S SERIES EURO V Application To Vehicles F1CE3481

S SERIES EURO V
Application to vehicles
F1CE3481
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 P1D32S015 E - 1st Ed. 10.2011
S SERIES EURO V 1
S SERIE EURO V
S Serie F1CE Part 1
Print P1D32S015 E Base - October 2011

2 S SERIES EURO V
Base - October 2011 Print P1D32S015 E

S SERIES EURO V INTRODUCTION 3
PREFACE TO USER'S GUIDELINE MANUAL

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 engine illustrating its features and working in general.
Section 2 describes the type of fuel feed.
Section 3 relates to the specific duty and is divided in four separate parts:
1. Mechanical part, related to the engine overhaul, limited to those components with different characteristics based on the
relating specific duty.
2. Electrical part, concerning wiring harness, electrical and electronic equipment with different characteristics based on the relating
specific duty.
3. Maintenance planning and specific overhaul.
4. Troubleshooting part dedicated to the operators who, being entitled to provide technical assistance, shall have simple and
direct instructions to identify the cause of the major inconveniences.
Sections 4 and 5 illustrate the overhaul operations of the engine overhaul on stand and the necessary equipment to execute
such 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 = housing for connecting rod small end bush

Tighten to torque
Tighten to torque + angular value
α
 2 Ø 2 = housing for connecting rod bearings

4 INTRODUCTION S SERIES EURO V
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.

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 16-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
available 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.

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.
NOTE Connectors present must be seen from cable side. Connectors views contained in the manual are representative of
cable side.

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

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE

INTERNATIONAL SYSTEM AND MOST USED DERIVED QUANTITIES
Power
1 kW = 1.36 metric HP
1 kW = 1.34 HP
1 metric HP = 0.736 kW
1 metric HP = 0.986 HP
1 HP = 0.746 kW
1 HP = 1.014 metric HP
Torque
1 Nm = 0.1019 kgm
1 kgm = 9.81 Nm
Revolutions per time unit
1 rad/s = 1 rpm x 0.1046
1 rpm = 1 rad/s x 9.5602
Pressure
1 bar = 1.02 kg/cm2
1 kg/cm2 = 0.981 bar
1 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

KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES
Type of Section Page

vehicle title number
Language Basic edition referred to When month - year

Printout
Publication month - year editorial update is present (revi) to
number
phase closing the basic edition


S SERIES EURO V 1
Part 1
F1CE3481 ENGINES
Section
General specifications 1
Operational diagrams 2
Electrical equipment 3
Maintenance schedule 4
Diagnostics 5
Removal - refitting of main components 6
General mechanical overhauling 7
Technical specifications 8
Tools 9
Safety prescriptions Appendix

2 S SERIES EURO V

Removal
Intake
Disconnection
Reinstallation
Exhaust
Connection
Removal
Operation
Disassembly
Positioning
Assembly
ρ Compression ratio
Tolerance
Tighten to torque
Weight difference
Tighten to torque + angle value Rolling torque

α
Press or caulk Rotation
Regulation Angle
Adjustment Angular value
Visual inspection
Preload
Installation position check
Measurement
Value to find Number of revolutions
Check
Equipment Temperature
Surface for machining

Pressure
Machine finish bar
Oversized
Interference
Greater than....
Strained assembly
Maximum, peak
Undersized
Thickness
Less than....
Clearance
Minimum
Lubrication Selection
Damp Classes
Grease Oversizing
Temperature < 0°C (32°F)
Sealant
Cold
Adhesive
Winter
Temperature > 0°C (32°F)
Air bleeding Hot
Summer

UPDATING
Section Description Page Date of revision

S SERIES EURO V SECTION I - GENERAL SPECIFICATIONS 1
SECTION 1
General specifications
Page
VIEWS OF ENGINE F1CE3481A/R . . . . . . . . . . . . 3
F1CE3481C*C124 . . . . . . . . . . . . . . . . . . . . . . . . . . 6
GENERAL MOTORS . . . . . . . . . . . . . . . . . . . . . . . 9
GENERAL CHARACTERISTICS . . . . . . . . . . . . . . . 10

2 SECTION I - GENERAL SPECIFICATIONS S SERIES EURO V

VIEWS OF ENGINE F1CE3481A/R
Figure 1
165378
LEFT-HAND SIDE VIEW
Figure 2
165378
RIGHT-HAND SIDE VIEW

Figure 3
166160
FRONT VIEW
Figure 4
166162
REAR VIEW

Figure 5
166161
TOP VIEW

F1CE3481C*C124
Figure 6
165376
LEFT-HAND SIDE VIEW
Figure 7
164020
RIGHT-HAND SIDE VIEW

Figure 8
165375
FRONT VIEW
Figure 9
164019
REAR VIEW

Figure 10
165377
TOP VIEW

GENERAL MOTORS
Type F1CE3481R F1CE3481 F1CE3481 F1CE3481 F1CE3481 F1CE3481

*A901 A*A001 A*A002 A*A004 A*A005 C*C124
Max. power
kW (CV) 107 (145) 80 (108) 107 (145) 90 (122) 80 (108) 125 (170)
(rpm) (3500) (-) (3500) (-) (-) (3500)
Max. torque
Nm (kgm) 370 (37) - (-) 370 (37) - (-) - (-) 400 (40)
(rpm) (1400) (-) (1400) (-) (-) (1250)
Min. enginespeed - - -
rpm - - -
Max. enginespeed
rpm - - - - - -

GENERAL CHARACTERISTICS
Type F1CE3481A/R F1CE3481
C*C124
Pressure at T.D.C.
*bar 20  26
Minimum permissible
bar pressure at T.D.C..
16
*bar
Bore x stroke mm 95,5 x 104
Displacement cm3
2998
TURBOCHARGING With intercooler
GARRETT DAVNT BORG WARNER
Turbochargertype: COOLED WATER K 03 B2
variable geometry with Waste-Gate
Turbocharger shaft radial play mm 0,086  0,117 0,396  0,602
Turbocharger shaft end float mm 0,030  0,083 0,034  0,106
Minimum stroke of pressure relief valve opening: mm -
Maximum stroke of pressure relief valve opening: mm -
-
Pressure corresponding to minimum stroke: bar
-
Pressure corresponding to maximum stroke: bar
LUBRICATION forced by gear pump,
pressure relief valve, oil mono-filtrationoilfilter
filterwith double filtering
bar
Oil pressure with engine hot
(100ºC  5ºC):
at idling speed bar 1,0 ≥ 0,6
at top speed bar 5,0 ≥4
COOLING by centrifugal pump, thermostat for adjustment,
coolanttemperature, fan with electromagnetic
coupling, radiator, heatexchanger
Water pump control by belt
Thermostat: N. I.
start of opening: 79 _C  2 _C
max opening: - 94 ºC  2 ºC
(*) The pressure is measured by setting the engine turning with the aid of just the starter motor, with an oil temperature of
40 - 50°C.

Cooling system (1) liters 6,9 -

Total capacity
Lubrication circuit (2)
Periodic replacement:
total capacity(3) litrers (kg) 7,0 (6,3) 7,3 (6,44)
cup at the minimum level litrers (kg) 4,2 (3,8) -
cup tothe maximum level litrers (kg) 6,6 (5,9) 6,6 (5,81)
Power steering oil(4) (6)
Fuel tank(5) (6)
(1) Quantity relative only to standard configuration engines. Use a mix of water and PARAFLU 11 at 50% even in summer. An
alternative option to PARAFLU 11, is to use a product that conforms to the international standard SAE J 1034.
(2) Use lubricants which meet the international standards ACEA C2/C3 SAE 5W30/SAE 5W40. The viscosity degree to be used
in relation to standard ambient temperature can be seen in the table found in the appendix. The oil used is considered to
be acceptable until reaching a quantity equal to 0.5% of fuel consumption.
(3) The quantities indicated relate to the first refuel only and are relative to the engine, oil sump and filter filling.
(4) The use of Tutela GI/A oil is recommended along with other types in compliance with specification ATF DEXRON IID.
(5) Use STANDARD fuel type that complies with standard EN 590 (2005/55 - 2005/78).
(6) Refer to the instructions provided by the vehicle’s manufacturer.


S SERIES EURO V SECTION 2 - OPERATIONAL DIAGRAMS 1
SECTION 2
Operational diagrams
Page
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . 3
- Fuel pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- High pressure pump CP4.1 description . . . . . . . 5
- Pressure control valve . . . . . . . . . . . . . . . . . . . . 6
- Hydraulic accumulator (rail) . . . . . . . . . . . . . . . 6
ELECTRO-INJECTORS . . . . . . . . . . . . . . . . . . . . . . 6
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REPLACEMENT OF INJECTORS ON VEHICLE . . 7
- Electro-injector reprogramming . . . . . . . . . . . . 7
ELECTRIC/ELECTRONIC COMPONENTS . . . . . . 9
- Electronic control unit EDC 17 . . . . . . . . . . . . 9
- Glow plug electronic control unit . . . . . . . . . . . 10
- Glow plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Engine speed sensor . . . . . . . . . . . . . . . . . . . . . 10
- Camshaft timing sensor . . . . . . . . . . . . . . . . . . . 10
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
- General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
OIL PUMP/DEPRESSOR UNIT . . . . . . . . . . . . . . . . 13
- Oil pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
- Vacuum pump . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Oil pressure adjusting valve . . . . . . . . . . . . . . . . 14
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
HEAT EXCHANGER . . . . . . . . . . . . . . . . . . . . . . . 15
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
OIL VAPOUR RECIRCULATION (BLOW-BY) . . . 17

2 SECTION 2 - OPERATIONAL DIAGRAMS S SERIES EURO V
Page
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Water pump description . . . . . . . . . . . . . . . . . . 21
- Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
TURBOCHARGING . . . . . . . . . . . . . . . . . . . . . . . . 22
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
TURBOCHARGER SYSTEM DESCRIPTION . . . . . 23
- GARRET variable geometry turbosupercharger 24
- Operation at low engine rpm . . . . . . . . . . . . . . 25
- Operation at high engine rpm . . . . . . . . . . . . . 25
- Borg Warner turbocharger description . . . . . . . 26
- Proportional solenoid valve controlling
turbocharger actuator . . . . . . . . . . . . . . . . . . . . 28
- Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 30
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
E.G.R. Assembly
(Exhaust gas recirculation) . . . . . . . . . . . . . . . . 31
- EGR flow regulator valve . . . . . . . . . . . . . . . . . 32
- Throttle valve assembly description . . . . . . . . . 32

OPERATION HYDRAULIC SYSTEM

In this injection system, the pressure regulator, located The hydraulic system is composed of:
upstream from the high-pressure pump, governs the flow of - tank
fuel needed in the low-pressure system. Afterwards, the
- fuel pre-filter
high-pressure pump correctly supplies the hydraulic
accumulator. - electric supply pump
- fuel filter
This solution, pressurizing solely the necessary fuel, improves - high pressure supply pump with supply pump built
the energy efficiency and limits heating the fuel in the system. inpressure regulator
The relief valve fitted on the high-pressure pump has the
- manifold (rail)
function of keeping the pressure, at the pressure regulator
inlet, constant at 5 bars; irrespective of the efficiency of the - electro-injectors
fuel filter and of the system upstream. The action of the relief - supply pipes and fuel recirculation
valve causes an increase in the flow of fuel in the
high-pressure pump cooling circuit.
The high-pressure pump continually keeps the fuel at the
working pressure, irrespective of the timing and the cylinder
that is to receive the injection and accumulates it in a duct Fuel pipes
common to all the electro-injectors.
Figure 1
At the electro-injector inlet, there is therefore always fuel at
the injection pressure calculated by the electronic control
unit.
When the solenoid valve of an electro-injector is energized
by the electronic control unit, fuel taken straight from the
hydraulic accumulator gets injected into the relevant cylinder.
The hydraulic system is made out of a low-pressure fuel
recirculation circuit and a high-pressure circuit.
The high-pressure circuit is composed of the following pipes:
- pipe connecting the high-pressure pump outlet to the
Rail;
- hydraulic accumulator;
- pipes supplying the electro-injectors.
The low-pressure circuit is composed of the following pipes: 88619
- fuel intake pipe from the tank to the pre-filter;

- pipes supplying the mechanical supply pump and the 1. Fuel filter mounting - 2. High-pressure pump supply pipe
pre-filter; quick-coupling fitting — 3. Supply pipe quick-coupling fitting.
- pipes supplying the high-pressure pump via the fuel filter.
If disconnecting the fuel pipes (2-3) from the mounting (1),
The fuel system is also fitted with the fuel exhaust circuit and it is necessary, when refitting, to make sure their fittings are
the electric injectors. perfectly clean. This is to avoid an imperfect seal and fuel
According to the high performance of this hydraulic system, getting out.
for reasons of safety it is necessary to:
- avoid connecting high-pressure pipe fittings with
approximate tightening;
- avoid disconnecting the high-pressure pipes with the
engine running (NEVER try bleeding, which is both
pointless and dangerous).
The integrity of the low-pressure circuit is also essential for
the system to work properly; it is therefore necessary to
avoid all manipulation and modifications and act only in the
event of leakage.

.
Figure 2
150686
High pressure fuel pipes
Low pressure fuel recirculation pipes
FUEL FEED AND CIRCULATION SYSTEM

1. Electric injector - 2. Pressure regulating valve (DRV) - 3. CP4.1 high-pressure pump - 4. Fuel delivery pipe to the
high-pressure pump - 5. Fuel return pipe to the tank - 6. High-pressure fuel delivery pipe to the hydraulic accumulator (rail) -
7 Pressure sensor - 8. Injector fuel exhaust pipe - 9. High-pressure fuel delivery pipe to the electric injectors -
10. Hydraulic accumulator (rail)
Check valve characteristics

opening pressure 0.5 + 0.05
- 0.1 bar
differential pressure less than 0.2 bar at 120 litres/h of fuel.

High pressure pump CP4.1 description

Figure 3
126023
Pump with one radial plunger controlled via a gear by the

timing belt; it needs no timing. NOTE The high-pressure pump cannot be overhauled;
The pump is lubricated and cooled by the fuel. therefore, it must not be removed or tampered
with. Only the following repairs are permitted:
The operating pressure is controlled as follows: replacing the drive gear and the pressure regulator.
- electronically by a solenoid valve located on the pump
casing and controlled by the ECU;
- by a regulator valve (DRV) mounted on the hydraulic
accumulator (Rail).
Fuel supply is provided by a transfer pump. This is built into
the fuel level indicator located in the fuel tank incorporated
into the fuel intake assembly (GAC) together with the fuel
level signalling device located in the fuel tank.

Pressure control valve Hydraulic accumulator (rail)

The fuel pressure regulator is mounted on the low-pressure
circuit of the CP4 pump. The pressure regulator modulates Figure 6
the amount of fuel sent to the high-pressure circuit according
to the commands received directly from the engine control
unit. The pressure regulator is mainly composed of the
following components:
- connector
- casing
- solenoid
- pre-load spring
- shutter cylinder.
When there is no signal, the pressure regulator is normally
open, therefore with the pump providing maximum delivery.
The engine control unit, via the PWM (Pulse Width
Modulation) signal, modulates the change in fuel flow rate in 88418
the high-pressure circuit by partially closing or opening the The hydraulic accumulator is fitted on the cylinder head on
sections of passage of the fuel in the low-pressure circuit. the suction side.
Operation
With its volume of approximately 8.8 cm3 it dampens the
Figure 4 pressure ripples of the fuel due to:
- the operation of the high-pressure pump;
- the opening of the electro-injectors.
On the hydraulic accumulator (1) there is the fuel pressure
sensor (2).
ELECTRO-INJECTORS
Figure 7
75574
1. Solenoid - 2. Magnetic core - 3. Shutter cylinder -

4. Fuel inlet - 5. Fuel outlet.
When the engine control unit governs the pressure regulator
(via PWM signal), the solenoid (1) is energized that, in its turn,
generates the movement of the magnetic core (2). The shift
of the core causes the shutter cylinder (3) to move axially,
126025
choking the flow of fuel.
The piezoelectric injectors are located on the engine head
and receive the fuel under pressure from the rail. They
Figure 5
operate both the high pressure fuel supply and recirculation
under atmospheric pressure of the excess fuel that has not
been injected.
The following are installed on the injector head :
- a central access pipe for fuel under high pressure;
- a lateral pipe for the recirculation of fuel under low
pressure with built-in throttle;
- the site for the electric connector that receives
commands from the control unit.
The electronic control unit controls the piezoelectric
75575 actuator inside the injector.
The piezoelectric actuator, due to reduced switching times,
1. Solenoid - 2. Magnetic core - 3. Pre-load spring - enables a very fast reaction to the commands sent from the
4. Shutter cylinder. engine control unit, making injection capacity more flexible
and increasing the number of injections per cycle.
When the solenoid (1) is not energized, the magnetic core
is pushed into the rest position by the pre-load spring (3). In
this condition, the shutter cylinder (4) is in such a position as
to offer the fuel the greatest section of passage.

Figure 8 REPLACEMENT OF INJECTORS ON

VEHICLE
Electro-injector reprogramming
Figure 9
150723
1. Electrical connection - 2. Connection for fuel return

flow - 3. Encapsuled piezoelectric actuator - 4. Control
valve - 5. Nozzle - 6. Hydraulic amplifier - 7. High
102394
pressure line
Operation 1. Production plant code - 2. IMA Matrix code -

3. Uncoded IMA code - 4. Bosch spare part No. -
When the piezoelectric actuator (3) is reached by an 5. Date of production - 6. Serial No. - 7. Production line
electrical load, commanded by the control unit, it increases code - 8. Iveco spare part No.
its length. The movement, amplified by the hydraulic amplifier
The electro-injectors are no longer divided into classes: Min
(6), act mechanically on the control valve (4) and it allows
therefore the injection of the fuel present in the high (01) - Med (02) - Max (03), so that deviations from the design
flow rates are measured, at the final testing phase, by the
pressure duct (7). While stopping the electrical load, the
manufacturer for each injector and stamped with the IMA
actuator reacts elastically and again assumes its initial
length.The springs add their contribution, winning the code (Injector Menge Abgleichung) on the injector magnet.
At the engine production facility, the I.M.A. code is read in line
pressures that act in balancing on the whole surface of the
by an automated reading station, converted into bar code,
components.
The fuel in excess is than recirculated in the fuel circuit printed on the engine identification label and applied to the
engine.
through the duct (2).
In the vehicle factory, the EDC 17 ECU is programmed at the
end of the line by automatically reading the engine label.

Figure 10 At the assistance centre the uncoded IMA code is required

(3, Figure 9) for the ECU replacement and reprogramming
procedure.
The table shows the conversion of OCR characters into
Arial fonts.
When electro-injectors on engine mounted on vehicle
require replacing, follow the instructions provided below:
- in cases where electro-injectors are removed and do
not need to be replaced, their individual positions need
to be noted in order to later re-install them in their
original positions; this is done to avoid having to
reprogram the ECU;
- after replacing one or more injectors, the ECU requires
reprogramming;
- before installing a new electro-injector, note the IMA
code stamped on the injector, as it becomes difficult to
read the code once the injector is in position;
- in the event the ECU is replaced, program the new
ECU with the IMA codes of the electro-injectors
installed on the engine and copy the correction
coefficients (ZFC) of the replaced ECU; if this is not
possible, they must be reset and auto-configuration
process must be restarted.
Whilst the engine is running, the EDC 17 ECU performs a
Conversion table of OCR number of tests on the electro-injectors' minimum flow
characters into ARIAL font 105067 rate.
In certain conditions (overrun: vehicle deceleration with
pedal released) an increasing (very small) quantity of fuel
starting from zero is injected and its effect on engine
rotation smoothness is observed. Injection start threshold
is detected and stored by the ECU.
This auto-configuration process is carried out on each
single cylinder.
Therefore, replacing an electro-injector requires that the
ECU be reprogrammed, entering the IMA codes of the new
electro-injectors and resetting the correction factors (ZFC)
of the cylinder concerned.
Replacing all electro-injectors makes it necessary to reset
all the correction coefficients (ZFC) of each single
electro-injector.
The correction coefficients (ZCF) can be zeroed using the
FPT. diagnostic tool, by reprogramming the ECU and
performing the sensor replacement procedure provided by
the diagnostic tool.

ELECTRIC/ELECTRONIC COMPONENTS In addition to controlling the system functions described in the

Electronic control unit EDC 17 respective charter, the electronic control unit is interfaced with
the other electronic systems found on the vehicle, such as ABS
Figure 11 - EBD, cruise control, speed limiter, EGR, preheating plugs.
K A On the vehicles equipped with D.P.F. catalyst, the control unit
also controls the catalyst regeneration system. In this case, after
any of the operations below is carried out:
- replacing one or several injectors,
- replacing all the injectors,
- replacing the air flow meter,
- replacing the hydraulic accumulator pressure sensor
(common rail),
- replacing the EDC 17 control unit;
- changing the engine oil,
- replacing the D.P.F. catalyst,
85711
- replacing the filter differential pressure (p) sensor,
- replacing any significant component as regards emission
PERSPECTIVE VIEW levels,
A. Engine side injection cable connector - K. Bonnet/cab - performing forced regeneration,
cable connector.
the control unit shall be programmed again by means of the

DAIMLER E-Tester tool, and the replacement procedure for
The control unit is of the ”flash EPROM” type, i.e. it can be the concerned component shall be performed, in accordance
reprogrammed from the outside without acting on its with the indications of the diagnosis instruments.
hardware.
The control unit processes the signals from the sensors by
applying software algorithms, and also controls the actuators
(in particular, the electric injectors and the pressure
regulator).
The control unit records, in the memory non-labile area, the
information on the engine parameters originally set or
acquired during engine operation.
The injection control unit incorporates the absolute pressure
sensor, in order to further improve the injection system
control.
The control unit is fitted to the left side of the engine
compartment and is connected to the vehicle wiring by
means of two connectors:
- 60-pole connector ”A” for the components available on
the engine;
- 94-pole connector ”K” for the components on the
vehicle.

Glow plug electronic control unit Engine speed sensor

It is an inductive sensor and is positioned on the phonic wheel
Figure 12 fitted on the front end of the drive shaft
It generates the signals resulting from the magnetic flow lines
which close through the teeth of the phonic wheel.
Tooth number 58.
The electronic control unit uses this signal to measure the
speed of rotation of the engine, its angular position and to
operate the electronic rev counter.
If this signal fails the rev counter will not work.
Camshaft timing sensor
It is an inductive sensor and is positioned on the camshaft
gear of the suction valves.
It generates the signals resulting from the magnetic flow lines
which close through a slot on the gear itself.
The signal generated by this sensor is used by the electronic
control unit as a redundant signal to measure the different
engine speeds.
75578
The engine control unit, in the phase of:

- starting
- after-starting
times the operation of the glow plug control unit according
to the engine temperature.
The spark plug control takes place through the spark plug
pre-warming control unit according to the engine
temperature under the direct control of the engine control
unit EDC 16.
The pre-heating control unit contains an “intelligent”
contactor that sends feedback to the control unit that is thus
informed about any fault with the pre-heating control unit or
shorting to earth of the glow plugs.
Glow plugs
Figure 13
75579
CONTROL VALUES
With a constant supply voltage of 11 V:
- max. current drawn 18 A
- in 5 sec. 11 1.5 A
- in 30 sec. 6 0.9 A
- temperature after 7 sec. 850C
- tightening torque 8-10 Nm

LUBRICATION
General
The engine is lubricated by forced circulation performed by the following parts:

- a gear oil pump with built-in depressor (GPOD);
- a pressure relief valve integrated in the oil pump;
- a heat exchanger made up of five elements;
- A double filtration oil filter with built-in safety valve.
Operation (see Figure 14)

Engine oil is drawn up from the sump by the oil pump via the suction strainer and delivered under pressure to the heat exchanger
where it is cooled.
The oil continues through the oil filter and goes to lubricate the relevant parts through ducts or pipes.
At the end of the lubrication cycle, the oil returns to the sump by gravity. The oil filter can be excluded by the safety valve built
into it if it gets clogged.
In addition, the lubricating oil feeds the chain hydraulic tightening devices for the control of the auxiliary elements and the timing
system and the hydraulic tappet.

Figure 14
Oil under pressure

Oil in freefall
Coolant
150681
A. Pressure regulating valve closed - B. Pressure regulating valve open.

OIL PUMP/DEPRESSOR UNIT Oil pump
Characteristic data
Figure 15 transmission ratio 1
displacement 23.52 cm3
pumping diameter 49.5 mm
number of teeth 7
height 16 mm
oil pump minimum speed 780 rpm
oil pump max. speed 3500 rpm
oil pump over-revs 4200 rpm
oil pump forced over-revs 4900 rpm
speed 3500 rpm
torque - Nm
power draw (calc.) - W
Oil temperature: 100C — closed recirculation —

max. outlet pressure 5 bars
88625
engine speed rpm
1. Oil pump - 2. Oil pressure adjusting valve - (oil pump speed — rpm) capacity (l/min)
3. Depressor.
780 (862)
3500 (4485)
NOTE Should the unit be faulty, not due to the oil
pressure adjusting valve, change the whole unit.
Figure 17
Figure 16
88690
SECTION B-B
Figure 18
88689
SECTIONS OF OIL PUMP/DEPRESSOR UNIT

1. Oil input pipe from cylinder block - 2. Oil suction pipe -
3. Oil pressure adjusting valve - 4. Oil delivery pipe -
5. Depressor air suction pipe - 6. Depressor oil suction
pipe.
88691
SECTION A-A

Vacuum pump Figure 20

The vacuum pump (2, Figure 15), with radial blades, is also
incorporated in the GPOD (1, Figure 16). It is driven directly
by the oil pump.
transmission ratio 1
displacement 150 cm3
volume to drain 4.5 litres
chamber diameter 65 mm
rotor diameter 45.5 mm
cam 7.5 mm
number of blades 3
height 34 mm
vacuum pump minimum speed 780 rpm
vacuum pump max. speed 3500 rpm
vacuum pump over-revs 4200 rpm
vacuum pump forced over-revs 4900 rpm 88627
theoretical flow rate at minimum (air) - l/min
Oil pressure adjusting valve open
actual flow rate at minimum (air) —
at atmospheric pressure - l/min If in pipe C the oil pressure is equal or above 4.4 bar, the valve
Theoretical speed at max. speed — (air) - l/min (1), as a result of the pressure itself, wins through the spring
Actual flow rate at max. speed — (air) reaction (2) and goes down, thus opening communication
at atmospheric pressure - l/min between the delivery pipe A and the suction pipe B, through
draining holes D-E, and therefore the pressure drops.
measured power draw (maximum) When the pressure falls below 4.4 bar, the spring (2) takes
speed 3500 rpm the valve (1) to the initial position of closed valve.
torque - Nm
power draw (calc.) - W
Oil temperature: 100C — engine speed 780 rpm

(pump speed 994 rpm) Disassembly
tank vacuum Figure 21
(litres) (bar) 0.5 0.8
4.5 4.5 12.5

time (sec)
9 9.5 26.0
Oil pressure adjusting valve
Figure 19
88058
Use the suitable wrench to remove the oil pressure adjusting

valve (1) from the oil pump.
88626
1. Oil input pipe from cylinder block - 2. Oil suction pipe -

3. Oil pressure adjusting valve - 4. Oil delivery pipe -
5. Depressor air suction pipe - 6. Depressor oil suction
pipe.
Pressure at opening start: 4.4 bar
Description of oil pressure adjusting valve closed
If in pipe C the oil pressure is below 4.4 bar, the valve (1)
closes the holes D - E.

Figure 22 OIL FILTER

Figure 24
88059
PARTS COMPRISING THE OIL PRESSURE

CONTROL VALVE
1. Split ring - 2. Valve - 3. Spring - 4. Valve casing.
88061
Use the suitable pliers to remove the snap ring (1), take off Oil filter with built in by-pass valve - differential opening
the valve (4) and the spring (3) from the valve body (2). pressure 2.5  0.2 bar.
HEAT EXCHANGER
Figure 23 Figure 25
88060
MAIN DATA OF THE OIL PRESSURE CONTROL

VALVE SPRING
88773
Assembly
For refitting, reverse the removal operations. HEAT EXCHANGER COMPONENT DETAILS
1. Heat exchanger made up of five elements - 2. Gasket -
3. Box - 4. Pipe union - 5. Screw - 6. Oil filter support -
7. Screw - 8. Heat exchanger box - 9. Gasket.
Disassembly
Remove the screws (5) and take off the heat exchanger (1)
from the box (3) with the gasket (8).
Remove the screws (7) and take off the oil filter support (6)
from the box (3).
Assembly
For refitting, reverse the removal operations and observe the
following warnings.
Clean accurately the heat exchanger (1).
Always change the gaskets (2, 9 and 8). Apply LOCTITE 577
on the threading of the pipe union (4) (if removed), drive it
in the support (1) and tighten it to the prescribed torque.
Tighten the screws to the prescribed torque.

Figure 26 Figure 28
88685
Figure 27 88687
Figure 29
88686 88688
HEAT EXCHANGER SECTIONS

Oil flow from heat exchanger to oil filter
Oil flow from oil filter to cylinder block
Oil flow from cylinder block to heat exchanger

OIL VAPOUR RECIRCULATION (BLOW-BY)

Part of the gas produced by the combustion during the engine operation blows by the piston snap ring ports, in the oil sump, and
mixes with the oil vapours present in the oil sump.
This mixture, conveyed from the chain compartment to the top, is partially separated from the oil by means of a device situated on
the top side of the distribution cover and is introduced in the air suction system. This device consists mainly of a rotating filter (3),
fit flush on the stem (1), a high pressure/shaft control and a cover (2) where the valves (4 and 5), usually closed, are fitted.
The diaphragm valve (4) regulates the partially purified mixture and keeps the pressure inside the chain compartment around a value
of ~ 10 ÷15 mbar.
The umbrella valve (5) discharges some of the oil still present in the mixture coming from the filter (3) in the chain compartment
and the oil condenses in the chamber (6).
Operation
The mixture which passes through the rotating filter (3) is partially purified from the oil particles, as a result of centrifugation, and so
these particles condense on the cover walls to return to the lubrication circuit.
The resulting purified mixture is let in through the stem holes (1) and the diaphragm valve consensus (4) inside the air vent upstream
of the turbocharger.
The opening/closing of the valve (4) depends mainly in the ratio between the pressure operating the diaphragm (4) and the depression
below it.
The oil still present in the mixture coming from the rotating filter (3) and which condenses in the chamber (6) is drained into the
chain compartment through the umbrella valve (5), when the pressure that keeps it closed drops as a result of the engine stop.

Figure 30
Gas with oil level above 10 g/h
Gas with oil level ~ 0,2 g/h
Condensed oil returning to the oil sump
150682

COOLING
Description
The engine cooling system is the type with forced circulation in a closed circuit. It comprises the following parts:
- An expansion tank whose plug has two valves incorporated in it: an outlet and an inlet, which govern the pressure of the
system.
- A coolant level sensor at the base of the expansion tank.
- A pressure switch (3) notifies EDC central unit when pressure inside expansion tank exceeds 0.4 bar value; in this case,
the central unit reduces engine performance level by modifying injection flow rate (De-rating).
- An engine cooling module to dissipate the heat taken from the engine by the coolant with a heat exchanger for the
intercooler.
- A heat exchanger to cool the lubricating oil.
- A centrifugal water pump incorporated in the crankcase.
- An electric fan comprising an electromagnetic coupling on whose shaft a hub turns idle that is fitted with an axially mobile
metal plate on which is mounted the impeller.
- A 3-way thermostat governing the circulation of the coolant.
Operation
The water pump driven by a poly-V belt by the crankshaft sends coolant into the crankcase and with a greater head into the
cylinder head.
When the coolant temperature reaches and exceeds the working temperature, it causes the thermostat to open and the fluid
is channelled from here to the radiator and cooled by the fan.
The pressure in the system due to the change in temperature is governed by the outlet (2) and inlet (1) valves incorporated
in the expansion tank filler plug (detail A).
The outlet valve (2) has a twofold function:
- to keep the system slightly pressurized so as to raise the boiling point of the coolant;
- to discharge into the atmosphere the excess pressure produced in case of high coolant temperatures.
The function of the inlet valve (1) is to permit transferring the coolant from the expansion tank to the radiator when a lower
pressure is created in the system due to the reduction in volume of the coolant as a result of its temperature lowering.
Outlet valve opening 1  0.1 kg/cm2.
Inlet valve opening 0.005 — 0.02 kg/cm2.

Figure 31
150683
Vent to expansion tank

To heating system
From heating system
To radiator
From radiator
Thermostat closed
Thermostat open
Hot
Very hot
Cold

Water pump description Thermostat

The water pump cannot be overhauled. If coolant leakage or
damage to the component or seals is identified, it must be Figure 33
replaced.
Figure 32
150684
The by-pass thermostat needs no adjustment.

If there is any doubt about its operation, replace it.
The thermostat casing is fitted with the thermometric
switch/transmitter and water temperature sensor.
Start of stroke at 79  2 C.
107755
LONGITUDINAL CROSS-SECTION OF WATER PUMP

1. Pump casing - 2. Pump drive shaft with bearing -
3. Seal - 4. Impeller.

TURBOCHARGING
For motors F1CE3481A/R
Figure 34
Air at atmospheric temperature

Hot compressed air
171590
Cold compressed air
Exhaust gas
Cold exhaust gas
Description The function of the turbocharger is to use the energy of the

The turbocharging system comprises an air filter, engine's exhaust gas to send pressurized air to the cylinders.
turbocharger and intercooler. The intercooler comprises a radiator included in the engine
The air filter is the dry type comprising a filtering cartridge to coolant radiator and its function is to lower the temperature
be periodically replaced. of the air leaving the turbocharger to send it to the cylinders.

TURBOCHARGER SYSTEM DESCRIPTION

For motor F1CE3481C*C124
Figure 35
Air at ambient temperature
Exhaust gas
Recirculated exhaust gas
Cold compressed air
Hot compressed air 137771
TURBOCHARGING DIAGRAM
The turbocharging system is composed of: an air filter, The function of the two-stage turbocharger is to use the
two-stage turbocharger and intercooler. energy of the engine's exhaust gas to deliver pressurized air
The air filter is a dry type comprising a filtering cartridge that to the cylinders.
should be periodically replaced. The intercooler consists of a radiator integrated in the
engine coolant radiator with the function of lowering the
temperature of the air leaving the turbocharger before it is
delivered to the cylinders.

GARRET variable geometry turbosupercharger

Figure 36
62871
The variable geometry turbosupercharger consists of the The variable geometry makes it possible to:
following:
- increase the speed of the exhaust gases at the turbine at
- centrifugal supercharger (1); low engine speeds;
- turbine (2); - slow down the speed of the exhaust gases at the turbine
- set of mobile blades (3); at high speeds;
- a pneumatic actuator (4) controlling the moving vanes. The variable geometry turbocharger makes it possible to
The actuator is controlled by a vacuum via a produce the maximum volumetric efficiency for the engine
proportional solenoid valve controlled by the engine at low rotation speeds (with the engine in load conditions).
management control unit.

Operation at low engine rpm Operation at high engine rpm

Figure 37 Figure 38
126017 126018
1. TURBINE - 2. MOBILE BLADES 1. TURBINE - 2. MOBILE BLADES -

3. PNEUMATIC ACTUATOR
When engine is running at low speed, the exhaust gases The ECU, through the actuator control solenoid valve,
show weak kinetic energy; under these conditions a modulates the vacuum acting on the diaphragm, so actuator
traditional turbine shall rotate slowly, thus providing a limited (3) controls through the tie rod, the gradual opening of the
booster pressure. mobile blades (2) until reaching the max. open position.
In the variable geometry turbine (1), the mobile blades (2) are Blade through-sections results larger thus producing a speed
set to max. closed position and the small through-sections decrease in exhaust gas flow through the turbine (1) with
between the blades increase the inlet gas speed. Higher inlet speeds equal to or lower than those of the low rpm
speeds involve higher tip speeds of the turbine and therefore condition.
of the turbosupercharger. Turbine (1) speed is therefore adjusted to a proper value
Engine speed increase results in a gradual increase of exhaust enabling suitable engine operation at high speed
gas kinetic energy, and also in turbine (1) speed and booster
pressure increase.

Borg Warner turbocharger description

Figure 39
137772
The Borg Warner turbocharger is a two-stage type with - a pressure relief valve fitted on the high pressure turbine
pressure relief valve. Essentially this consists of: casing. This separates a portion of the exhaust gas outlet
and sends part directly to the low pressure turbine via
- a first high-pressure turbocharger consisting of: the pipe connecting the two turbines when the
a) a central casing housing a shaft supported by supercharging pressure exceeds the set value. The
bushings at whose opposite ends are fitted the Waste-Gate valve is controlled by a modulator valve
turbine and the compressor wheels; which modulates the vacuum drawn from the air circuit
b) a small fixed geometry turbine casing and a of the servo brake, according to the information
compressor casing mounted at the end of the exchanged between the electronic control unit and the
central casing; sensors: engine rpm, throttle pedal position and
- a second low-pressure turbocharger consisting of: pressure/temperature fitted on the intake manifold.
c) a central casing housing a shaft supported by
bushings at whose opposite ends are fitted the
turbine and the compressor wheels;
d) a larger fixed geometry turbine casing and a
compressor casing mounted at the end of the
central casing;
- a gas pipe connecting the two turbines;
- a pipe connecting the compressed air between the
two compressors;

Figure 40
137773
OPERATION DIAGRAM
1. Vacuum tank - 2. Modulator solenoid valve - 3. Actuator (Waste Gate) - 4. Throttle valve -
5. High pressure turbocharger - 6. Low pressure turbocharger - 7. Air filter
Operation at low speed Operation at high engine rpm

At low engine speeds, the WG valve is closed and the When the engine speed increases, the kinetic energy of the
exhaust gases from the exhaust manifold provide little kinetic exhaust gases also increases, therefore the high-pressure
energy to rotate the high-pressure turbine slowly. The turbine speed increases, which in turn causes the WG valve
residual kinetic energy of the exhaust gases flowing out of the to intervene and cause a rise in turbo charging pressure.
high-pressure turbine also rotates the low-pressure turbine Waste Gate valve intervention allows the part of the exhaust
slowly, activating both compressors and thus allowing the gases with greater kinetic energy to bypass the high-pressure
outside air to be compressed and sent through the turbine and go directly to the low-pressure turbine, which is
connection piping to the intercooler with a limited rotating more quickly; also, by activating both compressors
turbocharged pressure. and thus allowing the outside air to be compressed, it is sent
through the connection piping to the intercooler with a
limited turbocharged pressure.

Proportional solenoid valve controlling Actuator

turbocharger actuator
Figure 43
Figure 41
62875
SECTION ON THE ACTUATOR

62876
The solenoid valve modulates the low pressure controlling

the turbocharger actuator, taken from the air circuit of the The actuator diaphragm, connected to the control rod, is
servo brake, according to the information exchanged governed by the low pressure on the top of the actuator.
between the electronic control unit and the sensors: engine The low pressure modulated by the proportional solenoid
speed, throttle pedal position and pressure/temperature valve varies the movement of the diaphragm and, as a result,
fitted on the intake manifold. of the rod governing the turbine's mobile blades.
As a result, the actuator varies the opening of the blades of
the turbocharger that adjust the flow of exhaust gases.

Figure 42
62869
TURBOCHARGING FUNCTIONAL DIAGRAM

1. Variable geometry turbocharger - 2. Pneumatic actuator - 3. Proportional solenoid valve - 4. Air filter -
5. EDC 16 control unit - 6. Servo brake - 7. Vacuum device - 8. High-pressure pump.
Figure 44
137774
DIAGRAM OF TURBOCHARGING FUNCTION

1. Two-stage turbocharger - 2. WG turbocharger actuator - 3. Proportional solenoid valve - 4. Air filter -
5. EDC 17 ECU - 6. Servo brake - 7. High pressure pump - 8. Vacuum pump

EXHAUST GAS RECIRCULATION (EGR) SYSTEM

Figure 45
150711
1. Electronic control unit - 2. Pressure drop pipe - 3. Air from intercooler -

4. Vacuum connector - 5. Water temperature sensor - 6. Engine revs sensor - 7. Flow regulation valve -
8. Air to intercooler. - 9. EBS Valve - 10. Exhaust gas
Operation
The E.D.C. 17 electronic control unit processes the information coming from the: atmospheric pressure sensor, water
temperature sensor, engine rpm sensor, accelerator pedal potentiometer and, in accordance with suitably programmed modes
in its memory, operate the opening of the plate in the E.G.R. valve by means of a PWM signal.
In this way, some of the exhaust gases are sent towards the heat exchanger where they are cooled and directed to the chamber
for the throttle valve assembly to be mixed with the air coming from the intercooler and flow to the intake manifold. If the vehicle
is fitted with a D.P.F. catalytic converter, at the same time, the E.D.C. 17 control unit, adapts the flow rate of the fuel to be injected
into the cylinders depending on the quantity of “recirculated” exhaust gases.
When the engine is running and the recirculation of the gases is not required (regeneration of the particulate filter, starting, engine
cold, idle speed, load request, high altitude), the control unit control signal is cancelled.

E.G.R. Assembly (Exhaust gas recirculation)

Figure 46
Engine coolant
Exhaust gas
150716
The E.G.R. assembly (Exhaust gas recirculation) comprises a heat exchanger (1) and a flow regulation valve (2).
The heat exchanger (1) has the task of lowering the temperature of the exhaust gases which are partly sent to the intake manifold.
This operation has only one aim: to lower the combustion temperature of the mixture. This takes place because the exhaust
gases, totally inert, mix with the mixture and slow down combustion. Lowering this temperature produces a considerable
decrease in NOx (nitrogen oxide) emissions which are harmful to the environment.
The body of the heat exchanger is composed of a tube bundle cooled on the outside by the coolant fluid circulating in the enigne.
Some of the exhaust gases destined for ”recirculation” pass inside the tube bundle and are cooled.
The flow regulation valve (2) is fitted on the end of the heat exchanger. The adjustment of the amount of recirculation exhaust
gases takes place by means of an electrically operated plate valve.
The valve is cooled by the engine coolant coming out of the heat exchanger thereby ensuring it is more efficient and lasts longer.

EGR flow regulator valve Throttle valve assembly description
Figure 47 Figure 48
108399
137777
1. Throttle valve - 2. Electrical actuator -
3. Throttle position signal - 4. Earth - 5. Voltage -
6. PWM signal
Pin - out Designation
Throttle valve assembly (normally open) , located on the inlet
1 Engine - manifold, has the task of regulating the air flow rate arriving
2 Engine + from the intercooler to be mixed with the exhaust gasses
3 Sensor - recirculated by the E.G.R. valve according to a programmed
percentage. The recirculated exhaust gas is mixed with air
4 Sensor signal from the intercooler in a duct machined into the cylinder
5 Sensor + head. The throttle valve is operated by an electric actuator
controlled by a PWM signal from the EDC 17 ECU.

S SERIES EURO V SECTION 3 - ELECTRICAL EQUIPMENT 1
SECTION 3
Electrical equipment
Page
ENGINE CONTROL EDC17 ELECTRONIC
CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . 3
F1C ENGINE HARNESS . . . . . . . . . . . . . . . . . . . . . 6
- Injection cable F1C . . . . . . . . . . . . . . . . . . . . . . 6
SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . 8
- Immobilizer recognition (if present) . . . . . . . . . 8

- Checking fuel temperature . . . . . . . . . . . . . . . . 8
- Checking engine coolant temperature . . . . . . . 8
- Checking quantity of fuel injected . . . . . . . . . . . 8
- Checking idling adjustment . . . . . . . . . . . . . . . . 8
- Fuel cut-off in release phase . . . . . . . . . . . . . . . 8
- Checking cylinder balancing on idling . . . . . . . . 8
- Checking regular engine rotation (anti-sawing) . 8
- Checking smokiness at exhaust on acceleration 8
- Checking exhaust gas recirculation . . . . . . . . . . 8
- Checking top speed limit . . . . . . . . . . . . . . . . . 8
- Checking regular rotation on acceleration . . . . 8
- Checking glow plug control unit . . . . . . . . . . . . 8

- Checking activation of air-conditioning system . 8
- Checking fuel pump . . . . . . . . . . . . . . . . . . . . . 8
- Checking diesel warming . . . . . . . . . . . . . . . . . . 9
- Checking cylinder position . . . . . . . . . . . . . . . . 9
- Checking pilot and main injection timing . . . . . 9
- Checking injection pressure closed cycle . . . . . 9
- Fuel supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2 SECTION 3 - ELECTRICAL EQUIPMENT S SERIES EURO V
Page
- Correcting flow rate according to water

temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Correcting flow rate to avoid noise, smoke or
overloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- De-rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Injection timing electronic test . . . . . . . . . . . . . 9
- Speed governor . . . . . . . . . . . . . . . . . . . . . . . . 9
- Engine starting . . . . . . . . . . . . . . . . . . . . . . . . . . 9
- Cold starting . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Warm starting . . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Run up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
- After run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Cut-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Cylinder balancing . . . . . . . . . . . . . . . . . . . . . . . 10
- Synchronization search . . . . . . . . . . . . . . . . . . . 10
- Driving shaft and camshaft unit . . . . . . . . . . . . . 11
- Camshaft revolution sensor . . . . . . . . . . . . . . . 12
- Driving shaft revolution sensor . . . . . . . . . . . . . 13
- Pressure regulator . . . . . . . . . . . . . . . . . . . . . . . 15
- Fuel pressure sensor (Rail) . . . . . . . . . . . . . . . . 16
- Electro-Injectors . . . . . . . . . . . . . . . . . . . . . . . . 17
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Airflow gauge . . . . . . . . . . . . . . . . . . . . . . . . . . 18
- Atmospheric pressure sensor . . . . . . . . . . . . . . 19
- Engine coolant temperature sensor . . . . . . . . . 19
- Preheat plug electronic centre . . . . . . . . . . . . . 20
- Preheat plugs . . . . . . . . . . . . . . . . . . . . . . . . . . 20
- BOSCH Alternator 12V . . . . . . . . . . . . . . . . . . 21
- Instructions for use . . . . . . . . . . . . . . . . . . . . . . 21
- Functional characteristics . . . . . . . . . . . . . . . . . 21
- Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . 22

ENGINE CONTROL EDC17 ELECTRONIC CONTROL UNIT
Figure 1
128680
The control unit is a flash type EEPROM, in other words it can be reprogrammed from the outside without intervening on the
hardware; it processes the signals coming from the sensors by applying the software algorithms and controls the actuators, in
particular the injectors and the pressure regulator. It has a built-in absolute pressure sensor to further improve the management
of the injection system.
It is mounted on the left side of the engine compartment and is linked to the vehicle's wiring by means of two connectors:
- CONNECTOR A, 60-pin for the components in the engine;
- CONNECTOR K, 94-pin for the components on the vehicle.
The engine ECU calculates the injection modes by processing the following parameters:
- engine speed;
- accelerator pedal position;
- air flow rate introduced;
- coolant temperature;
- battery voltage;
- fuel pressure.
Up to 2800 rpm pre-injection is also carried out in order to reduce the typical noise of direct diesel injection. Pre-injection and
main injection advance angles vary according to the engine operating conditions and temperature at that moment.

ECU connection to the injection cable on engine side (housing A)

Figure 2
85708
85710
Pin Function
1 Connection of solenoid valve 21 (injector on cylinder 3)
3 ---
4 ---
5 ---
6 Turbocharger pressure and temperature sensor
7 Speed sensor on timing system
8 Connection to rail pressure sensor
9 ---
10 ---
11 VGT Position sensor
14 Engine speed sensor connection
15 Rail pressure control solenoid valve
19 VGT Throttle valve actuator
20 ---
21 ---
22 Speed sensor on timing system
23 Engine coolant temperature sensor
24 ---
26 ---
27 EGR valve position sensor
28 ---
30 Fuel dosing valve on high pressure pump
34 Actuator brake engine
35 EGR throttle valve actuator

Pin Function
37 ---
38 Debimeter
39 Rail pressure sensor
40 ---
41 ---
42 Debimeter
43 Rail pressure sensor
44 Debimeter
45 Rail pressure control solenoid valve
49 ---
50 EGR throttle valve actuator
51 ---
52 ---
54 Engine cable disconnection
55 Engine coolant temperature sensor
56 ---
57 Engine cable disconnection
58 ---
59 ---
60 Fuel dosing valve on high pressure pump
F Power housings
f Signal housings
- The Pins not shown are not used

F1C ENGINE HARNESS

Injection cable F1C
Figure 3
171589

Figure 4
150708

SYSTEM OPERATION Checking regular engine rotation (anti-sawing)

Self-diagnosis — BLINK CODE It ensures regular engine rotation at a constant rate while
The control unit self-diagnosis system checks the signals from increasing revs.
the sensors, comparing them with the admitted limits (see The control unit processes the signals received from the
relative heading): sensors and determines the amount of fuel to be injected via:
- the pressure regulator;
Immobilizer recognition (if present) - the electro-injector opening time.
When the control unit receives the signal of the key on
”MAR” it communicates with the immobilizer control unit to Checking smokiness at exhaust on
enable starting. acceleration
With heavy acceleration, on the basis of the signals received
Checking fuel temperature from the air introduction meter and engine speed sensor, the
control unit determines the optimum amount of fuel to
With the fuel temperature greater than 75C, detected by inject:
the sensor on the fuel filter, the control unit operates the
pressure regulator to decrease the line pressure (injection - it operates the pressure regulator;
times are not changed). If the temperature exceeds 90C, the - it varies the electro-injector injection time.
power is reduced to 60%.
Checking exhaust gas recirculation
Checking engine coolant temperature Depending on the engine load and the signal from the
The control unit, depending on the temperature: accelerator pedal sensor, the control unit limits the amount
of air taken in, actuating partial suction of the exhaust gases.
- of the engine coolant, turbocharging air and fuel,
operates the electromagnetic fan (Baruffaldi) and Checking top speed limit
switches on the coolant temperature warning light.
Depending on the number of revs, the control unit actuates
Checking quantity of fuel injected two action strategies:
According to the signals from the sensors and the mapped - at 4250 rpm it cuts off the fuel, decreasing the
values, the control unit: electro-injector opening time;
- operates the pressure regulator; - over 5000 rpm it deactivates the electro-injectors.
- varies the ”pilot” injection time to 2200 rpm; Checking regular rotation on acceleration
- varies the ”main” injection time.
Regular progression is assured in all conditions by the control
Checking idling adjustment of the pressure regulator and the electro-injector opening
time.
The control unit processes the signals from the various
sensors and regulates the amount of fuel injected:
Checking glow plug control unit
- it operates the pressure regulator;
The injection control unit, in the phase of:
- it varies the injection times of the electro-injectors.
Within certain thresholds the speed takes account of the - starting
battery voltage. - after-starting
times operation of the glow plugs according to the engine
Fuel cut-off in release phase temperature.
In the phase of releasing the throttle pedal the control unit
actuates the following logic elements: Checking activation of air-conditioning system
- it cuts off supply to the electro-injectors; The control unit operates the air-conditioning compressor:
- it partially reactivates supply to the electro-injectors - switching it on/off when the relative switch is pressed;
before reaching idling speed; - momentarily turning it off (approximately 6 sec.) if the
- it operates the fuel pressure regulator. engine coolant reaches the set temperature.
Checking cylinder balancing on idling Checking fuel pump

According to the signals received from the sensors, the Irrespective of the speed, the control unit:
control unit controls the regularity of the torque at idling - supplies the auxiliary fuel pump with the key on MAR;
speed: - cuts off auxiliary pump supply if the engine is not started
- it varies the amount of fuel injected into the single up within a few seconds.
electro-injectors (injection time).

Checking diesel warming Correcting flow rate to avoid noise, smoke or

It times operation of diesel warming in relation to ambient
overloading
temperature. The behaviour that could lead to this kind of trouble is well
known.
Checking cylinder position The designer has therefore included special instructions in
During each turn of the engine, the control unit recognizes the control unit to avoid it.
which cylinder is in the power stroke and operates the
injection sequence for the appropriate cylinder. De-rating
In the event of the engine overheating, injection is modified,
Checking pilot and main injection timing decreasing the delivery to a varying degree, in proportion to
According to the signals from the various sensors, including the temperature reached by the coolant.
the absolute pressure sensor built into the control unit, the
control unit determines the optimum point of injection Injection timing electronic test
according to internal mapping.
The advance (start of delivery, expressed in degrees) may be
different from one injection to the next, also differentiated
Checking injection pressure closed cycle from one cylinder to another. It is calculated, similarly to the
Depending on the engine load, determined by processing the delivery, in relation to the engine load (accelerator position,
signals from the various sensors, the control unit operates the engine speed and air introduced).
regulator to obtain optimum line pressure. The advance is appropriately corrected:
- in phases of acceleration;
Fuel supply - according to the water temperature.
The fuel supply is calculated in relation to: And also to obtain:
- accelerator pedal position - lower emissions, noise and overloading;
- engine speed - better vehicle acceleration.
- quantity of air introduced. An extremely high advance is set on starting, depending on
The outcome may be corrected in relation to: the water temperature.
- the water temperature. Feedback from the start of delivery is supplied by the change
in impedance of the injector solenoid valve.
Or to avoid:
- noise Speed governor
- smoke The electronic speed governor has both features of
- overloading governors:
- overheating
- idling and top speed
- turbine over-revving.
- all speeds
The delivery can be modified in the case of:
It is stable in ranges where conventional, mechanical
- action of external devices (ABS), ABD, EDB governors are imprecise.
- serious trouble decreasing the load or stopping the
engine. Engine starting
After determining the mass of air introduced by measuring During the first few turns of the engine, the timing and
its volume and temperature, the control unit calculates the cylinder no. 1 recognition signals (flywheel sensor and
corresponding mass of fuel to inject into the relevant cylinder camshaft sensor) are synchronized.
(mg per delivery) also taking into account the temperature The accelerator pedal signal is ignored on starting. Starting
of the diesel. delivery is set only according to water temperature, by a
The mass of fuel calculated in this way is first converted into special map.
volume (mm3 per delivery) and then into degrees of throw, When the control unit detects such speed and acceleration
or duration of injection. of the flywheel as to be able to consider the engine started
up and no longer driven by the starter motor, it re-enables
Correcting flow rate according to water the accelerator pedal.
temperature
A cold engine meets with greater resistance during
operation: friction is high, the oil is still very viscous, and the
various clearances are not yet optimized.
In addition, the injected fuel tends to condense on the metal
surfaces that are still cold.
The fuel supply for a cold engine is therefore greater than for
a warm one.

Cold starting Cut-off

If even just one of the three temperature sensors (water, air This function cuts off fuel delivery when the vehicle is
or diesel) records a temperature lower than 10C, pre-post decelerating (accelerator pedal released).
heating is activated.
When the key makes contact the pre-heating indicator light Cylinder balancing
comes on and stays on for a length of time that varies in
relation to the temperature (while the glow plugs in the Individual cylinder balancing contributes to increasing
cylinder head heat the air), then flashes. It is now possible to comfort and handling.
start up the engine. This function permits individual, customized control over the
When the motor is running this indicator light goes out, while delivery of fuel and the start of delivery for each cylinder, even
the glow plugs continue to be powered for a certain length differently from one cylinder to another, to compensate for
of time (variable) for post-heating. the hydraulic tolerances of the injector.
If, with the indicator light flashing, the engine is not started up The differences in flow (delivery specifications) between the
within 20-25 seconds (inattention time), the operation is various injectors cannot be evaluated directly by the control
cancelled so as not to run down the batteries pointlessly. unit. This information is supplied by Modus reading the bar
The pre-heating curve is also variable in relation to the code of each injector at the time of assembly.
battery voltage.
Synchronization search
Warm starting
If there is no signal from the camshaft sensor, the control unit
If the reference temperatures all exceed 10C, when the key is anyhow able to recognize the cylinders into which the fuel
makes contact the indicator light comes on for approximately is to be injected.
2 sec., for a short test, and then goes out. It is now possible If this occurs when the engine is already running, the
to start up the engine. combustion sequence has already been acquired, so the
control unit continues with the sequence on which it has
Run up already been synchronized.
When the key makes contact, the control unit transfers the If this occurs when the machine is at a standstill, the control
information stored in memory when the engine was last unit energizes a single solenoid valve. Within at most 2 turns
stopped into the main memory (see After Run) and makes of the crankshaft, injection will take place in that cylinder, so
a diagnosis of the system. the control unit just needs to get synchronized on the firing
sequence and to start up the engine.
After run
Whenever the engine is switched off with the key, the
control unit stays powered for a few seconds by the main
relay.
This makes it possible for the microprocessor to transfer
some data from the main memory (volatile) to a non-volatile
memory, which can be erased and written over (EEPROM),
so as to make it available at the next start up (see Run Up).
These data basically consist of:
- various settings (engine idling adjustment, etc.);
- settings of some components;
- fault memory.
The process lasts a few seconds, typically from 2 to 7
(depending on the amount of data to save), after which the
ECU sends a command to the main relay and makes it
disconnect from the battery.
NOTE It is extremely important for this procedure not to

be broken off, for example by switching off the
engine with the battery cut-out, or by
disconnecting the battery cut-out before 10
seconds have passed since switching off the engine.
If this happens, the functioning of the system is
ensured, but repeated interruptions may damage
the control unit.

Driving shaft and camshaft unit

Figure 5
88056
1. R.p.m. sensor - 2. Phonic wheel on drive shaft - 3. Timing sensor - 4. Phonic wheel on camshaft.

Camshaft revolution sensor

A semiconductor layer, immersed in a magnetic field and through which current flows, generates a potential difference (called
Hall voltage) at its ends.
If current intensity remains constant, the generated voltage depends only on the magnetic field strength: periodical variation of
field strength is enough to obtain a modulated electric signal.
The smooth portion of the phonic wheel (distributing shaft pulley) covers, while moving, the sensor, thus blocking the magnetic
field with resulting low output signal.
On the contrary, the sensor generates a high signal next to the openings and when a magnetic field is available.
Phase sensor signals are acquired, and the engine position is recognized according to the sequence of the phonic wheel notches.
The mounting function makes it possible to identify signal errors and interferences (if any).
The resulting signal is supplied to the processor that controls the injection system.
The sensor is connected to the central unit at pins A 7/22.
Figure 6
150689
1. Phonic wheel on camshaft - 2. Identification slots - 3. Sensor.

Driving shaft revolution sensor Figure 8

A phonic wheel is fitted on the drive shaft. As the sensor
detects existing teeth passing, it provides the central unit with
the signal that is necessary to determine engine r.p.m.'s.
The variation of the signal generated by the lack of some teeth
(synchronisation gap) occurring at each drive shaft turn is the
reference signal which enables the central unit to detect the
lead of the pair of pistons 1-4 with respect to PMS.
This signal is also used by the control unit to detect the engine
rotation speed, the duration of injection and to control the rev
counter.
This is an inductive sensor.
The sensor is connected to the pins No 36, 53 and 14 of the
connector A in the electronic control unit.
87792
PHONIC WHEEL MOUNTING
Figure 7
Figure 9
0003319t
87793
TECHNICAL VIEW OF THE SOUND WHEEL AND 1. Phonic wheel.

SENSOR
1. Sound wheel - 2. Sensor.

Figure 10
RPM SENSOR AND CONNECTION CABLE
Figure 11
SENSOR CONNECTOR AND WIRING DIRAGRAM
Figure 12
85712
TIMING SENSOR
1. Earth - 2. Signal output - 3. Power supply positive.

Pressure regulator When solenoid (1) is not activated, the magnetic core is
moved to its rest position by preload spring (6).
It is mounted on the low pressure circuit of pump CP4.1.
In these conditions, cylinder (3) is in a position to offer
When the engine control centre pilots the pressure
maximum fuel passage cross-section.
regulator via the PWM signal, solenoid (1) is activated, which
in its turn generates movement of magnetic core (2). Drive solenoid valve is connected to pins 19 and 49 of
connector A of central unit EDC 17.
Core movement causes cylinder (3) axial displacement by
fuel delivery partialization.
Figure 13
003386t
4
1 1
2 2
3
5
3 6
4
6
75574 75575
1. Solenoid - 2. Magnetic core - 3. Cylinder - 4. Fuel input - 5. Fuel output - 6. Preloiad spring - 7. Connector.

Fuel pressure sensor (Rail)

Fitted to a rail end, it measures fuel pressure present to the purpose of determining existing fuel pressure. Pressure value is used
to control pressure and determine injection electric control duration.
It is connected to the central unit at pins A 8, 43, 39. It is fed at 5 V.
The hydraulic accumulator is mounted in the cylinder head on the side opposite aspiration.
By its volume, it damps fuel pressure oscillations owing to:
- high-pressure pump operation
- electro injector opening.
On hydraulic accumulator there is located the fuel pressure sensor.
Figure 14
88418
1. Rail - 2. Pressure sensor.
Figure 15
VOLTAGE
4.8V
4.5V
0.5V
0.2V Minimum
0 bar PRESSURE 1500 bar
PRESSURE LIMITER OPERATING GRAPH

Electro-Injectors Figure 17
Figure 16
126025 150723
The piezoelectric injectors are located on the engine head 1. Electrical connection - 2. Connection for fuel return
and receive the fuel under pressure from the rail. They flow - 3. Encapsuled piezoelectric actuator -
operate both the high pressure fuel supply and recirculation 4. Control valve - 5. Nozzle - 6. Hydraulic amplifier -
under atmospheric pressure of the excess fuel that has not 7. High pressure line
been injected.
The following are installed on the injector head : Operation
- a central access pipe for fuel under high pressure;
When the piezoelectric actuator (3) is reached by an
- a lateral pipe for the recirculation of fuel under low electrical load, commanded by the control unit, it increases
pressure with built-in throttle; its length. The movement, amplified by the hydraulic
- the site for the electric connector that receives amplifier (6), act mechanically on the control valve (4) and
commands from the control unit. it allows therefore the injection of the fuel present in the high
pressure duct (7). While stopping the electrical load, the
The electronic control unit controls the piezoelectric actuator reacts elastically and again assumes its initial
actuator inside the injector. length.The springs add their contribution, winning the
The piezoelectric actuator, due to reduced switching times, pressures that act in balancing on the whole surface of the
enables a very fast reaction to the commands sent from the components.
engine control unit, making injection capacity more flexible The fuel in excess is than recirculated in the fuel circuit
and increasing the number of injections per cycle. through the duct (2).
The injectors are connected individually to the control unit

at the following pins:
- A31 / A46 cylinder 1 injector

Airflow gauge Figure 18

This component incorporates a temperature sensor and a
pressure sensor. Course of sensor in relation to the pressure:
It is fitted on the engine intake manifold and measures the

maximum flow rate of the intake air which is used to
accurately calculate the amount of fuel to be injected at each
cycle.
It is connected to the central unit on connector ”A”.
Pin Pin
Sensor ECU Function
1 A6 ground
2 A12 temperature signal
3 A25 5 V power supply
4 A13 0  5V pressure signal
Course of sensor in relation to the temperature
Temperature Resistance
- 40 C 45.30 kOhm 150731
- 20 C 15.45 kOhm
AIR FLOW METER
0 C 5.89 kOhm
20 C 2.50 kOhm Figure 19
40 C 1.17 kOhm
60 C 0.59 kOhm
80 C 0.32 kOhm
100 C 0.18 kOhm
120 C 0.11 kOhm
Course of sensor in relation to the pressure:
See graph opposite.
AIR FLOW METER CONNECTION
Figure 20
150730
AIR FLOW METER OPERATING GRAPH

Atmospheric pressure sensor Figure 22

This is integrated inside the control unit.
It measures the atmospheric pressure to correct the flow rate
in relation to the altitude.
Engine coolant temperature sensor

This is an NTC sensor located on the thermostat box.
It detects the temperature of the coolant fluid to give the
control unit information about the engine temperature
conditions.
It is connected to pins 23 and 55 of connector A of central unit
EDC 17.
Course of the sensor in relation to the temperature: TECHNICAL VIEW OF ENGINE COOLANT
TEMPERATURE SENSOR
Temperature Resistance
Figure 23
- 40C 48.30 kOhm
- 20C 15.46 kOhm
0C 5.89 kOhm
20C 2.50 kOhm
40C 1.17 kOhm
60C 0.59 kOhm
80C 0.32 kOhm
100C 0.19 kOhm
NTC
120C 0.11 kOhm
WIRING DIAGRAM
Figure 24
Figure 21
102244
LOCATION OF F1C ENGINE COOLANT

TEMPERATURE SENSOR
1. EDC - 2. Signal instrument panel signal
COURSE OF SENSOR RESISTANCE IN RELATION TO

TEMPERATURE

Preheat plug electronic centre Figure 25

EDC central unit effects the timing of the functioning of glow
plugs pre-heating central unit depending on engine
temperature, which, in turn, activates the glow plugs.
The preheat centre contains an “intelligent” remote control
switch that sends a feed-back to the control centre for
information on any preheat centre defect or plug earth shirt
circuit.
Preheat centre pin-out

31 - Mass
86 - Start switch (+15)
ST - EDC electronic centre
DI - EDC electronic centre
30 - Battery positive (+30)
G1 - Preheat plugs
G2 - Preheat plugs
G3 - Preheat plugs
G4 - Preheat plugs 003332t
PREHEAT CENTRE
Figure 26
Preheat plugs
CONTROL VALUES
With constant di 11V power supply:
- maximum current absorbed 18 A
- in 5” 11  1,5 A
- in 30” 6  0.9 A
- temperature after 7” 850C
- torque 8-10 Nm 003331t
ELECTRICAL DIAGRAM
Figure 27
75579
PREHEAT PLUS
BOSCH Alternator 12V Figure 29

Figure 28
166164
BOSCH Alternator 12V

Figure 30
166163
Instructions for use

Can be used with batteries of all capacities
The alternatorcanbe usedwithoutconnecting to a battery
Never connect with inverted polarities
Never use on vehicles transporting hazardous goods
Functional characteristics
Nominal voltage 12V
166163
Nominal current output @ 25 °C
117 A at 6,000 rpm
Instructions for use
55 A at 1,800 rpm
Can be used with batteries of all capacities
Control side rotation direction clockwise The alternatorcanbe usedwithoutconnecting to a battery
Max. speed 13,000 rpm Never connect with inverted polarities
Never use on vehicles transporting hazardous goods
Current consumption in stand-by mode
0.3 mA
Functional characteristics
Nominal voltage 12V
Nominal current output @ 25 °C
150 A at 6,000 rpm
70 A at 1,800 rpm
Control side rotation direction clockwise
Max. speed 13,000 rpm
Current consumption in stand-by mode
0.3 mA

Figure 31 Figure 33
166165
166166
Starter motor
Manufa Electric Nominal

Motor type cturer installation output
F1CE3481A*A001
F1CE3481A*A002 2,5 kW
F1CE3481A*A002 BOSCH 12 V
F1CE3481A*A004
3 kW
F1CE3481A*A005
Figure 32
166165
The operating wiring diagram of the starter motor is as

follows:

S SERIES EURO V SECTION 4- MAINTENANCE SCHEDULE 1
SECTION 4
Maintenance schedule
Page
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Inspection and/or maintenance interventions . . 3
- Timed extra plan operations (to be carried
out possibly in combination with maintenance
service) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MAINTENANCE INTERVENTIONS . . . . . . . . . . . 5
- Change the engine oil . . . . . . . . . . . . . . . . . . . . 5
- Replace the engine oil filter . . . . . . . . . . . . . . . . 5
- Replace the fuel filter . . . . . . . . . . . . . . . . . . . . 6
- Check the auxiliary drive belts . . . . . . . . . . . . . 6
- Replace the water pump and alternator belts . . 7
- Replace air conditioner compressor belts . . . . . 7
- Clean the rear axle oil breather . . . . . . . . . . . . 8
- Change the rear axle differential oil . . . . . . . . . 8
- Replace the alternator movable belt tensioner . 8
- Replace the pre-heating glow plugs . . . . . . . . . 9

2 SECTION 4- MAINTENANCE SCHEDULE S SERIES EURO V

MAINTENANCE
At each oil replacement it is necessary to reset the counter of the particulate filter regeneration (DPF).
Such operation shall be carried out by means of diagnosis equipment, selecting "OIL REPLACEMENT" in the
"COMPONENTSREPLACEMENT" menu of the "SPECIFIC FUNCTIONS" area of the motor control unit EDC 17
 Average speed calculated at 50 km/h.

 If the number of kilometers travelled over the year is very low, or in any case under 40,000 km/year, the engineoil
and filter must be changed every 12 months.
 The engine oil and filter may require replacement prior to the scheduled date if the vehicle is used
predominantlyin cities where frequent particulate filter regeneration (on the vehicles equipped with such
component) may berequired. In this instance, the vehicle's computer will advise of the need to carry out this
unscheduled operation.
 If less than 40,000 km are covered per year, the rear axle oil should be changed at least every 2 years.
 If less than 40,000 km are covered per year, the gearbox oil should be changed at least every 3 years.
Inspection and/or maintenance interventions

Type of intervention Regular intervals
LUBRICATION, CHANGING OIL, FILTERS AND CHECKING FLUIDS
Change the engine oil Every 40,000 km/800 hours
Replace the engine oil filter Every 40,000 km/800 hours
Replace the fuel filter * Every 40,000 km/800 hours
ENGINE COMPARTMENT CHECKS
Check the auxiliary drive belts condition Every40,000 km/800 hours
Replace the water pump and alternator (1) belts Every120,000 km/2,400 hours
Replace air conditioner compressor belts (1) Every 120,000 km/2,400 hours
UNDER VEHICLE CHECKS
Clean the rear axle oil breather Every 120,000 km/2,400 hours
DIAGNOSTICS
Reset the particulate filter (DPF) regeneration with diagnostic Every 40,000 km/800 hours
tools
Check the engine EDC system with PT-BOX Every 120,000 km/2,400 hours
* If the warning light indicating that the filter is clogged lights up on the instrument panel, the filter should be replaced
beforereplacement is due.
(1) Replace every 60,000 km under heavy duty use (dust and/or heat).
(2) Vehicle and equipment handling activities in workshop.

Timed extra plan operations (to be carried out possibly in combination with maintenance service)
Type of intervention Regular intervals

REPLACEMENT
Change the rear axle differential oil (1) Every 80,000 km/1,600 hours
Replace the alternator movable belt tensioner Every 240,000 km or, in any case, every 5
years (or 4,800 hours)
Replace the pre-heating glow plugs Every 240,000 km or, in any case, every 5
years (or 4,800 hours)
Replace the timing system gears with the chains removed Every 400,000 km/8,000 hours)
Replace the exhaust gas catalytic converter Every 400,000 km/8,000 hours)
Replace the engine breather filter Every 400,000 km/8,000 hours)
Replace the primary and secondary timing system drive chains, in addition to Every 400,000 km/8,000 hours)
timing system drive chain tensioners
ORDINARY MAINTENANCE
Check the coolant density Each year prior to the winter season
Replace the supplementary heater fuel filter Each year prior to the winter season
EXTRAORDINARY MAINTENANCE
Replace the cartridge and clean the air filter housing (2) Every three years - even if there is no
indication of the air filter clogging
Change engine coolant (3) Every three years - even if there is no
indication of the air filter clogging
(1) If less than 40,000 km are covered per year, the rear axle oil should be changed at least every 2 years.
(2) Early clogging of the air filter is generally due to adverse environmental conditions. For this reason the filter must be replaced
when the sensor indicates such, regardless of when replacement is due. When specific indications are not given, the part
should be replaced according to schedule.
(3) Paraflu11 must be diluted 50% with water, whereas Paraflu FE is already diluted 50% with water.

MAINTENANCE INTERVENTIONS Whereas you replace the lubrication oil, it is necessary to

replace the filter.
NOTE After checking or changing parts, perform
functional testing of the vehicle. Replace the engine oil filter
Removal
Figure 1
Change the engine oil
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.
We recommend to carry out the oil drainage when the

motor is hot.
171597
- Place a proper container for the oil collecting under the
pan connected with the drain plug. Use tool 99360076 (1) to remove the oil filter (2) from the
- Unscrew the plug and then take out the control dipsick heat exchanger (3).
and the inserting plug to ease the downflow of the
lubrication oil.
Refitting
The oil motor is very pollutant and harmful.
In case of contact with the skin, wash with much NOTE Before reinstalling the new cartridges, moisten the
water and detergent. gasket with engine oil.
Protect properly skin and eyes: operate according to
safety rules.
Dispose of the residual properly following the rules.
Figure 2
- After the complete drainage, screw the plug and carry
out the clean oil filling.
Use only the recommended oil or oil having the re

! quested 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.
171597
- Check the level through the dipsick until when the filling Lubricate the seal ring of the oil filter (2) with engine oil and
is next to the maximum level notch indicated on the fasten it on the heat exchanger (3). Use tool 99360076 (1)
dipsick. to tighten the oil filter to the prescribed torque.

Replace the fuel filter Type UFI Filters

Type Filtrauto Figure 4
Figure 3
109063
Unscrew fuel filter housing (1) and replace the cartridge, then
screw the housing (1) and tighten it to 35±5 Nm.
112722
Disconnect the chassis cable connection (6) from the

electronic unit connection (7). Free the connection (7) from
the support bracket (8). Remove the clip (9), remove the
electronic unit (4) and place it carefully so that it does not get
damaged or dirty. Loosen the screw (3) and pull out the fuel
filter (1) upwards from the support (2). Install the new filter
(1) so that the notch (") is aligned with the joining point of
the support ends (2) and tighten the screw (3) to the
specified torque. Check the seal rings (5) and replace them
if damaged. Install the electronic unit (4) in the fuel filter (1)
until it stops, so that the clip (9) inserts properly in the annular
grooves of the electronic unit (4). Connect the connection
(7) to the bracket (8) and the connector (6) to the
connection.
Check the auxiliary drive belts
Visually check that the belts are not worn or

deteriorated, otherwise replace them as
described in the relative section.

Replace the water pump and alternator belts Replace air conditioner compressor belts
Removal Removal
Figure 5 Figure 6
88330
102201
Disassemble the compressor drive belt, as described in the Position the vehicle over the service pit or on the lift. Remove
relevant chapter. the middle soundproofing guard from under the vehicle.
Using the specific wrench on the automatic belt tensioner Remove the flexible belt (4) from the pulleys (1 and 5).
(2), reduce the tension of the belt (1) and remove it.
Refitting Refitting
Mount the drive belt (1) taking care to position its Fit the 99360186 drift (2) to pulley (1) with the
ribs correctly in the respective races of the pulleys. elastic belt (4), and position the belt on roller (3)
Release the automatic tightener (2). Rotate and pulley (5), making sure to fit the ribs of the belt
crankshaft by one revolution to settle the belt. in the grooves in the pulleys (1 and 5).
Mount the compressor drive belt, and adjust the tension as Turn the crankshaft anticlockwise (") until the belt (4) is
described in the relevant chapter. completely fitted onto the pulley (1).

Clean the rear axle oil breather Screw the cap. Unscrew the cap (2) and pour in the required
grade and quantity of lubricating oil (see fluids table in the
GENERAL chapter). Remove the oil vapour breather (1) and
Figure 7 clean it thoroughly.
Figure 9
62882
Check that the air breather (1) is not clogged; remove and
clean it thoroughly if clogged.
33123
NOTE For oil breather cleaning operations, refer to rear

axle 450517/2, and for 450511 NDA R.S. - NDA NOTE The oil change described refers to the 450517/2
R.G. axles, refer to Figure 9. rear axle.
Lubrication oil should be drained when it is warm.

Change the rear axle differential oil Place a special container under the plug (2). Take out the plug
and drain off the oil.
Screw the plug (2) back on. Unscrew the cap (1) and pour
in the required grade and quantity of lubricating oil (see fluids
NOTE If less than 40,000 km are covered per year, the rear table in the GENERAL chapter).
axle oil should be changed at least every 2 years. Remove the oil vapour vent and clean it thoroughly. (Shown
in Figure 8).
Figure 8 Replace the alternator movable belt tensioner

Removal
Figure 10
109065
NOTE The oil change shown refers to the NDA R.S. -

NDA R.G. - 450511 rear axles.
135029
Lubrication oil should be drained when it is warm. Place a Using (") the specific wrench on the automatic belt tensioner
container under the cap near the arrow; remove the cap and (2), slacken the tension of the belt (1) and remove it.
drain the oil.

Figure 11 Replace the pre-heating glow plugs

Removal
Figure 14
135030
Remove the screw (2) and remove the automatic belt

tensioner (1).
137157
Refitting Remove the throttle valve assembly, as described in the

relevant chapter. Disconnect electrical connections (1) from
Figure 12 the preheating glow plugs (2).
Figure 15
135039
Fit the automatic chain tensioner (1) insert in the screw (2)
and tighten to the specified torque.
137158
Figure 13 Use socket SP 2275 (1) to remove the preheating glow plugs.
Refitting
To refit, carry out the removal operations in reverse
order, observing the following instructions:
- replace gaskets with new parts;
- tighten the nuts and screws to the specified
torque.
135029
Using () a wrench on the automatic belt tensioner (2), fit

the belt (1), making sure that the ribs on the belt fit properly
into the grooves on the pulley.


S SERIES EURO V SECTION 5 - DIAGNOSTICS 1
SECTION 5
Diagnostics
Page
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
- DTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
DIAGNOSIS PER SYMPTOMS . . . . . . . . . . . . . . . . 236

2 SECTION 5 - DIAGNOSTICS S SERIES EURO V

PREFACE Every time there is a breakdown claim and this breakdown is

actually detected, it is necessary to proceed inquiring the
A successful troubleshooting is carried out with the electronic unit in one of the ways indicated and then proceed
competence acquired by years of experience and attending with the diagnostic research making trials and tests in order to
training courses. have a picture of the working conditions and identify the root
causes of the anomaly.
When the user complains for bad efficiency or working
anomaly, his indications must be kept into proper In case the electronic device is not providing any indication, it
consideration using them to acquire any useful information to will be necessary to proceed relying on the experience,
focus the intervention. 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.

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

PT-BOX INSTRUCTIONS Select your user configuration type and then follow the
relevant information.
Hardware installation
1. PT-PLUS configuration
- PC Panasonic user
This Sw may cause engine start-up. Be extremely - PT-BOX module
! careful. - PT-DIAGNOSIS sw
The user is responsible for the correct use of the 2. PT-DIAGNOSIS configuration
PT-DIAGNOSIS software so as not to any cause
injury to people or damage to items. - user with own PC
- PT-BOX module
The user is also responsible for complying with all - PT-DIAGNOSIS sw
the rules relating to security for activities on the
industrial applications (engine, pump, generating The PT-BOX module (Electronic Communication Interface)
set) carried out in the workshop.
Carefully read the user manual before using the PT-BOX is an interface module allowing the communication
diagnostic tool and follow the instructions displayed between the engine ecu's and the PC.
on the screen. - 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;
- all instruments ensuring the security must be applied as - Power supply: 6-32V;
indicated in the application; - Connection interfaces: USB and RS232 standard
- ensure that the PT-BOX module is connected to the Bluetooth optional;
diagnostic socket of the engine on which work is to be - Interface for engine electronic systems: 9 KL ISO 9141
carried out; lines - 2 channels CAN Bus 2.0B - 3 digital outputs - 3I/O
- in case of emergency, disconnect the PT-BOX module PWM.
from the engine or disconnect the USB cable; The led indicators on the front view allow to check the
- ensure that while using the software, there is nobody communication lines activity with the engine and with the PC
near the engine/vehicle you are working on; to which the instrument is connected.
- if it is necessary for more than one person to be working
on or near the engine/vehicle, they are all responsible for Figure 2
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). 156133
1. Led indicators to display the activity of the

The diagnosis system consists of: communication lines K/L. - 2. The upper led display the
ECU's communication activity. - 3. The lower led indicators
- a PC (Panasonic / your PC + Microsoft Windows 2000 display the CAN lines activity. - 4. The three upper led
or Windows XP Professional); indicators show the activity of the K/L communication lines.
- 5. The lower led indicator (fault) shows the presence of
- an instrument used as interface between engines/vehicles errors on the K/L lines. - 6. The upper led indicator shows
and PC (PT-BOX tester); that the PT-BOX is power-supplied. - 7. When blinking the
- a SW program (PT-DIAGNOSIS) to process data. lower led indicator (run) shows that the PT-BOX module is
correctly working. - 8. Led indicators to display the USB
By combinating the above indicated components 2 different ports (upper led). - 9. Led indicators to display the serial
configuration are possible. ports (lower led).

Connect the pt-box module Pt-box - engine/vehicle connection

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 The module is power-supplied by the diagnostic
cable; for this reason to work correctly it must be
Figure 4 connected to the engine.
System requirements
Minimum
- Processor: 300 MHz Pentium-II CPU;
- Hard disk space: 3 GB available;
- Ram: 256 MB;
156136
- Display: 800 x 600 video adapter and monitor;
Connector for the connection of the engine communication
cable. - Internet connection only needed for rss and pt-diagnosis
software update (eaus): modem;
- External ports: USB connector;
Pt-box - pc connection
- External reader: DVD-ROM reader;
Figure 5
- 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.
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
156137 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 - External ports: 2 USB 2.0 connectors, Bluetooth;
PT-BOX module (remove the holding screws from the
PT-BOX module, where present); - External reader: DVD-ROM reader;
- connect the USB cable to the PC; - Os: Microsoft WindowsTM XP Professional - Service Pack
3 (login with administrator privileges);
- turn the PC on.
- Browser: Internet Explorer 6.0.

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 The activation code received will be requested the

! first time you run the PT-DIAGNOSIS software.
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.
Registration form (OEM user)
For this reason:
- Check that the registration card has been delivered The Registration allows you to download the EVCA SYNC
together with the kit. WEB application which allows you to obtain the activation
code:
- Select www.eltrac.it/ivecomotors/default.asp.
- From the starting page, select the language.
- Select pt users registration.
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.

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 and then
EVCASyncWeb15-09-10 (Rel1.2.6).
3. Run setup.exe and continue with the installation of the
guided application.
NOTE 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 4. At the end of the installation, the icon of the
(registration data and number of registered instrument). EVCASyncWeb application is displayed on the desktop
of the PC.
7. Select the link to download and then select the save key,
to save the application on the PC.

Running the EVCA SYNC WEB (OEM user) application
3. Enter the PT-BOX serial number of and the Customer

PIN.
4. To continue, select the confirm key.
1. 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.
5. Enter the alpha code supplied with the Registration Card

(scrap the card).
The starting page EVCASyncWeb is displayed; some

functions are available (for more information read the manual
EVCASyncWeb).
2. Select the applications key for pc.

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 type of selected contract.
the activation date of the contract. During this phase it is
- The list of instruments (PT/PB) associated to the contract
only possible to associate one instrument to the contract.
with the generated activation codes
- Token (to be deducted):
- The expire date of the contract (in case of yearly fee) or
it is the payment for a single download of an application;
residual credit (coins):
it is possible to associate to the contract to 4 instruments.
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.

Download the applications Registration>Dealer users

Before using the PT-DIAGNOSIS diagnosis system you must
register on the FPT web site.
1. Connect to
http://www.fptpowertrain.com/index_main.htm.
The following information for each one of the available
2. Select the language.
applications for downloading is displayed: ECU, license, file
name, Release Date, Release Type and short description.
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.
3. Select Fiat Powertrain Technologies and then Partner Area.
NOTE The packets must be downloaded/installed one by

one.
4. Connect to the web site by selecting Click here.

5. Fill in the fields for the login procedure.
7. Go to the registration web page; select pt users registration

a fill-in form is displayed (on-line registration form).
NOTE For the new customers:
request username and password to
areapartner@fptpowertrain.com.
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:

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:
6. Please follow the indicated instructions the identification data and the Network characteristics are
automatically entered.
After Sales>Various>Diagnostic Instruments>Diagnostic
Tools

3. Fill in the yellow field by entering the alpha code supplied 6. Select the send key (only once!) wait
with the Registration Card (scrap the area on the card).
After sending a summary window is displayed waiting for the
4. Enter the serial number of the pt-box instrument. end of the registration procedure.
Wait for the following window:
- the activation code;
- the link to download the EAUS application (E.A.SY.
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
Figure 8 application, the system asks you to select the file or to directly
run it.
156139
The serial number is type PB-#####-##-##-##; to be

found on the back of the PT-BOX module.
1. Select the run key:
5. Read the note in compliance with art. 13 of Italian the system automatically downloads first and then installs
Legislative Degree 196 dated 30 June 2003 about the the EAUS application; run the operation required by the
processing of personal data Informative. system and wait for the end of operation.

Connection
Figure 9
156138
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
2. Select the end key to exit the installation. two USB cables provided with the module.
NOTE Before carrying out the registration we suggest to The PT-BOX module is supplied by the diagnosis
install the PT-Diagnosis SW. ! 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).
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.

5. Select the have disk> button to continue.

3. 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.
6. Enter the path:

ProgramFiles\EltracECI\Driver\PT-BOX.sys;
select the ok button.
4. Select the Don't search. I will choose the driver to install;

select the next> button to continue.
7. Select the next> button to continue.

4. The system asks you to enter the activation code received

from Field Service; select the tick button.
8. Driver set-up begins wait.

9. The procedure is completed; press the finish 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.
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 +

PT-BOX 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.
8. Select the stop button and restart PT-DIAGNOSIS.
Now all the software functions are available.

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:
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).
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.

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 The Operative

area contains Keys area contains available
for accessing the system and function
operative list referred to the
environments and intervention area.
the functions to
which they are
associated.

To go from one environment to another
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.
1. 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.
4. The window Choose Activity appears; it is here possible

to choose from four lists.
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; They allow you to go from one environment to another.
then press the navigation key (is active - green) to Enabled keys are displayed in green and disabled keys are
continue. displayed in grey.
Family Choice Window 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 navigation key forward enabled
information one page at a time; navigation tools are
available to navigate from page to page. navigation key back enabled
Database key
It allows you to access the Database

environment.
Browse key
To scroll long lists which cannot

be contained in a single window. ignition key
For the equipped engines, it allows you to operate engine

Detail of Keys area ignition directly via the diagnostic tool. Two positions (stop
In the Start Window the Keys area contains the Keys for and mar) and three states (enabled stop, disabled stop,
accessing the functions which are always available: 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.

Teleservices key
It allows you to access the remote connections services. Electronic control units key
Activations key
It allows you to access the Electronic Ecu's environment.
It allows you to access the management function of the The key appears on a yellow background (default status,
activation codes. environment Electronic Control Units enabled) or on a grey
Select the measure unit key background (environment Electronic Control Units disabled).
If you want to work at the same time with more Ecu's, select
It allows you to choose the measure unit system. the key environment electronic ecu's>add ecu.
Electrical diagrams key

It refers to a CLASSES list for which an electrical diagram is
The Metric System (SI), the international standard one, is available. The key appears on a yellow background
based on the meter, kilogram and second. The British System (environment Electrical Diagrams enabled) or on a grey
(fps) is based on the foot, pound and second. background (environment Electrical Diagrams disabled).
Select language key 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 Report key
It allows you to carry out the automatic update of the It allows you to access the Report environment.
PT-DIAGNOSIS software. The key appears on a yellow background (environment
Eci management key Report enabled) or on a grey background (environment
Report disabled). To access the Report environment select
It allows you to manage the connection (usb or Bluetooth) the report key.
PT-DIAGNOSIS - PT-BOX module.
On/Off-line key
It can be on-line or off-line.
The on-line key indicates that the PT-Diagnosis SW uses the
In the Start Window select the fami ly; by pressing the PT-BOX/PC module connection.
navigation key forward it is possible to access the next The off-line key indicates the PT-Diagnosis SW is working in
window. New icons appear in the Keys area for accessing simulated mode. To change the status select the key.
specific functions:

Acceptance
Environment DataBase key search
From the PT-DIAGNOSIS start window it is possible to select It allows you to search an engine by applying a filter (DATE,
a new engine or to select one from the database. 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.
key delete
1. Select the database button: you access the DataBase
environment (it contains the list of accepted engines). It deletes the selected engine from the database; it is active
only after selecting an engine.
2. The list of accepted engines is available.

They can be search by means of the following keys:
3. Select an engine from the list (the background is yellow);
- DATE it is possible:
- ENGINE MODEL - to analyse engine data (report button);
- CUSTOMER - to start again the diagnosis procedure on the engine
(navigation button forward);
- NUMBER PLATE
- to return to the start window (navigation button
back).

How to order the engines list 3. 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
- from the Buttons area at any time by selecting the
- ENGINE MODEL corresponding button;
- CUSTOMER - from the DataBase environment by selecting the
required engine and the report button.
- NUMBER PLATE

Environment Report
DIAGNOSIS REPORT LIST

KEY:
summary of all performed
ENGINE DATA KEY: diagnosis operations
engine identification data;
the fields can be always
changed (with the
exception of the engine
model and the date) can be PROGRAMMING
always changed REPORT LIST KEY:
summary of all performed
programming operations
SAVE KEY: AUTOMATIC

it allows you to save the ACCEPTANCE KEY:
engine sheet (to accept it) (enabled only if the
communication is active)

Acceptance When you read or cancel the faults memory or carry out a
programming it is not possible to return directly to the window
The acceptance (sheet saving) is mandatory when important Family Choice; by selecting the engine button the following
operations are performed on the engine (read or cancel faults windows are displayed:
memory, programming).
1. Read or cancel the faults memory or carry out a 1. Before continuing it is necessary to save the data of the
programming and then select from the corresponding performed activity; select the tick icon; the Report
environment the report button; you enter the Report environment appears.
environment.
2. Enter data.
2. Enter data.
3. Save the sheet by selecting the save button.
3. Save the sheet by selecting the save button.

4. From the Buttons area select the button of the operation
you want to perform. It is now possible to return to the Family Choice window.

Automatic acceptance
From the Report environment it is also possible to accept the
engine automatically.
This operation is only possible if the communication

! with the system has been activated.
1. Read or cancel the faults memory or carry out a

programming and then select from the corresponding
environment the report button.
5. The automatic acceptance reads the following

information:
- Engine Model (engine type + engine serial number)
- PIC
- Engine type
- Engine Serial Number
6. At the select the save key.
2. You enter the Report environment. ECU diagnosis

3. Select the button automatic acceptance.
1. Sselect the Family, the Class and then the System of engine
under diagnosis.
2. Press the navigation button forward (enabled - green) to
continue.
4. 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.

3. The window Choose Activity appears; it is here possible 2. PT-DIAGNOSIS system presents a pop-up window
to choose from four lists: where to select the automatic or the manual activation of
Window Choose Activity the ignition key; select the required mode; the key button
is disabled.
- diagnosis
Under the automatic mode all activation of the ignition key are
- test controlled by the diagnosis instrument (key button working).
- programming Under the manual mode all activation of the ignition key are
- specific functions controlled by the operator on the engine.
4. 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. Confirm the new message by pressing the tick icon.
1. To access the Read Identification environment select the

item Identification Code Reading from the Diagnosis list
and then press the navigation button forward.

Multitasking option
report key
PT-DIAGNOSIS introduces a very important news: it is
Shows the Diagnosis Report List (and allows you to print each
possible to associate more ECU's to the family of engine under
report).
test.
Add an ecu
print key
It is possible to interrupt the diagnosis with an ECU and to start
Prints the summary page of Identification Parameters. the procedure with another one.
4. Wait until the ECU is ready; the general information

about the electronic system under test is read:
- identification code
- HW version
- SW version 1. Select the button ecu's area>add ecu; the Choose Vehicle
- production date window will appear, where you can select the desired
ECU.
- 
Managing more ecu's
After identification code reading it is possible to carry out
other activities (step 5) or to return to the window Choose It is possible to operate with two or more connected ECU's
engine (step 6). 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 It is possible to stop the activity on one of the connected
Identification Code Reading, select the choose activities ECU's.
buttons: choose an activity; the system automatically access
the selected activity.
The choose activities buttons are shown in yellow when
selected.
6. To exit the diagnosis of the engine under test select the 1. Slect the button ecu's area>required ecu>cancel.
button ecu's area>ecu under test>cancel.
2. Select the required ECU.

Ignition Key Button Modes - on line/off line 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 1. To access the Read Faults Memory environment select the
automatic mode. item Faults Memory Reading from the list Diagnosis and
then press the navigation button forward.
1. After selecting the automatic mode a test procedure is

carried out.
2. Switch the ignition off. 2. PT-DIAGNOSIS system presents a pop-up window
where to select the automatic or the manual activation of
3. The engine chassis may move. the ignition key; select the required mode; the key button
The PT-DIAGNOSIS SW activates the ignition key and is disabled.
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.
3. Confirm the new message by pressing the tick icon.

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

Active when the communication with the ECU has been
interrupted it gives an analysis of the fault selected from the list;
On line Mode in particular other information (blink code, failure code and
Faults Memory Reading Icons fault mode) is available it can be gray (default status) or yellow
(when selected).
on key
The communication between the system and the ECU is report key
active: it performs again the Faults Reading; it updates the ECU
communication. It allows you to save the report of carried out operations see
Select the button to interrupt the reading. Report environment > button diagnosis report.
off key
The communication with the ECU has been interrupted. print key
Select the button to start again the electronic system reading. It allows you to print the displayed window.

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.

Parameters reading 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.
groups key
2. PT-DIAGNOSIS system presents a pop-up window
where to select the automatic or the manual activation It opens the GROUPS window showing the list of created
of the ignition key; select the required mode; the key group (A) and the keys to create/modify the groups (B).
button is disabled.
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.

Groups Management 9. 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.
Modify a parameters group

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.
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).

Cancel a parameters group 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
1. Select a group of customized parameters on the active area Duration.
2. Select delete; confirm or cancel the request.
Appendix parameter acquisition key
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).
1. Select the parameters acquisition key; the window Store

Parameter opens.
The key is only active under on line mode.
7. Select the archive key: the Archive window open showing
the list of available registration in the archive.
Parameters reading

Archive window
- 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
1. Select the Engine Family under diagnosis.

continue.
2. 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 3. Select the Class and the System under test to which the
display the time range (x-axle, seconds). engine belongs; select the forward navigation key
(enabled - green) to continue.

4. Select the programming option from the Programming 7. Read the displayed messages and select the green tick
list; select the forward navigation key (enabled - green). icon to continue.
5. If required, enter the required data, by following the 8. At the end the system permits access to the
indicated procedure. Programming environment; the components list is
displayed, on which tests can be carried out.
It is possible to carry out a programming only in During the programming do not disconnect the
! online mode. In case of error check the connections ! USB cable. Before carrying out the ECU
ECU/PT-BOX/PT-DIAGNOSIS. 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): - Data Reading

if the electronic system engine under test is fitted with this
function, select the automatic key. - Change the configuration
- PT-DIAGNOSIS shows the running activities. - Programming
- The ignition key ON is automatically activated. - PTO (only for the PT-DIAGNOSIS full version SW)
- The connection to the ECU starts.

The available function types are determined according to the Data Reading
type of ECU under test. The Keys area contains the buttons
for accessing the functions specific for the Programming This is used to view the data concerning the ECU and the
environment. respective programming state; tampering attempts are shown.
The following are indicated:

print key
- station type and number;
If enabled, select to print a report. - 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.

Active diagnosis
It is possible to carry out an active diagnosis only in
To start the Active Diagnosis online mode. In case of error check the following
!
connections ECU/PT-BOX/PT-DIAGNOSIS.
1. Select the Engine Family under diagnosis.

continue.
5. 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.
6. Read the displayed messages and select the green tick

icon 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.
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.
4. From the Test list select the option acti ve diagnosis;

select the forward navigation key (it is active, in green
displayed).

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 Components:

if selected it shows selectable list
information about
the electronic system
under test;
information about Browse key
the guide to the
diagnosis are not
provided.
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.


S SERIES EURO V
Print P1D32S014 E
DTC
Long
DTC Description Dfp Name MIL OBD Term Reason of failure Possible failure correction
Power red
System
Failure
1357 Air flow meter: AFSDrftAdjP OFF none YES Fouling or blockage of the air mass Clean sensor and check intake system, replace air mass
DFC for plausibility lausMax potential sensor, inaccurate sensor due to sensor if necessary, check EGR actuators and boost
check ageing, leakage or obstruction in the pressure actuator.
intake duct, jammed EGR actuator, Reinitialize drift compensation values using UDS
defective VTG/WG service Routine Control (Id $0242)
3357 Air flow meter: AFSDrftAdjP OFF none YES Fouling or blockage of the air mass Clean sensor and check intake system, replace air mass
DFC for plausibility lausNPL potential sensor, inaccurate sensor due to sensor if necessary, check EGR actuators and boost
check ageing, leakage or obstruction in the pressure actuator.
intake duct, jammed EGR actuator, Reinitialize drift compensation values using UDS
defective VTG/WG service Routine Control (Id $0242).
1657 Air flow meter: AFSDrftIdlA OFF none YES Fouling or blockage of the air mass Clean sensor and check intake system, replace air mass
AFS correction at djValMax potential sensor, inaccurate sensor due to sensor if necessary, check EGR actuators and boost
low idle exceeding ageing, leakage or obstruction in the pressure actuator.
the maximum drift intake duct, jammed EGR actuator, Reinitialize drift compensation values using UDS
limit defective VTG/WG service Routine Control (Id $0242)
2657 Air flow meter: AFSDrftIdlA OFF none YES Fouling or blockage of the air mass Clean sensor and check intake system, replace air mass
AFS correction at djValMin potential sensor, inaccurate sensor due to sensor if necessary, check EGR actuators and boost
low idle lower than ageing, leakage or obstruction in the pressure actuator
minimum drift limit intake duct, jammed EGR actuator, Reinitialize drift compensation values using UDS
defective VTG/WG service Routine Control (Id $0242)
1757 Air flow meter: AFSDrftLdA OFF none YES Fouling or blockage of the air mass Clean sensor and check intake system, replace air mass
AFS correction at djValMax potential sensor, inaccurate sensor due to sensor if necessary, check EGR actuators and boost
load point ageing, leakage or obstruction in the pressure actuator.
SECTION 5 - DIAGNOSTICS
exceeding the intake duct, jammed EGR actuator, Reinitialize drift compensation values using UDS
maximum drift limit defective VTG/WG service Routine Control (Id $0242)
2757 Air flow meter: AFSDrftLdA OFF none YES Fouling or blockage of the air mass Clean sensor and check intake system, replace air mass
AFS correction at djValMin potential sensor, inaccurate sensor due to sensor if necessary, check EGR actuators and boost
Base - October 2011
load point lower ageing, leakage or obstruction in the pressure actuator.

than the minimum intake duct, jammed EGR actuator, Reinitialize drift compensation values using UDS
drift limit defective VTG/WG service Routine Control (Id $0242)
41
Base - October 2011
42
Long
DTC Description Dfp Name MIL OBD Power red Term Reason of failure Possible failure correction
System
Failure
1857 Air flow meter: AFSDrftOvr OFF none YES Fouling or blockage of the air mass Clean sensor and check intake system, replace air mass
AFS correction at RunAdjValM potential sensor, inaccurate sensor due to sensor if necessary, check EGR actuators and boost
overrun higher ax ageing, leakage or obstruction in the pressure actuator.
than the maximum intake duct, jammed EGR actuator, Reinitialize drift compensation values using UDS
drift limit defective VTG/WG service Routine Control (Id $0242)
2857 Air flow meter: AFSDrftOvr OFF none YES Fouling or blockage of the air mass Clean sensor and check intake system, replace air mass
AFS correction at RunAdjValMi potential sensor, inaccurate sensor due to sensor if necessary, check EGR actuators and boost
overrun lower than n ageing, leakage or obstruction in the pressure actuator.
the minimum drift intake duct, jammed EGR actuator, Reinitialize drift compensation values using UDS
limit defective VTG/WG service Routine Control (Id $0242)
1257 Air flow meter: AFSOffsDrft ON EGR none YES Inaccurate or defective air mass Check wiring and the accuracy of the air mass sensor
Offset drift high Max potential sensor, or defect in the wiring of the and replace it if necessary
error for HFM HFM sensor.
sensor at engine
stand still
2257 Air flow meter: AFSOffsDrft ON EGR none YES Inaccurate or defective air mass Check wiring and the accuracy of the air mass sensor
Offset drift low Min potential sensor, or defect in the wiring of the and replace it if necessary
error for HFM HFM sensor.
sensor at engine
stand still
1347 Air fllow meter: AFSPhysRng ON EGR none YES direct Inaccurate or defective air mass Check wiring and the accuracy of the air mass sensor
Physical Range Hi sensor, or defect in the wiring of the and replace it if necessary
Check high for air HFM sensor
mass flow sensor
2347 Air fllow meter: AFSPhysRng ON EGR none YES direct Inaccurate or defective air mass Check wiring and the accuracy of the air mass sensor
S SERIES EURO V
Physical Range Lo sensor, or defect in the wiring of the and replace it if necessary
Print P1D32S014 E
Check low for air HFM sensor

mass flow sensor
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
1157 Air fllow meter: AFSSetyDrft ON EGR none YES direct Defect in wiring, inaccurate or Check wiring of the intake air mass sensor and its
Sensitivity drift high Max defective air mass sensor, leakage or accuracy and replace it if necessary, check intake duct
error for HFM obstruction in the intake duct, and boost pressure actuator.
sensor defective VTG/WG Reset HFM learning drift correction factors using UDS
service Routine Control (Id $0242)
2157 Air fllow meter: AFSSetyDrft ON EGR none YES direct Defect in wiring, inaccurate or Check wiring of the intake air mass sensor and its
Sensitivity drift Min defective air mass sensor, leakage or accuracy and replace it if necessary, check intake duct,
error low for HFM obstruction in the intake duct, EGR actuators and boost pressure actuator.
sensor jammed EGR actuator, defective Reset HFM learning drift correction factors using UDS
VTG/WG service Routine Control (Id $0242)
4147 Air fllow meter: AFSSigErr ON EGR none YES direct Defect in wiring or defective air mass Check wiring of the intake air mass sensor, replace air
Hardware error sensor mass sensor
detection for HFM
sensor
1147 Air fllow meter: AFSSRCCor ON EGR none YES direct Defect in wiring, defective air mass Check wiring of the air mass sensor, replace air mass
SRC high error for Max sensor and/or the temperature sensor
corrected value in sensor unit
HFM6 sensor
2147 Air fllow meter: AFSSRCCor ON EGR none YES direct Defect in wiring, defective air mass Check wiring of the air mass sensor, replace air mass
SRC low error for Min sensor and/or the temperature sensor
corrected value in sensor unit
HFM6 sensor
1247 Air fllow meter: AFSSRCRaw ON EGR none YES direct Defect in wiring, defective air mass Check wiring of the air mass sensor, replace air mass
Base - October 2011
SRC high error for Max sensor sensor

raw value in HFM6
sensor
43
Base - October 2011
44
Long
System
Failure
2247 Air fllow meter: AFSSRCRaw ON EGR none YES direct Defect in wiring, defective air mass Check wiring of the air mass sensor, replace air mass
SRC low error for Min sensor sensor
raw value in HFM6
sensor
1161 Air conditionar: AirCClntPAn OFF none NO Sensor defective or wiring short Check wiring or replace sensor
SRC high for AC aSRCMax circuit to external source
coolant pressure
2161 Air conditionar: AirCClntPAn OFF none NO Sensor defective or wiring short Check wiring or replace sensor
SRC low for AC aSRCMin circuit to ground
coolant pressure
1361 Air conditionar: AirCClntPdc OFF none NO Defective sensor or wiring prblem Check sensor and wiring
SRC high for AC ycSRCMax
coolant pressure
2361 Air conditionar: AirCClntPdc OFF none NO Defective sensor or wiring prblem Check sensor and wiring
SRC low for AC ycSRCMin
coolant pressure
1261 Air conditionar: AirCClntPPe OFF none NO Defective sensor or wiring prblem Check sensor and wiring
SRC high for AC rSRCMax
coolant pressure
2261 Air conditionar: AirCClntPPe OFF none NO Defective sensor or wiring prblem Check sensor and wiring
SRC low for AC rSRCMin
coolant pressure
5182 Air conditionar AirCCmprO OFF none NO Broken or disconnected wiring or Check of wiring or replacement of relay
compressor: No L defective relay
S SERIES EURO V
Print P1D32S014 E
load error on
power stage for
the compressor
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
8561 Air conditioner AirCCmprO OFF none NO High battery voltage, high No reaction needed if failure isn't present after short
compressor: Over vrTemp temperature inside ECU, high load or time, check load and output, check wiring, replace
Temperature of wiring problem ECU
the power stage
for AC
compressor.
5282 Air conditionar AirCCmprR OFF none NO Broken or disconnected wiring or Check of wiring or replacement of relay
compressor: No edTrqOL defective relay
load error on
power stage for
the reduce torque
instruction
8661 Air conditioner AirCCmprR OFF none NO High battery voltage, high No reaction needed if failure isn't present after short
compressor: Over edTrqOvrTe temperature inside ECU, high load or time, check load and output, check wiring, replace
Temperature on mp wiring problem ECU
the power stage
for reduce torque
instruction output.
6282 Air conditionar AirCCmprR OFF none NO Short circuit of wiring to external Check of wiring or replacement of relay
compressor: Short edTrqSCB source or inside relay
circuit to battery
error on power
stage for the
reduce torque
instruction
7282 Air conditionar AirCCmprR OFF none NO Short circuit of wiring to ground or Check of wiring or replacement of relay
compressor: Short edTrqSCG inside relay
circuit to ground
error on power
Base - October 2011
stage for the

reduce torque
instruction
45
Base - October 2011
46
Long
System
Failure
6182 Air conditionar AirCCmprS OFF none NO Short circuit of wiring to external Check of wiring or replacement of relay
compressor: Short CB source or inside relay
circuit to battery
error on power
stage for the
compressor
7182 Air conditionar AirCCmprS OFF none NO Short circuit of wiring to ground or Check of wiring or replacement of relay
compressor: Short CG inside relay
circuit to ground
error on power
stage for the
compressor
1182 Air conditionar: AirCPresMa OFF none NO AC fluid expansion valve blocked? Check AC coolant circuit, check pressure sensor
Coolant pressure x Pressure measurement not OK
too high
2182 Air conditionar: AirCPresMin OFF none NO AC fluid expansion valve blocked Check AC coolant circuit, check pressure sensor
Coolant pressure open? AC compressor defective?
too low Pressure measurement not OK
3182 Air conditionar: AirCPresNpl OFF none NO AC Compressor not correctly shut Check AC compressor, check pressure sensor
Coolant pressure off, pressure measurement incorrect
value not plausible
3461 Air conditionar: AirCSwtNpl OFF none NO CAN Timeout in message Check presence and correct connection of the A/C,
Plausibility error for Com_stAC, A/C supply defective, check A/C voltage supply, check wiring
CAN input CAN connection problem
4461 Air conditionar: AirCSwtSig OFF none NO A/C defective, A/C supply defective Check A/C supply, check A/C module
Signal error for
CAN input
1217 EGR Control: AirCtlGovD OFF none NO Defective air mass flow sensor, Check air mass flow sensor, air duct, EGR actuators
Positive governor vtEOMMax leakage in the air duct, electrical or and their wiring
deviation above mechanical defect in EGR actuators
limit for or defect in wiring of EGR actuators
regeneration (EGR
too high)
2217 EGR Control: AirCtlGovD OFF none NO Defective air mass flow sensor, Check air mass flow sensor, air duct, EGR actuators
S SERIES EURO V
Print P1D32S014 E
negative governor vtEOMMin obstruction or leackage in air duct, and their wiring
deviation below electrical or mechanical defect in
limit for EGR actuators or defect in wiring of
regeneration (EGR EGR actuators
too low)
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
1117 EGR Control: AirCtlGovD ON EGR none YES direct Defective air mass flow sensor, Check air mass flow sensor, air duct, EGR actuators
Positive governor vtMax leakage in the air duct, electrical or and their wiring
deviation above mechanical defect in EGR actuators
limit (EGR too or defect in wiring of EGR actuators
high)
2117 EGR Control: AirCtlGovD ON EGR none YES direct Defective air mass flow sensor, Check air mass flow sensor, air duct, EGR actuators
negative governor vtMin obstruction or leackage in air duct, and their wiring
deviation below electrical or mechanical defect in
limit (EGR too EGR actuators or defect in wiring of
low) EGR actuators
1317 EGR Control: AirCtlPlausM ON EGR none YES direct Defect in the EGR actuators (EGR Check for errors of the EGR actuators (correct
Positive governor ax valveor Throttle Valve at intake), installation, wiring, electrical connectors, jammed
deviation at closed obstruction or leakage in the intake actuator), check for obstruction or leakage in the
loop above limit duct or deviation in the measured air intake duct, check presence of failure related to HFM
(EGR too high) mass (HFM sensor)
2317 EGR Control: AirCtlPlausM ON EGR none YES direct Defect in the EGR actuators (EGR Check for errors of the EGR actuators (correct
negative governor in valve or Throttle Valve at intake), installation, wiring, electrical connectors, jammed
deviation at closed leakage in the intake duct or actuator), check for leakage in the intake duct, check
loop below limit deviation in the measured air mass presence of failure related to HFM
(EGR too low) (HFM sensor)
A627 EGR Valve: Error AirCtlRmpT OFF none NO Defect in the EGR actuators (EGR Check for errors of the EGR actuators (correct
path for too long Out and throttle valve) installation, wiring, electrical connectors, jammed
time spent in Calibration error (wrong layout of actuator)
transtion mode the open loop EGR control during Contact Help desk.
Rgn to Nrm transition from Regeneration to
normal mode)
Base - October 2011
1174 Air heater: DFC to AirHt_TstOf OFF none NO Short circuit of wiring to external Check wiring, check air heater
SRC High error fHi source or defective air heater
when heater is Off
47
Base - October 2011
48
Long
System
Failure
2174 Air heater: DFC to AirHt_TstOf OFF none NO Short circuit of wiring to ground or Check wiring, check air heater
SRC Low error fLo defective air heater
when heater is Off
1274 Air heater: DFC to AirHt_TstO OFF none NO Short circuit of wiring to external Check wiring, check air heater
SRC High error nHi source or defective air heater
when heater is On
2274 Air heater: DFC to AirHt_TstO OFF none NO Short circuit of wiring to ground or Check wiring, check air heater
SRC Low error nLo defective air heater
when heater is On
A174 Air heater: Grid AirHtStickO OFF none NO Short Circuit to Ground in wiring or Check wiring and Grid Heater
Heater always n Grid Heater
switched on
11C7 Selected AirTMonPlau OFF none NO The temperature sensor is drifted Check temperature sensor
Temperature s_0
sensor 1 delivering
implausible value
(check description
for detail)
Temperature s_1
sensor 2 delivering
implausible value
(check description
for detail)
Temperature s_2
S SERIES EURO V
sensor 3 delivering
Print P1D32S014 E
implausible value
(check description
for detail)
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
Temperature s_3
sensor 4 delivering
implausible value
(check description
for detail)
Temperature s_4
sensor 5 delivering
implausible value
(check description
for detail)
12C7 Two or more AirTMonPlau OFF none NO More than one temperature sensor Check all involved temperature sensor
Selected sTot considered for enhanced plausibility
Temperature check is drifted
sensors deliver
implausible value s
119C ECM problem: Appdesc_EE OFF none NO Wrong programming? EEPROM Reprogram ECM, replace ECM
EEPROM values P_ERR_CB defective?
for baud rate
cannot be read
A187 EGR: Too High ASModHard ON EGR none YES direct Inaccurate lambda sensor, problem Check lambda sensor for accuracy, check injectors,
NOx emission: NOxMon with EGR control or another check EGR control and other emission reduction
Hard limits of the emission reduction device, problem devices
NOx monitoring with injectors (wrong quantity)
A287 EGR: Too High ASModSoft ON EGR none YES direct Inaccurate lambda sensor, problem Check lambda sensor for accuracy, check injectors,
NOx emission: NOxMon with EGR control or another check EGR control and other emission reduction
Soft limits of the emission reduction device, problem devices
NOx monitoring with injectors (wrong quantity)
31B1 Exhaust Flap AuxBrkCut OFF none NO Short circuit in the Exhaust brake Check Exhaust brake switch
actuator: Engine request switch (permanent Exhaust
break active at brake request) Check Wiring harness of exhaust brake switch
vehicle stand still Short circuit in the wiring harness of
exhaust brake switch (permanent
Base - October 2011
Exhaust brake request)

5242 Auxiliariy Break AuxBrkLmp OFF none NO Broken or disconnected wiring or Check of wiring or replacement of auxiliary brake lamp
lamp: No load OL defective auxiliary brake lamp
error for Auxiliary
49
Brake Lamp
Base - October 2011
50
Long
System
Failure
8242 Break lamp: Over AuxBrkLmp OFF none NO High battery voltage, high No reaction needed if failure isn't present after short
temperature error OvrTemp temperature inside ECU, high load or time, check load and output, check wiring, replace
wiring problem ECU
6242 Auxiliariy Break AuxBrkLmpS OFF none NO Short circuit of wiring to external Check of wiring or replacement of auxiliary break lamp
lamp: Short circuit CB source or inside auxiliary break lamp
to battery error for
Auxiliary Brake
Lamp
7242 Auxiliariy Break AuxBrkLmpS OFF none NO Short circuit of wiring to ground or Check of wiring or replacement of auxiliary break lamp
lamp: Short circuit CG inside auxiliary break lamp
to ground error for
Auxiliary Brake
Lamp
111D Battery voltage: BattUSRCMa OFF none NO Alternator voltage governor defect Replace alternator governor device or alternator
SRC high for x
battery voltage
sensor
211D Battery voltage: BattUSRCMi OFF none NO Battery defect, alternator defect, Replace battery or alternator. Check ECU and wiring.
SRC low for n wiring problems (too high resistance)
battery voltage or ECU defect. Occurence possible
sensor during cold start.
3131 Brake Actuation: BrkNpl OFF none NO - The adjustment of the brake - Check the adjustment of the brake switches
Main and switches is not good enough. - Check the brake switches for short circuit
redundant brake - One of the brake switches has a - Check the wiring and the brake switches for open
switch state short circuit. lead
different - The circuit has an open lead.
4131 Break Actuation: BrkSig OFF none NO - One of the brake switches has a - Check the brake switches for short circuit
Sig Error for Brake short circuit. - Check the wiring and the brake switches for open
(signal via CAN) - The circuit has an open lead. lead
B51B CAN Bus: Error BusDiagBus OFF none NO Wrong configuration of CAN timing Check timing configuration with hardware
passive CAN Bus OffErrPasNo (Prescaler, synchronization jump compatibility, check termination resistors and network
Node A deA width, sampling, propagation and connection and contacts. Short circuits to external
S SERIES EURO V
phase segments), bad termination source, ground or CAN High to Low.Monitor CAN
Print P1D32S014 E
resistors, defective network communication for erroneous behaviour of a

connection and contacts or defective participant.
CAN controller with erroneous
messages.
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
Node B deB width, sampling, propagation and connection and contacts. Short circuits to external
messages.
Node C deC width, sampling, propagation and connection and contacts. Short circuits to external
messages.
Node D deD width, sampling, propagation and connection and contacts. Short circuits to external
messages.
CAN Bus Node A OffNodeA (Prescaler, synchronization jump compatibility, check termination resistors and network
width, sampling, propagation and connection and contacts. Short circuits to external
messages.
CAN Bus Node B OffNodeB (Prescaler, synchronization jump compatibility, check termination resistors and network
Base - October 2011
51
messages.
Base - October 2011
52
Long
System
Failure
CAN Bus Node C OffNodeC (Prescaler, synchronization jump compatibility, check termination resistors and network
messages.
CAN Bus Node D OffNodeD (Prescaler, synchronization jump compatibility, check termination resistors and network
messages.
A543 Charge-air cooler: CAClgEta ON Compre none NO Charge air-cooler defective Check charge-air cooler
efficiency too low hensive
B543 Charged air CACPlaus OFF none NO Charged air cooler efficiency low Check charged air cooler
pressure cooler
efficiency low
3313 Coolant temp CEngDsTAb OFF none NO Very cold ambient conditions and Ensure that engine was not running in extreme
sensor: defect fault sTst cabine heater(s) on full power ambient conditions.
check for Absolute (specially if additional heaters using Check wiring and connectors (corrosion)
plausibility test coolant temeprature installed in the Check accuracy of sensor, replacement of sensor
vehicle) Check Thermostate functionality
S SERIES EURO V
Additional electrical resistance in the
Print P1D32S014 E
wiring (corroded connector)

Inaccurate sensor (although sensor d
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
3413 Coolant temp CEngDsTDy OFF none NO Very cold ambient conditions and Ensure that engine was not running in extreme
sensor: defect fault nTst cabine heater(s) on full power ambient conditions.
check for dynamic (specially if additional heaters using Check wiring and connectors (corrosion)
plausibility test coolant temperature installed in the Check accuracy of sensor, replacement of sensor
vehicle) Check Thermostate functionality
Additional electrical resistance in the
wiring (corroded connector)
Inaccurate sensor (although sensor d
D113 Diagnostic Fault CEngDsTPhy OFF none NO Sensor defective or wrongly Check sensor and mounting
Check for Physical sRngHi connected
Signal above
maximum limit
E113 Diagnostic Fault CEngDsTPhy OFF none NO Sensor defective or wrongly Check sensor and mounting
Check for Physical sRngLo connected
Signal below
minimum limit
4213 Coolant temp CEngDsTSig OFF none NO Sensor defect, Problems with CAN Check Sensor
sensor: Error over Check CAN Wiring
CAN for Engine
coolant
temperature(down
stream)
1113 Coolant temp CEngDsTSR OFF none NO Sensor defective or short circuit to Check wiring or replace sensor
sensor: SRC High CMax external source
for Engine coolant
temperature(down
stream)
2113 Coolant temp CEngDsTSR OFF none NO Sensor defective or short circuit to Check wiring or replace sensor
sensor: SRC low CMin ground
Base - October 2011
for Engine coolant

temperature(down
stream)
53
Base - October 2011
54
Long
System
Failure
3113 Engine Coolant CEngDsTVD OFF none NO Coolant temperature sensor drifted Check sensor
Temperature: Plaus
failed plausibility
check at ECU start
2523 Coolant pressure: CEngPMin OFF YES NO Defective pressure switch, defect in Check pressure switch and wiring, check entire cooling
Min error (technical) wiring (open circuit), leakage in system for leakages, check cooling pump
detection for cooling system, defective cooling
coolant pressure pump
state sensor
3523 Coolant pressure: CEngPPlaus OFF none NO Defect in wiring (short circuit), Check wiring and pressure switch for proper
NPL error defective pressure switch (stuck in functioning, replace pressure switch sensor
detection for closed position)
coolant pressure
state sensor
F46C ECU Internal: Cj945SpiCo OFF none NO Electric disturbances, internal defect Replace ECU if failure remains present
Reported SPI and m1 of the ECU leading to a SPI bus
COM-Errors of a communication error
Cj945
51C2 Coolant Ctrl Lamp: ClntTLmpO OFF none NO Broken or disconnected wiring or Check of wiring or replacement of Coolant
Indicates No Load L defective Coolant Temperature Temperature Warning Lamp
Error Warning Lamp
81C2 Coolant Ctrl Lamp ClntTLmpO OFF none NO High battery voltage, high No reaction needed if failure isn't present after short
Ctrl Lamp: vrTemp temperature inside ECU, high load or time, check load and output, check wiring, replace
S SERIES EURO V
Print P1D32S014 E
Indicates Over wiring problem ECU

Temperature Error
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
61C2 Coolant Ctrl Lamp ClntTLmpSC OFF none NO Short circuit of wiring to external Check of wiring or replacement of Coolant
Ctrl Lamp: B source or inside Coolant Temperature Warning Lamp
Indicates Short Temperature Warning Lamp
Circuit to Battery
71C2 Coolant Ctrl Lamp ClntTLmpSC OFF none NO Short circuit of wiring to ground or Check of wiring or replacement of Coolant
Ctrl Lamp: G inside Coolant Temperature Warning Temperature Warning Lamp
Indicates Short Lamp
Circuit to Ground
3241 Clutch pedal: ClthNpl OFF none NO Clutch switch defective, wiring Check clutch switch, check wiring
Plausibility check broken or short circuit to ground,
for Clutch misuse of vehicle (starting engine
with engaged gear or change gear
without actuating clutch etc)
4241 Clutch pedal: Sig ClthSig OFF none NO Clutch switch defective or problem Check clutch switch. Check CAN connection
Error for Clutch on CAN comunication with cutch
switch
A1A6 Combustion: CmbMonGe OFF none YES non balanced cylinders possibly due try to identify the irregular cylinders by the deviations
Combustion of n potential to problem of one or more injectors. at failure recognition (snap shot): the 2 extreme
more than 1 cylinders have probably a problem.
cylinder not check regulirity of combustion (idle test or run up test)
equlibrated
11A6 Combustion: CmbMonMa OFF none YES injector of cylinder 1 has too low fuel check regulirity of combustion (idle test or run up test)
Base - October 2011
Combustion of x_0 potential quantity or the cylinder itself is defect and replace injector if necessary
cylinder no 1 low (no compression/misfiring)
55
Base - October 2011
56
Long
System
Failure
cylinder no 3 low (no compression)
21A6 Combustion: CmbMonMi OFF none YES injector of cylinder 1 has too high fuel check regulirity of combustion (idle test or run up test)
Combustion of n_0 potential quantity (open locked inejctor) and replace injector if necessary
cylinder no 1 too
high
cylinder no 3 too
high
S SERIES EURO V
cylinder no 4 too
Print P1D32S014 E
high
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
cylinder no 2 too
high
F11F Info: Torque CoETSBstPrt OFF none NO Active power redcution > 2.00s due No actions necessary due to this failure alone. If
Limitation active: TrqLim to turbo charger protection powerreduction occurred due to actual defect, the
Torque limitation failure triggering the torque limitation should also be in
caused by turbo the failure memory. Follow troubleshooting of this root
charger protection error.
F21F Info: Torque CoETSEngPr OFF none NO Active power redcution > 2.00s due No actions necessary due to this failure alone. If
Limitation active: tTrqLim to engine mechanics protection powerreduction occurred due to actual defect, the
Torque limitation failure triggering the torque limitation should also be in
caused by engine the failure memory. Follow troubleshooting of this root
protection error.
F31F Info: Torque CoETSInjSys OFF none NO Active power redcution > 2.00s due No actions necessary due to this failure alone. If
Limitation active: TrqLim to high pressure fuel pump powerreduction occurred due to actual defect, the
Torque limitation protection failure triggering the torque limitation should also be in
caused by injection the failure memory. Follow troubleshooting of this root
system error.
F41F Info: Torque CoETSNTC OFF none NO Active power redcution > 2.00s due No actions necessary due to this failure alone. If
Limitation active: TrqLim to torque rise limitation after engine powerreduction occurred due to actual defect, the
Torque limitation brake release. failure triggering the torque limitation should also be in
caused by engine the failure memory. Follow troubleshooting of this root
Base - October 2011
brake error.
57
Base - October 2011
58
Long
System
Failure
F51F Info: Torque CoETSPDiff OFF none NO Active power reduction > 5.00s due No actions necessary due to this failure alone. If
Limitation active: TrqLim to torque limitation for pressure drop powerreduction occurred due to actual defect, the
Torque limitation limitation over particulate filter. failure triggering the torque limitation should also be in
caused by the failure memory. Follow troubleshooting of this root
particulate filter error.
F61F Info: Torque CoETSPrflm OFF none NO Active power reduction due to the No actions necessary due to this failure alone. If
Limitation active: TrqLim OBD performance limiter because of powerreduction occurred due to actual defect, the
Torque limitation too high NOx emissions failure triggering the torque limitation should also be in
caused by OBD the failure memory. Follow troubleshooting of this root
performance error.
limiter
F71F Info: Torque CoETSSCRP OFF none NO Active power redcution due to No actions necessary due to this failure alone. If
Limitation active: rtTrqLim excessive temperatures in the SCR powerreduction occurred due to actual defect, the
Torque limitation catalyst failure triggering the torque limitation should also be in
caused by the failure memory. Follow troubleshooting of this root
SCRCAT error.
protection
F81F Info: Torque CoETSSmkT OFF none NO Active power redcution due to No actions necessary due to this failure alone. If
Limitation active: rqLim smoke limitation with unexpected powerreduction occurred due to actual defect, the
Torque limitation long duration > 5.00s failure triggering the torque limitation should also be in
caused by smoke If no other failure stored concerning the failure memory. Follow troubleshooting of this root
limitation EGR or Boost pressure control: error.
operation in extreme high altitude If no failruie stroed in memory
(>1800 m, i.e ambient pressure <
780mbar)
S SERIES EURO V
Print P1D32S014 E
sticking of VGT or EGR

S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
A18B CAN Bus: Timeout ComAmbCo OFF none NO Defective CAN Controller within Check the installation and the proper connection of
Error of nTO Chassis CAN, CAN Cables the Engine Control Unit to the CAN vehicle network.
CAN-Transmit-Fra disconnected or broken. Short circuit Check correct operating conditions of the CAN
me Ambient in wiring. controller.
conditions Check the vehicle wirings.
(AmbCon,
barometric
pressure, ambient
temperature)
B48B CAN Bus: Timeout ComAT1IM OFF none NO CAN bus overload, frame could not Check CAN bus wiring. A defect could cause error
Error of GTO be send. frames which lead to high bus load or send the CAN
CAN-Transmit-Fra controller to "bus off" state.
me AT1IMG
A12B CAN Bus MIL: ComBC1MIL ON Compre none NO Defective MIL/Body Controller or Check presence and correct connection of the Body
DFC for MIL LAMP hensive disturbed CAN communication Computer to the network, Check correct functioning
Error of the CAN controller and its voltage supply. Check
wiring.
B33A CAN Bus: Timeout ComCRI1T OFF none NO CAN bus overload or disturbed, Check CAN bus wiring. A defect could cause error
Error of O frame could not be received. frames which lead to high bus load or send the CAN
CAN-Receive-Fra controller to "bus off" state.
me CRI1 (Catalyst
reagent
information)
Base - October 2011
59
Base - October 2011
60
Long
System
Failure
A1AB CAN Bus Dash ComDashDs ON Compre none NO Defective CAN controller of Vehicle Check presence and correct connection of the VCM
Port: Timeout plTO hensive Control Module or Body controller, or Body Controller to the network, Check correct
Error of undervoltage of VCM or Body functioning of the VCM or Body Controller CAN
CAN-Receive-Fra controller, missing VCM or Body controller and its voltage supply. Check wiring.
me Dashboard controller, CAN cable connecting the
(DashDspl: fuel VCM or the Body controller is
level) disconnected or broken. Short circuit
in wiring.
AA3B CAN Bus: Timeout ComEBC1T OFF none NO Defective CAN controller of ABS / Check presence and correct connection of the ABS /
Error of O ASR / ESP, CAN cable disconnected ASR / ESP to the network, Check correct functioning
CAN-Receive-Fra or broken. Short circuit in wiring. of the CAN controller. Check wiring.
me Electronic
Brake Controller
(EBC1:
ASR,EBS,ABS,
Traction control,
retarder)1
AC3B CAN Bus: Timeout ComEBC2T OFF none NO Wheel speed frame could not be Please check EBC and CAN bus wiring. If CAN bus is
Error of O received. Defect of EBC module. disturbed, frames from other modules could possibly
CAN-Receive-Fra CAN bus overload or disturbed, . also not received.
me Wheel Speed
Information
AE8B CAN Bus: Active ComEDC2N none none NO No failure, Dew pont reached!! No intervention
DFC Timeout of OxDewPnt
EDC to NOx
Sensor Dew Point
Message
(EDC2NOx)
AD8B CAN Bus: Timeout ComEDC2N ON Compre none YES direct
Error of OXTO hensive
CAN-Transmit-Fra
me EDC to NOx
Sensor
(EDC2NOx:
S SERIES EURO V
Print P1D32S014 E
Engine operation
status, engine
speed,Dew point,
exhaust
temperatures)
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
B58B CAN Bus: Timeout ComEDC2N ON Compre none YES direct

Error of OXUSTO hensive
CAN-Transmit-Fra
me EDC to NOx
Upstream Sensor
(EDC2NOxUS:
Engine operation
status, engine
speed,Dew point,
exhaust
temperatures)
B18B CAN Bus: Timeout ComEEC1T OFF none NO Defective CAN controller, CAN Check the presence and correct connection of the
Error of O cable disconnected or broken. Short EDC to the network, Check correct functioning of the
CAN-Transmit-Fra circuit in wiring. CAN controller. Check wiring.
me Electronic
Engine Control 1
(EEC1: torque
informations)
me Electronic
Engine Control 2
(EEC2: accelerator
pedal informations)
A87B CAN VTO: ComEEC2V OFF none NO Defective CAN controller of Vehicle Check presence and correct connection of the Vehicle
Timeout Error of TO controller , undervoltage of VC, Controller to the network, check correct functioning
CAN-Receive-Fra missing VC, CAN cable connecting of the VC CAN controller and its voltage supply.
me Electronic the VC is disconnected or broken. Check wiring.
Engine COntrol 2 Short circuit in wiring.
from vehicle
Base - October 2011
controller (EEC2V:
CAN IDs and
charactheristics)
61
Base - October 2011
62
Long
System
Failure
me Electronic
Engine Control 3
(EEC3:
friction,desired
speed, estimated
engine parasitic
losses)
AF8B CAN Bus: Timeout ComEEC5T OFF none NO Defective CAN controller, CAN Check the presence and correct connection of the
me Electronic
Engine Control 5
(EEC5: EGR valve
position)
B68B CAN Bus: Timeout ComEFL_P1 OFF none NO Defective CAN controller, CAN Check the presence and correct connection of the
Error of TO cable disconnected or broken. Short EDC to the network, Check correct functioning of the
me EFL_P1 frame
(Engine Fluid
Level/Pressure)
A1F7 CAN Bus EGR ComEngGsFl OFF none NO EGR mass flow measure sensor Check EGR sensor, check CAN wiring
Rate: Timeout owRtTO connected via CAN is not sending a
Error of value because defective or CAN
CAN-Receive connection defective (wiring)
Frame Engine gas
flowrate
S SERIES EURO V
Print P1D32S014 E
(EngGsFlowRt:
EGR mass rate)
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
11F7 CAN Bus EGR ComEngGsFl OFF none NO EGR air mass flow sensor or wiring Check EGR air mass flow sensor and wiring
Rate: Open Circuit RtHtrMax defective
Error for Exhaust
Gas Mass Flow
Rate Signal
Rate: Short Circuit RtHtrMin defective
Error for Exhaust
Gas Mass Flow
Rate Signal
31F7 CAN Bus EGR ComEngGsFl OFF none NO Defective EGR sensor. Check wiring of EGR sensor and its proper functioning.
Rate: Not Plausible RtHtrNpl If necessary replace EGR sensor.
Error Circuit Error
for Exhaust Gas
Mass Flow Rate
Signal
Rate: Signal Error RtHtrSig defective
for Exhaust Gas
Mass Flow Rate
Signal
Base - October 2011
63
Base - October 2011
64
Long
System
Failure
A28B CAN Bus: Timeout ComEngRet OFF none NO

Error of CfgBAMTO
CAN-Transmit-Fra
me Engine
Retarder
Configuration
Broadcast
Announce Message
(EngRefCfgBAM)
A38B CAN Bus: Timeout ComEngRet OFF none NO

Error of CfgPACTO
CAN-Transmit-Fra
me Engine
Retarder
Configuration
Package
(EngRefCfgPAC:
retarder
parameters)
A2AB CAN Bus VCM: ComEngShO OFF engine stop NO

DFC of Auxiliary ffBC2EDC2 (indirect)
Engine Shutdown
Switch Message
A53B CAN Bus: Engine ComEngShO OFF none NO An Engine Shut off request was Check failure source for engine shut off
shut off request ffEBC1 activated by another another failure (Fid_EngShOff)
through CAN
A48B CAN Bus: Timeout ComEngTe OFF none NO Defective CAN controller, CAN Check the presence and correct connection of the
Error of mpTO cable disconnected or broken. Short EDC to the network, Check correct functioning of the
me ENGTEMP:
S SERIES EURO V
Print P1D32S014 E
Engine
temperatures
(Coolant, Oil,Fuel)
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
A76B CAN Bus: Timeout ComETC1T OFF none NO Defective CAN controller of Check presence and correct connection of the ETC to
Error of O Gearbox Control Unit , undervoltage the network, check correct functioning of the ETC
CAN-Receive-Fra of ETC, missing ETC, CAN cable CAN controller and its voltage supply. Check wiring.
me Electronic connecting the ETC is disconnected
Transmission or broken. Short circuit in wiring.
Control 1 (ETC1:
shift and clutching
informations)
A86B CAN Bus: Timeout ComETC2T OFF none NO Defective CAN controller of Check presence and correct connection of the ETC to
Error of O Gearbox Control Unit , undervoltage the network, check correct functioning of the ETC
CAN-Receive-Fra of ETC, missing ETC, CAN cable CAN controller and its voltage supply. Check wiring.
me Electronic connecting the ETC is disconnected
Transmission or broken. Short circuit in wiring.
Control 2 (ETC2:
selected gear, gear
ratio)
B78B CAN Bus: Timeout ComFlCTO OFF none NO Defective CAN controller, CAN Check the presence and correct connection of the
Error of cable disconnected or broken. Short EDC to the network, Check correct functioning of the
me Fuel
Consumption
message (FlC: total,
current cycle)
A58B CAN Bus: Timeout ComFlEcoT OFF none NO Defective CAN controller, CAN Check the presence and correct connection of the
me Fuel economy
message (FlEco:
Base - October 2011
fuel rate, instant

fuel)
65
Base - October 2011
66
Long
System
Failure
A29B CAN Bus: Timeout ComHRVD OFF none NO Defective CAN controller of Body Check presence and correct connection of the Body
Error of TO Computer , undervoltage of BC Computer to the network, Check correct functioning
CAN-Receive-Fra missing BC, CAN cable connecting of the BC CAN controller and its voltage supply.
me High the Body Computerr is disconnected Check wiring.
Resolution Vehicle or broken. Short circuit in wiring.
Distance (HRVD)
A93B CAN Bus: Timeout ComHRWS OFF YES NO Defective CAN controller of Body Check presence and correct connection of Body
Error of TO (technical) Controller or VCM, undervoltage, Controller or VCM to the network, check CAN
CAN-Receive-Fra CAN cable connecting Body controller and its voltage supply. Check wiring.
me High Controller or VCM is disconnected
Resolution Wheel or broken. Short circuit in wiring.
Speed Information
(HRWS: Fron Axle
Left/Right wheel
speed)
B88B CAN Bus: Timeout ComIC1TO OFF none NO CAN bus overload, frame could not Check CAN bus wiring. A defect could cause error
Error of be send. frames which lead to high bus load or send the CAN
CAN-Transmit-Fra controller to "bus off" state.
me IC1 (SAE
J1939)
146A CAN NOx Sensor: ComNOxSe ON Compre none YES direct Wiring defect Check wiring (specially heating wires)
Open Circuit Error nsHtrMax hensive NOx Sensor defect Check NOx Sensor
for Nox Sensor
246A CAN NOx Sensor: ComNOxSe ON Compre none YES direct Wiring harness has short circuit Check wiring harness
Short Circuit Error nsHtrMin hensive NOx Sensor defect Check Sensor
for Nox Sensor
S SERIES EURO V
Print P1D32S014 E
346A CAN NOx Sensor: ComNOxSe ON Compre none YES direct NOx Sensor defective Replace NOx sensor
NOx Signal out of nsNpl hensive
range
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
156A CAN NOx Sensor ComNOxSe ON Compre none YES direct Wiring defect Check wiring (specially heating wires)
Upstream: Open nsUsHtrMax hensive NOx Sensor upstream defect Check NOx Sensor Upstream
Circuit Error for
Nox Sensor
upstream
256A CAN NOx Sensor ComNOxSe ON Compre none YES direct Wiring defect Check wiring (specially heating wires)
Upstream: Short nsUsHtrMin hensive NOx Sensor upstream defect Check NOx Sensor Upstream
Circuit Error for
Nox Sensor
upstream
356A CAN NOx Sensor ComNOxSe ON Compre none YES direct

Upstream: NOx nsUsNpl hensive
Signal out of range
A1BB CAN Bus: Timeout ComRxACC OFF none NO Defective CAN controller of Radar Check presence and correct connection of the Radar
Error of 1TO Interface, CAN cable connecting the Interface to the network. Check wiring.
CAN-Receive-Fra interface is disconnected or broken.
me Adaptive Short circuit in wiring.
Cruise Control
Vehicle Speed
from Radar
Interface
A2BB CAN Bus: Timeout ComRxCCV OFF none NO Defective CAN controller of RDU, Check presence and correct connection of the RDU
Error of SRDUTO CAN cable disconnected or broken. to the network, Check correct functioning of the CAN
CAN-Receive-Fra Short circuit in wiring. controller. Check wiring.
me Cruise Control
Vehicle Speed
Base - October 2011
from Radar
Interface
67
Base - October 2011
68
Long
System
Failure
A5AB CAN Bus: Timeout ComRxCCV OFF none NO Defective CAN controller of Body Check presence and correct connection of the BC or
Error of STO Computer or Vehicle Control VCM to the network, check correct functioning of the
CAN-Receive-Fra Module , undervoltage of BC or BC or VCM CAN controller and its voltage supply.
me Cruise Control VCM, missing BC or VCM, CAN Check wiring.
Vehicle Speed cable connecting the BC or VCM is
(CCVS: parking disconnected or broken. Short circuit
brake switch,wheel in wiring.
based vehicle
speed, CC status,
brake switch, clutch
switch, PTO state)
12E7 CAN Bus: Open ComRxEngT OFF none NO Defective or incorrect functioning of Check EGR temperature measuring device for proper
Circuit Error for emp2SensM EGR temperature measuring device functioning
Exhaust Gas ax
temperature Signal
22E7 CAN Bus: Short ComRxEngT OFF none NO Defective or incorrect functioning of Check EGR temperature measuring device for proper
Circuit Error for emp2SensMi EGR temperature measuring device functioning
Exhaust Gas n
temperature signal
32E7 CAN Bus: NPL ComRxEngT OFF none NO Defective or incorrect functioning of Check EGR temperature measuring device for proper
Error Circuit Error emp2SensN EGR temperature measuring device functioning
for Exhaust Gas pl
Mass Temperature
S SERIES EURO V
Signal
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
42E7 CAN Bus: Sig Error ComRxEngT OFF none NO Defective or incorrect functioning of Check EGR temperature measuring device for proper
for Exhaust Gas emp2SensSig EGR temperature measuring device functioning
temperature Signal
A2E7 CAN Bus: Timeout ComRxEngT OFF none NO Defective CAN controller of EGR Check presence and correct connection of the EGR
Error of emp2TO Temperature Sensor , undervoltage Sensor to the network, check correct functioning of
CAN-Receive-Fra of EGR Sensor, missing EGR Sensor, the EGR Sensor CAN controller and its voltage supply.
me RxEngTemp2 CAN cable connecting the EGR Check wiring.
Sensor is disconnected or broken.
Short circuit in wiring.
A59B CAN Bus: Timeout ComRxVDT OFF none NO Defective CAN controller of Body Check presence and correct connection of Body
error of O Controller, CAN cable disconnected Controller to the network,
CAN-Receive-Fra or broken. Short circuit in wiring. Check correct functioning of the CAN controller.
me of Vehicle Check wiring.
Distance (RxVD)
A68B CAN Bus: Timeout ComShutDw OFF none NO Defective CAN Controller within Check the installation and the proper connection of
error of nTO Chassis CAN, CAN Cables the Engine Control Unit to the CAN vehicle network.
me Shut Down in wiring. controller.
(ShutDwn) Check the vehicle wirings.
A49B CAN Bus: Timeout ComTCO1T OFF YES NO Defective CAN controller of Check presence and correct connection of the
Error of O (technical) Tachograph or Instrument Cluster, Tachograph or of the Instrument Cluster to the
CAN-Receive-Fra CAN cable disconnected or broken. network, Check correct functioning of the CAN
Base - October 2011
me Tachograf Short circuit in wiring. controller. Check wiring.

(TCO1)
69
Base - October 2011
70
Long
System
Failure
A78B CAN Bus: Timeout ComTI1TO OFF none NO Defective CAN Controller within Check the installation and the proper connection of
Error of Chassis CAN, CAN Cables the Engine Control Unit to the CAN vehicle network.
me Urea Tank in wiring. controller.
Information (TI1: Check the vehicle wirings.
fostered catalyst
tank level; catalyst
temperature)
A3AB CAN Bus: Timeout ComTOBC2 OFF none NO Defective CAN controller of Body Check presence and correct connection of the BC to
Error of EDC1 Computer , undervoltage of BC, the network, Check correct functioning of the BC
CAN-Receive-Fra missing BC, CAN cable connecting CAN controller and its voltage supply. Check wiring.
me IVECO the BC is disconnected or broken.
proprietary Body Short circuit in wiring.
Computer to EDC
(BC2EDC1)
A6AB CAN Bus: Timeout ComTOBC2 OFF none NO Defective CAN controller of Body Check presence and correct connection of the BC to
Error of EDC2 Computer , undervoltage of BC, the network, Check correct functioning of the BC
CAN-Receive-Fra missing BC, CAN cable connecting CAN controller and its voltage supply. Check wiring.
me IVECO the BC is disconnected or broken.
proprietary Body Short circuit in wiring.
Computer to EDC
(BC2EDC2)
A88B CAN Bus: Timeout ComTOED OFF none NO Defective CAN controller, CAN Check the presence and correct connection of the
Error of C2BC cable disconnected or broken. Short EDC to the network, Check correct functioning of the
me IVECO
proprietary EDC to
S SERIES EURO V
Body Computer
Print P1D32S014 E
(EDC2BC)
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
A98B CAN Bus: Timeout ComTOERC OFF none NO Defective CAN controller, CAN Check the presence and correct connection of the
Error of 1 cable disconnected or broken. Short EDC to the network, Check correct functioning of the
me Electronic
Retarder
Controller 1
(ERC1)
ACAB CAN Bus: Timeout ComTOMux OFF none NO Defective CAN controller of Body Check presence and correct connection of the Body
Error of Info Computer or VCM, CAN cable Computer to the network, Check correct functioning
CAN-Receive-Fra disconnected or broken. Short circuit of the CAN controller. Check wiring.
me MuxInfo from in wiring.
Body Computer
for reverse gear
lights
A46A CAN NOx Sensor: ComTONO ON Compre none YES direct Defective CAN controller of NOx Check presence and correct connection of the NOx
Timeout Error of xSens hensive Sensor , undervoltage of NOx Sensor to the network, Check correct functioning of
CAN-Receive-Fra Sensor, missing NOx Sensor, CAN the NOx Sensor CAN controller and its voltage
me NOX sensor cable connecting the NOx Sensor is supply. Check wiring.
(NOxSens: NOX disconnected or broken. Short circuit
concentration,Lam in wiring.
bda
function,Oxygen
function, sensor
status, sensor
error)
A56A CAN NOx Sensor ComTONO ON Compre none YES direct Defective CAN controller of NOx Check presence and correct connection of the NOx
Upstream: Timeout xSensUs hensive Sensor Upstream , undervoltage of Sensor Upstream to the network, Check correct
Error of NOx Sensor, missing NOx Sensor functioning of the NOx Sensor Upstream CAN
CAN-Receive-Fra Upstream, CAN cable connecting the controller and its voltage supply. Check wiring.
me NOX sensor NOx Sensor Upstream is
upstream disconnected or broken. Short circuit
(NOxSens: NOX in wiring.
concentration,Lam
bda
Base - October 2011
function,Oxygen
function, sensor
status, sensor
71
error)
Base - October 2011
72
Long
System
Failure
A19B CAN Time Date: ComTOTim ON Compre none NO Defective CAN controller of Check presence and correct connection of the
Timeout Error of eDate hensive Tachograph or Instrument Cluster, Tachograph or of the Instrument Cluster to the
CAN-Receive-Fra CAN cable disconnected or broken. network, Check correct functioning of the CAN
me Time Date Short circuit in wiring. controller. Check wiring.
message
(TimeDate)
A13B CAN Bus: Active ComTOTSC OFF none NO Defective CAN controller of ABS / Check presence and correct connection of the ABS /
DFC TimeOut of 1AEAct ASR / ESP, CAN cable disconnected ASR / ESP to the network, Check correct functioning
Torque Speed or broken. Short circuit in wiring. of the CAN controller. Check wiring.
Control TSC1AE
Message
A23B CAN Bus: Passive ComTOTSC OFF none NO Defective CAN controller of ABS / Check presence and correct connection of the ABS /
DFC TimeOut of 1AEPas ASR / ESP, CAN cable disconnected ASR / ESP to the network, Check correct functioning
Control TSC1AE
Message
A33B CAN Bus: Active ComTOTSC OFF none NO Defective CAN controller of ABS / Check presence and correct connection of the ABS /
DFC TimeOut of 1ARAct ASR / ESP, CAN cable disconnected ASR / ESP to the network, Check correct functioning
Control TSC1AR
Message
A43B CAN Bus: Passive ComTOTSC OFF none NO Defective CAN controller of ABS / Check presence and correct connection of the ABS /
DFC TimeOut of 1ARPas ASR / ESP, CAN cable disconnected ASR / ESP to the network, Check correct functioning
S SERIES EURO V
Control TSC1AR
Print P1D32S014 E
Message
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
A14B CAN Bus: Passive ComTOTSC OFF none NO Defective CAN controller of Check presence and correct connection of the
DFC TimeOut of 1DEAct Driveline Retarder or RDU, CAN Driveline Retarder or RDU to the network, Check
Torque Speed cable disconnected or broken. Short correct functioning of the CAN controller. Check
Control TSC1DE circuit in wiring. wiring.
Message
DFC TimeOut of 1DEPas Driveline Retarder or RDU, CAN Driveline Retarder or RDU to the network, Check
Control TSC1DE circuit in wiring. wiring.
Message
DFC TimeOut of 1DRAct Driveline Retarder or RDU, CAN Driveline Retarder or RDU to the network, Check
Control TSC1DR circuit in wiring. wiring.
Message
DFC TimeOut of 1DRPas Driveline Retarder or RDU, CAN Driveline Retarder or RDU to the network, Check
Control TSC1DR circuit in wiring. wiring.
Message
A15B CAN Bus: Active ComTOTSC OFF none NO Defective CAN controller of PTO Check presence and correct connection of the PTO
DFC TimeOut of 1PEAct Controller, CAN cable disconnected Controller to the network, Check correct functioning
Control TSC1PE
Message
A25B CAN Bus: Passive ComTOTSC OFF none NO Defective CAN controller of PTO Check presence and correct connection of the PTO
DFC TimeOut of 1PEPas Controller, CAN cable disconnected Controller to the network, Check correct functioning
Control TSC1PE
Message
A16B CAN Bus: Active ComTOTSC OFF none NO Defective CAN controller of Check presence and correct connection of the
Base - October 2011
Time out for 1TEAct Transmission Controller, CAN cable Transmission Controller to the network, Check
Torque Speed disconnected or broken. Short circuit correct functioning of the CAN controller. Check
Control TSC1TE in wiring. wiring.
73
message
Base - October 2011
74
Long
System
Failure
Time out for 1TEPas Transmission Controller, CAN cable Transmission Controller to the network, Check
Control TSC1TE in wiring. wiring.
message
A36B CAN Bus: Active ComTOTSC OFF none NO Defective CAN controller of Check presence and correct connection of the
Time out for 1TRAct Transmission Controller, CAN cable Transmission Controller to the network, Check
Control TSC1TR in wiring. wiring.
message
Time out for 1TRPas Transmission Controller, CAN cable Transmission Controller to the network, Check
Control TSC1TR in wiring. wiring.
message
A17B CAN Bus: Active ComTOTSC OFF none NO Defective CAN controller of Vehicle Check presence and correct connection of the Vehicle
Time out for 1VEAct Controller, CAN cable disconnected Controller to the network, Check correct functioning
Control TSC1VE
message
A27B CAN Bus: Passive ComTOTSC OFF none NO Defective CAN controller of Vehicle Check presence and correct connection of the Body
Time out for 1VEPas Controller, CAN cable disconnected Computer to the network, Check correct functioning
Control TSC1VE
message
A37B CAN Bus: Active ComTOTSC OFF none NO Defective CAN controller of Body Check presence and correct connection of the Body
Time out for 1VRAct Computer, CAN cable disconnected Computer to the network, Check correct functioning
S SERIES EURO V
Print P1D32S014 E
Control TSC1VR
message
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
A47B CAN Bus: Passive ComTOTSC OFF none NO Defective CAN controller of Body Check presence and correct connection of the Body
Time out for 1VRPas Computer, CAN cable disconnected Computer to the network, Check correct functioning
Control TSC1VR
message
B98B CAN Bus: Timeout ComTOTxC OFF none NO Defective CAN controller, CAN Check the presence and correct connection of the
Error of CVS cable disconnected or broken. Short EDC to the network, Check correct functioning of the
me Cruise Control
Vehicle Speed
Setup Information
(TxCCVS)
A57B CAN Bus: Timeout ComTSC1V OFF none NO Defective CAN controller of Check presence and correct connection of the TCO
Error of ETO Tachograph Output , undervoltage of to the network, Check correct functioning of the TCO
CAN-Receive-Fra TCO, missing TCO, CAN cable CAN controller and its voltage supply. Check wiring.
me Torque Speed connecting the TCO is disconnected
Control TSC1VE or broken. Short circuit in wiring.
message
A67B CAN Bus: Timeout ComTSC1V OFF none NO Defective CAN controller of Check presence and correct connection of the TCO
Error of RTO Tachograph Output , undervoltage of to the network, Check correct functioning of the TCO
CAN-Receive-Fra TCO, missing TCO, CAN cable CAN controller and its voltage supply. Check wiring.
me Torque Speed connecting the TCO is disconnected
Control TSC1VR or broken. Short circuit in wiring.
message
A33A CAN Urea Level: ComUreaLvl OFF none NO Defective CAN controller of Urea Check presence and correct connection of the Urea
Timeout Error of TO tank level sensor , CAN cable tank level sensor to the network, Check correct
Base - October 2011
CAN-Receive-Fra connecting the sensor is functioning of the sensor CAN controller and its
me Urea Tank disconnected or broken. Short circuit voltage supply. Check wiring.
Level (UreaLvl) in wiring.
75
Base - October 2011
76
Long
System
Failure
A63B CAN Bus: Timeout ComVDC1T OFF none NO Defective CAN controller of Vehicle Check presence and correct connection of the VDCU
Error of O Dynamics Control Unit , to the network, check correct functioning of the
CAN-Receive-Fra undervoltage of VDCU, missing VDCU CAN controller and its voltage supply. Check
me Vehicle VDCU, CAN cable connecting the wiring.
Dynamic Stability VDCU is disconnected or broken.
Control 1 (VDC1: Short circuit in wiring.
VDC Info, Brake
light request, Roll
Over Prevention
active,Yaw Control
active)
A39B tbd ComVDTO OFF none NO
BA8B CAN Bus: Timeout ComVEP1T OFF none NO Defective CAN controller, CAN Check the presence and correct connection of the
me Vehicle Power
(VEP1: battery
voltage
information)
A77B CAN Bus: Timeout ComVM2ED OFF none NO Defective CAN controller of Vehicle Check presence and correct connection of the VCM
Error of CTO Control Module , undervoltage of to the network, Check correct functioning of the VCM
CAN-Receive-Fra VCM, missing VCM, CAN cable CAN controller and its voltage supply. Check wiring.
me Vehicle connecting the VCM is disconnected
Control Module to or broken. Short circuit in wiring.
EDC (VM2EDC:
low/high Idle,
Intermeduiate
speed
Gov.parameters)
F91F Info: Torque CoVehPrfmL OFF none NO Active power reduction due to the Check which failure activated the performance
Limitation active: imAct OBD performance limiter because of limitation (FID_CoVehPrfmLim%%OBD with
S SERIES EURO V
OBD performance too high NOx emissions %%=11,12,21 or 22) and perform troubleshooting on
Print P1D32S014 E
limiter is active. the basis of this defect.

Note: The OBD performance limiter can be disabled
with service tester at maximum 3.00- times
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
51D2 Cruise Control CrCLmpOL OFF none NO Broken or disconnected wiring or Check of wiring or replacement of Cruise Ctrl Lamp
Lamp: No load defective Cruise Ctrl Lamp
error for
powerstage.
81D2 Cruise Control CrCLmpOT OFF none NO High battery voltage, high No reaction needed if failure isn't present after short
Lamp: Over temperature inside ECU, high load or time, check load and output, check wiring, replace
temperature error. wiring problem ECU
61D2 Cruise Control CrCLmpSCB OFF none NO Short circuit of wiring to external Check of wiring or replacement cruise control lamp
Lamp: Short circuit source or inside cruise control lamp
to battery error for
powerstage.
71D2 Cruise Control CrCLmpSC OFF none NO Short circuit of wiring to ground or Check of wiring or replacement cruise control lamp
Lamp: Short circuit G inside cruise control lamp
to ground error for
powerstage.
D1F3 Crankcase CrCsPPhysR OFF none NO Inaccurate or defective crankcase Check wiring and the accuracy of the crankcase
differential pressure ngHi differential pressure sensor, defect in differential pressure sensor and replace it if necessary
: Physical signal the wiring
above upper limit
Base - October 2011
(physical SRC)
77
Base - October 2011
78
Long
System
Failure
E1F3 Crankcase CrCsPPhysR OFF none NO Inaccurate or defective crankcase Check wiring and the accuracy of the crankcase
differential pressure ngLo differential pressure sensor, defect in differential pressure sensor and replace it if necessary
: Physical signal the wiring
below lower limit
(physical SRC)
11F3 Crankcase CrCsPSRCM OFF none NO Short circuit of sensor to external Check wiring and sensor
differential pressure ax source or defective sensor
: Signal Range
Check high
21F3 Crankcase CrCsPSRCM OFF none NO Short circuit of sensor to ground or Check wiring or replace sensor
differential pressure in defective sensor
: Signal Range
Check low
A1F3 Crankcase CrCsVDiscIn OFF none NO Disconnection between blow-by Check blow-by duct
differential pressure tMnf hose and air duct
value above limit;
hose drop of
crankcase
ventilation
3291 Cruise control: CrCUIIrvrsN OFF none NO Failure in Cruise control module Check Cruise control unit
Irreversible fault pl (switches) Check wiring harness
path which Failure in wiring harness
indicates the invalid
combination of
cruise control keys
pressed
3391 Cruise control: CrCUIRvrsN OFF none NO Failure in Cruise control module Check Cruise control unit
Reversible fault pl (switches) Check wiring harness
S SERIES EURO V
Print P1D32S014 E
path which Failure in wiring harness

indicates the invalid
combination of
cruise control keys
pressed
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
A313 Coolant temp CtT OFF none NO Coolant temperature sensors does Check fucntionality of Thermostat
sensor: DFC-ID of not measure correct values or Check functionality of Coolant temperature sensor
CtT to be used Thermostat does not close correctly
with DSM (engine remains too cold for a too
long time)
F36C ECU Internal: Cy320SpiCo OFF none NO ECM internal failure Replace ECM
SPI/COM-Errors of m
the Cy320
114F Battery voltage: DevLibBattU OFF none NO Power supply is to high --> possibly Check battery status and voltage level,Disconnect
Powerstage Hi external power supply connected external device if connected or replace ECU if no
diagnosis could be (battery charger??) or internal failure supply problem is found.
disabled due to of ECU (wrong measurement of
high Battery supply voltage)
voltage
214F Battery voltage: DevLibBattU OFF none NO Too low battery voltage, possible Chech battery state (charge state). Check connectors
Powerstage Lo also during engine cranking (possibly and wiring harness to corrosion and/or too high
diagnosis could be in cold conditrion), too low electrical resistance
disabled due to measurement of battery voltage
low Battery voltage possibly due to corroded contacts or
wiring harness
Base - October 2011
79
Base - October 2011
80
Long
System
Failure
FFFF No description DSMDummy none none NO

available
A15A SCR Control: DStgyAge OFF none YES Catalyst aged due to the use at Check, if the SCR efficiency has really droped downs
Catalyst ageing potential higher temperature than expected (drive at ~constant vehicle speed with CAt
limit exceeded (>> 700°C). Temperature ~300 to 400°C and check, if demanded
NOx can be reached (with NOx sensor reading) and
the Closed loop controller factor within0.7 to 1.3). If
OK, r
A1EA SCR Control: DStgyCLCtrl ON Compre none YES Reagent with deviating UREA Check Reagent, if correct concentration
Closed loop NH3Corr hensive potential concentration Check Dosing quantity of SCR system
contribution Reagent injection deviating Check if engine raw emissions are OK (e.g. drive
outside tolerance Wrong NOx measurement vehicle at constant speed without Reagent injection
range Engine NOx raw emissions deviating and compare measured with estimated NOx with
from expected (humidity sensor tester), if not check:
measures wrong, injection timing Check NO
deviating, fuel pressure sensor
deviating...)
A25A SCR Control: Too DStgyHiEff OFF none NO Reagent with too high UREA Check Reagent, if correct concentration
high efficiency of concentration (>>32%) Check Dosing quantity of SCR system
the catalyst system Too high Reagent injection Check if engine raw emissions are OK (e.g. drive
Wrong NOx measurement (NOx vehicle at constant speed without Reagent injection
Sensor measures too low values) and compare measured with estimated NOx with
Engine NOx raw emissions lower tester), if not check:
than epxected (humidity sensor Check NO
measures too dry air, injection timing
retarded, fuel p
A2EA NOx sensing: NOx DStgyLambd ON Compre none YES direct Lambda sensor or NOx sensor If no LSU failures present NOx sensor probably
sensor lambda aRecMon hensive measurement deviating defective.
S SERIES EURO V
Print P1D32S014 E
measure deviating If also NOx plausibility failure is present NOx sensor

from LSU sensor defective, replace NOx sensor
measure
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
A35A SCR Control: NH3 DStgyNH3Sl OFF none NO Reagent with too high UREA Check Reagent, if correct concentration
slip DFC ip concentration (>>32%) Check Dosing quantity of SCR system
Too high Reagent injection Check if engine raw emissions are OK (e.g. drive
Wrong NOx measurement (NOx vehicle at constant speed without Reagent injection
Sensor measures too high values) and compare measured with estimated NOx with
Engine NOx raw emissions lower tester), if not check:
than epxected (humidity sensor Check NO
measures too dry air, injection timing
retarded, fuel
A16A NOx Sensing: Drift DStgyNOxD ON Exhaust none YES direct NOx Sensor dos not measure Check NOx sensor: drive and measure NOx Sensor
error of NOx rft Gas correctly signal - must indicate < 30.00ppm each time engine is
sensor value Sensor Continuous NH3 slip (in this case in overrun. If not, disable Reagent dosing and repeat
possibly also failure NOxLvl1 or test:
NOxLv2 active!) - If NOx concentration still > 30.00ppm in overrun
phase -> NOx sensor defect --> replace it.
A17A Too High NOx DStgyNOxL ON Exhaust none YES direct Reagent with too low UREA Check Reagent, if correct concentration
Emissions: Catalyst vl1 Gas concentration (<<32%) Check Dosing quantity of SCR system
efficiency lower Sensor Too low or no Reagent injection Check if engine raw emissions are OK (e.g. drive
than first NOx Wrong NOx measurement (NOx vehicle at constant speed without Reagent injection
production Sensor measures too high values) and compare measured with estimated NOx with
threshold level Engine NOx raw emissions higher tester), if not check:
than epxected (humidity sensor NOx Sens
measures too humid air, injection
timing anticip
A27A Too High NOx DStgyNOxL ON Exhaust none YES direct Reagent with too low UREA Check Reagent, if correct concentration
Emissions: Catalyst vl2 Gas concentration (<<32%) Check Dosing quantity of SCR system
efficiency lower Sensor Too low or no Reagent injection Check if engine raw emissions are OK (e.g. drive
than second NOx Wrong NOx measurement (NOx vehicle at constant speed without Reagent injection
production Sensor measures too high values) and compare measured with estimated NOx with
threshold level Engine NOx raw emissions higher tester), if not check:
Base - October 2011
than epxected (humidity sensor NOx Sens

measures too humid air, injection
timing anticip
81
Base - October 2011
82
Long
System
Failure
316A NOx Sensing: DStgyNOxPl OFF Exhaust none YES direct NOx Sensor dos not measure Check if engine raw emissions are OK (e.g. drive
Plausibility error of aus Gas correctly vehicle at constant speed without Reagent injection
NOx sensor value Sensor Engine NOx raw emissions different and compare measured with estimated NOx with
from expected (humidity sensor tester), if not check:
measures wrong humidty, injection NOx Sensor
timing not correct, fuel pressure Humidity Sensor
sensor measures wrong fuel Fuel pressure sensor
pressure...) Injection timing
Note for EURO OBD ap
322A SCR Temp DStgyPlausD OFF NOx none YES direct One of the SCR Temperature Check the SCR temperature sensors for correct
monitoring: yn Aftertrea sensors defective mounting (sensor in exhaust flow, not covered by
Dynamic plausibility tment One of the SCR Temperature insulation of SCR housing etc...), correct connectors
error sensors with corroded connector or (no corrosion) and wiring (correct insulation, not
defect wiring harness broken).
One of both SCR Temperature Check temperature sensors and replace them if
sensors not mounted correctly (e.g.
not in exhaust flow due to mounting
problems)
Temperature i
332A SCR Temp DStgyPlausT OFF NOx none YES direct AmbientTemperature sensor (in Check temperature sensor in humidity sensor.
monitoring: empBoth Aftertrea humidity sensor) defective. Check temperature sensors before and after SCR.
Plausibility tment Both, before and after SCR Check, if "special ambient conditions" (vehicle shifted
temperature temperature sensors defective. from cold ambeint to heated room without engine
monitoring when Vehicle "shifted" into "heated" room start) could have caused the problem.
with ambient or after long stand still in cold ambient.
catalyst
temperatures
S SERIES EURO V
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
342A SCR Temp DStgyPlausT OFF NOx none YES direct Temperature sensor after SCR Check Temperature sensor after SCR.
monitoring: empDs Aftertrea defective. Check temperature sensor before SCR.
Plausibility tment Exhaust system at "sunshine", rest of Check temperature sensor in humidity sensor.
temperature the system in "cold shadow" for a Check, if "special ambient conditions" (as sunshine at
monitoring with longer time. temperature after SCR) could have caused the
down stream Temperature sensor before SCR problem.
temperature defective.
Ambient temperature sensor
defective.
352A SCR Temp DStgyPlausT OFF NOx none YES direct Temperature sensor before SCR Check Temperature sensor after SCR.
monitoring: empUs Aftertrea defective. Check temperature sensor before SCR.
Plausibility tment Check temperature sensor in humidity sensor.
temperature Exhaust system at "sunshine", rest of Check, if "special ambient conditions" (as sunshine at
monitoring when the system in "cold shadow" for a temperature after SCR) could have caused the
with up stream longer time. problem.
temperature Temperature sensor after SCR
defective.
Ambient temperature sensor
defective.
A12A SCR Temp Sensing: DStgyPrs OFF none YES SCR Catalyst dismounted. Check if SCR not dismounted (i.e. not empty housing)
Catalyst present potential Check if SCR temperature sensors are connected
monitoring Temperature sensors before-after correctly (not interchanged)
SCR interchanged.
A22A SCR Control: State DStgySCRSt OFF NOx none YES direct Heating system not working. Check if reagent available.
monitoring of the ate Aftertrea Wrong temperature measurement of Check reagent heating system (not necessary, if failure
SCR system tment Reagent tank or Reagent pump occured at ambient temperature > 0°C and reagent
temperature (too low temp tank temperature > 0°C when failrue occurred)
measurement) Check Temperature sensors in Reagent tank and/or
No pressure built up possible in reagent pump for correct
Base - October 2011
Reagent dosing pump (e.g. leakage in

suction line, no Reagent in tank,
Pump defect)
83
Base - October 2011
84
Long
System
Failure
B13A SCR Reagent DStgyUrCnd OFF NOx none YES Sensor defect. Check UREA qualtity sensor
Qualtity: Urea Aftertrea potential Wiring harness defect. Checke wiring harness.
conductivity error tment Wrong reagent liquid. Check Reagent liquid.
C13A SCR Reagent DStgyUrQl OFF NOx none YES If also failure "DStgyUrCnd" stored: If also failure "DStgyUrCnd" stored: check sensor.
Qualtity: Urea Aftertrea potential sensor or wiring harness defect. Check Reagent quality, should be ~32% (between
quality error tment reagent liquid out of specification. 10.00% and 100.00%)
A13A SCR Reagent Level DStgyUTnkL OFF NOx none NO Level sensor defect Check Sensor.
Sensing: Urea level vl Aftertrea Wiring harness defect Check wiring harness.
tank error tment
3231 Break Actuation: EBrkPreSelPl OFF none NO - One of the preselection switches or - Check the switches for short circuit.
Engine break aus the wiring has a short circuit.
preselection not
plausible
4194 Engine ECBtnStopSi OFF none NO Engine compartment button stuck in Check stop button.
compartment g pressed position
button: stop
button pressed too
long
4294 Engine ECBtnStrtSig OFF none NO Engine compartment button stuck in Check start button.
compartment pressed position
button: start
S SERIES EURO V
button pressed too
Print P1D32S014 E
long
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
5177 EGR Valve: No ECBVlvOL ON EGR none YES direct Broken or disconnected wiring or Check of wiring replace EGR Cooling Bypass Valve
load error on defective EGR Cooling Bypass Valve Actuator
power stage for Actuator
EGR Cooling Valve
Bypass Actuator
8177 EGR Valve: Over ECBVlvOvrT OFF none YES High battery voltage, high Check battery voltage, wiring, power stage and
temperature error emp potential temperature inside ECU, high load or actuator
on powerstage for wiring problem or actuator defective
EGR cooler bypass
valve
1197 EGR Valve: Physical ECBVlvPhys OFF none NO Inaccurate or defective position Check wiring and the accuracy of the position sensor
Signal for EGR RngHi sensor, or defect in the wiring of the and replace it if necessary
Cooling Valve sensor
Bypass Actuator
above maximum
limit
2197 EGR Valve: Physical ECBVlvPhys OFF none NO Inaccurate or defective position Check wiring and the accuracy of the position sensor
Signal for EGR RngLo sensor, or defect in the wiring of the and replace it if necessary
Cooling Valve sensor
Bypass Actuator
below minimum
limit
6177 EGR Valve: Short ECBVlvSCB ON EGR none YES direct Short circuit of wiring to external Check of wiring or replace EGR Cooling Bypass Valve
circuit to battery source or defective EGR Cooling Actuator
error on power Bypass Valve Actuator
stage for EGR
Cooling Valve
Bypass Actuator
7177 EGR Valve: Short ECBVlvSCG ON EGR none YES direct Short circuit of wiring to ground or Check of wiring or replace EGR Cooling Bypass Valve
circuit to ground defective EGR Cooling Bypass Valve Actuator
Base - October 2011
error on power Actuator

stage for EGR
Cooling Valve
85
Bypass Actuator
Base - October 2011
86
Long
System
Failure
1177 EGR Valve: Fault ECBVlvSRC OFF none YES Short circuit of wiring to external Check wiring harness or replace sensor
check SRC Max Max potential source or defective position sensor
error of ECBVlv
position sensor
2177 EGR Valve: Fault ECBVlvSRC OFF none YES Short circuite at wiring harness or Check of wiring or replace EGR Cooling Bypass Valve
check SRC Min Min potential inside the EGR Cooling Bypass Valve position sensor
error of ECBVlv position sensor to ground or open
position sensor circuit
A14D ECU EEPROM: EEPEraseErr OFF none NO Wrong programming/flashing of the Try to flash the ECM correctly with a proper dataset, if
EEP Read Error ECM, internal defect of the ECM. defect persists: replace ECM.
based on the error
for more blocks
A24D ECU EEPROM: EEPRdErr OFF none NO Wrong programming/flashing of the Try to flash the ECM correctly with a proper dataset, if
EEP Read Error ECM, internal defect of the ECM. defect persists: replace ECM.
based on the error
for more blocks
A34D ECU EEPROM: EEPWrErr OFF none NO Wrong programming/flashing of the Try to flash the ECM correctly with a proper dataset, if
EEP Write Error ECM, internal defect of the ECM. defect persists: replace ECM.
based on the error
for one block
3417 EGR cooler or EGRCACPla ON EGR none YES EGR cooler or charged air cooler Check EGR cooler and charged air cooler
Charged air us potential efficiency low (error can not be
pressure cooler localised clearly)
efficiency low
S SERIES EURO V
Print P1D32S014 E
31A7 EGR cooler: EGRClgMon ON EGR none YES EGR cooler efficiency low Check EGR cooler
Cooler efficiency potential
low
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
32A7 EGR Valve: EGR EGRClgMon OFF none NO EGR cooler clogged, bypass valve Check EGR cooler bypass valve
cooler bypass Vlv stuck
clogged
33A7 EGR cooler: EGRClrPlaus ON EGR none YES EGR cooler efficiency low Check EGR cooler
Cooler efficiency potential
low
2517 Info: EGR shut off EGROff OFF none NO Only information path, no No intervention required
for intercooler or intervention required
EGR cooler
efficency test
B527 EGR Valve: EGRVlvCurr OFF none NO EGR Valve actuation current is higher Check EGR valve electric circuit
Current limited Lim than allowed to reach the desired Check mechanical EGR valve functionality
position: possibly electrical problem
inside EGR Valve actuator or wiring
harness ("short" circuit) or mechanical
sticking of valve
B427 EGR Valve: DFC EGRVlvDrft ON EGR none YES direct EGR valve does not fully close: Check Thightness of EGR valve and the corresponding
for valve drift at Clsd EGR valve blocked mechanically position
closed position Dirt on the valve seat
EGR valve position sensor
mismatched
C427 EGR Valve: DFC EGRVlvDrft ON EGR none YES direct EGR valve does not fully open: Check Functionality of EGR valve and the
for valve drift at Opn EGR valve blocked mechanically corresponding position
Base - October 2011
open position EGR valve sticks

mismatched
87
Base - October 2011
88
Long
System
Failure
3197 EGR Valve: Drifting EGRVlvDrftR OFF none NO EGR valve does not fully open: Check Functionality of EGR valve and the
detected ng EGR valve blocked mechanically corresponding position
EGR valve sticks
mismatched
4127 EGR Valve: Cold EGRVlvGov ON none YES Desired EGR valve position can not No action needed, as long as failure "jammed valve is
Start DvtCld potential be reached at cold status not detected"
EGR valve forzen
EGR valve sticks
mismatched
1127 EGR Valve: EGRVlvGov OFF none YES Desired EGR valve position can not No action needed, as long as failure "jammed valve is
Position deviation DvtMax potential be reached not detected"
above maximum EGR valve sticks
positive limit EGR valve position sensor
detected (too high mismatched
EGR)
2127 EGR Valve: EGRVlvGov OFF none YES Desired EGR valve position can not No action needed, as long as failure "jammed valve is
Position deviation DvtMin potential be reached not detected"
below maximum EGR valve sticks
negative limit EGR valve position sensor
detected (too low mismatched
EGR)
5127 EGR Valve: Open EGRVlvHBrg ON EGR none YES direct Electrical problem of the EGR valve Check wiring harnes on open circuit
load of H-Bridge OpnLd actuator: broken wiring harness, no Check EGR valve actuator on open circuit
S SERIES EURO V
contact of conector, internal broken
Print P1D32S014 E
line in actuator
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
1227 EGR Valve: Over EGRVlvHBrg ON EGR none YES direct Electrical problem of the EGR valve Check wiring harnes on partial short circuit
current of H-Bridge OvrCurr actuator: "short circuit" in wiring Check EGR valve actuator on partial short circuit
harness or internal "short circuit" in
actuator
8127 EGR Valve: Over EGRVlvHBrg ON EGR none YES direct High battery voltage, high No reaction needed if failure isn't present after short
temperature of OvrTemp temperature inside ECU, high load or time, check load and output, check wiring, replace
H-bridge wiring problem ECU
6127 EGR Valve: Short EGRVlvHBrg ON EGR none YES direct Short circuit of wiring to external Check of wiring
circuit to battery ShCirBatt1 source
on Out1 of
H-bridge
6227 EGR Valve: Short EGRVlvHBrg ON EGR none YES direct Short circuit of wiring to external Check of wiring
circuit to battery ShCirBatt2 source
on Out2 of
H-bridge
7127 EGR Valve: Short EGRVlvHBrg ON EGR none YES direct Short circuit of wiring to ground Check of wiring
circuit to ground ShCirGnd1
on Out1 of
Base - October 2011
H-bridge
89
Base - October 2011
90
Long
System
Failure
7227 EGR Valve: Short EGRVlvHBrg ON EGR none YES direct Short circuit of wiring to ground Check of wiring
circuit to ground ShCirGnd2
on Out2 of
H-bridge
7327 EGR Valve: Short EGRVlvHBrg ON EGR none YES direct Short circuit of wiring Check of wiring
circuit over load of ShCirOvrLd
H-bridge
8227 EGR Valve: EGRVlvHBrg ON EGR none YES direct Electrical problem of the EGR Valve Check wiring harnes on partial short circuit
Temperature TempOvrCu actuator: "short circuit" in wiring Check EGR Valve actuator on partial short circuit
dependent over rr harness, internal "short circuit" in
current of H-bridge actuator
7427 EGR Valve: Under EGRVlvHBrg ON EGR none YES direct Too high Voltage fluctuations in Check electrical system of vehicle
voltage of H-bridge UndrVltg system Replace ECU
internal failure of ECU
A227 EGR Valve: EGRVlvJamVl ON EGR none YES direct EGR valve can not be opened as Check Functionality of EGR valve and the
Jammed valve in vClsd desired within expected time corresponding position
closed state EGR valve blocked mechanically
EGR valve sticks
S SERIES EURO V
mismatched
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
B227 EGR Valve: EGRVlvJamVl ON EGR none YES direct EGR valve can not be closed as Check Functionality of EGR valve and the
Jammed valve in vOpn desired within expected time corresponding position
open state EGR valve blocked mechanically
EGR valve sticks
mismatched
1427 EGR Valve: valve EGRVlvPhys ON EGR none YES direct EGR valve position sensor gives Check wiring harness
position sensor SRCMax higher values than maximum due:to Check EGR valve position sensor electrically
physical SRC high electrical problems ("short circuit") or Check correct position in closed (0%) and fully opened
position sensor mismatch (100%) position
2427 EGR Valve: valve EGRVlvPhys ON EGR none YES direct EGR valve position sensor gives Check wiring harness
position sensor SRCMin lower values than minimum due to Check EGR valve position sensor electrically
physical SRC low electrical problems ("short circuit") or Check correct position in closed (0%) and fully opened
position sensor mismatch (100%) position
1327 EGR Valve: SRC EGRVlvSRC ON EGR none YES direct Short circuit of wiring to external Check of wiring or replace EGR valve postion sensor
high for valve Max source or defective EGR valve
position sensor position sensor
voltage
2327 EGR Valve: SRC EGRVlvSRC ON EGR none YES direct Short circuit of wiring to ground or Check of wiring or replace EGR valve postion sensor
low for valve Min defective EGR valve position sensor
position sensor
voltage
B127 EGR Valve: loose EGRVlvTmp OFF none NO Electrical problem in EGR valve Check EGR valve, check electrical connection
Base - October 2011
connection or Err (loose connection) or sticking flap

sticking valve
91
Base - October 2011
92
Long
System
Failure
A45A SCR NOx EGTCondN OFF none YES see leading failure (failure also stored see failure stored in memory, which activated
calculation: multi OxEst potential in memory, which activates FId_EGTCondGsCnstn
signal defects in FId_EGTCondGsCnstn)
NOx estimation
A15D ECU internal EngICO OFF engine stop NO Another failure requested engine No action, this is only an information path
Check: Injection (indirect) speed limitation.
cut off demand This failure path should always
(ICO) for shut off appear in failure memory with with
coordinator another lead failure from ECM
monitoring level (level 2)
A164 Engine Overspeed: EngPrtOvrSp OFF none NO Engine overspeed has occurred No reactions necessary only if this fault/information
Overspeed d status reoccurs frequently. In this case check driving
detection in conditions of vehicle, engine speed acquisition and
component engine injection system for quantity setpoint and actual value
protection during fault recognition, check also f
A454 Engine speed EngPrtTMF OFF none NO Engine stalled by driver mishap. No intervention necessary
sensing: Indicates if WShOff
a Two Mass
Flywheel resonance
shutoff condition is
active
S SERIES EURO V
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
51A2 Engine speed signal EngSpdOL OFF none NO Broken or disconnected wiring or Check of wiring or replace tachometer
output: No load defective tachometer
error on the
engine speed
output power
stage
81A2 DFC for OvrTemp EngSpdOvrT OFF none NO High battery voltage, high load and Check load and output, check wiring, replace
error on the PWM emp high ECU temperature, defective Tachometer or ECU
output powerstage wiring, Tachometer or ECU
for engine speed
output.
61A2 Engine speed signal EngSpdSCB OFF none NO Short circuit of wiring to external Check of wiring or replace tachometer
output: Short source or defective engine speed
circuit to battery limiter
error on the
engine speed
output power
stage
71A2 Engine speed signal EngSpdSCG OFF none NO Short circuit of wiring to ground or Check of wiring or replace tachometer
output: Short defective tachometer
circuit to ground
error on the
engine speed
output power
Base - October 2011
stage
93
Base - October 2011
94
Long
System
Failure
1139 Oxicat Temp EnhSRCMax OFF none NO Exhaust Temperature Sensor at Check wiring and connectors for correct contact
Monitoring: T1ExhTMon exhaust collector inlet measures (corrosion).
Diagnostic Fault wrong values
Check for Check sensor and replace it if necessary
enhanced
SRC-Max of First
exhaust gas
temperature
1239 DPF Temp EnhSRCMax OFF none NO Exhaust Temperature Sensor before Check wiring and connectors for correct contact
montioring: T2ExhTMon EGR exit measures wrong values (corrosion).
Diagnostic Fault Check sensor and replace it if necessary
Check for
enhanced
SRC-Max of
Second exhaust gas
temperature
172A SCR Temp EnhSRCMax ON NOx none YES direct Exhaust Temperature Sensor before Check wiring and connectors for correct contact
monitoring: T3ExhTMon Aftertrea DPF measures wrong values (corrosion).
Diagnostic Fault tment Check sensor and replace it if necessary
Check for
enhanced
SRC-Max of third
exhaust gas
temperature
192A Exhaust Temp EnhSRCMax ON NOx none YES direct Exhaust Temperature Sensor after Check wiring and connectors for correct contact
Check for
enhanced
S SERIES EURO V
SRC-Max of Fourth
Print P1D32S014 E
exhaust gas
temperature
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
1339 Exhaust Temp EnhSRCMax OFF none NO Exhaust Temperature Sensor after Check wiring and connectors for correct contact
monitoring: T5ExhTMon turbine measures wrong values (corrosion).
Check for
enhanced
SRC-Max of fifth
exhaust gas
temperature
1A2A Exhaust Temp EnhSRCMax ON NOx none YES direct Exhaust Temperature Sensor after Check wiring and connectors for correct contact
monitoring: T6ExhTMon Aftertrea turbine measures wrong values (corrosion).
Check for
enhanced
SRC-Max of sixth
exhaust gas
temperature
2139 Oxicat Temp EnhSRCMin OFF none NO Exhaust Temperature Sensor at Check wiring and connectors for correct contact
Monitoring: T1ExhTMon exhaust collector inlet measures (corrosion).
Diagnostic Fault wrong values Check sensor and replace it if necessary
Check for
enhanced SRC-Min
of First exhaust gas
temperature
2239 DPF Temp EnhSRCMin OFF none NO Exhaust Temperature Sensor before Check wiring and connectors for correct contact
montioring: T2ExhTMon EGR exit measures wrong values (corrosion).
Check for
enhanced SRC-Min
Base - October 2011
of Second exhaust
gas temperature
95
Base - October 2011
96
Long
System
Failure
272A SCR Temp EnhSRCMin ON NOx none YES direct Exhaust Temperature Sensor before Check wiring and connectors for correct contact
Check for
enhanced SRC-Min
of third exhaust gas
temperature
292A Exhaust Temp EnhSRCMin ON NOx none YES direct Exhaust Temperature Sensor after Check wiring and connectors for correct contact
Check for
enhanced SRC-Min
of Fourth exhaust
gas temperature
2339 Exhaust Temp EnhSRCMin OFF none NO Exhaust Temperature Sensor after Check wiring and connectors for correct contact
monitoring: T5ExhTMon turbine measures wrong values (corrosion).
Check for
enhanced SRC-Min
of fifth exhaust gas
temperature
2A2A Exhaust Temp EnhSRCMin ON NOx none YES direct Exhaust Temperature Sensor after Check wiring and connectors for correct contact
monitoring: T6ExhTMon Aftertrea turbine measures wrong values (corrosion).
Check for
enhanced SRC-Min
S SERIES EURO V
of sixth exhaust gas
Print P1D32S014 E
temperature
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
D193 Ambient pressure EnvPPhysRng OFF none NO Ambient pressure sensor inside ECU Replace ECU
sensor: Physical Hi is defect
Signal above
maximum limit
E193 Ambient pressure EnvPPhysRng ON Compre none YES Ambient pressure sensor inside ECU Replace ECU
sensor: Physical Lo hensive potential is defect
Signal below
minimum limit
4193 Ambient pressure EnvPSig OFF none NO Ambient pressure sensor is defect Check sensor and replace it if necessary
sensor: CAN
message reports a
defect
1193 Ambient pressure EnvPSRCMa OFF none NO Ambient pressure sensor inside ECU Replace ECU
sensor: SRC High x is defect
for Environment
Pressure
2193 Ambient pressure EnvPSRCMin OFF none NO Ambient pressure sensor inside ECU Replace ECU
sensor: SRC low is defect
for Environment
Base - October 2011
Pressure
97
Base - October 2011
98
Long
System
Failure
D2A3 Diagnostic Fault EnvTPhysRn OFF none NO Environment temperature sensor Check or replace temperature sensor
Check for Physical gHi defective
Signal above
maximum limit
E2A3 Diagnostic Fault EnvTPhysRn ON Compre none YES Environment temperature sensor Check or replace temperature sensor
Check for Physical gLo hensive potential defective
Signal below
minimum limit
42A3 Ambient EnvTSig OFF none NO Ambient temperature sensor Check sensor and replace it if necessary
temperature defective
sensor: DFC for
CAN message
12A3 Ambient EnvTSRCMa OFF none NO Sensor defective or short circuit in Check wiring or replace sensor
temperature x wiring to external source
sensor: SRC High
for Environment
Temperature
S SERIES EURO V
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
22A3 Ambient EnvTSRCMin OFF none NO Sensor defective or short circuit Check wiring or replace sensor
temperature wiring to ground
sensor: SRC low
for Environment
Temperature
4354 Engine speed EpmCaSI1Er OFF none NO Cam Shaft speed signal not stable: Check wiring, sensor installation and proper
sensing: DFC for rSig - electrical intermittent open circuit functioning of camshaft phase sensor (evaluate raw
camshaft signal - sensor not fixed correctly signals)
diagnosis - - electrical disturbances due to Check if sensor fixed correctly (should not be
disturbed signal damaged isolation of wiring harness moveable),check wiring harness and contacts, check if
- electrical disturbances due to electrical lines with high electric performance a
special electrical features
4154 Engine speed EpmCaSI1N OFF none NO Camshaft speed sensor defective Check if snesor mounted correctly
sensing: DFC for oSig Wiring harness "open circuit" Check wiring harness
camshaft signal Camshaft sensor not mounted Check sensor fucntionality and replace it if necessary
diagnosis - no
signal
A354 Engine speed EpmCaSI1Of OFF engine stop NO Camshaft sensor position deviates Check correct postions of camshaft signal wheel and
sensing: DFC for sErr (direct) form crankshaft position: crankshaft signal wheel to piston position
camshaft offset - camshaft mal positioned (e.g. tooth
angle exceeded belt: 1 tooth skipped)
- camshaft position wheel mal
positioned (if adjustable)
- camshaft sensor position mal
positioned (if adjustable)
Base - October 2011
- crankshaft signa
99
Base - October 2011
100 SECTION 5 - DIAGNOSTICS

Long
System
Failure
4454 Engine speed EpmCrSErrSi ON Compre YES YES - High vibration of crank shaft signal Check if sensor fixed correctly (should not be
sensing: Crankshaft g hensive (technical) potential sensor moveable)
signal disturbance - Intermettent open circuit of sensor Check wiring harness and contacts
- Electrical disturbances due to Check if electrical lines with high electric performance
damaged isolation of wiring harness are additionally installed (components not validated by
- Electrical disturbances due external the vehicle manufacturer)
electromagnetic disturbancies
4254 Engine speed EpmCrSNoS ON Compre YES YES Crank shaft speed sensor defect Check if crank shaft speed sensor mounted correctly
sensing: Crankshaft ig hensive (technical) potential Crank shaft speed sensor not Check wiring harness to open/short circuit
signal loss mounted correctly Check crank shaft speed sensor for correct function
Crank shaft speed sensor not and replace it if necessary
connected electrically, open circuit or
short circuit.
1176 Injector PCL: ETClbETFlt OFF none YES Clogged nozzles in the injector of Check injector of cylinder 1 for blocked nozzles and
Corrected Max_0 potential cylinder 1, mechanical defect partially jammed valve needle, check lambda sensor for
energising time of jamming the valve lift, implausible plausible signals, replace injector if necessary
Zero Fuelling lambda signal
Calibration for
injector 1 exceeds
maximum value
S SERIES EURO V
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
Calibration for
injector 3 exceeds
maximum value
Calibration for
injector 4 exceeds
maximum value
Calibration for
injector 2 exceeds
maximum value
2176 Injector PCL: ETClbETFlt OFF none YES Defective injector of cylinder 1, the Check injector of cylinder 1 for proper functioning,
Corrected Min_0 potential injector could be jammed and cannot check lambda sensor for plausible signals, replace
energising time of close entirely, implausible lambda injector if necessary
Zero Fuelling signal
Calibration for
injector 1 below
Base - October 2011
minimum value
101
Base - October 2011

Long
System
Failure
Calibration for
injector 3 below
minimum value
Calibration for
injector 4 below
minimum value
Calibration for
injector 2 below
minimum value
1399 DPF Exhaust Temp ETCtlInrLop OFF none NO Difficult ambient conditions resp Check Temperature sensors
control: Desired CtVMax vehicle use (demanded temprature Check air control system
Temperature can not reached due to ambient Check injection system
before Oxicat not conditions)
reached during Problems with temperature
DPF Regeneration measurement before Oxicat (sensor
defect or sensors before/after Oxicat
S SERIES EURO V
Print P1D32S014 E
interchanged)
Problems with Air control or i
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
2399 DPF Exhaust Temp ETCtlInrLop OFF none NO Problems with temperature Check Temperature sensors
control: Desired CtVMin measurement before Oxicat (sensor Check air control system
Temperature defect or sensors before/after Oxicat Check injection system
before Oxicat interchanged)
exceeded during Problems with Air control or
DPF Regeneration injection system
A399 DPF Exhaust Temp ETCtlInrLop OFF none NO Problems with temperature Check Temperature sensors
control: Control RpT measurement before Oxicat (sensor Check air control system
for increased defect or sensors before/after Oxicat Check injection system
temperature interchanged)
before Oxicat Problems with Air control or
active for too long injection system
time (too long DPF
Regeneration time)
1499 DPF Exhaust Temp ETCtlOutrLo OFF none NO Difficult ambient conditions resp Check Temperature sensors
control: Desired pCtVMax vehicle use (demanded temprature Check Oxicat (execute service regeneration --> does
Temperature after can not reached due to ambient tempa fter Oxicat increase with activated Post
Oxicat not reached conditions) injection?)
during DPF Problems with temperature Check injection system
Regeneration measurement after Oxicat (sensor
defect or sensors before/after Oxicat
interchanged)
Oxicat defective (does not burn
2499 DPF Exhaust Temp ETCtlOutrLo OFF none NO Problems with temperature Check Temperature sensors
control: Desired pCtVMin measurement after Oxicat (sensor Check Oxicat (execute service regeneration --> does
Temperature after measures much too high temp) tempa fter Oxicat increase with activated Post
Oxicat exceeded Problems with injection system (too injection?)
during DPF lhigh post injection quantity) Check injection system
Regeneration
A499 DPF Exhaust Temp ETCtlOutrLo OFF none NO Problems with temperature Check Temperature sensors
control: Control pRpT measurement after Oxicat (sensor Check Oxicat (execute service regeneration --> does
for increased defect or sensors before/after Oxicat tempa fter Oxicat increase with activated Post
temperature after interchanged) injection?)
Base - October 2011
Oxicat active for Oxicat defective (does not burn fuel) Check injection system
too long time (too Problems with injection system (too
long DPF low post injection quantity)
103
Regeneration time)
Base - October 2011

Long
System
Failure
5171 Exhaust flap: No ExhFlpLPOL OFF none YES Broken or disconnected wiring or Check of wiring, replace Exhaust Flap Actuator
load error on potential defective Exhaust Flap Actuator
power stage for
Exhaust Flap
Actuator
5162 Exhaust Flap ExhFlpLPOvr OFF none YES High battery voltage, high Check load and output, check wiring, replace ECU
actuator: Over Temp potential temperature inside ECU, high load or
temperature error wiring problem
on power stage for
Exhaust Flap
Actuator
6162 Exhaust Flap ExhFlpLPSC OFF none YES Short circuit of wiring to external Check of wiring or replace exhaust flap actuator
actuator: Short B potential source or defective exhaust flap
circuit to battery actuator
error on power
stage for Exhaust
Flap Actuator
7162 Exhaust Flap ExhFlpLPSC OFF none YES Short circuit of wiring to ground or First Check wiring, if no short circuit found replace
actuator: Short G potential defective Exhaust Flap Actuator Exhaust Flap Actuator
circuit to ground
error on power
stage for Exhaust
Flap Actuator
A362 Exhaust Flap ExhFlpLPTm OFF none YES Electrical problem in exhaust flap Check exhaust flap, check electrical connection
actuator: sticking pErr potential (loose connection) or sticking flap
S SERIES EURO V
Print P1D32S014 E
valve or loose
connection
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
B162 Exhaust Flap ExhFlpLPX2 OFF none YES Internal failure in Exhaust flap Check exhaust flap actuator and wiring
actuator: Actuator Err potential actuator or Exhaust Flap blocked
reports an error by mechanically or problem of wiring
a defined SCG (see separate documentation for
duration of PWM Exhaust flap)
wiring
A162 Exhaust Flap ExhFlpLPXEr OFF YES YES Internal failure in Exhaust flap Check exhaust flap actuator and wiring
actuator: Actuator r (technical) potential actuator or Exhaust Flap blocked
wiring
B262 Exhaust Flap ExhFlpLPY2E OFF none YES Internal failure in Exhaust flap Check exhaust flap actuator and wiring
actuator: Actuator rr potential actuator or Exhaust Flap blocked
wiring
A262 Exhaust Flap ExhFlpLPYEr OFF none YES Internal failure in Exhaust flap Check exhaust flap actuator
actuator: Actuator r potential actuator or Exhaust Flap blocked
wiring
A139 Oxicat Temp ExhTMonPla OFF none NO Exhaust Temperature Sensor at Note: Too fast ambient temperature change, e.g.
Monitoring: us_0 exhaust collector inlet measures vehicle (and dedicated temperature sensor) exposed
Base - October 2011
deviation from wrong values to sun shine after very cold night, or if the sensor is in
other sensors at a "warm air stream" (e.g. by additional engines like a
cold start cooling compressor for a cold compartment
105
Base - October 2011

Long
System
Failure
A239 Oxicat Temp ExhTMonPla OFF none NO Exhaust Temperature Sensor before Note: Too fast ambient temperature change, e.g.
Monitoring: us_1 EGR exit measures wrong values vehicle (and dedicated temperature sensor) exposed
deviation from to sun shine after very cold night, or if the sensor is in
A72A DPF Temp ExhTMonPla OFF none YES Exhaust Temperature Sensor before Note: Too fast ambient temperature change, e.g.
Monitoring: us_2 potential DPF measures wrong values vehicle (and dedicated temperature sensor) exposed
A92A SCR Temp ExhTMonPla ON NOx none YES direct Exhaust Temperature Sensor after Note: Too fast ambient temperature change, e.g.
monitoring: us_3 Aftertrea DPF measures wrong values vehicle (and dedicated temperature sensor) exposed
deviation from tment to sun shine after very cold night, or if the sensor is in
A339 Exhaust Temp ExhTMonPla OFF none NO Exhaust Temperature Sensor after Note: Too fast ambient temperature change, e.g.
monitoring: us_4 turbine measures wrong values vehicle (and dedicated temperature sensor) exposed
AA2A Exhaust Temp ExhTMonPla OFF NOx none YES direct Exhaust Temperature Sensor after Note: Too fast ambient temperature change, e.g.
monitoring: us_5 Aftertrea turbine measures wrong values vehicle (and dedicated temperature sensor) exposed
Diagnostic Fault tment to sun shine after very cold night, or if the sensor is in
check array for a "warm air stream" (e.g. by additional engines like a
cold start condition cooling compressor for a cold compartment
S SERIES EURO V
Print P1D32S014 E
of exhaust-gas
temperatureMore
S SERIES EURO V
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Long
System
Failure
A739 Exhaust Temp ExhTMonPla OFF none NO Several sensors have wrong Check with ambient conditions, which sensors show
monitoring: usGen measurement values. highest deviation form intake air temperature in AFS,
Diagnostic Fault Too fast change of ambient Boost temperature and Coolant temperature. If Boost
check during cold temperature (e.g. due to sun shining temperature and coolant temperature are similar but
start condition of in the morning after cold night...) --> higher than the exhaust temperatures --> failur
exhaust-gas see ambeint conditions
temperatures
3139 Oxicat Temp ExhTMonPla OFF none NO Bad electrical wiring (e.g. corroded Check wiring and connectors for correct isolation /
monitoring: usPos1 connector or damaged isolation of contact
Diagnostic Fault wire) or gain offset of sensor for Check sensor and replace it, if necessary
check for Model Exhaust Temperature at exhaust Note: failure can also be caused, if the real exhaust
based plausiblity collector inlet temperature differes from the calculated one due to a
check of first failure in the engine like:
exhaust-gas wrong injection
temperature
3239 DPF Temp ExhTMonPla OFF none NO Bad electrical wiring (e.g. corroded Check wiring and connectors for correct isolation /
montioring: usPos2 connector or damaged isolation of contact
check for Model Exhaust Temperature before EGR Note: failure can also be caused, if the real exhaust
based plausiblity exit temperature differes from the calculated one due to a
check of second failure in the engine like:
temperature
Base - October 2011
107
Base - October 2011

Long
System
Failure
372A SCR Temp ExhTMonPla OFF NOx none YES direct Bad electrical wiring (e.g. corroded Check wiring and connectors for correct isolation /
monitoring: usPos3 Aftertrea connector or damaged isolation of contact
Diagnostic Fault tment wire) or gain offset of sensor for Check sensor and replace it, if necessary
check for Model Exhaust Temperature before DPF Note: failure can also be caused, if the real exhaust
based plausiblity temperature differes from the calculated one due to a
check of third failure in the engine like:
temperature
392A Exhaust Temp ExhTMonPla OFF NOx none YES direct Bad electrical wiring (e.g. corroded Check wiring and connectors for correct isolation /
check for Model Exhaust Temperature after DPF Note: failure can also be caused, if the real exhaust
check of first failure in the engine like:
temperature
3339 Exhaust Temp ExhTMonPla OFF none NO Bad electrical wiring (e.g. corroded Check wiring and connectors for correct isolation /
monitoring: usPos5 connector or damaged isolation of contact
check for Model Exhaust Temperature after turbine Note: failure can also be caused, if the real exhaust
check of second failure in the engine like:
temperature
S SERIES EURO V
Print P1D32S014 E
S SERIES EURO V
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Long
System
Failure
3A2A Exhaust Temp ExhTMonPla OFF NOx none YES direct Bad electrical wiring (e.g. corroded Check wiring and connectors for correct isolation /
check for Model Exhaust Temperature after turbine Note: failure can also be caused, if the real exhaust
check of third failure in the engine like:
temperature
5114 Cooling fan FanDIOOL OFF none NO Broken or disconnected wiring or Check of wiring, replace fan actuator
control: No load defective relay
error
8114 Cooling fan FanDIOOvr OFF none NO High battery voltage, high No reaction needed if failure isn't present after short
control: Over Temp temperature inside ECU, high load or time, check load and output, check wiring, replace
temperature error wiring problem ECU
6114 Cooling fan FanDIOSCB OFF none NO Short circuit of wiring to external Check of wiring or replace fan acutator
control: Short source or defective fan actuator
circuit to battery
error
Base - October 2011
109
Base - October 2011

Long
System
Failure
7114 Cooling fan FanDIOSCG OFF none NO Short circuit of wiring to ground or Check of wiring or replace fan actuator
control: Short defective fan actuator
circuit to ground
error
5124 Cooling fan FanPWMOL OFF none NO Broken or disconnected wiring or Check of wiring, replace fan actuator
control: Fan0 _0 defective relay
PWM, No load
error
5224 Cooling fan FanPWMOL OFF none NO Broken or disconnected wiring or Check of wiring, replace fan actuator
control: Fan1 _1 defective relay
PWM, No load
error
8124 Cooling fan FanPWMOv OFF none NO High battery voltage, high Check load and output, check wiring, replace ECU
control: Fan0 rTemp_0 temperature inside ECU, high load or
PWM, Over wiring problem
temperature error
8224 Cooling fan FanPWMOv OFF none NO High battery voltage, high Check load and output, check wiring, replace ECU
control: Fan1 rTemp_1 temperature inside ECU, high load or
PWM, Over wiring problem
S SERIES EURO V
temperature error
Print P1D32S014 E
S SERIES EURO V
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Long
System
Failure
6124 Cooling fan FanPWMSC OFF none NO Short circuit of wiring to external Check of wiring or replace fan actuator
control: Fan0 B_0 source or defective fan actuator
PWM, Short circuit
to battery error
6224 Cooling fan FanPWMSC OFF none NO Short circuit of wiring to external Check of wiring or replace fan actuator
control: Fan1 B_1 source or defective fan actuator
PWM, Short circuit
to battery error
7124 Cooling fan FanPWMSC OFF none NO Short circuit of wiring to ground or Check of wiring or replace fan actuator
control: Fan0 G_0 defective fan actuator
PWM, Short circuit
to ground error
7224 Cooling fan FanPWMSC OFF none NO Short circuit of wiring to ground or Check of wiring or replace fan actuator
control: Fan1 G_1 defective fan actuator
PWM, Short circuit
to ground error
A5A6 Fuel Balancing FBCMon_0 ON Fuel none YES Injector of Cylinder 1 fuel Replace fuel injector of cylinder 1.
Control: fuel System potential introduction outside tolerance range
correction for
Injector of cylinder
1 outside tolerance
Base - October 2011
range
111
Base - October 2011

Long
System
Failure
correction for
3 outside tolerance
range
correction for
4 outside tolerance
range
correction for
2 outside tolerance
range
5172 Fuel filter heater: FlFltHtOL OFF none NO Broken or disconnected wiring or Check of wiring or replace fuel filter heater
No load error in defective fuel filter heater.
powerstage of fuel
filter heating
8172 Fuel filter heater: FlFltHtOvrT OFF none NO High battery voltage, high Check load and output, check wiring, replace ECU
Over Temperature emp temperature inside ECU, high load or
S SERIES EURO V
error at ECM wiring problem
Print P1D32S014 E
power stage
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
6172 Fuel filter heater: FlFltHtSCB OFF none NO Short circuit of wiring to external Check of wiring, replace fuel filter heater
Short circuit to source or inside fuel filter heater
battery error in
powerstage of fuel
filter heating
7172 Fuel filter heater: FlFltHtSCG OFF none NO Short circuit of wiring to ground or Check of wiring, replace fuel filter heater
Short circuit to inside fuel filter heater
ground error in
powerstage of fuel
filter heating
A2E1 Water in Fuel FlSys_WtDe OFF none NO Water in fuel filter Clean fuel filter filter
Determination: t Sensor defective
Water in Fuel Check Sensor
21A1 Fuel tank level: fuel FlSysTnkLo OFF none NO Empty Fuel tank Fill up fuel tank
tank below critical Wrong signal of Tank level sensor Check fuel level sensor and its wiring (additional
level or danger of resistance on connectors...)
an air
contaminated
hydraulic system
Base - October 2011
113
Base - October 2011

Long
System
Failure
12D7 Injector FMOqCorO OFF none YES Calculated lambda may be wrong: air Check air mass meter, injectors and lambda sensor.
Adjustement: BDMax potential mass meter defect or injectors
Injection quantity defect. Measured lambda-value
correction value wrong, check lambda sensor.
too high
22D7 Injector FMOqCorO OFF none YES Calculated lambda may be wrong: air Check air mass meter, injectors and lambda sensor.
Adjustement: BDMin potential mass meter defect or injectors
Injection quantity defect. Measured lambda-value
correction value wrong, check lambda sensor.
too low
A26A NOx Sensor FrmNOxSen none none NO Short Circuit or Open wire in wiring Check wiring harness
(CAN): NOx sNOx harness Check NOx Sensor
Sensor detects not Defective NOx Sensor Note for EURO OBD application: this failure activates
plausible values a Performance limitation due to legislation. Therefore
(NOx or Lambda) after repair following procedure must be done,
otherwise there is the risk tha performance limiter gets
ac
S SERIES EURO V
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
A36A NOx Sensor FrmNOxSen ON Exhaust none YES direct Short Circuit or Open wire in wiring Check wiring harness
Upstream (CAN): sUsNOx Gas harness Check NOx Upstream Sensor
Nox Sensor Defective NOx Upstream Sensor
Concentration
invalid
1283 Fuel low pressure FuelPDynTst OFF none NO Inaccurate fuel pressure sensor or Check pressure sensor accuracy and if necessary
cycle: Maximum Max excessive fuel pressure in system replace sensor. Also check fuel pressure in system.
fuel pressure error
in dynamic
plausibility test
(low pressure)
2283 Fuel low pressure FuelPDynTst OFF none NO Inaccurate fuel pressure sensor or Check pressure sensor accuracy and if necessary
cycle: Minimum Min too low fuel pressure in system replace sensor. Also check fuel pressure in system.
fuel pressure error
in dynamic
plausibility test
(low pressure)
Base - October 2011
115
Base - October 2011

Long
System
Failure
4383 Fuel low pressure FuelPSig OFF none NO Sensor defect Check Sensor
cycle: DFC for
CAN message of
fuel pressure
sensor (low
pressure)
1383 Fuel low pressure FuelPSRCMa OFF none NO Sensor defective or short circuit to Check wiring or replace sensor
cycle: SRC High for x external source
fuel pressure (low
pressure cycle)
2383 Fuel low pressure FuelPSRCMi OFF none NO Sensor defective or short circuit to Check wiring or replace sensor
cycle: SRC Low for n ground
fuel pressure (low
pressure cycle)
D173 Fuel Temperature FuelTPhysRn OFF none NO Fuel temperature sensor defective Check or replace sensor
Sensor: Physical gHi
Signal above
maximum limit
E173 Fuel Temperature FuelTPhysRn OFF none NO Fuel temperature sensor defective Check or replace sensor
Sensor: Physical gLo
Signal below
S SERIES EURO V
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minimum limit
S SERIES EURO V
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Long
System
Failure
1173 Fuel Temp Sensor: FuelTSRCMa OFF none NO Sensor defective or short circuit to Check wiring or replace sensor
SRC high for fuel x external source
temperature
sensor
2173 Fuel Temp Sensor: FuelTSRCMi OFF none NO Sensor defective or short circuit to Check wiring or replace sensor
SRC low for fuel n ground
temperature
sensor
3173 Fuel Temperature FuelTVDPlau OFF none NO Fuel temperature sensor defective Check sensor
Sensor: failed s
plausibility check at
ECU start
4181 Gear Box neutral: GbxNPosSig OFF none NO The gearbox neutral position switch Check the gearbox neutral position switch.
Check for error for is defective.
CAN input
Base - October 2011
117
Base - October 2011

Long
System
Failure
5132 Glow lamp: No GlwLmpOL OFF none NO Broken or disconnected wiring or Check of wiring or replace glow lamp
load error defective glow lamp
6132 Glow lamp: Short GlwLmpSCB OFF none NO Short circuit of wiring to external Check of wiring, replace glow lamp
circuit to battery source or inside glow lamp
error
7132 Glow lamp: Short GlwLmpSC OFF none NO Short circuit of wiring to ground or Check of wiring, replace glow lamp
circuit to ground G inside glow lamp
error
5144 Glow Plug: No GlwPlgOL OFF none NO Broken or disconnected wiring or Check of wiring or replace glow plug indicator lamp
load error defective glow plug indicator lamp
S SERIES EURO V
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S SERIES EURO V
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Long
System
Failure
8144 Glow Plug: Over GlwPlgOvrT OFF none NO High battery voltage, high No reaction needed if failure isn't present after short
temperature error emp temperature inside ECU, high load or time, check load and output, check wiring, replace
wiring problem or proble with glow ECU
plug (resp relay if system has a relay
between ECU and glow plug)
6144 Glow Plug: Short GlwPlgSCB OFF none NO Short circuit of wiring to external Check of wiring
circuit to battery source or inside glow plug (resp Check relay if available
error relay if system has a relay between Check and replace glow plug
ECU and glow plug)
7144 Glow Plug: Short GlwPlgSCG OFF none NO Short circuit of wiring to ground or Check of wiring
circuit to ground inside glow plug (resp relay if system Check relay if available
error has a relay between ECU and glow Check and replace glow plug
plug)
A144 Glow Plug: GlwPlgSVSFa OFF none NO Failure in glow plugs Check wiring between glow plug relay and glow plugs
Defective Glow il Failrue in wiring between Relay and Check glow plugs
Plugs (monitored glow plugs Check Glow plug relay
by Relay)
Base - October 2011
119
Base - October 2011

Long
System
Failure
A244 Glow Plug: Sticking GlwPlgSVSSt OFF none NO Failure in Glow plug relay Check Glow plug relay or replace it
Glow Plug Relay kRly
11A4 Engine speed HLSDem_M OFF none NO

exceeds the upper onOBDMax
limit while
High-Low Speed
Demand is active
21A4 Engine speed falls HLSDem_M OFF none NO

below the lower onOBDMin
limit while
High-Low Speed
Demand is active
5184 Air heater: Open IAirHtOL_0 OFF none NO Broken or disconnected wiring or Check of wiring or replace air heater
load on defective air heater
Powerstage 0
5284 Air heater: Open IAirHtOL_1 OFF none NO Broken or disconnected wiring or Check of wiring or replace air heater
load on defective air heater
Powerstage 1
8184 Air heater: Over IAirHtOvrTe OFF none NO High battery voltage, high Check load and output, check wiring, replace ECU
S SERIES EURO V
temperature on mp_0 temperature inside ECU, high load or
Print P1D32S014 E
Powerstage 0 wiring problem

S SERIES EURO V
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Long
System
Failure
8284 Air heater: Over IAirHtOvrTe OFF none NO High battery voltage, high Check load and output, check wiring, replace ECU
temperature on mp_1 temperature inside ECU, high load or
Powerstage 1 wiring problem
6184 Air heater: Short IAirHtSCB_0 OFF none NO Short circuit of wiring to external Check of wiring, replace air heater
circuit to battery source or inside air heater
on powerstage 0
6284 Air heater: Short IAirHtSCB_1 OFF none NO Short circuit of wiring to external Check of wiring, replace air heater
circuit to battery source or inside air heater
on powerstage 1
7184 Air heater: Short IAirHtSCG_ OFF none NO Short circuit of wiring to ground or Check of wiring, replace air heater
circuit to ground 0 inside air heater
error on
powerstage 0
7284 Air heater: Short IAirHtSCG_ OFF none NO Short circuit of wiring to ground or Check of wiring, replace air heater
circuit to ground 1 inside air heater
error on
powerstage 1
414A Intake Air humidity IndAHSig OFF none NO Disturbed CAN signal transmission, Check the CAN for proper configuration and
Base - October 2011
Sensor: DFC for sensor problem functioning, check air humidity sensor.
CAN message
121
Base - October 2011

Long
System
Failure
114A Info: Intake Air IndAHSRCM OFF none NO Sensor full with water droplets or NO action needed as long as the failure
humidity Sensor: ax Sensor defective or short circuit to IndAHSRCMaxDly is not active.
Probably water external source If failure IndAHSRCMaxDly is not active, check
droplets on Sensor duration of failure active: If a single duration lasts
longer than ~10 min --> there is probably an electrical
failure. --> Check wiring
124A Intake Air humidity IndAHSRCM OFF none NO Sensor full with water droplets Clean Sensor (dry it)
Sensor: Defect axDly Sensor defective or short circuit to Check wiring or replace sensor
Fault Check for external source
Signal value above
maximum limit
214A Intake Air humidity IndAHSRCM OFF none NO Short circuit of wiring to ground or Check wiring and sensor
Sensor: SRC low in defective sensor
for Induction Air
Humidity
S SERIES EURO V
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Print P1D32S014 E
Long
System
Failure
A396 Injector: Number InjCrvInjLim OFF none YES Application of number of requested Check check battery voltage, check power supply of
of injections is ChrgBal potential injections not compatible with system booster banks
limited by charge capability or charging of injector
balance of booster booster insufficient
capacity
A496 Injector: Number InjCrvInjLim OFF none YES Application of number of requested Check fuel temperature, check presence of other
of injections is QntBal potential injections not compatible with system failures regarding rail pressure deviation or fuel
limited by quantity capability or high pressure pump delivery.
balance of high efficiency limited due to ageing, CHeck High pressure pump.
pressure pump insufficient rail pressure or too high
fuel temperature.
A596 Injector: Number InjCrvInjLimS OFF none YES Dataset application wrong, too high Dataset should be replaced, contact Help Desk
of injections is ys potential number of injections allowed.
limited by system
2196 Injector: Number InjCrvNumIn OFF none YES Dataset application wrong, too high Dataset should be replaced, contact Help Desk
of injections is jRtmLim potential number of injections allowed.
limited by runtime
2296 Injector: check of InjVlvPresMi OFF none YES Rail pressure controller problem Check presence of other more specific failures related
minimum rail n potential (pressure control valve or metering to rail pressure controller. Check rail actuators, check
pressure unit sticking), High Pressure pump rail or injector leakages
Base - October 2011
efficiency to low or system leakages
123
Base - October 2011

Long
System
Failure
B136 Injector: SRC max IVActrVltgSR ON Fuel none YES Failure in wiring harness between Check wiring harness between ECU and injectors
error in the voltage CMax System potential ECU and injectors Check injectors
of the piezo Failure in injector (actuator) Check/Replace ECU
actuator Failure in ECU (power stage)
B236 Injector: SRC min IVActrVltgSR ON Fuel none YES Failure in wiring harness between Check wiring harness between ECU and injectors
error in the voltage CMin System potential ECU and injectors Check injectors
of the piezo Failure in injector (actuator) Check/Replace ECU
actuator Failure in ECU (power stage)
A116 Injector IVAdjDiaIVA OFF none YES Invalid IMA code has been Reprogram IMA code
Adjustement: IMA dj_0 potential programmed Reflash teh ECU (including EEPROM initialisation)
programming not wrong programming/flashing of the if defect persists: replace EDC
correct for injector EDC (initialization of EEPROM)
cyl 1 internal defect of the ECU
S SERIES EURO V
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
B116 Injector IVAdjIVA_0 OFF none YES Invalid IMA/ISA code has been Reprogram IMA/ISA code
Adjustement: potential programmed Reflash teh ECU (including EEPROM initialisation)
IMA/ISA wrong programming/flashing of the if defect persists: replace EDC
programming not EDC (initialization of EEPROM)
correct for cyl 1 internal defect of the ECU
Base - October 2011
125
Base - October 2011

Long
System
Failure
A146 Injector: IVCtlTiDiff_0 ON Fuel none YES Additional resistances in the wiring of Check wiring
Discharge-time out System potential injectors (connectors) Check injectors, replace them if necessary
of range injector Electric part of injectors Replace ECU
no 1 ECU internal defect (Injector
powerstage / Booster)
powerstage / Booste
S SERIES EURO V
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
B146 Injector: Opening IVCtlUDiffU ON Fuel none YES Additional resistances in the wiring of Check wiring
voltage out of p_0 System potential injectors (connectors) Check injectors, replace them if necessary
range injector no 1 Electric part of injectors Replace ECU
ECU internal defect (Injector
Base - October 2011
127
Base - October 2011

Long
System
Failure
C146 Injector: Corrected IVCtlUUp_0 ON Fuel none YES Additional resistances in the wiring of Check wiring
opening Voltage System potential injectors (connectors) Check injectors, replace them if necessary
out of range of Electric part of injectors Replace ECU
cylinder 1 ECU internal defect (Injector
S SERIES EURO V
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
A156 Injector: bank0, IVDiaBnkSh ON Fuel engine stop YES Short circuit in wiring or injector Check the wiring and injectors connected to bank 0.
short circuit Cir_0 System (direct) potential connected to bank 0
A256 Injector: bank1, IVDiaBnkSh ON Fuel engine stop YES Short circuit in wiring or injector Check the wiring and injectors.
short circuit Cir_1 System (direct) potential connected to bank 1.
Base - October 2011
129
Base - October 2011

Long
System
Failure
A356 Injector: bank0, IVDiaBnkSh ON Fuel engine stop YES Short circuit in wiring or injector Check the wiring and injectors connected to bank 0.
short circuit on CirChSwt_0 System (indirect) potential connected to bank 0
charge switch
A456 Injector: bank1, IVDiaBnkSh ON Fuel engine stop YES Short circuit of high-side to battery Check the wiring or replace injector.
short circuit on CirChSwt_1 System (indirect) potential or ground.
charge switch
B766 Injector: ECM IVDiaChp ON Fuel none YES Defective ECM Replace ECM
internal failure of System potential
Injector actuation
(chip error)
A166 Injector: IVDiaCylNo ON Fuel none YES Abnormal behaviour in injector of Replace fuel injector of cylinder 1.
non-classifiable Cls_0 System potential cylinder 1 is detected, symptoms
error at cylinder 1 cannot be matched to a specific
injector problem
S SERIES EURO V
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
injector problem
injector problem
injector problem
5166 Injector: open load, IVDiaCylNo ON Fuel none YES Open load for injector of cylinder 1 is Check wiring, replace fuel injector of cylinder 1.
injector cylinder 1 Ld_0 System potential detected.
Base - October 2011
131
Base - October 2011

Long
System
Failure
6166 Injector: short IVDiaCylShC ON Fuel engine stop YES Short circuit in wiring or injector Check wiring, replace fuel injector of cylinder 1.
circuit, injector ir_0 System (direct) potential
cylinder 1
cylinder 3
cylinder 4
S SERIES EURO V
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Long
System
Failure
cylinder 2
circuit of high side irHSLS_0 System (direct) potential
to low side for
injector of cylinder
1
to low side for
3
Base - October 2011
133
Base - October 2011

Long
System
Failure
to low side for
4
to low side for
2
B166 Injector: cylinder IVDiaCylShC ON Fuel engine stop YES Short circuit in wiring or injector Check wiring, replace fuel injector of cylinder 1.
short circuit irMeas_0 System (direct) potential
detected with
plausibility check of
1
S SERIES EURO V
Print P1D32S014 E
S SERIES EURO V
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Long
System
Failure
detected with
3
detected with
4
detected with
2
A126 Injector: DC/DC IVPSplyDCD ON Fuel engine stop YES Buffer capacitor cannot be charged, Check presence of other failures connected to injector
converter shut off COff_0 System (direct) potential problem can be located in the supply (short circuit), check capacitor, replace ECM if
capacitor or the powerstage itself. powerstage is responsible.
Base - October 2011
135
Base - October 2011

Long
System
Failure
A226 Injector: DC/DC IVPSplyDCD ON Fuel engine stop YES Buffer capacitor cannot be charged, Check presence of other failures connected to injector
converter shut COff_1 System (direct) potential problem can be located in the supply (short circuit), check capacitor, replace ECM if
offMore capacitor or the powerstage itself. powerstage is responsible.
B126 Injector: stop of IVPSplyStop ON Fuel engine stop YES DC/DC converter cannot be shut off Check presence of other failures connected to injector
DC/DC converter DCDC_0 System (direct) potential supply (short circuit), check capacitor, replace ECM if
failed powerstage is responsible.
B226 Injector: stop of IVPSplyStop ON Fuel engine stop YES DC/DC converter cannot be shut off Check presence of other failures connected to injector
DC/DC converter DCDC_1 System (direct) potential supply (short circuit), check capacitor, replace ECM if
failed powerstage is responsible.
412E Lambda sensor LSUCircNer ON Exhaust none YES Defect in wiring (open load in Nernst Check entire wiring of lambda sensor, check lambda
Wiring: Open nstSig Gas potential Cell (UN) line, Nernst cell; Due to sensor itself, if necessary replace lambda sensor (and
circuit at the Sensor SW bug: open load in heater line, reset all learning values in EEPROM with tester)
lambda sensor K51) of the lambda sensor, defective
Nernst cell pin lambda sensor Note for EURO OBD application: this failure activates
a Performance limitation due to legislation.
S SERIES EURO V
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
422E Lambda sensor LSUCircPmp ON Exhaust none YES Defect in wiring (open load in IP line, Check entire wiring of lambda sensor, check lambda
Wiring: open CurSig Gas potential pump current; of the lambda sensor, sensor itself, if necessary replace lambda sensor (and
circuit at the Sensor defective lambda sensor reset all learning values in EEPROM with tester)
lambda sensor
pump current pin - Note for EURO OBD application: this failure activates
IP (lambda = 1 a Performance limitation due to legislation.
detection)
432E Lambda sensor LSUCircVirt ON Exhaust none YES Defect in wiring (open load in Virtual Check entire wiring of lambda sensor, check lambda
Wiring: Open GndSig Gas potential Ground (VG) line, virtual ground; sensor itself, if necessary replace lambda sensor (and
circuit at the Sensor Due to SW bug: open load in heater reset all learning values in EEPROM with tester)
lambda sensor line, K51) of the lambda sensor,
Virtual ground pin defective lambda sensor Note for EURO OBD application: this failure activates
a Performance limitation due to legislation.
A14E Lambda Sensing: LSUDynChk ON Exhaust none YES Defect in wiring of lambda sensor, Check wiring, check injection system, replace lambda
Fault to indicate Gas potential defective lambda sensor, problems in sensor (and reset all learning values in EEPROM with
Dynamics of the Sensor injection system (e.g. leaky injectors) tester)
sensor signal too or EGR valve does not close in Note for EURO OBD application: this failure activates
small overrun condition a Performance limitation due to legislation. Therefore
after repair following procedur
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137
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Long
System
Failure
462E Lambda Sensor LSUHtCoup ON Exhaust none YES Defective lambda sensor Replace lambda sensor (and reset all learning values in
Heater: O2 Sig Gas potential EEPROM with tester)
concentration is Sensor Note for EURO OBD application: this failure activates
outside the a Performance limitation due to legislation. Therefore
predefined window after repair following procedure must be done,
during Heater otherwise there is the
coupling detection
111E Lambda Sensor LSUHtrMax ON Exhaust none YES Short circuit of wiring to external Check wiring and lambda sensor, if necessary replace
Heater: SCB error Gas potential source, defective lambda sensor or lambda sensor (and reset all learning values in
of the LSU Heater Sensor power stage EEPROM with tester) or ECU.
Powerstage Note for EURO OBD application: this failure activates
a Performance limitation due to legislation. Therefore
after repair fo
211E Lambda Sensor LSUHtrMin ON Exhaust none YES Short circuit of wiring to external Check wiring and lambda sensor, if necessary replace
Heater: SCG error Gas potential ground, defective lambda sensor or lambda sensor (and reset all learning values in
of the LSU Heater Sensor power stage EEPROM with tester) or ECU
Powerstage Note for EURO OBD application: this failure activates
after repair fol
S SERIES EURO V
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
311E Lambda Sensor LSUHtrNpl ON Exhaust none YES High battery voltage, high No reaction needed if failure isn't present after short
Heater: Over Gas potential temperature inside ECU, high load or time, check load and output, check wiring and lambda
temperature error Sensor wiring problem sensor, if necessary replace lambda sensor (and reset
of the LSU Heater all learning values in EEPROM with tester) or ECU
Powerstage Note for EURO OBD application: this fail
411E Lambda Sensor LSUHtrSig ON Exhaust none YES Broken or disconnected wiring or Check wiring and lambda sensor, if necessary replace
Heater: Open Gas potential defective lambda sensor lambda sensor (and reset all learning values in
Load error of the Sensor EEPROM with tester)
LSU Heater Note for EURO OBD application: this failure activates
Powerstage a Performance limitation due to legislation. Therefore
after repair following p
172E Lambda Sensing: LSULowBatt ON Exhaust none YES LSU heater problem Replace LSU sensor
Blow out Gas potential
maximum time Sensor
exceeded (LSU
heating insufficient)
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139
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Long
System
Failure
125E Lambda Sensing: LSUO2ClbM ON Exhaust none YES Defect in wiring of lambda sensor, Check wiring and accuracy of lambda sensor, check
Fault code to ax Gas potential inaccurate or defective lambda functioning of injection system and EGR actuators, if
indicate SRC High Sensor sensor, problems with EGR actuators necessary replace lambda sensor (and reset all learning
error for O2 or injection system values in EEPROM with tester)
calibration Note for EURO OBD application: this failure activates
a Performa
225E Lambda Sensing: LSUO2ClbM ON Exhaust none YES Defect in wiring of lambda sensor, Check wiring and accuracy of lambda sensor, check
Fault code to in Gas potential inaccurate or defective lambda functioning of injection system and EGR actuators, if
indicate SRC Low Sensor sensor, problems with EGR actuators necessary replace lambda sensor (and reset all learning
error for O2 or injection system values in EEPROM with tester)
calibration Note for EURO OBD application: this failure activates
a Performa
115E Lambda Sensing: LSUO2Max ON Exhaust none YES Defect in wiring (open circuit at line Reset the Calibration factor and measure the O2 signal
O2 value above Gas potential IA (Pump Cell)), Excessive drifting in in overrun phase. Let the system learn (see failure
the max threshold Sensor O2 concentration during overrun, LSU_O2ClbMin or Max: testing conditions are equalt
Defective lambda sensor, to learning condition) and read the voltage at motoring
Short circuit to external source (O2 content = 20.95%). If the signal stil
215E Lambda Sensing: LSUO2Min ON Exhaust none YES Defect in wiring, defective lambda Check lambda sensor and its entire wiring, if necessary
O2 value below Gas potential sensor, short circuit to ground replace lambda sensor (and reset all learning values in
the min threshold Sensor EEPROM with tester)
Note for EURO OBD application: this failure activates
S SERIES EURO V
after repair
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
315E Lambda Sensing: LSUO2Plaus ON Exhaust none YES Leakage or blockage in exhaust gas Check exhaust gas system, check wiring of lambda
Oxygen MaxFLd Gas potential system, defect in wiring of lambda sensor, check accuracy of lambda and air flow sensor,
concentration Sensor sensor, inaccurate lambda or air flow check injection system, if necessary replace lambda
implausibly high at sensor, problems in injection system sensor (and reset all learning values in EEPROM with
High Load (e.g. blockage in injectors) tester)
Note for EURO OBD application: this fa
Oxygen MaxOvrRun Gas potential system, defect in wiring of lambda sensor, check accuracy of lambda and air flow sensor,
concentration Sensor sensor, inaccurate lambda or air flow reset all learning factors of LSU in EEPROM and
implausibly high at sensor, problems in injection system recheck the accuracy of LSU, check injection system, if
Overrun (e.g. blockage in injectors) necessary replace lambda sensor (and reset all l
Oxygen MaxPartLd Gas potential system, defect in wiring of lambda sensor, check accuracy of lambda and air flow sensor,
implausibly high at sensor, problems in injection system recheck the accuracy of LSU, check injection system, if
Part Load (e.g. blockage in injectors) necessary replace lambda sensor (and reset all l
Oxygen MinFLd Gas potential system, defect in wiring of lambda sensor, check accuracy of lambda and air flow sensor,
implausibly low at sensor, problems in injection system recheck the accuracy of LSU, check injection system, if
High Load (e.g. leaky injectors) necessary replace lambda sensor (and reset all l
Base - October 2011
141
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Long
System
Failure
Oxygen MinOvrRun Gas potential system, defect in wiring of lambda sensor, check accuracy of lambda and air flow sensor,
Overrun (e.g. leaky injectors) necessary replace lambda sensor (and reset all l
Oxygen MinPartLd Gas potential system, defect in wiring of lambda sensor, check accuracy of lambda and air flow sensor,
part Load (e.g. leaky injectors) necessary replace lambda sensor (and reset all l
116E Lambda Sensing: LSUPresCo ON Exhaust none YES Wrong exhaust pressure caclulation Check if there is a failure stored conserning exhaust
Fault check for mpMax Gas potential due to: pressure caclulation due to:
k-value exceeding Sensor - wrong exhaust flow estimation - Boost pressure
maximum limit (Boost pressure, Boost temperature - Boost temperature
or HFM out of range, EGR rate not - HFM out of range
OK --> all cases should cause a - EGR rate not OK
special failure activation) - ambient pressure
- wrong ambient pressure (ambient Replace Lambda sensor (and reset learning values in
pressure sensor) EEPROM with tester)
No
S SERIES EURO V
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
216E Lambda Sensing: LSUPresCo ON Exhaust none YES Wrong exhaust pressure caclulation Check if there is a failure stored conserning exhaust
Fault check for mpMin Gas potential due to: pressure caclulation due to:
k-value below Sensor - wrong exhaust flow estimation - Boost pressure
minimum limit (Boost pressure, Boost temperature - Boost temperature
or HFM out of range, EGR rate not - HFM out of range
OK --> all cases should cause a - EGR rate not OK
special failure activation) - ambient pressure
- wrong ambient pressure (ambient Replace Lambda sensor (and reset learning values in
pressure sensor) EEPROM with tester)
112E Lambda sensor LSURiClbMa ON Exhaust none YES Defect in wiring of lambda sensor Check wiring and accuracy of lambda sensor, if
Wiring: Lambda x Gas potential (heater lines), inaccurate or defective necessary replace lambda sensor (and reset the
Sensor inner Sensor lambda sensor learning factors in EEPROM with tester)
Resistance Note for EURO OBD application: this failure activates
calibration value a Performance limitation due to legislation. Therefore
too High after repai
212E Lambda sensor LSURiClbMi ON Exhaust none YES Defect in wiring of lambda sensor Check wiring and accuracy of lambda sensor, if
Wiring: Lambda n Gas potential (heater lines), inaccurate or defective necessary replace lambda sensor (and reset the
Sensor inner Sensor lambda sensor learning factors in EEPROM with tester)
Resistance Note for EURO OBD application: this failure activates
calibration value a Performance limitation due to legislation. Therefore
too Low after repai
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143
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Long
System
Failure
223E Lambda Sensor LSUSPIBattL ON Exhaust none YES wiring defect, defective lambda Check Wiring of lambda sensor, if necessary replace
Supply: low battery owMin Gas potential sensor or SPI chip in ECU lambda sensor (and reset the learning factors in
voltage at the SPI Sensor EEPROM with tester) or ECU
chip Note for EURO OBD application: this failure activates
after repair foll
452E Lambda sensor LSUSPISig ON Exhaust none YES SPI chip in ECU defective Replace ECU
Wiring: Fault check Gas potential
to indicate SPI chip Sensor
error of lambda
sensor
113E Lambda Sensor LSUtExcMax ON Exhaust none YES Defect in wiring of sensor. Check entire wiring of the sensor and the sensor itself,
Temperature: LSU Gas potential Disconnected lambda sensor. check connection of lambda sensor,
sensor Sensor Short circuit to ground in UN line. if necessary replace lambda sensor (and reset the
temperature Ri Defective lambda sensor. learning factors in EEPROM with tester)
exceeds the Note for EURO OBD application: this failure activates
maximum limit a Performance lim
S SERIES EURO V
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
213E Lambda Sensor LSUtExcMin ON Exhaust none YES Disconnected lambda sensor. Check connection of lambda sensor,
Temperature: LSU Gas potential Open load in VM or UN sensor line check entire wiring of the sensor and the sensor itself,
sensor Sensor Defect in wiring of sensor if necessary replace lambda sensor (and reset the
temperature Ri is Defective lambda sensor learning factors in EEPROM with tester)
below the Note for EURO OBD application: this failure activates
minimum limit a Performance li
442E Lambda sensor LSUWireIPSi ON Exhaust none YES shunt in wire connections of lambda check wiring of lambda sensor, if necessary replace
Wiring: O2 Voltage g Gas potential sensor lambda sensor (and reset the learning factors in
exceeds the Sensor EEPROM with tester)
threshold value for Note for EURO OBD application: this failure activates
shunting a Performance limitation due to legislation. Therefore
after repair following p
612E Lambda sensor LSUWireSC ON Exhaust none YES Short circuit to external source in Check entire wiring of lambda sensor, check lambda
Wiring: short to B Gas potential one of the wiring lines of the lambda sensor itself, if necessary replace lambda sensor (and
battery at Pump Sensor sensor, open load in virtual ground reset the learning factors in EEPROM with tester)
Cell (IA,IP), Nernst VG, defective LSU Note for EURO OBD application: this failure activates
Cell (UN), or a Performance limitation due to legislation.
virtual ground VG
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Long
System
Failure
712E Lambda sensor LSUWireSC ON Exhaust none YES Short circuit to ground in one of the Check entire wiring of lambda sensor, check lambda
Wiring: short to G Gas potential wiring lines of the lambda sensor, sensor itself, if necessary replace lambda sensor (and
ground at Pump Sensor defective LSU reset the learning factors in EEPROM with tester)
Cell (IA,IP), Nernst Note for EURO OBD application: this failure activates
Cell (UN), or a Performance limitation due to legislation.
virtual ground
(VG)
1179 DPF Lube Oil LubFlMax OFF YES NO Excessive oil dilution by fuel due to Change lubrication oil and reset the fuel-in-oil
monitoring: Fuel in (technical) post injections during particulate filter calculation via tester, using UDS Routine Control
oil has exceded the regeneration Service (ID $0255)
Maximum limit
A179 DPF Lube Oil LubFlWarn OFF none NO Excessive oil dilution by fuel due to Change lubrication oil and reset the fuel-in-oil
monitoring: Fuel in post injections during particulate filter calculation via tester, using UDS Routine Control
oil has exceded the regenerations Service (ID $0255)
warning limit
A279 DPF Lube Oil LubSot OFF none NO Soot accumulation in the lubrication Change lubrication oil and reset the soot-in-oil
monitoring: Soot in oil too high calculation via tester, using UDS Routine Control
oil has exceded the Service (ID $0245)
Maximum limit
S SERIES EURO V
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
1351 PTO actuation: MaxPTOSwt OFF none NO PTO switch defective (possible short Check PTO switch and wiring
Defect Fault Check circuit)
for signal value
above maximum
limit
B145 Fuel metering unit: MeUnIntCtct OFF none NO Bad Contacts on Connector Check Connector
Error check for "Broken" wiring harness or Insulation Check Wiring Harness
loose contact (--> short circuits) Check Metering unit (MeUn)
between metering Defective Metering Unit (MeUn)
unit (MeUn) and
ECU
5145 Fuel metering unit: MeUnOL OFF none NO Broken or disconnected wiring, Check of wiring or metering unit
open load of defective metering unit
metering unit
output
A145 Fuel metering unit: MeUnOT OFF none NO High battery voltage, high Check of wiring or metering unit
over teperature of temperature inside ECU, high load or
device driver of wiring problem
metering unit
Base - October 2011
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Long
System
Failure
6145 Fuel metering unit: MeUnSCB OFF none NO Short circuit of wiring to external Check of wiring or metering unit
short circuit to source, defective metering unit
battery of metering
unit output
7145 Fuel metering unit: MeUnSCG OFF none NO Short circuit of wiring to ground, Check of wiring or replace metering unit
short circuit to defective metering unit
ground of metering
unit output
1145 Fuel metering unit: MeUnSRCM OFF none NO Metering unit defective or short Check wiring or replace metering unit
signal range check ax circuit to external source
high error of
metering unit
AD-channel
2145 Fuel metering unit: MeUnSRCMi OFF none NO Metering unit defective or short Check wiring or replace metering unit
signal range check n circuit to ground
low error of
metering unit
AD-channel
S SERIES EURO V
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
5112 OBD Lamp (MIL): MILOL ON Compre none NO Broken or disconnected wiring or Check of wiring or replace MIL
No load error hensive defective MIL.
8112 OBD Lamp (MIL): MILOvrTem ON none NO High battery voltage, high load and Check load and output, check wiring, replace MIL or
Over temperature p high ECU temperature, defective ECU
error wiring, MIL or ECU
6112 OBD Lamp (MIL): MILSCB ON Compre none NO Short circuit of wiring to external Check of wiring
Short circuit to hensive source
battery error
7112 OBD Lamp (MIL): MILSCG ON Compre none NO Short circuit of wiring to ground Check of wiring
Short circuit to hensive
ground error
2351 PTO actuation: MinPTOSwt OFF none NO PTO switch defective (possible short Check PTO switch and wiring
Defect Fault Check circuit)
for signal value
below minimum
limit
Base - October 2011
149
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Long
System
Failure
A186 Injectors: Misfiring: MisfDetMisfir OFF none NO Severe loss of compression or fuel Check the sealing of the combustion chamber (piston
Too many eCyl_0 injection failure ring, cylinder head...), look for injection failures of
detected misfires at cylinder 1
cylinder 1
cylinder 3
cylinder 4
cylinder 2
S SERIES EURO V
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
A586 Injectors: Misfiring: MisfDetMisfir OFF none NO Severe loss of compression or fuel If Failure Path for Misfiring of single cylinders are also
Too many eMul injection failure stored: check the dedicated cylinders.
recognized misfires If no Failure path of Misfiring of single cylidner is stored
in more than one (this means more than 1.00- show misfiring): check all
cylinder cylinders for correct injection and or c
F11C ECU Internal: MoCADCC OFF none NO ECM internal failure Replace ECM
Diagnostic fault mp
check to report
implausibility error
in ADC monitoring
of accelerator
pedal
F21C ECU Internal: MoCADCTs OFF none NO ECM internal failure Replace ECM
Diagnostic fault t
check to report the
ADC test error
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Long
System
Failure
F31C ECU Internal: MoCADCVlt OFF none NO ECM internal failure Replace ECM
Diagnostic fault gRatio
check to report the
error in Voltage
ratio in ADC
monitoring
F41C ECU Internal: MoCComErr OFF none NO Defective monitoring module or If error exists only temporary (i.e. injection reoccurs)
Diagnostic fault Cnt CPU (e.g. impaired functioning of the error can be ignored and error deleted in the fault
check to report CPU clock) of the EDC. Disturbed memory. In case of a permanent error the injection
errors in SPI-Bus. remains blocked and the ECU has to be replaced
query-/response-co
mmunication
F51C ECU Internal: MoCComSPI OFF none NO Disturbed SPI-Bus If ECM functions correctly after recovery only
Diagnostic fault temporary SPI error occurred and fault memory can
check to report be deleted and error ignored. If permanent SPI error is
errors in present and the ECM does not leave boot block -->
SPI-communication Replace ECM
S SERIES EURO V
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
F61C ECU Internal: MoCROMEr OFF none NO Corrupted datas in the ECM,ECM Reprogram ECM, replace ECM
Diagnostic fault rXPg internal failure
check to report
multiple error
while checking the
complete
ROM-memory
E11C ECU Internal MoCSOPErr OFF none NO ECM internal failure Contact Help desk
Check: MMRespByt
Communication e
timeout from CPU
to Monitoring
Module
E61C ECU Internal MoCSOPErr OFF YES NO ECM internal failure or injector Contact Help Desk
Check: Error during NoChk (technical) problem
Shut Off Path test;
uncertain cause
(defective injector
or shut-off path)
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Long
System
Failure
E21C ECU Internal MoCSOPErr OFF none NO ECM internal failure Contact Help Desk
Check: Wrong set RespTime
response time
E31C ECU Internal MoCSOPErr OFF none NO ECM internal failure Contact Help Desk
Check: Too many SPI
SPI errors during
Shut Off Pathtest
execution.
F81C ECU Internal: MoCSOPLo OFF none NO ECM internal failure Contact Help Desk
Diagnostic fault Li
check to report the
error in
undervoltage
monitoring
S SERIES EURO V
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
F91C ECU Internal: MoCSOPM OFF none NO ECM internal failure Contact Help Desk
Diagnostic fault M
check to report
that line to
powerstage supply
is not working
correct
E41C ECU Internal MoCSOPOS OFF none NO ECM internal failure Contact Help Desk
Check: OS timeout TimeOut
in the shut off path
test. Failure setting
the alarm task
period.
Base - October 2011
155
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Long
System
Failure
E71C ECU Internal MoCSOPPsv OFF none NO ECM internal failure Contact Help Desk
Check: Error during TstErr
positive test
FA1C ECU Internal: MoCSOPTi OFF none NO ECM internal failure Contact Help Desk
Diagnostic fault meOut
check to report the
timeout in the shut
off path test
FB1C ECU Internal: MoCSOPUp OFF none NO ECM internal failure Contact Help Desk
Diagnostic fault Li
check to report the
error in
overvoltage
monitoring
S SERIES EURO V
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
F32C ECU Internal: MoFAPP OFF none NO ECM internal failure or calibration Contact Helpdesk
Diagnostic fault error.
check to report the
accelerator pedal
position error
F42C ECU Internal: MoFESpd OFF none NO ECM internal failure or calibration Contact Helpdesk
check to report the
engine speed error
FC2C ECU Internal MoFInjDatET OFF none NO ECM internal failure or calibration Contact Helpdesk
Check: Error in the error.
plausibility of the
injection energizing
time
Base - October 2011
157
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Long
System
Failure
F52C ECU Internal: Error MoFInjDatPh OFF none NO ECM internal failure or calibration Contact Helpdesk
in the plausibility of i error.
the start of
energising angles
F72C ECU Internal: MoFInjQnt OFF none NO ECM internal failure or calibration Contact Helpdesk
check to report the
error due to non
plausibility in ZFC
F12C ECU Internal: MoFMode1 OFF none NO ECM internal failure or calibration Contact Helpdesk
Diagnosis fault error.
check to report the
demand for normal
mode due to an
error in the PoI2
quantity
S SERIES EURO V
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
F22C ECU Internal: MoFMode2 OFF none NO ECM internal failure or calibration Contact Helpdesk
Diagnosis fault error.
check to report the
error to demand
for an ICO due to
an error in the
PoI2 shut-off
FD2C ECU Internal: Error MoFMode3 OFF none NO ECM internal failure or calibration Contact Helpdesk
in the plausibility of error.
PoI3 efficiency.
F82C ECU Internal: MoFOvR OFF none NO Electronic disturbances, requested Contact Helpdesk
Diagnostic fault torque increase via tester, wrong
check to report the application of injection relevant
error due to Over parameters, defective ECU
Run
Base - October 2011
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Long
System
Failure
F92C ECU Internal: MoFQntCor OFF none NO ECU internal failure or calibration Contact Helpdesk
check to report the
error due to
injection quantity
correction
FA2C ECU Internal: MoFRailP OFF none NO ECU internal failure or calibration Contact Helpdesk
check to report the
plausibility error in
rail pressure
monitoring
FB2C ECU Internal: MoFTrqCmp OFF none NO ECU internal failure or calibration Contact Helpdesk
check to report the
error due to
torque comparison
S SERIES EURO V
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
F13C ECU Internal: MonLimCurr OFF none NO ECU internal failure Replace ECU
Diagnosis of lead
torque limitation
(for fuel pressure
control) forced by
ECU monitoring
level 2
F23C ECU Internal: MonLimLead OFF none NO ECU internal failure or failure in the Contact Help desk
Diagnosis of lead data set calibration of ECU or
torque limitation another vehcile cotnrol unit
(for Air Control)
forced by ECU
monitoring level 2
F33C ECU Internal: MonLimSet OFF none NO ECU internal failure or failure in the Contact Help desk
Diagnosis of engine data set calibration of ECU or
torque limitation another vehcile cotnrol unit
forced by ECU
monitoring level 2
Base - October 2011
161
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Long
System
Failure
117D ECU Voltage MonUMaxSu OFF none NO Excessive voltage supply of a CJ945 Check the battery for correct voltage supply, check
Supply: Reported pply1 component: High battery voltage, wiring. If defect remains replace ECM (internal defect)
OverVoltage of defective wiring, internal defect of the
Supply ECM
217D ECU Voltage MonUMinSu OFF none NO Insufficient voltage supply of a CJ945 Check the battery for sufficient voltage supply, check
Supply: Reported pply1 component: Low battery voltage, wiring. If defect remains replace ECM (internal defect)
UnderVoltage of defective wiring, internal defect of the
Supply ECM
A13D ECU Main relay: MRlyErlyOp ON Compre none NO The Main Relay is switrched off In case of vehicle equipped with "main electrical
Early opening ng hensive directly by Key 15 instead of the switch": inform driver of correct engine shut off by Key
defect of main request of ECU: 15.
relay - in case vehicle equipped with "main
electrical switch": engine stopped by In case of vehicle equipped with electronic "main
"main switch" instead of Key 15 OR electrical switch": check electronic of main switch for
Main switch disconnected before correct working (if opens after after
afterrun finished.
- due to wr
S SERIES EURO V
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
A23D ECU Main relay: MRlyStk ON Compre none NO Main relay has a short circuit or is Check wiring or replace main relay
DFC for stuck main hensive mechanically stuck in closed position
relay error
3359 DPF pressure NplHsChngP ON PM filter YES NO Differntial pressure sensor of filter Check differential pressure sensor mounting and
monitoring: Fault PFltDiff (technical) upside down, hoselines crossed hoselines.
check for Hoseline Reset offset drift compensation for diff.pressure sensor
connection of using dedicated UDS Routine Control Service (ID
differential pressor $0253)
sensor
31F3 Crankcase NplPresSens OFF none NO Inaccurate or defective crankcase Check wiring and the accuracy of the crankcase
differential pressure CrCsP differential pressure sensor, defect in differential pressure sensor and replace it if necessary
: Value measured the wiring
at ECM shut off
not plausible
Base - October 2011
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Long
System
Failure
3559 DPF pressure NplPresSens ON PM filter none NO Differential pressure sensor is Check accuracy of differential pressure sensor.
monitoring: Fault PPFltDiff inaccurate.
check for the
pressure sensor
plausibility
3351 PTO actuation: NplPTOSwt OFF none NO PTO switch defective Check and replace PTO switch
Defect Fault Check
for non plausible
signal value
F12F Info: OBD Long OBDGenFau OFF none YES direct NOx Level (HardNOx or Soft NOx) NONE - check the failure memory for other failures,
Time failure: fuel ltClct1 (ControlMa was exceeded and contemporanelly which could have caused the activation of the long
system sk) a failure of this system by time failure (FID for this Long time failure group set?)
FID_OBDGenFaultClct1 was activ and follow the repair action for that failure.
If the failure was not yet validated (i.e. sti
S SERIES EURO V
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
F23F Info: OBD Long OBDGenFau OFF none YES direct A failure of this system by NONE - check the failure memory for other failures,
Time failure: ltClct10 (ControlMa FID_OBDGenFaultClct10 was activ which could have caused the activation of the long
Reagent Quality sk) time failure (FID for this Long time failure group set?)
and follow the repair action for that failure.
Time failure: NOx ltClct11 (ControlMa FID_OBDGenFaultClct11 was activ which could have caused the activation of the long
Sensor sk) time failure (FID for this Long time failure group set?)
Time failure: ltClct12 (ControlMa FID_OBDGenFaultClct12 was activ which could have caused the activation of the long
Oxygen sensor sk) time failure (FID for this Long time failure group set?)
If the failure was not yet validated (i.e. stil
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Long
System
Failure
F53F Info: OBD Long OBDGenFau OFF none YES direct A failure of this system which NONE - check the failure memory for other failures,
Time failure: ltClct13 (ControlMa activates FID_OBDGenFaultClct13, is which could have caused the activation of the long
sk) activ time failure (FID for this Long time failure group set?)
Time failure: ltClct14 (ControlMa activates FID_OBDGenFailtClct14, is which could have caused the activation of the long
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Long
System
Failure
and follow the repair action for that failure. If the
failure was not yet validated (i.e. still
Time failure: ltClct2 (ControlMa was exceeded and contemporanelly which could have caused the activation of the long
Injection timing sk) a failure of this system by time failure (FID for this Long time failure group set?)
system FID_OBDGenFaultClct2 was activ and follow the repair action for that failure.
Time failure: air ltClct3 (ControlMa was exceeded and contemporanelly which could have caused the activation of the long
System: sk) a failure of this system by time failure (FID for this Long time failure group set?)
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Long
System
Failure
Time failure: EGR ltClct4 (ControlMa was exceeded and contemporanelly which could have caused the activation of the long
System: sk) a failure of this system by time failure (FID for this Long time failure group set?)
Time failure: SCR ltClct5 (ControlMa was exceeded and contemporanelly which could have caused the activation of the long
System sk) a failure of this system by time failure (FID for this Long time failure group set?)
Temperature sk) a failure of this system by time failure (FID for this Long time failure group set?)
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Long
System
Failure
Reagent Dosing: sk) a failure of this system by time failure (FID for this Long time failure group set?)
Time failure: No ltClct8 (ControlMa was exceeded and contemporanelly which could have caused the activation of the long
Reagent dosing sk) a failure of this system by time failure (FID for this Long time failure group set?)
Time failure: Empty ltClct9 (ControlMa FID_OBDGenFaultClct9 was activ which could have caused the activation of the long
Reagent Tank sk) time failure (FID for this Long time failure group set?)
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Long
System
Failure
F17C ECU Internal: OCWDACo OFF none NO ECM internal failure Contact Help Desk
Diagnostic fault m
check to report
"WDA active" due
to errors in
query-/response
communication
217C ECU Internal: OCWDALo OFF none NO ECM internal failure Contact Help Desk
Diagnostic fault wVltg
check to report
"ABE active" due to
undervoltage
detection
117C ECU Internal: OCWDAOv OFF none NO ECM internal failure Contact Help Desk
Diagnostic fault rVltg
check to report
"ABE active" due to
overvoltage
detection
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Long
System
Failure
A27C ECU Internal: Error OCWDARe OFF none NO ECM internal failure Contact Help Desk
report "ABE/WDA asUnkwn
active" due to an
unknown reason
A379 DPF Lube Oil OilLftRgnOil OFF YES NO Excessive engine running time under Replace engine oil and reset timer for oil dilution with
monitoring: Critical Dil (technical) oil dilution conditions, due to tester using the dedicated UDS service "Routine
time for oil dilution retarded post injection for filter Control ID =$245"
exceeded regeneration.
11B3 Oil Level sensor: OilLvlMax OFF none NO Defect in the oil level sensor or its Check wiring of sensor, check oil level sensor and the
Duty cycle greater electronic module, defect in wiring electronic module
than maximum connecting the sensor
21B3 Oil Level sensor: OilLvlMin OFF none NO Defect in the oil level sensor or its Check wiring of sensor, check oil level sensor and the
Duty cycle lesser electronic module, defect in wiring electronic module
than minimum connecting the sensor
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Long
System
Failure
31B3 Oil Level sensor: OilLvlNpl OFF none NO Defect in wiring, defect in oil level Warm up the engine, turn ignition off and let the
Plausibility Check sensor or electronic module OR too engine cool down entirely (afterrun must be
many repetitions of: interruped completed), check wiring of sensor, check oil level
engine afterruns (e.g. fast ignition key sensor and the electronic module
ON-OFF-ON), too short vehicle
stand stills, time signal not received
via CAN from Body Computer,
engine start
A1B3 Oil Level sensor: OilLvlSens OFF none NO Defect in the oil level sensor or its Check wiring of sensor, check oil level sensor and the
Oil level sensor electronic module, defect in wiring electronic module
fault connecting the sensor
11C3 Oil pressure OilPMin none none NO Low oil pressure or digital oil Check oil level and pressure, check oil pressure switch
sensing: Diagnostic pressure switch blocked
fault check for oil
pressure below
minimum limit
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Long
System
Failure
21C3 Oil pressure OilPNpl none none NO Oil pressure digital switch defective Check oil pressure digital switch
sensing: Plausibility
check for oil
pressure sensor
14D3 Oil Temperature OilTNplHigh OFF none NO Inaccurate oil temperature sensor or Check oil temperature sensor for accuracy and check
sensing: Oil defect (e.g. blockage, insufficient oil system
temperature too recirculation) in the oil system.
high plausibility
error
D5D3 Oil Temperature OilTPhysRng OFF none NO Oil temperature sensor inaccurate or Check or replace oil temperature sensor
sensing: Physical Hi defective
Signal above
maximum limit
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Long
System
Failure
E5D3 Oil Temperature OilTPhysRng OFF none NO Oil temperature sensor inaccurate or Check or replace oil temperature sensor
sensing: Physical Lo defective
Signal below
minimum limit
44D3 Oil Temperature OilTSig OFF none NO Oil temperature sensor defective Check sensor
sensing: Signal
error on CAN for
Oil Temperature
15D3 Oil Temperature OilTSRCMax OFF none NO Sensor defective or wiring short Check wiring or replace sensor
sensing: SRC High circuit to external source
for Oil
Temperature
25D3 Oil Temperature OilTSRCMin OFF none NO Sensor defective or wiring short Check wiring or replace sensor
sensing: SRC low circuit to ground
for Oil
Temperature
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Long
System
Failure
35D3 Oil Temperature: OilTVDPlaus OFF none NO Oil temperature sensor drifted Check sensor
failed plausibility
check at ECU start
3189 Oxicat Temp OxiCatMon ON NMHC none YES Temperature sensors before and Check correct connection of Temperature sensors at
Monitoring: Passive PasMin catalyst potential after Oxicat interchanged Oxicat
monitoring of the Oxicat thermal aged (too low Check / Replace Oxicat
oxidation catalyst efficiency) Check Injectors
Post injection not working
3289 Oxicat: Monitoring OxiCatMon OFF none NO Temperature sensors before and Check correct connection of Temperature sensors at
of OxiCat im Rapid RHU after Oxicat interchanged Oxicat
Heat Up Oxicat thermal aged (too low Check / Replace Oxicat
efficiency) Check Injectors
Post injection not working
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Long
System
Failure
3143 Boost pressure: PCACDsEnv ON Boost none YES direct Either the boost pressure or the Check which sensor deviates at engine stand still too
Ambient and Boost PPls Pressure ambient pressure sensor is is out of much from the actual ambient pressure by:
pressure are System specification - Analysing ambient condition (Snap Shot) of failure
different at start occurrence
- measuring both values with tester
- Ambient pressure: By external tool or estimated:
1000 m
A143 Boost pressure: PCACDsOv ON Boost none YES direct Boost pressure regulation device of Check for defects in the boost pressure control
Over Boost rBst Pressure the the turbocharger is functionality and ensure proper functioning of the
Detection System malfunctioning (sticking or blocked in regulation device (e.g. VGT or wastegate):
closed position) or Boost pressure - PWM pressure transducer (if available)
sensor measures too high pressure - VGT or Wastegate mechanism
- control mechanism is correct, then check
D143 Diagnostic Fault PCACDsPhy ON Boost none YES direct Inaccurate or defective pressure Check wiring and the accuracy of the pressure sensor
Check for Physical sRngHi Pressure sensor, defect in the wiring and replace it if necessary
Range Check low System
error
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Long
System
Failure
E143 Diagnostic Fault PCACDsPhy ON Boost none YES direct Inaccurate or defective pressure Check wiring and the accuracy of the pressure sensor
Check for Physical sRngLo Pressure sensor, defect in the wiring and replace it if necessary
Range Check low System
error
4143 Boost pressure: PCACDsSig ON Boost YES YES direct Disturbed CAN signal transmission Check the CAN for proper configuration and
CAN signal error Pressure (technical) or Boost pressure sensor is defective functioning
for Boost pressure System Check the Boost pressure sensor
1143 Boost pressure: PCACDsSR ON Boost none YES direct Sensor defective or short circuit to Check wiring or replace sensor
SRC High Boost CMax Pressure external source
pressure sensor System
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System
Failure
2143 Boost pressure: PCACDsSR ON Boost none YES direct Sensor defective or short circuit to Check wiring or replace sensor
SRC low for Boost CMin Pressure ground
pressure sensor System
1118 Boost pressure PCRGovDvt ON Compre YES YES direct Mechanically blocked boost pressure Check mechanical and electrical functionality of the
control: Too Low Max hensive (technical) actuator actuator for VTG
Boost pressure in Electrical defect in actuator If present: Check system of sub pressure
closed loop control In case of VTG control by pressure Ensure that the EGR actuators are functioning correctly
or vacuum: No sub pressure at VTG Check intake duct to deposits and/or leakages
actuator Check Boost pressure sensor
Foreign matter in the intake duct Check EGR sys
(deposits etc).
Leakage in air system (e.g. tube
compressor - Interc
2118 Boost pressure PCRGovDvt ON Compre YES YES direct Mechanically blocked boost pressure Check mechanical and electrical functionality of the
control: Too High Min hensive (technical) actuator actuator
Boost pressure in Electrical defect in actuator If there is not failure detected in VGT, check Boost
closed loop control Boost pressure sensor measures too pressure sensor
high values
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Long
System
Failure
1218 Boost pressure PCRPlausMa OFF none NO Defective boost pressure actuator Check boost pressure actuator for proper functioning,
control: VGT x (e.g. WG or VGT), defective air or clean intake duct, ensure correct functioning of EGR
actuator output vacuum supply (if present), intake actuators and EGR trhottle resp. exhaust flap
lower than duct blocked by foreign matter, EGR Check Boost pressure sensor
expected actuator jammed (closed position) or
boost pressure sensor gives wrong
signal (measured boost pressure
higher than
2218 Boost pressure PCRPlausMin OFF none NO Defective boost pressure actuator Check boost pressure actuator for proper functioning,
control: VGT (e.g. WG or VGT), defective air or clean intake duct, ensure correct functioning of EGR
actuator output vacuum supply (if present), intake actuators and EGR trhottle resp. exhaust flap
higher than duct blocked by foreign matter, EGR Check Boost pressure sensor
expected actuator jammed (open position) or
boost pressure sensor gives wrong
signal (measured boost pressure
lower than th
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Long
System
Failure
1255 Pressure control PCVfacAdap OFF none NO The actual pressure is higher for a Check wiring and pressure control valve.
valve: lerning factor tMax certain current than according Replace pressure control valve and reset EEPROM
too high specification. This can be caused by learning datas resp. execute first learning with tester.
an addtional current through the
pressure control valve (partial short
circuit in wiring) which is not
measured in ECU.
Fuel pressure control valve no
2255 Pressure control PCVfacAdap OFF none NO The actual pressure is lower for a Check wiring and pressure control valve.
valve: lerning factor tMin certain current than according Replace pressure control valve and reset EEPROM
too low specification. This can be caused by a learning datas resp. execute first learning with tester.
"current loss" by the wirning (partial
short circuit in wiring) which does
not go through the pressure cotnrol
valve.
Fuel pressure control valve not
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Long
System
Failure
A255 Pressure control PCVNoStrt OFF none NO Pressure can not rise fast enough Check ambient conditions: if fuelt temperature > 80°
valve: number of during cranking due to: C --> this could be the reason for the failed start -->
startup attempts - very high fuel temperatures during check the reason for high fuel temperature.
exceeded the limit starts (check ambient conditions) Check Fuel rail pressure control valve
- leaky fuel pressure control valve Ceck Fuel system for leakages and the high pressure
- wrong positon of the fuel quantity pump for e
cotnrol valve (MPROP)
- bad efficiency of high pressu
5155 Pressure control PCVOL OFF engine stop NO Broken or disconnected wiring or Check of wiring or replace relay or pressure control
valve: open load of (indirect) defective pressure control valve valve
pressure control
valve output
A155 Pressure control PCVOT OFF engine stop NO Short circuit of wiring or internal Check of wiring and pressure control valve.
valve: over (indirect) failure of pressure control valve
temperature of
device driver of
pressure control
valve
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System
Failure
6155 Pressure control PCVSCB OFF YES NO Short circuit of wiring to external Check of wiring and pressure control valve.
valve: short circuit (technical) source or internal failure of pressure
to battery of control valve
pressure control
valve output
7155 Pressure control PCVSCG OFF engine stop NO Short circuit of wiring to ground or Check of wiring and pressure control valve.
valve: short circuit (indirect) internal failure of pressure control
to ground of valve
pressure control
valve output
1155 Pressure control PCVSRCMax OFF YES NO Short circuit (to ground) or broken Check wiring and pressure control valve.
valve: signal range (technical) contact in wire or pressure control
check high error of valve itself. Possibly also failure in
pressure control ECU powerstage
valve AD-channel
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Long
System
Failure
2155 Pressure control PCVSRCMin OFF YES NO Short circuit in wire or pressure Check wiring and pressure control valve.
valve: signal range (technical) control valve itself. Possibly also
check low error of failure in ECU powerstage
pressure control
valve AD-channel
1169 DPF model PFltAshLdMa OFF none NO Accumulated ashes has reached Replace the filter or remove it and wash it.
plausibility: Ash x maximum volume.
load in DPF has
exceeded the limit
1159 DPF pressure PFltCharPDif OFF YES NO Filter is clogged or not installed Check filter for proper installation and function
monitoring: fMax (technical) correctly (exhaust flow restricted)
Diagnostic fault
check for
maximum pressure
differential
charecterstics
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System
Failure
2159 DPF pressure PFltCharPDif ON PM filter YES NO Filter is not installed or has an Check filter for proper installation and function (no
monitoring: fMin (technical) internal breakthrough black smoke at exhaust pipe)
Diagnostic fault
check for minimum
pressure differential
charecterstics
2169 DPF model PFltDstrMin ON PM filter none NO Cracked or dismounted particulate Check if black smoke is visible at exhaust pipe.
plausibility: filter
Diagnostic fault
check for damaged
particulate filter
AA69 DPF model PFltEff ON PM filter none NO Filter efficiency too low Check DPF integrity
plausibility: FIlter
soot accumulation
below expected
minimum
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Long
System
Failure
A169 DPF model PFltEngPrt ON PM filter YES NO DPF is clogged. Launch service regeneration via tester and check filter
plausibility: (technical) Filter regeneration was not successful and exhaust system.
Diagnostic fault or not possible.
check for SRC high
in Flow Resistance
A969 DPF model PFltFrdRgn OFF none NO Problem of regeneration, which is According the proposal a dedicated failure concerning
plausibility: Forced shown with dedicated Failure (see regeneration
Regeneration Error there)
AB69 Monitoring for too PFltFreq OFF none NO Inefficient DPF regeneration.
frequent
regeneration of the
particulate filter
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Long
System
Failure
A269 DPF model PFltLckHDN OFF none NO See Dfp_PFltLckRgn, only here an Check filter and state variable of saturation model,
plausibility: Fault umRgn2 error is triggered specifically for a look for sensor errors
path for maximum regeneration request of 2
number of locked
regenerations for
HD
A369 DPF model PFltLckHDN OFF none NO See Dfp_PFltLckRgn, only here an Check filter and state variable of saturation model,
plausibility: Fault umRgn3 error is triggered specifically for look for sensor errors
path for maximum regeneration request of 3
number of locked
regenerations for
HD
A469 DPF model PFltLckRgn ON PM filter YES NO Special ambient conditions or vehicle Check temperature sensor before Oxicat and before
plausibility: Fault (technical) use (city cycle) which lead to too low DPF for correct measuring
path for maximum DPF temperature for real Check Oxicat
number of locked regeneration. Check DPF
regenerations Temperature sensor before Oxicat
or before DPF show too low
temperature, so system dose not
detect real regeneration.
Oxicat does not wor
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System
Failure
51E2 DPF Control Lamp: PFltLmpOL OFF none NO Broken or disconnected wiring or Check of wiring or replace lamp
No load error defective lamp
81E2 DPF Control Lamp: PFltLmpOvr OFF none NO High battery voltage, high No reaction needed if failure isn't present after short
Over temperature Temp temperature inside ECU, high load or time, check load and output, check wiring, replace
error wiring problem ECU
61E2 DPF Control Lamp: PFltLmpSCB OFF none NO Short circuit of wiring to battery Check of wiring
Short circuit to
battery error
71E2 DPF Control Lamp: PFltLmpSCG OFF none NO Short circuit of wiring to ground Check of wiring
Short circuit to
ground error
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Long
System
Failure
1269 DPF model PFltNumRgn ON PM filter YES NO Special ambeint conditions and Service regeneration should be performed to reduce
plausibility: Fault Max (technical) vehicle use wich does not allow soot mass in the filter
path for too high correct DPF regeneration due to too If Service regeneration fails: see troubleshooting there.
regeneration low exhaust temperatures
request Temperature sensor before Oxicat
and/or before DPF shows too low
temperature
Oxicat does not work correctly (bad
HC burning) - in
2C69 Incomplete PFltRgnNoC OFF none NO

regeneration of the ompl
DPF
A569 DPF model PFltRgnPerm OFF none NO Special ambient conditions or vehicle Check temperature sensor before Oxicat and before
plausibility: use (city cycle) which lead to too low DPF for correct measuring
Diagnostic fault DPF temperature for real Check Oxicat
check for SRC high regeneration. Check DPF
in Flow Resistance Temperature sensor before Oxicat
or before DPF show too low
temperature, so system dose not
detect real regeneration.
Oxicat does not wor
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Long
System
Failure
1669 DPF model PFltSotMsDv ON PM filter none NO Increased raw particulate engine Check differential pressure sensor. check particulate
plausibility: tMax emissions because of a problem with filter mounting, check if other failure are present
Deviation between EGR, air mass sensor, injectors or concerning EGR, air mass sensor or injectors.
pressure differential injection timing deviation or
and soot load particulate filter mounting problem
charecterstics (increased exhaust flow resistance)
or differential pressure sensor
deviation.
2669 DPF model PFltSotMsDv OFF none NO Reduced particulate filter efficiency Check filter integrity (no black smoke at exhaust pipe),
plausibility: tMin (filter breach) or differential pressure check differential pressure sensor, check if other failure
Deviation between sensor deviation or raw particulate are present concerning EGR, air mass sensor or
pressure differential emissions lower than expected injectors.
and soot load because of air/injection system
charecterstics daviation, EGR problem or injection
timing deviation.
1869 DPF model PFltSotMsMa OFF none NO Regeneration could not be carried Perform particulate filter service regeneration.
plausibility: x out for too long
Maximum soot
mass in DPF
exceeded
1769 DPF model PFltSRCMax ON PM filter none NO Filter is clogged or not installed Check filter for proper installation and function
plausibility: SRC FlwRstn correctly, exhaust flow restricted Check Pressure Difference sensor over filter
High in DPF Flow Pressure difference sensor measures
Resistance too high values
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System
Failure
2769 DPF model PFltSRCMinF ON PM filter none NO Filter is not installed or has an Check filter for proper installation and function (no
plausibility: SRC lwRstn internal breakthrough black smoke at exhaust pipe)
Low in DPF Flow Difference pressure sensor measures
Resistance too low value due to: Check Hose line of Diffferential pressure sensor
- broken line before sensor (upstrem DPF)
. sensor itself
Check Differential Pressure sensor
1C69 DPF emergency PFltSwtRgnN OFF none NO Emergency regeneration switch Check emergency regeneration switch
regeneration PL pressed at high vehicle speed or
switch: Not switch defective
plausible switch
value
325D ECU internal PhyModNon OFF none NO Wrong application of the basic map Application error, the dataset has a faulty application
Check: Not MonMapNpl for conversion of injection quantity to and should not be used.
plausible fault: non inner torque and vice versa
strictly monotonus (FMTC_trq2qBas_MAP).
q curves quantity in
conversion maps
fuel quantity
/torque
D243 Boost pressure PIntkVUsPhy ON Boost none YES direct Inaccurate or defective boost Check wiring and the accuracy of the boost pressure
sensor: Physical sRngHi Pressure pressure sensor, defect in the wiring sensor and replace it if necessary
Signal above System
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System
Failure
E243 Boost pressure PIntkVUsPhy ON Boost none YES direct Inaccurate or defective boost Check wiring and the accuracy of the boost pressure
sensor: Physical sRngLo Pressure pressure sensor, defect in the wiring sensor and replace it if necessary
Signal below System
minimum limit
3343 Boost Pressure: PIntkVUsPls ON Boost YES YES direct Inaccurate or defective boost Check wiring and the accuracy of the boost pressure
Diagnostic Fault Hi Pressure (technical) pressure sensor, defect in the wiring sensor and replace it if necessary
Check for High System
Plausibility error
3443 Boost Pressure: PIntkVUsPlsL ON Boost YES YES direct Inaccurate or defective boost Check wiring and the accuracy of the boost pressure
Diagnostic Fault o Pressure (technical) pressure sensor, defect in the wiring sensor and replace it if necessary
Check for Low System
Plausibility error
1243 Boost pressure PIntkVUsSR ON Boost YES YES direct Short circuit of sensor to external Check wiring or replace sensor
sensor: Signal value CMax Pressure (technical) source or defective sensor
above maximum System
limit
2243 Boost pressure PIntkVUsSR ON Boost YES YES direct Short circuite at wiring harness or Check of wiring or replace boost pressure sensor
sensor: Signal value CMin Pressure (technical) inside the boost pressure sensor to
below minimum System ground or open circuit
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191
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System
Failure
91BA SCR Reagent PPCWUCRe OFF none YES direct Pump blocked Contact Helpdesk as failure active due to a calibration
Pump: Not sp heating system not OK failure: PPC_rDycPmpWUC not between 81 an 91%
Defrosted within with 0.00%.
time
A149 Diagnostic Fault PPFltDiffEnh ON PM filter none NO Signal range check of the DPF Please check differential pressure sensor as well as
Check for Signal SRCMax differential pressure sensor. Upper connection tubes. If failure remains, check particulate
value above limit exceeded, possibly Pressor filter substrate if blocked.
maximum limit -- sensor failure, connection tubes or
Enhanced check filter substrate.
B149 Diagnostic Fault PPFltDiffEnh OFF none NO Signal range check of the DPF Please check differential pressure sensor as well as
Check for Signal SRCMin differential pressure sensor. lower connection tubes. If failure remains, check particulate
value below limit exceeded, possibly Pressor filter substrate if missing.
minimum limit -- sensor failure, connection tubes or
Enhanced check filter substrate.
3149 Diagnostic Fault PPFltDiffNpl ON PM filter none NO Dynamic plausibility check of the DPF Please check differential pressure sensor as well as
Check for dynamic Dyn differential pressure sensor. Possibly connection tubes. If failure remains, check particulate
plausibility Pressor sensor failure, connection filter substrate if missing.
tubes or filter substrate.
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System
Failure
C149 Diagnostic Fault PPFltDiffNpl ON PM filter none NO Hose connection upstream from the Check mounting, check hoseline
Check for Hoseline HsLn particle filter detached or completely
Monitoring blocked.
Atmospheric pressure is constantly
present at the pressure connection
upstream from the particle filter.
D149 DPF differential PPFltDiffSot ON PM filter none NO Hoseline to differential pressure Check mounting, check hoseline
pressure sensor: sensor clogged or mounting incorrect
Sooted hoseline
detected
6149 DPF differential PPFltDiffSRC OFF none NO Short circuit of sensor to external Check wiring or replace sensor
pressure sensor: Max source or defective sensor
SRC value above
maximum limit
7149 DPF differential PPFltDiffSRC OFF none NO Short circuit of wiring to ground or Check wiring or replace sensor
pressure sensor: Min defective sensor
SRC value below
minimum limit
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Long
System
Failure
D249 DPF upstream PPFltUsPhys OFF none NO Inaccurate or defective DPF Check wiring and the accuracy of the pressure sensor
pressure sensor: RngHi upstream pressure sensor, defect in and replace it if necessary
Physical Signal the wiring
above maximum
limit
E249 DPF upstream PPFltUsPhys OFF none NO Inaccurate or defective DPF Check wiring and the accuracy of the pressure sensor
pressure sensor: RngLo upstream pressure sensor, defect in and replace it if necessary
Physical Signal the wiring
below minimum
limit
C249 Diagnostic fault PPFltUsSens OFF none NO DPF upstream pressure sensor is No action needed, if temperature is above freezeing
check for frozen Frz frozen due to very low temperature value sensor should work correctly
sensor
A249 DPF upstream PPFltUsSRC OFF none NO Short circuit of sensor to external Check wiring or replace sensor
pressure sensor: Max source or defective sensor
SRC value above
maximum limit
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System
Failure
B249 DPF upstream PPFltUsSRC OFF none NO Short circuit of sensor to ground or Check wiring or replace sensor
pressure sensor: Min defective sensor
SRC value below
minimum limit
51B2 Presupply pump: PSPOL OFF YES NO Broken or disconnected wiring or Check of wiring or replace presupply pump
open load of (technical) defective presupply pump
pre-supply pump
output
81B2 Presupply pump: PSPOvrTem OFF YES NO High battery voltage, high No reaction needed if failure isn't present after short
Over temperature p (technical) temperature inside ECU, high load or time, check load and output, check wiring, replace
error on ECU wiring problem ECU
powerstage for Pre
supply pump
61B2 Presupply pump: PSPSCB OFF YES NO Short circuit of wiring to external Check of wiring or replace presupply pump
short circuit to (technical) source or inside presupply pump
battery of
pre-supply pump
output
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System
Failure
71B2 Presupply pump: PSPSCG OFF YES NO Short circuit of wiring to ground or Check of wiring or replace presupply pump
short circuit to (technical) inside presupply pump
ground of
pre-supply pump
output
A115 Fuel pressure RailCPC1 OFF none YES Possible faults in high pressure part: Check low pressure system for clogging (specially fuel
control CPC: PCV potential injection nozzle stuck in open filter)
position not position, low efficiency of high Che tubing between presupply and gear pump
plausible (too pressure pump, internal leakage of Check feeding of presupply pump (possibly low due to
much closed) injector, leaking pressure control clogged tubes at tank outlet)
during rail press valve Check hgih pressure part for leakages (internal /
control "both Too low pressure at High pressure external)
devices" pump inlet due clogged filter, leaking Ch
lo
A215 Fuel pressure RailCPC3 OFF none YES Possible faults in high pressure part. Check low pressure system for clogging (specially fuel
control CPC: fuel potential injection nozzle stuck in open filter)
rail pressure below position, low efficiency of high Che tubing betweenmpresupply and gear pump
minimal threshold pressure pump, internal leakage of Check feeding of presupply pump (possibly low due to
during rail press injector, leaking pressure control clogged tubes at tank outlet)
control "both valve, leaking high pressure part itself Check hgih pressure part for leakages (internal /
devices" (tubing) external)
Too low pressure at High pressu Ch
S SERIES EURO V
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
A315 Fuel pressure RailCPC4 OFF none YES Pressure control valve (PCV) stucks Check Pressure control valve (PCV), if openning
control CPC: fuel potential in closed position (PWM = 0%)
rail pressure Too high current to PCV (due to Check metering Unit (MeUn), if closing (PWM =
exceeds maximal partial short circuite) 100%)
limit during rail Metering Unit (MeUn) stuck if "full Check electric wiring to PCV and MeUn
press control "both feeding position" Check low pressure fuel tubes (return from CP to tank
devices" Metering Unit (MeUn) without free?)
current Check zero delivery valve for correct wor
Zero delivery trhottle clogged or
pressure after Zero
3115 Fuel pressure RailCPCTnk OFF none YES Possible faults in high pressure part: Check low pressure system for clogging (specially fuel
control CPC: PCV Lo1 potential injection nozzle stuck in open filter)
position not position, low efficiency of high Che tubing between presupply and gear pump
plausible (too pressure pump, internal leakage of Check feeding of presupply pump (possibly low due to
much closed) injector, leaking pressure control clogged tubes at tank outlet)
during rail press valve Check hgih pressure part for leakages (internal /
control "both Too low pressure at High pressure external)
devices" with Low pump inlet due clogged filter, leaking Ch
Fuel level in Tank lo
1215 Fuel pressure RailCPCTnk OFF none YES Possible faults in high pressure part. Possible faults in high pressure part.
control CPC: fuel Lo3 potential injection nozzle stuck in open injection nozzle stuck in open position, low efficiency
rail pressure below position, low efficiency of high of high pressure pump, internal leakage of injector,
minimal threshold pressure pump, internal leakage of leaking pressure control valve, leaking high pressure
during rail press injector, leaking pressure control part itself (tubing)
control "both valve, leaking high pressure part itself
devices" with low (tubing)
Fuel level in Tank
Base - October 2011
197
Base - October 2011

Long
System
Failure
2315 Fuel pressure RailCPCTnk OFF none YES Pressure control valve (PCV) stucks Check Pressure control valve (PCV), if openning
control CPC: fuel Lo4 potential in closed position (PWM = 0%)
rail pressure Too high current to PCV (due to Check metering Unit (MeUn), if closing (PWM =
exceeds maximal partial short circuite) 100%)
limit during rail Metering Unit (MeUn) stuck if "full Check electric wiring to PCV and MeUn
press control "both feeding position" Check low pressure fuel tubes (return from CP to tank
devices" with low Metering Unit (MeUn) without free?)
Fuel level in Tank current Zero delivery trhottle Check zero delivery valve for correct wor
clogged or pressure after Zero
A125 Fuel pressure RailMeUn0 OFF YES YES Leakage in the high pressure system: Check low pressure system for clogging (specially fuel
control Metering (technical) potential injection nozzle stuck in open filter)
unit: Too low fuel position, low efficiency of high Che tubing between presupply and gear pump
rail pressure with pressure pump, internal leakage of Check feeding of presupply pump (possibly low due to
MeUn Control injector, leaking pressure control clogged tubes at tank outlet)
valve Check hgih pressure part for leakages (internal /
Too low pressure at High pressure external)
pump inlet due clogged filter, leaking Ch
low
A225 Fuel pressure RailMeUn1 OFF none YES Leakage in the high pressure system: Check low pressure system for clogging (specially fuel
control Metering potential injection nozzle stuck in open filter)
unit: Tool low fuel position, low efficiency of high Che tubing between presupply and gear pump
rail pressure pressure pump, internal leakage of Check feeding of presupply pump (possibly low due to
concerning the fuel injector, leaking pressure control clogged tubes at tank outlet)
feeding with MeUn valve Too low pressure at High Check hgih pressure part for leakages (internal /
Control pressure pump inlet due clogged external)
filter, leaking low Ch
S SERIES EURO V
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
A925 Fuel pressure (Rail) RailMeUn10 OFF none YES External leakage in the high pressure Check if system has no external leakage
control: Leakage in potential system. Check if back flow tube is free
high pressure Pressure in back flow tube too high Check if PCV is tighten
system (i.e. back flow tube clogged) Check if fuel pressure sensor signal is correct
Pressure Control valve PCV does not Check if injectors close well
close completely. Check High pressure pump delivery
Fuel pressure sensor signal shows
wrong (mainly too low) values.
Injectors leak inter
A325 Fuel pressure RailMeUn2 OFF YES NO Metering unit stuck in open position, Check metering Unit (MeUn), if closing (PWM =
control Metering (technical) zero-delivery throttle clogged, 100%)
unit: Too high fuel metering unit without power due to Check electric wiring to PCV and MeUn
fuel pressure with electricel error. Check low pressure fuel tubes (return from CP to tank
MeUn on Low pressure side: Pressure before free?)
0-delivery state gear pump too high (e.g. by pressure Check zero delivery valve for correct working
relieve valve), pressure after
zero-delivery throttle too hi
A425 Fuel pressure RailMeUn22 OFF none YES Metering unit stuck in open position, Check metering Unit (MeUn), if closing (PWM =
control Metering potential zero-delivery throttle clogged, 100%)
(second stage) relieve valve), pressure after
Base - October 2011
199
Base - October 2011

Long
System
Failure
A525 Fuel pressure RailMeUn3 OFF engine stop YES Leakage in the high pressure system: Check low pressure system for clogging (specially fuel
control Metering (indirect) potential injection nozzle stuck in open filter)
unit: Fuel rail position, low efficiency of high Che tubing between presupply and gear pump
pressure below pressure pump, internal leakage of Check feeding of presupply pump (possibly low due to
limit with MeUn injector, leaking pressure control clogged tubes at tank outlet)
Control valve Too low pressure at High Check hgih pressure part for leakages (internal /
pressure pump inlet due clogged external)
A625 Fuel pressure RailMeUn4 OFF YES YES Metering unit stuck in open position, Check metering Unit (MeUn), if closing (PWM =
control Metering (technical) potential zero-delivery throttle clogged, 100%)
unit: Fuel Rail metering unit without power due to Check electric wiring to PCV and MeUn
pressure above electricel error. Check low pressure fuel tubes (return from CP to tank
maximum limit Low pressure side: Pressure before free?)
with MeUn gear pump too high (e.g. by pressure Check zero delivery valve for correct working
Control relieve valve), pressure after
A725 Fuel pressure RailMeUn42 OFF none YES Metering unit stuck in open position, Check metering Unit (MeUn), if closing (PWM =
control Metering potential zero-delivery throttle clogged, 100%)
Control (second relieve valve), pressure after
stage) zero-delivery throttle too hi
S SERIES EURO V
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
A825 Fuel pressure RailMeUn5 OFF engine stop NO Leakage in the high pressure system: Check low pressure system for clogging (specially fuel
control Metering (indirect) injection nozzle stuck in open filter)
rail pressure in fast pressure pump, internal leakage of Check feeding of presupply pump (possibly low due to
transient condition injector, leaking pressure control clogged tubes at tank outlet)
with MeUn valve Too low pressure at High Check hgih pressure part for leakages (internal /
AA25 Fuel pressure RailMeUn8 OFF none YES Leakage in the high pressure system: Check low pressure system for clogging (specially fuel
control Metering potential injection nozzle stuck in open filter)
unit: Leakage in position, low efficiency of high Che tubing between presupply and gear pump
high pressure pressure pump, internal leakage of Check feeding of presupply pump (possibly low due to
system detected at injector, leaking pressure control clogged tubes at tank outlet)
idle valve Too low pressure at High Check hgih pressure part for leakages (internal /
1125 Fuel pressure RailMeUnTn OFF none YES Leakage in the high pressure system: Check low pressure system for clogging (specially fuel
control Metering kLo0 potential injection nozzle stuck in open filter)
rail pressure with pressure pump, internal leakage of Check feeding of presupply pump (possibly low due to
MeUn Control injector, leaking pressure control clogged tubes at tank outlet)
with empty Tank valve Too low pressure at High Check hgih pressure part for leakages (internal /
Base - October 2011
201
Base - October 2011

Long
System
Failure
unit: Tool low fuel position, low efficiency of high Che tubing between presupply and gear pump
rail pressure pressure pump, internal leakage of Check feeding of presupply pump (possibly low due to
concerning the fuel injector, leaking pressure control clogged tubes at tank outlet)
feeding with MeUn valve Too low pressure at High Check hgih pressure part for leakages (internal /
Control with pressure pump inlet due clogged external)
empty Tank filter, leaking low Ch
3125 Fuel pressure (Rail) RailMeUnTn OFF none YES External leakage in the high pressure Check if system has no external leakage
control: Leakage in kLo10 potential system. Check if back flow tube is free
high pressure Pressure in back flow tube too high Check if PCV is tighten
system with empty (i.e. back flow tube clogged) Check if fuel pressure sensor signal is correct
tank Pressure Control valve PCV does not Check if injectors close well
close completely. Check High pressure pump delivery
Fuel pressure sensor signal shows
wrong (mainly too low) values.
Injectors leak inter
2225 Fuel pressure RailMeUnTn OFF none NO Metering unit stuck in open position, Check metering Unit (MeUn), if closing (PWM =
control Metering kLo2 zero-delivery throttle clogged, 100%)
0-delivery state gear pump too high (e.g. by pressure
with empty tank relieve valve), pressure after
2125 Fuel pressure RailMeUnTn OFF none YES Metering unit stuck in open position, Check metering Unit (MeUn), if closing (PWM =
control Metering kLo22 potential zero-delivery throttle clogged, 100%)
S SERIES EURO V
Print P1D32S014 E
(second stage) relieve valve), pressure after
swith empty tank zero-delivery throttle too hi
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
2325 Fuel pressure RailMeUnTn OFF engine stop YES Leakage in the high pressure system: Check low pressure system for clogging (specially fuel
control Metering kLo3 (indirect) potential injection nozzle stuck in open filter)
unit: Fuel rail position, low efficiency of high Che tubing between presupply and gear pump
pressure below pressure pump, internal leakage of Check feeding of presupply pump (possibly low due to
limit with MeUn injector, leaking pressure control clogged tubes at tank outlet)
Control with valve Too low pressure at High Check hgih pressure part for leakages (internal /
empty tank pressure pump inlet due clogged external)
1425 Fuel pressure RailMeUnTn OFF none YES Metering unit stuck in open position, Check metering Unit (MeUn), if closing (PWM =
control Metering kLo4 potential zero-delivery throttle clogged, 100%)
Control with relieve valve), pressure after
empty tank zero-delivery throttle too hi
1325 Fuel pressure RailMeUnTn OFF none NO Metering unit stuck in open position, Check metering Unit (MeUn), if closing (PWM =
control Metering kLo42 zero-delivery throttle clogged, 100%)
Control (second relieve valve), pressure after
stage) with empty zero-delivery throttle too hi
tank
1525 Fuel pressure RailMeUnTn OFF none NO Leakage in the high pressure system: Check low pressure system for clogging (specially fuel
control Metering kLo5 injection nozzle stuck in open filter)
rail pressure in fast pressure pump, internal leakage of Check feeding of presupply pump (possibly low due to
transient condition injector, leaking pressure control clogged tubes at tank outlet)
Base - October 2011
with MeUn valve Too low pressure at High Check hgih pressure part for leakages (internal /
Control with pressure pump inlet due clogged external)
empty tank filter, leaking low Ch
203
Base - October 2011

Long
System
Failure
unit: Leakage in position, low efficiency of high Che tubing between presupply and gear pump
high pressure pressure pump, internal leakage of Check feeding of presupply pump (possibly low due to
system detected at injector, leaking pressure control clogged tubes at tank outlet)
idle an empty fuel valve Too low pressure at High Check hgih pressure part for leakages (internal /
tank pressure pump inlet due clogged external)
A135 Fuel pressure RailPCV0 OFF YES YES Leakage in the high pressure system: Check low pressure system for clogging (specially fuel
control Pressure (technical) potential injection nozzle stuck in open filter)
control valve: Too position, low efficiency of high Che tubing between presupply and gear pump
low fuel rail pressure pump, internal leakage of Check feeding of presupply pump (possibly low due to
pressure with PCV injector, leaking pressure control clogged tubes at tank outlet)
control valve Too low pressure at High Check hgih pressure part for leakages (internal /
A235 Fuel pressure RailPCV1 OFF engine stop YES Leakage in the high pressure system: Check low pressure system for clogging (specially fuel
control Pressure (indirect) potential injection nozzle stuck in open filter)
pressure injector, leaking pressure control clogged tubes at tank outlet)
concerning set valve Too low pressure at High Check hgih pressure part for leakages (internal /
value PCV (PCV pressure pump inlet due clogged external)
Control) filter, leaking low Ch
A335 Fuel pressure RailPCV2 OFF YES YES Pressure Control Valve (PCV) stuck Check PCV for opening (PWM=0% --> no pressure)
control Pressure (technical) potential in close position, additional current Check wiring harness for "external" electric power
control valve: Too trhough PCV due to electric problem (short circuit)
high fuel rail in wiring, return flow tube from PCV Check return tube from PCV to tank for clogging
pressure cloggged
S SERIES EURO V
concerning set
Print P1D32S014 E
value PCV (PCV

Control)
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
A435 Fuel pressure RailPCV22 OFF none YES Pressure Control Valve (PCV) stuck Check PCV for opening (PWM=0% --> no pressure)
control Pressure potential in closed position additional current Check wiring harness for "external" electric power
pressure cloggged
concerning set
value PCV- second
stage (PCV
Control)
A535 Fuel pressure RailPCV3 OFF engine stop YES Leakage in the high pressure system: Check low pressure system for clogging (specially fuel
control Pressure (indirect) potential injection nozzle stuck in open filter)
control valve: position, low efficiency of high Che tubing between presupply and gear pump
minimum rail pressure pump, internal leakage of Check feeding of presupply pump (possibly low due to
pressure not injector, leaking pressure control clogged tubes at tank outlet)
reached with PCV valve Too low pressure at High Check hgih pressure part for leakages (internal /
A635 Fuel pressure RailPCV4 OFF YES YES Pressure Control Valve (PCV) stuck Check PCV for opening (PWM=0% --> no pressure)
control Pressure (technical) potential in close position, Check wiring harness for "external" electric power
control valve: additional current trhough PCV due (short circuit)
maximum rail to electric problem in wiring, Check return tube from PCV to tank for clogging
pressure exceeded return flow tube from PCV cloggged Check metering Unit for 0-delivery (PWM=100% -->
with PCV control Metering Unit (MeUn) stuck in full no delivery)
feeding position Check wiring for metering u
No electrical power to metering unit
A735 Fuel pressure RailPCV42 OFF none YES Pressure Control Valve (PCV) stuck Check PCV for opening (PWM=0% --> no pressure)
control Pressure potential in close position, additional current Check wiring harness for "external" electric power
control valve: trhough PCV due to electric problem (short circuit)
maximum rail in wiring, return flow tube from PCV Check return tube from PCV to tank for clogging
Base - October 2011
pressure exceeded clogged Metering Unit (MeUn) stuck Check metering Unit for 0-delivery (PWM=100% -->
with PCV control in full feeding position no delivery)
(second stage) No electrical power to metering unit Check wiring for metering u
205
Base - October 2011

Long
System
Failure
1135 Fuel pressure RailPCVTnkL OFF none YES Leakage in the high pressure system: Check low pressure system for clogging (specially fuel
control Pressure o0 potential injection nozzle stuck in open filter)
pressure with PCV injector, leaking pressure control clogged tubes at tank outlet)
control with empty valve Check hgih pressure part for leakages (internal /
fuel tank Too low pressure at High pressure external)
pump inlet due clogged filter, leaking Ch
low
1235 Fuel pressure RailPCVTnkL OFF engine stop YES Leakage in the high pressure system: Check low pressure system for clogging (specially fuel
control Pressure o1 (indirect) potential injection nozzle stuck in open filter)
pressure injector, leaking pressure control clogged tubes at tank outlet)
concerning set valve Too low pressure at High Check hgih pressure part for leakages (internal /
value PCV (PCV pressure pump inlet due clogged external)
Control) with filter, leaking low Ch
empty fuel tank
2235 Fuel pressure RailPCVTnkL OFF none YES Pressure Control Valve (PCV) stuck Check PCV for opening (PWM=0% --> no pressure)
control Pressure o2 potential in close position, additional current Check wiring harness for "external" electric power
pressure clogged
concerning set
value PCV (PCV
Control) with
empty fuel tank
control Pressure o22 potential in closed position additional current Check wiring harness for "external" electric power
pressure clogged
concerning set
S SERIES EURO V
Print P1D32S014 E
value PCV- second

stage (PCV
Control) with
empty fuel tank
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
2335 Fuel pressure RailPCVTnkL OFF engine stop YES Leakage in the high pressure system: Check low pressure system for clogging (specially fuel
control Pressure o3 (indirect) potential injection nozzle stuck in open filter)
control valve: position, low efficiency of high Che tubing between presupply and gear pump
minimum rail pressure pump, internal leakage of Check feeding of presupply pump (possibly low due to
pressure not injector, leaking pressure control clogged tubes at tank outlet)
reached with PCV valve Too low pressure at High Check hgih pressure part for leakages (internal /
Control wit empty pressure pump inlet due clogged external)
fuel tank filter, leaking low Ch
control Pressure o4 potential in close position, additional current Check wiring harness for "external" electric power
control valve: trhough PCV due to electric problem (short circuit)
maximum rail in wiring, Check return tube from PCV to tank for clogging
pressure exceeded return flow tube from PCV cloggged Check metering Unit for 0-delivery (PWM=100% -->
with empty fuel feeding position Check wiring for metering u
tank No electrical power to metering unit
control Pressure o42 potential in close position, Check wiring harness for "external" electric power
control valve: additional current trhough PCV due (short circuit)
maximum rail to electric problem in wiring, Check return tube from PCV to tank for clogging
pressure exceeded return flow tube from PCV clogged Check metering Unit for 0-delivery (PWM=100% -->
(second stage) with feeding position Check wiring for metering u
empty fuel tank No electrical power to metering unit
A233 Fuel pressure (Rail) RailPGradM OFF none NO Periodical loose of contact in the Check wiring and connectors of Rail pressure sensor
sensor: Rail on weiring, the connectors or sensor for good contacts.
pressure raw value itself Check sensor, replace sensor if necessary and reset
is intermittent learning values in EEPROM / start New learning
1333 Fuel pressure (Rail) RailPOfsTst OFF YES YES Rail pressure sensor inaccurate Ensure correct wiring and proper functioning of rail
sensor: rail Max (technical) potential pressure sensor,
pressure raw value Replace sensor if necessary and reset learning values in
is above maximum EEPROM / start New learning
offset
Base - October 2011
2333 Fuel pressure (Rail) RailPOfsTst OFF YES YES Rail pressure sensor inaccurate Ensure correct wiring and proper functioning of rail
sensor: rail Min (technical) potential pressure sensor, replace sensor
pressure raw value Replace sensor if necessary and reset learning values in
is below minimum EEPROM / start New learning
207
offset
Base - October 2011

Long
System
Failure
1133 Fuel pressure (Rail) RailPSRCMa OFF YES NO Short circuit of wiring to external Check wiring and proper functioning of rail pressure
sensor: Sensor x (technical) source or defective pressure sensor sensor
voltage above Replace sensor if necessary and reset learning values in
upper limit EEPROM / start New learning
2133 Fuel pressure (Rail) RailPSRCMin OFF YES NO Short circuit of wiring to ground or Check wiring and proper functioning of rail pressure
sensor: Sensor (technical) defective pressure sensor sensor
voltage below Replace sensor if necessary and reset learning values in
lower limit EEPROM / start New learning
A55A Info: SCR reagent SCRCtl_War none NOx none NO Reducing agent tank level below first Refill reducing agent tank
tank level below nStgy_Warn Aftertrea warning level
first warning level, Lvl1 tment
DFC for triggering
warning action
dependent on
filling level of
reducing agent
A65A Info: SCR reagent SCRCtl_War OFF none NO Reducing agent tank level below low Refill reducing agent tank
tank level below nStgy_Warn second warning level
second warning Lvl2
level, DFC for
triggering warning
action dependent
on filling level of
reducing agent
A75A Info: SCR reagent SCRCtl_War OFF none NO Reducing agent tank level below third Refill reducing agent tank
tank level below nStgy_Warn warning level
third warning level, Lvl3
DFC for triggering
warning action
dependent on
filling level of
reducing agent
A85A Info: SCR reagent SCRCtl_War OFF none NO Reducing agent tank level below Refill reducing agent tank
tank level below nStgy_Warn fourth warning level
fourth warning Lvl4
S SERIES EURO V
Print P1D32S014 E
level, DFC for

triggering warning
action dependent
on filling level of
reducing agent
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
A7CA SCR Reagent SCRMonMet OFF NOx none YES direct UREA level too low (suction of air) Check if UREA level was OK whe failure occurred (see
Feeding: UREA CtlOvrPresE Aftertrea Back flow into tank clogged ambient conditions).
pressure too high rr tment Pump control not OK (e.g. pump is Check if back flow line into tank is open (with test:
running on max due to electr failure). adjust system to normal pressure (5bar) and check, if
UREA pressure sensor shows too pressure is constant, if not, stop pump --> pressure
high values. must drop down (=sy
A6CA SCR Reagent SCRMonMet OFF NOx none YES direct UREA level too low (suction of air) Check, if enough UREA was in tank when failure
Feeding: UREA CtlUndrPres Aftertrea occured (ambient conditions)
pressure too low Err tment Leakage in the UREA system outside Check if pump can reach enough pressure with tester:
or internal (i.e. back flow into tank, set system under normal pressure (5 bar) :
leakage into pump housing, external - chek if there is an external leakage (visible check)
leakage). - if 5bar reachable: open
Pump not delivering enough.
Reveting valve blocked "open"
(occurrence during normal operation
-
A5CA SCR Reagent SCRMonOvr OFF NOx none YES direct UREA level too low (suction of air) Check if UREA level was OK whe failure occurred (see
Feeding: UREA PresErr Aftertrea Back flow into tank clogged ambient conditions).
pressure too high tment Pump control not OK (e.g. pump is Check if back flow line into tank is open (with test:
(2nd level) running on max due to electr failure). adjust system to normal pressure (5bar) and check, if
UREA pressure sensor shows too pressure is constant, if not, stop pump --> pressure
high values. must drop down (=sy
A2CA SCR Reagent SCRMonPre OFF NOx none YES direct UREA level too low (suction of air) Check, if enough UREA was in tank when failure
Feeding: sBuildUpErr Aftertrea Suction tube leaky occured (ambient conditions)
Pressurisation after tment Leakage in the UREA system outside Check if pump can reach enough pressure with tester:
start not possible or internal (i.e. back flow into tank, set system under normal pressure (5 bar) :
leakage into pump housing, external - chek if there is an external leakage (visible check)
leakage). - if 5bar reachable: open
Dosing valve blocked open.
Pump not delivering enough.
Reverting valve bloc
A3CA SCR Reagent SCRMonPre OFF NOx none YES direct Reverse vavle does not work Check if Back flow tube free.
Feeding: Pressure sRdcErr Aftertrea (blocked closed). Check if Reverse valve works with tester: set UREA
release not tment Back flow tube into tank clogged. pressure to 5 bar (dosing valve closed) - wait unitl
possible UREA pressure sensor stuck. pressure stable - actuate reverse valve --> if pressure
Base - October 2011
does not drop down --> revers valve does not work.
318A SCR Dosing valve: SCRPODPla OFF NOx none YES direct Dosing valve blocked mechanically Check if dosing valve opens.
Dosing Valve is usUDosVlv Aftertrea (or frozen) Check if tube between pump and dosing valve is free.
209
Blocked closed tment
Base - October 2011

Long
System
Failure
319A SCR Reverting SCRPODPla OFF none NO Reverse vavle does not work Check if Back flow tube free.
Valve: Reverting usURevVlv (blocked closed). Check if Reverse valve works with tester: set UREA
Valve is Blocked Back flow tube into tank clogged. pressure to 5 bar (dosing valve closed) - wait unitl
closed UREA pressure sensor stuck. pressure stable - actuate reverse valve --> if pressure
does not drop down --> revers valve does not work.
C2AA SCR Tank heater: SCRPODTn OFF none NO Heater in "air bubble" with frozen Check tank heater
Urea tank heater is kTempResp UREA --> check ambient conditions, Check wiring harness
faulty if failure happened at temp < -10°
--> possible reason.
Tank heater defect
Wiring harness defect
A1DA SCR Reagent Tank SCRRCntErr OFF none NO Empty UREA Tank Fill Up UREA
Level: Maximum UREA Level Sensor defective (at Check UREA Level Sensor
number restarts empty position) Defreeze UREA Tank, if frozen
allowed with Possibly frozen UREA and Sensor in Note:To prevent "critical situation", 8.00- further
empty UREA Tank "air bubble" restarts can be activated by the Service tester to give
is exceeded the possibilit to drive to the next UREA filling station
or repair station. T
F15C Immobilizer: DFC Sia OFF none NO Immobilizer is inhibiting fuele release Check reason for immobilizer intervention (defective
to show the status key was used or or wrong key was used (possibly
of fuel released or carjacker with fake key) or communication between
blocked key and ICU disturbed)
F25C Immobilizer: DFC SiaCode OFF none NO TEN-code received OR UC-code First learn of transponder starten
to indicate that received if ECU is learned,
TEN-code or immobilizer is defective or it has
UC-code received been replaced and not yet learned
if ECU is learned.
F35C Immobilizer: DFC SiaNoCode OFF none NO CAN communication between ICM Check wiring, check other CAN messages
to indicate that no CAN and ECM disturbed or interrupted disturbancies
code is received via
CAN.
F45C Immobilizer DFC SiaWrongCo OFF none NO Wrong ICU mounted on vehicle, OR Check ICU, check ECM Immobilizer programming
to indicate that de ECM was replaced and immobilizer
wrong code is parameters not correctly
S SERIES EURO V
received. programmed OR
Print P1D32S014 E
hardware problem in the ICU

4351 PTO actuation: SigPTOSwt OFF none NO PTO Switch defective Check and replace PTO switch
Defect Fault Check
for Signal error
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
41BA SCR Reagent SigUPmpP OFF NOx none YES direct Disturbed CAN signal transmission Check Sensor.
Pump: Signal error Aftertrea or Sensor defective Check the CAN for proper configuration and
for CAN message tment functioning
1121 Accelerator Pedal: SRCHighAP OFF none NO Short circuit of wiring to external Check wiring or replace accelerator pedal
Signal Range Check P1 source or inside accelerator pedal
High for APP1
1221 Accelerator Pedal: SRCHighAP OFF none NO Short circuit of wiring to external Check wiring and accelerator pedal
Signal Range Check P2 source or inside accelerator pedal
High for APP2
2121 Accelerator Pedal: SRCLowAPP OFF none NO Short circuit to ground in wiring or in Check wiring or replace accelerator pedal
Signal Range Check 1 accelerator pedal
Low for APP1
2221 Accelerator Pedal: SRCLowAPP OFF none NO Short circuit to ground in wiring or in Check wiring or replace accelerator pedal
Signal Range Check 2 accelerator pedal
Low for APP2
11BA SCR Reagent SRCMaxUP OFF NOx none YES direct Short circuit of sensor to external Check wiring and sensor
Pump: SRC high mpP Aftertrea source or defective sensor
for Urea Urea tment
Pump Module
Pressure Sensor
21BA SCR Reagent SRCMinUPm OFF NOx none YES direct Short circuit of sensor to ground or Check wiring or replace sensor
Pump: SRC low for pP Aftertrea defective sensor
Urea Pump tment
Module Pressure
Sensor
A12D ECU Power Stage SSpMon1 ON Compre YES YES direct Excessive battery voltage, defect in Check battery voltage, check wiring for correct voltage
1: Error Sensor hensive (technical) wiring harness, electrical failure in supply of the connected sensor and the ECM.
supply for sensors connected sensors or in the ECM Replace ECM
(if mounted):
Accelerator Pedal
Base - October 2011
1, Cam Shaft , SCR

Reagent pressure,
VGT speed, VGT
actuator position,
211
EGR Diff. Pressure
Base - October 2011

Long
System
Failure
A22D ECU Power Stage SSpMon2 ON Compre YES YES direct Excessive battery voltage, defect in Check battery voltage, check wiring for correct voltage
2: Error Sensor hensive (technical) wiring harness, electrical failure in supply of the connected sensor and the ECM.
(if mounted):
Accelerator Pedal
2, Boost pressure ,
Fuel pressure in
Rail, A/C pressure
A32D ECU Power Stage SSpMon3 ON PM filter none YES direct Excessive battery voltage, defect in Check battery voltage, check wiring for correct voltage
3: Error Sensor wiring harness, electrical failure in supply of the connected sensor and the ECM.
(if mounted): DPF
Diff pressure, Oil
Pressure, EGR
valve Position, Air
Humidity
F16C ECU Internal: Stop StopCntTmr OFF none NO ECM internal problem Contact Help Desk
Counter Timer
accuracy
5222 Service lamp SVSOL OFF none NO Broken or disconnected wiring or Check of wiring or replace diagnostic lamp
Dashport: No load defective diagnostic lamp.
error
8222 Service lamp SVSOvrTem OFF none NO High battery voltage, high ECU Check load and output, check wiring, replace
Dashport: Over p temperature and high load OR diagnostic lamp or ECU
Temperature error defective wiring, diagnostic lamp or
ECU
6222 Service lamp SVSSCB OFF none NO Short circuit of wiring to external Check of wiring
Dashport: Short source
circuit to battery
error
S SERIES EURO V
Print P1D32S014 E
7222 Service lamp SVSSCG OFF none NO Short circuit of wiring to ground Check of wiring
Dashport: Short
circuit to ground
error
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
A16D ECU SW Reset: SWReset_0 OFF none NO Electronic disturbances, various Analyze what error triggered the recovery (Read out
Software Resets hardware defects (ECU internal) or label HWEMon_numRecovery and compare the value
visible to all testers configuration problems with the according table). If error occurs repeatedly,
reprogram EDC. If error remains, replace EDC.
Software Resets, hardware defects (ECU internal) or label HWEMon_numRecovery and compare the value
visible to configuration problems with the according table). If error occurs repeatedly,
manufacturer reprogram EDC. If error remains, replace EDC.
Tester only
Invisibility Software hardware defects (ECU internal) or label HWEMon_numRecovery and compare the value
Resets configuration problems with the according table). If error occurs repeatedly,
reprogram EDC. If error remains, replace EDC.
A321 Accelerator Pedal: SyncAPP OFF none NO Wiring problem, aged or defective Check wiring and accelerator pedal
it is the plausibility accelerator pedal
check between
APP1 and APP2
and in case of
potentiometer
switch accelerator
pedal, it is the
plausibility check
between APP1 and
idle switch
C321 Accelerator Pedal: SyncAPPDbl OFF none NO Wiring problem, aged or defective Check wiring and accelerator pedal
Diagnostic fault PotLIS accelerator pedal
check of
synchronism for
double
potentiometer and
Low idle
switch(LIS) .
Base - October 2011
A45D ECU Key 16: T50Err OFF none NO Too long cranking request, short Check ignition key module and wiring
Defective T50 circuit in ignition key module or in
213
switch wiring
Base - October 2011

Long
System
Failure
1163 Air Temp in AFS: TAFSPhysRn OFF none NO Inaccurate or defective air Check wiring and the accuracy of the air temperature
Physical Range high gHi temperature sensor, defect in the sensor and replace it if necessary
error for air wiring
temperature
sensor
2163 Air Temp in AFS: TAFSPhysRn OFF none NO Inaccurate or defective air Check wiring and the accuracy of the air temperature
Physical Range low gLo temperature sensor, defect in the sensor and replace it if necessary
error for air wiring
temperature
sensor
1263 Air Temp in AFS: TAFSSRCMa OFF none NO Short circuit of sensor to external Check wiring or replace sensor
SRC high for air x source or defective sensor
temperature
sensor
2263 Air Temp in AFS: TAFSSRCMi OFF none NO Short circuit of sensor to ground or Check wiring or replace sensor
SRC low for air n defective sensor
temperature
sensor
D153 Boost temperature: TCACDsPhy OFF none NO Inaccurate or defective temperature Check wiring and the accuracy of the temperature
Physical Signal sRngHi sensor, defect in the wiring sensor and replace it if necessary
above maximum
limit
E153 Boost temperature: TCACDsPhy OFF none NO Inaccurate or defective temperature Check wiring and the accuracy of the temperature
Physical Signal sRngLo sensor, defect in the wiring sensor and replace it if necessary
below minimum
limit
1153 Boost temperature: TCACDsSR OFF none NO Sensor defective or short circuit to Check wiring or replace sensor
S SERIES EURO V
SRC High for CMax external source
Print P1D32S014 E
Boost
Temperature
sensor
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
2153 Boost temperature: TCACDsSR OFF none NO Sensor defective or short circuit to Check wiring or replace sensor
SRC Low for Boost CMin ground
Temperature Note: This failrue can also be
sensor detected, if a very high boost
temeprature occured (> 350°C) e.g.
due to full flow of non cooled EGR
or fire ....
3153 Boost temperature: TCACDsVD OFF none NO One of the 2 sensors has an offset or Checkt the ambient conditions to define which sensor
Plausibility Check Plaus is miscalbrated is out of range
of the Boost Additional resistance in connector of Check the connector of sensor to corrosion
Temperature the dedicated sensor Check the sensor itself
sensor at cold start
D2E3 Diagnostic Fault TECUPhysR OFF none NO Inaccurate or defective temperature Check wiring and the accuracy of the temperature
Check for Physical ngHi sensor, defect in the wiring sensor and replace it if necessary
Signal above
maximum limit
E2E3 Diagnostic Fault TECUPhysR OFF none NO Inaccurate or defective temperature Check wiring and the accuracy of the temperature
Check for Physical ngLo sensor, defect in the wiring sensor and replace it if necessary
Signal below
minimum limit
31E3 ECU Temperature TECUSPIErr OFF none NO Temperature sensor defective (inside Replace ECM
sensing: SPI Error ECM)
ECU temperature
sensor (LM71)
A18C ECU Internal: ThmMngAct OFF none NO Excessive processor temperature If failure not sporadic , replace ECM
Defect Fault Check v reached, Internal ECM problem
Base - October 2011
for activation of
thermal
management
215
Base - October 2011

Long
System
Failure
118C ECU Internal: ThmMngMa OFF none NO Excessive processor temperature If failure not sporadic , replace ECM
Defect Fault Check xTemp reached, Internal ECM problem
for Signal value
above maximum
limit
5137 EGR Throttle: No ThrVlvOL OFF none NO Broken or disconnected wiring or Check of wiring, replace Throttle Valve Actuator
load error on defective Throttle Valve Actuator
power stage for
Throttle Valve
Actuator
8137 EGR Throttle: ThrVlvOvrT OFF none NO High battery voltage, high ECU Check battery voltage, wiring, power stage and
Over temperature emp temperature and high load or Throttle Valve Actuator
error on power defective wiring, power stage or
stage Throttle Valve Actuator defective
6137 EGR Throttle: ThrVlvSCB OFF none NO Short circuit of wiring to external Check of wiring or replace Throttle Valve Actuator
Short circuit to source or inside Throttle Valve
battery error on Actuator
power stage for
Throttle Valve
Actuator
7137 EGR Throttle: ThrVlvSCG OFF none NO Short circuit of wiring to ground or Check of wiring or replace Throttle Valve Actuator
Short circuit to inside Throttle Valve Actuator
ground error on
power stage for
Throttle Valve
Actuator
1137 EGR Throttle: SRC ThrVlvSRCM OFF none NO Short circuit of wiring to external Check of wiring or replace Throttle Valve Actuator.
High for TVA ax source or defective Throttle Valve
position Actuator.
S SERIES EURO V
Print P1D32S014 E
2137 EGR Throttle: SRC ThrVlvSRCM OFF none NO Short circuit of wiring to ground or Check of wiring or replace Throttle Valve Actuator.
low for TVA in defective Throttle Valve Actuator.
position
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
D253 Boost temperature: TIntkVUsPhy OFF none NO Inaccurate or defective temperature Check wiring and the accuracy of the temperature
Physical Signal sRngHi sensor, defect in the wiring sensor and replace it if necessary
above maximum
limit
E253 Boost temperature: TIntkVUsPhy OFF none NO Inaccurate or defective temperature Check wiring and the accuracy of the temperature
Physical Signal sRngLo sensor, defect in the wiring sensor and replace it if necessary
below minimum
limit
1253 Boost temperature: TIntkVUsSR OFF none NO Short circuit of sensor to external Check wiring or replace sensor
SRC high for air CMax source or defective sensor
intake temperature
2253 Boost temperature: TIntkVUsSR OFF none NO Short circuit of sensor to ground or Check wiring or replace sensor
SRC low for air CMin defective sensor
intake temperature
F26C ECU Internal: Tle6232Spi1 OFF none NO ECM internal failure Replace ECM
Reported SPI
errors of Tle6232
D119 Diagnostic Fault TOxiCatDsP ON NMHC none NO Inaccurate or defective temperature Check wiring and the accuracy of the temperature
Check for Physical hysRngHi catalyst sensor, defect in the wiring sensor and replace it if necessary
Signal below
minimum limit
E119 Diagnostic Fault TOxiCatDsP ON NMHC none NO Inaccurate or defective temperature Check wiring and the accuracy of the temperature
Check for Physical hysRngLo catalyst sensor, defect in the wiring sensor and replace it if necessary
Signal below
minimum limit
Base - October 2011
A119 Signal range check TOxiCatDsS ON NMHC none NO Short circuit of sensor to external Check wiring and sensor
high RCMax catalyst source or defective sensor
217
Base - October 2011

Long
System
Failure
B119 Signal range check TOxiCatDsS ON NMHC none NO Short circuit of sensor to ground or Check wiring or replace sensor
low RCMin catalyst defective sensor
A319 Oxicat Temp TOxiCatUs ON NMHC none NO An abnormal heating of the exhaust Let engine cool down before restarting and check
Sensing: Defect Npl catalyst system has occurred or OxiCat sensor accuracy.
Fault Check for upstream temperature sensor is If the real exhaust temperature really differes from the
"signal vnot inaccurate. calculated one due to a failure in the engine like:
plausible" wrong injection pressure,
wrong injection begin
wrong EGR rate
the engine syste
D219 Diagnostic Fault TOxiCatUsP ON NMHC none NO Inaccurate or defective temperature Check wiring and the accuracy of the temperature
Check for Physical hysRngHi catalyst sensor, defect in the wiring sensor and replace it if necessary
Signal below
minimum limit
E219 Diagnostic Fault TOxiCatUsP ON NMHC none NO Inaccurate or defective temperature Check wiring and the accuracy of the temperature
Check for Physical hysRngLo catalyst sensor, defect in the wiring sensor and replace it if necessary
Signal below
minimum limit
1319 Oxicat Temp TOxiCatUsS ON NMHC none NO Short circuit of sensor to external Check wiring and sensor
Sensing: Defect RCMax catalyst source or defective sensor
Fault Check for
"signal value above
maximum limit"
2319 Oxicat Temp TOxiCatUsS ON NMHC none NO Short circuit of sensor to ground or Check wiring or replace sensor
Sensing: Defect RCMin catalyst defective sensor
Fault Check for
"signal value below
minimum limit"
S SERIES EURO V
6129 Diagnostic Fault TPFltDsSRC OFF none NO Short circuit of sensor to external Check wiring and sensor
Print P1D32S014 E
Check for signal Max source or defective sensor

value above
maximum limit
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
7129 Diagnostic Fault TPFltDsSRC OFF none NO Short circuit of sensor to ground or Check wiring or replace sensor
Check for signal Min defective sensor
value below
minimum limit
3229 Diagnostic fault TPFltUsNpl OFF none NO An abnormal heating of the exhaust Let engine cool down before restarting and check
check for system has occurred or DPF sensor accuracy.
plausibility of upstream temperature sensor is If the real exhaust temperature really differes from the
particle filter inaccurate. calculated one due to a failure in the engine like:
upstream wrong injection pressure,
temperature wrong injection begin
wrong EGR rate
the engine syste
D229 Diagnostic Fault TPFltUsPhys OFF none NO Inaccurate or defective temperature Check wiring and the accuracy of the temperature
Check for Physical RngHi sensor, defect in the wiring sensor and replace it if necessary
Signal below
minimum limit
E229 Diagnostic Fault TPFltUsPhys OFF none NO Inaccurate or defective temperature Check wiring and the accuracy of the air temperature
Check for Physical RngLo sensor, defect in the wiring sensor and replace it if necessary
Signal below
minimum limit
6229 Defect Fault Check TPFltUsSRC OFF none NO Short circuit of sensor to external Check wiring and sensor
for "signal value Max source or defective sensor
above maximum
limit"
7229 Defect Fault Check TPFltUsSRC OFF none NO Short circuit of sensor to ground or Check wiring or replace sensor
Base - October 2011
for "signal value Min defective sensor

below minimum
limit"
219
Base - October 2011

Long
System
Failure
1128 Turbocharger TrbChGovD OFF none NO Desired VGT actuator position can Check Functionality of VGT actuator and the
control: vtMax not be reached (valve is not enough corresponding position
Turbocharger opened)
position too much VGT actuator blocked mechanically
open (Too low VGT actuator sticks
boost pressure) VGT actuator position sensor
mismatched
2128 Turbocharger TrbChGovD OFF none NO Desired VGT actuator position can Check Functionality of VGT actuator and the
control: vtMin not be reached (valve is too much corresponding position
Turbocharger opened)
position too much VGT actuator blocked mechanically
closed (Too high VGT actuator sticks
boost pressure) VGT actuator position sensor
mismatched
5128 Turbocharger TrbChHBrg ON Compre YES YES direct Electrical problem of the VGT Check wiring harnes on open circuit
control: Open load OpnLd hensive (technical) actuator: Check VGT actuator on open circuit
error for - broken wiring harness
powerstage - no contact of conector
- internal broken line in actuator
1228 Turbocharger TrbChHBrg ON Compre YES YES direct Electrical problem of the VGT Check wiring harnes on partial short circuit
control: Over OvrCurr hensive (technical) actuator: Check VGT actuator on partial short circuit
current error for - "short circuit" in wiring harness
H-bridge - internal "short circuit" in actuator
8128 Turbocharger TrbChHBrg ON Compre YES YES direct High battery voltage, high No reaction needed if failure isn't present after short
control: Over OvrTemp hensive (technical) temperature inside ECU, high load or time, check load and output, check wiring, replace
temperature error wiring problem ECU
for H-bridge
6128 Turbocharger TrbChHBrgS ON Compre YES YES direct Short circuit of wiring Check of wiring
control: Short hCirBatt1 hensive (technical)
circuit to battery
on Out1 error for
H-bridge
S SERIES EURO V
Print P1D32S014 E
control: Short hCirBatt2 hensive (technical)

circuit to battery
on Out2 error for
H-bridge
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
control: Short hCirGnd1 hensive (technical)
circuit to ground
on Out1 error for
H-bridge
control: Short hCirGnd2 hensive (technical)
circuit to ground
on Out2 error for
H-bridge
control: Short hCirOvrLd hensive (technical)
circuit over load
error for H-bridge
8228 Turbocharger TrbChHBrgT ON Compre YES YES direct Electrical problem of the VGT Check wiring harnes on partial short circuit
control: empOvrCurr hensive (technical) actuator: Check VGT actuator on partial short circuit
Temperature - "short circuit" in wiring harness
dependent over - internal "short circuit" in actuator
current error for
H-bridge
7428 Turbocharger TrbChHBrg ON Compre YES YES direct Too high Voltage fluctuations in Check electricla system of vehicle
control: Under UndrVltg hensive (technical) system Replace ECU
voltage error for internal failure of ECU
H-bridge
A228 Turbocharger TrbChJamVl OFF none NO VGT actuator can not be opened as Check Functionality of VGT actuator and the
control: Jammed v desired within expected time corresponding position
valve VGT actuator blocked mechanically
VGT actuator sticks
VGT actuator position sensor
mismateched
A328 Turbocharger TrbChLgTDr OFF none NO The position sensor has too high Check Functionality of VGT actuator:
control: Long time ft deviation in fully closed or open - fully opened position reachable?
drift of position position, that the learning correction - fully closed position reachable?
sensor factor will be too high: - postion signal valid in both conditions?
VGT actuator position sensor
mismatched
Base - October 2011
A428 Turbocharger TrbChOfsLr OFF none NO Desired position can not be reached Check Functionality of VGT actuator and the
control: Jammed nJamVlv VGT actuator blocked mechanically corresponding position
valve during offset VGT actuator sticks
221
learning VGT actuator position sensor
mismateched
Base - October 2011

Long
System
Failure
5228 Turbocharger TrbChOL ON Compre YES YES direct Broken or disconnected wiring, Check of wiring, replace PWM actuator
control: Open load hensive (technical) defective PWM actuator
of VTG actuator
8328 Turbocharger TrbChOvrT ON Compre YES YES direct High battery voltage, high ECU Check wiring, power stage and VGT actuator
control: Over emp hensive (technical) temperature and high load or
temperature of defective wiring, power stage or VGT
VTG actuator actuator
6328 Turbocharger TrbChSCB ON Compre YES YES direct Short circuit of wiring to external Check of wiring, replace PWM actuator
control: Short hensive (technical) source or inside PWM actuator
circuit to battery of
VTG actuator
7528 Turbocharger TrbChSCG ON Compre YES YES direct Short circuit of wiring to ground or Check of wiring, replace PWM actuator
control: Short hensive (technical) inside PWM
circuit to ground of
VTG actuator
A528 Turbocharger TrbChShTD OFF none NO Desired VGT actuator position can Check Functionality of VGT actuator and the
control: Short time rft not be reached corresponding position
drift of VGT VGT actuator position sensor
position sensor mismateched
1328 Turbocharger TrbChSRCM OFF none NO Short circuit of wiring to external Check of wiring or replace turbocharger control
control: Signal ax source or defective turbocharger
range check Max control
error on turbo
charger actuator
position sensor
2328 Turbocharger TrbChSRCM OFF none NO Short circuit of wiring to ground or Check of wiring or replace turbocharger control
control: Signal in defective turbocharger control
range check Min
error on turbo
charger actuator
position sensor
AD3B Torque or speed TSEACo_TS OFF none NO Defect on ABS / ASR / ESP Check correct functioning of the CAN controller.
control demand C1_TO_0 controller, CAN cable problem. Check wiring.
from ABS/ESR/ESP
exceeding the
maximum time
S SERIES EURO V
Print P1D32S014 E
A74B Torque or speed TSEACo_TS OFF none NO Defect on Driveline Retarder Check correct functioning of the CAN controller.
control demand C1_TO_1 controller, CAN cable problem. Check wiring.
from Driveline
Retarder exceeding
the maximum time
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
A45B Torque or speed TSEACo_TS OFF none NO Defect on PTO Controller, CAN Check correct functioning of the CAN controller.
control demand C1_TO_2 cable problem. Check wiring.
from PTO
exceeding the
maximum time
AC6B Torque or speed TSEACo_TS OFF none NO Defect on AMT controller, CAN Check correct functioning of the CAN controller.
from Transmission
Controller AMT
exceeding the
maximum time
A97B Torque or speed TSEACo_TS OFF none NO Defect on Vehicle Controller, CAN Check correct functioning of the CAN controller.
from Vehicle
Controller
exceeding the
maximum time
AE3B Continuous TSEACo_TS OFF none NO Defect on ABS / ASR / ESP Check correct functioning of the CAN controller.
negative torque C1_TO_5 controller, CAN cable problem. Check wiring.
control demand
from ABS/ESR/ESP
exceeding the
maximum time
A84B Continuous TSEACo_TS OFF none NO Defect on Driveline Retarder Check correct functioning of the CAN controller.
negative torque C1_TO_6 controller, CAN cable problem. Check wiring.
control demand
from Driveline
Retarder exceeding
the maximum time
AD6B Continuous TSEACo_TS OFF none NO Defect on AMT controller, CAN Check correct functioning of the CAN controller.
negative torque C1_TO_7 cable problem. Check wiring.
Base - October 2011
control demand
from Transmission
AMT exceeding
223
the maximum time
Base - October 2011

Long
System
Failure
AA7B Continuous TSEACo_TS OFF none NO Defect on Vehicle Controller, CAN Check correct functioning of the CAN controller.
negative torque C1_TO_8 cable problem. Check wiring.
control demand
from Vehicle
Controller
exceeding the
maximum time
D41A SCR Catalyst UCatDsTPhy OFF none NO UREA Catalyst temperature Check sensor
Temperature sRngHi downstream sensor drifted or not Check wiring
monitoring: correctly mounted
Downstream Partial short circuit on wiring harness
temperature above or sensor
physical maximum
value
E41A SCR Catalyst UCatDsTPhy OFF none NO UREA Catalyst temperature Check sensor
Temperature sRngLo downstream sensor drifted or not Check wiring
Downstream Partial short circuit on wiring harness
temperature below or sensor
physical minimum
value
441A SCR Catalyst UCatDsTSig OFF none NO Urea Catalyst downstream Check sensor and replace it if necessary
Temperature temperature defective
monitoring:
Downstream
temperature
sensor connected
via CAN reports
an error
141A SCR Catalyst UCatDsTSR OFF none NO Sensor defective or short circuit in Check wiring or replace sensor
Temperature CMax wiring to external source
sensing: SRC high
for Catalyst
temperature
downstream
241A SCR Catalyst UCatDsTSR OFF none NO Sensor defective or short circuit in Check wiring or replace sensor
S SERIES EURO V
Print P1D32S014 E
Temperature CMin wiring to ground

sensing: SRC low
for Catalyst
temperature
downstream
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
D51A SCR Catalyst UCatUsTPhy OFF none NO UREA Catalyst temperature Check sensor
Temperature sRngHi upstream sensor drifted or not Check wiring
Upstream Partial short circuit on wiring harness
temperature above or sensor
physical maximum
value
E51A SCR Catalyst UCatUsTPhy OFF none NO UREA Catalyst temperature Check sensor
Temperature sRngLo upstream sensor drifted or not Check wiring
Upstream Partial short circuit on wiring harness
temperature below or sensor
physical minimum
value
451A SCR Catalyst UCatUsTSig OFF none NO Urea Catalyst upstream temperature Check sensor and replace it if necessary
Temperature defective
monitoring:
Upstream
temperature
sensor connected
via CAN reports
an error
151A SCR Catalyst UCatUsTSR OFF none NO Sensor defective or short circuit in Check wiring or replace sensor
Temperature CMax wiring to external source
sensing: SRC high
for Catalyst
temperature
upstream
251A SCR Catalyst UCatUsTSR OFF none NO Sensor defective or short circuit in Check wiring or replace sensor
Temperature CMin wiring to ground
sensing: SRC low
for Catalyst
temperature
upstream
323A SCR Reagent Tank UDCRdcAg Blink NOx none YES direct Tank is empty Refill Urea tank
Level: Empty Urea Rmn Aftertrea
Base - October 2011
Tank tment
313A SCR Reagent Tank UDCstUTnk OFF none YES Tank level sensor is drifted, or Urea Check tank level sensor, check urea injection system
Level: Plausibility LvlPlaus potential injected quantity is drifted (wrong for correct dosing
225
check of urea tank urea consumption calculation)
level
Base - October 2011

Long
System
Failure
518A SCR Dosing valve: UDosVlvOL OFF NOx none YES direct Broken or disconnected wiring or Check of wiring, replace Urea Dosing Valve Actuator
Diagnostic error Aftertrea defective Urea Dosing Valve
check for open tment Actuator
load.
A18A SCR Dosing valve: UDosVlvOv OFF none YES Dosing valve not enough cooled by Check other failures connected too dosing system or
Dosing valve is ht potential Urea, system clogged? too high exhaust, check Urea dosing quantity
overheated exhaust temperatures? Check correct functionality of Dosing valve - if not
guarantedd: replace it.
Reset Overheating time in the EEPROm to 0.
818A SCR Dosing valve: UDosVlvOvr OFF NOx none YES direct High battery voltage, high ECU Check battery voltage, wiring, power stage and Urea
Diagnostic error Temp Aftertrea temperature and high load or Dosing Valve Actuator.
check for tment defective wiring, power stage or Urea
overtemperature. Dosing Valve Actuator defective
618A SCR Dosing valve: UDosVlvSC OFF NOx none YES direct Short circuit of wiring (Ground wire) Check of wiring or replace Urea Dosing Valve
Diagnostic error B Aftertrea to external source or inside Urea Actuator
check for short tment Dosing Valve Actuator
circuit to battery.
628A SCR Dosing valve: UDosVlvSC OFF NOx none YES Short circuit in the wiring (+ wire) to Check wiring harness
Diagnostic error BHS Aftertrea potential U-Batt Check Dosing valve actuator
check for short tment Short circuit inside dosing valve
circuit to battery actuator.
on the high side
switch.
718A SCR Dosing valve: UDosVlvSC OFF NOx none YES direct Short circuit of wiring (Ground Wire) Check of wiring or replace Urea Dosing Valve
Diagnostic error G Aftertrea to ground or inside Urea Dosing Actuator
check for short tment Valve Actuator
circuit to ground.
728A SCR Dosing valve: UDosVlvSC OFF NOx none YES Short circuit in the wiring (+ wire) to Check wiring harness
Diagnostic error GHS Aftertrea potential Ground Check Dosing valve actuator
check for short tment Short circuit inside dosing valve
circuit to ground actuator.
on the high side
switch.
S SERIES EURO V
Print P1D32S014 E
A2AA SCR Reagent UHCFailHtr OFF none NO The Power management could not Check System Voltage
Heating: DFC for Rls release the Heater Power stages due If OK, check if there is a too high voltage drop
failed heater to too low system voltage. between Control unit and Battery.
release
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
65AA SCR Reagent UHCPLExtS OFF none NO Short circuit error in the wiring or Check wiring or replace defective heater
Heating: External hCirErr the Urea Pressure Line Heater or
short circuit error Urea Module Supply Heater
55AA SCR Reagent UHCPLOLD OFF none NO Open circuit error in the wiring or Check wiring or replace defective heater
Heating: general urCtl the Urea Pressure Line Heater or
open circuit error Urea Module Supply Heater
Urea pressure
Line/Module
Supply Heater
75AA SCR Reagent UHCPLPTC OFF none NO Open circuit error in the PTC Check and replace heaters
Heating: PTC open OpCirErr element of Urea Pressure Line
circuit error Heater or in the Urea Supply Module
Heater
95AA SCR Reagent UHCPLPTC OFF none NO Short circuit in the PTC element of Check and replace heaters
Heating: PTC short ShCirErr Urea Pressure Line Heater or in the
circuit error Urea Supply Module Heater
67AA SCR Reagent UHCTnkExt OFF none NO Possible short circuit in the wiring or Check wiring and replace tank heater
Heating: External ShCirErr the Tank Heater
short circuit error
57AA SCR Reagent UHCTnkOL OFF none NO Open circuit error in the wiring or Check wiring or replace tank heater
Heating: general DurCtl the Tank Heater
open circuit error
tank
77AA SCR Reagent UHCTnkPT OFF none NO Open circuit error in the PTC Check and replace tank heater
Heating: PTC open COpCirErr element of Tank Heater
circuit error
97AA SCR Reagent UHCTnkPT OFF none NO Short circuit in the PTC element of Check and replace tank heater
Heating: PTC short CShCirErr Tank Heater
circuit error
B2AA SCR Reagent UHCTnkTO OFF none NO Tank heater permanently activated, Check tank heater, check temperature sensor
Heating: Urea Tank vht tank temperature sensor drifted
Base - October 2011
is overheated
51AA SCR Reagent UHtrPLOL OFF none NO Broken or disconnected wiring or Check of wiring, replace Urea Pressure Line heater
Heating: No load defective relay actuator
227
error
Base - October 2011

Long
System
Failure
13AA SCR Reagent UHtrPLPhys OFF none NO Possible internal short circuit in the Check wiring and heater for short circuit
Heating: Diagnostic RngHiDia heater or wiring
Fault Check for
Physical Signal
above maximum
limit
23AA SCR Reagent UHtrPLPhys OFF none NO Possible open load in the heater or Check wiring and heater
Heating: Diagnostic RngLoDia wiring
Fault Check for
Physical Signal
below minimum
limit
61AA SCR Reagent UHtrPLSCB OFF none NO Short circuit of wiring to external Check of wiring, replace SCR Reagent Heating
Heating: Short source or inside SCR Reagent
circuit to battery Heating
error
71AA SCR Reagent UHtrPLSCG OFF none NO Short circuit of wiring to ground or Check of wiring, replace SCR Reagent Heating
Heating: Short inside SCR Reagent Heating
circuit to ground
error
11AA SCR Reagent UHtrPLSRC OFF none NO Wiring Harness defect (short circuit) Check Wiring Harness
Heating: SRC high MaxDia Relay defect. Check Relay
for Urea pressure Heating element in pressure line Check Heating element in pressure line
line Heater defect
Diagnostic Signal
21AA SCR Reagent UHtrPLSRC OFF none NO Wiring Harness defect (short circuit Check Wiring Harness
Heating: SRC low MinDia or Open load) Check Relay
for Urea pressure Relay defect. Check Heating element in pressure line
line Heater Heating element in pressure line
Diagnostic Signal defect
52AA SCR Reagent UHtrTnkOL OFF none NO Broken or disconnected wiring or Check of wiring, replace Urea Tank Heater
Heating: No load defective Urea Tank Heater
error
14AA SCR Reagent UHtrTnkPhy OFF none NO Possible internal short circuit in the Check wiring and heater for short circuit
S SERIES EURO V
Print P1D32S014 E
Heating: Diagnostic sRngHiDia heater or wiring

Fault Check for
Physical Signal
above maximum
limit
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
24AA SCR Reagent UHtrTnkPhy OFF none NO Possible open load in the heater or Check wiring and heater
Heating: Diagnostic sRngLoDia wiring
Fault Check for
Physical Signal
below minimum
limit
62AA SCR Reagent UHtrTnkSC OFF none NO Short circuit of wiring to external Check of wiring, replace Urea Tank Heater
Heating: Short B source or inside Urea Tank Heater
circuit to battery
error
72AA SCR Reagent UHtrTnkSC OFF none NO Short circuit of wiring to ground or Check of wiring, replace Urea Tank Heater
Heating: Short G inside Urea Tank Heater
circuit to ground
error
12AA SCR Reagent UHtrTnkSR OFF none NO Wiring harness (short circuit) Check Wiring harness (short circuit)
Heating: SRC high CMaxDia Relay defect Check Relay
for Urea tank UREA Tank heater element defect Check UREA Tank heater element
Heater Diagnostic
Signal
22AA SCR Reagent UHtrTnkSR OFF none NO Wiring harness (short circuit) Check Wiring harness (short circuit)
Heating: SRC low CMinDia Relay defect Check Relay
for Urea tank UREA Tank heater element defect Check UREA Tank heater element
Heater Diagnostic
Base - October 2011
Signal
229
Base - October 2011

Long
System
Failure
1 0: Unused OFF Boost YES direct

Pressure (ControlMa
System sk)
Compre
hensive
EGR
Exhaust
Gas
Sensor
Fuel
System
NMHC
catalyst
Misfiring
NOx
Aftertrea
tment
PM filter
14BA SCR Reagent UPmpMotN OFF none NO Pump motor defective (blocked, Check if Pump is delivering:
Pump: Pump Dvt possibly due to cristallisation (after If OK: failure is only sporadic (possibly long still stand
motor speed long stind stall periode) or frozen periode or by frozen Reagent - check ambient
deviation UREA in case of cold ambient conditions) --> probably no action needed. If failure
condition) appears several times --> replace pump module.
If Not OK: Replace
51BA SCR Reagent UPmpMotO OFF NOx none YES direct Broken or disconnected wiring or Check of wiring, replace Urea pump motor
Pump: No load L Aftertrea defective relay
error on tment
powerstage for
S SERIES EURO V
urea pump motor
Print P1D32S014 E
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
81BA SCR Reagent UPmpMotO OFF NOx none YES direct High battery voltage, high No reaction needed if failure isn't present after short
Pump: Over vrTemp Aftertrea temperature inside ECU, high load or time, check load and output, check wiring, replace
temperature error tment wiring problem ECU
on powerstage for
urea pump motor
61BA SCR Reagent UPmpMotS OFF NOx none YES direct Short circuit of wiring to external Check of wiring, replace Urea pump motor
Pump: Short circuit CB Aftertrea source or inside Urea pump motor
to battery error on tment
powerstage for
urea pump motor
71BA SCR Reagent UPmpMotS OFF NOx none YES direct Short circuit of wiring to ground or Check of wiring, replace Urea pump motor
Pump: Short circuit CG Aftertrea inside Urea pump motor
to ground error on tment
powerstage for
urea pump motor
24BA Info: SCR Reagent UPmpMotW none none NO System in Warm Up State and Pump No Action needed (only info)
Pump: Pump UC motor not yet free (i.e. Pump motzor Check failure memory: If failure "PPCWUCResp"
Motor in Warm driver did not report an "SCG" or stored: see there
Up phase "OL" failure for a duration between
1.30s and 1.70s
D2BA Diagnostic Fault UPmpPPhys ON NOx none YES Sensor in Pump module inaccurate Check wiring and the accuracy of the pressure sensor
Check for Physical RngHi Aftertrea potential or defective, defect in the wiring and replace it if necessary
Signal above tment
maximum limit
E2BA Diagnostic Fault UPmpPPhys ON NOx none YES Sensor in Pump module inaccurate Check wiring and the accuracy of the pressure sensor
Base - October 2011
Check for Physical RngLo Aftertrea potential or defective, defect in the wiring and replace it if necessary
Signal below tment
minimum limit
231
Base - October 2011

Long
System
Failure
12BA SCR Reagent UPmpPPlaus OFF NOx none YES Sensor in Pump module defective Check sensor signal: Set Pump speed to 0, wait 1
pressure sensor: Max Aftertrea potential Possibly emptying not exectued minute (to give to the system for pressure release),
Drift to too high tment correctly (clogged tubes, reverting open dosing valve to 100%, wait again some seconds
pressure valve not openning etc) and measure the UREA pressure: the value must be
near 0 (between -32768.00hPa and 32.77bar)
If OK -
22BA SCR Reagent UPmpPPlaus OFF NOx none YES Sensor in Pump module defective Check sensor signal: Set Pump speed to 0, wait 1
pressure sensor: Min Aftertrea potential Possibly emptying not exectued minute (to give to the system for pressure release),
Drift to too low tment correctly (clogged tubes, reverting open dosing valve to 100%, wait again some seconds
pressure valve not openning etc) and measure the UREA pressure: the value must be
near 0 (between -32768.00hPa and 32.77bar)
If OK -
D13A Reagent quality not UQlSens ON NOx none YES direct The fluid in the reagent tank is not Empty the tank and refill with correct fluid.
conform Aftertrea Urea or its quality is insufficient Depending on the type of fluid found in the tank the
tment system could be damaged.
519A SCR Reverting URevVlvOL OFF NOx none YES direct Broken or disconnected wiring or Check of wiring, replace Urea Reverting Valve
Valve: No load Aftertrea defective Urea Reverting Valve Actuator
error tment Actuator
619A SCR Reverting URevVlvSCB OFF NOx none YES direct Short circuit of wiring to external Check of wiring, replace Urea Reverting Valve
Valve: Short circuit Aftertrea source or inside Urea Reverting Actuator
to battery error tment Valve Actuator
719A SCR Reverting URevVlvSC OFF NOx none YES direct Short circuit of wiring to ground or Check of wiring, replace Urea Reverting Valve
Valve: Short circuit G Aftertrea inside Urea Reverting Valve Actuator Actuator
to ground error tment
513A SCR Reagent Tank UTnkLvlPlau OFF none NO UREA Level Sensor defect Check and Replace Sensor
level sensing: Tank sErr
level plausibility
error
613A SCR Reagent Tank UTnkLvlSens OFF none NO Sensor Defect Check Sensor and replace it if not OK
level sensing: Tank Err
level sensor error
S SERIES EURO V
Print P1D32S014 E
713A SCR Reagent Tank UTnkLvlSens OFF none NO Sensor Supply defect Check wiring harness
level sensing: Tank Mon Wiring harness defect Cehck Sensor
level sensor Sensor defect
monitoring error
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
132A SCR Reagent Tank UTnkTPhysR OFF none NO Inaccurate or defective Urea tank Check wiring and the accuracy of the Urea tank
Temperature ngHi temperature sensor, or defect in the temperature sensor and replace it if necessary
sensing: Diagnostic wiring of the sensor
Fault Check for
Physical Signal
above maximum
limit
232A SCR Reagent Tank UTnkTPhysR OFF none NO Inaccurate or defective Urea tank Check wiring and the accuracy of the Urea tank
Temperature ngLo temperature sensor, or defect in the temperature sensor and replace it if necessary
sensing: Diagnostic wiring of the sensor
Fault Check for
Physical Signal
below minimum
limit
412A SCR Reagent Tank UTnkTSig OFF none NO Urea tank temperature sensor Check sensor and replace it if necessary
Temperature defective
sensing: Signal
error for CAN
message
112A SCR Reagent Tank UTnkTSRC OFF none NO Sensor defective or short circuit in Check wiring or replace sensor
Temperature Max wiring to external source
sensing: SRC high
for Urea
temperature
sensor
212A SCR Reagent Tank UTnkTSRC OFF none NO Short circuit of sensor to battery or Check wiring or replace sensor
Temperature Min defective sensor
sensing: SRC low
for Urea
temperature
sensor
4111 Vehicle speed VehVCANSi OFF none NO Defective or incorrect functioning of Check speed measuring device for proper functioning
sensor: Vehicle g vehicle speed measuring device
speed signal via
CAN defective
1211 Vehicle speed VehVMax OFF none NO Real overspeed, i.e. by engine tuning Check measuring device and replace it if necessary.
Base - October 2011
sensor: Maximum (??) No action in case of real vehicle over speed or engine
threshold error for Incorrect speed evaluation tuning
vehicle speed (depending on signal source by
233
Wheel Speed Information,
Tachograph Output, disturbed CAN)
Base - October 2011

Long
System
Failure
3311 Vehicle speed VehVNplMo OFF none NO Defective vehicle speed sensor, Check vehicle speed sensor, wiring harness and battery
sensor: sensor not n wiring defect, wrong voltage supply voltage
connected
1711 Vehicle speed VehVPhysRn OFF none NO Defective vehicle speed sensor. Check vehicle speed sensor
sensor: Physical gHi
signal range check
High
2711 Vehicle speed VehVPhysRn OFF none NO Defective vehicle speed sensor. Check vehicle speed sensor
sensor: Physical gLo
signal range check
Low
3411 Vehicle speed VehVPlaus OFF none NO Defective vehicle speed sensor. Check vehicle speed sensor
sensor: Vehicle Engine driven under load without Check if "external PTO" used
speed is not PTO (i.e. external PTO) Check if failure occured at very low engine
plausible to engine In very cold sitaution possible due to temperature < -10°C)
speed and torque "engine warming up at higher speed"
and vehicle stand still (high torque
request in case of "non liquid oil")
1511 Vehicle speed VehVSRCHi OFF none NO Defective vehicle speed sensor, Check vehicle speed sensor, wiring harness and battery
sensor: short circuit wiring defect, excessive voltage voltage
to battery supply
2511 Vehicle speed VehVSRCLo OFF none NO Defective vehicle speed sensor, Check vehicle speed sensor, wiring harness and battery
sensor: short circuit wiring defect, insufficient voltage voltage
to ground supply
1611 Vehicle speed VehVTachM OFF none NO Defect in the tachometer speed Check tachometer for broken components and
sensor: tachometer ax signal acquisition or wrong correct functioning, clean components or replace
signal - pulse width configuration of the device tachometer if necessary
too long
S SERIES EURO V
Print P1D32S014 E
2611 Vehicle speed VehVTachMi OFF none NO Defect in the tachometer speed Check tachometer for broken components and
sensor: tachometer n signal acquisition or wrong correct functioning, clean components or replace
signal - pulse width configuration of the device tachometer if necessary
too short
S SERIES EURO V
Print P1D32S014 E
Long
System
Failure
4611 Vehicle speed VehVTachSig OFF none NO Defect in the tachometer speed Check tachometer for broken components and
sensor: tachometer signal acquisition or wrong correct functioning, clean components or replace
signal - period configuration of the device tachometer if necessary
duration too short
5352 Vehicle speed VSLimLmpO OFF none NO Broken or disconnected wiring or Check of wiring or replacement of vehicle speed
limitation lamp: No L defective vehicle speed limitation limitation lamp
load error lamp
6352 Vehicle speed VSLimLmpS OFF none NO Short circuit of wiring to external Check of wiring, replace vehicle speed limitation lamp
limitation lamp: CB source or inside vehicle speed
Short circuit to limitation lamp
battery error
7352 Vehicle speed VSLimLmpS OFF none NO Short circuit of wiring to ground or Check of wiring, replace vehicle speed limitation lamp
limitation lamp: CG inside vehicle speed limitation lamp
Short circuit to
ground error
Base - October 2011
235
Base - October 2011
DIAGNOSIS PER SYMPTOMS

236
EDC
POSSIBLE RECOMMENDED
SIGNALLED BLINK WAR- POSSIBLE
RELATED TESTS OR REMARKS
ANOMALY CODE NING CAUSE
ANOMALIES MEASURES
LIGHT
The battery goes flat - - Pre-heating resistor Local overheating.

quickly. powered continuously.
The engine will stop or - - Fuel pre-filter clogged.

won't start.
Difficult start when the - - The 3.5 bar valve on fuel

engine is either hot or return is stuck open.
cold.
Slight overheating. - - Either 0.3 bar tank return

valve or return piping
clogged.
After the new vehicle - - Reversed tank suction / The engine is fed by the
has been delivered, the return pipes. return pipe, the suction
engine will stop after a of which in the tank is
short operation lower. When the pipe
time.The tank holds a sucks no more, the
lot of fuel; all the rest is engine will stop.
O.K.
Reduced power / - - Injection system / the Overheating Engine test: cylinder efficiency test. If
difficult engine engine operates with one the trouble is not related to electric
maneuverability. cylinder failing: components (Blink code 5.x), the
- injector plunger seizure; rocker arm holder shaft needs be
- valve rocker arm seizure. disassembled. Check the rocker arm
roller and bushing as well as the
respective cam.
Fuel consumption - - Air filter clogging with no Smoke. Check the cabling, connections and
increase. signal from the warning component.
light on the instrument
board.
S SERIES EURO V
Print P1D32S014 E
Print P1D32S014 E
S SERIES EURO V
EDC
POSSIBLE RECOMMENDED
SIGNALLED BLINK WAR- POSSIBLE
RELATED TESTS OR REMARKS
ANOMALY CODE NING CAUSE
ANOMALIES MEASURES
LIGHT
The engine does not - - The boosting pressure Smoke.

reach the other speeds sensor provides too high
under load conditions. values, which, in any case,
fall within the range.
The driver feels that the - - Impaired hydraulic Engine test: check-up Replace the injector of
engine is not working performance of an injector. the cylinder in which
correctly like it did Modus detects lower
before. performance levels
(compared with the
others) only after
verifying that the
control rocker arm
adjustment is correct.
The driver feels that the - - Wrong adjustment of an Engine test: check up. Perform correct
engine is not working injector control rocker arm. adjustment, then repeat
correctly like it did the engine test.
before.
The engine operates - - Plunger seizure. Possible overheating. Engine test: cylinder efficiency. Replace the injector of
with five cylinders; the cylinder in which
noise (knock). the diagnosis
instrument detects
lower performance
levels (compared with
the others).
Replace the injector of - - Wrong adjustment of the Possible mechanic damage to Engine test: cylinder efficiency. Replace the injector of
the cylinder in which injector control rocker arm the areas surrounding the the cylinder in which
the diagnosis (excessive travel) with injector. the diagnosis
instrument detects impact on the plunger on instrument detects
lower performance the nozzle. lower performance
levels (compared with levels (compared with
the others). the others).
The engine will stop or - - Presence of air in the fuel It might even not switch off; it Bleed air.
Base - October 2011
won't start again. supply circuit. might have operation

oscillations, or start, yet with
difficulty and after making
many attempts.
237
S SERIES EURO V SECTION 6 - REMOVAL - REFITTING OF MAIN COMPONENTS 1
SECTION 6
Removal - refitting of main components
Page
AIR CONDITIONING COMPRESSOR DRIVE BELT
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 3
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WATER PUMP-ALTERNATOR DRIVE BELT
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 3
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HIGH PRESSURE PUMP REPLACEMENT . . . . . . . 4
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CRANKSHAFT FRONT SEALING RING
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 6
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
VACUUM OIL PUMP UNIT (GPOD)
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 7
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CRANKSHAFT REAR SEAL RING
REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 8
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
REPLACEMENT OF INJECTORS . . . . . . . . . . . . . 9
- Injector recovery pipe removal . . . . . . . . . . . . . 9
- Injector delivery fuel pipe removal . . . . . . . . . . 9
- Injector removal . . . . . . . . . . . . . . . . . . . . . . . . 9

2 SECTION 6 - REMOVAL - REFITTING OF MAIN COMPONENTS S SERIES EURO V
Page
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
- Injector assembly . . . . . . . . . . . . . . . . . . . . . . . 10
- Injector delivery fuel pipe assembly . . . . . . . . . . 10
- Electro-injector reprogramming . . . . . . . . . . . . 11

AIR CONDITIONING COMPRESSOR WATER PUMP-ALTERNATOR DRIVE BELT

DRIVE BELT REPLACEMENT REPLACEMENT
For motor F1CE3481C*C124 For motor F1CE3481C*C124
Removal
Figure 2
Removal
Figure 1
88330
Disassemble the compressor drive belt, as described in the

relevant chapter.
102201 Using the specific wrench on the automatic belt tensioner (2),
reduce the tension of the belt (1) and remove it.
Position the vehicle over the service pit or on the lift. Remove
the middle soundproofing guard from under the vehicle.
Remove the flexible belt (4) from the pulleys (1 and 5).
Refitting
Mount the drive belt (1) taking care to position its
ribs correctly in the respective races of the pulleys.
Refitting Release the automatic tightener (2). Rotate
crankshaft by one revolution to settle the belt.
Fit the 99360186 drift (2) to pulley (1) with the
elastic belt (4), and position the belt on roller (3) and
pulley (5), making sure to fit the ribs of the belt in the
grooves in the pulleys (1 and 5).
Mount the compressor drive belt, if there is one, and adjust

the tension as described in the relevant chapter.
Fit the middle soundproofing guard back on.
Turn the crankshaft anticlockwise () until the belt (4) is
completely fitted onto the pulley (1).

Removal HIGH PRESSURE PUMP REPLACEMENT

Removal
Figure 3
Figure 4
102202
Drain off the coolant.

Remove the fan from the electromagnetic coupling. 134978
Remove the water pump/alternator drive belt, as described

in the relevant chapter. Remove the bolt (1) securing the bracket (2) for the high
Disconnect electrical connection (3) from the engine cable. pressure pipe.
Lock the rotation of the electromagnetic coupling (6) and Connect the oil drain pipe (3) to the high pressure turbine
remove nut (8). (4).
NOTE Unscrew nut (8) in a clockwise direction to undo Figure 5

it as it is left-handed.
Remove the hub (6) and pulley (5).

Cut the clamp (), remove the bolt (1) securing the cabling
clamp (3), remove the nuts (2) and detach the electromagnet
(4) from the water pump (7).
Remove the bolts and take off the water pump (7).
Refitting
To install, carry out the operations described in the
removal process in reverse order, tightening the 134977
screws and nuts to the specified torque.
Once installed, fill the engine coolant circuit, start the Disconnect the high pressure fuel pipe (1) from the hydraulic
engine and check for coolant leaks. accumulator (2).

Figure 6 Figure 8
135500
Lubricate a new seal ring (4) and fit it to the high pressure
135001 pump.
Make sure the flange (3) is fitted to the high pressure pump.
Unscrew and remove the screw (1). Unscrew and remove Make sure the high pressure pump is in a stable position, with
screws (3) with their washers (4). Remove the high-pressure the one of the two recesses (1) on the flange (3) in line with
pump (2) from its support (5). the reference on the pump itself (2).
Refitting
Figure 7
Figure 9
134999
NOTE To reinstall the high pressure pump, the camshafts

and crankshaft must be in phase.
Remove the inspection caps from the overhead and turn the
crankshaft with a suitable wrench until you can see the cam
shaft timing hole, and fit 99360614 tool (1).
NOTE Two revolutions of the crankshaft correspond to 135043

one revolution of the camshafts.
Vertical mounting position

CRANKSHAFT FRONT SEALING RING

REPLACEMENT NOTE The centrifugal filter (7) and cover seal ring (5)
Removal must be replaced each time the cover is removed.
Figure 10
Remove the screws (9) and remove the front cover (10).
Refitting
Figure 12
102207
Lock crankshaft rotation with a suitable tool (3), remove the

screw (2) and detach the damper pulley (1).
Use 99340059 tool (6), as shown, to remove the seal ring (5)
from the cover (4).
102214
NOTE To replace the seal ring only (5) (operation Fit the cover (1) with a new gasket. Screw down screws (2)
540442), insert the seal ring into the cover (4), as without tightening fully.
described in Figure 12.
Figure 13
Figure 11
102215
Thoroughly clean the seat of the cover seal ring (1).

102209
Screw part (2) of 99346258 tool into the crankshaft.
Lubricate the shank of the crankshaft and the outer surface
Remove the screw (11) and remove the oil dipstick pipe (4). of part (2) and fit the new seal ring (3).
Loosen clamp (3), remove screw (2) and remove the pipe (1) Position part (4) on part (2); screw down the nut (5) to fit the
from the cover (5). seal ring (3) fully inside the cover (1).
Remove the screws (6) and the cover (5). Remove the circlip
(8). Pull out the centrifugal filter (7).

Figure 14 VACUUM OIL PUMP UNIT (GPOD)

REPLACEMENT
Removal
Remove the front cover as described in the relevant chapter.
Figure 16
102216
Fit 99396039 tool (3) for centring the cover (1) into the set
of the centrifugal filter and tighten the screws (2) to the
specified torque. Remove 99346258 (4) and 99396039 (3)
tools.
160757
Figure 15
Remove the screws (3) and remove the oil pump - vacuum
pump assembly (2).
Remove the coupling (1) from the gear (4).
Refitting
Position the coupling (1) on the gear (4).
Fit the vacuum-oil pump assembly (2) inserting a
new gasket.
Fasten the screws (3) and tighten to the specified
torque.
To install the part, repeat the operations described
in the removal process in reverse order, tightening
102217
the screws and nuts to the specified torques.
Once installed, top up the engine cooling system,
and check the oil level of the engine, topping up if
Fit a new centrifugal filter (1). necessary. Start the engine and check for coolant
Install a new circlip (2). leaks.
Fit the cover (3), and tighten the screws (4) to the specified
torque.
NOTE The centrifugal filter (1) and cover seal ring (2)
must be replaced each time the cover is removed.
To install the part, repeat the operations described in the

removal process in reverse order, tightening the screws and
nuts to the specified torques.
Once installed, top up the engine cooling system, and check
the oil level of the engine, topping up if necessary. Start the
engine and check for coolant leaks.

CRANKSHAFT REAR SEAL RING Refitting

REPLACEMENT
Figure 19
Removal
Figure 17
102221
102219
Thoroughly clean the seal ring seat.
Lubricate the rear end of the crankshaft with engine oil.
Lock rotation of the flywheel (1) with 99360306 tool (3). Fit part (2) of tool 99346259 onto the rear end of the
Take out the screws (2) and remove the flywheel (1). crankshaft; secure it with the screws (5) and key the fresh seal
(3) onto it.
Position part (1) over part (2); tighten the nut (4) to fit the
seal ring (3) fully inside the crankcase.
Figure 18
Figure 20
102220
102222
Apply 99340060 tool (2) to the rear seal ring (1) and extract Mount the flywheel (1) and screw down the screws (4).
it from the crankcase. Fit 99360306 tool (3) onto the crankcase to lock rotation of
flywheel (1).
Tighten the screws (4) securing the flywheel (1) in two steps:
- Stage 1: with a torque wrench, to a torque of 30 Nm;
- Stage 2: tightening to 90°angle.
NOTE Use 99395216 tool (2) for angle tightening.
Remove 99360306 tool (3).

Now install the clutch, gearbox and drive shaft, as described
in the relevant sections of this manual.

REPLACEMENT OF INJECTORS Injector removal

Injector recovery pipe removal
Figure 21 Figure 23
107703 107705
Press the springs (3) in the direction indicated by the arrow Remove the screws (2) and the brackets (3) fixing the
and disconnect the pipe unions (1) recovering fuel from the electro-injectors (1) to the cylinder overhead.
electro-injectors (2).
Injector delivery fuel pipe removal
Figure 24
Figure 22
138230
Remove the screws (2) and the brackets (3) fixing the
107704 electro-injectors (1) to the cylinder overhead.
Disconnect the fuel pipes (2) from the electro-injectors (3)
and from the hydraulic accumulator (1) (rail).

Refitting Injector delivery fuel pipe assembly

Injector assembly
Figure 25 Figure 27
107747
107745
Connect the fuel pipes (2) to the electro-injectors (3) and to

Fit a new seal (3) on the electro-injector (1) and install the the rail (1).
component in the cylinder overhead (2). Tighten the screws (4) fixing the electro-injector brackets (5)
to the specified torque.
NOTE Whenever removed, the fuel pipes must be

replaced with new ones.
Figure 26
Figure 28
107705
Mount the brackets (3) securing the electro-injectors (1) and

tighten the screws (2) without locking them.
107748
Using the wrench (2) from the 99317915 series and

99389829 torque wrench (1), tighten the fuel pipe fittings (3)
and (4) to the specified torque.

At the assistance centre the uncoded IMA code is required

Electro-injector reprogramming (3, Figure 29) for the ECU replacement and reprogramming
procedure.
Figure 29
The table shows the conversion of OCR characters into Arial
fonts.
When electro-injectors on engine mounted on vehicle
require replacing, follow the instructions provided below:
- in cases where electro-injectors are removed and do not
need to be replaced, their individual positions need to be
noted in order to later re-install them in their original
positions; this is done to avoid having to reprogram the
ECU;
- after replacing one or more injectors, the ECU requires
reprogramming;
- before installing a new electro-injector, note the IMA
code stamped on the injector, as it becomes difficult to
102394
read the code once the injector is in position;
1. Production plant code - 2. IMA Matrix code - - in the event the ECU is replaced, program the new ECU
3. Uncoded IMA code - 4. Bosch spare part No. - with the IMA codes of the electro-injectors installed on
5. Date of production - 6. Serial No. - 7. Production line the engine and copy the correction coefficients (ZFC) of
code - 8. Iveco spare part No. the replaced ECU; if this is not possible, they must be
The electro-injectors are no longer divided into classes: Min reset and auto-configuration process must be restarted.
(01) - Med (02) - Max (03), so that deviations from the design Whilst the engine is running, the EDC 17 ECU performs a
flow rates are measured, at the final testing phase, by the number of tests on the electro-injectors' minimum flow rate.
manufacturer for each injector and stamped with the IMA In certain conditions (overrun: vehicle deceleration with
code (Injector Menge Abgleichung) on the injector magnet. pedal released) an increasing (very small) quantity of fuel
At the engine production facility, the I.M.A. code is read in line starting from zero is injected and its effect on engine rotation
by an automated reading station, converted into bar code, smoothness is observed. Injection start threshold is detected
printed on the engine identification label and applied to the and stored by the ECU.
engine. This auto-configuration process is carried out on each single
In the vehicle factory, the EDC 17 ECU is programmed at the cylinder.
end of the line by automatically reading the engine label. Therefore, replacing an electro-injector requires that the
ECU be reprogrammed, entering the IMA codes of the new
electro-injectors and resetting the correction factors (ZFC)
of the cylinder concerned.
Replacing all electro-injectors makes it necessary to reset all
Figure 30 the correction coefficients (ZFC) of each single
electro-injector.
The correction coefficients (ZCF) can be zeroed using the
FPT. diagnostic tool, by reprogramming the ECU and
performing the sensor replacement procedure provided by
the diagnostic tool.
Conversion table of OCR

characters into ARIAL font 105067


S SERIES EURO V SECTION 7 - GENERAL MECHANICAL OVERHAULING 1
SECTION 7
General mechanical overhauling
Page
ENGINES OVERHAUL . . . . . . . . . . . . . . . . . . . . . . 3
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . 16
- Checks and measurements . . . . . . . . . . . . . . . . 16
- Checking head mating surface on cylinder block 17
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
- Measuring main journals and crank pins . . . . . . 17
- Checking crankshaft . . . . . . . . . . . . . . . . . . . . . 19
- Journal on timing system side . . . . . . . . . . . . . . 20
- Intermediate journals no. 2-4 . . . . . . . . . . . . . . 20
- Intermediate journal no. 3 . . . . . . . . . . . . . . . . . 20
- Journal on flywheel side . . . . . . . . . . . . . . . . . . 20
- Crankpins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
- Replacing timing control gear . . . . . . . . . . . . . . 21
ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 21
- Assembling main bearings . . . . . . . . . . . . . . . . . 21
- Checking crankshaft end float . . . . . . . . . . . . . . 22
- Assembling rear seal . . . . . . . . . . . . . . . . . . . . . 23

CONNECTING ROD - PISTON ASSEMBLY . . . . . 23
- Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Measuring piston diameter . . . . . . . . . . . . . . . . 25
- Piston pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
- Conditions for correct pin-piston coupling . . . . 25
- Piston rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
- Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . 27
- Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
- Assembling connecting rod-piston assembly . . . 27
- Assembling piston rings . . . . . . . . . . . . . . . . . . . 28

2 SECTION 7 - GENERAL MECHANICAL OVERHAULING S SERIES EURO V
Page Page
- Assembling connecting rod — piston assemblies in SINGLE MASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

cylinder barrels . . . . . . . . . . . . . . . . . . . . . . . . . 28
REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
- Measuring crankpin assembly clearance . . . . . . 29
- Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . 58
- Checking piston protrusion . . . . . . . . . . . . . . . . 29
- Checking and adjusting pressure relief valve . . . 58
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . 30
- Changing the pressure relief valve . . . . . . . . . . . 58
- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
- Checking and adjusting the actuator . . . . . . . . . 59
- Disassembling valves . . . . . . . . . . . . . . . . . . . . . 30
- Checking cylinder head seal . . . . . . . . . . . . . . . 31
- Checking cylinder head mating surface . . . . . . . 31
VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
- Removing deposits, refacing and checking valves 31
- Checking clearance between valve stem and valve
guide and centring valves . . . . . . . . . . . . . . . . . 32
VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
- Replacing valve guide . . . . . . . . . . . . . . . . . . . . 32
- Boring valve guides . . . . . . . . . . . . . . . . . . . . . . 32
VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
- Regrinding - replacing valve seats . . . . . . . . . . . 33
VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
ROCKER ARMS - TAPPETS . . . . . . . . . . . . . . . . . . 34
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
ASSEMBLING CYLINDER HEADS . . . . . . . . . . . . . 35
- Overhead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
- Overhead removal . . . . . . . . . . . . . . . . . . . . . . 36
TIMING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
- Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
- Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
- Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
- Checking cam lift and pin alignment . . . . . . . . . 38
- Assembling overhead . . . . . . . . . . . . . . . . . . . . 39
DOUBLE COUNTERWEIGHT ENGINE
FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

ENGINES OVERHAUL Figure 2

Figure 1
88252
Remove the screws (4) and remove the mount (3).

107713
Take out the screw (1) and remove the fixed belt tensioner
(2).
Cut the rubber belt (1), as it cannot be reused.
Remove the screws (3) and remove the climate control
system compressor (4) from its mount (2).

For all motors Figure 5
Figure 3
151805 88241
Press the springs (3) in the direction shown by the arrow and
If the following parts have not already been removed, do so disconnect the fittings of the pipe (1) recovering fuel from the
now: electro-injectors (2).
- Dip-stick for oil level check;
- rail guard;
- engine wire, by disconnecting its electrical connections Figure 6
from: thermostat temperature sensor, phase sensor,
engine rev sensor, rail pressure sensor, air pressure/
temperature sensor of suction manifold;
- connector which connects the glow plugs to the
electronic control unit
To be able to fit the brackets onto the crankcase to secure
the engine to the stand for overhauling, it is necessary to
remove the left and right engine mounts (3) and disconnect
the oil pipe (2) from the turbocharger (1) and from the
crankcase.
NOTE Block the turbocharger air/exhaust gas inlets and

outlets to prevent foreign bodies getting inside. 88242
Disconnect the fuel pipes (2) from the electro-injectors (3)

and from the hydraulic accumulator (1) (rail).
Fit the brackets 99361041 to the crankcase and use these to Figure 7
secure the engine to the rotary stand 99322205. Drain the oil
from the engine by removing the plug from the oil sump.
Figure 4
88243
Take out the screws (2) and the brackets (3) fixing the
electro-injectors (1) to the cylinder overhead.
150733
Unscrew the screws (2) and remove the air tube (1) and the
end-plate (3).

Figure 8 Figure 11
138230
150734
Use tool 99360076 (1) to remove the oil filter (2) from the
Remove the injector (1) from the head using extractor heat exchanger (5).
99342156 (2) and mark it with the cylinder it belongs to. Remove the screws (4 and 3) and the heat exchanger (5)
with the relevant gasket and pipe (3).
Figure 9 Figure 12
150735
126618
Unscrew the connector (1) on the common rail. Unscrew To remove the low pressure pipes (1) from the high pressure
the connector (5) on the high pressure pump. Undo and pump it is necessary to loosen the band (4), adjust the rapid
remove the fixing screw (3) of the pipe (2) retaining bracket connector (3) and detach the pipes (1) from the clip (2).
(4). Remove the high pressure fuel pipe (2)
Figure 13
Figure 10
88246
Remove the screws (1) and the hydraulic accumulator (2) 150736
from the overhead device (3). Unscrew the screws (1) and remove the low-pressure fuel
hose assembly (2).

Figure 14 Figure 17
150737
130218
Remove the fixing screws and detach the power-steering
pump (1). Remove the retaining clamps (1) and (3).
Remove the pipe (2) from the cooler and from the cover.
Figure 15
Figure 18
127949
130219
Unscrew and remove the screw (1). Remove the clamp (1) and detach the pipe (2) from the EBS
Unscrew and remove the screws (3) with their spacers (4). (10). Remove the clamp (3) and detach the pipe (4) from the
Detach the high-pressure pump (2) from the support (5). EBS (10). Operating on the screw (8), loosen the clamp (7)
and detach the pipe (9) from the EBS unit (10). Operating on
Figure 16
the screw (5), loosen the clamp (6) and remove the EBS unit
(10) from the turboblower.
Figure 19
150738
Remove the fixing screws and detach the temperature and

air-pressure sensor (1), the clamp (4), the EGR tube (6) with
151806
its seal, the mixer (7) with its cover (5) and seals, and finally
the temperature regulator assembly (8). Unscrew and remove the union (1). Unscrew and remove
Using wrench SP.2275 (3), remove the glow plugs (2). the two screws (2) fastening the bracket (3) to the
turbo-blower. Unscrew and remove the fixing screw (4).
Remove tubes (5) and (6).

Figure 20 Figure 23
127960
Unscrew and remove the fixing screws (1) and (3). 135773
Remove the bracket (2). Unscrew and remove the two fixing nuts (1).
Figure 21
For all motors
Figure 24
128118
Remove the manifold (1) from the turbocharger (2).

128121
Unscrew the screw (4) and remove the clamp (2).

Detach the pipe (1) from the EGR unit (3).
Figure 22
Figure 25
128119
Unscrew the unions (3) and (5), then remove the pipe (2). 139545
Unscrew and remove the fixing nuts (1) and detach the guard
(4) taking care to retrieve all the spacers.
Unscrew and remove the fixing screws (1).
Remove the EGR unit (2)

For motors F1CE3481A/R For motor F1CE3481C*C124
Figure 26 Figure 28
134988
139546
Unscrew and remove the screws (2). Remove the turbocharger lubrication pipe fittings (1) and (2)
Remove the pipe (1) together with the supporting bracket. from the overhead.
Unscrew the two upper mounting screws (3) securing the
two-stage turbocharger to the exhaust manifold (4).
Figure 27
Figure 29
140821
Remove the clamp (6). Remove the pipe (5). Remove the
exhaust manifold (1) complete with turbo-blower (4).
Remove the metal gasket between the exhaust manifold and
the cylinder head. Take out the fixing screw (3) and remove
the rev sensor (2).
NOTE The centrifugal filter (1) and the seal ring of the
cover (4) must be changed at every removal.
134989
Undo the two lower bolts (1) securing the turbocharger

assembly to the exhaust manifold.
Remove the two-stage turbocharger (2) with its gaskets,
pipes and Waste-Gate valve (4).

Figure 30 Figure 32
134990 135030
Remove the nuts (1), washers ( 2) and remove the exhaust

Remove the screw (2) and remove the automatic belt
manifold (3) with gasket and complete with the exhaust gas
tensioner (1).
recirculation pipe from the cylinder head.
Figure 31 Figure 33
135029 135031
Using () the specific wrench on the automatic belt Remove screw (2) and bolt (4), then remove the alternator
tensioner (2), slacken the tension of the belt (1) and remove (3) from its support (1).
it.

Figure 34 Figure 36
150724
134991
Remove the bolts (1) and remove the support (2) from the Remove the fastening screw and the rev sensor (1).
crankcase. Remove the water pump (2) by removing the fixing screws.
For all motors
Figure 35 Figure 37
88264
150741
Remove tube (5). Remove the screws (3) and the cover (4).
Take off the snap ring (2). Pull out the centrifugal filter (1). Stop the rotation of the engine flywheel (2) by means of tool
99360306 (1).

Figure 38 Figure 41
88266
88268
Remove the screws (1) and the distribution cover (2).
Remove the hydraulic chain tightener: top (1) and lower (2).
Remove the pin (4) and disassemble the mobile skid: lower
(5) and top (3).
NOTE Tool 99340059 (4) is used to remove the seal ring
(3) from the cover (2) when the engine is installed
on the vehicle. Figure 42
Figure 39
150717
Remove the screw (3), the washer (2) and the gear (1).
88267
Remove the screw (7), the washer (6), the gear (5) and the
chain (4).
Remove the nut (1) and the phase sensor (2).
Remove the nuts (3) and the cover (4).
Figure 43
Figure 40
88270
88271
Remove the screws (3) and disassemble the depressor/oil Remove the cap (4), the screws (2 and 3) and the top fixed
pump unit (2). skid (1).
Remove the connection key (1).

Figure 44 Figure 47
88272 88275
Remove the screws (2) and the side fixed skid (1). Remove the gear (1) and the chain (3) from the high pressure
Remove the screws (4) and the lower fixed skid (3). pump control shaft (2).
Figure 45 Figure 48
90311 88276
Stop the rotation of the high pressure pump control shaft (1) Remove the high pressure pump control shaft (3).
by inserting the suitable wrench inside it. Remove the nuts (2) and the support (1).
Figure 46 Figure 49
88274 88277
Remove the screw (3) and the stem with the drive gear (2) Stop the rotation of the hydraulic power steering pump
from the high pressure pump control shaft (1). control shaft (2) by inserting tool 99360187 (3) in the shaft
and fastening the tool on the support (1) by means of the
screws (4).

Figure 50 Figure 53
88278 88281
Remove the screw (2) and the gear (1) from the hydraulic Remove the hydraulic tappets (1) with the rocker arms.
power steering control shaft (3). Remove the gasket (2).
Figure 51 Figure 54
88282
88279
Take out the screws (1) and remove the cylinder head (2).
Remove the hydraulic power steering control shaft (3).
Remove the nuts (2) and the support (1).
Figure 55
Figure 52
150710
Remove the cylinder head gasket (1).
NOTE Check the protrusion of the pistons (2) as

88280 described under the relevant heading to check the
Remove the screws (1) and take off the over-head (2) from possibility of facing the crankcase if it has deformed.
the cylinder head (3).

Figure 56 Figure 58
88284
88286
Remove the screws (2) and take off the oil sump (1) with its Block rotation of the flywheel (1) with tool 99360306 (4).
gasket and frame (3). Take out the screws (2) and remove the engine flywheel (1).
Take out the guard (3), if present.
Figure 57
88285
Remove the screws (2) and the suction rose (1).

Figure 59 Figure 61
88288
88738
Take out the screws (2) and remove the connecting rod caps Remove the screws (2) and take off the oil sump (1) with its
(3). gasket and frame (3).
Extract the pistons (1) from the top of the crankcase.
Figure 62
NOTE On the same side of the connecting rod and its

associated cap, indicate the number of the cylinder
from which the connecting rod has been removed.
Keep the bearing shells in their respective housings
since, if they are used, they will need to be fitted in
the position found during removal.
Figure 60
88289
NOTE Note the assembly position of the top main bearing

shells (2) since, if they are reused, they will need to
be fitted in the position found during removal.
88287
Apply tool 99340060 (2) to the rear O-ring (1) and extract
it from the crankcase.

Figure 63 REPAIRS
CYLINDER BLOCK
Checks and measurements
Figure 65
87793 18837
Once the engine removal is complete, carefully clean the

With the aid of a hoist and a rope, remove the crankshaft (1). cylinder block. For the cylinder block transportation use the
suitable rings.
Carefully check that the crankcase has no cracks in it.
NOTE Note the assembly position of the top main bearing Check the state of the plugs. If they are rusty or there is any
shells (2) since, if they are reused, they will need to doubt about their seal, replace them. Examine the surfaces
be fitted in the position found during removal. of the cylinder liners; they must show no sign of meshing,
scoring, ovalization, taper or excessive wear. The inside
diameter of the cylinder liners is checked, to ascertain the
extent of ovalization, taper and wear, using the bore meter
The central half-bearing (3) is fitted with shoulder half-rings. 99395687 (1) fitted with a dial gauge previously reset on the
ring gauge of the diameter of the cylinder liner or on a
micrometer.
Figure 64
Figure 66
87781
75290
The measurements must be made for each single cylinder at
Take out the couplings (1) and remove the oil jets (2). three different heights up the liner and on two planes at right
angles to each other: one parallel to the longitudinal axis of
the engine (B) and the perpendicular (A); the greatest wear
NOTE On completing engine removal, it is necessary to is generally found on this last plane with the first
clean the removed parts thoroughly and check measurement.
their integrity. On finding ovalization, taper or wear, go ahead and
The following pages give the instructions for the bore/grind and finish the face of the cylinder liners. The
main checks and measurements to make in order refacing of the cylinder liners should be done in relation to
to determine whether the parts can be reused. the diameter of the pistons supplied as spare parts oversized
by 0.4 mm of the nominal value and to the prescribed
assembly clearance.

Figure 67 Checking head mating surface on cylinder

block
Figure 69
88290
87782
See that the head mating surface, on the cylinder block, has
Figure 68 no deformation.
This check can be made, after taking out the grub screws (3),
with a surface plate spread with carbon black or with a
calibrated rule (1) and a feeler gauge (2). After ascertaining
the areas of deformation, level the bearing surface with a
grinding machine.
NOTE The crankcase can only be surfaced after making

sure that, on completing the work, the piston
protrudes from the cylinder liner by no more than
the prescribed value.
CRANKSHAFT
Measuring main journals and crank pins
Figure 70
87783
* Surface roughness parameters:

R1 = 4 ÷ 10 m
Rz = 3 ÷ 8 m 75298
Ra = 0,3 ÷ 0,6 m On finding signs of seizure, scoring or excessive ovalization

W1 < 2 m on main journals and crankpins, it is necessary to regrind the
Permissible surface porosity for machined cylinder pins. Before grinding the pins (2), measure the shaft pins with
(see Figure 68) a micrometer (1) to establish to what diameter it is necessary
ZONE B1 = Area of greatest mechanical stress, to decrease the pins.
segment/liner contact: No.2 C
non-continuous porosities are 100%
permissible max. 0.5x0.5.
ZONE B2 = Surface involved in segment rubbing: NOTE It is advisable to enter the measurements in a table.
No.2 non-contiguous porosities are C See Figure 71.
permissible max. 1x0.8.
100%
NOMINAL NOMINAL
Figure 71 VALUE VALUE
MINIMUM 
MAXIMUM 
NOMINAL
VALUE
MINIMUM 
MAXIMUM 
87784
TABLE IN WHICH TO ENTER THE MEASUREMENTS OF THE CRANKSHAFT MAIN JOURNALS AND CRANKPINS
NOTE The main journals and crankpins must always be For undersized crankpins, letter M.
ground to the same undersize class. For undersized main journals, letter B.
The undersizing performed, on the main journals or For undersized crankpins and main journals, letter MB.
crankpins, must be marked by punching on the side
of crank arm no. 1. The undersize classes are:
0.254 — 0.508 mm.

Checking crankshaft
Figure 72
87785
MAIN CRANKSHAFT TOLERANCES
TOLERANCES TOLERANCE CHARACTERISTIC GRAPHIC SYMBOL

Circularity ○
SHAPE
Cylindricality
Parallelism
ORIENTATION
Perpendicularity ⊥
POSITION Concentricity or coaxiality
Circular oscillation ↗
OSCILLATION
Total oscillation ↗↗
CLASS OF IMPORTANCE ASCRIBED TO THE PRODUCT CHARACTERISTICS GRAPHIC SYMBOL

CRITICAL E
IMPORTANT ⊕
SECONDARY ⊝
Figure 73
NOTE The checks on the tolerances indicated in the
figures must be made after grinding the crankshaft
pins.
SYMMETRY BETWEEN MAIN JOURNALS AND

CRANKPINS
1. Crankpins
2. Main journals
3. Normal position
After grinding, keep to the following:
- Round off the edges of deburring the holes for
lubrication of the main journals and crankpins.
87786

Journal on timing system side Journal on flywheel side

Figure 74 Figure 77
honed
honed
max. 0.1 on 360

Before rolling
waviness
in circumferential direction
waviness
87787 in axial direction
RACE AREA FOR ALL MAIN JOURNALS 87790
(MACHINED BY TURNING)
Intermediate journals no. 2-4

Crankpins
Figure 75 Figure 78
max. 0.1 on 360
Before rolling
honed
honed
max. 0.13 on 360
Before rolling
87791
* As far as both values are concerned, for the whole 360.

87788
NOTE Since, during the 0.254 and 0.508 mm undersizing

on the diameter of the crankpins and main journals,
the rolled portion of the side races of the pins may
Intermediate journal no. 3 get involved, it is necessary to turn the races
Figure 76 keeping to the data given in the figure and to do the
rolling keeping to the following instructions.
Rolling force:
- 1st main journal 925 25 daN.
- 2nd — 3rd — 4th — 5th main journal 1850 50
daN.
- crankpin 1850 50 daN.
honed
max. 0.1 on 360
- Rolling turns: 3 approach, 12 effective, 3 out.

Before rolling
- Rolling speed: 56 rpm.

- Reduction of the connecting rod pin slot diameter after
rolling: 0.15  0.30 mm*.
87789
- Reduction of the journal slots after rolling: 0.15  0.30
mm.
MAIN DATA OF MAIN JOURNALS AND CRANKPINS * Measured with calibrated rollers  2.5 mm.

Figure 79 Assembling main bearings

Figure 81
87792
Take out the screws (4) and replace the phonic wheel (3). 88345
The screws (4) are coated with LOCTITE 218 and must be
replaced with fresh ones after each disassembly. NOTE Not having found it necessary to replace the main
They must be tightened to a torque of 10  1 Nm. bearings, they need to be fitted back on in the same
sequence and position found upon disassembly.
Replacing timing control gear
On finding the timing control gear teeth (1) damaged or
worn, remove them from the crankshaft (2) using a suitable
extractor. The main bearings (1) are supplied as spare parts undersized
The new gear is fitted onto the crankshaft by heating it to a on the inside diameter by 0.254  0.508 mm.
temperature of 180C for no longer than 15 minutes.
On completing assembly and after the gear has cooled, it
must withstand a torque of 150 Nm without slipping. NOTE Do not do any accommodating on the bearings.
Thoroughly clean the top main bearing shells (1) and position
them in the crankcase.
ENGINE ASSEMBLY NOTE The middle half ring (2) is fitted with thrust washers.
The following parts must be replaced with new ones at the
time of assembly: retaining rings, seals and gaskets, screws
whose thread is coated with sealant.
Figure 82
Figure 80
90064
Mount the crankshaft (1).
75306
Fit on the oil spray nozzles (2) and tighten the couplings (1)
to the prescribed torque.

Figure 83 Figure 85
88294
88289 Thoroughly clean the crankcase / crankcase base mating

Thoroughly clean the bottom main bearing shells (2) and surface.
mount them in the crankcase base (1). Apply, on base, sealant LOCTITE 510, as indicated in the
scheme. The sealant must result to be even, not patchy.
NOTE Mount the crankcase base within 10 minutes of

applying the sealant.
Checking crankshaft end float Figure 86
Figure 84
88293
The end float is checked by setting a dial gauge (2) with a

magnetic base on the crankshaft (1) as shown in the figure.
The normal assembly clearance is 0.060 — 0.310 mm. 88292
If you find the clearance to be greater than as required,

replace the rear main bearing shells carrying the thrust Mount the crankcase base (12) and tighten the fixing screws
bearings and repeat the clearance check between the in three stages, following the sequence shown in the figure:
crankshaft pins and the main bearing shells. - Step 1: with a torque wrench, to a torque of 50 Nm.
If the end float of the crankshaft does not come within the - Step 2: closing to an angle of 60.
prescribed values, it is necessary to grind the crankshaft and
accordingly change the main bearing shells. - Step 3: closing to an angle of 60.
NOTE: The middle main bearing has half thrust washers
integrated in it, so it performs the function of a thrust bearing.
It is supplied as a spare part only with the normal shoulder
thickness. NOTE Use tool 99395216 (11) for the angle closing.

Figure 87 CONNECTING ROD - PISTON ASSEMBLY
Figure 89
88296
Then tighten the outer screws (1) to a torque of 26 - 30 Nm.
Assembling rear seal 75392
Figure 88
PISTON — CONNECTING ROD ASSEMBLY
1. Piston - 2. Piston ring - 3. Pin - 4. Trapezoidal ring -
5. Oil scraper ring - 6. Slotted oil scraper ring with spiral
spring - 7. Connecting rod body - 8. Bearing shells -
9. Connecting rod cap - 10. Cap fixing screws.
Check the pistons. They must show no signs of seizure,
scoring, cracking or excessive wear; replace them if they do.
88297
Carefully clean the seal seat.

Lubricate the rear shank of the crankshaft with engine oil.
Fit part (2) of tool 99346259 onto the rear shank of the
crankshaft; secure it with the screws (3) and key the fresh seal
(1) onto it.
Position part (4) on part (2); screw down the nut (5) to fit
the seal (1) fully inside the crankcase.

Figure 90 Figure 91
75394
75393
Remove the piston (1) from the connecting rod, taking out
Remove the piston rings (1) from the piston (2) using pliers the piston ring (2) and extracting the pin (3).
99360183 (3).
Figure 92
150726
MAIN DATA FOR MAHLE, PINS AND PISTON RINGS

* The value is measured at 1.5 mm from the outer diameter
** The value of the diameter measured is 91.4 mm

Pistons Piston pins

Measuring piston diameter
Figure 95
Figure 93
18857
87794
Measuring the diameter of the piston pin (1) with a

Using a micrometer (2), measure the diameter of the piston micrometer (2).
(1) to determine the assembly clearance. The diameter has
to be measured at the value shown.
NOTE The pistons are supplied as spare parts with the

standard, normal and 0.4mm oversize diameters
together with rings, pin and retaining rings.
Conditions for correct pin-piston coupling
Figure 96
Figure 94
75397
88300
Lubricate the pin (1) and its seat on the hubs of the piston
(2) with engine oil. The pin must go into the piston by lightly
The clearance between the piston and cylinder liner can also pressing with the fingers and must not drop out by gravity.
be checked using a feeler gauge (1) as illustrated in the figure.

Piston rings Figure 100

Figure 97
74947
41104
The trapezoidal split rings (1st slot) and the oil scraper rings
(2nd slot) have the word TOP etched in them; when fitting
them on the piston, the word TOP must be facing upwards. DIAGRAM FOR MEASURING THE CLEARANCE X
BETWEEN THE FIRST PISTON SLOT AND THE
Figure 98 TRAPEZOIDAL RING
1. Piston slot - 2. Trapezoidal piston ring -
3. Cylinder liner
Using a feeler gauge (1, Figure 99), check the clearance (X)
between the ring (2) and the slot (1); this clearance must
1 have the prescribed value.
16552
Figure 101
Check the thickness of the piston rings (2) with a micrometer
(1).
Figure 99
88301 75398
Check the clearance between the trapezoidal ring (2) (1st Check the clearance between the piston rings (2) of the 2nd
slot) and the associated slot on the piston with a feeler gauge and 3rd slot and the associated seats on the piston (3) with
(1), proceeding as follows: insert the piston into the cylinder a feeler gauge (1).
liner so that the ring (2) comes approximately half way out
of it.

Figure 102
NOTE Each connecting rod has its cap marked:
- with a letter: O or X indicating the diameter class of the

big end mounted in production;
- with a number indicating the weight class of the
connecting rod mounted in production.
In addition, it could be stamped with the number of the
cylinder in which it is fitted.
In the event of replacement it is therefore necessary to
number the new connecting rod with the same number as
the one replaced.
The numbering must be done on the opposite side to the
bearing shell retaining slots.
The connecting rods are supplied as spare parts with the
diameter of the big end 67.833 - 67.848 mm marked with the
letter O and the weight class marked with the number 33.
75399
It is not permissible to remove material.
Check the opening between the ends of the piston rings (2)
inserted in the cylinder liner using a feeler gauge (1).
Bushing
Check that the bush in the small end has not come loose and
shows no sign of seizure or scoring. If it does, replace the
complete connecting rod.
Assembling connecting rod-piston assembly

Connecting rods
Figure 104
Figure 103
87797
Etched on the top of the piston are: the type of engine (1),
class selection (2) and supplier (3) as well as the direction of
fitting the piston in the cylinder liner (4). The mark (5) is for
passing the 1st slot insert adhesion test.
87796
MAIN DATA OF THE CONNECTING ROD, BUSHING,

PISTON PIN AND BEARING SHELLS
* Internal diameter to obtain after driving into the small
end and grinding with a reamer.
** Dimension cannot be measured in the free state.
*** Thickness of the bearing shell supplied as a spare part.

Figure 105 Assembling piston rings

Figure 107
41097
Fit the piston rings (1) on the piston (2) using the pliers
99360183 (3).
NOTE The 1st and 2nd slot rings need to be mounted with
87798 the word ”TOP” facing upwards.
Assembling connecting rod — piston assemblies

Connect the piston (1) to the connecting rod (2) together in cylinder barrels
with its cap so that the piston assembly reference, position Figure 108
of the connecting rod and of the cap are observed as shown
in the figure.
Figure 106
88302
Lubricate the pistons well, including the piston rings and the
inside of the cylinder liners.
With the aid of the clamp 99360605 (2), fit the connecting
rod — piston assembly (1) in the cylinder liners, checking that:
- The number of each connecting rod corresponds to the
cap mating number.
- The openings of the piston rings are staggered 120 apart.
- The pistons are all of the same weight.
75394
- The symbol punched on the top of the pistons faces the
Position the piston (1) on the connecting rod, insert the pin engine flywheel, or the recess in the skirt of the pistons
(3) and secure it with the split rings (2). tallies with the oil spray nozzles.
NOTE Not finding it necessary to replace the connecting

rod bearings, you need to fit them back in exactly the
same sequence and position found on disassembly.

Measuring crankpin assembly clearance - Remove the cap (3) and determine the existing
clearance by comparing the width of the calibrated wire
Figure 109 (3, Figure 109) with the graduated scale on the case (2,
Figure 109) that contained the calibrated wire. On
finding a clearance other than as prescribed, replace the
bearing shells and repeat the check.
On obtaining the prescribed clearance, lubricate the
connecting rod bearing shells and fit them permanently
by tightening the connecting rod cap fixing screws as
described.
NOTE The connecting rod cap fixing screws must always

be replaced for permanent assembly.
88303 Manually check that the connecting rods slide axially on the
pins of the crankshaft.
To measure the clearance, carry out the following steps:
- Thoroughly clean parts (1) and (4) and eliminate all
traces of oil.
- Place a length of calibrated wire (3) on the crankshaft
pins (4).
Checking piston protrusion

Figure 110
Figure 111
88327
88326
At the end of the connecting rod-piston assembly refitting,
- Fit the connecting rod caps (3) with the associated check the piston protrusion (2) at the T.D.C. compared to
bearing shells. the top level of the cylinder block by means of a dial gauge
- Tighten the screws (2) in two steps: (1) and relevant base 99370415.
- Step 1: with a torque wrench, to a torque of 50 Nm.
- Step 2: closing to an angle of 70.
NOTE The difference between the minimum and
maximum protrusions of the four pistons must be
NOTE Use tool 99395216 (1) for the angle closing. = 0.15 mm.
The cylinder head gasket in the set of spare gaskets
needed for complete engine overhaul is supplied
with a single thickness. Clearly, it is supplied
separately too.

CYLINDER HEAD Figure 114

Disassembly
Figure 112
88426
The intake (1) and exhaust (2) valves have the same diameter
88328
mushroom.
The central cavity () of the mushroom of the intake valve
Apply the support SP. 2271 (5) on the cylinder head and (1) is distinguished from that of the exhaust valve (2).
tighten the support in a vice.
Remove the brackets (6) for lifting the engine.
Remove the sensors (1 and 2), if needed.
Take out the screws (3) and remove the thermostat casing NOTE Before removing the valves from the cylinder
(4). heads, number the valves in order to refit them
correctly if they are not changed.
A = intake side - S = exhaust side
Disassembling valves
Remove the intake (1) and exhaust (2) valves.
Figure 113
75412
Fit part (4) of tool 99360260 onto the cylinder head (5) and
secure it with the screws (3).
Fit part (2) of tool 99360260 onto part (4), screw down the
nut (1) so that on compressing the springs (8) it is possible
to remove the cotters (6). Then take out the plates (7) and
the springs (8).
Using suitable pliers, remove the oil seal (9).
Repeat these operations on the remaining valves.
Turn the cylinder head over.

Checking cylinder head seal VALVES

Check the hydraulic seal using a suitable tool.
Figure 116
Pump in water heated to approx. 90C at a pressure of 2 
3 bars.
Replace the cup plugs if they are found to leak at oil, using
a suitable drift for their removal - assembly.
NOTE Before mounting the plugs, apply LOCTITE 270

water-reacting sealant on their sealing surfaces.
If there is any leakage from the cylinder head, it must be

replaced.
Checking cylinder head mating surface 150727
MAIN DATA OF INTAKE AND EXHAUST VALVES

Figure 115
Removing deposits, refacing and checking
valves
Figure 117
88331
18625
The mating surface of the head (1) with the cylinder block Remove the carbon deposits on the valves with a wire brush.
is checked using a rule (2) and a feeler gauge (3). Check that the valves show no signs of seizure, cracking or
The deformation found on the entire length of the cylinder burning.
head must be no greater than 0.20 mm.
For greater values, regrind the cylinder head according to the
values and instructions given in the following figure. Figure 118
The nominal thickness A of the cylinder head is 112 0.1 mm;
the maximum permissible removal of metal must not exceed
a thickness of 0.2 mm.
NOTE After regrinding, check the valve recessing and if

necessary regrind the valve seats to make the
prescribed valve recessing.
18882
Use a micrometer (2) to measure the valve stem (1): it must

have the value shown in Figure 132. If necessary, grind the
valve seats by means of the grinding machine, and remove as
little material as possible.

Checking clearance between valve stem and Figure 121

valve guide and centring valves
Figure 119
88333
Remove the valve guides (2) with the drift.
Figure 122
88332
The checks are made using a dial gauge (2) with a magnetic
base, positioned as illustrated. The assembly clearance is
0.033 - 0.063 mm.
Making the valve (1) turn, check that the centring error is no
greater than 0.03 mm.
VALVE GUIDES
Replacing valve guide
Figure 120
88334
Warm up the cylinder head to 80  100C and, by means
of beater SP.2312 (1) fitted with element SP.2311 (2), fit the
new valve guides (3) previously lubricated with engine oil.
Driving force 10  25 KN.
If the above mentioned tools are not available, fit the valve
guides by positioning them in the cylinder head according to
the value shown in Figure 120.
Boring valve guides

Figure 123
87800
MAIN DATA OF VALVE GUIDES - SEATS

Valve guide seat inside  9.980  10.000 mm
Valve guide outside  10.028  10.039 mm
* Measurement to be made after driving in the valve guides.
88335
After driving in the valve guides (2), regrind them with the
smoother.

VALVE SEATS
Regrinding - replacing valve seats
Figure 124
87801
Check the valve seats. On finding any slight scoring or burns, Mount the valves, block the seat of the electro-injectors and
regrind them with an appropriate tool according to the glow plugs; using a suitable tool, check the seal of the
angles given in Figure 124. valves/seats.
Having to replace them, with the same tool and taking care
not to affect the cylinder head, remove as much material
Figure 126
from the valve seats as possible until, with a punch, it is
possible to extract them from the cylinder head.
Heat the cylinder head to 80  100C and, using a suitable
drift, fit in it the new valve seats, previously chilled in liquid
nitrogen.
Using a specific tool, regrind the valve seats according to the
angles given in Figure 124.
Figure 125
88337
Using a dial gauge (1), check that, from the plane of the
cylinder head, the valve recessing (2) and the protrusion of
the injector (3) and of the glow plug have the prescribed
value:
- Valve recessing: 0.375  0.525 mm.
88336 - Injector protrusion: 2.77  3.23 mm.
Using the milling cutter 99394038 (1), clean the injector seat - Glow plug protrusion: 3.78 mm.
of any deposits.

VALVE SPRINGS ROCKER ARMS - TAPPETS

Figure 127 Figure 128
50676
MAIN DATA TO CHECK INTAKE AND EXHAUST

VALVE SPRINGS
75461
COMPLETE ROCKER ARM ASSEMBLY

Height Under a load of The rocker arm assembly is composed of the rocker arm (1),
mm N hydraulic tappet (3), made integral with each other by the clip
(2).
H 55.05 Free
H1 45 P 320 12
H2 35 P1 657 24 Figure 129
75942
CROSS-SECTION OF THE HYDRAULIC TAPPET

A = 32.44 0.3, end of stroke
B = 31.30, working position
C = 29.75 0.25, start of stroke

Figure 130
87802
MAIN DATA HYDRAULIC TAPPETS - SEATS
Checks Figure 132

The sliding surface of the tappets must have no scoring/dents;
replace them if they do.
Using a micrometer, measure the diameter of the tappets
and, using a bore meter, measure the diameter of the seats
in the cylinder head; the difference in the measurements will
give the assembly clearance.
ASSEMBLING CYLINDER HEADS

Figure 131
75587
Position the springs (8) and plates (7) on the cylinder head
(5).
Fit the part (4) of tool 99360260 onto the cylinder head (5)
and secure it with the screws (3).
Fit the part (2) of tool 99360260 onto part (4), screw down
the nut (1) so that by compressing the springs (8) it is possible
to insert the retaining cotters (6); then unscrew the nut (1)
checking that the cotters (6) have settled in correctly.
Repeat these operations on the remaining valves.
87803
Lubricate the stem of the valves (1) and insert them into the
associated valve guides (4) according to the position marked
during removal. Using tool SP.2264 (2), mount the oil seals
(3) on the valve guides (4).
NOTE The suction valves (5) are different from the

exhaust ones for a slot () in the centre of the
valve head.

88340
88338
Remove the nuts (4) and the top skid (3).
Fit the thermostat casing (3) with a new seal and tighten the Remove the screws (1) and the shoulder plate (2).
fixing screws (4) to the prescribed torque.
Fit the temperature sensors (1 and 2) and tighten them to the
prescribed torque.
Fit the brackets for lifting the engine and tighten the fixing
screws to the prescribed torque.
Figure 136
Overhead
Overhead removal
Figure 134
88341
Tilt the over-head (1) and take care not to damage the seats,
then take off the camshafts (2 and 3) from the overhead.
88339
Remove the screws (2 and 3) and the covers (1 and 4)

together with the over-head seal rings.

TIMING SYSTEM Figure 138

Figure 137
88055
1. Rocker arm - 2. Reaction hydraulic tappet - 3. Valve

assembly - 4. Camshaft on exhaust side - 5. Camshaft on
suction side - 6. Camshaft control chain.
Description 88342
The timing system is the type with a twin camshaft in the head
and four valves per cylinder with hydraulic tappets. TIMING SYSTEM AND AUXILIARY SYSTEM DIAGRAM
The control is transmitted by two chains: 1. Camshaft control gear - 2. Single chain - 3. Hydraulic
- a double chain by 3/8” is set in motion by the driving shaft chain tightener - 4. Chain - 5. Drive gear on driving shaft -
and sets the control shafts in motion: oil pump/depressor 6. Fixed skid - 7. Oil pump/depressor control shaft gear -
- high pressure pump; Hydraulic power steering pump - 8. Double chain -
9. High pressure pump control shaft gear.
- a single chain is set in motion by the high pressure control
shaft gear and sets the camshafts in motion.
The camshaft gears are mutually interchangeable and are
fitted with slots to make it possible for the phase sensor to Figure 139
detect the phase.
The rocker arms, one for the valve, are kept in contact with
the corresponding cam by an hydraulic tappet, thus
eliminating the need for regular adjustments.
NOTE Change both chains, even if only one of them is

faulty.
87804
TIMING SYSTEM DIAGRAM

Camshaft Checking cam lift and pin alignment

Checks
The surfaces of the shaft supporting pins and of the cams
must be finely honed; if there is any sign of meshing or Figure 141
scoring, replace the shaft.
Figure 140
75474 87806
Using a micrometer (1), measure the diameter of the pins (2) Place the shaft (1) on the parallels and use a centesimal dial
of the camshaft and, using a bore meter, measure the gauge fitted on the central support to check that the
diameter of the supporting seats in the overhead. alignment error does not exceed 0.04 mm; otherwise,
The difference between these two measurements gives the change the shaft. Check also the cam lift: it must correspond
existing clearance. to the prescribed value; if different values are detected,
The nominal assembly clearance is 0.037  0.088 mm. change the shaft.
Figure 142
150725
MAIN DATA, CAMSHAFT PINS AND SEATS

1. Intake valve camshaft seats - 2. Exhaust valve camshaft seats - 3. Intake valve camshaft - 4. Exhaust valve camshaft.
The camshaft (3) of the suction valves can be recognised through the spring cup (4) and the dowel (6).
!

Assembling overhead Figure 145

Figure 143
88343
Lubricate the new seal rings (1) with engine oil and fit them 88340
on the covers (2).
Fit the covers (2) on the overhead, drive in the fastening
screws (3) and tighten them to the prescribed torque. Fit the top skid (3) and drive in the nuts (4), then tighten them
Fit the shoulder plate (2) and drive in the screws (1), then
Figure 144 tighten them to the prescribed torque.
Figure 146
88344
Lubricate the support pins of the suction camshafts (2) and

exhaust camshafts (4) and fit them on the overhead (1).
NOTE During this operation do not exchange the

assembly position of the shafts.
The suction camshaft can be recognised (2)
through the dowel (3) on the front side and the
retainer on the rear side.
In addition, take care not to damage the support
seats of the over-head shafts.
88346
Position the camshafts (3 and 4) so that the pins 99360614

(1) can be inserted in the camshaft slots (2) through the
over-head threaded holes.

DOUBLE COUNTERWEIGHT ENGINE Figure 149

FLYWHEEL
Figure 147
88299
Tighten the screws (2) fixing the engine flywheel (3) in two
steps:
- Step 1: with a torque wrench, to a torque of 30 Nm.
- Step 2: closing to an angle of 90.
88054
NOTE Use tool 99395216 (1) for the angle closing.
Double-mass engine flywheel, one integral with the drive
shaft and one with the input shaft of the gearbox and in
between a torsion elastic dampening system.
The advantages of this type of flywheel compared to the For motors F1CE3481A/R
normal one are: SINGLE MASS
- Dampening of engine irregularities transmitted to the The single mass flywheel consists of a single integral steel disc
gearbox and resulting drive noise reduction; with driving shaft. Compared to the double mass flywheel
- Noise reduction in the cabin as a result of the overall configuration, there are no advantages relating to damping
noise reduction. motor irregularities transmitted to the gearbox and noise
reduction in the cab, however it has advantages in terms of
Check the clutch disc mating surface, if there are too many
reducing production costs. It does not require fixed
scratches, change the engine flywheel (3).
positioning on the driving shaft since it is not fitted with a
Check the conditions of the bearing (2) and the crown gear reference pin. The fasteningholes are equidistant.
(1), if they are worn out or damaged change the engine
flywheel (3).
164018
88298 1. Motor side - 2. Transmission side
Position the metal sheet guard (3) on the cylinder block, if NOTE The assembly and disassembly procedure is the
present. same for both the single mass and double mass
Mount the engine flywheel (1) and screw down the screws (2). flywheel configuration.
Fit tool 99360306 (4) onto the crankcase to block rotation
of the engine flywheel (1).

Figure 74 Mount the suction strainer (1) together with the pipe.
Screw down the fixing screws (2) and tighten them to the
prescribed torque.
Figure 76
α
α
166740
Mount the engine flywheel (1) and screw down the screws (2).
Fit tool 99360306 (4) onto the crankcase to block rotation
of the engine flywheel (1).
88329
Fit the gasket (4) and the frame (3) onto the oil sump (1).
Tighten the screws (2) fixing the engine flywheel in two steps: Screw down the fixing screws (2) and tighten them to the
- Step 1: with a torque wrench, to a torque of 30 Nm. prescribed torque.
- Step 2: closing to an angle of 90. Screw down the oil drain plug (5) and tighten it to the
prescribed torque.
Figure 77
NOTE Use tool 99395216 (1) for the angle closing.
For all motors

Figure 75
88347
Rotate the driving shaft so that the tool 99360615 (1) can be
inserted in the shaft crank hole through the cylinder block
hole, in order to stop the engine in the timing system setting
condition.
88285

88348 88278
Lubricate the seal rings (1 and 2) with engine oil and fit them Fit the gear (1) on the stem (3) of the hydraulic power
on the support (3). steering pump.
Drive in the screw (2) without locking it.
88279 88349
Fit the support (1) and drive in the nuts (2), then tighten them Lubricate the new seal rings (1 and 2) with engine oil and fit
to the prescribed torque. them on the support (3).
Fit the stem (3).
Figure 160
Figure 157
88276
88277
Fit the support (1), drive in the nuts (2) and tighten them to
Stop the stem rotation (2) of the hydraulic power steering the prescribed torque.
pump by inserting in the latter the tool (3) and fastening the Fit the control stem (3) of the high pressure pump.
tool on the support (1) by means of the screws (4).

150710
88351
Position the chain (1) on the gears (2, 3 and 5) and fit the gear Check that the mating surfaces of the cylinder head and
(3) on the stem (4) so that the chain (1) in tracts A and B is crankcase are clean.
tensioned. Keep the cylinder head gasket clean.
Place the gasket (1) of the cylinder head with the thickness
Figure 162 given in section “Check piston protrusion”, with the “TOP”
sign facing the head.
NOTE It is essential to keep the gasket sealed in its package

until just before assembly.
Figure 165
88274
Fit the stem with the drive gear (2) on the high pressure
pump control stem (1).
Drive in the fastening screw (3).
Figure 163 α
88354
Mount the cylinder head (2).

Screw down the fixing screws (3) and tighten them, in three
successive stages, following the order and methods shown in
the following figure.
NOTE The angle closure is done with tool 99395216 (1).

88352
Check the conditions of the fixed skids (1 and 3) and change

them if worn out.
Fit the skid (1) and drive in the fastening screws (2), then
tighten them to the prescribed torque.
Fit the skid (3) and drive in the fastening screws (4), then
tighten them to the prescribed torque.
88355
88357
Diagram of the tightening sequence for the cylinder head Mount the overhead (1) together with the tools 99360614
fixing screws: (3) for the timing and tighten the fixing screws (2) to the
- 1st phase: pre-tightening with torque wrench prescribed torque.
 screws 1-2-3-4-5-6 to a torque of 130 Nm; Take out the tools SP. 2264 (4).
 screws 7-8-9-10 to a torque of 65 Nm.
- 2nd phase: angle closing
 screws 1-2-3-4-5-6 90;
 screws 7-8-9-10 90.
- 3rd phase: angle closing
 screws 1-2-3-4-5-6 90;
 screws 7-8-9-10 60.
- Screws A, to a torque of 25 Nm.
88270
88356
Fit the top fixed skid (1). Drive in the screws (2 and 3) and
Thoroughly clean the hydraulic tappets (2), lubricate them and tighten them to the prescribed torque.
fit them in the cylinder head (3), positioning the rocker arms (1) Fit the rubber cap (4) of the new gasket and tighten it to the
on the valves correctly. prescribed torque.
Fit on the gasket (5).
Insert the two tools SP. 2264 (4) into the electro-injector seats
for subsequent centring of the overhead on the cylinder head.

88360
88358
Check the conditions of the mobile skids (1 and 3), if worn
Position the chain (1) on the gear (5) and gear (2). out change them.
Mount the gear in such a way that fitting on aspiration valve Position the mobile skids (1 and 3) and clamp them on the
timing system shaft dowel makes slots A to result to be cylinder block by the pin (2) and tighten it to the prescribed
positioned as in figure. torque.
Figure 173
NOTE The chain arm (1) between the two gears must be
tensioned.
Drive in the fastening screw (4) with the washer (3) without
tightening it completely.
Figure 171
88361
Drive in the chain hydraulic tightener (1) and lock it to the

prescribed torque.
Figure 174
150718
Position the chain (1) on the gear (2) and fit the latter on the
camshaft of the exhaust valves.
Drive in the fastening screw (4) with the washer (3) without
tightening it completely.
88362
Tighten the fastening screw of the gear (1) on the hydraulic

power steering control stem to the prescribed torque.

90311 150721
Stop the rotation of the high pressure pump control shaft (1) Tighten the fastening screw of the gear (1) on the suction
by inserting the suitable wrench inside it. valve camshaft to the prescribed torque.
Figure 179
Figure 176
150719
88370
Make sure that the chain (3) in the tract between the gear
Make sure that the chain (2) and the tract between the gear (2) and gear (4) is tensioned.
(1) and gear (3) is tensioned.
Tighten the fastening screw of the gear (2) on the exhaust
Tighten the fastening screw of the stem with the drive gear
valve camshaft to the prescribed torque.
(1) on the high pressure pump control stem to the prescribed Remove tools 99360614 (1).
torque.
Figure 180
Figure 177
88374
Fit a new gasket (5) in the cover (2).

Fit the cover (2), drive in the screws (1) and tighten them to
88371
the prescribed torque.
Drive the in the chain hydraulic tightener (1) and lock it to Fit the phase sensor (4).
the prescribed torque. Drive in the fastening nut (3) and tighten it to the prescribed
torque.
Figure 181 Lubricate the tang of the driving shaft and the element
outside (2) and fit flush the new seal ring on this element (3).
Position the element (4) on element (2), lock the nut (5) until
fitting the seal ring (3) completely in the cover (1).
Figure 184
88375
Position the joint (5) in the gear (6).

Fit the oil pump/depressor unit (4) by inserting a new gasket
(1). Drive in the screws (2) and tighten them to the
prescribed torque.
Remove tool 99360615 (2).
Figure 182
90156
Mount tool 99396037 (3), for centering cover (1), into

centrifugal filter seat and tighten screws (2) at prescribed
torque. Remove: 99346258 (4) and 99396039 (3) tools.
Figure 185
88376
Fit the cover (1) with a new gasket. Drive in the screws (2)
without tightening them completely.
Figure 183
150741
Fit a new centrifugal filter (1).

Fit a new snap ring (2).
Fit the cover (3), drive in the screws (4) and tighten them to
the prescribed torque.
88377
Clean accurately the seat of the cover seal ring (1).

Drive in the element (2) of tool 99346258 in the driving shaft
tang.

128168
Refit the oil return pipe (2) on the turbocharger.

88378 Screw on the fixing bolts (1) and tighten it to a torque of 10 Nm.
Stop the rotation of the engine flywheel (2) by means of tool Install the cooling pipe (4) on the turbocharger
99360306 (1). Screw on without torque tightening the fixing nuts (3) in order
Fit the damper pulley (3). Drive in the screw (4) and tighten to allow the pipe (4) positioning while assembling the
it to the prescribed torque. turbocharger, exhaust manifold assembly on the crankcase
150728
Fit the water pump (2) with a new gasket. Drive in the screws
(1) and tighten them to the prescribed torque. 140821
Place a new metallic gasket on the crankcase, then fit up the

Fit the rev sensor (3), drive in the fastening screw and tighten exhaust manifold (1) complete with the turbocharger (4).
it to the prescribed torque. Fit the revolutions sensor (2) in its seat, forcing it manually up
to the position reached clic.
For motors F1CE3481A/R Screw on the fixing screw (3) and tighten it to a torque of 10 Nm.
Fit the pipe (5) and tighten the clamp (6)
Figure 188
Figure 191
128167
Fit the turbocharger (2) with relative gasket on the exhaust 129258
manifold (1).
Screw on without tightening the fixing nuts (3) leaving some Place the support bracket (1) between the crankcase and the
turbine. Drive in the screw (2) up to its halt.
clearance between turbocharger and exhaust manifold.
Drive in the screw (3) without tightening it to a torque.

129259
129261
Tighten the fixing nuts (1) between turbocharger and
exhaust manifold to a torque of 25 Nm. Assemble the piping (1) on the cylinder head retaining it by
Tighten the fixing screw (3) to a torque of 25 Nm. means of the collars (4) and (5).
Tighten the fixing screw (4) to a torque of 50 Nm. Put the screws (2) and (3) and tighten it to a torque of 25 Nm.
Put the cable extension (2) on the revolutions sensor Figure 196
Figure 193
128121
Fit the pipe (1) on the EGR unit (3).
Put the collar (2) positioning the screw (4) as shown in figure;
139546 tighten the screw (4).
Install the degasser (1).
Screw on the fixing screws (2) and tighten it to a torque of
25 Nm.
Figure 197
For all motors
Figure 194
135773
Tighten the two nuts (1) to a torque of 30 Nm

139545
Fit the EGR assembly (2) on the overhead and tighten the
fixing screws (1) to a tightening torque of 25 Nm.

128119
151806
Refit the protection (4).
Position the spacers and the nuts (1); tighten the nuts (1) to Fit the cooling pipe (5) on the turbocharger.
a torque of 25 Nm. Install the braket (3) on the manifold; tighten the screws (2)
Connect the oil pipe (2) to the turbocharger and the cylinder to a torque of 10 Nm.
head, and tighten the pipe unions (3) and (5) to the prescribed Screw in the union (1) on the turbocharger; tighten it to a
torque: 30 Nm torque of 25 Nm.
Tighten the screw (4) on the crankcase.
Figure 199
NOTE Connect the oil pipe (6)
128118
Refit the manifold (1) on the turbocharger
Figure 200
127960
Install the braket (2).
Drive in the screws (1) and (3) and tighten it to a torque of
25 Nm

For motor F1CE3481C*C124 Figure 204

Figure 202
135031
134991
Fit the support (2), and tighten the screws (1) to the specified Fit the alternator (3) to the mount (1), secure it with bolt (4)
torque. and screw (2), and tighten them to the specified torques.
Figure 205
Figure 203
135039
Fit the automatic chain tensioner (1) insert in the screw (2)
and tighten to the specified torque.
88419
The freewheel (2) prevents the idling oscillations of the

engine from affecting the alternator (1) via its drive belt. Figure 206
If necessary, replace the freewheel as follows (2).
Remove the freewheel cap (2).
Fit 99358026 tool (3 and 4) as shown in the diagram.
Block the rotation of the freewheel (2) with part (3) and
unscrew the shaft (5) of the alternator (1) with part (4).
Fit the new freewheel (2) in the reverse order. The freewheel
(2) must be secured to the shaft (5), applying a maximum
torque to the shaft of 85 Nm.
135029
Using () a wrench on the automatic belt tensioner (2), fit

the belt (1), making sure that the ribs on the belt fit properly
into the grooves on the pulley.

Figure 207 For motors F1CE3481A/R

Figure 209
134990
130219
Fit the exhaust manifold (3) with a new gasket.
Insert the spacers (1), screw on the nuts (2), then tighten
them to the specified torque. Refit the EBS unit (10) on the turbine outlet; place the collar
(6) and tighten the screw (5).
Fit the pipe (9) on the EBS unit (10).
Put on the collar (7) and position it so that the screw (8)
If the turbocharger is overhauled and/or replaced, doesn't go to interfere with the operation of the valve.
make sure all air pipes are whole, clean and free Insert the pipe (2) for EBS coolant (9) in the union. Drive the
from foreign bodies. collar (1) to a stop position.
Furthermore, check that the sealing gaskets Insert the pipe (4) for EBS coolant (10) in the union . Drive
operate correctly and that the connection sleeves the collar (3) to a stop position.
are fastened, checking that the intake ducts, air filter
and radiators (intercooler) are not clogged.
Check that the oil circulation pipes are not broken For all motors
nor clogged: otherwise replace them or fix the
problem. Figure 210
Figure 208
130218
Connect the pipe (2) with the heat exchanger and the cover.
Retain it by means of the collars (1) e (3).
134989
Fit the turbocharger unit (2) with a new gasket onto the
exhaust manifold complete with pipes and waste gate (4).
Insert the two lower screws (1) securing the turbocharger
assembly to the exhaust manifold and tighten them to the
specified torque.

139544 127952
Connent the pipe (3) between the degasser and the heat Install the pipe (1).
exchanger. Screw in the union (2) on the crankcase.
Fasten the pipe (3) to the adapters by means of the collars
(1) and (2). Figure 215
Figure 212
88423
Remove the fastening screws (1) and remove tool 99360187

139547
(2).
Connect the pipe (2).
Fasten the pipe (2) to the adapters by means of the collars (1)
e (2). Figure 216
Figure 213
151821
Position the joint (2) on the stem (3). Slightly lubricate the
seal ring (1) and fit it on the power steering pump (5).
127953
Connect the pipe (2) to the blow-by filter. Fit the power steering pump on the support (4).
Tighten the collars (3). Drive in the fastening screws (6) and tighten them to the
Tighten the nut (1). prescribed torque.
Fit the cover (4)

127945
128165 Fully tighten the fixing bolt (1) on the pump support side.
Tighten the three fixing bolts (3) complete with spacers (4)
in their seats. Tighten the three bolts (3) to a torque of 25
The relative position between the control shaft and the Nm. Tighten the bolt (1) to a torque of 10 Nm.
pump axis is determined by the flange fitted on the pump.
NOTE If a new high pressure pump is fitted it comes from Figure 220
Bosch in a stable balanced position (at BDC) with
the flange fitted.
If the high pressure pump is not replaced, it should be placed

in the stable balanced position (at BDC) turning the control
shaft (1) appropriately.
Figure 218 75508
Mount the glow plugs (1) and, using the box-type wrench
and torque wrench 99389819 (3), tighten them to a torque
of 8  10 Nm.
Figure 221
128166
Fit the pump (2) so that the control shaft teeth mesh in the
spider (1) seats.
Rotate the pump (keeping the shafts and the gears locked)
so that the openings are aligned with the ones for the
support (3). 150739
Mount the cover (2) on the mixer (1) using the appropriate
screws (3).Mount the plate (4) and the air tube (5) on the cover
using the screws (6).The EGR tube (6) must also be fixed to the
cover with the correct screws (7) using the appropriate seals.

88429
150740 Mount the brackets (3) fastening the electro-injectors (1)

Mount the rail (1) on the appropriate screws (2). and screw down the screws (2) without locking them.
Connect the fuel pipe (6) to the hydraulic accumulator (1)
and to the high-pressure pump (5).Proceed with assembly,
installing: low-pressure tubes (9)(3) electrical connections (7) Figure 225
Figure 223
88431
Connect the fuel pipes (2) to the electro-injectors (3) and to

the hydraulic accumulator (1).
Tighten the screws (4) fixing the electro-injector brackets (5)
75503
Fit a new seal (3) on the electro-injector (1) and mount this NOTE Whenever they get removed, the fuel pipes must
in the overhead (2). be replaced with new ones.

88239
88432
Apply the spring equalizing rocker arm on the engine lifting
Using the wrench (2) of the 99317915 series and the torque hooks, fasten the rocker arm to the hoist and remove the
wrench 99389829 (1), tighten the fuel pipe fittings (3) and (4) engine from the rotating stand (3).
to the prescribed torque. Remove the brackets 99361041(3).
Complete engine assembly.

Fit on the left and right engine mountings (3) and tighten the
Figure 227 fixing screws to the prescribed torque.
Connect the oil pipe (2) to the turbocharger (1) and to the
crankcase and tighten the fixing screws and the coupling of
the oil pipe (2) to the prescribed torque.
If applicable, mount the following parts:
- Engine cable, connecting its electrical connections to the
thermostat temperature sensor, timing sensor, engine
speed sensor, pressure regulator, rail pressure sensor
and intake manifold air pressure/temperature sensor.
- Hydraulic accumulator guard.
- Add the prescribed grade and quantity of lubricating oil
to the engine.
- Dip-stick for oil level check
- Fuel exhaust pipe from injectors
150734
Fit heat exchanger (5), complete with a new gasket, onto the Figure 229
engine base. Drive in the screws (4) and tighten them to the
prescribed torque. Lubricate a new seal and fit it on the pipe
(3). Fit the pipe (3) onto the heat exchanger (5).
Lubricate the seal ring of the oil filter (2) with engine oil and
fasten it on the heat exchanger (5). Use tool 99360076 (1)
to tighten the oil filter to the prescribed torque.
NOTE Whenever they get removed, the fuel pipes (3)

must be replaced with new ones.
Fasten the pipe (3) on the support bracket with the bolt (4)
tightened to the prescribed torque.
88056
The sensor gap is:
- 1 mm, between the gear (4) of the camshaft and the
phase sensor (1).
- 1 mm, between the phonic wheel (2) and speed sensor (1).

90650
134980
If present, mount the conditioner compressor (4), tighten the
mounting screws to the specified torque and fit the flexible
belt (3) as described below.
Insert the two upper screws (3) securing the turbocharger
assembly to the exhaust manifold (4) and tighten them to the
specified torque.
Screw the lubrication pipe fitting (1) and (2) to the NOTE The installation of the climate control unit
turbocharger assembly and tighten to the specified torque. compressor flexible belt requires the use of
99360186 tool (2). Different methods may cause
tensions impairing spring belt.
Figure 231 Fit the flexible belt (3) using 99360186 tool (2) onto the
pulley (4) and fit the tool on the pulley (1).
Turn the crankshaft in an anticlockwise direction () until
the belt is correctly seated on the pulley (1).
NOTE The flexible belt must be replaced with a new one

every time it is removed from the vehicle.
88252
If present, fit the mount (3), and tighten the screws (4) to the
specified torque.
Fit the fixed belt tensioner (2), insert the screw (1) and
tighten to the specified torque.

REPAIRS Figure 234
NOTE On finding irregular engine operation due to the

turbocharging system, it is first expedient to
perform the checks on the turbocharger, check the
efficiency of the seals and the fixing of the couplings,
additionally checking there is no clogging in the
intake sleeves, air filter or radiators. If the
turbocharger damage is due to a lack of lubrication,
check that the oil circulation pipes are not burst or
clogged, in which case replace them or eliminate
the trouble.
88623
Rest the tip of the dial gauge (1) with a magnetic base on the
end of the tie rod (2) and zero it. Using the device 99367121
(3), introduce compressed air into the valve casing (4) at the
prescribed pressure and make sure this value stays constant
throughout the check; replace the valve if it doesn't. In the
above conditions, the tie rod must have made the prescribed
Pressure relief valve travel.
Checking and adjusting pressure relief valve
Figure 235
Figure 233
88624
If a different value is detected, slacken the nut (3) and rotate

the tie rod (4) as required.
Changing the pressure relief valve

Remove the fastener (2) of the tie rod on the lever (1) and
88622
take off the valve (5) from the turbocharger by pulling out the
Cover the air, exhaust gas and lubricating oil inlets and fastening screws (6).
outlets. Thoroughly clean the outside of the turbocharger Fit the new valve by carrying out the operations for removal
using anticorrosive and antioxidant fluid. Disconnect the pipe in reverse order and adjust the travel of the tie rod as
(2) from the union of the pressure relief valve (1) and fit on described under the relevant heading.
it the pipe of the device 99367121 (3, Figure 234).
NOTE Before fitting the turbocharger on the engine, it is

necessary to fill the central body with engine
lubricating oil.

Checking and adjusting the actuator

NOTE NOT ALLOWED ARE:
Figure 236 - any replacement or regulation of the
actuator, since the calibration of such
component is made in an optimal way
for each turbocharger and is
guaranteed for the turbocharger;
- any operation on nut (5) and ring nut
(4), since such operation does not
change engine supply characteristics
but may impair engine reliability and
duration.
Ring nut (4) is sealed with antitempering
yellow paint.
In case of engines under guarantee, each
above specified intervention and/or
alteration to paint applied on ring nut (4)
causes the lapse of the guarantee.
62873
Cover air, exhaust gas and lubricant inlets and outlets.

Clean the turbosupercharger outside accurately using
anticorrosive and antioxidant fluid and check the actuator
(6).
Clamp the turbosupercharger in a vice.
Apply vacuometer 99367121 (1) pipe to actuator (6) hose.
Apply the magnetic base gauge (2) to exhaust gas inlet flange
in the turbine.
Set gauge (2) feeler pin on tie rod (3) end and set gauge (2)
to zero.
Operate the vacuum pump and check whether the tie rod
(3) stroke values correspond to the vacuum values shown in
the following table:
- vacuum 0 mm Hg Fully open valve

Valve stroke
- vacuum 180 mm Hg
2.5 mm
Valve stroke
- vacuum 450 mm Hg
10.5 mm
If a different value is found, replace the turbocharger..
NOTE During the check the vacuum value shall not fall,
otherwise the actuator shall be replaced.


S SERIES EURO V SECTION 8 - TECHNICAL SPECIFICATIONS 1
SECTION 8
Technical specifications
Page
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . 3
ASSEMBLY DATA — CLEARANCES . . . . . . . . . . . . 4
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . 9

2 SECTION 8 - TECHNICAL SPECIFICATIONS S SERIES EURO V

GENERAL SPECIFICATIONS
Type F1CE3481
Cycle Diesel 4 strokes

Supply Turbocharged with intercooler
Injection Direct
Number of cylinders 4 in line

Bore mm 95.8
Stroke mm 104
+ + +.. = Total displacement cm3 2998
A
TIMING SYSTEM
Start before T.D.C. A 24
end after B.D.C. B 26

B
C
Start before T.D.C. D 70

end after B.D.C. C 24
D
FUEL FEED
Injection high pressure common rail

Type: Bosch EDC17
Nozzle type Injectors BOSCH
Injection sequence 1-3-4-2
bar
Injection pressure bar 1800
Data, features and performances are valid only if the setter fully complies with all the installation prescriptions providedby
! FPT.
Furthermore, the users assembled by the setter shall always be in conformance to couple, power and number of
turnsbased on which the engine has been designed.

ASSEMBLY DATA — CLEARANCES
Type F1CE3481
CYLINDER ASSEMBLY AND CRANK MEMBERS

1 Cylinder liners:
1 95.802  95.822
Pistons:
1 supplied as spares type MAHLE
X measurement X 58
outside diameter 1 95.541  95.555
2 seat for pin 2 36.003  36.009
Piston — cylinder liners 0.197  0.231
Piston diameter 1 0.4
X
Piston protrusion
from crankcase X 0.3  0.6
3 Piston gudgeon pin 3 95.541  95.555
Piston gudgeon pin — pin seat 0.07  0.019

Type F1CE3481
CYLINDER ASSEMBLY AND CRANK MEMBERS mm

Type of piston -
X1* 2.200  2.230
X1
Piston ring slots X2 2.050  2.070
X2
X3 X3 2.540  2.560
* measured on  of 92.5 mm
Piston rings: S1* 2.068  2.097
S1 S2 1.970  1.990
S2
S3 2.470  2.495
S3
* measured at 1.5 mm from
the external .
Piston rings — slots 1 0.103  0.162
2 0.060  0.100
3 0.045  0.090
Piston rings 0.4
X1 Piston ring end opening in

cylinder liner:
X2
X1 0.20  0.35
X3
X2 0.60  0.80
X3 0.30  0.60
1 Small end bushing seat
Ø1 39.460  39.490
2 Connecting rod bearing seat*

Ø2 67.833  67.848
* connecting rod supplied as
spare part
Small end bushing diameter
4
outside 4 39.570  39.595
3 inside 3 36.010  36.020
S Big end bearing shells

supplied as spare part -
- top S 1.883  1.892
- bottom S 1.885  1.891
Small end bushing — seat
(interference) 0.08  0.135
Piston gudgeon pin — bushing 0.014  0.030
Big end bearing shells 0.254 - 0.508

Type F1CE3481
CYLINDER ASSEMBLY AND CRANK MEMBERS mm

X
Measurement X 125
Maximum error
on alignment of
connecting rod axes = 0.09
Main journals 1
1 2 No. 1-2-3-4 76.182  76.208
No. 5 83.182  83.208
Crankpins 2 64.015  64.038
Main bearing shells
S1* 2.165  2.174
S1 S 2 Big end bearing shells
S2* 1.883  1.892
* supplied as spare parts 1.885  1.891
Main bearing housings  3

3 No. 1-2-3-4 80.588  80.614
No. 5 87.588  87.614
Bearing shells -
main journals 0.032  0.102
Bearing shells —
crankpins 0.035  0.083
Main bearing shells 0.254  0.508
Big end bearing shells 0.254  0.508
Main journal
for shoulder X1 32.500  32.550
X 1
Main bearing housing

for shoulder X2 27.240  27.290
X 2
X3
Half thrust washers X3
32.310  32.460
Crankshaft shoulder 0.040  0.240

Type F1CE3481
CYLINDER HEAD — TIMING SYSTEM mm

 1
Guide valve seats

on cylinder head 1 9.980  10.000
 2
2 6.023  6.038
Valve guides
3 10.028  10.039
 3
Valve guides and seats on head

(interference) 0.028  0.059
Valve guides 0.05 - 0.10 - 0.25

 4 Valves:
4 5.985  6.000
 60 7.5'
4 5.975  5.990
  60 7.30'
Valve stem and relevant guide 0.023  0.053

Seat on head for valve seat:
1 34.490  34.415
 1
1 34.490  34.515
Outside diameter of valve

 2 seats; angle of valve seats on
cylinder head:
2 34.590  34.610
 59.5 5'
 2 34.590  34.610
 59.5 5'
X 0.375  0.525
X Recessing X 0.375  0.525
0.075 - 0.12
Between valve
seat and head
0.075 - 0.12
Valve seats -

Type F1CE3481
CYLINDER HEAD — TIMING SYSTEM mm

Valve spring height:
free spring H 55.05
H under a load of:
H1
H 2 N320 ± 16 H1 45
N657 ± 30 H2 35
Injector protrusion X 2.77  3.23

X
 Seats for tappets on

cylinder head normal  12.016  12.034
Normal diameter tappets 11.988  12.000


Between tappets and seats 0.016  0.046

Camshaft pin seats in
cylinder overhead
17
1 48.988  49.012
   2 46.988  47.012
3 35.988  36.012
 2
Camshaft supporting pins:
1 48.925  48.950
2 46.925  46.950
1 2 3
3 35.925  35.950
Supporting pins and seats 0.032  0.087
Useful cam height
H H
3.622
H
4.328

TIGHTENING TORQUES
TORQUE
PART
Nm kgm
M15x1.5 L 193 hex bolt securing inside of cylinder head
first stage: pre-tightening 130 ± 6.5 13 ± 0.65
second stage: angle 90°
third phase: angle 90°
M12x1.5 L 165 hex bolt securing cylinder head laterally
first stage: pre-tightening 65 ± 3.3 6.5 ± 0.325
second stage: angle 90°
third phase: angle 60º
M8x1.25 L 117/58 hex bolt securing cylinder head, chain housing side 25 ± 13.5 2.5 ± 0.13
Tapered threaded hexagon socket plug R 1/2" 40 ± 4 4 ± 0.4
Tapered threaded hexagon socket plug R 3/8" 29 ± 2.9 2.9 ± 0.3
Tapered threaded plug with hexagon socket head R 1/8" on cylinder head 7 ± 0.7 0.7 ± 0.07
Tapered threaded plug with hexagon socket head R 1/4" on cylinder head 9 ± 0.9 0.9 ± 0.09
Threaded male plug M26x1.5 50 ± 5 5 ± 0.5
Flanged screw M6x1 fixing camshaft rear cover 10 ± 1 1 ± 0.1
Flanged screw M6x1 fixing camshaft thrust plate 10 ± 1 1 ± 0.1
Hex screw with flange M8x1.25 L 30/40/77/100 fixing overhead 25 ± 2.5 2.5 ± 0.25
Threaded male plug M14x1.5 L 10 on timing cover 25 ± 2.5 2.5 ± 0.25
M6x1x25 cylindrical head hexagon socket screw securing timing cover 10 ± 1 1 ± 0.1
M6x1 flanged nut securing timing cover 10 ± 1 1 ± 0.1
M12x1.5 L 125 screw securing inside of lower crankcase
first stage: pre-tightening 50 ± 5 5 ± 0.5
second stage: angle 60º
third phase: angle 60º
Bolt M8x1.25 L 77.5/40 securing lower crankcase externally 26 ± 2.6 2.6 ± 0.26
Flanged hex bolt M11x1.25x49 securing con rod caps
second stage: angle 70
Flanged hex bolt M12x1.25x52.5 securing engine flywheel
second stage: angle 90
M6x1x15 hex socket screw securing pulser ring to crankshaft 15 ± 1.5 1.5 ± 0.15
M10x1 union for piston cooling nozzle 25 ± 2.5 2.5 ± 0.25
Tapered threaded hex socket plug R 3/8"x10 40 ± 4 4 ± 0.4
Hex screw with flange M20x1.5x58 fixing damper pulley on crankshaft 350 ± 17.5 35 ± 0.175
Tapered plug R 1/8 x 8 on crankcase base 7 ± 0.7 0.7 ± 0.07
Water drain plug M14x1.5 L10 on crankcase 25 ± 2.5 2.5 ± 0.25
Crankcase fitting for turbocharger oil return G 3/8" x 12 50 ± 5 5 ± 0.5
Screw M6x1 fixing suction strainer 10 ± 1 1 ± 0.1
Hex screw with flange M8x1.25 fixing oil and vacuum pump assembly 25 ± 2.5 2.5 ± 0.25
M12x1.5x35 drive pin of oil and vacuum pump assembly 130 ± 13 13 ± 0.13
Fitting R 1/4" for oil delivery to turbocharger 40 ± 4 4 ± 0.4
Hex screw with flange M8x1.5 L35 fixing frame retaining oil sump 25 ± 2.5 2.5 ± 0.25
Male threaded plug with O-ring M22x1.5 L10 50 ± 10 5±1
Hex screw with flange M8x1.25 L60 fixing oil and vacuum pump assembly 25 ± 2.5 2.5 ± 0.25
Hex screw with flange M8x1.25 fixing power steering pump mount 25 ± 2.5 2.5 ± 0.25

TORQUE
PART
Nm kgm
Flanged screw M8x1.25 L18 fixing timing cover 25 ± 2.5 2.5 ± 0.25
Screw with flange M6x1 L20 fixing Blow-by unit 10 ± 1 1 ± 0.1
Cap M14x1.5 L10 25 2.5
Hex screw with flange M8x1.25 L40 fixing inlet manifold 30 3
Flanged nut M8x1.25 fixing exhaust manifold 25 ± 2.5 2.5 ± 0.25
M10 x 1.25 x 50 Fixed idler 50 ± 5 5 ± 0.5
M8 x 1.25 x 45 Belt tensioner 25 ± 2.5 2.5 ± 0.25
M10 x 1.25 Alternator 50 ± 5 5 ± 0,5
M10 x 1.25 x 30 Alternator 50 ± 5 5 ± 0.5
M10 x 1.25 x 35 Alternator support 50 ± 5 5 ± 0.5
M10 x 1.25 x 100 Alternator support 50 ± 5 5 ± 0.5
M8 x 1.25 x 70 Alternator support 25 ± 2.5 2.5 ± 0.25
M8 x 1.25 x 30 Alternator support 25 ± 2.5 2.5 ± 0.25
Hex socket bolt M8x1.25 L65 for Poli-V automatic belt tensioner 25 2.5
Hex screw with flange M10x1.25 L22 for guide pulley roller for Poli-V belt 40 4
Flanged hex screw M12x1.75 L30 fixing gear to camshaft 110 11
Timing chain tensioner bolt M22x1.5x22 50 ± 2 5 ± 0.2
Bolt M10x1.5x12 for timing chain mobile pads 40 ± 2 4 ± 0.2
Cylindrical head hexagon socket screw M8x1.25x30 securing fixed pads 25 ± 2.5 2.5 ± 0.25
Cylindrical head hexagon socket screw M6x1 L16/20 securing pads 10 ± 1 1 ± 0.1
Bolt M12x1.5 fixing water temperature sensor 30 ± 3 3 ± 0.3
M6x1 cylindrical head hexagon socket screw securing air temperature/pressure sensor 10 ± 1 1 ± 0.1
M6x1 cylindrical head hexagon socket screw securing engine rpm sensor 10 ± 1 1 ± 0.1
M6x1 hexagon socket screw securing timing sensor 10 ± 1 1 ± 0.1
M8 x 1.25 Turbocharger 25 ± 2.5 2,5 ± 0.25
M14 x 1.5 Turbocharger oil delivery pipe 35 ± 3.5 3.5 ± 0.35
M6 x 1 x 20 Turbocharger oil return pipe 10 ± 1 1 ± 0.1
M22 x 1.5 Turbocharger oil return pipe 45 ± 4.5 4.5 ± 0.45
Nut M8x1.25 fixing turbocharger 25 ± 2.5 2.5 ± 0.25
Flanged hex screw M8x1.25 for turbocharger gas outlet pipe 25 ± 2.5 2.5 ± 0.25
Union M14x1.5 for fixing oil delivery pipe to turbocharger 35 ± 3.5 3.5 ± 0.35
Fitting M22x1.5 for oil return pipe from turbocharger 45 ± 4.5 4.5 ± 0.45
Flanged hex screw M6x1 fixing oil return pipe from turbocharger 10 ± 1 1 ± 0.1
M8 x 1.25 x 25 Complete support from valve to throttle body 25 ± 2.5 2.5 ± 0.25
Threaded pipe union R 1/4" 40 ± 4 4 ± 0.4
M10 x 1.25 x 35 Air compressor 50 ± 5 5 ± 0.5
M10 x 1.25 x 110 Air compressor 50 ± 5 5 ± 0.5
M12 x 1.25 x 48 Air compressor support 50 ± 5 5 ± 0.5
M22 x 1.5 Water inlet pipe 50 ± 5 5 ± 0.5
M14 x 1.5 Water delivery pipe 30 ± 3 1 ± 0.1
M16 x 1.5 Water pipe 50 ± 5 5 ± 0.5
M16 x 1.5 Water return pipe 35 ± 3.5 3.5 ± 0.35
M12 x 1.5 Water delivery pipe 40 ± 4 4 ± 0.4

TORQUE
PART
Nm kgm
R1/8” x 12.5 Oil delivery fitting from turbocharger on to the crankcase 35 ± 3.5 3.5 ± 0.35
M18 x 1.5 Air compressor control pulley 120 ± 12 12 ± 0.12
Hex screw with flange M6x1x16 fixing air pipe 10 ± 1 1 ± 0.1
M6x1 flanged hex screw securing oil fill pipe 10 ± 1 1 ± 0.1
Oil filter cartridge M22x1.5 25 ± 2.5 2.5 ± 0.25
Hex bolt M8x1.25x30 securing heat exchanger 25 ± 2.5 2.5 ± 0.25
Oil filter cartridge fitting M24x1.5 * 80 ± 8 8 ± 0.8
M6 x 1 x 12 Oil dipstick 10 ± 1 1 ± 0.1
M8x1.25x30/40 flanged hex screw securing heat exchanger internal element 25 ± 2.5 2.5 ± 0.25
M8x1.25 flanged hex screw securing cylinder head rear cover 25 ± 1.25 2.5 ± 0.125
Hex screw with flange M8x1.25 fixing coolant delivery pipe 25 ± 1.25 2.5 ± 0.125
M12x1.5 pressure switch on coolant tank 25 ± 2.5 2.5 ± 0.25
M6 x 1 x 18 Cooler internal element 10 ± 1 1 ± 0.1
Flanged nut M8x1.25 for coolant delivery pipe support bracket fastening 25  2.5 2.5  0.25
Flanged screw M8x1.25 for thermostat fastening 25  2.5 2,5 ± 0.25
Socket cylinder head screw M10x1.5 for alternator fastening 50 ± 5 5 ± 0.5
Flanged screw M10x1,25x110 for hydraulic power steering pump fastening 40 ± 4 4 ± 0.4
Flanged screw M12x1,25 securing the power steering pump 50 5
Flanged screw M8x1,25 securing the power steering tank support 25 ± 2.5 2.5 ± 0.25
Flanged screws M10x1.25 for power take off cover fastening 50 ± 5 5 ± 0.5
M12 x 1.25 x 12 Plug on the oil sensor base 25 ± 2.5 2.5 ± 0.25
G 3/8” x 12 Oil return fitting from turbocharger on to the crankcase 50 ± 5 5 ± 0.5
G 3/8” x 12 Plug 40 ± 4 4 ± 0.4
Oil pressure switch M14x1.5 25 ± 2.5 2.5 ± 0.25
M8x1.25 socket-head cap screw securing the E.G.R. valve to the exhaust manifold 25 ± 2.5 2.5 ± 0.25
M8x1.25 socket-head cap screw securing the E.G.R. valve to the exchanger 25 ± 2.5 2.5 ± 0.25
M8x1.25 flanged screw securing the heat exchanger 25 ± 2.5 2.5 ± 0.25
M6x1 socket-head cap screw for E.G.R. pipe fastening collar 5 ± 0,25 0.5 ± 0.03
G 1/4” Oil delivery fitting to turbocharger 40 ± 4 4 ± 0.4
M8 x 1.25 x 20 EGR valve to exhaust manifold 25 ± 2.5 2.5 ± 0.25
M6 x 1 EGR pipe (collar) 5 ± 0.5 0.5 ± 0.05
High-pressure injection system
Flanged nut M8x1.25 for high pressure pump support fastening 25 2.5
Hydraulic accumulator fastening screw M8x1.25 L50 28 2.8
High pressure pump fastening screw M8x1.25 L90 25 2.5
Screw M6x1x16 for fastening of fuel delivery pipe anchoring bracket 10 1
Pipe union for fuel delivery pipes to rail and electric injectors:
- M14x1.5 19 ± 2 1.9 ± 0.2
- M12x1.5 25 ± 2 2.5 ± 0.2
Socket cylinder head screw M8x1,25 for fastening of electric injector retaining bracket 28 ± 2.8 2.8 ± 0.3
Flanged nut M8x1,25 for anchoring bracket support fastening 25 ± 2,5 2.5 ± 0.25
Pin fastener M12x1.25 for high pressure pump 110 ± 11 11 ± 0.11
Flanged nut (M6x1) for low-pressure fuel pipe fastening 10 ± 1 1 ± 0.1
TE flanged screw (M8x1.25) for pipe supporting bracket fastening 25 ± 2.5 2.5 ± 0.25
Filler neck M12x1.5 for adjustable pipe union 25 ± 2.5 2.5 ± 0.25
M6 x 1 x 10 Diesel fuel LP pipe 10 ± 1 1 ± 0.1
* Apply LOCTITE 577 to the thread


S SERIES EURO V SECTION 9 - TOOLS 1
SECTION 9
Tools
Page
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 SECTION 9 - TOOLS S SERIES EURO V

TOOLS
TOOL NO. DESCRIPTION
99327281 PT-BOX
99305454 Tool used to check the low-/high-pressure system fuel supply

circuit
99317915 Set of 5 pin wrenches 9X12 (14-15-17-18-19 mm)
99322205 Revolving stand for overhauling units (1000daN/m capacity,

120daN/m torque)
99340059 Extraction tool for crankshaft front ring seal
99340060 Extraction tool for crankshaft rear gasket

99342156 Extractiontool for injectors
99346259 Key to fit crankshaft rear gasket
993462158 Key to fit crankshaft front gasket
99352115 Wrench for removing/refitting injector pipes

(ch. 17)
99358026 Wrench for removing/refitting the alternator freewheel

99360076 Tool to remove oil filter (engine)
99360186 Guide for fitting rubber belt
99360187 Tool for retaining power steering pump drive shaft
99360260 Tool for removing and installing engine valves
99360306 Tool to retain engine flywheel

99360605 Band for fitting piston into cylinder barrel (60 - 125 mm)
99360614 Tool (2) for camshaft timing
99360615 Tool for crankshaft timing
99361041 Brackets for fastening engine to 99322205 rotary stand
99367121 Manual pump for pressure and depression measures
99370415 Gauge base for different measurements (to be used with

99395603)

99389813 Torque Wrench

(20-120 Nm) with square 1/2 ”
99389817 Torque wrench

(60 ÷ 320 Nm) with 1/2” square head
99389818 Torque wrench (150-800 Nm) with 3/4” square head

(0-10 Nm) with 1/4” square head
99389829 Dog typedynamometric wrench 9x12 (5-60 Nm)

(10-60 Nm) with 3/8” square head

99394038 Milling cutter for grinding injector seats
99395216 Pair of gauges with ½” and ¾” square head for angle tightening
99395603 Dialgauge (0 - 5 mm)
99396030 Calibrated rings for the lay shaft bearing adjustment (use with
99370466)
99396039 Timer cover centring ring(use with 99346258)
SP2264 Pins for mounting valve guide gaskets

SP2271 Cylinder head support
SP2275 Bushing (8 mm) for the removal and remounting of glow plugs
SP2310 Sleeker for valve guide
SP2311 Punch for valve guide refitting (use with SP2312)
SP2312 Punch for valve guide removal








S SERIES EURO V APPENDIX 1
Appendix
Page
SAFETY PRESCRIPTIONS . . . . . . . . . . . . . . . . . 3

2 APPENDIX S SERIES EURO V

S SERIES EURO V APPENDIX 3
SAFETY PRESCRIPTIONS - Do not execute any intervention if not provided with

Standard safety prescriptions necessary instructions.
- Do not use any tool or equipment for any different
Particular attention shall be drawn on some precautions that
operation from the ones they've been designed and
must be followed absolutely in a standard working area and
whose non fulfillment will make any other measure useless provided for: serious injury may occur.
or not sufficient to ensure safety to the personnel in-charge - In case of test or calibration operations requiring engine
of maintenance. running, ensure that the area is sufficiently aerated or
Be informed and inform personnel as well of the laws in force utilize specific vacuum equipment to eliminate exhaust
regulating safety, providing information documentation gas. Danger: poisoning and death.
available for consultation.
- Keep working areas as clean as possible, ensuring During maintenance
adequate aeration.
- Ensure that working areas are provided with emergency - Never open filler cap of cooling circuit when the engine
boxes, that must be clearly visible and always provided is hot. Operating pressure would provoke high
with adequate sanitary equipment. temperature with serious danger and risk of burn. Wait
- Provide for adequate fire extinguishing means, properly unit the temperature decreases under 50ºC.
indicated and always having free access. Their efficiency - Never top up an overheated engine with cooler and
must be checked on regular basis and the personnel utilize only appropriate liquids.
must be trained on intervention methods and priorities. - Always operate when the engine is turned off: whether
- Organize and displace specific exit points to evacuate particular circumstances require maintenance
the areas in case of emergency, providing for adequate intervention on running engine, be aware of all risks
indications of the emergency exit lines. involved with such operation.
- Smoking in working areas subject to fire danger must be - Be equipped with adequate and safe containers for
strictly prohibited. drainage operation of engine liquids and exhaust oil.
- Provide Warnings throughout adequate boards signaling - Keep the engine clean from oil tangles, diesel fuel and or
danger, prohibitions and indications to ensure easy chemical solvents.
comprehension of the instructions even in case of - Use of solvents or detergents during maintenance may
emergency. originate toxic vapors. Always keep working areas
Prevention of injury aerated. Whenever necessary wear safety mask.
- Do not leave rags impregnated with flammable
- Do not wear unsuitable cloths for work, with fluttering substances close to the engine.
ends, nor jewels such as rings and chains when working - Upon engine start after maintenance, undertake proper
close to engines and equipment in motion. preventing actions to stop air suction in case of runaway
- Wear safety gloves and goggles when performing the speed rate.
following operations: - Do not utilize fast screw-tightening tools.
- filling inhibitors or anti-frost
- lubrication oil topping or replacement - Never disconnect batteries when the engine is running.
- utilization of compressed air or liquids under pressure - Disconnect batteries before any intervention on the
(pressure allowed:  2 bar) electrical system.
- Wear safety helmet when working close to hanging - Disconnect batteries from system aboard to load them
loads or equipment working at head height level. with the battery loader.
- Always wear safety shoes when and cloths adhering to - After every intervention, verify that battery clamp
the body, better if provided with elastics at the ends. polarity is correct and that the clamps are tight and safe
- Use protection cream for hands. from accidental short circuit and oxidation.
- Change wet cloths as soon as possible - Do not disconnect and connect electrical connections
in presence of electrical feed.
- In presence of current tension exceeding 48-60 V verify
efficiency of earth and mass electrical connections. - Before proceeding with pipelines disassembly
Ensure that hands and feet are dry and execute working (pneumatic, hydraulic, fuel pipes) verify presence of liquid
operations utilizing isolating foot-boards. Do not carry or air under pressure. Take all necessary precautions
out working operations if not trained for. bleeding and draining residual pressure or closing dump
valves. Always wear adequate safety mask or goggles.
- Do not smoke nor light up flames close to batteries and Non fulfillment of these prescriptions may cause serious
to any fuel material. injury and poisoning.
- Put the dirty rags with oil, diesel fuel or solvents in
anti-fire specially provided containers.

4 APPENDIX S SERIES EURO V
- Avoid incorrect tightening or out of couple. Danger: Respect of the Environment

incorrect tightening may seriously damage engine's
components, affecting engine's duration. - Respect of the Environment shall be of primary
importance: all necessary precautions to ensure
- Avoid priming from fuel tanks made out of copper alloys personnel's safety and health shall be adopted.
and/or with ducts not being provided with filters.
- Be informed and inform the personnel as well of laws in
- Do not modify cable wires: their length shall not be force regulating use and exhaust of liquids and engine
changed. exhaust oil. Provide for adequate board indications and
- Do not connect any user to the engine electrical organize specific training courses to ensure that
equipment unless specifically approved by FPT. personnel is fully aware of such law prescriptions and of
basic preventive safety measures.
- Do not modify fuel systems or hydraulic system unless
FPT specific approval has been released. Any - Collect exhaust oils in adequate specially provided
unauthorized modification will compromise warranty containers with hermetic sealing ensuring that storage is
assistance and furthermore may affect engine correct made in specific, properly identified areas that shall be
working and duration. aerated, far from heat sources and not exposed to fire
danger.
For engines equipped with electronic gearbox:
- Handle the batteries with care, storing them in aerated
- Do not execute electric arc welding without having environment and within anti-acid containers. Warning:
priory removed electronic gearbox. battery exhalation represent serious danger of
- Remove electronic gearbox in case of any intervention intoxication and environment contamination.
requiring heating over 80ºC temperature.
- 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.

S SERIES EURO V Application To Vehicles F1CE3481

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S SERIES EURO V

Technical and Repair manual

This publication has been drawn up for qualified and

Before performing any operation check that the part relevant

Operations are to be performed by following the indications

Each repair must aim to restore operating efficiency and safety

FPT cannot be held liable for modifications, alterations or other

FPT is not liable for repairing interventions.

FPT will provide further details required to carry out the

Data included in this publication may not be up-to-date

If issues on this publication differ from what is actually noticed

It is forbidden to copy this text or any of its parts and all

S Serie F1CE Part 1

Print P1D32S015 E Base - October 2011

Base - October 2011 Print P1D32S015 E

PREFACE TO USER'S GUIDELINE MANUAL

Danger for persons

Danger of serious damage for the assembly

NOTE It indicates an additional explanation for a piece of information.

1 Ø 1 = housing for connecting rod small end bush

Print P1D32S015 E Base - October 2011

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Print P1D32S015 E Base - October 2011

GENERAL WARNINGS ON THE ELECTRIC SYSTEM

Base - October 2011 Print P1D32S015 E

Bonding and screening

Further, following warnings are to be compulsorily observed for electronic components:

1. NEGATIVE CABLES “STAR“ CONNECTION TO SYSTEM BONDING M

2. SCREENING THROUGH METALLIC BRAIDING OF A CABLE TO AN ELECTRONIC COMPONENT — C. CONNECTOR

Print P1D32S015 E Base - October 2011

CONVERSIONS BETWEEN THE MAIN UNITS OF MEASUREMENT OF THE

Base - October 2011 Print P1D32S015 E

KEY OF LECTURE OF THE HEADINGS AND FOOTNOTES

Type of Section Page

Language Basic edition referred to When month - year

Print P1D32S015 E Base - October 2011

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Removal - refitting of main components 6

General mechanical overhauling 7

Safety prescriptions Appendix

Print P1D32S014 E Base - October 2011

Base - October 2011 Print P1D32S014 E

Tighten to torque + angle value Rolling torque

Press or caulk Rotation

Surface for machining

Print P1D32S015 E Base - October 2011

Section Description Page Date of revision

Base - October 2011 Print P1D32S015 E

Print P1D32S015 E Base - October 2011

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VIEWS OF ENGINE F1CE3481A/R

LEFT-HAND SIDE VIEW

RIGHT-HAND SIDE VIEW

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Print P1D32S015 E Base - October 2011

LEFT-HAND SIDE VIEW

RIGHT-HAND SIDE VIEW

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Print P1D32S015 E Base - October 2011

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Type F1CE3481R F1CE3481 F1CE3481 F1CE3481 F1CE3481 F1CE3481

Print P1D32S015 E Base - October 2011