SERIES NEF Eu 5/EEV Vehicular application
N40 N40 ENT
N60 N60 ENT
Technical and Repair manual
This publication provides unit and relevant component repair data, specifications, instructions and methodologies. This publication has been drawn up for qualified and specialised personnel. Before performing any operation check that the part relevant to the unit on which you must work is available along with all safety devices for accident-prevention, such as, goggles, helmet, gloves, shoes, etc. and hoisting and transporting equipment. Operations are to be performed by following the indications included here, using the special equipment indicated and assuring proper repair, compliance with schedule and operator's safety requirements. Each repair must aim to restore operating efficiency and safety in compliance with the FPT provisions. FPT cannot be held liable for modifications, alterations or other interventions non authorised by FPT on the vehicle and if the unit is warranted the above mentioned interventions will cause its expiration. FPT is not liable for repairing interventions. FPT will provide further details required to carry out the interventions and all the instructions that are not included on this publication. Data included in this publication may not be up-to-date therefore subject to Manufacturer's modifications that can be added at any time for technical or commercial purposes and also to meet new law regulations in other Countries. If issues on this publication differ from what is actually noticed on the unit, please get in touch with the FPT network before starting any intervention”. It is forbidden to copy this text or any of its parts and all illustrations included.
Publication edited by FIAT Powerrtrain Technologies Mkt. Advertising & Promotion Viale dell'Industria, 15/17 20010 Pregnana Milanese Milano (Italy) Print P2D32N020 E - 1st Ed. 05.2012
SERIES NEF Eu 5/EEV
INTRODUCTION
1
Introduction Page PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
- Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
- Service operations . . . . . . . . . . . . . . . . . . . . . .
3
GENERAL WARNINGS . . . . . . . . . . . . . . . . . . .
5
GENERAL WARNINGS ON THE ELECTRIC SYSTEM . . . . . . . . . . . . .
7
- Bonding and screening . . . . . . . . . . . . . . . . . . .
8
OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS . . . . . . . . . . . . . . . .
9
CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES . . . . . . . . . . . . . . . . . . . . . . . . .
9
KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES . . . . . . . . . . . . . . . . . . .
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INTRODUCTION
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INTRODUCTION
3
PREFACE Manuals for repairs are split into Parts and Sections, each one of which is marked by a numeral; the contents of these sections are indicated in the general table of contents. The sections dealing with things mechanic introduce the specifications, tightening torque values, tool lists, assembly detaching/reattaching operations, bench overhauling operations, diagnosis procedures and maintenance schedules. The sections (or parts) of the electric/electronic system include the descriptions of the electric network and the assembly's electronic systems, wiring diagrams, electric features of components, component coding and the diagnosis procedures for the control units peculiar to the electric system. Section 1 describes the engines illustrating its features and working in general. Section 2 describes the fuel supply type and engine operation. Section 3 is about the electrical equipment, dealing with wiring, electrical and electronic devices which are distinguished on the basis of their specific use. Section 4 describes scheduled maintenance and specific overhauling. Section 5 describes troubleshooting for those who require simple and direct indications in order to locate the cause of the faults while performing technical assistance. Section 6 deals with removal and refitting of the main engine components. Section 7 describes general mechanical servicing of the engine on the revolving stand. Section 8 gives engine technical characteristics such as data, installation clearances and tightening torques. Section 9 is about the tools necessary for performing these operations. The appendix contains a list of the general safety regulations to be respected by all installation and maintenance engineers in order to prevent serious accidents taking place. The manual uses proper symbols in its descriptions; the purpose of these symbols is to classify contained information. In particular, there have been defined a set of symbols to classify warnings and a set for assistance operations.
SYMBOLS - Warnings Danger for persons Missing or incomplete observance of these prescriptions can cause serious danger for persons' safety.
Danger of serious damage for the assembly Failure to comply, both fully or in part, with such prescriptions will involve serious damage to the assembly and may sometimes cause the warranty to become null and void.
!
General danger It includes the dangers of above described signals.
Environment protection Moreover, it describes the correct actions to be taken to ensure that the assembly is used in such a way so as to protect the environment as much as possible. NOTE
It indicates an additional explanation for a piece of information.
Service operations Example 1
Ø 1 = Seat of small end bush Ø 2 = Seat of connecting rod bearings.
2
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Close applying the required torque Close applying the required torque + angular α value
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INTRODUCTION
Removal Disconnection
Intake
Refitting Connection
Exhaust
Removal Disassembly
Operation
Fitting in place Assembly
α
ρ
Compression ratio
Tighten to torque
Tolerance Weight difference
Tighten to torque + angle value
Rolling torque
Press or caulk
Rotation
Regulation Adjustment
Angle Angular value
Visual inspection Fitting position check
Number of revolutions
Measurement Value to find Check
Temperature
Equipment
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SERIES NEF Eu 5/EEV
bar
Pressure
Surface for machining Machine finish
Oversized Higher than. Maximum, peak
Interference Strained assembly
Undersized Less than. Minimum
Thickness Clearance
Selection Classes Oversizing
Lubrication Damp Grease
Temperature < 0 C Cold Winter
Sealant Adhesive
Temperature > 0 C Hot Summer
Air bleeding
Preload
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INTRODUCTION
5
GENERAL WARNINGS
!
Warnings shown cannot be representative of all danger situations possibly occurring. Therefore, it is suggested to contact immediate superiors where a danger situation occurs which is not described. Use both specific and general-purpose toolings according to the prescriptions contained in respective use and maintenance handbooks. Check use state and suitability of tools not subjected to regular check. The manual handling of loads must be assessed in advance because it also depends, besides weight, on its size and on the path. Handling by mechanical means must be with hoisters proper as for weight as well as for shape and volume. Hoisters, ropes and hooks used must contain clear indications on maximum carrying capacity acceptable. The use of said means is compulsorily permitted to authorised personnel only. Stay duly clear of the load, and, anyhow, never under it. In disassembling operations, always observe provided prescriptions; prevent mechanical parts being taken out from accidentally striking workshop personnel. Workshop jobs performed in pairs must always be performed in maximum safety; avoid operations which could be dangerous for the co-operator because of lack of visibility or of his/her not correct position. Keep personnel not authorised to operations clear of working area. You shall get familiar with the operating and safety instructions for the assembly prior to operating on the latter. Strictly follow all the safety indications found on the assembly. Do not leave the running assembly unattended when making repairs. When carrying out work on the assembly lifted off the ground, verify that the assembly is firmly placed on its supporting stands, and that the manual/automatic safety devices have been actuated in the event that the assembly is to be lifted by means of a hoist. When you have to operate on assemblies powered by natural gas, follow the instructions contained in the document, as well as all the specific safety standards provided for. Only remove radiator cap when the engine is cold by cautiously unscrewing it in order to let system residual pressure out. Inflammable fuel and all inflammable fluids and liquids must be handled with care, according to what contained on harmful materials 16-point cards. Refuelling must be performed outdoors with the engine off, avoiding lit cigarettes, free flames or sparks in order to prevent sudden fires/bursts. Adequately store inflammable, corrosive and polluting fluids and liquids according to what provided by regulations in force. Compulsorily avoid to use food containers to store harmful liquids. Avoid to drill or bore pressurised containers, and throw cloths impregnated with inflammable substances into suitable containers. Worn out, damaged or consumable parts must be replaced by original spares. During workshop activity, always keep the work place clean; timely clear or clean floors from accidental liquid or oil spots. Electric sockets and electric equipment necessary to perform repair interventions must meet safety rules.
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INTRODUCTION
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Put on, where required by the intervention, garments and protections provided in accident prevention rules; contact with moving parts can cause serious injuries. Use suitable, preferably tight-fitted garments, and avoid to use jewels, scarves, etc. Do not leave the engine in motion at workshop locations not provided with a pipe to scavenge exhaust gas outside. Avoid to breathe fumes coming from heating or from paint welding because they can cause damages to health; operate outdoors or in suitably ventilated areas. Put on proper inspirator if paint powder is present. Avoid contact with hot water or steam coming from the engine, radiator and pipings because they could cause serious burns. Avoid direct contact with liquids and fluids present in vehicle systems; where an accidental contact has occurred, refer to 12-point cards for provisions to make.
Clean the assemblies and carefully verify that they are intact prior to overhauling. Tidy up detached or disassembled parts with their securing elements (screws, nuts, etc.) into special containers. Check for the integrity of the parts which prevent screws from being unscrewed: broken washers, dowels, clips, etc. Self-locking nuts with an insert made of nylon must always be replaced. Avoid contact of rubber parts with diesel oil, petrol or other not compatible substances. Before washing under pressure mechanical parts, protect electric connectors, and central units, if present. Tightening screws and nuts must always be according to prescriptions; FPT commercial and assistance network is avail able to give all clarifications necessary to perform repair interventions not provided in this document. Before welding: - Disconnect all electronic central units, take power cable off battery positive terminal (connect it to chassis bonding) and detach connectors. - Remove paint by using proper solvents or paint removers and clean relevant surfices with soap and water. - Await about 15 minutes before welding. - Equip with suitable fire resistant protections to protect hoses or other components where fluids or other materials flow which may catch fire easily on welding. Should the vehicle be subjected to temperatures exceeding 80 C (dryer ovens), disassemble drive electronic central units.
The disposal of all liquids and fluids must be performed with full observance of specific rules in force.
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INTRODUCTION
7
GENERAL WARNINGS ON THE ELECTRIC SYSTEM
!
If an intervention has to be made on the electric/electronic system, disconnect batteries from the system; in this case, always disconnect, as a first one, the chassis bonding cable from batteries negative terminal. Before connecting the batteries to the system, make sure that the system is well isolated. Disconnect the external recharging apparatus from the public utility network before taking apparatus pins off battery terminals. Do not cause sparks to be generated in checking if the circuit is energised. Do not use a test lamp in checking circuit continuity, but only use proper control apparatuses. Make sure that the electronic devices wiring harnesses (length, lead type, location, strapping, connection to screening braiding, bonding, etc.) comply with FPT system and are carefully recovered after repair or maintenance interventions. Measurements in drive electronic central units, plugged connections and electric connections to components can only be made on proper testing lines with special plugs and plug bushes. Never use improper means like wires, screwdrivers, clips and the like in order to avoid the danger of causing a short circuit, as well as of damaging plugged connections, which would later cause contact problems.
To start up the engine, do not use fast chargers. Start up must only be performed with either separate batteries or special truck. A wrong polarisation of supply voltage in drive electronic central units (for instance, a wrong polarisation of batteries) can cause them to be destroyed. Disconnect the batteries from the system during their recharging with an external apparatus. On connecting, only screw up connector (temperature sensors, pressure sensors etc.) nuts at prescribed tightening torque. Before disconnecting the junction connector from an electronic central unit, isolate the system. Do not directly supply electronic central units servo components at nominal vehicle voltage. Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure. Once the intervention on the electric system has been completed, recover connectors and wiring harnesses according to original arrangement.
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INTRODUCTION
SERIES NEF Eu 5/EEV
Bonding and screening Negative leads connected to a system bonded point must be both as short and possible and “star“-connected to each other, trying then to have their centering tidily and properly made (Figure 1, re. M). Further, following warnings are to be compulsorily observed for electronic components: -
Electronic central units must be connected to system bonding when they are provided with a metallic shell.
-
Electronic central units negative cables must be connected both to a system bonding point such as the dashboard opening bonding (avoiding “serial“ or “chain“ connections), and to battery negative terminal.
-
Analog bonding (sensors), although not connected to battery negative system/terminal bonding, must have optimal isolation. Consequently, particularly considered must be parasitic resistances in lugs: oxidising, clinching defects, etc.
-
Screened circuits braiding must only electrically contact the end towards the central unit entered by the signal (Figure 2).
-
If junction connectors are present, unscreened section d, near them, must be as short as possible (Figure 2).
-
Cables must be arranged such as to result to be parallel to reference plane, i.e. as close as possible to chassis/body structure.
Figure 1
1.
NEGATIVE CABLES “STAR“ CONNECTION TO SYSTEM BONDING M
Figure 2
88039
2.
SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT — C. CONNECTOR d. DISTANCE ! 0
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INTRODUCTION
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OPTIONAL ELECTRICAL AND MECHANICAL PARTS INSTALLATIONS Assemblies shall be modified and equipped with additions - and their accessories shall be fitted - in accordance with the assembling directives issued by FPT. It is reminded that, especially about the electric system, several electric sockets are provided for as series (or optional) sockets in order to simplify and normalise the electrical intervention that is care of preparation personnel.
It is absolutely forbidden to make modifications or connections to electric central units wiring harnesses; in particular, the data interconnection line between central units (CAN line) is to be considered inviolable.
CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES
Power 1 kW 1 kW 1 metric HP 1 metric HP 1 HP 1 HP
= = = = = =
1.36 metric HP 1.34 HP 0.736 kW 0.986 HP 0.746 kW 1.014 metric HP
Torque 1 Nm 1 kgm
= =
0.1019 kgm 9.81 Nm
OF
THE
Revolutions per time unit 1 rad/s = 1 rpm x 0.1046 1 rpm = 1 rad/s x 9.5602 Pressure 1 bar 1 kg/cm2 1 bar
= = =
1.02 kg/cm2 0.981 bar 105 Pa
Where accuracy is not particularly needed: - Nm unit is for the sake of simplicity converted into kgm according to ratio 10:1 1 kgm
=
10 Nm;
- bar unit is for the sake of simplicity converted into kg/cm2 according to ratio 1:1 1 kg/cm2
=
1 bar.
Temperature 0 C = 32 F 1 C = (1 x 1.8 + 32) F
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INTRODUCTION
SERIES NEF Eu 5/EEV
KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES Type of vehicle
Printout number
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Section title
Language Publication
Page number
Basic edition referred to month - year editorial phase closing
When month - year update is present (revi) to the basic edition
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1
F4AE ENGINES
Part 1 F4AE ENGINES Section General specifications
1
Operational diagrams
2
Electrical equipment
3
Scheduled maintenance
4
Diagnostics
5
Removal - refitting of main components
6
General mechanical overhauling
7
Technical specifications
8
Tools
9
Safety prescriptions
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Appendix
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2
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F4AE ENGINES
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3
F4AE ENGINES
UPDATING Section
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Description
Page
Date of revision
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F4AE ENGINES
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F4AE ENGINES
1
SECTION 1 - GENERAL SPECIFICATIONS
SECTION 1 General specifications
Page
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CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE . . . . . . . . . . . . .
3
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . .
4
- Engines F4AE3481 . . . . . . . . . . . . . . . . . . . . . .
4
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . .
7
- Engines F4AE3482E*U101 . . . . . . . . . . . . . . .
7
ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . .
10
- Engines F4AE3681 . . . . . . . . . . . . . . . . . . . . . .
10
GENERAL CHARACTERISTICS . . . . . . . . . . . . .
13
- 4-cylinder engine . . . . . . . . . . . . . . . . . . . . . . .
13
- 6-cylinder engine . . . . . . . . . . . . . . . . . . . . . . .
16
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SECTION 1 - GENERAL SPECIFICATIONS
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F4HFE ENGINES
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F4AE ENGINES
SECTION 1 - GENERAL SPECIFICATIONS
3
CORRESPONDENCE BETWEEN TECHNICAL CODE AND COMMERCIAL CODE
Technical Code F4AE3481C*S100 F4AE3481D*S100 F4AE3481B*S100 F4AE3481A*S100 F4AE3481C*U100 F4AE3481D*U100 F4AE3481B*U100 F4AE3481A*U100 F4AE3482E*U101 F4AE3681C*S100 F4AE3681B*S100 F4AE3681D*S100 F4AE3681E*S100 F4AE3681A*S100 F4AE3681C*U100 F4AE3681B*U100 F4AE3681D*U100 F4AE3681E*U100 F4AE3681A*U100
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Commercial Code
N40 ENT
N60 ENT
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SECTION 1 - GENERAL SPECIFICATIONS
F4HFE ENGINES
ENGINE VIEWS Engines F4AE3481 Figure 1
176511
LEFT-HAND SIDE VIEW Figure 2
176513
RIGHT-HAND SIDE VIEW Base - May 2012
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F4AE ENGINES
SECTION 1 - GENERAL SPECIFICATIONS
5
Figure 3
176512
FRONT VIEW Figure 4
176514
REAR VIEW Print P2D32N020 E
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SECTION 1 - GENERAL SPECIFICATIONS
F4HFE ENGINES
Figure 5
176509
TOP VIEW
Figure 6
176510
PERSPECTIVE VIEW Base - May 2012
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F4AE ENGINES
SECTION 1 - GENERAL SPECIFICATIONS
7
ENGINE VIEWS Engines F4AE3482E*U101 Figure 7
171581
LEFT-HAND SIDE VIEW
Figure 8
171583
RIGHT-HAND SIDE VIEW Print P2D32N020 E
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SECTION 1 - GENERAL SPECIFICATIONS
F4HFE ENGINES
Figure 9
171582
FRONT VIEW Figure 10
171580
REAR VIEW Base - May 2012
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F4AE ENGINES
SECTION 1 - GENERAL SPECIFICATIONS
9
Figure 11
171579
TOP VIEW
Figure 12
171585
PERSPECTIVE VIEW Print P2D32N020 E
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SECTION 1 - GENERAL SPECIFICATIONS
F4HFE ENGINES
ENGINE VIEWS Engines F4AE3681 Figure 13
176504
LEFT-HAND SIDE VIEW
Figure 14
176506
RIGHT-HAND SIDE VIEW Base - May 2012
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F4AE ENGINES
SECTION 1 - GENERAL SPECIFICATIONS
11
Figure 15
176505
FRONT VIEW Figure 16
176507
REAR VIEW Print P2D32N020 E
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SECTION 1 - GENERAL SPECIFICATIONS
F4HFE ENGINES
Figure 17
176508
TOP VIEW
Figure 18
176503
PERSPECTIVE VIEW Base - May 2012
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F4AE ENGINES
SECTION 1 - GENERAL SPECIFICATIONS
13
GENERAL CHARACTERISTICS 4-cylinder engines F4AE3481C*S100 F4AE3481C*U100
Type
ρ
Compression ratio
17 : 1
Maximum power
kW (hp) rpm
Maximum torque
Nm (kgm) rpm
Idle speed
rpm
Maximum engine speed Bore x stroke
rpm
Total displacement
cm3
103 (138) 2700
118 (158) 2700
460 (46.89) 1200
530 (54.03) 1200
102 x 120
TURBOCHARGING Turbocharger
F4AE3481D*S100 F4AE3481D*U100
3920 With intercooler
type
GARRET Forced by gear pump, pressure relief valve, oil filter
LUBRICATION Oil pressure with engine hot: bar
- at idle speed - at maximum speed
bar bar By centrifugal pump, thermostat for regulating, radiator, heat exchanger, intercooler Belt driven
COOLING Coolant pump control Thermostat: - start of opening - max. opening
ºC ºC
79 2 96
FILLING - engine sump
litres
15W40 ACEA E7/API CI-4 - engine sump 10W30 ACEA E7/API CI-4* + filter 10W40 ACEA E9/API CJ-4**
litres
* For ambient temperature < -15 °C ** Alternatively
NOTE These data, characteristics and performance figures are only valid if the fitter respects all FPT installation requirements. Anything fitted by the bodybuilder must always respect the engine design torque, power and speed.
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SECTION 1 - GENERAL SPECIFICATIONS
F4HFE ENGINES
F4AE3481B*S100 F4AE3481B*U100
Type
ρ
Compression ratio
F4AE3481A*S100 F4AE3481A*U100 17 : 1
Maximum power
kW (HP) rpm
130 (174) 2700
134 (180) 2700
Maximum torque
Nm (kgm) rpm
570 (58.10) 1250
610 (62.18) 1300
Idle speed
rpm
Maximum engine speed Bore x stroke
rpm
Total displacement
cm3
102 x 120
TURBOCHARGING Turbocharger
3920 With intercooler
type
GARRET Forced by gear pump, pressure relief valve, oil filter
LUBRICATION Oil pressure with engine hot: bar
- at idle speed - at maximum speed
bar bar By centrifugal pump, thermostat for regulating, radiator, heat exchanger, intercooler Belt driven
COOLING Coolant pump control Thermostat: - start of opening - max. opening
ºC ºC
79 2 96
FILLING - engine sump 15W40 ACEA E7/API CI-4 10W30 ACEA E7/API CI-4* - engine sump + filter 10W40 ACEA E9/API CJ-4**
litres litres
* For ambient temperature < -15 °C ** Alternatively
NOTE These data, characteristics and performance figures are only valid if the fitter respects all FPT installation requirements. Anything fitted by the bodybuilder must always respect the engine design torque, power and speed.
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F4AE ENGINES
SECTION 1 - GENERAL SPECIFICATIONS
Type
ρ
F4AE3482E*U101
Compression ratio
17 : 1
Maximum power
kW (HP) rpm
110 (150) 2500
Maximum torque
Nm (kgm) rpm
600 (61.16) 1300
Idle speed
rpm
Maximum engine speed Bore x stroke
rpm
Total displacement
cm3
102 x 120
TURBOCHARGING Turbocharger
15
3920 With intercooler
type
GARRET GT 22 Forced by gear pump, pressure relief valve, oil filter
LUBRICATION Oil pressure with engine hot: bar
- at idle speed - at maximum speed
bar bar
COOLING Coolant pump control Thermostat: - start of opening - max. opening
ºC ºC
1.2 3.8 By centrifugal pump, thermostat for regulating, radiator, heat exchanger, intercooler Belt driven 81 2 96
FILLING - engine sump 15W40 ACEA E7/API CI-4 10W30 ACEA E7/API CI-4* - engine sump + filter 10W40 ACEA E9/API CJ-4**
litres
8.4
litres
9.4
* For ambient temperature < -15 °C ** Alternatively
NOTE These data, characteristics and performance figures are only valid if the fitter respects all FPT installation requirements. Anything fitted by the bodybuilder must always respect the engine design torque, power and speed.
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SECTION 1 - GENERAL SPECIFICATIONS
F4HFE ENGINES
6-cylinder engines F4AE3681C*S100 F4AE3681C*U100
Type
ρ
Compression ratio
F4AE3681B*S100 F4AE3681B*U100 17 : 1
Maximum power
kW (hp) rpm
Maximum torque
Nm (kgm) rpm
135 (181) 2700
160 (214) 2700
650 (66.26) 1200
680 (69.32) 1200
Idle speed
rpm
Maximum engine speed Bore x stroke
rpm
Total displacement
cm3
5880 With intercooler
type
CCM HOLSET HX35W Forced by gear pump, pressure relief valve, oil filter
102 x 120
TURBOCHARGING Turbocharger LUBRICATION Oil pressure with engine hot: bar
- at idle speed - at maximum speed
bar bar By centrifugal pump, thermostat for regulating, radiator, heat exchanger, intercooler Belt driven
COOLING Coolant pump control Thermostat: - start of opening - max. opening
ºC ºC
79 2 96
FILLING - engine sump
litres
15W40 ACEA E7/API CI-4 - engine sump 10W30 ACEA E7/API CI-4* + filter 10W40 ACEA E9/API CJ-4**
litres
* For ambient temperature < -15 °C ** Alternatively
NOTE These data, characteristics and performance figures are only valid if the fitter respects all FPT installation requirements. Anything fitted by the bodybuilder must always respect the engine design torque, power and speed.
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F4AE ENGINES
SECTION 1 - GENERAL SPECIFICATIONS
F4AE3681D*S100 F4AE3681D*U100
Type
ρ
Compression ratio
F4AE3681E*S100 F4AE3681E*U100 17 : 1
Maximum power
kW (HP) rpm
185 (248) 2700
205 (275) 2500
Maximum torque
Nm (kgm) rpm
850 (86.65) 1250
950 (96.84) 1250
Idle speed
rpm
Maximum engine speed Bore x stroke
rpm
Total displacement
cm3
102 x 120
TURBOCHARGING Turbocharger
17
5880 With intercooler
type
CCM HOLSET HX35W Forced by gear pump, pressure relief valve, oil filter
LUBRICATION Oil pressure with engine hot: bar
- at idle speed - at maximum speed
bar bar By centrifugal pump, thermostat for regulating, radiator, heat exchanger, intercooler Belt driven
COOLING Coolant pump control Thermostat: - start of opening - max. opening
ºC ºC
79 2 96
FILLING - engine sump 15W40 ACEA E7/API CI-4 10W30 ACEA E7/API CI-4* - engine sump + filter 10W40 ACEA E9/API CJ-4**
litres litres
* For ambient temperature < -15 °C ** Alternatively
NOTE These data, characteristics and performance figures are only valid if the fitter respects all FPT installation requirements. Anything fitted by the bodybuilder must always respect the engine design torque, power and speed.
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SECTION 1 - GENERAL SPECIFICATIONS
F4HFE ENGINES
F4AE3681A*S100 F4AE3681A*U100
Type
ρ
Compression ratio
F4AE3682C*S100 F4AE3682C*U100 17 : 1
Maximum power
kW (HP) rpm
220 (295) 2500
160 (218) 2700
Maximum torque
Nm (kgm) rpm
1050 (107.03)
680 (69.32)
1300
1200
Idle speed
rpm
Maximum engine speed
rpm
Bore x stroke Total displacement
102 x 120 cm3
5880
TURBOCHARGING Turbocharger
With intercooler type
CCM HOLSET HX35W Forced by gear pump, pressure relief valve, oil filter
LUBRICATION Oil pressure with engine hot: bar
- at idle speed - at maximum speed COOLING Coolant pump control Thermostat: - start of opening - max. opening
bar bar By centrifugal pump, thermostat for regulating, radiator, heat exchanger, intercooler Belt driven ºC ºC
79 2 96
79 2 94
FILLING Total capacity - engine sump 15W40 ACEA E7/API CI-4 10W30 ACEA E7/API CI-4* - engine sump + filter 10W40 ACEA E9/API CJ-4**
litres
13.3
litres
* For ambient temperature < -15 °C ** Alternatively
NOTE These data, characteristics and performance figures are only valid if the fitter respects all FPT installation requirements. Anything fitted by the bodybuilder must always respect the engine design torque, power and speed.
Base - May 2012
Print P2D32N020 E
F4AE ENGINES
SECTION 1 - GENERAL SPECIFICATIONS
F4AE3682E*S100 F4AE3682E*U100
Type
ρ
Compression ratio
F4AE3682A*S100 F4AE3682A*U100 17 : 1
Maximum power
kW (HP) rpm
194 (264) 2500
220 (299) 2500
Maximum torque
Nm (kgm)
1000 (101.94)
1050 (107.03)
1400
1250
rpm Idle speed
rpm
Maximum engine speed
rpm
Bore x stroke Total displacement
102 x 120 cm3
TURBOCHARGING Turbocharger
19
5880 With intercooler
type
CCM HOLSET HX35W Forced by gear pump, pressure relief valve, oil filter
LUBRICATION Oil pressure with engine hot: bar
- at idle speed - at maximum speed COOLING Coolant pump control Thermostat: - start of opening - max. opening
bar bar By centrifugal pump, thermostat for regulating, radiator, heat exchanger, intercooler Belt driven ºC ºC
79 2 94
FILLING Total capacity - engine sump 15W40 ACEA E7/API CI-4 10W30 ACEA E7/API CI-4* - engine sump + filter 10W40 ACEA E9/API CJ-4**
litres litres
* For ambient temperature < -15 °C ** Alternatively
NOTE These data, characteristics and performance figures are only valid if the fitter respects all FPT installation requirements. Anything fitted by the bodybuilder must always respect the engine design torque, power and speed.
Print P2D32N020 E
Base - May 2012
20
SECTION 1 - GENERAL SPECIFICATIONS
Base - May 2012
F4HFE ENGINES
Print P2D32N020 E
F4AE ENGINES
SECTION 2 - OPERATIONAL DIAGRAMS
1
SECTION 2 Operational diagrams
Page
Print P2D32N020 E
HIGH PRESSURE ELECTRONIC INJECTION FUEL SYSTEM (COMMON RAIL) . . . . . . . . . . . . . .
3
- General Specifications . . . . . . . . . . . . . . . . . . .
3
ELECTRIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . .
3
- Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
- System functionality . . . . . . . . . . . . . . . . . . . . .
4
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . .
5
- Fuel system layout . . . . . . . . . . . . . . . . . . . . . .
7
FUEL SUPPLY SYSTEM COMPONENTS . . . . . .
9
- Fuel prefilter . . . . . . . . . . . . . . . . . . . . . . . . . .
9
- Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
- Mechanical supply pump . . . . . . . . . . . . . . . . .
10
- CP3 high-pressure pump . . . . . . . . . . . . . . . . .
11
- Rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
- Overpressure valve . . . . . . . . . . . . . . . . . . . . .
15
- Electro-injector . . . . . . . . . . . . . . . . . . . . . . . .
16
- Pressure limiter for fuel return . . . . . . . . . . . . .
17
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . .
18
- 4-cylinder engine version . . . . . . . . . . . . . . . . .
18
- 6-cylinder engine version . . . . . . . . . . . . . . . . .
19
- Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
- Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . .
20
- Oil pressure relief valve . . . . . . . . . . . . . . . . . .
21
OIL VAPOUR RECYCLING . . . . . . . . . . . . . . . .
22
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . .
23
- 4-cylinder engine version . . . . . . . . . . . . . . . . .
23
- 6-cylinder engine version . . . . . . . . . . . . . . . . .
24
- Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . .
25
- Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
Base - May 2012
2
SECTION 2 - OPERATIONAL DIAGRAMS
F4AE ENGINES
Page TURBOCHARGING SYSTEM . . . . . . . . . . . . . . .
26
- Description . . . . . . . . . . . . . . . . . . . . . . . . . .
26
- 4-cylinder engine version . . . . . . . . . . . . . . . .
26
- 6-cylinder engine version . . . . . . . . . . . . . . . .
26
- Turbocharger . . . . . . . . . . . . . . . . . . . . . . . .
27
- Waste gate . . . . . . . . . . . . . . . . . . . . . . . . . .
28
DeNOx 2 SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .
29
- General Information . . . . . . . . . . . . . . . . . . .
29
- Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
- Ad Blue fluid level gauge control . . . . . . . . . .
31
- Pump module . . . . . . . . . . . . . . . . . . . . . . . .
31
- Dosing module . . . . . . . . . . . . . . . . . . . . . . .
31
- SCR pipes . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
- Exhaust gas temperature sensor . . . . . . . . . .
32
- Humidity detecting sensor . . . . . . . . . . . . . . .
33
- Nitric oxide sensor . . . . . . . . . . . . . . . . . . . .
34
- Pin out DCU 15 D2-2 . . . . . . . . . . . . . . . . . .
35
Base - May 2012
Print P2D32N020 E
F4AE ENGINES
3
SECTION 2 - OPERATIONAL DIAGRAMS
HIGH PRESSURE ELECTRONIC INJECTION FUEL SYSTEM (COMMON RAIL) General Specifications In order to reduce PARTICULATES emissions, very high injection pressures are required. The Common Rail system allows injecting the fuel up to pressures reaching 1600 bar, at the same time, the injection precision, obtained by the electronic system control, optimizes the engine performance, reducing emissions and consumption.
ELECTRIC SYSTEM
Figure 1
107246
1. Injectors connections - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil temperature and pressure sensor - 5. Crankshaft sensor - 6. EDC7UC31 control unit - 7. Fuel flow rate regulator - 8. Fuel heater and fuel temperature sensor - 9. Camshaft sensor - 10. Air pressure/temperature sensor - 11. Injector.
Sensors Through the sensors, present on the engine, the ECU controls the engine operation. Air pressure/temperature sensor It is a component integrating a temperature sensor and a pressure sensor.
The outlet tension is proportional to the pressure or temperature obtained by the sensor. Engine oil temperature and pressure sensor Same as air pressure/temperature sensor, it is fitted on the engine oil filter, in a horizontal position. It measures engine oil temperature and pressure.
Fitted on the intake manifold, it measures the max. inlet air capacity to calculate precisely the fuel quantity to inject at every cycle. Print P2D32N020 E
Base - May 2012
4
SECTION 2 - OPERATIONAL DIAGRAMS
Fuel pressure sensor Assembled on a rail end, it measures the fuel pressure in the rail in order to determine the injection pressure. The injection pressure value is used to control the pressure and to determine the electric injection control length. Fuel temperature sensor It is a sensor that is equal to the previous one. It measures fuel temperature to provide the control unit with an index of the diesel fuel thermal state. Coolant temperature sensor It is a variable-resistance sensor suitable to measure the coolant temperature to provide the control unit with an index of the engine thermal state. Crankshaft sensor It is an inductive sensor placed on the front engine part. Signals generated through the magnetic flow that is closed on the phonic wheel, change their frequencies depending on output shaft rotation speed. Timing sensor It is an inductive sensor placed on the engine rear left part. It generates signals obtained from magnetic flow lines that are closed through holes obtained on the keyed gear on the camshaft. The signal generated by this sensor is used by the ECU as injection phase signal. Though being equal to the flywheel sensor, it is NOT interchangeable since it has a different outside shape.
System functionality Self-diagnosis The ECU self-diagnostic system checks signals coming from sensors by comparing them with threshold data. Engine pre-heating resistance check The pre-post heating is activated when even only one of the water, air or fuel temperature sensors signals a temperature that is less than 5 C. Timing recognition By means of signals coming from camshaft sensor and flywheel sensor, the cylinder on which fuel must be injected is recognised upon startup.
Base - May 2012
F4AE ENGINES
Injection control The control unit, depending on information coming from sensors, controls the flow rate regulator, and changes pre-injection and main injection modes. Closed-loop control for injection pressure Depending on engine load, measured by processing signals coming from various sensors, the control unit controls the regulator in order to always have the optimum pressure. Pilot and main injection spark advance control The control unit, depending on signals coming from various sensors, computes the optimum injection point according to an internal mapping. Idle speed control The control unit processes signals coming from various sensors and adjusts the amount of injected fuel. It controls the pressure regulator and changes the injection time of injectors. Within certain thresholds, it also takes into account the battery voltage. Maximum speed limiting At 2700 rpm, the control unit limits fuel flow-rate by reducing the injectors opening time. Over 3000 rpm it deactivates the injectors. Cut Off Fuel cut off upon release is controlled by the control unit performing the following logics: - it cuts off injectors supply; - it re-activates the injectors shortly before idle speed is reached; - it controls fuel flow rate regulator. Smoke control upon acceleration With strong load requests, the control unit, depending on signals received by air inlet meter and engine speed sensor, controls the flow rate regulator and changes the injectors actuation time, in order to avoid exhaust smokes. Fuel temperature control When the fuel temperature exceeds 75 C (measured by the sensor placed on fuel filter) the control unit intervenes by reducing injection pressure. If the temperature exceeds 90 C, the power is reduced to 60%. After Run The control unit microprocessor allows storing certain EPROM data, among which failure memory and Immobilizer information, in order to make them available upon the following startup.
Print P2D32N020 E
F4AE ENGINES
5
SECTION 2 - OPERATIONAL DIAGRAMS
HYDRAULIC SYSTEM The Common Rail system has a special pump that continuously keeps fuel at high pressure, independently from stroke and cylinder that has to receive the injection and accumulates fuel in a common duct for all injectors. Therefore, fuel at the injection pressure computed by the ECU is always available at the injectors inlet. When an injector solenoid valve is energised by the electronic control unit, the injection of fuel directly taken from rail takes place in the related cylinder. The hydraulic system is implemented by a low-pressure circuit and a high-pressure circuit. The high-pressure circuit is composed of the following pipings: - piping connecting high-pressure pump outlet to rail; - pipings supplying injectors from rail.
Figure 2 (D)
High Pressure Low Pressure
108499
(D) F4AE3481/2 1. Electro-injector - 2. Common Rail - 3. Fuel filter - 4. Mechanical vane pump - 5. High-pressure pump 6. Pre-filter mounted on the frame - 7. Common rail pressure relief valve - 8. Pressure limiting device for fuel return.
Print P2D32N020 E
Base - May 2012
6
SECTION 2 - OPERATIONAL DIAGRAMS
F4AE ENGINES
The low-pressure circuit is composed of the following pipings: - fuel suction piping from tank to prefilter; - pipings supplying the mechanical supply pump through the control unit heat exchanger, manual priming pump and prefilter; - pipings supplying the high-pressure pump through the fuel filter. The fuel draining circuit from rail and from injectors and the high-pressure pump cooling circuit complete the system.
Figure 3 (*)
High Pressure Low Pressure Fuel outlet 166062
(*) F4AE3681 1. Electro-injector - 2. Common Rail - 3. Fuel filter - 4. Mechanical vane pump - 5. High-pressure pump 6. Pre-filter mounted on the frame - 7. Common rail pressure relief valve - 8. Pressure limiting device for fuel return.
Base - May 2012
Print P2D32N020 E
F4AE ENGINES
Fuel system layout The flow rate regulator (15), placed upstream of the high-pressure pump, adjusts the fuel flow that is necessary on the low-pressure system. Afterwards, the high-pressure pump takes care of supplying the rail properly. This arrangement, by pressurising the necessary fuel only, improves the energetic efficiency and limits fuel heating in the system. Function of the pressure relief valve (2), assembled on the high-pressure pump, is keeping the pressure, at the flow rate regulator inlet, constant at 5 bars, independently from the efficiency of the fuel filter and of the system set upstream.
7
SECTION 2 - OPERATIONAL DIAGRAMS
The pressure relief valve (2) intervention brings about a fuel flow increase in the high-pressure pump cooling circuit, through inlet and drain piping (16) from piping (8). The pressure relief valve housed on the cylinder head, assembled on injector return (3), limits the fuel return flow from injectors at a pressure of 1.3 to 2 bars. Two by-pass valves are placed in parallel with the mechanical supply pump. The by-pass valve (18) allows fuel to flow from mechanical pump outlet to its inlet, when the fuel filter inlet pressure exceeds the allowed threshold value. The by-pass valve (17) allows filling the supply system through the manual priming pump (10).
Figure 4 (*)
EXHAUST INTAKE (LOW PRESSURE) HIGH-PRESSURE PUMP SUPPLY (LOW PRESSURE) HIGH PRESSURE
114545
(D) F4AE3481/2 1. High-pressure pump - 2. Pressure relief valve on high-pressure pump, 5 bars - 3. Pressure relief valve assembled on fuel return from injectors, 1.3 to 2 bars - 4. Rail overpressure valve - 5. Common Rail - 6. Pressure sensor - 7. Injector 8. Return piping - 9. Control unit heat exchanger - 10. Mechanical priming pump - 11. Prefilter assembled on chassis 12. Fuel tank - 13. Mechanical supply pump - 14. Fuel filter - 15. Flow rate regulator 16. High-pressure pump cooling piping - 17. By-pass valve - 18. By-pass valve.
Print P2D32N020 E
Base - May 2012
8
SECTION 2 - OPERATIONAL DIAGRAMS
F4AE ENGINES
HIGH PRESSURE
HIGH-PRESSURE PUMP SUPPLY (LOW PRESSURE)
INTAKE (LOW PRESSURE)
EXHAUST
Figure 5 (*)
108608
(*) F4AE3681
Base - May 2012
Print P2D32N020 E
F4AE ENGINES
SECTION 2 - OPERATIONAL DIAGRAMS
FUEL SUPPLY SYSTEM COMPONENTS Fuel prefilter
9
Fuel filter It is located on engine block in the circuit between feed pump and high pressure pump (CP3). On the support there are located: fuel temperature sensor and heater resistances.
Figure 6
Fuel temperature, signalled by relating sensor to EDC7UC31 central unit, enables a very accurate calculation of the flow rate of fuel to be injected into the cylinders. The electrical heater intervenes when fuel temperature is lower than 5 ºC.
Figure 7
70494
The fuel filter is of the high water separation type, is assembled on the vehicle chassis, and has the sensor (4) for detecting water in fuel placed on the cartridge (3) base. Manual priming pump (5) and air bleeding screw (2) from system are located on filter support. The presence of condensate into filter is signalled by sensor (4) when a warning light on the instrument panel is lit.
99231
1. Fuel filter support - 2. Fuel temperature sensor 3. Electric fuel heater - 4. Fuel filter - 5. Adapter 6. Heater connector - 7. Gasket A. Fitting for fuel drain outlet to tank B. Fitting for outlet to high pressure pump C. Fitting for drain from high pressure pump D. Fitting for fuel drain inlet from rail E. Fitting for inlet from feed pump
If the warning light is on, it is necessary to immediately operate to remove its cause; the common rail system components are quickly damaged by the presence of water or impurities in the fuel.
Print P2D32N020 E
Base - May 2012
10
SECTION 2 - OPERATIONAL DIAGRAMS
F4AE ENGINES
Bleeding conditions
Mechanical supply pump Feed mechanical pump is a gear pump, mounted on high pressure pump rear side, having the task of feeding high pressure pump. It is driven by high pressure pump shaft.
Figure 10
Normal operating conditions Figure 8
72594
72592
A. Fuel inlet from tank, B. fuel outlet to filter, 1-2 by-pass valves in close position
The by-pass valve (2) cuts in when, with engine off, the fuel system shall be filled through the priming pump. In this situation the by-pass valve (1) stays closed whereas by-pass valve (2) opens due to inlet pressure, and fuel is drained out through B.
Overpressure condition at outlet NOTE The mechanical supply pump cannot be replaced individually, therefore it cannot be removed from the high pressure pump.
Figure 9
72593
The by-pass valve (1) cuts in when overpressure is generated at outlet B. The existing pressure, overcoming valve spring (1) elastic strength, makes inlet and outlet communicating through duct (2).
Base - May 2012
Print P2D32N020 E
F4AE ENGINES
SECTION 2 - OPERATIONAL DIAGRAMS
11
CP3 high-pressure pump CP3 high pressure pump is a pump with 3 radial plungers which is driven through a timing system gear. High pressure pump does not require timing. On high pressure pump rear side, feed mechanical pump is mounted, driven by high pressure pump shaft.
NOTE The following work must be carried out on the feed pump / high-pressure pump assembly: - replacing the drive gear; - replacing the fuel flow rate regulator.
Figure 11
72595
1. Fuel outlet fitting to rail - 2. High-pressure pump - 3. Fuel flow rate regulator - 4. Control gear - 5. Fuel inlet fitting from filter - 6. Fuel outlet fitting to filter support - 7. Fuel inlet fitting from control unit heat exchanger - 8. Fuel outlet fitting from supply pump to filter - 9.Mechanical supply pump
Print P2D32N020 E
Base - May 2012
12
SECTION 2 - OPERATIONAL DIAGRAMS
F4AE ENGINES
High-pressure pump - inside structure Figure 12
Sec. B-B
Sec. C-C
70498
1. Cylinder - 2. Three-lobe element - 3. Cap intake valve - 4. Ball delivery valve - 5. Piston - 6. Pump shaft 7. Low-pressure fuel inlet - 8. Plungers supplying fuel ducts.
Each plunger is made up of: - one piston (5) driven by a three-lobe element (2) floating on pump shaft (6). Element (2) is floating on a misaligned side of shaft (6). Therefore, during shaft rotation, the element is not turning together with the shaft, but is just translated, according to a circular movement, to a wider radius. It results that the three pumping assemblies are driven alternatively; - one cap intake valve (3); - one delivery ball valve (4).
Base - May 2012
Print P2D32N020 E
F4AE ENGINES
SECTION 2 - OPERATIONAL DIAGRAMS
13
Operating principle Figure 13
Sec. B — B
Sec. D — D
72597
1. Fuel outlet fitting to rail - 2. Delivery valve to rail - 3. Plunger - 4. Pump shaft - 5. Plunger supply duct - 6. Pressure regulator supply duct - 7. Flow rate regulator.
Plunger (3) is oriented towards the cam that is present on pump shaft (4). During suction stroke, the plunger is fed through feed duct (5). The quantity of fuel to be sent to the plunger is set by flow rate regulator (7). Flow rate regulator, on the basis of PWM command received by control unit, partialises fuel inflow to the plunger. During plunger compression stroke, fuel reaches such a pressure that valve delivering the fuel to common rail (2) is opened and common rail is fed by the plunger through outlet (1).
Print P2D32N020 E
Base - May 2012
14
SECTION 2 - OPERATIONAL DIAGRAMS
F4AE ENGINES
Figure 14
Sec. C — C
Figure 15
72598
1. Plunger inlet - 2. Pump lubrication ducts - 3. Plunger inlet - 4. Main plunger supply duct - 5. Flow rate regulator - 6. Plunger inlet - 7. Regulator exhaust duct - 8. 5 bar pressure relief valve - 9. Fuel drain from regulator inlet.
Figure 14 shows low pressure fuel paths inside the path and highlights: main plunger supply duct (4), plunger supply ducts (1 — 3 — 6), pump lubrication ducts (2), flow rate regulator (5), 5 bar pressure relief valve (8) and fuel drain duct (7). Pump shaft is lubricated by fuel through delivery and return ducts (2). Flow rate regulator (5) establishes the fuel amount to send to plungers; excess fuel is drained out through duct (9). 5 bar pressure relief valve acts as fuel return regulator and keeps 5 bar constant pressure at regulator inlet.
Base - May 2012
72601
Sec. A — A 1. Fuel outlet duct - 2. Fuel outlet duct - 3. Fuel outlet from pump with high pressure pipe fitting for common rail.
Figure 15 shows high pressure fuel flow through plunger outlet ducts.
Replacing the pressure regulator - Greatest cleanliness must be ensured; - avoid letting impurities into the pump pressure channels; - replace the O-rings and moisten them with Vaseline; - tighten to the specified torque: 1st phase: 3 4 Nm, 2nd phase: 6 7 Nm.
Print P2D32N020 E
F4AE ENGINES
Operation The cylinder is filled through the cap intake valve only if the supply pressure is suitable to open the delivery valves set on the plungers (about 2 bars).
SECTION 2 - OPERATIONAL DIAGRAMS
15
Rail Figure 16
(Demonstration)
The amount of fuel supplying the high-pressure pump is metered by the flow rate regulator, placed on the low-pressure system; the flow rate regulator is controlled by the EDC7UC31 control unit through a PWM signal. When fuel is sent to a plunger, the related piston is moving downwards (suction stroke). When the piston stroke is reversed, the intake valve closes and the remaining fuel in the plunger chamber, not being able to come out, is compressed above the supply pressure value existing in the rail. The thereby-generated pressure makes the exhaust valve open and the compressed fuel reaches the high-pressure circuit. The plunger compresses the fuel till the top dead center (delivery stroke) is reached. Afterwards, the pressure decreases till the exhaust valve is closed. The plunger piston goes back towards the bottom dead center and the remaining fuel is decompressed. When the plunger chamber pressure becomes less than the supply pressure, the intake valve is again opened and the cycle is repeated. The delivery valves must always be free in their movements, free from impurities and oxidation. The pressure of fuel delivered to rail is modulated by electronic control unit through flow rate regulator solenoid valve.
107422
1. Rail - 2. Pressure sensor - 3. Fuel inlet from high-pressure pump - 4. Overpressure valve. The rail volume is of reduced sizes to allow a quick pressurisation at startup, at idle and in case of high flow-rates. It anyway has enough volume as to minimise use of plenum chambers caused by injectors openings and closings and by the high-pressure pump operation. This function is further enabled by a calibrated hole being set downstream of the high-pressure pump. A fuel pressure sensor (4) is screwed to the rail. The signal sent by this sensor to the electronic control unit is a feed-back information, depending on which the rail pressure value is checked and, if necessary, corrected.
The pump is lubricated and cooled by the fuel. The radialjet pump removal — refitting time on the engine is highly reduced in comparison with traditional injection pumps, because it does not require setting. If the pipe between fuel filter and high-pressure pump is to be removed-refitted, be sure that hands and components are absolutely clean.
Print P2D32N020 E
Overpressure valve Overpressure valve is mounted at one rail end. Overpressure valve task is to protect system components should rail pressure sensor or CP3 pump pressure regulator malfunctioning cause a pressure excessive increase in high pressure system. When pressure in rail is reaching 1800 bar, the valve at start operates in order to make fuel flow and consequently decrease pressure to safety values, then mechanically regulates pressure in rail. The valve enables to operate engine for long times with limited performance and prevents fuel excessive overheating, so preserving pipes for fuel return to tank.
Base - May 2012
16
SECTION 2 - OPERATIONAL DIAGRAMS
F4AE ENGINES
Injection start
Electro-injector The injector is similar as construction to the traditional ones, apart from the absence of plunger return springs. The injector can be deemed as composed of two parts: - actuator — spray nozzle composed of pressure rod (1), plunger (2) and nozzle (3); - control solenoid valve composed of coil (4) and pilot valve (5). The solenoid valve controls spray nozzle plunger lift.
Figure 18
Injector in rest position Figure 17
15
15
70506
1. Pressure rod - 2. Plunger - 3. Nozzle - 4. Coil - 5. Pilot valve - 6. Ball shutter - 7. Control area - 8. Pressure chamber - 9. Control volume - 10. Control duct 11. Supply duct - 12. Control fuel outlet - 13. Electric connection - 14. Spring - 15. High-pressure fuel inlet.
70505
1. Pressure rod - 2. Plunger - 3. Nozzle - 4. Coil - 5. Pilot valve - 6. Ball shutter - 7. Control area - 8. Pressure chamber - 9. Control volume - 10. Control duct 11. Supply duct - 12. Control fuel outlet - 13. Electric connection - 14. Spring - 15. High-pressure fuel inlet.
When coil (4) is energised, it makes shutter (6) move upwards. The control volume (9) fuel flows towards flow duct (12) making a pressure drop occur in control volume (9). Simultaneously the fuel pressure into pressure chamber (8) makes plunger (2) lift, with following fuel injection into the cylinder. Injection end When coil (4) is de-energised, shutter (6) goes back to its closing position, in order to re-create such a force balance as to make plunger (2) go back to its closing position and end the injection.
NOTE The injector cannot be overhauled and therefore it must not be disassembled.
Base - May 2012
Print P2D32N020 E
F4AE ENGINES
SECTION 2 - OPERATIONAL DIAGRAMS
17
Pressure limiter for fuel return It is housed on the rear of the cylinder head, and adjusts the pressure of fuel returning from injectors at a pressure 1.3 and 2 bars. By guaranteeing this pressure to the return fuel, the fuel vapours formation inside injectors is avoided, optimising fuel spraying and combustion.
Figure 19
70507
A
To tank — B From injectors
Print P2D32N020 E
Base - May 2012
18
SECTION 2 - OPERATIONAL DIAGRAMS
F4AE ENGINES
LUBRICATION 4-cylinder engine version Lubrication by forced circulation is achieved through oil rotary expansion pump, placed in the front part of the basement, driven by the straight-tooth gear splined to the shaft's bar hold.
Lubrication involves the heat exchanger as well, the turbo-blower and the eventual compressor for any eventual compressed air system. All these components may often vary according to the specific duty and will therefore be examined in the specific section.
From the pan, the lubrication oil flows to the driving shaft, to the camshaft and to the valve drive. Figure 20
(Demonstration)
Oil recover from the turbo-blower
To the exchanger and to the turbo-blower
Routing of oil return by gravity to sump
108511
Routing of oil return by gravity to sump Introduction of oil
LUBRICATION SYSTEM LAYOUT 4-cylinder engines Base - May 2012
Print P2D32N020 E
F4AE ENGINES
SECTION 2 - OPERATIONAL DIAGRAMS
6-cylinder engine version Even for the 6 cylinders version lubrication is obtained by forced circulation and achieved through an oil rotary expansion pump similar to the 4 cylinders' one.
Figure 21
19
Also in this case, the components such as the oil exchanger, the turbo-blower and the eventual compressor are specifically studied and made out to suit the equipment or the duty for which the engine has been developed.
(Demonstration)
Oil recover from the turbo-blower To the exchanger and to the turbo-blower
Routing of oil under pressure 108512
Routing of oil return by gravity to sump Introduction of oil
LUBRICATION SYSTEM LAYOUT 6-cylinder engines Print P2D32N020 E
Base - May 2012
20
SECTION 2 - OPERATIONAL DIAGRAMS
Oil pump
F4AE ENGINES
Figure 22
NOTE Since the oil pump cannot be overhauled. It shall be replaced when damaged.
70576
Heat exchanger Figure 23
166064
1. Heat exchanger body with filter bracket and oil filter - 2. Internal gasket - 3. Water-oil heat exchanger - 4. Gasket between heat exchanger unit and engine block - 5. Oil pressure relief valve - 6. By-pass valve to cut out clogged oil filter.
Base - May 2012
Print P2D32N020 E
F4AE ENGINES
SECTION 2 - OPERATIONAL DIAGRAMS
21
Oil pressure relief valve Figure 24
Loosen the plug (1), withdraw the spring (2) and the relief valve (3) from the support (4). Check whether the valve (3) is not scored and is sliding smoothly into its seat. The spring (2) shall not be broken or yielded. Pressure regulation at 100 C oil temperature: - 1.2 bar min pressure; - 3.8 bar max. pressure Figure 25
107418
By-pass valve (5) to cut out clogged oil filter.
Figure 26
Flow
70482 107419
MAIN DATA TO CHECK OIL PRESSURE RELIEF VALVE SPRING Print P2D32N020 E
Max blow-by: 20 cm3/1' at 0.83 bar pressure and at 26.7 C oil temperature.
Base - May 2012
22
SECTION 2 - OPERATIONAL DIAGRAMS
F4AE ENGINES
OIL VAPOUR RECYCLING Figure 27
70484
Oil condensate Oil vapours 1. Pre-separator - 2. Exhaust to the outside (temporary) - 3. Filter - 4. Return to engine. The tappet cover houses the pre-separator (1), whose shape and position determines an increase in oil vapour outlet speed and condenses a part of vapours at the same time. Condensate oil returns to the oil sump whereas the residual vapours are ducted, collected and filtered in the blow-by (3). In the blow-by (3), part of the vapours condense and return to the oil sump whereas the remaining part is put into cycle again through pipe (2).
Base - May 2012
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F4AE ENGINES
SECTION 2 - OPERATIONAL DIAGRAMS
23
The engine cooling system, closed circuit forced circulation type, generally incorporates the following components:
- Viscous pusher fan, having the duty to increase the heat dissipating power of the radiator. This component as well will be specifically equipped based on the engine's development.
- Expansion tank; placement, shape and dimensions are subject to change according to the engine's equipment.
- Heat exchanger to cool the lubrication oil: even this component is part of the engine's specific equipment.
- Radiator, which has the duty to dissipate the heat subtracted to the engine by the cooling liquid. Also this component will have specific peculiarities based on the equipment developed, both for what concerns the placement and the dimensions.
- Centrifugal water pump, placed in the front part of the engine block.
COOLING SYSTEM 4-cylinder engine version
Figure 28
- Thermostat regulating the circulation of the cooling liquid. - The circuit may eventually be extended to the compressor, if this is included in the equipment.
(Demonstration) Expansion tank
Expansion tank
Heater (optional)
Radiator
Radiator
Water coming out from thermostat Water recirculating in engine Water coming into pump 74194
COOLING SYSTEM LAYOUT 4-cylinder engines Print P2D32N020 E
Base - May 2012
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SECTION 2 - OPERATIONAL DIAGRAMS
F4AE ENGINES
6-cylinder engine version The engine cooling system, closed circuit forced circulation type, is of a similar design as the 4 cylinders engine. It incorporates necessary components such as the radiator, the heat exchanger, the expansion tank and some ancillary components such as the heater or the compressor for the compressed air. Such components always vary according to the engine's equipment and duty.
Figure 29
(Demonstration) Expansion tank
Expansion tank
Heater (optional)
Radiator
Radiator
Water coming out from thermostat Water recirculating in engine Water coming into pump 166066
COOLING SYSTEM LAYOUT 6-cylinder engines Base - May 2012
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F4AE ENGINES
SECTION 2 - OPERATIONAL DIAGRAMS
25
The water pump is located in a hollow obtained in the cylinder block and is driven by and a poly-V belt.
Water Pump Figure 30
An automatic tensioner keeps the belt tension.
Thermostat Figure 31
79458
Sec. A-A
Print P2D32N020 E
70486
The bypass thermostat (1) is housed in the cylinder head and needs no adjustment. Whenever there are doubts as to its condition, replace it. The thermometric switch/transmitter and coolant temperature sensor are mounted on the thermostat body. A = travel start at 77 81 C; B = travel at 95 C 7.5 mm
Base - May 2012
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SECTION 2 - OPERATIONAL DIAGRAMS
F4AE ENGINES
TURBOCHARGER Description The turbocharging system is composed of: air filter, turbocharger and intercooler. The air cleaner is a dry type composed of a filtering cartridge that is periodically changeable. The function of the turbocharger is to use the energy of the engine's exhaust gas to deliver pressurized air to the cylinders. The intercooler is composed of a radiator applied to the engine coolant radiator, with the function of lowering the turbocharger output air temperature before it is sent to the cylinders. Figure 32
4-cylinder engine version
TURBOCHARGER
AIR FILTRE
EXHAUST
INTERCOOLER
6-cylinder engine version
TURBOCHARGER
AIR FILTRE
EXHAUST
INTERCOOLER 74195
Base - May 2012
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F4AE ENGINES
SECTION 2 - OPERATIONAL DIAGRAMS
27
Turbocharger
The turbocharger is composed of the following main parts:
Figure 33 (D)
- a central body in which a shaft is housed, supported by bushings, the ends of which are connected to: the turbine rotor and the compressor rotor; - a turbine casing and a compressor casing mounted on the end of the central body; - a boost-pressure regulation valve (when present) fitted on the turbine casing. During engine operation, the exhaust gases pass through the turbine body spinning the turbine rotor. The compressor rotor is connected by a shaft to the turbine rotor, which it spins and in doing so compresses the air taken in through the air filter.
intake air compressed air exhaust
The air is then cooled by the intercooler and sent to the cylinders via the intake manifold. 166697
The turbocharger is fitted with a pressure regulation valve, mounted on the exhaust manifold before the turbine and controlled by a pneumatic actuator, connected via a pipe to the intake manifold.
(D) F4AE3481/2 CCM HOLSET HX35W TURBOCHARGER
Its job is to limit the quantity of exhaust gas acting on the turbine by sending part of it directly into the exhaust pipe when the boost pressure downstream of the compressor reaches the maximum value set.
Figure 34 (*)
intake air compressed air exhaust
The engine oil is used to cool and lubricate the turbocharger and the bearings.
166067
(*) F4AE3681 CCM HOLSET HX35W TURBOCHARGER
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Base - May 2012
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SECTION 2 - OPERATIONAL DIAGRAMS
F4AE ENGINES
NOTE Verifying an anomalous operation of the engine, due to the booster system, it is recommended, before performing controls on the turbosupercharger, to check the efficiency of the sealing gaskets and the fixing of the connection sleeves, making sure of clogging absence inside intake sleeves, air cleaner or inside radiators. If the turbosupercharger damage is due to a lack of lubrication, check that the oil circulation pipes are not broken or obstructed, in such case replace them or eliminate the trouble.
Bearing end play check Position the tracer point of the magnetic-base dial gauge on the turbocharger shaft end and set to zero the dial gauge. Move the turbocharger shaft axially and check that the clearance is not higher than the prescribed value.
Apply the magnetic-base dial gauge (2) on the exhaust gas inlet flange in the turbine. Position the tracer point of the gauge (2) on the tie rod (3) end and set to zero the gauge (2). Through the pump (1) let in compressed air, in the actuator (6), at the prescribed pressure and make sure that such value is kept constant for the whole check time, otherwise replace the actuator (6). In the above-mentioned conditions, the tie rod must have carried out the prescribe stroke.
NOTE During the operation, beat slightly the actuator (6) in order to eliminate possible sticking of the actuator internal spring. If a different value is found, loosen the nut (5) and operate properly the knurled ring nut (4).
Replace the turbocharger if a different value is found.
Actuator replacement
Waste gate
Figure 36 Check and adjustment Figure 35
5
4
3
2
1 166070
Remove the elastic clip (4) and withdraw the tie rod (3) from the lever (5). 62873
Cover the air, exhaust gas and lubrication oil inlets and outlets. Carry out an accurate external cleaning of the turbosupercharger, using the anticorrosive and antioxidant solution and perform the check on the actuator (6).
Remove the nuts (2) and remove the actuator (1) from the supporting bracket. Fit the new actuator following the removal operations in reverse order and fitting a new clip (4), tighten the nuts (2) to 5.6 — 6.8 Nm torque. Check and adjust the actuator (1), if required, as described in the relevant chapter.
Clamp the turbosupercharger in a vice.
Then, paint the nut (6) with safety paint.
Disconnect the pipe of the actuator (6) and apply to the actuator union, the pipe of pump 99367121 (1).
Before refitting the turbocharger on engine, fill the central body with engine oil.
Base - May 2012
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F4AE ENGINES
SECTION 2 - OPERATIONAL DIAGRAMS
29
DeNOx 2 SYSTEM General Information To limit the nitrogen oxide exhaust gas values (NOx) within the limits required by Euro 5, with low fuel consumption, the vehicles have been equipped with a post-treatment system for these substances contained in the exhaust gas, which is essentially an electronically controlled oxidative catalyst. Using the Selective Catalytic Reduction (SCR) process, the system transforms the nitrogen oxide (NOx) into inert compounds: free nitrogen (N2) and water vapour (H2O). The SCR process is based on a series of chemical reactions that, due to the reaction of ammonia with the oxygen in the exhaust gas, lead to the reduction of nitrogen oxides (NOx) contained in the exhaust gas. The system essentially comprises: - a tank (5) of reagent solution (water - urea: Ad Blue) with a level indicator; - a pump module (1); - a mixing and injection module (6); - a catalytic converter; - two temperature sensors (9 and 10) at the exhaust gas inlet and outlet to the catalytic converter; - a humidity sensor fitted on the engine air intake pipe downstream of the air filter. The SCR system is electronically managed by the DCU (Dosing Control Unit) incorporated in the pump module (1), which according to the number of engine revs, the torque delivered, the exhaust temperature, the amount of nitrogen oxides and humidity in the incoming air, adjusts the flow rate of the Ad Blue solution to be put into the system. The pump module (1) picks up the reagent solution from the tank (5) and sends it under pressure to the mixing and injection module (6) to be injected into the exhaust pipe upstream of the catalytic converter. The first phase of the process takes part in the first part of the catalytic converter: due to the effect of the exhaust gas temperature, the reagent solution evaporates instantly and, by hydrolysis, converts into ammonia (2NH3) and carbon dioxide (CO2). Evaporation of the solution causes lowering of the exhaust gas temperature, bringing it closer to the optimum temperature required by the process. The exhaust fumes, additioned with ammonia and at the reaction temperature, are introduced into the catalytic converter, where the second phase of the process takes place: by reacting with the oxygen in the exhaust gasses the ammonia is converted into free nitrogen (N2) and water vapour (H2O).
Print P2D32N020 E
Base - May 2012
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SECTION 2 - OPERATIONAL DIAGRAMS
F4AE ENGINES
Figure 37
148514
1. Pump module - 2. Tank level sensor - 3. Tank temperature sensor - 4. Ad Blue tank - 5. Prefilter - 6. Return flow valve 7. Dosing module - 8. MV2 - 9. Exhaust gas temperature sensor - 10. Catalyst - 11. Exhaust gas temperature sensor 12. NOx detection sensor - 13. Ad Blue pressure sensor - 14. Filter - 15. Diaphgram pump - 16. Reverting valve 17. Ad Blue temperature sensor
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SECTION 2 - OPERATIONAL DIAGRAMS
31
Pump module
Tank Figure 38
Figure 40
108508
The tank with the level indicator command (1) contains the reducing substance necessary for the SCR process, comprising a solution of 35% urea and water, known as Ad Blue.
148510
1. DCU control unit connector - 2. Pressure compensattion - 3. Ad Blue solution infeed - 4. Prefilter 5. Ad Blue solution outlet - 6. Ad Blue return pipe from dosing module - 7. Ad Blue l tank return - 8. Filter
Dosing module Figure 41
Ad Blue fluid level gauge control Figure 39
108129
1. Ad Blue infeed - 2. Electrical connection 3. Ad Blue outlet Has the job of dosing the Ad Blue solution to be sent into the exhaust pipe upstream of the catalytic converter.
SCR pipes 116181
1. Ad Blue fluid intake pipe - 2. Ad Blue fluid return pipe 3. Inlet pipe for hot engine coolant fluid - 4. NTC sensor 5. Outlet pipe for hot engine coolant fluid - 6. Float 7. AdBlue liquid heating coil (only versions equipped with 08277 optional) - 8. AdBlue breather
Print P2D32N020 E
NOTE The SCR pipe harnesses complete with the VOSS are only available for production. In case of repair operations, for the replacement of each component (cooling water pipes, AdBlue pipes, fittings, corrugated pipes, sectioning plates, etc.) refer to the supplied spare accessories.
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SECTION 2 - OPERATIONAL DIAGRAMS
F4AE ENGINES
Exhaust gas temperature sensor Figure 42
102303
Figure 43
102304
FUNCTIONAL WIRING DIAGRAM 1. Supply voltage - 2. Variable output voltage - 3. Connector - 4. Signal cable (grey) - 5. Earth cable (white) - 6. Sensor. The function of this sensor is to send the control unit the catalyst inlet and outlet exhaust gas temperature values required to calculate the amount of urea to be injected into the system.
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SECTION 2 - OPERATIONAL DIAGRAMS
33
Humidity detecting sensor Figure 44
102311
1. Temperature - 2. Earth - 3. Humidity percent value - 4. Power supply. This sensor is located on the air filter output conveyor, and is used to inform the control unit of the amount (percentage) of humidity found in sucked air, to determine the calculation of nitric oxide emissions.
Figure 45
102312
ELECTRIC BLOCK DIAGRAM 1. Earth - 2. Temperature - 3. Power supply unit - 4. Humidity percent value - A. Sample frequency generator B. Reference oscillator - C. NTC temperature sensor - D. Amplifier lowpass filter
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Base - May 2012
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SECTION 2 - OPERATIONAL DIAGRAMS
F4AE ENGINES
Nitric oxide sensor Figure 46
102302
1. Positive - 2. Mass - 3. CAN L line - 4. CAN H line - 5. Spare This sensor has the function to communicate the dosing of AdBlue liquid (Urea) and the catalyst conditions to the control unit. Base - May 2012
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SECTION 2 - OPERATIONAL DIAGRAMS
35
Pin out DCU 15 D2-2 Figure 47
UDS DCU15
113576
Pin No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
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Abbrev
Name
V_V_BAT+R V_V_BAT+R V_V_BAT+ V_V_BAT+ B_D_CANH1 B_D_CANL1 B_D_CANH2 B_D_CANL1 dnc O_S_CLH O_S_RAMV O_V_RAMV dnc G_G_BATG_G_BATdnc G_R_CATTSPRE I_A_RALS G_R_RALS
Battery + via main relay (output) Battery + via main relay (output) Battery plus Battery plus Controller Area Network 1 (high) Controller Area Network 1 (low) Controller Area Network 2 (high) Controller Area Network 2 (low) do not connect Compensation line heating Reduction agent metering valve Reduction agent metering valve supply (BAT+ ) do not connect Battery minus Battery minus do not connect Catalyst temperature sensor ground (upstream) Reduction agent level sensor signal Reduction agent level sensor ground/Reduction agent tank temperature sensor ground
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SECTION 2 - OPERATIONAL DIAGRAMS
Pin No 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
Base - May 2012
Abbrev
Name
dnc O_S_SVS O_S_HH1 O_S_RATH I_S_T15 G_R_CATTSPOST I_A_CATTSPOST dnc I_A_CATTSPRE I_A_TRATS V_V_5VRALS B_D_ISOK O_S_HH3 dnc O_S_HH4 O_S_HH2
do not connect Service soon available Hose heating 1 (Suction line heating) Reduction agent tank heating Terminal 15 (switched BAT+) Post-catalyst temperature sensor ground (downstream) Post-catalyst temperature sensor signal (downstream) do not connect Catalyst temperature sensor signal (upstream) Reduction agent tank temperature sensor signal Reduction agent level sensor supply ISO-K interface Hose heating 3 (Pressure line heating) do not connect Hose heating 4 (Back flow to supply module line heating) Hose heating 2 (Back flow to tank line heating)
F4AE ENGINES
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F4AE ENGINES
SECTION 2 - OPERATIONAL DIAGRAMS
37
Figure 48
148515
Print P2D32N020 E
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SECTION 2 - OPERATIONAL DIAGRAMS
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F4AE ENGINES
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F4AE ENGINES
1
SECTION 3 - ELECTRICAL EQUIPMENT
SECTION 3 Electrical equipment
Page
Print P2D32N020 E
LOCATION OF THE MAIN ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . .
3
CABLE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . .
4
- 4-cylinder engine version . . . . . . . . . . . . . . . . .
4
- 6-cylinder engine version . . . . . . . . . . . . . . . . .
5
ECU ELECTRONIC CONTROL UNIT (EDC7UC31) . . . . . . . . . . . . . . . . . . . . . . . . .
6
- Electroinjectors connector (A) . . . . . . . . . . . .
7
- Sensors connector (C) . . . . . . . . . . . . . . . . . .
8
FUEL SUPPLY SYSTEM ELECTRICAL COMPONENTS
9
- Crankshaft sensor . . . . . . . . . . . . . . . . . . . . . .
10
- Timing sensor . . . . . . . . . . . . . . . . . . . . . . . . .
10
- Supercharging air pressure - temperature sensor
11
- Engine oil temperature-pressure sensor . . . . .
11
- Fuel temperature and pressure sensor . . . . . .
12
- Electro-injectors . . . . . . . . . . . . . . . . . . . . . . .
13
- Pre-post heating resistance and contactor (if present) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
- Coolant temperature sensor . . . . . . . . . . . . . .
15
- Fuel temperature sensor . . . . . . . . . . . . . . . . .
16
- High pressure pump - fuel flow rate regulator
17
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SECTION 3 - ELECTRICAL EQUIPMENT
Base - May 2012
F4AE ENGINES
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F4AE ENGINES
SECTION 3 - ELECTRICAL EQUIPMENT
3
LOCATION OF THE MAIN ELECTRICAL COMPONENTS Figure 1
(Demonstration)
108641
The NEF F4HFE engines are fully driven by the electronic engine control module, which is assembled directly to the engine by means of a heat exchanger enabling its cooling, utilising rubber buffers to reduce vibration originated by the engine.
The electrical and electronic components of the engine are listed here following:
Through the engine control module it is possible to verify the correct working of the engine. (See SECTION 5 Diagnostics).
3. RAIL pressure sensor.
1. Coolant temperature sensor. 2. Electro-injector. 4. Air temperature/pressure sensor. 5. Starter motor. 6. Timing sensor. 7. Fuel flow rate regulator solenoid valve. 8. Fuel temperature sensor. 9. EDC electronic control unit. 10. Crankshaft sensor. 11. Engine oil pressure/temperature sensor. 12. Heating element for pre-post heating.
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Base - May 2012
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SECTION 3 - ELECTRICAL EQUIPMENT
F4AE ENGINES
CABLE ENGINE 4-cylinder engine version All the components described below refer to the engine cable in question, therefore the connections to the pins are a preliminary version, in other words at the approval stage.
Figure 2
166698
1. Injectors for cylinders 1-2 - 2 Injectors for cylinders 3-4 - 4. Engine rpm sensor 5. Timing sensor - 6. Engine oil pressure and temperature sensor - 7. Fuel temperature sensor 8. Coolant temperature sensor - 9. Air temperature and pressure sensor - 10. Fuel pressure sensor 11. Fuel flow rate regulator - 12. Connector C EDC control unit (signal) - 13. Connector A EDC control unit (power).
Base - May 2012
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SECTION 3 - ELECTRICAL EQUIPMENT
5
6-cylinder engine version All the components described below refer to the engine cable in question, therefore the connections to the pins are a preliminary version, in other words at the approval stage.
Figure 3
0051064t
1. Injectors for cylinders 1-2 - 2 Injectors for cylinders 3-4 - 3. Injectors for cylinders 5-6 - 4. Engine rpm sensor 5. Timing sensor - 6. Engine oil pressure and temperature sensor - 7. Fuel temperature sensor 8. Coolant temperature sensor - 9. Air temperature and pressure sensor - 10. Fuel pressure sensor 11. Fuel flow rate regulator - 12. Connector C EDC control unit (signal) - 13. Connector A EDC control unit (power).
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SECTION 3 - ELECTRICAL EQUIPMENT
F4AE ENGINES
ECU ELECTRONIC CONTROL UNIT (EDC7UC31) Figure 4
102373
A. Injector connector - B. Frame connector (refer to the vehicle which the engine is fitted to) C. Sensor connector
Base - May 2012
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F4AE ENGINES
7
SECTION 3 - ELECTRICAL EQUIPMENT
Electroinjectors connector (A) Figure 5
12
16
11
6
50350
1
5
Colour legend C ORANGE A LIGHT BLUE B WHITE L BLUE G YELLOW H GREY M BROWN N BLACK W LIGHT BROWN S PINK R RED V GREEN Z PURPLE Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Print P2D32N020 E
4-cylinder engines Cable colour HN HR MB HV V C BL HG MN MV
Description Cylinder 3 injector Cylinder 2 injector Cylinder 1 injector Cylinder 4 injector Fuel flow rate regulator Fuel flow rate regulator Cylinder 4 injector Cylinder 1 injector Cylinder 2 injector Cylinder 3 injector
6-cylinder engines Cable colour LR BC BL MB MV HR V C MN HN HG HV VN RG
Description Cylinder 5 injector Cylinder 6 injector Cylinder 4 injector Cylinder 1 injector Cylinder 3 injector Cylinder 2 injector Fuel flow rate regulator Fuel flow rate regulator Cylinder 2 injector Cylinder 3 injector Cylinder 1 injector Cylinder 4 injector Cylinder 6 injector Cylinder 5 injector Base - May 2012
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SECTION 3 - ELECTRICAL EQUIPMENT
F4AE ENGINES
Sensor connector (C) Figure 6
6
8
16
9
15
22
1
3
23 30
36
29
Colour legend C A B L G H M N W S R V Z
ORANGE LIGHT BLUE WHITE BLUE YELLOW GREY BROWN BLACK LIGHT BROWN PINK RED GREEN PURPLE
Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Base - May 2012
4 5
Description Signal from sensor of engine revolution counter on timing (phase sensor) Ground of sensor of engine revolution counter on timing (phase sensor) Fuel pressure sensor ground Fuel pressure sensor power supply Fuel pressure sensor signal Water temperature sensor signal Fuel temperature sensor ground Engine revolution counter sensor ground Signal from engine revolution counter sensor Oil pressure / temperature sensor ground Air pressure / Temperature ground Water temperature sensor ground Oil pressure sensor signal Oil temperature sensor signal Oil pressure / temperature sensor supply Air pressure / Temperature sensor supply Air pressure sensor signal Fuel temperature sensor signal Air temperature sensor signal
50350
Cable colour code B R BN HN RV CV CN B R GV GN BG GR NS MN CL LN BL BR Print P2D32N020 E
F4AE ENGINES
SECTION 3 - ELECTRICAL EQUIPMENT
9
FUEL SUPPLY SYSTEM ELECTRICAL COMPONENTS ALTERNATOR Supplier Rated voltage Current
BOSCH 28V 90A - 12000 RPM
Figure 7
(Demonstration)
B +
W L 15 S
PERSPECTIVE VIEW
7998
Characteristics Rated voltage Rated power Current at room temperature at 25 º C and Rated voltage Direction of rotation Weight
Figure 8
28 V 2,5kW 1800 RPM/35 A 6000 RPM/70 A clockwise, seen from pulley 6,4 kg
B
A
8003
WIRING DIAGRAM A. Alternator B. Voltage regulator Figure 9
8000
VOLTAGE REGULATOR TEMPERATURE CHARACTERISTICS (6000 RPM)
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SECTION 3 - ELECTRICAL EQUIPMENT
F4AE ENGINES
Crankshaft sensor This is an inductive sensor located at the front left hand side of the engine. The crankshaft sensor produces signals obtained from a magnetic flux field closing through the openings in a phonic wheel fitted on the crankshaft. The crankshaft sensor is connected to the control unit on pins 19C - 23C. The sensor impedance is 900 .
Figure 10
50319
Crankshaft sensor
Timing sensor This is an inductive sensor located at the rear left hand side of the engine. The timing sensor generates signals obtained from a magnetic flux field closing through the holes in the timing gear on the camshaft. The signal generated by this sensor is utilized by the electronic control unit as an injection phase signal. Although it is similar to the flywheel sensor, these two devices are NOT interchangeable because of the different external shape. The timing sensor is connected to the control unit on pins 9C - 10C. The sensor impedance is 900 . Figure 11
50320
Timing sensor Figure 12 3
2
1
50342
50288
Connector Ref. 1 2 3
Base - May 2012
Wiring diagram Description
Ground Signal Shield
ECU pin Camshaft sensor 19C 23C
Timing sensor 10C 9C
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F4AE ENGINES
SECTION 3 - ELECTRICAL EQUIPMENT
11
Supercharging air pressure - temperature sensor This component incorporates a temperature sensor and a pressure sensor. Mounted on the intake manifold, the sensor measures the maximum flow rate of air supplied, which serves to make an accurate calculation of the quantity of fuel to be injected in each cycle. The sensor is connected to the control unit on pins 25C - 36C - 33C - 34C. The power supply is 5 Volt Voltage at the sensor output is proportional to the detected pressure or temperature. Pin 36C Pin 34C
Temperature signal Pressure signal
Engine oil temperature-pressure sensor This component is analogous to the air temperature-pressure sensor. The engine oil temperature-pressure sensor is installed on the engine oil filter support in a vertical position. This sensor measures the engine oil temperature and pressure. The sensor is connected to the control unit on pins 24C - 28C - 32C - 27C. The sensor is supplied with 5 Volts. The signal detected is transmitted to the EDC control unit which, in turn, controls the relative device on the instrument panel (gauge + low pressure warning light). The oil temperature is not displayed on any gauges - this value is used exclusively by the control unit. Pin 28C Pin 27C
Temperature signal Pressure signal
Figure 13
50324
50344
Wiring diagram
Ref. 1 2 3 4
Print P2D32N020 E
Description Ground NTC signal (temperature) +5 V power input Signal (pressure)
ECU Pin Oil 24C 28C 32C 27C
Air 25C 36C 33C 34C
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SECTION 3 - ELECTRICAL EQUIPMENT
F4AE ENGINES
Fuel temperature and pressure sensor Mounted on one end of the rail, this sensor measures the internal fuel pressure and informs the control unit of the value (feedback). The injection pressure value is used as a pressure control feedback signal and to determine the duration of the electrical injection command. This sensor is connected to the control unit on pins 12C - 14C- 13C. The power supply is 5 Volt.
Figure 14
0051065t
Fuel pressure sensor connector
Ref. 1 2 3
Base - May 2012
Description Ground Signal Power supply
ECU pin 12C 14C 13C
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F4AE ENGINES
SECTION 3 - ELECTRICAL EQUIPMENT
13
Electro-injectors The electro-injectors are effectively N.O. solenoid valves. Each injector is connected to the EDC control unit on connector A. The impedance of the coil of each injector is 0.56 - 0.57 . 4-cylinder engine version Ref. CONNECTOR 1
CONNECTOR 2
1 2 3 4 1 2 3 4
Description
ECU pin 15 A 2A 13 A 4A 5A 12 A 1A 16 A
Description
ECU pin 11 A 6A 13 A 4A 14 A 3A 12 A 5A 15 A 2A 1A 16 A
Cylinder 2 injector Cylinder 2 injector Cylinder 1 injector Cylinder 1 injector Cylinder 4 injector Cylinder 4 injector Cylinder 3 injector Cylinder 3 injector
6-cylinder engine version Ref. CONNECTOR 1
CONNECTOR 2
CONNECTOR 3
1 2 3 4 1 2 3 4 1 2 3 4
Cylinder 2 injector Cylinder 2 injector Cylinder 1 injector Cylinder 1 injector Cylinder 4 injector Cylinder 4 injector Cylinder 3 injector Cylinder 3 injector Cylinder 6 injector Cylinder 6 injector Cylinder 5 injector Cylinder 5 injector
Figure 15
50343
Figure 16
50349
Print P2D32N020 E
Base - May 2012
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SECTION 3 - ELECTRICAL EQUIPMENT
F4AE ENGINES
Pre-post heating resistance and contactor (if present) The pre-post heating resistance is located on the intake manifold. The resistance serves to heat the air in pre / post heating operations. This resistance is powered by a contactor. The resistance impedance is approximately 0.5 .
Figure 17 B
A
108909
A. - B. Connection terminals
Figure 18
002371t
A. Control contactor
The control contactor is connected to the control unit B connector. The contactor is tripped with water and/or fuel temperature below 5 C. The contactor impedance is approximately 15 .
Do not use flammable gases or liquids to provoke the engine ignition. These substances in contact with the resistance could easily become inflamed creating situations of serious danger.
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SECTION 3 - ELECTRICAL EQUIPMENT
15
Coolant temperature sensor This is a variable resistance sensor able to read the coolant temperature in order to provide the control unit with an indication of the thermal status of the engine. The same signal is utilized by the control unit to drive an instrument panel gauge, if present. This sensor is connected to the control unit on pins 15C - 26C. The impedance of the coolant temperature sensor at 20 C is approximately 2.50 .
Figure 19
107471
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Base - May 2012
16
SECTION 3 - ELECTRICAL EQUIPMENT
F4AE ENGINES
Fuel temperature sensor This sensor is identical to the coolant temperature sensor. This sensor detects the fuel temperature to provide the control unit with a parameter defining the thermal status of the fuel. The fuel temperature sensor is connected to the control unit on pins 35C -18C. The sensor impedance at 20 C is approximately 2.50 . Figure 20
166060
1. Fuel temperature sensor - 2. Filter heating resistance. The ECU drives the filter heater contactor at fuel temperature 5 C. Figure 21
107799
107798
Connector
Ref. 1 2
Base - May 2012
Description Ground Temperature signal
ECU Pin Coolant 26C 15C
Fuel 18C 35C
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F4AE ENGINES
SECTION 3 - ELECTRICAL EQUIPMENT
17
High pressure pump - fuel flow rate regulator Pump with 3 radial pistons controlled by the timing gears, requiring no phase adjustment, with rotor type feed pump fitted to the back.
Figure 22
166091
1. Fuel flow rate regulator. The flow rate regulator is located at the inlet of the high-pressure pump on the low-pressure circuit; its function is to modulate the quantity of fuel to feed to the high-pressure pump on the basis of commands received from the electronic control unit. It basically consists of the following parts: - trapezoidal section shutter; - valve control pin; - pre-charging spring; - coils. In the absence of the control signal, the flow rate regulator is normally open, and hence the high pressure pump is in its maximum delivery conditions. The control unit modulates a PWM control signal which reduces, to a greater or lesser extent, the section carrying the fuel to the high pressure pump. This component cannot be replaced individually and hence it cannot be taken down. The quantity of fuel supplied to the high pressure pump is metered by the flow rate regulator on the low pressure system; the flow rate regulator is managed by the EDC7 control unit. Delivery pressure to the rail is modulated between 250 and 1600 bar by the electronic control unit by controlling the flow rate regulator solenoid valve. - This component is a N.O. solenoid valve. - The solenoid is connected to the control unit on pins 9A - 10A. - The solenoid valve impedance is approximately 3.2 .
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Base - May 2012
18
SECTION 3 - ELECTRICAL EQUIPMENT
Base - May 2012
F4AE ENGINES
Print P2D32N020 E
F4AE ENGINES
SECTION 4 - SCHEDULED MAINTENANCE
1
SECTION 4 Scheduled maintenance
Page
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SCHEDULED MAINTENANCE . . . . . . . . . . . . .
3
- Recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
- Regular maintenance and inspection planning .
3
- Checks not included in maintenance planning-daily checks . . . . . . . . . . . . . . . . . . .
4
MAINTENANCE PROCEDURES . . . . . . . . . . . .
4
- Checks and inspections . . . . . . . . . . . . . . . . . .
4
Base - May 2012
2
SECTION 4 - SCHEDULED MAINTENANCE
Base - May 2012
F4AE ENGINES
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F4AE ENGINES
SECTION 4 - SCHEDULED MAINTENANCE
3
SCHEDULED MAINTENANCE Recovery To ensure optimised working conditions, in the following pages we are providing instructions for the overhaul control interventions, checks and setting operations that must be performed on the engine at due planned dates. The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine and evaluate replacements and checks. It is not only allowed but recommended that the staff in charge of the maintenance should also carry out the necessary maintenance and controlling operations even if not being included in the ones listed here below but that may be suggested by common sense and by the specific conditions in which the engine is run. In case of evident engine malfunction, such as excessive smoke of exhaust gas, high coolant temperature or low oil pressure, immediately intervene in order to find the causes. We wish to remind that each maintenance operation, even the most simple must be performed in compliance with the accident prevention standards for the safety of maintenance personnel in charge.
Regular maintenance and inspection planning
Checks and periodical inspections Visual check of engine . . . . . . . . . . . . . . . . . . . . . . . . Inspection presence of water in fuel filter or pre-filter Checking tappet clearance . . . . . . . . . . . . . . . . . . . . EDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing the engine oil and oil filter . . . . . . . . . . . . . Fuel pre-filter replacement . . . . . . . . . . . . . . . . . . . . Replacement of fuel filter . . . . . . . . . . . . . . . . . . . . . Replacement of blow by filter . . . . . . . . . . . . . . . . . . Changing the alternator belt . . . . . . . . . . . . . . . . . . .
Frequency (hours) . . . . . . . . .
. . . . . . . . .
. . . . . . . . .
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. . . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . . . . .
. . . . . .
Daily Daily 2400 When anomaly occurs 500 500 500 1500 1000
NOTE The frequency of the maintenance operations is just an indication since the use of the engine is the main characteristic to determine and evaluate replacements and checks. The maintenance operations are valid only if the setter fully complies with all the installation prescriptions provided by FPT. Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of turns based on which the engine has been designed.
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Base - May 2012
4
SECTION 4 - SCHEDULED MAINTENANCE
F4AE ENGINES
Checks not included in maintenance planning-daily checks It is a good habit to execute, before engine start, a series of simple checks that might represent a valid warranty to avoid inconveniences, even serious, during engine running. Such checks are usually up to the operators and to the vehicle's drivers. - Level controls and checks of any eventual leakage from the fuel, cooling and lubricating circuits. - Notify the maintenance if any inconvenience is detected of if any filling is necessary. After engine start and while engine is running, proceed with the following checks and controls: - check presence of any eventual leakage from the fuel, cooling and lubricating circuits. - Verify absence of noise or unusual rattle during engine working. - Verify, using the vehicle devices, the prescribed pressure temperature and other parameters. - Visual check of fumes (colour of exhaust emissions) - Visual check of cooling liquid level, in the expansion tank.
MAINTENANCE PROCEDURES Checks and inspections Engine oil level check The check must be executed when the engine is disconnected and possibly cool.
Figure 1
The check can be made using the specially provided flexible rod. Draw off the rod from its slot and check that the level is within the etched tags of minimum and maximum level. Whether it should be difficult to make the evaluation, proceed cleaning the rod using a clean cloth with no rag grinding and put it back in its slot. Draw it off again and check the level. In case the level results being close to the tag showing minimum level, provide filling lubrication of the engine's components. Always ensure the oil added has the same characteristics of the oil contained in the sump. Mixing is not allowed as this would not guarantee correct lubrication of the internal parts of the engine. 166058
To provide filling, operate through the upper top or through the lateral top (2, Figure 1). During filling operation, the tops must be removed as well as the rod in order to make the oil flow easier”.
The engine oil is highly polluting and harmful. In case of contact with the skin, rinse well with water and detergent. Adequately protect the skin and the eyes, operate in full compliance with safety regulations. Disposal must be carried out properly, and in full compliance with the law and regulations in force. Base - May 2012
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F4AE ENGINES
Combustion system inspection The check must be executed both when the engine disconnected and when it is running. The check operation consists in examining the fuel pipelines running from the tank to the pre-filter (if provided in the specific equipment), to the filter, to the high pressure pump and to the rail diffuser and from this last one to the head. Special attention must be paid to the connections on the high pressure pipelines. Due to the high pressure within the pipelines running from the high-pressure pump to the rail diffuser and from this last one to the electro-injectors, special attention must be aid also in checking presence of any leakage or blow-by. Protect the eyes and the skin from any eventual high pressure jet: these may deeply penetrate under the skin surface provoking serious poisoning.
SECTION 4 - SCHEDULED MAINTENANCE
5
Lubricating system inspection The check must be executed both when the engine disconnected and when it is running. Verify the presence of any oil leakage or blow-by from the head, from the engine pan of from the heat exchanger.
The engine oil is highly polluting and harmful. In case of contact with the skin, rinse well with water and detergent. Adequately protect the skin and the eyes, operate in full compliance with safety regulations. Disposal must be carried out properly, and in full compliance with the law and regulations in force.
Inspection of water presence within fuel filter or pre-filter
Cooling system inspection The check must be executed both when the engine disconnected and when it is running. Check the pipelines from the engine to the radiator, from the expansion tank and vice-versa. Find out any blow-by, verify the status of the pipes specially close to the holding strips. Verify that the radiator is clean, the correct working of the fan flywheels, the presence of any leakage from the connectors, from the manifold and from the radiating unit.
Due to the high temperatures achieved by the system, do not operate immediately after the engine's disconnection, but wait for the time deemed necessary for the cooling. Protect the eyes and the skin from any eventual high pressure jet of cooling liquid.
The density of the cooling liquid must be checked any how every year before winter season and be replaced in any case every two year. NOTE In case of new filling, proceed bleeding system, through the bleeds on the engine.
NOTE The components of the common rail system can be damaged very quickly in presence of water or impurity within the fuel. Timely proceed operating on the pre-filter (not available on the engine block) to carry out the drainage of the water within the feed circuit.
Inspection of drive belt tensioning The drive belt tensioning control is made using an automatic tensioning device therefore no intervention is required apart from checking the wear status of the belt itself.
Check of belt's tear and wear status Carefully verify the belt's surface in order to detect any sign of incision, crack, excessive wear in correspondence of toothing; check end and surface grinding.
Danger: if the engine is switched off but is still hot, unexpected motion of the belt may occur. Wait for engine temperature cooling as a precaution in order to avoid serious danger injury.
If bleeding of the system is not carried out, serious inconvenience might be caused to the engine due to the presence of air pockets in the engine's head.
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Base - May 2012
6
SECTION 4 - SCHEDULED MAINTENANCE
F4AE ENGINES
Inspection/replacement of blow-by filter The filter in subject has been developed and equipped for the collection, filtering and condense of the lubricating oil vapours.
NOTE To carry out rocker arm - valve clearance adjustment more quickly, proceed as follows:
Within the filter unit (1) two cartridge filters are included (2).
- Rotate the crankshaft, balance cylinder 1 valves and adjust the valves marked by the asterisk as shown in the diagram:
Figure 2
cylinder no. intake exhaust
1 -
2 *
3 * -
4 *
5 * -
6 * *
- Rotate the crankshaft, balance cylinder 6 valves and adjust the valves marked by the asterisk as shown in the diagram:
1
2 74188
cylinder no. intake exhaust
1 * *
2 * -
3 *
4 * -
5 *
4 -
The check of the filtering element is carried out by removing the cover and drawing off the cartridges (2).
Inspection tappet clearance Figure 3
166059
Check the clearance between the rocker arms and valves using a feeler gauge (1). Clearance shall be as follows: - intake valves 0.25 0.05 mm - exhaust valves 0.50 0.05 mm.
Base - May 2012
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F4AE ENGINES
Oil motor and oil filter replacement
Warning: We recommend to wear proper protections because of high motor service temperature. The motor oil reaches very high temperature: you must always wear protection gloves.
Due to the several applications, the pan shape and the oil quantity can change slightly. However, the following operations are valid for all applications.
SECTION 4 - SCHEDULED MAINTENANCE
7
Whereas you replace the lubrication oil, it is necessary to replace the filter. According to the application the filter can be located in different positions: the following procedure is a valid guide for all applications. - The filter is composed by a support and a filtering cartridge. For the cartridge replacement use the 9936076-tool.
Warning: the oil filter contains inside a quantity of oil of about 1 kg. Place properly a container for the liquid.
We recommend to carry out the oil drainage when the motor is hot.
Warning: avoid the contact of skin with the motor oil: in case of contact wash the skin with running water.
- Place a proper container for the oil collecting under the pan connected with the drain plug.
The motor oil is very pollutant: it must be disposed of according to the rules.
- Unscrew the plug and then take out the control dipsick and the inserting plug to ease the downflow of the lubrication oil.
The oil motor is very pollutant and harmful.
- Replace the filtering cartidge with a new one and screw manually until when the gasket is in contact with the support.
In case of contact with the skin, wash with much water and detergent.
- Tighten further using tool 99360076 to a torque of 20±2 Nm.
Protect properly skin and eyes: operate according to safety rules.
- Operate the motor for some minutes and check the level through the dipsick again. If it is necessary, carry out a topping up to compensate the quantity of oil used for the filling of the filtering cartridge.
Dispose of the residual properly following the rules.
- After the complete drainage, screw the plug and carry out the clean oil filling.
!
Use only the recommended oil or oil having the requested features for the corrrect motor functioning. In case of topping up, don't mix oils having different features. If you don't comply with theses rules, the service warranty is no more valid.
- Check the level through the dipsick until when the filling is next to the maximum level notch indicated on the dipsick.
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Base - May 2012
8
SECTION 4 - SCHEDULED MAINTENANCE
Fuel filter replacement
F4AE ENGINES
Alternator belt replacement (demonstration) Due to several applications the belt run can change very much.
During this operation don't smoke and don't use free flames. Avoid to breathe the vapors coming from filter. Warning: with switched off motor (but still hot) the belt can operate without advance notice. According to the applications the filters position and the quantity can change.
Wait for the motor temperature lowering to avoid very serious accidents.
However the following operations are valid for all applications. - Drain the fuel inside the filter by operating the water release screw. Collect the fuel in a container without impurities. - Unscrew the cartridge by using the 99360076-tool. - Collect the eventual fuel inside the filtering cartridge. - Clean the gasket seat on the support and oil slightly the gasket on the new filtering cartridge.
For applications with automatic belt stretcher, the procedure is the following: Figure 4
- Screw manually the new filtering cartdrige until when the gasket is completely on its seat. - Tigthen through the 99360076-tool at 20 ± 2 Nm torque.
176526
- Operate on the tightener (1) and withdraw the belt (2) from the alternator and water pumps from pulleys and from the returns pumps. - Replace the worn belt with a new one. - Place the belt on the pulleys and the guide rollers. - Place the automatic tightener in order to key the belt in the functioning position. - Further adjustments are not required.
Base - May 2012
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F4AE ENGINES
SECTION 5 - DIAGNOSTICS
1
SECTION 5 Diagnostics Page
Print P2D32N020 E
PREFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
PT BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
PT-BOX INSTRUCTIONS . . . . . . . . . . . . . . . . .
5
- Hardware installation . . . . . . . . . . . . . . . . . . . .
5
- Software installation . . . . . . . . . . . . . . . . . . . . .
7
- Software Interface . . . . . . . . . . . . . . . . . . . . . .
18
- Acceptance . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
- ECU diagnosis . . . . . . . . . . . . . . . . . . . . . . . . .
26
- Programming . . . . . . . . . . . . . . . . . . . . . . . . . .
35
- Active diagnosis . . . . . . . . . . . . . . . . . . . . . . . .
38
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . .
40
N40 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . .
40
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . .
81
N60 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . .
81
GUIDE TO DIAGNOSIS THROUGH SYMPTOMS . . . . . . . . . . . . . . . . . . . . . . . . . .
121
Base - May 2012
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SECTION 5 - DIAGNOSTICS
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F4AE ENGINES
PREFACE A successful troubleshooting is carried out with the competence acquired by years of experience and attending training courses. When the user complains for bad efficiency or working anomaly, his indications must be kept into proper consideration using them to acquire any useful information to focus the intervention.
SECTION 5 - DIAGNOSTICS
3
Every time there is a breakdown claim and this breakdown is actually detected, it is necessary to proceed inquiring the electronic unit in one of the ways indicated and then proceed with the diagnostic research making trials and tests in order to have a picture of the working conditions and identify the root causes of the anomaly. In case the electronic device is not providing any indication, it will be necessary to proceed relying on the experience, adopting traditional diagnosis procedures.
Using FPT processing instruments, it is also possible to establish a bi-directional connection with the central unit, by which not only to decoding the failure codes but also input an enquiry relying on memory files, in order to achieve any further necessary information to identify the origin of the anomaly. NOTE Any kind of operation on the electronic center unit must be executed by qualified personnel, duly authorized by FPT. Any unauthorized tamper will involve decay of after-sales service in warranty.
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Base - May 2012
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SECTION 5 - DIAGNOSTICS
F4AE ENGINES
PT - BOX PT - BOX is a test tool to be connected to a Laptop.
Figure 1
120995
1. Data flow lamps (blinking) - 2. Ignition indicator - 3. USB indicator - 4. Operation indicator - 5. Serial port indicator 6. ”Error” indicator - 7. CAN line indicator - 8. Line K indicator for automatic management PT-BOX functions: -
ECU ID reading;
-
Failure memory reading;
-
Flight recorder reading;
-
Parameters reading;
-
Failure memory cleaning;
-
Active diagnosis: actuators activation/testing;
-
Programming of repalced components and parameters/second level;
-
Acquisition/Saving of parameters
Base - May 2012
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F4AE ENGINES
PT-BOX INSTRUCTIONS Hardware installation
!
This Sw may cause engine start-up. Be extremely careful. The user is responsible for the correct use of the PT-DIAGNOSIS software so as not to any cause injury to people or damage to items. The user is also responsible for complying with all the rules relating to security for activities on the industrial applications (engine, pump, generating set) carried out in the workshop. Carefully read the user manual before using the diagnostic tool and follow the instructions displayed on the screen.
SECTION 5 - DIAGNOSTICS
5
Select your user configuration type and then follow the relevant information. 1. PT-PLUS configuration - PC Panasonic user - PT-BOX module - PT-DIAGNOSIS sw 2. PT-DIAGNOSIS configuration - user with own PC - PT-BOX module - PT-DIAGNOSIS sw The PT-BOX module (Electronic Communication Interface) PT-BOX is an interface module allowing the communication between the engine ecu's and the PC. - Weight: 500 g; - Dimension: 175x75x30mm;
General rules for use
- Flash memory: 4Mb - RAM 1Mb;
The following instructions should always be strictly followed:
- Thermal tolerance: 0-50 °C;
-
- Power supply: 6-32V;
all instruments ensuring the security must be applied as indicated in the application;
-
ensure that the PT-BOX module is connected to the diagnostic socket of the engine on which work is to be carried out;
-
in case of emergency, disconnect the PT-BOX module from the engine or disconnect the USB cable;
-
ensure that while using the software, there is nobody near the engine/vehicle you are working on;
-
if it is necessary for more than one person to be working on or near the engine/vehicle, they are all responsible for complying with security regulations of the workshop;
-
we strongly suggest that the PT-BOX modules be visibly and uniquely identified (for example by using coloured adhesive tape, labels with names, etc).
!
By only accepting the use disposal it is possible to access PT-DIAGNOSIS (the green tick icon becomes active).
The diagnosis system consists of: -
a PC (Panasonic / your PC + Microsoft Windows 2000 or Windows XP Professional);
-
an instrument used as interface between engines/vehicles and PC (PT-BOX tester);
-
a SW program (PT-DIAGNOSIS) to process data.
By combinating the above indicated components 2 different configuration are possible.
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- Connection interfaces: USB and RS232 standard Bluetooth optional; - Interface for engine electronic systems: 9 KL ISO 9141 lines - 2 channels CAN Bus 2.0B - 3 digital outputs - 3I/O PWM. The led indicators on the front view allow to check the communication lines activity with the engine and with the PC to which the instrument is connected. Figure 2
156133
1. Led indicators to display the activity of the communication lines K/L. - 2. The upper led display the ECU's communication activity. - 3. The lower led indicators display the CAN lines activity. - 4. The three upper led indicators show the activity of the K/L communication lines. - 5. The lower led indicator (fault) shows the presence of errors on the K/L lines. - 6. The upper led indicator shows that the PT-BOX is power-supplied. - 7. When blinking the lower led indicator (run) shows that the PT-BOX module is correctly working. - 8. Led indicators to display the USB ports (upper led). - 9. Led indicators to display the serial ports (lower led).
Base - May 2012
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SECTION 5 - DIAGNOSTICS
F4AE ENGINES
PT-BOX - engine/vehicle connection
Connect the PT-BOX module On the PT-BOX module there are the communication ports for the connection to the PC and to the engine / vehicle.
Figure 6
Communication ports for the connection to the PC Figure 3
156138
-
connect the module to the engine/vehicle by using the specific connection cable.
156135
1. serial port - 2. USB port
NOTE
Figure 4
The module is power-supplied by the diagnostic cable; for this reason to work correctly it must be connected to the engine.
System requirements Minimum -
Processor: 300 MHz Pentium-II CPU;
-
Hard disk space: 3 GB available;
-
Ram: 256 MB;
-
Display: 800 x 600 video adapter and monitor;
-
Internet connection only needed for rss and pt-diagnosis software update (eaus): modem;
-
External ports: USB connector;
-
External reader: DVD-ROM reader;
-
Os: Microsoft WindowsTM XP Professional Service Pack 2 - Microsoft Windows 2000 Service Pack 4 plus Windows 2000-KB835732-x86-ENU.EXE (login with administrator privileges);
-
Browser: Internet Explorer 5.5.
156136
Connector for the connection of the engine communication cable. PT-BOX - PC connection Figure 5
Recommended -
Processor: 1 GHz Pentium IV - Centrino CPU;
-
Hard disk space: 5 GB available;
-
Ram: 512 MB;
-
Display: 1024 x 768 high colour video adapter and monitor;
-
Internet connection only needed for rss and pt-diagnosis software update (eaus): high-speed e.g. ADSL;
connect the USB cable (PT-BOX side marked) to the PT-BOX module (remove the holding screws from the PT-BOX module, where present);
-
External ports: 2 USB 2.0 connectors, Bluetooth;
-
External reader: DVD-ROM reader;
-
connect the USB cable to the PC;
-
-
turn the PC on.
Os: Microsoft WindowsTM XP Professional - Service Pack 3 (login with administrator privileges);
-
Browser: Internet Explorer 6.0.
156137
-
Base - May 2012
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F4AE ENGINES
SECTION 5 - DIAGNOSTICS
7
Software installation Registration Before using the PT-Diagnosis system you have to carry out the registration of the system being used. This procedure allows you to obtain the activation code. The registration procedure is carried out on-line and it is different according to the user type: - OEM users - Dealer users
NOTE
For both configurations (PT-PLUS and PT-DIAGNOSIS) the SW installation is the same. -
A fill-in form is displayed.
Registration>OEM users
!
Before using the PT-Diagnosis system you have to carry out the registration of the system being used. This procedure allows you to obtain the activation code. For this reason: -
Check that the registration card has been delivered together with the kit.
-
Select www.eltrac.it/ivecomotors/default.asp.
-
From the starting page, select the language.
-
Select pt users registration.
Print P2D32N020 E
The activation code received will be requested the first time you run the PT-DIAGNOSIS software.
Registration form (OEM user) The Registration allows you to download the EVCA SYNC WEB application which allows you to obtain the activation code:
In the registration form: 1.
Enter the Customer PIN: it is the customer authentication code; it is an alphanumeric code sent by e-mail to the user after having bought the PT-DIAGNOSIS system.
2.
Select the send key: the identification data and the Network characteristics areautomatically entered.
3.
Enter the serial number of the PT-BOX instrument.
Base - May 2012
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SECTION 5 - DIAGNOSTICS
F4AE ENGINES
Figure 7
NOTE
Before carrying out the registration we suggest to install the PT-Diagnosis SW.
Installing the EVCA SYNC WEB (OEM users) application To obtain the activation code it is necessary to install the EVCA SYNC WEW application, after saving it on the desired directory:
156139
The serial number is type PB-#####-##-##-##; to be found on the back of the PT-BOX module 4.
Read the note in compliance with art. 13 of Italian Legislative Degree 196 dated 30 June 2003 about the processing of personal data Informative
5.
Select the send key (only once!) wait
After sending a summary window is displayed waiting for the end of the registration procedure.
1.
Unzip the evcasyncweb1.2.6.zip (for example using WinZip: www.winzip.com/downwz.htm).
2.
Open the EVCASyncWeb1.2.6 EVCASyncWeb15-09-10 (Rel1.2.6).
3.
Run setup.exe and continue with the installation of the guided application.
NOTE
and
then
For further information about the installation of EVCASyncWeb it is possible to read the detailed guide EVCASyncWeb Setup.pdf in the directory EVCASyncWeb1.2.6.
Then a link is available to download the EVCA SYNC WEB application. It will be used to obtain the activation code: 6.
Select the print key for printing a summary report (registration data and number of registered instrument).
7.
Select the link to download and then select the save key, to save the application on the PC.
Base - May 2012
4.
At the end of the installation, the icon of the EVCASyncWeb application is displayed on the desktop of the PC.
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F4AE ENGINES
SECTION 5 - DIAGNOSTICS
9
Running the EVCA SYNC WEB (OEM user) application
1.
3.
Enter the PT-BOX serial number of and the Customer PIN.
4.
To continue, select the confirm key.
5.
Enter the alpha code supplied with the Registration Card (scrap the card).
6.
To continue, select the confirm key.
Double click on the icon EVCASyncWeb application.
At the start up of the application choose the Internet connection mode: - by means of the Proxy Server; it is necessary to enter the connection parameters; at the end select the okey. It is possible to pre-set the connection parameters: read the EVCASyncWeb manual; - without Proxy Server; select the okey.
The starting page EVCASyncWeb is displayed; some functions are available (for more information read the manual EVCASyncWeb). 2.
Select the applications key for pc.
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SECTION 5 - DIAGNOSTICS
F4AE ENGINES
Summary of the selected choices (OEM user) At the end of the activation procedure, the summary of the selected choices is available. The following data are displayed:
Contract Activation (OEM User) 7.
Select a contract type.
The contract types available for the OEM users are indicated below: - Fee (annually): the duration of the contract is for one year, starting from the activation date of the contract. During this phase it is only possible to associate one instrument to the contract. - Token (to be deducted): it is the payment for a single download of an application; it is possible to associate to the contract to 4 instruments. 8.
To continue, select the confirm key.
- The type of selected contract. - The list of instruments (PT/PB) associated to the contract with the generated activation codes - The expire date of the contract (in case of yearly fee) or residual credit (coins): 1.
We suggest you to print and keep the summary data: select the key print selections recap.
2.
Show and download the list of the available applications belonging to your profile (FPT activation): select the applications download key.
The window containing the activation codes is displayed. 9.
Print/copy the activation codes and keep them together with the instruments they are associated to.
10. Select the okey to end.
Base - May 2012
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Download the applications
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11
Registration>Dealer users Before using the PT-DIAGNOSIS diagnosis system you must register on the FPT web site.
The following information for each one of the available applications for downloading is displayed: ECU, license, file name, Release Date, Release Type and short description.
1.
Connect to http://www.fptpowertrain.com/index_main.htm.
2.
Select the language.
3.
Select Fiat Powertrain Technologies and then Partner Area.
4.
Connect to the web site by selecting Click here.
Each option can be used to sort the list: to sort the list in ascending/descending order according to a given key, select the title of the corresponding column. 1.
Select the application to be downloaded; the selected line is highlighted in red.
2.
Select the download the selected application key and follow the system instructions.
3.
Identify the path where the packets have been downloaded.
4.
At the end of the download install the packets (double click) one by one.
NOTE
The packets must be downloaded/installed one by one.
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5.
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Fill in the fields for the login procedure.
7. NOTE
For the new customers: request username and password
[email protected].
Go to the registration web page; select pt users registration a fill-in form is displayed (on-line registration form).
to
For the customers already registered: use username and password received by e-mail.
Registration form (Dealer user) The Registration allows you to download the EVCA SYNC WEB application which allows you to obtain the activation code.
In the registration form:
6.
Please follow the indicated instructions After Sales>Various>Diagnostic Instruments>Diagnostic Tools
Base - May 2012
1.
Enter the Customer PIN: it is the customer authentication code; it is an alphanumeric code sent by e-mail to the user after having bought the PT-DIAGNOSIS system.
2.
Select the send key: the identification data and the Network characteristics are automatically entered.
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SECTION 5 - DIAGNOSTICS
3.
Fill in the yellow field by entering the alpha code supplied with the Registration Card (scrap the area on the card).
4.
Enter the serial number of the pt-box instrument.
6.
13
Select the send key (only once!) wait
After sending a summary window is displayed waiting for the end of the registration procedure. Wait for the following window: - the activation code; - the link to download the EAUS application (EAsy Update Software). 7.
Print the activation codes (print key) and keep them together.
8.
Select the link to download the EAUS application.
Installation of EAUS application (Dealer user) The EAUS application is an update utility to automatically download all SW Updates for all ECU's activated for FPT. After having selected the link for downloading the EAUS application, the system asks you to select the file or to directly run it.
Figure 8
156139
The serial number is type PB-#####-##-##-##; to be found on the back of the PT-BOX module. 5.
Read the note in compliance with art. 13 of Italian Legislative Degree 196 dated 30 June 2003 about the processing of personal data Informative.
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1.
Select the run key: the system automatically downloads first and then installs the EAUS application; run the operation required by the system and wait for the end of operation.
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Connection Figure 9
156138
2.
Select the end key to exit the installation.
NOTE
1.
Connect the PT-BOX module to the engine/vehicle using the diagnosis cable.
2.
Connect the PT-BOX module to the PC, using one of the two USB cables provided with the module.
Before carrying out the registration we suggest to install the PT-Diagnosis SW.
!
The PT-BOX module is supplied by the diagnosis cable; therefore it must be connected to the engine/vehicle to be able to work. Figure 10
Run the EAUS (Dealer user) application
156140
3.
Switch the PC on.
PT-BOX module USB driver set-up (only for the PT-DIAGNOSIS configuration) This operation is required only if the PC in use has never been connected to an PT-BOX module:
1.
It is now possible to download the update by using the Automatic Update Function (tools>software update key).
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1.
Check that the PT-BOX module is correctly connected to the PC via the USB cable.
2.
The PC acknowledges the presence of a new hardware component; press the cross button to continue.
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3.
4.
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5.
Select the have disk> button to continue.
6.
Enter the path: ProgramFiles\EltracECI\Driver\PT-BOX.sys; select the ok button.
7.
Select the next> button to continue.
15
Automatically (Windows XP) the procedure starts to set-up the driver; select the Install from a list or specific location option; select the next> button to continue.
Select the Don't search. I will choose the driver to install; select the next> button to continue.
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8.
Driver set-up begins wait.
9.
The procedure is completed; press the finish button.
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4.
The system asks you to enter the activation code received from Field Service; select the tick button.
5.
Enter the activation code sent via Web.
6.
Select the register button; a message confirms that registration has taken place.
7.
Select the cross button to close the Activation Code window and go back to the PT-DIAGNOSIS screen.
8.
Select the stop button and restart PT-DIAGNOSIS.
10. The system informs that the new hardware has been correctly installed; select the cross button to continue. 11. Re-start the PC.
Activation - first time of use of PT-DIAGNOSIS sw + PTBOX module The first time the PT-DIAGNOSIS Diagnosis System is used, it is necessary to follow the procedure described below: 1.
Make sure you possess the activation codes (Web access).
2.
Connect the PT-BOX module to the Panasonic PC and to the engine/vehicle using the USB/BT module.
3.
Start the Panasonic PC.
Now all the software functions are available.
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17
Activating - new PT-BOX module The activation procedure is necessary every time you want to use an PT-BOX module that has not yet been paired to the PT-DIAGNOSIS diagnosis system in use; follow the operations described below:
1.
Make sure you have requested and obtained the activating code for the PT-BOX module.
2.
Connect the PT-BOX module to the Panasonic PC and to the engine/vehicle using the USB cable.
3.
Start the PT-DIAGNOSIS software: double click on the EASY icon (PT-DIAGNOSIS) placed on the desktop of PC.
4.
Select the tools>activations button.
5.
Select the entry button.
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6.
Enter the activation code received from Field Service.
7.
Select the register button; a message confirms that registration has taken place.
8.
Select the cross button to end activation.
9.
Re-start the PT-DIAGNOSIS (E.A.SY. icon).
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Software Interface The PT-DIAGNOSIS software interface is designed to facilitate access to tools, view functions and make diagnostic procedures clear and adaptable to various needs. All windows follow the same design with additional features which depend on the specific working environments. Each window presents three main areas to which specific functions are univocally associated: - Keys Area - Title Area - Operative Area
The Title area shows the selected function under test and previous choices by which you arrived.
The Keys area contains Keys for accessing the operative environments and the functions to which they are associated.
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The Operative area contains available system and function list referred to the intervention area.
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To go from one environment to another
1.
3.
Select the Class and the System under test to which the engine/ vehicle belongs; then press the navigation key (is active - green) to continue.
4.
The window Choose Activity appears; it is here possible to choose from four lists.
The Start Window shows the family.
Start Window - It is possible to select a new family or to choose a family from the database; - green identifies a pull-down menu.
Window Choose Activity It is now possible to choose: - diagnosis; - test; - programming; - specific functions. Navigation keys 2.
Select the fami ly of the engine/vehicle under diagnosis; then press the navigation key (is active - green) to continue.
Family Choice Window
They allow you to go from one environment to another. Enabled keys are displayed in green and disabled keys are displayed in grey. navigation key forward disabled
- Yellow identifies a selected item in a pull-down menu; - a paged list is used to display a large amount of information one page at a time; navigation tools are available to navigate from page to page.
navigation key forward enabled navigation key back enabled Database key It allows you to access the Database environment.
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Browse key To scroll long lists which cannot be contained in a single window.
ignition key
Detail of Keys area In the Start Window the Keys area contains the Keys for accessing the functions which are always available:
For the equipped engines, it allows you to operate engine ignition directly via the diagnostic tool. Two positions (stop and mar) and three states (enabled stop, disabled stop, enabled mar) are possible.
communication panel It indicates that the communication with the ECU is active or that the ECU is not present (no ecu). The lower leds indicate the communication state of the electronic system as shown below: Square LEDs: two states (green/red); green indicates that communication with the electronic system has been initialised; if red indicates the communication has been interrupted. Rectangular LEDs: blinking indicate that data exchange between electronic system and diagnostic system is in progress. Utilities key
stop key To quit PT-DIAGNOSIS application at any time.
engine/vehicle key It allows you to return to the Family Choice Window.
utilities key When selected the Key background will be yellow and allows you to access a menu.
guide to diagnosis key It allows you to access the environment Guide to Diagnosis (only available for some ranges). It is available in the Electrical Control Units environment.
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Teleservices key It allows you to access the remote connections services. Activations key It allows you to access the management function of the activation codes. Select the measure unit key It allows you to choose the measure unit system.
Electronic control units key It allows you to access the Electronic Ecu's environment. The key appears on a yellow background (default status, environment Electronic Control Units enabled) or on a grey background (environment Electronic Control Units disabled). If you want to work at the same time with more Ecu's, select the key environment electronic ecu's>add ecu.
Electrical diagrams key The Metric System (SI), the international standard one, is based on the meter, kilogram and second. The British System (fps) is based on the foot, pound and second. Select language key
It refers to a CLASSES list for which an electrical diagram is available. The key appears on a yellow background (environment Electrical Diagrams enabled) or on a grey background (environment Electrical Diagrams disabled). To enter the Electrical Diagrams environment select the key electrical diagrams area.
To change the language; restart the application to make the setting operational. Software update key It allows you to carry out the automatic update of the PT-DIAGNOSIS software. Eci management key It allows you to manage the connection (usb or Bluetooth) PT-DIAGNOSIS - PT-BOX module.
Report key It allows you to access the Report environment. The key appears on a yellow background (environment Report enabled) or on a grey background (environment Report disabled). To access the Report environment select the report key.
On/Off-line key
In the Start Window select the fami ly; by pressing the navigation key forward it is possible to access the next window. New icons appear in the Keys area for accessing specific functions:
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It can be on-line or off-line. The on-line key indicates that the PT-Diagnosis SW uses the PT-BOX/PC module connection. The off-line key indicates the PT-Diagnosis SW is working in simulated mode. To change the status select the key.
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Acceptance key search
Environment DataBase From the PT-DIAGNOSIS start window it is possible to select a new engine or to select one from the database.
It allows you to search an engine by applying a filter (DATE, engine mode l, CUSTOMER or NUMBER PLATE).
key delete search It cancel the filter; it is active only after a search.
key order It orders the list according to the selected ordering criterion.
key report It gives access to the summary environment; enabled after selecting an engine.
1.
2.
Select the database button: you access the DataBase environment (it contains the list of accepted engines).
The list of accepted engines is available. They can be search by means of the following keys:
key delete It deletes the selected engine from the database; it is active only after selecting an engine.
- DATE
3.
Select an engine from the list (the background is yellow); it is possible:
- ENGINE MODEL
-
to analyse engine data (report button);
- CUSTOMER
-
to start again the diagnosis procedure on the engine (navigation button forward);
-
to return to the start window (navigation button back).
- NUMBER PLATE
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How to order the engines list
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3.
23
If required, enter the word or the code to be searched and confirm by selecting the tick icon.
To cancel the search and display all elements from the archive select the cancel search key.
For the selection of a new engine see ECU Diagnosis.
!
1.
Select the order key.
2.
Select the order method. - DATE - ENGINE MODEL - CUSTOMER - NUMBER PLATE
Environment Report How to search for an engine from the database
When the engine sheet of the engine under test has been saved in the Report Environment, the engine has been accepted. You access the Report environment in the following ways:
1.
Select the search key.
2.
Select the search method. - DATE - ENGINE MODEL - CUSTOMER - NUMBER PLATE
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- from the Buttons area at any time by selecting the corresponding button; - from the DataBase environment by selecting the required engine and the report button.
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Environment Report
ENGINE DATA KEY: engine identification data; the fields can be always changed (with the exception of the engine model and the date) can be always changed
SAVE KEY: it allows you to save the engine sheet (to accept it)
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DIAGNOSIS REPORT LIST KEY: summary of all performed diagnosis operations
PROGRAMMING REPORT LIST KEY: summary of all performed programming operations
AUTOMATIC ACCEPTANCE KEY: (enabled only if the communication is active)
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Acceptance The acceptance (sheet saving) is mandatory when important operations are performed on the engine (read or cancel faults memory, programming).
1.
Read or cancel the faults memory or carry out a programming and then select from the corresponding environment the report button; you enter the Report environment.
2.
Enter data.
3.
Save the sheet by selecting the save button.
4.
From the Buttons area select the button of the operation you want to perform.
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When you read or cancel the faults memory or carry out a programming it is not possible to return directly to the window Family Choice; by selecting the engine button the following windows are displayed:
1.
Before continuing it is necessary to save the data of the performed activity; select the tick icon; the Report environment appears.
2.
Enter data.
3.
Save the sheet by selecting the save button.
It is now possible to return to the Family Choice window.
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Automatic acceptance From the Report environment it is also possible to accept the engine automatically.
! 1.
This operation is only possible if the communication with the system has been activated.
Read or cancel the faults memory or carry out a programming and then select from the corresponding environment the report button.
5.
The automatic information:
acceptance
reads
the
following
- Engine Model (engine type + engine serial number) - PIC - Engine type - Engine Serial Number 6.
2.
You enter the Report environment.
3.
Select the button automatic acceptance.
4.
At the select the save key.
ECU diagnosis
1.
Sselect the Family, the Class and then the System of engine under diagnosis.
2.
Press the navigation button forward (enabled - green) to continue.
By means of the automatic acceptance the system tries to communicate with the engine ECU: confirm the displayed message by pressing the tick icon; wait until the ECU is ready.
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3.
The window Choose Activity appears; it is here possible to choose from four lists:
SECTION 5 - DIAGNOSTICS
2.
Window Choose Activity - diagnosis - test - programming - specific functions
4.
27
PT-DIAGNOSIS system presents a pop-up window where to select the automatic or the manual activation of the ignition key; select the required mode; the key button is disabled.
Under the automatic mode all activation of the ignition key are controlled by the diagnosis instrument (key button working). Under the manual mode all activation of the ignition key are controlled by the operator on the engine.
The present Repair Guide describes the diagnosis environment and the specific functions to which it is associated: - Identification Code Reading - Faults Memory Reading - Parameters Reading
Identification code reading 3.
1.
Confirm the new message by pressing the tick icon.
To access the Read Identification environment select the item Identification Code Reading from the Diagnosis list and then press the navigation button forward.
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Multitasking option report key Shows the Diagnosis Report List (and allows you to print each report).
print key Prints the summary page of Identification Parameters.
4.
PT-DIAGNOSIS introduces a very important news: it is possible to associate more ECU's to the family of engine under test. Add an ecu It is possible to interrupt the diagnosis with an ECU and to start the procedure with another one.
Wait until the ECU is ready; the general information about the electronic system under test is read: - identification code - HW version - SW version
1.
- production date - After identification code reading it is possible to carry out other activities (step 5) or to return to the window Choose engine (step 6).
Select the button ecu's area>add ecu; the Choose Vehicle window will appear, where you can select the desired ECU.
Managing more ecu's It is possible to operate with two or more connected ECU's at the same time.
1.
Select the button ecu's area>desired ecu.
The activity remains interrupted for the not selected ECU's and can be started again at any time. Cancel an ecu 5.
To access the other activities from the environment Identification Code Reading, select the choose activities buttons: choose an activity; the system automatically access the selected activity.
It is possible to stop the activity on one of the connected ECU's.
The choose activities buttons are shown in yellow when selected.
6.
To exit the diagnosis of the engine under test select the button ecu's area>ecu under test>cancel.
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1.
Slect the button ecu's area>required ecu>cancel.
2.
Select the required ECU.
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Ignition Key Button Modes - on line/off line
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Read faults memory
At the system start up the on/off button is on-line if the PT-BOX module is activated and connected to the PC, otherwise is disabled (off-line). On line mode The function “Ignition Key” is active; it can be managed in automatic or manual mode; the ”ignition key” screen appears only after the selection of a function that requires it (e.g. diagnosis functions). In automatic mode all ignition key activations are managed by the diagnosis instrument. In manual mode all ignition key activations are managed by the operator on the engine. The automatic activation depends on the type of engine; make sure the engine supports the function before selecting automatic mode.
1.
After selecting the automatic mode a test procedure is carried out.
2.
Switch the ignition off.
3.
The engine chassis may move.
1.
To access the Read Faults Memory environment select the item Faults Memory Reading from the list Diagnosis and then press the navigation button forward.
2.
PT-DIAGNOSIS system presents a pop-up window where to select the automatic or the manual activation of the ignition key; select the required mode; the key button is disabled.
3.
Confirm the new message by pressing the tick icon.
The PT-DIAGNOSIS SW activates the ignition key and displays a screen page in which it asks to check the dashboard; if it is turned ”on” the diagnosis procedure can be continued; otherwise the system asks for position of the key to ON in manual mode. Both in manual and in automatic mode: 1.
Before ignition key activation a message is always displayed: request (manual mode) or warning (automatic).
2.
When the ECU is cancelled a message indicates that it is necessary to interrupt the communication and then to confirm the operation.
3.
The chosen mode remains until the engine under test is changed.
Off line mode The basis diagnosis is simulated and it is possible to read some information about the electronic system under test.
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cancel faults memory key It cancels the faults selected in the list; it is possible to cancel a fault at a time; the cancel operation will be effective when you confirm it by pressing the tick icon displayed in the next pop-up-window.
faults key It allows you to access the Faults environment; it can be yellow (the faults list is displayed) or gray (environment Faults disabled). 4.
Wait until the ECU is ready; the list and faults type occurred during the working are displayed. There are two types of failures: - failures present during the reading procedure (red); - intermittent failures not present during the reading operation but which occurred at least once before (black).
Detail of Buttons area of the Faults Memory area New icons appear in the window Read Faults Memory for accessing specific functions:
On line Mode Faults Memory Reading Icons environmental condi tions key Active when the communication with the ECU has been interrupted this is used to examine environmental conditions when the failure occurred. It can be gray (default status) or yellow (when selected).
repair guide key On line Mode Faults Memory Reading Icons on key The communication between the system and the ECU is active: it performs again the Faults Reading; it updates the ECU communication. Select the button to interrupt the reading. off key The communication with the ECU has been interrupted. Select the button to start again the electronic system reading.
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Active when the communication with the ECU has been interrupted it gives an analysis of the fault selected from the list; in particular other information (blink code, failure code and fault mode) is available it can be gray (default status) or yellow (when selected).
report key It allows you to save the report of carried out operations see Report environment > button diagnosis report.
print key It allows you to print the displayed window.
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31
Off line Mode
2.
Select the button environmental conditions.
Faults Memory Reading Icons
It examines the present environmental conditions at time of the fault.
blink code search key Appears only if the communication with the ECU interrupted is (under OFF LINE Mode) recognize the fault where blink code or required word appear. To go from one function to another (faults, environmental conditions, troubleshooting) select the corresponding button. Operations like Read and Cancel Faults Memory are very important: they are automatically stored and need the engine acceptance. How to get information about a fault 1.
Interrupt the communication with the ECU (button on/off) and select an item from the faults list: the fault is described in the below blank area; in particular the following information is available:
3.
Select the repair guide button; the following information is available: - the blink code - the failure code (DTC) - the failure mode (FMI)
Appears a new icon, the measures key measures key The Measurements pop-up window opens with a list of possible measurements and the relevant operating suggestions. - the fault - the signal type - the repetition type The button faults appears on yellow background because it is selected. Print P2D32N020 E
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Parameters reading
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3.
The read parameters are shown and the values assumed
4.
Select the groups key.
The groups key allows you to access the groups management functions (see group Management).
Detail of parameters buttons area New icons appears on the window Parameters Reading for accessing specific functions:
1.
To access the Parameters Reading environment select the item Parameters Reading from the Diagnosis List and then press the navigation button forward.
on key The communication between the system and the ECU is active: select the button to interrupt the reading. off key The communication with the ECU has been interrupted; select the button to start again the electronic system reading. 2.
PT-DIAGNOSIS system presents a pop-up window where to select the automatic or the manual activation of the ignition key; select the required mode; the key button is disabled.
groups key It opens the GROUPS window showing the list of created group (A) and the keys to create/modify the groups (B).
Pay close attention to the displayed messages and wait until the ECU is ready.
parameters acquisition key It allows to record the trend in time of the measurable parameters. report key It allows you to save the report of carried out operations. print key It allows you to print the displayed window. Base - May 2012
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Groups Management
SECTION 5 - DIAGNOSTICS
9.
33
From the drop down menu (above on the left), select one of the available parameter groups, excluding the parameter you are changing.
10. On the left-hand list the parameters of the selected group are shown; on the right-hand list the parameter of the group you are changing are shown. The parameters with a gray background on the left-hand list are parameters that have already been added and can not be selected.
5.
The Groups window opens.
The pre-defined parameter groups are first displayed then the customized ones; the pre-defined parameters (measurable and status) can not be modified.
11. To a parameter to the right-hand group, select it and confirm by pressing the right arrow key ( ). 12. To remove a parameter (from the right-hand list select it and confirm by pressing the left hand arrow key ( ). Select the save key to save and exit the groups management environment.
Create a new parameters group 6.
Select create.
7.
Enter the name of the group you want to create.
8.
Confirm by selecting the green tick icon.
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Modify a parameters group
1.
Select a customized parameters group.
2.
Select modify; the window for parameters groups management opens.
3.
Select the group you want to change and continue with step 9 (link).
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Cancel a parameters group
1.
Select a group of customized parameters
2.
Select delete; confirm or cancel the request.
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Window Store Parameter
2.
Select the sample time by using the arrows on the Sampling active area.
3.
Select the duration of registration by using the arrows key on the active area Duration.
4.
Select the key start/stop to start the registration (a new window open Notes where you can add a comment).
5.
Close the Notes window, the registration starts.
6.
Wait for the end of registration procedure (it is also possible to interrupt the registration, by using the stop key).
7.
Select the archive key: the Archive window open showing the list of available registration in the archive.
Appendix parameter acquisition key
1.
Select the parameters acquisition key; the window Store Parameter opens. The key is only active under on line mode.
Parameters reading
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SECTION 5 - DIAGNOSTICS
Archive window
35
- To display tables (horizontal or vertical). - To colour display the area indicated by the diagram. - Print. - To go back
Programming The consultation can be started To access the programming area of the ECU under test proceed as follows: 1.
From the Archive windows, select a registration; it is possible: - to cancel it (cancel key) - to read data (report key) - to show data (show key, opens the Data Reading window) - to print data (print key) - to save data in text format (save as key) - to go back (cross key)
Data Reading window
2.
1.
Select the Engine Family under diagnosis.
2.
Press the navigation button forward (enabled - green) to continue.
3.
Select the Class and the System under test to which the engine belongs; select the forward navigation key (enabled - green) to continue.
From the Archive window, select a registration and the show key; the Data Reading window opens; it is possible: - To select all parameters (fast selection key). - Deselect all parameters (fast deselection key). - To show the diagram with full-screen. - Increase, reduce or to bring back to the original display the time range (x-axle, seconds).
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4.
Select the programming option from the Programming list; select the forward navigation key (enabled - green).
7.
Read the displayed messages and select the green tick icon to continue.
5.
If required, enter the required data, by following the indicated procedure.
8.
At the end the system permits access to the Programming environment; the components list is displayed, on which tests can be carried out.
!
It is possible to carry out a programming only in online mode. In case of error check the connections ECU/PT-BOX/PT-DIAGNOSIS.
!
During the programming do not disconnect the USB cable. Before carrying out the ECU programming verify the charge left in the computer's battery. It is recommended to plug the PC in (connect it to the engine/vehicle or to the mains supply).
Programming environment It is possible to use specific functions, by selecting the corresponding key:
6.
Select the ignition key management (automatic/manual): if the electronic system engine under test is fitted with this function, select the automatic key.
- Data Reading
- PT-DIAGNOSIS shows the running activities.
- Programming
- The ignition key ON is automatically activated.
- PTO (only for the PT-DIAGNOSIS full version SW)
- Change the configuration
- The connection to the ECU starts.
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The available function types are determined according to the type of ECU under test. The Keys area contains the buttons for accessing the functions specific for the Programming environment.
37
Data Reading This is used to view the data concerning the ECU and the respective programming state; tampering attempts are shown.
The following are indicated: print key If enabled, select to print a report.
- station type and number; - programming date; - ECU software release.
cancel key If enabled, select to re-establish a configuration.
navigation keys If enabled, select to move between different environments.
cross key If enabled, select to cancel an operation. The system views the following data classes: - supplying data; - factory data (never updated); - service data (updated after each programming event).
scroll keys If enabled, select to scroll the list step by step.
fast scroll keys If enabled, select to scroll the list step by step.
Print P2D32N020 E
Base - May 2012
38
SECTION 5 - DIAGNOSTICS
F4AE ENGINES
Active diagnosis To start the Active Diagnosis
1.
Select the Engine Family under diagnosis.
2.
Press the navigation button forward (enabled - green) to continue.
!
5.
It is possible to carry out an active diagnosis only in online mode. In case of error check the following connections ECU/PT-BOX/PT-DIAGNOSIS.
Select the ignition key management (automatic/manual): if the electronic system engine under test is fitted with this function, select the automatic key. - PT-DIAGNOSIS displays some information about the activity in progress. - The ignition key ON is automatically activated. - The ECU connection starts.
3.
4.
6.
Read the displayed messages and select the green tick icon to continue.
7.
At the end the system permits access to the Active Diagnosis environment; the components list is displayed, on which tests can be carried out.
Select the Class and the System under test to which the engine belongs; select the forward navigation key (enabled - green) to continue.
From the Test list select the option acti ve diagnosis; select the forward navigation key (it is active, in green displayed).
Base - May 2012
Print P2D32N020 E
F4AE ENGINES
SECTION 5 - DIAGNOSTICS
39
Active Diagnosis environment The components of the selected electronic system are indicated in a list; use the browse keys to display all the elements of the list. 1.
Select the component on which the test will be carried out.
2.
Select the forward navigation key to continue and carry out the test.
Help key if selected it shows information about the electronic system under test; information about the guide to the diagnosis are not provided.
Components: selectable list
Browse key
Forward navigation key
Back navigation key It allows you to move one step back; if selected at this level it allows you to exit the Active Diagnosis environment.
Print P2D32N020 E
Base - May 2012
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
Power Red.
Mil.
SCRCatPlausIv
Terminal 15 failure
SCR Temperatures plausibility
$ 119
$ 11F
”Non”
Check wiring for correct installation and for short circuits
Temperature sensor downstream of catalyst is inaccurate or defective, defect in wiring (also check connectors)
Check wiring and signal of temperature sensor. Ensure complete cool down of vehicle (>10 hours) without sun exposure and and measure all 3 sensors signals. If temperature differences are above 20°C replace defective sensor
"catalyst monitoring"
Temperature sensor upstream of catalyst is inaccurate or defective, defect in wiring (also check connectors)
Check wiring and signal of temperature sensor. Ensure complete cool down of vehicle (>10 hours) without sun exposure and and measure all 3 sensors signals. If temperature differences are above 20°C replace defective sensor
No
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
"Mil OFF"
yes (OBD)
"Mil ON"
The fault codes depend on the application, therefore some may never be displayed during diagnosis.
T15CD
Due to a short circuit in the ignition switch the EDC is switched on, although T15 has not been activated.
SECTION 5 - DIAGNOSTICS
Vehicle 1 (Sensors/Plausibility checks)
40
DTC
FAULT CODES N40 ENGINE
Description
NOTE
Base - May 2012
Dfp Name
F4AE ENGINES
Print P2D32N020 E
SCRCatPlausIv
Description
SCR Temperatures plausibility
VSSCD2
Vehicle Speed Sensor failure
SCRCatAgeingIv
SCR Catalyst Thermal Ageing Limit exceeded
DTC
$ 11F
$ 211
$ 21D
Reason of Failure
Possible failure correction
Long TermFailure
Power Red.
Mil.
"catalyst monitoring"
Ambient temperature sensor or both upstream and downstream catalyst temperature sensors are inaccurate, defect in wiring (also check connectors)
If the ambient temperature sensor is inaccurate it is likely that the urea pump module (DTC $E4) and urea tank temperature (DTC $E5) are also reported implausible by the DCU. Check wiring and signal of temperature sensors. Ensure complete cool down of vehicle (>10 hours) without sun exposure and and measure all 3 sensors signals. If temperature differences are above 20°C replace the sensors which seem implausible.
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
yes (OBD)
"Mil ON"
"non"
Defective or incorrect functioning speed measuring device, see CAN message Tachograph Output (TCO1).
Check speed measuring device for proper functioning and for its CAN configuration
No
"Mil OFF"
"non"
Excessive ageing of SCR-Catatlyst
Replace catalyst and reset EEPROM value of catalyst ageing time via tester
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
"Mil OFF"
OBD-System
F4AE ENGINES
Print P2D32N020 E
Dfp Name
SECTION 5 - DIAGNOSTICS
41
Base - May 2012
SCRCatDCUStateIv
SCR Catalyst Efficiency below first threshold
DCU State Monitoring
DTC
$ 21E
$ 31D
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
”catalyst monitoring”
Measured catalyst efficiency lower than the estimated (NH3 slip present), inaccurate NOx measurement (value too high) downstream of catalyst, incorrect NOx estimation (value too low) upstream of catalyst, estimated catalyst efficiency too high (due to inaccuracies in the exhaust mass flow calculation, the estimated NH3 storage, temperature measurements upand downstream of the catalyst) or catalyst degradation, excessive urea deposits in exhaust system
Check urea dosing system for correct dosing amount (perform UDST and Dosing Valve Check, check DCU error memory for leakage failures), check accuracy of NOx-sensor and NOx-model (humidity, boost pressure and temperature) for plausible values, check NOx-conversion efficiency of catalyst, check exhaust system for excessive urea deposits
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
"catalyst monitoring”
Defect or abnormal behaviour of urea dosing system
Read out failure memory of the DCU and perform troubleshooting, check behaviour of urea dosing system closely
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
Power Red.
Mil.
SECTION 5 - DIAGNOSTICS
SCRCatNOxLvl1Iv
Description
42
Base - May 2012
Dfp Name
"Mil ON"
yes (OBD)
"Mil ON"
F4AE ENGINES
Print P2D32N020 E
SCRCatNOxLvl2Iv
Description
SCR Catalyst Efficiency below second threshold
DTC
$ 31E
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
Power Red.
Mil.
"catalyst monitoring”
Measured catalyst efficiency lower than the estimated (NH3 slip present), inaccurate NOx measurement (value too high) downstream of catalyst, incorrect NOx estimation (value too low) upstream of catalyst, estimated catalyst efficiency too high (due to inaccuracies in the exhaust mass flow calculation, the estimated NH3 storage, temperature measurements upand downstream of the catalyst) or catalyst degradation, excessive urea deposits in exhaust system
Check urea dosing system for correct dosing amount (perform UDST and Dosing Valve Check, check DCU error memory for leakage failures), check accuracy of NOx-sensor and NOx-model (humidity, boost pressure and temperature) for plausible values, check NOx-conversion efficiency of catalyst, check exhaust system for excessive urea deposits
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
yes (OBD)
"Mil ON"
F4AE ENGINES
Print P2D32N020 E
Dfp Name
SECTION 5 - DIAGNOSTICS
43
Base - May 2012
SCR Catalyst System Efficiency too high
DTC
$ 31F
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
"non"
Measured catalyst efficiency higher than the estimated (danger of NH3 slip), inaccurate NOx measurement (value too low) downstream of catalyst, incorrect NOx estimation (value too high) upstream of catalyst, estimated catalyst efficiency too low (due to inaccuracies in the exhaust mass flow calculation, the estimated NH3 storage, temperature measurements upand downstream of the catalyst), excessive urea deposits in exhaust system
Check urea dosing system for correct dosing amount (perform UDST and Dosing Valve Check, check DCU error memory for leakage failures), check accuracy of NOx-sensor and NOx-model (humidity, boost pressure and temperature) for plausible values, check exhaust system for excessive urea deposits
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
"Mil OFF"
No
"Mil OFF"
Power Red.
Mil.
SECTION 5 - DIAGNOSTICS
SCRCatHiEffIv
Description
44
Base - May 2012
Dfp Name
Vehicle 2 (Lamps/relays/actuators)
MRlyCD
Main Relay 2 failure (Grid Heater 1, Fan 1, VGT, Lambda Heater, EGR Bypass Valve, EGR Actuator, Blow By Valve))
$ 125
Short circuit of main relay 2 output to external source, defect in one of the connected components or defective main relay 2
Check the wiring and all components connected to main relay 2, if defect remains main relay inside ECU could be defective, replace ECU
Short circuit of main relay 2 output to ground, defect in one of the connected components or defective main relay 2o
Check the wiring and all components connected to main relay 2, if defect remains main relay inside ECU could be defective, replace ECU
"non"
F4AE ENGINES
Print P2D32N020 E
BattCD
MnRly1_SCB
MRlyCDMnRly3
Description
Battery Voltage failure
Main Relay 1 (High Pressure Pump) Short to Battery
Main Relay 3 failure (A/C Compressor, Fuel Filter Heater, Intercooler Bypass Valve, Additive Valve, Grid Heater 2, Fan 2, OBD/Cold Start/ Adjustable Speed Limiter Lamp)
DTC
$ 126
$ 128
$ 129
OBD-System
"non"
"non"
Reason of Failure
Possible failure correction
Alternator voltage governor defect
Replace alternator govenror device or alternator
Battery defect, alternator defect, wiring problems (too high resistance) or ECU defect. Occurence possible during cold start.
Replace battery or alternator. Check ECU and wiring.
Short circuit of main relay 1 output to external source, defect in one of the connected components or defective main relay 1
Check the wiring and all components connected to main relay 1, if defect remains main relay inside ECU could be defective, replace ECU
Short circuit of main relay 3 output to external source, defect in one of the connected components or defective main relay 3
Check the wiring and all components connected to main relay 3, if defect remains main relay inside ECU could be defective, replace ECU
Short circuit of main relay 3 output to ground, defect in one of the connected components or defective main relay 3o
Check the wiring and all components connected to main relay 3, if defect remains main relay inside ECU could be defective, replace ECU
"non"
Long TermFailure
Power Red.
Mil.
No
"Mil OFF"
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil OFF"
No
"Mil OFF"
F4AE ENGINES
Print P2D32N020 E
Dfp Name
SECTION 5 - DIAGNOSTICS
45
Base - May 2012
ArHt1
AirHtStickOnIv
MRlyCDAftRun
MnRly1_SCG
Engine-Brake Exhaust Valve (Main Relay 4) failure
Air Heater 1 Power Stage failure
Air Heater always on
Main Relay failure (Interrupted Afterrun))
Main Relay 1 (High Pressure Pump) Short to Ground
DTC
$ 12A
$ 12B
$ 12E
$ 225
$ 228
OBD-System
Reason of Failure
Possible failure correction
Check of wiring or replace relay
"non"
Short circuit of wiring to external source or inside relay, broken or disconnected wiring or defective relay Short circuit of wiring to ground or inside relay
Check of wiring or replace relay
Short circuit of wiring to external source or inside relay
Check of wiring or replace relay
Short circuit of wiring to ground or inside relay
Check of wiring or replace relay
Broken or disconnected wiring or defective relay
Check of wiring or replace relay
"non"
Short circuit to ground of grid heater
Long TermFailure
Power Red.
Mil.
No
"Mil OFF"
No
"Mil OFF"
Check grid heater switch and replace it
No
"Mil OFF"
"comprehensive components"
The ECU is switched off by main electrical switch instead of terminal 15, defective main relay, wiring problem
Inform driver about correct vehicle shut off, check wiring, replace main relay
No
"Mil ON"
"non"
Short circuit of main relay 1 output to ground, defect in one of the connected components or defective main relay 1
Check the wiring and all components connected to main relay 1, if defect remains main relay inside ECU could be defective, replace ECU
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil OFF"
"non"
SECTION 5 - DIAGNOSTICS
EVCD
Description
46
Base - May 2012
Dfp Name
F4AE ENGINES
Print P2D32N020 E
Description
DTC
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
Power Red.
Mil.
Engine 1 (Temperature and Pressure Sensors)
CTSCD
Coolant Temperature Sensor failure
Clg_DynTst
Coolant Temperature Dynamic failure
IATSCD
Boost Air Temperature Sensor failure
BPSCD
FTSCD
Boost Pressure Sensor failuree
Fuel Temperature Sensor failure
$ 131
$ 132
$ 133
$ 134
$ 135
"non"
"non"
"non"
"non"
"non"
Check wiring or replace sensor
Sensor defective or short circuit to ground
Check wiring or replace sensor
See OTS plausibility check (Dfp_OTSCD.Npl)
See OTS plausibility check (Dfp_OTSCD.Npl)
Extreme ambient conditions. Or inaccurate sensor (although sensor does not exceed its signal range)
Ensure that engine was not running in extreme ambient conditions. Check wiring and accuracy of sensor, replacement of sensor
Sensor defective or short circuit to external source
Check wiring or replace sensor
Sensor defective or short circuit to ground
Check wiring or replace sensor
Sensor defective or short circuit to external source
Check wiring or replace sensor
Sensor defective or short circuit to ground
Check wiring or replace sensor
Difference of ambient and boost pressure is out of range..
Check ambient and boost pressure sensor for accuracy
Sensor defective or short circuit to external source
Check wiring or replace sensor
Sensor defective or short circuit to ground
Check wiring or replace sensor
No
"Mil OFF"
No
"Mil OFF"
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
"Mil OFF"
Failure is a NOx dependent (potentially) longterm failure (via LTF group3 Air System)
"Mil OFF"
No
"Mil OFF"
47
Base - May 2012
SECTION 5 - DIAGNOSTICS
Sensor defective or short circuit to external source
F4AE ENGINES
Print P2D32N020 E
Dfp Name
PRVMon
OPSCD
Rail Pressure Sensor failure
Common Rail Pressure Limiting Valve failure
Oil Pressure Sensor failure
DTC
$ 136
$ 137
$ 138
OBD-System
Reason of Failure
Possible failure correction Check wiring and proper functioning of rail pressure sensor
"non"
Short circuit of wiring to external source or defective pressure sensor, rail pressure overshoot Short circuit of wiring to ground or defective pressure sensor
Check wiring and proper functioning of rail pressure sensor
Defective rail pressure sensor, defect in other injection relevant component
Check rail pressure sensor for plausible values, ensure proper functioning of the injection components
PRV does not open once the pressure limit is reached: Mechanical defect or wrong application parameter
Check application value of maximum rail pressure, check functioning of the PRV
PRV does not open even after pressure shock: Stuck PRV or wrong application parameter
Check application value of maximum rail pressure, check functioning of the PRV
Sensor defective or short circuit to external source
Check wiring or replace sensor
Sensor defective or short circuit to ground
Check wiring or replace sensor
"non"
"non"
Monitoring function for ADC Sig-error not explained in documentation???? Inaccurate oil pressure sensor or defect (e.g. blocked piping) in the oil system.
Long TermFailure
Power Red.
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
No
No
Mil.
"Mil OFF"
yes (technical)
SECTION 5 - DIAGNOSTICS
RailCD
Description
48
Base - May 2012
Dfp Name
"Mil OFF"
"Mil OFF"
Check oil pressure sensor for accuracy and check oil system
F4AE ENGINES
Print P2D32N020 E
Description
OTSCD
Oil Temperature Sensor failure
EATSCD
Ambient Air Temperature Sensor failure (of Humidity Sensor)
ClgAbsTst
RailCDOfsTst
Coolant Temperature Test failure
Rail Pressure Sensor Offset Monitoring
DTC
$ 13A
$ 13C
$ 232
$ 236
OBD-System
"non"
"non"
"non"
Reason of Failure
Possible failure correction
Sensor defective or short circuit to external source
Check wiring or replace sensor
Sensor defective or short circuit to ground
Check wiring or replace sensor
Inaccurate oil or coolant temperature sensors or insufficient oil or coolant recirculation (low coolant level etc.).
Check oil and coolant temperature sensor for accuracy and check oil and coolant system for proper functioning
Sensor defective or short circuit to external source
Check wiring or replace sensor
Sensor defective or short circuit to ground
Check wiring or replace sensor
Extreme ambient conditions. Or inaccurate sensor (although sensor does not exceed its signal range)
Ensure that engine was not running in extreme ambient conditions. Check wiring and accuracy of sensor, replacement of sensor
Rail pressure sensor inaccurate
Ensure correct wiring and proper functioning of rail pressure sensor, replace sensor
Rail pressure sensor inaccurate
Ensure correct wiring and proper functioning of rail pressure sensor, replace sensor
"comprehensive components"
Long TermFailure
Power Red.
Mil.
No
"Mil OFF"
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
"Mil OFF"
No
"Mil OFF"
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
yes (technical)
F4AE ENGINES
Print P2D32N020 E
Dfp Name
"Mil ON"
SECTION 5 - DIAGNOSTICS
49
Base - May 2012
OTSCD1
Oil Pressure too low
Temperatura olio eccessivamente alta
DTC
$ 238
$ 23A
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
"non"
Inaccurate oil pressure sensor or defect (e.g. too low oil level, leakage...) in the oil system
Check oil pressure sensor for accuracy and check oil system
No
"Mil OFF"
"non"
Inaccurate oil temperature sensor or defect (e.g. blockage, insufficient recirculation) in the oil system.
Check oil temperature sensor for accuracy and check oil system
No
"Mil OFF"
Power Red.
Mil.
SECTION 5 - DIAGNOSTICS
OPSCD1
Description
50
Base - May 2012
Dfp Name
Engine 2 (Speed sensing/actuators)
EngMCrS1
EngMBackUp
Crankshaft Speed Signal failure
Engine runs with Camshaft Speed only
$ 141
$ 142
"non"
"non"
Signal interrupted do to wiring problem, defective or incorrectly installed crankshaft speed sensor
Check wiring, sensor installation and proper functioning of crankshaft sensor (evaluate raw signals)
Signal interrupted do to wiring problem, defective or incorrectly installed crankshaft speed sensor
Check wiring, sensor installation and proper functioning of crankshaft sensor (evaluate raw signals)
Signal interrupted do to wiring problem, defective or incorrectly installed crankshaft speed sensor
Check wiring, sensor installation and proper functioning of crankshaft sensor (evaluated raw signals)
Failure is a NOx dependent (potentially) longterm failure (via LTF group2 Injection Timing System)
yes (technical)
"Mil ON"
No
yes (technical)
"Mil OFF"
F4AE ENGINES
Print P2D32N020 E
EngMCaS1
EngMOfsCaSCrS
EngPrtOvrSpd
Description
Camshaft Speed Signal failure
Offset between Camshaft and Crankshaft
Info: Engine Overspeed Protection
DTC
$ 143
$ 144
$ 14D
OBD-System
"non"
"non"
"non"
Reason of Failure
Possible failure correction
Long TermFailure
Power Red.
Mil.
Signal interrupted do to wiring problem, defective or incorrectly installed camshaft phase sensor
Check wiring, sensor installation and proper functioning of camshaft phase sensor (evaluate raw signals)
Signal interrupted do to wiring problem, defective or incorrectly installed camshaft phase sensor
Check wiring, sensor installation and proper functioning of camshaft phase sensor (evaluate raw signals)
No
yes (technical)
"Mil OFF"
Signal interrupted do to wiring problem, defective or incorrectly installed camshaft or crankshaft sensor
Check wiring, sensor installations and proper functioning of camshaft and crankshaft sensors (evaluate raw signals)
Failure is a NOx dependent (potentially) longterm failure (via LTF group2 Injection Timing System)
"Mil ON"
Engine overspeed has occurred
No reactions necessary only if this fault/information status reoccurs frequently. In this case check driving conditions of vehicle, engine speed acquisition and injection system for quantity setpoint and actual value during fault recognition, check also for ECU errors
No
"Mil OFF"
F4AE ENGINES
Print P2D32N020 E
Dfp Name
SECTION 5 - DIAGNOSTICS
51
Base - May 2012
CoVehPrflmAct
Info: OBD Performance Limiter Intervention by Legislation
ECBtCDStop
Engine Compartment Stop Button stuck
DTC
$ 14F
$ 24A
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
"non"
A defect has occurred (in the EDC or DCU) which triggered a performance limitation via corresponging Fids
Advice operator not to press button too long, check device for mechanical and electrical defects, check wiring
No
"Mil OFF"
"non"
Wrong manipulation of operator, button mechanically stuck in actuated position, electrical defect in device, defective wiring
Advice operator not to press button too long, check device for mechanical and electrical defects, check wiring
No
"Mil OFF"
Power Red.
Mil.
SECTION 5 - DIAGNOSTICS
Description
52
Base - May 2012
Dfp Name
Fuel metering CR Systems
RailMeUn1
Rail Pressure Positive Deviation High and High Fuel Flow Setpoint Value
$ 152
"non"
High pressure side: Leakage in high pressure section, injection nozzle stuck in open position, worn high pressure pump, worn injector, leaking pressure relieve valve Low pressure side: Pressure before gear pump too low, gear pump output too low (fuel filter clogged, leakage in low pressure side).
Check for defects according to 'reason of failure' list.
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System))
yes (technical)
"Mil OFF"
F4AE ENGINES
Print P2D32N020 E
RailMeUn2
RailMeUn3
Description
Rail Pressure Negative Deviation too High on Minimum Metering
PRail Pressure below Minimum Limit in Controlled Mode
DTC
$ 153
$ 154
OBD-System
"non"
"non"
Reason of Failure Metering unit stuck in open position, zero-delivery throttle clogged, metering unit without power due to electricel error. Low pressure side: Pressure before gear pump too high (e.g. by pressure relieve valve), pressure after zero-delivery throttle too high. High pressure side: Leakage in the high pressure section, injection nozzle stuck in open position, worn high pressure pump, worn injector, leaking pressure relieve valve. Low pressure side: Pressure before gear pump too low or gear pump output too low (clogged fuel filter, leak on output side).
Possible failure correction
Long TermFailure
Power Red.
Mil.
Check for defects according to 'reason of failure' list.
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
yes (technical)
"Mil OFF"
Check for defects according to 'reason of failure' list.
No
F4AE ENGINES
Print P2D32N020 E
Dfp Name
"Mil OFF"
SECTION 5 - DIAGNOSTICS
53
Base - May 2012
RailMeUn6
RailMeUn7
Rail Pressure above Maximum Limit in Controlled Mode
Rail Pressure Drop Rate too High
Setpoint of Rail Metering Unit not plausible in Overrun
DTC
$ 155
$ 156
$ 157
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
"non"
Metering unit stuck in open position, zero-delivery throttle clogged, metering unit without power due to electricel error. Low pressure side: Pressure before gear pump too high (e.g. by pressure relieve valve), pressure after zero-delivery throttle too high.
Check for defects according to 'reason of failure' list
No
"non"
Leakage in the high pressure section, injection nozzle stuck in open position, worn high pressure pump, worn injector, leaking pressure relieve valve, injector reflux too high.
Check for defects according to 'reason of failure' list.
No
yes (technical)
"Mil OFF"
"non"
High pressure system: Leakage in the high pressure section, injection nozzle stuck in open position, worn or defective high pressure pump, worn injector, leaking pressure relieve valve. Low pressure system: 'Zero delivery' is not active in metering unit (excessve leakage in metering unit).
Check for defects according to 'reason of failure' list.
No
yes (technical)
"Mil OFF"
Power Red.
Mil.
"Mil OFF"
SECTION 5 - DIAGNOSTICS
RailMeUn4
Description
54
Base - May 2012
Dfp Name
F4AE ENGINES
Print P2D32N020 E
RailMeUn10
Description
Fuel Flow Setpoint of Common Rail Metering Unit too low
DTC
$ 158
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
Power Red.
Mil.
"non"
High pressure system: Rail pressure sensor inaccurate, high pressure pump defective. Low pressure system: Metering unit reflux too low, fuel system leakage, metering unit jammed in closed position.
Check for defects according to 'reason of failure' list.
No
yes (technical)
"Mil OFF"
Broken or disconnected wiring or defective relay
Check of wiring or replace relay
Defective wiring, ECU, powerstage or metering unit
Check wiring, ECU, power stage and metering unit
"Mil OFF"
Wait until the 'High Pressure Test' has terminated
No
"Mil OFF"
"non"
High NOx emissions due to various possible defects
Identify the defect triggering this fault path and follow the troubleshooting procedure of that failure.
Failure is a direct longterm failure (via counter 576000 mins)
"Mil ON"
"non"
Short circuit of wiring to external source or inside relay
Check of wiring or replace relay
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil OFF"
"non"
High NOx emissions due to various possible defects
Identify the defect triggering this fault path and follow the troubleshooting procedure of that failure
Failure is a direct longterm failure (via counter 576000 mins)
"Mil ON"
MeUnCDNoLoad
$ 159
"non"
HpTst
Info Fault: High Pressure Test (Rail Pressure Monitoring deactivated)
$ 15B
"non"
The 'High Pressure Test' is requested via a diagnostic tester
OBDGFClct1
Info: Long Term Fuel system Failure
MeUnCDSCBat
Common Rail Metering Unit Power Stage Short to Battery
OBDGFClct2
Info: Long Term Injection timing Failure
$ 15F
$ 259
$ 25F
55
Base - May 2012
SECTION 5 - DIAGNOSTICS
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
Common Rail Metering Unit Power Stage failure
F4AE ENGINES
Print P2D32N020 E
Dfp Name
MeUnCDSCGnd
Common Rail Metering Unit Power Stage Short to Ground
OBDGFClct3
OBDGFClct4
OBDGFClct5
Info: Long Term air system failurea
Info: Long Term NOx Sensor Failure
Info: Long Term SCR System FailureR
DTC
$ 359
$ 35F
$ 45F
$ 55F
Possible failure correction
Long TermFailure
"non"
Short circuit of wiring to ground or inside relay
Check of wiring or replace relay
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil OFF"
"non"
High NOx emissions due to various possible defects
Identify the defect triggering this fault path and follow the troubleshooting procedure of that failure.
Failure is a direct longterm failure (via counter 576000 mins)
"Mil ON"
"non"
High NOx emissions due to various possible defects
Identify the defect triggering this fault path and follow the troubleshooting procedure of that failure.
Failure is a direct longterm failure (via counter 576000 mins)
"Mil ON"
"non"
High NOx emissions due to various possible defects
Identify the defect triggering this fault path and follow the troubleshooting procedure of that failure.
Failure is a direct longterm failure (via counter 576000 mins)
"Mil ON"
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil ON"
OBD-System
Reason of Failure
Power Red.
Mil.
SECTION 5 - DIAGNOSTICS
Description
56
Base - May 2012
Dfp Name
Injectors 1
InjVlvCyl1A
Injector Cylinder 1 failure
$ 161
"fuel system"
Short circuit in wiring with external source
Check the wiring or replace injector
BDefective coil of injector
Check the wiring and replace injector.
Depending on the pattern, various reasons can cause the defect, internal ECU problems also possible
Check the wiring and the injection signals, replace ECU
F4AE ENGINES
Print P2D32N020 E
InjVlvCyl2A
InjVlvCyl3A
InjVlvCyl4A
Description
Injector Cylinder 2 failure
Injector Cylinder 3 failure
njector Cylinder 4 failure
DTC
$ 162
$ 163
$ 164
OBD-System
"fuel system"
"fuel system"
"fuel system"
Reason of Failure
Possible failure correction
Short circuit in wiring with external source
Check the wiring or replace injector
Defective coil of injector
Check the wiring and replace injector.
Depending on the pattern, various reasons can cause the defect, internal ECU problems also possible
Check the wiring and the injection signals, replace ECU
Short circuit in wiring with external source
Check the wiring or replace injector
Defective coil of injector
Check the wiring and replace injector.
Depending on the pattern, various reasons can cause the defect, internal ECU problems also possible
Check the wiring and the injection signals, replace ECU
Short circuit in wiring with external source
Check the wiring or replace injector
Defective coil of injector
Check the wiring and replace injector.
Depending on the pattern, various reasons can cause the defect, internal ECU problems also possible
Check the wiring and the injection signals, replace ECU
Long TermFailure
Power Red.
Mil.
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil ON"
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil ON"
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil ON"
F4AE ENGINES
Print P2D32N020 E
Dfp Name
SECTION 5 - DIAGNOSTICS
57
Base - May 2012
InjVlvCyl6A
Injector Cylinder 5 failure
Injector Cylinder 6 failure
InjVlvCyl1B
Injector Cylinder 1 warning
InjVlvCyl2B
Injector Cylinder 1 warning
InjVlvCyl3B
Injector Cylinder 1 warning
DTC
$ 165
$ 166
$ 167
$ 168
$ 169
OBD-System
"non"
"non"
Reason of Failure
Possible failure correction
Short circuit in wiring with external source
Check the wiring or replace injector
Defective coil of injector
Check the wiring and replace injector.
Depending on the pattern, various reasons can cause the defect, internal ECU problems also possible
Check the wiring and the injection signals, replace ECU
Short circuit in wiring with external source
Check the wiring or replace injector
Defective coil of injector
Check the wiring and replace injector.
Depending on the pattern, various reasons can cause the defect, internal ECU problems also possible
Check the wiring and the injection signals, replace ECU
Long TermFailure
Power Red.
Mil.
No
"Mil OFF"
No
"Mil OFF"
"Mil ON"
"fuel system"
Broken wire or disconnection of wiring or inside injector
Check the wiring or replace injector.
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"fuel system"
Broken wire or disconnection of wiring or inside injector
Check the wiring or replace injector.
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil ON"
"fuel system"
Broken wire or disconnection of wiring or inside injector
Check the wiring or replace injector.
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil ON"
SECTION 5 - DIAGNOSTICS
InjVlvCyl5A
Description
58
Base - May 2012
Dfp Name
F4AE ENGINES
Print P2D32N020 E
Description
InjVlvCyl4B
Injector Cylinder 1 warning
InjVlvCyl5B
Injector Cylinder 1 warning
InjVlvCyl6B
Injector Cylinder 1 warning
InjVlvNumMinInj
Minimum Injections Number not reached
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
$ 16A
"fuel system"
Broken wire or disconnection of wiring or inside injector
Check the wiring or replace injector.
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil ON"
$ 16B
"non"
Broken wire or disconnection of wiring or inside injector
Check the wiring or replace injector.
No
"Mil OFF"
"non"
Broken wire or disconnection of wiring or inside injector
Check the wiring or replace injector.
No
"Mil OFF"
"non"
See individual injector and injection-bank errors (InjVlvCyl... and InjVlvBnk...) which have triggerd the shut-off or error in the component
See individual injector and injection-bank errors (InjVlvCyl... and InjVlvBnk...) which have triggerd the shut-off or error in the component
No
"Mil OFF"
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil ON"
DTC
$ 16C
$ 16E
Power Red.
Mil.
F4AE ENGINES
Print P2D32N020 E
Dfp Name
Iniettori 2
InjVlvBnk1A
Injector Bank 1 failure
$ 171
"fuel system"
Short circuit of high-side to battery or ground.
Check the wiring or replace injector.
Short circuit of low-side to ground in injector cable
Check the wiring or replace injector.
Depending on the pattern, various reasons can cause the defect, internal ECU problem
Check the wiring and the injection signals, replace ECU
SECTION 5 - DIAGNOSTICS
59
Base - May 2012
InjVlvChipA
InjVlvChipB
Injector Bank 2 failure
ECU Hardware for Injection: CY33X Chip specific failure (1)
ECU Hardware for Injection: CY33X Chip specific failure (2)
DTC
$ 173
$ 17C
$ 27C
OBD-System
"fuel system"
"non"
Reason of Failure
Possible failure correction
Short circuit of high-side to battery or ground.
Check the wiring or replace injector.
Short circuit of low-side to ground in injector cable.
Check the wiring or replace injector..
Depending on the pattern, various reasons can cause the defect, internal ECU problem
Check the wiring and the injection signals, replace ECU
Clock error or irrupton of the power supply voltage
Check the power supply or replace ECU if problem reoccurs.
Defective ECU
Reset ECU. If no recovery, replace ECU.
Internal failure of ECU or 'TESTMODE' takes too long
Check 'TESTMODE' parameters or replace ECU if problem reoccurs
Defective SPI-bus participant, timing problem due to software bug
Replace ECU if problem reoccurs (Send in ECU for investigation)
Defective ECU
Replace ECU if problem reoccurs
Defective ECU
Replace ECU if problem reoccurs
Defective ECU
Replace ECU if problem reoccurs
Defective ECU
Replace ECU if problem reoccurs
"non"
Long TermFailure
Power Red.
Mil.
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil ON"
No
"Mil OFF"
No
"Mil OFF"
SECTION 5 - DIAGNOSTICS
InjVlvBnk2A
Description
60
Base - May 2012
Dfp Name
F4AE ENGINES
Print P2D32N020 E
Description
DTC
OBD-System
Possible failure correction
Reason of Failure
Long TermFailure
Power Red.
Mil.
Air inlet system / EGR IEDPCDPDiff
Differential Pressure Sensor Failure between Exhaust and Intake (EGR Valve)
$ 181
"comprehensive componentsi"
No
"Mil ON"
No
"Mil OFF"
F4AE ENGINES
Print P2D32N020 E
Dfp Name
Boost system and turbine speed
SmkTrqLim
Torque Reduction due to Smoke Limitation
NOxEstIv
NOx Estimation failure
NTCTrqLim
Info: Torque Limitation due to Negative Torque Coordinator
$ 19E
$ 19F
$ 29D
Active power redcution due to smoke limitation
"non"
Application dependent: Implausible sensor signals or defective sensors etc.
Determine what defect has set the Fid and resolve the problem causing this original defect.
No
"Mil OFF"
Active power redcution due to engine break shut off event
No actions necessary due to this failure alone. If powerreduction occurred due to actual defect, the failure triggering the torque limitation should also be in the failure memory. Follow troubleshooting of this root error.
No
"Mil OFF"
"non"
61
Base - May 2012
SECTION 5 - DIAGNOSTICS
"non"
No actions necessary due to this failure alone. If powerreduction occurred due to actual defect, the failure triggering the torque limitation should also be in the failure memory. Follow troubleshooting of this root error.
EngPrtTrqLim
SCRPrtTrqLim
Info: Torque Limitation due to Turbo Charger Protection
Info: Torque Limitation due to Engine Protection (against Excessive Torque, Engine Overspeed and Overheat)
Info: Torque Limitation due to SCR Catalyst Overheat Protection
DTC
$ 39E
$ 49E
$ 59D
OBD-System
"non"
"non"
"non"
Reason of Failure
Possible failure correction
Long TermFailure
Active power redcution due to turbo charger protection
No actions necessary due to this failure alone. If powerreduction occurred due to actual defect, the failure triggering the torque limitation should also be in the failure memory. Follow troubleshooting of this root error.
No
"Mil OFF"
Active power redcution due to engine mechanics protection
No actions necessary due to this failure alone. If powerreduction occurred due to actual defect, the failure triggering the torque limitation should also be in the failure memory. Follow troubleshooting of this root error.
No
"Mil OFF"
Active power redcution due to excessive temperatures in the SCR catalyst
No actions necessary due to this failure alone. If powerreduction occurred due to actual defect, the failure triggering the torque limitation should also be in the failure memory. Follow troubleshooting of this root error.
No
"Mil OFF"
Power Red.
Mil.
SECTION 5 - DIAGNOSTICS
BstPrtTrqLim
Description
62
Base - May 2012
Dfp Name
F4AE ENGINES
Print P2D32N020 E
NsCtlTrqLim
QLimTrqLim
Description
Info: Torque Limitation due to Noise Limitation
Info: Torque Limitation due to Fuel Quantity Limitation because of Injection System Errors
DTC
$ 59E
$ 69E
OBD-System
"non"
"non"
Reason of Failure
Possible failure correction
Long TermFailure
Active power redcution due to noise control
No actions necessary due to this failure alone. If powerreduction occurred due to actual defect, the failure triggering the torque limitation should also be in the failure memory. Follow troubleshooting of this root error.
No
"Mil OFF"
Active power redcution due to limiting fuel quantity
No actions necessary due to this failure alone. If powerreduction occurred due to actual defect, the failure triggering the torque limitation should also be in the failure memory. Follow troubleshooting of this root error.
No
"Mil OFF"
Power Red.
Mil.
F4AE ENGINES
Print P2D32N020 E
Dfp Name
Exhaust system (Aftertreatment) FrmMngNOxSensNO xIv
NOx Sensor Plausiblity failure
$ 1A2
"comprehensive componentsi"
CAN communication disturbed, defective or inaccurate NOx sensor
Check for proper CAN communication and check accuracy and proper functioning of NOx sensor.
Failure is a NOx dependent (potentially) longterm failure (via LTF group4 NOx Sensor)
yes (OBD)
"Mil ON"
SECTION 5 - DIAGNOSTICS
63
Base - May 2012
FrmMngTONOxSensIv
FrmMngTODM1DCUIv
NOx Sensor Failure
CAN Message timeout Nox (from Nox Sensor)
CAN Message timeout DM1DCU (from DCU)
DTC
$ 1A3
$ 1A4
$ 1A5
Reason of Failure
Possible failure correction
Disconnected cable in the wiring of the NOx sensor or defective NOx sensor.
Check wiring of NOx sensor and its proper functioning. If necessary replace NOx sensor.
Short circuit in the wiring of the NOx sensor or defective NOx sensor.
Check wiring of NOx sensor and its proper functioning. If necessary replace NOx sensor.
Strange driving cycle or inproper installation of the sensor, defective NOx sensor
Check installation (including wiring) and functionality of sensor. If necessary change NOx sensor
"non"
Defective CAN controller of NOx Sensor , undervoltage of NOx Sensor, missing NOx Sensor, CAN cable connecting the NOx Sensor is disconnected or broken. Short circuit in wiring.
"catalyst monitoring"
Defective CAN controller of DCU, undervoltage of DCU, missing DCU, CAN cable connecting the DCU is disconnected or broken. Short circuit in wiring
OBD-System
"comprehensive components"
Long TermFailure
Power Red.
Mil.
Failure is a NOx dependent (potentially) longterm failure (via LTF group4 NOx Sensor)
yes (OBD)
"Mil ON"
Check presence and correct connection of the NOx Sensor to the network, Check correct functioning of the NOx Sensor CAN controller and its voltage supply. Check wiring.
Failure is a NOx dependent (potentially) longterm failure (via LTF group4 NOx Sensor)
yes (OBD)
"Mil ON"
Check presence and correct connection of the DCU to the network, check correct functioning of the DCU CAN controller and its voltage supply. Check wiring.
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
yes (OBD)
"Mil ON"
SECTION 5 - DIAGNOSTICS
FrmMngNOxSensIv
Description
64
Base - May 2012
Dfp Name
F4AE ENGINES
Print P2D32N020 E
FrmMngTOSCR1Iv
FrmMngSCR1ProtIv
IAHSCDStrtDly
FrmMngDM1SPN1Iv
Description
CAN Message timeout SCR1 (from DCU)
nfo: SCR Dosing Valve Overheat ProtectionR
Humidity Sensor Signal Ratio failure
Info: DCU Error1 via CAN message DM1DCU
DTC
$ 1A6
$ 1A8
$ 1AE
$ 1AF
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
Power Red.
Mil.
"catalyst monitoring
Defective CAN controller of Dosing Control Unit , undervoltage of DCU, missing DCU, CAN cable connecting the DCU is disconnected or broken. Short circuit in wiring
Check presence and correct connection of the DCU to the network, Check correct functioning of the DCU CAN controller and its voltage supply. Check wiring.
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
yes (OBD)
"Mil ON"
Failure due to engine switch off after a high load period, leading to high temperatur in exhaust system. A defect occurred in the urea dosing system which can impair the cooling of the urea dosing valve
LRead out the DCU failure memory and perform troubleshooting according to DCU support.
A defect occurred in the urea dosing system which can impair the cooling of the urea dosing valve
Read out the DCU failure memory and perform troubleshooting according to DCU support.
Sensor defective or short circuit to external source
Check wiring. Replace sensor if necessary
Sensor defective or short circuit to ground
Check wiring. Replace sensor if necessaryo
A certain error has occured in the DCU System and is reported via CAN to the EDC.
Check what SPN and corresponding DCU error is active and perform troubleshooting according to DCU support.
"non"
"non"
"non"
No
"Mil OFF"
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
"Mil OFF"
No
yes (OBD)
F4AE ENGINES
Print P2D32N020 E
Dfp Name
"Mil OFF"
SECTION 5 - DIAGNOSTICS
65
Base - May 2012
FrmMngTOSCR2Iv
NOx Sensor Drift failure
CAN Message timeout SCR2 (from DCU)
DTC
$ 2A2
$ 2A6
Reason of Failure
Possible failure correction
Long TermFailure
Power Red.
Mil.
"comprehensive components"
NOx sensor inaccurate or defective, defect in wiring, urea injection valve or fuel injector jammed open, excessive urea deposits in exhaust system, strange behaviour of SCR catalyst
Check NOx sensor for correct functioning (dismount sensor -> NOx value should be 0ppm during driving), check wiring of sensor, check fuel injectors, check urea dosing system for correct dosing amount (perform UDST and Dosing Valve Check, check DCU error memory for leakage failures), check SCR catalyst for correct functioning, check exhaust system for excessive urea deposits
Failure is a NOx dependent (potentially) longterm failure (via LTF group4 NOx Sensor)
yes (OBD)
"Mil ON"
"catalyst monitoring
Defective CAN controller of Dosing Control Unit , undervoltage of DCU, missing DCU, CAN cable connecting the DCU is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the DCU to the network, Check correct functioning of the DCU CAN controller and its voltage supply. Check wiring.
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
yes (OBD)
"Mil ON"
OBD-System
SECTION 5 - DIAGNOSTICS
SCRCatNOxDrIv
Description
66
Base - May 2012
Dfp Name
F4AE ENGINES
Print P2D32N020 E
Description
DTC
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
Power Red.
Mil.
If failure 1AE 'IAHSCDStrDly' also stored in memory: proceed according that description
IAHSCD
Info: Humidity Sensor possibly saturated with water droplets
$ 2AE
"non"
Sensor possibly saturated with water droplets
If failure ACTIVE: run engine at medium speed > 10 min, if failure does NOT get INACTIVE: check wiring harness and replace sensor if necessary If failure not active AND ratio 'active time' / 'occurrence' < 10 min/occurrence: no action needed
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
F4AE ENGINES
Print P2D32N020 E
Dfp Name
"Mil OFF"
If failure not active AND ratio 'active time' / 'occurrence' > 10 min/occurrence: possible short circuit: check wiring harness or replace sensor, if necessary
FrmMngDM1SPN2Iv
Info: DCU Error2 via CAN message DM1DCU
$ 2AF
"non"
Sensor defective or short circuit to ground
Check wiring. Replace sensor if necessaryo
A certain error has occured in the DCU System and is reported via CAN to the EDC.
Verificare quale SPN e relativo errore DCU è attivo ed individuare ed eliminare il problema secondo il supporto DCU.
No
yes (OBD)
"Mil ON"
SECTION 5 - DIAGNOSTICS
67
Base - May 2012
FrmMngDM1SPN4Iv
FrmMngDM1SPN5Iv
NOx Sensor Plausibility failure
Info: DCU Error4 via CAN message DM1DCU
Info: DCU Error5 via CAN message DM1DCU
DTC
$ 3A2
$ 4AF
$ 5AF
Reason of Failure
Possible failure correction
Long TermFailure
Power Red.
Mil.
"comprehensive componentsi"
NOx sensor inaccurate or defective, defect in wiring, inaccurate NOx estimation, urea injection valve jammed open or excessive urea deposits in exhaust system, defective SCR catalyst
Check urea dosing system for correct dosing amount (perform UDST and Dosing Valve Check, check DCU error memory for leakage failures), check NOx sensor for correct functioning, check wiring of sensor, check NOx estimation (humidity, boost pressure and temperature) for plausible values, check SCR catalyst for correct functioning, check exhaust system for excessive urea deposits
Failure is a NOx dependent (potentially) longterm failure (via LTF group4 NOx Sensor)
yes (OBD)
"Mil ON"
"non"
A certain error has occured in the DCU System and is reported via CAN to the EDC.
Check what SPN and corresponding DCU error is active and perform troubleshooting according to DCU support.
No
yes (OBD)
"Mil ON"
"non"
A certain error has occured in the DCU System and is reported via CAN to the EDC.
Check what SPN and corresponding DCU error is active and perform troubleshooting according to DCU support.
No
yes (OBD)
"Mil ON"
OBD-System
SECTION 5 - DIAGNOSTICS
SCRCatNOxPlIv
Description
68
Base - May 2012
Dfp Name
F4AE ENGINES
Print P2D32N020 E
Description
DTC
Possible failure correction
Long TermFailure
"non"
Wrong configuration of CAN timing (Prescaler, synchronization jump width, sampling, propagation and phase segments), bad termination resistors, defective network connection and contacts or defective CAN controller with erroneous messages.
Check timing configuration with hardware compatibility, check termination resistors and network connection and contacts. Short circuits to external source, ground or CAN High to Low.Monitor CAN communication for erroneous behaviour of a participant.
No
"Mil OFF"
"non"
Wrong configuration of CAN timing (Prescaler, synchronization jump width, sampling, propagation and phase segments), bad termination resistors, defective network connection and contacts or defective CAN controller with erroneous messages.
Check timing configuration with hardware compatibility, check termination resistors and network connection and contacts. Short circuits to external source, ground or CAN High to Low.Monitor CAN communication for erroneous behaviour of a participant.
No
"Mil OFF"
OBD-System
Reason of Failure
Power Red.
Mil.
Interfaces 1 (CAN-Bus)
NetMngCANAOff
NetMngCANBOff
CAN A Bus off
CAN B Bus off
$ 1B1
$ 1B2
F4AE ENGINES
Print P2D32N020 E
Dfp Name
SECTION 5 - DIAGNOSTICS
69
Base - May 2012
FrmMngTOBC2EDC1 Iv
FrmMngTOVM2EDCI v
FrmMngTxTO
CAN C Bus off
CAN Message timeout BC2EDC1 (from Body Computer)
CAN Message timeout VM2EDC (from VCM)
CAN Transmit Message timeout
DTC
$ 1B3
$ 1B4
$ 1B5
$ 1B7
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
"non"
Wrong configuration of CAN timing (Prescaler, synchronization jump width, sampling, propagation and phase segments), bad termination resistors, defective network connection and contacts or defective CAN controller with erroneous messages.
Check timing configuration with hardware compatibility, check termination resistors and network connection and contacts. Short circuits to external source, ground or CAN High to Low.Monitor CAN communication for erroneous behaviour of a participant.
No
"Mil OFF"
"non"
Defective CAN controller of Body Computer , undervoltage of BC, missing BC, CAN cable connecting the BC is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the BC to the network, Check correct functioning of the BC CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
"non"
Defective CAN controller of Vehicle Control Module , undervoltage of VCM, missing VCM, CAN cable connecting the VCM is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the VCM to the network, Check correct functioning of the VCM CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
"non"
Disturbed CAN, incorrect configuration of the CAN, EDC is disconnected from the network, EDC CAN controller defective
Check CAN communication, check CAN configuration, ensure proper connection of the EDC to the network, replace EDC
No
Power Red.
yes (OBD)
Mil.
SECTION 5 - DIAGNOSTICS
NetMngCANCOff
Description
70
Base - May 2012
Dfp Name
"Mil OFF"
F4AE ENGINES
Print P2D32N020 E
FrmMngBC1MILIv
FrmMngTODashDsplIv
FrmMngTORxAMCONIv
FrmMngTORxCCVS
Description
Info: MIL visualization not available
CAN Message timeout Dash Display (from VCM)
CAN Message timeout AMCON (from VCM)
CAN Message timeout CCVS (from Body Computer or VCM)
DTC
$ 1B9
$ 1BA
$ 1BC
$ 1BD
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
"comprehensive components"
Defective MIL/Body Controller or disturbed CAN communication
Consult trouble shooting of body controller and check correct functioning of the CAN communication.
No
"Mil ON"
"non"
Defective CAN controller of Vehicle Control Module , undervoltage of VCM, missing VCM, CAN cable connecting the VCM is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the VCM to the network, Check correct functioning of the VCM CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
"non"
Defective CAN controller of Vehicle Control Module , undervoltage of VCM, missing VCM, CAN cable connecting the VCM is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the VCM to the network, Check correct functioning of the VCM CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
"non"
Defective CAN controller of Body Computer or Vehicle Control Module , undervoltage of BC or VCM, missing BC or VCM, CAN cable connecting the BC or VCM is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the BC or VCM to the network, check correct functioning of the BC or VCM CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
Power Red.
Mil.
F4AE ENGINES
Print P2D32N020 E
Dfp Name
SECTION 5 - DIAGNOSTICS
71
Base - May 2012
CAN Message timeout BC2EDC2 (from Body Computer)
DTC
$ 2B4
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
"non"
Defective CAN controller of Body Computer , undervoltage of BC, missing BC, CAN cable connecting the BC is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the BC to the network, Check correct functioning of the BC CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
Power Red.
Mil.
Interfaces 2 (CAN messages timeout)
FrmMngTOETC1
CAN Message timeout ETC1 (from Electronic Transmission Controller)
FrmMngTOTCO1
CAN Message timeout TCO1 (from Tachograph Output)
FrmMngTOTSC1 PEActIv
CAN Message timeout active TSC1-PE (Torque/Speed Control Request from PTO to Engine)
$ 1C2
$ 1C3
$ 1C6
"non"
Defective CAN controller of Gearbox Control Unit , undervoltage of ETC, missing ETC, CAN cable connecting the ETC is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the ETC to the network, check correct functioning of the ETC CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
"non"
Defective CAN controller of Tachograph Output , undervoltage of TCO, missing TCO, CAN cable connecting the TCO is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the TCO to the network, check correct functioning of the TCO CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
Defective CAN controller of Power Take Off , undervoltage of PTO, missing PTO, CAN cable connecting the PTO is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the PTO to the network, Check correct functioning of the PTO CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
SECTION 5 - DIAGNOSTICS
FrmMngTOBC2EDC2Iv
Description
72
Base - May 2012
Dfp Name
F4AE ENGINES
Print P2D32N020 E
FrmMngTOTSC1VEA ctIv
Description
CAN Message timeout active TSC1-VE (Torque/Speed Control Request from VCM/BC to Engine)
FrmMngTOETC2
CAN Message timeout ETC2 (from Electronic Transmission Controller)
FrmMngTOTSC1PEPa sIv
CAN Message timeout inactive TSC1-PE (Torque/Speed Control Request from PTO to Engine)
FrmMngTOTSC1VRA ctIv
$ 1C8
$ 2C2
$ 2C6
$ 2C8
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
"non"
Defective CAN controller of Vehicle Control Module or Body Computer , undervoltage of VCM/BC, missing VCM/BC, CAN cable connecting the VCM/BC is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the VCM/BC to the network, Check correct functioning of the VCM/BC CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
"non"
Defective CAN controller of Gearbox Control Unit , undervoltage of ETC, missing ETC, CAN cable connecting the ETC is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the ETC to the network, Check correct functioning of the ETC CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
"non"
Defective CAN controller of Power Take Off , undervoltage of PTO, missing PTO, CAN cable connecting the PTO is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the PTO to the network, Check correct functioning of the PTO CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
"non"
Defective CAN controller of Vehicle Control Module or Body Computer , undervoltage of VCM/BC, missing VCM/BC, CAN cable connecting the VCM/BC is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the VCM/BC to the network, Check correct functioning of the VCM/BC CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
Power Red.
Mil.
73
Base - May 2012
SECTION 5 - DIAGNOSTICS
CAN Message timeout active TSC1-VR (Torque/Speed Control Request from VCM/BC to Retarder)
DTC
F4AE ENGINES
Print P2D32N020 E
Dfp Name
FrmMngTOTSC1 VEPasIv
FrmMngTOHRVDIv
FrmMngTOTSC1 VRPasIv
Time/Date CAN timeout (from Tachograph or VCM)
CAN Message timeout inactive TSC1-VE (Torque/Speed Control Request from VCM/BC to Engine)
CAN Message timeout HRVD (from Tachograph - High Resolution Vehicle Distance)
CAN Message timeout inactive TSC1-VR (Torque/Speed Control Request from VCM/BC to Retarder)
DTC
$ 2C9
$ 3C8
$ 3C9
$ 4C8
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
"non"
Defective CAN controller of Tachograph , undervoltage of TC, missing TC, CAN cable connecting the TC is disconnected or broken. Short circuit in wiring
Check presence and correct connection of the TC to the network, Check correct functioning of the TC CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
"non"
Defective CAN controller of Vehicle Control Module or Body Computer , undervoltage of VCM/BC, missing VCM/BC, CAN cable connecting the VCM/BC is disconnected or broken. Short circuit in wiring
Check presence and correct connection of the VCM/BC to the network, Check correct functioning of the VCM/BC CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
"non"
Defective CAN controller of Tachograph - High Resolution Vehicle Distance , undervoltage of BC, missing BC, CAN cable connecting the BC is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the BC to the network, Check correct functioning of the BC CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
"non"
Defective CAN controller of Vehicle Control Module or Body Computer , undervoltage of VCM/BC, missing VCM/BC, CAN cable connecting the VCM/BC is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the VCM/BC to the network, Check correct functioning of the VCM/BC CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
Power Red.
Mil.
SECTION 5 - DIAGNOSTICS
FrmMngTOTimeDateIv
Description
74
Base - May 2012
Dfp Name
F4AE ENGINES
Print P2D32N020 E
Description
DTC
OBD-System
Long TermFailure
Electric disturbances, internal defect of the ECU leading to a SPI bus communication error
Replace ECU if failure remains present
No
"Mil OFF"
Wrong programming/flashing of the EDC, internal defect of the EDC.
Try to flash the EDC correctly with a proper dataset, if defect persists: replace EDC.
Wrong programming/flashing of the EDC, internal defect of the EDC.
Try to flash the EDC correctly with a proper dataset, if defect persists: replace EDC.
No
"Mil OFF"
Wrong programming/flashing of the EDC, internal defect of the EDC.
Try to flash the EDC correctly with a proper dataset, if defect persists: replace EDC.
Electronic disturbances, various hardware defects (ECU internal) or configuration problems
Analyze what error triggered the recovery (Read out label HWEMon_numRecov ery and compare the value with the according table). If error occurs repeatedly, reprogram EDC. If error remains, replace EDC.
No
"Mil OFF"
Defective monitoring module or CPU (e.g. impaired functioning of the CPU clock) of the EDC. Disturbed SPI-Bus.
If error exists only temporary (i.e. injection reoccurs) error can be ignored and error deleted in the fault memory. In case of a permanent error the injection remains blocked and the ECU has to be replaced
No
"Mil OFF"
Power Red.
Mil.
ECU 1 (internal checks) HWEMonCom
HWEMonEEPROM
HWEMonRcyLocked
Montr
ECU Hardware: SPI Communication failure
ECU Hardware: EEPROM failure
ECU recovery locked
ECU Hardware: Microcontroller Watchdog failure
$ 1D1
$ 1D2
$ 1D3
$ 1D4
"non"
"non"
"non"
"non"
75
Base - May 2012
SECTION 5 - DIAGNOSTICS
Possible failure correction
Reason of Failure
F4AE ENGINES
Print P2D32N020 E
Dfp Name
ECU Hardware: Shut off during Initialization
DTC
$ 1D5
OBD-System
"non"
TPUMon
ECU Hardware: TPU Monitoring
$ 1D6
"non"
VarMngCodDs
ECU Software: Variant Dataset failure
$ 1D7
"non"
Reason of Failure
Possible failure correction
Watch dog switch off path defect
If failure remains after ECU initialisation: replace ECU
Electronic disturbances, internal ECU problem
If failure remains after ECU initialisation: replace ECU
Electronic disturbances, internal ECU problem
If failure remains after ECU initialisation: replace ECU
Electronic disturbances, wrong TPU timebase
If failure persists: Replace ECU
See general remarks
See general remarks
See general remarks
See general remarks If ECU functions correctly after recovery only temporary SPI error occurred and fault memory can be deleted and error ignored. If permanent SPI error is present and the ECU does not leave boot block --> Replace ECU
WdCom
ECU Hardware: Controller Watchdog failure
$ 1D8
"non"
Disturbed SPI-Bus
ADCMon
ADC Monitoring failure
$ 1D9
"non"
Buffer overrun
HWEMonRcy Suppressed
ECU recovery suppressed
$ 2D3
"non"
Electronic disturbances, various hardware defects (ECU internal) or configuration problems
Analyze what error triggered the recovery (Read out label HWEMon_numRecov ery and compare the value with the according table). If error occurs repeatedly, reprogram EDC. If error remains, replace EDC.
Long TermFailure
Power Red.
Mil.
No
yes (technical)
"Mil OFF"
No
"Mil OFF"
No
"Mil OFF"
No
"Mil OFF"
No
"Mil OFF"
No
"Mil OFF"
SECTION 5 - DIAGNOSTICS
SOPTst
Description
76
Base - May 2012
Dfp Name
F4AE ENGINES
Print P2D32N020 E
Description
HWEMonRcyVisible
ECU recovery - visible
StrtCDHS
ECU Hardware: High Side Power Stage Short to Ground or Battery
DTC
$ 3D3
OBD-System
"non"
Reason of Failure
Possible failure correction
Long TermFailure
Electronic disturbances, various hardware defects (ECU internal) or configuration problems
Analyze what error triggered the recovery (Read out label HWEMon_numRecov ery and compare the value with the according table). If error occurs repeatedly, reprogram EDC. If error remains, replace EDC.
No
Power Red.
Mil.
F4AE ENGINES
Print P2D32N020 E
Dfp Name
"Mil OFF"
ECU 2 (Powerst./Immobil./Overrun/Sensor supply)
ImmCtl
Immobilizer failure (no fuel release)
$ 1E1
$ 1E2
"non"
Short circuit of wiring to ground or inside relay
Check of wiring or replace relay
No
"non"
1) Defective CAN or immobilizer and new control unit (here no PIN entry is possible) OR T15 was toggled more than a calibratable value OR number of allowed incorrect PIN entries is exceeded. 2) Defective CAN or immobilizer OR wrong code AND code is kown by the EDC AND T15 has not been toggeled excessively
1) Ensure correct CAN functioning (timeout errors), unlock fuel release via a tester request, replace immobilizer 2) Enter PIN code via accelerator pedal or instrument cluster, ensure correct CAN functioning (timeout errors), replace immobilzer
No
"Mil OFF"
Check injection relevant application, if failure persists replace ECU
No
"Mil OFF"
If failure persists after reinitialization replace ECU
No
"Mil OFF"
Overrun Monitoring failure
$ 1E3
"non"
OvRMonSigA
Redundant Engine Speed in Overrun Monitoring
$ 1E4
"non"
Electronic disturbances, internal ECU problem
"Mil OFF"
77
Base - May 2012
SECTION 5 - DIAGNOSTICS
OvRMon
Electronic disturbances, requested torque increase via tester, wrong application of injection relevant parameters, defective ECU
yes (technical)
SSpMon1
SSpMon2
ECU Hardware: Sensor 12V Supply Voltage failure
ECU Hardware: Sensor Supply Voltage 1 failure
ECU Hardware: Sensor Supply Voltage 2 failure
DTC
$ 1E5
$ 1E6
$ 1E7
OBD-System
"non"
"comprehensive components"
"non"
Reason of Failure
Possible failure correction
Excessive battery voltage, defect in wiring harness, electrical failure of the EDC
Check battery voltage, check wiring for correct voltage supply of the sensor and the EDC, replace EDC
Insufficient battery voltage, defect in wiring harness, electrical failure of the EDC
Check battery voltage, check wiring for correct voltage supply of the sensor and the EDC, replace EDC
Excessive battery voltage, defect in wiring harness, electrical failure in connected sensors or in the EDC
Check battery voltage, check wiring for correct voltage supply of the sensor and the EDC, replace EDC
Insufficient battery voltage, defect in wiring harness, electrical failure connected sensors or in the EDC
Check battery voltage, check wiring for correct voltage supply of the sensor and the EDC, replace EDC
Excessive battery voltage, defect in wiring harness, electrical failure in connected sensors or in the EDC
Check battery voltage, check wiring for correct voltage supply of the sensor and the EDC, replace EDC
Insufficient battery voltage, defect in wiring harness, electrical failure connected sensors or in the EDC
Check battery voltage, check wiring for correct voltage supply of the sensor and the EDC, replace EDC
Long TermFailure
Power Red.
No
Mil.
"Mil OFF"
No
yes (technical)
"Mil ON"
No
yes (technical)
"Mil OFF"
SECTION 5 - DIAGNOSTICS
SSpMon12V
Description
78
Base - May 2012
Dfp Name
F4AE ENGINES
Print P2D32N020 E
SSpMon3
HWEMonUMaxSuppl y
HWEMonUMinSupply
Description
ECU Hardware: Sensor Supply Voltage 3 failure
ECU internal Supply Voltage too high
ECU internal Supply Voltage too low
DTC
$ 1E8
$ 1E9
$ 1EA
Reason of Failure
Possible failure correction
Excessive battery voltage, defect in wiring harness, electrical failure in connected sensors or in the EDC
Check battery voltage, check wiring for correct voltage supply of the sensor and the EDC, replace EDC
Insufficient battery voltage, defect in wiring harness, electrical failure connected sensors or in the EDC
Check battery voltage, check wiring for correct voltage supply of the sensor and the EDC, replace EDC
"non"
Excessive voltage supply of a CJ940 component: High battery voltage, defective wiring, internal defect of the EDC
Check the battery for correct voltage supply, check wiring. If defect remains replace EDC (internal defect)
No
"Mil OFF"
"non"
Insufficient voltage supply of a CJ940 component: Low battery voltage, defective wiring, internal defect of the EDC
Check the battery for sufficient voltage supply, check wiring. If defect remains replace EDC (internal defect)
No
"Mil OFF"
OBD-System
"non"
Long TermFailure
Power Red.
Mil.
No
yes (technical)
"Mil OFF"
F4AE ENGINES
Print P2D32N020 E
Dfp Name
SECTION 5 - DIAGNOSTICS
79
Base - May 2012
StrtCDLS
Atmospheric Pressure Sensor failure
ECU Hardware: Low Side Power Stage Short to Ground or Battery
DTC
$ 1EB
$ 2E1
OBD-System
"non"
"non"
Reason of Failure
Possible failure correction
Ambient pressure sensor inside ECU is defect
Replace ECU (not necessary if never running in high altitude and if turbocharger without VGT)
Ambient pressure sensor inside ECU is defect
Replace ECU (not necessary if never running in high altitude and if turbocharger without VGT)
Ambient pressure sensor inside ECU is defect
Replace ECU (not necessary if never running in high altitude and if turbocharger without VGT)
Short circuit of wiring to external source or inside relay
Check wiring or replace relay
Long TermFailure
Power Red.
No
No
Mil.
"Mil OFF"
yes (technical)
SECTION 5 - DIAGNOSTICS
APSCD
Description
80
Base - May 2012
Dfp Name
"Mil OFF"
F4AE ENGINES
Print P2D32N020 E
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
Power Red.
Mil.
Vehicle 1 (Sensor/Plausibility checks)
Terminal 15 failure
$ 119
"non"
Temperature sensor downstream of catalyst is inaccurate or defective, defect in wiring (also check connectors)
SCRCatPlausIv
SCR Temperatures plausibility
$ 11F
"catalyst monitoring"
Temperature sensor upstream of catalyst is inaccurate or defective, defect in wiring (also check connectors)
Check wiring for correct installation and for short circuits
Check wiring and signal of temperature sensor. Ensure complete cool down of vehicle (>10 hours) without sun exposure and and measure all 3 sensors signals. If temperature differences are above 20°C replace defective sensor Check wiring and signal of temperature sensor. Ensure complete cool down of vehicle (>10 hours) without sun exposure and and measure all 3 sensors signals. If temperature differences are above 20°C replace defective sensor
No
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
"Mil OFF"
yes (OBD)
"Mil ON"
81
Base - May 2012
SECTION 5 - DIAGNOSTICS
The fault codes depend on the application, therefore some may never be displayed during diagnosis.
T15CD
Due to a short circuit in the ignition switch the EDC is switched on, although T15 has not been activated.
F4AE ENGINES
DTC
FAULT CODES N60 ENGINE
Description
NOTE
Print P2D32N020 E
Dfp Name
SCR Temperatures plausibility
VSSCD2
Vehicle Speed Sensor failure
SCRCatAgeingIv
SCR Catalyst Thermal Ageing Limit exceeded
DTC
$ 11F
$ 211
$ 21D
OBD-System
Reason of Failure
Possible failure correction
Ambient temperature sensor or both upstream and downstream catalyst temperature sensors are inaccurate, defect in wiring (also check connectors)
If the ambient temperature sensor is inaccurate it is likely that the urea pump module (DTC $E4) and urea tank temperature (DTC $E5) are also reported implausible by the DCU. Check wiring and signal of temperature sensors. Ensure complete cool down of vehicle (>10 hours) without sun exposure and and measure all 3 sensors signals. If temperature differences are above 20°C replace the sensors which seem implausible.
"catalyst monitoring"
Long TermFailure
Power Red.
Mil.
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
yes (OBD)
"Mil ON"
SECTION 5 - DIAGNOSTICS
SCRCatPlausIv
Description
82
Base - May 2012
Dfp Name
Temperature sensor up- or downstream of the catalyst or both are inaccurate, defect in wiring (also check connectors), oil leakage into exhaust system
Check both sensor signals and their wiring, look for static implausibility, check for oil leakages, replace one or both sensors
"non"
Defective or incorrect functioning speed measuring device, see CAN message Tachograph Output (TCO1).
Check speed measuring device for proper functioning and for its CAN configuration
No
"Mil OFF"
"non"
Excessive ageing of SCR-Catatlyst
Replace catalyst and reset EEPROM value of catalyst ageing time via tester
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
"Mil OFF"
F4AE ENGINES
Print P2D32N020 E
SCRCatNOxLvl1Iv
SCRCatDCUStateIv
Description
SCR Catalyst Efficiency below first threshold
DCU State Monitoring
DTC
$ 21E
$ 31D
Reason of Failure
Possible failure correction
Long TermFailure
"catalyst monitoring"
Measured catalyst efficiency lower than the estimated (NH3 slip present), inaccurate NOx measurement (value too high) downstream of catalyst, incorrect NOx estimation (value too low) upstream of catalyst, estimated catalyst efficiency too high (due to inaccuracies in the exhaust mass flow calculation, the estimated NH3 storage, temperature measurements upand downstream of the catalyst) or catalyst degradation, excessive urea deposits in exhaust system
Check urea dosing system for correct dosing amount (perform UDST and Dosing Valve Check, check DCU error memory for leakage failures), check accuracy of NOx-sensor and NOx-model (humidity, boost pressure and temperature) for plausible values, check NOx-conversion efficiency of catalyst, check exhaust system for excessive urea deposits
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
"catalyst monitoring"
Measured catalyst efficiency lower than the estimated (NH3 slip present), inaccurate NOx measurement (value too high) downstream of catalyst, incorrect NOx estimation (value too low) upstream of catalyst, estimated catalyst efficiency too high (due to inaccuracies in the exhaust mass flow calculation, the estimated NH3 storage, temperature measurements upand downstream of the catalyst) or catalyst degradation, excessive urea deposits in exhaust system
Check urea dosing system for correct dosing amount (perform UDST and Dosing Valve Check, check DCU error memory for leakage failures), check accuracy of NOx-sensor and NOx-model (humidity, boost pressure and temperature) for plausible values, check NOx-conversion efficiency of catalyst, check exhaust system for excessive urea deposits
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
Power Red.
Mil.
"Mil ON"
yes (OBD)
"Mil ON" SECTION 5 - DIAGNOSTICS
83
Base - May 2012
OBD-System
F4AE ENGINES
Print P2D32N020 E
Dfp Name
SCRCatHiEffIv
SCR Catalyst Efficiency below second threshold
SCR Catalyst System Efficiency too high
DTC
$ 31E
$ 31F
Reason of Failure
Possible failure correction
Long TermFailure
Power Red.
Mil.
"catalyst monitoring"
Measured catalyst efficiency lower than the estimated (NH3 slip present), inaccurate NOx measurement (value too high) downstream of catalyst, incorrect NOx estimation (value too low) upstream of catalyst, estimated catalyst efficiency too high (due to inaccuracies in the exhaust mass flow calculation, the estimated NH3 storage, temperature measurements upand downstream of the catalyst) or catalyst degradation, excessive urea deposits in exhaust system
Check urea dosing system for correct dosing amount (perform UDST and Dosing Valve Check, check DCU error memory for leakage failures), check accuracy of NOx-sensor and NOx-model (humidity, boost pressure and temperature) for plausible values, check NOx-conversion efficiency of catalyst, check exhaust system for excessive urea deposits
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
yes (OBD)
"Mil ON"
"non"
Measured catalyst efficiency higher than the estimated (danger of NH3 slip), inaccurate NOx measurement (value too low) downstream of catalyst, incorrect NOx estimation (value too high) upstream of catalyst, estimated catalyst efficiency too low (due to inaccuracies in the exhaust mass flow calculation, the estimated NH3 storage, temperature measurements upand downstream of the catalyst), excessive urea deposits in exhaust system
Check urea dosing system for correct dosing amount (perform UDST and Dosing Valve Check, check DCU error memory for leakage failures), check accuracy of NOx-sensor and NOx-model (humidity, boost pressure and temperature) for plausible values, check exhaust system for excessive urea deposits
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
"Mil OFF"
F4AE ENGINES
Print P2D32N020 E
OBD-System
SECTION 5 - DIAGNOSTICS
SCRCatNOxLvl2Iv
Description
84
Base - May 2012
Dfp Name
Description
DTC
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
Power Red.
Mil.
Vehicle 2 (Lamps/relays/actuators)
MRlyCD
BattCD
MnRly1_SCB
Main Relay 2 failure (Grid Heater 1, Fan 1, VGT, Lambda Heater, EGR Bypass Valve, EGR Actuator, Blow By Valve)
Battery Voltage failure
Main Relay 1 (High Pressure Pump) Short to Battery
$ 125
$ 126
$ 128
Short circuit of main relay 2 output to external source, defect in one of the connected components or defective main relay 2
Check the wiring and all components connected to main relay 2, if defect remains main relay inside ECU could be defective, replace ECU
Short circuit of main relay 2 output to ground, defect in one of the connected components or defective main relay 2
Check the wiring and all components connected to main relay 2, if defect remains main relay inside ECU could be defective, replace ECU
Alternator voltage governor defect
Replace alternator govenror device or alternator
Battery defect, alternator defect, wiring problems (too high resistance) or ECU defect. Occurence possible during cold start.
Replace battery or alternator. Check ECU and wiring.
Short circuit of main relay 1 output to external source, defect in one of the connected components or defective main relay 1
Check the wiring and all components connected to main relay 1, if defect remains main relay inside ECU could be defective, replace ECU
"non"
"non"
"non"
No
"Mil OFF"
No
"Mil OFF"
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil OFF"
F4AE ENGINES
Print P2D32N020 E
Dfp Name
SECTION 5 - DIAGNOSTICS
85
Base - May 2012
EVCD
ArHt1
AirHtStickOnIv
Main Relay 3 failure (A/C Compressor, Fuel Filter Heater, Intercooler Bypass Valve, Additive Valve, Grid Heater 2, Fan 2, OBD/Cold Start/ Adjustable Speed Limiter Lamp)
Engine-Brake Exhaust Valve (Main Relay 4) failure
Air Heater 1 Power Stage failure
Air Heater always on
DTC
$ 129
$ 12A
$ 12B
$ 12E
OBD-System
Reason of Failure
Possible failure correction
Short circuit of main relay 3 output to external source, defect in one of the connected components or defective main relay 3
Check the wiring and all components connected to main relay 3, if defect remains main relay inside ECU could be defective, replace ECU
Short circuit of main relay 3 output to ground, defect in one of the connected components or defective main relay 3
Check the wiring and all components connected to main relay 3, if defect remains main relay inside ECU could be defective, replace ECU
Short circuit of wiring to external source or inside relay, broken or disconnected wiring or defective relay
Check of wiring or replace relay
Short circuit of wiring to ground or inside relay
Check of wiring or replace relay
Short circuit of wiring to external source or inside relay
Check of wiring or replace relay
Short circuit of wiring to ground or inside relay
Check of wiring or replace relay
Broken or disconnected wiring or defective relay
Check of wiring or replace relay
Short circuit to ground of grid heater
Check grid heater switch and replace it
"non"
"non"
"non"
"non"
Long TermFailure
Power Red.
Mil.
No
"Mil OFF"
No
"Mil OFF"
No
"Mil OFF"
No
"Mil OFF"
SECTION 5 - DIAGNOSTICS
MRlyCDMnRly3
Description
86
Base - May 2012
Dfp Name
F4AE ENGINES
Print P2D32N020 E
MRlyCDAftRun
MnRly1_SCG
Description
Main Relay failure (Interrupted Afterrun)
Main Relay 1 (High Pressure Pump) Short to Ground
DTC
$ 225
$ 228
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
"comprehensive components"
The ECU is switched off by main electrical switch instead of terminal 15, defective main relay, wiring problem
Inform driver about correct vehicle shut off, check wiring, replace main relay
No
"Mil ON"
"non"
Short circuit of main relay 1 output to ground, defect in one of the connected components or defective main relay 1
Check the wiring and all components connected to main relay 1, if defect remains main relay inside ECU could be defective, replace ECU
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil OFF"
No
"Mil OFF"
No
"Mil OFF"
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
"Mil OFF"
Power Red.
Mil.
F4AE ENGINES
Print P2D32N020 E
Dfp Name
Engine 1 (Temperature and Pressure Sensors)
CTSCD
Coolant Temperature Sensor failure
Clg_DynTst
Coolant Temperature Dynamic failure
IATSCD
Boost Air Temperature Sensor failure
$ 131
$ 132
$ 133
"non"
"non"
"non"
Check wiring or replace sensor
Sensor defective or short circuit to ground
Check wiring or replace sensor
See OTS plausibility check (Dfp_OTSCD.Npl)
See OTS plausibility check (Dfp_OTSCD.Npl)
Extreme ambient conditions. Or inaccurate sensor (although sensor does not exceed its signal range)
Ensure that engine was not running in extreme ambient conditions. Check wiring and accuracy of sensor, replacement of sensor
Sensor defective or short circuit to external source
Check wiring or replace sensor
Sensor defective or short circuit to ground
Check wiring or replace sensor
87
Base - May 2012
SECTION 5 - DIAGNOSTICS
Sensor defective or short circuit to external source
FTSCD
RailCD
PRVMon
Boost Pressure Sensor failure
Fuel Temperature Sensor failure
Rail Pressure Sensor failure
Common Rail Pressure Limiting Valve failure
DTC
$ 134
$ 135
$ 136
$ 137
OBD-System
"non"
"non"
"non"
"non"
Reason of Failure
Possible failure correction
Sensor defective or short circuit to external source
Check wiring or replace sensor
Sensor defective or short circuit to ground
Check wiring or replace sensor
Difference of ambient and boost pressure is out of range.
Check ambient and boost pressure sensor for accuracy
Sensor defective or short circuit to external source
Check wiring or replace sensor
Sensor defective or short circuit to ground
Check wiring or replace sensor
Short circuit of wiring to external source or defective pressure sensor, rail pressure overshoot
Check wiring and proper functioning of rail pressure sensor
Short circuit of wiring to ground or defective pressure sensor
Check wiring and proper functioning of rail pressure sensor
Defective rail pressure sensor, defect in other injection relevant component
Check rail pressure sensor for plausible values, ensure proper functioning of the injection components
PRV does not open once the pressure limit is reached: Mechanical defect or wrong application parameter
Check application value of maximum rail pressure, check functioning of the PRV
PRV does not open even after pressure shock: Stuck PRV or wrong application parameter
Check application value of maximum rail pressure, check functioning of the PRV
Long TermFailure
Power Red.
Mil.
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
"Mil OFF"
No
"Mil OFF"
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil OFF"
No
yes (technical)
SECTION 5 - DIAGNOSTICS
BPSCD
Description
88
Base - May 2012
Dfp Name
"Mil OFF"
F4AE ENGINES
Print P2D32N020 E
OPSCD
Description
Oil Pressure Sensor failure
OTSCD
Oil Temperature Sensor failure
EATSCD
Ambient Air Temperature Sensor failure (of Humidity Sensor)
ClgAbsTst
Coolant Temperature Test failure
DTC
$ 138
$ 13A
$ 13C
$ 232
OBD-System
"non"
"non"
"non"
"non"
Reason of Failure
Possible failure correction
Sensor defective or short circuit to external source
Check wiring or replace sensor
Sensor defective or short circuit to ground
Check wiring or replace sensor
Monitoring function for ADC Sig-error not explained in documentation???? Check oil pressure sensor for accuracy and check oil system
Sensor defective or short circuit to external source
Check wiring or replace sensor
Sensor defective or short circuit to ground
Check wiring or replace sensor
Inaccurate oil or coolant temperature sensors or insufficient oil or coolant recirculation (low coolant level etc.).
Check oil and coolant temperature sensor for accuracy and check oil and coolant system for proper functioning
Sensor defective or short circuit to external source
Check wiring or replace sensor
Sensor defective or short circuit to ground
Check wiring or replace sensor
Extreme ambient conditions. Or inaccurate sensor (although sensor does not exceed its signal range)
Ensure that engine was not running in extreme ambient conditions. Check wiring and accuracy of sensor, replacement of sensor
Power Red.
Mil.
No
"Mil OFF"
No
"Mil OFF"
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
"Mil OFF"
No
"Mil OFF"
89
Base - May 2012
SECTION 5 - DIAGNOSTICS
Inaccurate oil pressure sensor or defect (e.g. blocked piping) in the oil system.
Long TermFailure
F4AE ENGINES
Print P2D32N020 E
Dfp Name
OPSCD1
OTSCD1
Rail Pressure Sensor Offset Monitoring
Oil Pressure too low
Oil Temperature too high
DTC
$ 236
$ 238
$ 23A
Reason of Failure
Possible failure correction
Rail pressure sensor inaccurate
Ensure correct wiring and proper functioning of rail pressure sensor, replace sensor
Rail pressure sensor inaccurate
Ensure correct wiring and proper functioning of rail pressure sensor, replace sensor
"non"
Inaccurate oil pressure sensor or defect (e.g. too low oil level, leakage...) in the oil system.
Check oil pressure sensor for accuracy and check oil system
No
"Mil OFF"
"non"
Inaccurate oil temperature sensor or defect (e.g. blockage, insufficient recirculation) in the oil system.
Check oil temperature sensor for accuracy and check oil system
No
"Mil OFF"
OBD-System
"comprehensive components"
Long TermFailure
Power Red.
Mil.
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
yes (technical)
"Mil ON"
SECTION 5 - DIAGNOSTICS
RailCDOfsTst
Description
90
Base - May 2012
Dfp Name
Engine 2 (Speed sensing/actuators)
EngMCrS1
Crankshaft Speed Signal failure
$ 141
"non"
Signal interrupted do to wiring problem, defective or incorrectly installed crankshaft speed sensor
Check wiring, sensor installation and proper functioning of crankshaft sensor (evaluate raw signals)
Signal interrupted do to wiring problem, defective or incorrectly installed crankshaft speed sensor
Check wiring, sensor installation and proper functioning of crankshaft sensor (evaluate raw signals)
Failure is a NOx dependent (potentially) longterm failure (via LTF group2 Injection Timing System)
yes (technical)
"Mil ON"
F4AE ENGINES
Print P2D32N020 E
EngMBackUp
Description
Engine runs with Camshaft Speed only
EngMCaS1
Camshaft Speed Signal failure
EngMOfsCaSCrS
Offset between Camshaft and Crankshaft
DTC
$ 142
$ 143
$ 144
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
Power Red.
Mil.
"non"
Signal interrupted do to wiring problem, defective or incorrectly installed crankshaft speed sensor
Check wiring, sensor installation and proper functioning of crankshaft sensor (evaluated raw signals)
No
yes (technical)
"Mil OFF"
Signal interrupted do to wiring problem, defective or incorrectly installed camshaft phase sensor
Check wiring, sensor installation and proper functioning of camshaft phase sensor (evaluate raw signals)
Signal interrupted do to wiring problem, defective or incorrectly installed camshaft phase sensor
Check wiring, sensor installation and proper functioning of camshaft phase sensor (evaluate raw signals)
No
yes (technical)
"Mil OFF"
Signal interrupted do to wiring problem, defective or incorrectly installed camshaft or crankshaft sensor
Check wiring, sensor installations and proper functioning of camshaft and crankshaft sensors (evaluate raw signals)
"non"
"non"
Failure is a NOx dependent (potentially) longterm failure (via LTF group2 Injection Timing System)
F4AE ENGINES
Print P2D32N020 E
Dfp Name
"Mil ON"
SECTION 5 - DIAGNOSTICS
91
Base - May 2012
Description
Info: Engine Overspeed Protection
CoVehPrflmAct
Info: OBD Performance Limiter Intervention by Legislation
ECBtCDStop
Engine Compartment Stop Button stuck
$ 14D
$ 14F
$ 24A
Reason of Failure
Possible failure correction
Long TermFailure
"non"
Engine overspeed has occurred
No reactions necessary only if this fault/information status reoccurs frequently. In this case check driving conditions of vehicle, engine speed acquisition and injection system for quantity setpoint and actual value during fault recognition, check also for ECU errors
no
"Mil OFF"
"non"
A defect has occurred (in the EDC or DCU) which triggered a performance limitation via corresponging Fids
Check what faiure evoked the performance limitation and perform troubleshooting on the basis of this defect.
No
"Mil OFF"
"non"
Wrong manipulation of operator, button mechanically stuck in actuated position, electrical defect in device, defective wiring
Advice operator not to press button too long, check device for mechanical and electrical defects, check wiring
No
"Mil OFF"
OBD-System
Power Red.
Mil.
SECTION 5 - DIAGNOSTICS
EngPrtOvrSpd
DTC
92
Base - May 2012
Dfp Name
F4AE ENGINES
Print P2D32N020 E
Description
DTC
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
Power Red.
Mil.
Fuel metering CR Systems
RailMeUn1
RailMeUn2
Rail Pressure Positive Deviation High and High Fuel Flow Setpoint Value
Rail Pressure Negative Deviation too High on Minimum Metering
$ 152
$ 153
"non"
High pressure side: Leakage in high pressure section, injection nozzle stuck in open position, worn high pressure pump, worn injector, leaking pressure relieve valve Low pressure side: Pressure before gear pump too low, gear pump output too low (fuel filter clogged, leakage in low pressure side).
Check for defects according to 'reason of failure' list.
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
yes (technical)
"Mil OFF"
"non"
Metering unit stuck in open position, zero-delivery throttle clogged, metering unit without power due to electricel error. Low pressure side: Pressure before gear pump too high (e.g. by pressure relieve valve), pressure after zero-delivery throttle too high.
Check for defects according to 'reason of failure' list.
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
yes (technical)
"Mil OFF"
F4AE ENGINES
Print P2D32N020 E
Dfp Name
SECTION 5 - DIAGNOSTICS
93
Base - May 2012
RailMeUn4
RailMeUn6
Rail Pressure below Minimum Limit in Controlled Mode
Rail Pressure above Maximum Limit in Controlled Mode
Rail Pressure Drop Rate too High
DTC
$ 154
$ 155
$ 156
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
"non"
High pressure side: Leakage in the high pressure section, injection nozzle stuck in open position, worn high pressure pump, worn injector, leaking pressure relieve valve. Low pressure side: Pressure before gear pump too low or gear pump output too low (clogged fuel filter, leak on output side).
Check for defects according to 'reason of failure' list.
No
"Mil OFF"
"non"
Metering unit stuck in open position, zero-delivery throttle clogged, metering unit without power due to electricel error. Low pressure side: Pressure before gear pump too high (e.g. by pressure relieve valve), pressure after zero-delivery throttle too high.
Check for defects according to 'reason of failure' list.
No
"Mil OFF"
"non"
Leakage in the high pressure section, injection nozzle stuck in open position, worn high pressure pump, worn injector, leaking pressure relieve valve, injector reflux too high.
Check for defects according to 'reason of failure' list.
No
Power Red.
yes (technical)
Mil.
SECTION 5 - DIAGNOSTICS
RailMeUn3
Description
94
Base - May 2012
Dfp Name
"Mil OFF"
F4AE ENGINES
Print P2D32N020 E
RailMeUn7
RailMeUn10
Description
Setpoint of Rail Metering Unit not plausible in Overrun
Fuel Flow Setpoint of Common Rail Metering Unit too low
DTC
$ 157
$ 158
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
Power Red.
Mil.
"non"
High pressure system: Leakage in the high pressure section, injection nozzle stuck in open position, worn or defective high pressure pump, worn injector, leaking pressure relieve valve. Low pressure system: 'Zero delivery' is not active in metering unit (excessve leakage in metering unit).
Check for defects according to 'reason of failure' list.
No
yes (technical)
"Mil OFF"
"non"
High pressure system: Rail pressure sensor inaccurate, high pressure pump defective. Low pressure system: Metering unit reflux too low, fuel system leakage, metering unit jammed in closed position.
Check for defects according to 'reason of failure' list.
No
yes (technical)
"Mil OFF"
Broken or disconnected wiring or defective relay
Check of wiring or replace relay
Defective wiring, ECU, powerstage or metering unit
Check wiring, ECU, power stage and metering unit
The 'High Pressure Test' is requested via a diagnostic tester
Wait until the 'High Pressure Test' has terminated
MeUnCDNoLoad
Common Rail Metering Unit Power Stage failure
$ 159
"non"
HpTst
Info Fault: High Pressure Test (Rail Pressure Monitoring deactivated)
$ 15B
"non"
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil OFF"
No
"Mil OFF"
F4AE ENGINES
Print P2D32N020 E
Dfp Name
SECTION 5 - DIAGNOSTICS
95
Base - May 2012
Description
Info: Long Term Fuel system Failure
MeUnCDSCBat
Common Rail Metering Unit Power Stage Short to Battery
OBDGFClct2
Info: Long Term Injection timing Failure
MeUnCDSCGnd
Common Rail Metering Unit Power Stage Short to Ground
OBDGFClct3
OBDGFClct4
OBDGFClct5
Info: Long Term air system failure
Info: Long Term NOx Sensor Failure
Info: Long Term SCR System Failure
$ 15F
$ 259
$ 25F
$ 359
$ 35F
$ 45F
$ 55F
Reason of Failure
Possible failure correction
Long TermFailure
"non"
High NOx emissions due to various possible defects
Identify the defect triggering this fault path and follow the troubleshooting procedure of that failure.
Failure is a direct longterm failure (via counter 576000 mins)
"Mil ON"
"non"
Short circuit of wiring to external source or inside relay
Check of wiring or replace relay
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil OFF"
"non"
High NOx emissions due to various possible defects
Identify the defect triggering this fault path and follow the troubleshooting procedure of that failure.
Failure is a direct longterm failure (via counter 576000 mins)
"Mil ON"
"non"
Short circuit of wiring to ground or inside relay
Check of wiring or replace relay
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil OFF"
"non"
High NOx emissions due to various possible defects
Identify the defect triggering this fault path and follow the troubleshooting procedure of that failure.
Failure is a direct longterm failure (via counter 576000 mins)
"Mil ON"
"non"
High NOx emissions due to various possible defects
Identify the defect triggering this fault path and follow the troubleshooting procedure of that failure.
Failure is a direct longterm failure (via counter 576000 mins)
"Mil ON"
"non"
High NOx emissions due to various possible defects
Identify the defect triggering this fault path and follow the troubleshooting procedure of that failure.
Failure is a direct longterm failure (via counter 576000 mins)
"Mil ON"
OBD-System
Power Red.
Mil.
SECTION 5 - DIAGNOSTICS
OBDGFClct1
DTC
96
Base - May 2012
Dfp Name
F4AE ENGINES
Print P2D32N020 E
Description
DTC
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
Power Red.
Mil.
Injectors 1
Injectors 1
InjVlvCyl2A
InjVlvCyl3A
Injector Cylinder 1 failure
Injector Cylinder 2 failure
Injector Cylinder 3 failure
$ 161
$ 162
$ 163
"fuel system"
"fuel system"
"fuel system"
Short circuit in wiring with external source
Check the wiring or replace injector
Defective coil of injector
Check the wiring and replace injector.
Depending on the pattern, various reasons can cause the defect, internal ECU problems also possible
Check the wiring and the injection signals, replace ECU
Short circuit in wiring with external source
Check the wiring or replace injector
Defective coil of injector
Check the wiring and replace injector.
Depending on the pattern, various reasons can cause the defect, internal ECU problems also possible
Check the wiring and the injection signals, replace ECU
Short circuit in wiring with external source
Check the wiring or replace injector
Defective coil of injector
Check the wiring and replace injector.
Depending on the pattern, various reasons can cause the defect, internal ECU problems also possible
Check the wiring and the injection signals, replace ECU
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil ON"
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil ON"
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil ON"
F4AE ENGINES
Print P2D32N020 E
Dfp Name
SECTION 5 - DIAGNOSTICS
97
Base - May 2012
InjVlvCyl5A
InjVlvCyl6A
InjVlvCyl1B
Injector Cylinder 4 failure
Injector Cylinder 5 failure
Injector Cylinder 6 failure
Injector Cylinder 1 warning
DTC
$ 164
$ 165
$ 166
$ 167
OBD-System
"fuel system"
"fuel system"
"fuel system"
"fuel system"
Reason of Failure
Possible failure correction
Short circuit in wiring with external source
Check the wiring or replace injector
Defective coil of injector
Check the wiring and replace injector.
Depending on the pattern, various reasons can cause the defect, internal ECU problems also possible
Check the wiring and the injection signals, replace ECU
Short circuit in wiring with external source
Check the wiring or replace injector
Defective coil of injector
Check the wiring and replace injector.
Depending on the pattern, various reasons can cause the defect, internal ECU problems also possible
Check the wiring and the injection signals, replace ECU
Short circuit in wiring with external source
Check the wiring or replace injector
Defective coil of injector
Check the wiring and replace injector.
Depending on the pattern, various reasons can cause the defect, internal ECU problems also possible
Check the wiring and the injection signals, replace ECU
Broken wire or disconnection of wiring or inside injector
Check the wiring or replace injector.
Long TermFailure
Power Red.
Mil.
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil ON"
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil ON"
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil ON"
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil ON"
SECTION 5 - DIAGNOSTICS
InjVlvCyl4A
Description
98
Base - May 2012
Dfp Name
F4AE ENGINES
Print P2D32N020 E
Description
InjVlvCyl2B
Injector Cylinder 1 warning
InjVlvCyl3B
Injector Cylinder 1 warning
InjVlvCyl4B
Injector Cylinder 1 warning
InjVlvCyl5B
Injector Cylinder 1 warning
InjVlvCyl6B
InjVlvNumMinInj
Injector Cylinder 1 warning
Minimum Injections Number not reached
DTC
$ 168
$ 169
$ 16A
$ 16B
$ 16C
$ 16E
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
"fuel system"
Broken wire or disconnection of wiring or inside injector
Check the wiring or replace injector.
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil ON"
"fuel system"
Broken wire or disconnection of wiring or inside injector
Check the wiring or replace injector.
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil ON"
"fuel system"
Broken wire or disconnection of wiring or inside injector
Check the wiring or replace injector.
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil ON"
"fuel system"
Broken wire or disconnection of wiring or inside injector
Check the wiring or replace injector.
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil ON"
"fuel system"
Broken wire or disconnection of wiring or inside injector
Check the wiring or replace injector.
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil ON"
"non"
See individual injector and injection-bank errors (InjVlvCyl... and InjVlvBnk...) which have triggerd the shut-off or error in the component
See individual injector and injection-bank errors (InjVlvCyl... and InjVlvBnk...) which have triggerd the shut-off or error in the component
No
"Mil OFF"
Power Red.
Mil.
F4AE ENGINES
Print P2D32N020 E
Dfp Name
SECTION 5 - DIAGNOSTICS
99
Base - May 2012
Description
DTC
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
Power Red.
Mil.
InjVlvBnk1A
InjVlvBnk2A
InjVlvChipA
Injector Bank 1 failure
Injector Bank 2 failure
ECU Hardware for Injection: CY33X Chip specific failure (1)
$ 171
$ 173
$ 17C
"fuel system"
"fuel system"
"non"
Short circuit of high-side to battery or ground.
Check the wiring or replace injector.
Short circuit of low-side to ground in injector cable.
Check the wiring or replace injector.
Depending on the pattern, various reasons can cause the defect, internal ECU problem
Check the wiring and the injection signals, replace ECU
Short circuit of high-side to battery or ground.
Check the wiring or replace injector.
Short circuit of low-side to ground in injector cable.
Check the wiring or replace injector.
Depending on the pattern, various reasons can cause the defect, internal ECU problem
Check the wiring and the injection signals, replace ECU
Clock error or irrupton of the power supply voltage.
Check the power supply or replace ECU if problem reoccurs.
Defective ECU
Reset ECU. If no recovery, replace ECU.
Internal failure of ECU or 'TESTMODE' takes too long
Check 'TESTMODE' parameters or replace ECU if problem reoccurs
Defective SPI-bus participant, timing problem due to software bug
Replace ECU if problem reoccurs (Send in ECU for investigation)
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil ON"
Failure is a NOx dependent (potentially) longterm failure (via LTF group1 Fuel System)
"Mil ON"
No
"Mil OFF"
SECTION 5 - DIAGNOSTICS
Injectors 2
100
Base - May 2012
Dfp Name
F4AE ENGINES
Print P2D32N020 E
InjVlvChipB
Description
ECU Hardware for Injection: CY33X Chip specific failure (2)
DTC
$ 27C
OBD-System
Reason of Failure
Possible failure correction
Defective ECU
Replace ECU if problem reoccurs
Defective ECU
Replace ECU if problem reoccurs
Defective ECU
Replace ECU if problem reoccurs
Defective ECU
Replace ECU if problem reoccurs
"non"
Long TermFailure
Power Red.
Mil.
No
"Mil OFF"
No
"Mil ON"
No
"Mil OFF"
No
"Mil OFF"
F4AE ENGINES
Print P2D32N020 E
Dfp Name
Air inlet system / EGR IEDPCDPDiff
Differential Pressure Sensor Failure between Exhaust and Intake (EGR Valve)
$ 181
"comprehensive components"
Boost system and turbine speed
SmkTrqLim
Torque Reduction due to Smoke Limitation
NOxEstIv
NOx Estimation failure
$ 19E
$ 19F
"non"
Active power redcution due to smoke limitation
No actions necessary due to this failure alone. If powerreduction occurred due to actual defect, the failure triggering the torque limitation should also be in the failure memory. Follow troubleshooting of this root error.
"non"
Application dependent: Implausible sensor signals or defective sensors etc.
Determine what defect has set the Fid and resolve the problem causing this original defect.
SECTION 5 - DIAGNOSTICS
101
Base - May 2012
BstPrtTrqLim
EngPrtTrqLim
Info: Torque Limitation due to Negative Torque Coordinator
Info: Torque Limitation due to Turbo Charger Protection
Info: Torque Limitation due to Engine Protection (against Excessive Torque, Engine Overspeed and Overheat)
DTC
$ 29D
$ 39E
$ 49E
OBD-System
"non"
"non"
"non"
Reason of Failure
Possible failure correction
Long TermFailure
Active power redcution due to engine break shut off event
No actions necessary due to this failure alone. If powerreduction occurred due to actual defect, the failure triggering the torque limitation should also be in the failure memory. Follow troubleshooting of this root error.
No
"Mil OFF"
Active power redcution due to turbo charger protection
No actions necessary due to this failure alone. If powerreduction occurred due to actual defect, the failure triggering the torque limitation should also be in the failure memory. Follow troubleshooting of this root error.
No
"Mil OFF"
Active power redcution due to engine mechanics protection
No actions necessary due to this failure alone. If powerreduction occurred due to actual defect, the failure triggering the torque limitation should also be in the failure memory. Follow troubleshooting of this root error.
No
"Mil OFF"
Power Red.
Mil.
SECTION 5 - DIAGNOSTICS
NTCTrqLim
Description
102
Base - May 2012
Dfp Name
F4AE ENGINES
Print P2D32N020 E
SCRPrtTrqLim
NsCtlTrqLim
QLimTrqLim
Description
Info: Torque Limitation due to SCR Catalyst Overheat Protection
Info: Torque Limitation due to Noise Limitation
Info: Torque Limitation due to Fuel Quantity Limitation because of Injection System Errors
DTC
$ 59D
$ 59E
$ 69E
OBD-System
"non"
"non"
"non"
Possible failure correction
Long TermFailure
Active power redcution due to excessive temperatures in the SCR catalyst
No actions necessary due to this failure alone. If powerreduction occurred due to actual defect, the failure triggering the torque limitation should also be in the failure memory. Follow troubleshooting of this root error.
No
"Mil OFF"
Active power redcution due to noise control
No actions necessary due to this failure alone. If powerreduction occurred due to actual defect, the failure triggering the torque limitation should also be in the failure memory. Follow troubleshooting of this root error.
No
"Mil OFF"
Active power redcution due to limiting fuel quantity
No actions necessary due to this failure alone. If powerreduction occurred due to actual defect, the failure triggering the torque limitation should also be in the failure memory. Follow troubleshooting of this root error.
No
"Mil OFF"
Power Red.
Mil.
103
Base - May 2012
SECTION 5 - DIAGNOSTICS
Reason of Failure
F4AE ENGINES
Print P2D32N020 E
Dfp Name
Description
DTC
OBD-System
Reason of Failure
Possible failure correction
Power Red.
Mil.
Failure is a NOx dependent (potentially) longterm failure (via LTF group4 NOx Sensor)
yes (OBD)
"Mil ON"
Failure is a NOx dependent (potentially) longterm failure (via LTF group4 NOx Sensor)
yes (OBD)
"Mil ON"
Failure is a NOx dependent (potentially) longterm failure (via LTF group4 NOx Sensor)
yes (OBD)
"Mil ON"
Exhaust system (Aftertreatment) FrmMngNOxSensNO xIv
FrmMngNOxSensIv
FrmMngTONOxSensI v
NOx Sensor Plausiblity failure
NOx Sensor Failure
CAN Message timeout Nox (from Nox Sensor)
$ 1A2
$ 1A3
$ 1A4
"comprehensive components"
"comprehensive components"
"non"
CAN communication disturbed, defective or inaccurate NOx sensor
Check for proper CAN communication and check accuracy and proper functioning of NOx sensor.
Disconnected cable in the wiring of the NOx sensor or defective NOx sensor.
Check wiring of NOx sensor and its proper functioning. If necessary replace NOx sensor.
Short circuit in the wiring of the NOx sensor or defective NOx sensor.
Check wiring of NOx sensor and its proper functioning. If necessary replace NOx sensor.
Strange driving cycle or inproper installation of the sensor, defective NOx sensor
Check installation (including wiring) and functionality of sensor. If necessary change NOx sensor
Defective CAN controller of NOx Sensor , undervoltage of NOx Sensor, missing NOx Sensor, CAN cable connecting the NOx Sensor is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the NOx Sensor to the network, Check correct functioning of the NOx Sensor CAN controller and its voltage supply. Check wiring.
SECTION 5 - DIAGNOSTICS
Long TermFailure
104
Base - May 2012
Dfp Name
F4AE ENGINES
Print P2D32N020 E
FrmMngTODM1DCU Iv
FrmMngTOSCR1Iv
FrmMngSCR1ProtIv
Description
CAN Message timeout DM1DCU (from DCU)
CAN Message timeout SCR1 (from DCU)
Info: SCR Dosing Valve Overheat Protection
DTC
$ 1A5
$ 1A6
$ 1A8
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
Power Red.
Mil.
"catalyst monitoring"
Defective CAN controller of DCU, undervoltage of DCU, missing DCU, CAN cable connecting the DCU is disconnected or broken. Short circuit in wiring
Check presence and correct connection of the DCU to the network, check correct functioning of the DCU CAN controller and its voltage supply. Check wiring.
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
yes (OBD)
"Mil ON"
"catalyst monitoring"
Defective CAN controller of Dosing Control Unit , undervoltage of DCU, missing DCU, CAN cable connecting the DCU is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the DCU to the network, Check correct functioning of the DCU CAN controller and its voltage supply. Check wiring.
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
yes (OBD)
"Mil ON"
Failure due to engine switch off after a high load period, leading to high temperatur in exhaust system. A defect occurred in the urea dosing system which can impair the cooling of the urea dosing valve
Read out the DCU failure memory and perform troubleshooting according to DCU support.
A defect occurred in the urea dosing system which can impair the cooling of the urea dosing valve
Read out the DCU failure memory and perform troubleshooting according to DCU support.
"non"
No
F4AE ENGINES
Print P2D32N020 E
Dfp Name
"Mil OFF"
SECTION 5 - DIAGNOSTICS
105
Base - May 2012
FrmMngDM1SPN1Iv
SCRCatNOxDrIv
FrmMngTOSCR2Iv
Humidity Sensor Signal Ratio failure
Info: DCU Error1 via CAN message DM1DCU
NOx Sensor Drift failure
CAN Message timeout SCR2 (from DCU)
DTC
$ 1AE
$ 1AF
$ 2A2
$ 2A6
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
Check wiring. Replace sensor if necessary
"non"
Sensor defective or short circuit to external source Sensor defective or short circuit to ground
Check wiring. Replace sensor if necessary
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
A certain error has occured in the DCU System and is reported via CAN to the EDC.
Check what SPN and corresponding DCU error is active and perform troubleshooting according to DCU support.
Check what SPN and corresponding DCU error is active and perform troubleshooting according to DCU support.
yes (OBD)
"Mil OFF"
"comprehensive components"
NOx sensor inaccurate or defective, defect in wiring, urea injection valve or fuel injector jammed open, excessive urea deposits in exhaust system, strange behaviour of SCR catalyst
Check NOx sensor for correct functioning (dismount sensor -> NOx value should be 0ppm during driving), check wiring of sensor, check fuel injectors, check urea dosing system for correct dosing amount (perform UDST and Dosing Valve Check, check DCU error memory for leakage failures), check SCR catalyst for correct functioning, check exhaust system for excessive urea deposits
Failure is a NOx dependent (potentially) longterm failure (via LTF group4 NOx Sensor)
yes (OBD)
"Mil ON"
"catalyst monitoring"
Defective CAN controller of Dosing Control Unit , undervoltage of DCU, missing DCU, CAN cable connecting the DCU is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the DCU to the network, Check correct functioning of the DCU CAN controller and its voltage supply. Check wiring.
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
yes (OBD)
"Mil ON"
"non"
Power Red.
Mil.
"Mil OFF"
SECTION 5 - DIAGNOSTICS
IAHSCDStrtDly
Description
106
Base - May 2012
Dfp Name
F4AE ENGINES
Print P2D32N020 E
Description
DTC
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
Power Red.
Mil.
If failure 1AE 'IAHSCDStrDly' also stored in memory: proceed according that description
IAHSCD
Info: Humidity Sensor possibly saturated with water droplets
$ 2AE
"non"
Sensor possibly saturated with water droplets
If failure ACTIVE: run engine at medium speed > 10 min, if failure does NOT get INACTIVE: check wiring harness and replace sensor if necessary If failure not active AND ratio 'active time' / 'occurrence' < 10 min/occurrence: no action needed
Failure is a NOx dependent (potentially) longterm failure (via LTF group5 SCR System)
F4AE ENGINES
Print P2D32N020 E
Dfp Name
"Mil OFF"
If failure not active AND ratio 'active time' / 'occurrence' > 10 min/occurrence: possible short circuit: check wiring harness or replace sensor, if necessary
FrmMngDM1SPN2Iv
Info: DCU Error2 via CAN message DM1DCU
$ 2AF
"non"
Sensor defective or short circuit to ground
Check wiring. Replace sensor if necessary
A certain error has occured in the DCU System and is reported via CAN to the EDC.
Check what SPN and corresponding DCU error is active and perform troubleshooting according to DCU support.
No
yes (OBD)
"Mil ON"
SECTION 5 - DIAGNOSTICS
107
Base - May 2012
FrmMngDM1SPN4Iv
FrmMngDM1SPN5Iv
NOx Sensor Plausibility failure
Info: DCU Error4 via CAN message DM1DCU
Info: DCU Error5 via CAN message DM1DCU
DTC
$ 3A2
$ 4AF
$ 5AF
Reason of Failure
Possible failure correction
Long TermFailure
Power Red.
Mil.
"comprehensive components"
NOx sensor inaccurate or defective, defect in wiring, inaccurate NOx estimation, urea injection valve jammed open or excessive urea deposits in exhaust system, defective SCR catalyst
Check urea dosing system for correct dosing amount (perform UDST and Dosing Valve Check, check DCU error memory for leakage failures), check NOx sensor for correct functioning, check wiring of sensor, check NOx estimation (humidity, boost pressure and temperature) for plausible values, check SCR catalyst for correct functioning, check exhaust system for excessive urea deposits
Failure is a NOx dependent (potentially) longterm failure (via LTF group4 NOx Sensor)
yes (OBD)
"Mil ON"
SECTION 5 - DIAGNOSTICS
SCRCatNOxPlIv
Description
108
Base - May 2012
Dfp Name
"non"
A certain error has occured in the DCU System and is reported via CAN to the EDC.
Check what SPN and corresponding DCU error is active and perform troubleshooting according to DCU support.
No
yes (OBD)
"Mil ON"
"non"
A certain error has occured in the DCU System and is reported via CAN to the EDC.
Check what SPN and corresponding DCU error is active and perform troubleshooting according to DCU support.
No
yes (OBD)
"Mil ON"
OBD-System
F4AE ENGINES
Print P2D32N020 E
Description
DTC
Possible failure correction
Long TermFailure
"non"
Wrong configuration of CAN timing (Prescaler, synchronization jump width, sampling, propagation and phase segments), bad termination resistors, defective network connection and contacts or defective CAN controller with erroneous messages.
Check timing configuration with hardware compatibility, check termination resistors and network connection and contacts. Short circuits to external source, ground or CAN High to Low.Monitor CAN communication for erroneous behaviour of a participant.
No
"Mil OFF"
"non"
Wrong configuration of CAN timing (Prescaler, synchronization jump width, sampling, propagation and phase segments), bad termination resistors, defective network connection and contacts or defective CAN controller with erroneous messages.
Check timing configuration with hardware compatibility, check termination resistors and network connection and contacts. Short circuits to external source, ground or CAN High to Low.Monitor CAN communication for erroneous behaviour of a participant.
No
"Mil OFF"
OBD-System
Reason of Failure
Power Red.
Mil.
Interfaces 1 (CAN-Bus)
NetMngCANAOff
NetMngCANBOff
CAN A Bus off
CAN B Bus off
$ 1B1
$ 1B2
F4AE ENGINES
Print P2D32N020 E
Dfp Name
SECTION 5 - DIAGNOSTICS
109
Base - May 2012
FrmMngTOBC2EDC1 Iv
FrmMngTOVM2EDCI v
FrmMngTxTO
CAN C Bus off
CAN Message timeout BC2EDC1 (from Body Computer)
CAN Message timeout VM2EDC (from VCM)
CAN Transmit Message timeout
DTC
$ 1B3
$ 1B4
$ 1B5
$ 1B7
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
"non"
Wrong configuration of CAN timing (Prescaler, synchronization jump width, sampling, propagation and phase segments), bad termination resistors, defective network connection and contacts or defective CAN controller with erroneous messages.
Check timing configuration with hardware compatibility, check termination resistors and network connection and contacts. Short circuits to external source, ground or CAN High to Low.Monitor CAN communication for erroneous behaviour of a participant.
No
"Mil OFF"
"non"
Defective CAN controller of Body Computer , undervoltage of BC, missing BC, CAN cable connecting the BC is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the BC to the network, Check correct functioning of the BC CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
"non"
Defective CAN controller of Vehicle Control Module , undervoltage of VCM, missing VCM, CAN cable connecting the VCM is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the VCM to the network, Check correct functioning of the VCM CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
"non"
Disturbed CAN, incorrect configuration of the CAN, EDC is disconnected from the network, EDC CAN controller defective
Check CAN communication, check CAN configuration, ensure proper connection of the EDC to the network, replace EDC
No
Power Red.
yes (OBD)
Mil.
SECTION 5 - DIAGNOSTICS
NetMngCANCOff
Description
110
Base - May 2012
Dfp Name
"Mil OFF"
F4AE ENGINES
Print P2D32N020 E
FrmMngBC1MILIv
FrmMngTODashDsplI v
FrmMngTORxAMCO NIv
FrmMngTORxCCVS
Description
Info: MIL visualization not available
CAN Message timeout Dash Display (from VCM)
CAN Message timeout AMCON (from VCM)
CAN Message timeout CCVS (from Body Computer or VCM)
DTC
$ 1B9
$ 1BA
$ 1BC
$ 1BD
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
"comprehensive components"
Defective MIL/Body Controller or disturbed CAN communication
Consult trouble shooting of body controller and check correct functioning of the CAN communication.
No
"Mil ON"
"non"
Defective CAN controller of Vehicle Control Module , undervoltage of VCM, missing VCM, CAN cable connecting the VCM is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the VCM to the network, Check correct functioning of the VCM CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
"non"
Defective CAN controller of Vehicle Control Module , undervoltage of VCM, missing VCM, CAN cable connecting the VCM is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the VCM to the network, Check correct functioning of the VCM CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
"non"
Defective CAN controller of Body Computer or Vehicle Control Module , undervoltage of BC or VCM, missing BC or VCM, CAN cable connecting the BC or VCM is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the BC or VCM to the network, check correct functioning of the BC or VCM CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
Power Red.
Mil.
F4AE ENGINES
Print P2D32N020 E
Dfp Name
SECTION 5 - DIAGNOSTICS
111
Base - May 2012
CAN Message timeout BC2EDC2 (from Body Computer)
DTC
$ 2B4
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
"non"
Defective CAN controller of Body Computer , undervoltage of BC, missing BC, CAN cable connecting the BC is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the BC to the network, Check correct functioning of the BC CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
Power Red.
Mil.
Interfaces 2 (CAN messages timeout)
FrmMngTOETC1
CAN Message timeout ETC1 (from Electronic Transmission Controller)
FrmMngTOTCO1
CAN Message timeout TCO1 (from Tachograph Output)
FrmMngTOTSC1PEA ctIv
CAN Message timeout active TSC1-PE (Torque/Speed Control Request from PTO to Engine)
$ 1C2
$ 1C3
$ 1C6
"non"
Defective CAN controller of Gearbox Control Unit , undervoltage of ETC, missing ETC, CAN cable connecting the ETC is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the ETC to the network, check correct functioning of the ETC CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
"non"
Defective CAN controller of Tachograph Output , undervoltage of TCO, missing TCO, CAN cable connecting the TCO is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the TCO to the network, check correct functioning of the TCO CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
"non"
Defective CAN controller of Power Take Off , undervoltage of PTO, missing PTO, CAN cable connecting the PTO is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the PTO to the network, Check correct functioning of the PTO CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
SECTION 5 - DIAGNOSTICS
FrmMngTOBC2EDC2 Iv
Description
112
Base - May 2012
Dfp Name
F4AE ENGINES
Print P2D32N020 E
FrmMngTOTSC1VEA ctIv
Description
CAN Message timeout active TSC1-VE (Torque/Speed Control Request from VCM/BC to Engine)
FrmMngTOETC2
CAN Message timeout ETC2 (from Electronic Transmission Controller)
FrmMngTOTSC1PEPa sIv
CAN Message timeout inactive TSC1-PE (Torque/Speed Control Request from PTO to Engine)
FrmMngTOTSC1VRA ctIv
$ 1C8
$ 2C2
$ 2C6
$ 2C8
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
"non"
Defective CAN controller of Vehicle Control Module or Body Computer , undervoltage of VCM/BC, missing VCM/BC, CAN cable connecting the VCM/BC is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the VCM/BC to the network, Check correct functioning of the VCM/BC CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
"non"
Defective CAN controller of Gearbox Control Unit , undervoltage of ETC, missing ETC, CAN cable connecting the ETC is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the ETC to the network, Check correct functioning of the ETC CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
"non"
Defective CAN controller of Power Take Off , undervoltage of PTO, missing PTO, CAN cable connecting the PTO is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the PTO to the network, Check correct functioning of the PTO CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
"non"
Defective CAN controller of Vehicle Control Module or Body Computer , undervoltage of VCM/BC, missing VCM/BC, CAN cable connecting the VCM/BC is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the VCM/BC to the network, Check correct functioning of the VCM/BC CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
Power Red.
Mil.
113
Base - May 2012
SECTION 5 - DIAGNOSTICS
CAN Message timeout active TSC1-VR (Torque/Speed Control Request from VCM/BC to Retarder)
DTC
F4AE ENGINES
Print P2D32N020 E
Dfp Name
FrmMngTOTSC1VEP asIv
FrmMngTOHRVDIv
FrmMngTOTSC1VRP asIv
Time/Date CAN timeout (from Tachograph or VCM)
CAN Message timeout inactive TSC1-VE (Torque/Speed Control Request from VCM/BC to Engine)
CAN Message timeout HRVD (from Tachograph - High Resolution Vehicle Distance)
CAN Message timeout inactive TSC1-VR (Torque/Speed Control Request from VCM/BC to Retarder)
DTC
$ 2C9
$ 3C8
$ 3C9
$ 4C8
OBD-System
Reason of Failure
Possible failure correction
Long TermFailure
"non"
Defective CAN controller of Tachograph , undervoltage of TC, missing TC, CAN cable connecting the TC is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the TC to the network, Check correct functioning of the TC CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
"non"
Defective CAN controller of Vehicle Control Module or Body Computer , undervoltage of VCM/BC, missing VCM/BC, CAN cable connecting the VCM/BC is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the VCM/BC to the network, Check correct functioning of the VCM/BC CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
"non"
Defective CAN controller of Tachograph - High Resolution Vehicle Distance , undervoltage of BC, missing BC, CAN cable connecting the BC is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the BC to the network, Check correct functioning of the BC CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
"non"
Defective CAN controller of Vehicle Control Module or Body Computer , undervoltage of VCM/BC, missing VCM/BC, CAN cable connecting the VCM/BC is disconnected or broken. Short circuit in wiring.
Check presence and correct connection of the VCM/BC to the network, Check correct functioning of the VCM/BC CAN controller and its voltage supply. Check wiring.
No
"Mil OFF"
Power Red.
Mil.
SECTION 5 - DIAGNOSTICS
FrmMngTOTimeDateI v
Description
114
Base - May 2012
Dfp Name
F4AE ENGINES
Print P2D32N020 E
Description
DTC
OBD-System
Long TermFailure
Electric disturbances, internal defect of the ECU leading to a SPI bus communication error
Replace ECU if failure remains present
No
"Mil OFF"
Wrong programming/flashing of the EDC, internal defect of the EDC.
Try to flash the EDC correctly with a proper dataset, if defect persists: replace EDC.
Wrong programming/flashing of the EDC, internal defect of the EDC.
Try to flash the EDC correctly with a proper dataset, if defect persists: replace EDC.
No
"Mil OFF"
Wrong programming/flashing of the EDC, internal defect of the EDC.
Try to flash the EDC correctly with a proper dataset, if defect persists: replace EDC.
Electronic disturbances, various hardware defects (ECU internal) or configuration problems
Analyze what error triggered the recovery (Read out label HWEMon_numRecov ery and compare the value with the according table). If error occurs repeatedly, reprogram EDC. If error remains, replace EDC.
No
"Mil OFF"
Defective monitoring module or CPU (e.g. impaired functioning of the CPU clock) of the EDC. Disturbed SPI-Bus.
If error exists only temporary (i.e. injection reoccurs) error can be ignored and error deleted in the fault memory. In case of a permanent error the injection remains blocked and the ECU has to be replaced
No
"Mil OFF"
Power Red.
Mil.
ECU 1 (internal checks) HWEMonCom
HWEMonEEPROM
HWEMonRcyLocked
Montr
ECU Hardware: SPI Communication failure
ECU Hardware: EEPROM failure
ECU recovery locked
ECU Hardware: Microcontroller Watchdog failure
$ 1D1
$ 1D2
$ 1D3
$ 1D4
"non"
"non"
"non"
"non"
115
Base - May 2012
SECTION 5 - DIAGNOSTICS
Possible failure correction
Reason of Failure
F4AE ENGINES
Print P2D32N020 E
Dfp Name
ECU Hardware: Shut off during Initialization
DTC
$ 1D5
OBD-System
"non"
TPUMon
ECU Hardware: TPU Monitoring
$ 1D6
"non"
VarMngCodDs
ECU Software: Variant Dataset failure
$ 1D7
"non"
Reason of Failure
Possible failure correction
Watch dog switch off path defect
If failure remains after ECU initialisation: replace ECU
Electronic disturbances, internal ECU problem
If failure remains after ECU initialisation: replace ECU
Electronic disturbances, internal ECU problem
If failure remains after ECU initialisation: replace ECU
Electronic disturbances, wrong TPU timebase
If failure persists: Replace ECU
See general remarks
See general remarks
See general remarks
See general remarks If ECU functions correctly after recovery only temporary SPI error occurred and fault memory can be deleted and error ignored. If permanent SPI error is present and the ECU does not leave boot block --> Replace ECU
WdCom
ECU Hardware: Controller Watchdog failure
$ 1D8
"non"
Disturbed SPI-Bus
ADCMon
ADC Monitoring failure
$ 1D9
"non"
Buffer overrun
HWEMonRcySuppres sed
ECU recovery suppressed
$ 2D3
"non"
Electronic disturbances, various hardware defects (ECU internal) or configuration problems
Analyze what error triggered the recovery (Read out label HWEMon_numRecov ery and compare the value with the according table). If error occurs repeatedly, reprogram EDC. If error remains, replace EDC.
Long TermFailure
Power Red.
Mil.
No
yes (technical)
"Mil OFF"
No
"Mil OFF"
No
"Mil OFF"
No
"Mil OFF"
No
"Mil OFF"
No
"Mil OFF"
SECTION 5 - DIAGNOSTICS
SOPTst
Description
116
Base - May 2012
Dfp Name
F4AE ENGINES
Print P2D32N020 E
Description
HWEMonRcyVisible
ECU recovery - visible
StrtCDHS
ECU Hardware: High Side Power Stage Short to Ground or Battery
DTC
$ 3D3
OBD-System
"non"
Reason of Failure
Possible failure correction
Long TermFailure
Electronic disturbances, various hardware defects (ECU internal) or configuration problems
Analyze what error triggered the recovery (Read out label HWEMon_numRecov ery and compare the value with the according table). If error occurs repeatedly, reprogram EDC. If error remains, replace EDC.
No
Power Red.
Mil.
F4AE ENGINES
Print P2D32N020 E
Dfp Name
"Mil OFF"
ECU 2 (Powerst./Immobil./Overrun/Sensor supply)
ImmCtl
Immobilizer failure (no fuel release)
$ 1E1
$ 1E2
"non"
Short circuit of wiring to ground or inside relay
Check of wiring or replace relay
No
"non"
1) Defective CAN or immobilizer and new control unit (here no PIN entry is possible) OR T15 was toggled more than a calibratable value OR number of allowed incorrect PIN entries is exceeded. 2) Defective CAN or immobilizer OR wrong code AND code is kown by the EDC AND T15 has not been toggeled excessively
1) Ensure correct CAN functioning (timeout errors), unlock fuel release via a tester request, replace immobilizer 2) Enter PIN code via accelerator pedal or instrument cluster, ensure correct CAN functioning (timeout errors), replace immobilzer
No
"Mil OFF"
Check injection relevant application, if failure persists replace ECU
No
"Mil OFF"
If failure persists after reinitialization replace ECU
No
"Mil OFF"
Overrun Monitoring failure
$ 1E3
"non"
OvRMonSigA
Redundant Engine Speed in Overrun Monitoring
$ 1E4
"non"
Electronic disturbances, internal ECU problem
"Mil OFF"
117
Base - May 2012
SECTION 5 - DIAGNOSTICS
OvRMon
Electronic disturbances, requested torque increase via tester, wrong application of injection relevant parameters, defective ECU
yes (technical)
SSpMon1
SSpMon2
ECU Hardware: Sensor 12V Supply Voltage failure
ECU Hardware: Sensor Supply Voltage 1 failure
ECU Hardware: Sensor Supply Voltage 2 failure
DTC
$ 1E5
$ 1E6
$ 1E7
OBD-System
"non"
"comprehensive components"
"non"
Reason of Failure
Possible failure correction
Excessive battery voltage, defect in wiring harness, electrical failure of the EDC
Check battery voltage, check wiring for correct voltage supply of the sensor and the EDC, replace EDC
Insufficient battery voltage, defect in wiring harness, electrical failure of the EDC
Check battery voltage, check wiring for correct voltage supply of the sensor and the EDC, replace EDC
Excessive battery voltage, defect in wiring harness, electrical failure in connected sensors or in the EDC
Check battery voltage, check wiring for correct voltage supply of the sensor and the EDC, replace EDC
Insufficient battery voltage, defect in wiring harness, electrical failure connected sensors or in the EDC
Check battery voltage, check wiring for correct voltage supply of the sensor and the EDC, replace EDC
Excessive battery voltage, defect in wiring harness, electrical failure in connected sensors or in the EDC
Check battery voltage, check wiring for correct voltage supply of the sensor and the EDC, replace EDC
Insufficient battery voltage, defect in wiring harness, electrical failure connected sensors or in the EDC
Check battery voltage, check wiring for correct voltage supply of the sensor and the EDC, replace EDC
Long TermFailure
Power Red.
No
Mil.
"Mil OFF"
No
yes (technical)
"Mil ON"
No
yes (technical)
"Mil OFF"
SECTION 5 - DIAGNOSTICS
SSpMon12V
Description
118
Base - May 2012
Dfp Name
F4AE ENGINES
Print P2D32N020 E
SSpMon3
HWEMonUMaxSuppl y
HWEMonUMinSupply
Description
ECU Hardware: Sensor Supply Voltage 3 failure
ECU internal Supply Voltage too high
ECU internal Supply Voltage too low
DTC
$ 1E8
$ 1E9
$ 1EA
Reason of Failure
Possible failure correction
Excessive battery voltage, defect in wiring harness, electrical failure in connected sensors or in the EDC
Check battery voltage, check wiring for correct voltage supply of the sensor and the EDC, replace EDC
Insufficient battery voltage, defect in wiring harness, electrical failure connected sensors or in the EDC
Check battery voltage, check wiring for correct voltage supply of the sensor and the EDC, replace EDC
"non"
Excessive voltage supply of a CJ940 component: High battery voltage, defective wiring, internal defect of the EDC
Check the battery for correct voltage supply, check wiring. If defect remains replace EDC (internal defect)
No
"Mil OFF"
"non"
Insufficient voltage supply of a CJ940 component: Low battery voltage, defective wiring, internal defect of the EDC
Check the battery for sufficient voltage supply, check wiring. If defect remains replace EDC (internal defect)
No
"Mil OFF"
OBD-System
"non"
Long TermFailure
Power Red.
Mil.
No
yes (technical)
"Mil OFF"
F4AE ENGINES
Print P2D32N020 E
Dfp Name
SECTION 5 - DIAGNOSTICS
119
Base - May 2012
StrtCDLS
Atmospheric Pressure Sensor failure
ECU Hardware: Low Side Power Stage Short to Ground or Battery
DTC
$ 1EB
$ 2E1
OBD-System
"non"
"non"
Reason of Failure
Possible failure correction
Ambient pressure sensor inside ECU is defect
Replace ECU (not necessary if never running in high altitude and if turbocharger without VGT)
Ambient pressure sensor inside ECU is defect
Replace ECU (not necessary if never running in high altitude and if turbocharger without VGT)
Ambient pressure sensor inside ECU is defect
Replace ECU (not necessary if never running in high altitude and if turbocharger without VGT)
Short circuit of wiring to external source or inside relay
Check wiring or replace relay
Long TermFailure
Power Red.
No
No
Mil.
"Mil OFF"
yes (technical)
SECTION 5 - DIAGNOSTICS
APSCD
Description
120
Base - May 2012
Dfp Name
"Mil OFF"
F4AE ENGINES
Print P2D32N020 E
Insufficient fuel level in the tank.
RECOMMENDED TESTS OR INTERVENTION Check fuel level.
Possible exessive smoke.
REMARKS The excessive smoke is due to the fact that, in case of insufficient fuel feeding, the engine control module tries to compensate prolonging the injectors working time.
Fuel tank device partially obstructed by Check if the priming pump of the pre-filter impurities or deformed because of is working correctly. overheating. If the pump plunger is permanently depressed disassemble and check the tank pick.-up tube. If this is in order, replace the pre-filter.
Obstructed air filter.
Replace the air filter.
Excessive fuel blow-by from rail boost Check the O Rings and the correct valve. connection of the pipe fittings under the feeding pump (the lockers must stay outside and the fittings must be well locked). Visually check the low pressure pipeline integrity.
Solve the cause of the filter's obstruction.
Unless the leakage is significant, no performance failures will be detected. To verify O-rings integrity, extract from the tank the fuel recycling pipeline, seal the end and activate the priming pump driving the low pressure circuit.
The engine suddenly stops (with no Obstructed fuel filter. previous problems) and does not start again.
Replace the fuel filter.
121
Base - May 2012
Solve the cause of the filter's obstruction (empty and clean the tank and the part of the circuit over the filter, refill with clean fuel).
SECTION 5 - DIAGNOSTICS
Excessive fuel blow-by from rail boost Disconnect the pipe and visually check if valve. there are any significant blow-by from the boost gauge valve; in such case replace the valve.
F4AE ENGINES
Low performance at load request.
POSSIBLE CAUSE
GUIDE TO DIAGNOSIS THROUGH SYMPTOMS
Print P2D32N020 E
ANOMALY
POSSIBLE CAUSE
After having excluded any other possible cause, replace the high pressure pump .
Difficult start, low performance and engine Injector with obstructer or solenoid The non-working injector is easily running with one cylinder less. (mechanical part) blocked open. recognisable detecting by feeling the absence of pulsing within the relevant high pressure pipe.
In case of low entity blow-by, inficiating the mechanical working of the injector but not involving flow limiter activation, there is no error memorisation in the engine control module.
Starting requires in excess of ten seconds, Injector blocked in open position (with no The non-working injector is easily followed by huge white exhaust fumes, and return). recognisable detecting by feeling the a fuel smell. absence of pulsing within the relevant high pressure pipe.
Usually, whether such symptoms appear, it is instinctive to give up engine start. However, by insisting, it is possible to start the engine. As a matter of facts, by insisting, if within the rail the pressure makes the flow limiter close up, the engine starts with one cylinder less and gradually the grade of fumes reduces and disappears.
SECTION 5 - DIAGNOSTICS
Difficult start and low performance in all Inefficient high pressure pump. conditions.
122
Base - May 2012
RECOMMENDED TESTS OR REMARKS INTERVENTION The engine disconnects or does not start. EDC7UC31 ”burned” by short circuit on Eliminate the short circuit and replace the Verify that the wire line, close to the pedal, the wiring harness of the friction clutch. EDC7UC31. is not exposed to. ANOMALY
Breaking of high pressure pipeline from Strange vibrations provoked by slack of Replace the pipeline ensuring the correct It is very important, in addition to correct pump to rail. pipe bracket. tightening of the anti-vibration bracket blocking, to keep the brackets in the screws. original position.
The engine works with one cylinder less, Injector blocked in closed position. without memorising failure blink codes in the engine control module.
F4AE ENGINES
Print P2D32N020 E
Identify the injector that is not working any The non-working injector is easily more and the relating high pressure filler. recognisable detecting by feeling the absence of pulsing within the relevant high pressure pipe.
F4AE ENGINES
1
SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS
SECTION 6 Removal and installation of main components Page
Print P2D32N020 E
REMOVAL AND INSTALLATION AUXILIARY DRIVE BELT (DEMONSTRATION) . . . . . . . . . . . . .
3
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
ALTERNATOR REMOVAL AND INSTALLATION (DEMONSTRATION) . . . . . . . . . . . . . . . . . .
3
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
COOLANT PUMP REMOVAL AND INSTALLATION (DEMONSTRATION) . . . . . . . . . . . . . . . . . .
4
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
THERMOSTAT REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .
5
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
REMOVAL AND INSTALLATION STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
ENGINE CABLE REMOVAL AND INSTALLATION
6
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
REMOVAL AND INSTALLATION LOW-PRESSURE FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . .
7
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
Base - May 2012
2
SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS
F4AE ENGINES
Page
Page INJECTOR REMOVAL AND INSTALLATION . .
17
8
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
TURBOCHARGER REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .
19
REMOVAL AND INSTALLATION FUEL HOSE FROM HIGH PRESSURE PUMP TO COMMON RAIL . . . . . . . . . . . . . . . . . . . . . . .
ENGINE CONTROL UNIT REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .
9
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
EXHAUST MANIFOLD REMOVALINSTALLATION . . . . . . . . . . . . . . . . . . . . . . .
20
FUEL FILTER REMOVAL AND REFITTING . . . . .
9 - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
FUEL FILTER REMOVAL AND REFITTING . . . . .
10
INTAKE MANIFOLD REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .
21
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
REMOVAL AND INSTALLATION COMMON RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
CYLINDER HEAD REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .
22
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
OIL VAPOUR RECIRCULATION (BLOW-BY) SYSTEM REMOVAL AND INSTALLATION . .
12
ENGINE OIL FILTER REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .
24
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
TAPPET COVER REMOVAL AND INSTALLATION
13
REMOVAL AND INSTALLATION ENGINE OIL HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . .
25
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
OIL SUMP REMOVAL AND INSTALLATION (DEMONSTRATION) . . . . . . . . . . . . . . . . . . .
26
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
INJECTOR WIRING SUPPORT REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . .
14
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
REMOVAL AND INSTALLATION ROCKER ARM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
Base - May 2012
Print P2D32N020 E
F4AE ENGINES
3
SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS
REMOVAL AND INSTALLATION AUXILIARY DRIVE BELT (DEMONSTRATION) Removal
ALTERNATOR REMOVAL AND INSTALLATION (DEMONSTRATION) Removal Disconnect the electrical connections of the alternator.
Figure 1
Remove the auxiliary components drive belt as described in the relative procedure.
Figure 2
176526
Operate on the belt tensioner (1) and extract the belt (2) from the alternator pulleys, the coolant pump and the return pumps.
Installation
176527
Undo the screws (1) and disconnect the alternator (2).
Turn the automatic belt tensioner (2) to fit the belt (1) on pulleys and guide rollers.
Installation Place the alternator (2) in position, fasten the screws (1) and tighten them to the specified torque. Install the auxiliary components drive belt as described in the relative procedure. Connect the alternator electrical connections.
Print P2D32N020 E
Base - May 2012
4
SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS
COOLANT PUMP REMOVAL AND INSTALLATION (DEMONSTRATION) Removal
F4AE ENGINES
Figure 5
Position a suitable container to catch any coolant. Remove the auxiliary components drive belt as described in the relative procedure.
Figure 3
176528
Place the coolant pump (2) in position, fasten the screws (1) and tighten them to the specified torque. Install the auxiliary components drive belt as described in the relative procedure.
176528
Undo the screws (1) and remove the water pump (2).
Installation Figure 4
70221
Apply a new seal ring (2) to the coolant pump (1).
Base - May 2012
Print P2D32N020 E
F4AE ENGINES
SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS
THERMOSTAT REMOVAL AND INSTALLATION Removal
5
REMOVAL AND INSTALLATION STARTER MOTOR Removal Disconnect the starter motor electrical connections.
Figure 6 (D)
Figure 8
1
2 74166
176519
Unscrew the flywheel cover fastening screws (1) and remove the starter motor (2).
(D) 4-cylinder engine
Installation
Figure 7 (*)
Position the starter motor (2) on the internal part of the flywheel cover (1). Screw down the retaining screws and tighten them to the specified torque. Connect the starter motor electrical connections.
176529
(*) 6-cylinder engine Unscrew the fastening screws (1) and remove the coolant outlet coupling (2). Then remove the thermostat (3) with its gasket.
Installation Place the thermostat in position. Place the coolant outlet coupling (1) in position with a new gasket, screw in the retaining screws and tighten them to the specified torque.
Print P2D32N020 E
Base - May 2012
6
SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS
F4AE ENGINES
ENGINE CABLE REMOVAL AND INSTALLATION Removal Figure 9
107246
1. Electro-injector connections - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil temperature and pressure sensor - 5. Engine speed sensor - 6. EDC 7 control unit - 7. Fuel flow rate regulator - 8. Fuel temperature sensor - 9. Timing phase sensor - 10. Air temperature and pressure sensor - 11. Electro-injector
Disconnect the engine cable from the connectors: (1) electro-injector wiring; (10) air pressure/temperature sensor; (3) fuel pressure sensor; (6) EDC7 control unit; (9) camshaft timing sensor; (7) fuel flow rate sensor; (8) fuel temperature sensor; (2) engine coolant temperature sensor on thermostat; (4) engine oil temperature and pressure sensor; (5) engine speed sensor. Open the straps holding the engine cable to the engine block and remove it completely.
Installation Place the engine cable in position, close the retaining straps and connect the sensor, control unit and electro-injector connectors (refer to Figure 8).
Base - May 2012
Print P2D32N020 E
F4AE ENGINES
SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS
REMOVAL AND INSTALLATION LOWPRESSURE FUEL LINES Removal
7
Figure 12
Figure 10 (D)
116237
Position a suitable container to catch any fuel. To disconnect the low pressure fuel hose from the relevant connecting joint, you need to keep the clasp (1) pressed, and release the quick fitting joint (2). 173236
(D) F4AE3481/2
Installation To connect the low pressure fuel hose to the connection fitting, insert the quick-fit coupling (2) in the connection fitting and push it in until the catch (3) engages.
Figure 11 (*)
NOTE Check proper fuel hose connection.
166625
(*) F4AE3681 1. Hose from fuel pre-filter to heat exchanger on engine control unit - 2. Hose from heat exchanger on engine control unit to fuel pump - 3. Hose from fuel pump to fuel filter support - 4. Hose from fuel filter support to high pressure pump intake - 5. Fuel return Hose from common rail outlet and pressure limiter on cylinder head to filter support - 6. Fuel return hose from high pressure fuel pump outlet to filter support - 7. Fuel return hose from filter support to fuel tank
Print P2D32N020 E
Base - May 2012
8
SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS
REMOVAL AND INSTALLATION FUEL HOSE FROM HIGH PRESSURE PUMP TO COMMON RAIL Removal
F4AE ENGINES
Installation Position a new fuel supply hose (2) and tighten its couplings (1) to the high pressure pump and common rail to the specified torque.
Position a suitable container to catch any fuel. NOTE The high pressure fuel hose must always be replaced with a new one whenever it is removed. The hose couplings must be tightened to 20 Nm torque using spanner 99317915 and torque wrench 99389829.
Figure 13 (D)
173237
(D)
F4AE3481/2
Figure 14 (*)
166632
(*) F4AE3681
Base - May 2012
Print P2D32N020 E
F4AE ENGINES
SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS
ENGINE CONTROL UNIT REMOVAL AND INSTALLATION Removal
FUEL FILTER REMOVAL AND INSTALLATION Removal
Disconnect the engine cable from the engine control unit electrical connections, as described in the relative section.
Position a suitable container to catch any fuel.
Position a suitable container to catch any fuel. Disconnect the fuel hoses from the engine control unit heat exchanger, as described in the relative section.
9
Figure 16 (D)
Figure 15
1 173238
(D) F4AE3481/2
2
Figure 17 (*)
74174
Remove the retaining screws (1) and disconnect the ECU (2) including the heat exchanger.
Installation Position the ECU, (2) including the heat exchanger, on the crankcase and tighten the screws (1) to the specified torque.
166627
NOTE Replacing the elastic support elements is recommended.
(*) F4AE3681
Installation Connect the fuel hoses to the engine control unit heat exchanger, as described in the relative procedure.
Fully screw the fuel filter onto the connection on its support by hand, then further tighten to a torque of 202 Nm.
Connect the engine cable to the engine control unit electrical connections, as described in the relative procedure.
Print P2D32N020 E
Base - May 2012
10
SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS
F4AE ENGINES
INJECTION PUMP REMOVAL AND INSTALLATION Removal
REMOVAL AND INSTALLATION COMMON RAIL Removal
Position a suitable container to catch any fuel.
Position a suitable container to catch any fuel.
Disconnect the low pressure fuel hose from the mechanical fuel pump and the high-pressure pump as described in the relative procedure.
Disconnect the fuel pressure sensor connector as described in the procedure regarding the engine cable.
Remove the fuel hose from the high pressure pump to the common rail as described in the relative procedure.
Disconnect the low pressure fuel return hose from the common rail, as described in the relative procedure. Remove the fuel hose from the high pressure pump to the common rail as described in the relative procedure. Figure 19 (D)
Figure 18
166629
Remove the three retaining nuts (1) and remove the high pressure pump (2) complete with the fuel supply pump (3). 173239
Installation Position the high pressure pump (2) complete with the fuel supply pump (3) and tighten the three retaining nuts (1) to the specified torque.
(D) 4-cylinder engine
Figure 20 (*)
Install the fuel hose from the high pressure pump to the common rail as described in the relative procedure. Connect the low pressure fuel hose to the mechanical fuel pump and the high-pressure pump as described in the relative procedure.
166634
(*) 6-cylinder engine Disconnect the high pressure hose couplings (1) from the common rail (2) and injector manifolds (3), then remove them.
Base - May 2012
Print P2D32N020 E
F4AE ENGINES
SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS
Figure 21 (D)
11
Figure 23 (D)
173240
173241
(D) 4-cylinder engine (D) 4-cylinder engine Figure 24 (*) Figure 22 (*)
166636
(*) 6-cylinder engine 166635
(*) 6-cylinder engine Remove the intake manifold retaining screws (1) and remove the common rail (2).
Installation Place the common rail (2) in position and tighten the screws (1) fastening it to the intake manifold to the prescribed torque.
Place the new high pressure fuel hoses (1) in position and tighten the couplings to the electro-injector collectors (3) and the common rail (2) to the specified torque.
NOTE The hoses (1), as they are subject to high pressure, must be replaced every time they are removed. The hose couplings must be tightened to a torque of 24 ± 4 Nm, using spanner 99317915 (4) and torque wrench 99389829 (5).
Install the fuel hose from the high pressure pump to the common rail as described in the relative procedure. Connect the low pressure fuel return hose to the common rail, as described in the relative procedure. Connect the fuel pressure sensor connector as described in the procedure regarding the engine cable.
Print P2D32N020 E
Base - May 2012
12
SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS
F4AE ENGINES
Installation
OIL VAPOUR RECIRCULATION (BLOW- BY) SYSTEM REMOVAL AND INSTALLATION Removal
Place the blow-by filter (6) in position and tighten the fastening screws. Place the pipe (5) in position with new copper washers in the tappet cover and timing case couplings (4). Then tighten the couplings (4) to the specified torque.
Figure 25
Place the blow-by pipe (3) into the coupling located on the timing case and secure it with the elastic strap (2). Insert the upper coupling of the new blow-by pipe (5), with a new seal ring, into the tappet cover and tighten the screw (1).
166631
166631
Undo the screw (1). Loosen the elastic strap (2) and remove the blow-by pipe (3). Unscrew the couplings (4) and remove the pipe (5). Undo the screws and remove the blow-by filter (6).
Base - May 2012
Print P2D32N020 E
F4AE ENGINES
SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS
TAPPET COVER REMOVAL AND INSTALLATION Removal
13
Figure 28
Figure 26
166630
Install the tappet cover (7) and tighten the nuts (6) to the specified torque. 166630
Undo the screw (1). Loosen the elastic strap (2) and remove the blow-by pipe (3). Unscrew the couplings (4) and remove the pipe (5). Remove the nuts (6) and take off the tappet cover (7) complete with seal.
Place the pipe (5) in position with new copper washers in the tappet cover and timing case couplings (4). Then tighten the couplings (4) to the specified torque. Place the blow-by pipe (3) into the coupling located on the timing case and secure it with the elastic strap (2). Insert the upper coupling of the new blow-by pipe (5), with a new seal ring, into the tappet cover and tighten the screw (1).
Installation Figure 27
74757
Fit a new gasket (2) on the tappet cover (1).
Print P2D32N020 E
Base - May 2012
14
SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS
INJECTOR WIRING SUPPORT REMOVAL AND INSTALLATION Removal
F4AE ENGINES
Figure 31
Remove the tappet cover as described in the relative section. Disconnect the engine cable from the injector wiring connections, as described in the relative section.
Figure 29
99227
Fit the wiring bracket (2) and tighten the screws (1) to the specified torque.
NOTE Always check that the threads on the screws and their holes do not show any signs of wear or traces of dirt before fitting. 166637
Remove the nuts (1) and disconnect the electrical cables from the injectors (2).
Figure 32
Take out the screws (3) and remove the injector wiring bracket (4) together with the gasket.
Installation Figure 30
99228
Connect the electrical cables (1) to the injectors (3) and use the torque wrench 99389834 (4) to tighten the retaining nuts (2) to the specified torque. 74756
Check the condition of the electrical cables (5), if they are damaged replace them by cutting the straps (2) securing them to the bracket and removing the screws (4) securing the connectors to this (3).
Connect the engine cable to the injector wiring connections, as described in the relative procedure. Install the tappet cover as described in the relative section.
Fit a new gasket (1) on the bracket (2).
Base - May 2012
Print P2D32N020 E
F4AE ENGINES
SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS
REMOVAL AND INSTALLATION ROCKER ARM ASSEMBLY Removal
15
Figure 35
Remove the tappet cover as described in the relative section. Remove the injector wiring support as described in the relative section.
Figure 33
70343
ROCKER ARM ASSEMBLY COMPONENTS: 1. Screws - 2. Bracket - 3. Shafts - 4. Rocker arms Figure 36
70132
Loosen the tappet adjuster retaining nuts (1) and unscrew the adjusters. Unscrew the screws (2) and remove the rocker arm assembly (3), composed of: bracket (6), rocker arms (4), shafts (5). Remove the bridges (7) from the valves and extract the rods (8).
Installation
70344
Figure 34
SHAFT-ROCKER MAIN DATA Check that shaft/rocker arm coupling surfaces are not excessively worn or damaged. Figure 37
122587
The control rods of the rocker arms must have no deformations; the spherical seats for contact with the rocker arm adjustment screw and with the tappets (arrows) must show no trace of seizure or wear; if they do, replace them. The intake and exhaust valve control rods are identical and are therefore interchangeable.
74765
Fit the rods (2). Position the bridges (1) on the valves with the marks () facing the exhaust manifold. Print P2D32N020 E
Base - May 2012
16
SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS
Figure 38
F4AE ENGINES
NOTE In order to perform the rocker arm - valve clearance adjustment more quickly, proceed as follows: 4-cylinder engines - Rotate the crankshaft, balance the valves of cylinder no. 4 and adjust the valves marked by the asterisk as shown in the tables below:
cylinder no. intake exhaust
1 -
2 *
3 * -
4 *
- Rotate the crankshaft, balance the valves of cylinder no. 4 and adjust the valves marked by the asterisk as shown in the tables below: 70346
Check that tappet adjusters (1) are loosened to prevent their catching on the rods (2, Figure 37) when refitting the rocker arm assembly. Then install the rocker assembly consisting of the bracket (5), rockers (3) and shafts (4), securing them to the cylinder head by tightening the retaining screws to 36 ± 5 Nm.
Figure 39
cylinder no. intake exhaust
1 -
2 *
3 * -
4 *
6-cylinder engines - Rotate the crankshaft, balance the valves of cylinder no. 1 and adjust the valves marked by the asterisk as shown in the tables below:
cylinder no. intake exhaust
1 * *
2 * -
3 *
4 * -
5 *
6 -
- Rotate the crankshaft, balance the valves of cylinder no. 6 and adjust the valves marked by the asterisk as shown in the tables below: cylinder no. intake exhaust
1 * *
2 * -
3 *
4 * -
5 *
6 -
70520
Adjust the clearance between the rocker arms and valves using Allen key (1), box wrench (3) and feeler gauge (2). The operating clearance is:
Install the injector wiring support as described in the relative section. Install the tappet cover as described in the relative section.
- 0.25 0.05 mm for the intake valves - exhaust valves 0.51 0.05 mm.
Base - May 2012
Print P2D32N020 E
F4AE ENGINES
SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS
INJECTOR REMOVAL AND INSTALLATION Removal
17
Figure 42
Remove the tappet cover as described in the relative section. Remove the injector wiring support as described in the relative section. Remove the rocker arm assembly as described in the relative section. Position a suitable container to catch any fuel.
Figure 40 70133
Remove the injector fastening screws and use tool 99342101 (1) to remove the injectors (2) from the cylinder head.
Installation Figure 43
166638
Disconnect the high pressure hose couplings (1) from the common rail (2) and injector manifolds (3), then remove them. 70338
Fit a new seal ring (2) lubricated with vaseline and a new washer (3) on the injector (1).
Figure 41
Figure 44
166630
Unscrew the nuts (1) and remove the fuel manifolds (2).
70339
Place the injectors (1) in position on the cylinder head seats so that the fuel inlet hole (2) is facing the fuel manifold seat (3) side. Print P2D32N020 E
Base - May 2012
18
SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS
Figure 45
F4AE ENGINES
Figure 47
70342
Gradually and alternately tighten injector fixing screws (1) in four stages: 70133
Use tool 99342101 (1) to fit the injector (2) into position. Screw in the injector fastening screws without tightening them.
- 1st stage, tightening to 3.5 ± 0.35 Nm torque with dynamometric wrench. - 2nd stage, tightening to 25° ± 1° angle; - 3rd stage, tightening to 25° ± 1° angle; - 4th stage, tightening to 25° ± 1° angle. NOTE Tightening to angle is performed using tool 99395216.
Figure 46
Tighten the fuel manifold (3) retaining nuts (2) to 50 5 Nm. Figure 48
91572
Fit a new seal ring (3), lubricated with Vaseline, onto a new fuel manifold (2). Position the fuel manifold in place on the cylinder head seat so that the positioning balls (5) coincide with the relevant housing (4). NOTE Fuel manifolds (2) must not be reused after removal but rather replaced with new ones.
Screw on the fastening nuts (2, Figure 47) without tightening them fully. NOTE During this operation, manoeuvre the injector (1) so that the manifold (2) is properly inserted into the injector fuel inlet hole (2, Figure 44).
Base - May 2012
166640
Place the new high pressure fuel hoses (1) in position and tighten the couplings to the electro-injector collectors (3) and the common rail (2) to the specified torque. NOTE The hoses (1), as they are subject to high pressure, must be replaced every time they are removed. The hose couplings must be tightened to a torque of 20 Nm, using spanner 99317915 (4) and torque wrench 99389829 (5).
Install the rocker arm assemblies as described in the relative chapter. Install the injector wiring support as described in the relative section. Install the tappet cover as described in the relative section. Print P2D32N020 E
F4AE ENGINES
SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS
19
TURBOCHARGER REMOVAL AND INSTALLATION Removal Figure 49 (D)
Undo the retaining screws and remove the oil return pipe (1) from the engine block. Unscrew the couplings on the heat exchanger/oil filter and on the turbocharger and remove the oil supply pipe (2) from the turbocharger. Undo the nuts (3) and remove the turbocharger (4) from the exhaust manifold (5).
Installation Place the turbocharger (4) in position on the exhaust manifold (5), after fitting a new gasket. Screw down the retaining nuts (3) and tighten them to the specified torque. Place the oil supply pipe (2) in position on the turbocharger, after fitting a new gasket and tighten the couplings on the heat exchanger/oil filter bracket and on the turbocharger to the specified torque.
176520
Place the pipe (1) in position on the engine block, after fitting a new gasket and tighten the retaining screws (1) to the specified torque.
(D) F4AE3481/2 Figure 50 (*)
176530
(*) F4AE3681
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Base - May 2012
20
SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS
EXHAUST MANIFOLD REMOVAL AND INSTALLATION Removal Remove the turbocharger as described in the relative section.
F4AE ENGINES
Installation Place the exhaust manifold (2) with new gaskets in position. Insert the fixing screws (1) and tighten them to the specified torque. Install the turbocharger as described in the relative section.
Figure 51 (D)
176521
(D) F4AE3481/2
Figure 52 (*)
176531
(*) F4AE3681
Base - May 2012
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F4AE ENGINES
SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS
INTAKE MANIFOLD INSTALLATION Removal
REMOVAL
AND
21
Installation
Remove the common rail as described in the relative section.
Apply a sufficient layer of LOCTITE 5999 to the contact surface of the intake manifold (2) complete with the cold-start heater (if fitted).
Disconnect the cold-start heater electrical connections (if fitted).
Place the intake manifold (2) in position and tighten the retaining screws (1) to the specified torque. Install the common rail as described in the relative section.
Figure 53
Connect the cold-start heater electrical connections (if fitted).
(D)
176522
(D) F4AE3481/2
Figure 54 (*)
176532
(*) F4AE3681
Print P2D32N020 E
Base - May 2012
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SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS
F4AE ENGINES
CYLINDER HEAD REMOVAL AND INSTALLATION Removal Remove the engine cable as described in the relative section. Remove the thermostat as described in the relative section. Remove the common rail as described in the relative section. Remove the rocker arm assembly as described in the relative section. Remove the injectors as described in the relative section. Remove the turbocharger as described in the relative section. Remove the exhaust manifold as described in the relative section. Remove the intake manifold as described in the relative section.
Figure 55
74779
Undo the retaining screws, hook metal cables onto the brackets (1) and remove the cylinder head (2) from the engine block using a hoist. Remove the head gasket.
Base - May 2012
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F4AE ENGINES
SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS
Installation
23
Figure 58
Figure 56
75703
NOTE Before re-using retaining screws (1) measure diameters D1 and D2 as shown in the figure: - if D1-D2 < 0.1 mm the screw can be reused - if D1-D2 > 0.1 mm the screw must be replaced 70335
Clean the cylinder head and engine block contact surfaces. There are two types of head gasket: -
Type A 1.25 mm thick
-
Type B 1.15 mm thick
Check the average projection S of the pistons as indicated on page 29 of Section 7.
NOTE Always check that the threads on the screws and their holes do not show any signs of wear or traces of dirt before fitting.
If S > 0.40 mm use gasket type A. If S 0.40 mm use gasket type B. Take care not to get the cylinder head gasket dirty.
Figure 59
Arrange a new cylinder head gasket (1) on the engine block with the marking ”TOP” facing the head. The arrow shows the point where the gasket thickness is marked.
Figure 57 α
74766
Insert the cylinder head (1) retaining screws (2) and tighten them in three stages, following the order and method shown in the figure below.
NOTE The external screws are the shortest.
74779
Position the cylinder head (2), supported by the brackets (1), on the seal.
Print P2D32N020 E
NOTE Use tool 99395216 (3) for angle tightening.
Base - May 2012
24
SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS
F4AE ENGINES
ENGINE OIL FILTER INSTALLATION Removal
Figure 60 (D)
REMOVAL
AND
Position a suitable container to catch any engine oil.
Figure 62 α
A 70337
(D)
4-cylinder engine
Figure 61 (*)
A α
166649
70476
Installation
(*) 6-cylinder engine
Lubricate the seal ring (2) with engine oil and set it on the oil filter (1).
Diagram of the tightening sequence for the cylinder head fixing screws:
Screw the oil filter (1) all the way on to the support connection (3) by hand and then tighten to 182 Nm.
- 1st pre-tightening stage, with torque wrench:
Run the engine for a few minutes and then check the level using the dipstick: the level must be near the MAX mark on the dipstick.
Screw 12x1.75x130 ( ) 35 5 Nm Screw 12x1.75 x 150 ( ) 55 5 Nm
- 2nd tightening stage to a 90º 2º angle - 3rd tightening stage to a 90º 2º angle
If it is much below this level, top up with the necessary quantity.
A = Front side Install the intake manifold as described in the relative section. Install the exhaust manifold as described in the relative section. Install the turbocharger as described in the relative section. Install the injectors as described in the relative section. Install the rocker arm assemblies as described in the relative chapter. Install the common rail as described in the relative section. Install the thermostat as described in the relative section. Install the engine cable as described in the relative section.
Base - May 2012
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F4AE ENGINES
SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS
REMOVAL AND INSTALLATION ENGINE OIL HEAT EXCHANGER Removal
25
Installation Figure 64
Remove the auxiliary components drive belt as described in the relative procedure. Remove the alternator as described in the relative section. Position a suitable container to catch any engine oil. Remove the engine oil filter as described in the relative section.
Figure 63 107275
Fit the following on the engine block: a new gasket (1), the heat exchanger (2) a new gasket (3) and the oil filter bracket (4). Tighten the screws (5) to the specified torque.
NOTE Always check that the threads on the screws and their holes do not show any signs of wear or traces of dirt before fitting. 166651
Unscrew the coupling (1) and remove the turbocharger oil delivery pipe (2). Remove the screws (3) and the oil pressure / temperature sensor (4). Remove the screws (5) and disassemble the oil filter / heat exchanger bracket (6), intermediate plate (6) and relative gaskets.
Print P2D32N020 E
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26
SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS
F4AE ENGINES
OIL SUMP REMOVAL AND INSTALLATION (DEMONSTRATION) Removal
Figure 65
Place a suitable container under the oil sump drain plug to catch the oil. Open the oil filler on the cylinder head and remove the dipstick to aid the flow of oil. Unscrew the drain plug and let the oil in the sump drain completely.
NOTE It is recommended to drain the oil when the engine is hot. 166652
Place the oil temperature/pressure sensor (2) in position on the bracket (1) with a new seal ring then screw in the retaining screws (3) and tighten them to the specified torque.
Figure 66
Install the oil delivery pipe (1), screwing on the coupling (2). Install the engine oil filter as described in the relative section. Install the alternator as described in the relative section. Install the auxiliary components drive belt as described in the relative procedure. Check the oil level with the dipstick: the level must be near the MAX mark on the dipstick. If it is much below this level, top up with the necessary quantity. 74775
Undo the screws (2) then remove the plate (3) and oil sump (1), retaining the gasket.
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F4AE ENGINES
SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS
Installation
27
Figure 68
Figure 67
74775
74770
Set the gasket (1) on the oil sump (2).
NOTE If it does not show any signs of damage the gasket can be reused.
Place the oil sump (1) in position and apply the plate (3) to it. Tighten the screws (2) to the specified torque. Screw on the drain plug with a new washer and proceed to fill with clean oil.
Use only recommended oils or those with the required characteristics to ensure correct operation of the engine. Failure to observer these requirements shall void the guarantees.
Check the oil level with the dipstick: the level must be near the MAX mark on the dipstick. If it is much below this level, top up with the necessary quantity.
Print P2D32N020 E
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SECTION 6 - REMOVAL AND INSTALLATION OF MAIN COMPONENTS
Base - May 2012
F4AE ENGINES
Print P2D32N020 E
F4AE ENGINES
SECTION 7 - GENERAL MECHANICAL OVERHAULING
1
SECTION 7 General mechanical overhauling Page
Print P2D32N020 E
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . .
3
FITTING THE ENGINE TO THE ROTATING STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
REMOVAL OF MAIN COMPONENTS . . . . . . .
5
BENCH ENGINE BLOCK DISASSEMBLY . . . . .
13
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
- Controls and measurements . . . . . . . . . . . . . .
15
- Checking head supporting surface on cylinder unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .
16
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
- Cam lift check and pin alignment check . . . . .
17
BUSHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
- Bush replacement . . . . . . . . . . . . . . . . . . . . . .
18
TAPPETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
- Fitting tappets — camshaft . . . . . . . . . . . . . . . .
19
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . .
20
- Measuring journals and crankpins (4-cylinder) .
20
- Measuring journals and crankpins (6-cylinder) .
22
CONNECTING ROD — PISTON ASSEMBLY . .
24
- Connecting rod-piston assembly removal . . . .
24
- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
- Gudgeon pins . . . . . . . . . . . . . . . . . . . . . . . . .
25
- Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
- Connecting rods . . . . . . . . . . . . . . . . . . . . . . .
27
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SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Page
Page - Bushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
- Fitting connecting rod-piston assembly . . . .
28
REMOVING THE ENGINE FROM THE ROTATING STAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53
- Connecting rod-piston assembling . . . . . . .
28
COMPLETING ENGINE ASSEMBLY . . . . . . . . .
53
- Fitting split rings . . . . . . . . . . . . . . . . . . . . .
28
CHECKS AND INSPECTIONS . . . . . . . . . . . . . .
55
BENCH ENGINE BLOCK ASSEMBLY . . . . . . . .
29
- Replacing oil pump control gear . . . . . . . . .
29
- Fitting main bearings . . . . . . . . . . . . . . . . . .
29
- Crankshaft installation . . . . . . . . . . . . . . . . .
29
- Checking crankshaft end float . . . . . . . . . . .
30
- Fitting connecting rod half bearings . . . . . .
31
- Fitting connecting rod-piston assembly into cylinder barrels . . . . . . . . . . . . . . . . . . . . . .
31
- Checking piston protrusion . . . . . . . . . . . . .
32
CYLINDER HEAD DISMANTLING . . . . . . . . . .
33
- Removing the valves . . . . . . . . . . . . . . . . . .
33
- Checking cylinder head wet seal . . . . . . . . .
33
- Checking cylinder head supporting surface .
34
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
- Removing carbon deposits, checking and grinding valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
- Checking clearance between valve stem and valve guide and valve centering . . . . . . . . . .
35
VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . .
35
VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
- Regrinding - replacing the valve seats . . . . .
35
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . .
37
ASSEMBLING CYLINDER HEAD . . . . . . . . . . . .
38
REFITTING MAIN COMPONENTS . . . . . . . . . .
39
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SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
INTRODUCTION
3
Figure 2 (*)
The following description covers general mechanical overhaul starting from the engine which has been removed from the vehicle.
NOTE Refer to the specific publication for removing the engine from the vehicle. Engine removal operations, as with overhauling, must be carried out by specialised personnel with specific equipment.
166072
This section contains: - the operations to perform for mounting the engine on the rotating stand,
(*) F4AE3681
- the sequence of removal operations for the main com ponents,
To apply the brackets 99361037 to the engine block for fastening the engine to the overhaul stand, proceed as follows, working from the left side of the engine:
- overhaul of the engine block and the cylinder head,
- Position a suitable container to catch any fuel.
- the sequence of refitting operations for the main com ponents,
- Using tool 99360076, remove the fuel filter (1) from its support.
- operations required for completing engine assembly after removal from the rotating stand,
- Unplug the fuel temperature sensor and the camshaft timing sensor electrical connections (2).
- final checks and tests.
- Disconnect the low-pressure fuel hoses (3) from the filter support.
Part of the operations covered in this section can be performed directly on the engine still fitted in the vehicle, in relation to their accessibility in the engine compartment and on the vehicle version; these are listed in Section 6 Removal-refitting of main engine components.
- Unscrew the fastening screws and remove the fuel filter support (4) complete with the bracket, if fitted, from the engine block. - Unscrew the couplings, disconnect the high-pressure fuel hose (5) from the common rail and high-pressure pump, open the fastening straps and remove it from the engine block.
FITTING THE ENGINE TO THE ROTATING STAND Figure 1 (D)
173245
(D) F4AE3481/2 Print P2D32N020 E
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SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
- Disconnect the low-pressure fuel hose (6) supplying the mechanical pump connected to the high pressure pump via the electronic control unit heat exchanger.
Figure 5 (*)
- Remove the oil delivery pipe, if present, unscrewing and removing the retaining screws. Remove the O-ring from the pipe.
NOTE Because of the high pressure in the hoses running from the high pressure pump to the rail and from this to the injectors, you must absolutely avoid: -
Disconnecting the hoses when the engine is running
-
Reusing hoses after they have been removed 176533
(*) F4AE3681 From the right of the engine, unscrew the retaining screws and remove the oil outlet pipe (1) from the turbocharger (2) and the engine block.
Figure 3
Figure 6
1
116237
To disconnect the low pressure fuel hose from the relevant connecting joint, you need to keep the clasp (1) pressed, and release the quick fitting joint (2).
2 74166
Figure 4 (D)
Unscrew the flywheel cover retaining screws (1) and remove the starter motor (2). Fit brackets 99361037 to the engine block and use these to secure the engine to the rotating stand 99322205. Drain the oil from the engine by removing the plug from the oil sump. Remove the fan from the crankshaft pulley.
Dispose of the oil according to applicable laws.
176523
(D) F4AE3481/2 Base - May 2012
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F4AE ENGINES
SECTION 7 - GENERAL MECHANICAL OVERHAULING
5
REMOVAL OF MAIN COMPONENTS Figure 7
107246
1. Electro-injector connections - 2. Engine coolant temperature sensor - 3. Fuel pressure sensor - 4. Engine oil temperature and pressure sensor - 5. Engine speed sensor - 6. EDC 7 control unit - 7. Fuel flow rate regulator - 8. Fuel temperature sensor - 9. Camshaft timing sensor - 10. Air temperature and pressure sensor - 11. Electro-injector.
Disconnect the following engine cable connectors: (1) electro-injector wiring; (10) air pressure/temperature sensor; (3) fuel pressure sensor; (6) EDC7 control unit; (9) camshaft timing sensor; (7) fuel flow rate regulator; (8) fuel temperature sensor; (2) engine coolant temperature sensor on thermostat; (4) engine oil temperature and pressure sensor; (5) engine speed sensor. Open the straps holding the engine cable to the engine block and remove it completely.
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SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Figure 8 (D)
Figure 10
173247
(D)
4-cylinder engine Figure 9 (*) 166077
Disconnect the pipe (2) from the fuel return pressure relief valve (1), as described in Figure 3. Unscrew the screw (3), loosen the retaining strap (4) and remove the blow-by pipe (5). Unscrew the couplings (7) and remove the pipe (6). Undo the screws and remove the blow-by filter (8). Unscrew the nuts (10) and remove the tappet cover (9).
Figure 11 107247
(*) 6-cylinder engine Disconnect the fuel hose (3) from the rail (2) according to the procedures described in Figure 3. Disconnect the fuel hose (5) from the rail (2) and from the injector manifolds (4). Remove the screws (1) and remove the rail (2).
74744
Remove the nuts (7) and disconnect the electrical cables from the electro-injectors (8). Undo the screws (1) and remove the injector wiring support (2), complete with gasket. Remove the screws (5) and temperature/pressure sensor (6).
detach
the
air
Undo the nuts (3) and remove the fuel manifolds (4). NOTE Fuel manifolds (4) must not be reused after removal but rather replaced with new ones.
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SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Figure 12
Figure 14
70132
Loosen the tappet adjuster retaining nuts (1) and unscrew the adjusters. Remove screws (2), disassemble the rocker unit (3) including support (6), rocker arms (4),and shafts (5) and remove the bridges (7) from the valves. Remove the rods (8).
7
(Demonstration)
176526
Operate on the belt tensioner (1) and extract the belt (2) from the alternator pulleys, the coolant pump and the return pumps. Unscrew the fastening screw and remove the belt tensioner (1). Unscrew the screws fastening the alternator to its bracket and remove it.
Figure 13
70133
Undo the injector fastening screws and use tool 99342101 (1) to remove the injectors (2) from the cylinder head.
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SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Figure 15 (D)
Figure 17 (D)
176525
176524
(D) F4AE3481/2
(D) F4AE3481/2 Figure 18 (*)
Figure 16 (*)
176535
(*) F4AE3681 176534
(*) F4AE3681 Unscrew the couplings on the heat exchanger/oil filter support and on the turbine, disconnect the oil supply pipe (3) and remove it.
From the opposite side, undo the intake manifold (1) retaining screws and remove it, complete with the cold-start heater (if fitted). Figure 19
Remove the retaining nuts and disconnect the turbocharger (1) from the exhaust manifold (2). Undo the screws and remove the exhaust manifold (2) from the cylinder head.
74779
Undo and remove the cylinder head retaining screws. Hook metal cables onto the brackets (1) and remove the cylinder head (2) from the engine block using a hoist.
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SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Figure 20
9
Figure 23
1
4
3
2 166083
Undo the screws (1) and remove the alternator bracket (2). Use tool 99360076 to remove the oil filter (3).
74176
Undo the screws (3) and remove the cover (1). Retrieve the gasket (4), the PTO (2) and the second gasket (4). Figure 24
Figure 21
70145 166085
Remove the screws (1) and the oil pressure / temperature sensor (2). Undo the screws (3) and remove the oil filter / heat exchanger support (4), intermediate plate (5) and relative gaskets.
Remove nut (1) and detach the timing sensor (2). Remove the nuts (3) and disconnect the high pressure pump (4) including the fuel supply pump (5). Figure 25
Figure 22
1
2
74174
Remove the screws (1) and disconnect the electronic control unit (2) complete with heat exchanger. Print P2D32N020 E
70146
Apply the tool 99360351 (2) to the flywheel housing (1), to stop the flywheel (3) from rotating. Unscrew the screws (4). Base - May 2012
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SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Figure 26
Figure 29
108548
Undo the screws (3) and remove the damper (2) and the pulley (1). The flywheel blocking device can help aid removal of the damper (2) fitted to the pulley (1).
00904t
Fit the appropriate tie-rod (3) of tool 99363204 onto the external seal (2) as illustrated in the figure and, using the lever (4), extract it from the front cover (1).
Figure 27 Figure 30
176536
Undo the screws (1) and remove the coolant pump (2). Undo the screws (3) and remove the roller (4). Undo the screw (5) and remove the engine speed sensor (6).
176537
Remove screws (1 and 3) and take off the front cover (2).
NOTE Note down the installation positions of the screws (1) since they are of different lengths.
Figure 28
00900t
Extract the crankshaft front cover seal. Fit the tool 99340055 (4) onto the front shank (2) of the crankshaft. Through the guide holes in the tool, perforate the internal seal (1) with a drill bit (Ø 3.5 mm) to a depth of 5 mm. Secure the tool to the ring (1) with the 6 screws provided. Then extract the ring by screwing in the screw (3). Base - May 2012
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SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Figure 31
11
Figure 34
Undo the screws (1) and remove the oil pump (2). Figure 32
00903t
Extract the flywheel housing seal ring by fitting tool 99340056 (3) on the rear shank (5) of the drive shaft. Through the guide holes of the tool, perforate the internal seal ring with a drill bit (Ø 3.5 mm) to a depth of 5 mm. Fix tool 99340056 (3) to the ring (1) by means of the 6 screws (4) provided. Proceed to remove the ring (1) by screwing in the screw (2). Fit the appropriate tie-rod of tool 99363204 onto the flywheel housing external seal and extract it using the lever.
70151
Remove the two opposing screws (1) where the extraction pins will be inserted (2, Figure 33). Undo the remaining screws fastening the flywheel (3) to the drive shaft (4). Remove flywheel blocking tool 99360351.
Figure 35
Figure 33
70153
Undo the screws (2) and remove the flywheel housing (1). 70152
Screw two medium-length screws into the holes (4) in order to sling the flywheel with a hoist.
NOTE Note down the installation positions of the screws (2) since they are of different sizes.
Remove the flywheel (1) using the hoist, guided by the two guide pins (2) previously screwed into the holes in the drive shaft (3). Print P2D32N020 E
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SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Figure 36
Figure 38
74775 70156
Turn the engine over. Remove the screws (2), disassemble the frame (3) and remove the oil sump (1).
Remove the screws (1) and remove the gear (3) from the camshaft (2). Figure 39
NOTE The size and shape of the sump and suction strainer vary depending on the engine use. The illustrations therefore provide a general outline of the procedure to be performed. The procedures described are applicable in any case.
Figure 37 70157
Undo the screws (2) and remove the timing gear case (1).
NOTE Note down the installation positions of the screws (2) since they are of different sizes.
86516
Undo the screws (1 and 4) and remove the oil suction strainer (5). Undo the screws (2) and remove the stiffening plate (3).
NOTE The stiffening plate (4) has a single part in the engines.
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SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
BENCH ENGINE BLOCK DISASSEMBLY
13
Figure 42
Figure 40
70160
70158
Remove and remove the connecting rod cap (2) fixing screws (1). Extract the pistons together with the connecting rods from the top of the crankcase. NOTE Maintain the half-bearings in their relevant seats because, in the event of use, they should be mounted in the position detected when disassembling.
The second-last-main cap (1) and its relevant support have the half-bearing (2) equipped with shoulder.
NOTE Write down the upper and lower half-bearing assembling position, in the event of use, they should be mounted in the position detected when disassembling. Figure 43 (D)
Figure 41
70161
(D)
4-cylinder engine
Figure 44 (*)
70159
Remove the screws (1) and remove the main caps (2).
74774
(*) 6-cylinder engine Remove the crankshaft (2) from the block by means of tool 99360500 (1) and hoister. Print P2D32N020 E
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SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
zs
Figure 45
Figure 47
70164
70162
Carefully withdraw the camshaft (1) from the crankcase.
Remove the main half-bearings (1). Remove the screws (2) and remove the oil nozzles (3). Figure 48 Figure 46
70163 70165
Remove the screws (1) and remove the camshaft (3) check plate (2) Withdraw the tappets (1) from crankcase. NOTE Write down the plate (2) assembling position.
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SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
CRANKCASE Controls and measurements
15
Figure 51
Figure 49 (D)
s
70167
70166
(D)
4-cylinder engine
The measurements must be performed for each individual cylinder at three different heights from the barrel and on two perpendicular surfaces: one parallel to the longitudinal engine axis (A) and the other one perpendicular (B); usually the max wear is detected on this latter surface and in correspondence with the first measurement. If you detect any ovalization, taper or wear, ream and grind the cylinders. The cylinder barrel regrinding must be performed in relation to the diameter of the spare pistons oversized of 0.4 or 0.8 mm in respect of the nominal value and prescribed assembling clearance.
Figure 50 (*)
Figure 52
75386
(*) 6-cylinder engine Carefully clean the crankcase, when performed the engine disassembly.
α
Use the proper rings to transfer the crankcase. Carefully check that the block does not present any cracks. Check the plug conditions. Replace them if they are rusty or in case of doubt about their conditions. Examine the cylinder bore surfaces; they must not present any seizing, scoring, ovalization, taper, and excessive wearing traces. The internal diameter check of the cylinder bore, to verify the ovalization, taper and wearing entity, is performed by means of bore meter (1) equipped with dial gange previously set to zero on the ring gauge (2) of the cylinder barrel diameter. 176515
NOTE If you do not have at your disposal the ring gauge, use a micrometer for the zero setting operation.
Print P2D32N020 E
NOTE In the event of grinding operation, all the cylinders must result of the same oversize (0.4 or 0.8 mm)
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16
SECTION 7 - GENERAL MECHANICAL OVERHAULING
Check the main bearing seats, proceeding as follows: - mount the main caps on the supports without bearings; - tighten the fixing screws to the torque prescribed; - by means of an adequate gauge, verify that the internal diameter of the seats correspond to the value pre scribed.
F4AE ENGINES
Checking head supporting surface on cylinder unit When finding the distortion areas, replace the cylinder unit. Planarity error shall not exceed 0.075 mm. Check cylinder unit operating plug conditions, replace them in case of uncertain seal or if rusted.
If you detect a higher value, replace the crankcase.
TIMING SYSTEM Camshaft Figure 53
70169
CAMSHAFT MAIN DATA (4 cyl.) Specified data refer to pin standard diameter
Figure 54
84089
MAIN DATA ABOUT CAMSHAFT PINS (6 F4HE684 engine cylinders) Specified data refer to pin standard diameter Camshaft pin and cam surfaces shall be absolutely smooth; if they show any traces of seizing or scoring replace the Base - May 2012
camshaft and the bush. Print P2D32N020 E
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Checking cam lift and pin alignment
17
BUSHES
Set the camshaft on the tailstock and using a 1/100 gauge set on the central support, check whether the alignment error is not exceeding 0.04 mm, otherwise replace the camshaft. Check cam lift; found values shall be: 6.045 mm for exhaust cams and 7.582 mm for intake cams, in case of different values replace the camshaft.
Figure 56
Figure 55
70172
70171
Camshaft bush (2) shall be pressed into its housing. Internal surface must not show seizing or wear. Use bore dial gauge (3) to measure camshaft bush (2) and intermediate housing (1) diameter. Measurements shall be performed on two perpendicular axes.
Check camshaft (2) pin diameter using micrometer (1) on two perpendicular axes.
Figure 57
Sec. A-A
107399
CAMSHAFT BUSH AND HOUSING MAIN DATA (4 cyl.) * Value to be obtained after driving the bush. Print P2D32N020 E
Base - May 2012
18
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Figure 58
176518
MAIN DATA OF THE BUSH FOR THE CAMSHAFT AND THE RELEVANT SEAT (6-engine cylinders) *Dimension to be obtained after driving the bushing.
Bush replacement
TAPPETS
Figure 59
Figure 60
70174
To replace rear bushing (1), use, for dismounting and mounting it, beater 99360362 (2) and handgrip 99370006 (3). NOTE
Base - May 2012
112890
MAIN DATA CONCERNING THE TAPPETS AND THE RELEVANT HOUSINGS ON THE ENGINE BLOCK
Bushing (1), on mounting, must be oriented in such a way that lubrication holes match the holes present on block seat.
Print P2D32N020 E
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Fitting tappets — camshaft
19
Figure 64
Figure 61
70179
70176
Lubricate the tappets (1) and fit them into the relevant housings on the engine block.
Check camshaft end float (1). It shall be 0.23 0.13 mm. Figure 65
Figure 62
70180
70164
Fit nozzles (2) and tighten the fastening screws (1) to the specified torque.
Lubricate the bushing and other timing system shaft support seats and mount camshaft (1) taking care that, during the operation, the bushing or support seats are not being damaged. Figure 63
70238
Set camshaft (3) retaining plate (1) with the slot facing the top of the engine block and the marking facing the operator, then tighten the screws (2) to the specified torque. Print P2D32N020 E
Base - May 2012
20
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
CRANKSHAFT Measuring journals and crankpins (4-cylinder)
NOTE
It is recommended to insert the found values in the proper table. See next Figure.
Figure 66 Undersize classes are:
NOTE Journals and crankpins shall always be ground to the same undersize class. Journals and crankpins undersize shall be marked on the side of the crank arm No.1. For undersized crankpins: letter M For undersized journals: letter B For undersized crankpins and journals: letters MB.
70182
Grind journals and crankpins if seizing, scoring or excessive ovalisation are found. Before grinding the pins (2) measure them with a micrometer (1) to decide the final diameter to which the pins are to be ground.
Figure 67
108487
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES (4 CYL.) *Rated value
Base - May 2012
Print P2D32N020 E
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
21
Figure 68
measured on > 45.5 mm radius between adjacent journals 70183
OUTPUT SHAFT MAIN TOLERANCES Figure 69 MAIN BEARING ON TIMING SYSTEM CONTROL SIDE
INTERMEDIATE MAIN BEARINGS
FIRST MAIN BEARING ON FRONT SIDE
70237
TOLERANCES SHAPE DIRECTION POSITION OSCILLATION
TOLERANCE CHARACTERISTIC Roundness Cilindricity Parallelism Verticality Straightness Concentricity or coaxiality Circular oscillation Total oscillation
LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS
GRAPHIC SYMBOL ○ /○/ //
GRAPHIC SYMBOL
CRITICAL
IMPORTANT
⊕
SECONDARY
⊝
Print P2D32N020 E
Base - May 2012
22
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Measuring journals and crankpins (6-cylinder)
NOTE
It is recommended to insert the found values in the proper table. See next Figure.
Figure 70 Undersize classes are: 0.250 — 0.500 mm
NOTE
Journals and crankpins shall always be ground to the same undersize class. Journals and crankpins undersize shall be marked on the side of the crank arm No.1. For undersized crankpins: letter M For undersized journals: letter B For undersized crankpins and journals: letters MB
70182
Grind journals and crankpins if seizing, scoring or excessive ovalisation are found. Before grinding the journals (2) measure them with a micrometer (1) to decide the final diameter to which the pins are to be ground.
Figure 71
107269
FILL THIS TABLE WITH OUTPUT SHAFT JOURNAL AND CRANKPIN MEASURED VALUES (6 CYL.) *Rated value
Base - May 2012
Print P2D32N020 E
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
23
Figure 72
* **
Measured on a radius greater than 45.5 mm ↗ 0.500
70577
between adjacent main journals MAIN CRANKSHAFT TOLERANCES
Figure 73 MAIN BEARING ON TIMING SYSTEM CONTROL SIDE
INTERMEDIATE MAIN BEARINGS
FIRST MAIN BEARING ON FRONT SIDE
70237
TOLERANCES SHAPE DIRECTION POSITION OSCILLATION
TOLERANCE CHARACTERISTIC Roundness Cilindricity Parallelism Verticality Straightness Concentricity or coaxiality Circular oscillation Total oscillation
LEVELS OF IMPORTANCE FOR PRODUCT CHARACTERISTICS
GRAPHIC SYMBOL ○ /○/ //
GRAPHIC SYMBOL
CRITICAL
IMPORTANT
⊕
SECONDARY
⊝
Print P2D32N020 E
Base - May 2012
24
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
CONNECTING ROD — PISTON ASSEMBLY Connecting rod-piston assembly removal
Figure 75
Figure 74
32613
70191
Remove split rings (1) from piston (2) using pliers 99360183 (3).
CONNECTING ROD — PISTON ASSEMBLY COMPONENTS 1. Stop rings - 2. Pin - 3. Piston - 4. Piston rings - 5. Screws - 6. Half bearings - 7. Connecting rod - 8. Bush.
NOTE
Figure 76
Pistons are supplied spare with 0.4 or 0.8 mm oversize.
32614
Piston pin (1) split rings (2) are removed using a scriber (3).
Figure 77
176517
MAIN DATA OF THE PISTON WITH PIN TUNNEL AND PLASTIC RINGS * Value measured on 101 mm diameter Base - May 2012
Print P2D32N020 E
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Pistons
25
Gudgeon pins
Measuring piston diameter Figure 78
Figure 80
32615
18857
Using a micrometer (2), measure the diameter of the piston (1) to determine the assembly clearance.
To measure the piston pin (1) diameter use the micrometer (2). Conditions for proper pin-piston coupling
Figure 79
Figure 81
70192
The clearance between the piston and the cylinder barrel can be checked also with a feeler gauge (1) as shown in the figure.
Print P2D32N020 E
32619
Lubricate the pin (1) and its seat on piston hubs with engine oil; the pin shall be fitted into the piston with a slight finger pressure and shall not be withdrawn by gravity.
Base - May 2012
26
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Piston rings
Figure 84
Figure 82
16552
Use a micrometer (1) to check split ring (2) thickness.
41104
DIAGRAM FOR MEASURING THE CLEARANCE X BETWEEN THE FIRST PISTON SLOT AND THE TRAPEZOIDAL RING Since the first sealing ring section is trapezoidal, the clearance between the slot and the ring shall be measured as follows: make the piston (1) protrude from the engine block so that the ring (2) protrudes half-way from the cylinder barrel (3).
Figure 83
In this position, use a feeler gauge to check the clearance (X) between ring and slot: found value shall be the specified one.
Figure 85
32620
Check the clearance between the sealing rings (3) of the 2nd and 3rd slot and the relevant housings on the piston (2), using a feeler gauge (1).
70194
Use feeler gauge (1) to measure the clearance between the ends of the split rings (2) fitted into the cylinder barrel (3).
Base - May 2012
Print P2D32N020 E
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Connecting rods
27
Figure 87
Figure 86 CONNECTING ROD BODY CONN. WEIGHT ROD Nr.
CAP CONN. ROD Nr.
*
CONNECTING ROD CAP
F
176516
MAIN DATA FOR CONNECTING ROD, BUSH, PISTON PIN AND HALF BEARINGS
DAY
YEAR F = 2003 G = 2004 H = 2005 I = 2006
70196
NOTE Every connecting rod is marked as follows: - On body and cap with a number showing their coupling and the corresponding cylinder. In case of replacement it is therefore necessary to mark the new connecting rod with the same numbers of the replaced one.
* Value for inside diameter to be obtained after driving in connecting rod small end and grinding.
NOTE The surface of connecting rod and rod cap are knurled to ensure better coupling. Therefore, it is recommended not to smooth the knurls.
- On body with a letter showing the weight of the connecting rod assembled at production:
S
V, 1560 to 1600 g (yellow marking);
S
W, 1601 to 1640 g (green marking);
S
X, 1641 to 1680 g (blue marking);
Spare connecting rods are of the W class with green marking *. Material removal is not allowed.
Bushes Check that the bush in the connecting rod small end is free from scoring or seizing and that it is not loosen. Otherwise replace. Removal and refitting shall be performed using the proper beater. When refitting take care to make coincide the oil holes set on the bush with those set on the connecting rod small end. Grind the bush to obtain the specified diameter.
Print P2D32N020 E
Base - May 2012
28
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Fitting connecting rod-piston assembly Connecting rod-piston assembling
Figure 90
Figure 88 FLYWHEEL SIDE
126312
FAN SIDE 162243
The piston crown is marked as follows: 1. Part number and design modification number; 2. Arrow showing piston assembling direction into cylinder barrel, this arrow shall face the front key of the engine block (fan side); 3. Marking showing 1st slot insert testing; 4. Manufacturing date; 5. Product traceability
Position the piston on the connecting rod according to the diagram shown in the figure, fit the pin and stop it by the split rings (2).
Fitting split rings Figure 91
Figure 89
126311
Use pliers 99360183 (1) to fit the split rings on the piston (2). Split rings shall be fitted with the marking “TOP” facing upwards and their openings shall be displaced with each other by 120.
162244
Connect piston (2) to connecting rod (4) with pin (3) so that the reference arrow (1) for fitting the piston (2) into the cylinder barrel and the numbers (5) marked on the connecting rod (5) are read as shown in the figure.
Base - May 2012
NOTE Split rings are supplied spare with the following sizes: -
standard; 0.4 mm oversize; 0.8 mm oversize.
Print P2D32N020 E
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
29
Crankshaft installation
BENCH ENGINE BLOCK ASSEMBLY Replacing oil pump control gear
Figure 94 (D)
Figure 92
70161
(D) 4-cylinder engine
70184
Figure 95 (*)
Check that gear toothing (1) is not damaged or worn, otherwise remove it using the proper puller (3). On mounting the new gear, the gear has to be heated for 10' at 180 ºC temperature and keyed on engine shaft by putting the key in between.
Fitting main bearings Figure 93
74774
(*) 6-cylinder engine Refit the output shaft (2).
70185
NOTE Refit the main bearings that have not been replaced, in the same position found at removal.
Main bearings (1) are supplied spare with 0.250 — 0.500 mm undersize on the internal diameter.
NOTE
Do not try to adapt the bearings.
Clean accurately the main half bearings (1) having the lubricating hole and fit them into their housings. The second last main half bearing (1) is fitted with shoulder half rings. Print P2D32N020 E
Base - May 2012
30
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Figure 96
Figure 98
α
70188 128169
-
2nd
stage, with tool 99395216 (1) set as shown in the figure, tighten the screws (2) with 90 2 angle.
- Clean accurately the parts and remove any trace of oil; - fit caps (1), including the half bearings (2) on the relevant supports.
Checking crankshaft end float Figure 99 NOTE Before reusing the fastening screws (1), perform two diameter measurements as shown in figure, registering diameters D1 and D2: if D1-D2 < 0.1 mm the screw may be reused if D1-D2 > 0.1 mm the screw must be replaced
75703 70190
This check is performed by setting a magnetic-base dial gauge (2) on the crankshaft (3) as shown in the figure.
Figure 97
If higher value is found, replace main thrust half bearings of the second last rear support (1) and repeat the clearance check between crankshaft journals and main half bearings.
70187
Tighten the pre-lubricated screws (1) in the following two successive stages: - 1st stage, with torque wrench to 80 6 Nm.
Base - May 2012
Print P2D32N020 E
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Fitting connecting rod half bearings
31
Figure 102
Figure 100
162245 70200
Fit half bearings (1) on connecting rod and cap.
DIAGRAM FOR INSTALLING CONNECTING ROD PISTON ASSEMBLY INTO CYLINDER (viewed from front) - split ring openings shall be displaced with each other by 120;
NOTE Refit the main bearings that have not been replaced, in the same position found at removal. Do not try to adapt the half bearings.
- connecting rod-piston assemblies shall have the same weight; - the arrow marked on the piston crown shall be facing the front side of the engine block or the slot obtained on the piston skirt shall be corresponding to the oil nozzle position.
Fitting connecting rod-piston assembly into cylinder barrels Figure 103
Figure 101
70201 128170
Lubricate accurately the pistons, including the split rings and the cylinder barrel inside. Use band 99360605 (2) to fit the connecting rod-piston assembly (1) into the cylinder barrels and check the following: - the number of each connecting rod shall correspond to the cap coupling number.
Print P2D32N020 E
- Clean the parts accurately and remove any trace of oil; - install the big end caps (1) with the relative half-bearings (2).
Base - May 2012
SECTION 7 - GENERAL MECHANICAL OVERHAULING
32
F4AE ENGINES
Checking piston protrusion
Figure 104
Figure 107
70204
- lubricate the screws (1) with engine oil and then tighten them to the specified torque using the torque wrench (2).
166655
Once connecting rod-piston assemblies refitting is over, use dial gauge 99395603 (1) fitted with base 99370415 (2) to check piston (3) protrusion at T.D.C. with respect to the top of the engine block, carrying out the following operations:
Figure 105 - measure the protrusions S1 and S2 of piston no. 1 from the top surface of the engine block at a distance of 45 mm from the centre of the piston and then calculate the average protrusion:
α
S cil1 = S1 + S2 2
70205
- apply tool 99395216 (1) to the socket wrench and tighten screws (2) of 60° ± 2°.
- For 4-cylinder versions: repeat the operation to calculate the average protrusion of pistons 2, 3 and 4, then calculate the average value of the protrusions: S + S cil2 + S cil3 + S cil4 S = cil1 4 - For 6-cylinder versions: repeat the operation to calculate the average protrusion of pistons 2, 3, 4, 5 and 6, then calculate the average value of the protrusions:
Figure 106
S=
S cil1 + S cil2 + S cil3 + S cil4 + S cil5 + S cil6 6
70207
Check manually that the connecting rods (1) are sliding axially on the output shaft pins and that their end float, measured with feeler gauge (2) is 0.10 — 0.33 mm.
Base - May 2012
Print P2D32N020 E
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
CYLINDER HEAD DISMANTLING Removing the valves
33
Figure 110
Figure 108
70322
70319
Remove the sealing rings (1 and 2) from the relevant valve guides.
Intake (1) and exhaust (2) valves have heads with the same diameter. The central notch () of the exhaust valve (2) head distinguishes it from the intake valve. NOTE
Should valves be not replaced, number them before removing in order to refit them in the same position. A = intake side — S = exhaust side
NOTE Sealing rings (1) for intake valves are yellow. Sealing rings (2) for exhaust valves are green.
Checking cylinder head wet seal Figure 111
Figure 109
70323
This check shall be performed using the proper tools.
70321
Valve removal shall be performed using tool 99360268 (1) and pressing the cap (3) so that when compressing the springs (4) the cotters (2) can be removed. Then remove the cap (3) and the springs (4). Repeat this operation for all the valves. Overturn the cylinder head and withdraw the valves (5).
Use a pump to fill with water heated to approx. 90 C and 2 to 3 bar pressure. Replace the cup plugs (1) if leaks are found, use the proper beater for their removal/refitting.
NOTE Before refitting, smear the plug surfaces with water-repellent sealant.
Replace the cylinder head if leaks are found.
Print P2D32N020 E
Base - May 2012
34
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Checking cylinder head supporting surface
VALVES
Distortion found along the whole cylinder head shall not exceed 0.20 mm. If higher values are found grind the cylinder head according to values and indications shown in the following figure.
Figure 113 EXHAUST VALVE
INTAKE VALVE
Figure 112
162247
INTAKE AND EXHAUST VALVE MAIN DATA 70325
The rated thickness A for the cylinder head is 105 0.25 mm, max. metal removal shall not exceed thickness B by 0.13 mm.
Removing carbon deposits, checking and grinding valves Figure 114
NOTE After grinding, check valve sinking. Regrind the valve seats, if required, to obtain the specified value.
18625
Remove carbon deposits from valves using the proper metal brush. Check that the valves show no signs of seizing, scoring or cracking. Regrind the valve seats, if required, removing as less material as possible.
Base - May 2012
Print P2D32N020 E
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
35
VALVE GUIDES
Figure 115
Figure 117
18882
Check the valve stem (1) using a micrometer (2), it shall be 6.990 7.010 mm.
Checking clearance between valve stem and valve guide and valve centering Figure 116
INTAKE
EXHAUST 79457
Use a bore dial gauge to measure the inside diameter of the valve guides, the read value shall comply with the value shown in the figure.
VALVE SEATS Regrinding — replacing the valve seats Figure 118
70327
Use a magnetic base dial gauge (1) set as shown in the figure, the assembling clearance shall be 0.032 0.072 mm. Turn the valve (2) and check that the centering error is not exceeding 0.03 mm.
70330
Check the valve seats (2). If slight scoring or burnout is found, regrind seats using tool (1) according to the angle values shown in Figure 119.
Print P2D32N020 E
Base - May 2012
36
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Figure 119
INTAKE
EXHAUST
107281
MAIN DATA OF ENGINE VALVE SEATS The valve seats are cast in the cylinder head and machined.
Figure 120
EXHAUST
INTAKE
107282
If the valve seats cannot be restored by only regrinding, it is possible to mount the inserts supplied as spares. In this case, it is necessary to make the seats on the cylinder head with the dimensions shown in the figure and to mount the valve seats.
Base - May 2012
To mount the valve seats in the cylinder head it is necessary to heat the cylinder head to 80 - 100 C and, using a suitable drift, mount the new valve seats (2) in them after they have been cooled. Then use the specific tool to grind the valve seats to the values given in Figure 121.
Print P2D32N020 E
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
37
Figure 121
EXHAUST
INTAKE
162248
MAIN VALVE SEAT DATA
VALVE SPRINGS
Figure 122
Figure 123
50676
70333
After regrinding, check with the base 99370415 (2) and the dial gauge 99395603 (1) that the valve recessing (3) is as prescribed.
MAIN DATA TO CHECK INTAKE AND EXHAUST VALVE SPRINGS Prior to assembly, check valve spring flexibility using a suitable tool. Compare the elastic deformation and load data with those for new springs given in the following table.
H H1 H2
Print P2D32N020 E
Height mm 35.33 35.33 25.2
Under a load of N Free P1 339.8 9 P2 741 39
Base - May 2012
38
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
ASSEMBLING CYLINDER HEAD Figure 124
70334
Lubricate the valve stems (1) and fit them into the relevant valve guides according to the position marked at removal. Fit the sealing rings (2 and 3) on the valve guide.
NOTE Sealing rings (2) for intake valves are yellow and sealing rings (3) for exhaust valves are green.
Figure 125
770321
Position on the cylinder head: the spring (4) and upper plate (3): using tool 99360268 (1), compress the spring (4) and fasten the plate (3) to the valve (5) with the cotters (2).
Base - May 2012
Print P2D32N020 E
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
REFITTING MAIN COMPONENTS
39
Figure 127
Figure 126
70210 70209
LOCTITE 5205 SEALANT APPLICATION AREAS Clean accurately the timing gear case (1) and the engine block.
NOTE Perfect seal is only obtained by cleaning accurately the surface to seal. Smear the case with LOCTITE 5205 to obtain a bead of few mm diameter. It shall be uniform (no clots), without air bubbles, thin areas or discontinuities. Any imperfection shall be corrected as soon as possible. Avoid to use excess material to seal the joint. Excessive sealant could come out from joint sides and cause lubricant passage clogging. After applying the sealant, the joint shall be assembled immediately (10 — 20 minutes).
DIAGRAM FOR TIGHTENING THE REAR TIMING GEAR CASE FASTENING SCREWS Refit the case (1) to the engine block. Screw the fastening screws in the same position found at removal and tighten them to the following torque values in the sequence shown in the figure: Screws M12 65 to 89 Nm Screws M8 20 to 28 Nm Screws M10 42 to 52 Nm NOTE Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt.
Figure 128
70211
With a felt-tip pen, highlight the conducting gear tooth (1) mounted on the engine shaft (2) upon the side surface of which a groove has been created for the ignition timing.
NOTE Fasten screwing of the two pins to facilitate the operation of engine driving shaft rotation.
Print P2D32N020 E
Base - May 2012
40
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Figure 129
NOTE Perfect seal is only obtained by cleaning accurately the surface to seal. Smear the case with LOCTITE 5205 to obtain a bead of few mm diameter. It shall be uniform (no clots), without air bubbles, thin areas or discontinuities. Any imperfection shall be corrected as soon as possible. Avoid to use excess material to seal the joint. Excessive sealant could come out from joint sides and cause lubricant passage clogging. After applying the sealant, the joint shall be assembled immediately (10 — 20 minutes).
114791
Turn the engine shaft (3) and the distribution shaft (4) so that by mounting the bevel gear on the latter (1) the stencilled mark on the gear (1) coincides with the groove on the gear tooth (2).
Figure 132
Figure 130
70215
70213
Tighten the screws (1) fastening gear (2) to camshaft (3) to the specified torque. Figure 131
SEQUENCE FOR TIGHTENING THE FLYWHEEL HOUSING FASTENING SCREWS Refit the housing (1) to the engine block and screw the fastening screws in the same position found at removal and tighten them to the following torque values in the sequence shown in the figure: Screws M12 75 to 95 Nm Screws M10 44 to 53 Nm
NOTE Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt.
70214
LOCTITE 5205 SEALANT APPLICATION AREAS Base - May 2012
Print P2D32N020 E
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Figure 133
41
Figure 135
70152
0901t
Apply tool 99346252 part (6) to the rear output shaft tang (5), secure it by screws (4) and fit the new sealing ring (3). Position part (1) on part (5), screw nut (2) until completing sealing ring (3) fitting into flywheel housing (7).
Screw two pins (2) having suitable length into shaft holes (3) and remove the engine flywheel (1) using proper sling and hoister. Figure 136
Figure 134
Apply tool 99360339 (2) to the flywheel housing to stop engine flywheel (3) rotation. Tighten the screws (1) fastening the engine flywheel (3) to the output shaft. Figure 137
70217
Check the supporting surface (1) of the clutch plate and if it is scratched, it is necessary to carry out turning. Check ring gear teeth (2), if breakage or excessive wear is found remove the ring gear from the engine flywheel (1, Figure 133) using a suitable hammer and fit the new one, previously heated to 150 C for 15 to 20 minutes. Chamfering on ring gear inside diameter shall be facing the engine flywheel.
α
70219
Tighten engine flywheel (2) fastening screws (1) in two stages: - 1st stage, tightening to 50 ± 5 Nm torque with dynamometric wrench; - 2nd stage, tightening to 60 2° angle. NOTE Tightening to angle is performed using tool 99395216. Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt.
Print P2D32N020 E
Base - May 2012
42
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Figure 138
Figure 141
106549 70220
Fit the oil pump (1). Tighten the fastening screws (2) to the specified torque.
Remove the sealing ring (2) from the front cover (1), clean accurately the coupling surfaces and smear them with LOCTITE 5205. Figure 142
Figure 139
106550 70221
Clean accurately the front cover (2) surface and refit it. Tighten the screws (1) to the specified torque.
Apply a new sealing ring (2) to the water pump (1). Figure 143 Figure 140
00902t 70222
Fit the water pump (1). Tighten the screws (2) to the specified torque.
Base - May 2012
Apply tool 99346252 part (4) to the front output shaft tang (6), secure it by screws (5) and fit the new sealing ring (7). Position part (2) on part (4), screw nut (3) until completing sealing ring (7) fitting into front cover (1).
Print P2D32N020 E
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Figure 144
43
Figure 146
74775
108553
Fit the plate (1), the oil pick up tube (2) and tighten the fastening screws (3) to the specified torque. Figure 145
Place the oil sump (1) in position and apply the plate (3) to it. Tighten the screws (2) to the specified torque.
NOTE Always check that the threads on the screws and their holes do not show any signs of wear or traces of dirt before fitting
Figure 147
74770
Set the gasket (1) on the oil sump (2).
NOTE If it does not show any signs of damage the gasket can be reused. 108548
Fit the pulley (1) and the damper flywheel (2) onto the crankshaft. Tighten the fastening screws (3) to 68 ± 7 Nm torque.
Print P2D32N020 E
Base - May 2012
44
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Figure 148
Figure 150
116245 108578
Fit a new seal ring on the speed sensor (3). Fit the speed sensor (3) on the front cover (1) and tighten the retaining screw (2) to the specified torque.
Lubricate the seal ring (2) with engine oil and place it on the oil filter (3). Screw the oil filter (3) all the way on to the bracket connection (1) by hand and then tighten the oil filter (3) to 18 ± 2 Nm.
Figure 149
Apply a new seal ring to the oil temperature/pressure sensor (4) and fit it on the support (1). Tighten the screws (5) to the specified torque. Fit a new seal ring (6) in the engine block seat.
108576
Fit the following on the engine block: a new gasket (1), the heat exchanger (2) a new gasket (3) and the oil filter bracket (4). Tighten the screws (5) to the specified torque.
NOTE Always check that the threads on the screws and their holes do not show any signs of wear or traces of dirt before fitting.
Base - May 2012
Print P2D32N020 E
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Figure 151
45
Figure 153
176538 70234
Position the alternator support (1) so that pins (3 and 4) are set against the engine block. Tighten the screws (2) to the specified torque.
Refit the automatic belt tensioner (2). Tighten the screw (3) to the specified torque using a wrench, turn the automatic belt tensioner (2) to fit the belt (1) on pulleys and guide rollers. Figure 154
NOTE Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt.
Figure 152
70145
Refit the high pressure pump (6) including the feed pump (5) and tighten the nuts (3) to the specified torque. Fit the support (4) with a new sealing ring, the timing sensor (2) with a new sealing ring and tighten the relevant fastening nut (1) to the specified torque. Figure 155 176539
1
4
3
Refit the alternator (1). Tighten the screw (2) to the specified torque.
2 74176
Insert the power take-off (2) equipped with the gasket (4), the cover (I) and its gasket (4). Tighten the screws (3) to the prescribed matching couple. Print P2D32N020 E
Base - May 2012
46
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Figure 156
Figure 158
1
2
74174
Assemble the electronic gearbox (2) equipped with the exchanger to the engine, fixing it with the screws (1). In case the rubber buffers are cracked or excessively deformed, provide replacing them.
74779
Direct the output shaft (4) and the camshaft (2) so that when fitting the driven gear (1) on the camshaft the marks on the gears (1 and 3) are coinciding. NOTE Before reusing the fastening screws (1), perform two diameter measurements as shown in figure, registering diameters D1 and D2: if D1-D2 < 0.1 mm the screw may be reused if D1-D2 > 0.1 mm the screw must be replaced
Figure 157
D2
D1
75703
Figure 159
70335
Check cleanness of cylinder head and engine block coupling surface. There are two types of head gasket: -
Type A - 1.25 mm thick
-
Type B - 1.15 mm thick
Check the average protrusion S of the pistons as indicated on page 29. If S > 0.40 mm use gasket type A. If S 0.40 mm use gasket type B.
α
70336
Assemble cylinder head (1), tighten the screws (2) in three following steps, following order and mode shown in the figure below.
Do not get the cylinder head gasket dirty. Place the gasket (1) in position with the marking “TOP” (1) facing the head.
NOTE The angle tightening is carried out through tool 99395216 (3).
The arrow shows the point where the gasket thickness is given. NOTE Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt. Base - May 2012
Print P2D32N020 E
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Figure 160 (D)
47
Figure 163
α
A 70337
(D)
4-cylinder engine
Figure 161 (*)
70339
Fit injectors (1) on the cylinder head seats, directed so that the fuel inlet hole (2) is facing the fuel manifold seat (3) side.
A
α
Figure 164
70476
(*) 6-cylinder engine Tightening order layout for cylinder head fastening screws: - 1st step pre-tightening with dynamometric wrench: Screw 12x1.75x130 ( ) 35 ± 5 Nm Screw 12x1.75 x 150 ( ) 55 ± 5 Nm - 2nd step tightening with a 90 2 angle - 3rd step tightening with a 90 2 angle A = Front side
70133
Use tool 99342101 (1) to fit the injector (2) into its seat.
Figure 162
Screw injector fastening screws without tightening them.
70338
Fit a new sealing ring (2) lubricated with petroleum jelly and a new sealing washer (3) on injector (1).
Print P2D32N020 E
Base - May 2012
48
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Figure 165
NOTE Tightening to angle is performed using tool 99395216. Tighten the fuel manifold (3) fastening nuts (2) to 50 5 Nm torque. Carry out the assembly of the equalisers' unit , after previous check of the components. Figure 167 (D)
91572
Fit a new sealing ring (3) lubricated with petroleum jelly on the fuel manifold (2) and fit it into the cylinder head seat so that the positioning ball (5) is coinciding with the relevant housing (4).
NOTE Disassembled fuel manifolds (2) must not be used again. Replace with new items. The fuel manifolds (2) for engines have 2 positioning spheres.
176525
(D) F4AE3481/2 Figure 168 (*)
Screw the fastening nuts (2, Figure 166) without locking them. NOTE During this operation, the injector (1) shall be moved so that the manifold (2, Figure 163) is properly inserted into the fuel inlet hole (2, Figure 165).
Figure 166
176535
(*) F4AE3681 Apply to the coupling surface of the intake manifold (1) with the cylinder head, a sufficient coat of LOCTITE 5999. Place the intake manifold (1), complete with the cold-start heater (if fitted), in position and tighten the retaining screws to the specified torque. 70342
Tighten gradually and alternately the injector fastening screws (1) in four stages: - 1st stage, tightening to 3.5 ± 0.35 Nm torque with dynamometric wrench. - 2nd stage, tightening to 25° ± 1° angle; - 3rd stage, tightening to 25° ± 1° angle; - 4th stage, tightening to 25° ± 1° angle. Base - May 2012
Print P2D32N020 E
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
49
Place the exhaust manifold (2) in position with new gaskets and tighten the retaining screws to the specified torque. Sling the turbocharger (1) and position it above the exhaust manifold after fitting it with a new gasket, tighten the fastening nuts to the specified torque. Place the the oil supply pipe (3) in position on the turbocharger and tighten the couplings on the turbocharger and on the heat exchanger/oil filter bracket to the specified torque.
Figure 169 (D)
Figure 171 176524
(D) F4AE3481/2
Figure 170 (*)
70343
176534
ROCKER ASSEMBLY COMPONENTS: 1. Screws - 2. Bracket - 3. Shafts - 4. Rockers.
(*) F4AE3681
Print P2D32N020 E
Base - May 2012
50
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Figure 172
Figure 175
SHAFT-ROCKER MAIN DATA Check that shaft/rocker coupling surfaces are not showing excessive wear or damages. 70346
Check that tappet adjusters (1) are loose to prevent their balking on the rods (2, Figure 174) when refitting the rocker assembly. Then refit the rocker assembly consisting of: bracket (5), rockers (3), shafts (4) and secure them to the cylinder head by tightening the fastening screws (2) to 36 ± 5 Nm torque.
Figure 173
122587
Figure 176
Rocker control rods shall not be distorted; the ball seats in touch with the rocker adjusting screw and with tappets (arrows) shall not show seizing or wear; otherwise replace them. Intake and exhaust valve control rods are identical and are therefore interchangeable.
Figure 174
70520
Adjust clearance between rockers and valves using setscrew wrench (1), box wrench (3) and feeler gauge (2). Clearance shall be as follows: - intake valves 0.25 0.05 mm - exhaust valves 0.50 0.05 mm.
70345
Fit the rods (2). Position jumpers (1) on valves with marks () facing the exhaust manifold.
Base - May 2012
Print P2D32N020 E
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
51
Figure 180 (*)
Figure 177 (D)
173250
(D)
4-cylinder engine
Figure 178 (*)
166640
(*) 6-cylinder engine Place the new high pressure fuel hoses (1) in position and tighten the couplings to the electro-injector collectors (3) and the common rail (2) to the specified torque. NOTE
The hoses (1), as they are subject to high pressure, must be replaced every time they are removed. The hose couplings must be tightened to a torque of 24 ± 4 Nm, using spanner 99317915 (5) and torque wrench 99389829.
107286
(*) 6-cylinder engine Fit the rail (2) and tighten the screws (1) to the specified torque, connect the ground cable (3) to the intake manifold (4) and tighten the fastening nut to the specified torque.
Figure 181
Figure 179 (D)
70352
Check the condition of the electrical cables (5), if they are damaged replace them by cutting the straps (2) securing them to the bracket and removing the screws (4) securing the connectors to this (3). Fit a new gasket (1) on the bracket (2).
173251
(D)
4-cylinder engine
Print P2D32N020 E
Base - May 2012
52
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Figure 182
Figure 185
108570
Fit the wiring support (2) and tighten the screws (1) to the specified torque. 166077
NOTE Before any assembly operation always verify that the hole and screw threads have no evidence of wear or dirt.
Figure 183
Fit the tappet cover (9) and tighten the nuts (10) to the specified torque. Place the blow-by filter (8) in position and tighten the fastening screws. Place the pipe (6) in position with new copper washers in the tappet cover and timing case couplings (7). Then tighten the couplings (7) to the specified torque. Place the blow-by pipe (5) into the coupling located on the timing case and secure it with the elastic strap (4). Insert the upper coupling of the new blow-by pipe (5), with a new seal ring, into the tappet cover and tighten the screw (3). Connect the fuel return pipe (2) to the pressure limiter (1) and common rail as shown in following figure.
Figure 186 108571
Connect the electrical cables (1) to the injectors (3) and use the torque wrench 99389834 (4) to tighten the fastening nuts (2) to the specified torque. Figure 184
116237
To connect the low pressure fuel hose to the connection fitting, insert the quick-fit coupling (2) in the connection fitting and push it in until the catch (3) engages.
NOTE Check proper fuel hose connection.
70355
Fit a new gasket (2) on the tappet cover (1).
Base - May 2012
Place the engine cable in position, close the retaining straps and connect the sensor, control unit and electro-injector connectors (refer to Figure 8 on page 5). Print P2D32N020 E
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
REMOVING THE ENGINE ROTATING STAND
FROM
THE
53
Figure 187 (*)
Support the engine appropriately with a hoist, disconnect it from the rotating stand, remove brackets 99341009 and place it on a suitable support to complete engine assembly.
COMPLETING ENGINE ASSEMBLY Refit the fan to the crankshaft pulley.
Figure 189
1
176533
(*) F4AE3681 From the right-hand side of the engine, place the oil drain pipe (1) in position and tighten the screws fastening it to the turbocharger and engine block to the specified torque.
2 74166
Position the starter motor (2) on the internal part of the flywheel cover (1). Screw down the retaining screws and tighten them to the specified torque.
Figure 188 (D)
176523
(D) F4AE3481/2
Print P2D32N020 E
Base - May 2012
54
SECTION 7 - GENERAL MECHANICAL OVERHAULING
F4AE ENGINES
Perform the following operations from the left-hand side of the engine: - Place the oil delivery tube in position, if present, with a new o-ring, and tighten the retaining screws. - Connect the low-pressure fuel hose (6) supplying the mechanical pump connected to the high pressure pump via the electronic control unit exchanger. - Connect a new high-pressure fuel hose (5) between the high-pressure pump and the common rail, tighten the couplings to the specified torque and fasten it to the engine block with the respective clamps
Figure 190 (D)
NOTE Due the high pressures in the hoses running from the high pressure pump to the rail and from this to the injectors, reuse of these hoses after removal must absolutely be avoided. 173245
(D) F4AE3481/2
-
Figure 191 (*)
-
Place the fuel filter support (4) in position together with the bracket, if present, and tighten the retaining screws to the specified torque. Connect the low-pressure fuel hoses (3) to the filter support. Connect the fuel temperature sensor and camshaft timing sensor electrical connections (2). Fully screw the fuel filter onto the connection on its support by hand, then further tighten to a torque of 20 ± 2 Nm.
166072
(*) F4AE3681
Base - May 2012
Print P2D32N020 E
F4AE ENGINES
SECTION 7 - GENERAL MECHANICAL OVERHAULING
55
CHECKS AND INSPECTIONS NOTE The following checking inspections must be carried out after the engine assembly on the vehicle .
Start the engine and leave it running just above the idling speed, wait until the coolant reaches the temperature necessary to open the thermostat and then check: - that there are no water leaks from the connecting sleeves of engine cooling circuit pipes and cab internal heating pipes, tighten the clamping collars if required; - check carefully the connection between the low pressure fuel pipes and the relevant connectors; - that there are no oil leaks between the cover and the cylinder head, between oil sump and engine block, between heat exchanger oil filter and the relevant housings and between the different pipes in the lubricating circuit; - that there are no fuel leaks from the fuel pipes; - that there are no air leaks from pneumatic pipes (if fitted); - check also proper operation of the warning lights set on the instrument panel and of the equipment disconnected when engine was removed. - Carefully check and bleed the engine cooling equipment by repeated draining operations.
Print P2D32N020 E
Base - May 2012
56
SECTION 7 - GENERAL MECHANICAL OVERHAULING
Base - May 2012
F4AE ENGINES
Print P2D32N020 E
F4AE ENGINES
SECTION 8 - TECHNICAL SPECIFICATIONS
1
SECTION 8 Technical specifications
Page
Print P2D32N020 E
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . .
3
CLEARANCE DATA . . . . . . . . . . . . . . . . . . . . .
4
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . .
10
Base - May 2012
2
SECTION 8 - TECHNICAL SPECIFICATIONS
Base - May 2012
F4AE ENGINES
Print P2D32N020 E
F4AE ENGINES
SECTION 8 - TECHNICAL SPECIFICATIONS
3
GENERAL SPECIFICATIONS Type
4 CYLINDERS
6 CYLINDERS
Cycle
Four-stroke diesel engine
Power
Turbocharged with intercooler
Injection
Direct
Number of cylinders
4
6
+
+
Bore
mm
102
Stroke
mm
120
+.. = Total displacement
cm3
3920
5880
TIMING start before T.D.C. end after B.D.C.
A B
8º 30' 8º 30'
start before B.D.C. end after T.D.C.
D C
51º 00' 12º 30'
Checking timing mm 0.2 to 0.30
X
X
mm 0.46 to 0.56 FUEL FEED Injection Type:
Bosch
high pressure common rail EDC7 UC31
Injector
CRIN2
Nozzle type
DSLA
Injection sequence
1-3-4-2
1-5-3-6-2-4
bar
Injection pressure
Print P2D32N020 E
bar
250 - 1600
Base - May 2012
4
SECTION 8 - TECHNICAL SPECIFICATIONS
F4AE ENGINES
CLEARANCE DATA
Type
4 CYLINDERS
CYLINDER UNIT AND CRANKSHAFT COMPONENTS 1
102.01 to 102.03
1
0.4 - 0.8
Size Outside diameter Pin housing
X 1 2
12 / 60.5* 101.58 to 101.73 / 101.781 to 101.799* 40.010 to 40.016 / 40.008 to 40.014*
Piston diameter
1
0.4 - 0.8
X X 2
mm
1
Cylinder barrels
1
6 CYLINDERS
Spare pistons type:
Piston - cylinder liners
0.28 to 0.45 / 0.211 to 0.249*
X
3
Piston protrusion
X
Piston pin
3
Piston pin — pin housing
0.28 to 0.52
39.994 to 40.000 0.010 to 0.022 / 0.0078 to 0.0202*
(*) F4AE3482E*U101
Base - May 2012
Print P2D32N020 E
F4AE ENGINES
SECTION 8 - TECHNICAL SPECIFICATIONS
Type
4 CYLINDERS
CYLINDER UNIT AND CRANKSHAFT COMPONENTS X1 X2 X3 S 1 S 2 S 3
X1 X2
2
6 CYLINDERS mm
2.705 to 2.735 2.430 to 2.450 / 2.420 to 2.440* 4.040 to 4.060 / 4.020 to 4.040*
* measured on 101 mm 2.560 to 2.605 2.350 to 2.380 3.975 to 4.000
Split rings
S 1* S2 S3
Split rings - slots
1 2 3
0.100 to 0.175 0.040 to 0.090 0.040 to 0.085 / 0.040 to 0.065*
Split rings
1 2 3
0.4 - 0.8 0.4 - 0.8 0.4 - 0.8
Split ring end opening
X3
1
X1* X2 X3
Split ring slots
5
Small end bush housing Big end bearing housing
X1 X2 X3
0.30 to 0.40 0.60 to 0.80 0.25 to 0.55
1
42.987 to 43.013
2
72.987 to 73.013
3
Small end bush diameter
S
Inside Big end half bearings
3 S
40.019 to 40.033 1.955 to 1.968
Piston pin — bush
0.025 to 0.033
Big end half bearings
0.250 - 0.500
(*) F4AE3482E*U101
Print P2D32N020 E
Base - May 2012
6
SECTION 8 - TECHNICAL SPECIFICATIONS
F4AE ENGINES
Type
4 CYLINDERS
CYLINDER UNIT AND CRANKSHAFT COMPONENTS
6 CYLINDERS mm
X Size
X
Max. tolerance on connecting rod axis alignment
-
-
2
1
S 1
S 2
3
Journals Crankpins
1 2
82.990 to 83.010 / 82.993 to 83.013* 68.987 to 69.013
Main half bearings Big end half bearings
S1 S2
2.456 to 2.464 1.955 to 1.968
Main bearings No. 1 - 7 No. 2 - 3 - 4 - 5 - 6
3 3
87.982 to 88.008 87.977 to 88.013
Half bearings — Journals No. 1 - 7 No. 2 - 3 - 4 - 5 - 6
0.044 to 0.106 0.039 to 0.111
Half bearings - Crankpins
0.033 to 0.041 / 0.039 to 0.116*
Main half bearings Big end half bearings
0.250 - 0.500
Shoulder journal
X1
37.475 to 37.545
Shoulder main bearing
X2
32.180 to 32.280
Shoulder half-rings
X3
37.28 to 37.38
X 1
X 2 X 3
Output shaft shoulder
0.095 to 0.265
(*) F4AE3482E*U101
Base - May 2012
Print P2D32N020 E
F4AE ENGINES
SECTION 8 - TECHNICAL SPECIFICATIONS
Type
4 CYLINDERS
CYLINDER HEAD — TIMING SYSTEM 1
6 CYLINDERS mm
Valve guide seats on cylinder head
4
7
1
7.042 to 7.062
4
6.990 to 7.010 60o 0.25o
4
6.990 to 7.010 45o 0.25o
Valves:
Valve stem and guide
0.032 to 0.072
Housing on head for valve seat:
1
1
34.837 to 34.863
1
34.837 to 34.863
Valve seat outside diameter; valve seat angle on cylinder head: 2
2
2
X
Sinking Between valve seat and head Valve seats
34.917 to 34.931 60o 34.917 to 34.931 45o
X
0.59 to 1.11
X
0.96 to 1.48 0.054 to 0.094 0.054 to 0.094 -
(*) F4AE3482E*U101
Print P2D32N020 E
Base - May 2012
8
SECTION 8 - TECHNICAL SPECIFICATIONS
F4AE ENGINES
Type
4 CYLINDERS
CYLINDER HEAD — TIMING SYSTEM
6 CYLINDERS mm
Valve spring height: free spring H
H1
H 2 under a load equal to: 339.8 9 N 741 39 N Injector protrusion
H
47.75
H1 H2
35.33 25.2
X
-
X Camshaft bush housings No. 1 (flywheel side) 1 23 4 5 2
1
59.222 to 59.248
Camshaft pin seats No. 2-3-4-5-6-7
54.083 to 54.147
Camshaft journals: 17
53.995 to 54.045
Bush inside diameter
54.083 to 54.147
3
Bushes and journals
0.038 to 0.152
Cam lift: H
H
6.045
H
7.582
(*) F4AE3482E*U101
Base - May 2012
Print P2D32N020 E
F4AE ENGINES
SECTION 8 - TECHNICAL SPECIFICATIONS
Type
4 CYLINDERS
CYLINDER HEAD — TIMING SYSTEM
9
6 CYLINDERS mm
1 Tappet cap housing on block 2 3
Tappet cap outside diameter:
2
1
16.000 to 16.030
2 3
15.924 to 15.954 15.960 to 15.975
Between tappets and housings Tappets
0.025 to 0.070 -
1 Rocker shaft
1
21.965 to 21.977
Rockers
2
22.001 to 22.027
2 Between rockers and shaft
Print P2D32N020 E
0.024 to 0.062
Base - May 2012
10
SECTION 8 - TECHNICAL SPECIFICATIONS
F4AE ENGINES
TIGHTENING TORQUE TORQUE
COMPONENT
Nm 77 12 47 5 24 4 81 24 4 24 4 24 4 36 2 43 5 105 5 24 4 24 4 36 5 12 2 3.5 0.35
M12x1.75 screw fastening rear gear case M10x1.50 screw fastening rear gear case M8x1.25 screw fastening rear gear case M8x1.25 screw fastening oil pump
1st stage 2nd stage
M8x1.25 screw fastening front cover M8x1.25 screw fastening camshaft longitudinal retaining plate M8x1.25 screw fastening camshaft gear M10x1.50 screw fastening crankcase plate M18x1.50 nut fastening high pressure pump gear M8x1.25 nuts fastening fuel pump ½ inch plug on cylinder head ¾ inch plug on cylinder head ¼ inch plug on cylinder head M6x1 screw fastening injectors
M22x1.5 fastening nut injector feed connector M8x1.25 screw fastening intake manifold M12x1.75 screw fastening rear brackets for engine lifting M8x1.25 screws fastening Common Rail M12x1.75x130 screw fastening cylinder head M12x1.75x150 screw fastening cylinder head
1st stage 2nd stage 3rd stage 4th stage
}1
st
25º 1º 25º 1º 25º 1º
stage
50 5 24 4 77 12 36 5 35 5
5 0.5 2.4 0.4 7.7 1.2 3.6 0.5 3.5 0.5
55 5
5.5 0.5
2nd
90º 2º 90º 2º
stage 3rd stage
M8x1.25 screw fastening rocker bracket Valve clearance adjusting nuts M8x1.25 M14x1.5 nuts fastening fuel pipes from high pressure pump to Common Rail M8 screw fastening high pressure pipe connector M6 screw fastening wiring bulkhead M8 screw fastening electric wiring support for injector feed Nuts M4 fastening wiring on each injector M12x1.75 screw fastening fuel filter bracket (industrial) Fuel filter M22 screw fastening oil pressure relief valve on oil filter support M27x2 coupling fastening oil filter 11/8 inch connection on filter support for turbine lubrication M12 nut fastening turbine lubrication pipe M10 screw fastening engine coolant inlet connection
Base - May 2012
kgm 7.7 1.2 4.7 0.5 2.4 0.4 0.8 0.1 2.4 0.4 2.4 0.4 2.4 0.4 3.6 0.2 4.3 0.4 10.5 0.5 2.4 0.4 2.4 0.4 3.6 0.5 1.2 0.2 0.35 0.035
36 5 24 4 24 4 24 4 10 2 24 4 1.5 0.25 80 8 20 2 80 8 20 2 24 4 10 2 43 6
3.6 0.5 2.4 0.4 2.4 0.4 2.4 0.4 1 0.2 2.4 0.4 0.15 0.025 8 0.8 2 0.2 8 0.8 2 0.2 2.4 0.4 1 0.2 4.3 0.6
Print P2D32N020 E
F4AE ENGINES
SECTION 8 - TECHNICAL SPECIFICATIONS
TORQUE
COMPONENT M10x1.5 screw fastening exhaust manifold on cylinder head M12 screw fastening damper adapter 1st stage and damper on output shaft 2nd stage M10x1,25 screw fastening pulley on output shaft M8x1.25 screw fastening water pump M10x1.50 screw fastening auxiliary component control belt tensioners M10x1.50 screw fastening fixed pulleys for auxiliary component control belt M12x1,75 screw fastening flywheel housing M10x1.50 screw fastening flywheel housing Nut M8x1.25 fastening valve cover M6x1 screw fastening camshaft sensor M6x1 screw fastening crankshaft sensor M14x1.5 screw fastening coolant temperature sensor M6x1 screw fastening oil pressure/temperature sensor Screw fastening fuel pressure sensor M14 screw fastening fuel temperature sensor M6x1 screw fastening air temperature/pressure sensor on intake manifold M12x1.5 screw fastening engine oil level sensor pins M10 Turbine fixing to exhaust manifold 6-cyl. nuts M10x1.5 M16 couplings fastening oil delivery pipe to turbocharger Pipe fixing on adapter M10 for turbine lubrication Oil pipe fixing on adapter M10 for turbine lubrication to block M8x1.25 screws fastening oil drain pipe to turbine Screw M12x1.25 screws fastening engine flywheel 1st stage 2nd stage M8x1.25 screws fastening front bracket for engine lifting M8x1.25 screws fastening engine oil sump M8 screws fastening cylinder barrel lubricating nozzles M12 screws fastening crankshaft caps 1st stage 2nd stage
{
M10x1.25 screw fastening connecting rod caps Alternator M10x1.5 screw bracket fixing on water feed pipefitting M10x1.5 screw alternator locking Starter M10x1.5 nut fastening starter motor
Print P2D32N020 E
11
1st stage 2nd stage
Nm 53 5 50 5
kgm 5.3 0.5 5 0.5 90º 5º
68 7 24 4 43 6 43 6 85 10 49 5 24 4 10 2 10 2 24 4 10 2 35 5 25 2 10 2 10 2 71 43 6 36 5 35 5 43 6 24 4 50 5
6.8 0.7 2.4 0.4 4.3 0.6 4.3 0.6 8.5 1 4.9 0.5 2.4 0.4 1 0.2 1 0.2 2.4 0.4 1 0.2 3.5 0.5 2.5 0.2 1 0.2 1 0.2 0.7 0.1 4.3 0.6 3.6 0.5 3.5 0.5 4.3 0.6 2.4 0.4 5 0.5 60º 2º
36 5 24 4 15 3 80 6
3.6 0.5 2.4 0.4 1.5 0.3 8 0.6 90º 2º
60 5
6 0.5 60º 2º
43 6 43 6
4.3 0.6 4.3 0.6
43 6
4.3 0.6
Base - May 2012
12
SECTION 8 - TECHNICAL SPECIFICATIONS
COMPONENT M8x1.25 screws fastening heat exchanger and oil filter support M8x1.25 screws fastening housing M8x1.25 screws fastening suction strainer M10x1.5 screws fastening suction strainer bracket M18x1.5 heat exchanger valve cap M18x1.5 nut (left-handed) fastening compressor drive gear M12x1.75 nuts fastening compressor M8x1.25 screws fastening compressor support bracket M6x1 screws fastening thermostat cover M18x1.5 caps to engine block M10x1.5 screws fastening rail tube bracket M18x1.5 couplings M6x1 screws fastening plate M10x1.5 screws fastening power steering pump 3/4” coupling M6x1 screws fastening breather plate M6x1 screw fastening breather plate to tappet cover M12x1.5 breather fastening couplings M8x1.25 screws fastening dipstick M6x1 screws fastening dipstick clamp M12x1.5 coupling on cylinder head Fuel filter adapter Oil filter adapter M7x1 screws fastening intake elbow M8x1.25 screws fastening intake elbow bracket M8x1.25 screws fastening control unit M10x1 cap M6x1 screws fastening control unit to bracket M12x1.5 coupling on control unit bracket M8x1.25 nuts fastening heater
Base - May 2012
F4AE ENGINES
TORQUE Nm 26 4 24 4 24 4 43 5 60 9 165 10 77 12 24 4 10 2 24 4 40 5 24 4 24 4 43 6 36 4 10 2 10 2 20 4 24 4 10 2 22 2 30 2 80 8 13 2 24 4 24 4 24 4 10 2 12 2 13 3
kgm 2.6 0.4 2.4 0.4 2.4 0.4 4.3 0.5 6.0 0.9 16.5 1.0 7.7 1.2 2.4 0.4 1.0 0.2 2.4 0.4 4.0 0.2 2.4 0.4 2.4 0.4 4.3 0.6 3.6 0.4 1.0 0.2 1.0 0.2 2.0 0.4 2.4 0.4 1.0 0.2 2.2 0.2 3.0 0.2 8.0 0.8 1.3 0.2 2.4 0.4 2.4 0.4 2.4 0.4 1.0 0.2 1.2 0.2 1.3 0.2
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F4AE ENGINES
SECTION 9 - TOOLS
1
SECTION 9 Tools
Page TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 9 - TOOLS
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F4AE ENGINES
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F4AE ENGINES
SECTION 9 - TOOLS
3
TOOLS TOOL NO.
DESCRIPTION
99317915
Set of 5 9x12 pin wrenches (14 — 15 - 17 — 18 - 19 mm)
99322205
Revolving stand for overhauling units (700 daN/m capacity, 120daN/m torque)
99340055
Tool to remove output shaft front gasket
99340056
Tool to remove output shaft rear gasket
99341001
Double actingpuller
99341009
Pair of brackets
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SECTION 9 - TOOLS
F4AE ENGINES
TOOL NO.
DESCRIPTION
99341015
Press
99342101
Tool to removeinjectors
99346252
Tool for fitting output shaft front gasket
99346253
Tool for fitting output shaft rear gasket
99360076
Tool to remove oil filter (engine)
99360183
Pliers for removing/refitting piston rings (65 - 110 mm)
Base - May 2012
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F4AE ENGINES
SECTION 9 - TOOLS
TOOL NO.
DESCRIPTION
99360221
Engine flywheel rotation tool (use with 99360222)
99360222
Pinion (use with 99360221)
99360268
Tool for removing/refitting engine valves
99360330
Flywheelcrankhandle
99360351
Equipment for flywheel holding
99360362
Beater for removing/refitting camshaft bushes (to be used with 993700069)
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SECTION 9 - TOOLS
F4AE ENGINES
TOOL NO.
DESCRIPTION
99360500
Tool for lifting the output shaft
99360595
Lifting rig for engine removal/refitting
99360605
Band for fitting piston into cylinder barrel (60 - 125 mm)
99361037
Brackets for fastening engine to revolving stand 99322205
99363204
Tool to removegaskets
99367121
Manual pump for pressure and vacuum measurements
Base - May 2012
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F4AE ENGINES
SECTION 9 - TOOLS
TOOL NO.
DESCRIPTION
99370006
Handgrip for interchangeablebeaters
99370415
Gauge base for different measurements (to be used with 99395603)
99389829
Dog type dynamometric wrench 9x12 (5-60 Nm)
99389834
Torque screwdriver for injector solenoid valve connector stop nutsetting
99395216
Pair of gauges with ½” and ¾” square head for angle tightening
99395603
Dialgauge (0 - 5 mm)
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SECTION 9 - TOOLS
F4AE ENGINES
TOOL NO.
DESCRIPTION
99305453
Device for checking the diesel supply circuit and common-rail injectionsystem
Base - May 2012
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F4AE ENGINES
APPENDIX
1
Appendix Page
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SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . .
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- Standard safety prescriptions . . . . . . . . . . . . . .
3
- Prevention of injury . . . . . . . . . . . . . . . . . . . . .
3
- During maintenance . . . . . . . . . . . . . . . . . . . .
3
- Respect of the Environment . . . . . . . . . . . . . .
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APPENDIX
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F4AE ENGINES
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F4AE ENGINES
APPENDIX
3
SAFETY PRESCRIPTIONS Standard safety prescriptions
- Do not execute any intervention if not provided with necessary instructions.
Particular attention shall be drawn on some precautions that must be followed absolutely in a standard working area and whose non fulfillment will make any other measure useless or not sufficient to ensure safety to the personnel in-charge of maintenance.
- Do not use any tool or equipment for any different operation from the ones they've been designed and provided for: serious injury may occur.
- Be informed and inform personnel as well of the laws in force regulating safety, providing information documentation available for consultation. - Keep working areas as clean as possible, ensuring adequate aeration. - Ensure that working areas are provided with emergency boxes, that must be clearly visible and always provided with adequate sanitary equipment. - Provide for adequate fire extinguishing means, properly indicated and always having free access. Their efficiency must be checked on regular basis and the personnel must be trained on intervention methods and priorities. - Organize and displace specific exit points to evacuate the areas in case of emergency, providing for adequate indications of the emergency exit lines. - Smoking in working areas subject to fire danger must be strictly prohibited. - Provide Warnings throughout adequate boards signaling danger, prohibitions and indications to ensure easy comprehension of the instructions even in case of emergency.
Prevention of injury - Do not wear unsuitable cloths for work, with fluttering ends, nor jewels such as rings and chains when working close to engines and equipment in motion. - Wear safety gloves and goggles when performing the following operations: - filling inhibitors or anti-frost - lubrication oil topping or replacement - utilization of compressed air or liquids under pressure (pressure allowed: 2 bar)
- In case of test or calibration operations requiring engine running, ensure that the area is sufficiently aerated or utilize specific vacuum equipment to eliminate exhaust gas. Danger: poisoning and death.
During maintenance - Never open filler cap of cooling circuit when the engine is hot. Operating pressure would provoke high temperature with serious danger and risk of burn. Wait unit the temperature decreases under 50 ºC. - Never top up an overheated engine with cooler and utilize only appropriate liquids. - Always operate when the engine is turned off: whether particular circumstances require maintenance intervention on running engine, be aware of all risks involved with such operation. - Be equipped with adequate and safe containers for drainage operation of engine liquids and exhaust oil. - Keep the engine clean from oil tangles, diesel fuel and or chemical solvents. - Use of solvents or detergents during maintenance may originate toxic vapors. Always keep working areas aerated. Whenever necessary wear safety mask. - Do not leave rags impregnated with flammable substances close to the engine. - Upon engine start after maintenance, undertake proper preventing actions to stop air suction in case of runaway speed rate. - Do not utilize fast screw-tightening tools. - Never disconnect batteries when the engine is running. - Disconnect batteries before any intervention on the electrical system.
- Wear safety helmet when working close to hanging loads or equipment working at head height level.
- Disconnect batteries from system aboard to load them with the battery loader.
- Always wear safety shoes when and cloths adhering to the body, better if provided with elastics at the ends.
- After every intervention, verify that battery clamp polarity is correct and that the clamps are tight and safe from accidental short circuit and oxidation.
- Use protection cream for hands. - Change wet cloths as soon as possible - In presence of current tension exceeding 48-60 V verify efficiency of earth and mass electrical connections. Ensure that hands and feet are dry and execute working operations utilizing isolating foot-boards. Do not carry out working operations if not trained for. - Do not smoke nor light up flames close to batteries and to any fuel material.
- Do not disconnect and connect electrical connections in presence of electrical feed. - Before proceeding with pipelines disassembly (pneumatic, hydraulic, fuel pipes) verify presence of liquid or air under pressure. Take all necessary precautions bleeding and draining residual pressure or closing dump valves. Always wear adequate safety mask or goggles. Non fulfillment of these prescriptions may cause serious injury and poisoning.
- Put the dirty rags with oil, diesel fuel or solvents in anti-fire specially provided containers.
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APPENDIX
- Avoid incorrect tightening or out of couple. Danger: incorrect tightening may seriously damage engine's components, affecting engine's duration. - Avoid priming from fuel tanks made out of copper alloys and/or with ducts not being provided with filters. - Do not modify cable wires: their length shall not be changed. - Do not connect any user to the engine electrical equipment unless specifically approved. - Do not modify fuel systems or hydraulic system unless specific approval has been released. Any unauthorized modification will compromise warranty assistance and furthermore may affect engine correct working and duration. For engines equipped with electronic gearbox: - Do not execute electric arc welding without having priory removed electronic gearbox. - Remove electronic gearbox in case of any intervention requiring heating over 80 ºC temperature.
F4AE ENGINES
Respect of the Environment - Respect of the Environment shall be of primary importance: all necessary precautions to ensure personnel's safety and health shall be adopted. - Be informed and inform the personnel as well of laws in force regulating use and exhaust of liquids and engine exhaust oil. Provide for adequate board indications and organize specific training courses to ensure that personnel is fully aware of such law prescriptions and of basic preventive safety measures. - Collect exhaust oils in adequate specially provided containers with hermetic sealing ensuring that storage is made in specific, properly identified areas that shall be aerated, far from heat sources and not exposed to fire danger. - Handle the batteries with care, storing them in aerated environment and within anti-acid containers. Warning: battery exhalation represent serious danger of intoxication and environment contamination.
- Do not paint the components and the electronic connections. - Do not vary or alter any data filed in the electronic gearbox driving the engine. Any manipulation or alteration of electronic components shall totally compromise engine assistance warranty and furthermore may affect engine correct working and duration.
Base - May 2012
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