Beruflich Dokumente
Kultur Dokumente
ormation
Group 593
Release01
89130181
DRAFT
Malfunction ..............................................................................................................................1
P06B1 - Sensor Power Supply A Circuit Low ...............................................................................1
P06B2 - Sensor Power Supply A Circuit High...............................................................................2
P0105 - Manifold Absolute Pressure/Barometric Pressure Sensor...................................................4
P0108 - Manifold Absolute Pressure/Barometric Pressure Sensor Circuit High..................................6
P1116 - Manifold Absolute Pressure Moderately Too High..............................................................8
P1118 - Manifold Absolute Pressure Too High ............................................................................ 11
P2226 - Barometric Pressure Circuit......................................................................................... 14
P2229 - Barometric Pressure Circuit High ................................................................................. 15
P0110 - Intake Air Temperature Sensor 1 Bank 1........................................................................ 16
P0112 - Intake Air Temperature Sensor 1 Circuit Low Bank 1........................................................ 18
P1119 - Intake Manifold Temperature Moderately Too High .......................................................... 20
P111A - Intake Manifold Temperature Too High .......................................................................... 21
P0217 - Engine Coolant Over Temperature Condition ................................................................. 23
P111E - Engine Coolant Temperature Moderately High................................................................ 25
P0115 - Engine Coolant Temperature Sensor 1 .......................................................................... 27
P0117 - Engine Coolant Temperature Circuit Low ....................................................................... 29
P0201 - Cylinder 1 Injector A ................................................................................................... 31
P0262 - Injector 1 Short Circuit High......................................................................................... 33
P02CC - Cylinder 1 Fuel Injector Offset Learning at Min Limit ....................................................... 34
P02CD - Cylinder 1 Fuel Injector Offset Learning at Max Limit ...................................................... 36
P0261 - Cylinder 1 Injector Circuit Low...................................................................................... 37
P0202 - Cylinder 2 Injector A ................................................................................................... 39
P0265 - Injector 2 Short Circuit High......................................................................................... 41
P02CE - Cylinder 2 Fuel Injector Offset Learning At Min Limit....................................................... 42
P02CF - Cylinder 2 Fuel Injector Offset Learning at Max Limit....................................................... 44
P0264 - Cylinder 2 Injector Circuit Low...................................................................................... 45
P0203 - Cylinder 3 Injector A ................................................................................................... 47
P0268 - Injector 3 Short Circuit High......................................................................................... 49
P02D0 - Cylinder 3 Fuel Injector Offset Learning At Min Limit ....................................................... 50
P02D1 - Cylinder 3 Fuel Injector Offset Learning at Max Limit....................................................... 52
P0267 - Cylinder 3 Injector Circuit Low...................................................................................... 53
P0204 - Cylinder 4 Injector A ................................................................................................... 55
P0271 - Injector 4 Short Circuit High......................................................................................... 57
P02D2 - Cylinder 4 Fuel Injector Offset Learning At Min Limit ....................................................... 58
P02D3 - Cylinder 4 Fuel Injector Offset Learning at Max Limit....................................................... 60
P0270 - Cylinder 4 Injector Circuit Low...................................................................................... 61
P0335 - Crankshaft Position Sensor A ...................................................................................... 63
P0336 - Crankshaft Position Sensor A Circuit Range/Performance................................................ 65
P0339 - Crankshaft Position Sensor A Circuit Intermittent............................................................ 66
P0524 - Engine Oil Pressure Too Low....................................................................................... 67
P0520 - Engine Oil Pressure Sensor/Switch A ........................................................................... 70
P1093 - Engine Oil Pressure Moderately Low ............................................................................ 72
P0522 - Engine Oil Pressure Circuit Low................................................................................... 75
P0340 - Camshaft Position Sensor A Bank 1 or Single Sensor ..................................................... 76
P0341 - Camshaft Position Sensor A Circuit Range/Performance ................................................. 78
P0016 - Crankshaft Position - Camshaft Position Correlation........................................................ 79
P0615 - Starter Relay............................................................................................................. 81
P0616 - Starter Relay Circuit Low ............................................................................................ 82
P0617 - Starter Relay Circuit High............................................................................................ 83
P1176 - Starter Motor Deactivated - Over Temperature................................................................ 85
P1178 - Starter Motor Deactivated - Cogwheels of Starter Motor and Engine Stuck.......................... 86
P1179 - Starter Motor Deactivated - PTO Active ......................................................................... 88
P0666 - Control Module Internal Temperature Sensor A .............................................................. 89
P0668 - PCM/ECM/TCM Internal Temperature Sensor Circuit Low................................................ 90
P1104 - Factory Mode ............................................................................................................ 91
P1141 - Buffered Idle Validation Switch Wire - ECM Side ............................................................. 92
P0091 - Fuel Pressure Regulator Control Circuit Low .................................................................. 94
P0092 - Fuel Pressure Regulator Control Circuit High ................................................................. 96
P0090 - Fuel Pressure Regulator 1 Control................................................................................ 97
DRAFT
P0088 - Fuel Rail/System Pressure - Too High Bank 1 ................................................................ 99
P1147 - Fuel Rail/System Bank 1 Pressure - Moderately Too High .............................................. 101
P0087 - Fuel Rail/System Pressure - Too Low Bank 1 ............................................................... 103
P00C6 - Fuel Rail Pressure Too Low - Engine Cranking ............................................................ 104
P0192 - Engine Injection Control Pressure Circuit Low .............................................................. 106
P0190 - Fuel Rail Pressure Sensor Bank 1 .............................................................................. 107
P228E - Fuel Pressure Regulator 1 Exceeded Learning Limits - Too Low ..................................... 109
P228F - Fuel Pressure Regulator 1 Exceeded Learning Limits - Too High......................................111
P016E - Closed Loop Fuel Pressure Control At Limit - Pressure Too High .................................... 115
P016F - Closed Loop Fuel Pressure Control At Limit - Pressure Too Low ..................................... 117
U0010 - CAN Communication Backbone 1 Net ........................................................................ 118
U0001 - CAN Communication Backbone 2 Net ........................................................................ 121
U0155 - Lost Communication With Instrument Panel Cluster (IPC) Control Module ........................ 123
P1154 - Body Control Module A - Lost Communication With Instrument Panel Cluster (IPC) Control
Module .............................................................................................................................. 126
U0141 - Lost Communication With VMCU ............................................................................... 129
Group 593 P06B1 - Sensor Power Supply A Circuit Low
DRAFT
P06B1 - Sensor Power Supply A Circuit Low
Malfunction
Voltage measurement
1
Group 593 Resistance measurement
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Supply Voltage On 26 – 02 A14.J1:88 – U = 4.75 V – 9998699,
A14.J1:64 5.25 V 9990062,
88890227,
88890074
Resistance measurement
2
Group 593 Voltage measurement
Fault
type
P06B2
Condition for Fault
•
DRAFT
The voltage at pin A14.J1:88 is
Observable Symptoms
• Wiring harness.
FTB 00 more than 5.5 V. fold air pressure sensor. • Connector.
• Low power. • Sensor.
• Inlet manifold pressure gauge
shows 0.
Voltage measurement
Resistance measurement
3
P0105 - Manifold Absolute Pressure/Barometric Pressure
Group 593
DRAFT
Sensor
Voltage measurement
4
Group 593 Resistance measurement
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Supply Voltage On 02– 26 A14.J1:64– U = 4.75 V – 9998699,
A14.J1:88 5.25 V 9990062,
88890074,
88890227
Signal Voltage On 02– 31 A14.J1:64– U = 0.8 V – 1.2 9998699,
A14.J1:93 V (Engine not 9990062,
running) 88890074,
88890227
Resistance measurement
5
P0108 - Manifold Absolute Pressure/Barometric Pressure
Group 593
DRAFT
Sensor Circuit High
Voltage measurement
6
Group 593 Resistance measurement
Resistance measurement
7
Group 593 P1116 - Manifold Absolute Pressure Moderately Too High
DRAFT
P1116 - Manifold Absolute Pressure Moderately Too High
Voltage measurement
8
Group 593 Resistance measurement
Resistance measurement
9
Group 593 Overflow valve opening pressure, Check
Action:
Visual check:
• Check that the air hoses are not damaged or pinched and
that they are free from folds.
• Check if the fault is in the actuator or at the by-pass
shutter.
• Check the By pass shutter for easy turning or functioning
by hand.
• Check the hoses and actuator for air leakage.
10
Group 593 P1118 - Manifold Absolute Pressure Too High
DRAFT
P1118 - Manifold Absolute Pressure Too High
Voltage measurement
11
Group 593 Resistance measurement
Resistance measurement
12
Group 593 Overflow valve opening pressure, Check
Action:
Visual check:
• Check that the air hoses are not damaged or pinched and
that they are free from folds.
• Check if the fault is in the actuator or at the by-pass
shutter.
• Check the By pass shutter for easy turning or functioning
by hand.
• Check the hoses and actuator for air leakage.
13
Group 593 P2226 - Barometric Pressure Circuit
14
Group 593 P2229 - Barometric Pressure Circuit High
15
Group 593 P0110 - Intake Air Temperature Sensor 1 Bank 1
DRAFT
P0110 - Intake Air Temperature Sensor 1 Bank 1
Resistance measurement
16
Group 593 Reference Table
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Component Off 1– 2 B37:1– B37:2 Reference 9990216,
resistance Table 88890074
Reference Table
17
P0112 - Intake Air Temperature Sensor 1 Circuit Low Bank
Group 593
DRAFT
1
Resistance measurement
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Component Off 1– 2 B37:1– B37:2 Reference 9990216,8889-
resistance Table 0074
Reference Table
19
Group 593 P1119 - Intake Manifold Temperature Moderately Too High
DRAFT
P1119 - Intake Manifold Temperature Moderately Too High
Resistance measurement
20
Group 593 Visual checks:
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Component Off 1– 2 B37:1– B37:2 R = 1kΩ - 10 9990216,8889-
resistance kΩ 0074
Visual checks:
• Check the charge air cooler for damage to tanks, cells and
connections.
• Check the charge air cooler, the radiator and the air condi-
tioning condenser for external clogging.
• Check that the charge air cooler is clean internally at the
hose connections (Oil in the charge air cooler indicates
leakage at the turbo).
• Check the turbo for damage to the compressor wheel.
P111A - Intake Manifold Temperature Too High
21
Group 593 Resistance measurement
Fault
type
P111A
Condition for Fault
•
DRAFT
Charge air temperature too high.
Observable Symptoms Possible cause
Resistance measurement
Visual checks:
• Check the charge air cooler for damage to tanks, cells and
connections.
• Check the charge air cooler, the radiator and the air condi-
tioning condenser for external clogging.
• Check that the charge air cooler is clean internally at the
hose connections (Oil in the charge air cooler indicates
leakage at the turbo).
• heck the turbo for damage to the compressor wheel.
22
Group 593 P0217 - Engine Coolant Over Temperature Condition
DRAFT
P0217 - Engine Coolant Over Temperature Condition
23
Group 593 Resistance measurement
Resistance measurement
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Component Off 1– 2 B231:1– Reference 9990216,
resistance B231:2 Table 88890074
Component Off 1– 2 B123:1– 0Ω when the 9990008,
resistance B123:2 float is at the 88890074
lower end posi-
tion and infinite
when the float
is at the upper
end
Reference Table
Visual check:
• Check engine coolant level. • Check if the coolant is contaminated.
24
Group 593 P111E - Engine Coolant Temperature Moderately High
•
•
DRAFT
Check the Cylinder head gasket, cylinder liner, oil cooler
for leakage and do the pressure test of cylinder head.
Check the radiator and charge air cooler free from residue.
• Check the coolant thermostat and pump for proper
functioning.
• Check radiator and hoses for leakage.
P111E - Engine Coolant Temperature Moderately High
Resistance measurement
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Component Off 1– 2 B231:1– Reference 9990216,
resistance B231:2 Table 88890074
Reference Table
Visual check:
• Check engine coolant level. • Check the coolant thermostat and pump for proper
• Check if the coolant is contaminated. functioning.
• Check the Cylinder head gasket, cylinder liner, oil cooler • Check radiator and hoses for leakage.
for leakage and do the pressure test of cylinder head.
• Check the radiator and charge air cooler free from residue.
26
Group 593 P0115 - Engine Coolant Temperature Sensor 1
DRAFT
P0115 - Engine Coolant Temperature Sensor 1
Resistance measurement
27
Group 593 Reference Table
Reference Table
28
Group 593 P0117 - Engine Coolant Temperature Circuit Low
DRAFT
P0117 - Engine Coolant Temperature Circuit Low
Resistance measurement
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Component Off 1– 2 B231:1– Reference 9990216,
resistance B231:2 Table 88890074
Reference Table
30
Group 593 P0201 - Cylinder 1 Injector A
Resistance measurement
31
Group 593 Resistance measurement
32
Group 593 P0262 - Injector 1 Short Circuit High
Resistance measurement
33
P02CC - Cylinder 1 Fuel Injector Offset Learning at Min
Group 593
DRAFT
Limit
34
Group 593 Visual Check:
Fault
type
P02CC
Condition for Fault
• Low power.
Possible causes
• Nozzle.
FTB00
• Cylinder balancing data too • Uneven operation. • Power Take Off (PTO).
high. • Abnormal noise. • Camshaft.
• Low compression.
Visual Check:
• Check the compression pressure on all cylinder.
• Check for leakage at the attachment point of the unit injec-
tor and fuel lines.
• Check if the cylinder head gasket is free from cracks and
damages.
• Check if the cylinder head and cylinder liner is free from
damage or cracks.
• Check if there are combustion gases entering the fuel sys-
tem by using carbon monoxide tester.
• Check that the fuel is of good quality and water separator
is free from residue.
• Visual check the Injector for any damage.
• Check the parameter code of Injectors.
• Adjust the valves (clearance) and Injectors for any fault.
• Check the Injector tip for damage and cracks.
• Check if there are exhaust gases entering the cooling sys-
tem by using carbon monoxide tester..
• Check that the fuel tank is free from rubbish and other
contaminants.
Leakage in the fuel system, Check
Action:
Evaluation:
35
P02CD - Cylinder 1 Fuel Injector Offset Learning at Max
Group 593
DRAFT
Limit
Visual Check:
• Check the compression pressure on all cylinder. • Check the Injector tip for damage and cracks.
• Check for leakage at the attachment point of the unit injec- • Check if there are exhaust gases entering the cooling sys-
tor and fuel lines. tem by using carbon monoxide tester..
• Check if the cylinder head gasket is free from cracks and • Check that the fuel tank is free from rubbish and other
damages. contaminants.
• Check if the cylinder head and cylinder liner is free from
damage or cracks.
• Check if there are combustion gases entering the fuel sys-
tem by using carbon monoxide tester.
• Check that the fuel is of good quality and water separator
is free from residue.
• Visual check the Injector for any damage.
• Check the parameter code of Injectors.
•36 Adjust the valves (clearance) and Injectors for any fault.
Group 593 Leakage in the fuel system, Check
•
DRAFT
Remove the supply line from the fuel tank.
• Connect 88800175 Kit on the supply line connection.
• Attach the pressure gauge to the fuel hose and connect
the pressure gauge to the pneumatic system in the
workshop.
• Check that the reduction valve on the pressure gauge and
the shut-off valve are open.
• Pressure test the fuel system..
• Build up the pressure to 200 kPa (29 psi).
• Apply soapy water to the lines and connections.
Evaluation:
37
Group 593 Resistance measurement
Fault
type
P0261
Condition for Fault
• Low power.
Possible cause
• Connector.
FTB00
• Abnormal noise. • Wiring harness.
• Engine is operating on only 3 • Engine control module (ECM).
cylinders.
Resistance measurement
38
Group 593 P0202 - Cylinder 2 Injector A
Resistance measurement
39
Group 593 Resistance measurement
40
Group 593 P0265 - Injector 2 Short Circuit High
Resistance measurement
41
P02CE - Cylinder 2 Fuel Injector Offset Learning At Min
Group 593
DRAFT
Limit
42
Group 593 Visual Check:
Fault
type
P02CE
Condition for Fault
• Low power.
Possible cause
• Nozzle.
FTB00
• Cylinder balancing data too • Uneven operation. • Power Take Off (PTO).
high. • Abnormal noise. • Camshaft.
• Low compression.
Visual Check:
• Check the compression pressure on all cylinder.
• Check for leakage at the attachment point of the unit injec-
tor and fuel lines.
• Check if the cylinder head gasket is free from cracks and
damages.
• Check if the cylinder head and cylinder liner is free from
damage or cracks.
• Check if there are combustion gases entering the fuel sys-
tem by using carbon monoxide tester.
• Check that the fuel is of good quality and water separator
is free from residue.
• Visual check the Injector for any damage.
• Check the parameter code of Injectors.
• Adjust the valves (clearance) and Injectors for any fault.
• Check the Injector tip for damage and cracks.
• Check if there are exhaust gases entering the cooling sys-
tem by using carbon monoxide tester..
• Check that the fuel tank is free from rubbish and other
contaminants.
Leakage in the fuel system, Check
Action:
Evaluation:
43
P02CF - Cylinder 2 Fuel Injector Offset Learning at Max
Group 593
DRAFT
Limit
Visual Check:
• Check the compression pressure on all cylinder. • Check the Injector tip for damage and cracks.
• Check for leakage at the attachment point of the unit injec- • Check if there are exhaust gases entering the cooling sys-
tor and fuel lines. tem by using carbon monoxide tester..
• Check if the cylinder head gasket is free from cracks and • Check that the fuel tank is free from rubbish and other
damages. contaminants.
• Check if the cylinder head and cylinder liner is free from
damage or cracks.
• Check if there are combustion gases entering the fuel sys-
tem by using carbon monoxide tester.
• Check that the fuel is of good quality and water separator
is free from residue.
• Visual check the Injector for any damage.
• Check the parameter code of Injectors.
•44 Adjust the valves (clearance) and Injectors for any fault.
Group 593 Leakage in the fuel system, Check
•
DRAFT
Remove the supply line from the fuel tank.
• Connect 88800175 Kit on the supply line connection.
• Attach the pressure gauge to the fuel hose and connect
the pressure gauge to the pneumatic system in the
workshop.
• Check that the reduction valve on the pressure gauge and
the shut-off valve are open.
• Pressure test the fuel system..
• Build up the pressure to 200 kPa (29 psi).
• Apply soapy water to the lines and connections.
Evaluation:
45
Group 593 Resistance measurement
Fault
type
P0264
Condition for Fault
• Low power.
Possible cause
• Connector.
FTB00
• Abnormal noise. • Wiring harness.
• Engine is operating on only 3 • Engine control module (ECM).
cylinders.
Resistance measurement
46
Group 593 P0203 - Cylinder 3 Injector A
Resistance measurement
47
Group 593 Resistance measurement
48
Group 593 P0268 - Injector 3 Short Circuit High
Resistance measurement
49
P02D0 - Cylinder 3 Fuel Injector Offset Learning At Min
Group 593
DRAFT
Limit
50
Group 593 Visual Check:
Fault
type
P02D0
Condition for Fault
• Low power.
Possible cause
• Nozzle.
FTB00
• Cylinder balancing data too • Uneven operation. • Power Take Off (PTO).
high. • Abnormal noise. • Camshaft.
• Low compression.
Visual Check:
• Check the compression pressure on all cylinder.
• Check for leakage at the attachment point of the unit injec-
tor and fuel lines.
• Check if the cylinder head gasket is free from cracks and
damages.
• Check if the cylinder head and cylinder liner is free from
damage or cracks.
• Check if there are combustion gases entering the fuel sys-
tem by using carbon monoxide tester.
• Check that the fuel is of good quality and water separator
is free from residue.
• Visual check the Injector for any damage.
• Check the parameter code of Injectors.
• Adjust the valves (clearance) and Injectors for any fault.
• Check the Injector tip for damage and cracks.
• Check if there are exhaust gases entering the cooling sys-
tem by using carbon monoxide tester..
• Check that the fuel tank is free from rubbish and other
contaminants.
Leakage in the fuel system, Check
Action:
Evaluation:
51
P02D1 - Cylinder 3 Fuel Injector Offset Learning at Max
Group 593
DRAFT
Limit
Visual Check:
• Check the compression pressure on all cylinder. • Check the Injector tip for damage and cracks.
• Check for leakage at the attachment point of the unit injec- • Check if there are exhaust gases entering the cooling sys-
tor and fuel lines. tem by using carbon monoxide tester..
• Check if the cylinder head gasket is free from cracks and • Check that the fuel tank is free from rubbish and other
damages. contaminants.
• Check if the cylinder head and cylinder liner is free from
damage or cracks.
• Check if there are combustion gases entering the fuel sys-
tem by using carbon monoxide tester.
• Check that the fuel is of good quality and water separator
is free from residue.
• Visual check the Injector for any damage.
• Check the parameter code of Injectors.
•52 Adjust the valves (clearance) and Injectors for any fault.
Group 593 Leakage in the fuel system, Check
•
DRAFT
Remove the supply line from the fuel tank.
• Connect 88800175 Kit on the supply line connection.
• Attach the pressure gauge to the fuel hose and connect
the pressure gauge to the pneumatic system in the
workshop.
• Check that the reduction valve on the pressure gauge and
the shut-off valve are open.
• Pressure test the fuel system..
• Build up the pressure to 200 kPa (29 psi).
• Apply soapy water to the lines and connections.
Evaluation:
53
Group 593 Resistance measurement
Fault
type
P0267
Condition for Fault
• Low power.
Possible cause
• Connector.
FTB00
• Abnormal noise. • Wiring harness.
• Engine is operating on only 3 • Engine control module (ECM).
cylinders.
Resistance measurement
54
Group 593 P0204 - Cylinder 4 Injector A
Resistance measurement
55
Group 593 Resistance measurement
56
Group 593 P0271 - Injector 4 Short Circuit High
Resistance measurement
57
P02D2 - Cylinder 4 Fuel Injector Offset Learning At Min
Group 593
DRAFT
Limit
58
Group 593 Visual Check:
Fault
type
P02D2
Condition for Fault
• Low power.
Possible cause
• Nozzle.
FTB00
• Cylinder balancing data too • Uneven operation. • Power Take Off (PTO).
high. • Abnormal noise. • Camshaft.
• Low compression.
Visual Check:
• Check the compression pressure on all cylinder.
• Check for leakage at the attachment point of the unit injec-
tor and fuel lines.
• Check if the cylinder head gasket is free from cracks and
damages.
• Check if the cylinder head and cylinder liner is free from
damage or cracks.
• Check if there are combustion gases entering the fuel sys-
tem by using carbon monoxide tester.
• Check that the fuel is of good quality and water separator
is free from residue.
• Visual check the Injector for any damage.
• Check the parameter code of Injectors.
• Adjust the valves (clearance) and Injectors for any fault.
• Check the Injector tip for damage and cracks.
• Check if there are exhaust gases entering the cooling sys-
tem by using carbon monoxide tester..
• Check that the fuel tank is free from rubbish and other
contaminants.
Leakage in the fuel system, Check
Action:
Evaluation:
59
P02D3 - Cylinder 4 Fuel Injector Offset Learning at Max
Group 593
DRAFT
Limit
Visual Check:
• Check the compression pressure on all cylinder. • Check the Injector tip for damage and cracks.
• Check for leakage at the attachment point of the unit injec- • Check if there are exhaust gases entering the cooling sys-
tor and fuel lines. tem by using carbon monoxide tester..
• Check if the cylinder head gasket is free from cracks and • Check that the fuel tank is free from rubbish and other
damages. contaminants.
• Check if the cylinder head and cylinder liner is free from
damage or cracks.
• Check if there are combustion gases entering the fuel sys-
tem by using carbon monoxide tester.
• Check that the fuel is of good quality and water separator
is free from residue.
• Visual check the Injector for any damage.
• Check the parameter code of Injectors.
•60 Adjust the valves (clearance) and Injectors for any fault.
Group 593 Leakage in the fuel system, Check
•
DRAFT
Remove the supply line from the fuel tank.
• Connect 88800175 Kit on the supply line connection.
• Attach the pressure gauge to the fuel hose and connect
the pressure gauge to the pneumatic system in the
workshop.
• Check that the reduction valve on the pressure gauge and
the shut-off valve are open.
• Pressure test the fuel system..
• Build up the pressure to 200 kPa (29 psi).
• Apply soapy water to the lines and connections.
Evaluation:
61
Group 593 Resistance measurement
Fault
type
P0270
Condition for Fault
• Low power.
Possible cause
• Connector.
FTB00
• Abnormal noise. • Wiring harness.
• Engine is operating on only 3 • Engine control module (ECM).
cylinders.
Resistance measurement
62
Group 593 P0335 - Crankshaft Position Sensor A
Resistance measurement
63
Group 593 Visual check:
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Component Off 1– 2 B04:1– B04:2 R = 750 – 1000 9990216,
resistance Ω 88890074
Visual check:
• Check the Tooth wheel for any damage or loose fitting.
• Check the camshaft intermediate gear for any damage or
loose fitting.
• Check the sensor for faulty connection.
• Check that the sensor is free from external damage.
64
P0336 - Crankshaft Position Sensor A Circuit Range/
Group 593
DRAFT
Performance
Visual check:
• Check the Tooth wheel for any damage or loose fitting.
• Check the sensor for proper signal.
• Check the camshaft intermediate gear for any damage or
loose fitting.
• Check the sensor for faulty connection.
• Check that the sensor is free from external damage.
65
Group 593 P0339 - Crankshaft Position Sensor A Circuit Intermittent
DRAFT
P0339 - Crankshaft Position Sensor A Circuit Intermittent
Visual check:
• Check the Tooth wheel for any damage or loose fitting.
• Check the sensor for proper signal.
• Check the camshaft intermediate gear for any damage or
loose fitting.
• Check the sensor for faulty connection.
• Check that the sensor is free from external damage.
66
Group 593 P0524 - Engine Oil Pressure Too Low
Voltage measurement
9996398, 9992873
Action:
Test Procedure 2:
68
Group 593 Visual check:
•
•
Perform a test drive.
DRAFT
Run the engine at full load at the engine speeds that are
specified in Impact (700 rpm, 1100 rpm, 1400 rpm).
• Check if the engine oil pressure and the piston cooling
pressure reach the minimum pressures according to
specifications.
Visual check:
• Check the oil for external leakage.
• Check the oil pan and suction strainer for plugged or re-
stricted and clogged.
• Check the oil lines for leakage and damage.
• Check the oil pump for clogged and damage or wear.
Found oil too thin and smells like diesel fuel, check:
• Check that there is no fuel leakage into the engine oil from
the fuel system.
• Check for leakage at the attachment point of the unit
injector.
• Do the Pressure test of fuel system.
69
Group 593 P0520 - Engine Oil Pressure Sensor/Switch A
DRAFT
P0520 - Engine Oil Pressure Sensor/Switch A
Voltage measurement
70
Group 593 Resistance measurement
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Supply Voltage On 29 – 05 A14.J1:91 – U = 4.75 V – 9998699,
A14.J1:67 5.25 V 9990062,
88890074
Signal Voltage On 34 – 05 A14.J1:96 – U = 0.4 V – 0.6 9998699,
A14.J1:67 V (Engine not 9990062,
running) 88890074
Resistance measurement
71
Group 593 P1093 - Engine Oil Pressure Moderately Low
Voltage measurement
9996398, 9992873
Action:
Test Procedure 2:
73
Group 593 Visual check:
•
•
Perform a test drive.
DRAFT
Run the engine at full load at the engine speeds that are
specified in Impact (700 rpm, 1100 rpm, 1400 rpm).
• Check if the engine oil pressure and the piston cooling
pressure reach the minimum pressures according to
specifications.
Visual check:
• Check the oil for external leakage.
• Check the oil pan and suction strainer for plugged or re-
stricted and clogged.
• Check the oil lines for leakage and damage.
• Check the oil pump for clogged and damage or wear.
Found oil too thin and smells like diesel fuel, check:
• Check that there is no fuel leakage into the engine oil from
the fuel system.
• Check for leakage at the attachment point of the unit
injector.
• Do the Pressure test of fuel system.
74
Group 593 P0522 - Engine Oil Pressure Circuit Low
Resistance measurement
75
P0340 - Camshaft Position Sensor A Bank 1 or Single
Group 593
DRAFT
Sensor
Resistance measurement
76
Group 593 Visual check:
Visual check:
• Check the Tooth wheel for any damage or loose fitting.
• Check that the camshaft is correctly adjusted.
• Check the camshaft intermediate gear for any damage or
loose fitting.
• Check the sensors for faulty connection.
• Check that the sensors is free from external damage.
• Check the distance between the flywheel sensor and the
flywheel.
• Check the distance between the camshaft sensor and a
camshaft tooth wheel pin .
77
P0341 - Camshaft Position Sensor A Circuit Range/
Group 593
DRAFT
Performance
Resistance measurement
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Component Off 1– 2 B05:1 - B05:2 R = 750 Ω - 9990216,
resistance 1000 Ω 88890074
Component Off 1– 2 B04:1 - B04:2 R = 750 Ω - 9990216,
resistance 1000 Ω 88890074
Visual check:
• Check the Tooth wheel for any damage or loose fitting.
• Check that the camshaft is correctly adjusted.
• Check the camshaft intermediate gear for any damage or
loose fitting.
• Check the sensors for faulty connection.
• Check that the sensors is free from external damage.
• Check the distance between the flywheel sensor and the
flywheel.
• Check the distance between the camshaft sensor and a
camshaft tooth wheel pin.
79
Group 593 Resistance measurement
Fault
type
P0016
Condition for Fault
•
DRAFT
The cam shaft sensor signal is
Observable Symptoms
• Engine transmission.
FTB 76 dislocated compared to the fly
wheel sensor signal.
Resistance measurement
Visual check:
• Check the Tooth wheel for any damage or loose fitting.
• Check that the camshaft is correctly adjusted.
• Check the camshaft intermediate gear for any damage or
loose fitting.
• Check the sensors for faulty connection.
• Check that the sensors is free from external damage.
• Check the distance between the flywheel sensor and the
flywheel.
• Check the distance between the camshaft sensor and a
camshaft tooth wheel pin.
80
Group 593 P0615 - Starter Relay
Voltage measurement
81
Group 593 Resistance measurement
Resistance measurement
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Open circuit Off M04.K01A:85 – M04.K01A:85 - R = 0 Ω – 10 Ω 9998699,
check 19 A14.J1:81 9990062,
88890227,
88890074
Open circuit Off M04.K01A:86 – M04.K01A:86 - R = 0 Ω – 10 Ω 9998699,
check 08 A14.J1:08 9990062,
88890227,
88890074
82
Group 593 Resistance measurement
Resistance measurement
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Open circuit Off M04.K01A:85 – M04.K01A:85 – R=0Ω— 9998699,
check 19 A14.J1:81 10 Ω 9990062,
88890227,
88890074
83
Group 593 Voltage measurement
Voltage measurement
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Short circuit to On NA M04.K01A:85 – U = 20 V – 30 88890074
battery voltage Engine ground V
Resistance measurement
84
Group 593 P1176 - Starter Motor Deactivated - Over Temperature
DRAFT
P1176 - Starter Motor Deactivated - Over Temperature
Visual check:
• Check the Air filter element for cleanliness. • Check if the overflow valve opens at the specified opening
• Check that the fuel is of good quality and water separator pressure (pressure = 300 kPa — 550 kPa).
is free from residue. • Check the fuel pump for proper functioning.
• Check that the fuel tank is free from rubbish and other
contaminants.
• Check fuel hoses and connections.
• Check the fuel supply pressure using an external pressure
sensor to eliminate a fault in the pressure sensor (Fuel
supply pressure at 600 rpm 300 kPa , Fuel supply pres-
sure at 1200 rpm 300 kPa).
• Check the fuel filter for clogged by Comparing the pres-
sure before the filter to the pressure after the filter, using
Special tools (9996398, 9992936, 968126).The pressure
may not decrease more than 40 kPa (5.8 psi) over the fuel
filter.
85
Group 593 Leakage in the fuel system, Check
•
DRAFT
Remove the supply line from the fuel tank.
• Connect 88800175 Kit on the supply line connection.
• Attach the pressure gauge to the fuel hose and connect
the pressure gauge to the pneumatic system in the
workshop.
• Check that the reduction valve on the pressure gauge and
the shut-off valve are open.
• Pressure test the fuel system.
• Build up the pressure to 200 kPa (29 psi).
• Apply soapy water to the lines and connections.
Evaluation:
86
Group 593 Voltage measurement
Fault
type
P1178
Condition for Fault
•
DRAFT
Starter motor activated, no
Observable Symptoms
• Batteries.
FTB 00 speed signal. • Starter motor solenoid.
• Open circuit electric cables.
• The starter pinion does not
mesh with the gear ring on the
fly wheel.
• Starter motor.
Voltage measurement
Resistance measurement
Visual check:
• Check the Starter motor connection for fault free and prop-
erly installed.
• Check that the connectors are properly connected and
locked into position..
87
Group 593 P1179 - Starter Motor Deactivated - PTO Active
DRAFT
P1179 - Starter Motor Deactivated - PTO Active
Action:
• Put the power take-off switch in off position and try to start
again.
88
Group 593 P0666 - Control Module Internal Temperature Sensor A
DRAFT
P0666 - Control Module Internal Temperature Sensor A
Action:
• Conform the internal fault of EMS.
89
P0668 - PCM/ECM/TCM Internal Temperature Sensor
Group 593
DRAFT
Circuit Low
Action:
• Conform the internal fault of EMS.
90
Group 593 P1104 - Factory Mode
Action:
• Conform the internal fault of EMS.
91
Group 593 P1141 - Buffered Idle Validation Switch Wire - ECM Side
DRAFT
P1141 - Buffered Idle Validation Switch Wire - ECM Side
Resistance measurement
92
Group 593 Resistance measurement
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Short Circuit Off 17 — All pins A149.PB:17 - R = Open 9998699,
at connectors A149.PA, PB circuit 9998533,
PA and PB 9813194,
88890074,
9990008
Resistance measurement
94
Group 593 Resistance measurement
Resistance measurement
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Short circuit to Off 32 – Engine A14.J1:32 – R = Open 88890074,
ground check ground point Engine ground circuit 9990062,
point 9998699,
88890227
95
Group 593 P0092 - Fuel Pressure Regulator Control Circuit High
DRAFT
P0092 - Fuel Pressure Regulator Control Circuit High
Resistance measurement
96
Group 593 P0090 - Fuel Pressure Regulator 1 Control
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Component Off NA Y108:1 – R = 8 Ω – 10 88890074,999-
resistance Y108:2 Ω 0008
97
Group 593 Resistance measurement
Resistance measurement
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Open circuit Off 31 – 32 A14.J1:31 – R = 8 Ω – 10 88890074,
check A14.J1:32 Ω 9990062,
9998699,
88890227
Short circuit to Off 31 – 35 A14.J1:31 – R = Open 88890074,
higher voltage A14.J2:01 circuit 9990062,
9998699,
88890227
98
Group 593 P0088 - Fuel Rail/System Pressure - Too High Bank 1
DRAFT
P0088 - Fuel Rail/System Pressure - Too High Bank 1
Voltage measurement
99
Group 593 Resistance measurement
Resistance measurement
100
P1147 - Fuel Rail/System Bank 1 Pressure - Moderately Too
Group 593
DRAFT
High
Voltage measurement
101
Group 593 Resistance measurement
Resistance measurement
102
Group 593 P0087 - Fuel Rail/System Pressure - Too Low Bank 1
DRAFT
P0087 - Fuel Rail/System Pressure - Too Low Bank 1
Voltage measurement
103
Group 593 Resistance measurement
Resistance measurement
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Short circuit Off 33 – Engine A14.J1:95 – R = Open 88890074,
check ground point Engine ground circuit 9990062,
point 9998699,
88890227
104
Group 593 Resistance measurement
Resistance measurement
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Component Off 1–2 Y108:1 – R = 8 Ω - 10 Ω 88890074,999-
Resistance Y108:2 0216
Check
88840089, 85116548
Action:
Visual Checks:
• Check if the fuel filter is clogged.
• Check if there is leakage in fuel hoses or connections.
• Check that the fuel hoses are properly clamped and not
pinched.
• Check that the fuel hoses are not damaged or pinched and
that they are free from folds.
105
Group 593 P0192 - Engine Injection Control Pressure Circuit Low
DRAFT
P0192 - Engine Injection Control Pressure Circuit Low
Resistance measurement
106
Group 593 P0190 - Fuel Rail Pressure Sensor Bank 1
107
Group 593 Voltage Measurement
Fault
type
P0190
Condition for Fault
• Open Circuit.
DRAFT Observable Symptoms
• Engine derate.
Probable cause
Voltage Measurement
Resistance measurement
108
P228E - Fuel Pressure Regulator 1 Exceeded Learning
Group 593
DRAFT
Limits - Too Low
109
Group 593 High pressure pump, Check
•
DRAFT
Connect a transparent hose or special tool 85116548,
88840089, 20592695.
• Start the engine and Check for leakage.
• If leakage occurs shut of the engine immediately and carry
out necessary work before continuing the test.
• Read and Compare the common rail pressure with the
graphs.
Evaluation:
110
P228F - Fuel Pressure Regulator 1 Exceeded Learning
Group 593
DRAFT
Limits - Too High
• Start the engine and check for air in the fuel system.
Evaluation:
Evaluation:
Action:
Evaluation:
Evaluation:
T2084641
113
Group 593 Internal leakage in the fuel injectors, Check
DRAFT
Internal leakage in the fuel injectors, Check
Special Tools:
Evaluation:
Visual Checks:
• Check if the fuel filter is clogged.
• Check if there is leakage in fuel hoses or connections.
• Check that the fuel hoses are properly clamped and not
pinched.
• Check that the fuel hoses are not damaged or pinched and
that they are free from folds.
• Check the cam lobes for damages.
114
P016E - Closed Loop Fuel Pressure Control At Limit -
Group 593
DRAFT
Pressure Too High
Voltage Measurement
115
Group 593 Resistance measurement
Resistance measurement
DRAFT
Measuring Key position Measurement points Reference Measured Other (Special
value value tool No.)
Breakout box Wiring
diagram
Component re- Off 1– 2 Y108:1 – R = 8 Ω – 10 88890074,999-
sistance check Y108:2 Ω 0216
116
P016F - Closed Loop Fuel Pressure Control At Limit -
Group 593
DRAFT
Pressure Too Low
Visual Checks:
• Check if there is leakage in fuel hoses or connections.
• Check that the fuel hoses are properly clamped and not
pinched.
• Check that the fuel hoses are not damaged or pinched and
that they are free from folds.
117
Group 593 U0010 - CAN Communication Backbone 1 Net
•
• DRAFT
Remove the hollow screw from the fuel return connection.
Disconnect the connector between the prefilter and the
fuel return hose from the engine.
• Connect a transparent hose according to illustration.
• Pump with the hand pump until the hose is visibly free from
air.
• Run the engine speed to 600 rpm.
• Check the fuel for air bubbles.
• At engine start air bubbles may appear due to connection
of hoses.
• If there are air bubbles in the fuel it indicates either air or
gas leakage.
• If air bubbles only appear on the injector return line the
most probable fault is exhaust gas leakage by the injector.
118
Group 593 Voltage measurement
Fault
type
U0010
Condition for Fault
DRAFT Observable Symptoms Probable cause
Voltage measurement
Resistance measurement
Voltage measurement
119
Group 593 Resistance measurement
Resistance measurement
Voltage measurement
Resistance measurement
DRAFT
• Check ground wire for open circuit.
U0001 - CAN Communication Backbone 2 Net
Voltage measurement
121
Group 593 Resistance measurement
Resistance measurement
Voltage measurement
Resistance measurement
DRAFT
(IPC) Control Module
Voltage measurement
123
Group 593 Resistance measurement
Resistance measurement
Voltage measurement
Resistance measurement
Voltage measurement
124
Group 593 Resistance measurement
Resistance measurement
125
P1154 - Body Control Module A - Lost Communication With
Group 593
DRAFT
Instrument Panel Cluster (IPC) Control Module
Voltage measurement
126
Group 593 Resistance measurement
Resistance measurement
Voltage measurement
Resistance measurement
Voltage measurement
127
Group 593 Resistance measurement
Resistance measurement
128
Group 593 U0141 - Lost Communication With VMCU
DRAFT
U0141 - Lost Communication With VMCU
Voltage measurement
129
Group 593 Resistance measurement
Resistance measurement
Voltage measurement
Resistance measurement
Voltage measurement
130
Group 593 Resistance measurement
Resistance measurement
131
DRAFT