Sensor A

DRAFT
P0666 - Control Module Internal Temperature Sensor A

Fault Condition for Fault Observable Symptoms Probable cause


type
P0666
FTB13
• Internal fault in control unit. • Engine Control Module (ECM).

Action:
• Conform the internal fault of EMS.

89
P0668 - PCM/ECM/TCM Internal Temperature Sensor
Group 593

DRAFT
Circuit Low

P0668 - PCM/ECM/TCM Internal Temperature Sensor Circuit Low

Fault Condition for Fault Observable Symptoms Probable cause


type
P0668
FTB00
• Internal fault in control unit. • Engine Control Module (ECM).

Action:
• Conform the internal fault of EMS.

90
Group 593 P1104 - Factory Mode

P1104 - Factory Mode DRAFT

Fault Condition for Fault Observable Symptoms Probable cause


type
P0668 • Internal fault in control unit. • Engine Control Module (ECM).
FTB00

Action:
• Conform the internal fault of EMS.

91
Group 593 P1141 - Buffered Idle Validation Switch Wire - ECM Side

DRAFT
P1141 - Buffered Idle Validation Switch Wire - ECM Side

Fault Condition for Fault Observable Symptoms Probable cause


type
P1141
FTB 23
• Accelerator pedal signal does • The engine does not respond • Wiring harness.
not correspond to actual accel- when accelerator pedal is • Accelerator pedal.
erator pedal position. pressed..
• IECU - Integrated Electronic
Control Unit.

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Component Off NA B25:F - B25:B R = 3 kΩ — 5 9990008,
resistance kΩ 88890074
Component Off NA B25:D- B25:B R = Open 9990008,
resistance circuit 88890074

92
Group 593 Resistance measurement

DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Short Circuit Off 17 — All pins A149.PB:17 - R = Open 9998699,
at connectors A149.PA, PB circuit 9998533,
PA and PB 9813194,
88890074,
9990008

Fault Condition for Fault Observable Symptoms Probable cause


type
P1141
FTB 24
• Accelerator pedal signal does • The engine does not respond • Wiring harness.
not correspond to actual accel- when accelerator pedal is • Accelerator pedal.
erator pedal position. pressed.
• Cruise control does not function.
• IECU - Integrated Electronic
Control Unit.

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Component Off NA B25:F - B25:B R = 3 kΩ – 5 9990008,
resistance kΩ 88890074
Component Off NA B25:D - B25:B R = Open 9990008,
resistance circuit 88890074

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short Circuit Off 17 – All pins at A149.PB:17 - R = Open 9998699,
connectors PA A149.PA, PB circuit 9998533,
and PB 9813194,
88890074
Short Circuit to Off 61 –17 A14.J2:27 – R = 0 Ω – 10 Ω 9998699,
ground in Sig- A149.PB:17 88890227,
nal wire 9990062,
9998533,
88890074
93
Group 593 P0091 - Fuel Pressure Regulator Control Circuit Low

Measuring Key position


DRAFT
Measurement points
Breakout box Wiring
diagram
Reference
value
Measured
value
Other (Special
tool No.)

Short Circuit to Off 17 – Chassis A149.PB:17 - R = Open 9998699,


ground in Sig- ground point Chassis circuit 9998533,
nal wire ground point 88890074
Short Circuit to Off 61 – 36 A14.J2:27 – R = Open 9998699,
ground in Sig- A14.J2:02 circuit 9990062,
nal wire 88890227,
88890074

P0091 - Fuel Pressure Regulator Control Circuit Low

Fault Condition for Fault Observable Symptoms Probable cause


type
P0091 • Short circuit to ground. • Low torque. • Wiring harness between compo-
FTB 00
• Common rail safety valve: The nent connector and control unit
connector.
safety valve is open.
• Damaged or faulty component.

94
Group 593 Resistance measurement

Resistance measurement
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Short circuit to Off 32 – Engine A14.J1:32 – R = Open 88890074,
ground check ground point Engine ground circuit 9990062,
point 9998699,
88890227

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short circuit Off 32 – All pins at A14.J1:32 – All R = Open 88890074,
between wires connectors J1 pins at connec- circuit 9990062,
and J2 tors J1 and J2 9998699,
88890227
Short circuit to Off 32 – Engine A14.J1:32 – R = Open 88890074,
ground check ground point Engine ground circuit 9990062,
point 9998699,
88890227
Short circuit to Off 31 – Engine A14.J1:31 – R = Open 88890074,
ground check ground point Engine ground circuit 9990062,
point 9998699,
88890227

95
Group 593 P0092 - Fuel Pressure Regulator Control Circuit High

DRAFT
P0092 - Fuel Pressure Regulator Control Circuit High

Fault Condition for Fault Observable Symptoms Probable cause


type
P0092
FTB 00
• Short circuit to voltage supply. • Low torque. • Wiring harness between compo-
• Common rail safety valve: The nent connector and control unit
safety valve is open. connector.
• Damaged or faulty component.
• Damaged connector.

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short circuit be- Off 31 – All pins at A14.J1:31 – All R = Open 88890074,
tween wires connectors J1 pins at connec- circuit 9990062,
and J2 tors J1 and J2 9998699,
88890227

96
Group 593 P0090 - Fuel Pressure Regulator 1 Control

DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Component Off NA Y108:1 – R = 8 Ω – 10 88890074,999-
resistance Y108:2 Ω 0008

P0090 - Fuel Pressure Regulator 1 Control

Fault Condition for Fault Observable Symptoms Probable cause


type
P0090
FTB 13
• Short circuit or open circuit. • Low torque. • Wiring harness between compo-
• Common rail safety valve: The nent connector and control unit
connector.
safety valve is open.
• Damaged or faulty component.
• Damaged connector.

97
Group 593 Resistance measurement

Resistance measurement
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Open circuit Off 31 – 32 A14.J1:31 – R = 8 Ω – 10 88890074,
check A14.J1:32 Ω 9990062,
9998699,
88890227
Short circuit to Off 31 – 35 A14.J1:31 – R = Open 88890074,
higher voltage A14.J2:01 circuit 9990062,
9998699,
88890227

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short circuit be- Off 32 – All pins at A14.J1:32 – All R = Open 88890074,
tween wires connectors J1 pins at connec- circuit 9990062,
and J2 tors J1 and J2 9998699,
88890227
Open circuit Off 31 – 1 A14.J1:31 – R = 0 Ω – 10 Ω 88890074,
check Y108:1 9990062,
9998699,
88890227,
9990008
Open circuit Off 32 – 2 A14.J1:32 – R = 0 Ω – 10 Ω 88890074,
check Y108:1 9990062,
9998699,
88890227,
9990008

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Component Off NA Y108:1 – R = 8 Ω – 10 88890074,999-
resistance Y108:2 Ω 0008

98
Group 593 P0088 - Fuel Rail/System Pressure - Too High Bank 1

DRAFT
P0088 - Fuel Rail/System Pressure - Too High Bank 1

Fault Condition for Fault Observable Symptoms Probable cause


type
P0088
FTB 00
• The rail pressure deviates from • Low power. • Rail pressure sensor.
set point. • Engine speed limited to 1500 • Wiring harness between compo-
rpm. nent connector and control unit
connector.

Voltage measurement

99
Group 593 Resistance measurement

Measuring Key position


DRAFT
Measurement points
Breakout box Wiring
diagram
Reference
value
Measured
value
Other (Special
tool No.)

Short circuit Off 25 – 01 A14.J1:87 – U = 4.75 V - 88890074,


check A14.J1:63 5.25 V 9990062,
9998699,
88890227
Short circuit Off 33 – 01 A14.J1:95 – U = 0.2 V - 0.8 88890074,
check A14.J1:63 V 9990062,
9998699,
88890227

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Open circuit Off 3 – Engine B172:3 – En- R = 0 Ω - 10 Ω 88890074,
check ground point gine ground 9990216
point

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Open circuit Off 33 – 02 A14.J1:95 – R = 0 Ω - 10 Ω 88890074,
check B172:2 9990062,
9998699,
88890227,
9990216
Open circuit Off 25 – 01 A14.J1:87 – R = 0 Ω - 10 Ω 88890074,
check B172:1 9990062,
9998699,
88890227,
9990216
Short circuit Off 25 – 33 A14.J1:87 – R = Open 88890074,
check A14.J1:95 circuit 9990062,
9998699,
88890227
Short circuit Off 33 – All pins at A14.J1:95 – All R = Open 88890074,
check connector J1 pins at connec- circuit 9990062,
tor J1 9998699,
88890227

100
P1147 - Fuel Rail/System Bank 1 Pressure - Moderately Too
Group 593

DRAFT
High

P1147 - Fuel Rail/System Bank 1 Pressure - Moderately Too High

Fault Condition for Fault Observable Symptoms Probable cause


type
P1147
FTB 00
• The rail pressure deviates from • Low power. • Rail pressure sensor.
set point. • Engine speed limited to 1500 • Wiring harness between compo-
rpm. nent connector and control unit
connector.

Voltage measurement

101
Group 593 Resistance measurement

Measuring Key position


DRAFT
Measurement points
Breakout box Wiring
diagram
Reference
value
Measured
value
Other (Special
tool No.)

Short circuit Off 25 – 01 A14.J1:87 – U = 4.75 V - 88890074,


check A14.J1:63 5.25 V 9990062,
9998699,
88890227
Short circuit Off 33 – 01 A14.J1:95 – U = 0.2 V - 0.8 88890074,
check A14.J1:63 V 9990062,
9998699,
88890227

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Open circuit Off 3 – Engine B172:3 – En- R = 0 Ω - 10 Ω 88890074,
check ground point gine ground 9990216
point

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Open circuit Off 33 – 02 A14.J1:95 – R = 0 Ω - 10 Ω 88890074,
check B172:2 9990062,
9998699,
88890227,
9990216
Open circuit Off 25 – 01 A14.J1:87 – R = 0 Ω - 10 Ω 88890074,
check B172:1 9990062,
9998699,
88890227,
9990216
Short circuit Off 25 – 33 A14.J1:87 – R = Open 88890074,
check A14.J1:95 circuit 9990062,
9998699,
88890227
Short circuit Off 33 – All pins at A14.J1:95 – All R = Open 88890074,
check connector J1 pins at connec- circuit 9990062,
tor J1 9998699,
88890227

102
Group 593 P0087 - Fuel Rail/System Pressure - Too Low Bank 1

DRAFT
P0087 - Fuel Rail/System Pressure - Too Low Bank 1

Fault Condition for Fault Observable Symptoms Probable cause


type
P0087
FTB 00
• Low common rail pressure. • Low power. • Rail pressure sensor.
• Engine speed limited to 1500 • Wiring harness between compo-
rpm. nent connector and control unit
connector.

Voltage measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short circuit Off 33 – 01 A14.J1:95 – U = 0.2 V - 0.8 88890074,
check A14.J1:63 V 9990062,
9998699,
88890227

103
Group 593 Resistance measurement

Resistance measurement
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Short circuit Off 33 – Engine A14.J1:95 – R = Open 88890074,
check ground point Engine ground circuit 9990062,
point 9998699,
88890227

P00C6 - Fuel Rail Pressure Too Low - Engine Cranking

Fault Condition for Fault Observable Symptoms Probable cause


type
P00C6
FTB 00
• The rail pressure deviates from • Air in fuel system check.
set point. • Clogged filter.
• Fuel leakage.
• Fuel line(s) is blocked.
• High pressure pump.

104
Group 593 Resistance measurement

Resistance measurement
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Component Off 1–2 Y108:1 – R = 8 Ω - 10 Ω 88890074,999-
Resistance Y108:2 0216
Check

Air in the fuel system, Check


Special Tool:

88840089, 85116548

Action:

• Connect the special tools.


• Start the engine and check for air in the fuel system.
Evaluation:

• Run the engine at 600 rpm.


• If there are air bubbles in the fuel it indicates either air or
gas leakage.
• Air in the fuel can cause starting problems.

Visual Checks:
• Check if the fuel filter is clogged.
• Check if there is leakage in fuel hoses or connections.
• Check that the fuel hoses are properly clamped and not
pinched.
• Check that the fuel hoses are not damaged or pinched and
that they are free from folds.

105
Group 593 P0192 - Engine Injection Control Pressure Circuit Low

DRAFT
P0192 - Engine Injection Control Pressure Circuit Low

Fault Condition for Fault Observable Symptoms Probable cause


type
P0192
FTB 00
• Short circuit to Ground. • Engine derate. • Short circuit to ground, Signal
wire.
• Faulty sensor.
• Engine control module (ECM).

Resistance measurement

106
Group 593 P0190 - Fuel Rail Pressure Sensor Bank 1

Measuring Key position


DRAFT
Measurement points
Breakout box Wiring
diagram
Reference
value
Measured
value
Other (Special
tool No.)

Short circuit Off 33 – Engine A14.J1:95 – R = Open 88890074,999-


check ground point Engine ground circuit 8699,
point 9990062,
88890227
Short circuit Off 33 – All pins at A14.J1:95 – All R = Open 88890074,999-
between wires connectors J1 pins at connec- circuit 8699,
and J2 tors J1 and J2 9990062,
88890227

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Controller Re- Off 33 – 1 A14.J1:95 – R = 3 kΩ - 7 kΩ 88890074,999-
sistance Check A14.J1:63 0062,
9998699,
88890227

P0190 - Fuel Rail Pressure Sensor Bank 1

107
Group 593 Voltage Measurement

Fault
type
P0190
Condition for Fault

• Open Circuit.
DRAFT Observable Symptoms

• Engine derate.
Probable cause

• Open circuit, Signal wire.


FTB 13
• Open circuit, Supply wire.
• Open circuit, Ground wire.
• Faulty sensor.
• Engine control module (ECM).
• Short circuit to voltage supply,
signal wire.

Voltage Measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short circuit Off 33 – 01 A14.J1:95 – U = 0.2 V - 0.8 88890074,999-
check A14.J1:63 V 8699,
9990062,
88890227

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Open circuit Off 3 – Engine B172:3 – En- R = 0 Ω – 10 Ω 88890074,999-
check ground point gine ground 0216
point

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short circuit Off 33 – All pins at A14.J1:95 – All R = Open 88890074,999-
between wires connectors J1 pins at connec- circuit 0062,
check and J2 tors J1 and J2 9998699,
88890227

108
P228E - Fuel Pressure Regulator 1 Exceeded Learning
Group 593

DRAFT
Limits - Too Low

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Open circuit Off 33 – 2 A14.J1:95 – R = 0 Ω - 10 Ω 88890074,999-
check B172:2 0062,
9998699,
88890227,
9990216
Open circuit Off 25 – 1 A14.J1:87 – R = 0 Ω - 10 Ω 88890074,999-
check B172:1 0062,
9998699,
88890227,
9990216

P228E - Fuel Pressure Regulator 1 Exceeded Learning Limits - Too


Low

Fault Condition for Fault Observable Symptoms Probable cause


type
P228E
FTB 00
• The rail pressure deviates from • Low power. • Rail pressure sensor.
set point. • High pressure pump.
• Injector.

109
Group 593 High pressure pump, Check

High pressure pump, Check


Action:


DRAFT
Connect a transparent hose or special tool 85116548,
88840089, 20592695.
• Start the engine and Check for leakage.
• If leakage occurs shut of the engine immediately and carry
out necessary work before continuing the test.
• Read and Compare the common rail pressure with the
graphs.

Evaluation:

• Graph 1 shows an example of a test with a new and fault


free pump.
• Graph 2 shows an example of when a faulty pump gives a
low pressure with a lot of variations: The test result is con-
sidered NOT OK
• A faulty rail pressure sensor or high pressure pump may
affect the pressure in the common rail system.
• Expected value is equal to or greater than 40000 kPa
(Idle).
• If the engine fails to start, misfires or idles unevenly the
test is considered not OK.
• After common rail pressure test, Check the injector for
faulty.
Graph 1 and Graph 2

110
P228F - Fuel Pressure Regulator 1 Exceeded Learning
Group 593

DRAFT
Limits - Too High

P228F - Fuel Pressure Regulator 1 Exceeded Learning Limits - Too


High

Fault Condition for Fault Observable Symptoms Probable cause


type
P228F
FTB 00
• The rail pressure deviates from • Engine derate. • Air in the fuel system.
set point. • Low torque. • Leakage in the common rail
• Low common rail pressure. • Fuel leakage. system.
• Injector.
• High pressure pump.
• Rail pressure sensor.

Air in the fuel system, Check


Special Tool: • If there are air bubbles in the fuel it indicates either air or
gas leakage.
88840089, 85116548, Part no:20592695
• Air in the fuel can cause starting problems.
Action: • If system is free from air, run the same test in 1500 rpm
• Connect the special tools. (Run the engine for 3 min.) and check the system for air.

• Start the engine and check for air in the fuel system.
Evaluation:

• Run the engine at 600 rpm.


111
Group 593 Leakage in the fuel system, Check

Leakage in the fuel system, Check


Action:
DRAFT
• Remove the supply line from the fuel tank.
• Connect 88800175 Kit on the supply line connection.
• Attach the pressure gauge to the fuel hose and connect
the pressure gauge to the pneumatic system in the
workshop.
• Check that the reduction valve on the pressure gauge and
the shut-off valve are open.
• Pressure test the fuel system.
• Build up the pressure to 200 kPa (29 psi).
• Apply soapy water to the lines and connections.

Evaluation:

• Leakage in fuel hoses and connections can cause air in


the fuel system.
• Air in the fuel can cause starting problems.

Combustion gases entering in the fuel system, Check


Special Tools: • At engine start air bubbles may appear due to connection
of hoses.
• 88840085 Hose (Included in tool kit 88840084).
• If air bubbles only appear on the injector return line the
• 88840086 Hose (Included in tool kit 88840084). most probable fault is exhaust gas leakage by the injector.
• 88840089 Test nipple (Included in tool kit 88840084).
• 88840090 Test nipple (Included in tool kit 88840084).
• 2X 85116548 Nipple (Included in tool kit 88840084).
• 2X Part Number: 20592695 Fuel nipple (Included in tool kit
88840084).

Action:

• Remove the hollow screw from the fuel return connection.


• Connect the nipple 88840090 and the fuel hose
88840086.
• Lead the hose to a container.
• Disconnect the connector between the prefilter and the
fuel return hose from the engine.
• Connect a transparent hose.
• Pump with the hand pump until the hose is visibly free from
air.
• Run the engine at 600 rpm and Check the fuel for air
bubbles

Evaluation:

• At engine start air bubbles may appear due to connection


of hoses.
112
Group 593 High pressure pump, Check

High pressure pump, Check


Action:
DRAFT
• Connect a transparent hose or special tool 9990149.
• Start the engine and Check for leakage.
• If leakage occurs shut of the engine immediately and carry
out necessary work before continuing the test.
• Read and Compare the common rail pressure with the
graphs.

Evaluation:

• Graph 1 shows an example of a test with a new and fault


free pump.
• Graph 2 shows an example of when a faulty pump gives a
low pressure with a lot of variations: The test result is con-
sidered NOT OK
• A faulty rail pressure sensor or high pressure pump may
affect the pressure in the common rail system.
• Expected value is equal to or greater than 40000 kPa
(Idle).
• If the engine fails to start, misfires or idles unevenly the
test is considered not OK.
Graph 1 and Graph 2

T2084641
113
Group 593 Internal leakage in the fuel injectors, Check

DRAFT
Internal leakage in the fuel injectors, Check
Special Tools:

• 88840086 Hose (Included in tool kit 88840084).


• 88840090 Test nipple (Included in tool kit 88840084).
Action:

• Remove the hollow screw from the fuel return connection.


• Connect the nipple 88840090 and the fuel hose
88840086.
• Put the hose in a graduated glass.
• Run the engine at 600 rpm and measure the fuel volume
during 2 min
• Note the measured volume
• Note: For correct measurement results the engine temper-
ature must be above 70 °C
• Adjust the engine speed to 1500 rpm.
• Measure the fuel volume during 2 min.
• Note the measured volume
• Adjust the engine speed to 2000 rpm.
• Measure the fuel volume during 2 min.
• Note the measured volume.
• Compare the measured value to the table in the
illustration.
• Restore after the performed procedure.

A (D5F) B (D7E or D7F)


700 rpm — 90 cm3 600 rpm — 200 cm3
1200 rpm — 130 cm3 1500 rpm — 340 cm3
2000 rpm — 520 cm3

Evaluation:

• If there is no leakage the fuel volume should be approxi-


mately or lower than (A) or (B).
• Values that exceed the table values indicate internal leak-
age in one or several injectors or injector pressure pipes.

Visual Checks:
• Check if the fuel filter is clogged.
• Check if there is leakage in fuel hoses or connections.
• Check that the fuel hoses are properly clamped and not
pinched.
• Check that the fuel hoses are not damaged or pinched and
that they are free from folds.
• Check the cam lobes for damages.

114
P016E - Closed Loop Fuel Pressure Control At Limit -
Group 593

DRAFT
Pressure Too High

P016E - Closed Loop Fuel Pressure Control At Limit - Pressure Too


High

Fault Condition for Fault Observable Symptoms Probable cause


type
P016E
FTB 00
• The system pressure is too • Solenoid valve, stuck in one
high. position.
• Rail pressure sensor
malfunction.

Voltage Measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short circuit Off 2 – Engine Y108:2 – En- U=0V-3V 88890074,999-
check ground point gine ground 0216
point

115
Group 593 Resistance measurement

Resistance measurement
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Component re- Off 1– 2 Y108:1 – R = 8 Ω – 10 88890074,999-
sistance check Y108:2 Ω 0216

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short circuit Off 31 – All pins at A14.J1:31 – All R = Open 88890074,999-
between wires connectors J1 pins at connec- circuit 0062,
check and J2 tors J1 and J2 9998699,
88890227
Short circuit Off 33 – 01 A14.J1:95 – R = Open 88890074,999-
check A14.J1:63 circuit 0062,
9998699,
88890227

116
P016F - Closed Loop Fuel Pressure Control At Limit -
Group 593

DRAFT
Pressure Too Low

P016F - Closed Loop Fuel Pressure Control At Limit - Pressure Too


Low

Fault Condition for Fault Observable Symptoms Probable cause


type
P016F
FTB 00
• The system pressure is too • High pressure pump.
high. • Worn injector.
• Low fuel pressure.
• Rail pressure sensor
malfunction.

Visual Checks:
• Check if there is leakage in fuel hoses or connections.
• Check that the fuel hoses are properly clamped and not
pinched.
• Check that the fuel hoses are not damaged or pinched and
that they are free from folds.

Air leakage, Check


Special Tools: • 88840090 Test nipple (Included in tool kit 88840084).

• 88840086 Hose (Included in tool kit 88840084). Action:

117
Group 593 U0010 - CAN Communication Backbone 1 Net


• DRAFT
Remove the hollow screw from the fuel return connection.
Disconnect the connector between the prefilter and the
fuel return hose from the engine.
• Connect a transparent hose according to illustration.
• Pump with the hand pump until the hose is visibly free from
air.
• Run the engine speed to 600 rpm.
• Check the fuel for air bubbles.
• At engine start air bubbles may appear due to connection
of hoses.
• If there are air bubbles in the fuel it indicates either air or
gas leakage.
• If air bubbles only appear on the injector return line the
most probable fault is exhaust gas leakage by the injector.

U0010 - CAN Communication Backbone 1 Net

118
Group 593 Voltage measurement

Fault
type
U0010
Condition for Fault
DRAFT Observable Symptoms Probable cause

• Voltage drop out or discon-


FTB88 nected control unit.
• Open-circuit on CAN data link
near the connection to the con-
trol unit.
• Short-circuit between the wires
on the data link, short-circuit to
higher voltage or to ground on a
data link wire.

Checks on EMS control unit:

Voltage measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short circuit On 49 – Reliable A14.J2:15 – U = >=1 V – 9998699,
ground point Reliable <=3 V 88890227,
ground point 88890074
Short circuit On 48 – Reliable A14.J2:14 – U = >=2 V – 9998699,
ground point Reliable <=4 V 88890227,
ground point 88890074

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Resistance be- Off 48 – 49 A14.J2:14 – R = 50 Ω — 70 9998699,
tween data link A14.J2:15 Ω 88890227,
wires 88890074

Checks on IC control unit:

Voltage measurement

119
Group 593 Resistance measurement

Measuring Key position


DRAFT
Measurement points
Breakout box Wiring
diagram
Reference
value
Measured
value
Other (Special
tool No.)

Short circuit On 10 – Reliable A03.A:10 – Re- U = >=1 V – 9998699,


ground point liable ground <=3 V 88890209,
point 88890074
Short circuit On 9 – Reliable A03.A:9 – Reli- U = >=2 V – 9998699,
ground point able ground <=4 V 88890209,
point 88890074

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Resistance be- Off 9 – 10 A03.A:09 – R = 50 Ω — 70 9998699,
tween data link A03.A:10 Ω 88890209,
wires 88890074

Checks on IECU control unit:

Voltage measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short circuit On 30 – Reliable A149.PC:5 – U = >=1 V – 9998699,
ground point Reliable <=3 V 9998604,
ground point 88890074
Short circuit On 29 – Reliable A149.PC:4 – U = >=2 V – 9998699,
ground point Reliable <=4 V 9998604,
ground point 88890074

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Resistance be- Off 29 – 30 A149.PC:4 – R = 50 Ω — 70 9998699,
tween data link A149.PC:5 Ω 9998604,
wires 88890074

Voltage Supply Check:


• Check all relevant connectors for voltage supply and • Check that correct voltage reaches the component.
ground connection.
120
Group 593 U0001 - CAN Communication Backbone 2 Net

DRAFT
• Check ground wire for open circuit.
U0001 - CAN Communication Backbone 2 Net

Fault Condition for Fault Observable Symptoms Probable cause


type
U0001 • Voltage drop out or discon-
FTB 88 nected control unit.
• Open-circuit on CAN data link
near the connection to the con-
trol unit.
• Short-circuit between the wires
on the data link, short-circuit to
higher voltage or to ground on a
data link wire.

Checks on EMS control unit:

Voltage measurement

121
Group 593 Resistance measurement

Measuring Key position


DRAFT
Measurement points
Breakout box Wiring
diagram
Reference
value
Measured
value
Other (Special
tool No.)

Short circuit On 47 – Reliable A14.J2:13 – U = >=1 V – 9998699,


ground point Reliable <=3 V 88890227,
ground point 88890074
Short circuit On 60 – Reliable A14.J2:26 – U = >=2 V – 9998699,
ground point Reliable <=4 V 88890227,
ground point 88890074

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Resistance be- Off 60 – 47 A14.J2:26 – R = 50 Ω — 70 9998699,
tween data link A14.J2:13 Ω 88890227,
wires 88890074

Checks on IECU control unit:

Voltage measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short circuit On 16 – Reliable A149.PA:16 – U = >=1 V – 9998699,
ground point Reliable <=3 V 9813194,
ground point 88890074
Short circuit On 15 – Reliable A149.PA:15 – U = >=2 V – 9998699,
ground point Reliable <=4 V 9813194,
ground point 88890074

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Resistance be- Off 15 – 16 A149.PA:15 – R = 50 Ω — 70 9998699,
tween data link A149.PA:16 Ω 9813194,
wires 88890074

Voltage Supply Check:


• Check all relevant connectors for voltage supply and • Check that correct voltage reaches the component.
ground connection.
122
U0155 - Lost Communication With Instrument Panel Cluster
Group 593

DRAFT
(IPC) Control Module

• Check ground wire for open circuit.


U0155 - Lost Communication With Instrument Panel Cluster (IPC)
Control Module

Fault Condition for Fault Observable Symptoms Probable cause


type
U0155
FTB 00
• Voltage drop out or discon-
nected control unit.
• Open-circuit on CAN data link
near the connection to the con-
trol unit.
• Short-circuit between the wires
on the data link, short-circuit to
higher voltage or to ground on a
data link wire.

Checks on EMS control unit:

Voltage measurement

123
Group 593 Resistance measurement

Measuring Key position


DRAFT
Measurement points
Breakout box Wiring
diagram
Reference
value
Measured
value
Other (Special
tool No.)

Short circuit On 49 – Reliable A14.J2:15 – U = >=1 V – 9998699,


ground point Reliable <=3 V 88890227,
ground point 88890074
Short circuit On 48 – Reliable A14.J2:14 – U = >=2 V – 9998699,
ground point Reliable <=4 V 88890227,
ground point 88890074

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Resistance be- Off 48 – 49 A14.J2:14 – R = 50 Ω — 70 9998699,
tween data link A14.J2:15 Ω 88890227,
wires 88890074

Checks on IC control unit:

Voltage measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short circuit On 10 – Reliable A03.A:10 – Re- U = >=1 V – 9998699,
ground point liable ground <=3 V 88890209,
point 88890074
Short circuit On 9 – Reliable A03.A:9 – Reli- U = >=2 V – 9998699,
ground point able ground <=4 V 88890209,
point 88890074

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Resistance be- Off 9 – 10 A03.A:09 – R = 50 Ω — 70 9998699,
tween data link A03.A:10 Ω 88890209,
wires 88890074

Checks on IECU control unit:

Voltage measurement

124
Group 593 Resistance measurement

Measuring Key position


DRAFT
Measurement points
Breakout box Wiring
diagram
Reference
value
Measured
value
Other (Special
tool No.)

Short circuit On 30 – Reliable A149.PC:5 – U = >=1 V – 9998699,


ground point Reliable <=3 V 9998604,
ground point 88890074
Short circuit On 29 – Reliable A149.PC:4 – U = >=2 V – 9998699,
ground point Reliable <=4 V 9998604,
ground point 88890074

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Resistance be- Off 29 – 30 A149.PC:4 – R = 50 Ω — 70 9998699,
tween data link A149.PC:5 Ω 9998604,
wires 88890074

Voltage Supply Check:


• Check all relevant connectors for voltage supply and
ground connection.
• Check that correct voltage reaches the component.
• Check ground wire for open circuit.

125
P1154 - Body Control Module A - Lost Communication With
Group 593

DRAFT
Instrument Panel Cluster (IPC) Control Module

P1154 - Body Control Module A - Lost Communication With


Instrument Panel Cluster (IPC) Control Module

Fault Condition for Fault Observable Symptoms Probable cause


type
P1154
FTB 00
• Voltage drop out or discon-
nected control unit.
• Open-circuit on CAN data link
near the connection to the con-
trol unit.
• Short-circuit between the wires
on the data link, short-circuit to
higher voltage or to ground on a
data link wire.

Checks on EMS control unit:

Voltage measurement

126
Group 593 Resistance measurement

Measuring Key position


DRAFT
Measurement points
Breakout box Wiring
diagram
Reference
value
Measured
value
Other (Special
tool No.)

Short circuit On 49 – Reliable A14.J2:15 – U = >=1 V – 9998699,


ground point Reliable <=3 V 88890227,
ground point 88890074
Short circuit On 48 – Reliable A14.J2:14 – U = >=2 V – 9998699,
ground point Reliable <=4 V 88890227,
ground point 88890074

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Resistance be- Off 48 – 49 A14.J2:14 – R = 50 Ω — 70 9998699,
tween data link A14.J2:15 Ω 88890227,
wires 88890074

Checks on IC control unit:

Voltage measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short circuit On 10 – Reliable A03.A:10 – Re- U = >=1 V – 9998699,
ground point liable ground <=3 V 88890209,
point 88890074
Short circuit On 9 – Reliable A03.A:9 – Reli- U = >=2 V – 9998699,
ground point able ground <=4 V 88890209,
point 88890074

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Resistance be- Off 9 – 10 A03.A:09 – R = 50 Ω — 70 9998699,
tween data link A03.A:10 Ω 88890209,
wires 88890074

Checks on IECU control unit:

Voltage measurement

127
Group 593 Resistance measurement

Measuring Key position


DRAFT
Measurement points
Breakout box Wiring
diagram
Reference
value
Measured
value
Other (Special
tool No.)

Short circuit On 30 – Reliable A149.PC:5 – U = >=1 V – 9998699,


ground point Reliable <=3 V 9998604,
ground point 88890074
Short circuit On 29 – Reliable A149.PC:4 – U = >=2 V – 9998699,
ground point Reliable <=4 V 9998604,
ground point 88890074

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Resistance be- Off 29 – 30 A149.PC:4 – R = 50 Ω — 70 9998699,
tween data link A149.PC:5 Ω 9998604,
wires 88890074

Voltage Supply Check:


• Check all relevant connectors for voltage supply and
ground connection.
• Check that correct voltage reaches the component.
• Check ground wire for open circuit.

128
Group 593 U0141 - Lost Communication With VMCU

DRAFT
U0141 - Lost Communication With VMCU

Fault Condition for Fault Observable Symptoms Probable cause


type
P1154 • Voltage drop out or discon-
FTB 00 nected control unit.
• Open-circuit on CAN data link
near the connection to the con-
trol unit.
• Short-circuit between the wires
on the data link, short-circuit to
higher voltage or to ground on a
data link wire.

Checks on EMS control unit:

Voltage measurement

129
Group 593 Resistance measurement

Measuring Key position


DRAFT
Measurement points
Breakout box Wiring
diagram
Reference
value
Measured
value
Other (Special
tool No.)

Short circuit On 49 – Reliable A14.J2:15 – U = >=1 V – 9998699,


ground point Reliable <=3 V 88890227,
ground point 88890074
Short circuit On 48 – Reliable A14.J2:14 – U = >=2 V – 9998699,
ground point Reliable <=4 V 88890227,
ground point 88890074

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Resistance be- Off 48 – 49 A14.J2:14 – R = 50 Ω — 70 9998699,
tween data link A14.J2:15 Ω 88890227,
wires 88890074

Checks on IC control unit:

Voltage measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Short circuit On 10 – Reliable A03.A:10 – Re- U = >=1 V – 9998699,
ground point liable ground <=3 V 88890209,
point 88890074
Short circuit On 9 – Reliable A03.A:9 – Reli- U = >=2 V – 9998699,
ground point able ground <=4 V 88890209,
point 88890074

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Resistance be- Off 9 – 10 A03.A:09 – R = 50 Ω — 70 9998699,
tween data link A03.A:10 Ω 88890209,
wires 88890074

Checks on IECU control unit:

Voltage measurement

130
Group 593 Resistance measurement

Measuring Key position


DRAFT
Measurement points
Breakout box Wiring
diagram
Reference
value
Measured
value
Other (Special
tool No.)

Short circuit On 30 – Reliable A149.PC:5 – U = >=1 V – 9998699,


ground point Reliable <=3 V 9998604,
ground point 88890074
Short circuit On 29 – Reliable A149.PC:4 – U = >=2 V – 9998699,
ground point Reliable <=4 V 9998604,
ground point 88890074

Resistance measurement

Measuring Key position Measurement points Reference Measured Other (Special


value value tool No.)
Breakout box Wiring
diagram
Resistance be- Off 29 – 30 A149.PC:4 – R = 50 Ω — 70 9998699,
tween data link A149.PC:5 Ω 9998604,
wires 88890074

Voltage Supply Check:


• Check all relevant connectors for voltage supply and
ground connection.
• Check that correct voltage reaches the component.
• Check ground wire for open circuit.

131
DRAFT

89130181 English ... Printed in Sweden